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

TM 5-3805-291-10 TECHNICAL MANUAL

OPERATOR’S MANUAL FOR

LOADER, HEAVY, SCOOP: DIESEL ENGINE DRIVEN (DED), 4-WHEEL DRIVE 4.5 CUBIC YARD ROCK BUCKET NSN 3805-01-533-1857 AND

5.0 CUBIC YARD GENERAL PURPOSE BUCKET NSN 3805-01-533-1853 MODEL 966H

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

HEADQUARTERS, DEPARTMENT OF THE ARMY -$18$5< 20

TM 5-3805-291-10

WARNING SUMMARY This warning summary contains general safety warnings and hazardous materials warnings that must be understood and applied during operation and maintenance of this equipment. Failure to observe these precautions could result in serious injury or death to personnel. Also included are explanations of safety and hazardous materials icons used within the technical manual. BIOLOGICAL - abstract symbol bug shows that a material may contain bacteria or viruses that present a danger to life or health.

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

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

ELECTRICAL - electrical wire to arm with electricity symbol running through human body shows that shock hazard is present.

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

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

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

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

a

TM 5-3805-291-10 HEAVY PARTS - hand with heavy object on top shows that heavy parts can crush and kill.

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

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

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

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

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

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

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TM 5-3805-291-10

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 of headache, dizziness, loss of muscular control, apparent drowsiness, and coma. Permanent brain damage or death to personnel can result from severe exposure. • Carbon monoxide occurs in exhaust fumes from internal combustion engines. It also occurs in exhaust fumes from engine coolant heater (arctic machine only). Carbon monoxide can become dangerously concentrated under conditions of inadequate ventilation. The following precautions must be observed to ensure safety of personnel when engine of loader is operated.

1.

DO NOT operate engine in enclosed areas without adequate ventilation.

2.

DO NOT idle engine without adequate ventilation.

3.

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

4.

BE ALERT for exhaust poisoning symptoms. They are:

5.

•

Headache

•

Dizziness

•

Sleepiness

•

Loss of muscular control

If you see another person with exhaust poisoning symptoms: •

6.

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.

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

The Best Defense Against Carbon Monoxide Poisoning Is Good Ventilation! c

TM 5-3805-291-10

WARNING BATTERIES •

To avoid injury, eye protection and acid-resistant gloves must be worn when working around batteries. DO NOT smoke, use open flame, make sparks, or create other ignition sources around batteries. If a battery is giving off gases, it can explode and cause injury to personnel. Remove all jewelry such as rings, ID tags, watches, and bracelets. If jewelry or a tool contacts a battery terminal, a direct short will result in instant heating or electrical shock, damage to equipment, and injury to personnel.

•

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

1.

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

2.

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

3.

Internal. If corrosion or electrolyte is ingested, drink large amounts of water or milk. Follow with milk of magnesia, 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 SYSTEM Blackout lighting system disables backup alarm, horn, and exterior lights, posing a hazard to personnel in the area. Follow proper safety procedures when operating in blackout mode. Failure to follow this warning may cause injury or death to personnel or damage to equipment.

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

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

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TM 5-3805-291-10

WARNING ENGINE COOLANT (ARCTIC) HEATER (ARCTIC MACHINE ONLY) Use of an arctic heater requires that coolant in system to be heated contain a proper mixture of water and antifreeze to prevent coolant from freezing or slushing. If coolant freezes or slushes, coolant pump cannot move coolant, causing blockage in circulating system. Pressure build-up in arctic heater can cause coolant hose at heater connection to burst or blow off. Injury to personnel or damage to engine could result.

WARNING ETHER COLD START SYSTEM •

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

•

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

WARNING FIRE EXTINGUISHER Discharging large quantities of dry chemical fire extinguisher inside an enclosed cab may result in temporary breathing difficulty during and immediately after the discharge event. Discharge fire extinguisher from outside the cab. Ventilate cab thoroughly prior to reentry. Failure to follow this warning may cause injury to personnel.

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TM 5-3805-291-10

WARNING FRAME ARTICULATION AREA/STEERING FRAME LOCK •

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 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 servicing machine in frame articulation area. Disconnect steering frame lock and secure in stowed position before resuming operation. Failure to follow this warning may result in injury or death to personnel 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 equipment.

•

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 system, 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 DISPOSAL When 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. If further information is needed, please contact The Army Environmental Hotline at 1-800872-3845.

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

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TM 5-3805-291-10

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

WARNING HYDRAULIC SYSTEM PRESSURE DO NOT disconnect or remove any hydraulic system line or fitting unless engine is shut down and hydraulic system pressure has been relieved. Tighten all connections before applying pressure. Escaping 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 arm drop area. Ensure no one is under or near frame articulation area. Failure to follow this warning may result in injury or death to personnel.

WARNING MACHINE OPERATION •

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

•

BE ALERT for personnel in the area while operating machine. Always check to ensure area is clear of personnel and obstructions before moving. Failure to follow this warning may result in injury or death to personnel or damage to equipment.

•

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

•

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

•

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

•

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

•

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

•

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

•

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

TM 5-3805-291-10

WARNING MANUAL RELEASE OF PARKING BRAKE Ensure wheels are blocked before manually releasing parking brake. Failure to follow this warning may result in machine rolling, causing injury or death to personnel or damage to equipment.

WARNING NBC EXPOSURE •

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

•

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

•

NBC contaminated filters must be handled using adequate precautions and must be disposed of by trained personnel.

•

Failure to follow these warnings may cause injury or death.

WARNING IF NBC EXPOSURE IS SUSPECTED ALL AIR FILTER MEDIA WILL BE HANDLED BY PERSONNEL WEARING FULL NBC PROTECTIVE EQUIPMENT. SEE OPERATOR/ MAINTENANCE MANUAL. 7690-01-114-3702

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

WARNING PRESSURIZED COOLING SYSTEM •

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

•

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

•

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

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TM 5-3805-291-10

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

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 during slave 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 toxic material. However, it may be irritating to the eyes and skin. Use protective gloves and goggles. Use in well-ventilated areas. Keep away from open flames and other sources of ignition. Failure to follow this warning may cause injury or death to personnel.

WARNING TIRES •

Operating machine with underinflated or defective tire may lead to tire failure and loss of traction or control. Failure to follow this warning may cause injury or death to personnel or damage to equipment.

•

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

•

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

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TM 5-3805-291-10

WARNING TOWING MACHINE •

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

•

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

•

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

•

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

•

When drive shafts are removed, machine has NO parking or secondary brakes. To prevent machine from rolling, wheels must be blocked securely. Failure to follow this warning may cause injury or death to personnel.

•

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

•

DO NOT return to service a machine that has been towed, without first ensuring that all necessary repairs and adjustments have been performed. Failure to do so could result in injury to personnel or damage to equipment.

WARNING

TRANSPORTING MACHINE •

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

•

Always use a ground guide when operating machine up or down ramps in preparation for transport. Failure to use a ground guide may cause injury or death to personnel or damage to equipment.

•

DO NOT remove exhaust stack until it has cooled to the touch. Wear gloves and protective clothing as required to guard against burns. Failure to follow this warning may result in injury to personnel.

•

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

•

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

•

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

•

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

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TM 5-3805-291-10

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 damage to equipment.

•

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

•

Use caution when handling heavy parts. Provide adequate support and use assistance during procedure. Ensure that any lifting device used is in good condition and of suitable load capacity. Keep clear of heavy parts supported only by lifting device. Failure to follow this warning may cause injury or death to personnel.

•

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

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TM 5-3805-291-10 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 . . . . . . . 1-DQXDU\20 Total number of pages for front and rear matter is 38 and total number of work packages is 28 consisting of the following: Page/WP No.

Change No.

Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Warning Summary (12 pgs.) . . . . . . . . . . . . . i-vi (4 pgs.) . . . . . . . . . . . . . . . . . . . . . . . . . . CHAPTER 1 title page . . . . . . . . . . . . . . . . . WP 0001 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . WP 0002 00 (16 pgs.) . . . . . . . . . . . . . . . . . . WP 0003 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . CHAPTER 2 title page . . . . . . . . . . . . . . . . . WP 0004 00 (74 pgs.) . . . . . . . . . . . . . . . . . . WP 0005 00 (18 pgs.) . . . . . . . . . . . . . . . . . . WP 0006 00 (14 pgs.) . . . . . . . . . . . . . . . . . . WP 0007 00 (12 pgs.) . . . . . . . . . . . . . . . . . . CHAPTER 3 title page . . . . . . . . . . . . . . . . . WP 0008 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . WP 0009 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . WP 0010 00 (14 pgs.) . . . . . . . . . . . . . . . . . . CHAPTER 4 title page . . . . . . . . . . . . . . . . . WP 0011 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . WP 0012 00 (54 pgs.) . . . . . . . . . . . . . . . . . . CHAPTER 5 title page . . . . . . . . . . . . . . . . . WP 0013 00 (2 pgs.) . . . . . . . . . . . . . . . . . . .

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

Page/WP No.

Change No.

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

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TM 5-3805-291-10

TECHNICAL MANUAL TM 5-3805-291-10

HEADQUARTERS DEPARTMENT OF THE ARMY Washington, D.C., -DQXDU\ 20

OPERATOR’S MANUAL FOR LOADER, HEAVY, SCOOP: DIESEL ENGINE DRIVEN (DED), 4-WHEEL DRIVE 4.5 CUBIC YARD ROCK BUCKET NSN 3805-01-533-1857 AND 5.0 CUBIC YARD GENERAL PURPOSE BUCKET NSN 3805-01-533-1853 MODEL 966H REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS You can help improve this publication. If you find any errors, or if you would like to recommend any improvements to the procedures in this publication, please let us know. The preferred method is to submit your DA Form 2028 (Recommended Changes to Publications and Blank Forms) through the Internet, on the Army Electronic Product Support (AEPS) website. The Internet address is https://aeps.ria.army.mil. The DA Form 2028 is located under the Public Applications section in the AEPS Public Home Page. Fill out the form and click on SUBMIT. Using this form on the AEPS will enable us to respond quicker to your comments and better manage the DA Form 2028 program. You may also mail, email, or fax your comments or DA Form 2028 directly to the U.S. Army TACOM Life Cycle Management Command. The postal mail address is U.S. Army TACOM Life Cycle Management Command, ATTN: AMSTA-LCLMPP/TECH PUBS, 1 Rock Island Arsenal, Rock Island, IL 61299-7630. The email address is [email protected]. The fax number is DSN 793-0726 or Commercial (309) 782-0726. DISTRIBUTION STATEMENT A - Approved for public release; distribution is unlimited.

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TM 5-3805-291-10

Table of Contents

Page Number Warning Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a How To Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv CHAPTER 1

INTRODUCTORY INFORMATION, EQUIPMENT DESCRIPTION, AND THEORY OF OPERATION 1 WP 0001 00 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0001 00-1 WP 0002 00 Equipment Description and Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0002 00-1 WP 0003 00 Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0003 00-1 CHAPTER 2

OPERATOR INSTRUCTIONS 1 WP 0004 00 WP 0005 00 WP 0006 00 WP 0007 00

Description and Use of Operator Controls and Indicators . . . . . . . . . . . . . . . . Operation Under Usual Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operation Under Unusual Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stowage and Decal, Data Plate, and Stencil Guide . . . . . . . . . . . . . . . . . . . . . .

0004 00-1 0005 00-1 0006 00-1 0007 00-1

CHAPTER 3

OPERATOR TROUBLESHOOTING 1 WP 0008 00 Troubleshooting Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-1 WP 0009 00 Troubleshooting Symptom Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0009 00-1 WP 0010 00 Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010 00-1 CHAPTER 4

PMCS MAINTENANCE INSTRUCTIONS 1 WP 0011 00 Preventive Maintenance Checks and Services (PMCS) Introduction . . . . . . . . 0011 00-1 WP 0012 00 Preventive Maintenance Checks and Services (PMCS) Including Lubrication Instructions 0012 00-1 CHAPTER 5

MAINTENANCE INSTRUCTIONS 1 WP 0013 00 WP 0014 00 WP 0015 00 WP 0016 00

Refueling and Fuel System Priming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Air Precleaner Service and Air Cleaner Service . . . . . . . . . . . . . . . . . . Steering Frame Lock Connection and Disconnection . . . . . . . . . . . . . . . . . . . . Circuit Breaker and Fuses Reset/Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0013 00-1 0014 00-1 0015 00-1 0016 00-1

CHAPTER 6

TRANSPORT PROCEDURES 1 WP 0017 00 WP 0018 00 WP 0019 00 WP 0020 00 WP 0021 00

Preparation for Transport Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Roading Machine (Self-Deployment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Highway Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rail Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rail Tiedown Procedures on a DODX Rail Car . . . . . . . . . . . . . . . . . . . . . . . . ii

0017 00-1 0018 00-1 0019 00-1 0020 00-1 0021 00-1

TM 5-3805-291-10

Table of Contents - Continued

WP 0022 00 Marine Transport (RO/RO Procedures) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0022 00-1 WP 0023 00 Air Transport by C-5 and C-17 Aircraft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0023 00-1 WP 0024 00 Configure Machine for Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0024 00-1 CHAPTER 7

SUPPORTING INFORMATION 1 WP 0025 00 WP 0026 00 WP 0027 00 WP 0028 00

References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Components of End Item (COEI) and Basic Issue Items (BII) Lists . . . . . . . . Expendable and Durable Items List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Additional Authorization List (AAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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0025 00-1 0026 00-1 0027 00-1 0028 00-1

TM 5-3805-291-10

HOW TO USE THIS MANUAL NOTE If at any time you are unsure how to use this manual or you cannot locate the information you need, notify your supervisor.

INTRODUCTION 1.

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

2.

This manual is written in work package format:

3.

a.

Chapters divide the manual into major categories of information (e.g., Introductory Information, Equipment Description, and Theory of Operation; Operator Instructions; Operator Troubleshooting; PMCS Maintenance Instructions; Maintenance Instructions; Transport Procedures, and Supporting Information).

b.

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

c.

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

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

CONTENTS OF THIS MANUAL 1.

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

2.

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

The Table of Contents also provides Reporting Errors and Recommending Improvements information with DA Form 2028 addresses for the submittal of corrections to this manual.

b.

If you cannot find what you are looking for in the Table of Contents, refer to the alphabetical Index at the back of the manual.

3.

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

4.

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

5.

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

6.

Chapters 4 and 5 cover Maintenance Instructions. Major areas covered are Operator Preventive Maintenance Checks and Services (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). iv

TM 5-3805-291-10

FEATURES OF THIS MANUAL 1.

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

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

CAUTION A CAUTION is a reminder of safety practices or directs attention to usage practices that may result in damage to equipment.

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

2.

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

3.

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

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

b.

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

4.

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

5.

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

6.

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

v/(vi blank)

TM 5-3805-291-10

CHAPTER 1 INTRODUCTORY INFORMATION, EQUIPMENT DESCRIPTION, AND THEORY OF OPERATION

4 TM 5-3805-291-10

GENERAL INFORMATION

0001 00

SCOPE 1.

Type of Manual. This manual is for use in operating and performing operator troubleshooting and maintenance on the 966H Wheel Loader.

2.

Equipment Name and Model Number. Loader, Heavy, Scoop: Diesel Engine Driven (DED) 4-Wheel Drive, Model 966H.

3.

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

Purpose of Equipment. The 966H Wheel Loader is used in worldwide earthmoving and construction projects by U.S. Army forces in engineer troop support.

MAINTENANCE FORMS, RECORDS, AND REPORTS

0001 00

Department of the Army forms and procedures used for the equipment maintenance will be those prescribed by DA PAM 750-8, TAMMS Users Manual. REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIR)

0001 00

If your loader needs improvement, let us know. Send us an EIR. You, the user, are the only one who can tell us what you don’t like about your equipment. Let us know why you don’t like the design or performance. (E-Mail: [email protected]) We will send you a reply. The preferred method for submitting Quality Deficiency Reports (QDRs) is through the Army Electronic Product Support (AEPS) website under the Electronic Deficiency Reporting System (EDRS). The web address is: https://aeps.ria.army.mil. If the above method is not available to you, put it on an SF 368 (Product Quality Deficiency Report), and mail it to us at: Department of the Army, U.S. Army Tank-automotive and Armaments Command, AMSRD-TAR-E, PDQR MS 268, 6501 E. 11 Mile Road, Warren, MI 48397-5000. CORROSION PREVENTION AND CONTROL (CPC)

0001 00

1.

CPC of Army materiel is a continuing concern. It is important that any corrosion problems with this item be reported so that the problem can be corrected and improvements can be made to prevent the problem in future items.

2.

Corrosion specifically occurs with metals. It is an electrochemical process that causes the degradation of metals. It is commonly caused by exposure to moisture, acids, bases, or salts. An example is the rusting of iron. Corrosion damage in metals can be seen, depending on the metal, as tarnishing, pitting, fogging, surface residue, and/or cracking.

3.

Plastics, composites, and rubbers can also degrade. Degradation is caused by thermal (heat), oxidation (oxygen), solvation (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 Equipment 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. 0001 00-1

TM 5-3805-291-10

GENERAL INFORMATION - CONTINUED

0001 00

NOMENCLATURE CROSS-REFERENCE LIST

0001 00

OFFICIAL NOMENCLATURE

COMMON NOMENCLATURE

Tilt Back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rack LIST OF ABBREVIATIONS/ACRONYMS

0001 00

NOTE Refer to ASME Y14.38-1999, Abbreviations and Acronyms, for standard abbreviations. ABBREVIATION/ACRONYM

DEFINITION

AAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Additional Authorization List AAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Association of American Railroads AC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Conditioning AR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . As Required ATAAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air-to-Air Aftercooling BII . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Basic Issue Items B.O. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Blackout CCA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cold Cranking Amps CG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Center of Gravity CID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cubic Inch Displacement cm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Centimeter COEI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Components of End Item CONUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Continental United States CPC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Corrosion Prevention and Control DED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Diesel Engine Driven ECM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electronic Control Module EIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Equipment Improvement Recommendation ET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electronic Technician F/N/R. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Forward/Neutral/Reverse GIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Gabarit International de Chargement GP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .General Purpose kg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kilogram km . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kilometer kPa. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kilopascal kph . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kilometers per Hour kW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kilowatt L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Liter LASH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lighter Aboard Ship lb-ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pound Foot LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Left Hand m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Meter mm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Millimeter 0001 00-2

TM 5-3805-291-10

GENERAL INFORMATION - CONTINUED

0001 00

LIST OF ABBREVIATIONS/ACRONYMS - CONTINUED

0001 00

ABBREVIATION/ACRONYM

DEFINITION

NATO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . North Atlantic Treaty Organization NBC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nuclear, Biological, and Chemical Nm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Newton Meter OCONUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Outside Continental United States PLS-EMM-DB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Palletized Load System-Engineer Mission Module-Dump Body PMCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Preventive Maintenance Checks and Services PR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ply Rating RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Right Hand RO/RO. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Roll-on/Roll-off ROPS/FOPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rollover Protective Structure/Falling Object Protective Structure SDDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Surface Deployment and Distribution Command SDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sorbent Decontamination System SEABEE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Navy Construction Engineer, Sea Barge TOE/MTOE. . . . . . . . . . . . . . . . . . . . . Table of Organization and Equipment/Modified Table of Organization and Equipment WAVS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Work Area Vision System END OF WORK PACKAGE

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

16 TM 5-3805-291-10

EQUIPMENT DESCRIPTION AND DATA

0002 00

EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES

0002 00

1.

Characteristics. a.

The 966H Wheel Loader is an integral part of the Army’s mission to efficiently build roads, airstrips, and other engineering assets in a wide variety of geographic, environmental, and tactical situations: (1) The 966H Type I Wheel Loader uses a 4.5 yd3 (3.5 m3) Rock bucket to operate in quarries to lift and stockpile blast rock. (2) The 966H Type II Wheel Loader uses a 5.0 yd3 (3.8 m3) GP bucket to excavate, dig, lift/load, strip, level, and perform stockpiling operations.

b. 2.

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

Capabilities and Features.

NOTE Refer 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 articulation.

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 disconnection 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 Lifting 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 Decontamination System (SDS). 0002 00-1

TM 5-3805-291-10

EQUIPMENT DESCRIPTION AND DATA - CONTINUED

0002 00

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 Semitrailer. 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.

0002 00-2

TM 5-3805-291-10

EQUIPMENT DESCRIPTION AND DATA - CONTINUED

0002 00

LOCATION AND DESCRIPTION OF MAJOR COMPONENTS

0002 00

KEY

COMPONENT

DESCRIPTION

1

Bucket

Hardened steel bucket has teeth, bolt-on segments, and corner guards. The Type I machine uses a 4.5 yd3 (3.5 m3) Rock bucket. The Type II machine uses a 5.0 yd3 (3.8 m3) GP bucket. Refer 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.

0002 00-3

TM 5-3805-291-10

EQUIPMENT DESCRIPTION AND DATA - CONTINUED

0002 00

LOCATION AND DESCRIPTION OF MAJOR COMPONENTS - CONTINUED

KEY

COMPONENT

DESCRIPTION

14

Blackout (B.O.) Drive Light

Used when operating in blackout mode.

15

Interior Rearview Mirror

Provides operator with a view to rear and side of machine. Located on both sides of machine, inside cab.

16

Cab

Air conditioned/heated enclosure contains 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.

0002 00-4

TM 5-3805-291-10

EQUIPMENT DESCRIPTION AND DATA - CONTINUED

0002 00

LOCATION AND DESCRIPTION OF MAJOR COMPONENTS - CONTINUED

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.

0002 00-5

TM 5-3805-291-10

EQUIPMENT DESCRIPTION AND DATA - CONTINUED

0002 00

LOCATION AND DESCRIPTION OF MAJOR COMPONENTS - CONTINUED

KEY

COMPONENT

DESCRIPTION

32

Fuse Panel

Provides access to fuses.

33

Horns

Horns sound to alert personnel near machine.

34

Front Service Lights

Inside light with white lens is service light. Outside amber light is turnlamp. Located on both sides.

35

Loader Arm

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

36

Lift Cylinders

Two hydraulic cylinders raise and lower loader arm.

37

Windshield Washer Fill

Provides a means to fill windshield washer reservoir.

38

Oil Fill Tube

Used to add engine oil to engine crankcase.

39

Fuel Tank Filler

Provides a means to fill fuel tank.

40

Rear Composite Lights

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

0002 00-6

TM 5-3805-291-10

EQUIPMENT DESCRIPTION AND DATA - CONTINUED

0002 00

LOCATION AND DESCRIPTION OF MAJOR COMPONENTS - CONTINUED

KEY

COMPONENT

DESCRIPTION

41

Ether Starting Aid

Aids in starting engine in very cold weather.

42

Camera

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

43

Steering Lock Link

Stops all articulation when machine is being serviced, lifted, or transported.

44

BII Box

Storage compartment for BII.

45

Emergency Shutoff Switch

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

0002 00-7

TM 5-3805-291-10

EQUIPMENT DESCRIPTION AND DATA - CONTINUED

0002 00

LOCATION AND DESCRIPTION OF MAJOR COMPONENTS - CONTINUED

KEY

COMPONENT

DESCRIPTION

46

Forklift Attachment

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

47

Rotary Sweeper Attachment

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

0002 00-8

TM 5-3805-291-10

EQUIPMENT DESCRIPTION AND DATA - CONTINUED

0002 00

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)

0002 00-9

TM 5-3805-291-10

EQUIPMENT DESCRIPTION AND DATA - CONTINUED

0002 00

EQUIPMENT DATA - CONTINUED Machine Dimensions (with GP Bucket)

KEY

DESCRIPTION

DIMENSION

1

Height to top of ROPS/FOPS cab

141 in. (3.58 m)

2

Height to top of exhaust stack

138 in. (3.54 m)

3

Height to top of hood

100 in. (2.54 m)

4

Ground clearance

17.5 in. (44.5 cm)

5

Bucket pin height at maximum lift

165 in. (4.19 m)

6

Overall height - bucket raised

224 in. (5.69 m)

7

Length - rear axle to bumper

100 in. (2.54 m)

8

Wheelbase

136 in. (3.45 m)

9

Bucket pin height at carry

18 in. (45.7 cm)

10

Length - rear axle to articulation point

68 in. (1.73 m)

11

Rack back (tilt) angle at maximum lift

55 degrees

12

Dump angle at maximum lift

50 degrees

13

Rack back (tilt) angle at carry

47 degrees

14

Rack back (tilt) angle at ground

42 degrees

15

Axle housing clearance

16 in. (40.6 cm)

16

Overall length

372 in. (9.45 m)

17

Digging depth

5 in. (12.7 cm)

18

Reach at maximum lift and 45 degree dump

60 in. (1.27 m)

19

Height to center of axle

31 in. (78.7 cm) 0002 00-10

TM 5-3805-291-10

EQUIPMENT DESCRIPTION AND DATA - CONTINUED

0002 00

EQUIPMENT DATA - CONTINUED 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

164-4069

72 in. (1.83 m)

RATED PLACEMENT OPERATING HEIGHT (A) LOAD 159 in. (4.04 m)

0002 00-11

10,000 lb (4,536 kg)

LOAD CENTER (B) 48 in. (1.22 m)

TM 5-3805-291-10

EQUIPMENT DESCRIPTION AND DATA - CONTINUED

0002 00

EQUIPMENT DATA - CONTINUED Machine Dimensions with Rotary Sweeper

KEY 1

DESCRIPTION Overall length

DIMENSION 30 ft (9.14 m)

0002 00-12

TM 5-3805-291-10

EQUIPMENT DESCRIPTION AND DATA - CONTINUED EQUIPMENT DATA - CONTINUED Refill Capacities Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 gal. (404 L) Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.2 gal. (42.3 L) Front Drive Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.9 gal. (64 L) Rear Drive Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.9 gal. (64 L) Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 gal. (110 L) Hydraulic System (Including Tank). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52.3 gal. (198 L) Engine Crankcase. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.25 gal. (35 L) Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.2 gal. (50 L) Engine Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Caterpillar Inc. Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C11 Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diesel, turbocharged, after-cooled Horsepower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259 hp (net) 283 hp (gross) (193 and 211 kW) @ 1,800 rpm Engine rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,450 (high idle); 825 (low idle) Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6, inline Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 680 CID (11.1 L) Type of Combustion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Direct injection Compression Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17:1 Valves per Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Valve Lash Inlet Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.015 ± 0.003 in. (0.38 ± 0.08 mm) Exhaust Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.025 ± 0.003 in. (0.64 ± 0.08 mm) Firing Order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1, 5, 3, 6, 2, 4 Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.12 in. (13.00 cm) Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.51 in. (14.00 cm) Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,270 lb (1,030 kg) Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Direct injection with electronic unit injectors Cooling System, Water Temperature Regulator Range . . . . . . . . . . . . . . . . . . . . . . . 178 -198 F (81 -92 C) Transmission Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Caterpillar Inc. Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 speeds forward, 4 reverse Range Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Autoshift; single lever control with remote F/N/R Axles Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Caterpillar Inc. Type Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fixed Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oscillating (±13 degrees) Front and Rear Differentials Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Caterpillar Inc. Type Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Limited slip Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Conventional 0002 00-13

0002 00

TM 5-3805-291-10

EQUIPMENT DESCRIPTION AND DATA - CONTINUED

0002 00

EQUIPMENT DATA - CONTINUED Brakes Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Enclosed wet-disc; fully hydraulic Secondary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Provided by nitrogen-charged accumulators Parking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brake actuator Machine Shipping Weight Rock Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53,500 lb (24,267 kg) GP Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52,500 lb (23,814 kg) Miscellaneous Fording Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 in. (76.2 cm) Maximum Travel Speed (Empty) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 mph (37 kph) Location of Center of Gravity (CG): . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 in. (1.73 m) forward of rear axle centerline; 52 in. (1.32 m) above ground level; 0 in. (0 mm) left or right of machine front-to-rear centerline Bucket (Rock)

0002 00

Type I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heavy-duty, rock Ground-Engaging Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Teeth and segments Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 in. (3.25 m) Rated Volume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 yd3 (3.5 m3) Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5,200 lb (2,330 kg) Bucket (GP) Type II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .General purpose Ground-engaging Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Teeth and segments Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 in. (3.02 m) Rated Volume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.0 yd3 (3.8 m3) Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4,200 lb (1,905 kg) Fork Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 in. (2.21 m) Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,650 lb (1,202 kg) Sweeper Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 in. (3.20 m) Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,450 lb (658 kg) Tires Size. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26.5-25 Ply Rating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 PR; L-4 (Rock Bucket), L-3 (GP Bucket) Load Rating Front (Each Tire) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41,000 lb (18,597 kg) Rear (Each Tire) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18,000 lb (8,165 kg) Inflation Pressure Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60 psi (414 kPa) Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 psi (276 kPa) 0002 00-14

TM 5-3805-291-10

EQUIPMENT DESCRIPTION AND DATA - CONTINUED

0002 00

EQUIPMENT DATA - CONTINUED Tires - Continued Axle Load Front (Rock Bucket) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front (GP Bucket). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear (Rock Bucket) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear (GP Bucket) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Average Tire Contact Area

28,000 lb (12,701 kg) 27,500 lb (12,474 kg) 25,500 lb (11,567 kg) 25,000 lb (11,340 kg)

Rock Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390 in.2 (1,374 cm2) each tire GP Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 450 in.2 (2,903 cm2) each tire Steering Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Center-point frame articulation, load sensing primary and secondary systems Number of Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Electrical System System Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Batteries: Quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Cold Cranking Amps Rating: Standard Machine: Down to -25 F (-32 C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 @ 1,400 CCA Batteries (-40 F Arctic Kit): Quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Cold Cranking Amps Rating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 @ 1,400 CCA 2 @ 1,000 CCA END OF WORK PACKAGE

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

4 TM 5-3805-291-10

THEORY OF OPERATION

0003 00

INTRODUCTION 1.

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

2.

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

3.

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

ENGINE

0003 00

1.

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

2.

Fuel System. a.

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

b.

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

c.

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

3.

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

4.

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

5.

Exhaust System. a.

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

b.

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

POWERTRAIN 1.

0003 00

Transmission. a.

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

b.

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

c.

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

d.

A transmission neutralizer system allows the operator to disengage the transmission by pressing the service brake pedals. This serves to stop the machine while increasing hydraulic response. This function can be turned off using Messenger.

2.

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

3.

Rear Axle. This axle is trunnion mounted to allow axle oscillation of ±13 degrees. 0003 00-1

TM 5-3805-291-10

THEORY OF OPERATION - CONTINUED

0003 00

BRAKE SYSTEMS

0003 00

1.

2.

Service Brakes. a.

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

b.

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

c.

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

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 1.

0003 00

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

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

b.

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

2.

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

3.

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

4.

The following major systems comprise the electrical system: a.

Starting 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 operation.

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 fittings.

c.

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

d.

In the event of primary steering system failure, a secondary system automatically activates. An electric supplemental steering pump provides emergency steering power. 0003 00-2

TM 5-3805-291-10

THEORY OF OPERATION - CONTINUED

0003 00

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 rotary sweeper).

b.

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

c.

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

RIDE CONTROL SYSTEM

0003 00

1.

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

2.

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

3.

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

EARTHMOVING EQUIPMENT

0003 00

1.

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

2.

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

3.

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

END OF WORK PACKAGE

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

TM 5-3805-291-10

CHAPTER 2 OPERATOR INSTRUCTIONS

30 TM 5-3805-291-10

DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS

Maintenance Task Title

0004 00

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 controls and indicators, as described in this work package. 0004 00-1

TM 5-3805-291-10

DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS - CONTINUED

0004 00

OVERVIEW - CONTROLS AND INDICATORS INSIDE CAB

0004 00

427-C0020

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

0004 00-2

TM 5-3805-291-10

DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS - CONTINUED

0004 00

OVERVIEW - CONTROLS AND INDICATORS INSIDE CAB - CONTINUED

0004 00

KEY

CONTROL OR INDICATOR

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

0004 00-3

TM 5-3805-291-10

DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS - CONTINUED

0004 00

OVERVIEW - CONTROLS AND INDICATORS INSIDE CAB - CONTINUED

0004 00

KEY

CONTROL OR INDICATOR

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

0004 00-4

TM 5-3805-291-10

DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS - CONTINUED

0004 00

OVERVIEW - CONTROLS AND INDICATORS INSIDE CAB - CONTINUED

0004 00

KEY

CONTROL OR INDICATOR

29

Remote F/N/R Switch

30

Auxiliary Hydraulic Control (Forks and Sweeper)

31

Horn

32

Lift Control

33

Tilt Control

34

Hydraulic Lockout

0004 00-5

TM 5-3805-291-10

DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS - CONTINUED

0004 00

OVERVIEW - CONTROLS AND INDICATORS INSIDE CAB - CONTINUED

0004 00

KEY

CONTROL OR INDICATOR

35

Transmission Downshift Switch

36

Display for Work Area Vision System (WAVS) Camera

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

CAUTION NEVER turn battery disconnect switch to OFF position when engine is running. Damage to electrical system could result.

3.

Turn battery disconnect switch counterclockwise (to the left) to OFF position (2) to deactivate entire electrical system.

4.

When machine will not be used for an extended period of time (1 month or longer), battery disconnect switch should be turned to OFF position (2). This will prevent a short circuit or other electrical system components from draining batteries.

427-C0049

0004 00-6

TM 5-3805-291-10

DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS - CONTINUED

0004 00

TRANSMISSION CONTROL

0004 00

Direction Selection

NOTE Backup 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 transmission 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.

427-C0026

Remote F/N/R Switch Once machine is started, NEUTRAL lamp should be on. Machine may be placed into gear either by using shifter or remote F/N/R switch. In order to use shifter, ensure that remote F/N/R switch is in NEUTRAL position. Use shifter to select direction. The appropriate direction indicator should illuminate. In order to use remote F/N/R switch, place shifter in NEUTRAL position. Select direction that is desired by using remote F/N/R switch. The appropriate direction indicator should illuminate. Transmission will be placed in NEUTRAL position if both shifter and remote F/N/R switch indicate a state that is not NEUTRAL during operation. NEUTRAL lamp will be OFF. Both shifter and remote F/N/R switch must be placed in NEUTRAL position before normal operation can resume.

427-C0027

Speed (Gear) Selection a.

To manually shift transmission, autoshift switch (see callout 24 on page 0004 00-4) must be in MANUAL position. 0004 00-7

TM 5-3805-291-10

DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS - CONTINUED

0004 00

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 switch forward or backward to increase or decrease speed of transmission. Transmission will remain in selected speed until lever is rotated to different speed. Speed of the machine is displayed on front dash.

c.

When transmission downshift switch (see callout 34 on page 0004 00-6) is depressed, it signals powertrain ECM to downshift transmission by one speed. If second speed forward or second speed reverse is selected, transmission will shift to first speed when switch is depressed. Transmission will remain in first speed until transmission direction and speed control lever is shifted to opposite direction or to NEUTRAL. 427-C0029

SERVICE BRAKE CONTROL (PEDALS) 1.

Left Service Brake Pedal (1). a.

2.

0004 00

Left service brake pedal provides three functions: (1)

Aggressive automatic downshifting of transmission

(2)

Neutralization of transmission

(3)

Conventional braking

b.

Left brake pedal is used to initiate automatic downshifting of transmission at higher ground speeds than standard automatic downshifting.

c.

When left service brake pedal is depressed to a certain point, automatic downshifting and neutralization of transmission will occur for all positions of autoshift switch. Automatic downshifting and neutralizing of transmission saves wear on service brakes, axles, and components of powertrain.

d.

Use left brake pedal for most conditions when adequate traction is available.

427-C0045

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 adequately. 0004 00-8

TM 5-3805-291-10

DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS - CONTINUED

0004 00

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)

427-C0030

Initial travel (A) of left brake pedal will cause transmission to aggressively downshift. Transmission will downshift to lowest available speed. Lowest available speed depends on position of autoshift switch. Refer to Modes of Operation for Transmission Neutralizer table later in this work package for lowest available speed. Each downshift of transmission will reduce speed of machine. The transmission will downshift at higher speeds than normal automatic downshift speeds. The transmission will only downshift if an engine overspeed will not occur. The transmission will not upshift until left brake pedal is fully released. The transmission will be engaged again after left brake pedal is released 4 degrees from pedal position (F). This will only happen if transmission was neutralized. Service brakes will still be applied. This will allow transmission to be engaged when brakes are applied. This will help to prevent unwanted movement while operating on a slope. 0004 00-9

TM 5-3805-291-10

DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS - CONTINUED

0004 00

SERVICE BRAKE CONTROL (PEDALS) - CONTINUED

0004 00

Left Brake Pedal Operation - Continued

NOTE You should wait for at least 1 second after you release left brake pedal for 4 degrees before you completely 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 return to 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.

427-C0469

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

0004 00-10

TM 5-3805-291-10

DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS - CONTINUED THROTTLE CONTROL

0004 00

0004 00

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

427-C0046

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-C0032

0004 00-11

TM 5-3805-291-10

DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS - CONTINUED

0004 00

SEAT BELT

0004 00

1.

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

2.

Ensure seat belt is snug across lap.

427-C0062

LIGHTS

0004 00

Military Light Switch. Located on right side of operator’s seat. Controls operation of machine’s service, blackout, parking, 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.

NOTE For 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 selector switch is correctly positioned.

3.

Operate the instrument panel light switch (3) to turn on and vary the brightness of the instrumentation lighting. Push down on the instrument panel light switch (3) to select the parking lights.

0004 00-12

TM 5-3805-291-10

DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS - CONTINUED

0004 00

LIGHTS - CONTINUED

0004 00

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

MODE

LIGHT ACTIVATION AVAILABLE

B.O. DRIVE

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

B.O. MARKER

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

All OFF

All lights OFF

STOP LIGHT

Service Stop Light ON when brakes are applied Service Turn Indicators when switch is activated Backup Lights and Alarm are also active

NOTE

SER DRIVE

To switch between high and low beam headlights, use the multi-purpose column switch. Service Stop Light ON when brakes applied Service Tail Light Service Turn Indicators when switch activated Service Headlights PARK

Parking Lights

Interior Light Switch

NOTE Light 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.

0004 00-13

TM 5-3805-291-10

DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS - CONTINUED

0004 00

LIGHTS - CONTINUED

0004 00

Directional Turnlamp 1.

Left Turnlamp (1). Push turnlamp lever forward to position.

2.

Right Turnlamp (2). Pull turnlamp lever rearward to position.

3.

Off. Move turnlamp lever to center position in order to deactivate either turnlamp.

4.

An indicator light on front dash panel will flash when turnlamp is activated.

427-C0044

WIPER CONTROLS 1.

0004 00

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.

NOTE Machine is equipped with intermittent front wipers. There are several positions that will control wipers.

2.

c.

Turn knob clockwise from OFF position for desired setting (INTERMITTENT, LOW, or HIGH).

d.

Delay speed of wipers can be adjusted by turning knob clockwise through INTERMITTENT position.

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-C0470

0004 00-14

TM 5-3805-291-10

DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS - CONTINUED

0004 00

HEATING AND AIR CONDITIONING CONTROLS

0004 00

Heating and AC controls are located on switch panel in upper right side of cab. 1.

2.

3.

4.

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.

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.

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.

Defrost. Press bottom of switch (1) in order to turn on AC. Set fan speed switch (2) to desired speed. Adjust temperature control knob (3) so that windows remain free of moisture.

427-C0471

0004 00-15

TM 5-3805-291-10

DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS - CONTINUED

0004 00

PARKING BRAKE CONTROL

0004 00

CAUTION • Do not engage the parking brake while the machine is moving unless the service brake fails. The use of the 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. If necessary, have brake repaired before operating machine. • Parking brake function activates a warning on Messenger whenever parking brake is engaged. Parking brake indicator will flash. 1.

2.

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 is engaged, transmission will not shift out of NEUTRAL to first speed forward or first speed reverse. If transmission is in first speed forward or first speed reverse and parking brake is moved to engaged position, transmission will shift into NEUTRAL. All transmission clutch modulating valves are de-energized. If transmission is in second speed 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 indicator will flash.

c.

When parking brake is engaged and transmission is in first speed, powertrain ECM shifts transmission to NEUTRAL and sends parking brake status to Messenger via CAT Data Link. When parking brake is engaged, alert indicator for parking brake flashes on Messenger. If operator selects FORWARD or REVERSE and parking brake is engaged, Messenger causes parking break indicator and action lamp to flash, and action alarm to sound.

4-Way Hazard Light Switch. Toggle switch upward to engage hazard lights. Toggle switch downward to disengage hazard lights.

427-C0472

WARNING Personal injury could result from the sudden stop of the machine. The parking brake is automatically engaged 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 pressure. Action light will also flash when lights on monitoring system flash. 0004 00-16

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DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS - CONTINUED

0004 00

ENGINE START SWITCH

0004 00

NOTE If engine fails to start, return engine start switch to OFF position. This must be done before you attempt to start engine again. 1.

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

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DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS - CONTINUED

0004 00

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 position. 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.

CAUTION If the boom is 12 in. (30.5 cm) or less above the lower kickout position, placing the lift control lever in the 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

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DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS - CONTINUED

0004 00

RIDE CONTROL

0004 00

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

Ride Control Switch.

WARNING Never perform loading operations with ride control switch in ON (manual) position. Failure to do so may result in injury to personnel.

2.

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 ride control system will automatically turn on if the ground speed exceeds 6 mph (9.6 kph). The ride control system will 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 system 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 enabled when operator places ride control switch in ON or AUTO position. In ON position, ride control is activated at all times and powertrain ECM continuously energizes ride control solenoid. This mode should only be used when machine is being serviced. Never perform loading operations with ride control switch in ON position. In AUTO position, ride control is activated when machine ground speed increases above approximately 6 mph (10 kph). In AUTO 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.

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

427-C0474

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DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS - CONTINUED

0004 00

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 control switch (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 control switch (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 pressurized 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 (for rotary 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 will not be activated if the operator does not release the thumb wheel within 1 second of releasing the continuous flow switch.

d.

Move the thumb wheel (1) or the continuous flow switch (2) in order to stop the flow to the auxiliary hydraulic circuit.

427-C0475

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DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS - CONTINUED

0004 00

LIFT CONTROL

0004 00

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

NOTE If the attachment is greater than 12 in. (30.5 cm) from the lower kickout position, a lower kickout will occur 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 will cause 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 FLOAT position until the joystick is moved at least 6 degrees from the HOLD position.

2.

Lower (2). Push the joystick forward in order to lower the attachment. The joystick will return to the HOLD position when the joystick is released.

3.

Hold (3). The joystick will return to the HOLD position when the joystick is released from the RAISE position or from the LOWER position. The attachment will remain in the selected position.

4.

Raise (4). Pull the joystick backward in order to raise the attachment. The joystick will return to the HOLD position when the joystick is released.

427-C0042

The joystick control is detented in the fully raised position. When the joystick is moved into the soft detent, the operator will feel an increased resistance from the joystick. Once in the detent, the joystick should be released in order to automatically return to the HOLD position. The attachment will continue to raise until the attachment reaches the lift kickout height. In order to manually override the detent, the joystick must be moved at least 6 degrees from the 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 FLOAT position. When the joystick is moved into the soft detent, the operator will feel an increased resistance from the joystick. Once in the detent position, the joystick should be released in order to automatically return to the HOLD position. The attachment will continue to lower until the attachment reaches the kickout height. In order to manually override the detent, the joystick must be moved at least 6 degrees from the HOLD position. The detent will not be activated if the joystick is held in the detent position for more than 1 second. 0004 00-21

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DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS - CONTINUED

0004 00

BUCKET CONTROL

0004 00

1.

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

2.

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

3.

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

427-C0043

NOTE A machine with ride control may experience partial lowering of the lift arms when the joystick is held in the DUMP position with the bucket against the bucket stops and the lift arms are fully raised. To avoid 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 operator will feel an increased resistance from the joystick. Once in the detent, the joystick should be released in order to automatically return to the HOLD position. The attachment will continue to tilt back until the attachment reaches the digging angle that is preset by the tilt kickout. In order to manually override the detent, the joystick must be moved at least 6 degrees from the 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 operator will feel an increased resistance from the joystick. Once in the detent, the joystick should be released in order to automatically return to the HOLD position. The attachment will continue to dump until the attachment reaches the digging angle that is preset by the tilt kickout. In order to manually override the detent, the joystick must be moved at least 6 degrees from the HOLD position. The detent will not be activated if the joystick is held in the detent position for more than 1 second.

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DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS - CONTINUED

0004 00

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 Reference Guide later in this work package.

427-C1974

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 tank is 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 in the 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 on the 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, stop the 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 the red area, reduce the load on the system. If the gage needle remains in the red area, stop the machine and investigate the cause 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 indicator may also indicate a failure of the primary steering. The secondary steering (if equipped) should be automatically activated. If this alert indicator flashes during operation, stop the machine immediately and engage the parking brake. Stop the engine and investigate the cause of the fault. Refer to Troubleshooting Introduction (WP 0008 00). 0004 00-23

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DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS - CONTINUED

0004 00

MONITORING SYSTEM - CONTINUED

0004 00

Front Dash Indicators - Continued

WARNING Do not operate the machine until the steering fault has been corrected. Failure to follow this warning may cause injury or death to personnel.

NOTE Secondary steering only works while the machine is moving. Directional changes can be made when the machine operates under secondary steering. 3.

Secondary Steering (10). This indicator illuminates when the secondary steering is functioning. When you turn the engine 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 of the fault. Refer to Troubleshooting Introduction (WP 0008 00). Do not operate the machine until the fault has been corrected.

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 the transmission. Immediately stop the machine. Stop the engine. Investigate the cause. Refer to Troubleshooting Introduction (WP 0008 00).

6.

Parking Brake (13). This indicator illuminates when the parking brake is engaged. The indicator should flash during start-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 Troubleshooting Introduction (WP 0008 00).

427-C0477

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DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS - CONTINUED

0004 00

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 voltage 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 system turns off within 1 minute, the electrical system is operating normally. Overload can occur during periods of low engine speeds.

b.

Revise the operating cycle in order to avoid overloading the electrical system. Overloading the electrical system could 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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DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS - CONTINUED

0004 00

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 has stopped. When audible clicks are heard, release toggle switch. Failure to release toggle switch will result 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 to position (1) in order to raise the hood. Release the toggle switch. The toggle switch will return to the middle position (2).

4.

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

427-C0057

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 0026 00) 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 the hood. Turn the shaft counterclockwise (to the left) to lower the hood.

427-C1973

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DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS - CONTINUED

0004 00

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 fill from lowest point on crosshatched area.

427-C0061

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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DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS - CONTINUED

0004 00

FLUID LEVEL INDICATORS - CONTINUED

0004 00

3.

Coolant Level Sight Gage (1).

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

a.

Open the access door on the left-rear side of the machine.

b.

Coolant level sight gage (1) is located on the top radiator.

c.

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

427-C0060

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DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS - CONTINUED

0004 00

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, remove filler cap (1) slowly and add oil.

427-C0058

ETHER STARTING AID SYSTEM

0004 00

1.

Ether starting aid cylinder is located in engine compartment on left side of machine next to air cleaner.

2.

When ambient temperature is below 0°F (-18°C), a measured amount of ether is injected automatically into engine air intake system when starting engine.

3.

Operator DOES NOT manually inject ether.

427-C1708

MESSENGER REFERENCE GUIDE

0004 00

NOTE See PDF beginning on page 0004 00-30.

0004 00-29

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MESSENGER REFERENCE GUIDE 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

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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Messenger Reference Guide

Engine Speed (e.g. 1500 RPM) Ground Speed/Direction (e.g. 13.8 kph, -3.4 mph)

Top Level Screen Time/Date

Performance

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

Settings

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

Totals

Torque Converter Temperature (e.g. 78C,-14F) Fuel Level (e.g. 46%)

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

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.

Display Settings

Settings Menu Diagram

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Messenger Reference Guide

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)

•

Aggressive

•

Moderate

•

Disable

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Messenger Reference Guide

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 fourcalibrated 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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Messenger Reference Guide

Slope Operation Screens Use the up or down arrow key to change the default setting for the specific mode selected. Each time the arrow is depressed, the setting will change by 1.0% in the direction of the arrow (up arrow increases the setpoint and down arrow decreases the setpoint). Once the setting is acceptable, press OK to accept and store the value. Go to the next screen for the next adjustment. After the Aggressive Slope adjustment, press OK and you will be returned to 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 Aggressive Slope setting.

•

The Aggressive Slope setting cannot be set below or equal to the slope setting or above the maximum allowed setting.

•

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

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

Back & Down/Right

Fuel Economy Mode

Press Simultaneously to: Toggle the Neutralizer to Disable or from Disable to Level

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 following three 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. 0004 00-35

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Messenger Reference Guide •

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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Messenger Reference Guide

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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Messenger Reference Guide

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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Messenger Reference Guide

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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Messenger Reference Guide

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, MM-DD-YY

•

24-hour, YYYY-MM-DD

•

12-hour, DD-MM-YY

•

12-hour, MM-DD-YY

•

24-hour, DD-MM-YY

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Messenger Reference Guide

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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Messenger Reference Guide

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

Transmission Hrs

•

Fwd Distance

•

Total Distance

•

Rev Distance

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

Total Hours

•

Percentage Idle Time

•

Total Idle Time

•

Lifetime Eng Revs

•

Total Fuel

•

Average RPM

•

Total Idle Fuel

•

Avg Fuel Rate

•

Total Eng Starts

•

Overall Load Factor

•

Total Max Fuel

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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Messenger Reference Guide

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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Messenger Reference Guide

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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Messenger Reference Guide

SYSTEM PARAMETERS This menu item displays current settings and operational readings.

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

Display Settings

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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Messenger Reference Guide

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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Messenger Reference Guide

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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Messenger Reference Guide

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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Messenger Reference Guide

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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Messenger Reference Guide

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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Messenger Reference Guide

Valve Calibrations: Implement Lower: *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 450–500 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: *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 450–500 mm

4.

Set tilt cylinder extension to 200–250 mm

5.

Set Engine Speed to high idle

6.

Release lever ..’Next’

7.

Move tilt lever to full rackback & hold

8.

CALIBRATING

9.

Release lever ..’Next’

Valve Calibrations: Implement Dump: *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 450–500 mm

4.

Set tilt cylinder. extension to 200–250 mm

5.

Set Engine Speed to high idle

6.

Release lever ..’Next’

7.

Move tilt lever to full dump & hold

8.

CALIBRATING

9.

Release lever ..’Next’

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Messenger Reference Guide Valve Calibrations: 3rd Function Rearward: *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.

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

4.

Set Engine Speed to high idle

5.

Release lever ..’Next’

6.

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

7.

CALIBRATING

8.

Release lever ..’Next’

Valve Calibrations: 3rd Function Forward: *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.

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

4.

Set Engine Speed to high idle

5.

Release lever ..’Next’

6.

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

7.

CALIBRATING

8.

Release lever ..’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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Messenger Reference Guide

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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Messenger Reference Guide

Service: Tattletale Menu Diagram

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Messenger Reference Guide

Service: Tattletale Screens

OPERATOR Multiple 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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Messenger Reference Guide

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

•

Raise Kickout Cylinder Extension

•

Language

•

Lower Kickout Cylinder Extension

•

Units

•

Dump Rate Control Enable Status

•

Startup Screen

•

Full Rack Angle Control Enable Status

•

Date Format

•

Dump Stop Snubbing Enable Status

•

Time Format

•

Neutralizer Operation Mode

•

Contrast

•

Neutralizer settings

•

Lights On

•

Level operation neutralizer set point

•

Lights Off

•

•

Forward to Reverse Gear

Moderate slope operation neutralizer set point

•

Reverse to Forward Gear

•

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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Messenger Reference Guide

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

Raise Kickout Cylinder Extension

•

•

Language - English

•

Dump Rate Control Enable Status- Disabled

•

Units - English

•

•

Startup Screen – Top Level Screen

Full Rack Angle Control Enable Stats Disabled

•

Time Format – 12 Hr

•

•

Date Format – YYY/MM/DD

Dump Stop Snubbing Enable Status Disabled

•

Contrast – 50%

•

Neutralizer Operation Mode - Level

•

Lights On – 50%

•

Neutralizer settings

•

Lights Off – 50%

•

Level operation neutralizer set point – 2%

•

Forward to Reverse Gear – 2

•

Moderate slope operation neutralizer set point – 8%

•

Reverse to Forward Gear – 2

•

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.

0004 00-57

2

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DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS - CONTINUED WORK AREA VISION SYSTEM (WAVS)

0004 00-59 0000 00

Operation and Maintenance Manual starts on page 0004 00-61 Systems Operation Testing and Adjusting starts on page 0004 00-81

0004 00-58

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i01658146

Important Safety Information Most accidents that involve product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills and tools to perform these functions properly. Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death. Do not operate or perform any lubrication, maintenance or repair on this product, until you have read 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 warnings are not heeded, bodily injury or death could occur to you or to other persons. The hazards are identied 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 pictorially presented. Operations that may cause product damage are identied by “NOTICE” labels on the product and in this 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 specically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or repair procedures that you choose. The information, specications, and illustrations in this publication are on the basis of information that was available at the time that the publication was written. The specications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job. Caterpillar dealers have the most current information available.

When replacement parts are required for this product Caterpillar recommends using Caterpillar replacement parts or parts with equivalent specications including, but not limited to, physical dimensions, type, strength and material. Failure to heed this warning can lead to premature failures, product damage, personal injury or death.

0004 00-59

Foreword

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Foreword Literature Information This manual should be stored in the literature holder. This manual contains safety information, operation instructions, and maintenance recommendations. Some photographs or illustrations in this publication show details or attachments that can be different from your product. Continuing improvement and advancement of product design might have caused changes to your product 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.

Safety The safety section lists basic safety precautions. In addition, this section identies the text and locations of warning signs and labels used on the machine.

Operation The operation section is a reference for the new operator and a refresher for the experienced operator. This section includes a discussion of gauges, switches, product controls, attachment controls, and programming information. Photographs and illustrations guide the operator through correct procedures of checking, starting, operating and stopping the product. Operating techniques outlined in this publication are basic. Skill and techniques develop as the operator gains knowledge of the product and its capabilities.

Maintenance The maintenance section is a guide to equipment care.

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Safety Section i02726365

Safety

Safety Section Safety

If the display that is used with this system was installed on another machine, Caterpillar recommends conguring the settings for the display by qualied service personnel. A new conguration will ensure proper performance in the new application.

SMCS Code: 7348

Do not operate or work on this machine unless you have read and understand the instructions and warnings in the Operation and Maintenance Manuals. Failure to follow the instructions or heed the warnings could result in injury or death. Contact your Caterpillar dealer for replacement manuals. Proper care is your responsibility. This machine is equipped with the Caterpillar Work Area Vision System (WAVS). The system may include one, two, or three cameras. The system has been set up by the factory or by a Caterpillar dealer in order to provide views which comply with the guidelines that have been documented. WAVS is designed in order to supplement the view for the operator during machine operation. This system is not intended as a substitute for proper operating techniques. This system is not intended as a substitute for safe operating techniques. This system is not intended to take the place of other standard systems for supplemental vision such as mirrors with rear view and side view. Before you begin operating the machine, ensure that the features of the display screen for WAVS are properly adjusted. Consult Unit Maintenance before any adjustments are made to the system. Prior to operation of the machine, always conrm that the view that is provided by any camera is adequate for your viewing. If necessary, make adjustments prior to operating the machine. Prior to operating the machine, ensure proper orientation of images by the camera. Rear facing cameras should yield a mirror image. Ensure that the brightness and the contrast are adjusted prior to operating the machine. Ensure that the brightness and the contrast are adjusted after changes in the conditions for ambient light. Due to the environment, the camera lens and the display screen will require periodic cleaning. The instructions on properly cleaning the camera lens and the display are described in "Display - Clean" and “ Camera - Clean”.

0004 00-61

Operation Section General Information

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Systems Operation Section i02506417

General Information SMCS Code: 7347; 7348

Safety This machine is equipped with the Caterpillar Work Area Vision System (WAVS). The system may include one, two, or three cameras. The system has been set up by the factory or a Caterpillar dealer in order to provide views which comply with documented guidelines. While the system is serviced, be sure to observe safe access procedures. Ensure that an appropriate 3-point contact system can be safely maintained during the cleaning procedure and/or use of an appropriate safety harness.

Illustration 1

g01178357

Display

Notify Unit Maintenance before any adjustments are made to the system. Any adjustments to the WAVS by anyone other than a qualified technician can be detrimental to the specified purpose of this system. Due to the environment, the camera lens and the display screen will require periodic cleaning. The instructions on how to properly clean the camera lens and the display are described in the Maintenance section of the Operation and Maintenance Manual. IF THE DISPLAY THAT IS USED WITH THIS SYSTEM WAS PREVIOUSLY INSTALLED ON A DIFFERENT MACHINE, IT IS IMPORTANT THAT THE DISPLAY SETTINGS BE RE-CONFIGURED BY QUALIFIED SERVICE PERSONNEL TO INSURE PROPER PERFORMANCE IN THE NEW APPLICATION.

System Overview

Illustration 2

This machine is equipped with the Caterpillar Work Area Vision System (WAVS). WAVS is a closed circuit video monitoring system. WAVS consists of a 178mm (7 inch) LCD color display and may include one, two, or three cameras. The display is mounted in the machine cab. The cameras are mounted on the frame of the machine. The location of the camera(s) is dependant on machine type.

g01178360

Camera Assembly

Marker Line Your system may have been configured to show a green horizontal “Marker” line that is shown on the display. The “Marker” provides a fixed distance reference line from the machine. There are no operator controls available in order to adjust the “Marker” (15). Refer to Illustration 3.

0004 00-62

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Illustration 3

g01178367

Operation Section General Information

Illustration 4

g01178363

Rear Camera View with Marker

Example of a Single Camera Installation on a Wheel Loader

(15) Marker Line

(21) (22) (23) (24) (25)

Power on/off Power is supplied to the system when the operator turns the key switch to the ON position and the light switch selector 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 this document for an Illustration of the power button. The power button is shown in the “Display Keypad” Illustration.

Rearward Looking Camera Possible Video Cable Route Machine Cab Display in Cab 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 to adjust the display settings for a single camera system. Make sure the display in not in the “Standby” mode. Note: If the single camera system can be placed in manual mode, PLEASE notify service personnel.

Single Camera System Overview The WAVS single camera system only has one mode of operation, automatic mode.

Note: The orientation for the camera image is set during installation. The rearward looking camera image is set to provide a “reversed” image, similar to a mirror view. If the camera image orientation is not correct, contact service personnel immediately.

Multi-Camera System Overview The WAVS multi-camera system has two modes of operation, manual mode and automatic mode. Automatic mode is the preferred mode of operation. In the automatic mode, the display will provide the camera view(s) that are defined by the configuration of the system. The configuration of the system is determined upon installation of the system.

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Operation Section General Information

Modes Of Operation

In a multiple camera system, the operator can override the automatic view by either of the following selections:

SMCS Code: 7348

• Selecting “Manual Mode” on the display

Automatic Mode for the Single Camera System

• Pressing the “Alternate Camera” switch

i02727240

The single camera system is available only with the automatic mode “enabled”. The single camera system can be placed in “Standby” if the system is congured. Refer to the “Standby” for an explanation of the “Standby” option. Manual mode is intended for use only with the multiple camera applications. Manual mode is disabled for use in a single camera system. Note: If the “single camera” system can be placed in manual mode, notify Unit Maintenance. In a single camera system, the system will automatically display the camera view that is based on current machine operation which is determined by the system conguration. For example, WAVS may be congured to display the view from a rearward looking camera when the operator selects reverse gear.

Standby Your single camera system installation may be congured with the “Standby” feature that is enabled or disabled. If “Standby” is enabled, the display will remain dark unless the camera view has been activated by machine operation. Standby may be useful at the following times:

In the “Automatic” mode, automatic selection of each camera will be enabled and the appropriate camera will be activated. In automatic mode, the display can also be placed in “Standby”. Note: The preferred camera view will always be shown on the display screen unless the display is placed in “Manual” mode.

Alternate Camera Switch The Alternate camera switch allows the third camera to be activated. In the example of the Off-Highway Truck, the third camera is the side camera. The switch is a momentary switch that will need to be held down in order to activate the third camera. The image on the display will return to the front camera or the rear camera when the switch is released. This action is dependent on which of the cameras that the machine is trying to activate. If the switch is congured, this switch may also be providing power to a light that concentrates on the viewing area of the side camera. If the system is congured this way, the light will turn on any time that the third camera is activated with the Alternate camera switch.

• Travel at night. • Reverse will not be used. If the “Standby” feature is disabled and if the display is on constantly, the operator has the option of adjusting the brightness of the display. If the “Standby” feature is disabled and if the display is on constantly, the operator has the option of adjusting the contrast of the display.

