Caterpillar cat 960 f wheel loader (prefix 9zj) service repair manual (9zj00001 and up)

Service Repair Manual
Models
960F Wheel Loader

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Product: WHEEL LOADER
Model: 960F WHEEL LOADER 9ZJ
Configuration: 960F Wheel Loader 9ZJ00001-UP (MACHINE) POWERED BY 3116 Engine
Disassembly and Assembly
960F WHEEL LOADER POWER TRAIN
Media Number -SENR6667-03 Publication Date -01/12/2004 Date Updated -08/03/2006
SENR66670005
Front Drive Shaft & Carrier Bearing
SMCS - 3253; 3267-015; 3267-016; 3267-010
Remove & Install Front Drive Shaft & Carrier Bearing
Start By:
a. remove center drive shaft
b. remove parking brake*
*This operation is in the 960F Wheel Loader Machine Systems Disassembly & Assembly module,
Form No. SENR6675.
1. Remove four bolts (1) and two straps (2). Disconnect front drive shaft (3) from the front
differential.
1/4960F Wheel Loader 9ZJ00001-UP (MACHINE) POWERED BY 3116 Engine(SEBP2...
2020/3/14https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis...

Rear Side Of Front Drive Shaft & Carrier Bearing Shown
2. Disconnect grease tube assembly (5) from the bearing housing.
3. Remove six bolts (6) and the washers that hold the front drive shaft and the carrier bearing in
position.
4. Using two persons, remove front drive shaft and carrier bearing (4) from the front loader frame.
The weight of the unit is approximately 34 kg (75 lb).
NOTE: The following steps are for the installation of the front drive shaft and carrier housing.
5. Using two persons, put front drive shaft and carrier bearing (4) in position in the front loader
frame. Install six bolts (6) and the washers that hold it.
6. Connect grease tube assembly (5) to the bearing housing.
7. Connect front drive shaft (3) to the front differential. Install two straps (2) and four bolts (1).
Tighten four bolts (1) to a torque of 60 ± 7 N·m (44 ± 5 lb ft).
End By:
a. install parking brake*
b. install center drive shaft
*This operation is in the 960F Wheel Loader Machine Systems Disassembly & Assembly module,
Form No. SENR6675.
Disassemble Front Drive Shaft & Carrier Bearing
Start By:
a. remove front drive shaft and carrier bearing
1. Remove two bolts (1), and remove housing (2) from housing (3).

2. Remove lip seal (4) from housing (2).
3. Using a press as shown, press shaft (5) out of bearing (6).
4. Remove O-ring seal (6), bearing (7) and lip seal (8) from housing (3).
Assemble Front Drive Shaft & Carrier Bearing
1. Use Tool (A) to install lip seal in housing (3). Install the seal until it makes contact with the
counterbore in the housing.

2. Lower the temperature of bearing (6), and install it in housing (3). Install the bearing until it
makes contact with the counterbore in the housing.
3. Check the condition of O-ring seal (7). If the seal is worn or damaged, use a new part for
replacement. Put 5P-0960 Multipurpose Grease on O-ring seal (7), and install it in housing (3).
4. Put 5P-0960 Multipurpose Grease on the lips of the lip seal in housing (3).
5. Using a press as shown, press front drive shaft assembly (8) into the bearing in housing (3).
6. Use Tool (A) to install the lip seal in housing (2). Install the seal until it makes contact with the
counterbore in the housing.
7. Put 5P-0960 Multipurpose Grease on the lips of the seal in housing (2). Put housing (2) in
position on housing (3), and install bolts (1) that hold it.
End By:
a. install front drive shaft and carrier bearing
Copyright 1993 - 2020 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Sat Mar 14 21:02:04 UTC+0800 2020

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SENR66670006
Rear Drive Shaft
SMCS - 3253-010
Remove & Install Rear Drive Shaft
View From Under Machine
1. Remove eight bolts (2) and four straps (1) that hold the rear drive shaft to the universal joints.
2. Remove rear drive shaft (3).
NOTE: The following steps are for the installation of the rear drive shaft.
3. Be sure the universal joints are positioned on the same center line with the rear drive shaft.
4. Put rear drive shaft (3) in position on the universal joints.
5. Install four straps (1) and eight bolts (2) that hold the rear drive shaft in position. Tighten bolts
(2) to a torque of 60 ± 7 N·m (44 ± 5 lb ft).
Sat Mar 14 21:02:53 UTC+0800 2020

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SENR66670007
Front Axle Housing Group (Fixed)
SMCS - 3278-010
Remove & Install Front Axle Housing Group (Fixed)
Start By:
a. remove front tire and rim assemblies
1. Start the machine. Raise the bucket and lift arms, and put Tooling (A) in position under the lift
arms for support. Lower the weight of the bucket and lift arms onto Tooling (A), as shown. Shut
the machine off.

2. Disconnect hose and tube assembly (1) from the front axle housing group.
3. Remove four bolts (2) and the two straps, and disconnect front drive shaft (3) from differential
pinion yoke (4).
4. Fasten a lifting strap to each side of the front axle housing group as shown. Fasten a hoist to
both lifting straps.
5. Remove two bolts (5), the washers and plate (6) from each side of the front axle housing group.
6. Remove eight bolts (7) and the washers that hold the front axle housing group to the front
loader frame. Lower the front axle housing group from the machine. The weight of the front axle
housing group is approximately 1134 kg (2500 lb).
NOTE: The following steps are for the installation of the front axle housing group.
7. Be sure the mounting surfaces of front axle housing group and the front loader frame are clean
and free of dirt and debris prior to installation of the front axle housing group.
8. Fasten lifting straps and a hoist to both ends of the front axle housing group. Raise the front
axle housing group into position against the front loader frame. Install eight bolts (7) and the
washers that hold it. Tighten the bolts to a torque of 900 ± 100 N·m (660 ± 75 lb ft).
9. Install plate (6), the two washers and bolts (5) which hold it.

10. Put front drive shaft (3) in position in differential pinion yoke (4). Install the two straps and
four bolts (2). Tighten four bolts (2) to a torque of 60 ± 7 N·m (44 ± 5 lb ft).
11. Connect the hose and tube assembly (1) to the front axle housing group.
12. Start the machine, and raise the lift arms and bucket. Remove Tooling (A), and lower the
bucket to the ground.
End By:
a. install front tire and rim assemblies
Sat Mar 14 21:03:42 UTC+0800 2020

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SENR66670008
Rear Axle Housing Group (Oscillating)
SMCS - 3278-010
Remove & Install Rear Axle Housing Group (Oscillating)
Start By:
a. remove rear tire and rim assemblies
b. remove rear drive shaft
1. Disconnect hose and tube assembly (1) from the top of the rear axle housing group.
2. Fasten a lifting strap to each side of the rear axle housing group. Fasten a hoist to both lifting
straps.

3. Disconnect tube (2) from the rear axle housing group. Remove four bolts (3) and the nuts that
hold the rear support to the frame of the machine.
Typical Example
4. Fasten a chain around the axle, front support (6) and yoke (5) to prevent the support and the
yoke from falling as the axle is removed. Remove four bolts (7) and the nuts that hold front
support (6) to the frame of the machine.
5. Lower the rear axle housing group evenly, so that dowel (4) does not bind and prevent lowering
of the rear axle housing group. The weight of the rear axle housing group is approximately 1223
kg (2700 lb).
NOTE: The following steps are for the installation of the rear axle housing group.
6. Fasten a chain to support the front support and yoke. Raise the rear axle housing group into
position. Install four bolts (7) and four bolts (3) that hold the front and rear supports for the rear
axle housing group to the frame. Tighten the bolts to a torque of 475 ± 60 N·m (350 ± 45 lb ft).
7. Connect tube (2) to the rear axle housing group. Connect hose and tube assembly (1) to the top
of the rear axle housing group.
8. Lubricate the front and rear supports for the rear axle housing group. See Operation &
Maintenance Manual for the correct lubricating procedure.
End By:
a. install rear drive shaft
b. install rear tire and rim assemblies
Sat Mar 14 21:04:32 UTC+0800 2020

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SENR66670009
Front Support (Rear Axle Housing Group)
SMCS - 3268-011; 3268-012
Remove Front Support (Rear Axle Housing Group)
Start By:
a. remove rear axle housing group (oscillating)
1. Remove yoke (2) from the differential pinion shaft.
2. Fasten a hoist to front support (1), and slide the front support off of the rear axle housing. The
weight of the front support is approximately 34 kg (75 lb).
3. Remove lip seal (3) from the front support. Remove retaining ring (4) that holds sleeve bearing
(5) in the front support.

4. Turn the front support over, and remove the other lip seal. Using a press, remove sleeve bearing
(5) from the front support.
Install Front Support (Rear Axle Housing Group)
1. Use a press and Tool (A) to install the sleeve bearing in front support (1) until it makes contact
with the counterbore in the support.
2. Install the retaining ring that holds the bearing in the front support.
3. Use a press and Tool (B) to install lip seal (3) in both sides of the front support. Install the seals
until they make contact with the counterbores in the front support and with the lip of each seal
facing toward the outside of the front support as shown.
4. Put 5P-0960 Multipurpose Grease on the lips of seals (3).
5. Fasten a hoist to front support (1), and install it on the rear axle group.
6. Install yoke (2) on the differential pinion shaft.

End By:
a. install rear axle housing group (oscillating)
Sat Mar 14 21:05:21 UTC+0800 2020

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SENR66670010
Rear Support (Rear Axle Housing Group)
SMCS - 3268-011; 3268-012
Remove Rear Support (Rear Axle Housing Group)
Start By:
a. remove rear axle housing group (oscillating)
1. Remove the bolts and washers that hold cover (1) to the rear support. Remove the cover.
2. Fasten a hoist to the rear support.
3. Remove four bolts (2), the washers, thrust washer (3) and plate (4). Remove the thrust washer
that is behind plate (4).
4. Remove the rear support. The weight of the rear support is 45 kg (100 lb).

5. Remove lip seal (6) and sleeve bearing (7) from the rear support.
Typical Example
6. Remove bolts (8), the washers and trunnion (9). The weight of the trunnion is 20 kg (45 lb).
Install Rear Support (Rear Axle Housing)
1. Put 6V-6640 Gasket Maker on the mating surface of trunnion (9) and the oscillating housing
assembly. Put the trunnion in position on the oscillating housing assembly, and install bolts (8)
and the washers which hold it. Tighten the bolts to a torque of 300 ± 40 N·m (220 ± 30 lb ft).
2. Use Tool (A) and a press to install the sleeve bearing in the rear support.

3. Use Tool (A) to install the lip seal in the support. Be sure the lip is facing toward the outside of
the rear support as shown.
4. Fasten lifting straps and a hoist to the rear support. Put the rear support in position on the
trunnion.
5. Put 5P-0960 Multipurpose Grease on the two thrust washers.
6. Install a thrust washer, plate (4), washers (3) and four bolts (2). Tighten four bolts (2) to a
torque of 570 ± 80 N·m (420 ± 60 lb ft).
7. Install cover (1). Tighten the bolts to a torque of 270 ± 40 N·m (200 ± 30 lb ft).
End By:
a. install rear axle housing group (oscillating)
Sat Mar 14 21:06:10 UTC+0800 2020

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Previous Screen
SENR66670011
Axle Shaft Assemblies
SMCS - 3260-017
Disassemble & Assemble Axle Shaft Assemblies
Start By:
a. remove front axle housing group (fixed)
b. remove rear axle housing group (oscillating)
NOTE: The axle shaft assemblies used in the front and rear axle housing groups are similar. The
removal, disassembly, assembly and installation procedures are the same for both axle groups.

