902 Caterpillar Compact Wheel Loader Operation and Maintenance Manual by quality service repair manual

Product:COMPACTWHEELLOADER

Model:902COMPACTWHEELLOADER7ES

Configuration:902CompactWheelLoader7ES00001-UP(MACHINE)POWEREDBY3024Engine

OperationandMaintenanceManual 902and906CompactWheelLoaders

MediaNumber-SEBU7137-02PublicationDate-01/09/1998DateUpdated-12/05/2004

Foreword

SMCS-6700

LiteratureInformation

Thismanualshouldbestoredintheoperator'scompartmentintheliteratureholderorseatback literaturestoragearea.

Thismanualcontainssafetyinformation,operationinstructions,transportationinformation, lubricationinformationandmaintenanceinformation.

Somephotographsorillustrationsinthispublicationshowdetailsorattachmentsthatcanbedifferent fromyourmachine.Guardsandcoversmighthavebeenremovedforillustrativepurposes.

Continuingimprovementandadvancementofproductdesignmighthavecausedchangestoyour machinewhicharenotincludedinthispublication.Read,studyandkeepthismanualwiththe machine.

Wheneveraquestionarisesregardingyourmachine,orthispublication,pleaseconsultyourCat dealerforthelatestavailableinformation.

Safety

Thesafetysectionlistsbasicsafetyprecautions.Inaddition,thissectionidentifiesthetextand locationsofwarningsignsandlabelsusedonthemachine.

Readandunderstandthebasicprecautionslistedinthesafetysectionbeforeoperatingorperforming lubrication,maintenanceandrepaironthismachine.

Operation

s00037320

Theoperationsectionisareferenceforthenewoperatorandarefresherfortheexperiencedoperator. Thissectionincludesadiscussionofgauges,switches,machinecontrols,attachmentcontrols, transportationandtowinginformation.

Photographsandillustrationsguidetheoperatorthroughcorrectproceduresofchecking,starting, operatingandstoppingthemachine.

Operatingtechniquesoutlinedinthispublicationarebasic.Skillandtechniquesdevelopasthe operatorgainsknowledgeofthemachineanditscapabilities.

Maintenance

Themaintenancesectionisaguidetoequipmentcare.TheMaintenanceIntervalSchedule(MIS)lists theitemstobemaintainedataspecificserviceinterval.Itemswithoutspecificintervalsarelisted underthe"WhenRequired"serviceinterval.TheMaintenanceIntervalScheduleliststhepage numberforthestep-by-stepinstructionsrequiredtoaccomplishthescheduledmaintenance.Usethe MaintenanceIntervalScheduleasanindexor"onesafesource"forallmaintenanceprocedures.

MaintenanceIntervals

Usetheservicehourmetertodetermineservicingintervals.Calendarintervalsshown(daily,weekly, monthly,etc.)canbeusedinsteadofservicehourmeterintervalsiftheyprovidemoreconvenient servicingschedulesandapproximatetheindicatedservicehourmeterreading.Recommendedservice shouldalwaysbeperformedattheintervalthatoccursfirst.

Underextremelysevere,dustyorwetoperatingconditions,morefrequentlubricationthanisspecified inthemaintenanceintervalschartmightbenecessary.

Performserviceonitemsatmultiplesoftheoriginalrequirement.Forexample,atevery500service hoursor3months,alsoservicethoseitemslistedunderevery250servicehoursormonthlyandevery 10servicehoursordaily.

CaliforniaProposition65Warning

DieselengineexhaustandsomeofitsconstituentsareknowntotheStateofCaliforniatocause cancer,birthdefects,andotherreproductiveharm.

Batteryposts,terminalsandrelatedaccessoriescontainleadandleadcompounds.Washhandsafter handling.

CertifiedEngineMaintenance

Propermaintenanceandrepairisessentialtokeeptheengineandmachinesystemsoperating correctly.Astheheavydutyoff-roaddieselengineowner,youareresponsiblefortheperformanceof therequiredmaintenancelistedintheOwnerManual,OperationandMaintenanceManual,and ServiceManual.

