Maintenance Intervals

MAINTENANCE INTERVALS
Operation and Maintenance

Manual Excerpt
® ®
© 2010 Caterpillar
All Rights Reserved
SEBU7458-07
October 2005
Operation and
Maintenance
Manual
966G Series II and 972G Series II
Wheel Loaders
AXC1-Up (Machine)
AXE1-Up (Machine)
AXJ1-Up (Machine)
AXL1-Up (Machine)
AXN1-Up (Machine)
AWP1-Up (Machine)
AXP1-Up (Machine)
ANT1-Up (Machine)
ANY1-Up (Machine)
AWY1-Up (Machine)
ANZ1-Up (Machine)
AWZ1-Up (Machine)
SEBU7458-07 113
Maintenance Section
Maintenance Interval Schedule
i02407125 Hydraulic System Oil Level - Check ................... 158

Seat Belt - Inspect .............................................. 163
Maintenance Interval Schedule Transmission Oil Level - Check .......................... 167
Windows - Clean ................................................. 169
SMCS Code: 7000
Every 50 Service Hours or Weekly
Ensure that all safety information, warnings, and
instructions are read and understood before any Bucket Lower Pivot Bearings - Lubricate ............ 120
operation or any maintenance procedures are Cab Air Filter - Clean/Replace ............................ 123
performed. Tire Inflation - Check ........................................... 165
The user is responsible for the performance of Every 100 Service Hours or 2 Weeks
maintenance, including all adjustments, the use of
proper lubricants, fluids, filters, and the replacement Axle Oscillation Bearings - Lubricate ................... 116
of components due to normal wear and aging. Failure Bucket Linkage and Loader Cylinder Bearings -
to adhere to proper maintenance intervals and Lubricate ........................................................... 120
procedures may result in diminished performance of Bucket Upper Pivot Bearings - Lubricate ............ 123
the product and/or accelerated wear of components. Logging Fork Clamp - Lubricate ......................... 159
Steering Cylinder Bearings - Lubricate ............... 164
Use mileage, fuel consumption, service hours, or
calendar time, WHICH EVER OCCURS FIRST, Every 250 Service Hours or Monthly
in order to determine the maintenance intervals.
Products that operate in severe operating conditions Battery - Clean ..................................................... 117
may require more frequent maintenance. Belts - Inspect/Adjust/Replace ............................. 118
Brake Accumulator - Check ................................. 119
Note: Before each consecutive interval is performed, Braking System - Test .......................................... 119
all maintenance from the previous interval must be Differential and Final Drive Oil Level - Check ..... 130
performed. Drive Shaft Spline (Center) - Lubricate ............... 132
Engine Crankcase Breather - Clean ................... 137
When Required Engine Oil Sample - Obtain ................................ 142
Engine Oil and Filter - Change ........................... 142
Automatic Lubrication Grease Tank - Fill ............. 115 Quick Coupler - Lubricate ................................... 160
Automatic Lubrication Grease Tank - Fill ............. 116
Battery - Recycle ................................................. 117 Initial 500 Hours (for New Systems, Refilled
Battery or Battery Cable - Inspect/Replace ......... 118 Systems, and Converted Systems)
Bucket Wear Plates - Inspect/Replace ............... 123
Circuit Breakers - Reset ...................................... 124 Cooling System Coolant Sample (Level 2) -
Engine Air Filter Primary Element - Obtain ............................................................... 128
Clean/Replace .................................................. 134
Engine Air Filter Secondary Element - Replace .. 136 Every 500 Service Hours
Engine Air Precleaner - Clean ............................ 137
Ether Starting Aid Cylinder - Replace ................. 147 Cooling System Coolant Sample (Level 1) -
Fuel System - Prime ........................................... 147 Obtain ............................................................... 127
Fuses - Replace .................................................. 151
Fuses - Replace .................................................. 152 Every 500 Service Hours or 3 Months
Oil Filter - Inspect ................................................ 160
Differential and Final Drive Oil Sample - Obtain .. 131
Quick Coupler - Check ........................................ 160 Engine Oil (High Speed) and Oil Filter - Change .. 138
Radiator Core - Clean ......................................... 161
Engine Oil and Filter - Change ........................... 142
Ride Control Accumulator - Check ..................... 162
Fuel System Primary Filter (Water Separator)
Window Washer Reservoir - Fill .......................... 168 Element - Replace ............................................ 149
Window Wiper - Inspect/Replace ........................ 169
Fuel Tank Cap and Strainer - Clean ................... 150
Hydraulic System Biodegradable Oil Filter Element -
Every 10 Service Hours or Daily Replace ............................................................. 154
Backup Alarm - Test ............................................. 117 Hydraulic System Oil Filter - Replace ................. 157
Bucket Cutting Edges - Inspect/Replace ............. 119 Hydraulic System Oil Sample - Obtain ............... 158
Bucket Tips - Inspect/Replace ............................ 121 Transmission Oil Filter - Replace ........................ 167
Cooling System Coolant Level - Check .............. 127 Transmission Oil Sample - Obtain ...................... 168
Engine Oil Level - Check .................................... 141
Fuel System Primary Filter (Water Separator) - Every 1000 Service Hours or 6 Months
Drain ................................................................. 148
Articulation Bearings - Lubricate .......................... 115
Fuel Tank Water and Sediment - Drain ............... 151
Battery Hold-Down - Tighten ................................ 118
114 SEBU7458-07
Maintenance Section
Maintenance Interval Schedule
Case Drain Screen (Strainer) (Steering Pump,

Hydraulic Fan Pump, Motor) - Clean ................ 124
Drive Shaft Support Bearing - Lubricate ............. 133
Drive Shaft Universal Joints - Lubricate .............. 133
Fuel System Secondary Filter - Replace ............ 150
Hood Tilt Actuator - Lubricate ............................. 154
Roading Fender Hinges - Lubricate .................... 162
Rollover Protective Structure (ROPS) - Inspect .. 162
Steering Pilot Oil Screen (Command Control
Steering) - Clean/Replace ................................. 164
Transmission Oil - Change ................................. 165
Every 2000 Service Hours or 1 Year

Brake Discs - Check ............................................ 119
Differential and Final Drive Oil - Change ............ 129
Electronic Unit Injector - Inspect/Adjust .............. 133
Engine Valve Lash - Check ................................. 146
Engine Valve Rotators - Inspect ......................... 146
Hydraulic System Oil - Change ........................... 155
Hydraulic Tank Breaker Relief Valve - Clean ...... 159
Steering Shaft (Command Control Steering) -
Lubricate ........................................................... 165
Every Year
Cooling System Coolant Sample (Level 2) -
Obtain ............................................................... 128
Refrigerant Dryer - Replace ................................ 161
Every 3 Years After Date of Installation or

Every 5 Years After Date of Manufacture
Seat Belt - Replace ............................................. 163
Every 4000 Service Hours or 2 Years

Hydraulic System Oil - Change ........................... 155
Every 6000 Service Hours or 3 Years

Cooling System Coolant Extender (ELC) - Add .. 126
Cooling System Water Temperature Regulator -
Replace ............................................................. 129
Every 12 000 Service Hours or 6 Years

Cooling System Coolant (ELC) - Change ........... 125
SEBU7458-07 115
Maintenance Section
Articulation Bearings - Lubricate
i02405939
Articulation Bearings -
A pressure hazard is present. Severe personal in-
Lubricate jury or death can result from removing hoses or
fittings that are under pressure. Relieve the pres-
SMCS Code: 7057-086-BD; 7065-086-BD; sure in the system before you remove hoses or
7066-086-BD fittings.
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.
g01067897
Illustration 154
Filling the Reservoir

g00879717
Illustration 153
1. The Lincoln Quicklub pump (1) is located near the
rear fender on the right side of the machine.
Apply grease to one fitting on the upper pivot bearing
and one fitting on the lower pivot bearing.
2. Fill the reservoir (2) through the grease fitting (3).
The grease fitting (3) is located at the base of the
i02093114 reservoir (2).
Automatic Lubrication Grease Reference: For the correct type of grease, refer
Tank - Fill to Operation and Maintenance Manual, “Lubricant
Viscosities”.
(If Equipped)
3. Refill the reservoir when the grease reaches the
SMCS Code: 7540-544-TNK “MIN” mark on the reservoir.
S/N: AWP1-Up 4. Fill the reservoir to the “MAX” mark on the
reservoir.
S/N: ANT1-Up
S/N: ANY1-Up Priming the System
S/N: ANZ1-Up After the reservoir has been filled with the
recommended lubricant, loosen the fitting to the
The Lincoln Quicklub Lubrication supply line. Operate the pump until lubricant flows
from the outlet. Then, tighten fitting.
System
Reference: Before any service work is performed on
the lubrication system, refer to Special Instructions,
REHS1396 or consult your Caterpillar dealer.
116 SEBU7458-07
Maintenance Section
Automatic Lubrication Grease Tank - Fill
i02094776 Filling the Reservoir

Automatic Lubrication Grease 1. Remove the dust cap (2) from the grease reservoir
Tank - Fill (1).
(If Equipped) 2. Clean the filler tube assembly (3) and the coupling
on the filler assembly.
SMCS Code: 7540-544-TNK
3. Install the filler assembly onto the filler tube
S/N: AXC1-Up
assembly (3).
S/N: AXE1-Up
4. Fill the grease reservoir (1) with grease to the
S/N: AXJ1-Up maximum level which is indicated on the grease
reservoir (1).
S/N: AXL1-Up
S/N: AXN1-Up Reference: For the correct type of grease, refer
to Operation and Maintenance Manual, “Lubricant
S/N: AXP1-Up Viscosities”.
S/N: AWY1-Up 5. Remove the filler assembly and install the dust
cap (2).
S/N: AWZ1-Up
The Groeneveld Automatic TWIN i02405745
Greasing System Axle Oscillation Bearings -

Reference: Refer to System Operation, RENR
Lubricate
6331for more information on the Automatic TWIN SMCS Code: 3268-086-BD; 3278-086-BD
Greasing System.

A pressure hazard is present. Severe personal in- switch is in the OFF position and that the parking
jury or death can result from removing hoses or brake is engaged before entering the articulation
fittings that are under pressure. Relieve the pres- area. Failure to do so could result in serious injury
sure in the system before you remove hoses or or death.
fittings.
g01007809
g01068678
Illustration 156
Illustration 155
Open the rear access panel that is located on the
Grease reservoir (1) is located near the rear fender left side of the machine in order to gain access to
on the right side of the machine. the remote grease fittings.
SEBU7458-07 117
Maintenance Section
Backup Alarm - Test
A three-position switch on the backup alarm regulates

the volume of the alarm.
The backup alarm is set for the highest sound level

when the machine is shipped from the factory. The
setting should remain on HIGH unless the job site
requires a lower sound level.
i01897517
Battery - Clean
SMCS Code: 1401-070
g00881949
Illustration 157
Wipe all fittings before lubricating.
The top remote grease fitting will lubricate the axle

pivot bearing that is on the front of the rear axle. The
bottom remote grease fitting will lubricate the axle
pivot bearing that is on the rear of the rear axle.
Note: 5P-0960 Molybdenum Grease is preferred.

1P-0808 Multipurpose Grease grease may be used.
i01897507
g00987179
Illustration 159
Backup Alarm - Test
Open the battery compartment on the left rear side of
(If Equipped) the machine. Remove the battery hold-down.
SMCS Code: 7406-081
Clean the battery terminals and the surfaces of
the batteries with a clean cloth. Coat the battery
Turn the engine start switch to the ON position in
terminals with petroleum jelly. Make sure that the
order to perform the test.
battery cables are installed securely.
Apply the service brake. Place the transmission into
Replace the battery hold-down. Refer to Operation
REVERSE.
and Maintenance Manual, “Battery Hold-Down -
Tighten” for the correct torque. Close the battery
The backup alarm should sound immediately.
compartment.
The backup alarm will continue to sound until
the transmission is placed into NEUTRAL or into
FORWARD. i00993589
Battery - Recycle
SMCS Code: 1401-561
Always recycle a battery. Never discard a battery.
Always return used batteries to one of the following

locations:
• A battery supplier
• An authorized battery collection facility
g00881968
• Recycling facility
Illustration 158
118 SEBU7458-07
Maintenance Section
Battery Hold-Down - Tighten
i01897534 7. Make any necessary repairs. If necessary, replace

the battery cables or the battery.
Battery Hold-Down - Tighten
8. Connect the positive battery cable at the battery.
SMCS Code: 7257-527
9. Connect the negative battery cable at the battery.
10. Connect the battery cable at the battery

disconnect switch.
11. Install the key and turn the battery disconnect

switch ON.
i01714078
Belts - Inspect/Adjust/Replace
SMCS Code: 1357-025; 1357-040; 1357-510;
1397-025; 1397-040; 1397-510
g00882014
Illustration 160
Your machine is equipped with a single serpentine
Open the battery compartment on the left rear side belt. Stop the engine. Open the rear hood. The belt is
of the machine. located at the rear of the engine.
Over time, the vibration of an operating machine can

cause the battery hold-down to loosen. To help to
prevent loose batteries and the possibility of loose
cable connections, tighten the locknut in the center of
the hold-down to a torque of 14 ± 3 N·m (10 ± 2 lb ft).
i01770834
Battery or Battery Cable -

Inspect/Replace
SMCS Code: 1401-040; 1401-510; 1402-040;
1402-510
1. Turn the engine start switch key OFF. Turn all of

the switches OFF.
2. Turn the battery disconnect switch OFF. Remove

the key.
g00746146
Illustration 161
3. Disconnect the negative battery cable from the
disconnect switch. (1) Compressor
(2) Alternator
(3) Idler
Note: Do not allow the disconnected battery cable to (4) Tensioner
contact the disconnect switch. (5) Square drive hole
(6) Idler
(7) Serpentine belt
4. Disconnect the negative battery cable at the (8) Crankshaft pulley
battery.
A tensioner (4) keeps the correct tension on the belt
5. Disconnect the positive battery cable at the (7). Insert a ratchet with a square drive into the hole
battery. (5). Rotate the tensioner counterclockwise in order to
relieve tension on the belt. Remove the belt.
6. Inspect the battery terminals for corrosion. Inspect
the battery cables for wear or damage.
SEBU7458-07 119
Maintenance Section
Brake Accumulator - Check
Install the new belt. Be sure that the new belt is i01732078
routed correctly, as shown. Rotate the tensioner
counterclockwise in order to install the new belt. Brake Discs - Check
Release the tensioner when the new belt is installed.
The correct tension will automatically be applied. SMCS Code: 4255-535
Reference: For the correct procedure, refer to the

i01714079 Testing and Adjusting Service Manual of the braking
system for your machine or consult your Caterpillar
Brake Accumulator - Check dealer.
SMCS Code: 4263-535
i02056278
Braking System - Test

SMCS Code: 4251-081; 4267-081
In order to test the braking system, refer to theTesting

and Adjusting Service Manual of the braking system
for your machine or consult your Caterpillar dealer.
i02196469
Bucket Cutting Edges -

Inspect/Replace
g00882020
Illustration 162
SMCS Code: 6801-040; 6801-510
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. Personal injury or death can result from bucket
falling.
2. Start the engine. Run the engine at half speed for
two minutes in order to increase the accumulator Block the bucket before changing bucket cutting
pressure. The alert indicator for brake oil pressure edges.
should go off.
3. Stop the engine. Apply the service brake pedal

and release the service brake pedal until the alert
indicator for brake oil pressure comes on. This will
decrease the accumulator pressure. A minimum
of five applications of the service brake pedal are
required.
4. If the alert indicator comes on after less than

five applications of the brake, measure the
accumulator precharge pressure. An authorized
Caterpillar dealer can measure the nitrogen gas
pressure in the accumulator. Use only dry nitrogen
gas for recharging.
g00764365
Illustration 163
Check the cutting edges and the end bits for wear
and for damage. Use the following procedure to
service the cutting edges and the end bits:
1. Raise the bucket and place blocking under the

bucket.
120 SEBU7458-07
Maintenance Section
Bucket Linkage and Loader Cylinder Bearings - Lubricate
2. Lower the bucket onto the blocking. Stop the

engine.
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.
If both sides are worn, install a new cutting edge.
6. Install bolts (1). Tighten the bolts to the specified g00807071

torque. Illustration 165
Reference: Refer to Specifications, SENR3130, To lubricate pins (1), (5) and (6), apply grease
“Ground Engaging Tool (G.E.T.) Fasteners”. through the remote fittings that are located on the left
side of the machine near the articulation joint.
7. Start the engine. Raise the bucket and remove the
blocking. Lower the bucket to the ground. The pins (2), (3), (4) and (7) do not have remote
grease fittings. These pins have standard grease
8. After a few hours of operation, check the bolts for fittings.
proper torque.
i01924084
i01923622
Bucket Lower Pivot Bearings
Bucket Linkage and Loader - Lubricate
Cylinder Bearings - Lubricate SMCS Code: 6101-086-BD; 6107-086-BD
SMCS Code: 5102-086-BD; 5104-086-BD;
6107-086-BD
Wipe off the fittings before any lubricant is applied.
g01001411
Illustration 166
Wipe off all fittings before any lubricant is applied.
Illustration 164
g01001072 Apply lubricant through one fitting on each side of
the machine.
SEBU7458-07 121
Maintenance Section
Bucket Tips - Inspect/Replace
i02421156 The loss of bucket tips can often be attributed to

the improper installation of the retaining pin into
Bucket Tips - Inspect/Replace the tip and the adapter. Bucket tips are lost more
frequently on excavators because the tips are closer
SMCS Code: 6805-040; 6805-510 together. Inserting the pin from the correct side (right
side) of the adapter is difficult due to the small gap.
More clearance can be obtained by installing the
pin through the tip and the adapter from the left
Personal injury or death can result from the bucket side, and then by driving the pin against the retainer.
falling. This procedure will often cause the spiral retainer to
become distorted, resulting in either a loss of retainer
Block the bucket before changing bucket tips. grip or an increased difficulty in removing the pin.
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 168
Improper installation
Bucket Tips
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 167
(1) Usable
(2) Replace this bucket tip.
(3) Overworn
g01201332
Check the bucket tips for wear. If the bucket tip has a Illustration 169
hole, replace the bucket tip. Proper installation
Install pin from the right side.
1. Remove the pin from the bucket tip. The pin can
be removed by one of the following methods:
• Use a hammer and a punch from the retainer

side of the bucket to drive out the pin.
122 SEBU7458-07
Maintenance Section
Bucket Tips - Inspect/Replace
• Use a Pin-Master. Follow Step 1.a through Step • Use a Pin-Master. Follow Step 5.a through Step
1.c for the procedure. 5.e for the procedure.
a. Place the Pin-Master on the bucket tooth.
b. Align extractor (5) with the pin.
c. Strike the Pin-Master at the back of the tool

(4) and remove the pin.
g00590666
Illustration 172
(4) Back of Pin-Master
(9) Pin setter
(10) Pin holder
a. Insert the pin through the bucket tooth.
Illustration 170
g00590819 b. Place the Pin-Master over the bucket tooth and
(6) Retainer
locate the pin in the hole of the holder (10).
(7) Retaining Washer
(8) Adapter c. Strike the tool with a hammer at the back of the
tool (4) in order to start the pin.
2. Clean the adapter and the pin.
d. Slide pin holder (10) away from the pin and
3. Fit retainer (6) into retaining washer (7). Install this rotate the tool slightly in order to align pin setter
assembly into the groove that is in the side of the (9) with the pin.
adapter (8).
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 14.
Table 14
Size of the Tip Pin Remover

J200, J225 143-2459
J250, J300, J350 143-2460
g00101359 J350, J400, J460 196-1331
Illustration 171
J550 203-4290
4. Install the new bucket tip into the adapter.
Note: The bucket tip can be rotated by 180 degrees in

order to allow greater penetration or less penetration.
5. Drive the pin through the bucket tip. The pin can
be installed by using one of the following methods:
• From the other side of the retainer, drive the pin

through the following components: the bucket
tip, the adapter, and the retainer.
SEBU7458-07 123
Maintenance Section
Bucket Upper Pivot Bearings - Lubricate
i01924086 Inspect the wear plates. Replace the wear plates

before damage to the bottom of the bucket occurs.
Bucket Upper Pivot Bearings Consult your Caterpillar dealer for replacement of
- Lubricate wear plates.
SMCS Code: 6101-086-BD; 6107-086-BD i01449996
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.
g01001416
Illustration 173
Wipe off the fitting before any lubricant is applied.
Apply lubricant through the fitting.
i01709216
Bucket Wear Plates -

Inspect/Replace
SMCS Code: 6120-040; 6120-510
g00759048
Illustration 175
1. Remove the filter cover behind the seat. Two

Personal injury or death can result from the bucket threaded knobs (1) are used in order to remove
falling. the cover. Remove the filter element (2).
Block the bucket before changing bucket wear 2. Open the access door (3) on the left side of the
plates. 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

new filter element.
5. Install the filter elements. Install the filter cover

and close the access door.
g00879740
Illustration 174
124 SEBU7458-07
Maintenance Section
Case Drain Screen (Strainer) (Steering Pump, Hydraulic Fan Pump, Motor) - Clean
i02057872 3. Wash the case drain screen (2) in a clean

nonflammable solvent.
Case Drain Screen (Strainer)
(Steering Pump, Hydraulic Fan 4. Dry the case drain screen (2) by using pressurized
air.
Pump, Motor) - Clean
5. Inspect the case drain screen (2) for damage.
SMCS Code: 4304-070-Z3; 5057-070-Z3
Note: If the case drain screen (2) is damaged,
replace the case drain screen (3).
6. Install the case drain screen (3).
7. Connect hydraulic line (3).
8. Repeat Step1 through Step 7 for hydraulic line (4)

and case drain screen (5).
i02126503
Circuit Breakers - Reset

SMCS Code: 1420-529
Depress the button in order to reset the circuit

breakers. If the circuit is functioning properly, the
button will remain depressed. If the button will not
remain depressed, check the appropriate electrical
circuit.
g01056467
Illustration 176
Top view of the location of the case drain screens (2) and (5).
Case drain screen (2) and case drain screen (5) are
located in hydraulic line (3) and hydraulic line (4).
Hydraulic line (3) and hydraulic line (4) are located
behind the hydraulic oil tank (1).
g00882200
Illustration 178
(1) 20 Amp Circuit Breaker
The circuit breakers are located on the right side of

the machine in the service door.
g01056742
Illustration 177
Detail A
1. Disconnect hydraulic line (3) from the hydraulic

tank (1).
2. Remove the case drain screen (2) from the

hydraulic line (2).
SEBU7458-07 125
Maintenance Section
Cooling System Coolant (ELC) - Change
Reference: For information about adding Extender

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

flush the cooling system with clean water. No other
cleaning agents are required. Use the following
procedure to change the Extended Life Coolant.
g00882203
Illustration 179
Circuit breakers on electrohydraulic machines are

also located in the fuse panel that is located behind
the operator’s seat. These circuit breakers are both
15 amp.
Note: Machines that are equipped with

electrohydraulic controls and conventional steering
will not have circuit breakers that are located in the
cab.
i01921776
Cooling System Coolant (ELC)

- Change g00807153
Illustration 180
SMCS Code: 1350-044-NL
The cooling system pressure cap (1) is located under
the engine hood at the rear of the machine.
1. Slowly loosen the cooling system pressure cap in

Pressurized system: Hot coolant can cause seri-
order to relieve any system pressure.
ous burn. To open cap, stop engine, wait until ra-
diator is cool. Then loosen cap slowly to relieve
2. Open the access door on the left side of the
the pressure.
machine in order to access coolant drain valve (2).
Open the drain valve at the bottom of the radiator.
NOTICE Allow the coolant to drain into a suitable container.
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test- 3. Flush the cooling system with clean water until the
ing, adjusting and repair of the product. Be prepared to draining water is clean. Close drain valve (2).
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo- 4. Replace the water temperature regulator.
nent containing fluids.
Reference: Refer to Operation and Maintenance
Refer to Special Publication, NENG2500, “Caterpillar Manual, “Cooling System Water Temperature
Tools and Shop Products Guide” for tools and supplies Regulator - Replace” for the correct procedure.
suitable to collect and contain fluids on Caterpillar
products.
Dispose of all fluids according to local regulations and

mandates.
126 SEBU7458-07
Maintenance Section
Cooling System Coolant Extender (ELC) - Add
i01921794
NOTICE
Topping off or mixing Cat ELC with other products that
Cooling System Coolant
do not meet Caterpillar EC-1 specifications reduces Extender (ELC) - Add
the effectiveness of the coolant and shortens coolant
service life. SMCS Code: 1352-544-NL
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
the pressure.
shortened cooling system component life.
5. Add the Extended Life Coolant. NOTICE

Reference: Refer to Operation and Maintenance during performance of inspection, maintenance, test-
Manual, “Capacities (Refill)” for the capacity of ing, adjusting and repair of the product. Be prepared to
the cooling system. collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
6. Start the engine. Run the engine without the nent containing fluids.
cooling system pressure cap until the water
temperature regulator opens and the coolant level Refer to Special Publication, NENG2500, “Caterpillar
stabilizes. Tools and Shop Products Guide” for tools and supplies
products.

