Caterpillar cat 904 h compact wheel loader service repair manual (h4t00001 and up)

Service Repair Manual
Models
904H COMPACT
WHEEL LOADER

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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 Power Train
Media Number -KENR7636-01 Publication Date -01/10/2011 Date Updated -31/10/2011
i03132349
System Pressure - Release
SMCS - 4250-553-PX; 4300-553-PX; 4350-553-PX; 5050-553-PX
Release Procedure
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. Lower the implements to the ground.
2. Shut off the engine.
3. Turn the key to the ON position before moving control levers.
4. Move the control levers through the full range of travel in order to release the hydraulic
pressure.
5. Depress the brake pedal repeatedly in order to release the hydraulic pressure.
6. Slowly loosen the filler cap in order to release the tank pressure.
7. Tighten the filler cap.
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2019/9/6https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/siswe...

8. The pressure in the hydraulic system has been released. Lines and components can be
removed.
Copyright 1993 - 2019 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Fri Sep 6 14:52:48 UTC+0800 2019
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i03132299
Bottom Guard - Remove and Install
SMCS - 7153
Removal Procedure
Illustration 1 g01687014
1. Place Tooling (A) under bottom guard (2). Remove bolts (1). Remove bottom guard (2).
The weight of bottom guard (2) is approximately 18 kg (40 lb).
Installation Procedure
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1. Position bottom guard (2) on Tooling (A). Position bottom guard (2) and install bolts (1).
The weight of the bottom guard (2) is approximately 18 kg (40 lb).
Fri Sep 6 14:53:36 UTC+0800 2019
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i03132305
Hydrostatic Pump Drive Mounting Hub and Flange -
Remove
SMCS - 3203-011-FLG; 3203-011-HU
Removal Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 138-7573 Link Bracket 4
Start By:
A. Remove the piston pump. Refer to Disassembly and Assembly, "Piston Pump (Hydrostat) -
Remove".
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1. Install Tooling (A) to adapter plate (1). Remove adapter plate (1) .
2. Remove bolts (2) and flange (3) .
3. Loosen bolt (4) and remove hub (5) from piston pump (6) .
Fri Sep 6 14:54:23 UTC+0800 2019
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i03132309
Hydrostatic Pump Drive Mounting Hub and Flange - Install
SMCS - 3203-012-FLG; 3203-012-HU
Installation Procedure
Table 1
Required Tools
A 138-7573 Link Bracket 4
1. Position hub (5) on piston pump (6). Install bolt (4). Tighten bolt (4) to a torque of 55 ± 5
N·m (40.6 ± 3.7 lb ft).
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2. Install flange (3). Install bolts (2) .
3. Install Tooling (A) in order to install adapter plate (1) .
End By: Install the piston pump. Refer to Disassembly and Assembly, "Piston Pump (Hydrostat) -
Install".
Fri Sep 6 14:55:11 UTC+0800 2019
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i03310024
Piston Pump (Hydrostatic) - Remove
SMCS - 3203-011-QP; 5070-011-H7
Removal Procedure
Table 1
Tool Part Number Description Quantity
A 140-7742 Sleeve 1
B
1U-9200 Ratchet 1
189-0410 Shackle 1
Start By:
A. Remove the seat. Refer to Disassembly and Assembly, "Seat - Remove".
B. Remove the gear pump. Refer to Disassembly and Assembly, "Gear Pump (Implement)
(Steering) (Hydraulic Fan) - Remove".
Make sure all of the work tools have been lowered to the ground, and
the 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.
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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, 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 regulations and mandates.
1. Disconnect hose assembly (2) and hose (3) from piston pump (1) .
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2. Disconnect harness assembly (4) .
3. Disconnect hose assemblies (7), (8), (9), (10), and (5). Disconnect cable assembly (6) .
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4. Attach Tooling (A) and Tooling (B) to the cab.
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5. Attach Tooling (B) and a suitable lifting device to piston pump (1) .
6. Remove mounting bolts (11) from piston pump (1). Remove piston pump (1). The weight of
piston pump (1) is approximately 45 kg (100 lb).
Fri Sep 6 14:55:58 UTC+0800 2019
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i02338391
Piston Pump (Hydrostatic) - Remove
SMCS - 3203-011-QP; 5070-011-H7
Removal Procedure
Table 1
Tool Part Number Description Quantity
A 140-7742 Sleeve 1
B
1U-9200 Ratchet 1
189-0410 Shackle 1
C 242-6163 Wrench 1
Start By:
A. Remove the seat. Refer to Disassembly and Assembly, "Seat - Remove".
B. Remove the gear pump. Refer to Disassembly and Assembly, "Gear Pump - Remove".
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.
1/8(W)w

