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Bienvenido: cr080x0063895x02
Producto: WHEEL LOADER
Modelo: 966G WHEEL LOADER 3SW
Configuración: 966G Wheel Loader 3SW00001-UP (MACHINE) POWERED BY 3306 Engine
Desarmado y Armado
966G and 972G Wheel Loaders Power Train
Número de medio -RENR2106-08 Fecha de publicación -01/05/2004 Fecha de actualización -28/05/2004
i06064263
Assembly Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 138-7575 Link Bracket 3
B 1P-0520 Driver Gp 1
D FT-2746 Guide Pin 2
E 1P-0510 Driver Gp 1
F - Loctite 5127 1
Note: Cleanliness is an important factor. Before assembly, all parts should be 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.
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Illustration 1 g00460318
Note: O-ring seal (137) is not installed at this time. The O-ring seal is shown in order to
clarify the installation in Step 11.
1. Raise the temperature of bearing (135) and the race. Install bearing (135) and the race onto
input shaft (134) , as shown.
2. Apply clean transmission oil to ring seals (136) . Install two ring seals (136) on input shaft
(134) .
Illustration 2 g00460315
4. Install retaining ring (132) in order to hold the input shaft and the bearing in place.
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Illustration 3 g00460313
Illustration 4 g00460237
5. Install bearings (130) in planetary gears (129) . Install the gear assemblies, thrust discs
(128) , and planetary shafts (127) in carrier assembly (119) .
6. Use a hammer and a punch to install spring pins (131) that hold planetary shafts (127) in
carrier assembly (119) . Make sure that the spring pins are flush with the counterbore in the
carrier.
Illustration 5 g00460233
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8. Use Tooling (B) to install bearing (125) . Install retaining ring (124) .
Note: Coupling (120) may be installed on carrier assembly (119) at this time. Refer to Step
13 for the procedure.
Illustration 6 g00460209
Illustration 7 g00460208
10. Place suitable cribbing under the housing. Install clutch piston (121) in the clutch housing.
Make sure that the lips of the seals are facing downward.
11. Install O-ring seal (137) . Apply clean transmission oil to O-ring seal (137) and the O-ring
seal groove on the shaft. Refer to Illustration 1 for the location of the O-ring seal.
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Illustration 8 g00460207
13. If necessary, install coupling (120) on carrier assembly (119) . Use small steel rods (118) to
compress the retaining ring that holds coupling (120) to carrier assembly (119) .
Illustration 9 g00460934
Illustration 10 g00720054
Note: For assembly purposes, use Tooling (D) to hold the clutch plates in place. Do not
remove Tooling (D) until Step 85 is completed.
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14. Install one clutch plate (117) in the housing so that the small hole in the clutch plate is
aligned with the small hole in the housing, as shown.
15. Install Tooling (D) in two of the five threaded holes in the housing through clutch plate
(117) , as shown. Do not remove Tooling (D) until Step 85 is completed.
16. Install friction discs (114) and clutch plates (117) in alternating order. Start with a friction
disc. Install clutch plates (117) so that Tooling (D) passes through the bolt holes in the
clutch plates. Install the clutch plates with the small holes on the opposite side of Tooling
(D) in comparison to the first clutch plate (117) that was installed in Step 14.
Illustration 11 g00460178
Illustration 12 g00460135
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Illustration 13 g00460081
19. Install bearings (109) in planetary gears (108) . Install the gear assemblies, thrust discs
(107) , and planetary shafts (106) in carrier assembly (99) .
20. Use a hammer and a punch to install spring pins (110) that hold planetary shafts (106) in
carrier assembly (99) . Make sure that the spring pins are flush with the counterbore in the
carrier.
Illustration 14 g00460141
Illustration 15 g00569395
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21. Use Tooling (B) and a press to install bearing (111) . Install retaining ring (104) .
22. Install O-ring seal (112) on sun gear (103) . Apply clean transmission oil to O-ring seal
(112) and the O-ring seal groove on sun gear (103) .
Illustration 16 g00460074
Note: Gear (100) is not installed at this time. The gear is shown in order to clarify the
installation in Step 27.
25. Use small steel rods (101) to compress the retaining ring. Install carrier assembly (99) in
ring gear (102) until the retaining ring fits into the groove in the ring gear.
Illustration 17 g00720063
26. Install carrier assembly (99) on the input shaft. The weight of the carrier assembly is
approximately29 kg (65 lb).
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Illustration 18 g00460067
Typical Example
30. Install O-ring seals (97) and (98) . Install springs (95) .
Illustration 19 g00460045
31. Install seal rings (92) and (93) on clutch piston (89) .
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Illustration 20 g01151694
32. Install friction discs (90) and clutch plates (91) in alternating order. Start with a friction
disc. Start with a friction disc. Install clutch plates (91) so that Tooling (D) passes through
the bolt holes in the clutch plates. Install the last clutch plate so that the small holes in the
clutch plate are over springs (95) , as shown. Install rods (67) .