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

that have passed the Caterpillar EC-1 specification for
Illustration 181
g01000160 pre-mixed or concentrate coolants. Use only Extender
with Cat ELC.
7. Maintain the coolant level in sight gauge (3) on
the upper radiator. Failure to follow these recommendations can result in
shortened cooling system component life.
8. Install the cooling system pressure cap. Stop the
engine. When a Caterpillar Extended Life Coolant (ELC) is
used, an Extender must be added to the cooling
system.
Use a 8T-5296 Coolant Test Kit to check the

concentration of the coolant.
Reference: For additional information about

the addition of Extender, refer to Special
Publication, SEBU6250, “Caterpillar Machine Fluids
Recommendations” or consult your Caterpillar dealer.
SEBU7458-07 127
Maintenance Section
Cooling System Coolant Level - Check
5. Install the cooling system pressure cap. Close the

engine hood.
i01921821
Cooling System Coolant Level

- Check
SMCS Code: 1350-535-FLV

the pressure.
g00807153
Illustration 182
Cooling system pressure cap (1) is located under the

hood at the rear of the machine. Tilt the hood in order
to access the cooling system pressure cap.
1. Slowly loosen the cooling system pressure cap in

order to relieve any system pressure. Remove the
cooling system pressure cap.
2. If necessary, drain enough coolant from the

radiator in order to allow the addition of the Illustration 184
g01000175
Extender to the cooling system. The cooling
system drain valve (2) is located on the lower left Open the access door on the left side of the machine.
side of the radiator. Coolant level sight gauge (1) is located on the top
radiator.
3. Add 1.18 L (40 fl oz) of Extender to the cooling
system. Maintain the coolant level within the sight gauge. Add
coolant, if necessary.
Note: If it is necessary to add coolant daily, inspect

the cooling system for leaks.
i02250368

Sample (Level 1) - Obtain
SMCS Code: 1350-008; 1395-008; 7542
Note: It is not necessary to obtain a Coolant

g01000160 Sample (Level 1) if the cooling system is filled
Illustration 183
with Cat ELC (Extended Life Coolant). Cooling
systems that are filled with Cat ELC should have
4. Check the coolant level at sight gauge (3). a Coolant Sample (Level 2) that is obtained at
the recommended interval that is stated in the
Reference: Refer to Operation and Maintenance Maintenance Interval Schedule.
Manual, “Cooling System Coolant Level - Check”
for the correct procedure.
128 SEBU7458-07
Maintenance Section
Cooling System Coolant Sample (Level 2) - Obtain
Note: Obtain a Coolant Sample (Level 1) if the • Keep the unused sampling bottles stored in plastic
cooling system is filled with any other coolant bags.
instead of Cat ELC. This includes the following
types of coolants. • Obtain coolant samples directly from the coolant
sample port. You should not obtain the samples
• Commercial long life coolants that meet the from any other location.
Caterpillar Engine Coolant Specification -1
(Caterpillar EC-1) • Keep the lids on empty sampling bottles until you
are ready to collect the sample.
• Cat Diesel Engine Antifreeze/Coolant (DEAC)
• Place the sample in the mailing tube immediately
• Commercial heavy-duty coolant/antifreeze after obtaining the sample in order to avoid
contamination.
NOTICE
Always use a designated pump for oil sampling, and • Never collect samples from expansion bottles.
use a separate designated pump for coolant sampling.
Using the same pump for both types of samples may • Never collect samples from the drain for a system.
contaminate the samples that are being drawn. This
contaminate may cause a false analysis and an incor- Submit the sample for Level 1 analysis.
rect interpretation that could lead to concerns by both
dealers and customers. For additional information about coolant analysis, see
Special Publication, SEBU6250, “Caterpillar Machine
Fluids Recommendations” or consult your Caterpillar
Note: Level 1 results may indicate a need for dealer.
Level 2 Analysis.
i02059852

Sample (Level 2) - Obtain
SMCS Code: 1350-008; 1395-008; 7542
NOTICE
Always use a designated pump for oil sampling, and
use a separate designated pump for coolant sampling.
Using the same pump for both types of samples may
contaminate the samples that are being drawn. This
contaminate may cause a false analysis and an incor-
g01055516 rect interpretation that could lead to concerns by both
Illustration 185
dealers and customers.
The sampling valve (1) for the cooling system is
located on top of the engine toward the front of the
engine on the right side of the engine.
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: g01055516
Illustration 186
• Complete the information on the label for the

sampling bottle before you begin to take the The sampling valve (1) for the cooling system is
samples. located on top of the engine toward the front of the
engine on the right side of the machine.
SEBU7458-07 129
Maintenance Section
Cooling System Water Temperature Regulator - Replace
Obtain the sample of the coolant as close as possible

to the recommended sampling interval. Supplies
for collecting samples can be obtained from your
Caterpillar dealer.
Refer to Operation and Maintenance Manual,

“Cooling System Coolant Sample (Level 1) - Obtain”
for the guidelines for proper sampling of the coolant.
Submit the sample for Level 2 analysis.
Reference: For additional information about coolant

analysis, refer to Special Publication, SEBU6250,
“Caterpillar Machine Fluids Recommendations” or
consult your Caterpillar dealer. g01000190
Illustration 187
Water temperature regulator housing
i01921913
Replace the water temperature regulator in order
Cooling System Water to reduce the chance of problems with the cooling
Temperature Regulator - system.
Replace Replace the water temperature regulator and the
seals while the cooling system is completely drained
SMCS Code: 1355-510; 1393-010 or while the coolant is drained to a level that is below
the water temperature regulator housing.
Note: If you are only replacing the water temperature

Pressurized system: Hot coolant can cause seri- regulator, drain the coolant to a level that is below the
ous burn. To open cap, stop engine, wait until ra- water temperature regulator housing.
the pressure. Reference: Refer to Disassembly and Assembly,
SENR9537, “3176C and 3196 Engines for Caterpillar
Built Machines” for the correct procedure for replacing
NOTICE the water temperature regulator.
Failure to replace the engine’s thermostat on a regu-
larly scheduled basis could cause severe engine dam-
age. i01921952
Differential and Final Drive Oil

NOTICE - Change
Caterpillar engines incorporate a shunt design cooling
system and require operating the engine with a ther- SMCS Code: 3278-044; 4011-044
mostat installed.
NOTICE
If the thermostat is installed wrong, it will cause the
engine to overheat. Inspect gaskets before assembly
during performance of inspection, maintenance, test-
and replace if worn or damaged.
ing, adjusting and repair of the product. Be prepared to
Refer to Special Publication, NENG2500, “Caterpillar

Tools and Shop Products Guide” for tools and supplies
products.

mandates.
130 SEBU7458-07
Maintenance Section
Differential and Final Drive Oil Level - Check
4. Remove the dipstick/fill plugs. Fill each axle with

1.0 L (1.06 qt) of 1U-9891 Hydraulic Oil Additive.
Fill the axles with oil.

Manual, “Lubricant Viscosities and Refill
Capacities” for the type of lubricant and for the
refill capacity.
5. Clean the dipstick/fill plugs and install the

dipstick/fill plugs.
6. 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.
g00287529 i01102280
Illustration 188
Front axle Differential and Final Drive Oil
Level - Check
SMCS Code: 3278-535-FLV; 4011-535-FLV
Note: Before you measure the oil level, operate the

machine for a few minutes in order to equalize the
oil level.
1. Park the machine on level ground. Lower the

bucket and apply slight downward pressure.
Engage the parking brake. Stop the engine.
g00287531
Illustration 189
Rear axle
Note: The axle housings are equipped with ecology

drain valves.
1. Remove drain plugs (2). Attach a hose to a

126-7914 Oil Drain Coupling. Install the threaded
end of the coupling into the drain valve. Allow the
oil to drain into a suitable container.
2. Clean the drain plugs and install the drain plugs. g00285312
Illustration 190
3. Wipe off dipstick/fill plugs (1) and the surfaces Front Axle
around dipstick/fill plugs (1).
SEBU7458-07 131
Maintenance Section
Differential and Final Drive Oil Sample - Obtain
i01921974
Differential and Final Drive Oil

Sample - Obtain
SMCS Code: 3278-008; 4011-008; 4070-008; 7542
NOTICE

products.
g00287527 Dispose of all fluids according to local regulations and

Illustration 191
mandates.
Rear Axle
2. Remove dipstick/fill plug (1) on the left side of the 1. Operate the machine for a few minutes before
axle. Wipe off the level gauge with a clean cloth obtaining the oil sample. This will thoroughly mix
and reinsert the plug. This will ensure a more the differential oil for a more accurate sample.
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
installed completely, an incorrect oil level reading can
occur.
3. Remove dipstick/fill plug (1) again and check the

oil level. Maintain the oil level between the ADD
mark and the FULL mark. Add oil, if necessary.

refill capacity. g00884056
Illustration 192
4. Clean the plug and install the plug. Rear axle
g00884059
Illustration 193
Front axle
132 SEBU7458-07
Maintenance Section
Drive Shaft Spline (Center) - Lubricate
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.
Extract the oil through the filler openings on the
differential and final drives.
3. Complete any additional required work. Fill the

differential and final drives with oil, as required.
Install the dipstick/fill plugs.
Reference: For more information, refer to Special

Recommendations”, “S·O·S Oil Analysis” and Special
Publication, PEHP6001, “How To Take A Good Oil
Sample”.
i01922113
Drive Shaft Spline (Center) -

Lubricate Illustration 194
g01000590
SMCS Code: 3253-086-SN 3. Apply grease to the fitting (1). Apply grease until
the relief (2) overruns.
Wipe all of the fittings before you apply grease to
the fittings. Note: 5P-0960 Molybdenum Grease is preferred.
1P-0808 Multipurpose Grease may be used.
NOTICE
To prevent damage to the seal, articulate the machine 4. Start the engine. Raise the bucket. Release
full right or left, before lubricating the splines. the parking brake. Reposition the machine in a
straight direction without articulation.
1. Start the engine. Raise the bucket. Release the 5. Lower the bucket to the ground. Apply a slight
parking brake. Articulate the machine to the right down pressure. Engage the parking brake. Stop
or to the left in order to gain better access to the the engine.
splined shaft.
2. Lower the bucket to the ground. Engage the

parking brake. Stop the engine.
SEBU7458-07 133
Maintenance Section
Drive Shaft Support Bearing - Lubricate
i02407815
Drive Shaft Support Bearing -

Lubricate
SMCS Code: 3267-086-BD
S/N: AXC1-Up
S/N: AXJ1-Up
S/N: AXN1-Up
S/N: AWP1-Up
S/N: ANT1-Up g00882522
Illustration 196
S/N: ANY1-Up
Apply lubricant through two fittings on each universal
S/N: AWY1-Up joints. There is a total of ten fittings.
S/N: ANZ1-Up
Note: Use only 1P-0808 Multipurpose Grease. Do
NOT use Molybdenum Disulfide Grease.
i02061807
switch is in the OFF position and that the parking
brake is engaged before entering the articulation
Electronic Unit Injector -
area. Failure to do so could result in serious injury Inspect/Adjust
or death.
SMCS Code: 1251-025; 1251-040; 1290-025;
1290-040
The Electronic Control module produces high

voltage. To prevent personal injury make sure the
Electronic Control Module is not powered and the
unit injector solenoids are disconnected.
NOTICE
The camshafts must be correctly timed with the crank-
shaft before an adjustment of the unit injector lash
is made. The timing pins must be removed from the
Illustration 195
g00807149 camshafts before the crankshaft is turned or damage
to the cylinder block will be the result.
The operation of Caterpillar engines with improper
Apply lubricant through one remote fitting near the adjustments of the electronic unit injector can reduce
articulation joint on the left side of the machine. engine efficiency. This reduced efficiency could result
in excessive fuel usage and/or shortened engine
i01714637 component life.
Drive Shaft Universal Joints - Adjust the electronic unit injector at the same interval
Lubricate as the valve lash adjustment.
Refer to your machine’s Service Manual or your

SMCS Code: 3251-086
Caterpillar dealer for the complete adjustment
procedure.
134 SEBU7458-07
Maintenance Section
Engine Air Filter Primary Element - Clean/Replace
i01605387 Cleaning Primary Air Filter

Engine Air Filter Primary Elements
Element - Clean/Replace NOTICE
Caterpillar recommends certified air filter cleaning ser-
SMCS Code: 1054-070-PY; 1054-510-PY vices available at participating Caterpillar dealers. The
Caterpillar cleaning process uses proven procedures
1. The rear hood should be opened in order to to assure consistent quality and sufficient filter life.
access the air filter. The air filter is located on the
right side of the machine. Observe the following guidelines if you attempt to
clean the filter element:
Do not tap or strike the filter element in order to re-

move dust.
Do not wash the filter element.
Use low pressure compressed air in order to remove

the dust from the filter element. Air pressure must not
exceed 207 kPa (30 psi). Direct the air flow up the
pleats and down the pleats from the inside of the filter
element. Take extreme care in order to avoid damage
to the pleats.
g00806893 Do not use air filters with damaged pleats, gaskets, or

