Caterpillar Cat 966H Wheel Loader (Prefix TAL) Service Repair Manual (TAL00001 and up).pdf

Service Repair Manual
Models
966H Wheel Loader

Shutdown SIS
Previous Screen
Product: WHEEL LOADER
Model: 966H WHEEL LOADER TAL
Configuration: 966H Wheel Loader TAL00001-UP (MACHINE) POWERED BY C11 Engine
Disassembly and Assembly
966H and 972H Wheel Loaders Power Train
Media Number -RENR8847-07 Publication Date -01/03/2013 Date Updated -04/03/2013
i03894983
Torque Converter (Freewheel Stator) - Disassemble
SMCS - 3101-015
S/N - A6D1-UP
S/N - A6G1-UP
S/N - A6J1-UP
S/N - RYF1-UP
S/N - TAL1-UP
Disassembly Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 138-7575 Link Bracket 2
B 1P-0510 Driver Gp 1
C 2P-8312 Retaining Ring Pliers 1
Start By:
A. Separate the torque converter from the transmission and from output transfer gears.
Note: Cleanliness is an important factor. Before the disassembly procedure, the exterior of the
component should be thoroughly cleaned. This will help to prevent dirt from entering the internal
mechanism.
1/11
966H Wheel Loader TAL00001-UP (MACHINE) POWERED BY C11 Engine(SEBP...
2020/4/4
https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw...

NOTICE
Care must be taken to ensure that fluids are contained during
performance of inspection, maintenance, testing, adjusting and repair
of the product. Be prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any component
containing fluids.
Refer to Special Publication, NENG2500, "Caterpillar Dealer Service
Tool Catalog" for tools and supplies suitable to collect and contain
fluids on Caterpillar products.
Dispose of all fluids according to local regulations and mandates.
Illustration 1 g02139353
1. Use Tooling (A) and a suitable lifting device to position torque converter assembly (1) on
suitable blocking, as shown. The weight of torque converter assembly (1) is approximately
186 kg (410 lb).
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2. Remove torque converter speed sensor (2), the seal, and the washer.
3. Remove gear (3) from torque converter assembly (1) .
4. Remove bolts (4) and washers that hold the torque converter to the torque converter
housing.
5. Remove O-ring seal (5) .
6. Remove pump drive flange (6) .
3/11
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7. Remove bolt (7) and the washer that holds drive gear shaft (8) to the torque converter
housing.
8. Remove drive gear shaft (8) from pump drive gear (9) .
9. Use Tooling (A) and a suitable lifting device to remove the torque converter housing. The
weight of torque converter housing is approximately 100 kg (220 lb).
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10. Remove pump drive gear (9) from the torque converter housing.
11. Remove bearing (10) from pump drive gear (9). Use Tooling (B) in order to remove bearing
(10) .
Note: For disassembly of carrier shaft (14), refer to Steps 30 through 34.
12. Remove bolts (11) and washers. Use a suitable lifting device to remove impeller (12) from
rotating housing (13). The weight of impeller assembly (12) is approximately 36 kg (80 lb).
Note: If the torque converter is equipped with a freewheel stator, continue with Steps 13
through 19.
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13. Turn impeller (12) to opposite side.
14. Remove retaining ring (15) and spacer (16) from carrier shaft (14) .
15. Remove stator (17) .
16. Remove retaining ring (18) and washer (19) from stator (17). Repeat the procedure for
opposite side of stator (17) .
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17. Remove bearing race (20), freewheel rollers (21), freewheel springs (22), and freewheel
cam (23) from stator (17) .
18. Remove spacer (24) from impeller (12) .
7/11
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19. Use a suitable press to remove carrier shaft (14) from impeller (12) .
20. Remove drive gear (25) .
21. Remove bearing (26) from impeller (12) .
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22. Remove retaining ring (27) and end cover (28) from rotating housing (13) .
23. Remove O-ring seal (29) .
24. Use Tooling (C) in order to remove retaining ring (30) .
25. Remove bearing spacer (31) from rotating housing (13) .
26. Turn rotating housing (13) onto opposite side. Remove turbine (32) .
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27. Remove bolts (33) and washers. Separate turbine (34) from turbine hub assembly (35) .
28. If necessary, remove locating dowel (36) .
29. Remove bearing (37) and ring (38) from rotating housing (13) .
10/11
966H Wheel Loader TAL00001-UP (MACHINE) POWERED BY C11 Engine(SEB...
2020/4/4

30. Remove retaining ring (44) and plate (43) .
31. Use a soft faced hammer to remove shaft assembly (39) from carrier shaft (14) .
32. Remove outer bearing (42) .
33. Use a suitable press to remove inner race (41) from shaft (39) .
34. Remove ring (40) from shaft (39) .
Copyright 1993 - 2020 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Sat Apr 4 12:08:26 UTC+0800 2020
11/11
2020/4/4

Shutdown SIS
Previous Screen
i03894987
Torque Converter (Freewheel Stator) - Assemble
SMCS - 3101-016
S/N - A6D1-UP
S/N - A6G1-UP
S/N - A6J1-UP
S/N - RYF1-UP
S/N - TAL1-UP
Assembly Procedure
Table 1
Required Tools
B 1P-0510 Driver Gp 1
C 2P-8312 Retaining Ring Pliers 1
D 7F-6068 Sleeve 1
Note: Cleanliness is an important factor. Before assembly, all parts should be thoroughly cleaned
in cleaning fluid. Allow the parts to air dry. Wiping cloths or rags should not be used to dry parts.
Lint may be deposited on the parts which may cause later trouble. Inspect all parts. If any parts are
worn or damaged, use new parts for replacement.
1/10
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1. Install bearing (37) and ring (38) on rotating housing (13) .
1. Install locating dowel (36) in turbine hub assembly (35) .
2. Install turbine hub assembly (35) to turbine (34). Install bolts (33) and the washers. The
torque for bolts (33) is 60 ± 7 N·m (44 ± 5 lb ft).
2/10
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3. Turn rotating housing (13) onto opposite side. Install turbine (32) .
4. Install bearing spacer (31) .
5. Use Tooling (C) in order to install retaining ring (30) on turbine hub assembly (13).
Retaining ring (30) must be securely seated in the groove.
6. Install O-ring seal (29) .
7. Install end cover (28) and retaining ring (27) in rotating housing (13) .
3/10
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8. Lower the temperature of bearing (26) .
9. Install bearing (26) in impeller (12) .
10. Install drive gear (25). The torque for bolts (25A) is 105 ± 15 N·m (75 ± 11 lb ft).
Note: If the torque converter is equipped with a freewheel stator, continue with Steps 11
through 16.
4/10
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11. Use a suitable press to install carrier shaft (14) in impeller (12) .
12. Install spacer (24) over shaft (14) .
13. Install freewheel cam (23), freewheel springs (22), freewheel rollers (21), and bearing race
(20) in stator (17) .
Note: If necessary, raise the temperature of stator (17) to a maximum temperature of 135 °C
(275 °F). Install the cam with the IMPELLER SIDE facing downward. Continue with the
installation until freewheel cam (23) contacts the retaining ring (not shown).
Note: Install freewheel springs (22) with the maximum number of loops toward the outside
diameter of freewheel cam (23) .
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14. Install washer (19) and retaining ring (18) on stator (17). Repeat the procedure for the
opposite side of stator (17) .
15. Install stator (17) on impeller (12) .
16. Install spacer (16) and retaining ring (15) on carrier shaft (14) .
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17. Assemble carrier shaft (14), as follows.
18. Install ring (40) on shaft (39) .
19. Use a suitable press in order to install inner race (41) onto shaft (39) .
20. Install outer bearing (42) .
21. Use Tooling (B), Tooling (D), and a suitable press to install shaft assembly (39) and outer
bearing (42) into carrier shaft (14) .
22. Install plate (43) and retaining ring (44) .
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23. Install impeller (12) on rotating housing (13). The weight of the impeller assembly (12) is
approximately 36 kg (80 lb).
24. Install bolts (11) and washers. The torque for bolts (11) is 60 ± 7 N·m (44 ± 5 lb ft).
25. Use Tooling (B) to install bearing (10) in pump drive gear (9) .
8/10
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26. Use Tooling (A) and a suitable lifting device to install the torque converter housing over the
torque converter. The weight of the torque converter housing is approximately 100 kg (220
lb).
27. Install pump drive gear (9) and drive gear shaft (8) .
28. Install bolt (7) and the washer that holds drive gear shaft (8) to the torque converter housing.
The torque for bolt (7) is 240 ± 40 N·m (180 ± 30 lb ft).
29. Install pump drive flange (6) and bolts (6A). The torque for bolts (6A) is 60 ± 12 N·m (44 ±
9 lb ft).
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30. Install bolts (4) and the washers that hold the torque converter to the torque converter
housing. The torque for bolts (4) is 50 ± 10 N·m (37 ± 7 lb ft).
31. Install O-ring seal (5) .
32. Install gear (3). The torque for bolt (3A) is 120 ± 20 N·m (90 ± 15 lb ft).
33. Install torque converter speed sensor (2), the seal, and the washer. Adjust torque converter
speed sensor (2) in order to maintain an air gap of 0.71 ± 0.18 mm (0.028 ± 0.007 inch). The
torque for torque converter speed sensor (4) is 25 ± 5 N·m (18 ± 4 lb ft).
End By: Connect the torque converter to the transmission and to the output transfer gears.
Copyright 1993 - 2020 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Sat Apr 4 12:09:22 UTC+0800 2020
10/10
2020/4/4

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Shutdown SIS
Previous Screen
i03965720
Transmission from Output Transfer Gears - Separate
SMCS - 3002-076
S/N - A6D1-UP
S/N - A6G1-UP
S/N - A6J1-UP
S/N - RYF1-UP
S/N - TAL1-UP
Separation Procedure
Table 1
Required Tools
B 154-6181 Forcing Screw 3
Start By:
A. Separate the torque converter from the transmission.
Note: Cleanliness is an important factor. Before the disassembly procedure, the exterior of the
component should be cleaned thoroughly. This will help to prevent dirt from entering the internal
mechanism.
1/4
2020/4/4

1. Remove bolts (1) and tube assembly (2) .
2. Disconnect harness assembly (3) .
3. Attach Tooling (A) and a suitable lifting device to transmission (4).
2/4
2020/4/4

4. Remove bolts (5) and (6) that connect transmission (4) to transfer gears (7) .
5. Use Tooling (B) in order to separate transmission (4) from output transfer gears (7) .
3/4
2020/4/4

Caterpillar Cat 966H Wheel Loader (Prefix TAL) Service Repair Manual (TAL00001 and up).pdf

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Caterpillar Cat 966H Wheel Loader (Prefix TAL) Service Repair Manual (TAL00001 and up).pdf