Operation and Maintenance Manual Excerpt - Bob …bobwardjrequipment.com/pdf/963c.pdfThe circuit breakers are located behind the console panel on the left side of the machine. Illustration

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MAINTENANCE INTERVALSOperation and Maintenance Manual Excerpt

SEBU7403-05December 2006

Operation andMaintenanceManual963C Track-Type LoaderBBD1-Up (Machine)

70 SEBU7403-05Maintenance SectionMaintenance Interval Schedule

i02664781

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.

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

When Required

Battery - Recycle .................................................. 72Battery, Battery Cable or Battery Disconnect Switch -Replace ............................................................... 72

Bucket Teeth and Cutting Edges - Inspect/Replace ............................................................... 73

Cab Air Filter - Clean/Replace .............................. 74Circuit Breakers and Fuses - Reset/Replace ........ 75Engine Air Filter Primary Element - Clean/Replace ............................................................... 84

Engine Air Filter Secondary Element - Replace ... 85Engine Air Precleaner - Clean .............................. 86Equalizer Bar Pins - Inspect ................................. 90Front Idler Position - Check .................................. 92Fuel System - Prime ............................................. 93Oil Filter - Inspect ................................................ 104Radiator Core - Clean ......................................... 107Radiator Pressure Cap - Clean/Replace ............ 108Ripper Tip and Shank Protector - Inspect/Replace ............................................................. 109

Windows - Clean .................................................. 112Window Washer Reservoir - Fill ........................... 113Window Wiper - Inspect/Replace ......................... 113

Every 10 Service Hours or Daily

Backup Alarm - Test .............................................. 72Bucket Lower Pivot Pin - Lubricate ....................... 73Cooling System Level - Check .............................. 82Engine Oil Level - Check ...................................... 87Fuel System Water Separator - Drain ................... 96Hydraulic System Oil Level - Check ..................... 99

Indicators and Gauges - Test .............................. 103Pump Drive Gearbox Oil Level - Check .............. 106Seat Belt - Inspect .............................................. 109

Every 50 Service Hours or Weekly

Idler Swing Link - Lubricate ................................ 102Track Pins - Inspect ............................................. 112

Every 100 Service Hours or 2 Weeks

Loader Linkage Pins - Lubricate ......................... 104Multipurpose Bucket - Lubricate ......................... 104

Initial 250 Service Hours

Engine Oil and Filter - Change ............................. 88Fuel System Primary Filter (Water Separator)Element - Replace .............................................. 94

Fuel System Secondary Filter - Replace .............. 95

Every 250 Service Hours or Monthly

Battery - Inspect .................................................... 72Belt - Inspect/Replace ........................................... 73Engine Oil Sample - Obtain .................................. 88Equalizer Bar Pins - Lubricate .............................. 90Final Drive Oil Level - Check ................................ 91Fuel Tank Water and Sediment - Drain ................. 96Pivot Shaft Oil Level - Check .............................. 105Recoil Piston - Lubricate ..................................... 108Track - Check/Adjust ............................................ 110

Initial 500 Service Hours

Engine Valve Lash - Check ................................... 89

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

Cooling System Coolant Sample (Level 2) -Obtain ................................................................. 79

Every 500 Service Hours or 3 Months


Engine Crankcase Breather - Clean ..................... 86Engine Oil and Filter - Change ............................. 88Final Drive Oil Sample - Obtain ............................ 91Fuel System Primary Filter (Water Separator)Element - Replace .............................................. 94

Fuel System Secondary Filter - Replace .............. 95Fuel Tank Cap and Strainer - Clean ..................... 96Hydrostatic Transmission and Hydraulic System OilSample - Obtain ................................................ 101

Pump Drive Gearbox Oil Sample - Obtain .......... 106

Every 1000 Service Hours

Hydrostatic Transmission and Hydraulic SystemFilters - Replace ................................................ 100

SEBU7403-05 71Maintenance Section

Maintenance Interval Schedule

Every 2000 Service Hours

Engine Valve Lash - Check ................................... 89

Every 2000 Service Hours or 1 Year

Final Drive Oil - Change ....................................... 90Hydraulic System Oil - Change ............................. 97Pump Drive Gearbox Oil - Change ..................... 105

Every Year


Refrigerant Dryer - Replace ................................ 109

Every 3000 Service Hours or 2 Years

Cooling System Water Temperature Regulator -Clean/Replace .................................................... 83

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

Seat Belt - Replace .............................................. 110

Every 6000 Service Hours or 3 Years

Cooling System Extended Life Coolant Extender -Add ...................................................................... 82

Every 12 000 Service Hours or 6 Years

Cooling System Extended Life Coolant - Change .. 80

72 SEBU7403-05Maintenance SectionBackup Alarm - Test

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Backup Alarm - Test(If Equipped)SMCS Code: 7406-081

g00956382Illustration 89

The backup alarm is located at the rear of themachine behind the radiator grill.

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

Move the speed/direction control lever to theREVERSE position.

The backup alarm should sound immediately.The backup alarm should continue to sound untilthe speed/direction control lever is moved to theNEUTRAL position or to the FORWARD position.

i00529764

Battery - InspectSMCS Code: 1401-040

Tighten the battery retainers on all batteries at every1000 hour interval.

Perform the following procedures at every 1000 hourinterval. Check the following areas more often, asrequired:

• Clean the top of the batteries with a clean cloth.

• Keep the terminals clean and coat the terminalswith petroleum jelly.

• Keep the terminal covers in place.

1. Open the battery access covers. The batteryaccess covers are located on both sides of themachine at the rear of the machine.

2. Clean the top of the batteries with a cleancloth. Keep the terminals clean and coated withpetroleum jelly. Install the terminal covers afteryou coat the terminals.

3. Close the battery access covers.

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

i00637583

Battery, Battery Cable orBattery Disconnect Switch -ReplaceSMCS Code: 1401-510; 1402-510; 1411-510

1. Turn the engine start switch key to the OFFposition. Turn all of the switches to the OFFposition.

2. Turn the battery disconnect switch to the OFFposition. Remove the key.

3. Disconnect the battery cable at the batterydisconnect switch. The battery disconnect switchis connected to the machine frame.

4. Disconnect the negative battery cable at thebattery.

5. Make necessary repairs or replace the battery.

6. Connect the negative battery cable at the battery.

7. Connect the battery cable at the battery disconnectswitch.

8. Install the key and turn the battery disconnectswitch to the ON position.


Belt - Inspect/Replace

i01897267

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

Inspect the Belt1. Open the engine compartment access cover that

is located on the left hand side of the machine.


2. Inspect the condition of the belt. Measure the beltdeflection. The belt should deflect 13 to 19 mm(.50 to .75 inch) under 110 N (25 lb) of force.

Replace the Belt

Remove the Belt

1. Open the engine compartment access cover thatis located on the left hand side of the machine.


2. Insert a 1/2 inch breaker bar into square hole onthe belt tensioner.

3. Push up the 1/2 inch breaker bar in order toremove the tension from the belt.

4. Remove the belt from the pulleys.

5. Remove the belt from the machine.

Install the Belt

1. Install a new belt over the fan.

2. Insert a 1/2 inch breaker bar on the tensioner.

3. Push up the 1/2 inch breaker bar in order to installthe new belt on the tensioner.

4. Close the engine compartment access cover thatis located on the left hand side of the machine.

i01871932

Bucket Lower Pivot Pin -LubricateSMCS Code: 6108-086-PN


Lubricate two fittings. There is one fitting on eachside of the bucket.

i01928050

Bucket Teeth and CuttingEdges - Inspect/ReplaceSMCS Code: 6801-040; 6801-510; 6822-040;

6822-510

Personal injury or death can result from bucketfalling.

Block the bucket before changing bucket tips.

1. Raise the bucket and block up the bucket. Onlyblock up the bucket to a sufficient height forremoving the bucket tips.

74 SEBU7403-05Maintenance SectionCab Air Filter - Clean/Replace

2. Shut off the engine.

3. Drive the pin out of the bucket tip from the retainerside of the bucket tip. Remove the bucket tip andthe retainer.

4. Clean the adapter, the pin, and the retainer. Installthe retainer in the groove.

5. Install a new bucket tip over the retainer in therunner position or in the digger position.

6. Drive the pin through the retainer, through theadapter, and through the bucket tip from theopposite side of the retainer.

