Installation of Automatic Lubrication for the 966G and the 972G Wheel Loaders{7540} Caterpillar

Wheel Loader:

966G (S/N: 3SW1-UP; 3ZS1-UP)

972G (S/N: 4WW1-UP; 7LS1-UP)

Introduction

Note: The following Information is contained in this publication:

(1.) Field installation of the 2Q-8581 Automatic Lubrication Gp (Kit) for the 966G Wheel Loader and the 972G Wheel Loader

(2.) Installation of the 2Q-8364 Automatic Lubrication Ar for the 966G

(3.) Installation of the 2Q-8404 Automatic Lubrication Ar for the 972G

A complete listing of the parts that are contained in the kit is listed in the Parts Manual, SEBC1327. This supplemental product support literature should be used with the appropriate Service Manual that is available for this standard machine.

Do not perform any procedure and do not order parts that are outlined in this publication until you understand the information that is contained in this document.

Reference: Operation and Maintenance Manual, SEBC6978, "Machine Parking"

Note: For further information, refer to the operator Manual from Lincoln Industrial. Form number 402724.

Show/hide table

Personal injury or death can result from fumes, gases and ultraviolet rays from the weld arc. Welding can cause fumes, burn skin and produce ultraviolet rays. Keep your head out of the fumes. Use ventilation, exhaust at the arc, or both, to keep fumes and gases from your breathing area. Wear eye, ear and body protection before working. Protect yourself and others; read and understand this warning. Fumes and gases can be dangerous to your health. Ultraviolet rays from the weld arc can injure eyes and burn skin. Electric shock can cause death. Read and understand the manufacturer's instructions and your employer's safety practices. Do not touch live electrical parts. See "American National Standard Z49.1, Safety in Welding and Cutting" published by the American Welding Society. American Welding Society 2501 N.W. 7th Street Miami, Florida 33125 See "OSHA Safety and Health Standards, 29 CFR 1910", available from U.S. Department of Labor. U.S. Department of Labor Washington, D.C. 20210

Removal of the 119-4394 Grease Lines Group

Illustration 1	g00829734
Partial view of frame (A) 119-4394 Grease Lines Group

1. Remove the 119-4394 Grease Lines Group (A) .

Removal of 4V-7099 Pin As and Installation of 177-2323 Pin As

Illustration 2	g00829857
Partial right side view of bucket control linkage (B) 4V-7099 Pin As

1. Remove the 4V-7099 Pin As (B) .

2. Install the 177-2323 Pin As in place of the 4V-7099 Pin As (B) .

Removal of the 164-0793 Bracket and Installation of the 070-0299 Bracket

Illustration 3	g00829867
Partial view of right side of rear frame and loader frame

1. Remove the existing bracket. Save existing hardware.

2. Use original hardware and install the 070-0299 Bracket (7) in the place of the original bracket.

Installation of welded hardware on the 070-0444 Lever and Bearing

Illustration 4	g00830466
Right side view of lever assembly (A) 50 mm (1.96 inch) (B) 193 mm (7.59 inch) (C) 5° ± 2° (D) 675.5 mm (26.59 inch) (E) 280 mm (11.02 inch) (F) 100 mm (3.93 inch) (G) 430 mm (16.92 inch) (H) 450 mm (17.71 inch) (J) 24° ± 2° (K) 155 mm (6.10 inch) (L) 872.5 mm (34.35 inch) (M) 17 mm (0.66 inch) (N) 178 mm (7.00 inch)

This illustration shows all of the location dimensions for the welded parts on the 070-0444 Lever and Bearing .

Locate the following parts and weld the following parts onto the Lever and Bearing:

• Two 2R-1920 Blocks (1)

• One 171-8862 Block (2)

• Two 110-2023 Weld Studs (3)

Installation of welded hardware on the 070-0443 Arm As for the 966G

Illustration 5	g00870309
Right side and top views of arm assembly (C) 236 ± 4 mm (9.2913 ± 0.1575 inch) (D) 556 ± 4 mm (21.8897 ± 0.1575 inch) (E) 36 ± 3 mm (1.4173 ± 0.1181 inch) (F) 58 ± 3 mm (2.2835 ± 0.1181 inch) (G) 140 ± 4 mm (5.5118 ± 0.1575 inch) (H) 128 ± 3 mm (5.0394 ± 0.1181 inch) (J) 9° ±2° (K) 746 ± 4 mm (29.3700 ± 0.1575 inch) (L) 575 ± 4 mm (22.6378 ± 0.1575 inch) (M) 341 ± 3 mm (13.42 ± 0.12 inch) (N) 112 ± 3 mm (4.41 ± 0.12 inch) (P) 200 ± 6 mm (7.87 ± 0.24 inch) (R) 200 ± 6 mm (7.87 ± 0.24 inch) (S) 1367 ± 6 mm (53.82 ± 0.24 inch) (T) 70 ± 6 mm (2.75 ± 0.24 inch) (V) 224 ± 6 mm (8.82 ± 0.24 inch) (X) 80 ± 3 mm (3.15 ± 0.12 inch) (Y) 26 ± 3 mm (1.02 ± 0.12 inch) (Z) 12 ± 3 mm (0.47 ± 0.12 inch) (CC) 1813 ± 3 mm (71.38 ± 0.12 inch) (DD) 2184 ± 3 mm (85.98 ± 0.12 inch) (EE) 2283 ± 3 mm (89.88 ± 0.12 inch) (FF) 2675 ± 3 mm (105.31 ± 0.12 inch) (GG) 46 ± 3 mm (1.81 ± 0.12 inch)

This illustration shows all of the location dimensions for the welded parts on the 070-0443 Arm As .