Illustration 197
seals. Dirt entering the engine will cause damage to
engine components.
2. Remove the cover on air filter housings (3).
3. Remove primary element (2) from the air filter The primary air filter element can be used up to
housing. six times if the element is properly cleaned and
inspected. When the primary air filter element is
4. Clean the inside of air filter housing (1). cleaned, check for rips or tears in the filter material.
The primary air filter element should be replaced at
5. Inspect the primary element. If the pleats, the least one time per year. This replacement should be
gaskets, or the seals are damaged, discard the performed regardless of the number of cleanings.
element. Replace a damaged primary element
with a clean primary element.
NOTICE
Do not clean the air filter elements by bumping or tap-
ping. This could damage the seals. Do not use ele-
ments with damaged pleats, gaskets, or seals. Dam-
aged elements will allow dirt to pass through. Engine
damage could result.
Visually inspect the primary air filter elements before

cleaning. Inspect the air filter elements for damage
to the seal, the gaskets, and the outer cover. Discard
any damaged air filter elements.
There are two common methods that are used to

clean primary air filter elements:
• Pressurized air
• Vacuum cleaning
SEBU7458-07 135
Maintenance Section
Engine Air Filter Primary Element - Clean/Replace
Pressurized Air Inspecting the Primary Air Filter

Pressurized air can be used to clean primary air filter
Elements
elements that have not been cleaned more than two
times. Pressurized air will not remove deposits of
carbon and oil. Use filtered, dry air with a maximum
pressure of 207 kPa (30 psi).
g00281693
Illustration 199
Inspect the clean, dry primary air filter element. Use

a 60 watt blue light in a dark room or in a similar
g00281692
facility. Place the blue light in the primary air filter
Illustration 198 element. Rotate the primary air filter element. Inspect
the primary air filter element for tears and/or holes.
Note: When the primary air filter elements are Inspect the primary air filter element for light that may
cleaned, always begin with the clean side (inside) show through the filter material. If it is necessary in
in order to force dirt particles toward the dirty side order to confirm the result, compare the primary air
(outside). filter element to a new primary air filter element that
has the same part number.
Aim the hose so that the air flows inside the element
along the length of the filter in order to help prevent Do not use a primary air filter element that has any
damage to the paper pleats. Do not aim the stream of tears and/or holes in the filter material. Do not use
air directly at the primary air filter element. Dirt could a primary air filter element with damaged pleats,
be forced further into the pleats. gaskets or seals. Discard damaged primary air filter
elements.
Vacuum Cleaning
Storing Primary Air Filter Elements
Vacuum cleaning is another method for cleaning
primary air filter elements which require daily cleaning If a primary air filter element that passes inspection
because of a dry, dusty environment. Cleaning with will not be used, the primary air filter element can
pressurized air is recommended prior to vacuum be stored for future use.
cleaning. Vacuum cleaning will not remove deposits
of carbon and oil.
g00281694
Illustration 200
136 SEBU7458-07
Maintenance Section
Engine Air Filter Secondary Element - Replace
Do not use paint, a waterproof cover, or plastic as a

protective covering for storage. An airflow restriction
may result. To protect against dirt and damage, wrap
the primary air filter elements in Volatile Corrosion
Inhibited (VCI) paper.
Place the primary air filter element into a box for

storage. For identification, mark the outside of the
box and mark the primary air filter element. Include
the following information:
• Date of cleaning
• Number of cleanings
g00864077
Store the box in a dry location. Illustration 201
2. Remove the secondary element.

i01693619
Engine Air Filter Secondary

Element - Replace
SMCS Code: 1054-510-SE
NOTICE
Service the air filter only with the engine stopped. En-
gine damage could result.
NOTICE
Always replace the secondary element. Do not at-
tempt to reuse it by cleaning. Engine damage could g00864079
Illustration 202
result.
3. Cover the air inlet opening. Clean the inside of
Note: Replace the secondary element when you the air cleaner housing.
service the primary element for the third time. If
a clean primary element has been installed and 4. Inspect the gasket between the air inlet pipe and
a warning for the air filter still occurs, replace the the air cleaner housing. Replace the gasket if the
secondary element. Also if the exhaust smoke gasket is damaged.
remains black and a clean primary element has been
installed, replace the secondary element. 5. Uncover the air inlet opening. Install a new
secondary element.
1. Remove the primary element.
6. Install a clean primary element and the cover for
Reference: Refer to Operation and Maintenance the air cleaner housing.
Manual, “Engine Air Filter Primary Element -
Clean/Replace” for the correct procedure. 7. Close the access door.
8. Repeat the procedure for the other air cleaner.

SEBU7458-07 137
Maintenance Section
Engine Air Precleaner - Clean
i01715277 i01424864
Engine Air Precleaner - Clean Engine Crankcase Breather -

SMCS Code: 1055-070 Clean
SMCS Code: 1317-070
g00882640
Illustration 203
NOTICE
Service the air cleaner only with the engine stopped.
Engine damage could result.
1. Remove the precleaner.

g00758107
Illustration 204
2. Inspect the air inlet screen for dirt and for trash.
Remove the screen. Clean the screen if the Open the hood on the rear of machine in order to
screen is dirty. access the engine compartment. The crankcase
breather is located on the right side of the engine.
3. Inspect the precleaner tube openings. Remove
dirt and debris. 1. Remove the four bolts (1) that hold the breather
(3) onto the cover. Remove the breather.
4. Clean the precleaner with compressed air or wash
the precleaner in warm water. Dry all the parts. 2. Check the condition of the cover seal (5). Replace
the seal if the seal is damaged.
5. Install the precleaner screen.
3. Wash the breather (3) and the filter element (4) in
a clean nonflammable solvent.
4. Shake the breather or use pressure air in order

to dry the breather.
5. Inspect the hose for damage. Replace the hose if

it is necessary.
6. Install the breather assembly. Install the hose and

install the hose clamp.
7. Close the access door.

138 SEBU7458-07
Maintenance Section
Engine Oil (High Speed) and Oil Filter - Change
i02102142 Abnormally harsh operating cycles or harsh

environments can shorten the service life of
Engine Oil (High Speed) and the engine oil. Arctic temperatures, corrosive
Oil Filter - Change environments, or extremely dusty conditions may
require a reduction in engine oil change intervals
SMCS Code: 1318-510-HZ from the recommendations in Table 15 and Table 16.
Also refer to Special Publication, SEBU5898, “Cold
Weather Recommendations”. Poor maintenance of
Selection of the Oil Change Interval air filters or of fuel filters requires reduced oil change
intervals. See your Caterpillar dealer for more
NOTICE information if this product will experience abnormally
This machine is equipped with an engine that meets harsh operating cycles or harsh environments.
EPA Tier 2, Euro Stage II, or MOC Step 2 emission
regulations. A 500 hour engine oil change interval is
available, provided that operating conditions and rec-
ommended multigrade oil types are met. When these
requirements are not met, shorten the oil change
interval to 250 hours, or use an S·O·S oil sampling
and analysis program to determine an acceptable oil
change interval.
If you select an interval for oil and filter change that is

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

15 and in Table 16. Do not use single grade oils.
g00753767
Illustration 205
API Trademark
Commercial oils that are licensed by the American Petroleum
Institute (API) bear this trademark. Commercial oils that do
not bear this trademark are not licensed and these oils are not
recommended. Oils that are not listed in Table 15 and in Table 16
are not recommended.
SEBU7458-07 139
Maintenance Section
Table 15 Table 16
966G Series II Wheel Loader 972G Series II Wheel Loader
Engine Oil Change Interval(1) Engine Oil Change Interval(1)
Operating Conditions Operating Conditions
Severe Severe
Normal(2) High Fuel Altitude Normal(2) High Fuel Altitude
Load Sulfur above Load Sulfur above
Multigrade Factor(3) from 1830 m Multigrade Factor(3) from 1830 m
Oil Type above 0.3% to (6000 ft) Oil Type above 0.3% to (6000 ft)
27 L 0.5% 30 L 0.5%
(7.1 US (4)
(7.9 US (4)
gal) per gal) per
hr of hr of
fuel fuel
Cat DEO Cat DEO
500 hr 500 hr 500 hr 250 hr(6) 500 hr 500 hr 500 hr 250 hr(6)
Preferred Preferred
API CH-4 API CH-4
11.0 11.0
minimum 500 hr 500 hr 500 hr 250 hr(6) minimum 500 hr 500 hr 500 hr 250 hr(6)
TBN(4) TBN(4)
Preferred Preferred
API CH-4 API CH-4
TBN(4) 500 hr 500 hr 250 hr(5) 250 hr(6) TBN(4) 500 hr 500 hr 250 hr(5) 250 hr(6)
below 11.0 below 11.0
API CG-4 250 hr (5) 250 hr(5) 250 hr(5) 250 hr(6) API CG-4 250 hr (5) 250 hr(5) 250 hr(5) 250 hr(6)
API CF-4 250 hr (6) 250 hr(6) 250 hr(6) 250 hr(6) API CF-4 250 hr (6) 250 hr(6) 250 hr(6) 250 hr(6)
(1) The traditional oil change interval for engines is 250 hours. The (1) The traditional oil change interval for engines is 250 hours. The
standard oil change interval in this machine is 500 hours, if the standard oil change interval in this machine is 500 hours, if the
operating conditions and recommended oil types that are listed operating conditions and recommended oil types that are listed
in this table are met. Improvements in the engine allow this in this table are met. Improvements in the engine allow this
engine oil change interval. This new standard interval is not engine oil change interval. This new standard interval is not
permitted for other machines. Refer to the applicable Operation permitted for other machines. Refer to the applicable Operation
and Maintenance Manuals for the other machines. and Maintenance Manuals for the other machines.
(2) Normal conditions include these factors: Fuel sulfur below (2) Normal conditions include these factors: Fuel sulfur below
0.3%, altitude below 1830 m (6000 ft), and good air filter and 0.3%, altitude below 1830 m (6000 ft), and good air filter and
fuel filter maintenance. Normal conditions do not include high fuel filter maintenance. Normal conditions do not include high
load factor, harsh operating cycles, or harsh environments. load factor, harsh operating cycles, or harsh environments.
(3) High load factors can shorten the service life of your engine oil. (3) High load factors can shorten the service life of your engine oil.
Continuous heavy load cycles and very little idle time result Continuous heavy load cycles and very little idle time result
in increased fuel consumption and oil contamination. These in increased fuel consumption and oil contamination. These
factors deplete the oil additives more rapidly. If the average fuel factors deplete the oil additives more rapidly. If the average fuel
consumption of your 966G Series II Wheel Loader exceeds consumption of your 972G Series II Wheel Loader exceeds
27 L (7.1 US gal) per hour, follow the “High Load Factor” 30 L (7.9 US gal) per hour, follow the “High Load Factor”
recommendations in Table 15. To determine average fuel recommendations in Table 16. To determine average fuel
consumption, measure average fuel consumption for a period consumption, measure average fuel consumption for a period
of 50 to 100 hours. If the application of the machine is changed, of 50 to 100 hours. If the application of the machine is changed,
the average fuel consumption may change. the average fuel consumption may change.
(4) For sulfur content above 0.5%, refer to Operation and (4) For sulfur content above 0.5%, refer to Operation and
Maintenance Manual, “Total Base Number (TBN) and Fuel Maintenance Manual, “Total Base Number (TBN) and Fuel
Sulfur Levels for Direct Injection (DI) Diesel Engines” in the Sulfur Levels for Direct Injection (DI) Diesel Engines” in the
“Lubricant” section of this manual. Also, you may refer to this “Lubricant” section of this manual. Also, you may refer to this
topic in Special Publication, SEBU6250. topic in Special Publication, SEBU6250.
(5) In order to verify an oil change interval of 500 hours, refer to (5) In order to verify an oil change interval of 500 hours, refer to
“Program A” below. “Program A” below.
(6) Use “Program B” below to determine an appropriate interval. (6) Use “Program B” below to determine an appropriate interval.
Adjustment of the Oil Change Interval

Note: Your Caterpillar dealer has additional
information on these programs.
140 SEBU7458-07
Maintenance Section
Program A Procedure for Changing the Engine

Verification for an Oil Change Interval of 500 Hours
Oil and Filter
This program consists of three oil change intervals of NOTICE
500 hours. Oil sampling and analysis is done at 250 Care must be taken to ensure that fluids are contained
hours and 500 hours for each of the three intervals during performance of inspection, maintenance, test-
for a total of six oil samples. The analysis includes ing, adjusting and repair of the product. Be prepared to
oil viscosity and infrared (IR) analysis of the oil. If collect the fluid with suitable containers before open-
all of the results are satisfactory, the 500 hour oil ing any compartment or disassembling any compo-
change interval is acceptable for the machine in that nent containing fluids.
application. Repeat Program A if you change the
application of the machine. Refer to Special Publication, NENG2500, “Caterpillar
If a sample does not pass the oil analysis, take one suitable to collect and contain fluids on Caterpillar
of these actions: products.
• Shorten the oil change interval to 250 hours. Dispose of all fluids according to local regulations and
mandates.
• Proceed to Program B.
Your machine may be equipped with a high speed
• Change to a preferred oil type in Table 15 or Table arrangement for changing the engine oil. The high
16. speed arrangement allows service personnel to
change the oil from the engine access door on
Program B the right side of the machine. The high speed
arrangement allows the oil to be changed faster than
Optimizing Oil Change Intervals conventional methods.
Begin with a 250 hour oil change interval. The oil

change intervals are adjusted by increments. Each
interval is adjusted an additional 50 hours. Periodic oil
sampling and analysis is done during each interval.
The analysis includes oil viscosity and infrared (IR)
analysis of the oil. Repeat Program B if you change
the application of the machine.
If an oil sample does not pass the analysis, shorten

the oil change interval, or change to a preferred
multigrade oil type in the listing above.
References
Reference: Form, PEDP7035, “Optimizing Oil

Change Intervals”
Reference: Form, PEDP7036, “S·O·S Fluid Analysis”
Reference: Form, PEHP7076, “Understanding S·O·S

Services Test” Illustration 206
g00812715
1. Open the service door that is located on the right

side of the machine.
2. Remove the cap that protects the male coupler.

