Caterpillar Cat 962G Wheel Loader (Prefix 3BS) Service Repair Manual (3BS00001 and up).pdf

Service Repair Manual
Models
962G WHEEL LOADER

Shutdown SIS
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Product: WHEEL LOADER
Model: 962G WHEEL LOADER 3BS
Configuration: 962G Wheel Loader 3BS00001-UP (MACHINE) POWERED BY 3126 Engine
Disassembly and Assembly
950G and 962G Wheel Loaders and IT62G Integrated Toolcarrier Power Train
Media Number -SENR1381-10 Publication Date -01/10/2007 Date Updated -25/10/2007
i07093515
Axle Housing - Disassemble
SMCS - 3260-015
Disassembly Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 138-7573 Link Bracket 2
B
1P-2420 Transmission Repair Stand 1
FT-0996 Positioning Group 4
FT-0957 Adapter Group 4
C 1P-1863 Pliers 1
D 4C-8358 Lifting Eyes 3
E
6V-7820 Torque Multiplier 1
120-9877 Spanner Wrench As(1)
1
1U-9478 Spanner Wrench As(2)
1
F
150-1782 Crossblock 1
5F-7366 Forcing Screw 1
3H-0466 Nut 1
3H-0468 Plate 2
9U-7692 Threaded Rod 2
(1)
For use with M105 bearing nut.
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962G Wheel Loader 3BS00001-UP (MACHINE) POWERED BY 3126 Engine(SEBP...
2020/3/30
https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis...

(2)
Start By:
a. Remove the fixed axle. Refer to Disassembly and Assembly, "Fixed Axle (Front) - Remove
and Install".
b. Remove the oscillating axle. Refer to Disassembly and Assembly, "Oscillating Axle (Rear) -
Remove".
Note: The axle housing assemblies that are used in the front fixed axle and in the rear
oscillating axle are similar. Therefore, both axle housing assemblies can be removed in the
same manner.
Illustration 1 g00301040
Typical Example
1. Install the axle housing in a vertical position on Tooling (B).
Note: Carefully remove the axle housing assembly. Part of the wear gauge pin will remain
in the axle housing assembly. The pin will remain in the axle housing assembly. The spring
and the piston will remain in the differential housing.
2. Fasten Tooling (A) and a hoist to the rim of the axle shaft, as shown. Remove bolts (1) that
secure axle housing assembly (2) to the differential housing. Carefully remove the axle
housing assembly. The weight of axle housing assembly (2) is 295 kg (650 lb).
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3. Remove the bottom half of the axle housing from Tooling (B). Install axle housing
assembly (2) on Tooling (B), as shown.
Note: To remove retaining ring (3), planetary carrier assembly (5) must be disassembled.
4. Use Tooling (C) to remove retaining ring (3) from axle shaft (4).
5. Install Tooling (D) and suitable lifting slings to planetary carrier assembly (5), as shown.
6. Use a hoist to remove the planetary carrier assembly from the axle housing assembly. The
weight of the planetary carrier assembly is 80 kg (175 lb).
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7. Use the following steps to disassemble planetary carrier assembly (5):
a. Use a hammer and a punch to push spring pin (7) all the way into shaft (6).
b. Remove shaft (6), thrust washers , and (8) planetary gear (9) from the carrier.
c. Remove bearing (10) from planetary gear (9).
d. Use a hammer and a punch to remove spring pin (7) from shaft (6).
e. Repeat Steps 7.a through 7.d for the remaining two planetary gears.
f. Remove retaining ring (3) from the carrier.
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8. Install two bolts (11) of a suitable size in the rim of the axle flange. This will prevent the
axle shaft from turning when bearing nut (12) is removed.
9. Use Tooling (E) to remove bearing nut (12) from the axle shaft.
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10. Install Tooling (A) and suitable lifting slings to the axle housing, as shown. Put slight lifting
tension on the axle housing.
Note: The bearing cone which is located under bearing nut (12) will be removed at the same
time as the axle housing.
11. Fasten Tooling (F) to the axle housing, as shown. Use the center stud to push the axle shaft
and the bearing cone from the axle housing. Make sure that upward pressure is constantly
applied.
12. Use the hoist to remove the axle housing and the inner bearing cone from the axle shaft. The
weight of the axle housing is 105 kg (231 lb).
13. Remove the inner bearing cone from the axle housing.
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14. Remove inner bearing cup (13) from the axle housing.
Note: Planetary ring gear (15) will be destroyed during removal.
