Carta de Servicio: Before or After Failure

966G Wheel Loader 3ZS00001-00790 (MACHINE) POWERED BY 3306 Engine(...
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Producto: WHEEL LOADER

Modelo: 966G WHEEL LOADER 3ZS
Configuración: 966G Wheel Loader 3ZS00001-00790 (MACHINE) POWERED
BY 3306 Engine
Carta de Servicio
PRODUCT SUPPORT PROGRAM THE REPLACING FAILED IMPLEMENT PUMPS ON
CERTAIN 966G, 966GII, 972G AND 972GII WHEEL LOADERS
Número de medio -SEBE8916-00 Fecha de publicación -27/09/2004 Fecha de actualización -28/09/2004
CONFIDENTIAL
SEBE89160001
SEBE8916
September 27, 2004

U-273
A-190
D-210
O-238
PRODUCT SUPPORT PROGRAM THE REPLACING

before or
FAILED IMPLEMENT PUMPS ON CERTAIN 966G,
after failure 966GII, 972G AND 972GII WHEEL LOADERS
5055 5073 5084 PS41500
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
"PS41500" as the Part number and "7755" as the
Group Number. If administered before failure,
use "56" as the Warranty Claim Description
Code and use "T" as the SIMS Description Code.
If administered after failure, use "96" as the
Warranty Claim Description Code and use "Z" as
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the SIMS Description Code.
NOTE: The information supplied in this service

letter may not be valid after the termination
date of this program. Do not perform the work
outlined in this Service Letter after the
termination date without first contacting your
Caterpillar product analyst.
Termination Date
September 30, 2006
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
966G 3ZS1-Up
3SW1-Up
966G II ANT1-225
ANZ1-741
972G 4WW1-Up
7LS1-Up
972G II ANY1-345
AWP1-296
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
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 - 2389105 Bracket Assembly

1 – 2409980 Plate Assembly
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 Caterpillar Dealer Suggested Customer Suggested
Pump
Hours Labor
Parts Parts Labor Hrs Parts Labor Hrs
Hrs
0-4500 /
100% 25 0 0 0 0
0-36 mo
4501-
9000 /37- 33 1/3% 12.5 0 0 50% 12.5
60 mo
NOTE: This is a 25-hour job.
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
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 the hydraulic fluids and dispose of 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

Assembly – 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".
Remove Implement Pump. Refer to Disassembly and Assembly, "Vane

Pump (Implement) - Remove".
Procedure for returning machine to operating condition

Assembly – 966G Wheel Loader and 972G
Wheel Loader Machine Systems

Assembly – 966G Series II Wheel Loader
and 972G Series II Wheel Loader
Machine Systems
Reference: SENR3130 – Torque

Specifications
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 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. 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 13.
5. Install 6V8625 Elbow, using 3K0360 and 6V8398 seals, into the
2445447 Pump Group bearing drain port.
6. Remove 6V8626 Elbow from steering pump case drain port and
replace with a 6V8776 Tee, using 2M9780 and 7J9108 seals.
7. 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.
8. 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.
9. Install Pilot and Brake Pump.
10. Refer to Illustration 4 for steps 11 through 15.
11. Remove 1376949 Hose Assembly and replace it with 2398038 Hose
Assembly.
Assembly.
Assembly.
14. Install new 2389105 Bracket Assembly to Implement Pump
discharge port. Refer to Illustration 4.
15. 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.
16. 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.
17. 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.).
18. Replace 1G8878 Hydraulic Oil Filter.
19. 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.
20. 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.
21. Check the oil level in the hydraulic tank. If necessary, refill
the tank.
22. Start the engine at low idle. Allow the engine to run for
several seconds. Stop the engine.

the tank.
24. Start engine and maintain low idle. Maintain hydraulic oil
level until it reaches the full mark on hydraulic oil level
site gauge.
25. Cycle, at low idle, the tilt cylinder a minimum of three times.
Do not allow the circuit to go into relief.
the tank.
27. Cycle, at low idle, the lift cylinders a minimum of three
times. Do not allow the circuit to go into relief.
the tank.
29. Cycle, at low idle with frame lock installed, the steering
circuit to a full right and full left turn.
30. Lower lift arms, remove frame lock link, cycle steering to full
right and full left.
31. Check hydraulic oil level and add oil if necessary.
32. 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.
33.
Illustration 1 - 2385630 Lines GP – Hydraulic
Shows Implement Pump discharge hose. Refer to 1194421 Lines GP

– Hydraulic for current configuration.
Illustration 2
Location of Isolation Mount to reduce cab vibration. Refer to

Section A - A for detail.
Section A - A. Detail of Isolation Mount.
966G Wheel Loader 3ZS00001-00790 (MACHINE) POWERED BY 3306 Engin... Página 10 de 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.
Illustration 3 - Changes to Lines GP – Steer
Refer to service literature for current configuration.
Copyright 1993 - 2006 Caterpillar Inc. Tue Apr 11 20:17:55 UTC-0400 2006
Todos los derechos reservados.
Red privada para licenciados del SIS.

Carta de Servicio: Before or After Failure

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Carta de Servicio: Before or After Failure

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966G Wheel Loader 3ZS00001-00790 (MACHINE) POWERED BY 3306 Engine(...

Producto: WHEEL LOADER

September 27, 2004

PRODUCT SUPPORT PROGRAM THE REPLACING

5055 5073 5084 PS41500

NOTE: This Program can be administered either

the SIMS Description Code.

NOTE: The information supplied in this service

1 - 5F3106 Seal - O-Ring

1 - 7J9108 Seal - O-Ring

1 - 3K0360 Seal - O-Ring

1 - 2M9780 Seal - O-Ring

3 - 8T4121 Washer - Hard

1 - 6V8398 Seal - O-Ring

1 - 6V8625 Elbow - 90 Degrees

1 - 6V8776 Tee - Face Seal

1 - 9X7371 Seal - O-Ring

1 - 2307549 Hose Assembly

1 - 2326546 Coupling Kit

1 - 2384936 Hose Assembly

1 - 2389105 Bracket Assembly

1 - 2389824 Hose Assembly

1 - 2398037 Hose Assembly

1 - 2398038 Hose Assembly

1 – 2413424 Block Assembly

2 – 2432076 Washer - Hard

1 - 2445447 Pump Group

SERVICE CLAIM ALLOWANCES

NOTE: This is a 25-hour job.

NOTE: To compensate for machines that have

Note: If a failure of the implement pump has

Remove the hydraulic fluids and dispose of in accordance with local

Procedure for removing implement pump from vehicle

Reference: RENR2116 – Disassembly and

Reference: RENR4366 – Disassembly and

1. Remove cab. Refer to Disassembly and Assembly, "Cab - Remove –

Remove Implement Pump. Refer to Disassembly and Assembly, "Vane

Procedure for returning machine to operating condition

Reference: RENR2116 – Disassembly and

Reference: RENR4366 – Disassembly and

Reference: SENR3130 – Torque

Reference: SEBF8493 – Contamination

Reference: SEBU6250 – Caterpillar

1. Remove 1354626 Pump Discharge Hose Assembly. Refer to

Note: Refer to Illustration 2 and Section A – A.

3. Replace the 1354626 pump discharge hose with a 2384936 Hose

Note: The 5P3099 short drop coupling must be attached to the

in good condition. Replace 5F3106 O-ring Seal. Refer to

Note: Do not install 1540273 Clips to secure steering lines.

several seconds. Stop the engine.

Illustration 1 - 2385630 Lines GP – Hydraulic

Shows Implement Pump discharge hose. Refer to 1194421 Lines GP

Location of Isolation Mount to reduce cab vibration. Refer to

Section A - A. Detail of Isolation Mount.

Illustration 3 - 2379055 Pump Group

Pump stack mounting information for 966G, 972G Series I and II

Illustration 3 - Changes to Lines GP – Steer

Refer to service literature for current configuration.

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