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Caterpillar Cat 966M Wheel Loader (Prefix KJP) Service Repair Manual (KJP00001 and up)

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Caterpillar Cat 966M Wheel Loader (Prefix KJP) Service Repair Manual (KJP00001 and up)

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  1. Service Repair Manual Models 966M WheelLoader

  2. 966M Wheel Loader KJP00001-UP (MACHINE) POWERED BY C9.3 Engine(SEBP... 1/17 Shutdown SIS Previous Screen Product: WHEEL LOADER Model: 966M WHEEL LOADER KJP Configuration: 966M Wheel Loader KJP00001-UP (MACHINE) POWERED BY C9.3 Engine Disassembly and Assembly 966M and 972M Wheel Loaders Power Train Media Number -UENR0378-12 Publication Date -01/09/2015 Date Updated -05/10/2017 i05275562 Torque Converter (Freewheel Stator) (Lockup) - Disassemble SMCS - 3101-015-L7 Disassembly Procedure Table 1 Required Tools Tool Part Number Part Description Qty A 422-5472 Lifting Eye Assembly 3 B 1P-0520 Driver Gp 1 C 8H-0663 Bearing Puller Gp 1 Start By: a. Separate the torque converter from the transmission and from the output transfer gears. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2021/7/26

  3. 966M Wheel Loader KJP00001-UP (MACHINE) POWERED BY C9.3 Engine(SEBP... 2/17 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, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat 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). Illustration 2 g03569471 2. Remove torque converter speed sensor (2), the seal, and the washer. 3. Remove gear (3) from torque converter assembly (1). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2021/7/26

  4. 966M Wheel Loader KJP00001-UP (MACHINE) POWERED BY C9.3 Engine(SEBP... 3/17 Illustration 3 g02139369 4. Remove bolts (4) and washers that hold the torque converter to the torque converter housing. 5. Remove O-ring seal (5). Illustration 4 g02139386 6. Remove pump drive flange (6). Illustration 5 g02139389 https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2021/7/26

  5. 966M Wheel Loader KJP00001-UP (MACHINE) POWERED BY C9.3 Engine(SEBP... 4/17 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). Illustration 6 g03355946 9. Use Tooling (A) and a suitable lifting device to torque converter housing (10). The weight of torque converter housing (10) is approximately 100 kg (220 lb). Use Tooling (A) and the suitable lifting device in order to remove torque converter housing (10). Illustration 7 g03356175 10. Remove pump drive gear (9) from the torque converter housing. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2021/7/26

  6. https://www.aservicemanualpdf.com/ My Dear Friend! Thank you very much for visiting. Full manual if required, please enter the following URL into your browser. https://www.aservicemanualpdf.com/

  7. 966M Wheel Loader KJP00001-UP (MACHINE) POWERED BY C9.3 Engine(SEBP... 5/17 Illustration 8 g03356180 11. Remove bearing (11) from pump drive gear (9). Use Tooling (B) in order to remove bearing (11). Illustration 9 g03355259 12. Position torque converter (12) on the opposite side that is shown. Illustration 10 g03355265 13. Remove seal (14). Remove bolts (13). Illustration 11 g03355293 https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2021/7/26

  8. 966M Wheel Loader KJP00001-UP (MACHINE) POWERED BY C9.3 Engine(SEBP... 6/17 14. Install two bolts (13), as shown. Use bolts (13) as pusher bolts in order to separate housing assembly (15) from the torque converter. Illustration 12 g03355307 15. Remove bushing (16) from housing assembly (15). Remove O-ring seal (17). Illustration 13 g03355310 16. Remove piston (18). Illustration 14 g03355350 17. Remove seal ring (19) from piston (18). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2021/7/26

  9. 966M Wheel Loader KJP00001-UP (MACHINE) POWERED BY C9.3 Engine(SEBP... 7/17 Illustration 15 g03355353 18. Remove bolts (20) and remove coupling assembly (21). Illustration 16 g03355362 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. 19. Remove bolts (22) from coupling assembly (21). Remove plate (23). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2021/7/26

