Product:WHEELLOADER
Model:928GWHEELLOADER6XR
Configuration:928GWheelLoader6XR00001-UP(MACHINE)POWEREDBY3116Engine
OperationandMaintenanceManual
928GWHEELLOADERHYDRAULICQUICKCOUPLERATTACHMENTTHISMODULEINCLUDES MediaNumber-GESR0052-00PublicationDate-01/05/1975DateUpdated-10/10/2001
GeneralHazardInformation
SMCS-7338
ManualInformation
Theinformationinthismanualspecificallyaddressesthemaintenance,operation,andrepairofthe attachment.
Thismanualshouldbestoredintheoperator'scompartmentintheliteraturefolderorseatbackliterature storagearea.
Thismanualcontainssafety,operation,transportation,lubrication,andmaintenanceinformation.
Somephotographsorillustrationsinthepublicationshowdetailsorattachmentsthatmaybedifferentfrom yourmachine.Guardsandcoversmayhavebeenremovedforillustrativepurposes.
Continuingimprovementandadvancementofproductdesignmayhavecausedchangestoyourmachine whicharenotincludedinthispublication.
Read,study,andkeepthismanualwiththemachine.
Whenaquestionarisesregardingyourattachment,ofthispublication,pleaseconsultyourCaterpillardealer forthelatestavailableinformation.
AttachmentSafetyOperation
Attacha"DONOTOPERATE"orsimilarwarningtagtostartswitchorcontrolsbeforeservicingor repairingthemachine.Thesetags,FormSEHS7332,areavailablefromyourCaterpillardealer.
Knowthewidthofyourattachmentsoproperclearancecanbemaintainedwhenoperatingnearfences, boundaryobstacles,etc.
Wearahardhat,protectiveglassesandotherprotectiveequipmentasrequiredbyjobconditions.
Information
Donotwearlooseclothingorjewelrythatcancatchoncontrolsorotherpartsofthemachine.
Makecertainallprotectiveguardsandcoversaresecuredinplaceonthemachine.
Neverputmaintenancefluidsintoglasscontainers.
Useallcleaningsolutionswithcare.
Reportallneededrepairs.
Donotallowunauthorizedpersonnelonthemachine.
Performallmaintenanceunlessotherwisespecifiedasfollows:
*Themachineparkedonlevelground.
*TheattachmentcontrolsinHOLD.
*ThetransmissioncontrolinNEUTRAL.
*Theparking/secondarybrakeengaged.
*Theenginestopped.
*Thekeystartswitchoffandthekeyremoved.
*Thedisconnectswitchoffandthekeyremoved.
ProtectiveEquipment
Alwayswearahardhat,protectiveglasses,protectiveshoesandotherprotectiveequipmentasrequiredby jobconditionswhenworkingaroundthisproduct.Inparticular,wearprotectiveglasseswhenpoundingon anypartoftheproductwithahammerorsledge.usewelder'sgloves,hood/goggles,apron,andother protectiveclothingappropriatetotheweldingjobbeingperformed.
PressurizedItems
Relieveallpressureinair,oilorwatersystemsbeforeanylines,fittings,orrelateditemsaredisconnectedor removed.Alwaysmakesureallraisedcomponentsareblockedcorrectlyandbealerttopossibletrapped pressurewhendisconnectinganydevicethatutilizespressure.
Lowertheattachmenttothegroundbeforeperforminganywork.Ifthiscannotbedone,makesurethe attachmentisblockedcorrectlytopreventitfromdroppingunexpectedly.
Pressureaircancausepersonalinjury.Whenusingpressureairforcleaning,wearaprotectivefaceshield, protectiveclothingandprotectiveshoes.
Themaximumairpressuremustbebelow205kPa(30psi)forcleaningpurposes.
FluidPenetration
Alwaysuseaboardorcardboardwhencheckingforaleak.Escapingfluidunderpressure,evenapin-hole sizeleak,canpenetratebodytissue,causingseriousinjuryandpossibledeath.Iffluidisinjectedintoyour skin,itmustbetreatedbyadoctorfamiliarwiththistypeofinjuryimmediately.
Lifting
Useahoistwhenliftingcomponentsthatweigh23kg(50lb)ormore,toavoidbackinjury.Makesureall chains,hooks,slings,etc.areingoodconditionandarethecorrectcapacity.Besurehooksarepositioned correctly.Liftingeyesarenottobeexcessivelysideloadedduringaliftingoperation.
CrushingOrCuttingPrevention
Properlysupporttheequipmentortheattachmentwhenworkingbeneaththeequipmentorattachment.Do notdependonhydrauliccylinderstoholditup.Anyattachmentcanfallifacontrolismoved,orifa hydrauliclinebreaks.
Neverattemptadjustmentswhilethemachineismovingortheengineisrunningunlessotherwisespecified.
Whenthereareattachmentlinkages,theclearanceinthelinkageareawillincreaseanddecreasewith movementoftheattachment.
Donotuseakinkedorfrayedwireropecable.Weargloveswhenhandlingawireropecable.
Retainingpins,whenstruckwithforce,canflyoutandinjurenearbypersons.Makesuretheareaisclearof peoplewhendrivingtheretainerpins.
Wearprotectiveglasseswhenstrikingaretainerpintoavoidinjurytoyoureyes.
Chipsorotherdebriscanflyoffobjectswhenstruck.Makesurenoonecanbeinjuredbyflyingdebris beforestrikinganyobject.
BurnPrevention
Hotoilandoil-carryingcomponentscancausepersonalinjury.Donotallowhotoiloroil-carrying componentstocontactyourskin.
Relieveallpressureintheairandoilsystemsbeforeanylines,fittings,tubes,hoses,orrelateditemsare disconnectedorremoved.
FireAndExplosionPrevention
Mostlubricantsareflammable.
Cleanandtightenallelectricalconnections.Checkdailyforlooseorfrayedelectricalwires.Havealllooseor frayedelectricalwirestightened,repaired,orreplacedbeforeoperatingthemachine.
Keepalllubricantsstoredinproperlymarkedcontainersandawayfromallunauthorizedpersons.
Storealloilyragsorotherflammablematerialinaprotectivecontainer,inasafeplace.
Donotweldorflamecutonpipesortubesthatcontainflammablesolventbeforeweldingorflamecuttingon them.
Removeallflammablematerialssuchasoilorotherdebrisbeforetheyaccumulateontheattachment.
Looseordamagedlubricationandhydrauliclines,tubesandhosescancausefires.Donotbendorstrikehigh pressurelinesorinstalloneswhichhavebeenbentordamaged.Checklines,tubes,andhosescarefully.Do notuseyourbarehandstocheckforleaks.Pinholeleakscanresultinahighvelocityfluidstreamthatwill beinvisibleclosetothehose,tubeorline.
SafetySigns
ReadandunderstandallWarningsignsontheproductbeforeoperating,lubricating,orrepairingthisproduct. Replaceanydamaged,illegibleormissingwarningplates,signsordecals.
Repair
1.Disconnectbatteryanddischargeanycapacitorsbeforestartingtoworkontheproduct.Attacha"DoNot Operate"tagintheOperator'sCompartment.Thesetags,FormNumberSEHS7332,areavailablefromyour CaterpillarDealer.
2.Ifpossible,makerepairswiththemachineparkedonalevel,hardsurface.Blockmachinetopreventit fromrollingwhileworkingonorundermachine.
3.Donotworkonanyattachmentsupportedonlybyliftjacksorahoist.Alwaysuseblocksorjackstandsto supporttheattachmentbeforeperforminganyserviceordisassembly.
4.Becarefulwhenremovingcoverplates.Graduallybackoffthelasttwoboltsornutslocatedatthe oppositeendsofthecoverordevice.Then,prythecoverloosetorelieveanyspringorotherpressure,before removingthelasttwoboltsandnutscompletely.
5.Alwaysusetoolsthatareingoodconditionandbesureyouunderstandhowtousethembefore performinganyserviceoperation.
6.Replaceallfastenerswiththesamepartnumber.Donotusealesserqualityfastenerifreplacementsare necessary.
7.Weldingrepairsshouldbeperformedonlywiththebenefitoftheappropriatereferenceinformationandby personneladequatelytrainedandknowledgeableinweldingprocedures.Determinetypesofmetalbeing weldedandselectcorrectweldingprocedureandelectrodes,rods,orwiretoprovideaweldmetalstrength equivalentorbetterthantheparentmetal.
8.Donotdamagewiringduringremovaloperation.Reinstallthewiringsoitisnotdamagedorwillnotbe damagedinoperationbycontactingsharpcorners,orbyrubbingagainstsomeobjectorhotsurface.Donot connectwiringtoalinecontainingfluid.
9.Besureallprotectivedevicesincludingguardsandshieldsareproperlyinstalledandfunctioningcorrectly beforestartingarepair.Ifaguardorshieldmustberemovedtoperformtherepairwork,useextracaution. Repairanylooseordamagedfluidlines,tubes,orhosesbecauseleakscancausefires./
10.Tightenconnectionstothecorrecttorque.Allheatshields,clamps,andguardsmustbeinstalledcorrectly toavoidexcessiveheat,vibration,orrubbingagainstotherpartsduringoperation.
11.Storeragsthathaveoilorotherflammablematerialonthem,inprotectivecontainers,awayfromopen fires,weldingorcuttingareas.
Product:WHEELLOADER
Model:928GWHEELLOADER6XR
Configuration:928GWheelLoader6XR00001-UP(MACHINE)POWEREDBY3116Engine
OperationandMaintenanceManual
928GWHEELLOADERHYDRAULICQUICKCOUPLERATTACHMENTTHISMODULEINCLUDES MediaNumber-GESR0052-00PublicationDate-01/05/1975DateUpdated-10/10/2001
Introduction
SMCS-7338
Whenthewords"useagain"areinthedescription,thespecificationgivencanbeusedtodetermineifapart canbeusedagain.Ifthepartisequaltoorwithinthespecificationgiven,usethepartagain.
Whentheword"permissible"isinthedescription,thespecificationgivenisthe"maximumorminimum" tolerancepermittedbeforeadjustment,repairand/ornewpartsareneeded.
Acomparisoncanbemadebetweenthemeasurementsofawornpartandthespecificationsforanewpartto findtheamountofwear.Apartthatisworncanbesafetouseifanestimateoftheremainderofitsservice lifeisgood.Ifashortservicelifeisexpected,replacethepart.
Disconnectbatteriesbeforeperformanceofallserviceworkwiththe exceptionofperformingvoltagetesting.
Atoperatingtemperature,thehydraulicoiltankishotandunder pressure.Hotoilcancauseburns.Removethebreatherfiltercaponly whentheengineisstoppedandthebreatherfiltercapiscoolenoughto touch.Slowlyloosenthebreathercaptoreleaseanypressureinthe hydraulictank.Becautiousofhotoilwhenanylinesaredisconnectedin thehydraulicsystem.
HydraulicCoupler
HydraulicQuickCoupler
HydraulicQuickCoupler
FriMar1210:42:59UTC+05302021
PreviousScreen
Product:WHEELLOADER
Model:928GWHEELLOADER6XR Configuration:928GWheelLoader6XR00001-UP(MACHINE)POWEREDBY3116Engine
OperationandMaintenanceManual
LOCKED-Movetheleverlockandpushthepinintothehole.Thislockstheattachmentcontrollever.
NOTE:PlacetheattachmentcontrolleverintotheLOCKEDpositionifyouareroadingthemachineoryou aretransportingthemachine.
UNLOCKED-Pullthepinoutofthehole.Movetheleverlockawayfromtheattachmentcontrollever.This releasestheattachmentcontrollever.
AttachmentAuxiliaryControl
SMCSCode:5063;5258;5700
Movethedivertervalvelevertotheauxiliarypositioninordertodivertflowtotheattachment.
Pullbacktheleverinordertopressurizetheleftsupplyline.
Pushtheleverforwardinordertopressurizetherightsupplyline.
Divertervalvelevermustbereturnedtotheverticalauxiliaryposition beforeoperatinghydraulicattachmentstoensurecouplerpinsare locked.Failuretodosomaycausetheattachmenttofalloffandcausing personalinjury.
SMCSCode:5056;5258;5700
Improperattachmentofattachmentscouldresultininjuryordeath.
Donotoperatethismachineuntilyouhavepositiveindicationthatthe couplerpinsarefullyengaged.Checkforengagementby:
1.Pushthetiltcontroltotilttheattachmentdown.
2.Putdownpressureontheattachment.
3.Backthemachineupandmakesurethereisnotmovement betweentheattachmentandthecoupler.
Movethedivertervalvelevertothecouplerpositioninordertoprovideflowtothecoupler.
Disengage(1)-Movethelevertoposition(1)inordertodisengagethecouplerpins.Releasetheleverin ordertoreturnthelevertotheHOLDposition.
Hold(2)-Releasethelever.Thecouplerpinswillremainintheengagedpositionorinthedisengaged position.
Engage(3)-Movethelevertoposition(3)inordertoengagethecouplerpins.Releasetheleverinorderto returnthelevertotheHOLDposition.
OperatingTechniques AttachmentCouplerOperation
Improperattachmentofattachmentscouldresultininjuryordeath.
Donotoperatethismachineuntilyouhavepositiveindicationthatthe couplerpinsarefullyengaged.Checkforengagementby:
1.Pushthetiltcontroltotilttheattachmentdown.
2.Putdownpressureontheattachment.
3.Backthemachineupandmakesurethereisnotmovement betweentheattachmentandthecoupler.
1.Pushtheattachmentcouplerleverforwardinordertodisengagethecouplerpins.
2.Tiltthecouplerassemblyforward.
3.Slowly,drivethemachineforward.Aligntheattachmenthookswiththecouplerassembly.
4.Pullbackontheliftleverinordertoslightlyraisethecoupler.Raisethecoupleruntilthecouplerassembly contactstheattachmenthooksandtheattachmentisliftedupslightly.
Makesurethattheattachmentislevelfromonesidetotheotherside.
5.Tiltbackthecouplerassemblyuntilthealignmentbaroftheattachmentcontactsthecoupler.
6.Pullbackonthecouplerleverinordertoengagethecouplerpinsintotheattachmentretainer.
NOTE:Ensurethatthetoolisfirmlyattachedandcontinuewithsteps7through9.
This is the sample of the manual Click on the download link for complete Manual
7.Pushthetiltleverinordertotilttheattachmentdownward.
8.Pushtheliftleverforwardinordertoputdownpressureontheattachment.
9.Backupthemachineandmakesurethatthereisnomovementbetweentheattachmentandthecoupler. Steps7through9indicatethatthecouplerpinshavefullyengagedintotheattachmentretainerholes.
AttachmentsThatRequireHydraulics
Followtheprocedurethatisdescribedin"FrontAttachmentCouplerforToolsThatDoNotRequire Hydraulics".
Auxiliaryquickconnectors(1)withdivertervalve(2)intheauxiliaryposition.
Divertervalvelevermustbereturnedtotheverticalauxiliaryposition beforeoperatinghydraulicattachmentstoensurecouplerpinsare locked.Failuretodosomaycausetheattachmenttofalloffandcausing personalinjury.
Beforeconnectingordisconnectingthequickdisconnectplugs,followthehintsbelow.
1.Stoptheengine.
2.Moveallofthehydraulicattachmentcontrolleversinordertorelievethepressureinthehydrauliclines.
3.ReturnalloftheleverstotheHOLDposition.
ConnectingLinesAndDisconnectingLines
1.Disconnectthehydrauliclinesofthetoolthatwillbeused.Wipeoffallforeignmaterial.
2.Removetheplugsandconnectthelines.
Whencarriermachinesareequippedwithfrontattachmentsotherthan buckets,liftingaloadthatisgreaterthanshownintheLoadingChart forthatmachinecouldcausetheattachmenttorotatedownward, allowingtheloadtoslideorpitchforwardresultinginpersonalinjury ordeath.
Thecombinedweightofthecoupler,attachment,andloadmustnotbegreaterthanthemaximumallowable loadattheloadapplicationpointasshownintheLoadingChartforthecarriermachine.Theweightofthe coupleris250kg.
Whencarriermachinesareequippedwithfrontattachmentsotherthan buckets,liftingaloadthatisgreaterthanshownintheLoadingChart forthatmachinecouldcausetheattachmenttorotatedownward, allowingtheloadtoslideorpitchforwardresultinginpersonalinjury ordeath.
Thecombinedweightofthecoupler,attachment,andloadmustnotbegreaterthanthemaximumallowable loadattheloadapplicationpointasshownintheLoadingChartforthecarriermachine.Theweightofthe coupleris551lb.
FriMar1210:43:10UTC+05302021
Product:WHEELLOADER
Model:928GWHEELLOADER6XR
Configuration:928GWheelLoader6XR00001-UP(MACHINE)POWEREDBY3116Engine
OperationandMaintenanceManual
Specifications
StandardTorqueForFasteners
NOTE:Takecaretoavoidmixingmetricandinchdimensionedfasteners.Mismatchedorincorrectfasteners canresultinvehicledamageormalfunction,orpossibleinjury.Exceptionstothesetorquesaregiveninthis ServiceManualwhereneeded.
NOTE:Priortoinstallationofanyhardware,besurecomponentsareinsatisfactorycondition.Boltand threadsmustnotbewornordamaged.Hardwaremustbefreeofrustandcorrosion.Cleanhardwarewitha non-corrosivecleanerandapplyengineoiltothreadsandbearingface.Ifthreadlockorothercompoundsare tobeapplied,donotapplyengineoil.
StandardTorqueForO-RingFaceSealFittingsAnd37°FlaredFittings
NOTE:Use50percentoftheabovetorquevalueswheneitherthefittingorportmaterialisnon-ferrous.
O-RingFaceSealFitting
O-RingFaceSealFittings
1.O-ringfacesealfitting.2.O-ringgroove.3.O-ringfacesealnut.4.O-ring.5.StraightthreadO-ringportendfitting.
FittingInstallation
HydraulicLineInstallation
1.Forametaltubetohoseconnection,installthetubeandtightenallboltsfingertight.
2.Tightentheboltsattherigidend.
3.Installthehoseandtightenallboltsfingertight.
4.Putthehoseinapositionsothatisdoesnotmakecontactwiththemachineoranotherhose.
5.Tightentheboltsonbothconnections.
6.Starttheengine.
7.Movetheimplementcontrolleverstoallpositions.
8.Lookatthehoseduringmovementoftheimplement.Makesurehoseisnotincontactwiththemachineor otherhoses.
9.Shutofftheengine.
10.Ifnecessary,putthehoseinanewpositionwhereitwillnotmakecontactwhentheimplementismoved.
AssemblyOffFittingsWithStraightThreadsAndO-RingSeals
Thistypeoffittingisusedinmanyapplications.Thetubeendofthefittingwillbedifferentindesignsothat itcanbeusedinmanydifferentapplications.However,theinstallationprocedureofthefittingisthesame.If thetubeendofthefittingbodyisthesameasintheinstallation(eitheranelboworastraightbody)itwillbe necessarytoassemblethesleeveonthetubebeforeconnectingthetubetotheend.
1.Endoffittingbody(connectstotube).2.Fittingbody.3.Locknut.4.Backupwasher.5.O-ringseal.6.Endoffittingthatgoes intootherparts.
1.Putlocknut(3),backupwasher(4)andO-ringseal(5)asfarbackonthefittingbody(2)aspossible.Hold thesecomponentsinthisposition.Turnthefittingintothepartitisusedonuntilbackupwasher(4)just makescontactwiththefaceofthepartitisusedon.
2.Toputthefittingassemblyinitscorrectposition,turnthefittingbody(2)out(counterclockwise)a maximumof359degrees.Tightenlocknut(3)tothetorqueshowninthecorrectchartforthefittingused.
NOTE:Ifthefittingisaconnector(straightfitting),thehexonthebodytakestheplaceofthelocknut.To installthistypeoffitting,tightenthehexagainstthefaceofthepartitgoesinto.
TorquesForFlaredAndO-RingFittings
Thetorquesshowninthechartsthatfollowaretobeusedonthenutpartof37DegreeFlared,45Degree Flared,andinvertedFlaredfittings(whenusedwithsteeltubing),O-Ringplugs,O-Ringfittingsandswivel nutswhenusedinapplicationsto20700kPa(3000psi)
37°FlaredFittings
45°Flaredand45°InvertedFlareFittings
TaperedPipeThreadFittings
TighteningOtherFittings
HiDuty(ShearSleeve)TubeFittings
Aftertubehasbeenputthroughthenutandmakescontactagainstthetubeshoulderinthefittingbody,turn thenutwithawrenchuntilasmalldecreaseintorqueisfelt.Thisisanindicationthatthesleevehasbeen brokenoffthenut.Holdthetubetopreventturningandtightenthenut11/2turns.
HiSealFittings
Putnutandsleeveoverthetubingwiththeshortheavyendofthesleevefacingtheendoftubing.Putthe tubeendagainstthecounterboreinthebodyofthefittingandtightenuntilnutisoverthelastthreadonthe body.Theremainderofspaceisusedwheneverthefittingisremovedandinstalledagain.
TorquesForConstantTorqueHoseClamps
Aconstanttorquehoseclampcanbeusedinplaceofanystandardhoseclamp.Makesuretheconstant torquehoseclampisthesamesizeasthestandardclamp.Duetoextremetemperaturechanges,hosewill heatseat.Heatsettingcauseshoseclampstoloosen.Loosehoseclampscanresultinleaks.Therehavebeen reportsofcomponentfailurescausedbyhoseclampsloosening.Thenew,constanttorquehoseclampwill helppreventthesefailures.
Eachinstallationapplicationcanbedifferentdependingonthetypeofhose,fittingmaterialandanticipated expansionorcontractionofthehoseandfittings.Atorquewrenchshouldbeusedforproperinstallationof thenew,constanttorquehoseclamps.Constanttorquehoseclampsshouldbeinstalledasfollows:
*Toallowformaximumexpansioninstallclampsat5.7N·m(50lbin).
*Toallowforequalexpansionandcontraction,installclampsat10.2N·m(90lbin).
*Toallowformaximumcontraction,installclampsat14.1N·m(125lbin).
FriMar1210:43:25UTC+05302021
This is the sample of the manual Click on the download link for complete Manual