NOTICE
of the machine. Be prepared to collect the fluid with suitable containers
containing fluids.
Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop
Products Guide", for tools and supplies suitable to collect and contain
fluids in Caterpillar machines.
Note: Put identification marks on all lines, on all hoses, on all wires, and on all tubes for
installation purposes. Plug all lines, all hoses and all tubes. This helps to prevent fluid loss and this
helps to keep contaminants from entering the system.
1. Remove plate (1) .
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2. Disconnect harness assembly (2) .
3. Disconnect hose assemblies (3) and (4) from piston pump (5) .
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6. Disconnect cable assembly (10) from piston pump (5). Disconnect hose assembly (11) from
piston pump (5) .
7. Disconnect hose assembly (12) from the bottom of piston pump (5) .
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8. Attach Tooling (A) and Tooling (B) to the cab.
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9. Attach Tooling (B) and a suitable lifting device to piston pump (5) .
10. Use Tooling (C) in order to remove mounting bolts (13) from piston pump (5) and mounting
flange (14) .
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11. Raise piston pump (5) in order to remove the pump from the machine. The weight of piston
pump (5) is approximately 45 kg (100 lb).
Fri Sep 6 14:56:46 UTC+0800 2019
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i02327908
Piston Pump (Hydrostatic) - Disassemble
SMCS - 3203-015-QP; 5070-015-H7
Disassembly Procedure
Table 1
Required Tools
A 1P-0510 Driver Group 1
B 1P-1861 Retaining Ring Pliers 1
C 5P-4758 Internal Pliers 1
D 1U-7600 Slide Hammer Puller 1
E 1P-1859 Retaining Ring Pliers 1
F 1P-1857 Retaining Ring Pliers 1
G 1S-4208 Spanner Wrench 1
Start By:
A. Remove the hydraulic drive pump. Refer to Disassembly and Assembly, "Hydraulic Drive
Pump - Remove".
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Make sure all of the work tools have been lowered to the ground, and
the 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.
Note: Cleanliness is an important factor. Before the disassembly procedure, the exterior of the
component should be thoroughly cleaned. This will help to prevent dirt from entering the internal
mechanism. Dirt and contaminants can damage the components of the pump or the motor. All
disassembly and assembly procedures must be performed on a clean work surface. Clean all the
interior components in clean solvent. Dry all the interior components with compressed air. Plug
ports and plug hoses on the machine during repair.
NOTICE
of the product. Be prepared to collect the fluid with suitable containers
containing fluids.
Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop
Products Guide" for tools and supplies suitable to collect and contain
fluids on Caterpillar products.
1. Remove bolts (1) and remove charge pump (2) .
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Note: Mark the location of the charge pump on the head assembly. Crescent (M) of gear set
(4) must face toward the valves for installation purposes. The valves are indicated by
arrows.
2. Remove O-ring seal (3). Remove gear set (4). Keep the gear set together in order to ensure
proper installation of the gear set.
3. Remove bushing (5). Note the orientation of the bushing. The bushing must be installed in
the original location.
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4. Remove plate (6). Note the position of the plate.
5. Remove shaft (7) and O-ring seal (8) .
6. Remove retaining ring (9) and key (10) from the shaft.
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7. Remove bolts (11) and head assembly (12) .
8. Remove O-ring seals (13) and (14) from the head.
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9. Use Tooling (A) in order to remove bushing (15) .
10. Remove bushing (16) .
Note: Mark orientation of groove in bushing (16) for later installation of new bushing into
the original location.
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Note: Mark the position of the port plate for installation purposes. The groove in the port
plate must face the two valves on the head assembly.
11. Remove port plate (17) and bearing (18), if necessary.
Note: Perform Steps 12 and 13, if equipped.
12. Remove plug assembly (19) from the head.
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13. Disassemble the plug assembly, as follows: O-ring seal (20), O-ring seal (21) and locking
plug (22) .
14. Remove valve (23) from the head.
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15. Disassemble the valve, as follows: O-ring seal (26), backup ring (25) and O-ring seal (24) .
16. Remove valve (27) from the head. Refer to Step 15 for the disassembly procedure.
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