27156844-TM-5-3805-291-10-CATERPILLAR-MDL-966H.pdf

TM 5-3805-291-10TECHNICAL MANUAL

OPERATOR’S MANUAL

FOR

LOADER, HEAVY, SCOOP:DIESEL ENGINE DRIVEN (DED), 4-WHEEL DRIVE

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

AND

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

MODEL 966H

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

HEADQUARTERS, DEPARTMENT OF THE ARMY

JANUARY 2010

TM 5-3805-291-10

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

understood and applied during operation and maintenance of this equipment. Failure to observe these precautionscould result in serious injury or death to personnel. Also included are explanations of safety and hazardous materialsicons used within the technical manual.

BIOLOGICAL - abstract symbol bug shows that a material may contain bacteria or viruses thatpresent a danger to life or health.

CHEMICAL - drop of liquid on hand shows that the material will cause burns or irritation tohuman 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 showsthat shock hazard is present.

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

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

FLYING PARTICLES - arrows bouncing off face shield show that particles flying through the airwill harm face.

HEAVY OBJECT - human figure stooping over heavy object shows physical injury potential fromimproper lifting techniques.

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

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

HEAVY PARTS - heavy object pinning human figure against wall shows that heavy, moving partspresent a danger to life or limb.

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

HYDRAULIC FLUID PRESSURE - hydraulic fluid spraying human hand shows that fluidescaping under great pressure can cause injury or death to personnel.

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

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

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

WARNING

CARBON MONOXIDE (EXHAUST GASES) CAN KILL!• Carbon monoxide is a colorless, odorless, deadly poison which, when breathed, deprives the body of

oxygen and causes suffocation. Exposure to air containing carbon monoxide produces symptoms ofheadache, dizziness, loss of muscular control, apparent drowsiness, and coma. Permanent brain damageor death to personnel can result from severe exposure.

• Carbon monoxide occurs in exhaust fumes from internal combustion engines. It also occurs in exhaust fumesfrom engine coolant heater (arctic machine only). Carbon monoxide can become dangerously concentratedunder conditions of inadequate ventilation. The following precautions must be observed to ensure safety ofpersonnel when engine of loader is operated.

1. DO NOT operate engine in enclosed areas without adequate ventilation.2. DO NOT idle engine without adequate ventilation.3. DO NOT drive machine with inspection plates or cover plates removed.4. BE ALERT for exhaust poisoning symptoms. They are:

• Headache• Dizziness• Sleepiness• Loss of muscular control

5. If you see another person with exhaust poisoning symptoms:• Remove person from area.• Expose to fresh air.• Keep person warm.• DO NOT permit physical exercise.• Administer cardiopulmonary resuscitation (CPR) if necessary.• Notify a medic.

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

The Best Defense Against Carbon Monoxide Poisoning Is Good Ventilation!

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WARNING

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

teries. DO NOT smoke, use open flame, make sparks, or create other ignition sources around bat-teries. If a battery is giving off gases, it can explode and cause injury to personnel. Remove alljewelry such as rings, ID tags, watches, and bracelets. If jewelry or a tool contacts a battery termi-nal, a direct short will result in instant heating or electrical shock, damage to equipment, andinjury to personnel.

• Sulfuric acid contained in batteries can cause serious burns. If battery corrosion or electrolytemakes contact with skin, eyes, or clothing, take immediate action to stop the corrosive burningeffects. Failure to follow these procedures may result in injury or death to personnel.

1. Eyes. Flush with cold water for no less than 15 minutes and seek medical attention immediately.2. Skin. Flush with large amounts of cold water until all acid is removed. Seek medical attention as required.3. Internal. If corrosion or electrolyte is ingested, drink large amounts of water or milk. Follow with milk of magne-

sia, beaten egg, or vegetable oil. Seek medical attention immediately.4. Clothing/Equipment. Wash area with large amounts of cold water. Neutralize acid with baking soda or household

ammonia.

WARNING

BLACKOUT LIGHTING SYSTEMBlackout lighting system disables backup alarm, horn, and exterior lights, posing a hazard to person-nel in the area. Follow proper safety procedures when operating in blackout mode. Failure to followthis warning may cause injury or death to personnel or damage to equipment.

WARNING

BRAKE SYSTEMIf emergency use of parking brake is required due to service brake failure, ensure that brakes areinspected and repaired, if necessary, before resuming machine operation. Injury or death to personnelor equipment damage could result from improperly or non-functioning brakes.

WARNING

COMPRESSED AIRParticles blown by compressed air are hazardous. DO NOT exceed 15 psi (103 kPa) nozzle pressurewhen drying parts with compressed air. Use a maximum of 30 psi (207 kPa) when cleaning compo-nents. DO NOT direct compressed air against human skin. Failure to follow this warning may resultin injury or death to personnel. Make sure air stream is directed away from user and other personnelin the area. To prevent injury, user must wear protective goggles or face shield.

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WARNING

ENGINE COOLANT (ARCTIC) HEATER (ARCTIC MACHINE ONLY)

Use of an arctic heater requires that coolant in system to be heated contain a proper mixture of waterand antifreeze to prevent coolant from freezing or slushing. If coolant freezes or slushes, coolant pumpcannot move coolant, causing blockage in circulating system. Pressure build-up in arctic heater cancause coolant hose at heater connection to burst or blow off. Injury to personnel or damage to enginecould result.

WARNING

ETHER COLD START SYSTEM

• Ether fuel is extremely flammable and toxic. DO NOT smoke and make sure you are in a well-ventilated area, away from heat, open flames or sparks. Wear eye protection. Avoid contact withskin and eyes and avoid breathing ether fumes. If fluid enters or fumes irritate the eyes, washimmediately with large quantities of clean water for 15 minutes. Seek medical attention immedi-ately if ether is inhaled or causes eye irritation. Failure to follow this warning may cause seriousinjury or death to personnel.

• NEVER use aerosol engine starting aids. Failure to follow this warning may cause an explosion,resulting in injury or death to personnel.

WARNING

FIRE EXTINGUISHER

Discharging large quantities of dry chemical fire extinguisher inside an enclosed cab may result intemporary breathing difficulty during and immediately after the discharge event. Discharge fireextinguisher from outside the cab. Ventilate cab thoroughly prior to reentry. Failure to follow thiswarning may cause injury to personnel.

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WARNING

FRAME ARTICULATION AREA/STEERING FRAME LOCK• Stand clear of frame articulation area when machine is operating. There is no clearance for per-

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

• DO NOT operate machine with steering frame lock connected. Steering frame lock must be dis-connected and securely stowed. If not properly stowed, loss of steering control could result. Fail-ure to follow this warning may result in injury or death to personnel or damage to equipment.

• Connect steering frame lock between front and rear frames before lifting, transporting, or servic-ing machine in frame articulation area. Disconnect steering frame lock and secure in stowed posi-tion before resuming operation. Failure to follow this warning may result in injury or death topersonnel or damage to equipment.

WARNING

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

Be sure hose nozzle is grounded against filler tube during refueling to prevent static electricity.Failure to follow this warning may result in injury or death to personnel, or damage to equip-ment.

• Operating personnel must wear fuel-resistant gloves when handling fuels. If exposed to fuel,promptly wash exposed skin and change fuel-soaked clothing.

• ALWAYS stop engine prior to refueling. If equipped with an arctic cold weather starting aid sys-tem, turn engine coolant heater off.

• DO NOT perform fuel system checks, inspections, or maintenance while smoking or near fire,flames, or sparks. Fuel may ignite, causing injury or death to personnel or damage to equipment.

WARNING

HAZARDOUS WASTE DISPOSALWhen servicing this machine, performing maintenance, or disposing of materials such as engine cool-ant, hydraulic fluid, lubricants, battery acids or batteries, windshield cleaning compound, and CARCpaint, consult your unit/local hazardous waste disposal center or safety office for local regulatoryguidance. If further information is needed, please contact The Army Environmental Hotline at 1-800-872-3845.

WARNING

HEARING PROTECTIONHearing protection is required if within 20 ft (6 m) of an operating machine. Hearing protection is alsorequired when operating machine without ROPS/FOPS during transport procedures. Failure to wearhearing protection may cause hearing loss.

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WARNING

HIGH PRESSURE ACCUMULATOR

This system contains high pressure gas. DO NOT expose to fire. DO NOT weld. DO NOT drill. Relievepressure before discharging. Failure to follow instructions and warnings could result in an explosion,causing injury or death to personnel.

WARNING

HYDRAULIC SYSTEM PRESSURE

DO NOT disconnect or remove any hydraulic system line or fitting unless engine is shut down andhydraulic system pressure has been relieved. Tighten all connections before applying pressure. Escap-ing hydraulic fluid under pressure can penetrate the skin, causing injury or death to personnel.

WARNING

LOWERING LOADER ARM WITH ENGINE STOPPED

Loader arm can drop when lowering it with engine stopped. Keep all personnel away from loader armdrop area. Ensure no one is under or near frame articulation area. Failure to follow this warning mayresult in injury or death to personnel.

WARNING

MACHINE OPERATION

• Use caution and maintain three-point contact at all times when mounting or dismountingmachine. 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 isclear of personnel and obstructions before moving. Failure to follow this warning may result ininjury or death to personnel or damage to equipment.

• Use of seat belt while operating machine is mandatory. Fasten belt BEFORE operating machine.Trying to fasten belt during operation creates a hazardous condition. Failure to follow this warn-ing may result in injury or death to personnel in the event of an accident or machine overturn.

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

• NEVER leave operator compartment without engaging parking brake. Failure to follow thiswarning may result in injury or death to personnel.

• DO NOT use parking/emergency brake to stop a moving machine under usual conditions. Only ifservice brakes fail, engage parking/emergency brake. Failure to follow this warning may result ininjury to personnel or damage to equipment.

• DO NOT perform excavating, loading, or digging tasks without ROPS/FOPS installed. Machinehas no rollover/falling object protection without ROPS/FOPS. Operation without ROPS/FOPS isonly for air or trailer transport at a slow speed. Failure to follow this warning may cause injury ordeath to personnel or damage to equipment.

• Always use a ground guide when driving machine with work tools, if visibility is impaired. Failureto use a ground guide may cause injury or death to personnel or damage to equipment.

• Machine without work tool attached is light in the front and therefore susceptible to overturning.When driving without work tool attached to loader arm, drive slowly and DO NOT make sharpturns. Failure to follow this warning may cause injury or death to personnel or damage to equip-ment.

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WARNING

MANUAL RELEASE OF PARKING BRAKE

Ensure wheels are blocked before manually releasing parking brake. Failure to follow this warningmay result in machine rolling, causing injury or death to personnel or damage to equipment.

WARNING

NBC EXPOSURE

• If NBC exposure is suspected, personnel wearing protective equipment must handle all air cleanermedia. Consult your NBC Officer or NBC NCO for appropriate handling or disposal procedures.

• Refer to FM 3-11.3, Multiservice Tactics, Techniques, and Procedures for Chemical, Biological,Radiological, and Nuclear Contamination Avoidance, and FM 3-11.5, Multiservice Tactics, Tech-niques, and Procedures for Chemical, Biological, Radiological, and Nuclear Decontamination.

• NBC contaminated filters must be handled using adequate precautions and must be disposed ofby trained personnel.

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

To order this NBC decal use:National Stock Number (NSN) - 7690-01-114-3702Part Number (PN) - 12296626Commercial and Government Entity Code (CAGEC) - 19207

WARNING

PRESSURIZED COOLING SYSTEM

• DO NOT service cooling system unless engine has cooled. This is a pressurized cooling system andescaping steam or hot coolant may cause serious burns.

• DO NOT remove cooling system radiator cap when engine is hot. Allow engine to cool down.Loosen cap to first stop and let any pressure out of cooling system, then remove cap. Failure to fol-low this warning may cause serious burns.

• Wear effective eye, hand, and skin protection when handling coolants. Failure to follow this warn-ing may cause injury to personnel.

WARNINGIF NBC EXPOSURE IS SUSPECTED ALL AIRFILTER MEDIA WILL BE HANDLED BY PER-SONNEL WEARING FULL NBC PROTEC-TIVE EQUIPMENT. SEE OPERATOR/MAINTENANCE MANUAL.

7690-01-114-3702

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WARNING

QUICK COUPLER OPERATION

Before disengaging quick coupler from work tool, use extreme caution to ensure work tool is in a safeand stable position before proceeding. Work tool must NOT be loaded. All personnel must stand clear.Failure to follow this warning may result in injury or death to personnel or damage to equipment.

WARNING

SLAVE STARTING

When slave starting machine:

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

• DO NOT proceed if cable is not available.

• DO NOT use civilian-type jumper cables.

• DO NOT allow “dead” and “live” machines to come in contact with each other at any time duringslave starting.

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

WARNING

SOLVENT CLEANING COMPOUND

Solvent cleaning compound MIL-PRF-680 Type III is an environmentally compliant and low toxicmaterial. However, it may be irritating to the eyes and skin. Use protective gloves and goggles. Use inwell-ventilated areas. Keep away from open flames and other sources of ignition. Failure to follow thiswarning may cause injury or death to personnel.

WARNING

TIRES

• Operating machine with underinflated or defective tire may lead to tire failure and loss of trac-tion or control. Failure to follow this warning may cause injury or death to personnel or damageto equipment.

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

• Use a self-attaching inflation chuck and stand at a distance behind tire when inflating tire. Failureto follow this warning may cause injury or death to personnel.

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WARNING

TOWING MACHINE

• Ensure proper towing procedures are followed when towing machine. Failure to follow propertowing procedures may cause injury or death to personnel or damage to equipment.

• When attaching towing connections, carefully move towing machine into position. Always use aground guide and DO NOT stand directly between machines.

• DO NOT tow faster than 2 mph (3 kph).• DO NOT allow operator on machine unless operator can control steering and/or brakes.• When drive shafts are removed, machine has NO parking or secondary brakes. To prevent

machine from rolling, wheels must be blocked securely. Failure to follow this warning may causeinjury or death to personnel.

• Always block wheels before removing axle shafts or disengaging parking brake.• DO NOT return to service a machine that has been towed, without first ensuring that all neces-

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

WARNING

TRANSPORTING MACHINE

• Position machine, apply parking brake, and connect steering frame lock between front and rearframes before transporting machine. Failure to follow this warning may result in injury or deathto personnel or damage to equipment.

• Always use a ground guide when operating machine up or down ramps in preparation for trans-port. Failure to use a ground guide may cause injury or death to personnel or damage to equip-ment.

• DO NOT remove exhaust stack until it has cooled to the touch. Wear gloves and protective cloth-ing as required to guard against burns. Failure to follow this warning may result in injury to per-sonnel.

• When operating machine up or down ramps, drive with extreme caution and in 1st gear forwardor reverse ONLY. Failure to follow this warning may cause injury or death to personnel or dam-age to equipment.

• If operating machine without ROPS/FOPS, drive with extreme caution, at low idle, and in 1stgear forward or reverse ONLY. Machine has no rollover/falling object protection without ROPS/FOPS. Failure to follow this warning may cause injury or death to personnel or damage to equip-ment.

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

• All personnel working in machine operating areas during RO/RO operations must wear hearingprotection. Failure to wear hearing protection may result in hearing loss.

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WARNING

WORK SAFETY• Lifting cables, chains, hooks, and slings used for lifting machine must be in good condition and of

suitable capacity. Failure to follow this warning may cause injury or death to personnel and dam-age to equipment.

• Improper use of lifting equipment and improper attachment of cables to machine may causeinjury to personnel and damage to equipment. Observe all standard rules of safety.

• Use caution when handling heavy parts. Provide adequate support and use assistance during pro-cedure. Ensure that any lifting device used is in good condition and of suitable load capacity. Keepclear of heavy parts supported only by lifting device. Failure to follow this warning may causeinjury or death to personnel.

• DO NOT perform maintenance under loader arm/work tool, unless loader arm/work tool arelowered to the ground. If procedure requires loader arm/work tool to be raised, a suitable supportdevice must be used to provide support. Failure to follow this warning may cause injury or deathto personnel or damage to equipment.

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LIST OF EFFECTIVE PAGES/WORK PACKAGES

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

Date of issue for original manual is:

Original . . . . . . . 15 January 2010

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

A/(B Blank)

Page/WP No. Change No. Page/WP No. Change No.Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0Warning Summary (12 pgs.) . . . . . . . . . . . . . 0i-vi (4 pgs.) . . . . . . . . . . . . . . . . . . . . . . . . . . 0CHAPTER 1 title page . . . . . . . . . . . . . . . . . 0WP 0001 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0WP 0002 00 (16 pgs.) . . . . . . . . . . . . . . . . . . 0WP 0003 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0CHAPTER 2 title page . . . . . . . . . . . . . . . . . 0WP 0004 00 (74 pgs.) . . . . . . . . . . . . . . . . . . 0WP 0005 00 (18 pgs.) . . . . . . . . . . . . . . . . . . 0WP 0006 00 (14 pgs.) . . . . . . . . . . . . . . . . . . 0WP 0007 00 (12 pgs.) . . . . . . . . . . . . . . . . . . 0CHAPTER 3 title page . . . . . . . . . . . . . . . . . 0WP 0008 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . 0WP 0009 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . 0WP 0010 00 (14 pgs.) . . . . . . . . . . . . . . . . . . 0CHAPTER 4 title page . . . . . . . . . . . . . . . . . 0WP 0011 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0WP 0012 00 (54 pgs.) . . . . . . . . . . . . . . . . . . 0CHAPTER 5 title page . . . . . . . . . . . . . . . . . 0WP 0013 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . 0

WP 0014 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0WP 0015 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . 0WP 0016 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0CHAPTER 6 title page . . . . . . . . . . . . . . . . . 0WP 0017 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . 0WP 0018 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . 0WP 0019 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0WP 0020 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . 0WP 0021 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0WP 0022 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0WP 0023 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0WP 0024 00 (10 pgs.) . . . . . . . . . . . . . . . . . . 0CHAPTER 7 title page . . . . . . . . . . . . . . . . . 0WP 0025 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . 0WP 0026 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . 0WP 0027 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0WP 0028 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . 0Index (6 pgs.) . . . . . . . . . . . . . . . . . . . . . . . . 0Metric conversion chart . . . . . . . . . . . . . . . . 0Back cover . . . . . . . . . . . . . . . . . . . . . . . . . . 0

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

Washington, D.C., 15 January 2010

OPERATOR’S MANUAL

FOR

LOADER, HEAVY, SCOOP:DIESEL ENGINE DRIVEN (DED), 4-WHEEL DRIVE

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

AND5.0 CUBIC YARD GENERAL PURPOSE BUCKET

NSN 3805-01-533-1853

MODEL 966H

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

REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS

You can help improve this publication. If you find any errors, or if you would like to recommend any improvements to the procedures in this publication, please let us know. The preferred method is to submit yourDA Form 2028 (Recommended Changes to Publications and Blank Forms) through the Internet, on the ArmyElectronic Product Support (AEPS) website. The Internet address is https://aeps.ria.army.mil. The DA Form2028 is located under the Public Applications section in the AEPS Public Home Page. Fill out the form and clickon 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 2028directly to the U.S. Army TACOM Life Cycle Management Command. The postal mail address is U.S. ArmyTACOM Life Cycle Management Command, ATTN: AMSTA-LCL-MPP/TECH PUBS, 1 Rock Island Arsenal,Rock Island, IL 61299-7630. The email address is [email protected]. The fax number isDSN 793-0726 or Commercial (309) 782-0726.

TM 5-3805-291-10

Table of Contents

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PageNumber

Warning Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . aHow To Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv

CHAPTER 1

INTRODUCTORY INFORMATION, EQUIPMENTDESCRIPTION, AND THEORY OF OPERATION 1

WP 0001 00 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0001 00-1WP 0002 00 Equipment Description and Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0002 00-1WP 0003 00 Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0003 00-1

CHAPTER 2

OPERATOR INSTRUCTIONS 1WP 0004 00 Description and Use of Operator Controls and Indicators . . . . . . . . . . . . . . . . 0004 00-1WP 0005 00 Operation Under Usual Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0005 00-1WP 0006 00 Operation Under Unusual Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0006 00-1WP 0007 00 Stowage and Decal, Data Plate, and Stencil Guide . . . . . . . . . . . . . . . . . . . . . . 0007 00-1

CHAPTER 3

OPERATOR TROUBLESHOOTING 1WP 0008 00 Troubleshooting Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-1WP 0009 00 Troubleshooting Symptom Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0009 00-1WP 0010 00 Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010 00-1

CHAPTER 4

PMCS MAINTENANCE INSTRUCTIONS 1WP 0011 00 Preventive Maintenance Checks and Services (PMCS) Introduction . . . . . . . . 0011 00-1WP 0012 00 Preventive Maintenance Checks and Services (PMCS)

Including Lubrication Instructions 0012 00-1

CHAPTER 5

MAINTENANCE INSTRUCTIONS 1WP 0013 00 Refueling and Fuel System Priming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0013 00-1WP 0014 00 Engine Air Precleaner Service and Air Cleaner Service . . . . . . . . . . . . . . . . . . 0014 00-1WP 0015 00 Steering Frame Lock Connection and Disconnection . . . . . . . . . . . . . . . . . . . . 0015 00-1WP 0016 00 Circuit Breaker and Fuses Reset/Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0016 00-1

CHAPTER 6

TRANSPORT PROCEDURES 1WP 0017 00 Preparation for Transport Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0017 00-1WP 0018 00 Roading Machine (Self-Deployment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018 00-1WP 0019 00 Highway Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0019 00-1WP 0020 00 Rail Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020 00-1WP 0021 00 Rail Tiedown Procedures on a DODX Rail Car . . . . . . . . . . . . . . . . . . . . . . . . 0021 00-1

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Table of Contents - Continued

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WP 0022 00 Marine Transport (RO/RO Procedures) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0022 00-1WP 0023 00 Air Transport by C-5 and C-17 Aircraft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0023 00-1WP 0024 00 Configure Machine for Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0024 00-1

CHAPTER 7

SUPPORTING INFORMATION 1WP 0025 00 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0025 00-1WP 0026 00 Components of End Item (COEI) and Basic Issue Items (BII) Lists . . . . . . . . 0026 00-1WP 0027 00 Expendable and Durable Items List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0027 00-1WP 0028 00 Additional Authorization List (AAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0028 00-1

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iv

HOW TO USE THIS MANUAL

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

INTRODUCTION

1. This manual is designed to help you operate the 966H Wheel Loader and to perform operator troubleshooting andmaintenance 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, EquipmentDescription, and Theory of Operation; Operator Instructions; Operator Troubleshooting; PMCS MaintenanceInstructions; Maintenance Instructions; Transport Procedures, and Supporting Information).

b. Each Chapter is divided into work packages, which are identified by a 6-digit number (e.g., 0001 00, 0002 00)located in the upper right-hand corner of each page. The work package page number (e.g., 0001 00-1, 0001 00-2) islocated centered at the bottom of each page.

c. If a Change Package is issued to this manual, added work packages use the 5th and 6th digits of their number toindicate new material. For instance, work packages inserted between WP 0001 00 and WP 0002 00 are numberedWP 0001 01, WP 0001 02, etc.

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

CONTENTS OF THIS MANUAL

1. A Warning Summary is located at the beginning of this manual. Become familiar with these warnings before operating orperforming operator troubleshooting or maintenance on the machine.

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

a. The Table of Contents also provides Reporting Errors and Recommending Improvements information with DAForm 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 ofthe manual.

3. Chapter 1, Introductory Information, Equipment Description and Data, and Theory of Operation, provides generalinformation on the manual and the equipment.

4. Chapter 2, Operator Instructions, explains and illustrates all operator controls and indicators and contains a Stowage andDecal, Data Plate, and Stencil Guide. It also describes how to perform all operating procedures for the machine:Operation Under Usual Conditions and Operation Under Unusual Conditions.

5. Chapter 3 covers all Operator Troubleshooting. WP 0009 00 contains a Troubleshooting Symptom Index. If the machinemalfunctions, this index should always be consulted to locate the appropriate troubleshooting procedure.

6. Chapters 4 and 5 cover Maintenance Instructions. Major areas covered are Operator Preventive Maintenance Checks andServices (PMCS) and operator-level maintenance tasks.

7. Chapter 6 describes Transport Procedures.

8. Chapter 7 includes Supporting Information: References, Components of End Item (COEI) and Basic Issue Items (BII)Lists, Expendable and Durable Items List, and Additional Authorization List (AAL).

TM 5-3805-291-10

v/(vi blank)

FEATURES OF THIS MANUAL

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

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

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

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

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

3. Within a procedural step, reference may be made to another work package in this manual or to another manual. Thesereferences indicate where you should look for more complete information.

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

b. If you are told: “For complete information on servicing batteries, refer to TM 9-6140-200-14,” go to theReferences work package (WP 0025 00) for complete information.

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

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

6. Technical instructions include metric units as well as standard units. For your reference, a Metric Conversion Chart islocated on the inside back cover of the manual.

TM 5-3805-291-10

CHAPTER 1

INTRODUCTORY INFORMATION, EQUIPMENTDESCRIPTION, AND THEORY OF OPERATION

TM 5-3805-291-10

0001 00-1

GENERAL INFORMATION 0001 00

SCOPE

1. Type of Manual. This manual is for use in operating and performing operator troubleshooting and maintenance on the966H Wheel Loader.

2. Equipment Name and Model Number. Loader, Heavy, Scoop: Diesel Engine Driven (DED) 4-Wheel Drive, Model966H.

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 DAPAM 750-8, TAMMS Users Manual.

REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIR) 0001 00

If your loader needs improvement, let us know. Send us an EIR. You, the user, are the only one who can tell us what youdon’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 QualityDeficiency Report), and mail it to us at: Department of the Army, U.S. Army Tank-automotive and Armaments Command,AMSRD-TAR-E, PDQR MS 268, 6501 E. 11 Mile Road, Warren, MI 48397-5000.

CORROSION PREVENTION AND CONTROL (CPC) 0001 00

1. CPC of Army materiel is a continuing concern. It is important that any corrosion problems with this item be reported sothat 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 iscommonly caused by exposure to moisture, acids, bases, or salts. An example is the rusting of iron. Corrosion damage inmetals can be seen, depending on the metal, as tarnishing, pitting, fogging, surface residue, and/or cracking.

3. Plastics, composites, and rubbers can also degrade. Degradation is caused by thermal (heat), oxidation (oxygen), solva-tion (solvents), or photolytic (light, typically UV) processes. The most common exposures are excessive heat or light.Damage from these processes will appear as cracking, softening, swelling, and/or breaking.

4. SF Form 368, Product Quality Deficiency Report should be submitted to the address specified in DA PAM 750-8,TAMMS Users Manual.

DESTRUCTION OF ARMY MATERIEL TO PREVENT ENEMY USE 0001 00

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

PREPARATION FOR STORAGE OR SHIPMENT 0001 00

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

WARRANTY INFORMATION

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

4

TM 5-3805-291-10

GENERAL INFORMATION - CONTINUED 0001 00

0001 00-2

NOMENCLATURE CROSS-REFERENCE LIST 0001 00

OFFICIAL NOMENCLATURE COMMON NOMENCLATURE

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

LIST OF ABBREVIATIONS/ACRONYMS 0001 00

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

ABBREVIATION/ACRONYM DEFINITION

AAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Additional Authorization ListAAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Association of American RailroadsAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air ConditioningAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . As RequiredATAAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air-to-Air AftercoolingBII . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Basic Issue ItemsB.O. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .BlackoutCCA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cold Cranking AmpsCG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Center of GravityCID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cubic Inch Displacementcm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CentimeterCOEI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Components of End ItemCONUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Continental United StatesCPC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Corrosion Prevention and ControlDED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Diesel Engine DrivenECM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electronic Control ModuleEIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Equipment Improvement RecommendationET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electronic TechnicianF/N/R. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Forward/Neutral/ReverseGIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Gabarit International de ChargementGP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .General Purposekg. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kilogramkm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . KilometerkPa. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kilopascalkph. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kilometers per HourkW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . KilowattL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LiterLASH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lighter Aboard Shiplb-ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pound FootLH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Left Handm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Metermm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Millimeter

TM 5-3805-291-10

GENERAL INFORMATION - CONTINUED 0001 00

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

LIST OF ABBREVIATIONS/ACRONYMS - CONTINUED 0001 00

ABBREVIATION/ACRONYM DEFINITION

NATO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . North Atlantic Treaty OrganizationNBC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nuclear, Biological, and ChemicalNm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Newton MeterOCONUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Outside Continental United StatesPLS-EMM-DB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Palletized Load System-Engineer Mission Module-Dump BodyPMCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Preventive Maintenance Checks and ServicesPR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ply RatingRH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Right HandRO/RO. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Roll-on/Roll-offROPS/FOPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rollover Protective Structure/Falling Object Protective StructureSDDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Surface Deployment and Distribution CommandSDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sorbent Decontamination SystemSEABEE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Navy Construction Engineer, Sea BargeTOE/MTOE. . . . . . . . . . . . . . . . . . . . . Table of Organization and Equipment/Modified Table of Organization and EquipmentWAVS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Work Area Vision System

END OF WORK PACKAGE

TM 5-3805-291-10

0002 00-1

EQUIPMENT DESCRIPTION AND DATA 0002 00

EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES 0002 001. Characteristics.

a. The 966H Wheel Loader is an integral part of the Army’s mission to efficiently build roads, airstrips, and otherengineering assets in a wide variety of geographic, environmental, and tactical situations:

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

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

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

2. Capabilities and Features.

NOTERefer to Equipment Data at the end of this work package for machine dimensions, weights, fluid capacities,and other miscellaneous equipment data.

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

b. The loader is capable of lifting, clearing, and dumping loads into the following dump trucks/bodies:(1) M917 Series, with 114 in. (2.90 m) sideboard height;(2) Palletized Load System-Engineer Mission Module-Dump Body (PLS-EMM-DB): Truck-Mounted, with 124 in.

(3.15 m) sideboard height; and Trailer-Mounted, with 112 in. (2.84 m) sideboard height.c. The machine has the following capabilities and features:

(1) Caterpillar C11 heavy-duty EPA Tier III compliant turbocharged diesel engine with six in-line cylinders,generating 259 hp (net) and 283 hp (gross) (193 and 211 kW) @ 1,800 rpm;

(2) Capable of operating for 10 hours on a tank of fuel;(3) Ether assist in cold weather starting down to -25�F (-32�C);(4) Caterpillar autoshift transmission with four forward and four reverse speeds;(5) 4-wheel drive: front fixed and rear oscillating axles with outboard planetary final drives;(6) Self-adjusting service brakes with secondary and parking brake systems;(7) Articulated frame steering with two double-acting steering cylinders;(8) Air conditioned enclosed cab with adjustable seat and tilt steering wheel, gages and warning indicators, work

tool hydraulic controls, and heater/defroster/AC controls;(9) Removable bolt-on Rollover Protective Structure/Falling Object Protective Structure (ROPS/FOPS);(10) Interchangeable work tools, including forklift pallet forks and rotary sweeper;(11) Z-bar loader arm with hydraulically-activated quick coupler, that allows for easy and quick connection and dis-

connection of work tools without the need for operator to leave cab;(12) Lift and tiedown provisions conforming to MIL-STD-209K, Department of Defense Interface Standard for Lift-

ing and Tiedown Provisions;(13) NATO slave receptacle; (14) One toolbox, located below the battery box (LH side); and(15) Mounting provisions for M16A1, M16A2, or M4 rifle; portable fire extinguisher; and M100 Sorbent Decontam-

ination System (SDS).

16

TM 5-3805-291-10

EQUIPMENT DESCRIPTION AND DATA - CONTINUED 0002 00

0002 00-2

EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES - CONTINUED

d. The loader is transportable as follows:(1) RO/RO onto C-5 and C-17 for aircraft transport.(2) RO/RO onto marine vessels. (3) Remove ROPS/FOPS, exhaust stack, and rear handrails for highway transport when using M870 Series Semi-

trailer. A permit for width or removal of bucket may also be necessary.(4) Remove ROPS/FOPS and exhaust stack for CONUS and NATO rail transport. OCONUS requires removal of

front and rear handrails.e. The loader can fresh-water ford to a depth of 30 in. (76 cm) without damage or contamination of lubricants.f. Machines that operate in extreme cold weather, from -25�F to -40�F (-32�C to -40�C), are factory equipped with an

arctic cold weather starting aid system which includes:(1) Diesel-fired engine coolant heater,(2) Four heavy-duty batteries, and(3) Larger, heavy-duty starter.

TM 5-3805-291-10


0002 00-3

LOCATION AND DESCRIPTION OF MAJOR COMPONENTS 0002 00

KEY COMPONENT DESCRIPTION1 Bucket Hardened steel bucket has teeth, bolt-on segments, and corner guards.

The Type I machine uses a 4.5 yd3 (3.5 m3) Rock bucket. The Type II machine uses a 5.0 yd3 (3.8 m3) GP bucket. Refer to Equipment Data in this work package for more information.

2 Tilt Cylinder Single hydraulic cylinder tilts work tool.3 Front Worklights Illuminate work area to front of machine. Mounted to roof bracket on

both sides of machine.4 ROPS/FOPS Bolt-on structure provides rollover and falling object protection for

operator. Must be removed for transport by M870 Series Semitrailer and AAR rail.

5 Grabhandle/Hand Rails Provides a handhold for personnel climbing on machine.6 Hydraulic Tank Stores hydraulic fluid used in machine hydraulic systems. Contains

sight gage for fluid level check.7 Hood Electrically activated tilt design opens for access to engine

compartment.8 Fender Located over rear tire, on both sides of machine.9 Platform Skid-free surface for gaining access to cab and top of machine. Located

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

sides of machine.11 Battery Box Provides protection for batteries.12 NATO Slave Receptacle Provides connection point for NATO slave cable to slave start

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

TM 5-3805-291-10


0002 00-4

LOCATION AND DESCRIPTION OF MAJOR COMPONENTS - CONTINUED

KEY COMPONENT DESCRIPTION14 Blackout (B.O.) Drive Light Used when operating in blackout mode.15 Interior Rearview Mirror Provides operator with a view to rear and side of machine. Located on

both sides of machine, inside cab.16 Cab Air conditioned/heated enclosure contains operator’s seat and all

driving and hydraulic controls.17 Rear Worklights Illuminate work area to rear of machine. Mounted to roof bracket on

both sides of machine.18 Engine Air Precleaner Self-cleaning precleaner removes debris filtered from incoming air to

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

by M870 Series Semitrailer and rail.20 Backup Alarm Sounds when transmission is in reverse. Alerts personnel behind

machine that machine is backing up. Disabled in blackout mode.21 Fan Housing Housing opens to provide access to cooling fan. Tilt hood must be

closed before fan housing can be opened.22 Towing Lugs Provide attachment points for towbar.23 Rear Tiedown Points Used to tie machine down when being transported. There is one

tiedown point on each side of rear frame section. Refer to WP 0017 00, Preparation for Transport Introduction, for an illustration of all tiedown points.

24 Arctic Heater (Optional) Aids in starting engine in extreme cold temperatures.25 Front Tiedown Points Used to tie machine down when being transported. There is one

tiedown point on each side of front frame section. Refer to WP 0017 00, Preparation for Transport Introduction, for an illustration of all tiedown points.

TM 5-3805-291-10


0002 00-5


KEY COMPONENT DESCRIPTION

26 ROPS/FOPS Lift Points (4) Attachment points for removing ROPS/FOPS for highway and rail transport (2 on each side).

27 Windshield Protects operator from inclement weather and flying objects. Includes windshield wipers/washers.

28 Lift Points Attachment points for overhead lifting device. There is one lift point on each side of front and rear frame sections. Refer to WP 0017 00, Preparation for Transport Introduction, for an illustration of all lift points.

29 Quick Coupler Equipped with hydraulically-activated pins to connect/disconnect buckets, forks, or sweepers.

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

31 Steering Cylinders Two hydraulic cylinders provide for 40 degree right or left turns with articulated frame steering system.

TM 5-3805-291-10


0002 00-6



32 Fuse Panel Provides access to fuses.

33 Horns Horns sound to alert personnel near machine.

34 Front Service Lights Inside light with white lens is service light. Outside amber light is turnlamp. Located on both sides.

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

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

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

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

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

40 Rear Composite Lights Contain the following lights: blackout marker, tail, parking, brake, and directional signals. Located on both sides.

TM 5-3805-291-10


0002 00-7



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

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

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

44 BII Box Storage compartment for BII.

45 Emergency Shutoff Switch Provides a means to shut down engine if engine does not shut down when engine start switch is turned to OFF position.

TM 5-3805-291-10


0002 00-8



46 Forklift Attachment Attachment that allows loader to function as a forklift. Refer to Equipment Data later in this work package for more information.

47 Rotary Sweeper Attachment Hydraulically powered attachment clears debris or snow from roadways. Sweeper can operate in forward or reverse direction.

TM 5-3805-291-10


0002 00-9

EQUIPMENT DATA 0002 00

Machine Dimensions (with Rock Bucket)

KEY DESCRIPTION DIMENSION

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

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

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

4 Ground clearance 18.5 in. (47.0 cm)

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

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

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

8 Wheelbase 136 in. (3.45 m)

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

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

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

12 Dump angle at maximum lift 50 degrees

13 Rack back (tilt) angle at carry 47 degrees

14 Rack back (tilt) angle at ground 42 degrees

15 Axle housing clearance 17 in. (43.2 cm)

16 Overall length 372 in. (9.45 m)

17 Digging depth 4 in. (10.2 cm)

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

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

TM 5-3805-291-10


0002 00-10

EQUIPMENT DATA - CONTINUED

Machine Dimensions (with GP Bucket)


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

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

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

4 Ground clearance 17.5 in. (44.5 cm)

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

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

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

8 Wheelbase 136 in. (3.45 m)

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

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

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

12 Dump angle at maximum lift 50 degrees

13 Rack back (tilt) angle at carry 47 degrees

14 Rack back (tilt) angle at ground 42 degrees

15 Axle housing clearance 16 in. (40.6 cm)

16 Overall length 372 in. (9.45 m)

17 Digging depth 5 in. (12.7 cm)

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

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

TM 5-3805-291-10


0002 00-11


Machine Dimensions with Pallet Forks

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

FORK PART NUMBER

FORK TINE LENGTH

PLACEMENT HEIGHT (A)

RATED OPERATING

LOADLOAD

CENTER (B)

164-4069 72 in.(1.83 m)

159 in.(4.04 m)

10,000 lb(4,536 kg)

48 in.(1.22 m)

TM 5-3805-291-10


0002 00-12


Machine Dimensions with Rotary Sweeper


1 Overall length 30 ft(9.14 m)

TM 5-3805-291-10


0002 00-13


Refill CapacitiesFuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 gal. (404 L)Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.2 gal. (42.3 L)Front Drive Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.9 gal. (64 L)Rear Drive Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.9 gal. (64 L)Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 gal. (110 L)Hydraulic System (Including Tank). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52.3 gal. (198 L)Engine Crankcase. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.25 gal. (35 L)Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.2 gal. (50 L)

EngineManufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Caterpillar Inc.Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C11 Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diesel, turbocharged, after-cooledHorsepower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259 hp (net) 283 hp (gross) (193 and 211 kW) @ 1,800 rpmEngine rpm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,450 (high idle); 825 (low idle)Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6, inlineDisplacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 680 CID (11.1 L)Type of Combustion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Direct injectionCompression Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17:1Valves per Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Valve Lash

Inlet Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.015 ± 0.003 in. (0.38 ± 0.08 mm)Exhaust Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.025 ± 0.003 in. (0.64 ± 0.08 mm)

Firing Order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1, 5, 3, 6, 2, 4Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.12 in. (13.00 cm)Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.51 in. (14.00 cm)Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,270 lb (1,030 kg)Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Direct injection with electronic unit injectorsCooling System, Water Temperature Regulator Range . . . . . . . . . . . . . . . . . . . . . . . 178�-198�F (81�-92�C)

TransmissionManufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Caterpillar Inc.Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 speeds forward, 4 reverseRange Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Autoshift; single lever control with remote F/N/R

AxlesManufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Caterpillar Inc.Type

Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FixedRear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oscillating (±13 degrees)

Front and Rear DifferentialsManufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Caterpillar Inc.Type

Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Limited slipRear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Conventional

TM 5-3805-291-10


0002 00-14


BrakesService . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Enclosed wet-disc; fully hydraulicSecondary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Provided by nitrogen-charged accumulatorsParking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brake actuator

Machine Shipping WeightRock Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53,500 lb (24,267 kg)GP Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52,500 lb (23,814 kg)

MiscellaneousFording Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 in. (76.2 cm)Maximum Travel Speed (Empty) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 mph (37 kph)Location of Center of Gravity (CG): . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 in. (1.73 m) forward of rear axle

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

right of machine front-to-rearcenterline

Bucket (Rock) 0002 00Type I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Heavy-duty, rockGround-Engaging Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Teeth and segmentsWidth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 in. (3.25 m)Rated Volume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 yd3 (3.5 m3)Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5,200 lb (2,330 kg)

Bucket (GP)Type II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .General purposeGround-engaging Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Teeth and segmentsWidth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 in. (3.02 m)Rated Volume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.0 yd3 (3.8 m3)Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4,200 lb (1,905 kg)

ForkWidth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 in. (2.21 m)Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,650 lb (1,202 kg)

SweeperWidth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 in. (3.20 m)Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,450 lb (658 kg)

TiresSize. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26.5-25Ply Rating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 PR; L-4 (Rock Bucket), L-3 (GP Bucket)Load Rating

Front (Each Tire) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41,000 lb (18,597 kg)Rear (Each Tire) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18,000 lb (8,165 kg)

Inflation PressureFront . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60 psi (414 kPa)Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 psi (276 kPa)

TM 5-3805-291-10


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


Tires - ContinuedAxle Load

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

Average Tire Contact AreaRock Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390 in.2 (1,374 cm2) each tireGP Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 450 in.2 (2,903 cm2) each tire

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

primary and secondary systemsNumber of Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Electrical SystemSystem Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Batteries:

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

Standard Machine: Down to -25�F (-32�C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 @ 1,400 CCABatteries (-40�F Arctic Kit):

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

2 @ 1,000 CCA

END OF WORK PACKAGE

TM 5-3805-291-10

0003 00-1

THEORY OF OPERATION 0003 00

INTRODUCTION

1. The 966H Wheel Loader consists of the following functional systems: engine; power train; brake systems; electricalsystem; and steering, hydraulic, ride control, and earthmoving equipment.

