Caterpillar Cat 966C WHEEL LOADER (Prefix 76J) Service Repair Manual (76J06389-09655)

Service

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Product: WHEEL LOADER

Model: 966C WHEEL LOADER 76J

Configuration: 966C WHEEL LOADER 76J06389-09655 (MACHINE) POWERED BY 3306 ENGINE

Disassembly and Assembly

966 WHEEL LOADER POWER TRAIN

Axles

SMCS - 3259-11; 3259-12

Remove Axles

1. Remove plug (3). Drain the oil from the final drive.

2. Remove bolts (1). Remove cover assembly (2) from the final drive planet carrier.

Shutdown SIS

3. Pull axle (4) and gear part way out of the final drive.

NOTE: If the axle can not be removed, move the machine a small amount to the front or rear until the axle can be pulled from the final drive.

4. Fasten a hoist to the axle. Remove axle (4). The weight of the axle is 55 lb. (25 kg).

5. Remove retainer ring (6). Remove gear (5) and washer (7) from the axle.

Install Axles

1. Make sure the axles are clean and free of all dirt or foreign material.

2. Put washer (2) [with the steel side next to the gear] and gear (1) in position on the axle. Install retainer ring (3).

3. Fasten a hoist to the axle. Put axle (4) in position in the final drive.

4. Remove the retainer ring from the axle. Pull gear (1) part way off the axle. Put a piece of pipe (5) which has a 2" (5.1 cm) outside diameter and is approximately 24 in. (61 cm) long in the gear as shown. Push down on the pipe and slide the axle into position.

5. Remove the pipe. Slide gear (1) into position in the final drive planetary. Install the retainer ring on the axle.

6. Turn the flat sides of the three shafts (7) as shown to give clearance for counterbore in cover.

7. Check the O-ring seal in the cover assembly for wear or damage. If necessary, make a replacement.

NOTICE

If the cover does not fit flat up against the final drive without force, remove the cover and do Step 6 again.

8. Install cover assembly (6) on the final drive planetary carrier.

9. Fill the final drive with oil to the correct level. See LUBRICATION AND MAINTENANCE GUIDE.

Copyright 1993 - 2020 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees.

Shutdown SIS

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Product: WHEEL LOADER

Model: 966C WHEEL LOADER 76J

Configuration: 966C WHEEL LOADER 76J06389-09655 (MACHINE) POWERED BY 3306 ENGINE

Disassembly and Assembly

966 WHEEL LOADER POWER TRAIN

Final Drive Planet Carriers

SMCS - 4092-11; 4092-12

Remove Final Drive Planet Carriers

start by:

a) remove axles

1. Remove two bolts (1) (180° apart). Install two 5/8"-11 NC guide bolts in their place.

2. Fasten tooling (A) and a hoist to the final drive planet carrier as shown. Remove the remainder of the bolts that hold the final drive planet carrier to the wheel assembly.

3. Install two 1/2"-13 NC forcing screws (2) and loosen the final drive planet carrier from the wheel assembly.

4. Remove final drive planet carrier (3). The weight of the carrier is 100 lb. (45 kg).

Install Final Drive Planet Carrier

1. Check the O-ring on the back of the planet carrier for damage or wear. If necessary, make a replacement.

2. Install two 5/8"-11 NC guide bolts (2) in the wheel assembly 180° apart as shown.

3. Fasten tooling (A) and a hoist to the planet carrier. Put final drive planet carrier (1) in position in the wheel assembly. Install the bolts that hold it. Remove guide bolts (2). Install the remainder of the bolts. Tighten the bolts to a torque of 150 ± 20 lb.ft. (205 ± 27 N·m).

end by:

a) install axles

Copyright 1993 - 2020 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees.

Previous Screen

Product: WHEEL LOADER

Model: 966C WHEEL LOADER 76J

Configuration: 966C WHEEL LOADER 76J06389-09655 (MACHINE) POWERED BY 3306 ENGINE

Disassembly and Assembly

966 WHEEL LOADER POWER TRAIN

Final Drive Planet Carriers

SMCS - 4092-15; 4092-16

Disassemble Final Drive Planet Carriers

start by:

a) remove final drive planet carriers

1. Remove shafts (1) from the carrier.

2. Remove three gears (2) and twelve washers.

3. Remove retainer ring (4) from the shafts.

4. Remove two bearings (3) and spacer (5) from the gears.

Assemble Final Drive Planet Carriers

Shutdown SIS

1. Install bearings (1) and (3) and spacers (2) in gears (4).

2. Install retainer rings (5) on the shaft.

3. Put gears and washers in position in the carrier with steel washers (7) next to the gears and bronze washers (8) between the carrier and steel washers.