7. To change the cutting edges, remove the two boltsand two nuts. Then, remove the cutting edge.

8. Install the new cutting edge, the two bolts and twonuts.

9. Start the engine.

10. Raise the bucket and remove the supportingblock. Lower the bucket to the ground.

i01871950

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

Note: Clean filters more often in dusty conditions.


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

2. Turn the handle in order to open the door.


3. Remove the filter element. Install a new filterelement or clean the filter element. Clean the filterelement with pressure air. Close and latch thedoor.

4. Close the access door for the engine compartment.


5. Remove the filter element cover that is located inthe operator’s compartment behind the operatorseat.

6. Remove the filter element. Clean the filter elementwith pressure air.

7. Install the filter element. Install the filter cover.


Circuit Breakers and Fuses - Reset/Replace

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Circuit Breakers and Fuses -Reset/ReplaceSMCS Code: 1417-510; 1417-529; 1420-529

Reset Circuit Breakers


The circuit breakers are located behind the consolepanel on the left side of the machine.


Circuit Breaker Reset – Push in thebutton in order to reset the circuit breaker. Ifthe electrical system is working properly, the

button will remain depressed. If the button does notremain depressed, check the appropriate electricalcircuit. Repair the electrical circuit, if necessary.

Replace Fuses


The fuses are located inside the left hand consolecover. Remove the two screws in order to removethe cover.

Fuses – Fuses protect the electricalsystem from damage that is caused byoverloaded electrical circuits. Replace

a fuse if the element separates. If the fuse ofa particular electrical system requires frequentreplacement, check the electrical circuit. Repair theelectrical circuit, if necessary.

NOTICEAlways replace fuses with the same type and capacityfuse that was removed. Otherwise, electrical damagecould result.

NOTICEIf it is necessary to replace fuses frequently, an elec-trical problem may exist.

Contact your Caterpillar dealer.

76 SEBU7403-05Maintenance SectionCircuit Breakers and Fuses - Reset/Replace

(S/N: BBD1-1999)


Spare (1) – 15 Amp




Front and Rear Windshield Wiper/Washer(5) – 15 Amp

Electronic Monitoring System (6) – 10Amp

Transmission (7) – 10 Amp


Air Conditioner (9) – 15 Amp

Bucket (10) – 10 Amp

Seat (11) – 10 Amp

Beacon (12) – 10 Amp


Circuit Breakers and Fuses - Reset/Replace

Horn (13) – 10 Amp

Note: The dome lamp and the display backlight onthe monitoring system also use this fuse.

Electronic Fuel Injection (14) – 15 Amp

Flood Lamp Group (15) – 15 Amp

Trailer Connector and Alarm (16) – 10Amp

Note: The machine security system and the productlink also use this fuse.

12 Volt Power Terminal (17) – 15 Amp

Note: The power converter and the radio also usethis fuse.

Key Start Switch (18) – 10 Amp



(S/N: BBD2000-Up)


Auxiliary circuit (1) – 15 Amp

Air conditioning (2) – 15 Amp



Front and Rear Windshield Wiper/Washer(5) – 15 Amp

Electronic Monitoring System (6) – 10Amp

Transmission (7) – 10 Amp

78 SEBU7403-05Maintenance SectionCooling System Coolant Sample (Level 1) - Obtain



Bucket (10) – 10 Amp

Seat (11) – 10 Amp

Beacon (12) – 10 Amp

Horn (13) – 10 Amp

Note: The dome lamp and the display backlight onthe monitoring system also use this fuse.

Electronic Fuel Injection (14) – 15 Amp

Flood Lamp Group (15) – 15 Amp

Trailer Connector and Alarm (16) – 10Amp

Note: The machine security system and the productlink also use this fuse.

12 Volt Power Terminal (17) – 15 Amp

Note: The power converter and the radio also usethis fuse.

Key Start Switch (18) – 10 Amp



i02391129

Cooling System CoolantSample (Level 1) - ObtainSMCS Code: 1350-008; 1395-008; 1395-554; 7542

NOTICEAlways use a designated pump for oil sampling, anduse a separate designated pump for coolant sampling.Using the same pump for both types of samples maycontaminate the samples that are being drawn. Thiscontaminate may cause a false analysis and an incor-rect interpretation that could lead to concerns by bothdealers and customers.

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.

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

Obtain the sample of the coolant as close as possibleto the recommended sampling interval. In orderto receive the full effect of S·O·S 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.

The recommended sampling interval for Level 1Coolant Analysis is every 500 service hours.

Use the following guidelines for proper sampling ofthe coolant:


Cooling System Coolant Sample (Level 2) - Obtain

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

• Keep the unused sampling bottles stored in plasticbags.

• 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.


Pressurized System: Hot coolant can cause seri-ous burns. To open the cooling system filler cap,stop the engine and wait until the cooling systemcomponents are cool. Loosen the cooling systempressure cap slowly in order to relieve the pres-sure.

1. The machine needs to be operated in order tocirculate the coolant. Collect the sample after anormal workday. Collect the samples from one totwo hours after the engine has been shut off.

2. Start the engine momentarily in order to circulatethe coolant again.


4. The sampling valve for the cooling system islocated on the left side of the machine above thewater pump.

5. Obtain a sample. For additional informationabout coolant analysis, see Special Publication,SEBU6250, “Caterpillar Machine FluidsRecommendations” or consult your Caterpillardealer.

6. Do not allow dirt or other contaminants to enterthe sampling bottle. Fill the sampling bottlethree-fourths from the top. Do not fill the bottlecompletely.

7. Place the sampling bottle with the completed labelinto the mailing tube.

Submit the sample for Level 1 analysis.

i02391117

Cooling System CoolantSample (Level 2) - ObtainSMCS Code: 1350-008; 1395-008; 1395-554; 7542





Obtain the sample of the coolant as close as possibleto the recommended sampling interval. In orderto receive the full effect of S·O·S 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.

80 SEBU7403-05Maintenance SectionCooling System Extended Life Coolant - Change

Perform a Coolant Analysis (Level 2) at initial 500hours for systems that contain extended life coolant(ELC). Perform the analysis yearly after the initial500 hours.

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.

• 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.


Pressurized System: Hot coolant can cause seri-ous burns. To open the cooling system filler cap,stop the engine and wait until the cooling systemcomponents are cool. Loosen the cooling systempressure cap slowly in order to relieve the pres-sure.

1. The machine needs to be operated in order tocirculate the coolant. Collect the sample after anormal workday. Collect the samples from one totwo hours after the engine has been shut off.

2. Start the engine momentarily in order to circulatethe coolant again.


4. The sampling valve for the cooling system islocated on the left side of the machine above thewater pump.

5. Obtain a sample. For additional informationabout coolant analysis, see Special Publication,SEBU6250, “Caterpillar Machine FluidsRecommendations” or consult your Caterpillardealer.

6. Do not allow dirt or other contaminants to enterthe sampling bottle. Fill the sampling bottlethree-fourths from the top. Do not fill the bottlecompletely.

7. Place the sampling bottle with the completed labelinto the mailing tube.

Submit the sample for Level 2 analysis.

i02098208

Cooling System Extended LifeCoolant - ChangeSMCS Code: 1350-044; 1395-044

Personal injury can result from hot coolant, steamand alkali.

At operating temperature, engine coolant is hotand under pressure. The radiator and all linesto heaters or the engine contain hot coolant orsteam. Any contact can cause severe burns.

Remove cooling system pressure cap slowly torelieve pressure only when engine is stopped andcooling system pressure cap is cool enough totouch with your bare hand.

Do not attempt to tighten hose connections whenthe coolant is hot, the hose can come off causingburns.

Cooling System Coolant Additive contains alkali.Avoid contact with skin and eyes.

NOTICECare must be taken to ensure that fluids are containedduring performance of inspection, maintenance, test-ing, adjusting, and repair of the machine. Be preparedto collect the fluid with suitable containers beforeopening any compartment or disassembling any com-ponent containing fluids.



Cooling System Extended Life Coolant - Change

NOTICEMixing ELC with other products reduces the effective-ness of the ELC and shortens the ELC service life. Useonly Caterpillar products or commercial products thathave passed the Caterpillar EC-1 specification for pre-mixed or concentrate coolants. Use only CaterpillarELC Extender with Caterpillar ELC. Failure to followthese recommendations can result in shortened cool-ing system component life.

Some engines utilize Extended Life Coolant (ELC).

Reference: See the Operation and MaintenanceManual, “Maintenance Interval Schedule” for theproper service interval.

If an ELC was previously used, flush the coolingsystem with clean water. No other cleaning agentsare required.

Change the engine coolant more frequently if youfind any of the following conditions:

• The cooling system is heavily contaminated.

• The engine overheats.

• You observe foaming in the radiator.

• Fuel has contaminated the cooling system.

• The cooling system contains non-Caterpillarproducts.

It is important to replace the water temperatureregulator in order to avoid unexpected failure. This isa good preventive maintenance practice that reducesthe chances of unscheduled downtime.

NOTICEOperating a machine with a faulty temperature regu-lator can cause severe engine damage due to over-heating of the engine or overcooling of the engine.

NOTICEFailure to replace the water temperature regulator ona regularly scheduled basis could cause severe en-gine damage.

Note: In a situation that only requires the watertemperature regulator to be replaced, drain thecoolant from the cooling system so that the level ofthe coolant is below the regulator housing.

Draining the Coolant System


1. Slowly loosen the radiator cap in order to relievesystem pressure. Remove the radiator cap.


2. The access plate for the drain hose is located atthe rear of the machine under the bottom radiatorguard. Remove the bolts and the access plate.

3. Pull the drain hose for the radiator from theopening.

4. The drain valve is under the radiator. Open thedrain valve. Allow the coolant to drain into asuitable container.

5. Close the drain valve. Fill the system with asolution which consists of clean water and ofcooling system cleaner. The concentration of thecooling system cleaner should be 6 to 10 percent.

6. Start the engine. Run the engine for 90 minutes.Stop the engine. Drain the cleaning solution into asuitable container.

7. While the engine is stopped, flush the system withwater. Flush the system until the draining wateris clear.

82 SEBU7403-05Maintenance SectionCooling System Extended Life Coolant Extender - Add

8. Close the drain valve. Replace the drain hose andthe access plate.

9. Add the coolant solution.

Refer to Operation and Maintenance Manual,“Capacities (Refill)” for the cooling systemcapacity.

10. Start the engine. Run the engine without theradiator cap until the thermostat opens and thecoolant level stabilizes.

11. Maintain the coolant level within 13 mm (.5 inches)of the bottom of the filler pipe.

12. If the gasket is damaged, replace the radiatorcap. Install the radiator cap.

13. Stop the engine.

i02644101

Cooling System Extended LifeCoolant Extender - AddSMCS Code: 1350; 1352-544-NL; 1395-544-NL

When a Caterpillar Extended Life Coolant (ELC)is used, an extender must be added to the coolingsystem. See the Operation and MaintenanceManual, “Maintenance Interval Schedule” for theproper service interval. The amount of extender isdetermined by the cooling system capacity.

Table 8

RECOMMENDED AMOUNT OF EXTENDER BYCOOLING SYSTEM CAPACITY

Cooling System Capacity Recommended Amountof Extender

22 to 30 L (6 to 8 US gal) 0.57 L (.60 qt)

30 to 38 L (8 to 10 US gal) 0.71 L (.75 qt)

38 to 49 L (10 to 13 US gal) 0.95 L (1 qt)

49 to 64 L (13 to 17 US gal) 1.18 L (1.25 qt)

Refer to Operation and Maintenance Manual,“Capacities (Refill)” for the cooling system capacity.

NOTICEDo not add any Extended Life Coolant (ELC) Exten-ders to the cooling system for this machine after the re-duction or complete depletion of nitrites in the coolantsample.

Adding ELC Extender to the cooling system with de-pleted nitrites has undesirable results. The pH levelincreases to a high level and an odor of ammonia ap-pears.

The cooling system will stabilize and continue to func-tion normally after the complete depletion of nitrite.Add ELC Extender on the scheduled maintenance in-terval only.

For additional information about adding an extender,see Special Publication, SEBU6250, “CaterpillarMachine Fluids Recommendations”, “Extended LifeCoolant (ELC)” or consult your Caterpillar dealer.

i01872305

Cooling System Level - CheckSMCS Code: 1353-535-FLV; 1395-535-FLV

The machine is equipped with a sensor in the radiatortank. The monitoring system is equipped with aindicator for the coolant level.



Cooling System Water Temperature Regulator - Clean/Replace


1. Turn the key to the ON position.

2. The monitoring system goes through a start-upprocedure when the key is turned to the ONposition. The self testing feature verifies that themodules of the monitoring system are operatingproperly. The amount of time for the self testingfeature is approximately three seconds.

3. If the coolant system is low the indicator willilluminate for approximately twenty seconds.

i01880453

Cooling System WaterTemperature Regulator -Clean/ReplaceSMCS Code: 1355-070; 1355-510; 1393

Replace the thermostat on a regular basis in order toreduce the chance of unscheduled downtime and ofproblems with the cooling system.

A new thermostat should be installed after the coolingsystem has been cleaned. Install the thermostatwhile the cooling system is completely drained orwhile the cooling system coolant is drained to a levelthat is below the thermostat housing.

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

Note: If you are only installing a new thermostat,drain the cooling system coolant to a level that isbelow the thermostat housing.


1. Loosen the hose clamp and remove the hose fromthe elbow. Disconnect the hose assembly fromthe thermostat housing assembly.

2. Remove the bolts from the elbow. Remove theelbow and the thermostat housing assembly.

3. Remove the gasket, the thermostat, and the sealfrom the thermostat housing.

NOTICEA used thermostat can be installed if the thermostatconforms to test specifications, and the thermostat isnot damaged. Do not install a used thermostat that hasexcessive buildup or deposits.

NOTICESince Caterpillar engines incorporate a shunt designcooling system, it is mandatory to always operate theengine with a thermostat.

Depending on load, failure to operate with a thermo-stat could result in either an overheating or an over-cooling condition.

NOTICEIf the thermostat is installed incorrectly, it will causethe engine to overheat.

4. Install a new seal in the thermostat housing. Installa new thermostat and a new gasket. Install thethermostat housing on the engine cylinder head.

5. Install the elbow and the hose. Tighten the hoseclamp.

84 SEBU7403-05Maintenance SectionEngine Air Filter Primary Element - Clean/Replace

i01872361

Engine Air Filter PrimaryElement - Clean/ReplaceSMCS Code: 1051-070-PY; 1051-510-PY;

1054-070-PY; 1054-510-PY


1. Open the front access door on the left side of themachine.


2. Remove the air cleaner cover.


3. Clean the inside of the air cleaner housing.


4. Remove the primary filter element from the aircleaner housing.

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

NOTICEDo not clean the filter elements by bumping or tappingthem. Do not use filter elements with damaged pleats,gaskets or seals. Engine damage can result.

Make sure the cleaned filter elements are completelydry before installing into the filter housing. Water re-maining in the elements can cause false indicationsof contamination in Scheduled Oil Sampling test re-sults.


Engine Air Filter Secondary Element - Replace

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

The filter elements can be cleaned by using thefollowing method:

• Pressure air

When you use pressure air, the maximum airpressure is 205 kPa (30 psi).


7. When you clean the inside pleats and the outsidepleats, direct the air along the pleats.

8. Inspect the filter elements after you clean the filterelements. Do not use a filter if the pleats, thegaskets or the seals are damaged.

9. Cover the clean filter elements. Store the elementsin a clean, dry location.

A primary element may be cleaned for a maximumof six times. Also replace the primary element ifthe primary element has been used for one year.

10. Install a clean primary filter element.

11. Clean the cover and install the cover.


12. Reset the filter element indicator.

13. Start the engine. If the yellow piston in the filterelement indicator moves into the red zone, installa new primary filter element. Also if the exhaustsmoke is black, install a new primary filter element.

14. Close the access door.

i01872402

Engine Air Filter SecondaryElement - ReplaceSMCS Code: 1051-510-SE; 1054-510-SE

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

Note: Replace the secondary filter element whenyou service the primary element for the third time.If a clean primary element has been installedand the filter element indicator still enters the redzone, replace the secondary filter element. Alsoif the exhaust smoke remains black and a cleanprimary filter element has been installed, replace thesecondary filter element.


1. Open the front access cover on the left side ofthe machine.

2. Remove the housing cover and the primaryelement.

3. Thoroughly clean the inside of the air cleanerhousing prior to removing the secondary elementin order to prevent dust from contaminating theengine.

86 SEBU7403-05Maintenance SectionEngine Air Precleaner - Clean


4. Remove the secondary element.

5. Install a new secondary element.

6. Install the primary element and the air cleanerhousing cover.


i01872425

Engine Air Precleaner - CleanSMCS Code: 1050-070


1. Inspect the air inlet for dirt and for trash.

2. Remove the bowl. Clean the bowl.

3. Inspect the precleaner tube for dirt and for dust.

4. Clean the precleaner tube with pressure air if theprecleaner tube is dirty.

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


Run the engine at high idle. If the yellow piston in thefilter element indicator enters the red zone, stop theengine and service the air cleaner .

i01872433

Engine Crankcase Breather -CleanSMCS Code: 1317-070


1. The access door is located on the right side of themachine. Open the access door.


Engine Oil Level - Check


2. Loosen the breather outlet hose clamps. Removethe hose from the breather cover.

3. Loosen the breather inlet hose clamp. Removethe engine crankcase breather.

4. Check the condition of the cover seal. Replace thecover seal if the cover seal is damaged.

5. Wash the breather element and the breatherelement cover assembly in a clean, nonflammablesolvent.

6. Shake the breather element until the breatherelement is dry. You may also use pressure air todry the breather element.

7. Check the condition of the hose. Replace the hoseif the hose is damaged.

8. Install the breather element cover assembly.

9. Install the hose and the breather outlet hoseclamps.


i01872444

Engine Oil Level - CheckSMCS Code: 1302-535-FLV; 1326-535-FLV

Hot oil and components can cause personal in-jury.

Do not allow hot oil or components to contactskin.

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


1. Open the rear access door that is on the rightside of the machine behind the operator’scompartment.


2. Check the dipstick (1) while the engine is stopped.Maintain the oil level between the “LOW” markand the “FULL” mark.

Note: When you operate the machine on severeslopes, the oil level in the engine crankcase must beat the “FULL” mark on the dipstick.

3. Remove oil filler cap (2). If necessary, add oil.

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


88 SEBU7403-05Maintenance SectionEngine Oil Sample - Obtain

i01872458

Engine Oil Sample - ObtainSMCS Code: 1000-008; 7542-008

Hot oil and hot components can cause personalinjury. Do not allow hot oil or hot components tocontact the skin.

Obtain the Sample and the AnalysisIn addition to a good preventive maintenanceprogram, Caterpillar recommends using S·O·S oilanalysis at regular scheduled intervals in orderto monitor the condition of the engine and themaintenance requirements of the engine.

Each oil sample should be taken when the oil is warmand when the oil is well mixed in order to ensure thatthe sample is representative of the oil that is in thecrankcase.

Obtain the S·O·S Sample



Open the access door on the right side of themachine.


Sampling valve (1) for the engine oil is located on theright side of the engine above the oil filter.

Refer to Special Publication, SEBU6250, “S·O·S OilAnalysis” for information that pertains to obtaining asample of the engine oil. Refer to Special Publication,PEHP6001, “How To Take A Good Oil Sample” formore information about obtaining a sample of theengine oil.

i02098213

Engine Oil and Filter - ChangeSMCS Code: 1308-510; 1318-510






Note: Be sure that you obtain an S·O·S oil samplebefore you drain the engine oil.


Engine Valve Lash - Check


1. Remove the crankcase drain access cover, whichis in the crankcase guard.

2. Remove the section of hose from the tool box.Remove the crankcase drain plug. Install thehose. Open the valve. Allow the oil to drain into asuitable container.


3. Open the access cover. Remove the crankcase oilfilter element and discard the crankcase oil filterelement properly. Make sure that all of the old filterseal is removed from the filter base.

4. Apply a thin coat of oil to the new filter seals.Install the new crankcase oil filter elements byhand. When the gaskets contact the filter base,tighten the filter elements by an additional turn of270 degrees. Rotation index marks are on the newfilter elements. These rotation index marks arespaced at 90 degree intervals. Use these rotationindex marks as a guide for proper tightening.

5. Remove the hose. Close the valve. Return thehose to the tool box. Install the crankcase drainplug. Install the crankcase drain access cover.


6. Remove the oil filler cap (2). Fill the crankcasewith new oil. See Operation and MaintenanceManual, “Capacities (Refill)”. Clean the oil fillercap and install the oil filler cap.

7. Always measure the oil level with dipstick (1) inorder to ensure that the correct amount of oil wasadded.

8. On the dipstick, maintain the oil level between the“ADD” mark and “FULL” mark.

9. Close the access cover.

i02391153

Engine Valve Lash - CheckSMCS Code: 1102-535; 1105-535

Consult your dealer in order to adjust the enginevalve lash setting. Your dealer has the tools and thetrained personnel for this service.

90 SEBU7403-05Maintenance SectionEqualizer Bar Pins - Inspect

i01145941

Equalizer Bar Pins - InspectSMCS Code: 7206-040-PN; 7207-040-PN



Check the equalizer bar pins for looseness and forunusual wear. The pins are located on the top of thetrack roller frame behind the idler.

If unusual wear is evident, see the Service Manual orconsult your Caterpillar dealer for an inspection andfor repair instructions.

i01873376

Equalizer Bar Pins - LubricateSMCS Code: 7206-086-PN; 7207-086-PN

NOTICEApply lubricant to the fittings with a hand operatedgrease gun only. Use of pressure operated lubricatingequipment damages the seals.


Lubricate the equalizer bar pins through the fittings.There is one fitting on each side of the machine.

i02098222

Final Drive Oil - ChangeSMCS Code: 4050-044-FLV




Wipe the covers and the surfaces around openingsbefore checking or adding oil.


Final Drive Oil Level - Check


Note: Perform the following procedure to the finaldrive on each side of the machine.

1. Move the machine so that drain plug (3) is locatedon the bottom of the final drive.

2. Remove filler plug (1). Remove drain plug (3) inthe outer compartment. Drain the oil into a suitablecontainer.


3. Remove drain plug (4) from the inner compartment.Allow the oil to drain into a suitable container.

4. Clean the drain plugs and install the drain plugs.

5. Slowly fill the final drive with oil. The oil level is atthe bottom of opening (2). Refer to Operation andMaintenance Manual, “Capacities (Refill)”for therefill capacity of each final drive.

6. Clean the filler plug and the oil level plug. Installthe plugs.

7. Repeat this procedure for the opposite side of themachine.

i01874049

Final Drive Oil Level - CheckSMCS Code: 4050-535-FLV


1. Remove center oil level plug (1).

2. Maintain the oil level to the bottom of the openingfor plug (1).

3. If oil is required, remove oil filler plug (2) and addoil.

4. Clean the plugs and reinstall the plugs.

5. Check for leakage or excessive sprocket wear.

6. Repeat the procedure on the other side of themachine.

i01874051

Final Drive Oil Sample - ObtainSMCS Code: 4050-008


92 SEBU7403-05Maintenance SectionFront Idler Position - Check

Obtain the Sample and the AnalysisIn addition to a good preventive maintenanceprogram, Caterpillar recommends using S·O·S oilanalysis at regular scheduled intervals in order tomonitor the condition of the final drives.

Each oil sample should be taken when the oil is warmand when the oil is well mixed in order to ensure thatthe sample is representative of the oil in the finaldrive.



