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MAINTENANCE INTERVALS - Safety

1. Illustration 185 g00753635 2 The engine crankcase breather is located near the air cleaner housing Loosen hose clamp 3 and remove the outlet hose from breather 1 3 Remove bolt 2 and the breather 4 Check the condition of the seal on the breather cover Replace the seal if the seal is damaged 5 Wash the breather cover and the element in a clean nonflammable solvent 6 Shake the element dry or use pressure air to dry the element 7 Inspect the outlet hose for damage Replace the hose if necessary 8 Install breather 1 and bolt 2 9 Install the outlet hose and hose clamp 3 10 Close the engine hood 124 Maintenance Section Engine Oil High Speed and Oil Filter Change SEBU7459 09 Engine Oil High Speed and Oil Filter Change SMCS Code 1318 510 HZ Selection of the Oil Change Interval NOTICE This machine is equipped with an engine that meets EPA Tier 2 Euro Stage Il or MOC Step 2 emission regulations A 500 hour engine oil change interval is available provided that operating conditions and rec ommended multigrade oil types are met When these requirements are not met shorten the oil change interval to 250 hours or use an S O S oil sampling and analysis program to determine an acceptable oil change interval If you select an interval fo
2. Illustration 231 g00765667 Wipe off the fittings before any lubricant is applied Open the access door on the right side of the machine Apply lubricant through two remote fittings These remote fittings lubricate the head end of the steering cylinders Apply lubricant through the fittings on the rod ends of both steering cylinders There is a total of four fittings 150 Maintenance Section SEBU7459 09 Steering Pilot Oil Screen Command Control Steering Clean Replace 101467209 Steering Pilot Oil Screen Command Control Steering Clean Replace SMCS Code 4304 070 Z3 4304 510 Z3 S N AYB1 Up S N AYD1 Up S N AYE1 Up S N AYG1 Up S N AXR1 Up S N AXS1 Up Personal injury can result from working with cleaning solvent Because of the volatile nature of many cleaning solvents extreme caution must be exercised when using them If unsure about a particular cleaning fluid refer to the manufacturer s instruc tions and directions Always wear protective clothing and eye protec tion when working with cleaning solvents Illustration 232 g00765737 The screen group for the steering oil is located in the articulation joint near the steering neutralizer valve on the right side 1 Disconnect two hoses 2 Remove two connectors 2 from screen group 3 3 Use an allen wrench to remove one screen
3. the machine Illustration 144 g00765808 For pin joint 4 apply lubricant through a remote 102421156 fitting on the right side of the machine Use the fitting Bucket Tips p Inspect Replace that is toward the front of the machine SMCS Code 6805 040 6805 510 Personal injury or death can result from the bucket falling Block the bucket before changing bucket tips 108 Maintenance Section Bucket Tips Inspect Replace SEBU7459 09 Personal injury can result from driving out retainer pins Retainer pins when struck with force can fly out and cause injury to nearby people Make sure the area is clear of people when driving out retainer pins Wear protective glasses when striking a retainer pin Bucket Tips Illustration 146 g00101352 1 Usable 2 Replace this bucket tip 3 Overworn Check the bucket tips for wear If the bucket tip has a hole replace the bucket tip The loss of bucket tips can often be attributed to the improper installation of the retaining pin into the tip and the adapter Bucket tips are lost more frequently on excavators because the tips are closer together Inserting the pin from the correct side right side of the adapter is difficult due to the small gap More clearance can be obtained by installing the pin through the tip and the adapter from the left side and then by driving the pin against the retainer This procedure will often cause the spiral retainer
4. Apply lubricant through the fitting 101709216 Bucket Wear Plates Inspect Replace SMCS Code 6120 040 6120 510 Personal injury or death can result from the bucket falling Block the bucket before changing bucket wear plates Illustration 153 g00879740 Inspect the wear plates Replace the wear plates before damage to the bottom of the bucket occurs Consult your Caterpillar dealer for replacement of wear plates 101449996 Cab Air Filter Clean Replace SMCS Code 7342 070 7342 510 Note Clean the cab air filters more often if the machine is being operated in dusty conditions Illustration 154 g00759048 1 Remove the filter cover behind the seat Two threaded knobs 1 are used in order to remove the cover Remove the filter element 2 2 Open the access door 3 on the left side of the cab Remove the filter element SEBU7459 09 111 Maintenance Section Case Drain Screen Strainer Steering Pump Hydraulic Fan Pump Motor Clean 3 Clean the filter elements with pressure air or wash the filter elements in warm water with a nonsudsing household detergent 4 If water and detergent are used to clean the filter elements rinse the filter elements in clean water and allow the filter elements to air dry thoroughly Note If either filter element is damaged install a new filter element 5 Install the filter elements Install the filter cover and close the acce
5. Note Make sure that the plug is installed completely before you check the oil level If the plug is not installed completely an incorrect oil level reading can occur 3 Remove the dipstick fill plug again and check the oil level Maintain the oil level between the ADD mark and the FULL mark Add oil if necessary Reference Refer to Operation and Maintenance Manual Lubricant Viscosities and Refill Capacities for the type of lubricant and for the refill capacity 4 Clean the plug and install the plug 5 Repeat Step 2 through Step 4 for the rear axle 101911031 Differential and Final Drive Oil Sample Obtain SMCS Code 3278 008 4011 008 4070 008 7542 Illustration 172 g00667052 Front axle Illustration 173 g00667053 SEBU7459 09 119 Maintenance Section Drive Shaft Spline Center Lubricate The axles are not equipped with sampling valves Obtaining a sample of the differential and final drive oil will require a vacuum pump or an equivalent Withdraw the fluid through the filler opening on the right side of each axle Reference Refer to Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations for more information about obtaining an fluid sample 101462847 Drive Shaft Spline Center Lubricate SMCS Code 3253 086 SN Note For better access to the fitting articulate the machine to the right or to the left Since the steering frame lock cannot
6. Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates ie O iH E oe p P h A T fo S io aao a o 2 a YV a Illustration 164 g00767660 116 Maintenance Section Cooling System Water Temperature Regulator Replace SEBU7459 09 Obtain the sample of the coolant as close as possible to the recommended sampling interval Supplies for collecting samples can be obtained from your Caterpillar dealer Refer to Operation and Maintenance Manual Cooling System Coolant Sample Level 1 Obtain for the guidelines for proper sampling of the coolant Submit the sample for Level 2 analysis Reference For additional information about coolant analysis refer to Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations or consult your Caterpillar dealer 101738747 Cooling System Water Temperature Regulator Replace SMCS Code 1355 510 1393 010 Pressurized system Hot coolant can cause seri ous burn To open cap stop engine wait until ra diator is cool Then loosen cap slowly to relieve the pressure NOTICE Failure to replace the engine s thermostat on a
7. 101461907 Battery Hold Down Tighten SMCS Code 7257 527 Illustration 136 g00764269 Open the battery compartment on the left rear side of the machine Over time the vibration of an operating machine can cause the battery hold down to loosen To help to prevent loose batteries and the possibility of loose cable connections tighten the locknut in the center of the hold down to a torque of 14 3 N m 10 2 Ib ft 101770834 Battery or Battery Cable Inspect Replace SMCS Code 1401 040 1401 510 1402 040 1402 510 1 Turn the engine start switch key OFF Turn all of the switches OFF 2 Turn the battery disconnect switch OFF Remove the key 3 Disconnect the negative battery cable from the disconnect switch Note Do not allow the disconnected battery cable to contact the disconnect switch 4 Disconnect the negative battery cable at the battery 5 Disconnect the positive battery cable at the battery 6 Inspect the battery terminals for corrosion Inspect the battery cables for wear or damage 7 Make any necessary repairs If necessary replace the battery cables or the battery 8 Connect the positive battery cable at the battery 9 Connect the negative battery cable at the battery 10 Connect the battery cable at the battery disconnect switch 11 Install the key and turn the battery disconnect switch ON 101437375 Belts Inspect Adjust Replace SMCS Code 1357 025 1357 04
8. 1054 070 PY 1054 510 PY To avoid personal injury always wear eye and face protection when using pressurized air NOTICE Caterpillar recommends certified air filter cleaning ser vices that are available at Caterpillar dealers The Caterpillar cleaning process uses proven procedures to assure consistent quality and sufficient filter life Observe the following guidelines if you attempt to clean the filter element Do not tap or strike the filter element in order to re move dust Do not wash the filter element Use low pressure compressed air in order to remove the dust from the filter element Air pressure must not exceed 207 kPa 30 psi Direct the air flow up the pleats and down the pleats from the inside of the filter element Take extreme care in order to avoid damage to the pleats Do not use air filters with damaged pleats gaskets or seals Dirt entering the engine will cause damage to engine components NOTICE Service the air filter only with the engine stopped En gine damage could result 1 Open the engine compartment The air filter is located on the right side of the machine Illustration 177 g00845360 2 Loosen the cover latches and remove the air cleaner cover Note The latches for the air cleaner housing may snap open when you release the latches Illustration 178 g00101415 3 Remove the primary filter element from the air cleaner housing In order to remove
9. Allow the oil to drain into a suitable container Clean the drain plug and install the drain plug 4 Remove four cover bolts and magnetic strainer cover 3 5 Remove suction screen 4 and tube 6 from the housing Remove three magnets 5 from the tube 6 Wash the tube and the screen in a clean nonflammable solvent 7 Use a cloth a stiff bristle brush or pressurized air to clean the magnets NOTICE Do not drop or rap the magnets against any hard sur face Replace any damaged magnets 8 Clean the cover and inspect the cover seal Replace the seal if necessary 9 Install three magnets 5 on the tube Insert suction screen 4 and tube 6 in the housing 10 Install the cover and the cover bolts 11 Replace the transmission oil filter Reference Refer to Operation and Maintenance Manual Transmission Oil Filter Replace for the correct procedure g00766254 Illustration 237 12 The filler tube for the transmission is located near the center hitch Remove the filler cap 8 and fill the transmission with oil Reference Refer to Operation and Maintenance Manual Lubricant Viscosities and Refill Capacities for the correct type of oil and for the correct amount of oil 13 Remove the transmission breather from the top of the transfer case Wash the breather i
10. Note Replace the secondary element when you service the primary element for the third time If a clean primary element has been installed and a warning for the air filter still occurs replace the secondary element Also if the exhaust smoke remains black and a clean primary element has been installed replace the secondary element 1 Remove the primary element Reference Refer to Operation and Maintenance Manual Engine Air Filter Primary Element Clean Replace for the correct procedure Z 8 Repeat the procedure for the other air cleaner 101438467 Engine Air Precleaner Clean SMCS Code 1055 070 Illustration 181 g00864077 2 Remove the secondary element g00864079 Illustration 182 3 Cover the air inlet opening Clean the inside of the air cleaner housing 4 Inspect the gasket between the air inlet pipe and the air cleaner housing Replace the gasket if the gasket is damaged 5 Uncover the air inlet opening Install a new secondary element 6 Install a clean primary element and the cover for the air cleaner housing 7 Close the access door ON Illustration 183 g00764735 NOTICE Service the air cleaner only with the engine stopped Engine damage could result 1 Remove the precleaner 2 Inspect the air inlet screen for dirt and for trash Remove the screen Clean the screen if the screen is dirty 3 Inspect the precleaner
11. efficiency the brake holding ability etc Service Brake Holding Ability Test Personal injury can result if the machine moves while testing If the machine begins to move during test reduce the engine speed immediately and engage the parking brake 1 Start the engine Raise the implement slightly Apply the service brake Release the parking brake 2 Move the transmission control to THIRD SPEED FORWARD while the service brakes are applied Make sure that the autoshift control is in the OFF position 3 Gradually increase the engine speed to high idle The machine should not move 4 Reduce the engine speed to low idle Move the transmission direction control to the NEUTRAL position Engage the parking brake Lower the implement to the ground Stop the engine If the machine moved during the test consult your Caterpillar dealer for a brake inspection Make any necessary repairs before the machine is returned to operation Parking Brake Holding Ability Test Personal injury can result if the machine moves while testing If the machine begins to move reduce the engine speed immediately and apply the service brake pedal This test is performed when the parking brake is engaged If the machine begins to move compare the engine rpm to the engine rpm of a prior test This will indicate the amount of system deterioration 1 Start the engine Raise the implement slightly Engage the parking brake 2 Move
12. Engine Oil Level Check 0 eee 127 Fuel System Primary Filter Water Separator DAI a a Tes eters eee A 132 Hydraulic System Oil Level Check sese 143 Quick Coupler Check ccccccsseceeeesteeeeeeeeees 145 Seat Belt Inspect 1 2 0 eeeeceeeeeeeceeeeeeeeeeeesteeeeees 148 Transmission Oil Level Check 0ccc ce 154 Windows Clean ou cece cceccceeeccesee esses eeeeeeneeeaes 155 Every 50 Service Hours or Weekly Bucket Lower Pivot Bearings Lubricate 107 Cab Air Filter Clean Replace ceeee 110 Fuel Tank Water and Sediment Drain 136 Tire Inflation Check c cccceceeeeeeeeeeeeeseeeeaeees 151 Every 100 Service Hours or 2 Weeks Axle Oscillation Bearings Lubricate 101 Bucket Linkage and Loader Cylinder Bearings LUDIICAtG nerona o cette ts tee aera 106 Bucket Upper Pivot Bearings Lubricate 110 Logging Fork Clamp Lubricate 0 eeeeee 144 Steering Cylinder Bearings Lubricate 149 Initial 250 Service Hours Transmission Oil Filter Replace 00 153 Every 250 Service Hours Engine Oil Sample Obtain a i 127 Every 250 Service Hours or Monthly Battery ClOAIn EE 101 Belts Inspect Adjust Replace ee 102 Brake Accumulator Check cccceeeeetteeeees 104 Braking System Test ceesseeeseeeeeeeeeeeeneeeees 105 Differ
13. Normal conditions include these factors Fuel sulfur below 0 3 altitude below 1830 m 6000 ft and good air filter and fuel filter maintenance Normal conditions do not include high load factor harsh operating cycles or harsh environments High load factors can shorten the service life of your engine oil Continuous heavy load cycles and very little idle time result in increased fuel consumption and oil contamination These factors deplete the oil additives more rapidly If the average fuel consumption exceeds 25 L 6 5 US gal per hour for the 962G Series II Wheel Loader follow the High Load Factor recommendations in Table 18 To determine average fuel consumption measure average fuel consumption for a period of 50 to 100 hours If the application of the machine is changed the average fuel consumption may change For sulfur content above 0 5 refer to Operation and Maintenance Manual SEBU6250 Caterpillar Machine Fluids Recommendations Total Base Number TBN and Fuel Sulfur Levels for Direct Injection DI Diesel Engines In order to verify an oil change interval of 500 hours refer to Program A below Use Program B below to determine an appropriate interval 2 3 4 5 6 Adjustment of the Oil Change Interval Note Your Caterpillar dealer has additional information on these programs Program A Verification for an Oil Change Interval of 500 Hours This program consists of three
14. Reference Refer to Operation and Maintenance Manual Fuel System Prime for the correct procedure Close the engine hood 101464102 Fuel Tank Cap and Strainer Clean SMCS Code 1273 070 Z2 1273 070 STR The fuel tank cap is located on the left side of the machine Illustration 203 1 g00765153 Remove fuel tank cap 1 and strainer 3 from fuel tank 4 Remove seal 2 from the cap Wash the strainer and the fuel tank cap in a clean nonflammable solvent Install the strainer into the filler opening Inspect the seal for damage Replace the seal if necessary Install the fuel tank cap 136 Maintenance Section Fuel Tank Water and Sediment Drain SEBU7459 09 101464158 Fuel Tank Water and Sediment Drain SMCS Code 1273 543 M amp S Illustration 204 g00765256 The drain valve is located under the fuel tank 1 Open the drain valve and allow the water and sediment to drain into a suitable container 2 Close the drain valve Note If water and sediment are regularly found at weekly maintenance intervals drain the sediment daily 102069536 Fuses Replace SMCS Code 1417 510 NOTICE Replace fuses with the same type and size only Oth erwise electrical damage can result If itis necessary to replace fuses frequently an electri cal problem may exist Contact your Caterpillar dealer Fuses The fuses protect t
15. Remove the wiper and lubricate the entire length of the inner post by hand 3 Wipe off the fittings before you apply any lubricant Apply lubricant through the two fittings on the cylinder Apply approximately 15 to 20 pumps of grease 4 Close the engine hood 101617406 Hydraulic System Biodegradable Oil Filter Element Replace SMCS Code 5068 510 S N AYB1 Up S N BAB1 Up S N AYE1 Up S N AYL1 Up NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent 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 Dispose of all fluids according to local regulations and mandates Illustration 210 g00765498 The hydraulic filter is located on the right side of the machine 1 Use a strap type wrench to remove the filter element Dispose of the used filter element properly 2 Clean the filter mounting base Make sure that all of the used gasket is completely removed Illustration 211 g00101318 3 Lubricate the gasket of the new filter element with clean hydraulic oil 4 In
16. Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates NOTICE Do not fill fuel filters with fuel before installing them Contaminated fuel will cause accelerated wear to fuel system parts SEBU7459 09 135 Maintenance Section Fuel Tank Cap and Strainer Clean Illustration 201 1 g00754126 Open the engine hood The secondary fuel filter 1 is located on the right side of the engine The secondary fuel filter is inverted The filter must be properly drained before removal Open the drain valve 2 Drain the fuel into a suitable container The secondary fuel filter can now be removed Remove the filter by using a strap type wrench Inspect the fuel filter element for debris by cutting the filter open Discard the used fuel filter element properly Clean the filter mounting base Make sure that all of the used seal is removed from the filter mounting base Illustration 202 g00101318 6 Apply a thin coat of clean diesel fuel to the sealing surface of the new fuel filter element Install the new fuel filter element by hand When the seal contacts the filter base tighten the fuel filter element by an additional 3 4 turn This will tighten the fuel filter element sufficiently Prime the fuel system
17. allow greater penetration or less penetration 5 Drive the pin through the bucket tip The pin can be installed by using one of the following methods e From the other side of the retainer drive the pin through the following components the bucket tip the adapter and the retainer e Use a Pin Master Follow Step 5 a through Step 5 e for the procedure g00590666 Illustration 151 4 Back of Pin Master 9 Pin setter 10 Pin holder a Insert the pin through the bucket tooth b Place the Pin Master over the bucket tooth and locate the pin in the hole of the holder 10 c Strike the tool with a hammer at the back of the tool 4 in order to start the pin d Slide pin holder 10 away from the pin and rotate the tool slightly in order to align pin setter 9 with the pin e Strike the end of the tool until the pin is fully inserted 6 After you drive the pin make sure that the retainer fits snugly into the pin groove The tools that are available for driving the pins are shown in Table 16 Table 16 Size of the Tip Pin Remover J200 J225 143 2459 J250 J300 J350 143 2460 J350 J400 J460 196 1331 J550 203 4290 110 Maintenance Section Bucket Upper Pivot Bearings Lubricate SEBU7459 09 101897750 Bucket Upper Pivot Bearings Lubricate SMCS Code 6101 086 BD 6107 086 BD Illustration 152 g00987399 Wipe off the fitting before any lubricant is applied
18. be connected in this case remove the engine start switch key and turn the battery disconnect switch to the OFF position Wipe off the fitting before you apply any lubricant Illustration 174 g00764632 Apply lubricant through the fitting for the center drive shaft spline 102407816 Drive Shaft Support Bearing Lubricate SMCS Code 3267 086 BD Crushing Hazard Insure that the machine ignition switch is in the OFF position and that the parking brake is engaged before entering the articulation area Failure to do so could result in serious injury or death Wipe off the fitting before any lubricant is applied Illustration 175 g00764668 Apply lubricant through the remote fitting on the right side of the machine Use the fitting that is toward the rear of the machine 102067023 Drive Shaft Universal Joints Lubricate SMCS Code 3251 086 Note Check for sealed universal joints that do not require lubrication Wipe off all fittings before any lubricant is applied 120 Maintenance Section Engine Air Filter Primary Element Clean Replace SEBU7459 09 Illustration 176 g00291135 Apply lubricant through one fitting on each universal joint There are a total of five fittings 101902270 Engine Air Filter Primary Element Clean Replace SMCS Code
19. brake and stop the engine Illustration 238 g00766360 2 The transmission oil filter is located on the left side of the machine near the articulation joint Use a strap type wrench to remove the transmission oil filter Dispose of the used oil filter properly 3 Clean the filter mounting base Remove all of the used filter gasket from the filter mounting base Illustration 239 g00101318 4 Apply a thin coat of clean transmission oil to the gasket of the new filter element Install the new filter element by hand When the gasket contacts the filter mounting base tighten the transmission oil filter by an additional 3 4 turn 5 Start the engine Slowly operate the transmission controls in order to circulate the transmission oil 6 Move the transmission control to the NEUTRAL position Inspect the transmission oil filter for leaks 7 Check the transmission oil level Reference Refer to Operation and Maintenance Manual Transmission Oil Level Check for the correct procedure 154 Maintenance Section Transmission Oil Level Check SEBU7459 09 101468938 Transmission Oil Level Check SMCS Code 3030 535 FLV Illustration 240 g00766406 The sight gauge for the transmission oil level is located on the left side of the machine near the articulation joint 1 Operate the machine for a few minutes in order to warm the transmission oil 2 Park the
20. circumstances e The primary fuel filter has been changed e The secondary fuel filter has been changed e The fuel injectors have been removed e The engine has run out of fuel Note The volume of air in the water separator is small Usually it is not necessary to prime the fuel system if only the water separator element has been changed Your machine is equipped with an electric fuel priming pump The priming pump is located on the right side of the engine above the primary fuel filter Illustration 197 g01127683 1 Open the engine hood in order to access the fuel priming pump The fuel priming pump is located on the right side of the machine 2 Place the drain hose 3 into a suitable container in order to catch the fuel Open the drain valve 2 Move the toggle switch 1 in order to activate the priming pump 3 Operate the priming pump until fuel comes out of the drain hose Operate the priming pump until the fuel that flows from the drain hose has no air bubbles Turn off the drain valve Turn off the priming pump 101439459 Fuel System Primary Filter Water Separator Drain SMCS Code 1263 543 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of
21. death can result from removing hoses or fittings that are under pressure Relieve the pres sure in the system before you remove hoses or fittings Illustration 132 g01068678 Grease reservoir 1 is located near the rear fender on the right side of the machine Filling the Reservoir 1 Remove the dust cap 2 from the grease reservoir 1 2 Clean the filler tube assembly 3 and the coupling on the filler assembly 3 Install the filler assembly onto the filler tube assembly 3 4 Fill the grease reservoir 1 with grease to the maximum level which is indicated on the grease reservoir 1 Reference For the correct type of grease refer to Operation and Maintenance Manual Lubricant Viscosities 5 Remove the filler assembly and install the dust cap 2 SEBU7459 09 101 Maintenance Section Axle Oscillation Bearings Lubricate 102405757 Axle Oscillation Bearings Lubricate SMCS Code 3268 086 BD 3278 086 BD Crushing Hazard Insure that the machine ignition switch is in the OFF position and that the parking brake is engaged before entering the articulation area Failure to do so could result in serious injury or death Wipe off all fittings before you apply any lubricant i 2 8 D S ad Illustration 133 g00752649 Open the access door on the right side of the machine Apply lubricant through two remo
22. from each opening of the screen group 4 Wash the screens in a clean nonflammable solvent 5 Dry each screen with pressure air Inspect each screen for damage Replace any damaged screens 6 Install the screens and tighten the allen head screws until the screens are snug 7 Install two connectors 2 and two hoses 1 101619649 Steering Shaft Command Control Steering Lubricate SMCS Code 4343 086 JF S N AYB1 Up S N AYD1 Up S N AYE1 Up S N AYG1 Up S N AXR1 Up S N AXS1 Up Wipe off all fittings before any lubricant is applied PAN g00812993 Illustration 233 1 Remove the steering shaft from the machine SEBU7459 09 151 Maintenance Section Tire Inflation Check Reference Refer to Disassembly and Assembly Steering Shaft Remove and Install for the machine that is being serviced for the correct procedure 2 Apply 5P 0960 Molybdenum Grease through fittings 3 4 5 and 8 3 Apply 1P 0808 Multipurpose Grease through fittings 1 2 6 and 7 4 Install the steering shaft 102305841 Tire Inflation Check SMCS Code 4203 535 Al IN IN g01160201 Illustration 234 Always obtain proper tire inflation pressures and maintenance recommendations for the tires on your machine from your tire supplier Measu