1. Install the axle housing group on Tool (G) in a vertical position as shown.
2. Fasten Tool (A) and a hoist to the rim flange of the axle shaft as shown. Remove twenty four
bolts (1) and the washers that hold axle shaft assembly (2) to the differential housing. Carefully
remove the axle shaft assembly. The weight of the axle shaft assembly is approximately 295 kg
(650 lb).
3. Remove the bottom half of the axle housing group from Tool (G). Install axle shaft assembly on
Tool (G) with planetary carrier assembly (5) facing up as shown.
NOTE: To completely remove retaining ring (3) from the axle shaft assembly, planetary carrier
assembly (5) must be removed and disassembled.
4. Use Tool (B) to remove retaining ring (3) from the groove in the end of the axle shaft (4).
Position the retaining ring in the planetary carrier.
5. Fasten Tool (C) and a hoist to planetary carrier assembly (5) as shown. Remove the planetary
carrier assembly from the axle shaft housing. The weight of the planetary carrier assembly is
approximately 80 kg (175 lb).

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6. Disassemble planetary carrier assembly (5) as follows:
a. Using a hammer and punch, push spring pin (7) all the way into shaft (6).
b. Remove shaft (6), thrust washers (11) and (8) and planetary gear (10) from the carrier.
c. Remove bearing (9) from planetary gear (10).
d. Remove spring pin (7) from shaft (6) with a hammer and punch.
e. Remove the other two planetary gears (10) from the carrier as in Steps 6a through 6d.
f. Remove retaining ring (3) from the carrier.
The axle shaft housing has been removed from the axle shaft for better photo illustration of mounting the axle shaft to
Tool (G).

7. Fasten the rim flange of the axle shaft to Tool (G) with suitable size bolts as shown in Photo
C42124P1. Installation of the bolt will prevent the axle shaft from turning when bearing nut (12)
is removed. Use Tooling (D) to remove bearing nut (12) from the axle shaft.
8. Fasten Tooling (A) and a hoist to the axle shaft housing as shown. Put slight lifting tension on
the axle shaft housing.
NOTE: The bearing cone which is located under bearing nut (12) will be removed at the same
time that the axle shaft housing is being removed from the axle shaft.
9. Fasten Tool (E) to the axle shaft housing as shown. Put a hand operated hydraulic jack between
Tool (E) and the end of the axle shaft as shown. Operate the hydraulic jack to push the axle shaft
bearing and inner bearing cone off of the axle shaft. Remove the axle shaft housing and inner
bearing cone from the axle shaft. The weight of the axle shaft housing is approximately 105 kg
(231 lb).
10. Remove the inner bearing cone from the axle shaft housing.

11. Remove inner bearing cup (13) from the axle shaft housing.
NOTICE
Ring gear (14) will be destroyed when it is removed from the axle shaft
housing.
12. Remove ring gear (14) from the axle shaft housing. Using a torch, cut the ring gear in three
places. Cut the ring gear at the position of the three locating dowels in the axle shaft housing. An
alternate method is to make three welds equally spaced around the circumference of the ring gear
to cause it to shrink. Remove the three locating dowels for ring gear (14).
13. Remove Duo-Cone seal (15) and outer bearing cup (16) from the opposite end of the axle shaft
housing.
14. Remove Duo-Cone seal (18) and outer bearing cone (17) from the axle shaft.
NOTE: The following steps are for the assembly of the axle shaft assemblies.
15. Fasten the rim flange of the axle shaft to Tool (G) with suitable size bolts as shown. Heat outer
bearing cone (17) to a maximum temperature of 135°C (275°F), and install the bearing cone on

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