Caterpillar Cat 966H Wheel Loader (Prefix BJ6) Service Repair Manual (BJ600001 and up).pdf

Service Repair Manual
Models
966H Wheel Loader

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Product: WHEEL LOADER
Model: 966H WHEEL LOADER BJ6
Configuration: 966H Wheel Loader BJ600001-UP (MACHINE) POWERED BY C11 Engine
Disassembly and Assembly
C11 and C13 Engines for Caterpillar Built Machines
Media Number -RENR9214-23 Publication Date -01/05/2015 Date Updated -22/05/2018
i06931709
Gear Group (Rear) - Remove and Install
SMCS - 1206-010; 1212-010
Removal Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 1P-0520 Driver Gp. 1
B 1P-0510 Driver Gp 1
Start By:
a. Remove the electric starting motor.
b. Remove the flywheel.
1. Support the engine.
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966H Wheel Loader BJ600001-UP (MACHINE) POWERED BY C11 Engine(SEBP5...
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Illustration 1 g06002548
2. Remove bolts (2) and rear crankshaft seal (1).
3. Remove bolts (4) and the washers. Remove cover (3) and the seal.
4. Remove gear (7), bolts (6), and gear (5).
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5. Remove O-ring seal (8) from gear (7).
6. Use Tooling (A) to remove bushing (7A) from gear assembly (7).
7. Remove bolts (9), adapter assembly (10), and the O-ring seal.
8. Use Tooling (B) to remove bearing (11) from adapter assembly (10).
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9. Remove gear assembly (12).
10. Remove cover (13) and the O-ring seal.
11. Use Tooling (B) to remove bearing (14).
Installation Procedure
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Table 2
Required Tools
A 095-0706 Bolt 2
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1. Lower the temperature of bearing (14). Be sure to match Dimension (B) and Dimension (C)
when installing bearing (14.). Dimension (B) indicates the angle of the joint on bearing (14).
Dimension (B) is 15° ± 1°. Dimension (C) shows the distance from bearing (14) to the end
of the bore. Dimension (C) is 4.000 ± 0.500 mm (0.1575 ± 0.0197 inch).
2. Install the O-ring seal and cover (9).
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3. Install gear assembly (12) with oil passage plug (12A) facing out.
4. Lower the temperature of bearing (11). Be sure to match Dimension (F) and Dimension (G)
when installing bearing (11) into adapter assembly (10). Dimension (F) indicates the angle
of the joint on bearing (11). Dimension (F) is 15° ± 1°. Dimension (G) shows the distance
from bearing (11) to the end of the bore. Dimension (G) is 3.500 ± 0.500 mm
(0.1378 ± 0.0197 inch).
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5. Install the O-ring seal, adapter assembly (10), and bolts (9).
6. Lower the temperature of bearing (7A). Install bearing (7A) into gear assembly (7). Be sure
that each relief (H) is within 2° of each relief in gear assembly (7).
7. Install O-ring seal (8) onto gear (7).
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8. Install gear (5) and bolts (6).
Note: Tooling (A) is for supporting gear (7) during the installation of the cover and the rear
crankshaft seal.
Note: The bolt holes in gear (7) are not symmetrical. When installing Tooling (C), check
the rest of the bolts holes in gear (7) are aligned with the holes in the crankshaft.
9. Install gear (7) and Tooling (C).
10. Install cover (3), the seal, bolts (4), and the washers.
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11. Install rear crankshaft seal (1) and bolts (2).
12. Remove Tooling (C).
End By:
a. Install the flywheel.
b. Install the electric starting motor.
Copyright 1993 - 2020 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Mon Mar 30 14:55:37 UTC+0800 2020
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966H Wheel Loader BJ600001-UP (MACHINE) POWERED BY C11 Engine(SEB...
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i02249234
Flywheel - Remove
SMCS - 1156-011
Removal Procedure
Table 1
Required Tools
A 138-7574 Link Bracket 1
B FT2712 Guide Stud 1
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1. Attach Tooling (A) and a suitable lifting device to flywheel (2). The weight of flywheel (2)
is approximately 79 kg (175 lb).
2. Remove top bolt (1). Install Tooling (B).
3. Remove remaining bolts (1).
4. Remove flywheel (2).
5. Use a hammer and a punch in order to remove the ring gear.
Mon Mar 30 14:56:33 UTC+0800 2020
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i06123534
Flywheel - Install
SMCS - 1156-012
Table 1
Required Tools
A 138-7574 Link Bracket 1
B FT2712 Guide Stud 1
C - Loctite 242 1
Always wear protective gloves when handling parts that have been
heated.
1. Raise the temperature of the ring gear. Position the ring gear with the part number toward
the crankshaft. Install the ring gear on the flywheel. Allow the ring gear to cool. Use a soft
hammer in order to seat the ring gear against the shoulder of the flywheel.
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2. Attach Tooling (A) and a suitable lifting device to flywheel (2) . The weight of flywheel (2)
3. Position flywheel (2) on Tooling (B) .
4. Apply Tooling (C) to bolts (1) .
5. Install bolts (1) . Remove Tooling (B) . Install remaining bolt (1) . Tighten the bolts evenly
to a torque of 300 ± 40 N·m (221 ± 30 lb ft).
6. Check the flywheel runout. Refer to Testing and Adjusting, "Flywheel - Inspect" for the
correct procedure.
Mon Mar 30 14:57:29 UTC+0800 2020