Automatic Mode for a Multiple Camera System When the system is in the automatic mode, the system automatically selects the preferred camera view that is based on current machine operation which is determined by the system conguration. For example, WAVS may be congured to display the view from the rearward looking camera when the operator selects reverse gear. 0004 00-64

Operation Section General Information

TM 5-3805-291-10

Camera Wash i02726609

amera

Camera Description SMCS Code: 7348

Camera

Illustration 9

g01178970

Assembly for the Camera

The system has been set up by the factory or by a Caterpillar dealer in order to provide views which comply with the guidelines that have been documented. Notify Unit Maintenance before any adjustments are made to the system. Proper operation of the system will require periodic cleaning of the camera lens and the display. Refer to "Display - Clean" and "Camera - Clean". After installation, there should be no need to make any physical adjustments to any of the cameras under normal operating conditions. The cameras are “xed focused” cameras. The cameras have been installed by the following service personnel: factory, Caterpillar dealer, and qualied technician.

0004 00-65

Wash

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Operation Section Adjustments

Adjustments i02727631

Display Position Adjustment SMCS Code: 7347 Do not position the display in order to cover any warning stickers or other important information. Do not position the display in order to impede the entry to the machine cab or exit from the machine cab. Illustration 12

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

g01368064

(3) Ball Mount Base

Do not position the display in order to obstruct the operator’s view of machine instrumentation. Do not position the display in order to impair access to operator controls or movement of operator controls.

Position the Display

Illustration 13

g01367988

Installation of the Display and Mounting Assembly Illustration 11 Mounting Clamp Assembly (1) Clamp (2) Clamp Handle

g01367987

(3) (4) (5) (6) (7)

Base for the Ball Mount Display Mounting Clamps Dumbbell Mounting Clamp Handles

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

0004 00-66

Operation Section Adjustments

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i02727626

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

Single Camera System Ensure that the display is not in the “Standby” mode. Refer to "Display Description" for information on the operation of the buttons for the display. Note: If the single camera system can be placed in manual mode, notify Unit Maintenance.

Illustration 14

g01368029

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

Example of an Installation on a Wheel Loader (3) (4) (5) (8) (9)

Base for the Ball Mount Display Mounting Clamp Mounting Bracket for the Display Mounting Bolt for the Ball Mount

Adjustment for Brightness In order to adjust the brightness, perform the following 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 the right of the button for adjusting the brightness will illuminate indicating that you have entered the mode 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 to exit the mode for adjusting the brightness. The “RED” LED light that is above and to the right of button for adjusting the brightness will turn OFF. Note: If the level for brightness is set to high and if the “Auto Brightness” is not enabled, then there is a possibly that in a well lighted area the display would appear completely “white”.

Illustration 15 Example of an Installation on a Wheel Loader (10) Installed WAVS

g01368041

Adjustment for Contrast In order to adjust the contrast, perform the following procedure: 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 of the button for adjusting the contrast will illuminate in order to indicate that you have entered the mode for adjusting the contrast.

0004 00-67

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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 order to exit the mode for adjusting the contrast. The “RED” LED light that is above and to the right of the 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 the right of the button for automatic brightness will illuminate in order to indicate that the auto brightness/dimming option is enabled. 2. Press the button for automatic brightness again in order to disable the option for automatic brightness. The “RED” LED light that is above and to the right of the button for automatic brightness will turn off in order to indicate that the auto brightness/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 enable standby. The “Red” LED light that is above and to the right of the button for the standby option will illuminate in order to indicate that standby is enabled. The display should go dark. The display will remain dark until an input for the system is activated. 2. Press the standby button again in order to disable the standby option. The “Red” LED light that is above and to the right of the button for the standby option will turn OFF. The display will remain in the ON position.

Multiple Camera System

0004 00-68

Operation Section Adjustments

Maintenance Section Maintenance Interval Schedule

TM 5-3805-291-10

Maintenance Section i02736179

Display - Clean SMCS Code: 7347-070 In order to maintain sufcient vision, the display and the camera lens may need to be cleaned periodically due to the environment. Use a soft, damp cloth with water only in order to clean the display. The display has a soft plastic surface that is easily damaged by any material that is abrasive.

Adjust the spray nozzle within one inch of the camera lens in order for the camera wash system to perform proper operation. adjust the spray nozzle within one inch of the camera lens. The angle of the spray nozzle should be between 30 degrees and 45 degrees from the lens of the camera. Note: When you are adjusting, verify that the spray nozzle is not in the view of the camera. The preferred method of adjustment would require two people:

• One person in the cab that is looking at the image

Note: The display is not sealed. The display can not be immersed. The display can not have a pressure wash.

on the display

• One person that is making the adjustment on the

i02736175

Camera - Clean SMCS Code: 7348-070

Camera If necessary, use a damp cloth in order to clean the glass of the camera. The camera is sealed. The camera is not affected by a wash with high pressure spray. The camera is equipped with an internal heater to help counteract the following effects: condensation, snow, and accumulation of ice. Note: When you access the cameras for cleaning, be sure to observe safe procedures for access. Maintain a three-point contact and/or use a safety harness. Note: Alternatively, cameras may be cleaned from ground level by using a wash with a high pressure spray or a damp rag on a wand.

Camera Wash System The camera wash system is installed typically on the rear facing camera for easy cleaning. The cleaning is performed by pressing the switch for two second durations until the camera is clean. activating the camera wash system at the end of the shift in order to clear the water and the debris. This will ensure that the water and debris does not freeze up the spray head.

0004 00-69

spray nozzle

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Systems Operation Section

i02506525

Configuration SMCS Code: 7347; 7348

g01178371

Illustration 7 Display 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 Contrast Adjustment Button (8) Power ON/OFF Function May Be Disabled (9) Camera Select LEDs (10) Button Status LEDs (11) Light Sensor

Accessing All System Options In order to configure or verify certain options, there is a particular procedure that must be used in order to access the options.

Mirror Image The display is supplied by Caterpillar with the “Mirror” image set as the default. The mirror image is used only for rearward looking cameras. In order to provide the correct image for cameras that are mounted in other locations other than a rearward looking camera location (in a multi camera system), the image must be changed to “Normal”. That is, for example, if cameras are mounted on the front and the side of a machine, then the image must be changed to “Normal” in order to provide the correct 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) and button 3 (Standby On/Off), simultaneously, for 20 seconds. Note: The display will blink, then change to the opposite image. 3. Press button 1 (camera select) again in order to select the next camera that is to be viewed and/or have its settings adjusted. 4. Press and hold button 1 (camera select) and button 3 (Standby On/Off), simultaneously, for 20 seconds in order to toggle the image. 5. Repeat step 3 and step 4 in order to toggle the last camera image. Note: If the machine is equipped with a rearward looking camera, ensure that the image is set to the "Mirror" image. The proper orientation must be verified before the system is put into service. Press button 1 (camera select) for two seconds in order to place the system in automatic mode. The LED that is above and to the right of the camera select button will turn off.

0004 00-70

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

Systems Operation Section

1. Press button 4 (Contrast) and button 5 (Brightness) simultaneously in order to access this option. 2. Press button 6 (Minus) or button 7 (Plus) button in order to change the level of color. Press any other display button, other than the button 6 (Minus) or button 7 (Plus) buttons, in order to exit the Color Adjustment option.

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 the right of button 1 (camera select) will flash in order to indicate that the system is in manual mode. 2. Press and hold button 1 (camera select) and button 2 (Auto Brightness) simultaneously for 40 seconds in order to invert the image of the camera view that is shown on the display screen. 3. Press button 1 (camera select) again in order to select the next camera that is to be viewed and/or have its settings adjusted. 4. Again, press and hold button 1 (camera select) and button 2 (Auto Brightness) simultaneously for 40 seconds in order to invert the image of the camera view that is shown on the display screen. 5. Repeat step 3 and step 4 for the third camera.

Note: Before the marker option is enabled, the appropriate “on-sight” personel should be contacted. The technician will need information in order to accurately set the marker at the desired position. The display provides an option that is called the “Marker” line. The “Marker” is a small green line that provides a fixed distance reference line from the machine. This Marker line can be turned on or off. The position of the Marker line can also be set by a qualified technician. In order to turn the Marker on: 1. Press button 2 (Auto Brightness) and button 3 (Standby) simultaneously for 10 seconds. The marker will appear on the display screen. 2. After the “Marker” appears, press either button 6 (Minus) or button 7 (Plus) in order to adjust the position of the “Marker”.

In order to revert to a previous image: 1. Follow the preceding steps to select the appropriate camera. 2. Press and hold button 1 (camera select) and button 2 (Auto Brightness) simultaneously for 40 seconds.

Display Power ON/OFF The display on/off button may be disabled. If disabled, the button serves no other function. The LED that is above and to the right of the display on/off button will illuminate in order to show the system is on.

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

Marker ON/OFF

3. Once the position is set, press any other display button except button 6 (Minus) or button 7 (Plus) in order to exit the “Marker” set option. Note: After the marker has been activated, if any other button on the display is pressed other than button 6 (Minus) or button 7 (Plus), the marker will be set to the current position on the display. The marker position can be changed as long as the marker option has not been exited. In order to access all other options, please refer to the following information in the “Single Camera System” or the “Multi Camera System” sections of this document. Reset Marker In order to reset the marker, the marker must be turned off, then turned back on and moved to the desired position on the display screen using button 6 (Minus) or button 7 (Plus), before any other button on the display is pressed. In order to reset the marker:

0004 00-71

Systems Operation Section

TM 5-3805-291-10

1. Press button 2 (Auto Brightness) and button 3 (Standby) simultaneously for 10 seconds in order to turn the existing marker off. 2. Press button 2 (Auto Brightness) and button 3 (Standby) simultaneously for 10 seconds again in order to turn the marker back on.

Manual Camera Selection Manual mode is available only on WAVS multi-camera installations. That is, manual mode is not available for WAVS single camera installations. Automatic Brightness ON/OFF

3. Use button 6 (Minus) or button 7 (Plus) in order to adjust marker position. 4. Press any other button, other than button 6 (Minus) or button 7 (Plus) in order to exit the marker set option.

Switch Off Key Board

The Automatic Brightness ON/OFF option allows the operator to set the display to change the brightness level automatically. The WAVS display is equipped with a sensor to detect ambient light. When WAVS is placed in the “Automatic Brightness” mode, the display will brighten or dim automatically as the ambient light increases or decreases.

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

The brightness starting set point can be changed by the operator while in the manual or automatic mode. In order to change the set point, turn the auto brightness on and perform the brightness adjustment to the desired level for the starting point.

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

Your single camera system installation may be configured with the “Standby” feature enabled or disabled. If “Standby” is enabled, the display will remain dark unless the camera view has been activated by machine operation or by the operator.

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

Single Camera System Available Operator Selections for the WAVS Display

Standby ON/OFF

“Standby” may be useful at times when the operator feels that the display image is not needed, such as when travelling at night or when reverse will not be used. If “Standby” is disabled, the operator still has the option to adjust the brightness and/or contrast if the display is on constantly.

The selections that are listed in this section have been made available to the operator of the machine. The selections for the WAVS display can be changed by the operator as needed. Refer to table 1 and Illustration 7. Brightness Adjustment The brightness adjustment option allows the operator to vary the brightness of the view that is shown on the display. If the brightness level is set to high and if the “Auto Brightness” is not enabled, then there is a possibly that in a well lit area the display would appear completely “white”. Contrast Adjustment The contrast adjustment option allows the operator to vary the contrast of the view that is shown on the display.

0004 00-72

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Systems Operation Section

Table 1

Display Button Operation for Single Camera Systems Procedure

Operation Brightness Adjustment

Contrast Adjustment

Automatic Brightness ON/OFF

Standby ON/OFF

Notes

Press button 5 in order to enable the “Brightness Adjustment”, then press either button 6 or 7 in order to adjust the brightness.

If “Auto Brightness ”is enabled, the brightness starting set point can be changed by the operator while in the manual or automatic mode. Press any other display key in order to exit brightness adjustment mode.

Press button 4 in order to enable the Contrast Adjustment, then press either button 6 or 7 in order to adjust the contrast level.

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

Press button 2 in order to turn the automatic brightness option ON/OFF.

When WAVS is placed in the “Automatic Brightness” mode, the display will brighten or dim automatically as the ambient light increases or decreases.

Press button 3 in order to turn the standby option ON/OFF.

If the standby mode is ON, the display will remain dark until a WAVS input is detected, however, the power and standby 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 off because 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

END OF WORK PACKAGE

2. If the machine has a second camera, press button 1 (camera select) again in order to select the next camera that is to be viewed and/or have its settings adjusted.

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

3. If the machine has a third camera, press button 1 (camera select) again in order to select the next camera that is to be viewed and/or have its settings adjusted.

With “Camera Select” enabled, individual cameras can be selected, configured, and positioned in order to pride the desired view.

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

In order to enable “Camera Select”: 1. Press and hold button 1 (camera select) and button 4 (contrast), simultaneously for 40 seconds. This will enable the camera select option. After “Camera Select” has been enabled, you will be able to press button 1 (camera select) in order to 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 that the system is in manual mode. One of the indicator LED’s (C1, C2, or C3) that are to the left of the display buttons will indicate which camera view is displayed. Refer to Illustration 7 (9).

Available Operator Selections for the WAVS Display The selections that are listed in this section have been made available to the operator of the machine. The selections for the WAVS display can be changed by the operator as needed. Refer to table 2 and to Illustration 7. Brightness Adjustment The brightness adjustment option allows the operator to vary the brightness of the view that is shown on the display. If the brightness level is set to high and if the “Auto Brightness” is not enabled, then there is a possibly that in a well lit area the display would appear completely “white”.

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

18 TM 5-3805-291-10

OPERATION UNDER USUAL CONDITIONS

0005 00

THIS WORK PACKAGE COVERS Introduction

Parking Machine

Mounting and Dismounting Machine

Stopping Engine if an Electrical Malfunction Occurs

Initial Adjustments and Daily Checks

Lowering Loader Arm with Engine Stopped

Starting Engine

Relieving Hydraulic System Pressure

Machine Warmup

Quick Coupler Operation

Operating Machine Steering Machine

Operating Work Tools

Operating on Slopes

Portable Fire Extinguisher Operation

INITIAL SETUP References

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

WP 0004 00 WP 0006 00

Materials/Parts

WP 0008 00

Rag, wiping (Item 13, WP 0027 00)

WP 0011 00

Personnel Required MOS 21E, Heavy Construction Equipment Operator (2)

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.

0005 00-1

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OPERATION UNDER USUAL CONDITIONS - CONTINUED

0005 00

MOUNTING AND DISMOUNTING MACHINE

0005 00

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

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 1.

0005 00

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

WARNING 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 warning 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.

WARNING Use of seat belt while operating machine is mandatory. Fasten belt BEFORE operating machine. Trying to fasten belt during operation creates a hazardous condition. Failure to follow this warning may result in injury or death to personnel 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.

0005 00-2

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OPERATION UNDER USUAL CONDITIONS - CONTINUED

0005 00

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 the outside. 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 of personnel and obstructions before starting engine. Failure to follow this warning may result in injury or death to personnel. • Hearing protection is required if within 20 ft (6 m) of an operating machine. Hearing protection is also required if operating machine without ROPS/FOPS during transport procedures. Failure to wear hearing protection may cause hearing loss.

NOTE To 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.

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.

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.

0005 00-3

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OPERATION UNDER USUAL CONDITIONS - CONTINUED

0005 00

STARTING ENGINE - CONTINUED

0005 00

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

CAUTION DO NOT crank starter motor for more than 30 seconds at a time. After 30 seconds, allow starter motor to cool for at least 2 minutes before attempting to start engine again. Excessive heating of starter motor may result 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.

CAUTION Turbocharger 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 perform troubleshooting (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 10 minutes.

2.

During warmup, monitor alert indicators and gages for any signs of abnormal temperatures or pressures. Shut down engine 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 functioning properly. Engage work tool hydraulic controls as follows:

4.

a.

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

b.

Cycle hydraulic controls through all positions.

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. 0005 00-4

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OPERATION UNDER USUAL CONDITIONS - CONTINUED

0005 00

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

1.

2.

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.

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.

0005 00-5

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OPERATION UNDER USUAL CONDITIONS - CONTINUED

0005 00

STEERING MACHINE

0005 00

WARNING 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 warning may result in injury or death to personnel or damage to equipment.

1.

Operator controls machine direction using steering wheel.

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.

2.

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

3.

Avoid oversteering. Become familiar with steering characteristics of machine before attempting maneuvers in limited space.

4.

In the event of primary steering system failure, primary steering failure alert indicator will light and action alarm will sound. Secondary steering electric pump will automatically come on, as will the secondary steering alert indicator. Perform 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

WARNING DO 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 tipping is always present.

5.

When traveling uphill or downhill with a loaded bucket, keep bucket on uphill side, as low as possible. If machine starts to 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 overspeed when you are going downhill. 0005 00-6

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OPERATION UNDER USUAL CONDITIONS - CONTINUED

0005 00

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 may result in injury or death to personnel.

e. 2.

Engage parking brake.

Stopping Engine.

CAUTION • Stopping engine immediately after it has been operating under a load can result in overheating and accelerated wear of engine components. • The following shutdown procedures allow engine to cool. This will prevent excessive temperatures in turbocharger center housing. Failure to shut down engine properly may cause premature engine failure.

3.

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.

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 this warning 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). 0005 00-7

TM 5-3805-291-10

OPERATION UNDER USUAL CONDITIONS - CONTINUED

0005 00

STOPPING ENGINE IF AN ELECTRICAL MALFUNCTION OCCURS 0005 00 1.

Turn engine start switch to OFF position.

2.

If engine does not stop, perform the following steps:

3.

a.

Locate emergency shutdown switch at left center of machine.

b.

Move switch upward to stop engine.

Report problem to your supervisor. DO NOT operate machine until problem has been corrected.

427-C0013

LOWERING LOADER ARM WITH ENGINE STOPPED

0005 00

WARNING Loader arm can drop when lowering it with engine stopped. Keep all personnel away from loader arm drop area. Ensure no one is under or near frame articulation area. Failure to follow this warning may result in injury 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 operator 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 in LOWER position, and lower loader arm.

d.

If loader arm does not lower, pilot supply ON/OFF solenoid may be inoperable. Perform procedure for No Electrical Power/Pilot Supply ON/OFF Solenoid Inoperable on the next page. 0005 00-8

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OPERATION UNDER USUAL CONDITIONS - CONTINUED

0005 00

LOWERING LOADER ARM WITH ENGINE STOPPED - CONTINUED

0005 00

2.

No Electrical Power/Pilot Supply ON/OFF Solenoid Inoperable. a. If there is no electrical power or pilot supply ON/ OFF solenoid is inoperable, loader arm must be lowered manually. b.

To lower loader arm manually, perform the following steps on right side of machine: (1)

Use adjustable wrench (Item 13, Table 2, WP 0026 00) to turn square stem of ball valve clockwise (to the right) 90 degrees.

(2)

Loader arm will begin to lower when ball valve is open. After loader arm has lowered, turn square stem of ball valve counterclockwise (to the left) 90 degrees to close valve.

(3)

0005 00-9

427-C1701

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OPERATION UNDER USUAL CONDITIONS - CONTINUED

0005 00

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 fluid under 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 hydraulic lines. 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 the accumulator. 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 result in injury or death to personnel.

1.

2.

Introduction. a.

Hydraulic oil can remain under pressure in hydraulic system even after engine has been shut down and hydraulic pump has stopped.

b.

It is important to relieve this pressure before disconnecting any hydraulic line or performing hydraulic system service.

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 and accelerated 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. 0005 00-10

TM 5-3805-291-10

OPERATION UNDER USUAL CONDITIONS - CONTINUED

0005 00

RELIEVING HYDRAULIC SYSTEM PRESSURE - CONTINUED k.

To relieve pressure in hydraulic tank, perform the following steps: (1)

Locate hydraulic tank breather relief valve on top of hydraulic tank behind cab.

(2)

Press button on top of hydraulic tank breaker relief valve.

427-C0015

QUICK COUPLER OPERATION 1.

2.

0005 00

Introduction. a.

The quick coupler design allows operator, without assistance, to connect loader to work tools.

b.

The rotary sweeper and forklift pallet forks also require hydraulic connections for its operation.

c.

The following instructions apply to quick coupler engagement to all 966H work tools.

Engaging Quick Coupler to Work Tool.

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

427-C0361

a.

If pins on quick coupler are in engaged (locked) position, press top of quick coupler control switch. This disengages (unlocks) quick coupler pins.

b.

Tilt quick coupler forward. Ensure it is lowered sufficiently below level of hooks on work tool. 0005 00-11

TM 5-3805-291-10

OPERATION UNDER USUAL CONDITIONS - CONTINUED

0005 00

QUICK COUPLER OPERATION - CONTINUED c.

Drive machine slowly forward. Steer machine to align quick coupler with hooks on work tool.

d.

Slightly raise quick coupler, until quick coupler contacts hooks on work tool and work tool is lifted up slightly. Ensure work tool is level from side to side.

e.

Tilt quick coupler all the way back to allow work tool lower attaching points to rest against quick coupler stops.

f.

Press bottom of quick coupler control switch to engage (lock) quick coupler pins into retainer holes of work tool.

g.

To check for correct engagement of quick coupler 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 are not engaged. Retract pins and repeat procedure.

427-C0361

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

If engaging quick coupler to rotary sweeper or forklift, relieve hydraulic system pressure. Refer to Relieving Hydraulic System Pressure earlier in this work package.

i.

Remove protective caps from two quick disconnect fittings on quick coupler.

j.

Remove two protective plugs from quick disconnect fittings of sweeper, or two protective caps from forklift.

k.

Fasten caps together. 0005 00-12

427-C0363

TM 5-3805-291-10

OPERATION UNDER USUAL CONDITIONS - CONTINUED

0005 00

QUICK COUPLER OPERATION - CONTINUED

CAUTION Wipe area clean around all hydraulic connections to be opened during procedure. Contamination of hydraulic system could result in premature failure.

l.

Use a rag (Item 13, WP 0027 00) to remove any foreign material from quick disconnect fittings.

427-C0364

m.

Connect hydraulic lines from sweeper or forklift to fittings of quick coupler.

NOTE The following step is for sweeper.

n. 3.

Remove locking pin and pin, raise up leg and reinstall pin and locking pin. Repeat for other side.

Disengaging Quick Coupler from Work Tool.

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

a.

If work tool is loaded, unload work tool.

b.

Lower work tool to the ground and place so that it is stable. 0005 00-13

TM 5-3805-291-10

OPERATION UNDER USUAL CONDITIONS - CONTINUED

0005 00

QUICK COUPLER OPERATION - CONTINUED

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 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 to Relieving Hydraulic System Pressure earlier in this work package.

CAUTION Wipe area clean around all hydraulic connections to be opened during procedure. Contamination of hydraulic system could result in premature failure.

d.

Use a rag (Item 13, WP 0027 00) to remove any foreign material from quick disconnect fittings.

e.

Disconnect quick disconnect fittings of sweeper or forklift hydraulic lines from quick disconnect fittings at quick coupler.

f.

Install protective caps or plugs on all four quick disconnect fittings.

427-C0361

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.

0005 00-14

TM 5-3805-291-10

OPERATION UNDER USUAL CONDITIONS - CONTINUED

0005 00

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 or death to personnel or damage to equipment. • Always use a ground guide when driving machine with work tools if visibility is impaired. Failure to use a ground guide may cause injury or death to personnel or damage to equipment. • DO NOT perform excavating, loading, or digging tasks without ROPS/FOPS installed. 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 equipment.

1.

2.

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.

Automatic Lift Kickout. The joystick control is detented in the fully raised position. When the joystick is pulled back into the soft detent, the operator will feel an increased resistance from the joystick. Once in the detent, the joystick should be released in order to automatically return to the HOLD position. The attachment will continue to rise until the attachment reaches the lift kickout height. In order to manually override the detent, the joystick must be moved at least 6 degrees from the HOLD position. 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, the operator will feel an increased resistance from the joystick. Once in the detent position, the joystick should be released in order to automatically return to the HOLD position. The attachment will continue to lower until the attachment reaches the kickout height. In order to manually override the detent, the joystick must be moved at least 6 degrees from the HOLD position. The detent will not be activated if the joystick is held in the detent position for more than 1 second.

NOTE If the attachment is greater than 12 in. (30.5 cm) from the lower kickout position, a lower kickout will occur 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 will cause the attachment to float to the ground.

4.

Operating GP Bucket and Rock Bucket.

NOTE Refer 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. 0005 00-15

TM 5-3805-291-10

OPERATION UNDER USUAL CONDITIONS - CONTINUED

0005 00

OPERATING WORK TOOLS - CONTINUED

0005 00

g.

To provide simultaneous control of machine hydraulics while changing direction of travel, use remote F/N/R switch 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 transmission to downshift automatically.

k.

Go as far as possible into pile, with bucket fully lowered, until loader meets increased resistance as bucket is filling.

NOTE Raising 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. Transmission 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 (for rotary 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 will not be activated if the operator does not release the thumb wheel within 1 second of releasing the continuous flow switch.

d.

Move the thumb wheel (1) or the continuous flow switch (2) in order to stop the flow to the auxiliary hydraulic circuit.

427-C0475

0005 00-16

TM 5-3805-291-10

OPERATION UNDER USUAL CONDITIONS - CONTINUED

0005 00

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

WARNING Discharging large quantities of dry chemical fire extinguisher inside an enclosed cab may result in temporary breathing difficulty during and immediately after the discharge event. Discharge fire extinguisher from outside the cab. Ventilate cab thoroughly prior to reentry. Failure to follow this warning may 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

0005 00-17/(0005 00-18 Blank)

14 TM 5-3805-291-10

OPERATION UNDER UNUSUAL CONDITIONS

0006 00

THIS WORK PACKAGE COVERS Introduction

Operation in Extreme Heat

Slave Starting Machine

Operation in Saltwater Areas

Towing Machine

Operation in Mud or Soft Surfaces

Recovery Procedure - Loader Arms Down on Dead Machine

Operation in Sandy or Dusty Conditions Operation at High Altitudes

Manually Disconnect Quick Coupler Parking Brake Manual Release

Operation in Snow and Ice

Operation in Extreme Cold

Fording

Arctic Cold Weather Starting Aid System

Sorbent Decontamination System (SDS), M100

INITIAL SETUP Tools and Special Tools

References - Continued

Wrench, adjustable (Item 13, Table 2, WP 0026 00)

TM 3-4230-236-10 WP 0004 00

References

WP 0005 00

FM 9-207

WP 0008 00

FM 21-305

WP 0011 00

FM 3-11.3

WP 0012 00

FM 3-11.5

WP 0013 00

FM 31-70

WP 0014 00

FM 31-71

WP 0015 00

FM 90-3

WP 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 temperatures and other environmental conditions.

0006 00-1

TM 5-3805-291-10

OPERATION UNDER UNUSUAL CONDITIONS - CONTINUED

0006 00

SLAVE STARTING MACHINE

0006 00

WARNING When 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 slave starting.

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 caution will damage transmission.

NOTE If machine other than another 966H is used to slave start loader, refer to Operator’s Manual for that machine 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. 0006 00-2

TM 5-3805-291-10

OPERATION UNDER UNUSUAL CONDITIONS - CONTINUED

0006 00

TOWING MACHINE

0006 00

WARNING Ensure proper towing procedures are followed when towing machine: • When attaching towing connections, carefully move towing machine into position. Always use a ground guide and DO NOT stand directly between machines. • DO NOT tow faster than 2 mph (3 kph). • DO NOT allow operator on machine unless operator can control steering and/or brakes. • When drive shafts are removed, machine has NO parking or secondary brakes. To prevent machine from rolling, wheels must be blocked securely. Failure to follow this warning may cause injury or death to personnel. • Always block wheels before removing axle shafts or disengaging parking brake. Failure to follow proper towing procedures may cause injury or death to personnel or damage to equipment.

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 more than 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 brake capacity, weight, and power to do the job. Towing machine must be able to control both machines for the grade and distance 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 machine moves without moving disabled machine.

0006 00-3

TM 5-3805-291-10

OPERATION UNDER UNUSUAL CONDITIONS - CONTINUED

0006 00

TOWING MACHINE - CONTINUED

0006 00

WARNING DO NOT return to service a machine that has been towed without first ensuring that all necessary repairs and adjustments have been performed. Failure to do so could result in injury to personnel or damage to equipment.

j. 2.

3.

Before returning machine to service, ensure all necessary repairs and adjustments have been performed.

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.

Towing Machine With Engine Stopped.

NOTE Assistance from Unit Maintenance is required.

a.

Block wheels of disabled machine.

NOTE Ensure that steering cylinder hoses are connected correctly by Unit Maintenance before resuming machine operation. With hose connections reversed, steering system will not function.

b.

Notify Unit Maintenance to reverse hose connections on one steering cylinder only. This will allow 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. 427-C0009

WARNING When drive shafts are removed, machine has NO parking or secondary brakes. To prevent machine from rolling, wheels must be blocked securely. Failure to follow this warning may cause injury or death to personnel.

c.

If failure of internal transmission or drive line is suspected, notify Unit Maintenance to remove center and rear drive shafts.

d.

Manually release parking brake on disabled machine. Refer to Parking Brake Manual Release later in this work package.

e.

Notify Unit Maintenance to inspect machine for powertrain damage. 0006 00-4

TM 5-3805-291-10

OPERATION UNDER UNUSUAL CONDITIONS - CONTINUED

0006 00

TOWING MACHINE - CONTINUED

0006 00

WARNING Carefully move towing machines into position. Always use a ground guide and DO NOT stand directly between 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 1.

Use adjustable wrench (Item 13, Table 2, WP 0026 00) to turn square stem on top of ball valve clockwise (to the right) 90 degrees.

2.

Lift loader arms using another machine. Once loader arms are raised sufficiently to tow dead machine, restrain loader arms to frame using chains or comealong.

3.

Turn square step of ball valve counterclockwise (to the left) 90 degrees to close valve.

4.

Dead machine can now be towed.

0006 00

427-C1701

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 of ball valve clockwise (to the right) 90 degrees.

3.

The quick coupler pins can now be manually moved out.

4.

Use adjustable wrench to turn square stem on top of ball valve counterclockwise (to the left) 90 degrees.

5.

