966 Cat

Service Information System
Page 1 of 12
Service Letter
PRODUCT SUPPORT PROGRAM FOR REPLACING FAILED IMPLEMENT PUMPS ON CERTAIN
966G, 966G II, 972G AND 972G II WHEEL LOADERS
Media Number -SEBE8599-02
Publication Date -09/12/2003
Date Updated -17/03/2005
CONFIDENTIAL
SEBE8599-02
View Image
December 9, 2003
(Revised March 2005)
U-337
A-230
D-246
O-279
before or
after failure
5055
PRODUCT SUPPORT PROGRAM FOR REPLACING FAILED

IMPLEMENT PUMPS ON CERTAIN 966G, 966G II,
972G AND 972G II WHEEL LOADERS
PS41464
NOTE: This Program can be administered either
before or after failure. In either case the
decision whether to apply the Program is made by
the dealer. When reporting the repair, use
"PS41464" as the Part number and "7755" as the
Group Number. If adminstered before failure, use
"56" as the Warranty Claim Description Code and
use "T" as the SIMS Description Code. If
adminstered after failure, use "96" as the
Warranty Claim Description Code and use "Z" as
the SIMS Description Code.
NOTE: The Revised Service Letter replaces the
December 9, 2003 (Revised February 2005) Service
Letter. Changes have been made to the Affected
Product.
https://sis.cat.com/sisweb/sisweb/techdoc/content.jsp?calledpage=/sisweb/sisweb/medias...
20/11/2007
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TERMINATION DATE
December 31, 2005
PROBLEM
The vane-type implement pump may fail and needs to be replaced with a
gear-type pump on certain 966G, 966G II, 972G and 972G II Wheel
Loaders. A typical vane pump failure will have scoring on the
pressure plates and rotor. This can result in a loss of efficiency
and increased noise from the pump. The failure may also include
cracking or breaking of the rotor. The gear-type pump is a more
robust design and will eliminate this failure and provide improved
implement pump life.
AFFECTED PRODUCT
Model
Identification Number
966G
9RS1-Up
AAH1-Up
3PW1-Up
8XW1-Up
966G II
AXJ1-1418
AWY1-867
972G
1EW1-Up
AAW1-Up
6AW1-Up
9GW1-Up
8TS1-25
972G II
AXN1-340
AXC1-719
PARTS NEEDED
1 - 7D7233 Clip
1 - 5F3106 Seal - O-Ring
2 4J0520 Seal - O-Ring
1 - 7J9108 Seal - O-Ring
1 - 3K0360 Seal - O-Ring
20/11/2007
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1 - 2M9780 Seal - O-Ring

3 1P3705 Seal
2 - 4S4455 Clip
2 6S6251 Mount - ISO
3 - 8T4121 Washer - Hard
3 - 8T4136 Bolt
2 8T4648 Bolt
2 - 6V5844 Bolt
1 - 6V8398 Seal - O-Ring
1 - 6V8625 Elbow - 90 Degrees
1 - 6V8776 Tee - Face Seal
4 6V9746 Seal - O-Ring
1 - 9X7371 Seal - O-Ring
2 - 9X8268 Washer
1 - 2307549 Hose Assembly
1 - 2326546 Coupling Kit
1 - 2384936 Hose Assembly (Discharge)
1 2582140 Hose Assembly (Suction)
1 2622013 Tube Assembly
1 2H6338 Seal
2 2094580 Clamp T-Bolt
1 - 2389105 Bracket Assembly
1 2409980 Plate Assembly
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1 2410107 Plate
1 2413424 Block Assembly
2 2432076 Washer - Hard
1 - 2445447 Pump Group
ACTION REQUIRED
Replace vane-type implement pump with gear-type implement pump. See
attached rework procedure.
SERVICE CLAIM ALLOWANCES