33. Install clutch piston (89) . Make sure that the lips of the seals are facing upward.
Illustration 21 g00565282
Typical Example
34. Use Tooling (A) and a suitable lifting device to install housing (88) . The weight of housing
(88) is approximately 61 kg (135 lb).
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Illustration 22 g00460034
35. If bearings (87) were removed, lower the temperature of the two bearings. Then, put the
bearings in position in both ends of output shaft (82) .
Illustration 23 g01153103
Note: For the 966F, install the bearing to a depth of 12.0 ± 0.5 mm (0.47 ± 0.02 inch) on the
gear end of the output shaft. After assembly, the inside diameter of bearing (87) must be
34.988 ± 0.039 mm (1.3775 ± 0.0015 inch). Repeat for the opposite end of the output shaft.
Note: For the 972F, install the bearing to a depth of 13.00 ± 0.25 mm (0.512 ± 0.010 inch)
on the gear end of the output shaft. After assembly, the inside diameter of bearing (87) must
be 56.650 ± 0.061 mm (2.2303 ± 0.0024 inch). Install the bearing on the other end of the
output shaft to a depth of 25.50 ± 0.25 mm (1.004 ± 0.010 inch). After assembly, the inside
diameter of bearing must be 35.629 ± 0.039 mm (1.4028 ± 0.0016 inch).
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Illustration 24 g00461572
Note: Make sure that the locating dowel fits into the notch in the bearing. Also, the groove
in the bearing must face the top of the output shaft.
37. Raise the temperature of bearing (86) and install the bearing on output shaft (82) .
Illustration 25 g00460029
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Illustration 26 g00459776
Illustration 27 g00720135
42. Install retaining ring (81) that holds output shaft (82) to the carrier assembly.
Illustration 28 g00459646
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Illustration 29 g00459643
43. Install bearings (79) in planetary gears (78) . Install the gear assemblies, thrust discs (77) ,
and planetary shafts (76) in carrier assembly (69) .
44. Use a hammer and a punch to install spring pins (80) that hold planetary shafts (76) in
carrier assembly (69) . Make sure that the spring pins are flush with the counterbore in the
carrier.
Illustration 30 g00459638
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Illustration 31 g00459634
46. Use steel rods (73) to compress the retaining ring. Install carrier assembly (69) in ring gear
(74) until the retaining ring fits into the groove in the ring gear.
Illustration 32 g00459622
Illustration 33 g00459619
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Illustration 34 g01151699
49. Install carrier assembly (69) . Make sure that all of the gear teeth are correctly engaged.
50. Install springs (68) . Install O-ring seals (65) and (66) .
51. Install friction discs (63) and clutch plates (64) in alternating order. Install clutch plates (64)
so that Tooling (D) passes through the bolt holes in the clutch plates. Install the last clutch
plate so that the small holes in the clutch plate are over springs (68) , as shown. Start with a
friction disc.
Illustration 35 g00459540
52. Install seal rings (61) and (62) on clutch piston (60) .
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Illustration 36 g00720165
53. Install clutch piston (60) . Make sure that the lips of the seals are facing upward.
Note: Clutch piston (60) may be installed in housing (59) before the housing is placed in
position.
Illustration 37 g00565199
Typical Example
54. Use Tooling (A) and a suitable lifting device to install housing (59) . The weight of housing
(59) is approximately 66 kg (145 lb).
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Illustration 38 g00459506
55. Install seal rings (57) and (58) on clutch piston (54) .
Illustration 39 g00720171
56. Install clutch piston (54) . Make sure that the lips of the seals are facing downward.
57. Install hub (46) . Install retaining ring (45) on the output shaft.
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Illustration 40 g00720321
59. Install friction discs (52) and clutch plates (53) in alternating order. Install clutch plates (53)
so that Tooling (D) passes through the bolt holes in clutch plates (53) . Install the first clutch
plate so that the pins pass through the small holes in the clutch plate, as shown. Start with a
clutch plate.
Illustration 41 g00720327
Illustration 42 g00565685
61. Install friction discs (47) and clutch plates (48) in alternating order. Start with a friction
disc.
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Illustration 43 g00459393
Illustration 44 g00459387
Illustration 45 g00459375
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63. Stack clutch piston (42) , coned disc springs (41) , and retainer plate (40) on the clutch
housing. Make sure that the outside edges of the coned disc springs contact each other first.
64. Use steel spacers and a press to push on retainer plate (40) . Install retaining ring (39) on the
clutch housing.