Close hydraulic system access door and install two washers and bolts.

427-C0014

0006 00-5

TM 5-3805-291-10

OPERATION UNDER UNUSUAL CONDITIONS - CONTINUED

0006 00

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:

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

a.

Block wheels of disabled machine.

WARNING Connect steering frame lock between front and rear frames before lifting, transporting, or servicing machine in frame articulation area. Disconnect steering frame lock and secure in stowed position before resuming operation. DO NOT operate machine with steering frame lock connected. Failure to follow this warning 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.

427-C2056

f.

Disconnect and stow steering frame lock (WP 0015 00), then move disabled machine as needed.

CAUTION Ensure 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 functioning properly.

g.

When parking machine, connect steering frame lock (WP 0015 00), then fully tighten locknut on rod to engage parking brake. 0006 00-6

TM 5-3805-291-10

OPERATION UNDER UNUSUAL CONDITIONS - CONTINUED

0006 00

OPERATION IN EXTREME COLD

0006 00

NOTE Refer to FM 9-207, Operation and Maintenance of Ordnance Materiel in Cold Weather, FM 31-70, Basic Cold Weather Manual, and FM 31-71, Northern Operations, for additional information on cold weather operation and maintenance.

1.

2.

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.

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 to follow this warning may cause serious burns.

•

Wear effective eye, glove, and skin protection when handling coolants. Failure to follow this warning 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.

0006 00-7

TM 5-3805-291-10

OPERATION UNDER UNUSUAL CONDITIONS - CONTINUED

0006 00

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 this warning 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 wash exposed skin and change fuel-soaked clothing. • ALWAYS stop engine prior to refueling. If equipped with an arctic cold weather starting aid system, turn arctic heater off.

4.

5.

a.

Do not allow fuel tank to remain partially empty in extremely cold weather. Fill fuel tank after each work period to help 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.

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.

Lubrication. Use lubricants as specified at the end of PMCS (WP 0012 00) with the temperature range that applies to the lowest expected 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 cold weather starting aid system. Refer to Arctic Cold Weather Starting Aid System on the next page for engine starting procedures.

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.

CAUTION Low idling speeds during extremely cold temperatures can result in incomplete combustion and heavy deposit formations on valves. These deposits can cause burned valves, bent pushrods, or other damage to valve components.

d.

After engine has started, allow engine time to reach operating temperature. Run engine at reduced speed only long enough 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. 0006 00-8

TM 5-3805-291-10

OPERATION UNDER UNUSUAL CONDITIONS - CONTINUED

0006 00

OPERATION IN EXTREME COLD - CONTINUED 7.

8.

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 warmup period 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.

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, park machine 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 possible 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 1.

0006 00

General. a.

Machines that operate in extremely 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) 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 and antifreeze to prevent coolant from freezing or slushing. If coolant freezes or slushes, coolant pump cannot move coolant, causing blockage in circulating system. Pressure build-up in arctic heater can cause coolant hose at heater connection to burst or blow off. Injury to personnel or damage to 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 that arctic heater must first be operated to preheat engine coolant. 0006 00-9

TM 5-3805-291-10

OPERATION UNDER UNUSUAL CONDITIONS - CONTINUED

0006 00

ARCTIC COLD WEATHER STARTING AID SYSTEM - CONTINUED

0006 00

2.

Arctic Heater Operation.

WARNING DO NOT operate arctic heater in enclosed areas due to the dangers of carbon monoxide poisoning from exhaust fumes. Always start and operate heater in a well-ventilated area and, if in an enclosed area, vent exhaust 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 on when 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-down procedure has finished.

CAUTION DO NOT operate starter for more than 60 seconds when in extreme cold temperature. Doing so could cause starter damage. e.

Start engine (WP 0005 00).

OPERATION IN EXTREME HEAT

0006 00

CAUTION During very hot weather, operating procedures may require altering to prevent machine overheating. Avoid continuous high engine rpm.

NOTE Refer 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. 0006 00-10

TM 5-3805-291-10

OPERATION UNDER UNUSUAL CONDITIONS - CONTINUED

0006 00

OPERATION IN EXTREME HEAT - CONTINUED

0006 00

2.

Cooling System.

WARNING

3.

4.

•

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 to follow this warning may cause serious burns.

•

Wear effective eye, glove, and skin protection when handling coolants. Failure to follow this warning may cause injury to personnel.

a.

Check coolant level at frequent intervals and keep radiator cap tight (WP 0012 00). Add coolant, if necessary (WP 0012 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.

Lubrication. a.

Use lubricants according to PMCS (WP 0012 00) with the temperature range that applies to the highest expected ambient temperature.

b.

Notify Unit Maintenance to shorten differential and final drive oil change interval.

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, and Procedures for Chemical, Biological, Radiological, and Nuclear Decontamination. • NBC contaminated filters must be handled using adequate precautions and must be disposed of by trained personnel. • Failure to follow these warnings may cause injury or death.

5.

a.

Check air cleaner service indicator frequently (WP 0004 00).

b.

Service air cleaner as necessary (WP 0014 00).

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). 0006 00-11

TM 5-3805-291-10

OPERATION UNDER UNUSUAL CONDITIONS - CONTINUED

0006 00

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 area at 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 the point where wheels spin, if possible.

3.

Notify Unit Maintenance to clean and inspect for proper lubrication.

OPERATION IN SANDY OR DUSTY CONDITIONS

0006 00

NOTE Refer to FM 90-3, Desert Operations.

1.

Maintain steady, even movement with transmission in lower gears. Try to keep machine rolling without straining engine and powertrain. If machine gets stuck, notify Unit Maintenance.

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, and Procedures for Chemical, Biological, Radiological, and Nuclear Decontamination. • NBC contaminated filters must be handled using adequate precautions and must be disposed of by trained personnel. • Failure to follow these warnings may cause injury or death.

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 levels. 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 sandy or 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 improved traction. 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. 0006 00-12

TM 5-3805-291-10

OPERATION UNDER UNUSUAL CONDITIONS - CONTINUED

0006 00

OPERATION AT HIGH ALTITUDES

0006 00

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 to follow this warning may cause serious burns.

•

Wear effective eye, glove, and skin protection when handling coolants. Failure to follow this warning may cause injury to personnel.

NOTE Engine 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 1.

0006 00

General.

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 this warning 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 wash exposed skin and change fuel-soaked clothing. • ALWAYS stop engine prior to refueling. If equipped with an arctic cold weather starting aid system, turn arctic heater off.

2.

a.

Fuel tank should be kept full. Keep snow and ice away from fuel filler.

b.

Clean snow away from windshields and lights.

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. 0006 00-13

TM 5-3805-291-10

OPERATION UNDER UNUSUAL CONDITIONS - CONTINUED

0006 00

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

CAUTION Do not exceed maximum fording depth as damage to equipment may occur.

1.

Maximum fording depth is 30 in. (76 cm).

427-C1706

2.

Before fording, ensure engine is operating properly and all indicators are indicating normal operating pressures and temperatures.

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 normal operation 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 degrees Fahrenheit. Refer to TM 3-4230-236-10 for instructions on the use of SDS. END OF WORK PACKAGE 0006 00-14

12 TM 5-3805-291-10

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

0007 00-1

TM 5-3805-291-10

STOWAGE AND DECAL, DATA PLATE, AND STENCIL GUIDE - CONTINUED

0007 00

DECALS

0007 00

427-C1562

0007 00-2

TM 5-3805-291-10

STOWAGE AND DECAL, DATA PLATE, AND STENCIL GUIDE - CONTINUED

0007 00

DECALS - CONTINUED

0007 00

427-C1563

0007 00-3

TM 5-3805-291-10

STOWAGE AND DECAL, DATA PLATE, AND STENCIL GUIDE - CONTINUED

0007 00

DECALS - CONTINUED

0007 00

427-C1564

0007 00-4

TM 5-3805-291-10

STOWAGE AND DECAL, DATA PLATE, AND STENCIL GUIDE - CONTINUED

0007 00

DECALS - CONTINUED

0007 00

427-C1565

0007 00-5

TM 5-3805-291-10

STOWAGE AND DECAL, DATA PLATE, AND STENCIL GUIDE - CONTINUED

0007 00

DECALS - CONTINUED

0007 00

427-C2041

0007 00-6

TM 5-3805-291-10

STOWAGE AND DECAL, DATA PLATE, AND STENCIL GUIDE - CONTINUED

0007 00

DATA PLATES

0007 00

427-C1566

0007 00-7

TM 5-3805-291-10

STOWAGE AND DECAL, DATA PLATE, AND STENCIL GUIDE - CONTINUED

0007 00

DATA PLATES - CONTINUED

0007 00

427-C1567

427-C1568

0007 00-8

TM 5-3805-291-10

STOWAGE AND DECAL, DATA PLATE, AND STENCIL GUIDE - CONTINUED

0007 00

STENCILS

0007 00

0007 00-9

TM 5-3805-291-10

STOWAGE AND DECAL, DATA PLATE, AND STENCIL GUIDE - CONTINUED

0007 00

STENCILS - CONTINUED

0007 00

427-C1570

0007 00-10

TM 5-3805-291-10

STOWAGE AND DECAL, DATA PLATE, AND STENCIL GUIDE - CONTINUED

0007 00

STENCILS - CONTINUED

0007 00

END OF WORK PACKAGE

0007 00-11/(0007 00-12 Blank)

TM 5-3805-291-10

CHAPTER 3 OPERATOR TROUBLESHOOTING

2 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 the 966H Wheel Loader.

2.

The Troubleshooting Symptom Index in WP 0009 00 lists common malfunctions which may occur and refers you to the proper 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 WP 0004 00.

4.

Before performing troubleshooting, read and follow all safety instructions found in the Warning Summary at the front of this manual.

5.

The Troubleshooting Symptom Index cannot list all malfunctions that may occur nor all tests, inspections, or corrective actions. 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: MALFUNCTION, 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 task unless 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

0008 00-1/(0008 00-2 Blank)

2 TM 5-3805-291-10

TROUBLESHOOTING SYMPTOM INDEX

0009 00 Troubleshooting Procedure Page

Malfunction/Symptom BRAKES - SERVICE AND PARKING/EMERGENCY 1.

Brake Oil Pressure Alert Indicator Comes On During Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

2.

Parking Brake Alert Indicator Does Not Come On When Parking Brake is Engaged. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.

Parking/Emergency Brake Will Not Disengage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

4.

Parking/Emergency Brake Will Not Engage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

5.

Service Brakes Do Not Operate Correctly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

6.

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

2.

Blackout Drive Light Will Not Operate When B.O. DRIVE Function is Selected. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

3.

Blackout Drive Marker Light(s) Do Not Operate When B.O. MARKER Function is Selected. . . . . . . . . . . . . . . . . . . . 3-4

4.

Directional Turnlamp or Hazard Flasher Control are Not Working. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

5.

Worklights Inoperative. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

6.

Service Light(s) Do Not Operate When SER. DRIVE or PARK Functions are Selected. . . . . . . . . . . . . . . . . . . . . . . . . 3-4

7.

Horn Will Not Sound When Button is Pressed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

8.

Messenger is Inoperative. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

9.

Stoplights Do Not Operate When Brakes are Applied. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

10. Taillights Do Not Come On. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 11. Windshield Washer Not Working. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 12. Windshield Wiper Not Working. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 WORK AREA VISUAL SYSTEM (WAVS) 1.

Display or Camera Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

2.

Display is Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

3.

Display has Wrong Image Orientation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

4.

Display has Inverted Image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

5.

Display has Blurred Image. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

6.

Display’s Color is Incorrect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

ENGINE 1.

Engine Cranks but Fails to Start: Operating Temperature Above -25 F (-32 C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

2.

Engine Cranks but Fails to Start: Operating Temperature -25 F to -40 F (-32 C to -40 C). . . . . . . . . . . . . . . . . . . . 3-8

3.

Engine Does Not Develop Full Power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

4.

Engine Does Not Idle Properly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

5.

Engine Fails to Crank When Engine Start Switch is Turned to START. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 0009 00-1

TM 5-3805-291-10

TROUBLESHOOTING SYMPTOM INDEX - CONTINUED Malfunction/Symptom

0009 00 Troubleshooting Procedure Page

6.

Engine Starts but Misfires or Runs Rough After Warmup Period. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

7.

Excessive Engine Oil Consumption. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

8.

Excessive Exhaust Smoke (At Normal Operating Speed). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

9.

Excessive Exhaust Smoke (White) During Startup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

10. 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.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

2.

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

3.

Machine Turns Correctly During Normal Driving Conditions but Turns Slowly With a Load. . . . . . . . . . . . . . . . . . . . 3-13

4.

Machine Turns Slowly in Both Directions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

5.

Machine Turns Slowly in One Direction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

6.

Oil Temperature is Too Hot (Hydraulic Oil Temperature Gage in Red Range). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

7.

Steering is Erratic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

8.

Turning Steering Wheel is Difficult. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

TRANSMISSION 1.

Slow or Erratic Transmission Engagement.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

2.

Transmission Oil Temperature Gage Indicates Overheating and Action Light Comes On (During Normal Operation). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010 00-13

3.

Transmission Does Not Operate in Any Gear.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

4.

Transmission Does Not Shift From One Direction to Another.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

5.

Transmission Does Not Shift From One Gear to Another. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

6.

Transmission Engages, but Machine Does Not Move. Engine Stops Running. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

END OF WORK PACKAGE

0009 00-2

14 TM 5-3805-291-10

TROUBLESHOOTING PROCEDURES

0010 00

MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

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 to personnel or damage to equipment.

BRAKES - SERVICE AND PARKING/EMERGENCY

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.

1. Brake Oil Pressure Alert Indicator Comes On During Operation.

Stop machine and shut down engine Notify Unit Maintenance. immediately (WP 0005 00).

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.

2.

Parking Brake Alert Indicator Does Not Stop machine and shut down engine Notify Unit Maintenance. Come On When Parking Brake is immediately (WP 0005 00). Engaged.

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.

3.

4.

Parking/Emergency Brake Will Not Disengage.

Parking/Emergency Brake Will Not Engage.

1.

Engage and disengage parking brake (WP 0004 00).

If problem still exists, go to test step 2.

2.

Stop machine and shut down Notify Unit Maintenance. engine immediately (WP 0005 00).

Stop machine and shut down engine Notify Unit Maintenance. immediately (WP 0005 00).

0010 00-1

TM 5-3805-291-10

TROUBLESHOOTING PROCEDURES - CONTINUED MALFUNCTION

0010 00

TEST OR INSPECTION

CORRECTIVE ACTION

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-functioning brakes.

5.

6.

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 under brake pedals. If problem still exists, go to test step 2.

2.

Bring machine to a safe stop and shut down engine immediately (WP 0005 00).

Notify Unit Maintenance.

WARNING

Service Brakes Do Not Release Correctly.

Park machine on level ground, stop engine, and lower work tool to ground to prevent injury to operator and/or severe damage to machine.

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 under brake pedals. If problem still exists, go to test step 2.

2.

Ensure parking brake is disengaged (WP 0004 00).

Disengage parking brake. If problem still exists, go to test step 3.

3.

Bring machine to a safe stop and shut down engine immediately (WP 0005 00).

Notify Unit Maintenance.

CHARGING SYSTEM Electrical System Alert Indicator Comes 1. On. 2.

Check that circuit breakers are not Reset circuit breakers. If problem tripped (WP 0016 00). still exists, go to test step 2. Check for loose or broken serpentine belt.

0010 00-2

If loose or broken belt is found, or if belt is OK and problem still exists, notify Unit Maintenance.

TM 5-3805-291-10

TROUBLESHOOTING PROCEDURES - CONTINUED MALFUNCTION

0010 00

TEST OR INSPECTION

CORRECTIVE ACTION

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 coolants. 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 to monitor temperature. If indication is still in red or orange range, go to test step 2.

2.

Allow engine to idle at 825 rpm to cool down.

If problem still exists, go to test step 3.

3.

Check cooling system for leaks.

If leaks are found, notify Unit Maintenance. If no leaks are found, 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 Unit Maintenance.

ELECTRICAL SYSTEM 1. Backup Alarm Will Not Sound When Machine is Placed in Reverse.

NOTE A 30-minute cool down time may be required before circuit breaker automatically resets.

Ensure STOP LIGHT or SER. DRIVE Select STOP LIGHT or SER. function has been selected on military DRIVE. If problem still exists, light switch (WP 0004 00). notify Unit Maintenance. 2.

Blackout Drive Light Will Not Operate When B.O. DRIVE Function is Selected.

NOTE A 30-minute cool down time may be required before circuit breaker automatically resets.

Ensure B.O. DRIVE function has been Select B.O. DRIVE function. If selected on military light switch (WP problem still exists, notify Unit 0004 00). Maintenance.

0010 00-3

TM 5-3805-291-10

TROUBLESHOOTING PROCEDURES - CONTINUED MALFUNCTION

0010 00

TEST OR INSPECTION

CORRECTIVE ACTION

ELECTRICAL SYSTEM - CONTINUED 3.

NOTE

Blackout Drive Marker Light(s) Do Not Operate When B.O. MARKER Function is Selected.

A 30-minute cool down time may be required before circuit breaker automatically resets.

Ensure B.O. DRIVE function has been Select B.O. DRIVE function. If selected on military light switch (WP problem still exists, notify Unit 0004 00). Maintenance. 4.

5.

6.

Directional Turnlamp or Hazard Flasher Control are Not Working.

Worklights Inoperative.

Service Light(s) Do Not Operate When SER. DRIVE or PARK Functions are Selected.

1.

Ensure STOP LIGHT or SER. Select STOP LIGHT or SER. DRIVE function has been selected DRIVE. If problem still exists, go on military light switch (WP 0004 to test step 2. 00).

2.

Check turnlamp lights (front)/ composite lights (rear) for disconnected connectors or damage.

Reconnect connectors, if disconnected. If any damage to lights is found, notify Unit Maintenance. If connectors and lights are OK, go to test step 3.

3.

Check for blown turnlamp fuse at fuse panel (WP 0016 00).

If fuse is blown, request replacement fuse from Unit Maintenance. If problem still exists, notify Unit Maintenance.

1.

Ensure STOP LIGHT or SER. Select STOP LIGHT or SER. DRIVE function has been selected DRIVE. If problem still exists, go on military light switch (WP 0004 to test step 2. 00).

2.

Check for blown worklight fuse at If fuse is blown, request fuse panel (WP 0016 00). replacement fuse from Unit Maintenance. If fuse is good, go to test step 3.

3.

Check worklights for disconnected connector or damage.

Reconnect connector, if disconnected. If any damage to worklights is found, notify Unit Maintenance.

1.

Check service light(s) for disconnected connectors or damage.

Reconnect connectors, if disconnected. If any damage to service light(s) is found, notify Unit Maintenance. If connectors and headlights are OK, go to test step 2.

0010 00-4

TM 5-3805-291-10

TROUBLESHOOTING PROCEDURES - CONTINUED MALFUNCTION

0010 00

TEST OR INSPECTION

CORRECTIVE ACTION

ELECTRICAL SYSTEM - CONTINUED 6.

7.

NOTE

Service Light(s) Do Not Operate When SER. DRIVE or PARK Functions are Selected - Continued.

Horn Will Not Sound When Button is Pressed.

A 30-minute cool down time may be required before circuit breaker automatically resets.

2.

Check that circuit breakers are not Reset circuit breakers. If problem tripped (WP 0016 00). still exists, notify Unit Maintenance.

1.

Ensure STOP LIGHT or SER. Select STOP LIGHT or SER. DRIVE function has been selected DRIVE. If problem still exists, go on military light switch (WP 0004 to test step 2. 00).

2.

Check horn for disconnected connector or damage.

Reconnect connector, if disconnected. If any damage to horn is found, notify Unit Maintenance. If connector and horn are OK, go to test step 3.

3.

Check for blown horn fuse at fuse panel (WP 0016 00).

If fuse is blown, request replacement fuse from Unit Maintenance. If fuse is good, or problem still exists, notify Unit Maintenance. Notify Unit Maintenance.

8.

Messenger is Inoperative.

9.

Stoplights Do Not Operate When Brakes 1. are Applied.

10. Taillights Do Not Come On.

Ensure STOP LIGHT or SER. Select STOP LIGHT or SER. DRIVE function has been selected DRIVE. If problem still exists, go on military light switch (WP 0004 to test step 2. 00).

2.

Check composite lights for disconnected connectors or damage.

If any damage to lights is found, notify Unit Maintenance. If no damage is found, go to test step 3.

3.

Check for blown stoplight fuse (WP 0016 00).

If fuse is blown, request replacement fuse from Unit Maintenance. If fuse is good, notify Unit Maintenance.

1.

Ensure STOP LIGHT or SER. Select STOP LIGHT or SER. DRIVE function has been selected DRIVE. If problem still exists, go on military light switch (WP 0004 to test step 2. 00).

2.

Check composite lights for disconnected connectors or damage.

0010 00-5

If any damage to lights is found, notify Unit Maintenance. If no damage is found, go to test step 3.

TM 5-3805-291-10

TROUBLESHOOTING PROCEDURES - CONTINUED MALFUNCTION

0010 00

TEST OR INSPECTION

CORRECTIVE ACTION

ELECTRICAL SYSTEM - CONTINUED

NOTE

10. Taillights Do Not Come On - Continued.

A 30-minute cool down time may be required before circuit breaker automatically resets.

11. Windshield Washer Not Working.

12. Windshield Wiper Not Working.

3.

Check for blown taillight fuse (WP If fuse is blown, request 0016 00). replacement fuse from Unit Maintenance. If fuse is good, notify Unit Maintenance.

1.

Check windshield washer fluid reservoir.

2.

Check for blown fuse at fuse panel If fuse is blown, request (WP 0016 00). replacement fuse from Unit Maintenance. If fuse is good and problem still exists, go to test step 3.

3.

Check for loose or disconnected electrical connectors (WP 0012 00).

If reservoir is empty, fill reservoir (WP 0012 00). If problem still exists, go to test step 2.

Reconnect electrical connectors, if required. If problem still exists, notify Unit Maintenance.

Check for blown fuse at fuse panel (WP If fuse is blown, request 0016 00). replacement fuse from Unit Maintenance. If fuse is good, notify Unit Maintenance.

WORK AREA VISUAL SYSTEM (WAVS) 1. Display or Camera Inoperative

Check if light switch selector lever is in 1. either STOP LIGHT or SER DRIVE 2. mode.

If not, select either STOP LIGHT or SER DRIVE mode. 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 set 1. correctly (WP 0004 00, WAVS section, Table 1). 2.

If not, set brightness level correctly. If brightness level is set correctly and problem still exists, notify Unit Maintenance.

3.

Display has Wrong Image Orientation

Check if image orientation is set 1. correctly (should appear as if looking in a rear view mirror) (WP 0004 00, 2. WAVS section, Accessing All System Options – Mirror Image).

If not, set image orientation correctly. If image orientation is set correctly and problem still exists, notify Unit maintenance.

0010 00-6

TM 5-3805-291-10

TROUBLESHOOTING PROCEDURES - CONTINUED MALFUNCTION

0010 00

TEST OR INSPECTION

CORRECTIVE ACTION

WORK AREA VISUAL SYSTEM (WAVS) - CONTINUED 4.

Display has Inverted Image

Check if image is set correctly (WP 1. 0004 00, WAVS section, Accessing 2. All System Options – Inverted Image).

If not, set image correctly. If image is set correctly and problem still exists, notify Unit Maintenance.

5.

Display has Blurred Image

Check if camera lens is dirty.

If lens is dirty, clean. If lens is clean and problem still exists, notify Unit Maintenance.

6.

Display’s Color is Incorrect

Check if color is set correctly (WP 1. 0004 00, WAVS section, Accessing 2. All System Options – Color Adjustment).

1. 2.

If not, set color correctly. 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).

If fuse is blown, request replacement fuse from Unit Maintenance. If fuse is good, notify Unit Maintenance.

0010 00-7

TM 5-3805-291-10

TROUBLESHOOTING PROCEDURES - CONTINUED MALFUNCTION

0010 00

TEST OR INSPECTION

CORRECTIVE ACTION

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 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 equipment.

•

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 system, turn engine coolant 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).

If fuse is blown, request replacement fuse from Unit Maintenance. If fuse is good, notify Unit Maintenance.

4.

Check for blown arctic heater fuse If fuse is blown, request (WP 0016 00). replacement fuse from Unit Maintenance. If fuse is good, go to test step 5.

5.

Check for blown start aid fuse at fuse panel (WP 0016 00).

If fuse is blown, request replacement fuse from Unit Maintenance. If engine still will not 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 or empty, notify Unit Maintenance.

0010 00-8

TM 5-3805-291-10

TROUBLESHOOTING PROCEDURES - CONTINUED MALFUNCTION

0010 00

TEST OR INSPECTION

CORRECTIVE ACTION

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 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, and Procedures for Chemical, Biological, Radiological, and Nuclear Decontamination. NBC contaminated filters must be handled using adequate precautions and must be disposed of by trained personnel. Failure to follow these warnings may cause injury or death.

Check front dash indicator (WP 0004 If indicator is on, service engine air 00). cleaner (WP 0014 00) and retest step. If problem still exists, notify Unit Maintenance. 4.

Engine Does Not Idle Properly.

Check front dash indicator (WP 0004 If indicator is on, service engine air 00). cleaner (WP 0014 00) and retest step. If problem still exists, notify Unit Maintenance.

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 lever and remote F/N/R switch in N (NEUTRAL). If problem still exists, go to test step 2.

2.

Check position of battery disconnect switch (WP 0004 00).

Place battery disconnect switch to ON. If problem still exists, go to test step 3.

3.

Check for blown engine start switch fuse (WP 0016 00).

If fuse is blown, request replacement fuse from Unit Maintenance. If fuse is good, go to test step 4.

NOTE A 30-minute cool down time may be required before circuit breaker automatically resets.

4.

Auxiliary circuit breaker may have Allow circuit breaker to reset. If tripped (WP 0016 00). problem still exists, go to test step 5.

0010 00-9

TM 5-3805-291-10

TROUBLESHOOTING PROCEDURES - CONTINUED MALFUNCTION

0010 00

TEST OR INSPECTION

CORRECTIVE ACTION

ENGINE - CONTINUED

5.

6.

Engine Fails to Crank When Engine Start Switch is Turned to START Continued.

5.

Check for tripped breaker (WP 0016 00).

Reset circuit breaker. If problem still exists, go to test step 6.

6.

Check both batteries for dirty, loose, or damaged battery cables (WP 0012 00).

Clean cables if dirty. If cable is damaged or loose, notify Unit Maintenance.

7.

Check connection of four harness connectors at right rear of cab cover.

If problem still exists, notify Unit Maintenance.

Engine Starts but Misfires or Runs Rough After Warmup Period.

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 this warning 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 wash exposed skin and change fuel-soaked clothing.

•

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

Check fuel/water separator moisture (WP 0012 00).

7.

Excessive Engine Oil Consumption.

for Open fuel/water separator drain valve and drain (WP 0012 00). If problem still exists, notify Unit Maintenance.

Check for loose oil lines and oil leaks. If oil lines are loose or leaks are found, notify Unit Maintenance.

0010 00-10

TM 5-3805-291-10

TROUBLESHOOTING PROCEDURES - CONTINUED MALFUNCTION

0010 00

TEST OR INSPECTION

CORRECTIVE ACTION

ENGINE - CONTINUED 8.

Excessive Exhaust Smoke (At Normal Operating Speed).

1.

Check fuel/water separator for moisture (WP 0012 00).

Drain fuel/water separator (WP 0012 00). If problem still exists, go to test step 2.

WARNING

2.

9.

Excessive Exhaust Smoke (White) During Startup.

10. Low Engine Oil Pressure Alert Indicator, Action Light, and Action Alarm are On.

•

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 equipment.

•

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 system, turn engine coolant heater off.

Check front dash indicator (WP 0004 00).

If indicator is on, service engine air cleaner (WP 0014 00) and retest step. If problem still exists, notify Unit Maintenance.

Check and monitor coolant Allow engine to warm up to temperature gage (WP 0004 00). operating temperature. If problem still exists, notify Unit Maintenance.

CAUTION When action alarm sounds, immediate shutdown of machine is required to prevent damage to machine.

Check engine oil level (WP 0004 00).

0010 00-11

If engine oil is low, fill to correct level (WP 0012 00). If problem still exists, notify Unit Maintenance.

TM 5-3805-291-10

TROUBLESHOOTING PROCEDURES - CONTINUED MALFUNCTION

0010 00

TEST OR INSPECTION

CORRECTIVE ACTION

HYDRAULIC SYSTEM 1. Travel Time of Lift Cylinders is Slow.

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.

2.

1.

Check hydraulic oil level (WP 0004 00).

If hydraulic oil level is low, fill to correct level (WP 0004 00). If problem still exists, go to test step 2.

2.

Check hydraulic lift cylinders for any buildup of debris.

Clean any debris from cylinder(s). If problem still exists, go to test step 3.

3.

Check loader control joystick for damage that would restrict freedom of movement.

If any damage is found, notify Unit Maintenance.

Work Tool/Loader Arm Operating Speeds are Too Slow.

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.

1.

Check hydraulic oil level (WP 0004 00).

If hydraulic oil level is low, fill to correct level (WP 0004 00). If problem still exists, go to test step 2.

2.

Check hydraulic lift cylinders, tilt cylinder, and linkage for buildup of debris.

Clean any debris from cylinders and linkage. If problem still exists, notify Unit Maintenance.

0010 00-12

TM 5-3805-291-10

TROUBLESHOOTING PROCEDURES - CONTINUED MALFUNCTION

0010 00

TEST OR INSPECTION

CORRECTIVE ACTION

STEERING 1. Machine Slowly Drifts (Either Direction), Wanders, or Pulls to One Side on Level Pavement, Even When Steering Wheel is in Straight Position.

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.

Check tires for proper inflation Inflate tires to proper pressure pressure: Front - 60 psi (414 kPa); rear (WP 0012 00). If problem still - 40 psi (276 kPa). exists, notify Unit Maintenance. 2.

Machine Steering Slow or Intermittent to Respond.

Check hydraulic oil level (WP 0004 If oil level is low, fill to correct 00). level (WP 0004 00). If oil level is OK, 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, notify Unit Maintenance. If no leaks are found, go to test step 2.

2.

Check hydraulic oil level (WP 0004 00).

If hydraulic oil level is low, fill to correct level (WP 0004 00). If problem still exists, notify Unit Maintenance.

Check hydraulic oil level (WP 0004 If oil level is low, fill to correct 00). level (WP 0004 00). If oil level is OK, notify Unit Maintenance.

4.

Machine Turns Slowly in Both Directions.

5.

Machine Turns Slowly in One Direction. 1.

Check for oil leaks at steering cylinders.

If any oil leaks are found, notify Unit Maintenance.

2.

Check hydraulic oil level (WP 0004 00).

If hydraulic oil level is low, fill to correct level (WP 0004 00). If problem still exists, notify Unit Maintenance.

6.

Oil Temperature is Too Hot (Hydraulic Oil Temperature Gage in Red Range).

Check hydraulic oil level (WP 0004 If hydraulic oil level is low, fill to 00). correct level (WP 0004 00). If problem still exists, notify Unit Maintenance.

7.

Steering is Erratic.

Check hydraulic oil level (WP 0004 If hydraulic oil level is low, fill to 00). correct level (WP 0004 00). If problem still exists, notify Unit Maintenance.

8.

Turning Steering Wheel is Difficult.

1.

Check hydraulic temp gage for correct temperature.

0010 00-13

If problem still exists after normal operating temperature is reached, go to test step 2.

TM 5-3805-291-10

TROUBLESHOOTING PROCEDURES - CONTINUED MALFUNCTION

TEST OR INSPECTION

0010 00 CORRECTIVE ACTION

STEERING - CONTINUED 8.

Turning Steering Wheel is Difficult Continued.

2.

Check hydraulic oil level (WP 0004 00).

If hydraulic oil level is low, fill to correct level (WP 0004 00). If problem still exists, notify Unit Maintenance.

TRANSMISSION 1. Slow or Erratic Transmission Engagement.

2.

Check transmission oil level (WP 0004 If transmission oil is low, fill to 00). correct level (WP 0004 00). If problem still exists, notify Unit Maintenance. Ensure proper transmission range is selected for machine operation (WP 0004 00).

Select proper transmission range (WP 0004 00). If proper range was used, go to test step 2.

2.

Reduce load and continue to monitor temperature.

If problem still exists, go to test step 3.

3.

Check transmission oil level (WP 0004 00).

If transmission oil is low, fill to correct level (WP 0004 00). If problem still exists, notify Unit Maintenance.

Transmission Oil Temperature Gage 1. Indicates Overheating and Action Light Comes On (During Normal Operation).

3.

Transmission Does Not Operate in Any Gear.

Check transmission oil level (WP 0004 If transmission oil is low, fill to 00). correct level (WP 0004 00). If problem still exists, notify Unit Maintenance.

4.

Transmission Does Not Shift From One Direction to Another.

1.

Check position of parking brake switch.

Disengage parking brake. If problem still exists, go to test step 2.

2.

Shift transmission to N (NEUTRAL) and back to appropriate direction.

If problem still exists, go to test step 3.

3.

Check transmission oil level (WP 0004 00).

If transmission oil is low, fill to correct level (WP 0004 00). If problem still exists, notify Unit Maintenance.

1.

Check transmission oil level (WP 0004 00).

If transmission oil is low, fill to correct level (WP 0004 00). If problem still exists, notify Unit Maintenance.

2.

Ensure that autoshift switch is in desired mode (manual/auto).

If problem still exists, notify Unit Maintenance.

5.

6.

Transmission Does Not Shift From One Gear to Another.

Transmission Engages, but Machine Does Not Move. Engine Stops Running.

Restart engine.

END OF WORK PACKAGE 0010 00-14

If problem still exists, notify Unit Maintenance.

TM 5-3805-291-10

CHAPTER 4 PMCS MAINTENANCE INSTRUCTIONS

4 TM 5-3805-291-10

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 that defects 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 corrections to be performed by the operator to keep your equipment in good operating condition and ready for its primary mission.

EXPLANATION OF TABLE ENTRIES 1.

Item Number (Item No.) Column. Numbers in this column are for reference. When completing DA Form 2404 or DA Form 5988-E (Equipment Inspection and Maintenance Worksheet), include the item number for the check/service indicating 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.

NOTE The WARNINGs and CAUTIONs appearing in your PMCS table should always be observed. WARNINGs and CAUTIONs appear before applicable procedures. You must observe these WARNINGs to prevent injury 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 Item to Check/Service column, to know if the equipment is ready or available for its intended mission. You must perform the procedure 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 equipment from being capable of performing its primary mission. If you perform check/service procedures that show faults listed in this column, the equipment is not mission-capable. Follow standard operating procedures for maintaining the equipment or 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 anything wrong in a hurry. If the machine does not perform as required, refer to the appropriate troubleshooting procedure in 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 something 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 is needed to make all the checks. You will always need a rag (Item 13, WP 0027 00) or two. 0011 00-1

TM 5-3805-291-10

PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INTRODUCTION - CONTINUED

0011 00

GENERAL PMCS PROCEDURES - CONTINUED

WARNING Solvent cleaning compound MIL-PRF-680 Type III is an environmentally compliant and low toxic material. However, it may be irritating to the eyes and skin. Use protective gloves and goggles. Use in wellventilated areas. Keep away from open flames and other sources of ignition. Failure to follow this warning may 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 work and 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.

WARNING When 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. If further 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 find one 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 connectors. 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 spots indicate leaks, but a stain around a fitting or connector can also mean a leak. If a leak comes from a loose fitting or connector, 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 following are definitions of the types/classes of leakage you need to know to be able to determine the status of your machine. Learn and be familiar with them, and remember: when in doubt, notify your supervisor.

0011 00-2

TM 5-3805-291-10

PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INTRODUCTION - CONTINUED GENERAL PMCS PROCEDURES - CONTINUED

CAUTION Operation 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, check fluid levels more frequently. Class III leaks must be reported immediately to your supervisor. Failure to do this will result in damage to machine and/or components.

NOTE Notify your supervisor of any leaks you cannot fix.

Class I Class II Class III

Leakage Definitions for PMCS Leakage indicated by wetness or discoloration, but not great enough to form drops. Leakage great enough to form drops, but not enough to cause drops to drip from the item being checked/inspected. Leakage great enough to form drops that fall from the item being checked/ inspected.

END OF WORK PACKAGE

0011 00-3/(0011 00-4 Blank)

0011 00

54 TM 5-3805-291-10

PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INCLUDING LUBRICATION INSTRUCTIONS

0012 00

PMCS INITIAL SETUP References

Tools and Special Tools

FM 3-11.3

Basic Issue Items (Table 2, WP 0026 00)

FM 3-11.5

Materials/Parts

FM 9-207

Antifreeze (Item 1, WP 0027 00) Cleaning compound, solvent (Item 2, WP 0027 00) Cleaning compound, windshield (Item 3, WP 0027 00)

TM 9-6140-200-14 WP 0004 00 WP 0007 00

Detergent (Item 4, WP 0027 00)

WP 0013 00

Fuel (Item 5, 6, or 7, WP 0027 00)

WP 0014 00

Grease, GAA (Item 8, WP 0027 00)

WP 0015 00

Oil, lubricating (Item 9, 10, 11, or 12, WP 0027 00)

WP 0024 00 Equipment Conditions

Rag, wiping (Item 13, WP 0027 00)

Machine parked on level ground (WP 0005 00)

Test kit, SCA (Item 17, WP 0027 00)

Work tool lowered to ground (WP 0005 00)

Personnel Required MOS 21E, Heavy Construction Equipment Operator

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

NOTE Refer to the Messenger Reference Guide in WP 0004 00.

0012 00-1

TM 5-3805-291-10 PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INCLUDING LUBRICATION INSTRUCTIONS - CONTINUED

0012 00

Table 1. Preventive Maintenance Checks and Services (PMCS) for the 966H Wheel Loader. LOCATION ITEM NO.

INTERVAL

MANHOURS

ITEM TO CHECK/ SERVICE

NOT FULLY MISSION CAPABLE IF:

PROCEDURE

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 preventive maintenance and lubrication with machine parked on level ground, work tool lowered to ground, parking brake lever engaged, transmission in N (NEUTRAL), and engine shut down.

FRONT AND LEFT SIDE 1

Before 0012 00

Overall View

a. Check on ground under machine Class III oil or coolant leaks for evidence of fluid leakage such are evident. Any fuel leakas oil, coolant, or fuel. age is evident. b. Check machine for obvious dam- Damage that would impair age that would impair operation. operation is evident. Check for cracked, bent, or otherwise Cracks or damage that would impair operation is damaged forks and fork frame. evident.

2

Before

Forklift Pallet Forks (If Equipped)

3

Before

Bucket and a. Check bucket for bends, cracks, or Cracks or damage that Bucket Tips (If would impair operation is other damage. Equipped) evident. b. Check for missing tip. Replace if necessary.

4

Before

Sweeper (If Equipped)

Check sweeper for damage.

Damage that would impair operation is evident.

5

Before

Quick Coupler, Tilt Cylinder, and Lift Arms

a. Check quick coupler for cracks Cracks are evident. Wear and wear in pin area. that would impair security of coupling is evident. b. Ensure protective caps are installed on two quick disconnect fittings. c. Check for leaking hydraulic lines Class III leaks are evident. on work tool, quick coupler, lift arms, and tilt cylinder. 0012 00-2

TM 5-3805-291-10 PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INCLUDING LUBRICATION INSTRUCTIONS - CONTINUED

0012 00

Table 1. Preventive Maintenance Checks and Services (PMCS) for the 966H Wheel Loader - Continued. LOCATION ITEM NO.

INTERVAL

6

Before

MANHOURS

ITEM TO CHECK/ SERVICE Left-Front Wheel and Tire

PROCEDURE a. Check for missing bolts.

NOT FULLY MISSION CAPABLE IF: Two or more bolts are missing.

b. Check tread and sidewall for cuts Damage to tire that would and foreign material in treads. lead to tire failure is evident. c. Visually check tire inflation.

Tire is flat.

d. Check back side of wheel for oil Class III oil leaks are evident. leaks from final drive.

7

Before

Left-Front Lights

a. Check that left-front service light Lights are missing or dam427-C0064 if required for misassembly (service lights and turn- aged, sion. lamps) is present and not damaged. b. Check that blackout drive light is Blackout drive light is missing or damaged, if required present and not damaged. for mission.

8

Before

Frame Articulation Area

a. Check for cracks or breaks in drive Cracks or breaks are evident. shaft. b. Inspect hydraulic hoses for dam- If cracks, splits, bulges, or soft spots are evident in age or leaks. hoses, or Class III leaks are evident. c. Inspect for missing, damaged, or leaking remote grease fittings.

0012 00-3

TM 5-3805-291-10 PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INCLUDING LUBRICATION INSTRUCTIONS - CONTINUED

0012 00

Table 1. Preventive Maintenance Checks and Services (PMCS) for the 966H Wheel Loader - Continued. LOCATION ITEM NO. 8 (Cont)

INTERVAL Before

MANHOURS

ITEM TO CHECK/ SERVICE Frame Articulation Area

PROCEDURE

NOT FULLY MISSION CAPABLE IF:

d. Check that left-side steering cylin- Steering cylinder is not securely attached to front der pin is secure. frame section. e. Inspect upper and lower articulation pin/bearing assemblies for evidence of cracks, breaks, missing mounting bolts, or damaged or missing grease fittings.

Upper and lower articulation pin/bearing assemblies are cracked, have breaks, missing mounting bolts, or damaged or missing grease fittings.

f. Check that transmission oil cap is Transmission oil cap is present. Ensure there are no oil missing. Class III oil leaks are evident. leaks. g. Check transmission oil level and fill if necessary (WP 0004 00). h. Check that steering frame lock is disconnected and stowed. If connected, disconnect IAW instructions in WP 0015 00.

9

Before

Left-Side Cab, Door, Ladder, and Operator Platform

a. Inspect front, left, and rear of cab Damage is noted that would for damage and broken glass. impair operation. Check for damaged or missing front and rear windshield wipers/ washers. b. Check that front and rear left-side worklights are present and not damaged. c. Check for damage to door, door handle, and grabhandles.

0012 00-4

TM 5-3805-291-10 PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INCLUDING LUBRICATION INSTRUCTIONS - CONTINUED

0012 00

Table 1. Preventive Maintenance Checks and Services (PMCS) for the 966H Wheel Loader - Continued. LOCATION ITEM NO. 9 (Cont)

INTERVAL Before

MANHOURS

ITEM TO CHECK/ SERVICE Left-Side Cab, Door, Ladder, and Operator Platform

NOT FULLY MISSION CAPABLE IF:

PROCEDURE

NOTE If left-side ladder and/or platform are damaged, operator may use right-side ladder and/or platform.

d. Check that ladder is securely mounted and in good condition. e. Check that operator platform is securely mounted and in good condition. f. Inspect ROPS/FOPS mounting Bolts are missing or loose. bolts at two left corners outside cab. Check for missing or loose bolts (WP 0024 00). 10

Before

Left-Rear Wheel and Tire

a. Check for missing bolts.

Two or more bolts are missing.

b. Check tread and sidewall for cuts Damage to tire that would and foreign material in treads. lead to tire failure is evident. c. Visually check tire inflation.

Tire is flat.

d. Check back side of wheel for oil Class III oil leaks are evileaks from final drive. dent. 11

Before

Left-Side Engine Enclosure

a. Open left-side access door.

b. Check for evidence of hydraulic/ Class III leaks are evident. coolant leaks. c. Close left-side access door.

0012 00-5

TM 5-3805-291-10 PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INCLUDING LUBRICATION INSTRUCTIONS - CONTINUED

0012 00

Table 1. Preventive Maintenance Checks and Services (PMCS) for the 966H Wheel Loader - Continued. LOCATION ITEM NO.

INTERVAL

12

Before

MANHOURS

ITEM TO CHECK/ SERVICE

NOT FULLY MISSION CAPABLE IF:

PROCEDURE

Engine Coola. Tilt hood to open position (WP Hood does not open. ant Level 0004 00). 0012 00 b. Check coolant overflow tank sight Coolant level is not visible gage for presence of coolant. in sight gage. c. If necessary, add coolant as follows:

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. Loosen cap to first stop and let any pressure out of cooling system, then remove cap. Failure to follow this warning may cause serious burns.

•

Wear effective eye, glove, and skin protection when handling 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 the left), and remove cap from coolant overflow tank. (3) Add a 50/50 mixture of antifreeze and clean water to bring level up to FULL mark on coolant overflow sight gage. 60/40 mixture of antifreeze and water is used in arctic operation. (4) Inspect filler cap for damage to Gasket is missing or damcap or cap gasket, foreign mate- aged. rial, and deposits. (5) Reinstall cap by pushing down on cap and turning clockwise (to the right).

0012 00-6

TM 5-3805-291-10 PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INCLUDING LUBRICATION INSTRUCTIONS - CONTINUED

0012 00

Table 1. Preventive Maintenance Checks and Services (PMCS) for the 966H Wheel Loader - Continued. LOCATION ITEM NO.

INTERVAL

MANHOURS

ITEM TO CHECK/ SERVICE

12 (Cont)

Before

Engine Coolant Level

13

Before

Left Side of Engine

PROCEDURE

NOT FULLY MISSION CAPABLE IF:

a. Ensure that aftercooler and air Tubes are intake tubes are secure. mounted.

not

securely

b. Inspect around turbocharger and Exhaust leaks are evident. exhaust manifold for exhaust Any oil leaks or soot are leaks. Check for black soot evident. between turbocharger and muffler. Visually check for oil leaks at turbocharger. c. Check the transmission and Damage that would impair hydraulic oil coolers, aftercooler, cooling is evident. and radiator for damaged components. 14

Before

Battery Box, NATO Slave Receptacle

a. Check that left-side battery box cover is closed and secure. b. Ensure that cover is installed on NATO slave receptacle.

0012 00-7

TM 5-3805-291-10 PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INCLUDING LUBRICATION INSTRUCTIONS - CONTINUED

0012 00

Table 1. Preventive Maintenance Checks and Services (PMCS) for the 966H Wheel Loader - Continued. LOCATION ITEM NO.

INTERVAL

15

Before

MANHOURS

ITEM TO CHECK/ SERVICE

NOT FULLY MISSION CAPABLE IF:

PROCEDURE

Ether Starting Aid System 0012 00

WARNING Ether fuel is extremely flammable and toxic. DO NOT smoke and make sure you are in a well-ventilated area away from heat, open flames or sparks. Wear eye protection. Avoid contact with skin and eyes and avoid breathing ether fumes. If fluid enters or fumes irritate the eyes, wash immediately with large quantities of clean water for 15 minutes. Seek medical attention immediately if ether is inhaled or causes eye irritation. Failure to follow this warning 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 present Ether canister or cap is and securely installed. missing. b. Close hood (WP 0004 00). REAR AND RIGHT SIDE 16

Before

Overall View

Check on ground under machine for Class III oil or coolant leaks evidence of fluid leakage such as oil, are evident. Any fuel leakage is evident. coolant, or fuel.

17

Before

Rear of Machine

a. Check that rear lights are present Rear lights are missing or damaged, if required for and not damaged. mission. b. Open rear access door. c. Ensure fuel tank filler cap is Fuel tank filler cap is missing. installed. d. Check for evidence of any fuel Any fuel leaks are evident. leaks. e. Close rear access door.

0012 00-8

Rear access door will not close and latch securely.

TM 5-3805-291-10 PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INCLUDING LUBRICATION INSTRUCTIONS - CONTINUED

0012 00

Table 1. Preventive Maintenance Checks and Services (PMCS) for the 966H Wheel Loader - Continued. LOCATION ITEM NO.

INTERVAL

18

Before

MANHOURS

ITEM TO CHECK/ SERVICE Right-Side Engine Enclosure

PROCEDURE

NOT FULLY MISSION CAPABLE IF:

a. Tilt hood to open position (WP 0004 00).

b. Check for evidence of leaks.

0012 00-9

Class III leaks are evident. Any fuel leaks are evident.

TM 5-3805-291-10 PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INCLUDING LUBRICATION INSTRUCTIONS - CONTINUED

0012 00

Table 1. Preventive Maintenance Checks and Services (PMCS) for the 966H Wheel Loader - Continued. LOCATION ITEM NO.

INTERVAL

MANHOURS

19

Before

0.2 Hour

ITEM TO CHECK/ SERVICE

PROCEDURE

NOT FULLY MISSION CAPABLE IF:

Engine Oil a. Wipe area clean around dipstick. Level 0012 00

CAUTION When removing dipstick, be alert for evidence of fuel or antifreeze contamination. Antifreeze has a characteristic odor which can be detected. Fuel will separate from engine oil and leave a bullseye stain on rag.

b. Remove dipstick and inspect condition of oil. Look for evidence of antifreeze or fuel contamination. Report any problem to your supervisor. c. Wipe dipstick clean, then reinsert into dipstick tube until fully seated. Remove dipstick and take reading. d. Level must be within crosshatched area on dipstick. e. If level is low, turn filler cap clockwise (to the left) and add engine oil (Item 9, 10, 11, or 12, WP 0027 00) through filler tube opening until level on dipstick is correct. Refer to KEY at end of this work package for correct grade of oil for expected temperature range. f. Reinstall filler cap and turn clockwise (to the right) until tight.

0012 00-10

TM 5-3805-291-10 PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INCLUDING LUBRICATION INSTRUCTIONS - CONTINUED

0012 00

Table 1. Preventive Maintenance Checks and Services (PMCS) for the 966H Wheel Loader - Continued. LOCATION ITEM NO. 19 (Cont)

INTERVAL

MANHOURS

Before

0.2 Hour

ITEM TO CHECK/ SERVICE

NOT FULLY MISSION CAPABLE IF:

PROCEDURE

Engine Oil Level 0012 00

427-C-1674

0012 00-11

TM 5-3805-291-10 PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INCLUDING LUBRICATION INSTRUCTIONS - CONTINUED

0012 00

Table 1. Preventive Maintenance Checks and Services (PMCS) for the 966H Wheel Loader - Continued. LOCATION ITEM NO.

INTERVAL

20

Before

MANHOURS

ITEM TO CHECK/ SERVICE

NOT FULLY MISSION CAPABLE IF:

PROCEDURE

Fuel/Water Separator Drain 0012 00

WARNING •

•

DO NOT smoke or permit any open flame in area of machine while you are servicing fuel system. Failure to follow this warning may cause injury to personnel or equipment damage. Operating personnel must wear fuel-resistant gloves when handling fuels. If exposed to fuel, promptly wash exposed skin and change fuel-soaked clothing.

a. Place container under drain valve. b. Turn drain valve counterclockwise (to the left) and drain all water and sediment from sediment bowl. c. Turn drain valve clockwise (to the right) to close valve. d. Dispose of drained fluid IAW local policy and ordinances.

427-C1675

0012 00-12

TM 5-3805-291-10 PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INCLUDING LUBRICATION INSTRUCTIONS - CONTINUED

0012 00

Table 1. Preventive Maintenance Checks and Services (PMCS) for the 966H Wheel Loader - Continued. LOCATION ITEM NO.

INTERVAL

21

Before

MANHOURS

ITEM TO CHECK/ SERVICE Fan Housing

PROCEDURE

NOT FULLY MISSION CAPABLE IF:

a. Check for leaks and damage to fan Damage that would impair housing and fan motor. operation is evident. Class III 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 are missing.

b. Check tread and sidewall for cuts Damage to tire that would and foreign material in treads. lead to tire failure is evident. c. Visually check tire inflation.

Tire is flat.

d. Check back side of wheel for oil Class III oil leaks are evileaks from final drive. dent. 23

Before

Right-Side Cab, Ladder, and Operator Platform

a. Inspect right side of cab for dam- Damage is noted that would age and broken glass. impair operation.

b. Check that front and rear right-side worklights are present and not damaged. c. Inspect ROPS/FOPS mounting Bolts are missing or loose. bolts at two right corners outside cab. Check for missing or loose bolts (WP 0024 00).

0012 00-13

TM 5-3805-291-10 PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INCLUDING LUBRICATION INSTRUCTIONS - CONTINUED

0012 00

Table 1. Preventive Maintenance Checks and Services (PMCS) for the 966H Wheel Loader - Continued. LOCATION ITEM NO.

INTERVAL

24

Before

MANHOURS

ITEM TO CHECK/ SERVICE Frame Articulation Area

NOT FULLY MISSION CAPABLE IF:

PROCEDURE

a. Inspect hydraulic hoses for dam- If cracks, splits, bulges, or age or leaks. soft spots are evident in hoses, or Class III leaks are evident. b. Check that right-side steering cyl- Steering cylinder is not inder attachment to front frame securely attached to front section is secure. frame section.

427-C0019

25

Before

Right-Front Lights and Horn

a. Check that right-front service Lights are missing or damlights and turnlamps are present aged, if required for misand not damaged. sion. b. Check that horn is present and not Horn is missing. damaged.

0012 00-14

TM 5-3805-291-10 PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INCLUDING LUBRICATION INSTRUCTIONS - CONTINUED

0012 00

Table 1. Preventive Maintenance Checks and Services (PMCS) for the 966H Wheel Loader - Continued. LOCATION ITEM NO.

INTERVAL

26

Before

MANHOURS

ITEM TO CHECK/ SERVICE Right-Front Wheel and Tire

PROCEDURE a. Check for missing bolts.

NOT FULLY MISSION CAPABLE IF: Two or more bolts are missing.

b. Check tread and sidewall for cuts Damage to tire that would and foreign material in treads. lead to tire failure is evident. c. Visually check tire inflation.

Tire is flat.

d. Check back side of wheel for oil Class III oil leaks are evileaks from final drive. dent. 27

Before

Quick Coupler and Lift Arms

a. Check quick coupler for cracks Cracks are evident. Wear and wear in pin area. that would impair security of coupling is evident. b. Check for leaking hydraulic lines Class III leaks are evident. on work tool, quick coupler, lift arms, and tilt cylinder.

OPERATOR STATION 28

Before

Platform and Top of Machine

a. Use left-side ladder and grabhandles to open door and latch in fully open position against cab wall. Climb up onto platform. b. Check that hydraulic tank filler Hydraulic tank filler cap is cap is present. Check for damage missing. Class III leaks are or leaks. evident. c. Ensure oil is visible in green area Oil is not visible in sight of hydraulic tank sight gage. gage.

0012 00-15

TM 5-3805-291-10 PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INCLUDING LUBRICATION INSTRUCTIONS - CONTINUED

0012 00

Table 1. Preventive Maintenance Checks and Services (PMCS) for the 966H Wheel Loader - Continued. LOCATION ITEM NO. 28 (Cont)

INTERVAL Before

MANHOURS

ITEM TO CHECK/ SERVICE Platform and Top of Machine

NOT FULLY MISSION CAPABLE IF:

PROCEDURE d. If oil is not visible in red area of sight gage, add oil as follows: (1) Remove filler cap.

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

NOTE Remove spring in order to remove screen.

(2) Check filler opening screen for debris. If necessary, remove screen and clean with solvent cleaning compound (Item 2, WP 0027 00), dry thoroughly, and reinstall. (3) Add oil (Item 9, 10, 11, or 12, WP 0027 00) through filler opening until oil level is visible in sight gage.

0012 00-16

TM 5-3805-291-10 PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INCLUDING LUBRICATION INSTRUCTIONS - CONTINUED

0012 00

Table 1. Preventive Maintenance Checks and Services (PMCS) for the 966H Wheel Loader - Continued. LOCATION ITEM NO. 28 (Cont)

INTERVAL Before

MANHOURS

ITEM TO CHECK/ SERVICE

PROCEDURE

NOT FULLY MISSION CAPABLE IF:

Platform and Top of Machine

427-C1703

(4) Install filler cap. 29

Before

Cab Interior

a. Enter cab and close door. b. Visually check for missing or Fire extinguisher is missing damaged fire extinguisher. Ensure or damaged. it is securely mounted in bracket. (1) Check gage for reading in green Pressure gage needle is in area. red area. (2) Check for damaged or missing Seal is broken or missing. seal. (3) Inspect fire extinguisher inspection tag. c. Check if seat belt is frayed, torn, or Seat belt is damaged or has other damage. Check inspec- inspection date is more than tion date. 3 years.

0012 00-17

TM 5-3805-291-10 PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INCLUDING LUBRICATION INSTRUCTIONS - CONTINUED

0012 00

Table 1. Preventive Maintenance Checks and Services (PMCS) for the 966H Wheel Loader - Continued. LOCATION ITEM NO. 29 (Cont)

INTERVAL Before

MANHOURS

ITEM TO CHECK/ SERVICE

NOT FULLY MISSION CAPABLE IF:

PROCEDURE

WARNING

Cab Interior

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

d. Occupy seat. Adjust seat and interior rearview mirrors. Fasten seat belt (WP 0004 00). e. Adjust steering column and check Steering column does not if it locks into place. lock into place. f. Check switches, gages, indicators, Damage is evident that and military light switch for dam- would impair operation. age. g. Check for damage to throttle and Damage is evident that brake pedals. There should be free would impair operation. movement. h. Check for damage to loader con- Damage is evident that trol joystick and auxiliary hydrau- would impair operation. lic control thumb wheel. They should move freely. 30

Before

Engine Startup

a. Start engine and allow to warm up (WP 0005 00). b. Ensure all alert indicators are func- Alert indicator or gage maltioning properly. Check gages for functions. proper operation (WP 0004 00). c. Check operation of all lights and turnlamps.

NOTE Backup alarm and horn will not sound if operating in blackout mode.

31

Before

Backup Alarm a. Check operation of horn at both Horn does not operate. locations. b. Place transmission in R Backup (REVERSE) and listen for backup sound. alarm to sound. c. Return transmission to N (NEUTRAL). Machine is now ready to operate.

0012 00-18

alarm

does

not

TM 5-3805-291-10 PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INCLUDING LUBRICATION INSTRUCTIONS - CONTINUED

0012 00

Table 1. Preventive Maintenance Checks and Services (PMCS) for the 966H Wheel Loader - Continued. LOCATION ITEM NO.

INTERVAL

32

Before

MANHOURS

ITEM TO CHECK/ SERVICE

PROCEDURE

NOT FULLY MISSION CAPABLE IF:

WARNING

Parking Brake

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

Disengage parking brake switch. 33

Before

Parking brake switch does not disengage.

Transmission a. Select transmission autoshift mode Machine does not respond Controls and and place transmission in F (FOR- to transmission selection. Service Brakes WARD). b. Move machine ahead slowly. Brakes do not stop machine. Depress both brake pedals and ensure machine stops.

34

Before

Work Tool Hydraulic Controls

Unlock hydraulic controls. Cycle Controls do not function loader control joystick. properly.

0012 00-19

TM 5-3805-291-10 PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INCLUDING LUBRICATION INSTRUCTIONS - CONTINUED

0012 00

Table 1. Preventive Maintenance Checks and Services (PMCS) for the 966H Wheel Loader - Continued. LOCATION ITEM NO. 35

INTERVAL During 0012 00

MANHOURS

ITEM TO CHECK/ SERVICE Overall Machine

PROCEDURE

NOT FULLY MISSION CAPABLE IF:

a. Be alert for evidence of fluid leaks Class III oil or coolant leaks such as oil, coolant, or fuel. are evident. Any fuel leaks are evident. b. Be alert for proper operation of Brakes and power train brakes and power train compo- components malfunction. nents. c. Be alert for proper operation of Steering system malfuncsteering components. tions. d. Be alert for proper operation of Work tools do not function work tool hydraulic controls. properly.

36

During

Gages, Switches, and Indicators

a. Monitor all gages for proper oper- Gage indicates an abnormal ation and readings in normal reading. ranges. b. Monitor all indicators to ensure Indicators indicate an abnormachine systems are operating mal condition (WP 0004 00). within normal range. c. Shut down engine (WP 0005 00).

0012 00-20

TM 5-3805-291-10 PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INCLUDING LUBRICATION INSTRUCTIONS - CONTINUED

0012 00

Table 1. Preventive Maintenance Checks and Services (PMCS) for the 966H Wheel Loader - Continued. LOCATION ITEM NO.

INTERVAL

MANHOURS

ITEM TO CHECK/ SERVICE

NOT FULLY MISSION CAPABLE IF:

PROCEDURE

FRONT AND LEFT SIDE 37

After 0012 00

Overall View

a. Check under machine for evidence Class III leaks oil or coolant of fluid leakage such as oil, cool- are evident. Any fuel leaks ant, or fuel. are evident. b. Check machine for obvious dam- Damage that would impair age that would impair operation. operation is evident. Check for cracked, bent, or otherwise Cracks or damage that damaged forks and fork frame. would impair operation is evident.

38

After

Forklift Pallet Forks (If Equipped)

39

After

Bucket and Check bucket and bucket tips for Bucket Tips (If bends, cracks, or other damage. Equipped)

40

After

Sweeper (If Equipped)

Check sweeper for damage.

41

After

Quick Coupler, Tilt Cylinder, and Lift Arms

a. Check quick coupler for cracks Cracks are evident. Wear and wear in pin area. that would impair security of coupling is evident.

Cracks or damage that would impair operation is evident. Damage that would impair operation is evident.

b. Ensure protective caps are installed on two quick disconnect fittings. c. Check for loose hose clamps or Loose hose clamps or Class leaking hydraulic lines on work III leaks are evident. tool, quick coupler, lift arms, and tilt cylinder. d. Ensure tilt scratched. 42

After

Left-Front Wheel and Tire

cylinder

is

not Damage that would impair operation is evident.

a. Check for loose or missing bolts, Two or more bolts are misscracks, and loose components. ing. Loose components are evident. b. Check tread and sidewall for cuts Damage to tire that would and foreign material in treads. lead to tire failure is evident. Remove foreign material from treads. c. Visually check tire inflation.

0012 00-21

Tire is flat.

TM 5-3805-291-10 PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INCLUDING LUBRICATION INSTRUCTIONS - CONTINUED

0012 00

Table 1. Preventive Maintenance Checks and Services (PMCS) for the 966H Wheel Loader - Continued. LOCATION ITEM NO. 42 (Cont)

INTERVAL After

MANHOURS

ITEM TO CHECK/ SERVICE Left-Front Wheel and Tire

PROCEDURE

NOT FULLY MISSION CAPABLE IF:

d. Look behind tire to ensure axle Axle seal is leaking. seal is not leaking. A leaking axle seal will leave streaks of oil on inside of wheel. e. Check back side of wheel for oil Class III oil leaks are evileaks from final drive. dent.

43

After

Left-Front Lights

a. Check left-front service lights and Lights are missing or damturnlamps are present and not aged, if required for misdamaged. sion. b. Check that blackout drive light is Blackout drive light is misspresent and not damaged. ing or damaged, if required for mission.

44

After

Frame Articulation Area

a. Check for cracks or breaks in drive Cracks or breaks are evishaft. dent. b. Inspect hydraulic hoses for dam- If cracks, splits, bulges, or age or leaks. soft spots are evident in hoses, or Class III leaks are evident. c. Check left-side steering cylinder Steering cylinder is not attachment to front frame section securely attached to front is secure. frame section. d. Inspect upper and lower articulation pin/bearing assemblies for evidence of cracks, breaks, loose or missing mounting bolts, or damaged or missing grease fittings. e. Check that steering frame lock is present and in good condition. Ensure it is disconnected and stowed.

0012 00-22

Upper and lower articulation pin/bearing assemblies are cracked, have breaks, loose or missing mounting bolts, or damaged or missing grease fittings.

TM 5-3805-291-10 PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INCLUDING LUBRICATION INSTRUCTIONS - CONTINUED

0012 00

Table 1. Preventive Maintenance Checks and Services (PMCS) for the 966H Wheel Loader - Continued. LOCATION ITEM NO.

INTERVAL

45

After

MANHOURS

ITEM TO CHECK/ SERVICE Left-Side Cab, Door, Ladder, and Operator Platform

PROCEDURE

NOT FULLY MISSION CAPABLE IF:

a. Inspect front, left, and rear of cab Damage that would impair for damage and broken glass. operation is evident. Check for damaged or missing front and rear windshield wipers/ washers. b. Check that front and rear left-side worklights are present and not damaged.

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

c. Check for damage to door, door handle, and grabhandles. d. Check that ladder is securely mounted and in good condition. e. Check that operator platform is securely mounted and in good condition.

0012 00-23

TM 5-3805-291-10 PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INCLUDING LUBRICATION INSTRUCTIONS - CONTINUED

0012 00

Table 1. Preventive Maintenance Checks and Services (PMCS) for the 966H Wheel Loader - Continued. LOCATION ITEM NO.

INTERVAL

46

After

MANHOURS

ITEM TO CHECK/ SERVICE Batteries, Left-Side Battery Box, and NATO Slave Receptacle 0012 00

NOT FULLY MISSION CAPABLE IF:

PROCEDURE

WARNING •

To avoid injury, eye protection and acid-resistant gloves must be worn when working around batteries. Do not smoke, use open flame, make sparks, or create other ignition sources around batteries. If a battery is giving off gases, it can explode and cause injury to personnel. Remove all jewelry such as rings, ID tags, watches, and bracelets. If jewelry or a tool contacts a battery terminal, a direct short will result in instant heating, damage to equipment, and injury to personnel.

•

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

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 box Battery is leaking electrocover is closed and secure. Be alert lyte. for any evidence of electrolyte leakage coming from battery box. b. Open battery access cover under Battery is missing. left side of operator platform. c. Inspect battery for obvious dam- Any electrolyte leakage is age such as a cracked case and evident or damage to batterelectrolyte leakage. ies. d. Check battery hold-down for pres- Hold-down is missing, loose ence, looseness, and damage. If or damaged. loose, tighten wingnuts. e. Check battery for broken and cor- Broken and corroded conroded connections or frayed/ nections or frayed/burned/ burned/melted cables and clamps. melted cables and clamps are evident.

0012 00-24

TM 5-3805-291-10 PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INCLUDING LUBRICATION INSTRUCTIONS - CONTINUED

0012 00

Table 1. Preventive Maintenance Checks and Services (PMCS) for the 966H Wheel Loader - Continued. LOCATION ITEM NO. 46 (Cont)

47

INTERVAL After

After

MANHOURS

ITEM TO CHECK/ SERVICE

PROCEDURE

NOT FULLY MISSION CAPABLE IF:

Batteries, Left-Side Battery Box, and NATO Slave Receptacle

f. Ensure battery is clean and battery Battery cables are secure. secure.

Windshield

a. Check for damage and leaks on windshield washer fluid reservoir.

Washer Fluid Reservoir

cables

are

not

g. Close access cover and secure. h. Ensure that cover is installed on NATO slave receptacle.

b. Check level of windshield washer fluid. If level is low, remove cap and add windshield-cleaning compound until level is up to top of filler neck. Reinstall cap.

427-C1680

48

After

Left-Rear Wheel and Tire

a. Check for loose or missing bolts, Two or more bolts are missing. Loose components are cracks, and loose components. evident. b. Check tread and sidewall for cuts Damage to tire that would and foreign material in treads. lead to tire failure is evident. Remove foreign material from treads. c. Visually check tire inflation.

Tire is flat.

d. Look behind tire to ensure axle Axle seal is leaking. seal is not leaking. A leaking axle seal will leave streaks of oil on inside of wheel.

0012 00-25

TM 5-3805-291-10 PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INCLUDING LUBRICATION INSTRUCTIONS - CONTINUED

0012 00

Table 1. Preventive Maintenance Checks and Services (PMCS) for the 966H Wheel Loader - Continued. LOCATION ITEM NO.

INTERVAL

MANHOURS

ITEM TO CHECK/ SERVICE

48 (Con’t)

After

Left-Rear Wheel and Tire

49

After

Left-Side Engine Enclosure

PROCEDURE

NOT FULLY MISSION CAPABLE IF:

e. Check back side of wheel for oil Class III oil leaks are evileaks from final drive. dent.

CAUTION Screen prevents stones or other flying debris from entering engine compartment and causing damage to oil coolers and radiator. Ensure screen is maintained in good condition.

a. Inspect left-side access door for damage. Remove any foreign material from screen. b. Check for debris and damage to Damage is evident. If hoses, tubes, and wires/connectors cracks, splits, bulges, or soft in left-side engine enclosure. spots are evident in hoses. Remove any debris found. c. Check for evidence of leaks.

Class III leaks are evident. Any fuel leakage is evident.

d. Inspect around turbocharger and Exhaust leaks are evident. exhaust manifold for exhaust leaks. REAR AND RIGHT SIDE 50

After

Overall View

a. Check on ground under machine Class III oil or coolant leaks for evidence of fluid leakage such are evident. Any fuel leaks as oil, coolant, or fuel. are evident. b. Check machine for obvious dam- Damage that would impair age that would impair operation. operation is evident.

51

After

Rear of Machine

a. Check that rear lights are present Rear lights are missing or and not damaged. damaged, if required for mission. b. Open rear access door. c. Ensure fuel tank filler cap is Fuel tank filler cap is missinstalled. ing. d. Check for evidence of any leak.

0012 00-26

Any fuel leaks are evident.

TM 5-3805-291-10 PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INCLUDING LUBRICATION INSTRUCTIONS - CONTINUED

0012 00

Table 1. Preventive Maintenance Checks and Services (PMCS) for the 966H Wheel Loader - Continued. LOCATION ITEM NO. 51 (Con’t)

INTERVAL After

MANHOURS

ITEM TO CHECK/ SERVICE

NOT FULLY MISSION CAPABLE IF:

PROCEDURE

Rear of Machine

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 this warning 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 wash exposed skin and change fuel-soaked clothing.

•

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

NOTE Ensure portable fire extinguisher is within reach prior to refueling. e. Refuel machine, if required (WP 0013 00). f. Unlatch cooler assembly and Damage that would impair swing rearward. Ensure that fins of cooling is evident. transmission and hydraulic oil coolers, aftercooler, and radiator are 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 Damage that would impair inspection panels and inspect for cooling is evident. damage.

0012 00-27

TM 5-3805-291-10 PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INCLUDING LUBRICATION INSTRUCTIONS - CONTINUED

0012 00

Table 1. Preventive Maintenance Checks and Services (PMCS) for the 966H Wheel Loader - Continued. LOCATION ITEM NO.

INTERVAL

52

After

MANHOURS

ITEM TO CHECK/ SERVICE Right-Side Engine Enclosure

PROCEDURE

NOT FULLY MISSION CAPABLE IF:

CAUTION Screen prevents stones or other flying debris from entering engine compartment and causing damage to oil coolers and radiator. Ensure screen is maintained in good condition.

a. Inspect right-side access door for damage. Remove any foreign material from screen. b. Check for debris and damage to Damage is evident. If hoses, tubes, fuel filters, and cracks, splits, bulges, or soft wires/connectors in right-side spots are evident in hoses. engine enclosure. Remove any debris found. c. Check for evidence of leaks. 53

After

0.2 Hour

Engine Oil Level

Class III leaks are evident. Any fuel leaks are evident.

a. Wipe area clean around dipstick.

CAUTION When removing dipstick, be alert for evidence of fuel or antifreeze contamination. Antifreeze has a characteristic odor which can be detected. Fuel will separate from engine oil and leave a bulls eye stain on rag.

b. Remove dipstick and inspect condition of oil. Look for evidence of antifreeze or fuel contamination. Report any problem to your supervisor. c. Wipe dipstick clean, then reinsert into dipstick tube until fully seated. Remove dipstick and take reading. d. Level must be within crosshatched area on dipstick. e. If level is low, turn filler cap counterclockwise (to the left) and add lubricating oil (Item 9, 10, 11, or 12, WP 0027 00) through filler tube opening until level on dipstick is correct. Refer to KEY at end of this work package for correct grade of oil for expected temperature range.

0012 00-28

TM 5-3805-291-10 PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INCLUDING LUBRICATION INSTRUCTIONS - CONTINUED

0012 00

Table 1. Preventive Maintenance Checks and Services (PMCS) for the 966H Wheel Loader - Continued. LOCATION ITEM NO. 53 (Cont)

INTERVAL

MANHOURS

After

0.2 Hour

ITEM TO CHECK/ SERVICE Engine Oil Level

PROCEDURE

NOT FULLY MISSION CAPABLE IF:

f. Reinstall dipstick and turn clockwise (to the right) until tight. g. Tilt hood to open position (WP Hood does not open. 0004 00).

54

After

Right-Rear Wheel and Tire

a. Check for loose or missing bolts, Two or more bolts are misscracks, and loose rim components. ing. Loose components are evident. b. Check tread and sidewall for cuts Damage to tire that would and foreign material in treads. lead to tire failure is evident. Remove foreign material from treads. c. Visually check tire inflation.

Tire is flat.

d. Look behind tire to ensure axle Axle seal is leaking. seal is not leaking. A leaking axle seal will leave streaks of oil on inside of wheel. e. Check backside of wheel for oil Class III oil leaks are evileaks from final drive. dent. 55

After

Right-Side Cab, Ladder, and Operator Platform

a. Inspect right side of cab for dam- Damage is noted that would impair operation. age and broken glass. b. Check that front and rear right-side worklights are present and not damaged. c. Check for damage to windows and grabhandles. d. Check that ladder is securely mounted and in good condition. e. Check that operator platform is securely mounted and in good condition. f. Inspect for missing, damaged, or Remote grease fittings are leaking remote grease fittings. missing or damaged. Leaks that would prevent proper lubrication are evident.

56

After

Frame Articulation Area

a. Inspect hydraulic hoses for dam- If cracks, splits, bulges, or age or leaks. soft spots are evident in hoses, or Class III leaks are evident.

0012 00-29

TM 5-3805-291-10 PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INCLUDING LUBRICATION INSTRUCTIONS - CONTINUED

0012 00

Table 1. Preventive Maintenance Checks and Services (PMCS) for the 966H Wheel Loader - Continued. LOCATION ITEM NO. 56 (Con’t)

INTERVAL After

MANHOURS

ITEM TO CHECK/ SERVICE Frame Articulation Area

PROCEDURE

NOT FULLY MISSION CAPABLE IF:

b. Check that right-side steering cyl- Steering cylinder is not inder attachment to front frame securely attached to front section is secure. frame section. c. Inspect upper and lower articulation pin/bearing assemblies for evidence of cracks, breaks, loose or missing mounting bolts, or damaged or missing grease fittings.

Upper and lower articulation pin/bearing assemblies are cracked, have breaks, loose or missing mounting bolts, or damaged or missing grease fittings.

57

After

Right-Front Lights

Check right-front service lights and Lights are turnlamps for damage. damaged.

missing

or

58

After

Right-Front Wheel and Tire

a. Check for loose or missing bolts, Two or more bolts are misscracks, and loose rim components. ing. Loose components are evident. b. Check tread and sidewall for cuts Damage to tire that would and foreign material in treads. lead to tire failure is evident. Remove foreign material from treads. c. Visually check tire inflation. Tire is flat. d. Look behind tire to ensure axle Class III oil leak is evident. seal is not leaking. A leaking axle seal will leave streaks of oil on inside of wheel. e. Check back side of wheel for oil Class III oil leaks are evileaks from final drive. dent.

59

After

Quick Coupler and Lift Arms

a. Check quick coupler for cracks Cracks are evident. Wear and wear in pin area. that would impair security of coupling is evident. b. Check for loose hose clamps or Loose hose clamps or Class leaking hydraulic lines on work III leaks are evident. tool, quick coupler, lift arms, and tilt cylinder.

OPERATOR STATION 60

After

Platform and a. Use left-side ladder and grabhanTop of dles to open door. Latch door in Machine fully open position against cab 0012 00 wall. Climb up onto platform. 0012 00

0012 00-30

TM 5-3805-291-10 PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INCLUDING LUBRICATION INSTRUCTIONS - CONTINUED

0012 00

Table 1. Preventive Maintenance Checks and Services (PMCS) for the 966H Wheel Loader - Continued. LOCATION ITEM NO. 60 (Con’t)

INTERVAL After

MANHOURS

ITEM TO CHECK/ SERVICE

NOT FULLY MISSION CAPABLE IF:

PROCEDURE

Platform and b. Check that hydraulic tank filler Hydraulic tank filler cap is Top of cap is present. Check for damage damaged or missing. Class III leaks are evident. Machine or leaks. 0012 00 c. Ensure oil is visible in hydraulic Oil is not visible in sight gage. tank sight gage.

427-C1703

61

After

Cab Exterior

a. Inspect front and rear windshields for damage and cleanliness. If dirty, use windshield cleaning compound to clean. b. Inspect front and rear windshield wipers/washers for damage. Ensure wiper blades are in good condition.

62

After

ROPS/FOPS

a. Check for cracks, bends, and bro- ROPS/FOPS has cracks, ken welds. bends, or broken welds.

NOTE The top portion of cab can be removed for transport. There are four bolts to secure top of cab. There are four different bolts that secure the entire cab to chassis.

b. Inspect ROPS/FOPS mounting Bolts are missing or loose. bolts at four corners outside cab. Check for missing or loose bolts. c. Check four exterior bolts at split Bolts are missing or loose. line. 0012 00-31

TM 5-3805-291-10 PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INCLUDING LUBRICATION INSTRUCTIONS - CONTINUED

0012 00

Table 1. Preventive Maintenance Checks and Services (PMCS) for the 966H Wheel Loader - Continued. LOCATION ITEM NO.

INTERVAL

63

After

MANHOURS

ITEM TO CHECK/ SERVICE

NOT FULLY MISSION CAPABLE IF:

PROCEDURE

Hood and Bat- a. Tilt hood to close position (WP tery Discon0004 00). nect Switch b. Turn battery disconnect switch to OFF position (WP 0004 00).

64

Weekly 0012 00

Engine Air Precleaner and Air Cleaner

65

Weekly 0012 00

Cab Air Filters 0012 00

Service engine air precleaner and air cleaner (WP 0014 00).

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, and Procedures for Chemical, Biological, Radiological, and Nuclear Decontamination. NBC contaminated filters must be handled using adequate precautions and must be disposed of by trained personnel. Failure to follow these warnings may cause injury or death.

NOTE Perform this procedure daily if conditions necessitate it.

0012 00-32

TM 5-3805-291-10 PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INCLUDING LUBRICATION INSTRUCTIONS - CONTINUED

0012 00

Table 1. Preventive Maintenance Checks and Services (PMCS) for the 966H Wheel Loader - Continued. LOCATION ITEM NO.

INTERVAL

65 (Con’t)

Weekly 0012 00

MANHOURS

ITEM TO CHECK/ SERVICE

PROCEDURE

NOT FULLY MISSION CAPABLE IF:

Cab Air FilThere are two cab air filters. First filters 0012 00 ter is located on the left side of the operator seat and second is behind access door on left side of cab. Service as indicated in the following steps: a. Turn counterclockwise (to the left) and remove two thumbscrews and grille from left of operator seat.

427-C1677

b. Inspect air filter for tears or holes. If torn or otherwise damaged, obtain a replacement from Unit Maintenance. c. Wash air filter in a solution of detergent and water. Rinse thoroughly and air dry. d. Install air filter and tighten two thumbscrews by turning clockwise (to the right). 0012 00-33

427-C1676

TM 5-3805-291-10 PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INCLUDING LUBRICATION INSTRUCTIONS - CONTINUED

0012 00

Table 1. Preventive Maintenance Checks and Services (PMCS) for the 966H Wheel Loader - Continued. LOCATION ITEM NO. 65 (Cont)

INTERVAL Weekly

MANHOURS

ITEM TO CHECK/ SERVICE Cab Air Filters

PROCEDURE

NOT FULLY MISSION CAPABLE IF:

e. Open access door on left side of cab. f. Remove air filter from left side of cab.

427-C1678 427-C1679

0012 00-34

TM 5-3805-291-10 PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INCLUDING LUBRICATION INSTRUCTIONS - CONTINUED

0012 00

Table 1. Preventive Maintenance Checks and Services (PMCS) for the 966H Wheel Loader - Continued. LOCATION ITEM NO. 65 (Cont)

INTERVAL Weekly

MANHOURS

ITEM TO CHECK/ SERVICE

NOT FULLY MISSION CAPABLE IF:

PROCEDURE

Cab Air Filters

WARNING Particles blown by compressed air are hazardous. DO NOT exceed 15 psi (103 kPa) nozzle pressure when drying parts with compressed air. Use a maximum of 30 psi (207 kPa) when cleaning components. DO NOT direct compressed air against human skin. Failure to follow this warning may result in injury. 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.

g. Clean air filter with compressed air. Filter may also be washed in a solution of detergent and water. Dry thoroughly.

NOTE Do NOT reinstall any damaged air filter component. If air filter or angle bracket are damaged or gasket sealing is not OK, filter will not function properly to remove dust from inside cab.

h. Inspect air filter for torn or otherwise damaged pleats. If damaged, obtain a replacement from Unit Maintenance. i. Install air filter on left side of cab. j. Close filter access door on left side of cab. 66

Weekly

Wheels and Tires

a. Check if bolts are loose.

0012 00-35

Bolts are loose.

TM 5-3805-291-10 PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INCLUDING LUBRICATION INSTRUCTIONS - CONTINUED

0012 00

Table 1. Preventive Maintenance Checks and Services (PMCS) for the 966H Wheel Loader - Continued. LOCATION ITEM NO. 66 (Cont)

INTERVAL Weekly

MANHOURS

ITEM TO CHECK/ SERVICE Wheels and Tires

PROCEDURE

NOT FULLY MISSION CAPABLE IF:

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 to equipment or injury to personnel.

•

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

b. Clean area around valve stem with a rag, then remove valve stem cap. c. Check air pressure in each tire with tire pressure gage (Item 11, Table 2, WP 0026 00). Tire inflation should be 60 psi (414 kPa) for front tires and 40 psi (276 kPa) for rear tires.

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

d. Adjust air pressure in tire as required. e. Install valve stem cap. f. Check tread depth.

0012 00-36

Tread depth is less than 11/32 in. (8.8 mm).

TM 5-3805-291-10 PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INCLUDING LUBRICATION INSTRUCTIONS - CONTINUED

0012 00

Table 1. Preventive Maintenance Checks and Services (PMCS) for the 966H Wheel Loader - Continued. LOCATION ITEM NO.

INTERVAL

MANHOURS

67

Weekly

0.4 Hour

ITEM TO CHECK/ SERVICE Remote Grease Fittings

PROCEDURE

NOT FULLY MISSION CAPABLE IF:

a. Open access door on right side of operator platform. b. Wipe seven grease fittings clean with a rag. c. Apply GAA grease to seven grease fittings. Wipe off excess grease from fittings.

427-C1682 427-C1681

0012 00-37

TM 5-3805-291-10 PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INCLUDING LUBRICATION INSTRUCTIONS - CONTINUED

0012 00

Table 1. Preventive Maintenance Checks and Services (PMCS) for the 966H Wheel Loader - Continued. LOCATION ITEM NO.

INTERVAL

MANHOURS

68

Weekly

0.1 Hour

ITEM TO CHECK/ SERVICE

PROCEDURE

Steering Cylin- a. Wipe steering cylinder rod end der Rod Ends grease fittings clean with a rag. Grease Fitb. Apply GAA grease to grease fittings ting. Wipe off excess grease with a rag. c. Repeat to lubricate steering cylinder rod end on other side of machine.

427-C1683

0012 00-38

NOT FULLY MISSION CAPABLE IF:

TM 5-3805-291-10 PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INCLUDING LUBRICATION INSTRUCTIONS - CONTINUED

0012 00

Table 1. Preventive Maintenance Checks and Services (PMCS) for the 966H Wheel Loader - Continued. LOCATION ITEM NO.

INTERVAL

MANHOURS

69

Weekly

0.3 Hour

ITEM TO CHECK/ SERVICE Bucket Linkage and Loader Cylinder Bearings

PROCEDURE

NOT FULLY MISSION CAPABLE IF:

a. Wipe four grease fittings clean with a rag. b. Apply GAA grease to four fittings. Wipe off excess grease from fittings.

427-C1685

427-C1684

0012 00-39

TM 5-3805-291-10 PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INCLUDING LUBRICATION INSTRUCTIONS - CONTINUED

0012 00

Table 1. Preventive Maintenance Checks and Services (PMCS) for the 966H Wheel Loader - Continued. LOCATION ITEM NO.

INTERVAL

MANHOURS

70

Weekly

0.2 Hour

ITEM TO CHECK/ SERVICE Lift Arm Lower Pivot Bearings

PROCEDURE a. Wipe two grease fittings clean with a rag. b. Apply GAA grease to two fittings. Wipe off excess grease from fittings.

427-C1686

71

Weekly

0.2 Hour

Lift Arm Upper Pivot Bearings

a. Wipe two grease fitting clean with a rag. b. Apply GAA grease to two fittings. Wipe off excess grease from fittings.

427-C1687

0012 00-40

NOT FULLY MISSION CAPABLE IF:

TM 5-3805-291-10 PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INCLUDING LUBRICATION INSTRUCTIONS - CONTINUED

0012 00

Table 1. Preventive Maintenance Checks and Services (PMCS) for the 966H Wheel Loader - Continued. LOCATION ITEM NO.

INTERVAL

MANHOURS

72

Weekly

0.3 Hour

ITEM TO CHECK/ SERVICE

PROCEDURE

NOT FULLY MISSION CAPABLE IF:

Quick Coupler a. Wipe four grease fittings clean with a rag. b. Apply GAA grease to four fittings. Wipe off excess grease from fittings.

427-C1688

73

Weekly

0.2 Hour

Articulation a. Wipe two grease fittings clean Bearings with a rag. 0012 00 b. Apply GAA grease to two fittings. Wipe off excess grease from fittings.

427-C1690

427-C1689

0012 00-41

TM 5-3805-291-10 PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INCLUDING LUBRICATION INSTRUCTIONS - CONTINUED

0012 00

Table 1. Preventive Maintenance Checks and Services (PMCS) for the 966H Wheel Loader - Continued. LOCATION ITEM NO. 74

INTERVAL

MANHOURS

Monthly 0.2 Hour 0012 00

ITEM TO CHECK/ SERVICE Hood Tilt Actuator Grease Fittings

NOT FULLY MISSION CAPABLE IF:

PROCEDURE

a. Tilt hood to open position (WP Hood does not open. 0004 00). b. Wipe two grease fittings clean with a rag. c. Apply GAA grease to two fittings. Wipe off excess grease from fittings. d. Close hood (WP 0004 00).

427-C1691

75

Monthly

0.3 Hour

Drive Shaft Spline (Center)

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.

CAUTION To prevent damage to seal, fully articulate machine to the right or to the left BEFORE lubricating drive shaft spline (center).

a. Start engine (WP 0005 00). Raise work tool (WP 0004 00). b. Disengage parking brake. Fully articulate machine right or left (WP 0004 00). 0012 00-42

TM 5-3805-291-10 PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INCLUDING LUBRICATION INSTRUCTIONS - CONTINUED

0012 00

Table 1. Preventive Maintenance Checks and Services (PMCS) for the 966H Wheel Loader - Continued. LOCATION ITEM NO. 75 (Con’t)

INTERVAL

MANHOURS

Monthly

0.3 Hour

ITEM TO CHECK/ SERVICE Drive Shaft Spline (Center)

NOT FULLY MISSION CAPABLE IF:

PROCEDURE c. Lower work tool to ground. Engage parking brake (WP 0004 00). d. Shut down engine (WP 0005 00). e. Wipe grease fitting clean with a rag. f. Apply GAA grease to grease fitting. Apply grease until relief overruns. Wipe off excess grease with a rag. g. Start engine (WP 0005 00). Raise bucket off ground (WP 0004 00). h. Disengage parking brake and articulate machine until it is straight (WP 0004 00). i. Lower bucket to ground and apply slight downward pressure (WP 0004 00). j. Shut down engine (WP 0005 00). Engage parking brake (WP 0004 00).

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 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 to follow this warning may cause serious burns. Wear effective eye, glove, and skin protection when handling coolants. Failure to do so may cause injury.

Use test strips (Item 17, WP 0027 00) to test nitrites level in coolant. If test strip indicates nitrites level is too low, notify Unit Maintenance to replace coolant.

0012 00-43

TM 5-3805-291-10 PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INCLUDING LUBRICATION INSTRUCTIONS - CONTINUED

0012 00

Table 1. Preventive Maintenance Checks and Services (PMCS) for the 966H Wheel Loader - Continued. LOCATION ITEM NO.

INTERVAL

77

Monthly

MANHOURS

ITEM TO CHECK/ SERVICE

PROCEDURE

NOT FULLY MISSION CAPABLE IF:

Brake Accua. Turn engine start switch to ON mulator Check position. Low brake pressure alert indicator should come on if brake system pressure is not at normal operating pressure (WP 0004 00). b. Start engine (WP 0005 00). Run engine at half speed for two minutes to allow accumulator pressure to increase. Low brake pressure alert indicator should go off. c. Shut down engine (WP 0005 00). d. Apply service brakes and release service brakes until low brake pressure alert indicator comes on (due to decrease in accumulator pressure). A minimum of five service brake applications are required. e. If less than five applications were Accumulator is discharged. required, accumulator needs recharging. Notify Unit Maintenance.

78

Monthly

Service Brake Holding Ability Test

WARNING If machine begins to move during test, reduce engine speed immediately and engage parking brake. Personal injury can result if machine moves during test.

a. Observe the following conditions/ precautions: (1) Test brakes on a dry, level surface. (2) Ensure steering frame lock is disconnected and stowed (WP 0015 00). (3) Check area around machine to ensure machine is clear of personnel and obstructions.

0012 00-44

TM 5-3805-291-10 PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INCLUDING LUBRICATION INSTRUCTIONS - CONTINUED

0012 00

Table 1. Preventive Maintenance Checks and Services (PMCS) for the 966H Wheel Loader - Continued. LOCATION ITEM NO. 78 (Cont)

INTERVAL Monthly

MANHOURS

ITEM TO CHECK/ SERVICE Service Brake Holding Ability Test

PROCEDURE

NOT FULLY MISSION CAPABLE IF:

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

(4) Fasten seat belt before testing brakes. b. Start engine (WP 0005 00). Raise work tool slightly (WP 0004 00). c. Apply right service brake pedal and disengage parking brake (WP 0004 00). d. Use messenger to disable transmission neutralizer (WP 0004 00). e. Place autoshift control switch in MANUAL mode (WP 0004 00). Move transmission control lever to 3rd speed F (FORWARD) (WP 0004 00). f. Gradually increase engine speed to high idle. Machine should not move. g. Reduce engine speed to low idle. Move transmission control lever to N (NEUTRAL) (WP 0004 00). h. Lower work tool to ground (WP 0004 00). i. Engage parking brake (WP 0004 00). Shut down engine (WP 0005 00). j. If machine moved during test, notify Unit Maintenance.

