Caterpillar cat 903 d compact wheel loader (prefix mzy) service repair manual (mzy00001 and up)

Service Repair Manual
Models
903D COMPACT
WHEEL LOADER

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Product: COMPACT WHEEL LOADER
Model: 903D COMPACT WHEEL LOADER MZY
Configuration: 903D Compact Wheel Loader MZY00001-UP (MACHINE) POWERED BY C2.4 Engine
Disassembly and Assembly
903D Compact Wheel Loader Machine Systems
Media Number -M0094117-00 Publication Date -01/10/2018 Date Updated -22/10/2018
i07466073
Steering Frame Lock - Remove and Install
SMCS - 7506-010
Installation Procedure
Personal injury or death can result from machine articulation or
movement.
Machine frames can move and a person can be crushed.
Connect the steering frame lock link between the front and rear frames
before working on machine. Secure clevis pin with locking pin.
Before operating the machine, fasten the steering frame lock link into
the stored position and secure the clevis pin with locking pin.
Failure to lock into the stored position before operating can result in loss
of steering.
1. Move the machine to a hard, level surface. Position the machine in a manner in which the
bores are aligned. Park the machine in the straight ahead position and engage the parking
brake.
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2019/9/1https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/siswe...

Illustration 1 g06335223
2. Remove pin (2). Remove steering frame lock (1) from the stored position.
3. Install steering frame lock (1). Install pin (2).
Removal Procedure
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Personal injury or death can result from machine articulation or
movement.
Machine frames can move and a person can be crushed.
Connect the steering frame lock link between the front and rear frames
before working on machine. Secure clevis pin with locking pin.
Before operating the machine, fasten the steering frame lock link into
the stored position and secure the clevis pin with locking pin.
Failure to lock into the stored position before operating can result in loss
of steering.
1. Position the machine in a manner in which steering frame lock (1) can rotate in the bore.
Remove pin (2) and steering frame lock (1).
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2. Install steering frame lock (1) to the stored position. Install pin (2).
Copyright 1993 - 2019 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Sun Sep 1 11:28:51 UTC+0800 2019
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i07420631
Hydraulic Tank - Remove and Install
SMCS - 4332-010; 5056-010; 5056-011; 5056-012
Removal Procedure
Table 1
Required Tools
Tool Part Number Description Qty
A 422-5472 Lifting Eye Assembly 1
Start By:
a. Release the hydraulic system pressure.
b. Remove the cab.
NOTICE
Care must be taken to ensure that fluids are 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, PERJ1017, "Dealer Service Tool
Catalog" for tools and supplies suitable to collect and contain fluids on
Cat®
products.
Dispose of all fluids according to local regulations and mandates.
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Personal injury can result from hydraulic oil pressure and hot oil.
Hydraulic oil pressure can remain in the hydraulic system after the
engine has been stopped. Serious injury can be caused if this pressure is
not released before any service is done on the hydraulic system.
Make sure all of the attachments have been lowered, oil is cool before
removing any components or lines. Remove the oil filler cap only when
the engine is stopped, and the filler cap is cool enough to touch with
your bare hand.
1. Drain the hydraulic tank into a suitable container. Refer to Operation and Maintenance
Manual, "Hydraulic Oil - Change" for the correct draining procedures.
2. Remove bolts (1).
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3. Disconnect harness assembly (2). Disconnect harness assembly (3).
4. Disconnect hose assembly (4). Disconnect hose assemblies (5) and (6). Disconnect fitting
(7).
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5. Remove hose (8).
6. Remove fitting (12). Remove fitting (9). Remove fittings (10) and (11).
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7. Attach Tooling (A) and a suitable lifting device. Remove bolts (13) and (14). Remove
hydraulic tank (15). The weight of hydraulic tank (15) is approximately 28 kg (62 lb.)
8. Remove vent (16). Remove bolts (17). Remove plate (18).
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9. Remove strainer (19).
1. Install hydraulic tank (15) in the reverse order of removal.
Sun Sep 1 11:29:39 UTC+0800 2019
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i07521628
Joystick Control and Mounting - Remove and Install
SMCS - 5059-010-MT; 5705-010-MT
Removal Procedure
Start By:
a. Release the hydraulic system pressure.
1. Open the right side cab door. Remove cover (4). Remove cover (3). Remove knob (1).
Remove cover (2).
