Manual de Mantenimiento CAT 950G

MAINTENANCE INTERVALSOperation and Maintenance Manual Excerpt © 2010 Caterpillar All Rights Reserved ® ® SEBU7018-08 September 2006 Operation and Maintenance Manual IT62G Integrated Toolcarrier and 950G and 962G Wheel Loaders AKP1-Up (Machine) BDP1-Up (Machine) 2JS1-Up (Machine) 3BS1-Up (Machine) 4BS1-Up (Machine) 5AS1-Up (Machine) 5RS1-Up (Machine) 6NS1-Up (Machine) 6PS1-Up (Machine) 3JW1-Up (Machine) 4PW1-Up (Machine) 5FW1-Up (Machine) 5MW1-Up (Machine) 6EW1-Up (Machine) 6HW1-Up (Machine) 7BW1-Up (Machine) 8JW1-Up (Machine) 102 Maintenance Section Maintenance Interval Schedule SEBU7018-08 i02625049 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 consecutive interval is performed, all maintenance from the previous interval must be performed. Seat Belt - Inspect .............................................. 152 Transmission Oil Level - Check .......................... 158 Windows - Clean ................................................. 160 Every 50 Service Hours or Weekly Bucket Lower Pivot Bearings - Lubricate ............. 110 Cab Air Filter - Clean/Replace ............................. 115 Fuel Tank Water and Sediment - Drain ............... 141 Hydraulic System Biodegradable Oil Filter Restriction - Check .............................................................. 143 Tire Inflation - Check ........................................... 155 Every 100 Service Hours or 2 Weeks Axle Oscillation Bearings - Lubricate .................. 104 Bucket Linkage and Loader Cylinder Bearings Lubricate ........................................................... 109 Bucket Upper Pivot Bearings - Lubricate ............. 115 Logging Fork Clamp - Lubricate ......................... 148 Steering Cylinder Bearings - Lubricate ............... 153 Every 250 Service Hours Engine Oil Sample - Obtain ................................ 131 Every 250 Service Hours or Monthly Battery - Clean .................................................... Belts - Inspect/Adjust/Replace ............................ Brake Accumulator - Check ................................ Braking System - Test ......................................... Differential and Final Drive Oil Level - Check ..... Drive Shaft Spline (Center) - Lubricate ............... Engine Air Filter Service Indicator Inspect/Replace ................................................ Engine Oil and Filter - Change ........................... 105 106 108 109 123 124 128 131 When Required Battery - Recycle ................................................ 105 Battery or Battery Cable - Inspect/Replace ........ 105 Bucket Wear Plates - Inspect/Replace ................ 115 Circuit Breakers - Reset ....................................... 116 Engine Air Filter Primary Element Clean/Replace .................................................. 125 Engine Air Filter Secondary Element - Replace .. 127 Ether Starting Aid Cylinder - Replace ................. 135 Fuel System - Prime ........................................... 135 Fuses - Replace .................................................. 141 Hydraulic System Biodegradable Oil Filter Element Replace ............................................................. 143 Oil Filter - Inspect ................................................ 149 Radiator Core - Clean ......................................... 149 Ride Control Accumulator - Check ..................... 151 Window Washer Reservoir - Fill .......................... 159 Window Wiper - Inspect/Replace ........................ 159 Initial 500 Hours (for New Systems, Refilled Systems, and Converted Systems) Cooling System Coolant Sample (Level 2) Obtain ............................................................... 120 Refrigerant Dryer - Replace ................................ 151 Every 500 Service Hours Cooling System Coolant Sample (Level 1) Obtain ............................................................... 120 Hydraulic System Oil Sample - Obtain ............... 147 Transmission Oil Sample - Obtain ...................... 159 Every 10 Service Hours or Daily Backup Alarm - Test ............................................ 104 Bucket Cutting Edges - Inspect/Replace ............ 109 Bucket Tips - Inspect/Replace ............................. 111 Bucket Tips - Inspect/Replace ............................. 112 Cooling System Coolant Level - Check ............... 119 Engine Air Filter Service Indicator - Inspect ........ 127 Engine Air Precleaner - Clean ............................ 128 Engine Oil Level - Check .................................... 130 Fuel System Primary Filter (Water Separator) Drain ................................................................. 136 Hydraulic System Oil Level - Check ................... 147 Every 500 Service Hours or 3 Months Differential and Final Drive Oil Sample - Obtain .. Engine Crankcase Breather - Clean ................... Fuel System Primary Filter (Water Separator) Element - Replace ............................................ Fuel System Secondary Filter Number One Replace ............................................................. Fuel Tank Cap and Strainer - Clean ................... Hydraulic System Oil Filter - Replace ................. Transmission Oil Filter - Replace ........................ 123 129 137 138 140 146 157 ......Change ......... Rollover Protective Structure (ROPS) .Replace .......... Differential and Final Drive Oil .......................... Hydraulic System Oil ...Lubricate ........ 153 Every 6000 Service Hours or 3 Years Cooling System Coolant Extender (ELC) ......................Check ..Check .......................... 118 Every 6000 Service Hours or 6 Years Cooling System Water Temperature Regulator Replace ..Clean .......Inspect .............. 116 ... Roading Fender Hinges ............... 104 105 124 125 139 152 152 154 156 Every 2000 Service Hours or 1 Year Brake Discs ...... Hydraulic Tank Breaker Relief Valve .Change ...................................................... Fuel Injection Timing ....................................................Lubricate ............................................................ 120 Refrigerant Dryer ........... Steering Pilot Oil Screen (Command Control Steering) ...............................SEBU7018-08 103 Maintenance Section Maintenance Interval Schedule Every 1000 Service Hours or 6 Months Articulation Bearings ...............................Replace ...Check ........ 129 Every 3 Years After Date of Installation or Every 5 Years After Date of Manufacture Seat Belt .......Replace .......Lubricate ... Service Brake Disc Wear Indicator ....................... Battery Hold-Down ......Check ..... Transmission Oil ....... Engine Governor Oil Supply Screen Clean/Inspect/Replace .. Drive Shaft Support Bearing ............................................................. Drive Shaft Universal Joints .. 121 Every 12 000 Service Hours or 6 Years Cooling System Coolant (ELC) .Tighten ...Add ....... 108 121 130 134 135 142 144 148 153 155 Every Year Cooling System Coolant Sample (Level 2) Obtain ...............................Lubricate ................................ 151 Every 3000 Service Hours or 2 Years Engine Auxiliary Air Filter .............................Clean/Replace ..Change ..... Fuel System Secondary Filter Number Two Replace ......... Hood Tilt Actuator ..........................Lubricate .......................................... Engine Valve Lash ........................... Steering Shaft (Command Control Steering) Lubricate .....Change .................... Insure that the machine ignition switch is in the OFF position and that the parking brake is engaged before entering the articulation area.Test (If Equipped) SMCS Code: 7406-081 Turn the engine start switch to the ON position in order to perform the test. Place the transmission into REVERSE. The backup alarm should sound immediately. Apply lubricant through two remote fittings (1) and (2). Illustration 141 g00752649 Open the access door on the right side of the machine. 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. Illustration 142 g00881968 . Wipe all fittings before applying grease.Lubricate SEBU7018-08 i02405939 Articulation Bearings Lubricate SMCS Code: 7057-086-BD. Failure to do so could result in serious injury or death. i01897507 Illustration 140 g00879717 Backup Alarm . 3278-086-BD Crushing Hazard. Failure to do so could result in serious injury or death. Apply the service brake.104 Maintenance Section Articulation Bearings . i02405757 Axle Oscillation Bearings Lubricate SMCS Code: 3268-086-BD. Apply grease to one fitting on the upper pivot bearing and one fitting on the lower pivot bearing. 7065-086-BD. Wipe off all fittings before you apply any lubricant. The backup alarm will continue to sound until the transmission is placed into NEUTRAL or into FORWARD. Always wear protective glasses when working with batteries. Coat the battery terminals with petroleum jelly. The backup alarm is set for the highest sound level when the machine is shipped from the factory. the vibration of an operating machine can cause the battery hold-down to loosen. Make sure that the battery cables are installed securely. Do not allow jumper cable ends to contact each other or the engine. Close the battery compartment. “Battery Hold-Down Tighten” for the correct torque.Clean A three-position switch on the backup alarm regulates the volume of the alarm. Improper jumper cable connections can cause an explosion. 1. tighten the locknut in the center of the hold-down to a torque of 14 ± 3 N·m (10 ± 2 lb ft). 1402-040.Recycle SMCS Code: 1401-561 Always recycle a battery. 1402-510 Personal injury may occur from failure to properly service the batteries.Clean SMCS Code: 1401-070 Illustration 144 g00882014 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. Over time. Turn the engine start switch key OFF. i00993589 Battery or Battery Cable Inspect/Replace SMCS Code: 1401-040. Replace the battery hold-down. Turn all of the switches OFF. i02517652 Illustration 143 g00987179 Open the battery compartment on the left rear side of the machine. Prevent sparks near the batteries. Always return used batteries to one of the following locations: • A battery supplier • An authorized battery collection facility • Recycling facility . Electrolyte is an acid and can cause personal injury if it contacts the skin or eyes. Batteries give off flammable fumes that can explode. 1401-510. Remove the battery hold-down. i01897517 i01897534 Battery Hold-Down . To help to prevent loose batteries and the possibility of loose cable connections. Never discard a battery.SEBU7018-08 105 Maintenance Section Battery . Sparks could cause vapors to explode. Battery . The setting should remain on HIGH unless the job site requires a lower sound level.Tighten SMCS Code: 7257-527 Battery . Refer to Operation and Maintenance Manual. 2. Alternator Belt 1. The tension of a new belt with 30 minutes of operation or less at rated speed should be 534 ± 22 N (120 ± 5 lb). 10. Use a BT-33-97 Borroughs Gauge to check the tension of the alternator belt. Tighten adjustment bolt (2) and mounting bolt (4). Use a BT-33-97 Borroughs Gauge to check the tension of the air conditioner belt. 1357-040. i01908348 1. repeat the adjustment procedure. The tension of a used belt with more than 30 minutes of operation at rated speed should be 400 ± 44 N (90 ± 10 lb). Note: Do not allow the disconnected battery cable to contact the disconnect switch. Belts . Use the ratchet as a lever to rotate alternator (3). 9. replace the belt. Inspect the condition of the alternator belt. If the tension of the belt is incorrect. Turn the battery disconnect switch OFF. Connect the negative battery cable at the battery. If the belt is cracked or frayed. 11.Inspect/Adjust/Replace SEBU7018-08 2. Disconnect the negative battery cable at the battery. Air Conditioner Belt 1. 3. 3. Recheck the tension of belt (5). Access the alternator from the left side of the machine. Loosen one mounting bolt (4) and adjustment bolt (2). Disconnect the positive battery cable at the battery. 4. If necessary. 5. 3. Make any necessary repairs. 4. 1357-510 Note: Stop the engine before you perform any of the following procedures. 6. Rotate the alternator until the correct belt tension is reached. Access the compressor from the right side of the machine. Inspect the battery cables for wear or damage. 2. Connect the positive battery cable at the battery. If the belt is cracked or frayed. .Inspect/Adjust/Replace SMCS Code: 1357-025. Disconnect the negative battery cable from the disconnect switch. Inspect the battery terminals for corrosion. Remove the key. Adjusting the Tension of the Alternator Belt Illustration 145 g00592143 7. Inspect the condition of the air conditioner belt. Install the key and turn the battery disconnect switch ON.106 Maintenance Section Belts . Connect the battery cable at the battery disconnect switch. Insert a ratchet with a square drive into the hole in mounting bracket (1). 8. Earlier Machines (1W-9693 V-Belt) The tension of a used belt with more than 30 minutes of operation at rated speed should be 400 ± 44 N (90 ± 10 lb). replace the battery cables or the battery. The tension of a new belt with 30 minutes of operation or less at rated speed should be 712 ± 22 N (160 ± 5 lb). Later Machines (1P-4334 V-Belt) The tension of a used belt with more than 30 minutes of operation at rated speed should be 445 ± 44 N (100 ± 10 lb). 3. The tension of a new belt with 30 minutes of operation or less at rated speed should be 534 ± 22 N (120 ± 5 lb). replace the belt. 2. The tension of a used belt with more than 30 minutes of operation at rated speed should be 400 ± 44 N (90 ± 10 lb). Open the engine hood in order to access the axle oil cooler pump. The tension of a new belt with 30 minutes of operation or less at rated speed should be 534 ± 22 N (120 ± 5 lb). If the belt is cracked or frayed. If the tension of the belt is incorrect. Belt for the Axle Oil Cooler Pump (If Equipped) 1. 3. The tension of a used belt with more than 30 minutes of operation at rated speed should be 400 ± 44 N (90 ± 10 lb). Loosen one mounting bolt (14) and adjustment bolt (12). 4. Inspect the condition of the water pump drive belt. Tighten adjustment bolt (12) and mounting bolt (14). repeat the adjustment procedure. .Inspect/Adjust/Replace Adjusting the Tension of the Air Conditioner Belt Adjusting the Tension of the Water Pump Drive Belt Illustration 146 g00994370 Illustration 147 g00994371 1. replace the belt. 3. Insert a ratchet with a square drive into the hole in mounting bracket (7). Tighten adjustment bolt (6) and mounting bolt (10). 3. Water Pump Drive Belt 1. 2. Use a BT-33-97 Borroughs Gauge to check the tension of the water pump drive belt. 3. Inspect the condition of the belt. If the belt is cracked or frayed. 1. 2. Insert a ratchet with a square drive into the hole in mounting bracket (15). Rotate the compressor until the correct belt tension is reached.SEBU7018-08 107 Maintenance Section Belts . 4. replace the belt. Rotate the water pump until the correct belt tension is reached. Use the ratchet as a lever to rotate compressor (8). If the tension of the belt is incorrect. 2. repeat the adjustment procedure. The tension of a new belt with 30 minutes of operation or less at rated speed should be 534 ± 22 N (120 ± 5 lb). Use the ratchet as a lever to rotate water pump (11). Loosen one mounting bolt (10) and adjustment bolt (6). Use a BT-33-97 Borroughs Gauge to check the tension of the belt. 2. Open the engine hood in order to access the water pump drive belt. Recheck the tension of belt (9). Recheck the tension of belt (13). 4. Rotate the axle oil cooler pump until the correct belt tension is reached.Check SEBU7018-08 Adjusting the Tension of the Belt for the Axle Oil Cooler Pump i01714079 Brake Accumulator . measure the accumulator precharge pressure. Insert a ratchet with a square drive into the hole in mounting bracket (19).Check SMCS Code: 4263-535 Illustration 149 g00882020 1. If the alert indicator comes on after less than five applications of the brake. The alert indicator for brake oil pressure should come on if the braking system is not at normal operating pressure. Apply the service brake pedal and release the service brake pedal until the alert indicator for brake oil pressure comes on. Turn the engine start switch to the ON position. 3. 2. A minimum of five applications of the service brake pedal are required. i01732078 Illustration 148 g00994372 1. The alert indicator for brake oil pressure should go off. 4. If the tension of the belt is incorrect. 3. Run the engine at half speed for two minutes in order to increase the accumulator pressure. This will decrease the accumulator pressure. Use only dry nitrogen gas for recharging. Start the engine. Tighten adjustment bolt (18) and mounting bolt (17). refer to the Testing and Adjusting Service Manual of the braking system for your machine or consult your Caterpillar dealer. An authorized Caterpillar dealer can measure the nitrogen gas pressure in the accumulator. Brake Discs .Check SMCS Code: 4255-535 Reference: For the correct procedure. 2.108 Maintenance Section Brake Accumulator . . Loosen one mounting bolt (17) and adjustment bolt (18). Recheck the tension of belt (16). Stop the engine. Use the ratchet as a lever to rotate axle oil cooler pump (20). repeat the adjustment procedure. 6107-086-BD Personal injury or death can result from bucket falling. Raise the bucket and place blocking under the bucket. If the opposite side of the cutting edge is not worn.Test SMCS Code: 4251-081. There are a total of 24 fittings.) Fasteners”.T. check the bolts for proper torque. 2. Reference: Refer to Specifications.SEBU7018-08 109 Maintenance Section Braking System . Block the bucket before changing bucket cutting edges.E. Start the engine. Illustration 151 g00764050 Apply lubricant through twelve fittings on each side of the machine. Tighten the bolts to the specified torque. cutting edge (2) and the end bits. 6. “Ground Engaging Tool (G. Illustration 150 g00764365 Check the cutting edges and the end bits for wear and for damage. Remove bolts (1). use the opposite side of the cutting edge. Stop the engine. install a new cutting edge. Use the following procedure to service the cutting edges and the end bits: 1. 4. 6801-510 Bucket Linkage and Loader Cylinder Bearings . 5104-086-BD. Integrated Toolcarrier Wipe off all of the fittings before you apply any lubricant. 7. 3. 4267-081 In order to test the braking system.Test i02056278 If both sides are worn. SENR3130. Lower the bucket onto the blocking. . i01897623 Braking System . Lower the bucket to the ground. 8. Wheel Loader Wipe off all fittings before any lubricant is applied. refer to theTesting and Adjusting Service Manual of the braking system for your machine or consult your Caterpillar dealer. i02196469 Bucket Cutting Edges Inspect/Replace SMCS Code: 6801-040. The end bits are not reversible. After a few hours of operation. Install bolts (1). 5. Raise the bucket and remove the blocking.Lubricate SMCS Code: 5102-086-BD. Clean all contact surfaces. 110 Maintenance Section Bucket Lower Pivot Bearings . Apply lubricant through one fitting on each side of the machine. apply lubricant through a remote fitting on the right side of the machine. Illustration 153 g00765618 For pin joint (1). apply lubricant through one remote fitting on each side of the machine. Illustration 154 g00765808 Illustration 155 g00987389 For pin joint (4). .Lubricate SMCS Code: 6101-086-BD. (6) and (7).Lubricate SEBU7018-08 i01897748 Bucket Lower Pivot Bearings . 6107-086-BD S/N: BDP1-Up S/N: 2JS1-Up S/N: 3BS1-Up S/N: 4BS1-Up Illustration 152 g00987705 S/N: 5AS1-Up S/N: 5RS1-Up S/N: 6NS1-Up S/N: 3JW1-Up S/N: 4PW1-Up S/N: 5FW1-Up S/N: 5MW1-Up S/N: 6EW1-Up S/N: 6HW1-Up S/N: 7BW1-Up S/N: 8JW1-Up Apply lubricant through fittings (2) and (3) on both lift cylinders. Use the fitting that is toward the front of the machine. Apply lubricant through fittings (5). Wipe off all fittings before any lubricant is applied. 1. 6805-510 S/N: BDP1-Up S/N: 2JS1-Up Personal injury or death can result from the bucket falling. Follow Step 1.Inspect/Replace SMCS Code: 6805-040. Align extractor (5) with the pin. Illustration 158 (6) Retainer (7) Retaining washer (8) Adapter g00590819 • Use a hammer and a punch from the retainer side of the bucket to drive out the pin. The pin can be removed by one of the following methods. If the bucket tip has a hole. Place the Pin-Master on the bucket tooth.SEBU7018-08 111 Maintenance Section Bucket Tips .c for the procedure.Inspect/Replace i02420559 Bucket Tips . 2. Install this assembly into the groove that is in the side of adapter (8). Strike the Pin-Master at the back of the tool (4) and remove the pin. Block the bucket before changing bucket tips. Remove the pin from the bucket tip. Illustration 156 (1) Usable (2) Replace (3) Replace g00101352 Check the bucket tips for wear. Fit retainer (6) into retaining washer (7). Illustration 157 (4) Back of Pin-Master (5) Extractor g00590670 Bucket Tips a.a through Step . c. Clean the adapter and the pin. 3. b. 1. replace the bucket tip. • Use a Pin-Master. 112 Maintenance Section Bucket Tips . 6805-510 S/N: AKP1-Up S/N: 2JS1-Up S/N: 3BS1-Up S/N: 4BS1-Up S/N: 5AS1-Up S/N: 5RS1-Up S/N: 6NS1-Up S/N: 3JW1-Up S/N: 4PW1-Up S/N: 5FW1-Up S/N: 5MW1-Up S/N: 6EW1-Up S/N: 6HW1-Up S/N: 7BW1-Up S/N: 8JW1-Up 4. The pin can be installed by using one of the following methods: • From the other side of the retainer. . Place the Pin-Master over the bucket tooth and locate the pin in the hole of holder (10). Strike the tool with a hammer at the back of the tool (4) in order to start the pin. e. 5. Personal injury or death can result from the bucket falling. make sure that the retainer fits snugly into the pin groove. Slide pin holder (10) away from the pin and rotate the tool slightly in order to align pin setter (9) with the pin. the adapter. 5. the pin must be driven in from the right side of the tooth. a. Strike the end of the tool until the pin is fully inserted. 6. Insert the pin through the bucket tooth. Note: The bucket tip can be rotated by 180 degrees in order to allow greater penetration or less penetration.a through Step Note: To correctly install the pin into the retainer. drive the pin through the bucket tip.Inspect/Replace SEBU7018-08 c. Follow Step 5. i02421156 Illustration 159 g00101359 Bucket Tips . b. After you drive the pin. d. Install the new bucket tip onto the adapter. Improper installation of the pin can result in the loss of the bucket tip.e for the procedure. Drive the pin through the bucket tip. Illustration 160 (4) Back of Pin-Master (9) Pin setter (10) Pin holder g00590666 Block the bucket before changing bucket tips. and the retainer.Inspect/Replace SMCS Code: 6805-040. • Use a Pin-Master. Inspect/Replace Personal injury can result from driving out retainer pins. replace the bucket tip. Bucket Tips Illustration 162 Improper installation g01201331 By driving from the right side of the adapter. Remove the pin from the bucket tip.SEBU7018-08 113 Maintenance Section Bucket Tips . Strike the Pin-Master at the back of the tool (4) and remove the pin. Inserting the pin from the correct side (right side) of the adapter is difficult due to the small gap. Place the Pin-Master on the bucket tooth. b. the retainer is properly supported by the counterbore of the adapter. The pin can be removed by one of the following methods: • Use a hammer and a punch from the retainer side of the bucket to drive out the pin. This procedure will often cause the spiral retainer to become distorted. Follow Step 1. when struck with force can fly out and cause injury to nearby people.a through Step a. Align extractor (5) with the pin. Illustration 163 Proper installation Install pin from the right side. resulting in either a loss of retainer grip or an increased difficulty in removing the pin. and then by driving the pin against the retainer. 1. If the bucket tip has a hole. More clearance can be obtained by installing the pin through the tip and the adapter from the left side. Wear protective glasses when striking a retainer pin. (3) Overworn g00101352 Check the bucket tips for wear. Make sure the area is clear of people when driving out retainer pins. . g01201332 1. This procedure will show that the pin chamfer is centered in the inside diameter of the retainer more clearly. c. • Use a Pin-Master. Illustration 161 (1) Usable (2) Replace this bucket tip. Bucket tips are lost more frequently on excavators because the tips are closer together.c for the procedure. The loss of bucket tips can often be attributed to the improper installation of the retaining pin into the tip and the adapter. Retainer pins. Follow Step 5. b. • Use a Pin-Master. J460 J550 Pin Remover 143-2459 143-2460 196-1331 203-4290 • From the other side of the retainer. drive the pin through the following components: the bucket tip. Strike the end of the tool until the pin is fully inserted. Strike the tool with a hammer at the back of the tool (4) in order to start the pin. make sure that the retainer fits snugly into the pin groove. Drive the pin through the bucket tip. and the retainer. Install this assembly into the groove that is in the side of the adapter (8). Note: The bucket tip can be rotated by 180 degrees in order to allow greater penetration or less penetration. Table 13 Illustration 165 g00101359 4. 3.Inspect/Replace SEBU7018-08 Illustration 164 (6) Retainer (7) Retaining Washer (8) Adapter g00590819 Illustration 166 (4) Back of Pin-Master (9) Pin setter (10) Pin holder g00590666 2. J350 J350. Install the new bucket tip into the adapter. J300. The pin can be installed by using one of the following methods: Size of the Tip J200. J225 J250.a through Step . J400. Insert the pin through the bucket tooth. The tools that are available for driving the pins are shown in Table 13. 6. d. 5.e for the procedure. Place the Pin-Master over the bucket tooth and locate the pin in the hole of the holder (10). e. the adapter. c. Clean the adapter and the pin. 5.114 Maintenance Section Bucket Tips . Slide pin holder (10) away from the pin and rotate the tool slightly in order to align pin setter (9) with the pin. After you drive the pin. Fit retainer (6) into retaining washer (7). a. Illustration 168 g00987485 Inspect the wear plates. Illustration 167 g00987399 Wipe off the fitting before any lubricant is applied. i01908538 Cab Air Filter . Apply lubricant through the fitting. Block the bucket before changing bucket wear plates. 6107-086-BD S/N: BDP1-Up S/N: 2JS1-Up S/N: 3BS1-Up S/N: 4BS1-Up S/N: 5AS1-Up S/N: 5RS1-Up S/N: 6NS1-Up S/N: 3JW1-Up S/N: 4PW1-Up S/N: 5FW1-Up S/N: 5MW1-Up S/N: 6EW1-Up S/N: 6HW1-Up S/N: 7BW1-Up S/N: 8JW1-Up Bucket Wear Plates Inspect/Replace SMCS Code: 6120-040.Lubricate i01897750 i01897951 Bucket Upper Pivot Bearings . Consult your Caterpillar dealer for replacement of wear plates. Illustration 169 g00994599 .Clean/Replace SMCS Code: 7342-070. Replace the wear plates before damage to the bottom of the bucket occurs. 7342-510 Note: Clean the cab air filters more often if the machine is being operated in dusty conditions.Lubricate SMCS Code: 6101-086-BD.SEBU7018-08 115 Maintenance Section Bucket Upper Pivot Bearings . 6120-510 Personal injury or death can result from the bucket falling. Fan Motor (1) – 15 amp Seat Air Compressor (2) – 15 amp . Illustration 170 g00994614 Circuit breakers are located on the fuse panel at the rear of the cab. Then loosen cap slowly to relieve the pressure.Reset SEBU7018-08 1. Alternator (4) – 80 amp i01898004 Cooling System Coolant (ELC) .116 Maintenance Section Circuit Breakers . Dispose of all fluids according to local regulations and mandates.Change SMCS Code: 1350-044-NL Pressurized system: Hot coolant can cause serious burn. adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Remove the filter element. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection. Open the access door on the left side of the cab. Check the appropriate electrical circuit if the button does not stay depressed. i01908608 Illustration 171 g00994616 Two circuit breakers are located on the right side of the engine compartment below the air cleaner. Install the filter cover and close the access door. 5. Remove the filter cover behind the seat. Remove the filter element. wait until radiator is cool. stop engine. 2. The button will stay depressed if the circuit is working properly. testing. Install the filter elements. If water and detergent are used to clean the filter elements. install a new filter element. Note: If either filter element is damaged. rinse the filter elements in clean water and allow the filter elements to air dry thoroughly. “Caterpillar Tools and Shop Products Guide” for tools and supplies suitable to collect and contain fluids on Caterpillar products. Main Circuit (3) – 80 amp Circuit Breakers . To open cap. maintenance.Reset SMCS Code: 1420-529 Circuit Breaker Reset – Push the button in order to reset the circuit breakers. Clean the filter elements with pressure air or wash the filter elements in warm water with a nonsudsing household detergent. NENG2500. 3. Refer to Special Publication. 4. Reference: For information about the addition of Extender to your cooling system. “Cooling System Water Temperature Regulator . Drain valve (2) can be accessed from the left side of the machine. “Cooling System Coolant Extender (ELC) . Run the engine without the cooling system pressure cap until the water temperature regulator opens and the coolant level stabilizes. Illustration 172 g00981214 The cooling system pressure cap is located under the hood at the rear of the machine. Close drain valve (2). “Capacities (Refill)” for the refill capacity of the cooling system. Illustration 174 g00987549 2. Use only Extender with Cat ELC.Replace”. 3. Open drain valve (2) on the bottom of the radiator. SENR3611. Replace the water temperature regulator at this time. Add the Extended Life Coolant. Reference: Refer to Operation and Maintenance Manual. 4. No other cleaning agents are required. 1. “3126 Engines for Caterpillar Built Machines”. Allow the coolant to drain into a suitable container.SEBU7018-08 117 Maintenance Section Cooling System Coolant (ELC) . Start the engine.Change 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. Slowly loosen cooling system pressure cap (1) in order to relieve system pressure. flush the cooling system with clean water. Reference: Refer to Operation and Maintenance Manual. Illustration 173 g00987548 . Flush the cooling system with clean water until the draining water is clean. Failure to follow these recommendations can result in shortened cooling system component life. Use only Caterpillar products or commercial products that have passed the Caterpillar EC-1 specification for pre-mixed or concentrate coolants. 5. Reference: Refer to Disassembly and Assembly. If an Extended Life Coolant was previously used. see Operation and Maintenance Manual. Use the following procedure to change the Extended Life Coolant.Add” or consult your Caterpillar dealer. 6. testing. Then loosen cap slowly to relieve the pressure. Dispose of all fluids according to local regulations and mandates. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection. SEBU6250. Failure to follow these recommendations can result in shortened cooling system component life.Add SMCS Code: 1352-544-NL Pressurized system: Hot coolant can cause serious burn.Add SEBU7018-08 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. Illustration 175 g00987559 7. stop engine. NENG2500. Use only Caterpillar products or commercial products that have passed the Caterpillar EC-1 specification for pre-mixed or concentrate coolants. an Extender must be added to the cooling system. Stop the engine. Maintain the coolant level in sight gauge (3) on the upper right side of the radiator.118 Maintenance Section Cooling System Coolant Extender (ELC) . Refer to Special Publication. i01898080 When a Caterpillar Extended Life Coolant (ELC) is used. Cooling System Coolant Extender (ELC) . Reference: For additional information about the addition of Extender. “Caterpillar Tools and Shop Products Guide” for tools and supplies suitable to collect and contain fluids on Caterpillar products. Use only Extender with Cat ELC. To open cap. Tilt the hood in order to access the cooling system pressure cap. 8. adjusting and repair of the product. “Caterpillar Machine Fluids Recommendations” or consult your Caterpillar dealer. Illustration 176 g00981214 The cooling system pressure cap is located under the engine hood at the rear of the machine. refer to Special Publication. Install pressure cap (1). Use a 8T-5296 Coolant Test Kit to check the concentration of the coolant. wait until radiator is cool. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. maintenance. . 18 L (40 fl oz) of Extender to the cooling system. 4. Install pressure cap (1). 5. Note: If it is necessary to add coolant daily. Then loosen cap slowly to relieve the pressure. Illustration 179 g00981214 Illustration 178 g00987549 2. Illustration 180 g00987619 Open the access door on the right side of the machine. . 3. Reference: Refer to Operation and Maintenance Manual. if necessary. To open cap. Add coolant. Check the coolant level. Remove the cooling system pressure cap.Check i01898095 Cooling System Coolant Level . inspect the cooling system for leaks. Coolant level sight gauge (1) is located on the right front side of the radiator. stop engine. Cooling system drain valve (2) is located on the lower left side of the radiator. Close the engine hood. Illustration 177 g00987548 1.SEBU7018-08 119 Maintenance Section Cooling System Coolant Level . drain enough coolant from the radiator in order to allow the addition of the Extender to the cooling system.Check SMCS Code: 1350-535-FLV Pressurized system: Hot coolant can cause serious burn. wait until radiator is cool.Check” for the correct procedure. Add 1. Maintain the coolant level within sight gauge(1). Slowly loosen cooling system pressure cap (1) in order to relieve any system pressure. If necessary. “Cooling System Coolant Level . perform consistent samplings that are evenly spaced. In order to receive the full effect of S·O·S analysis.Obtain SEBU7018-08 i01901890 • Keep the unused sampling bottles stored in plastic bags.Obtain SMCS Code: 1350-008. Failure to do so may cause a false analysis which could lead to customer and dealer concerns.Obtain SMCS Code: 1350-008. Failure to do so may cause a false analysis which could lead to customer and dealer concerns. 7542 NOTICE Do not use the same vacuum sampling pump for extracting oil samples that is used for extracting coolant samples. Use the following guidelines for proper sampling of the coolant: • Complete the information on the label for the sampling bottle before you begin to take the samples. you must establish a consistent trend of data. Cooling System Coolant Sample (Level 1) .120 Maintenance Section Cooling System Coolant Sample (Level 1) . • Keep the lids on empty sampling bottles until you • Place the sample in the mailing tube immediately after obtaining the sample in order to avoid contamination. Submit the sample for Level 1 analysis. You should not obtain the samples from any other location. Withdraw the coolant through filler cap (1) on the top of the radiator. see Special Publication. Use a vacuum pump in order to obtain a sample of the coolant. For additional information about coolant analysis. A small residue of either type sample may remain in the pump and may cause a false positive analysis for the sample being taken. • Never collect samples from expansion bottles. Supplies for collecting samples can be obtained from your Caterpillar dealer. Always use a designated pump for oil sampling and a designated pump for coolant sampling. “Caterpillar Machine Fluids Recommendations” or consult your Caterpillar dealer. 1395-008. 1395-008. Note: Level 1 results may indicate a need for Level 2 Analysis. Always use a designated pump for oil sampling and a designated pump for coolant sampling. 7542 NOTICE Do not use the same vacuum sampling pump for extracting oil samples that is used for extracting coolant samples. • Never collect samples from the drain for a system. Obtain the sample of the coolant as close as possible to the recommended sampling interval. Illustration 181 g00987548 Note: The cooling system is not equipped with a sampling valve. i01901920 Cooling System Coolant Sample (Level 2) . • Obtain coolant samples directly from the coolant sample port. A small residue of either type sample may remain in the pump and may cause a false positive analysis for the sample being taken. are ready to collect the sample. In order to establish a pertinent history of data. . SEBU6250. Inspect gaskets before assembly and replace if worn or damaged. If the thermostat is installed wrong. .Obtain” for the guidelines for proper sampling of the coolant. Illustration 182 g00987548 Note: The cooling system is not equipped with a sampling valve. Cooling System Water Temperature Regulator Replace SMCS Code: 1355-510. Use a vacuum pump in order to obtain a sample of the coolant. To open cap. wait until radiator is cool.Change SMCS Code: 3278-044. Dispose of all fluids according to local regulations and mandates. Withdraw the coolant through filler cap (1) on the top of the radiator. Replace the water temperature regulator in order to reduce the chance of problems with the cooling system. Reference: For additional information about coolant analysis. maintenance. Note: If you are only replacing the water temperature regulator. “3126 Engines for Caterpillar Built Machines” for the correct procedure for replacing the water temperature regulator. “Caterpillar Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar products. Refer to Special Publication. it will cause the engine to overheat.Replace NOTICE Caterpillar engines incorporate a shunt design cooling system and require operating the engine with a thermostat installed. “Caterpillar Machine Fluids Recommendations” or consult your Caterpillar dealer. i02441594 Differential and Final Drive Oil .SEBU7018-08 121 Maintenance Section Cooling System Water Temperature Regulator . refer to Special Publication. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. drain the coolant to a level that is below the water temperature regulator housing. stop engine. Obtain the sample of the coolant as close as possible to the recommended sampling interval. Then loosen cap slowly to relieve the pressure. NOTICE Failure to replace the engine’s thermostat on a regularly scheduled basis could cause severe engine damage. 4011-044 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection. NENG2500. Supplies for collecting samples can be obtained from your Caterpillar dealer. Submit the sample for Level 2 analysis. i01898114 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. SEBU6250. 1393-010 Pressurized system: Hot coolant can cause serious burn. adjusting and repair of the product. “Cooling System Coolant Sample (Level 1) . Reference: Refer to Disassembly and Assembly. Refer to Operation and Maintenance Manual. testing. SENR3611. Clean the dipstick/fill plugs and install the dipstick/fill plugs. 1. 2. 5. Install a drain adapter into each drain valve. Reference: Refer to Operation and Maintenance Manual. 7. Add 0.Change SEBU7018-08 Illustration 183 Machine without axle oil cooler g00989676 Illustration 185 Dipstick/fill plug for the front axle g00989672 Illustration 184 Machine with axle oil cooler g00630605 Illustration 186 Dipstick/fill plug for the rear axle g00989674 Note: The axle housings are equipped with ecology drain valves. Remove the drain plugs. Clean the drain plugs and install the drain plugs. Wipe off the dipstick/fill plugs and the surfaces around the dipstick/fill plugs. “Differential and Final Drive Oil Level Check” for the correct procedure. 4. 3. Allow the oil to drain into a suitable container. Fill the axles with oil.5 qt) of 1U-9891 Hydraulic Oil Additive to each axle. “Lubricant Viscosities and Refill Capacities” for the type of lubricant and for the refill capacity. Remove the drain adapters from the drain valves. Run the machine on level ground for a few minutes in order to equalize the oil level in the axle. 6. Reference: Refer to Operation and Maintenance Manual. . Check the oil level in the axle.122 Maintenance Section Differential and Final Drive Oil . Remove the dipstick/fill plugs.5 L (0. Attach a hose to a suitable drain adapter. Wipe off the level gauge with a clean cloth and reinsert the plug. Dispose of all fluids according to local regulations and mandates. 3. “Caterpillar Tools and Shop Products Guide” for tools and supplies suitable to collect and contain fluids on Caterpillar products. adjusting and repair of the product.Check SMCS Code: 3278-535-FLV. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. This will thoroughly mix the differential oil for a more accurate sample. Remove the dipstick/fill plug again and check the oil level. Stop the engine. g00989672 Illustration 189 Dipstick/fill plug for the front axle . 4011-535-FLV Note: Before you measure the oil level. Illustration 187 Dipstick/fill plug for the front axle g00989672 Refer to Special Publication. NENG2500. testing. Add oil. maintenance. an incorrect oil level reading can occur. 1.Check i01902117 Differential and Final Drive Oil Level . Operate the machine for a few minutes before obtaining the oil sample. Engage the parking brake. operate the machine for a few minutes in order to equalize the oil level. Repeat Step 2 through Step 4 for the rear axle. If the plug is not installed completely.Obtain SMCS Code: 3278-008. if necessary. 4011-008. Lower the bucket and apply slight downward pressure. Remove the dipstick/fill plug. i01902178 Differential and Final Drive Oil Sample . 4. 1.SEBU7018-08 123 Maintenance Section Differential and Final Drive Oil Level . Reference: Refer to Operation and Maintenance Manual. Illustration 188 Dipstick/fill plug for the rear axle g00989674 2. Park the machine on level ground. 7542 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection. Maintain the oil level between the ADD mark and the FULL mark. 4070-008. 5. Clean the plug and install the plug. This will ensure a more accurate measurement of the oil level. “Lubricant Viscosities and Refill Capacities” for the type of lubricant and for the refill capacity. Note: Make sure that the plug is installed completely before you check the oil level. Extract the oil through the filler openings on the differential and final drives. The differential and final drives are not equipped with sampling valves. “How To Take A Good Oil Sample”. i01462847 Illustration 191 g00764632 Apply lubricant through the fitting for the center drive shaft spline. remove the engine start switch key and turn the battery disconnect switch to the OFF position. Wipe off the fitting before any lubricant is applied. 3. articulate the machine to the right or to the left.Lubricate SEBU7018-08 Illustration 190 Dipstick/fill plug for the rear axle g00989674 2. Illustration 192 g00764668 . “Caterpillar Machine Fluids Recommendations”. i02407816 Drive Shaft Support Bearing Lubricate SMCS Code: 3267-086-BD Drive Shaft Spline (Center) Lubricate SMCS Code: 3253-086-SN Note: For better access to the fitting. Reference: For more information. Failure to do so could result in serious injury or death. Insure that the machine ignition switch is in the OFF position and that the parking brake is engaged before entering the articulation area. Fill the differential and final drives with oil. Crushing Hazard. PEHP6001.124 Maintenance Section Drive Shaft Spline (Center) . SEBU6250. refer to Special Publication. Wipe off the fitting before you apply any lubricant. as required. Complete any additional required work. Since the steering frame lock cannot be connected in this case. “S·O·S Oil Analysis” and Special Publication. Install the dipstick/fill plugs. Obtaining an oil sample will require the use of a vacuum pump or equivalent in order to extract the oil from the component. NOTICE Service the air filter only with the engine stopped. 1. Use the fitting that is toward the rear of the machine.Clean/Replace SMCS Code: 1054-070-PY.Lubricate Apply lubricant through the remote fitting on the right side of the machine.SEBU7018-08 125 Maintenance Section Drive Shaft Universal Joints . Do not use air filters with damaged pleats. Take extreme care in order to avoid damage to the pleats. i01119388 i01902270 Engine Air Filter Primary Element . 1054-510-PY Drive Shaft Universal Joints Lubricate SMCS Code: 3251-086 S/N: AKP1-Up S/N: 2JS1-Up S/N: 3BS1-Up S/N: 4BS1-Up S/N: 5AS1-Up S/N: 5RS1-Up S/N: 6NS1-Up S/N: 6PS1-Up S/N: 3JW1-Up S/N: 4PW1-Up S/N: 5FW1-Up S/N: 5MW1-Up S/N: 6EW1-Up S/N: 6HW1-Up S/N: 7BW1-Up S/N: 8JW1-Up Wipe off all fittings before any lubricant is applied. Illustration 194 g00845360 . Air pressure must not exceed 207 kPa (30 psi). The air filter is located on the right side of the machine. Use low pressure compressed air in order to remove the dust from the filter element. or seals. NOTICE Caterpillar recommends certified air filter cleaning services that are available at Caterpillar dealers. gaskets. To avoid personal injury. Direct the air flow up the pleats and down the pleats from the inside of the filter element. The Caterpillar cleaning process uses proven procedures to assure consistent quality and sufficient filter life. Open the engine compartment. Do not wash the filter element. Engine damage could result. There is a total of five fittings. Observe the following guidelines if you attempt to clean the filter element: Do not tap or strike the filter element in order to remove dust. Illustration 193 g00291135 Apply lubricant through one fitting on each universal joint. Dirt entering the engine will cause damage to engine components. always wear eye and face protection when using pressurized air. the gaskets. When you clean the primary element. or the seals are damaged. Do not use a primary element with damaged pleats. Direct the air along the length (inside) of the filter. rock the element. Illustration 196 g00328468 10. dry air at a maximum pressure of 207 kPa (30 psi). Inspect the primary element. Remove the primary filter element from the air cleaner housing. Dirt could be forced further into the pleats. Inspect the primary element while you rotate the element. 5. Place a light bulb inside the filter element. If the primary element is not damaged. clean the primary element. Do not use a primary element that has any tears and/or holes in the filter material. pull the element outward. 9. In order to remove the engine air filter primary element. This may be necessary in order to confirm the results of the inspection. compare the primary element to a new primary element.126 Maintenance Section Engine Air Filter Primary Element . Discard a damaged primary element. This will force dirt particles toward the outside of the element (dirty side).Clean/Replace SEBU7018-08 2. If it is necessary. Use Steps 4 through 6 in order to clean the primary element: 4. If the pleats. or seals. Use a 60 watt blue light in a dark room or in a similar facility. Pressurized air can be used to clean a primary element that has not been cleaned more than two times. Use filtered. always begin in the inside of the element (clean side). 6. gaskets. 8. Illustration 197 g00328470 7. While you pull the element outward. Note: The latches for the air cleaner housing may snap open when you release the latches. discard the element. Note: Do not aim the stream of air directly at the primary element. . This will help prevent damage to the paper pleats. 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. Inspect the primary element for tears and/or holes. Loosen the cover latches and remove the air cleaner cover. Use Steps 7 through 10 in order to inspect the primary element: Illustration 195 g00101415 3. Replace a damaged primary element with a clean primary element. Use a new primary element that has the same part number. Note: Pressurized air will not remove deposits of carbon and oil. Inspect the primary element for light that may show through the filter material. Inspect the gasket between the air inlet pipe and the air filter housing. Note: Refer to Operation and Maintenance Manual. 2. Illustration 198 g00864077 Open the access door on the right side of the machine in order to access the service indicator. The air filter is located on the right side of the machine. . Fasten the clips in order to secure the cover on the air filter housing. Close the engine hood. Install a new secondary filter element. 1. 13. 8.Inspect SMCS Code: 7452-040 NOTICE Service the air cleaner only with the engine stopped. “Engine Air Filter Primary Element . Cover the air inlet opening.SEBU7018-08 127 Maintenance Section Engine Air Filter Secondary Element . 3. Uncover the air inlet opening. Reset the filter element indicator. Apply firm pressure to the end of the primary element as you gently rock the filter element. This seats the primary element. 12. Replace the gasket if the gasket is damaged.Clean/Replace ” for the procedure to remove the primary filter element. The secondary filter element should be replaced at the time the primary element is serviced for the third time. Open the engine hood. or if the exhaust smoke is still black.Replace 11. Install a clean primary filter element over the engine air filter secondary element. Engine damage could result. Install the primary filter element. 6. Clean the cover for the air cleaner housing. Remove the secondary filter element. 7. The secondary filter element should also be replaced if the yellow piston in the filter element indicator enters the red zone after installation of a clean primary element. Remove the primary element from the air filter housing. Close the engine. Never attempt to reuse it by cleaning. 10. i01902345 4. 5. Align the slot on the cover with the pin on the air cleaner housing. Engine Air Filter Secondary Element . Clean the inside of the air filter housing. Install the cover. i01902363 Engine Air Filter Service Indicator .Replace SMCS Code: 1054-510-SE NOTICE Always replace the secondary filter element. Clean the cover of the air filter housing and install the cover on the air filter housing. Illustration 199 g00989798 9. Illustration 201 g00989798 To check the condition of the service indicator. 2. 4. 7452-510 Illustration 202 g00764735 NOTICE Service the air cleaner only with the engine stopped. After the governor control pedal is released. Clean the precleaner with compressed air or wash the precleaner in warm water. 5. i01902376 Engine Air Filter Service Indicator . try resetting the service indicator. Clean the screen if the screen is dirty. Remove dirt and debris. Install the precleaner screen. Dry all the parts. 1.Inspect/Replace SMCS Code: 7452-040. replace the service indicator. Remove the precleaner. the yellow piston should remain at the highest position that was achieved during acceleration. Inspect the precleaner tube openings. check the movement of the yellow piston in the service indicator. i01438467 Engine Air Precleaner . .Clean SMCS Code: 1055-070 Illustration 200 g00989798 Service the air cleaner when the yellow piston in the service indicator is in the red zone. Engine damage could result. Inspect the air inlet screen for dirt and for trash. 3.128 Maintenance Section Engine Air Filter Service Indicator . Start the engine and accelerate the engine to high idle for a few seconds. Remove the screen. If either of these conditions are not met. The service indicator can be checked when the engine is running or stopped. This should require less than three pushes of the reset button.Inspect/Replace SEBU7018-08 Next. Remove the auxiliary air filter element. 4. 4.Replace i01902420 i01908770 Engine Auxiliary Air Filter Replace (If Equipped) SMCS Code: 1054-070-AX. nonflammable solvent. . Clean the inside of the auxiliary air filter housing. 5. Replace the seal if the seal is damaged. Shake the element dry or use pressure air to dry the element.SEBU7018-08 129 Maintenance Section Engine Auxiliary Air Filter . 10. Install outlet hose (3) and the hose clamp. 6. Wash the breather cover and the element in a clean. Inspect the outlet hose for damage. Install access cover (2) and four nuts (1). Remove four bolts and the access plate on the engine hood. Check the condition of the seal on the breather cover. Replace the hose. 3. 7. 1. 5. 8. 2. Remove bolt (2) and the breather. Use the following procedure to replace the auxiliary air filter. Install breather (1) and bolt (2). Install a new auxiliary air filter element. if necessary. 6. Loosen the hose clamp and remove outlet hose (3) from breather (1). Illustration 203 Side view of the auxiliary air filter housing g00351832 3. Open the engine hood. Remove four nuts (1) and access cover (2) from the top of auxiliary air filter housing (3). The engine crankcase breather is located on the right side of the machine. 9. 1054-510-AX Some machines may be equipped with an auxiliary air filter that is located behind the main air filter housing. Uncover the air outlet. Engine Crankcase Breather Clean SMCS Code: 1317-070 1. 7. Close the engine hood. Illustration 204 g00994742 2. Install the access plate on the engine hood and secure the access plate with the four bolts. Cover air outlet (4). Maintain the engine oil within the crosshatched region on dipstick (2). Wash the screen in a clean. i01902569 Engine Oil Level . Close the engine access door. Disconnect oil supply tube (1). Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication. Then. Stop the engine and make any necessary repairs. maintenance. 1278-510-Z3. 9. Remove fitting (2) and seal (3) from governor housing (4). Illustration 206 Illustration 205 g00989961 g00989985 2. Start the engine and check the engine governor for leaks. 7. 1278-571-Z3 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection. 6. 3.130 Maintenance Section Engine Governor Oil Supply Screen . Open the engine hood. Install the screen far enough into the governor housing in order to allow clearance for the seal and for the fitting. testing. Replace the screen and/or the seal. 2. 5. 4.Clean/Inspect/Replace SEBU7018-08 i01902546 Engine Governor Oil Supply Screen . if necessary. Use a 6 mm hexagon wrench to remove the screen from governor housing (4). NENG2500. This will give a more accurate measurement of the oil level. 3. Dispose of all fluids according to local regulations and mandates. 1. adjusting and repair of the product. 8. Either condition can cause engine damage. 1. Stop the engine. 1264-571-Z3. fitting (2). reinsert the dipstick and remove the dipstick again. 4. and oil supply tube (1). Install seal (3).Clean/Inspect/Replace SMCS Code: 1264-510-Z3. Open the engine access door on the right side of the machine. “Caterpillar Tools and Shop Products Guide” for tools and supplies suitable to collect and contain fluids on Caterpillar products. Remove dipstick (2) and wipe off the dipstick with a clean cloth. remove filler cap (1) and add oil. Close the engine hood. . Inspect the screen and the seal for damage. The engine governor is on the right side of the machine.Check SMCS Code: 1000-535-FLV NOTICE Do not under fill or overfill engine crankcase with oil. nonflammable solvent. If necessary. 7542 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection. If you select an interval for oil and filter change that is too long. Operate the machine for a few minutes before obtaining the oil sample. When these requirements are not met. SEBU6250. Dispose of all fluids according to local regulations and mandates. adjusting and repair of the product. PEHP6001. 3. Selection of the Oil Change Interval NOTICE A 500 hour engine oil change interval is available. Reference: For more information. provided that the operating conditions and recommended multigrade oil types are met. testing. Caterpillar oil filters are recommended. Dispose of all fluids according to local regulations and mandates. “S·O·S Oil Analysis” and Special Publication. i02625081 Engine Oil and Filter . Refer to Special Publication. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. “How To Take A Good Oil Sample”. “Caterpillar Tools and Shop Products Guide” for tools and supplies suitable to collect and contain fluids on Caterpillar products.Obtain SMCS Code: 1348-008. This will thoroughly mix the engine oil for a more accurate sample. refer to Special Publication. NENG2500. “Caterpillar Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar products. shorten the oil change interval to 250 hours. Use the in-line sampling valve in order to obtain a sample of engine oil. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. adjusting and repair of the product. Close the engine hood. Refer to Special Publication. NENG2500. Illustration 207 g00990042 The in-line sampling valve is located on the right side of the engine compartment.SEBU7018-08 131 Maintenance Section Engine Oil Sample . maintenance. Do not use single grade oils. or use an S·O·S oil sampling and analysis program to determine an acceptable oil change interval. Recommended multigrade oil types are listed in Table 14 and in Table 15. “Caterpillar Machine Fluids Recommendations”. Open the engine hood. 1. testing. 4. maintenance.Obtain i01902584 Engine Oil Sample . . 2. you may damage the engine.Change SMCS Code: 1318-510 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection. Improvements in the engine allow this engine oil change interval. follow the “High Load Factor” recommendations in Table 14. For sulfur content above 0. . If the average fuel consumption of your 950G Wheel Loader exceeds 23 L (6 US gal) per hour. SEBU5898. measure average fuel consumption for a period of 50 to 100 hours.3% to 0. SEBU6250. Normal conditions include these factors: Fuel sulfur below 0. or extremely dusty conditions may require a reduction in engine oil change intervals from the recommendations in Table 14 and Table 15. In order to verify an oil change interval of 500 hours. The standard oil change interval in this machine is 500 hours. corrosive environments. “Cold Weather Recommendations”. harsh operating cycles. or harsh environments. Arctic temperatures. if the operating conditions and recommended oil types that are listed in this table are met. 500 hr 500 hr 500 hr 250 hr(6) 500 hr 500 hr 500 hr 250 hr(5) 250 hr(5) 250 hr(5) 250 hr(6) 250 hr(6) (2) (3) (4) (5) (6) The traditional oil change interval for engines is 250 hours. To determine average fuel consumption. Continuous heavy load cycles and very little idle time result in increased fuel consumption and oil contamination.0 API CG-4 (1) 500 hr 500 hr 250 hr(6) Abnormally harsh operating cycles or harsh environments can shorten the service life of the engine oil.5% (4) Altitude above 1830 m (6000 ft) Illustration 208 g01126916 Cat DEO Preferred ECF-1 11. High load factors can shorten the service life of your engine oil.0 minimum TBN(4) Preferred ECF-1 TBN(4) below 11. refer to “Program A” below. the average fuel consumption may change. Poor maintenance of air filters or of fuel filters requires reduced oil change intervals. Use “Program B” below to determine an appropriate interval.132 Maintenance Section Engine Oil and Filter . See your Caterpillar dealer for more information if this product will experience abnormally harsh operating cycles or harsh environments. refer to Special Publication.5%. Normal conditions do not include high load factor.Change SEBU7018-08 Table 14 950G Wheel Loader Engine Oil Change Interval(1) Operating Conditions Severe Normal(2) Multigrade Oil Type High Load Factor(3) above 23 L (6 US gal) per hr of fuel 500 hr Fuel Sulfur from 0. This new standard interval is not permitted for other machines. If the application of the machine is changed. altitude below 1830 m (6000 ft). and good air filter and fuel filter maintenance. “Total Base Number (TBN) and Fuel Sulfur Levels for Direct Injection (DI) Diesel Engines” . Refer to the applicable Operation and Maintenance Manuals for the other machines.3%. Also refer to Special Publication. These factors deplete the oil additives more rapidly. If the average fuel consumption of your 962G Wheel Loader exceeds 25 L (6.5% (4) Altitude above 1830 m (6000 ft) This program consists of three oil change intervals of 500 hours. SEBU6250.0 minimum TBN(4) Preferred ECF-1 TBN(4) below 11. Refer to the applicable Operation and Maintenance Manuals for the other machines. Each interval is adjusted an additional 50 hours. Normal conditions do not include high load factor. The crankcase drain valve is located on the right side of the oil pan beneath the machine. Continuous heavy load cycles and very little idle time result in increased fuel consumption and oil contamination. Improvements in the engine allow this engine oil change interval. These factors deplete the oil additives more rapidly. altitude below 1830 m (6000 ft). References Reference: Form. The oil change intervals are adjusted by increments. Repeat Program B if you change the application of the machine. “Optimizing Oil Change Intervals” Reference: Form. The analysis includes oil viscosity and infrared (IR) analysis of the oil. follow the “High Load Factor” recommendations in Table 15. Program A Verification for an Oil Change Interval of 500 Hours . refer to “Program A” below. or change to a preferred multigrade oil type in the listing above.5%.0 API CG-4 (1) 500 hr 500 hr 250 hr(6) • Change to a preferred oil type in Table 14 or Table 15. “Understanding S·O·S Services Test” 1. harsh operating cycles. shorten the oil change interval. PEDP7035. Close the drain valve.SEBU7018-08 133 Maintenance Section Engine Oil and Filter .5 US gal) per hour. PEDP7036.3% to 0. Program B Optimizing Oil Change Intervals 500 hr 500 hr 500 hr 250 hr(6) 500 hr 500 hr 500 hr 250 hr(5) 250 hr(5) 250 hr(5) 250 hr(6) 250 hr(6) (2) (3) (4) (5) (6) The traditional oil change interval for engines is 250 hours. To determine average fuel consumption. If an oil sample does not pass the analysis. Open the engine hood. Repeat Program A if you change the application of the machine. refer to Special Publication. Open the crankcase drain valve and allow the oil to drain into a suitable container. measure average fuel consumption for a period of 50 to 100 hours. PEHP7076. Adjustment of the Oil Change Interval Note: Your Caterpillar dealer has additional information on these programs. take one of these actions: • Shorten the oil change interval to 250 hours. The standard oil change interval in this machine is 500 hours. and good air filter and fuel filter maintenance. Normal conditions include these factors: Fuel sulfur below 0. If the application of the machine is changed.5 US gal) per hr of fuel 500 hr Fuel Sulfur from 0. In order to verify an oil change interval of 500 hours. “Total Base Number (TBN) and Fuel Sulfur Levels for Direct Injection (DI) Diesel Engines”. if the operating conditions and recommended oil types that are listed in this table are met.Change Table 15 962G Wheel Loader IT62G Integrated Toolcarrier Engine Oil Change Interval(1) Operating Conditions Severe Normal(2) Multigrade Oil Type High Load Factor(3) above 25 L (6. If all of the results are satisfactory. “S·O·S Fluid Analysis” Reference: Form. the 500 hour oil change interval is acceptable for the machine in that application. Periodic oil sampling and analysis is done during each interval. If a sample does not pass the oil analysis. or harsh environments. Cat DEO Preferred ECF-1 11. High load factors can shorten the service life of your engine oil. The analysis includes oil viscosity and infrared (IR) analysis of the oil. This new standard interval is not permitted for other machines. Begin with a 250 hour oil change interval. • Proceed to Program B. the average fuel consumption may change. 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. For sulfur content above 0. 2.3%. Use “Program B” below to determine an appropriate interval. Reference: Refer to Operation and Maintenance Manual. . Clean the filter housing base.134 Maintenance Section Engine Valve Lash . Start the engine and allow the oil to warm. Reference: Refer to Operation and Maintenance Manual. tighten the filter by an additional 3/4 turn. Install the new filter element by hand. Reference: Refer to Operation and Maintenance Manual. 11. Use Steps 3 through 6 to replace the bypass oil filter. 4. Note: A qualified mechanic should adjust the engine valve lash because special tools and training are required.Check” for the correct procedure. 6.Check SMCS Code: 1105-535 For the correct procedure. 8. Clean the filler cap and install the filler cap. refer to the appropriate Service Manual module for your machine’s engine or consult your Caterpillar dealer. “Oil Filter .Inspect”. Use a strap type wrench to remove filter element (1) from the left side of the machine. Inspect the oil filter. Remove filler cap (3). Fill the crankcase with new oil. Check for leaks. “Engine Oil Level . Close the engine hood and stop the engine. 7. Make sure that all of the used filter gasket is completely removed. Some machines are equipped with an additional bypass oil filter (2) on the right side of the machine near the fuel filter. Apply a thin coat of clean engine oil to the sealing surface of the new filter element. 10. Check the oil level on dipstick (4). After the gasket contacts the filter base.Check SEBU7018-08 Illustration 209 g00990394 Illustration 211 g00996379 3. “Lubricant Viscosities and Refill Capacities” for the correct type of oil and for the correct amount of oil. i01181536 5. Illustration 210 g00101318 12. 9. Engine Valve Lash . Fuel timing specifications may vary for different engine applications and/or for different power ratings. 5. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. 3. Close the engine hood. Dispose of all fluids according to local regulations and mandates. it is not necessary to prime the fuel system if only the water separator element was changed. Note: The correct fuel timing specification is found on the Engine Information Plate. Tighten the ether cylinder clamp securely. Note: The volume of the air in the water separator is small.SEBU7018-08 135 Maintenance Section Ether Starting Aid Cylinder . 1. 4. Open the engine hood. The fuel priming pump is located above the primary fuel filter on the right side of the machine. testing. Fuel System . Stop the engine and open the engine hood. NENG2500. Loosen the cylinder retaining clamp (1). “Caterpillar Tools and Shop Products Guide” for tools and supplies suitable to collect and contain fluids on Caterpillar products. Unscrew and remove the empty ether cylinder (2). Remove the used gasket. The ether cylinder is located on the left side of the engine.Prime SMCS Code: 1250-548 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection. i00643879 Fuel Injection Timing . Illustration 212 g00995605 2. Tighten the cylinder hand tight. Usually.Check SMCS Code: 1290-531-FT Refer to the Service Manual for the complete adjustment procedure for the Fuel injector timing. Illustration 213 Manual Priming Pump g00990031 . Refer to Special Publication. Install the new cylinder. A qualified mechanic should adjust the fuel injector timing because special tools and training are required.Replace i01911242 i01902620 Ether Starting Aid Cylinder Replace (If Equipped) SMCS Code: 1456-510-CD 1. maintenance. adjusting and repair of the product. Install the new gasket that is provided with each new cylinder. Note: Approximately 100 strokes will be needed with a manual fuel priming pump in order to prime the fuel system to this point. Open drain valve (4) that is located toward the right side of the fuel filter base. This will fill water separator element (3) with fuel. Fuel System Primary Filter (Water Separator) . i01902645 Illustration 214 Electric Priming Pump g00700133 Note: Some machines may not be equipped with vent valve (1). Close drain valve (4) on the fuel filter base. testing. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. The water separator is located on the bottom of the primary fuel filter on the right side of the machine. Refer to Special Publication. Operate an electric fuel pump for approximately 30 seconds for this additional priming. Operate an electric fuel pump for approximately 60 seconds in order to prime the fuel system to this point. Close vent valve (1). Dispose of all fluids according to local regulations and mandates. 1. Open the engine hood. This additional priming will take approximately 100 strokes with a manual fuel priming pump. Open vent valve (1) at the fuel transfer pump and operate priming pump (2) until the fuel that flows from the hose has no air bubbles. . NENG2500. 4.136 Maintenance Section Fuel System Primary Filter (Water Separator) . adjusting and repair of the product. proceed to Step 4. 5. Catch the fuel in a suitable container. 2. Start the engine.Drain SMCS Code: 1263-543 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection. Operate priming pump (2) until fuel that flows from the hose has no air bubbles. Do not open the drain valve that is located toward the left side of the fuel filter base. Note: Approximately 300 strokes will be needed with a manual priming pump in order to prime the fuel system to this point. 3. In this case. Note: Additional priming may be needed if you are priming because of the following circumstances: • The engine will not start. • The engine starts but the engine continues to misfire. “Caterpillar Tools and Shop Products Guide” for tools and supplies suitable to collect and contain fluids on Caterpillar products. This will fill the secondary fuel filters with fuel. maintenance.Drain SEBU7018-08 7. 6. Catch the fuel in a suitable container. • The fuel injectors have been removed from the engine. • The engine starts but the engine continues to emit smoke. Operate an electric fuel pump for approximately 30 seconds in order to prime the fuel system to this point. • The engine has run out of fuel. Close drain valve (1). Replace the O-ring seal. i01902690 Illustration 216 g00284523 2. The fuel system should be primed prior to starting the engine. 4. 5. Remove water separator bowl (3) from the filter element. 8. Tighten the drain valve securely in order to prevent air leakage into the fuel system. 7. Fuel System Primary Filter (Water Separator) Element Replace SMCS Code: 1260-510. Install water separator bowl (3) onto the new filter element by hand until the filter element is snug. Inspect the O-ring seal on the water separator bowl. Open drain valve (1) on the bottom of the water separator bowl. Open the engine hood. Refer to Special Publication. Contaminated fuel will cause accelerated wear to fuel system parts. Dispose of all fluids according to local regulations and mandates. Lubricate the O-ring seal with clean diesel fuel or with engine oil. Open drain valve (1) on the bottom of water separator bowl (3). Allow the water and the fuel to drain into a suitable container. 1263-510-FQ NOTICE Care must be taken to ensure that fluids are contained during performance of inspection. Place the O-ring seal in the water separator bowl. testing. adjusting and repair of the product. 1.SEBU7018-08 137 Maintenance Section Fuel System Primary Filter (Water Separator) Element . Support the water separator element and rotate the retaining ring (2) counterclockwise. maintenance. 3. Do not discard the water separator bowl. “Caterpillar Tools and Shop Products Guide” for tools and supplies suitable to collect and contain fluids on Caterpillar products. Remove the water separator element from the mounting base. Remove the retaining ring (2). Note: The water separator is under suction during normal engine operation. . 4. Clean the water separator bowl and the O-ring groove.Replace NOTICE Do not fill fuel filters with fuel before installing them. 6. if necessary. Do not use tools to tighten the filter element. NENG2500. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. The primary fuel filter is located on the right side of the machine. Illustration 215 g00990072 2. Note: The water separator bowl is reusable. The fuel will not be filtered and could be contaminated. Close the engine hood. 3. Allow the water and the fuel to drain into a suitable container. 138 Maintenance Section Fuel System Secondary Filter Number One - Replace SEBU7018-08 9. Install the new filter element. Rotate retaining ring (2) clockwise in order to fasten the filter to the mounting base. Continue to turn the retaining ring until an audible click is heard. If a click is not heard, the retaining ring has not been rotated far enough and the filter element is not in the locked position. 10. Close drain valve (1). 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. 11. 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. 12. Close the engine hood. i01902696 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, “Caterpillar 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 the fuel filters with fuel before installing the fuel filters. The fuel will not be filtered and could be contaminated. Contaminated fuel will cause accelerated wear to fuel system parts. Open the engine hood. The secondary fuel filter is located on the right side of the machine. Note: This machine is equipped with two secondary spin-on filters on a single filter base. The upper filter is upside-down. Always drain the inverted filter before you remove either filter. Fuel System Secondary Filter Number One - Replace SMCS Code: 1261-510-SE Personal injury or death may result from failure to adhere to the following procedures. Fuel leaked or spilled onto hot surfaces or electrical 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. Illustration 217 g00990097 1. To drain upper filter (2) (inverted filter), place a suitable container under the drain valves and open drain valve (3). Then, immediately open drain valve (4) and allow the fuel to drain into the suitable container. SEBU7018-08 139 Maintenance Section Fuel System Secondary Filter Number Two - Replace When the fuel stops draining, keep the drain valves open and loosen upper filter (2) by a 1/4 turn. As the filter is loosened, additional fuel may drain from the drain valves. Keep turning the filter by 1/4 turns until fuel does not drain from the drain valves. Then, close the drain valves and properly dispose of the fuel. Note: Make sure that the drain valves are opened in the proper order. If you open the wrong drain valve first, an air lock in the fuel system may occur. This will not allow fuel to drain from the upper filter. 2. Hand tighten the upper filter until the seal contacts the filter base. Then, tighten upper filter (2) by an additional 3/4 turn. Rotation index marks are positioned on the filter at 90 degree intervals. Use these rotation index marks as a guide when you tighten the filter. 3. Remove lower filter (1). Note: Lower filter (1) has not been drained. The filter contains fuel. When you remove the lower filter, use caution in order to avoid spilling the fuel. 4. Inspect the fuel filter element for debris by cutting the filter open. Discard the used fuel filter element properly. 5. Clean the filter mounting base. Make sure that all of the used seal is removed from the filter mounting base. 8. Prime the fuel system. Reference: Refer to Operation and Maintenance Manual, “Fuel System - Prime” for the correct procedure. 9. Close the engine hood. i01902711 Fuel System Secondary Filter Number Two - Replace SMCS Code: 1261-510-SE Personal injury or death may result from failure to adhere to the following procedures. Fuel leaked or spilled onto hot surfaces or electrical 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, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, “Caterpillar 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 the fuel filters with fuel before installing the fuel filters. The fuel will not be filtered and could be contaminated. Contaminated fuel will cause accelerated wear to fuel system parts. Open the engine hood. The secondary fuel filter is located on the right side of the machine. Note: This machine is equipped with two secondary spin-on filters on a single filter base. The upper filter is upside-down. Always drain the inverted filter before you remove either filter. Illustration 218 g00101318 6. Apply a thin coat of clean diesel fuel to the sealing surface of the new fuel filter element. 7. 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. Rotation index marks are positioned on the filter at 90 degree intervals. Use these rotation index marks as a guide when you tighten the filter. 140 Maintenance Section Fuel Tank Cap and Strainer - Clean SEBU7018-08 Illustration 220 g00101318 5. Apply a thin coat of clean diesel fuel to the sealing surface of the new fuel filter element. 6. 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. Rotation index marks are positioned on the filter at 90 degree intervals. Use these rotation index marks as a guide when you tighten the filter. 7. Prime the fuel system. Reference: Refer to Operation and Maintenance Manual, “Fuel System - Prime” for the correct procedure. 8. Close the engine hood. i01464102 Illustration 219 g00990097 1. To drain upper filter (2) (inverted filter), place a suitable container under the drain valves and open drain valve (3). Then, immediately open drain valve (4) and allow the fuel to drain into the suitable container. When the fuel stops draining, keep the drain valves open and loosen the inverted filter by a 1/4 turn. As the filter is loosened, additional fuel may drain from the drain valves. Keep turning the filter by 1/4 turns until fuel does not drain from the drain valves. Then, close the drain valves and properly dispose of the fuel. Note: Make sure that the drain valves are opened in the proper order. If you open the wrong drain valve first, an air lock in the fuel system may occur. This will not allow fuel to drain from the upper filter. 2. Remove upper filter (2). 3. Inspect the fuel filter element for debris by cutting the filter open. Dispose of the used fuel filter element properly. 4. Clean the filter mounting base. Make sure that all of the used seal is removed from the filter mounting base. 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. i01902769 Fuses .Drain SMCS Code: 1273-543-M&S Illustration 223 g00990294 The fuse panel is located at the rear of the operator compartment. Wash the strainer and the fuel tank cap in a clean. If the element of a new fuse separates. Note: If water and sediment are regularly found at weekly maintenance intervals. Otherwise. If it is necessary to replace fuses frequently. Remove fuel tank cap (1) and strainer (3) from fuel tank (4). Close the drain valve. 3. check and repair the circuit. Quick Coupler(4) (if equipped) – 10 amp . Fuses – The fuses protect the electrical system from a circuit that has been overloaded. Install the strainer into the filler opening. i01464158 Fuel Tank Water and Sediment . an electrical problem exists. 2. Install the fuel tank cap. 4. drain the sediment daily.Drain 2. Inspect the seal for damage. if necessary. Change a fuse if the element separates. Transmission Control (1) – 10 amp Secondary Steering (2) (if equipped) – 10 amp Turn Signals and Rotating Beacon (3) – 10 amp Illustration 222 g00765256 The drain valve is located under the fuel tank. Illustration 221 g00765153 1. Remove seal (2) from the cap. Contact your Caterpillar dealer. electrical damage can result. Replace the seal.Replace SMCS Code: 1417-510 NOTICE Replace the fuses with the same type and size only. Open the drain valve and allow the water and sediment to drain into a suitable container. nonflammable solvent. 1.SEBU7018-08 141 Maintenance Section Fuel Tank Water and Sediment . Lubricate Front Floodlights (10) – 15 amp SMCS Code: 7275-086 Lighter (11) – 10 amp Axle Oil Cooler (12) (if equipped) – 10 amp Hydraulic System (13) – 10 amp Implements (14) – 10 amp Illustration 225 g00279633 1. . Then. Wipe off both fittings on the cylinder.142 Maintenance Section Hood Tilt Actuator . The hood tilt actuator is located on the right side of the machine. 2. apply lubricant through the two fittings until the lubricant escapes back through each fitting. 4. 3.Lubricate SEBU7018-08 Window Wipers (5) – 10 amp Backup Alarm (15) – 10 amp Payload Control System (6) – 10 amp Brake Lights (16) – 10 amp Electric Converter (7) – 10 amp Engine Start Switch (17) – 10 amp Digital Electrical Monitoring System (8) – 10 amp Rear Floodlights (9) – 15 amp Horn (18) – 10 amp i01316855 Hood Tilt Actuator . lubricate the entire length of the inner post. Then. Fully extend the cylinder and wipe off the inner post with a clean cloth. Raise the engine hood. Illustration 224 g00990364 Additional fuses are located in the engine compartment on the right side of the machine. Close the engine hood. Open the engine hood. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. 7. Lower the attachment to the ground. Operate the machine in order to warm the hydraulic oil to operating temperature. Insert a new filter element into the filter housing.Replace i01908975 Hydraulic System Biodegradable Oil Filter Element . 2. Remove the used filter element. 4.SEBU7018-08 143 Maintenance Section Hydraulic System Biodegradable Oil Filter Element . “Caterpillar Tools and Shop Products Guide” for tools and supplies suitable to collect and contain fluids on Caterpillar products. Open the engine hood. Start the engine and run the engine for a few minutes. nonflammable solvent. adjusting and repair of the product. Reference: Refer to Operation and Maintenance Manual. Dispose of the used filter element properly. 5. maintenance. Clean the filter housing and the filter housing base with a clean. 3. Tighten the filter housing by hand. Remove filter housing drain plug (1). Engage the parking brake. 2. 9. Install filter housing (2) onto the filter housing base. Inspect the seal on the filter housing. i01911223 Hydraulic System Biodegradable Oil Filter Restriction . “Hydraulic System Oil Level . Allow the oil to drain into a suitable container. NENG2500. Close the engine hood. Install filter housing drain plug (1). 3. 8.Check (If Equipped) SMCS Code: 5068-535-RS. Dispose of all fluids according to local regulations and mandates.Replace (If Equipped) SMCS Code: 5068-510 S/N: BDP1-Up S/N: 2JS1-Up S/N: 3BS1-Up S/N: 5FW1-Up S/N: 7BW1-Up 1. 6. 7450-535-HR S/N: BDP1-Up Illustration 226 g00994854 S/N: 2JS1-Up S/N: 3BS1-Up S/N: 5FW1-Up S/N: 7BW1-Up 1. Replace the seal if the seal is damaged. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection. .Check” for the correct procedure. Use a strap type wrench to remove filter housing (2). 10. The oil filter is located on the right side of the machine. The oil filter is located on the right side of the machine. testing. Refer to Special Publication. Check the hydraulic oil level. the clutches. The standard change interval is 2000 hours.0 ± 0.2 bars and 2. 5. Read the value on the pressure gauge. magnesium. Hydraulic System Oil .5 ± 0. • Caterpillar Hydraulic Oil (HYDO) • Caterpillar Transmission and Drive Train Oil (TDTO) Illustration 227 g00995595 • Caterpillar TDTO (TMS) • Caterpillar Diesel Engine Oil • Caterpillar Biodegradable Hydraulic Oils (HEES) • Caterpillar Multipurpose Tractor Oil (MTO) • Heavy-duty diesel engine oils with a minimum zinc content of 900 ppm (CF.5 ± 0. 4. If an oil sampling program is not available.2 bars. The current guidelines for cleanliness of the oil should be observed. and CH-4) Note: Industrial hydraulic oils are not recommended in Caterpillar hydraulic systems. replace the biodegradable hydraulic oil filter element. “Hydraulic System Biodegradable Oil Filter Element . If the pressure is between 1. Install a pressure gauge on pressure tap (1) that is on the top of the filter housing. Oil The 4000 hour interval for changing the oil is for the following oil types. aluminum. 7. lead. These . Operate the engine at high idle. • Significant changes in the following additives should be monitored: zinc. CG-4. the standard 2000 oil change interval should be used. and phosphorus. • Contaminants should not be present. The hydraulic oil is in the system that is not integral to the service brakes. the biodegradable hydraulic oil filter is clean.2 bars or more.Change SEBU7018-08 Oil Filters Caterpillar oil filters are recommended. The interval for changing the oil filter should be 500 hours. calcium. Water content should be . the final drives. i01773322 Monitoring the Condition of the Oil The oil should be monitored during intervals of 500 hours. These oils are more likely to cause corrosion and excessive wear. or the differentials. Press the button on the top of hydraulic tank breaker relief valve (2) in order to relieve any tank pressure. These metals include iron.144 Maintenance Section Hydraulic System Oil . The extended 4000 hour interval can be used if the following criteria are met. copper. contaminants include fuel and antifreeze.5 percent or less. Refer to “Measured Data”.Replace” for the correct procedure. The oil should be monitored during intervals of 500 hours. chromium. the biodegradable hydraulic oil filter is plugged. Reference: Refer to Operation and Maintenance Manual. and tin. 6. CF-4. If the pressure is 2. • Significant changes in wear metals should be monitored. If the biodegradable hydraulic oil filter is plugged. Caterpillar’s standard SOS Fluids Analysis or an equivalent oil sampling program should be used.Change SMCS Code: 5056-044 Measured Data The following information should be monitored through sampling of the oil: Selection of the Oil Change Interval Your machine may be able to use a 4000 hour interval for the hydraulic oil. Park the machine on level ground. Install the strainer. nonflammable solvent. • The allowable level of oxidation is 40 percent (0. 9. Action should be taken in order to determine the cause of the contamination. Dispose of all fluids according to local regulations and mandates. silicon. testing. The cleanliness should be monitored by particle count analysis. Lower the attachment to the ground and apply slight downward pressure. Remove the hydraulic tank filler cap (2) and the filler strainer (3). 8.12 • The kinematic viscosity of 100 °C (212 °F) should not exceed a 2 cSt change from new. Inspect the gasket on the hydraulic tank filler cap for damage. 4. copper. The particle counts should be monitored. Change the hydraulic oil filter. Abs units). 5. . Wash the filler cap and the strainer in a clean. Install the drain plug. Operate the machine in order to warm the hydraulic oil. The hydraulic tank is located on the right side of the machine. 1. “Caterpillar Tools and Shop Products Guide” for tools and supplies suitable to collect and contain fluids on Caterpillar products. Press the button on the breaker relief valve (1) in order to relieve any tank pressure. and potassium. “Hydraulic System Oil Filter . Engage the parking brake and stop the engine. 6. Illustration 228 g00765367 Procedure for Changing the Hydraulic Oil NOTICE Care must be taken to ensure that fluids are contained during performance of inspection. 3. • The recommended level of cleanliness for Caterpillar machines that are operated in the field is ISO 18/15 or cleaner. 2.SEBU7018-08 145 Maintenance Section Hydraulic System Oil . Reference: Refer to Operation and Maintenance Manual. The system should be returned to the original levels of contamination. adjusting and repair of the product. Remove the drain plug (5) from the bottom of the hydraulic tank.Replace” for the correct procedure. Install the threaded end of the coupling into the drain valve in order to unseat the internal drain valve. The levels of contamination should not exceed the normal by more than two ISO codes. 7. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Wash the drain plug in a clean. Close the drain valve. Refer to Special Publication. Attach a hose to a 126-7914 Oil Drain Coupling. if necessary. • There should not be significant changes in sodium. NOTICE Never start the engine while the hydraulic oil tank is being drained or while the hydraulic oil tank is empty. NENG2500. maintenance. The hydraulic tank is equipped with an ecology drain valve. Replace the gasket. Excessive wear and damage to the hydraulic components can occur. nonflammable solvent.Change • The silicon level should not exceed 15 parts per million for new oil. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Illustration 229 g00765498 The hydraulic filter is located on the right side of the machine. Top off the hydraulic tank so that the oil level is at the “FULL” mark on the sight gauge. Clean the filter mounting base. Dispose of the used filter element properly. “Caterpillar Tools and Shop Products Guide” for tools and supplies suitable to collect and contain fluids on Caterpillar products. Reference: Refer to Operation and Maintenance Manual. NENG2500. Stop the engine. Note: The oil must be free of air bubbles. Cycle the implements so that all hydraulic systems are filled with oil. 12. Then. Note: If the alert indicator for a low oil level comes on. Make sure that the oil level is at the “FULL” mark on the sight gauge (4). Add hydraulic oil to the tank until the oil level is at the “FULL” mark on the sight gauge. 11. Install the filler cap. Dispose of all fluids according to local regulations and mandates. Replace any damaged hoses. Inspect the hydraulic suction line and the hose clamps. Make sure that all of the used gasket is completely removed. . If necessary. Install the filler cap. adjusting and repair of the product. 15. testing. air is entering the hydraulic system. The oil level should not be below the suction ports in the hydraulic tank while the engine is running. 14. 13. Fill the hydraulic tank with clean oil. maintenance. “Lubricant Viscosities and Refill Capacities” for the correct type of oil and for the correct amount of oil.Replace SEBU7018-08 10. i01465406 Hydraulic System Oil Filter Replace SMCS Code: 5068-510 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection. 2. Start the engine and run the engine for at least ten seconds. 1. stop the engine and add hydraulic oil to the tank until the oil level is at the “FULL” mark on the sight gauge.146 Maintenance Section Hydraulic System Oil Filter . If air bubbles are present in the hydraulic oil. tighten any loose clamps or any loose connections. Use a strap type wrench to remove the filter element. Refer to Special Publication. stop the engine and immediately add oil to the hydraulic tank. Install the filler cap. Start the engine and run the engine at low idle. Add hydraulic oil. 5.Check i01465502 Hydraulic System Oil Level Check SMCS Code: 5056-535-FLV Illustration 230 g00101318 3. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Inspect the hydraulic system for leaks. Lubricate the gasket of the new filter element with clean hydraulic oil. Illustration 232 g00765515 The hydraulic tank is located on the right side of the machine. tighten the filter element by an additional 3/4 turn. Dispose of all fluids according to local regulations and mandates. Refer to Special Publication.Obtain SMCS Code: 5050-008. After the gasket contacts the filter mounting base. i01903274 Hydraulic System Oil Sample . maintenance. 7542 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection. if necessary. Maintain the oil level above the “ADD COLD” mark on sight gauge (2). Install the new filter element by hand. 5056-008. Maintain the oil level above the “ADD COLD” mark on the sight gauge. “Caterpillar Tools and Shop Products Guide” for tools and supplies suitable to collect and contain fluids on Caterpillar products. Illustration 231 g00765515 6. 4. adjusting and repair of the product.SEBU7018-08 147 Maintenance Section Hydraulic System Oil Level . If necessary. . remove filler cap (1) slowly and add oil. Start the engine and run the engine at low idle. testing. NENG2500. nonflammable solvent. Illustration 235 g00765560 The hydraulic tank breaker relief valve is located on the top of the hydraulic tank on the right side of the machine. “Caterpillar Machine Fluids Recommendations”.Clean SEBU7018-08 1. refer to Special Publication. Press the button on the top of the hydraulic breaker in order to relieve the pressure in the hydraulic tank. 3. Operate the machine for a few minutes before obtaining the oil sample. Illustration 234 g00994422 3. SEBU6250. This will thoroughly mix the hydraulic oil for a more accurate sample. i01465512 Hydraulic Tank Breaker Relief Valve .Clean SMCS Code: 5118-070 Illustration 233 g00990418 2. . i01718807 Logging Fork Clamp Lubricate SMCS Code: 6113-086-BD. Close the engine access door. Reference: For more information. Use the in-line sampling valve in order to obtain a sample of hydraulic oil. The sampling valve for the hydraulic oil is located on the hydraulic oil filter base beneath the cab on the left side of the machine. 1. PEHP6001. 2. Shake the breaker relief valve dry or use pressure air to dry the breaker relief valve. Open the engine access door on the left side of the machine. Install the hydraulic tank breaker relief valve. 6410-086-BD Wipe off all fittings before any lubricant is applied. “S·O·S Oil Analysis” and Special Publication. Clean the hydraulic tank breaker relief valve in a clean.148 Maintenance Section Hydraulic Tank Breaker Relief Valve . “How To Take A Good Oil Sample”. 4. Operate the hydraulic controls. Remove the hydraulic tank breaker relief valve. Illustration 237 The element is shown with debris. i01114617 Illustration 236 g00883679 Apply lubricant through three fittings on each side of the logging fork. If metals are found in the filter element. There is a total of six fittings. and to other parts. rod bearings. g00315688 Illustration 239 2. Consult your Caterpillar dealer in order to arrange for further analysis if an excessive amount of debris is found. The radiator assembly is located at the rear of the machine. Open the engine hood. This could be caused by friction and by normal wear. Remove two bolts (1). Using an oil filter element that is not recommended by Caterpillar can result in severe engine damage to engine bearings. g00100013 Use a filter cutter to cut the filter element open. 3067-507.Clean SMCS Code: 1353-070-KO Oil Filter . to the crankshaft. Spread apart the pleats and inspect the element for metal and for other debris. Small amounts of debris may be found in the filter element.Inspect SMCS Code: 1308-507. a magnet can be used to differentiate between ferrous metals and nonferrous metals.Inspect Nonferrous metals can indicate wear on the aluminum parts of the engine such as main bearings. 3004-507. Ferrous metals can indicate wear on steel parts and on cast iron parts. . This can result in larger particles in unfiltered oil. An excessive amount of debris in the filter element can indicate a possible failure. i02106227 Radiator Core .SEBU7018-08 149 Maintenance Section Oil Filter . or turbocharger bearings. Swing hydraulic oil cooler (2) away from radiator (3). 5068-507 Inspect a Used Filter for Debris Illustration 238 g00290860 1. The particles could enter the lubricating system and the particles could cause damage. You can use compressed air. Illustration 241 g00101939 4. Remove two bolts (3). Illustration 244 g00101939 . 7.Clean SEBU7018-08 Low Sound Machines and Blue Angel Machines Illustration 240 g00315690 3. Push the button and open the radiator grill that is located on the rear of the machine. Close the engine hood. Swing the air conditioner condenser back into the operating position and replace the two bolts. Swing air conditioner condenser (5) away from radiator (3). Swing the hydraulic oil cooler back into the operating position and replace the two bolts. However. Illustration 242 g00480311 1. 3. high pressure water. Swing hydraulic oil cooler (2) away from the radiator.150 Maintenance Section Radiator Core . Remove two bolts (4). or steam to remove dust and other debris from the radiator fins. the use of compressed air is preferred. 5. Illustration 243 g00480313 2. 6. Remove bolt (1). Swing air conditioner condenser (4) away from the radiator. high pressure water. “950G Wheel Loader. 7. You can use compressed air. Slowly loosen the fitting.Replace 4. the use of compressed air is preferred. 6. However. Use a certified recovery and recycling cart to properly remove the refrigerant from the air conditioning system. i01914104 Refrigerant Dryer .Remove and Install” for the replacement procedure of the in-line refrigerant dryer. . 5. SENR1390. 962G Wheel Loader and IT62G Integrated Toolcarrier Hydraulic System” or consult your Caterpillar dealer. Do not smoke when servicing air conditioners or wherever refrigerant gas may be present. Refer to Service Manual. Note: Special tools and equipment are required to test the accumulator. can cause bodily harm or death. Swing the hydraulic oil cooler back into the operating position and replace the bolt. 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 conditioner refrigerant gas. even if the gauges indicate the system is empty of refrigerant. Always use precaution when a fitting is removed. i01157525 Ride Control Accumulator Check SMCS Code: 5077-535-R6 The ride control accumulator reduces the pitching of the machine. SENR5664. refer to Testing and Adjusting. replace the in-line refrigerant dryer after every 1000 service hours or 6 months.SEBU7018-08 151 Maintenance Section Refrigerant Dryer . If the system is still under pressure. Note: When you operate the machine in a climate with high humidity. Contact with refrigerant can cause frost bite. check the charge in the ride control accumulator.Replace SMCS Code: 7322-510 Personal injury can result from contact with refrigerant. release it slowly in a well ventilated area. Protective goggles must always be worn when refrigerant lines are opened. Swing the air conditioner condenser back into the operating position and replace the two bolts. Reference: For more information. Illustration 245 g00996935 Access the refrigerant accumulator from the right side of the machine. “In-Line Refrigerant Dryer . Keep face and hands away to help prevent injury. Access the in-line refrigerant dryer from the left side of the machine. If the machine seems to be bouncing excessively. Close the radiator grill. or steam to remove dust and other debris from the radiator fins. 