0012 00-45

TM 5-3805-291-10 PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INCLUDING LUBRICATION INSTRUCTIONS - CONTINUED

0012 00

Table 1. Preventive Maintenance Checks and Services (PMCS) for the 966H Wheel Loader - Continued. LOCATION ITEM NO.

INTERVAL

79

Monthly

MANHOURS

ITEM TO CHECK/ SERVICE Parking Brake Holding Ability Test

NOT FULLY MISSION CAPABLE IF:

PROCEDURE

WARNING If machine begins to move during test, reduce engine speed immediately and engage service brake. Personal injury can result if machine moves during test.

a. Observe the following conditions/ precautions: (1) Test brakes on a dry, level surface. (2) Ensure steering frame lock is disconnected and stowed (WP 0015 00). (3) Check area around machine to ensure machine is clear of personnel and obstructions.

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

(4) Fasten seat belt before testing brakes. b. Start engine (WP 0005 00). Raise work tool slightly (WP 0004 00). c. Engage parking brake (WP 0004 00).

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 and speed control in THIRD SPEED FORWARD position. e. Place autoshift control in MANUAL mode. f. Gradually increase engine speed to high idle. Machine should not move.

0012 00-46

TM 5-3805-291-10 PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INCLUDING LUBRICATION INSTRUCTIONS - CONTINUED

0012 00

Table 1. Preventive Maintenance Checks and Services (PMCS) for the 966H Wheel Loader - Continued. LOCATION ITEM NO. 79 (Cont)

INTERVAL Monthly

MANHOURS

ITEM TO CHECK/ SERVICE

NOT FULLY MISSION CAPABLE IF:

PROCEDURE

Parking Brake g. Reduce engine speed to low idle. Holding AbilMove transmission control lever to ity Test N (NEUTRAL) (WP 0004 00). h. Lower work tool to ground (WP 0004 00). i. Engage parking brake (WP 0004 00). Shut down engine (WP 0005 00). j. If machine moved during test, notify Unit Maintenance. Have parking brakes inspected and repaired, if necessary, before returning machine to service.

80

Monthly

Decals and Data Plates

Ensure all decals and data plates are present and legible (WP 0007 00).

81

Monthly

Arctic Heater (If Equipped)

Start arctic heater and run for 15 to 20 Arctic heater does not funcminutes. Shut off. tion.

82

Monthly

All Systems Machine Exercise

CAUTION DO NOT perform this PMCS exercise when temperature is below 0 F (-18 C). Doing so can cause damage to equipment.

NOTE DO NOT exercise machine if it has been operated within the past month.

a. Perform Before operation PMCS. b. Start and warm up engine (WP 0005 00). c. While machine is warming up, Class III oil or coolant leaks perform a walkaround inspection, are evident. Any fuel leaks checking for evidence of leaks. are evident.

NOTE If temperature is below 32 F (0 C), operate controls prior to moving machine.

d. When machine has warmed up, begin to operate ALL controls slowly (WP 0004 00): (1) Transmission in including reverse.

0012 00-47

all

ranges

TM 5-3805-291-10 PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INCLUDING LUBRICATION INSTRUCTIONS - CONTINUED

0012 00

Table 1. Preventive Maintenance Checks and Services (PMCS) for the 966H Wheel Loader - Continued. LOCATION ITEM NO. 82 (Cont)

INTERVAL Monthly

MANHOURS

ITEM TO CHECK/ SERVICE All Systems Machine Exercise

PROCEDURE (2) Service brakes applied and released. (3) Parking brake engaged and disengaged. (4) Steering from full left to full right. (5) All hydraulic controls (loader control joystick and auxiliary hydraulic control). e. Operate controls for another 5 minutes. f. Move machine and operate all controls through full motion to bring all systems to operating temperature. g. Move machine and continue to operate all controls through full motion for 30 minutes AFTER machine systems have reached operating temperature. h. Stop machine and allow to idle for 5 minutes. i. Shut down engine (WP 0005 00). j. Perform After operation PMCS.

0012 00-48

NOT FULLY MISSION CAPABLE IF:

TM 5-3805-291-10 PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INCLUDING LUBRICATION INSTRUCTIONS - CONTINUED

0012 00

LUBRICATION INSTRUCTIONS

0012 00

WARNING When 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. If further 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 periods. 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, extended idling 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 covers clean and do not allow dust, dirt, or other foreign material to mix with lubricants. Keep lubrication equipment clean and ready for use.

WARNING Solvent cleaning compound MIL-PRF-680 Type III is an environmentally compliant and low toxic material. However, it may be irritating to the eyes and skin. Use protective gloves and goggles. Use in wellventilated areas. Keep away from open flames and other sources of ignition. Failure to follow this warning may 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 lubricating 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 750-8 for forms and procedures to record and report any findings.

0012 00-49

TM 5-3805-291-10 PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INCLUDING LUBRICATION INSTRUCTIONS - CONTINUED

0012 00

LUBRICATION INSTRUCTIONS – CONTINUED

NOTE Only lubricants authorized for use by the operator are listed in this KEY.

- KEYLUBRICANT/ COMPONENT

REFILL CAPACITY

EXPECTED TEMPERATURES*

D - Daily W - Weekly M - Monthly

OE/HDO Lubricating Oil, ICE, Tactical Service (MIL-PRF-2104) 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)

GAA Grease, 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

11.2 gal. (42.3 L)

See Table 3

ANTIFREEZE Cooling System

INTERVALS

* For arctic operation, refer to FM 9-207.

0012 00-50

TM 5-3805-291-10 PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INCLUDING LUBRICATION INSTRUCTIONS - CONTINUED

0012 00

LUBRICATION INSTRUCTIONS – CONTINUED

0012 00

Table 2. Lubricants. COMPARTMENT Engine

Transmission

Hydraulic

Axles

Grease

COMMERCIAL LUBRICANT CF-4 or Better

TO-4

CF or Better

TO-4

MPG NLGI

VISCOSITY GRADE SAE 5W-40

MILITARY LUBRICANT OE/HDO-5/40

TEMPERATURE RANGE -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)

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)

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

SAE 50

N/A

50oF to 120oF (10oC to 49oC)

SAE 0W-30

OEA-30

-40oF to 50oF (-40oC to 10oC)

No. 2

GAA

-25oF to 120oF (-32oC to 49oC)

-40oF to 100oF (-40oC to 38oC)

Table 3. Coolants.

Engine Coolant

I-Ethylene Glycol II-Propylene Glycol

60/40

MILITARY COOLANT A-A-52624

Engine Coolant

I-Ethylene Glycol II-Propylene Glycol

50/50

A-A-52624

COOLANT

TYPE

MIXTURE

0012 00-51

TEMPERATURE RANGE -50oF to 120oF (-46oC to 49oC)

-30oF to 120oF (-34oC to 49oC)

TM 5-3805-291-10 PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INCLUDING LUBRICATION INSTRUCTIONS - CONTINUED

0012 00

LUBRICATION INSTRUCTIONS – CONTINUED

0012 00

LUBRICANT •

INTERVAL

INTERVAL •

LUBRICANT

427-C0365

0012 00-52

TM 5-3805-291-10 PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INCLUDING LUBRICATION INSTRUCTIONS- CONTINUED

0012 00

LUBRICATION INSTRUCTIONS – CONTINUED

0012 00

LUBRICANT •

INTERVAL

INTERVAL •

LUBRICANT

427-C0366

END OF WORK PACKAGE

0012 00-53/(0012 00-54 Blank)

TM 5-3805-291-10

CHAPTER 5 MAINTENANCE INSTRUCTIONS

2 TM 5-3805-291-10

REFUELING AND FUEL SYSTEM PRIMING

0013 00

THIS WORK PACKAGE COVERS Refueling, Fuel System Priming

INITIAL SETUP Tools and Special Tools

Equipment Conditions Machine parked on level ground (WP 0005 00)

Extinguisher, fire (Item 4, Table 2, WP 0026 00)

Work tool lowered to ground (WP 0005 00)

Materials/Parts

Parking brake engaged (WP 0005 00)

Fuel (Item 5, 6, or 7, WP 0027 00)

Engine OFF (WP 0005 00)

Rag, wiping (Item 13, WP 0027 00)

Engine coolant heater OFF, if equipped with arctic operation machine (WP 0004 00)

Personnel Required MOS 21E, Heavy Construction Equipment Operator

Battery disconnect switch in OFF position (WP 0004 00)

REFUELING

0013 00

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 this warning 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 wash exposed skin and change fuel-soaked clothing. • ALWAYS stop engine prior to refueling. If equipped with an arctic cold weather starting aid system, turn engine coolant heater off.

NOTE Ensure 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 tank filler opening.

5.

Inspect filler cap for a damaged or missing gasket. If damaged or missing, contact Unit Maintenance to obtain a replacement gasket.

6.

If strainer in filler opening is filled with debris, remove debris. 0013 00-1

TM 5-3805-291-10

REFUELING AND FUEL SYSTEM PRIMING - CONTINUED

0013 00

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 to prime fuel system.

•

Fuel priming pump is located above primary fuel filter on right side of engine.

1.

Tilt hood (WP 0004 00).

2.

Turn fuel priming pump toggle switch to ON position and operate pump for approximately 60 seconds. Turn switch to OFF position.

427-C1675

3.

Start engine (WP 0005 00).

4.

Operate fuel priming pump for additional time if any of the following conditions exist:

5.

a.

Engine continues to not start.

b.

Engine starts but continues to misfire or emit smoke.

Lower hood (WP 0004 00).

END OF WORK PACKAGE 0013 00-2

4 TM 5-3805-291-10

ENGINE AIR PRECLEANER SERVICE AND AIR CLEANER SERVICE

0014 00

THIS WORK PACKAGE COVERS Service

INITIAL SETUP Equipment Conditions

Materials/Parts

Machine parked on level ground (WP 0005 00)

Rag, wiping (Item 13, WP 0027 00)

Work tool lowered to ground (WP 0005 00)

Personnel Required

Parking brake engaged (WP 0005 00) MOS 21E, Heavy Construction Equipment Operator

Engine OFF (WP 0005 00) Battery disconnect switch in OFF position (WP 0004 00)

References FM 3-11.3 FM 3-11.5

SERVICE

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, and Procedures for Chemical, Biological, Radiological, and Nuclear Decontamination. • NBC contaminated filters must be handled using adequate precautions and must be disposed of by trained personnel. • Failure to follow these warnings may cause injury or death.

CAUTION Never service air cleaner with engine running. Engine damage could result if service is performed with engine running.

0014 00-1

TM 5-3805-291-10

ENGINE AIR PRECLEANER SERVICE AND AIR CLEANER SERVICE - CONTINUED

0014 00

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.

427-C0003

5.

Clean inside of air cleaner housing with a rag.

CAUTION DO 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 any damage is evident. Obtain replacement from Unit Maintenance.

7.

If primary filter element appears OK, clean as follows:

WARNING Particles blown by compressed air are hazardous. Use a maximum of 30 psi (207 kPa) when cleaning components. DO NOT direct compressed air against human skin. Failure to follow this warning may result in injury. 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. 0014 00-2

TM 5-3805-291-10

ENGINE AIR PRECLEANER SERVICE AND AIR CLEANER SERVICE - CONTINUED

0014 00

SERVICE - CONTINUED

NOTE A 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 primary filter element if any damage is evident. Obtain replacement from Unit Maintenance.

NOTE Secondary 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.

NOTE Primary filter element should be replaced after being cleaned a maximum of six times. If primary filter element 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

0014 00-3/(0014 00-4 Blank)

2 TM 5-3805-291-10

STEERING FRAME LOCK CONNECTION AND DISCONNECTION

0015 00

THIS WORK PACKAGE COVERS General Information, Connection, Disconnection

INITIAL SETUP Equipment Conditions

Tools and Special Tools

Machine parked on level ground (WP 0005 00)

COEI (Items 2 thru 4, Table 1, WP 0026 00)

Work tool lowered to ground (WP 0005 00)

Personnel Required MOS 21E, Heavy Construction Equipment Operator (2)

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 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 servicing machine in frame articulation area. Disconnect steering frame lock and secure in stowed position before resuming operation. 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.

0015 00-1

TM 5-3805-291-10

STEERING FRAME LOCK CONNECTION AND DISCONNECTION - CONTINUED

0015 00

CONNECTION 1.

Remove retainer pin from pin.

427-C0007

2.

Move steering frame lock into position at front frame section.

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.

NOTE It may be necessary to move front frame section to align pin bores. 3.

Install pin and retainer pin.

427-C0008

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 0015 00-2

4 TM 5-3805-291-10

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 the circuit 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

CAUTION Replace 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 the element of a new fuse separates, notify Unit Maintenance.

2.

Fuses are located in cab on right side of operator seat.

427-C0367

0016 00-1

TM 5-3805-291-10

CIRCUIT BREAKER AND FUSES RESET/REPLACE - CONTINUED

0016 00

FUSE REPLACEMENT - CONTINUED Fuse Block

FUSE

RELAY

DESCRIPTION

F1

rear worklights

F2

front worklights

F3

power converter

F4

wipers

F5

seat

F6

LH brake pedal sensor/shift lever

F7

position sensors

F8

ECM switch power

F9

spare

F10

spare

F11

implement lockout/ quick coupler

F12

spare

F13

secondary steering

F14

spare

F15

spare

F16

spare

F17

spare

F18

spare

F19

spare

F20

spare

F21

power converter

F22

spare

F23

implement ECM

F24

engine ECM

FUSE

RELAY

DESCRIPTION

F25

powertrain ECM

F26

headlamps

F27

arctic heater

F28

engine start switch

F29

spare

F30

hood actuator control switch

F31

instrument cluster/ Messenger

F32

backup alarm

F33

horn

CB1

spare

CB2

hood tilt actuator

CB3

HVAC blower

D1

backlights

D2

flasher

D3

LH turnlamp

D4

RH turnlamp

0016 00-2

R1

secondary steering

R2

spare

R3

spare

R4

spare

R5

spare

R6

spare

R7

backup alarm

R8

spare

TM 5-3805-291-10

CIRCUIT BREAKER AND FUSES RESET/REPLACE - CONTINUED FUSE REPLACEMENT - CONTINUED Switched Fuse Block

FUSE

RELAY

F1

DESCRIPTION blackout switch fuse

R1

turnlamp hazard blackout

R2

horn/dome lamps blackout

R3

headlamps blackout

R4

front worklight blackout

R5

rear worklight blackout

END OF WORK PACKAGE

0016 00-3/(0016 00-4 Blank)

0016 00

TM 5-3805-291-10

CHAPTER 6 TRANSPORT PROCEDURES

2 TM 5-3805-291-10

PREPARATION FOR TRANSPORT INTRODUCTION

0017 00

INTRODUCTION 1.

2.

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)

Depending on mode of transportation selected, assistance from Unit Maintenance may be required to configure the machine for transport (WP 0024 00).

LIFT AND TIEDOWN PROVISIONS

0017 00

NOTE The following illustration shows the location of lift and tiedown points on the machine.

427-C1383

To lift loader, raise loader arm to level position, install shackle and slings, and lift machine. After machine is lowered onto ground or transport item, remove shackle and slings, and lower loader arm until work tool is on ground or transport item surface. END OF WORK PACKAGE

0017 00-1/(0017 00-2 Blank)

2 TM 5-3805-291-10

ROADING MACHINE (SELF-DEPLOYMENT)

0018 00

THIS WORK PACKAGE COVERS Roading Machine

INITIAL SETUP Personnel Required

References

MOS 21E, Heavy Construction Equipment Operator

WP 0004 00 WP 0011 00 WP 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)

WARNING If operating machine without work tool attached, front end of machine is light and therefore susceptible to overturning. When driving without work tool attached to loader arm, drive slowly and DO NOT make sharp turns. Failure to follow this warning may cause injury or death to personnel or damage to 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 components 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

0018 00-1/(0018 00-2 Blank)

4 TM 5-3805-291-10

HIGHWAY TRANSPORT

0019 00

THIS WORK PACKAGE COVERS Introduction, Configure Machine for Highway Transport, Loading Machine on Trailer, Unloading Machine from Trailer, Return Machine to Operational Configuration

INITIAL SETUP Tools and Special Tools

Personnel Required MOS 21E, Heavy Construction Equipment Operator (2)

Cord, elastic (Item 1, Table 2, WP 0026 00) Plug (Item 6, Table 2, WP 0026 00)

References

Plug-electrical (Item 7, Table 2, WP 0026 00)

WP 0004 00

Tarp (Item 10, Table 2, WP 0026 00)

WP 0005 00 WP 0015 00

Materials/Parts

WP 0017 00

Tape, duct (Item 16, WP 0027 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 gear forward or reverse ONLY. Machine has no rollover/falling object protection without ROPS/FOPS. Failure to follow this warning may cause injury or death to personnel or damage to equipment.

5.

As part of this procedure, the top portion of the ROPS/FOPS cab is removed from machine. Operation of the machine without ROPS/FOPS, to drive on and off the trailer, is required. 0019 00-1

TM 5-3805-291-10

HIGHWAY TRANSPORT - CONTINUED

0019 00

INTRODUCTION - CONTINUED

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.

6.

Throughout procedure, be aware of potential hazards from frame articulation area. Stand clear of frame articulation area when machine is operating.

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 to personnel 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 1.

0019 00

Chock wheels of trailer.

WARNING Backup alarm does not work with ROPS/FOPS removed. Failure to follow this warning may result in injury 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.

6.

Turn engine start switch to ON position and leave it there for 30 seconds.

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.

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). 0019 00-2

TM 5-3805-291-10

HIGHWAY TRANSPORT - CONTINUED

0019 00

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 warning may 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).

WARNING Connect steering frame lock between front and rear frames before transporting machine. DO NOT operate machine with steering frame lock connected. Failure to follow this warning may result in injury or death to personnel 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 HOLD position (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 equipment damage in transit. • Exhaust opening must be taped closed to prevent wind from entering exhaust system and causing turbocharger to spin, without the benefit of lubrication. Failure to cover exhaust opening may damage turbocharger.

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 of tiedown 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. 0019 00-3

TM 5-3805-291-10

HIGHWAY TRANSPORT - CONTINUED

0019 00

UNLOADING MACHINE FROM TRAILER - CONTINUED

0019 00

5.

Remove vandalism protection devices.

6.

Remove tape from exhaust opening.

WARNING 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 warning may result in injury or death to personnel or damage to equipment.

7.

Disconnect and securely stow steering frame lock (WP 0015 00).

8.

Turn battery disconnect switch to ON position (WP 0004 00).

9.

Turn engine start switch to ON position and leave it there for 30 seconds.

10.

Turn engine start switch to OFF position and leave it there for 30 seconds.

11.

Turn engine start switch to ON position and leave it there for 30 seconds.

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.

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 from under 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 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 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).

17.

Shut down engine (WP 0005 00).

18.

Turn battery disconnect switch to OFF position (WP 0004 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 Refer to WP 0024 00. END OF WORK PACKAGE 0019 00-4

0019 00

6 TM 5-3805-291-10

RAIL TRANSPORT

0020 00

THIS WORK PACKAGE COVERS Introduction, Loading Machine on Flatcar, Unloading Machine from Flatcar

INITIAL SETUP Tools and Special Tools

References

Cord, elastic (Item 1, Table 2, WP 0026 00)

WP 0004 00

Plug (Item 6, Table 2, WP 0026 00)

WP 0005 00

Plug-electrical (Item 7, Table 2, WP 0026 00)

WP 0011 00

Tarp (Item 10, Table 2, WP 0026 00) WP 0012 00 Materials/Parts

WP 0015 00

Tape, duct (Item 16, WP 0027 00) WP 0017 00 Personnel Required MOS 21E, Heavy Construction Equipment Operator (2)

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 the Continental United States (CONUS), Canada, and Mexico. The machine is most often loaded/unloaded on a rail flatcar using drive-on/drive-off procedures at the railhead.

2.

CONUS rail transport is governed by Association of American Railroads (AAR) regulations.

WARNING • Hearing protection is required if within 20 ft (6 m) of an operating machine. Hearing protection is also required when operating without 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 gear forward or reverse ONLY. Machine has no rollover/falling object protection without ROPS/FOPS. Failure to follow this warning may cause injury or death to personnel or damage to 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 removed from machine to meet height requirements. Refer to WP 0024 00 (Configure Machine for Transport) for procedures to remove ROPS/FOPS, exhaust stack, and rear handrails. 0020 00-1

TM 5-3805-291-10

RAIL TRANSPORT - CONTINUED

0020 00

INTRODUCTION - CONTINUED 4.

To remove front handrails, remove three bolts (1), washers (2), and front handrail (3). Repeat for other side. (Reverse procedure to install front handrails.)

5.

Before transporting machine, check with proper authorities to obtain any necessary permits or licenses.

6.

Ensure cooling system of machine has proper antifreeze protection if being transported to a colder climate.

7.

Safest rail transport is with fuel tank as close to empty as possible. Rail transport with fuel tank more than three-quarters full is prohibited.

427-C1572

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. 8.

Throughout procedure, be aware of potential hazards from frame articulation area. Stand clear of frame articulation area when machine is operating.

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 to personnel or damage to equipment.

9.

Ground guide assistance is MANDATORY when driving machine on or off flatcar.

LOADING MACHINE ON FLATCAR 1.

0020 00

Chock wheels of flatcar.

WARNING Backup alarm does not work with ROPS/FOPS removed. Failure to follow this warning may result in injury 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. 0020 00-2

TM 5-3805-291-10

RAIL TRANSPORT - CONTINUED

0020 00

LOADING MACHINE ON FLATCAR - CONTINUED

0020 00

5.

Turn engine start switch to OFF position and leave it there for 30 seconds.

6.

Turn engine start switch to ON position and leave it there for 30 seconds.

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. 7.

Start loader engine and allow to warm up (WP 0005 00).

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 or death to personnel or damage to equipment. • When driving machine onto 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.

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 direction.

10.

Once machine is correctly positioned on flatcar bed, lower loader arm (WP 0004 00). Rest work tool on blocking.

11.

Place transmission in N (NEUTRAL) and engage parking brake (WP 0004 00).

12.

Shut down engine (WP 0005 00).

13.

Connect steering frame lock between front and rear frames (WP 0015 00).

WARNING Connect steering frame lock between front and rear frames before transporting machine. DO NOT operate machine with steering frame lock connected. Failure to follow this warning may result in injury or death to personnel or damage to equipment. 14.

Move hydraulic control levers through all positions to relieve hydraulic system pressure in lines. Return levers to HOLD position (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). 0020 00-3

TM 5-3805-291-10

RAIL TRANSPORT - CONTINUED

0020 00

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 equipment damage in transit. • Exhaust pipe must be taped closed to prevent wind from entering exhaust system and causing turbocharger to spin, 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.

18.

Secure machine against vandalism.

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 illustration of tiedown points in WP 0017 00 and instructions in WP 0021 00.

UNLOADING MACHINE FROM FLATCAR 1.

Chock wheels of flatcar.

2.

Remove blocking and tiedowns from machine.

3.

Remove tarp and plugs.

4.

Remove vandalism protection devices.

5.

Remove tape from exhaust pipe.

0020 00

WARNING 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 warning may result in injury or death to personnel or damage to equipment.

6.

Disconnect and securely stow steering frame lock (WP 0015 00).

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.

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.

10.

Start engine and allow to warm up (WP 0005 00).

11.

Press bottom of hydraulic lockout (IMPLEMENT DISABLE) switch to unlock hydraulic controls (WP 0004 00).

12.

Raise loader arm (WP 0004 00). Remove blocking from under work tool. 0020 00-4

TM 5-3805-291-10

RAIL TRANSPORT - CONTINUED

0020 00

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 railhead. a.

Use 1st gear ONLY.

b.

When passing over spanners between flatcars, maintain a constant speed. DO NOT jam on brakes or reverse direction.

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

0020 00-5/(0020 00-6 Blank)

4 TM 5-3805-291-10

RAIL TIEDOWN PROCEDURES ON A DODX RAIL CAR

0021 00

THIS WORK PACKAGE COVERS 966H with Broom Attachment and Fork Carriage/5-Yard Bucket

INITIAL SETUP Personnel Required

Tools and Special Tools

MOS 21E, Heavy Construction Equipment Operator (2)

1/2-in. wire steel cables (3) 1/2-in. cable clamps (AR)

References

3/4-in. sheet of plywood

WP 0005 00

Tiedown chains (AR)

WP 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/utility) 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.

NOTE The 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 the cable through the carriage above the lower crossmember (Figure 1) and underneath the bucket. Pull the ends of the cable tight and secure the ends of the cable together with a minimum of four 1/2-in. cable clamps. This keeps the fork carriage and 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 bucket and 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 45degree 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).

0021 00-1

TM 5-3805-291-10

RAIL TIEDOWN PROCEDURES ON A DODX RAIL CAR - CONTINUED

0021 00

966H WITH BROOM ATTACHMENT AND FORK CARRIAGE/5-YARD BUCKET - CONTINUED

CAUTION The broom cannot be transported by itself; it must always be attached to the 966H Wheel Loader since it does not have tiedown provisions.

8.

The 966H can also be shipped without the cab, if necessary, to accommodate low tunnels or overpasses. Remove the cab from the machine in accordance with the instructions WP 0024 00. The machine’s exhaust stack and rear handrails must also be removed. The front handrails must temporarily be removed in order to remove the front cab retaining bolts; the front handrails should be reinstalled after removal of the upper cab assembly. It is recommended that plugs be installed on the electrical interconnect cables (4 each) to prevent damage during shipment along with taping the exhaust port. The rear handrails and exhaust can be placed and secured in the cab using large plastic wire ties. Ensure the cab components are 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.

427-C2037

Figure 1. Rear tiedowns on the fork and bucket of the FOL. Note the cabling connecting the bucket and fork.

0021 00-2

TM 5-3805-291-10

RAIL TIEDOWN PROCEDURES ON A DODX RAIL CAR - CONTINUED

0021 00

966H WITH BROOM ATTACHMENT AND FORK CARRIAGE/5-YARD BUCKET - CONTINUED

427-C2038

Figure 2. FOL front roadside tiedowns.

427-C2040

Figure 3. FOL rear tiedowns.

0021 00-3

TM 5-3805-291-10

RAIL TIEDOWN PROCEDURES ON A DODX RAIL CAR - CONTINUED

0021 00

966H WITH BROOM ATTACHMENT AND FORK CARRIAGE/5-YARD BUCKET - CONTINUED

427-C2039

Figure 4. FOL cab detached from machine and secured on car. END OF WORK PACKAGE

0021 00-4

4 TM 5-3805-291-10

MARINE TRANSPORT (RO/RO PROCEDURES)

0022 00

THIS WORK PACKAGE COVERS Introduction, RO/RO Regulations, Loading Machine on Ship, Unloading Machine from Ship

INITIAL SETUP Personnel Required

References - Continued

MOS 21E, Heavy Construction Equipment Operator (2) References

WP 0005 00 WP 0011 00 WP 0012 00

WP 0004 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 and unloading 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 accomplished by 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 of personnel and obstructions before moving. Failure to follow this warning may result in injury or death to personnel 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 MANDATORY 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 regulations and procedures. 0022 00-1

TM 5-3805-291-10

MARINE TRANSPORT (RO/RO PROCEDURES) - CONTINUED

0022 00

RO/RO REGULATIONS

0022 00

WARNING Safe RO/RO operation depends on strict adherence to RO/RO regulations. Failure to do so may result in injury or death to personnel or damage to equipment.

1.

Only qualified and screened operators are permitted to drive machine in RO/RO operations.

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

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) port call message.

LOADING MACHINE ON SHIP

0022 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.

1.

Start loader engine and allow to warm up (WP 0005 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 to follow 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. 0022 00-2

TM 5-3805-291-10

MARINE TRANSPORT (RO/RO PROCEDURES) - CONTINUED

0022 00

LOADING MACHINE ON SHIP - CONTINUED

0022 00

WARNING Connect steering frame lock between front and rear frames before transporting machine. DO NOT operate machine with steering frame lock connected. Failure to follow this warning may result in injury or death to personnel or damage to equipment.

5.

Lower loader arm (WP 0004 00). Rest on shoring.

6.

Place transmission in N (NEUTRAL) and engage parking brake (WP 0004 00).

7.

Shut down engine (WP 0005 00).

8.

Connect steering frame lock between front and rear frames (WP 0015 00).

9.

Move hydraulic control levers through all positions to relieve hydraulic system pressure in lines. Return levers to HOLD position (WP 0005 00).

10.

Press top of hydraulic lockout (IMPLEMENT DISABLE) switch to lock hydraulic controls (WP 0004 00).

11.

Turn battery disconnect switch to OFF position (WP 0004 00).

12.

Secure machine against vandalism.

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.

2.

Remove vandalism protection devices.

WARNING 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 warning may result in injury or death to personnel or damage to equipment.

3.

Disconnect and securely stow steering frame lock (WP 0015 00).

4.

Turn battery disconnect switch to ON position (WP 0004 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.

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 ship ramps (WP 0004 00). Remove blocking from under loader arm. 0022 00-3

TM 5-3805-291-10

MARINE TRANSPORT (RO/RO PROCEDURES) - CONTINUED

0022 00

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

0022 00-4

4 TM 5-3805-291-10

AIR TRANSPORT BY C-5 AND C-17 AIRCRAFT

0023 00

THIS WORK PACKAGE COVERS Introduction, Load Machine, Unload Machine

INITIAL SETUP Personnel Required

References

MOS 21E, Heavy Construction Equipment Operator (2)

WP 0004 00 WP 0005 00 WP 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.

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

5.

Throughout procedure, be aware of potential hazards from frame articulation area. Stand clear of frame articulation area when machine is operating.

0023 00-1

TM 5-3805-291-10

AIR TRANSPORT BY C-5 AND C-17 AIRCRAFT - CONTINUED

0023 00

LOAD MACHINE

0023 00

WARNING Always use a ground guide when operating machine up ramp to load onto aircraft. Failure to use a ground guide 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).

WARNING Connect steering frame lock between front and rear frames before transporting machine. DO NOT operate machine with steering frame lock connected. Failure to follow this warning may result in injury or death to personnel or damage to equipment.

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.

0023 00-2

TM 5-3805-291-10

AIR TRANSPORT BY C-5 AND C-17 AIRCRAFT - CONTINUED

0023 00

UNLOAD MACHINE

0023 00

1.

Remove blocking and tiedowns from machine.

2.

Remove vandalism protection devices.

WARNING 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 warning may result in injury or death to personnel or damage to equipment.

