Service Information

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Parts Manual 966H/ 972H
966H Wheel Loader (A6D) SEPB3743
972H Wheel Loader (A7D) SEPB3744
Service Manual 966H/ 972H
Specification / Systems Operation / Testing & Adjusting (2 Vol.) RENR8840
Binder Label Vol. 1 RENR8841
Contents Page Vol. 1 RENR8842
Binder Label Vol. 2 RENR8848
Contents Page Vol. 2 RENR8849
Engine
Engine Specifications SENR9887
Engine System Operation/Testing & Adjusting SENR9888
Engine Troubleshooting RENR9318
Engine Disassembly & Assembly RENR9214
Disassembly & Assembly Supplement RENR8843
Power Train
Specification RENR8844
Systems Operation RENR8845
Troubleshooting/Testing & Adjusting RENR8846
Disassembly & Assembly RENR8847
Systems
Specifications Steering System RENR8850
Steering Systems Operation RENR8851
Steering Testing & Adjusting RENR8852
Specification Braking & Hydraulic Fan System RENR8853
Braking & Hydraulic Fan Systems Operation RENR8854
Braking & Hydraulic Fan Systems Testing & Adjusting RENR8855
Specifications Electrohydraulic Systems RENR8856
Electrohydraulic Systems Operation RENR8857
Electrohydraulic Systems Troubleshooting/Testing & Adjusting RENR8858
Electrohydraulic Systems Schematic RENR8828
Machine Systems Specifications RENR8829
Machine Systems Disassembly & Assembly RENR8859
Contour Series Seat SENR6615
Payload Control System SENR6614
Caterpillar Monitoring System SENR1394
Machine Security System RENR2462
Electrical System
Schematic RENR6332
 Translations

Operation & Maintenance Manual

English SEBU7887
 966H Wheel Loaders
Contamination Control Guidelines
Contamination is anything that doesn't belong in machine fluid systems; paint flakes, rag fibers,
metals, greases, weld spatter, sealing materials, and more. When systems are contaminated,
efficiency drops, cycle times increase and component and fluid life is shortened. Eventually,
contamination can lead to catastrophic failure, unplanned downtime, and costly repairs for
customers.

Customer demand for increased productivity has produced industry trends toward electro-
hydraulics, higher system pressures and tighter internal clearances. As a result of these
trends, today's fluid systems (hydraulics, transmissions, steering, power train, engines, and
fuel) will not tolerate dirt and other contaminants like their predecessors. Fluid contamination
threatens reliability throughout the life cycle of today's machines and engines. Therefore,
Caterpillar's goal is to create a Cultural Change by educating Caterpillar Plants, Caterpillar
Dealers and Caterpillar Customers to become Leaders in Contamination Control. Servicing an
older Caterpillar machine population in the past was quite different than servicing today's
machines. The time to invest in product reliability via Contamination Control is NOW!

By addressing this very important aspect of machine operation and life cycle, you will:

· Improve component life and machine productivity

· Lower customer costs and increase customer satisfaction
· Extend product and component life
· Increase rental fleet value
· Reduce Hazardous waste generation
· Reduce service/repair redo

A partial list of the available contamination control information for this vehicle is listed below.
Visit our Contamination Control Web Site at: https://nacd.cat.com/infocast/frames/prodsupp/cc/

Contamination Control Information

Form # Description
SEBF8493 Procedure for Kidney Looping Wheel Loader, Landfill and Soil Compactor, and
Integrated Tool Carrier Hydraulic Oil
SEBF8452 Procedure for Kidney Looping Wheel Loader Transmission Oil Equipped With
Ecology Drain
PEGP8029 An Introduction to Contamination Control
SEBF8452 Kidney Loop Filtering Wheel Loader Transmissions
SEHS9043 Installing S.O.S Sampling Valves
PEVN4638 How to Take a Proper Oil Sample
PERV4632 Fluid Contamination Control-The Silent Thief (Video)
PERV4632 Fluid Contamination Control-The Silent Thief (CD)
PEVN4831 Count on Caterpillar Particle Analyzers (Video)
NEXG5038 Count on Caterpillar Particle Analyzers (CD)
Contacts:
Jim McClintock, Contamination Control, (309) 675-8970
 966H Wheel Loader
Reusability & Salvage/Repair Guidelines

C11 Engine
Form # Description
Engine Block
REHS2133 Cylinder Block Salvage Procedure for Using Belzona Ceramic R Metal
GMG00981 Using 1P-3537 Dial Bore Gauge Group To Check Cylinder Bore Size
SMHS7606 Use of 1P-4000 Line Boring Tool Group
SEBF8882 Using LOCK-N-STITCH® Procedures for Casting Salvage
SEHS8919 Salvage Weld Procedure for Iron Cylinder Blocks
Cylinder Head
SEBF8162 Specifications to Measure and Salvage Cylinder Head Assemblies and Related
Components
SEHS9498 Using the 9U-5383 Vacuum Tester
Piston/Connecting Rods
SEBF8063 Visual Inspection of Connecting Rods
SEBF8049 Pistons
SEBF8051 Piston Pins and Retaining Rings
SEBF8064 Salvage of Non-Serrated Connecting Rods
SEBF8242 Verification of Connecting Rod Eye Bushing Retention Using 5P-8639 Connecting
Rod Bushing Press Group
SEBF8259 Procedure to Clean and Inspect Two-Piece Pistons in 3176 Engines
SEBF8303 Procedure to Inspect Piston Pins
SEBF8290 Visual Inspection of Two-Piece Pistons
Fuel System
SEBU6250 Caterpillar Machine Fluids Recommendations
SEBU6251 Caterpillar Commercial Diesel Engine Fluids Recommendations
SEBU6385 Caterpillar On-Highway Truck Engine Fluids Recommendations
SEHS8922 Installation of 1U-6667 Conversion Group
Lubrication/Cooling System
SEBD0640 Oil and Your Engine
REHS1758 Test Procedure for Brazed and Rubber End Sheet Oil Coolers
Crankshaft
SEBF8041 Crankshaft Measurement
SEBF8054 Procedure to Measure and Straighten Bent Crankshafts
SEBF8094 Procedure to Grind Crankshafts
SEBF8009 Main and Connecting Rod Bearings
SEBF8043 Visual Inspection of Crankshafts
SEBF8039 Inspection of Crankshafts for Cracks
SEBF8042 Procedure to Polish Crankshafts
Turbocharger
SEBF8018 Turbochargers
SEBF8019 Specifications for Reusable Turbocharger Components
SEBF8071 Procedure to Salvage Turbocharger Components
Valve Mechanism
SEBF8097 Camshaft Measurement
SEBF8146 Visual Inspection of Camshafts
SEBF8067 Slipper Followers and Camshaft Roller Followers
SEBF8002 Valves, Valve Springs, Valve Rotators, and Locks
Gear Train
SEBF8045 Timing Gears For All Engines
Miscellaneous
SEBF8046 Cast Iron and Steel Pulleys
SEBF8301 Inspection and Reuse of Critical Fasteners Used in All Engines
SEBF8405 Kidney Loop Filtration Process for Rebuilt Engines
SEBF8887 Specifications to Machine Reaction Faces of Flywheel Assemblies on C11/C13
Engines

Contacts:
Simon Bishop, Engine Guidelines, (309) 494-5974
Jim McClintock, Hydraulic Systems, (309) 675-8970
Jon Feucht, Power Train, (309) 675-6304
Steve Brannan, Undercarriage, (309) 675-6585
 966H Wheel Loader
Repair Processes - Hydraulic Systems
Reuse and Salvage Guidelines can be accessed through SIS Web. In SIS Web, select
Advanced Full Text Search. Then select Guidelines for Reusable Parts and Salvage
Operations.

Hydraulic Systems - Machine Specific

Form # Description
None CHS Inspection Form
REHS1376 Pump & Motor Bench Test Procedure
Hydraulic Systems - Machine Non-Specific
Form # Description
SELD0475 Hydraulic Repair Procedures
PEGP6025 Custom Hydraulic Service Guidebook
NEHT6503 Procedure for Testing Hydraulic Cylinders using the 9U6803 Caterpillar Cylinder
Tester

Contacts:
Simon Bishop, Engine Guidelines, (309) 494-5974
Jim McClintock, Hydraulic Systems, (309) 675-8970
Jon Feucht, Power Train, (309) 675-6304
Steve Brannan, Undercarriage, (309) 675-6585
 966H Wheel Loader
Repair Processes - Power Train
Reuse and Salvage Guidelines can be accessed through SIS Web. In SIS Web, select
Advanced Full Text Search. Then select, Guidelines for Reusable Parts and Salvage
Operations.

Power Train - Machine Specific

Form # Description
SEBF8317 Torque Converter, Divider, Drive Line, and Drive Axle Salvage and Reuse Manual
Contents
SEBF8173 Salvage of Transmission Transfer Gear Case for Wheel Loaders; Wheel Tractors;
Compactors; Motor Graders
SEBF8048 Procedure to Machine Damaged Transmission and Differential Yokes
SEBF8098 Transmission Clutch Plates and Disc Assemblies With RAYFLEX® Clutch Friction
Material
SEBF8313 Transmission Reuse and Salvage Manual Contents
SEBF8312 Transmission Reuse and Salvage Index
SEBF8134 Individual Clutch Modulation (ICM) Control Valves
SEBF8031 Transmission Clutch Plates And Disc Assemblies With F37 and F37X Clutch
Friction Material
SEBF8017 Clutch Ring Gears For All Power Shift Transmissions
SEBF8118 Salvage of Center Bearing in Torque Converter Input Housing
SEBF8008 Turbine Wheel For Torque Converters Used With Power Shift Transmissions
SEBF8013 Transmission Clutch Plates and Disc Assemblies with Sintered Bronze Friction
Material
SEBF8036 Transmission Parts Damaged By Cast Iron And Vespel Seal Rings
SEBF8060 Repair of Transmission, Torque Converter and Torque Divider Shafts
SEBF8316 Torque Converter, Divider, Drive Line, and Drive Axle Reuse and Salvage Index
SEBF8257 Procedure to Salvage Tang Slots and Reaction Dowel Holes in Transmission
Clutch Plates, Pistons, and Housings
SEBF8178 Procedure to Salvage Tang Slots on Transmission and Brake Pistons
SEBF8147 Replacing Tubes In Housings That Are Installed With Mechanical Joints
(Expanded and Welded)
SEBF8115 Transmission Clutch Plates and Disc Assemblies With Cellulose (Paper) Friction
Material
SEBF8114 Identification of Non-Metallic Discs used in Power Shift Transmissions
SEBF8091 Transmission Components
SEBF8044 Repair of Torque Converter Stator Wheels
SEBF8014 Identification and Applications of Transmission Clutch Plates and Specifications to
machine Reaction Faces for Power Shift Transmissions
SEBF8130 Salvage Of Folded Core Radiators
SEBF8761 Transmission, Torque Converter, and Relief Valve Bench Test Procedures
Reference Manual Contents Page
SEBF8093 Planetary Final Drives for Wheel Loaders, Wheel Tractors, and Compactors
SEBF8163 Procedures To Salvage Planet Carrier Thrust Faces
SEBF8099 Repair of Reaction Dowel Holes in Transmission Clutch Housings
SEBF8119 Differential Housing Components for Wheel Loaders, Off-Highway Trucks and
Tractors, Articulated Dump Trucks, Wheel Tractors, Compactors, and Integrated
Toolcarriers
SEBF8321 Final Drive Steering System, Wheel Braking System, and Wheels & Tires Salvage
and Reuse Manual Contents
SEBF8841 Planetary Final Drives for Small and Medium Wheel Loaders and Small Integrated
Tool Carriers
Power Train - Non-Machine Specific
Form # Description
RENR3640 Assembly and Installation of Conventional Duo-Cone Seals (Wall Chart)
SERF8473 Arc Spray Guide (CD ROM)
SERF8705 HVOF Spray Guide (CD ROM)
SERF8704 Flame Spray Guide (CD ROM)
SEBF8029 Index of Publications on Reusability or Salvage of Used Parts
SEBF8782 Application of Abrasion-Resistant Material
SEBF8728 Inspection and Reuse of Drive Line Fasteners
SEBF8148 General Salvage and Reconditioning Techniques
SEBF8187 Standardized Parts Marking Procedures

Contacts:
Simon Bishop, Engine Guidelines, (309) 494-5974
Jim McClintock, Hydraulic Systems, (309) 675-8970
Jon Feucht, Power Train, (309) 675-6304
Jon Wier, Undercarriage, (309) 494-5308
966H, Serial Number Prefix A6D, A6G
Recommended Dealer Stocking List, as of September 1, 200
Does not include slow moving parts, basic hardware or fittings,
Does not include Caterpillar Remanufactured part #s
Based upon "ROL Parts Consumption List" from previous mode

Recomm.
Fast or Quantity
Medium through Part
Moving 6000 hrs. Part # Name

F 2 146-0240 SWITCH AS
F 2 188-8844 VALVE-BREAKER
F 2 190-8977 PUMP GP-F
F 2 194-6722 SENSOR GP
F 1 197-8418 GASKET
F 2 197-8419 GASKET
F 18 1R-0716 FILTER AS
F 18 1R-0762 FILTER AS
F 1 1R-0770 FILTER AS
F 18 1R-1809 ELEMENT AS
F 1 1T-1621 RING-SEAL
F 1 200-2371 SEAL KIT
F 2 209-7309 PLUG
F 3 211-0587 BEARING
F 8 214-0586 SPRING -V
F 1 218-0652 SWITCH AS
F 1 218-0653 SWITCH AS
F 3 219-7489 BELT TENSIONER
F 6 224-3028 VALVE-INLET
F 8 224-4441 SPRING-VA
F 6 224-5389 GASKET
F 9 225-4118 FILTER AS
F 1 229-5711 SEAL-VALVE COVER
F 3 230-3518 GASKET-MANIFOLD
F 6 237-7253 BRIDGE AS
F 2 239-3478 SENSOR GP
F 6 245-3819 ELEMENT AS
F 6 251-1005 LIFTER AS
F 3 257-2015 GASKET
F 2 263-9574 BATTERY
F 4 265-1113 RING-PIST
F 1 281-2725 VALVE GP
F 2 2K-0715 WASHER-TH
F 1 2S-4750 GASKET
F 1 3N-8506 RING-SEAL
F 2 3T-9960 DISC-FRIC
F 2 4E-3196 PIN AS
F 2 4N-1059 GASKET
F 2 4V-1901 BEARING
F 3 4V-7099 PIN AS
F 2 4V-7101 PIN AS
F 2 4V-8519 BEARING
F 2 4V-8520 BEARING
F 2 4V-8673 BEARING
F 2 4V-8674 BEARING
F 2 4V-8675 BEARING
F 1 5K-1568 CAP-FILLER
F 1 6V-6923 RING-BACK
F 2 6Y-5352 DISC-FRIC
F 1 7C-1583 GASKET
F 1 7C-3954 SPRING AS
F 1 7H-1447 CAP-FILLER
F 1 7T-3267 BUSHING
F 2 7T-3456 DISC-FRIC
F 2 7V-6715 PIN AS
F 12 7X-6041 FILTER
F 1 8C-3655 BRUSH KIT
F 4 8E-9849 DISC AS-F
F 3 8M-8489 DOWEL
F 2 9G-1234 SPRING-DISC
F 2 9G-5127 BREATHER
F 1 9T-8676 BEARING
F 12 9W-1442 FUSE
F 4 9X-3463 BULB
F 1 9Y-1758 GASKET-BR
M 1 116-4491 BRACKET AS
M 6 129-4296 BEARING
M 1 133-9012 FUSE
M 1 145-0326 FILM-INST
M 2 185-7523 WINDOW
M 1 187-8972 GEAR-CRAN
M 1 189-4717 BEARING
M 2 200-0727 BEZEL-INS
M 2 203-1558 SEAL KIT
M 2 203-6470 GASKET KIT
M 2 203-6473 GASKET
M 3 209-0381 CONT GP
M 6 217-3674 FASTENER
M 6 219-4458 PIN-DOWEL
M 1 223-7468 CAMSHAFT
M 2 223-9147 PUMP GP-W
M 2 225-3755 GASKET
M 1 229-2887 SUPPORT-F
M 2 257-4323 CARTRIDGE GP-TURBO
M 2 260-7760 GAGE AS-O
M 2 3J-5553 GASKET
M 2 6E-0381 RING-BACK
M 2 6T-3633 RING-LOCK
M 1 7C-3082 RETAINER
F 1.56716 146-0241 SWITCH AS
 MAINTENANCE PARTS
PART
DESCRIPTION NUMBER QTY WHERE USED PAGE

AIR INLET AND EXHAUST SYSTEM

FILTER ELEMENT AS-AIR (PRIMARY) 245-3818 1 AIR CLEANER GP 90
FILTER ELEMENT AS-AIR 245-3819 1 AIR CLEANER GP 90
(SECONDARY)
HOSE-ELBOW 217-1601 1 LINES GP-AFTERCOOLER AIR 91

BASIC ENGINE
BELT-SERPENTINE 260-1527 1 BELT TENSIONER GP 12
BREATHER AS (CRANKCASE) 9Y-4357 1 BASE GP-VALVE COVER 10
GASKET (CRANKCASE BREATHER) 9Y-1758 1 BASE GP-VALVE COVER 10
PLUG-DRAIN (ENGINE OIL PAN) 9X-6451 1 PAN GP-OIL 41
SEAL-VALVE COVER 229-5711 1 COVER GP-VALVE MECHANISM 16
(VALVE MECHANISM COVER)

COOLING SYSTEM
CAP-RADIATOR (7-PSI) 6L-8617 1 TANK GP-RADIATOR TOP 88
REGULATOR-WATER TEMPERATURE 248-5513 1 LINES GP-WATER 76
(92-DEG C) (COOLANT)
SEAL-LIP TYPE (WATER 3S-9643 1 LINES GP-WATER 76
TEMPERATURE REGULATOR)
SEAL (TEMPERATURE REGULATOR 227-5075 1 LINES GP-WATER 76
HOUSING)

ELECTRICAL AND STARTING SYSTEM

BELT-DRIVE (WARNING BEACON) 9X-8139 1 LAMP GP-WARNING BEACON 166
CIRCUIT BREAKER AS (105-AMPERE) 171-2212 1 WIRING GP-CHASSIS 258
(ALTERNATOR)
CIRCUIT BREAKER AS (15-AMPERE) 3T-2662 1 WIRING GP-WASTE HANDLER 307
(POWER GUARD ACTUATOR)
CIRCUIT BREAKER AS (15-AMPERE) 3T-2662 1 WIRING GP-CHASSIS 260
(RUNNING LIGHTS)
CIRCUIT BREAKER AS (30-AMPERE) 6N-9349 1 WIRING GP-CHASSIS 260
(UNSWITCHED BAT POWER TO CAB)
CIRCUIT BREAKER AS (50-AMPERE) 171-2206 1 WIRING GP-CHASSIS 258
(ENGINE START)
CIRCUIT BREAKER AS (80-AMPERE) 171-2210 1 WIRING GP-CHASSIS 258
(MAIN)
CIRCUIT BREAKER GP (20-AMPERE) 6T-3644 1 WIRING GP-CHASSIS 260
(HOOD TILT ACTUATOR)
ELEMENT AS-JACKET WATER HEATER 246-2686 1 HEATER GP-JACKET WATER 150
(120-VOLT, 1500-WATT)
FLASHER AS (24-VOLT) 217-8166 1 SWITCH GP-SIGNAL 233
1 SWITCH GP-SIGNAL 235
1 SWITCH GP-SIGNAL 237
FUSE (10-AMPERE) 9W-1442 24 WIRING GP-CAB 250
24 WIRING GP-OPEN ROPS 287
FUSE (15-AMPERE) 9W-1441 7 WIRING GP-CAB 250
6 WIRING GP-OPEN ROPS 287
FUSE (20-AMPERE) 9W-1446 1 WIRING GP-CAB 250
2 WIRING GP-OPEN ROPS 287
KEY AS-ELECTRONIC (SECURITY) 206-5162 2 INSTALLATION GP-SECURITY 152
LAMP-HALOGEN (24-VOLT, 65-WATT) 9X-3463 1 LAMP GP-FLOOD 157
(FLOODLIGHT)
1 LAMP GP-FLOOD 158

A58 MAINTENANCE PARTS SEBP3743-01

 MAINTENANCE PARTS
PART
DESCRIPTION NUMBER QTY WHERE USED PAGE

LAMP (12-VOLT, 24-VOLT, 35-WATT) 209-6638 1 LAMP GP-FLOOD 155

1 LAMP GP-FLOOD 156
LAMP (24-VOLT) 3E-8825 1 WIRING GP-CAB 248
7N-5876 4 WIRING GP-CAB 250
4 WIRING GP-OPEN ROPS 287
7N-9943 1 LAMP GP-DOME 154
LAMP (24-VOLT) (RUNNING LAMP) 100-3245 1 LAMP GP-HEAD & SIGNAL 161
LAMP (24-VOLT) (RUNNING LIGHTS) 100-3245 1 LAMP GP-HEAD & SIGNAL 159
LAMP (24-VOLT) (TURN SIGNAL) 100-3245 1 LAMP GP-HEAD & SIGNAL 159
1 LAMP GP-HEAD & SIGNAL 161
LAMP (24-VOLT, 21-WATT) 9X-4493 1 LAMP GP-STOP & TAIL 165
LAMP (24-VOLT, 21-WATT) (SIGNAL) 9X-4493 1 LAMP GP-SIGNAL 163
LAMP (24-VOLT, 21-WATT) 9X-4493 1 LAMP GP-HEAD & SIGNAL 159
(TURN SIGNAL)
1 LAMP GP-HEAD & SIGNAL 161
LAMP (24-VOLT, 5-WATT) 9X-4492 1 LAMP GP-STOP & TAIL 165
LAMP (24-VOLT, 70-WATT) 9X-7849 1 LAMP GP-WARNING BEACON 166
LAMP (24-VOLT, 75/70-WATT) 9X-3465 1 LAMP GP-HEAD & SIGNAL 159
(HIGH/LOW BEAM)
LAMP (24-VOLT, 75/70-WATT) 9X-3465 1 LAMP GP-HEAD & SIGNAL 161
(HIGH/LOW BEAM)(RH)
LENS-AMBER (SIGNAL) 9X-3066 1 LAMP GP-SIGNAL 163
LENS (AMBER) (TURN SIGNAL) 100-3250 1 LAMP GP-HEAD & SIGNAL 159
1 LAMP GP-HEAD & SIGNAL 161
LENS AS (AMBER) (TURN SIGNAL) 136-3848 1 LAMP GP-HEAD & SIGNAL 159
1 LAMP GP-HEAD & SIGNAL 161
LENS AS (HEADLIGHT) 100-3248 1 LAMP GP-HEAD & SIGNAL 159
(HIGH/LOW BEAM)
1 LAMP GP-HEAD & SIGNAL 161

FRAME AND BODY

FILTER AS-GREASE 196-1062 1 PUMP GP-LUBRICATION 506
SCREEN AS (RADIATOR) 244-3407 1 GRILL GP-RADIATOR 449

FUEL SYSTEM
CAP AS-FILLER 101-8909 1 TANK GP-FUEL 119
CAP AS-FILLER (FUEL) 123-6319 1 TANK GP-FUEL 119
FILTER AS-FUEL 1R-0762 1 FILTER GP-FUEL 108
FILTER AS-WATER SEP & FUEL 1R-0770 1 FILTER GP-WATER SEP & FUEL 109
(PRIMARY)
SEAL (FUEL, WATER SEPARATOR) 220-8678 1 FILTER GP-WATER SEP & FUEL 109
STRAINER-FUEL 9P-7121 1 TANK GP-FUEL 119
VALVE-BREAKER RELIEF 188-8844 1 TANK GP-FUEL 119

SEBP3743-01 MAINTENANCE PARTS A59

 MAINTENANCE PARTS
PART
DESCRIPTION NUMBER QTY WHERE USED PAGE

HYDRAULIC SYSTEM
CAP-FILLER 7H-1447 1 TANK GP-HYDRAULIC 693
FILTER AS-OIL 144-0832 1 FILTER GP-OIL 643
(HYDRAULIC CASE DRAIN)
FILTER ELEMENT AS-OIL (HYDRAULIC) 225-4118 1 FILTER GP-OIL 642
PLUG-DRAIN 9J-7031 1 VALVE GP-DRAIN 722
SCREEN 6E-5066 1 MANIFOLD GP-VALVE 676
1 MANIFOLD GP-VALVE 678
SCREEN AS (HYDRAULIC TANK) 9T-9227 2 TANK GP-HYDRAULIC 693
SCREEN (CONTROL VALVE MANIFOLD) 6E-5066 1 MANIFOLD GP-CONTROL 674
STRAINER AS (HYDRAULIC TANK FILL) 5D-7927 1 TANK GP-HYDRAULIC 693

LUBRICATION SYSTEM
BREATHER AS (CRANKCASE) 9Y-4357 1 BREATHER GP 61
CAP AS-FILLER (ENGINE OIL) 5L-2952 1 FILLER GP-ENGINE OIL 62
FILTER ELEMENT AS-ENGINE OIL 1R-1808 1 FILTER GP-ENGINE OIL 63
GASKET (CRANKCASE BREATHER) 9Y-1758 1 BREATHER GP 61
HOSE (FUMES DISPOSAL) 237-9759 1 FUMES DISPOSAL GP 64

OPERATOR STATION
BATTERY (LITHIUM) 101-1785 1 CONTROL GP-MONITOR 865
BELT-SERPENTINE 260-1528 1 COMPRESSOR GP-REFRIGERANT 861
(A/C COMPRESSOR)
BLADE AS-WIPER 6V-7419 2 WIPER GP-WINDOW 1036
FILTER-CAB AIR 7X-6041 2 DUCT & FILTER GP-AIR 872
FUSE (15-AMPERE) 133-9012 1 AIR CONDITIONER GP 848
1 HEATER GP-CAB 895
KEY-HANDLE 3V-7476 1 DUCT & FILTER GP-AIR 872
LAMP (24-VOLT) 7N-5876 1 MONITOR GP-PAYLOAD 941
ORIFICE AS-AIR CONDITIONER 189-1707 1 LINES GP-AIR CONDITIONER 915
PADLOCK GP 5P-8502 2 GUARD GP-VANDALISM 884
SEAT BELT GP 236-7019 1 SEAT GP-SUSPENSION 1006
1 SEAT GP-SUSPENSION 1007

POWER TRAIN
BREATHER AS 9G-5127 1 CASE & PARTS GP-PLANETARY 318
CAP-FILLER 5K-1568 1 FILLER GP-POWER TRAIN OIL 334
FILTER ELEMENT AS-OIL 1R-1809 1 FILTER GP-OIL 338
PADLOCK GP 5P-8502 1 COVER GP-TMSN OIL FILLER CAP 327
PLUG 138-1510 1 GEAR GP-OUTPUT TRANSFER 345
175-4966 1 DRAIN GP-ECOLOGY 333
PLUG-DRAIN 8M-9307 1 COOLER GP-TRANSMISSION OIL 325
(TRANSMISSION OIL COOLER)
PLUG-MAGNETIC 5P-4484 1 HOUSING GP-FIXED AXLE 352
1 HOUSING GP-FIXED AXLE 354
1 HOUSING GP-FIXED AXLE 356
1 HOUSING GP-OSCILLATING AXLE 358
1 HOUSING GP-OSCILLATING AXLE 360
SCREEN GP-MAGNETIC 4S-8603 1 GEAR GP-OUTPUT TRANSFER 345
SCREEN-SUCTION 4S-8598 1 GEAR GP-OUTPUT TRANSFER 345

SERVICE EQUIPMENT AND SUPPLIES

PADLOCK GP 246-2641 1 PROTECTION GP-VANDALISM 1059

A60 MAINTENANCE PARTS SEBP3743-01

 MAINTENANCE PARTS
PART
DESCRIPTION NUMBER QTY WHERE USED PAGE

STEERING SYSTEM
SCREEN 6E-5066 2 SCREEN GP-CASE DRAIN 578

SEBP3743-01 MAINTENANCE PARTS A61

 Page 1 Planned Maintenance Parts 9/21/2005

Model 966H Serial Prefix A6D Serial Range 00001-99999 Family WHEEL LOADERS/ITC
OMM Media Number SEBU7887 Parts Book Media Number SEBP3743

Note: This list contains only maintenance parts specified to be replaced at one or more planned maintenance intervals
as per the Operation and Maintenance Manual. Parts usage may vary by product configuration. For complete
information, reference the BUILDER data for this serial number, available on SIS Web.

