Manual de Operacion y Mantenimiento 962G OP&MANTTO.

MAINTENANCE INTERVALS
Operation 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 SEBU7018-08
Maintenance Section
Maintenance Interval Schedule
i02625049 Seat Belt - Inspect .............................................. 152

Transmission Oil Level - Check .......................... 158
Maintenance Interval Schedule Windows - Clean ................................................. 160
SMCS Code: 7000 Every 50 Service Hours or Weekly
Ensure that all safety information, warnings, and Bucket Lower Pivot Bearings - Lubricate ............. 110
instructions are read and understood before any Cab Air Filter - Clean/Replace ............................. 115
operation or any maintenance procedures are Fuel Tank Water and Sediment - Drain ............... 141
performed. Hydraulic System Biodegradable Oil Filter Restriction
- Check .............................................................. 143
The user is responsible for the performance of Tire Inflation - Check ........................................... 155
maintenance, including all adjustments, the use of
proper lubricants, fluids, filters, and the replacement Every 100 Service Hours or 2 Weeks
of components due to normal wear and aging. Failure
to adhere to proper maintenance intervals and Axle Oscillation Bearings - Lubricate .................. 104
procedures may result in diminished performance of Bucket Linkage and Loader Cylinder Bearings -
the product and/or accelerated wear of components. Lubricate ........................................................... 109
Bucket Upper Pivot Bearings - Lubricate ............. 115
Use mileage, fuel consumption, service hours, or Logging Fork Clamp - Lubricate ......................... 148
calendar time, WHICH EVER OCCURS FIRST, Steering Cylinder Bearings - Lubricate ............... 153
in order to determine the maintenance intervals.
Products that operate in severe operating conditions Every 250 Service Hours
may require more frequent maintenance.
Engine Oil Sample - Obtain ................................ 131
Note: Before each consecutive interval is performed,
all maintenance from the previous interval must be Every 250 Service Hours or Monthly
performed.
Battery - Clean .................................................... 105
Belts - Inspect/Adjust/Replace ............................ 106
When Required Brake Accumulator - Check ................................ 108
Battery - Recycle ................................................ 105 Braking System - Test ......................................... 109
Battery or Battery Cable - Inspect/Replace ........ 105 Differential and Final Drive Oil Level - Check ..... 123
Bucket Wear Plates - Inspect/Replace ................ 115 Drive Shaft Spline (Center) - Lubricate ............... 124
Circuit Breakers - Reset ....................................... 116 Engine Air Filter Service Indicator -
Engine Air Filter Primary Element - Inspect/Replace ................................................ 128
Clean/Replace .................................................. 125 Engine Oil and Filter - Change ........................... 131
Engine Air Filter Secondary Element - Replace .. 127
Ether Starting Aid Cylinder - Replace ................. 135 Initial 500 Hours (for New Systems, Refilled
Fuel System - Prime ........................................... 135 Systems, and Converted Systems)
Fuses - Replace .................................................. 141
Hydraulic System Biodegradable Oil Filter Element - Cooling System Coolant Sample (Level 2) -
Replace ............................................................. 143 Obtain ............................................................... 120
Oil Filter - Inspect ................................................ 149 Refrigerant Dryer - Replace ................................ 151
Radiator Core - Clean ......................................... 149
Ride Control Accumulator - Check ..................... 151 Every 500 Service Hours
Window Washer Reservoir - Fill .......................... 159 Cooling System Coolant Sample (Level 1) -
Window Wiper - Inspect/Replace ........................ 159
Obtain ............................................................... 120
Hydraulic System Oil Sample - Obtain ............... 147
Every 10 Service Hours or Daily Transmission Oil Sample - Obtain ...................... 159
Backup Alarm - Test ............................................ 104
Bucket Cutting Edges - Inspect/Replace ............ 109 Every 500 Service Hours or 3 Months
Bucket Tips - Inspect/Replace ............................. 111 Differential and Final Drive Oil Sample - Obtain .. 123
Bucket Tips - Inspect/Replace ............................. 112
Engine Crankcase Breather - Clean ................... 129
Cooling System Coolant Level - Check ............... 119
Fuel System Primary Filter (Water Separator)
Engine Air Filter Service Indicator - Inspect ........ 127 Element - Replace ............................................ 137
Engine Air Precleaner - Clean ............................ 128
Fuel System Secondary Filter Number One -
Engine Oil Level - Check .................................... 130
Replace ............................................................. 138
Fuel System Primary Filter (Water Separator) - Fuel Tank Cap and Strainer - Clean ................... 140
Drain ................................................................. 136
Hydraulic System Oil Filter - Replace ................. 146
Hydraulic System Oil Level - Check ................... 147
Transmission Oil Filter - Replace ........................ 157
SEBU7018-08 103
Maintenance Section
Maintenance Interval Schedule
Every 1000 Service Hours or 6 Months

Articulation Bearings - Lubricate ......................... 104
Battery Hold-Down - Tighten ............................... 105
Drive Shaft Support Bearing - Lubricate ............. 124
Drive Shaft Universal Joints - Lubricate .............. 125
Fuel System Secondary Filter Number Two -
Replace ............................................................. 139
Roading Fender Hinges - Lubricate .................... 152
Rollover Protective Structure (ROPS) - Inspect .. 152
Steering Pilot Oil Screen (Command Control
Steering) - Clean/Replace ................................. 154
Transmission Oil - Change ................................. 156
Every 2000 Service Hours or 1 Year

Brake Discs - Check ........................................... 108
Differential and Final Drive Oil - Change ............ 121
Engine Governor Oil Supply Screen -
Clean/Inspect/Replace ...................................... 130
Engine Valve Lash - Check ................................. 134
Fuel Injection Timing - Check ............................. 135
Hood Tilt Actuator - Lubricate ............................. 142
Hydraulic System Oil - Change ........................... 144
Hydraulic Tank Breaker Relief Valve - Clean ...... 148
Service Brake Disc Wear Indicator - Check ........ 153
Steering Shaft (Command Control Steering) -
Lubricate ........................................................... 155
Every Year
Cooling System Coolant Sample (Level 2) -
Obtain ............................................................... 120
Refrigerant Dryer - Replace ................................ 151
Every 3000 Service Hours or 2 Years

Engine Auxiliary Air Filter - Replace ................... 129
Every 3 Years After Date of Installation or

Every 5 Years After Date of Manufacture
Seat Belt - Replace ............................................. 153

Cooling System Coolant Extender (ELC) - Add ... 118

Cooling System Water Temperature Regulator -
Replace ............................................................. 121
Every 12 000 Service Hours or 6 Years

Cooling System Coolant (ELC) - Change ............ 116
104 SEBU7018-08
Maintenance Section
Articulation Bearings - Lubricate
i02405939
Articulation Bearings -
Lubricate
SMCS Code: 7057-086-BD; 7065-086-BD;
7066-086-BD
Crushing Hazard. Insure that the machine ignition

switch is in the OFF position and that the parking
brake is engaged before entering the articulation
area. Failure to do so could result in serious injury
or death.
Wipe all fittings before applying grease.
g00752649
Illustration 141
Open the access door on the right side of the

machine.
Apply lubricant through two remote fittings (1) and (2).
i01897507
Backup Alarm - Test

g00879717
(If Equipped)
Illustration 140
SMCS Code: 7406-081
Apply grease to one fitting on the upper pivot bearing
and one fitting on the lower pivot bearing. Turn the engine start switch to the ON position in
order to perform the test.
i02405757
Apply the service brake. Place the transmission into
Axle Oscillation Bearings - REVERSE.
Lubricate The backup alarm should sound immediately.

The backup alarm will continue to sound until
SMCS Code: 3268-086-BD; 3278-086-BD the transmission is placed into NEUTRAL or into
FORWARD.

switch is in the OFF position and that the parking
brake is engaged before entering the articulation
or death.
Wipe off all fittings before you apply any lubricant.
g00881968
Illustration 142
SEBU7018-08 105
Maintenance Section
Battery - Clean
A three-position switch on the backup alarm regulates i01897534

the volume of the alarm.
Battery Hold-Down - Tighten
The backup alarm is set for the highest sound level
when the machine is shipped from the factory. The SMCS Code: 7257-527
setting should remain on HIGH unless the job site
requires a lower sound level.
i01897517
Battery - Clean
SMCS Code: 1401-070
g00882014
Illustration 144
Open the battery compartment on the left rear side

of the machine.
Over time, the vibration of an operating machine can

cause the battery hold-down to loosen. To help to
prevent loose batteries and the possibility of loose
g00987179 cable connections, tighten the locknut in the center of
Illustration 143
the hold-down to a torque of 14 ± 3 N·m (10 ± 2 lb ft).
Open the battery compartment on the left rear side of
the machine. Remove the battery hold-down. i02517652
Clean the battery terminals and the surfaces of Battery or Battery Cable -
the batteries with a clean cloth. Coat the battery
terminals with petroleum jelly. Make sure that the
Inspect/Replace
battery cables are installed securely. SMCS Code: 1401-040; 1401-510; 1402-040;
1402-510
Replace the battery hold-down. Refer to Operation
and Maintenance Manual, “Battery Hold-Down -
Tighten” for the correct torque. Close the battery
compartment.
Personal injury may occur from failure to properly
service the batteries.
i00993589
Batteries give off flammable fumes that can ex-
Battery - Recycle plode. Electrolyte is an acid and can cause per-
sonal injury if it contacts the skin or eyes.
SMCS Code: 1401-561
Prevent sparks near the batteries. Sparks could
Always recycle a battery. Never discard a battery. cause vapors to explode. Do not allow jumper ca-
ble ends to contact each other or the engine. Im-
Always return used batteries to one of the following proper jumper cable connections can cause an ex-
locations: plosion.
• A battery supplier Always wear protective glasses when working
with batteries.
• An authorized battery collection facility
• Recycling facility 1. Turn the engine start switch key OFF. Turn all of
the switches OFF.
106 SEBU7018-08
Maintenance Section
Belts - Inspect/Adjust/Replace
2. Turn the battery disconnect switch OFF. Remove Adjusting the Tension of the Alternator
the key. Belt
3. Disconnect the negative battery cable from the
disconnect switch.
Note: Do not allow the disconnected battery cable to

contact the disconnect switch.
4. Disconnect the negative battery cable at the

battery.
5. Disconnect the positive battery cable at the

battery.
6. Inspect the battery terminals for corrosion. Inspect

the battery cables for wear or damage.
g00592143
Illustration 145
7. Make any necessary repairs. If necessary, replace
the battery cables or the battery. 1. Loosen one mounting bolt (4) and adjustment bolt
(2).
8. Connect the positive battery cable at the battery.
2. Insert a ratchet with a square drive into the hole in
9. Connect the negative battery cable at the battery. mounting bracket (1). Use the ratchet as a lever to
rotate alternator (3). Rotate the alternator until the
10. Connect the battery cable at the battery correct belt tension is reached.
disconnect switch.
3. Tighten adjustment bolt (2) and mounting bolt (4).
11. Install the key and turn the battery disconnect
switch ON. 4. Recheck the tension of belt (5). If the tension of the
belt is incorrect, repeat the adjustment procedure.
i01908348
Air Conditioner Belt
1. Access the compressor from the right side of the
SMCS Code: 1357-025; 1357-040; 1357-510 machine.
Note: Stop the engine before you perform any of the 2. Inspect the condition of the air conditioner belt. If
following procedures. the belt is cracked or frayed, replace the belt.
Alternator Belt 3. Use a BT-33-97 Borroughs Gauge to check the

tension of the air conditioner belt.
1. Access the alternator from the left side of the
machine. Earlier Machines (1W-9693 V-Belt)
2. Inspect the condition of the alternator belt. If the The tension of a used belt with more than 30
belt is cracked or frayed, replace the belt. minutes of operation at rated speed should be
400 ± 44 N (90 ± 10 lb). The tension of a new belt
3. Use a BT-33-97 Borroughs Gauge to check the with 30 minutes of operation or less at rated speed
tension of the alternator belt. should be 534 ± 22 N (120 ± 5 lb).
The tension of a used belt with more than 30 Later Machines (1P-4334 V-Belt)
minutes of operation at rated speed should be
400 ± 44 N (90 ± 10 lb). The tension of a new belt The tension of a used belt with more than 30
with 30 minutes of operation or less at rated speed minutes of operation at rated speed should be
should be 534 ± 22 N (120 ± 5 lb). 445 ± 44 N (100 ± 10 lb). The tension of a new
belt with 30 minutes of operation or less at rated
speed should be 712 ± 22 N (160 ± 5 lb).
SEBU7018-08 107
Maintenance Section
Adjusting the Tension of the Air Adjusting the Tension of the Water Pump
Conditioner Belt Drive Belt
g00994370 g00994371
Illustration 146 Illustration 147
1. Loosen one mounting bolt (10) and adjustment 1. Loosen one mounting bolt (14) and adjustment
bolt (6). bolt (12).
2. Insert a ratchet with a square drive into the hole in 2. Insert a ratchet with a square drive into the hole in
mounting bracket (7). Use the ratchet as a lever mounting bracket (15). Use the ratchet as a lever
to rotate compressor (8). Rotate the compressor to rotate water pump (11). Rotate the water pump
until the correct belt tension is reached. until the correct belt tension is reached.
3. Tighten adjustment bolt (6) and mounting bolt (10). 3. Tighten adjustment bolt (12) and mounting bolt
(14).
4. Recheck the tension of belt (9). If the tension of the
belt is incorrect, repeat the adjustment procedure. 4. Recheck the tension of belt (13). If the tension
of the belt is incorrect, repeat the adjustment
procedure.
Water Pump Drive Belt
1. Open the engine hood in order to access the Belt for the Axle Oil Cooler Pump
water pump drive belt.
(If Equipped)
2. Inspect the condition of the water pump drive belt.
1. Open the engine hood in order to access the axle
If the belt is cracked or frayed, replace the belt.
oil cooler pump.
3. Use a BT-33-97 Borroughs Gauge to check the
2. Inspect the condition of the belt. If the belt is
tension of the water pump drive belt.
cracked or frayed, replace the belt.
The tension of a used belt with more than 30
3. Use a BT-33-97 Borroughs Gauge to check the
tension of the belt.
with 30 minutes of operation or less at rated speed
The tension of a used belt with more than 30
should be 534 ± 22 N (120 ± 5 lb).
with 30 minutes of operation or less at rated speed
should be 534 ± 22 N (120 ± 5 lb).
108 SEBU7018-08
Maintenance Section
Brake Accumulator - Check
Adjusting the Tension of the Belt for the i01714079
Axle Oil Cooler Pump Brake Accumulator - Check

SMCS Code: 4263-535
g00882020
Illustration 149
1. Turn the engine start switch to the ON position.

The alert indicator for brake oil pressure should
come on if the braking system is not at normal
operating pressure.
2. Start the engine. Run the engine at half speed for

two minutes in order to increase the accumulator
pressure. The alert indicator for brake oil pressure
should go off.
g00994372
Illustration 148
3. Stop the engine. Apply the service brake pedal
1. Loosen one mounting bolt (17) and adjustment and release the service brake pedal until the alert
bolt (18). indicator for brake oil pressure comes on. This will
decrease the accumulator pressure. A minimum
2. Insert a ratchet with a square drive into the hole in of five applications of the service brake pedal are
mounting bracket (19). Use the ratchet as a lever required.
to rotate axle oil cooler pump (20). Rotate the
axle oil cooler pump until the correct belt tension 4. If the alert indicator comes on after less than
is reached. five applications of the brake, measure the
accumulator precharge pressure. An authorized
3. Tighten adjustment bolt (18) and mounting bolt Caterpillar dealer can measure the nitrogen gas
(17). pressure in the accumulator. Use only dry nitrogen
gas for recharging.
4. Recheck the tension of belt (16). If the tension
of the belt is incorrect, repeat the adjustment
procedure. i01732078
Brake Discs - Check

SMCS Code: 4255-535
Reference: For the correct procedure, refer to the

Testing and Adjusting Service Manual of the braking
system for your machine or consult your Caterpillar
dealer.
SEBU7018-08 109
Maintenance Section
Braking System - Test
i02056278 If both sides are worn, install a new cutting edge.

Braking System - Test 6. Install bolts (1). Tighten the bolts to the specified
torque.
SMCS Code: 4251-081; 4267-081
Reference: Refer to Specifications, SENR3130,
In order to test the braking system, refer to theTesting “Ground Engaging Tool (G.E.T.) Fasteners”.
and Adjusting Service Manual of the braking system
for your machine or consult your Caterpillar dealer. 7. Start the engine. Raise the bucket and remove the
blocking. Lower the bucket to the ground.
i02196469
8. After a few hours of operation, check the bolts for
Bucket Cutting Edges - proper torque.
Inspect/Replace
i01897623
SMCS Code: 6801-040; 6801-510
Bucket Linkage and Loader
Cylinder Bearings - Lubricate
Personal injury or death can result from bucket SMCS Code: 5102-086-BD; 5104-086-BD;
falling. 6107-086-BD
Block the bucket before changing bucket cutting Integrated Toolcarrier

edges.
Wipe off all of the fittings before you apply any
lubricant.
g00764365
Illustration 150
g00764050
Illustration 151
Check the cutting edges and the end bits for wear
and for damage. Use the following procedure to
service the cutting edges and the end bits: Apply lubricant through twelve fittings on each side
of the machine.
1. Raise the bucket and place blocking under the
bucket. There are a total of 24 fittings.
2. Lower the bucket onto the blocking. Stop the Wheel Loader
engine.
Wipe off all fittings before any lubricant is applied.
3. Remove bolts (1), cutting edge (2) and the end
bits.
4. Clean all contact surfaces.
5. If the opposite side of the cutting edge is not worn,

use the opposite side of the cutting edge. The end
bits are not reversible.
110 SEBU7018-08
Maintenance Section
Bucket Lower Pivot Bearings - Lubricate
i01897748
Bucket Lower Pivot Bearings

- Lubricate
SMCS Code: 6101-086-BD; 6107-086-BD
S/N: BDP1-Up
S/N: 2JS1-Up
S/N: 3BS1-Up
S/N: 4BS1-Up
g00987705
S/N: 5AS1-Up
Illustration 152
S/N: 5RS1-Up
Apply lubricant through fittings (2) and (3) on both
lift cylinders. Apply lubricant through fittings (5), (6) S/N: 6NS1-Up
and (7). 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
g00765618
Illustration 153
For pin joint (1), apply lubricant through one remote

fitting on each side of the machine.
g00765808 g00987389
For pin joint (4), apply lubricant through a remote Wipe off all fittings before any lubricant is applied.
fitting on the right side of the machine. Use the fitting
that is toward the front of the machine. Apply lubricant through one fitting on each side of
the machine.
SEBU7018-08 111
Maintenance Section
Bucket Tips - Inspect/Replace
i02420559

SMCS Code: 6805-040; 6805-510
S/N: BDP1-Up
S/N: 2JS1-Up
Personal injury or death can result from the bucket

falling.
g00590670
Block the bucket before changing bucket tips. Illustration 157
(4) Back of Pin-Master
(5) Extractor
Bucket Tips
a. Place the Pin-Master on the bucket tooth.
b. Align extractor (5) with the pin.
c. Strike the Pin-Master at the back of the tool

(4) and remove the pin.
g00101352
Illustration 156
(1) Usable
(2) Replace
(3) Replace
Check the bucket tips for wear. If the bucket tip has a
g00590819
hole, replace the bucket tip. Illustration 158
(6) Retainer
1. Remove the pin from the bucket tip. The pin can (7) Retaining washer
be removed by one of the following methods. (8) Adapter
• Use a hammer and a punch from the retainer 2. Clean the adapter and the pin.
side of the bucket to drive out the pin.
3. Fit retainer (6) into retaining washer (7). Install
• Use a Pin-Master. Follow Step 1.a through Step this assembly into the groove that is in the side
1.c for the procedure. of adapter (8).
112 SEBU7018-08
Maintenance Section
c. Strike the tool with a hammer at the back of the

tool (4) in order to start the pin.
d. Slide pin holder (10) away from the pin and

rotate the tool slightly in order to align pin setter
(9) with the pin.
e. Strike the end of the tool until the pin is fully

inserted.
6. After you drive the pin, make sure that the retainer
fits snugly into the pin groove.
i02421156
g00101359
Illustration 159
4. Install the new bucket tip onto the adapter.
SMCS Code: 6805-040; 6805-510
Note: The bucket tip can be rotated by 180 degrees in S/N: AKP1-Up
order to allow greater penetration or less penetration.
S/N: 2JS1-Up
5. Drive the pin through the bucket tip. The pin can
be installed by using one of the following methods: S/N: 3BS1-Up
S/N: 4BS1-Up
• From the other side of the retainer, drive the
pin through the bucket tip, the adapter, and the S/N: 5AS1-Up
retainer.
S/N: 5RS1-Up
• Use a Pin-Master. Follow Step 5.a through Step
5.e for the procedure. S/N: 6NS1-Up
S/N: 3JW1-Up
Note: To correctly install the pin into the retainer, the
pin must be driven in from the right side of the tooth. S/N: 4PW1-Up
Improper installation of the pin can result in the loss
of the bucket tip. S/N: 5FW1-Up
S/N: 5MW1-Up
S/N: 6EW1-Up
S/N: 6HW1-Up
S/N: 7BW1-Up
S/N: 8JW1-Up

falling.
g00590666
Illustration 160 Block the bucket before changing bucket tips.
(4) Back of Pin-Master
(9) Pin setter
(10) Pin holder
a. Insert the pin through the bucket tooth.
b. Place the Pin-Master over the bucket tooth and

locate the pin in the hole of holder (10).
SEBU7018-08 113
Maintenance Section
Personal injury can result from driving out retainer

pins.
Retainer pins, when struck with force can fly out

and cause injury to nearby people.
Make sure the area is clear of people when driving

out retainer pins.
Wear protective glasses when striking a retainer

pin.
g01201331
Illustration 162
Bucket Tips Improper installation
By driving from the right side of the adapter, the

retainer is properly supported by the counterbore of
the adapter. This procedure will show that the pin
chamfer is centered in the inside diameter of the
retainer more clearly.
g00101352
Illustration 161
(1) Usable
(2) Replace this bucket tip.
(3) Overworn
Check the bucket tips for wear. If the bucket tip has a
hole, replace the bucket tip. g01201332
Illustration 163
The loss of bucket tips can often be attributed to Proper installation

the improper installation of the retaining pin into Install pin from the right side.
the tip and the adapter. Bucket tips are lost more
frequently on excavators because the tips are closer 1. Remove the pin from the bucket tip. The pin can
together. Inserting the pin from the correct side (right be removed by one of the following methods:
side) of the adapter is difficult due to the small gap.
More clearance can be obtained by installing the • Use a hammer and a punch from the retainer
pin through the tip and the adapter from the left side of the bucket to drive out the pin.
side, and then by driving the pin against the retainer.
This procedure will often cause the spiral retainer to • Use a Pin-Master. Follow Step 1.a through Step
become distorted, resulting in either a loss of retainer 1.c for the procedure.
grip or an increased difficulty in removing the pin.
a. Place the Pin-Master on the bucket tooth.
b. Align extractor (5) with the pin.
c. Strike the Pin-Master at the back of the tool

(4) and remove the pin.
114 SEBU7018-08
Maintenance Section
g00590819 g00590666
(6) Retainer (4) Back of Pin-Master
(7) Retaining Washer (9) Pin setter
(8) Adapter (10) Pin holder
2. Clean the adapter and the pin. a. Insert the pin through the bucket tooth.
3. Fit retainer (6) into retaining washer (7). Install this b. Place the Pin-Master over the bucket tooth and
assembly into the groove that is in the side of the locate the pin in the hole of the holder (10).
adapter (8).
c. Strike the tool with a hammer at the back of the
tool (4) in order to start the pin.
d. Slide pin holder (10) away from the pin and

rotate the tool slightly in order to align pin setter
(9) with the pin.
e. Strike the end of the tool until the pin is fully

inserted.
6. After you drive the pin, make sure that the retainer
fits snugly into the pin groove.
The tools that are available for driving the pins are
shown in Table 13.
g00101359
Illustration 165
Table 13
4. Install the new bucket tip into the adapter. Size of the Tip Pin Remover
Note: The bucket tip can be rotated by 180 degrees in J200, J225 143-2459
order to allow greater penetration or less penetration. J250, J300, J350 143-2460
5. Drive the pin through the bucket tip. The pin can J350, J400, J460 196-1331
be installed by using one of the following methods: J550 203-4290
• From the other side of the retainer, drive the pin

through the following components: the bucket
tip, the adapter, and the retainer.
• Use a Pin-Master. Follow Step 5.a through Step

5.e for the procedure.
SEBU7018-08 115
Maintenance Section
Bucket Upper Pivot Bearings - Lubricate
i01897750 i01897951
Bucket Upper Pivot Bearings Bucket Wear Plates -

- Lubricate Inspect/Replace
SMCS Code: 6101-086-BD; 6107-086-BD SMCS Code: 6120-040; 6120-510
S/N: BDP1-Up
S/N: 2JS1-Up
S/N: 3BS1-Up falling.
S/N: 4BS1-Up
Block the bucket before changing bucket wear
S/N: 5AS1-Up plates.
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 g00987485
Illustration 168
S/N: 8JW1-Up
Inspect the wear plates. Replace the wear plates
before damage to the bottom of the bucket occurs.
Consult your Caterpillar dealer for replacement of
wear plates.
i01908538
Cab Air Filter - Clean/Replace

SMCS Code: 7342-070; 7342-510
Note: Clean the cab air filters more often if the

machine is being operated in dusty conditions.
g00987399
Illustration 167
Wipe off the fitting before any lubricant is applied.
Apply lubricant through the fitting.
g00994599
Illustration 169
116 SEBU7018-08
Maintenance Section
Circuit Breakers - Reset
1. Remove the filter cover behind the seat. Remove

the filter element.
2. Open the access door on the left side of the cab.