4. Install shafts (6) in the carrier. end by:

a) install final drive planet carriers

Copyright 1993 - 2020 Caterpillar Inc.

All Rights Reserved. Private Network For SIS Licensees.

Mon Apr 13 23:38:59 UTC+0800 2020

Previous Screen

Product: WHEEL LOADER

Model: 966C WHEEL LOADER 76J

Configuration: 966C WHEEL LOADER 76J06389-09655 (MACHINE) POWERED BY 3306 ENGINE

Disassembly and Assembly

966 WHEEL LOADER POWER TRAIN

Final Drive Ring Gears And Hubs

SMCS - 4054; 4055-12; 4055-11

Remove Final Drive And Gears And Hubs

Shutdown SIS

start by:

a) remove tires and rims (front or rear)

b) remove final drive planet carriers

1. Remove lockwire (2). Remove bolts (1) from nut (3).

2. Fasten tool (A) and a hoist to the wheel assembly as shown. Put an up force on the wheel assembly with the hoist.

3. Use tooling (B) to remove nut (3) from the spindle.

4. Use two persons to remove ring gear (4) and hub from the spindle. The weight of the ring gear and hub is 80 lb. (36 kg).

5. Remove bolts (5). Remove locks (6) and plates and remove hub assembly (7) from the ring gear.

6. Use tooling (C) to remove bearing cone (8) from the hub.

Install Final Drive Ring Gears And Hubs

a

of

1. Heat the bearing cone to

maximum temperature

275° (135°C). Install bearing cone (1) on the hub.

2. Put hub assembly (2) in position in the ring gear.

3. Install plates (3), locks and bolts that hold the hub in the ring gear.

4. Use two persons to put ring gear (4) and hub in position on the spindle.

6. Make an adjustment to the wheel bearings as follows:

a) Use an 8 in. (20.3 cm) long torque wrench (9S7354) on the wheel stud to slowly turn the wheel assembly while nut (5) is tightened with tooling (B). Tighten nut (5) until it takes a torque of 160 ± 50 lb.in. (18.1 ± 5.7 N·m) to turn the wheel assembly one complete revolution.

NOTE: Make sure the torque wrench is installed on the wheel stud so it is in line with the center of the wheel as shown.

b) Loosen nut (5). Tighten nut (5) again until it takes a torque of 75 ± 25 lb.in. (8.5 ± 2.8 N·m) to slowly turn the wheel assembly one complete revolution with an 8 in. (20.3 cm) torque wrench (9S7354) at the wheel stud.

NOTE: For torque wrenches of different lengths use the following formula for the correct torque:

5. Install nut (5) on the spindle. Remove tool (A) and the hoist from the wheel assembly.

C is the torque wrench reading.

A is the length of the torque wrench.

B is the distance from the center of the axle housing to the wheel stud.

T is torque to turn the wheel assembly.

T=160 ± 50 lb.in. (18.1 ± 5.7 N·m) for Step (a) and 75 ± 25 lb.in. (8.5 ± 2.8 N·m) for Step (b).

7. Install bolts (7) in the hub assembly. If necessary, turn nut (5) in a clockwise direction until the holes in the nut are in alignment with the holes in the hub assembly. Install lockwire (6) through the bolts.

end by:

a) install final drive planet carriers

b) install tires and rims (front or rear)

Copyright 1993 - 2020 Caterpillar Inc.

Previous Screen

Product: WHEEL LOADER

Model: 966C WHEEL LOADER 76J

Configuration: 966C WHEEL LOADER 76J06389-09655 (MACHINE) POWERED BY 3306 ENGINE

Disassembly and Assembly

966 WHEEL LOADER POWER TRAIN

Wheels, Bearings And Duo-Cone Seals

SMCS - 4208-11; 4208-12

Remove Wheels, Bearings And Duo-Cone Seals

Shutdown SIS

start by:

a) remove final drive ring gears and hubs

1. Use tool (A) and a hoist to remove wheel assembly (1) from the spindle. The weight of the wheel assembly is 330 lb. (149 kg).

2. Remove Duo-Cone seal (2) from the wheel assembly.

3. Remove bolts (3) and locks. Use two persons to remove brake drum (4) from the wheel assembly. The weight of the brake drum is 100 lb. (45 kg).

4. Remove bearing cups (5) from the wheel assembly.

5. Remove bearing cone (7) from the spindle.

6. Remove Duo-Cone seal (6) from the retainer.

7. If necessary, remove locks, bolts and bars (8). Remove retainer (9) from the spindle. Remove the O-ring seal from the back of the retainer.

Install Wheels, Bearings And Duo-Cone Seals

1. If retainer was removed, install O-ring seal on the back of the retainer. Put retainer in position on the spindle and install the bars, locks and bolts that hold it.

2. Make sure the rubber torus seals are clean and dry. Make sure all metal surfaces that make contact with the rubber torus seals are clean and dry. Use tool (A) to install the Duo-Cone seal in the retainer. Put a small amount of clean SAE 30 oil on the surfaces of the metal seals that make contact with each other.

3. Install bearing cone (1) on the spindle.

4. Lower the temperature of the bearing cups. Install bearing cups (2) in the wheel assembly.

5. Use two persons to install brake drum (4) on the wheel assembly. Install locks and bolts (3).

6. Make sure rubber torus seals are clean and dry. Make sure all metal surfaces that make contact with the rubber torus seals are clean and dry. Use tool (A) to install the Duo-Cone seal in the wheel assembly. Put a small amount of clean SAE 30 oil on the surfaces of the metal seals that make contact with each other.

end by:

a) install final drive ring gears and hubs

Copyright 1993 - 2020 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees.

Mon Apr 13 23:40:51 UTC+0800 2020

7. Fasten tool (B) and a hoist to the wheel assembly. Put wheel assembly (5) in position on the spindle.

Previous Screen

Product: WHEEL LOADER

Model: 966C WHEEL LOADER 76J

Configuration: 966C WHEEL LOADER 76J06389-09655 (MACHINE) POWERED BY 3306 ENGINE

Disassembly and Assembly

966 WHEEL LOADER POWER TRAIN

Brake Shoes

SMCS - 4253-12; 4253-11

Remove Brake Shoes

start by:

a) remove wheels, bearings and Duo-Cone seals

1. Remove covers (1) from the spindle.

2. Use an acceptable brake tool to remove springs (2) from the brake shoes.

Shutdown SIS

3. Remove lockwire (5). Loosen bolts (3) approximately .50 in. (12.7 mm).

4. Remove springs (4) from the pins.

5. Remove retainers (7) and felt washers.

6. Remove pins (6). Remove brake shoes (8). Remove springs, retainers and felt washers from the other end of pins (6).

Install Brake Shoes

1. Install the felt washers, retainers and springs on one end of pins (2).

2. Put brake shoes (3) in position on the spider and bearing assembly and install pins (2).

3. Install felt washers and retainers (1) on the pins.

4. Install springs (5) on the pins.

5. Tighten bolts (4). Make sure the holes in the pins are in alignment with the bolts before the bolts are tightened.

6. Use an acceptable brake tool (6) to install springs (7) on the brake shoes.

7. Install covers (8) on the spindle.

NOTE: After the final drive ring gears and hubs have been installed, make an adjustment to the brakes. See BRAKE ADJUSTMENT, 966C AIR SYSTEM AND BRAKES.

end by:

a) install wheels, bearings and Duo-Cone seals

Copyright 1993 - 2020 Caterpillar Inc.

Previous Screen

Product: WHEEL LOADER

Model: 966C WHEEL LOADER 76J

Configuration: 966C WHEEL LOADER 76J06389-09655 (MACHINE) POWERED BY 3306 ENGINE

Disassembly and Assembly

966 WHEEL LOADER POWER TRAIN

Wheel Spindles

SMCS - 4205-12; 4205-11

Remove Wheel Spindles

start by:

a) remove brake shoes

1. Turn slack adjuster (3) to release any force on pin (1).

2. Remove retainer ring (2) from the brake camshaft.

Shutdown SIS

3. Remove brake camshaft (5). Remove washers (4) from between the bracket assembly and slack adjuster assembly and from between the brake camshaft and spindle housing.

