Manual Cargadora

2010 CaterpillarAll Rights Reserved

MAINTENANCE INTERVALSOperation and Maintenance Manual Excerpt

SEBU7581-09March 2010

Operation andMaintenanceManual938G Series II Wheel Loader andIT38G Series II Integrated ToolcarrierCRD1-Up (938G)RTB1-Up (938G)PHN1-Up (938G)B9Y1-Up (938G)CSX1-Up (IT38G)JAN1-Up (IT38G II)

SAFETY.CAT.COM

SEBU7581-09 91Maintenance Section

Maintenance Interval Schedule

i03895883

Maintenance Interval ScheduleSMCS Code: 7000

Ensure that all safety information, warnings andinstructions are read and understood before anyoperation or any maintenance procedures areperformed.

The user is responsible for the performance ofmaintenance, including all adjustments, the use ofproper lubricants, fluids, filters, and the replacementof components due to normal wear and aging. Failureto adhere to proper maintenance intervals andprocedures may result in diminished performance ofthe product and/or accelerated wear of components.

Use mileage, fuel consumption, service hours, orcalendar time, WHICH EVER OCCURS FIRST,in order to determine the maintenance intervals.Products that operate in severe operating conditionsmay require more frequent maintenance. Refer to themaintenance procedure for any other exceptions thatmay change the maintenance intervals.

Note: Before each consecutive interval is performed,all maintenance from the previous interval must beperformed.

Note: If Cat HYDO Advanced hydraulic oils areused, the hydraulic oil change interval is extendedto 3000 hours. SOS services may extend the oilchange even longer. Consult your Caterpillar dealerfor details.

When Required

Battery - Recycle .................................................. 95Battery or Battery Cable - Inspect/Replace .......... 96Bucket Wear Plates - Inspect/Replace ............... 106Circuit Breakers - Reset ...................................... 107Engine Air Filter Primary Element - Clean/Replace .............................................................. 117Engine Air Filter Secondary Element - Replace .. 119Engine Air Precleaner - Clean ............................ 121Fuel System - Prime ........................................... 126Fuses - Replace .................................................. 131Hydraulic System Biodegradable Oil Filter Element -Replace ............................................................. 132Oil Filter - Inspect ................................................ 138Radiator Core - Clean ......................................... 139Ride Control Accumulator - Check ..................... 141Window Washer Reservoir - Fill .......................... 147Window Wiper - Inspect/Replace ........................ 147

Every 10 Service Hours or Daily

Backup Alarm - Test .............................................. 94Bucket Cutting Edges - Inspect/Replace ............ 100Bucket Tips - Inspect/Replace ............................ 101

Bucket Tips - Inspect/Replace ............................ 104Cooling System Coolant Level - Check ............... 110Engine Air Filter Service Indicator - Inspect ........ 120Engine Oil Level - Check .................................... 122Fuel System Primary Filter (Water Separator) -Drain ................................................................. 127Hydraulic System Oil Level - Check ................... 136Quick Coupler - Check ........................................ 139Seat Belt - Inspect .............................................. 142Transmission Oil Level - Check .......................... 146Windows - Clean ................................................. 148

Every 50 Service Hours or Weekly

Bucket Lower Pivot Bearings - Lubricate ............ 101Cab Air Filter - Clean/Replace ............................ 106Fuel Tank Water and Sediment - Drain ............... 131Tire Inflation - Check ........................................... 143

Every 100 Service Hours or 2 Weeks

Axle Oscillation Bearings - Lubricate .................... 94Bucket Linkage and Loader Cylinder Bearings -Lubricate ........................................................... 101Bucket Upper Pivot Bearings - Lubricate ............ 106Steering Cylinder Bearings - Lubricate ............... 143

Initial 250 Service Hours

Transmission Oil Filter - Replace ........................ 145

Every 250 Service Hours

Engine Oil Sample - Obtain ................................ 122

Every 250 Service Hours or Monthly

Belt - Inspect/Adjust/Replace ................................ 96Brake Accumulator - Check .................................. 98Braking System - Test ........................................... 99Differential and Final Drive Oil Level - Check ...... 115Drive Shaft Spline (Center) - Lubricate ................ 116Engine Air Filter Service Indicator -Inspect/Replace ................................................ 120Engine Oil and Filter - Change ........................... 123Quick Coupler - Lubricate ................................... 139

Initial 500 Hours (for New Systems, RefilledSystems, and Converted Systems)

Cooling System Coolant Sample (Level 2) -Obtain ................................................................ 112

Every 500 Service Hours

Cooling System Coolant Sample (Level 1) -Obtain ................................................................ 111Differential and Final Drive Oil Sample - Obtain .. 115Hydraulic System Oil Sample - Obtain ............... 137Transmission Oil Sample - Obtain ...................... 147

92 SEBU7581-09Maintenance SectionMaintenance Interval Schedule

Every 500 Service Hours or 3 Months

Engine Crankcase Breather - Clean ................... 121Engine Oil and Filter - Change ........................... 123Fuel System Primary Filter (Water Separator)Element - Replace ............................................ 128Fuel System Secondary Filter - Replace ............ 129Fuel Tank Cap and Strainer - Clean ................... 130Hydraulic System Oil Filter - Replace ................. 135Transmission Oil Filter - Replace ........................ 145

Every 1000 Service Hours or 6 Months

Articulation Bearings - Lubricate ........................... 93Axle Oil Cooler Magnetic Filter - Clean/Replace .. 93Battery - Clean ...................................................... 95Battery Hold-Down - Tighten ................................. 96Drive Shaft Support Bearing - Lubricate .............. 116Drive Shaft Universal Joints - Lubricate ............... 117Roading Fender Hinges - Lubricate .................... 141Rollover Protective Structure (ROPS) - Inspect .. 141Transmission Oil - Change ................................. 144

Every 2000 Service Hours or 1 Year

Brake Discs - Check ............................................. 99Differential and Final Drive Oil - Change ............. 113Engine Valve Lash - Check ................................. 126Hood Tilt Actuator - Lubricate ............................. 132Hydraulic System Oil - Change ........................... 133Hydraulic Tank Breaker Relief Valve - Clean ...... 138Refrigerant Accumulator (With Desiccant) -Replace ............................................................. 141Service Brake Wear Indicator - Check ................ 143

Every Year

Cooling System Coolant Sample (Level 2) -Obtain ................................................................ 112

Every 3 Years After Date of Installation orEvery 5 Years After Date of Manufacture

Seat Belt - Replace ............................................. 142

Every 4000 Service Hours or 2 Years

Hydraulic System Oil - Change ........................... 133

Every 6000 Service Hours or 3 Years

Cooling System Coolant Extender (ELC) - Add .. 109

Every 12 000 Service Hours or 6 Years

Cooling System Coolant (ELC) - Change ........... 108Cooling System Water Temperature Regulator -Replace .............................................................. 113


Articulation Bearings - Lubricate

i02405470

Articulation Bearings -LubricateSMCS Code: 7057-086-BD; 7065-086-BD;7066-086-BD

Crushing Hazard. Insure that the machine ignitionswitch is in the OFF position and that the parkingbrake is engaged before entering the articulationarea. Failure to do so could result in serious injuryor death.

g00107435Illustration 96

Note: On certain models, the fittings will beaccessible from the left side of the machine.

Wipe off the fittings before any lubricant is applied.

Apply lubricant through fittings (1) and (2) on thearticulation hitches.

i01700204

Axle Oil Cooler Magnetic Filter- Clean/ReplaceSMCS Code: 3004-070-MGS; 3004-510-MGS


1. Open the engine hood. The magnetic filters forthe axle oil cooler are located on the right side ofthe engine.


2. Remove the two magnetic filters from the axle oilcooler lines.

3. Wash the filters in a clean nonflammable solvent.Inspect the filters for damage. Replace the filters ifthe filters are damaged.

Note: If the oil samples for the differential oil show aparticle count that is higher than normal, clean thefilters for the axle oil cooler at an earlier interval.

4. Install the two filters for the axle oil cooler.

94 SEBU7581-09Maintenance SectionAxle Oscillation Bearings - Lubricate

5. Close the engine hood.

6. Start the engine. Operate the machine in orderto circulate the oil.

7. Stop the engine.


Front Differential and Final Drive Filler Plug

g00110469Illustration 100Rear Differential and Final Drive Filler Plug

8. Remove the dipstick/fill plug for the frontdifferential and the dipstick/fill plug for the reardifferential. Check the oil level.

