5031668 JOHNSON WASHER

Introduction
This Special Instruction provides the procedure in order to repower a 966F Wheel Loader. The replacement engine will be a Tier I Level 3306 engine. The 966F Wheel Loader was originally equipped with a 3306 engine which is unregulated.
Table 1
Engine Arrangement    
Original Engine     Machine S/N Prefix     Replacement Engine    
6N-3055 Engine Ar
    S/N:1SL
S/N:4YG
S/N:8BG     122-4210 Engine Ar (1)    
7E-0082 Engine Ar     10R-1636 Engine Ar (2)
6I-2965 Engine Ar     10R-7404 Engine Ar (3)
106-3145 Engine Ar    
( 1 ) New Repower Engine
( 2 ) Reman
( 3 ) New Replacement Engine Exchange - NREENote: Refer to tables 2 and 4 for more information about the changed parts. This Special Instruction will provide the information in order to install the Tier I level replacement engine. This 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.ReferenceService Manual, Parts Manual, Operation and Maintenance Manual.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 in order 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.
Disconnect the negative terminal from the battery.
Disconnect the engine electronic components from the wiring harnesses: ECM, throttle actuator, actuator for the turbocharger compressor bypass, fuel metering valve and sensors.
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 ground cable of the welder directly to the engine component that will be welded. Place the clamp as close as possible to the weld in order to reduce the possibility of welding current damage.
Use standard welding procedures to weld the materials together.Changed Parts
New Replacement Engine
Note: The following tables include comparisons of the engine arrangements and the installation arrangements.Note: The following is not a complete listing of the 122-4210 Engine Arrangement and 10R-7404 Engine Ar . Note: A spur gear is used for the Tier I Level 3306 Engines. Old compressors or pumps that are driven from the front gear group will NOT work with the new gears. Old gears are made with a helical cut. In order to use the machines current compressor or pumps driven off the water pump, use the parts that are listed in the table below.
Table 2
6I-3803 Air Compressor Lines Gp    
Quantity     Description     Part Number    
2     Flared Elbow     2N-1287    
1     Governor Tube Assembly &n