Itisprohibitedforanypersonengagedinthebusinessofrepairing,servicing,selling,leasing,or tradingenginesormachinestoremove,alter,orrenderinoperativeanyemissionrelateddeviceor elementofdesigninstalledonorinanengineormachinethatisincompliancewiththeregulations (40CFRPart89).Certainelementsofthemachineandenginesuchastheexhaustsystem,fuel system,electricalsystem,intakeairsystemandcoolingsystemmaybeemissionrelatedandshould notbealteredunlessapprovedbyCaterpillar.

MachineCapacity

Additionalattachmentsormodificationsmayexceedmachinedesigncapacitywhichcanadversely affectperformancecharacteristics.Includedwouldbestabilityandsystemcertificationssuchas brakes,steering,androlloverprotectivestructures(ROPS).ContactyourCatdealerforfurther information.

CatProductIdentificationNumber

EffectiveFirstQuarter2001theCatProductIdentificationNumber(PIN)haschangedfrom8to17 characters.Inanefforttoprovideuniformequipmentidentification,Caterpillarandotherconstruction equipmentmanufacturersaremovingtocomplywiththelatestversionoftheproductidentification numberingstandard.Non-roadmachinePINsaredefinedbyISO10261.ThenewPINformatwill applytoallCatmachinesandgeneratorsets.ThePINplatesandframemarkingwilldisplaythe17 characterPIN.Thenewformatwilllooklikethefollowing:

2.MachineDescriptor(characters4-8)

3.CheckCharacter(character9)

4.MachineIndicatorSection(MIS)orProductSequenceNumber(characters10-17).Thesewere previouslyreferredtoastheSerialNumber.

MachinesandgeneratorsetsproducedbeforeFirstQuarter2001willmaintaintheir8characterPIN format.

Componentssuchasengines,transmissions,axles,etc.andworktoolswillcontinuetousean8 characterSerialNumber(S/N).

TueMar915:48:38UTC+05302021

Product:COMPACTWHEELLOADER

Model:902COMPACTWHEELLOADER7ES

Configuration:902CompactWheelLoader7ES00001-UP(MACHINE)POWEREDBY3024Engine

MediaNumber-SEBU7137-02PublicationDate-01/09/1998DateUpdated-12/05/2004

AftermarketOilAdditives

SMCS-7581

Caterpillardoesnotrecommendtheuseofaftermarketadditivesinoil.Itisnotnecessarytouse aftermarketadditivesinordertoachievethemachine'smaximumservicelifeorratedperformance. Fullyformulated,finishedoilsconsistofbaseoilsandofcommercialadditivepackages.These additivepackagesareblendedintothebaseoilsatprecisepercentagesinordertohelpprovide finishedoilswithperformancecharacteristicsthatmeetindustrystandards.

Therearenoindustrystandardteststhatevaluatetheperformanceorthecompatibilityofaftermarket additivesinfinishedoil.Aftermarketadditivesmaynotbecompatiblewiththefinishedoil'sadditive package,whichcouldlowertheperformanceofthefinishedoil.Theaftermarketadditivecouldfailto mixwiththefinishedoil.Thiscouldproducesludge.Caterpillardiscouragestheuseofaftermarket additivesinfinishedoils.

ToachievethebestperformancefromCaterpillarmachines,conformtothefollowingguidelines:

•SelecttheproperCaterpillaroilorselectcommercialoilthatmeetsthespecifications designatedbyCaterpillarforthecompartment.

•Seetheappropriate“LubricantViscositiesforAmbientTemperatures”tableinthispublication inordertofindthecorrectoilviscositygradeforthemachinecompartment.