9. Maintain the oil level between the ADD mark andthe FULL mark on the dipstick/fill plug. Add oil, ifnecessary. Replace the dipstick/fill plug.

i02405487

Axle Oscillation Bearings -LubricateSMCS Code: 3268-086-BD; 3278-086-BD

Crushing Hazard. Insure that the machine ignitionswitch is in the OFF position and that the parkingbrake is engaged before entering the articulationarea. Failure to do so could result in serious injuryor death.


Wipe off the fittings before you apply any lubricant.

Apply lubricant through two remote fittings near thearticulation hitch on the right side of the machine.

i01808955

Backup Alarm - TestSMCS Code: 7406-081

Turn the engine start switch key to the ON position inorder to perform the test.

Apply the service brake. Move the transmissiondirection control lever to REVERSE position.

The backup alarm should immediately sound.The backup alarm will continue to sound until thetransmission direction control lever is moved to theNEUTRAL position or to the FORWARD position.


Battery - Clean


The backup alarm is mounted in the back of themachine behind the rear grill.


A three-position switch at the rear of the backup alarmregulates the sound of the alarm. The sound of thealarm can be adjusted to HIGH, LOW, or MEDIUM.

The alarm is set at the maximum sound level whenthe machine is shipped from the factory. The settingshould remain on high, unless the job site requires alower sound level.

i01894639

Battery - CleanSMCS Code: 1401-070


The batteries are located in the battery compartmenton the left rear bumper.

Clean the battery surfaces with a clean cloth. Keepthe terminals clean and keep the terminals coatedwith petroleum jelly. Install the post covers after youcoat the terminal posts with petroleum jelly.

i00993589

Battery - RecycleSMCS Code: 1401-561

Always recycle a battery. Never discard a battery.

Always return used batteries to one of the followinglocations:

A battery supplier

An authorized battery collection facility

Recycling facility

96 SEBU7581-09Maintenance SectionBattery Hold-Down - Tighten

i01894716

Battery Hold-Down - TightenSMCS Code: 7257-527


The batteries are located in the battery compartmenton the left rear bumper.

Tighten the hold-downs for the battery in order toprevent the batteries from moving during machineoperation.

i03657099

Battery or Battery Cable -Inspect/ReplaceSMCS Code: 1401-040; 1401-510; 1402-040;1402-510

Personal injury may occur from failure to properlyservice the batteries.

Batteries give off flammable fumes that can ex-plode. Electrolyte is an acid and can cause per-sonal injury if it contacts the skin or eyes.

Prevent sparks near the batteries. Sparks couldcause vapors to explode. Do not allow jumper ca-ble ends to contact each other or the engine. Im-proper jumper cable connections can cause an ex-plosion.

Always wear protective glasses when workingwith batteries.

1. Turn the engine start switch key OFF. Turn all ofthe switches OFF.

2. Turn the battery disconnect switch OFF. Removethe key.

3. Disconnect the negative battery cable from thedisconnect switch.

Note: Do not allow the disconnected battery cable tocontact the disconnect switch.

4. Disconnect the negative battery cable at thebattery.

5. Disconnect the positive battery cable at thebattery.

6. Inspect the battery terminals for corrosion. Inspectthe battery cables for wear or damage.

7. Make any necessary repairs. If necessary, replacethe battery cables or the battery.

8. Connect the positive battery cable at the battery.

9. Connect the negative battery cable at the battery.

10.Connect the battery cable at the batterydisconnect switch.

11. Install the key and turn the battery disconnectswitch ON.

Recycle the BatteryAlways recycle a battery. Never discard a battery.

Always return used batteries to one of the followinglocations:

A battery supplier

An authorized battery collection facility

Recycling facility

i02211920

Belt - Inspect/Adjust/ReplaceSMCS Code: 1397-025; 1397-040; 1397-510

Your machine is equipped with a single serpentinebelt. Stop the engine. Open the rear hood. Thebelt is located at the rear of the engine. Inspect thecondition of the serpentine belt. Replace the belt ifthe belt is cracked or frayed.


Belt - Inspect/Adjust/Replace


(1) Idler pulley(2) Idler pulley(3) Alternator(4) Square hole

(5) Tensioner(6) Water pump(7) Serpentine belt(8) Crankshaft pulley

(9) Compressor (If Equipped)(10) Idler pulley

A tensioner (5) keeps the correct tension on the belt(7). Insert a ratchet with a square drive into the hole(4). Rotate the tensioner clockwise in order to relievetension on the belt. Remove the belt.

Install the new belt. Be sure that the new belt is routedcorrectly, as shown. View (A) represents machinesthat are not equipped with an air conditioner. View(B) represents machines that are equipped with anair conditioner. Rotate the tensioner clockwise inorder to install the new belt. Release the tensionerwhen the new belt is installed. The correct tensionwill automatically be applied.

Belt for the Axle Oil Cooler Pump(If Equipped)Your machine is equipped with a single serpentinebelt. Stop the engine. Open the rear hood. Thebelt is located at the rear of the engine. Inspect thecondition of the serpentine belt. Replace the belt ifthe belt is cracked or frayed.

98 SEBU7581-09Maintenance SectionBrake Accumulator - Check


(1) Axle oil cooler pump(2) Idler pulley(3) Idler pulley(4) Alternator

(5) Square hole(6) Tensioner(7) Water pump(8) Serpentine belt

(9) Crankshaft pulley(10) Compressor (If Equipped)

A tensioner (6) keeps the correct tension on the belt(8). Insert a ratchet with a square drive into the hole(5). Rotate the tensioner clockwise in order to relievetension on the belt. Remove the belt.

Install the new belt. Be sure that the new belt is routedcorrectly, as shown. View (A) represents machinesthat are not equipped with an air conditioner. View(B) represents machines that are equipped with anair conditioner. Rotate the tensioner clockwise inorder to install the new belt. Release the tensionerwhen the new belt is installed. The correct tensionwill automatically be applied.

i01703170

Brake Accumulator - CheckSMCS Code: 4263-535


1. Turn the engine start switch to the ON position.The alert indicator (1) for brake oil pressure shouldcome on if the braking system is not at normaloperating pressure.

SEBU7581-09 99Maintenance SectionBrake Discs - Check

2. Start the engine. Run the engine at half speed fortwo minutes in order to increase the accumulatorpressure. The alert indicator (1) for brake oilpressure should go off.

3. Stop the engine. Apply the service brake pedaland release the service brake pedal until the alertindicator for brake oil pressure comes on. This willdecrease the accumulator pressure. A minimumof five applications of the service brake pedal arerequired.

Note: The parking brake indicator light (2) will be onwhen the alert indicator for brake oil pressure comeson.

4. If the alert indicator comes on after less thanfive applications of the brake, measure theaccumulator precharge pressure. An authorizedCaterpillar dealer can measure the nitrogen gaspressure in the accumulator. Use only dry nitrogengas for recharging.

i01732078

Brake Discs - CheckSMCS Code: 4255-535

Reference: For the correct procedure, refer to theTesting and Adjusting Service Manual of the brakingsystem for your machine or consult your Caterpillardealer.

i01361824

Braking System - TestSMCS Code: 4251-081; 4267-081

Park the machine on a dry, level surface.

Check the area around the machine. Make surethat the machine is clear of personnel and clear ofobstacles.

Make sure that the steering frame lock is in theunlocked position.

Fasten the seat belt before you test the brakes.

The following tests are used to determine whetherthe braking system is functional. These tests are notintended to measure the maximum brake holdingeffort. The required brake holding effort for sustaininga machine at a specific engine rpm varies from onemachine to another machine. The variations includedifferences in the engine setting, the power trainefficiency, the brake holding ability, etc.

Service Brake Holding Ability Test

Personal injury can result if the machine moveswhile testing.

If the machine begins to move during test, reducethe engine speed immediately and engage theparking brake.

1. Start the engine. Raise the implement slightly.Apply the service brake. Release the parkingbrake.

2. Press the top of the transmission neutralizeroverride switch.

3. Make sure that the autoshift control is in the OFFposition.

4. Move the transmission control to THIRD SPEEDFORWARD while the service brakes are applied.

5. Gradually increase the engine speed to high idle.The machine should not move.

6. Reduce the engine speed to low idle. Move thetransmission direction control to the NEUTRALposition. Engage the parking brake. Lower theimplement to the ground. Stop the engine.

If the machine moved during the test, consult yourCaterpillar dealer for a brake inspection. Make anynecessary repairs before the machine is returned tooperation.

Parking Brake Holding Ability Test

Personal injury can result if the machine moveswhile testing.

If the machine begins to move, reduce the enginespeed immediately and apply the service brakepedal.

This test is performed when the parking brake isengaged. If the machine begins to move, comparethe engine rpm to the engine rpm of a prior test. Thiswill indicate the amount of system deterioration.

1. Start the engine. Raise the implement slightly.Engage the parking brake.

2. Make sure that the autoshift control is in the OFFposition.

100 SEBU7581-09Maintenance SectionBucket Cutting Edges - Inspect/Replace

3. Move the transmission control to THIRD SPEEDFORWARD. Then, move the transmissioncontrol to NEUTRAL and back to THIRD SPEEDFORWARD. This will override the transmissionneutralizer.

The parking brake indicator light should come on.

4. Gradually increase the engine speed to high idle.The machine should not move.

5. Reduce the engine speed to low idle. Move thetransmission direction control to the NEUTRALposition. Lower the implement to the ground. Stopthe engine.

If the machine moved during the test, consult yourCaterpillar dealer for a brake inspection. Make anynecessary repairs before the machine is returned tooperation.

i03657238

Bucket Cutting Edges -Inspect/ReplaceSMCS Code: 6801-040; 6801-510

Personal injury or death can result from bucketfalling.

Block the bucket before changing bucket cuttingedges.

g00764365Illustration 109(1) Bolts for Cutting Edge(2) Cutting Edge

Check the cutting edges and the end bits for wearand for damage. Use the following procedure toservice the cutting edges and the end bits:

1. Raise the bucket and place blocking under thebucket.

2. Lower the bucket onto the blocking. Stop theengine.

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

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 endbits are not reversible.

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

6. Install bolts (1). Tighten the bolts to the specifiedtorque.

Reference: Refer to Specifications, SENR3130,Ground Engaging Tool (G.E.T.) Fasteners.

7. Start the engine. Raise the bucket and remove theblocking. Lower the bucket to the ground.

8. After a few hours of operation, check the bolts forproper torque.

Bucket Wear Plates

Personal injury or death can result from the bucketfalling.

Block the bucket before changing bucket wearplates.


Inspect the wear plates. Replace the wear platesbefore damage to the bottom of the bucket occurs.Consult your Caterpillar dealer for replacement ofwear plates.


Bucket Linkage and Loader Cylinder Bearings - Lubricate

i01940922

Bucket Linkage and LoaderCylinder Bearings - LubricateSMCS Code: 5102-086-BD; 5104-086-BD;6107-086-BD

Wheel Loader


1. Wipe off the fittings before you apply lubricant.

2. Apply lubricant to the grease fittings.

Integrated Toolcarrier


1. Wipe off the fittings before you apply lubricant.

2. Apply lubricant to the grease fittings.

i01889917

Bucket Lower Pivot Bearings- LubricateSMCS Code: 6101-086-BD; 6107-086-BD

1. Wipe off the fittings before you apply any lubricant.


2. Apply lubricant through the fitting on each lowerpivot bearing.

i02421156

Bucket Tips - Inspect/ReplaceSMCS Code: 6805-040; 6805-510

S/N: RTB1-Up

S/N: CRD1-Up

S/N: PHN1-Up

S/N: CSX1-Up

S/N: B9Y1-Up


Block the bucket before changing bucket tips.

102 SEBU7581-09Maintenance SectionBucket Tips - Inspect/Replace

Personal injury can result fromdriving out retainerpins.

Retainer pins, when struck with force can fly outand cause injury to nearby people.

Make sure the area is clear of people when drivingout retainer pins.

Wear protective glasses when striking a retainerpin.

Bucket Tips

g00101352Illustration 114(1) Usable(2) Replace this bucket tip.(3) Overworn

Check the bucket tips for wear. If the bucket tip has ahole, replace the bucket tip.

The loss of bucket tips can often be attributed tothe improper installation of the retaining pin intothe tip and the adapter. Bucket tips are lost morefrequently on excavators because the tips are closertogether. Inserting the pin from the correct side (rightside) of the adapter is difficult due to the small gap.More clearance can be obtained by installing thepin through the tip and the adapter from the leftside, and then by driving the pin against the retainer.This procedure will often cause the spiral retainer tobecome distorted, resulting in either a loss of retainergrip or an increased difficulty in removing the pin.

g01201331Illustration 115Improper installation

By driving from the right side of the adapter, theretainer is properly supported by the counterbore ofthe adapter. This procedure will show that the pinchamfer is centered in the inside diameter of theretainer more clearly.


Proper installationInstall pin from the right side.

1. Remove the pin from the bucket tip. The pin canbe removed by one of the following methods:

Use a hammer and a punch from the retainerside of the bucket to drive out the pin.

Use a Pin-Master. Follow Step 1.a through Step1.c for the procedure.

a. Place the Pin-Master on the bucket tooth.

b. Align extractor (5) with the pin.

c. Strike the Pin-Master at the back of the tool (4)and remove the pin.


Bucket Tips - Inspect/Replace

g00590819Illustration 117(6) Retainer(7) Retaining Washer(8) Adapter

2. Clean the adapter and the pin.

3. Fit retainer (6) into retaining washer (7). Install thisassembly into the groove that is in the side of theadapter (8).


4. Install the new bucket tip into the adapter.

Note: The bucket tip can be rotated by 180 degrees inorder to allow greater penetration or less penetration.

5. Drive the pin through the bucket tip. The pin canbe installed by using one of the following methods:

From the other side of the retainer, drive the pinthrough the following components: the buckettip, the adapter, and the retainer.

Use a Pin-Master. Follow Step 5.a through Step5.e for the procedure.

g00590666Illustration 119(4) Back of Pin-Master(9) Pin setter(10) Pin holder

a. Insert the pin through the bucket tooth.

b. Place the Pin-Master over the bucket tooth andlocate the pin in the hole of the holder (10).

c. Strike the tool with a hammer at the back of thetool (4) in order to start the pin.

d. Slide pin holder (10) away from the pin androtate the tool slightly in order to align pin setter(9) with the pin.

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

6. After you drive the pin, make sure that the retainerfits snugly into the pin groove.

The tools that are available for driving the pins areshown in Table 14.

Table 14

Size of the Tip Pin Remover

J200, J225 143-2459

J250, J300, J350 143-2460

J350, J400, J460 196-1331

J550 203-4290

104 SEBU7581-09Maintenance SectionBucket Tips - Inspect/Replace

i03657242

Bucket Tips - Inspect/ReplaceSMCS Code: 6805-040; 6805-510

S/N: JAN1-Up


Block the bucket before changing bucket tips.

Bucket Tips

g00101352Illustration 120(1) Usable(2) Replace the tip.(3) Replace the tip.

Check the bucket tips for wear. If the bucket tip has ahole, replace the bucket tip.

1. Remove the pin from the bucket tip. The pin canbe removed by one of the following methods.

Use a hammer and a punch from the retainerside of the bucket to drive out the pin.

Use a Pin-Master. Follow Step 1.a through Step1.c for the procedure.

g00590670Illustration 121(4) Back of Pin-Master(5) Extractor

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.


(6) Retainer(7) Retaining washer(8) Adapter

2. Clean the adapter and the pin.

3. Fit retainer (6) into retaining washer (7). Installthis assembly into the groove that is in the sideof adapter (8).


Bucket Tips - Inspect/Replace


4. Install the new bucket tip onto the adapter.

Note: The bucket tip can be rotated by 180 degrees inorder to allow greater penetration or less penetration.

5. Drive the pin through the bucket tip. The pin canbe installed by using one of the following methods:

From the other side of the retainer, drive thepin through the bucket tip, the adapter, and theretainer.

Use a Pin-Master. Follow Step 5.a through Step5.e for the procedure.

Note: To correctly install the pin into the retainer, thepin must be driven in from the right side of the tooth.Improper installation of the pin can result in the lossof the bucket tip.

g00590666Illustration 124(4) Back of Pin-Master(9) Pin setter(10) Pin holder

a. Insert the pin through the bucket tooth.

b. Place the Pin-Master over the bucket tooth andlocate the pin in the hole of holder (10).

c. Strike the tool with a hammer at the back of thetool (4) in order to start the pin.

d. Slide pin holder (10) away from the pin androtate the tool slightly in order to align pin setter(9) with the pin.

