Caterpillar cat 960 f wheel loader (prefix 1ym) service repair manual (1ym00001 and up)

Service Repair Manual
Models
960F Wheel Loader

Shutdown SIS
Previous Screen
Product: WHEEL LOADER
Model: 960F WHEEL LOADER 1YM
Configuration: 960F Wheel Loader 1YM00001-UP (MACHINE) POWERED BY 3116 Engine
Disassembly and Assembly
960F WHEEL LOADER MACHINE SYSTEMS
Media Number -SENR6675-01 Publication Date -01/08/2004 Date Updated -27/09/2004
SENR66750023
Implement, Steering & Pilot Systems Hydraulic Pump
SMCS - 5055-010; 5055-015; 5055-016
Remove & Install Implement, Steering & Pilot Systems
Hydraulic Pump
1. Activate the parking brake.
2. Connect the steering frame lock link. See the topic "Separate & Connect Steering Frame Lock
Link" in this module.
3. Release the pressure in the hydraulic system as follows:
a. Move the lift control lever to the "Float" position.
b. Shut off the engine.
c. Move the lift control lever to the "Hold" position.
At operating temperature, the hydraulic oil tank is hot and under
pressure. Hot oil can cause burns. Remove the filler cap on the
hydraulic oil tank only when the engine is stopped, and the filler cap is
cool enough to touch with your bare hand. Be sure all the hydraulic
pressure is released before any fittings, hoses or components are
loosened, tightened, removed or adjusted.
d. Carefully loosen the filler cap on the hydraulic oil tank to release the pressure.
1/18960F Wheel Loader 1YM00001-UP (MACHINE) POWERED BY 3116 Engine(SEBP...
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e. Carefully loosen the plugs at the rear of the tilt cylinder. When the oil from the loosened plugs
stops draining, tighten the two plugs.
NOTE: To release the pressure in the attachment cylinders, carefully loosen the two large plugs
near the plugs at the top of the loader frame. When the oil from the loosened plugs stops draining,
tighten the two large plugs.
f. Tighten the filler cap on the hydraulic oil tank.
g. The pressure in the hydraulic system has now been released.
4. Using two persons, remove the seat assembly from the cab. The weight of the seat assembly is
approximately 23 kg (50 lb).
5. Drain the oil from the hydraulic oil tank until the level is below the implement, steering and
pilot systems hydraulic pump.
6. Remove bolts (2), and disconnect tube assembly (1) from the bottom side of the hydraulic
pump.
Typical Example
7. Disconnect hose assemblies (3), (4) and (5) from the hydraulic pump.
8. Remove bolts (6), and disconnect hose assembly (7) from the hydraulic pump.

9. Remove bolts (9), and disconnect hose assembly (8) from the hydraulic pump.
10. Fasten a hoist or use two persons to hold the hydraulic pump in position.
11. Remove bolts (10), and remove implement, steering and pilot systems hydraulic pump (11).
The weight of the hydraulic pump is 27 kg (60 lb).
NOTE: The following steps are for the installation of the implement, steering and pilot systems
hydraulic pump.
12. Check the condition of all O-ring seals used for installation of the implement, steering and
pilot systems hydraulic pump. If any of the seals are worn or damaged, use new parts for
replacement.
13. Be sure O-ring seal (12) is in position in the transmission oil pump as shown.
14. Use a hoist or two persons to put the implement, steering and pilot systems hydraulic pump in
position in the transmission oil pump. Install two bolts (10) that hold the hydraulic pump in
position.
15. Connect hose assembly (8) to the hydraulic pump.
16. Connect hose assembly (7) to the hydraulic pump.
17. Connect hose assemblies (5), (4) and (3) to the hydraulic pump.
18. Connect tube assembly (1) to the bottom side of the hydraulic pump.
19. Reinstall the seat assembly in the cab.
20. Fill the hydraulic oil tank with oil to the correct level. See the Operation & Maintenance
Manual for the correct filling procedure.
21. Separate the steering frame lock link. See the topic "Separate & Connect Steering Frame Lock

Disassemble Implement, Steering & Pilot Systems Hydraulic
Pump
Start By:
a. remove implement, steering and pilot systems hydraulic pump
1. For the correct assembly of the parts, the pump rotation is counterclockwise when viewed from
the drive end of the pump.
2. Remove O-ring seal (1) from the pump body.
3. Remove the bolts, cover (4) and ring assembly (2) from the pump.
4. Remove spring (3) from ring assembly (2).

