TM 5-3805-291-23-2

(1)

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.

HEADQUARTERS, DEPARTMENT OF THE ARMY

-$18$5<20

(2)

(3)

a

This 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 - 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.

(4)

b

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.

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.

(5)

c

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.

(6)

d

• 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 or causes eye irritation. Failure to follow this warning may cause injury or death to personnel.

WARNING

BATTERIES

WARNING

COMPRESSED AIR

WARNING

(7)

e

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.

WARNING

FIRE EXTINGUISHER

WARNING

FUEL HANDLING

WARNING

HAZARDOUS WASTE DISPOSAL

WARNING

HEARING PROTECTION

(8)

f

• 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. Failure to follow this warning may result in injury to personnel.

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.

WARNING

(9)

g

• 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, Decontamination

System, Sorbent: MIC, and 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.

WARNING

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

(10)

h

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 an 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. DO NOT operate machine with steering frame lock connected. Failure to lock steering frame lock into stowed position can result in loss of steering and injury or death to personnel.

WARNING

SOLVENT CLEANING COMPOUND

WARNING

WORK SAFETY

(11)

Date of issue for original manual is:

NOTE: Zero in the “Change No.” column indicates an original page or work package. Original . . . 1-DQXDU\

Total number of pages for front and rear matter is 54 and total number of work packages is 237 consisting of the following:

A

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

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 WP 0053 00 (10 pgs.) . . . 0 WP 0054 00 (2 pgs.) . . . 0 WP 0055 00 (14 pgs.) . . . 0 WP 0056 00 (6 pgs.) . . . 0 WP 0057 00 (8 pgs.) . . . 0 WP 0058 00 (6 pgs.) . . . 0 WP 0059 00 (2 pgs.) . . . 0 WP 0060 00 (6 pgs.) . . . 0 WP 0061 00 (4 pgs.) . . . 0 WP 0062 00 (4 pgs.) . . . 0 WP 0063 00 (12 pgs.) . . . 0 WP 0064 00 (4 pgs.) . . . 0 WP 0065 00 (2 pgs.) . . . 0 WP 0066 00 (4 pgs.) . . . 0 WP 0067 00 (2 pgs.) . . . 0 WP 0068 00 (2 pgs.) . . . 0 WP 0069 00 (6 pgs.) . . . 0 WP 0070 00 (6 pgs.) . . . 0 WP 0071 00 (12 pgs.) . . . 0 WP 0072 00 (4 pgs.) . . . 0 WP 0073 00 (2 pgs.) . . . 0 WP 0074 00 (2 pgs.) . . . 0 WP 0075 00 (4 pgs.) . . . 0 WP 0076 00 (4 pgs.) . . . 0 WP 0077 00 (2 pgs.) . . . 0 WP 0078 00 (2 pgs.) . . . 0 WP 0079 00 (2 pgs.) . . . 0 WP 0080 00 (4 pgs.) . . . 0 WP 0081 00 (2 pgs.) . . . 0 WP 0082 00 (4 pgs.) . . . 0 WP 0083 00 (4 pgs.) . . . 0 WP 0084 00 (2 pgs.) . . . 0 WP 0085 00 (6 pgs.) . . . 0 WP 0086 00 (4 pgs.) . . . 0 WP 0087 00 (2 pgs.) . . . 0 WP 0088 00 (2 pgs.) . . . 0 WP 0089 00 (6 pgs.) . . . 0 WP 0090 00 (2 pgs.) . . . 0 WP 0091 00 (4 pgs.) . . . 0 WP 0092 00 (4 pgs.) . . . 0 WP 0093 00 (4 pgs.) . . . 0 WP 0094 00 (2 pgs.) . . . 0 WP 0095 00 (2 pgs.) . . . 0 WP 0096 00 (6 pgs.) . . . 0 WP 0097 00 (12 pgs.) . . . 0 WP 0098 00 (4 pgs.) . . . 0 WP 0099 00 (2 pgs.) . . . 0 WP 0100 00 (6 pgs.) . . . 0 WP 0101 00 (4 pgs.) . . . 0 WP 0102 00 (6 pgs.) . . . 0 WP 0103 00 (4 pgs.) . . . 0 WP 0104 00 (8 pgs.) . . . 0 WP 0105 00 (4 pgs.) . . . 0 WP 0106 00 (4 pgs.) . . . 0 WP 0107 00 (4 pgs.) . . . 0 WP 0108 00 (4 pgs.) . . . 0 WP 0109 00 (4 pgs.) . . . 0 WP 0110 00 (4 pgs.) . . . 0 WP 0111 00 (2 pgs.) . . . 0 WP 0112 00 (6 pgs.) . . . 0 WP 0113 00 (8 pgs.) . . . 0 WP 0114 00 (10 pgs.) . . . 0 WP 0115 00 (4 pgs.) . . . 0 WP 0116 00 (4 pgs.) . . . 0 WP 0117 00 (14 pgs.) . . . 0 WP 0118 00 (4 pgs.) . . . 0 WP 0119 00 (4 pgs.) . . . 0 WP 0120 00 (4 pgs.) . . . 0 WP 0121 00 (10 pgs.) . . . 0 WP 0122 00 (4 pgs.) . . . 0 WP 0123 00 (4 pgs.) . . . 0 WP 0124 00 (10 pgs.) . . . 0 WP 0125 00 (6 pgs.) . . . 0 WP 0126 00 (4 pgs.) . . . 0 WP 0127 00 (10 pgs.) . . . 0 WP 0128 00 (4 pgs.) . . . 0 WP 0129 00 (22 pgs.) . . . 0 WP 0130 00 (4 pgs.) . . . 0 WP 0131 00 (18 pgs.) . . . 0 WP 0132 00 (16 pgs.) . . . 0 WP 0133 00 (34 pgs.) . . . 0 WP 0134 00 (12 pgs.) . . . 0

