Procedure to Improve Cold Starting Capability for 950H Wheel Loader, 962H Wheel Loader , and IT62H Integrated Toolcarrier{1000, 1456, 7000} Caterpillar

Integrated Toolcarrier:

IT62H (S/N: M5G1-UP)

Wheel Loader:

950H (S/N: N1A1-UP; M1G1-UP; J5J1-UP; K5K1-UP)

962H (S/N: N4A1-UP; M3G1-UP; K6K1-UP; J6J1-UP)

Introduction

This Special Instruction contains procedures that will improve the cold starting capability of the 950H Wheel Loader, 962H Wheel Loader, and IT62H 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.

Note: The ether starting aid will be active if the coolant temperature is below the value that is shown in Table 1 and the air inlet temperature is no more than 11 °C higher than the coolant temperature. The air inlet heater activates if the ether starting aid does not activate and the sum of the coolant temperature and the air inlet temperature is less than 25 °C.

If the ether starting aid is already installed on the machine, refer to Step 13 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 115 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, SEBU7889, "IT62H Integrated Toolcarrier and 950H and 962H 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 (S/N: K5K1-1221; N1A1-1146,1149; J5J1-428; M1G1-797; K6K1-261; N4A1-463,465-468,474-475; J6J1-210,214,222; M3G1-273; M5G1-304)

Note: The new engine software is already installed on machines that were produced after the machines that are listed above.

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

Note: Machines with S/N:J5J and ; S/N:J6J serial number prefixes that are sold into Japan will require different software. The MLITSTEP3 software for the 950H is 307-3086 Engine Ratings Electronic Software Gp . The MLITSTEP3 software for the 962H is 307-3085 Engine Ratings Electronic Software Gp . Both of these files are available from the Service Information System.

Illustration 1	g01336969

1. Illustration 1 shows the configuration screen that is used in order to set the "Ether Solenoid Configuration" parameter. The "Ether Solenoid Configuration" parameter will be set to "Not Installed" or "Continuous Flow Solenoid".

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

3. Verify that the "Ether Solenoid Configuration" parameter is set to "Continuous Flow Solenoid".

   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

Illustration 2	g01342336
Right Side View (1) 3Y-2888 Connector (7) 258-0733 Atomizer (9) 130-5300 Clip (10) 3J-1907 O-Ring Seal (13) 6V-2686 Clip (14) 8T-4121 Hard Washer (18) 8T-4195 Bolt

Illustration 3	g01342314
View A-A (2) 7N-2059 Clamp As (3) 9R-2081 Bracket As (11) 5C-7261 Nut (13) 6V-2686 Clip (14) 8T-4121 Hard Washer (16) 8T-4189 Bolt (17) 8T-4191 Bolt (18) 8T-4195 Bolt (19) 8T-4224 Hard Washer (20) 174-9169 Tube

Illustration 4	g01342283
View B-B (5) 239-1134 Ether Starting Valve (6) 241-4194 Fitting (8) 263-1774 Plate As (14) 8T-4121 Hard Washer (16) 8T-4189 Bolt (18) 8T-4195 Bolt (19) 8T-4224 Hard Washer

1. Install 263-1774 Plate As (8). Use two 8T-4121 Hard Washers (14) and two 8T-4195 Bolts (18) in order to install the plate. Refer to Illustration 3 and Illustration 4.

2. Install 241-4194 Fitting (6) into the port on 239-1134 Ether Starting Valve (5). Refer to Illustration 4.

3. 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. Tighten the bolts for the fixture. Use two 8T-4189 Bolts (16) and two 8T-4224 Hard Washers (19) in order to attach the valve. Refer to Illustration 4.

4. Install 7N-2059 Clamp As (2) above the ether valve. Use two 8T-4189 Bolts (16) and two 8T-4224 Hard Washers (19) in order to attach the valve. Refer to Illustration 3 and Illustration 4.

5. Install 130-5300 Clip (9). Use one 8T-4195 Bolt (18) and one 8T-4121 Hard Washer (14) in order to attach the clip. Refer to Illustration 2.

6. Install 174-9169 Tube (20). Refer to Illustration 2 through Illustration 4 for the routing of the tube. Use three 6V-2686 Clips (13) in order to hold the tube. Use one 8T-4191 Bolt (17) and one 8T-4121 Hard Washer (14) to install each clip. Refer to Illustration 3 for the locations of these clips.

7. Attach 9R-2081 Bracket As (3) to the inlet manifold. Use 5C-7261 Nut (11) and one 8T-4224 Hard Washer (19) in order to attach the bracket to the inlet manifold. Refer to Illustration 2 and Illustration 3.

8. Secure tube (20) to bracket (3). Use one 6V-2686 Clip (13), one 8T-4121 Hard Washer (14), and one 8T-4195 Bolt (18) in order to secure the tube.

9. Use the nut and the sleeve from the 241-4194 Fitting in order to attach the end of the tube to 241-4194 Fitting (6). Refer to Illustration 4.

10. Use one 6V-2686 Clip (13) in order to secure tube (20) near the ether starting valve. Refer to Illustration 2.

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Illustration 5	g01345180
View C-C (4) 9R-5008 Spacer (12) 6V-1889 Clip (13) 6V-2686 Clip (14) 8T-4121 Hard Washer (15) 8T-4133 Nut (18) 8T-4195 Bolt

Note: If the machine was equipped with air conditioning from the factory, perform the following step. If the machine was not equipped with air conditioning from the factory, proceed to Step 12.

11. Use one 6V-2686 Clip (13) and one 6V-1889 Clip (12) in order to secure the tube to the air conditioner lines. Place 9R-5008 Spacer (4) between the two clips. Use one 8T-4195 Bolt (18), one 8T-4133 Nut (15), and two 8T-4121 Hard Washers (14) in order to connect the two clips. Refer to Illustration 5.

12. Remove the existing plug and the existing O-ring seal from the air intake. Install 3J-1907 O-Ring Seal (10) and 3Y-2888 Connector (1). Refer to Illustration 2.

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Illustration 6	g01336899
Orientation of arrow on atomizer

13. 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 6.

14. Remove any excess tubing before you attach the tube to the atomizer. Use the compression fitting from the atomizer in order to attach the tube to the atomizer.

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Illustration 7	g01345232
Wiring for Ether Starting Aid (Top View)

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Illustration 8	g01345233
View E-E (21) 263-6668 Starting Aid Harness As (22) 5P-9085 Clip

15. Install 263-6668 Starting Aid Harness As (21). Refer to Illustration 7 and Illustration 8 for the routing of the harness. Use one 5P-9085 Clip (22) in order to hold the harness. Refer to Illustration 8 for the location of the clip.

Improvements to the Starting System (S/N: K5K1-1242; N1A1-1352; J5J1-534; M1G1-797; K6K1-264; N4A1-529; J6J1-227; M3G1-281; M5G1-305)

Note: The improvements are already installed on machines that were produced after the machines that are listed above.

Replacing the Electric Starting Motor

The electric starting motor for the machine should be replaced with the 207-1551 Electric Starting Motor . This motor will improve the performance of the machine during cold starting.

1. Disconnect the cables from the existing starting motor.

2. Remove the existing starting motor from the machine.

   ReferenceFor more information about removing the starting motor, refer to Disassembly and Assembly, RENR8863, "IT62H Integrated Toolcarrier and 950H and 962H Wheel Loaders Engine Supplement", "Electric Starting Motor - Remove".

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Illustration 9	g01343135

3. Install the 207-1551 Electric Starting Motor Gp . It may be necessary to tilt the starting motor at an angle in order to obtain clearance for the installation. Refer to Illustration 9.

   ReferenceFor more information about installing the starting motor, refer to Disassembly and Assembly, RENR8863, "IT62H Integrated Toolcarrier and 950H and 962H Wheel Loaders Engine Supplement", "Electric Starting Motor - Install".

4. Reconnect the cables to the new starting motor.

Replacing the Batteries

Modify the Battery Box

1. Disconnect the cables from both batteries.

2. Remove the hold-down for the batteries. Remove the batteries.

3. Remove the battery box from the machine.

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Illustration 10	g01343140
Battery Box (23) Bolt (24) Hard Washer (25) Spacer

4. Remove two bolts (23), two hard washers (24), and two spacers (25) from the floor of the battery box. Refer to Illustration 10.

   Note: These parts may not be present on all machines. If your machine does not contain these parts, proceed to Step 5.

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Illustration 11	g01345289
Battery Box (26) Weld Nut

5. Remove weld nut (26) from the bottom of the battery box. Refer to Illustration 11.

6. After you remove the weld nut, enlarge the hole at the same location. Enlarge the hole to a diameter of 13.8 mm (0.543 inch).

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Illustration 12	g01345293
Battery Box (Bottom View) (F) 162 mm (6.378 inch)

7. Drill a second hole that is in line with the first hole. The second hole also has a diameter of 13.8 mm (0.543 inch). The distance between the centers of the two holes should be 162 mm (6.378 inch). Refer to Illustration 12.

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Illustration 13	g01345294
Battery Box (Bottom View) (27) 8T-3490 Weld Nut

8. Weld one 8T-3490 Weld Nut (27) over each of the two holes on the bottom of the box. Refer to Illustration 13.

9. Reinstall the battery box into the machine.

Install Additional Support

Note: If your machine is equipped with a toolbox below the battery box, proceed to ""Install New Batteries" ". If the machine is not equipped with a toolbox, additional support will be needed in order to support the new batteries. Perform the following steps in order to install the additional support.

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Illustration 14	g01345640
Ladder (Left Side View)

1. Disconnect bracket (28) from the ladder. Remove bracket (28) from the bottom of the battery box. Refer to Illustration 14.

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Illustration 15	g01345651
Ladder (Left Side View) (29) 304-5182 Support As

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Illustration 16	g01345655
View G-G (29) 304-5182 Support As (30) 5P-1076 Hard Washer (31) 8T-4139 Bolt

2. Install 304-5182 Support As (29). Use four 5P-1076 Hard Washers (30) and four 8T-4139 Bolts (31) in order to secure the support. Refer to Illustration 15 and Illustration 16.

Install New Batteries

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Illustration 17	g01345534
Battery Box (Top View) (32) 3S-2093 Cable Strap (33) 8V-0622 Cable As (34) 153-5710 Battery (35) 153-6281 Battery Hold-Down (36) 9R-3979 Rod (37) 7X-7729 Washer (38) 8T-0389 Locknut

1. Install two 153-5710 Batteries (34) into the battery box. Refer to Illustration 17.

2. Thread 9R-3979 Rod (36) into each of the weld nuts that were added to the battery box. Place 153-6281 Battery Hold-Down (35) over the rods and the batteries. Use two 7X-7729 Washers (37) and two 8T-0389 Locknuts (38) in order to tighten the hold-down. Refer to Illustration 17.

3. Use 8V-0622 Cable As (33) in order to connect the positive terminal on the left battery to the negative terminal on the right battery. Refer to Illustration 17. Use two 3S-2093 Cable Straps (32) in order to secure the boots to the cable.

4. Reattach the cables to the remaining battery terminals.