15. Remove ring gear (15) from the axle housing. Use a torch to cut the ring gear in two places
that are directly across from each other. Cut the ring gear at the position of the locating
dowels. For an alternate method, make three welds that are equally spaced around the
circumference of the ring gear. This will cause the ring gear to shrink.
16. Remove dowels (14).
17. Remove Duo-Cone seal (16) and bearing cup (17) from the opposite end of the axle
housing.
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18. Remove Duo-Cone seal (19) and bearing cone (18) from the axle shaft.
Copyright 1993 - 2020 Caterpillar Inc.
All Rights Reserved.
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Mon Mar 30 10:39:14 UTC+0800 2020
8/8
2020/3/30

Shutdown SIS
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i01076945
Duo-Cone Conventional Seals - Install
SMCS - 7561-012
Installation Procedure
Note: This procedure is only for Duo-Cone conventional seals. This procedure does not pertain to
Duo-Cone floating seals.
It is extremely important to follow the correct procedure for installing Duo-Cone seals. Many seal
failures are the direct result of mistakes during installation of the seal components.
(1) Rubber toric ring. (2) Seal ring. (3) Housing retaining lip. (4) Housing ramp. (5) Seal ring housing.
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(6) Seal ring face. (7) Seal ring ramp. (8) Installation tool. (9) Seal ring retaining lip.
Use caution when you are using isopropyl alcohol. Avoid prolonged skin
contact with isopropyl alcohol.
Vapors may be harmful if inhaled. Use only in a well ventilated area. Do
not smoke while using isopropyl alcohol.
Isopropyl alcohol is flammable. Do not use near an open flame or near
welding operations. Keep isopropyl alcohol away from heated surfaces
exceeding 482°C (900°F).
1. Remove any oily film, dust or other foreign matter from all of the seal components. Use
isopropyl alcohol and a clean cloth to wipe the components. (Paper towels may also be
used.)
Note: Do not allow oil to contact rubber toric rings (1) or seal ring ramps (7) before both
seal rings (2) are assembled in Step 10.
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2. Put rubber toric ring (1) on seal ring (2). Make sure that the toric ring is at the bottom of
seal ring ramp (7) and against seal ring retaining lip (9).
Note: Make sure that rubber toric ring (1) is straight on seal ring (2). There must not be a
twist in the toric ring. Be careful when you are working on the rubber toric ring. Nicks, cuts
and scratches can cause leaks.
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3. Put installation tool (8) on seal ring (2) with rubber toric ring (1). Lower the rings into a
container of isopropyl alcohol until all surfaces of rubber toric ring (1) are wet.
Note: Do not use Stanisol or any other liquid that may leave an oily film.
4. While all surfaces of rubber toric ring (1) are still wet, use installation tool (8) to position
seal ring (2) and the toric ring squarely against seal ring housing (5), as shown.
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5. Measure dimension (A) from seal ring face (6) to the top surface of seal ring housing (5).
Check dimension (A) in at least four places (90 degree intervals). The measurements must
not differ by more than 1 mm (.04 inch).
Note: If small adjustments are necessary, do not push on seal ring (2). Use installation tool
(8).
6. Rubber toric ring (1) can twist if the toric ring is not completely wet during installation.
Burrs on housing retaining lip (3) or on seal ring housing (5) can also cause a twist.
If a twist occurs or if the toric ring is misaligned, repeat Steps 3 through 5.
7. Before further installation, wait for at least two minutes so that the isopropyl alcohol can
evaporate. This will prevent slippage on seal ring ramps (7) and on housing ramps (4). The
toric ring must roll only on the seal ring ramps and on the housing ramps.
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8. Use a clean cloth or a paper towel to wipe off seal ring faces (6).
Note: No particles of any kind can be left on the sealing surfaces. A small piece from a
paper towel can cause a leak by keeping the sealing surfaces from contacting each other.
9. Apply a thin film of clean oil on seal ring faces (6). Use an applicator, a disposable tissue or
a clean finger to distribute the oil evenly. Be careful so that no oil contacts the toric rings.
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10. Make sure that both seal ring housings (5) are correctly aligned and concentric. Slowly
move the seals toward each other.
Note: Do not slam the seals together. High impact can damage the seal components and
leakage will occur.
11. When the seals are in place, fasten all of the parts securely.
Mon Mar 30 10:40:14 UTC+0800 2020
7/7
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Shutdown SIS
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i07307652
Axle Housing - Assemble
SMCS - 3260-016
Assembly Procedure
Table 1
Required Tools
B
C 1P-1863 Pliers 1
D 4C-8358 Lifting Eyes 3
E
6V-7820 Torque Multiplier 1
120-9877 Spanner Wrench As(1)
1
1U-9478 Spanner Wrench As(2)
1
F 1U-6439 Duo-Cone Seal Installer 1
G FT-2530 Bar (Rolling Torque) 1
H - Loctite 5127 -
(1)
(2)
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Note: The axle housing assemblies that are used in the fixed axle and in the oscillating axle are
similar. Therefore, both axle assemblies can be assembled in the same manner.