Remove the filter element.
3. Clean the filter elements with pressure air or

wash the filter elements in warm water with a
nonsudsing household detergent.
4. If water and detergent are used to clean the filter

elements, rinse the filter elements in clean water
and allow the filter elements to air dry thoroughly.
Note: If either filter element is damaged, install a g00994616

new filter element. Illustration 171
5. Install the filter elements. Install the filter cover Two circuit breakers are located on the right side of
and close the access door. the engine compartment below the air cleaner.
Main Circuit (3) – 80 amp

i01908608
Circuit Breakers - Reset

Alternator (4) – 80 amp
SMCS Code: 1420-529
Circuit Breaker Reset – Push the button

in order to reset the circuit breakers. The
button will stay depressed if the circuit is i01898004
working properly. Check the appropriate electrical
circuit if the button does not stay depressed. Cooling System Coolant (ELC)
- Change
SMCS Code: 1350-044-NL
Pressurized system: Hot coolant can cause seri-

ous burn. To open cap, stop engine, wait until ra-
diator is cool. Then loosen cap slowly to relieve
the pressure.
NOTICE
Care must be taken to ensure that fluids are contained
Illustration 170
g00994614 during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
Circuit breakers are located on the fuse panel at the collect the fluid with suitable containers before open-
rear of the cab. ing any compartment or disassembling any compo-
nent containing fluids.
Fan Motor (1) – 15 amp
Refer to Special Publication, NENG2500, “Caterpillar
Tools and Shop Products Guide” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Seat Air Compressor (2) – 15 amp
Dispose of all fluids according to local regulations and
mandates.
SEBU7018-08 117
Maintenance Section
Cooling System Coolant (ELC) - Change
1. Slowly loosen cooling system pressure cap (1) in

NOTICE order to relieve system pressure.
Topping off or mixing Cat ELC with other products that
do not meet Caterpillar EC-1 specifications reduces
the effectiveness of the coolant and shortens coolant
service life.
Use only Caterpillar products or commercial products

that have passed the Caterpillar EC-1 specification for
pre-mixed or concentrate coolants. Use only Extender
with Cat ELC.
Failure to follow these recommendations can result in

shortened cooling system component life.
Reference: For information about the addition of

Extender to your cooling system, see Operation
and Maintenance Manual, “Cooling System Coolant
Extender (ELC) - Add” or consult your Caterpillar
dealer.
If an Extended Life Coolant was previously used,

flush the cooling system with clean water. No other g00987549
cleaning agents are required. Use the following Illustration 174
procedure to change the Extended Life Coolant.
2. Open drain valve (2) on the bottom of the radiator.
Drain valve (2) can be accessed from the left side
of the machine. Allow the coolant to drain into a
suitable container.
3. Flush the cooling system with clean water until the

draining water is clean. Close drain valve (2).
4. Replace the water temperature regulator at this

time.
Reference: Refer to Operation and Maintenance

Manual, “Cooling System Water Temperature
Regulator - Replace”.
Illustration 172
g00981214 Reference: Refer to Disassembly and Assembly,
SENR3611, “3126 Engines for Caterpillar Built
The cooling system pressure cap is located under Machines”.
the hood at the rear of the machine.
5. Add the Extended Life Coolant.

Manual, “Capacities (Refill)” for the refill capacity
of the cooling system.
6. Start the engine. Run the engine without the

cooling system pressure cap until the water
temperature regulator opens and the coolant level
stabilizes.
g00987548
Illustration 173
118 SEBU7018-08
Maintenance Section
Cooling System Coolant Extender (ELC) - Add
NOTICE
Topping off or mixing Cat ELC with other products that
do not meet Caterpillar EC-1 specifications reduces
the effectiveness of the coolant and shortens coolant
service life.
Use only Caterpillar products or commercial products

that have passed the Caterpillar EC-1 specification for
pre-mixed or concentrate coolants. Use only Extender
with Cat ELC.
Failure to follow these recommendations can result in

shortened cooling system component life.
g00987559
Illustration 175
When a Caterpillar Extended Life Coolant (ELC) is
7. Maintain the coolant level in sight gauge (3) on the used, an Extender must be added to the cooling
upper right side of the radiator. system.
8. Install pressure cap (1). Stop the engine. Use a 8T-5296 Coolant Test Kit to check the
concentration of the coolant.
i01898080
Reference: For additional information about
Cooling System Coolant the addition of Extender, refer to Special
Publication, SEBU6250, “Caterpillar Machine Fluids
Extender (ELC) - Add Recommendations” or consult your Caterpillar dealer.
SMCS Code: 1352-544-NL

the pressure.
NOTICE
during performance of inspection, maintenance, test-
g00981214
collect the fluid with suitable containers before open- Illustration 176
ing any compartment or disassembling any compo-
nent containing fluids. The cooling system pressure cap is located under the
engine hood at the rear of the machine. Tilt the hood
Refer to Special Publication, NENG2500, “Caterpillar in order to access the cooling system pressure cap.
products.

mandates.
SEBU7018-08 119
Maintenance Section
Cooling System Coolant Level - Check
i01898095
Cooling System Coolant Level

- Check
SMCS Code: 1350-535-FLV

the pressure.
g00987548
Illustration 177
1. Slowly loosen cooling system pressure cap (1) in

order to relieve any system pressure. Remove the
cooling system pressure cap.
g00981214
Illustration 179
g00987549
Illustration 178
2. If necessary, drain enough coolant from the

radiator in order to allow the addition of the g00987619
Illustration 180
Extender to the cooling system. Cooling system
drain valve (2) is located on the lower left side of
the radiator.
machine. Coolant level sight gauge (1) is located on
the right front side of the radiator.
3. Add 1.18 L (40 fl oz) of Extender to the cooling
system.
Maintain the coolant level within sight gauge(1). Add
coolant, if necessary.
4. Check the coolant level.
Note: If it is necessary to add coolant daily, inspect
the cooling system for leaks.
Manual, “Cooling System Coolant Level - Check”
for the correct procedure.
5. Install pressure cap (1). Close the engine hood.

120 SEBU7018-08
Maintenance Section
Cooling System Coolant Sample (Level 1) - Obtain
i01901890 • Keep the unused sampling bottles stored in plastic

bags.
Cooling System Coolant
Sample (Level 1) - Obtain • Obtain coolant samples directly from the coolant
sample port. You should not obtain the samples
SMCS Code: 1350-008; 1395-008; 7542 from any other location.
NOTICE
• Keep the lids on empty sampling bottles until you
are ready to collect the sample.
Do not use the same vacuum sampling pump for ex-
tracting oil samples that is used for extracting coolant
samples.
• Place the sample in the mailing tube immediately
after obtaining the sample in order to avoid
contamination.
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.
Always use a designated pump for oil sampling and a

• Never collect samples from the drain for a system.
designated pump for coolant sampling. Submit the sample for Level 1 analysis.
Failure to do so may cause a false analysis which For additional information about coolant analysis, see
could lead to customer and dealer concerns. Special Publication, SEBU6250, “Caterpillar Machine
Fluids Recommendations” or consult your Caterpillar
Note: Level 1 results may indicate a need for dealer.
Level 2 Analysis.
i01901920
Cooling System Coolant

Sample (Level 2) - Obtain
SMCS Code: 1350-008; 1395-008; 7542
NOTICE
Do not use the same vacuum sampling pump for ex-
tracting oil samples that is used for extracting coolant
samples.
A small residue of either type sample may remain in

g00987548
the pump and may cause a false positive analysis for
Illustration 181 the sample being taken.
Note: The cooling system is not equipped with a Always use a designated pump for oil sampling and a
sampling valve. Use a vacuum pump in order to designated pump for coolant sampling.
obtain a sample of the coolant. Withdraw the coolant
through filler cap (1) on the top of the radiator. Failure to do so may cause a false analysis which
could lead to customer and dealer concerns.
Obtain the sample of the coolant as close as possible
to the recommended sampling interval. In order
to receive the full effect of S·O·S analysis, you
must establish a consistent trend of data. In order
to establish a pertinent history of data, perform
consistent samplings that are evenly spaced.
Supplies for collecting samples can be obtained from
your Caterpillar dealer.
Use the following guidelines for proper sampling of

the coolant:
• Complete the information on the label for the

sampling bottle before you begin to take the
samples.
SEBU7018-08 121
Maintenance Section
Cooling System Water Temperature Regulator - Replace
NOTICE
Caterpillar engines incorporate a shunt design cooling
system and require operating the engine with a ther-
mostat installed.
If the thermostat is installed wrong, it will cause the

engine to overheat. Inspect gaskets before assembly
and replace if worn or damaged.
Replace the water temperature regulator in order

to reduce the chance of problems with the cooling
system.
g00987548
Illustration 182 Replace the water temperature regulator and replace
the seals while the cooling system is completely
Note: The cooling system is not equipped with a drained or while the coolant is drained to a level that
sampling valve. Use a vacuum pump in order to is below the water temperature regulator housing.
obtain a sample of the coolant. Withdraw the coolant
through filler cap (1) on the top of the radiator. Note: If you are only replacing the water temperature
regulator, drain the coolant to a level that is below the
Obtain the sample of the coolant as close as possible water temperature regulator housing.
to the recommended sampling interval. Supplies
for collecting samples can be obtained from your Reference: Refer to Disassembly and Assembly,
Caterpillar dealer. SENR3611, “3126 Engines for Caterpillar Built
Machines” for the correct procedure for replacing the
Refer to Operation and Maintenance Manual, water temperature regulator.
“Cooling System Coolant Sample (Level 1) - Obtain”
for the guidelines for proper sampling of the coolant.
i02441594
Submit the sample for Level 2 analysis.

Differential and Final Drive Oil
Reference: For additional information about coolant - Change
analysis, refer to Special Publication, SEBU6250,
“Caterpillar Machine Fluids Recommendations” or SMCS Code: 3278-044; 4011-044
consult your Caterpillar dealer.
NOTICE
i01898114 Care must be taken to ensure that fluids are contained
Cooling System Water ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
Temperature Regulator - ing any compartment or disassembling any compo-
Replace nent containing fluids.
SMCS Code: 1355-510; 1393-010 Refer to Special Publication, NENG2500, “Caterpillar

Dealer Service Tool Catalog” for tools and supplies
products.
Pressurized system: Hot coolant can cause seri- Dispose of all fluids according to local regulations and
ous burn. To open cap, stop engine, wait until ra- mandates.
the pressure.
NOTICE
Failure to replace the engine’s thermostat on a regu-
larly scheduled basis could cause severe engine dam-
age.
122 SEBU7018-08
Maintenance Section
Differential and Final Drive Oil - Change
g00989676 g00989672
Machine without axle oil cooler Dipstick/fill plug for the front axle
g00630605 g00989674
Machine with axle oil cooler Dipstick/fill plug for the rear axle
Note: The axle housings are equipped with ecology 4. Wipe off the dipstick/fill plugs and the surfaces
drain valves. around the dipstick/fill plugs.
1. Remove the drain plugs. Attach a hose to a 5. Remove the dipstick/fill plugs. Add 0.5 L (0.5 qt) of
suitable drain adapter. Install a drain adapter into 1U-9891 Hydraulic Oil Additive to each axle. Fill
each drain valve. Allow the oil to drain into a the axles with oil.
suitable container.
2. Remove the drain adapters from the drain valves. Manual, “Lubricant Viscosities and Refill
Capacities” for the type of lubricant and for the
3. Clean the drain plugs and install the drain plugs. refill capacity.
6. Clean the dipstick/fill plugs and install the

dipstick/fill plugs.
7. Run the machine on level ground for a few

minutes in order to equalize the oil level in the
axle. Check the oil level in the axle.

Manual, “Differential and Final Drive Oil Level -
Check” for the correct procedure.
SEBU7018-08 123
Maintenance Section
Differential and Final Drive Oil Level - Check
i01902117 3. Remove the dipstick/fill plug again and check the

oil level. Maintain the oil level between the ADD
Differential and Final Drive Oil mark and the FULL mark. Add oil, if necessary.
Level - Check Reference: Refer to Operation and Maintenance
SMCS Code: 3278-535-FLV; 4011-535-FLV Manual, “Lubricant Viscosities and Refill
Capacities” for the type of lubricant and for the
Note: Before you measure the oil level, operate the refill capacity.
machine for a few minutes in order to equalize the
oil level. 4. Clean the plug and install the plug.
1. Park the machine on level ground. Lower the 5. Repeat Step 2 through Step 4 for the rear axle.
bucket and apply slight downward pressure.
Engage the parking brake. Stop the engine. i01902178
Differential and Final Drive Oil

Sample - Obtain
SMCS Code: 3278-008; 4011-008; 4070-008; 7542
NOTICE
g00989672
Illustration 187 Refer to Special Publication, NENG2500, “Caterpillar
Dipstick/fill plug for the front axle Tools and Shop Products Guide” for tools and supplies
products.

mandates.
1. Operate the machine for a few minutes before

obtaining the oil sample. This will thoroughly mix
the differential oil for a more accurate sample.
g00989674
Illustration 188
Dipstick/fill plug for the rear axle
2. Remove the dipstick/fill plug. Wipe off the level

gauge with a clean cloth and reinsert the plug.
This will ensure a more accurate measurement
of the oil level.
Note: Make sure that the plug is installed completely

before you check the oil level. If the plug is not Illustration 189
g00989672
installed completely, an incorrect oil level reading can Dipstick/fill plug for the front axle
occur.
124 SEBU7018-08
Maintenance Section
Drive Shaft Spline (Center) - Lubricate
g00989674
Illustration 190
Dipstick/fill plug for the rear axle
2. The differential and final drives are not equipped

with sampling valves. Obtaining an oil sample will
require the use of a vacuum pump or equivalent
in order to extract the oil from the component. Illustration 191
g00764632
Extract the oil through the filler openings on the
differential and final drives. Apply lubricant through the fitting for the center drive
shaft spline.
3. Complete any additional required work. Fill the
differential and final drives with oil, as required.
Install the dipstick/fill plugs. i02407816
Reference: For more information, refer to Special Drive Shaft Support Bearing -
Recommendations”, “S·O·S Oil Analysis” and Special
Lubricate
Publication, PEHP6001, “How To Take A Good Oil SMCS Code: 3267-086-BD
Sample”.
i01462847
Drive Shaft Spline (Center) - switch is in the OFF position and that the parking
Lubricate brake is engaged before entering the articulation
SMCS Code: 3253-086-SN or death.
Note: For better access to the fitting, articulate the Wipe off the fitting before any lubricant is applied.
machine to the right or to the left. Since the steering
frame lock cannot be connected in this case, remove
the engine start switch key and turn the battery
disconnect switch to the OFF position.
Wipe off the fitting before you apply any lubricant.
g00764668
Illustration 192
SEBU7018-08 125
Maintenance Section
Drive Shaft Universal Joints - Lubricate
Apply lubricant through the remote fitting on the right i01902270

side of the machine. Use the fitting that is toward the
rear of the machine. Engine Air Filter Primary
Element - Clean/Replace
i01119388
SMCS Code: 1054-070-PY; 1054-510-PY
Drive Shaft Universal Joints -
Lubricate
SMCS Code: 3251-086 To avoid personal injury, always wear eye and face
protection when using pressurized air.
S/N: AKP1-Up
S/N: 2JS1-Up NOTICE
Caterpillar recommends certified air filter cleaning ser-
S/N: 3BS1-Up
vices that are available at Caterpillar dealers. The
S/N: 4BS1-Up Caterpillar cleaning process uses proven procedures
to assure consistent quality and sufficient filter life.
S/N: 5AS1-Up
Observe the following guidelines if you attempt to
S/N: 5RS1-Up clean the filter element:
S/N: 6NS1-Up
Do not tap or strike the filter element in order to re-
S/N: 6PS1-Up move dust.
S/N: 3JW1-Up Do not wash the filter element.

S/N: 4PW1-Up Use low pressure compressed air in order to remove
S/N: 5FW1-Up the dust from the filter element. Air pressure must not
exceed 207 kPa (30 psi). Direct the air flow up the
S/N: 5MW1-Up pleats and down the pleats from the inside of the filter
element. Take extreme care in order to avoid damage
S/N: 6EW1-Up to the pleats.
S/N: 6HW1-Up
Do not use air filters with damaged pleats, gaskets, or
S/N: 7BW1-Up seals. Dirt entering the engine will cause damage to
engine components.
S/N: 8JW1-Up
Wipe off all fittings before any lubricant is applied. NOTICE

Service the air filter only with the engine stopped. En-
gine damage could result.
1. Open the engine compartment. The air filter is

located on the right side of the machine.
g00291135
Illustration 193
Apply lubricant through one fitting on each universal

joint. There is a total of five fittings.
g00845360
Illustration 194
126 SEBU7018-08
Maintenance Section
Engine Air Filter Primary Element - Clean/Replace
2. Loosen the cover latches and remove the air 6. When you clean the primary element, always
cleaner cover. begin in the inside of the element (clean side).
This will force dirt particles toward the outside of
Note: The latches for the air cleaner housing may the element (dirty side).
snap open when you release the latches.
Direct the air along the length (inside) of the filter.
This will help prevent damage to the paper pleats.
Note: Do not aim the stream of air directly at the

primary element. Dirt could be forced further into the
pleats.
Use Steps 7 through 10 in order to inspect the

primary element:
g00101415
Illustration 195
3. Remove the primary filter element from the air

cleaner housing. In order to remove the engine air
filter primary element, pull the element outward.
While you pull the element outward, rock the
element.
Use Steps 4 through 6 in order to clean the

g00328470
primary element: Illustration 197
4. Inspect the primary element. If the pleats, the 7. Place a light bulb inside the filter element. Use a
gaskets, or the seals are damaged, discard the 60 watt blue light in a dark room or in a similar
element. Replace a damaged primary element facility. Inspect the primary element for light that
with a clean primary element. may show through the filter material.
8. Inspect the primary element while you rotate the

element. Inspect the primary element for tears
and/or holes. Do not use a primary element that
has any tears and/or holes in the filter material. Do
not use a primary element with damaged pleats,
gaskets, or seals.
9. If it is necessary, compare the primary element

to a new primary element. Use a new primary
element that has the same part number. This may
be necessary in order to confirm the results of the
inspection.
10. Discard a damaged primary element.

g00328468
Illustration 196
Use Steps 11 through 13 to install a clean
5. If the primary element is not damaged, clean the primary element:
primary element.
NOTICE
Pressurized air can be used to clean a primary
Do not use a filter if the pleats, the gaskets or the seals
element that has not been cleaned more than two
are damaged.
times. Use filtered, dry air at a maximum pressure
of 207 kPa (30 psi).
Note: Pressurized air will not remove deposits of

carbon and oil.
SEBU7018-08 127
Maintenance Section
Engine Air Filter Secondary Element - Replace
11. Install a clean primary filter element over the 4. Cover the air inlet opening. Clean the inside of
engine air filter secondary element. Apply firm the air filter housing.
pressure to the end of the primary element as
you gently rock the filter element. This seats the 5. Inspect the gasket between the air inlet pipe and
primary element. the air filter housing. Replace the gasket if the
gasket is damaged.
12. Clean the cover for the air cleaner housing. Align
the slot on the cover with the pin on the air cleaner 6. Uncover the air inlet opening. Install a new
housing. Install the cover. secondary filter element.
13. Close the engine. 7. Install the primary filter element.
8. Clean the cover of the air filter housing and install

i01902345
the cover on the air filter housing. Fasten the
Engine Air Filter Secondary clips in order to secure the cover on the air filter
housing.
Element - Replace
SMCS Code: 1054-510-SE
NOTICE
Always replace the secondary filter element. Never
attempt to reuse it by cleaning.
The secondary filter element should be replaced at the

time the primary element is serviced for the third time.
The secondary filter element should also be replaced

if the yellow piston in the filter element indicator en-
ters the red zone after installation of a clean primary
element, or if the exhaust smoke is still black.
1. Open the engine hood. The air filter is located on

the right side of the machine.
2. Remove the primary element from the air filter

housing. g00989798
Illustration 199
Note: Refer to Operation and Maintenance Manual,
“Engine Air Filter Primary Element - Clean/Replace ” 9. Reset the filter element indicator.
for the procedure to remove the primary filter element.
10. Close the engine hood.
i01902363
Engine Air Filter Service

Indicator - Inspect
SMCS Code: 7452-040
NOTICE
Service the air cleaner only with the engine stopped.
Engine damage could result.
Illustration 198
g00864077 Open the access door on the right side of the
machine in order to access the service indicator.
3. Remove the secondary filter element.
128 SEBU7018-08
Maintenance Section
Engine Air Filter Service Indicator - Inspect/Replace
Next, check the movement of the yellow piston in the

service indicator. Start the engine and accelerate
the engine to high idle for a few seconds. After
the governor control pedal is released, the yellow
piston should remain at the highest position that was
achieved during acceleration.
If either of these conditions are not met, replace the

service indicator.
i01438467
Engine Air Precleaner - Clean

SMCS Code: 1055-070
g00989798
Illustration 200
Service the air cleaner when the yellow piston in

the service indicator is in the red zone. The service
indicator can be checked when the engine is running
or stopped.
i01902376
g00764735
Engine Air Filter Service Illustration 202
Indicator - Inspect/Replace NOTICE

Service the air cleaner only with the engine stopped.
SMCS Code: 7452-040; 7452-510 Engine damage could result.
1. Remove the precleaner.
2. Inspect the air inlet screen for dirt and for trash.
Remove the screen. Clean the screen if the
screen is dirty.
3. Inspect the precleaner tube openings. Remove

dirt and debris.
4. Clean the precleaner with compressed air or wash

the precleaner in warm water. Dry all the parts.
5. Install the precleaner screen.
g00989798
Illustration 201
To check the condition of the service indicator, try

resetting the service indicator. This should require
less than three pushes of the reset button.
SEBU7018-08 129
Maintenance Section
Engine Auxiliary Air Filter - Replace
i01902420 i01908770
Engine Auxiliary Air Filter - Engine Crankcase Breather -

Replace Clean
(If Equipped) SMCS Code: 1317-070
SMCS Code: 1054-070-AX; 1054-510-AX 1. Open the engine hood. The engine crankcase
breather is located on the right side of the
Some machines may be equipped with an auxiliary
machine.
air filter that is located behind the main air filter
housing. Use the following procedure to replace the
auxiliary air filter.
1. Remove four bolts and the access plate on the

engine hood.
g00994742
Illustration 204
2. Loosen the hose clamp and remove outlet hose

(3) from breather (1).
g00351832
3. Remove bolt (2) and the breather.
Illustration 203
Side view of the auxiliary air filter housing 4. Check the condition of the seal on the breather
cover. Replace the seal if the seal is damaged.
2. Remove four nuts (1) and access cover (2) from
the top of auxiliary air filter housing (3). 5. Wash the breather cover and the element in a
clean, nonflammable solvent.
3. Remove the auxiliary air filter element.
6. Shake the element dry or use pressure air to dry
4. Cover air outlet (4). Clean the inside of the the element.
auxiliary air filter housing.
7. Inspect the outlet hose for damage. Replace the
5. Uncover the air outlet. Install a new auxiliary air hose, if necessary.
filter element.
8. Install breather (1) and bolt (2).
6. Install access cover (2) and four nuts (1).
9. Install outlet hose (3) and the hose clamp.
7. Install the access plate on the engine hood and
secure the access plate with the four bolts. 10. Close the engine hood.
130 SEBU7018-08
Maintenance Section
Engine Governor Oil Supply Screen - Clean/Inspect/Replace
i01902546 8. Start the engine and check the engine governor for
leaks. Stop the engine and make any necessary
Engine Governor Oil Supply repairs.
Screen - Clean/Inspect/Replace 9. Close the engine hood.
SMCS Code: 1264-510-Z3; 1264-571-Z3;
1278-510-Z3; 1278-571-Z3 i01902569
NOTICE Engine Oil Level - Check

during performance of inspection, maintenance, test- SMCS Code: 1000-535-FLV
collect the fluid with suitable containers before open- NOTICE
ing any compartment or disassembling any compo- Do not under fill or overfill engine crankcase with oil.
nent containing fluids. Either condition can cause engine damage.

Tools and Shop Products Guide” for tools and supplies 1. Stop the engine. Open the engine access door on
suitable to collect and contain fluids on Caterpillar the right side of the machine.
products.

mandates.
1. Open the engine hood. The engine governor is on

g00989985
Illustration 206
g00989961
Illustration 205
2. Remove dipstick (2) and wipe off the dipstick
2. Disconnect oil supply tube (1). with a clean cloth. Then, reinsert the dipstick and
remove the dipstick again. This will give a more
3. Remove fitting (2) and seal (3) from governor accurate measurement of the oil level.
housing (4).
3. Maintain the engine oil within the crosshatched
4. Use a 6 mm hexagon wrench to remove the region on dipstick (2). If necessary, remove filler
screen from governor housing (4). cap (1) and add oil.
5. Wash the screen in a clean, nonflammable 4. Close the engine access door.
solvent. Inspect the screen and the seal for
damage. Replace the screen and/or the seal, if
necessary.
6. Install the screen far enough into the governor

housing in order to allow clearance for the seal
and for the fitting.
7. Install seal (3), fitting (2), and oil supply tube (1).
SEBU7018-08 131
Maintenance Section
Engine Oil Sample - Obtain
i01902584 Reference: For more information, refer to Special

Engine Oil Sample - Obtain Recommendations”, “S·O·S Oil Analysis” and Special
Publication, PEHP6001, “How To Take A Good Oil
SMCS Code: 1348-008; 7542 Sample”.
NOTICE
i02625081
Engine Oil and Filter - Change
collect the fluid with suitable containers before open- SMCS Code: 1318-510
NOTICE
products.
mandates.
Dealer Service Tool Catalog” for tools and supplies
1. Operate the machine for a few minutes before suitable to collect and contain fluids on Caterpillar
obtaining the oil sample. This will thoroughly mix products.
the engine oil for a more accurate sample.
2. Open the engine hood. mandates.
Selection of the Oil Change Interval

NOTICE
A 500 hour engine oil change interval is available, pro-
vided that the operating conditions and recommend-
ed multigrade oil types are met. When these require-
ments are not met, shorten the oil change interval to
250 hours, or use an S·O·S oil sampling and analysis
program to determine an acceptable oil change inter-
val.
If you select an interval for oil and filter change that is

too long, you may damage the engine.
Caterpillar oil filters are recommended.
Recommended multigrade oil types are listed in Table

14 and in Table 15. Do not use single grade oils.
g00990042
Illustration 207
The in-line sampling valve is located on the right side of the engine
compartment.
3. Use the in-line sampling valve in order to obtain

a sample of engine oil.