Illustration 46 g00459394
Note: Each seal ring has a small gap. The gaps on the different seal rings should not be in
line with each other.
Illustration 47 g00459372
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Illustration 48 g00720343
67. Install clutch housing (37) in the ring gear. Install retaining ring (36) . Install springs (51) .
Illustration 49 g00459352
68. Lower the temperature of bearing (35) . Install bearing (35) in manifold (28) . Install
retaining ring (34) .
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Illustration 50 g00459322
Typical Example
69. Use Tooling (A) and a suitable lifting device to install manifold (28) . The weight of
manifold (28) is approximately 85 kg (190 lb).
Note: When installing manifold (28) ensure proper alignment of dowel on output shaft (82)
in notch of bearing (35) .
70. Install bolt (33) which holds the harness assembly in place.
Illustration 51 g00462047
Typical Example
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Illustration 52 g00459316
72. Install gear (30) . Use two screwdrivers to lift the clutch housing. Install retaining ring (31) .
Illustration 53 g00720354
Typical example
73. Apply Tooling (F) to both sides of the washers for bolts (27) . Install bolts (27) in manifold
(28) . Tighten bolts (27) to a torque of 280 ± 20 N·m (207 ± 15 lb ft).
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Illustration 54 g00324725
Illustration 55 g00459150
75. Install bearings (24) in planetary gears (23) . Install the gear assemblies, thrust discs (22)
and planetary shafts (21) in carrier assembly (19) .
76. Use a hammer and a punch to install spring pins (25) that hold planetary shafts (21) in
carrier assembly (19) . Make sure that the spring pins are flush with the counterbore in the
carrier.
Illustration 56 g00459138
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Illustration 57 g00720364
Illustration 58 g00720368
80. Install transmission speed sensors (18) , the seals, and the washers. Refer to Testing and
Adjusting, RENR4387, "Speed Sensor (Transmission) - Adjust". Tighten the locknuts. The
torque for the locknuts is 25 ± 5 N·m (220 ± 45 lb in).
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Illustration 59 g00720388
81. Install clutch plates (15) and friction discs (16) in alternating order. Install clutch plates (15)
so that the guide pins pass through the bolt holes in the clutch plates. Start with a friction
disc.
82. Install springs (13) and clutch plate (14) . Make sure that clutch plate (14) is installed so that
the small holes are over springs (13) , as shown.
Illustration 60 g00459079
83. Install seal rings (11) and (12) on clutch piston (10) .
84. Install clutch piston (10) in No. 6 clutch housing (6) . Make sure that the lips of the seals are
facing downward.
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Illustration 61 g00720402
85. Install No. 6 clutch housing (6) and five new bolts (9) . Tighten bolts (9) until bolts (9) are
snug. Remove Tooling (D) .
Illustration 62 g00720411
86. Install the two remaining bolts (9) . Tighten bolts (9) to a torque of 110 ± 10 N·m (80 ± 7 lb
ft).
Illustration 63 g00459073
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Illustration 64 g00462148
Typical Example
88. Apply 690 to 1030 kPa (100 to 150 psi) of shop air pressure into each oil passage (140)
(total of six).
If the clutch pistons do not move, apply a small amount of clean transmission oil in each oil
passage and check for movement again. If the clutch pistons do not move, the transmission
must be disassembled again so that the clutch pistons and the seal rings can be checked.
Note: The mounting surfaces for the transmission modulating valves must be completely
clean. Clean the surfaces before installation of the transmission modulating valves.
Illustration 65 g00565113
89. Install transmission modulating valves (29) on the transmission housing. The torque for the
mounting bolts is 30 ± 4 N·m (265 ± 35 lb in).
90. Connect the harness assemblies which attach to the transmission modulating valves.
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Illustration 66 g00459030
91. The No. 6 clutch housing (6) is facing upward. Use Tooling (A) and a suitable lifting device
to position the transmission onto the opposite end so that the No. 1 clutch housing is facing
upward. The weight of the transmission is approximately 544 kg (1200 lb).
Illustration 67 g00459007
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Illustration 68 g00458960
93. Install drive gear (4) on the end of the input shaft, as shown.
94. Install retainer (2) and bolt (3) . Tighten bolt (3) to a torque of 100 ± 20 N·m (75 ± 15 lb ft).
95. Apply clean transmission oil on O-ring seal (1) . Install O-ring seal (1) on the housing.
End By: Connect the transmission to the output transfer gears. Refer to Disassembly and
Assembly, "Transmission to Output Transfer Gears - Connect".
Copyright 1993 - 2018 Caterpillar Inc. Mon Oct 29 12:10:01 EST 2018
Todos los derechos reservados. cr080x0063895x02
Red privada para licenciados del SIS.
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