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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
injury or death to personnel.
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
injury or death to personnel.
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
CHAPTER 2 title page . . . . . . . . . . . . . . . . . 0
WP 0004 00 (74 pgs.) . . . . . . . . . . . . . . . . . . 0WP 0005 00 (18 pgs.) . . . . . . . . . . . . . . . . . . 0
WP 0006 00 (14 pgs.) . . . . . . . . . . . . . . . . . . 0
WP 0007 00 (12 pgs.) . . . . . . . . . . . . . . . . . . 0
CHAPTER 3 title page . . . . . . . . . . . . . . . . . 0
WP 0008 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0009 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0010 00 (14 pgs.) . . . . . . . . . . . . . . . . . . 0
CHAPTER 4 title page . . . . . . . . . . . . . . . . . 0
WP 0011 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0012 00 (54 pgs.) . . . . . . . . . . . . . . . . . . 0
CHAPTER 5 title page . . . . . . . . . . . . . . . . . 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
CHAPTER 6 title page . . . . . . . . . . . . . . . . . 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
CHAPTER 7 title page . . . . . . . . . . . . . . . . . 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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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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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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CHAPTER 1
INTRODUCTORY INFORMATION, EQUIPMENT
DESCRIPTION, AND THEORY OF OPERATION
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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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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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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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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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KEY COMPONENT DESCRIPTION
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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KEY COMPONENT DESCRIPTION
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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KEY COMPONENT DESCRIPTION
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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KEY COMPONENT DESCRIPTION
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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KEY COMPONENT DESCRIPTION
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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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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Machine Dimensions (with GP Bucket)
KEY DESCRIPTION DIMENSION
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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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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Machine Dimensions with Rotary Sweeper
KEY DESCRIPTION DIMENSION
1 Overall length 30 ft
(9.14 m)
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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
Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Caterpillar Inc.
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 speeds forward, 4 reverse
Range Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Autoshift; single lever control with remote F/N/R
Axles
Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Caterpillar Inc.
Type
Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fixed
Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oscillating (13 degrees)
Front and Rear Differentials
Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Caterpillar Inc.
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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EQUIPMENT DESCRIPTION AND DATA - CONTINUED 0002 00
0002 00-15/(0002 00-16 Blank)
EQUIPMENT DATA - CONTINUED
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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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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .