Caterpillar Cat 966H WHEEL LOADER (Prefix A6J) Service Repair Manual (A6J00001-01800)

Service Repair Manual

Models

966H WHEEL LOADER

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Disassembly and Assembly 966H and 972H Wheel Loaders Machine Systems Media Number -RENR8859-07

Publication Date -01/03/2014

Date Updated -14/12/2016

i05415906

Loader Frame from Rear Frame - Separate SMCS - 7051-076; 7054-076

Separation Procedure Table 1 Required Tools Tool

A

B

C

D

Part Number

Part Description

Qty

9U-7536

Stand

2

350-7768

Electric Hydraulic Pump Gp (115 V)

1

350-7769

Electric Hydraulic Pump Gp (230 V)

1

8T-5255

Hydraulic Jack

1

350-7768

Electric Hydraulic Pump Gp (115 V)

1

350-7769

Electric Hydraulic Pump Gp (230 V)

1

6V-3160

Hydraulic Puller

1

4C-9633

Stud

1

1A-1935

Nut

2

1P-1841

Bearing Puller Adapter

1

6V-2097

Sleeve

1

350-7768

Electric Hydraulic Pump Gp (115 V)

1

350-7769

Electric Hydraulic Pump Gp (230 V)

1

6V-3160

Hydraulic Puller

1

4C-9633

Stud

1

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966H WHEEL LOADER A6J00001-01800 (MACHINE) POWERED BY C11 ENGI...

1A-1935

Nut

2

9U-5336

Bearing Puller Adapter

1

6V-2097

Sleeve

1

350-7768

Electric Hydraulic Pump Gp (115 V)

1

350-7769

Electric Hydraulic Pump Gp (230 V)

1

6V-3160

Hydraulic Puller

1

4C-9633

Stud

1

1A-1935

Nut

2

1M-6756

Sleeve

1

7F-5283

Adapter

1

1P-1844

Bearing Puller Adapter

1

1U-5230

Hand Hydraulic Pump

1

E

F Start By:

a. Remove the cab. b. Remove the center drive shaft. c. Separate the steering frame lock.

When you are using hydraulic cylinders and puller studs, always ensure that the rated capacity of the puller stud meets or exceeds the rated capacity of the hydraulic cylinder. If the puller stud does not meet or exceed the rated capacity of the hydraulic cylinder, a sudden failure of the puller stud could occur. The sudden failure of the puller stud could result in personal injury or death.

NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.

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Refer to Special Publication, NENG2500, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat products.

Dispose of all fluids according to local regulations and mandates.

Note: Put identification marks on all hoses, on all hose assemblies, on all wires, and on all tube assemblies for installation purposes. Plug all hose assemblies and all tube assemblies. This helps to prevent fluid loss, and this helps to keep contaminants from entering the system.

1. Drain the oil from the hydraulic tank into a suitable container for storage or disposal. Refer to Operation and Maintenance Manual, "Hydraulic System Oil - Change".

Illustration 1

g01161541

2. Remove clamp (1). Disconnect harness assembly (2).

Illustration 2

g01161563

3. Disconnect hose assemblies (3), (4), (5), (6), (7), and (8).

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Illustration 3

g01161569

4. Remove bolt (9) and pin assembly (10). Position steering cylinder (11) away from the loader frame. Repeat for the remaining steering cylinder.

Illustration 4

g00432878

5. Position Tooling (A) under the rear frame.

Illustration 5

g01162333

6. Position suitable cribbing under the front of the rear frame.

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Illustration 6

g01161601

7. Attach a suitable lifting device to the loader frame.

Illustration 7

g01162330

8. Remove bolts (12) and (13). Remove plate (14). Remove shim (15) (not shown).

Illustration 8

g01161727

9. Use Tooling (B) in order to remove pin (16).

Note: Use the suitable lifting device in order to relieve pressure from pin assembly (16) during removal.

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Illustration 9

g01161739

10. Remove spacer (17) from the lower hitch.

Illustration 10

g01162379

Illustration 11

g01161762

11. Remove bolt (18) from pin assembly (19).

12. Use Tooling (B) in order to remove pin assembly (19) from the upper hitch.

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Note: Use the suitable lifting device in order to relieve pressure from pin (19) during removal.

Illustration 12

g01162004

13. Attach Tooling (F) to the end of brake actuator (20) in order to release the parking brake.

Illustration 13

g00364111

Illustration 14

g01161788

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14. Use a suitable lift truck and the suitable lifting device in order to separate the loader frame from the rear frame. Use suitable cribbing in order to support the loader frame and the rear frame.

Illustration 15

g01162236

Illustration 16

g01162377

15. Mark the position of caps (21) and (25). Remove bolts (22) and remove cap (21), shim (23) (not shown), and cap (25) from the upper hitch of the loader frame. Remove lip seal (24) from cap (21). Remove lip seal (26) from cap (25).

