904B Caterpillar Compact Wheel Loader Operation and Maintenance Manual by quality service repair manual

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Product:COMPACTWHEELLOADER

Model:904BCOMPACTWHEELLOADERB4L

Configuration:904BCompactWheelLoaderB4L00001-UP(MACHINE)POWEREDBYS4Q2TEngine

OperationandMaintenanceManual 904BCompactWheelLoader

MediaNumber-SEBU7891-03PublicationDate-01/10/2009DateUpdated-28/10/2009

Foreword

SMCS-1000;7000;7405

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).

TueFeb210:14:51UTC+05302021

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Product:COMPACTWHEELLOADER

Model:904BCOMPACTWHEELLOADERB4L

Configuration:904BCompactWheelLoaderB4L00001-UP(MACHINE)POWEREDBYS4Q2TEngine

OperationandMaintenanceManual 904BCompactWheelLoader

MediaNumber-SEBU7891-03PublicationDate-01/10/2009DateUpdated-28/10/2009

AccessDoorsandCovers

SMCS-7273-572;7273-573

i02279457

Illustration2g01141018

Thewindshieldwasherreservoirislocatedbehindtheaccessdoorontherightside.

EngineHood

Illustration3g01141027

Pushthebutton(1)andraisetheenginehooduntilthehoodsupportlocksinposition.

Illustration4g01141028

Pulltheknob(2)ofthehingeinordertolowerthehood.Lowerthehooduntilthehoodlatches.

TueFeb215:17:28UTC+05302021

PreviousScreen

Product:COMPACTWHEELLOADER

Model:904BCOMPACTWHEELLOADERB4L

Configuration:904BCompactWheelLoaderB4L00001-UP(MACHINE)POWEREDBYS4Q2TEngine

OperationandMaintenanceManual 904BCompactWheelLoader

MediaNumber-SEBU7891-03PublicationDate-01/10/2009DateUpdated-28/10/2009

ArticulationBearings-Lubricate

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

Thegreasefittingsforthearticulationbearingsareaccessedontheleftside.

i02275117

Illustration2g01139575

Wipethegreasefittings(1)beforeyoulubricatethegreasefittings. Applylubricanttothegreasefittingsforthearticulationbearings.

TueFeb215:20:14UTC+05302021

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Product:COMPACTWHEELLOADER

Model:904BCOMPACTWHEELLOADERB4L

Configuration:904BCompactWheelLoaderB4L00001-UP(MACHINE)POWEREDBYS4Q2TEngine

OperationandMaintenanceManual 904BCompactWheelLoader

MediaNumber-SEBU7891-03PublicationDate-01/10/2009DateUpdated-28/10/2009

AxleOscillationBearings-Lubricate

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

Thegreasefittingsfortheaxleoscillationbearingsareaccessedontheleftside.

i02293379

Illustration1g01139574

Illustration2g01148656

Wipethegreasefittings(1)beforeyoulubricatethegreasefittings. Applylubricanttotheremotegreasefittingsfortheaxleoscillationbearings.

TueFeb215:20:27UTC+05302021

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Product:COMPACTWHEELLOADER

Model:904BCOMPACTWHEELLOADERB4L

Configuration:904BCompactWheelLoaderB4L00001-UP(MACHINE)POWEREDBYS4Q2TEngine

OperationandMaintenanceManual 904BCompactWheelLoader

MediaNumber-SEBU7891-03PublicationDate-01/10/2009DateUpdated-28/10/2009

BackupAlarm-Test

SMCS-7406-081

Thebackupalarmismountedbelowtheradiatorintheenginecompartment. Thebackupalarmhasonesoundlevel.Thesoundlevelisnotadjustable.

TurntheenginestartswitchkeytotheONpositioninordertoperformthetest. Applytheservicebrake.MovethedirectioncontrolswitchtotheREVERSEposition.

i01390799

Thebackupalarmshouldimmediatelysound.Thebackupalarmwillcontinuetosounduntilthe directioncontrolswitchismovedtotheNEUTRALpositionortotheFORWARDposition.

TueFeb215:20:41UTC+05302021

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

PreviousScreen

Product:COMPACTWHEELLOADER

Model:904BCOMPACTWHEELLOADERB4L

Configuration:904BCompactWheelLoaderB4L00001-UP(MACHINE)POWEREDBYS4Q2TEngine

OperationandMaintenanceManual 904BCompactWheelLoader

MediaNumber-SEBU7891-03PublicationDate-01/10/2009DateUpdated-28/10/2009 i03738384

BatteryorBatteryCable-Inspect/Replace

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

1.TurntheenginestartswitchtotheOFFposition.TurnallswitchestotheOFFposition.

2.Thebatteryislocatedundertheaccesspanelontheleftsideofthemachine.Opentheaccess panel.

