904H Caterpillar Compact Wheel Loader Service Manual

Product: COMPACT WHEEL LOADER

Model: 904H COMPACT WHEEL LOADER H4T

Configuration: 904H Wheel Loader H4T00001-UP (MACHINE) POWERED BY S4Q2T Engine

Disassembly and Assembly 904H

Compact Wheel Loader Engine Supplement

Media Number -KENR7633-00

Publication Date -01/12/2008

Air Cleaner - Remove and Install

SMCS - 1051-010

Removal Procedure Illustration 1

Date Updated -08/01/2009

Illustration 2

2. Remove primary air filter (3) from air cleaner housing (1) .

Illustration 3

3. Remove secondary air filter (4) from air cleaner housing (1) .

Illustration 4 g01163026

4. Remove bolts (5) .

Illustration 5 g01163029

5. Loosen hose clamp (7). Disconnect hose (6). Remove air cleaner housing (1). Check air cleaner indicator (8).

Installation Procedure

1. Install air cleaner indicator (8). Install air cleaner housing (1) into position. Connect rubber hose (6). Tighten clamp (7) .

2. Install bolts (5) .

8

Illustration 10

5. Install cover (2) onto air cleaner housing (1) .

Copyright 1993 - 2020 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees.

Wed Jul 22 12:13:55 UTC+0530 2020

Product: COMPACT WHEEL LOADER

Model: 904H COMPACT WHEEL LOADER H4T

Configuration: 904H Wheel Loader H4T00001-UP (MACHINE) POWERED BY S4Q2T Engine

Disassembly and Assembly 904H

Compact Wheel Loader Engine Supplement

Media Number -KENR7633-00

Alternator - Remove and Install - Engine In Chassis

SMCS - 1405-010

Removal Procedure

1. Open the access panel on the left side of the machine.

Illustration 1

Updated -08/01/2009

i03131822

2. Move the rubber terminal covers and disconnect battery cables (1) on the battery. Move the battery cables away from the terminals.

Note: Remove the negative battery cable first.

Note: This machine doesnot have a battery disconnect switch.

3. Remove bolt (4) from alternator (2) .

4. Move alternator (2) toward the engine and remove V-belt (3) from the alternator pulley.

5. Remove bolt (5) from alternator (2) and remove alternator (2) from the bracket.

6. Remove harness assembly (6) from the back of alternator (2) .

7. Move rubber boot (7). Remove the nut and remove the harness assembly from alternator (2) .

8. Remove cable strap (8).

9. Remove alternator (2) from the machine.

Installation procedure

Illustration 4

g01156394

1. Install alternator (2) into position. Do not install the alternator at this time.

2. Install harnessassembly (6) onto the back of alternator (2) .

3. Install the harness assembly onto the back of alternator (2). Move rubber boot (7) into position.

4. Install cable strap (8) onto the harness assembly.

Illustration 5

5. Install alternator (2) into the bracket.

6. Install bolt (5) through the bracket and alternator (2). Do not tighten bolt (5) at this time.

7. Install bolt (4) through the bracket and alternator (2). Do not tighten bolt (4) at this time.

8. Install alternator belt (3) on the alternator pulley.

9. Refer to the Operation and Maintenance Manual for the correct tightening procedure for the alternator belt.

10. Tighten bolts (4) and (5) when the proper belt tension is achieved.

Illustration 6

11. Connect both terminals(1) of the battery. Install the rubber battery covers. Close the access panel on the left side of the machine.

Note: This machine doesnot have a battery disconnect switch.

12. Start the engine. Check for the proper operation of the alternator.

Product: COMPACT WHEEL LOADER

Model: 904H COMPACT WHEEL LOADER H4T

Configuration: 904H Wheel Loader H4T00001-UP (MACHINE) POWERED BY S4Q2T Engine

Disassembly and Assembly 904H

Compact Wheel Loader Engine Supplement

Media Number -KENR7633-00 Publication Date -01/12/2008 Date Updated -08/01/2009

Battery - Remove and Install

SMCS - 1401-010

Separation Procedure

1. Lower the work tool to the ground.

Illustration 1 g01611635

i03132372

2. Put the engine key in lock (1) in order to unlock the accessdoor (2). Open the access door (2) .

2

3. Move rubber terminal covers (3) and disconnect battery cables (4) on the battery (5). Move the battery cables (4) away from the terminals.

Note: Remove the negative battery cable first.

Note: This machine doesnot have a battery disconnect switch.

4. Remove bolt (6) and remove bracket (7) .

5. Remove battery (5) from the machine.

Connection Procedure

Illustration 3

1. Install battery (5) in position in the machine.

Note: The positive battery cable must attach to the positive terminal of the battery.

Note: Check battery terminals and the posts of the battery for cleanliness prior to installation.

2. Connect battery cables (4) and rubber terminal covers (3) .

3. Install bracket (7) and bolt (6) .

4

4. Close the access door (2). Use engine key in lock (1) in order to lock the access door.

5. Start the machine. Check the battery for proper functioning.

Copyright 1993 - 2020 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees. Wed Jul 22 12:11:30 UTC+0530 2020

Product: COMPACT WHEEL LOADER

Model: 904H COMPACT WHEEL LOADER H4T

Configuration: 904H Wheel Loader H4T00001-UP (MACHINE) POWERED BY S4Q2T Engine

Disassembly and Assembly

904H

Compact Wheel Loader Engine Supplement

Media Number -KENR7633-00

Cooling System

Package

(Radiator, Hydraulic Oil Cooler, Fan)

- Install

SMCS - 1353-012; 1356-012; 1374-012

Installation Procedure

Table 1

Required Tools

A 138-7573 Link Bracket 2 NOTICE

Care must be taken to ensure that fluidsare contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.

Refer to Special Publication, NENG2500, "Caterpillar Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products.

Dispose of all fluids according to local regulationsand mandates.

Connection of Radiator and Hydraulic Oil Cooler

Illustration 1 g01788073

1. Install oil cooler (31) to shroud assembly (32). Install bolts (30) .

Illustration 2 g01787913

2. Install oil cooler assembly (29) to the radiator assembly (27). Install four bolts (28) .

Installation of Cooling Package into the Machine

Illustration 3

g01744017

1. Install spacer (26) and fan (24). Install bolts (25) .

Illustration 4

2. Install V-belt (23). Tighten V-belt (23). Refer to Operation and Maintenance Manual, "BeltsInspect/Adjust/Replace".

Illustration 5 g01740753

3. Use Tooling (A) and a suitable lifting device to position cooling package (21) in the machine.

Illustration 6 g01743953

4. Install mounting bolts (22). Repeat for the other side of cooling package (21) .

5. Remove Tooling (A) and the suitable lifting device.

7

6. Install fan guard assembly (19) and the bolts.

7. Connect lower radiator hose (20) to the water pump.

8

8. Position heater hose (18). Connect clamp (15), clamp (16), and clamp (17) .

Illustration 9

9. Install exhaust extension (13). Install bolts(14). Repeat on the other side of exhaust extension (13).

Illustration 10

g01758721

10. Position overflow tank (12). Connect clamp (11). Connect hose (10) .

11. Position the base and water separator (9) and install bolts (7) .

12. Install radiator hose (5) and tighten clamps (8). Connect bracket (6) .

Illustration 11

13. Connect drain hose (3) and tighten the clamp. Connect hose assemblies (4) and (2) .

12

14. Close valve (1). Fill the cooling system. Refer to Operation and Maintenance Manual, "Cooliong System Coolant (ELC) - Change" for the proper filling procedure.

15. Connect the battery. Refer to Operation and Maintenance Manual, "Battery or Battery Cable –Inspect/Replace".

End By:

a. Install the counterweight. Refer to Disassembly and Assembly, "Counterweight - Remove and Install".

b. Install the hood. Refer to Disassembly and Assembly, "Hood - Remove and Install".

Copyright 1993 - 2020 Caterpillar Inc.

Product: COMPACT WHEEL LOADER

Model: 904H COMPACT WHEEL LOADER H4T

Configuration: 904H Wheel Loader H4T00001-UP (MACHINE) POWERED BY S4Q2T Engine

Disassembly and Assembly

904H

Compact Wheel Loader Engine Supplement

Media Number -KENR7633-00

Cooling System Package (Radiator, Hydraulic Oil Cooler, Fan)

- Remove

SMCS - 1353-011; 1356-011; 1374-011

Removal Procedure

Table 1

Required Tools

A 138-7573 Link Bracket 2

Start By:

A. Remove the hood. Refer to Disassembly and Assembly, "Hood - Remove and Install".

B. Remove the counterweight. Refer to Disassembly and Assembly, "Counterweight - Remove and Install".

NOTICE

Care must be taken to ensure that fluidsare contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.

Refer to Special Publication, NENG2500, "Caterpillar Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products.

Dispose of all fluids according to local regulationsand mandates.

Personal injury canresult from hot coolant, steam and alkali. At operating temperature, engine coolant ishot andunder pressure. The radiator and all lines to heaters or the engine contain hot coolant or steam. Any contact cancause severe burns.

Remove filler cap slowly to relieve pressure only when engine isstopped and radiator cap is cool enough to touchwith your bare hand.

Do not attempt to tighten hose connections when the coolant ishot, the hose can come off causing burns.

Cooling System Conditioner contains alkali. Avoidcontact withskin and eyes.

Note: Put identification marks on all lines, hoses, wires, and tubes for installation purposes. Plug all lines, hoses, and tubes. This helps prevent fluid lossand contamination of the cooling system.

1. Disconnect the battery. Refer to Operation and Maintenance Manual, "Battery or Battery Cable – Inspect/Replace".

Illustration 1

2. Open valve (1) in order to drain the coolant into a suitable container for storage or for disposal. Refer to Operation and Maintenance Manual, "Cooling System Coolant (ELC) - Change"for the proper draining procedure.

Illustration 2

g01738755

3. Disconnect hose assemblies(2) and (4). Loosen the clamp and disconnect drain hose (3) .

Illustration 3

4. Loosen clamp (8) and remove radiator hose (5). Disconnect bracket (6) .

5. Remove bolts (7) and position the base and water separator (9) out of the way.

6. Disconnect hose (10). Disconnect clamp (11). Position overflowtank (12) out of the way.

Illustration 4

7. Remove bolts (14). Repeat on the other side of exhaust extension (13). Remove exhaust extension (13) .

5

8. Disconnect clamp (17), clamp (16), and clamp (15). Position heater hose (18) out of the way.

6

9. Disconnect lower radiator hose (20) from the water pump.

10. Remove the bolts and fan guard assembly (19) .

7

11. Attach Tooling (A) and a suitable lifting device to cooling package (21) .

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