  10. 966M Wheel Loader KJP00001-UP (MACHINE) POWERED BY C9.3 Engine(SEBP... 8/17 Illustration 17 g03355386 20. Remove springs (24). Remove springs (25) and (26) from the insides of springs (24). Note: Notice the difference in lengths of springs (25) and (26). Illustration 18 g03355408 21. Remove plate (27). Illustration 19 g03355416 22. Remove clutch disc (28). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2021/7/26

  11. 966M Wheel Loader KJP00001-UP (MACHINE) POWERED BY C9.3 Engine(SEBP... 9/17 Illustration 20 g03355474 23. Remove spline plate (29). Illustration 21 g03355477 24. Remove backing plate (30). Illustration 22 g03355481 25. Remove bearing (31). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2021/7/26

  12. 966M Wheel Loader KJP00001-UP (MACHINE) POWERED BY C9.3 Engine(SE... 10/17 Illustration 23 g03355490 26. Remove retaining ring (32) and washer (33). Illustration 24 g03355497 27. Install two bolts (20), as shown, through turbine (34) and into turbine hub (35). Remove turbine (34) and turbine hub (35) as one unit. Illustration 25 g03355507 28. Remove bolts (20) and separate turbine (34) from turbine hub (35). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2021/7/26

  13. 966M Wheel Loader KJP00001-UP (MACHINE) POWERED BY C9.3 Engine(SE... 11/17 Illustration 26 g03355511 29. Remove thrust bearing (36). Illustration 27 g03355513 30. Remove stator (37). Illustration 28 g03357296 31. Remove retaining ring (38). Remove plate (39). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2021/7/26

  14. 966M Wheel Loader KJP00001-UP (MACHINE) POWERED BY C9.3 Engine(SE... 12/17 Illustration 29 g03357298 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. 32. Flip stator (37) over and remove retaining ring (40). Remove plate (41). Illustration 30 g03357299 33. Remove race (42), freewheel rollers (44), and freewheel springs (43). Note: Mark the orientation of freewheel springs for assembly purposes. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2021/7/26

  15. 966M Wheel Loader KJP00001-UP (MACHINE) POWERED BY C9.3 Engine(SE... 13/17 Illustration 31 g03357305 34. Use Tooling (B) and a suitable press in order to remove cam (45) (not shown) from stator (37). Illustration 32 g03355514 35. Remove thrust bearing (46). Illustration 33 g03355520 36. Remove bolts (47). Remove impeller hub (48) and impeller (49). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2021/7/26

  16. 966M Wheel Loader KJP00001-UP (MACHINE) POWERED BY C9.3 Engine(SE... 14/17 Illustration 34 g03355529 37. Remove impeller (49) from impeller hub (48). Illustration 35 g03355533 38. Remove retaining ring (50) and remove stator carrier assembly (51). Illustration 36 g03355612 39. Remove retaining ring (52) from stator carrier assembly (51). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2021/7/26

  17. 966M Wheel Loader KJP00001-UP (MACHINE) POWERED BY C9.3 Engine(SE... 15/17 Illustration 37 g03355615 40. Use a suitable press in order to separate gear (53) from stator carrier assembly (51). Illustration 38 g03355618 41. Use Tooling (B) and a suitable press in order to remove bearing (54) (not shown) from gear (53). Illustration 39 g03355621 42. Remove seal (55) from stator carrier assembly (51). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2021/7/26

  18. 966M Wheel Loader KJP00001-UP (MACHINE) POWERED BY C9.3 Engine(SE... 16/17 Illustration 40 g03355625 43. Remove retaining ring (56) and bearing (57). Illustration 41 g03355638 44. Remove seals (59) from shaft (58). Remove seal (60). Illustration 42 g03355644 45. Use Tooling (C) and a suitable press in order to remove bearing race (61) from shaft (58). Copyright 1993 - 2021 Caterpillar Inc. Mon Jul 26 09:04:19 UTC+0800 2021 All Rights Reserved. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2021/7/26

  19. 966M Wheel Loader KJP00001-UP (MACHINE) POWERED BY C9.3 Engine(SEBP... 1/16 Shutdown SIS Previous Screen Product: WHEEL LOADER Model: 966M WHEEL LOADER KJP Configuration: 966M Wheel Loader KJP00001-UP (MACHINE) POWERED BY C9.3 Engine Disassembly and Assembly 966M and 972M Wheel Loaders Power Train Media Number -UENR0378-12 Publication Date -01/09/2015 Date Updated -05/10/2017 i05277906 Torque Converter (Freewheel Stator) (Lockup) - Assemble SMCS - 3101-016-L7 Assembly Procedure Table 1 Required Tools Tool Part Number Part Description Qty A 422-5472 Lifting Eye Assembly 3 B 1P-0520 Driver Gp 1 NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2021/7/26

  20. 966M Wheel Loader KJP00001-UP (MACHINE) POWERED BY C9.3 Engine(SEBP... 2/16 Illustration 1 g03355787 1. Use a suitable press in order to install bearing race (61) onto shaft (58). Illustration 2 g03355638 2. Install seals (59) onto shaft (58). Install seal (60). Illustration 3 g03355625 3. Install bearing (57) and retaining ring (56). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2021/7/26

  21. 966M Wheel Loader KJP00001-UP (MACHINE) POWERED BY C9.3 Engine(SEBP... 3/16 Illustration 4 g03355621 4. Install seal (55) onto stator carrier assembly (51). Illustration 5 g03355790 5. Use Tooling (B) and a suitable press in order to install bearing (54) (not shown) into gear (53). Illustration 6 g03355793 6. Use Tooling (B) and a suitable press in order to install stator carrier assembly (51) into gear (53). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2021/7/26

  22. 966M Wheel Loader KJP00001-UP (MACHINE) POWERED BY C9.3 Engine(SEBP... 4/16 Illustration 7 g03355612 7. Install retaining ring (52) onto stator carrier assembly (51). Illustration 8 g03355807 8. Install stator carrier assembly (51) onto shaft (58). Install retaining ring (50). Illustration 9 g03355529 9. Install impeller hub (48) to impeller (49). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2021/7/26

  23. 966M Wheel Loader KJP00001-UP (MACHINE) POWERED BY C9.3 Engine(SEBP... 5/16 Illustration 10 g03355520 10. Install impeller hub (48) and impeller (49). Install bolts (47). Tighten bolts (47) to a torque of 60 ± 7 N·m (44 ± 5 lb ft). Illustration 11 g03355514 11. Install thrust bearing (46). Illustration 12 g03357305 12. Use Tooling (B) and a suitable press in order to install cam (45) (not shown) into stator (37). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2021/7/26

  24. 966M Wheel Loader KJP00001-UP (MACHINE) POWERED BY C9.3 Engine(SEBP... 6/16 Illustration 13 g03357299 Illustration 14 g03357350 13. Install race (42), freewheel springs (43), and freewheel rollers (44). Note: Be sure to install freewheel springs with the lesser number of loops going toward race (42), as shown in Illustration 14. Illustration 15 g03357298 https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2021/7/26

  25. 966M Wheel Loader KJP00001-UP (MACHINE) POWERED BY C9.3 Engine(SEBP... 7/16 Improper assembly of parts that are spring loaded can cause bodily injury. To prevent possible injury, follow the established assembly procedure and wear protective equipment. 14. Install plate (41) and retaining ring (40) into stator (37). Illustration 16 g03357296 15. Flip the stator over and install plate (39) and retaining ring (38). Illustration 17 g03355513 16. Install stator (37). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2021/7/26