Interval PartNumber Quantit Parts Description Notes

PM 1 5P-0960 1 CARTRIDGE-GREASE Quick coupler lubrication

PM 1 5P-0960 1 CARTRIDGE-GREASE Tilt hood actuator lubrication

PM 1 9Y-1758 1 GASKET Engine crankcase breather gasket.

PM 1 SOS 1 SCHEDULED OIL SAMPLE Engine oil sample

PM 1 SOS COOL-1 1 LEVEL 1 COOLANT CHECK Coolant sample

PM 1F 5P-5678 3 SEAL Engine valve cover gasket/seal , order by

the meter

PM 2 144-0832 1 FILTER AS-OIL Hydraulic oil filter

PM 2 1R-0770 1 FILTER AS-SEP Fuel / water separator element - install dry,

prime system

PM 2 1R-1808 1 FILTER - ENGINE OIL Engine oil filter

PM 2 220-8678 1 SEAL Bowl seal

PM 2 245-3818 1 PRIMARY AIR FILTER Primary engine air filter

PM 2 9X-8600 1 SEAL Use this seal on 101-8909 fuel cap

PM 2 SOS 1 SCHEDULED OIL SAMPLE Differential & final drive oil sample - Front

PM 2 SOS 1 SCHEDULED OIL SAMPLE Differential & final drive oil sample - Rear

PM 2 SOS 1 SCHEDULED OIL SAMPLE Hydraulic oil sample

PM 2 SOS 1 SCHEDULED OIL SAMPLE Transmission oil sample

PM 2F SOS COOL-2 1 LEVEL 2 COOLANT CHECK

 Page 2 Planned Maintenance Parts 9/21/2005

Model 966H Serial Prefix A6D Serial Range 00001-99999 Family WHEEL LOADERS/ITC
OMM Media Number SEBU7887 Parts Book Media Number SEBP3743

Note: This list contains only maintenance parts specified to be replaced at one or more planned maintenance intervals
as per the Operation and Maintenance Manual. Parts usage may vary by product configuration. For complete
information, reference the BUILDER data for this serial number, available on SIS Web.

Interval PartNumber Quantit Parts Description Notes

PM 3 130-0229 1 SEAL-O-RING Transmission oil filter housing seal

PM 3 1R-0762 1 FILTER Secondary fuel filter - install dry, prime

system

PM 3 1R-1809 1 TRANSMISSION FILTER Transmission oil filter

PM 3 245-3819 1 SECONDARY AIR FILTER Secondary engine air filter

PM 3 5P-0960 1 CARTRIDGE-GREASE Articulation bearing lubrication

PM 3 5P-0960 1 CARTRIDGE-GREASE Roading fender hinge lubrication

PM 3 7X-6041 2 FILTER-CAB AIR Cab air filter - fresh air

PM 3 8H-7521 1 SEAL-O-RING Magnetic screen filter cover seal

PM 4 1U-9891 1 ADDITIVE (HYD) Hydraulic oil additive

PM 4 257-3227 1 RECEIVER DRYER Cab air conditioning in-line dryer

PM 4 5P-5678 3 SEAL Engine valve cover gasket/seal , order by

the meter

PM 4 SOS COOL-2 1 LEVEL 2 COOLANT CHECK Coolant sample

PM12000 222-0345 1 SEAT BELT GP Seat belt

PM12000 227-5075 1 SEAL Water temperature regulator gasket

PM12000 248-5513 1 REGULATOR Water temperature regulators

PM12000 3S-9643 1 SEAL-LIP Water temperature regulator seals

PM3000 222-0345 1 SEAT BELT GP Seat belt

 Page 3 Planned Maintenance Parts 9/21/2005

Model 966H Serial Prefix A6D Serial Range 00001-99999 Family WHEEL LOADERS/ITC
OMM Media Number SEBU7887 Parts Book Media Number SEBP3743

Note: This list contains only maintenance parts specified to be replaced at one or more planned maintenance intervals
as per the Operation and Maintenance Manual. Parts usage may vary by product configuration. For complete
information, reference the BUILDER data for this serial number, available on SIS Web.

Interval PartNumber Quantit Parts Description Notes

PM4000 9H-6454 1 GASKET Hydraulic oil tank filler cap seal.

PM6000 119-5152 1.5 EXTENDER-ELC

PM6000 222-0345 1 SEAT BELT GP Seat belt

PM6000 227-5075 1 SEAL Water temperature regulator gasket

PM6000 248-5513 1 REGULATOR Water temperature regulators

PM6000 3S-9643 1 SEAL-LIP Water temperature regulator seals

Page 1 Planned Maintenance Fluids- Metric 9/21/2005

Model 966H Serial Prefix A6D Serial Range 00001-99999 Family WHEEL LOADERS/ITC

OMM Media Number SEBU7887 Parts Book Media Number SEBP3743

Note: This list contains only maintenance fluids specified to be replaced at one or more planned maintenance intervals
as per the Operation and Maintenance Manual. Parts usage may vary by product configuration. For complete
information, reference the BUILDER data for this serial number, available on SIS Web.

Interval Fluid Type Order Quantity Fluid Description Notes

Amount
PM 2 DEO (L) 35 35 DIESEL ENGINE OIL Engine oil
(LITERS

PM 2 DEO (L) 35 35 DIESEL ENGINE OIL Engine oil

(LITERS

PM 2 DEO (L) 35 35 DIESEL ENGINE OIL Engine oil

(LITERS

PM 3 TDTO (L) 50 50 TRAN/DRV TRN OIL Transmission oil

(LITERS)

PM 3 TDTO (L) 50 50 TRAN/DRV TRN OIL Transmission oil

(LITERS)

PM 4 TDTO (L) 63 63 TRAN/DRV TRN OIL Front axle oil

(LITERS)

PM 4 TDTO (L) 63 63 TRAN/DRV TRN OIL Rear axle oil

(LITERS)

PM12000 COOLANT (L) 43 42.3 EXT LIFE COOLANT

(LITERS)

PM4000 HYDO (L) 110 110 HYDRAULIC OIL (LITERS) Hydraulic oil
Page 1 Planned Maintenance Fluids- U.S. Customary 9/21/2005

Model 966H Serial Prefix A6D Serial Range 00001-99999 Family WHEEL LOADERS/ITC

OMM Media Number SEBU7887 Parts Book Media Number SEBP3743

Note: This list contains only maintenance fluids specified to be replaced at one or more planned maintenance intervals
as per the Operation and Maintenance Manual. Parts usage may vary by product configuration. For complete
information, reference the BUILDER data for this serial number, available on SIS Web.

Interval Fluid Type Order Quantity Fluid Description Notes

Amount
PM 2 DEO 10 9.3 DIESEL ENGINE OIL Engine oil

PM 2 DEO 10 9.3 DIESEL ENGINE OIL Engine oil

PM 2 DEO 10 9.3 DIESEL ENGINE OIL Engine oil

PM 3 TDTO 14 13.2 TRANS/DRIVE TRAIN OIL Transmission oil

PM 3 TDTO 14 13.2 TRANS/DRIVE TRAIN OIL Transmission oil

PM 4 TDTO 17 16.6 TRANS/DRIVE TRAIN OIL Differential & final drive oil - front - 16.9
gal - 0.3 gal additive

PM 4 TDTO 17 16.6 TRANS/DRIVE TRAIN OIL Differential & final drive oil - rear - 16.9
gal - 0.3 gal additive

PM12000 COOLANT 12 11.2 EXTENDED LIFE COOLANT

PM4000 HYDO 29 29 HYDRAULIC OIL Hydraulic oil

100 SEBU7887-01
Maintenance Section
Maintenance Interval Schedule

i02356171 Bucket Upper Pivot Bearings - Lubricate ............ 109

Logging Fork Clamp - Lubricate ......................... 144
Maintenance Interval Schedule Steering Cylinder Bearings - Lubricate ............... 148
SMCS Code: 7000 Initial 250 Service Hours
Note: All safety information, warnings, and Electronic Unit Injector - Inspect/Adjust ............... 119
instructions must be read and understood before Engine Oil Sample - Obtain ................................ 127
you perform any operation or any maintenance Engine Valve Lash - Check ................................. 131
procedure. Engine Valve Rotators - Inspect ......................... 131
Transmission Oil Filter - Replace ........................ 151
Before each consecutive interval is performed, all
of the maintenance requirements from the previous Every 250 Service Hours or Monthly
interval must also be performed.
Battery - Clean .................................................... 103
When Required Belt - Inspect/Adjust/Replace .............................. 105
Brake Accumulator - Check ................................ 105
Automatic Lubrication Grease Tank - Fill ............ 102 Braking System - Test ......................................... 106
Battery - Recycle ................................................ 104 Cooling System Coolant Sample (Level 1) -
Battery or Battery Cable - Inspect/Replace ........ 104 Obtain ................................................................ 114
Bucket Wear Plates - Inspect/Replace ................ 110 Differential and Final Drive Oil Level - Check ...... 118
Circuit Breakers - Reset ....................................... 111 Drive Shaft Spline (Center) - Lubricate ................ 119
Engine Air Filter Primary Element - Engine Crankcase Breather - Clean ................... 123
Clean/Replace .................................................. 120 Engine Oil Sample - Obtain ................................ 127
Engine Air Filter Secondary Element - Replace .. 122 Hood Tilt Actuator - Lubricate ............................. 138
Ether Starting Aid Cylinder - Replace ................. 132 Quick Coupler - Lubricate ................................... 145
Fuel System - Prime ........................................... 132
Fuses - Replace .................................................. 136 Initial 500 Hours (for New Systems, Refilled
High Intensity Discharge Lamp (HID) - Replace .. 137 Systems, and Converted Systems)
Oil Filter - Inspect ................................................ 144
Quick Coupler - Check ........................................ 145 Cooling System Coolant Sample (Level 2) -
Radiator Core - Clean ......................................... 145 Obtain ................................................................ 115
Ride Control Accumulator - Check ..................... 146
Window Washer Reservoir - Fill .......................... 153 Every 500 Service Hours or 3 Months
Window Wiper - Inspect/Replace ........................ 153
Differential and Final Drive Oil Sample - Obtain .. 118
Every 10 Service Hours or Daily Engine Oil (High Speed) and Oil Filter - Change .. 123
Engine Oil and Filter - Change ........................... 128
Backup Alarm - Test ............................................ 103 Fuel System Primary Filter (Water Separator)
Bucket Cutting Edges - Inspect/Replace ............ 107 Element - Replace ............................................ 134
Bucket Tips - Inspect/Replace ............................ 108 Fuel Tank Cap and Strainer - Clean ................... 135
Cooling System Coolant Level - Check ............... 114 Hydraulic System Biodegradable Oil Filter Element -
Engine Oil Level - Check .................................... 127 Replace ............................................................. 138
Fuel System Primary Filter (Water Separator) - Hydraulic System Oil Filter - Replace ................. 142
Drain ................................................................. 133 Hydraulic System Oil Sample - Obtain ............... 143
Fuel Tank Water and Sediment - Drain ............... 136 Transmission Oil Sample - Obtain ...................... 153
Hydraulic System Oil Level - Check ................... 143
Seat Belt - Inspect .............................................. 147 Every 1000 Service Hours or 6 Months
Transmission Oil Level - Check .......................... 152
Windows - Clean ................................................. 154 Articulation Bearings - Lubricate ......................... 102
Battery Hold-Down - Tighten ............................... 104
Every 50 Service Hours or Weekly Case Drain Screen (Strainer) (Steering Pump,
Hydraulic Fan Pump, Motor) - Clean ................. 111
Bucket Lower Pivot Bearings - Lubricate ............ 108 Fuel System Secondary Filter - Replace ............ 135
Cab Air Filter - Clean/Replace ............................. 110 Rollover Protective Structure (ROPS) - Inspect .. 147
Tire Inflation - Check ........................................... 150 Steering Pilot Oil Screen (Command Control
Steering) - Clean/Replace ................................. 149
Every 100 Service Hours or 2 Weeks Transmission Oil - Change ................................. 150
Transmission Oil Filter - Replace ........................ 151
Axle Oscillation Bearings - Lubricate .................. 103
Bucket Linkage and Loader Cylinder Bearings -
Lubricate ........................................................... 107
SEBU7887-01 101
Maintenance Section
Maintenance Interval Schedule

Every 2000 Service Hours

Brake Discs - Check ........................................... 106

Every 2000 Service Hours or 1 Year

Brake Discs - Check ........................................... 106
Differential and Final Drive Oil - Change ............. 117
Electronic Unit Injector - Inspect/Adjust ............... 119
Engine Valve Lash - Check ................................. 131
Engine Valve Rotators - Inspect ......................... 131
Hydraulic System Oil - Change ........................... 139
Hydraulic Tank Breaker Relief Valve - Clean ...... 144
Service Brake Wear Indicator - Check ................ 148
Steering Shaft (Command Control Steering) -
Lubricate ........................................................... 149

Every Year
Cooling System Coolant Sample (Level 2) -
Obtain ................................................................ 115
Refrigerant Dryer - Replace ................................ 146

Every 3 Years After Date of Installation or

Every 5 Years After Date of Manufacture
Seat Belt - Replace ............................................. 147

Every 6000 Service Hours or 3 Years

Cooling System Coolant Extender (ELC) - Add ... 113
Cooling System Water Temperature Regulator -
Replace .............................................................. 116

Every 12 000 Service Hours or 6 Years

Cooling System Coolant (ELC) - Change ............ 112
114 SEBU7887-01
Maintenance Section
Cooling System Coolant Level - Check

5. Install the cooling system pressure cap. Close the

engine hood.

i01921821

Cooling System Coolant Level

- Check
SMCS Code: 1350-535-FLV

Pressurized system: Hot coolant can cause seri-

ous burn. To open cap, stop engine, wait until ra-
diator is cool. Then loosen cap slowly to relieve
the pressure.

g00807153
Illustration 164

Cooling system pressure cap (1) is located under the

hood at the rear of the machine. Tilt the hood in order
to access the cooling system pressure cap.

