966F II Caterpillar Wheel Loader Service Manual by quality service repair manual

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Product: WHEEL LOADER

Model: 966F II WHEEL LOADER 9YJ

Configuration: 966F Series II Wheel Loader 9YJ00001-UP (MACHINE) POWERED BY 3306 Engine

Disassembly and Assembly

3306 VEHICULAR ENGINE FOR 966D WHEEL LOADER

Media Number -SENR2149-00

Hood

SMCS - 7251-11; 7251-12

Remove Hood

Publication Date -01/04/1981

Date Updated -11/10/2001

1. Remove the bolts and exhaust pipe (2).

2. Loosen the clamp and disconnect hose (3) from the tube.

3. Loosen the clamp that holds the precleaner in place. Remove precleaner (1) from the hood.

4. Remove the bolts and plate (4).

5. Remove bolts (5) that hold the hood in place.

6. Fasten a hoist to hood (6) and remove it. The weight of the hood is 44 kg (98 lb.).

Install Hood

1. Fasten a hoist to hood (1) and put it in place. Install the bolts that hold the hood in place.

2. Put plate (2) in place and install the bolts.

3. Put precleaner (3) and hose (4) in place and install the clamps.

4. Install exhaust pipe (5) and the bolts on the hood.

Wed Dec 14 00:29:24 UTC+0530 2022

Product: WHEEL LOADER

Model: 966F II WHEEL LOADER 9YJ

Configuration: 966F Series II Wheel Loader 9YJ00001-UP (MACHINE) POWERED BY 3306 Engine

Disassembly and Assembly

3306 VEHICULAR ENGINE FOR 966D WHEEL LOADER

Media Number -SENR2149-00

Alternator

SMCS - 1405-11; 1405-12

Remove Alternator

Publication Date -01/04/1981

1. Disconnect the wires at the batteries.

2. Disconnect wires (1) and (2) from the alternator.

3. Loosen lower nut (3) on the adjusting rod.

4. Remove vee belts (6) from the alternator pulley.

5. Remove bolts (4) and (5) and remove the alternator.

Install Alternator

Date Updated -11/10/2001

This is the sample of the manual

Click on the download link for complete manual

1. Put alternator (3) in position and install bolts (1) and (4).

2. Put vee belts (2) in position on the pulley.

3. Use a belt tension gauge such as Borroughs Tool Company Part No. BT-33-72C or an equivalent and make an adjustment of vee belts (2). Measure the belt nearest the radiator. Tighten new belts until the gauge indication is 120 ± 5. Tighten the bolts (7) that hold the alternator in position. Operate the engine at high idle for a minimum of 30 minutes after Steps 4 and 5. Make another adjustment of the belt tension. The correct gauge indication for used belts is 90 ± 10.

4. Connect wires (5) and (6) to the alternator.

5. Connect the wires to the battery.

Wed Dec 14 00:29:37 UTC+0530 2022

Product: WHEEL LOADER

Model: 966F II WHEEL LOADER 9YJ

Configuration: 966F Series II Wheel Loader 9YJ00001-UP (MACHINE) POWERED BY 3306 Engine

Disassembly and Assembly

3306 VEHICULAR ENGINE FOR 966D WHEEL LOADER

Media Number -SENR2149-00

Electric Starting Motor

Publication Date -01/04/1981

Date Updated -11/10/2001

SMCS - 1453-11; 1453-12

Remove Electric Starting Motor

1. Disconnect the battery cables from the batteries.

2. Disconnect wires (1) and (2) from the starting motor.

3. Remove bolts (3) and remove starting motor (4). The weight of the starting motor is 32 kg (70 lb.).

Install Electric Starting Motor

1. Put the gasket in position and install starting motor (2) in position and install bolts (1).

2. Connect wires (3) and (4) to the starting motor and to the solenoid.

3. Connect the battery cables to the batteries.

Product: WHEEL LOADER

Model: 966F II WHEEL LOADER 9YJ

Configuration: 966F Series II Wheel Loader 9YJ00001-UP (MACHINE) POWERED BY 3306 Engine

Disassembly and Assembly

3306 VEHICULAR ENGINE FOR 966D WHEEL LOADER

Media Number -SENR2149-00 Publication Date -01/04/1981 Date Updated -11/10/2001

Air Conditioner Compressor

SMCS - 1357-10

Remove And Install Air Conditioner Compressor

Always wear goggles when the air conditioning system is opened. This system is charged with Freon-12 (CCL2F2-Dichlorodifluoromethane) which is not toxic or flammable. But there is a reason for caution. When Freon-12 makes contact with a flame, lethal phosgene gas is made. INHALING FREON THROUGH A LIGHTED CIGARETTE CAN CAUSE VIOLENT ILLNESS. This system is under pressure at all times, engine running or not. HEAT MUST NEVER BE PUT ON A CHARGED SYSTEM. See AIR CONDITIONING AND HEATING SERVICE MANUAL Form No. SENR7454 for more information on procedures and safety requirements on removal and installation of lines and refrigerant from the system.