Implement
Pump
Age/Hours
Caterpillar
Parts
Labor
Hrs
Dealer Suggested
Parts
Labor Hrs
Customer Suggested
Parts
Labor Hrs
Before Failure
0-4500 /
0-36 mo
100%
10
10
45019000 /3760 mo
33 1/3%
50%
15
After Failure
0-4500 /
0-36 mo
100%
25
45019000 /3760 mo
33 1/3%
12.5
50%
12.5
NOTE: This program pays 10-hours for before

failure repairs and 25-hours for after
failure repairs.
NOTE: To compensate for machines that have
experienced an implement pump failure in
the past, this program is based on the
hours currently on the implement pump when
the service letter is applied.
PARTS DISPOSITION
20/11/2007
Page 5 of 12
Handle the parts in accordance with your Warranty Bulletin on

warranty parts handling.
Rework Procedure
NOTE: All safety related information must be read
and practiced when performing this procedure.
NOTE: If a failure of the implement pump has
occurred, a complete hydraulic oil change is
required before returning the machine to
operation.
Remove and dispose of hydraulic fluids in accordance with local and
mandated guidelines.
Procedure for removing implement pump from vehicle
Reference: RENR2116 Disassembly and Assembly
966G Wheel Loader and 972G Wheel Loader Machine
Systems
966G Series II Wheel Loader and 972G Series II
Wheel Loader Machine Systems
1. Remove cab. Refer to Disassembly and Assembly, "Cab - Remove
Removal Procedure".
2. Remove Pilot and Brake Pump. Refer to Disassembly and Assembly,
"Vane Pump (Pilot and Braking-Remove".
3. Remove Steering Pump. Refer to Disassembly and Assembly, "Piston
Pump (Steering) - Remove".
4. Remove Implement Pump. Refer to Disassembly and Assembly, "Vane
Pump (Implement) - Remove
Procedure for returning machine to operating condition
966G Wheel Loader and 972G Wheel Loader Machine
Systems
966G Series II Wheel Loader and 972G Series II
Wheel Loader Machine Systems
Reference: SENR3130 Torque Specifications
20/11/2007
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Reference: SEBF8493 Contamination Control

Guideline Procedure for Kidney Looping Small
and Medium Wheel Loader, Landfill and Soil
Compactor, and Integrated Tool Carrier Hydraulic
Oil
Reference: SEBU6250 Caterpillar Machine Fluids
Recommendations
1. Remove 1354626 Pump Discharge Hose Assembly. Refer to
Illustration 1 for hose location.
2. Remove the 1433649 Discharge Block Assembly and replace it with
the 2413424 Block Assembly. Install the 6S6251 Isolation Mount
and required hardware.
Note: Refer to Illustration 2 and Section A A.
3. Replace the 1354626 pump discharge hose with a 2384936 Hose
assembly. Refer to Illustration 1.
Note: The 5P3099 short drop coupling must be attached to the pump
discharge port.
4. Replace suction tube and hose to implement gear pump. Refer to
Illustration 1 for suction tube and hose location.
Note: Replace the 1349545 Tube Assembly (Suction) and 4V1878 Hose
with the new 2622013 Tube Assembly (Suction) and 2582140 Hose.
Follow the shape of the 1349545 Tube Assembly for the orientation
of the new 2622013 Tube Assembly
NOTE: Connect the new tube assembly to the hose. Connect the hose
to the pump with 2 2094580 Clamp T-Bolt and 2H6338 Seal. Tighten
Clamp T-Bolt to 7.5Nm +/- 1Nm.
5. Install 2445447 Pump Group and connect new discharge hose. The
1329713 Coupling Assembly and mounting bolts may be reused if in
good condition. Replace 5F3106 O-ring Seal. Refer to Illustration
3 for pump orientation and additional information needed in the
next steps.
Note: Do not install 1540273 Clips to secure steering lines.
These clips will be replaced in step 15.
20/11/2007
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6. Install 6V8625 Elbow, using 3K0360 and 6V8398 seals, into the
2445447 Pump Group bearing drain port.
7. Remove 6V8626 Elbow from steering pump case drain port and
replace with a 6V8776 Tee, using 2M9780 and 7J9108 seals.
8. Install Steering pump using a 2326546 Coupling kit. Use new
9X7371 O-ring Seal between steering pump and 2445447 Pump Group.
Fasten steer pump to 2445447 Pump Group using 6V5686 Bolts with
9X8268 Washers.
9. Connect the 2307549 Hose assembly between the implement pump
bearing drain port and the steering pump case drain port. Connect
existing Steering Pump case drain line to the Tee assembly.
10. Install Pilot and Brake Pump.
11. Refer to Illustration 4 for steps 11 through 15.
12. Remove 1376949 Hose Assembly and replace it with 2398038 Hose
Assembly.
Assembly.
Assembly.
15. Install new 2389105 Bracket Assembly to Implement Pump discharge
port. Refer to Illustration 4.
16. Attach 2398038 Hose Assembly and 2398037 Hose Assembly to new
2389105 Bracket Assembly using (2) 4S4455 Clips. Attach 2389824
Hose Assembly to new bracket assembly using a 7D7233 Clip. Use
(3) 8T4136 Bolts, and (3) 8T4121 Washers to fasten clips to
bracket assembly.
17. Pre-fill the implement, steering, pilot and brake pumps with
recommended hydraulic oil before installing cab. Always use clean
oil when you add oil to the system. Clean oil must be at an ISO
level of at least 16/13.
18. Install Cab. Refer to Disassembly and Assembly, "Cab Install".
Tighten the four cab mounting bolts to a torque of 850 +/- 100
N.m (629 +/- 74 lb. ft.).
19. Replace 1G8878 Hydraulic Oil Filter.
20. Before starting engine, fill hydraulic tank with recommended
hydraulic oil. Always use clean oil when you add oil to the
system. Clean oil must be at an ISO level of at least 16/13.
21. Crank the engine at least five times without starting the engine.
Wait for at least five seconds between cranks in order to allow
the oil to flow smoothly through the system.
22. Check the oil level in the hydraulic tank. If necessary, refill
the tank.
23. Start the engine at low idle. Allow the engine to run for several
seconds. Stop the engine.
the tank.
25. Start engine and maintain low idle. Maintain hydraulic oil level
until it reaches the full mark on hydraulic oil level site gauge.
20/11/2007
Page 8 of 12
26. Cycle, at low idle, the tilt cylinder a minimum of three times.
Do not allow the circuit to go into relief.
the tank.
28. Cycle, at low idle, the lift cylinders a minimum of three times.
Do not allow the circuit to go into relief.
the tank.
30. Cycle, at low idle with frame lock installed, the steering
circuit to a full right and full left turn.
31. Lower lift arms, remove frame lock link, cycle steering to full
right and full left.
32. Check hydraulic oil level and add oil if necessary.
33. Take a Scheduled Oil Sample (SOS). Refer to Contamination Control
Guidelines, SEBF8758. If cleanliness is not at the acceptable ISO
level of 18/15, perform a kidney looping procedure. Use 2047392
Filter Cart for kidney looping in accordance with Contamination
Control Guidelines, SEBF8493.
34. View Image
Illustration 1 - 2385630 Lines GP Hydraulic

