903C2 Caterpillar Compact Wheel Loader Operation and Maintenance Manual by quality service repair manual

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Product:COMPACTWHEELLOADER

Model:903C2COMPACTWHEELLOADERMW8

Configuration:903C2CompactWheelLoaderMW800001-UP(MACHINE)POWEREDBYC2.4Engine

OperationandMaintenanceManual 903C2CompactWheelLoader

MediaNumber-SEBU9372-06PublicationDate-01/08/2015DateUpdated-13/02/2018

Foreword

SMCS-1000;7000

CaliforniaProposition65Warning

s03548206

DieselengineexhaustandsomeofitsconstituentsareknowntotheStateofCaliforniatocause cancer,birthdefects,andotherreproductiveharm.

WARNING-Thisproductcanexpose youtochemicalsincludingethylene glycol,whichisknowntotheStateof Californiatocausebirthdefectsorother reproductiveharm.Formoreinformation goto:

www.P65Warnings.ca.gov

Donotingestthischemical.Washhandsafterhandlingtoavoidincidentalingestion.

WARNING-Thisproductcanexpose youtochemicalsincludingleadandlead compounds,whichareknowntotheState ofCaliforniatocausecancer,birthdefects, orotherreproductiveharm.Formore informationgoto:

www.P65Warnings.ca.gov

Washhandsafterhandlingcomponentsthatmaycontainlead.

LiteratureInformation

Thismanualshouldbestoredintheoperator'scompartmentintheliteratureholderorseatback literaturestoragearea.

Thismanualcontainssafetyinformation,operationinstructions,transportationinformation, lubricationinformation,andmaintenanceinformation.

Somephotographsorillustrationsinthispublicationshowdetailsorattachmentsthatcanbedifferent fromyourmachine.Guardsandcoversmighthavebeenremovedforillustrativepurposes.

Continuingimprovementandadvancementofproductdesignmighthavecausedchangestoyour machinewhicharenotincludedinthispublication.Read,study,andkeepthismanualwiththe machine.

Wheneveraquestionarisesregardingyourmachine,orthispublication,pleaseconsultyourCat dealerforthelatestavailableinformation.

Safety

Thesafetysectionlistsbasicsafetyprecautions.Inaddition,thissectionidentifiesthetextand locationsofwarningsignsandlabelsusedonthemachine.

Readandunderstandthebasicprecautionslistedinthesafetysectionbeforeoperatingorperforming lubrication,maintenance,andrepaironthismachine.

Operation

Theoperationsectionisareferenceforthenewoperatorandarefresherfortheexperiencedoperator. Thissectionincludesadiscussionofgauges,switches,machinecontrols,attachmentcontrols, transportation,andtowinginformation.

Photographsandillustrationsguidetheoperatorthroughcorrectproceduresofchecking,starting, operating,andstoppingthemachine.

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.)canbeusedinsteadofservicehourmeterintervalsifthecalendarintervalsprovide moreconvenientservicingschedulesandapproximatetheindicatedservicehourmeterreading. Performtherecommendedserviceattheintervalthatoccursfirst.

Undersevere,dusty,orwetoperatingconditions,morefrequentlubricationthanisspecifiedinthe maintenanceintervalschartmightbenecessary.

Performserviceonitemsatmultiplesoftheoriginalrequirement.Forexample,atevery500service hoursor3months,alsoservicethoseitemslistedunderevery250servicehoursormonthlyandevery 10servicehoursordaily.

CertifiedEngineMaintenance

Propermaintenanceandrepairareessentialtokeeptheengineandmachinesystemsoperating correctly.Astheheavy-dutyoff-roaddieselengineowner,youareresponsiblefortheperformanceof therequiredmaintenancelistedintheOwnerManual,OperationandMaintenanceManual,and ServiceManual.

Itisprohibitedforanypersonengagedinthebusinessofrepairing,servicing,selling,leasing,or tradingenginesormachinestoremove,alter,ortorenderinoperative,anyemission-relateddeviceor elementofdesigninstalledonorinanengineormachinethatisincompliancewithallapplicable regulationsoftheintendedcountrytowhichithasbeenshipped.Certainelementsofthemachineand enginesuchastheexhaustsystem,fuelsystem,electricalsystem,intakeairsystem,andcooling systemmaybeemission-relatedandshouldnotbealteredunlessapprovedbyCaterpillar.