1. Slowly loosen the cooling system pressure cap in

order to relieve any system pressure. Remove the
cooling system pressure cap.

2. If necessary, drain enough coolant from the

radiator in order to allow the addition of the Illustration 166
g01000175
Extender to the cooling system. The cooling
system drain valve (2) is located on the lower left Open the access door on the left side of the machine.
side of the radiator. Coolant level sight gauge (1) is located on the top
radiator.
3. Add 1.18 L (40 fl oz) of Extender to the cooling
system. Maintain the coolant level within the sight gauge. Add
coolant, if necessary.

Note: If it is necessary to add coolant daily, inspect

the cooling system for leaks.

i02375131

Cooling System Coolant

Sample (Level 1) - Obtain
SMCS Code: 1350-008; 1395-008; 7542

Note: It is not necessary to obtain a Coolant

g01000160 Sample (Level 1) if the cooling system is filled
Illustration 165
with Cat ELC (Extended Life Coolant). Cooling
systems that are filled with Cat ELC should have
4. Check the coolant level at sight gauge (3). a Coolant Sample (Level 2) that is obtained at
the recommended interval that is stated in the
Reference: Refer to Operation and Maintenance Maintenance Interval Schedule.
Manual, “Cooling System Coolant Level - Check”
for the correct procedure.
SEBU7887-01 115
Maintenance Section
Cooling System Coolant Sample (Level 2) - Obtain

Note: Obtain a Coolant Sample (Level 1) if the • Keep the unused sampling bottles stored in plastic
cooling system is filled with any other coolant bags.
instead of Cat ELC. This includes the following
types of coolants. • Obtain coolant samples directly from the coolant
sample port. You should not obtain the samples
• Commercial long life coolants that meet the from any other location.
Caterpillar Engine Coolant Specification -1
(Caterpillar “EC−1”) • Keep the lids on empty sampling bottles until you
are ready to collect the sample.
• Cat Diesel Engine Antifreeze/Coolant (DEAC)
• Place the sample in the mailing tube immediately
• Commercial heavy-duty coolant/antifreeze after obtaining the sample in order to avoid
contamination.
NOTICE
Always use a designated pump for oil sampling, and • Never collect samples from expansion bottles.
use a separate designated pump for coolant sampling.
Using the same pump for both types of samples may • Never collect samples from the drain for a system.
contaminate the samples that are being drawn. This
contaminate may cause a false analysis and an incor- Submit the sample for Level 1 analysis.
rect interpretation that could lead to concerns by both
dealers and customers. For additional information about coolant analysis, see
Special Publication, SEBU6250, “Caterpillar Machine
Fluids Recommendations” or consult your Caterpillar
Note: Level 1 results may indicate a need for dealer.
Level 2 Analysis.
i02375133

Cooling System Coolant

Sample (Level 2) - Obtain
SMCS Code: 1350-008; 1395-008; 7542

NOTICE
Always use a designated pump for oil sampling, and
use a separate designated pump for coolant sampling.
Using the same pump for both types of samples may
contaminate the samples that are being drawn. This
contaminate may cause a false analysis and an incor-
g01185306 rect interpretation that could lead to concerns by both
Illustration 167
dealers and customers.
Left side of machine

The sampling valve (1) for the cooling system is

located on top of the engine toward the front of the
engine on the left side of the machine.

Obtain the sample of the coolant as close as possible

to the recommended sampling interval. In order
to receive the full effect of S·O·S analysis, you
must establish a consistent trend of data. In order
to establish a pertinent history of data, perform
consistent samplings that are evenly spaced.
Supplies for collecting samples can be obtained from
your Caterpillar dealer.

Use the following guidelines for proper sampling of g01185306

Illustration 168
the coolant:
Left side of the machine

• Complete the information on the label for the

sampling bottle before you begin to take the
samples.
116 SEBU7887-01
Maintenance Section
Cooling System Water Temperature Regulator - Replace

The sampling valve (1) for the cooling system is

located on top of the engine toward the front of the
engine on the left side of the machine.

Obtain the sample of the coolant as close as possible

to the recommended sampling interval. Supplies
for collecting samples can be obtained from your
Caterpillar dealer.

Refer to Operation and Maintenance Manual,

“Cooling System Coolant Sample (Level 1) - Obtain”
for the guidelines for proper sampling of the coolant.

Submit the sample for Level 2 analysis.

Reference: For additional information about coolant

analysis, refer to Special Publication, SEBU6250,
“Caterpillar Machine Fluids Recommendations” or
consult your Caterpillar dealer.

i02186511 g01105775
Illustration 169
Cooling System Water
Replace the water temperature regulator in order
Temperature Regulator - to reduce the chance of problems with the cooling
Replace system.

SMCS Code: 1355-510; 1393-010 Replace the water temperature regulator and the
seals while the cooling system is completely drained
or while the coolant is drained to a level that is below
the water temperature regulator housing.
Pressurized system: Hot coolant can cause seri- Note: If you are only replacing the water temperature
ous burn. To open cap, stop engine, wait until ra- regulator, drain the coolant to a level that is below the
diator is cool. Then loosen cap slowly to relieve water temperature regulator housing.
the pressure.
Reference: Refer to Disassembly and Assembly,
RENR9214, “C11 and C13 Engines for Caterpillar
NOTICE
Built Machines” for the correct procedure for replacing
Failure to replace the engine’s thermostat on a regu-
the water temperature regulator.
larly scheduled basis could cause severe engine dam-
age.

NOTICE
Caterpillar engines incorporate a shunt design cooling
system and require operating the engine with a ther-
mostat installed.

If the thermostat is installed wrong, it will cause the

engine to overheat. Inspect gaskets before assembly
and replace if worn or damaged.
118 SEBU7887-01
Maintenance Section
Differential and Final Drive Oil Level - Check

i01102280 2. Remove dipstick/fill plug (1) on the left side of the

axle. Wipe off the level gauge with a clean cloth
Differential and Final Drive Oil and reinsert the plug. This will ensure a more
Level - Check accurate measurement of the oil level.

SMCS Code: 3278-535-FLV; 4011-535-FLV Note: Make sure that the plug is installed completely
before you check the oil level. If the plug is not
Note: Before you measure the oil level, operate the installed completely, an incorrect oil level reading can
machine for a few minutes in order to equalize the occur.
oil level.
3. Remove dipstick/fill plug (1) again and check the
1. Park the machine on level ground. Lower the oil level. Maintain the oil level between the ADD
bucket and apply slight downward pressure. mark and the FULL mark. Add oil, if necessary.
Engage the parking brake. Stop the engine.
Reference: Refer to Operation and Maintenance
Manual, “Lubricant Viscosities and Refill
Capacities” for the type of lubricant and for the
refill capacity.

4. Clean the plug and install the plug.

i01921974

Differential and Final Drive Oil

Sample - Obtain
SMCS Code: 3278-008; 4011-008; 4070-008; 7542

NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
g00285312 nent containing fluids.
Illustration 172
Front Axle Refer to Special Publication, NENG2500, “Caterpillar
Tools and Shop Products Guide” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.

Dispose of all fluids according to local regulations and

mandates.

1. Operate the machine for a few minutes before

obtaining the oil sample. This will thoroughly mix
the differential oil for a more accurate sample.

g00287527
Illustration 173
Rear Axle
SEBU7887-01 119
Maintenance Section
Drive Shaft Spline (Center) - Lubricate

NOTICE
To prevent damage to the seal, articulate the machine
full right or left, before lubricating the splines.

1. Start the engine. Raise the bucket. Release the

parking brake. Articulate the machine to the right
or to the left in order to gain better access to the
splined shaft.

2. Lower the bucket to the ground. Engage the

parking brake. Stop the engine.

g00884056
Illustration 174
Rear axle

g01106848
Illustration 176

3. Apply grease to the fitting (1). Apply grease until

the relief (2) overruns.
g00884059
Illustration 175
Front axle Note: 5P-0960 Molybdenum Grease is preferred.
1P-0808 Multipurpose Grease may be used.
2. The differential and final drives are not equipped
with sampling valves. Obtaining an oil sample will 4. Start the engine. Raise the bucket. Release
require the use of a vacuum pump or equivalent the parking brake. Reposition the machine in a
in order to extract the oil from the component. straight direction without articulation.
Extract the oil through the filler openings on the
differential and final drives. 5. Lower the bucket to the ground. Apply a slight
down pressure. Engage the parking brake. Stop
3. Complete any additional required work. Fill the the engine.
differential and final drives with oil, as required.
Install the dipstick/fill plugs.
i02061807

Reference: For more information, refer to Special

Publication, SEBU6250, “Caterpillar Machine Fluids
Electronic Unit Injector -
Recommendations”, “S·O·S Oil Analysis” and Special Inspect/Adjust
Publication, PEHP6001, “How To Take A Good Oil
Sample”. SMCS Code: 1251-025; 1251-040; 1290-025;
1290-040
i02189535

Drive Shaft Spline (Center) -

The Electronic Control module produces high
Lubricate voltage. To prevent personal injury make sure the
Electronic Control Module is not powered and the
SMCS Code: 3253-086-SN unit injector solenoids are disconnected.
Wipe all of the fittings before you apply grease to
the fittings.
SEBU7887-01 127
Maintenance Section
Engine Oil Level - Check

i02188149 i02188187

Engine Oil Level - Check Engine Oil Sample - Obtain

SMCS Code: 1000-535-FLV SMCS Code: 1348-008; 7542

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

Refer to Special Publication, NENG2500, “Caterpillar

Tools and Shop Products Guide” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.

Dispose of all fluids according to local regulations and

mandates.

1. Operate the machine for a few minutes before

obtaining the oil sample. This will thoroughly mix
the engine oil for a more accurate sample.
g01106343
Illustration 188
2. Open the engine hood.
Open the service door that is located on the right
side of the machine. The oil level dipstick is located
in the service door.

g01106355
Illustration 190

3. Use the sampling valve in order to obtain a

Illustration 189
g00746755 sample of engine oil.

Maintain the oil level between the FULL mark and 4. Close the engine hood.
ADD mark on the dipstick. Check the level of the
engine oil while the engine is shut off. Add oil, if Reference: For more information, refer to Special
necessary. Publication, SEBU6250, “Caterpillar Machine Fluids
Recommendations”, “S·O·S Oil Analysis” and Special
Publication, PEHP6001, “How To Take A Good Oil
Sample”.
SEBU7887-01 143
Maintenance Section
Hydraulic System Oil Level - Check

6. The oil gauge and the hydraulic oil filler are on i02375351
the left side of the machine above the platform.
Maintain the oil level above the “ADD COLD” mark Hydraulic System Oil Sample
on the sight gauge. Add hydraulic oil, if necessary. - Obtain
i02375341
SMCS Code: 5050-008; 5056-008; 7542

Hydraulic System Oil Level - NOTICE

Check Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
SMCS Code: 5056-535-FLV ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.

Refer to Special Publication, NENG2500, “Caterpillar

Dealer Service Tool Catalog” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.

Dispose of all fluids according to local regulations and

mandates.

1. Operate the machine for a few minutes before

obtaining the oil sample. Operate the hydraulic
g01185406 controls. This will thoroughly mix the hydraulic oil
Illustration 216
for a more accurate sample.

g01185435
Illustration 217 g01185445
Illustration 218

The hydraulic tank is located on the left side of the

machine behind the cab. 2. If the machine is equipped with conventional oil,
open the access door to the service center on
The lift arms must be lowered with the bucket flat in the right side of the machine. The hydraulic oil
order to check the hydraulic oil. Check the hydraulic filter is above the shelf. The sampling valve for the
oil level while the engine is stopped. Maintain the oil hydraulic oil is located on the hydraulic oil filter
level above the “ADD COLD” mark on sight gauge base.
(2). If necessary, remove filler cap (1) slowly and add
oil. 3. If the machine is equipped with biodegradable
hydraulic oil, open the access door to the service
center on the right side of the machine. The
hydraulic oil filter is above the shelf. The sampling
valve for the hydraulic oil is located on the
hydraulic oil filter base.

4. Use the in-line sampling valve in order to obtain a

sample of hydraulic oil.
144 SEBU7887-01
Maintenance Section
Hydraulic Tank Breaker Relief Valve - Clean

5. Close the access door to the service center on the

right side of the machine.

Reference: For more information, refer to Special

Publication, SEBU6250, “Caterpillar Machine Fluids
Recommendations”, “S·O·S Oil Analysis” and Special
Publication, PEHP6001, “How To Take A Good Oil
Sample”.

i02375419

Hydraulic Tank Breaker Relief

Valve - Clean
g01107035
SMCS Code: 5118-070 Illustration 220

Apply lubricant through three fittings on each side

of the logging fork.

