Cat 966gii HL

Installation Manual
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1. Preface - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5
1.1. General information - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6
1.2. Use of symbols - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7
1.3. Safety precautions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8
1.4. General fitting instructions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8
2. System lay-out - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9
2.1.1. F 170951 Twin 18-port block, excl. tubing - - - - - - - - - - - - - - - - - - - - - 14
2.1.2. F 171251 Twin 18-port block, stainless steel and excl. tubing - - - - - - - 16
2.2.1. F 170954 Twin 6+6-port block, excl. tubing - - - - - - - - - - - - - - - - - - - - 18
2.2.2. F 171526 Twin 6+6-port block, stainless steel and excl. tubing - - - - - - 19
2.3.1. F 170745 Twin 18-port block, complete - - - - - - - - - - - - - - - - - - - - - - - 20
2.3.2. F 170995 Twin 18-port block, stainless steel, complete - - - - - - - - - - - - 22
2.4.1. F 171529 Twin 6+6-port block, complete - - - - - - - - - - - - - - - - - - - - - - 24
2.4.2. F 170997 Twin 6+6-port block, stainless steel, complete - - - - - - - - - - - 26
3. Grease point location - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 29
4. Drilling activities - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 33
5. Welding activities - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 39
6. Grease pump installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 55

6.1. F 170746 Twin pumpkit Caterpillar 966 / 972 G II - - - - - - - - - - - - - - - 56
7. Electrical components - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 59
8. Distribution blocks - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 65
8.1.1. F 170747 Installation kit 18-port block / F 170745 B1 - - - - - - - - - - - - - 66
8.1.2. F 171001 Installation kit 18-port block / F 170995 SST B1 - - - - - - - - - 68
8.2.1. F 171531 Installation kit 6+6-port block / F 171529 B2 - - - - - - - - - - - 72
8.2.2. F 171003 Installation kit 6+6-port block / F 170997 SST B2 - - - - - - - - 74
9. Installation main line - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 79

9.1.1. F 171535 Twin Main line kit Caterpillar 966 / 972 G II - - - - - - - - - - - - - 80
9.1.2. F 171536 Main line kit Caterpillar 966 / 972 G II Stainless steel - - - - - - 80
10. After market kit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 85

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10.1.1. F 172038 After market kit Caterpillar 966G II / 972G II - - - - - - - - - - - - 86

10.1.2. F 172048 After market kit Caterpillar 966G II / 972G II Stainless Steel - 88
11. Parameter settings - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 91
12. Testing of the system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 93
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This installation manual describes the mounting of the Twin-system on the
Caterpillar Wheel Loader type 966G II High Lift and 972G II Standard / High Lift.
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For starting installation, carry out the following tasks:
• Remove ignition key to prevent engine from starting while you are working.
• Block all moving parts, like lifting frames, breaking points and mast parts.
• Block the wheels.
• Follow machine manufacturer’s guidelines for general safety and precautions.
During activities that require a lifting jack:

• The machine should not rest on the lifting jack solely. Use additional support.
General:
• Always keep your work area clean.
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Before
• Check if all the parts of the Twin-system are present by using the parts list.
• Check if all the grease points are open and provided with grease. Lubricate
the grease points if there is not sufficient grease. This way damage due to
insufficient grease is prevented.
During installation
• Prevent dirt from entering the system during installation.
• Use clean tools.
• Clean the machine at points, where the pump and the distribution blocks
have to be installed. Even small pollution can cause failure of the system!
• Even if stud couplings or plugs are not provided with an O-ring sealing or
sealing ring, use teflon tape or a liquid sealing agent.
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Kitnumbers F 170586, F 170588 and F 170590 for the Caterpillar 966G II High Lift
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Kitnumbers F 170587, F 170589 and F 170591 for the Caterpillar 966G II High Lift
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Kitnumber F 172039 (after market kit) for the Caterpillar 966G II High Lift and the
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Kitnumber F 171502 (after market kit) for the Caterpillar 966G II High Lift and the
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NR NIVã TTPMN NSNJVMPM m^=íìÄÉ=N=ñ=›S=ãã=ñ=NIR=éÉê=ãíê
NS NIPã TTPMN NSNJVMPM m^=íìÄÉ=N=ñ=›S=ãã=ñ=NIR=éÉê=ãíê
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NR NIVã TTPMN NSNJVMPM m^=íìÄÉ=N=ñ=›S=ãã=ñ=NIR=éÉê=ãíê
NS NIPã TTPMN NSNJVMPM m^=íìÄÉ=N=ñ=›S=ãã=ñ=NIR=éÉê=ãíê
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NR N QPNOO NTUJOTNR jÉíÉêáåÖ=ìåáí=åçKV=J=NKMMMÅÅLjOOLSããLppq
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• Wear safety goggles.
• Make sure there are no vital parts behind the hole to be drilled.
aêáää
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• Ask the workshop manager whether welding is allowed in this room
• Disconnect the earthing cable from the battery or remove the earthing key.
• Disconnect any computors present. In case of doubt, always refer to the
supplier of the machine.
• Wear welding goggles and overalls.
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Consumption metering units each cycle : 8,4 cc
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• Remove the end-plugs out of the distributions blocks.
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• Start the pump manually with the Gina; leave the 5/2 magnet valve non-
excited (exit A).
• Close the distribution blocks with an end-plug as soon as main pipe (A) is
completely clear of air and dirt.
• Stop the pump.
• Remove main pipe A.
aÉJ~Éê~íÉ=éáéÉ=_
• Mount main pipe (B) on exit A of the pump.
• Start the pump manually with the Gina; leave the 5/2 magnet valve non-
excited (exit A).
• Close the distribution blocks with an end-plug as soon as main pipe (B) is
completely clear of air and dirt.
• Stop the pump.
• Connect main pipe (B) to exit B and main pipe (A) to exit A.
^ÅÅÉäÉê~íÉÇ=íÉëí
• Start an accelerated test by means of the test button on the pump or with the
GINA.
• Check the main pipe for leakage.
• Check if all the grease points are provided with grease.
• Terminate the accelerated test by switching off the ignition.
• Switch the machine back on.

• Operate the machine in all positions and check if all the parts of the Twin-
lubrication have enough tolerance and do not jam or scrape.
• Check the timer settings by means of the GINA (if available).
• Shut the machine down. a~íÉ=çÑ=áëëìÉW=aÉÅÉãÄÉê=OMMN
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Cat 966gii HL

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Cat 966gii HL

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Installation Manual

3. Grease point location - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 29

6. Grease pump installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 55

9. Installation main line - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 79

10. After market kit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 85

10.1.1. F 172038 After market kit Caterpillar 966G II / 972G II - - - - - - - - - - - - 86

11. Parameter settings - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 91

12. Testing of the system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 93

j~ÅÜáåÉ=íóéÉ kìãÄÉê= dêçÉåÉîÉäÇ= `~íÉêéáää~ê= ^ÑíÉê= j~åì~ä==

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T N SSRMN NTTJPRNV mêÉëëìêÉ=ëïáíÅÜ=NRM=Ä~ê==_o

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NN N UPTMN NTUJOTQV oÉÇìÅíáçå=~Ç~éíçê=jOOJNLQ=pKlK==_o

NO N UPUMN NTUJOTRM oÉÇìÅíáçå=~Ç~éíçê=jOOJNLQ=_KlK==_o

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