Make sure the air pressure in the brake system is zero before any lines are disconnected.

4. Disconnect air lines (6) from the chamber assembly.

5. Remove bolts (9). Remove bracket assembly (8), slack adjuster assembly and chamber assembly from the spindle assembly as a unit.

6. Fasten a hoist to the wheel spindle assembly. Remove nuts (7) and washers. Remove wheel spindle assembly (10). The weight of the wheel spindle assembly is 100 lb. (45 kg).

7. Remove O-ring seal (13) from the spindle.

8. Use four 1/2"-13 NC forcing screws to remove spider and bearing assembly (12) from spindle (11).

9. Remove sleeve (14), lip seal and bearing from the spider.

Install Wheel Spindles

1. Use tooling (A) to install sleeve (3) in the spider. Use tooling (A) to install bearing and lip seal in the opposite side of the spider. Install the seal with the lip toward the bearing.

2. Install spindle (4) in spider and bearing assembly (2). Put 1P808 General Purpose Lubricant in the bearing and bore of the spider assembly.

3. Install O-ring seal (1) on the spindle.

4. Fasten a hoist to the wheel spindle assembly. Install wheel spindle assembly (5) on the axle housing. Install the washers and nuts that hold it. Tighten the nuts to a torque of 345 ± 30 lb.ft. (465 ± 40 N·m).

5. Install bracket assembly (7), slack adjuster assembly and chamber assembly on the spindle assembly as a unit.

6. Connect air lines (6) to the chamber assembly.

7. Install washer (8) on the brake camshaft. Install brake camshaft (9) in spider and bracket assemblies. Install washer and slack adjuster assembly (10) on brake camshaft (9). Install the retainer ring on the brake camshaft.

end by:

a) install brake shoes

Copyright 1993 - 2020 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees.

Mon Apr 13 23:42:42 UTC+0800 2020

Shutdown SIS

Previous Screen

Product: WHEEL LOADER

Model: 966C WHEEL LOADER 76J

Configuration: 966C WHEEL LOADER 76J06389-09655 (MACHINE) POWERED BY 3306 ENGINE

Disassembly and Assembly

966 WHEEL LOADER POWER TRAIN

Front Differential And Carrier

SMCS - 3258-12; 3258-11

Remove Front Differential And Carrier

start by:

a) remove axles (front only)

1. Remove plug (1). Drain the oil from the front axle housing.

2. Remove spider and bearing assembly (4) from the front drive shaft (3) and differential pinion shaft.

3. Remove yoke (2) from the differential pinion shaft.

Make sure the air pressure in the brake system is zero before any lines are disconnected.

4. Disconnect three lines (5) from the tee fitting.

5. Disconnect three lines (6) from the quick release valve.

6. Disconnect clips (7) from each side of the axle housing and pull the air lines clear of the differential and carrier.

7. Fasten tooling (A) to the front differential and carrier as shown. Remove bolts (9). Install two 1/2"-13 NC forcing screws and remove differential and carrier (8) from the axle housing. The weight of the differential and carrier is 350 lb. (158 kg).

Install Front Differential And Carrier

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1. Fasten tooling (A) to the differential and carrier as shown. Put differential and carrier (1) in position in the axle housing. Install the bolts that hold it. Tighten the bolts to a torque of 195 ± 18 lb.ft. (265 ± 24 N·m).

2. Connect three air lines (2) to the tee fitting.

3. Connect three air lines (3) to the quick release valve.

4. Connect the clips that hold the air lines in position on the axle housing.

5. Install yoke (4) on the differential pinion shaft.

6. Install spider and bearing assembly (5) on the yoke and front drive shaft. Tighten the bolts to a torque of 100 ± 10 lb.ft. (135 ± 14 N·m).

7. Install the drain plug and fill the front axle housing with oil to the correct level. See LUBRICATION AND MAINTENANCE GUIDE.

end by:

a) install axles (front only)

Copyright 1993 - 2020 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees.