Installation Of Brake Oil Cooler Kit{1365} Caterpillar

Wheel Loaders:

966F (PIN: 4YG1-UP; 8BG1-1999; 3XJ1-UP; 1SL1-506)

966F Series II (PIN: 8BG2000-UP; 9YJ1-UP; 1SL507-UP)

970F (PIN: 7SK1-UP; 9JK1-UP; 7PL1-UP)

Introduction

This Special Instruction provides the necessary information required to install the 2Z-9956 Brake Oil Cooler Kit on the wheel loaders listed.

Do not perform any procedure outlined in this publication or order any parts until you read and understand the information contained within this document.

Preparatory Steps For Installation Of The 2Z-9956 Brake Oil Cooler Kit

Note: Refer to the appropriate Service Manual, Disassembly And Assembly, for the correct procedures to follow in this section.

Note: Fluid Spillage Containment - Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Tool And Shop Products Guide, NENG2500 for tools and supplies suitable to collect and contain fluids in AVSpare machines. Dispose fluids according to local regulations and mandates.

Use the following preparatory steps to aid in the installation procedure.

1. Clean the machine. This will make the process of installing the brake oil cooler kit easier.

2. Connect the steering frame lock link between the front frame and the rear frame before the installation of the 2Z-9956 Brake Oil Cooler Kit .

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Personal injury or death can result from machine articulation or movement. Machine frames can move and a person can be crushed. Connect the steering frame lock link between the front and rear frames before working on machine. Do not disconnect the lock link until the machine is made operational and the commissioning procedure is completed.

3. Remove the rear mounted counterweights.

4. Move the machine onto stands for easier access to the underside of the machine.

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Make sure the lifting cables and other lifting devices are strong enough to support the machine.

5. Remove any guards that are installed on the front axle, the rear axle, and the power train.

6. Remove the wheels on the rear axle. This facilitates the removal and installation of parts. Use appropriate lift and carry devices, and service tools to remove the wheels.

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Personal injury or death can result from axle movement. Personal injury can result from axle movement if blocking is not used. When the rear axle is raised, it is necessary to place blocking under the axles to prevent possible axle movement.

7. Drain the hydraulic tank oil, the front axle oil, and the rear axle oil before the process of installing the 2Z-9956 Brake Oil Cooler Kit .

8. Drain the transmission tank only if the machine uses the 8R-3947 Power Train Oil Filler Group (Engineering Change 06 or lower). This former oil filler group should be removed in order to mount the rear axle pump and motor mounting group on the machine.

9. Remove the grill from the front of the radiator as this will facilitate the installation of the cooler cores. Use appropriate lift and carry devices and service tools to remove the grill.

Removal Of Parts For Installation Of The 2Z-9956 Brake Oil Cooler Kit

The removal of parts in this section is required only in the following machines.

• 966F Wheel Loaders (PIN: 4YG1-UP; 1SL1-506)

• 970F Wheel Loaders (PIN: 7SK1-223)

Remove the parts from the 8R-3947 Power Train Oil Filler Group and other locations, before installation of the parts in the 2Z-9956 Brake Oil Cooler Kit . Refer to Table 1 for a list of parts to be removed in order to install the 2Z-9956 Brake Oil Cooler Kit .

Table 1

Removal Of Parts From Powertrain Oil Filler Group And Other Locations
Item	Part Number	Description	Quantity
1	0L-1351	Bolt	2
2	0S-0509	Bolt	2
3	4S-5971	Cover	1
4	5M-3154	Cover	1
5	7F-8268	O-Ring Seal	1
6	7H-3270	Gasket	1
7	8R-3947	Powertrain Oil Filler Group	1
8	8T-4896	Hard Washer	4
9	2W-8493	Fan Pulley	1
10	2W-8952	V-Belt Set	1
11	1P-3707	Rectangular Seal	2
12	3K-6905	Breather Valve	1
13	4K-5537	Gasket	1
14	5K-0461	Clip	1
15	5M-6213	Pipe Plug	1
16	5S-7383	Bolt	2
17	6G-9333	Oil Filler Cap	1
18	6V-1322	Bolt	1
19	6V-8801	Nut	1
20	7J-8611	Pipe Elbow	1
21	7K-1401	Clip	1
22	7K-1402	Bracket	1
23	8R-3948	Tube Assembly	1
24	8T-4205	Hard Washer	1
25	9B-7237	Bolt	1
26	9G-5127	Breather	1
27	9U-0764	Tube Assembly	1
28	9U-0767	Plunger Assembly	1

Installation Of The 2Z-9956 Brake Oil Cooler Kit

This section provides a list of parts in the 2Z-9956 Brake Oil Cooler Kit , that should be installed on the wheel loaders listed at the beginning of the document. Refer to Table 2 and appropriate tables and illustrations in this document to install the parts in the 2Z-9956 Brake Oil Cooler Kit .

Table 2

2Z-9956 Brake Oil Cooler Kit Group
Item	Part Number	Description	Quantity
1	2Q-2819	Brake Oil Cooler Guard Group	1
2	2Q-3513	Brake Oil Cooler Pump And Drive Group	1
3	2Q-3514	Oil Temperature Gauge	1
4	2Q-3855	Brake Oil Cooler Group	1
5	2Q-3885	Frame Plate Group	1
6	2Q-3948	Brake Oil Cooler Lines Group	1
7	7C-3559	V-Belt Set	1
8	9N-6611	Fan Pulley	1
9	131-2303	Front Axle Pump And Motor Mounting Group	1
10	134-6379	Rear Axle Pump And Motor Mounting Group	1

Installation Of The 2Q-3885 Frame Plate Group

The parts in the 2Q-3885 Frame Plate Group should be installed using the following procedure. Refer to Table 3 and the illustrations for parts in the 2Q-3885 Frame Plate Group .

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NOTICE
Do not drill holes or use other machining practices on the radiator or lower front radiator assembly, without a thermal blanket around the air reservoir. If the drilling or machining is performed without a thermal blanket, damage to the machine may occur.

Note: Use the appropriate weld specifications provided in this section.

Table 3

2Q-3885 Frame Plate Group
Item	Part Number	Description	Quantity
1	136-4651	Plate	1
2	5T-5192	Boss	2
3	9T-6943	Block	1
4	112-9478	Plate	1
5	4E-3986	Plate	1

1. Weld the 136-4651 Plate (1) to the rear frame. Refer to Illustration 1 and Illustration 2. Use a 6 mm (0.24 inch) fillet weld (E), with a penetration of 1.5 mm (0.06 inch). This is for the installation of the 135-8729 Valve Assembly (for the directional control). The 135-8729 Valve Assembly is part of the 2Q-3948 Brake Oil Cooler Lines Group . See section titled Installation Of The 2Q-3948 Brake Oil Cooler Lines Group.

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Illustration 1	g00104982
(A) Frame assembly. (C) 316 mm (12.44 inch). (D) 60 mm (2.36 inch). (F) 384.5 mm (15.14 inch). (G) 410 mm (16.14 inch). (H) 107 mm (4.21 inch). (J) 139 mm (5.47 inch). (K) 190 mm (7.48 inch). (L) 194 mm (7.64 inch). (N) Center of machine. (O) Center of hitch. (P) 237.5 mm (9.35 inch). (Q) 47 mm (1.85 inch). (R) 1.5 mm (0.06 inch).