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

6. After you drive the pin, make sure that the retainerfits snugly into the pin groove.

K-Series Tip

Removal


Note: Retainers are often damaged during theremoval process. Caterpillar recommends theinstallation of a new retainer when bucket tips arerotated or replaced.


1. Use a pry bar in order to disengage retainer (5).

2. Use the pry bar in order to remove retainer (5)from bucket tip (4).

3. Remove bucket tip (4) from adapter (6) with aslight counterclockwise rotation.

106 SEBU7581-09Maintenance SectionBucket Upper Pivot Bearings - Lubricate

4. Clean adapter (6).

Installation

1. Clean the adapter and the area around the latch,if necessary.

2. Install the new bucket tip onto the adapter with aslight clockwise rotation.


3. Install the retainer. Make sure that the retainer'slatch catches under the tip pocket.

4. Make sure that the latch is properly seated bytrying to remove the bucket tip.

i01889915

Bucket Upper Pivot Bearings- LubricateSMCS Code: 6101-086-BD; 6107-086-BD

1. Wipe off the fitting before you apply any lubricant.


2. Apply lubricant through the fitting on the upperpivot bearing.

i01709216

Bucket Wear Plates -Inspect/ReplaceSMCS Code: 6120-040; 6120-510


Block the bucket before changing bucket wearplates.


Inspect the wear plates. Replace the wear platesbefore damage to the bottom of the bucket occurs.Consult your Caterpillar dealer for replacement ofwear plates.

i01234809

Cab Air Filter - Clean/ReplaceSMCS Code: 7342-070; 7342-510

Note: Clean the filter elements more often in dustyconditions. If there is a noticeable reduction in theairflow from the air vents, check the filter elements.


Circuit Breakers - Reset


1. Remove the filter cover under the steps on theleft side of the operator compartment. Removethe filter elements. Do not wash the filter elementswhile the filter elements are installed on themachine.


2. Raise the seat. Remove the filter cover and thefilter elements on the left side of the seat.

3. Clean the filter elements with compressed air.

You can also wash the filter elements in a solutionof warm water with a nonsudsing householddetergent. Rinse the filter elements in clean water.Air dry the filter elements thoroughly.

4. Install the filter elements and the filter covers.Replace any filter elements that are worn ordamaged.

Note: Make sure that the seals on the filter elementsnext to the seat are facing toward the parking brakelever when you install the filter elements.

i01362876

Circuit Breakers - ResetSMCS Code: 1420-529

Circuit Breaker Reset Push the buttonin order to reset the circuit breakers. Thebutton will stay depressed if the circuit is

working properly. Check the appropriate electricalcircuit if the button does not stay depressed.



Open the engine hood. The circuit breakers arelocated in the engine compartment on the right sideof the machine.

Alternator (1) 80 amp

Main Circuit (2) 80 amp

108 SEBU7581-09Maintenance SectionCooling System Coolant (ELC) - Change

i01889406

Cooling System Coolant (ELC)- ChangeSMCS Code: 1350-044-NL

Pressurized system: Hot coolant can cause seri-ous burn. To open cap, stop engine, wait until ra-diator is cool. Then loosen cap slowly to relievethe pressure.

NOTICECare must be taken to ensure that fluids are containedduring performance of inspection, maintenance, test-ing, adjusting and repair of the product. Be prepared tocollect the fluid with suitable containers before open-ing any compartment or disassembling any compo-nent containing fluids.

Refer to Special Publication, NENG2500, CaterpillarTools and Shop Products Guide for tools and suppliessuitable to collect and contain fluids on Caterpillarproducts.

Dispose of all fluids according to local regulations andmandates.

NOTICETopping off or mixing Cat ELC with other products thatdo not meet Caterpillar EC-1 specifications reducesthe effectiveness of the coolant and shortens coolantservice life.

Use only Caterpillar products or commercial productsthat have passed the Caterpillar EC-1 specification forpre-mixed or concentrate coolants. Use only Extenderwith Cat ELC.

Failure to follow these recommendations can result inshortened cooling system component life.

Reference: For information about adding Extenderto the cooling system, refer to Operation andMaintenance Manual, Cooling System CoolantExtender (ELC) - Add or consult your Caterpillardealer.


The cooling system pressure cap is located underthe engine hood at the rear of the machine.


1. Open the engine hood. Slowly loosen coolingsystem pressure cap (1) in order to relieve anysystem pressure. Remove the cooling systempressure cap.


Cooling System Coolant Extender (ELC) - Add


2. Drain valve (3) is located on the bottom cornerof the radiator. Open the drain valve. Allow thecoolant to drain into a suitable container.

3. If an Extended Life Coolant (ELC) was previouslyused, flush the cooling system with clean waterand close the drain valve. No other cleaningagents are required.

If you change from another type of coolant to anExtended Life Coolant, close the drain valve. Fillthe cooling system with a solution that consistsof water with a 6 to 10 percent concentration ofCaterpillar cleaning agent. Run the engine for 90minutes. Then, drain the solution. After you drainthe solution, thoroughly flush the cooling systemwith clean water. All of the cleaning agent mustbe removed from the cooling system.

4. Replace the water temperature regulator.

Reference: Refer to Operation and MaintenanceManual, Cooling System Water TemperatureRegulator - Replace for the correct procedure.

5. Add the Extended Life Coolant.

Reference: Refer to Operation and MaintenanceManual, Capacities (Refill) for the proper amount.

6. Start the engine. Run the engine without thecooling system pressure cap until the thermostatopens and the coolant level stabilizes.

7. Stop the engine. Maintain the coolant level in sightgauge (2) on the radiator.

8. Inspect the cooling system pressure cap andthe cap seal. Clean the cooling system pressurecap with a clean cloth. If necessary, replace thecooling system pressure cap.

9. Install the cooling system pressure cap. Close theengine hood.

i01889516

Cooling System CoolantExtender (ELC) - AddSMCS Code: 1352-544-NL

Pressurized system: Hot coolant can cause seri-ous burn. To open cap, stop engine, wait until ra-diator is cool. Then loose the cap slowly to relievethe pressure.







When a Caterpillar Extended Life Coolant (ELC) isused, an Extender must be added to the coolingsystem.

Use a 8T-5296 Coolant Test Kit to check theconcentration of the coolant.

Reference: For additional information about addingExtender, refer to Special Publication, SEBU6250,Caterpillar Machine Fluids Recommendations orconsult your Caterpillar dealer.

110 SEBU7581-09Maintenance SectionCooling System Coolant Level - Check


The cooling system pressure cap is located underthe engine hood at the rear of the machine.


1. Open the engine hood. Slowly loosen coolingsystem pressure cap (1) in order to relieve anysystem pressure. Remove the cooling systempressure cap.


2. If necessary, open drain valve (3) and drainenough coolant from the radiator in order to allowthe addition of the Extender to the cooling system.

3. Add one bottle of 111-2372 (ELC) Extender tothe coolant system.

4. Maintain the coolant level in sight gauge (2) onthe radiator.

5. Install the cooling system pressure cap. Close theengine hood.

i01930829

Cooling System Coolant Level- CheckSMCS Code: 1350-535-FLV






Cooling System Coolant Sample (Level 1) - Obtain




g00981214Illustration 140The sight gauge is located on the right side of the machine.


1. Maintain the coolant level within the sight gauge.

2. If the coolant level is low, slowly remove coolingsystem pressure cap (1).

3. Add the required coolant in order to maintain thecoolant level within sight gauge (2).

Note: If it is necessary to add coolant daily, checkfor leaks.

4. Inspect the cooling system pressure cap and thecap seal. Clean the cap and install the cap. If thecap is damaged, install a new cooling systempressure cap.

5. Inspect the radiator core for debris. Clean theradiator core, if necessary.

Reference: Refer to Operation and MaintenanceManual, Radiator Core - Clean for moreinformation.

i01889351

Cooling System CoolantSample (Level 1) - ObtainSMCS Code: 1350-008; 1395-008; 7542

NOTICEDo not use the same vacuum sampling pump for ex-tracting oil samples that is used for extracting coolantsamples.

A small residue of either type sample may remain inthe pump and may cause a false positive analysis forthe sample being taken.

