Caterpillar Cat 966H Wheel Loader (Prefix BJ6) Service Repair Manual Instant Download

1
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 Required Tools Required Tools Required Tools
Tool Part Number Part Description Qty
A 1P-0520 Driver Gp. 1
B 1P-0510 Driver Gp 1

• Start By
• Remove the electric starting motor.
• Remove the flywheel.
• Support the engine.

3
Illustration 1 g06002548 2. Remove bolts (2) and
rear crankshaft seal (1).
Illustration 2 g06002556 3. Remove bolts (4) and
the washers. Remove cover (3) and the seal.
Illustration 3
g06002558
4. Remove gear (7), bolts (6), and gear (5).
Illustration 4
g06002564
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5. Remove O-ring seal (8) from gear (7).
Illustration 5 g06172622 6. Use Tooling (A) to
remove bushing (7A) from gear assembly (7).
Illustration 6 g06172537 7. Remove bolts (9),
adapter assembly (10), and the O-ring seal.
Illustration 7 g06172541 8. Use Tooling (B) to
remove bearing (11) from adapter assembly (10).
6
Illustration 8
g06172549
9. Remove gear assembly (12).
Illustration 9
g06172554
10. Remove cover (13) and the O-ring seal.
Illustration 10
g06172557
11. Use Tooling (B) to remove bearing (14).
Installation Procedure
7
Table 2
Required Tools Required Tools Required Tools Required Tools
Tool Part Number Part Description Qty
A 095-0706 Bolt 2
Illustration 11
g06172557
Illustration 12
g06172580
8
Illustration 13 g06172587 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).
Illustration 14
g06172554
2. Install the O-ring seal and cover (9).
9
Illustration 15 g06172597 3. Install gear
assembly (12) with oil passage plug (12A) facing
out.
Illustration 16
g06172601
Illustration 17 g06172609 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).
10
Illustration 18 g06172537 5. Install the O-ring
seal, adapter assembly (10), and bolts (9).
Illustration 19 g06172619 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).
Illustration 20
g06002564
7. Install O-ring seal (8) onto gear (7).
11
Illustration 21
g06002578

• 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.
• Install gear (7) and Tooling (C).

Illustration 22 g06002581 10. Install cover (3),
the seal, bolts (4), and the washers.
12

• Illustration 23 g06002592
• Install rear crankshaft seal (1) and bolts (2).
• Remove Tooling (C).
• End By
• Install the flywheel.
• Install the electric starting motor.

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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
i02249234
Flywheel - Remove SMCS - 1156-011 Removal
Procedure Table 1
Required Tools Required Tools Required Tools Required Tools
Tool Part Number Part Description Qty
A 138-7574 Link Bracket 1
B FT2712 Guide Stud 1
14

• Illustration 1 g01132214
• Attach Tooling (A) and a suitable lifting device
  to flywheel (2). The weight of flywheel (2) is
  approximately 79 kg (175 lb).
• Remove top bolt (1). Install Tooling (B).
• Remove remaining bolts (1).
• Remove flywheel (2).
• Use a hammer and a punch in order to remove the
  ring gear.

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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
i06123534
Flywheel - Install SMCS - 1156-012 Installation
Procedure Table 1
Required Tools Required Tools Required Tools Required Tools
Tool Part Number Part Description Qty
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.
16

• Illustration 1 g01132214
• Attach Tooling (A) and a suitable lifting device
  to flywheel (2) . The weight of flywheel (2) is
  approximately 79 kg (175 lb).
• Position flywheel (2) on Tooling (B) .
• Apply Tooling (C) to bolts (1) .
• Install bolts (1) . Remove Tooling (B) . Install
  remaining bolt (1) . Tighten the bolts evenly to
  a torque of 300 40 Nm (221 30 lb ft).
• Check the flywheel runout. Refer to Testing and
  Adjusting, "Flywheel - Inspect" for the correct
  procedure.

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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
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.
18
Illustration 1
g01132235

• Remove bolts (1).
• 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.

Copyright 1993 - 2020 Caterpillar Inc. All
Rights Reserved. Private Network For SIS
Licensees.
Mon Mar 30 145825 UTC0800 2020
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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
i06010890
Crankshaft Rear Seal - Install SMCS -
1161-012 Installation Procedure Table 1
Required Tools Required Tools Required Tools Required Tools
Tool Part Number Part Description Qty
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.
20
Illustration 1
g01140085
Illustration 2 Numerical tightening sequence for
bolts (2).
g03698745
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,
21

• 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.
• 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.
• Clean and polish the crankshaft of imperfections.
• Use Tooling (A) to clean the outside diameter of
  the crankshaft and the inside diameter of the
  crankshaft wear sleeve.
• Apply Tooling (B) to the outside diameter of the
  crankshaft and the inside diameter of the
  crankshaft wear sleeve.
• 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.
• Lubricate the O-ring seal with clean engine oil
  that is on the back of the crankshaft rear seal
  (1).
• 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.

Copyright 1993 - 2020 Caterpillar Inc. All
Rights Reserved. Private Network For SIS
Licensees.
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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
i02249340

• Flywheel Housing - Remove and Install
• SMCS - 1157-010
• Removal Procedure
• Start By
• Remove the electric starting motor. Refer to
  Disassembly and Assembly, "Electric Starting
  Motor - Remove and Install".
• Remove the flywheel. Refer to Disassembly and
  Assembly, "Flywheel - Remove".
• Support the engine.

Illustration 1
g01132273
23

• Attach a suitable lifting device to flywheel
  housing (2). The weight of flywheel housing (2)
  is approximately 62 kg (137 lb).
• Remove bolts (1) and flywheel housing (2).
• Installation Procedure
• Table 1

Required Tools Required Tools Required Tools Required Tools
Tool Part Number Part Description Qty
A 1U-8846 Gasket Sealant 1
1. Apply Tooling (A) to the face of the cylinder
block.

• Illustration 2 g01132273
• 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.
• Install bolts (1).
• End By
• Install the flywheel. Refer to Disassembly and
  Assembly, "Flywheel - Install".
• Install the electric starting motor. Refer to
  Disassembly and Assembly, "Electric Starting
  Motor - Remove and Install".

Copyright 1993 - 2020 Caterpillar Inc. All
Rights Reserved.
Mon Mar 30 150016 UTC0800 2020
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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
i02249982
Vibration Damper and Pulley - Remove and
Install SMCS - 1205-010 Removal Procedure
25
Illustration 1
g01132580

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).

Installation Procedure
26
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• Illustration 2 g01132580
• 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.
• Install bolts (2).
• Install belt (1).

Copyright 1993 - 2020 Caterpillar Inc. All
Rights Reserved. Private Network For SIS
Licensees.
Mon Mar 30 150112 UTC0800 2020
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ooklibonline.com