TM 5-3805-291-10 CATERPILLAR MDL 966H

8/14/2019 TM 5-3805-291-10 CATERPILLAR MDL 966H

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TM 5-3805-291-10

TECHNICAL MANUAL

OPERATORS MANUAL

FOR

LOADER, HEAVY, SCOOP:

DIESEL ENGINE DRIVEN (DED), 4-WHEEL DRIVE

4.5 CUBIC YARD ROCK BUCKET

NSN 3805-01-533-1857

AND

5.0 CUBIC YARD GENERAL PURPOSE BUCKETNSN 3805-01-533-1853

MODEL 966H

DISTRIBUTION STATEMENT A - Approved for public release; distribution is unlimited.

HEADQUARTERS, DEPARTMENT OF THE ARMY

20


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WARNING SUMMARYThis warning summary contains general safety warnings and hazardous materials warnings that must be

understood and applied during operation and maintenance of this equipment. Failure to observe these precautions

could result in serious injury or death to personnel. Also included are explanations of safety and hazardous materials

icons used within the technical manual.

BIOLOGICAL - abstract symbol bug shows that a material may contain bacteria or viruses that

present a danger to life or health.

CHEMICAL - drop of liquid on hand shows that the material will cause burns or irritation to

human skin or tissue.

EAR PROTECTION - headphones over ears show that noise level will harm ears.

ELECTRICAL - electrical wire to arm with electricity symbol running through human body shows

that shock hazard is present.

EYE PROTECTION - person with goggles shows that the material will injure the eyes.

FIRE - flame shows that a material may ignite and cause burns.

FLYING PARTICLES - arrows bouncing off face shield show that particles flying through the air

will harm face.

HEAVY OBJECT - human figure stooping over heavy object shows physical injury potential from

improper lifting techniques.


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HEAVY PARTS - hand with heavy object on top shows that heavy parts can crush and kill.

HEAVY PARTS - heavy object on human figure shows that heavy parts present a danger to life or

limb.

HEAVY PARTS - heavy object pinning human figure against wall shows that heavy, moving parts

present a danger to life or limb.

HOT AREA - hand over object radiating heat shows that part is hot and can burn.

HYDRAULIC FLUID PRESSURE - hydraulic fluid spraying human hand shows that fluid

escaping under great pressure can cause injury or death to personnel.

RADIOACTIVE - identifies a material that emits radioactive energy and can injure human tissue or

organs.

VAPOR - human figure in a cloud shows that material vapors present a danger to life or health.


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FOR INFORMATION ON FIRST AID, REFER TO FM 4-25.11.

WARNINGCARBON MONOXIDE (EXHAUST GASES) CAN KILL!

Carbon monoxide is a colorless, odorless, deadly poison which, when breathed, deprives the body of

oxygen and causes suffocation. Exposure to air containing carbon monoxide produces symptoms of

headache, dizziness, loss of muscular control, apparent drowsiness, and coma. Permanent brain damage

or death to personnel can result from severe exposure.

Carbon monoxide occurs in exhaust fumes from internal combustion engines. It also occurs in exhaust fumes

from engine coolant heater (arctic machine only). Carbon monoxide can become dangerously concentrated

under conditions of inadequate ventilation. The following precautions must be observed to ensure safety of

personnel when engine of loader is operated.

1. DO NOT operate engine in enclosed areas without adequate ventilation.

2. DO NOT idle engine without adequate ventilation.

3. DO NOT drive machine with inspection plates or cover plates removed.

4. BE ALERT for exhaust poisoning symptoms. They are:

Headache

Dizziness

Sleepiness

Loss of muscular control

5. If you see another person with exhaust poisoning symptoms:

Remove person from area.

Expose to fresh air.

Keep person warm.

DO NOT permit physical exercise.

Administer cardiopulmonary resuscitation (CPR) if necessary.

Notify a medic.

6. BE AWARE. The field protective mask for nuclear-biological-chemical (NBC) protection will NOT protect you

from carbon monoxide poisoning.

The Best Defense Against Carbon Monoxide Poisoning Is Good Ventilation!


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WARNINGBATTERIES

To avoid injury, eye protection and acid-resistant gloves must be worn when working around bat-

teries. DO NOT smoke, use open flame, make sparks, or create other ignition sources around bat-

teries. If a battery is giving off gases, it can explode and cause injury to personnel. Remove alljewelry such as rings, ID tags, watches, and bracelets. If jewelry or a tool contacts a battery termi-

nal, a direct short will result in instant heating or electrical shock, damage to equipment, and

injury to personnel.

Sulfuric acid contained in batteries can cause serious burns. If battery corrosion or electrolyte

makes contact with skin, eyes, or clothing, take immediate action to stop the corrosive burning

effects. Failure to follow these procedures may result in injury or death to personnel.

1. Eyes. Flush with cold water for no less than 15 minutes and seek medical attention immediately.

2. Skin. Flush with large amounts of cold water until all acid is removed. Seek medical attention as required.

3. Internal. If corrosion or electrolyte is ingested, drink large amounts of water or milk. Follow with milk of magne-

sia, beaten egg, or vegetable oil. Seek medical attention immediately.

4. Clothing/Equipment. Wash area with large amounts of cold water. Neutralize acid with baking soda or householdammonia.

WARNINGBLACKOUT LIGHTING SYSTEM

Blackout lighting system disables backup alarm, horn, and exterior lights, posing a hazard to person-

nel in the area. Follow proper safety procedures when operating in blackout mode. Failure to follow

this warning may cause injury or death to personnel or damage to equipment.

WARNINGBRAKE SYSTEM

If emergency use of parking brake is required due to service brake failure, ensure that brakes are

inspected and repaired, if necessary, before resuming machine operation. Injury or death to personnel

or equipment damage could result from improperly or non-functioning brakes.

WARNINGCOMPRESSED AIR

Particles blown by compressed air are hazardous. DO NOT exceed 15 psi (103 kPa) nozzle pressure

when drying parts with compressed air. Use a maximum of 30 psi (207 kPa) when cleaning compo-nents. DO NOT direct compressed air against human skin. Failure to follow this warning may result

in injury or death to personnel. Make sure air stream is directed away from user and other personnel

in the area. To prevent injury, user must wear protective goggles or face shield.


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WARNING

ENGINE COOLANT (ARCTIC) HEATER (ARCTIC MACHINE ONLY)

Use of an arctic heater requires that coolant in system to be heated contain a proper mixture of water

and antifreeze to prevent coolant from freezing or slushing. If coolant freezes or slushes, coolant pump

cannot move coolant, causing blockage in circulating system. Pressure build-up in arctic heater can

cause coolant hose at heater connection to burst or blow off. Injury to personnel or damage to enginecould result.

WARNING

ETHER COLD START SYSTEM

Ether fuel is extremely flammable and toxic. DO NOT smoke and make sure you are in a well-

ventilated area, away from heat, open flames or sparks. Wear eye protection. Avoid contact with

skin and eyes and avoid breathing ether fumes. If fluid enters or fumes irritate the eyes, wash

immediately with large quantities of clean water for 15 minutes. Seek medical attention immedi-ately if ether is inhaled or causes eye irritation. Failure to follow this warning may cause serious

injury or death to personnel.

NEVER use aerosol engine starting aids. Failure to follow this warning may cause an explosion,

resulting in injury or death to personnel.

