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

Product:COMPACTWHEELLOADER

Model:910COMPACTWHEELLOADER80U

Configuration:910WHEELLOADER80U06735-UP(MACHINE)POWEREDBY3204ENGINE

OperationandMaintenanceManual 910WHEELLOADER

MediaNumber-SEBU5525-00PublicationDate-01/10/1983DateUpdated-11/10/2001

(1)Radiator

Alwaysinspectcoolingsystemwithenginestopped. Removefillercapslowlytorelievepressure.Steamcancauseinjury.

Inhibitorcontainsalkali.Avoidcontactwithskinandeyestoprevent injury.

1.Machinelevel,bucketloweredwithslightdownpressure,andparkingbrakeapplied.

2.Observecoolantlevel.Coolantshouldbevisibleinsightgauge.

(2)Precleaner

1.Inspectvisually.Cupshouldbeemptiedwheneverdirtreachesindicatormark.

2.Loosenwingnutontopofcapandremovecapandcup.

3.Emptycup.Installcupandcap.Periodicallywashentireprecleanerinwater.

(3)EngineCrankcase

1.Observeoillevelwithmachinelevel,bucketloweredwithslightdownpressure,enginestopped andparkingbrakeapplied.

2.Measureoillevel.MaintainoillevelbetweenADDandFULLmarksondipstick.

(4)FuelTank

Openfueltankdrainvalveandallowsedimentandmoisturetodrain.Closedrainvalve.

TueMay1110:19:23UTC+05302021

Product:COMPACTWHEELLOADER

Model:910COMPACTWHEELLOADER80U

Configuration:910WHEELLOADER80U06735-UP(MACHINE)POWEREDBY3204ENGINE

Oilwarm,machinelevel,bucketloweredwithslightdownpressure,parkingbrakesetandengine stopped.

2.Removefilterelementwithastraptypewrench.

3.Cleanfilterbase.Makesuretoremoveallofoldgasket.

4.Applyalightcoatofengineoiltogasketofnewfilterelement.

5.Installnewfilterelementbyhand.

6.Whengasketcontactsfilter,tightenelement1/2turnmore.

3.Measureliningsanddisc.Replaceifwornbeyondpermissiblelimits,asshownbelow.

4.Newliningis.625inch(15.88mm)thick.Minimumpermissibleliningthicknessis.125inch(3.18 mm).

5.Minimumpermissiblediscthicknessis.450inch(11.43mm).

6.Inspectpistons(1),caps(2),pipeplugsandbleeders(3),brakelines(4),andbrakehead(5)for leakage.

(18)ParkingBrake

Blockwheelssecurelysothatmachinecannotmove.

Parkingbrakeisproperlyadjustedwhenthereisareasonablyhardpulltosnaplevertotheapplied position,andthemachinewillnotmovewhenin2ndgear,withbrakeapplied.Brakeliningmustbe freewhenbrakeisreleased.

1.Moveparkingbrakelevertoreleasedposition.

2.Turnclockwisetotightenbrake,counterclockwisetoloosen,Inspectadjustment.

(19)FanAndAlternatorBelt

1.Inspectconditionandadjustmentofbelt,replaceifwornordamaged.

2.Measureamountofdeflection.Beltshoulddeflect9/16to13/16inch(14to20mm)under25lbs. (11.5kg)pressure.

3.Toadjustbelt,loosenbracketboltandpryalternatorinrequireddirection.Tightenbolt.Measure adjustmentagain.

(20)TransmissionScreen

Hotoilandcomponentscancauseinjury.Donotallowhotoilor componentstocontactskin.

1.Removefloorplateonrightside.Removetransmissionscreencover.

3.Removetransmissionscreen.

Whenusingpressureairwearsafetyfaceshieldandprotectiveclothing. Maximumairpressuremustbebelow30PSI(205kPa)forcleaning purposes.

Useallcleaningsolutionswithcare.

4.Washscreenincleannon-flammablesolvent.Shakeorblowdry.

5.Inspectscreenfordamage.Usenewoneifdamaged.Installscreen.

6.Inspectcovergasketandusenewoneifnecessary.Installcover.

TueMay1110:21:47UTC+05302021

Product:COMPACTWHEELLOADER

Model:910COMPACTWHEELLOADER80U

Configuration:910WHEELLOADER80U06735-UP(MACHINE)POWEREDBY3204ENGINE

OperationandMaintenanceManual 910WHEELLOADER

MediaNumber-SEBU5525-00PublicationDate-01/10/1983DateUpdated-11/10/2001

Every6Months SMCS-7606

(21)HydraulicSystem

Hotoilandcomponentscancauseinjury.Donotallowhotoilor componentstocontactskin.

Machinelevel,oilwarm,enginestopped,bucketloweredwithslightdownpressure,andparking brakeset.

1.Movehydrauliccontrolstohelprelievepressure.

2.Removehydraulictankfillercapslowlytorelievepressure.

3.Unlatchseatandtipbackuntilretainerlatchengages.

4.Removeboltandremovefilterhousing.Removeanddiscardfilterelement.

5.Cleanfilterbaseandfilterhousing.

6.Inspectseal,useanewsealifnecessary.

7.Installnewfilterelementintofilterhousing.

8.Installfilterhousing.Makecertainsealisproperlyseated.Tightenboltto40±5lb.ft.(55±7 N·m).

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

9.Inspectfillercapgasket.Usenewgasketifnecessary.Installfillercap.

10.Inspectsuctionhoseandreplaceifdamagedorbulging.Tightenhoseclamps.

11.Startengineandrunatlowidleforafewminutestocirculateoil.Inspectforleaks.

12.Stopengineandinspectoillevel.OilshouldbetoFULLmarkongauge.

(22)CoolingSystem-AddCorrosionInhibitor

Alwaysinspectcoolingsystemwithenginestopped.

Removefillercapslowlytorelievepressure.Steamcancauseinjury.

Inhibitorcontainsalkali.Avoidcontactwithskinandeyestoprevent injury.

AddCaterpillarCorrosionInhibitororequivalent.CarefullyfollowApplicationChartoncontainer.

1.Lubricate1fittingeachinfrontandrearuniversalsofrearshaft.

2.Lubricate1fittingeachinfrontandrearuniversalsofcentershaft.

3.Lubricate1fittinginuniversaloffrontshaft.Total5fittings.

(24)FuelTankFillerCapAndScreen

1.Removefillercap,disassembleandwashincleannon-flammablesolvent.Assembleandoil elementslightly.

2.Removefillerscreen.Washincleannon-flammablesolventandinstall.

3.Inspectfillercapgasket.Usenewgasketifnecessary.Installfillercap.

TueMay1110:22:02UTC+05302021

Product:COMPACTWHEELLOADER

Model:910COMPACTWHEELLOADER80U

Configuration:910WHEELLOADER80U06735-UP(MACHINE)POWEREDBY3204ENGINE

OperationandMaintenanceManual 910WHEELLOADER

MediaNumber-SEBU5525-00PublicationDate-01/10/1983DateUpdated-11/10/2001

Foreword

SMCS-7606

Thissectionisaguidetoequipmentcare.Theillustrated,step-by-stepinstructionsaregroupedby servicingintervals;itemswithoutspecificintervalsarelistedunder"WhenRequired".Circled numbersintheLubricationandMaintenanceChartaretokeythecharteditemstotheinstructionsin thebook.

Usetheservicemetertodeterminetheserviceintervaloftheengineoilandfilter.Calendarintervals (daily,weekly,monthly,etc.)shownareusedtodeterminedservicingintervalsforallotheritems.

NOTE:Underextremelysevere,dustyorwetoperatingconditions,morefrequentlubricationthanis specifiedinthe"LUBRICATIONANDMAINTENANCECHART"maybenecessary.

Performpreviousintervalitemsatmultiplesoftheoriginalrequirement.Forexample,atMONTHLY, alsoperformallthoseitemslistedunderWEEKLYandDAILY.

Somephotographsinthispublicationmayshowdetailsorattachmentsthatmaybedifferentfrom yourunit.Also,forsomephotographs,theROPS(RollOverProtectiveStructure)mayhavebeen removedforillustrativepurposes.

ElectricServiceMeter

Continuingimprovementandadvancementofproductdesignmaycausechangestoyourmachine whichmaynotbeincludedinthispublication.Eachpublicationisreviewedandrevised,asrequired, toupdateandincludethesechangesinlatereditions.

WheneveraquestionarisesregardingyourCaterpillarproduct,orthispublication,pleaseconsultyour Caterpillardealerforthelatestavailableinformation.

TueMay1110:15:58UTC+05302021

Product:COMPACTWHEELLOADER

Model:910COMPACTWHEELLOADER80U

Configuration:910WHEELLOADER80U06735-UP(MACHINE)POWEREDBY3204ENGINE

OperationandMaintenanceManual 910WHEELLOADER

MediaNumber-SEBU5525-00PublicationDate-01/10/1983DateUpdated-11/10/2001

FuelAndLubricantSpecifications

SMCS-7606

NOTE:TheabbreviationslistedbelowfollowS.A.E.J754nomenclature.Theclassificationsfollow S.A.E.J183classifications.TheMILspecificationsareU.S.A.MilitarySpecifications.These definitionswillbeofassistanceinpurchasing.Thespecificclassificationsforthismachinearefound onthe"RECOMMENDEDLUBRICANTS"chart.

DieselFuel

DistillatefuelsthatconformtoASTMNo.1orNo.2FuelOilorNo.1DorNo.2DDieselFuelOil. Specificationswithaminimumcetaneof35forpre-chamberenginesand40fordirectinjection enginesarethepreferredfuelsandprovideprovenmaximumengineservicelife.

Somecrudeoilsandblendedfuelsareregardedaspermissibleandcanbeusedwithextrafuelfilters andadjustedoilchangeperiods.However,thiswillresultinlessthanmaximumengineservicelife.

ContactyourCaterpillardealerregardingtheCaterpillarSPECIALINSTRUCTIONtitled"FUELS FORCATERPILLARDIESELENGINES",FORMSEHS7067,whichspecifiesrequirementsfor otherpreferredandpermissiblefuels.

EngineOils(EO)

CD-UseoilsthatmeetEngineServiceClassificationCDorMIL-L-2104C.

CC-UseoilsthatmeetEngineServiceClassificationCC,MIL-L-2104BorMIL-L-46152.

EO-CDorCC.

HydraulicBrakeFluid(BF)

UseheavydutyhydraulicbrakefluidmeetingtherequirementsofSAEJ1703e.

LubricatingGrease(MPG)

UseMultipurpose-typeGrease(MPG).Multipurpose-typegreasewhichcontains3%to5% molybdenumdisulfideisalsoacceptable,andpreferred.NLGINo.2Gradeissuitableformost temperatures.UseNLGINo.1orNo.0Gradeforextremelylowtemperatures.

HydraulicOil(HYDO)

Use(EO)orindustrial-typehydraulicoilswhicharecertifiedbythesupplierashavinganti-wear, anti-foam,anti-rustandanti-oxidationadditivepropertiesforheavydutyuse.

Multipurpose-typeGearLubricant(MPL)

UseGearLubricantClassificationGL-5orMIL-L-2105B.

TueMay1110:18:52UTC+05302021

PreviousScreen

Product:COMPACTWHEELLOADER

Model:910COMPACTWHEELLOADER80U

Configuration:910WHEELLOADER80U06735-UP(MACHINE)POWEREDBY3204ENGINE

OperationandMaintenanceManual 910WHEELLOADER

MediaNumber-SEBU5525-00PublicationDate-01/10/1983DateUpdated-11/10/2001

G.E.T.BoltTorque

SMCS-7606

TueMay1110:23:39UTC+05302021

Product:COMPACTWHEELLOADER

Model:910COMPACTWHEELLOADER80U

Configuration:910WHEELLOADER80U06735-UP(MACHINE)POWEREDBY3204ENGINE

OperationandMaintenanceManual 910WHEELLOADER

MediaNumber-SEBU5525-00PublicationDate-01/10/1983DateUpdated-11/10/2001

TueMay1110:19:09UTC+05302021

Product:COMPACTWHEELLOADER

Model:910COMPACTWHEELLOADER80U

Configuration:910WHEELLOADER80U06735-UP(MACHINE)POWEREDBY3204ENGINE

OperationandMaintenanceManual 910WHEELLOADER

MediaNumber-SEBU5525-00PublicationDate-01/10/1983DateUpdated-11/10/2001

MaintenanceRecommendations

SMCS-7606

Cooling

NOTICE

Neveraddcoolanttoanoverheatedengine,allowenginetocoolfirst.

Measurespecificgravityofantifreezesolutionfrequentlyincold weathertoassureadequateprotection.

Whenpermanentantifreezeandwatersolutionsareusedinthecooling system,thesolutionshouldbedrainedandreplacedevery2000hours oryearly.

Whenadditionsofcorrosioninhibitoraremadetothecoolingsystem EVERY500SERVICEHOURSOR3MONTHS,itisnotnecessaryto drainandrefillyearly.Coolingsystemdrainperiodcanthenbe extendedto4000servicehoursor2Years.

Maintaina3%concentrationofCaterpillarCorrosionInhibitoror equivalentinthecoolingsystemregardlessofantifreezeconcentration.

DonotuseCaterpillarCoolingSystemInhibitorwithDowtherm209 coolant.

Ifmachineistobestoredin,orshippedtoanareawithbelowfreezing temperatures,thecoolingsystemmustbeprotectedtolowestexpected ambienttemperatureordrainedcompletely.

NOTE:Theenginecoolingsystemisprotectedto-20°F(-29°C),withpermanent-typeantifreeze, whenshippedfromthefactory.

Pureundilutedantifreezewillfreezeat-10°F(-23°C).

Usecleanwaterthatislowinscaleformingminerals,notsoftenedwater.AddCaterpillarCorrosion Inhibitororequivalenttothewatertoprovidecorrosionprotection.Followtherecommendationson thecontainerforthequantityrequired.

Wheneverdrainingandrefillingcoolingsystem,alwaysmeasurethecoolantlevelwhentheengine reachesnormaloperatingtemperature.

Fillingatover5gpm(19litres/min)ratecancauseairpocketsinthecoolingsystem.

Whenmeasuringthecoolantlevel,inspectthefillercapgasket.Replacegasketifitisdamaged.

Premixantifreezesolutiontoprovideprotectiontothelowestexpectedambienttemperature.

Operatewithathermostatinthecoolingsystemallyearround.Coolingsystemproblemscanarise withoutathermostat.

Fuel NOTICE

Fillfueltankattheendofeachdayofoperationtodriveoutmoisture ladenairandtopreventcondensation.Donotfillthetanktothebrim. Thefuelexpandswhenitgetswarmandmayoverflow.

Waterandsedimentshouldbedrainedfromthetankatthestartofeachshiftorafterthefueltankhas beenfilledandallowedtostandfor5to10minutes.

Ifenginefuelsystemisequippedwithawaterseparator,drainwaterfromwaterseparatordaily beforestartingengine.Alwaysdrainwaterfromseparatorbeforeitbecomesone-halffull.Frequent drainingmaybenecessaryinareasofhighhumidityorwhenfuelsupplyiscontaminatedwithwater.

Drainwaterandsedimentfromthemainfuelstoragetankweekly,andbeforethetankisrefilled.This willhelppreventwaterorsedimentfrombeingpumpedfromthestoragetankintothemachinefuel tank.

Measurefuellevelwithdipstickinfilleropening.

Afterchangingfuelfilter,alwaysbleedfuelsystemtoremoveairbubblesfromsystem.

Inspectairintakeprecleanerdailyforaccumulationofdustanddebris.

ServiceaircleanerswhenREDbandinindicatorlocksinvisibleposition.

Electrical

NOTICE

Whenusingexternalelectricalsourcetostartmachineswithdirect electricstarting,turndisconnectswitchoffandremovekeybefore attachingcabletoemergencystartingreceptacle.

Whenusingjumpercables,besuretoconnectinparallel:POSITIVE (+)toPOSITIVE(+)andNEGATIVE(-)toNEGATIVE(-).

Donotallowfreeendofjumpercablestotoucheithermachine.This helpsavoidelectricalshock.

Whenstartingamachinewithjumpercables,removeallcapsfrombothbatteries.Leavetheseoff duringthestartingprocesstoallowventingofhydrogengas.

Connectonecabletotheungroundedterminalofthebatteryofmachinetobestarted.

Connecttheotherendofthiscabletotheterminalofthesamepolarity[positive(+)topositive(+) andnegative(-)tonegative(-)]ontheauxiliarybattery.

Connectsecondcabletotheotherterminalofthestrongerbattery.

Finally,connecttheremainingcableendtothestartergroundterminal.

Anemergencystartingkitfacilitatesstartingfromanexternalpowersource.Itprovidesapermanent receptacleonthemachinetopluginajumpercable.Twodifferentcablesareneededforauxiliary startingfromanoperatingmachineorfromanauxiliarypowerpack.

HydraulicSystem

NOTICE

Make-upoiladdedtothehydraulicsystemmustmixwiththeoil alreadyinthetank.Useonlypetroleumproductsunlesssystemis equippedforusewithspecialproducts.

Ifhydraulicoilbecomescloudy,waterorairisenteringthehydraulic system.Drainfluid,purgesystem*,andretightenhydraulicsuctionline clamps.Waterorairinthehydraulicsystemcancausepumpfailure.

*ContactyourCaterpillardealerforcorrectpurgingprocedure.

General NOTICE

Accumulatedgreaseandoilonamachineisafirehazard.Removethis debriswithsteamcleaningorhighpressurewaterevery1000hoursor eachtimeanysignificantquantityofoilisspilledonamachine.

Wipeallfittings,capsandplugsbeforeservicing.

TueMay1110:18:17UTC+05302021

Product:COMPACTWHEELLOADER

Model:910COMPACTWHEELLOADER80U

Configuration:910WHEELLOADER80U06735-UP(MACHINE)POWEREDBY3204ENGINE

OperationandMaintenanceManual 910WHEELLOADER

MediaNumber-SEBU5525-00PublicationDate-01/10/1983DateUpdated-11/10/2001

(9)BrakeMasterCylinder

1.Removeplug.Maintainfluidlevel1/2inch(12mm)belowfillerplugopening.

2.Cleanandinstallplug.

(10)FramePivots

1.Lubricate1fittinginframeupperpivotand1fittinginlowerpivot.Total2fittings.

(11)RearAxleTrunnionBearings

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