Connect an oil pump to the fitting. The fitting on
the machine is a male coupler.
3. Turn on the oil pump and withdraw the engine oil

from the engine oil pan.
4. Open the engine hood.

SEBU7458-07 141
Maintenance Section
Engine Oil Level - Check
9. Tighten the filter according to the instructions that

are printed on the filter. Use the index marks as
a guide.
10. Connect an oil pump to the male coupler for the

high speed arrangement. Fill the crankcase with
new oil.

Capacities” for the correct type of oil and for the
correct amount of oil.
11. Clean the end of the male coupler. Clean the cap
that covers the male coupler and install the cap.
12. Start the engine and allow the oil to warm. Check
the machine for oil leaks.
13. Check the engine oil level.
Illustration 207
g00812740 Reference: Refer to Operation and Maintenance
The engine oil filter is located on the left side of the machine.
Manual, “Engine Oil Level - Check” for the correct
procedure.
5. Use a strap type wrench to remove the filter
element (1). Inspect the filter. 14. Stop the engine. Close the engine access door
and the engine hood.
Manual, “Oil Filter - Inspect”. i02097829
6. Clean the filter mounting base with a clean cloth. Engine Oil Level - Check
Make sure that the used filter gasket has been
completely removed. SMCS Code: 1000-535-FLV
g00101318
Illustration 208
7. Apply a thin film of clean engine oil to the sealing

surface of the new filter element.
8. Install the engine oil filter element (1) hand tight

until the seal of the engine oil filter element (1) Illustration 209
g00882679
contacts the oil filter base.
Open the service door that is located on the right
Note: Note the position of the index marks on the side of the machine. The oil level dipstick is located
oil filter element (1) in relation to a fixed point on the in the service door.
filter base.
142 SEBU7458-07
Maintenance Section
Engine Oil Sample - Obtain
g00746755 g01000614
Illustration 210 Illustration 211
The sampling valve is located on the left side of the engine
Maintain the oil level between the FULL mark and compartment.
ADD mark on the dipstick. Check the level of the
engine oil while the engine is shut off. Add oil, if 3. Use the sampling valve in order to obtain a
necessary. sample of engine oil.
4. Close the engine hood.

i01922669
Engine Oil Sample - Obtain Reference: For more information, refer to Special
SMCS Code: 1348-008; 7542 Recommendations”, “S·O·S Oil Analysis” and Special
Sample”.
NOTICE
during performance of inspection, maintenance, test- i02093702
collect the fluid with suitable containers before open- Engine Oil and Filter - Change
nent containing fluids. SMCS Code: 1318-510
Refer to Special Publication, NENG2500, “Caterpillar Selection of the Oil Change Interval
products. NOTICE
This machine is equipped with an engine that meets
Dispose of all fluids according to local regulations and EPA Tier 2, Euro Stage II, or MOC Step 2 emission
mandates. regulations. A 500 hour engine oil change interval is
available, provided that operating conditions and rec-
ommended multigrade oil types are met. When these
1. Operate the machine for a few minutes before requirements are not met, shorten the oil change
obtaining the oil sample. This will thoroughly mix interval to 250 hours, or use an S·O·S oil sampling
the engine oil for a more accurate sample. and analysis program to determine an acceptable oil
change interval.
2. Open the engine hood.
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

17 and in Table 18. Do not use single grade oils.
SEBU7458-07 143
Maintenance Section
Engine Oil and Filter - Change
Table 17
966G Series II Wheel Loader
Engine Oil Change Interval(1)
Operating Conditions
Severe
Normal(2) High Fuel Altitude
Load Sulfur above
Multigrade Factor(3) from 1830 m
Oil Type above 0.3% to (6000
27 L 0.5% ft)
(7.1 US (4)
gal) per
hr of
g00753767 fuel
Illustration 212
API Trademark Cat DEO
500 hr 500 hr 500 hr 250 hr(6)
Preferred
Commercial oils that are licensed by the American Petroleum
Institute (API) bear this trademark. Commercial oils that do API CH-4
not bear this trademark are not licensed and these oils are not 11.0
recommended. Oils that are not listed in Table 17 and in Table 18
minimum 500 hr 500 hr 500 hr 250 hr(6)
are not recommended.
TBN(4)
Preferred
Abnormally harsh operating cycles or harsh
environments can shorten the service life of API CH-4
the engine oil. Arctic temperatures, corrosive TBN(4) 500 hr 500 hr 250 hr(5) 250 hr(6)
environments, or extremely dusty conditions may below 11.0
require a reduction in engine oil change intervals API CG-4 250 hr (5) 250 hr(5) 250 hr(5) 250 hr(6)
from the recommendations in Table 17 and Table 18.
Also refer to Special Publication, SEBU5898, “Cold API CF-4 250 hr (6) 250 hr(6) 250 hr(6) 250 hr(6)
Weather Recommendations”. Poor maintenance of (1) The traditional oil change interval for engines is 250 hours. The
air filters or of fuel filters requires reduced oil change standard oil change interval in this machine is 500 hours, if the
intervals. See your Caterpillar dealer for more operating conditions and recommended oil types that are listed
in this table are met. Improvements in the engine allow this
information if this product will experience abnormally engine oil change interval. This new standard interval is not
harsh operating cycles or harsh environments. 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 966G Series II Wheel Loader exceeds
27 L (7.1 US gal) per hour, follow the “High Load Factor”
recommendations in Table 17. To determine average fuel
consumption, measure average fuel consumption for a period
of 50 to 100 hours. If the application of the machine is changed,
the average fuel consumption may change.
(4) For sulfur content above 0.5%, refer to Operation and
Maintenance Manual, “Total Base Number (TBN) and Fuel
Sulfur Levels for Direct Injection (DI) Diesel Engines” in the
“Lubricant” section of this manual. Also, you may refer to this
topic in Special Publication, SEBU6250.
(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.
144 SEBU7458-07
Maintenance Section
Table 18 Program A
972G Series II Wheel Loader
Engine Oil Change Interval(1) Verification for an Oil Change Interval of 500 Hours
Operating Conditions This program consists of three oil change intervals of

Severe 500 hours. Oil sampling and analysis is done at 250
hours and 500 hours for each of the three intervals
Normal(2) High Fuel Altitude for a total of six oil samples. The analysis includes
Load Sulfur above oil viscosity and infrared (IR) analysis of the oil. If
Multigrade Factor(3) from 1830 m
Oil Type
all of the results are satisfactory, the 500 hour oil
above 0.3% to (6000 change interval is acceptable for the machine in that
30 L 0.5% ft)
(7.9 US application. Repeat Program A if you change the
gal) per
(4)
application of the machine.
hr of
fuel If a sample does not pass the oil analysis, take one
of these actions:
Cat DEO
500 hr 500 hr 500 hr 250 hr(6)
Preferred
• Shorten the oil change interval to 250 hours.
API CH-4
11.0 • Proceed to Program B.
minimum 500 hr 500 hr 500 hr 250 hr(6)
TBN(4) • Change to a preferred oil type in Table 17 or Table
Preferred 18.
API CH-4
TBN(4) 500 hr 500 hr 250 hr(5) 250 hr(6) Program B
below 11.0
Optimizing Oil Change Intervals
API CG-4 250 hr (5) 250 hr(5) 250 hr(5) 250 hr(6)
API CF-4 250 hr (6) 250 hr(6) 250 hr(6) 250 hr(6) Begin with a 250 hour oil change interval. The oil
(1) The traditional oil change interval for engines is 250 hours. The
change intervals are adjusted by increments. Each
standard oil change interval in this machine is 500 hours, if the interval is adjusted an additional 50 hours. Periodic oil
operating conditions and recommended oil types that are listed sampling and analysis is done during each interval.
in this table are met. Improvements in the engine allow this The analysis includes oil viscosity and infrared (IR)
engine oil change interval. This new standard interval is not analysis of the oil. Repeat Program B if you change
permitted for other machines. Refer to the applicable Operation
and Maintenance Manuals for the other machines.
the application of the machine.
(2) Normal conditions include these factors: Fuel sulfur below
0.3%, altitude below 1830 m (6000 ft), and good air filter and If an oil sample does not pass the analysis, shorten
fuel filter maintenance. Normal conditions do not include high the oil change interval, or change to a preferred
load factor, harsh operating cycles, or harsh environments. multigrade oil type in the listing above.
(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 References
factors deplete the oil additives more rapidly. If the average fuel
consumption of your 972G Series II Wheel Loader exceeds Reference: Form, PEDP7035, “Optimizing Oil
30 L (7.9 US gal) per hour, follow the “High Load Factor” Change Intervals”
recommendations in Table 18. To determine average fuel
consumption, measure average fuel consumption for a period
of 50 to 100 hours. If the application of the machine is changed, Reference: Form, PEDP7036, “S·O·S Fluid Analysis”
the average fuel consumption may change.
(4) For sulfur content above 0.5%, refer to Operation and Reference: Form, PEHP7076, “Understanding S·O·S
Maintenance Manual, “Total Base Number (TBN) and Fuel Services Test”
Sulfur Levels for Direct Injection (DI) Diesel Engines” in the
“Lubricant” section of this manual. Also, you may refer to this
topic in Special Publication, SEBU6250.
(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.
Adjustment of the Oil Change Interval

Note: Your Caterpillar dealer has additional
information on these programs.
SEBU7458-07 145
Maintenance Section
Procedure for Changing the Oil

NOTICE

products.
g00101318
Illustration 214
mandates. 5. Install the engine oil filter element (1) hand tight
until the seal of the engine oil filter element (1)
1. Open the engine hood. contacts the oil filter base.
2. The drain plug is located on the left side of the Note: Note the position of the index marks on the
engine oil pan toward the rear of the machine. oil filter element (1) in relation to a fixed point on the
Open the oil drain valve and allow the oil to drain filter base.
into a suitable container. Close the drain valve.
6. Tighten the filter according to the instructions that
are printed on the filter. Use the index marks as
a guide.
g01000626
Illustration 213
3. Use a strap type wrench to remove the engine

oil filter from the right side of the engine. Inspect
the oil filter.

Manual, “Oil Filter - Inspect”.
4. Clean the filter mounting base. Make sure that all g00806758
Illustration 215
of the used gasket has been completely removed.
7. Remove oil filler cap (1) on the right side of the
engine. Fill the crankcase with new oil.

8. Clean the oil filler cap and install the oil filler cap.
146 SEBU7458-07
Maintenance Section
Engine Valve Lash - Check
9. Start the engine and allow the oil to warm. Check

for any oil leaks.
10. Check the oil level on dipstick (2).