WARNING

FIRE EXTINGUISHER

Discharging large quantities of dry chemical fire extinguisher inside an enclosed cab may result in

temporary breathing difficulty during and immediately after the discharge event. Discharge fire

extinguisher from outside the cab. Ventilate cab thoroughly prior to reentry. Failure to follow this

warning may cause injury to personnel.


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WARNINGFRAME ARTICULATION AREA/STEERING FRAME LOCK

Stand clear of frame articulation area when machine is operating. There is no clearance for per-

sonnel in this area when machine turns. Crushing could occur, resulting in injury or death to per-sonnel.

DO NOT operate machine with steering frame lock connected. Steering frame lock must be dis-

connected and securely stowed. If not properly stowed, loss of steering control could result. Fail-

ure to follow this warning may result in injury or death to personnel or damage to equipment.

Connect steering frame lock between front and rear frames before lifting, transporting, or servic-

ing machine in frame articulation area. Disconnect steering frame lock and secure in stowed posi-

tion before resuming operation. Failure to follow this warning may result in injury or death to

personnel or damage to equipment.

WARNINGFUEL HANDLING

DO NOT smoke or permit any open flame in area of machine while you are servicing fuel system.

Be sure hose nozzle is grounded against filler tube during refueling to prevent static electricity.

Failure to follow this warning may result in injury or death to personnel, or damage to equip-

ment.

Operating personnel must wear fuel-resistant gloves when handling fuels. If exposed to fuel,

promptly wash exposed skin and change fuel-soaked clothing.

ALWAYS stop engine prior to refueling. If equipped with an arctic cold weather starting aid sys-

tem, turn engine coolant heater off.

DO NOT perform fuel system checks, inspections, or maintenance while smoking or near fire,

flames, or sparks. Fuel may ignite, causing injury or death to personnel or damage to equipment.

WARNINGHAZARDOUS WASTE DISPOSAL

When servicing this machine, performing maintenance, or disposing of materials such as engine cool-

ant, hydraulic fluid, lubricants, battery acids or batteries, windshield cleaning compound, and CARC

paint, consult your unit/local hazardous waste disposal center or safety office for local regulatory

guidance. If further information is needed, please contact The Army Environmental Hotline at 1-800-

872-3845.

WARNINGHEARING PROTECTION

Hearing protection is required if within 20 ft (6 m) of an operating machine. Hearing protection is also

required when operating machine without ROPS/FOPS during transport procedures. Failure to wear

hearing protection may cause hearing loss.


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WARNINGHIGH PRESSURE ACCUMULATOR

This system contains high pressure gas. DO NOT expose to fire. DO NOT weld. DO NOT drill. Relieve

pressure before discharging. Failure to follow instructions and warnings could result in an explosion,

causing injury or death to personnel.

WARNINGHYDRAULIC SYSTEM PRESSURE

DO NOT disconnect or remove any hydraulic system line or fitting unless engine is shut down and

hydraulic system pressure has been relieved. Tighten all connections before applying pressure. Escap-

ing hydraulic fluid under pressure can penetrate the skin, causing injury or death to personnel.

WARNINGLOWERING LOADER ARM WITH ENGINE STOPPED

Loader arm can drop when lowering it with engine stopped. Keep all personnel away from loader arm

drop area. Ensure no one is under or near frame articulation area. Failure to follow this warning mayresult in injury or death to personnel.

WARNINGMACHINE OPERATION

Use caution and maintain three-point contact at all times when mounting or dismounting

machine. Failure to follow this warning may result in injury or death to personnel.

BE ALERT for personnel in the area while operating machine. Always check to ensure area is

clear of personnel and obstructions before moving. Failure to follow this warning may result in

injury or death to personnel or damage to equipment.

Use of seat belt while operating machine is mandatory. Fasten belt BEFORE operating machine.Trying to fasten belt during operation creates a hazardous condition. Failure to follow this warn-

ing may result in injury or death to personnel in the event of an accident or machine overturn.

DO NOT allow riders on machine. Failure to follow this warning may result in injury or death to

personnel.

NEVER leave operator compartment without engaging parking brake. Failure to follow this

warning may result in injury or death to personnel.

DO NOT use parking/emergency brake to stop a moving machine under usual conditions. Only if

service brakes fail, engage parking/emergency brake. Failure to follow this warning may result in

injury to personnel or damage to equipment.

DO NOT perform excavating, loading, or digging tasks without ROPS/FOPS installed. Machine

has no rollover/falling object protection without ROPS/FOPS. Operation without ROPS/FOPS isonly for air or trailer transport at a slow speed. Failure to follow this warning may cause injury or

death to personnel or damage to equipment.

Always use a ground guide when driving machine with work tools, if visibility is impaired. Failure

to use a ground guide may cause injury or death to personnel or damage to equipment.

Machine without work tool attached is light in the front and therefore susceptible to overturning.

When driving without work tool attached to loader arm, drive slowly and DO NOT make sharp

turns. Failure to follow this warning may cause injury or death to personnel or damage to equip-

ment.


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WARNINGMANUAL RELEASE OF PARKING BRAKE

Ensure wheels are blocked before manually releasing parking brake. Failure to follow this warning

may result in machine rolling, causing injury or death to personnel or damage to equipment.

WARNINGNBC EXPOSURE

If NBC exposure is suspected, personnel wearing protective equipment must handle all air cleaner

media. Consult your NBC Officer or NBC NCO for appropriate handling or disposal procedures.

Refer to FM 3-11.3, Multiservice Tactics, Techniques, and Procedures for Chemical, Biological,

Radiological, and Nuclear Contamination Avoidance, and FM 3-11.5, Multiservice Tactics, Tech-

niques, and Procedures for Chemical, Biological, Radiological, and Nuclear Decontamination.

NBC contaminated filters must be handled using adequate precautions and must be disposed of

by trained personnel.

Failure to follow these warnings may cause injury or death.

To order this NBC decal use:

National Stock Number (NSN) - 7690-01-114-3702Part Number (PN) - 12296626

Commercial and Government Entity Code (CAGEC) - 19207

WARNINGPRESSURIZED COOLING SYSTEM

DO NOT service cooling system unless engine has cooled. This is a pressurized cooling system and

escaping steam or hot coolant may cause serious burns.

DO NOT remove cooling system radiator cap when engine is hot. Allow engine to cool down.

Loosen cap to first stop and let any pressure out of cooling system, then remove cap. Failure to fol-

low this warning may cause serious burns.

Wear effective eye, hand, and skin protection when handling coolants. Failure to follow this warn-

ing may cause injury to personnel.

WARNING

IF NBC EXPOSURE IS SUSPECTED ALL AIR

FILTER MEDIA WILL BE HANDLED BY PER-

SONNEL WEARING FULL NBC PROTEC-

TIVE EQUIPMENT. SEE OPERATOR/

MAINTENANCE MANUAL.7690-01-114-3702


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WARNINGQUICK COUPLER OPERATION

Before disengaging quick coupler from work tool, use extreme caution to ensure work tool is in a safe

and stable position before proceeding. Work tool must NOT be loaded. All personnel must stand clear.

Failure to follow this warning may result in injury or death to personnel or damage to equipment.

WARNINGSLAVE STARTING

When slave starting machine:

Use NATO slave cable that does NOT have loose or missing insulation.