There is a total of six fittings.

i02106227

Oil Filter - Inspect

SMCS Code: 1308-507; 3004-507; 3067-507;
5068-507

Inspect a Used Filter for Debris

g01185542
Illustration 219

The hydraulic tank breaker relief valve is located on

the top of the hydraulic tank behind the cab of the
machine.

1. Press the button on the top of the hydraulic

breaker in order to relieve the pressure in the
hydraulic tank. Remove the hydraulic tank breaker
relief valve.

2. Clean the hydraulic tank breaker relief valve in a

clean, nonflammable solvent. Shake the breaker
relief valve dry or use pressure air to dry the
breaker relief valve.
g00100013
Illustration 221
3. Install the hydraulic tank breaker relief valve. The element is shown with debris.

Use a filter cutter to cut the filter element open.

i02189793
Spread apart the pleats and inspect the element for
Logging Fork Clamp - metal and for other debris. An excessive amount of
debris in the filter element can indicate a possible
Lubricate failure.

SMCS Code: 6113-086-BD; 6410-086-BD If metals are found in the filter element, a magnet can
be used to differentiate between ferrous metals and
Wipe off all fittings before any lubricant is applied. nonferrous metals.

Ferrous metals can indicate wear on steel parts and

on cast iron parts.
SEBU7887-01 153
Maintenance Section
Transmission Oil Sample - Obtain

i02195036 i02189520

Transmission Oil Sample - Window Washer Reservoir -

Obtain Fill
SMCS Code: 3080-008; 7542 SMCS Code: 7306-544

NOTICE NOTICE
Care must be taken to ensure that fluids are contained When operating in freezing temperatures, use
during performance of inspection, maintenance, test- Caterpillar nonfreezing window washer solvent or
ing, adjusting and repair of the product. Be prepared to equivalent. System damage can result from freezing.
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.

Refer to Special Publication, NENG2500, “Caterpillar

Tools and Shop Products Guide” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.

Dispose of all fluids according to local regulations and

mandates.

1. Operate the machine for a few minutes before

obtaining the oil sample. This will thoroughly mix
the transmission oil for a more accurate sample. g01106828
Illustration 242

Window Washer Reservoir – The window

washer reservoir is located under an access
door on the platform on the right side of the
machine. Fill the window washer reservoir through
the filler opening.

i01552025

Window Wiper -
Inspect/Replace
SMCS Code: 7305-040; 7305-510
g01108497
Illustration 241

2. The sampling valve for the transmission oil is

located on the transmission oil filter base on the
right side of the machine under the platform. Use
the in-line sampling valve in order to obtain a
sample of transmission oil.

Reference: For more information, refer to Special

Publication, SEBU6250, “Caterpillar Machine Fluids
Recommendations”, “S·O·S Oil Analysis” and Special
Publication, PEHP6001, “How To Take A Good Oil
Sample”.

g00807031
Illustration 243

Inspect the condition of the wiper blades. Replace

the wiper blades if the wiper blades are worn or
damaged or if the streaking occurs.
SEBU7887-01 97
Maintenance Section
Lubricant Viscosities and Refill Capacities

i02194317 Table 14

Capacities (Refill) Approximate Refill Capacities 972H

Compartment or US
SMCS Code: 7560 Liters Imp Gal
System Gal

Table 13 Cooling System 42.3 11.2 9.3

Approximate Refill Capacities 966H Fuel Tank 404 106 88.9
Compartment or US Engine Crankcase 35 9.25 7.7
Liters Imp Gal
System Gal
Transmission 50 13.2 11.0
Cooling System 42.3 11.2 9.3
Hydraulic Tank(1) 110 29 24.2
Fuel Tank 404 106 88.9
Two-Valve
200 52.8 44
Engine Crankcase 35 9.25 7.7 Hydraulic System(2)
Transmission 50 13.2 11.0 Three-Valve
202 53.4 44.4
Hydraulic System(2)
Hydraulic Tank(1) 110 29 24.2
Front Drive Axle(3) 64 16.9 14.1
Two-Valve
196 51.8 43.1 Rear Drive Axle(3) 64 16.9 14.1
Hydraulic System(2)
Three-Valve Groeneveld
198 52.3 43.6 Automatic TWIN
Hydraulic System(2) 4 1 .88
Greasing System
Front Drive Axle(3) 64 16.9 14.1 Reservoir
Rear Drive Axle(3) 64 16.9 14.1 (1) This capacity is only for the hydraulic tank.
(2) This capacity includes the hydraulic tank, the hydraulic lines,
Groeneveld and all hydraulic components.
Automatic TWIN (3) The amount that is shown includes 1 L (0.3 US gal) of 1U-9891
4 1 .88
Greasing System Hydraulic Oil Additive.
Reservoir
(1) This capacity is only for the hydraulic tank.
(2) i01822901
This capacity includes the hydraulic tank, the hydraulic lines,

(3)
and all hydraulic components.
The amount that is shown includes 1 L (0.3 US gal) of 1U-9891
S·O·S Information
Hydraulic Oil Additive.
SMCS Code: 1348; 1350; 3080; 4070; 4250; 4300;
5050; 7542

S·O·S Services is a highly recommended process

for Caterpillar customers to use in order to minimize
owning and operating cost. Customers provide
oil samples, coolant samples, and other machine
information. The dealer uses the data in order to
provide the customer with recommendations for
management of the equipment. In addition, S·O·S
Services can help determine the cause of an existing
product problem.

Refer to Special Publication, SEBU6250, “Caterpillar

Machine Fluid Recommendations” for detailed
information concerning S·O·S Services.

Refer to the Operation and Maintenance Manual,

“Maintenance Interval Schedule” for a specific
sampling location and a service hour maintenance
interval.

Consult your Caterpillar dealer for complete

information and assistance in establishing an S·O·S
program for your equipment.
94 SEBU7887-01
Maintenance Section
Lubricant Viscosities and Refill Capacities

Lubricant Viscosities and Lubricant Viscosities for Ambient

Refill Capacities Temperatures
NOTICE
i02228915 Do NOT use only the “Oil Viscosities” column when
determining the recommended oil for a machine com-
Lubricant Viscosities partment. The “Oil Type and Classification” column
MUST also be used.
SMCS Code: 7581

NOTICE
Selecting the Viscosity The footnotes are a key part of the “Lubricant
Ambient temperature is the temperature of the air in Viscosities for Ambient Temperatures” tables. Read
ALL footnotes that pertain to the machine compart-
the immediate vicinity of the machine. This may differ
ment in question.
due to the machine application and from the generic
ambient temperature for a geographic region. In order
to select the proper oil viscosity, review the regional Note: Use the oil type and the classification
ambient temperature and the potential ambient that is recommended for the various machine
temperature for a given machine application. Use the compartments.
higher temperature of the two ambient temperatures
in order to select the oil viscosity. Use the highest oil Note: Some machine compartments allow the use of
viscosity that is allowed for the ambient temperature more than one oil type. For the best results, do not
when you start the machine. For arctic applications, mix oil types.
the preferred method is the use of heaters for
machine compartments and a high viscosity oil. Note: Different brands of oils may use different
additive packages. For the best results, do not mix
The proper oil viscosity grade is determined by the oil brands.
minimum outside ambient temperature. This is the
temperature when the machine is started and while Note: Caterpillar oil is the preferred oil. All other listed
the machine is operated. In order to determine the oils are acceptable oils.
proper oil viscosity grade, refer to the “Min” column
in the table. This information reflects the coldest
ambient temperature condition for starting a cold
machine and for operating a cold machine. Refer to
the “Max” column in Table 12 in order to select the
oil viscosity grade for operating the machine at the
highest temperature that is anticipated.

Machines that are operated continuously should

use oils that have the higher oil viscosity in the final
drives and in the differentials. The oils that have the
higher oil viscosity will maintain the highest possible
oil film thickness. Consult your dealer if additional
information is needed.

Note: SAE 0W oil and SAE 5W oil are not

recommended for heavily loaded machines or
machines that are operated continuously. These
viscosity grades are not recommended for use in
hydraulic hammers. The oils that have the higher
oil viscosity will maintain the highest possible oil
film thickness. Consult your dealer if additional
information is needed.

Note: Some machine models and/or machine

compartments do not allow the use of all available
viscosity grades.
SEBU7887-01 95
Maintenance Section
Lubricant Viscosities and Refill Capacities

Table 12
Lubricant Viscosities for Ambient Temperatures(1)
°C °F
Compartment or System Oil Type and Classification Oil Viscosities
Min Max Min Max
SAE 0W20 −40 +10 −40 +50
SAE 0W30 −40 +30 −40 +86
SAE 0W40 −40 +40 −40 +104
Cat DEO Multigrade
Cat DEO SYN SAE 5W30 −30 +30 −22 +86
Engine Crankcase(2)(3) Cat Arctic DEO SYN(4)
Cat ECF-1(5) SAE 5W40 -30 +50 −22 +122
API CG-4 Multigrade(6)
SAE 10W30(7) -18 +40 0 +104
SAE 10W40 -18 +50 0 +122
SAE 15W40 -9.5 +50 +15 +122
SAE 0W20(8) −40 +10 −40 +50
SAE 0W30(8) −40 +20 −40 +68
SAE 5W30(8) −30 +20 −22 +68
Cat TDTO
Power Shift Transmission Cat TDTO-TMS SAE 10W −20 +10 −4 +50
commercial TO-4
SAE 30(9) 0 +35 +32 +95
SAE 50(9)(10) +10 +50 +50 +122
TDTO-TMS(9)(11) −10 +43 +14 +110
SAE 0W20 −40 +40 −40 +104
SAE 0W30 −40 +40 −40 +104
Cat HYDO SAE 5W30 −30 +40 −22 +104
Cat DEO
Cat MTO SAE 5W40 −30 +40 −22 +104
Cat TDTO SAE 10W −20 +40 −4 +104
Cat TDTO-TMS
Cat DEO SYN SAE 30 +10 +50 +50 +122
Hydraulic Systems
Cat ECF-1
Cat BIO HYDO (HEES) SAE 10W30 −20 +40 −4 +104
API CG-4 SAE 15W40 −15 +50 +5 +122
API CF
commercial TO-4 Cat MTO −25 +40 −13 +104
commercial BF-1(12)
Cat BIO HYDO
−40 +43 −40 +110
(HEES)(12)
TDTO-TMS(11) −20 +50 -4 +122
(continued)
96 SEBU7887-01
Maintenance Section
Lubricant Viscosities and Refill Capacities

(Table 12, contd)

Lubricant Viscosities for Ambient Temperatures(1)
°C °F
Compartment or System Oil Type and Classification Oil Viscosities
Min Max Min Max
SAE 0W20(8) −40 0 −40 +32
SAE 0W30(8) −40 +10 −40 +50
SAE 5W30(8) −35 +10 −31 +50
Cat TDTO
Drive Axles Cat TDTO-TMS SAE 10W −25 +15 −13 +59
commercial TO-4
SAE 30 −20 +43 −4 +110
SAE 50(10) +10 +50 +50 +122
TDTO-TMS(11) −30 +43 −22 +110
(1) When you are operating the machine in temperatures below −20°C (−4°F), refer to Special Publication, SEBU5898, “Cold Weather
Recommendations”. This is available from your Caterpillar dealer.
(2) Supplemental heat is recommended for cold-soaked starts below the minimum ambient temperature. Supplemental heat may be required
for cold-soaked starts that are above the minimum temperature that is stated, depending on the parasitic load and other factors.
Cold-soaked starts occur when the engine has not been operated for a period of time, allowing the oil to become more viscous due to
cooler ambient temperatures.
(3) API CF oils are not recommended for Caterpillar 3500 Series and smaller Direct Injection (DI) diesel engines. API CF-4 oils are not
recommended for Caterpillar machine diesel engines.
(4) Cat Arctic DEO SYN is an SAE 0W-30 viscosity grade oil.
(5) API CI-4, API CI-4 PLUS, and API CH-4 oils are acceptable if the requirements of Caterpillar’s ECF-1 (Engine Crankcase Fluid specification
- 1) are met. API CI-4, API CI-4 PLUS, and API CH-4 oils that have not met the requirements of Caterpillar’s ECF-1 specification may cause
reduced engine life.
(6) API CG-4 oils are acceptable for use in all Caterpillar machine diesel engines. When API CG-4 oils are used, the oil change interval
should not exceed 250 hours. API CG-4 oils that also meet API CI-4, API CI-4 PLUS, or API CH-4 must also meet the requirements
of the Caterpillar ECF-1 specification.
(7) SAE 10W-30 is the preferred viscosity grade for the 3116, 3126, C7, C-9 and the C9 diesel engines when the ambient temperature is
between -18° C (0° F) and 40° C (104° F).
(8) First Choice: Oils of full synthetic base stock without viscosity index improvers that meet the performance requirements of the TO-4
specification for the SAE 30 viscosity grade. Typical viscosity grades are SAE 0W20, SAE 0W30, and SAE 5W30. Second choice: Oils with
a TO-4 type additive package and a lubricant viscosity grade of SAE 0W20, SAE 0W30, or of SAE 5W30.
(9) Except for the gear case for the hydraulic driven winch, use SAE 30 viscosity grade for 0 °C (32 °F) to 43 °C (110 °F) or TMS for −10 °C
(14 °F) to 50 °C (122 °F).
(10) Do not use SAE 50 viscosity grade oil in ICM controlled transmissions. Do not use SAE 50 viscosity grade for the gear case of the
hydraulic driven winch.
(11) This oil exceeds the requirements of the TO-4/TO-4M specification.
(12) Commercial Biodegradable Hydraulic Oil (HEES) must conform to the Caterpillar BF-1 specification. This ambient temperature range is for
Caterpillar Biodegradable Hydraulic Oil (HEES) only. This range is not for commercial BF-1 oil.
 966H&972H A6D1 to A7J1-UP
Wheel Loader 08-16-05
Service Tools

Part Part Tool Dealer

Number Name Function Qty Net

Relief Valve (Steering and Implement Pilot)

FT-1114 Vacuum Cap R & I Relief Valve 1

5P-0306 Vacuum Transducer R & I Relief Valve 1

6V-4142 Fitting R & I Relief Valve 1

5K-5068 Fitting R & I Relief Valve 1

6V-9509 Plug R & I Relief Valve 1

6V-9830 Cap As. R & I Relief Valve 1

6V-9511 Plug R & I Relief Valve 1

6V-9832 Cap As. R & I Relief Valve 1

6V-4143 Coupler Test & Adjust Relief Valve 1

177-7860 Hose As. Test & Adjust Relief Valve 1

8T-4188 Union Adapter Test & Adjust Relief Valve 1

6V-3966 Fitting Test & Adjust Relief Valve 1

8T-0855 Gauge Test & Adjust Relief Valve 1

6V-4144 Coupler Test & Adjust Relief Valve 1

Pilot Control Actuator Pressure Check

6V-4143 Coupler Test & Adjust Relief Valve 1

177-7860 Hose As. Test & Adjust Relief Valve 1

8T-4188 Union Adapter Test & Adjust Relief Valve 1

6V-3966 Fitting Test & Adjust Relief Valve 1

8T-0855 Gauge Test & Adjust Relief Valve 1

6V-4144 Coupler Test & Adjust Relief Valve 1

8T-8902 Tee Test & Adjust Reducing Valve 1

6V-3965 Fitting Test & Adjust Reducing Valve 1

3J-1907 O-Ring Seal Test & Adjust Reducing Valve 1

Main Relief Valve & Relief Valves for Hyd. Cylinders

6V-4143 Coupler Test & Adjust Relief Valve 1

177-7860 Hose As. Test & Adjust Relief Valve 1

8T-4188 Union Adapter Test & Adjust Relief Valve 1

6V-3966 Fitting Test & Adjust Relief Valve 1

8T-0855 Gauge Test & Adjust Relief Valve 1

6V-4144 Coupler Test & Adjust Relief Valve 1

-1-
Caterpillar: Confidential Green
Last Modified: 10/05/05
 Hood and Engine Enclosure
*138-7575 Link Bracket Used to lift engine enclosure 4

Belt Tensioner
8H-8558 Breaker Bar Used to rotate belt tensioner 1

Electric Starting Motor

*138-7575 Link Bracket Used to lift starting motor 1

Radiator Core
178-3704 Lifting Bracket Used to lift radiator cores 1

Fan Shroud
*138-7575 Link Bracket Used to lift fan assembly 2

Fan
*138-7575 Link Bracket Used to lift fan 2

Hydraulic Oil Cooler

*138-7575 Link Bracket Used to lift oil cooler 2

Aftercooler
*138-7575 Link Bracket Used to lift aftercooler 2

Engine and Torque Converter

*8B-7554 Bearing Cup Puller Used to remove bearing cups, 1

*8B-7548 Push-Puller Tool Gp Used to remove bearing cups and cones 1

*8H-0663 Bearing Puller Used to remove bearing cones 1

*8H-0684 Ratchet Wrench Used to remove bearing cones 1

*8B-7560 Step Plate Used to remove bearing cones 1

*1P-0510 Driver Gp Used to remove bearing cones 1

*1P-0520 Driver Gp Used to install seal 1

*8H-8581 Feeler Gauge Used to set bearing end play 1

*138-7576 Link Bracket Used to lift engine and torque converter assembly 1

6V-6146 Load Leveler (10,000 lb cap.) Used to lift engine and torque converter assembly 1

1U-9759 5 Ton Jack Stand Used to support engine and torque converter assembly 4

*138-7574 Link Bracket Used to lift torque converter 2

Crankcase Guard
*1U-7505 Floor Jack Used to support crankcase guard 1

Power Train Guard (Transmission)

*1U-7505 Floor Jack Used to support power train guard 1

-2-
Caterpillar: Confidential Green
Last Modified: 10/05/05
 Torque Converter and Pump Drive Housing
138-7574 Link Bracket R & I Torque Converter As. 1

*138-7575 Link Bracket R & I Torque Converter As. 3

1U-9200 Lever Hoist R & I Torque Converter As. 1

Torque Converter
*138-7573 Link Bracket Used to lift torque converter assembly 1

*138-7575 Link Bracket Used to lift torque converter assembly and carrier assembly 2

*8B-7548 Push-Puller Tool Group Used to remove ring seal 1

*8H-0684 Ratchet Wrench Used to remove ring seal 1

*8B-7549 Puller Leg Used to remove ring seal and bearing 2

5P-4808 Cap Used to remove ring seal 2

*8B-7554 Bearing Cup Puller Used to remove ring seal 1

*5F-7366 Screw Used to remove seal carrier and bearing 1

*3H-0465 Plate Used to remove seal carrier and bearing 2

*1P-5546 Crossblock Used to remove seal carrier and bearing 1

*5H-7369 Puller Leg Used to remove seal carrier 2

*8B-7551 Bearing Puller Used to remove seal carrier 1

*6B-6682 ¾” – 16 NF Nut Used to remove seal carrier and bearing 2

*1P-0520 Driver Group Used to remove seal carrier, bearing, and install seal 1

154-6182 M12 x 1.75 Forcing Screw Used to Lift Adapter 2

*5F-7343 Bearing Puller Used to remove bearing 1

*5F-7342 Adapter Used to remove bearing 2

*138-7574 Link Bracket Used to lift adapter 2

8T-5096 Gauge Tool Gp Used to check bearing end play 1

Torque Converter (Freewheel Stator)

*138-7575 Link Bracket Used to lift torque converter assembly 2

1P-0510 Driver Gp. D & A of the Unit 1

2P-8312 Ring Pliers D & A of the Unit 1

7F-6068 Sleeve D & A of the Unit 1

Transmission Oil Pump

126-7181 Sliding Plate Used to remove cage assembly and bearing 2

126-7177 Puller Leg Used to remove cage assembly and bearing 2

*6V-3009 Crossbar Used to remove cage assembly and bearing 1

*4C-5653 Threaded Adapter Used to remove cage assembly and bearing 2

9S-9155 Spacer Used to remove cage assembly and bearing 1

6B-6684 Full Nut Used to remove cage assembly and bearing 2

*6V-4832 Screw Used to remove cage assembly and bearing 1

2M-0849 Hard Washer Used to remove cage assembly and bearing 2

8B-7557 Threaded Adapter Used to remove bearing 2

-3-
Caterpillar: Confidential Green
Last Modified: 10/05/05
 *8H-0663 Bearing Puller Used to remove bearing 1

*1P-0510 Driver Gp Used to install bearings 1

*1P-0520 Driver Gp Used to install cage assembly 1

*138-7573 Link Bracket Used to lift oil pump 1

Transmission, Input Transfer Gears, and Output Transfer Gears

*138-7573 Link Bracket Used to lift transmission assembly 3

154-6181 Forcing Screw Used to lift transmission assembly 3

138-7574 Link Bracket Used to lift transmission assembly 1

138-7575 Link Bracket Used to lift transmission assembly 3

1U-9200 Pull Hoist Used to lift transmission assembly 1

189-0411 Shackle Used to lift transmission assembly 1

Input Transfer Gears

*8B-7554 Bearing Cup Puller Used to remove bearing cups, 1

*8B-7548 Push-Puller Tool Gp Used to remove bearing cups and cones 1

*8B-7551 Bearing Puller Used to remove bearing cones 1

*8H-0684 Ratchet Wrench Used to remove bearing cones 1

*8B-7560 Step Plate Used to remove bearing cones 1

*1P-0510 Driver Gp Used to remove bearing cones 1

*1P-0520 Driver Gp Used to install seal 1

8T-5096 Dial Indicator Gp. Used to set bearing end play 1

1P-7405 Eyebolt D & A Gears 1

5P-3413 Pipe Sealant D & A Gears 1

Transmission Planetary
*1P-2420 Transmission Repair Stand D & A Trans. Planetary 1

*138-7575 Link Bracket D & A Trans. Planetary 3

138-7573 Link Bracket D & A Trans. Planetary 3

*1P-0520 Driver Gp D & A Trans. Planetary 1

1P-0510 Driver Gp. D & A Trans. Planetary 1

FT-2746 Guide Pins D & A Trans. Planetary 2

Output Transfer Gears

138-7573 Link Brackets D & A of Output Transfer Gears 3

*1P-0520 Driver Gp D & A of Output Transfer Gears 1

1P-2322 Puller Assembly D & A of Output Transfer Gears 1

8S-2328 Dial Indicator D & A of Output Transfer Gears 1

7M-7260 Gasket Compound D & A of Output Transfer Gears 1

154-6181 Forcing Screw D & A of Output Transfer Gears 3

Drive Shaft (Front) and Drive Shaft Support Bearing

*1P-0520 Driver Gp R & I and D & A Support Bearing 1

138-7575 Link Bracket R & I and D & A Support Bearing 1

-4-
Caterpillar: Confidential Green
Last Modified: 10/05/05
 1U-7505 Hyd. Jack R & I and D & A Support Bearing 1

FT-1114 Vacumn Cap R & I and D & A Support Bearing 1

5P-0306 Vacumn Transducer R & I and D & A Support Bearing 1

6V-4142 Fitting R & I and D & A Support Bearing 1

5K-5068 Fitting R & I and D & A Support Bearing 1

1U-9200 Lever Hoist R & I and D & A Support Bearing 1

M12 x 1.75 x 150.0 Forcing
154-6182 R & I and D & A Support Bearing 2
Bolt
6V-9509 Plug R & I and D & A Support Bearing 1

6V-9830 Cap As. R & I and D & A Support Bearing 1

Drive Shaft (Center) & (Rear)

1U-7485 Mobile Lifting Crane Used to lift drive shaft 1

FT-2582 Wrench Assembly Used to R & I drive shaft 1

Tire and Rim (Front)

138-7573 Link Bracket Used to R & I Fender 2

3S-6224 Hydraulic Pump Used to raise machine 1

5P-5201 Hyd. Cylinder Used to raise machine 1

8S-7615 Pin Used to raise machine 1

8S-7621 Tube Used to raise machine 1

8S-7640 Stand Used to raise machine 1

155-3597 Wheel Choke Used to block machine 4

4C-8352 Guide Pin Used to Line up Wheel Bolts 2

Tire and Rim (Rear)

*9U-7536 Lift Stand Used to raise machine 2

*4C-5809 Hydraulic Pump Used to raise machine 1

155-3597 Wheel Choke Used to block machine 4

4C-8352 Guide Pin Used to line up Wheel Bolts 2

Fixed Axle (Front)

8S-7630 Stand Used to R & I axle 2

8S-7641 Tube Used to R & I axle 2

8S-7615 Pin Used to R & I axle 2

8S-8048 Saddle Used to R & I axle 2

Oscillating Axle (Rear)

*138-7576 Link Bracket Used to lift axle 4

*137-4370 Load Leveler (10 Ton) Used to lift axle 1

189-0411 Clevis Used to lift axle 2

5P-3931 Anti-Seize Compound Used to Install axle 1

Trunnion Support (Oscillating Axle - Front)

1P-0520 Driver Gp. Install new Sleeve Bearing 1

-5-
Caterpillar: Confidential Green
Last Modified: 10/05/05
 5P-0960 Grease Used to Install axle 1

Trunnion Support (Oscillating Axle – Rear)

1P-0520 Driver Gp. Used to install sleeve bearing 1

5P-0960 Grease Cartridge Used to Install Axle 1

1U-8846 Sealant Used to Install Axle 1

Axle Housing and Axle Shaft

138-7573 Link Bracket D & A Axle Housing 2

1P-2420 Transmission Stand D & A Axle Housing 1

FT-0996 Positioning Gp. D & A Axle Housing 4

FT-0957 Positioning Gp. D & A Axle Housing 4

1P-1863 Pliers D & A Axle Housing 1

138-7575 Link Bracket D & A Axle Housing 3

6V-7820 Torque Multiplier D & A Axle Housing 1

186-0240 Spanner Wrench D & A Axle Housing 1

186-0241 Spanner Wrench D & A Axle Housing 1

150-1782 Crossblock D & A Axle Housing 1

3H-0470 Screw D & A Axle Housing 1

3H-0466 Pull Nut D & A Axle Housing 1

3H-0468 Pull Plate D & A Axle Housing 2

9U-7692 Threaded Rod D & A Axle Housing 2

1U-6436 Seal Installer D & A Axle Housing 1

FT-2619 Torque Bar D & A Axle Housing 1

6V-6640 Sealant D & A Axle Housing 1

Final Drive, Brake and Wheel

*4C-6486 Stand Used to support axle 2

*8S-7615 Pin Used to support axle 2

*8S-8048 Saddle Used to support axle 2

*8S-7611 Tube Used to support axle 2

*138-7574 Link Bracket Used to lift final drive 2

Service Brake
138-7573 Link Bracket R & I Service Brake 2

1P-2420 Trans. Repair Stand R & I Service Brake 1

FT-0996 Positioning Gp. R & I Service Brake 4

FT-0957 Positioning Gp. R & I Service Brake 4

8C-8422 Sealant R & I Service Brake 1

6V-6640 Sealant R & I Service Brake 1

Final Drive and Wheel

*138-7573 Link Bracket R & I Final Drive 2

1U-9200 Lever Hoist R & I Final Drive 3

-6-
Caterpillar: Confidential Green
Last Modified: 10/05/05
 154-6182 Bolt (1/2 – 13 x 6 NC) R & I Final Drive 3

*138-7574 Link Bracket R & I Final Drive 3

140-7742 Sleeve R & I Final Drive 2

*6V-2012 Depth Micrometer Used to determine shim requirements 1

Micrometer 1.0 – 2.0 in. Used to determine shim requirements 1

Differential and Bevel Gear

*138-7574 Link Bracket Used to lift differential 2

*1P-2420 Transmission Repair Stand Used to support differential during D&A 1

*138-7573 Link Bracket Used to lift pinion housing 2

8B-7551 Bearing Puller Used to remove bearing cones 1

*5F-7343 Bearing Puller Used to remove bearing cones 1

186-0240 Spanner Wrench Used for Differential D & A 1

186-0241 Spanner Wrench Used for Differential D & A 1

FT-0996 Positioning Gp. Used for Differential D & A 4

FT-0957 Positioning Gp. Used for Differential D & A 4

1U-6690 Socket Wrench As. Used for Differential D & A 1

1H-3110 Bearing Puller Used for Differential D & A 1

*8T-5096 Dial Indicator Gp Used to check backlash 1

1U-9895 Crossblock Used to check rolling torque of pinion shaft 1

1U-5477 Driver Ring Used to check rolling torque of pinion shaft 1

1P-0526 Drive Plate Used to check rolling torque of pinion shaft 1

7X-2556 Bolt Used to check rolling torque of pinion shaft 1

9X-8257 Washer Used to check rolling torque of pinion shaft 1

8T-4132 Nut Used to check rolling torque of pinion shaft 1

7X-2546 Bolt Used to check rolling torque of pinion shaft 2

8T-4121 Washer Used to check rolling torque of pinion shaft 2

8T-4223 Washer Used to check rolling torque of pinion shaft 2

9X-8257 Washer Used to check rolling torque of pinion shaft 2

Heat Exchanger (Axle Oil Cooler)

1P-2420 Transmission Stand R & I Heat Exchanger 1

FT-0996 Positioning Gp. R & I Heat Exchanger 4

FT-0957 Positioning Gp. R & I Heat Exchanger 4

8C-8422 Sealant R & I Heat Exchanger 1

Control Manifold (Axle Oil Flow Divider)

FT-1114 Vacumn Cap R & I Manifold 1

5P-0306 Vacumn Transducer R & I Manifold 1

6V-4142 Fitting R & I Manifold 1

5K-5068 Fitting R & I Manifold 1

1P-1853 Ring Pliers D & A Manifold 1

1P-0510 Driver Gp. D & A Manifold 1

-7-
Caterpillar: Confidential Green
Last Modified: 10/05/05
 Hydraulic Tank
*138-7575 Link Bracket R & I Hydraulic Tank 4

5P-9119 Sealant D & A Hydraulic Tank 1

Piston Pump (Steering)

Nylon Straps Used to R & I pump 2

1P-1861 Retaining Pliers Used to remove retaining ring 1

*8H-8581 Feeler Gauge Used to check shim requirements 1

*8T-5096 Dial Indicator Gp Used to check bearing end play 1

*1S-0256 Pliers Used to check bearing end play 1

*1U-7978 Screwdriver Used to check bearing end play 1

Gear Pump (Secondary Steering)

FT-1114 Vacuum Cap R & I Gear Pump 1

5P-0306 Vacuum Transducer R & I Gear Pump 1

6V-4142 Fitting R & I Gear Pump 1

5K-5068 Fitting R & I Gear Pump 1

1P-1857 Ring Pliers D & A Gear Pump 1

Pilot Valve and Command Control Steering

1P-0510 Driver Gp. D & A Valve 1

Steering Neutralizer Valve

*1P-0510 Driver Gp Used to remove and install seals 1

Steering Cylinder
FT1114 Vacumn Cap R & I Steering Cylinder 1

5P-0306 Vacumn Transducer R & I Steering Cylinder 1

6V-4142 Fitting R & I Steering Cylinder 1

5K-5068 Fitting R & I Steering Cylinder 1

*138-7573 Link Bracket R & I Steering Cylinder 3

127-4904 Hyd. Cylinder Repair Bench D & A Steering Cylinder 1

195-4609 Seal Pick D & A Steering Cylinder 1

4C-4032 Brg. Mount compound D & A Steering Cylinder 1

1P-0808 Grease D & A Steering Cylinder 1

Parking Brake
1U-5230 Hand Hyd. Pump R & I Brake 1

Brake Control Valve (Service and Parking)

FT-1114 Vacumn Cap R & I Brake Valve 1

5P-0306 Vacumn Transducer R & I Brake Valve 1

6V-4142 Valve R & I Brake Valve 1

-8-
Caterpillar: Confidential Green
Last Modified: 10/05/05
 5K-5068 Valve R & I Brake Valve 1

9S-3263 Thread Lock Compound Assemble Valve 1

138-7573 Link Bracket R & I Parking Valve 3

1P-1854 Ring Pliers D & A Parking Valve 1

Piston Pump (Implement, Pilot Displacement)

1U-9200 Pull Hoist Used to R & I pump 1

136-1452 Pliers Used to D & A Pump 1

1U-7600 Slide Hammer puller Gp. Used to D & A Pump 1

4C-5648 Threaded Adapter Gp. Used to D & A Pump 1

154-9731 Thread Lock Compound Used to secure bolts 1

Piston Motor (Hyd. Fan Drive)

*1P-0510 Driver Gp Used to compress spring in barrel, and remove and install seal 1

1P-1861 Pliers Used to remove retaining ring 1

6V-2166 Brg. Puller Gp. Used to remove Bearing 1

9U-7402 Multitach Test & Adjust Fan Speed 1

IBM Compatible PC Test & Adjust Fan Speed 1

7X-1700 Comm. Adapter Test & Adjust Fan Speed 1

7X-1425 Cable As. Test & Adjust Fan Speed 1

139-4166 Cable As. Test & Adjust Fan Speed 1

ET Software Test & Adjust Fan Speed 1

1U-6605 Reflective Tape Test & Adjust Fan Speed 1

Main Control Valve

8S-7630 Stand Used to lift control valve 1

8S-7641 Tube Used to lift control valve 1

8S-7615 Pin Used to lift control valve 1

8S-8048 Saddle Used to lift control valve 1

1U-9200 Lever Hoist Used to lift control valve 1

138-7575 Link Bracket Used to lift control valve 2

189-0411 Shackle As. Used to lift control valve 1

Brake Accumulator
FT-1114 Vacuum Cap R & I Valve 1

5P-0306 Vacuum Transducer R & I Valve 1

6V-4142 Fitting R & I Valve 1

5K-5068 Fitting R & I Valve 1

175-5507 Nitrogen Charge Gp. Test & Charge Accumulator 1

Pilot Oil Accumulator (Dead Engine Lower)

8S-7630 Stand R & I Accumulator 2

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Caterpillar: Confidential Green
Last Modified: 10/05/05
 8S-7641 Tube R & I Accumulator 2

8S-7615 Pin R & I Accumulator 2

8S-8048 Saddle R & I Accumulator 2

Bucket
6S-6224 Hydraulic Pump Bucket R & I 1

6V-3175 Cylinder Gp. Bucket R & I 1

4C-9634 Threaded Rod Bucket R & I 1

9U-6832 Nut Bucket R & I 1

6V-4035 Sleeve Bucket R & I 1

Tilt Cylinder
*3S-6224 Electric Hydraulic Pump R & I Tilt Cylinder 1

6V-3175 Hydraulic Cylinder R & I Tilt Cylinder 1

4C-9634 Threaded Rod R & I Tilt Cylinder 1

9U-6832 Nut R & I Tilt Cylinder 1

4K-0684 Washer R & I Tilt Cylinder 1

6V-4035 Sleeve R & I Tilt Cylinder 1

6F-8343 Adapter R & I Tilt Cylinder 1

127-4904 Hyd. Cylinder Bench D & A Tilt Cylinder 1

195-4609 Seal Pick D & A Tilt Cylinder 1

7M-7456 Bearing Compound D & A Tilt Cylinder 1

1P-0808 Multi Grease D & A Tilt Cylinder 1

132-5139 Seal Guide D & A Tilt Cylinder 1

1P-1833 Adapter D & A Tilt Cylinder 1

1A-1935 Nut D & A Tilt Cylinder 1

4C-9633 Stud D & A Tilt Cylinder 1

6V-3160 Hyd. Cyl. D & A Tilt Cylinder 1

9S-5565 Puller Sleeve D & A Tilt Cylinder 1

3S-6224 Hyd. Pump D & A Tilt Cylinder 1

1P-0510 Driver Gp. D & A Tilt Cylinder 1

9U-7868 Spanner Wrench D & A Tilt Cylinder 1

127-8064 Adjustable Plate D & A Tilt Cylinder 1

4C-9507 Compound D & A Tilt Cylinder 1

Bucket (Tilt) Links

*3S-6224 Electric Hydraulic Pump Bucket Links R & I 1

6V-3175 Hydraulic Cylinder Bucket Links R & I 1

4C-9634 Puller Stud Bucket Links R & I 1

4K-0684 Washer Bucket Links R & I 1

9U-6832 Fast Runner Nut Bucket Links R & I 1

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Caterpillar: Confidential Green
Last Modified: 10/05/05
 6V-4035 Sleeve Bucket Links R & I 1

5P-4184 Stud Bucket Links R & I 1

1P-0543 Nut Bucket Links R & I 1

1P-1839 Puller Adapter Bucket Links R & I 1

1P-0520 Driver Gp. Bucket Links R & I 1

5P-0960 Grease Bucket Links R & I 1

Tilt Lever
1U-9758 Jack Stand Gp. Tilt Lever R & I 1

*3S-6224 Electric Hydraulic Pump Tilt Lever R & I 1

6V-3175 Hydraulic Cylinder Tilt Lever R & I 1

4C-9634 Puller Stud Tilt Lever R & I 1

4K-0684 Washer Tilt Lever R & I 1

9U-6832 Fast Runner Nut Tilt Lever R & I 1

6V-4035 Sleeve Tilt Lever R & I 1

5P-4184 Stud Tilt Lever R & I 1

1P-0544 Nut Tilt Lever R & I 1

1P-1844 Puller Adapter Tilt Lever R & I 1

9U-6832 Nut Tilt Lever R & I 1

5P-5201 Hyd. Cyl. Tilt Lever R & I 1

9U-6751 Sleeve Tilt Lever R & I 1

9T-2240 Rod Tilt Lever R & I 4

8T-4133 Nut Tilt Lever R & I 4

8T-4121 Washer Tilt Lever R & I 4

9U-7763 Stud Tilt Lever R & I 1

8T-7781 Nut Tilt Lever R & I 1

9S-5431 Sleeve Tilt Lever R & I 1

1P-0520 Driver Gp. Tilt Lever R & I 1

5P-0960 Grease Tilt Lever R & I 1

Lift Cylinder (Left & Right Side)

FT-1114 Vacuum Cap Lift Cylinder R & I 1

5P-0306 Vacuum Transducer Lift Cylinder R & I 1

8S-7630 Stand Lift Cylinder R & I 2

8S-7641 Tube Lift Cylinder R & I 2

8S-7615 Pin Lift Cylinder R & I 2

8S-8048 Saddle Lift Cylinder R & I 2

3S-6224 Hyd. Pump Lift Cylinder R & I 1

6V-3175 Hyd. Cyl. Lift Cylinder R & I 1

6V-4035 Sleeve Lift Cylinder R & I 1

4C-9634 Stud Lift Cylinder R & I 1

4K-0684 Washer Lift Cylinder R & I 1

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Caterpillar: Confidential Green
Last Modified: 10/05/05
 1P-0544 Fast Nut Lift Cylinder R & I 1

138-7573 Link Bracket Lift Cylinder R & I 2

127-4904 Cylinder Repair Stand Lift Cylinder D & A 1

4C-9507 Compound Lift Cylinder D & A 1

1P-1833 Adapter Lift Cylinder D & A 1

4C-9633 Stud Lift Cylinder D & A 1

1A-1935 Nut Lift Cylinder D & A 1

6V-3160 Hyd. Cyl. Lift Cylinder D & A 1

9S-5565 Pull Sleeve Lift Cylinder D & A 1

1P-0510 Driver Gp. Lift Cylinder D & A 1

1P-0808 Grease Lift Cylinder D & A 1

9U-7868 Spanner Wrench Lift Cylinder D & A 1

127-8064 Adj. Plate Lift Cylinder D & A 1

195-4609 Seal Pick Lift Cylinder D & A 1

7M-7456 Brg. Compound Lift Cylinder D & A 1

9U-7456 Seal Guide Lift Cylinder D & A 1

Lift Arms
*8S-7630 Stand Used to support boom 2

*8S-7641 Tube Used to support boom 2

*8S-8048 Saddle Used to support boom 2

*8S-7615 Pin Used to support boom 2

*6V-3175 Double Acting Cylinder Used to remove and install the pins and the bearings 1

*3S-6224 Electric Hydraulic Pump Used to remove and install the pins and the bearings 1

4C-9634 Puller Stud Used to remove and install the pins and the bearings 1

9U-6832 Fast Nut Used to remove and install the pins and the bearings 1

6V-4035 Sleeve Used to remove and install the pins and the bearings 1

FT-1028 Sleeve Used to remove and install the pins and the bearings 1

1P-1835 Brg. Puller Adapter Used to remove and install the pins and the bearings 1

1P-1837 Brg. Puller Adapter Used to remove and install the pins and the bearings 1

1P-1839 Brg. Puller Adapter Used to remove and install the pins and the bearings 1

1P-0510 Driver Gp. Used to remove and install the pins and the bearings 1

1P-0520 Driver Gp. Used to remove and install the pins and the bearings 1

Boom Bearings and Seals

5P-5201 Double Acting Cylinder Used to remove and install the pins and the bearings 1

*3S-6224 Electric Hydraulic Pump Used to remove and install the pins and the bearings 1

137-8792 Sleeve Used to remove and install the pins and the bearings 1

7Y-1460 Nut Used to remove and install the pins and the bearings 1

9U-6800 Nut Used to remove and install the pins and the bearings 1

4C-6504 Pull Rod Used to remove and install the pins and the bearings 1

4C-8152 Retaining Plate Used to remove and install the pins and the bearings 1

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Caterpillar: Confidential Green
Last Modified: 10/05/05
 9T-2240 Rod Used to remove and install the pins and the bearings 4