Illustration 17

g01161805

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16. Use Tooling (C) in order to remove bearing cups (27) (not shown) and bearing cones (28) (not shown) from the upper hitch of the loader frame.

Illustration 18

g01161816

17. Use Tooling (D) in order to remove sleeve bearing (29) from the upper hitch of the rear frame.

Illustration 19

g01161823

18. Use Tooling (D) in order to remove sleeve bearing (30) from the upper hitch of the rear frame.

Illustration 20

g01161934

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Illustration 21

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g01161944

19. Mark the position of caps (31) and (35). Remove bolts (33). Remove caps (31) and (35) and shim (34) (not shown). Remove lip seal (32) from cap (31). Remove lip seal (36) from cap (35).

Illustration 22

g01161929

20. Use Tooling (E) in order to remove bearing cups (37) (not shown) and bearing cones (38) (not shown) from the lower hitch of the rear frame.

Copyright 1993 - 2020 Caterpillar Inc.

Sat Mar 28 02:11:07 UTC+0800 2020

All Rights Reserved.

Private Network For SIS Licensees.

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Shutdown SIS Previous Screen Product: WHEEL LOADER Model: 966H WHEEL LOADER A6J Configuration: 966H WHEEL LOADER A6J00001-01800 (MACHINE) POWERED BY C11 ENGINE

Disassembly and Assembly 966H and 972H Wheel Loaders Machine Systems Media Number -RENR8859-07

Publication Date -01/03/2014

Date Updated -14/12/2016

i07235609

Loader Frame to Rear Frame - Connect SMCS - 7051-077; 7054-077

Connection Procedure Table 1 Required Tools Tool

Part Number

Part Description

Qty

9U-7536

Stand

2

350-7768

Electric Hydraulic Pump Gp (115 V)

1

350-7769

Electric Hydraulic Pump Gp (230 V)

1

8T-5255

Hydraulic Jack

1

8F-6302

Bolt

1

1B-4330

Nut

2

1P-0502

Driver Plate

2

H

1P-0520

Driver Group

1

J

-

Loctite C5A

1

K

5P-0960

Grease Cartridge

1

A

B

G

NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine. Be prepared to collect the fluid with suitable containers

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before opening any compartment or disassembling any component containing fluids.

Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide", for tools and supplies suitable to collect and contain fluids in Caterpillar machines.

Dispose of all fluids according to local regulations and mandates.

Note: Apply Tooling (J) to all bores when you connect the frames. Lubricate all pin bores, all seals, and all pins with Tooling (K) before installation.

Note: The following steps are for the assembly of the lower hitch bearings.

Illustration 1

g01162162

1. Position cap (35) and install four bolts (33) that are equally spaced. Ensure that cap (35) is seated firmly against the frame.

2. Lower the temperature of lower bearing cup (37). Use Tooling (H) to install lower bearing cup (37) so that lower bearing cup (37) makes contact with cap (35). Apply clean oil to lower bearing cone (38) and install lower bearing cone (38).

3. Apply clean oil to upper bearing cone (38) and install upper bearing cone (38). Lower the temperature of upper bearing cup (37). Use Tooling (H) to install upper bearing cup (37) so that upper bearing cup (37) makes contact with upper bearing cone (38).

4. Remove bolts (33) and cap (35).

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Illustration 2

g01162135

Illustration 3

g01162187

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5. Position shims (34). Install cap (31) and (35) with four bolts (33).

6. Install Tooling (G) (not shown). Use a suitable torque wrench and Tooling (G) (not shown) to measure the rolling torque. Adjust the number of shims (34) to achieve a rolling torque that is between 23 N·m (204 lb in) and 8 N·m (71 lb in). Remove Tooling (G) (not shown).

7. Remove bolts (33) and caps (31) and (35).

Illustration 4

g01162373

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8. Use Tooling (H) to install lip seal (36) in cap (35), with the spring of the lip seal facing down. Use Tooling (H) to install lip seal (32) in cap (31), with the spring of the lip seal facing up.

Illustration 5

g01162153

9. Position the required number of shims (34) (not shown). Position caps (31) and (35) and the spacer. Install bolts (33).

Note: The following steps are for the assembly of the upper hitch bearings.

Illustration 6

g01162170

10. Position cap (25) and install three bolts (22) that are equally spaced. Ensure that cap (25) is seated firmly against the frame. Apply Tooling (J) to the bores.

11. Lower the temperature of lower bearing cup (27). Use Tooling (H) to install lower bearing cup (27) so that lower bearing cup (27) makes contact with cap (25). Apply clean oil to lower bearing cone (28) and install lower bearing cone (28).

12. Apply clean oil to upper bearing cone (28) and install upper bearing cone (28). Lower the temperature of upper bearing cup (27). Use Tooling (H) to install upper bearing cup (27) so that upper bearing cup (27) makes contact with upper bearing cone (28).

13. Remove bolts (22) and cap (25).

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Illustration 7

g01162206

Illustration 8

g01162219

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14. Position shims (23). Position cap (21) and (25) and install three bolts (22) that are evenly spaced.

15. Install Tooling (G) (not shown). Use a suitable torque wrench and Tooling (G) (not shown) to measure the rolling torque. Adjust the number of shims (23) to achieve a rolling torque that is between 14 N¡m (124 lb in) and 2 N¡m (18 lb in). Remove Tooling (G) (not shown).

16. Remove bolts (22) and caps (21) and (25).

Illustration 9

g01162377

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17. Use Tooling (H) to install lip seal (26) in cap (25) with the spring of the lip seal up. Use Tooling (H) to install lip seal (24) in cap (21) with the spring of the lip seal facing down.

Illustration 10

g01162236

18. Position the required number of shims (23) (not shown). Position caps (21) and (25). Install bolts (22).

Illustration 11

g01162307

19. Lower the temperature of sleeve bearings (29) and (30). Install sleeve bearings (29) and (30) in the upper rear hitch.

Illustration 12

g01161601

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20. Attach a suitable lifting device to the front frame and apply slight lifting tension.

Illustration 13

g01162336

Illustration 14

g00364111

21. Remove the suitable cribbing from the front frame. Use a suitable lift truck and the suitable lifting device to connect the front frame and the rear frame.

Illustration 15

g00432878

22. Use Tooling (A) and the suitable lifting device to align the pin bores.

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Illustration 16

g01162379

23. Install pin assembly (19). Install bolt (18).

Illustration 17

g01162324

24. Install pin (16).

Illustration 18

g01161739

25. Install spacer (17) to the lower hitch.

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Illustration 19

9/11

g01162330

26. Install plate (14). Install bolts (13). Tighten bolts (13) to a torque of 530 ± 70 N·m (390 ± 50 lb ft).

27. Use a suitable feeler gauge to measure the distance between the frame and plate (16). Check completely around the lower hitch mount plate. Record the minimum measurement that is found.

28. Remove plate (14).

29. Install shims (15) (not shown) under plate (14). The thickness of shims (15) (not shown) should equal the measurement from Step 27.

30. Install bolts (13). Tighten bolts (13) to a torque of 530 ± 70 N·m (390 ± 50 lb ft). Install bolts (12). Tighten bolts (12) to a torque of 100 ± 20 N·m (75 ± 15 lb ft).

Illustration 20

g01161601

31. Remove the suitable lifting device from the loader frame.

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Illustration 21

10/11

g01162333

32. Remove the suitable cribbing from the rear frame.

Illustration 22

g00432878

33. Remove Tooling (A) from the rear frame.

Illustration 23

g01161569

34. Position steering cylinder (11). Install pin assembly (10) and install bolt (9). Repeat for the remaining steering cylinder.

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Illustration 24

11/11

g01161563

35. Connect hose assemblies (3), (4), (5), (6), (7), and (8).

Illustration 25

g01161541

36. Connect harness assembly (2). Install clamp (1).

37. Fill the hydraulic tank with oil. Refer to Operation and Maintenance Manual, "Hydraulic System Oil - Change".

End By: a. Install the cab. b. Install the center drive shaft. c. Disconnect the steering frame lock.

Copyright 1993 - 2020 Caterpillar Inc.

Sat Mar 28 02:12:03 UTC+0800 2020

All Rights Reserved.

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Shutdown SIS Previous Screen Product: WHEEL LOADER Model: 966H WHEEL LOADER A6J Configuration: 966H WHEEL LOADER A6J00001-01800 (MACHINE) POWERED BY C11 ENGINE

Disassembly and Assembly Comfort Series Seat For Caterpillar Machines Media Number -RENR2165-12

Publication Date -01/10/2013

Date Updated -31/10/2013

i02140400

Comfort Seat with Front Controls - Disassemble SMCS - 7324-015

Disassembly Procedure 1. Remove the seat from the machine.

2. Place the seat in the fully upright position.

Illustration 1

g01075179

3. Remove stop bolt (2). Remove seat assembly (1) from suspension assembly (3).

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Illustration 2

g01075180

4. Remove bolts (4). Remove cover (5).

Illustration 3

g01075181

5. Remove bolt (9) and retainer (8). Remove nuts (7). Remove armrest (6).

Illustration 4

g01075238

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6. Remove bolt (11) and the spacer from belt assembly (10).

Illustration 5

g01075241

7. Use a prybar in order to remove the bottom of seat cushion (12).

Illustration 6

g01075244

8. Remove nuts (14) and the bolts. Remove support assembly (13).

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