Shows Implement Pump discharge hose. Refer to 1194421 Lines GP
Hydraulic for current configuration.
View Image
20/11/2007
Page 9 of 12
Illustration 2 - Location of Isolation Mount to reduce cab

vibration. Refer to Section A - A for detail.
View Image
Section AA - Detail of Isolation Mount

View Image
20/11/2007
Page 10 of 12
Illustration 3 - 2379055 Pump Group

Pump stack mounting information for 966G, 972G Series I and II
machines. Refer to service literature for current configuration.
View Image
20/11/2007
Page 11 of 12
Illustration 4 - Changes to Lines GP Steer

Refer to service literature for current configuration
20/11/2007
Copyright 1993 - 2007 Caterpillar Inc.

All Rights Reserved.
Private Network For SIS Licensees.
Page 12 of 12
Tue Nov 20 12:56:09 UTC+0330 2007
20/11/2007

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Service Information System

Publication Date -09/12/2003

Date Updated -17/03/2005

PRODUCT SUPPORT PROGRAM FOR REPLACING FAILED

Service Information System

Service Information System

1 - 2M9780 Seal - O-Ring

Service Information System

SERVICE CLAIM ALLOWANCES

NOTE: This program pays 10-hours for before

Service Information System

Handle the parts in accordance with your Warranty Bulletin on

Service Information System

Reference: SEBF8493 Contamination Control

Service Information System

Service Information System

Illustration 1 - 2385630 Lines GP Hydraulic

Service Information System

Illustration 2 - Location of Isolation Mount to reduce cab

Section AA - Detail of Isolation Mount

Service Information System

Illustration 3 - 2379055 Pump Group

Service Information System

Illustration 4 - Changes to Lines GP Steer

Service Information System

Copyright 1993 - 2007 Caterpillar Inc.

Tue Nov 20 12:56:09 UTC+0330 2007

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