132 SEBU7018-08
Maintenance Section
Table 14
950G Wheel Loader
Engine Oil Change Interval(1)
Operating Conditions
Severe
Normal(2) High Fuel Altitude
Multigrade Load Sulfur above
Oil Type Factor(3) from 1830 m
above 0.3% to (6000 ft)
23 L (6 0.5%
US gal) (4)
per hr
of fuel
g01126916
Illustration 208 Cat DEO
500 hr 500 hr 500 hr 250 hr(6)
Preferred
Abnormally harsh operating cycles or harsh
ECF-1
environments can shorten the service life of 11.0
the engine oil. Arctic temperatures, corrosive minimum 500 hr 500 hr 500 hr 250 hr(6)
environments, or extremely dusty conditions may TBN(4)
require a reduction in engine oil change intervals Preferred
from the recommendations in Table 14 and Table 15.
Also refer to Special Publication, SEBU5898, “Cold ECF-1
TBN(4) 500 hr 500 hr 250 hr(5) 250 hr(6)
Weather Recommendations”. Poor maintenance of below 11.0
air filters or of fuel filters requires reduced oil change
intervals. See your Caterpillar dealer for more API CG-4 500 hr 250 hr(5) 250 hr(5) 250 hr(6)
information if this product will experience abnormally (1) The traditional oil change interval for engines is 250 hours. The
harsh operating cycles or harsh environments. standard oil change interval in this machine is 500 hours, if the
operating conditions and recommended oil types that are listed
in this table are met. Improvements in the engine allow this
engine oil change interval. This new standard interval is not
permitted for other machines. Refer to the applicable Operation
and Maintenance Manuals for the other machines.
(2) Normal conditions include these factors: Fuel sulfur below
0.3%, altitude below 1830 m (6000 ft), and good air filter and
fuel filter maintenance. Normal conditions do not include high
load factor, harsh operating cycles, or harsh environments.
(3) High load factors can shorten the service life of your engine
oil. Continuous heavy load cycles and very little idle time
result in increased fuel consumption and oil contamination.
These factors deplete the oil additives more rapidly. If the
average fuel consumption of your 950G Wheel Loader exceeds
23 L (6 US gal) per hour, follow the “High Load Factor”
recommendations in Table 14. To determine average fuel
consumption, measure average fuel consumption for a period
of 50 to 100 hours. If the application of the machine is changed,
the average fuel consumption may change.
(4) For sulfur content above 0.5%, refer to Special Publication,
SEBU6250, “Total Base Number (TBN) and Fuel Sulfur Levels
for Direct Injection (DI) Diesel Engines” .
(5) In order to verify an oil change interval of 500 hours, refer to
“Program A” below.
(6) Use “Program B” below to determine an appropriate interval.
SEBU7018-08 133
Maintenance Section
Table 15 This program consists of three oil change intervals of

962G Wheel Loader
500 hours. Oil sampling and analysis is done at 250
IT62G Integrated Toolcarrier hours and 500 hours for each of the three intervals
Engine Oil Change Interval(1) for a total of six oil samples. The analysis includes
oil viscosity and infrared (IR) analysis of the oil. If
Operating Conditions all of the results are satisfactory, the 500 hour oil
Severe change interval is acceptable for the machine in that
application. Repeat Program A if you change the
Normal(2) High Fuel Altitude application of the machine.
Load Sulfur above
Multigrade Factor(3) from 1830 m
Oil Type If a sample does not pass the oil analysis, take one
above 0.3% to (6000 ft)
25 L 0.5% of these actions:
(6.5 US (4)
gal) per • Shorten the oil change interval to 250 hours.
hr of
fuel • Proceed to Program B.
Cat DEO
Preferred
500 hr 500 hr 500 hr 250 hr(6) • Change to a preferred oil type in Table 14 or Table
15.
ECF-1
11.0 Program B
minimum 500 hr 500 hr 500 hr 250 hr(6)
TBN(4) Optimizing Oil Change Intervals
Preferred
ECF-1 Begin with a 250 hour oil change interval. The oil
TBN(4) 500 hr 500 hr 250 hr(5) 250 hr(6) change intervals are adjusted by increments. Each
below 11.0 interval is adjusted an additional 50 hours. Periodic oil
sampling and analysis is done during each interval.
API CG-4 500 hr 250 hr(5) 250 hr(5) 250 hr(6)
The analysis includes oil viscosity and infrared (IR)
(1) The traditional oil change interval for engines is 250 hours. The analysis of the oil. Repeat Program B if you change
standard oil change interval in this machine is 500 hours, if the the application of the machine.
operating conditions and recommended oil types that are listed
in this table are met. Improvements in the engine allow this
engine oil change interval. This new standard interval is not If an oil sample does not pass the analysis, shorten
permitted for other machines. Refer to the applicable Operation the oil change interval, or change to a preferred
and Maintenance Manuals for the other machines. multigrade oil type in the listing above.
(2) Normal conditions include these factors: Fuel sulfur below
0.3%, altitude below 1830 m (6000 ft), and good air filter and
fuel filter maintenance. Normal conditions do not include high References
load factor, harsh operating cycles, or harsh environments.
(3) High load factors can shorten the service life of your engine Reference: Form, PEDP7035, “Optimizing Oil
oil. Continuous heavy load cycles and very little idle time Change Intervals”
result in increased fuel consumption and oil contamination.
These factors deplete the oil additives more rapidly. If the
average fuel consumption of your 962G Wheel Loader exceeds Reference: Form, PEDP7036, “S·O·S Fluid Analysis”
25 L (6.5 US gal) per hour, follow the “High Load Factor”
recommendations in Table 15. To determine average fuel Reference: Form, PEHP7076, “Understanding S·O·S
consumption, measure average fuel consumption for a period Services Test”
of 50 to 100 hours. If the application of the machine is changed,
the average fuel consumption may change.
(4) For sulfur content above 0.5%, refer to Special Publication, 1. Open the engine hood.
SEBU6250, “Total Base Number (TBN) and Fuel Sulfur Levels
for Direct Injection (DI) Diesel Engines”. 2. The crankcase drain valve is located on the right
(5) In order to verify an oil change interval of 500 hours, refer to side of the oil pan beneath the machine. Open the
“Program A” below. crankcase drain valve and allow the oil to drain
(6) Use “Program B” below to determine an appropriate interval.
into a suitable container. Close the drain valve.
Adjustment of the Oil Change Interval

Note: Your Caterpillar dealer has additional
information on these programs.
Program A
Verification for an Oil Change Interval of 500 Hours

134 SEBU7018-08
Maintenance Section
Engine Valve Lash - Check
g00990394 g00996379
3. Use a strap type wrench to remove filter element 7. Some machines are equipped with an additional
(1) from the left side of the machine. Inspect the bypass oil filter (2) on the right side of the machine
oil filter. near the fuel filter. Use Steps 3 through 6 to
replace the bypass oil filter.
Manual, “Oil Filter - Inspect”. 8. Remove filler cap (3). Fill the crankcase with new
oil.
4. Clean the filter housing base. Make sure that all of
the used filter gasket is completely removed. Reference: Refer to Operation and Maintenance
Manual, “Lubricant Viscosities and Refill
Capacities” for the correct type of oil and for the
correct amount of oil.
9. Clean the filler cap and install the filler cap.
10. Start the engine and allow the oil to warm. Check
for leaks.
11. Check the oil level on dipstick (4).

Manual, “Engine Oil Level - Check” for the correct
procedure.
g00101318
Illustration 210 12. Close the engine hood and stop the engine.
5. Apply a thin coat of clean engine oil to the sealing

surface of the new filter element. i01181536
6. Install the new filter element by hand. After the

Engine Valve Lash - Check
gasket contacts the filter base, tighten the filter by
SMCS Code: 1105-535
an additional 3/4 turn.
For the correct procedure, refer to the appropriate
Service Manual module for your machine’s engine or
consult your Caterpillar dealer.
Note: A qualified mechanic should adjust the engine

valve lash because special tools and training are
required.
SEBU7018-08 135
Maintenance Section
Ether Starting Aid Cylinder - Replace
i01911242 i01902620
Ether Starting Aid Cylinder - Fuel System - Prime

Replace SMCS Code: 1250-548
(If Equipped)
NOTICE
SMCS Code: 1456-510-CD Care must be taken to ensure that fluids are contained
1. Open the engine hood. The ether cylinder is ing, adjusting and repair of the product. Be prepared to
located on the left side of the engine. collect the fluid with suitable containers before open-

products.

mandates.
Note: The volume of the air in the water separator

is small. Usually, it is not necessary to prime the
fuel system if only the water separator element was
Illustration 212
g00995605 changed.
2. Loosen the cylinder retaining clamp (1). Unscrew 1. Stop the engine and open the engine hood. The
and remove the empty ether cylinder (2). fuel priming pump is located above the primary
fuel filter on the right side of the machine.
3. Remove the used gasket. Install the new gasket
that is provided with each new cylinder.
4. Install the new cylinder. Tighten the cylinder hand

tight. Tighten the ether cylinder clamp securely.
i00643879
Fuel Injection Timing - Check

SMCS Code: 1290-531-FT
Refer to the Service Manual for the complete

adjustment procedure for the Fuel injector timing.
Note: The correct fuel timing specification is

found on the Engine Information Plate. Fuel
timing specifications may vary for different engine
applications and/or for different power ratings. g00990031
Illustration 213
A qualified mechanic should adjust the fuel injector Manual Priming Pump
timing because special tools and training are
required.
136 SEBU7018-08
Maintenance Section
Fuel System Primary Filter (Water Separator) - Drain
7. Start the engine.
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.
• The engine starts but the engine continues to emit

smoke.
• The engine has run out of fuel.

• The fuel injectors have been removed from the
engine.
This additional priming will take approximately 100

strokes with a manual fuel priming pump. Operate
an electric fuel pump for approximately 30 seconds
Illustration 214
g00700133 for this additional priming.
Electric Priming Pump
i01902645
Note: Some machines may not be equipped with
vent valve (1). In this case, proceed to Step 4. Fuel System Primary Filter
2. Open vent valve (1) at the fuel transfer pump and
(Water Separator) - Drain
operate priming pump (2) until the fuel that flows
SMCS Code: 1263-543
from the hose has no air bubbles. This will fill
water separator element (3) with fuel.
NOTICE
Catch the fuel in a suitable container. Care must be taken to ensure that fluids are contained
Note: Approximately 100 strokes will be needed with ing, adjusting and repair of the product. Be prepared to
a manual fuel priming pump in order to prime the fuel collect the fluid with suitable containers before open-
system to this point. Operate an electric fuel pump ing any compartment or disassembling any compo-
for approximately 30 seconds in order to prime the nent containing fluids.
fuel system to this point.
3. Close vent valve (1). Tools and Shop Products Guide” for tools and supplies
4. Open drain valve (4) that is located toward the products.
right side of the fuel filter base. Do not open the
drain valve that is located toward the left side Dispose of all fluids according to local regulations and
of the fuel filter base. mandates.
5. Operate priming pump (2) until fuel that flows 1. Open the engine hood. The water separator is
from the hose has no air bubbles. This will fill the located on the bottom of the primary fuel filter on
secondary fuel filters with fuel. the right side of the machine.
Catch the fuel in a suitable container.
Note: Approximately 300 strokes will be needed with

a manual priming pump in order to prime the fuel
system to this point. Operate an electric fuel pump
for approximately 60 seconds in order to prime the
fuel system to this point.
6. Close drain valve (4) on the fuel filter base.