DO NOT proceed if cable is not available.

DO NOT use civilian-type jumper cables.

DO NOT allow dead and live machines to come in contact with each other at any time during

slave starting.

Failure to follow these warnings may cause injury or death to personnel.

WARNINGSOLVENT CLEANING COMPOUND

Solvent cleaning compound MIL-PRF-680 Type III is an environmentally compliant and low toxicmaterial. However, it may be irritating to the eyes and skin. Use protective gloves and goggles. Use in

well-ventilated areas. Keep away from open flames and other sources of ignition. Failure to follow this

warning may cause injury or death to personnel.

WARNINGTIRES

Operating machine with underinflated or defective tire may lead to tire failure and loss of trac-

tion or control. Failure to follow this warning may cause injury or death to personnel or damage

to equipment.

If tire pressure is 20 psi (138 kPa) or less, DO NOT inflate. Notify Unit Maintenance. Failure tofollow this warning may cause injury or death to personnel.

Use a self-attaching inflation chuck and stand at a distance behind tire when inflating tire. Failure

to follow this warning may cause injury or death to personnel.


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WARNING

TOWING MACHINE

Ensure proper towing procedures are followed when towing machine. Failure to follow proper

towing procedures may cause injury or death to personnel or damage to equipment.

When attaching towing connections, carefully move towing machine into position. Always use a

ground guide and DO NOT stand directly between machines.

DO NOT tow faster than 2 mph (3 kph).

DO NOT allow operator on machine unless operator can control steering and/or brakes.

When drive shafts are removed, machine has NO parking or secondary brakes. To prevent

machine from rolling, wheels must be blocked securely. Failure to follow this warning may cause


Always block wheels before removing axle shafts or disengaging parking brake.

DO NOT return to service a machine that has been towed, without first ensuring that all neces-

sary repairs and adjustments have been performed. Failure to do so could result in injury to per-

sonnel or damage to equipment.

WARNING

TRANSPORTING MACHINE

Position machine, apply parking brake, and connect steering frame lock between front and rear

frames before transporting machine. Failure to follow this warning may result in injury or death

to personnel or damage to equipment.

Always use a ground guide when operating machine up or down ramps in preparation for trans-

port. Failure to use a ground guide may cause injury or death to personnel or damage to equip-

ment.

DO NOT remove exhaust stack until it has cooled to the touch. Wear gloves and protective cloth-

ing as required to guard against burns. Failure to follow this warning may result in injury to per-

sonnel.

When operating machine up or down ramps, drive with extreme caution and in 1st gear forward

or reverse ONLY. Failure to follow this warning may cause injury or death to personnel or dam-

age to equipment.

If operating machine without ROPS/FOPS, drive with extreme caution, at low idle, and in 1st

gear forward or reverse ONLY. Machine has no rollover/falling object protection without ROPS/

FOPS. Failure to follow this warning may cause injury or death to personnel or damage to equip-

ment.

Safe Roll-on/Roll-off (RO/RO) operation depends on strict adherence to RO/RO regulations. Fail-ure to do so may result in injury or death to personnel or damage to equipment.

All personnel working in machine operating areas during RO/RO operations must wear hearing

protection. Failure to wear hearing protection may result in hearing loss.


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WARNING

WORK SAFETY

Lifting cables, chains, hooks, and slings used for lifting machine must be in good condition and ofsuitable capacity. Failure to follow this warning may cause injury or death to personnel and dam-

age to equipment.

Improper use of lifting equipment and improper attachment of cables to machine may cause

injury to personnel and damage to equipment. Observe all standard rules of safety.

Use caution when handling heavy parts. Provide adequate support and use assistance during pro-

cedure. Ensure that any lifting device used is in good condition and of suitable load capacity. Keep

clear of heavy parts supported only by lifting device. Failure to follow this warning may cause


DO NOT perform maintenance under loader arm/work tool, unless loader arm/work tool are

lowered to the ground. If procedure requires loader arm/work tool to be raised, a suitable support

device must be used to provide support. Failure to follow this warning may cause injury or death

to personnel or damage to equipment.


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LIST OF EFFECTIVE PAGES/WORK PACKAGES

NOTE: Zero in the "Change No." column indicates and original page or work package.

Date of issue for original manual is:

Original . . . . . . . 120

Total number of pages for front and rear matter is 38 and total number of work packages is 28 consisting of the following:

A/(B Blank)

Page/WP No. Change No. Page/WP No. Change No.

Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0

Warning Summary (12 pgs.) . . . . . . . . . . . . . 0

i-vi (4 pgs.) . . . . . . . . . . . . . . . . . . . . . . . . . . 0

CHAPTER 1 title page . . . . . . . . . . . . . . . . . 0

WP 0001 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0

WP 0002 00 (16 pgs.) . . . . . . . . . . . . . . . . . . 0

WP 0003 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0


WP 0004 00 (74 pgs.) . . . . . . . . . . . . . . . . . . 0WP 0005 00 (18 pgs.) . . . . . . . . . . . . . . . . . . 0

WP 0006 00 (14 pgs.) . . . . . . . . . . . . . . . . . . 0

WP 0007 00 (12 pgs.) . . . . . . . . . . . . . . . . . . 0


WP 0008 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . 0

WP 0009 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . 0

WP 0010 00 (14 pgs.) . . . . . . . . . . . . . . . . . . 0


WP 0011 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0

WP 0012 00 (54 pgs.) . . . . . . . . . . . . . . . . . . 0


WP 0013 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . 0

WP 0014 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0

WP 0015 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . 0

WP 0016 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0


WP 0017 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . 0

WP 0018 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . 0

WP 0019 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0

WP 0020 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . 0

WP 0021 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0

WP 0022 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0

WP 0023 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0

WP 0024 00 (10 pgs.) . . . . . . . . . . . . . . . . . . 0


WP 0025 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . 0

WP 0026 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . 0

WP 0027 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0

WP 0028 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . 0

Index (6 pgs.) . . . . . . . . . . . . . . . . . . . . . . . . 0

Metric conversion chart . . . . . . . . . . . . . . . . 0

Back cover . . . . . . . . . . . . . . . . . . . . . . . . . . 0


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TECHNICAL MANUAL HEADQUARTERSTM 5-3805-291-10 DEPARTMENT OF THE ARMY

Washington, D.C., 20

OPERATORS MANUAL

FOR

LOADER, HEAVY, SCOOP:

DIESEL ENGINE DRIVEN (DED), 4-WHEEL DRIVE

4.5 CUBIC YARD ROCK BUCKETNSN 3805-01-533-1857

AND5.0 CUBIC YARD GENERAL PURPOSE BUCKET

NSN 3805-01-533-1853

MODEL 966H

DISTRIBUTION STATEMENT A - Approved for public release; distribution is unlimited.

REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS

You can help improve this publication. If you find any errors, or if you would like to recommend any

improvements to the procedures in this publication, please let us know. The preferred method is to submit your

DA Form 2028 (Recommended Changes to Publications and Blank Forms) through the Internet, on the Army

Electronic Product Support (AEPS) website. The Internet address is https://aeps.ria.army.mil. The DA Form

2028 is located under the Public Applications section in the AEPS Public Home Page. Fill out the form and click

on SUBMIT. Using this form on the AEPS will enable us to respond quicker to your comments and better

manage the DA Form 2028 program. You may also mail, email, or fax your comments or DA Form 2028

directly to the U.S. Army TACOM Life Cycle Management Command. The postal mail address is U.S. Army

TACOM Life Cycle Management Command, ATTN: AMSTA-LCLMPP/TECH PUBS, 1 Rock Island Arsenal,

Rock Island, IL 61299-7630. The email address is [email protected]. The fax number is

DSN 793-0726 or Commercial (309) 782-0726.