1. Locate the following parts and weld the following parts onto the Lever and Bearing:
   • One 2R-1920 Block (1)

   • One 171-8862 Block (3)

   • One 7X-0752 Weld Boss (4)

   • Five 8T-3851 Boss (5)

   • One 8T-4967 Weld Stud (6)

   • Eight 8T-6462 Weld Boss (7)

Installation of welded hardware on the 070-0625 Arm As for the 972G

Illustration 6	g00831097
Right side view of arm assembly (X) 1374 ± 6 mm (54.09 ± 0.23 inch) (Y) 1475 ± 6 mm (58.07 ± 0.23 inch) (Z) 1934 ± 3 mm (76.14 ± 0.11 inch) (AA) 2308 ± 3 mm (90.86 ± 0.11 inch) (BB) 2409 ± 3 mm (94.84 ± 0.11 inch) (CC) 2803 ± 4 mm (110.35 ± 0.15 inch) (DD) 49 ± 4 mm (1.92 ± 0.15 inch) (EE) 11 ± 3 mm (0.43 ± 0.11 inch) (FF) 2 ± 3 mm (0.07 ± 0.11 inch) (GG) 34 ± 3 mm (1.33 ± 0.11 inch) (HH) 80 ± 6 mm (3.14 ± 0.23 inch) (JJ) 386 ± 6 mm (15.19 ± 0.23 inch) (KK) 1729 ± 6 mm (68.07 ± 0.23 inch)

Illustration 7	g00831035
Top view of arm assembly (V) 200 ± 6 mm (7.87 ± 0.23 inch) (W) 200 ± 6 mm (7.87 ± 0.23 inch)

Illustration 8	g00830464
Section A-A of Illustration 7 (A) 58 ± 3 mm (2.28 ± 0.11 inch) (B) 123 ± 3 mm (4.84 ± 0.11 inch) (C) 153 ± 4 mm (6.023 ± 0.15 inch) (D) 312 ± 3 mm (12.28 ± 0.11 inch) (E) 586 ± 4 mm (23.07 ± 0.15 inch) (F) 897 ± 3 mm (35.31 ± 0.11 inch) (G) 925 ± 3 mm (36.41 ± 0.11 inch) (H) 1011 ± 3 mm (39.80 ± 0.11 inch) (J) 1427 ± 3 mm (56.18 ± 0.11 inch) (K) 1033 ± 3 mm (40.66 ± 0.11 inch) (L) 1014 ± 3 mm (39.92 ± 0.11 inch) (M) 107 ± 3 mm (4.21 ± 0.11 inch) (N) 148 ± 3 mm (5.82 ± 0.11 inch) (P) 319 ± 3 mm (12.55 ± 0.11 inch) (R) 953 ± 3 mm (37.51 ± 0.11 inch)

These illustrations show all of the location dimensions for the welded parts on the 070-0625 Arm As .

Locate the following parts and weld the following parts onto the Lever and Bearing:

• One 2R-1920 Block (1)

• One 171-8862 Block (2)

• Six 8T-3851 Boss (3)

• One 8T-4967 Weld Stud (4)

• Eight 8T-6462 Weld Boss (5)

Installation of the 189-7985 Loader Frame Hardware Gp (Automatic Lubrication)

Illustration 9	g00830460
Rear view of loader frame (Y) 290 ± 3 mm (11.42 ± 0.1181 inch) (Z) 10 mm (0.39 inch)

Illustration 10	g00831362
Section views of Illustration 9 (F) 818 ± 3 mm (32.20 ± 0.11 inch) (G) 736 ± 3 mm (28.97 ± 0.11 inch) (H) 304 ± 3 mm (11.9685 ± 0.11 inch) (J) 304 ± 3 mm (11.9685 ± 0.11 inch) (K) 568 ± 3 mm (22.3622 ± 0.11 inch) (L) 355 ± 3 mm (13.9764 ± 0.11 inch) (M) 135 ± 3 mm (5.31 ± 0.11 inch) (P) 425 ± 3 mm (16.73 ± 0.11 inch) (Q) 995 ± 3 mm (39.17 ± 0.11 inch) (S) 115 ± 3 mm (4.5276 ± 0.1181 inch) (T) 305 ± 3 mm (12.00 ± 0.11 inch) (U) 355 ± 3 mm (13.9764 ± 0.11 inch) (V) 568 ± 3 mm (22.36 ± 0.11 inch) (W) 39 ± 3 mm (1.53 ± 0.11 inch) (X) 685 ± 3 mm (26.96 ± 0.11 inch)

These illustrations show all of the location dimensions for the welded parts on the loader frame.

Locate the following parts and weld the following parts onto the loader frame:

• One 171-8862 Block (1)

• Seven 8T-4967 Weld Studs (2)

• Two 110-2023 Weld Studs (3)

Installation of the 189-7984 Rear Frame Hardware

Illustration 11	g00830637
Front view of rear frame (E) 1016 ± 3 mm (39.99 ± 0.11 inch) (F) 35 ± 2 mm (1.37 ± 0.07 inch) (G) 10 ± 2 mm (0.39 ± 0.07 inch) (R) 46 ± 3 mm (1.81 ± 0.11 inch) (S) 9 ± 2 mm (0.35 ± 0.08 inch) (T) 56 ± 2 mm (2.20 ± 0.08 inch) (U) 57 ± 3 mm (2.24 ± 0.11 inch) (X) 225 ± 3 mm (8.86 ± 0.11 inch)

Illustration 12	g00829893
Section views from Illustration 11 (H) 192 ± 3 mm (7.55 ± 0.11 inch) (J) 190 ± 3 mm (7.48 ± 0.11 inch) (K) 40 ± 3 mm (1.57 ± 0.11 inch) (L) 25 ± 3 mm (0.98 ± 0.11 inch) (M) 133 ± 3 mm (5.23 ± 0.11 inch) (N) 54 ± 3 mm (2.12 ± 0.11 inch) (P) 59 ± 3 mm (2.32 ± 0.11 inch)

These illustrations show all of the location dimensions for the welded parts on the rear frame.