MachineCapacity

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

ProductIdentificationNumber

EffectiveFirstQuarter2001theProductIdentificationNumber(PIN)haschangedfrom8to17 characters.Toprovideuniformequipmentidentification,constructionequipmentmanufacturersare movingtocomplywiththelatestversionoftheproductidentificationnumberingstandard.Non-road machinePINsaredefinedbyISO10261.ThenewPINformatwillapplytoallmachinesand generatorsets.ThePINplatesandframemarkingwilldisplaythe17characterPIN.Thenewformat willlooklikethefollowing:

Illustration1g03891925

Where:

1.WorldManufacturingCode(characters1-3)

2.MachineDescriptor(characters4-8)

3.CheckCharacter(character9)

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

MachinesandgeneratorsetsproducedbeforeFirstQuarter2001willmaintaintheir8characterPIN format.

Componentssuchasengines,transmissions,axles,andworktoolswillcontinuetousean8character SerialNumber(S/N).

TueFeb210:33:35UTC+05302021

PreviousScreen

Product:COMPACTWHEELLOADER

Model:903C2COMPACTWHEELLOADERMW8

Configuration:903C2CompactWheelLoaderMW800001-UP(MACHINE)POWEREDBYC2.4Engine

OperationandMaintenanceManual 903C2CompactWheelLoader

MediaNumber-SEBU9372-06PublicationDate-01/08/2015DateUpdated-13/02/2018 i06231877

AccessDoorsandCovers

SMCS-7273-572;7273-573

Thebatteryislocatedontherightsideattherearofmachine.

Illustration2g03368305

Thecircuitbreakerandmainrelaysarelocatedbehindtheaccessdoorontherightside.

Illustration3g03865011

Thefusepanelislocatedbehindthedoorundertheseat.

EngineHood

Illustration4g03345838 Pushthebutton(1)andraisetheenginehooduntilthehoodsupportlocksinposition.

Illustration5g03345856

Pushthebottomofthegascylinder(2)ofthehingeinordertolowerthehood.Lowerthehooduntil thehoodlatches.

TueFeb210:47:25UTC+05302021

PreviousScreen

Product:COMPACTWHEELLOADER

Model:903C2COMPACTWHEELLOADERMW8

Configuration:903C2CompactWheelLoaderMW800001-UP(MACHINE)POWEREDBYC2.4Engine

OperationandMaintenanceManual 903C2CompactWheelLoader

MediaNumber-SEBU9372-06PublicationDate-01/08/2015DateUpdated-13/02/2018

AirCleanerDustValve-Clean/Inspect

SMCS-1051-571-VL

1.Opentheenginehood.

2.Theairfilterhousingislocatedontheleftsideoftheenginecompartment.

i06176662

3.Checkthedustvalveafterevery10servicehoursorattheendofeachday.Actuatethevalve bysqueezingthelipsofthevalveinordertoremoveanyaccumulateddebris.

4.Closetheenginehood.

TueFeb210:52:57UTC+05302021

PreviousScreen

Product:COMPACTWHEELLOADER

Model:903C2COMPACTWHEELLOADERMW8

Configuration:903C2CompactWheelLoaderMW800001-UP(MACHINE)POWEREDBYC2.4Engine

OperationandMaintenanceManual 903C2CompactWheelLoader

MediaNumber-SEBU9372-06PublicationDate-01/08/2015DateUpdated-13/02/2018

ArticulationBearings-Lubricate

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

Thegreasefittingsforthearticulationbearingsareaccessedontheleftside.

i06176741

Illustration2g03837536

1.Wipethegreasefittingsbeforeyoulubricatethegreasefittings.

2.Applylubricanttothegreasefittingsforthearticulationbearings.

TueFeb210:53:36UTC+05302021

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

PreviousScreen

Product:COMPACTWHEELLOADER

Model:903C2COMPACTWHEELLOADERMW8

Configuration:903C2CompactWheelLoaderMW800001-UP(MACHINE)POWEREDBYC2.4Engine

OperationandMaintenanceManual 903C2CompactWheelLoader

MediaNumber-SEBU9372-06PublicationDate-01/08/2015DateUpdated-13/02/2018

AxleOscillationBearings-Lubricate

SMCS-3268-086-BD;3278-086-BD

Illustration1g06274952

Thegreasefittingsfortheaxleoscillationbearingsareaccessedontheleftside.

i07286959

Illustration2g06274953 (1)AxleOscillationbearingsgreasezerks

Wipethegreasefittings(1)beforeyoulubricatethegreasefittings. Applylubricanttotheremotegreasefittingsfortheaxleoscillationbearings.

TueFeb210:53:49UTC+05302021

PreviousScreen

Product:COMPACTWHEELLOADER

Model:903C2COMPACTWHEELLOADERMW8

Configuration:903C2CompactWheelLoaderMW800001-UP(MACHINE)POWEREDBYC2.4Engine

OperationandMaintenanceManual 903C2CompactWheelLoader

MediaNumber-SEBU9372-06PublicationDate-01/08/2015DateUpdated-13/02/2018

BackupAlarm-Test

SMCS-7406-081

Thebackupalarmismountedintheleftsideofcounterweight.

Thebackupalarmhasonesoundlevel.Thesoundlevelisnotadjustable.

TurntheenginestartswitchkeytotheONpositioninordertoperformthetest. Applytheservicebrake.MovethedirectioncontrolswitchtotheREVERSEposition.

i05321057

Thebackupalarmshouldimmediatelysound.Thebackupalarmwillcontinuetosounduntilthe directioncontrolswitchismovedtotheNEUTRALpositionortotheFORWARDposition.

TueFeb210:54:03UTC+05302021

PreviousScreen

Product:COMPACTWHEELLOADER

Model:903C2COMPACTWHEELLOADERMW8

Configuration:903C2CompactWheelLoaderMW800001-UP(MACHINE)POWEREDBYC2.4Engine

OperationandMaintenanceManual 903C2CompactWheelLoader

MediaNumber-SEBU9372-06PublicationDate-01/08/2015DateUpdated-13/02/2018

i05254556

BatteryorBatteryCable-Inspect/Replace

SMCS-1401-040;1401-510;1402-040;1402-510

1.TurntheenginestartswitchtotheOFFposition.TurnallswitchestotheOFFposition.

LocationofBattery

2.Thebatteryislocatedontherightsideattherearofmachine.

Thebatterycablesorthebatteriesshouldnotberemovedwiththe batterycoverinplace.Thebatterycovershouldberemovedbeforeany servicingisattempted.

Removingthebatterycablesorthebatterieswiththecoverinplacemay causeabatteryexplosionresultinginpersonalinjury.

3.Disconnectthenegativebatterycableatthebattery.

4.Performthenecessaryrepairs.Replacethecableorthebattery,asneeded.

5.Disconnectthepositivebatterycable.Removetheoldbatteryfromthemachine.

6.Placethenewbatteryinthemachine.Connectthepositivebatterycabletothebattery.

7.Connectthenegativebatterycableatthebattery.

8.Closethebatterycover.

RecycletheBattery

Alwaysrecycleabattery.Neverdiscardabattery.

Alwaysreturnusedbatteriestooneofthefollowinglocations:

•Abatterysupplier

•Anauthorizedbatterycollectionfacility

•Recyclingfacility

AllRightsReserved.

PrivateNetworkForSISLicensees.

TueFeb210:54:17UTC+05302021

Product:COMPACTWHEELLOADER

Model:903C2COMPACTWHEELLOADERMW8

Configuration:903C2CompactWheelLoaderMW800001-UP(MACHINE)POWEREDBYC2.4Engine

OperationandMaintenanceManual 903C2CompactWheelLoader

MediaNumber-SEBU9372-06PublicationDate-01/08/2015DateUpdated-13/02/2018

Belts-Inspect/Adjust/Replace

SMCS-1357-025;1357-040;1357-510

i06177835

Ifanewbeltisinstalled,checkthebeltadjustmentafter30minutesofoperation.Abeltisconsidered usedafter30minutesofoperation.

Stoptheengineinordertoinspectthebelts.

Inspecttheconditionofthebeltsandtheadjustmentofthebelts.Thebeltsshoulddeflect7mm (0.28inch)to9mm(0.35inch)underastraightpushof98N(22lb).Theairconditioningcompressor beltshoulddeflect8mm(0.32inch)to11mm(0.43inch)underastraightpushof98N(22lb).This measurementshouldbetakenbetweenthealternatorpulleyandthecrankshaftpulleyorthis measurementshouldbetakenbetweenthecrankshaftpulleyandtheairconditionercompressor pulley.

Note:A144-0235BorroughsBeltTensionGaugemaybeusedtomeasurebelttension.

Illustration1g03838367

1.7L(901C2)

Illustration2g03838406 C2.4(902C2/903C2)

Illustration3g03865116

1.Loosenthebolts(1).

2.Movethealternatoruntilthecorrecttensionisreached.

3.Tightenthebolts.

4.Recheckthebeltdeflection.Iftheamountofdeflectionisincorrect,repeattheadjustment procedure.

5.Ensurethatthewiringharnessfromthealternatorisintheproperlocation.

TueFeb210:54:51UTC+05302021

Product:COMPACTWHEELLOADER

Model:903C2COMPACTWHEELLOADERMW8

Configuration:903C2CompactWheelLoaderMW800001-UP(MACHINE)POWEREDBYC2.4Engine

OperationandMaintenanceManual 903C2CompactWheelLoader

MediaNumber-SEBU9372-06PublicationDate-01/08/2015DateUpdated-13/02/2018

BrakeandInchingPedalInspection

SMCS-3162-040;4269-040

(1)Checkifthestrokeissettoanappropriatevalue.

Note:Setstroketo15.7mm.

i06239911

(2)Checktheofficialstrokeusingatapemeasure.Normallythestrokeischeckedbysteppingonthe pedal.

(3)Ifthestrokeisnotsettoanappropriatevalue,consultyourCatdealer.

TueFeb210:55:19UTC+05302021

PreviousScreen

Product:COMPACTWHEELLOADER

Model:903C2COMPACTWHEELLOADERMW8

Configuration:903C2CompactWheelLoaderMW800001-UP(MACHINE)POWEREDBYC2.4Engine

OperationandMaintenanceManual 903C2CompactWheelLoader

MediaNumber-SEBU9372-06PublicationDate-01/08/2015DateUpdated-13/02/2018

BrakingSystem-Test

SMCS-4011-081;4267-081

ServiceBrakeHoldingAbilityTest

Personalinjurycanresultifthemachinemoveswhiletesting.

Ifthemachinebeginstomoveduringtest,reducetheenginespeed immediatelyandengagetheparkingbrake.

i05321465

Checktheareaaroundthemachine.Makesurethatthemachineisclearofpersonnelandclearof obstacles.

MakesurethatthesteeringframelocklinkisintheSTOREDposition. Testthebrakesonadry25%slope.

Fastentheseatbeltbeforeyoutestthebrakes.

Thefollowingtestsareusedtodetermineiftheservicebrakeisfunctional.Thesetestsarenot intendedtomeasurethemaximumbrakeholdingeffort.

1.Starttheengine.Raisetheworktoolslightly.

2.Applytheservicebrake.Releasetheparkingbrake.

Themachineshouldnotmoveunderthefollowingconditions. Theengineisatlowidle.

Thebucketisempty.

Themachineiswarmedupandthemachineisfullystopped.

Theservicebrakeisfirmlydepressed.

Ifthemachinemoves,consultyourCaterpillardealer.

3.Engagetheparkingbrake.Lowertheworktooltotheground.Stoptheengine.

NOTICE

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

TueFeb210:55:33UTC+05302021

PreviousScreen

Product:COMPACTWHEELLOADER

Model:903C2COMPACTWHEELLOADERMW8

Configuration:903C2CompactWheelLoaderMW800001-UP(MACHINE)POWEREDBYC2.4Engine

OperationandMaintenanceManual 903C2CompactWheelLoader

MediaNumber-SEBU9372-06PublicationDate-01/08/2015DateUpdated-13/02/2018

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.

TueFeb210:56:14UTC+05302021

PreviousScreen

Product:COMPACTWHEELLOADER

Model:903C2COMPACTWHEELLOADERMW8

Configuration:903C2CompactWheelLoaderMW800001-UP(MACHINE)POWEREDBYC2.4Engine

OperationandMaintenanceManual 903C2CompactWheelLoader

MediaNumber-SEBU9372-06PublicationDate-01/08/2015DateUpdated-13/02/2018

CabAirFilter-Clean/Replace

SMCS-7342-070;7342-510

i06232625

Note:Cleanthefilterelementsmoreoftenindustyconditions.Ifthereisanoticeablereductioninthe airflowfromtheairvents,checkthefilterelements.

CleanExternalFilterElement(IfEquipped)

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/m2/2/2021 ...

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