23. fuse panel system from a circuit that has been overloaded Change a fuse if the element separates If the element of a new fuse separates check the circuit Repair the circuit if necessary Fuses The fuses protect the electrical Illustration 207 g01000750 138 Maintenance Section Hood Tilt Actuator Lubricate SEBU7459 09 Illustration 208 g01078009 The fuses are located in the cab on the right side of the operator seat 1 Spare aen aE A 10 Amperes 2 Neutralizer Override Switch 10 Amperes 3 HVAC Blower ccccecceeeeeeeeeees 20 Amperes 4 Quick Coupler and Alarm for Aggregate Autodig SYSTEM nenepi editei eei aaen 10 Amperes 5 Rear Floodlights 0 ceee 15 Amperes 6 Air Seat and Heated Seat 15 Amperes 7 Secondary Steering 10 Amperes 8 Engine ECM and Ether Injection 10 Amperes 9 Front Floodlights 0 00e 15 Amperes 10 Beacon mo onere a ir 10 Amperes 11 Front and Rear Flasher Relays 10 Amperes 12 Product Link for the Machine Security S ETE E 10 Amperes 13 Lh Indicator Display and Rh Indicator Display en Ara aa 10 Amperes 14 Tilt Position Sensor and Lift Position DENSON aare e
24. hr API CF 4 250 hr 250 hr 250 hr 250 hr 1 The traditional oil change interval for engines is 250 hours The standard oil change interval in this machine is 500 hours if the operating conditions and recommended oil types that are listed in this table are met Improvements in the engine allow this engine oil change interval This new standard interval is not permitted for other machines Refer to the applicable Operation and Maintenance Manuals for the other machines Normal conditions include these factors Fuel sulfur below 0 3 altitude below 1830 m 6000 ft and good air filter and fuel filter maintenance Normal conditions do not include high load factor harsh operating cycles or harsh environments High load factors can shorten the service life of your engine oil Continuous heavy load cycles and very little idle time result in increased fuel consumption and oil contamination These factors deplete the oil additives more rapidly If the average fuel consumption exceeds 23 L 6 US gal per hour for the 950G Series II Wheel Loader follow the High Load Factor recommendations in Table 17 To determine average fuel consumption measure average fuel consumption for a period of 50 to 100 hours If the application of the machine is changed the average fuel consumption may change 4 For sulfur content above 0 5 refer to Operation and Maintenance Manual SEBU6250 Caterpillar Machine Flu
25. level sight gauge is located on the left side of the radiator Maintain the coolant level within the sight gauge Add coolant if necessary Note If it is necessary to add coolant daily inspect the cooling system for leaks SEBU7459 09 115 Maintenance Section Cooling System Coolant Sample Level 1 Obtain 101910955 Cooling System Coolant Sample Level 1 Obtain SMCS Code 1350 008 1395 008 7542 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent 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 Dispose of all fluids according to local regulations and mandates Note Level 1 results may indicate a need for Level 2 Analysis is O iH E TE p P id e o o oO ate all bol 2 g00767660 Illustration 163 Obtain the sample of the coolant as close as possible to the recommended sampling interval In order to receive the full effect of S O S analysis you must establish a consistent trend
26. machine on a hard level surface Put the transmission control into the NEUTRAL position Lower the bucket to the ground with a slight downward pressure Engage the parking brake Note Before the machine is started the transmission oil level should be above MIN START mark 1 on the upper end of the sight gauge 3 Check the oil level while the engine is running at low idle While the engine is running at low idle the transmission oil level should be between the MIN mark 3 and the MAX mark 2 4 If necessary remove the filler cap and add oil 101912832 Transmission Oil Sample Obtain SMCS Code 3080 008 7542 Illustration 241 g00752426 The sampling valve for the transmission oil is located on the transmission oil filter base on the left side of the articulation joint Refer to Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations S O S Oil Analysis for information that pertains to obtaining an oil sample from the transmission housing Refer to Special Publication PEHP6001 How To Take A Good Oil Sample for more information about obtaining an oil sample from the transmission housing 101468974 Window Washer Reservoir Fill SMCS Code 7306 544 NOTICE When operating in freezing temperatures use Caterpillar or any commercially available nonfreezing
27. of data In order to establish a pertinent history of data perform consistent samplings that are evenly spaced Supplies for collecting samples can be obtained from your Caterpillar dealer Use the following guidelines for proper sampling of the coolant e Complete the information on the label for the sampling bottle before you begin to take the samples e Keep the unused sampling bottles stored in plastic bags Obtain coolant samples directly from the coolant sample port You should not obtain the samples from any other location Keep the lids on empty sampling bottles until you are ready to collect the sample Place the sample in the mailing tube immediately after obtaining the sample in order to avoid contamination Never collect samples from expansion bottles Never collect samples from the drain for a system Submit the sample for Level 1 analysis For additional information about coolant analysis see Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations or consult your Caterpillar dealer 101910979 Cooling System Coolant Sample Level 2 Obtain SMCS Code 1350 008 1395 008 7542 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids
28. of the belt g00752925 The tension of a used belt with more than 30 minutes of operation at rated speed should be 400 44 N 90 10 Ib The tension of a new belt with 30 minutes of operation or less at rated speed should be 534 22 N 120 5 Ib 104 Maintenance Section Brake Accumulator Check SEBU7459 09 Adjusting the Tension of the Belt for the Axle Oil Cooler Pump i01714079 Brake Accumulator Check SMCS Code 4263 535 Illustration 138 1 g00592147 Loosen one mounting bolt 2 and adjustment bolt 3 Insert a ratchet with a square drive into the hole in mounting bracket 4 Use the ratchet as a lever to rotate axle oil cooler pump 5 Rotate the axle oil cooler pump until the correct belt tension is reached Tighten adjustment bolt 3 and mounting bolt 2 Recheck the tension of belt 1 If the tension of the belt is incorrect repeat the adjustment procedure OO0OO0O eee se Illustration 139 1 g00882020 Turn the engine start switch to the ON position The alert indicator for brake oil pressure should come on if the braking system is not at normal operating pressure Start the engine Run the engine at half speed for two minutes in order to increase the accumulator pressure The alert indicator for brake oil pressure should go off Stop the engine Apply the service brake pedal and rel
29. procedure 14 Stop the engine Close the engine access door and the engine hood 102097831 Engine Oil Level Check SMCS Code 1000 535 FLV NOTICE Do not under fill or overfill engine crankcase with oil Either condition can cause engine damage Illustration 190 g00753678 1 Stop the engine Open the access door on the right side of the machine 2 Remove dipstick 2 and wipe off the dipstick with a clean cloth Then reinsert the dipstick and remove the dipstick again This will give a more accurate measurement of the oil level 3 Maintain the engine oil between the FULL mark and the ADD mark on dipstick 2 If necessary remove filler cap 1 and add oil 4 Close the engine access door Engine Oil Sample Obtain SMCS Code 1348 008 7542 Illustration 191 g00890510 Obtain a sample of the engine oil from the engine oil sampling valve The sampling valve is located in the engine compartment on the left side of the machine Refer to Special Publication SEBU6250 S O S Oil Analysis for information that pertains to obtaining a sample of the engine oil Refer to Special Publication PEHP6001 How To Take A Good Oil Sample for more information about obtaining a sample of the engine oil 128 Maintenance Section Engine Oil and Filter Change SEBU7459 09 102093707 Engine Oil and Filter Change SMCS Code 1318 510 Sele
30. regu larly scheduled basis could cause severe engine dam age NOTICE Caterpillar engines incorporate a shunt design cooling system and require operating the engine with a ther mostat installed If the thermostat is installed wrong it will cause the engine to overheat Inspect gaskets before assembly and replace if worn or damaged Illustration 165 g00890574 Replace the water temperature regulator in order to reduce the chance of problems with the cooling system The water temperature regulator is located on the left side of the machine near the alternator Replace the water temperature regulator and replace the seals while the cooling system is completely drained or while the coolant is drained to a level that is below the water temperature regulator housing Note If you are only replacing the water temperature regulator drain the coolant to a level that is below the water temperature regulator housing Reference Refer to Disassembly and Assembly SENR3611 3126 Engines for Caterpillar Built Machines for the correct procedure for replacing the water temperature regulator SEBU7459 09 117 Maintenance Section Differential and Final Drive Oil Change 102441594 Differential and Final Drive Oil Change SMCS Code 3278 044 4011 044 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the pr
31. remove filter element 1 Inspect the filter Reference For more information refer to Operation and Maintenance Manual Oil Filter Inspect 6 Clean the filter mounting base with a clean cloth Make sure that the used filter gasket has been completely removed Illustration 189 g00101318 7 Apply a thin film of clean engine oil to the sealing surface of the new filter element 8 Install the engine oil filter element 1 hand tight until the seal of the engine oil filter element 1 contacts the oil filter base Note Note the position of the index marks on the oil filter element 1 in relation to a fixed point on the filter base SEBU7459 09 127 Maintenance Section Engine Oil Level Check 9 Tighten the filter according to the instructions that are printed on the filter Use the index marks as a guide 10 Connect an oil pump to the male coupler for the high speed arrangement Fill the crankcase with new oil Reference Refer to Operation and Maintenance Manual Lubricant Viscosities and Refill Capacities for the correct type of oil and for the correct amount of oil 11 Clean the end of the male coupler Clean the cap that covers the male coupler and install the cap 12 Start the engine and allow the oil to warm Check the machine for oil leaks 13 Check the engine oil level Reference Refer to Operation and Maintenance Manual Engine Oil Level Check for the correct
32. ride control accumulator Note Special tools and equipment are required to test the accumulator Reference For more information refer to Testing and Adjusting SENR1390 950G Wheel Loader 962G Wheel Loader and IT62G Integrated Toolcarrier Hydraulic System or consult your Caterpillar dealer 101457015 Roading Fender Hinges Lubricate SMCS Code 7252 086 HNG S N BAA1 Up S N AYB1 Up S N BAB1 Up S N BAC1 Up S N AYD1 Up S N BAD1 Up S N AYE1 Up S N AYG1 Up S N AYL1 Up S N AXR1 Up S N AXS1 Up S N AYS1 Up S N AXX1 Up S N AXY1 Up Wipe off the fitting before any lubricant is applied 148 Maintenance Section Rollover Protective Structure ROPS Inspect SEBU7459 09 Illustration 227 g00761700 Swing open the roading fender Apply lubricant through one fitting on the hinge There is one hinge on each side of the machine 101457460 Rollover Protective Structure ROPS Inspect SMCS Code 7323 040 7325 040 Illustration 228 g00762107 Inspect the ROPS for bolts that are loose or damaged Use original equipment parts only to replace bolts that are damaged or missing Tighten the four cab mounting bolts to a torque of 850 100 N m 629 74 lb ft Note Apply oil to all bolt threads before installation Failure to apply oil can result in improper bolt torque Do not repair the ROPS by welding reinforc
33. the normal by more than two ISO codes Action should be taken in order to determine the cause of the contamination The system should be returned to the original levels of contamination There should not be significant changes in sodium silicon copper and potassium The allowable level of oxidation is 40 percent 0 12 Abs units SEBU7459 09 141 Maintenance Section Hydraulic System Oil Change e The kinematic viscosity of 100 C 212 F should not exceed a 2 cSt change from new Procedure for Changing the Hydraulic Oil NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent 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 Dispose of all fluids according to local regulations and mandates 1 Operate the machine in order to warm the hydraulic oil 2 Park the machine on level ground Lower the attachment to the ground and apply slight downward pressure Engage the parking brake and stop the engine Illustration 213 g00765367 3 The hydraulic tank is located on the right side of the
34. the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent 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 Dispose of all fluids according to local regulations and mandates SEBU7459 09 133 Maintenance Section Fuel System Primary Filter Water Separator Element Replace Illustration 198 g00753954 1 Open the engine hood The water separator is located on the bottom of the primary fuel filter on the right side of the machine 2 Attach a hose to the bottom of the drain valve 2 Open the drain valve 1 on the bottom of the water separator bowl Allow the water and the fuel to drain into a suitable container 3 Close the drain valve Note The water separator is under suction during normal engine operation Tighten the drain valve securely in order to prevent air leakage into the fuel system 4 Close the engine hood 101439536 Fuel System Primary Filter Water Separator Element Replace SMCS Code 1260 510 1263 510 FQ NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing a