Always use a designated pump for oil sampling and adesignated pump for coolant sampling.

Failure to do so may cause a false analysis whichcould lead to customer and dealer concerns.

Note: Level 1 results may indicate a need forLevel 2 Analysis.

112 SEBU7581-09Maintenance SectionCooling System Coolant Sample (Level 2) - Obtain


Obtain the sample of the coolant as close as possibleto the recommended sampling interval. In orderto receive the full effect of SOS analysis, youmust establish a consistent trend of data. In orderto establish a pertinent history of data, performconsistent samplings that are evenly spaced.Supplies for collecting samples can be obtained fromyour Caterpillar dealer.

Use the following guidelines for proper sampling ofthe coolant:

Complete the information on the label for thesampling bottle before you begin to take thesamples.

Keep the unused sampling bottles stored in plasticbags.

Obtain coolant samples directly from the coolantsample port. You should not obtain the samplesfrom any other location.

Keep the lids on empty sampling bottles until youare ready to collect the sample.

Place the sample in the mailing tube immediatelyafter obtaining the sample in order to avoidcontamination.

Never collect samples from expansion bottles.

Never collect samples from the drain for a system.

Submit the sample for Level 1 analysis.

For additional information about coolant analysis, seeSpecial Publication, SEBU6250, Caterpillar MachineFluids Recommendations or consult your Caterpillardealer.

i01889386

Cooling System CoolantSample (Level 2) - ObtainSMCS Code: 1350-008; 1395-008; 7542

NOTICEDo not use the same vacuum sampling pump for ex-tracting oil samples that is used for extracting coolantsamples.

A small residue of either type sample may remain inthe pump and may cause a false positive analysis forthe sample being taken.

Always use a designated pump for oil sampling and adesignated pump for coolant sampling.

Failure to do so may cause a false analysis whichcould lead to customer and dealer concerns.


Obtain the sample of the coolant as close as possibleto the recommended sampling interval. Suppliesfor collecting samples can be obtained from yourCaterpillar dealer.

Refer to Operation and Maintenance Manual,Cooling System Coolant Sample (Level 1) - Obtainfor the guidelines for proper sampling of the coolant.

Submit the sample for Level 2 analysis.


Cooling System Water Temperature Regulator - Replace

Reference: For additional information about coolantanalysis, refer to Special Publication, SEBU6250,Caterpillar Machine Fluids Recommendations orconsult your Caterpillar dealer.

i01940916

Cooling System WaterTemperature Regulator -ReplaceSMCS Code: 1355-510; 1393-010





Replace the water temperature regulator (thermostat)on a regular basis in order to reduce the chance ofunscheduled downtime and of problems with thecooling system.

The thermostat should be replaced after the coolingsystem has been cleaned. Replace the thermostatand replace the seals while the cooling system iscompletely drained or while the cooling systemcoolant is drained to a level that is below thethermostat housing.

Note: If you are only replacing the thermostat, drainthe cooling system coolant to a level that is belowthe thermostat housing.

NOTICEFailure to replace the engine's thermostat on a regu-larly scheduled basis could cause severe engine dam-age.

Reference: For information on replacing the watertemperature regulator, refer to Service Manual,SENR6069, Disassembly and Assembly, 938G IIWheel Loader and IT38G II Integrated ToolcarrierEngine Supplement.

i02768027

Differential and Final Drive Oil- ChangeSMCS Code: 3278-044; 4011-044


Refer to Special Publication, NENG2500, CaterpillarDealer Service Tool Catalog for tools and suppliessuitable to collect and contain fluids on Caterpillarproducts.


g00110467Illustration 144Front Differential and Final Drive Drain Plug

114 SEBU7581-09Maintenance SectionDifferential and Final Drive Oil - Change

g00110468Illustration 145Rear Differential and Final Drive Drain Plug

1. Remove the drain plugs for both differentials.Allow the oil to drain into a suitable container.

Note: If your machine is equipped with the axle oilcooler, there are 2 magnetic filters that need to becleaned. If your machine is not equipped with theaxle oil cooler, skip the next step.


2. Remove the magnetic plug on the front filter. Cleanthe magnetic plug with a clean nonflammablesolvent. Install the magnetic plug. Repeat theprocess for the rear magnetic filter.

3. Clean the drain plugs and install the drain plugs.

g00277215Illustration 147Front Differential and Final Drive Filler Plug


Note:Wipe the covers and surfaces around openingsbefore you remove the dipstick/fill plug.

4. Remove the dipstick/fill plugs for both differentials.Fill the differentials with oil. Maintain the oilbetween the ADD mark and the FULL mark onthe dipstick/fill plug of each differential.

Reference: Refer to Operation and MaintenanceManual, Lubricant Viscosities and Capacities(Refill).

Note: Make sure that the dipstick/fill plugs areinstalled completely before you check the oil level.If the dipstick/fill plug is not installed completely, anincorrect oil level reading can occur.

5. Install the dipstick/fill plugs for each differential.Operate the machine for a few minutes and allowthe oil to flow completely through the axles.Remove the dipstick/fill plugs and check the oillevel. Add oil, if necessary.

6. Clean the dipstick/fill plugs and install thedipstick/fill plugs.


Differential and Final Drive Oil Level - Check

i01234718

Differential and Final Drive OilLevel - CheckSMCS Code: 3278-535-FLV; 4011-535-FLV




1. Operate the machine for a few minutes. This willallow all of the oil to reach a common level.

2. Park the machine on level ground. Lower theattachment and apply slight downward pressure.Engage the parking brake. Stop the machine.


Front Differential and Final Drive Filler Plug


3. Remove the dipstick/fill plug for the differential.Wipe off the dipstick and reinstall the dipstick/fillplug completely. This will ensure a more accuratemeasurement.

4. Remove the dipstick/fill plug for the differentialagain. Check the oil level. Maintain the oil levelbetween the ADD mark and the FULL mark.Add oil, if necessary.

5. Install the dipstick/fill plug.

i01897324

Differential and Final Drive OilSample - ObtainSMCS Code: 3278-008; 4011-008; 4070-008; 7542




1. Operate the machine for a few minutes beforeobtaining the oil sample. This will thoroughly mixthe differential oil for a more accurate sample.

116 SEBU7581-09Maintenance SectionDrive Shaft Spline (Center) - Lubricate

g00277215Illustration 151Front Differential and Final Drive Filler Plug


2. The differential and final drives are not equippedwith sampling valves. Obtaining an oil sample willrequire the use of a vacuum pump or equivalentin order to extract the oil from the component.Extract the oil through the filler openings on thedifferential and final drives.

3. Complete any additional required work. Fill thedifferential and final drives with oil, as required.Install the dipstick/fill plugs.

Reference: For more information, refer to SpecialPublication, SEBU6250, Caterpillar MachineFluids Recommendations and Special Publication,PEHP6001, How To Take A Good Oil Sample.

i01351848

Drive Shaft Spline (Center) -LubricateSMCS Code: 3253-086-SN


Wipe off the fitting before any lubricant is applied.

Apply lubricant through the fitting on the drive shaftspline.

i01351853

Drive Shaft Support Bearing -LubricateSMCS Code: 3267-086-BD

Note: For better access, articulate the machine tothe right or to the left. Because the steering framelock cannot be connected, remove the engine startswitch key and turn the battery disconnect switch tothe OFF position in order to keep the machine frombeing articulated.



Drive Shaft Universal Joints - Lubricate


Wipe off the fitting before any lubricant is applied.

Apply lubricant through the fitting on the drive shaftsupport bearing.

i02096936

Drive Shaft Universal Joints -LubricateSMCS Code: 3251-086


1. Wipe off the grease fittings before lubricating.

2. Lubricate all five grease fittings on the universaljoints.

i01701887

Engine Air Filter PrimaryElement - Clean/ReplaceSMCS Code: 1054-070-PY; 1054-510-PY

To avoid personal injury, always wear eye and faceprotection when using pressurized air.

NOTICECaterpillar recommends certified air filter cleaning ser-vices that are available at Caterpillar dealers. TheCaterpillar cleaning process uses proven proceduresto assure consistent quality and sufficient filter life.

Observe the following guidelines if you attempt toclean 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 removethe dust from the filter element. Air pressure must notexceed 207 kPa (30 psi). Direct the air flow up thepleats and down the pleats from the inside of the filterelement. Take extreme care in order to avoid damageto the pleats.

