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

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Product:WHEELLOADER

Model:916WHEELLOADER2XB

Configuration:916WHEELLOADER2XB00001-UP(MACHINE)POWEREDBY3204ENGINE

OperationandMaintenanceManual

916WHEELLOADER

MediaNumber-SEBU5995-01PublicationDate-01/11/1988DateUpdated-11/10/2001

Coolant,FuelandLubricantSpecifications

SMCS-7000

CoolantSpecifications

NOTICE

Useamixtureofwater,ethyleneglycol(antifreeze)andcoolingsystem conditioner.Pure,undilutedantifreezewillfreezeat-23°C(-10°F).

Excessivecoolantconditioner(greaterthantherecommended6% initialfill)togetherwithconcentrationsofantifreezegreaterthan65% causedepositstoformandmayresultinradiatortubeblockageand overheating.

DonotuseCaterpillarcoolingsystemconditionerorcoolant conditionerelementswithDowtherm209Full-Fillcoolant.Followthe instructionsprovidedwiththeDowtherm209Full-Fillcoolant.

Referto"KnowYourCoolingSystem,"FormSEBD0518,formoredetailedspecifications.

Water Acceptablewaterforuseintheethyleneglycolandwatermixtureisshowninthechartbelow:

Antifreeze

Usethecorrectamountofethyleneglycolmixedwithwater,toprovidefreezeprotectiontothelowest expectedoutsidetemperature.

Conditioner

NOTICE

Alwaysaddliquidcoolingsystemconditionertowater,orinstalla coolantconditionerelement(ifequipped).Neverusewateronly.

Neverusebothliquidcoolingsystemconditionerandacoolant conditionerelement(ifequipped)atthesametime.

UseCaterpillarliquidcoolingsystemconditioneroracoolantconditionerelement(ifequipped).This willprovidea3%to6%concentrationofconditionerinthecoolingsystemtohelppreventcorrosion.

ConditionercanbepurchasedfromyourCaterpillardealer.

FuelSpecificationsandInformation

TypesofFuel

Caterpillardieselengineshavetheabilitytoburnawidevarietyoffuels.Thesefuelsaredividedinto twogeneralgroups,preferredandpermissible.

Thepreferredfuelsprovidemaximumengineservicelifeandperformance.Theyaredistillatefuels. Theyarecommonlycalleddieselfuel,furnaceoil,gasoilorkerosene.

Thepermissiblefuelsarecrudeoilsorblendedfuels.Useofthesefuelscanresultinhigher maintenancecostsandreducedengineservicelife.

Referto"FuelsforCaterpillarDieselEngines,"FormSEHS7067,foradetailedsummaryofpreferred andpermissiblefuelsandtheirspecifications.

RefertoS.A.E.J313DieselFuelsforinformationaboutbetterqualityfuels,suchasignitionquality, gravity/density,viscosity,cloudpoint,sulfurcontent,etc.

FuelSulfurContent

Thepercentageofsulfurinthefuelwillaffecttheengineoilrecommendations.See"EngineOils" under"LubricantSpecifications."

Fuelsulfurischemicallychangedduringcombustiontoformsulfuricacid.Theacidchemically attacksmetalsurfacesandcausescorrosivewear.HigherengineoilTBNvaluesareessentialto minimizecorrosivewear.

Periodicallyrequestfuelsulfurcontentinformationfromyourfuelsupplier.Fuelsulfurcontentcan changewitheachbulkdelivery.

FuelCetaneRequirement

Theminimumfuelcetanenumberrecommendedforthedirectinjectionengineis40.

FuelCloudPoint

Fuelwaxingcanplugthefuelfiltersincoldweather.Thefuelcloudpointmustbebelowthe temperatureofthesurroundingairtopreventfilterwaxingandpowerloss.Fuelheatingattachments areavailablefromyourCaterpillardealertominimizefuelfilterwaxing.

LubricantSpecifications

TheabbreviationslistedbelowfollowS.A.E.J754nomenclature.TheclassificationsfollowS.A.E. J183classifications.TheMILspecificationsareU.S.A.MilitarySpecifications.Thesedefinitionswill beofassistanceinpurchasinglubricants.Therecommendedoilviscositiesarefoundonthe "LubricantViscosityRecommendations"chart.

Theprefix"SPC"isageneralabbreviationusedbyCaterpillartoidentifyspecialoilssuchas syntheticsorsemi-syntheticoils.

EngineOils

UseoilsthatmeettheEngineServiceClassificationCD/SEorCD/SF(MIL-L-2104D).

Consultthe"EMALubricatingOilsDataBook,"FormSEBU5939,foralistingofCD/SEorCD/SF oilbrands.

Thepercentageofsulfurinthefuelwillaffecttheengineoilrecommendations.Ifthefuelhasover 0.5%sulfurcontent,theCD/SEorCD/SFengineoilmusthaveaTBNof20timesthepercentageof fuelsulfur(TBNasmeasuredbytheASTMD-2896method).Ifthesulfurcontentisgreaterthan 1.5%byweight,useanoilwithaTBNof30andreducetheoilchangeintervalbyonehalf.Consult yourCaterpillardealerforcorrectengineoilrecommendations.

HigherTBNvaluesareessentialtoretardthecorrosivedamagetometalengineparts.

Youroilsuppliershouldbeabletofurnishthecorrectoils.

PowerTrainSystemOil-DifferentialsandFinalDrives,Transmission,TorqueConverterand ClutchOil(CD/TO-2)

UseServiceClassificationCDoilsthathavesatisfactoryperformanceintheCaterpillarOilTest NumberTO-2.TheseoilsarereferredtoasServiceClassificationCD/TO-2oils.

HydraulicOils(HYDO)

UseEngineServiceClassificationCC(MIL-L-2104B),CC/SF(MIL-L-46152B),CD(MIL-L-2104D) orindustrial-typehydraulicoilsthatarecertifiedbytheoilsuppliertohaveantiwear,antifoam, antirust,andantioxidationadditivepropertiesforheavydutyuse.

LubricatingGrease(MPGM)

UseMultipurpose-typegrease(MPGM)whichcontains3%to5%molybdenumdisulfide.NLGINo. 2Gradeissuitableformosttemperatures.UseNLGINo.1orNo.0Gradeforextremelylow temperatures.

HydraulicBrakeFluid(BF)

UseheavydutyhydraulicbrakefluidcertifiedbytheoilsuppliertomeetSAE1703fspecifications.

ThuMay2011:46:55UTC+05302021

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Product:WHEELLOADER

Model:916WHEELLOADER2XB

Configuration:916WHEELLOADER2XB00001-UP(MACHINE)POWEREDBY3204ENGINE

OperationandMaintenanceManual 916WHEELLOADER

MediaNumber-SEBU5995-01PublicationDate-01/11/1988DateUpdated-11/10/2001

Walk-AroundInspection InspectMachine

Lines,TubesandHoses

Inspectallhydraulic,pressureoil,fuel,hightemperaturewater,etc.,lines,tubesandhosesfor damage,excessivewearandrecommendedtorques.Donotuseyourbarehandstocheckforleaks.

Replacedamaged,worn,etc.,lines,tubesandhosesorcontactyourCaterpillardealerforrepairor replacement.

Forotheritemstobeinspectedsee"Walk-AroundInspection"inthe"BeforeStartingtheEngine" sectionofthispublication.

Openthefueltankdrainvalve.Drainwaterandsediment.Closethedrainvalve.

EngineCrankcase

MeasureOilLevel

1.Measureoillevelwiththemachinelevel.Lowerthebucketwithslightdownpressureandapplythe parking/secondarybrake.

2.Thelevelismeasuredwiththeenginestopped.

Withtheenginestopped,theoillevelshouldbebetweentheADDandFULLmarksonthedipstick.

3.Ifitisnecessarytoaddoil,removetheengineoilfillercap.

4.Addoiltothecorrectlevel.

5.Inspectthecapseal.Replacetheseal,ifitisdamaged.

6.Installtheoilfillercap.

Checkthehydraulicoillevelinthesightgauge.Whentheoiliscold,theoillevelshouldbejust abovetheADDmark.Whentheoilishot,itshouldfillthesightgaugecompletely.

1.Ifitisnecessarytoaddoil,removethehydraulictankcapslowlytorelieveanypressure.Addoilto bringtheoilleveljustabovetheADDmarkinthesightgauge.

2.Inspectthehydraulictankcapgasket.Replacethegasket,ifitisdamaged.

3.Installthehydraulictankcap.

Drainvalvelocatedundertherearofthemachine.Drainvalveaccessisthroughtheholeintheguard.

Openthedrainvalvetodrainanymoistureandsediment.Closethevalve.

NOTE:Yourmachinemaybeequippedwithanadditionalairtankfortheparkingbrake.Ifso, followthesameproceduretodrainmoistureandsedimentfromthesecondairtank.

NOTE:Yourmachinemaybeequippedwithanairdryer.Ifso,checktheairtank"Every250Service HoursorMonthly"toseeifitiscollectingwateroroil.Somewaterisnormal.Ifexcessivewateris observed,contactyourCaterpillardealerformorespecificmaintenanceprocedures. Radiator

Pressureaircancausepersonalinjury.

Whenusingpressureairforcleaning,wearaprotectivefaceshield, protectiveclothingandprotectiveshoes.

Themaximumairpressuremustbebelow205kPa(30psi)forcleaning purposes.

Compressedair,highpressurewaterorsteamcanbeusedtoremovedust,leavesandgeneraldebris fromafoldedcoreradiator.Cleanasrequiredbyconditionofradiator.

Theuseofcompressedairispreferred.

Referto"KnowYourCoolingSystem,"FormSEBD0518,forthecompleteprocedureand instructions.

CheckCoolantLevel

Atoperatingtemperature,enginecoolantishotandunderpressure.

Steamcancausepersonalinjury.

CheckcoolantlevelONLYwhenengineisstoppedandradiatorfiller capiscoolenoughtotouchwithyourbarehand.

Removefillercapslowlytorelievepressure.

Coolingsystemconditionercontainsalkali.Avoidcontactwithskinand eyestopreventpersonalinjury.

Useallcleaningsolutionswithcare.

Themachinemustbeparkedonlevelgroundandtheenginestopped.Lockthetransmissioncontrolin NEUTRAL.

Lowerthebucketwithslightdownpressure.Applytheparking/secondarybrake.

1.Observethecoolantlevelwiththeenginestoppedandcool.Removetheradiatorcapslowlyto relievethepressure.

2.Maintainthecoolantlevel1cm(1/2inch)belowthefillerneck.

3.Addcoolant,ifnecessary,tobringthecoolantleveltowithin1cm(1/2inch)belowthefillerneck.

4.Inspecttheradiatorcapgasketandreplaceitifitisdamaged.Installtheradiatorcap.

Transmission

MeasureOilLevel

Hotoilandcomponentscancauseinjury.Donotallowhotoilor componentstocontacttheskin.

Thetransmissionoillevelcanbecheckedwiththeoilcoldorhot.

Themachinemustbeparkedonlevelgroundandtheenginestopped.Lockthetransmissioncontrolin NEUTRAL.

Lowerthebucketwithslightdownpressure.Applytheparking/secondarybrake.

1.Measuretheoillevel.

WithCOLDOIL:Maintainoillevelatthe"MINSAFESTART-COLDOIL"markonthedipstick.

WithHOTOIL:MaintainoillevelbetweentheADDandFULLmarksonthe"ENGINEATLOW IDLE"sideofthedipstick.

2.Inspectthetransmissionfillercapgasket.Replacethegasket,ifitisdamaged.

3.Installthetransmissionfillercap.

IndicatorsandGauges

TestandInspect

Withtheenginerunning,movethepaneltestswitchtotheTESTposition.Allindicatorlightsshould comeonandthefaultalarmshouldsound.

Themainfaultlightshouldflashwhenthepaneltestswitchisactivated.Investigateandreportany malfunction.

Inspectallgaugesforbrokenlensesorindicators.Haveanyneededrepairsmade.

ThuMay2011:48:50UTC+05302021

Product:WHEELLOADER

Model:916WHEELLOADER2XB

Configuration:916WHEELLOADER2XB00001-UP(MACHINE)POWEREDBY3204ENGINE OperationandMaintenanceManual

Whenusingpressureair,wearaprotectivefaceshieldandprotective clothing.Themaximumairpressureatthenozzlemustbelessthan205 kPa(30psi)forcleaningpurposes.

1.Removethecoverintherearofthecab.Removethefilterelement.

2.Cleanthefilterelementwithpressureairorwashtheelementinwarmwaterandanonsudsing householddetergent.

3.Rinseincleanwaterandairdrythoroughly.

4.Installcleanelement.Installthecover.

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ChangeAirConditionerFilter-CleanAirConditioner

Whenusingpressureairwearaprotectivefaceshieldandprotective clothing.Themaximumairpressureatthenozzlemustbelessthan205 kPa(30psi)forcleaningpurposes.

1.Removethecoverintherightsideofthecab.Removethefilterelement.

2.Cleanthecondensercoil.Useavacuumcleaner,ifnecessary.

3.Installacleanfilterelement.Installthecover.

BucketLowerPivotPins

Lubricate

Lubricateonefittingoneachsideofthebucket.

Totaloftwofittings.

ThuMay2011:49:03UTC+05302021

Product:WHEELLOADER

Model:916WHEELLOADER2XB

Configuration:916WHEELLOADER2XB00001-UP(MACHINE)POWEREDBY3204ENGINE

OperationandMaintenanceManual 916WHEELLOADER

MediaNumber-SEBU5995-01PublicationDate-01/11/1988DateUpdated-11/10/2001

RearAxleTrunnionBearings

1.Lubricateonefittinginthefronttrunnionoftherearaxle.

2.Lubricateonefittinginthereartrunnionoftherearaxle. Totaloftwofittings.

1.Lubricateonefittingintheheadendlubeblockofthesteeringcylinderoneachsideofthe machine.

2.Lubricateonefittingintherodendofthesteeringcylinderoneachsideofthemachine. Totaloffourfittings.

BucketCylinderandLinkageBearings Lubricate

1.Lubricateonefittingontheupperpivotpinofthebucket.

2.Lubricatetwofittingsoneachsideofthemachine.

3.Lubricateonefittingonthebucketcylinderandtwofittingsontheliftcylinder(oneoneachsideof themachine.

4.Lubricateonefittingonthelowerbucketlink.

5.Lubricatetwofittingsonthebuckettiltlink. Totalof11fittings.

Batteries

CheckElectrolyteLevel

Donotsmokewhenobservingthebatteryelectrolytelevel.Batteries giveofffumesthatcanexplode.

Electrolyteisanacidandcancausepersonalinjuryifitcontactsthe skinoreyes.

1.Unlatchthebatterycompartmentintheradiatorcompartmentofthemachine.

2.Cleanthetopofthebatteries.Coatallpostswithpetroleumjelly.

LowMaintenanceBatterieswithRefillableCellsOnly

3.Removeeachfillcap.Inspecttheelectrolytelevel.

4.Ifnecessary,adddistilledwatertobringtheelectrolyteleveltothebottomofthefillopening. Atproperchargerateinatemperateclimate,abatterywillnotrequiremorethan30cc(1ounce)of waterpercellperweek.

5.Installallfillcaps.

Product:WHEELLOADER

Model:916WHEELLOADER2XB

Configuration:916WHEELLOADER2XB00001-UP(MACHINE)POWEREDBY3204ENGINE

Hotoilandcomponentscancauseinjury.Donotallowhotoilor componentstocontacttheskin.

NOTICE

Neverinstalladamagedfilter.Damagedfilterscancausesevere damagetotheengine. Themachinemustbelevelandtheengineoilwarm.Lowerthebucketwithslightdownpressure.

Applytheparking/secondarybrakeandstoptheengine.

1.Removethecrankcasedrainpluganddraintheoil.

2.Removethefilterwithastrap-typewrench.

3.Cleanthefilterbase.Removealloftheoldgasket.

4.Applyalightcoatofengineoiltothegasketofthenewfilter.

5.Installthenewfilterbyhand.

6.Whenthegasketcontactsthefilterbase,tightenthefilter1/2turnmore.

7.Installthecrankcasedrainplug.

8.Fillthecrankcasewithnewoil.Seethe"RefillCapacities"chart.

9.Starttheengineandallowtheoiltowarm.Checkforleaks.Stoptheengine.Afterfiveminutes, measuretheoillevel.

10.Addoil,ifnecessary,tobringtheoilleveltotheFULLmarkontheENGINESTOPPEDsideof thedipstick.

CoolingSystem

AddLiquidCoolingSystemConditioner

Atoperatingtemperature,theenginecoolantishotandunderpressure. Steamcancausepersonalinjury.

InspectthecoolantlevelONLYwhentheengineisstoppedandthe radiatorcapiscoolenoughtotouchwithyourbarehand. Removetheradiatorcapslowlytorelievepressure.

Thecoolingsystemconditionercontainsalkali,avoidcontactwiththe skinandeyestopreventpersonalinjury.

NOTICE

Neveraddcoolanttoanoverheatedengine,allowtheenginetocool first.

DonotuseCaterpillarcoolingsystemconditionerwithDowtherm209 Full-Fillcoolant.Followtherecommendationsprovidedwith Dowtherm209Full-Fillcoolant.

DoNOTaddliquidcoolingsystemconditionermonthlyunlessthe machinehasactuallyoperated250servicehours.Addingcooling systemconditionerbefore250servicehourswillgiveanexcessive concentrationofconditioner.

Ifthecoolingsystemwasdrainedandrefilled,seethetopic"CoolingSystem"under"Every2000 ServiceHoursor1Year."