2. This work package explains how the systems and components of the machine work together. A functional description isprovided for each major component and system.

3. The machine has a sound suppressing Rollover Protective Structure/Falling Object Protective Structure (ROPS/FOPS)cab with insulation, heater, and air conditioning, which allows for all-weather operation. Removal of the ROPS/FOPSand exhaust stack is required for highway, Gabarit International de Chargement (GIC) rail transport, and Association ofAmerican Railroads (AAR).

ENGINE 0003 00

1. General. The machine is equipped with a Caterpillar C11 heavy-duty, Air-to-Air Aftercooling (ATAAC) diesel enginewith six in-line cylinders, generating 259 hp (net) and 283 hp (gross) at 1,800 rpm.

2. Fuel System.

a. Diesel fuel is drawn from the tank by a mechanical transfer pump, filtered by a primary fuel filter and a fuel/waterseparator, routed to the fuel injection pump and secondary filter, and then injected through the fuel injector nozzlesinto the engine cylinders.

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

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

3. Cooling System. The cooling system provides coolant to the engine. Coolant is circulated through the engine by a gear-driven water pump. Hydraulic oil, transmission oil, and aftercoolers are located near the radiator. The engine oil cooleris mounted on the right side of the engine.

4. Lubrication System. The engine lubrication system consists of a gear-driven oil pump, oil filter, oil cooler, and oil pan.The engine is lubricated by cooled and pressurized oil that is circulated through the engine block and head.

5. Exhaust System.

a. The exhaust system routes exhaust gases from the engine through the exhaust manifold and turbocharger. Thegases flow into exhaust pipes and a muffler to the atmosphere above the cab.

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

POWERTRAIN 0003 00

1. Transmission.

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

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

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

d. A transmission neutralizer system allows the operator to disengage the transmission by pressing the service brakepedals. This serves to stop the machine while increasing hydraulic response. This function can be turned off usingMessenger.

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

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

4

TM 5-3805-291-10

THEORY OF OPERATION - CONTINUED 0003 00

0003 00-2

BRAKE SYSTEMS 0003 00

1. Service Brakes.

a. An engine-mounted, gear-driven pump provides hydraulic pressure for the service brakes. The service brakes are awet brake system mounted to the planetary.

b. Two service brake pedals operate a hydraulic valve, which directs hydraulic pressure through hydraulic lines forengaging multiple oil disc brake assemblies for each wheel.

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

2. Parking Brakes.

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

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

ELECTRICAL SYSTEM 0003 00

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

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

b. Arctic operation machines have four batteries. Two have a rating of 1,400 CCA each and two have a rating of1,000 CCA each.

2. The system contains all the necessary switches, circuit breakers, fuses, relays, harnesses, and connectors to operate themachine, including a NATO slave receptacle.

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

4. The following major systems comprise the electrical system:

a. Starting system

b. Charging system

c. Electronic engine, transmission, and machine system controls

d. Instrumentation

e. Service, work, and blackout lights

HYDRAULIC SYSTEM 0003 00

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

2. Steering System.

a. The machine’s hydraulic steering system changes the machine’s angle of articulation.

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

c. Two steering cylinders mounted to the loader rear frame section turn the front wheels. The cylinders are poweredby the hydraulic system and controlled by the steering wheel.

d. In the event of primary steering system failure, a secondary system automatically activates. An electric supplemen-tal steering pump provides emergency steering power.

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THEORY OF OPERATION - CONTINUED 0003 00

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

HYDRAULIC SYSTEM - CONTINUED

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

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

b. A single tilt cylinder centered over the loader arm controls tilt functions.c. Two lift cylinders, mounted between the front frame section and the loader arm, raise and lower the loader arm.

RIDE CONTROL SYSTEM 0003 00

1. The ride control system provides the means for absorbing forces from the lift cylinders while the machine is traveling.This system minimizes machine pitching when traveling over rough terrain.

2. The main components of the ride control system are accumulator, ride control valve, lift cylinders, and ride controlswitch on the operator console inside the cab.

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

EARTHMOVING EQUIPMENT 0003 00

1. A loader arm with hydraulically activated quick coupler allows for easy and quick connection and disconnection ofwork tools without the need for operator to leave the cab.

2. The 966H Type I machine uses a Rock bucket with 4.5 yd3 (3.5 m3) capacity. The 966H Type II machine uses a GPbucket with 5.0 yd3 (3.8 m3) capacity.

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

END OF WORK PACKAGE

TM 5-3805-291-10

CHAPTER 2

OPERATOR INSTRUCTIONS

TM 5-3805-291-10

0004 00-1

DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS 0004 00

Maintenance Task Title Page

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

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

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

Transmission Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-7

Service Brake Control (Pedals) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-8

Transmission Neutralizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-10

Throttle Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0004 00-11

Hydraulic Control Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0004 00-11

Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-12

Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-12

Wiper Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-14

Heating and Air Conditioning Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-15

Parking Brake Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-16

Engine Start Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-17

Bucket Kickout Set Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-18

Ride Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-19

Auxiliary Hydraulic Control For Sweeper and Fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-20

Lift Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-21

Bucket Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-22

Monitoring System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-23

Hood Tilt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-26

Hood Tilt - Manual Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-26

Fluid Level Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-27

Ether Starting Aid System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-29

Messenger Reference Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-29

Work Area Vision System (WAVS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-59

GENERAL 0004 00

Before operating the 966H Wheel Loader, read and become familiar with the location and function of all operator controlsand indicators, as described in this work package.

30

TM 5-3805-291-10

DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS - CONTINUED 0004 00

0004 00-2

OVERVIEW - CONTROLS AND INDICATORS INSIDE CAB 0004 00

KEY CONTROL OR INDICATOR

1 Steering Control

2 Loader/Work Tool Joystick Control

3 Hydraulic Control Support

4 Throttle Control

5 Service Brake Controls

6 Tilt Control for Steering Wheel

7 Transmission Control

8 Horn

427-C0020

TM 5-3805-291-10


0004 00-3

OVERVIEW - CONTROLS AND INDICATORS INSIDE CAB - CONTINUED 0004 00


9 Parking Brake Switch

10 12V Power Receptacle

11 12V Accessory Outlet

12 Inclinometer

13 Engine Start Switch

14 Hazard Switch

15 Diagnostic Connector

16 Continuous Flow Control

17 Not Used

18 Worklights Switch

TM 5-3805-291-10


0004 00-4



19 Front Windshield Wiper/Washer Switch

20 Rear Windshield Wiper/Washer Switch

21 Quick Coupler Switch

22 Bucket Kickout Set Switch

23 Secondary Steering

24 Ride Control Switch

25 Autoshift Control

26 Fan Speed Switch

27 AC and Heat Select Switch

28 Temperature Control

TM 5-3805-291-10


0004 00-5



29 Remote F/N/R Switch

30 Auxiliary Hydraulic Control (Forks and Sweeper)

31 Horn

32 Lift Control

33 Tilt Control

34 Hydraulic Lockout

TM 5-3805-291-10


0004 00-6


BATTERY DISCONNECT SWITCH 0004 00

1. Battery disconnect switch is on left side of machine. Open access door.2. Open access door and turn battery disconnect switch clockwise (to the right) to ON position (1) to activate entire electri-

cal system. Switch must be in ON position to start engine.

CAUTIONNEVER turn battery disconnect switch to OFF position when engine is running. Damage to electrical system could result.

3. Turn battery disconnect switch counterclockwise (tothe left) to OFF position (2) to deactivate entire elec-trical system.

4. When machine will not be used for an extended periodof time (1 month or longer), battery disconnect switchshould be turned to OFF position (2). This will preventa short circuit or other electrical system componentsfrom draining batteries.


35 Transmission Downshift Switch

36 Display for Work Area Vision System (WAVS) Camera

427-C0049

TM 5-3805-291-10


0004 00-7

TRANSMISSION CONTROL 0004 00

Direction Selection

NOTEBackup alarm sounds when in reverse.

Direction is determined by position of lever that is located on left side of steering column or by remote forward/neutral/reverse (F/N/R) switch that is located next to bucket controls.1. Forward (1). Push lever forward to place transmis-

sion in FORWARD.2. Neutral (2). Place lever in middle position to place

transmission in NEUTRAL.3. Reverse (3). Pull lever rearward to place transmission

in REVERSE.

Remote F/N/R Switch

Once machine is started, NEUTRAL lamp should beon. Machine may be placed into gear either by using shifteror remote F/N/R switch. In order to use shifter, ensure thatremote F/N/R switch is in NEUTRAL position. Use shifterto select direction. The appropriate direction indicatorshould illuminate.

In order to use remote F/N/R switch, place shifter inNEUTRAL position. Select direction that is desired by usingremote F/N/R switch. The appropriate direction indicatorshould illuminate.

Transmission will be placed in NEUTRAL position ifboth shifter and remote F/N/R switch indicate a state that isnot NEUTRAL during operation. NEUTRAL lamp will beOFF. Both shifter and remote F/N/R switch must be placedin NEUTRAL position before normal operation can resume.

Speed (Gear) Selection

a. To manually shift transmission, autoshift switch (see callout 24 on page 0004 00-4) must be in MANUAL posi-tion.

427-C0026

427-C0027

TM 5-3805-291-10


0004 00-8

TRANSMISSION CONTROL - CONTINUED 0004 00

Speed (Gear) Selection - Continued

b. Speed of machine is selected by rotating end of lever that is located on left side of steering column. Rotate switchforward or backward to increase or decrease speed of transmission. Transmission will remain in selected speeduntil lever is rotated to different speed. Speed of the machine is displayed on front dash.

c. When transmission downshift switch (see callout34 on page 0004 00-6) is depressed, it signalspowertrain ECM to downshift transmission byone speed. If second speed forward or secondspeed reverse is selected, transmission will shiftto first speed when switch is depressed. Trans-mission will remain in first speed until transmis-sion direction and speed control lever is shiftedto opposite direction or to NEUTRAL.

SERVICE BRAKE CONTROL (PEDALS) 0004 001. Left Service Brake Pedal (1).

a. Left service brake pedal provides three func-tions:

(1) Aggressive automatic downshifting oftransmission

(2) Neutralization of transmission

(3) Conventional braking

b. Left brake pedal is used to initiate automaticdownshifting of transmission at higher groundspeeds than standard automatic downshifting.

c. When left service brake pedal is depressed to acertain point, automatic downshifting and neu-tralization of transmission will occur for all posi-tions of autoshift switch. Automaticdownshifting and neutralizing of transmissionsaves wear on service brakes, axles, and compo-nents of powertrain.

d. Use left brake pedal for most conditions whenadequate traction is available.

2. Right Service Brake Pedal (2). a. Right service brake pedal is used to slow down machine’s ground speed when operator does not wish to have

transmission downshift aggressively.b. Right service brake pedal is normally used for braking when autoshift transmission control is downshifting ade-

quately.

427-C0029

427-C0045

TM 5-3805-291-10


0004 00-9

SERVICE BRAKE CONTROL (PEDALS) - CONTINUED 0004 00

Left Brake Pedal Operation

Functions of left brake pedal depend on position of left brake pedal and on position of autoshift switch.

a. Initial travel (A)

b. Downshifting and service brake application (B)

c. Additional travel (application of service brakes) (C)

d. Calibrated initial brake pressure point (D)

e. Set point for neutralization (E)

f. Pedal position for stopping the machine (F)

g. Maximum pedal travel (full application of service brakes) (G)

Initial travel (A) of left brake pedal will cause transmission to aggressively downshift. Transmission will downshift tolowest available speed. Lowest available speed depends on position of autoshift switch. Refer to Modes of Operation forTransmission Neutralizer table later in this work package for lowest available speed. Each downshift of transmission willreduce speed of machine. The transmission will downshift at higher speeds than normal automatic downshift speeds. Thetransmission will only downshift if an engine overspeed will not occur. The transmission will not upshift until left brake pedalis fully released.

The transmission will be engaged again after left brake pedal is released 4 degrees from pedal position (F). This will onlyhappen if transmission was neutralized. Service brakes will still be applied. This will allow transmission to be engaged whenbrakes are applied. This will help to prevent unwanted movement while operating on a slope.

427-C0030

TM 5-3805-291-10


0004 00-10

SERVICE BRAKE CONTROL (PEDALS) - CONTINUED 0004 00

Left Brake Pedal Operation - Continued

NOTEYou should wait for at least 1 second after you release left brake pedal for 4 degrees before youcompletely release pedal. This will allow transmission to fully engage.

Depressing left pedal will neutralize transmission again. When left brake pedal is fully released, transmission will returnto normal operation. Transmission will remain in current speed if the autoshift switch is in MANUAL.

TRANSMISSION NEUTRALIZER 0004 00

NOTE• Messenger can be used to disable transmission neutralizer.• When transmission is neutralized, the readout on the Monitoring Messenger System continues to show

the selected speed but the direction will read Neutral.• When the transmission neutralizer is disabled, the neutralizer disable indicator on the dash is active.

MODES OF OPERATION FOR TRANSMISSION NEUTRALIZER

Autoshift Switch Manual Mode 2-4 1-4

Shift Pattern 4th-3rd-2nd 4th-3rd-2nd 4th-3rd-2nd

Lowest Available Speed 2nd 2nd 1st

427-C0469

TM 5-3805-291-10


0004 00-11

THROTTLE CONTROL 0004 00

Depress throttle pedal in order to increase speed ofengine. Release pedal in order to allow speed of engine todecrease.

HYDRAULIC CONTROL SUPPORT 0004 00

1. Armrest (1). 2. Control Button (2). Allows fore and aft movement of entire joystick and support (3). 3. Support (3). 4. Control Knob (4). Allows vertical movement of support (3). 5. Control Knob (5). Allows tilt and vertical movement of hydraulic control support (1).6. Control Knob (6). Allows tilt and vertical movement of hydraulic control support (1).

427-C0046

427-C0032

TM 5-3805-291-10


0004 00-12

SEAT BELT 0004 00

1. Pull seat belt all the way out of retractor and press seatbelt tab into buckle until it locks.

2. Ensure seat belt is snug across lap.

LIGHTS 0004 00

Military Light Switch. Located on right side of operator’s seat. Controls operation of machine’s service, blackout, park-ing, and instrument panel lights. When operating in blackout mode, work lights, service, and directional lights are disabled.Backup alarm and horn are also disabled in blackout mode.

NOTEFor B.O. DRIVE, B.O. MARKER, STOPLIGHT, and SER DRIVE, use the UNLOCK lever.

1. Turn ON the battery disconnect switch.2. Push up the UNLOCK lever (1) to release selector

switch (2). Release the unlock lever once the selectorswitch is correctly positioned.

3. Operate the instrument panel light switch (3) to turnon and vary the brightness of the instrumentationlighting. Push down on the instrument panel lightswitch (3) to select the parking lights.

427-C0062

TM 5-3805-291-10


0004 00-13

LIGHTS - CONTINUED 0004 00

The following lights will be activated when the corresponding switch positions are selected:

Interior Light Switch

NOTELight does not operate in blackout mode.

Located on vertical posts to the left and right of the operator’s seat.a. Press either side of switch to turn interior light on.b. Move switch to center position to turn interior light off.

MODE LIGHT ACTIVATION AVAILABLE

B.O. DRIVE B.O. Driving LightB.O. Marker LightB.O. Stop Light ON when brakes are applied

B.O. MARKER B.O. Marker LightB.O. Stop Light ON when brakes are applied

All OFF All lights OFF

STOP LIGHT Service Stop Light ON when brakes are appliedService Turn Indicators when switch is activatedBackup Lights and Alarm are also active

SER DRIVE NOTETo switch between high and low beam headlights, use themulti-purpose column switch.

Service Stop Light ON when brakes appliedService Tail LightService Turn Indicators when switch activatedService Headlights

PARK Parking Lights

TM 5-3805-291-10


0004 00-14

LIGHTS - CONTINUED 0004 00

Directional Turnlamp

1. Left Turnlamp (1). Push turnlamp lever forward toposition.

2. Right Turnlamp (2). Pull turnlamp lever rearward toposition.

3. Off. Move turnlamp lever to center position in order todeactivate either turnlamp.

4. An indicator light on front dash panel will flash whenturnlamp is activated.

WIPER CONTROLS 0004 00

1. Front Windshield Wiper/Washer Switch (1). a. Turn knob in order to turn on window wiper.b. Push knob in order to activate window washer.

NOTEMachine is equipped with intermittent front wipers. There are several positions that will controlwipers.

c. Turn knob clockwise from OFF position fordesired setting (INTERMITTENT, LOW, orHIGH).

d. Delay speed of wipers can be adjusted by turningknob clockwise through INTERMITTENT posi-tion.

2. Rear Windshield Wiper/Washer Switch (2). a. Turn knob in order to turn on window wiper. b. Push knob in order to activate window washer. c. Turn knob clockwise from OFF position for

desired setting (LOW or HIGH).

427-C0044

427-C0470

TM 5-3805-291-10


0004 00-15

HEATING AND AIR CONDITIONING CONTROLS 0004 00

Heating and AC controls are located on switch panel in upper right side of cab.1. Heater/AC Switch (1).

a. Press top of switch to turn on heater.b. Press bottom of switch to turn on AC.c. Place switch into middle position to turn off heater and AC.

2. Fan Speed Switch (2). Switch controls speed of blower fan motor for heating and AC system.a. LOW – Press in bottom of switch to turn on fan blower at lowest speed.b. MEDIUM – Place switch into middle position to turn on fan blower at medium speed.c. HIGH – Press in top of switch to turn on fan blower at highest speed.

3. Temperature Control Knob (3). Temperature control knob is a rotary switch. a. Turn knob clockwise for warmer air. b. Turn knob counterclockwise for cooler air.

4. Defrost. Press bottom of switch (1) in order to turn onAC. Set fan speed switch (2) to desired speed. Adjusttemperature control knob (3) so that windows remainfree of moisture.

427-C0471

TM 5-3805-291-10


0004 00-16

PARKING BRAKE CONTROL 0004 00

CAUTION

• Do not engage the parking brake while the machine is moving unless the service brake fails. The use ofthe parking brake as a service brake in regular operation will cause severe damage to the parking brake.

• Moving machine with the parking brake engaged can cause excessive wear or damage to brake. Ifnecessary, have brake repaired before operating machine.

• Parking brake function activates a warning on Messenger whenever parking brake is engaged. Parkingbrake indicator will flash.

1. Parking Brake Switch. Switch is located to left of steering column. Use parking brake after machine has been stopped.Toggle switch upward to engage parking brake. Toggle switch downward to disengage parking brake.

a. When parking brake control is disengaged, transmission will shift normally. When parking brake control isengaged, transmission will not shift out of NEUTRAL to first speed forward or first speed reverse. If transmissionis in first speed forward or first speed reverse and parking brake is moved to engaged position, transmission willshift into NEUTRAL. All transmission clutch modulating valves are de-energized. If transmission is in secondspeed forward or third speed forward, transmission will remain engaged.

b. Parking brake function activities a warning on Messenger whenever parking brake is engaged. Parking brake indi-cator will flash.

c. When parking brake is engaged and transmissionis in first speed, powertrain ECM shifts transmis-sion to NEUTRAL and sends parking brake sta-tus to Messenger via CAT Data Link. Whenparking brake is engaged, alert indicator forparking brake flashes on Messenger. If operatorselects FORWARD or REVERSE and parkingbrake is engaged, Messenger causes parkingbreak indicator and action lamp to flash, andaction alarm to sound.

2. 4-Way Hazard Light Switch. Toggle switch upwardto engage hazard lights. Toggle switch downward todisengage hazard lights.

WARNING

Personal injury could result from the sudden stop of the machine. The parking brake is automaticallyengaged when brake oil pressure drops below an adequate operating pressure.

3. Alert Indicator. If brakes lose oil pressure, an alert indicator for brakes will flash and an action alarm will sound.Anticipate a sudden stop. Correct cause of loss of oil pressure. Do not operate machine without normal brake oil pres-sure. Action light will also flash when lights on monitoring system flash.

427-C0472

TM 5-3805-291-10


0004 00-17

ENGINE START SWITCH 0004 00

NOTEIf engine fails to start, return engine start switch to OFF position. This must be done before youattempt to start engine again.

1. Off. To disconnect power to electrical circuits in cab, turn engine start switch to OFF position. Also, turn engine startswitch to OFF position in order to stop engine.

2. On. To activate electrical circuits in cab, turn engine start switch clockwise (to the right) to ON position.3. Start. To start engine, turn engine start switch clockwise (to the right) to START position. When engine start switch is

released, engine start switch will return to ON position.

TM 5-3805-291-10


0004 00-18

BUCKET KICKOUT SET SWITCH 0004 00

To set the lift kickout, raise the bucket to the desired position above the midway point. Then depress the top of switch.The boom will return to the programmed position when the raise detent is activated and the boom is below the kickout posi-tion.

To set the lower kickout, lower the bucket to the desired position below the midway point. Then depress the top of switch.The boom will return to the programmed position when the float detent is activated and the boom is at least 12 in. (30.5 cm)above the kickout position.

CAUTIONIf the boom is 12 in. (30.5 cm) or less above the lower kickout position, placing the lift control lever inthe float detent will cause the bucket to float and the bucket will hit the ground.

To set the rotation of the tiltback for the work tool,depress the bottom of switch.

427-C0473

TM 5-3805-291-10


0004 00-19

RIDE CONTROL 0004 00

Travel at high speeds over rough terrain may cause bucket movement and a pitching motion. The ride control system actsas a shock absorber by dampening forces from the bucket. This helps to stabilize the entire machine. Ride control switch islocated on the switch panel.1. Ride Control Switch.

WARNINGNever perform loading operations with ride control switch in ON (manual) position. Failure to do somay result in injury to personnel.

a. Manual Ride Control – Press the bottom of switch in order to turn on the ride control system at all travel speeds.Indicator will be illuminated.

b. Automatic Ride Control – Press the top of switch in order to activate the automatic ride control system. The ridecontrol system will automatically turn on if the ground speed exceeds 6 mph (9.6 kph). The ride control systemwill automatically turn off if the ground speed is less than 6 mph (9.6 kph) and if the bucket is being operated.

c. Place switch into the middle position in order to turn off the ride control system completely. The ride control sys-tem should be in the automatic mode or in the off position during loading operations.

d. Ride control is enabled by a programmable parameter via Electronic Technician (ET). Ride control is enabledwhen operator places ride control switch in ON or AUTO position. In ON position, ride control is activated at alltimes and powertrain ECM continuously energizes ride control solenoid. This mode should only be used whenmachine is being serviced. Never perform loading operations with ride control switch in ON position. In AUTOposition, ride control is activated when machine ground speed increases above approximately 6 mph (10 kph). InAUTO position, ride control is deactivated when machine ground speed is below approximately 5.5 mph (8.8 kph).Default speed can be changed in ET configuration screen.

2. Indicator. Ride control indicator (see callout 14 onPage 0004 00-23) will illuminate only when the ridecontrol system is on.

427-C0474

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0004 00-20

AUXILIARY HYDRAULIC CONTROL FOR SWEEPER AND FORK 0004 00

1. Sweeper Control.

FORWARD – Move the thumb wheel (1) forward in order to rotate the sweeper forward. Use continuous flow controlswitch (2) to maintain sweeper rotation.

HOLD – The thumb wheel (1) will return when released. The sweeper will stop rotating.

REVERSE – Move the thumb wheel (1) backward in order to rotate the sweeper in reverse. Use continuous flow controlswitch (2) to maintain sweeper rotation.

2. Fork Positioning Control.

CLOSE – Move the thumb wheel (1) forward in order to reduce fork spacing.

HOLD – The thumb wheel (1) will return when released. The left supply line and the right supply line will not be pressur-ized when the thumb wheel is released.

OPEN – Move the thumb wheel (1) backward in order to increase fork spacing.

3. Continuous Flow Control Switch.

The continuous flow control switch supplies continuous flow of hydraulic fluid to the auxiliary hydraulic circuit (forrotary sweeper operations) without continuously holding the auxiliary hydraulic control (thumb wheel [1]).

a. Move thumb wheel (1) for the auxiliary control to the desired flow rate.

b. Press and hold the continuous flow switch (2).

c. Release the thumb wheel (1) after you release the continuous flow switch (2). The continuous flow function willnot be activated if the operator does not release the thumb wheel within 1 second of releasing the continuous flowswitch.

d. Move the thumb wheel (1) or the continuous flow switch (2) in order to stop the flow to the auxiliary hydraulic cir-cuit.

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LIFT CONTROL 0004 00

CAUTION

Never use the FLOAT position to lower a loaded bucket. Machine damage can result from a bucketthat falls too fast.

NOTE

If the attachment is greater than 12 in. (30.5 cm) from the lower kickout position, a lower kickout willoccur when the joystick control is placed in the FLOAT position. If the attachment is less than 12 in.(30.5 cm) from the lower kickout position, then placing the lift control lever in the float detent willcause the attachment to float to the ground.

1. Float (1). Push the joystick forward into the soft detent. The attachment will follow along the contour of the ground.

The joystick will return to the HOLD position when the joystick is released. The attachment will remain in the FLOATposition until the joystick is moved at least 6 degrees from the HOLD position.

2. Lower (2). Push the joystick forward in order to lowerthe attachment. The joystick will return to the HOLDposition when the joystick is released.

3. Hold (3). The joystick will return to the HOLD posi-tion when the joystick is released from the RAISEposition or from the LOWER position. The attachmentwill remain in the selected position.

4. Raise (4). Pull the joystick backward in order to raisethe attachment. The joystick will return to the HOLDposition when the joystick is released.

The joystick control is detented in the fully raised position. When the joystick is moved into the soft detent, the operatorwill feel an increased resistance from the joystick. Once in the detent, the joystick should be released in order to automaticallyreturn to the HOLD position. The attachment will continue to raise until the attachment reaches the lift kickout height. In orderto manually override the detent, the joystick must be moved at least 6 degrees from the HOLD position. The detent will not beactivated if the joystick is held in the detent position for more than 1 second.

The joystick control is detented in the FLOAT position. When the joystick is moved into the soft detent, the operator willfeel an increased resistance from the joystick. Once in the detent position, the joystick should be released in order to automati-cally return to the HOLD position. The attachment will continue to lower until the attachment reaches the kickout height. Inorder to manually override the detent, the joystick must be moved at least 6 degrees from the HOLD position. The detent willnot be activated if the joystick is held in the detent position for more than 1 second.

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0004 00-22

BUCKET CONTROL 0004 00

1. Tilt Back (1). Move the joystick to the left in order totilt the bucket backward.

2. Hold (2). When you release the joystick, the joystickwill return the HOLD position. The bucket will remainin the selected position.

3. Dump (3). Move the joystick to the right in order todump a load from the bucket.

NOTEA machine with ride control may experience partial lowering of the lift arms when the joystick is heldin the DUMP position with the bucket against the bucket stops and the lift arms are fully raised. Toavoid partial lowering of the lift arms, return the joystick to the HOLD position.

The joystick control is detented in the full TILT BACK position. When the joystick is moved into the soft detent, the oper-ator will feel an increased resistance from the joystick. Once in the detent, the joystick should be released in order to automat-ically return to the HOLD position. The attachment will continue to tilt back until the attachment reaches the digging anglethat is preset by the tilt kickout. In order to manually override the detent, the joystick must be moved at least 6 degrees fromthe HOLD position. The detent will not be activated if the joystick is held in the detent position for more than 1 second.

The joystick control is detented in the full DUMP position. When the joystick is moved into the soft detent, the operatorwill feel an increased resistance from the joystick. Once in the detent, the joystick should be released in order to automaticallyreturn to the HOLD position. The attachment will continue to dump until the attachment reaches the digging angle that is pre-set by the tilt kickout. In order to manually override the detent, the joystick must be moved at least 6 degrees from the HOLDposition. The detent will not be activated if the joystick is held in the detent position for more than 1 second.

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0004 00-23

MONITORING SYSTEM 0004 00

Monitoring systems continuously monitor machine systems. The monitoring system consists of the following displays:

1. Tachometer (1).

2. Speedometer, Gear, and Service Meter Digital Display (2).

3. Messenger Electronic Display (3). Located in the upper-front corner of the cab. Refer to the Messenger ReferenceGuide later in this work package.

4. Fuel Level (4). This gage indicates the amount of fuel in the fuel tank. If the gage needle is in the red zone, the fuel tankis low on fuel. Refuel the machine as soon as possible.

5. Transmission Oil Temperature (5). This gage indicates excessive transmission oil temperature. If the gage needle is inthe red area, reduce the load on the machine. If the gage needle is in the red area and if the action light (see callout 15 onthe next page) continues to flash after approximately 5 minutes, stop the machine and investigate the cause of the fault.Refer to Troubleshooting Introduction (WP 0008 00).

6. Coolant Temperature (6). This gage indicates excessive coolant temperature. If the gage needle is in the red area, stopthe machine and investigate the cause of the fault. Refer to Troubleshooting Introduction (WP 0008 00).

7. Hydraulic Oil Temperature (7). This gage indicates excessive hydraulic oil temperature. If the gage needle is in thered area, reduce the load on the system. If the gage needle remains in the red area, stop the machine and investigate thecause of the fault. Refer to Troubleshooting Introduction (WP 0008 00).

Front Dash Indicators

1. Left Turnlamp (8). This indicator illuminates when the left turnlamp is activated.

2. Primary Steering (9). This indicator illuminates when the oil pressure for the primary steering is low. The indicatormay also indicate a failure of the primary steering. The secondary steering (if equipped) should be automatically acti-vated. If this alert indicator flashes during operation, stop the machine immediately and engage the parking brake. Stopthe engine and investigate the cause of the fault. Refer to Troubleshooting Introduction (WP 0008 00).

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0004 00-24

MONITORING SYSTEM - CONTINUED 0004 00

Front Dash Indicators - Continued

WARNINGDo not operate the machine until the steering fault has been corrected. Failure to follow this warningmay cause injury or death to personnel.

NOTESecondary steering only works while the machine is moving. Directional changes can be made whenthe machine operates under secondary steering.

3. Secondary Steering (10). This indicator illuminates when the secondary steering is functioning. When you turn theengine start switch to the ON position, the alert indicator for the secondary steering will come on for 3 seconds. Then,the alert indicator will go off. If the alert indicator for the secondary steering does not come on, investigate the cause ofthe fault. Refer to Troubleshooting Introduction (WP 0008 00). Do not operate the machine until the fault has been cor-rected.

4. Transmission Neutralizer (11). This indicator illuminates when the transmission neutralizer is deactivated.

5. Transmission Failure (12). This indicator illuminates when a serious problem exists in the electronic system of thetransmission. Immediately stop the machine. Stop the engine. Investigate the cause. Refer to Troubleshooting Introduc-tion (WP 0008 00).

6. Parking Brake (13). This indicator illuminates when the parking brake is engaged. The indicator should flash duringstart-up.

7. Ride Control (14). This indicator illuminates when the ride control is activated.

8. Action Light (15). This indicator illuminates when a fault has been detected by the monitoring system. Refer to Trou-bleshooting Introduction (WP 0008 00).

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0004 00-25

MONITORING SYSTEM - CONTINUED 0004 00

Front Dash Indicators - Continued

9. Electrical System (16). This indicator illuminates when there is a malfunction in the electrical system. The system volt-age is too high for normal machine operation or the system voltage is too low for normal machine operation.a. If the electrical loads (air conditioning and/or lighting) are high and the engine speed is low, then increase the

engine speed. This will generate more output from the alternator. If the alert indicator for the electrical systemturns off within 1 minute, the electrical system is operating normally. Overload can occur during periods of lowengine speeds.

b. Revise the operating cycle in order to avoid overloading the electrical system. Overloading the electrical systemcould result in discharging the batteries.

c. Reducing loads will also help. Use the medium fan speed instead of the high fan speed.d. If this procedure does not cause the alert indicator to turn off, stop the machine and investigate the cause of the

fault. Refer to Troubleshooting Introduction (WP 0008 00).10. Engine Warning (17). 11. Service Lights (18). 12. High Beam Lights (19). 13. Hydraulic System Warning (20). This indicator illuminates when there is a hydraulic system malfunction. Stop the

engine and investigate the cause of the fault. Refer to Troubleshooting Introduction (WP 0008 00).14. Engine Start Aid Status (21). This indicator illuminates when ether is being injected to assist with engine start.15. Right Turnlamp (22). This indicator illuminates when the right turnlamp is activated.16. Brake System Warning (23). This indicator illuminates when there is a brake system malfunction. Stop the engine and

investigate the cause of the fault. Refer to Troubleshooting Introduction (WP 0008 00).

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0004 00-26

HOOD TILT 0004 00

The switch that controls the engine hood is located in a compartment on the left side of the machine.

CAUTION

Do not continue to hold toggle switch in open or in closed position after movement of hood hasstopped. When audible clicks are heard, release toggle switch. Failure to release toggle switch willresult in damage to actuator.

1. Open the access door.

2. Turn battery disconnect switch to ON position.

3. Pull out the toggle switch. Move the toggle switch toposition (1) in order to raise the hood. Release the tog-gle switch. The toggle switch will return to the middleposition (2).

4. Pull out the toggle switch. Move the toggle switch toposition (3) in order to lower the hood. Hold theswitch in this position until the hood is fully closed.Release the toggle switch. The toggle switch willreturn to the middle position (2).

HOOD TILT - MANUAL OPERATION 0004 00

The hood can be opened manually by using a ratchet, two extensions, and socket (Items 2, 3, 8, and 9, Table 2, WP 002600) to turn the shaft of the lift motor.

1. Remove four bolts and cover.

2. Insert socket through the hole and onto the shaft of the lift motor. Turn the shaft clockwise (to the right) to raise thehood. Turn the shaft counterclockwise (to the left) to lower the hood.

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0004 00-27

FLUID LEVEL INDICATORS 0004 00

1. Engine Oil Level Dipstick. a. Open the service door that is located on the right side of the machine. That is where the oil level dipstick (1) is

located.b. Maintain the oil level between the FULL mark and ADD mark, range (A) on the dipstick. Check the level of the

engine oil while the engine is shut off. If necessary, remove oil fill cap (2) and add oil. It takes 1 gal. (4.55 L) to fillfrom lowest point on crosshatched area.

2. Transmission Oil Level Sight Gage. a. The transmission oil level sight gage (1) is located on the front of the transfer case on the left side of the machine.b. The red indicator should be within WARM IDLE range (B) when the oil is warm and the machine is running at

low idle. c. The red indicator should be within COLD START range (A) when the oil is cold and the machine is not running. If

necessary, remove fill cap (2) and add oil through the filler tube (3).

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0004 00-28

FLUID LEVEL INDICATORS - CONTINUED 0004 00

3. Coolant Level Sight Gage (1).

NOTEIf it is necessary to add coolant daily, inspect the cooling system for leaks.

a. Open the access door on the left-rear side of themachine.

b. Coolant level sight gage (1) is located on the topradiator.

c. Maintain the coolant level within the sight gage.If necessary, remove filler cap (2) and add cool-ant.

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0004 00-29

FLUID LEVEL INDICATORS - CONTINUED

4. Hydraulic Tank Sight Gage (2). a. The hydraulic tank is located on the left side of

the machine behind the cab. b. The lift arms must be lowered with the bucket

flat in order to check the hydraulic oil. c. Check the hydraulic oil level while the engine is

stopped. d. Maintain the oil level above the ADD COLD

mark on sight gage (2). If necessary, removefiller cap (1) slowly and add oil.

ETHER STARTING AID SYSTEM 0004 00

1. Ether starting aid cylinder is located in engine com-partment on left side of machine next to air cleaner.

2. When ambient temperature is below 0°F (-18°C), ameasured amount of ether is injected automaticallyinto engine air intake system when starting engine.

3. Operator DOES NOT manually inject ether.

MESSENGER REFERENCE GUIDE 0004 00

NOTESee PDF beginning on page 0004 00-30.

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MESSENGER REFERENCE GUIDE

0004 00-30

GENERAL NAVIGATION SUMMARY

Button 1 – Go “back” one level

Button 2 – Go left or up in the current level

Button 3 – Go down or right in the current level

Button 4 – Select a menu or item

TOP-LEVEL SCREEN The top-level screen, consisting of the local time and date, is the screen that will be displayed when all menus have been exited. To return to top-level screen, press button 1 until time and date are displayed.

Top Level Screen

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Messenger Reference Guide

0004 00-31

Main Menu Structure

Performance Menu

Performance Menu

The Performance Menu allows the operator to view critical parameters that directly affect machine performance.The following performance parameters will be displayed:

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0004 00-32

Top Level ScreenTime/Date

Settings

Service

Totals

Performance

Operator

Engine Speed (e.g. 1500 RPM)

Actual Gear (e.g. 3F, 2N, 1R)

Fuel Level (e.g. 46%)

Torque Converter Temperature (e.g. 78C,-14F)

Hydraulic Oil Temperature (e.g. 78C,-14F)

Engine Coolant Temperature (e.g. 78 C, -14 F)

Ground Speed/Direction (e.g. 13.8 kph, -3.4 mph)

Shift Level (e.g. 3F, 2N, 1R)

Performance Parameters Diagram

Settings Menu The Settings Menu allows the operator the capability to set machine systems to fit the application requirements.

Settings Menu Diagram

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Display Settings


0004 00-33

The following system functions are available in the Settings Menu.

TRANSMISSION SETTINGS MENU The Transmission Settings Menu allows the operator to view and program settings for the transmission system.

Transmission Settings Menu

Neutralizer Settings The Neutralizer Setpoint Setting Level Menu allows the operator to configure the neutralizer portion of the Integrated Braking System (IBS) for the left brake pedal, according to their application requirements. Initial Left Brake Pedal travel will downshift the transmission, further travel applies brakes, and further travel will neutralize the transmission if ground speed is less than 6.5 mph.

Transmission Settings: Neutralizer Setpoint Setting Level Screen

The operator has four calibrated choices to select, depending on the application requirements, when setting the Neutralizer Setpoint, including:

• Level (factory default)

• Moderate

• Aggressive

• Disable

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0004 00-34

To select one of the settings/submenus, highlight the desired selection (by pressing arrows up/down), then press OK. See below for an example of how the screen might look.

Neutralizer Setpoint Settings Screens

The operator has two additional options in the main Neutralizer Setpoint Setting Level screen, beyond the four-calibrated choices described above: Adjust and Reset.

• Adjust – Allows the operator to modify the calibrated setpoint values.

• Reset – Resets the Neutralizer Setpoint Settings back to the default calibrated values.

Adjust and Reset Neutralizer Setpoint Settings Screens

To select Reset, press OK when Reset is highlighted. To select Adjust, press OK when Adjust is highlighted. The adjustment screen for Level Operation will be displayed.

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0004 00-35

Slope Operation Screens

Use the up or down arrow key to change the default setting for the specific mode selected. Each time the arrow isdepressed, the setting will change by 1.0% in the direction of the arrow (up arrow increases the setpoint and downarrow decreases the setpoint). Once the setting is acceptable, press OK to accept and store the value. Go to thenext screen for the next adjustment. After the Aggressive Slope adjustment, press OK and you will be returnedto the Neutralizer Setpoint Level Setting main screen.

• The Level Operation setting cannot be set below the brake point (0% offset) or above or equal to the Moderate Slope setting.

• The Moderate Slope setting cannot be set below or equal to the level setting or above or equal to the AggressiveSlope setting.

• The Aggressive Slope setting cannot be set below or equal to the slope setting or above the maximumallowed setting.

• If Reset is selected, the values are changed back to the default calibrated values.

Fuel Economy Mode The Fuel Economy Mode Menu allows the operator to select the engine rpm at which the transmission shift points occur, thus better matching the machine to application requirements.

Transmission Settings: Fuel Economy Mode Screen

The Fuel Economy Mode screen shows which mode is currently selected and also allows operator to select either of followingthree modes:

• Economy – Transmission shifts will occur at lower engine speeds (1,300–1,500 rpm). This mode is the most fuel efficient setting and will improve shift quality (operator comfort). In load and carry applications, lower rpm transmission shift may help reduce material spill.

• Midrange – Transmission shifts moderately at engine speeds (1,600–1,800 rpm). This is the recommended position for many operations.

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In addition to using the Neutralizer Settings menu a shortcut to toggle the Neutralizer between Disable and level is available.

Back & Down/RightPress Simultaneously to: Toggle the Neutralizer to Disable or from Disable to Level


0004 00-36

• Power – Transmission shifts aggressively at higher engine speeds (1,900–2,100 rpm).

Fuel Economy Mode Settings Screens

Maximum Forward Gear The Maximum Forward Gear menu selection shows the operator’s currently set maximum forward gear.

Transmission Settings: Maximum Forward Gear Screens

It also allows the operator to set maximum forward gear according to his application by pressing the OK button and using Up or Down arrow key to increment or decrement the gear selection.

Maximum Reverse Gear Similar to the Maximum Forward Gear menu, this menu selection shows the currently set maximum reverse gear. It also allows operator to set maximum reverse gear according to their application by pressing the OK button and using Up or Down arrow key to increment or decrement the gear selection.

Transmission Settings: Maximum Reverse Gear Screens

Forward to Reverse Desired Gear This screen allows the operator to select what gear (1st or 2nd) the machine will start in after making a directional change from forward to reverse.

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0004 00-37

Transmission Settings: Forward to Reverse Desired Gear Screen

Reverse to Forward Desired Gear This screen allows the operator to select what gear (1st or 2nd) the machine will start in after making a directional change from reverse to forward.

Transmission Settings: Reverse to Forward Desired Gear Screen

IMPLEMENT SETTINGS MENU Selecting the Implement Settings Menu allows the operator to view and program settings for the implements on the machine.

Implement Settings Menu Screen

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0004 00-38

Fine Modulation Mode Allows the operator to turn Fine Modulation Mode On or Off. Fine Modulation allows for more precise implement controls in certain applications.

Implement Settings: Fine Modulation Mode Screen

Pressing the OK button will take the operator to a screen similar to the OFF/ON selection screen shown below. Using the Left or Right arrow key will allow the operator to switch between the two selections. When the desired option is highlighted, press the OK button to turn ON or OFF the Fine Modulation Mode and take you back to the Fine Modulation Mode screen. Pressing the BACK button takes you back to the Fine Modulation Mode screen without making changes to already existing settings.

Implement Settings: Fine Modulation Mode ON/OFF Screen T

DISPLAY SETTINGS This menu allows the operator to view and program the language, units, contrast, backlight, time/date format, and startup screen settings for the Messenger display.

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0004 00-39

Display Settings Screen

Language This submenu lets the operator select from the available languages to display the language of text on the Messenger display.

The operator can use the UP or DOWN arrow keys to switch between the language selections. A particular language can be selected by pressing OK.

Display Settings: Language Screens

Units The units for numerical parameters can be selected as either English or metric on the Messenger display. English is the default setting for language and units.

Display Settings: Units Screens

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0004 00-40

Contrast and Backlight The contrast and backlight settings on Messenger will be displayed and adjusted with bar graphs. The contrast and backlight (lights ON/OFF) settings will default to a midrange level. The lights ON setting adjusts the backlight when the headlights are on. The lights OFF setting adjusts the backlight when the headlights are off.

Display Settings: Contrast and Backlight Screens

Time/Date The time/date on the default screen can be changed in the settings menu. To change the time, date, or date format, use the navigation keys to highlight the fields and click on the OK button to go to the next screen to adjust your values or make your choices. Please note that time is always entered in military time.

• 12-hour, YYYY-MM-DD (default)

• 24-hour, YYYY-MM-DD

• 12-hour, MM-DD-YY

• 24-hour, MM-DD-YY

• 12-hour, DD-MM-YY

• 24-hour, DD-MM-YY

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0004 00-41

Display Settings: Time/Date Adjustment Screens

Startup Screen The startup screen setting allows the user to select which screen Messenger will display when it is powered on, after the splash screens disappear. The radial button next to the text in Messenger will indicate which choice is currently selected. Selections are:

• Top Level Screen

• Neutralizer Settings Screen (from Transmission Settings menu)

• Fine Modulation Mode Screen (from Implement Settings menu)

• User Defined Screen

In addition to these selections, the operator can define any screen in the Messenger menu structure to be used as the startup screen. To designate a screen as the user defined startup screen, the operator will navigate to the screen of his or her choice. Once at that screen, the operator will simultaneously press and release all four buttons on Messenger. When Messenger detects that all four buttons have been simultaneously pressed, it shall designate the current screen as the startup screen until a different startup screen is chosen from the menu or designated by another four-button press.

Totals Menu This menu allows the operator to view all the machine parameters that are accumulated over the lifetime.

Totals Screen

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0004 00-42

Totals Menu Diagram

TRANSMISSION TOTALS Allows the operator to view following transmission parameters that are accumulated over the lifetime of the system.

• Transmission Hrs

• Total Distance

• Fwd Distance

• Rev Distance

ENGINE TOTALS Allows the operator to view following engine parameters that are accumulated over the lifetime of the system.

• Total Hours

• Total Idle Time

• Total Fuel

• Total Idle Fuel

• Total Eng Starts

• Total Max Fuel

• Percentage Idle Time

• Lifetime Eng Revs

• Average RPM

• Avg Fuel Rate

• Overall Load Factor

Service Menu The service mode is used to view active and logged diagnostic codes and events, perform machine checkout using the system parameter information, perform calibrations, and identify ECM serial no and software information, in addition to tattletales.

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0004 00-43

Service Screen

Service Menu Diagram

DIAGNOSTIC/EVENT FEATURE Displays the diagnostic and event codes, along with recommended operator action and descriptions. Both active and logged diagnostics/events can be viewed. The following information will be displayed for each diagnostic/event:

• Source of diagnostic code/event, CID-FMI or EID-WCI

• Count

• Active/Logged indication

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0004 00-44

Service: Diagnostic/Events Screens

In order to view the descriptions of the code, select the code using UP/DOWN key and press OK.

Service: Diagnostic/Events Code Description Screen

Serious events and diagnostics will cause a popup screen to appear and will display recommended actions for critical problems. These popups can be snoozed by pressing the OK button. Level 2 events may be snoozed indefinitely and at any time. Level 3 events and diagnostics cannot be snoozed and will disappear when the level 3 diagnostic is no longer active.

The following information will be displayed for each diagnostic/event after the user selects the code from the list and presses OK:

• Description

• Recommended action text

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0004 00-45

SYSTEM PARAMETERS

Service: System Parameters Menu Diagram

CALIBRATIONS MENU When the operator selects a calibration from the menu, before each calibration begins, the operator can choose to view information about the last calibration of that type that was performed on the machine. This information includes the service hour reading at the time it was last calibrated and the final status of that calibration.

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Park Brake Switch Park Brake F Axle Oil Temp R Axle Oil Temp Man Diff Lock Switch

This menu item displays current settings and operational readings.

Auto Diff Lock

Display Settings


0004 00-46

Service: Calibrations Menu Diagram

Transmission Calibrations

Allows the operator to perform calibration procedures on the transmission system. The following calibrations can be performed in transmission using Messenger.

Neutralizer Set Point/Pedal Calibrations: This option performs the Neutralizer Set Point/Pedal Calibration. Following are the steps that will be displayed for the calibration.

Calibrations: Neutralizer Set Point/Pedal Screen

Step Number Step and Display String 1. Set Park break & Set to Neutral,’Next’

2. Push L brake ‘til press is 10 psi.’Next’

3. Completely depress left brake.’Next’

4. Completely release left brake.’Next’

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0004 00-47

Transmission Fill Calibration: This option performs the Transmission Fill calibration. Following are the steps that will be displayed for the calibration.

Calibrations: Transmission Fill Screen

Step Number Step and Display String 1. Prk brk, ntrl, warm tran, hi idle..’Next’2. Calibration Initializing

3. Calibrating clutch #1

4. Calibrating clutch #2 5. Calibrating clutch #3 6. Calibrating Clutch #4 7. Calibrating Clutch #5 8. Calibrating Clutch #6 9. Calibrating Clutch #7

10. Calibrating Clutch #8 11. Calibrating Clutch #9 12. Calibrating Clutch #10 13. Calibrating Lockup Clutch

Implement Calibrations

Allows the operator to perform calibration procedures on the implement system. When the operator selects a calibration from the menu, before each calibration begins, the operator can choose to view information about the last calibration of that type that was performed on the machine. This information includes the service hour reading at the time it was last calibrated and the final status of that calibration.

Allows the operator to perform calibration procedures on the levers controlling the implement on the machine.

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0004 00-48

Calibrations: Lever Calibrations Screen

The following lever calibrations can be performed using this sub menu:

• Lift Lever calibration

• Tilt Lever calibration

• Third Function Lever calibration

Lift Lever Calibration:

Step Number Step and Display String 1. Press next button to start 2. Set parking brake 3. Engage implement lockout switch 4. Place lift lever in HOLD. ‘Next’ 5. Place lift lever in full RAISE. ‘Next’ 6. Place lift lever in full LOWER. ‘Next’

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0004 00-49

Calibrations: Lift Lever Calibration Screens

Tilt Lever Calibration:

Step Number Step and Display String 1. Press next button to start 2. Set parking brake 3. Engage implement lockout switch 4. Place tilt lever in HOLD..’Next’ 5. Place tilt lever in RACKBACK..’Next’6. Place lift lever in full DUMP..’Next’

Third Function Lever Calibration:

Step Number Step and Display String 1. Press next button to start 2. Set parking brake 3. Engage implement lockout switch 4. Place 3rd lever in HOLD ..’Next’ 5. Place 3rd lever full REARWARD..’Next’6. Place 3rd lever full FORWARD.. ‘Next’

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0004 00-50

Linkage/Cylinder Calibration Menu:

Allows the operator to perform calibration procedures on the linkages and cylinders of the implement on the machine. The following lever calibrations can be performed using this sub menu:

Lift Linkage Position Sensor Calibration:

Step Number Step and Display String 1. Press next button to start 2. Set parking brake 3. Raise linkage to max position ..’Next’ 4. Place bucket into full rackback ..’Next’5. Lower linkage to min position ..’Next’

Tilt Linkage Position Sensor Calibration:

Step Number Step and Display String 1. Press next button to start 2. Set parking brake 3. Place bucket into full rackback ..’Next’4. Lower linkage to min position ..’Next’

5. Raise linkage to max position ..’Next’

6. Place bucket into full dump ..’Next’

Valve Calibrations Implement Raise:

*Set the engine speed to high idle before starting calibration.

Step Number Step and Display String 1. Set park brake, unlock implement 2. Disengage Implement Lockout Switch 3. Set lift cylinder extension to 450-500mm

4. Set tilt cylinder extension to 200-250mm

5. Set Engine Speed to high idle

6. Release lever ..’Next’

7. Move lift lever to full raise and hold 8. CALIBRATING 9. Release lever ..’Next’

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0004 00-51

Valve Calibrations: Implement Lower:


Step Number Step and Display String 1. Set park brake, unlock implement 2. Disengage Implement Lockout Switch 3. Set lift cylinder. extension to 450–500 mm

4. Set tilt cylinder extension to 200–250 mm

5. Set Engine Speed to high idle 6. Release lever ..’Next’

7. Move lift lever to full lower and hold

8. CALIBRATING 9. Release lever ..’Next’

Valve Calibrations: Implement Rackback:


Step Number Step and Display String 1. Set park brake, unlock implement 2. Disengage Implement Lockout Switch 3. Set lift cylinder. extension to 450–500 mm

4. Set tilt cylinder extension to 200–250 mm


7. Move tilt lever to full rackback & hold


Valve Calibrations: Implement Dump:


Step Number Step and Display String 1. Set park brake, unlock implement 2. Disengage Implement Lockout Switch. 3. Set lift cylinder. extension to 450–500 mm

4. Set tilt cylinder. extension to 200–250 mm


7. Move tilt lever to full dump & hold


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0004 00-52

Valve Calibrations: 3rd Function Rearward:


Step Number Step and Display String

1. Set park brake, unlock implement 2. Disengage Implement Lockout Switch

3. Move 3rd function cylinder to mid length ..'Next'


6. Move 3rd function lever to full back until implement moves..next


Valve Calibrations: 3rd Function Forward:


Step Number Step and Display String 1. Set park brake, unlock implement 2. Disengage Implement Lockout Switch

3. Move 3rd function cylinder to mid length ..'Next'


6. Move 3rd function lever to full forward until implement moves..next


Valve Calibrations: Implement Rackback & Dump Current:

Step Number Step and Display String 1. Set park brake, unlock implement 2. Move linkage to mid-height ..'Next' 3. Place bucket into full dump ..'Next' 4. Move bucket 50-200mm off ground ..'next'5. Set Engine Speed to high idle 6. Move tilt lever to full rackback & hold 7. Release lever ..’Next’

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0004 00-53

SYSTEM INFO This menu allows the operator to view information such as ECM part number, S/W part number, S/W release date, S/W description, location code, and serial number for the various systems and components on the machine. The following diagram describes the System Info menu structure:

Service: System Info Menu Diagram

TATTLETALE This menu allows the operator to view extreme recorded values of critical operating parameters and system information. When this feature is accessed, both Messenger and the instrument cluster will display these values.

The operator can request a full tattletale readout, during which all the indicators that have been activated during the session will light, all the gauges will be set to the maximum value (minimum for the fuel gauge) encountered during operation, and the maximum ground speed will be displayed on the LCD. The operator can also step through the tattletale value of each gauge, during which all of the inactive gauges will be set to the minimum value.

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0004 00-54

Service: Tattletale Menu Diagram

TM 5-3805-291-10


0004 00-55

Service: Tattletale Screens

OPERATORMultiple operators can enter an identification code via the graphical display and then store the current settings. Next time on the machine, the operator may recall their own settings by entering the same identification code as when they saved their settings.

Operator Menu Diagram

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0004 00-56

Operator Screen

The following presents a more detailed description of the six functions in order of display.

SELECT PROFILE Operator selects a previously saved profile name and associated saved settings from a list.

VIEW CURRENT Operator can view current settings. Scrolling to the end of settings list, operator has option to save these settings to the currently active operator profile.

View Current list includes:

• Operator ID

• Language

• Units

• Startup Screen

• Date Format

• Time Format

• Contrast

• Lights On

• Lights Off

• Forward to Reverse Gear

• Reverse to Forward Gear

• Raise Kickout Cylinder Extension

• Lower Kickout Cylinder Extension

• Dump Rate Control Enable Status

• Full Rack Angle Control Enable Status

• Dump Stop Snubbing Enable Status

• Neutralizer Operation Mode

• Neutralizer settings

• Level operation neutralizer set point

• Moderate slope operation neutralizer set point

• Aggressive slope operation neutralizer set point

CREATE PROFILE Operator can enter up to 14 characters for a profile name. Selecting OK then saves this name to the profile name list.

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0004 00-57

SAVE PROFILE Selecting this option will save the current settings under the operator ID# entered on the screen. The graphical display will request reads of all the parameters in the list that are external parameters and save these values along with the current values of the internal parameters.

DELETE PROFILE Selecting this option will delete the settings for the operator ID# entered on the screen. The graphical display module will clear out the space for this operator ID# and hence leave space for a new operator ID# to be stored. If no new operator ID# was entered following a delete of an operator ID#, the graphical display module will not perform any changes to any settings when exiting the menu.

FACTORY SETTINGS Selecting this option will recall the factory settings for the machine.

Factory Settings are:

• Operator ID – Factory Settings

• Language - English

• Units - English

• Startup Screen – Top Level Screen

• Time Format – 12 Hr

• Date Format – YYY/MM/DD

• Contrast – 50%

• Lights On – 50%

• Lights Off – 50%

• Forward to Reverse Gear – 2

• Reverse to Forward Gear – 2

• Raise Kickout Cylinder Extension

• Dump Rate Control Enable Status- Disabled

• Full Rack Angle Control Enable Stats - Disabled

• Dump Stop Snubbing Enable Status - Disabled

• Neutralizer Operation Mode - Level

• Neutralizer settings

• Level operation neutralizer set point – 2%

• Moderate slope operation neutralizer set point – 8%

• Aggressive slope operation neutralizer set point – 18%

NOTE: It is up to the user or fleet manager to assign the operator a number that is different than any other user on that particular machine. The operator ID can be anything from 1 to 99999. However, it is up to the graphical display application to limit the maximum number of different operators, due to memory restrictions. If the total number of operator profiles have been reached the graphical display will return an error when trying to save another user profile. Hence, a profile needs to be deleted or overwritten first before storing. The operator can list the existing user profile ID# by pressing list and then OK once.

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DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS - CONTINUED 0004 00-59

WORK AREA VISION SYSTEM (WAVS) 0000 00

Operation and Maintenance Manual starts on page 0004 00-61

Systems Operation Testing and Adjusting starts on page 0004 00-81

2

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i01658146

Important Safety InformationMost accidents that involve product operation, maintenance and repair are caused by failure to observebasic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardoussituations before an accident occurs. A person must be alert to potential hazards. This person should alsohave the necessary training, skills and tools to perform these functions properly.

Improper operation, lubrication, maintenance or repair of this product can be dangerous andcould result in injury or death.Do not operate or perform any lubrication, maintenance or repair on this product, until you haveread and understood the operation, lubrication, maintenance and repair information.Safety precautions and warnings are provided in this manual and on the product. If these hazard warningsare not heeded, bodily injury or death could occur to you or to other persons.

The hazards are identi�ed by the “Safety Alert Symbol” and followed by a “Signal Word” such as“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.The message that appears under the warning explains the hazard and can be either written or pictoriallypresented.

Operations that may cause product damage are identi�ed by “NOTICE” labels on the product and inthis publication.

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.The warnings in this publication and on the product are, therefore, not all inclusive. If a tool,procedure, work method or operating technique that is not speci�cally recommended by Caterpillaris used, you must satisfy yourself that it is safe for you and for others. You should also ensure thatthe product will not be damaged or be made unsafe by the operation, lubrication, maintenance orrepair procedures that you choose.The information, speci�cations, and illustrations in this publication are on the basis of information thatwas available at the time that the publication was written. The speci�cations, torques, pressures,measurements, adjustments, illustrations, and other items can change at any time. These changes canaffect the service that is given to the product. Obtain the complete and most current information before youstart any job. Caterpillar dealers have the most current information available.

When replacement parts are required for thisproduct Caterpillar recommends using Caterpil-lar replacement parts or parts with equivalentspeci�cations including, but not limited to, phys-ical dimensions, type, strength and material.

Failure to heed this warning can lead to prema-ture failures, product damage, personal injury ordeath.

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0004 00-59

Foreword

ForewordLiterature InformationThis manual should be stored in the literature holder.

This manual contains safety information, operationinstructions, and maintenance recommendations.

Some photographs or illustrations in this publicationshow details or attachments that can be differentfrom your product.

Continuing improvement and advancement ofproduct design might have caused changes to yourproduct which are not included in this publication.Read, study and keep this manual with the product.

Whenever a question arises regarding your product,or this publication, please notify Unit Maintenance.

SafetyThe safety section lists basic safety precautions. Inaddition, this section identi�es the text and locationsof warning signs and labels used on the machine.

OperationThe operation section is a reference for the newoperator and a refresher for the experiencedoperator. This section includes a discussion ofgauges, switches, product controls, attachmentcontrols, and programming information.

Photographs and illustrations guide the operatorthrough correct procedures of checking, starting,operating and stopping the product.

Operating techniques outlined in this publication arebasic. Skill and techniques develop as the operatorgains knowledge of the product and its capabilities.

MaintenanceThe maintenance section is a guide to equipmentcare.

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0004 00-60

Safety SectionSafety

Safety Sectioni02726365

SafetySMCS Code: 7348

Do not operate or work on this machine unlessyou have read and understand the instructionsand warnings in the Operation and MaintenanceManuals. Failure to follow the instructions or heedthe warnings could result in injury or death. Con-tact your Caterpillar dealer for replacement manu-als. Proper care is your responsibility.

This machine is equipped with the Caterpillar WorkArea Vision System (WAVS). The system mayinclude one, two, or three cameras. The system hasbeen set up by the factory or by a Caterpillar dealerin order to provide views which comply with theguidelines that have been documented.

WAVS is designed in order to supplement the viewfor the operator during machine operation. Thissystem is not intended as a substitute for properoperating techniques. This system is not intendedas a substitute for safe operating techniques. Thissystem is not intended to take the place of otherstandard systems for supplemental vision such asmirrors with rear view and side view.

Before you begin operating the machine, ensurethat the features of the display screen for WAVS areproperly adjusted. Consult Unit Maintenancebefore any adjustments are made to the system.

Prior to operation of the machine, always con�rm thatthe view that is provided by any camera is adequatefor your viewing. If necessary, make adjustmentsprior to operating the machine.

Prior to operating the machine, ensure properorientation of images by the camera. Rear facingcameras should yield a mirror image.

Ensure that the brightness and the contrast areadjusted prior to operating the machine. Ensure thatthe brightness and the contrast are adjusted afterchanges in the conditions for ambient light.

Due to the environment, the camera lens and thedisplay screen will require periodic cleaning. Theinstructions on properly cleaning the camera lensand the display are described in "Display - Clean" and“ Camera - Clean”.

If the display that is used with this systemwas installed on another machine, Caterpillarrecommends con�guring the settings for thedisplay by quali�ed service personnel. A newcon�guration will ensure proper performance in thenew application.

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0004 00-61

Operation SectionGeneral Information

Systems Operation Sectioni02506417

General InformationSMCS Code: 7347; 7348

SafetyThis machine is equipped with the Caterpillar WorkArea Vision System (WAVS). The system may includeone, two, or three cameras. The system has beenset up by the factory or a Caterpillar dealer in orderto provide views which comply with documentedguidelines.

While the system is serviced, be sure to observesafe access procedures. Ensure that an appropriate3-point contact system can be safely maintainedduring the cleaning procedure and/or use of anappropriate safety harness.

Notify Unit Maintenance before any adjustmentsare made to the system. Any adjustments to theWAVS by anyone other than a qualifiedtechnician can be detrimental to the specifiedpurpose of this system.

Due to the environment, the camera lens and thedisplay screen will require periodic cleaning. Theinstructions on how to properly clean the camera lensand the display are described in the Maintenancesection of the Operation and Maintenance Manual.

IF THE DISPLAY THAT IS USED WITH THISSYSTEM WAS PREVIOUSLY INSTALLED ON ADIFFERENT MACHINE, IT IS IMPORTANT THATTHE DISPLAY SETTINGS BE RE-CONFIGUREDBY QUALIFIED SERVICE PERSONNEL TOINSURE PROPER PERFORMANCE IN THE NEWAPPLICATION.

System OverviewThis machine is equipped with the Caterpillar WorkArea Vision System (WAVS). WAVS is a closedcircuit video monitoring system. WAVS consists of a178mm (7 inch) LCD color display and may includeone, two, or three cameras. The display is mountedin the machine cab. The cameras are mounted on theframe of the machine. The location of the camera(s)is dependant on machine type.

g01178357Illustration 1

Display

g01178360Illustration 2Camera Assembly

Marker Line

Your system may have been configured to showa green horizontal “Marker” line that is shown onthe display. The “Marker” provides a fixed distancereference line from the machine. There are nooperator controls available in order to adjust the“Marker” (15). Refer to Illustration 3.

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0004 00-62



Rear Camera View with Marker(15) Marker Line

Power on/off

Power is supplied to the system when the operator turns the key switch to the ON position and the light switchselector lever in either STOPLIGHT or SERDRIVE. The power On/Off button that is on the display may be disabled. Refer to the “Display Description” section of thisdocument for an Illustration of the power button. The power button is shown in the “Display Keypad” Illustration.

Single Camera System Overview

The WAVS single camera system only has one modeof operation, automatic mode.


Example of a Single Camera Installation on a Wheel Loader(21) Rearward Looking Camera(22) Possible Video Cable Route(23) Machine Cab(24) Display in Cab(25) Machine Bucket

Refer to information in the “Display Button Operation”table or to the “How to Select Display Settings”section of this document which describes how toadjust the display settings for a single camerasystem. Make sure the display in not in the “Standby”mode.

Note: If the single camera system can be placed inmanual mode, PLEASE notify service personnel.

Note: The orientation for the camera image is setduring installation. The rearward looking cameraimage is set to provide a “reversed” image, similar toa mirror view. If the camera image orientation is notcorrect, contact service personnel immediately.

Multi-Camera System Overview

The WAVS multi-camera system has two modesof operation, manual mode and automatic mode.Automatic mode is the preferred mode of operation.In the automatic mode, the display will provide thecamera view(s) that are defined by the configurationof the system. The configuration of the system isdetermined upon installation of the system.

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0004 00-63


i02727240

Modes Of OperationSMCS Code: 7348

Automatic Mode for the SingleCamera SystemThe single camera system is available only withthe automatic mode “enabled”. The single camerasystem can be placed in “Standby” if the system iscon�gured. Refer to the “Standby” for an explanationof the “Standby” option.

Manual mode is intended for use only with themultiple camera applications. Manual mode isdisabled for use in a single camera system.

Note: If the “single camera” system can be placed inmanual mode, notify Unit Maintenance.

In a single camera system, the system willautomatically display the camera view that is basedon current machine operation which is determined bythe system con�guration. For example, WAVS maybe con�gured to display the view from a rearwardlooking camera when the operator selects reversegear.

Standby

Your single camera system installation may becon�gured with the “Standby” feature that is enabledor disabled. If “Standby” is enabled, the displaywill remain dark unless the camera view has beenactivated by machine operation. Standby may beuseful at the following times:

• Travel at night.

• Reverse will not be used.

If the “Standby” feature is disabled and if thedisplay is on constantly, the operator has the optionof adjusting the brightness of the display. If the“Standby” feature is disabled and if the display is onconstantly, the operator has the option of adjustingthe contrast of the display.

Automatic Mode for a MultipleCamera SystemWhen the system is in the automatic mode, thesystem automatically selects the preferred cameraview that is based on current machine operationwhich is determined by the system con�guration. Forexample, WAVS may be con�gured to display theview from the rearward looking camera when theoperator selects reverse gear.

In a multiple camera system, the operator canoverride the automatic view by either of the followingselections:

• Selecting “Manual Mode” on the display

• Pressing the “Alternate Camera” switch

In the “Automatic” mode, automatic selection of eachcamera will be enabled and the appropriate camerawill be activated. In automatic mode, the display canalso be placed in “Standby”.

Note: The preferred camera view will always beshown on the display screen unless the display isplaced in “Manual” mode.

Alternate Camera Switch

The Alternate camera switch allows the third camerato be activated. In the example of the Off-HighwayTruck, the third camera is the side camera. Theswitch is a momentary switch that will need to beheld down in order to activate the third camera. Theimage on the display will return to the front cameraor the rear camera when the switch is released.This action is dependent on which of the camerasthat the machine is trying to activate. If the switch iscon�gured, this switch may also be providing powerto a light that concentrates on the viewing area ofthe side camera. If the system is con�gured this way,the light will turn on any time that the third camera isactivated with the Alternate camera switch.

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0004 00-64


i02726609

Camera DescriptionSMCS Code: 7348

Camera

g01178970Illustration 9Assembly for the Camera

The system has been set up by the factory orby a Caterpillar dealer in order to provide viewswhich comply with the guidelines that have beendocumented.

Notify Unit Maintenance before anyadjustments are made to the system.

Proper operation of the system will require periodiccleaning of the camera lens and the display. Referto "Display - Clean" and "Camera - Clean".

amera Wash

After installation, there should be no need to makeany physical adjustments to any of the camerasunder normal operating conditions. The cameras are“�xed focused” cameras. The cameras have beeninstalled by the following service personnel: factory,Caterpillar dealer, and quali�ed technician.

Camera Wash

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0004 00-65

Operation Section Adjustments

Adjustmentsi02727631

Display Position AdjustmentSMCS Code: 7347

Do not position the display in order to cover anywarning stickers or other important information.

Do not position the display in order to impede theentry to the machine cab or exit from the machinecab.

Do not position the display in order to obstruct theoperator’s outside view.

Do not position the display in order to obstruct theoperator’s view of machine instrumentation.

Do not position the display in order to impair access tooperator controls or movement of operator controls.

Position the Display

g01367987Illustration 11Mounting Clamp Assembly

(1) Clamp(2) Clamp Handle

g01368064Illustration 12(3) Ball Mount Base


Installation of the Display and Mounting Assembly(3) Base for the Ball Mount(4) Display(5) Mounting Clamps(6) Dumbbell(7) Mounting Clamp Handles

Refer to Illustration 13. In order to position thedisplay (4), hold the display (4) securely. Loosenthe mounting clamp handle or handles (7) on themounting clamps (5) for the display . Adjust thedisplay (4). Tighten the handle or handles (7) onthe mounting clamps (5) for the display (4) after thedisplay (4) is positioned.

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0004 00-66

Operation SectionAdjustments

g01368029Illustration 14Example of an Installation on a Wheel Loader

(3) Base for the Ball Mount(4) Display(5) Mounting Clamp(8) Mounting Bracket for the Display(9) Mounting Bolt for the Ball Mount

g01368041Illustration 15Example of an Installation on a Wheel Loader

(10) Installed WAVS

i02727626

Display Picture Adjustment(Select Display Settings)SMCS Code: 7347

Single Camera SystemEnsure that the display is not in the “Standby” mode.

Refer to "Display Description" for information onthe operation of the buttons for the display.

Note: If the single camera system can be placedin manual mode, notify Unit Maintenance.

Note: If the display does a sequence to the next groupof stored settings, this may alter the appearance ofthe view or the orientation of the camera view.

Adjustment for Brightness

In order to adjust the brightness, perform thefollowing procedure:

1. Press the button for adjusting the brightness (5)in order to enable the adjustment for brightness.The “RED” LED light that is above and to theright of the button for adjusting the brightness willilluminate indicating that you have entered themode for adjusting the brightness.

2. Press the “Minus” button (6) or the “Plus” button(7) in order to adjust the brightness level.

3. Press any other button on the display in order toexit the mode for adjusting the brightness. The“RED” LED light that is above and to the right ofbutton for adjusting the brightness will turn OFF.

Note: If the level for brightness is set to high and ifthe “Auto Brightness” is not enabled, then there is apossibly that in a well lighted area the display wouldappear completely “white”.

Adjustment for Contrast

In order to adjust the contrast, perform the followingprocedure:

1. Press the button for adjusting the contrast (4)in order to enable adjustment for contrast. The“RED” LED light that is above and to the right ofthe button for adjusting the contrast will illuminatein order to indicate that you have entered themode for adjusting the contrast.

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0004 00-67

Operation Section Adjustments

2. Press the “Minus” button (6) or the “Plus” button(7) in order to adjust the contrast level.

3. Press any other button on the display in orderto exit the mode for adjusting the contrast. The“RED” LED light that is above and to the right ofthe button for adjusting the contrast will turn OFF.

Automatic Brightness ON/OFF

In order to enable the option for automatic brightness,perform the following procedure:

1. Press the button for automatic brightness (2).The “RED” LED light that is above and to theright of the button for automatic brightnesswill illuminate in order to indicate that the autobrightness/dimming option is enabled.

2. Press the button for automatic brightness againin order to disable the option for automaticbrightness. The “RED” LED light that is above andto the right of the button for automatic brightnesswill turn off in order to indicate that the autobrightness/dimming option is disabled.

Standby ON/OFF

In order to enable the Standby ON/OFF option,perform the following procedure:

1. Press the standby button (3)in order to enablestandby. The “Red” LED light that is above andto the right of the button for the standby optionwill illuminate in order to indicate that standby isenabled. The display should go dark. The displaywill remain dark until an input for the system isactivated.

2. Press the standby button again in order to disablethe standby option. The “Red” LED light that isabove and to the right of the button for the standbyoption will turn OFF. The display will remain in theON position.

Multiple Camera System

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0004 00-68

Maintenance SectionMaintenance Interval Schedule

Maintenance Sectioni02736179

Display - CleanSMCS Code: 7347-070

In order to maintain suf�cient vision, the display andthe camera lens may need to be cleaned periodicallydue to the environment.

Use a soft, damp cloth with water only in order toclean the display. The display has a soft plasticsurface that is easily damaged by any material thatis abrasive.

Note: The display is not sealed. The display can notbe immersed. The display can not have a pressurewash.

i02736175

Camera - CleanSMCS Code: 7348-070

CameraIf necessary, use a damp cloth in order to clean theglass of the camera. The camera is sealed. Thecamera is not affected by a wash with high pressurespray.

The camera is equipped with an internal heater tohelp counteract the following effects: condensation,snow, and accumulation of ice.

Note: When you access the cameras for cleaning, besure to observe safe procedures for access. Maintaina three-point contact and/or use a safety harness.

Note: Alternatively, cameras may be cleaned fromground level by using a wash with a high pressurespray or a damp rag on a wand.

Camera Wash SystemThe camera wash system is installed typically on therear facing camera for easy cleaning. The cleaningis performed by pressing the switch for two seconddurations until the camera is clean.

activating the camera wash system at the end of theshift in order to clear the water and the debris. Thiswill ensure that the water and debris does not freezeup the spray head.

Adjust the spray nozzle within one inch of thecamera lens in order for the camera wash system toperform proper operation. adjust the spray nozzlewithin one inch of the camera lens. The angle of thespray nozzle should be between 30 degrees and 45degrees from the lens of the camera.

Note: When you are adjusting, verify that the spraynozzle is not in the view of the camera.

The preferred method of adjustment would requiretwo people:

• One person in the cab that is looking at the imageon the display

• One person that is making the adjustment on thespray nozzle

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0004 00-69

Systems Operation Section

i02506525

ConfigurationSMCS Code: 7347; 7348

g01178371Illustration 7Display Keypad(1) Camera Selection Button(2) Automatic Brightness ON/OFF(3) Standby Function ON/OFF(4) Contrast Button(5) Brightness Button(6) Reduce Brightness or Contrast

Adjustment Button

(7) Increase Brightness or ContrastAdjustment Button

(8) Power ON/OFF Function May BeDisabled

(9) Camera Select LEDs(10) Button Status LEDs(11) Light Sensor

Accessing All System OptionsIn order to configure or verify certain options, there isa particular procedure that must be used in order toaccess the options.

Mirror Image

The display is supplied by Caterpillar with the “Mirror”image set as the default. The mirror image is usedonly for rearward looking cameras.

In order to provide the correct image for cameras thatare mounted in other locations other than a rearwardlooking camera location (in a multi camera system),the image must be changed to “Normal”.

That is, for example, if cameras are mounted onthe front and the side of a machine, then the imagemust be changed to “Normal” in order to provide thecorrect image for the front and the side cameras.

In order to select “Mirror” or “Normal” image:

1. Press button 1 (camera select) in order to enter“Manual” mode.

2. Press and hold button 1 (camera select) andbutton 3 (Standby On/Off), simultaneously, for 20seconds.

Note: The display will blink, then change to theopposite image.

3. Press button 1 (camera select) again in order toselect the next camera that is to be viewed and/orhave its settings adjusted.

4. Press and hold button 1 (camera select) andbutton 3 (Standby On/Off), simultaneously, for 20seconds in order to toggle the image.

5. Repeat step 3 and step 4 in order to toggle thelast camera image.

Note: If the machine is equipped with a rearwardlooking camera, ensure that the image is set tothe "Mirror" image. The proper orientation mustbe verified before the system is put into service.

Press button 1 (camera select) for two seconds inorder to place the system in automatic mode. TheLED that is above and to the right of the cameraselect button will turn off.

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0004 00-70


Inverted Image

This option can be used in order to invert the image.That is, this option will switch the orientation of theimage so that the top will appear at the bottom ofthe display screen and the bottom will appear atthe top of the display screen. Therefore, the imagewill appear to be upside down if the inverted imageoption is selected.

In order to invert the image:

1. Press button 1 (camera select) in order to enter“Manual” mode. The LED that is above and to theright of button 1 (camera select) will flash in orderto indicate that the system is in manual mode.

2. Press and hold button 1 (camera select) andbutton 2 (Auto Brightness) simultaneously for 40seconds in order to invert the image of the cameraview that is shown on the display screen.

3. Press button 1 (camera select) again in order toselect the next camera that is to be viewed and/orhave its settings adjusted.

4. Again, press and hold button 1 (camera select)and button 2 (Auto Brightness) simultaneouslyfor 40 seconds in order to invert the image of thecamera view that is shown on the display screen.

5. Repeat step 3 and step 4 for the third camera.

In order to revert to a previous image:

1. Follow the preceding steps to select theappropriate camera.

2. Press and hold button 1 (camera select) andbutton 2 (Auto Brightness) simultaneously for 40seconds.

Display Power ON/OFF

The display on/off button may be disabled. If disabled,the button serves no other function. The LED that isabove and to the right of the display on/off button willilluminate in order to show the system is on.

Color Adjustment

The “Color Adjustment” option is used to vary thelevel of color on the display. The level of color of thedisplay can be varied in order to show a full colorimage or a black and white image.

In order to access the color adjustment option:

1. Press button 4 (Contrast) and button 5(Brightness) simultaneously in order to accessthis option.

2. Press button 6 (Minus) or button 7 (Plus) buttonin order to change the level of color.

Press any other display button, other than the button6 (Minus) or button 7 (Plus) buttons, in order to exitthe Color Adjustment option.

Marker ON/OFF

Note: Before the marker option is enabled,the appropriate “on-sight” personel should becontacted. The technician will need informationin order to accurately set the marker at thedesired position.

The display provides an option that is called the“Marker” line. The “Marker” is a small green line thatprovides a fixed distance reference line from themachine. This Marker line can be turned on or off.The position of the Marker line can also be set by aqualified technician.

In order to turn the Marker on:

1. Press button 2 (Auto Brightness) and button 3(Standby) simultaneously for 10 seconds. Themarker will appear on the display screen.

2. After the “Marker” appears, press either button 6(Minus) or button 7 (Plus) in order to adjust theposition of the “Marker”.

3. Once the position is set, press any other displaybutton except button 6 (Minus) or button 7 (Plus)in order to exit the “Marker” set option.

Note: After the marker has been activated, if anyother button on the display is pressed other thanbutton 6 (Minus) or button 7 (Plus), the marker will beset to the current position on the display. The markerposition can be changed as long as the marker optionhas not been exited.

In order to access all other options, pleaserefer to the following information in the “SingleCamera System” or the “Multi Camera System”sections of this document.

Reset Marker

In order to reset the marker, the marker must beturned off, then turned back on and moved to thedesired position on the display screen using button6 (Minus) or button 7 (Plus), before any other buttonon the display is pressed.

In order to reset the marker:

TM 5-3805-291-10

0004 00-71


1. Press button 2 (Auto Brightness) and button 3(Standby) simultaneously for 10 seconds in orderto turn the existing marker off.

2. Press button 2 (Auto Brightness) and button 3(Standby) simultaneously for 10 seconds again inorder to turn the marker back on.

3. Use button 6 (Minus) or button 7 (Plus) in order toadjust marker position.

4. Press any other button, other than button 6(Minus) or button 7 (Plus) in order to exit themarker set option.

Switch Off Key Board

The “Switch Off Key Board” option is provided in orderto restrict access to the WAVS settings. However,even if the key board is switched off, the displaywill continue to be active. Therefore, if the WAVSencounters any camera system inputs, the displaywill show the view from the active input. However, anyother key board operations or functions are disabled.

Press and hold button 1 (camera select) and button 5(brightness) at the same time for 15 seconds in orderto disable input from the key board.

In order to enable the key board once again, pressand hold button 1 (camera select) and 5 (brightness)at the same time for 15 seconds.

Single Camera System

Available Operator Selections for theWAVS Display

The selections that are listed in this section havebeen made available to the operator of the machine.The selections for the WAVS display can be changedby the operator as needed. Refer to table 1 andIllustration 7.

Brightness Adjustment

The brightness adjustment option allows the operatorto vary the brightness of the view that is shown onthe display. If the brightness level is set to high andif the “Auto Brightness” is not enabled, then there isa possibly that in a well lit area the display wouldappear completely “white”.

Contrast Adjustment

The contrast adjustment option allows the operatorto vary the contrast of the view that is shown on thedisplay.

Manual Camera Selection

Manual mode is available only on WAVSmulti-camera installations. That is, manualmode is not available for WAVS single camerainstallations.

Automatic Brightness ON/OFF

The Automatic Brightness ON/OFF option allows theoperator to set the display to change the brightnesslevel automatically. The WAVS display is equippedwith a sensor to detect ambient light. When WAVSis placed in the “Automatic Brightness” mode, thedisplay will brighten or dim automatically as theambient light increases or decreases.

The brightness starting set point can be changedby the operator while in the manual or automaticmode. In order to change the set point, turn the autobrightness on and perform the brightness adjustmentto the desired level for the starting point.

Standby ON/OFF

Your single camera system installation may beconfigured with the “Standby” feature enabled ordisabled. If “Standby” is enabled, the display willremain dark unless the camera view has beenactivated by machine operation or by the operator.

“Standby” may be useful at times when the operatorfeels that the display image is not needed, such aswhen travelling at night or when reverse will not beused.

If “Standby” is disabled, the operator still has theoption to adjust the brightness and/or contrast if thedisplay is on constantly.

TM 5-3805-291-10

0004 00-72


Table 1

Display Button Operation for Single Camera Systems

Operation Procedure Notes

Brightness Adjustment Press button 5 in order to enable the“Brightness Adjustment”, then presseither button 6 or 7 in order to adjustthe brightness.

If “Auto Brightness ”is enabled, thebrightness starting set point can bechanged by the operator while in themanual or automatic mode.Press any other display key in order toexit brightness adjustment mode.

Contrast Adjustment Press button 4 in order to enable theContrast Adjustment, then press eitherbutton 6 or 7 in order to adjust thecontrast level.

Press any other display key in order toexit the contrast adjustment mode.

Automatic Brightness ON/OFF Press button 2 in order to turn theautomatic brightness option ON/OFF.

When WAVS is placed in the “AutomaticBrightness” mode, the display willbrighten or dim automatically as theambient light increases or decreases.

Standby ON/OFF Press button 3 in order to turn thestandby option ON/OFF.

If the standby mode is ON, the displaywill remain dark until a WAVS inputis detected, however, the power andstandby LED should remain on.

LED Indication

If the LED for button 8 and the LED of the camera that is selected (C1, C2, or C3) flash together, the image is switched offbecause the ambient temperature is below �25 °C (�13°F) or is above 70 °C (158 °F).

Multi Camera System

Camera Select - for Multi Camera System

camera select function disabled. The cameraselect function must be enabled for a multicamera system.

With “Camera Select” enabled, individual camerascan be selected, configured, and positioned in orderto pride the desired view.

In order to enable “Camera Select”:

1. Press and hold button 1 (camera select) andbutton 4 (contrast), simultaneously for 40 seconds.This will enable the camera select option.

After “Camera Select” has been enabled, you willbe able to press button 1 (camera select) in orderto place the system in “Manual” mode.

The LED that is above and to the right of button 1(camera select) will flash in order to indicate thatthe system is in manual mode.

One of the indicator LED’s (C1, C2, or C3) that areto the left of the display buttons will indicate whichcamera view is displayed. Refer to Illustration 7(9).

2. If the machine has a second camera, press button1 (camera select) again in order to select thenext camera that is to be viewed and/or have itssettings adjusted.

3. If the machine has a third camera, press button1 (camera select) again in order to select thenext camera that is to be viewed and/or have itssettings adjusted.

Press and hold the camera select button for twoseconds in order to exit the “Manual” mode.

Available Operator Selections for theWAVS Display

The selections that are listed in this section havebeen made available to the operator of the machine.The selections for the WAVS display can be changedby the operator as needed. Refer to table 2 and toIllustration 7.