Manual, “Engine Oil Level - Check” for the correct
procedure.
11. Close the engine hood and stop the engine.
i01181536
Engine Valve Lash - Check

g00882731
Illustration 216
SMCS Code: 1105-535
Start the engine and run the engine at low idle. Watch
For the correct procedure, refer to the appropriate the top surface of each valve rotator. Whenever an
Service Manual module for your machine’s engine or inlet valve closes or an exhaust valve closes, each
consult your Caterpillar dealer. valve rotator should turn.
Note: A qualified mechanic should adjust the engine If a valve rotator fails to turn, consult your Caterpillar
valve lash because special tools and training are dealer for service.
required.
i01935374
Engine Valve Rotators - Inspect

SMCS Code: 1109-040
When inspecting the valve rotators, protective

glasses or face shield and protective clothing
must be worn, to prevent being burned by hot oil
or spray.
Caterpillar recommends replacing valve rotators that

are operating improperly. An improperly operating
valve rotator will shorten valve life because of
accelerated wear on the valves. Also, metal particles
from a damaged valve rotator could fall into the
cylinder and damage to the piston head and to the
cylinder head may result.
SEBU7458-07 147
Maintenance Section
Ether Starting Aid Cylinder - Replace
i01715493 3. Remove the gasket. Install the new gasket that is

provided with each new ether starting aid cylinder.
Ether Starting Aid Cylinder -
Replace 4. Install new ether starting aid cylinder (2) hand
tight. Tighten retaining clamp (1) securely.
(If Equipped)
SMCS Code: 1456-510-CD
i01715517
Fuel System - Prime

Ether is poisonous and flammable.
SMCS Code: 1250-548
Breathing ether vapors or repeated contact of
ether with skin can cause personal injury. NOTICE
Use ether only in well ventilated areas. during performance of inspection, maintenance, test-
Do not smoke while changing ether cylinders. collect the fluid with suitable containers before open-
Use ether with care to avoid fires. nent containing fluids.
Do not store replacement ether cylinders in living Refer to Special Publication, NENG2500, “Caterpillar
areas or in the operator’s compartment. Tools and Shop Products Guide” for tools and supplies
Do not store ether cylinders in direct sunlight or products.
at temperatures above 49 °C (120 °F).
Discard cylinders in a safe place. Do not puncture mandates.
or burn cylinders.
Keep ether cylinders out of the reach of unautho- Note: The volume of the air in the water separator
rized personnel. is small. Usually, it is not necessary to prime the
fuel system if only the water separator element was
To avoid possible injury, be sure the brakes are ap- changed.
plied and all controls are in Hold or Neutral when
starting the engine.
g00882764
Illustration 217
1. Open the access door. The ether starting aid

cylinder is mounted on the left side of the machine
next to the air cleaner.
2. Loosen retaining clamp (1) and unscrew ether

starting aid cylinder (2).
148 SEBU7458-07
Maintenance Section
Fuel System Primary Filter (Water Separator) - Drain
i01715535
Fuel System Primary Filter

(Water Separator) - Drain
SMCS Code: 1263-543
NOTICE

products.

mandates.
g00882774
Illustration 218
1. Stop the engine and open the engine hood. The

fuel priming pump is located above the primary
fuel filter on the right side of the machine. This
machine is equipped with an electric fuel priming
pump. The toggle switch for the pump is located
on the filter base. Operate the fuel pump for
approximately 60 seconds.
2. 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.
g00882783
• The engine has run out of fuel. Illustration 219
• The fuel injectors have been removed from the 1. Open the engine hood. The water separator is
engine. located on the bottom of the primary fuel filter on
the right side of the machine.
Operate an electric fuel pump for approximately 30
seconds for this additional priming. 2. Open the drain valve on the bottom of the water
separator bowl. Allow the water and the fuel to
drain into a suitable container.
3. Close the drain valve.

SEBU7458-07 149
Maintenance Section
Fuel System Primary Filter (Water Separator) Element - Replace
Note: The water separator is under suction during

normal engine operation. Tighten the drain valve
securely in order to prevent air leakage into the fuel
system.
i02250381
Fuel System Primary Filter

(Water Separator) Element -
Replace
SMCS Code: 1260-510; 1263-510-FQ
NOTICE
collect the fluid with suitable containers before open- Illustration 220
g00806773
nent containing fluids. 2. Open drain valve (3) on the bottom of water
separator bowl (2). Allow the water and the fuel to
Refer to Special Publication, NENG2500, “Caterpillar drain into a suitable container.
suitable to collect and contain fluids on Caterpillar 3. Use a strap type wrench in order to remove the
products. primary fuel filter (1). Unscrew the sediment bowl
from the fuel filter.
mandates. 4. Clean the water separator bowl and the O-ring
groove.
NOTICE
Do not fill fuel filters with fuel before installing them. Note: The water separator bowl is reusable. Do not
The fuel will not be filtered and could be contaminated. discard the water separator bowl.
Contaminated fuel will cause accelerated wear to fuel
system parts. The fuel system should be primed prior 5. Inspect the O-ring seal on the water separator
to starting the engine. bowl. Replace the O-ring seal, if necessary.
6. Lubricate the O-ring seal with clean diesel fuel or

1. Open the engine hood. The primary fuel filter is with engine oil. Place the O-ring seal in the water
located on the right side of the machine. separator bowl.
7. Install the water separator bowl onto the new filter

element until the filter element is snug.
8. Apply a thin coat of clean diesel fuel to the seal on

the new filter. Install the new fuel filter hand tight
until the seal of the fuel filter contacts the base.
Note the position of the index marks on the filter in
relation to a fixed point on the filter base.
Note: There are rotation index marks on the fuel filter

that are spaced 90 degrees or 1/4 of a turn away
from each other. When you tighten the fuel filter, use
the rotation index marks as a guide.
150 SEBU7458-07
Maintenance Section
Fuel System Secondary Filter - Replace
9. Tighten the filter according to the instructions 4. Lubricate the gasket of a new filter with clean
that are printed on the filter. Use the index marks diesel fuel.
as a guide. For non-Caterpillar filters, use the
instructions that are provided with the filter. 5. Install the new filter by hand. When the gasket
contacts the filter base, tighten the filter by an
Note: You may need to use a Caterpillar strap additional 3/4 turn.
wrench, or another suitable tool, in order to turn
the filter to the amount that is required for final There are rotation index marks on the filter at 90
installation. Make sure that the installation tool does degree intervals. Use these marks as a guide for
not damage the filter. proper tightening.
10. Close drain valve (1). NOTICE

Do not fill fuel filters with fuel before installing them.
Note: The water separator element is under suction Contaminated fuel will cause accelerated wear to fuel
during normal engine operation. Tighten the drain system parts.
valve securely in order to prevent air leakage into
the fuel system.
6. Prime the fuel system.
11. Prime the fuel system in order to fill the water
separator element with fuel. Reference: Refer to Operation and Maintenance
Manual, “Fuel System - Prime” for the correct
Reference: Refer to Operation and Maintenance procedure.
Manual, “Fuel System - Prime” for the correct
procedure. 7. Close the engine hood.

i01715574
i01922763 Fuel Tank Cap and Strainer -

Fuel System Secondary Filter - Clean
Replace SMCS Code: 1273-070-STR; 1273-070-Z2
SMCS Code: 1261-510-SE
g00882838
Illustration 222
g01000661
Illustration 221 Open the rear grill in order to access the fuel tank
cap.
1. Open the hood. Secondary fuel filter (1) is located
on the right side of the machine. 1. Lift lever (2) and turn the lever counterclockwise
until the lever stops. Remove the fuel tank cap.
2. Open drain valve (2) in order to allow fuel to flow
from the filter. The fuel will flow out of hose (3). 2. Inspect seal (4) for damage. Replace the seal, if
Catch the fuel in a suitable container and dispose necessary.
of the fuel properly. Close the drain valve. Remove
the fuel filter. Dispose of the used filter properly. 3. Remove screws (1), filter assembly (3), valve (5)
and the gaskets.
3. Clean the filter mounting base. Make sure that all
of the used gasket is removed. 4. Remove the strainer from the filler tube.
SEBU7458-07 151
Maintenance Section
Fuel Tank Water and Sediment - Drain
5. Wash the fuel tank cap and the strainer in a clean, i02069536
nonflammable solvent.
Fuses - Replace
6. Install a new cap filter kit. Install the other
components in reverse order. SMCS Code: 1417-510
7. Install the strainer and the fuel tank cap. NOTICE

Replace fuses with the same type and size only. Oth-
erwise, electrical damage can result.
i01922977
Fuel Tank Water and Sediment If it is necessary to replace fuses frequently, an electri-
cal problem may exist. Contact your Caterpillar dealer.
- Drain
SMCS Code: 1273-543-M&S Fuses – The fuses protect the electrical
system from a circuit that has been
overloaded. Change a fuse if the element
NOTICE separates. If the element of a new fuse separates,
Care must be taken to ensure that fluids are contained check the circuit. Repair the circuit, if necessary.

products.

mandates.
g01000750
Illustration 224
g01000726
Illustration 223
The drain valve is under the fuel tank at the rear of

the machine.
1. Open drain valve (1). Allow the water and the

sediment to drain into a suitable container.
2. Close the drain valve.

g01060133
Illustration 225
The fuses are located in the cab on the right side of

the operator seat.
(1) Fourth Function or Grapple ............. 10 Amperes

152 SEBU7458-07
Maintenance Section
Fuses - Replace
(2) Neutralizer Override Switch ............. 10 Amperes (29) Horn ............................................... 10 Amperes
(3) Ether Injection .................................. 10 Amperes (30) Voltage Converter Memory

(Standard) ........................................ 10 Amperes
(4) Quick Coupler .................................. 10 Amperes
(31) Key Start Switch ............................ 10 Amperes
(5) Rear Floodlights .............................. 15 Amperes
(32) Dome Lamps ................................. 10 Amperes
(6) Axle Oil Coolers ............................... 10 Amperes
i02126498
(7) Secondary Steering ......................... 10 Amperes
(8) Engine ECM ADEM III ..................... 10 Amperes

Fuses - Replace
(Machines that are Equipped
(9) Front Floodlights .............................. 15 Amperes
with Electrohydraulic Controls
(10) Beacon .......................................... 10 Amperes and Conventional Steering)
(11) Front and Rear Flasher Relays ...... 10 Amperes SMCS Code: 1417-510
(12) Product Link for the Machine Security S/N: AXJ1-Up

System ............................................. 20 Amperes
S/N: AXN1-Up
(13) Lh Indicator Display and Rh Indicator
Display ............................................. 10 Amperes NOTICE
Replace fuses with the same type and size only. Oth-
(14) Lift Position Sensor ........................ 10 Amperes erwise, electrical damage can result.
(15) Transmission ECM and the Lh Brake Pedal If it is necessary to replace fuses frequently, an electri-
Sensor ............................................. 10 Amperes cal problem may exist. Contact your Caterpillar dealer.
(16) Spare ............................................. 10 Amperes

Note: Machines that are equipped with
electrohydraulic controls and conventional steering
(17) EMS, Quad Gauge, Tachometer, and
will not have circuit breakers that are located by the
Backlights ........................................ 10 Amperes
fuse panel.
(18) Wiper and Washer for the Front and the Rear
Fuses – The fuses protect the electrical
Windows .......................................... 10 Amperes
system from a circuit that has been
overloaded. Change a fuse if the element
(19) Payload Control System ................ 15 Amperes
separates. If the element of a new fuse separates,
check the circuit. Repair the circuit, if necessary.
(20) Voltage Converter for Radio .......... 10 Amperes
(21) Center Indicator Display ................ 15 Amperes
(22) Spare ............................................. 10 Amperes
(23) Product Link ................................... 10 Amperes
(24) Voltage Converter Memory ............ 20 Amperes
(25) ECAP ............................................. 10 Amperes
(26) Lh Tail Lamps and Clearance

Lamps .............................................. 10 Amperes
(27) Hood Actuator ................................ 10 Amperes
(28) Stop Lamp and Backup Alarm with

Lamps .............................................. 10 Amperes
SEBU7458-07 153
Maintenance Section
Fuses - Replace
(11) Front and Rear Flasher Relays ...... 10 Amperes
(12) Product Link for the Machine Security

System ............................................. 10 Amperes
(13) Lh Indicator Display and Rh Indicator

Display ............................................. 10 Amperes
(14) Tilt Position Sensor and Lift Position

Sensor ............................................. 10 Amperes
(15) Transmission ECM and the Sensor for the Lh

Brake Pedal ..................................... 10 Amperes
(16) Implement ECM and Lever

Sensors ........................................... 10 Amperes
(17) EMS, Quad Gauge, Tachometer, and

Backlights ........................................ 10 Amperes
(18) Wiper and Washer for the Front and the Rear
Illustration 226
g01000750 Windows .......................................... 10 Amperes
(19) Payload Control System (PCS) ..... 10 Amperes
(20) Voltage Converter for Radio .......... 10 Amperes
(21) Center Indicator Display ................ 10 Amperes
(22) Spare ............................................. 10 Amperes
(23) Product Link ................................... 10 Amperes
(24) Voltage Converter Memory

(Attachment) .................................... 20 Amperes
(25) ECAP ............................................. 10 Amperes

g01078009
Illustration 227
(26) Lh Tail Lamps and Clearance
The fuses are located in the cab on the right side of Lamps .............................................. 10 Amperes
the operator seat.
(27) Hood Actuator ................................ 10 Amperes
(1) Spare ............................................... 10 Amperes
(28) Stop Lamp and Backup Alarm with
(2) Neutralizer Override Switch ............. 10 Amperes Lamps .............................................. 10 Amperes
(3) HVAC Blower ................................... 20 Amperes (29) Horn ............................................... 10 Amperes
(4) Quick Coupler and Alarm for Aggregate Autodig (30) Voltage Converter Memory
System ............................................. 10 Amperes (Standard) ........................................ 10 Amperes
(5) Rear Floodlights .............................. 15 Amperes (31) Key Start Switch and Machine Security System
(MSS) .............................................. 10 Amperes
(6) Air Seat and Heated Seat ................ 15 Amperes
(32) Dome Lamps ................................. 10 Amperes
(7) Secondary Steering ......................... 10 Amperes
(8) Engine ECM and Ether Injection ..... 10 Amperes
(9) Front Floodlights .............................. 15 Amperes
(10) Beacon .......................................... 10 Amperes

154 SEBU7458-07
Maintenance Section
Hood Tilt Actuator - Lubricate
i01923036 i01617406
Hood Tilt Actuator - Lubricate Hydraulic System

SMCS Code: 7275-086 Biodegradable Oil Filter
Element - Replace
Wipe all fittings before lubricating.
SMCS Code: 5068-510
S/N: AXC1-Up
S/N: AXJ1-Up
S/N: AXN1-Up
S/N: AWY1-Up
NOTICE
g00882932 ing any compartment or disassembling any compo-
Illustration 228
1. Raise the engine hood. The hood tilt actuator is
located on the right side of the machine.
2. Fully extend the cylinder and wipe off the inner
products.
post with a clean cloth. Then, lubricate the entire
length of the inner post.
mandates.
3. Wipe off both fittings on the cylinder. Then, apply
lubricant through the two fittings until the lubricant
escapes back through each fitting.
g00765498
Illustration 229
The hydraulic filter is located on the right side of the

machine.

element. Dispose of the used filter element
properly.
SEBU7458-07 155
Maintenance Section
Hydraulic System Oil - Change
2. Clean the filter mounting base. Make sure that all i01773322
of the used gasket is completely removed.
SMCS Code: 5056-044
Selection of the Oil Change Interval

Your machine may be able to use a 4000 hour
interval for the hydraulic oil. The hydraulic oil is in
the system that is not integral to the service brakes,
the clutches, the final drives, or the differentials.
The standard change interval is 2000 hours. The oil
should be monitored during intervals of 500 hours.
The extended 4000 hour interval can be used if the
following criteria are met.
g00101318
Illustration 230
Oil Filters
3. Lubricate the gasket of the new filter element with
Caterpillar oil filters are recommended. The interval
clean hydraulic oil.
for changing the oil filter should be 500 hours.
4. Install the new filter element by hand. After the
gasket contacts the filter mounting base, tighten Oil
the filter element by an additional 3/4 turn.
The 4000 hour interval for changing the oil is for the
5. Start the engine and run the engine at low idle. following oil types.
Inspect the hydraulic system for leaks.
• Caterpillar Hydraulic Oil (HYDO)
• Caterpillar Transmission and Drive Train Oil
(TDTO)
• Caterpillar TDTO (TMS)

• Caterpillar Diesel Engine Oil
• Caterpillar Biodegradable Hydraulic Oils (HEES)
• Caterpillar Multipurpose Tractor Oil (MTO)
• Heavy-duty diesel engine oils with a minimum zinc
content of 900 ppm (CF, CF-4, CG-4, and CH-4)
Note: Industrial hydraulic oils are not recommended

in Caterpillar hydraulic systems. These oils are more
likely to cause corrosion and excessive wear.
Monitoring the Condition of the Oil

g00765515
Illustration 231
The oil should be monitored during intervals of 500
6. Maintain the oil level above the “ADD COLD” mark hours. Caterpillar’s standard SOS Fluids Analysis or
on the sight gauge. Add hydraulic oil, if necessary. an equivalent oil sampling program should be used.
The current guidelines for cleanliness of the oil

should be observed. Refer to “Measured Data”.
If an oil sampling program is not available, the

standard 2000 oil change interval should be used.
156 SEBU7458-07
Maintenance Section
Measured Data 1. Operate the machine in order to warm the

hydraulic oil.
The following information should be monitored
through sampling of the oil: 2. Park the machine on level ground. Lower the
attachment to the ground and apply slight
• Significant changes in wear metals should be downward pressure. Engage the parking brake
monitored. These metals include iron, copper, and stop the engine.
chromium, lead, aluminum, and tin.
• Significant changes in the following additives

should be monitored: zinc, calcium, magnesium,
and phosphorus.
• Contaminants should not be present. These

contaminants include fuel and antifreeze. Water
content should be .5 percent or less.
• 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 g00765367
Illustration 232
the original levels of contamination.
3. The hydraulic tank is located on the right side of
• There should not be significant changes in sodium, the machine. Press the button on the breaker relief
silicon, copper, and potassium.
valve (1) in order to relieve any tank pressure.
• The allowable level of oxidation is 40 percent (0.12 4. Remove the hydraulic tank filler cap (2) and
Abs units).
the filler strainer (3). Wash the filler cap and the
strainer in a clean, nonflammable solvent. Install
• The kinematic viscosity of 100 °C (212 °F) should the strainer.
not exceed a 2 cSt change from new.
5. Inspect the gasket on the hydraulic tank filler cap
Procedure for Changing the for damage. Replace the gasket, if necessary.
Hydraulic Oil 6. Remove the drain plug (5) from the bottom of the
hydraulic tank. Wash the drain plug in a clean,
NOTICE nonflammable solvent.
during performance of inspection, maintenance, test- 7. The hydraulic tank is equipped with an ecology
ing, adjusting and repair of the product. Be prepared to drain valve. Attach a hose to a 126-7914 Oil
collect the fluid with suitable containers before open- Drain Coupling. Install the threaded end of the
ing any compartment or disassembling any compo- coupling into the drain valve in order to unseat
nent containing fluids. the internal drain valve.
Refer to Special Publication, NENG2500, “Caterpillar NOTICE

Tools and Shop Products Guide” for tools and supplies Never start the engine while the hydraulic oil tank is
suitable to collect and contain fluids on Caterpillar being drained or while the hydraulic oil tank is empty.
products. Excessive wear and damage to the hydraulic compo-
nents can occur.
mandates.
8. Close the drain valve. Install the drain plug.
SEBU7458-07 157
Maintenance Section
Hydraulic System Oil Filter - Replace
9. Change the hydraulic oil filter. i01465406
Reference: Refer to Operation and Maintenance Hydraulic System Oil Filter -

Manual, “Hydraulic System Oil Filter - Replace” for
the correct procedure.
Replace
SMCS Code: 5068-510
10. Fill the hydraulic tank with clean oil. Make sure
that the oil level is at the “FULL” mark on the sight
NOTICE
gauge (4). Install the filler cap.
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.
products.
12. Start the engine and run the engine at low idle.
Cycle the implements so that all hydraulic systems
mandates.
are filled with oil.
Note: If the alert indicator for a low oil level comes

on, stop the engine and immediately add oil to the
hydraulic tank. The oil level should not be below the
suction ports in the hydraulic tank while the engine
is running.
13. Add hydraulic oil to the tank until the oil level is at
the “FULL” mark on the sight gauge.
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 233
The hydraulic filter is located on the right side of the

machine.

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.
158 SEBU7458-07
Maintenance Section
Hydraulic System Oil Level - Check
i01465502
Hydraulic System Oil Level -

Check
g00101318
Illustration 234
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 236
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.
i01923343
Hydraulic System Oil Sample

- Obtain
SMCS Code: 5050-008; 5056-008; 7542
NOTICE
Illustration 235
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.
SEBU7458-07 159
Maintenance Section
Hydraulic Tank Breaker Relief Valve - Clean
1. Operate the machine for a few minutes before i01923448

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
g01000919
Illustration 237
2. If the machine is equipped with conventional oil, g01000921

Illustration 239
open the engine access door on the left side of
the machine. The sampling valve for the hydraulic The hydraulic tank is located on the right side of the
oil is located on the hydraulic oil filter base on the machine.
left side of the machine.
The breaker relief valve is located on the front side
of the hydraulic tank near the top.
1. Remove the breaker relief valve by turning the

breaker relief valve counterclockwise.
2. Clean the breaker relief valve in a nonflammable

solvent. Dry the breaker relief valve thoroughly by
shaking or using compressed air.
3. Install the breaker relief valve by turning the

breaker relief valve clockwise.
i01718807
g00884072
Illustration 238
Logging Fork Clamp -
3. If the machine is equipped with biodegradable Lubricate
hydraulic oil, open the engine access door on the
right side of the machine. The sampling valve SMCS Code: 6113-086-BD; 6410-086-BD
for the hydraulic oil is located on the rear of the
machine near the radiator. Wipe off all fittings before any lubricant is applied.
4. Use the in-line sampling valve in order to obtain a
sample of hydraulic oil.
5. Close the engine access door.

Recommendations”, “S·O·S Oil Analysis” and Special
Sample”.
160 SEBU7458-07
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 240 and the particles could cause damage.
Apply lubricant through three fittings on each side
of the logging fork. i01794005
There is a total of six fittings. Quick Coupler - Check

SMCS Code: 6129-535
i02106227
When you install a work tool on the quick coupler,
Oil Filter - Inspect inspect the engagement of the coupler pins. If there is
play between the coupler pins and the corresponding
SMCS Code: 1308-507; 3004-507; 3067-507; bores, inspect the coupler pins and the bores for
5068-507 damage or wear.
Inspect a Used Filter for Debris If there is play between the quick coupler and the
hooks of the work tool, inspect the quick coupler and
the hooks for wear or for damage.
Make any necessary repairs before you operate the

work tool.
i02062586
Quick Coupler - Lubricate

SMCS Code: 6129-086
Note: Refer to Operation and Maintenance Manual,

“Lubricant Viscosities” for more information on
g00100013
the types of grease to use. Refer to Special
Illustration 241 Publication, SEBU6250, “Caterpillar Machine Fluids
The element is shown with debris. Recommendations” for more information on grease.
Use a filter cutter to cut the filter element open. Wipe off all lubricant fittings before you apply
Spread apart the pleats and inspect the element for lubricant through the lubricant fittings.
metal and for other debris. An excessive amount of
debris in the filter element can indicate a possible Do not lubricate the wedge and the wear plates.
failure. Friction is needed in order to hold the wedge in place
during backfilling.
If metals are found in the filter element, a magnet can
be used to differentiate between ferrous metals and
nonferrous metals.
Ferrous metals can indicate wear on steel parts and

on cast iron parts.
SEBU7458-07 161
Maintenance Section
Radiator Core - Clean
i01442049 5. Swing the air conditioner condenser back into the

operating position and replace the two bolts.
Radiator Core - Clean
SMCS Code: 1353-070-KO
1. Open the engine hood. The radiator assembly is i01923479

located at the rear of the machine.
Refrigerant Dryer - Replace
SMCS Code: 7322-510
Personal injury can result from contact with refrig-

erant.
Contact with refrigerant can cause frost bite. Keep

face and hands away to help prevent injury.
Protective goggles must always be worn when re-

frigerant lines are opened, even if the gauges in-
dicate the system is empty of refrigerant.
Always use precaution when a fitting is removed.

Slowly loosen the fitting. If the system is still un-
der pressure, release it slowly in a well ventilated
area.
Illustration 242
g00765907 Personal injury or death can result from inhaling
refrigerant through a lit cigarette.
2. Remove bolt (2). Swing the condenser away
from the radiator. Use the control knob (1) in Inhaling air conditioner refrigerant gas through a
order to release the hydraulic oil cooler. Swing lit cigarette or other smoking method or inhaling
the hydraulic oil cooler (3) and the condenser (4) fumes released from a flame contacting air con-
away from the radiator. ditioner refrigerant gas, can cause bodily harm or
death.
Do not smoke when servicing air conditioners or

wherever refrigerant gas may be present.
Use a certified recovery and recycling cart to prop-

erly remove the refrigerant from the air condition-
ing system.
g00101939
Illustration 243
3. You can use compressed air, high pressure water,

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

operating position and replace the two bolts. Illustration 244
g01000952
162 SEBU7458-07
Maintenance Section
Ride Control Accumulator - Check
Access refrigerant accumulator (1) from the right side

of the machine. Access in-line refrigerant dryer (2)
from the right side of the machine.
Refer to Service Manual, SENR5664, “Refrigerant

Accumulator - Remove and Install” for the
replacement procedure of accumulator (1).
Refer to Service Manual, SENR5664, “In-Line

Refrigerant Dryer - Remove and Install” for the
replacement procedure of refrigerant dryer (2).
Note: When you operate the machine in a climate

with high humidity, replace the in-line refrigerant dryer
after every 1000 service hours or 6 months.
i01767205
Ride Control Accumulator -

Check
g00761700
Illustration 245
SMCS Code: 5077-535-R6
Swing open the roading fender. Apply lubricant
Note: When the ride control accumulator is properly through one fitting on the hinge. There is one hinge
charged, the fore and aft motion of the machine is on each side of the machine.
reduced by the ride control accumulator.
Special tools and equipment are required in order i01457460

to test the accumulator.
Rollover Protective Structure
Reference: For more information, refer to Testing (ROPS) - Inspect
and Adjusting, RENR4397, “966G Series II Wheel
Loader and 972G Series II Wheel Loader Hydraulic SMCS Code: 7323-040; 7325-040
System”, “Ride Control Accumulator - Test and
Charge” or consult your Caterpillar dealer.
i01457015
Roading Fender Hinges -