1. Remove plate (3) and disconnect hose assemblies (4) from the air conditioner compressor.

2. Put plate (3) back in position on the compressor to keep out foreign material.

3. Loosen adjusting bolt (1) and remove vee belt (2).

4. Disconnect the wires from the compressor.

5. Remove bolts (6) and remove compressor (5).

NOTE: The following steps are for installation of the air conditioning compressor.

6. Put the air conditioner compressor in position and install the bolts.

7. Connect wires (7) to the compressor.

8. Install the belt on the compressor. Make an adjustment of the belt. See MAINTENANCE GUIDE.

9. Put hose assemblies (4) in position and install plate (3).

10. See AIR CONDITIONING AND HEATING SERVICE MANUAL Form No. SENR7454 for correct procedure for evacuating and charging the system.

Wed Dec 14 00:30:03 UTC+0530 2022

Product: WHEEL LOADER

Model: 966F II WHEEL LOADER 9YJ

Configuration: 966F Series II Wheel Loader 9YJ00001-UP (MACHINE) POWERED BY 3306 Engine

Disassembly and Assembly

3306 VEHICULAR ENGINE FOR 966D WHEEL LOADER

Media Number -SENR2149-00

Fan

SMCS - 1356-11; 1356-12

Remove Fan

Publication Date -01/04/1981

1. Drain the coolant from the cooling system.

Date Updated -11/10/2001

2. Loosen the nut on bolt (1) and remove vee belts (2).

3. Loosen hose clamp (3) and remove elbow (4).

4. Remove fan guards (5) from the radiator.

NOTICE

Do not damage the radiator core with fan (6).

5. Remove the bolts that hold fan (6) to the adapter. Put the fan carefully in position in the radiator as shown. The weight of the fan is 39 kg (85 lb.).

6. Remove adapter (7) from the pulley.

7. Remove fan (6) from the radiator.

Install Fan

NOTICE

Do not damage the radiator core with fan (1).

1. Put fan (1) in position in the radiator.

2. Install adapter (2) on the fan drive pulley. Make sure the vee belts are on the pulley.

3. Install fan (1) on the adapter.

4. Put guards (3) in position on the radiator.

5. Install the gasket and elbow (4). Connect the hose at the top.

6. Put vee belts (6) on the alternator. Tighten the nut on bolt (5). Use a belt tension gauge such as Borroughs Tool Company Part No. BT-33-72C or an equivalent and make an adjustment of the vee belts. Measure the belt nearest the radiator. Tighten new belts until the gauge indication is 534 ± 22 N (120 ± 5 lb.). Tighten the bolts that hold the alternator in position. Operate the engine at high idle for a minimum of 30 minutes. Make another adjustment of the belt tension. The correct gauge indication for used belts is 400 ± 44 N (90 ± 10 lb.).

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Wed Dec 14 00:30:16 UTC+0530 2022

Product: WHEEL LOADER

Model: 966F II WHEEL LOADER 9YJ

Configuration: 966F Series II Wheel Loader 9YJ00001-UP (MACHINE) POWERED BY 3306 Engine

Disassembly and Assembly

3306 VEHICULAR ENGINE FOR 966D WHEEL LOADER

Media Number -SENR2149-00

Fan Drive

Publication Date -01/04/1981

SMCS - 1359-16; 1359-11; 1359-12; 1359-15

Remove Fan Drive

1. Loosen the nut on rod (1).

2. Remove vee belts (2) from the pulleys.

Date Updated -11/10/2001

NOTICE

Do not damage the radiator core with the fan.

3. Fasten a hoist to the fan and adapter (3). Remove the bolts that hold adapter (3) to the fan drive.

4. Carefully lean the fan against the radiator core.

5. Fasten a hoist to pulley and fan drive (4).

6. Remove the bolts that hold the fan drive to the cylinder head and to support bracket (5). Remove the fan drive.

Install Fan Drive

1. Put fan drive (1) in position and install bolts (2) and (3).

2. Put adapter (4) and the fan in position and install the bolts. Make sure the vee belts are on or behind the pulley.

3. Put the vee belts in position on the pulleys.

4. Use a belt tension gauge such as Borroughs Tool Company Part No. BT-33-72C or an equivalent and make an adjustment of vee belts. Measure the belt nearest the radiator. Tighten new belts until the gauge indication is 534 ± 22N (120 ± 5 lb.). Tighten the bolts that hold the alternator in position. Operate the engine at high idle for a minimum of 30 minutes. Make another adjustment of the belt tension. The correct gauge indication for used belts is 400 ± 44N (90 ± 10 lb.).