Brightness Adjustment

The brightness adjustment option allows the operatorto vary the brightness of the view that is shown onthe display. If the brightness level is set to high andif the “Auto Brightness” is not enabled, then there isa possibly that in a well lit area the display wouldappear completely “white”.

TM 5-3805-291-10

0004 00-73/(0004 00-74 Blank)

END OF WORK PACKAGE

TM 5-3805-291-10

0005 00-1

OPERATION UNDER USUAL CONDITIONS 0005 00

THIS WORK PACKAGE COVERS

IntroductionMounting and Dismounting MachineInitial Adjustments and Daily ChecksStarting EngineMachine WarmupOperating MachineSteering MachineOperating on Slopes

Parking Machine

Stopping Engine if an Electrical Malfunction Occurs

Lowering Loader Arm with Engine Stopped

Relieving Hydraulic System Pressure

Quick Coupler Operation

Operating Work Tools

Portable Fire Extinguisher Operation

INITIAL SETUP

Tools and Special ToolsWrench, adjustable (Item 13, Table 2, WP 0026 00)

Materials/PartsRag, wiping (Item 13, WP 0027 00)

Personnel RequiredMOS 21E, Heavy Construction Equipment Opera-

tor (2)

References

WP 0004 00

WP 0006 00

WP 0008 00

WP 0011 00

WP 0012 00

WP 0015 00

INTRODUCTION

1. This work package contains instructions for safely operating the 966H Wheel Loader under usual conditions. 2. Unusual conditions are defined and described in WP 0006 00.3. Refer to WP 0004 00 for the location and function of all controls and indicators required for machine operation.

18

TM 5-3805-291-10

OPERATION UNDER USUAL CONDITIONS - CONTINUED 0005 00

0005 00-2

MOUNTING AND DISMOUNTING MACHINE 0005 00

WARNINGUse caution and maintain three-point contact at all times when mounting or dismounting machine. Failureto follow this warning may result in injury or death to personnel.

1. Mount and dismount machine only at locations with ladders and grabhandles.2. Ensure ladders and grabhandles are clean and secure before using them.3. Face machine when mounting and dismounting.4. Maintain minimum three-point contact at all times, i.e., two feet and one hand or two hands and one foot.5. NEVER mount or dismount a moving machine.6. NEVER jump from machine.7. DO NOT mount or dismount machine while carrying tools or supplies.

INITIAL ADJUSTMENTS AND DAILY CHECKS 0005 00

1. Always perform Before operation PMCS (WP 0011 00 and WP 0012 00) BEFORE operating machine.

WARNINGDO NOT operate machine with steering frame lock connected. Steering frame lock must be disconnectedand securely stowed. If not properly stowed, loss of steering control could result. Failure to follow thiswarning may result in injury or death to personnel or damage to equipment.

2. Ensure steering frame lock is disconnected and securely stowed (WP 0015 00). 3. Turn battery disconnect switch to ON position.4. Open door and climb up into cab, using ladder and grabhandles. Refer to Mounting and Dismounting Machine above.5. Occupy seat.6. Adjust left and right interior rearview mirrors.

WARNINGUse of seat belt while operating machine is mandatory. Fasten belt BEFORE operating machine. Trying tofasten belt during operation creates a hazardous condition. Failure to follow this warning may result ininjury or death to personnel in the event of an accident or machine overturn.

7. Fasten seat belt. Adjust belt so that it is snug across lap.8. Adjust seat.9. Adjust steering column tilt.

TM 5-3805-291-10


0005 00-3

STARTING ENGINE 0005 00

WARNING• DO NOT operate engine in enclosed areas due to the dangers of carbon monoxide poisoning from exhaust

fumes. Always start and operate engine in a well-ventilated area and, if in an enclosed area, vent exhaust to theoutside. Failure to follow this warning may cause injury or death to personnel.

• BE ALERT for personnel in the area while operating machine. Always check to ensure area is clear ofpersonnel and obstructions before starting engine. Failure to follow this warning may result in injury or deathto personnel.

• Hearing protection is required if within 20 ft (6 m) of an operating machine. Hearing protection is alsorequired if operating machine without ROPS/FOPS during transport procedures. Failure to wear hearingprotection may cause hearing loss.

NOTETo start engine in temperatures from -25 F to -40 F (-32 C to -40 C), refer to WP 0006 00.

1. Ensure equipment is lowered to the ground.2. Ensure transmission controls are in N (NEUTRAL).3. Ensure parking brake is engaged.4. Ensure hydraulic control levers are in HOLD position.5. Ensure all accessories are off.

WARNINGStand clear of frame articulation area when machine is operating. There is no clearance for personnel inthis area when machine turns. Crushing could occur, resulting in injury or death to personnel.

6. Ensure all personnel are clear of machine.7. Turn engine start switch to ON position.8. Pause for 15 seconds to allow auto-diagnostics and secondary steering system self-check to cycle.

TM 5-3805-291-10


0005 00-4

STARTING ENGINE - CONTINUED 0005 00

WARNINGNEVER use aerosol engine starting aids. Failure to follow this warning may cause an explosion, resulting ininjury or death to personnel.

CAUTIONDO NOT crank starter motor for more than 30 seconds at a time. After 30 seconds, allow starter motor tocool for at least 2 minutes before attempting to start engine again. Excessive heating of starter motor mayresult in damage or premature starter failure.

NOTE• Ether injection, when ambient temperature is below 0 F (-18 C), is controlled automatically by engine

Electronic Control Module (ECM). Operator DOES NOT manually inject ether.

• DO NOT push down on throttle pedal.

9. Turn engine start switch to START to engage starter motor.

10. Release engine start switch when engine starts.

CAUTIONTurbocharger damage can result if engine rpm is not kept low until engine oil pressure is sufficient.

11. If low engine oil pressure alert indicator does not turn off within 10 seconds after engine starts, stop engine and performtroubleshooting (WP 0008 00).

12. After engine has started, proceed to Machine Warmup below.

MACHINE WARMUP 0005 00

1. Operate engine at idle for 5 minutes to warm up engine. If temperature is below 0°F (-18°C), allow engine to idle for 10minutes.

2. During warmup, monitor alert indicators and gages for any signs of abnormal temperatures or pressures. Shut downengine at the first sign of a problem.

3. To assist in hydraulic system warmup, operate steering and work tool hydraulic controls. Ensure that all are functioningproperly. Engage work tool hydraulic controls as follows:

a. Press bottom of hydraulic lockout (IMPLEMENT DISABLE) switch to unlock hydraulic controls.

b. Cycle hydraulic controls through all positions.

4. Continue to warm up machine as follows:

a. If temperature is greater than 32ºF (0ºC), warm up machine for a total of approximately 15 minutes.

b. If temperature is less than 32ºF (0ºC), warm up machine for a total of approximately 30 minutes.

c. If temperature is less than 0ºF (-18ºC) or if hydraulic functions are sluggish, additional time may be needed.

TM 5-3805-291-10


0005 00-5

OPERATING MACHINE 0005 00

WARNING• 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 topersonnel or damage to equipment.

• DO NOT allow riders on machine. Failure to follow this warning may result in injury or death to personnel.1. General Information.

a. Ensure that personnel are not working on or near machine before moving out.b. Keep machine under control at all times.c. Reduce engine speed when maneuvering in tight quarters or when going downhill.d. Select correct gear speed before starting down a grade. Use same gear speed as you would use to go uphill. DO

NOT change gears while going downhill.e. DO NOT allow engine to overspeed when going downhill. Use service brakes to control engine speed.f. When load will be pushing machine, i.e., when backing downhill with a load, put transmission control lever in

FIRST gear.2. Changing Direction and Speed.

a. Operator can change from low gear to high gear at full engine speed. b. Directional changes at full engine speed are also possible. However, when changing directions, it is best to reduce

engine speed and to brake machine.c. Keep a loaded bucket close to the ground.d. Stop machine, if necessary, to avoid an unstable machine.e. To change direction and speed, perform the following:

(1) Lower engine speed with throttle pedal.(2) Use service brakes to slow machine or to stop machine.(3) Move shifter or remote F/N/R switch to desired direction.(4) If transmission is in manual mode, rotate transmission control lever to desired speed.(5) Release service brakes.(6) Increase engine speed with throttle pedal.

TM 5-3805-291-10


0005 00-6

STEERING MACHINE 0005 00


1. Operator controls machine direction using steering wheel.


2. The loader is capable of 37-degree turns in either direction. Because machine articulates when turning, it is crucial thatpersonnel stand clear when machine is operating.

3. Avoid oversteering. Become familiar with steering characteristics of machine before attempting maneuvers in limitedspace.

4. In the event of primary steering system failure, primary steering failure alert indicator will light and action alarm willsound. Secondary steering electric pump will automatically come on, as will the secondary steering alert indicator. Per-form the following steps to bring machine to a safe stop:

a. Steer machine carefully to a safe location.

b. Stop machine and engage parking brake.

c. Shut down engine.

d. Troubleshoot malfunction.

e. DO NOT operate machine until problem has been corrected.

OPERATING ON SLOPES 0005 00

WARNINGDO NOT attempt to jump clear of a tipping machine. Machine tips faster than driver can jump free.Failure to follow this warning may result in injury or death to personnel.

1. Reduce engine speed when you maneuver in tight quarters or when you are going over a hill.

2. Select the necessary gear speed before you start downgrade. DO NOT change gears while you are going downhill.

3. When you go downgrade, use the same gear speed that would be used to go upgrade.

4. Always travel straight up and down slopes, never at an angle or perpendicular to slope. Remember that the danger of tip-ping is always present.

5. When traveling uphill or downhill with a loaded bucket, keep bucket on uphill side, as low as possible. If machine startsto slip or becomes unstable, lower bucket to ground and stop machine immediately.

6. DO NOT allow the engine to overspeed when you go downhill. Use the service brake pedal to reduce engine overspeedwhen you are going downhill.

TM 5-3805-291-10


0005 00-7

PARKING MACHINE 0005 00

1. Stopping Machine.

a. Choose a level surface to stop machine whenever possible.

b. Apply service brakes to stop machine.

c. Lower work tool to the ground and apply light downward pressure.

d. Move both transmission control lever and remote F/N/R switch to N (NEUTRAL).

WARNING

NEVER leave operator compartment without engaging parking brake. Failure to follow this warning mayresult in injury or death to personnel.

e. Engage parking brake.

2. Stopping Engine.

CAUTION

• Stopping engine immediately after it has been operating under a load can result in overheating andaccelerated wear of engine components.

• The following shutdown procedures allow engine to cool. This will prevent excessive temperatures inturbocharger center housing. Failure to shut down engine properly may cause premature engine failure.

a. Run engine at low idle for 5 minutes.

b. Turn off lights and accessories.

c. Turn engine start switch to OFF position.

d. Move all work tool hydraulic controls back and forth to relieve hydraulic system pressure.

e. Return all work tool hydraulic controls to HOLD position.

f. Press top of hydraulic lockout (IMPLEMENT DISABLE) switch to lock hydraulic controls.

3. Leaving Machine.

a. Inspect cab interior for debris. Remove debris.

WARNING

Use caution and maintain three-point contact at all times when dismounting machine. Failure to follow thiswarning may result in injury or death to personnel.

b. Dismount machine using grabhandles and ladder. Face machine when dismounting.

c. Turn battery disconnect switch to OFF position.

d. Secure machine against vandalism. Install all covers and vandalism protection locks.

e. Perform After operation PMCS (WP 0011 00 and WP 0012 00).

TM 5-3805-291-10


0005 00-8

STOPPING ENGINE IF AN ELECTRICAL MALFUNC-TION OCCURS 0005 00

1. Turn engine start switch to OFF position. 2. If engine does not stop, perform the following steps:

a. Locate emergency shutdown switch at left centerof machine.

b. Move switch upward to stop engine.3. Report problem to your supervisor. DO NOT operate

machine until problem has been corrected.

LOWERING LOADER ARM WITH ENGINE STOPPED 0005 00

WARNINGLoader arm can drop when lowering it with engine stopped. Keep all personnel away from loader arm droparea. Ensure no one is under or near frame articulation area. Failure to follow this warning may result ininjury or death to personnel.

1. Electrical Power Available/Pilot Supply ON/OFF Solenoid Operable.

a. If electrical power is available and pilot supply ON/OFF solenoid is operable, loader arm can be lowered by oper-ator from inside the cab.

b. To lower loader arm under these conditions, perform the following steps:

(1) Turn engine start switch to ON position.

(2) Press bottom of hydraulic lockout (IMPLEMENT DISABLE) switch to unlock hydraulic controls.

(3) Place loader control joystick in LOWER position.

(4) Move hydraulic lockout control to the locked position.

(5) Turn engine start switch to OFF position.

c. If engine has been off for more than 10 minutes but is operable, start engine, place loader control joystick inLOWER position, and lower loader arm.

d. If loader arm does not lower, pilot supply ON/OFF solenoid may be inoperable. Perform procedure for No Electri-cal Power/Pilot Supply ON/OFF Solenoid Inoperable on the next page.

427-C0013

TM 5-3805-291-10


0005 00-9

LOWERING LOADER ARM WITH ENGINE STOPPED - CONTINUED 0005 00

2. No Electrical Power/Pilot Supply ON/OFF Sole-noid Inoperable. a. If there is no electrical power or pilot supply ON/

OFF solenoid is inoperable, loader arm must belowered manually.

b. To lower loader arm manually, perform the fol-lowing steps on right side of machine:(1) Use adjustable wrench (Item 13, Table 2,

WP 0026 00) to turn square stem of ballvalve clockwise (to the right) 90 degrees.

(2) Loader arm will begin to lower whenball valve is open.

(3) After loader arm has lowered, turnsquare stem of ball valve counterclock-wise (to the left) 90 degrees to closevalve.

427-C1701

TM 5-3805-291-10


0005 00-10

RELIEVING HYDRAULIC SYSTEM PRESSURE 0005 00

WARNING• 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 fluidunder pressure can penetrate the skin, causing injury or death to personnel.

• At operating temperature, hydraulic oil is hot. Allow hydraulic oil to cool before disconnecting any hydrauliclines. Failure to follow this warning may result in injury to personnel.

• The accumulator is filled with dry nitrogen. DO NOT loosen or remove the valve or cap from the top of theaccumulator. Failure to follow this warning may result in injury to personnel.

• Never leave operator compartment without engaging parking brake. Failure to follow this warning may resultin injury or death to personnel.

1. Introduction.

a. Hydraulic oil can remain under pressure in hydraulic system even after engine has been shut down and hydraulicpump has stopped.

b. It is important to relieve this pressure before disconnecting any hydraulic line or performing hydraulic system ser-vice.

2. Relieving Hydraulic System Pressure.

a. Park machine on a level surface.

b. Lower work tool to the ground.

c. Engage parking brake.

d. If locked, press bottom of hydraulic lockout (IMPLEMENT DISABLE) switch to unlock hydraulic controls.

CAUTION

Stopping engine immediately after it has been operating under a load can result in overheating andaccelerated wear of engine components. Refer to page 0005 00-7.

e. Shut down engine.

f. Depress brake pedals repeatedly. This will relieve pressure in brake hydraulic system.

g. Turn engine start switch to ON position without starting engine.

h. Move loader controls through all positions to relieve pressure in implement hydraulic system.

i. Turn steering wheel several times in both directions to relieve pressure in steering hydraulic system.

j. Turn engine start switch to OFF position.

TM 5-3805-291-10


0005 00-11

RELIEVING HYDRAULIC SYSTEM PRESSURE - CONTINUED

k. To relieve pressure in hydraulic tank, performthe following steps:(1) Locate hydraulic tank breather relief

valve on top of hydraulic tank behindcab.

(2) Press button on top of hydraulic tankbreaker relief valve.

QUICK COUPLER OPERATION 0005 00

1. Introduction.

a. The quick coupler design allows operator, with-out assistance, to connect loader to work tools.

b. The rotary sweeper and forklift pallet forks alsorequire hydraulic connections for its operation.

c. The following instructions apply to quick cou-pler engagement to all 966H work tools.

2. Engaging Quick Coupler to Work Tool.

WARNINGBefore engaging quick coupler to worktool, use extreme caution to ensure worktool is in a safe and stable positionbefore proceeding. Work tool mustNOT be loaded. All personnel muststand clear. Failure to follow this warn-ing may result in injury or death to per-sonnel or damage to equipment.

a. If pins on quick coupler are in engaged (locked)position, press top of quick coupler controlswitch. This disengages (unlocks) quick couplerpins.

b. Tilt quick coupler forward. Ensure it is loweredsufficiently below level of hooks on work tool.

427-C0015

427-C0361

TM 5-3805-291-10


0005 00-12

QUICK COUPLER OPERATION - CONTINUED

c. Drive machine slowly forward. Steer machine toalign quick coupler with hooks on work tool.

d. Slightly raise quick coupler, until quick couplercontacts hooks on work tool and work tool islifted up slightly. Ensure work tool is level fromside to side.

e. Tilt quick coupler all the way back to allow worktool lower attaching points to rest against quickcoupler stops.

f. Press bottom of quick coupler control switch toengage (lock) quick coupler pins into retainerholes of work tool.

g. To check for correct engagement of quick cou-pler to work tool, perform the following steps:(1) Tilt work tool forward onto ground and

apply slight downward pressure.(2) Slowly back up machine.(3) If there is movement between work tool

and quick coupler, then locking pins arenot engaged. Retract pins and repeat pro-cedure.

WARNINGDO NOT disconnect or remove anyhydraulic system line or fitting unlessengine is shut down and hydraulic sys-tem pressure has been relieved. Tightenall connections before applying pres-sure. Escaping hydraulic fluid underpressure can penetrate the skin, causinginjury or death to personnel.

h. If engaging quick coupler to rotary sweeper orforklift, relieve hydraulic system pressure. Referto Relieving Hydraulic System Pressure earlier inthis work package.

i. Remove protective caps from two quick discon-nect fittings on quick coupler.

j. Remove two protective plugs from quick discon-nect fittings of sweeper, or two protective capsfrom forklift.

k. Fasten caps together.

427-C0361

427-C0363

TM 5-3805-291-10


0005 00-13


CAUTIONWipe area clean around all hydraulic connections to be opened during procedure. Contamination ofhydraulic system could result in premature failure.

l. Use a rag (Item 13, WP 0027 00) to remove anyforeign material from quick disconnect fittings.

m. Connect hydraulic lines from sweeper or forklift to fittings of quick coupler.

NOTEThe following step is for sweeper.

n. Remove locking pin and pin, raise up leg and reinstall pin and locking pin. Repeat for other side.

3. Disengaging Quick Coupler from Work Tool.

WARNINGBefore disengaging quick coupler from work tool, use extreme caution to ensure work tool is in a safe andstable position before proceeding. Work tool must NOT be loaded. All personnel must stand clear. Failureto follow this warning may result in injury or death to personnel or damage to equipment.

a. If work tool is loaded, unload work tool.

b. Lower work tool to the ground and place so that it is stable.

427-C0364

TM 5-3805-291-10


0005 00-14


WARNINGDO NOT disconnect or remove any hydraulic system line or fitting unless engine is shut down andhydraulic system pressure has been relieved. Tighten all connections before applying pressure. Escapinghydraulic fluid under pressure can penetrate the skin, causing injury or death to personnel.

c. If disengaging quick coupler from rotary sweeper, relieve hydraulic system pressure before proceeding. Refer toRelieving Hydraulic System Pressure earlier in this work package.

CAUTIONWipe area clean around all hydraulic connections to be opened during procedure. Contamination ofhydraulic system could result in premature failure.

d. Use a rag (Item 13, WP 0027 00) to remove anyforeign material from quick disconnect fittings.

e. Disconnect quick disconnect fittings of sweeperor forklift hydraulic lines from quick disconnectfittings at quick coupler.

f. Install protective caps or plugs on all four quickdisconnect fittings.

g. Press top of quick coupler control switch to disengage (unlock) quick coupler pins from work tool.h. Tilt quick coupler forward while backing away from work tool.

427-C0361

TM 5-3805-291-10


0005 00-15

OPERATING WORK TOOLS 0005 00

WARNING• BE ALERT for personnel in the area while operating machine with work tools. Always check to ensure area is

clear of personnel and obstructions before moving. Failure to follow this warning may result in injury ordeath to personnel or damage to equipment.

• Always use a ground guide when driving machine with work tools if visibility is impaired. Failure to use aground guide may cause injury or death to personnel or damage to equipment.

• DO NOT perform excavating, loading, or digging tasks without ROPS/FOPS installed. Machine has norollover/falling object protection without ROPS/FOPS. Failure to follow this warning may cause injury ordeath to personnel or damage to equipment.

1. Introduction. a. Survey work site before operation to become familiar with job requirements and ground conditions. b. Be alert for personnel in the area. Ensure work area is clear of personnel before proceeding.c. When operating work tool, keep cab doors closed.

2. Automatic Lift Kickout. The joystick control is detented in the fully raised position. When the joystick is pulled back into the soft detent, theoperator will feel an increased resistance from the joystick. Once in the detent, the joystick should be released in order toautomatically return to the HOLD position. The attachment will continue to rise until the attachment reaches the liftkickout height. In order to manually override the detent, the joystick must be moved at least 6 degrees from the HOLDposition. The detent will not be activated if the joystick is held in the detent position for more than 1 second.

3. Return to Work. The joystick control is detented in the FLOAT position. When the joystick is pushed forward into the soft detent, theoperator will feel an increased resistance from the joystick. Once in the detent position, the joystick should be releasedin order to automatically return to the HOLD position. The attachment will continue to lower until the attachmentreaches the kickout height. In order to manually override the detent, the joystick must be moved at least 6 degrees fromthe HOLD position. The detent will not be activated if the joystick is held in the detent position for more than 1 second.

NOTEIf the attachment is greater than 12 in. (30.5 cm) from the lower kickout position, a lower kickout will occurwhen the joystick control is placed in the FLOAT position. If the attachment is less than 12 in. (30.5 cm)from the lower kickout position, then placing the lift control lever in the float detent will cause theattachment to float to the ground.

4. Operating GP Bucket and Rock Bucket.

NOTERefer to WP 0004 00 for operation of loader control joystick, including detents for automatic lift kickout,tilt (return to work) kickout, and return to carry kickout positions.

a. Ensure machine hydraulic controls are unlocked.b. Press bottom of fork/bucket control switch, to activate tilt kickout for bucket.c. Press top of kickout ON/OFF switch to activate lift, tilt (return to work), and return to carry kickouts.d. Ensure machine is properly adjusted to allow efficient loading and dumping. e. To ensure efficient transmission operation during loading, and to maximize amount of bucket fill, move autoshift

control switch to middle position for automatic mode.f. Keep transmission control lever in N (NEUTRAL). Rotate lever to appropriate gear speed; 3rd gear is a good

choice.

TM 5-3805-291-10


0005 00-16

OPERATING WORK TOOLS - CONTINUED 0005 00

g. To provide simultaneous control of machine hydraulics while changing direction of travel, use remote F/N/Rswitch on loader control joystick to operate transmission.

h. Approach pile of material to be loaded and fully lower bucket to correct dig height.

i. Drive straight into pile, with bucket fully lowered at correct dig height. Enter pile of material at the toe.

j. When more power is required, press and hold downshift switch on loader control joystick. This will cause trans-mission to downshift automatically.

k. Go as far as possible into pile, with bucket fully lowered, until loader meets increased resistance as bucket is fill-ing.

NOTERaising bucket while driving into pile improves traction by transferring weight to loader front tires.

l. Begin to raise bucket and continue to drive into pile.

m. While still driving into pile, begin to tilt load backward while continuing to raise load.

n. When load is fully tilted (“racked”), move transmission into R (REVERSE) and back away from pile. Transmis-sion will be in 2nd gear.

5. Spreading a Load with GP Bucket. Dump load while moving machine slowly forward or in reverse, as needed.

6. Operating Rotary Sweeper.

The continuous flow control switch supplies continuous flow of hydraulic fluid to the auxiliary hydraulic circuit (forrotary sweeper operations) without continuously holding the auxiliary hydraulic control (thumb wheel [1]).

a. Move thumb wheel (1) for the auxiliary control to the desired flow rate.

b. Press and hold the continuous flow switch (2).

c. Release the thumb wheel (1) after you release the continuous flow switch (2). The continuous flow function willnot be activated if the operator does not release the thumb wheel within 1 second of releasing the continuous flowswitch.

d. Move the thumb wheel (1) or the continuous flow switch (2) in order to stop the flow to the auxiliary hydraulic cir-cuit.

427-C0475

TM 5-3805-291-10


0005 00-17/(0005 00-18 Blank)

OPERATING WORK TOOLS - CONTINUED

7. Operating Forklift Pallet Forks. a. Move slowly into position, with forks fully lowered and centered square with pallet.b. Move forks as far apart as possible to provide improved load support. Space forks evenly between pallet stringers.c. Drive forward slowly to fully engage forks into pallet.d. Raise and tilt backward as needed to secure load.e. Travel to unload area with load at carry weight.f. If hauling a bulky load that impairs visibility, travel in reverse. Use a ground guide.g. At unload area, lower forks slowly and tilt forward, until pallet is resting on the ground.h. Back carefully away from pallet. Be alert for personnel or obstructions in the area.

PORTABLE FIRE EXTINGUISHER OPERATION 0005 00

WARNINGDischarging large quantities of dry chemical fire extinguisher inside an enclosed cab may result intemporary breathing difficulty during and immediately after the discharge event. Discharge fireextinguisher from outside the cab. Ventilate cab thoroughly prior to reentry. Failure to follow this warningmay cause injury to personnel.

1. Remove fire extinguisher from mounting bracket inside cab.2. Hold fire extinguisher upright. Stand back 8 ft (2.4 m) from fire, point nozzle toward base of fire, break seal, and pull

safety pin.3. Squeeze lever, discharging chemical at base of fire. Use a side-to-side motion to spread chemical.4. After using fire extinguisher, notify Unit Maintenance to have fire extinguisher recharged.

END OF WORK PACKAGE

TM 5-3805-291-10

0006 00-1

OPERATION UNDER UNUSUAL CONDITIONS 0006 00


IntroductionSlave Starting MachineTowing MachineRecovery Procedure - Loader Arms Down on Dead

MachineManually Disconnect Quick CouplerParking Brake Manual ReleaseOperation in Extreme ColdArctic Cold Weather Starting Aid System

Operation in Extreme Heat

Operation in Saltwater Areas

Operation in Mud or Soft Surfaces

Operation in Sandy or Dusty Conditions

Operation at High Altitudes

Operation in Snow and Ice

Fording

Sorbent Decontamination System (SDS), M100

INITIAL SETUP

Tools and Special Tools

Wrench, adjustable (Item 13, Table 2, WP 0026 00)

References

FM 9-207

FM 21-305

FM 3-11.3

FM 3-11.5

FM 31-70

FM 31-71

FM 90-3

References - ContinuedTM 3-4230-236-10WP 0004 00WP 0005 00WP 0008 00WP 0011 00WP 0012 00WP 0013 00WP 0014 00WP 0015 00WP 0025 00

INTRODUCTION

1. This work package contains instructions for safely operating the 966H Wheel Loader under unusual conditions.2. In addition to normal preventive maintenance, special care must be taken to keep machine operational in extreme tem-

peratures and other environmental conditions.

14

TM 5-3805-291-10

OPERATION UNDER UNUSUAL CONDITIONS - CONTINUED 0006 00

0006 00-2

SLAVE STARTING MACHINE 0006 00

WARNINGWhen slave starting machine:

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

• DO NOT proceed if suitable cable is not available.

• DO NOT use civilian-type jumper cables.

• DO NOT allow “dead” and “live” machines to come in contact with each other at any time during slavestarting.

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

CAUTION

Under no circumstances can machine be started by being towed or pushed. Failure to follow this cautionwill damage transmission.

NOTE

If machine other than another 966H is used to slave start loader, refer to Operator’s Manual for thatmachine for any special slave starting procedures.

1. Ensure battery disconnect switch is in OFF position on “dead” and “live” machines.

2. Ensure transmission on “dead” machine is in N (NEUTRAL).

3. Engage hydraulic lockout control on “dead” machine.

NOTE

NATO slave receptacle is located near the battery on the left side of machine.

4. Remove cover and connect NATO slave cable to receptacle on “dead” machine.

5. Remove cover and connect other end of NATO slave cable to receptacle on “live” machine.

6. Place battery disconnect switch on “dead” machine to ON position.

7. Start engine of “live” machine and run at a speed just above idle.

8. Allow “live” machine to run for approximately 2 minutes to charge batteries on “dead” machine.

9. Start engine of “dead” machine (WP 0005 00). If engine on “dead” machine fails to start, notify Unit Maintenance.

10. Disconnect NATO slave cable from “live” machine, then from “dead” machine.

11. Install covers.

TM 5-3805-291-10


0006 00-3

TOWING MACHINE 0006 00

WARNINGEnsure proper towing procedures are followed when towing machine:

• When attaching towing connections, carefully move towing machine into position. Always use a ground guideand DO NOT stand directly between machines.

• DO NOT tow faster than 2 mph (3 kph).• DO NOT allow operator on machine unless operator can control steering and/or brakes.• When drive shafts are removed, machine has NO parking or secondary brakes. To prevent machine from

rolling, wheels must be blocked securely. Failure to follow this warning may cause injury or death topersonnel.

• Always block wheels before removing axle shafts or disengaging parking brake.Failure to follow proper towing procedures may cause injury or death to personnel or damage toequipment.

1. General Instructions.

a. These instructions are for towing machine for a short distance of less than 5 miles (8 km) at low speed, no morethan 2 mph (3 kph).

b. These instructions are for emergencies only.

c. Always transport machine if longer distance moving is required.

d. Normally, towing machine should be as large as towed machine. Towing machine must have sufficient brakecapacity, weight, and power to do the job. Towing machine must be able to control both machines for the grade anddistance that is involved.

e. As required by grade and towing conditions, additional towing machines may be used.

f. If towed machine is loaded, it MUST be equipped with operational brakes.

g. Always block machine wheels before preparing for towing.

h. Do not allow operator on machine during towing unless operator can control steering and/or brakes.

i. Place an observer in a safe position in order to watch towing procedure. Towing must stop if towing machinemoves without moving disabled machine.

TM 5-3805-291-10


0006 00-4

TOWING MACHINE - CONTINUED 0006 00

WARNINGDO NOT return to service a machine that has been towed without first ensuring that all necessary repairsand adjustments have been performed. Failure to do so could result in injury to personnel or damage toequipment.

j. Before returning machine to service, ensure all necessary repairs and adjustments have been performed.2. Towing Machine With Engine Running.

a. Machine can be towed for a short distance if powertrain and steering system are operational.b. Tow for a short distance in order to pull machine out of mud or to side of road.c. Operator on towed machine must steer machine in the direction of the tow line.d. Follow general instructions as outlined above.

3. Towing Machine With Engine Stopped.

NOTEAssistance from Unit Maintenance is required.

a. Block wheels of disabled machine.

NOTEEnsure that steering cylinder hoses are connected correctly by Unit Maintenance before resuming machineoperation. With hose connections reversed, steering system will not function.

b. Notify Unit Maintenance to reverse hose connec-tions on one steering cylinder only. This willallow steering cylinders to move freely:(1) Disconnect hose from fitting on head

end of steering cylinder.(2) Disconnect hose from fitting on rod end

of steering cylinder.(3) Reconnect hose for rod end to fitting on

head end of steering cylinder.(4) Reconnect hose for head end to fitting on

rod end of steering cylinder.

WARNINGWhen drive shafts are removed, machine has NO parking or secondary brakes. To prevent machine fromrolling, wheels must be blocked securely. Failure to follow this warning may cause injury or death topersonnel.

c. If failure of internal transmission or drive line is suspected, notify Unit Maintenance to remove center and reardrive shafts.

d. Manually release parking brake on disabled machine. Refer to Parking Brake Manual Release later in this workpackage.

e. Notify Unit Maintenance to inspect machine for powertrain damage.

427-C0009

TM 5-3805-291-10


0006 00-5

TOWING MACHINE - CONTINUED 0006 00

WARNINGCarefully move towing machines into position. Always use a ground guide and DO NOT stand directlybetween machines. Failure to follow this warning may result in injury or death to personnel.

f. Remove blocks from wheels.g. Tow machine at low speed. DO NOT exceed 2 mph (3 kph).

RECOVERY PROCEDURE - LOADER ARMS DOWN ON DEAD MACHINE 0006 00

1. Use adjustable wrench (Item 13, Table 2, WP 0026 00)to turn square stem on top of ball valve clockwise (tothe right) 90 degrees.

2. Lift loader arms using another machine. Once loaderarms are raised sufficiently to tow dead machine,restrain loader arms to frame using chains or come-along.

3. Turn square step of ball valve counterclockwise (tothe left) 90 degrees to close valve.

4. Dead machine can now be towed.

MANUALLY DISCONNECT QUICK COUPLER 0006 00

1. Use adjustable wrench (Item 13, Table 2, WP 0026 00)to remove two bolts and washers from hydraulic door.Open door.

2. Use adjustable wrench to turn square stem on top ofball valve clockwise (to the right) 90 degrees.

3. The quick coupler pins can now be manually movedout.

4. Use adjustable wrench to turn square stem on top ofball valve counterclockwise (to the left) 90 degrees.

5. Close hydraulic system access door and install twowashers and bolts.

427-C1701

427-C0014

TM 5-3805-291-10


0006 00-6

PARKING BRAKE MANUAL RELEASE 0006 00

1. The machine is equipped with spring-applied, oil-pressure-released parking brakes.2. If engine or brake oil system is not operating, parking brake is applied and machine will not move.3. Perform the following steps to manually release parking brake:

WARNINGEnsure wheels are blocked before manually releasing parking brake. Failure to follow this warning mayresult in machine rolling, causing injury or death to personnel or damage to equipment.

a. Block wheels of disabled machine.

WARNINGConnect steering frame lock between front and rear frames before lifting, transporting, or servicingmachine in frame articulation area. Disconnect steering frame lock and secure in stowed position beforeresuming operation. DO NOT operate machine with steering frame lock connected. Failure to follow thiswarning may result in injury or death to personnel or damage to equipment.

b. Connect steering frame lock (WP 0015 00).c. Locate parking brake actuator mounted in middle of front frame above front drive shaft.d. Use an adjustable wrench (Item 13, Table 2, WP 0026 00) to loosen locknut by 3/4 in. (19 mm).e. Turn rod until rod moves out of actuator enough to totally release parking brake.

f. Disconnect and stow steering frame lock (WP 0015 00), then move disabled machine as needed.

CAUTIONEnsure parking brake is serviced and adjusted by Unit Maintenance before resuming machine operation.Failure to do so could damage parking brake components or prevent parking brake from functioningproperly.

g. When parking machine, connect steering frame lock (WP 0015 00), then fully tighten locknut on rod to engageparking brake.

427-C2056

TM 5-3805-291-10


0006 00-7

OPERATION IN EXTREME COLD 0006 00

NOTERefer to FM 9-207, Operation and Maintenance of Ordnance Materiel in Cold Weather, FM 31-70, Basic ColdWeather Manual, and FM 31-71, Northern Operations, for additional information on cold weather operationand maintenance.

1. General. Extreme cold causes many problems:a. Lubricants thicken or congeal.b. Batteries may freeze or lose their electrical efficiency.c. Electrical insulation may crack and cause short circuits.d. Fuel may not readily atomize for combustion.e. Various materials become hard, brittle, and easily damaged.f. Cooling system requires adequate protection from extreme cold.g. Fuels, lubricants, and antifreeze compounds require special storage, handling, and use.

2. Cooling System.

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

escaping steam or hot coolant will cause serious burns.• DO NOT remove cooling system radiator cap when engine is hot. Allow engine to cool down.

Loosen cap to first stop and let any pressure out of cooling system, then remove cap. Failure tofollow this warning may cause serious burns.

• Wear effective eye, glove, and skin protection when handling coolants. Failure to follow thiswarning may cause injury to personnel.

a. Inspect for leaks and general condition.b. Ensure hose clamps are tight.c. Check coolant level in sight gage at top of radiator tank. If necessary, add coolant to correct level (WP 0012 00).d. Notify Unit Maintenance if system needs service beyond adding coolant.

TM 5-3805-291-10


0006 00-8

OPERATION IN EXTREME COLD - CONTINUED

3. Fuel System.

WARNING• DO NOT smoke or permit any open flame in area of machine while you are servicing fuel system. Be sure hose

nozzle is grounded against filler tube during refueling to prevent static electricity. Failure to follow thiswarning may result in injury or death to personnel, or damage to equipment.

• Operating personnel must wear fuel-resistant gloves when handling fuels. If exposed to fuel, promptly washexposed skin and change fuel-soaked clothing.

• ALWAYS stop engine prior to refueling. If equipped with an arctic cold weather starting aid system, turnarctic heater off.

a. Do not allow fuel tank to remain partially empty in extremely cold weather. Fill fuel tank after each work period tohelp avoid water condensation in tank (WP 0013 00).

b. Remove all ice and snow from around fuel filler opening before refueling.

c. Regularly drain water and sediment from fuel/water separator.

4. Electrical System.

a. Inspect battery cables, wiring harnesses, and wiring.

b. Check for breaks or cracks caused by cold weather. Report any problems found to Unit Maintenance.

c. Save batteries. Use lights and other electrical equipment as little as possible when engine is not running.

5. Lubrication.

Use lubricants as specified at the end of PMCS (WP 0012 00) with the temperature range that applies to the lowestexpected ambient temperature.

6. Engine Operation.

a. Machines operating in arctic conditions, from -25�F to -40�F (-32�C to -40�C), are equipped with an arctic coldweather starting aid system. Refer to Arctic Cold Weather Starting Aid System on the next page for engine startingprocedures.

b. Before starting, ensure fuel and oil in engine and transmission are thin enough to flow.

c. If oil drips from engine oil level dipstick, oil is thin enough for engine to be started.

CAUTIONLow idling speeds during extremely cold temperatures can result in incomplete combustion and heavydeposit formations on valves. These deposits can cause burned valves, bent pushrods, or other damage tovalve components.

d. After engine has started, allow engine time to reach operating temperature. Run engine at reduced speed only longenough to circulate oil through engine. Then increase engine speed and warm up engine.

e. Cover radiator, if necessary, to bring engine up to operating temperature.

TM 5-3805-291-10


0006 00-9

OPERATION IN EXTREME COLD - CONTINUED

7. Machine Operation.

a. When moving out, be alert that tires may be frozen to ground.

b. Test brakes and machine controls carefully.

c. Move all hydraulic controls slowly to warm hydraulic oil. Cycle each control several times. Normal warmupperiod in extreme cold is 30 minutes.

d. Operate under a light load for the first 5 minutes of operation.

e. Start driving very slowly for about 100 yd (91.4 m). If a problem is noted, notify Unit Maintenance as required.

8. Parking Machine.

a. If machine will be parked for a short period, park in a sheltered area out of wind. If shelter is not available, parkmachine so that radiator does not face into wind.

b. If machine will be parked for a long shutdown period, try to park on high ground. Keep tires out of snow, water,ice, and mud, if possible.

c. Clean snow, ice, and mud from engine compartment, hydraulic cylinders, wheels, and work tool as soon as possi-ble after shutdown.

d. If machine will be parked for a long period of time, notify Unit Maintenance to prepare machine for storage.

e. Ensure tires are properly inflated.

ARCTIC COLD WEATHER STARTING AID SYSTEM 0006 00

1. General.

a. Machines that operate in extremely cold weather, from -25�F to -40�F (-32�C to -40�C), are factory equipped withan arctic cold weather starting aid system which includes:

(1) A diesel-fired arctic heater, mounted on left-rear of machine.

(2) Two additional batteries (1,000 CCA each).

WARNING

Use of an arctic heater requires that coolant in system to be heated contains a proper mixture of water andantifreeze to prevent coolant from freezing or slushing. If coolant freezes or slushes, coolant pump cannotmove coolant, causing blockage in circulating system. Pressure build-up in arctic heater can cause coolanthose at heater connection to burst or blow off. Injury to personnel or damage to engine could result.

b. Extreme care should be taken to ensure a proper mixture of water and antifreeze is used in engine cooling system(WP 0012 00).

c. Engine starting procedures for the arctic operation machine are the same as for the standard machine, except thatarctic heater must first be operated to preheat engine coolant.

TM 5-3805-291-10


0006 00-10

ARCTIC COLD WEATHER STARTING AID SYSTEM - CONTINUED 0006 00

2. Arctic Heater Operation.

WARNINGDO NOT operate arctic heater in enclosed areas due to the dangers of carbon monoxide poisoning fromexhaust fumes. Always start and operate heater in a well-ventilated area and, if in an enclosed area, ventexhaust to the outside. Failure to follow this warning may cause injury or death to personnel.

a. Press arctic heater switch, located at right side of operator seat, to turn heater ON. Lamp inside switch will turn onwhen system is operating.

b. Allow arctic heater to operate for 30 minutes.

c. Press switch again to turn arctic heater OFF.d. Wait until lamp inside switch turns off (at least 3

minutes). This indicates that heater shut-downprocedure has finished.

CAUTIONDO NOT operate starter for more than60 seconds when in extreme cold tem-perature. Doing so could cause starterdamage.

e. Start engine (WP 0005 00).

OPERATION IN EXTREME HEAT 0006 00

CAUTIONDuring very hot weather, operating procedures may require altering to prevent machine overheating.Avoid continuous high engine rpm.

NOTERefer to FM 90-3, Desert Operations.

1. Driving Machine. a. Keep a close eye on machine alert indicators and coolant, transmission, and hydraulic temperature gages.

b. If alert indicators signal an alert or if a temperature gage reads unusually high, stop and perform troubleshooting(WP 0008 00).

c. If indicators stay on after more than 10 minutes of reduced workload, stop machine and notify Unit Maintenance.

TM 5-3805-291-10


0006 00-11

OPERATION IN EXTREME HEAT - CONTINUED 0006 00

2. Cooling System.


escaping steam or hot coolant will cause serious burns.