3.

Disconnect and securely stow steering frame lock (WP 0015 00).

4.

Turn battery disconnect switch to ON position (WP 0004 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.

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.

WARNING Always use a ground guide when operating machine down ramp to unload from aircraft. Failure to use a ground 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

0023 00-3/(0023 00-4 Blank)

10 TM 5-3805-291-10

CONFIGURE MACHINE FOR TRANSPORT

0024 00

THIS WORK PACKAGE COVERS Introduction, Tools and Equipment, ROPS/FOPS Removal, Exhaust Stack Removal, Rear Handrail Removal, Rear Handrail Installation, Exhaust Stack Installation, ROPS/FOPS Installation

INITIAL SETUP References

Tools and Special Tools Basic Issue Items (Table 2, WP 0026 00)

WP 0004 00

Notify Unit Maintenance to bring general mechanic’s tool kit, common no. 1 shop equipment, and field maintenance shop equipment Lifting equipment, 1,500-lb capacity

WP 0011 00 WP 0012 00 WP 0019 00

Materials/Parts

WP 0020 00

Grease (Item 8, WP 0027 00) Equipment Conditions

Tag, marker (Item 15, WP 0027 00)

Work tool removed (WP 0005 00)

Personnel Required MOS 2IE, Heavy Construction Equipment Operator

Machine parked on level ground (WP 0005 00)

MOS 62B, Construction Equipment Repairer (2)

Parking brake engaged (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.

NOTE These procedures are included in this manual as a reference. This does not authorize performance by the operator.

2.

Assistance from two Unit Maintenance mechanics is required to configure the machine for transport.

0024 00-1

TM 5-3805-291-10

CONFIGURE MACHINE FOR TRANSPORT - CONTINUED

0024 00

INTRODUCTION - CONTINUED

WARNING Use extreme caution when handling heavy parts. Provide adequate support and use assistance during procedure. Ensure any lifting device used is in good condition and of lifting capacity. Keep clear of heavy parts supported 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 work practices when handling them. Lifting equipment available at the staging area must be used.

TOOLS AND EQUIPMENT 1.

2.

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 maintenance shop equipment); and

c.

1,500-lb capacity lifting equipment.

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.

0024 00-2

TM 5-3805-291-10

CONFIGURE MACHINE FOR TRANSPORT - CONTINUED

0024 00

ROPS/FOPS REMOVAL - CONTINUED

0024 00

WARNING Use extreme caution when handling heavy parts. Provide adequate support and use assistance during procedure. Ensure any lifting device used is in good condition and of suitable lift capacity. Keep clear of heavy parts supported only by lifting device. Failure to follow this warning may result in injury or death to personnel.

7.

Remove four bolts (2, 3, 4, and 5) located on the cab exterior. Place bolts in lower half of cab.

427-C0463

427-C0464

427-C0466

8.

Retract spring-loaded front and rear wiper arms by pulling away from glass. Use elastic cords (Item 1, Table 2, WP 0026 00) to keep wiper arms away from cab. 0024 00-3

TM 5-3805-291-10

CONFIGURE MACHINE FOR TRANSPORT - CONTINUED

0024 00

ROPS/FOPS REMOVAL - CONTINUED

0024 00

WARNING DO NOT remove exhaust stack until it has cooled to the touch. Wear gloves and protective clothing to guard against burns. Failure to follow this warning may result in injury to personnel.

NOTE ROPS/FOPS weighs 1,000 lb (454 kg). 9.

Attach lifting device to four lift points (A) on ROPS/ FOPS roof brackets.

427-C1975

10.

Close cab door securely.

11.

Slide deadbolt latch upward on left-side cab door to separate upper and lower door sections.

CAUTION Ensure ROPS/FOPS is lifted straight up until fully clear of operator station. Failure to do so could result in damage 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.

0024 00-4

TM 5-3805-291-10

CONFIGURE MACHINE FOR TRANSPORT - CONTINUED

0024 00

EXHAUST STACK REMOVAL

0024 00

Loosen bolt (6) and remove clamp (7) and exhaust stack (8).

427-C0066

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 and secure with velcro strap.

3.

Secure top portion of ROPS/FOPS cab to shipping pallet 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-C1571

0024 00-5

TM 5-3805-291-10

CONFIGURE MACHINE FOR TRANSPORT - CONTINUED

0024 00

REAR HANDRAIL INSTALLATION

0024 00

1.

Remove tarp.

2.

Install rear handrail (11), six washers (10), and bolts (9). Repeat for other side.

427-C1571

EXHAUST STACK INSTALLATION

0024 00

NOTE Exhaust 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-C0066

0024 00-6

TM 5-3805-291-10

CONFIGURE MACHINE FOR TRANSPORT - CONTINUED

0024 00

ROPS/FOPS INSTALLATION - CONTINUED

0024 00

WARNING Use extreme caution when handling heavy parts. Provide adequate support and use assistance during procedure. Ensure any lifting device used is in good condition and of suitable lift capacity. Keep clear of heavy parts supported only by lifting device. Failure to follow this warning may result in death or injury to personnel.

NOTE ROPS/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 from pallet.

b.

Apply GAA grease (Item 8, WP 0027 00) to four alignment legs.

427-C1595

0024 00-7

TM 5-3805-291-10

CONFIGURE MACHINE FOR TRANSPORT - CONTINUED

0024 00

ROPS/FOPS INSTALLATION - CONTINUED

0024 00

CAUTION Ensure top portion of ROPS/FOPS cab is lowered straight down until fully seated on lower. Failure to do so could 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.

NOTE Movement in wedge pins is normal during installation of bolts.

e.

Loosely install four bolts (2, 3, 4, and 5) at each corner of cab.

f.

Tighten four bolts (2, 3, 4, and 5) at corners of cab.

427-C0466

427-C0464

427-C0463

0024 00-8

TM 5-3805-291-10

CONFIGURE MACHINE FOR TRANSPORT - CONTINUED

0024 00

ROPS/FOPS INSTALLATION - CONTINUED

0024 00

g.

Remove three sets of plugs and connect four connectors (three electrical and one coaxial) (1) at right-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 00-9/(0024 00-10 Blank)

0024 00

TM 5-3805-291-10

CHAPTER 7 SUPPORTING INFORMATION

2 TM 5-3805-291-10

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 relating to material covered in this technical manual. Consolidated Index of Army Publications and Blank Forms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DA PAM 25-30 The Army Maintenance Management System (TAMMS) Users Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DA PAM 750-8 FORMS

NOTE Refer to DA PAM 750-8, The Army Maintenance Management System (TAMMS) Users Manual, for instructions on the use of maintenance forms.

Equipment Inspection and Maintenance Worksheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .DA Form 2404, DA Form 5988-E Product Quality Deficiency Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SF Form 368 Recommended Changes to Publications and Blank Forms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DA Form 2028 FIELD MANUALS Basic Cold Weather Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 31-70 Desert Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 90-3 First Aid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 4-25.11 Manual for the Wheeled Vehicle Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 21-305 Multiservice Tactics, Techniques, and Procedures for Chemical, Biological, Radiological, and Nuclear Contamination Avoidance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 3-11.3 Multiservice Tactics, Techniques, and Procedures for Chemical, Biological, Radiological, and Nuclear Decontamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 3-11.5 Northern Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 31-71 Operation 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 3-4230-236-10 Operator’s, Unit, Direct Support, and General Support Maintenance Manual for Lead-Acid Storage Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 9-6140-200-14 Procedures for Destruction of Equipment to Prevent Enemy Use (Mobility Equipment Command) . . . . . . . . . TM 750-244-3 OTHER PUBLICATIONS Abbreviations and Acronyms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASME Y14.38-1999 Army Medical Department Expendable/Durable Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CTA 8-100 Department of Defense Interface Standard for Lifting and Tiedown Provisions . . . . . . . . . . . . . . . . . . . . . . . . MIL-STD-209K Expendable/Durable Items (Except Medical, Class V, Repair Parts, and Heraldic Items) . . . . . . . . . . . . . . . . . . . . CTA 50-970 END OF WORK PACKAGE 0025 00-1/(0025 00-2 Blank)

6 TM 5-3805-291-10

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 efficient 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 shipment. As part of the end item, these items must be with the end item whenever it is issued or transferred between property accounts. 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 operate it and to perform emergency repairs. Although shipped separately packaged, BII must be with the loader during operation and whenever it is transferred between property accounts. This manual is your authority to request/requisition replacement BII, based on TOE/MTOE authorization of end item. Illustrations are furnished to assist you in identifying the items.

EXPLANATION OF COLUMNS 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 the Commercial 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 in Column (2).

6.

Column (6) - Quantity Required (Qty Rqd). Indicates the quantity of the item required.

0026 00-1

TM 5-3805-291-10

COMPONENTS OF END ITEM (COEI) AND BASIC ISSUE ITEMS (BII) LISTS - CONTINUED

0026 00

Table 1. Components of End Item List.

427-C1573

(1)

(2)

(3)

(4)

(5)

(6)

ILLUS NUMBER

NATIONAL STOCK NUMBER

DESCRIPTION, CAGEC, AND PART NUMBER

USABLE ON CODE

U/M

QTY RQD

1

CYLINDER, ETHER (11083) 275-3634

EA

1

2

LINK, STEERING LOCK (11083) 127-1579

EA

1

3

PIN (11083) 80-3791

EA

2

PIN, STRAIGHT-HEADED (11083) 5V-6380

EA

2

4

5315-01-162-8738

0026 00-2

TM 5-3805-291-10

COMPONENTS OF END ITEM (COEI) AND BASIC ISSUE ITEMS (BII) LISTS - CONTINUED

0026 00

Table 2. Basic Issue Items List.

427-C1574-1

(1)

(2)

(3)

(4)

(5)

(6)

ILLUS NUMBER

NATIONAL STOCK NUMBER

DESCRIPTION, CAGEC, AND PART NUMBER

USABLE ON CODE

U/M

QTY RQD

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

0026 00-3

TM 5-3805-291-10

COMPONENTS OF END ITEM (COEI) AND BASIC ISSUE ITEMS (BII) LISTS - CONTINUED

0026 00

Table 2. Basic Issue Items List - Continued.

427-C1574-2

(1)

(2)

(3)

(4)

(5)

(6)

Illus Number

National Stock Number

Description, CAGEC, and Part Number

Usable on Code

U/M

Qty Rqd

6

PLUG, ELECTRICAL CAP (11083) 246-2932

EA

3

7

PLUG-CONNECTOR, ELECTRICAL CAP FOR HARNESS (11083) 268-8749

EA

3

RATCHET: 8 in., 3/8 in. drive (11083) 239-6824

EA

1

SOCKET: 11 mm, 3/8 in. drive (11083) 194-3490

EA

1

8 9

5120-01-535-2969

0026 00-4

TM 5-3805-291-10

COMPONENTS OF END ITEM (COEI) AND BASIC ISSUE ITEMS (BII) LISTS - CONTINUED

0026 00

Table 2. Basic Issue Items List - Continued.

427-C2015

(1)

(2)

(3)

(4)

(5)

(6)

Illus Number

National Stock Number

Description, CAGEC, and Part Number

Usable on Code

U/M

Qty Rqd

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

END OF WORK PACKAGE

0026 00-5/(0026 00-6 Blank)

4 TM 5-3805-291-10

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 to you 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. EXPLANATION OF COLUMNS 1.

Column (1) - Item Number. This number is referenced in the appropriate work package Initial Setup list or in the narrative 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 requisition it.

4.

Column (4) - Description, CAGEC, and Part Number. This provides the other information you need to identify the item.

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.

0027 00-1

TM 5-3805-291-10

EXPENDABLE AND DURABLE ITEMS LIST - CONTINUED

0027 00

(1)

(2)

(3)

(4)

(5)

ITEM NUMBER

LEVEL

NATIONAL STOCK NUMBER

DESCRIPTION, CAGEC, AND PART NUMBER

U/M

1

C

ANTIFREEZE 6850-01-383-4068 6850-01-441-3257 6850-01-383-3918

2

C

C

C

C

C

C

DR

1 Gallon Can 5 Gallon Can 55 Gallon Drum

CN CN DR

16 Ounce Bottle

BT

1 Gallon Can

CN

Bulk 5 Gallon Can 55 Gallon Drum

GL CN DR

DIESEL FUEL: DF-2 Grade (81346) ASTM D 975 9140-00-286-5294 9140-00-286-5295 9140-00-286-5296

7

(58536) A-A-52624 55 Gallon Drum

DIESEL FUEL: DF-1 Grade, Arctic (81346) ASTM D 975 9140-00-286-5286 9140-00-286-5287 9140-00-286-5288

6

CN

DETERGENT: General Purpose, Liquid (83421) 7930-00-282-9699 7930-00-282-9699

5

(58536) A-A-52624 5 Gallon Can

CLEANING COMPOUND: Windshield (0FTT5) 0854-000 6850-00-926-2275

4

GL

CLEANING COMPOUND: Solvent, Type III (81349) MIL-PRF-680 6850-01-474-2318 6850-01-474-2320 6850-01-474-2321

3

(1QK63) 672 4354 1 Gallon Bottle

9130-01-031-5816

Bulk 5 Gallon Can 55 Gallon Drum FUEL, TURBINE: Aviation (81349) MIL-T-83133 GR JP-8

0027 00-2

GL CN DR GL

TM 5-3805-291-10

EXPENDABLE AND DURABLE ITEMS LIST - CONTINUED

0027 00

(1)

(2)

(3)

(4)

(5)

ITEM NUMBER

LEVEL

NATIONAL STOCK NUMBER

DESCRIPTION, CAGEC, AND PART NUMBER

U/M

8

C

GREASE: Automotive and Artillery (GAA) 9150-01-197-7688 9150-01-197-7693 9150-01-197-7690 9150-01-197-7692

9

C

C

C

9150-00-402-2372 9150-01-491-7197 C

(81349) M-10924-C 1-3/4 Pound Can

CN

(81349) M-10924-E 35 Pound Can

CN

55 Gallon Drum

DR

1 Quart Can 5 Gallon Can 55 Gallon Drum

CN CN DR

(81349) MIL-L-46167 1 Quart Can (81349) MIL-PRF-46167 5 Gallon Can (81349) MIL-PRF-46167 55 Gallon Drum

QT GL DR

OIL: Lubricating, OE/HDO-5/40 (81349) MIL-PRF-2104 9150-01-524-9155

13

CA

OIL: Lubricating, OEA-30 Arctic 9150-00-402-4478

12

(81349) M-10924-B 14 Ounce Cartridge

OIL: Lubricating, OE/HDO-15/40 (81349) MIL-PRF-2104 9150-01-152-4117 9150-01-152-4118 9150-01-152-4119

11

TU

OIL: Lubricating, OE/HDO-40 (81349) MIL-PRF-2104 9150-00-188-9862

10

(81349) M-10924-A 1-1/4 Ounce Tube

C

55 Gallon Drum

GL

RAG: Wiping (64067) 7920-00-205-1711 7920-00-205-1711

50 Pound Bale

0027 00-3

BL

TM 5-3805-291-10

EXPENDABLE AND DURABLE ITEMS LIST - CONTINUED

0027 00

(1)

(2)

(3)

(4)

(5)

ITEM NUMBER

LEVEL

NATIONAL STOCK NUMBER

DESCRIPTION, CAGEC, AND PART NUMBER

U/M

14

C

STRAP, TIEDOWN, ELECTRICAL COMPONENTS 5975-00-903-2284 5975-00-984-6582 5975-00-935-5946

15

C

C

C

6 Inch Length, Black, Package of 100 (96906) MS3367-1-0

HD

13.35 Inch Minimum Length, Brown (96906) MS3367-2-1

EA

Bundle of 50

BD

TAPE: Duct, 2 in. Wide (39482) 1791K70 5640-00-103-2254

17

HD

TAG, MARKER (64067) 9905-00-537-8954 9905-00-537-8954

16

4 Inch Length, Black, Package of 100 (96906) MS3367-4-0

6850-01-154-3653

60 Yard Roll TEST STRIPS, NITRATE (89524) 500P3205.88

END OF WORK PACKAGE

0027 00-4

RL EA

TM 5-3805-291-10

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. These items are all authorized to you by CTA, MTOE, TDA, or JTA. EXPLANATION OF COLUMNS 1.

Column (1) - National Stock Number (NSN). Identifies the stock number of the item to be used for requisitioning purposes.

2.

Column (2) - Description, Commercial and Government Entity Code (CAGEC), and Part Number (P/N). Identifies the Federal item name (in all capital letters) followed by a minimum description when needed. The line below the description 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 different models 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 NSN shown in column (1).

5.

Column (4) - Quantity Recommended (QTY RECM). Indicates the quantity recommended. Table 1. AAL for the 966H Wheel Loader. (1)

(2)

(3)

NSN

DESCRIPTION, CAGEC, P/N

USABLE ON CODE

5340-01-466-5928

4230-01-466-9095

(4)

(5) QTY

U/I

RECM

SORBENT DECONTAMINATION SYSTEM (SDS) MOUNTING BRACKET (4X630) 8640-100-0001

EA

1

SDS (81361) EA-PRF-2163

EA

1

END OF WORK PACKAGE

0028 00-1/(0028 00-2 Blank)

TM 5-3805-291-10

INDEX Subject

Work Package/Page

A Abbreviations/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

Attachment Broom, 966H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fork Carriage/5-yard Bucket, 966H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0021 00-1 0021 00-1

Auxiliary Hydraulic Control for Fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sweeper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0004 00-20 0004 00-20

B Basic 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

Bucket Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kickout Set Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0002 00-14 0004 00-22 0004 00-18

C Cab 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

D Data 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

Index-1

TM 5-3805-291-10

INDEX - Continued Subject

Work Package/Page

E Electrical Stopping Engine if Malfunction Occurs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . System, Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0005 00-8 0003 00-2

Engine Air Cleaner Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Precleaner Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Coolant Level (PMCS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Level (PMCS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Start Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0014 00-1 0014 00-1 0012 00-6 0012 00-10 0005 00-3 0004 00-17 0003 00-1

Equipment Characteristics, Capabilities, and Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Improvement Recommendations (EIRs), Reporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0002 00-1 0002 00-9 0001 00-1

Ether Starting Aid System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starting Aid System (PMCS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0004 00-29 0012 00-8

Exhaust Stack Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0024 00-6 0024 00-5

Expendable and Durable Items List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0027 00-1

Extreme Cold, Operate in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heat, Operate in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0006 00-7 0006 00-10

F Fire 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

H Heating Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0004 00-15

Highway Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0019 00-1

Hood Tilt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tilt - Manual Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0004 00-26 0004 00-26

Index-2

TM 5-3805-291-10

INDEX - Continued Subject

Work Package/Page

Hydraulic Control Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0004 00-11

Hydraulic System Relieving Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0005 00-10 0003 00-2

I Initial Adjustments and Daily Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0005 00-2

L Lift and Tiedown Provisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0017 00-1

Lift Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0004 00-21

Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0004 00-12

List Abbreviations/Acronyms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Basic Issue Items (BII) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Components of End Item (COEI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0001 00-2 0026 00-1 0026 00-1

Loader Arm, Lowering with Engine Stopped . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0005 00-8

Loader Arms Down on Dead Machine Recovery Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . .

0006 00-5

Loading Machine on Flatcar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Machine on Ship . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Machine on Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0020 00-2 0022 00-2 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

M Machine Load onto C-5 and C-17 Aircraft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Loading on Flatcar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Loading on Ship . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Loading on Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mounting and Dismounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Roading (Self-Deployment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Slave Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Unload from C-5 and C-7 Aircraft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Unloading from Flatcar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Unloading From Ship . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Unloading from Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index-3

0023 00-2 0020 00-2 0022 00-2 0019 00-2 0005 00-2 0005 00-5 0005 00-7 0018 00-1 0006 00-2 0005 00-6 0006 00-3 0023 00-3 0020 00-4 0022 00-3 0019 00-3

TM 5-3805-291-10

INDEX - Continued Subject

Work Package/Page

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

O Operate At High Altitudes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Decontamination Apparatus, Portable (DAP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . In Extreme Cold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . In Extreme Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . In Mud or Soft Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . In Saltwater Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . In Sandy or Dusty Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . In Snow and Ice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . On Slopes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Work Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0006 00-13 0006 00-14 0006 00-7 0006 00-10 0006 00-12 0006 00-12 0006 00-12 0006 00-13 0005 00-5 0005 00-6 0005 00-15

P Parking Brake Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brake Manual Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0004 00-16 0006 00-6 0005 00-7

Platform and Top of Machine (PMCS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0012 00-30

PMCS After . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Articulation Bearings (Weekly) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Before . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cab Air Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Coolant Nitrites Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . During . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Monthly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Platform and Top of Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Weekly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0012 00-21 0012 00-42 0012 00-2 0012 00-33 0012 00-44 0012 00-20 0011 00-1 0012 00-43 0012 00-30 0012 00-1 0012 00-33

Portable Fire Extinguisher Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0005 00-17

Index-4

TM 5-3805-291-10

INDEX - Continued Subject

Work Package/Page

Powertrain, Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0003 00-1

Preparation for Storage or Shipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0001 00-1

Q Quick Coupler Manually Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0006 00-5 0005 00-11

R Rail Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0020 00-1

Rail Tiedown Procedures On A DODX Rail Car . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0021 00-1

Rear Handrail Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0024 00-6 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/FOPS Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0024 00-6 0024 00-2

S Sandy 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

Steering Frame Lock Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Frame Lock Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0015 00-1 0015 00-1 0005 00-6

Stopping Engine if an Electrical Malfunction Occurs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0005 00-8

Index-5

TM 5-3805-291-10

INDEX - Continued Subject

Work Package/Page

Storage or Shipment, Preparation for . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0001 00-1

T Theory of Operation Brake Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Powertrain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ride Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Work Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0003 00-2 0003 00-2 0003 00-1 0003 00-2 0003 00-1 0003 00-3 0003 00-3

Throttle Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0004 00-11

Towing Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0006 00-3

Transmission Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Neutralizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0004 00-7 0004 00-10

Transport Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Highway . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Marine (RO/RO Procedures) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0023 00-1 0019 00-1 0022 00-1 0020 00-1

Troubleshooting Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Symptom Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0008 00-1 0010 00-1 0009 00-1

U Unloading Machine from Aircraft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Machine from Flatcar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Machine from Ship . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Machine from Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0023 00-3 0020 00-4 0022 00-3 0019 00-3

W Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0001 00-1

Windshield Wiper Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0004 00-14

Work Tools Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0005 00-15 0003 00-3

Index-6

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).

TO: (Forward to proponent of publication or form) (Include ZIP Code)

FROM: (Activity and location) (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

Your mailing address

DATE

Date you filled out this form.

PART I – ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS Title Operator's Manual PUBLICATION/FORM NUMBER DATE

TM 5-3805-291-10 ITEM NO.

PAGE NO.

PARAGRAPH

15 Jan 10 LINE NO. *

001700-2

TYPED NAME, GRADE OR TITLE

Your Name DA FORM 2028, FEB 74

FIGURE TABLE NO. NO.

for Loader, Heavy, Scoop: DED, 4-Wheel Drive, 4.5 Cubic Yard and 5.0 Cubic Yard, Model 966H

RECOMMENDED CHANGES AND REASON (Provide exact wording of recommended changes, if possible).

Part number supplied for item 2 is incorrect.

*Reference to line numbers within the paragraph or subparagraph. TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION Signature

Your Signature

REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED.

USAPPC V3.00

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 PUBLICATION NUMBER

TM 5-3805-291-10

PAGE NO.

COLM NO.

LINE NO.

FROM: (Activity and location) (Include ZIP Code)

DATE Date you filled out this form

Your address

PART II – REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS TITLE Operator's Manual for Loader, Heavy, DATE

15 Jan 10

NATIONAL STOCK REFERENCE FIGURE ITEM NO. NO. NO. NUMBER

Scoop: DED, 4.5 & 5 Cubic Yd, Model 966H

TOTAL NO. OF MAJOR ITEMS SUPPORTED

RECOMMENDED ACTION

SAMPLE

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

RECOMMENDED CHANGES TO PUBLICATIONS AND BLANK FORMS

Use Part II (reverse) for Repair Parts and Special Tool Lists (RPSTL) and Supply Catalogs/Supply Manuals (SC/SM). For use of this form, see AR 25-30; the proponent agency is ODISC4.

TO: (Forward to proponent of publication or form)(Include ZIP Code)

DATE

FROM: (Activity and location) (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

PART I – ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS

PUBLICATION/FORM NUMBER

DATE

TM 5-3805-291-10 ITEM NO.

PAGE NO.

PARAGRAPH

15 Jan 10 LINE NO. *

FIGURE TABLE NO. NO.

TITLE Operator's Manual for Loader, Heavy, Scoop: DED, 4-Wheel Drive, 4.5 and 5.0 Cubic Yard, Model 966H 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

DA FORM 2028, FEB 74

TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION

SIGNATURE

REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED.

USAPPC V3.00

TO: (Forward direct to addressee listed in publication)

DATE

FROM: (Activity and location) (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 NUMBER

TM 5-3805-291-10

PAGE NO.

COLM NO.

LINE NO.

PART II – REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS TITLE Operator's Manual for Loader, Heavy, Scoop: DATE

15 Jan 10

NATIONAL STOCK REFERENCE FIGURE NO. NO. NUMBER

PART III – REMARKS

TYPED NAME, GRADE OR TITLE

ITEM NO.

DED, 4-Wheel Drive, 4.5 and 5 CY, Model 966H

TOTAL NO. OF MAJOR ITEMS SUPPORTED

RECOMMENDED ACTION

(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.)

TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION

SIGNATURE

USAPPC V3.00

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

TO: (Forward to proponent of publication or form) (Include ZIP Code) FROM: (Activity and location) (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 TM 5-3805-291-10

ITEM NO.

PAGE NO.

PARAGRAPH

LINE NO. *

DATE 15 Jan 10 FIGURE NO.

TABLE NO.

TITLE Operator's Manual for Loader, Heavy. Scoop, DED 4-Wheel Drive, 4.5 and 5.0 Cubic Yard, Model 966H 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

DA FORM 2028, FEB 74

TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION

SIGNATURE

REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED.

USAPPC V3.00

TO: (Forward direct to addressee listed in publication)

FROM: (Activity and location) (Include ZIP Code)

DATE

U. S. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS 1 Rock Island Arsenal, Rock Island, IL 61299-7630 PUBLICATION NUMBER

PART II – REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS TITLE Operator's Manual for Loader, Heavy, Scoop: DATE

TM 5-3805-291-10

PAGE NO.

COLM NO.

LINE NO.

PART III – REMARKS

TYPED NAME, GRADE OR TITLE

15 Jan 10

NATIONAL STOCK REFERENCE FIGURE NO. NO. NUMBER

DED, 4-Wheel Drive, 4.5 and 5 CY, Model 966H

ITEM NO.

TOTAL NO. OF MAJOR ITEMS SUPPORTED

RECOMMENDED ACTION

(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.)

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 Staff Official:

0924401

DISTRIBUTION: To be distributed in accordance with the initial distribution requirements for IDN: 251008, requirements for TM 5-3805-291-10.

THE METRIC SYSTEM AND EQUIVALENTS Linear Measure

Square Measure

1 Centimeter = 10 Millimeters = 0.01 Meters = 0.3937 Inches 1 Meter = 100 Centimeters = 1000 Millimeters = 39.37 Inches 1 Kilometer = 1000 Meters = 0.621 Miles

1 Sq Centimeter = 100 Sq Millimeters = 0.155 Sq Inches 1 Sq Meter = 10,000 Sq Centimeters = 10.76 Sq Feet 1 Sq Kilometer = 1,000,000 Sq Meters = 0.0386 Sq Miles

Weights

Cubic Measure

1 Gram = 0.001 Kilograms = 1000 Milligrams = 0.035 Ounces 1 Kilogram = 1000 Grams = 2.2 Pounds 1 Metric Ton = 1000 Kilograms = 1 Megagram = 1.1 Short Tons

1 Cu Centimeter = 1,000 Cu Millimeters = 0.06 Cu Inches 1 Cu Meter = 1,000,000 Cu Centimeters = 35.31 Cu Feet Temperature

Liquid Measure 1 Milliliter = 0.001 Liters = 0.0338 Fluid Ounces 1 Liter = 1000 Milliliters = 33.82 Fluid Ounces

5/9 ( F - 32) = C 212 Fahrenheit is equivalent to 100 Celsius 90 Fahrenheit is equivalent to 32.2 Celsius 32 Fahrenheit is equivalent to 0 Celsius 9/5 C +32 = F

APPROXIMATE CONVERSION FACTORS To Change

To

Multiply By

To Change

To

Multiply By

Inches

Centimeters

2.540

Centimeters

Inches

0.394

Feet

Meters

0.305

Meters

Feet

3.280

Yards

Meters

0.914

Meters

Yards

1.094

Miles

Kilometers

1.609

Kilometers

Miles

0.621

Sq Inches

Sq Centimeters

6.451

Sq Centimeters

Sq Inches

0.155

Sq Feet

Sq Meters

0.093

Sq Meters

Sq Feet

10.764

Sq Yards

Sq Meters

0.836

Sq Meters

Sq Yards

1.196

Sq Miles

Sq Kilometers

2.590

Sq Kilometers

Sq Miles

0.386

Acres

Sq Hectometers

0.405

Sq Hectometers

Acres

2.471

Cubic Feet

Cubic Meters

0.028

Cubic Meters

Cubic Feet

35.315

Cubic Yards

Cubic Meters

0.765

Cubic Meters

Cubic Yards

1.308

Fluid Ounces

Milliliters

29.573

Milliliters

Fluid Ounces

0.034

Pints

Liters

0.473

Liters

Pints

2.113

Quarts

Liters

0.946

Liters

Quarts

1.057

Gallons

Liters

3.785

Liters

Gallons

0.264

Ounces

Grams

28.349

Grams

Ounces

0.035

Pounds

Kilograms

0.454

Kilograms

Pounds

2.205

Short Tons

Metric Tons

0.907

Metric Tons

Short Tons

1.102

Pound-Feet

Newton-Meters

1.356

Newton-Meters

Pound-Feet

0.738

Pounds per Sq Inch

Kilopascals

6.895

Kilopascals

Pounds per Sq Inch

0.145

Miles per Gallon

Kilometers per Liter

0.425

Kilometers per Liter

Miles per Gallon

2.354

Miles per Hour

Kilometers per Hour

1.609

Kilometers per Hour

Miles per Hour

0.621

PIN: 084058-000