  26. 966M Wheel Loader KJP00001-UP (MACHINE) POWERED BY C9.3 Engine(SEBP... 8/16 Illustration 18 g03355511 17. Install thrust bearing (36). Illustration 19 g03355507 18. Connect turbine (34) to turbine hub (35). Install two bolts (20) in order to keep turbine (34) and turbine hub (35) together during the Step 19. Illustration 20 g03355497 19. Install turbine (34) to turbine hub (35) as one unit. Remove bolts (20). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2021/7/26

  27. 966M Wheel Loader KJP00001-UP (MACHINE) POWERED BY C9.3 Engine(SEBP... 9/16 Illustration 21 g03355490 20. Install washer (33) and retaining ring (32). Illustration 22 g03355481 21. Install bearing (31). Illustration 23 g03355477 22. Install backing plate (30). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2021/7/26

  28. 966M Wheel Loader KJP00001-UP (MACHINE) POWERED BY C9.3 Engine(SE... 10/16 Illustration 24 g03355474 23. Install spline plate (29). Illustration 25 g03355416 24. Install clutch disc (28). Illustration 26 g03355408 25. Install plate (27). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2021/7/26

  29. 966M Wheel Loader KJP00001-UP (MACHINE) POWERED BY C9.3 Engine(SE... 11/16 Illustration 27 g03355386 26. Install springs (26) and (25) inside of springs (24). Install springs (24) in an alternating pattern. An example would be to install a spring (24) and with a spring (25) inside. The next one would be to install a spring (24) with a spring (26) inside. Illustration 28 g03355362 Improper assembly of parts that are spring loaded can cause bodily injury. To prevent possible injury, follow the established assembly procedure and wear protective equipment. 27. Install plate (23) to coupling assembly (21). Install bolts (22). Tighten bolts (22) to a torque of 50 ± 10 N·m (37 ± 7 lb ft). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2021/7/26

  30. 966M Wheel Loader KJP00001-UP (MACHINE) POWERED BY C9.3 Engine(SE... 12/16 Illustration 29 g03355353 28. Install coupling assembly (21). Install bolts (20). Tighten bolts (20) to a torque of 60 ± 7 N·m (44 ± 5 lb ft). Illustration 30 g03355350 29. Install seal ring (19) into piston (18). Illustration 31 g03355310 30. Install piston (18). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2021/7/26

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  32. 966M Wheel Loader KJP00001-UP (MACHINE) POWERED BY C9.3 Engine(SE... 13/16 Illustration 32 g03355307 31. Install O-ring seal (17). Install bushing (16) into housing assembly (15). Illustration 33 g03355853 32. Install housing assembly (15) into the torque converter. Illustration 34 g03355265 33. Install bolts (13). Tighten bolts (13) to a torque of 60 ± 7 N·m (44 ± 5 lb ft). Install seal (14). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2021/7/26

  33. 966M Wheel Loader KJP00001-UP (MACHINE) POWERED BY C9.3 Engine(SE... 14/16 Illustration 35 g03355259 34. Position torque converter (12) as shown. Illustration 36 g03356180 35. Use Tooling (B) in order to install bearing (11) in pump drive gear (9). Illustration 37 g03355946 36. Attach Tooling (A) and a suitable lifting device to torque converter housing (10). The weight of torque converter housing (10) is approximately 100 kg (220 lb). Use Tooling (A) and the suitable lifting device in order to install torque converter housing (10) over the torque converter. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2021/7/26

  34. 966M Wheel Loader KJP00001-UP (MACHINE) POWERED BY C9.3 Engine(SE... 15/16 Illustration 38 g02139389 37. Install pump drive gear (9) and drive gear shaft (8). 38. Install bolt (7) and the washer that holds drive gear shaft (8) to the torque converter housing. Tighten bolt (7) to a torque of 240 ± 40 N·m (180 ± 30 lb ft). Illustration 39 g03356370 39. Install pump drive flange (6) and bolts (62). Tighten bolts (62) to a torque of 60 ± 12 N·m (44 ± 9 lb ft). Illustration 40 g02139369 https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2021/7/26

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