Caterpillar cat 966 h wheel loader (prefix a6j) service repair manual (a6j01801 and up)

Service Repair Manual
Models
966H WHEEL LOADER

Shutdown SIS
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Product: WHEEL LOADER
Model: 966H WHEEL LOADER A6J
Configuration: 966H WHEEL LOADER A6J01801-UP (MACHINE) POWERED BY C11
Disassembly and Assembly
966H and 972H Wheel Loaders Power Train
Media Number -RENR8847-07 Publication Date -01/03/2013 Date Updated -04/03/2013
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
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
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.
1/10966H WHEEL LOADER A6J01801-UP (MACHINE) POWERED BY C11(XEBP101...
2020/3/28https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis...

Illustration 1 g02140488
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).

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) .

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.

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) .

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) .

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) .

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) .

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).

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 Mar 28 17:51:51 UTC+0800 2020

Shutdown SIS
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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
Tool Part Number Part Description Qty
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. Remove bolts (1) and tube assembly (2) .
2. Disconnect harness assembly (3) .
3. Attach Tooling (A) and a suitable lifting device to transmission (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) .

6. Remove transmission (4). The weight of transmission (4) is approximately 425 kg (936 lb).
Copyright 1993 - 2020 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Sat Mar 28 17:52:47 UTC+0800 2020

Shutdown SIS
Previous Screen
i06125079
Transmission Planetary - Disassemble
SMCS - 3160-015
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
B -
Steel Rods (3.175 mm (0.1250 inch) diameter and one
pointed tip)
6
C 1P-0520 Driver Gp 1
D 8B-7551 Bearing Puller 1
Start By:
A. Separate the transmission from the output transfer gears.
Note: Cleanliness is an important factor. Before the disassembly procedure, clean the exterior of
the component to prevent dirt from entering the internal mechanism.

1. Remove O-ring seal (1) from the housing.
2. Remove bolt (2) and the retainer. Remove drive gear (3) from the end of the input shaft.
3. Remove plate (4) .

4. Attach Tooling (A) and a suitable lifting device to the transmission, as shown. The weight
of the transmission is approximately 425 kg (936 lb).
5. Carefully position the planetary group on the opposite end so that No. 6 clutch housing (5)
is facing upward, as shown.
Personal injury can result from being struck by parts propelled by a
released spring force.
Make sure to wear all necessary protective equipment.
Follow the recommended procedure and use all recommended tooling to
release the spring force.
6. Remove retaining ring (6) from output shaft assembly (7) . Remove bolts (8) , the washers,
and No. 6 clutch housing (5) . Mark the location of the long bolts.

7. Remove clutch piston (9) from No. 6 clutch housing (5) .
8. Remove seal rings (10) and (11) from clutch piston (9) .
9. Remove plate (12) and springs (13) .

10. Remove plates (12) and discs (14) . Remove dowels (15) .
11. Remove ring gear (16) .
12. Remove carrier assembly (17) . Remove bolts (18) and the washers.

13. Remove metal seal ring (19) from carrier assembly (17) .
14. Push spring pins (20) through carrier assembly (17) and into planetary shafts (21) . Remove
planetary shafts (21) from carrier assembly (17) .
15. Remove thrust discs (22) , planetary gears (23) , and bearings (24) from the carrier
assembly. Remove spring pins (20) from planetary shafts (21) .

16. Disconnect harness assemblies (25) which are attached to transmission modulating valves
(26) . Remove transmission modulating valves (26) from the transmission housing.
17. Remove retaining ring (27) and (28) .

18. Use Tooling (A) and a suitable lifting device in order to remove housing assembly (29) .
The weight of housing assembly (29) is approximately 88 kg (195 lb).
19. Remove bearing (30) from housing assembly (29) .
20. Remove retaining ring (31) and clutch housing (32) . Remove springs (33) and rods (34) .

Personal injury can result from being struck by parts propelled by a
released spring force.
Make sure to wear all necessary protective equipment.
Follow the recommended procedure and use all recommended tooling to
release the spring force.
21. Use steel spacers and a suitable press to lower retainer plate (35) . Remove retaining ring
(37) from sun gear (36) .

22. Separate retaining ring (37) , retainer plate (35) , and five coned disc springs (38) from sun
gear (36) . Remove seal rings (41) from clutch piston (39) . Remove seal rings (42) from
clutch housing (40) .
23. Remove discs (44) and plates (43) .

24. Remove retaining ring (45) from the output shaft assembly (7) . Remove hub (46) .
25. Remove discs (47) and plates (48) .
26. Remove ring gear (49) .

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27. Remove retaining ring (50) and reaction plate (51) from ring gear (49) .
28. Remove clutch piston (52) . Remove O-ring seal (53) . Use Tooling (A) and a suitable
lifting device in order to remove housing (54) .
Note: Remove clutch piston (52) in the bottom of housing (54) . Clutch piston (52) may be
stuck in housing (54) . As housing (54) is removed, the other clutch piston may fall.

29. Remove seal rings (55) and (56) from clutch pistons (52) .
30. Remove dowels (57) . Remove O-ring seal (58) . Remove plate (59) . Remove springs (60) .
31. Remove remaining plates (59) and discs (61) .
32. Remove carrier assembly (62) .

33. Use Tooling (B) to compress the retaining ring that holds carrier assembly (62) to ring gear
(65) .
34. Remove carrier assembly (62) from ring gear (65) . Remove ring seal (63) .
35. Remove retaining ring (66) from carrier assembly (62) .

Caterpillar cat 966 h wheel loader (prefix a6j) service repair manual (a6j01801 and up)

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