Do not use air filters with damaged pleats, gaskets, orseals. Dirt entering the engine will cause damage toengine components.

Clean the engine air filter primary element whenthe clogged air filter indicator is displayed on theCaterpillar controller. Clean the engine air filterprimary element as soon as convenient.


118 SEBU7581-09Maintenance SectionEngine Air Filter Primary Element - Clean/Replace

1. Open the access door on the right side of themachine.


2. Loosen the four cover latches and remove the aircleaner cover.

Note: The latches for the air cleaner housing maysnap open when you release the latches.


3. Remove the primary filter element from the aircleaner housing. In order to remove the engine airfilter primary element, pull the element outward.While you pull the element outward, rock theelement.

Use Steps 4 through 6 in order to clean theprimary element:

4. Inspect the primary element. If the pleats, thegaskets, or the seals are damaged, discard theelement. Replace a damaged primary elementwith a clean primary element.


5. If the primary element is not damaged, clean theprimary element.

Pressurized air can be used to clean a primaryelement that has not been cleaned more than twotimes. Use filtered, dry air at a maximum pressureof 207 kPa (30 psi).

Note: Pressurized air will not remove deposits ofcarbon and oil.

6. When you clean the primary element, alwaysbegin in the inside of the element (clean side).This will force dirt particles toward the outside ofthe element (dirty side).

Direct the air along the length (inside) of the filter.This will help prevent damage to the paper pleats.

Note: Do not aim the stream of air directly at theprimary element. Dirt could be forced further into thepleats.

Use Steps 7 through 10 in order to inspect theprimary element:



Engine Air Filter Secondary Element - Replace

7. Place a light bulb inside the filter element. Usea 60 watt blue light in a dark room or in a similarfacility. Inspect the primary element for light thatmay show through the filter material.

8. Inspect the primary element while you rotate theelement. Inspect the primary element for tearsand/or holes. Do not use a primary element thathas any tears and/or holes in the filter material. Donot use a primary element with damaged pleats,gaskets, or seals.

9. If it is necessary, compare the primary elementto a new primary element. Use a new primaryelement that has the same part number. This maybe necessary in order to confirm the results of theinspection.

10.Discard a damaged primary element.

Use Steps 11 through 14 to install a cleanprimary element:

NOTICEDo not use a filter if the pleats, the gaskets or the sealsare damaged.

11. Install a clean primary filter element over theengine air filter secondary element. Apply firmpressure to the end of the primary element asyou gently rock the filter element. This seats theprimary element.

12.Clean the cover for the air cleaner housing. Alignthe slot on the cover with the pin on the air cleanerhousing. Install the cover.


13.Reset the air filter service indicator, if necessary.

14.Close the access door.

i01702009

Engine Air Filter SecondaryElement - ReplaceSMCS Code: 1054-510-SE

NOTICEService the air filter only with the engine stopped. En-gine damage could result.

NOTICEAlways replace the secondary element. Do not at-tempt to reuse it by cleaning. Engine damage couldresult.

Note: Replace the secondary element when youservice the primary element for the third time. Ifa clean primary element has been installed anda warning for the air filter still occurs, replace thesecondary element. Also if the exhaust smokeremains black and a clean primary element has beeninstalled, replace the secondary element.

1. Remove the primary element.

Reference: Refer to Operation and MaintenanceManual, Engine Air Filter Primary Element -Clean/Replace for the correct procedure.


2. Remove the secondary element.

3. Cover the air inlet opening. Clean the inside ofthe air cleaner housing.

4. Inspect the gasket between the air inlet pipe andthe air cleaner housing. Replace the gasket if thegasket is damaged.

5. Uncover the air inlet opening. Install a newsecondary element.

120 SEBU7581-09Maintenance SectionEngine Air Filter Service Indicator - Inspect

6. Install a clean primary element and the cover forthe air cleaner housing.

7. Close the access door.

i01701828

Engine Air Filter ServiceIndicator - InspectSMCS Code: 7452-040

NOTICEService the air cleaner only with the engine stopped.Engine damage could result.



1. Open the engine access door on the right sideof the machine. The air filter service indicator islocated in the engine compartment on the rightside of the machine.

2. If the yellow piston in the air filter service indicatorenters the red zone, service the air cleaner.

3. Check the condition of the air filter serviceindicator. If the air filter service indicator isdamaged, then replace the air filter serviceindicator.

4. Close the engine access door.

i01701769

Engine Air Filter ServiceIndicator - Inspect/ReplaceSMCS Code: 7452-040; 7452-510



To check the condition of the service indicator, tryresetting the service indicator. This should requireless than three pushes of the reset button.


Engine Air Precleaner - Clean

Next, check the movement of the yellow piston in theservice indicator. Start the engine and acceleratethe engine to high idle for a few seconds. Afterthe governor control pedal is released, the yellowpiston should remain at the highest position that wasachieved during acceleration.

If either of these conditions are not met, replace theservice indicator.

i00103643

Engine Air Precleaner - CleanSMCS Code: 1055-070

Use the ladder and the platform in order to accessthe precleaner bowl. The ladder and the platform arelocated on the right side of the machine.

1. Empty the precleaner bowl whenever the dirtreaches the FULL mark.


2. Loosen the wing nut on the cover and removethe cover.

3. Empty the precleaner bowl. Wash the precleanerbowl and wash the cover.

4. Install the precleaner bowl and install the cover.Tighten the wing nut until the wing nut is only fingertight. Do not use a tool to tighten the wing nut.

i01700274

Engine Crankcase Breather -CleanSMCS Code: 1317-070


Open the engine hood. The crankcase breather islocated on the right side of the machine.


1. Loosen the breather outlet hose clamp . Removethe breather hose from the breather cover.

2. Remove the breather element cover assembly .

3. Check the condition of the cover seal. If the usedseal is damaged, replace the seal with a new seal.

4. Wash the element and the cover assembly inclean, nonflammable solvent.

5. To dry the element, shake the element or use airpressure.

122 SEBU7581-09Maintenance SectionEngine Oil Level - Check

6. Inspect the breather hose for damage. Replacethe breather hose, if necessary.

7. Install the breather element. Install the breatherelement cover assembly.

8. Install the breather hose and breather outlet hoseclamp.


i02097055

Engine Oil Level - CheckSMCS Code: 1000-535-FLV




NOTICEDo not under fill or overfill engine crankcase with oil.Either condition can cause engine damage.


1. Open the engine access door on the right side ofthe machine. The engine oil dipstick (2) is locatedon the right side of the machine.


2. While the engine is stopped, maintain the oil levelat the FULL mark on the engine oil dipstick (2).

3. If necessary, remove the engine oil filler cap (1)and add oil.

4. Clean the engine oil filler cap and install theengine oil filler cap.

5. Close the engine access door.

i01897281

Engine Oil Sample - ObtainSMCS Code: 1348-008; 7542




1. Operate the machine for a few minutes beforeobtaining the oil sample. This will thoroughly mixthe engine oil for a more accurate sample.


Engine Oil and Filter - Change


2. Open the engine hood.


The in-line sampling valve is located on the right side of the enginecompartment.


On Low Sound machines and Blue Angel machines, the in-linesampling valve for the engine oil is located on the right side of theengine near the number two secondary fuel filter.

3. Use the in-line sampling valve in order to obtaina sample of engine oil.


Reference: For more information, refer to SpecialPublication, SEBU6250, Caterpillar MachineFluids Recommendations and Special Publication,PEHP6001, How To Take A Good Oil Sample.

i02235802

Engine Oil and Filter - ChangeSMCS Code: 1318-510

Selection of the Oil Change Interval

NOTICEA 500 hour engine oil change interval is available, pro-vided that the operating conditions and recommend-ed multigrade oil types are met. When these require-ments are not met, shorten the oil change interval to250 hours, or use an SOS oil sampling and analysisprogram to determine an acceptable oil change inter-val.

If you select an interval for oil and filter change that istoo long, you may damage the engine.

Caterpillar oil filters are recommended.

Recommended multigrade oil types are listed in Table15. Do not use single grade oils.


Abnormally harsh operating cycles or harshenvironments can shorten the service life ofthe engine oil. Arctic temperatures, corrosiveenvironments, or extremely dusty conditions mayrequire a reduction in engine oil change intervalsfrom the recommendations in Table 15. Also referto Special Publication, SEBU5898, Cold WeatherRecommendations. Poor maintenance of air filtersor of fuel filters requires reduced oil change intervals.See your Caterpillar dealer for more information if thisproduct will experience abnormally harsh operatingcycles or harsh environments.

