CAT + Caterpillar 966K XE Wheel Loader Service Repair Manual by Heavy Equipment Manual

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Product: WHEEL LOADER

Model: 966K XE WHEEL LOADER NGX

Configuration: 966K Series XE Wheel Loader NGX00001-UP (MACHINE) POWERED BY C9.3 Engine

Disassembly and Assembly

C9.3

Engines for Caterpillar Built Machines

Media Number -KENR8149-07 Publication Date -01/05/2014 Date Updated -29/05/2014

Air Cleaner Housing - Remove and Install

SMCS - 1051-010

Removal Procedure

Illustration 1

1. Remove bolts (3) and remove bolts (1).

i03634657

g01950245

2. Use two people in order to remove the air cleaner housing (2) from the machine. The weight of the air cleaner housing is approximately 20 kg (44 lb).

Illustration 2

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3. Release spring clips(1) and remove cover (2).

Illustration 3

g01950251

4. Remove primary air filter (6) from housing (7).

Illustration 4

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5. Remove secondary air filter (8) from housing (7).

Product: WHEEL LOADER

Model: 966K XE WHEEL LOADER NGX

Configuration: 966K Series XE Wheel Loader NGX00001-UP (MACHINE) POWERED BY C9.3 Engine

Disassembly and Assembly

C9.3

Engines for Caterpillar Built Machines

Media Number -KENR8149-07

Publication Date -01/05/2014

Air Compressor - Remove and Install

SMCS - 1803-010

Removal Procedure

Date Updated -29/05/2014

Do not disconnect the air linesuntil the air pressure in the system is at zero. If hose is disconnectedunder pressure it cancause personal injury.

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear andshortened component life.

NOTICE

Care must be taken to ensure that fluids are containedduring performance of inspection, maintenance, testing, adjusting, and repair of the product. Be preparedto 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 andsupplies suitable to collect and contain fluids on Cat® products.

Dispose of all fluids according to local regulations and mandates.

1. Ensure that the No. 1 cylinder isat the top center compression stroke. Refer to Testing and Adjusting, "Finding Top Center Position for No. 1 Piston".

2. Remove the air pressure from the air tank.

3. Drain the coolant from the cooling system into a suitable container for storage or for disposal. Refer to Operation and Maintenance Manual, "Cooling System Coolant (ELC) - Change".

4. Disconnect tube assembly (1), tube assembly (2), tube assembly (3), and tube assembly (4).

5. Remove clamp assembly (5).

Illustration 1

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Illustration 2

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6. Attach a suitable lifting device onto air compressor (6). The weight of air compressor (6) is approximately 32 kg (70 lb).

Illustration 3

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Illustration 4

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7. Remove bolts (9) and cover (10). Ensure that the timing mark on the crankshaft of the compressor is positioned between the timing marks on the housing for the compressor. Reinstall cover (10) and bolts (9). Remove bolts (7). Remove bracket (8).

Illustration 5

g01356874

8. Remove bolts (11). Remove the air compressor and the O-ring seal from the engine.

Installation Procedure

1. Ensure that the No. 1 cylinder isat the top center compression stroke. Refer to Testing and Adjusting, "Finding Top Center Position for No. 1 Piston".

Illustration 6

g01356660

Note: Check the O-ring seal for wear or for damage. If necessary, replace the O-ring seal.

2. Attach a suitable lifting device onto air compressor (6). The weight of air compressor (6) is approximately 32 kg (70 lb). Position the O-ring seal and air compressor (6) onto the engine.

Illustration 7

3. Install bolts (11).

Illustration 8

g01356874

g01356872

4. Remove bolts (9) and cover (10). Ensure that the timing mark on the crankshaft of the compressor is positioned between the timing marks on the housing for the compressor. Install cover (10) and bolts (9). Install bracket (8). Install bolts (7).

Illustration 10

g01356642

Note: Removal of the timing pin is necessary prior to connecting tube assembly (4).

5. Connect tube assembly (4), tube assembly (3), tube assembly (2), and tube assembly (1).

6. Install clamp assembly (5).

7. Fill the cooling system with coolant. Refer to Operation and Maintenance Manual, "Cooling System Coolant (ELC) - Change.".

Fri Dec 11 10:39:19 UTC+0530 2020

Illustration

g01271799

Product: WHEEL LOADER

Model: 966K XE WHEEL LOADER NGX

Configuration: 966K Series XE Wheel Loader NGX00001-UP (MACHINE) POWERED BY C9.3 Engine

Disassembly and Assembly

C9.3

Engines for Caterpillar Built Machines

Media Number -KENR8149-07 Publication Date -01/05/2014 Date Updated -29/05/2014

i04130332

Air Control Valve - Remove and Install - Control Module, Clean Emissions Module

SMCS - 108A-010

Removal Procedure

Illustration 1

g02327953

1. Remove tube assembly (1) and disconnect harness assemblies (4) .

2. Remove bolts (3) and remove Control Module (2) .

Installation Procedure

1. Install the Control Module (2) in the reverse order.

Fri Dec 11 09:57:48 UTC+0530 2020

Product: WHEEL LOADER

Model: 966K XE WHEEL LOADER NGX

Configuration: 966K Series XE Wheel Loader NGX00001-UP (MACHINE) POWERED BY C9.3 Engine

Disassembly and Assembly

C9.3

Engines for Caterpillar Built Machines

Media Number -KENR8149-07

Publication Date -01/05/2014 Date Updated -29/05/2014

Air Control Valve - Remove and Install

SMCS - 108A-010

Removal Procedure

Illustration 1 g02161617 View of theAir Control Valve which is locatedon the CleanEmissions Module.

1. Remove cable straps (2). Disconnect harness assemblies (1) and position the harness assembly out of the way.

2. Remove tube assembly (3).

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Illustration 2

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3. Loosen clamp assembly (5). Remove bolts (4) and remove air control valve (6).

Illustration 3

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4. Remove bolts (11). Separate housings (10) and (7) from the air control valve actuator (8). Remove both seals (9) from the housings.

Installation Procedure

1. Install air control valve (8) in the reverse order of removal.

Product: WHEEL LOADER

Model: 966K XE WHEEL LOADER NGX

Configuration: 966K Series XE Wheel Loader NGX00001-UP (MACHINE) POWERED BY C9.3 Engine

Disassembly and Assembly

C9.3

Engines for Caterpillar Built Machines

Media Number -KENR8149-07

Publication Date -01/05/2014

Atmospheric Pressure Sensor - Remove and Install

SMCS - 1923-010

Removal Procedure

Illustration 1 g02142868

The pressure sensor is locatednear the engine inlet manifold.

Date Updated -29/05/2014

1. Disconnect the harness assembly (1) and remove atmospheric pressure sensor (2).

Installation Procedure

Note: Do not pre-tighten the sensor using the plastic portion of the sensor. Pre-tighten the sensor using the metal hex portion of the sensor. Damage can occur to the sensor if pre-tightened using the plastic portion of the sensor.

i05296603

1. Install pressure sensor (1) in reverse order of removal.

a. Tighten sensor (1) to a torque of 10 ±2 N·m (89 ± 18 lb in).

Product: WHEEL LOADER

Model: 966K XE WHEEL LOADER NGX

Configuration: 966K Series XE Wheel Loader NGX00001-UP (MACHINE) POWERED BY C9.3 Engine

Disassembly and Assembly

C9.3

Engines for Caterpillar Built Machines

Media Number -KENR8149-07 Publication Date -01/05/2014 Date Updated -29/05/2014

Bearing Clearance - Check

SMCS - 1203-535; 1219-535

Measurement Procedure

Table 1 Required Tools

Plastic Gauge (Green)

to 0.076 mm (0.001 to 0.003 inch)

Plastic Gauge (Red)

to 0.152 mm (0.002 to 0.006 inch)

Plastic Gauge (Blue)

to 0.229 mm (0.004 to 0.009 inch)

Plastic Gauge (Yellow) 0.230 to 0.510 mm (0.009 to 0.020 inch)

Note: Plastic gauge may not be necessary when the engine is in the chassis.

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Keep all parts clean from contaminants.

Contaminants may cause rapid wear andshortened component life.

Note: Cat does not recommend the checking of the actual bearing clearancesparticularly on small engines. This is because of the possibility of obtaining inaccurate resultsand the possibility of damaging the bearing or the journal surfaces. Each Cat engine bearing is quality checked for specific wall thickness.