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Illustration 2	g00105027
(T) Rear frame (right hand side behind rear axle). (U) Location of 135-8729 Valve Assembly (for the directional control).

2. Weld the two 5T-5192 Bosses (2) to the rear frame. Refer to Illustration 1 and Illustration 3. Use a 6 mm (0.24 inch) fillet weld (B), with a penetration of 1.5 mm (0.06 inch). This is for the installation of the 135-2075 Valve Group (for the flow divider). The 135-2075 Valve Group is part of the 2Q-3948 Brake Oil Cooler Lines Group . See section titled Installation Of The 2Q-3948 Brake Oil Cooler Lines Group.

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Illustration 3	g00105030
(T) Rear frame (right hand side behind rear axle). (V) Location of 135-2075 Valve Group (for the flow divider).

3. Weld the 9T-6943 Block (3) to the rear frame. Refer to Illustration 1. Use a 6 mm (0.24 inch) fillet weld (M), with a penetration of 1.5 mm (0.06 inch). This is for the installation of the 134-6379 Rear Axle Pump And Motor Mounting Group . The 134-6379 Rear Axle Pump And Motor Mounting Group is the rear axle brake oil cooler pump and motor group. See section titled Installation Of The Rear Axle Parts, where the location of the 9T-6943 Block is shown in Illustration 18.

4. Weld the 112-9478 Plate (4) to the rear frame. Refer to Illustration 1. Use a 5 mm (0.20 inch) fillet weld (S). This is for the routing of hose lines in the 2Q-3948 Brake Oil Cooler Lines Group .

5. Weld the 4E-3986 Plate (5) to the front frame. Refer to Illustration 4. Use an 8 mm (0.32 inch) fillet weld (W), with a penetration of 1.5 mm (0.06 inch). Use an 8 mm (0.32 inch) fillet weld (Y), with a penetration of 1.5 mm (0.06 inch), on the two sides. This is for the installation of the 131-2303 Front Axle Pump And Motor Mounting Group . The 131-2303 Front Axle Pump And Motor Mounting Group is the front axle brake oil cooler pump and motor group. See section titled Installation Of The Front Axle Parts, where the location of the 4E-3986 Plate is shown in Illustration 28.

Illustration 4	g00105029
View of the front frame for welding the 4E-3986 Plate (5). (X) 21.5 mm (0.85 inch). (Z) 225 mm (8.86 inch).

Installation Of The 9N-6611 Fan Pulley And 7C-3559 V-Belt Set

Remove the former 2W-8493 Fan Pulley and 2W-8952 V-Belt Set on the machine. The removal of these parts is also addressed in the section titled Removal Of Parts For Installation Of The 2Z-9956 Brake Oil Cooler Kit. Install the new 9N-6611 Fan Pulley and 7C-3559 V-Belt Set that are part of the 2Z-9956 Brake Oil Cooler Kit on the machine. Refer to the appropriate Service Manual, Engine Disassembly And Assembly, for the procedure to remove and install the new fan pulley and v-belt.

Installation Of The 2Q-3855 Brake Oil Cooler Group

Install the 2Q-3855 Brake Oil Cooler Group consisting of the two 4Q-5614 Cooler Cores and related parts, using the following procedure. Refer to Table 4 and the illustrations in this section for parts to be installed in the 2Q-3855 Brake Oil Cooler Group .

Note: The radiator grill should be removed by loosening the side bolts (D, Illustration 6). This facilitates installation of parts in the 2Q-3855 Brake Oil Cooler Group .

Table 4

2Q-3855 Brake Oil Cooler Group
Item	Part Number	Description	Quantity
1	6V-8638	Connector	2
2	2M-9780	Seal	8
3	133-9382	Hose Assembly	2
4	6V-8398	Seal	6
5	4Q-5614	Core Assembly	2
6	6V-8555	Nut	4
7	6V-8939	Reducer	4
8	130-9704	Valve Group	2
9	7J-9108	Seal	4
10	8T-0249	Elbow	2
11	3K-0360	Seal	2
12	6V-7420	Adapter	2
13	8T-4121	Washer	20
14	8T-4186	Bolt (M10)	4
15	8T-4195	Bolt (M10)	16
16	131-5372	Bracket Assembly	1
17	6V-8721	Elbow	4
18	131-5373	Bracket Assembly	1
19	8T-4133	Nut (M10)	4

Illustration 5	g00105032

Illustration 6	g00105034
(A) 4Q-5614 Cooler Core. (B) 131-5373 Bracket Assembly (Upper). (C) 131-5372 Bracket Assembly (Lower). (D) Location of the bolts to be removed, in order to remove the grill from the radiator front.

Installation Of The 131-5373 Bracket Assembly (Upper)

Installation of the 131-5373 Bracket Assembly (Upper) at the radiator front is required in order to install the two 4Q-5614 Cooler Cores .

To install the 131-5373 Bracket Assembly (Upper), use the following procedure.

1. Locate the 131-5373 Bracket Assembly (Upper) on the 133-8734 Channel Assembly and 133-8735 Channel Assembly (E). Refer to Illustration 6 and Illustration 7. Drill two holes in each channel assembly (H, J). Refer to Illustration 8.

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Illustration 7	g00105044
(E) Location of the 133-8734 Channel Assembly and the 133-8735 Channel Assembly. (F) Radiator guard. (G) Frame.

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Illustration 8	g00105045
Detail B, Illustration 5. (H) and (J) are the locations of the new holes drilled in the 133-8734 Channel Assembly and 133-8735 Channel Assembly. Drill the two holes of diameter 13.8 mm (0.54 inch) through the channel assemblies. (K) 49 ± 2 mm (1.93 ± 0.08 inch). (L) 90 ± 2 mm (3.54 ± 0.08 inch). (M) 43 ± 2 mm (1.70 ± 0.08). (N) 75 ± 2 mm (2.95 ± 0.08 inch).

2. Use two 8T-4195 Bolts (15), two 8T-4121 Washers (13), and two 8T-4133 Nuts (19), to secure the 131-5373 Bracket Assembly (Upper) to the channel assemblies. This should be done on the 133-8734 Channel Assembly and 133-8735 Channel Assembly .

Installation Of The Two 4Q-5614 Cooler Cores To The 131-5373 Bracket Assembly (Upper)

Note: The 4Q-5614 Cooler Core on the left hand side is for the front axle pump and motor mounting group. The 4Q-5614 Cooler Core on the right hand side is for the rear axle pump and motor mounting group.

Note: Refer to Illustration 5 for location of parts for this installation procedure.

1. Install the two 4Q-5614 Cooler Cores to the 131-5373 Bracket Assembly (Upper). Use three 8T-4195 Bolts (15) and three 8T-4121 Washers (13) to secure the cooler cores to the 131-5373 Bracket Assembly (Upper). This should be done for both the cooler cores.

   Note: Make sure that correct alignment of the bracket assembly and cooler cores is obtained.

Installation Of The 131-5372 Bracket Assembly (Lower)

To install the 131-5372 Bracket Assembly (Lower), use the following procedure.

Note: Refer to Illustration 5 for location of parts for this installation procedure.

1. Assemble the 131-5372 Bracket Assembly (Lower) loosely to the two cooler cores earlier installed to the 131-5373 Bracket Assembly (Upper). Use three 8T-4195 Bolts (15) and three 8T-4121 Washers (13) on each side, to loosely secure the 131-5372 Bracket Assembly (Lower) to the two cooler cores.

2. Mark the dimensions on the 7E-3555 Support Plate and 7E-3556 Support Plate to drill two holes in each of the support plates. See O and P, Illustration 9.

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Illustration 9	g00105047
Detail C, Illustration 5. (O) and (P) are the locations of the new holes drilled in the 7E-3555 Support Plate and 7E-3556 Support Plate. Drill the two holes of diameter 13.8 mm (0.54 inch) through the support plates. (Q) 137 ± 2 mm (5.39 ± 0.08 inch). (R) 99 ± 2 mm (3.90 ± 0.08 inch). (S) 53 ± 2 mm (2.09 ± 0.08 inch).

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NOTICE
Use a higher penetration drill bit and plenty of lubrication oil at the drill locations, as heat and smoke will be generated there. Use a locating board at the backside of the support plates when drilling the holes. If the locating board is not used, the drill bit may affect the bracket at the back of the support plates.

3. Remove the loosely assembled 131-5372 Bracket Assembly (Lower) from the cooler cores.

4. Drill two holes in each support plate. See O and P, Illustration 9. This requires the use of a drill with higher penetration capabilities, as the support plate is very thick for the lower bracket installation.

Installation Of The Two 4Q-5614 Cooler Cores To The 131-5372 Bracket Assembly (Lower)

1. Install the two hanging 4Q-5614 Cooler Cores to the 131-5372 Bracket Assembly (Lower). Use three 8T-4195 Bolts (15) and three 8T-4121 Washers (13) to secure the 131-5373 Bracket Assembly (Lower) to the cooler cores. This should be done for both the cooler cores.

2. Use two 8T-4186 Bolts (14) and two 8T-4121 Washers (13) to secure the 131-5372 Bracket Assembly (Lower) to the support plates, at the two locations shown in Illustration 5 and Illustration 10.

Illustration 10	g00105048
(T) Location of 7E-3555 Support Plate (7E-3556 Support Plate on the other side). (U) Securing the 131-5373 Bracket Assembly (lower) to the support plates.

Installation Of The Relief Valve, Hose Assembly And Related Parts In The 2Q-3855 Brake Oil Cooler Group

Note: Refer to Illustration 5 for location of parts for this installation procedure.

1. Install the 6V-8721 Elbow (17) and 2M-9780 Seal (2) combination to the four inner locations of the two cooler cores. The elbow and seal are for the inlet and outlet lines for the cooler group and axle. See Illustration 5.

2. Install the 2M-9780 Seal (2) and 6V-8638 Connector (1) combination to the two outer locations (Upper) of the two cooler cores. The connector and seal are for installing the hose and valve assembly for the two cooler cores.

3. Install the 2M-9780 Seal (2) and 6V-7420 Adapter (12) combination to the two outer locations (Lower) of the two cooler cores. The adapter and seal are for installing the hose and valve assembly for the two cooler cores.

4. Install the two 133-9382 Hose Assemblies (3) and two 6V-8398 Seals (4) on the sides of the two cooler cores.

5. Install the 130-9704 Valve Group (8) and 7J-1908 Seal (9) to the two 6V-8555 Nut (6) and two 6V-8939 Reducer (7) combinations. This is on both sides of the cooler cores.

6. Assemble the hose assembly from Step 4 to the upper nut/reducer combination from Step 5.

7. Assemble the hose and valve assembly from Step 6 to the 3K-0360 Seal (11), 6V-8398 Seal (4) and 8T-0249 Elbow (10). This is on both sides of the cooler cores.

Note: See Detail A (Illustration 5) for the correct arrow position on installation of the two 130-9704 Valve Groups . The two 130-9704 Valve Groups are installed to the left hand side cooler core and to the right hand side cooler core.

8. Assemble from Step 7 to the 2M-9780 Seal and 6V-7420 Adapter (see Step 3).

Machining Of A Notch In Front Of The Radiator Cooler Cores

A notch (W) should be cut in the sheet metal in front of the radiator group. Refer to Illustration 12. Refer to Illustration 11 for the location of the new notch. This notch (W) is cut for the purpose of routing the existing wiring harness (Z), the new inlet coolant lines, and the new outlet coolant lines (Y). See section titled Installation Of The 2Q-3948 Brake Oil Cooler Lines Group, where the coolant lines are installed in front of the cooler cores.

Note: The area of the notch should be cleaned and prepared for cutting. Use a wheel or other cutting tool to cut the notch. The repair person should use a ladder to reach the notch area.

Illustration 11	g00105049
(V) Rear frame (left hand side behind rear axle). (W) Location of the notch to be machined in front of the radiator. (X) Ladder for personnel support.

Illustration 12	g00105050
(Y) Location of the new coolant lines for the axle oil coolers. (W) View of notch at the radiator front. (Z) Wiring harness that already exists on the machine. The wiring harness is routed in the space created by machining the notch.

Installation Of The 2Q-3514 Oil Temperature Gauge

Install the 2Q-3514 Oil Temperature Gauge in the cab location shown in Illustration 13 using the following procedure. Refer to Table 5 and the illustrations in this section, for a list of parts in the 2Q-3514 Oil Temperature Gauge that should be installed in this procedure.

Table 5

2Q-3514 Oil Temperature Gauge
Item	Part Number	Description	Quantity
1	3S-2093	Strap	20
2	135-3132	Bracket	1
3	130-9955	Indicator Assembly	2
4	7N-5876	Miniature Lamp	2
5	9X-2045	Truss Head Screw	2
6	3K-8782	Fuse	1
7	135-7089	Harness Assembly	1
8	135-7090	Harness Assembly	1
9	8K-6211	Clip	5

1. Open the right side cab door, to access the area to install the 2Q-3514 Oil Temperature Gauge .

2. Install the 135-3132 Bracket (2) at the location shown in Illustration 14 and Illustration 17. Use two 9X-2045 Truss Head Screws (5) to secure the bracket.

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Illustration 13	g00105054
(A) and (B) are the panels to be removed in order to install the parts. (C) The wall area.

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Illustration 14	g00105055

3. Install two 130-9955 Indicator Assemblies (3) and two 7N-5876 Miniature Lamps (4) on the 135-3132 Bracket (2). See Illustration 17.

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Illustration 15	g00105051
(A) Spare fuse holder (10 A). (B) Purple (CKT 614). (C) Running light switch (Terminal 12). (D) White (CKT 123). (E) 135-7090 Harness Assembly to the sender at the front axle manifold, and the sender at the rear axle manifold.

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Illustration 16	g00105052
View A-A, Illustration 15. (F) Purple (CKT 446, Terminal 14). (G) Yellow (CKT 429, Terminal 4). (H) Black (CKT 200). (J) Instrument panel harness connection.

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Illustration 17	g00105053
View B-B, Illustration 15. (B) Purple (CKT 614). (D) White (CKT 123). (E) Black (CKT 200). (F) Purple (CKT 446). (G) Yellow (CKT 429). (H) Black (CKT 200).

4. Refer to the Illustration 15 through Illustration 17 in this section, for the color and circuit codes for the 135-7089 Harness Assembly (7) and 135-7090 Harness Assembly (8) to be connected in this procedure. The 135-7090 Harness Assembly should be later connected to the 131-4797 Sender located at the front axle and at the rear axle. Refer to Step 9. See section titled Installation Of The 2Q-3948 Brake Oil Cooler Lines Group.

5. Open enclosures A and B and also the wall area C (Illustration 13). This is for the purpose of gaining access to the installation location, and to route the harness assemblies in the cab.

6. Install the 3K-8782 Fuse (6) in the spare fuse holder (A, Illustration 15).

7. Remove the two 9X-2044 Screws from the instrument panel. Refer to Illustration 16 for the location of the instrument panel (J). Also remove the four 8T-8737 Plugs from the Instrument Panel Harness Connection (J). There are two plugs on each side.

8. Connect the two harness assemblies from Step 4 to the instrument panel shown in Illustration 14. Use appropriate color and circuit codes to connect the harness assemblies.

9. Route the 135-7090 Harness Assembly (8) from the wall area (C, Illustration 13) to the two 135-2080 Manifolds . The 135-2080 Manifolds are located at the front axle and rear axle. See section titled Installation Of The 2Q-3948 Brake Oil Cooler Lines Group. The two 131-4797 Senders at the two 135-2080 Manifolds should be connected to the 135-7090 Harness Assembly (8) from the cab. Use the 8K-6211 Clips (9) and 3S-2093 Straps (1) to secure the 135-7089 Harness Assembly (7) and 135-7090 Harness Assembly (8) in the cab.

Installation Of The Rear Axle Parts

The 134-6379 Rear Axle Pump And Motor Mounting Group and related rear axle parts should be installed using the following procedure and step by step explanation. Refer to Table 6 and to appropriate tables and illustrations, for a list of parts used in this installation procedure.

Table 6

134-6379 Rear Axle Pump And Motor Mounting Group
Item	Part Number	Description	Quantity
1	130-7467	Pump And Motor Group	1
2	135-0210	Bracket	1
3	8T-4139	Bolt	2
4	8T-4223	Washer	4
5	6V-8624	Elbow	1
6	2M-9780	Seal	1
7	8T-5429	Elbow	2
8	3D-2824	Seal	2
9	9S-4191	Plug	1
10	3J-1907	Seal	1
11	6V-8628	Elbow	1
12	3J-7354	Seal	1
13	5P-0492	Adapter	1
14	7B-7169	Nipple	1
15	130-9505	Filter	1
16	7M-8485	Seal	1
17	5K-9090	Seal	1
18	8C-6875	Connector	1
19	6V-9854	Elbow	1
20	8T-4195	Bolt	2

Assembly And Installation Of The 134-6379 Rear Axle Pump And Motor Mounting Group

Illustration 18	g00105057
(A) 9T-6943 Block for installing the rear pump and motor group. (B) 134-6379 Rear Axle Pump And Motor Mounting Group (rear axle brake oil cooler pump and motor group).

Illustration 19	g00105065

Note: Lubricate the seals lightly with oil prior to the assembly. Use thread sealant compound for straight threads and pipe threads to prevent fluid leakage.

Note: Refer to Illustration 18 for location of the 134-6379 Rear Axle Pump And Motor Mounting Group . Refer to Illustration 19 for the procedure of assembling and installing the 134-6379 Rear Axle Pump And Motor Mounting Group to the rear axle.

1. Install one 3D-2824 Seal (8) and one 8T-5429 Elbow (7) to the 130-7467 Pump And Motor Group (1). This is the inlet line for the oil from the engine driven pump to the pump and motor group.

2. Install the other 3D-2824 Seal (8) and the other 8T-5429 Elbow (7) to the 130-7467 Pump And Motor Group (1). This is the outlet line for the oil return from the pump and motor group to the hydraulic tank.

3. Install the 3J-7354 Seal (12) and 6V-8628 Elbow (11) to the 130-7467 Pump And Motor Group (1). This is the case drain from the pump and motor group to the hydraulic tank.

4. Install the 6V-8624 Elbow (5) and 2M-9780 Seal (6) to the 130-7467 Pump And Motor Group (1). This is the rear axle oil outlet to the brake oil cooler.

5. Install the 9S-4191 Plug (9) and the 3J-1907 Seal (10) to the 130-7467 Pump And Motor Group (1). This is the external drain line.

6. Install the 5P-0492 Adapter (13) with 7M-8485 Seal (16) to the 130-7467 Pump And Motor Group (1).

7. Assemble the 5P-0492 Adapter (13) to the 130-9505 Filter (15) with a 7B-7169 Nipple (14).

8. Install the 8C-6875 Connector (18) to the 130-9505 Filter (15).

9. Connect the 90° angled 6V-9854 Elbow (19) with 5K-9090 Seal (17) to the 8C-6875 Connector (18).

10. Install the 135-0210 Bracket (2) to the 9T-6943 Block that is part of the 2Q-3885 Frame Plate Group . Use two 8T-4195 Bolts (20) and two 8T-4223 Washers (4) for the installation. The 9T-6943 Block was earlier welded to the rear frame. See section titled Installation Of The 2Q-3885 Frame Plate Group for instructions to weld the 9T-6943 Block .

11. Position and install the assembled 134-6379 Rear Axle Pump And Motor Mounting Group for the rear axle on the 135-0210 Bracket (2). See Illustration 18 for location of the bracket. Use two 8T-4139 Bolts (3) and two 8T-4223 Washers (4) for the installation.

Modifications To 8R-3947 Power Train Oil Filler Group

In case of machines equipped with the 8R-3947 Power Train Oil Filler Group the following change may be required. If the 8R-3947 Power Train Oil Filler Group is equipped with the fill tube and dipstick on the opposite side of the drop box (see Table 7, Illustration 20), the change should be made. Remove the fill tube and dipstick, and cover the opening with the parts in Table 8 (Illustration 21).

Note: The parts to be removed from the earlier 8R-3947 Power Train Oil Filler Group can also be found in Table 1. See section titled Removal Of Parts For The Installation Of The 2Z-9956 Brake Oil Cooler Kit.

The removal of parts in this section is required only in the following machines.

• 966F Wheel Loaders (PIN: 4YG1-UP; 1SL1-506)

• 970F Wheel Loaders (PIN: 7SK1-223)

Table 7

8R-3947 Power Train Oil Filler Group (Parts For Removal)
Item	Part Number	Description	Quantity
1	8R-3948	Tube Assembly	1
2	3K-6905	Valve	1
3	9U-0764	Tube Assembly	1
4	5K-0461	Clip	1
5	9U-0767	Plunger Assembly	1
6	6G-9333	Cap	1
7	6V-1322	Bolt	1
8	8T-4205	Washer	1
9	9G-5127	Breather	1
10	7K-1401	Clip	1
11	7K-1402	Bracket	1
12	9B-7237	Bolt	1
13	7J-8611	Elbow	1
14	6V-8801	Nut	1
15	7X-3186	Bolt	4
16	8T-4896	Washer	6
17	4K-5537	Gasket	1
18	5M-6213	Plug	1
19	1P-3707	Seal	1

Illustration 20	g00105067

Table 8

New 8R-3947 Power Train Oil Filler Group
Item	Part Number	Description	Quantity
1	7X-0366	Bolt (3/4)	1
2	5P-8248	Washer	2
3	6W-2342	Spacer	1
4	110-9572	Bracket Assembly	1
5	5P-8444	Grommet	1
6	6V-8188	Nut (1/2)	1
7	5P-2566	Bolt (1/2)	1
8	8T-4223	Washer	1
9	5P-7468	Clip	1
10	5P-7469	Clip	1
11	108-5680	Gauge	1
12	109-0684	Tube Assembly	1
13	2S-4750	Gasket	1

Illustration 21	g00105068
Location of parts for the correct configuration of the 8R-3947 Power Train Oil Filler Group.

Installation Of The 135-2080 Manifold And Related Parts

Note: Refer to Illustration 22 for the procedure of installing the 135-2080 Manifold and related parts.

Illustration 22	g00105058
(C) 135-2080 Manifold. (D) 131-4797 Sender.

The 135-2080 Manifold referred to in this section is part of the 2Q-3948 Brake Oil Cooler Lines Group . See section titled Installation Of The 2Q-3948 Brake Oil Cooler Lines Group.

The 135-2080 Manifold (C, Illustration 22) to circulate axle oil in the rear axle should be installed first. Remove the 5P-4484 Plug , 7M-8485 Seal and 9S-4181 Plug from the rear oscillating axle. See Illustration 22 for the location of the parts removal.

Install the 9S-4181 Plug and the 135-2080 Manifold (C, Illustration 22) to the rear axle. Install the 131-4797 Sender (D) to the 135-2080 Manifold (C). Use four 7M-8485 Seals and two 3K-0360 Seals for the installation.

The sender connects to the 135-7090 Harness Assembly from the cab ( 2Q-3514 Oil Temperature Gauge ). See section titled Installation Of The 2Q-3514 Oil Temperature Gauge. The sender indicates the temperature of the axle oil in the rear axle under difficult braking conditions.

Installation Of The 4E-3673 Tube Assembly And 4E-3676 Tube Assembly

Note: Refer to Illustration 23 for the location of the 4E-3673 Tube Assembly and 4E-3676 Tube Assembly (E).

Illustration 23	g00105059
(E) Tube Assemblies (4E-3673 And 4E-3676). (F) 2Q-2819 Brake Oil Cooler Guard Group.

The 4E-3673 Tube Assembly and 4E-3676 Tube Assembly and related parts referred to in this section are part of the 2Q-3948 Brake Oil Cooler Lines Group . See section titled Installation Of The 2Q-3948 Brake Oil Cooler Lines Group for additional installation information.

1. Assemble the 4E-3673 Tube Assembly and 4E-3676 Tube Assembly . Each tube assembly should be assembled using two end Sleeves ( 6V-8560 and 6V-9620 ), two Nuts ( 6V-8553 and 6V-8554 ) and the 8T-1679 Tube .

2. Connect the 4E-3673 Tube Assembly and 4E-3676 Tube Assembly using a 6V-8789 Tee and 6V-8398 Seal .

3. Install the 6V-8724 Elbow and 6V-8397 Seal , and the 9T-5212 Adapter and 3J-1907 Seal , to the rear axle.

The 4E-3673 Tube Assembly and 4E-3676 Tube Assembly provide for the return of the axle oil from the right hand cooler to the rear axle.

Assembly And Installation Of The 2Q-2819 Brake Oil Cooler Guard Group (To The Rear Axle)

The 2Q-2819 Brake Oil Cooler Guard Group should be assembled and installed to the rear axle. Refer to Table 9, and Illustration 23 through 26, for a list of parts that should be installed in this procedure.

Table 9

2Q-2819 Oil Cooler Guard Group (Parts For The Rear Axle)
Item	Part Number	Description	Quantity
1	7Y-3557	Bolt (16)	6
2	2Q-2825	Plate Assembly	2
3	2Q-2821	Plate Assembly	2
4	6V-7675	Bolt (16)	6
5	2Q-2820	Plate	2
6	6V-3668	Bolt (12)	12
7	5P-8245	Washer	12

Illustration 24	g00105060
Install the plate assembly starting with the bolt next to (G). (H) Rear oscillating axle.

Illustration 25	g00105061

Illustration 26	g00105062
(J) Rear axle. (K) Tighten to a specification of 300 ± 40 N·m (221.3 ± 29.5 lb ft).

1. Assemble the 2Q-2820 Plate (5) to the two side plates 2Q-2825 (2) and 2Q-2821 (3), as shown in Illustration 24. Follow the directions in Step 2 and Step 3.

2. Use three 7Y-3557 Bolts (1) to assemble the 2Q-2825 Plate (2) to the 2Q-2820 Plate (5).

3. Use three 6V-7675 Bolts (4) to assemble the 2Q-2821 Plate (3) to the 2Q-2820 Plate (5).

4. Install the 2Q-2820 Plate (with the 2Q-2825 Plate and 2Q-2821 Plate assembled) below the 135-2080 Manifold . Use six 6V-3668 Bolts (6) and six 5P-8245 Washers (7) to attach the plate assembly to the rear axle.

Note: Install the plate assemblies, starting with the bolt next to the first bolt. See Illustration 24 showing the offset from the first bolt (G).

The 134-6379 Rear Axle Pump And Motor Mounting Group and related rear axle parts have been installed using the procedure in this section.

Installation Of The Front Axle Parts

The 131-2303 Front Axle Pump And Motor Mounting Group and related front axle parts should be installed using the following procedure. Refer to Table 10, and to appropriate tables and illustrations, for a list of parts used in this installation procedure.

Table 10

131-2303 Front Axle Pump And Motor Mounting Group
Item	Part Number	Description	Quantity
1	130-7467	Motor And Pump Group	1
2	6V-3668	Bolt	2
3	5P-8245	Washer	2
4	6V-8624	Elbow	1
5	2M-9780	Seal	1
6	8T-5429	Elbow	2
7	3D-2824	Seal	2
8	9S-4191	Plug	1
9	3J-1907	Seal	1
10	6V-8628	Elbow	1
11	3J-7354	Seal	1
12	5P-0492	Adapter	1
13	7B-7169	Nipple	1
14	130-9505	Filter	1
15	7M-8485	Seal	1
16	5K-9090	Seal	1
17	8C-6875	Connector	1

Assembly And Installation Of The 131-2303 Front Axle Pump And Motor Mounting Group

Note: Lubricate the seals lightly with oil prior to the assembly. Use thread sealant compound for straight threads and pipe threads to prevent fluid leakage.

Note: Refer to Illustration 28 for location of the 131-2303 Front Axle Pump And Motor Mounting Group . Refer to Illustration 27 for the procedure of assembling and installing the 131-2303 Front Axle Pump And Motor Mounting Group .

Illustration 27	g00105076

1. Install the 3D-2824 Seal (7) and 8T-5429 Elbow (6) to the 130-7467 Pump And Motor Group (1) (front axle). This is the inlet line for the oil from the engine driven pump to the pump and motor group.

2. Install the 3D-2824 Seal (7) and 8T-5429 Elbow (6) to the 130-7467 Pump And Motor Group (1). This is the outlet line for the oil return from the pump and motor group to the hydraulic tank.

3. Install the 3J-7354 Seal (11) and 6V-8628 Elbow (10) to the 130-7467 Pump And Motor Group . This is the case drain from the pump and motor group to the hydraulic tank.

4. Install the 6V-8624 Elbow (4) and 2M-9780 Seal (5) to the 130-7467 Pump And Motor Group . This is the front axle oil outlet to the cooler.

5. Install the 9S-4191 Plug (8) and 3J-1907 Seal (9) to the 130-7467 Pump And Motor Group . This is the external drain line.

6. Install the 5P-0492 Adapter (12) with 7M-8485 Seal (15) to the 130-7467 Pump And Motor Group .

7. Assemble the 5P-0492 Adapter (12) to the 130-9505 Filter (14) with a 7B-7169 Nipple (13). Install the 5K-9090 Seal (16) and 8C-6875 Connector (17) to this assembly.

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Illustration 28	g00105070
(A) Front frame. (B) 4E-3986 Plate for installing the front pump and motor group. (C) 131-2303 Front Axle Pump And Motor Mounting Group (front axle brake oil cooler pump and motor group).

8. Install the assembled 131-2303 Front Axle Pump And Motor Mounting Group for the front axle on the 4E-3986 Plate (B, Illustration 28). Use two 6V-3668 Bolts (2) and two 5P-8245 Washers (3) for the installation.

   Note: The 4E-3986 Plate is part of the 2Q-3885 Frame Plate Group . The 4E-3986 Plate was earlier welded to the front frame. See section titled Installation Of The 2Q-3885 Frame Plate Group for instructions to weld the 4E-3986 Plate .

Installation Of The 135-2080 Manifold And Related Parts

Note: Refer to Illustration 29 for the procedure of installing the 135-2080 Manifold and related parts.

Illustration 29	g00105071
(D) 135-2080 Manifold. (E) 131-4797 Sender.

The 135-2080 Manifold referred to in this section is part of the 2Q-3948 Brake Oil Cooler Lines Group . See section titled Installation Of The 2Q-3948 Brake Oil Cooler Lines Group.

The 135-2080 Manifold (D, Illustration 29) to circulate axle oil in the front axle should be installed first. Remove the 5P-4484 Plug , 7M-8485 Seal and 9S-4181 Plug from the front axle. See Illustration 29 for the location of the parts removal.

Install the 9S-4181 Plug and the 135-2080 Manifold (D, Illustration 29) to the front axle. Install the 131-4797 Sender (E) to the 135-2080 Manifold (D). Use four 7M-8485 Seals and two 3K-0360 Seals for the installation.

The sender connects to the 135-7089 Harness Assembly from the cab ( 2Q-3514 Oil Temperature Gauge ). See section titled Installation Of The 2Q-3514 Oil Temperature Gauge. The sender indicates the temperature of the axle oil in the front axle under difficult braking conditions.

Installation Of The 4E-3673 Tube Assembly And 4E-3676 Tube Assembly

Note: Refer to Illustration 30 for the location of the 4E-3673 Tube Assembly and 4E-3676 Tube Assembly (F).

Illustration 30	g00105072
(F) Tube Assemblies (4E-3673 And 4E-3676). (G) 2Q-2819 Brake Oil Cooler Guard Group.

The 4E-3673 Tube Assembly and 4E-3676 Tube Assembly and related parts referred to in this section are part of the 2Q-3948 Brake Oil Cooler Lines Group . See section titled Installation Of The 2Q-3948 Brake Oil Cooler Lines Group for additional installation information.

1. Assemble the 4E-3673 Tube Assembly and 4E-3676 Tube Assembly . Each tube assembly should be assembled using two end Sleeves ( 6V-8560 and 6V-9620 ), two Nuts ( 6V-8553 and 6V-8554 ) and the 8T-1679 Tube .

2. Connect the 4E-3673 Tube Assembly and 4E-3676 Tube Assembly using a 6V-8789 Tee and 6V-8398 Seal .

3. Install the 6V-8724 Elbow and 6V-8397 Seal , and the 9T-5212 Adapter and 3J-1907 Seal , to the front axle.

The 4E-3673 Tube Assembly and 4E-3676 Tube Assembly provide for the return of the axle oil from the left hand cooler to the front axle.

Assembly And Installation Of The 2Q-2819 Brake Oil Cooler Guard Group (To The Front Axle)

The 2Q-2819 Brake Oil Cooler Guard Group should be assembled and installed to the front axle. Refer to Table 11 and Illustration 30 through Illustration 33 for a list of parts that should be installed in this procedure.

Table 11

2Q-2819 Oil Cooler Guard Group (Parts For The Front Axle)
Item	Part Number	Description	Quantity
1	7Y-3557	Bolt (16)	6
2	2Q-2825	Plate Assembly	2
3	2Q-2821	Plate Assembly	2
4	6V-7675	Bolt (16)	6
5	2Q-2820	Plate	2
6	6V-3668	Bolt (12)	12
7	5P-8245	Washer	12

Note: The parts in the 2Q-2819 Brake Oil Cooler Guard Group are also used in order to install the brake oil cooler guard for the rear axle. See section titled Installation Of The Rear Axle Parts.

Illustration 31	g00105073
Install the plate assembly starting with the bolt next to (H). (J) Front axle.

Illustration 32	g00105074

Illustration 33	g00105075
(H) Front axle. (K) Tighten to a specification of 300 ± 40 N·m (221.3 ± 29.5 lb ft).

1. Assemble the 2Q-2820 Plate (5) to the 2Q-2825 Plate (2) and 2Q-2821 Plate (3) as shown in Illustration 33. Follow the directions in Step 2 and Step 3.

2. Use three 7Y-3557 Bolts (1) to assemble the 2Q-2825 Plate (2) to the 2Q-2820 Plate (5).

3. Use three 6V-7675 Bolts (4) to assemble the 2Q-2821 Plate (3) to the 2Q-2820 Plate (5).

4. Install the 2Q-2820 Plate (with the 2Q-2825 Plate and 2Q-2821 Plate assembled) below the 135-2080 Manifold . Use six 6V-3668 Bolts (6) and six 5P-8245 Washers (7) to attach the plate assembly to the front axle.

Note: Install the plate assemblies, starting with the bolt next to the first bolt. See Illustration 31 showing the offset from the first bolt (H).

The 131-2303 Front Axle Pump And Motor Mounting Group and related front axle parts have been installed using the procedure in this section.

Installation Of The 2Q-3513 Brake Oil Cooler Pump And Drive Group And Related Parts

The 2Q-3513 Brake Oil Cooler Pump And Drive Group and related parts should be installed using the following procedure. Refer to the appropriate tables and illustrations, for a list of parts used in this installation procedure.

Removal Of The 8N-9703 Oil Filler Group

Remove the 8N-9703 Oil Filler Group from the basic engine arrangement. Refer to Table 12 and Illustration 34 for a list of parts to be removed.

Table 12

8N-9703 Oil Filler Group
Item	Part Number	Description	Quantity
1	1W-4930	Pipe Assembly	1
2	5F-3106	Seal	1
3	0S-1566	Bolt	2

Illustration 34	g00105079
(A) Tighten to a specification of 100 ± 10 N·m (73.8 ± 7.4 lb ft).