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Table of Contents

ii

Page

NumberWarning Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a

How To Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv

CHAPTER 1

INTRODUCTORY INFORMATION, EQUIPMENT

DESCRIPTION, AND THEORY OF OPERATION 1WP 0001 00 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0001 00-1

WP 0002 00 Equipment Description and Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0002 00-1

WP 0003 00 Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0003 00-1

CHAPTER 2

OPERATOR INSTRUCTIONS 1WP 0004 00 Description and Use of Operator Controls and Indicators . . . . . . . . . . . . . . . . 0004 00-1

WP 0005 00 Operation Under Usual Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0005 00-1

WP 0006 00 Operation Under Unusual Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0006 00-1

WP 0007 00 Stowage and Decal, Data Plate, and Stencil Guide. . . . . . . . . . . . . . . . . . . . . . 0007 00-1

CHAPTER 3

OPERATOR TROUBLESHOOTING 1WP 0008 00 Troubleshooting Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-1

WP 0009 00 Troubleshooting Symptom Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0009 00-1

WP 0010 00 Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010 00-1

CHAPTER 4

PMCS MAINTENANCE INSTRUCTIONS 1WP 0011 00 Preventive Maintenance Checks and Services (PMCS) Introduction . . . . . . . . 0011 00-1

WP 0012 00 Preventive Maintenance Checks and Services (PMCS)

Including Lubrication Instructions 0012 00-1

CHAPTER 5

MAINTENANCE INSTRUCTIONS 1WP 0013 00 Refueling and Fuel System Priming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0013 00-1

WP 0014 00 Engine Air Precleaner Service and Air Cleaner Service . . . . . . . . . . . . . . . . . . 0014 00-1

WP 0015 00 Steering Frame Lock Connection and Disconnection. . . . . . . . . . . . . . . . . . . . 0015 00-1

WP 0016 00 Circuit Breaker and Fuses Reset/Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0016 00-1

CHAPTER 6

TRANSPORT PROCEDURES 1WP 0017 00 Preparation for Transport Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0017 00-1

WP 0018 00 Roading Machine (Self-Deployment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018 00-1

WP 0019 00 Highway Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0019 00-1

WP 0020 00 Rail Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020 00-1

WP 0021 00 Rail Tiedown Procedures on a DODX Rail Car . . . . . . . . . . . . . . . . . . . . . . . . 0021 00-1


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Table of Contents - Continued

iii

WP 0022 00 Marine Transport (RO/RO Procedures) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0022 00-1

WP 0023 00 Air Transport by C-5 and C-17 Aircraft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0023 00-1WP 0024 00 Configure Machine for Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0024 00-1

CHAPTER 7

SUPPORTING INFORMATION 1WP 0025 00 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0025 00-1

WP 0026 00 Components of End Item (COEI) and Basic Issue Items (BII) Lists . . . . . . . . 0026 00-1

WP 0027 00 Expendable and Durable Items List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0027 00-1

WP 0028 00 Additional Authorization List (AAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0028 00-1


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TM 5-3805-291-10

iv

HOW TO USE THIS MANUAL

NOTEIf at any time you are unsure how to use this manual or you cannot locate the information you need, notify

your supervisor.

INTRODUCTION

1. This manual is designed to help you operate the 966H Wheel Loader and to perform operator troubleshooting and

maintenance on the equipment.

2. This manual is written in work package format:

a. Chapters divide the manual into major categories of information (e.g., Introductory Information, Equipment

Description, and Theory of Operation; Operator Instructions; Operator Troubleshooting; PMCS Maintenance

Instructions; Maintenance Instructions; Transport Procedures, and Supporting Information).

b. Each Chapter is divided into work packages, which are identified by a 6-digit number (e.g., 0001 00, 0002 00)

located in the upper right-hand corner of each page. The work package page number (e.g., 0001 00-1, 0001 00-2) islocated centered at the bottom of each page.

c. If a Change Package is issued to this manual, added work packages use the 5th and 6th digits of their number to

indicate new material. For instance, work packages inserted between WP 0001 00 and WP 0002 00 are numbered

WP 0001 01, WP 0001 02, etc.

3. Read through this manual to become familiar with its organization and contents before attempting to operate or maintain

the equipment.

CONTENTS OF THIS MANUAL

1. A Warning Summary is located at the beginning of this manual. Become familiar with these warnings before operating or

performing operator troubleshooting or maintenance on the machine.

2. A Table of Contents, located in the front of the manual, lists all chapters and work packages in the publication.

a. The Table of Contents also provides Reporting Errors and Recommending Improvements information with DA

Form 2028 addresses for the submittal of corrections to this manual.

b. If you cannot find what you are looking for in the Table of Contents, refer to the alphabeticalIndex at the back of

the manual.

3. Chapter 1, Introductory Information, Equipment Description and Data, and Theory of Operation, provides general

information on the manual and the equipment.

4. Chapter2, Operator Instructions, explains and illustrates all operator controls and indicators and contains a Stowage and

Decal, Data Plate, and Stencil Guide. It also describes how to perform all operating procedures for the machine:

Operation Under Usual Conditions and Operation Under Unusual Conditions.

5. Chapter3 covers all Operator Troubleshooting. WP 0009 00 contains a Troubleshooting Symptom Index. If the machine

malfunctions, this index should always be consulted to locate the appropriate troubleshooting procedure.

6. Chapters 4 and 5 coverMaintenance Instructions. Major areas covered are Operator Preventive Maintenance Checks and

Services (PMCS) and operator-level maintenance tasks.

7. Chapter 6 describes Transport Procedures.

8. Chapter7 includes Supporting Information: References, Components of End Item (COEI) and Basic Issue Items (BII)

Lists,Expendable and Durable Items List, andAdditional Authorization List (AAL).


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v/(vi blank)

FEATURES OF THIS MANUAL

1. WARNINGs, CAUTIONs, NOTEs, subject headings, and other important information are highlighted in BOLD print as a

visual aid.

WARNINGA WARNING indicates a hazard which may result in injury or death to personnel.

CAUTIONA CAUTION is a reminder of safety practices or directs attention to usage practices that may result in

damage to equipment.

NOTEA NOTE is a statement containing information that will make the procedures easier to perform.

2. Statements and words of particular interest may be printed, underlined, or in CAPITAL LETTERS to create emphasis.

3. Within a procedural step, reference may be made to another work package in this manual or to another manual. These

references indicate where you should look for more complete information.

a. If you are told: Start engine (WP 0005 00), go to WP 0005 00 in this manual for instructions on engine starting.

b. If you are told: For complete information on servicing batteries, refer to TM 9-6140-200-14, go to the

References work package (WP 0025 00) for complete information.

4. Illustrations are placed after, and as close to, the procedural steps to which they apply. Callouts placed on the art are text or

numbers.

5. Numbers located at lower right corner of art (e.g., 427-C001, 427-C002) are art control numbers and are used for tracking

purposes only.