Note: The measurements should be within specifications and the correct bearings should be used. If the crankshaft journals and the bores for the block and the rods were measured during disassembly, no further checks are necessary. However, if the technician still wants to measure the bearing clearances, Tooling (A) is an acceptable method. Tooling (A) is less accurate on journals with small diameters if clearances are less than 0.10 mm (0.004 inch).

NOTICE

Lead wire, shim stock or a dial bore gauge can damage the bearing surfaces.

The technician must be very careful to use Tooling (A) correctly. The following points must be remembered:

• Ensure that the backs of the bearings and the bores are clean and dry.

• Ensure that the bearing locking tabs are properly seated in the tab grooves.

• The crankshaft must be free of oil at the contact pointsof Tooling (A).

1. Put a piece of Tooling (A) on the crown of the bearing that is in the cap.

Note: Do not allow Tooling (A) to extend over the edge of the bearing.

2. Use the correct torque-turn specifications in order to install the bearing cap. Do not use an impact wrench. Be careful not to dislodge the bearing when the cap is installed.

Note: Do not turn the crankshaft when Tooling (A) is installed.

3. Carefully remove the cap, but do not remove Tooling (A). Measure the width of Tooling (A) while Tooling (A) is in the bearing cap or on the crankshaft journal. Refer to Illustration 1.

Illustration 1 g01152855

TypicalExample

4. Remove all of Tooling (A) before you install the bearing cap.

Note: When Tooling (A) is used, the readings can sometimes be unclear. For example, all partsof Tooling (A) are not the same width. Measure the major width in order to ensure that the partsare within the specification range. Refer to Specifications Manual, "Connecting Rod Bearing Journal" and SpecificationsManual, "Main Bearing Journal" for the correct clearances.

Product: WHEEL LOADER

Model: 966K XE WHEEL LOADER NGX

Configuration: 966K Series XE Wheel Loader NGX00001-UP (MACHINE) POWERED BY C9.3 Engine

Disassembly and Assembly

C9.3

Engines for Caterpillar Built Machines

Media Number -KENR8149-07

Publication Date -01/05/2014

Belt Tensioner - Remove and Install

SMCS - 1358-010

Removal Procedure

Date Updated -29/05/2014

1. Remove the drive belt. Refer to Operation and Maintenance Manual, "Belt - Replace".

Illustration 1

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2. Remove bolt (1) and remove belt tensioner (2).

Installation Procedure

i06653775

Illustration 2 g06060776

1. Position belt tensioner (2) and install bolt (1).

2. Install the drive belt. Refer to Operation and Maintenance Manual, "Belt - Replace".

Product: WHEEL LOADER

Model: 966K XE WHEEL LOADER NGX

Configuration: 966K Series XE Wheel Loader NGX00001-UP (MACHINE) POWERED BY C9.3 Engine

Disassembly and Assembly C9.3

Engines for Caterpillar Built Machines

Media Number -KENR8149-07

Camshaft - Install

SMCS - 1210-012

Installation Procedure Table 1 Required Tools

Publication Date -01/05/2014

Date Updated -29/05/2014

Keep all parts clean from contaminants.

Contaminants may cause rapid wear andshortened component life.

1 g03356215

NOTICE

Do not damage the lobesor the bearings when the camshaft is removed or installed.

Note: During the installation of the camshaft, rotate the camshaft in both directions in order to prevent binding in the camshaft bearing bores.

1. Lubricate the camshaft lobes and the valve lifter bore with a 50/50 mixture of Tooling (B). Apply clean engine oil on the camshaft bearing journals. Carefully install camshaft (10) in the cylinder block.

Illustration

Illustration 2

(5) Gear for the high-pressure fuel pump

(6) Camshaft gear

(7) Idler gear

(8) Crankshaft gear

(9) Timing marks

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NOTICE

When installing the camshaft, make sure the number one cylinder isat top center of the compression stroke withthe timing bolt installed in the flywheel. The camshaft timing is very important. The timing mark on the camshaft drive gear must line up with the timing mark on the idler gear. Refer to the Specifications Manual for more information.

2. Correct fuel injection timing and correct valve mechanism operation is determined by properly timing crankshaft gear (8) and camshaft gear (6) to idler gear (7). Also, high-pressure fuel pump gear (5) must be timed to camshaft gear (6). During installation of the front gear, timing marks (9) on idler gear (7)

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