Itmaybenecessarytodrainenoughcoolanttoallowfortheadditionofcoolingsystemconditioner.

Add1/2liter(1pint)ofCaterpillarliquidcoolingsystemconditioner,orequivalent,tothiscooling system.Thiswillmaintaintherequired3%concentrationofconditioner.

Make-upcoolantshouldcontaina3%concentrationofconditioner-1literofconditionerper33liters ofwater(1pintper4gallons).

1.Loosentheradiatorcapslowlytorelieveanypressure.Removetheradiatorcap.

2.Add1/2liter(1pint)ofliquidcoolingsystemconditioner.

3.Inspecttheradiatorcapgasketandreplaceit,ifitisdamaged.

4.Installtheradiatorcap.

1.Disconnectthesteeringframelocklink.Starttheengine.

2.Turnthemachinefullrightorleft.

3.Lowerthebucket,applytheparkingbrakeandstoptheengine.

4.Lubricateonefitting.

Straightenthemachineandconnectthesteeringframelocklinkafter servicingthedriveshaftspline.

1.Starttheengineandoperateitathighidle.

2.Moveselectorswitch(1)totheairconditioningpositionforcooling.Movefancontrolswitch(2)to HIGHspeed.Turntemperaturecontrolknob(3)tomaximumcold.

3.Allowtwominutesfortheairconditioningsystemtostabilize.

4.Checkforfreoninthesystemasfollows:Feelthesuctionline(1)andthedischargeline(2).

Ifthesystemcontainsfreon,thedischargelinewillbewarmerthanthesuctionline.

Ifthesystemdoesnotcontain,orisverylowonfreon,poorcoolingwillresult.

5.Turnofftheenginetoinspectthecompressorbelt.

6.Inspecttheconditionandtheadjustmentofthecompressorbelt.Thebeltshoulddeflect14to20 mm(9/16to13/16inch)under110N(25lb)force.

7.Toadjust,loosenthecompressorbracketboltsandlocknut.

8.Turntheadjustingnutuntilthecorrectbelttensionisreached.

9.Tightenthecompressorlocknutto150±20N·m(110±15lbft).

10.Tightenthecompressorbracketbolts.

11.Recheckthebeltadjustment.

12.Repeatsteps7through10.

13.Ifpoorcoolingisexperienced,turnofftheairconditioner.Stoptheengine.Contactyour Caterpillardealerforairconditionersystemservice,ifnecessary.

Belts-AlternatorandFan

InspectCondition

Inspecttheconditionandtheadjustmentofthebelts.Replacewornordamagedbelts.

NOTE:Replacebeltsinmatchedsets,eventhoughonlyonemaybedamagedorworn.

1.Inspecttheadjustment.Thebeltsshoulddeflect14to20mm(9/16to13/16inch)under110N(25 lb)force.

2.Loosenthealternatormountingbolts.

3.Loosenadjustinglocknut(1).Turnadjustingnut(2)untilthecorrectbelttensionisreached.

4.Tightentheadjustinglocknutto150±20N·m(110±15lbft).

5.Tightenthealternatormountingbolts.

BrakeFluidReservoirs

InspectFluidLevel

1.Opentheaccesscoverinthehood.

2.Unlocktheretainers.

3.Removethelidsfrombothbrakefluidreservoirs.

NOTE:Maintainthebrakefluidwithin1cm(1/2inch)ofthetopofeachreservoir.

4.Inspectallseals,andreplacethemifnecessary.

5.Replacethelidsonthereservoirs.Securethemwiththeretainers.Closetheaccesscover.

ServiceBrakes

TestHoldingAbility

Besuretheareaaroundmachineisclearofpersonnelandobstructions.

Besurethesteeringframelocklinkisinstoredposition.

Testthebrakesonadry,levelsurface.

Fastentheseatbeltbeforetestingthebrakes.

1.Startengine,andraisebucketslightly.Applyservicebrake(rightbrakepedalonly)andreleasethe parking/secondarybrake.

2.Withtheservicebrakeapplied(rightbrakepedalonly),shiftthetransmissionto2ndspeedforward.

3.Graduallyincreasetheenginespeedtohighidle.Themachineshouldnotmove.

Ifthemachinebeginstomove,reducetheenginespeedimmediatelyand applytheparking/secondarybrake.

4.Reducetheenginespeedtolowidle,shiftthetransmissiontoNEUTRAL.Applythe parking/secondarybrake,lowerthebuckettothegroundandstoptheengine.

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