35. the transmission control to THIRD SPEED FORWARD Make sure that the autoshift control is in the OFF position The parking brake indicator light should come on 3 Gradually increase the engine speed to high idle The machine should not move 4 Reduce the engine speed to low idle Move the transmission direction control to the NEUTRAL position Lower the implement to the ground Stop the engine If the machine moved during the test consult your Caterpillar dealer for a brake inspection Make any necessary repairs before the machine is returned to operation 102196469 Bucket Cutting Edges Inspect Replace SMCS Code 6801 040 6801 510 Personal injury or death can result from bucket falling Block the bucket before changing bucket cutting edges 106 Maintenance Section Bucket Linkage and Loader Cylinder Bearings Lubricate SEBU7459 09 Illustration 140 g00764365 Check the cutting edges and the end bits for wear and for damage Use the following procedure to service the cutting edges and the end bits 1 Raise the bucket and place blocking under the bucket Lower the bucket onto the blocking Stop the engine Remove bolts 1 cutting edge 2 and the end bits Clean all contact surfaces If the opposite side of the cutting edge is not worn use the opposite side of the cutting edge The end bits are not reversible If both sides are worn install a new cutting e
36. water separator bowl 7 Install the sediment bowl onto the new filter element Do not use tools to tighten the filter element 8 Install the new filter element hand tight until the seal contacts the mounting base Then tighten the filter element for an additional 3 4 of a turn 9 Close drain valve 3 Note The water separator element is under suction during normal engine operation Tighten the drain valve securely in order to prevent air leakage into the fuel system 10 Prime the fuel system in order to fill the water separator element with fuel Reference Refer to Operation and Maintenance Manual Fuel System Prime for the correct procedure 11 Close the engine hood 101439739 Fuel System Secondary Filter Replace SMCS Code 1261 510 SE Personal injury or death can result from a fire Fuel leaked or spilled onto hot surfaces or electri cal components can cause a fire Clean up all leaked or spilled fuel Do not smoke while working on the fuel system Turn the disconnect switch OFF or disconnect the battery when changing fuel filters NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar
37. 0 1357 510 1397 025 1397 040 1397 510 Your machine is equipped with a single serpentine belt Stop the engine Open the rear hood The belt is located at the rear of the engine Inspect the condition of the serpentine belt Replace the belt if the belt is worn or frayed SEBU7459 09 103 Maintenance Section Belts Inspect Adjust Replace Illustration 137 1 Idler Pulley 6 Water Pump 2 Idler Pulley 7 Serpentine Belt 3 Alternator 8 Crankshaft Pulley 4 Square Hole 9 Compressor If Equipped 5 Tensioner 10 Idler Pulley A tensioner 5 keeps the correct tension on the belt 7 Insert a ratchet with a square drive into the hole 4 Rotate the tensioner counterclockwise in order to relieve tension on the belt Remove the belt Install the new belt Be sure that the new belt is routed correctly as shown View A represents machines that are not equipped with an air conditioner View B represents machines that are equipped with an air conditioner Rotate the tensioner counterclockwise in order to install the new belt Release the tensioner when the new belt is installed The correct tension will automatically be applied Belt for the Axle Oil Cooler Pump If Equipped 1 Open the engine hood in order to access the axle oil cooler pump 2 Inspect the condition of the belt If the belt is cracked or frayed replace the belt 3 Use a BT 33 97 Borroughs Gauge to check the tension
38. 105 535 For the correct procedure refer to the appropriate Service Manual module for your machine s engine or consult your Caterpillar dealer Note A qualified mechanic should adjust the engine valve lash because special tools and training are required 100643879 Fuel Injection Timing Check SMCS Code 1290 531 FT Refer to the Service Manual for the complete adjustment procedure for the Fuel injector timing Note The correct fuel timing specification is found on the Engine Information Plate Fuel timing specifications may vary for different engine applications and or for different power ratings A qualified mechanic should adjust the fuel injector timing because special tools and training are required 132 Maintenance Section Fuel System Prime SEBU7459 09 102235915 Fuel System Prime SMCS Code 1250 548 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent 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 Dispose of all fluids according to local regulations and mandates The fuel system needs to be primed due to the following
39. 18871 Wipe off the coupler pins Coat the coupler pins with new grease 101442049 Radiator Core Clean SMCS Code 1353 070 KO 1 Open the engine hood The radiator assembly is located at the rear of the machine Illustration 225 g00765907 2 Remove bolt 2 Swing the condenser away from the radiator Use the control knob 1 in order to release the hydraulic oil cooler Swing the hydraulic oil cooler 3 and the condenser 4 away from the radiator Illustration 226 g00101939 3 You can use compressed air high pressure water or steam to remove dust and other debris from the radiator fins However the use of compressed air is preferred 4 Swing the hydraulic oil cooler back into the operating position and replace the two bolts 5 Swing the air conditioner condenser back into the operating position and replace the two bolts 6 Close the engine hood SEBU7459 09 147 Maintenance Section Refrigerant Dryer Replace 102252730 Refrigerant Dryer Replace SMCS Code 7322 510 Personal injury can result from contact with refrig erant Contact with refrigerant can cause frost bite Keep face and hands away to help prevent injury Protective goggles must always be worn when re frigerant lines are opened even
40. 912731 Hydraulic System Oil Sample Obtain SMCS Code 5050 008 5056 008 7542 Illustration 217 g00765515 The hydraulic tank is located on the right side of the machine Maintain the oil level above the ADD COLD mark on sight gauge 2 If necessary remove filler cap 1 slowly and add oil Illustration 218 g00767586 Obtain a sample of the hydraulic oil from the hydraulic oil sampling valve The sampling valve is located on the hydraulic oil filter base beneath the cab on the left side of the machine Refer to Special Publication SEBU6250 S O S Oil Analysis for information that pertains to obtaining a sample of hydraulic oil Refer to Special Publication PEHP6001 How To Take A Good Oil Sample for more information about obtaining a sample of hydraulic oil 144 Maintenance Section Hydraulic Tank Breaker Relief Valve Clean SEBU7459 09 101465512 Hydraulic Tank Breaker Relief Valve Clean SMCS Code 5118 070 Illustration 219 g00765560 The hydraulic tank breaker relief valve is located on the top of the hydraulic tank on the right side of the machine 1 Press the button on the top of the hydraulic breaker in order to relieve the pressure in the hydraulic tank Remove the hydraulic tank breaker relief valve 2 Clean th
41. 9594 Seat Belt Replace SMCS Code 7327 510 Within three years of the date of installation or within five years of the date of manufacture replace the seat belt Replace the seat belt at the date which occurs first A date label for determining the age of the seat belt is attached to the seat belt the seat belt buckle and the seat belt retractor 1 2 oon ewe 4 g01152685 Illustration 230 1 Date of installation retractor 2 Date of installation buckle 3 Date of manufacture tag fully extended web 4 Date of manufacture underside buckle Consult your Caterpillar dealer for the replacement of the seat belt and the mounting hardware If your machine is equipped with a seat belt extension also perform this replacement procedure for the seat belt extension 102197967 Service Brake Wear Indicator Check SMCS Code 4255 535 IND Reference For information about checking the service brake wear indicator refer to Testing and Adjusting Braking System for the machine that is being serviced or consult your Caterpillar dealer 102405758 Steering Cylinder Bearings Lubricate SMCS Code 4303 086 BD Crushing Hazard Insure that the machine ignition switch is in the OFF position and that the parking brake is engaged before entering the articulation area Failure to do so could result in serious injury or death
42. Caterpillar dealer for more information Table 19 950G Series II Wheel Loader Engine Oil Change Interval Operating Conditions Severe Normale High Fuel Altitude Multigrad Load Sulfur above seh hen Factor from 1830m Oil Type above 0 3 to 6000 ft 23 L 6 0 5 US gal w per hr of fuel Cat DEO S00Ohr 500hr 500hr 250 hr Preferred API CH 4 11 0 minimum 500 hr 500 hr 500 hr 250 hr TBN Preferred API CH 4 TBN 500 hr 500 hr 250 hr 250 hr below 11 0 API CG 4 250 hr 250 hr 250 hr 250 hr API CF 4 250 hr 250 hr 250 hr 250 hr 1 The traditional oil change interval for engines is 250 hours The standard oil change interval in this machine is 500 hours if the operating conditions and recommended oil types that are listed in this table are met Improvements in the engine allow this engine oil change interval This new standard interval is not permitted for other machines Refer to the applicable Operation and Maintenance Manuals for the other machines Normal conditions include these factors Fuel sulfur below 0 3 altitude below 1830 m 6000 ft and good air filter and fuel filter maintenance Normal conditions do not include high load factor harsh operating cycles or harsh environments High load factors can shorten the service life of your engine oil Continuous heavy load cycles and very little idle time result in increased
43. Fluids Recommendations or consult your Caterpillar dealer 1 Fa ne JE iek Pe o oe oo Ha ik a fe 7 H 2 g00764449 Illustration 161 The cooling system pressure cap is located under the engine hood at the rear of the machine Tilt the hood in order to access the cooling system pressure cap The cap is located on the radiator tank on the left side of the machine 1 Slowly loosen the cooling system pressure cap 1 in order to relieve any system pressure Remove the cooling system pressure cap 2 If necessary drain enough coolant from the radiator in order to allow the addition of the Extender to the cooling system The cooling system drain valve 2 is located on the lower left side of the radiator 3 Add 1 5 L 1 6 qt of Extender to the cooling system Reference Refer to Operation and Maintenance Manual Capacities Refill for the correct amount 4 Check the coolant level Reference Refer to Operation and Maintenance Manual Cooling System Level Check for the correct procedure 5 Install the cooling system pressure cap Close the engine hood i01910924 Cooling System Coolant Level Check SMCS Code 1350 535 FLV Illustration 162 g00753303 Open the service door on the left side of the machine The coolant
44. Hydraulic System Oil Change cee 140 Every 6000 Service Hours or 3 Years Cooling System Coolant Extender ELC Add 113 Every 6000 Service Hours or 6 Years Cooling System Water Temperature Regulator RE plaGe esa arae a oiea danie ea a cadena det 116 Every 12 000 Service Hours or 6 Years Cooling System Coolant ELC Change 112 SEBU7459 09 99 Maintenance Section Articulation Bearings Lubricate 102399592 Articulation Bearings Lubricate SMCS Code 7057 086 BD 7065 086 BD 7066 086 BD Crushing Hazard Insure that the machine ignition switch is in the OFF position and that the parking brake is engaged before entering the articulation area Failure to do so could result in serious injury or death Illustration 130 g00763990 Wipe off all fittings before any lubricant is applied Apply lubricant through one fitting on the upper hitch and through one fitting on the lower hitch 102093114 Automatic Lubrication Grease Tank Fill If Equipped SMCS Code 7540 544 TNK S N AXR1 Up S N AXS1 Up S N AXX1 Up S N AXY1 Up The Lincoln Quicklub Lubrication System Reference Before any service work is performed on the lubrication system refer to Special Instructions REHS1396 or consult your Caterpillar dealer A pressure hazard is present Severe personal in jury or death can result f
45. MAINTENANCE INTERVALS Operation and Maintenance Manual Excerpt 2010 Caterpillar CATERPILLAR All Rights Reserved CATERPILLAR Oster 205 LUI Operation and Maintenance Manual IT62G Series II Integrated Toolcarrier and 950G Series II and 962G Series II Wheel Loaders AYA1 Up Machine BAA1 Up Machine AYB1 Up Machine BAB1 Up Machine BAC1 Up Machine AYD1 Up Machine BAD1 Up Machine AYE1 Up Machine AYG1 Up Machine AYL1 Up Machine AXR1 Up Machine AXS1 Up Machine AYS1 Up Machine AXX1 Up Machine AXY1 Up Machine SEBU7459 09 97 Maintenance Section Maintenance Interval Schedule 102425994 Maintenance Interval Schedule SMCS Code 7000 Ensure that all safety information warnings and instructions are read and understood before any operation or any maintenance procedures are performed The user is responsible for the performance of maintenance including all adjustments the use of proper lubricants fluids filters and the replacement of components due to normal wear and aging Failure to adhere to proper maintenance intervals and procedures may result in diminished performance of the product and or accelerated wear of components Use mileage fuel consumption service hours or calendar time WHICH EVER OCCURS FIRST in order to determine the maintenance intervals Products that operate in severe operating conditions may require more frequent maintenance Note Before each co