Installation Of The 2P-6855 Oil Filler Group

Install the 2P-6855 Oil Filler Group to the engine arrangement. Refer to Table 13 and Illustration 35 for a list of parts to be installed in the 2P-6855 Oil Filler Group . The orientation of the new 2P-6855 Oil Filler Group should be as shown by the dotted line configuration in Illustration 35.

Table 13

2P-6855 Oil Filler Group
Item	Part Number	Description	Quantity
1	2P-2720	Gasket	1
2	1A-2029	Bolt	2
3	9M-5732	Rivet	1
4	6N-2985	Cap Assembly	1
5	2P-2719	Pipe	1
6	2A-3211	Washer	1
7	5M-2894	Washer	2

Illustration 35	g00105080
(B) The correct configuration (dotted line).

Installation Of The 2Q-3513 Brake Oil Cooler Pump And Drive Group

Install the 2Q-3513 Brake Oil Cooler Pump And Drive Group at the rear of the timing gear, using the following procedure. Use the parts listed in Table 14 and Illustration 36, for the installation.

Table 14

2Q-3513 Main Drive Pump Group
Item	Part Number	Description	Quantity
1	130-7465	Pump Group	1
2	7E-3202	Adapter	1
3	5F-3106	Seal	1
4	6N-9547	Gear	1
5	4P-9037	Gear	1
6	4K-8341	Nut	1
7	8T-4223	Washer	1
8	6D-1004	Gasket	1
9	0S-0532	Stud	2
10	6V-8801	Nut	2
11	8T-4896	Washer	2
12	134-0140	Key	1
13	7X-0345	Bolt	2
14	2P-6855	Filler Group	1

Illustration 36	g00105078
(C) Apply thread sealant to the studs before assembly. (D) Lubricate seal lightly with oil before assembly.

1. Remove the timing gear cover.

2. Install the correct gear using the 4K-8341 Nut (6) and 8T-4223 Washer (7). Install the 6D-1004 Gasket (8) and two 0S-0532 Studs (9), and the two 6V-8801 Nuts (10) and two 8T-4896 Washers (11). Install the 134-0140 Key when assembling the gear. Apply thread sealant when assembling the stud. Refer to the following notes to install the correct gear for the basic engine arrangement of the wheel loader to which the 2Z-9956 Brake Oil Cooler Kit is being installed.

   Note: Use a 4P-9037 Spur Gear (Hydraulic) on the 966F Series II (PIN: 1SL1665-UP) and 970F (PIN: 7SK692-UP) Wheel Loaders. This is for the 122-4210 Basic Engine Arrangement .

   Note: Use a 6N-9547 Helical Gear (Hydraulic Pump Drive) on the 966F Series II (PIN: 1SL1-1664) and 970F (PIN: 7SK1-691) Wheel Loaders. This is for the 6I-2965 Basic Engine Arrangement and 106-3145 Basic Engine Arrangement .

3. Install the timing gear cover.

4. Install the 130-7465 Pump Group to the rear of the timing gear cover. Use the 7E-3202 Adapter (2), 5F-3106 Seal (3) and two 7X-0345 Bolts (13) for the installation. Lubricate the seal for the assembly lightly for the installation.

Installation Of The 2Q-3948 Brake Oil Cooler Lines Group

The 2Q-3948 Brake Oil Cooler Lines Group should be installed using the following procedure. Refer to Table 15 and illustrations in this section for a list of parts used in this installation procedure.

Table 15

2Q-3948 Oil Cooler Lines Group
Item	Part Number	Description	Quantity
1	7M-8485	Seal	12
2	6V-9005	Elbow	1
3	5K-9090	Seal	7
4	134-5362	Hose Assembly	1
5	6V-8714	Connector	1
6	3D-2824	Seal	3
7	6V-8398	Seal	32
8	134-5125	Hose Assembly	1
9	6V-8625	Elbow	4
10	3K-0360	Seal	10
11	135-2075	Valve Group	1
12	8B-2377	Bolt	2
13	4B-5269	Washer	4
14	9S-4185	Plug	1
15	6V-9002	Elbow	2
16	134-5282	Hose Assembly	1
17	134-5284	Hose Assembly	1
18	135-1767	Hose Assembly	1
19	6V-8789	Tee	2
20	4E-3676	Tube Assembly	2
21	4E-3673	Tube Assembly	2
22	6V-8397	Seal	6
23	6V-8724	Elbow	4
24	3J-1907	Seal	6
25	9T-5212	Adapter	4
26	135-1846	Hose Assembly	1
27	135-2080	Manifold	2
28	131-4797	Sender	2
29	9S-4181	Plug	2
30	6V-8635	Connector	2
31	134-5563	Hose Assembly	1
32	135-1624	Hose Assembly	1
33	135-2171	Hose Assembly	1
34	135-2176	Hose Assembly	1
35	7X-0347	Bolt	1
36	4D-6351	Clip	2
37	4P-7582	Clip	1
38	6R-8919	Tie	100
39	135-2170	Hose Assembly	1
40	6V-9837	Tee	1
41	6V-8556	Nut	2
42	6V-8942	Reducer	2
43	8T-1685	Tee	1
44	135-2169	Hose Assembly	1
45	134-5048	Hose Assembly	2
46	4J-5477	Seal	7
47	6V-9835	Tee	1
48	6V-8627	Elbow	1
49	4E-3660	Flange	1
50	134-5562	Hose Assembly	1
51	6V-8981	Elbow	1
52	6V-9169	Nut	1
53	8C-8989	Elbow	1
54	136-9354	Hose Assembly	1
55	1P-8016	Clip	1
56	9F-7716	Clip	1
57	135-8729	Valve Assembly	1
58	5P-2675	Bolt	2
59	136-5852	Hose Assembly	1
60	8T-0077	Connector	1
61	136-5853	Hose Assembly	1
62	6V-8934	Reducer Assembly	2
63	6V-8781	Tee	1
64	8T-4223	Washer	1
65	6V-8801	Nut	1

Note: Refer to Illustration 37 through Illustration 44 for the location of parts in the 2Q-3948 Brake Oil Cooler Lines Group .

1. Install the 7M-8485 Seal (1), 6V-9005 Elbow (2), 5K-9090 Seal (3), 134-5362 Hose Assembly (4), 5K-9090 Seal (3), 6V-8714 Connector (5), and 3D-2824 Seal (6). This is the suction line from the hydraulic tank to the main drive pump. Refer to letter (A) in the illustrations.

2. Install the 3K-0360 Seal (10), 6V-9002 Elbow (15), 6V-8398 Seal (7), 134-5125 Hose Assembly (8), 6V-8398 Seal (7), 6V-8625 Elbow (9), and 3K-0360 Seal (10). This is the main engine drive pump outlet to the frame mounted directional valve group. Refer to letter (B) in the illustrations.

3. Install the 135-2075 Valve Group (11), two 8B-2377 Bolts (12), two 4B-5269 Washers (13), 9S-4185 Plug (14), and 3K-0360 Seal (10). This is the line for the frame mounted flow divider.

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Illustration 37	g00105088
Side view of the front end of the machine.

4. Install the 3K-0360 Seal (10), 6V-9002 Elbow (15), 134-5282 Hose Assembly (16), and two 6V-8398 Seals (7). This is the line from the frame mounted flow divider to the front axle pump and motor group. Refer to letter (D) in the illustrations.

5. Install the 3K-0360 Seal (10), 6V-8625 Elbow (9), 134-5284 Hose Assembly (17), and two 6V-8398 Seals (7). This is the line from the frame mounted flow divider to the rear pump and motor group. Refer to letter (E) in the illustrations.

6. Install two 6V-8398 Seals (7) and 135-1767 Hose Assembly (18). Install the 6V-8789 Tee (19), two 6V-8398 Seals (7), 4E-3676 Tube Assembly (20), 4E-3673 Tube Assembly (21), two 6V-8397 Seals (22), two 6V-8724 Elbows (23), two 3J-1907 Seals (24), two 9T-5212 Adapters (25), and two 7M-8485 Seals (1) for the rear axle tube assembly. Install the 136-9354 Hose Assembly (54) with three 6V-8398 Seals (7), 6V-8981 Elbow (51), 6V-9169 Nut (52), and 8C-8989 Elbow (53). This is the right hand cooler core return line to the rear axle. Refer to letters F1 and F2 in the illustrations.

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Illustration 38	g00105089
Side view of the front end of the machine.

7. Install two 6V-8398 Seals (7) and 135-1846 Hose Assembly (26). Install the 6V-8789 Tee (19), two 6V-8398 Seals (7), 4E-3676 Tube Assembly (20), 4E-3673 Tube Assembly (21), two 6V-8397 Seals (22), two 6V-8724 Elbows (23), two 3J-1907 Seals (24), two 9T-5212 Adapters (25), and two 7M-8485 Seals (1) for the front axle tube assembly. This is the left hand cooler core return line to the front axle. Refer to letter (G) in the illustrations.

8. Install the 135-2080 Manifold (27), 7M-8485 Seal (1), 131-4797 Sender (28), 3K-0360 Seal (10), 9S-4181 Plug (29), 7M-8485 Seal (1). This is the manifold for axle suction line to the front pump and motor group, and the manifold for axle suction line to the rear pump and motor group. See the section titled Installation Of The Rear Axle Parts, and the section titled Installation Of The Front Axle Parts for related installation instructions.

9. Install the 6V-8635 Connector (30), 5K-9090 Seal (3), 134-5563 Hose Assembly (31), 5K-9090 Seal (3), and 7M-8485 Seal (1). This is the suction line from the front axle to the front pump and motor group. Refer to letter (H1) in the illustrations.

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Illustration 39	g00105090
View B-B, Illustration 38.

10. Install the 6V-8635 Connector (30), 5K-9090 Seal (3), 135-1624 Hose Assembly (32), 5K-9090 Seal (3), and 7M-8485 Seal (1). This is the suction line from the rear axle to the rear pump and motor group. Refer to letter (J) in the illustrations.

11. Install the 7X-0347 Bolt (35), 4D-6351 Clip (36), 4P-7582 Clip (37), 6R-8919 Ties (38), 1P-8016 Clip (55), and 9F-7716 Clip (56). Use the clips and ties as required.

12. Install two 6V-8398 Seals (7) and 135-2171 Hose Assembly (33). This is the line for the front axle oil from the front pump and motor group to the left hand side cooler. Refer to letter (L) in the illustrations.

13. Install two 6V-8398 Seals (7) and 135-2176 Hose Assembly (34). This is the line for the rear axle oil from the rear pump and motor group to the right hand side cooler. Refer to letter (M) in the illustrations.

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Illustration 40	g00105091
Top view of the front end of the machine.

14. Install the 3D-2824 Seal (6), two 6V-8398 Seals (7), 131-2170 Hose Assembly (39), three 6V-8398 Seals (7), 6V-8397 Tee (40), 6V-8556 Nut (41), 6V-8942 Reducer (42), 8T-1685 Tee (43), and 7M-8485 Seal (1). This is the return line for the front axle pump and motor group to the hydraulic tank. Refer to letter (N) in the illustrations.

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Illustration 41	g00105092
View C-C, Illustration 40 (upper part of illustration). View D-D, Illustration 40 (lower part of illustration).

15. Install the 3D-2824 Seal (6), 6V-8398 Seal (7), 135-2169 Hose Assembly (44), and 6V-8398 Seal (7). This is the return line for the rear axle pump and motor group to the hydraulic tank. Refer to letter (O) in the illustrations.

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Illustration 42	g00105093
Side view of the engine end.

16. Install the 4J-5477 Seal (46), 134-5562 Hose Assembly (50), 4J-5477 Seal (46), 6V-9835 Tee (47), 4J-5477 Seal (46), 6V-8934 Reducer Assembly (62), 6V-8397 Seal (22), 6V-8781 Tee (63), 3J-1907 Seal (24), and 4E-3660 Flange (49). This is the line for the rear axle pump and motor case drain to the hydraulic tank. Refer to letter (P) in the illustrations.

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Illustration 43	g00105094
View A-A, Illustration 42.

17. Install the 134-5048 Hose Assembly (45) and two 4J-5477 Seals (46). This is the line for the front axle pump and motor case drain to the hydraulic tank. Refer to letter (Q) in the illustrations.

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Illustration 44	g00105095
Top view of the engine end.

18. Install the 135-8729 Valve Assembly (57), two 5P-2675 Bolts (58), and 4B-5269 Washer (13). These are the parts in the directional valve group located on the rear frame.

    Note: Use a thread lock up material with the valve handle. The thread lock up material prevents the valve handle from falling during machine operation.

19. Install the 3K-0360 Seal (10), 6V-8625 Elbow (9), 6V-8398 Seal (7), 136-5852 Hose Assembly (59), 6V-8398 Seal (7), 6V-8625 Elbow (9), and 3K-0360 Seal (10). This is the line for the directional valve group to the flow divider. Refer to letter (S) in the illustrations.

20. Install the 3K-0360 Seal (10), 8T-0077 Connector (60), two 6V-8398 Seals (7), and 136-5853 Hose Assembly (61). This is the line for the directional valve group to the hydraulic tank. Refer to letter (T) in the illustrations.

21. Install the 3J-1907 Seal (24), 6V-8627 Elbow (48), 4J-5477 Seal (46), 134-5048 Hose Assembly (45), 4J-5477 Seal (46), 6V-8934 Reducer Assembly (62), and 6V-8397 Seal (22). This is the line for the main engine pump case drain to the hydraulic tank. Refer to letter (W) in the illustrations.

Completion Of The Installation

After installing the parts in the 2Z-9956 Brake Oil Cooler Kit , use the following steps to complete the procedure.

1. Fill the front axle oil and rear axle oil to about 60% of the capacity.

2. Fill the hydraulic tank to the appropriate capacity.

3. Install the rear mounted counterweights.

4. Fill the transmission tank if the oil dipstick has been changed during the installation procedure.

5. Install the wheels on the rear axle.

6. Install the grill at the radiator front.

   Note: Use appropriate lift and carry devices, and service tools to install the grill and the wheels.

7. Paint the surfaces that are affected by the installation procedure.

8. Move the machine off the stands.

Note: Use appropriate service tools make the machine operable after the installation procedure.