Remove the center plug in order to obtain a sampleof the oil.


Use a 1U-5718 Vacuum Pump or an equivalentpump. Insert the suction tube into the final drive anddraw an oil sample from the final drive.

Clean the plug and install the plug.

The recommended interval for oil samples is every500 service hours or every three months. Therecommended oil change interval is every 2000hours.

Refer to Special Publication, PEHP6001 for moreinformation on obtaining a good oil sample. Consultyour Caterpillar dealer for complete information andassistance in establishing an S·O·S program for yourmachine.

i02305943

Front Idler Position - CheckSMCS Code: 4159

SystemOne UndercarriageThe following check is for Caterpillar SystemOneUndercarriages that have the center tread idler.


963C Track-Type Loader front idler (SystemOne)Adjustment shim (center tread idler)

1. Park the machine on a hard, flat surface. Makesure that the bottom track is tight. Make sure thatfirst link bushing (2) lies directly below the trackidler shaft (1). This ensures that the measuredgrouser tip is at the lowest point. Measuredgrouser tip (3) is the first grouser tip on grousertrack shoe (4).

2. Measure the height (A) from the flat groundsurface to grouser tip (3) that is first on grousertrack shoe (4) below bushing link (2) and trackidler shaft (1).

3. Maintain the grouser height (rise) to the followingdimensions.

a. (A) Front Idlers

Minimum – 0 mm (0 inch)

SEBU7403-05 93Maintenance SectionFuel System - Prime

Maximum – 16 mm (0.63 inch)

4. Repeat Steps 1 through 3 in order to determinethe proper height dimension under each front idler.

5. For machines with the SystemOne Undercarriage,remove the shim between the track roller frameand the idler guard when the wear on the link androller system is at 50%.

Consult your Caterpillar dealer for detailedinformation about adjustments to the center treadidler.

See Operation and Maintenance Manual, “TrackAdjustment - Adjust” for information on needed trackadjustments.

Reference: See Operation and MaintenanceManual, “Reference Material” for publications andSpecial Instructions on removal and installation ofSystemOne Track, as needed.

i01874056

Fuel System - PrimeSMCS Code: 1258

If the engine does not start, air may be trapped in thefuel lines to the engine. Use the following procedurein order to purge air from the fuel lines.

Fuel Priming Pump1. Open the forward engine access door in order to

access the fuel priming pump. The fuel primingpump is located on the right side of the machine.


2. Unlock the priming pump plunger. Operate theplunger until you feel resistance.

3. Push in the plunger. Hand tighten the plunger.

4. Start the engine. If the engine does not start,or if the engine continues to misfire or smoke,additional priming is necessary.

5. Run the engine at the LOW IDLE position until theengine runs smoothly.

Electric Fuel Priming Pump (IfEquipped)Your machine may be equipped with an electric fuelpriming pump. The priming pump is located on theright side of the engine above the primary fuel filter.


1. Open the forward engine access door in order toaccess the fuel priming pump. The fuel primingpump is located on the right side of the machine.

2. Attach a drain hose to drain valve (2). Place thedrain hose into a suitable container in order tocatch the fuel. Open drain valve (2). Move thetoggle switch (1) in order to activate the primingpump.

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.

94 SEBU7403-05Maintenance SectionFuel System Primary Filter (Water Separator) Element - Replace

i01874442

Fuel System Primary Filter(Water Separator) Element -ReplaceSMCS Code: 1260-070; 1260-510; 1261

Personal injury can result from air pressure.

Personal injury can result without following prop-er procedure. When using pressure air, wear a pro-tective face shield and protective clothing.

Maximum air pressure at the nozzle must be lessthan 205 kPa (30 psi) for cleaning purposes.

Personal injury or death can result from engineoverspeed.

If the engine overspeeds, it can cause injury orparts damage.

Be prepared to stop the engine by closing the airoff to the air inlets or by manually pushing down-ward on the governor shutdown rod.

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 filter with fuel before installing the fuelfilter. Contaminated fuel causes accelerated wear tofuel system parts.

1. Open the access door for the engine compartment.The access door is located on the left side of themachine.


2. Turn red handle (1) of the fuel shutoff valve inorder to shut off the fuel supply.

3. Remove water collection bowl (3). Unscrew thebowl from element (2).

4. Unscrew element (2).

5. Install the new element onto the filter base.

6. Clean the water collection bowl. Install the bowlon the new element.

Note: The water collection bowl is reusable. Whenyou can no longer see the contents of the bowl,replace the bowl.

7. Open the fuel shutoff valve.

8. Prime the fuel system. Refer to Operation andMaintenance Manual, “Fuel System - Prime” formore information. Close the access door.

Replace the Inverted SecondaryFuel FilterReplace the inverted secondary fuel filter at every500 service hour interval. Refer to Operation andMaintenance Manual, “Fuel System Secondary Filter- Replace” at every 500 service hour interval.


Fuel System Secondary Filter - Replace

i01874724

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.





This machine is equipped with an inverted secondaryfuel filter. Always drain the inverted filter before youremove the filter.

1. Shut off the fuel tank supply valve. Shut off thereturn valve for the fuel tank.

2. Drain secondary fuel filter (1). Place a suitablecontainer under the drain valve. Open drain valve(2). Drain the fuel into a suitable container. Whenthe fuel stops draining, keep the drain valve open.Loosen the inverted filter for 1/4 turn. As the filteris loosened, additional fuel may drain from thedrain valve. When the fuel stops draining, loosenthe filter for an additional 1/4 turn. Observe theflow of the fuel. Repeat this procedure until fueldoes not drain from the drain valve. Close thedrain valve. Properly dispose of the fuel.

3. Remove secondary fuel filter (1).

4. Clean the filter mounting base. Make sure that theold seal is removed.

5. Coat the seal of the new filter with clean dieselfuel.

6. Install new secondary fuel filter (1). Hand tightenthe filter. When the seal contacts the base, tightenthe filter for an additional 3/4 turn.

Rotation index marks are positioned on the filterat 90 degree intervals. Use these rotation indexmarks as a guide when you tighten the filter.

Note: Install a new, dry filter. Never fill a new filterwith fuel before you install the filter. Dirty fuel candamage the fuel injectors. This damage will causepremature problems in the fuel system.

7. Open the fuel tank supply valve. Open the returnvalve for the fuel tank.

8. Prime the fuel system. Refer to Operation andMaintenance Manual, “Fuel System - Prime” foradditional information. When you are priming thefuel system, open drain valve (2) in order to allowair to escape.

9. In order to unlock the priming pump plunger, turnthe handle of the priming pump counterclockwise.Operate the priming pump until the fuel begins toflow out of drain valve (2). When the fuel beginsto drain from the drain, close the drain valve.Operate the priming pump for an additional tenstrokes. These additional strokes will ensure thatthe remainder of the fuel system is primed. Allof the air will be purged from the lines. Push thepriming pump plunger downward. Turn the handlefor the plunger clockwise until the priming pumpplunger is locked in the down position.

96 SEBU7403-05Maintenance SectionFuel System Water Separator - Drain

10. Before you start the engine, make sure that thedrain valves are completely closed. Start theengine. Check for leaks.

i01874744

Fuel System Water Separator- DrainSMCS Code: 1263-543


1. Attach a rubber hose to the drain of waterseparator bowl (1), which is located under theprimary filter/water separator. Extend the hoseinto a suitable container.

2. Open the drain for a 1/2 turn.

3. Open the vent in order to allow the water to draininto a suitable container.

4. After the separator is completely drained, closethe vent. Close the drain.

i01874746

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


1. Remove the fuel tank cap and the strainer.

2. Disassemble the fuel cap. Wash the cap andthe strainer. Wash these components in a clean,nonflammable solvent.

3. Inspect the seal of the fuel cap. Replace the sealif the seal is damaged.

4. Put a light coat of oil on the cap components.

5. Install the strainer.

6. Assemble the fuel cap and install the fuel cap.

i01874749

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





Hydraulic System Oil - Change

The drain valve is located on the right side of themachine.