SEBU7018-08 137
Maintenance Section
Fuel System Primary Filter (Water Separator) Element - Replace
NOTICE
Do not fill fuel filters with fuel before installing them.
The fuel will not be filtered and could be contaminated.
Contaminated fuel will cause accelerated wear to fuel
system parts. The fuel system should be primed prior
to starting the engine.
1. Open the engine hood. The primary fuel filter is

g00990072
Illustration 215
2. Open drain valve (1) on the bottom of the water

separator bowl. Allow the water and the fuel to
drain into a suitable container. Illustration 216
g00284523
3. Close drain valve (1). 2. Open drain valve (1) on the bottom of water
separator bowl (3). Allow the water and the fuel to
Note: The water separator is under suction during drain into a suitable container.
normal engine operation. Tighten the drain valve
securely in order to prevent air leakage into the fuel 3. Support the water separator element and rotate
system. the retaining ring (2) counterclockwise. Remove
the retaining ring (2).
4. Remove the water separator element from the
i01902690 mounting base.
Fuel System Primary Filter 5. Remove water separator bowl (3) from the filter
(Water Separator) Element - element. Clean the water separator bowl and the
O-ring groove.
Replace
Note: The water separator bowl is reusable. Do not
SMCS Code: 1260-510; 1263-510-FQ discard the water separator bowl.
NOTICE 6. Inspect the O-ring seal on the water separator

Care must be taken to ensure that fluids are contained bowl. Replace the O-ring seal, if necessary.
ing, adjusting and repair of the product. Be prepared to 7. Lubricate the O-ring seal with clean diesel fuel or
collect the fluid with suitable containers before open- with engine oil. Place the O-ring seal in the water
ing any compartment or disassembling any compo- separator bowl.
8. Install water separator bowl (3) onto the new filter
Refer to Special Publication, NENG2500, “Caterpillar element by hand until the filter element is snug.
Tools and Shop Products Guide” for tools and supplies Do not use tools to tighten the filter element.
products.

mandates.
138 SEBU7018-08
Maintenance Section
Fuel System Secondary Filter Number One - Replace
9. Install the new filter element. Rotate retaining

ring (2) clockwise in order to fasten the filter to NOTICE
the mounting base. Continue to turn the retaining Care must be taken to ensure that fluids are contained
ring until an audible click is heard. If a click is not during performance of inspection, maintenance, test-
heard, the retaining ring has not been rotated far ing, adjusting and repair of the product. Be prepared to
enough and the filter element is not in the locked collect the fluid with suitable containers before open-
position. ing any compartment or disassembling any compo-
10. Close drain valve (1).
Note: The water separator element is under suction Tools and Shop Products Guide” for tools and supplies
during normal engine operation. Tighten the drain suitable to collect and contain fluids on Caterpillar
valve securely in order to prevent air leakage into products.
the fuel system.
11. Prime the fuel system in order to fill the water mandates.
separator element with fuel.
Reference: Refer to Operation and Maintenance NOTICE

Manual, “Fuel System - Prime” for the correct Do not fill the fuel filters with fuel before installing the
procedure. fuel filters. The fuel will not be filtered and could be
contaminated. Contaminated fuel will cause acceler-
12. Close the engine hood. ated wear to fuel system parts.
i01902696 Open the engine hood. The secondary fuel filter is

Fuel System Secondary Filter
Note: This machine is equipped with two secondary
Number One - Replace spin-on filters on a single filter base. The upper filter
is upside-down. Always drain the inverted filter before
SMCS Code: 1261-510-SE
you remove either filter.
Personal injury or death may result from failure to

adhere to the following procedures.
Fuel leaked or spilled onto hot surfaces or electri-

cal components can cause a fire.
Clean up all leaked or spilled fuel. Do not smoke

while working on the fuel system.
Turn the disconnect switch OFF or disconnect the

battery when changing fuel filters.
g00990097
Illustration 217
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 8. Prime the fuel system.
valves open and loosen upper filter (2) by a 1/4
turn. As the filter is loosened, additional fuel may Reference: Refer to Operation and Maintenance
drain from the drain valves. Keep turning the filter Manual, “Fuel System - Prime” for the correct
by 1/4 turns until fuel does not drain from the drain procedure.
valves. Then, close the drain valves and properly
dispose of the fuel. 9. Close the engine hood.
Note: Make sure that the drain valves are opened in

i01902711
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.
Fuel System Secondary Filter
Number Two - Replace
2. Hand tighten the upper filter until the seal contacts
the filter base. Then, tighten upper filter (2) by an SMCS Code: 1261-510-SE
additional 3/4 turn.
Rotation index marks are positioned on the filter

at 90 degree intervals. Use these rotation index Personal injury or death may result from failure to
marks as a guide when you tighten the filter. adhere to the following procedures.
3. Remove lower filter (1). Fuel leaked or spilled onto hot surfaces or electri-
cal components can cause a fire.
Note: Lower filter (1) has not been drained. The filter
contains fuel. When you remove the lower filter, use Clean up all leaked or spilled fuel. Do not smoke
caution in order to avoid spilling the fuel. while working on the fuel system.
4. Inspect the fuel filter element for debris by cutting Turn the disconnect switch OFF or disconnect the
the filter open. Discard the used fuel filter element battery when changing fuel filters.
properly.
5. Clean the filter mounting base. Make sure that NOTICE

all of the used seal is removed from the filter Care must be taken to ensure that fluids are contained
mounting base. during performance of inspection, maintenance, test-

products.

mandates.
NOTICE
Illustration 218
g00101318 Do not fill the fuel filters with fuel before installing the
fuel filters. The fuel will not be filtered and could be
6. Apply a thin coat of clean diesel fuel to the sealing contaminated. Contaminated fuel will cause acceler-
surface of the new fuel filter element. ated wear to fuel system parts.
7. Install the new fuel filter element by hand. When Open the engine hood. The secondary fuel filter is
the seal contacts the filter base, tighten the fuel located on the right side of the machine.
filter element by an additional 3/4 turn. This will
tighten the fuel filter element sufficiently. Note: This machine is equipped with two secondary
spin-on filters on a single filter base. The upper filter
Rotation index marks are positioned on the filter is upside-down. Always drain the inverted filter before
at 90 degree intervals. Use these rotation index you remove either filter.
marks as a guide when you tighten the filter.
140 SEBU7018-08
Maintenance Section
Fuel Tank Cap and Strainer - Clean
g00101318
Illustration 220
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

g00990097 the seal contacts the filter base, tighten the fuel
Illustration 219
filter element by an additional 3/4 turn. This will
tighten the fuel filter element sufficiently.
1. To drain upper filter (2) (inverted filter), place a
suitable container under the drain valves and Rotation index marks are positioned on the filter
open drain valve (3). Then, immediately open at 90 degree intervals. Use these rotation index
drain valve (4) and allow the fuel to drain into the marks as a guide when you tighten the filter.
suitable container.
7. Prime the fuel system.
When the fuel stops draining, keep the drain
valves open and loosen the inverted filter by a 1/4 Reference: Refer to Operation and Maintenance
turn. As the filter is loosened, additional fuel may Manual, “Fuel System - Prime” for the correct
drain from the drain valves. Keep turning the filter procedure.
by 1/4 turns until fuel does not drain from the drain
valves. Then, close the drain valves and properly 8. Close the engine hood.
dispose of the fuel.
Note: Make sure that the drain valves are opened in i01464102
the proper order. If you open the wrong drain valve
first, an air lock in the fuel system may occur. This will Fuel Tank Cap and Strainer -
not allow fuel to drain from the upper filter. Clean
2. Remove upper filter (2). SMCS Code: 1273-070-Z2; 1273-070-STR
3. Inspect the fuel filter element for debris by cutting The fuel tank cap is located on the left side of the
the filter open. Dispose of the used fuel filter machine.
element properly.
4. Clean the filter mounting base. Make sure that

all of the used seal is removed from the filter
mounting base.
SEBU7018-08 141
Maintenance Section
Fuel Tank Water and Sediment - Drain
2. Close the drain valve.
Note: If water and sediment are regularly found at

weekly maintenance intervals, drain the sediment
daily.
i01902769
Fuses - Replace
SMCS Code: 1417-510
NOTICE
Replace the fuses with the same type and size only.
Otherwise, electrical damage can result.
If it is necessary to replace fuses frequently, an elec-

trical problem exists. Contact your Caterpillar dealer.
Fuses – The fuses protect the electrical

g00765153
Illustration 221 system from a circuit that has been
overloaded. Change a fuse if the element
1. Remove fuel tank cap (1) and strainer (3) from separates. If the element of a new fuse separates,
fuel tank (4). Remove seal (2) from the cap. check and repair the circuit.
2. Wash the strainer and the fuel tank cap in a clean,

nonflammable solvent.
3. Install the strainer into the filler opening.
4. Inspect the seal for damage. Replace the seal, if

necessary. Install the fuel tank cap.
i01464158
Fuel Tank Water and Sediment

- Drain
SMCS Code: 1273-543-M&S Illustration 223
g00990294
The fuse panel is located at the rear of the operator

compartment.
Transmission Control (1) – 10 amp
Secondary Steering (2) (if equipped) –

10 amp
Turn Signals and Rotating Beacon (3) –

10 amp
g00765256
Illustration 222
The drain valve is located under the fuel tank. Quick Coupler(4) (if equipped) – 10 amp
1. Open the drain valve and allow the water and

sediment to drain into a suitable container.
142 SEBU7018-08
Maintenance Section
Hood Tilt Actuator - Lubricate
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 Horn (18) – 10 amp

(8) – 10 amp
Rear Floodlights (9) – 15 amp

i01316855
Hood Tilt Actuator - 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
g00279633
Illustration 225
Implements (14) – 10 amp
1. Raise the engine hood. The hood tilt actuator is
2. Fully extend the cylinder and wipe off the inner

post with a clean cloth. Then, lubricate the entire
length of the inner post.
3. Wipe off both fittings on the cylinder. Then, apply

lubricant through the two fittings until the lubricant
escapes back through each fitting.
g00990364
Illustration 224
Additional fuses are located in the engine

compartment on the right side of the machine.
SEBU7018-08 143
Maintenance Section
Hydraulic System Biodegradable Oil Filter Element - Replace
i01908975 4. Remove the used filter element. Dispose of the

used filter element properly.
Hydraulic System
Biodegradable Oil Filter 5. Clean the filter housing and the filter housing base
with a clean, nonflammable solvent.
Element - Replace
(If Equipped) 6. Inspect the seal on the filter housing. Replace the
seal if the seal is damaged.
SMCS Code: 5068-510
7. Insert a new filter element into the filter housing.
S/N: BDP1-Up
8. Install filter housing drain plug (1). Install filter
S/N: 2JS1-Up housing (2) onto the filter housing base. Tighten
the filter housing by hand.
S/N: 3BS1-Up
S/N: 5FW1-Up 9. Close the engine hood.
S/N: 7BW1-Up 10. Start the engine and run the engine for a few
minutes. Check the hydraulic oil level.
1. Open the engine hood. The oil filter is located on
the right side of the machine. Reference: Refer to Operation and Maintenance
Manual, “Hydraulic System Oil Level - Check” for
the correct procedure.
i01911223
Hydraulic System
Biodegradable Oil Filter
Restriction - Check
(If Equipped)
SMCS Code: 5068-535-RS; 7450-535-HR
S/N: BDP1-Up
g00994854
Illustration 226
S/N: 2JS1-Up
NOTICE S/N: 3BS1-Up
during performance of inspection, maintenance, test- S/N: 5FW1-Up
S/N: 7BW1-Up
1. Operate the machine in order to warm the
hydraulic oil to operating temperature.
2. Lower the attachment to the ground. Engage the
parking brake.
products.
3. Open the engine hood. The oil filter is located on
mandates.
2. Remove filter housing drain plug (1). Allow the oil

to drain into a suitable container.
3. Use a strap type wrench to remove filter housing

(2).
144 SEBU7018-08
Maintenance Section
Hydraulic System Oil - Change
Oil Filters
Caterpillar oil filters are recommended. The interval
for changing the oil filter should be 500 hours.
Oil
The 4000 hour interval for changing the oil is for the
following oil types.
• Caterpillar Hydraulic Oil (HYDO)

• Caterpillar Transmission and Drive Train Oil
(TDTO)
g00995595
Illustration 227
• Caterpillar TDTO (TMS)
4. Press the button on the top of hydraulic tank
breaker relief valve (2) in order to relieve any tank • Caterpillar Diesel Engine Oil
pressure.
• Caterpillar Biodegradable Hydraulic Oils (HEES)
5. Install a pressure gauge on pressure tap (1) that
is on the top of the filter housing. • Caterpillar Multipurpose Tractor Oil (MTO)
6. Operate the engine at high idle. Read the value • Heavy-duty diesel engine oils with a minimum zinc
on the pressure gauge. content of 900 ppm (CF, CF-4, CG-4, and CH-4)
If the pressure is between 1.0 ± 0.2 bars and 2.5 Note: Industrial hydraulic oils are not recommended
± 0.2 bars, the biodegradable hydraulic oil filter in Caterpillar hydraulic systems. These oils are more
is clean. likely to cause corrosion and excessive wear.
If the pressure is 2.5 ± 0.2 bars or more, the Monitoring the Condition of the Oil
biodegradable hydraulic oil filter is plugged.
The oil should be monitored during intervals of 500
7. If the biodegradable hydraulic oil filter is plugged, hours. Caterpillar’s standard SOS Fluids Analysis or
replace the biodegradable hydraulic oil filter an equivalent oil sampling program should be used.
element.
The current guidelines for cleanliness of the oil
Reference: Refer to Operation and Maintenance should be observed. Refer to “Measured Data”.
Manual, “Hydraulic System Biodegradable Oil
Filter Element - Replace” for the correct procedure. If an oil sampling program is not available, the
standard 2000 oil change interval should be used.
i01773322
Measured Data
The following information should be monitored
SMCS Code: 5056-044 through sampling of the oil:
• Significant changes in wear metals should be

Selection of the Oil Change Interval monitored. These metals include iron, copper,
chromium, lead, aluminum, and tin.
Your machine may be able to use a 4000 hour
interval for the hydraulic oil. The hydraulic oil is in • Significant changes in the following additives
the system that is not integral to the service brakes, should be monitored: zinc, calcium, magnesium,
the clutches, the final drives, or the differentials. and phosphorus.
The standard change interval is 2000 hours. The oil
should be monitored during intervals of 500 hours. • Contaminants should not be present. These
The extended 4000 hour interval can be used if the contaminants include fuel and antifreeze. Water
following criteria are met. content should be .5 percent or less.
SEBU7018-08 145
Maintenance Section
• The silicon level should not exceed 15 parts per

million for new oil. The particle counts should be
monitored.
• The recommended level of cleanliness for

Caterpillar machines that are operated in the field
is ISO 18/15 or cleaner. The cleanliness should
be monitored by particle count analysis. The
levels of contamination should not exceed the
normal by more than two ISO codes. Action should
be taken in order to determine the cause of the
contamination. The system should be returned to
the original levels of contamination.
• There should not be significant changes in sodium,

silicon, copper, and potassium.
• The allowable level of oxidation is 40 percent (0.12

Abs units).
• The kinematic viscosity of 100 °C (212 °F) should

not exceed a 2 cSt change from new. Illustration 228
g00765367
Procedure for Changing the 3. The hydraulic tank is located on the right side of
the machine. Press the button on the breaker relief
Hydraulic Oil valve (1) in order to relieve any tank pressure.
NOTICE 4. Remove the hydraulic tank filler cap (2) and

Care must be taken to ensure that fluids are contained the filler strainer (3). Wash the filler cap and the
during performance of inspection, maintenance, test- strainer in a clean, nonflammable solvent. Install
ing, adjusting and repair of the product. Be prepared to the strainer.
ing any compartment or disassembling any compo- 5. Inspect the gasket on the hydraulic tank filler cap
nent containing fluids. for damage. Replace the gasket, if necessary.
Refer to Special Publication, NENG2500, “Caterpillar 6. Remove the drain plug (5) from the bottom of the
Tools and Shop Products Guide” for tools and supplies hydraulic tank. Wash the drain plug in a clean,
suitable to collect and contain fluids on Caterpillar nonflammable solvent.
products.
7. The hydraulic tank is equipped with an ecology
Dispose of all fluids according to local regulations and drain valve. Attach a hose to a 126-7914 Oil
mandates. Drain Coupling. Install the threaded end of the
coupling into the drain valve in order to unseat
the internal drain valve.
1. Operate the machine in order to warm the
hydraulic oil.
NOTICE
2. Park the machine on level ground. Lower the Never start the engine while the hydraulic oil tank is
attachment to the ground and apply slight being drained or while the hydraulic oil tank is empty.
downward pressure. Engage the parking brake Excessive wear and damage to the hydraulic compo-
and stop the engine. nents can occur.
8. Close the drain valve. Install the drain plug.
9. Change the hydraulic oil filter.

Manual, “Hydraulic System Oil Filter - Replace” for
the correct procedure.
146 SEBU7018-08
Maintenance Section
Hydraulic System Oil Filter - Replace
10. Fill the hydraulic tank with clean oil. Make sure i01465406
that the oil level is at the “FULL” mark on the sight
gauge (4). Install the filler cap. Hydraulic System Oil Filter -
Replace
Manual, “Lubricant Viscosities and Refill SMCS Code: 5068-510
NOTICE
11. Start the engine and run the engine for at least ten
seconds. Then, stop the engine and add hydraulic
oil to the tank until the oil level is at the “FULL”
mark on the sight gauge. Install the filler cap.
12. Start the engine and run the engine at low idle.
Cycle the implements so that all hydraulic systems
are filled with oil.
Note: If the alert indicator for a low oil level comes
products.
on, stop the engine and immediately add oil to the
hydraulic tank. The oil level should not be below the
suction ports in the hydraulic tank while the engine
mandates.
is running.
13. Add hydraulic oil to the tank until the oil level is at
the “FULL” mark on the sight gauge.
14. Stop the engine. Top off the hydraulic tank so that
the oil level is at the “FULL” mark on the sight
gauge. Install the filler cap.
Note: The oil must be free of air bubbles. If air

bubbles are present in the hydraulic oil, air is entering
the hydraulic system. Inspect the hydraulic suction
line and the hose clamps.
15. If necessary, tighten any loose clamps or any

loose connections. Replace any damaged hoses.
g00765498
Illustration 229
The hydraulic filter is located on the right side of the

machine.
1. Use a strap type wrench to remove the filter

element. Dispose of the used filter element
properly.
2. Clean the filter mounting base. Make sure that all

of the used gasket is completely removed.
SEBU7018-08 147
Maintenance Section
Hydraulic System Oil Level - Check
i01465502
Hydraulic System Oil Level -

Check
g00101318
Illustration 230
3. Lubricate the gasket of the new filter element with

clean hydraulic oil.
4. Install the new filter element by hand. After the

gasket contacts the filter mounting base, tighten
the filter element by an additional 3/4 turn.
5. Start the engine and run the engine at low idle.

Inspect the hydraulic system for leaks.
g00765515
Illustration 232
The hydraulic tank is located on the right side of the

machine.
Maintain the oil level above the “ADD COLD” mark

on sight gauge (2). If necessary, remove filler cap (1)
slowly and add oil.
i01903274
Hydraulic System Oil Sample

- Obtain
SMCS Code: 5050-008; 5056-008; 7542
NOTICE
Illustration 231
g00765515 during performance of inspection, maintenance, test-
6. Maintain the oil level above the “ADD COLD” mark collect the fluid with suitable containers before open-
on the sight gauge. Add hydraulic oil, if necessary. ing any compartment or disassembling any compo-

products.

mandates.
148 SEBU7018-08
Maintenance Section
Hydraulic Tank Breaker Relief Valve - Clean
1. Operate the machine for a few minutes before i01465512

obtaining the oil sample. Operate the hydraulic
controls. This will thoroughly mix the hydraulic oil Hydraulic Tank Breaker Relief
for a more accurate sample. Valve - Clean
SMCS Code: 5118-070
g00990418
Illustration 233
2. Open the engine access door on the left side of

the machine. 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.
g00765560
Illustration 235
The hydraulic tank breaker relief valve is located on

the top of the hydraulic tank on the right side of the
machine.
1. Press the button on the top of the hydraulic

breaker in order to relieve the pressure in the
hydraulic tank. Remove the hydraulic tank breaker
relief valve.
2. Clean the hydraulic tank breaker relief valve in a

g00994422 clean, nonflammable solvent. Shake the breaker
Illustration 234
relief valve dry or use pressure air to dry the
3. Use the in-line sampling valve in order to obtain a breaker relief valve.
sample of hydraulic oil.
3. Install the hydraulic tank breaker relief valve.
4. Close the engine access door.
i01718807
Reference: For more information, refer to Special
Logging Fork Clamp -
Publication, PEHP6001, “How To Take A Good Oil Lubricate
Sample”.
SMCS Code: 6113-086-BD; 6410-086-BD
Wipe off all fittings before any lubricant is applied.

SEBU7018-08 149
Maintenance Section
Oil Filter - Inspect
Nonferrous metals can indicate wear on the

aluminum parts of the engine such as main bearings,
rod bearings, or turbocharger bearings.
Small amounts of debris may be found in the filter

element. This could be caused by friction and by
normal wear. Consult your Caterpillar dealer in order
to arrange for further analysis if an excessive amount
of debris is found.
Using an oil filter element that is not recommended

by Caterpillar can result in severe engine damage
to engine bearings, to the crankshaft, and to other
parts. This can result in larger particles in unfiltered
g00883679
oil. The particles could enter the lubricating system
Illustration 236 and the particles could cause damage.
Apply lubricant through three fittings on each side
of the logging fork. i01114617
There is a total of six fittings. Radiator Core - Clean

SMCS Code: 1353-070-KO
i02106227
Oil Filter - Inspect

SMCS Code: 1308-507; 3004-507; 3067-507;
5068-507
Inspect a Used Filter for Debris
g00290860
Illustration 238
1. Open the engine hood. The radiator assembly is

located at the rear of the machine.
g00100013
Illustration 237
The element is shown with debris.
Use a filter cutter to cut the filter element open.

Spread apart the pleats and inspect the element for
metal and for other debris. An excessive amount of
debris in the filter element can indicate a possible
failure.
If metals are found in the filter element, a magnet can

be used to differentiate between ferrous metals and Illustration 239
g00315688
nonferrous metals.
2. Remove two bolts (1). Swing hydraulic oil cooler
Ferrous metals can indicate wear on steel parts and (2) away from radiator (3).
on cast iron parts.
150 SEBU7018-08
Maintenance Section
Radiator Core - Clean
Low Sound Machines and Blue

Angel Machines
g00315690
Illustration 240
3. Remove two bolts (4). Swing air conditioner g00480311

condenser (5) away from radiator (3). Illustration 242
1. Push the button and open the radiator grill that is

located on the rear of the machine.
g00101939
Illustration 241
4. You can use compressed air, high pressure water, g00480313

Illustration 243
or steam to remove dust and other debris from
the radiator fins. However, the use of compressed
air is preferred. 2. Remove bolt (1). Swing hydraulic oil cooler (2)
away from the radiator.
5. Swing the hydraulic oil cooler back into the
operating position and replace the two bolts. 3. Remove two bolts (3). Swing air conditioner
condenser (4) away from the radiator.
6. Swing the air conditioner condenser back into the
operating position and replace the two bolts.
g00101939
Illustration 244
SEBU7018-08 151
Maintenance Section
Refrigerant Dryer - Replace
4. You can use compressed air, high pressure water,

or steam to remove dust and other debris from
the radiator fins. However, the use of compressed
air is preferred.
5. Swing the hydraulic oil cooler back into the

operating position and replace the bolt.
6. Swing the air conditioner condenser back into the

operating position and replace the two bolts.
7. Close the radiator grill.
i01914104
Refrigerant Dryer - Replace

SMCS Code: 7322-510
g00996935
Illustration 245
Personal injury can result from contact with refrig-
erant.
Access the refrigerant accumulator from the right
side of the machine. Access the in-line refrigerant
Contact with refrigerant can cause frost bite. Keep
dryer from the left side of the machine.
face and hands away to help prevent injury.
Refer to Service Manual, SENR5664, “In-Line
Protective goggles must always be worn when re-
Refrigerant Dryer - Remove and Install” for the
frigerant lines are opened, even if the gauges in-
replacement procedure of the in-line refrigerant dryer.
dicate the system is empty of refrigerant.
Note: When you operate the machine in a climate
Always use precaution when a fitting is removed.
with high humidity, replace the in-line refrigerant dryer
Slowly loosen the fitting. If the system is still un-
after every 1000 service hours or 6 months.
der pressure, release it slowly in a well ventilated
area.
i01157525
Personal injury or death can result from inhaling
refrigerant through a lit cigarette. Ride Control Accumulator -
Inhaling air conditioner refrigerant gas through a
Check
lit cigarette or other smoking method or inhaling SMCS Code: 5077-535-R6
fumes released from a flame contacting air con-
ditioner refrigerant gas, can cause bodily harm or The ride control accumulator reduces the pitching of
death. the machine. If the machine seems to be bouncing
excessively, check the charge in the ride control
Do not smoke when servicing air conditioners or accumulator.
wherever refrigerant gas may be present.
Note: Special tools and equipment are required to
Use a certified recovery and recycling cart to prop- test the accumulator.
erly remove the refrigerant from the air condition-
ing system. Reference: For more information, refer to Testing
and Adjusting, SENR1390, “950G Wheel Loader,
962G Wheel Loader and IT62G Integrated Toolcarrier
Hydraulic System” or consult your Caterpillar dealer.
152 SEBU7018-08
Maintenance Section
Roading Fender Hinges - Lubricate
i01457015 i01457460
Roading Fender Hinges - Rollover Protective Structure

Lubricate (ROPS) - Inspect
SMCS Code: 7252-086-HNG SMCS Code: 7323-040; 7325-040
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.
g00762107
Illustration 247
Inspect the ROPS for bolts that are loose or damaged.

Use original equipment parts only to replace bolts
that are damaged or missing. Tighten the four
cab mounting bolts to a torque of 850 ± 100 N·m
(629 ± 74 lb ft).
Note: Apply oil to all bolt threads before installation.