46. al wear Consult your Caterpillar dealer in order to arrange for further analysis if an excessive amount of debris is found Using an oil filter element that is not recommended by Caterpillar can result in severe engine damage to engine bearings to the crankshaft and to other parts This can result in larger particles in unfiltered oil The particles could enter the lubricating system and the particles could cause damage 101362822 Quick Coupler Check SMCS Code 6129 535 S N AYA1 Up S N AYB1 Up S N BAB1 Up S N BAC1 Up S N AYE1 Up S N AYL1 Up S N AXR1 Up S N AXS1 Up S N AYS1 Up S N AXX1 Up S N AXY1 Up Illustration 222 g00718871 When you install a work tool on the quick coupler inspect the engagement of the coupler pins If there is play between the coupler pins and the corresponding bores inspect the coupler pins and the bores for damage or wear Illustration 223 g00718876 If there is play between the quick coupler and the hooks of the work tool inspect the quick coupler and the hooks for wear or for damage Make any necessary repairs before you operate the work tool 146 Maintenance Section Quick Coupler Lubricate SEBU7459 09 101362849 Quick Coupler Lubricate SMCS Code 6129 086 S N AYA1 Up S N AYB1 Up S N BAB1 Up S N BAC1 Up S N AYE1 Up S N AYL1 Up S N AXR1 Up S N AXS1 Up S N AYS1 Up S N AXX1 Up S N AXY1 Up Illustration 224 g007
47. ap is located on top of the radiator tank on the left side of the machine Illustration 159 g00753215 2 Open the drain valve on the bottom of the radiator The drain valve can be accessed from the left side of the machine Allow the coolant to drain into a suitable container 3 Flush the cooling system with clean water until the draining water is clean Close the drain valve 4 Replace the water temperature regulator Reference Refer to Operation and Maintenance Manual Cooling System Water Temperature Regulator Replace for the correct procedure 5 Add the Extended Life Coolant Reference Refer to Operation and Maintenance Manual Capacities Refill for the refill capacity of the cooling system 6 Start the engine Run the engine without the cooling system pressure cap until the water temperature regulator opens and the coolant level stabilizes Illustration 160 g00753224 7 Maintain the coolant level in the sight gauge on the upper right side of the radiator 8 Install the cooling system pressure cap Stop the engine 101732076 Cooling System Coolant Extender ELC Add SMCS Code 1352 544 NL Pressurized system Hot coolant can cause seri ous burn To open cap stop engine wait until ra diator is cool Then loosen cap slowly to reliev
48. commendations Total Base Number TBN and Fuel Sulfur Levels for Direct Injection DI Diesel Engines In order to verify an oil change interval of 500 hours refer to Program A below Use Program B below to determine an appropriate interval 2 3 4 5 6 Adjustment of the Oil Change Interval Note Your Caterpillar dealer has additional information on these programs Program A Verification for an Oil Change Interval of 500 Hours This program consists of three oil change intervals of 500 hours Oil sampling and analysis is done at 250 hours and 500 hours for each of the three intervals for a total of six oil samples The analysis includes oil viscosity and infrared IR analysis of the oil If all of the results are satisfactory the 500 hour oil change interval is acceptable for the machine in that application Repeat Program A if you change the application of the machine If a sample does not pass the oil analysis take one of these actions e Shorten the oil change interval to 250 hours e Proceed to Program B e Change to a preferred oil type in Table 20 Program B Optimizing Oil Change Intervals Begin with a 250 hour oil change interval The oil change intervals are adjusted by increments Each interval is adjusted an additional 50 hours Periodic oil sampling and analysis is done during each interval The analysis includes oil viscosity and infrared IR analysis of the oil Repea
49. ction of the Oil Change Interval NOTICE This machine is equipped with an engine that meets EPA Tier 2 Euro Stage Il or MOC Step 2 emission regulations A 500 hour engine oil change interval is available provided that operating conditions and rec ommended multigrade oil types are met When these requirements are not met shorten the oil change interval to 250 hours or use an S O S oil sampling and analysis program to determine an acceptable oil change interval If you select an interval for oil and filter change that is too long you may damage the engine Caterpillar oil filters are recommended Recommended multigrade oil types are listed in the tables Do not use single grade oils Illustration 192 g00753767 API Trademark Commercial oils that are licensed by the American Petroleum Institute API bear this trademark Commercial oils that do not bear this trademark are not licensed and these oils are not recommended Oils that are not listed in the tables are not recommended Abnormally harsh operating cycles or harsh environments can shorten the service life of the engine oil Arctic temperatures corrosive environments or extremely dusty conditions may require a reduction in engine oil change intervals Poor maintenance of air filters or of fuel filters requires reduced oil change intervals Reference Refer to Operation and Maintenance Manual SEBU5898 Cold Weather Recommendations or see your
50. dge Install bolts 1 Tighten the bolts to the specified torque Reference Refer to Specifications SENR3130 Ground Engaging Tool G E T Fasteners Start the engine Raise the bucket and remove the blocking Lower the bucket to the ground After a few hours of operation check the bolts for proper torque 101897623 Bucket Linkage and Loader Cylinder Bearings Lubricate SMCS Code 5102 086 BD 5104 086 BD 6107 086 BD Integrated Toolcarrier Wipe off all of the fittings before you apply any lubricant Illustration 141 g00764050 Apply lubricant through twelve fittings on each side of the machine There are a total of 24 fittings Wheel Loader Wipe off all fittings before any lubricant is applied Illustration 142 g00987705 Apply lubricant through fittings 2 and 3 on both lift cylinders Apply lubricant through fittings 5 6 and 7 SEBU7459 09 107 Maintenance Section Bucket Lower Pivot Bearings Lubricate 101897748 Bucket Lower Pivot Bearings Lubricate SMCS Code 6101 086 BD 6107 086 BD Illustration 143 g00765618 For pin joint 1 apply lubricant through one remote fitting on each side of the machine Illustration 145 g00987389 fa g i Z n Ps Wipe off all fittings before any lubricant is applied Apply lubricant through one fitting on each side of
51. e Refer to Operation and Maintenance Manual Engine Oil Level Check for the correct procedure 12 Close the engine hood and stop the engine Procedure for Replacing the Centrifugal Oil Filter 962G Series II Wheel Loader only Illustration 196 g00888545 1 Open the engine hood in order to access the centrifugal oil filter engine The centrifugal oil filter is located on the top of the engine valve cover 2 Remove filter housing 1 by loosening the nut on top of the housing Note Oil from the centrifugal filter drains into the top of the valve cover into the engine 3 Remove inner filter 2 from the center shaft by lifting the filter Note The rotating filter traps contaminated particles inside the filter 4 Clean the filter housing and clean the base Make sure that all of the used filter gasket is removed from the housing and the base 5 Install the new 202 9875 Centrifugal Filter Kit The kit includes a new filter and a new gasket Note Replace the centrifugal filter wnen the engine oil is changed 6 Install filter housing 1 Install the nut on the top of the housing 7 Tighten the nut to 20 5 N m 177 44 Ib in 8 After changing the engine oil and the filter start the engine and check for leaks 9 Close the engine hood 101181536 Engine Valve Lash Check SMCS Code 1
52. e the pressure NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent 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 Dispose of all fluids according to local regulations and mandates 114 Maintenance Section Cooling System Coolant Level Check SEBU7459 09 NOTICE Topping off or mixing Cat ELC with other products that do not meet Caterpillar EC 1 specifications reduces the effectiveness of the coolant and shortens coolant service life Use only Caterpillar products or commercial products that have passed the Caterpillar EC 1 specification for pre mixed or concentrate coolants Use only Extender with Cat ELC Failure to follow these recommendations can result in shortened cooling system component life When a Caterpillar Extended Life Coolant ELC is used an Extender must be added to the cooling system Use a 8T 5296 Coolant Conditioner Test Kit to check the concentration of the coolant Reference For additional information about the addition of Extender refer to Operation and Maintenance Manual SEBU6250 Caterpillar Machine
53. e Heavy duty diesel engine oils with a minimum zinc content of 900 ppm CF CF 4 CG 4 and CH 4 Note Industrial hydraulic oils are not recommended in Caterpillar hydraulic systems These oils are more likely to cause corrosion and excessive wear Monitoring the Condition of the Oil The oil should be monitored during intervals of 500 hours Caterpillar s standard SOS Fluids Analysis or an equivalent oil sampling program should be used The current guidelines for cleanliness of the oil should be observed Refer to Measured Data If an oil sampling program is not available the standard 2000 oil change interval should be used Measured Data The following information should be monitored through sampling of the oil e Significant changes in wear metals should be monitored These metals include iron copper chromium lead aluminum and tin e Significant changes in the following additives should be monitored zinc calcium magnesium and phosphorus e Contaminants should not be present These contaminants include fuel and antifreeze Water content should be 5 percent or less e The silicon level should not exceed 15 parts per million for new oil The particle counts should be monitored e The recommended level of cleanliness for Caterpillar machines that are operated in the field is ISO 18 15 or cleaner The cleanliness should be monitored by particle count analysis The levels of contamination should not exceed
54. e hydraulic tank breaker relief valve in a clean nonflammable solvent Shake the breaker relief valve dry or use pressure air to dry the breaker relief valve 3 Install the hydraulic tank breaker relief valve 101718807 Logging Fork Clamp Lubricate SMCS Code 6113 086 BD 6410 086 BD Wipe off all fittings before any lubricant is applied hen N Pai Illustration 220 g00883679 Apply lubricant through three fittings on each side of the logging fork There is a total of six fittings i02106227 Oil Filter Inspect SMCS Code 1308 507 3004 507 3067 507 5068 507 Inspect a Used Filter for Debris Illustration 221 g00100013 The element is shown with debris Use a filter cutter to cut the filter element open Spread apart the pleats and inspect the element for metal and for other debris An excessive amount of debris in the filter element can indicate a possible failure If metals are found in the filter element a magnet can be used to differentiate between ferrous metals and nonferrous metals Ferrous metals can indicate wear on steel parts and on cast iron parts SEBU7459 09 145 Maintenance Section Quick Coupler Check Nonferrous metals can indicate wear on the aluminum parts of the engine such as main bearings rod bearings or turbocharger bearings Small amounts of debris may be found in the filter element This could be caused by friction and by norm
55. ease the service brake pedal until the alert indicator for brake oil pressure comes on This will decrease the accumulator pressure A minimum of five applications of the service brake pedal are required If the alert indicator comes on after less than five applications of the brake measure the accumulator precharge pressure An authorized Caterpillar dealer can measure the nitrogen gas pressure in the accumulator Use only dry nitrogen gas for recharging 101732078 Brake Discs Check SMCS Code 4255 535 Reference For the correct procedure refer to the Testing and Adjusting Service Manual of the braking system for your machine or consult your Caterpillar dealer SEBU7459 09 105 Maintenance Section Braking System Test 101739721 Braking System Test SMCS Code 4251 081 4267 081 e Fasten the seat belt before you test the brakes e Park the machine on a dry level surface e Check the area around the machine Make sure that the machine is clear of personnel and clear of obstacles e Make sure that the steering frame lock is in the unlocked position The following tests are used to determine whether the braking system is functional These tests are not intended to measure the maximum brake holding effort The required brake holding effort for sustaining a machine at a specific engine rpm varies from one machine to another machine The variations include differences in the engine setting the power train