1. Open the engine compartment access cover.


2. Remove the drain line from the opening.


3. Open the drain valve.


4. Operate the plunger in order to drain the sediment.Allow the water and the sediment to drain into asuitable container.

5. Close the drain valve. Place the drain line backinto the opening.

6. Close the engine compartment access cover.

i01917581

Hydraulic System Oil - ChangeSMCS Code: 5050-044

4000 Hour Oil Change IntervalA 4000 hour maintenance interval for hydraulicoil (change) is available. The extended intervalrequires S·O·S monitoring of the hydraulic oil. Theinterval for S·O·S monitoring is every 500 hours. Themaintenance interval for the hydraulic oil filter is notchanged. If S·O·S monitoring is not performed, the2000 hour maintenance interval must be used.

Machines that are used in severe conditions arenot included in the 4000 hour maintenance interval.Machines that are used in severe conditions mustuse the interval in the Maintenance Interval Schedule.

Lubricants

Approved hydraulic oil must be used to obtain the4000 hour hydraulic oil change. Refer to the list thatfollows for approved oils.

Caterpillar Hydraulic Oils

• Cat HYDO

• TDTO

• TDTO (TMS)

• DEO

• Biodegradable Hydraulic Oil (HEES)

• MTO

Commercial Oils

Diesel engine oils (Heavy Duty) with a minimumzinc content of 900 ppm can be used. Acceptablecommercial oils are identified by the AmericanPetroleum Institute trademark (API) . Refer to the listthat follows for acceptable types of hydraulic oils.

• CF

• CF-4

• CG-4

98 SEBU7403-05Maintenance SectionHydraulic System Oil - Change

• CH-4

Note: Industrial hydraulic oils are not recommendedfor the hydraulic systems of Caterpillar machines.Industrial hydraulic oils are more likely to allowcorrosion and Industrial hydraulic oils are more likelyto allow excessive wear.

Procedure to Change the HydraulicOilOperate the machine in order to warm the oil.

Park the machine on level ground. Lower allimplements to the ground with a slight downwardpressure. Move the transmission lock switch into theLOCKED position. Stop the engine.


1. Remove the hydraulic tank filler cap slowly in orderto relieve any pressure. Check the cap seal. If thecap seal is cut or damaged, replace the cap seal.


2. Remove the filler strainer. Wash the filler strainerin a clean nonflammable solvent.


3. Remove the bottom hydraulic tank cover.


4. Remove oil drain plug (2). Open drain valve (1).Drain all the oil into a suitable container. Closedrain valve (1).

5. Install drain plug (2).

6. Install the cover. Tighten the cover bolts.

7. See Operation and Maintenance Manual,“Hydraulic System Oil Filter - Replace”. Changethe hydraulic system filter.

8. See Operation and Maintenance Manual,“Capacities (Refill)” in order to determine theamount of hydraulic oil that is needed to fill thehydraulic oil tank.

Note: The above procedure is for draining the tank.Consult your Caterpillar dealer or refer to the ServiceManual for instructions on completely draining thehydraulic system.


Hydraulic System Oil Level - Check

Procedure for Filling the HydraulicOil Tank


1. Install the filler strainer.

2. Fill the hydraulic oil tank to various levels within thegreen zone of the sight gauge with the machineon level ground and the bucket flat on the ground.

3. Inspect the filler cap gasket. Replace the gasket ifdamage or wear is evident.

4. Install the filler cap.

5. Start the engine. Run the engine for a few minutes.

6. Extend both the lift and tilt cylinders completely.Shut off the engine. Observe the hydraulic oil levelon the sight gauge. If the oil level on the sightgauge is below the “Add” mark or in the red zonerecord the level of the oil on the sight gauge.

7. Start the engine. Return the bucket to the ground.

8. Shut off the engine. Verify the oil level on the sightgauge. Check for air in the system.

9. If the oil level on the sight gauge in step 6has changed repeat steps 2 through 8 until aconsistent oil level is achieved at the beginningand the end of the procedure.


10. Maintain the oil level in the green colored areaabove the “Add” mark in the sight gauge. Add oil,if necessary.

i01876733

Hydraulic System Oil Level -CheckSMCS Code: 5056-535-FLV; 7479

The sight gauge for the hydraulic tank is located onthe right front side of the machine.

1. Park the machine on a hard, level surface. Lowerall implements. Place slight downward pressureon the implements.


2. Maintain the oil level in the green colored areaabove the “Add” mark in the sight gauge. Add oil,if necessary.

100 SEBU7403-05Maintenance SectionHydrostatic Transmission and Hydraulic System Filters - Replace


3. If the hydraulic system requires additionalhydraulic oil, remove the filler cap and add oilthrough the filler tube.

4. Clean the filler cap and install the filler cap.

i01876742

Hydrostatic Transmission andHydraulic System Filters -ReplaceSMCS Code: 3067-510-FI

Use caution when changing oil or changing filters.Hot oil or components can cause burns if theycontact skin.


1. Slowly remove the hydraulic tank filler cap in orderto relieve the system pressure.


2. Remove the bolts and the cover.


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

4. Remove the charge filter and remove the casedrain filter.

5. Wipe the sealing surfaces of the filter bases. Makesure that you remove all of the former filter seal.

6. Apply a thin coat of oil to the seals of the newfilters. Install a new charge filter and a new casedrain filter.



Hydrostatic Transmission and Hydraulic System Oil Sample - Obtain


8. Remove the bolts from the filter cover. Use thehandle to pull up the filter assembly. Remove thefilter assembly.

9. Remove the filter elements. Properly discard thefilter elements.

Apply a thin coat of oil to the seal on the new filter.

10. Install the new filter element by hand. When theseal contacts the base, tighten the filter elementfor an additional 3/4 turn.

11. Check the condition of the seal for the filter cover.If the seal is damaged or if the seal is cut, replacethe seal. Lubricate the seal with clean hydraulic oil.


12. Install the filter assembly in the filter housing. Usecaution to align the filter assembly properly. Installthe cover and tighten the cover bolts.


13. Install the cover and tighten the cover bolts.Remove the filler strainer and clean the fillerstrainer. Install the filler strainer and the filler cap.

i02648063

Hydrostatic Transmission andHydraulic System Oil Sample- ObtainSMCS Code: 7542-008



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


102 SEBU7403-05Maintenance SectionIdler Swing Link - Lubricate

Obtain the Sample and the AnalysisIn addition to a good preventive maintenanceprogram, Caterpillar recommends using S·O·S oilanalysis at regular scheduled intervals in order tomonitor the condition of the hydraulic system and themaintenance requirements of the hydraulic system.

Each oil sample should be taken when the oil is warmand when the oil is well mixed in order to ensure thatthe sample is representative of the oil in the hydraulicsystem.


At operating temperature, the hydraulic tank is hotand under pressure.

Hot oil and components can cause personal in-jury. Do not allow hot oil or components to contactskin.

Remove the filler cap only when the engine isstopped, and the filler cap is cool enough totouch with your bare hand. Remove the filler capslowly in order to relieve pressure.


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

2. Sampling port (1) is for the hydrostatictransmission and the hydraulic system.

g01328934Illustration 159BBD2533-Up

3. Sampling port (2) is for the hydrostatictransmission and the hydraulic system for 963CTrack-Type Loaders with higher PIN numbers.

4. Obtain a sample.


Refer to the Operation and Maintenance Manual,“S·O·S Information”.

i02097896

Idler Swing Link - LubricateSMCS Code: 4159-086


Apply lubricant through a total of four fittings. Thereare two fittings on each idler. There is one fitting foreach link. There is one link on each side of the idler.Lubricate the fitting on each end of the shaft that isin each link.


Indicators and Gauges - Test

Note: If you lubricate the fittings with the lift arms inthe raised position, use 236-1192 Brace Assemblyin order to support the bucket when the lift cylindersare in the RAISE position.

i01876791

Indicators and Gauges - TestSMCS Code: 4100-081; 7000-081; 7450-081


Check the operation of the Caterpillar MonitoringSystem. Observe the self test when you start theengine.

The system performs an automatic self test whenyou turn the engine start switch to the ON position.