Locate the following parts and weld the following parts onto the rear frame:

• One 171-8862 Block (1)

• One 110-2023 Weld Stud (2)

• Two 7X-0752 Weld Boss (3)

• Two 8T-4219 Weld Studs (4)

• One 8T-4967 Weld Stud (5)

• One 8T-3851 Weld Boss (6)

Installation of Lube Distribution Valves

Installation of 177-4689 Lubrication Distribution Valve Gp for the 189-8168 Lubrication Valve and Lines Gp

Illustration 13	g00831803
Partial view of right side of rear frame and loader frame

1. Use the following hardware to install the 177-4689 Lube Distribution Valve (34) .
   • Two 7X-2534 Bolts (16)

   • Two 9X-8256 Washers (24)

Installation of 177-4688 Lubrication Distribution Valve Gp for the 183-5430 Lubrication Lines Gp

Illustration 14	g00832522
Partial top view of rear frame and loader frame

1. Use the following hardware to install 189-7939 Bracket (10) :
   • Two 8T-4121 Hard Washers (18)

   • Two 8T-4133 Nuts (19)

2. Use the following hardware to install 177-4688 Control Valve (40) :
   • Two 5C-2890 Nuts (14)

   • Two 7X-2534 Bolts (16)

   • Four 9X-8256 Washers (24)

Installation of 183-2348 Lubrication Distribution Valve Gp for the 183-5431 Lubrication Lines Gp

Illustration 15	g00832674
View of right side of loader frame

1. Use the following hardware to install the 183-2348 Control Valve (16) :
   • Two 7X-2534 Bolt (6)

   • Two 9X-8256 Washer (12)

2. Install one 4M-8973 Elbow (26) onto the top of the 183-2348 Control Valve (16) .

Installation of the 171-8873 Lubrication Distribution Valve Gp for the 183-5432 Lubrication Lines Gp and the 183-5433 Lubrication Lines Gp on the 966G

Illustration 16	g00870659
View of right side of arm assembly

1. Use the following hardware to install two 171-8873 Lube Distribution Valves (36) :
   • Four 7X-2534 Bolts (25)

   • Four 9X-8256 Washers (34)

Installation of 171-8873 Lubrication Distribution Valve Gp for the 189-8008 Lubrication Lines Gp and the 070-0646 Lubrication Lines Gp on the 972G

Illustration 17	g00832786
View of right side of arm assembly

1. Use the following hardware to install two 171-8873 Lube Distribution Valves (37) :
   • Four 7X-2534 Bolts (27)

   • Four 9X-8256 Washers (35)

Installation of 189-7931 Automatic Lubrication Lines Gp

Illustration 18	g00831685
Overall view of 189-7931 Automatic Lubrication Lines Gp (A) 189-8168 Lubrication Valve and Lines Gp (B) 183-5430 Lubrication Lines Gp

Installation of 171-8823 Grease Tank

Illustration 19	g00831710
Right side view of tank

1. Refer to Illustration 19. Use the following hardware to install the 171-8823 Grease Tank (7) onto the 070-0299 Bracket :
   • Three 6V-9189 Locknuts (15)

   • Three 7X-2537 Bolts (17)

   • Six 8T-4224 Hard Washers (22)

Installation of 172-6302 Lubrication Lines Gp

Illustration 20	g00832149
Partial view of right side of rear frame and loader frame

See the following list for the part that is serviced by each injector:

Number 1: 189-8007 Lubrication Lines Gp (Right Hand)

Number 2: 189-8007 Lubrication Lines Gp (Left Hand)

Number 3: Closed

Number 4: Closed

Number 5: Closed

Number 6: 183-5431 Lubrication Lines Gp

Number 7: 183-5430 Lubrication Lines Gp

Number 8: Closed

Number 9: Closed

Number 10: Closed

1. Connect one end of 183-5379 Hose As (26) onto the 171-8823 Grease Tank (7) .

2. Connect the other end of 183-5379 Hose As (26) onto the top of 177-4689 Lube Distribution Valve (34). Use two 4D-7794 Clips (12) to secure the 183-5379 Hose As (26) .

3. Install one 3B-6552 Elbow (32) into the number seven injector of the 177-4689 Lube Distribution Valve (34) .

4. Connect one end of 183-5380 Hose As (27) onto the 3B-6552 Elbow (32) .

5. Connect the other end of 183-5380 Hose As (27) onto the tee on the top of 177-4688 Lube Distribution Valve . Refer to Illustration 14. Use three 4D-7794 Clips (12) to secure the 183-5380 Hose As (27) .

6. Install one 4M-8973 Elbow (33) onto the number six injector of 177-4689 Lube Distribution Valve (34) .

7. Connect one end of 189-8170 Hose As (30) onto the 4M-8973 Elbow (33) .

8. Use a 4M-8973 Elbow (13) and a 4K-3026 Extension (41) in order to connect the other end of 189-8170 Hose As (30) onto the tee on the top of 183-2348 Lube Distribution Valve (34). Refer to Illustration 15.

9. Install one 4M-8973 Elbow (33) onto the number one injector of 177-4689 Lube Distribution Valve (34) .

10. Connect one end of 183-5442 Hose As (28) onto the 4M-8973 Elbow (33) .

11. Install one 3B-6487 Coupling (31) into the other end of 183-5442 Hose As (28) .

12. Install one 4M-8973 Elbow (33) onto the number two injector that is part of the 177-4689 Lube Distribution Valve (34) .

13. Connect one end of 189-8169 Hose As (29) onto the 4M-8973 Elbow (33) .

14. Install one 3B-6487 Coupling (31) into the other end of 183-5382 Hose As (29) .

15. Route the 183-5442 Hose As (28) and the 189-8169 Hose As (29). Refer to Illustration 20. These hoses will be connected in a later step.

16. Refer to Illustration 20. Use the following hardware to secure the four hoses that are connected to the injectors that are on the 177-4689 Lube Distribution Valve (34) :
    • One 4D-7794 Clip (12)

    • One 8T-4121 Hard Washer (18)

    • One 8T-4133 Nut (19)

17. Use the following hardware to secure the 183-5442 Hose As (28) and the 189-8169 Hose As (29) to the loader frame:
    • One 124-3019 Bracket (3)

    • One 154-6626 Bracket (5)

    • Two 4D-7794 Clips (12)

    • Five 8T-4121 Hard Washers (18)

    • One 8T-4136 Bolt (20)

    • Four 8T-4137 Bolts (21)

    • Three 9M-8406 (23)

Installation of 183-5430 Lubrication Lines Gp

Illustration 21	g00833302
Top view of rear frame and loader frame

Illustration 22	g00833403
Section views from Illustration 21

See the following list for the part that is serviced by each injector:

Number 1: Rear trunnion for the rear axle

Number 2: Right steering cylinder

Number 3: Lower hitch pin

Number 4: Left steering cylinder

Number 5: Closed

Number 6: Front trunnion for the rear axle

1. Connect one end of 183-5509 Hose As (35) onto the number three injector that is part of the 177-4688 Lube Distribution Valve (40) .

2. Install a 4M-8973 Elbow (13) into the lower hitch pin.

3. Connect the other end of 183-5509 Hose As (35) onto the 4M-8973 Elbow (13) .

4. Refer to section "L-L" in Illustration 21. Use the following hardware to secure 183-5509 Hose As (35) :
   • One 124-3019 Bracket (3)

   • One 4D-7794 Clip (12)

   • Two 8T-4121 Hard Washers (18)

   • One 8T-4133 Nut (19)

   • One 8T-4137 Bolt (21)

5. Connect one end of 183-5510 Hose As (36) onto the number four injector that is part of the 177-4688 Lube Distribution Valve (40) .

6. Install 140-1650 Tube As (4) .

7. Install a 5K-9979 Flared Connector (1) onto the straight end of 140-1650 Tube As (4) .

8. Connect the other end of 183-5510 Hose As (36) onto the 5K-9979 Flared Connector (1) .

9. Install a 9S-7712 Flared Elbow (2) onto the other end of the 140-1650 Tube As (4) .

10. Connect the end of 155-3163 Hose As (6) with the single nut onto the 9S-7712 Flared Elbow (2) .

11. Connect the other end of 155-3163 Hose As (6) onto the lower hitch pin.

12. Refer to Section "A-A" in Illustration 21. Use the following hardware to secure the 140-1650 Tube As (4) :
    • One 2B-2404 Clip (11)

    • One 8T-4121 Hard Washer (18)

    • One 8T-4137 Bolt (21)

13. Connect one end of 183-5511 Hose As (37) onto the number six injector that is part of the 177-4688 Lube Distribution Valve (40) .

14. Install a 3B-6552 Elbow (32) onto the front trunnion that is part of the rear axle .

15. Connect the other end of 183-5511 Hose As (37) onto the 3B-6552 Elbow (32) .

16. Refer to Section "G-G" in Illustration 21. Use the following hardware in order to secure the 183-5510 Hose As (36) and the 183-5511 Hose As (37) :
    • One 4D-7794 Clip (12)

    • One 8T-4121 Hard Washer (18)

    • One 8T-4137 Bolt (21)

    • One 9X-8582 Clip (25)

17. Connect one end of 183-5512 Hose As (38) onto the number two injector that is part of the 177-4688 Lube Distribution Valve (40) .

18. Install a 4M-8973 Elbow (13) onto the right steering cylinder.

19. Connect the other end of 183-5512 Hose As (38) onto the 4M-8973 Elbow (13) .

20. Connect one end of 189-8048 Hose As (39) onto the number one injector that is part of the 177-4688 Lube Distribution Valve (40) .

21. Connect the other end of the 189-8048 Hose As (39) onto the rear trunnion.

22. Refer to Section "J-J" in Illustration 21. Use the following hardware to secure the hoses to the frame:
    • Three 4D-7794 Clips (12)

    • Three 8T-4121 Hard Washers (18)

    • Two 8T-4133 Nuts (19)

    • One 8T-4137 Bolt (21)

23. In Illustration 21, refer to the following Sections:"E-E", "F-F" and "M-M":

24. Use the following hardware to secure the hoses to the frame:
    • One 4D-7794 Clip (12)

    • Two 8T-4121 Hard Washers (18)

    • Two 8T-4137 Bolts (21)

    • One 9M-8406 Clip (23)

Installation of 189-7930 Automatic Lubrication Lines Gp

Illustration 23	g00833934
Overall view of 189-7930 Automatic Lubrication Lines Gp

Installation of the 183-5431 Lubrication Lines Gp

Illustration 24	g00834002
Partial rear view of loader frame

Illustration 25	g00833947
Partial top view of rear frame and loader frame

See the following list for the part that is serviced by each injector:

Number 1: Left steering cylinder

Number 2: Right steering cylinder

Number 3: Left lift cylinder

Number 4: Right lift cylinder

Number 5: Tilt cylinder

Number 6: Upper hitch

Number 7: Closed

Number 8: Closed

Number 9: Left lift arm

Number 10: Right lift arm

Number 11: Closed

Number 12: Closed

1. Connect one end of 183-5814 Hose As (18) onto the number one injector that is part of the 183-2348 Lube Distribution Valve (16) .

2. Install a 3B-6552 Elbow (25) into the left steering cylinder.

3. Connect the other end of 183-5814 Hose As (18) onto the 3B-6552 Elbow (25) .

4. Connect one end of 183-5815 Hose As (19) onto the number three injector that is part of the 183-2348 Lube Distribution Valve (16) .

5. Install a 8B-4884 Elbow (27) onto a 3B-7734 Pipe Nipple (4) .

6. Install the 3B-7734 Pipe Nipple (4) into the left lift cylinder.

7. Connect the other end of 183-5815 Hose As (19) onto the 8B-4884 Elbow (27) .

8. Use the following hardware in order to secure the 183-5814 Hose As (18) and the 183-5815 Hose As (19) :
   • One 160-1744 Bracket (2)

   • Three 4D-7794 Clips (5)

   • Eight 8T-4121 Hard Washers (9)

   • Six 8T-4133 Nuts (10)

   • One 8T-4136 Bolt (11)

   • One 8T-4195 Bolt (12)

   • Two 9X-8582 Clips (15)

9. Connect one end of 183-5819 Hose As (22) onto the number five injector that is part of the 183-2348 Lube Distribution Valve (16) .

10. Install a 3B-6552 Elbow (25) into the tilt cylinder.

11. Connect the other end of 183-5819 Hose As (22) onto the 3B-6552 Elbow (25) .

12. Connect one end of 187-1666 Hose As (24) onto the number nine injector that is part of the 183-2348 Lube Distribution Valve (16) .

13. Connect the other end of 187-1666 Hose As (24) onto the left lift arm.

14. Use the following hardware in order to secure the 183-5819 Hose As (22) and the 187-1666 Hose As (24) :
    • Two 9X-8582 Clips (15)

15. Connect one end of 183-5820 Hose As (23) onto the number ten injector that is part of the 183-2348 Lube Distribution Valve (16) .

16. Connect the other end of 188-5820 Hose As (23) onto the right lift arm.

17. Use the following hardware to secure the 183-5820 Hose As (23) :
    • One 147-3150 Angle (1)

    • Two 4D-7794 Clips (5)

    • One 8T-4121 Hard Washer (9)

    • One 8T-4133 Nut (10)

18. Connect the end of 183-5813 Hose As (17) with the single nut onto the number six injector that is part of the 183-2348 Lube Distribution Valve (16) .

19. Connect the other end of 183-5813 Hose As (17) onto the upper hitch.

20. Use the following hardware to secure the 183-5813 Hose As (17) :
    • One 4D-7794 Clips (5)

    • One 6V-3265 Clip (6)

    • One 8T-4121 Hard Washers (9)

    • One 8T-4133 Nuts (10)

21. Connect one end of 183-5817 Hose As (20) onto the number four injector that is part of the 183-2348 Lube Distribution Valve (16) .

22. Install a 8B-4884 Elbow (27) onto a 3B-7734 Pipe Nipple (4) .

23. Install the 3B-7734 Pipe Nipple (4) into the right lift cylinder.

24. Connect the other end of 183-5817 Hose As (20) onto the 8B-4884 Elbow (27) .

25. Connect one end of 183-5818 Hose As (21) onto the number two injector that is part of the 183-2348 Lube Distribution Valve (16) .

26. Install a 3B-6552 Elbow (25) onto the right steering cylinder.

27. Connect the other end of 183-5818 Hose As (21) onto the 3B-6552 Elbow (25) .

28. Use the following hardware to secure the following hoses: 183-5813 Hose As (17), 183-5817 Hose As (20) and 183-5818 Hose As (21) :
    • One 160-1744 Bracket (2)

    • Four 4D-7794 Clips (5)

    • Eight 8T-4121 Hard Washers (9)

    • Six 8T-4133 Nuts (10)

    • One 8T-4136 Bolt (11)

    • One 8T-4195 Bolt (12)

    • Two 9X-8582 Clips (15)

Installation of 183-2346 Automatic Lubrication Lines Gp for the 966G

Illustration 26	g00870637
Overall view of 183-2346 Automatic Lubrication Lines Gp (9) 183-5432 Lubrication Lines Gp (B Pins and Lift Cylinders) (10) 183-5433 Lubrication Lines Gp (Link Pins, Tilt Cylinder, Bellcrank) (12) 189-7986 Lubrication Lines Gp (Lift Arm)

Illustration 27	g00870980
Top view of loader frame

Illustration 28	g00871002
View of Section "C-C" in Illustration 27

1. Install a 6L-3616 Flared Connector (2) into the right hand "B" pin.

2. Install the following parts: a 183-5392 Tube As (8), a 183-7820 Guard (11) and a 189-7993 Guard (14). Use the following hardware:
   • Four 2B-2404 Clips (17)

   • Four 8T-4121 Hard Washers (28)

   • Four 8T-4136 Bolts (30)

3. Install a 6L-3616 Flared Connector (2) into the left hand "B" pin.

4. Install the following parts: a 183-5391 Tube As (7), a 183-7820 Guard (11) and a 189-7992 Guard (13). Use the following hardware:
   • Four 2B-2404 Clips (17)

   • Four 8T-4121 Hard Washers (28)

   • Four 8T-4136 Bolts (30)

Installation of the 189-7986 Lubrication Lines Gp (Lift Arm) for the 966G

Illustration 29	g00871063
View of the 189-7986 Lubrication Lines Gp (W) Mounting block

1. Connect one end of 189-7553 Hose As (43) onto one of the 3B-6487 Couplings (31) that are shown in Section "N-N" in Illustration 20.

2. Connect the other end of 189-7553 Hose As (43) onto mounting block (W) .

3. Install a 4M-8973 Elbow (21) into block (W) .

4. Connect the end of the 189-7983 Hose As (41) without the hose guard onto the 4M-8973 Elbow (21) .

5. Connect the other end of 189-7983 Hose As (41) onto the top of 171-8873 Lube Distribution Valve (37) that is located on the tilt lever.

6. Connect one end of 189-7550 Hose As (42) onto one of the 3B-6487 Couplings (31) that are shown in Section "N-N" in Illustration 20.

7. Install a 3B-6552 Elbow (18) onto the top of the 171-8873 Lube Distribution Valve (37) on the lift arm.

8. Connect the other end of 189-7550 Hose As (42) onto the 3B-6552 Elbow (18) .

9. Install the following hoses: (41), (42) and (43). Use the following hardware in order to secure hoses:
   • One 4D-7794 Clip (20)

   • Four 8T-4121 Hard Washers (28)

   • Three 8T-4133 Nuts (29)

   • One 8T-4137 Bolt (31)

   • Three 9X-8582 Clips (35)

Installation of 183-5432 Lubrication Lines Gp (B Pins and Lift Cylinders) for the 966G

Illustration 30	g00871129
Partial top view of rear frame and loader frame

Refer to Illustration 30.

See the following list for the part that is serviced by each injector:

Number 1: Left "B" pin

Number 2: Right "B" pin

Number 3: Closed

Number 4: Closed

Number 5: Left lift cylinder

Number 6: Right lift cylinder

Number 7: Closed

Number 8: Closed

1. Connect one end of 189-7540 Hose As (38) onto the number six injector that is part of the 171-8873 Lube Distribution Valve (36) .

2. Install a 3B-7733 Fitting (19) into the right lift cylinder.

3. Install a 8B-4884 Elbow (26) onto the 3B-7733 Fitting (19) .

4. Connect the other end of the 189-7540 Hose As (38) onto the 8B-4884 Elbow (28) .

5. Connect one end of 189-7981 Hose As (39) onto the number two injector that is part of the 171-8873 Lube Distribution Valve (36) .

6. Install a 5K-9979 Flared Connector (1) onto the other end of 189-7981 Hose As (39) .

7. Connect the 5K-9979 Flared Connector (1) onto the 183-5392 Tube Assembly (8). Refer to Illustration 28.

8. Connect one end of 189-7030 Hose As (37) onto the number five injector that is part of the 171-8873 Lube Distribution Valve (36) .

9. Install a 3B-7733 Fitting (19) into the left lift cylinder.

10. Install a 8B-4884 Elbow (26) onto the 3B-7733 Fitting (19) .

11. Connect one end of 189-7982 Hose As (40) onto the number one injector that is part of the 171-8873 Lube Distribution Valve (36) .

12. Install a 5K-9979 Flared Connector (1) onto the other end of 189-7030 Hose As (37) .

13. Use the following hardware in order to secure hoses (38) and (39) :
    • One 4D-7794 Clips (20)

    • One 8M-2772 Clips (27)

    • Three 8T-4121 Hard Washers (28)

    • Three 8T-4137 Bolts (31)

    • Two 9X-8582 Clips (35)

14. Use the following hardware in order to secure hoses (37) and (40) :
    • One 4D-7794 Clips (20)

    • One 8M-2772 Clips (27)

    • Two 8T-4121 Hard Washers (28)

    • Two 8T-4137 Bolts (31)

    • One 9X-8582 Clips (35)

15. Connect the 5K-9979 Flared Connector (1) onto the 183-5391 Tube As (7). Refer to Illustration 28.

Installation of 183-5433 Lubrication Lines Gp (Link Pins, Tilt Cylinder, Bellcrank) for the 966G

Illustration 31	g00871296
Partial top view of loader frame (W1) Mounting block (W2) Mounting block

Refer to Illustration 31.

See the following list for the part that is serviced by each injector:

Number 1: Rear link pin

Number 2: Tilt cylinder

Number 3: Closed

Number 4: Closed

Number 5: Front link pin

Number 6: Bellcrank

Number 7: Closed

Number 8: Closed

1. Install a 6L-3616 Flared Connector (2) into the number six injector that is part of the 171-8873 Lubrication Distribution Valve Gp (36) .

2. Connect one end of the 183-5388 Tube As (6) onto the 6L-3616 Flared Connector (2). Do not tighten the nut.

3. Install a 4M-8973 Elbow (21) into the bellcrank.

4. Install a 6L-3616 Flared Connector (2) into the 4M-8973 Elbow (21) .

5. Connect the other end of the 183-5388 Tube As (6) onto the 6L-3616 Flared Connector (2) .

6. Install a 6L-3616 Flared Connector (2) into the number two injector of the 171-8873 Lubrication Distribution Valve Gp (36) .

7. Connect one end of the 183-5387 Tube As (5) onto the 6L-3616 Flared Connector (2). Do not tighten the nut.

8. Install a 6L-3616 Flared Connector (2) into the mounting block (W1).

9. Connect the other end of the 183-5387 Tube As (5) onto the 6L-3616 Flared Connector (2). Do not tighten the nut.

10. Use the following hardware in order to secure tubes (5) and (6) :
    • One 5K-2298 Clip (22)

    • One 8M-2772 Clip (27)

    • Two 8T-4121 Hard Washers (28)

    • Two 8T-4133 Nuts (29)

11. Tighten the nuts that are on tubes (5) and (6) .

12. Install a 6K-6967 Pipe Adapter (48) into the tilt cylinder.

13. Install a 3B-6552 Pipe Elbow (18) into the 6K-6967 Pipe Adapter (48) .

14. Connect one end of the 183-5826 Hose As (44) onto the 3B-6552 Pipe Elbow (18) .

15. Connect the other end of the 183-5826 Hose As (44) onto the mounting block (W1) .

16. Install a 8L-5008 Pipe Elbow (49) into the number one injector that is part of the 171-8873 Lubrication Distribution Valve Gp (36) .

17. Install a 8L-5008 Pipe Elbow (49) into the number five injector that is part of the 171-8873 Lubrication Distribution Valve Gp (36) .

18. Connect one end of the 189-7552 Hose As (47) onto the 8L-5008 Pipe Elbow (49) that is installed in the number five injector that is part of the 171-8873 Lubrication Distribution Valve Gp (36) .

19. Connect the other end of the 189-7552 Hose As (47) onto the mounting block (W2) .

20. Install a 110-8796 Pipe (15) into the rear link pin.

21. Install a 8B-4884 Elbow (26) onto the 110-8796 Pipe (15) .

22. Connect one end of the 189-7531 Hose As (46) onto the 8L-5008 Pipe Elbow (49) that is installed in the number one injector that is part of the 171-8873 Lubrication Distribution Valve Gp (36) .

23. Connect the other end of the 189-7531 Hose As (46) onto the 8B-4884 Elbow (26) .

24. Install a 8L-5008 Pipe Elbow (49) into mounting block (W2) .

25. Install a 6K-6967 Pipe Adapter (48) into the front link pin.

26. Install a 8L-5008 Pipe Elbow (49) onto the 6K-6967 Pipe Adapter (48) .

27. Connect one end of the 183-5827 Hose As (45) onto the 8L-5008 Pipe Elbow (49) that is installed into mounting block (W2) .

28. Connect the other end of the 183-5827 Hose As (45) onto the 8L-5008 Pipe Elbow (49) that is installed in the front link pin.

29. Install the two 130-8433 Grommets (16) onto the bucket link.

30. Install the 177-8769 Guard (4) .

31. Use the following hardware to secure the 183-5827 Hose As (45) :
    • One 171-8861 Bracket (3)

    • One 4D-7794 Clip (20)

    • Two 6V-4356 Clips (23)

    • Two 6V-4357 Clips (24)

    • Six 8T-4121 Hard Washers (28)

    • Three 8T-4133 Nuts (29)

    • One 8T-4136 Bolt (30)

    • One 8T-4186 Bolt (32)

    • One 8T-4196 Bolt (33)

Installation of 070-0623 Automatic Lubrication Lines Gp for the 972G

Illustration 32	g00834572
Overall view of 070-0623 Automatic Lubrication Lines Gp (5) 070-0646 Lubrication Lines Gp (16) 189-8007 Lubrication Lines Gp (17) 189-8008 Lubrication Lines Gp

Illustration 33	g00834592
Top view of loader frame

Illustration 34	g00835548
Sections "B-B" and "F-F" from Illustration 33 (W) Mounting block

Illustration 35	g00835590
Section "E-E" from Illustration 33

Illustration 36	g00835693
Section "H-H" from Illustration 33 (X) Mounting block (Y) Mounting block (Z) Mounting block

Installation of 189-8007 Lubrication Lines Gp

1. Refer to Illustration 34. Connect one end of 189-7553 Hose As (44) onto one of the 3B-6487 Couplings (31) that are shown in Section "N-N" in Illustration 20.

2. Connect the other end of 189-7553 Hose As (44) onto mounting block (W) .

3. Install a 4M-8973 Elbow (24) into mounting block (W) .

4. Connect the end of the 189-8009 Hose As (45) without the hose guard onto the 4M-8973 Elbow (24) .

5. Connect the other end of 189-8009 Hose As (45) onto the top of 171-8873 Lube Distribution Valve (37) on the tilt lever. Refer to Illustration 35.

6. Refer to Illustration 34. Connect one end of 189-7550 Hose As (43) onto the other 3B-6487 Coupling (31) that is shown in Section " N-N" in Illustration 20.

7. Install a 3B-6552 Elbow (20) onto the top of the 171-8873 Lube Distribution Valve (37) on the lift arm.

8. Connect the other end of 189-7550 Hose As (43) onto the 3B-6552 Elbow (20) .

9. Refer to Illustrations 34 and 35. Use the following hardware to secure hoses (43), (44) and (45) :
   • One 4D-7794 Clip (22)

   • Four 8T-4121 Hard Washers (31)

   • Three 8T-4133 Nuts (32)

   • One 8T-4137 Bolt (34)

   • Three 9X-8582 Clips (36)

Installation of 070-0646 Lubrication Lines Gp

Refer to Illustration 35.

See the following list for the part that is serviced by each injector:

Number 1: Rear link pin

Number 2: Tilt cylinder

Number 3: Closed

Number 4: Closed

Number 5: Front link pin

Number 6: Bellcrank

Number 7: Closed

Number 8: Closed

1. Install a 6L-3616 Flared Connector (2) in each end of 183-5387 Tube As (7) .

2. Connect one end of 183-5387 Tube As (7) onto the number two injector that is part of the 171-8873 Lube Distribution Valve (37) .

3. Connect the other end of 183-5387 Tube As (7) onto mounting block (W) .

4. Connect the end of the 183-5826 Hose As (46) without the hose guard onto mounting block (W) .

5. Install a 6K-6967 Pipe Adapter (26) into the tilt cylinder.

6. Install a 3B-6552 Elbow (20) into the 6K-6967 Pipe Adapter (26) .

7. Connect the other end of 183-5826 Hose As (46) onto the 3B-6552 Elbow (20) .

8. Install a 6L-3616 Flared Connector (2) in each end of 183-5388 Tube As (8) .

9. Connect one end of 183-5388 Tube As (8) onto the number six injector that is part of the 171-8873 Lube Distribution Valve (37) .

10. Install a 4M-8973 Elbow (24) into the bellcrank.

11. Connect the other end of 183-5388 Tube As (8) onto the 4M-8973 Elbow (24) .

12. Use the following hardware in order to secure the 183-5387 Tube As (7) and the 183-5388 Tube As (8) :
    • One 5K-2298 Clip (25)

    • One 8M-2772 Clip (30)

    • Two 8T-4121 Hard Washers (31)

    • Two 8T-4133 Nuts (32)

13. Install a 8L-5008 Pipe Elbow (29) into the number one injector that is part of the 171-8873 Lube Distribution Valve (37) .

14. Install a 8L-5008 Pipe Elbow (29) into the number five injector that is part of the 171-8873 Lube Distribution Valve (37) .

15. Connect one end of 189-7531 Hose As (49) onto the 8L-5008 Pipe Elbow (29) that is mounted on the number one injector that is part of the 171-8873 Lube Distribution Valve (37) .

16. Install a 110-8796 Pipe (18) into the rear link pin.

17. Install a 8B-4884 Elbow (28) onto the 110-8796 Pipe (18) .

18. Connect the other end of the 189-7531 Hose As (49) onto the 8B-4884 Elbow (28) .

19. Connect one end of 189-7552 Hose As (48) onto the 8L-5008 Pipe Elbow (29) that is mounted on the number five injector that is part of the 171-8873 Lube Distribution Valve (37) .

20. Connect the other end of the 189-7552 Hose As (48) onto mounting block (W) .

21. Install the two 189-7032 Rods (12) and the two 189-7034 Plates (13) onto the link and bearing assembly.

22. Install a 4K-3026 Extension (23) into the front end of the link and bearing assembly.

23. Install a 8L-5008 Pipe Elbow (29) onto the 4K-3026 Extension (23) .

24. Install a 8L-5008 Pipe Elbow (29) onto mounting block (W) .

25. Connect the end of 189-7035 Hose As (47) with the hose guard onto the 8L-5008 Pipe Elbow (29) .

26. Connect the other end of the 189-7035 Hose As (47) onto the 8L-5008 Pipe Elbow (29) and the 4K-3026 Extension (23) .

27. Use the following hardware to secure the 189-7035 Hose As (47) :
    • One 171-8861 Bracket (6)

    • Three 4D-7794 Clips (22)

    • Five 8T-4121 Hard Washer (31)

    • Three 8T-4133 Nut (32)

    • One 8T-4136 Bolt (33)

    • Two 8T-4137 Bolt (34)

Installation of tube assemblies

1. Refer to Illustration 33.

2. Install a 6L-3616 Flared Connector (2) into the end of 070-0645 Tube As (4) .

3. Install a 6K-6967 Pipe Adapter (26) into the right side "B" pin.

4. Connect the 070-0645 Tube As (4) onto the 6K-6967 Pipe Adapter (26) .

5. Use the following hardware to install the 183-7820 Guard (11) and the 183-7993 Guard (15) :
   • Four 2B-2404 Clips (19)

   • Four 8T-4121 Hard Washers (31)

   • Four 8T-4136 Bolts (33)

6. Refer to Illustration 34.

7. Install a 6L-3616 Flared Connector (2) into the end of 070-0644 Tube As (3) .

8. Install a 6K-6967 Pipe Adapter (26) into the left side "B" pin.

9. Connect the 070-0644 Tube As (3) onto the 6K-6967 Pipe Adapter (26) .

10. Use the following hardware to install the 183-7820 Guard (11) and the 183-7992 Guard (14) :
    • Four 2B-2404 Clips (19)

    • Four 8T-4121 Hard Washers (31)

    • Four 8T-4136 Bolts (33)

Installation of 189-8008 Lubrication Lines Gp

Refer to Illustration 34.

See the following list for the part that is serviced by each injector:

Number 1: Left lift cylinder

Number 2: Right lift cylinder

Number 3: Closed

Number 4: Closed

Number 5: Left "B" pin

Number 6: Right "B" pin

Number 7: Closed

Number 8: Closed

1. Refer to Illustrations 34 and 36. Connect one end of 189-7543 Hose As (40) onto the number six injector that is part of the 171-8873 Lube Distribution Valve (37) .

2. Install a 5K-9979 Flared Connector (1) onto the other end of 189-7543 Hose As (40).

3. Connect the 5K-9979 Flared Connector (1) onto the 070-0645 Tube As (4) .

4. Connect one end of 189-7540 Hose As (41) onto the number two injector that is part of the 171-8873 Lube Distribution Valve (37) .

5. Install a 3B-7733 Fitting (21) into the right lift cylinder.

6. Install a 8B-4884 Elbow (28) onto the 3B-7733 Fitting (21) .

7. Connect the other end of the 189-7540 Hose As (41) onto the 8B-4884 Elbow (28) .

8. Connect one end of 189-7982 Hose As (42) onto the number five injector that is part of the 171-8873 Lube Distribution Valve (37) .

9. Install a 5K-9979 Flared Connector (1) onto the other end of 189-7982 Hose As (42) .

10. Connect the 5K-9979 Flared Connector (1) onto the 070-0644 Tube As (3) .

11. Connect one end of 189-7030 Hose As (38) onto the number one injector that is part of the 171-8873 Lube Distribution Valve (37) .

12. Install a 3B-7733 Fitting (21) into the left lift cylinder.

13. Install a 8B-4884 Elbow (28) onto the 3B-7733 Fitting (21) .

14. Connect the other end of the 189-7030 Hose As (38) onto the 8B-4884 Elbow (28) .

15. Use the following hardware in order to secure hoses (38), (40), (41) and (42) :
    • Three 4D-7794 Clips (22)

    • Two 8M-2772 Clips (30)

    • Five 8T-4121 Hard Washers (31)

    • Five 8T-4137 Bolts (34)

    • Two 9X-8582 Clips (36)

Installation of the 184-4965 Autolube Control Wiring Gp

Illustration 37	g00869009
Partial right side and top views of cab (B) This plug connects to the start switch. (C) This plug connects to the main harness. (D) This lug connects to the stud for the cab ground.

1. Refer to Illustration 37. Install the 184-4964 Control Harness As (1) .

2. Remove the plug that has four sockets from the key switch. Connect the plug that has four sockets to plug (C) .

3. Connect plug (B) onto the key start switch.

4. Connect the ground terminal (D) to the stud for the cab ground.

5. Use the 3S-2093 Cable Straps (3) in order to secure the 184-4964 Control Harness As (1) .

6. Install two 3K-8781 Fuses (2) into the fuse holders on the 184-4964 Control Harness As (1) .