0325603 JOHNSON CYLINDER HEAD

Introduction
This Special Instruction provides the procedure to repower a 966D, 966E, 966F Series II, 966F Wheel Loaders, 815B Soil Compactors. The replacement engine will be a Tier 3 level C7 engine. See the following table for the engine arrangement numbers. The 815B Soil Compactor, 966D, 966E, 966F Series II, and 966F Wheel Loader was originally equipped with a 3306 engine. The original 3306 engine is not regulated for emissions. This Special Instruction will provide the information to install the Tier 3 level replacement engine.
Table 1
Engine Arrangements
Original Engine Replacement Engine
6N-5908
9Y-4951
9Y-1719
6N-3055
6I-2965
7E-0082
106-3145 312-8512(1)
(1) New Repower EngineThis Special Instruction does not include procedures that can be found in your existing manuals. Refer to the original Service Manual, Parts Manual, and Operation and Maintenance Manual for more information.When you have completed this procedure, prepare the machine for service. Refer to the Operation and Maintenance Manual.Note: Do not perform any procedure in this Special Instruction until the information has been read and understood.Reference: Service Manual, Parts Manual, Operation and Maintenance Manual.Note: This instruction contains some procedures that come from dealer feedback. The emissions replacement engine is not a direct replacement. Additional parts and additional labor hours may be needed to complete this engine replacement. Variations in machine serial number breaks or options could cause a discrepancy in the modifications, parts needed, and labor hours to complete this repower. This documentation is a guideline for Caterpillar dealer personnel to complete the repower procedure. If errors are found, submit feedback in SIS Web or contact the Emissions Retrofit Group.
Machine serial number
Original engine arrangement number
Original engine serial number
Emissions engine arrangement number
Details of the error
Photos of the error and photos after the proposed solutionRegistering the Retrofit
Reference: Special Instruction, REHS5097, "Instructions to Register the Retrofit"Documenting changes to a machine configuration is an advantage to Caterpillar and the dealer technicians that are sent to repair a machine. By identifying that the machine has been reconfigured, the technician will have a better opportunity to have the correct parts, tooling, and service information. Identifying that the machine has been reconfigured will also allow Caterpillar to include the retrofitted serial numbers in applicable Service Letters.Safety
Personal injury or death can result from sudden machine movement.Sudden movement of the machine can cause injury to persons on or near the machine.To prevent injury or death, make sure that the area around the machine is clear of personnel and obstructions before operating the machine.
Do not attempt to assemble this machine until you read and you understand the assembly instructions.Improper assembly procedures could result in injury or death.
Personal injury or death can result from improper lifting or blocking.When a hoist or jack is used to lift any part or component, stand clear of the area. Be sure the hoist or jack has the correct capacity to lift a component. Install blocks or stands before performance of any work under a heavy component.Approximate weights of the components are shown. Clean all surfaces where parts are to be installed.
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.
Welding on Electronically Controlled Engines
Proper welding procedures are necessary to avoid damage to electronic controls. Perform welding on the engine according to the following procedure.
Set the engine control to the "STOP" mode.
Turn OFF the fuel supply to the engine.
If equipped, turn the battery disconnect switch to the OFF position. If there is no battery disconnect switch, remove the negative battery cable at the battery.
Protect the wiring harnesses from welding debris and/or from welding spatter.
Do NOT use electrical components (ECM or sensors) or electronic component grounding points for grounding the welder.
Connect the welder ground cable directly to the engine component that will be welded. Place the clamp as close as possible to the weld to reduce the 5 mm (0.20 inch) possibility of welding current damage to the engine bearings, to the electrical components, and to other engine components.
Use standard welding procedures to weld the materials together.Installation of Cooling System