There is spring force against plug (8). To prevent possible personal
injury, release the spring force by holding the plug as it is being
removed.
5. Carefully remove plug (8) to release the spring force. Remove spring (6) and spool assembly (5)
from cover (4).
6. Remove O-ring seal (7) from plug (8).
There is spring force against bolt (13). To prevent possible personal
injury, release the spring force by holding the bolt as it is being
removed.
7. Carefully remove bolt (13) to release the spring force. Remove shims (12), valve (11) and
spring (10) from valve spool (9).
8. Remove plate (20), O-ring seal (19) and rotor assembly (18) from ring (17).
9. Remove plate (14) and dowels (16) from ring (17).
10. Remove O-ring seal (15) from plate (14).

11. Remove vanes (21) from rotor assembly (18).
12. Remove bolts (22), and separate cartridge assembly (23) from the cover group.
NOTICE
Make a note of the direction of the arrows at locations (X) and (Y) and
the location of bolts (24) for assembly purposes.
13. Remove cartridge (25) and O-ring seal (26) from body (27).
14. Remove seal ring (28) from body (27).

15. Remove back-up seal (29) and O-ring seal (30) from the cartridge.
16. Remove bolts (24) and cover (30) from the cartridge.
17. Remove seals (31) from cover (30).
18. Remove plate (32) from the cartridge.
19. Remove ring (33) and rotor assembly (34) from the plate.

20. Remove vanes (36) and inserts (35) from the rotor.
21. Remove plate (37) from end plate (38).
22. Remove seals (39) from end plate (38).
23. Remove bolts (41), and remove housing (40) from body assembly (42).

24. Remove cartridge assembly (43) from shaft (44).
NOTICE
Make a note of the direction of the arrows nearest the bolts and the
direction of the arrow on the ring for assembly purposes.
25. Do Steps 16 through 23 again for the disassembly of cartridge (43).
26. Remove seal ring (45) and O-ring seal (46) from body assembly (42).
27. Remove spiral ring (47), and remove shaft assembly (44) from the housing.
28. Use Tooling (A) to remove snap ring (49). Remove bearing (48) from the shaft.

29. Remove washer (51) and lip-type seal (50) from the housing.
30. Remove lip-type seal (52) from the housing.
Assemble Implement, Steering & Pilot Systems Hydraulic
Pump
1. Check the condition of all parts in the implement, steering and pilot systems hydraulic pump. If
any of the parts are worn or damaged, use new parts for replacement.
NOTE: For the correct assembly of the parts, the pump rotation is counterclockwise when viewed
from the drive end of the pump.
2. Install O-ring seal (54) and then seal ring (53) on the end plate.
10/18960F Wheel Loader 1YM00001-UP (MACHINE) POWERED BY 3116 Engine(SE...

3. Put the O-ring seals in position in the plastic seals. Install seal assemblies (39) on end plate (38)
with the O-ring seal toward the plate.
4. Put plate (37) in position so the brass side is toward the rotor.
5. Put ring (33) on plate (37) as shown. The arrow on the chamfer of ring (5) must be in the same
direction as the rotation of the rotor.
6. Install inserts (35) and vanes (36) in rotor (34). The sharp edge of the vanes must be in the same
direction as the arrow on the rotor.

7. Put rotor assembly (34) in position in ring (33). Be sure the sharp edge of the vanes and the
arrow on the chamfer are in the same direction.
8. Put plate (32) in position on the cartridge assembly. Be sure the brass side of the plate is toward
the rotor assembly. Also, be sure the notches on outside diameters of plates (37) and (32) are in
alignment. Alignment these notches with the chamfers on ring (33).
9. Put the O-ring seals in position in the plastic seals. Install seal assemblies (31) on plate (30)
with the O-ring side of the seal toward plate (30).
10. Install plate (30) on the cartridge assembly as shown. Install bolts (24) in the holes nearest to
the arrows on the plate that show the direction of rotation of the pump.

11. Use Tool (B) to install the lip-type seal in body (42). Install the seal with the lip facing down
as shown.
12. Turn body (42) over. Install the lip-type seal with Tooling (B). Be sure the lip of the seal is
facing toward the cartridge assembly.
13. Install washer (51) in the body.
14. Install bearing (48) on the shaft.
15. Use Tool (A) to install snap ring (49) on the shaft that holds the bearing in place.

16. Put shaft assembly (44) in position on the body assembly.
17. Install spiral ring (47) that holds the shaft assembly in place.
18. Install seal ring (45) and O-ring seal (46) on body assembly (42).
19. Install cartridge assembly (43) on the shaft assembly.
20. Align the dowels in the cartridge with the holes in the housing. Install housing (40) on the
body.
21. Install bolts (41) that hold the housing to the body. Tighten the bolts to a torque of 203 ± 14
N·m (152 ± 10 lb ft).
22. Do Steps 1 through 10 again for the assembly of cartridge (25).
23. Install cartridge (25) in the cover group as shown.

24. Install seal ring (28) and O-ring seal (26) in the body.
25. Install cartridge assembly (23) on the cover group. Install bolts (22). Tighten the bolts to a
torque of 95 ± 7 N·m (70 ± 5 lb ft).
26. Install O-ring seal (15) on the body.
27. Install dowels (16) in the body.

28. Install plate (14) on the dowels as shown.
29. Install O-ring seal (19) on the adapter.
30. Install ring (17) on the dowels. Be sure the arrows on the outer edge of the ring are facing in
the same direction as the rotation of the pump.
31. Install vanes (21) in rotor (18). Be sure the vanes are installed so the rounded edge is to the
outside.

32. Install rotor assembly (18) on the shaft in the ring.
33. Install plate (20) on the dowels.
34. Install O-ring seal (53) on the plate.
35. Install spring (3) on the plate.
36. Install spring (10), valve (11), shims (12) and bolts (13) in valve spool (9).

37. Install O-ring seal (7) on plug (8).
38. Install spool assembly (5), spring (6) and plug (8) in cover (4).
39. Install cover assembly (4) on the pump group. Install the four bolts that hold the cover.
Tighten the bolts to a torque of 55 ± 7 N·m (40 ± 5 lb ft).
40. Install O-ring seal (1) on the body.
End By:
a. install implement, steering and pilot systems hydraulic pump
Copyright 1993 - 2020 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Mon Apr 20 09:55:20 UTC+0800 2020

Shutdown SIS
Previous Screen
Product: WHEEL LOADER
Model: 960F WHEEL LOADER 1YM
Configuration: 960F Wheel Loader 1YM00001-UP (MACHINE) POWERED BY 3116 Engine
Disassembly and Assembly
960F WHEEL LOADER MACHINE SYSTEMS
Media Number -SENR6675-01 Publication Date -01/08/2004 Date Updated -27/09/2004
SENR66750024
Hydraulic Oil Tank
SMCS - 5056-010; 5056-017
Remove & Install Hydraulic Oil Tank
1. Activate the parking brake.
2. Connect the steering frame lock link. See the topic "Separate & Connect Steering Frame Lock
3. Release the pressure in the hydraulic system as follows:
a. Move the lift control lever to the "Float" position.
b. Shut off the engine.
c. Move the lift control lever to the "Hold" position.
At operating temperature, the hydraulic oil tank is hot and under
pressure. Hot oil can cause burns. Remove the filler cap on the
hydraulic oil tank only when the engine is stopped, and the filler cap is
cool enough to touch with your bare hand. Be sure all the hydraulic
pressure is released before any fittings, hoses or components are
loosened, tightened, removed or adjusted.

d. Carefully loosen the filler cap on the hydraulic oil tank to release the pressure.
e. Carefully loosen the plugs at the rear of the tilt cylinder. When the oil from the loosened plugs
stops draining, tighten the two plugs.
NOTE: To release the pressure in the attachment cylinders, carefully loosen the two large plugs
near the plugs at the top of the loader frame. When the oil from the loosened plugs stops draining,
tighten the two large plugs.
f. Tighten the filler cap on the hydraulic oil tank.
g. The pressure in the hydraulic system has now been released.
4. Drain the oil from the hydraulic oil tank into a suitable container for storage or disposal. The
capacity of the hydraulic oil tank is 88 liters (22.9 U.S. gal).
5. Fasten Tool (A) and a hoist to right hand fender assembly (1). Remove the bolts and washers
that hold the right hand fender assembly in position. Remove the right hand fender assembly. The
weight of the right hand fender assembly is approximately 73 kg (160 lb).
6. Remove three bolts (2) and the washers that hold steering valve (3) the hydraulic oil tank.
View From Under Hydraulic Oil Tank
7. Disconnect two connectors (6).

8. Disconnect four tube assemblies (5) from the rear of the hydraulic oil tank.
9. Disconnect small tube assembly (4) at the hydraulic oil tank.
View From Under Hydraulic Oil Tank
10. Remove three bolts (7) and the washers that hold the hydraulic oil tank to the bottom support
bracket.
11. Fasten a hoist to hydraulic oil tank (8) as shown.
12. Remove the two bolts and the washers that hold the hydraulic oil tank to the frame of the
machine. Remove the hydraulic oil tank. The weight of the hydraulic oil tank is 118 kg (260 lb).
NOTE: The following steps are for the installation of the hydraulic oil tank.
13. Check the condition of the O-ring seals used in the installation of the hydraulic oil tank. If the
seals are worn or damaged, use new parts for replacement.
14. Fasten a hoist to hydraulic oil tank (8), and put it in position on the frame of the machine.
Install the two bolts and the washers that hold the hydraulic oil tank in position.
15. Install three bolts (7) and the washers that hold the hydraulic oil tank to the bottom support
bracket.
16. Connect small tube assembly (4) at the rear of the hydraulic oil tank.
17. Connect four tube assemblies (5) at the rear of the hydraulic oil tank.
18. Connect two connector (6).
19. Put steering valve (3) in position on the hydraulic oil tank, and install three bolts (2) and the
washers which hold it.
20. Fasten Tool (A) and a hoist right hand fender assembly (1). Put the right hand fender assembly
in position on the machine. Install the bolts and washers that hold it.

21. Fill the hydraulic oil tank with oil to the correct level. See the Operation & Maintenance
Manual for the correct filling procedure.
22. Separate the steering frame lock link. See the topic "Separate & Connect Steering Frame Lock
23. Start the machine, and check for leaks.
Disassemble & Assemble Hydraulic Oil Tank
Start By:
a. remove hydraulic oil tank
1. Remove oil temperature sensor (5) from the hydraulic oil tank.
2. Remove high oil level switch (4) from the hydraulic oil tank.
3. Remove fitting (3) and wiring harness clip (6).
4. Remove two bolts (2), the washers and mounting bracket (1) from the hydraulic oil tank.
5. Remove eight nuts (8), the washers and two hydraulic oil filter assemblies (7) from the
hydraulic oil tank.

NOTE: For complete information concerning servicing of the hydraulic oil filter assembly, see
the topic "Hydraulic Oil System" In the Operation & Maintenance Manual.
6. Disassemble both hydraulic oil filter assemblies (7) as follows:
a. Remove locknut (12) and washer (16) from the end of the taperlock stud.
b. Remove retainer assembly (11).
c. Remove filter (14).
d. Remove O-ring seal (15) from retainer assembly (11).
e. Remove O-ring seal (13) from cover assembly (9).
f. If necessary, remove taperlock stud (10) and the plug from the cover assembly.
7. Remove four nuts (18), the washers and filler assembly (17) from the hydraulic oil tank.
8. Remove cap (19), strainer (20) and O-ring seals (21) and (23) from filler (22).

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9. Remove sixty two bolts (24) and the locknuts that hold the halves of the hydraulic oil tank
together.
10. Fasten Tool (A) and a hoist to cover (25) as shown. Remove the cover. The weight of the
cover is 43 kg (95 lb). The weight of the other half of the hydraulic oil tank is 50 kg (110 lb).
11. Remove two nuts (29), the washers and drain assembly (27).
12. Remove two bolts (26), the washers and oil level sight gauge (28) from cover (25).
13. Disassemble drain assembly (27). Remove guide (34), spring (33) and valve (32) from body
(31). Remove O-ring seal (30) from the body. Remove the drain plug and O-ring seal from the
body.

14. Disassemble oil level sight gauge (28). Remove grommet (39), glass (37) and plate (film) (36)
from retainer (35). Remove two O-ring seals (38) from the retainer.
15. Remove the four bolts and washers that hold suction block (40) in position. Remove the
suction block.
16. Remove four O-ring seals (41), two O-ring seals (42) and O-ring seal (43) from suction block
(40).
17. Remove the bolt and washer that holds supplemental steering suction manifold (44) in
position. Remove the suction manifold.

18. Remove six O-ring seals (46) and four O-ring seals (45) from the suction manifold.
19. Remove fitting (47) and the O-ring seals from the suction manifold.
20. Remove the bolts and washers that hold filter bases (48) in position. Remove the filter bases.
21. Disassemble filter bases (48) as follows:
a. Remove six O-ring seals (49) and O-ring seal (50) from manifold (51).
There is spring force against flange (56). When bolts (54) are removed,
the spring force will be released. To prevent possible personal injury,
flange (56) must be held in position when bolts (54) are being removed.

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