Thebatterycablesorthebatteriesshouldnotberemovedwiththe batterycoverinplace.Thebatterycovershouldberemovedbeforeany servicingisattempted.

Removingthebatterycablesorthebatterieswiththecoverinplace maycauseabatteryexplosionresultinginpersonalinjury.

3.Disconnectthenegativebatterycableatthebattery.

4.Performthenecessaryrepairs.Replacethecableorthebattery,asneeded.

Illustration2g01152902

5.Inordertoremovethebattery,thebatterycovermustberemoved.Removethebolts(1)that holdthecoverinplace.Removethecover.

6.Disconnectthepositivebatterycable.Removetheoldbatteryfromthemachine.

7.Placethenewbatteryinthemachine.Connectthepositivebatterycabletothebattery.

8.Replacethebatterycoverandthefourbolts.

9.Connectthenegativebatterycableatthebattery.

RecycletheBattery

Alwaysrecycleabattery.Neverdiscardabattery.

Alwaysreturnusedbatteriestooneofthefollowinglocations:

•Abatterysupplier

•Anauthorizedbatterycollectionfacility

•Recyclingfacility

TueFeb215:20:56UTC+05302021

Product:COMPACTWHEELLOADER

Model:904BCOMPACTWHEELLOADERB4L

Configuration:904BCompactWheelLoaderB4L00001-UP(MACHINE)POWEREDBYS4Q2TEngine

OperationandMaintenanceManual 904BCompactWheelLoader

MediaNumber-SEBU7891-03PublicationDate-01/10/2009DateUpdated-28/10/2009

Belts-Inspect/Adjust/Replace

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

Ifanewbeltisinstalled,checkthebeltadjustmentafter30minutesofoperation.Abeltisconsidered tobeusedafter30minutesofoperation.

Stoptheengineinordertoinspectthebelts.

Inspecttheconditionofthebeltsandtheadjustmentofthebelts.Thebeltsshoulddeflect10mm (0.39inch)to11mm(0.43inch)underastraightpushof98N(22lb).Thismeasurementshouldbe takenbetweenthealternatorpulleyandthecrankshaftpulleyorthismeasurementshouldbetaken betweenthecrankshaftpulleyandtheairconditionercompressorpulley.

Note:A144-0235BorroughsBeltTensionGaugemaybeusedtomeasurebelttension.

i03112200

Illustration1g01141351

1.Loosenthebolts(1).

2.Movethealternatoruntilthecorrecttensionisreached.

3.Tightenthebolts.

4.Recheckthebeltdeflection.Iftheamountofdeflectionisincorrect,repeattheadjustment procedure.

5.Ensurethatthewiringharnessfromthealternatorisintheproperlocation.

6.Repeattheprocedurefortheairconditioningcompressorbelt(2).

TueFeb215:21:10UTC+05302021

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Product:COMPACTWHEELLOADER

Model:904BCOMPACTWHEELLOADERB4L

Configuration:904BCompactWheelLoaderB4L00001-UP(MACHINE)POWEREDBYS4Q2TEngine

OperationandMaintenanceManual

904BCompactWheelLoader

MediaNumber-SEBU7891-03PublicationDate-01/10/2009DateUpdated-28/10/2009

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.

i02319974

Themachineshouldnotmoveunderthefollowingconditions. Theengineisatlowidle.

Thebucketisempty.

Themachineiswarmedupandthemachineisfullystopped.

Theservicebrakeisfirmlydepressed.

Ifthemachinemoves,consultyourCaterpillardealer.

3.Engagetheparkingbrake.Lowertheworktooltotheground.Stoptheengine.

NOTICE

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

SecondaryBrakeHoldingAbilityTest

Checktheareaaroundthemachine.Makesurethatthemachineisclearofpersonnelandclearof obstacles.

MakesurethatthesteeringframelocklinkisintheSTOREDposition. Testthebrakesonadry20%slope.

Note:ThetestconditionisdifferentfromtheServiceBraketest. Fastentheseatbeltbeforeyoutestthebrakes.

Thefollowingtestsareusedtodetermineiftheparkingbrakeisfunctional.Thesetestsarenot intendedtomeasurethemaximumbrakeholdingeffort.

1.Starttheengine.Raisetheworktoolslightly.

2.Engagetheparkingbrake.Releasetheservicebrakegradually.

Note:Theparkingbrakeindicatorlightshouldcomeonandtheparkingbrakelightshould flash.

Themachineshouldnotmoveunderthefollowingconditions. Theengineisatlowidle.

Thebucketisempty.

Themachineiswarmedupandthemachineisfullystopped.

Theparkingbrakeispulledupfirmly.

Ifthemachinemoves,consultyourCaterpillardealer.

Ifthemachinebeginstomove,reducetheenginespeedimmediatelyand applytheservicebrakepedal.

3.Lowerthebuckettotheground.Stoptheengine.

NOTICE

Ifthemachinemovedwhiletestingthebrakes,contactyour Caterpillardealer.

Havethedealerinspectand,ifnecessary,repairtheparkingbrakes beforereturningthemachinetooperation.

TueFeb215:21:24UTC+05302021

PreviousScreen

Product:COMPACTWHEELLOADER

Model:904BCOMPACTWHEELLOADERB4L

Configuration:904BCompactWheelLoaderB4L00001-UP(MACHINE)POWEREDBYS4Q2TEngine

OperationandMaintenanceManual

904BCompactWheelLoader

MediaNumber-SEBU7891-03PublicationDate-01/10/2009DateUpdated-28/10/2009

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.

TueFeb215:21:38UTC+05302021

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Product:COMPACTWHEELLOADER

Model:904BCOMPACTWHEELLOADERB4L

Configuration:904BCompactWheelLoaderB4L00001-UP(MACHINE)POWEREDBYS4Q2TEngine

OperationandMaintenanceManual 904BCompactWheelLoader

MediaNumber-SEBU7891-03PublicationDate-01/10/2009DateUpdated-28/10/2009

BucketTips-Inspect/Replace

SMCS-6805-040;6805-510

Personalinjuryordeathcanresultfrombucketfalling. Blockthebucketbeforechangingbucketcuttingedges.

1.Lowertheliftarmsfully.Tiltbackthebucketsothatthebuckettipsareaccessible.

2.Placeblocksundertheraisededgeofthebucket.

3.Removethemountingbolts.Removethebuckettips.

4.Cleanthemountingsurface.

5.Replacethebuckettips.

6.Installthebolts.

7.Removetheblocksthatareunderthebucket.

8.Afterafewhoursofoperation,checktheboltsforpropertorque.

TueFeb215:21:53UTC+05302021

PreviousScreen

Product:COMPACTWHEELLOADER

Model:904BCOMPACTWHEELLOADERB4L

Configuration:904BCompactWheelLoaderB4L00001-UP(MACHINE)POWEREDBYS4Q2TEngine

OperationandMaintenanceManual

904BCompactWheelLoader

MediaNumber-SEBU7891-03PublicationDate-01/10/2009DateUpdated-28/10/2009

BucketWearPlates-Inspect/Replace

SMCS-6120-040;6120-510

Personalinjuryordeathcanresultfromfallingbucket. Whenworkingunderoraroundthebucketorlinkage,withthebucket raised,propersupportmustbeprovidedforthebucketand/orthe linkage.

Replacethewearplatesbeforedamagetothebottomofthebucketoccurs.

1.Raisethebucketandblockupthebucket.

2.Loosenboltsandremovewearplates.

3.Installnewwearplates.Tightentheboltstothespecifiedtorque.

Reference:Formoreinformation,refertoSpecifications,SENR3130,"TorqueSpecifications".

TueFeb215:22:06UTC+05302021

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Product:COMPACTWHEELLOADER

Model:904BCOMPACTWHEELLOADERB4L

Configuration:904BCompactWheelLoaderB4L00001-UP(MACHINE)POWEREDBYS4Q2TEngine

OperationandMaintenanceManual 904BCompactWheelLoader

MediaNumber-SEBU7891-03PublicationDate-01/10/2009DateUpdated-28/10/2009

CabAirFilter-Clean/Replace

SMCS-7342-070;7342-510

i02287294

Note:Cleanthefilterelementsmoreoftenindustyconditions.Ifthereisanoticeablereductioninthe airflowfromtheairvents,checkthefilterelements.

CleanExternalFilterElement

Illustration1g01144815

1.Removethethumbscrews(1)thatholdtheexternalcabairfilterinplace.

2.Removethefilterelement.Cleanthefilterelementwithcompressedair.

3.Installthefilterelementandreplacethethumbscrews.

CleanInternalFilterElement

Illustration2g01144817

1.Removethetwonuts(2)thatholdtheinternalcabairfilterinplace.

2.Removethefilterelement.Cleanthefilterelementwithcompressedair.Youcanalsowashthe filterelementswithasolutionofwarmwaterandofanonsudsinghouseholddetergent.

Donotwashthefilterelementwhilethefilterelementisinstalledonthemachine.

3.Rinsethefilterelementincleanwater.Airdrythefilterelementthoroughly.

4.Installthefilterelementandreplacethenuts.

TueFeb215:22:19UTC+05302021

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Product:COMPACTWHEELLOADER

Model:904BCOMPACTWHEELLOADERB4L

Configuration:904BCompactWheelLoaderB4L00001-UP(MACHINE)POWEREDBYS4Q2TEngine

OperationandMaintenanceManual 904BCompactWheelLoader

MediaNumber-SEBU7891-03PublicationDate-01/10/2009DateUpdated-28/10/2009

i02287450

Capacities(Refill) SMCS-7560

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