124 SEBU7581-09Maintenance SectionEngine Oil and Filter - Change

Table 15

938G Series II Wheel LoaderIT38G Series II Integrated Toolcarrier

Engine Oil Change Interval(1)

Operating Conditions

Severe

FuelSulfurfrom0.3% to0.5%

MultigradeOil Type

Normal(2) HighLoadFactor(3)above18 L (4.8US gal)per hrof fuel

(4)

Altitudeabove1830 m(6000 ft)

Cat DEOPreferred 500 hr 500 hr 500 hr 250 hr

(6)

ECF-111.0

minimumTBN(4)Preferred

500 hr 500 hr 500 hr 250 hr(6)

ECF-1TBN(4)

below 11.0500 hr 500 hr 250 hr(5) 250 hr(6)

API CG-4 500 hr 250 hr(5) 250 hr(5) 250 hr(6)

(1) The traditional oil change interval for engines is 250 hours.The standard oil change interval in this machine is 500 hours, ifthe operating conditions and recommended oil types that arelisted in this table are met. Improvements in the engine allowthis engine oil change interval. This new standard interval is notpermitted for other machines. Refer to the applicable Operationand Maintenance Manuals for the other machines.

(2) Normal conditions include these factors: Fuel sulfur below0.3%, altitude below 1830 m (6000 ft), and good air filter andfuel filter maintenance. Normal conditions do not include highload factor, harsh operating cycles, or harsh environments.

(3) High load factors can shorten the service life of your engineoil. Continuous heavy load cycles and very little idle time resultin increased fuel consumption and oil contamination. Thesefactors deplete the oil additives more rapidly. If the average fuelconsumption of your 938G Series II Wheel Loader or IT38GSeries II Integrated Toolcarrier exceeds 18 L (4.8 US gal)perhour, follow the High Load Factor recommendations inTable 15. To determine average fuel consumption, measureaverage fuel consumption for a period of 50 to 100 hours. Ifthe application of the machine is changed, the average fuelconsumption may change.

(4) For sulfur content above 0.5%, refer to Special Publication,SEBU6250, Total Base Number (TBN) and Fuel Sulfur Levelsfor Direct Injection (DI) Diesel Engines.

(5) In order to verify an oil change interval of 500 hours, refer toProgram A below.

(6) Use Program B below to determine an appropriate interval.

Adjustment of the Oil Change Interval

Note: Your Caterpillar dealer has additionalinformation on these programs.

Program A

Verification for an Oil Change Interval of 500 Hours

This program consists of three oil change intervals of500 hours. Oil sampling and analysis is done at 250hours and 500 hours for each of the three intervalsfor a total of six oil samples. The analysis includesoil viscosity and infrared (IR) analysis of the oil. Ifall of the results are satisfactory, the 500 hour oilchange interval is acceptable for the machine in thatapplication. Repeat Program A if you change theapplication of the machine.

If a sample does not pass the oil analysis, take oneof these actions:

Shorten the oil change interval to 250 hours.

Proceed to Program B.

Change to a preferred oil type in Table 15.

Program B

Optimizing Oil Change Intervals

Begin with a 250 hour oil change interval. The oilchange intervals are adjusted by increments. Eachincrement is an additional 50 hours. Periodic oilsampling and analysis is done during each interval.The analysis includes oil viscosity and infrared (IR)analysis of the oil. Repeat Program B if you changethe application of the machine.

If an oil sample does not pass the analysis, shortenthe oil change interval, or change to a preferredmultigrade oil type in the listing above.

References

Reference: Form, PEDP7035, Optimizing OilChange Intervals

Reference: Form, PEDP7036, SOS Fluid Analysis

Reference: Form, PEDP7076, Understanding theSOS Oil Analysis Tests


Engine Oil and Filter - Change

Procedure for Changing the EngineOil and Filter





1. Open the engine access door on the right side ofthe machine.


Bottom View

2. The crankcase drain valve is on the left side ofthe oil pan. Open the crankcase drain valve. Allowthe oil to drain into a suitable container. Close thedrain valve.


3. Open the engine access door on the left side ofthe machine.


4. Remove the filter element with a strap typewrench.

Reference: Refer to Operation and MaintenanceManual, Oil Filter - Inspect for information aboutinspecting used filter elements for metal and forother debris.

5. Clean the filter housing base. Make sure that theused filter gasket is completely removed.


126 SEBU7581-09Maintenance SectionEngine Valve Lash - Check

6. Apply a thin coat of clean engine oil to the seal onthe new filter. Install a new engine oil filter handtight until the seal of the engine oil filter contactsthe base. Note the position of the index marks onthe filter in relation to a fixed point on the filterbase.

Note: There are rotation index marks on the engineoil filter that are spaced 90 degrees or 1/4 or a turnaway from each other. When you tighten the engineoil filter, use the rotation index marks as a guide.

7. Tighten the filter according to the instructionsthat are printed on the filter. Use the index marksas a guide. For non-Caterpillar filters, use theinstructions that are provided with the filter.

Note: You may need to use a Caterpillar strapwrench, or another suitable tool, in order to turnthe filter to the amount that is required for finalinstallation. Make sure that the installation tool doesnot damage the filter.


Note: The oil filler plug (1) and the dipstick (2) are onthe right side of the machine.

8. Remove oil filler plug (1). Fill the crankcase withnew oil. Clean the filler plug and install the fillerplug.

Reference: Refer to Operation and MaintenanceManual, Capacities (Refill) in order to determinethe correct amount of oil.

9. Start the engine and allow the oil to warm. Checkthe engine for leaks.

10.While the engine is running, check the LOWIDLE side of dipstick (2). Maintain the oil betweenthe ADD mark and the FULL mark. If necessary,add oil.

11.Close the engine access doors and stop theengine.

i01181536

Engine Valve Lash - CheckSMCS Code: 1105-535

For the correct procedure, refer to the appropriateService Manual module for your machine's engine orconsult your Caterpillar dealer.

Note: A qualified mechanic should adjust the enginevalve lash because special tools and training arerequired.

i02235915

Fuel System - PrimeSMCS Code: 1250-548




The fuel system needs to be primed due to thefollowing circumstances:

The primary fuel filter has been changed.

The secondary fuel filter has been changed.

The fuel injectors have been removed.

The engine has run out of fuel.

Note: The volume of air in the water separator issmall. Usually, it is not necessary to prime the fuelsystem if only the water separator element has beenchanged.

Your machine is equipped with an electric fuel primingpump. The priming pump is located on the right sideof the engine above the primary fuel filter.


Fuel System Primary Filter (Water Separator) - Drain


1. Open the engine hood in order to access the fuelpriming pump. The fuel priming pump is locatedon the right side of the machine.

2. Place the drain hose (3) into a suitable containerin order to catch the fuel. Open the drain valve(2). Move the toggle switch (1) in order to activatethe priming pump.

3. Operate the priming pump until fuel comes out ofthe drain hose. Operate the priming pump untilthe fuel that flows from the drain hose has noair bubbles. Turn off the drain valve. Turn off thepriming pump.

i01801585

Fuel System Primary Filter(Water Separator) - DrainSMCS Code: 1263-543





The water separator is located in the enginecompartment on the right side of the machine.



2. Loosen the drain valve on the bottom of thewater separator element. Allow the water and thesediment to drain into a suitable container.

3. Tighten the drain valve.

Note: The water separator is under suction duringnormal engine operation. Tighten the drain valve inorder to prevent air leakage into the fuel system.

4. If the engine fails to start, change the fuel filter. Ifthere is a power loss, change the fuel filter.


128 SEBU7581-09Maintenance SectionFuel System Primary Filter (Water Separator) Element - Replace

i01801565

Fuel System Primary Filter(Water Separator) Element -ReplaceSMCS Code: 1260-510; 1263-510-FQ




NOTICEDo not fill fuel filters with fuel before installing them.The fuel will not be filtered and could be contaminated.Contaminated fuel will cause accelerated wear to fuelsystem parts. The fuel system should be primed priorto starting the engine.


The water separator element is located in the enginecompartment on the right side of the machine.