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.Inspect SMCS Code: 7323-040.152 Maintenance Section Roading Fender Hinges .Lubricate SEBU7018-08 i01457015 i01457460 Roading Fender Hinges Lubricate SMCS Code: 7252-086-HNG S/N: BDP1-Up S/N: 2JS1-Up S/N: 3BS1-Up S/N: 5FW1-Up S/N: 7BW1-Up Wipe off the fitting before any lubricant is applied. or in any metal section of the ROPS. i02429589 Seat Belt . Rollover Protective Structure (ROPS) . 7325-040 Illustration 247 g00762107 Inspect the ROPS for bolts that are loose or damaged. Note: Apply oil to all bolt threads before installation. Do not repair the ROPS by welding reinforcement plates to the ROPS. Failure to apply oil can result in improper bolt torque. Replace any parts that are damaged or worn before you operate the machine. Consult your Caterpillar dealer for repair of cracks in any welds. . Tighten the four cab mounting bolts to a torque of 850 ± 100 N·m (629 ± 74 lb ft). Illustration 246 g00761700 Swing open the roading fender. There is one hinge on each side of the machine. Apply lubricant through one fitting on the hinge. in any castings. Use original equipment parts only to replace bolts that are damaged or missing. Crushing Hazard. Note: Within three years of the date of installation or within five years of the date of manufacture. 962G Wheel Loader and IT62G Integrated Toolcarrier Braking System”. Insure that the machine ignition switch is in the OFF position and that the parking brake is engaged before entering the articulation area. “950G Wheel Loader. replace the seat belt. Failure to do so could result in serious injury or death. If your machine is equipped with a seat belt extension.Replace Illustration 249 Illustration 248 Typical example g00932801 g01152685 (1) (2) (3) (4) Date of installation (retractor) Date of installation (buckle) Date of manufacture (tag) (fully extended web) Date of manufacture (underside) (buckle) Check the seat belt mounting hardware (1) for wear or for damage. If the buckle is worn or damaged. and the seat belt retractor. and the seat belt retractor. i02429594 Consult your Caterpillar dealer for the replacement of the seat belt and the mounting hardware. Replace the seat belt at the date which occurs first. also perform this inspection procedure for the seat belt extension. SENR1387. the seat belt buckle. Replace the seat belt at the date which occurs first.SEBU7018-08 153 Maintenance Section Seat Belt . . i01898262 Service Brake Disc Wear Indicator . replace the seat belt. A date label for determining the age of the seat belt is attached to the seat belt. Make sure that the mounting bolts are tight. Replace any mounting hardware that is worn or damaged. Inspect the seat belt (3) for webbing that is worn or frayed. also perform this replacement procedure for the seat belt extension. Replace the seat belt if the seat belt is worn or frayed. A date label for determining the age of the seat belt is attached to the seat belt. refer to Testing and Adjusting. the seat belt buckle. Consult your Caterpillar dealer for the replacement of the seat belt and the mounting hardware. replace the seat belt . If your machine is equipped with a seat belt extension.Check SMCS Code: 4255-535-IND Reference: For information about checking the wear indicator for the service brake disc.Replace SMCS Code: 7327-510 Within three years of the date of installation or within five years of the date of manufacture. i02405758 Steering Cylinder Bearings Lubricate SMCS Code: 4303-086-BD Seat Belt . Check buckle (2) for wear or for damage. These remote fittings lubricate the head end of the steering cylinders. Apply lubricant through two remote fittings. Personal injury can result from working with cleaning solvent. Illustration 251 g00765737 The screen group for the steering oil is located in the articulation joint near the steering neutralizer valve on the right side. Apply lubricant through the fittings on the rod ends of both steering cylinders.154 Maintenance Section Steering Pilot Oil Screen (Command Control Steering) . refer to the manufacturer’s instructions and directions. Because of the volatile nature of many cleaning solvents. extreme caution must be exercised when using them. 1.Clean/Replace SEBU7018-08 i01467209 Steering Pilot Oil Screen (Command Control Steering) Clean/Replace SMCS Code: 4304-070-Z3. Always wear protective clothing and eye protection when working with cleaning solvents. There is a total of four fittings. 4304-510-Z3 S/N: 2JS1-Up S/N: 3BS1-Up S/N: 4BS1-Up S/N: 5AS1-Up S/N: 5RS1-Up S/N: 6NS1-Up Illustration 250 g00765667 Wipe off the fittings before any lubricant is applied. . Disconnect two hoses. Open the access door on the right side of the machine. If unsure about a particular cleaning fluid. Lubricate SMCS Code: 4343-086-JF S/N: 2JS1-Up S/N: 3BS1-Up S/N: 4BS1-Up S/N: 5AS1-Up S/N: 5RS1-Up S/N: 6NS1-Up Tire Inflation . Inspect each screen for damage. Install the steering shaft on the machine. 7. Dry each screen with pressure air. Measure the tire pressure on each tire. Inflate the tires with nitrogen . Remove the steering shaft from the machine. . 962G Wheel Loader and IT62G Integrated Toolcarrier Machine Systems” for the removal procedure and for the installation procedure. Reference: Refer to the “Tire Inflation Information” section of the Operation and Maintenance Manual for more information.SEBU7018-08 155 Maintenance Section Steering Shaft (Command Control Steering) . SENR1392. 6. (2). Illustration 252 g00352373 1. 3. i01326236 Reference: Refer to Disassembly and Assembly. (6). 4.Check SMCS Code: 4203-535-AI Illustration 253 g01160201 Always obtain proper tire inflation pressures and maintenance recommendations for the tires on your machine from your tire supplier. “950G Wheel Loader. Apply 5P-0960 Molybdenum Grease through fittings (1). 2. Wipe off all of the fittings before any lubricant is applied. Use an allen wrench to remove one screen from each opening of the screen group. (3) and (4). nonflammable solvent. Replace any damaged screens.Lubricate 2. 4. 5. Install the screens and tighten the allen head screws until the screens are snug. 3. if necessary. Remove two connectors (2) from screen group (3). Wash the screens in a clean. Apply 1P-0808 Multipurpose Grease through fittings (5). i02305841 Steering Shaft (Command Control Steering) . (7) and (8). Install two connectors (2) and two hoses (1). 5. 7. Lower the bucket to the ground with a slight downward pressure. NENG2500. Allow the oil to drain into a suitable container. 10. 4. maintenance. Remove the transmission guard on the underside of the machine in order to access the magnetic strainer. Note: Remove the bolts (1) that hold the transmission guard (2). “Caterpillar Tools and Shop Products Guide” for tools and supplies suitable to collect and contain fluids on Caterpillar products. 11. Reference: Refer to Operation and Maintenance Manual. Park the machine on a hard. level surface. Operate the engine for a few minutes in order to warm the transmission oil. Remove transmission oil drain plug (7). Wash the tube and the screen in a clean. Use a cloth. adjusting and repair of the product. Replace the transmission oil filter. 6. Clean the drain plug and install the drain plug. Illustration 255 g00766094 1.Change SEBU7018-08 i01468034 Transmission Oil . Replace the seal. 3.Replace” for the correct procedure. Remove four cover bolts and magnetic strainer cover (3). NOTICE Do not drop or rap the magnets against any hard surface. Dispose of all fluids according to local regulations and mandates. Clean the cover and inspect the cover seal. a stiff bristle brush or pressurized air to clean the magnets. 2. Refer to Special Publication. Install three magnets (5) on the tube. Remove suction screen (4) and tube (6) from the housing. nonflammable solvent. if necessary. 9.Change SMCS Code: 3030-044 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection. Remove three magnets (5) from the tube. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Illustration 254 g00766059 8. Replace any damaged magnets. Install the cover and the cover bolts. Insert suction screen (4) and tube (6) in the housing. 5. . Engage the parking brake and stop the engine. “Transmission Oil Filter .156 Maintenance Section Transmission Oil . testing. Slowly operate the transmission controls in order to circulate the oil. Park the machine on a hard. Dispose of the used oil filter properly. Lower the bucket to the ground with a slight downward pressure.Check” for the correct procedure. maintenance. Inspect the transmission for leaks. 13. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. The transmission oil filter is located on the left side of the machine near the articulation joint. The transmission oil should be at the mark (10) if the engine is off. Wash the breather in a clean. 12. Illustration 257 g00766360 2. 15. Remove the transmission breather from the top of the transfer case.Replace i01468833 Transmission Oil Filter Replace SMCS Code: 3067-510 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection. nonflammable solvent.SEBU7018-08 157 Maintenance Section Transmission Oil Filter . The filler tube for the transmission is located near the center hitch. The sight gauge (9) is located near the filler tube. The oil should be between marks (11) and (12) when the engine is idling. Engage the parking brake and stop the engine. “Transmission Oil Level . . Use a strap type wrench to remove the transmission oil filter. Refer to Special Publication. Clean the filter mounting base. 1. Reference: Refer to Operation and Maintenance Manual. Illustration 256 g00766254 Dispose of all fluids according to local regulations and mandates. “Caterpillar Tools and Shop Products Guide” for tools and supplies suitable to collect and contain fluids on Caterpillar products. Remove all of the used filter gasket from the filter mounting base. NENG2500. Move the transmission control to the NEUTRAL position. level surface. Install the breather. Start the engine. 14. Stop the engine. Remove the filler cap (8) and fill the transmission with oil. “Lubricant Viscosities and Refill Capacities” for the correct type of oil and for the correct amount of oil. Check the transmission oil level. adjusting and repair of the product. 16. Reference: Refer to Operation and Maintenance Manual. 3. testing. Illustration 259 g00766406 The sight gauge for the transmission oil level is located on the left side of the machine near the articulation joint. 7. Slowly operate the transmission controls in order to circulate the transmission oil. Check the oil level while the engine is running at low idle. Note: Before the machine is started. While the engine is running at low idle. Park the machine on a hard. 5. Check the transmission oil level.Check” for the correct procedure. Move the transmission control to the NEUTRAL position. 6.Check SMCS Code: 3030-535-FLV Illustration 258 g00101318 4. the transmission oil level should be above “MIN START” mark (1) on the upper end of the sight gauge. Operate the machine for a few minutes in order to warm the transmission oil.158 Maintenance Section Transmission Oil Level . level surface. Start the engine. Reference: Refer to Operation and Maintenance Manual. When the gasket contacts the filter mounting base. 1. tighten the transmission oil filter by an additional 3/4 turn. If necessary. 4. 3. the transmission oil level should be between the “MIN” mark (3) and the “MAX” mark (2). . remove the filler cap and add oil. Inspect the transmission oil filter for leaks. “Transmission Oil Level . Lower the bucket to the ground with a slight downward pressure. Engage the parking brake. Apply a thin coat of clean transmission oil to the gasket of the new filter element. Put the transmission control into the NEUTRAL position.Check SEBU7018-08 i01468938 Transmission Oil Level . 2. Install the new filter element by hand. This will thoroughly mix the transmission oil for a more accurate sample. Use the in-line sampling valve in order to obtain a sample of transmission oil. Reference: For more information. “Caterpillar Machine Fluids Recommendations”. testing. Operate the machine for a few minutes before obtaining the oil sample. NENG2500. PEHP6001.Obtain i01903302 i01468974 Transmission Oil Sample Obtain SMCS Code: 3080-008. Illustration 261 g00766424 Window Washer Reservoir – The window washer reservoir is located on the right side of the machine. Dispose of all fluids according to local regulations and mandates. “Caterpillar Tools and Shop Products Guide” for tools and supplies suitable to collect and contain fluids on Caterpillar products. Window Washer Reservoir Fill SMCS Code: 7306-544 NOTICE When operating in freezing temperatures. The sampling valve for the transmission oil is located on the transmission oil filter base on the left side of the articulation joint. 7305-510 Illustration 260 g00990463 2.SEBU7018-08 159 Maintenance Section Transmission Oil Sample . Refer to Special Publication. i01469067 Window Wiper Inspect/Replace SMCS Code: 7305-040. Fill the reservoir through the filler opening. 1. “S·O·S Oil Analysis” and Special Publication. Illustration 262 g00766456 Inspect the wiper blades. 7542 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection. maintenance. refer to Special Publication. use Caterpillar or any commercially available nonfreezing window washer solvent. . SEBU6250. Replace the wiper blades if the wiper blades are worn or damaged or if streaking occurs. “How To Take A Good Oil Sample”. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. adjusting and repair of the product. Clean SMCS Code: 7310-070 Illustration 263 g00038949 Use commercially available window cleaning solutions in order to clean the windows.Clean SEBU7018-08 i00037755 Windows . Clean the outside windows from the ground unless handholds are available.160 Maintenance Section Windows . .