Lubricate
SMCS Code: 7252-086-HNG
Wipe off the fitting before any lubricant is applied.
g00762107
Illustration 246
SEBU7458-07 163
Maintenance Section
Seat Belt - Inspect
Inspect the ROPS for bolts that are loose or damaged. Note: Within three years of the date of installation or
Use original equipment parts only to replace bolts within five years of the date of manufacture, replace
that are damaged or missing. Tighten the four the seat belt. Replace the seat belt at the date which
cab mounting bolts to a torque of 850 ± 100 N·m occurs first. A date label for determining the age of
(629 ± 74 lb ft). the seat belt is attached to the seat belt, the seat belt
buckle, and the seat belt retractor.
Note: Apply oil to all bolt threads before installation.
Failure to apply oil can result in improper bolt torque. If your machine is equipped with a seat belt
extension, also perform this inspection procedure for
Do not repair the ROPS by welding reinforcement the seat belt extension.
plates to the ROPS. Consult your Caterpillar dealer
for repair of cracks in any welds, in any castings, or
i02429594
in any metal section of the ROPS.
Seat Belt - Replace
i02429589
SMCS Code: 7327-510
Seat Belt - Inspect
Within three years of the date of installation or within
SMCS Code: 7327-040 five years of the date of manufacture, replace the
seat belt . Replace the seat belt at the date which
Always check the condition of the seat belt and the occurs first. A date label for determining the age of
condition of the seat belt mounting hardware before the seat belt is attached to the seat belt, the seat belt
you operate the machine. Replace any parts that are buckle, and the seat belt retractor.
damaged or worn before you operate the machine.
g01152685
Illustration 248
(1) Date of installation (retractor)
g00932801 (2) Date of installation (buckle)
Illustration 247 (3) Date of manufacture (tag) (fully extended web)
Typical example (4) Date of manufacture (underside) (buckle)
Check the seat belt mounting hardware (1) for wear Consult your Caterpillar dealer for the replacement of
or for damage. Replace any mounting hardware that the seat belt and the mounting hardware.
is worn or damaged. Make sure that the mounting
bolts are tight. If your machine is equipped with a seat belt
extension, also perform this replacement procedure
Check buckle (2) for wear or for damage. If the buckle for the seat belt extension.
is worn or damaged, replace the seat belt.
Inspect the seat belt (3) for webbing that is worn or

frayed. Replace the seat belt if the seat belt is worn
or frayed.
Consult your Caterpillar dealer for the replacement of

the seat belt and the mounting hardware.
164 SEBU7458-07
Maintenance Section
Steering Cylinder Bearings - Lubricate
i02405747 i01923541
Steering Cylinder Bearings - Steering Pilot Oil Screen

Lubricate (Command Control Steering) -
SMCS Code: 4303-086-BD
Clean/Replace
SMCS Code: 4304-070-Z3; 4304-510-Z3
S/N: AXC1-Up
switch is in the OFF position and that the parking S/N: AXE1-Up
brake is engaged before entering the articulation S/N: ANT1-Up
area. Failure to do so could result in serious injury
or death. S/N: ANY1-Up
S/N: AWY1-Up
S/N: AWZ1-Up
Personal injury can result from working with

cleaning solvent.
Because of the volatile nature of many cleaning

solvents, extreme caution must be exercised
when using them. If unsure about a particular
cleaning fluid, refer to the manufacturer’s instruc-
tions and directions.
g01000972
Illustration 249
Always wear protective clothing and eye protec-
Wipe off the fittings before any lubricant is applied. tion when working with cleaning solvents.
The rod end of the steering cylinders are lubricated
by using standard grease fittings (1).
The head ends of the steering cylinders are lubricated

by using two remote grease fittings (2) that are
located near the center hitch of the machine.
g01000991
Illustration 250
The screen group (3) is located behind the cab.
1. Disconnect hoses (1) and (2) that are connected

to the screen group (3).
2. Remove the two connectors that are attached to

the block.
3. Use an allen wrench in order to remove the two

screens from screen group (3).
SEBU7458-07 165
Maintenance Section
Steering Shaft (Command Control Steering) - Lubricate
4. Wash the screens in a clean, nonflammable 3. Apply 1P-0808 Multipurpose Grease through
solvent. fittings (1), (2), (6) and (7).
5. Dry each screen with pressure air. Inspect each 4. Install the steering shaft.
screen for damage. Replace the screen if the
screen is damaged.
i02305841
6. Install the screens. Install the connectors and

connect the hoses.
Tire Inflation - Check
SMCS Code: 4203-535-AI
i01619649
Steering Shaft (Command

Control Steering) - Lubricate
SMCS Code: 4343-086-JF
S/N: AXC1-Up
S/N: AXE1-Up
S/N: ANT1-Up
S/N: ANY1-Up
S/N: AWY1-Up g01160201
Illustration 252
S/N: AWZ1-Up
Always obtain proper tire inflation pressures and
Wipe off all fittings before any lubricant is applied. 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.
i01927964
Transmission Oil - Change

SMCS Code: 3030-044
NOTICE
g00812993
Illustration 251 nent containing fluids.
1. Remove the steering shaft from the machine. Refer to Special Publication, NENG2500, “Caterpillar
Reference: Refer to Disassembly and Assembly, suitable to collect and contain fluids on Caterpillar
“Steering Shaft - Remove and Install” for the products.
machine that is being serviced for the correct
procedure. Dispose of all fluids according to local regulations and
mandates.
2. Apply 5P-0960 Molybdenum Grease through
fittings (3), (4), (5) and (8).
166 SEBU7458-07
Maintenance Section
Transmission Oil - Change
1. Operate the engine in order to warm the 7. Wash the screen in a clean, nonflammable
transmission oil. Park the machine on level solvent. Use a bristle brush or pressure air to
ground. Lower the bucket and apply slight clean the screen. Clean the magnets. Replace
downward pressure. any damaged magnets.
2. Engage the parking brake. Stop the engine. 8. Clean the cover. Inspect the cover seal. Replace
the cover seal if the seal is damaged.
9. Insert the magnets and the screen into the transfer

case housing. Install the seal, the cover and the
four bolts.
10. Clean the transmission oil drain plug and install

the transmission oil drain plug.
g01002772
Illustration 253
3. Remove drain plug (1) on the bottom of the

transfer case.
4. Change the transmission oil filter.

g00884726
Manual, “Transmission Oil Filter - Replace” for the Illustration 255
correct procedure.
11. Remove the oil filler cap on the left side of the
machine and fill the transmission with oil.

refill capacity.
g00884724
Illustration 254 g01002778
Illustration 256
5. The magnetic strainer is on the right rear side 12. Remove the breather from the top of the transfer
of the transfer case. Remove the four bolts, the case. Wash the breather in a clean, nonflammable
cover and the seal that holds the magnets and solvent. Install the breather.
the screen in place.
13. Start and run the engine at low idle. Inspect the
6. Remove the screen and the magnets from the machine for leaks. Slowly operate the transmission
transfer case housing. controls in order to circulate the transmission oil.
SEBU7458-07 167
Maintenance Section
Transmission Oil Filter - Replace
14. Check the transmission oil level. 5. Use a strap type wrench to remove the filter
housing.
Manual, “Transmission Oil Level - Check” for the 6. Remove the used filter element. Dispose of the
correct procedure. used filter element properly.
7. Clean the filter housing and the filter housing base

i01551419
with a clean, nonflammable solvent.
Transmission Oil Filter - 8. Inspect the filter housing seal. Replace the seal
Replace if the seal is damaged.
SMCS Code: 3004-510; 3067-510 9. Install the new filter element into the transmission
filter housing. Clean the filter housing drain plug
NOTICE and install the drain plug.
during performance of inspection, maintenance, test- 10. Start the engine. Slowly operate the transmission
ing, adjusting and repair of the product. Be prepared to controls in order to circulate the transmission oil.
collect the fluid with suitable containers before open- Check the machine for oil leaks.
nent containing fluids. 11. Check the transmission oil level.
Refer to Special Publication, NENG2500, “Caterpillar Reference: Refer to Operation and Maintenance
Tools and Shop Products Guide” for tools and supplies Manual, “Transmission Oil Level - Check” for the
suitable to collect and contain fluids on Caterpillar correct procedure.
products.
i01720770
mandates. Transmission Oil Level - Check
g00807056
Illustration 257
g00884784
The transmission oil filter is located on the left side of Illustration 258
the machine near the steering cylinder.
The sight gauge for the transmission oil level is
1. Operate the machine in order to warm the oil. Park located on the front of the transfer case on the left
the machine on level ground. Lower the bucket to side of the machine.
the ground and apply slight downward pressure.
2. Engage the parking brake and stop the engine.
3. Remove the access panel.
4. Remove the filter housing drain plug and allow the

oil in the filter to drain into a suitable container.
168 SEBU7458-07
Maintenance Section
Transmission Oil Sample - Obtain
g01001021
Illustration 260
2. The sampling valve for the transmission oil is

located on the transmission oil filter base on the
left side of the machine. Use the in-line sampling
valve in order to obtain a sample of transmission
g00284626 oil.
Illustration 259

The red indicator should be within “WARM IDLE” Publication, SEBU6250, “Caterpillar Machine Fluids
range (B) when the oil is warm and the machine is Recommendations”, “S·O·S Oil Analysis” and Special
running at low idle. The red indicator should be within Publication, PEHP6001, “How To Take A Good Oil
“COLD START” range (A) when the oil is cold and Sample”.
the machine is not running. Add oil through the filler
tube, if necessary.
i01552051
i01923561 Window Washer Reservoir -

Transmission Oil Sample - Fill
Obtain SMCS Code: 7306-544
SMCS Code: 3080-008; 7542
NOTICE
When operating in freezing temperatures, use
NOTICE Caterpillar nonfreezing window washer solvent or
Care must be taken to ensure that fluids are contained equivalent. System damage can result from freezing.

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.
SEBU7458-07 169
Maintenance Section
Window Wiper - Inspect/Replace
i00037755
Windows - Clean
SMCS Code: 7310-070
g00038949
Illustration 263
g00807046
Illustration 261 Use commercially available window cleaning
solutions in order to clean the windows. Clean the
Window Washer Reservoir – The window outside windows from the ground unless handholds
washer reservoir is located above the are available.
hydraulic tank on the right side of the
machine. Fill the window washer reservoir through
the filler opening.
i01552025
Window Wiper -
Inspect/Replace
SMCS Code: 7305-040; 7305-510
g00807031
Illustration 262
Inspect the condition of the wiper blades. Replace

the wiper blades if the wiper blades are worn or
damaged or if the streaking occurs.

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MAINTENANCE INTERVALS

Operation and Maintenance

i02407125 Hydraulic System Oil Level - Check ................... 158

Case Drain Screen (Strainer) (Steering Pump,

Every 2000 Service Hours or 1 Year

Every 3 Years After Date of Installation or

Every 4000 Service Hours or 2 Years

Every 6000 Service Hours or 3 Years

Every 12 000 Service Hours or 6 Years

Crushing Hazard. Insure that the machine ignition

Wipe all fittings before applying grease.

Filling the Reservoir

i02094776 Filling the Reservoir

The Groeneveld Automatic TWIN i02405745

Greasing System Axle Oscillation Bearings -

Crushing Hazard. Insure that the machine ignition

A three-position switch on the backup alarm regulates

The backup alarm is set for the highest sound level

Wipe all fittings before lubricating.

The top remote grease fitting will lubricate the axle

Note: 5P-0960 Molybdenum Grease is preferred.

Always recycle a battery. Never discard a battery.

Always return used batteries to one of the following

i01897534 7. Make any necessary repairs. If necessary, replace

10. Connect the battery cable at the battery

11. Install the key and turn the battery disconnect

Over time, the vibration of an operating machine can

Battery or Battery Cable -

1. Turn the engine start switch key OFF. Turn all of

2. Turn the battery disconnect switch OFF. Remove

Reference: For the correct procedure, refer to the

Braking System - Test

In order to test the braking system, refer to theTesting

Bucket Cutting Edges -

3. Stop the engine. Apply the service brake pedal

4. If the alert indicator comes on after less than

1. Raise the bucket and place blocking under the

2. Lower the bucket onto the blocking. Stop the

3. Remove bolts (1), cutting edge (2) and the end

4. Clean all contact surfaces.

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

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

6. Install bolts (1). Tighten the bolts to the specified g00807071

Wipe off the fittings before any lubricant is applied.

Wipe off all fittings before any lubricant is applied.

i02421156 The loss of bucket tips can often be attributed to

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

• Use a hammer and a punch from the retainer

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

a. Insert the pin through the bucket tooth.

Size of the Tip Pin Remover

Note: The bucket tip can be rotated by 180 degrees in

• From the other side of the retainer, drive the pin

i01924086 Inspect the wear plates. Replace the wear plates

SMCS Code: 6101-086-BD; 6107-086-BD i01449996