6. Technical instructions include metric units as well as standard units. For your reference, aMetric Conversion Chartis

located on the inside back cover of the manual.


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TM 5-3805-291-10

CHAPTER 1

INTRODUCTORY INFORMATION, EQUIPMENT

DESCRIPTION, AND THEORY OF OPERATION


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TM 5-3805-291-10

0001 00-1

GENERAL INFORMATION 0001 00

SCOPE

1. Type of Manual. This manual is for use in operating and performing operator troubleshooting and maintenance on the

966H Wheel Loader.

2. Equipment Name and Model Number. Loader, Heavy, Scoop: Diesel Engine Driven (DED) 4-Wheel Drive, Model

966H.

a. Type I, 4.5 Cubic Yard Rock Bucket, NSN 3805-01-533-1857

b. Type II, 5.0 Cubic Yard General Purpose (GP) Bucket, NSN 3805-01-533-1853

3. Purpose of Equipment. The 966H Wheel Loader is used in worldwide earthmoving and construction projects by U.S.

Army forces in engineer troop support.

MAINTENANCE FORMS, RECORDS, AND REPORTS 0001 00

Department of the Army forms and procedures used for the equipment maintenance will be those prescribed by DA

PAM 750-8, TAMMS Users Manual.

REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIR) 0001 00

If your loader needs improvement, let us know. Send us an EIR. You, the user, are the only one who can tell us what you

dont like about your equipment. Let us know why you dont like the design or performance. (E-Mail: TACOM-TECH-

[email protected]) We will send you a reply. The preferred method for submitting Quality Deficiency Reports (QDRs)

is through the Army Electronic Product Support (AEPS) website under the Electronic Deficiency Reporting System (EDRS).

The web address is: https://aeps.ria.army.mil. If the above method is not available to you, put it on an SF 368 (Product Quality

Deficiency Report), and mail it to us at: Department of the Army, U.S. Army Tank-automotive and Armaments Command,

AMSRD-TAR-E, PDQR MS 268, 6501 E. 11 Mile Road, Warren, MI 48397-5000.

CORROSION PREVENTION AND CONTROL (CPC) 0001 00

1. CPC of Army materiel is a continuing concern. It is important that any corrosion problems with this item be reported so

that the problem can be corrected and improvements can be made to prevent the problem in future items.

2. Corrosion specifically occurs with metals. It is an electrochemical process that causes the degradation of metals. It is

commonly caused by exposure to moisture, acids, bases, or salts. An example is the rusting of iron. Corrosion damage in

metals can be seen, depending on the metal, as tarnishing, pitting, fogging, surface residue, and/or cracking.

3. Plastics, composites, and rubbers can also degrade. Degradation is caused by thermal (heat), oxidation (oxygen), solva-

tion (solvents), or photolytic (light, typically UV) processes. The most common exposures are excessive heat or light.

Damage from these processes will appear as cracking, softening, swelling, and/or breaking.

4. SF Form 368 , Product Quality Deficiency Reportshould be submitted to the address specified in DA PAM 750-8,

TAMMS Users Manual.

DESTRUCTION OF ARMY MATERIEL TO PREVENT ENEMY USE 0001 00

For destruction of Army materiel to prevent enemy use, refer to TM 750-244-3, Procedures for Destruction of Equip-

ment to Prevent Enemy Use.

PREPARATION FOR STORAGE OR SHIPMENT 0001 00

Notify Unit Maintenance to perform preparation for storage or shipment procedures.

WARRANTY INFORMATION

For warranty information refer to TB 5-3805-291-14, Warranty Technical Bulletin for the 966H Wheel Loader.

4


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TM 5-3805-291-10

GENERAL INFORMATION - CONTINUED 0001 00

0001 00-2

NOMENCLATURE CROSS-REFERENCE LIST 0001 00

OFFICIAL NOMENCLATURE COMMON NOMENCLATURE

Tilt Back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rack

LIST OF ABBREVIATIONS/ACRONYMS 0001 00

NOTERefer to ASME Y14.38-1999,Abbreviations and Acronyms, for standard abbreviations.

ABBREVIATION/ACRONYM DEFINITION

AAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Additional Authorization List

AAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Association of American Railroads

AC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Conditioning

AR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . As Required

ATAAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air-to-Air Aftercooling

BII . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Basic Issue Items

B.O. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Blackout

CCA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cold Cranking Amps

CG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Center of Gravity

CID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cubic Inch Displacement

cm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Centimeter

COEI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Components of End Item

CONUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Continental United States

CPC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Corrosion Prevention and Control

DED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Diesel Engine Driven

ECM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electronic Control Module

EIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Equipment Improvement Recommendation

ET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electronic Technician

F/N/R. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Forward/Neutral/Reverse

GIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Gabarit International de Chargement

GP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .General Purpose

kg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kilogram

km . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kilometer

kPa. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kilopascal

kph. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kilometers per Hour

kW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kilowatt

L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Liter

LASH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lighter Aboard Ship

lb-ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pound Foot

LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Left Hand

m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Meter

mm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Millimeter


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GENERAL INFORMATION - CONTINUED 0001 00

0001 00-3/(0001 00-4 Blank)

LIST OF ABBREVIATIONS/ACRONYMS - CONTINUED 0001 00

ABBREVIATION/ACRONYM DEFINITION

NATO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . North Atlantic Treaty Organization

NBC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nuclear, Biological, and Chemical

Nm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Newton Meter

OCONUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Outside Continental United States

PLS-EMM-DB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Palletized Load System-Engineer Mission Module-Dump Body

PMCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Preventive Maintenance Checks and Services

PR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ply Rating

RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Right Hand

RO/RO. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Roll-on/Roll-off

ROPS/FOPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rollover Protective Structure/Falling Object Protective Structure

SDDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Surface Deployment and Distribution Command

SDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sorbent Decontamination SystemSEABEE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Navy Construction Engineer, Sea Barge

TOE/MTOE. . . . . . . . . . . . . . . . . . . . . Table of Organization and Equipment/Modified Table of Organization and Equipment

WAVS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Work Area Vision System

END OF WORK PACKAGE


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0002 00-1

EQUIPMENT DESCRIPTION AND DATA 0002 00

EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES 0002 00

1. Characteristics.

a. The 966H Wheel Loader is an integral part of the Armys mission to efficiently build roads, airstrips, and other

engineering assets in a wide variety of geographic, environmental, and tactical situations:

(1) The 966H Type I Wheel Loader uses a 4.5 yd3 (3.5 m3) Rock bucket to operate in quarries to lift and stockpile

blast rock.

(2) The 966H Type II Wheel Loader uses a 5.0 yd3 (3.8 m3) GP bucket to excavate, dig, lift/load, strip, level, and

perform stockpiling operations.

b. The buckets can be interchanged with forklift pallet forks and a rotary sweeper to further increase machine versa-

tility.

2. Capabilities and Features.

NOTERefer toEquipment Data at the end of this work package for machine dimensions, weights, fluid capacities,

and other miscellaneous equipment data.

a. The loader consists of two sections, front frame section and rear frame section, with center-point frame articula-

tion.

b. The loader is capable of lifting, clearing, and dumping loads into the following dump trucks/bodies:

(1) M917 Series, with 114 in. (2.90 m) sideboard height;

(2) Palletized Load System-Engineer Mission Module-Dump Body (PLS-EMM-DB): Truck-Mounted, with 124 in.

(3.15 m) sideboard height; and Trailer-Mounted, with 112 in. (2.84 m) sideboard height.

c. The machine has the following capabilities and features:

(1) Caterpillar C11 heavy-duty EPA Tier III compliant turbocharged diesel engine with six in-line cylinders,

generating 259 hp (net) and 283 hp (gross) (193 and 211 kW) @ 1,800 rpm;

(2) Capable of operating for 10 hours on a tank of fuel;(3) Ether assist in cold weather starting down to -25F (-32C);

(4) Caterpillar autoshift transmission with four forward and four reverse speeds;

(5) 4-wheel drive: front fixed and rear oscillating axles with outboard planetary final drives;

(6) Self-adjusting service brakes with secondary and parking brake systems;

(7) Articulated frame steering with two double-acting steering cylinders;

(8) Air conditioned enclosed cab with adjustable seat and tilt steering wheel, gages and warning indicators, work

tool hydraulic controls, and heater/defroster/AC controls;

(9) Removable bolt-on Rollover Protective Structure/Falling Object Protective Structure (ROPS/FOPS);

(10) Interchangeable work tools, including forklift pallet forks and rotary sweeper;

(11) Z-bar loader arm with hydraulically-activated quick coupler, that allows for easy and quick connection and dis-connection of work tools without the need for operator to leave cab;

(12) Lift and tiedown provisions conforming to MIL-STD-209K,Department of Defense Interface Standard for Lift-

ing and Tiedown Provisions;

(13) NATO slave receptacle;

(14) One toolbox, located below the battery box (LH side); and

(15) Mounting provisions for M16A1, M16A2, or M4 rifle; portable fire extinguisher; and M100 Sorbent Decontam-

ination System (SDS).

16


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EQUIPMENT DESCRIPTION AND DATA - CONTINUED 0002 00

0002 00-2

EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES - CONTINUED

d. The loader is transportable as follows:

(1) RO/RO onto C-5 and C-17 for aircraft transport.

(2) RO/RO onto marine vessels.

(3) Remove ROPS/FOPS, exhaust stack, and rear handrails for highway transport when using M870 Series Semi-

trailer. A permit for width or removal of bucket may also be necessary.

(4) Remove ROPS/FOPS and exhaust stack for CONUS and NATO rail transport. OCONUS requires removal of

front and rear handrails.

e. The loader can fresh-water ford to a depth of 30 in. (76 cm) without damage or contamination of lubricants.

f. Machines that operate in extreme cold weather, from -25F to -40F (-32C to -40C), are factory equipped with an

arctic cold weather starting aid system which includes:

(1) Diesel-fired engine coolant heater,

(2) Four heavy-duty batteries, and

(3) Larger, heavy-duty starter.


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0002 00-3

LOCATION AND DESCRIPTION OF MAJOR COMPONENTS 0002 00

KEY COMPONENT DESCRIPTION

1 Bucket Hardened steel bucket has teeth, bolt-on segments, and corner guards.

The Type I machine uses a 4.5 yd3 (3.5 m3) Rock bucket. The Type II

machine uses a 5.0 yd3 (3.8 m3) GP bucket. Refer toEquipment Data

in this work package for more information.

2 Tilt Cylinder Single hydraulic cylinder tilts work tool.

3 Front Worklights Illuminate work area to front of machine. Mounted to roof bracket on

both sides of machine.

4 ROPS/FOPS Bolt-on structure provides rollover and falling object protection for

operator. Must be removed for transport by M870 Series Semitrailer

and AAR rail.

5 Grabhandle/Hand Rails Provides a handhold for personnel climbing on machine.

6 Hydraulic Tank Stores hydraulic fluid used in machine hydraulic systems. Contains

sight gage for fluid level check.

7 Hood Electrically activated tilt design opens for access to engine

compartment.

8 Fender Located over rear tire, on both sides of machine.

9 Platform Skid-free surface for gaining access to cab and top of machine. Located

on both sides of machine.10 Ladder Provides access to cab and platform. Located at front and rear, on both

sides of machine.

11 Battery Box Provides protection for batteries.

12 NATO Slave Receptacle Provides connection point for NATO slave cable to slave start

machine.

13 Fender Located over front tire, on both sides of machine.


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0002 00-4

LOCATION AND DESCRIPTION OF MAJOR COMPONENTS - CONTINUED


14 Blackout (B.O.) Drive Light Used when operating in blackout mode.

15 Interior Rearview Mirror Provides operator with a view to rear and side of machine. Located on

both sides of machine, inside cab.

16 Cab Air conditioned/heated enclosure contains operators seat and all

driving and hydraulic controls.

17 Rear Worklights Illuminate work area to rear of machine. Mounted to roof bracket on

both sides of machine.

18 Engine Air Precleaner Self-cleaning precleaner removes debris filtered from incoming air to

engine.

19 Exhaust Stack Directs exhaust away from machine. Must be removed for transport

by M870 Series Semitrailer and rail.

20 Backup Alarm Sounds when transmission is in reverse. Alerts personnel behind

machine that machine is backing up. Disabled in blackout mode.

21 Fan Housing Housing opens to provide access to cooling fan. Tilt hood must be

closed before fan housing can be opened.

22 Towing Lugs Provide attachment points for towbar.

23 Rear Tiedown Points Used to tie machine down when being transported. There is one

tiedown point on each side of rear frame section. Refer to WP 001700,Preparation for Transport Introduction, for an illustration of all

tiedown points.

24 Arctic Heater (Optional) Aids in starting engine in extreme cold temperatures.

25 Front Tiedown Points Used to tie machine down when being transported. There is one

tiedown point on each side of front frame section. Refer to WP 0017

00, Preparation for Transport Introduction, for an illustration of all

tiedown points.


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0002 00-5



26 ROPS/FOPS Lift Points (4) Attachment points for removing ROPS/FOPS for highway and rail

transport (2 on each side).

27 Windshield Protects operator from inclement weather and flying objects. Includes

windshield wipers/washers.

28 Lift Points Attachment points for overhead lifting device. There is one lift point

on each side of front and rear frame sections. Refer to WP 0017 00,Preparation for Transport Introduction, for an illustration of all lift

points.

29 Quick Coupler Equipped with hydraulically-activated pins to connect/disconnect

buckets, forks, or sweepers.

30 Axles Powered by planetary final drives inboard from wheel ends.

31 Steering Cylinders Two hydraulic cylinders provide for 40 degree right or left turns with

articulated frame steering system.


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32 Fuse Panel Provides access to fuses.

33 Horns Horns sound to alert personnel near machine.

34 Front Service Lights Inside light with white lens is service light. Outside amber light is

turnlamp. Located on both sides.

35 Loader Arm One-piece steel construction, mounted to front frame section.

36 Lift Cylinders Two hydraulic cylinders raise and lower loader arm.

37 Windshield Washer Fill Provides a means to fill windshield washer reservoir.

38 Oil Fill Tube Used to add engine oil to engine crankcase.

39 Fuel Tank Filler Provides a means to fill fuel tank.

40 Rear Composite Lights Contain the following lights: blackout marker, tail, parking, brake, and

directional signals. Located on both sides.


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41 Ether Starting Aid Aids in starting engine in very cold weather.

42 Camera Provides video for the Work Area Vision system (WAVS).

43 Steering Lock Link Stops all articulation when machine is being serviced, lifted, or

transported.

44 BII Box Storage compartment for BII.

45 Emergency Shutoff Switch Provides a means to shut down engine if engine does not shut down

when engine start switch is turned to OFF position.


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46 Forklift Attachment Attachment that allows loader to function as a forklift. Refer to

Equipment Data later in this work package for more information.

47 Rotary Sweeper Attachment Hydraulically powered attachment clears debris or snow from

roadways. Sweeper can operate in forward or reverse direction.


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0002 00-9

EQUIPMENT DATA 0002 00

Machine Dimensions (with Rock Bucket)

KEY DESCRIPTION DIMENSION

1 Height to top of ROPS/FOPS cab 142 in. (3.61 m)

2 Height to top of exhaust stack 139 in. (3.53 m)

3 Height to top of hood 101 in. (2.57 m)

4 Ground clearance 18.5 in. (47.0 cm)

5 Bucket pin height at maximum lift 166 in. (4.22 m)

6 Overall height - bucket raised 225 in. (5.72 m)

7 Length - rear axle to bumper 100 in. (2.54 m)

8 Wheelbase 136 in. (3.45 m)

9 Bucket pin height at carry 19 in. (48.3 cm)

10 Length - rear axle to articulation point 68 in. (1.73 m)

11 Rack back (tilt) angle at maximum lift 55 degrees

12 Dump angle at maximum lift 50 degrees

13 Rack back (tilt) angle at carry 47 degrees

14 Rack back (tilt) angle at ground 42 degrees

15 Axle housing clearance 17 in. (43.2 cm)

16 Overall length 372 in. (9.45 m)

17 Digging depth 4 in. (10.2 cm)

18 Reach at maximum lift and 45 degree dump 58 in. (1.47 m)

19 Height to center of axle 32 in. (81.3 cm)


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0002 00-10

EQUIPMENT DATA - CONTINUED

Machine Dimensions (with GP Bucket)


1 Height to top of ROPS/FOPS cab 141 in. (3.58 m)

2 Height to top of exhaust stack 138 in. (3.54 m)

3 Height to top of hood 100 in. (2.54 m)

4 Ground clearance 17.5 in. (44.5 cm)

5 Bucket pin height at maximum lift 165 in. (4.19 m)

6 Overall height - bucket raised 224 in. (5.69 m)

7 Length - rear axle to bumper 100 in. (2.54 m)

8 Wheelbase 136 in. (3.45 m)

9 Bucket pin height at carry 18 in. (45.7 cm)

10 Length - rear axle to articulation point 68 in. (1.73 m)

11 Rack back (tilt) angle at maximum lift 55 degrees

12 Dump angle at maximum lift 50 degrees

13 Rack back (tilt) angle at carry 47 degrees

14 Rack back (tilt) angle at ground 42 degrees

15 Axle housing clearance 16 in. (40.6 cm)

16 Overall length 372 in. (9.45 m)

17 Digging depth 5 in. (12.7 cm)

18 Reach at maximum lift and 45 degree dump 60 in. (1.27 m)

19 Height to center of axle 31 in. (78.7 cm)


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0002 00-11


Machine Dimensions with Pallet Forks

966H Rated Loads for Pallet Forks per SAE J1197 (50% of Full Turn Tipping Load)

FORK PART

NUMBER

FORK TINE

LENGTH

PLACEMENT

HEIGHT (A)

RATED

OPERATING

LOAD

LOAD

CENTER (B)

164-4069 72 in.(1.83 m)

159 in.(4.04 m)

10,000 lb(4,536 kg)

48 in.(1.22 m)


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0002 00-12


Machine Dimensions with Rotary Sweeper


1 Overall length 30 ft

(9.14 m)


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0002 00-13


Refill Capacities

Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 gal. (404 L)

Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.2 gal. (42.3 L)Front Drive Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.9 gal. (64 L)

Rear Drive Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.9 gal. (64 L)

Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 gal. (110 L)

Hydraulic System (Including Tank). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52.3 gal. (198 L)

Engine Crankcase. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.25 gal. (35 L)

Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.2 gal. (50 L)

Engine

Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Caterpillar Inc.

Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C11

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diesel, turbocharged, after-cooled

Horsepower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .259 hp (net) 283 hp (gross) (193 and 211 kW) @ 1,800 rpm

Engine rpm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,450 (high idle); 825 (low idle)

Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6, inline

Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .680 CID (11.1 L)

Type of Combustion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Direct injection

Compression Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17:1

Valves per Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Valve Lash

Inlet Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.015 0.003 in. (0.38 0.08 mm)

Exhaust Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.025 0.003 in. (0.64 0.08 mm)

Firing Order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1, 5, 3, 6, 2, 4

Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.12 in. (13.00 cm)Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.51 in. (14.00 cm)

Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,270 lb (1,030 kg)

Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Direct injection with electronic unit injectors

Cooling System, Water Temperature Regulator Range . . . . . . . . . . . . . . . . . . . . . . . 178-198F (81-92C)

Transmission


Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 speeds forward, 4 reverse

Range Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Autoshift; single lever control with remote F/N/R

Axles


Type

Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fixed

Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oscillating (13 degrees)

Front and Rear Differentials


Type

Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Limited slip

Rear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Conventional


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Brakes

Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Enclosed wet-disc; fully hydraulic

Secondary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Provided by nitrogen-charged accumulatorsParking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brake actuator

Machine Shipping Weight

Rock Bucket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53,500 lb (24,267 kg)

GP Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52,500 lb (23,814 kg)

Miscellaneous

Fording Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 in. (76.2 cm)

Maximum Travel Speed (Empty) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 mph (37 kph)

Location of Center of Gravity (CG): . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 in. (1.73 m) forward of rear axle

centerline; 52 in. (1.32 m) aboveground level; 0 in. (0 mm) left or

right of machine front-to-rearcenterline

Bucket (Rock) 0002 00

Type I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heavy-duty, rock

Ground-Engaging Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Teeth and segments

Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 in. (3.25 m)

Rated Volume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 yd3 (3.5 m3)

Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5,200 lb (2,330 kg)

Bucket (GP)

Type II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .General purpose

Ground-engaging Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Teeth and segmentsWidth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 in. (3.02 m)

Rated Volume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.0 yd3 (3.8 m3)

Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4,200 lb (1,905 kg)

Fork

Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 in. (2.21 m)

Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,650 lb (1,202 kg)

Sweeper

Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 in. (3.20 m)

Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,450 lb (658 kg)

Tires

Size. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26.5-25

Ply Rating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 PR; L-4 (Rock Bucket), L-3 (GP Bucket)

Load Rating

Front (Each Tire) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41,000 lb (18,597 kg)

Rear (Each Tire) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18,000 lb (8,165 kg)

Inflation Pressure

Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60 psi (414 kPa)

Rear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 psi (276 kPa)


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0002 00-15/(0002 00-16 Blank)


Tires - Continued

Axle Load

Front (Rock Bucket) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28,000 lb (12,701 kg)Front (GP Bucket). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27,500 lb (12,474 kg)Rear (Rock Bucket) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25,500 lb (11,567 kg)Rear (GP Bucket) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25,000 lb (11,340 kg)

Average Tire Contact Area

Rock Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390 in.2(1,374 cm2) each tire

GP Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 450 in.2 (2,903 cm2) each tire

Steering

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Center-point frame articulation, load sensing

primary and secondary systems

Number of Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Electrical System

System Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Batteries:

Quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Cold Cranking Amps Rating:

Standard Machine: Down to -25F (-32C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 @ 1,400 CCA

Batteries (-40F Arctic Kit):

Quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Cold Cranking Amps Rating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 @ 1,400 CCA

2 @ 1,000 CCA

END OF WORK PACKAGE


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TM 5-3805-291-10

0003 00-1

THEORY OF OPERATION 0003 00

INTRODUCTION

1. The 966H Wheel Loader consists of the following functional systems: engine; power train; brake systems; electrical

system; and steering, hydraulic, ride control, and earthmoving equipment.

2. This work package explains how the systems and components of the machine work together. A functional description is

provided for each major component and system.

3. The machine has a sound suppressing Rollover Protective Structure/Falling Object Protective Structure (ROPS/FOPS)

cab with insulation, heater, and air conditioning, which allows for all-weather operation. Removal of the ROPS/FOPS

and exhaust stack is required for highway, Gabarit International de Chargement (GIC) rail transport, and Association of

American Railroads (AAR).

ENGINE 0003 00

1. General. The machine is equipped with a Caterpillar C11 heavy-duty, Air-to-Air Aftercooling (ATAAC) diesel engine

with six in-line cylinders, generating 259 hp (net) and 283 hp (gross) at 1,800 rpm.

2. Fuel System.

a. Diesel fuel is drawn from the tank by a mechanical transfer pump, filtered by a primary fuel filter and a fuel/water

separator, routed to the fuel injection pump and secondary filter, and then injected through the fuel injector nozzles

into the engine cylinders.

b. Air is drawn in through dry-type, replaceable filter elements. A precleaner removes incoming dust from the air.

c. An Electronic Control Module (ECM) functions as the throttle and computer for the fuel system.

3. Cooling System. The cooling system provides coolant to the engine. Coolant is circulated through the engine by a gear-

driven water pump. Hydraulic oil, transmission oil, and aftercoolers are located near the radiator. The engine oil cooler

is mounted on the right side of the engine.

4. Lubrication System. The engine lubrication system consists of a gear-driven oil pump, oil filter, oil cooler, and oil pan.

The engine is lubricated by cooled and pressurized oil that is circulated through the engine block and head.

5. Exhaust System.

a. The exhaust system routes exhaust gases from the engine through the exhaust manifold and turbocharger. The

gases flow into exhaust pipes and a muffler to the atmosphere above the cab.

b. The turbocharger has a wastegate, which helps improve engine emissions.

POWERTRAIN 0003 00

1. Transmission.

a. The machine is equipped with an ECM-controlled Caterpillar autoshift transmission with four forward speeds and

four reverse speeds.

b. Manual, automatic, or economy modes of transmission operation can be selected.

c. To increase operator efficiency, direction of travel can be controlled by using either a steering column-mountedtransmission control lever or a transmission direction control switch (remote F/N/R switch) on the loader control

joystick.

d. A transmission neutralizer system allows the operator to disengage the transmission by pressing the service brake

pedals. This serves to stop the machine while increasing hydraulic response. This function can be turned off using

Messenger.

2. Front Axle. This axle is fixed and mounted to the frame.

3. Rear Axle. This axle is trunnion mounted to allow axle oscillation of 13 degrees.

4


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THEORY OF OPERATION - CONTINUED 0003 00

0003 00-2

BRAKE SYSTEMS 0003 00

1. Service Brakes.

a. An engine-mounted, gear-driven pump provides hydraulic pressure for the service brakes. The service brakes are a

wet brake system mounted to the planetary.

b. Two service brake pedals operate a hydraulic valve, which directs hydraulic pressure through hydraulic lines for

engaging multiple oil disc brake assemblies for each wheel.

c. The brake system has two accumulators, which ensure proper brake pressure is maintained.

2. Parking Brakes.

a. The parking brake is engaged via a switch on the dash in the cab.

b. If service brakes are lost, the parking brake can be applied to aid in stopping the machine.

ELECTRICAL SYSTEM 0003 00

1. The electrical system consists of two 12V batteries connected in series-parallel with negative grounding, providing 24Vto operate the electrical systems and components.

a. Standard machines have two batteries with a Cold Cranking Amps (CCA) rating of 1,400 each.

b. Arctic operation machines have four batteries. Two have a rating of 1,400 CCA each and two have a rating of

1,000 CCA each.

2. The system contains all the necessary switches, circuit breakers, fuses, relays, harnesses, and connectors to operate the

machine, including a NATO slave receptacle.

3. The Messenger system allows the operator to view critical parameters that directly affect machine performance.

4. The following major systems comprise the electrical system:

a. Starting systemb. Charging system

c. Electronic engine, transmission, and machine system controls

d. Instrumentation

e. Service, work, and blackout lights

HYDRAULIC SYSTEM 0003 00

1. General. A main hydraulic pump driven by the engine provides power for steering and earthmoving equipment opera-

tion.

2. Steering System.

a. The machines hydraulic steering system changes the machines angle of articulation.

b. Major components of the steering system are piston pump, metering pump, steering cylinders, and lines and fit-

tings.

c. Two steering cylinders mounted to the loader rear frame section turn the front wheels. The cylinders are powered

by the hydraulic system and controlled by the steering wheel.

d. In the event of primary steering system failure, a secondary system automatically activates. An electric supplemen-

tal steering pump provides emergency steering power.


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THEORY OF OPERATION - CONTINUED 0003 00

0003 00-3/(0003 00-4 Blank)

HYDRAULIC SYSTEM - CONTINUED

3. Loader Hydraulic System.

a. Work tool height (lift) and tilt movements are controlled using a single-lever joystick loader control. A rotary

thumb wheel on top of the joystick controls auxiliary hydraulic flow to the work tool (forklift pallet forks or rotarysweeper).

b. A single tilt cylinder centered over the loader arm controls tilt functions.

c. Two lift cylinders, mounted between the front frame section and the loader arm, raise and lower the loader arm.

RIDE CONTROL SYSTEM 0003 00

1. The ride control system provides the means for absorbing forces from the lift cylinders while the machine is traveling.

This system minimizes machine pitching when traveling over rough terrain.

2. The main components of the ride control system are accumulator, ride control valve, lift cylinders, and ride control

switch on the operator console inside the cab.

3. The operator can choose three modes of ride control: OFF, MANUAL, or AUTOMATIC.

EARTHMOVING EQUIPMENT 0003 00

1. A loader arm with hydraulically activated quick coupler allows for easy and quick connection and disconnection of

work tools without the need for operator to leave the cab.

2. The 966H Type I machine uses a Rock bucket with 4.5 yd3 (3.5 m3) capacity. The 966H Type II machine uses a GP

bucket with 5.0 yd3 (3.8 m3) capacity.

3. Buckets can be interchanged with forklift pallet forks and a rotary sweeper.

END OF WORK PACKAGE


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CHAPTER 2

OPERATOR INSTRUCTIONS


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0004 00-1

DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS 0004 00

Maintenance Task Title Page

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-1

Overview - Controls and Indicators Inside Cab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-2

Battery Disconnect Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-6

Transmission Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TM 5-3805-291-10 CATERPILLAR MDL 966H

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Transcript of TM 5-3805-291-10 CATERPILLAR MDL 966H