56. ement plates to the ROPS Consult your Caterpillar dealer for repair of cracks in any welds in any castings or in any metal section of the ROPS 102429589 Seat Belt Inspect SMCS Code 7327 040 Always check the condition of the seat belt and the condition of the seat belt mounting hardware before you operate the machine Replace any parts that are damaged or worn before you operate the machine Illustration 229 g00932801 Typical example Check the seat belt mounting hardware 1 for wear or for damage Replace any mounting hardware that is worn or damaged Make sure that the mounting bolts are tight Check buckle 2 for wear or for damage If the buckle is worn or damaged replace the seat belt Inspect the seat belt 3 for webbing that is worn or frayed Replace the seat belt if the seat belt is worn or frayed Consult your Caterpillar dealer for the replacement of the seat belt and the mounting hardware SEBU7459 09 149 Maintenance Section Seat Belt Replace Note Within three years of the date of installation or within five years of the date of manufacture replace the seat belt Replace the seat belt at the date which occurs first A date label for determining the age of the seat belt is attached to the seat belt the seat belt buckle and the seat belt retractor If your machine is equipped with a seat belt extension also perform this inspection procedure for the seat belt extension 10242
57. ential and Final Drive Oil Level Check 118 Drive Shaft Spline Center Lubricate 119 Engine Oil High Speed and Oil Filter Change 124 Engine Oil and Filter Change n se 128 Quick Coupler Lubricate ccceetee 146 Initial 500 Hours for New Systems Refilled Systems and Converted Systems Cooling System Coolant Sample Level 2 ODA eriten e eaae a aa ta nein 115 Every 500 Service Hours or 3 Months Cooling System Coolant Sample Level 1 OD aN RA AE E E EE EAN 115 Differential and Final Drive Oil Sample Obtain 118 Engine Crankcase Breather Clean aaas 123 Engine Oil High Speed and Oil Filter Change 124 Engine Oil and Filter Change n a 128 Fuel System Primary Filter Water Separator Element Replace ececceeeeeeeeeeeteeeeees 133 Fuel Tank Cap and Strainer Clean 5 135 Hydraulic System Biodegradable Oil Filter Element Replace ninn a a a alee 139 Hydraulic System Oil Filter Replace 142 Hydraulic System Oil Sample Obtain 143 Transmission Oil Filter Replace 05 153 Transmission Oil Sample Obtain 05 154 98 Maintenance Section Maintenance Interval Schedule SEBU7459 09 Every 1000 Service Hours or 6 Months Articulation Bearings Lubricate 0 ceeeee 99 Battery Hold Down Tighten eeeeeeeeeees 102 Case Drain Screen Stra
58. era aa e atA 10 Amperes 15 Transmission ECM and the Sensor for the Lh Brake Pedal 2 eeeeeeeeeeeeees 10 Amperes 16 Implement ECM and Lever SOCNSOMS a a aa 10 Amperes 17 EMS Quad Gauge Tachometer and Backlights onneni 10 Amperes 18 Wiper and Washer for the Front and the Rear WINJOWS eies a a aa 10 Amperes 19 Payload Control System PCS 10 Amperes 20 Voltage Converter for Radio 10 Amperes 21 Center Indicator Display 10 Amperes 22 SPAG se mr i r SeA 10 Amperes 23 Product INK eesi a 10 Amperes 24 Voltage Converter Memory Attachment eeeeeeseeeeineesrrnseeennns 20 Amperes 25 EGAP uone nE a a 10 Amperes 26 Lh Tail Lamps and Clearance LAMPS eid sts aa a aa 10 Amperes 27 Hood Actuator s es 10 Amperes 28 Stop Lamp and Backup Alarm with Lamp Sia e raaa 10 Amperes 29 OMe A A eee 10 Amperes 30 Voltage Converter Memory Standard reiia iinnat E AAAS 10 Amperes 31 Key Start Switch and Machine Security System MSS eeina a 10 Amperes 32 Dome Lamps asessseeeeesreeeerrresrress 10 Amperes i01615750 Hood Tilt Actuator Lubricate SMCS Code 7275 086 Illustration 209 g00765332 The hood tilt actuator is located on the right side of the machine SEBU7459 09 139 Maintenance Section Hydraulic System Biodegradable Oil Filter Element Replace 1 Raise the engine hood in order to extend the tilt hood actuator 2
59. fuel consumption and oil contamination These factors deplete the oil additives more rapidly If the average fuel consumption exceeds 23 L 6 US gal per hour for the 950G Series II Wheel Loader follow the High Load Factor recommendations in Table 19 To determine average fuel consumption measure average fuel consumption for a period of 50 to 100 hours If the application of the machine is changed the average fuel consumption may change For sulfur content above 0 5 refer to Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations Total Base Number TBN and Fuel Sulfur Levels for Direct Injection DI Diesel Engines In order to verify an oil change interval of 500 hours refer to Program A below 6 Use Program B below to determine an appropriate interval R g S 5 SEBU7459 09 129 Maintenance Section Engine Oil and Filter Change Table 20 962G Series II Wheel Loader IT62G Series II Integrated Toolcarrier Engine Oil Change Interval Operating Conditions Severe Normal High Fuel Altitude Load Sulfur above Multigrade Factor from 1830 m Oil Type above 0 3 to 6000 ft 25 L 0 5 6 5 US gal per hr of fuel See 500 hr 500hr 500 hr 250 hr API CH 4 11 0 minimum 500 hr 500 hr 500 hr 250 hr TBN Preferred API CH 4 TBN 500 hr 500 hr 250 hr 250 hr below 11 0 API CG 4 250 hr 250 hr 250 h
60. gine and run the engine for at least ten seconds Then stop the engine and add hydraulic oil to the tank until the oil level is at the FULL mark on the sight gauge Install the filler cap 12 Start the engine and run the engine at low idle Cycle the implements so that all hydraulic systems are filled with oil Note If the alert indicator for a low oil level comes on stop the engine and immediately add oil to the hydraulic tank The oil level should not be below the suction ports in the hydraulic tank while the engine is running 13 Add hydraulic oil to the tank until the oil level is at the FULL mark on the sight gauge 142 Maintenance Section Hydraulic System Oil Filter Replace SEBU7459 09 14 Stop the engine Top off the hydraulic tank so that the oil level is at the FULL mark on the sight gauge Install the filler cap Note The oil must be free of air bubbles If air bubbles are present in the hydraulic oil air is entering the hydraulic system Inspect the hydraulic suction line and the hose clamps 15 If necessary tighten any loose clamps or any loose connections Replace any damaged hoses 101465406 Hydraulic System Oil Filter Replace SMCS Code 5068 510 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before ope
61. h oil Reference Refer to Operation and Maintenance Manual Lubricant Viscosities and Refill Capacities for the type of lubricant and for the refill capacity 6 Clean the dipstick fill plugs and install the dipstick fill plugs 7 Run the machine on level ground for a few minutes in order to equalize the oil level in the axle Check the oil level in the axle 118 Maintenance Section Differential and Final Drive Oil Level Check SEBU7459 09 Reference Refer to Operation and Maintenance Manual Differential and Final Drive Oil Level Check for the correct procedure 101902117 Differential and Final Drive Oil Level Check SMCS Code 3278 535 FLV 4011 535 FLV Note Before you measure the oil level operate the machine for a few minutes in order to equalize the oil level 1 Park the machine on level ground Lower the bucket and apply slight downward pressure Engage the parking brake Stop the engine Nia Illustration 170 g00989672 Dipstick fill plug for the front axle Illustration 171 g00989674 Dipstick fill plug for the rear axle 2 Remove the dipstick fill plug Wipe off the level gauge with a clean cloth and reinsert the plug This will ensure a more accurate measurement of the oil level
62. he electrical system from a circuit that has been overloaded Change a fuse if the element separates If the element of a new fuse separates check the circuit Repair the circuit if necessary Illustration 205 g01000750 Illustration 206 g01060133 The fuses are located in the cab on the right side of the operator seat 1 Fourth Function or Grapple 10 Amperes 2 Neutralizer Override Switch 10 Amperes 3 Ether Injection ieee 10 Amperes 4 Quick Coupler ccceeesseeeeeeeeeees 10 Amperes 5 Rear Floodlights 00 0 0 15 Amperes 6 Axle Oil Coolers iesene 10 Amperes 7 Secondary Steering c eee 10 Amperes 8 Engine ECM ADEM Ill 10 Amperes 9 Front Floodlights 0 cceeeeeeeee 15 Amperes 10 BEACON a a 10 Amperes SEBU7459 09 137 Maintenance Section Fuses Replace 11 Front and Rear Flasher Relays 10 Amperes 12 Product Link for the Machine Security SYSTOM arnari AAPARINNE 20 Amperes 13 Lh Indicator Display and Rh Indicator Displ y c e aai 10 Amperes 14 Lift Position Sensor 0 eee 10 Amperes 15 Transmission ECM and the Lh Brake Pedal SENSON aeaa eanan Andie eee 10 Amperes 16 SPNO o aE aA 10 Amperes 17 EMS Q
63. ids Recommendations Total Base Number TBN and Fuel Sulfur Levels for Direct Injection DI Diesel Engines 5 In order to verify an oil change interval of 500 hours refer to Program A below 6 Use Program B below to determine an appropriate interval R g SEBU7459 09 125 Maintenance Section Engine Oil High Speed and Oil Filter Change Table 18 962G Series II Wheel Loader IT62G Series II Integrated Toolcarrier Engine Oil Change Interval Operating Conditions Severe Normal High Fuel Altitude Load Sulfur above Multigrade Factor from 1830 m Oil Type above 0 3 to 6000 ft 25 L 0 5 6 5 US P gal per hr of fuel a DEO soohr 500hr 500hr 250 hro referred API CH 4 11 0 minimum 500 hr 500 hr 500 hr 250 hr TBN Preferred API CH 4 TBN 500 hr 500 hr 250hr6 250 hr below 11 0 API CG 4 250 hr 250 hr amp 250 hr 250 hr API CF 4 250 hr 250 hr 250 hr6 250 hr 1 The traditional oil change interval for engines is 250 hours The standard oil change interval in this machine is 500 hours if the operating conditions and recommended oil types that are listed in this table are met Improvements in the engine allow this engine oil change interval This new standard interval is not permitted for other machines Refer to the applicable Operation and Maintenance Manuals for the other machines
64. if the gauges in dicate the system is empty of refrigerant Always use precaution when a fitting is removed Slowly loosen the fitting If the system is still un der pressure release it slowly in a well ventilated area Personal injury or death can result from inhaling refrigerant through a lit cigarette Inhaling air conditioner refrigerant gas through a lit cigarette or other smoking method or inhaling fumes released from a flame contacting air con ditioner refrigerant gas can cause bodily harm or death Do not smoke when servicing air conditioners or wherever refrigerant gas may be present Use a certified recovery and recycling cart to prop erly remove the refrigerant from the air condition ing system NOTICE If the refrigerant system has been open to the outside air without being plugged for more than 30 minutes the receiver dryer must be replaced Moisture will en ter an open refrigerant system and cause corrosion which will lead to component failure Refer to Service Manual SENR5664 Air Conditioning and Heating System with R 134a Refrigerant for All Caterpillar Machines for the proper procedure to change the receiver dryer assembly and for the procedure to reclaim the refrigerant gas 101157525 Ride Control Accumulator Check SMCS Code 5077 535 R6 The ride control accumulator reduces the pitching of the machine If the machine seems to be bouncing excessively check the charge in the
65. iner Steering Pump Hydraulic Fan Pump Motor Clean 111 Drive Shaft Support Bearing Lubricate 119 Drive Shaft Universal Joints Lubricate 119 Fuel System Secondary Filter Replace 134 Hood Tilt Actuator Lubricate oe 138 Roading Fender Hinges Lubricate 147 Rollover Protective Structure ROPS Inspect 148 Steering Pilot Oil Screen Command Control Steering Clean Replace cceceeeeeeee 150 Transmission Oil Change seeen 151 Every 2000 Service Hours or 1 Year Brake Discs Check ccceecesseeeeeeeeeteeeeeeeeaaes 104 Differential and Final Drive Oil Change 117 Engine Valve Lash Check isses 131 Fuel Injection Timing Check seeen 131 Hydraulic System Oil Change n 140 Hydraulic Tank Breaker Relief Valve Clean 144 Refrigerant Dryer Replace eeeeeeeeeeeeees 147 Service Brake Wear Indicator Check 149 Steering Shaft Command Control Steering UDI C ALG eisa ina E aetesde nantes gece 150 Every Year Cooling System Coolant Sample Level 2 OD aI aaa a E a tee eat aed 115 Every 3000 Service Hours or 2 Years Engine Auxiliary Air Filter Replace 122 Every 3 Years After Date of Installation or Every 5 Years After Date of Manufacture Seat Belt Replace cccccccceceeeeeeeeeeeteeeeeeees 149 Every 4000 Service Hours or 2 Years
66. l Filter Change SEBU7459 09 Procedure for Changing the Engine Oil and Filter NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent 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 Dispose of all fluids according to local regulations and mandates Your machine may be equipped with a high speed arrangement for changing the engine oil The high speed arrangement allows service personnel to change the oil from the engine access door on the right side of the machine The high speed arrangement allows the oil to be changed faster than conventional methods Illustration 187 g00812715 1 Open the service door that is located on the right side of the machine 2 Remove the cap that protects the male coupler Connect an oil pump to the fitting The fitting on the machine is a male coupler 3 Turn on the oil pump and withdraw the engine oil from the engine oil pan 4 Open the engine hood Illustration 188 g00890554 The oil filter is located on the left side of the machine 5 Use a strap type wrench to
67. m the left side of the machine Inspect the oil filter Reference For more information refer to Operation and Maintenance Manual Oil Filter Inspect 4 Clean the filter housing base Make sure that all of the used filter gasket is completely removed Illustration 194 g00101318 5 Apply a thin coat of clean engine oil to the sealing surface of the new filter element 6 Install the engine oil filter element 1 hand tight until the seal of the engine oil filter element 1 contacts the oil filter base Note Note the position of the index marks on the oil filter element 1 in relation to a fixed point on the filter base 7 Tighten the filter according to the instructions that are printed on the filter Use the index marks as a guide o E3 o 4 oo i ol oo gt o B H oj P 3 H g J Illustration 195 g00888778 8 Remove filler cap 3 Fill the crankcase with new oil Reference For the correct type of oil and for the correct amount of oil refer to Operation and Maintenance Manual Lubricant Viscosities and Refill Capacities SEBU7459 09 131 Maintenance Section Engine Valve Lash Check 9 Clean the filler cap and install the filler cap 10 Start the engine and allow the oil to warm Check for leaks 11 Check the oil level on dipstick 4 Referenc
