FIELD MAINTENANCE MANUAL
(Includes Unit and Direct Support Maintenance)
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 BUCKET
NSN 3805-01-533-1853
MODEL 966H
DISTRIBUTION STATEMENT A - Approved for public release; distribution is unlimited.
or death to personnel. Also included are explanations of safety and hazardous materials icons used within the technical
manual.
BIOLOGICAL - abstract symbol shows that a material may contain bacteria or viruses that
present a danger to life or health.
CHEMICAL - drops 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 with face shield shows that particles
fly-ing through the air will harm face.
HEAVY PARTS - hand with heavy object on top shows that heavy parts can crush and
harm.
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.
SLICK FLOOR - wavy line on floor with legs prone shows that slick floor presents a
dan-ger from falling.
VAPOR - human figure in a cloud shows that material vapors present a danger to life or
health.
WARNING
CARBON MONOXIDE (EXHAUST GASES) CAN KILL!
• Carbon monoxide is a colorless, odorless, deadly poison which, when breathed, deprives the body of
oxy-gen and causes suffocation. Exposure to air containing carbon monoxide produces symptoms of
head-ache, dizziness, loss of muscular control, apparent drowsiness, and coma. Permanent brain damage or
death can result from severe exposure.
• Carbon monoxide occurs in exhaust fumes of internal combustion engines. Carbon monoxide can
become dangerously concentrated under conditions of inadequate ventilation. The following precautions
must be observed to ensure safety of personnel when engine is operated.
1.
DO NOT operate engine in enclosed areas.
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, and Chemical (NBC) protection will not protect
you from carbon monoxide poisoning.
• To avoid injury, eye protection and acid-resistant gloves must be worn when working around batteries.
DO NOT smoke, use open flame, make sparks, or create other ignition sources around batteries. If a
bat-tery is giving off gases, it can explode and cause injury to personnel. Remove all jewelry such as rings, ID
tags, watches, and bracelets. If jewelry or a tool contacts a battery terminal, a direct short will result in
instant heating or electric 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 death or serious injury to personnel.
a.
Eyes. Flush with cold water for no less than 15 minutes and seek medical attention immediately.
b.
Skin. Flush with large amounts of cold water until all acid is removed. Seek medical attention as required.
c.
Internal. If corrosion or electrolyte is ingested, drink large amounts of water or milk. Follow with milk of
magnesia, beaten egg, or vegetable oil. Seek medical attention immediately.
d.
Clothing/Equipment. Wash area with large amounts of cold water. Neutralize acid with baking soda or
household ammonia.
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. 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. Failure to follow this warning may result in injury to personnel.
Ether fuel is extremely flammable and toxic. DO NOT smoke and make sure you are in a
well-venti-lated 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 immediately if ether is inhaled
BATTERIES
WARNING
COMPRESSED AIR
WARNING
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.
• DO NOT smoke or permit any open flame in area of loader 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 to personnel or equipment damage.
• 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.
• Operating personnel must wear fuel-resistant gloves when handling fuels. If exposed to fuel, promptly
wash exposed skin and change fuel-soaked clothing. Failure to follow this warning may result in injury
to personnel.
• When servicing this machine, performing maintenance, or disposing of materials such as engine coolant,
hydraulic fluid, lubricants, battery acids or batteries, and CARC paint, consult your unit/local
hazard-ous 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.
• Lubricating/hydraulic oils and engine coolant used in the performance of maintenance can be very
slip-pery. Immediately wipe up any spills. Failure to follow this warning may result in injury to personnel.
Your hearing can be PERMANENTLY DAMAGED if you are exposed to constant high noise levels of
85 dB or greater. Hearing protection is required when operating machine or when working on
machine while it is operating. Failure to wear hearing protection may result in hearing loss.
FIRE EXTINGUISHER
WARNING
FUEL HANDLING
WARNING
HAZARDOUS WASTE DISPOSAL
WARNING
HEARING PROTECTION
• 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. Escaping
hydraulic fluid under pressure can penetrate the skin, causing injury to personnel.
• At operating temperature, hydraulic oil is hot. Allow hydraulic oil to cool before disconnecting any
hydraulic lines. Failure to follow this warning may result in injury to personnel.
WARNING
HYDRAULIC SYSTEM PRESSURE
The accumulator is filled with dry nitrogen. DO NOT loosen or remove the valve or cap from the top
of the accumulator.
WARNING
MACHINE OPERATION
• Use caution and maintain three-point contact at all times when mounting or dismounting machine. DO
NOT use steering wheel as a handhold. 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.
• 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 warning may result
in injury or death to personnel.
• DO NOT allow riders on machine. Failure to follow this warning may result in injury or death to
person-nel.
• NEVER leave operator compartment without applying 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, apply parking/emergency brake. Failure to follow this warning may result in injury to
per-sonnel or damage to equipment.
• NEVER use starting fluid or spray to aid in starting the engine, other than the on-board ether cold start
system. Failure to follow this warning may cause injury or death to personnel or damage to equipment.
• Always use a ground guide when driving machine up or down ramps in preparation for highway or
marine transport. Failure to use a ground guide may cause injury or death to personnel or damage to
equipment.
• 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 3-3, Chemical and Biological Contamination Avoidance, TM 3-4230-236-10, Operator’s
Manual for Decontamination System, Sorbent: M100, FM 3-3-1, Nuclear Contamination Avoidance.
• 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 personnel.
To order this NBC decal use:
National Stock Number (NSN) - 7690-01-114-3702
Part Number (PN) - 12296626
Commercial and Government Entity Code (CAGEC) - 19207
• DO NOT service cooling system unless engine has been allowed to cool down. This is a pressurized
cool-ing system and escapcool-ing steam or hot coolant may result in 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 follow this warning
may result in serious burns.
• Wear effective eye, hand, and skin protection when handling coolants. Failure to do so may result in
injury to personnel.
NBC EXPOSURE
WARNING
IF NBC EXPOSURE IS SUSPECTED ALL AIR
FILTER MEDIA WILL BE HANDLED BY
PER-SONNEL WEARING FULL NBC PROTECTIVE
EQUIPMENT. SEE
OPERATOR/MAINTE-NANCE MANUAL.
7690-01-114-3702
WARNING
Solvent cleaning compound MIL-PRF-680 Type III is an environmentally compliant and low toxic
material. 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 do so may
result in injury or death to personnel.
WARNING
TIRES
• Operating machine with underinflated or defective tire may lead to tire failure and loss of traction or
control. Failure to follow this warning may cause damage to equipment or injury to personnel.
• If tire pressure is 0 psi (0 kPa) DO NOT inflate. Notify Unit Maintenance. Failure to follow this warning
may cause injury or death to personnel.
• Use a self-inflating chuck and stand at a distance behind tire when inflating tire. Failure to follow this
warning may cause injury or death to personnel.
• Lifting cables, chains, hooks, and slings used for lifting machine must be in good condition and of
suit-able capacity. Failure to follow this warning may cause injury or death to personnel and damage 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.
• Hitch and steering movement can reduce clearances suddenly and cause injury. Always stop engine
BEFORE working in area of hitch link.
• Use extreme caution when handling heavy parts. Provide adequate support and use assistance during
procedure. Ensure that any lifting equipment used is in good condition and of suitable load capacity.
Keep clear of heavy parts supported only by lifting equipment. Failure to follow this warning may cause
injury or death to personnel.
• Wear suitable eye protection and keep face and eyes away from exhausting air tank drain valves. Failure
to do so may cause injury to personnel.
• Hot oil or metal parts can cause severe burns. Wear insulated gloves, long sleeves, and eye protection
when working with heated parts.
• Before operating machine, secure the steering frame lock in stowed position. Failure to lock steering
frame lock into stowed position can result in loss of steering and injury or death to personnel.
SOLVENT CLEANING COMPOUND
WARNING
WORK SAFETY
Original . . . 1-DQXDU\
Total number of volumes is 2. Total number of pages for front and rear matter is 114 and total number of work packages is
237, consisting of the following:
Page/WP No.
Change No. Page/WP No. Change No.
Volume I
Front Cover . . . 0
Warning Summary (8 pgs.) . . . 0
i thru xii . . . 0
CHAPTER 1 title page . . . 0
WP 0001 00 (122 pgs.) . . . 0
WP 0002 00 (16 pgs.) . . . 0
WP 0003 00 (188 pgs.) . . . 0
CHAPTER 2 title page . . . 0
WP 0004 00 (6 pgs.) . . . 0
WP 0005 00 (16 pgs.) . . . 0
WP 0006 00 (10 pgs.) . . . 0
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WP 0015 00 (38 pgs.) . . . 0
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WP 0017 00 (70 pgs.) . . . 0
WP 0018 00 (22 pgs.) . . . 0
CHAPTER 3 title page . . . 0
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CHAPTER 5 title page . . . 0
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WP 0232 00 (22 pgs.) . . . 0
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WP 0234 00 (22 pgs.) . . . 0
WP 0235 00 (8 pgs.) . . . 0
WP 0236 00 (6 pgs.) . . . 0
WP 0237 00 (2 pgs.) . . . 0
Index-1 to Index-22 . . . 0
Foldouts (52 pgs.) . . . 0
Metric conversion chart . . . 0
Back Cover . . . 0
Volume II
Front Cover (2 pgs). . . 0
Warning Summary (8 pgs.). . . 0
i thru x. . . 0
WP 0050 00 (14 pgs.) . . . 0
WP 0051 00 (10 pgs.) . . . 0
WP 0052 00 (10 pgs.) . . . 0
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WP 0113 00 (8 pgs.) . . . 0
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WP 0121 00 (10 pgs.) . . . 0
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WP 0157 00 (12 pgs.) . . . 0
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WP 0159 00 (16 pgs.) . . . 0
WP 0160 00 (2 pgs.) . . . 0
WP 0161 00 (12 pgs.) . . . 0
WP 0162 00 (26 pgs.) . . . 0
WP 0163 00 (4 pgs.) . . . 0
WP 0164 00 (6 pgs.) . . . 0
WP 0165 00 (4 pgs.) . . . 0
WP 0166 00 (4 pgs.) . . . 0
CHAPTER 4 title page . . . 0
WP 0171 00 (38 pgs.) . . . 0
WP 0172 00 (12 pgs.) . . . 0
WP 0173 00 (6 pgs.) . . . 0
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WP 0195 00 (24 pgs.) . . . 0
WP 0196 00 (8 pgs.) . . . 0
WP 0197 00 (6 pgs.) . . . 0
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WP 0224 00 (4 pgs.) . . . 0
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WP 0226 00 (6 pgs.) . . . 0
WP 0227 00 (10 pgs.) . . . 0
WP 0228 00 (16 pgs.) . . . 0
WP 0229 00 (16 pgs.) . . . 0
CHAPTER 5 title page . . . 0
WP 0230 00 (2 pgs.) . . . 0
WP 0231 00 (4 pgs.) . . . 0
WP 0232 00 (22 pgs.) . . . 0
WP 0233 00 (6 pgs.) . . . 0
WP 0234 00 (22 pgs.) . . . 0
WP 0235 00 (8 pgs.) . . . 0
WP 0236 00 (6 pgs.) . . . 0
WP 0237 00 (2 pgs.) . . . 0
Index-1 to Index-16 . . . 0
Foldouts (52). . . 0
Metric conversion chart . . . 0
TECHNICAL MANUAL
FIELD MAINTENANCE MANUAL
(Includes Unit and Direct Support Maintenance)
FORLOADER, 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 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
improve-ments 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.
Page
VOLUME I
Warning Summary . . . a
WP Figure 2. How To Use This Manual . . . . xii
CHAPTER 1. INTRODUCTORY INFORMATION, EQUIPMENT
DESCRIPTION AND DATA, AND THEORY OF OPERATION
WP 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. TROUBLESHOOTING PROCEDURES
WP 0004 00 Troubleshooting Introduction . . . 0004 00-1
WP 0005 00 How to Use MSD with ET . . . 0005 00-1
WP 0006 00 How To Use On-Board Diagnostics . . . 0006 00-1
WP 0007 00 Troubleshooting Symptom Index . . . 0007 00-1
WP 0008 00 Troubleshooting Without a Diagnostic Code . . . 0008 00-1
WP 0009 00 Troubleshooting With a Diagnostic Code . . . 0009 00-1
WP 0010 00 Engine Tests, Inspections, and Adjustments . . . 0010 00-1
WP 0011 00 Fuel System Tests, Inspections, and Adjustments. . . 0011 00-1
WP 0012 00 Cooling System Tests, Inspections, and Adjustments. . . 0012 00-1
WP 0013 00 Electrical System Tests, Inspections, and Adjustments . . . 0013 00-1
WP 0014 00 Powertrain Tests, Inspections, and Adjustments. . . 0014 00-1
WP 0015 00 Brake System Tests, Inspections, and Adjustments . . . 0015 00-1
WP 0016 00 Steering System Tests, Inspections, and Adjustments . . . 0016 00-1
WP 0017 00 Hydraulic System Tests, Inspections, and Adjustments . . . 0017 00-1
WP 0018 00 Air Conditioning System Tests, Inspections, and Adjustments . . . 0018 00-1
CHAPTER 3. UNIT MAINTENANCE INSTRUCTIONS
WP 0019 00 Preventive Maintenance Checks and Services (PMCS) Introduction . . . 0019 00-1
WP 0020 00 Preventive Maintenance Checks and Services (PMCS)
Including Lubrication Instructions . . . 0020 00-1
WP 0021 00 Service Upon Receipt . . . 0021 00-1
WP 0022 00 Electrical General Maintenance Instructions. . . 0022 00-1
WP 0023 00 Mechanical General Maintenance Instructions . . . 0023 00-1
WP 0024 00 Valve Cover and Base Replacement . . . 0024 00-1
WP 0025 00 Changing Engine Oil and Filter. . . 0025 00-1
WP 0026 00 Crankcase Breather Replacement . . . 0026 00-1
WP 0027 00 Engine Oil Cooler Core Replacement . . . 0027 00-1
WP 0028 00 Engine Oil Filter Base Replacement . . . 0028 00-1
WP 0029 00 Engine Oil Filler Tube and Dipstick Tube Replacement . . . 0029 00-1
WP 0030 00 Air Cleaner and Precleaner Replacement . . . 0030 00-1
WP 0031 00 Air Intake Assembly Hoses and Lines Replacement . . . 0031 00-1
WP 0032 00 Turbocharger Assembly, Air Lines, and Oil Lines Replacement . . . 0032 00-1
WP 0033 00 Fuel Tank Replacement. . . 0033 00-1
WP 0034 00 Fuel Filter Lines and Fittings Replacement. . . 0034 00-1
WP 0035 00 Primary Fuel Filter and Water Separator Replacement. . . 0035 00-1
Page
WP 0037 00 Ether Starting Aid Replacement . . . 0037 00-1
WP 0038 00 Fuel Priming Pump Replacement . . . 0038 00-1
WP 0039 00 Throttle Pedal and Throttle Position Sensor Maintenance . . . 0039 00-1
WP 0040 00 Muffler and Exhaust Pipe Replacement . . . 0040 00-1
WP 0041 00 Cooling System Service . . . 0041 00-1
WP 0042 00 Radiator Top Tank Replacement. . . 0042 00-1
WP 0043 00 Cooling System Lines Replacement . . . 0043 00-1
WP 0044 00 Thermostat Replacement . . . 0044 00-1
WP 0045 00 Water Pump Replacement . . . 0045 00-1
WP 0046 00 Alternator Replacement. . . 0046 00-1
WP 0047 00 Belt Tensioner and Idler Pulleys Replacement . . . 0047 00-1
WP 0048 00 Serpentine Belt Replacement . . . 0048 00-1
WP 0049 00 Blower Motor Resistor Replacement . . . 0049 00-1
CHAPTER 5. SUPPORTING INFORMATION
WP 0230 00 References . . . 0230 00-1
WP 0231 00 Maintenance Allocation Chart (MAC) Introduction . . . 0231 00-1
WP 0232 00 Maintenance Allocation Chart (MAC) . . . 0232 00-1
WP 0233 00 . . . .
. 0233 00-1
WP 0233 00 Expendable and Durable Items List . . . 0233 00-1
WP 0234 00 Torque Limits . . . 0234 00-1
WP 0235 00 Preparation for Storage or Shipment . . . 0235 00-1
WP 0236 00 Nomenclature Cross-Reference List . . . 0236 00-1
WP 0237 00 Schematics Introduction . . . 0237 00-1
Index . . . Index-1
Electrical
Figure 1. Electrical Schematics - Key to Components . . . .FP-1/(FP-2 Blank)
Figure 1. Electrical Schematics - Key to Harnesses . . . .FP-3/(FP-4 Blank)
Figure 1. Electrical Schematics - Lighting Circuit (Sheet 1 of 21) . . . .FP-5/(FP-6 Blank)
Figure 1. Electrical Schematics - Lighting Circuit (Sheet 2 of 21) . . . .FP-7/(FP-8 Blank)
Figure 1. Electrical Schematics - Accessories Circuit (Sheet 3 of 21) . . . FP-9/(FP-10 Blank)
Figure 1. Electrical Schematics - Accessories Circuit (Sheet 4 of 21) . . . FP-11/(FP-12 Blank)
Figure 1. Electrical Schematics - Accessories Circuit (Sheet 5 of 21) . . . FP-13/(FP-14 Blank)
Figure 1. Electrical Schematics - Accessories Circuit (Sheet 6 of 21) . . . FP-15/(FP-16 Blank)
Figure 1. Electrical Schematics - Implement Circuit (Sheet 7 of 21) . . . FP-17/(FP-18 Blank)
Figure 1. Electrical Schematics - Implement Circuit (Sheet 8 of 21) . . . FP-19/(FP-20 Blank)
Figure 1. Electrical Schematics - Implement Circuit (Sheet 9 of 21) . . . FP-21/(FP-22 Blank)
Figure 1. Electrical Schematics - Implement Circuit (Sheet 10 of 21) . . . FP-23/(FP-24 Blank)
Figure 1. Electrical Schematics - Implement Circuit (Sheet 11 of 21) . . . FP-25/(FP-26 Blank)
Figure 1. Electrical Schematics - Engine Circuit (Sheet 12 of 21) . . . .FP-27/(FP-28 Blank)
Page
Electrical - Continued
Figure 1. Electrical Schematics - Transmission Circuit (Sheet 14 of 21) . . . FP-31/(FP-32 Blank)
Figure 1. Electrical Schematics - Transmission Circuit (Sheet 15 of 21) . . . FP-33/(FP-34 Blank)
Figure 1. Electrical Schematics - Transmission Circuit (Sheet 16 of 21) . . . FP-35/(FP-36 Blank)
Figure 1. Electrical Schematics - Starting Circuit (Sheet 17 of 21). . . FP-37/(FP-38 Blank)
Figure 1. Electrical Schematics - Starting Circuit (Sheet 18 of 21). . . FP-39/(FP-40 Blank)
Figure 1. Electrical Schematics - Power Distribution Circuit (Sheet 19 of 21). . . FP-41/(FP-42 Blank)
Figure 1. Electrical Schematics - Messenger Circuit (Sheet 20 of 21) . . . FP-43/(FP-44 Blank)
Figure 1. Electrical Schematics - Legend (Sheet 21 of 21) . . . FP-45/(FP-46 Blank)
Hydraulic
Figure 2. Hydraulic Component Locator (Sheet 1 of 3) . . . FP-47/(FP-48 Blank)
Figure 2. Hydraulic Schematic (Sheet 2 of 3) . . . FP-49/(FP-50 Blank)
Figure 2. Hydraulic Schematic Legend (Sheet 3 of 3). . . FP-51/(FP-52 Blank)
VOLUME II
Warning Summary . . . a
How To Use This Manual . . . ix
Electrical System
WP 0050 00 Rearview Camera, Cable, and Display Replacement . . . 0050 00-1
WP 0051 00 Starter Replacement. . . 0051 00-1
WP 0052 00 HVAWP 0052 00C Blend Door Actuator Replacement . . . 0052 00-1
WP 0053 00 Fuse, Relay, Circuit Breaker, and Arc Suppressor Replacement . . . 0053 00-1
WP 0054 00 Instrument Cluster Replacement . . . 0054 00-1
WP 0055 00 Instrument Panels and Switches Replacement . . . 0055 00-1
WP 0056 00 Messenger ECM Replacement . . . 0056 00-1
WP 0057 00 Engine Electronic Control Module (ECM) Replacement . . . 0057 00-1
WP 0058 00 Hood Tilt Actuator Replacement. . . 0058 00-1
WP 0059 00 Hood Tilt Switch and Wiring Harness Replacement . . . 0059 00-1
WP 0060 00 Implement Electronic Control Module (ECM) Replacement . . . 0060 00-1
WP 0061 00 Main Light Switch and Arctic Heater Switch Replacement . . . 0061 00-1
WP 0062 00 Power Converter Replacement . . . 0062 00-1
WP 0063 00 Powertrain Electronic Control Module (ECM) Replacement . . . 0063 00-1
WP 0064 00 Stoplight Limit Switch Maintenance. . . 0064 00-1
WP 0065 00 Turnlamp Flasher Replacement. . . 0065 00-1
WP 0066 00 Turnlamp Switch Replacement . . . 0066 00-1
WP 0067 00 Windshield Wiper Switches Replacement . . . 0067 00-1
WP 0068 00 Blackout Drive Light Replacement . . . 0068 00-1
WP 0069 00 Dome Lamp Replacement . . . 0069 00-1
Page
Electrical System - Continued
WP 0071 00 Service Lights and Front Turnlamp Replacement. . . 0071 00-1
WP 0072 00 Worklights Maintenance . . . 0072 00-1
WP 0073 00 Atmospheric Pressure Sensor Replacement . . . 0073 00-1
WP 0074 00 Boost Pressure Sensor Replacement . . . 0074 00-1
WP 0075 00 Brake Pedal Position Sensor Replacement . . . 0075 00-1
WP 0076 00 Camshaft Speed/Timing Sensor (Secondary) Replacement . . . 0076 00-1
WP 0077 00 Coolant Temperature Sensor Replacement . . . 0077 00-1
WP 0078 00 Crankshaft Speed/Timing Sensor (Primary) Replacement . . . 0078 00-1
WP 0079 00 Engine Oil Pressure Sensor Replacement . . . 0079 00-1
WP 0080 00 Fuel Level Sending Unit Replacement . . . 0080 00-1
WP 0081 00 Front and Rear Axle Oil Temperature Sensors Replacement . . . 0081 00-1
WP 0082 00 Fuel Temperature Sensor Replacement. . . 0082 00-1
WP 0083 00 Hydraulic Oil Temperature Sensor Replacement . . . 0083 00-1
WP 0084 00 Intake Manifold Air Temperature Sensor Replacement . . . 0084 00-1
WP 0085 00 Lift Kickout Position Sensor and Mounting Replacement . . . 0085 00-1
WP 0086 00 Parking Brake Oil Pressure Switch Replacement . . . 0086 00-1
WP 0087 00 Service Brake Oil Pressure Switch Replacement . . . 0087 00-1
WP 0088 00 Steering Oil Pressure Switches Replacement . . . 0088 00-1
WP 0089 00 Tilt Kickout Position Sensor and Mounting Replacement . . . 0089 00-1
WP 0090 00 Torque Converter Oil Temperature Sensor Replacement . . . 0090 00-1
WP 0091 00 Torque Converter Output Speed Sensor Replacement . . . 0091 00-1
Transmission System
WP 0092 00 Transmission Oil Temperature Sensors Replacement. . . 0092 00-1
WP 0093 00 Transmission Output Speed Sensor Replacement. . . 0093 00-1
WP 0094 00 Backup Alarm Replacement . . . 0094 00-1
WP 0095 00 Horn Replacement . . . 0095 00-1
WP 0096 00 Batteries Replacement . . . 0096 00-1
WP 0097 00 Battery Cables Replacement . . . 0097 00-1
WP 0098 00 Battery Disconnect Switch Replacement . . . 0098 00-1
WP 0099 00 NATO Slave Receptacle Replacement . . . 0099 00-1
WP 0100 00 Transmission Service. . . 0100 00-1
WP 0101 00 Shift Lever Replacement . . . 0101 00-1
WP 0102 00 Transmission Oil Cooler Lines Replacement . . . 0102 00-1
WP 0103 00 Transmission Oil Filler Tube Replacement. . . 0103 00-1
WP 0104 00 Transmission Oil Filter Base, Lines, and Bypass Switch Replacement . . . 0104 00-1
WP 0105 00 Transmission Oil Filter Element Replacement . . . 0105 00-1
WP 0106 00 Transmission Test Lines and Fittings Replacement . . . 0106 00-1
Propeller and Propeller Shafts
WP 0107 00 Center Drive Shaft (Slip Joint) Replacement . . . 0107 00-1
WP 0108 00 Front Drive Shaft Carrier Bearing Replacement . . . 0108 00-1
WP 0109 00 Front Drive Shaft Replacement . . . 0109 00-1
WP 0110 00 Rear Drive Shaft Replacement . . . 0110 00-1
Page
Brake System
WP 0112 00 Parking Brake Actuator Replacement . . . 0112 00-1
WP 0113 00 Parking Brake Maintenance . . . 0113 00-1
WP 0114 00 Brake Accumulator Maintenance . . . 0114 00-1
WP 0115 00 Parking Brake Control Valve Replacement . . . 0115 00-1
WP 0116 00 Service Brake Control Valve Replacement. . . 0116 00-1
WP 0117 00 Service Brake Lines and Hoses Replacement . . . 0117 00-1
WP 0118 00 Brake Pedals Replacement . . . 0118 00-1
Wheel and Tire Maintenance
WP 0119 00 Wheel and Tire Assembly (Front) Replacement . . . 0119 00-1
WP 0120 00 Wheel and Tire Assembly (Rear) Replacement . . . 0120 00-1
Steering System
WP 0121 00 Steering Column Replacement . . . 0121 00-1
WP 0122 00 Steering Wheel Replacement . . . 0122 00-1
WP 0123 00 Secondary Steering Pump and Electric Motor Maintenance. . . 0123 00-1
WP 0124 00 Steering Hoses, Lines, and Fittings Replacement . . . 0124 00-1
WP 0125 00 Steering Cylinders Replacement . . . 0125 00-1
WP 0126 00 Secondary Steering Valve Replacement . . . 0126 00-1
WP 0127 00 Steering Control Valve Maintenance . . . 0127 00-1
WP 0128 00 Steering Metering Pump Replacement . . . 0128 00-1
Frame
WP 0129 00 Remote Lubrication Lines, Hoses, and Fittings Replacement . . . 0129 00-1
WP 0130 00 Counterweight Replacement . . . 0130 00-1
Body and Cab
WP 0131 00 Cab Doors Maintenance . . . 0131 00-1
WP 0132 00 Cab Remove/Install . . . 0132 00-1
WP 0133 00 Chassis Guard, Side Panels, Hydraulic Service Box, Circuit
Breaker Box, and Battery Box Replacement. . . 0133 00-1
WP 0134 00 Handrails, Ladders, and Steps Replacement . . . 0134 00-1
WP 0135 00 Side Covers and Hood Replacement . . . 0135 00-1
WP 0136 00 Front Fenders Replacement. . . 0136 00-1
WP 0137 00 Rear Fenders Replacement . . . 0137 00-1
WP 0138 00 Cab Liners and Dome Light Replacement . . . 0138 00-1
WP 0139 00 Cab Sun Visor and Mirrors Replacement . . . 0139 00-1
WP 0140 00 Seat Assembly Replacement . . . 0140 00-1
WP 0141 00 Seat Belt Replacement. . . 0141 00-1
WP 0142 00 Rifle Rack Replacement . . . 0142 00-1
WP 0143 00 Toolbox Replacement . . . 0143 00-1
Body, Chassis, Accessory Items
WP 0144 00 Windshield Washer Bottle and Hoses Replacement . . . 0144 00-1
WP 0145 00 Front Windshield Wipers and Motor Replacement. . . 0145 00-1
Page
Body, Chassis, Accessory Items - Continued
WP 0147 00 Data Plates Replacement . . . 0147 00-1
WP 0148 00 Hydraulic System Oil Change and Filter Replacement. . . 0148 00-1
Hydraulic System
WP 0149 00 Quick Coupler Diverter Valve Replacement. . . 0149 00-1
WP 0150 00 Pilot Oil Accumulator Maintenance . . . 0150 00-1
WP 0151 00 Ride Control Accumulator Maintenance. . . 0151 00-1
WP 0152 00 Tilt Cylinders Replacement. . . 0152 00-1
WP 0153 00 Lift Cylinders Replacement. . . 0153 00-1
WP 0154 00 Hydraulic System Oil Filter Bases and Cooler
Hoses, Lines, and Fittings Replacement . . . 0154 00-1
WP 0155 00 Hydraulic System Oil Filter Bases Replacement . . . 0155 00-1
WP 0156 00 Implement Hydraulic Hoses, Lines, and Fittings Replacement . . . 0156 00-1
WP 0157 00 Main Control Valve and Implement Pump Hydraulic
Hoses, Lines, and Fittings Replacement . . . 0157 00-1
WP 0158 00 Quick Coupler Cylinder Replacement. . . 0158 00-1
WP 0159 00 Hydraulic Tank Replacement . . . 0159 00-1
WP 0160 00 Sight Gage Replacement . . . 0160 00-1
Special Purpose Kits
WP 0161 00 Arctic Heater Replacement . . . 0161 00-1
WP 0162 00 Arctic Heater Installation . . . 0162 00-1
WP 0163 00 Bristles Replacement . . . 0163 00-1
WP 0164 00 Broom Hose, Manifold, and Link Replacement . . . 0164 00-1
WP 0165 00 Broom Motor Replacement . . . 0165 00-1
WP 0166 00 Broom Shields and Springs Replacement . . . 0166 00-1
WP 0167 00 Pallet Forks Repair . . . 0167 00-1
Air Conditioning
WP 0168 00 Air Conditioning/Heater Blower Motor Replacement . . . 0168 00-1
Earthmoving Equipment
WP 0169 00 Quick Coupler Replacement . . . 0169 00-1
WP 0170 00 Bucket Tips and Cutting Edges Replacement . . . 0170 00-1
CHAPTER 4. DIRECT SUPPORT MAINTENANCE INSTRUCTIONS
Engine
WP 0171 00 Engine Replacement . . . 0171 00-1
WP 0172 00 Cylinder Head Replacement . . . 0172 00-1
WP 0173 00 Crankshaft Vibration Damper and Pulley Replacement . . . 0173 00-1
WP 0174 00 Front Main Seal Replacement . . . 0174 00-1
WP 0175 00 Rear Main Seal Replacement . . . 0175 00-1
WP 0176 00 Flywheel Housing Replacement . . . 0176 00-1
WP 0177 00 Flywheel Replacement . . . 0177 00-1
WP 0178 00 Front Cover Replacement . . . 0178 00-1
Page
Engine - Continued
WP 0180 00 Rocker Arms and Push Rods Maintenance . . . 0180 00-1
WP 0181 00 Engine Oil Pan Maintenance . . . 0181 00-1
WP 0182 00 Engine Oil Pump Replacement . . . 0182 00-1
WP 0183 00 Piston Cooling Jets Replacement . . . 0183 00-1
WP 0184 00 Exhaust Manifold Replacement . . . 0184 00-1
WP 0185 00 Intake Manifold Replacement . . . 0185 00-1
WP 0186 00 Idler Gears Replacement . . . 0186 00-1
Fuel
WP 0187 00 Fuel Injectors and Wiring Harness Maintenance . . . 0187 00-1
WP 0188 00 Fuel Transfer Pump Replacement . . . 0188 00-1
WP 0189 00 Aftercooler Replacement. . . 0189 00-1
Cooling System
WP 0190 00 Cooling System Package (Radiator, Fan,
Aftercooler, and Oil Cooler) Replacement . . . 0190 00-1
WP 0191 00 Radiator Replacement . . . 0191 00-1
WP 0192 00 Fan Hydraulic Motor and Fan Group Replacement . . . 0192 00-1
WP 0193 00 Hydraulic Oil Cooler Replacement . . . 0193 00-1
Electrical System
WP 0194 00 Accessory Support Brackets Replacement . . . 0194 00-1
WP 0195 00 Cab Wiring Harness and Fuse/Relay Block Replacement . . . 0195 00-1
WP 0196 00 Engine Wiring Harness Replacement . . . 0196 00-1
WP 0197 00 Front Chassis Wiring Harness Replacement . . . 0197 00-1
WP 0198 00 Heater and Air Conditioning Wiring Harness Replacement . . . 0198 00-1
WP 0199 00 Rear Chassis Wiring Harness Replacement . . . 0199 00-1
WP 0200 00 Secondary Steering Wiring Harness Replacement . . . 0200 00-1
Transmission
WP 0201 00 Transmission Control Wiring Harness Replacement . . . 0201 00-1
WP 0202 00 Transmission Hydraulic Control Relief Valve Replacement . . . 0202 00-1
WP 0203 00 Transmission Modulating Valve Replacement . . . 0203 00-1
WP 0204 00 Transmission and Torque Converter Replacement . . . 0204 00-1
WP 0205 00 Transmission Oil Cooler Replacement . . . 0205 00-1
WP 0206 00 Transmission Oil Pump (Gear Pump) Replacement . . . 0206 00-1
Front Axle
WP 0207 00 Front Axle Replacement . . . 0207 00-1
Rear Axle
WP 0208 00 Rear Axle Replacement. . . 0208 00-1
WP 0209 00 Rear Axle Trunnion Replacement . . . 0209 00-1
Page
Frame
WP 0211 00 Separate Front Loader Frame and Rear Frame . . . 0211 00-1
Body and Cab
WP 0212 00 Engine Compartment Shield Replacement . . . 0212 00-1
WP 0213 00 Windshield Front/Rear and Doors Glass Replacement . . . 0213 00-1
Hydraulic System
WP 0214 00 Seat Assembly Repair . . . 0214 00-1
WP 0215 00 Braking and Hydraulic Fan Pump Replacement . . . 0215 00-1
WP 0216 00 Piston Pumps (Steering and Implement/Pilot) Replacement. . . 0216 00-1
WP 0217 00 Brake Charge and Hydraulic Fan Control Manifold Replacement . . . 0217 00-1
WP 0218 00 Main Hydraulic Control Valve Replacement . . . 0218 00-1
WP 0219 00 Electrohydraulic Control (Joystick) Replacement. . . 0219 00-1
Refrigeration and Air Conditioning
WP 0220 00 Heater Core Replacement . . . 0220 00-1
WP 0221 00 Air Conditioning System Compressor Replacement. . . 0221 00-1
WP 0222 00 Air Conditioning System Service . . . 0222 00-1
WP 0223 00 Refrigerant Hoses, Lines, Valves, Flanges, and Fittings Replacement. . . 0223 00-1
WP 0224 00 Inline Refrigerant Dryer Replacement . . . 0224 00-1
WP 0225 00 Refrigerant Accumulator Replacement . . . 0225 00-1
WP 0226 00 Air Conditioning System Condenser Replacement. . . 0226 00-1
Earthmoving Equipment
WP 0227 00 Evaporator Core Replacement. . . 0227 00-1
WP 0228 00 Bucket Tilt Lever and Link Replacement . . . 0228 00-1
WP 0229 00 Bucket Lift Arms Replacement . . . 0229 00-1
CHAPTER 5. SUPPORTING INFORMATION
WP 0230 00 References . . . 0230 00-1
WP 0231 00 Maintenance Allocation Chart (MAC) Introduction . . . 0231 00-1
WP 0232 00 Maintenance Allocation Chart (MAC) . . . 0232 00-1
WP 0233 00 Expendable and Durable Items List . . . 0233 00-1
WP 0234 00 Torque Limits . . . 0234 00-1
WP 0235 00 Preparation for Storage or Shipment . . . 0235 00-1
WP 0236 00 Nomenclature Cross-Reference List . . . 0236 00-1
WP 0237 00 Schematics Introduction . . . 0237 00-1
Index . . . Index-1
Electrical
Figure 1. Electrical Schematics - Key to Components . . . .FP-1/(FP-2 Blank)
Figure 1. Electrical Schematics - Key to Harnesses . . . .FP-3/(FP-4 Blank)
Figure 1. Electrical Schematics - Lighting Circuit (Sheet 1 of 21) . . . .FP-5/(FP-6 Blank)
Figure 1. Electrical Schematics - Lighting Circuit (Sheet 2 of 21) . . . .FP-7/(FP-8 Blank)
Page
Electrical - Continued
Figure 1. Electrical Schematics - Accessories Circuit (Sheet 4 of 21) . . . FP-11/(FP-12 Blank)
Figure 1. Electrical Schematics - Accessories Circuit (Sheet 5 of 21) . . . FP-13/(FP-14 Blank)
Figure 1. Electrical Schematics - Accessories Circuit (Sheet 6 of 21) . . . FP-15/(FP-16 Blank)
Figure 1. Electrical Schematics - Implement Circuit (Sheet 7 of 21) . . . FP-17/(FP-18 Blank)
Figure 1. Electrical Schematics - Implement Circuit (Sheet 8 of 21) . . . FP-19/(FP-20 Blank)
Figure 1. Electrical Schematics - Implement Circuit (Sheet 9 of 21) . . . FP-21/(FP-22 Blank)
Figure 1. Electrical Schematics - Implement Circuit (Sheet 10 of 21) . . . FP-23/(FP-24 Blank)
Figure 1. Electrical Schematics - Implement Circuit (Sheet 11 of 21) . . . FP-25/(FP-26 Blank)
Figure 1. Electrical Schematics - Engine Circuit (Sheet 12 of 21) . . . .FP-27/(FP-28 Blank)
Figure 1. Electrical Schematics - Engine Circuit (Sheet 13 of 21) . . . .FP-29/(FP-30 Blank)
Figure 1. Electrical Schematics - Transmission Circuit (Sheet 14 of 21) . . . FP-31/(FP-32 Blank)
Figure 1. Electrical Schematics - Transmission Circuit (Sheet 15 of 21) . . . FP-33/(FP-34 Blank)
Figure 1. Electrical Schematics - Transmission Circuit (Sheet 16 of 21) . . . FP-35/(FP-36 Blank)
Figure 1. Electrical Schematics - Starting Circuit (Sheet 17 of 21). . . FP-37/(FP-38 Blank)
Figure 1. Electrical Schematics - Starting Circuit (Sheet 18 of 21). . . FP-39/(FP-40 Blank)
Figure 1. Electrical Schematics - Power Distribution Circuit (Sheet 19 of 21). . . FP-41/(FP-42 Blank)
Figure 1. Electrical Schematics - Messenger Circuit (Sheet 20 of 21) . . . FP-43/(FP-44 Blank)
Figure 1. Electrical Schematics - Legend (Sheet 21 of 21) . . . FP-45/(FP-46 Blank)
Hydraulic
Figure 2. Hydraulic Component Locator (Sheet 1 of 3) . . . FP-47/(FP-48 Blank)
Figure 2. Hydraulic Schematic (Sheet 2 of 3) . . . FP-49/(FP-50 Blank)
Figure 2. Hydraulic Schematic Legend (Sheet 3 of 3). . . FP-51/(FP-52 Blank)
If 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 troubleshoot and maintain the 966H Wheel Loader Type I and II and to perform
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 Data, and Theory of Operation, Troubleshooting Procedures, Unit Maintenance Instructions,
Direct Support and Maintenance Instructions, 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 on the upper right-hand corner of each page. The work package page number (e.g., 0001 00-1, 0001 00-2)
is located centered at the bottom of each page.
c.
If a Change Package is issued to this manual, added work packages use the 5
thand 6
thdigits 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.
4. This manual is published in two volumes: Volume I covers Theory of Operations and Troubleshooting.
5. The second volume (TM 5-3805-291-23-2) covers Field Level Maintenance Instructions.
CONTENTS OF THIS MANUAL
1. A Warning Summary is located at the beginning of each volume of the manual. Become familiar with these warnings
before operating or performing operator troubleshooting or maintenance on the machine.
2. A Table of Contents in Volume I lists the contents of Volumes I and II. The Table of Contents in Volume II lists the
contents of Volume II only.
a.
The Table of Contents also provides Reporting Errors and Recommending Improvements information and 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 alphabetical Index at the back of
the manual. The alphabetical index for each volume lists only those work packages found in that volume.
3. Chapter 1, Introductory Information, Equipment Description and Data, and Theory of Operation, provides general
information on the manual and the equipment.
4. Chapter 2, covers all Troubleshooting Procedures. Soldier becomes familiar with how to use MSD in order to
troubleshoot 966H Wheel Loader. WP 0005 00 explains how to use MSD with ET. WP 0007 00 contains a
Troubleshooting Symptom Index. If the machine malfunctions, this index should always be consulted to locate the
appropriate troubleshooting procedure.
5. Chapter 3, describes Unit Maintenance Instructions. Major areas covered are Preventive Maintenance Checks and
Services (PMCS).
6. Chapter 4, covers Direct Support Maintenance Instructions.
7. Chapter 5, in both volumes, includes Supporting Information: References, Maintenance Allocation Chart (MAC)
WARNING
A WARNING indicates a hazard which may result in injury or death to personnel.
CAUTION
A CAUTION is a reminder of safety practices or directs attention to usage practices that may result in
damage to equipment.
NOTE
A NOTE is a statement containing information that will make the procedures easier to perform.
2. Statements and words of particular interest may be printed 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: “Perform PMCS (WP 0020 00),” go to WP 0020 00 in this manual for instructions.
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 0224 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. Dashed leader lines used in the Lubrication Chart (WP 0020 00) and in the PMCS Table (WP 0020 00) indicate that called
out lubrication points are located on both sides of the machine.
7. Technical instructions include metric units as well as standard units. For your reference, a Metric Conversion Chart is
located on the inside back cover of the manual.
CHAPTER 1
INTRODUCTORY INFORMATION, EQUIPMENT
Maintenance Task Title
Page
Scope . . . 0001 00-1
Maintenance Forms, Records, and Reports . . . 0001 00-1
Reporting Equipment Improvement Recommendations (EIR) . . . 0001 00-1
Corrosion Prevention and Control (CPC) . . . 0001 00-1
Destruction of Army Materiel to Prevent Enemy Use. . . 0001 00-2
Preparation for Storage or Shipment . . . 0001 00-2
List of Abbreviations/Acronyms . . . 0001 00-2
Warranty Information. . . 0001 00-4
SCOPE
0001 00
1.
Type of Manual. This manual is for use in performing field level 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 738-750, Functional Users Manual for The Army Maintenance Management System (TAMMS).
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
don’t like about your equipment. Let us know why you don’t like the design or performance. (E-Mail:
[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
Arma-ments Command, AMSRD-TAR-E, PDQR MS 268, 6501 E. 11 Mile Road, Warren, MI 38397-5000.
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.
For destruction of Army materiel to prevent enemy use, refer to TM 750-244-3, Procedure for Destruction of Equipment
to Prevent Enemy Use.
PREPARATION FOR STORAGE OR SHIPMENT
0001 00
Refer to WP 0235 00.
LIST OF ABBREVIATIONS/ACRONYMS
0001 00
NOTE
Refer to ASME Y14.38-1999, Abbreviations and Acronyms, for standard abbreviations.
ABBREVIATIONS/ACRONYMS
DEFINITION
AAL. . . Additional Authorization List
AAR . . . Association of American Railroads
AC . . . Air Conditioning
AC . . . Alternating Current
AOAP . . . Army Oil Analysis Program
ATAAC . . . .Air-to-air After Cooler
AWG . . . American Wire Gage
B.O. . . Blackout
BII . . . Basic Issue Items
BTC . . . Before Top Center
C . . . Celsius
CAGEC . . . Commercial and Government Entity Code
CCA. . . Cold Cranking Amps
CG . . . Center of Gravity
CI. . . .Component Identifier
CID . . . .Cubic Inch Displacement
cm . . . Centimeter
COEI . . . Components of End Item
CONUS . . . Continental United States
CPC . . . Corrosion Prevention and Control
DC . . . Direct Current
DED. . . .Diesel Engine Driven
DIT . . . Direct Injection Turbocharged
ECM . . . Electronic Control Module
ECU. . . Electronic Control Unit
EEC . . . Electronic Engine Control
EID . . . Event Identifier
EIR . . . Equipment Improvement Recommendations
ET . . . Electronic Technician
ABBREVIATIONS/ACRONYMS
DEFINITION
FLS . . . Full Load Setting
FMI . . . Failure Mode Identifier
FMTV . . . Family of Medium Tactical Vehicles
F/N/R. . . .Forward/Neutral/Reverse
FRC . . . Fuel Ration Control
FTS . . . Full Torque Setting
gal. . . Gallon
GCWR. . . Gross Combination Weight Rating
GIC . . . .Gabarit International de Chargement
GP . . . .General Purpose
GVWR. . . Gross Vehicle Weight Rating
Hz . . . Hertz
in. . . . Inch
kg. . . Kilogram
km . . . Kilometer
kPa. . . Kilopascal
kph. . . Kilometers per Hour
kW . . . Kilowatt
L . . . Liter
LASH . . . Lighter Aboard Ship
lb . . . Pound
lb-in. . . . Pound Inch
lb-ft . . . .Pound Foot
LH . . . Left Hand
m . . . Meter
min. . . Minute
mm. . . Millimeter
MMS . . . Machine Monitor System
MP . . . Multi-Purpose
MPH . . . Miles per Hour
MSD . . . Maintenance Support Drive
N . . . Neutral
NATO . . . North Atlantic Treaty Organization
NBC. . . Nuclear, Biological, and Chemical
N/C . . . Normally Closed
Nm. . . Newton Meter
N/O . . . Normally Open
OCONUS . . . .Outside Continental United States
ABBREVIATIONS/ACRONYMS
DEFINITION
PLS-EMM-CMM . . . Palletized Load System-Engineer Mission Module-Concrete Mobile Mixer
PLS-EMM-DB . . . Palletized Load System-Engineer Mission Module-Dump Body
PMCS . . . .Preventive Maintenance Checks and Services
PPPC . . . Proportional, Priority, Pressure Compensated System
PQDR . . . Product Quality Deficiency Report
PR . . . Ply Rating
psi . . . Pounds per Square Inch
PWM . . . Pulse Width Modulation
RH . . . .Right Hand
RO/RO. . . Roll-On/Roll-Off
ROPS/FOPS . . . Rollover Protective Structure/Falling Object Protective Structure
rpm . . . Repetitions per Minute
SDDC . . . Surface Deployment and Distribution Command
SDS . . . Sorbent Decontamination System: M100
SG . . . Spheroidal Graphite
SRC . . . Source
T/S . . . Trouble Shooting
TAMMS. . . Functional Users Manual for The Army Maintenance Management System
TOE/MTOE. . . Table of Organization and Equipment/Modified Table of Organization and Equipment
US gpm . . . US Gallon per Minute
VLPM . . . Voltage Load Protection Module
WCA . . . Warranty Claim Action
yd. . . Yard
WARRANTY INFORMATION
0001 00
For warranty information refer to TB 5-3805-291-14, Warranty Technical Bulletin for the 966H Wheel Loader. For a
list of Caterpillar Dealers please see Table 1. They are also located in the Warranty TB.
Caterpillar Dealers
Table 1. Caterpillar Dealers.
Dealer Name
Country
City
State/Province/Region
Phone
ALLIED MACHINERY
LIMITED AFGHANISTAN KARACHI SIND PROVINCE
93 (20) 220 0287 GENERAL INFO ALLIED MACHINERY
LIMITED AFGHANISTAN KARACHI SIND PROVINCE
93 (20) 2200287 GENERAL INFO MAIA SHQIPERI SH.P.K. ALBANIA TIRANA TIRANA RRETH 355 (42) 71.386 GENERAL INFO
MAGELLAN ALGERIA PICARDIE REGION 213 (2) 60.88.47 GENERAL INFO HAWTHORNE MACHINERY
OF SAMOA, AMERICAN SAMOA PAGO PAGO EASTERN DISTRICT
684 () 699 4320 GENERAL INFO BARLOWORLD
EQUIPAMENTOS ANGOLA LUANDA LUANDA PROVINCIA
244 (2) 399-824 GENERAL INFO FINNING ARGENTINA S.A. ARGENTINA SAN FERNANDO BUENOS AIRES PROVINCIA 54 (11) 4725-8800
GENERAL INFO FINNING ARGENTINA S.A. ARGENTINA RESISTENCIA CHACO PROVINCIA 54 (3722) 428869 GENERAL INFO FINNING ARGENTINA S.A. ARGENTINA COMODORO RIVADAVIA CHUBUT PROVINCIA 54 (297) 4485232 GENERAL INFO FINNING ARGENTINA S.A. ARGENTINA NEUQUEN NEUQUEN PROVINCIA 54 (299) 4436334 GENERAL INFO FINNING ARGENTINA S.A. ARGENTINA SALTA SALTA PROVINCIA 54 (387) 4270648
GENERAL INFO FINNING ARGENTINA S.A. ARGENTINA RIO GRANDE TIERRA DEL FUEGO 54 (2964) 426626 GENERAL INFO FINNING ARGENTINA S.A. ARGENTINA SAN MIGUEL DE
TUCUMAN TUCUMAN PROVINCIA
54 (381) 4270777 GENERAL INFO
ZEPPELIN ARMENIA LLC ARMENIA ZUG 7 (374) 10 55 17 53
GENERAL INFO ZEPPELIN ARMENIA LLC ARMENIA ZUG 7 (374) 10 55 17 53 GENERAL INFO WESTRAC PTY. LTD. AUSTRALIA FYSHWICK AUSTRALIAN CAPITAL TERRITORY 61 (2) 6290 4500 GENERAL INFO WESTRAC PTY. LTD. AUSTRALIA ALBURY NEW SOUTH WALES STATE 61 (2) 6025 6799 GENERAL INFO WESTRAC PTY. LTD. AUSTRALIA BATHURST NEW SOUTH WALES STATE 61 (2) 6331 6411
GENERAL INFO CAVILL POWER PRODUCTS
PTY. LTD. AUSTRALIA BROKEN HILL NEW SOUTH WALES STATE
61 (8) 8088 3877 GENERAL INFO WESTRAC PTY. LTD. AUSTRALIA DUBBO NEW SOUTH WALES STATE 61 (02) 6885 8000
GENERAL INFO WESTRAC PTY. LTD. AUSTRALIA GRAFTON NEW SOUTH WALES STATE 61 (2) 6642 8211
GENERAL INFO WESTRAC PTY. LTD. AUSTRALIA MOREE NEW SOUTH WALES STATE 61 (2) 6752 4500 GENERAL INFO WESTRAC PTY. LTD. AUSTRALIA MUSWELLBROOK NEW SOUTH WALES STATE 61 (2) 6541 5449 GENERAL INFO WESTRAC PTY. LTD. AUSTRALIA SOUTH TWEED
HEADS NEW SOUTH WALES STATE
61 (7) 5513 1920 GENERAL INFO WESTRAC PTY. LTD. AUSTRALIA TAMWORTH NEW SOUTH WALES STATE 61 (2) 6701 7222 GENERAL INFO WESTRAC PTY. LTD. AUSTRALIA THORNTON NEW SOUTH WALES STATE 61 (2) 4949 1866 GENERAL INFO WESTRAC PTY. LTD. AUSTRALIA THORNTON NEW SOUTH WALES STATE 61 (2) 4949 1888 GENERAL INFO
WESTRAC PTY. LTD. AUSTRALIA UNANDERRA NEW SOUTH WALES STATE 61 (2) 4271 8925 GENERAL INFO WESTRAC PTY. LTD. AUSTRALIA WAGGA WAGGA NEW SOUTH WALES STATE 61 (2) 6971 7688 GENERAL INFO WESTRAC PTY. LTD. (NSW) AUSTRALIA WEST WYALONG NEW SOUTH WALES STATE 61 (02) 6752 4500 GENERAL INFO WESTRAC PTY. LTD. AUSTRALIA WETHERILL PARK NEW SOUTH WALES STATE 61 (2) 9609 8888
GENERAL INFO WESTRAC PTY. LTD. AUSTRALIA WETHERILL PARK NEW SOUTH WALES STATE 61 (2) 9609 8801 GENERAL INFO HASTINGS DEERING
(AUSTRALIA) AUSTRALIA ALICE SPRINGS NORTHERN TERRITORY
61 (8) 8952 1888 GENERAL INFO ENERGY POWER SYSTEMS
AUSTRALIA AUSTRALIA DARWIN NORTHERN TERRITORY
61 (8) 8941 4309 GENERAL INFO HASTINGS DEERING
(AUSTRALIA) AUSTRALIA DARWIN NORTHERN TERRITORY
61 (8) 8984 1221 GENERAL INFO HASTINGS DEERING
(AUSTRALIA) AUSTRALIA NHULUNBUY NORTHERN TERRITORY
61 (8) 8987 1478 GENERAL INFO HASTINGS DEERING
(AUSTRALIA) AUSTRALIA PALMERSTON NORTHERN TERRITORY
61 (8) 8984 1200 GENERAL INFO ENERGY POWER SYSTEMS
AUSTRALIA AUSTRALIA ARCHERFIELD QUEENSLAND STATE
61 (07) 3722 1400 GENERAL INFO HASTINGS DEERING
(AUSTRALIA) AUSTRALIA ARCHERFIELD QUEENSLAND STATE
61 (7) 3365 9229 GENERAL INFO HASTINGS DEERING
(AUSTRALIA) AUSTRALIA ARCHERFIELD QUEENSLAND STATE
61 (7) 3365 9229 GENERAL INFO HASTINGS DEERING
(AUSTRALIA) AUSTRALIA BURLEIGH HEADS QUEENSLAND STATE
61 (7) 5520 3200 GENERAL INFO ENERGY POWER SYSTEMS
AUSTRALIA AUSTRALIA CAIRNS QUEENSLAND STATE
61 (7) 4035 0324 GENERAL INFO HASTINGS DEERING
(AUSTRALIA) AUSTRALIA CAIRNS QUEENSLAND STATE
61 (7) 4035 0335 GENERAL INFO HASTINGS DEERING
(AUSTRALIA) AUSTRALIA DYSART QUEENSLAND STATE
61 (7) 4958 1200 GENERAL INFO HASTINGS DEERING
(AUSTRALIA) AUSTRALIA EMERALD QUEENSLAND STATE
61 (7) 4982 2555 GENERAL INFO HASTINGS DEERING
(AUSTRALIA) AUSTRALIA GARBUTT QUEENSLAND STATE
61 (7) 4727 7699 GENERAL INFO HASTINGS DEERING
(AUSTRALIA) AUSTRALIA GLADSTONE QUEENSLAND STATE
61 (07) 4976 9745 GENERAL INFO HASTINGS DEERING
(AUSTRALIA) AUSTRALIA MACKAY QUEENSLAND STATE
61 (7) 4952 0777 GENERAL INFO HASTINGS DEERING
(AUSTRALIA) AUSTRALIA MOUNT ISA QUEENSLAND STATE
61 (7) 4744 1444 GENERAL INFO HASTINGS DEERING
(AUSTRALIA) AUSTRALIA ROCKHAMPTON QUEENSLAND STATE
61 (7) 4930 8688 GENERAL INFO HASTINGS DEERING
(AUSTRALIA) AUSTRALIA TOOWOOMBA QUEENSLAND STATE
61 (7) 4631 0700 GENERAL INFO