Failure to apply oil can result in improper bolt torque.
g00761700
Illustration 246 Do not repair the ROPS by welding reinforcement
plates to the ROPS. Consult your Caterpillar dealer
Swing open the roading fender. Apply lubricant for repair of cracks in any welds, in any castings, or
through one fitting on the hinge. There is one hinge in any metal section of the ROPS.
on each side of the machine.
i02429589
Seat Belt - Inspect

SMCS Code: 7327-040
Always check the condition of the seat belt and the

condition of the seat belt mounting hardware before
you operate the machine. Replace any parts that are
damaged or worn before you operate the machine.
SEBU7018-08 153
Maintenance Section
Seat Belt - Replace
g01152685
Illustration 249
Illustration 248
g00932801 (1) Date of installation (retractor)
(2) Date of installation (buckle)
Typical example (3) Date of manufacture (tag) (fully extended web)
(4) Date of manufacture (underside) (buckle)
Check the seat belt mounting hardware (1) for wear
or for damage. Replace any mounting hardware that Consult your Caterpillar dealer for the replacement of
is worn or damaged. Make sure that the mounting the seat belt and the mounting hardware.
bolts are tight.
If your machine is equipped with a seat belt
Check buckle (2) for wear or for damage. If the buckle extension, also perform this replacement procedure
is worn or damaged, replace the seat belt. for the seat belt extension.
Inspect the seat belt (3) for webbing that is worn or

i01898262
frayed. Replace the seat belt if the seat belt is worn
or frayed. Service Brake Disc Wear
Consult your Caterpillar dealer for the replacement of Indicator - Check
the seat belt and the mounting hardware.
SMCS Code: 4255-535-IND
Note: Within three years of the date of installation or
within five years of the date of manufacture, replace Reference: For information about checking the wear
the seat belt. Replace the seat belt at the date which indicator for the service brake disc, refer to Testing
occurs first. A date label for determining the age of and Adjusting, SENR1387, “950G Wheel Loader,
the seat belt is attached to the seat belt, the seat belt 962G Wheel Loader and IT62G Integrated Toolcarrier
buckle, and the seat belt retractor. Braking System”.
If your machine is equipped with a seat belt

i02405758
extension, also perform this inspection procedure for
the seat belt extension. Steering Cylinder Bearings -
Lubricate
i02429594
SMCS Code: 4303-086-BD
Seat Belt - Replace
SMCS Code: 7327-510
Within three years of the date of installation or within Crushing Hazard. Insure that the machine ignition
five years of the date of manufacture, replace the switch is in the OFF position and that the parking
seat belt . Replace the seat belt at the date which brake is engaged before entering the articulation
occurs first. A date label for determining the age of area. Failure to do so could result in serious injury
the seat belt is attached to the seat belt, the seat belt or death.
buckle, and the seat belt retractor.
154 SEBU7018-08
Maintenance Section
Steering Pilot Oil Screen (Command Control Steering) - Clean/Replace
i01467209
Steering Pilot Oil Screen

(Command Control Steering) -
Clean/Replace
SMCS Code: 4304-070-Z3; 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
g00765667
Illustration 250
Personal injury can result from working with
cleaning solvent.
Wipe off the fittings before any lubricant is applied.
Because of the volatile nature of many cleaning
solvents, extreme caution must be exercised
machine. Apply lubricant through two remote fittings.
when using them. If unsure about a particular
These remote fittings lubricate the head end of the
cleaning fluid, refer to the manufacturer’s instruc-
steering cylinders.
tions and directions.
Apply lubricant through the fittings on the rod ends of
Always wear protective clothing and eye protec-
both steering cylinders.
tion when working with cleaning solvents.
There is a total of four fittings.
g00765737
Illustration 251
The screen group for the steering oil is located in the

articulation joint near the steering neutralizer valve
on the right side.
1. Disconnect two hoses.

SEBU7018-08 155
Maintenance Section
Steering Shaft (Command Control Steering) - Lubricate
2. Remove two connectors (2) from screen group (3). Reference: Refer to Disassembly and Assembly,
SENR1392, “950G Wheel Loader, 962G Wheel
3. Use an allen wrench to remove one screen from Loader and IT62G Integrated Toolcarrier Machine
each opening of the screen group. Systems” for the removal procedure and for the
installation procedure.
4. Wash the screens in a clean, nonflammable
solvent. 2. Wipe off all of the fittings before any lubricant is
applied.
5. Dry each screen with pressure air. Inspect each
screen for damage. Replace any damaged 3. Apply 5P-0960 Molybdenum Grease through
screens. fittings (1), (2), (3) and (4).
6. Install the screens and tighten the allen head 4. Apply 1P-0808 Multipurpose Grease through
screws until the screens are snug. fittings (5), (6), (7) and (8).
7. Install two connectors (2) and two hoses (1). 5. Install the steering shaft on the machine.
i01326236 i02305841
Steering Shaft (Command Tire Inflation - Check

Control Steering) - Lubricate SMCS Code: 4203-535-AI
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
g01160201
Illustration 253
Always obtain proper tire inflation pressures and

maintenance recommendations for the tires on your
machine from your tire supplier. Measure the tire
pressure on each tire.
Inflate the tires with nitrogen , if necessary.
Reference: Refer to the “Tire Inflation Information”

section of the Operation and Maintenance Manual
for more information.
g00352373
Illustration 252
1. Remove the steering shaft from the machine.

156 SEBU7018-08
Maintenance Section
Transmission Oil - Change
i01468034
Transmission Oil - Change

SMCS Code: 3030-044
NOTICE

products.

mandates.
g00766094
Illustration 255
1. Operate the engine for a few minutes in order to
warm the transmission oil. 3. Remove transmission oil drain plug (7). Allow the
oil to drain into a suitable container. Clean the
2. Park the machine on a hard, level surface. Lower drain plug and install the drain plug.
the bucket to the ground with a slight downward
pressure. Engage the parking brake and stop the 4. Remove four cover bolts and magnetic strainer
engine. cover (3).
5. Remove suction screen (4) and tube (6) from the

housing. Remove three magnets (5) from the tube.
6. Wash the tube and the screen in a clean,

nonflammable solvent.
7. Use a cloth, a stiff bristle brush or pressurized air

to clean the magnets.
NOTICE
Do not drop or rap the magnets against any hard sur-
face. Replace any damaged magnets.
g00766059
Illustration 254 8. Clean the cover and inspect the cover seal.
Replace the seal, if necessary.
Note: Remove the bolts (1) that hold the transmission
guard (2). Remove the transmission guard on the 9. Install three magnets (5) on the tube. Insert
underside of the machine in order to access the suction screen (4) and tube (6) in the housing.
magnetic strainer.
10. Install the cover and the cover bolts.
11. Replace the transmission oil filter.

Manual, “Transmission Oil Filter - Replace” for the
correct procedure.
SEBU7018-08 157
Maintenance Section
Transmission Oil Filter - Replace
i01468833
Transmission Oil Filter -

Replace
SMCS Code: 3067-510
NOTICE

products.
g00766254
Illustration 256 mandates.
12. The filler tube for the transmission is located near
the center hitch. Remove the filler cap (8) and fill 1. Park the machine on a hard, level surface. Lower
the transmission with oil. the bucket to the ground with a slight downward
pressure. Engage the parking brake and stop the
Reference: Refer to Operation and Maintenance engine.
Manual, “Lubricant Viscosities and Refill
13. Remove the transmission breather from the top of

the transfer case. Wash the breather in a clean,
nonflammable solvent. Install the breather.
14. Start the engine. Slowly operate the transmission

controls in order to circulate the oil.
15. Move the transmission control to the NEUTRAL

position. Stop the engine. Inspect the transmission
for leaks.
16. Check the transmission oil level. The sight gauge

(9) is located near the filler tube. The transmission
oil should be at the mark (10) if the engine is off.
The oil should be between marks (11) and (12)
when the engine is idling.
Reference: Refer to Operation and Maintenance Illustration 257

g00766360
Manual, “Transmission Oil Level - Check” for the
correct procedure. 2. The transmission oil filter is located on the left side
of the machine near the articulation joint. Use a
strap type wrench to remove the transmission oil
filter. Dispose of the used oil filter properly.
3. Clean the filter mounting base. Remove all of the

used filter gasket from the filter mounting base.
158 SEBU7018-08
Maintenance Section
Transmission Oil Level - Check
i01468938
Transmission Oil Level - Check

g00101318
Illustration 258
4. Apply a thin coat of clean transmission oil to the

gasket of the new filter element. Install the new
filter element by hand. When the gasket contacts
the filter mounting base, tighten the transmission
oil filter by an additional 3/4 turn.
5. Start the engine. Slowly operate the transmission

controls in order to circulate the transmission oil.
6. Move the transmission control to the NEUTRAL Illustration 259

g00766406
position. Inspect the transmission oil filter for
leaks. The sight gauge for the transmission oil level is
located on the left side of the machine near the
7. Check the transmission oil level. articulation joint.
Reference: Refer to Operation and Maintenance 1. Operate the machine for a few minutes in order to
Manual, “Transmission Oil Level - Check” for the warm the transmission oil.
correct procedure.
2. Park the machine on a hard, level surface. Put the
transmission control into the NEUTRAL position.
Lower the bucket to the ground with a slight
downward pressure. Engage the parking brake.
Note: Before the machine is started, the transmission

oil level should be above “MIN START” mark (1) on
the upper end of the sight gauge.
3. Check the oil level while the engine is running at

low idle.
While the engine is running at low idle, the

transmission oil level should be between the “MIN”
mark (3) and the “MAX” mark (2).
4. If necessary, remove the filler cap and add oil.

SEBU7018-08 159
Maintenance Section
Transmission Oil Sample - Obtain
i01903302 i01468974
Transmission Oil Sample - Window Washer Reservoir -

Obtain Fill
SMCS Code: 3080-008; 7542 SMCS Code: 7306-544
NOTICE NOTICE
Care must be taken to ensure that fluids are contained When operating in freezing temperatures, use
during performance of inspection, maintenance, test- Caterpillar or any commercially available nonfreezing
ing, adjusting and repair of the product. Be prepared to window washer solvent.

products.

mandates.
1. Operate the machine for a few minutes before

obtaining the oil sample. This will thoroughly mix
the transmission oil for a more accurate sample. g00766424
Illustration 261
Window Washer Reservoir – The window

washer reservoir is located on the right side
of the machine. Fill the reservoir through
the filler opening.
i01469067
Window Wiper -
Inspect/Replace
SMCS Code: 7305-040; 7305-510
g00990463
Illustration 260
2. The sampling valve for the transmission oil is

located on the transmission oil filter base on the
left side of the articulation joint. Use the in-line
sampling valve in order to obtain a sample of
transmission oil.
Reference: For more information, refer to Special

Publication, PEHP6001, “How To Take A Good Oil
Sample”.
g00766456
Illustration 262
Inspect the wiper blades. Replace the wiper blades if

the wiper blades are worn or damaged or if streaking
occurs.
160 SEBU7018-08
Maintenance Section
Windows - Clean
i00037755
Windows - Clean
SMCS Code: 7310-070
g00038949
Illustration 263
Use commercially available window cleaning

solutions in order to clean the windows. Clean the
outside windows from the ground unless handholds
are available.

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MAINTENANCE INTERVALS

Operation and Maintenance

i02625049 Seat Belt - Inspect .............................................. 152

Every 1000 Service Hours or 6 Months

Every 2000 Service Hours or 1 Year

Every 3000 Service Hours or 2 Years

Every 3 Years After Date of Installation or

Every 6000 Service Hours or 3 Years

Every 6000 Service Hours or 6 Years

Every 12 000 Service Hours or 6 Years

Crushing Hazard. Insure that the machine ignition

Wipe all fittings before applying grease.

Open the access door on the right side of the

Apply lubricant through two remote fittings (1) and (2).

Backup Alarm - Test

Lubricate The backup alarm should sound immediately.

Crushing Hazard. Insure that the machine ignition

Wipe off all fittings before you apply any lubricant.

A three-position switch on the backup alarm regulates i01897534

Open the battery compartment on the left rear side

Over time, the vibration of an operating machine can

Note: Do not allow the disconnected battery cable to

4. Disconnect the negative battery cable at the

5. Disconnect the positive battery cable at the

6. Inspect the battery terminals for corrosion. Inspect

Alternator Belt 3. Use a BT-33-97 Borroughs Gauge to check the

Adjusting the Tension of the Belt for the i01714079

Axle Oil Cooler Pump Brake Accumulator - Check

1. Turn the engine start switch to the ON position.

2. Start the engine. Run the engine at half speed for

Brake Discs - Check

Reference: For the correct procedure, refer to the

i02056278 If both sides are worn, install a new cutting edge.

Block the bucket before changing bucket cutting Integrated Toolcarrier

4. Clean all contact surfaces.

5. If the opposite side of the cutting edge is not worn,

Bucket Lower Pivot Bearings

For pin joint (1), apply lubricant through one remote

Bucket Tips - Inspect/Replace

Personal injury or death can result from the bucket

b. Align extractor (5) with the pin.

c. Strike the Pin-Master at the back of the tool

c. Strike the tool with a hammer at the back of the

d. Slide pin holder (10) away from the pin and

e. Strike the end of the tool until the pin is fully

Personal injury or death can result from the bucket

a. Insert the pin through the bucket tooth.

b. Place the Pin-Master over the bucket tooth and

Personal injury can result from driving out retainer

Retainer pins, when struck with force can fly out

Make sure the area is clear of people when driving

Wear protective glasses when striking a retainer

By driving from the right side of the adapter, the

The loss of bucket tips can often be attributed to Proper installation

b. Align extractor (5) with the pin.

c. Strike the Pin-Master at the back of the tool

d. Slide pin holder (10) away from the pin and

e. Strike the end of the tool until the pin is fully