The self test verifies that the monitoring panel andthe display modules are operating properly.

The internal circuits, the indicators, and the gaugesare automatically checked.


The operator must observe the indicators and thegauges in order to determine whether module (1),module (2), module (3), the indicators, and thegauges are operating properly. The self test lasts forapproximately three seconds.

During the self test, all alert indicators flash.

The digital display shows the following readouts:

• All indicators of units (Deg C, kPa, rpm, and liters)

• “X10” readout

• Symbol for the hour meter

• “8.8.8.X.8.8” readout

The pointers in the gauges point upward. Then, thepointers point to the left. Then, the pointers pointto the right. Then, the pointers point to the finalpositions.

• The speed readout shows “188”, “MPH”, and“km/h”.

• The action light stays illuminated.

• The action alarm sounds once.

The monitoring panel is then in the normal operatingmode.

If the above tests are not correctly completed, thesystem will not function in the normal operatingmode. Consult your Caterpillar dealer for an electricalsystem check. Any repairs must be made before youstart the engine.

Turn on all of the machine lights. Check for properoperation. Sound the forward horn.

Stop the engine.

Make any necessary repairs before you operate themachine.

104 SEBU7403-05Maintenance SectionLoader Linkage Pins - Lubricate

i01876793

Loader Linkage Pins -LubricateSMCS Code: 6118-086-PN


g00975204Illustration 164Lubricate all fittings.

Use 236-1192 Brace Assembly in order to supportthe bucket whenever the lift cylinders are raised forservice.

i00544389

Multipurpose Bucket -LubricateSMCS Code: 6104-086


Apply lubricant through one fitting on each side ofthe bucket.

There is a total of two fittings.

i00543304

Oil Filter - InspectSMCS Code: 1318-507; 3067-507; 5068-507

Inspect A Used Filter for Debris

g00100013Illustration 166The element is shown with debris.

Use a 4C-5084 Filter Cutter to cut the filter elementopen. Spread apart the pleats and inspect theelement for metal and for other debris. An excessiveamount of debris in the filter element can indicate apossible failure.


Pivot Shaft Oil Level - Check

If metals are found in the filter element, a magnet canbe used to differentiate between ferrous metals andnonferrous metals.

Ferrous metals can indicate wear on steel parts andon cast iron parts.

Nonferrous metals can indicate wear on thealuminum parts of the engine such as main bearings,rod bearings, or turbocharger bearings.

Small amounts of debris may be found in the filterelement. This could be caused by friction and bynormal wear. Consult your Caterpillar dealer in orderto arrange for further analysis if an excessive amountof debris is found.

Using an oil filter element that is not recommended byCaterpillar can result in severe damage to the engineand/or the hydraulic system. Engine bearings, thecrankshaft, pumps, valves, cylinders and other partsmay be damaged. This can result in larger particles inunfiltered oil. The particles could enter the lubricatingsystem and the particles could cause damage.

i01876796

Pivot Shaft Oil Level - CheckSMCS Code: 4153-535-FLV




The oil plugs are located on both sides of themachine.

Remove the plug on one side of the machine. Checkthe oil level. Maintain the oil level within 13 mm(0.5 inch) of the bottom of the filler plug opening. Ifnecessary, add oil.

Repeat the procedure on the other side of themachine.

i02098232

Pump Drive Gearbox Oil -ChangeSMCS Code: 3080-044






Open the engine compartment access cover on theright side of the machine. Also, open the bottomaccess door.


Front view of the pump drive gearbox

106 SEBU7403-05Maintenance SectionPump Drive Gearbox Oil Level - Check

1. The capacity of the gearbox is 3.8 L (1.0 US gal).Remove the drain plug at the bottom of thegearbox and drain the oil into a suitable container.

2. Clean the drain plug. Inspect the O-Ring seal forthe plug. If the seal is worn or damaged, install anew seal. Install the drain plug.


3. Remove filler cap (2) and add the required amountof oil. See the Operation and Maintenance Manual,“Capacities (Refill)” for the correct amount of oil.

4. Check the oil level on dipstick (1). Maintain the oillevel between the “ADD” and the “FULL” markson the dipstick.

5. Replace the cap on the filler tube. Close bothaccess doors.

i01876853

Pump Drive Gearbox Oil Level- CheckSMCS Code: 3080-535


1. Open the front engine compartment access coveron the right side of the machine. Also, open thebottom access door.

2. Check dipstick (1). Maintain the oil level betweenthe “ADD” and the “FULL” marks. If it is necessaryto add oil, remove oil filler cap (2) and add oilthrough the filler tube.

3. Close both access doors.

i01876855

Pump Drive Gearbox OilSample - ObtainSMCS Code: 3080-554



Radiator Core - Clean




Obtain the Sample and the AnalysisIn addition to a good preventive maintenanceprogram, Caterpillar recommends using S·O·S oilanalysis at regular scheduled intervals in order tomonitor the condition of the pump drive gear boxand the maintenance requirements of the pump drivegear box.

Each oil sample should be taken when the oil is warmand the oil is well mixed in order to ensure that thesample is representative of the oil in the gear box.



1. Open the front engine compartment access coveron the right side of the machine. Also, open thebottom access door.

2. Remove the cap for the filler tube for the pumpdrive gear box. Use a 1U-5718 Vacuum Pump oran equivalent pump. Insert the suction tube in thefiller tube and draw an oil sample.

3. Replace the cap on the filler tube.

4. Close both access doors.


i00682275

Radiator Core - CleanSMCS Code: 1353-070; 1805; 1810


You can use compressed air (30 psi maximum), highpressure water, or steam to remove dust and otherdebris from the radiator core. However, the use ofcompressed air is preferred.

See Special Publication, SEBD0518, “Know YourCooling System” for the complete procedure oncleaning the radiator core.

108 SEBU7403-05Maintenance SectionRadiator Pressure Cap - Clean/Replace

i01876897

Radiator Pressure Cap -Clean/ReplaceSMCS Code: 1353-070-Z2; 1353-510-Z2


1. Slowly remove the radiator cap in order to relievesystem pressure.

2. Inspect the radiator cap for damage, for deposits,or for foreign material. Clean the radiator capwith a clean cloth. Replace the radiator cap if theradiator cap is damaged.

3. Install the radiator cap.

i01876932

Recoil Piston - LubricateSMCS Code: 4157-086


1. Remove the plug in the track roller frame.


2. Connect a grease gun to the fitting. Lubricate therecoil piston through the fitting.

3. Install the plug in the track roller frame.

4. Repeat the procedure for the other recoilcompartment.


Refrigerant Dryer - Replace

i01876936

Refrigerant Dryer - ReplaceSMCS Code: 7322-510

Personal injury can result from contact with refrig-erant.

Contact with refrigerant can cause frost bite. Keepface 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 ventilatedarea.

Personal injury or death can result from inhalingrefrigerant through a lit cigarette.

Inhaling air conditioner refrigerant gas through alit cigarette or other smoking method or inhalingfumes released from a flame contacting air con-ditioner refrigerant gas, can cause bodily harm ordeath.

Do not smoke when servicing air conditioners orwherever refrigerant gas may be present.

Use a certified recovery and recycling cart to prop-erly remove the refrigerant from the air condition-ing system.

NOTICEIf the refrigerant system has been open to the outsideair (without being plugged) for more than 30 minutes,the receiver-dryer must be replaced. Moisture will en-ter an open refrigerant system and cause corrosionwhich will lead to component failure.

Refer to Service Manual, SENR5664, “AirConditioning and Heating R-134a For All CaterpillarMachines” for the proper procedure to change thereceiver-dryer assembly and for the procedure toreclaim the refrigerant gas.

i00541342

Ripper Tip and Shank Protector- Inspect/ReplaceSMCS Code: 6808-040; 6808-510; 6810; 6812-040;

6812-510

When the ripper tip is worn close to the shank,replace the ripper tip. When the shank protector isworn close to the shank, replace the shank protector.If the tip is too blunt, the tip will not penetrate properly.