(12)

B WP 0136 00 (4 pgs.) . . . 0 WP 0137 00 (4 pgs.) . . . 0 WP 0138 00 (10 pgs.) . . . 0 WP 0139 00 (4 pgs.) . . . 0 WP 0140 00 (6 pgs.) . . . 0 WP 0141 00 (2 pgs.) . . . 0 WP 0142 00 (2 pgs.) . . . 0 WP 0143 00 (4 pgs.) . . . 0 WP 0144 00 (12 pgs.) . . . 0 WP 0145 00 (6 pgs.) . . . 0 WP 0146 00 (6 pgs.) . . . 0 WP 0147 00 (4 pgs.) . . . 0 WP 0148 00 (6 pgs.) . . . 0 WP 0149 00 (6 pgs.) . . . 0 WP 0150 00 (8 pgs.) . . . 0 WP 0151 00 (12 pgs.) . . . 0 WP 0152 00 (12 pgs.) . . . 0 WP 0153 00 (10 pgs.) . . . 0 WP 0154 00 (12 pgs.) . . . 0 WP 0155 00 (6 pgs.) . . . 0 WP 0156 00 (26 pgs.) . . . 0 WP 0157 00 (12 pgs.) . . . 0 WP 0158 00 (6 pgs.) . . . 0 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 WP 0167 00 (8 pgs.) . . . 0 WP 0168 00 (10 pgs.) . . . 0 WP 0169 00 (6 pgs.) . . . 0 WP 0170 00 (8 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 WP 0174 00 (4 pgs.) . . . 0 WP 0175 00 (4 pgs.) . . . 0 WP 0176 00 (6 pgs.) . . . 0 WP 0177 00 (4 pgs.) . . . 0 WP 0178 00 (4 pgs.) . . . 0 WP 0179 00 (6 pgs.) . . . 0 WP 0180 00 (4 pgs.) . . . 0 WP 0181 00 (6 pgs.) . . . 0 WP 0182 00 (6 pgs.) . . . 0 WP 0183 00 (2 pgs.) . . . 0 WP 0184 00 (2 pgs.) . . . 0 WP 0185 00 (6 pgs.) . . . 0 WP 0186 00 (4 pgs.) . . . 0 WP 0188 00 (4 pgs.) . . . 0 WP 0189 00 (10 pgs.) . . . 0 WP 0190 00 (14 pgs.) . . . 0 WP 0191 00 (10 pgs.) . . . 0 WP 0192 00 (12 pgs.) . . . 0 WP 0193 00 (4 pgs.) . . . 0 WP 0194 00 (4 pgs.) . . . 0 WP 0195 00 (24 pgs.) . . . 0 WP 0196 00 (8 pgs.) . . . 0 WP 0197 00 (6 pgs.) . . . 0 WP 0198 00 (4 pgs.) . . . 0 WP 0199 00 (32 pgs.) . . . 0 WP 0200 00 (4 pgs.) . . . 0 WP 0201 00 (4 pgs.) . . . 0 WP 0202 00 (4 pgs.) . . . 0 WP 0203 00 (4 pgs.) . . . 0 WP 0204 00 (20 pgs.) . . . 0 WP 0205 00 (4 pgs.) . . . 0 WP 0206 00 (4 pgs.) . . . 0 WP 0207 00 (8 pgs.) . . . 0 WP 0208 00 (10 pgs.) . . . 0 WP 0209 00 (8 pgs.) . . . 0 WP 0210 00 (4 pgs.) . . . 0 WP 0211 00 (18 pgs.) . . . 0 WP 0212 00 (10 pgs.) . . . 0 WP 0213 00 (4 pgs.) . . . 0 WP 0214 00 (28 pgs.) . . . 0 WP 0215 00 (10 pgs.) . . . 0 WP 0216 00 (12 pgs.) . . . 0 WP 0217 00 (6 pgs.) . . . 0 WP 0218 00 (14 pgs.) . . . 0 WP 0219 00 (2 pgs.) . . . 0 WP 0220 00 (2 pgs.) . . . 0 WP 0221 00 (4 pgs.) . . . 0 WP 0222 00 (8 pgs.) . . . 0 WP 0223 00 (16 pgs.) . . . 0 WP 0224 00 (4 pgs.) . . . 0 WP 0225 00 (4 pgs.) . . . 0 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

(13)

C/D (Blank)

(14)

(15)

i

DEPARTMENT OF THE ARMY

Washington, D.C., 1_-DQXDU\

TECHNICAL MANUAL

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.

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-LC-LMPP/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.

(16)

ii

WP 0050 00 Rearview Camera, Cable, and Display Replacement . . . 0050 00-1 WP 0051 00 Starter Replacement. . . 0051 00-1 WP 0052 00 HVAC 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 WP 0070 00 Stoplight Assembly and Bracket Replacement . . . 0070 00-1 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

(17)

Table of Contents - Continued

Page Number

iii

Electrical System-Continued

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 WP 0111 00 Differential and Final Drive Oil Change . . . 0111 00-1

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

(18)

Table of Contents - Continued

Page Number

iv

Steering System-Continued

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 WP 0146 00 Rear Windshield Wiper and Motor Replacement . . . 0146 00-1 WP 0147 00 Data Plates Replacement . . . 0147 00-1

Hydraulic System

WP 0148 00 Hydraulic System Oil Change and Filter Replacement. . . 0148 00-1 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

(19)

Table of Contents - Continued

Page Number

v

Hydraulic System-Continued

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 WP 0179 00 Intake/Exhaust Valve Lash Adjustment . . . 0179 00-1 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

(20)

Table of Contents - Continued

Page Number

vi

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

Steering System

WP 0210 00 Steering Neutralizer Valve Replacement . . . 0210 00-1

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

(21)

Table of Contents - Continued

Page Number

vii

Refrigeration and Air Conditioning

WP 0219 00 Electrohydraulic Control (Joystick) Replacement. . . 0219 00-1 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

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) Figure 1. Electrical Schematics - Engine Circuit (Sheet 13 of 21) . . . .FP-29/(FP-30 Blank)

(22)

Table of Contents - Continued

Page Number

viii

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 . . . FP-47/(FP-48 Blank) Figure 2. Hydraulic Schematic (Sheet 1 of 2) . . . FP-49/(FP-50 Blank) Figure 2. Hydraulic Schematic Legend (Sheet 2 of 2). . . FP-51/(FP-52 Blank)

(23)

ix

NOTE

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 operate the 966H Loader 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 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.

4. This manual is published in two volumes: Volume I covers Chapters 1 and 2. Both volumes contain Chapter 5, Supporting Information.

5. The second volume (TM 5-3805-291-23-2) contains Chapters 3 and 4.

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. 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

Ser-vices (PMCS) and unit level maintenance tasks.

6. Chapter 4, covers Direct Support Maintenance Instructions.

7. Chapter 5, includes Supporting Information: References, Maintenance Allocation Chart (MAC) Introduction, Mainte-nance Allocation Chart (MAC), Expendable and Durable Items List, Torque Limits, Preparation for Storage or Shipment, Nomenclature Cross-Reference List, and Schematics.

(24)

x

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

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 dam-age 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: “Start engine (TM 5-3805-291-10),” go to TM 5-3805-291-10 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 0230 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 and in the PMCS Table 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.

(25)

0050 00-1

REARVIEW CAMERA, CABLE, AND DISPLAY REPLACEMENT 0050 00

THIS WORK PACKAGE COVERS

Removal, Cleaning and Inspection, Installation

INITIAL SETUP Maintenance Level

Unit

Tools and Special Tools

Tool kit, general mechanic’s, automotive (Item 90, WP 0232 00)

Materials/Parts

Cleaning compound, solvent, type III (Item 7, WP 0233 00)

Rag, wiping (Item 35, WP 0233 00)

Strap, tiedown, electrical components (Item 42, WP 0233 00)

Locknuts (4)

Personnel Required

MOS 62B, Construction Equipment Repairer

Equipment Conditions

Machine parked on level ground (TM 5-3805-291-10)

Work tool lowered to ground (TM 5-3805-291-10) Parking brake engaged (TM 5-3805-291-10) Wheels chocked

Battery disconnect switch in OFF position (TM 5-3805-291-10)

Drawings Required

TM 5-3805-291-23P, Figure 54

Estimated Time to Complete Task

6.0 hr

Ensure battery disconnect switch is in OFF position before performing this task. Failure to follow this warning may result in injury to personnel or damage to equipment.

NOTE

If only display requires replacement, proceed to Steps 24 through 26 and 28 through 30.

(26)

0050 00-2

REMOVAL

1. Open rear door on hood (TM 5-3805-291-10).

2. Disconnect camera connector (1) from rear camera cable (7).

3. Remove four locknuts (2) and washers (4) from bracket (3). Discard locknuts. 4. Push grommet (5) through hood (6).

5. Remove bracket (3) from hood (6).

6. Remove two nuts (9), washers (10), camera (14) and gasket (15) from bracket (3). 7. Remove two bolts (13), nuts (12), camera bracket (11) from camera (14).

(27)

0050 00-3

REMOVAL - CONTINUED

9. Remove seven bolts (16), washers (18), and clamps (17) from hood (6) and rear camera cable (7).

10. Close rear door on hood and open hood (TM 5-3805-291-10).

11. Remove four bolts (19) and washers (20) from rear plate (22) and position rear panel aside. 12. Remove and discard tiedown straps (21) from rear camera cable (7) toward rear of cab.

(28)

0050 00-4

13. Disconnect rear camera cable (7) from rear connector (24). 14. Remove rear camera cable (7) from machine.

15. Remove nut (23) from rear connector (24).

(29)

0050 00-5

17. Disconnect cab camera cable (30) from rear connector (24).

18. Disconnect cab camera cable (30) from upper connec-tor (32) and remove cable from machine.

19. Disconnect camera display cable (31) from upper con-nector (32).

20. Remove nut (33) and upper connector (32) from panel (34).

(30)

0050 00-6

21. Remove four bolts (39) from trim panel (38) and pull trim panel aside. 22. Remove four bolts (36) from rear console (37).

(31)

0050 00-7

24. Pull down display cable (31) and cab harness (50) from headliner (42) and disconnect from camera display harness (49). 25. Remove four bolts (45), washers (44), and display (48) with mount (46) from mount bracket (43).

26. Remove two bolts (52) and mount bracket (43) from support bracket (51).

27. Remove and discard tiedown straps (47) from camera display cable (31) and remove camera display cable from machine.

28. Remove four bolts (53), washers (54) and mount (46) from camera display (48). 29. Remove two screws (55) and cover (56) from camera display (48).

(32)

0050 00-8

CLEANING AND INSPECTION

• 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.

• Particles blown by compressed air are hazardous. DO NOT exceed 15 psi (103 kPa) nozzle pressure when drying parts with compressed air. 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 per-sonnel.

1. Clean all metal parts and surfaces with solvent cleaning compound. 2. Dry parts with compressed air.

3. Inspect all parts for damage, wear, pitting, cracks, or corrosion and replace if necessary. 4. Clean upholstery with detergent.

INSTALLATION

1. Connect camera display harness (49) to camera display (48). 2. Install cover (56) on camera display (48) with two screws (55).

3. Install mount (46) on camera display (48) with four bolts (53) and washers (54.)

NOTE

If only display requires replacement, proceed to Steps 5 through 7.

(33)

0050 00-9

INSTALLATION - CONTINUED

4. Position camera display cable (31) in machine and secure with tiedown straps (47). 5. Install mount bracket (43) on support bracket (51) with two bolts (52).

6. Install display (48) with mount (46) on mount bracket (43) with four washers (44) and bolts (45).

7. Connect camera display harness (49) to cab harness (50) and camera display cable (31). Position cab harness and camera display cable behind headliner (42).

(34)

0050 00-10

8. Secure front console (35) in cab with two bolts (41) and two bolts (40). 9. Secure rear console (37) in cab with four bolts (36).

(35)

0050 00-11

11. Install upper connector (32) in panel (34) with nut (33).

12. Connect camera display cable (31) to upper connector (32).

13. Connect cab camera cable (30) to upper connector (32).

(36)

0050 00-12

15. Install rear panel (27) in cab with two plastic washers (29) and bolts (28) and three washers (26) and bolts (25).

16. Install nut (23) on rear connector (24).

(37)

0050 00-13

18. Install new tiedown straps (21) on rear camera cable (7).

19. Secure rear plate (22) on machine with four washers (20) and volts (19).

20. Close hood and open rear door on hood (TM 5-3805-291-10).

21. Install seven clamps (17) on rear camera cable (7) and hood (6) with washers (18) and bolts (16).

(38)

0050 00-14

22. Install two bolts (8) on bracket (11).

23. Install camera bracket (11) on camera (14) with two bolts (13) and nuts (12).

24. Install camera (14) and gasket (15) on bracket (3) with two nuts (9), and washers (10). 25. Position bracket (3) on hood (6).

26. Push grommet (5) through hood (6).

27. Install four washers (4) and new locknuts (2) on bracket (3). 28. Connect camera connector (1) to rear camera cable (7). 29. Close rear door on hood (TM 5-3805-291-10).

30. Switch on machine (TM 5-3805-291-10).

31. Check for correct operation of rearview camera (TM 5-3805-291-10). 32. Switch off machine (TM 5-3805-291-10).

33. Close hood (TM 5-3805-291-10).

END OF WORK PACKAGE

(39)

0051 00-1

STARTER REPLACEMENT 0051 00

Removal, Installation, Pinion Clearance Adjustment

Unit

Shop equipment, automotive maintenance and repair: organizational maintenance, common no. 1 (Item 70, WP 0232 00)

Lifting equipment, 90-lb capacity

Wrench, torque, click, ratcheting, 3/8” drive, 75 lb-ft (Item 98, WP 0232 00)

Materials/Parts

Rag, wiping (Item 35, WP 0233 00) Tag, marker (Item 43, WP 0233 00) Locknut

Lockwasher

MOS 62B, Construction Equipment Repairer (2)

References

WP 0013 00

Hood opened (TM 5-3805-291-10)

Battery cables disconnected from batteries (WP 0096 00)

TM 5-3805-291-23P, Figure 48

2.0 hr

Ensure battery cables are disconnected before performing this task. Failure to follow this warning may result in injury to personnel or damage to equipment.

CAUTION

Always test starter before replacing it. Refer to Starting Motor Test (WP 0013 00). Failure to do so may result in unnecessary replacement of starter.

NOTE

• Tag wires prior to removal to ensure correct installation. • Wipe area clean around component before removal.

(40)

0051 00-2

REMOVAL

1. Remove starter cable nut (1) from starter solenoid (2). 2. Disconnect starter cable (3) from starter solenoid (2). 3. Remove starter solenoid cover nut (4) and lockwasher

(5) from starter solenoid (2). Discard lockwasher. 4. Remove starter solenoid cover (6) from starter

sole-noid (2).

5. Remove two nuts (7) and washers (8) and disconnect ground cables (9) from starter (10).

427-C0069

(41)

0051 00-3

6. Remove nut (11), cover (12), and locknut (13) and dis-connect chassis wiring harness (14). Discard locknut.

7. Remove three bolts (15) and washers (16) from starter (10).

427-C0071

(42)

0051 00-4

Use extreme caution when handling heavy parts. Provide adequate support and use assistance during pro-cedure. 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 result in injury or death to personnel.

NOTE

The starter weighs approximately 60 lb (27 kg).

8. Remove bolt (17), washer (18), and clip (19) from frame (20).

9. Loosen bolt (21) and slide starter (10) toward rear. 10. Attach lifting equipment to starter (10).

11. Remove bolt (21) and washer (22) from starter (10). 12. With assistance, use lifting equipment to remove

starter (10) from machine.

WARNING

(43)

0051 00-5

INSTALLATION

Use extreme caution when handling heavy parts. Provide adequate support and use assistance during pro-cedure. 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 result in injury or death to personnel.

NOTE

The starter weighs approximately 60 lb (27 kg).

1. With assistance, use lifting equipment to position starter (10) on machine. 2. Install washer (22) and bolt (21) on starter (10).

3. Install clip (19), washer (18), and bolt (17) on frame (20). 4. Install three washers (16) and bolts (15) on starter

(10).

WARNING

(44)

0051 00-6

5. Connect chassis wiring harness (14) and install new locknut (13), cover (12), and nut (11).

6. Position two ground cables (9) on starter (10) and install two washers (8) and nuts (7). Tighten nuts to 22 ± 3 lb-ft (30.5 ± 3.5 Nm).

427-C0071

(45)

0051 00-7

7. Position starter solenoid cover (6) on starter solenoid (2) and install starter solenoid cover nut (4) and new lockwasher (5).

8. Position starter cable (3) on starter solenoid (2) and install starter cable nut (1). Tighten starter cable nut to 22 ± 3 lb-ft (30.5 ± 3.5 Nm).

9. Connect battery cables to batteries (WP 0096 00). 10. Close hood (TM 5-3805-291-10).

(46)

0051 00-8

PINION CLEARANCE ADJUSTMENT

NOTE

When the solenoid is installed, make an adjustment of the pinion clearance. The adjustment should be made with the starting motor removed.

1. Disconnect starting motor negative wire from “G” ground terminal of solenoid.

2. Connect batteries directly to solenoid as shown below. Connect positive side of battery cable to “S” terminal of starting motor solenoid. Connect negative side of battery to “G” terminal of starting motor.

3. Temporarily, touch a wire from “G” terminal to “Mtr” terminal. Pinion will shift to crank position and stay there until battery is disconnected.

4. Remove plug from starter.

5. Push pinion toward commutator in order to remove free movement.

6. Measure clearance (X) from pinion to pinion drive housing. Pinion clearance (X) must be 0.36 ± 0.03 in. (9.10 ± 0.8 mm).

427-C1979

(47)

0051 00-9/(0051 00-10 Blank)

PINION CLEARANCE ADJUSTMENT - CONTINUED

7. If clearance is not correct, remove plug on pinion drive housing. Turn adjustment nut until clearance is correct. Turning nut clockwise will decrease clearance (X).

NOTE

The plunger may turn when the adjustment nut is being turned. If the plunger turns, disconnect the battery from the solenoid. Remove the solenoid from the starting motor. Hold the plunger from the turning and adjust the nut. This procedure may need to be performed several times until the correct clearance is obtained.

8. Disconnect the batteries from solenoid and install plug in shift lever housing.

(48)

(49)

0052 00-1

HVAC BLEND DOOR ACTUATOR REPLACEMENT 0052 00

Removal, Cleaning and Inspection, Installation

Unit

Materials/Parts

Cleaning compound, solvent, type III (Item 7, WP 0233 00)

Primer coating (Item 34, WP 0233 00)

References

TM 5-3805-291-10

TM 5-3805-291-23P, Figure 172

(50)

0052 00-2

REMOVAL

1. Remove three screws (1) from tray (2).

(51)

0052 00-3

3. Remove three screws (4) from cover assembly (5).

(52)

0052 00-4

5. Loosen two thumbwheel screws (8) on air filter cover (9) and remove from cover assembly (5).

(53)

0052 00-5

7. Remove screw (11) from cover assembly (5). 8. Remove cover assembly (5) from machine.

9. Disconnect harness (13) from actuator (15).

(54)

0052 00-6

CLEANING AND INSPECTION

• 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.

• Particles blown by compressed air are hazardous. DO NOT exceed 15 psi (103 kPa) nozzle pressure when drying parts with compressed air. 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 per-sonnel.

1. Clean all metal parts and surfaces with solvent cleaning compound. 2. Dry parts with compressed air.

3. Inspect all parts for damage, wear, pitting, cracks, or corrosion and replace if necessary.

INSTALLATION

1. Install actuator (15) and three bolts (14) on housing (12). 2. Connect harness (13) on actuator (15).

(55)

0052 00-7

3. Position cover assembly (5) on machine. 4. Install screw (11) on cover assembly (5).

(56)

0052 00-8

5. Install filter (10) on cover assembly (5).

6. Position air filter cover (9) on cover assembly (5). 7. Tighten two thumbwheel screws (8) on air filter cover (9).

(57)

0052 00-9

8. Install three washers (7) and screws (6) on cover assembly (5).

(58)

0052 00-10

10. Position tray (2) on machine. 11. Install screw (3) on tray (2).

12. Install three screws (1) on tray (2).

13. Verify correct operation of machine (TM 5-3805-291-10).

(59)

0053 00-1

FUSE, RELAY, CIRCUIT BREAKER, AND ARC SUPPRESSOR REPLACEMENT 0053 00

Fuse: Removal, Installation

Hood Tilt Relay: Removal, Installation Cab Circuit Breaker: Removal, Installation Panel Box Circuit Breaker: Removal, Installation Arc Suppressor: Removal, Installation

Unit

Materials/Parts

Rag, wiping (Item 35, WP 0233 00) Tag, marker (Item 43, WP 0233 00) Tiestraps

References

TM 5-3805-291-10

Right rear interior cover removed (interior wiring) (WP 0138 00)

TM 5-3805-291-23P, Figures 51 and 56

0.3 hr

FUSE REMOVAL 0053 00

CAUTION

Replace fuses with same type and size only. Otherwise, electrical damage can result.

NOTE

• These procedures show one fuse, relay, or circuit replacement. Replacement is the same for each fuse, relay, or circuit.

• Refer to inside cover of fuse box for fuse locations.

• Tag wiring harnesses prior to disconnection to ensure correct installation.

(60)

0053 00-2

(61)

0053 00-3

FUSE REMOVAL - CONTINUED

1. Open access door (1).

2. Remove fuse box cover (2) from fuse box (3).

(62)

0053 00-4

FUSE REMOVAL - CONTINUED

3. Remove fuse (4) from fuse box (3).

FUSE INSTALLATION

1. Install fuse (4) in fuse box (3).

2. Install fuse box cover (2) on fuse box (3).

427-C1337

(63)

0053 00-5

FUSE INSTALLATION - CONTINUED

3. Close access door (1).

HOOD TILT RELAY REMOVAL 0053 00

1. Remove three bolts (5), washers (6), and panel (7) from machine.

(64)

0053 00-6

HOOD TILT RELAY REMOVAL - CONTINUED

2. Disconnect wiring harness (8) from wiring harness (9). 3. Remove four bolts (10) and washers (11) from relay (12). 4. Remove relay (12) from panel.

HOOD TILT RELAY INSTALLATION

1. Position relay (12) on panel.

2. Install four washers (11) and bolts (10) on relay (12). 3. Connect wiring harness (9) to wiring harness (8)

(65)

0053 00-7

CAB CIRCUIT BREAKER REMOVAL 0053 00

1. Remove two nuts (13) and bolts (14) from circuit breaker (15).

2. Remove circuit breaker (15) from bracket (16). 3. Remove two screws (17) and disconnect two wiring

harnesses (18) from circuit breaker (15).

CAB CIRCUIT BREAKER INSTALLATION

1. Connect two wiring harnesses (18) and install two screws (17) on circuit breaker (15). 2. Position circuit breaker (15) on bracket (16).

3. Install two bolts (14) and nuts (13) on circuit breaker (15).

PANEL BOX CIRCUIT BREAKER REMOVAL 0053 00

NOTE

This procedure shows one circuit replacement in the panel box. Replacement is the same for each circuit in the panel box.

1. Remove nut (19) from circuit breaker (20).

2. Loosen nut (21) and remove one end of buss bar (22) from circuit breaker (20).

3. Remove nut (23), washer (24), and wiring harness (25) from circuit breaker (20).

4. Remove two screws (26) from circuit breaker (20). 5. Remove circuit breaker (20) from machine.

427-C1334

(66)

0053 00-8

PANEL BOX CIRCUIT BREAKER INSTALLATION

1. Position circuit breaker (20) on machine. 2. Install four nuts (26) on circuit breaker (20).

3. Install wiring harness (25), washer (24), and nut (23) on circuit breaker (20).

4. Install one end of buss bar (22) and tighten nut (21) on circuit breaker (20).

5. Install nut (19) on circuit breaker (20).

6. Install right rear interior cover (WP 0138 00).

7. Verify correct operation of electrical accessories and components (TM 5-3805-291-10).

(67)

0053 00-9/(0053 00-10 Blank)

ARC SUPPRESSOR

NOTE

All arc suppressors are replaced in the same manner. Removal

1. Cut tie strap (27) and discard.

2. Remove arc suppressor (28) from wiring harness (29).

Installation

1. Install arc suppressor (28) on wiring harness (29). 2. Install new tie strap (27).

(68)

(69)

0054 00-1

INSTRUMENT CLUSTER REPLACEMENT 0054 00

Removal, Installation

Unit

Materials/Parts

Rag, wiping (Item 35, WP 0233 00) Tag, marker (Item 43, WP 0233 00)

TM 5-3805-291-23P, Figure 50

0.2 hr

(70)

0054 00-2

REMOVAL

NOTE

Tag wiring harness prior to removal to ensure correct installation.

1. Remove 12 screws (1) from instrument cluster (2). 2. Pull out instrument cluster (2) from duct assembly (3).

3. Disconnect upper cab wiring harness (4) from instru-ment cluster (2).

4. Remove instrument cluster (2) from duct assembly (3).

INSTALLATION

1. Connect upper cab wiring harness (4) to instrument cluster (2). 2. Install instrument cluster (2) on duct assembly (3).

3. Install 12 screws (1) on instrument cluster (2).

4. Verify correct operation of instrument cluster (TM 5-3805-291-10).

TM 5-3805-291-23-2

MAINTENANCE MANUAL

(Includes Unit and Direct Support Maintenance)

LOADER, HEAVY, SCOOP:

DIESEL ENGINE DRIVEN (DED), 4-WHEEL DRIVE

4.5 CUBIC YARD ROCK BUCKET

NSN 3805-01-533-1857

5.0 CUBIC YARD GENERAL PURPOSE BUCKET

NSN 3805-01-533-1853

MODEL 966H

HEADQUARTERS, DEPARTMENT OF THE ARMY

-$18$5<20

WARNING

CARBON MONOXIDE (EXHAUST GASES) CAN KILL!

WARNING

BATTERIES

WARNING

COMPRESSED AIR

WARNING

WARNING

FIRE EXTINGUISHER

WARNING

FUEL HANDLING

WARNING

HAZARDOUS WASTE DISPOSAL

WARNING

HEARING PROTECTION

WARNING

HYDRAULIC SYSTEM PRESSURE

WARNING

MACHINE OPERATION

WARNING

WARNING

NBC EXPOSURE

WARNING

WARNING

WARNING

TIRES

WARNING

SOLVENT CLEANING COMPOUND

WARNING

WORK SAFETY

TECHNICAL MANUAL

FIELD MAINTENANCE MANUAL

(Includes Unit and Direct Support Maintenance)

LOADER, HEAVY, SCOOP:

DIESEL ENGINE DRIVEN (DED), 4-WHEEL DRIVE

4.5 CUBIC YARD ROCK BUCKET

NSN 3805-01-533-1857

5.0 CUBIC YARD GENERAL PURPOSE BUCKET

NSN 3805-01-533-1853

MODEL 966H

Table of Contents

Table of Contents - Continued

Table of Contents - Continued

Table of Contents - Continued

Table of Contents - Continued

Table of Contents - Continued

Table of Contents - Continued

NOTE

WARNING

CAUTION

NOTE

NOTE

NOTE

CAUTION

NOTE

NOTE

WARNING

NOTE

WARNING

NOTE

NOTE

CAUTION

NOTE

NOTE

NOTE

NOTE

-$18$5<20