2. Open the drain valve (1) on the water separatorbowl (3). Allow the water and fuel to drain into asuitable container.

3. Support the water separator element and rotatethe retaining ring (2) counterclockwise. Removethe retaining ring (2).

4. Remove the water separator element from themounting base.

5. Remove the water separator bowl (3) from thefilter element. Clean the water separator bowl (3)and clean the O-ring groove.

Note: The water separator bowl (3) is reusable. Donot discard the water separator bowl (3).

6. Inspect the O-ring seal of the water separatorbowl (3) for damage. Replace the O-ring seal, ifnecessary.

7. Lubricate the O-ring seal with clean diesel fuel orlubricate the O-ring seal with motor oil. Place theO-ring seal in the water separator bowl (3).

8. Spin the water separator bowl (3) onto the newfilter element by hand until the filter element issnug. Do not use tools to tighten the filter element.

9. Install the new water separator element. Rotatethe retaining ring (2) clockwise in order to fastenthe filter to the mounting base. Continue to turnthe retaining ring until an audible click is heard. Ifa click is not heard, then the retaining ring has notbeen rotated far enough and the element is not inthe locked position.

10. Tighten the drain valve (1) on the water separatorbowl (3).

Note: The water separator element is under suctionduring normal engine operation. Tighten drain valve(1) in order to prevent air leakage into the fuel system.


Fuel System Secondary Filter - Replace

11.Prime the fuel system in order to fill the waterseparator element with fuel. Refer to Operationand Maintenance Manual, Fuel System Prime.

12.Close the engine hood.

i02235924

Fuel System Secondary Filter -ReplaceSMCS Code: 1261-510-SE

Personal injury or death can result from a fire.

Fuel leaked or spilled onto hot surfaces or electri-cal components can cause a fire.

Clean up all leaked or spilled fuel. Do not smokewhile working on the fuel system.

Turn the disconnect switch OFF or disconnect thebattery when changing fuel filters.




NOTICEDo not fill fuel filters with fuel before installing them.Contaminated fuel will cause accelerated wear to fuelsystem parts.


Open the rear hood. The secondary fuel filter islocated on the right side of the machine.


1. Place a suitable container under the drain valves.Open drain valve (3) first. Then, immediatelyopen drain valve (2). Drain the fuel into a suitablecontainer. When the fuel stops draining, keep thedrain valves open. Loosen inverted filter (1) for1/4 turn. As the filter is loosened, additional fuelmay drain from the drain valves. When the fuelstops draining, loosen the filter for an additional1/4 turn. Observe the flow of the fuel. Repeat thisprocedure until fuel does not drain from the drainvalves. Close the drain valves. Properly disposeof the fuel.

Note: Make sure that the drain valves are opened inthe proper order. If you open the wrong drain valvefirst, an air lock in the fuel system may occur. This willnot allow fuel to drain from the filter.

2. Remove the filter (1).

3. Inspect the fuel filter element for debris by cuttingthe filter open. Discard the used fuel filter elementproperly.

130 SEBU7581-09Maintenance SectionFuel Tank Cap and Strainer - Clean

4. Clean the mounting base of the fuel filter. Makesure that all of the old seal is removed from themounting base of the fuel filter.


5. Apply a thin coat of clean diesel fuel to the sealingsurface of the new fuel filter element. Install a newfuel filter hand tight until the seal of the fuel filtercontacts the base. Note the position of the indexmarks on the filter in relation to a fixed point onthe filter base.

Note: There are rotation index marks on the filter thatare spaced 90 degrees or 1/4 of a turn away fromeach other. When you tighten the fuel filter, use therotation index marks as a guide.

6. Tighten the filter according to the instructionsthat are printed on the filter. Use the index marksas a guide. For non-Caterpillar filters, use theinstructions that are provided with the filter.

You may need to use a Caterpillar strap wrench,or another suitable tool, in order to turn the filterto the amount that is required for final installation.Make sure that the installation tool does notdamage the filter.

7. Prime the fuel system.

Reference: For more information, refer toOperation and Maintenance Manual, Fuel System- Prime.


i01701109

Fuel Tank Cap and Strainer -CleanSMCS Code: 1273-070-Z2; 1273-070-STR


The fuel cap is located at the rear of the machine.


1. Open the engine access door on the right side ofthe engine. Lift the lever (5) and turn the lever (5)counterclockwise until the lever stops. Removethe cap.

2. Inspect seal (4) for damage. Replace the seal, ifnecessary.

3. Remove screws (1), filter assembly (2), drainvalve (3) and the gaskets.

4. Remove the strainer that is located in the filleropening.

5. Wash the strainer and the fuel tank cap in a clean,nonflammable solvent.

6. Install a new cap filter kit. Install the gaskets, drainvalve (3), filter assembly (2), and screws (1).


Fuel Tank Water and Sediment - Drain

7. Install the strainer into the filler opening.

8. Install the fuel tank cap. Close the engine accessdoor.

i01703779

Fuel Tank Water and Sediment- DrainSMCS Code: 1273-543-M&S




Note: If the water separator bowl is full on a dailybasis, drain the fuel tank on a daily basis.


The fuel tank drain valve is located at the rear of themachine underneath the machine.

Slowly remove the fuel tank cap in order to relievepressure.


Open the fuel tank drain valve. Allow the water andsediment to drain into a suitable container.

Close the fuel tank drain valve.

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Fuses - ReplaceSMCS Code: 1417-510

NOTICEReplace the fuses with the same type and size only.Otherwise, electrical damage can result.

If it is necessary to replace fuses frequently, an electri-cal problem may exist. Contact your Caterpillar dealer

Fuses protect the electrical system from damage thatis caused by overloaded circuits.


132 SEBU7581-09Maintenance SectionHood Tilt Actuator - Lubricate

Open the cab door on the right side of the machinein order to access the fuse panel.

Replace the fuse if the element separates. If theelement of a new fuse separates, check the circuit.Repair the circuit, if necessary.

i01316855

Hood Tilt Actuator - LubricateSMCS Code: 7275-086


1. Raise the engine hood. The hood tilt actuator islocated on the right side of the machine.

2. Fully extend the cylinder and wipe off the innerpost with a clean cloth. Then, lubricate the entirelength of the inner post.

3. Wipe off both fittings on the cylinder. Then, applylubricant through the two fittings until the lubricantescapes back through each fitting.


i01235285

Hydraulic SystemBiodegradable Oil FilterElement - Replace(If Equipped)SMCS Code: 5068-510

S/N: JAN1-Up

S/N: PHN1-Up


1. Remove four bolts (1) and plate (2) in order toaccess the oil filter.


2. Close valve (3) in order to prevent oil leakage.

3. Remove filter housing drain plug (4). Allow the oilto drain into a suitable container.

4. Use a strap type wrench to remove the lower partof filter housing (5).

5. Remove the used filter element. Dispose of theused filter element properly.

6. Clean the filter housing and the filter housing basewith a clean, nonflammable solvent.


Hydraulic System Oil - Change

7. Inspect the filter housing seal. Replace the sealif the seal is damaged.

8. Insert a new filter element into the filter housing.

9. Install filter housing drain plug (4). Install filterhousing (5) into the filter housing base. Tightenthe filter housing by hand.

10.Open valve (3).

11. Install plate (2) and four bolts (1).

12.Start the engine and run the engine for a fewminutes. Maintain the hydraulic oil level tothe FULL mark in the sight gauge. Add oil, ifnecessary.

13.Stop the engine.

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Hydraulic System Oil - ChangeSMCS Code: 5056-044

Selection of the Oil Change IntervalYour machine may be able to use a 4000 hourinterval for the hydraulic oil. The hydraulic oil is inthe 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 oilshould be monitored during intervals of 500 hours.The extended 4000 hour interval can be used if thefollowing criteria are met.

Oil Filters

Caterpillar oil filters are recommended. The intervalfor changing the oil filter should be 500 hours.

Oil

The 4000 hour interval for changing the oil is for thefollowing oil types.

Caterpillar Hydraulic Oil HYDO

Caterpillar Transmission/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 oil with a minimum zinccontent of 900 ppm

If Caterpillar oils cannot be used, use heavy-dutyoils with the following classification: Cat ECF-1, APICG-4, API CF, and TO-4

These oils must have a minimum zinc additive of0.09 percent (900 ppm).

Note: Industrial hydraulic oils are not recommendedin Caterpillar hydraulic systems.

Monitoring the Condition

Manual Cargadora

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