1. Raise the ripper. Place blocking under the ripper.Lower the ripper onto the blocking. The rippershould be high enough so that the ripper tip or theshank protector can be removed. Do not place theripper too high.

2. If the ripper tip is worn, drive out the pin. Removethe tip and the shank pin retainer.

3. Clean the shank pin retainer and the pin.

4. Install the new tip and the retainer.

5. Install the pin from the opposite side of theretainer.

6. Raise the ripper and remove the blocking.

7. Lower the ripper to the ground.

i02429589

Seat Belt - InspectSMCS Code: 7327-040

Always check the condition of the seat belt and thecondition of the seat belt mounting hardware beforeyou operate the machine. Replace any parts that aredamaged or worn before you operate the machine.


Typical example

110 SEBU7403-05Maintenance SectionSeat Belt - Replace

Check the seat belt mounting hardware (1) for wearor for damage. Replace any mounting hardware thatis worn or damaged. Make sure that the mountingbolts are tight.

Check buckle (2) for wear or for damage. If the buckleis worn or damaged, replace the seat belt.

Inspect the seat belt (3) for webbing that is worn orfrayed. Replace the seat belt if the seat belt is wornor frayed.

Consult your Caterpillar dealer for the replacement ofthe seat belt and the mounting hardware.

Note: Within three years of the date of installation orwithin five years of the date of manufacture, replacethe seat belt. Replace the seat belt at the date whichoccurs first. A date label for determining the age ofthe seat belt is attached to the seat belt, the seat beltbuckle, and the seat belt retractor.

If your machine is equipped with a seat beltextension, also perform this inspection procedure forthe seat belt extension.

i02429594

Seat Belt - ReplaceSMCS Code: 7327-510

Within three years of the date of installation or withinfive years of the date of manufacture, replace theseat belt . Replace the seat belt at the date whichoccurs first. A date label for determining the age ofthe seat belt is attached to the seat belt, the seat beltbuckle, and the seat belt retractor.

g01152685Illustration 177(1) Date of installation (retractor)(2) Date of installation (buckle)(3) Date of manufacture (tag) (fully extended web)(4) Date of manufacture (underside) (buckle)

Consult your Caterpillar dealer for the replacement ofthe seat belt and the mounting hardware.

If your machine is equipped with a seat beltextension, also perform this replacement procedurefor the seat belt extension.

i02068317

Track - Check/AdjustSMCS Code: 4170-025; 4170-036

Check the TrackCheck the track for wear and for excessive dirtbuildup.

1. Move the machine forward to a distance that istwo times the length of the machine. Allow themachine to stop without the use of the servicebrake. Shut off the engine.


2. Stand on the track between the front idler and thetrack carrier roller in order to produce as muchtrack sag as possible.

3. Attach one end of a string to the grouser tip onthe track shoe that is directly above track carrierroller (1). Make the string tight by pulling on thestring. Attach the opposite end of the string to thegrouser tip on the track shoe (2) that is directlyabove the front idler .

4. Measure the distance between the string and thetip of the grouser that is on the track shoe directlybetween the front idler and the track carrier rollerin order to obtain dimension (A).

5. Dimension (A) should be approximately 50 mm(2.0 inch). If dimension (A) is not correct, adjustthe track.

SEBU7403-05 111Maintenance SectionTrack - Check/Adjust

Track Adjustment

Grease is under high pressure.

Grease coming out of the relief valve under pres-sure can penetrate the body causing injury ordeath.

Do not watch the relief valve to see if grease is es-caping. Watch the track or track adjustment cylin-der to see if the track is being loosened.

Loosen the relief valve only one turn.

1. Move the machine forward for a distance of twotimes the length of the machine. Allow the machineto a stop without the use of the service brakes.Shut off the engine. Adjust the tracks while youare in the machine’s typical operating conditions.If packing conditions prevail on the job, the tracksshould be adjusted with packing material.


2. Remove the cover for the track adjustingmechanism.


3. Add grease with a grease gun in order to movethe idler forward until the track is fully tight.


4. Use a straight edge against the face. Mark the rodwith a pencil or with a marking pen. Make a markthat is in line with the face.


5. Mark the rod 10 mm (.40 inch) toward the idlerfrom the first mark.

6. Open the relief valve. Allow the idler to move backuntil the second mark is behind the face. Closethe relief valve.

7. Use the grease gun to move the idler forward untilthe second mark is in line with the face.

112 SEBU7403-05Maintenance SectionTrack Pins - Inspect


8. Measure dimension (X), as shown above.Dimension (X) is the distance from the face ofthe bulkhead to the center of the pin in the yoke.If dimension (X) is less than 98 mm (3.9 inch),proceed to Step 9.

If dimension (X) is greater than 98 mm (3.9 inch),the front idler must be moved forward to asecondary position. Refer to Power TrainDisassembly and Assembly, RENR5232, “Track -Adjust” for this procedure.

9. Install the cover and tighten the bolts to a torqueof 75 ± 15 N·m (55.50 ± 11 lb ft).

Note: The track sag after this adjustment procedureshould be 50.0 mm (2.0 inch). If track sag is not50.0 mm (2.0 inch), repeat the procedure.

10. Repeat Step 2 through Step 9 for the other track.

Bolt Torque for Track Shoes


The torque requirement for track shoe bolts is170 ± 40 N·m (120 ± 30 lb ft). Tighten the bolts foran additional 120 degrees. If you are using boltswith a master link, tighten the bolts to a torque of170 ± 40 N·m (120 ± 30 lb ft). Tighten the bolts for anadditional 180 degrees.

i01989298

Track Pins - InspectSMCS Code: 4175-040-PN

Fingers can be burned from hot pins and bush-ings.

The pins and bushings in a dry joint can becomevery hot. It is possible to burn the fingers if thereis more than brief contact with these components.

Use the recommendations in order to extend the lifeof the undercarriage. Use the recommendations inorder to avoid excessive downtime.

1. During the machine operation, listen for unusualsqueaking and for unusual squealing. This canindicate a dry joint.

2. Check the machine for dry joints weekly. Checkfor dry joints immediately after machine operation.After machine operation, lightly touch the end ofeach track pin or bushing. Touch the track pinor the track bushing with the back of your hand.Make a mark on any dry track pin joint that is veryhot to the touch.

Consult your Caterpillar dealer’s Custom TrackService expert if you detect dry joints or leaks. YourCaterpillar dealer’s Custom Track Service expert canperform track inspection.

i01876957

Windows - CleanSMCS Code: 7310-070; 7340-070

Use commercially available window cleaningsolutions in order to clean the windows.

Clean the outside of the windows from the groundunless handholds are available.


Window Washer Reservoir - Fill

Cleaning MethodsApply the cleaner with a soft cloth. Rub the windowwith moderate pressure until all the dirt is removed.Allow the cleaner to dry. Wipe off the cleaner with aclean soft cloth.

Soap and Water

Use a clean sponge or a soft cloth. Wash the windowswith a mild soap or with a mild detergent. Alsouse plenty of lukewarm water. Rinse the windowsthoroughly. Dry the windows with a moist chamois orwith a moist cellulose sponge.

Stubborn Dirt and Grease

Wash the windows with a good grade of naphtha,isopropyl alcohol, or Butyl Cellosolve. Then, washthe windows with soap and with water.

i01876958

Window Washer Reservoir -FillSMCS Code: 7306-544

NOTICEWhen operating in freezing temperatures, useCaterpillar or any commercially available nonfreezingwindow washer solvent.

The window washer reservoir is located on the leftside of the machine in the engine compartment.


Window Washer Reservoir – Removecap (1) from the filler tube in order to fill thereservoir.

i01876960

Window Wiper -Inspect/ReplaceSMCS Code: 7305-040; 7305-510



Inspect the front window wiper blades and the rearwindow wiper blades.

Replace the window wiper blades if any of thefollowing conditions exist:

• The window wiper blades are excessively worn.

• The window wiper blades are damaged.

• The window wiper blades streak the windows.

Documents

Operation and Maintenance Manual Excerpt - Bob …bobwardjrequipment.com/pdf/963c.pdfThe circuit breakers are located behind the console panel on the left side of the machine. Illustration