68. machine Press the button on the breaker relief valve 1 in order to relieve any tank pressure 4 Remove the hydraulic tank filler cap 2 and the filler strainer 3 Wash the filler cap and the strainer in a clean nonflammable solvent Install the strainer 5 Inspect the gasket on the hydraulic tank filler cap for damage Replace the gasket if necessary 6 Remove the drain plug 5 from the bottom of the hydraulic tank Wash the drain plug in a clean nonflammable solvent 7 The hydraulic tank is equipped with an ecology drain valve Attach a hose to a 126 7914 Oil Drain Coupling Install the threaded end of the coupling into the drain valve in order to unseat the internal drain valve NOTICE Never start the engine while the hydraulic oil tank is being drained or while the hydraulic oil tank is empty Excessive wear and damage to the hydraulic compo nents can occur 8 Close the drain valve Install the drain plug 9 Change the hydraulic oil filter Reference Refer to Operation and Maintenance Manual Hydraulic System Oil Filter Replace for the correct procedure 10 Fill the hydraulic tank with clean oil Make sure that the oil level is at the FULL mark on the sight gauge 4 Install the filler cap Reference Refer to Operation and Maintenance Manual Lubricant Viscosities and Refill Capacities for the correct type of oil and for the correct amount of oil 1 _ Start the en
69. n ing any compartment or disassembling any compo nent 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 Dispose of all fluids according to local regulations and mandates Illustration 214 g00765498 The hydraulic filter is located on the right side of the machine 1 Use a strap type wrench to remove the filter element Dispose of the used filter element properly 2 Clean the filter mounting base Make sure that all of the used gasket is completely removed Illustration 215 g00101318 3 Lubricate the gasket of the new filter element with clean hydraulic oil 4 Install the new filter element by hand After the gasket contacts the filter mounting base tighten the filter element by an additional 3 4 turn 5 Start the engine and run the engine at low idle Inspect the hydraulic system for leaks Illustration 216 g00765515 6 Maintain the oil level above the ADD COLD mark on the sight gauge Add hydraulic oil if necessary SEBU7459 09 143 Maintenance Section Hydraulic System Oil Level Check 101465502 Hydraulic System Oil Level Check SMCS Code 5056 535 FLV 101
70. n a clean nonflammable solvent Install the breather 14 Start the engine Slowly operate the transmission controls in order to circulate the oil 15 Move the transmission control to the NEUTRAL position Stop the engine Inspect the transmission for leaks 16 Check the transmission oil level The sight gauge 9 is located near the filler tube The transmission oil should be at the mark 10 if the engine is off The oil should be between marks 11 and 12 when the engine is idling Reference Refer to Operation and Maintenance Manual Transmission Oil Level Check for the correct procedure SEBU7459 09 153 Maintenance Section Transmission Oil Filter Replace 101468833 Transmission Oil Filter Replace SMCS Code 3004 510 3067 510 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent 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 Dispose of all fluids according to local regulations and mandates 1 Park the machine on a hard level surface Lower the bucket to the ground with a slight downward pressure Engage the parking
71. nsecutive interval is performed all maintenance from the previous interval must be performed When Required Automatic Lubrication Grease Tank Fill 99 Automatic Lubrication Grease Tank Fill 100 Battery RECYCIO oo ecceeeeeeneeeeeeeeeenteeeeeeenaaes 102 Battery or Battery Cable Inspect Replace 102 Bucket Wear Plates Inspect Replace 110 Circuit Breakers Reset eeeeeeeceeeeeeees 111 Engine Air Filter Primary Element Clean Replace 0 cccceeeeeeeeeeeeceeceeeeeeeteteeeeees 120 Engine Air Filter Secondary Element Replace 121 Engine Air Precleaner Clean 0 eee 122 Fuel System Prime cceccecceeeeeeeeeeenteeeeeeeneaes 132 Fuses Replace 00 cc cccccccceeeeeeeeeeeeeecceeeeeeeeteees 136 Fuses Replace ccccccceceeeeeeeeeeeteceeeeeeeeeeteees 137 Oil Filter Inspect ceeeeeeeceeeeeeeeeeeeeeeeteeeees 144 Radiator Core Clean ccececeeeeeceeeeeeeeeeeeees 146 Ride Control Accumulator Check 00 147 Window Washer Reservoir Fill 0006 154 Window Wiper Inspect Replace 0 155 Every 10 Service Hours or Daily Backup Alarm Test cceeeeeeeeeecceeeeeeeeeeeeees 101 Bucket Cutting Edges Inspect Replace 105 Bucket Tips Inspect Replace ccceeee 107 Cooling System Coolant Level Check 114
72. ny compartment or disassembling any compo nent 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 Dispose of all fluids according to local regulations and mandates NOTICE Do not fill fuel filters with fuel before installing them Contaminated fuel will cause accelerated wear to fuel system parts Fuel system should be primed prior to starting the engine Illustration 199 g00765025 1 Open the engine hood The primary fuel filter is located on the right side of the machine 2 Open drain valve 3 on the bottom of water separator bowl 2 Allow the water and the fuel to drain into a suitable container 134 Maintenance Section Fuel System Secondary Filter Replace SEBU7459 09 3 Support the sediment bowl and rotate the retaining ring 2 counterclockwise Remove the sediment bowl Clean the water separator bowl and the O ring groove Note The water separator bowl is reusable Do not discard the water separator bowl 4 Remove the water separator element 1 from the mounting base by using a strap type wrench 5 Inspect the O ring seal on the water separator bowl Replace the O ring seal if necessary Illustration 200 g00101318 6 Lubricate the O ring seal with clean diesel fuel Place the O ring seal in the
73. oduct Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent 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 Illustration 166 g00989676 Machine without axle oil cooler Illustration 167 g00630605 Machine with axle oil cooler Note The axle housings are equipped with ecology drain valves 1 Remove the drain plugs Attach a hose to a suitable drain adapter Install a drain adapter into each drain valve Allow the oil to drain into a suitable container 2 Remove the drain adapters from the drain valves 3 Clean the drain plugs and install the drain plugs v 5 Illustration 168 g00989672 Dipstick fill plug for the front axle Illustration 169 g00989674 Dipstick fill plug for the rear axle 4 Wipe off the dipstick fill plugs and the surfaces around the dipstick fill plugs 5 Remove the dipstick fill plugs Add 0 5 L 0 5 qt of 1U 9891 Hydraulic Oil Additive to each axle Fill the axles wit
74. oil change intervals of 500 hours Oil sampling and analysis is done at 250 hours and 500 hours for each of the three intervals for a total of six oil samples The analysis includes oil viscosity and infrared IR analysis of the oil If all of the results are satisfactory the 500 hour oil change interval is acceptable for the machine in that application Repeat Program A if you change the application of the machine If a sample does not pass the oil analysis take one of these actions e Shorten the oil change interval to 250 hours e Proceed to Program B e Change to a preferred oil type Program B Optimizing Oil Change Intervals Begin with a 250 hour oil change interval The oil change intervals are adjusted by increments Each interval is adjusted an additional 50 hours Periodic oil sampling and analysis is done during each interval The analysis includes oil viscosity and infrared IR analysis of the oil Repeat Program B if you change the application of the machine If an oil sample does not pass the analysis shorten the oil change interval or change to a preferred multigrade oil type in the listing above References Reference Special Publication PEDP7035 Optimizing Oil Change Intervals Reference Special Publication PEDP7036 S O S Fluid Analysis Reference Special Publication PEDP7076 Understanding the S O S Oil Analysis Tests 126 Maintenance Section Engine Oil High Speed and Oi
75. r 250 hr API CF 4 250 hr 250 hr 250 hr 250 hr 1 The traditional oil change interval for engines is 250 hours The standard oil change interval in this machine is 500 hours if the operating conditions and recommended oil types that are listed in this table are met Improvements in the engine allow this engine oil change interval This new standard interval is not permitted for other machines Refer to the applicable Operation and Maintenance Manuals for the other machines Normal conditions include these factors Fuel sulfur below 0 3 altitude below 1830 m 6000 ft and good air filter and fuel filter maintenance Normal conditions do not include high load factor harsh operating cycles or harsh environments High load factors can shorten the service life of your engine oil Continuous heavy load cycles and very little idle time result in increased fuel consumption and oil contamination These factors deplete the oil additives more rapidly If the average fuel consumption exceeds 25 L 6 5 US gal per hour for the 962G Series II Wheel Loader follow the High Load Factor recommendations in Table 20 To determine average fuel consumption measure average fuel consumption for a period of 50 to 100 hours If the application of the machine is changed the average fuel consumption may change For sulfur content above 0 5 refer to Special Publication SEBU6250 Caterpillar Machine Fluids Re
76. r oil and filter change that is too long you may damage the engine Caterpillar oil filters are recommended Recommended multigrade oil types are listed in the tables Do not use single grade oils Illustration 186 g00753767 API Trademark Commercial oils that are licensed by the American Petroleum Institute API bear this trademark Commercial oils that do not bear this trademark are not licensed and these oils are not recommended Abnormally harsh operating cycles or harsh environments can shorten the service life of the engine oil Arctic temperatures corrosive environments or extremely dusty conditions may require a reduction in engine oil change intervals Poor maintenance of air filters or of fuel filters requires reduced oil change intervals Reference For more information refer to Operation and Maintenance Manual SEBU5898 Cold Weather Recommendations or see your Caterpillar dealer Table 17 950G Series II Wheel Loader Engine Oil Change Interval Operating Conditions Severe Normale High Fuel Altitude Multigrad Load Sulfur above Lana sh Factor from 1830 m Oil Type above 0 3 to 6000 23 L 6 0 5 ft US gal w per hr of fuel Cat DEO soohr 500hr 500hr 250hr Preferred API CH 4 11 0 minimum 500 hr 500 hr 500 hr 250 hr TBN Preferred API CH 4 TBN 500 hr 500 hr 250 hr 250 hr below 11 0 API CG 4 250 hr 250 hr 250 hr 250
77. re the tire pressure on each tire Inflate the tires with nitrogen if necessary Reference Refer to the Tire Inflation Information section of the Operation and Maintenance Manual for more information 101468034 Transmission Oil Change SMCS Code 3030 044 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent 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 Dispose of all fluids according to local regulations and mandates 1 Operate the engine for a few minutes in order to warm the transmission oil 2 Park the machine on a hard level surface Lower the bucket to the ground with a slight downward pressure Engage the parking brake and stop the engine Illustration 235 g00766059 Note Remove the bolts 1 that hold the transmission guard 2 Remove the transmission guard on the underside of the machine in order to access the magnetic strainer 152 Maintenance Section Transmission Oil Change SEBU7459 09 Illustration 236 g00766094 3 Remove transmission oil drain plug 7
78. rom removing hoses or fittings that are under pressure Relieve the pres sure in the system before you remove hoses or fittings Illustration 131 g01067897 Filling the Reservoir 1 The Lincoln Quicklub pump 1 is located near the rear fender on the right side of the machine 100 Maintenance Section Automatic Lubrication Grease Tank Fill SEBU7459 09 2 Fill the reservoir 2 through the grease fitting 3 The grease fitting 3 is located at the base of the reservoir 2 Reference For the correct type of grease refer to Operation and Maintenance Manual Lubricant Viscosities 3 Refill the reservoir when the grease reaches the MIN mark on the reservoir 4 Fill the reservoir to the MAX mark on the reservoir Priming the System After the reservoir has been filled with the recommended lubricant loosen the fitting to the supply line Operate the pump until lubricant flows from the outlet Then tighten fitting 102094776 Automatic Lubrication Grease Tank Fill If Equipped SMCS Code 7540 544 TNK S N AYA1 Up S N BAA1 Up S N AYB1 Up S N BAB1 Up S N BAC1 Up S N AYD1 Up S N BAD1 Up S N AYE1 Up S N AYG1 Up S N AYL1 Up S N AYS1 Up The Groeneveld Automatic TWIN Greasing System Reference Refer to System Operation RENR 6331for more information on the Automatic TWIN Greasing System A pressure hazard is present Severe personal in jury or
79. ss door 102067499 Case Drain Screen Strainer Steering Pump Hydraulic Fan Pump Motor Clean SMCS Code 4304 070 Z3 5057 070 Z3 Illustration 155 g01059455 Case drain screen 3 and case drain screen 5 are located in hydraulic line 2 and hydraulic line 4 Hydraulic line 2 and hydraulic line 4 are located behind the hydraulic oil tank 1 Hydraulic line 2 is the case drain for the hydraulic fan pump Hydraulic line 4 is the case drain for the steering pump 1 Disconnect the hydraulic line 2 from the hydraulic tank 1 2 Remove the case drain screen 3 from the hydraulic line 2 3 Wash the case drain screen 3 in a clean nonflammable solvent 4 Dry the case drain screen 3 by using pressurized air 5 Inspect the case drain screen 3 for damage Note If the case drain screen 3 is damaged replace the case drain screen 3 6 Install the case drain screen 3 7 Connect hydraulic line 2 8 Repeat Step 1 through Step 7 for hydraulic line 4 and case drain screen 5 102126545 Circuit Breakers Reset SMCS Code 1420 529 in order to reset the circuit breakers The button will stay depressed if the circuit is working properly Check the appropriate electrical circuit if the button does not stay depressed a Circuit Breaker Reset Push the button Illustration 156 g00753091 Two circuit breakers are located in
80. stall the new filter element by hand After the gasket contacts the filter mounting base tighten the filter element by an additional 3 4 turn 5 Start the engine and run the engine at low idle Inspect the hydraulic system for leaks 140 Maintenance Section Hydraulic System Oil Change SEBU7459 09 Illustration 212 g00765515 6 Maintain the oil level above the ADD COLD mark on the sight gauge Add hydraulic oil if necessary 101773322 Hydraulic System Oil Change SMCS Code 5056 044 Selection of the Oil Change Interval Your machine may be able to use a 4000 hour interval for the hydraulic oil The hydraulic oil is in the system that is not integral to the service brakes the clutches the final drives or the differentials The standard change interval is 2000 hours The oil should be monitored during intervals of 500 hours The extended 4000 hour interval can be used if the following criteria are met Oil Filters Caterpillar oil filters are recommended The interval for changing the oil filter should be 500 hours Oil The 4000 hour interval for changing the oil is for the following oil types e Caterpillar Hydraulic Oil HYDO e Caterpillar Transmission and Drive Train Oil TDTO e Caterpillar TDTO TMS e Caterpillar Diesel Engine Oil e Caterpillar Biodegradable Hydraulic Oils HEES e Caterpillar Multipurpose Tractor Oil MTO
81. t Program B if you change the application of the machine If an oil sample does not pass the analysis shorten the oil change interval or change to a preferred multigrade oil type in the listing above References Reference Special Publication PEDP7035 Optimizing Oil Change Intervals Reference Special Publication PEDP7036 S O S Fluid Analysis Reference Special Publication PEDP7076 Understanding the S O S Oil Analysis Tests 130 Maintenance Section Engine Oil and Filter Change SEBU7459 09 Procedure for Changing the Engine Oil NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent 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 Dispose of all fluids according to local regulations and mandates 1 Open the engine hood Illustration 193 g00888573 2 The crankcase drain valve 2 is located on the left side of the oil pan beneath the machine Open the crankcase drain valve and allow the oil to drain into a suitable container Close the drain valve 3 Use a strap type wrench to remove oil filter 1 fro
82. te fittings 1 and 2 Backup Alarm Test SMCS Code 7406 081 Turn the engine start switch to the ON in order to perform the test Apply the service brake Place the transmission into reverse The backup alarm should start to sound immediately The backup alarm will continue to sound until the transmission is placed into neutral or into forward Illustration 134 g00764199 A three position switch on the backup alarm regulates the volume of the alarm The backup alarm is located on the rear of the machine The backup alarm is set for the highest sound level when the machine is shipped from the factory The setting should remain on HIGH unless the job site requires a lower sound level 101461884 Battery Clean SMCS Code 1401 070 Illustration 135 g00764246 102 Maintenance Section Battery Recycle SEBU7459 09 Open the battery compartment on the left rear side of the machine Clean the battery terminals and the surfaces of the batteries with a clean cloth Coat the battery terminals with petroleum jelly Make sure that the battery cables are installed securely 100993589 Battery Recycle SMCS Code 1401 561 Always recycle a battery Never discard a battery Always return used batteries to one of the following locations e A battery supplier e An authorized battery collection facility e Recycling facility
83. terpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates NOTICE Topping off or mixing Cat ELC with other products that do not meet Caterpillar EC 1 specifications reduces the effectiveness of the coolant and shortens coolant service life Use only Caterpillar products or commercial products that have passed the Caterpillar EC 1 specification for pre mixed or concentrate coolants Use only Extender with Cat ELC Failure to follow these recommendations can result in shortened cooling system component life Reference For information about the addition of Extender to your cooling system see Operation and Maintenance Manual Cooling System Coolant Extender ELC Add or consult your Caterpillar dealer If an Extended Life Coolant was previously used flush the cooling system with clean water No other cleaning agents are required Use the following procedure to change the Extended Life Coolant The cooling system pressure cap is located under the hood at the rear of the machine lo ob EF FF j Illustration 158 g00753186 SEBU7459 09 113 Maintenance Section Cooling System Coolant Extender ELC Add 1 Slowly loosen the cooling system pressure cap in order to relieve system pressure The pressure c
84. the cab behind the operator s seat These circuit breakers are located behind the fuses 1 Heating and Air Conditioning SYSTEM soci ived en teadends erR 15 Amperes 2 Operator Seat ee eeeeeeeeeees 15 Amperes Note Machines that are equipped with electrohydraulic controls and conventional steering will not have circuit breakers that are located in the cab 112 Maintenance Section Cooling System Coolant ELC Change SEBU7459 09 o m a x Lo A A 4 3 4 5 6 Illustration 157 g00753113 Circuit breakers are also located in the engine compartment on the right side of the machine 3 Alternator 0 cceeceeeeeeeeeteeteeeeeeeeees 80 Amperes 4 Main Circuit ee 80 Amperes 5 Cab aer en ee eats 15 Amperes 6 ENGINE serian a ERO 20 Amperes i01732072 Cooling System Coolant ELC Change SMCS Code 1350 044 NL Pressurized system Hot coolant can cause seri ous burn To open cap stop engine wait until ra diator is cool Then loosen cap slowly to relieve the pressure NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Ca
85. the engine air filter primary element pull the element outward While you pull the element outward rock the element Use Steps 4 through 6 in order to clean the primary element 4 Inspect the primary element If the pleats the gaskets or the seals are damaged discard the element Replace a damaged primary element with a clean primary element SEBU7459 09 121 Maintenance Section Engine Air Filter Secondary Element Replace Illustration 179 g00328468 5 If the primary element is not damaged clean the primary element Pressurized air can be used to clean a primary element that has not been cleaned more than two times Use filtered dry air at a maximum pressure of 207 kPa 30 psi Note Pressurized air will not remove deposits of carbon and oil 6 When you clean the primary element always begin in the inside of the element clean side This will force dirt particles toward the outside of the element dirty side Direct the air along the length inside of the filter This will help prevent damage to the paper pleats Note Do not aim the stream of air directly at the primary element Dirt could be forced further into the pleats Use Steps 7 through 10 in order to inspect the primary element Illustration 180 g00328470 7 Place a light bulb inside the filter element Use a 60 watt blue light in a dark room or in a similar facility Inspect the primary element for light that may sho
86. to become distorted resulting in either a loss of retainer grip or an increased difficulty in removing the pin Illustration 147 g01201331 Improper installation By driving from the right side of the adapter the retainer is properly supported by the counterbore of the adapter This procedure will show that the pin chamfer is centered in the inside diameter of the retainer more clearly N55 q Illustration 148 g01201332 Proper installation Install pin from the right side 1 Remove the pin from the bucket tip The pin can be removed by one of the following methods e Use a hammer and a punch from the retainer side of the bucket to drive out the pin e Use a Pin Master Follow Step 1 a through Step 1 c for the procedure a Place the Pin Master on the bucket tooth b Align extractor 5 with the pin c Strike the Pin Master at the back of the tool 4 and remove the pin SEBU7459 09 109 Maintenance Section Bucket Tips Inspect Replace Illustration 149 g00590819 6 Retainer 7 Retaining Washer 8 Adapter 2 Clean the adapter and the pin 3 Fit retainer 6 into retaining washer 7 Install this assembly into the groove that is in the side of the adapter 8 Illustration 150 g00101359 4 Install the new bucket tip into the adapter Note The bucket tip can be rotated by 180 degrees in order to
87. tube openings Remove dirt and debris 4 Clean the precleaner with compressed air or wash the precleaner in warm water Dry all the parts 5 Install the precleaner screen 101902420 Engine Auxiliary Air Filter Replace If Equipped SMCS Code 1054 070 AX 1054 510 AX Some machines may be equipped with an auxiliary air filter that is located behind the main air filter housing Use the following procedure to replace the auxiliary air filter 1 Remove four bolts and the access plate on the engine hood SEBU7459 09 123 Maintenance Section Engine Crankcase Breather Clean e e 7 L To TP fa o Ub ae Illustration 184 g00351832 Side view of the auxiliary air filter housing 2 Remove four nuts 1 and access cover 2 from the top of auxiliary air filter housing 3 3 Remove the auxiliary air filter element 4 Cover air outlet 4 Clean the inside of the auxiliary air filter housing 5 Uncover the air outlet Install a new auxiliary air filter element 6 Install access cover 2 and four nuts 1 7 Install the access plate on the engine hood and secure the access plate with the four bolts 101438568 Engine Crankcase Breather Clean SMCS Code 1317 070 1 Open the engine hood The engine crankcase breather is located on the right side of the machine
88. uad Gauge Tachometer and Backlights oertain a 10 Amperes 18 Wiper and Washer for the Front and the Rear WINdOWS 2 0 cecceeeeeeeeeeeeeeenetteees 10 Amperes 19 Payload Control System 15 Amperes 20 Voltage Converter for Radio 10 Amperes 21 Center Indicator Display 15 Amperes 22 Spare iieteievitinnee sah ese tess 10 Amperes 23 Product Link orein araara 10 Amperes 24 Voltage Converter Memory 20 Amperes 20 ECAP enia aaa 10 Amperes 26 Lh Tail Lamps and Clearance LAMPS e ien e debe 10 Amperes 27 Hood Actuator ccceeeeeeeeeeeneee 10 Amperes 28 Stop Lamp and Backup Alarm with LAMPS e248 eet eset 10 Amperes 29 HOM ve ciccceecnceeee et iaai 10 Amperes 30 Voltage Converter Memory Standard oeei ane iari 10 Amperes 31 Key Start Switch 2 000 eee 10 Amperes 32 Dome Lamps ceeeeeereeeeeenees 10 Amperes 102126498 Fuses Replace Machines that are Equipped with Electrohydraulic Controls and Conventional Steering SMCS Code 1417 510 S N BAB1 Up S N AYL1 Up NOTICE Replace fuses with the same type and size only Oth erwise electrical damage can result If it is necessary to replace fuses frequently an electri cal problem may exist Contact your Caterpillar dealer Note Machines that are equipped with electrohydraulic controls and conventional steering will not have circuit breakers that are located by the
89. w through the filter material 8 Inspect the primary element while you rotate the element Inspect the primary element for tears and or holes Do not use a primary element that has any tears and or holes in the filter material Do not use a primary element with damaged pleats gaskets or seals 9 If it is necessary compare the primary element to a new primary element Use a new primary element that has the same part number This may be necessary in order to confirm the results of the inspection 10 Discard a damaged primary element Use Steps 11 through 13 to install a clean primary element NOTICE Do not use a filter if the pleats the gaskets or the seals are damaged 11 Install a clean primary filter element over the engine air filter secondary element Apply firm pressure to the end of the primary element as you gently rock the filter element This seats the primary element 12 Clean the cover for the air cleaner housing Align the slot on the cover with the pin on the air cleaner housing Install the cover 13 Close the engine i01693619 Engine Air Filter Secondary Element Replace SMCS Code 1054 510 SE NOTICE Service the air filter only with the engine stopped En gine damage could result NOTICE Always replace the secondary element Do not at tempt to reuse it by cleaning Engine damage could result 122 Maintenance Section Engine Air Precleaner Clean SEBU7459 09
90. window washer solvent SEBU7459 09 155 Maintenance Section Window Wiper Inspect Replace Illustration 242 g00766424 ee Window Washer Reservoir The window washer reservoir is located on the right side of the machine Fill the reservoir through the filler opening 101469067 Window Wiper Inspect Replace SMCS Code 7305 040 7305 510 Illustration 243 g00766456 Inspect the wiper blades Replace the wiper blades if the wiper blades are worn or damaged or if streaking occurs 100037755 Windows Clean SMCS Code 7310 070 Illustration 244 g00038949 Use commercially available window cleaning solutions in order to clean the windows Clean the outside windows from the ground unless handholds are available

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