8T-4133 Nut Used to remove and install the pins and the bearings 4

8T-4121 Washer Used to remove and install the pins and the bearings 4

197-6684 Puller Adapter Used to remove and install the pins and the bearings 1

185-3542 Puller Plate Used to remove and install the pins and the bearings 1

9U-6751 Sleeve Used to remove and install the pins and the bearings 1

137-8460 Stud Used to remove and install the pins and the bearings 1

217-4428 Puller Plate Used to remove and install the pins and the bearings 1

9U-5346 Nut Used to remove and install the pins and the bearings 2

9X-8399 Washer Used to remove and install the pins and the bearings 2

1P-0520 Driver Gp. Used to remove and install the pins and the bearings 1

Operator Cab
FT-1114 Vacumn Cap Used to Remove and Install Cab 1

5P-0306 Vacumn Transducer Used to Remove and Install Cab 1

6V-4142 Fitting Used to Remove and Install Cab 1

5K-5068 Fitting Used to Remove and Install Cab 1

*138-7574 Link Bracket Used to Remove and Install Cab 4

1U-6221 Hyd. Torque Wrench Used to Remove and Install Cab 1

132-8223 Hyd. Pump Gp. Used to Remove and Install Cab 1

Loader Frame and Rear Frame Separate

8T-5255 Hydraulic Jack Used to raise machine 1

*9U-7536 Lift Stand Used to raise machine 2

*4C-5809 Hydraulic Pump Used to raise machine 1

6V-3160 Hyd. Puller Used to Separate Frames 1

4C-9633 Stud Used to Separate Frames 1

1A-1935 Nut Used to Separate Frames 1

1P-1841 Brg. Puller Adapter Used to Separate Frames 1

6V-2097 Sleeve Used to Separate Frames 1

9U-5336 Brg. Puller Adapter Used to Separate Frames 1

1M-6756 Sleeve Used to Separate Frames 1

7F-5283 Adapter Used to Separate Frames 1

1P-1844 Brg. Puller Adapter Used to Separate Frames 1

1U-5230 Hand Hyd. Pump Used to Separate Frames 1

8F-6302 Bolt Used to Separate Frames 1

1B-4330 Nut Used to Separate Frames 1

1P-0502 Drive Plate Used to Separate Frames 1

1P-0520 Driver Gp. Used to Separate Frames 1

5P-3931 Anti-Seize Compound Used to Separate Frames 1

5P-0960 Grease Used to Separate Frames 1

- 13 -
Caterpillar: Confidential Green
Last Modified: 10/05/05
 8S-7610 Base As. 1

155-3597 Wheel Choke 4

5P-0960 Moly Grease General Use for Pin and Bushing install 1

5P-3931 Anti-Seize Compound General Use for Pin and Bushing install 1

Diagnostic Tooling Required

JERD2124 ET Program Dealer Full Service 1
JERD2129 ET Subscription Dealer Full Service 1
146-4080 CAT Digital Multimeter 1
164-3310 Infrared Thermometer 1
171-4400 Comm. Adapter II Group 1
175-3700 Deutsch DT Connector Service Kit 1
190-8900 Deutsch HD Connector Field Repair Kit 1
Connector Repair Kit (Sure
6V-3000 1
Seal)
198-4240 Digital Pressure Indicator Group 1
8T-3224 Needle Tip Gp. 1

Diagnostic Tooling Recommended

131-5051 DataView Group Portable TechStation 1
143-6092 Differential Pressure Meter 1
152-7213 Fluke123 Scopemeter 120 VAC 1
154-8100 Fuel Flowmeter Group Medium Engine 3408 and 3412 Electronic Engine or D300 and 3500 1
155-5176 AC/DC Current Probe All engines below 3500 1
177-2330 Digital Battery Analyzer 1
179-0710 Burn Rate Meter System All engines below 3500 1
187-8520 Wireless ET Link Group With CAT DATA Link 1
189-1720 Analog Gauge Tester Group 1
1U-5470 Engine Pressure Group 1
4C-6500 Digital Thermometer Group 1
4C-8195 Control Service Tool Used with CMS II 1
5P-7277 Voltage Tester 1
6V-2150 Starting /Charging Analyzer Gr. 1
8T-0500 Continuity Testing Light 1
8T-1000 Electronic Position Indicator Gr. 1
8T-5200 Signal Generator/Counter Gr. 1
8T-5300 Timing Indicator Group 1
8T-5301 Diesel Timing Adapter Group (300, 1100, 3200, 3300, and 3400 Series Engines) 1
9U-7500 Transmission Analyzer II Group Machines with Electronic Transmission Control 1
9U-7560 Field Soldering Iron Group 1

Multitach
1U-9139 Universal Fuel Line Pickup All non-unit-injection Caterpillar Diesel Engines 1
- 14 -
Caterpillar: Confidential Green
Last Modified: 10/05/05
 9U -7400 Multitach II Group 1

Multimeter
257-9140 80 Series Digital Multimeter 1
Digital Multimeter with Infrared
237-5130 1
Thermometer
212-2160 Digital Multimeter General function DMM 1
6V-7070 Digital Multimeter Used in CAT field service environment, water resistant 1
9U-7330 Fluke 87 Multimeter Full service DMM, Hz, % Duty Cycle 1

Borescopes
146-1738 Rigid Tube Borescope Battery-Operated 1
186-0170 Flexible Shaft Borescope Length 24”; Dia .236”; field of view 50 degrees 1
190-8160 Light Source, 220 VAC Used with 1U-5268, 9U-6940, and 186-0180 1
1U-5265 Battery Light Source Used with 1U-5268, 9U-6940, and 186-0180 1
1U-5266 Light Source, 110 VAC Used with 1U-5268, 9U-6940, and 186-0180 1
1U-5268 Rigid Tube Straight Viewing Length 23”; Dia .256”; field of view 60 degrees 1
1U-5269 Mirror Tube Adaptor Right-Angles used with 1U-5268 1
6V-9459 Rigid Tube Fiber Optic Cable Used with 1U-5268, 9U-6940, and 186-0180 1
6V-9461 Rigid Tube Adaptor Right-Angle Viewing used with 1U-5268 1
8T-9290 Rigid Tube Borescope Battery-Operated 1
9U-6940 Rigid Tube Fixed Right-Angle Length 22.5”; Dia .256”; field of view 60 degrees 1

Fuelmeter
154-8100 Fuel Flowmeter Group Medium Engine 3408 and 3412 Electronic Engine or D300 and 3500 1
179-0710 Burn Rate Meter System All engines below 3500 1

Blowby
1U-8860 Large Engine Blowby Group. 3500 engines, Larger 300 family engines 1
8T-2700 Blowby/ Air Flow Indicator All engines 3500 & below 1

Cable
122-8840 Harness Assembly Breakout ‘T’ 2-pin Packard connector speed Timing Sensor Test Cable 3100 Engine 1
2-pin Packard connector injection Actuator Pressure Control Test
122-8842 Harness Assembly Breakout 1
Harness 3100 engine
125-3662 Sensor Bypass Cable (3116, 3126) HEUI bypass cable to isolate and test sensors for faults 1
127-6359 Cable Assembly Provides test points for injection harnesses 3116 and 3126 HEUI 1
Provides access to data link directly from the 40-Pin ECM and also power
129-2018 Service Bypass Harness 1
service tool during cranking (3176B, 3116HEUI, 3126HEUI, C-15 & C-16)
40-Pin square C/D to A/B adapter cable, connection of 7X-1715 3500,
134-5195 Adapter Cable Assembly 1
3600
Used to access monitor & adjust air-fuel ratio parameters for proper
136-7874 Cable Adapter 1
emissions
139-4166 Breakout “T” CRB 139-4166 Cat Data Link (CDL) to171-4400 Comm. Adapter 1
Harness Assembly, 70-Pin Provides test points for individual wires in engine wiring harness of
140-2266 1
Breakout “T” electronic engine control system 3176E, C-10, C-12, 3406E, C-15 & C-16
- 15 -
Caterpillar: Confidential Green
Last Modified: 10/05/05
 140-9944 Terminal Kit All Caterpillar Engines 1
147-6456 Wedge Removal Tool 1
151-6320 Removal Tool Used with 14, 16, 18 gauge SXL/GXL (with Electronic Control) 1
Requires to bench flash the ADEM III ECM on 3126 and model year 1999
Service Bypass Harness 70-Pin
167-9225 because ADEM III connection is not possible Engine harness connector 1
ECM
and auxiliary battery (3126, 3406E, C-10, C-12, C-15 & C-16)
179-1875 Lock Removal Tool 1
195-7970 Deutsch DFN Style Connector Service Tool (with Electronic Control) 1
197-7876 Connector Removal Tool 1
Breakout “T” Harness 70-pin Used to provide test point for all individual wires in engine wiring (3176B,
208-0059 1
Connector C-10, C-12, 3406E C-15 & C-16)
6V-3000 Sure Seal Repair Kit All models with Sure Seal Connectors 1
6V-4148 Electrical Connector Repair Kit Some models with electronic controls 1
4C-6805 RS232 Adapter AT-XT Communications 1
7X-1170 Adapter Cable Used with 7X-1200 EUI Injector Interface Timing Adapter Group on 3176 1
7X-1395 Cable Adapter Used with 7X-1695 to allow connection to TDC adapter for SI engines 1
7X-1695 Deutsch DT 2-pin DC Calibrator Top Dead Center (TDC) Cable (All Engines with Electronic Control) 1
7X-1700 Comm. Adapter 1
7X-1425 Data Link Cable As. 1
Used with 6V-7070 DMM to measure voltage in wire harnesses without
7X-1710 Probe Group 1
disconnecting them
Cable Assembly, 40-Pin Allowing voltage checks on any wire or between two wires, Square
7X-1715 1
Breakout ECM Connector 3406E C-15 & C-16and 3176B
8T-5319 CE/VE Connector Tool Group 1
8T-8726 Adapter Cable As. 1
9X-1160 Adapter Cable 40-Pin Breakout Use with 8T-8697 ECAP 3176 Engines rectangular 1
9X-1314 Red Wire Assembly Used with 40-pin breakout cable 1
9X-1315 Black Wire Assembly Used on 40-pin breakout cable 1

Tools with the * are duplicated in this document.

- 16 -
Caterpillar: Confidential Green
Last Modified: 10/05/05
 Reman Offerings for 966H
Name Part# Reman# Notes

ALTERNATOR GP Unassigned 2357133 Preliminary Marketing Info

ARM AS-ROCKER 10R2133 2410844 Information Release Memo

ARM AS-ROCKER 10R2133 2410844 Complete

ARM AS-ROCKER 10R2134 2408460 Information Release Memo

ARM AS-ROCKER 10R2135 2408462 Information Release Memo

CAMSHAFT AS. 10R2132 2237468 Complete

CARTRIDGE GP Unassigned 2574323 NPI Research

COMPRESSOR-GP Unassigned 1630872 Preliminary Marketing Info

CORE AS-OIL CLR 10R2128 2368745 Technical Supplement

CORE AS-OIL CLR 10R3644 1873523 Manufacturing Evaluation

CORE AS-OIL CLR Unassigned 2448840 NPI Research

CORE AS-OIL CLR Unassigned 2511110 NPI Research

CRANKSHAFT A-UTN (UTN) 10R3075 2219362 Technical Supplement

CYLINDER AS-HYD (GENERAL) Unassigned 1354688 Financial Analysis

CYLINDER AS-HYD (GENERAL) Unassigned 2444513 NPI Research

CYLINDER AS-HYD (GENERAL) Unassigned 2447030 NPI Research

CYLINDER AS-HYD (GENERAL) Unassigned 2448776 NPI Research

CYLINDER AS-HYD (GENERAL) Unassigned 2457502 NPI Research

CYLINDER PACK Unassigned 2382711 Marketing Evaluation

CYLINDER PACK Unassigned 2651111 Marketing Evaluation

DAMPER AS Unassigned 1678125 Canceled

FLYWHEEL AS Unassigned 1608210 Canceled

HEAD AS-CYL (UTN) 10R2602 2574095 Technical Supplement

HEAD GP-CYL 10R3394 2574095 Manufacturing Evaluation

INJECTOR GP-FUEL 10R3147 2490712 Information Release Memo

LIFTER AS-VALVE Unassigned 2511005 Canceled

LIFTER AS-VALVE Unassigned 2511005 Canceled

MOTOR GP-ELEC 0R7757 1654619 Complete

MOTOR GP-HYD (GENERAL) Unassigned 1845093 NPI Research

MOTOR GP-HYD (GENERAL) Unassigned 2120211 NPI Research

MOTOR GP-HYD (GENERAL) Unassigned 2548501 NPI Research

PUMP GP-ENG OIL 10R2296 2335220 Complete

PUMP GP-F TRF Unassigned 2662522 Marketing Evaluation

PUMP GP-HYD (GENERAL) Unassigned 2304176 NPI Research

PUMP GP-HYD (GENERAL) Unassigned 2369105 NPI Research

PUMP GP-HYD (GENERAL) Unassigned 2419157 NPI Research

PUMP GP-HYD (GENERAL) Unassigned 2544109 NPI Research

PUMP GP-WATER 10R2833 2285811 Complete

ROD AS-CONN 10R2788 1608192 Technical Supplement

ROD AS-CONN Unassigned 2239133 NPI Research

ROD AS-HYD (GENERAL) 10R3717 1354690 Stock Authorization Memo

ROD AS-HYD (GENERAL) Unassigned 2447025 NPI Research

ROD AS-HYD (GENERAL) Unassigned 2474834 NPI Research

ROD AS-HYD (GENERAL) Unassigned 2478492 NPI Research

ROD AS-HYD (GENERAL) Unassigned 2478493 NPI Research

TURBO GP-BASIC Unassigned 2506115 NPI Research