•Atthespecifiedinterval,servicetheengineorservicetheothermachinecompartments.Use appropriatenewoilandinstallanappropriatenewoilfilter.

i02870032

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Product:COMPACTWHEELLOADER

Model:902COMPACTWHEELLOADER7ES

Configuration:902CompactWheelLoader7ES00001-UP(MACHINE)POWEREDBY3024Engine

MediaNumber-SEBU7137-02PublicationDate-01/09/1998DateUpdated-12/05/2004

ArticulationBearings-Lubricate

SMCS-7057-086;7065-086;7066-086

Wipethegreasefittingsbeforeyoulubricatethegreasefittings.

i00664171

Illustration2g00292730

Applylubricanttotheremotegreasefittingsforthepivotbearings. Thereisatotaloftwogreasefittings.

ThuMar1110:26:26UTC+05302021

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Product:COMPACTWHEELLOADER

Model:902COMPACTWHEELLOADER7ES

Configuration:902CompactWheelLoader7ES00001-UP(MACHINE)POWEREDBY3024Engine OperationandMaintenanceManual 902and906CompactWheelLoaders

MediaNumber-SEBU7137-02PublicationDate-01/09/1998DateUpdated-12/05/2004

AxleOscillationBearings-Lubricate

SMCS-3268-086;3278-086

Wipeallgreasefittingsbeforeyouapplygreasetothefittings.

i00663589

Illustration2g00292732

Applygreasetotheremotegreasefittingsfortheaxleoscillationbearings. Thereisatotaloftwogreasefittings.

ThuMar1110:26:52UTC+05302021

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Product:COMPACTWHEELLOADER

Model:902COMPACTWHEELLOADER7ES

Configuration:902CompactWheelLoader7ES00001-UP(MACHINE)POWEREDBY3024Engine

MediaNumber-SEBU7137-02PublicationDate-01/09/1998DateUpdated-12/05/2004

BackupAlarm-Test

SMCS-7406-081

Thebackupalarmismountedbelowtheradiatorintheenginecompartment. Thebackupalarmhasonesoundlevel.Thesoundlevelisnotadjustable.

TurntheenginestartswitchkeytotheONpositioninordertoperformthetest. Applytheservicebrake.MovethedirectioncontrolswitchtotheREVERSEposition.

i01390799

Thebackupalarmshouldimmediatelysound.Thebackupalarmwillcontinuetosounduntilthe directioncontrolswitchismovedtotheNEUTRALpositionortotheFORWARDposition.

ThuMar1110:27:15UTC+05302021

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Product:COMPACTWHEELLOADER

Model:902COMPACTWHEELLOADER7ES

Configuration:902CompactWheelLoader7ES00001-UP(MACHINE)POWEREDBY3024Engine OperationandMaintenanceManual 902and906CompactWheelLoaders

MediaNumber-SEBU7137-02PublicationDate-01/09/1998DateUpdated-12/05/2004

Battery-Inspect

SMCS-1401-040

Tightenallofthebatteryretainersatevery1000hours. Checkthefollowingitemsatevery1000hours.Ifnecessary,checkthefollowingitemsmoreoften.

•Cleanthetopofthebatterieswithacleancloth.

•Cleanthebatteryterminals.Asneeded,coatthebatteryterminalswithpetroleumjelly.

i00714635

2.Removethebatterycoverinordertoattaintheposts.

3.Cleanthebatterysurfacewithacleancloth.Keeptheterminalscleanandkeeptheterminals coatedwithpetroleumjelly.Installthepostcoverafteryoucoatthepostwithpetroleumjelly.

4.Replacethebatterycover.

5.Closetheaccesspanel.

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Product:COMPACTWHEELLOADER

Model:902COMPACTWHEELLOADER7ES

Configuration:902CompactWheelLoader7ES00001-UP(MACHINE)POWEREDBY3024Engine

OperationandMaintenanceManual 902and906CompactWheelLoaders

MediaNumber-SEBU7137-02PublicationDate-01/09/1998DateUpdated-12/05/2004

Battery-Recycle

SMCS-1401-561

Alwaysrecycleabattery.Neverdiscardabattery.Returnusedbatteriestooneofthefollowing locations:

•Abatterysupplier

•Anauthorizedbatterycollectionfacility

•Arecyclingfacility

ThuMar1110:27:46UTC+05302021

i02039199

This is the sample of the manual Click on the download link for complete Manual

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Product:COMPACTWHEELLOADER

Model:902COMPACTWHEELLOADER7ES

Configuration:902CompactWheelLoader7ES00001-UP(MACHINE)POWEREDBY3024Engine OperationandMaintenanceManual 902and906CompactWheelLoaders

MediaNumber-SEBU7137-02PublicationDate-01/09/1998DateUpdated-12/05/2004

Battery,BatteryCableorBatteryDisconnectSwitch-Replace

SMCS-1401-510;1402-510;1411-510

1.TurntheenginestartswitchtotheOFFposition.TurnallswitchestotheOFFposition.

Illustration1g00295810

2.Opentheaccesspanelontheleftsideofthemachine.

i00703014

3.Ifthemachineisequippedwithabatterydisconnectswitch,turntheswitchtotheOFFposition. Removethebatterydisconnectswitchkey.

Note:Ifthemachineisnotequippedwithabatterydisconnectswitch,disconnectthenegative batterycablefromtheframe.Then,continuewithstep5.

NOTICE

Donotallowthedisconnectedbatterycabletocontactthedisconnect switch.

4.Atthebatterydisconnectswitch,disconnectthenegativebatterycablethatisconnectedtothe frame. Illustration3g00348192

5.Removethebatterycover.Disconnectthenegativebatterycableatthebattery.

6.Performthenecessaryrepairs.Replacethecableorthebattery,asneeded.

7.Connectthenegativebatterycableatthebattery.Replacethebatterycover.

8.Connectthebatterycableatthebatterydisconnectswitch,ifequipped.Ifthemachineisnot equippedwithabatterydisconnectswitch,connectthenegativecabletotheframe.

9.Installthebatterydisconnectswitchkey.TurnthebatterydisconnectswitchtotheONposition.

ThuMar1110:28:31UTC+05302021

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Product:COMPACTWHEELLOADER

Model:902COMPACTWHEELLOADER7ES

Configuration:902CompactWheelLoader7ES00001-UP(MACHINE)POWEREDBY3024Engine

OperationandMaintenanceManual 902and906CompactWheelLoaders

MediaNumber-SEBU7137-02PublicationDate-01/09/1998DateUpdated-12/05/2004

BatteryElectrolyteLevel-Check

SMCS-1401-535-FLV Table1 BATTERYELECTROLYTE

Battery Interval

Conventional100Hours

LowMaintenance250Hours

MaintenanceFreeMaintenanceFree

Tightenthebatteryretainersatevery1000hours.

Checkthefollowingitemsatevery1000hours.Ifnecessary,checkthefollowingitemsmoreoften.

•Cleanthetopofthebatterieswithacleancloth.

•Cleanthebatteryterminals.Asneeded,coatthebatteryterminalswithpetroleumjelly.

Abatteryshouldnotrequiremorethan30cc(1oz)ofwaterpercellperweek.Thisshouldexistwith theproperchargingrateandwithamoderateclimate.

Inextremetemperatures,checkthewaterinthecellsweekly.

i00662832

Illustration1g00295810

1.Opentheaccesspanelthatislocatedontheleftsideofthemachine.

Illustration2g00348192

2.Removethebatterycover.

3.Cleanthebatterysurfacewithacleancloth.Keeptheterminalscleanandkeeptheterminals coatedwithpetroleumjelly.Installthepostcoverafteryoucoatthepostwithpetroleumjelly.

4.Inspecttheelectrolytelevelineachbatterycell.Amaintenancefreebatterydoesnotrequire inspection.Maintaintheelectrolyteleveltothebottomofthefilleropenings.Usedistilled water.Ifdistilledwaterisnotavailable,usecleandrinkingwater.

5.Replacethebatterycover.

ThuMar1110:28:07UTC+05302021

Product:COMPACTWHEELLOADER

Model:902COMPACTWHEELLOADER7ES

Configuration:902CompactWheelLoader7ES00001-UP(MACHINE)POWEREDBY3024Engine

OperationandMaintenanceManual 902and906CompactWheelLoaders

MediaNumber-SEBU7137-02PublicationDate-01/09/1998DateUpdated-12/05/2004 i01979163

Belts-Inspect/Adjust/Replace

SMCS-1357-025;1357-040;1357-510;1359-040;1359-510;1359-025;1361-025;1361-040;1361510;1405-040;1405-510;1405-025;7320-025;7320-040;7320-510

Ifanewbeltisinstalled,checkthebeltadjustmentafter30minutesofoperation.Abeltisconsidered tobeusedafter30minutesofoperation.

Stoptheengineinordertoinspectthebelts.

Inspecttheconditionofthebeltsandtheadjustmentofthebelts.Thebeltsshoulddeflect17±3mm (0.7±0.1inch)underastraightpullof110N(25lb).Thismeasurementshouldbetakenbetweenthe alternatorpulleyandthecrankshaftpulleyorthismeasurementshouldbetakenbetweenthe crankshaftpulleyandtheairconditionercompressorpulley.

Note:A144-0235BorroughsBeltTensionGaugemaybeusedtomeasurebelttension. Table1

902and906

Illustration2g00918578

Illustration3g01026323

906MER1-UP

908TAR1-UP

1.RemovetheguardfortheV-belts.

2.Loosenthebolts(1)and(2).

3.Movethealternatoruntilthecorrecttensionisreached.

4.Tightenthebolts.

5.Recheckthebeltdeflection.Iftheamountofdeflectionisincorrect,repeattheadjustment procedure.

6.Repeattheprocedurefortheairconditioningcompressorbelt(ifequipped).

7.InstalltheguardfortheV-belts.

ThuMar1110:48:12UTC+05302021

Product:COMPACTWHEELLOADER

Model:902COMPACTWHEELLOADER7ES

Configuration:902CompactWheelLoader7ES00001-UP(MACHINE)POWEREDBY3024Engine

BrakePads-Check

Thebrakepadsarelocatedbehindthefrontaxleonthedriveshaft.Measurethethicknessofthebrake pads.Ifthethicknessofeitherofthetwobrakepadsislessthan4.00mm(0.16inch),replacethe brakepads.RefertoDisassemblyandAssembly,SENR1293,"BrakeCaliper-Remove"and DisassemblyandAssembly,SENR1293,"BrakeCaliper-Install".

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Product:COMPACTWHEELLOADER

Model:902COMPACTWHEELLOADER7ES

Configuration:902CompactWheelLoader7ES00001-UP(MACHINE)POWEREDBY3024Engine

OperationandMaintenanceManual 902and906CompactWheelLoaders

MediaNumber-SEBU7137-02PublicationDate-01/09/1998DateUpdated-12/05/2004

BrakingSystem-Test

SMCS-4011-081;4267-081

ServiceBrakeHoldingAbilityTest

Personalinjurycanresultifthemachinemoveswhiletesting.

Ifthemachinebeginstomoveduringtest,reducetheenginespeed immediatelyandengagetheparkingbrake.

Checktheareaaroundthemachine.Makesurethatthemachineisclearofpersonnelandclearof obstacles.

MakesurethatthesteeringframelocklinkisintheSTOREDposition. Testthebrakesonadry25%slope.

Fastentheseatbeltbeforeyoutestthebrakes.

Thefollowingtestsareusedtodetermineiftheservicebrakeisfunctional.Thesetestsarenot intendedtomeasurethemaximumbrakeholdingeffort.

1.Starttheengine.Raisetheworktoolslightly.

2.Applytheservicebrake.Releasetheparkingbrake.

i01156334

Themachineshouldnotmoveunderthefollowingconditions. Theengineisatlowidle.

Thebucketisempty.

Themachineiswarmedupandthemachineisfullystopped.

Theparkingbrakeisfirmlydepressed.

Ifthemachinemoves,consultyourCaterpillardealer.

3.Engagetheparkingbrake.Lowertheworktooltotheground.Stoptheengine.

NOTICE

Ifthemachinemovedwhiletestingthebrakes,contactyour Caterpillardealer.Havethedealerinspectand,ifnecessary,repairthe servicebrakebeforereturningthemachinetooperation.

SecondaryBrakeHoldingAbilityTest

Checktheareaaroundthemachine.Makesurethatthemachineisclearofpersonnelandclearof obstacles.

MakesurethatthesteeringframelocklinkisintheSTOREDposition. Testthebrakesonadry25%slope.

Fastentheseatbeltbeforeyoutestthebrakes.

Thefollowingtestsareusedtodetermineiftheparkingbrakeisfunctional.Thesetestsarenot intendedtomeasurethemaximumbrakeholdingeffort.

1.Starttheengine.Raisetheworktoolslightly.

2.Engagetheparkingbrake.

Note:Theparkingbrakeindicatorlightshouldcomeonandtheparkingbrakelightshould flash.

Themachineshouldnotmoveunderthefollowingconditions. Theengineisatlowidle.

Thebucketisempty.

Themachineiswarmedupandthemachineisfullystopped. Theparkingbrakeispulledupfirmly.

Ifthemachinemoves,consultyourCaterpillardealer.

Ifthemachinebeginstomove,reducetheenginespeedimmediatelyand applytheservicebrakepedal.

3.Lowerthebuckettotheground.Stoptheengine.

NOTICE

Ifthemachinemovedwhiletestingthebrakes,contactyour Caterpillardealer.

Havethedealerinspectand,ifnecessary,repairtheparkingbrakes beforereturningthemachinetooperation.

ThuMar1110:29:21UTC+05302021

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Product:COMPACTWHEELLOADER

Model:902COMPACTWHEELLOADER7ES

Configuration:902CompactWheelLoader7ES00001-UP(MACHINE)POWEREDBY3024Engine

OperationandMaintenanceManual 902and906CompactWheelLoaders

MediaNumber-SEBU7137-02PublicationDate-01/09/1998DateUpdated-12/05/2004

BucketCuttingEdges-Inspect/Replace

SMCS-6801-040;6801-510

Personalinjuryordeathcanresultfrombucketfalling. Blockthebucketbeforechangingbucketcuttingedges.

1.Raisethebucket.Placeablockunderthebucket.

2.Lowerthebuckettotheblocking.

Donotblockupthebuckettoohigh.Blockupthebucketsothatthebucketishighenoughto removethecuttingedgesandtheendbits.

3.Removethebolts.Removethecuttingedgeandtheendbits.

4.Cleanthecontactsurfaces.

5.Usetheoppositesideofthecuttingedge,ifthissideisnotworn.

6.Installanewcuttingedge,ifbothedgesareworn.

7.Installthebolts.Tightentheboltstothespecifiedtorque.

8.Raisethebucket.Removetheblocks.

9.Lowerthebuckettotheground.

i01920076

10.Afterafewhoursofoperation,checktheboltsforpropertorque.

ThuMar1110:32:47UTC+05302021

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Product:COMPACTWHEELLOADER

Model:902COMPACTWHEELLOADER7ES

Configuration:902CompactWheelLoader7ES00001-UP(MACHINE)POWEREDBY3024Engine OperationandMaintenanceManual 902and906CompactWheelLoaders

MediaNumber-SEBU7137-02PublicationDate-01/09/1998DateUpdated-12/05/2004

TiltCylinderBearingsandBucketLinkageBearingsLubricate

SMCS-5104-086;6107-086

Wipeallgreasefittingsbeforeyouapplylubricant.

Illustration1g00292889

Lubricatethegreasefitting(1)fortheheadendofthetiltcylinder.

Lubricatethegreasefitting(2)fortherodendofthetiltcylinder.Thereisonegreasefittinginthe centerofthemachine.

Lubricatethegreasefittings(3)fortheupperpivotpinofthetiltlinkage.Thereisagreasefittingfor eachsideofthemachine.

i00665405

This is the sample of the manual Click on the download link for complete Manual