Rework of Lines Group Hydraulic Oil Hose Assembly on Certain 966K XE Wheel Loaders{4304, 5057, 7554} Caterpillar

Wheel Loader:

966K (S/N: NGX1-107,201-441)

Introduction

Illustration 1	g03831274
966K XE production view

Illustration 2	g03831277
View of 966K XE with rework of lines group

The following instructions will describe the steps to rework the lines group hydraulic oil hose between implement pump 1 and implement pump 2 by utilizing longer hose assemblies that are easier to manufacture and install. Read the entire Special Instruction.

Understand the information before you perform any procedures. Understand the information before you order any parts or perform any work.

Safety

Show/hide table

Do not operate or work on this machine unless you have read and understand the instructions and warnings in the Operation and Maintenance Manuals. Failure to follow the instructions or heed the warnings could result in injury or death. Contact any Caterpillar dealer for replacement manuals. Proper care is your responsibility. For machines equipped with quick coupler, improper attachment of work tools could result in injury or death. Do not operate this machine until you have positive indication that the coupler pins are fully engaged. Follow recommended procedure in Operation and Maintenance Manual. Securely fasten radio (if equipped) and all loose items such as lunch boxes or tools. Failure to do so could allow items to shift position during rough machine operation or tip over and result in injury. Refer to the Operation and Maintenance Manual for specific fastening and latching requirements.

Show/hide table

Sudden movement or accidental starting of the machine can cause personal injury or death to persons on or near the machine. To prevent personal injury or death, perform the following: Park the machine on a smooth level surface. Lower the blade and or attachments to the ground. Stop the engine and engage the parking brake. Block the wheels and install the steering frame lock. Turn the battery disconnect switch to the OFF position and remove the key. Place a Special Instruction, SEHS7332, "Do Not Operate" tag at the battery disconnect switch location to inform personnel that the machine is being worked on.

Show/hide table

Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact skin. At operating temperature, the engine coolant is hot and under pressure. Steam can cause personal injury. Check the coolant level only after the engine has been stopped and the cooling system pressure cap is cool enough to touch with your bare hand. Remove the cooling system pressure cap slowly to relieve pressure. Cooling system conditioner contains alkali. Avoid contact with the skin and eyes to prevent personal injury.

Show/hide table

Personal injury can result from improper handling of chemicals. Make sure you use all the necessary protective equipment required to do the job. Make sure that you read and understand all directions and hazards described on the labels and material safety data sheet of any product used to clean the components. Observe all safety precautions recommended by the chemical manufacturer for handling, storage, and disposal of cleaning agents.

To prevent personal injury or death, do not let engine fluids stay on your skin. Clean skin and nails using hand cleaner and wash with soap and water. Wash or discard clothing and rags contaminated with engine fluids.

Engine Fluids (Oil, Fuel and Coolant) are a threat to the environment. Properly recycle or dispose of engine fluids according to local regulations. Never put engine fluids in the trash, on the ground, in sewers or bodies of water.

Wear gloves and other protective gear while working with hot engine fluids. Use caution when draining hot engine fluids and avoid direct skin contact.

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools in order to perform these functions properly. Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. If a tool, a procedure, a work method, or operating technique that is not recommended by Caterpillar is used, make sure that procedure is safe for you and for other people to use. Make sure that the product will not be damaged or the product will be made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.

Required Parts

Rework Procedure

Illustration 3	g03831396
(V) Four M10 nuts (W) Two M12 bolts

To provide access to the machine components remove the steering cylinder cover guard on the machine right-hand side (if equipped) and open the hydraulic service center door. The guard can be removed by removing the four M10 (V) nuts that affix the guard to the frame. The door can be opened by removing the two M12 (W) bolts.

Illustration 4	g03824305
(D) 372-1228 Hose As (G) 372-1229 Hose As (M) Manifold plate (P) Pump port

Illustration 5	g03824311

1. Remove and discard 372-1228 Hose As (D) .

2. Remove and discard flanges, seals, adapters, and hardware on pump ports (P)

3. Remove and discard 372-1229 Hose As (G)

4. Remove and discard flanges, seals, adapters, and hardware on manifold plate (M) .

Show/hide table



Illustration 6	g03831428
Global view of 966K XE with modified hose routing (AA) New routing path for existing 337-7469 Hose As (detailed view shown in Illustration 7) (BB) New routing path for existing diagnostic lines (detailed view shown in Illustration 8) (CC) New routing path for existing 394-9937 Hose As . (if equipped, detailed view shown in Illustration 9 and Illustration 10)

Show/hide table



Illustration 7	g03823859
(R) New routing path for existing 337-7469 Hose As (T) Existing 200-6345 Mount (X) Previous routing path for existing 337-7469 Hose As

Show/hide table



Illustration 8	g03823756
(E) Existing hoses

Show/hide table



Illustration 9	g03823886

5. In order to provide clearance to new hoses, 337-7460 Hose As (steering line), the machine diagnostic lines, and 394-9937 Hose As (quick coupler line - if equipped) must be rerouted.

