Procedure to Improve Cold Starting Capability for 950G Series II Wheel Loader, 962G Series II Wheel Loader, and IT62G Series II Integrated Toolcarrier{1000, 1456, 7000} Caterpillar

Integrated Toolcarrier:

IT62G Series II (S/N: AYA1-UP)

Wheel Loader:

950G Series II (S/N: BAA1-UP; AYB1-UP; AYD1-UP; AYL1-UP; AXR1-UP; AYS1-UP; AXX1-UP)

962G Series II (S/N: BAB1-UP; BAC1-UP; BAD1-UP; AYE1-UP; AYG1-UP; AXS1-UP; AXY1-UP)

Introduction

This Special Instruction contains procedures that will improve the cold starting capability of the 950G Series II Wheel Loader, 962G Series II Wheel Loader, and IT62G Series II Integrated Toolcarrier.

Ensure that you are following the""Recommended Practices" " and ""Fluid Recommendations" ". Perform the procedures that are listed in ""Procedure to Update the Engine Software" ". Then perform the procedures that are listed in ""Procedure to Install the Ether Starting Aid" ". The installation of the ether starting aid and the adjustments that are performed by the new software will improve the performance of the machine during cold starting.

Illustration 1	g01805594
Typical illustration

Note: Check the parameter for the grade of the engine oil in Caterpillar ET. Refer to illustration 1. The default setting is "Automatic Detection". For optimal cold starting, the actual grade of the engine oil should be used. The options for the parameter can be changed from "Automatic Detection" to the following options: "Automatic Detection", 0W-20, 10W-30 and 15W-40

1. Select 0W-20 if you are using 0W-20, 0W-30, 0W-40, 5W-30 or 5W-40.

2. Select 10W-30 if you are using 10W-30 or 10W-40.

3. Select 15W-40 if you are using 15W-40.

Note: The ether starting aid will be active if the engine oil temperature is below 9 °C (48 °F).

If the ether starting aid is already installed on the machine, refer to Step 9 of ""Procedure to Install the Ether Starting Aid" "for information about the orientation of the ether atomizer. Proper orientation of the atomizer is critical to improving the performance of the machine during cold starting.

Very cold environments may require additional improvements. If you have performed the procedures that are listed above and the machine will not start, perform the procedures that are listed in ""Improvements to the Starting System" ".

Note: In order for the machine to start, a minimum cranking speed of 100 rpm must be achieved.

Note: Do not press the accelerator pedal while you attempt to start the machine with any of these improvements. If the accelerator pedal is pressed before starting, during starting, or within a few moments after starting, the machine may not start successfully.

Do not perform any procedure in this publication or order any parts until you understand the information that is contained in this publication.

Safety

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Do not attempt to disassemble or assemble this machine until you read and understand the disassembly and assembly instructions. Improper disassembly and assembly procedures could result in injury or death.

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Accidental engine starting can cause injury or death to personnel working on the equipment. To avoid accidental engine starting, disconnect the battery cable from the negative (−) battery terminal. Completely tape all metal surfaces of the disconnected battery cable end in order to prevent contact with other metal surfaces which could activate the engine electrical system. Place a Do Not Operate tag at the Start/Stop switch location to inform personnel that the equipment is being worked on.

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Breathing ether vapors or repeated contact of ether with skin can cause personal injury. Personal injury may occur from failure to adhere to the following procedures. Use ether only in well ventilated areas. Do not smoke while changing ether cylinders. Use ether with care to avoid fires. Do not store replacement ether cylinders in living areas or in the operator's compartment. Do not store ether cylinders in direct sunlight or at temperatures above 49 °C (120 °F). Discard cylinders in a safe place. Do not puncture or burn cylinders. Keep ether cylinders out of the reach of unauthorized personnel.

Recommended Practices

The battery disconnect switch should be placed in the OFF position when the machine is not being operated. This practice will result in increased life of the battery and improved performance.

The ether bottle should be removed if ether will not be required and the temperature will be above 16 °C (60 °F) for an extended period of time. When the ether bottle is removed, replace the cap on the ether valve. Store the ether bottle in a location that is cool and dry.

Fluid Recommendations

Ensure that you are using the proper fluids for the environment of the machine. Refer to the following publications:

• Operation and Maintenance Manual, SEBU7459, "IT62G Series II Integrated Toolcarrier and 950G Series II and 962G Series II Wheel Loaders"

• Operation and Maintenance Manual, SEBU6250, "Caterpillar Machine Fluids Recommendations"

• Operation and Maintenance Manual, SEBU5898, "Cold Weather Recommendations for all Caterpillar Machines"

Procedure to Update the Engine Software

Note: Check the service information system for the latest ECM flash files.

Illustration 2	g01346772

1. Illustration 2 shows the configuration screen that is used in order to set the"Ether Control" parameter. The "Ether Control"parameter will be set to "Enabled" or "Disabled".

2. Refer to Table 1 in order to find the correct software for your machine. Download the new software. Install the software to your machine.

3. After you install the new software, verify that the "Ether Control" parameter is set to "Enabled".

Note: After you install the new software, turn the engine start switch to the OFF position. Then turn the engine start switch to the ON position. This will allow the updated software to function properly.

Procedure to Install the Ether Starting Aid

Procedure

Illustration 3	g01338532
Ether Starting Aid (Top View) (10) 1V-3113 Clip (13) 6V-2686 Clip (18) 174-9169 Tube

Illustration 4	g01338624
Ether Starting Aid (Right Side View) (1) 3Y-2888 Connector (7) 258-0733 Atomizer Assembly (8) 258-7609 Starting Aid Harness As (9) 7K-1181 Cable Strap (11) 1V-6645 Spacer (12) 3J-1907 O-Ring Seal (14) 8T-4121 Hard Washer (15) 8T-4182 Bolt (19) 130-5300 Clip

Illustration 5	g01337143
Ether Starting Aid (View A-A) (2) 5P-6313 Flareless Nut (3) 5P-6314 Sleeve (4) 7N-2059 Clamp Assembly (5) 239-1134 Ether Starting Valve Group (6) 241-4194 Fitting (13) 6V-2686 Clip (16) 8T-4189 Bolt (17) 8T-4224 Hard Washer

1. Install 241-4194 Fitting (6) into the port on 239-1134 Ether Starting Valve (5). Refer to Illustration 5.

2. Install 239-1134 Ether Starting Valve (5). Loosen the bolts that hold the valve body in the fixture. Rotate the valve body by 90 degrees. Use two 8T-4189 Bolts (16) and 8T-4224 Hard Washers (17) in order to attach the valve. Tighten the bolts that hold the valve body in the fixture. Refer to Illustration 5.

3. Install 7N-2059 Clamp Assembly (4) above the ether valve. Use two 8T-4189 Bolts (16) and 8T-4224 Hard Washers (17) in order to attach the valve. Refer to Illustration 5.

4. Install 130-5300 Clip (19). Use 1V-6645 Spacer (11), 8T-4121 Hard Washer (14), and 8T-4182 Bolt (15) in order to attach the clip. Attach the wiring from the ether valve to the wiring harness at this location. Refer to Illustration 4.

5. Install tube 174-9169 Tube (18). Refer to Illustration 3 for the routing of the tube. Use one 1V-3113 Clip (10) and one 6V-2686 Clip (13) in order to hold the tube. Refer to Illustration 3 for the locations of these clips. Use the existing bolts at these locations to hold the clips.

6. Use the nut and the sleeve from the 241-4194 Fitting (6) in order to attach the end of the tube to 241-4194 Fitting (6). Refer to Illustration 5.

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Illustration 6	g01346861
Ether Starting Aid (View B-B) (1) 3Y-2888 Connector (7) 258-0733 Atomizer Assembly (10) 1V-3113 Clip (12) 3J-1907 O-Ring Seal

7. Use 1V-3113 Clip (10) in order to hold the tube. Refer to Illustration 6 for the location of the clip. Use the existing bolt at this location in order to hold the clip.

8. Remove the existing plug and the existing O-ring seal from the air intake. Install 3J-1907 O-Ring Seal (12) and 3Y-2888 Connector (1). Refer to Illustration 6.

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Illustration 7	g01336899
Orientation of arrow on atomizer

9. Install the 258-0733 Atomizer Assembly (7) into 3Y-2888 Connector (1). The spray from the atomizer must be directed against the flow of the intake air. An arrow is stamped onto one flat of the atomizer in order to properly orient the atomizer. Orient the atomizer in the inlet manifold. The arrow on the atomizer should face away from the engine. Refer to Illustration 7.

10. Remove any excess tube before you attach the tube to the atomizer. Use the nut and the sleeve from the atomizer in order to attach the tube to the atomizer.

Installation of Wiring Harness

Illustration 8	g01342841
Wiring for Ether Starting Aid (Front View) (20) ECM Ground Connection (21) Connection to ECM (8) 258-7609 Starting Aid Harness Assembly (9) 7K-1181 Cable Strap

Illustration 9	g01346400
Ether Starting Aid (Section A-A)

Illustration 10	g01346411
Ether Starting Aid (Section B-B) (9) 7K-1181 Cable Strap

Install 258-7609 Starting Aid Harness Assembly (8). Refer to Illustration 8 through Illustration 10 for the routing of the harness. Secure the harness in place with eleven 7K-1181 Cable Straps (9) .

Remove the seal plug from position "11" on the J1 ECM connector. Insert the pin of the harness into this position. Connect the ground terminal to the ECM ground connection. Refer to Illustration 8.

The remaining plug on the harness will connect to the wiring from the ether valve.

Improvements to the Starting System

Removal of Existing Battery Box

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Illustration 11	g01342988
Location of Battery Box

1. Remove the cover from the battery box. Disconnect the cables from the battery terminals. Remove the hold-down and the batteries from the box.

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Illustration 12	g01342957
Battery Box (Top View) (22) Angle assembly

2. Remove the battery box from the frame of the machine. Do not remove angle assembly (22). Refer to Illustration 12. An air carbon arc is the preferred method of removing the welds that hold the battery box to the frame. By using this method, damage to the frame is minimized. If the surfaces of the frame are gouged, fill the damaged surface with a weld. Grind the surfaces flush.

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Illustration 13	g01351464
Rail Plate (A) 105 mm (4.134 inch)

3. Shorten the rail plate by 105 mm (4.134 inch) in order to avoid interference with the new battery box. Refer to Illustration 13.

Install the New Battery Box

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Illustration 14	g01339881
Battery Box (Left Side View)

1. Position the 303-8539 Battery Box battery box on the frame.

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Illustration 15	g01339901
Front Side of Battery Box

2. Weld a 6 mm (0.24 inch) fillet weld with 1.5 mm (0.06 inch) of penetration from point "M" to point "N" on the front side of the battery box. Refer to Illustration 15.

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Illustration 16	g01339914
Rear Side of Battery Box

3. Weld a 6 mm (0.24 inch) fillet weld with 1.5 mm (0.06 inch) of penetration from point "P" to point "R" on the rear side of the battery box. Refer to Illustration 16.

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Illustration 17	g01339932
Bottom Side of Battery Box

4. Weld a 6 mm (0.24 inch) fillet weld with 1.5 mm (0.06 inch) of penetration from point "S" to point "T" and from point "U" to point "V" on the bottom side of the battery box. Refer to Illustration 17.

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Illustration 18	g01339934
Battery Box (Top View)

5. Weld a 6 mm (0.24 inch) fillet weld with 1.5 mm (0.06 inch) of penetration from point "W" to point "X" and from point "Y" to point "Z" on the inside of the battery box. Refer to Illustration 18.

Installation of Batteries and Hardware

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Illustration 19	g01339956
Battery Box with 153-5710 Batteries (Top View)

1. Place two 153-5710 Batteries into the new battery box. Refer to Illustration 19.

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Illustration 20	g01339959
Battery Box (Top View) (21) 9R-3979 Rod (22) 7X-7729 Washer (23) 8T-0389 Locknut (24) 153-6281 Battery Hold-Down

2. Thread one 9R-3979 Rod (21) into each of the holes in the bottom of the battery box. Install 153-6281 Battery Hold-Down (24) over the rods. Use two 7X-7729 Washers (22) and two 8T-0389 Locknuts (23) in order to tighten the hold-down. Refer to Illustration 20.

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Illustration 21	g01339977
Battery Box (Top View) (25) 8V-0622 Cable As

3. Attach 8V-0622 Cable As (25) to the negative terminal of the left battery and to the positive terminal of the right battery. Use two 3S-2093 Straps in order to secure the boots to the cable. Refer to Illustration 21.

4. Attach the existing cables to the remaining terminals on the batteries.

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Illustration 22	g01339986
Underside of Cover for Battery Box (26) 570 ± 10 mm (22.44 ± 0.39 inch) of 5P-7211 Seal (27) 585 ± 5 mm (23.03 ± 0.20 inch) of 5P-5637 Seal (28) 570 ± 5 mm (22.44 ± 0.20 inch) of 5P-5637 Seal (29) 210 ± 3 mm (8.27 ± 0.12 inch) of 5P-5637 Seal (30) 8T-4121 Hard Washer

5. Install the 5P-7211 Seal (26) and 5P-5637 Seal (27, 28, 29) to the underside of the 305-8573 Cover . Refer to Illustration 22. 8T-4121 Hard Washers (30) should be positioned between the cover and angle assembly (19) .

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Illustration 23	g01339988
Battery Box with Cover (Top View) (31) 8T-4136 Bolt (32) 7X-7729 Washer

6. Install the cover on the battery box. Use seven 8T-4136 Bolts (31) and seven 7X-7729 Washers (32) in order to tighten the cover. Refer to Illustration 23.