Caterpillar cat 966 h wheel loader (prefix a6j) service repair manual (a6j00001 01800)

Service Repair Manual
Models
966H WHEEL LOADER

Shutdown SIS
Previous Screen
Product: WHEEL LOADER
Model: 966H WHEEL LOADER A6J
Configuration: 966H WHEEL LOADER A6J00001-01800 (MACHINE) POWERED BY C11 ENGINE
Disassembly and Assembly
966H and 972H Wheel Loaders Machine Systems
Media Number -RENR8859-07 Publication Date -01/03/2014 Date Updated -14/12/2016
i05415906
Loader Frame from Rear Frame - Separate
SMCS - 7051-076; 7054-076
Separation Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A
9U-7536 Stand 2
350-7768 Electric Hydraulic Pump Gp (115 V) 1
B 8T-5255 Hydraulic Jack 1
C
6V-3160 Hydraulic Puller 1
4C-9633 Stud 1
1A-1935 Nut 2
1P-1841 Bearing Puller Adapter 1
6V-2097 Sleeve 1
D 350-7768 Electric Hydraulic Pump Gp (115 V) 1
4C-9633 Stud 1
1/10966H WHEEL LOADER A6J00001-01800 (MACHINE) POWERED BY C11 ENGI...
2020/3/28https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis...

1A-1935 Nut 2
9U-5336 Bearing Puller Adapter 1
6V-2097 Sleeve 1
E
4C-9633 Stud 1
1A-1935 Nut 2
1M-6756 Sleeve 1
7F-5283 Adapter 1
1P-1844 Bearing Puller Adapter 1
F 1U-5230 Hand Hydraulic Pump 1
Start By:
a. Remove the cab.
b. Remove the center drive shaft.
c. Separate the steering frame lock.
When you are using hydraulic cylinders and puller studs, always ensure
that the rated capacity of the puller stud meets or exceeds the rated
capacity of the hydraulic cylinder. If the puller stud does not meet or
exceed the rated capacity of the hydraulic cylinder, a sudden failure of
the puller stud could occur. The sudden failure of the puller stud could
result in personal injury or death.
NOTICE
Care must be taken to ensure that fluids are contained during
performance of inspection, maintenance, testing, adjusting, and repair
of the product. Be prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any component
containing fluids.

Refer to Special Publication, NENG2500, "Dealer Service Tool
Catalog" for tools and supplies suitable to collect and contain fluids on
Cat products.
Dispose of all fluids according to local regulations and mandates.
Note: Put identification marks on all hoses, on all hose assemblies, on all wires, and on all tube
assemblies for installation purposes. Plug all hose assemblies and all tube assemblies. This helps
to prevent fluid loss, and this helps to keep contaminants from entering the system.
1. Drain the oil from the hydraulic tank into a suitable container for storage or disposal. Refer
to Operation and Maintenance Manual, "Hydraulic System Oil - Change".
Illustration 1 g01161541
2. Remove clamp (1). Disconnect harness assembly (2).
3. Disconnect hose assemblies (3), (4), (5), (6), (7), and (8).

4. Remove bolt (9) and pin assembly (10). Position steering cylinder (11) away from the
loader frame. Repeat for the remaining steering cylinder.
5. Position Tooling (A) under the rear frame.
6. Position suitable cribbing under the front of the rear frame.

7. Attach a suitable lifting device to the loader frame.
8. Remove bolts (12) and (13). Remove plate (14). Remove shim (15) (not shown).
9. Use Tooling (B) in order to remove pin (16).
Note: Use the suitable lifting device in order to relieve pressure from pin assembly (16)
during removal.

10. Remove spacer (17) from the lower hitch.
11. Remove bolt (18) from pin assembly (19).
12. Use Tooling (B) in order to remove pin assembly (19) from the upper hitch.

Note: Use the suitable lifting device in order to relieve pressure from pin (19) during
removal.
13. Attach Tooling (F) to the end of brake actuator (20) in order to release the parking brake.

14. Use a suitable lift truck and the suitable lifting device in order to separate the loader frame
from the rear frame. Use suitable cribbing in order to support the loader frame and the rear
frame.
15. Mark the position of caps (21) and (25). Remove bolts (22) and remove cap (21), shim (23)
(not shown), and cap (25) from the upper hitch of the loader frame. Remove lip seal (24)
from cap (21). Remove lip seal (26) from cap (25).

16. Use Tooling (C) in order to remove bearing cups (27) (not shown) and bearing cones (28)
(not shown) from the upper hitch of the loader frame.
17. Use Tooling (D) in order to remove sleeve bearing (29) from the upper hitch of the rear
frame.
18. Use Tooling (D) in order to remove sleeve bearing (30) from the upper hitch of the rear
frame.

19. Mark the position of caps (31) and (35). Remove bolts (33). Remove caps (31) and (35) and
shim (34) (not shown). Remove lip seal (32) from cap (31). Remove lip seal (36) from cap
(35).
20. Use Tooling (E) in order to remove bearing cups (37) (not shown) and bearing cones (38)
(not shown) from the lower hitch of the rear frame.
Copyright 1993 - 2020 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Sat Mar 28 02:11:07 UTC+0800 2020
10/10966H WHEEL LOADER A6J00001-01800 (MACHINE) POWERED BY C11 EN...

Shutdown SIS
Previous Screen
966H and 972H Wheel Loaders Machine Systems
i07235609
Loader Frame to Rear Frame - Connect
SMCS - 7051-077; 7054-077
Connection Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A
9U-7536 Stand 2
B 8T-5255 Hydraulic Jack 1
G
8F-6302 Bolt 1
1B-4330 Nut 2
1P-0502 Driver Plate 2
H 1P-0520 Driver Group 1
J - Loctite C5A 1
K 5P-0960 Grease Cartridge 1
NOTICE
Care must be taken to ensure that fluids are contained during
performance of inspection, maintenance, testing, adjusting and repair
of the machine. Be prepared to collect the fluid with suitable containers

before opening any compartment or disassembling any component
containing fluids.
Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop
Products Guide", for tools and supplies suitable to collect and contain
fluids in Caterpillar machines.
Dispose of all fluids according to local regulations and mandates.
Note: Apply Tooling (J) to all bores when you connect the frames. Lubricate all pin bores, all
seals, and all pins with Tooling (K) before installation.
Note: The following steps are for the assembly of the lower hitch bearings.
1. Position cap (35) and install four bolts (33) that are equally spaced. Ensure that cap (35) is
seated firmly against the frame.
2. Lower the temperature of lower bearing cup (37). Use Tooling (H) to install lower bearing
cup (37) so that lower bearing cup (37) makes contact with cap (35). Apply clean oil to
lower bearing cone (38) and install lower bearing cone (38).
3. Apply clean oil to upper bearing cone (38) and install upper bearing cone (38). Lower the
temperature of upper bearing cup (37). Use Tooling (H) to install upper bearing cup (37) so
that upper bearing cup (37) makes contact with upper bearing cone (38).
4. Remove bolts (33) and cap (35).

5. Position shims (34). Install cap (31) and (35) with four bolts (33).
6. Install Tooling (G) (not shown). Use a suitable torque wrench and Tooling (G) (not shown)
to measure the rolling torque. Adjust the number of shims (34) to achieve a rolling torque
that is between 23 N·m (204 lb in) and 8 N·m (71 lb in). Remove Tooling (G) (not shown).
7. Remove bolts (33) and caps (31) and (35).

8. Use Tooling (H) to install lip seal (36) in cap (35), with the spring of the lip seal facing
down. Use Tooling (H) to install lip seal (32) in cap (31), with the spring of the lip seal
facing up.
9. Position the required number of shims (34) (not shown). Position caps (31) and (35) and the
spacer. Install bolts (33).
Note: The following steps are for the assembly of the upper hitch bearings.
10. Position cap (25) and install three bolts (22) that are equally spaced. Ensure that cap (25) is
seated firmly against the frame. Apply Tooling (J) to the bores.
11. Lower the temperature of lower bearing cup (27). Use Tooling (H) to install lower bearing
cup (27) so that lower bearing cup (27) makes contact with cap (25). Apply clean oil to
lower bearing cone (28) and install lower bearing cone (28).
12. Apply clean oil to upper bearing cone (28) and install upper bearing cone (28). Lower the
temperature of upper bearing cup (27). Use Tooling (H) to install upper bearing cup (27) so
that upper bearing cup (27) makes contact with upper bearing cone (28).
13. Remove bolts (22) and cap (25).

14. Position shims (23). Position cap (21) and (25) and install three bolts (22) that are evenly
spaced.
15. Install Tooling (G) (not shown). Use a suitable torque wrench and Tooling (G) (not shown)
to measure the rolling torque. Adjust the number of shims (23) to achieve a rolling torque
that is between 14 N·m (124 lb in) and 2 N·m (18 lb in). Remove Tooling (G) (not shown).
16. Remove bolts (22) and caps (21) and (25).

17. Use Tooling (H) to install lip seal (26) in cap (25) with the spring of the lip seal up. Use
Tooling (H) to install lip seal (24) in cap (21) with the spring of the lip seal facing down.
18. Position the required number of shims (23) (not shown). Position caps (21) and (25). Install
bolts (22).
19. Lower the temperature of sleeve bearings (29) and (30). Install sleeve bearings (29) and (30)
in the upper rear hitch.

20. Attach a suitable lifting device to the front frame and apply slight lifting tension.
21. Remove the suitable cribbing from the front frame. Use a suitable lift truck and the suitable
lifting device to connect the front frame and the rear frame.
22. Use Tooling (A) and the suitable lifting device to align the pin bores.

23. Install pin assembly (19). Install bolt (18).
24. Install pin (16).
25. Install spacer (17) to the lower hitch.

26. Install plate (14). Install bolts (13). Tighten bolts (13) to a torque of 530 ± 70 N·m
(390 ± 50 lb ft).
27. Use a suitable feeler gauge to measure the distance between the frame and plate (16). Check
completely around the lower hitch mount plate. Record the minimum measurement that is
found.
28. Remove plate (14).
29. Install shims (15) (not shown) under plate (14). The thickness of shims (15) (not shown)
should equal the measurement from Step 27.
30. Install bolts (13). Tighten bolts (13) to a torque of 530 ± 70 N·m (390 ± 50 lb ft). Install
bolts (12). Tighten bolts (12) to a torque of 100 ± 20 N·m (75 ± 15 lb ft).
31. Remove the suitable lifting device from the loader frame.

32. Remove the suitable cribbing from the rear frame.
33. Remove Tooling (A) from the rear frame.
34. Position steering cylinder (11). Install pin assembly (10) and install bolt (9). Repeat for the
remaining steering cylinder.

35. Connect hose assemblies (3), (4), (5), (6), (7), and (8).
36. Connect harness assembly (2). Install clamp (1).
37. Fill the hydraulic tank with oil. Refer to Operation and Maintenance Manual, "Hydraulic
System Oil - Change".
End By:
a. Install the cab.
b. Install the center drive shaft.
c. Disconnect the steering frame lock.
Copyright 1993 - 2020 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Sat Mar 28 02:12:03 UTC+0800 2020

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Comfort Series Seat For Caterpillar Machines
i02140400
Comfort Seat with Front Controls - Disassemble
SMCS - 7324-015
Disassembly Procedure
1. Remove the seat from the machine.
2. Place the seat in the fully upright position.
3. Remove stop bolt (2). Remove seat assembly (1) from suspension assembly (3).

4. Remove bolts (4). Remove cover (5).
5. Remove bolt (9) and retainer (8). Remove nuts (7). Remove armrest (6).

6. Remove bolt (11) and the spacer from belt assembly (10).
7. Use a prybar in order to remove the bottom of seat cushion (12).
8. Remove nuts (14) and the bolts. Remove support assembly (13).

Caterpillar cat 966 h wheel loader (prefix a6j) service repair manual (a6j00001 01800)

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Caterpillar cat 966 h wheel loader (prefix a6j) service repair manual (a6j00001 01800)