6. Add 8C-8988 Elbow (5) and 6V-8397 O-Ring Seal (6). Adjust to the orientation shown in Illustration 7. Torque to 45 ± 5 N·m (33 ± 4 lb ft)

7. Reorient existing 142-3331 Bracket As (B), add 297-1546 Clip (2) and 142-3953 Stud (1). Stack and orient hardware as shown in Illustration 8. Torque to 55 ± 10 N·m (40 ± 7 lb ft)

8. Relocate existing 200-6345 Mount (T) using 2 204-2281 Cable Straps . (7). Refer to Illustration 7.

9. Reroute the diagnostic lines by installing 8T-6466 Bolt (3) and 133-6934 Spacer (4). Torque to 55 ± 10 N·m (40 ± 7 lb ft). Reuse existing washers, nut, and saddle mount. Affix the existing diagnostic bundle to existing 142-3331 Bracket As (B) in new orientation. Refer to Illustration 9.

Show/hide table



Illustration 10	g03824221
If equipped with a quick coupler, reroute of 394-9937 Hose As (C) Existing 8M-2773 Clip (H) Existing 372-1205 Hose As (N) New routing path for existing 394-9937 Hose As (Z) Previous routing path for existing 394-9937 Hose As

10. Steps 10 through 13 are for machines equipped with a quick coupler. Reroute from previous routing path of existing 394-9937 Hose As (Z) to new routing path (N). Refer to Illustration 10.

11. Add 8M-2773 Clip (8). Refer to Illustration 10. Torque to 55 ± 10 N·m (40 ± 7 lb ft).

12. Attach 177-2215 Strap (9) to hose (N) and hose (H). Refer to Illustration 10.

13. Reorient existing clip (C). Refer to Illustration 10. Torque to 55 ± 10 N·m (40 ± 7 lb ft)

Show/hide table



Illustration 11	g03824382

Show/hide table



Illustration 12	g03824400

Show/hide table



Illustration 13	g03824402

14. Install 426-5498 Hose As (15) using two 1P-5767 Half Flanges (10), four 8T-4194 Bolts (11), four 8T-4223 Hard Washers (12), and one 1P-3704 Rectangular Seal (14) at the pump port. Refer to Illustration 11. Torque to 100 ± 20 N·m (74 ± 15 lb ft).

15. Install 426-5499 Hose As (16) using two 1P-5767 Half Flanges (10), four 8T-4194 Bolts (11), four 8T-4223 Hard Washers (12), and one 1P-3704 Rectangular Seal (14) at the pump port. Refer to Illustration 11. Torque to 100 ± 20 N·m (74 ± 15 lb ft).

16. Install 108-4351 Adapter Plate (17), 1P-3703 Rectangular Seal (18), and four 6V-8200 Bolts (19). Torque to 100 ± 20 N·m (74 ± 15 lb ft).

17. Install 6V-8785 Tee (20), two 5K-9090 O-Ring Seals (21), and 7M-8485 O-Ring Seal (22). Torque to 350 ± 53 N·m (258 ± 39 lb ft).

18. Install 6V-9854 Elbow (23) and 5K-9090 O-Ring Seals (21). Torque to 220 ± 33 N·m (162 ± 24 lb ft).

19. Install hoses 426-5498 Hose As (15) and 426-5499 Hose As (16) to 6V-9854 Elbow (23) elbow and 6V-8785 Tee (20). Refer to Illustration 12. Torque to 220 ± 33 N·m (162 ± 24 lb ft).

Show/hide table



Illustration 14	g03831396

20. Reinstall steering cylinder cover guard (if equipped). Torque nuts (V) to 55 ± 10 N·m (40 ± 7 lb ft). Reinstall hydraulic service center door. Torque nuts (W) to 100 ± 20 N·m (74 ± 15 lb ft).

21. Check and refill hydraulic oil as needed, refer to Operation and Maintenance Manual, "Hydraulic System Oil Level".