• DO NOT remove cooling system radiator cap when engine is hot. Allow engine to cool down.Loosen cap to first stop and let any pressure out of cooling system, then remove cap. Failure tofollow this warning may cause serious burns.


a. Check coolant level at frequent intervals and keep radiator cap tight (WP 0012 00). Add coolant, if necessary (WP0012 00).

b. Be sure radiator is free of bugs, dust, and other foreign matter.

c. Report a damaged or loose serpentine belt to Unit Maintenance.

3. Lubrication.

a. Use lubricants according to PMCS (WP 0012 00) with the temperature range that applies to the highest expectedambient temperature.

b. Notify Unit Maintenance to shorten differential and final drive oil change interval.

4. Air Cleaner.

WARNING• If NBC exposure is suspected, personnel wearing protective equipment must handle all air cleaner media.

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

• Refer to FM 3-11.3, Multiservice Tactics, Techniques, and Procedures for Chemical, Biological,Radiological, and Nuclear Contamination Avoidance, and FM 3-11.5, Multiservice Tactics, Techniques, andProcedures for Chemical, Biological, Radiological, and Nuclear Decontamination.

• NBC contaminated filters must be handled using adequate precautions and must be disposed of by trainedpersonnel.


a. Check air cleaner service indicator frequently (WP 0004 00).

b. Service air cleaner as necessary (WP 0014 00).

5. Parking Machine.

a. Park machine under cover, if possible.

b. Ensure all tires are inflated to proper pressure (WP 0012 00).

c. Check frequently for rust. Clean and lubricate machine to help prevent deterioration (WP 0012 00).

TM 5-3805-291-10


0006 00-12

OPERATION IN SALTWATER AREAS 0006 00

1. Keep machine as clean as possible. Wash down with fresh water after use.

2. Inspect wiring connections closely for corrosion.

3. Keep lubrication points clean and well lubricated.

OPERATION IN MUD OR SOFT SURFACES 0006 00

1. Before entering mud or other soft surfaces, check conditions. Select appropriate transmission gear range. Enter soft areaat a medium speed for gear range selected.

2. Maintain steady pressure on throttle pedal to keep machine rolling until solid ground is reached. Do not accelerate to thepoint where wheels spin, if possible.

3. Notify Unit Maintenance to clean and inspect for proper lubrication.

OPERATION IN SANDY OR DUSTY CONDITIONS 0006 00

NOTERefer to FM 90-3, Desert Operations.

1. Maintain steady, even movement with transmission in lower gears. Try to keep machine rolling without straining engineand powertrain. If machine gets stuck, notify Unit Maintenance.






2. Whenever operating in sandy or dusty areas, you should:

a. Service engine air cleaner more frequently.

b. Ensure each tire has a valve cap.

c. If machine overheats, stop and perform troubleshooting procedures.

d. Ensure engine and transmission dipsticks and oil filler caps are cleaned before they are removed to check fluid lev-els. Clean accumulations of sand and dirt from around fluid filler locations before checking or adding fluids.

e. Clean spouts of fuel containers and area around filler cap on fuel tank before adding fuel. Under extremely sandyor dusty conditions, filter fuel when filling tank.

f. Notify Unit Maintenance to clean, inspect, and lubricate more frequently.

g. When operating the machine on soft sand at slow speeds, tire inflation pressure may be decreased for improvedtraction. Refer to FM 21-305, Manual for the Wheeled Vehicle Driver.

h. Check hydraulic cylinders frequently. Do not allow dust, dirt, or sand to collect on cylinder rods.

TM 5-3805-291-10


0006 00-13

OPERATION AT HIGH ALTITUDES 0006 00


escaping steam or hot coolant will cause serious burns.• DO NOT remove cooling system radiator cap when engine is hot. Allow engine to cool down.

Loosen cap to first stop and let any pressure out of cooling system, then remove cap. Failure tofollow this warning may cause serious burns.


NOTEEngine operates at less than peak performance at high altitudes.

1. Coolant level and engine indicators must be watched closely.

2. Add coolant, if necessary (WP 0012 00).

OPERATION IN SNOW AND ICE 0006 00

1. General.




• ALWAYS stop engine prior to refueling. If equipped with an arctic cold weather starting aid system, turnarctic heater off.

a. Fuel tank should be kept full. Keep snow and ice away from fuel filler.

b. Clean snow away from windshields and lights.

2. Driving.

a. Accelerate slowly to avoid spinning tires.

b. Drive at slower speeds.

c. Give signals sooner.

d. Apply brakes sooner to give early warning of intention to stop. This will also help to avoid skidding.

e. Maintain double the normal distance from the machine ahead.

f. Keep windshields and lights clean and free of snow and ice.

g. If approaching a difficult stretch of road, stop and inspect road carefully before driving on it.

h. Select transmission gear range that best suits road condition.

TM 5-3805-291-10


0006 00-14

OPERATION IN SNOW AND ICE - CONTINUED

3. Stopping.

a. Ease up on throttle pedal, leaving machine in gear.

b. Apply service brakes lightly and evenly. DO NOT pump service brake pedals.

c. Always avoid sudden braking.

FORDING 0006 00

CAUTIONDo not exceed maximum fording depth as damage to equipment may occur.

1. Maximum fording depth is 30 in. (76 cm).

2. Before fording, ensure engine is operating properly and all indicators are indicating normal operating pressures and tem-peratures.

3. Raise loader arm to 6 to 12 in. (15.2 to 30.5 cm) above surface of water.

4. Place transmission in 1st gear and enter water slowly. Fording speed should not exceed 3 to 4 mph (5 to 6 kph).

5. After fording, wash machine with fresh water, if available.

6. Allow engine to run for awhile to dry out any accumulated water.

7. Drain and dry any area where water has accumulated.

8. Test service brakes after fording by operating brake system.

9. Perform PMCS as soon as possible (WP 0011 00 and WP 0012 00).

SORBENT DECONTAMINATION SYSTEM (SDS), M100 0006 00

The SDS mounting bracket shall be installed in an upright position in a manner which shall not interfere with the normaloperation of the equipment and shall be accessible to personnel on the ground. The SDS fits into a 3-1/4-inch x 6-inch x 14-1/2-inch container and weighs less than 5 lb. The SDS is designed to operate at temperatures between -25 and 120 degreesFahrenheit. Refer to TM 3-4230-236-10 for instructions on the use of SDS.

END OF WORK PACKAGE

427-C1706

TM 5-3805-291-10

0007 00-1

STOWAGE AND DECAL, DATA PLATE, AND STENCIL GUIDE 0007 00

INTRODUCTION

1. This work package provides the location of the BII (refer to WP 0026 00).2. This work package also shows the location of all decals, data plates, and stencils. Some are located inside access panels

or doors.

NOMENCLATURE QTY STOWAGE LOCATION

Cord, Elastic 1 In BII box located on left side of machine

Extension: 6 in. 1 In BII box located on left side of machine

Extension: 12 in. 1 In BII box located on left side of machine

Extinguisher, Fire 1 In BII box located on left side of machine

Lubricating Gun, Hand 1 In BII box located on left side of machine

Plug, Electrical Cap 4 In BII box located on left side of machine

Plug-Connector, Electrical Cap for Harness 4 In BII box located on left side of machine

Ratchet 1 In BII box located on left side of machine

Socket: 11 mm 1 In BII box located on left side of machine

Tarpaulin: 12 ft. x 14 ft. 1 In BII box located on left side of machine

Tire Gage 1 In BII box located on left side of machine

Tool Bag 1 In BII box located on left side of machine

Wrench, Adjustable 1 In BII box located on left side of machine

12

TM 5-3805-291-10

STOWAGE AND DECAL, DATA PLATE, AND STENCIL GUIDE - CONTINUED 0007 00

0007 00-2

DECALS 0007 00

427-C1562

TM 5-3805-291-10


0007 00-3

DECALS - CONTINUED 0007 00

427-C1563

TM 5-3805-291-10


0007 00-4


427-C1564

TM 5-3805-291-10


0007 00-5


427-C1565

TM 5-3805-291-10


0007 00-6


427-C2041

TM 5-3805-291-10


0007 00-7

DATA PLATES 0007 00

427-C1566

TM 5-3805-291-10


0007 00-8

DATA PLATES - CONTINUED 0007 00

427-C1567

427-C1568

TM 5-3805-291-10


0007 00-9

STENCILS 0007 00

TM 5-3805-291-10


0007 00-10

STENCILS - CONTINUED 0007 00

427-C1570

TM 5-3805-291-10


0007 00-11/(0007 00-12 Blank)

STENCILS - CONTINUED 0007 00

END OF WORK PACKAGE

TM 5-3805-291-10

CHAPTER 3

OPERATOR TROUBLESHOOTING

0008 00-1/(0008 00-2 Blank)

TM 5-3805-291-10

TROUBLESHOOTING INTRODUCTION 0008 00

GENERAL

1. This chapter provides information for identifying and correcting malfunctions which may develop while operating the966H Wheel Loader.

2. The Troubleshooting Symptom Index in WP 0009 00 lists common malfunctions which may occur and refers you to theproper page in WP 0010 00 for a troubleshooting procedure.

3. If you are unsure of the location of an item mentioned in troubleshooting, refer to WP 0002 00, WP 0003 00, or WP0004 00.

4. Before performing troubleshooting, read and follow all safety instructions found in the Warning Summary at the front ofthis manual.

5. The Troubleshooting Symptom Index cannot list all malfunctions that may occur nor all tests, inspections, or correctiveactions. If a malfunction is not listed or is not corrected by the listed corrective actions, notify your supervisor.

6. When troubleshooting a malfunction:a. Locate the symptom or symptoms in WP 0009 00 that best describe the malfunction.b. Turn to the page in WP 0010 00 where the troubleshooting procedures for the malfunction in question are

described. Headings at the top of each page show how each troubleshooting procedure is organized: MALFUNC-TION, TEST OR INSPECTION (in step number order), and CORRECTIVE ACTION.

c. Perform each step in the order listed until the malfunction is corrected. DO NOT perform any maintenance taskunless the troubleshooting procedure tells you to do so.

EXPLANATION OF COLUMNS

The columns in the Table in WP 0010 00 are defined as follows:1. MALFUNCTION. A visual or operational indication that something is wrong with the equipment.2. TEST OR INSPECTION. A procedure to isolate the problem in a system or component.3. CORRECTIVE ACTION. A procedure to correct the problem.

END OF WORK PACKAGE

2

TM 5-3805-291-10

0009 00-1

TROUBLESHOOTING SYMPTOM INDEX 0009 00

Malfunction/Symptom Troubleshooting Procedure Page

BRAKES - SERVICE AND PARKING/EMERGENCY

1. Brake Oil Pressure Alert Indicator Comes On During Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12. Parking Brake Alert Indicator Does Not Come On When Parking Brake is Engaged. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13. Parking/Emergency Brake Will Not Disengage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14. Parking/Emergency Brake Will Not Engage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15. Service Brakes Do Not Operate Correctly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26. Service Brakes Do Not Release Correctly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

CHARGING SYSTEM

Electrical System Alert Indicator Comes On. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

COOLING SYSTEM

Coolant Temperature Gage Indicates Engine is Overheating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

ELECTRICAL SYSTEM

1. Backup Alarm Will Not Sound When Machine is Placed in Reverse. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32. Blackout Drive Light Will Not Operate When B.O. DRIVE Function is Selected. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33. Blackout Drive Marker Light(s) Do Not Operate When B.O. MARKER Function is Selected. . . . . . . . . . . . . . . . . . . . 3-44. Directional Turnlamp or Hazard Flasher Control are Not Working. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45. Worklights Inoperative. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46. Service Light(s) Do Not Operate When SER. DRIVE or PARK Functions are Selected. . . . . . . . . . . . . . . . . . . . . . . . . 3-47. Horn Will Not Sound When Button is Pressed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-58. Messenger is Inoperative. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59. Stoplights Do Not Operate When Brakes are Applied. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-510. Taillights Do Not Come On. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-511. Windshield Washer Not Working. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-612. Windshield Wiper Not Working. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6WORK AREA VISUAL SYSTEM (WAVS)1. Display or Camera Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-62. Display is Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-63. Display has Wrong Image Orientation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-64. Display has Inverted Image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-75. Display has Blurred Image. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-76. Display’s Color is Incorrect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

ENGINE

1. Engine Cranks but Fails to Start: Operating Temperature Above -25�F (-32�C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-72. Engine Cranks but Fails to Start: Operating Temperature -25�F to -40�F (-32�C to -40�C). . . . . . . . . . . . . . . . . . . . 3-83. Engine Does Not Develop Full Power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-94. Engine Does Not Idle Properly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-95. Engine Fails to Crank When Engine Start Switch is Turned to START. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

2

TM 5-3805-291-10

TROUBLESHOOTING SYMPTOM INDEX - CONTINUED 0009 00

0009 00-2

Malfunction/Symptom Troubleshooting Procedure Page

6. Engine Starts but Misfires or Runs Rough After Warmup Period. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-107. Excessive Engine Oil Consumption. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-108. Excessive Exhaust Smoke (At Normal Operating Speed). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-119. Excessive Exhaust Smoke (White) During Startup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1110. Low Engine Oil Pressure Alert Indicator, Action Light, and Action Alarm are On.. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

HYDRAULIC SYSTEM

1. Travel Time of Lift Cylinders is Slow.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-122. Work Tool/Loader Arm Operating Speeds are Too Slow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

STEERING

1. Machine Slowly Drifts (Either Direction), Wanders, or Pulls to One Side on Level Pavement,Even When Steering Wheel is in Straight Position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010 00-12

2. Machine Steering Slow or Intermittent to Respond. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-133. Machine Turns Correctly During Normal Driving Conditions but Turns Slowly With a Load. . . . . . . . . . . . . . . . . . . . 3-134. Machine Turns Slowly in Both Directions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-135. Machine Turns Slowly in One Direction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-136. Oil Temperature is Too Hot (Hydraulic Oil Temperature Gage in Red Range). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-137. Steering is Erratic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-138. Turning Steering Wheel is Difficult. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

TRANSMISSION

1. Slow or Erratic Transmission Engagement.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-142. Transmission Oil Temperature Gage Indicates Overheating and Action Light Comes On

(During Normal Operation). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010 00-133. Transmission Does Not Operate in Any Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-144. Transmission Does Not Shift From One Direction to Another.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-145. Transmission Does Not Shift From One Gear to Another. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-146. Transmission Engages, but Machine Does Not Move. Engine Stops Running. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

END OF WORK PACKAGE

TM 5-3805-291-10

0010 00-1

TROUBLESHOOTING PROCEDURES 0010 00

MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION

WARNINGBE ALERT for personnel in the area while operating machine.Always check to ensure area is clear of personnel and obstructionsbefore moving. Failure to follow this warning may result in injury ordeath to personnel or damage to equipment.

BRAKES - SERVICE AND PARKING/EMERGENCY

WARNINGPark machine on level ground, stop engine, and lower work tool toground to prevent injury to operator and/or severe damage tomachine.

1. Brake Oil Pressure Alert Indicator Comes On During Operation.

Stop machine and shut down engineimmediately (WP 0005 00).

Notify Unit Maintenance.


2. Parking Brake Alert Indicator Does Not Come On When Parking Brake is Engaged.




3. Parking/Emergency Brake Will Not Disengage.

1. Engage and disengage parking brake (WP 0004 00).

If problem still exists, go to teststep 2.

2. Stop machine and shut down engine immediately (WP 0005 00).


4. Parking/Emergency Brake Will Not Engage.



14

0010 00-2

TM 5-3805-291-10

TROUBLESHOOTING PROCEDURES - CONTINUED 0010 00

BRAKES - SERVICE AND PARKING/EMERGENCY - CONTINUED

WARNING• Park machine on level ground, stop engine, and lower work tool to

ground to prevent injury to operator and/or severe damage to machine.

• If emergency use of parking brake is required due to service brake failure, ensure that brakes are inspected and repaired, if necessary, before resuming machine operation. Injury or death to personnel or damage to equipment could result from improperly or non-func-tioning brakes.

5. Service Brakes Do Not Operate Correctly.

1. Bring machine to a safe stop and check for mud or dirt under brake pedals.

Clean mud or dirt from underbrake pedals. If problem stillexists, go to test step 2.

2. Bring machine to a safe stop and shut down engine immediately (WP 0005 00).


6. Service Brakes Do Not Release Correctly.


1. Bring machine to a safe stop and check for mud or dirt under brake pedals, causing pedals to stick.

Clean mud or dirt from underbrake pedals. If problem stillexists, go to test step 2.

2. Ensure parking brake is disengaged (WP 0004 00).

Disengage parking brake. Ifproblem still exists, go to test step3.

3. Bring machine to a safe stop and shut down engine immediately (WP 0005 00).


CHARGING SYSTEM

Electrical System Alert Indicator Comes On.

1. Check that circuit breakers are not tripped (WP 0016 00).

Reset circuit breakers. If problemstill exists, go to test step 2.

2. Check for loose or broken serpentine belt.

If loose or broken belt is found, orif belt is OK and problem stillexists, notify Unit Maintenance.


0010 00-3

TM 5-3805-291-10


COOLING SYSTEM

Coolant Temperature Gage Indicates Engine is Overheating.

WARNING• DO NOT service cooling system unless engine has been allowed to

cool down. This is a pressurized cooling system and escaping steam or hot coolant will cause serious burns.

• DO NOT remove cooling system radiator cap when engine is hot. Allow engine to cool down. Failure to follow this warning may cause serious burns.

• Wear effective eye, glove, and skin protection when handling cool-ants. Failure to do so may cause injury.

1. Check coolant temperature gage for an indication in red or orange range (WP 0004 00).

Reduce load and continue tomonitor temperature. If indicationis still in red or orange range, go totest step 2.

2. Allow engine to idle at 825 rpm to cool down.


3. Check cooling system for leaks. If leaks are found, notify UnitMaintenance. If no leaks arefound, go to test step 4.

4. Check coolant level (WP 0004 00).

If low, add coolant (WP 0004 00).If coolant level is OK, notify UnitMaintenance.

ELECTRICAL SYSTEM

1. Backup Alarm Will Not Sound When Machine is Placed in Reverse.

NOTEA 30-minute cool down time may be required before circuit breakerautomatically resets.

Ensure STOP LIGHT or SER. DRIVEfunction has been selected on militarylight switch (WP 0004 00).

Select STOP LIGHT or SER.DRIVE. If problem still exists,notify Unit Maintenance.

2. Blackout Drive Light Will Not Operate When B.O. DRIVE Function is Selected.


Ensure B.O. DRIVE function has beenselected on military light switch (WP0004 00).

Select B.O. DRIVE function. Ifproblem still exists, notify UnitMaintenance.


0010 00-4

TM 5-3805-291-10


ELECTRICAL SYSTEM - CONTINUED

3. Blackout Drive Marker Light(s) Do Not Operate When B.O. MARKER Function is Selected.


Ensure B.O. DRIVE function has beenselected on military light switch (WP0004 00).

Select B.O. DRIVE function. Ifproblem still exists, notify UnitMaintenance.

4. Directional Turnlamp or Hazard Flasher Control are Not Working.

1. Ensure STOP LIGHT or SER. DRIVE function has been selected on military light switch (WP 0004 00).

Select STOP LIGHT or SER.DRIVE. If problem still exists, goto test step 2.

2. Check turnlamp lights (front)/composite lights (rear) for disconnected connectors or damage.

Reconnect connectors, ifdisconnected. If any damage tolights is found, notify UnitMaintenance. If connectors andlights are OK, go to test step 3.

3. Check for blown turnlamp fuse at fuse panel (WP 0016 00).

If fuse is blown, requestreplacement fuse from UnitMaintenance. If problem stillexists, notify Unit Maintenance.

5. Worklights Inoperative. 1. Ensure STOP LIGHT or SER. DRIVE function has been selected on military light switch (WP 0004 00).


2. Check for blown worklight fuse at fuse panel (WP 0016 00).

If fuse is blown, requestreplacement fuse from UnitMaintenance. If fuse is good, go totest step 3.

3. Check worklights for disconnected connector or damage.

Reconnect connector, ifdisconnected. If any damage toworklights is found, notify UnitMaintenance.

6. Service Light(s) Do Not Operate When SER. DRIVE or PARK Functions are Selected.

1. Check service light(s) for disconnected connectors or damage.

Reconnect connectors, ifdisconnected. If any damage toservice light(s) is found, notifyUnit Maintenance. If connectorsand headlights are OK, go to teststep 2.


0010 00-5

TM 5-3805-291-10



6. Service Light(s) Do Not Operate When SER. DRIVE or PARK Functions are Selected - Continued.


2. Check that circuit breakers are not tripped (WP 0016 00).

Reset circuit breakers. If problemstill exists, notify UnitMaintenance.

7. Horn Will Not Sound When Button is Pressed.



2. Check horn for disconnected connector or damage.

Reconnect connector, ifdisconnected. If any damage tohorn is found, notify UnitMaintenance. If connector andhorn are OK, go to test step 3.

3. Check for blown horn fuse at fuse panel (WP 0016 00).

If fuse is blown, requestreplacement fuse from UnitMaintenance. If fuse is good, orproblem still exists, notify UnitMaintenance.

8. Messenger is Inoperative. Notify Unit Maintenance.

9. Stoplights Do Not Operate When Brakes are Applied.



2. Check composite lights for disconnected connectors or damage.

If any damage to lights is found,notify Unit Maintenance. If nodamage is found, go to test step 3.

3. Check for blown stoplight fuse (WP 0016 00).

If fuse is blown, requestreplacement fuse from UnitMaintenance. If fuse is good,notify Unit Maintenance.

10. Taillights Do Not Come On. 1. Ensure STOP LIGHT or SER. DRIVE function has been selected on military light switch (WP 0004 00).


2. Check composite lights for disconnected connectors or damage.

If any damage to lights is found,notify Unit Maintenance. If nodamage is found, go to test step 3.


0010 00-6

TM 5-3805-291-10



10. Taillights Do Not Come On - Continued. NOTEA 30-minute cool down time may be required before circuit breakerautomatically resets.

3. Check for blown taillight fuse (WP 0016 00).


11. Windshield Washer Not Working. 1. Check windshield washer fluid reservoir.

If reservoir is empty, fill reservoir(WP 0012 00). If problem stillexists, go to test step 2.

2. Check for blown fuse at fuse panel (WP 0016 00).

If fuse is blown, requestreplacement fuse from UnitMaintenance. If fuse is good andproblem still exists, go to test step3.

3. Check for loose or disconnected electrical connectors (WP 0012 00).

Reconnect electrical connectors, ifrequired. If problem still exists,notify Unit Maintenance.

12. Windshield Wiper Not Working. Check for blown fuse at fuse panel (WP0016 00).


WORK AREA VISUAL SYSTEM (WAVS)

1. Display or Camera Inoperative Check if light switch selector lever is ineither STOP LIGHT or SER DRIVEmode.

1. If not, select either STOP LIGHT or SER DRIVE mode.

2. If light switch is in either STOP LIGHT or SER DRIVE mode and problem still exists, notify Unit Maintenance.

2. Display is Blank Check if brightness level is setcorrectly (WP 0004 00, WAVSsection, Table 1).

1. If not, set brightness level correctly.

2. If brightness level is set correctly and problem still exists, notify Unit Maintenance.

3. Display has Wrong Image Orientation Check if image orientation is setcorrectly (should appear as if lookingin a rear view mirror) (WP 0004 00,WAVS section, Accessing All SystemOptions – Mirror Image).

1. If not, set image orientation correctly.

2. If image orientation is set correctly and problem still exists, notify Unit maintenance.


0010 00-7

TM 5-3805-291-10


WORK AREA VISUAL SYSTEM (WAVS) - CONTINUED

4. Display has Inverted Image Check if image is set correctly (WP0004 00, WAVS section, AccessingAll System Options – Inverted Image).

1. If not, set image correctly.2. If image is set correctly and

problem still exists, notify Unit Maintenance.

5. Display has Blurred Image Check if camera lens is dirty. 1. If lens is dirty, clean.2. If lens is clean and problem

still exists, notify Unit Maintenance.

6. Display’s Color is Incorrect Check if color is set correctly (WP0004 00, WAVS section, AccessingAll System Options – ColorAdjustment).

1. If not, set color correctly.2. If color is adjusted correctly

and problem still exists, notify Unit Maintenance.

ENGINE

1. Engine Cranks but Fails to Start: Operating Temperature Above -25 F(-32 C)

1. Check fuel tank gage with engine start switch ON.

If indication is empty, add fuel(WP 0013 00). If indication is OK,go to test step 2.

2. Make sure emergency shutoff is disengaged.

Disengage if necessary.

3. Check for blown key start fuse at fuse panel (WP 0016 00).



0010 00-8

TM 5-3805-291-10


ENGINE - CONTINUED

2. Engine Cranks but Fails to Start: Operating Temperature -25 F to -40 F(-32 C to -40 C).

WARNING• DO NOT smoke or permit any open flame in area of

machine while you are servicing fuel system. Be sure hosenozzle is grounded against filler tube during refueling toprevent static electricity. Failure to follow this warningmay result in injury or death to personnel, or damage toequipment.

• Operating personnel must wear fuel-resistant gloves whenhandling fuels. If exposed to fuel, promptly wash exposedskin and change fuel-soaked clothing.

• ALWAYS stop engine prior to refueling. If equipped withan arctic cold weather starting aid system, turn enginecoolant heater off.

1. Check fuel tank gage with engine start switch ON.

If indication is empty, add fuel(WP 0013 00). If indication is OK,go to test step 2.

2. Make sure emergency shutoff is disengaged.

Disengage if necessary.

3. Check for blown key start fuse at fuse panel (WP 0016 00).


4. Check for blown arctic heater fuse (WP 0016 00).


5. Check for blown start aid fuse at fuse panel (WP 0016 00).

If fuse is blown, requestreplacement fuse from UnitMaintenance. If engine still willnot start, notify Unit Maintenance.

6. Check for missing or empty ether starting aid bottle at temperatures from -25�F to 10�F (-32�C to-12�C) (WP 0004 00).

If ether canister is missing orempty, notify Unit Maintenance.


0010 00-9

TM 5-3805-291-10


ENGINE - CONTINUED

3. Engine Does Not Develop Full Power.

WARNING• If NBC exposure is suspected, personnel wearing protective

equipment must handle all air cleaner media. Consult yourNBC Officer or NBC NCO for appropriate handling or dis-posal procedures.

• Refer to FM 3-11.3, Multiservice Tactics, Techniques,and Procedures for Chemical, Biological, Radiological,and Nuclear Contamination Avoidance, and FM 3-11.5,Multiservice Tactics, Techniques, and Procedures forChemical, Biological, Radiological, and NuclearDecontamination.

• NBC contaminated filters must be handled using adequateprecautions and must be disposed of by trained personnel.


Check front dash indicator (WP 000400).

If indicator is on, service engine aircleaner (WP 0014 00) and reteststep. If problem still exists, notifyUnit Maintenance.

4. Engine Does Not Idle Properly. Check front dash indicator (WP 000400).


5. Engine Fails to Crank When Engine Start Switch is Turned to START.

1. Check position of transmission control lever and remote F/N/R switch.

Place transmission control leverand remote F/N/R switch in N(NEUTRAL). If problem stillexists, go to test step 2.

2. Check position of battery disconnect switch (WP 0004 00).

Place battery disconnect switch toON. If problem still exists, go totest step 3.

3. Check for blown engine start switch fuse (WP 0016 00).



4. Auxiliary circuit breaker may have tripped (WP 0016 00).

Allow circuit breaker to reset. Ifproblem still exists, go to test step5.


0010 00-10

TM 5-3805-291-10


ENGINE - CONTINUED

5. Check for tripped breaker (WP 0016 00).

Reset circuit breaker. If problemstill exists, go to test step 6.

5. Engine Fails to Crank When Engine Start Switch is Turned to START - Continued.

6. Check both batteries for dirty, loose, or damaged battery cables (WP 0012 00).

Clean cables if dirty. If cable isdamaged or loose, notify UnitMaintenance.

7. Check connection of four harness connectors at right rear of cab cover.

If problem still exists, notify UnitMaintenance.

6. Engine Starts but Misfires or Runs Rough After Warmup Period.





Check fuel/water separator formoisture (WP 0012 00).

Open fuel/water separator drainvalve and drain (WP 0012 00). Ifproblem still exists, notify UnitMaintenance.

7. Excessive Engine Oil Consumption. Check for loose oil lines and oil leaks. If oil lines are loose or leaks arefound, notify Unit Maintenance.


0010 00-11

TM 5-3805-291-10


ENGINE - CONTINUED

8. Excessive Exhaust Smoke (At Normal Operating Speed).

1. Check fuel/water separator for moisture (WP 0012 00).

Drain fuel/water separator (WP0012 00). If problem still exists, goto test step 2.





2. Check front dash indicator (WP 0004 00).


9. Excessive Exhaust Smoke (White) During Startup.

Check and monitor coolanttemperature gage (WP 0004 00).

Allow engine to warm up tooperating temperature. If problemstill exists, notify UnitMaintenance.

10. Low Engine Oil Pressure Alert Indicator, Action Light, and Action Alarm are On.

CAUTIONWhen action alarm sounds, immediate shutdown of machine isrequired to prevent damage to machine.

Check engine oil level (WP 0004 00). If engine oil is low, fill to correctlevel (WP 0012 00). If problemstill exists, notify UnitMaintenance.


0010 00-12

TM 5-3805-291-10


HYDRAULIC SYSTEM

1. Travel Time of Lift Cylinders is Slow.

WARNINGStand clear of frame articulation area when machine is operat-ing. There is no clearance for personnel in this area whenmachine turns. Crushing could occur, resulting in injury ordeath to personnel.

1. Check hydraulic oil level (WP 0004 00).

If hydraulic oil level is low, fill tocorrect level (WP 0004 00). Ifproblem still exists, go to test step2.

2. Check hydraulic lift cylinders for any buildup of debris.

Clean any debris from cylinder(s).If problem still exists, go to teststep 3.

3. Check loader control joystick for damage that would restrict freedom of movement.

If any damage is found, notify UnitMaintenance.

2. Work Tool/Loader Arm Operating Speeds are Too Slow.

WARNINGStand clear of frame articulation area when machine is operat-ing. There is no clearance for personnel in this area whenmachine turns. Crushing could occur, resulting in injury ordeath to personnel.


If hydraulic oil level is low, fill tocorrect level (WP 0004 00). Ifproblem still exists, go to test step2.

2. Check hydraulic lift cylinders, tilt cylinder, and linkage for buildup of debris.

Clean any debris from cylindersand linkage. If problem still exists,notify Unit Maintenance.


0010 00-13

TM 5-3805-291-10


STEERING

1. Machine Slowly Drifts (Either Direction), Wanders, or Pulls to One Side on Level Pavement, Even When Steering Wheel is in Straight Position.

WARNINGStand clear of frame articulation area when machine is operating.There is no clearance for personnel in this area when machine turns.Crushing could occur, resulting in injury or death to personnel.

Check tires for proper inflationpressure: Front - 60 psi (414 kPa); rear- 40 psi (276 kPa).

Inflate tires to proper pressure(WP 0012 00). If problem stillexists, notify Unit Maintenance.

2. Machine Steering Slow or Intermittent to Respond.

Check hydraulic oil level (WP 000400).

If oil level is low, fill to correctlevel (WP 0004 00). If oil level isOK, notify Unit Maintenance.

3. Machine Turns Correctly During Normal Driving Conditions but Turns Slowly With a Load.

1. Check steering system for oil leaks.

If any oil leaks are found, notifyUnit Maintenance. If no leaks arefound, go to test step 2.


If hydraulic oil level is low, fill tocorrect level (WP 0004 00). Ifproblem still exists, notify UnitMaintenance.

4. Machine Turns Slowly in Both Directions.


If oil level is low, fill to correctlevel (WP 0004 00). If oil level isOK, notify Unit Maintenance.

5. Machine Turns Slowly in One Direction. 1. Check for oil leaks at steering cylinders.

If any oil leaks are found, notifyUnit Maintenance.



6. Oil Temperature is Too Hot (Hydraulic Oil Temperature Gage in Red Range).



7. Steering is Erratic. Check hydraulic oil level (WP 000400).


8. Turning Steering Wheel is Difficult. 1. Check hydraulic temp gage for correct temperature.

If problem still exists after normaloperating temperature is reached,go to test step 2.


0010 00-14

TM 5-3805-291-10


END OF WORK PACKAGE

STEERING - CONTINUED

8. Turning Steering Wheel is Difficult - Continued.



TRANSMISSION

1. Slow or Erratic Transmission Engagement.

Check transmission oil level (WP 000400).

If transmission oil is low, fill tocorrect level (WP 0004 00). Ifproblem still exists, notify UnitMaintenance.

2. Transmission Oil Temperature Gage Indicates Overheating and Action Light Comes On (During Normal Operation).

1. Ensure proper transmission range is selected for machine operation (WP 0004 00).

Select proper transmission range(WP 0004 00). If proper range wasused, go to test step 2.

2. Reduce load and continue to monitor temperature.


3. Check transmission oil level (WP 0004 00).


3. Transmission Does Not Operate in Any Gear.

Check transmission oil level (WP 000400).


4. Transmission Does Not Shift From One Direction to Another.

1. Check position of parking brake switch.

Disengage parking brake. Ifproblem still exists, go to test step2.

2. Shift transmission to N (NEUTRAL) and back to appropriate direction.




5. Transmission Does Not Shift From One Gear to Another.



2. Ensure that autoshift switch is in desired mode (manual/auto).

If problem still exists, notify UnitMaintenance.

6. Transmission Engages, but Machine Does Not Move. Engine Stops Running.

Restart engine. If problem still exists, notify UnitMaintenance.


TM 5-3805-291-10

CHAPTER 4

PMCS MAINTENANCE INSTRUCTIONS

TM 5-3805-291-10

0011 00-1

PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INTRODUCTION 0011 00

GENERAL

1. To ensure that the 966H Wheel Loader is ready for operation at all times, it must be inspected on a regular basis so thatdefects may be found and corrected before they result in injury, damage, or equipment failure.

2. The PMCS Table in WP 0012 00 contains systematic instructions on inspections, lubrications, services, tests, and cor-rections to be performed by the operator to keep your equipment in good operating condition and ready for its primarymission.

EXPLANATION OF TABLE ENTRIES

1. Item Number (Item No.) Column. Numbers in this column are for reference. When completing DA Form 2404 or DAForm 5988-E (Equipment Inspection and Maintenance Worksheet), include the item number for the check/service indi-cating a fault. Item numbers also appear in the order that you must perform checks and services for the interval listed.

2. Interval Column. This column tells you when you must perform the procedure in the Procedure column.

a. Before procedures must be done immediately before you operate the loader.

b. During procedures must be done while you are operating the loader.

c. After procedures must be done immediately after you have operated the loader.

d. Weekly procedures must be done once each week.

e. Monthly procedures must be done once each month.

3. Man-Hours Column. This column indicates man-hours required to complete prescribed lubrication.

4. Location, Item to Check/Service Column. This column provides the location and item to be checked or serviced.

NOTEThe WARNINGs and CAUTIONs appearing in your PMCS table should always be observed. WARNINGsand CAUTIONs appear before applicable procedures. You must observe these WARNINGs to preventinjury or death to yourself and others, and CAUTIONs to prevent your equipment from being damaged.

5. Procedure Column. This column gives the procedure you must perform to check or service the item listed in the Itemto Check/Service column, to know if the equipment is ready or available for its intended mission. You must perform theprocedure at the time stated in the Interval column.

6. Not Fully Mission Capable If: Column. Information in this column tells you what faults will keep your equipmentfrom being capable of performing its primary mission. If you perform check/service procedures that show faults listed inthis column, the equipment is not mission-capable. Follow standard operating procedures for maintaining the equipmentor reporting equipment failure.

GENERAL PMCS PROCEDURES

1. Always perform PMCS in the same order so it gets to be a habit. Once you have had some practice, you will spot any-thing wrong in a hurry. If the machine does not perform as required, refer to the appropriate troubleshooting procedurein Chapter 3.

2. If anything looks wrong and you cannot fix it, write it on your DA Form 2404 or DA Form 5988-E. If you find some-thing seriously wrong, IMMEDIATELY report it to your supervisor.

3. Before performing preventive maintenance, read all the checks required for the applicable interval and prepare all that isneeded to make all the checks. You will always need a rag (Item 13, WP 0027 00) or two.

4

TM 5-3805-291-10

PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INTRODUCTION - CONTINUED 0011 00

0011 00-2

GENERAL PMCS PROCEDURES - CONTINUED

WARNINGSolvent cleaning compound MIL-PRF-680 Type III is an environmentally compliant and low toxicmaterial. However, it may be irritating to the eyes and skin. Use protective gloves and goggles. Use in well-ventilated areas. Keep away from open flames and other sources of ignition. Failure to follow this warningmay result in injury or death to personnel.

a. Keep It Clean. Dirt, grease, oil, and debris get in the way and may cover up a serious problem. Clean as you workand as needed. Use solvent cleaning compound (Item 2, WP 0027 00) on all metal surfaces. Use detergent (Item 4,0027 00) and water when you clean rubber, plastic, and painted surfaces.

WARNINGWhen servicing this machine, performing maintenance or disposing of materials such as engine coolant,hydraulic fluid, lubricants, battery acids or batteries, windshield cleaning compound, and CARC paint,consult your unit/local hazardous waste disposal center or safety office for local regulatory guidance. Iffurther information is needed, please contact The Army Environmental Hotline at 1-800-872-3845.

b. Hazardous Waste Disposal. Ensure all spills are cleaned up and disposed of IAW local policy and ordinances.c. Rust and Corrosion. Check metal parts for rust and corrosion. If any bare metal or corrosion exists, clean and

apply a light coat of lubricating oil (Item 9, 10, 11, or 12, WP 0027 00). Report it to your supervisor.d. Bolts, Nuts, and Screws. Check bolts, nuts, and screws for obvious looseness, missing, bent, or broken condition.

You cannot try them all with a tool, but look for chipped paint, bare metal, or rust around bolt heads. If you findone is loose, notify your supervisor.

e. Welds. Look for loose or chipped paint, rust, or gaps where parts are welded together. If you find a bad weld,report it to your supervisor.

f. Electric Wires and Connectors. Look for cracked or broken insulation, bare wires, and loose or broken connec-tors. Reconnect loose connectors. Ensure that wires are in good condition.

g. Hoses and Fluid Lines. Look for wear, damage, and signs of leaks. Check for loose clamps and fittings. Wet spotsindicate leaks, but a stain around a fitting or connector can also mean a leak. If a leak comes from a loose fitting orconnector, notify your supervisor. If something is broken or worn out, report it to your supervisor.

h. Fluid Leakage. It is necessary for you to know how fluid leakage affects the status of your machine. The follow-ing are definitions of the types/classes of leakage you need to know to be able to determine the status of yourmachine. Learn and be familiar with them, and remember: when in doubt, notify your supervisor.

TM 5-3805-291-10

PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INTRODUCTION - CONTINUED 0011 00

0011 00-3/(0011 00-4 Blank)

GENERAL PMCS PROCEDURES - CONTINUED

CAUTIONOperation is allowable with Class I and Class II leakage, EXCEPT for fuel, where NO leaks are allowed.WHEN IN DOUBT, NOTIFY YOUR SUPERVISOR. When operating with Class I or Class II leaks, checkfluid levels more frequently. Class III leaks must be reported immediately to your supervisor. Failure to dothis will result in damage to machine and/or components.

NOTENotify your supervisor of any leaks you cannot fix.

Leakage Definitions for PMCSClass I Leakage indicated by wetness or discoloration, but not great enough to form

drops.Class II Leakage great enough to form drops, but not enough to cause drops to drip from

the item being checked/inspected.Class III Leakage great enough to form drops that fall from the item being checked/

inspected.

END OF WORK PACKAGE

TM 5-3805-291-10

0012 00-1

PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INCLUDING LUBRICATION INSTRUCTIONS 0012 00

PMCS INITIAL SETUP


Basic Issue Items (Table 2, WP 0026 00)

Materials/Parts

Antifreeze (Item 1, WP 0027 00)

Cleaning compound, solvent (Item 2, WP 0027 00)

Cleaning compound, windshield (Item 3, WP 002700)

Detergent (Item 4, WP 0027 00)

Fuel (Item 5, 6, or 7, WP 0027 00)

Grease, GAA (Item 8, WP 0027 00)

Oil, lubricating (Item 9, 10, 11, or 12, WP 0027 00)

Rag, wiping (Item 13, WP 0027 00)

Test kit, SCA (Item 17, WP 0027 00)

Personnel Required

MOS 21E, Heavy Construction Equipment Opera-tor

References

FM 3-11.3

FM 3-11.5

FM 9-207

TM 9-6140-200-14

WP 0004 00

WP 0007 00

WP 0013 00

WP 0014 00

WP 0015 00

WP 0024 00

Equipment Conditions

Machine parked on level ground (WP 0005 00)

Work tool lowered to ground (WP 0005 00)

Parking brake engaged (WP 0005 00)

Engine OFF (WP 0005 00)

Interval/Maintenance Task Title Page

Before . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0012 00-2

During . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0012 00-20

After . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0012 00-21

Weekly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0012 00-32

Monthly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0012 00-42

Lubrication Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0012 00-49

NOTERefer to the Messenger Reference Guide in WP 0004 00.

54

TM 5-3805-291-10

PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INCLUDING LUBRICATION INSTRUCTIONS - CONTINUED 0012 00

0012 00-2

Table 1. Preventive Maintenance Checks and Services (PMCS) for the 966H Wheel Loader.

ITEM NO. INTERVAL

MAN-HOURS

LOCATION

PROCEDURENOT FULLY MISSION

CAPABLE IF:

ITEM TOCHECK/SERVICE

NOTE• Review all WARNINGs, CAUTIONs, and NOTEs

before performing PMCS on the 966H Wheel Loader.• Perform all weekly and before operation PMCS checks

if:a. You are the assigned operator but have not operated the

loader since the last weekly checks.b. You are operating the loader for the first time.

• Unless otherwise indicated, perform all preventivemaintenance and lubrication with machine parked onlevel ground, work tool lowered to ground, parkingbrake lever engaged, transmission in N (NEUTRAL),and engine shut down.

FRONT AND LEFT SIDE

1 Before0012 00

Overall View a. Check on ground under machinefor evidence of fluid leakage suchas oil, coolant, or fuel.

Class III oil or coolant leaksare evident. Any fuel leak-age is evident.

b. Check machine for obvious dam-age that would impair operation.

Damage that would impairoperation is evident.

2 Before Forklift Pallet Forks (If Equipped)

Check for cracked, bent, or otherwisedamaged forks and fork frame.

Cracks or damage thatwould impair operation isevident.

3 Before Bucket and Bucket Tips (If Equipped)

a. Check bucket for bends, cracks, orother damage.


b. Check for missing tip. Replace ifnecessary.

4 Before Sweeper (If Equipped)

Check sweeper for damage. Damage that would impairoperation is evident.

5 Before Quick Cou-pler, Tilt Cyl-inder, and Lift Arms

a. Check quick coupler for cracksand wear in pin area.

b. Ensure protective caps areinstalled on two quick disconnectfittings.

Cracks are evident. Wearthat would impair securityof coupling is evident.

c. Check for leaking hydraulic lineson work tool, quick coupler, liftarms, and tilt cylinder.

Class III leaks are evident.

TM 5-3805-291-10


0012 00-3

6 Before Left-Front Wheel and Tire

a. Check for missing bolts. Two or more bolts are miss-ing.

b. Check tread and sidewall for cutsand foreign material in treads.

Damage to tire that wouldlead to tire failure is evident.

c. Visually check tire inflation. Tire is flat.d. Check back side of wheel for oil

leaks from final drive.Class III oil leaks are evi-dent.

7 Before Left-Front Lights

a. Check that left-front service lightassembly (service lights and turn-lamps) is present and not dam-aged.

Lights are missing or dam-aged, if required for mis-sion.

b. Check that blackout drive light ispresent and not damaged.

Blackout drive light is miss-ing or damaged, if requiredfor mission.

8 Before Frame Articu-lation Area

a. Check for cracks or breaks in driveshaft.

Cracks or breaks are evi-dent.

b. Inspect hydraulic hoses for dam-age or leaks.

If cracks, splits, bulges, orsoft spots are evident inhoses, or Class III leaks areevident.

c. Inspect for missing, damaged, orleaking remote grease fittings.

Table 1. Preventive Maintenance Checks and Services (PMCS) for the 966H Wheel Loader - Continued.

ITEM NO. INTERVAL

MAN-HOURS

LOCATION


CAPABLE IF:


427-C0064

TM 5-3805-291-10


0012 00-4

8(Cont)

Before Frame Articu-lation Area

d. Check that left-side steering cylin-der pin is secure.

Steering cylinder is notsecurely attached to frontframe section.

e. Inspect upper and lower articula-tion pin/bearing assemblies forevidence of cracks, breaks, miss-ing mounting bolts, or damaged ormissing grease fittings.

Upper and lower articula-tion pin/bearing assembliesare cracked, have breaks,missing mounting bolts, ordamaged or missing greasefittings.

f. Check that transmission oil cap ispresent. Ensure there are no oilleaks.

Transmission oil cap ismissing. Class III oil leaksare evident.

g. Check transmission oil level andfill if necessary (WP 0004 00).

h. Check that steering frame lock isdisconnected and stowed. If con-nected, disconnect IAW instruc-tions in WP 0015 00.

9 Before Left-Side Cab, Door, Ladder, and Operator Platform

a. Inspect front, left, and rear of cabfor damage and broken glass.Check for damaged or missingfront and rear windshield wipers/washers.

Damage is noted that wouldimpair operation.

b. Check that front and rear left-sideworklights are present and notdamaged.

c. Check for damage to door, doorhandle, and grabhandles.


ITEM NO. INTERVAL

MAN-HOURS

LOCATION


CAPABLE IF:


TM 5-3805-291-10


0012 00-5

9(Cont)

Before Left-Side Cab, Door, Ladder, and Operator Platform

NOTEIf left-side ladder and/or platform are damaged, operatormay use right-side ladder and/or platform.

d. Check that ladder is securelymounted and in good condition.

e. Check that operator platform issecurely mounted and in good con-dition.

f. Inspect ROPS/FOPS mountingbolts at two left corners outsidecab. Check for missing or loosebolts (WP 0024 00).

Bolts are missing or loose.

10 Before Left-Rear Wheel and Tire






11 Before Left-Side Engine Enclo-sure

a. Open left-side access door.

b. Check for evidence of hydraulic/coolant leaks.


c. Close left-side access door.


ITEM NO. INTERVAL

MAN-HOURS

LOCATION


CAPABLE IF:


TM 5-3805-291-10


0012 00-6

12 Before Engine Cool-ant Level

0012 00

a. Tilt hood to open position (WP0004 00).

Hood does not open.

b. Check coolant overflow tank sightgage for presence of coolant.

Coolant level is not visiblein sight gage.

c. If necessary, add coolant as fol-lows:

WARNING• DO NOT service cooling system unless engine has been

allowed to cool down. This is a pressurized cooling sys-tem and escaping steam or hot coolant will cause seri-ous burns.

• DO NOT remove cooling system radiator cap whenengine is hot. Allow engine to cool down. Loosen cap tofirst stop and let any pressure out of cooling system,then remove cap. Failure to follow this warning maycause serious burns.

• Wear effective eye, glove, and skin protection whenhandling coolants. Failure to do so may cause injury.

(1) Wipe filler cap clean with a rag.(2) Push down on filler cap, turn

cap counterclockwise (to theleft), and remove cap from cool-ant overflow tank.

(3) Add a 50/50 mixture of anti-freeze and clean water to bringlevel up to FULL mark on cool-ant overflow sight gage. 60/40mixture of antifreeze and wateris used in arctic operation.

(4) Inspect filler cap for damage tocap or cap gasket, foreign mate-rial, and deposits.

Gasket is missing or dam-aged.

(5) Reinstall cap by pushing downon cap and turning clockwise(to the right).


ITEM NO. INTERVAL

MAN-HOURS

LOCATION


CAPABLE IF:


TM 5-3805-291-10


0012 00-7

12(Cont)

Before Engine Cool-ant Level

13 Before Left Side of Engine

a. Ensure that aftercooler and airintake tubes are secure.

Tubes are not securelymounted.

b. Inspect around turbocharger andexhaust manifold for exhaustleaks. Check for black sootbetween turbocharger and muffler.Visually check for oil leaks at tur-bocharger.

Exhaust leaks are evident.Any oil leaks or soot areevident.

c. Check the transmission andhydraulic oil coolers, aftercooler,and radiator for damaged compo-nents.

Damage that would impaircooling is evident.

14 Before Battery Box, NATO Slave Receptacle

a. Check that left-side battery boxcover is closed and secure.

b. Ensure that cover is installed onNATO slave receptacle.


ITEM NO. INTERVAL

MAN-HOURS

LOCATION


CAPABLE IF:


TM 5-3805-291-10


0012 00-8

15 Before Ether Starting Aid System

0012 00

WARNINGEther fuel is extremely flammable and toxic. DO NOTsmoke and make sure you are in a well-ventilated areaaway from heat, open flames or sparks. Wear eye protec-tion. Avoid contact with skin and eyes and avoid breathingether fumes. If fluid enters or fumes irritate the eyes, washimmediately with large quantities of clean water for 15minutes. Seek medical attention immediately if ether isinhaled or causes eye irritation. Failure to follow this warn-ing may cause serious injury or death to personnel.

NOTE• Ether canister needs to be installed when starting

below 40°F (4°C).• If canister is not installed, ensure cap is installed on

solenoid valve.

a. Check that ether canister is presentand securely installed.

Ether canister or cap ismissing.

b. Close hood (WP 0004 00).

REAR AND RIGHT SIDE

16 Before Overall View Check on ground under machine forevidence of fluid leakage such as oil,coolant, or fuel.

Class III oil or coolant leaksare evident. Any fuel leak-age is evident.

17 Before Rear of Machine

a. Check that rear lights are presentand not damaged.

Rear lights are missing ordamaged, if required formission.

b. Open rear access door.c. Ensure fuel tank filler cap is

installed.Fuel tank filler cap is miss-ing.

d. Check for evidence of any fuelleaks.

Any fuel leaks are evident.

e. Close rear access door. Rear access door will notclose and latch securely.


ITEM NO. INTERVAL

MAN-HOURS

LOCATION


CAPABLE IF:


TM 5-3805-291-10


0012 00-9

18 Before Right-Side Engine Enclo-sure


b. Check for evidence of leaks. Class III leaks are evident.Any fuel leaks are evident.


ITEM NO. INTERVAL

MAN-HOURS

LOCATION


CAPABLE IF:


TM 5-3805-291-10


0012 00-10

19 Before 0.2 Hour Engine Oil Level 0012 00

a. Wipe area clean around dipstick.

CAUTIONWhen removing dipstick, be alert for evidence of fuel orantifreeze contamination. Antifreeze has a characteristicodor which can be detected. Fuel will separate from engineoil and leave a bullseye stain on rag.

b. Remove dipstick and inspect con-dition of oil. Look for evidence ofantifreeze or fuel contamination.Report any problem to your super-visor.

c. Wipe dipstick clean, then reinsertinto dipstick tube until fullyseated. Remove dipstick and takereading.

d. Level must be within cross-hatched area on dipstick.

e. If level is low, turn filler capclockwise (to the left) and addengine oil (Item 9, 10, 11, or 12,WP 0027 00) through filler tubeopening until level on dipstick iscorrect. Refer to KEY at end of thiswork package for correct grade ofoil for expected temperature range.

f. Reinstall filler cap and turn clock-wise (to the right) until tight.


ITEM NO. INTERVAL

MAN-HOURS

LOCATION


CAPABLE IF:


TM 5-3805-291-10


0012 00-11

19(Cont)

Before 0.2 Hour Engine Oil Level 0012 00


ITEM NO. INTERVAL

MAN-HOURS

LOCATION


CAPABLE IF:


427-C-1674

TM 5-3805-291-10


0012 00-12

20 Before Fuel/Water SeparatorDrain 0012 00


machine while you are servicing fuel system. Failure tofollow this warning may cause injury to personnel orequipment damage.

• Operating personnel must wear fuel-resistant gloveswhen handling fuels. If exposed to fuel, promptly washexposed skin and change fuel-soaked clothing.

a. Place container under drain valve. b. Turn drain valve counterclockwise

(to the left) and drain all water andsediment from sediment bowl.

c. Turn drain valve clockwise (to theright) to close valve.

d. Dispose of drained fluid IAWlocal policy and ordinances.


ITEM NO. INTERVAL

MAN-HOURS

LOCATION


CAPABLE IF:


427-C1675

TM 5-3805-291-10


0012 00-13

21 Before Fan Housing a. Check for leaks and damage to fanhousing and fan motor.

Damage that would impairoperation is evident. ClassIII leaks are evident.

b. Close hood (WP 0004 00).22 Before Right-Rear

Wheel and Tire

a. Check for missing lug nuts. Two or more lug nuts aremissing.





23 Before Right-Side Cab, Ladder, and Operator Platform

a. Inspect right side of cab for dam-age and broken glass.


b. Check that front and rear right-sideworklights are present and notdamaged.

c. Inspect ROPS/FOPS mountingbolts at two right corners outsidecab. Check for missing or loosebolts (WP 0024 00).



ITEM NO. INTERVAL

MAN-HOURS

LOCATION


CAPABLE IF:


TM 5-3805-291-10


0012 00-14

24 Before Frame Articu-lation Area

a. Inspect hydraulic hoses for dam-age or leaks.


b. Check that right-side steering cyl-inder attachment to front framesection is secure.


25 Before Right-Front Lights and Horn

a. Check that right-front servicelights and turnlamps are presentand not damaged.


b. Check that horn is present and notdamaged.

Horn is missing.


ITEM NO. INTERVAL

MAN-HOURS

LOCATION


CAPABLE IF:


427-C0019

TM 5-3805-291-10


0012 00-15

26 Before Right-Front Wheel and Tire






27 Before Quick Cou-pler and Lift Arms



b. Check for leaking hydraulic lineson work tool, quick coupler, liftarms, and tilt cylinder.


OPERATOR STATION

28 Before Platform and Top of Machine

a. Use left-side ladder and grabhan-dles to open door and latch in fullyopen position against cab wall.Climb up onto platform.

b. Check that hydraulic tank fillercap is present. Check for damageor leaks.

Hydraulic tank filler cap ismissing. Class III leaks areevident.

c. Ensure oil is visible in green areaof hydraulic tank sight gage.

Oil is not visible in sightgage.


ITEM NO. INTERVAL

MAN-HOURS

LOCATION


CAPABLE IF:


TM 5-3805-291-10


0012 00-16

28(Cont)

Before Platform and Top of Machine

d. If oil is not visible in red area ofsight gage, add oil as follows:

(1) Remove filler cap.

WARNINGSolvent cleaning compound MIL-PRF-680 Type III is anenvironmentally compliant and low toxic material. How-ever, it may be irritating to the eyes and skin. Use protectivegloves and goggles. Use in well-ventilated areas. Keep awayfrom open flames and other sources of ignition. Failure tofollow this warning may cause injury or death to personnel.

NOTERemove spring in order to remove screen.

(2) Check filler opening screen fordebris. If necessary, removescreen and clean with solventcleaning compound (Item 2,WP 0027 00), dry thoroughly,and reinstall.

(3) Add oil (Item 9, 10, 11, or 12,WP 0027 00) through filleropening until oil level is visiblein sight gage.


ITEM NO. INTERVAL

MAN-HOURS

LOCATION


CAPABLE IF:


TM 5-3805-291-10


0012 00-17

28(Cont)

Before Platform and Top of Machine

(4) Install filler cap.29 Before Cab Interior a. Enter cab and close door.

b. Visually check for missing ordamaged fire extinguisher. Ensureit is securely mounted in bracket.

Fire extinguisher is missingor damaged.

(1) Check gage for reading in greenarea.

Pressure gage needle is inred area.

(2) Check for damaged or missingseal.

Seal is broken or missing.

(3) Inspect fire extinguisher inspec-tion tag.

c. Check if seat belt is frayed, torn, orhas other damage. Check inspec-tion date.

Seat belt is damaged orinspection date is more than3 years.


ITEM NO. INTERVAL

MAN-HOURS

LOCATION


CAPABLE IF:


427-C1703

TM 5-3805-291-10


0012 00-18

29(Cont)

Before Cab Interior WARNINGUse of seat belt while operating machine ismandatory. Fasten belt BEFORE operatingmachine. Trying to fasten belt during operationcreates a hazardous condition. Failure to follow thiswarning may result in injury or death to personnelin the event of an accident or machine overturn.

d. Occupy seat. Adjust seat and inte-rior rearview mirrors. Fasten seatbelt (WP 0004 00).

e. Adjust steering column and checkif it locks into place.

Steering column does notlock into place.

f. Check switches, gages, indicators,and military light switch for dam-age.

Damage is evident thatwould impair operation.

g. Check for damage to throttle andbrake pedals. There should be freemovement.


h. Check for damage to loader con-trol joystick and auxiliary hydrau-lic control thumb wheel. Theyshould move freely.


30 Before Engine Start-up

a. Start engine and allow to warm up(WP 0005 00).

b. Ensure all alert indicators are func-tioning properly. Check gages forproper operation (WP 0004 00).

Alert indicator or gage mal-functions.

c. Check operation of all lights andturnlamps.

NOTEBackup alarm and horn will not sound if operating inblackout mode.

31 Before Backup Alarm a. Check operation of horn at bothlocations.

Horn does not operate.

b. Place transmission in R(REVERSE) and listen for backupalarm to sound.

Backup alarm does notsound.

c. Return transmission to N (NEU-TRAL). Machine is now ready tooperate.


ITEM NO. INTERVAL

MAN-HOURS

LOCATION


CAPABLE IF:


TM 5-3805-291-10


0012 00-19

32 Before Parking Brake WARNINGEnsure wheels are blocked before manuallyreleasing parking brake. Failure to follow thiswarning may result in machine rolling, causinginjury or death to personnel or damage toequipment.

Disengage parking brake switch. Parking brake switch doesnot disengage.

33 Before Transmission Controls and Service Brakes

a. Select transmission autoshift modeand place transmission in F (FOR-WARD).

Machine does not respondto transmission selection.

b. Move machine ahead slowly.Depress both brake pedals andensure machine stops.

Brakes do not stop machine.

34 Before Work Tool Hydraulic Controls

Unlock hydraulic controls. Cycleloader control joystick.

Controls do not functionproperly.


ITEM NO. INTERVAL

MAN-HOURS

LOCATION


CAPABLE IF:


TM 5-3805-291-10


0012 00-20

35 During0012 00

Overall Machine

a. Be alert for evidence of fluid leakssuch as oil, coolant, or fuel.

Class III oil or coolant leaksare evident. Any fuel leaksare evident.

b. Be alert for proper operation ofbrakes and power train compo-nents.

Brakes and power traincomponents malfunction.

c. Be alert for proper operation ofsteering components.

Steering system malfunc-tions.

d. Be alert for proper operation ofwork tool hydraulic controls.

Work tools do not functionproperly.

36 During Gages, Switches, and Indicators

a. Monitor all gages for proper oper-ation and readings in normalranges.

Gage indicates an abnormalreading.

b. Monitor all indicators to ensuremachine systems are operatingwithin normal range.

Indicators indicate an abnor-mal condition (WP 000400).

c. Shut down engine (WP 0005 00).


ITEM NO. INTERVAL

MAN-HOURS

LOCATION


CAPABLE IF:


TM 5-3805-291-10


0012 00-21

FRONT AND LEFT SIDE

37 After0012 00

Overall View a. Check under machine for evidenceof fluid leakage such as oil, cool-ant, or fuel.

Class III leaks oil or coolantare evident. Any fuel leaksare evident.



38 After Forklift Pallet Forks (If Equipped)

Check for cracked, bent, or otherwisedamaged forks and fork frame.


39 After Bucket and Bucket Tips (If Equipped)

Check bucket and bucket tips for bends, cracks, or other damage.


40 After Sweeper (If Equipped)

Check sweeper for damage. Damage that would impairoperation is evident.

41 After Quick Cou-pler, Tilt Cyl-inder, and Lift Arms



b. Ensure protective caps areinstalled on two quick disconnectfittings.

c. Check for loose hose clamps orleaking hydraulic lines on worktool, quick coupler, lift arms, andtilt cylinder.

Loose hose clamps or ClassIII leaks are evident.

d. Ensure tilt cylinder is notscratched.


42 After Left-Front Wheel and Tire

a. Check for loose or missing bolts,cracks, and loose components.

Two or more bolts are miss-ing. Loose components areevident.

b. Check tread and sidewall for cutsand foreign material in treads.Remove foreign material fromtreads.


c. Visually check tire inflation. Tire is flat.


ITEM NO. INTERVAL

MAN-HOURS

LOCATION


CAPABLE IF:


TM 5-3805-291-10


0012 00-22

42(Cont)

After Left-Front Wheel and Tire

d. Look behind tire to ensure axleseal is not leaking. A leaking axleseal will leave streaks of oil oninside of wheel.

Axle seal is leaking.

e. Check back side of wheel for oilleaks from final drive.

Class III oil leaks are evi-dent.

43 After Left-Front Lights

a. Check left-front service lights andturnlamps are present and notdamaged.


b. Check that blackout drive light ispresent and not damaged.

Blackout drive light is miss-ing or damaged, if requiredfor mission.

44 After Frame Articu-lation Area

a. Check for cracks or breaks in driveshaft.

Cracks or breaks are evi-dent.

b. Inspect hydraulic hoses for dam-age or leaks.


c. Check left-side steering cylinderattachment to front frame sectionis secure.


d. Inspect upper and lower articula-tion pin/bearing assemblies forevidence of cracks, breaks, looseor missing mounting bolts, ordamaged or missing grease fit-tings.

Upper and lower articula-tion pin/bearing assembliesare cracked, have breaks,loose or missing mountingbolts, or damaged or miss-ing grease fittings.

e. Check that steering frame lock ispresent and in good condition.Ensure it is disconnected andstowed.


ITEM NO. INTERVAL

MAN-HOURS

LOCATION


CAPABLE IF:


TM 5-3805-291-10


0012 00-23

45 After Left-Side Cab, Door, Ladder, and Operator Platform

a. Inspect front, left, and rear of cabfor damage and broken glass.Check for damaged or missingfront and rear windshield wipers/washers.


b. Check that front and rear left-sideworklights are present and notdamaged.

WARNINGUse caution and maintain three-point contact at all timeswhen mounting or dismounting machine. Failure to followthis warning may result in injury or death to personnel.

c. Check for damage to door, doorhandle, and grabhandles.




ITEM NO. INTERVAL

MAN-HOURS

LOCATION


CAPABLE IF:


TM 5-3805-291-10


0012 00-24

46 After Batteries, Left-Side Bat-tery Box, and NATO SlaveReceptacle

0012 00WARNING

• To avoid injury, eye protection and acid-resistantgloves must be worn when working around batteries.Do not smoke, use open flame, make sparks, or createother ignition sources around batteries. If a battery isgiving off gases, it can explode and cause injury to per-sonnel. Remove all jewelry such as rings, ID tags,watches, and bracelets. If jewelry or a tool contacts abattery terminal, a direct short will result in instantheating, damage to equipment, and injury to person-nel.

• Sulfuric acid contained in batteries can cause seriousburns. If battery corrosion or electrolyte makes contactwith skin, eyes or clothing, take immediate action tostop the corrosive burning effects. Failure to followthese procedures may result in injury or death to per-sonnel.

NOTE• For complete information on servicing batteries, refer

to TM 9-6140-200-14.• Perform service on both batteries.

a. Check that left-side battery boxcover is closed and secure. Be alertfor any evidence of electrolyteleakage coming from battery box.

Battery is leaking electro-lyte.

b. Open battery access cover underleft side of operator platform.

Battery is missing.

c. Inspect battery for obvious dam-age such as a cracked case andelectrolyte leakage.

Any electrolyte leakage isevident or damage to batter-ies.

d. Check battery hold-down for pres-ence, looseness, and damage. Ifloose, tighten wingnuts.

Hold-down is missing, looseor damaged.

e. Check battery for broken and cor-roded connections or frayed/burned/melted cables and clamps.

Broken and corroded con-nections or frayed/burned/melted cables and clampsare evident.


ITEM NO. INTERVAL

MAN-HOURS

LOCATION


CAPABLE IF:


TM 5-3805-291-10


0012 00-25

46(Cont)

After Batteries, Left-Side Bat-tery Box, and NATO SlaveReceptacle

f. Ensure battery is clean and batterycables are secure.

g. Close access cover and secure.h. Ensure that cover is installed on

NATO slave receptacle.

Battery cables are notsecure.

47 After WindshieldWasher FluidReservoir

a. Check for damage and leaks onwindshield washer fluid reservoir.

b. Check level of windshield washerfluid. If level is low, remove capand add windshield-cleaning com-pound until level is up to top offiller neck. Reinstall cap.

48 After Left-Rear Wheel and Tire

a. Check for loose or missing bolts,cracks, and loose components.




c. Visually check tire inflation. Tire is flat.d. Look behind tire to ensure axle

seal is not leaking. A leaking axleseal will leave streaks of oil oninside of wheel.



ITEM NO. INTERVAL

MAN-HOURS

LOCATION


CAPABLE IF:


427-C1680

TM 5-3805-291-10


0012 00-26

48(Con’t)

After Left-Rear Wheel and Tire



49 After Left-Side Engine Enclo-sure

CAUTIONScreen prevents stones or other flying debris from enteringengine compartment and causing damage to oil coolers andradiator. Ensure screen is maintained in good condition.

a. Inspect left-side access door fordamage. Remove any foreignmaterial from screen.

b. Check for debris and damage tohoses, tubes, and wires/connectorsin left-side engine enclosure.Remove any debris found.

Damage is evident. Ifcracks, splits, bulges, or softspots are evident in hoses.

c. Check for evidence of leaks. Class III leaks are evident.Any fuel leakage is evident.

d. Inspect around turbocharger andexhaust manifold for exhaustleaks.

Exhaust leaks are evident.

REAR AND RIGHT SIDE

50 After Overall View a. Check on ground under machinefor evidence of fluid leakage suchas oil, coolant, or fuel.




51 After Rear of Machine

a. Check that rear lights are presentand not damaged.

Rear lights are missing ordamaged, if required formission.

b. Open rear access door.c. Ensure fuel tank filler cap is

installed.Fuel tank filler cap is miss-ing.

d. Check for evidence of any leak. Any fuel leaks are evident.


ITEM NO. INTERVAL

MAN-HOURS

LOCATION


CAPABLE IF:


TM 5-3805-291-10


0012 00-27

51(Con’t)

After Rear of Machine


machine while you are servicing fuel system. Be surehose nozzle is grounded against filler tube duringrefueling to prevent static electricity. Failure to fol-low this warning may result in injury or death to per-sonnel, or damage to equipment.

• Operating personnel must wear fuel-resistant gloveswhen handling fuels. If exposed to fuel, promptlywash exposed skin and change fuel-soaked clothing.

• ALWAYS stop engine prior to refueling. If equippedwith an arctic cold weather starting aid system, turnengine coolant heater off.

NOTEEnsure portable fire extinguisher is withinreach prior to refueling.

e. Refuel machine, if required (WP0013 00).

f. Unlatch cooler assembly andswing rearward. Ensure that fins oftransmission and hydraulic oilcoolers, aftercooler, and radiatorare not bent, torn, or punctured.Close cooler assembly.


g. Close rear access door.h. Tilt hood to open position (WP

0004 00).i. Use key to open left and right side

inspection panels and inspect fordamage.



ITEM NO. INTERVAL

MAN-HOURS

LOCATION


CAPABLE IF:


TM 5-3805-291-10


0012 00-28

52 After Right-Side Engine Enclo-sure

CAUTIONScreen prevents stones or other flying debris from enteringengine compartment and causing damage to oil coolers andradiator. Ensure screen is maintained in good condition.

a. Inspect right-side access door fordamage. Remove any foreignmaterial from screen.

b. Check for debris and damage tohoses, tubes, fuel filters, andwires/connectors in right-sideengine enclosure. Remove anydebris found.

Damage is evident. Ifcracks, splits, bulges, or softspots are evident in hoses.

c. Check for evidence of leaks. Class III leaks are evident.Any fuel leaks are evident.

53 After 0.2 Hour Engine Oil Level

a. Wipe area clean around dipstick.

CAUTIONWhen removing dipstick, be alert for evidence of fuel orantifreeze contamination. Antifreeze has a characteristicodor which can be detected. Fuel will separate from engineoil and leave a bulls eye stain on rag.

b. Remove dipstick and inspect con-dition of oil. Look for evidence ofantifreeze or fuel contamination.Report any problem to your super-visor.

c. Wipe dipstick clean, then reinsertinto dipstick tube until fullyseated. Remove dipstick and takereading.

d. Level must be within cross-hatched area on dipstick.

e. If level is low, turn filler cap coun-terclockwise (to the left) and addlubricating oil (Item 9, 10, 11, or12, WP 0027 00) through fillertube opening until level on dip-stick is correct. Refer to KEY atend of this work package for cor-rect grade of oil for expected tem-perature range.


ITEM NO. INTERVAL

MAN-HOURS

LOCATION


CAPABLE IF:


TM 5-3805-291-10


0012 00-29

53(Cont)

After 0.2 Hour Engine Oil Level

f. Reinstall dipstick and turn clock-wise (to the right) until tight.

g. Tilt hood to open position (WP0004 00).

Hood does not open.

54 After Right-Rear Wheel and Tire

a. Check for loose or missing bolts,cracks, and loose rim components.







e. Check backside of wheel for oilleaks from final drive.


55 After Right-Side Cab, Ladder, and Operator Platform

a. Inspect right side of cab for dam-age and broken glass.

b. Check that front and rear right-sideworklights are present and notdamaged.


c. Check for damage to windows andgrabhandles.



f. Inspect for missing, damaged, orleaking remote grease fittings.

Remote grease fittings aremissing or damaged. Leaksthat would prevent properlubrication are evident.

56 After Frame Articu-lation Area

a. Inspect hydraulic hoses for dam-age or leaks.



ITEM NO. INTERVAL

MAN-HOURS

LOCATION


CAPABLE IF:


TM 5-3805-291-10


0012 00-30

56(Con’t)

After Frame Articu-lation Area

b. Check that right-side steering cyl-inder attachment to front framesection is secure.


c. Inspect upper and lowerarticulation pin/bearing assembliesfor evidence of cracks, breaks,loose or missing mounting bolts,or damaged or missing greasefittings.

Upper and lower articula-tion pin/bearing assembliesare cracked, have breaks,loose or missing mountingbolts, or damaged or miss-ing grease fittings.

57 After Right-Front Lights

Check right-front service lights andturnlamps for damage.

Lights are missing ordamaged.

58 After Right-Front Wheel and Tire

a. Check for loose or missing bolts,cracks, and loose rim components.






Class III oil leak is evident.



59 After Quick Cou-pler and Lift Arms



b. Check for loose hose clamps orleaking hydraulic lines on worktool, quick coupler, lift arms, andtilt cylinder.

Loose hose clamps or ClassIII leaks are evident.

OPERATOR STATION

60 After Platform and Top of Machine

0012 00

a. Use left-side ladder and grabhan-dles to open door. Latch door infully open position against cabwall. Climb up onto platform.

0012 00


ITEM NO. INTERVAL

MAN-HOURS

LOCATION


CAPABLE IF:


TM 5-3805-291-10


0012 00-31

60(Con’t)

After Platform and Top of Machine

0012 00

b. Check that hydraulic tank fillercap is present. Check for damageor leaks.

Hydraulic tank filler cap isdamaged or missing. ClassIII leaks are evident.

c. Ensure oil is visible in hydraulictank sight gage.

Oil is not visible in sightgage.

61 After Cab Exterior a. Inspect front and rear windshieldsfor damage and cleanliness. Ifdirty, use windshield cleaningcompound to clean.

b. Inspect front and rear windshieldwipers/washers for damage.Ensure wiper blades are in goodcondition.

62 After ROPS/FOPS a. Check for cracks, bends, and bro-ken welds.

ROPS/FOPS has cracks,bends, or broken welds.

NOTEThe top portion of cab can be removed for transport. Thereare four bolts to secure top of cab. There are four differentbolts that secure the entire cab to chassis.

b. Inspect ROPS/FOPS mountingbolts at four corners outside cab.Check for missing or loose bolts.


c. Check four exterior bolts at splitline.



ITEM NO. INTERVAL

MAN-HOURS

LOCATION


CAPABLE IF:


427-C1703

TM 5-3805-291-10


0012 00-32

63 After Hood and Bat-tery Discon-nect Switch

a. Tilt hood to close position (WP0004 00).

b. Turn battery disconnect switch toOFF position (WP 0004 00).

64 Weekly0012 00

Engine Air Precleaner and Air Cleaner

Service engine air precleaner and aircleaner (WP 0014 00).

65 Weekly0012 00

Cab Air Fil-ters

0012 00

WARNING• If NBC exposure is suspected, personnel wearing pro-

tective equipment must handle all air cleaner media.Consult your NBC Officer or NBC NCO for appropri-ate handling or disposal procedures.

• Refer to FM 3-11.3, Multiservice Tactics,Techniques, and Procedures for Chemical,Biological, Radiological, and NuclearContamination Avoidance, and FM 3-11.5,Multiservice Tactics, Techniques, and Proceduresfor Chemical, Biological, Radiological, and NuclearDecontamination.

• NBC contaminated filters must be handled using ade-quate precautions and must be disposed of by trainedpersonnel.

• Failure to follow these warnings may cause injury ordeath.

NOTEPerform this procedure daily if conditions necessitate it.


ITEM NO. INTERVAL

MAN-HOURS

LOCATION


CAPABLE IF:


TM 5-3805-291-10


0012 00-33

65(Con’t)

Weekly0012 00

Cab Air Fil-ters 0012 00

There are two cab air filters. First fil-ter is located on the left side of theoperator seat and second is behindaccess door on left side of cab. Serviceas indicated in the following steps:a. Turn counterclockwise (to the left)

and remove two thumbscrews andgrille from left of operator seat.

b. Inspect air filter for tears or holes.If torn or otherwise damaged,obtain a replacement from UnitMaintenance.

c. Wash air filter in a solution ofdetergent and water. Rinse thor-oughly and air dry.

d. Install air filter and tighten twothumbscrews by turning clockwise(to the right).


ITEM NO. INTERVAL

MAN-HOURS

LOCATION


CAPABLE IF:


427-C1676427-C1677

TM 5-3805-291-10


0012 00-34

65(Cont)

Weekly Cab Air Fil-ters

e. Open access door on left side ofcab.

f. Remove air filter from left side ofcab.


ITEM NO. INTERVAL

MAN-HOURS

LOCATION


CAPABLE IF:


427-C1679427-C1678

TM 5-3805-291-10


0012 00-35

65(Cont)

Weekly Cab Air Fil-ters

WARNINGParticles blown by compressed air are hazardous. DO NOTexceed 15 psi (103 kPa) nozzle pressure when drying partswith compressed air. Use a maximum of 30 psi (207 kPa)when cleaning components. DO NOT direct compressed airagainst human skin. Failure to follow this warning mayresult in injury. Make sure air stream is directed away fromuser and other personnel in the area. To prevent injury,user must wear protective goggles or face shield.

g. Clean air filter with compressedair. Filter may also be washed in asolution of detergent and water.Dry thoroughly.

NOTEDo NOT reinstall any damaged air filter component. If airfilter or angle bracket are damaged or gasket sealing is notOK, filter will not function properly to remove dust frominside cab.

h. Inspect air filter for torn or other-wise damaged pleats. If damaged,obtain a replacement from UnitMaintenance.

i. Install air filter on left side of cab.j. Close filter access door on left side

of cab.66 Weekly Wheels and

Tiresa. Check if bolts are loose. Bolts are loose.


ITEM NO. INTERVAL

MAN-HOURS

LOCATION


CAPABLE IF:


TM 5-3805-291-10


0012 00-36

66(Cont)

Weekly Wheels and Tires

WARNING• 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 toequipment or injury to personnel.

• If tire pressure is 20 psi (138 kPa) or less, do NOTinflate. Notify Unit Maintenance. Failure to follow thiswarning may cause injury or death to personnel.

b. Clean area around valve stem witha rag, then remove valve stem cap.

c. Check air pressure in each tirewith tire pressure gage (Item 11,Table 2, WP 0026 00). Tire infla-tion should be 60 psi (414 kPa) forfront tires and 40 psi (276 kPa) forrear tires.

WARNINGUse a self-inflating chuck and stand at a distance behindtire when inflating tire. Failure to follow this warning maycause injury or death to personnel.

d. Adjust air pressure in tire asrequired.

e. Install valve stem cap.f. Check tread depth. Tread depth is less than

11/32 in. (8.8 mm).


ITEM NO. INTERVAL

MAN-HOURS

LOCATION


CAPABLE IF:


TM 5-3805-291-10


0012 00-37

67 Weekly 0.4 Hour Remote Grease Fit-tings

a. Open access door on right side ofoperator platform.

b. Wipe seven grease fittings cleanwith a rag.

c. Apply GAA grease to seven greasefittings. Wipe off excess greasefrom fittings.


ITEM NO. INTERVAL

MAN-HOURS

LOCATION


CAPABLE IF:


427-C1682427-C1681

TM 5-3805-291-10


0012 00-38

68 Weekly 0.1 Hour Steering Cylin-der Rod Ends Grease Fit-tings

a. Wipe steering cylinder rod endgrease fittings clean with a rag.

b. Apply GAA grease to grease fit-ting. Wipe off excess grease with arag.

c. Repeat to lubricate steering cylin-der rod end on other side ofmachine.


ITEM NO. INTERVAL

MAN-HOURS

LOCATION


CAPABLE IF:


427-C1683

TM 5-3805-291-10


0012 00-39

69 Weekly 0.3 Hour Bucket Link-age and Loader Cylin-der Bearings

a. Wipe four grease fittings cleanwith a rag.

b. Apply GAA grease to four fittings.Wipe off excess grease from fit-tings.


ITEM NO. INTERVAL

MAN-HOURS

LOCATION


CAPABLE IF:


427-C1684 427-C1685

TM 5-3805-291-10


0012 00-40

70 Weekly 0.2 Hour Lift Arm Lower Pivot Bearings

a. Wipe two grease fittings cleanwith a rag.

b. Apply GAA grease to two fittings.Wipe off excess grease from fit-tings.

71 Weekly 0.2 Hour Lift Arm Upper Pivot Bearings

a. Wipe two grease fitting clean witha rag.



ITEM NO. INTERVAL

MAN-HOURS

LOCATION


CAPABLE IF:


427-C1686

427-C1687

TM 5-3805-291-10


0012 00-41

72 Weekly 0.3 Hour Quick Coupler a. Wipe four grease fittings cleanwith a rag.

b. Apply GAA grease to four fittings.Wipe off excess grease from fit-tings.

73 Weekly 0.2 Hour Articulation Bearings

0012 00

a. Wipe two grease fittings cleanwith a rag.



ITEM NO. INTERVAL

MAN-HOURS

LOCATION


CAPABLE IF:


427-C1688

427-C1690427-C1689

TM 5-3805-291-10


0012 00-42

74 Monthly0012 00

0.2 Hour Hood Tilt ActuatorGrease Fit-tings


b. Wipe two grease fittings cleanwith a rag.

Hood does not open.

c. Apply GAA grease to two fittings.Wipe off excess grease from fit-tings.

d. Close hood (WP 0004 00).

75 Monthly 0.3 Hour Drive Shaft Spline (Cen-ter)

WARNINGStand clear of frame articulation area when machine isoperating. There is no clearance for personnel in this areawhen machine turns. Crushing could occur, resulting ininjury or death to personnel.

CAUTIONTo prevent damage to seal, fully articulate machine to theright or to the left BEFORE lubricating drive shaft spline(center).

a. Start engine (WP 0005 00). Raisework tool (WP 0004 00).

b. Disengage parking brake. Fullyarticulate machine right or left(WP 0004 00).


ITEM NO. INTERVAL

MAN-HOURS

LOCATION


CAPABLE IF:


427-C1691

TM 5-3805-291-10


0012 00-43

75(Con’t)

Monthly 0.3 Hour Drive Shaft Spline (Cen-ter)

c. Lower work tool to ground.Engage parking brake (WP 000400).

d. Shut down engine (WP 0005 00).e. Wipe grease fitting clean with a

rag.f. Apply GAA grease to grease fit-

ting. Apply grease until reliefoverruns. Wipe off excess greasewith a rag.

g. Start engine (WP 0005 00). Raisebucket off ground (WP 0004 00).

h. Disengage parking brake and artic-ulate machine until it is straight(WP 0004 00).

i. Lower bucket to ground and applyslight downward pressure (WP0004 00).

j. Shut down engine (WP 0005 00).Engage parking brake (WP 000400).

76 Monthly 0.2 Hour Coolant Nitrites Level

0012 00

WARNING• DO NOT service cooling system unless engine has been

allowed to cool down. This is a pressurized cooling sys-tem and escaping steam or hot coolant will cause seri-ous burns.

• DO NOT remove cooling system radiator cap whenengine is hot. Allow engine to cool down. Loosen cap tofirst stop and let any pressure out of cooling system,then remove cap. Failure to follow this warning maycause serious burns.

• Wear effective eye, glove, and skin protection whenhandling coolants. Failure to do so may cause injury.

Use test strips (Item 17, WP 0027 00)to test nitrites level in coolant. If teststrip indicates nitrites level is too low,notify Unit Maintenance to replacecoolant.


ITEM NO. INTERVAL

MAN-HOURS

LOCATION


CAPABLE IF:


TM 5-3805-291-10


0012 00-44

77 Monthly Brake Accu-mulator Check

a. Turn engine start switch to ONposition. Low brake pressure alertindicator should come on if brakesystem pressure is not at normaloperating pressure (WP 0004 00).

b. Start engine (WP 0005 00). Runengine at half speed for two min-utes to allow accumulator pressureto increase. Low brake pressurealert indicator should go off.

c. Shut down engine (WP 0005 00).d. Apply service brakes and release

service brakes until low brakepressure alert indicator comes on(due to decrease in accumulatorpressure). A minimum of five ser-vice brake applications arerequired.

e. If less than five applications wererequired, accumulator needsrecharging. Notify Unit Mainte-nance.

Accumulator is discharged.

78 Monthly Service Brake Holding Abil-ity Test

WARNINGIf machine begins to move during test, reduce engine speedimmediately and engage parking brake. Personal injurycan result if machine moves during test.

a. Observe the following conditions/precautions:

(1) Test brakes on a dry, level sur-face.

(2) Ensure steering frame lock isdisconnected and stowed (WP0015 00).

(3) Check area around machine toensure machine is clear of per-sonnel and obstructions.


ITEM NO. INTERVAL

MAN-HOURS

LOCATION


CAPABLE IF:


TM 5-3805-291-10


0012 00-45

78(Cont)

Monthly Service Brake Holding Abil-ity Test

WARNINGUse of seat belt while operating machine is mandatory. Fas-ten belt BEFORE operating machine. Trying to fasten beltduring operation creates a hazardous condition. Failure tofollow this warning may result in injury or death to person-nel in the event of an accident or machine overturn.

(4) Fasten seat belt before testingbrakes.

b. Start engine (WP 0005 00). Raisework tool slightly (WP 0004 00).

c. Apply right service brake pedaland disengage parking brake (WP0004 00).

d. Use messenger to disable trans-mission neutralizer (WP 0004 00).

e. Place autoshift control switch inMANUAL mode (WP 0004 00).Move transmission control lever to3rd speed F (FORWARD) (WP0004 00).

f. Gradually increase engine speed tohigh idle. Machine should notmove.

g. Reduce engine speed to low idle.Move transmission control lever toN (NEUTRAL) (WP 0004 00).

h. Lower work tool to ground (WP0004 00).

i. Engage parking brake (WP 000400). Shut down engine (WP 000500).

j. If machine moved during test,notify Unit Maintenance.


ITEM NO. INTERVAL

MAN-HOURS

LOCATION


CAPABLE IF:


TM 5-3805-291-10


0012 00-46

79 Monthly Parking Brake Holding Abil-ity Test

WARNINGIf machine begins to move during test, reduce engine speedimmediately and engage service brake. Personal injury canresult if machine moves during test.

a. Observe the following conditions/precautions:

(1) Test brakes on a dry, level sur-face.

(2) Ensure steering frame lock isdisconnected and stowed (WP0015 00).

(3) Check area around machine toensure machine is clear of per-sonnel and obstructions.

WARNINGUse of seat belt while operating machine is mandatory. Fas-ten belt BEFORE operating machine. Trying to fasten beltduring operation creates a hazardous condition. Failure tofollow this warning may result in injury or death to person-nel in the event of an accident or machine overturn.

(4) Fasten seat belt before testingbrakes.

b. Start engine (WP 0005 00). Raisework tool slightly (WP 0004 00).

c. Engage parking brake (WP 000400).

NOTE• Ensure military light switch is in SER. DRIVE mode.• Parking brake alert indicator should come on and

action alarm should sound.

d. Place transmission direction andspeed control in THIRD SPEEDFORWARD position.

e. Place autoshift control in MAN-UAL mode.

f. Gradually increase engine speed tohigh idle. Machine should notmove.


ITEM NO. INTERVAL

MAN-HOURS

LOCATION


CAPABLE IF:


TM 5-3805-291-10


0012 00-47

79(Cont)

Monthly Parking Brake Holding Abil-ity Test

g. Reduce engine speed to low idle.Move transmission control lever toN (NEUTRAL) (WP 0004 00).

h. Lower work tool to ground (WP0004 00).

i. Engage parking brake (WP 000400). Shut down engine (WP 000500).

j. If machine moved during test,notify Unit Maintenance. Haveparking brakes inspected andrepaired, if necessary, beforereturning machine to service.

80 Monthly Decals and Data Plates

Ensure all decals and data plates arepresent and legible (WP 0007 00).

81 Monthly Arctic Heater (If Equipped)

Start arctic heater and run for 15 to 20minutes. Shut off.

Arctic heater does not func-tion.

82 Monthly All Systems -Machine Exer-cise

CAUTIONDO NOT perform this PMCS exercise when temperature isbelow 0 F (-18 C). Doing so can cause damage to equip-ment.

NOTEDO NOT exercise machine if it has been operated withinthe past month.

a. Perform Before operation PMCS.b. Start and warm up engine (WP

0005 00). c. While machine is warming up,

perform a walkaround inspection,checking for evidence of leaks.


NOTEIf temperature is below 32 F (0 C), operate controls priorto moving machine.

d. When machine has warmed up,begin to operate ALL controlsslowly (WP 0004 00):

(1) Transmission in all rangesincluding reverse.


ITEM NO. INTERVAL

MAN-HOURS

LOCATION


CAPABLE IF:


TM 5-3805-291-10


0012 00-48

82(Cont)

Monthly All Systems -Machine Exer-cise

(2) Service brakes applied andreleased.

(3) Parking brake engaged and dis-engaged.

(4) Steering from full left to fullright.

(5) All hydraulic controls (loadercontrol joystick and auxiliaryhydraulic control).

e. Operate controls for another 5minutes.

f. Move machine and operate allcontrols through full motion tobring all systems to operating tem-perature.

g. Move machine and continue tooperate all controls through fullmotion for 30 minutes AFTERmachine systems have reachedoperating temperature.

h. Stop machine and allow to idle for5 minutes.

i. Shut down engine (WP 0005 00).j. Perform After operation PMCS.


ITEM NO. INTERVAL

MAN-HOURS

LOCATION


CAPABLE IF:


TM 5-3805-291-10


0012 00-49

LUBRICATION INSTRUCTIONS 0012 00

WARNINGWhen servicing this machine, performing maintenance, or disposing of materials such as engine coolant,hydraulic fluid, lubricants, battery acids or batteries, windshield cleaning compound, and CARC paint,consult your unit/local hazardous waste disposal center or safety office for local regulatory guidance. Iffurther information is needed, please contact The Army Environmental Hotline at 1-800-872-3845.

NOTE• Lubrication instructions contained in this PMCS are MANDATORY.• Overall view of lubrication points is located at the end of this work package. Localized views are located,

together with specific lubrication instructions, in the PMCS Table.• The loader is not enrolled in the Army Oil Analysis Program (AOAP). • Refer to FM 9-207 for lubrication in arctic operation.

1. Included in this PMCS are lubrication services to be performed by the operator. 2. Lubrication intervals are based on normal operation. Lubricate more during constant use and less during inactive peri-

ods. Use correct grade of lubricant for seasonal temperature expected. Refer to the KEY on the next page.3. For equipment under manufacturer’s warranty, hardtime intervals shall be followed. Shorten intervals if lubricants are

known to be contaminated or if operation is under adverse conditions (e.g., longer than usual operating hours, extendedidling periods, extreme dust, etc.).

4. Keep all lubricants in a closed container and store in a clean, dry place away from extreme heat. Keep container coversclean and do not allow dust, dirt, or other foreign material to mix with lubricants. Keep lubrication equipment clean andready for use.

WARNINGSolvent cleaning compound MIL-PRF-680 Type III is an environmentally compliant and low toxicmaterial. However, it may be irritating to the eyes and skin. Use protective gloves and goggles. Use in well-ventilated areas. Keep away from open flames and other sources of ignition. Failure to follow this warningmay result in injury or death to personnel.

5. Clean area around lubrication points with solvent cleaning compound (Item 2, WP 0027 00) or equivalent before lubri-cating equipment. Keep all external parts of equipment not requiring lubrication free of lubricants. After lubrication,wipe off excess lubricant to prevent accumulation of foreign matter.

6. Maintain a record of lubrication performed and report any problems noted during lubrication. Refer to DA PAM 750-8for forms and procedures to record and report any findings.

TM 5-3805-291-10


0012 00-50

LUBRICATION INSTRUCTIONS – CONTINUED

NOTEOnly lubricants authorized for use by the operator are listed in this KEY.

- KEY-

LUBRICANT/COMPONENT

REFILLCAPACITY INTERVALSEXPECTED TEMPERATURES*

OE/HDOLubricating Oil, ICE,Tactical Service(MIL-PRF-2104)

D - DailyW - WeeklyM - Monthly

Engine Crankcase 9.25 gal.(35 L)

See Table 2

Transmission 13.2 gal.(50 L)

See Table 2

Hydraulic Tank 29 gal.(110 L)

See Table 2

Hydraulic System 52.3 gal.(198 L)

GAAGrease, Automotive and Artillery

Remote Grease Fittings As Reqd See Table 2

Lift Arms and Linkage As Reqd See Table 2

Steering Cylinder Rod Ends As Reqd See Table 2

Hood Tilt Cylinder As Reqd See Table 2

ANTIFREEZE

Cooling System 11.2 gal.(42.3 L)

See Table 3

* For arctic operation, refer to FM 9-207.

TM 5-3805-291-10


0012 00-51

LUBRICATION INSTRUCTIONS – CONTINUED 0012 00

Table 2. Lubricants.

COMPARTMENT COMMERCIAL LUBRICANT

VISCOSITY GRADE

MILITARYLUBRICANT

TEMPERATURERANGE

Engine CF-4 or Better SAE 5W-40 OE/HDO-5/40 -25oF to 120oF (-32oC to 49oC)SAE 15W-40 OE/HDO-15/40 15oF to 120oF (-9oC to 49oC)SAE 0W-30 OEA-30 -40oF to 90oF (-40oC to 32oC)

Transmission TO-4 SAE 40 OE/HDO-40 40oF to 120oF (4oC to 49oC)SAE 50 N/A 50oF to 120oF (10oC to 49oC)SAE 0W-30 OEA-30 -40oF to 70oF (-40oC to 21oC)

Hydraulic CF or Better SAE 5W-40 OE/HDO-5/40 -25oF to 120oF (-32oC to 49oC)SAE 15W-40 OE/HDO-15/40 5oF to 120oF (-15oC to 49oC)SAE 0W-30 OEA-30 -40oF to 100oF (-40oC to 38oC)

Axles TO-4 SAE 50 N/A 50oF to 120oF (10oC to 49oC)SAE 0W-30 OEA-30 -40oF to 50oF (-40oC to 10oC)

Grease MPG NLGI No. 2 GAA -25oF to 120oF (-32oC to 49oC)

Table 3. Coolants.

COOLANT TYPE MIXTURE MILITARY COOLANT

TEMPERATURERANGE

EngineCoolant

I-Ethylene GlycolII-Propylene Glycol

60/40 A-A-52624 -50oF to 120oF (-46oC to 49oC)

EngineCoolant

I-Ethylene GlycolII-Propylene Glycol

50/50 A-A-52624 -30oF to 120oF (-34oC to 49oC)

TM 5-3805-291-10


0012 00-52


LUBRICANT • INTERVAL INTERVAL • LUBRICANT

427-C0365

0012 00-53/(0012 00-54 Blank)

TM 5-3805-291-10

PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INCLUDING LUBRICATION INSTRUCTIONS- CONTINUED 0012 00


END OF WORK PACKAGE

LUBRICANT • INTERVAL INTERVAL • LUBRICANT

427-C0366

TM 5-3805-291-10

CHAPTER 5

MAINTENANCE INSTRUCTIONS

TM 5-3805-291-10

0013 00-1

REFUELING AND FUEL SYSTEM PRIMING 0013 00


Refueling, Fuel System Priming

INITIAL SETUP


Extinguisher, fire (Item 4, Table 2, WP 0026 00)

Materials/Parts

Fuel (Item 5, 6, or 7, WP 0027 00)


Personnel Required


Equipment ConditionsMachine parked on level ground (WP 0005 00)

Work tool lowered to ground (WP 0005 00)Parking brake engaged (WP 0005 00)Engine OFF (WP 0005 00)

Engine coolant heater OFF, if equipped with arcticoperation machine (WP 0004 00)

Battery disconnect switch in OFF position (WP0004 00)

REFUELING 0013 00




• ALWAYS stop engine prior to refueling. If equipped with an arctic cold weather starting aid system, turnengine coolant heater off.

NOTEEnsure portable fire extinguisher is within reach prior to refueling.

1. Open rear access door at rear of machine.

2. Locate fuel tank filler cap at right-rear of machine.

3. Remove any dirt from around filler cap.

4. Lift up on black tab, turn filler cap one quarter turn counterclockwise (to the left), and remove filler cap from fuel tankfiller opening.

5. Inspect filler cap for a damaged or missing gasket. If damaged or missing, contact Unit Maintenance to obtain a replace-ment gasket.

6. If strainer in filler opening is filled with debris, remove debris.

2

TM 5-3805-291-10

REFUELING AND FUEL SYSTEM PRIMING - CONTINUED 0013 00

0013 00-2

REFUELING - CONTINUED

7. If necessary to remove strainer to facilitate cleaning, reach in with your fingers and pull strainer out of filler opening.

8. Clean debris and reinstall strainer in filler opening.

NOTE• Fuel tank capacity is 106 gal. (404 L).• DO NOT overfill fuel tank. If fuel starts foaming from fuel tank, stop IMMEDIATELY to avoid fuel spillage.• Ensure any fuel spillage is cleaned up.

9. Fill fuel tank with fuel. Use correct grade of fuel IAW expected temperature range of operation.

10. Position filler cap in filler opening and turn black tab one quarter turn clockwise (to the right).

11. Fold black tab down into green tab.

12. Close rear access door.

FUEL SYSTEM PRIMING 0013 00

NOTE• If engine fails to start because loader

ran out of fuel, it may be necessary toprime fuel system.

• Fuel priming pump is located aboveprimary fuel filter on right side ofengine.

1. Tilt hood (WP 0004 00).2. Turn fuel priming pump toggle switch to ON position

and operate pump for approximately 60 seconds. Turnswitch to OFF position.

3. Start engine (WP 0005 00).

4. Operate fuel priming pump for additional time if any of the following conditions exist:

a. Engine continues to not start.

b. Engine starts but continues to misfire or emit smoke.

5. Lower hood (WP 0004 00).

END OF WORK PACKAGE

427-C1675

TM 5-3805-291-10

0014 00-1

ENGINE AIR PRECLEANER SERVICE AND AIR CLEANER SERVICE 0014 00


Service

INITIAL SETUP

Materials/Parts


Personnel Required


References

FM 3-11.3

FM 3-11.5



Work tool lowered to ground (WP 0005 00)


Engine OFF (WP 0005 00)

Battery disconnect switch in OFF position (WP0004 00)

SERVICE






CAUTION

Never service air cleaner with engine running. Engine damage could result if service is performed withengine running.

4

TM 5-3805-291-10

ENGINE AIR PRECLEANER SERVICE AND AIR CLEANER SERVICE - CONTINUED 0014 00

0014 00-2

SERVICE - CONTINUED

1. Tilt hood (WP 0004 00). Access air cleaner on right side of machine.

2. Release three clamps and remove cover from air cleaner housing.

3. Remove primary filter element from air cleaner housing.

4. Remove secondary filter element from air cleaner housing. Cover air inlet opening with a rag.

5. Clean inside of air cleaner housing with a rag.

CAUTIONDO NOT use a damaged primary filter element. Engine damage can result.

6. Inspect primary filter element for damaged pleats, tears, holes, gaskets, and seals. Discard primary filter element if anydamage is evident. Obtain replacement from Unit Maintenance.

7. If primary filter element appears OK, clean as follows:

WARNINGParticles blown by compressed air are hazardous. Use a maximum of 30 psi (207 kPa) when cleaning com-ponents. DO NOT direct compressed air against human skin. Failure to follow this warning may result ininjury. 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.

CAUTION• To prevent damage, DO NOT clean primary filter element by bumping or tapping.

• DO NOT wash primary filter element.

a. Direct compressed air inside primary filter element, from top to bottom along length of filter pleats.

b. Direct compressed air outside, from top to bottom along length of filter pleats.

427-C0003

TM 5-3805-291-10

ENGINE AIR PRECLEANER SERVICE AND AIR CLEANER SERVICE - CONTINUED 0014 00

0014 00-3/(0014 00-4 Blank)

SERVICE - CONTINUED

NOTEA light may be used to inspect for damage inside primary filter element.

8. After cleaning, inspect primary filter element again for damaged pleats, tears, holes, gaskets, and seals. Discard primaryfilter element if any damage is evident. Obtain replacement from Unit Maintenance.

NOTESecondary filter element must be replaced for every third primary filter element replacement.

9. Uncover air inlet opening and install secondary filter element inside air cleaner housing.

NOTEPrimary filter element should be replaced after being cleaned a maximum of six times. If primary filterelement has been in service for 1 year, it should also be replaced.

10. Install primary filter element in air cleaner housing.11. Ensure cover and dust ejector are clean. Clean as needed.12. Position cover on air cleaner housing with dust ejector facing down. Secure cover with three clamps.13. Run engine and check for proper operation (WP 0005 00). Ensure that engine air filter indicator does not come on (WP

0004 00).14. Lower hood (WP 0004 00).

END OF WORK PACKAGE

TM 5-3805-291-10

0015 00-1

STEERING FRAME LOCK CONNECTION AND DISCONNECTION 0015 00


General Information, Connection, Disconnection

INITIAL SETUP

Tools and Special ToolsCOEI (Items 2 thru 4, Table 1, WP 0026 00)


tor (2)

Equipment ConditionsMachine parked on level ground (WP 0005 00)Work tool lowered to ground (WP 0005 00)Parking brake engaged (WP 0005 00)Engine shut down (WP 0005 00)

WARNING• Stand clear of frame articulation area when machine is operating. There is no clearance for personnel in this

area when machine turns. Crushing could occur, resulting in injury or death to personnel.• DO NOT operate machine with steering frame lock connected. Steering frame lock must be disconnected and

securely stowed. If not properly stowed, loss of steering control could result. Failure to follow this warningmay result in injury or death to personnel or damage to equipment.

• Connect steering frame lock between front and rear frames before lifting, transporting, or servicing machinein frame articulation area. Disconnect steering frame lock and secure in stowed position before resumingoperation. Failure to follow this warning may result in injury or death to personnel or damage to equipment.

GENERAL INFORMATION

1. The 966H Wheel Loader has a front frame section and a rear frame section with center-point frame articulation. 2. Clearances in frame articulation area can be greatly reduced as machine turns.3. To stop all articulation when machine is being serviced, lifted, or transported, a steering frame lock (located on left side

of machine) is connected between front and rear frame sections.4. To allow full steering during operation, the steering frame lock is disconnected from front frame section and stowed on

rear frame section.

2

TM 5-3805-291-10

STEERING FRAME LOCK CONNECTION AND DISCONNECTION - CONTINUED 0015 00

0015 00-2

CONNECTION

1. Remove retainer pin from pin.

2. Move steering frame lock into position at front frame section.


NOTEIt may be necessary to move front framesection to align pin bores.

3. Install pin and retainer pin.

DISCONNECTION

1. Remove retainer pin from pin.2. Move steering frame lock to stowed position on rear frame section.3. Install pin and retainer pin.

END OF WORK PACKAGE

427-C0007

427-C0008

TM 5-3805-291-10

0016 00-1

CIRCUIT BREAKER AND FUSES RESET/REPLACE 0016 00

CIRCUIT BREAKERS RESET 0016 00

The circuit breakers are located on the left side of the machine in front of the steps. Press the button in order to reset thecircuit breakers. If the circuit is functioning properly, the button will remain depressed. If the button will not remain depressed,check the appropriate electrical circuit (WP 0008 00).

1. 80 Amp Circuit Breaker (1).2. 80 Amp Circuit Breaker (2).3. 50 Amp Circuit Breaker (3).

FUSE REPLACEMENT 0016 00

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

1. Fuses protect the electrical system from a circuit that has been overloaded. Change a fuse if the element separates. If theelement of a new fuse separates, notify Unit Maintenance.

2. Fuses are located in cab on right side of operator seat.

427-C0367

4

TM 5-3805-291-10

CIRCUIT BREAKER AND FUSES RESET/REPLACE - CONTINUED 0016 00

0016 00-2

FUSE REPLACEMENT - CONTINUED

Fuse Block

FUSE RELAY DESCRIPTION

F1 rear worklightsF2 front worklightsF3 power converterF4 wipersF5 seatF6 LH brake pedal

sensor/shift leverF7 position sensorsF8 ECM switch powerF9 spareF10 spareF11 implement lockout/

quick couplerF12 spareF13 secondary steeringF14 spareF15 spareF16 spareF17 spareF18 spareF19 spareF20 spareF21 power converterF22 spareF23 implement ECM F24 engine ECM

F25 powertrain ECMF26 headlampsF27 arctic heaterF28 engine start switchF29 spareF30 hood actuator

control switchF31 instrument cluster/

MessengerF32 backup alarmF33 hornCB1 spareCB2 hood tilt actuatorCB3 HVAC blowerD1 backlightsD2 flasherD3 LH turnlampD4 RH turnlamp

R1 secondary steeringR2 spareR3 spareR4 spareR5 spareR6 spareR7 backup alarmR8 spare


TM 5-3805-291-10

CIRCUIT BREAKER AND FUSES RESET/REPLACE - CONTINUED 0016 00

0016 00-3/(0016 00-4 Blank)

FUSE REPLACEMENT - CONTINUED

Switched Fuse Block

END OF WORK PACKAGE


F1 blackout switch fuse

R1 turnlamp hazard blackout

R2 horn/dome lamps blackout

R3 headlamps blackout

R4 front worklight blackout

R5 rear worklight blackout

TM 5-3805-291-10

CHAPTER 6

TRANSPORT PROCEDURES

0017 00-1/(0017 00-2 Blank)

TM 5-3805-291-10

PREPARATION FOR TRANSPORT INTRODUCTION 0017 00

INTRODUCTION

1. This chapter describes how to prepare the 966H Wheel Loader for the following modes of transport:a. Roading machine (self-deployment) (WP 0018 00)b. Highway transport (WP 0019 00)c. Rail transport (WP 0020 00 and WP 0021 00)d. Marine transport (RO/RO procedures) (WP 0022 00)e. Air transport by C-5 and C-17 aircraft (WP 0023 00)

2. Depending on mode of transportation selected, assistance from Unit Maintenance may be required to configure themachine for transport (WP 0024 00).

LIFT AND TIEDOWN PROVISIONS 0017 00

NOTEThe following illustration shows the location of lift and tiedown points on the machine.

To lift loader, raise loader arm to level position, install shackle and slings, and lift machine. After machine is loweredonto ground or transport item, remove shackle and slings, and lower loader arm until work tool is on ground or transport itemsurface.

END OF WORK PACKAGE

427-C1383

2

0018 00-1/(0018 00-2 Blank)

TM 5-3805-291-10

ROADING MACHINE (SELF-DEPLOYMENT) 0018 00


Roading Machine

INITIAL SETUP


tor

ReferencesWP 0004 00WP 0011 00WP 0012 00

1. Check with proper authorities to obtain any necessary permits or licenses.2. Perform Before operation PMCS (WP 0011 00 and WP 0012 00).3. Ensure tires are inflated to correct pressure:

a. Front: 60 psi (414 kPa)b. Rear: 40 psi (276 kPa)

WARNINGIf operating machine without work tool attached, front end of machine is light and thereforesusceptible to overturning. When driving without work tool attached to loader arm, drive slowly andDO NOT make sharp turns. Failure to follow this warning may cause injury or death to personnel ordamage to equipment.

4. Ensure work tool is NOT loaded.5. Raise loader arm sufficiently off ground to ensure adequate road clearance (WP 0004 00). 6. Place hydraulic control levers in HOLD position (WP 0004 00).7. Press top of hydraulic lockout (IMPLEMENT DISABLE) switch to lock hydraulic control levers (WP 0004 00).8. Travel at a moderate speed. Maximum travel speed for loader is 23 mph (37 kph).9. When traveling longer distances, stop for 30 minutes each hour or 25 miles (40 km) traveled to allow tires and compo-

nents to cool.10. Watch gages and alert indicators for any evidence of malfunction or overheating (WP 0004 00).11. During stops, inspect machine for evidence of fluid leaks. Check fluid levels and maintain at optimum levels (WP 0012

00).

END OF WORK PACKAGE

2

TM 5-3805-291-10

0019 00-1

HIGHWAY TRANSPORT 0019 00


Introduction, Configure Machine for Highway Transport, Loading Machine on Trailer, Unloading Machine from Trailer,Return Machine to Operational Configuration

INITIAL SETUP


Cord, elastic (Item 1, Table 2, WP 0026 00)

Plug (Item 6, Table 2, WP 0026 00)

Plug-electrical (Item 7, Table 2, WP 0026 00)

Tarp (Item 10, Table 2, WP 0026 00)

Materials/Parts

Tape, duct (Item 16, WP 0027 00)

Personnel Required

MOS 21E, Heavy Construction Equipment Opera-tor (2)

References

WP 0004 00

WP 0005 00

WP 0015 00

WP 0017 00

WP 0024 00

INTRODUCTION

1. This work package describes how to load and unload machine from the trailer for highway transport.

2. Machine must be configured to meet highway transport height requirements.

3. Before transporting machine, check with proper authorities to obtain any necessary permits or licenses.

4. Ensure cooling system of machine has proper antifreeze protection if being transported to a colder climate.

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

required when operating without Rollover Protective Structure/Falling Object Protective Structure (ROPS/FOPS) during transport procedures. Failure to wear hearing protection may cause hearing loss.

• When operating machine without ROPS/FOPS, drive with extreme caution, at low idle, and in 1st gearforward or reverse ONLY. Machine has no rollover/falling object protection without ROPS/FOPS. Failure tofollow this warning may cause injury or death to personnel or damage to equipment.

5. As part of this procedure, the top portion of the ROPS/FOPS cab is removed from machine. Operation of the machinewithout ROPS/FOPS, to drive on and off the trailer, is required.

4

TM 5-3805-291-10

HIGHWAY TRANSPORT - CONTINUED 0019 00

0019 00-2

INTRODUCTION - CONTINUED


6. Throughout procedure, be aware of potential hazards from frame articulation area. Stand clear of frame articulation areawhen machine is operating.

WARNING

BE ALERT for personnel in the area while operating machine. Always check to ensure area is clear ofpersonnel and obstructions before moving. Failure to follow this warning may result in injury or death topersonnel or damage to equipment.

7. Ground guide assistance is MANDATORY when driving machine on or off trailer.

CONFIGURE MACHINE FOR HIGHWAY TRANSPORT 0019 00

Refer to WP 0024 00.

LOADING MACHINE ON TRAILER 0019 00

1. Chock wheels of trailer.

WARNING

Backup alarm does not work with ROPS/FOPS removed. Failure to follow this warning may result ininjury or death to personnel.

2. Turn battery disconnect switch to ON position (WP 0004 00).

3. Remove tarp and plugs.

4. Turn engine start switch to ON position and leave it there for 30 seconds.

5. Turn engine start switch to OFF position and leave it there for 30 seconds.



7. Start loader engine and allow to warm up (WP 0005 00).

8. Raise loader arm as required so that loader arm will clear crest of trailer ramp (WP 0004 00).

TM 5-3805-291-10


0019 00-3

LOADING MACHINE ON TRAILER - CONTINUED

WARNING• Always use a ground guide when operating machine up ramp to load on trailer. Failure to use a ground guide

may cause injury or death to personnel or damage to equipment.• When operating machine without ROPS/FOPS, drive with extreme caution, at low idle, and in 1st gear reverse

ONLY. Machine has no rollover/falling object protection without ROPS/FOPS. Failure to follow this warningmay cause injury or death to personnel or damage to equipment.

9. Using ground guide assistance and in 1st gear ONLY, back machine onto trailer bed SLOWLY.

10. Once machine is correctly positioned on trailer bed, lower loader arm (WP 0004 00).

11. Place transmission in N (NEUTRAL) and engage parking brake (WP 0004 00).

WARNINGConnect steering frame lock between front and rear frames before transporting machine. DO NOT operatemachine with steering frame lock connected. Failure to follow this warning may result in injury or death topersonnel or damage to equipment.

12. Shut down engine (WP 0005 00).

13. Connect steering frame lock between front and rear frames (WP 0015 00).

14. Move hydraulic control levers through all positions to relieve hydraulic system pressure in lines. Return levers to HOLDposition (WP 0005 00).

15. Press top of hydraulic lockout (IMPLEMENT DISABLE) switch to lock hydraulic controls (WP 0004 00).

16. Turn battery disconnect switch to OFF position (WP 0004 00).

CAUTION• Machines transported without proper safeguards may incur wind damage. Ensure all doors and

compartments are securely latched and secured against flying open. Failure to do so may cause equipmentdamage in transit.

• Exhaust opening must be taped closed to prevent wind from entering exhaust system and causingturbocharger to spin, without the benefit of lubrication. Failure to cover exhaust opening may damageturbocharger.

17. Use duct tape (Item 16, WP 0027 00) to cover exhaust opening.

18. Secure machine against vandalism.

19. Install four set of plugs on electrical connectors and install tarp to protect cab.

20. Secure machine on trailer bed with blocking and tiedowns, in accordance with shipping data plate and illustration oftiedown points in WP 0017 00.

21. Load and secure shipping pallet.

UNLOADING MACHINE FROM TRAILER 0019 00

1. Chock wheels of trailer.2. Unload shipping pallet and remove tiedowns from ROPS/FOPS, exhaust stack, and shipping pallet.3. Remove blocking and tiedowns from machine.4. Remove tarp and plugs.

TM 5-3805-291-10


0019 00-4

UNLOADING MACHINE FROM TRAILER - CONTINUED 0019 00

5. Remove vandalism protection devices.

6. Remove tape from exhaust opening.


7. Disconnect and securely stow steering frame lock (WP 0015 00).






12. Start engine and allow to warm up (WP 0005 00).

13. Press bottom of hydraulic lockout (IMPLEMENT DISABLE) switch to unlock hydraulic controls (WP 0004 00).

14. Raise loader arm as required so that loader arm will clear crest of trailer ramp (WP 0004 00). Remove blocking fromunder work tool.

WARNING• Always use a ground guide when operating machine down ramp to unload from trailer. Failure to use a

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

• When operating machine without ROPS/FOPS, drive with extreme caution, at low idle, and in 1st gear reverseONLY. Machine has no rollover/falling object protection without ROPS/FOPS. Failure to follow this warningmay cause injury or death to personnel or damage to equipment.

15. Using ground guide assistance and in 1st gear ONLY, SLOWLY drive straight off trailer until clear of ramp.

16. Park machine in staging area clear of trailer (WP 0005 00).



19. Install four sets of plugs (Items 6 and 7, Table 2, WP 0026 00) on electrical connectors and install tarp (Items 1 and 10,Table 2, WP 0026 00) to protect cab.

RETURN MACHINE TO OPERATIONAL CONFIGURATION 0019 00Refer to WP 0024 00.

END OF WORK PACKAGE

TM 5-3805-291-10

0020 00-1

RAIL TRANSPORT 0020 00


Introduction, Loading Machine on Flatcar, Unloading Machine from Flatcar

INITIAL SETUP


Cord, elastic (Item 1, Table 2, WP 0026 00)

Plug (Item 6, Table 2, WP 0026 00)

Plug-electrical (Item 7, Table 2, WP 0026 00)

Tarp (Item 10, Table 2, WP 0026 00)

Materials/Parts

Tape, duct (Item 16, WP 0027 00)

Personnel Required


References

WP 0004 00

WP 0005 00

WP 0011 00

WP 0012 00

WP 0015 00

WP 0017 00

WP 0021 00

WP 0024 00

INTRODUCTION

1. This work package describes how to load and unload the 966H Wheel Loader on a flatcar for rail transport within theContinental United States (CONUS), Canada, and Mexico. The machine is most often loaded/unloaded on a rail flatcarusing drive-on/drive-off procedures at the railhead.

2. CONUS rail transport is governed by Association of American Railroads (AAR) regulations.


required when operating without ROPS/FOPS during transport procedures. Failure to wear hearingprotection may cause hearing loss.

• When operating machine without ROPS/FOPS, drive with extreme caution, at low idle, and in 1st gearforward or reverse ONLY. Machine has no rollover/falling object protection without ROPS/FOPS. Failure tofollow this warning may cause injury or death to personnel or damage to equipment.

3. Outside Continental United States (OCONUS) rail transport is governed by Gabarit International de Chargement (GIC)regulations. OCONUS rail transport requires that ROPS/FOPS, exhaust stack and front and rear handrails be removedfrom machine to meet height requirements. Refer to WP 0024 00 (Configure Machine for Transport) for procedures toremove ROPS/FOPS, exhaust stack, and rear handrails.

6

TM 5-3805-291-10

RAIL TRANSPORT - CONTINUED 0020 00

0020 00-2


4. To remove front handrails, remove three bolts (1),washers (2), and front handrail (3). Repeat for otherside. (Reverse procedure to install front handrails.)

5. Before transporting machine, check with properauthorities to obtain any necessary permits or licenses.

6. Ensure cooling system of machine has proper anti-freeze protection if being transported to a colder cli-mate.

7. Safest rail transport is with fuel tank as close to emptyas possible. Rail transport with fuel tank more thanthree-quarters full is prohibited.

WARNINGStand clear of frame articulation area when machine is operating. There is no clearance for personnelin this area when machine turns. Crushing could occur, resulting in injury or death to personnel.


WARNINGBE ALERT for personnel in the area while operating machine. Always check to ensure area is clear ofpersonnel and obstructions before moving. Failure to follow this warning may result in injury or death topersonnel or damage to equipment.

9. Ground guide assistance is MANDATORY when driving machine on or off flatcar.

LOADING MACHINE ON FLATCAR 0020 00

1. Chock wheels of flatcar.

WARNINGBackup alarm does not work with ROPS/FOPS removed. Failure to follow this warning may result ininjury or death to personnel.

2. Turn battery disconnect switch to ON position (WP 0004 00).3. Remove tarp and plugs.4. Turn engine start switch to ON position and leave it there for 30 seconds.

427-C1572

TM 5-3805-291-10


0020 00-3

LOADING MACHINE ON FLATCAR - CONTINUED 0020 00



WARNINGStand clear of frame articulation area when machine is operating. There is no clearance for personnelin this area when machine turns. Crushing could occur, resulting in injury or death to personnel.


8. Raise loader arm (WP 0004 00).

WARNING

• Always use ground guides when loading machine on flatcar. Failure to use ground guides may cause injury ordeath to personnel or damage to equipment.

• When driving machine onto flatcar, drive with extreme caution and in 1st gear ONLY. Failure to follow thiswarning may cause injury or death to personnel or damage to equipment.

9. Following instructions from flatcar load master and ground guides, slowly drive straight onto flatcars.

a. Use 1st gear ONLY.

b. When passing over spanners between flatcars, maintain a constant speed. DO NOT jam on brakes or reverse direc-tion.

10. Once machine is correctly positioned on flatcar bed, lower loader arm (WP 0004 00). Rest work tool on blocking.




WARNINGConnect steering frame lock between front and rear frames before transporting machine. DO NOToperate machine with steering frame lock connected. Failure to follow this warning may result ininjury or death to personnel or damage to equipment.




TM 5-3805-291-10


0020 00-4

LOADING MACHINE ON FLATCAR - CONTINUED 0020 00

CAUTION• Machines transported without proper safeguards may incur wind damage. Ensure all doors and

compartments are securely latched and secured against flying open. Failure to do so may cause equipmentdamage in transit.

• Exhaust pipe must be taped closed to prevent wind from entering exhaust system and causing turbocharger tospin, without the benefit of lubrication. Failure to cover exhaust pipe may damage turbocharger.

17. Use duct tape (Item 16, WP 0027 00) to cover exhaust pipe.


19. Install four sets of plugs (Items 6 and 7, Table 2, WP 0026 00) on electrical connectors and install tarp (Items 1 and 10,Table 2, WP 0026 00) to protect cab.

20. Secure machine on flatcar bed with blocking and tiedowns, in accordance with shipping data plate on machine and illus-tration of tiedown points in WP 0017 00 and instructions in WP 0021 00.

UNLOADING MACHINE FROM FLATCAR 0020 00

1. Chock wheels of flatcar.

2. Remove blocking and tiedowns from machine.

3. Remove tarp and plugs.


5. Remove tape from exhaust pipe.



7. Turn battery disconnect switch to ON position and leave it there for 30 seconds.

8. Turn battery disconnect switch to OFF position and leave it there for 30 seconds.

9. Turn battery disconnect switch to ON position and leave it there for 30 seconds.




12. Raise loader arm (WP 0004 00). Remove blocking from under work tool.

TM 5-3805-291-10


0020 00-5/(0020 00-6 Blank)

UNLOADING MACHINE FROM FLATCAR - CONTINUED

WARNING• Always use ground guides when unloading machine from flatcar. Failure to use ground guides may cause

injury or death to personnel or damage to equipment.• When driving machine off flatcar, drive with extreme caution and in 1st gear ONLY. Failure to follow this

warning may cause injury or death to personnel or damage to equipment.13. Following instructions from flatcar load master and ground guides, slowly drive straight off flatcars until clear of rail-

head. a. Use 1st gear ONLY.b. When passing over spanners between flatcars, maintain a constant speed. DO NOT jam on brakes or reverse direc-

tion.14. Park machine in staging area (WP 0005 00).15. Shut down engine (WP 0005 00).16. Turn battery disconnect switch to OFF position (WP 0004 00).17. Install plugs on electrical connectors and install tarp to protect cab.18. When ROPS/FOPS becomes available, return machine to operational configuration (WP 0024 00).19. Inspect machine to ensure it is operational. Perform Before Operation PMCS (WP 0011 00 and WP 0012 00).

END OF WORK PACKAGE

TM 5-3805-291-10

0021 00-1

RAIL TIEDOWN PROCEDURES ON A DODX RAIL CAR 0021 00


966H with Broom Attachment and Fork Carriage/5-Yard Bucket

INITIAL SETUP


1/2-in. wire steel cables (3)

1/2-in. cable clamps (AR)

3/4-in. sheet of plywood

Tiedown chains (AR)


tor (2)

ReferencesWP 0005 00WP 0024 00

966H WITH BROOM ATTACHMENT AND FORK CARRIAGE/5-YARD BUCKET 0021 00

1. Attach the forklift kit for the 966H in accordance with instructions in WP 0005 00. Engage the 5-yard bucket (rock/util-ity) with the forks fully spread and the bucket centered on the fork carriage.

2. Drive the assemblage onto the rail car or load from the side of the car, depending on mission requirements.

NOTEThe bucket/fork carriage assembly may be transported laterally or longitudinally on the rail car.

3. Disconnect the fork carriage from the 966H Wheel Loader. Place a 1/2-in. wire steel cable around bucket and pass thecable through the carriage above the lower crossmember (Figure 1) and underneath the bucket. Pull the ends of the cabletight and secure the ends of the cable together with a minimum of four 1/2-in. cable clamps. This keeps the fork carriageand bucket together as a package for shipment.

4. Place a 1/2-in. wire steel cable through the fork carriage tiedown and through the upper guard for the bucket, pull tight,and secure with four cable clamps. Repeat the procedure on the other side of the bucket. This holds the top of the bucketand forklift carriage together for shipment (Figure 1).

5. Secure one each rail tiedown chain to the carriage tiedown provisions and the bucket tiedown provisions. Maintain a 45-degree angle on the chain tiedowns (Figure 1).

6. Attach the broom attachment to the 966H Wheel Loader in accordance with instructions in WP 0005 00.7. Drive the 966H with broom attachment onto the rail car. Center the assemblage on the rail car and secure two each rail

car tiedowns to each of the front and rear tiedown provisions for a total of eight tiedowns (Figures 2 and 3).

4

TM 5-3805-291-10

RAIL TIEDOWN PROCEDURES ON A DODX RAIL CAR - CONTINUED 0021 00

0021 00-2

966H WITH BROOM ATTACHMENT AND FORK CARRIAGE/5-YARD BUCKET - CONTINUED

CAUTIONThe broom cannot be transported by itself; it must always be attached to the 966H Wheel Loader since itdoes not have tiedown provisions.

8. The 966H can also be shipped without the cab, if necessary, to accommodate low tunnels or overpasses. Remove the cabfrom the machine in accordance with the instructions WP 0024 00. The machine’s exhaust stack and rear handrails mustalso be removed. The front handrails must temporarily be removed in order to remove the front cab retaining bolts; thefront handrails should be reinstalled after removal of the upper cab assembly. It is recommended that plugs be installedon the electrical interconnect cables (4 each) to prevent damage during shipment along with taping the exhaust port. Therear handrails and exhaust can be placed and secured in the cab using large plastic wire ties. Ensure the cab componentsare protected from damage during this task.

9. Place a 3/4 in. sheet of plywood on the deck of the rail car and place the upper cab on it.10. Secure the upper cab to the rail car using the rail tiedown chains (4 each) and the tiedown provisions on the top of the

cab (Figure 4).11. Ensure that the parking brake is engaged and the gear selector is in N (NEUTRAL). The cab and machine are now ready

to ship by rail.

Figure 1. Rear tiedowns on the fork and bucket of the FOL. Note the cabling connecting the bucket and fork.

427-C2037

TM 5-3805-291-10


0021 00-3


Figure 2. FOL front roadside tiedowns.

Figure 3. FOL rear tiedowns.

427-C2038

427-C2040

TM 5-3805-291-10


0021 00-4


Figure 4. FOL cab detached from machine and secured on car.

END OF WORK PACKAGE

427-C2039

TM 5-3805-291-10

0022 00-1

MARINE TRANSPORT (RO/RO PROCEDURES) 0022 00


Introduction, RO/RO Regulations, Loading Machine on Ship, Unloading Machine from Ship

INITIAL SETUP

Personnel Required


References

WP 0004 00

References - Continued

WP 0005 00

WP 0011 00

WP 0012 00

WP 0015 00

INTRODUCTION

1. The 966H Wheel Loader may be transported on the following types of marine vessels:

a. Roll-on/Roll-off (RO/RO).

b. Break bulk (general cargo).

c. Barge carrying (LASH and SEABEE).

2. This work package describes how to load and unload machine onto vessels using RO/RO procedures.

3. At all times, the machine’s movements are under the overall control of the RO/RO vehicle director. Loading andunloading is accomplished by following the vehicle director’s traffic control pattern.

4. Machines are loaded by moving them from dockside to the appropriate level and hold on board ship. Once parked,crews secure machines for shipping by lashing, shoring, blocking or bracing, as appropriate. Unloading is accomplishedby moving machines from on board ship to dockside.

WARNING

BE ALERT for personnel in the area while operating machine. Always check to ensure area is clear ofpersonnel and obstructions before moving. Failure to follow this warning may result in injury or death topersonnel or damage to equipment.

5. In order to accomplish RO/RO, the machine must operate up and down ramps. The grade of the ramps will vary,depending on the tide and the weight of the ship at the time of loading or unloading. Ground guide assistance is MAN-DATORY when operating on ramps.

6. In order to ensure the safety of all personnel involved, the machine’s operator must be familiar with all RO/RO regula-tions and procedures.

4

TM 5-3805-291-10

MARINE TRANSPORT (RO/RO PROCEDURES) - CONTINUED 0022 00

0022 00-2

RO/RO REGULATIONS 0022 00

WARNINGSafe RO/RO operation depends on strict adherence to RO/RO regulations. Failure to do so may result ininjury or death to personnel or damage to equipment.

1. Only qualified and screened operators are permitted to drive machine in RO/RO operations.

WARNINGAll personnel working in machine operating areas during RO/RO operations must wear hearingprotection. Failure to wear hearing protection may result in hearing loss.

2. All personnel working in machine operating areas must wear hearing protection.

3. Do not move machine about vessel without ground guide assistance.

4. Do not start machine until directed to do so. Before moving out, test brakes.

5. Operate machine with lights on.

6. Only one machine may transit a ramp at any time.

7. Do not leave machine engine running unattended.

8. Fuel tank on machine must be filled in accordance with Surface Deployment and Distribution Command (SDDC) portcall message.

LOADING MACHINE ON SHIP 0022 00



2. Raise loader arm as required so that loader arm and work tool will clear ship ramps (WP 0004 00).

WARNING• Always use a ground guide when operating machine up or down ramps. Failure to use a ground guide may

cause injury or death to personnel or damage to equipment.

• When operating machine up or down ramps, drive with extreme caution and in 1st gear ONLY. Failure tofollow this warning may cause injury or death to personnel or damage to equipment.

3. With ground guide assistance, negotiate ramps in 1st gear ONLY.

4. After loading, park machine where directed to do so.

TM 5-3805-291-10


0022 00-3

LOADING MACHINE ON SHIP - CONTINUED 0022 00


5. Lower loader arm (WP 0004 00). Rest on shoring.








13. Provide assistance, as required, to ship’s crew in blocking/shoring/lashing machine for transport.

UNLOADING MACHINE FROM SHIP 0022 00

1. Provide assistance, as required, to ship’s crew in removing blocking/shoring/lashing from machine.








7. Raise loader arm as required so that loader arm and work tool will clear crest of ship ramps (WP 0004 00). Removeblocking from under loader arm.

TM 5-3805-291-10


0022 00-4

UNLOADING MACHINE FROM SHIP - CONTINUED 0022 00

WARNING• Always use a ground guide when operating machine down ramp to unload from trailer. Failure to use a

ground guide may cause injury or death to personnel or damage to equipment.• When operating machine down ramp, drive with extreme caution and in 1st gear ONLY. Failure to follow this

warning may cause injury or death to personnel or damage to equipment.8. With ground guide assistance, negotiate ramps in 1st gear ONLY. 9. Park machine clear of ship loading/unloading zone (WP 0005 00).10. Inspect machine to ensure it is operational. Perform Before Operation PMCS (WP 0011 00 and WP 0012 00).

END OF WORK PACKAGE

TM 5-3805-291-10

0023 00-1

AIR TRANSPORT BY C-5 AND C-17 AIRCRAFT 0023 00


Introduction, Load Machine, Unload Machine

INITIAL SETUP


tor (2)

ReferencesWP 0004 00WP 0005 00WP 0015 00

INTRODUCTION

1. This work package describes how to load and unload machine into C-5 and C-17 aircraft.2. Machine must be configured to meet air transport weight and height requirements. Machine components that exceed

these requirements must be relocated or removed prior to loading. 3. Machine is loaded/unloaded using drive on/drive off procedures. 4. The amount of fuel left in machine’s fuel tank must comply with guidance from SDDC: 25% to a maximum of 75% fuel

tank capacity is allowed.


required when operating without ROPS/FOPS during transport procedures. Failure to wear hearingprotection may cause hearing loss.

• Stand clear of frame articulation area when machine is operating. There is no clearance for personnel in thisarea when machine turns. Crushing could occur, resulting in injury or death to personnel.


4

TM 5-3805-291-10

AIR TRANSPORT BY C-5 AND C-17 AIRCRAFT - CONTINUED 0023 00

0023 00-2

LOAD MACHINE 0023 00

WARNINGAlways use a ground guide when operating machine up ramp to load onto aircraft. Failure to use a groundguide may cause injury or death to personnel or damage to equipment.

1. Using ground guide assistance and in 1st gear reverse ONLY, SLOWLY back into aircraft.2. Once machine is correctly positioned in aircraft, lower loader arm (WP 0004 00). Rest work tool on blocking. 3. Place transmission in N (NEUTRAL) and engage parking brake (WP 0004 00).4. Shut down engine (WP 0005 00).


5. Connect steering frame lock between front and rear frames (WP 0015 00).6. Relieve hydraulic system pressure from brake, steering, and implement hydraulic systems (WP 0005 00).7. Press top of hydraulic lockout (IMPLEMENT DISABLE) switch to lock hydraulic controls (WP 0004 00).8. Turn battery disconnect switch to OFF position (WP 0004 00).9. Secure machine against vandalism.10. Secure machine inside aircraft with blocking and tiedowns.

TM 5-3805-291-10

AIR TRANSPORT BY C-5 AND C-17 AIRCRAFT - CONTINUED 0023 00

0023 00-3/(0023 00-4 Blank)

UNLOAD MACHINE 0023 00

1. Remove blocking and tiedowns from machine.2. Remove vandalism protection devices.


3. Disconnect and securely stow steering frame lock (WP 0015 00).4. Turn battery disconnect switch to ON position (WP 0004 00).


5. Start engine and allow to warm up (WP 0005 00).6. Press bottom of hydraulic lockout (IMPLEMENT DISABLE) switch to unlock hydraulic controls (WP 0004 00).7. Raise loader arm as required so that loader arm and work tool will clear crest of aircraft ramp (WP 0004 00). Remove

blocking from under work tool.

WARNINGAlways use a ground guide when operating machine down ramp to unload from aircraft. Failure to use aground guide may cause injury or death to personnel or damage to equipment.

8. Using ground guide assistance and in 1st gear forward ONLY, SLOWLY drive straight off aircraft until clear of ramp.9. Park machine in staging area clear of aircraft (WP 0005 00).

END OF WORK PACKAGE

TM 5-3805-291-10

0024 00-1

CONFIGURE MACHINE FOR TRANSPORT 0024 00


Introduction, Tools and Equipment, ROPS/FOPS Removal, Exhaust Stack Removal, Rear Handrail Removal, Rear Hand-rail Installation, Exhaust Stack Installation, ROPS/FOPS Installation

INITIAL SETUP

Tools and Special ToolsBasic Issue Items (Table 2, WP 0026 00)Notify Unit Maintenance to bring general

mechanic’s tool kit, common no. 1 shop equip-ment, and field maintenance shop equipment

Lifting equipment, 1,500-lb capacity

Materials/PartsGrease (Item 8, WP 0027 00)Tag, marker (Item 15, WP 0027 00)

Personnel RequiredMOS 2IE, Heavy Construction Equipment OperatorMOS 62B, Construction Equipment Repairer (2)

References

WP 0004 00

WP 0011 00

WP 0012 00

WP 0019 00

WP 0020 00


Work tool removed (WP 0005 00)



INTRODUCTION

1. This work package describes how to configure the machine for transport on highway (WP 0019 00) and OCONUS(GIC) rail (WP 0020 00) and how to return machine to operational configuration after transport.

NOTEThese procedures are included in this manual as a reference. This does not authorize performance by theoperator.

2. Assistance from two Unit Maintenance mechanics is required to configure the machine for transport.

10

TM 5-3805-291-10

CONFIGURE MACHINE FOR TRANSPORT - CONTINUED 0024 00

0024 00-2


WARNINGUse extreme caution when handling heavy parts. Provide adequate support and use assistance during pro-cedure. Ensure any lifting device used is in good condition and of lifting capacity. Keep clear of heavy partssupported only by lifting device. Failure to follow this warning may result in injury or death to personnel.

3. Components removed and installed during this procedure are very heavy. Use assistance, caution, and follow safe workpractices when handling them. Lifting equipment available at the staging area must be used.

TOOLS AND EQUIPMENT

1. Tools and equipment required to prepare the machine for transport are:

a. stowed in BII box on machine (Table 2, WP 0026 00);

b. provided by Unit Maintenance (general mechanic’s tool kit, common no. 1 shop equipment, and field maintenanceshop equipment); and

c. 1,500-lb capacity lifting equipment.

2. Reinstall mounting hardware for all removed components on machine to secure against loss during transport.

ROPS/FOPS REMOVAL 0024 00

NOTE

• Tag electrical harnesses and hoses as they are disconnected to ensure correct connection.

• Work tool must be removed prior to cab removal.

1. Place transmission switch in manual mode.2. Turn engine start switch to OFF position (WP 0004

00).3. Remove fire extinguisher and secure with BII.4. Disconnect four connectors (three electrical and one

coaxial) (1) at right-rear corner of cab.5. Install three sets of plugs (Items 6 and 7, Table 2, WP

0026 00) on electrical connectors in cab and on ROPS.6. Close and secure right-side window.

TM 5-3805-291-10


0024 00-3

ROPS/FOPS REMOVAL - CONTINUED 0024 00

WARNINGUse extreme caution when handling heavy parts. Provide adequate support and use assistance during pro-cedure. Ensure any lifting device used is in good condition and of suitable lift capacity. Keep clear of heavyparts supported only by lifting device. Failure to follow this warning may result in injury or death to per-sonnel.

7. Remove four bolts (2, 3, 4, and 5) located on the cab exterior. Place bolts in lower half of cab.

8. Retract spring-loaded front and rear wiper arms by pulling away from glass. Use elastic cords (Item 1, Table 2, WP 002600) to keep wiper arms away from cab.

427-C0463

427-C0464

427-C0466

TM 5-3805-291-10


0024 00-4

ROPS/FOPS REMOVAL - CONTINUED 0024 00

WARNINGDO NOT remove exhaust stack until it has cooled to the touch. Wear gloves and protective clothing toguard against burns. Failure to follow this warning may result in injury to personnel.

NOTEROPS/FOPS weighs 1,000 lb (454 kg).

9. Attach lifting device to four lift points (A) on ROPS/FOPS roof brackets.

10. Close cab door securely.11. Slide deadbolt latch upward on left-side cab door to separate upper and lower door sections.

CAUTIONEnsure ROPS/FOPS is lifted straight up until fully clear of operator station. Failure to do so could result indamage to operator station and operator components.

12. Slowly raise top portion of ROPS/FOPS cab approximately 1 in. (25.4 mm) until clear of operator station.

13. Ensure all mechanical and electrical connections are disconnected. Remove top portion of ROPS/FOPS cab.14. Lower top portion of ROPS/FOPS cab on shipping pallet.

427-C1975

TM 5-3805-291-10


0024 00-5

EXHAUST STACK REMOVAL 0024 00

Loosen bolt (6) and remove clamp (7) and exhauststack (8).

REAR HANDRAIL REMOVAL 0024 00

1. Remove six bolts (9), washers (10), and rear handrail(11). Repeat for other side.

2. Place in lower half of cab behind driver’s seat andsecure with velcro strap.

3. Secure top portion of ROPS/FOPS cab to shippingpallet using tiedowns.

4. Return hand tools to BII box.5. Install tarp (Items 1 and 10, Table 2, WP 0026 00) to

protect cab.

427-C0066

427-C1571

TM 5-3805-291-10


0024 00-6

REAR HANDRAIL INSTALLATION 0024 00

1. Remove tarp.2. Install rear handrail (11), six washers (10), and bolts

(9). Repeat for other side.

EXHAUST STACK INSTALLATION 0024 00

NOTEExhaust stack must be installed so that exhaust fumes will be directed to the rear, away from operator.

Install clamp (7) and exhaust stack (8) on muffler support and tighten bolt (6).

ROPS/FOPS INSTALLATION 0024 00

1. Remove elastic cord from front wiper arm.2. Install top portion of ROPS/FOPS cab onto lower half

of cab:

427-C1571

427-C0066

TM 5-3805-291-10


0024 00-7

ROPS/FOPS INSTALLATION - CONTINUED 0024 00

WARNINGUse extreme caution when handling heavy parts. Provide adequate support and use assistance during pro-cedure. Ensure any lifting device used is in good condition and of suitable lift capacity. Keep clear of heavyparts supported only by lifting device. Failure to follow this warning may result in death or injury to per-sonnel.

NOTEROPS/FOPS weighs 1,000 lb (454 kg).

a. Attach lifting device to four lift points on top portion of ROPS/FOPS cab. Lift top portion of ROPS/FOPS cab frompallet.

b. Apply GAA grease (Item 8, WP 0027 00) to four alignment legs.

427-C1595

TM 5-3805-291-10


0024 00-8


CAUTIONEnsure top portion of ROPS/FOPS cab is lowered straight down until fully seated on lower. Failure to do socould result in damage to operator station and operator components.

c. Slowly lower ROPS/FOPS onto operator station,aligning mounting bolt holes in ROPS/FOPS.Lower ROPS/FOPS until fully seated.

d. Remove elastic cord from rear wiper arm.

NOTEMovement in wedge pins is normal duringinstallation of bolts.

e. Loosely install four bolts (2, 3, 4, and 5) at eachcorner of cab.

f. Tighten four bolts (2, 3, 4, and 5) at corners ofcab.

427-C0466

427-C0464 427-C0463

TM 5-3805-291-10


0024 00-9/(0024 00-10 Blank)


g. Remove three sets of plugs and connect four con-nectors (three electrical and one coaxial) (1) atright-rear corner of cab.

3. Inspect machine to ensure it is operational. Perform Before Operation PMCS (WP 0011 00 and WP 0012 00).4. Stow tools in BII box (Table 2, WP 0026 00).5. Install fire extinguisher.

END OF WORK PACKAGE

0024 00

TM 5-3805-291-10

CHAPTER 7

SUPPORTING INFORMATION

TM 5-3805-291-10

0025 00-1/(0025 00-2 Blank)

REFERENCES 0025 00

SCOPE

This work package lists the publications referenced in this manual.

PUBLICATION INDEXES

The following indexes should be consulted frequently for the latest changes or revisions and for new publications relat-ing to material covered in this technical manual.Consolidated Index of Army Publications and Blank Forms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DA PAM 25-30The Army Maintenance Management System (TAMMS) Users Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DA PAM 750-8

FORMS

NOTERefer to DA PAM 750-8, The Army Maintenance Management System (TAMMS) Users Manual, forinstructions on the use of maintenance forms.

Equipment Inspection and Maintenance Worksheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .DA Form 2404, DA Form 5988-EProduct Quality Deficiency Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SF Form 368Recommended Changes to Publications and Blank Forms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .DA Form 2028

FIELD MANUALS

Basic Cold Weather Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 31-70Desert Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 90-3First Aid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 4-25.11Manual for the Wheeled Vehicle Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 21-305Multiservice Tactics, Techniques, and Procedures for Chemical, Biological, Radiological, and

Nuclear Contamination Avoidance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 3-11.3Multiservice Tactics, Techniques, and Procedures for Chemical, Biological, Radiological, and

Nuclear Decontamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 3-11.5Northern Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 31-71Operation and Maintenance of Ordnance Materiel in Cold Weather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 9-207

TECHNICAL BULLETIN

Warranty Technical Bulletin for the 966H Wheel Loader. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TB 5-3805-291-14

TECHNICAL MANUALS

Decontamination System, Sorbent: M100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 3-4230-236-10Operator’s, Unit, Direct Support, and General Support Maintenance

Manual for Lead-Acid Storage Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 9-6140-200-14Procedures for Destruction of Equipment to Prevent Enemy Use (Mobility Equipment Command) . . . . . . . . . TM 750-244-3

OTHER PUBLICATIONS

Abbreviations and Acronyms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASME Y14.38-1999Army Medical Department Expendable/Durable Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CTA 8-100Department of Defense Interface Standard for Lifting and Tiedown Provisions . . . . . . . . . . . . . . . . . . . . . . . .MIL-STD-209KExpendable/Durable Items (Except Medical, Class V, Repair Parts, and Heraldic Items) . . . . . . . . . . . . . . . . . . . . CTA 50-970

END OF WORK PACKAGE

2

TM 5-3805-291-10

0026 00-1

COMPONENTS OF END ITEM (COEI) AND BASIC ISSUE ITEMS (BII) LISTS 0026 00

SCOPE

This work package lists COEI and BII for the 966H Wheel Loader to help you inventory items required for safe and effi-cient operation.

GENERAL

The COEI and BII information is divided into the following lists:1. Table 1, Components of End Item List. This listing is for informational purposes only and is not authority to requisition

replacements. These items are part of the end item, but are removed and separately packaged for transportation or ship-ment. As part of the end item, these items must be with the end item whenever it is issued or transferred between propertyaccounts. Illustrations are furnished to assist you in identifying the items.

2. Table 2, Basic Issue Items List. These are the minimum essential items required to place the loader in operation, to oper-ate it and to perform emergency repairs. Although shipped separately packaged, BII must be with the loader during oper-ation and whenever it is transferred between property accounts. This manual is your authority to request/requisitionreplacement BII, based on TOE/MTOE authorization of end item. Illustrations are furnished to assist you in identifyingthe items.


Below is an explanation of columns found in the tabular listings:1. Column (1) - Illustration Number (Illus Number). This column indicates the number of the illustration that shows the

item.2. Column (2) - National Stock Number. Indicates the National Stock Number (NSN) assigned to the item and will be used

for requisitioning purposes.3. Column (3) - Description, CAGEC, and Part Number. Indicates the Federal item name (in all capital letters) and, if

required, a minimum description in parentheses to identify and locate the item. The entry for each item ends with theCommercial and Government Entity Code (CAGEC) in parentheses followed by the part number.

4. Column (4) - Usable on Code. Indicates a code if the item needed is not the same for different models of equipment.Usable on Codes are not applicable for the 966H Wheel Loader.

5. Column (5) - Unit of Measure (U/M). Indicates how the item is issued for the National Stock Number shown inColumn (2).

6. Column (6) - Quantity Required (Qty Rqd). Indicates the quantity of the item required.

6

TM 5-3805-291-10

COMPONENTS OF END ITEM (COEI) AND BASIC ISSUE ITEMS (BII) LISTS - CONTINUED 0026 00

0026 00-2

Table 1. Components of End Item List.

(1)

ILLUSNUMBER

(2)

NATIONALSTOCK NUMBER

(3)

DESCRIPTION, CAGEC,AND PART NUMBER

(4)

USABLEON CODE

(5)

U/M

(6)

QTYRQD

1 CYLINDER, ETHER(11083) 275-3634

EA 1

2 LINK, STEERING LOCK(11083) 127-1579

EA 1

3 PIN(11083) 80-3791

EA 2

4 5315-01-162-8738 PIN, STRAIGHT-HEADED(11083) 5V-6380

EA 2

427-C1573

TM 5-3805-291-10


0026 00-3

Table 2. Basic Issue Items List.

(1)

ILLUSNUMBER

(2)


(3)


(4)

USABLEON CODE

(5)

U/M

(6)

QTYRQD

1 CORD, ELASTIC(11083) 262-9305

EA 8

2 EXTENSION: 6 in., 3/8 in. drive(11083) 8H-8575

EA 1

3 EXTENSION: 12 in., 3/8 in. drive(11083) 3P-2240

EA 1

4 4210-00-889-2221 EXTINGUISHER, FIRE(58536) A-A-393

EA 1

5 4930-00-253-2478 LUBRICATING GUN, HAND(11083) 8F9866

EA 1

427-C1574-1

TM 5-3805-291-10


0026 00-4

Table 2. Basic Issue Items List - Continued.

(1)

IllusNumber

(2)

NationalStock Number

(3)

Description, CAGEC,and Part Number

(4)

Usable on Code

(5)

U/M

(6)

QtyRqd

6 PLUG, ELECTRICAL CAP(11083) 246-2932

EA 3

7 PLUG-CONNECTOR, ELECTRICAL CAP FOR HARNESS(11083) 268-8749

EA 3

8 5120-01-535-2969 RATCHET: 8 in., 3/8 in. drive(11083) 239-6824

EA 1

9 SOCKET: 11 mm, 3/8 in. drive(11083) 194-3490

EA 1

427-C1574-2

TM 5-3805-291-10


0026 00-5/(0026 00-6 Blank)

Table 2. Basic Issue Items List - Continued.

END OF WORK PACKAGE

(1)

IllusNumber

(2)

NationalStock Number

(3)

Description, CAGEC,and Part Number

(4)

Usable on Code

(5)

U/M

(6)

QtyRqd

10 8340-00-935-1844 TARPAULIN: 12 x 14 ft(81349) MIL-DTL-82288

EA 1

11 4910-00-204-3170 TIRE GAGE(27783) 7188BH

EA 1

12 5140-01-524-7563 TOOL BAG(11083) 211-0136

EA 1

13 5120-01-437-1727 WRENCH, ADJUSTABLE: 8 in.(11083) 214-7323

EA 1

427-C2015

TM 5-3805-291-10

0027 00-1

EXPENDABLE AND DURABLE ITEMS LIST 0027 00

SCOPE

This work package lists expendable and durable items you will need to operate and maintain the 966H Wheel Loader.This listing is for informational purposes only and is not authority to requisition the listed items. These items are authorized toyou by CTA 50-970, Expendable/Durable Items (Except Medical, Class V Repair Parts, and Heraldic Items), or CTA 8-100,Army Medical Department Expendable/Durable Items.


1. Column (1) - Item Number. This number is referenced in the appropriate work package Initial Setup list or in the narra-tive instructions to identify the item; e.g., Use antifreeze (Item 1, WP 0027 00).

2. Column (2) - Level. This column identifies the lowest level of maintenance that requires the listed item.C - Operator/Crew

3. Column (3) - National Stock Number. This is the National Stock Number assigned to the item, which you can use to req-uisition it.

4. Column (4) - Description, CAGEC, and Part Number. This provides the other information you need to identify theitem.

5. Column (5) - Unit of Measure (U/M). This column shows the physical measurement or count of an item, such as gallon,dozen, gross, etc.

4

TM 5-3805-291-10

EXPENDABLE AND DURABLE ITEMS LIST - CONTINUED 0027 00

0027 00-2

(1)

ITEMNUMBER

(2)

LEVEL

(3)


(4)


(5)

U/M

1 C ANTIFREEZE

6850-01-383-4068 (1QK63) 672 43541 Gallon Bottle GL

6850-01-441-3257 (58536) A-A-526245 Gallon Can CN

6850-01-383-3918 (58536) A-A-5262455 Gallon Drum DR

2 C CLEANING COMPOUND: Solvent, Type III(81349) MIL-PRF-680

6850-01-474-23186850-01-474-23206850-01-474-2321

1 Gallon Can5 Gallon Can55 Gallon Drum

CNCNDR

3 C CLEANING COMPOUND: Windshield(0FTT5) 0854-000

6850-00-926-2275 16 Ounce Bottle BT

4 C DETERGENT: General Purpose, Liquid(83421) 7930-00-282-9699

7930-00-282-9699 1 Gallon Can CN

5 C DIESEL FUEL: DF-1 Grade, Arctic(81346) ASTM D 975

9140-00-286-52869140-00-286-52879140-00-286-5288

Bulk5 Gallon Can55 Gallon Drum

GLCNDR

6 C DIESEL FUEL: DF-2 Grade(81346) ASTM D 975

9140-00-286-52949140-00-286-52959140-00-286-5296

Bulk5 Gallon Can55 Gallon Drum

GLCNDR

7 C 9130-01-031-5816 FUEL, TURBINE: Aviation(81349) MIL-T-83133 GR JP-8

GL

TM 5-3805-291-10


0027 00-3

8 C GREASE: Automotive and Artillery (GAA)

9150-01-197-7688 (81349) M-10924-A1-1/4 Ounce Tube TU

9150-01-197-7693 (81349) M-10924-B14 Ounce Cartridge CA

9150-01-197-7690 (81349) M-10924-C1-3/4 Pound Can CN

9150-01-197-7692 (81349) M-10924-E35 Pound Can CN

9 C OIL: Lubricating, OE/HDO-40(81349) MIL-PRF-2104

9150-00-188-9862 55 Gallon Drum DR

10 C OIL: Lubricating, OE/HDO-15/40(81349) MIL-PRF-2104

9150-01-152-41179150-01-152-41189150-01-152-4119

1 Quart Can5 Gallon Can55 Gallon Drum

CNCNDR

11 C OIL: Lubricating, OEA-30 Arctic

9150-00-402-4478

9150-00-402-2372

9150-01-491-7197

(81349) MIL-L-461671 Quart Can(81349) MIL-PRF-461675 Gallon Can(81349) MIL-PRF-4616755 Gallon Drum

QT

GL

DR

12 C OIL: Lubricating, OE/HDO-5/40(81349) MIL-PRF-2104

9150-01-524-9155 55 Gallon Drum GL

13 C RAG: Wiping(64067) 7920-00-205-1711

7920-00-205-1711 50 Pound Bale BL

(1)

ITEMNUMBER

(2)

LEVEL

(3)


(4)


(5)

U/M

TM 5-3805-291-10


0027 00-4

END OF WORK PACKAGE

14 C STRAP, TIEDOWN, ELECTRICAL COMPONENTS

5975-00-903-2284 4 Inch Length, Black, Package of 100(96906) MS3367-4-0 HD

5975-00-984-6582 6 Inch Length, Black, Package of 100(96906) MS3367-1-0 HD

5975-00-935-5946 13.35 Inch Minimum Length, Brown(96906) MS3367-2-1 EA

15 C TAG, MARKER(64067) 9905-00-537-8954

9905-00-537-8954 Bundle of 50 BD

16 C TAPE: Duct, 2 in. Wide(39482) 1791K70

5640-00-103-2254 60 Yard Roll RL

17 C 6850-01-154-3653 TEST STRIPS, NITRATE(89524) 500P3205.88

EA

(1)

ITEMNUMBER

(2)

LEVEL

(3)


(4)


(5)

U/M

TM 5-3805-291-10

0028 00-1/(0028 00-2 Blank)

ADDITIONAL AUTHORIZATION LIST (AAL) 0028 00

SCOPE

This work package lists items you are authorized for the support of the 966H Wheel Loader.

GENERAL

This list identifies items that do not have to accompany the trailer and that do not have to be turned in with it. Theseitems are all authorized to you by CTA, MTOE, TDA, or JTA.


1. Column (1) - National Stock Number (NSN). Identifies the stock number of the item to be used for requisitioning pur-poses.

2. Column (2) - Description, Commercial and Government Entity Code (CAGEC), and Part Number (P/N). Identi-fies the Federal item name (in all capital letters) followed by a minimum description when needed. The line below thedescription is the CAGEC (in parentheses) and the P/N.

3. Column (3) - Usable On Code. When applicable, gives you a code if the item you need is not the same for differentmodels of equipment.

4. Column (4) - Unit of Issue (U/I). U/I indicates the physical measurement or count of the item as issued per the NSNshown in column (1).

5. Column (4) - Quantity Recommended (QTY RECM). Indicates the quantity recommended.

END OF WORK PACKAGE

Table 1. AAL for the 966H Wheel Loader.

(1)

NSN

(2)

DESCRIPTION, CAGEC, P/N

(3)USABLE

ON CODE

(4)

U/I

(5)QTY

RECM

5340-01-466-5928 SORBENT DECONTAMINATIONSYSTEM (SDS) MOUNTING BRACKET(4X630) 8640-100-0001

EA 1

4230-01-466-9095 SDS(81361) EA-PRF-2163

EA 1

TM 5-3805-291-10

Index-1

INDEXSubject Work Package/Page

AAbbreviations/Acronyms, List of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0001 00-2

Air Conditioning Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-15

Air Filters, Cab (PMCS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0012 00-33

Arctic Cold Weather Starting Aid System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0006 00-9

Articulation Bearings, Weekly (PMCS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0012 00-42

AttachmentBroom, 966H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0021 00-1Fork Carriage/5-yard Bucket, 966H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0021 00-1

Auxiliary Hydraulic Control forFork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-20Sweeper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-20

BBasic Issue Items (BII) List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0026 00-1

Batteries, Left-Side Battery Box and NATO Slave Receptacle (PMCS) . . . . . . . . . . . . . . . . . . 0012 00-24

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

Brake Systems, Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0003 00-2

BucketCapacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0002 00-14Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-22Kickout Set Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-18

CCab Air Filters (PMCS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0012 00-33

Circuit Breaker Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0016 00-1

Components of End Item (COEI) List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0026 00-1

Configure Machine for Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0024 00-1

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

Coolant Nitrites Level (PMCS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0012 00-44

Corrosion Prevention and Control (CPC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0001 00-1

DData Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0007 00-7

Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0007 00-2

Decontamination Apparatus, System, Sorbent (SDS), M100 . . . . . . . . . . . . . . . . . . . . . . . . . . 0006 00-14

Destruction of Army Materiel to Prevent Enemy Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0001 00-1

TM 5-3805-291-10

INDEX - ContinuedSubject Work Package/Page

Index-2

EElectrical

Stopping Engine if Malfunction Occurs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0005 00-8System, Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0003 00-2

EngineAir Cleaner Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0014 00-1Air Precleaner Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0014 00-1Coolant Level (PMCS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0012 00-6Oil Level (PMCS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0012 00-10Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0005 00-3Start Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-17Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0003 00-1

EquipmentCharacteristics, Capabilities, and Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0002 00-1Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0002 00-9Improvement Recommendations (EIRs), Reporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0001 00-1

EtherStarting Aid System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-29Starting Aid System (PMCS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0012 00-8

Exhaust StackInstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0024 00-6Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0024 00-5

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

ExtremeCold, Operate in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0006 00-7Heat, Operate in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0006 00-10

FFire Extinguisher Operation, Portable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0005 00-17

Fluid Level Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-27

Fording . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0006 00-14

Fuel System, Priming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0013 00-2

Fuel/Water Separator Drain (PMCS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0012 00-12

Fuse Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0016 00-1

HHeating Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-15

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

HoodTilt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-26Tilt - Manual Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-26

TM 5-3805-291-10


Index-3

Hydraulic Control Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-11

Hydraulic SystemRelieving Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0005 00-10Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0003 00-2

IInitial Adjustments and Daily Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0005 00-2

LLift and Tiedown Provisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0017 00-1

Lift Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-21

Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-12

ListAbbreviations/Acronyms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0001 00-2Basic Issue Items (BII) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0026 00-1Components of End Item (COEI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0026 00-1

Loader Arm, Lowering with Engine Stopped . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0005 00-8

Loader Arms Down on Dead Machine Recovery Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . 0006 00-5

LoadingMachine on Flatcar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020 00-2Machine on Ship . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0022 00-2Machine on Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0019 00-2

Location and Description of Major Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0002 00-3

Lowering Loader Arm with Engine Stopped . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0005 00-8

Lubrication Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0012 00-50

MMachine

Load onto C-5 and C-17 Aircraft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0023 00-2Loading on Flatcar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020 00-2Loading on Ship . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0022 00-2Loading on Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0019 00-2Mounting and Dismounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0005 00-2Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0005 00-5Parking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0005 00-7Roading (Self-Deployment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018 00-1Slave Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0006 00-2Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0005 00-6Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0006 00-3Unload from C-5 and C-7 Aircraft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0023 00-3Unloading from Flatcar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020 00-4Unloading From Ship . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0022 00-3Unloading from Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0019 00-3

TM 5-3805-291-10


Index-4

Warmup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0005 00-4

Maintenance Forms, Records, and Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0001 00-1

Major Components, Location and Description of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0002 00-3

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

Messenger Reference Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-29

Monitoring System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-23

Mounting and Dismounting Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0005 00-2

Mud or Soft Surfaces, Operate in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0006 00-12

OOperate

At High Altitudes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0006 00-13Decontamination Apparatus, Portable (DAP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0006 00-14In Extreme Cold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0006 00-7In Extreme Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0006 00-10In Mud or Soft Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0006 00-12In Saltwater Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0006 00-12In Sandy or Dusty Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0006 00-12In Snow and Ice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0006 00-13Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0005 00-5On Slopes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0005 00-6Work Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0005 00-15

PParking

Brake Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-16Brake Manual Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0006 00-6Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0005 00-7

Platform and Top of Machine (PMCS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0012 00-30

PMCSAfter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0012 00-21Articulation Bearings (Weekly) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0012 00-42Before . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0012 00-2Cab Air Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0012 00-33Coolant Nitrites Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0012 00-44During . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0012 00-20Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011 00-1Monthly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0012 00-43Platform and Top of Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0012 00-30Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0012 00-1Weekly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0012 00-33

Portable Fire Extinguisher Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0005 00-17

TM 5-3805-291-10


Index-5

Powertrain, Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0003 00-1

Preparation for Storage or Shipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0001 00-1

QQuick Coupler

Manually Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0006 00-5Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0005 00-11

RRail

Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020 00-1

Rail Tiedown Procedures On A DODX Rail Car . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0021 00-1

Rear HandrailInstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0024 00-6Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0024 00-5

Recovery Procedure - Loader Arms Down on Dead Machine . . . . . . . . . . . . . . . . . . . . . . . . . 0006 00-5

References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0025 00-1

Refueling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0013 00-1

Relieving Hydraulic System Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0005 00-10

Reporting Equipment Improvement Recommendations (EIRs) . . . . . . . . . . . . . . . . . . . . . . . . 0001 00-1

Ride Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-19

Ride Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0003 00-3

RO/RO Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0022 00-2

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

ROPS/FOPSInstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0024 00-6Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0024 00-2

SSandy or Dusty Conditions, Operate in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0006 00-12

Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-12

Service Brake Control (Pedals) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-8

Slave Starting Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0006 00-2

Start Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0005 00-3

SteeringFrame Lock Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0015 00-1Frame Lock Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0015 00-1Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0005 00-6

Stopping Engine if an Electrical Malfunction Occurs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0005 00-8

TM 5-3805-291-10


Index-6

Storage or Shipment, Preparation for . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0001 00-1

TTheory of Operation

Brake Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0003 00-2Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0003 00-2Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0003 00-1Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0003 00-2Powertrain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0003 00-1Ride Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0003 00-3Work Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0003 00-3

Throttle Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-11

Towing Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0006 00-3

TransmissionControl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-7Neutralizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-10

TransportAir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0023 00-1Highway . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0019 00-1Marine (RO/RO Procedures) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0022 00-1Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020 00-1

TroubleshootingIntroduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-1Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010 00-1Symptom Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0009 00-1

UUnloading

Machine from Aircraft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0023 00-3Machine from Flatcar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020 00-4Machine from Ship . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0022 00-3Machine from Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0019 00-3

WWarranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0001 00-1

WindshieldWiper Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-14

Work ToolsOperate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0005 00-15Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0003 00-3

RECOMMENDED CHANGES TO PUBLICATIONS AND BLANK FORMS

For use of this form, see AR 25-30; the proponent agency is ODISC4.

Use Part II (reverse) for Repair Parts and Special Tool Lists (RPSTL) and Supply Catalogs/Supply Manuals (SC/SM).

DATE

Date you filled out this form.

TO: (Forward to proponent of publication or form) (Include ZIP Code) U.S. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS 1 Rock Island Arsenal, Rock Island, IL 61299-7630

FROM: (Activity and location) (Include ZIP Code)

Your mailing address

PART I – ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS PUBLICATION/FORM NUMBER DATE Title Operator's Manual for Loader, Heavy, Scoop: DED, 4-Wheel Drive, 4.5 Cubic TM 5-3805-291-10 15 Jan 10 Yard and 5.0 Cubic Yard, Model 966H ITEMNO.

PAGENO.

PARA-GRAPH

LINENO. *

FIGURENO.

TABLENO.

RECOMMENDED CHANGES AND REASON (Provide exact wording of recommended changes, if possible).

*Reference to line numbers within the paragraph or subparagraph. TYPED NAME, GRADE OR TITLE

Your Name

TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION Signature

Your Signature

DA FORM 2028, FEB 74 REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED. USAPPC V3.00

001700-2 Part number supplied for item 2 is incorrect.

TO: (Forward direct to addressee listed in publication) U. S. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS 1 Rock Island Arsenal, Rock Island, IL 61299-7630


Your address DATEDate you filled out this form

PART II – REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS PUBLICATION NUMBER DATE TITLE Operator's Manual for Loader, Heavy,

PAGENO.

COLMNO.

LINENO.

NATIONAL STOCK NUMBER

REFERENCENO.

FIGURENO.

ITEMNO.

TOTAL NO.OF MAJOR

ITEMSSUPPORTED

RECOMMENDED ACTION

PART III – REMARKS (Any general remarks or recommendations, or suggestions for improvement of publications and blank forms. Additional blank sheets may be used if more space is needed.)

TYPED NAME, GRADE OR TITLE

Your Name

TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION SIGNATURE

Your Signature

USAPPC V3.00

SAMPLE

TM 5-3805-291-10 15 Jan 10 Scoop: DED, 4.5 & 5 Cubic Yd, Model 966H




DATE

U.S. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS 1 Rock Island Arsenal, Rock Island, IL 61299-7630


PART I – ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS PUBLICATION/FORM NUMBER DATE TITLE Operator's Manual for Loader, Heavy, Scoop: DED,

TM 5-3805-291-10 15 Jan 10 4-Wheel Drive, 4.5 and 5.0 Cubic Yard, Model 966H

ITEMNO.

PAGENO.

PARA-GRAPH

LINENO. *

FIGURENO.

TABLENO.


*Reference to line numbers within the paragraph or subparagraph.

TYPED NAME, GRADE OR TITLE TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION

SIGNATURE


TO: (Forward to proponent of publication or form)(Include ZIP Code)

TO: (Forward direct to addressee listed in publication) U. S. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS1 Rock Island Arsenal, Rock Island, IL 61299-7630

FROM: (Activity and location) (Include ZIP Code) DATE

PART II – REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS

PUBLICATION NUMBER DATE TITLE Operator's Manual for Loader, Heavy, Scoop:

PAGENO.

COLMNO.

LINENO.


REFERENCENO.

FIGURENO.

ITEMNO.

TOTAL NO.OF MAJOR

ITEMSSUPPORTED

RECOMMENDED ACTION


TYPED NAME, GRADE OR TITLE TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION SIGNATURE

USAPPC V3.00

TM 5-3805-291-10 15 Jan 10 DED, 4-Wheel Drive, 4.5 and 5 CY, Model 966H




DATE

TO: (Forward to proponent of publication or form) (Include ZIP Code) U. S. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS 1 Rock Island Arsenal, Rock Island, IL 61299-7630


PUBLICATION/FORM NUMBER DATE TITLE Operator's Manual for Loader, Heavy. Scoop, DED TM 5-3805-291-10 15 Jan 10 4-Wheel Drive, 4.5 and 5.0 Cubic Yard, Model 966H

ITEM NO.

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FIGURENO.

TABLENO.


*Reference to line numbers within the paragraph or subparagraph.

TYPED NAME, GRADE OR TITLE TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION

SIGNATURE


TO: (Forward direct to addressee listed in publication)U. S. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS1 Rock Island Arsenal, Rock Island, IL 61299-7630

FROM: (Activity and location) (Include ZIP Code) DATE

PART II – REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS

PUBLICATION NUMBER DATE TITLE Operator's Manual for Loader, Heavy, Scoop: TM 5-3805-291-10 15 Jan 10 DED, 4-Wheel Drive, 4.5 and 5 CY, Model 966H

PAGENO.

COLMNO.

LINENO.


REFERENCENO.

FIGURENO.

ITEMNO.

TOTAL NO.OF MAJOR

ITEMSSUPPORTED

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TYPED NAME, GRADE OR TITLE TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION SIGNATURE

USAPPC V3.00

By Order of the Secretary of the Army:

GEORGE W. CASEY, JR.General, United States Army

Chief of StaffOfficial:

DISTRIBUTION: To be distributed in accordance with the initial distribution requirements for IDN: 251008, require-ments for TM 5-3805-291-10.

0924401

THE METRIC SYSTEM AND EQUIVALENTS

APPROXIMATE CONVERSION FACTORS

Linear Measure

1 Centimeter = 10 Millimeters = 0.01 Meters = 0.3937 Inches1 Meter = 100 Centimeters = 1000 Millimeters = 39.37 Inches1 Kilometer = 1000 Meters = 0.621 Miles

Weights

1 Gram = 0.001 Kilograms = 1000 Milligrams = 0.035 Ounces1 Kilogram = 1000 Grams = 2.2 Pounds1 Metric Ton = 1000 Kilograms = 1 Megagram = 1.1 Short Tons

Liquid Measure

1 Milliliter = 0.001 Liters = 0.0338 Fluid Ounces1 Liter = 1000 Milliliters = 33.82 Fluid Ounces

Square Measure

1 Sq Centimeter = 100 Sq Millimeters = 0.155 Sq Inches1 Sq Meter = 10,000 Sq Centimeters = 10.76 Sq Feet1 Sq Kilometer = 1,000,000 Sq Meters = 0.0386 Sq Miles

Cubic Measure

1 Cu Centimeter = 1,000 Cu Millimeters = 0.06 Cu Inches1 Cu Meter = 1,000,000 Cu Centimeters = 35.31 Cu Feet

Temperature

5/9 ( F - 32) = C212 Fahrenheit is equivalent to 100 Celsius90 Fahrenheit is equivalent to 32.2 Celsius32 Fahrenheit is equivalent to 0 Celsius9/5 C +32 = F

To Change To Multiply By

Inches Centimeters 2.540

Feet Meters 0.305

Yards Meters 0.914

Miles Kilometers 1.609

Sq Inches Sq Centimeters 6.451

Sq Feet Sq Meters 0.093

Sq Yards Sq Meters 0.836

Sq Miles Sq Kilometers 2.590

Acres Sq Hectometers 0.405

Cubic Feet Cubic Meters 0.028

Cubic Yards Cubic Meters 0.765

Fluid Ounces Milliliters 29.573

Pints Liters 0.473

Quarts Liters 0.946

Gallons Liters 3.785

Ounces Grams 28.349

Pounds Kilograms 0.454

Short Tons Metric Tons 0.907

Pound-Feet Newton-Meters 1.356

Pounds per Sq Inch

Kilopascals 6.895

Miles per Gallon Kilometers per Liter 0.425

Miles per Hour Kilometers per Hour 1.609

To Change To Multiply By

Centimeters Inches 0.394

Meters Feet 3.280

Meters Yards 1.094

Kilometers Miles 0.621

Sq Centimeters Sq Inches 0.155

Sq Meters Sq Feet 10.764

Sq Meters Sq Yards 1.196

Sq Kilometers Sq Miles 0.386

Sq Hectometers Acres 2.471

Cubic Meters Cubic Feet 35.315

Cubic Meters Cubic Yards 1.308

Milliliters Fluid Ounces 0.034

Liters Pints 2.113

Liters Quarts 1.057

Liters Gallons 0.264

Grams Ounces 0.035

Kilograms Pounds 2.205

Metric Tons Short Tons 1.102

Newton-Meters Pound-Feet 0.738

Kilopascals Pounds per Sq Inch

0.145

Kilometers per Liter Miles per Gallon 2.354

Kilometers per Hour Miles per Hour 0.621

PIN: 084058-000

Documents

27156844-TM-5-3805-291-10-CATERPILLAR-MDL-966H.pdf