Disassemble Fan Drive

start by:

a) remove fan drive

1. Remove O-ring seal (2) from around the bearing.

2. Bend the tabs on lock (1) down.

3. Remove the bolts, lock (1) and washer (3).

4. Remove pulley (4), the spacer and the hub from shaft assembly (5).

5. Remove bearing (6) from the hub. Remove the pulley from the hub.

NOTE: Bearing (7) and lip type seal (8) can stay with the pulley and hub when it is removed.

6. Remove bearing (7) and lip type seal (8) from shaft assembly (5).

7. Remove the spacer from the shaft assembly.

Assemble Fan Drive

1. Install pulley (1) on hub (2) as shown.

NOTE: The pulley must be installed on the hub with the spacer down against the shoulder of the hub.

2. Install the bearing in the hub.

3. Use tooling (A) to install lip type seal (4) in the hub with the lip of the seal up. The top of the seal must be even with the end of the hub.

4. Put 5P960 Multipurpose Type Grease on the lip of the seal.

5. Install spacer (3) in seal (4).

NOTE: Make sure mounting bolts (7) are put in position before the pulley and hub are installed on the shaft.

6. Put pulley and hub assembly (5) on shaft assembly (6).

7. Install spacer (8) on the shaft assembly.

8. Fill the hub with 5P960 Multipurpose Type Grease.

9. Put bearing (9) in position in the hub. Make sure the bearing make a seat in the counterbore of the hub.

10. Put washer (10) in position on the bearing.

11. Install lock (13) and bolts (12). Bend the tabs on the lock around the bolts.

Product: WHEEL LOADER

Model: 966F II WHEEL LOADER 9YJ

Configuration: 966F Series II Wheel Loader 9YJ00001-UP (MACHINE) POWERED BY 3306 Engine

Disassembly and Assembly

3306 VEHICULAR ENGINE FOR 966D WHEEL LOADER

Media Number -SENR2149-00

Publication Date -01/04/1981

Air Cleaner Elements And Housing

SMCS - 1051-11; 1051-12; 1054

Remove Air Cleaner Elements And Housing

1. Loosen rod assemblies (1) and remove cup assembly (2).

Date Updated -11/10/2001

2. Remove primary element (3) and the secondary element from the housing.

3. Loosen clamp (4) and remove the inlet hose.

4. Remove bolts (6) from inside the housing.

5. Remove housing (5).

Install Air Cleaner Elements And Housing

1. Put housing (2) in position and tighten the bolts.

2. Connect air inlet hose (1) to the air cleaner housing.

3. Install secondary element (3) and the nuts.

4. Put primary element (6) in position.

5. Install cup (5) and tighten rod assemblies (4).

Product: WHEEL LOADER

Model: 966F II WHEEL LOADER 9YJ

Configuration: 966F Series II Wheel Loader 9YJ00001-UP (MACHINE) POWERED BY 3306 Engine

Disassembly and Assembly

3306 VEHICULAR ENGINE FOR 966D WHEEL LOADER

Media Number -SENR2149-00

Water Pump

Publication Date -01/04/1981

SMCS - 1361-16; 1361-11; 1361-12; 1361-15

Date Updated -11/10/2001

Remove Water Pump

1. Drain the coolant from the cooling system.

2. Loosen the clamp and disconnect hose (1).

3. Loosen hose clamp (3) that holds hose (2) to the elbow.

4. Loosen hose clamps (5) and move hose (4) down away from the water pump.

5. Remove bolt (6) and the bolts that hold water pump (8) to the timing gear cover.

6. Make a separation of elbow (7) and the water pump.

Install Water Pump

1. Install the gasket and elbow (1) on the water pump.

2. Make sure the O-ring seal is in position on the water pump.

3. Install water pump (2) and the bolts. Make an alignment of the hose for elbow (1).

This is the sample of the manual

Click on the download link for complete manual

4. Put hose (3) in position and install the hose clamps.

5. Connect hose (4) and tighten the clamp.

6. Tighten hose clamp (5).

7. Fill the cooling system with coolant to the correct level.

Disassemble Water Pump

start by:

a) remove water pump

1. Remove cover (1) from water pump (2).