Product:COMPACTWHEELLOADER
Model:904HCOMPACTWHEELLOADERH4T
Configuration:904HWheelLoaderH4T00001-UP(MACHINE)POWEREDBYS4Q2TEngine
OperationandMaintenanceManual 904HCompactWheelLoader
MediaNumber-SEBU8355-02PublicationDate-01/10/2009DateUpdated-28/10/2009
Foreword
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
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).
Copyright1993-2021CaterpillarInc. AllRightsReserved. PrivateNetworkForSISLicensees.
WedFeb309:34:01UTC+05302021
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Product:COMPACTWHEELLOADER
Model:904HCOMPACTWHEELLOADERH4T
Configuration:904HWheelLoaderH4T00001-UP(MACHINE)POWEREDBYS4Q2TEngine OperationandMaintenanceManual 904HCompactWheelLoader
MediaNumber-SEBU8355-02PublicationDate-01/10/2009DateUpdated-28/10/2009
AccessDoorsandCovers
SMCS-7273-572;7273-573
Thebatteryislocatedbehindtheaccessdoorontheleftside. Illustration2g01517057
Thefusepanelandthewindshieldwasherreservoirarelocatedbehindtheaccessdoorontheright side.
Illustration3g01517058
Pushthebutton(1)andraisetheenginehooduntilthehoodsupportlocksinposition.
Illustration4g01517059
Pulltheknob(2)ofthehingeinordertolowerthehood.Lowerthehooduntilthehoodlatches.
Copyright1993-2021CaterpillarInc. AllRightsReserved. PrivateNetworkForSISLicensees.
WedFeb309:50:57UTC+05302021
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Product:COMPACTWHEELLOADER
Model:904HCOMPACTWHEELLOADERH4T
Configuration:904HWheelLoaderH4T00001-UP(MACHINE)POWEREDBYS4Q2TEngine
OperationandMaintenanceManual 904HCompactWheelLoader
MediaNumber-SEBU8355-02PublicationDate-01/10/2009DateUpdated-28/10/2009
AirCleanerDustValve-Clean/Inspect
SMCS-1051-571-VL
1.Opentheenginehood.
2.Theairfilterhousingislocatedontheleftsideoftheenginecompartment.
i03017978
3.Checkthedustvalveaftereverytenservicehoursorattheendofeachday.Actuatethevalve bysqueezingthelipsofthevalveinordertoremoveanyaccumulateddebris.
4.Closetheenginehood. Copyright1993-2021CaterpillarInc.
WedFeb310:13:41UTC+05302021
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Product:COMPACTWHEELLOADER
Model:904HCOMPACTWHEELLOADERH4T
Configuration:904HWheelLoaderH4T00001-UP(MACHINE)POWEREDBYS4Q2TEngine
OperationandMaintenanceManual 904HCompactWheelLoader
MediaNumber-SEBU8355-02PublicationDate-01/10/2009DateUpdated-28/10/2009
ArticulationBearings-Lubricate
SMCS-7057-086-BD;7065-086-BD;7066-086-BD Illustration1g01523613
Thegreasefittingsforthearticulationbearingsareaccessedontherightside.
Illustration2g01523614
Wipethegreasefittingsbeforeyoulubricatethegreasefittings. Applylubricanttothegreasefittingsforthearticulationbearings.
Copyright1993-2021CaterpillarInc. AllRightsReserved. PrivateNetworkForSISLicensees.
WedFeb310:13:55UTC+05302021
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Product:COMPACTWHEELLOADER
Model:904HCOMPACTWHEELLOADERH4T
Configuration:904HWheelLoaderH4T00001-UP(MACHINE)POWEREDBYS4Q2TEngine
OperationandMaintenanceManual 904HCompactWheelLoader
MediaNumber-SEBU8355-02PublicationDate-01/10/2009DateUpdated-28/10/2009
AxleOscillationBearings-Lubricate
SMCS-3268-086-BD;3278-086-BD
Thegreasefittingsfortheaxleoscillationbearingsareaccessedontheleftside.
i02992062
This is the sample of the manual Click on the download link for complete Manual
Illustration2g01517080
Wipethegreasefittingsbeforeyoulubricatethegreasefittings. Applylubricanttotheremotegreasefittingsfortheaxleoscillationbearings.