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2. Remove bolts (5). Disconnect cable assembly (6) and cable assembly (7) from the hydraulic
hand control group.
3. Disconnect harness assemblies (10). Remove screws (9) and joystick control and mounting
(8).
1. Install joystick control and mounting (8) in the reverse order of removal.
Sun Sep 1 11:30:27 UTC+0800 2019
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i07424176
Metering Pump (Steering) - Remove and Install
SMCS - 4312-010; 4312-011
Removal Procedure
NOTICE
containing fluids.
Cat®
products.
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your bare hand.
Note: Mark all hoses and all hose assemblies for installation purposes.
1. Release the system pressure. Refer to Operation and Maintenance Manual, "System
Pressure Release".
2. Remove cover (1).
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3. Disconnect hose assembly (2). Disconnect hose assembly (3).
4. Disconnect hose assembly (4).
5. Disconnect hose assemblies (5).
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6. Remove bolt (6).
7. Remove bolt (7).
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Some components may be removed for the purpose of clarity.
8. Remove bolt (8).
9. Remove metering pump (9).
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Incorrect installation of the pilot supply lines for the Hand Metering
Unit (HMU) with the presence of pressure in the steering supply circuit
will cause the steering system to turn unexpectedly or turn in the wrong
direction. These conditions can also cause the steering wheel to turn
independently with or without an operator present in the cab. These
situations could result in personal injury or death.
Ensure that the pilot supply lines for the HMU have been installed
correctly in the proper locations on the HMU before operating the
machine.
1. Install metering pump (9) in the reverse order of removal.
a. Start the machine. Turn the steering wheel in both directions. Purge all air from the
hydraulic system.
b. Check the hydraulic fluid level. Refer to Operations and Maintenance Manual,
"Hydraulic Oil - Change".
Sun Sep 1 11:31:15 UTC+0800 2019
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i07424475
Steering Cylinder - Remove and Install
SMCS - 4303-010
Removal Procedure
Start By:
a. Install the steering lock.
b. Remove the front cover.
NOTICE
containing fluids.
Cat®
products.
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your bare hand.
1. Release the hydraulic system pressure. Refer to Operation and Maintenance Manual, "System
Pressure Release".
2. Disconnect hose assemblies (3). Remove clamp (2). Remove pin (1). Remove the shims.
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3. Remove clamp (4). Remove pin (5). Remove steering cylinder (6). Remove the shims.
1. Install steering cylinder (6) in the reverse order of removal.
Disassembly Information
Table 1
Required Tooling
Item Part Number Part Description Qty
A 152-4251 Hydraulic Cylinder Repair Stand 1
B - Loctite 262 1
1. (1) Head. The torque for head (1) is 441 ± 44 N·m (325 ± 33 lb ft).
2. (2) O-ring seal.
3. (3) Bushing.
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4. (4) U-Cup seal.
5. (5) Backup ring.
6. (6) O-ring seal.
7. (7) Piston.
8. (8) Piston ring.
9. (9) Wear ring.
10. (10) Piston nut. Apply Tooling (B) to the threads of piston nut (B). The torque for piston nut
(10) is 324 ± 33 N·m (239 ± 24 lb ft).
11. (11) Dust seal.
12. (12) Retaining ring.
13. (13) Bushing.
14. (14) Tube assembly. The torque for tube assembly (14) is 66 ± 12 N·m (550 ± 9 lb ft).
Sun Sep 1 11:32:03 UTC+0800 2019
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i07427535
Brake Accumulator - Remove and Install
SMCS - 4263-010
Personal injury or death can result from sudden machine movement.
Sudden movement of the machine can cause injury to persons on or
near the machine.
To prevent injury or death, make sure that the area around the machine
is clear of personnel and obstructions before operating the machine.
your bare hand.
Removal Procedure
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Start By:
a. Connect the steering frame lock.
1. Release the brake pressure: Cycle the brake pedal up and down until all brake pressure is
released. Refer to Operation and Maintenance Manual, "System Pressure Release".
2. Remove floor mat (1).
3. Remove screws (3) and cover (2).
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Some components may be removed or altered for the sake of clarity.
Some components may be removed or altered for the sake of clarity.
4. Remove brake accumulator (4).
1. Install brake accumulator (4) in the reverse order of removal.
a. Tighten brake accumulator (4) to a torque of 60 ± 6 N·m (44 ± 4 lb ft).
Sun Sep 1 11:32:51 UTC+0800 2019
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Caterpillar cat 903 d compact wheel loader (prefix mzy) service repair manual (mzy00001 and up)

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