1. Use bolts of a suitable size to fasten the rim of the axle shaft to Tooling (B).
2. Heat bearing cone (17) to a maximum temperature of 135°C (275°F).
3. Install bearing cone (17) on the axle shaft, as shown. Make sure that the bearing cone is
seated against the shoulder.
Note: Allow the bearing cone and the axle to reach a uniform temperature.
4. Use a suitable driver or a press to reset the bearing cone. This will ensure that the bearing
cone is seated properly.
5. Apply a thin coat of clean SAE 30 oil on bearing cone (17).
Note: Make sure that the rubber seals and all surfaces that contact the seals are clean and
dry. After installation of the seals, apply clean SAE 30 oil on the contact surfaces of the
metal seals.
6. Use Tooling (F) to install the Duo-Cone seal in the axle assembly. Refer to Disassembly and
Assembly, "Duo-Cone Conventional Seals - Install".
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7. Lower the temperature of bearing cup (16). Install bearing cup (16) in the end of the axle
housing. Make sure that the bearing cup is seated with the mating surface.
8. Use a suitable driver or a press to reset bearing cup (16). This will ensure that bearing cup
(16) is seated properly.
Note: Make sure that the rubber seals and all surfaces that contact the seals are clean and
dry. After installation of the seals, apply clean SAE 30 oil on the contact surfaces of the
metal seals.
9. Use Tooling (F) to install Duo-Cone seal (15) in the end of the axle housing. Refer to
Disassembly and Assembly, "Duo-Cone Conventional Seals - Install".
10. Lower the temperature of bearing cup (13). Install bearing cup (13) in the opposite end of
the axle housing, as shown. Make sure that the bearing cup is seated on the mating surface.
11. Use a suitable driver or a press to reset bearing cup (12). This will ensure that bearing cup
(12) is seated properly.
Note: The following steps are for the installation of the ring gear.
Note: Dowels (14) are used to locate ring gear (15).
12. Locate the position of the ring gear in relation to the axle housing. Align the holes to install
the dowels. Put alignment marks on the ring gear and on the axle housing to ensure correct
installation.
13. Lower the temperature of ring gear (15) to −70°C (−94°F). Install ring gear (15) in the axle
housing.
14. Install dowels (14). Peen the axle housing near the dowels to retain the dowels.
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15. Install Tooling (A) on the axle housing, as shown. Attach a hoist and suitable lifting slings
to Tooling (A).
16. Use the hoist to install the axle housing on the axle shaft. The weight of the axle housing is
105 kg (231 lb).
17. Heat bearing cone (20) to a maximum temperature of 135°C (275°F).
18. Install bearing cone (20) on the axle shaft so that there is slight end play. When bearing
cone (20) is cool, apply clean SAE 30 oil to the bearing cone.
Note: The adjusting nut must be installed so that the part number is facing away from
bearing cone (20).
19. Apply clean SAE 30 oil on bearing nut (12). Install bearing nut (12) on the axle shaft.
Tighten the nut until a small amount of end play remains.
20. The seal drag torque is the torque that is needed to rotate the axle housing. Use one of the
following methods to measure the seal drag torque:
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a. To measure seal drag torque, install Tooling (G) on the axle housing. Place a torque
wrench on the bolt at the center of the bar, as shown. Use the torque wrench to rotate
the housing. Record the reading on the torque wrench.
b. To measure seal drag torque, install a bolt and a nut through an outer mounting hole
on the axle housing. Install a torque wrench on the bolt. Make sure that the handle is
aligned with the center of the axle shaft. Use the torque wrench to rotate the housing.
Record the reading on the torque wrench. Use the following formula to calculate the
actual seal drag torque:
Table 2
B
"SDT" is the actual seal drag torque in newton meters (N·m).
"C" is the torque wrench reading in newton meters (N·m).
"B" is the length of the torque wrench in meters.
"A" is the bolt circle radius of axle housing (2) in meters. This is equal to 0.229 m
(9.016 inch).
21. Tighten nut (11) by using one of the following methods:
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a. Rotate the axle housing. Use Tooling (E) to tighten bearing nut (11). Install Tooling
(G) on the axle housing. Place a torque wrench on the bolt at the center of Tooling
(G). The torque wrench reading is equal to the seal drag torque plus the axle bearing
preload rolling torque. Use the seal drag torque that was recorded in Step 20.
Note: The preload rolling torque for new bearings is 9 to 16 N·m (7 to 12 lb ft). The
preload rolling torque for used bearings is 4.5 to 8 N·m (3.5 to 6 lb ft).
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b. Use the torque wrench to rotate the axle housing. Use Tooling (E) to tighten nut (11).
The torque wrench reading must equal the axle bearing preload rolling torque plus the
actual seal drag torque. Use the seal drag torque that was recorded in Step 20. Use the
following formula to calculate the required torque wrench reading. This formula is
used to measure torque at the bolt circle.
Table 3
B + A
"C" is the torque wrench reading in newton meters (N·m).
"B" is the length of the torque wrench in meters.
"A" is the bolt circle radius of axle housing (2) in meters. This equals 0.229 m
(9.016 inch).
"SDT" is the actual seal drag torque in newton meters (N·m).
"T" is the axle bearing preload rolling torque. The preload rolling torque for new
bearings is 9 to 16 N·m (7 to 12 lb ft). The preload rolling torque for used bearings is
4.5 to 8 N·m (3.5 to 6 lb ft).
22. Make sure that axle shaft (4) has zero end play.
23. If the axle bearing preload rolling torque exceeds the specification, back off nut (11) by 1/8
turn and reseat bearing cone (13) against nut (11). Perform Step 21 again.
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24. The following steps are for the assembly of planetary carrier assembly (5):
a. Install retaining ring (3) in the carrier.
b. Apply a thin coat of clean SAE 30 oil on all parts of planetary carrier assembly (5).
c. Install bearing (10) in planetary gear (9).
d. Install thrust washers (8), planetary gear (9), and shaft (7) in the carrier.
Note: If thrust washers (8) have alignment tabs, the alignment tabs should be installed
towards the center of the carrier.
e. Install shaft (6) in the carrier. Make sure that the spring pin hole in the shaft is aligned
with the spring pin hole in the carrier. Install new spring pin (7) through the carrier
and in shaft (6). Install spring pin (7) slightly below the outside surface of the carrier.
f. Repeat Steps 24.a through 24.e for the remaining two planetary gears.
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25. Install Tooling (D) and suitable lifting slings to planetary carrier assembly (5).
26. Use a hoist to install the planetary carrier assembly in the axle housing assembly. The
weight of the planetary carrier assembly is 80 kg (175 lb).
27. Use Tooling (C) to install retaining ring (3) on axle shaft (4).
28. Remove axle housing assembly (2) from Tooling (B). Install the bottom half of the axle
group on Tooling (B) in a vertical position.
29. Apply 6V-6640 RTV Silicone Sealant on the mating surfaces of the axle housing and of the
differential housing.
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30. Apply a thin layer of Tooling (H) to the mating surface of the axle housing. Attach Tooling
(A) and a suitable lifting device to axle housing assembly (2). The weight of axle housing
assembly (2) is approximately 295 kg (650 lb). Carefully install the axle housing assembly.
31. Install bolts (1) that secure axle housing assembly (2) to the differential housing. Tighten
bolts (1) to a torque of 300 ± 40 N·m (220 ± 30 lb ft).
End By:
a. Install the fixed axle. Refer to Disassembly and Assembly, "Fixed Axle (Front) - Remove
and Install".
b. Install the oscillating axle. Refer to Disassembly and Assembly, "Oscillating Axle (Rear) -
Install".
Mon Mar 30 10:41:13 UTC+0800 2020
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962G Wheel Loader 3BS00001-UP (MACHINE) POWERED BY 3126 Engine(SE...
2020/3/30

Shutdown SIS
Previous Screen
i02457299
Service Brakes - Remove
SMCS - 4011-011; 4251-011
Removal Procedure
Table 1
Required Tools
B
Start By:
A. Remove the fixed axle. Refer to Disassembly and Assembly, "Fixed Axle (Front) - Remove".
B. Remove the oscillating axle. Refer to Disassembly and Assembly, "Oscillating Axle (Rear) -
Remove".
Note: The axle housing assemblies that are used in the front fixed axle and in the rear oscillating
axle are similar. Therefore, both axle housing assemblies can be disassembled in the same manner.
1/5
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Caterpillar Cat 962G Wheel Loader (Prefix 3BS) Service Repair Manual (3BS00001 and up).pdf

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Caterpillar Cat 962G Wheel Loader (Prefix 3BS) Service Repair Manual (3BS00001 and up).pdf