Copyright1993-2021CaterpillarInc. AllRightsReserved. PrivateNetworkForSISLicensees.
WedFeb310:15:16UTC+05302021
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Product:COMPACTWHEELLOADER
Model:904HCOMPACTWHEELLOADERH4T
Configuration:904HWheelLoaderH4T00001-UP(MACHINE)POWEREDBYS4Q2TEngine
OperationandMaintenanceManual 904HCompactWheelLoader
MediaNumber-SEBU8355-02PublicationDate-01/10/2009DateUpdated-28/10/2009
BackupAlarm-Test
SMCS-7406-081
Thebackupalarmismountedbelowtheradiatorintheenginecompartment. Thebackupalarmhasonesoundlevel.Thesoundlevelisnotadjustable.
TurntheenginestartswitchkeytotheONpositioninordertoperformthetest. Applytheservicebrake.MovethedirectioncontrolswitchtotheREVERSEposition.
i01390799
Thebackupalarmshouldimmediatelysound.Thebackupalarmwillcontinuetosounduntilthe directioncontrolswitchismovedtotheNEUTRALpositionortotheFORWARDposition.
Copyright1993-2021CaterpillarInc. AllRightsReserved. PrivateNetworkForSISLicensees.
WedFeb310:15:30UTC+05302021
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Product:COMPACTWHEELLOADER
Model:904HCOMPACTWHEELLOADERH4T
Configuration:904HWheelLoaderH4T00001-UP(MACHINE)POWEREDBYS4Q2TEngine
OperationandMaintenanceManual 904HCompactWheelLoader
MediaNumber-SEBU8355-02PublicationDate-01/10/2009DateUpdated-28/10/2009
i03738420
BatteryorBatteryCable-Inspect/Replace
SMCS-1401-040;1401-510;1402-040;1402-510
1.TurntheenginestartswitchtotheOFFposition.TurnallswitchestotheOFFposition.
Illustration1g01523666
Batterycompartment
LocationofBattery
2.Thebatteryislocatedundertheaccesspanelontheleftsideofthemachine.Usetheignition keyinordertoopentheaccesspanel.
Thebatterycablesorthebatteriesshouldnotberemovedwiththe batterycoverinplace.Thebatterycovershouldberemovedbeforeany servicingisattempted.
Removingthebatterycablesorthebatterieswiththecoverinplace maycauseabatteryexplosionresultinginpersonalinjury.
3.Disconnectthenegativebatterycableatthebattery.
4.Performthenecessaryrepairs.Replacethecableorthebattery,asneeded.
5.Disconnectthepositivebatterycable.Removetheoldbatteryfromthemachine.
6.Placethenewbatteryinthemachine.Connectthepositivebatterycabletothebattery.
7.Connectthenegativebatterycableatthebattery.
8.Closethebatterycover.
RecycletheBattery
Alwaysrecycleabattery.Neverdiscardabattery.
Alwaysreturnusedbatteriestooneofthefollowinglocations:
•Abatterysupplier
•Anauthorizedbatterycollectionfacility
•Recyclingfacility
Copyright1993-2021CaterpillarInc.
AllRightsReserved.
PrivateNetworkForSISLicensees.
WedFeb310:20:49UTC+05302021
Product:COMPACTWHEELLOADER
Model:904HCOMPACTWHEELLOADERH4T
Configuration:904HWheelLoaderH4T00001-UP(MACHINE)POWEREDBYS4Q2TEngine
OperationandMaintenanceManual 904HCompactWheelLoader
MediaNumber-SEBU8355-02PublicationDate-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.
Illustration1g01141351
1.Loosenthebolts(1).
2.Movethealternatoruntilthecorrecttensionisreached.
3.Tightenthebolts.
4.Recheckthebeltdeflection.Iftheamountofdeflectionisincorrect,repeattheadjustment procedure.
5.Ensurethatthewiringharnessfromthealternatorisintheproperlocation.
6.Repeattheprocedurefortheairconditioningcompressorbelt(2).
Copyright1993-2021CaterpillarInc.
WedFeb310:21:03UTC+05302021
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Product:COMPACTWHEELLOADER
Model:904HCOMPACTWHEELLOADERH4T
Configuration:904HWheelLoaderH4T00001-UP(MACHINE)POWEREDBYS4Q2TEngine
OperationandMaintenanceManual 904HCompactWheelLoader
MediaNumber-SEBU8355-02PublicationDate-01/10/2009DateUpdated-28/10/2009
BrakeSystemFluid-Change
SMCS-4258-044;7579-044-BRK
Hotoilandcomponentscancausepersonalinjury. Donotallowhotoilorcomponentstocontactskin.
NOTICE
Caremustbetakentoensurethatfluidsarecontainedduring performanceofinspection,maintenance,testing,adjustingandrepair oftheproduct.Bepreparedtocollectthefluidwithsuitablecontainers beforeopeninganycompartmentordisassemblinganycomponent containingfluids.
RefertoSpecialPublication,NENG2500,"CaterpillarDealerService ToolCatalog"fortoolsandsuppliessuitabletocollectandcontain fluidsonCaterpillarproducts.
Disposeofallfluidsaccordingtolocalregulationsandmandates. Purgevalvesforthebrakesystemarelocatedonservicebrakecylinders.Thecylindersarelocatedon thedriveaxle.Accessthepurgevalvesbelowthemachine.
1.Parkthemachineonahard,levelsurface.Stoptheengine.Allowthefluidtocoolforfive minutes.However,thebrakefluidshouldbewarmforthisprocedure.
2.Thoroughlycleantheoutsideofthepurgevalves.Attachalinetothepurgevalve.Drainthe fluidfromeachpurgevalveintoasuitablecontainer.
Illustration1g01449906
3.Removethelidonthebrakefluidreservoir.Thefluidreservoirislocatedunderthefrontofthe cabinthearticulationjoint.Addthecorrecttypeofbrakefluidtothereservoir.Referto OperationandMaintenanceManual,"LubricantViscositiesChart"forthecorrectfluid.
4.Openthepurgevalve.
5.Fullydepresstheservicebrakethatisbeingpurged.
6.Closethepurgevalve.
7.Releasetheservicebrake.
8.RepeatSteps4through7untilnoairisinthefluidthatdrainsfromthepurgevalve.Ensurethat thereservoirremainsfulloffluid.
9.Starttheengine.Runthemachineforafewminutes.Checkforanyleaks.Maintainthefluid levelbetweenthemarksonthereservoir.
Copyright1993-2021CaterpillarInc. AllRightsReserved. PrivateNetworkForSISLicensees.
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Product:COMPACTWHEELLOADER
Model:904HCOMPACTWHEELLOADERH4T
Configuration:904HWheelLoaderH4T00001-UP(MACHINE)POWEREDBYS4Q2TEngine
OperationandMaintenanceManual 904HCompactWheelLoader
MediaNumber-SEBU8355-02PublicationDate-01/10/2009DateUpdated-28/10/2009 i02699196
BrakeSystemFluidLevel-Check-IfEquipped
SMCS-4258-535-FLV;7579-535-BRK
Hotoilandcomponentscancausepersonalinjury. Donotallowhotoilorcomponentstocontactskin.
NOTICE
Caremustbetakentoensurethatfluidsarecontainedduring performanceofinspection,maintenance,testing,adjusting,andrepair oftheproduct.Bepreparedtocollectthefluidwithsuitablecontainers beforeopeninganycompartmentordisassemblinganycomponent containingfluids.
RefertoSpecialPublication,NENG2500,"DealerServiceTool Catalog"fortoolsandsuppliessuitabletocollectandcontainfluidson Catproducts.
Disposeofallfluidsaccordingtolocalregulationsandmandates.
Note:Brakefluidreservoirsareavailableonlyonstandardmachines.
1.Parkthemachineonahard,levelsurface.
2.Thefluidreservoirislocatedinthecompartmentinfrontofthecab.
3.Checkthefluidlevelwhentheengineisstopped.
4.Maintainthefluidlevelbetweenthemarksonthereservoir.
5.Ifthefluidlevelislow,addfluid.
a.Removethelidonthebrakefluidreservoir.
b.Addthecorrecttypeofbrakefluidtothereservoir.RefertoOperationandMaintenance Manual,"LubricantViscositiesChart"forthecorrectfluid.
c.Installthelidonthereservoir.
6.Checkforanyleaks.Maintainthefluidlevelbetweenthemarksonthereservoir.
Copyright1993-2021CaterpillarInc. AllRightsReserved. PrivateNetworkForSISLicensees.
WedFeb310:21:32UTC+05302021
Product:COMPACTWHEELLOADER
Model:904HCOMPACTWHEELLOADERH4T
Configuration:904HWheelLoaderH4T00001-UP(MACHINE)POWEREDBYS4Q2TEngine
OperationandMaintenanceManual 904HCompactWheelLoader
MediaNumber-SEBU8355-02PublicationDate-01/10/2009DateUpdated-28/10/2009
Brakes-Inspect/Adjust
SMCS-4251-025;4251-040
Thebrakedrumislocatedbehindthefrontaxleonthedriveshaft.Measurethethicknessofthebrake shoes.Ifthethicknessofeitherofthetwobrakeshoesislessthan4.00mm(0.16inch),replacethe brakeshoes.RefertoDisassemblyandAssemblyManualfortheprocedure.
Copyright1993-2021CaterpillarInc. AllRightsReserved. PrivateNetworkForSISLicensees. WedFeb310:21:47UTC+05302021
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Product:COMPACTWHEELLOADER
Model:904HCOMPACTWHEELLOADERH4T
Configuration:904HWheelLoaderH4T00001-UP(MACHINE)POWEREDBYS4Q2TEngine
OperationandMaintenanceManual 904HCompactWheelLoader
MediaNumber-SEBU8355-02PublicationDate-01/10/2009DateUpdated-28/10/2009
BrakingSystem-Test
SMCS-4011-081;4267-081
ServiceBrakeHoldingAbilityTest
Personalinjurycanresultifthemachinemoveswhiletesting.
Ifthemachinebeginstomoveduringtest,reducetheenginespeed immediatelyandengagetheparkingbrake.
i02319974
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.
SecondaryBrakeHoldingAbilityTest
Checktheareaaroundthemachine.Makesurethatthemachineisclearofpersonnelandclearof obstacles.
MakesurethatthesteeringframelocklinkisintheSTOREDposition. Testthebrakesonadry20%slope.
Note:ThetestconditionisdifferentfromtheServiceBraketest. Fastentheseatbeltbeforeyoutestthebrakes.
Thefollowingtestsareusedtodetermineiftheparkingbrakeisfunctional.Thesetestsarenot intendedtomeasurethemaximumbrakeholdingeffort.
1.Starttheengine.Raisetheworktoolslightly.
2.Engagetheparkingbrake.Releasetheservicebrakegradually.
Note:Theparkingbrakeindicatorlightshouldcomeonandtheparkingbrakelightshould flash.
Themachineshouldnotmoveunderthefollowingconditions. Theengineisatlowidle.
This is the sample of the manual Click on the download link for complete Manual