Procedure to Improve Cold Starting Capability for 938G Series II Wheel Loader and IT38G Series II Integrated Toolcarrier{1000, 1456, 7000} Caterpillar

Integrated Toolcarrier:

IT38G Series II (S/N: JAN1-UP; CSX1-UP)

Wheel Loader:

938G Series II (S/N: RTB1-UP; CRD1-UP; PHN1-UP; B9Y1-UP)

Introduction

This Special Instruction contains procedures to improve the cold starting capability of the 938G Series II Wheel Loader and IT38G Series II Integrated Toolcarrier.

Ensure that you are following the ""Recommended Practices" " and ""Fluid Recommendations" ". Perform the procedures that are listed in ""Procedure to Install the Ether Starting Aid" " and ""Procedure to Update the Engine Software" ". 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	g01805433

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, SEBU7581, "IT38G Series II Integrated Toolcarrier and 938G Series II Wheel Loader"

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

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

Procedure to Install the Ether Starting Aid

Note: Some machines will need an additional wiring harness in order to complete the installation of the ether starting aid. The instructions for the installation of the wiring harness can be found below in ""Installation of Wiring Harness" ". Refer to Table 2 for a list of machines that will require the additional harness.

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Illustration 2	g01336788
Ether Starting Aid (Top View)

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Illustration 3	g01336784
Ether Starting Aid (Right Side View)

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Illustration 4	g01336789
Ether Starting Aid (View A-A) (2) 7N-2059 Clamp As (3) 239-1134 Ether Starting Valve (4) 241-4194 Fitting (6) 130-5300 Clip (9) 6V-2686 Clip (10) 8T-4121 Hard Washer (11) 8T-4137 Bolt (12) 8T-4189 Bolt (13) 8T-4224 Hard Washer (14) 174-9169 Tube

Note: Before you install the ether valve, check the plate in order to ensure that the mounting holes are present. Some older machines will not have mounting holes for the valve or the clamp assembly. If your machine does not have the mounting holes, refer to ""Modifying the Mounting Plate" ".

1. Install 241-4194 Fitting (4) into the port on 239-1134 Ether Starting Valve (3). Refer to Illustration 4.

2. Install 239-1134 Ether Starting Valve (3). Use two 8T-4189 Bolts (12) and 8T-4224 Hard Washers (13) in order to attach the valve. Refer to Illustration 4.

3. Install 7N-2059 Clamp As (2) above the ether valve. Use two 8T-4189 Bolts (12) and 8T-4224 Hard Washers (13) in order to attach the valve. Refer to Illustration 4.

4. Install 130-5300 Clip (6). Use 8T-4121 Hard Washer (10) and 8T-4137 Bolt (11) in order to attach the clip. Attach the wiring from the ether valve to the wiring harness at this location. Refer to Illustration 4.

   Note: The machines that are listed in Table 2 will not have an existing wiring harness at this location. Refer to ""Installation of Wiring Harness" ".

5. Install tube (14). Refer to Illustration 2, Illustration 3, and Illustration 4 for the routing of the tube. Use three 6V-2686 Clips (9) in order to hold the tube. Refer to Illustration 4 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 in order to attach the end of the tube to 241-4194 Fitting (6). Refer to Illustration 4.

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Illustration 5	g01336791
Ether Starting Aid (View B-B) (1) 3Y-2888 Connector (5) 258-0733 Atomizer (7) 1V-3113 Clip (8) 3J-1907 O-Ring Seal

7. Use 1V-3113 Clip (7) in order to hold the tube. Refer to Illustration 5 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 (8) and 3Y-2888 Connector (1). Refer to Illustration 5.

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Illustration 6	g01336899
Orientation of arrow on atomizer

9. Install 258-0733 Atomizer (5) 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.

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.

Modifying the Mounting Plate

Illustration 7	g01337076
201-2088 Plate As (15) 11.5 mm (0.45 inch) holes (16) 13.8 mm (0.54 inch) hole

Refer to Illustration 7. Holes (15) are necessary in order to install the ether valve and the clamp assembly. Hole (16) is needed in order to install the clip for the wiring. Some older machines may not have these holes. If your machine does not have these holes, perform the following procedure.

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Illustration 8	g01337093
Locations of mounting holes (A) 108.8 mm (4.284 inch) (B) 19.9 mm (0.784 inch) (C) 232 mm (9.134 inch) (D) 92 mm (3.622 inch) (E) 22 mm (0.866 inch) (F) 13.4 mm (0.528 inch) (G) 115.3 mm (4.539 inch) (H) 139 mm (5.472 inch)

1. Drill four holes (15) that are 11.5 mm (0.453 inch) in diameter. Refer to Illustration 8 for the locations of the holes.

2. Drill one hole (16) that is 13.8 mm (0.543 inch) in diameter. Refer to Illustration 8 for the location of the hole.

3. Weld one 8T-3612 Weld Nut at each hole (15). Weld the nuts on the side of the plate that faces the front of the machine.

4. Weld one 8T-3490 Weld Nut at hole (16). Weld the nut of the side of the plate that faces the front of the machine.

Installation of Wiring Harness

Note: The following procedure is for the machines that are listed above in Table 2.

Illustration 9	g01341431
Wiring for Ether Starting Aid (Top View) (17) 259-7164 Starting Aid Harness As (18) 7K-1181 Cable Strap

Illustration 10	g01341432
Wiring for Ether Starting Aid (Right Side View) (19) ECM Ground Connection (20) Connection to ECM

Illustration 11	g01341433
View C-C (17) 259-7164 Starting Aid Harness As

Illustration 12	g01341434
View D-D (17) 259-7164 Starting Aid Harness As (19) ECM Ground Connection (20) Connection to ECM

Install 259-7164 Starting Aid Harness As (17). Refer to Illustration 9 through Illustration 12 for the routing of the harness. Secure the harness in place with nine 7K-1181 Cable Straps (18) .

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 ECM ground connection (19). Refer to Illustration 10.

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

Procedure to Update the Engine Software (S/N: CRD1-2312,2314-2315; PHN1-3078,3082-3119,3121-3136,3138-3145,3147-3154,3158-3170; B9Y1-761; RTB1-3495; JAN1-458; CSX1-UP)

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.

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Illustration 13	g01342813
Typical Configuration Screen

1. Illustration 13 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 5 in order to find the correct software for your machine. Download the new software. Install the new software to your machine.

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

Improvements to the Starting System (S/N: CRD1-UP; PHN1-UP; B9Y1-UP; RTB1-UP; JAN1-UP; CSX1-UP)

Removal of Existing Battery Box

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Illustration 14	g01339111
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 15	g01339233
Battery Box (Top View) (21) Angle assembly

2. Remove the battery box from the frame of the machine. Do not remove angle assembly (21). Refer to Illustration 15. 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 16	g01339616
Rail Plate (J) 40 mm (1.575 inch) (K) 105 mm (4.134 inch) (L) 33 mm (1.299 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 16. Add a new slot to the end of the plate. The center of the new slot should be 40 mm (1.575 inch) from the end of the plate and 33 mm (1.299 inch) from the inside edge of the plate. The slot should be 20 mm (0.787 inch) in length and 11.5 mm (0.453 inch) in width.

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Illustration 17	g01339769
Battery Box and Frame (Top View) (22) Lug

4. Remove the lug (22) that is closest to the rear of the machine. An air carbon arc is the preferred method of removing the welds that hold the lug 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.

5. Reattach the lug to the frame. The hole in the lug should be in line with the slot in the rail plate that was created in Step 3.

Install the New Battery Box

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Illustration 18	g01339881
Battery Box (Left Side View)

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

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Illustration 19	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 19.

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Illustration 20	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 20.

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Illustration 21	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 21.

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Illustration 22	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 22.

Installation of Batteries and Hardware

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Illustration 23	g01339956
Battery Box with 153-5710 Batteries (Top View)

1. Place two 153-5710 Batteries into the new battery box. Refer to Illustration 23.

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Illustration 24	g01339959
Battery Box (Top View) (23) 9R-3979 Rod (24) 7X-7729 Washer (25) 8T-0389 Locknut (26) 153-6281 Battery Hold-Down

2. Thread 9R-3979 Rod (23) into each of the holes in the bottom of the battery box. Install 153-6281 Battery Hold-Down (26) over the rods. Use two 7X-7729 Washers (24) and two 8T-0389 Locknuts (25) in order to tighten the hold-down. Refer to Illustration 24.

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Illustration 25	g01339977
Battery Box (Top View) (27) 8V-0622 Cable As

3. Attach 8V-0622 Cable As (27) to the negative terminal of the left battery and to the positive terminal of the right battery. Use two 3S-2093 Cable Straps in order to secure the boots to the cable. Refer to Illustration 25.

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

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Illustration 26	g01339986
Underside of Cover for Battery Box (28) 570 ± 10 mm (22.44 ± 0.39 inch) of 5P-7211 Seal (29) 585 ± 5 mm (23.03 ± 0.20 inch) of 5P-5637 Seal (30) 570 ± 5 mm (22.44 ± 0.20 inch) of 5P-5637 Seal (31) 210 ± 3 mm (8.27 ± 0.12 inch) of 5P-5637 Seal (32) 8T-4121 Hard Washer

5. Install 5P-7211 Seal (28) and 5P-5637 Seal (29, 30, 31) to the underside of the 305-8573 Cover . Refer to Illustration 26. 8T-4121 Hard Washers (32) should be positioned between the cover and angle assembly (21) .

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Illustration 27	g01339988
Battery Box with Cover (33) 8T-4136 Bolt (34) 7X-7729 Washer

6. Install the cover on the battery box. Use seven 8T-4136 Bolts (33) and seven 7X-7729 Washers (34) in order to tighten the cover. Refer to Illustration 27.