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i06010889
Crankshaft Rear Seal - Remove
SMCS - 1161-011
Removal Procedure
Start By:
a. Remove the flywheel. Refer to Disassembly and Assembly, "Flywheel - Remove".
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, "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.
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1. Remove bolts (1).
2. Remove crankshaft rear seal (2).
Note: Refer to Reuse and Salvage Guidelines, SEBF8039, "Crankshaft Visual Inspection and
Magnetic Particle Inspection" for the correct inspection procedure of the crankshaft seal surface.
Note: Refer to Reuse and Salvage Guidelines, SEBF9217, "Specifications for Crankshafts C7, C9,
C-9, C10, C11, C12, C-12, C13, C-13, C15, C-15, C18, C-18, C27, C30, and C32 Engines" or the
correct specifications of the crankshaft.
Mon Mar 30 14:58:25 UTC+0800 2020
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i06010890
Crankshaft Rear Seal - Install
SMCS - 1161-012
Table 1
Required Tools
A - Loctite 7649 Primer N -
B - Loctite 620 Retaining Compound -
C 147-2675 Wear Sleeve Installer 1
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
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Numerical tightening sequence for bolts (2).
Note: If required, install a crankshaft wear sleeve at engine overhaul. For more information
please refer to the following Reuse and Salvage Guidelines. Refer to Reuse and Salvage
Guidelines, SEBF9217, "Specifications for Crankshafts C7, C9, C-9, C10, C11, C12, C-12,
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C13, C-13, C15, C-15, C18, C-18, C27, C30, and C32 Engines" or the correct specifications
of the crankshaft. Refer to Reuse and Salvage Guidelines, SEBF8039, "Crankshaft Visual
Inspection and Magnetic Particle Inspection" for the correct inspection procedure of the
crankshaft seal surface.
1. If a crankshaft wear sleeve is necessary, refer to Step 1.a through Step 1.d to install the
crankshaft wear sleeve. If a crankshaft wear sleeve is not necessary, refer to Step 2.
a. Clean and polish the crankshaft of imperfections.
b. Use Tooling (A) to clean the outside diameter of the crankshaft and the inside
diameter of the crankshaft wear sleeve.
c. Apply Tooling (B) to the outside diameter of the crankshaft and the inside diameter of
the crankshaft wear sleeve.
d. Use Tooling (C) to install the crankshaft wear sleeve.
Note: Leave the shipping sleeve in place to install the crankshaft rear seal. The crankshaft
rear seal must be installed dry.
Note: If the seal group, O-ring seal, and the shipping sleeve are separated, these
components should not be used.
2. Lubricate the O-ring seal with clean engine oil that is on the back of the crankshaft rear seal
(1).
3. Position crankshaft rear seal (1) and the shipping sleeve over the crankshaft. Push
crankshaft rear seal (1) in place to dislodge the shipping sleeve.
Note: Do not remove the shipping sleeve until bolts (2) are installed.
4. Install new bolts (2) hand tight. Then, tighten bolts (2) in numerical sequence, shown in
Illustration 2. Tighten bolts (2) to a torque of 12 ± 3 N·m (106 ± 27 lb in).
End By:
a. Install the flywheel. Refer to Disassembly and Assembly, "Flywheel - Install".
Mon Mar 30 14:59:20 UTC+0800 2020
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i02249340
Flywheel Housing - Remove and Install
SMCS - 1157-010
Removal Procedure
Start By:
a. Remove the electric starting motor. Refer to Disassembly and Assembly, "Electric Starting
Motor - Remove and Install".
b. Remove the flywheel. Refer to Disassembly and Assembly, "Flywheel - Remove".
1. Support the engine.
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2. Attach a suitable lifting device to flywheel housing (2). The weight of flywheel housing (2)
3. Remove bolts (1) and flywheel housing (2).
Table 1
Required Tools
A 1U-8846 Gasket Sealant 1
1. Apply Tooling (A) to the face of the cylinder block.
2. Attach a suitable lifting device to flywheel housing (2). The weight of flywheel housing (2)
is approximately 62 kg (137 lb). Position flywheel housing (2) on the rear of the cylinder
block.
3. Install bolts (1).
End By:
a. Install the flywheel. Refer to Disassembly and Assembly, "Flywheel - Install".
b. Install the electric starting motor. Refer to Disassembly and Assembly, "Electric Starting
Motor - Remove and Install".
Mon Mar 30 15:00:16 UTC+0800 2020
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i02249982
Vibration Damper and Pulley - Remove and Install
SMCS - 1205-010
Removal Procedure
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1. Remove belt (1).
2. Attach a suitable lifting device to crankshaft vibration damper and pulley (3). The weight of
crankshaft vibration damper and pulley (3) is approximately 27 kg (60 lb). Remove bolts
(2).
3. Remove crankshaft vibration damper and pulley (3).
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1. Attach a suitable lifting device to crankshaft vibration damper and pulley (3). The weight of
crankshaft vibration damper and pulley (3) is approximately 27 kg (60 lb). Position
crankshaft vibration damper and pulley (3) on the engine.
2. Install bolts (2).
3. Install belt (1).
Mon Mar 30 15:01:12 UTC+0800 2020
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Caterpillar Cat 966H Wheel Loader (Prefix BJ6) Service Repair Manual (BJ600001 and up).pdf

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