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.
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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:
• Headache
• Dizziness
• Sleepiness
• Loss of muscular control
5. If you see another person with exhaust poisoning symptoms:
• Remove person from area.
• Expose to fresh air.
• Keep person warm.
• DO NOT permit physical exercise.
• Administer cardiopulmonary resuscitation (CPR) if necessary.
• Notify a medic.
6. BE AWARE. The field protective mask for nuclear-biological-chemical (NBC) protection will NOT protect you
from carbon monoxide poisoning.
The Best Defense Against Carbon Monoxide Poisoning Is Good Ventilation!
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TM 5-3805-291-10
WARNING
BATTERIES
• To avoid injury, eye protection and acid-resistant gloves must be worn when working around bat-
teries. DO NOT smoke, use open flame, make sparks, or create other ignition sources around bat-
teries. If a battery is giving off gases, it can explode and cause injury to personnel. Remove all
jewelry such as rings, ID tags, watches, and bracelets. If jewelry or a tool contacts a battery termi-
nal, a direct short will result in instant heating or electrical shock, damage to equipment, and
injury to personnel.
• Sulfuric acid contained in batteries can cause serious burns. If battery corrosion or electrolyte
makes contact with skin, eyes, or clothing, take immediate action to stop the corrosive burning
effects. Failure to follow these procedures may result in injury or death to personnel.
1. Eyes. Flush with cold water for no less than 15 minutes and seek medical attention immediately.
2. Skin. Flush with large amounts of cold water until all acid is removed. Seek medical attention as required.
3. Internal. If corrosion or electrolyte is ingested, drink large amounts of water or milk. Follow with milk of magne-
sia, beaten egg, or vegetable oil. Seek medical attention immediately.
4. Clothing/Equipment. Wash area with large amounts of cold water. Neutralize acid with baking soda or household
ammonia.
WARNING
BLACKOUT LIGHTING SYSTEM

Blackout lighting system disables backup alarm, horn, and exterior lights, posing a hazard to person-
nel in the area. Follow proper safety procedures when operating in blackout mode. Failure to follow
this warning may cause injury or death to personnel or damage to equipment.
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 compo-
nents. DO NOT direct compressed air against human skin. Failure to follow this warning may result
in injury or death to personnel. Make sure air stream is directed away from user and other personnel
in the area. To prevent injury, user must wear protective goggles or face shield.
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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 well-
ventilated area, away from heat, open flames or sparks. Wear eye protection. Avoid contact with
skin and eyes and avoid breathing ether fumes. If fluid enters or fumes irritate the eyes, wash
immediately with large quantities of clean water for 15 minutes. Seek medical attention immedi-
ately if ether is inhaled or causes eye irritation. Failure to follow this warning may cause serious
injury or death to personnel.
• NEVER use aerosol engine starting aids. Failure to follow this warning may cause an explosion,
resulting in injury or death to personnel.
WARNING
FIRE EXTINGUISHER
Discharging large quantities of dry chemical fire extinguisher inside an enclosed cab may result in
temporary breathing difficulty during and immediately after the discharge event. Discharge fire
extinguisher from outside the cab. Ventilate cab thoroughly prior to reentry. Failure to follow this
warning may cause injury to personnel.
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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 per-
sonnel in this area when machine turns. Crushing could occur, resulting in injury or death to per-
sonnel.
• DO NOT operate machine with steering frame lock connected. Steering frame lock must be dis-
connected and securely stowed. If not properly stowed, loss of steering control could result. Fail-
ure to follow this warning may result in injury or death to personnel or damage to equipment.
• Connect steering frame lock between front and rear frames before lifting, transporting, or servic-
ing machine in frame articulation area. Disconnect steering frame lock and secure in stowed posi-
tion before resuming operation. Failure to follow this warning may result in injury or death to
personnel or damage to equipment.
WARNING
FUEL HANDLING
• DO NOT smoke or permit any open flame in area of machine while you are servicing fuel system.
Be sure hose nozzle is grounded against filler tube during refueling to prevent static electricity.
Failure to follow this warning may result in injury or death to personnel, or damage to equip-
ment.
• Operating personnel must wear fuel-resistant gloves when handling fuels. If exposed to fuel,
promptly wash exposed skin and change fuel-soaked clothing.
• ALWAYS stop engine prior to refueling. If equipped with an arctic cold weather starting aid sys-
tem, turn engine coolant heater off.
• DO NOT perform fuel system checks, inspections, or maintenance while smoking or near fire,
flames, or sparks. Fuel may ignite, causing injury or death to personnel or damage to equipment.
WARNING
HAZARDOUS WASTE DISPOSAL

When servicing this machine, performing maintenance, or disposing of materials such as engine cool-
ant, hydraulic fluid, lubricants, battery acids or batteries, windshield cleaning compound, and CARC
paint, consult your unit/local hazardous waste disposal center or safety office for local regulatory
guidance. If further information is needed, please contact The Army Environmental Hotline at 1-800-
872-3845.
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. Escap-
ing hydraulic fluid under pressure can penetrate the skin, causing injury or death to personnel.
WARNING
LOWERING LOADER ARM WITH ENGINE STOPPED

Loader arm can drop when lowering it with engine stopped. Keep all personnel away from loader 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 warn-
ing may result in injury or death to personnel in the event of an accident or machine overturn.
• DO NOT allow riders on machine. Failure to follow this warning may result in injury or death to
personnel.
• NEVER leave operator compartment without engaging parking brake. Failure to follow this
warning may result in injury or death to personnel.
• DO NOT use parking/emergency brake to stop a moving machine under usual conditions. Only if
service brakes fail, engage parking/emergency brake. Failure to follow this warning may result in
injury to personnel or damage to equipment.
• DO NOT perform excavating, loading, or digging tasks without ROPS/FOPS installed. Machine
has no rollover/falling object protection without ROPS/FOPS. Operation without ROPS/FOPS 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 equip-
ment.
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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, Tech-
niques, and Procedures for Chemical, Biological, Radiological, and Nuclear Decontamination.
• NBC contaminated filters must be handled using adequate precautions and must be disposed of
by trained personnel.
• Failure to follow these warnings may cause injury or death.
WARNING
IF NBC EXPOSURE IS SUSPECTED ALL AIR
FILTER MEDIA WILL BE HANDLED BY PER-
SONNEL WEARING FULL NBC PROTEC-
TIVE EQUIPMENT. SEE OPERATOR/
MAINTENANCE MANUAL.
7690-01-114-3702
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 fol-
low this warning may cause serious burns.
• Wear effective eye, hand, and skin protection when handling coolants. Failure to follow this warn-
ing may cause injury to personnel.
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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 trac-
tion or control. Failure to follow this warning may cause injury or death to personnel or damage
to equipment.
• If tire pressure is 20 psi (138 kPa) or less, DO NOT inflate. Notify Unit Maintenance. Failure 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
• Always block wheels before removing axle shafts or disengaging parking brake.
• DO NOT return to service a machine that has been towed, without first ensuring that all neces-
sary repairs and adjustments have been performed. Failure to do so could result in injury to per-
sonnel or damage to equipment.
WARNING
TRANSPORTING MACHINE
• Position machine, apply parking brake, and connect steering frame lock between front and rear
frames before transporting machine. Failure to follow this warning may result in injury or death
to personnel or damage to equipment.
• Always use a ground guide when operating machine up or down ramps in preparation for trans-
port. Failure to use a ground guide may cause injury or death to personnel or damage to equip-
ment.
• DO NOT remove exhaust stack until it has cooled to the touch. Wear gloves and protective cloth-
ing as required to guard against burns. Failure to follow this warning may result in injury to per-
sonnel.
• When operating machine up or down ramps, drive with extreme caution and in 1st gear forward
or reverse ONLY. Failure to follow this warning may cause injury or death to personnel or dam-
age to equipment.
• If operating machine without ROPS/FOPS, drive with extreme caution, at low idle, and in 1st
gear forward or reverse ONLY. Machine has no rollover/falling object protection without ROPS/
FOPS. Failure to follow this warning may cause injury or death to personnel or damage to equip-
ment.
• Safe Roll-on/Roll-off (RO/RO) operation depends on strict adherence to RO/RO regulations. Fail-
ure to do so may result in injury or death to personnel or damage to equipment.
• All personnel working in machine operating areas during RO/RO operations must wear hearing
protection. Failure to wear hearing protection may result in hearing loss.
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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 dam-
age to equipment.
• Improper use of lifting equipment and improper attachment of cables to machine may cause
injury to personnel and damage to equipment. Observe all standard rules of safety.
• Use caution when handling heavy parts. Provide adequate support and use assistance during pro-
cedure. Ensure that any lifting device used is in good condition and of suitable load capacity. Keep
clear of heavy parts supported only by lifting device. Failure to follow this warning may cause
• 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.
k/(l Blank)
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. Page/WP No. Change No.

Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 WP 0014 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0
Warning Summary (12 pgs.) . . . . . . . . . . . . . 0 WP 0015 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . 0
i-vi (4 pgs.) . . . . . . . . . . . . . . . . . . . . . . . . . . 0 WP 0016 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0
CHAPTER 1 title page . . . . . . . . . . . . . . . . . 0 CHAPTER 6 title page . . . . . . . . . . . . . . . . . 0
WP 0001 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0017 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0002 00 (16 pgs.) . . . . . . . . . . . . . . . . . . 0 WP 0018 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0003 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0019 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0
CHAPTER 2 title page . . . . . . . . . . . . . . . . . 0 WP 0020 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0004 00 (74 pgs.) . . . . . . . . . . . . . . . . . . 0
WP 0021 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0005 00 (18 pgs.) . . . . . . . . . . . . . . . . . . 0
WP 0022 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0006 00 (14 pgs.) . . . . . . . . . . . . . . . . . . 0
WP 0023 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0007 00 (12 pgs.) . . . . . . . . . . . . . . . . . . 0
WP 0024 00 (10 pgs.) . . . . . . . . . . . . . . . . . . 0
CHAPTER 3 title page . . . . . . . . . . . . . . . . . 0
WP 0008 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . 0 CHAPTER 7 title page . . . . . . . . . . . . . . . . . 0
WP 0009 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0025 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0010 00 (14 pgs.) . . . . . . . . . . . . . . . . . . 0 WP 0026 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . 0
CHAPTER 4 title page . . . . . . . . . . . . . . . . . 0 WP 0027 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0011 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0028 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0012 00 (54 pgs.) . . . . . . . . . . . . . . . . . . 0 Index (6 pgs.) . . . . . . . . . . . . . . . . . . . . . . . . 0
CHAPTER 5 title page . . . . . . . . . . . . . . . . . 0 Metric conversion chart . . . . . . . . . . . . . . . . 0
WP 0013 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . 0 Back cover . . . . . . . . . . . . . . . . . . . . . . . . . . 0
A/(B Blank)
TM 5-3805-291-10
TECHNICAL MANUAL HEADQUARTERS

TM 5-3805-291-10 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 tacomlcmc.daform2028@us.army.mil. 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 Description and Use of Operator Controls and Indicators . . . . . . . . . . . . . . . . 0004 00-1
WP 0005 00 Operation Under Usual Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0005 00-1
WP 0006 00 Operation Under Unusual Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0006 00-1
WP 0007 00 Stowage and Decal, Data Plate, and Stencil Guide . . . . . . . . . . . . . . . . . . . . . . 0007 00-1
CHAPTER 3
OPERATOR TROUBLESHOOTING 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 Refueling and Fuel System Priming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0013 00-1
WP 0014 00 Engine Air Precleaner Service and Air Cleaner Service . . . . . . . . . . . . . . . . . . 0014 00-1
WP 0015 00 Steering Frame Lock Connection and Disconnection . . . . . . . . . . . . . . . . . . . . 0015 00-1
WP 0016 00 Circuit Breaker and Fuses Reset/Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0016 00-1
CHAPTER 6
TRANSPORT PROCEDURES 1
WP 0017 00 Preparation for Transport Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0017 00-1
WP 0018 00 Roading Machine (Self-Deployment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018 00-1
WP 0019 00 Highway Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0019 00-1
WP 0020 00 Rail Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020 00-1
WP 0021 00 Rail Tiedown Procedures on a DODX Rail Car . . . . . . . . . . . . . . . . . . . . . . . . 0021 00-1
ii
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 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0025 00-1
WP 0026 00 Components of End Item (COEI) and Basic Issue Items (BII) Lists . . . . . . . . 0026 00-1
WP 0027 00 Expendable and Durable Items List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0027 00-1
WP 0028 00 Additional Authorization List (AAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0028 00-1
iii
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:
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.
3. Read through this manual to become familiar with its organization and contents before attempting to operate or maintain
the equipment.
CONTENTS OF THIS MANUAL
1. A Warning Summary is located at the beginning of this manual. Become familiar with these warnings before operating or
performing operator troubleshooting or maintenance on the machine.
2. A Table of Contents, located in the front of the manual, lists all chapters and work packages in the publication.
a. The Table of Contents also provides Reporting Errors and Recommending Improvements information with DA
Form 2028 addresses for the submittal of corrections to this manual.
b. If you cannot find what you are looking for in the Table of Contents, refer to the 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.
a. Type I, 4.5 Cubic Yard Rock Bucket, NSN 3805-01-533-1857
b. Type II, 5.0 Cubic Yard General Purpose (GP) Bucket, NSN 3805-01-533-1853
3. Purpose of Equipment. The 966H Wheel Loader is used in worldwide earthmoving and construction projects by U.S.
Army forces in engineer troop support.
MAINTENANCE FORMS, RECORDS, AND REPORTS 0001 00
Department of the Army forms and procedures used for the equipment maintenance will be those prescribed by DA
PAM 750-8, TAMMS Users Manual.
REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIR) 0001 00
If your loader needs improvement, let us know. Send us an EIR. You, the user, are the only one who can tell us what you
don’t like about your equipment. Let us know why you don’t like the design or performance. (E-Mail: TACOM-TECH-
PUBS@conus.army.mil) We will send you a reply. The preferred method for submitting Quality Deficiency Reports (QDRs)
is through the Army Electronic Product Support (AEPS) website under the Electronic Deficiency Reporting System (EDRS).
The web address is: https://aeps.ria.army.mil. If the above method is not available to you, put it on an SF 368 (Product Quality
Deficiency Report), and mail it to us at: Department of the Army, U.S. Army Tank-automotive and Armaments Command,
AMSRD-TAR-E, PDQR MS 268, 6501 E. 11 Mile Road, Warren, MI 48397-5000.
CORROSION PREVENTION AND CONTROL (CPC) 0001 00
1. CPC of Army materiel is a continuing concern. It is important that any corrosion problems with this item be reported so
that the problem can be corrected and improvements can be made to prevent the problem in future items.
2. Corrosion specifically occurs with metals. It is an electrochemical process that causes the degradation of metals. It is
commonly caused by exposure to moisture, acids, bases, or salts. An example is the rusting of iron. Corrosion damage in
metals can be seen, depending on the metal, as tarnishing, pitting, fogging, surface residue, and/or cracking.
3. Plastics, composites, and rubbers can also degrade. Degradation is caused by thermal (heat), oxidation (oxygen), solva-
tion (solvents), or photolytic (light, typically UV) processes. The most common exposures are excessive heat or light.
Damage from these processes will appear as cracking, softening, swelling, and/or breaking.
4. SF Form 368, Product Quality Deficiency Report should be submitted to the address specified in DA PAM 750-8,
TAMMS Users Manual.
DESTRUCTION OF ARMY MATERIEL TO PREVENT ENEMY USE 0001 00
For destruction of Army materiel to prevent enemy use, refer to TM 750-244-3, Procedures for Destruction of Equip-
ment to Prevent Enemy Use.
PREPARATION FOR STORAGE OR SHIPMENT 0001 00
Notify Unit Maintenance to perform preparation for storage or shipment procedures.
WARRANTY INFORMATION
For warranty information refer to TB 5-3805-291-14, Warranty Technical Bulletin for the 966H Wheel Loader.
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. The buckets can be interchanged with forklift pallet forks and a rotary sweeper to further increase machine versa-
tility.
2. 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 articula-
tion.
b. The loader is capable of lifting, clearing, and dumping loads into the following dump trucks/bodies:
(1) M917 Series, with 114 in. (2.90 m) sideboard height;
(2) Palletized Load System-Engineer Mission Module-Dump Body (PLS-EMM-DB): Truck-Mounted, with 124 in.
(3.15 m) sideboard height; and Trailer-Mounted, with 112 in. (2.84 m) sideboard height.
c. The machine has the following capabilities and features:
(1) Caterpillar C11 heavy-duty EPA Tier III compliant turbocharged diesel engine with six in-line cylinders,
generating 259 hp (net) and 283 hp (gross) (193 and 211 kW) @ 1,800 rpm;
(2) Capable of operating for 10 hours on a tank of fuel;
(3) Ether assist in cold weather starting down to -25 F (-32 C);
(4) Caterpillar autoshift transmission with four forward and four reverse speeds;
(5) 4-wheel drive: front fixed and rear oscillating axles with outboard planetary final drives;
(6) Self-adjusting service brakes with secondary and parking brake systems;
(7) Articulated frame steering with two double-acting steering cylinders;
(8) Air conditioned enclosed cab with adjustable seat and tilt steering wheel, gages and warning indicators, work
tool hydraulic controls, and heater/defroster/AC controls;
(9) Removable bolt-on Rollover Protective Structure/Falling Object Protective Structure (ROPS/FOPS);
(10) Interchangeable work tools, including forklift pallet forks and rotary sweeper;
(11) Z-bar loader arm with hydraulically-activated quick coupler, that allows for easy and quick connection and dis-
connection of work tools without the need for operator to leave cab;
(12) Lift and tiedown provisions conforming to MIL-STD-209K, Department of Defense Interface Standard for Lift-
ing and Tiedown Provisions;
(13) NATO slave receptacle;
(14) One toolbox, located below the battery box (LH side); and
(15) Mounting provisions for M16A1, M16A2, or M4 rifle; portable fire extinguisher; and M100 Sorbent Decontam-
ination System (SDS).
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 Semi-
trailer. A permit for width or removal of bucket may also be necessary.
(4) Remove ROPS/FOPS and exhaust stack for CONUS and NATO rail transport. OCONUS requires removal of
front and rear handrails.
e. The loader can fresh-water ford to a depth of 30 in. (76 cm) without damage or contamination of lubricants.
f. Machines that operate in extreme cold weather, from -25 F to -40 F (-32 C to -40 C), are factory equipped with an
arctic cold weather starting aid system which includes:
(1) Diesel-fired engine coolant heater,
(2) Four heavy-duty batteries, and
(3) Larger, heavy-duty starter.
0002 00-2
TM 5-3805-291-10
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
LOCATION AND DESCRIPTION OF MAJOR COMPONENTS - CONTINUED

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

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

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

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

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 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 DATA - CONTINUED
Machine Dimensions (with GP Bucket)

1 Height to top of ROPS/FOPS cab 141 in. (3.58 m)
2 Height to top of exhaust stack 138 in. (3.54 m)
3 Height to top of hood 100 in. (2.54 m)
4 Ground clearance 17.5 in. (44.5 cm)
5 Bucket pin height at maximum lift 165 in. (4.19 m)
6 Overall height - bucket raised 224 in. (5.69 m)
7 Length - rear axle to bumper 100 in. (2.54 m)
8 Wheelbase 136 in. (3.45 m)
9 Bucket pin height at carry 18 in. (45.7 cm)
10 Length - rear axle to articulation point 68 in. (1.73 m)
11 Rack back (tilt) angle at maximum lift 55 degrees
12 Dump angle at maximum lift 50 degrees
13 Rack back (tilt) angle at carry 47 degrees
14 Rack back (tilt) angle at ground 42 degrees
15 Axle housing clearance 16 in. (40.6 cm)
16 Overall length 372 in. (9.45 m)
17 Digging depth 5 in. (12.7 cm)
18 Reach at maximum lift and 45 degree dump 60 in. (1.27 m)
19 Height to center of axle 31 in. (78.7 cm)
0002 00-10
TM 5-3805-291-10

Machine Dimensions with Pallet Forks
966H Rated Loads for Pallet Forks per SAE J1197 (50% of Full Turn Tipping Load)
RATED
FORK PART FORK TINE PLACEMENT OPERATING LOAD
NUMBER LENGTH HEIGHT (A) LOAD CENTER (B)
164-4069 72 in. 159 in. 10,000 lb 48 in.

(1.83 m) (4.04 m) (4,536 kg) (1.22 m)
0002 00-11
TM 5-3805-291-10

Machine Dimensions with Rotary Sweeper

1 Overall length 30 ft
(9.14 m)
0002 00-12
TM 5-3805-291-10

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
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 speeds forward, 4 reverse
Range Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Autoshift; single lever control with remote F/N/R
Axles
Type
Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fixed
Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oscillating (±13 degrees)
Front and Rear Differentials
Type
Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Limited slip
Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Conventional
0002 00-13
TM 5-3805-291-10

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

Tires - Continued
Axle Load
Front (Rock Bucket) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28,000 lb (12,701 kg)
Front (GP Bucket). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27,500 lb (12,474 kg)
Rear (Rock Bucket) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25,500 lb (11,567 kg)
Rear (GP Bucket) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25,000 lb (11,340 kg)
Average Tire Contact Area
Rock Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390 in.2 (1,374 cm2) each tire
GP Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 450 in.2 (2,903 cm2) each tire
Steering
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Center-point frame articulation, load sensing
primary and secondary systems
Number of Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Electrical System
System Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Batteries:
Quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 gear-
driven water pump. Hydraulic oil, transmission oil, and aftercoolers are located near the radiator. The engine oil cooler
is mounted on the right side of the engine.
4. Lubrication System. The engine lubrication system consists of a gear-driven oil pump, oil filter, oil cooler, and oil pan.
The engine is lubricated by cooled and pressurized oil that is circulated through the engine block and head.
5. Exhaust System.
a. The exhaust system routes exhaust gases from the engine through the exhaust manifold and turbocharger. The
gases flow into exhaust pipes and a muffler to the atmosphere above the cab.
b. The turbocharger has a wastegate, which helps improve engine emissions.
POWERTRAIN 0003 00
1. Transmission.
a. The machine is equipped with an ECM-controlled Caterpillar autoshift transmission with four forward speeds and
four reverse speeds.
b. Manual, automatic, or economy modes of transmission operation can be selected.
c. To increase operator efficiency, direction of travel can be controlled by using either a steering column-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. Service Brakes.
a. An engine-mounted, gear-driven pump provides hydraulic pressure for the service brakes. The service brakes are a
wet brake system mounted to the planetary.
b. Two service brake pedals operate a hydraulic valve, which directs hydraulic pressure through hydraulic lines for
engaging multiple oil disc brake assemblies for each wheel.
c. The brake system has two accumulators, which ensure proper brake pressure is maintained.
2. Parking Brakes.
a. The parking brake is engaged via a switch on the dash in the cab.
b. If service brakes are lost, the parking brake can be applied to aid in stopping the machine.
ELECTRICAL SYSTEM 0003 00
1. The electrical system consists of two 12V batteries connected in series-parallel with negative grounding, providing 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 opera-
tion.
2. Steering System.
a. The machine’s hydraulic steering system changes the machine’s angle of articulation.
b. Major components of the steering system are piston pump, metering pump, steering cylinders, and lines and fit-
tings.
c. Two steering cylinders mounted to the loader rear frame section turn the front wheels. The cylinders are powered
by the hydraulic system and controlled by the steering wheel.
d. In the event of primary steering system failure, a secondary system automatically activates. An electric supplemen-
tal steering pump provides emergency steering power.
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 0004 00
Maintenance Task Title Page
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-1
Overview - Controls and Indicators Inside Cab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-2

Battery Disconnect Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-6
Transmission Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-7
Service Brake Control (Pedals) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-8

Transmission Neutralizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-10
Throttle Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0004 00-11

Hydraulic Control Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0004 00-11
Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-12
Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-12
Wiper Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-14
Heating and Air Conditioning Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-15
Parking Brake Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-16

Engine Start Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-17
Bucket Kickout Set Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-18

Ride Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-19
Auxiliary Hydraulic Control For Sweeper and Fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-20
Lift Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-21
Bucket Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-22

Monitoring System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-23
Hood Tilt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-26

Hood Tilt - Manual Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-26
Fluid Level Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-27
Ether Starting Aid System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-29

Messenger Reference Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-29
Work Area Vision System (WAVS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-59
GENERAL 0004 00
Before operating the 966H Wheel Loader, read and become familiar with the location and function of all operator 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
OVERVIEW - CONTROLS AND INDICATORS INSIDE CAB - CONTINUED 0004 00
9 Parking Brake Switch
10 12V Power Receptacle
11 12V Accessory Outlet
12 Inclinometer
13 Engine Start Switch
14 Hazard Switch
15 Diagnostic Connector
16 Continuous Flow Control
17 Not Used
18 Worklights Switch
0004 00-3
TM 5-3805-291-10
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
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
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 electri-
cal 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 elec-
trical 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
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 transmis-
sion in FORWARD.
2. Neutral (2). Place lever in middle position to place
transmission in NEUTRAL.
3. Reverse (3). Pull lever rearward to place transmission
in REVERSE.
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 posi-
tion.
0004 00-7
TM 5-3805-291-10
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. Trans-
mission will remain in first speed until transmis-
sion direction and speed control lever is shifted
to opposite direction or to NEUTRAL.
427-C0029
SERVICE BRAKE CONTROL (PEDALS) 0004 00

1. Left Service Brake Pedal (1).
a. Left service brake pedal provides three func-
tions:
(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 neu-
tralization of transmission will occur for all posi-
tions of autoshift switch. Automatic
downshifting and neutralizing of transmission
saves wear on service brakes, axles, and compo-
nents of powertrain.
d. Use left brake pedal for most conditions when 427-C0045
adequate traction is available.

2. Right Service Brake Pedal (2).
a. Right service brake pedal is used to slow down machine’s ground speed when operator does not wish to have
transmission downshift aggressively.
b. Right service brake pedal is normally used for braking when autoshift transmission control is downshifting ade-
quately.
0004 00-8
TM 5-3805-291-10
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
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
THROTTLE CONTROL 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
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, park-
ing, and instrument panel lights. When operating in blackout mode, work lights, service, and directional lights are disabled.
Backup alarm and horn are also disabled in blackout mode.
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
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
SER DRIVE NOTE

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
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 0004 00

1. Front Windshield Wiper/Washer Switch (1).
a. Turn knob in order to turn on window wiper.
b. Push knob in order to activate window washer.
NOTE
Machine is equipped with intermittent front wipers. There are several positions that will control
wipers.
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 posi-
tion.
2. Rear Windshield Wiper/Washer Switch (2).
a. Turn knob in order to turn on window wiper.
b. Push knob in order to activate window washer.
c. Turn knob clockwise from OFF position for
desired setting (LOW or HIGH).
427-C0470
0004 00-14
TM 5-3805-291-10
HEATING AND AIR CONDITIONING CONTROLS 0004 00

Heating and AC controls are located on switch panel in upper right side of cab.
1. Heater/AC Switch (1).
a. Press top of switch to turn on heater.
b. Press bottom of switch to turn on AC.
c. Place switch into middle position to turn off heater and AC.
2. Fan Speed Switch (2). Switch controls speed of blower fan motor for heating and AC system.
a. LOW – Press in bottom of switch to turn on fan blower at lowest speed.
b. MEDIUM – Place switch into middle position to turn on fan blower at medium speed.
c. HIGH – Press in top of switch to turn on fan blower at highest speed.
3. Temperature Control Knob (3). Temperature control knob is a rotary switch.
a. Turn knob clockwise for warmer air.
b. Turn knob counterclockwise for cooler air.
4. Defrost. Press bottom of switch (1) in order to turn 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
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. 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 indi-
cator will flash.
c. When parking brake is engaged and transmission

is in first speed, powertrain ECM shifts transmis-
sion to NEUTRAL and sends parking brake sta-
tus 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.
2. 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 pres-
sure. Action light will also flash when lights on monitoring system flash.
0004 00-16
TM 5-3805-291-10
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.
0004 00-17
TM 5-3805-291-10
BUCKET KICKOUT SET SWITCH 0004 00

To set the lift kickout, raise the bucket to the desired position above the midway point. Then depress the top of switch.
The boom will return to the programmed position when the raise detent is activated and the boom is below the kickout posi-
tion.
To set the lower kickout, lower the bucket to the desired position below the midway point. Then depress the top of switch.
The boom will return to the programmed position when the float detent is activated and the boom is at least 12 in. (30.5 cm)
above the kickout position.
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
0004 00-18
TM 5-3805-291-10
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.
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 sys-
tem should be in the automatic mode or in the off position during loading operations.
d. Ride control is enabled by a programmable parameter via Electronic Technician (ET). Ride control is 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.
2. Indicator. Ride control indicator (see callout 14 on
Page 0004 00-23) will illuminate only when the ride
control system is on.
427-C0474
0004 00-19
TM 5-3805-291-10
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 pressur-
ized when the thumb wheel is released.
OPEN – Move the thumb wheel (1) backward in order to increase fork spacing.
3. Continuous Flow Control Switch.
The continuous flow control switch supplies continuous flow of hydraulic fluid to the auxiliary hydraulic circuit (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 cir-
cuit.
427-C0475
0004 00-20
TM 5-3805-291-10
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 posi-
tion 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 automati-
cally 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
TM 5-3805-291-10
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 oper-
ator will feel an increased resistance from the joystick. Once in the detent, the joystick should be released in order to automat-
ically return to the HOLD position. The attachment will continue to tilt back until the attachment reaches the digging 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 pre-
set 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.
0004 00-22
TM 5-3805-291-10
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 acti-
vated. 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
TM 5-3805-291-10
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 cor-
rected.
4. Transmission Neutralizer (11). This indicator illuminates when the transmission neutralizer is deactivated.
5. Transmission Failure (12). This indicator illuminates when a serious problem exists in the electronic system of the
transmission. Immediately stop the machine. Stop the engine. Investigate the cause. Refer to Troubleshooting Introduc-
tion (WP 0008 00).
6. Parking Brake (13). This indicator illuminates when the parking brake is engaged. The indicator should flash 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 Trou-
bleshooting Introduction (WP 0008 00).
427-C0477
0004 00-24
TM 5-3805-291-10
MONITORING SYSTEM - CONTINUED 0004 00
Front Dash Indicators - Continued
9. Electrical System (16). This indicator illuminates when there is a malfunction in the electrical system. The system volt-
age is too high for normal machine operation or the system voltage is too low for normal machine operation.
a. If the electrical loads (air conditioning and/or lighting) are high and the engine speed is low, then increase the
engine speed. This will generate more output from the alternator. If the alert indicator for the electrical 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).
0004 00-25
TM 5-3805-291-10
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 tog-
gle 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
0004 00-26
TM 5-3805-291-10
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).
0004 00-27
TM 5-3805-291-10
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 cool-
ant.
427-C0060
0004 00-28
TM 5-3805-291-10
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 com-
partment 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
TM 5-3805-291-10
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
0004 00-30
TM 5-3805-291-10
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:
0004 00-31
TM 5-3805-291-10
Engine Speed (e.g. 1500 RPM)
Ground Speed/Direction (e.g. 13.8 kph, -3.4 mph)
Performance Engine Coolant Temperature (e.g. 78 C, -14 F)
Settings Hydraulic Oil Temperature (e.g. 78C,-14F)
Torque Converter Temperature (e.g. 78C,-14F)

Top Level Screen Totals
Time/Date
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
0004 00-32
TM 5-3805-291-10
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
0004 00-33
TM 5-3805-291-10
To select one of the settings/submenus, highlight the desired selection (by pressing arrows up/down), then press OK.
See below for an example of how the screen might look.
Neutralizer Setpoint Settings Screens

The operator has two additional options in the main Neutralizer Setpoint Setting Level screen, beyond the four-
calibrated choices described above: Adjust and Reset.
• Adjust – Allows the operator to modify the calibrated setpoint values.
• Reset – Resets the Neutralizer Setpoint Settings back to the default calibrated values.
Adjust and Reset Neutralizer Setpoint Settings Screens

To select Reset, press OK when Reset is highlighted.
To select Adjust, press OK when Adjust is highlighted. The adjustment screen for Level Operation will be displayed.
0004 00-34
TM 5-3805-291-10
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.
Press Simultaneously to:
Back & Down/Right Toggle the Neutralizer to
Disable or from Disable to
Level
Fuel Economy Mode
The Fuel Economy Mode Menu allows the operator to select the engine rpm at which the transmission shift points
occur, thus better matching the machine to application requirements.
Transmission Settings: Fuel Economy Mode Screen

The Fuel Economy Mode screen shows which mode is currently selected and also allows operator to select either of 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
TM 5-3805-291-10
• 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.
0004 00-36
TM 5-3805-291-10
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
0004 00-37
TM 5-3805-291-10
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.
0004 00-38
TM 5-3805-291-10
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
0004 00-39
TM 5-3805-291-10
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
0004 00-40
TM 5-3805-291-10
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
0004 00-41
TM 5-3805-291-10
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.
0004 00-42
TM 5-3805-291-10
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
0004 00-43
TM 5-3805-291-10
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
0004 00-44
TM 5-3805-291-10
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.
0004 00-45
TM 5-3805-291-10
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’
0004 00-46
TM 5-3805-291-10
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

1. Prk brk, ntrl, warm tran, hi idle..’Next’
2. Calibration Initializing
3. Calibrating clutch #1
6. Calibrating Clutch #4
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.
0004 00-47
TM 5-3805-291-10
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:

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’
0004 00-48
TM 5-3805-291-10
Calibrations: Lift Lever Calibration Screens

Tilt Lever Calibration:

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:

4. Place 3rd lever in HOLD ..’Next’
5. Place 3rd lever full REARWARD..’Next’
6. Place 3rd lever full FORWARD.. ‘Next’
0004 00-49
TM 5-3805-291-10
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:

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:

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.

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
0004 00-50
TM 5-3805-291-10
Valve Calibrations: Implement Lower:


3. Set lift cylinder. extension to 450–500 mm
4. Set tilt cylinder extension to 200–250 mm

7. Move lift lever to full lower and hold
8. CALIBRATING
Valve Calibrations: Implement Rackback:


4. Set tilt cylinder extension to 200–250 mm

7. Move tilt lever to full rackback & hold
8. CALIBRATING
Valve Calibrations: Implement Dump:


2. Disengage Implement Lockout Switch.
4. Set tilt cylinder. extension to 200–250 mm
7. Move tilt lever to full dump & hold
8. CALIBRATING
0004 00-51
TM 5-3805-291-10
Valve Calibrations: 3rd Function Rearward:


3. Move 3rd function cylinder to mid length ..'Next'
6. Move 3rd function lever to full back until implement moves..next
7. CALIBRATING
Valve Calibrations: 3rd Function Forward:


3. Move 3rd function cylinder to mid length ..'Next'
6. Move 3rd function lever to full forward until implement moves..next
7. CALIBRATING
Valve Calibrations: Implement Rackback & Dump Current:

2. Move linkage to mid-height ..'Next'
3. Place bucket into full dump ..'Next'
4. Move bucket 50-200mm off ground ..'next'
6. Move tilt lever to full rackback & hold
0004 00-52
TM 5-3805-291-10
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.
0004 00-53
TM 5-3805-291-10
Service: Tattletale Menu Diagram
0004 00-54
TM 5-3805-291-10
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
0004 00-55
TM 5-3805-291-10
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 • Moderate slope operation neutralizer set
point
• Forward to Reverse Gear
• Aggressive slope operation neutralizer set
• Reverse to Forward Gear 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.
0004 00-56
TM 5-3805-291-10
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
• Full Rack Angle Control Enable Stats -
• Startup Screen – Top Level Screen Disabled
• Time Format – 12 Hr • Dump Stop Snubbing Enable Status -
Disabled
• Date Format – YYY/MM/DD
• Neutralizer Operation Mode - Level
• Contrast – 50%
• Neutralizer settings
• Lights On – 50%
• Level operation neutralizer set point – 2%
• Lights Off – 50%
• Moderate slope operation neutralizer set
• Forward to Reverse Gear – 2 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
TM 5-3805-291-10
DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS - CONTINUED 0004 00-59
WORK AREA VISION SYSTEM (WAVS) 0000 00
Operation and Maintenance Manual starts on page 0004 00-61
Systems Operation Testing and Adjusting starts on page 0004 00-81
0004 00-58
TM 5-3805-291-10 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 Caterpil-
lar replacement parts or parts with equivalent
specications including, but not limited to, phys-
ical dimensions, type, strength and material.
Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or
death.
0004 00-59
TM 5-3805-291-10
Foreword
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.
0004 00-60
TM 5-3805-291-10
Safety Section
Safety
Safety Section If the display that is used with this system

was installed on another machine, Caterpillar
recommends conguring the settings for the
i02726365 display by qualied service personnel. A new
conguration will ensure proper performance in the
Safety 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. Con-
tact your Caterpillar dealer for replacement manu-
als. 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
TM 5-3805-291-10
Operation Section
General Information
Systems Operation Section

i02506417
General Information
SMCS Code: 7347; 7348
Safety
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
g01178357
during the cleaning procedure and/or use of an Illustration 1
appropriate safety harness. 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

g01178360
Camera Assembly
Area Vision System (WAVS). WAVS is a closed
circuit video monitoring system. WAVS consists of a Marker Line
178mm (7 inch) LCD color display and may include
one, two, or three cameras. The display is mounted Your system may have been configured to show
in the machine cab. The cameras are mounted on the a green horizontal “Marker” line that is shown on
frame of the machine. The location of the camera(s) the display. The “Marker” provides a fixed distance
is dependant on machine type. 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
TM 5-3805-291-10
Operation Section
General Information
g01178367 g01178363
Illustration 3 Illustration 4
Rear Camera View with Marker Example of a Single Camera Installation on a Wheel Loader
(15) Marker Line (21) Rearward Looking Camera
(22) Possible Video Cable Route
(23) Machine Cab
Power on/off (24) Display in Cab
(25) Machine Bucket
Power is supplied to the system when the operator turns
the key switch to the ON position and the light switch Refer to information in the “Display Button Operation”
selector lever in either STOPLIGHT or SERDRIVE. table or to the “How to Select Display Settings”
The power On/Off button that is on the display may be section of this document which describes how to
disabled. Refer to the “Display Description” section of this adjust the display settings for a single camera
document for an Illustration of the power button. The system. Make sure the display in not in the “Standby”
power button is shown in the “Display Keypad” Illustration. mode.
Single Camera System Overview Note: If the single camera system can be placed in
manual mode, PLEASE notify service personnel.
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.
0004 00-63
TM 5-3805-291-10
Operation Section
General Information
i02727240 In a multiple camera system, the operator can

override the automatic view by either of the following
Modes Of Operation selections:
SMCS Code: 7348 • Selecting “Manual Mode” on the display
Automatic Mode for the Single • Pressing the “Alternate Camera” switch
Camera System
In the “Automatic” mode, automatic selection of each
The single camera system is available only with camera will be enabled and the appropriate camera
the automatic mode “enabled”. The single camera will be activated. In automatic mode, the display can
system can be placed in “Standby” if the system is also be placed in “Standby”.
congured. Refer to the “Standby” for an explanation
of the “Standby” option. Note: The preferred camera view will always be
shown on the display screen unless the display is
Manual mode is intended for use only with the placed in “Manual” mode.
multiple camera applications. Manual mode is
disabled for use in a single camera system. Alternate Camera Switch
Note: If the “single camera” system can be placed in The Alternate camera switch allows the third camera
manual mode, notify Unit Maintenance. to be activated. In the example of the Off-Highway
Truck, the third camera is the side camera. The
In a single camera system, the system will switch is a momentary switch that will need to be
automatically display the camera view that is based held down in order to activate the third camera. The
on current machine operation which is determined by image on the display will return to the front camera
the system conguration. For example, WAVS may or the rear camera when the switch is released.
be congured to display the view from a rearward This action is dependent on which of the cameras
looking camera when the operator selects reverse that the machine is trying to activate. If the switch is
gear. congured, this switch may also be providing power
to a light that concentrates on the viewing area of
Standby the side camera. If the system is congured this way,
the light will turn on any time that the third camera is
Your single camera system installation may be activated with the Alternate camera switch.
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:
• 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
TM 5-3805-291-10
Operation Section
General Information
Camera Wash
i02726609 amera Wash
Camera Description
SMCS Code: 7348
Camera
g01178970
Illustration 9
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
TM 5-3805-291-10
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.
g01368064
Illustration 12
Do not position the display in order to obstruct the (3) Ball Mount Base
operator’s outside view.
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
g01367988
Illustration 13
Installation of the Display and Mounting Assembly
g01367987 (3) Base for the Ball Mount
Illustration 11 (4) Display
Mounting Clamp Assembly (5) Mounting Clamps
(6) Dumbbell
(1) Clamp (7) Mounting Clamp Handles
(2) Clamp Handle
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
TM 5-3805-291-10
Operation Section
Adjustments
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.
Note: If the display does a sequence to the next group

g01368029 of stored settings, this may alter the appearance of
Illustration 14
the view or the orientation of the camera view.
Example of an Installation on a Wheel Loader
(3) Base for the Ball Mount
(4) Display
Adjustment for Brightness
(5) Mounting Clamp
(8) Mounting Bracket for the Display In order to adjust the brightness, perform the
(9) Mounting Bolt for the Ball Mount 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
g01368041 Adjustment for Contrast
Example of an Installation on a Wheel Loader
(10) Installed WAVS
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
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
TM 5-3805-291-10
Operation Section
Adjustments
2. Press the “Minus” button (6) or the “Plus” button

(7) in order to adjust the contrast level.
3. Press any other button on the display in order

to exit the mode for adjusting the contrast. The
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
TM 5-3805-291-10
Maintenance Section
Maintenance Interval Schedule
Maintenance Section
i02736179 Adjust the spray nozzle within one inch of the
camera lens in order for the camera wash system to
Display - Clean perform proper operation. adjust the spray nozzle
within one inch of the camera lens. The angle of the
SMCS Code: 7347-070 spray nozzle should be between 30 degrees and 45
degrees from the lens of the camera.
In order to maintain sufcient vision, the display and
the camera lens may need to be cleaned periodically Note: When you are adjusting, verify that the spray
due to the environment. nozzle is not in the view of the camera.
Use a soft, damp cloth with water only in order to The preferred method of adjustment would require
clean the display. The display has a soft plastic two people:
surface that is easily damaged by any material that
is abrasive. • One person in the cab that is looking at the image
on the display
Note: The display is not sealed. The display can not
be immersed. The display can not have a pressure • One person that is making the adjustment on the
wash. spray nozzle
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
TM 5-3805-291-10
i02506525
Configuration
SMCS Code: 7347; 7348
g01178371
Illustration 7
Display Keypad
(1) Camera Selection Button (7) Increase Brightness or Contrast
(2) Automatic Brightness ON/OFF Adjustment Button
(3) Standby Function ON/OFF (8) Power ON/OFF Function May Be
(4) Contrast Button Disabled
(5) Brightness Button (9) Camera Select LEDs
(6) Reduce Brightness or Contrast (10) Button Status LEDs
Adjustment Button (11) Light Sensor
Accessing All System Options 2. Press and hold button 1 (camera select) and
button 3 (Standby On/Off), simultaneously, for 20
In order to configure or verify certain options, there is seconds.
a particular procedure that must be used in order to
access the options. Note: The display will blink, then change to the
opposite image.
Mirror Image
3. Press button 1 (camera select) again in order to
The display is supplied by Caterpillar with the “Mirror” select the next camera that is to be viewed and/or
image set as the default. The mirror image is used have its settings adjusted.
only for rearward looking cameras.
4. Press and hold button 1 (camera select) and
In order to provide the correct image for cameras that button 3 (Standby On/Off), simultaneously, for 20
are mounted in other locations other than a rearward seconds in order to toggle the image.
looking camera location (in a multi camera system),
the image must be changed to “Normal”. 5. Repeat step 3 and step 4 in order to toggle the
last camera image.
That is, for example, if cameras are mounted on
the front and the side of a machine, then the image Note: If the machine is equipped with a rearward
must be changed to “Normal” in order to provide the looking camera, ensure that the image is set to
correct image for the front and the side cameras. the "Mirror" image. The proper orientation must
be verified before the system is put into service.
In order to select “Mirror” or “Normal” image:
Press button 1 (camera select) for two seconds in
1. Press button 1 (camera select) in order to enter order to place the system in automatic mode. The
“Manual” mode. LED that is above and to the right of the camera
select button will turn off.
0004 00-70
TM 5-3805-291-10
Inverted Image 1. Press button 4 (Contrast) and button 5

(Brightness) simultaneously in order to access
This option can be used in order to invert the image. this option.
That is, this option will switch the orientation of the
image so that the top will appear at the bottom of 2. Press button 6 (Minus) or button 7 (Plus) button
the display screen and the bottom will appear at in order to change the level of color.
the top of the display screen. Therefore, the image
will appear to be upside down if the inverted image Press any other display button, other than the button
option is selected. 6 (Minus) or button 7 (Plus) buttons, in order to exit
the Color Adjustment option.
In order to invert the image:
Marker ON/OFF
1. Press button 1 (camera select) in order to enter
“Manual” mode. The LED that is above and to the Note: Before the marker option is enabled,
right of button 1 (camera select) will flash in order the appropriate “on-sight” personel should be
to indicate that the system is in manual mode. contacted. The technician will need information
in order to accurately set the marker at the
2. Press and hold button 1 (camera select) and desired position.
button 2 (Auto Brightness) simultaneously for 40
seconds in order to invert the image of the camera The display provides an option that is called the
view that is shown on the display screen. “Marker” line. The “Marker” is a small green line that
provides a fixed distance reference line from the
3. Press button 1 (camera select) again in order to machine. This Marker line can be turned on or off.
select the next camera that is to be viewed and/or The position of the Marker line can also be set by a
have its settings adjusted. qualified technician.
4. Again, press and hold button 1 (camera select) In order to turn the Marker on:
and button 2 (Auto Brightness) simultaneously
for 40 seconds in order to invert the image of the 1. Press button 2 (Auto Brightness) and button 3
camera view that is shown on the display screen. (Standby) simultaneously for 10 seconds. The
marker will appear on the display screen.
5. Repeat step 3 and step 4 for the third camera.
2. After the “Marker” appears, press either button 6
In order to revert to a previous image: (Minus) or button 7 (Plus) in order to adjust the
position of the “Marker”.
1. Follow the preceding steps to select the
appropriate camera. 3. Once the position is set, press any other display
button except button 6 (Minus) or button 7 (Plus)
2. Press and hold button 1 (camera select) and in order to exit the “Marker” set option.
button 2 (Auto Brightness) simultaneously for 40
seconds. Note: After the marker has been activated, if any
other button on the display is pressed other than
Display Power ON/OFF button 6 (Minus) or button 7 (Plus), the marker will be
set to the current position on the display. The marker
The display on/off button may be disabled. If disabled, position can be changed as long as the marker option
the button serves no other function. The LED that is has not been exited.
above and to the right of the display on/off button will
illuminate in order to show the system is on. In order to access all other options, please
refer to the following information in the “Single
Color Adjustment Camera System” or the “Multi Camera System”
sections of this document.
The “Color Adjustment” option is used to vary the
level of color on the display. The level of color of the Reset Marker
display can be varied in order to show a full color
image or a black and white image. In order to reset the marker, the marker must be
turned off, then turned back on and moved to the
In order to access the color adjustment option: 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
TM 5-3805-291-10
1. Press button 2 (Auto Brightness) and button 3 Manual Camera Selection

(Standby) simultaneously for 10 seconds in order
to turn the existing marker off. Manual mode is available only on WAVS
multi-camera installations. That is, manual
2. Press button 2 (Auto Brightness) and button 3 mode is not available for WAVS single camera
(Standby) simultaneously for 10 seconds again in installations.
order to turn the marker back on.
Automatic Brightness ON/OFF
3. Use button 6 (Minus) or button 7 (Plus) in order to
adjust marker position. The Automatic Brightness ON/OFF option allows the
operator to set the display to change the brightness
4. Press any other button, other than button 6 level automatically. The WAVS display is equipped
(Minus) or button 7 (Plus) in order to exit the with a sensor to detect ambient light. When WAVS
marker set option. is placed in the “Automatic Brightness” mode, the
display will brighten or dim automatically as the
Switch Off Key Board ambient light increases or decreases.
The “Switch Off Key Board” option is provided in order The brightness starting set point can be changed
to restrict access to the WAVS settings. However, by the operator while in the manual or automatic
even if the key board is switched off, the display mode. In order to change the set point, turn the auto
will continue to be active. Therefore, if the WAVS brightness on and perform the brightness adjustment
encounters any camera system inputs, the display to the desired level for the starting point.
will show the view from the active input. However, any
other key board operations or functions are disabled. Standby ON/OFF
Press and hold button 1 (camera select) and button 5 Your single camera system installation may be
(brightness) at the same time for 15 seconds in order configured with the “Standby” feature enabled or
to disable input from the key board. disabled. If “Standby” is enabled, the display will
remain dark unless the camera view has been
In order to enable the key board once again, press activated by machine operation or by the operator.
and hold button 1 (camera select) and 5 (brightness)
at the same time for 15 seconds. “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
Single Camera System used.
Available Operator Selections for the If “Standby” is disabled, the operator still has the
WAVS Display 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
TM 5-3805-291-10
Table 1
Display Button Operation for Single Camera Systems

Operation Procedure Notes
Brightness Adjustment Press button 5 in order to enable the If “Auto Brightness ”is enabled, the
“Brightness Adjustment”, then press brightness starting set point can be
either button 6 or 7 in order to adjust changed by the operator while in the
the brightness. manual or automatic mode.
Press any other display key in order to
exit brightness adjustment mode.
Contrast Adjustment Press button 4 in order to enable the Press any other display key in order to
Contrast Adjustment, then press either exit the contrast adjustment mode.
button 6 or 7 in order to adjust the
contrast level.
Automatic Brightness ON/OFF Press button 2 in order to turn the When WAVS is placed in the “Automatic
automatic brightness option ON/OFF. Brightness” mode, the display will
brighten or dim automatically as the
ambient light increases or decreases.
Standby ON/OFF Press button 3 in order to turn the If the standby mode is ON, the display
standby option ON/OFF. 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 2. If the machine has a second camera, press button
1 (camera select) again in order to select the
Camera Select - for Multi Camera System next camera that is to be viewed and/or have its
END OF WORK PACKAGE settings adjusted.
camera select function disabled. The camera 3. If the machine has a third camera, press button
select function must be enabled for a multi 1 (camera select) again in order to select the
camera system. 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 Press and hold the camera select button for two
to pride the desired view. seconds in order to exit the “Manual” mode.
In order to enable “Camera Select”: Available Operator Selections for the

WAVS Display
1. Press and hold button 1 (camera select) and
button 4 (contrast), simultaneously for 40 seconds. The selections that are listed in this section have
This will enable the camera select option. been made available to the operator of the machine.
The selections for the WAVS display can be changed
After “Camera Select” has been enabled, you will by the operator as needed. Refer to table 2 and to
be able to press button 1 (camera select) in order Illustration 7.
to place the system in “Manual” mode.
Brightness Adjustment
The LED that is above and to the right of button 1
(camera select) will flash in order to indicate that The brightness adjustment option allows the operator
the system is in manual mode. to vary the brightness of the view that is shown on
the display. If the brightness level is set to high and
One of the indicator LED’s (C1, C2, or C3) that are if the “Auto Brightness” is not enabled, then there is
to the left of the display buttons will indicate which a possibly that in a well lit area the display would
camera view is displayed. Refer to Illustration 7 appear completely “white”.
(9).
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
Tools and Special Tools References

Wrench, adjustable (Item 13, Table 2, WP 0026 00) WP 0004 00
Materials/Parts WP 0006 00
Rag, wiping (Item 13, WP 0027 00) WP 0008 00
WP 0011 00
Personnel Required
MOS 21E, Heavy Construction Equipment Opera- WP 0012 00
tor (2) 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
TM 5-3805-291-10
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 0005 00
1. 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
TM 5-3805-291-10
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
TM 5-3805-291-10
STARTING ENGINE - CONTINUED 0005 00
WARNING
NEVER use aerosol engine starting aids. Failure to follow this warning may cause an explosion, resulting in
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:
a. Press bottom of hydraulic lockout (IMPLEMENT DISABLE) switch to unlock hydraulic controls.
b. Cycle hydraulic controls through all positions.
4. Continue to warm up machine as follows:
a. If temperature is greater than 32ºF (0ºC), warm up machine for a total of approximately 15 minutes.
b. If temperature is less than 32ºF (0ºC), warm up machine for a total of approximately 30 minutes.
c. If temperature is less than 0ºF (-18ºC) or if hydraulic functions are sluggish, additional time may be needed.
0005 00-4
TM 5-3805-291-10
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
• DO NOT allow riders on machine. Failure to follow this warning may result in injury or death to personnel.
1. General Information.
a. Ensure that personnel are not working on or near machine before moving out.
b. Keep machine under control at all times.
c. Reduce engine speed when maneuvering in tight quarters or when going downhill.
d. Select correct gear speed before starting down a grade. Use same gear speed as you would use to go uphill. DO
NOT change gears while going downhill.
e. DO NOT allow engine to overspeed when going downhill. Use service brakes to control engine speed.
f. When load will be pushing machine, i.e., when backing downhill with a load, put transmission control lever in
FIRST gear.
2. Changing Direction and Speed.
a. Operator can change from low gear to high gear at full engine speed.
b. Directional changes at full engine speed are also possible. However, when changing directions, it is best to reduce
engine speed and to brake machine.
c. Keep a loaded bucket close to the ground.
d. Stop machine, if necessary, to avoid an unstable machine.
e. To change direction and speed, perform the following:
(1) Lower engine speed with throttle pedal.
(2) Use service brakes to slow machine or to stop machine.
(3) Move shifter or remote F/N/R switch to desired direction.
(4) If transmission is in manual mode, rotate transmission control lever to desired speed.
(5) Release service brakes.
(6) Increase engine speed with throttle pedal.
0005 00-5
TM 5-3805-291-10
STEERING MACHINE 0005 00
WARNING
1. Operator controls machine direction using steering wheel.
WARNING
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. Per-
form the following steps to bring machine to a safe stop:
a. Steer machine carefully to a safe location.
b. Stop machine and engage parking brake.
c. Shut down engine.
d. Troubleshoot malfunction.
e. DO NOT operate machine until problem has been corrected.
OPERATING ON SLOPES 0005 00
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 tip-
ping is always present.
5. When traveling uphill or downhill with a loaded bucket, keep bucket on uphill side, as low as possible. If machine 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
TM 5-3805-291-10
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. Engage parking brake.
2. 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.
a. Run engine at low idle for 5 minutes.
b. Turn off lights and accessories.
c. Turn engine start switch to OFF position.
d. Move all work tool hydraulic controls back and forth to relieve hydraulic system pressure.
e. Return all work tool hydraulic controls to HOLD position.
f. Press top of hydraulic lockout (IMPLEMENT DISABLE) switch to lock hydraulic controls.
3. Leaving Machine.
a. Inspect cab interior for debris. Remove debris.
WARNING
Use caution and maintain three-point contact at all times when dismounting machine. Failure to follow 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
STOPPING ENGINE IF AN ELECTRICAL MALFUNC-

TION OCCURS 0005 00
1. Turn engine start switch to OFF position.
2. If engine does not stop, perform the following steps:
a. Locate emergency shutdown switch at left center
of machine.
b. Move switch upward to stop engine.
3. 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
1. Electrical Power Available/Pilot Supply ON/OFF Solenoid Operable.
a. If electrical power is available and pilot supply ON/OFF solenoid is operable, loader arm can be lowered by oper-
ator from inside the cab.
b. To lower loader arm under these conditions, perform the following steps:
(1) Turn engine start switch to ON position.
(2) Press bottom of hydraulic lockout (IMPLEMENT DISABLE) switch to unlock hydraulic controls.
(3) Place loader control joystick in LOWER position.
(4) Move hydraulic lockout control to the locked position.
(5) Turn engine start switch to OFF position.
c. If engine has been off for more than 10 minutes but is operable, start engine, place loader control joystick 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 Electri-
cal Power/Pilot Supply ON/OFF Solenoid Inoperable on the next page.
0005 00-8
TM 5-3805-291-10
LOWERING LOADER ARM WITH ENGINE STOPPED - CONTINUED 0005 00

2. No Electrical Power/Pilot Supply ON/OFF Sole-
noid Inoperable.
a. If there is no electrical power or pilot supply ON/
OFF solenoid is inoperable, loader arm must be
lowered manually.
b. To lower loader arm manually, perform the fol-
lowing steps on right side of machine:
(1) Use adjustable wrench (Item 13, Table 2,
WP 0026 00) to turn square stem of ball
valve clockwise (to the right) 90 degrees.
(2) Loader arm will begin to lower when
ball valve is open.
(3) After loader arm has lowered, turn
427-C1701
square stem of ball valve counterclock-
wise (to the left) 90 degrees to close
valve.
0005 00-9
TM 5-3805-291-10
RELIEVING HYDRAULIC SYSTEM PRESSURE 0005 00
WARNING
• DO NOT disconnect or remove any hydraulic system line or fitting unless engine is shut down and hydraulic
system pressure has been relieved. Tighten all connections before applying pressure. Escaping hydraulic 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. 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 ser-
vice.
2. Relieving Hydraulic System Pressure.
a. Park machine on a level surface.
b. Lower work tool to the ground.
c. Engage parking brake.
d. If locked, press bottom of hydraulic lockout (IMPLEMENT DISABLE) switch to unlock hydraulic controls.
CAUTION
Stopping engine immediately after it has been operating under a load can result in overheating 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
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 0005 00
1. Introduction.
a. The quick coupler design allows operator, with-
out assistance, to connect loader to work tools.
b. The rotary sweeper and forklift pallet forks also
require hydraulic connections for its operation.
c. The following instructions apply to quick cou-
pler engagement to all 966H work tools.
2. Engaging Quick Coupler to Work Tool.
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 warn-
ing may result in injury or death to per-
427-C0361
sonnel or damage to equipment.
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
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 cou-
pler to work tool, perform the following steps:
(1) Tilt work tool forward onto ground and
apply slight downward pressure.
(2) Slowly back up machine.
(3) If there is movement between work tool
and quick coupler, then locking pins are 427-C0361
not engaged. Retract pins and repeat pro-
cedure.
WARNING
DO NOT disconnect or remove any
hydraulic system line or fitting unless
engine is shut down and hydraulic sys-
tem pressure has been relieved. Tighten
all connections before applying pres-
sure. Escaping hydraulic fluid under
pressure can penetrate the skin, causing
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 discon-
nect fittings on quick coupler.
j. Remove two protective plugs from quick discon-
nect fittings of sweeper, or two protective caps
427-C0363
from forklift.
k. Fasten caps together.
0005 00-12
TM 5-3805-291-10
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. Remove locking pin and pin, raise up leg and reinstall pin and locking pin. Repeat for other side.
3. Disengaging Quick Coupler from Work Tool.
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
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
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
• 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
1. Introduction.
a. Survey work site before operation to become familiar with job requirements and ground conditions.
b. Be alert for personnel in the area. Ensure work area is clear of personnel before proceeding.
c. When operating work tool, keep cab doors closed.
2. Automatic Lift Kickout.
The joystick control is detented in the fully raised position. When the joystick is pulled back into the soft detent, 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
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 trans-
mission to downshift automatically.
k. Go as far as possible into pile, with bucket fully lowered, until loader meets increased resistance as bucket is fill-
ing.
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. Transmis-
sion will be in 2nd gear.
5. Spreading a Load with GP Bucket. Dump load while moving machine slowly forward or in reverse, as needed.
6. Operating Rotary Sweeper.
The continuous flow control switch supplies continuous flow of hydraulic fluid to the auxiliary hydraulic circuit (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 cir-
cuit.
427-C0475
0005 00-16
TM 5-3805-291-10
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
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
Operation in Sandy or Dusty Conditions
Machine
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 tem-
peratures 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
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
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. Before returning machine to service, ensure all necessary repairs and adjustments have been performed.
2. Towing Machine With Engine Running.
a. Machine can be towed for a short distance if powertrain and steering system are operational.
b. Tow for a short distance in order to pull machine out of mud or to side of road.
c. Operator on towed machine must steer machine in the direction of the tow line.
d. Follow general instructions as outlined above.
3. Towing Machine With Engine Stopped.
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 connec-

tions 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
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 0006 00
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 come-
along.
3. Turn square step of ball valve counterclockwise (to
the left) 90 degrees to close valve.
4. Dead machine can now be towed.
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
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
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 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. General. Extreme cold causes many problems:
a. Lubricants thicken or congeal.
b. Batteries may freeze or lose their electrical efficiency.
c. Electrical insulation may crack and cause short circuits.
d. Fuel may not readily atomize for combustion.
e. Various materials become hard, brittle, and easily damaged.
f. Cooling system requires adequate protection from extreme cold.
g. Fuels, lubricants, and antifreeze compounds require special storage, handling, and use.
2. Cooling System.
WARNING
escaping steam or hot coolant will cause serious burns.
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
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 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.
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.
4. Electrical System.
a. Inspect battery cables, wiring harnesses, and wiring.
b. Check for breaks or cracks caused by cold weather. Report any problems found to Unit Maintenance.
c. Save batteries. Use lights and other electrical equipment as little as possible when engine is not running.
5. Lubrication.
Use lubricants as specified at the end of PMCS (WP 0012 00) with the temperature range that applies to the 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 IN EXTREME COLD - CONTINUED
7. Machine Operation.
a. When moving out, be alert that tires may be frozen to ground.
b. Test brakes and machine controls carefully.
c. Move all hydraulic controls slowly to warm hydraulic oil. Cycle each control several times. Normal 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.
8. Parking Machine.
a. If machine will be parked for a short period, park in a sheltered area out of wind. If shelter is not available, 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 possi-
ble after shutdown.
d. If machine will be parked for a long period of time, notify Unit Maintenance to prepare machine for storage.
e. Ensure tires are properly inflated.
ARCTIC COLD WEATHER STARTING AID SYSTEM 0006 00
1. General.
a. Machines that operate in extremely cold weather, from -25 F to -40 F (-32 C to -40 C), are factory equipped 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
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 tem-
perature. 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 IN EXTREME HEAT - CONTINUED 0006 00

2. Cooling System.
WARNING
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.
3. 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.
4. Air Cleaner.
WARNING
• If NBC exposure is suspected, personnel wearing protective equipment must handle all air cleaner media.
Consult your NBC Officer or NBC NCO for appropriate handling or disposal procedures.
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.
a. Check air cleaner service indicator frequently (WP 0004 00).
b. Service air cleaner as necessary (WP 0014 00).
5. Parking Machine.
a. Park machine under cover, if possible.
b. Ensure all tires are inflated to proper pressure (WP 0012 00).
c. Check frequently for rust. Clean and lubricate machine to help prevent deterioration (WP 0012 00).
0006 00-11
TM 5-3805-291-10
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
personnel.
2. Whenever operating in sandy or dusty areas, you should:
a. Service engine air cleaner more frequently.
b. Ensure each tire has a valve cap.
c. If machine overheats, stop and perform troubleshooting procedures.
d. Ensure engine and transmission dipsticks and oil filler caps are cleaned before they are removed to check fluid lev-
els. Clean accumulations of sand and dirt from around fluid filler locations before checking or adding fluids.
e. Clean spouts of fuel containers and area around filler cap on fuel tank before adding fuel. Under extremely 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 AT HIGH ALTITUDES 0006 00
WARNING
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 0006 00
1. General.
WARNING
arctic heater off.
a. Fuel tank should be kept full. Keep snow and ice away from fuel filler.
b. Clean snow away from windshields and lights.
2. Driving.
a. Accelerate slowly to avoid spinning tires.
b. Drive at slower speeds.
c. Give signals sooner.
d. Apply brakes sooner to give early warning of intention to stop. This will also help to avoid skidding.
e. Maintain double the normal distance from the machine ahead.
f. Keep windshields and lights clean and free of snow and ice.
g. If approaching a difficult stretch of road, stop and inspect road carefully before driving on it.
h. Select transmission gear range that best suits road condition.
0006 00-13
TM 5-3805-291-10
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 tem-
peratures.
3. Raise loader arm to 6 to 12 in. (15.2 to 30.5 cm) above surface of water.
4. Place transmission in 1st gear and enter water slowly. Fording speed should not exceed 3 to 4 mph (5 to 6 kph).
5. After fording, wash machine with fresh water, if available.
6. Allow engine to run for awhile to dry out any accumulated water.
7. Drain and dry any area where water has accumulated.
8. Test service brakes after fording by operating brake system.
9. Perform PMCS as soon as possible (WP 0011 00 and WP 0012 00).
SORBENT DECONTAMINATION SYSTEM (SDS), M100 0006 00

The SDS mounting bracket shall be installed in an upright position in a manner which shall not interfere with the 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
DECALS - CONTINUED 0007 00
427-C1563
0007 00-3
TM 5-3805-291-10
427-C1564
0007 00-4
TM 5-3805-291-10
427-C1565
0007 00-5
TM 5-3805-291-10
427-C2041
0007 00-6
TM 5-3805-291-10
DATA PLATES 0007 00
427-C1566
0007 00-7
TM 5-3805-291-10
DATA PLATES - CONTINUED 0007 00
427-C1567
427-C1568
0007 00-8
TM 5-3805-291-10
STENCILS 0007 00
0007 00-9
TM 5-3805-291-10
STENCILS - CONTINUED 0007 00
427-C1570
0007 00-10
TM 5-3805-291-10
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: MALFUNC-
TION, TEST OR INSPECTION (in step number order), and CORRECTIVE ACTION.
c. Perform each step in the order listed until the malfunction is corrected. DO NOT perform any maintenance 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
Malfunction/Symptom Troubleshooting Procedure Page
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 0009 00
Malfunction/Symptom 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
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 Stop machine and shut down engine Notify Unit Maintenance.
Comes On During Operation. immediately (WP 0005 00).
WARNING
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
machine.
3. Parking/Emergency Brake Will Not 1. Engage and disengage parking If problem still exists, go to test
Disengage. brake (WP 0004 00). step 2.
2. Stop machine and shut down Notify Unit Maintenance.
engine immediately (WP 0005 00).
4. Parking/Emergency Brake Will Not Stop machine and shut down engine Notify Unit Maintenance.
Engage. immediately (WP 0005 00).
0010 00-1
TM 5-3805-291-10
TROUBLESHOOTING PROCEDURES - CONTINUED 0010 00
BRAKES - SERVICE AND PARKING/EMERGENCY - CONTINUED

WARNING
• Park machine on level ground, stop engine, and lower work tool to
machine.
• If emergency use of parking brake is required due to service brake
failure, ensure that brakes are inspected and repaired, if necessary,
before resuming machine operation. Injury or death to personnel
or damage to equipment could result from improperly or non-func-
tioning brakes.
5. Service Brakes Do Not Operate 1. Bring machine to a safe stop and Clean mud or dirt from under
Correctly. check for mud or dirt under brake brake pedals. If problem still
pedals. exists, go to test step 2.
2. Bring machine to a safe stop and Notify Unit Maintenance.
shut down engine immediately
(WP 0005 00).
6. Service Brakes Do Not Release WARNING
Correctly.
machine.
1. Bring machine to a safe stop and Clean mud or dirt from under
check for mud or dirt under brake brake pedals. If problem still
pedals, causing pedals to stick. exists, go to test step 2.
2. Ensure parking brake is Disengage parking brake. If
disengaged (WP 0004 00). problem still exists, go to test step
3.
3. Bring machine to a safe stop and Notify Unit Maintenance.
shut down engine immediately
(WP 0005 00).
CHARGING SYSTEM
Electrical System Alert Indicator Comes 1. Check that circuit breakers are not Reset circuit breakers. If problem
On. tripped (WP 0016 00). still exists, go to test step 2.
2. Check for loose or broken If loose or broken belt is found, or
serpentine belt. if belt is OK and problem still
exists, notify Unit Maintenance.
0010 00-2
TM 5-3805-291-10
COOLING SYSTEM
Coolant Temperature Gage Indicates
Engine is Overheating.
WARNING
• DO NOT service cooling system unless engine has been allowed to
cool down. This is a pressurized cooling system and escaping steam
or hot coolant will cause serious burns.
• DO NOT remove cooling system radiator cap when engine is hot.
Allow engine to cool down. Failure to follow this warning may cause
serious burns.
• Wear effective eye, glove, and skin protection when handling cool-
ants. Failure to do so may cause injury.
1. Check coolant temperature gage Reduce load and continue to
for an indication in red or orange monitor temperature. If indication
range (WP 0004 00). is still in red or orange range, go to
test step 2.
2. Allow engine to idle at 825 rpm to If problem still exists, go to test
cool down. 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 If low, add coolant (WP 0004 00).
00). If coolant level is OK, notify Unit
Maintenance.
ELECTRICAL SYSTEM
1. Backup Alarm Will Not Sound When NOTE
Machine is Placed in Reverse.
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 NOTE
When B.O. DRIVE Function is Selected.
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
ELECTRICAL SYSTEM - CONTINUED

3. Blackout Drive Marker Light(s) Do Not NOTE
Operate When B.O. MARKER Function
is Selected. 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. Directional Turnlamp or Hazard 1. Ensure STOP LIGHT or SER. Select STOP LIGHT or SER.
Flasher Control are Not Working. 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)/ Reconnect connectors, if
composite lights (rear) for disconnected. If any damage to
disconnected connectors or lights is found, notify Unit
damage. Maintenance. If connectors and
lights are OK, go to test step 3.
3. Check for blown turnlamp fuse at If fuse is blown, request
fuse panel (WP 0016 00). replacement fuse from Unit
Maintenance. If problem still
exists, notify Unit Maintenance.
5. Worklights Inoperative. 1. Ensure STOP LIGHT or SER. Select STOP LIGHT or SER.
DRIVE function has been selected DRIVE. If problem still exists, go
00).
2. Check for blown worklight fuse at If fuse is blown, request
Maintenance. If fuse is good, go to
test step 3.
3. Check worklights for Reconnect connector, if
disconnected connector or disconnected. If any damage to
damage. worklights is found, notify Unit
Maintenance.
6. Service Light(s) Do Not Operate When 1. Check service light(s) for Reconnect connectors, if
SER. DRIVE or PARK Functions are disconnected connectors or disconnected. If any damage to
Selected. damage. 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

6. Service Light(s) Do Not Operate When NOTE
SER. DRIVE or PARK Functions are
Selected - Continued. automatically resets.
2. Check that circuit breakers are not Reset circuit breakers. If problem
tripped (WP 0016 00). still exists, notify Unit
Maintenance.
7. Horn Will Not Sound When Button is 1. Ensure STOP LIGHT or SER. Select STOP LIGHT or SER.
Pressed. DRIVE function has been selected DRIVE. If problem still exists, go
00).
2. Check horn for disconnected Reconnect connector, if
connector or damage. 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 If fuse is blown, request
panel (WP 0016 00). replacement fuse from Unit
Maintenance. If fuse is good, or
problem still exists, notify Unit
Maintenance.
8. Messenger is Inoperative. Notify Unit Maintenance.
9. Stoplights Do Not Operate When Brakes 1. Ensure STOP LIGHT or SER. Select STOP LIGHT or SER.
are Applied. DRIVE function has been selected DRIVE. If problem still exists, go
00).
2. Check composite lights for If any damage to lights is found,
disconnected connectors or notify Unit Maintenance. If no
damage. damage is found, go to test step 3.
3. Check for blown stoplight fuse If fuse is blown, request
(WP 0016 00). replacement fuse from Unit
Maintenance. If fuse is good,
notify Unit Maintenance.
10. Taillights Do Not Come On. 1. Ensure STOP LIGHT or SER. Select STOP LIGHT or SER.
DRIVE function has been selected DRIVE. If problem still exists, go
00).
2. Check composite lights for If any damage to lights is found,
disconnected connectors or notify Unit Maintenance. If no
damage. damage is found, go to test step 3.
0010 00-5
TM 5-3805-291-10

10. Taillights Do Not Come On - Continued. NOTE
3. Check for blown taillight fuse (WP If fuse is blown, request
0016 00). replacement fuse from Unit
11. Windshield Washer Not Working. 1. Check windshield washer fluid If reservoir is empty, fill reservoir
reservoir. (WP 0012 00). If problem still
exists, go to test step 2.
2. Check for blown fuse at fuse panel If fuse is blown, request
Maintenance. If fuse is good and
problem still exists, go to test step
3.
3. Check for loose or disconnected Reconnect electrical connectors, if
electrical connectors (WP 0012 required. If problem still exists,
00). notify Unit Maintenance.
12. Windshield Wiper Not Working. Check for blown fuse at fuse panel (WP If fuse is blown, request
0016 00). replacement fuse from Unit
WORK AREA VISUAL SYSTEM (WAVS)
1. Display or Camera Inoperative Check if light switch selector lever is in 1. If not, select either STOP
either STOP LIGHT or SER DRIVE LIGHT or SER DRIVE mode.
mode. 2. If light switch is in either
STOP LIGHT or SER DRIVE
mode and problem still exists,
2. Display is Blank Check if brightness level is set 1. If not, set brightness level
correctly (WP 0004 00, WAVS correctly.
section, Table 1). 2. If brightness level is set
correctly and problem still
exists, notify Unit
Maintenance.
3. Display has Wrong Image Orientation Check if image orientation is set 1. If not, set image orientation
correctly (should appear as if looking correctly.
in a rear view mirror) (WP 0004 00, 2. If image orientation is set
WAVS section, Accessing All System correctly and problem still
Options – Mirror Image). exists, notify Unit
maintenance.
0010 00-6
TM 5-3805-291-10
WORK AREA VISUAL SYSTEM (WAVS) - CONTINUED

4. Display has Inverted Image Check if image is set correctly (WP 1. If not, set image correctly.
0004 00, WAVS section, Accessing 2. If image is set correctly and
All System Options – Inverted Image). problem still exists, notify
Unit Maintenance.
5. Display has Blurred Image Check if camera lens is dirty. 1. If lens is dirty, clean.
2. If lens is clean and problem
still exists, notify Unit
Maintenance.
6. Display’s Color is Incorrect Check if color is set correctly (WP 1. If not, set color correctly.
0004 00, WAVS section, Accessing 2. If color is adjusted correctly
All System Options – Color and problem still exists, notify
Adjustment). Unit Maintenance.
ENGINE
1. Engine Cranks but Fails to Start: 1. Check fuel tank gage with engine If indication is empty, add fuel
Operating Temperature Above -25 F start switch ON. (WP 0013 00). If indication is OK,
(-32 C) go to test step 2.
2. Make sure emergency shutoff is Disengage if necessary.
disengaged.
3. Check for blown key start fuse at If fuse is blown, request
0010 00-7
TM 5-3805-291-10
ENGINE - CONTINUED
2. Engine Cranks but Fails to Start:
Operating Temperature -25 F to -40 F
(-32 C to -40 C).
WARNING
• DO NOT smoke or permit any open flame in area of
machine while you are servicing fuel system. Be sure 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 If indication is empty, add fuel
start switch ON. (WP 0013 00). If indication is OK,
go to test step 2.
2. Make sure emergency shutoff is Disengage if necessary.
disengaged.
3. Check for blown key start fuse at If fuse is blown, request
4. Check for blown arctic heater fuse If fuse is blown, request
test step 5.
5. Check for blown start aid fuse at If fuse is blown, request
Maintenance. If engine still will
not start, notify Unit Maintenance.
6. Check for missing or empty ether If ether canister is missing or
starting aid bottle at temperatures empty, notify Unit Maintenance.
from -25 F to 10 F (-32 C to
-12 C) (WP 0004 00).
0010 00-8
TM 5-3805-291-10
ENGINE - CONTINUED
3. Engine Does Not Develop Full Power.
WARNING
• If NBC exposure is suspected, personnel wearing protective
equipment must handle all air cleaner media. Consult your
NBC Officer or NBC NCO for appropriate handling or dis-
posal procedures.
• Refer to FM 3-11.3, Multiservice Tactics, Techniques,
and Procedures for Chemical, Biological, Radiological,
and Nuclear Contamination Avoidance, and FM 3-11.5,
Multiservice Tactics, Techniques, and Procedures for
Chemical, Biological, Radiological, and Nuclear
Decontamination.
• NBC contaminated filters must be handled using adequate
precautions and must be disposed of by trained personnel.
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
Unit Maintenance.
5. Engine Fails to Crank When Engine 1. Check position of transmission Place transmission control lever
Start Switch is Turned to START. control lever and remote F/N/R and remote F/N/R switch in N
switch. (NEUTRAL). If problem still
exists, go to test step 2.
2. Check position of battery Place battery disconnect switch to
disconnect switch (WP 0004 00). ON. If problem still exists, go to
test step 3.
3. Check for blown engine start If fuse is blown, request
switch fuse (WP 0016 00). replacement fuse from Unit
test step 4.
NOTE
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
ENGINE - CONTINUED
5. Check for tripped breaker (WP Reset circuit breaker. If problem
0016 00). still exists, go to test step 6.
5. Engine Fails to Crank When Engine 6. Check both batteries for dirty, Clean cables if dirty. If cable is
Start Switch is Turned to START - loose, or damaged battery cables damaged or loose, notify Unit
Continued. (WP 0012 00). Maintenance.
7. Check connection of four harness If problem still exists, notify Unit
connectors at right rear of cab Maintenance.
cover.
6. Engine Starts but Misfires or Runs
Rough After Warmup Period.
WARNING
equipment.
coolant heater off.
Check fuel/water separator for Open fuel/water separator drain
moisture (WP 0012 00). valve and drain (WP 0012 00). If
Maintenance.
7. Excessive Engine Oil Consumption. 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
ENGINE - CONTINUED
8. Excessive Exhaust Smoke (At Normal 1. Check fuel/water separator for Drain fuel/water separator (WP
Operating Speed). moisture (WP 0012 00). 0012 00). If problem still exists, go
to test step 2.
WARNING
equipment.
coolant heater off.
2. Check front dash indicator (WP If indicator is on, service engine air
0004 00). cleaner (WP 0014 00) and retest
Unit Maintenance.
9. Excessive Exhaust Smoke (White) Check and monitor coolant Allow engine to warm up to
During Startup. temperature gage (WP 0004 00). operating temperature. If problem
Maintenance.
10. Low Engine Oil Pressure Alert CAUTION
Indicator, Action Light, and Action
When action alarm sounds, immediate shutdown of machine is
Alarm are On. required to prevent damage to machine.
Check engine oil level (WP 0004 00). If engine oil is low, fill to correct
level (WP 0012 00). If problem
Maintenance.
0010 00-11
TM 5-3805-291-10
HYDRAULIC SYSTEM
1. Travel Time of Lift Cylinders is Slow.
WARNING
Stand clear of frame articulation area when machine is operat-
ing. 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 If hydraulic oil level is low, fill to
0004 00). correct level (WP 0004 00). If
2.
2. Check hydraulic lift cylinders for Clean any debris from cylinder(s).
any buildup of debris. If problem still exists, go to test
step 3.
3. Check loader control joystick for If any damage is found, notify Unit
damage that would restrict Maintenance.
freedom of movement.
2. Work Tool/Loader Arm Operating
Speeds are Too Slow.
WARNING
Stand clear of frame articulation area when machine is operat-
ing. There is no clearance for personnel in this area when
machine turns. Crushing could occur, resulting in injury or
death to personnel.
2.
2. Check hydraulic lift cylinders, tilt Clean any debris from cylinders
cylinder, and linkage for buildup and linkage. If problem still exists,
of debris. notify Unit Maintenance.
0010 00-12
TM 5-3805-291-10
STEERING
1. Machine Slowly Drifts (Either Direction),
Wanders, or Pulls to One Side on Level
Pavement, Even When Steering Wheel is
in Straight Position.
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 Check hydraulic oil level (WP 0004 If oil level is low, fill to correct
to Respond. 00). level (WP 0004 00). If oil level is
OK, notify Unit Maintenance.
3. Machine Turns Correctly During 1. Check steering system for oil If any oil leaks are found, notify
Normal Driving Conditions but Turns leaks. Unit Maintenance. If no leaks are
Slowly With a Load. found, go to test step 2.
Maintenance.
4. Machine Turns Slowly in Both Check hydraulic oil level (WP 0004 If oil level is low, fill to correct
Directions. 00). level (WP 0004 00). If oil level is
OK, notify Unit Maintenance.
5. Machine Turns Slowly in One Direction. 1. Check for oil leaks at steering If any oil leaks are found, notify
cylinders. Unit Maintenance.
Maintenance.
6. Oil Temperature is Too Hot (Hydraulic Check hydraulic oil level (WP 0004 If hydraulic oil level is low, fill to
Oil Temperature Gage in Red Range). 00). correct level (WP 0004 00). If
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
Maintenance.
8. Turning Steering Wheel is Difficult. 1. Check hydraulic temp gage for If problem still exists after normal
correct temperature. operating temperature is reached,
go to test step 2.
0010 00-13
TM 5-3805-291-10
STEERING - CONTINUED
8. Turning Steering Wheel is Difficult - 2. Check hydraulic oil level (WP If hydraulic oil level is low, fill to
Continued. 0004 00). correct level (WP 0004 00). If
Maintenance.
TRANSMISSION
1. Slow or Erratic Transmission Check transmission oil level (WP 0004 If transmission oil is low, fill to
Engagement. 00). correct level (WP 0004 00). If
Maintenance.
2. Transmission Oil Temperature Gage 1. Ensure proper transmission range Select proper transmission range
Indicates Overheating and Action Light is selected for machine operation (WP 0004 00). If proper range was
Comes On (During Normal Operation). (WP 0004 00). used, go to test step 2.
2. Reduce load and continue to If problem still exists, go to test
monitor temperature. step 3.
3. Check transmission oil level (WP If transmission oil is low, fill to
Maintenance.
3. Transmission Does Not Operate in Any Check transmission oil level (WP 0004 If transmission oil is low, fill to
Gear. 00). correct level (WP 0004 00). If
Maintenance.
4. Transmission Does Not Shift From One 1. Check position of parking brake Disengage parking brake. If
Direction to Another. switch. problem still exists, go to test step
2.
2. Shift transmission to N If problem still exists, go to test
(NEUTRAL) and back to step 3.
appropriate direction.
3. Check transmission oil level (WP If transmission oil is low, fill to
Maintenance.
5. Transmission Does Not Shift From One 1. Check transmission oil level (WP If transmission oil is low, fill to
Gear to Another. 0004 00). correct level (WP 0004 00). If
Maintenance.
2. Ensure that autoshift switch is in If problem still exists, notify Unit
desired mode (manual/auto). Maintenance.
6. Transmission Engages, but Machine Restart engine. If problem still exists, notify Unit
Does Not Move. Engine Stops Running. Maintenance.
END OF WORK PACKAGE
0010 00-14
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 cor-
rections 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 indi-
cating a fault. Item numbers also appear in the order that you must perform checks and services for the interval listed.
2. Interval Column. This column tells you when you must perform the procedure in the Procedure column.
a. Before procedures must be done immediately before you operate the loader.
b. During procedures must be done while you are operating the loader.
c. After procedures must be done immediately after you have operated the loader.
d. Weekly procedures must be done once each week.
e. Monthly procedures must be done once each month.
3. Man-Hours Column. This column indicates man-hours required to complete prescribed lubrication.
4. Location, Item to Check/Service Column. This column provides the location and item to be checked or serviced.
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 any-
thing 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 some-
thing seriously wrong, IMMEDIATELY report it to your supervisor.
3. Before performing preventive maintenance, read all the checks required for the applicable interval and prepare all that 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
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 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 connec-
tors. Reconnect loose connectors. Ensure that wires are in good condition.
g. Hoses and Fluid Lines. Look for wear, damage, and signs of leaks. Check for loose clamps and fittings. Wet 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 follow-
ing 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 0011 00
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.
Leakage Definitions for PMCS
Class I Leakage indicated by wetness or discoloration, but not great enough to form
drops.
Class II Leakage great enough to form drops, but not enough to cause drops to drip from
the item being checked/inspected.
Class III Leakage great enough to form drops that fall from the item being checked/
inspected.
END OF WORK PACKAGE
0011 00-3/(0011 00-4 Blank)

54
TM 5-3805-291-10
PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)

INCLUDING LUBRICATION INSTRUCTIONS 0012 00
PMCS INITIAL SETUP
Basic Issue Items (Table 2, WP 0026 00) FM 3-11.3

FM 3-11.5
Materials/Parts
FM 9-207
Antifreeze (Item 1, WP 0027 00)
TM 9-6140-200-14
Cleaning compound, solvent (Item 2, WP 0027 00)
WP 0004 00
Cleaning compound, windshield (Item 3, WP 0027
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
Rag, wiping (Item 13, WP 0027 00) Equipment Conditions
Test kit, SCA (Item 17, WP 0027 00) Machine parked on level ground (WP 0005 00)
Work tool lowered to ground (WP 0005 00)
Personnel Required
Parking brake engaged (WP 0005 00)
MOS 21E, Heavy Construction Equipment Opera-
tor 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

INCLUDING LUBRICATION INSTRUCTIONS - CONTINUED 0012 00
Table 1. Preventive Maintenance Checks and Services (PMCS) for the 966H Wheel Loader.
LOCATION
ITEM TO
ITEM MAN- CHECK/ NOT FULLY MISSION
NO. INTERVAL HOURS SERVICE PROCEDURE CAPABLE IF:
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 Overall View a. Check on ground under machine Class III oil or coolant leaks
0012 00 for evidence of fluid leakage such are evident. Any fuel leak-
as 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.
2 Before Forklift Pallet Check for cracked, bent, or otherwise Cracks or damage that
Forks (If damaged forks and fork frame. would impair operation is
Equipped) evident.
3 Before Bucket and a. Check bucket for bends, cracks, or Cracks or damage that
Bucket Tips (If other damage. would impair operation is
Equipped) evident.
b. Check for missing tip. Replace if
necessary.
4 Before Sweeper (If Check sweeper for damage. Damage that would impair
Equipped) operation is evident.
5 Before Quick Cou- a. Check quick coupler for cracks Cracks are evident. Wear
pler, Tilt Cyl- and wear in pin area. that would impair security
inder, and Lift of coupling is evident.
Arms 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

Table 1. Preventive Maintenance Checks and Services (PMCS) for the 966H Wheel Loader - Continued.
LOCATION
ITEM TO
6 Before Left-Front a. Check for missing bolts. Two or more bolts are miss-
Wheel and ing.
Tire
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 evi-
leaks from final drive. dent.
7 Before Left-Front a. Check that left-front service light Lights are missing or dam-
Lights assembly (service lights and turn- aged, if required for mis-
427-C0064
lamps) is present and not dam- sion.

aged.
b. Check that blackout drive light is Blackout drive light is miss-
present and not damaged. ing or damaged, if required
for mission.
8 Before Frame Articu- a. Check for cracks or breaks in drive Cracks or breaks are evi-
lation Area shaft. 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. Inspect for missing, damaged, or
leaking remote grease fittings.
0012 00-3
TM 5-3805-291-10

LOCATION
ITEM TO
8 Before Frame Articu- d. Check that left-side steering cylin- Steering cylinder is not
(Cont) lation Area der pin is secure. securely attached to front
frame section.
e. Inspect upper and lower articula- Upper and lower articula-
tion pin/bearing assemblies for tion pin/bearing assemblies
evidence of cracks, breaks, miss- are cracked, have breaks,
ing mounting bolts, or damaged or missing mounting bolts, or
missing grease fittings. 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
leaks. are evident.
g. Check transmission oil level and
fill if necessary (WP 0004 00).
h. Check that steering frame lock is
disconnected and stowed. If con-
nected, disconnect IAW instruc-
tions in WP 0015 00.
9 Before Left-Side Cab, a. Inspect front, left, and rear of cab Damage is noted that would
Door, Ladder, for damage and broken glass. impair operation.
and Operator Check for damaged or missing
Platform 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

LOCATION
ITEM TO
9 Before Left-Side Cab, NOTE
(Cont) Door, Ladder,
If left-side ladder and/or platform are damaged, operator
and Operator
may use right-side ladder and/or platform.
Platform
d. Check that ladder is securely
mounted and in good condition.
e. Check that operator platform is
securely mounted and in good con-
dition.
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 a. Check for missing bolts. Two or more bolts are miss-
Wheel and ing.
Tire
11 Before Left-Side a. Open left-side access door.
Engine Enclo-
sure
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

LOCATION
ITEM TO
12 Before Engine Cool- a. 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 fol-
lows:
WARNING
• DO NOT service cooling system unless engine has been
allowed to cool down. This is a pressurized cooling sys-
tem and escaping steam or hot coolant will cause seri-
ous burns.
• DO NOT remove cooling system radiator cap 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 cool-
ant overflow tank.
(3) Add a 50/50 mixture of anti-
freeze and clean water to bring
level up to FULL mark on cool-
ant 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 dam-
cap 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

LOCATION
ITEM TO
12 Before Engine Cool-
(Cont) ant Level
13 Before Left Side of a. Ensure that aftercooler and air Tubes are not securely
Engine intake tubes are secure. mounted.
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 tur-
bocharger.
c. Check the transmission and Damage that would impair
hydraulic oil coolers, aftercooler, cooling is evident.
and radiator for damaged compo-
nents.
14 Before Battery Box, a. Check that left-side battery box
NATO Slave cover is closed and secure.
Receptacle
b. Ensure that cover is installed on
NATO slave receptacle.
0012 00-7
TM 5-3805-291-10

LOCATION
ITEM TO
15 Before 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 protec-
tion. 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 warn-
ing may cause serious injury or death to personnel.
NOTE
• Ether canister needs to be installed when starting
below 40°F (4°C).
• If canister is not installed, ensure cap is installed on
solenoid valve.
a. Check that ether canister is 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 leak-
coolant, or fuel. age is evident.
17 Before Rear of a. Check that rear lights are present Rear lights are missing or
Machine 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 miss-
installed. ing.
d. Check for evidence of any fuel Any fuel leaks are evident.
leaks.
e. Close rear access door. Rear access door will not
close and latch securely.
0012 00-8
TM 5-3805-291-10

LOCATION
ITEM TO
18 Before Right-Side a. Tilt hood to open position (WP
Engine Enclo- 0004 00).
sure
b. Check for evidence of leaks. Class III leaks are evident.

Any fuel leaks are evident.
0012 00-9
TM 5-3805-291-10

LOCATION
ITEM TO
19 Before 0.2 Hour 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 con-
dition of oil. Look for evidence of
antifreeze or fuel contamination.
Report any problem to your super-
visor.
c. Wipe dipstick clean, then reinsert
into dipstick tube until fully
seated. Remove dipstick and take
reading.
d. Level must be within cross-
hatched 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 clock-
wise (to the right) until tight.
0012 00-10
TM 5-3805-291-10

LOCATION
ITEM TO
19 Before 0.2 Hour Engine Oil
(Cont) Level 0012 00
427-C-1674
0012 00-11
TM 5-3805-291-10

LOCATION
ITEM TO
20 Before Fuel/Water
Separator
Drain 0012 00
WARNING
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
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

LOCATION
ITEM TO
21 Before Fan Housing 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 a. Check for missing lug nuts. Two or more lug nuts are
Wheel and missing.
Tire
23 Before Right-Side a. Inspect right side of cab for dam- Damage is noted that would
Cab, Ladder, age and broken glass. impair operation.
and Operator
Platform
b. Check that front and rear right-side
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

LOCATION
ITEM TO
24 Before Frame Articu- a. Inspect hydraulic hoses for dam- If cracks, splits, bulges, or
lation Area age or leaks. soft spots are evident in
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 a. Check that right-front service Lights are missing or dam-
Lights and lights and turnlamps are present aged, if required for mis-
Horn and not damaged. sion.
b. Check that horn is present and not Horn is missing.
damaged.
0012 00-14
TM 5-3805-291-10

LOCATION
ITEM TO
26 Before Right-Front a. Check for missing bolts. Two or more bolts are miss-
Wheel and ing.
Tire
27 Before Quick Cou- a. Check quick coupler for cracks Cracks are evident. Wear
pler and Lift and wear in pin area. that would impair security
Arms 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 a. Use left-side ladder and grabhan-

Top of dles to open door and latch in fully
Machine 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

LOCATION
ITEM TO
28 Before Platform and d. If oil is not visible in red area of
(Cont) Top of sight gage, add oil as follows:
Machine
(1) Remove filler cap.
WARNING
Solvent cleaning compound MIL-PRF-680 Type III is an
environmentally compliant and low toxic material. How-
ever, 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

LOCATION
ITEM TO
28 Before Platform and
(Cont) 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 inspec-
tion 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

LOCATION
ITEM TO
29 Before Cab Interior WARNING
(Cont)
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 inte-
rior 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 Start- a. Start engine and allow to warm up
up (WP 0005 00).
b. Ensure all alert indicators are func- Alert indicator or gage mal-
tioning 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 alarm does not
(REVERSE) and listen for backup sound.
alarm to sound.
c. Return transmission to N (NEU-
TRAL). Machine is now ready to
operate.
0012 00-18
TM 5-3805-291-10

LOCATION
ITEM TO
32 Before 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.
Disengage parking brake switch. Parking brake switch does
not disengage.
33 Before 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 Unlock hydraulic controls. Cycle Controls do not function
Hydraulic loader control joystick. properly.
Controls
0012 00-19
TM 5-3805-291-10

LOCATION
ITEM TO
35 During Overall a. Be alert for evidence of fluid leaks Class III oil or coolant leaks
0012 00 Machine 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 malfunc-
steering components. tions.
d. Be alert for proper operation of Work tools do not function
work tool hydraulic controls. properly.
36 During Gages, a. Monitor all gages for proper oper- Gage indicates an abnormal
Switches, and ation and readings in normal reading.
Indicators ranges.
b. Monitor all indicators to ensure Indicators indicate an abnor-
machine systems are operating mal condition (WP 0004
within normal range. 00).
c. Shut down engine (WP 0005 00).
0012 00-20
TM 5-3805-291-10

LOCATION
ITEM TO
FRONT AND
LEFT SIDE
37 After Overall View a. Check under machine for evidence Class III leaks oil or coolant
0012 00 of fluid leakage such as oil, cool- are evident. Any fuel leaks
ant, or fuel. are evident.
38 After Forklift Pallet Check for cracked, bent, or otherwise Cracks or damage that
Forks (If damaged forks and fork frame. would impair operation is
Equipped) evident.
39 After Bucket and Check bucket and bucket tips for Cracks or damage that
Bucket Tips (If bends, cracks, or other damage. would impair operation is
Equipped) evident.
40 After Sweeper (If Check sweeper for damage. Damage that would impair
Equipped) operation is evident.
41 After Quick Cou- a. Check quick coupler for cracks Cracks are evident. Wear
pler, Tilt Cyl- and wear in pin area. that would impair security
inder, and Lift of coupling is evident.
Arms
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 cylinder is not Damage that would impair
scratched. operation is evident.
42 After Left-Front a. Check for loose or missing bolts, Two or more bolts are miss-
Wheel and cracks, and loose components. ing. Loose components are
Tire evident.
Remove foreign material from
treads.
0012 00-21
TM 5-3805-291-10

LOCATION
ITEM TO
42 After Left-Front d. Look behind tire to ensure axle Axle seal is leaking.
(Cont) Wheel and seal is not leaking. A leaking axle
Tire seal will leave streaks of oil on
inside of wheel.
e. Check back side of wheel for oil Class III oil leaks are evi-
43 After Left-Front a. Check left-front service lights and Lights are missing or dam-
Lights turnlamps are present and not aged, if required for mis-
damaged. sion.
b. Check that blackout drive light is Blackout drive light is miss-
present and not damaged. ing or damaged, if required
for mission.
44 After Frame Articu- a. Check for cracks or breaks in drive Cracks or breaks are evi-
lation Area shaft. dent.
b. Inspect hydraulic hoses for dam- If cracks, splits, bulges, or
age or leaks. soft spots are evident in
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 articula- Upper and lower articula-
tion pin/bearing assemblies for tion pin/bearing assemblies
evidence of cracks, breaks, loose are cracked, have breaks,
or missing mounting bolts, or loose or missing mounting
damaged or missing grease fit- bolts, or damaged or miss-
tings. ing grease fittings.
e. Check that steering frame lock is
present and in good condition.
Ensure it is disconnected and
stowed.
0012 00-22
TM 5-3805-291-10

LOCATION
ITEM TO
45 After Left-Side Cab, a. Inspect front, left, and rear of cab Damage that would impair
Door, Ladder, for damage and broken glass. operation is evident.
and Operator Check for damaged or missing
Platform front and rear windshield wipers/
washers.
b. Check that front and rear left-side
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.
dition.
0012 00-23
TM 5-3805-291-10

LOCATION
ITEM TO
46 After Batteries,
Left-Side Bat-
tery Box, and
NATO Slave
Receptacle WARNING
0012 00
• 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 per-
sonnel. 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 person-
nel.
• 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 per-
sonnel.
NOTE
• For complete information on servicing batteries, refer
to TM 9-6140-200-14.
• Perform service on both batteries.
a. Check that left-side battery box Battery is leaking electro-
cover 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 batter-
electrolyte 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 con-
roded 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

LOCATION
ITEM TO
46 After Batteries, f. Ensure battery is clean and battery Battery cables are not
(Cont) Left-Side Bat- cables are secure. secure.
tery Box, and g. Close access cover and secure.
NATO Slave
Receptacle h. Ensure that cover is installed on
NATO slave receptacle.
47 After Windshield a. Check for damage and leaks on
Washer Fluid windshield washer fluid reservoir.
Reservoir b. Check level of windshield washer
fluid. If level is low, remove cap
and add windshield-cleaning com-
pound until level is up to top of
filler neck. Reinstall cap.
427-C1680
48 After Left-Rear a. Check for loose or missing bolts, Two or more bolts are miss-
Wheel and cracks, and loose components. ing. Loose components are
Tire evident.
treads.
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

LOCATION
ITEM TO
48 After Left-Rear e. Check back side of wheel for oil Class III oil leaks are evi-
(Con’t) Wheel and leaks from final drive. dent.
Tire
49 After Left-Side CAUTION
Engine Enclo- Screen prevents stones or other flying debris from entering
sure 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.
51 After Rear of a. Check that rear lights are present Rear lights are missing or
Machine 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 miss-
installed. ing.
d. Check for evidence of any leak. Any fuel leaks are evident.
0012 00-26
TM 5-3805-291-10

LOCATION
ITEM TO
51 After Rear of
(Con’t) Machine
WARNING
machine while you are servicing fuel system. Be sure
hose nozzle is grounded against filler tube during
refueling to prevent static electricity. Failure to fol-
low this warning may result in injury or death to per-
sonnel, or damage to equipment.
• Operating personnel must wear fuel-resistant 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

LOCATION
ITEM TO
52 After Right-Side CAUTION
Engine Enclo-
Screen prevents stones or other flying debris from entering
sure
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. Class III leaks are evident.
Any fuel leaks are evident.
53 After 0.2 Hour Engine Oil a. Wipe area clean around dipstick.
Level
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 con-
dition of oil. Look for evidence of
antifreeze or fuel contamination.
Report any problem to your super-
visor.
c. Wipe dipstick clean, then reinsert
into dipstick tube until fully
seated. Remove dipstick and take
reading.
d. Level must be within cross-
hatched area on dipstick.
e. If level is low, turn filler cap coun-
terclockwise (to the left) and add
lubricating oil (Item 9, 10, 11, or
12, WP 0027 00) through filler
tube opening until level on dip-
stick is correct. Refer to KEY at
end of this work package for cor-
rect grade of oil for expected tem-
perature range.
0012 00-28
TM 5-3805-291-10

LOCATION
ITEM TO
53 After 0.2 Hour Engine Oil f. Reinstall dipstick and turn clock-
(Cont) Level wise (to the right) until tight.
g. Tilt hood to open position (WP Hood does not open.
0004 00).
54 After Right-Rear a. Check for loose or missing bolts, Two or more bolts are miss-
Wheel and cracks, and loose rim components. ing. Loose components are
Tire evident.
treads.
d. Look behind tire to ensure axle Axle seal is leaking.
inside of wheel.
e. Check backside of wheel for oil Class III oil leaks are evi-
55 After Right-Side a. Inspect right side of cab for dam- Damage is noted that would
Cab, Ladder, age and broken glass. impair operation.
and Operator b. Check that front and rear right-side
Platform worklights are present and not
damaged.
c. Check for damage to windows and
grabhandles.
dition.
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 Articu- a. Inspect hydraulic hoses for dam- If cracks, splits, bulges, or
lation Area age or leaks. soft spots are evident in
evident.
0012 00-29
TM 5-3805-291-10

LOCATION
ITEM TO
56 After Frame Articu- b. Check that right-side steering cyl- Steering cylinder is not
(Con’t) lation Area inder attachment to front frame securely attached to front
section is secure. frame section.
c. Inspect upper and lower Upper and lower articula-
articulation pin/bearing assemblies tion pin/bearing assemblies
for evidence of cracks, breaks, are cracked, have breaks,
loose or missing mounting bolts, loose or missing mounting
or damaged or missing grease bolts, or damaged or miss-
fittings. ing grease fittings.
57 After Right-Front Check right-front service lights and Lights are missing or
Lights turnlamps for damage. damaged.
58 After Right-Front a. Check for loose or missing bolts, Two or more bolts are miss-
Wheel and cracks, and loose rim components. ing. Loose components are
Tire evident.
treads.
d. Look behind tire to ensure axle Class III oil leak is evident.
inside of wheel.
e. Check back side of wheel for oil Class III oil leaks are evi-
59 After Quick Cou- a. Check quick coupler for cracks Cracks are evident. Wear
pler and Lift and wear in pin area. that would impair security
Arms 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 grabhan-

Top 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

LOCATION
ITEM TO
60 After Platform and b. Check that hydraulic tank filler Hydraulic tank filler cap is
(Con’t) Top of cap is present. Check for damage damaged or missing. Class
Machine or leaks. III leaks are evident.
0012 00
c. Ensure oil is visible in hydraulic Oil is not visible in sight
tank sight gage. 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

LOCATION
ITEM TO
63 After Hood and Bat- a. Tilt hood to close position (WP
tery Discon- 0004 00).
nect Switch b. Turn battery disconnect switch to
OFF position (WP 0004 00).
64 Weekly Engine Air Service engine air precleaner and air
0012 00 Precleaner cleaner (WP 0014 00).
and Air
Cleaner
65 Weekly Cab Air Fil-
0012 00 ters
0012 00
WARNING
• If NBC exposure is suspected, personnel wearing pro-
tective equipment must handle all air cleaner media.
Consult your NBC Officer or NBC NCO for appropri-
ate handling or disposal procedures.
• Refer to FM 3-11.3, Multiservice Tactics,
Techniques, and Procedures for Chemical,
Biological, Radiological, and 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 ade-
quate 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

LOCATION
ITEM TO
65 Weekly Cab Air Fil- There are two cab air filters. First fil-
(Con’t) 0012 00 ters 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-C1676
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 thor-
oughly and air dry.
d. Install air filter and tighten two
thumbscrews by turning clockwise
(to the right).
0012 00-33
TM 5-3805-291-10

LOCATION
ITEM TO
65 Weekly Cab Air Fil- e. Open access door on left side of
(Cont) ters cab.
f. Remove air filter from left side of
cab.
427-C1678
427-C1679
0012 00-34
TM 5-3805-291-10

LOCATION
ITEM TO
65 Weekly Cab Air Fil-
(Cont) ters
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 other-
wise 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 a. Check if bolts are loose. Bolts are loose.
Tires
0012 00-35
TM 5-3805-291-10

LOCATION
ITEM TO
66 Weekly Wheels and WARNING
(Cont) Tires
• Operating machine with underinflated or defective tire
may lead to tire failure and loss of traction or control.
Failure to follow this warning may cause damage to
equipment or injury to personnel.
• If tire pressure is 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 infla-
tion 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. Tread depth is less than
11/32 in. (8.8 mm).
0012 00-36
TM 5-3805-291-10

LOCATION
ITEM TO
67 Weekly 0.4 Hour Remote a. Open access door on right side of
Grease Fit- operator platform.
tings
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

LOCATION
ITEM TO
68 Weekly 0.1 Hour Steering Cylin- a. Wipe steering cylinder rod end
der Rod Ends grease fittings clean with a rag.
Grease Fit- b. Apply GAA grease to grease fit-
tings ting. Wipe off excess grease with a
rag.
c. Repeat to lubricate steering cylin-
der rod end on other side of
machine.
427-C1683
0012 00-38
TM 5-3805-291-10

LOCATION
ITEM TO
69 Weekly 0.3 Hour Bucket Link- a. Wipe four grease fittings clean
age and with a rag.
Loader Cylin- b. Apply GAA grease to four fittings.
der Bearings Wipe off excess grease from fit-
tings.
427-C1685
427-C1684
0012 00-39
TM 5-3805-291-10

LOCATION
ITEM TO
70 Weekly 0.2 Hour Lift Arm a. Wipe two grease fittings clean
Lower Pivot with a rag.
Bearings
b. Apply GAA grease to two fittings.
Wipe off excess grease from fit-
tings.
427-C1686
71 Weekly 0.2 Hour Lift Arm a. Wipe two grease fitting clean with
Upper Pivot a rag.
Bearings
tings.
427-C1687
0012 00-40
TM 5-3805-291-10

LOCATION
ITEM TO
72 Weekly 0.3 Hour Quick Coupler a. Wipe four grease fittings clean
with a rag.
b. Apply GAA grease to four fittings.
tings.
427-C1688
73 Weekly 0.2 Hour Articulation a. Wipe two grease fittings clean

Bearings with a rag.
0012 00
tings.
427-C1689 427-C1690
0012 00-41
TM 5-3805-291-10

LOCATION
ITEM TO
74 Monthly 0.2 Hour Hood Tilt a. Tilt hood to open position (WP Hood does not open.
0012 00 Actuator 0004 00).
Grease Fit- b. Wipe two grease fittings clean
tings with a rag.
c. Apply GAA grease to two fittings.
tings.
d. Close hood (WP 0004 00).
427-C1691
75 Monthly 0.3 Hour Drive Shaft

Spline (Cen-
ter)
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
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

LOCATION
ITEM TO
75 Monthly 0.3 Hour Drive Shaft c. Lower work tool to ground.
(Con’t) Spline (Cen- Engage parking brake (WP 0004
ter) 00).
d. Shut down engine (WP 0005 00).
e. Wipe grease fitting clean with a
rag.
f. Apply GAA grease to grease fit-
ting. Apply grease until 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 artic-
ulate 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 sys-
tem and escaping steam or hot coolant will cause seri-
ous 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

LOCATION
ITEM TO
77 Monthly Brake Accu- a. 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 min-
utes 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 ser-
vice brake applications are
required.
e. If less than five applications were Accumulator is discharged.
required, accumulator needs
recharging. Notify Unit Mainte-
nance.
78 Monthly Service Brake WARNING
Holding Abil-
If machine begins to move during test, reduce engine speed
ity Test
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 sur-
face.
(2) Ensure steering frame lock is
disconnected and stowed (WP
0015 00).
(3) Check area around machine to
ensure machine is clear of per-
sonnel and obstructions.
0012 00-44
TM 5-3805-291-10

LOCATION
ITEM TO
78 Monthly Service Brake WARNING
(Cont) Holding Abil-
Use of seat belt while operating machine is mandatory. Fas-
ity Test
ten 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 person-
nel 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 trans-
mission 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,
0012 00-45
TM 5-3805-291-10

LOCATION
ITEM TO
79 Monthly Parking Brake WARNING
Holding Abil-
If machine begins to move during test, reduce engine speed
ity Test
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 sur-
face.
(2) Ensure steering frame lock is
disconnected and stowed (WP
0015 00).
(3) Check area around machine to
ensure machine is clear of per-
sonnel and obstructions.
WARNING
Use of seat belt while operating machine is mandatory. Fas-
ten 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 person-
nel 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 MAN-
UAL mode.
f. Gradually increase engine speed to
high idle. Machine should not
move.
0012 00-46
TM 5-3805-291-10

LOCATION
ITEM TO
79 Monthly Parking Brake g. Reduce engine speed to low idle.
(Cont) Holding Abil- Move 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 Ensure all decals and data plates are
Data Plates present and legible (WP 0007 00).
81 Monthly Arctic Heater Start arctic heater and run for 15 to 20 Arctic heater does not func-
(If Equipped) minutes. Shut off. tion.
82 Monthly All Systems - CAUTION
Machine Exer-
DO NOT perform this PMCS exercise when temperature is
cise
below 0 F (-18 C). Doing so can cause damage to equip-
ment.
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 all ranges
including reverse.
0012 00-47
TM 5-3805-291-10

LOCATION
ITEM TO
82 Monthly All Systems - (2) Service brakes applied and
(Cont) Machine Exer- released.
cise
(3) Parking brake engaged and dis-
engaged.
(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 tem-
perature.
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
TM 5-3805-291-10

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 peri-
ods. Use correct grade of lubricant for seasonal temperature expected. Refer to the KEY on the next page.
3. For equipment under manufacturer’s warranty, hardtime intervals shall be followed. Shorten intervals if lubricants are
known to be contaminated or if operation is under adverse conditions (e.g., longer than usual operating hours, 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
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 result in injury or death to personnel.
5. Clean area around lubrication points with solvent cleaning compound (Item 2, WP 0027 00) or equivalent before lubri-
cating equipment. Keep all external parts of equipment not requiring lubrication free of lubricants. After lubrication,
wipe off excess lubricant to prevent accumulation of foreign matter.
6. Maintain a record of lubrication performed and report any problems noted during lubrication. Refer to DA PAM 750-8
for forms and procedures to record and report any findings.
0012 00-49
TM 5-3805-291-10

LUBRICATION INSTRUCTIONS – CONTINUED

NOTE
Only lubricants authorized for use by the operator are listed in this KEY.
- KEY-
LUBRICANT/ REFILL
COMPONENT CAPACITY EXPECTED TEMPERATURES* INTERVALS
OE/HDO D - Daily
Lubricating Oil, ICE, W - Weekly
Tactical Service M - Monthly
(MIL-PRF-2104)
Engine Crankcase 9.25 gal. See Table 2

(35 L)
Transmission 13.2 gal. See Table 2
(50 L)
Hydraulic Tank 29 gal. See Table 2

(110 L)
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
ANTIFREEZE
Cooling System 11.2 gal. See Table 3

(42.3 L)
* For arctic operation, refer to FM 9-207.
0012 00-50
TM 5-3805-291-10

LUBRICATION INSTRUCTIONS – CONTINUED 0012 00
Table 2. Lubricants.
COMPARTMENT COMMERCIAL VISCOSITY MILITARY TEMPERATURE
LUBRICANT GRADE LUBRICANT RANGE
Engine CF-4 or Better SAE 5W-40 OE/HDO-5/40 -25oF to 120oF (-32oC to 49oC)
SAE 15W-40 OE/HDO-15/40 15oF to 120oF (-9oC to 49oC)
SAE 0W-30 OEA-30 -40oF to 90oF (-40oC to 32oC)
Transmission TO-4 SAE 40 OE/HDO-40 40oF to 120oF (4oC to 49oC)

SAE 50 N/A 50oF to 120oF (10oC to 49oC)
Hydraulic CF or Better SAE 5W-40 OE/HDO-5/40 -25oF to 120oF (-32oC to 49oC)

SAE 15W-40 OE/HDO-15/40 5oF to 120oF (-15oC to 49oC)
Axles TO-4 SAE 50 N/A 50oF to 120oF (10oC to 49oC)

Grease MPG NLGI No. 2 GAA -25oF to 120oF (-32oC to 49oC)
Table 3. Coolants.
MILITARY TEMPERATURE
COOLANT TYPE MIXTURE
COOLANT RANGE
Engine I-Ethylene Glycol 60/40 A-A-52624 -50oF to 120oF (-46oC to 49oC)
Coolant II-Propylene Glycol
Engine I-Ethylene Glycol 50/50 A-A-52624 -30oF to 120oF (-34oC to 49oC)

Coolant II-Propylene Glycol
0012 00-51
TM 5-3805-291-10

LUBRICANT • INTERVAL INTERVAL • LUBRICANT
427-C0365
0012 00-52
TM 5-3805-291-10

INCLUDING 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
Refueling, Fuel System Priming
INITIAL SETUP
Tools and Special Tools Equipment Conditions

Extinguisher, fire (Item 4, Table 2, WP 0026 00) Machine parked on level ground (WP 0005 00)
Materials/Parts
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
Personnel Required operation machine (WP 0004 00)
MOS 21E, Heavy Construction Equipment Opera- Battery disconnect switch in OFF position (WP
tor 0004 00)
REFUELING 0013 00
WARNING
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 replace-
ment 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:
a. Engine continues to not start.
b. Engine starts but continues to misfire or emit smoke.
5. Lower hood (WP 0004 00).
END OF WORK PACKAGE
0013 00-2
4
TM 5-3805-291-10
ENGINE AIR PRECLEANER SERVICE AND AIR CLEANER SERVICE 0014 00
Service
INITIAL SETUP
Materials/Parts Equipment Conditions
Rag, wiping (Item 13, WP 0027 00) Machine parked on level ground (WP 0005 00)

Personnel Required
tor Engine OFF (WP 0005 00)
Battery disconnect switch in OFF position (WP

References 0004 00)
FM 3-11.3
FM 3-11.5
SERVICE
WARNING
personnel.
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 com-
ponents. 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
General Information, Connection, Disconnection
INITIAL SETUP
Tools and Special Tools Equipment Conditions

COEI (Items 2 thru 4, Table 1, WP 0026 00) Machine parked on level ground (WP 0005 00)
Personnel Required Work tool lowered to ground (WP 0005 00)
MOS 21E, Heavy Construction Equipment Opera- Parking brake engaged (WP 0005 00)
tor (2) 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
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).

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

F25 powertrain ECM
F1 rear worklights
F26 headlamps
F2 front worklights
F27 arctic heater
F3 power converter
F28 engine start switch
F4 wipers
F29 spare
F5 seat
F30 hood actuator
F6 LH brake pedal
control switch
sensor/shift lever
F31 instrument cluster/
F7 position sensors
Messenger
F8 ECM switch power
F32 backup alarm
F9 spare
F33 horn
F10 spare
CB1 spare
F11 implement lockout/
CB2 hood tilt actuator
quick coupler
CB3 HVAC blower
F12 spare
D1 backlights
F13 secondary steering
D2 flasher
F14 spare
D3 LH turnlamp
F15 spare
D4 RH turnlamp
F16 spare
R1 secondary steering
F17 spare
R2 spare
F18 spare
R3 spare
F19 spare
R4 spare
F20 spare
R5 spare
F21 power converter
R6 spare
F22 spare
R7 backup alarm
F23 implement ECM
R8 spare
F24 engine ECM
0016 00-2
TM 5-3805-291-10
CIRCUIT BREAKER AND FUSES RESET/REPLACE - CONTINUED 0016 00
FUSE REPLACEMENT - CONTINUED
Switched Fuse Block
F1 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)

TM 5-3805-291-10
CHAPTER 6
TRANSPORT PROCEDURES
2
TM 5-3805-291-10
PREPARATION FOR TRANSPORT INTRODUCTION 0017 00
INTRODUCTION
1. This chapter describes how to prepare the 966H Wheel Loader for the following modes of transport:
a. Roading machine (self-deployment) (WP 0018 00)
b. Highway transport (WP 0019 00)
c. Rail transport (WP 0020 00 and WP 0021 00)
d. Marine transport (RO/RO procedures) (WP 0022 00)
e. Air transport by C-5 and C-17 aircraft (WP 0023 00)
2. Depending on mode of transportation selected, assistance from Unit Maintenance may be required to configure 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
Roading Machine
INITIAL SETUP
Personnel Required References

tor 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 compo-
nents to cool.
10. Watch gages and alert indicators for any evidence of malfunction or overheating (WP 0004 00).
11. During stops, inspect machine for evidence of fluid leaks. Check fluid levels and maintain at optimum levels (WP 0012
00).
END OF WORK PACKAGE
0018 00-1/(0018 00-2 Blank)

4
TM 5-3805-291-10
HIGHWAY TRANSPORT 0019 00
Introduction, Configure Machine for Highway Transport, Loading Machine on Trailer, Unloading Machine from Trailer,
Return Machine to Operational Configuration
INITIAL SETUP
Tools and Special Tools Personnel Required
Cord, elastic (Item 1, Table 2, WP 0026 00) MOS 21E, Heavy Construction Equipment Opera-
tor (2)
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
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
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
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
7. Ground guide assistance is MANDATORY when driving machine on or off trailer.
CONFIGURE MACHINE FOR HIGHWAY TRANSPORT 0019 00
Refer to WP 0024 00.
LOADING MACHINE ON TRAILER 0019 00
1. Chock wheels of trailer.
WARNING
Backup alarm does not work with ROPS/FOPS removed. Failure to follow this warning may result in
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.
WARNING
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
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
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
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.
0019 00-3
TM 5-3805-291-10
UNLOADING MACHINE FROM TRAILER - CONTINUED 0019 00
5. Remove vandalism protection devices.

6. Remove tape from exhaust opening.
WARNING
7. Disconnect and securely stow steering frame lock (WP 0015 00).
WARNING
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
• 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
15. Using ground guide assistance and in 1st gear ONLY, SLOWLY drive straight off trailer until clear of ramp.
16. Park machine in staging area clear of trailer (WP 0005 00).
19. Install four sets of plugs (Items 6 and 7, Table 2, WP 0026 00) on electrical connectors and install tarp (Items 1 and 10,
Table 2, WP 0026 00) to protect cab.
RETURN MACHINE TO OPERATIONAL CONFIGURATION 0019 00
Refer to WP 0024 00.
END OF WORK PACKAGE
0019 00-4
6
TM 5-3805-291-10
RAIL TRANSPORT 0020 00
Introduction, Loading Machine on Flatcar, Unloading Machine from Flatcar
INITIAL SETUP

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
WP 0021 00
tor (2) 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
required when operating without ROPS/FOPS during transport procedures. Failure to wear hearing
• 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
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
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 anti-
freeze protection if being transported to a colder cli-
mate.
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.
WARNING
9. Ground guide assistance is MANDATORY when driving machine on or off flatcar.
LOADING MACHINE ON FLATCAR 0020 00
1. Chock wheels of flatcar.
WARNING
Backup alarm does not work with ROPS/FOPS removed. Failure to follow this warning may result in
0020 00-2
TM 5-3805-291-10
LOADING MACHINE ON FLATCAR - CONTINUED 0020 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.
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
• 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 direc-
tion.
10. Once machine is correctly positioned on flatcar bed, lower loader arm (WP 0004 00). Rest work tool on blocking.
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
0020 00-3
TM 5-3805-291-10
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.
19. Install four sets of plugs (Items 6 and 7, Table 2, WP 0026 00) on electrical connectors and install tarp (Items 1 and 10,
Table 2, WP 0026 00) to protect cab.
20. Secure machine on flatcar bed with blocking and tiedowns, in accordance with shipping data plate on machine and illus-
tration of tiedown points in WP 0017 00 and instructions in WP 0021 00.
UNLOADING MACHINE FROM FLATCAR 0020 00
1. Chock wheels of flatcar.

5. Remove tape from exhaust pipe.
WARNING
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

12. Raise loader arm (WP 0004 00). Remove blocking from under work tool.
0020 00-4
TM 5-3805-291-10
UNLOADING MACHINE FROM FLATCAR - CONTINUED
WARNING
• Always use ground guides when unloading machine from flatcar. Failure to use ground guides may cause
• When driving machine off flatcar, drive with extreme caution and in 1st gear ONLY. Failure to follow this
13. Following instructions from flatcar load master and ground guides, slowly drive straight off flatcars until clear of rail-
head.
a. Use 1st gear ONLY.
b. When passing over spanners between flatcars, maintain a constant speed. DO NOT jam on brakes or reverse direc-
tion.
14. Park machine in staging area (WP 0005 00).
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
966H with Broom Attachment and Fork Carriage/5-Yard Bucket
INITIAL SETUP
Tools and Special Tools Personnel Required
1/2-in. wire steel cables (3) MOS 21E, Heavy Construction Equipment Opera-
tor (2)
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/util-
ity) with the forks fully spread and the bucket centered on the fork carriage.
2. Drive the assemblage onto the rail car or load from the side of the car, depending on mission requirements.
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 45-
degree angle on the chain tiedowns (Figure 1).
6. Attach the broom attachment to the 966H Wheel Loader in accordance with instructions in WP 0005 00.
7. Drive the 966H with broom attachment onto the rail car. Center the assemblage on the rail car and secure two each rail
car tiedowns to each of the front and rear tiedown provisions for a total of eight tiedowns (Figures 2 and 3).
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
427-C2038
Figure 2. FOL front roadside tiedowns.
427-C2040
Figure 3. FOL rear tiedowns.
0021 00-3
TM 5-3805-291-10
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
Introduction, RO/RO Regulations, Loading Machine on Ship, Unloading Machine from Ship
INITIAL SETUP
Personnel Required References - Continued

tor (2)
WP 0011 00
References 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
5. In order to accomplish RO/RO, the machine must operate up and down ramps. The grade of the ramps will vary,
depending on the tide and the weight of the ship at the time of loading or unloading. Ground guide assistance is MAN-
DATORY when operating on ramps.
6. In order to ensure the safety of all personnel involved, the machine’s operator must be familiar with all RO/RO regula-
tions and procedures.
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
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

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
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
LOADING MACHINE ON SHIP - CONTINUED 0022 00
WARNING
5. Lower loader arm (WP 0004 00). Rest on shoring.

13. Provide assistance, as required, to ship’s crew in blocking/shoring/lashing machine for transport.
UNLOADING MACHINE FROM SHIP 0022 00
1. Provide assistance, as required, to ship’s crew in removing blocking/shoring/lashing from machine.

WARNING
WARNING

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
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
• When operating machine down ramp, drive with extreme caution and in 1st gear ONLY. Failure to follow this
8. With ground guide assistance, negotiate ramps in 1st gear ONLY.
9. Park machine clear of ship loading/unloading zone (WP 0005 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
Introduction, Load Machine, Unload Machine
INITIAL SETUP
Personnel Required References

tor (2) 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
required when operating without ROPS/FOPS during transport procedures. Failure to wear hearing
• 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.
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.
WARNING
6. Relieve hydraulic system pressure from brake, steering, and implement hydraulic systems (WP 0005 00).
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

WARNING
WARNING
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
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
Introduction, Tools and Equipment, ROPS/FOPS Removal, Exhaust Stack Removal, Rear Handrail Removal, Rear Hand-
rail Installation, Exhaust Stack Installation, ROPS/FOPS Installation
INITIAL SETUP

Basic Issue Items (Table 2, WP 0026 00) WP 0004 00
Notify Unit Maintenance to bring general
WP 0011 00
mechanic’s tool kit, common no. 1 shop equip-
ment, and field maintenance shop equipment WP 0012 00
Lifting equipment, 1,500-lb capacity WP 0019 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
WARNING
Use extreme caution when handling heavy parts. Provide adequate support and use assistance during pro-
cedure. Ensure any lifting device used is in good condition and of lifting capacity. Keep clear of heavy 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. 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.
2. Reinstall mounting hardware for all removed components on machine to secure against loss during transport.
ROPS/FOPS REMOVAL 0024 00
NOTE
• Tag electrical harnesses and hoses as they are disconnected to ensure correct connection.
• Work tool must be removed prior to cab removal.
1. Place transmission switch in manual mode.

2. Turn engine start switch to OFF position (WP 0004
00).
3. Remove fire extinguisher and secure with BII.
4. Disconnect four connectors (three electrical and one
coaxial) (1) at right-rear corner of cab.
5. Install three sets of plugs (Items 6 and 7, Table 2, WP
0026 00) on electrical connectors in cab and on ROPS.
6. Close and secure right-side window.
0024 00-2
TM 5-3805-291-10
ROPS/FOPS REMOVAL - CONTINUED 0024 00
WARNING
cedure. 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 per-
sonnel.
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
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
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
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
ROPS/FOPS INSTALLATION - CONTINUED 0024 00
WARNING
cedure. 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 per-
sonnel.
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
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

g. Remove three sets of plugs and connect four con-
nectors (three electrical and one coaxial) (1) at
right-rear corner of cab.
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 relat-
ing 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 effi-
cient operation.
GENERAL
The COEI and BII information is divided into the following lists:
1. Table 1, Components of End Item List. This listing is for informational purposes only and is not authority to requisition
replacements. These items are part of the end item, but are removed and separately packaged for transportation or ship-
ment. As part of the end item, these items must be with the end item whenever it is issued or transferred between 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 oper-
ate it and to perform emergency repairs. Although shipped separately packaged, BII must be with the loader during oper-
ation and whenever it is transferred between property accounts. This manual is your authority to request/requisition
replacement BII, based on TOE/MTOE authorization of end item. Illustrations are furnished to assist you in identifying
the items.
Below is an explanation of columns found in the tabular listings:
1. Column (1) - Illustration Number (Illus Number). This column indicates the number of the illustration that shows the
item.
2. Column (2) - National Stock Number. Indicates the National Stock Number (NSN) assigned to the item and will be used
for requisitioning purposes.
3. Column (3) - Description, CAGEC, and Part Number. Indicates the Federal item name (in all capital letters) and, if
required, a minimum description in parentheses to identify and locate the item. The entry for each item ends with 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 NATIONAL DESCRIPTION, CAGEC, USABLE QTY

NUMBER STOCK NUMBER AND PART NUMBER ON CODE U/M RQD
1 CYLINDER, ETHER EA 1
(11083) 275-3634
2 LINK, STEERING LOCK EA 1
(11083) 127-1579
3 PIN EA 2
(11083) 80-3791
4 5315-01-162-8738 PIN, STRAIGHT-HEADED EA 2
(11083) 5V-6380
0026 00-2
TM 5-3805-291-10
Table 2. Basic Issue Items List.
427-C1574-1
(1) (2) (3) (4) (5) (6)
ILLUS NATIONAL DESCRIPTION, CAGEC, USABLE QTY

NUMBER STOCK NUMBER AND PART NUMBER ON CODE U/M RQD
1 CORD, ELASTIC EA 8
(11083) 262-9305
2 EXTENSION: 6 in., 3/8 in. drive EA 1
(11083) 8H-8575
3 EXTENSION: 12 in., 3/8 in. drive EA 1
(11083) 3P-2240
4 4210-00-889-2221 EXTINGUISHER, FIRE EA 1
(58536) A-A-393
5 4930-00-253-2478 LUBRICATING GUN, HAND EA 1
(11083) 8F9866
0026 00-3
TM 5-3805-291-10
Table 2. Basic Issue Items List - Continued.
427-C1574-2
(1) (2) (3) (4) (5) (6)
Illus National Description, CAGEC, Usable on Qty

Number Stock Number and Part Number Code U/M Rqd
6 PLUG, ELECTRICAL CAP EA 3
(11083) 246-2932
7 PLUG-CONNECTOR, EA 3
ELECTRICAL CAP FOR
HARNESS
(11083) 268-8749
8 5120-01-535-2969 RATCHET: 8 in., 3/8 in. drive EA 1
(11083) 239-6824
9 SOCKET: 11 mm, 3/8 in. drive EA 1
(11083) 194-3490
0026 00-4
TM 5-3805-291-10
Table 2. Basic Issue Items List - Continued.
427-C2015
(1) (2) (3) (4) (5) (6)
Illus National Description, CAGEC, Usable on Qty

Number Stock Number and Part Number Code U/M Rqd
10 8340-00-935-1844 TARPAULIN: 12 x 14 ft EA 1
(81349) MIL-DTL-82288
11 4910-00-204-3170 TIRE GAGE EA 1
(27783) 7188BH
12 5140-01-524-7563 TOOL BAG EA 1
(11083) 211-0136
13 5120-01-437-1727 WRENCH, ADJUSTABLE: 8 in. EA 1
(11083) 214-7323
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.
1. Column (1) - Item Number. This number is referenced in the appropriate work package Initial Setup list or in the narra-
tive instructions to identify the item; e.g., Use antifreeze (Item 1, WP 0027 00).
2. Column (2) - Level. This column identifies the lowest level of maintenance that requires the listed item.
C - Operator/Crew
3. Column (3) - National Stock Number. This is the National Stock Number assigned to the item, which you can use to req-
uisition it.
4. Column (4) - Description, CAGEC, and Part Number. This provides the other information you need to identify 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 NATIONAL DESCRIPTION, CAGEC,

NUMBER LEVEL STOCK NUMBER AND PART NUMBER U/M
1 C ANTIFREEZE
6850-01-383-4068 (1QK63) 672 4354
1 Gallon Bottle GL
6850-01-441-3257 (58536) A-A-52624
5 Gallon Can CN
6850-01-383-3918 (58536) A-A-52624
55 Gallon Drum DR
2 C CLEANING COMPOUND: Solvent, Type III
(81349) MIL-PRF-680
6850-01-474-2318 1 Gallon Can CN
6850-01-474-2320 5 Gallon Can CN
6850-01-474-2321 55 Gallon Drum DR
3 C CLEANING COMPOUND: Windshield
(0FTT5) 0854-000
6850-00-926-2275 16 Ounce Bottle BT
4 C DETERGENT: General Purpose, Liquid
(83421) 7930-00-282-9699
7930-00-282-9699 1 Gallon Can CN
5 C DIESEL FUEL: DF-1 Grade, Arctic
(81346) ASTM D 975
9140-00-286-5286 Bulk GL
9140-00-286-5287 5 Gallon Can CN
9140-00-286-5288 55 Gallon Drum DR
6 C DIESEL FUEL: DF-2 Grade
(81346) ASTM D 975
9140-00-286-5294 Bulk GL
9140-00-286-5295 5 Gallon Can CN
9140-00-286-5296 55 Gallon Drum DR
7 C 9130-01-031-5816 FUEL, TURBINE: Aviation GL
(81349) MIL-T-83133 GR JP-8
0027 00-2
TM 5-3805-291-10
(1) (2) (3) (4) (5)

8 C GREASE: Automotive and Artillery (GAA)

9150-01-197-7688 (81349) M-10924-A
1-1/4 Ounce Tube TU
9150-01-197-7693 (81349) M-10924-B
14 Ounce Cartridge CA
9150-01-197-7690 (81349) M-10924-C
1-3/4 Pound Can CN
9150-01-197-7692 (81349) M-10924-E
35 Pound Can CN
9 C OIL: Lubricating, OE/HDO-40
(81349) MIL-PRF-2104
9150-00-188-9862 55 Gallon Drum DR
10 C OIL: Lubricating, OE/HDO-15/40
(81349) MIL-PRF-2104
9150-01-152-4117 1 Quart Can CN
9150-01-152-4118 5 Gallon Can CN
9150-01-152-4119 55 Gallon Drum DR
11 C OIL: Lubricating, OEA-30 Arctic
9150-00-402-4478 (81349) MIL-L-46167
1 Quart Can QT
9150-00-402-2372 (81349) MIL-PRF-46167
5 Gallon Can GL
9150-01-491-7197 (81349) MIL-PRF-46167
55 Gallon Drum DR
12 C OIL: Lubricating, OE/HDO-5/40
(81349) MIL-PRF-2104
9150-01-524-9155 55 Gallon Drum GL
13 C RAG: Wiping
(64067) 7920-00-205-1711
7920-00-205-1711 50 Pound Bale BL
0027 00-3
TM 5-3805-291-10
(1) (2) (3) (4) (5)

14 C STRAP, TIEDOWN, ELECTRICAL

COMPONENTS
5975-00-903-2284 4 Inch Length, Black, Package of 100
(96906) MS3367-4-0 HD
5975-00-984-6582 6 Inch Length, Black, Package of 100
(96906) MS3367-1-0 HD
5975-00-935-5946 13.35 Inch Minimum Length, Brown
(96906) MS3367-2-1 EA
15 C TAG, MARKER
(64067) 9905-00-537-8954
9905-00-537-8954 Bundle of 50 BD
16 C TAPE: Duct, 2 in. Wide
(39482) 1791K70
5640-00-103-2254 60 Yard Roll RL
17 C 6850-01-154-3653 TEST STRIPS, NITRATE EA
(89524) 500P3205.88
END OF WORK PACKAGE
0027 00-4
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.
1. Column (1) - National Stock Number (NSN). Identifies the stock number of the item to be used for requisitioning pur-
poses.
2. Column (2) - Description, Commercial and Government Entity Code (CAGEC), and Part Number (P/N). Identi-
fies the Federal item name (in all capital letters) followed by a minimum description when needed. The line below 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) (4) (5)

USABLE QTY
NSN DESCRIPTION, CAGEC, P/N ON CODE U/I RECM
5340-01-466-5928 SORBENT DECONTAMINATION EA 1
SYSTEM (SDS) MOUNTING BRACKET
(4X630) 8640-100-0001
4230-01-466-9095 SDS EA 1
(81361) EA-PRF-2163
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0021 00-1
Fork Carriage/5-yard Bucket, 966H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0021 00-1
Auxiliary Hydraulic Control for
Fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-20
Sweeper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0002 00-14
Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-22
Kickout Set Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
E
Electrical
Stopping Engine if Malfunction Occurs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0005 00-8
System, Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0003 00-2
Engine
Air Cleaner Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0014 00-1
Air Precleaner Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0014 00-1
Coolant Level (PMCS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0012 00-6
Oil Level (PMCS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0012 00-10
Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0005 00-3
Start Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-17
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0003 00-1
Equipment
Characteristics, Capabilities, and Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0002 00-1
Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0002 00-9
Improvement Recommendations (EIRs), Reporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0001 00-1
Ether
Starting Aid System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-29
Starting Aid System (PMCS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0012 00-8
Exhaust Stack
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0024 00-6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0024 00-5
Expendable and Durable Items List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0027 00-1
Extreme
Cold, Operate in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0006 00-7
Heat, Operate in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-26
Tilt - Manual Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-26
Index-2
TM 5-3805-291-10
INDEX - Continued
Hydraulic Control Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-11

Hydraulic System
Relieving Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0005 00-10
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0001 00-2
Basic Issue Items (BII) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0026 00-1
Components of End Item (COEI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0026 00-1
Loader Arm, Lowering with Engine Stopped . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0005 00-8
Loader Arms Down on Dead Machine Recovery Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . 0006 00-5
Loading
Machine on Flatcar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020 00-2
Machine on Ship . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0022 00-2
Machine on Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0019 00-2
Location and Description of Major Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0002 00-3
Lowering Loader Arm with Engine Stopped . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0005 00-8
Lubrication Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0012 00-50
M
Machine
Load onto C-5 and C-17 Aircraft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0023 00-2
Loading on Flatcar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020 00-2
Loading on Ship . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0022 00-2
Loading on Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0019 00-2
Mounting and Dismounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0005 00-2
Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0005 00-5
Parking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0005 00-7
Roading (Self-Deployment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018 00-1
Slave Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0006 00-2
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0005 00-6
Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0006 00-3
Unload from C-5 and C-7 Aircraft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0023 00-3
Unloading from Flatcar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020 00-4
Unloading From Ship . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0022 00-3
Unloading from Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0019 00-3
Index-3
TM 5-3805-291-10
INDEX - Continued
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0006 00-13
Decontamination Apparatus, Portable (DAP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0006 00-14
In Extreme Cold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0006 00-7
In Extreme Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0006 00-10
In Mud or Soft Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0006 00-12
In Saltwater Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0006 00-12
In Sandy or Dusty Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0006 00-12
In Snow and Ice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0006 00-13
Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0005 00-5
On Slopes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0005 00-6
Work Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0005 00-15
P
Parking
Brake Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-16
Brake Manual Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0006 00-6
Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0005 00-7
Platform and Top of Machine (PMCS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0012 00-30
PMCS
After . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0012 00-21
Articulation Bearings (Weekly) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0012 00-42
Before . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0012 00-2
Cab Air Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0012 00-33
Coolant Nitrites Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0012 00-44
During . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0012 00-20
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011 00-1
Monthly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0012 00-43
Platform and Top of Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0012 00-30
Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0012 00-1
Weekly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0012 00-33
Portable Fire Extinguisher Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0005 00-17
Index-4
TM 5-3805-291-10
INDEX - Continued
Powertrain, Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0003 00-1

Preparation for Storage or Shipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0001 00-1
Q
Quick Coupler
Manually Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0006 00-5
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0005 00-11
R
Rail
Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020 00-1
Rail Tiedown Procedures On A DODX Rail Car . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0021 00-1
Rear Handrail
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0024 00-6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0024 00-6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0015 00-1
Frame Lock Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0015 00-1
Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0005 00-6
Stopping Engine if an Electrical Malfunction Occurs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0005 00-8
Index-5
TM 5-3805-291-10
INDEX - Continued
Storage or Shipment, Preparation for . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0001 00-1

T
Theory of Operation
Brake Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0003 00-2
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0003 00-2
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0003 00-1
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0003 00-2
Powertrain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0003 00-1
Ride Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0003 00-3
Work Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0003 00-3
Throttle Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-11
Towing Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0006 00-3
Transmission
Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-7
Neutralizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-10
Transport
Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0023 00-1
Highway . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0019 00-1
Marine (RO/RO Procedures) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0022 00-1
Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020 00-1
Troubleshooting
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-1
Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010 00-1
Symptom Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0009 00-1
U
Unloading
Machine from Aircraft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0023 00-3
Machine from Flatcar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020 00-4
Machine from Ship . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0022 00-3
Machine from Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0019 00-3
W
Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0001 00-1
Windshield
Wiper Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-14
Work Tools
Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0005 00-15
Index-6
RECOMMENDED CHANGES TO PUBLICATIONS Use Part II (reverse) for Repair Parts and DATE
AND BLANK FORMS Special Tool Lists (RPSTL) and Supply
Date you filled out
Catalogs/Supply Manuals (SC/SM).
For use of this form, see AR 25-30; the proponent agency is ODISC4. this form.
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 Your mailing address
1 Rock Island Arsenal, Rock Island, IL 61299-7630
PART I – ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS
PUBLICATION/FORM NUMBER DATE Title Operator's Manual for Loader, Heavy,
Scoop: DED, 4-Wheel Drive, 4.5 Cubic
TM 5-3805-291-10 15 Jan 10 Yard and 5.0 Cubic Yard, Model 966H
ITEM PAGE PARA- LINE FIGURE TABLE RECOMMENDED CHANGES AND REASON
NO. NO. GRAPH NO. * NO. NO. (Provide exact wording of recommended changes, if possible).
001700-2 Part number supplied for item 2 is incorrect.
*Reference to line numbers within the paragraph or subparagraph.

TYPED NAME, GRADE OR TITLE TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION Signature
Your Signature
Your Name
DA FORM 2028, FEB 74 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 Your address Date you filled out this
ATTN: AMSTA-LCL-MPP/TECH PUBS form
PART II – REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS
TITLE Operator's Manual for Loader, Heavy,
PUBLICATION NUMBER DATE
TM 5-3805-291-10 15 Jan 10 Scoop: DED, 4.5 & 5 Cubic Yd, Model 966H
TOTAL NO.
PAGE COLM LINE NATIONAL STOCK REFERENCE FIGURE ITEM OF MAJOR
NO. NO. NO. NUMBER NO. NO. NO. ITEMS RECOMMENDED ACTION
SUPPORTED
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 TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION SIGNATURE
Your Name Your Signature

USAPPC V3.00
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) FROM: (Activity and location) (Include ZIP Code)
U.S. Army TACOM Life Cycle Management Command

ATTN: AMSTA-LCL-MPP/TECH PUBS
PART I – ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS
PUBLICATION/FORM NUMBER DATE TITLE Operator's Manual for Loader, Heavy, Scoop: DED,
TM 5-3805-291-10 15 Jan 10 4-Wheel Drive, 4.5 and 5.0 Cubic Yard, Model 966H
TYPED NAME, GRADE OR TITLE TELEPHONE EXCHANGE/AUTOVON, PLUS SIGNATURE

EXTENSION
TO: (Forward direct to addressee listed in publication) FROM: (Activity and location) (Include ZIP Code) DATE
U. S. Army TACOM Life Cycle Management Command
PUBLICATION NUMBER DATE TITLE Operator's Manual for Loader, Heavy, Scoop:
TM 5-3805-291-10 15 Jan 10 DED, 4-Wheel Drive, 4.5 and 5 CY, Model 966H
TOTAL NO.
SUPPORTED
USAPPC V3.00
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) FROM: (Activity and location) (Include ZIP Code)
PUBLICATION/FORM NUMBER DATE TITLE Operator's Manual for Loader, Heavy. Scoop, DED
TM 5-3805-291-10 15 Jan 10 4-Wheel Drive, 4.5 and 5.0 Cubic Yard, Model 966H

TYPED NAME, GRADE OR TITLE TELEPHONE EXCHANGE/AUTOVON, PLUS SIGNATURE
EXTENSION
FROM: (Activity and location) (Include ZIP Code) DATE
TO: (Forward direct to addressee listed in publication)
PUBLICATION NUMBER DATE TITLE Operator's Manual for Loader, Heavy, Scoop:
TM 5-3805-291-10 15 Jan 10 DED, 4-Wheel Drive, 4.5 and 5 CY, Model 966H
TOTAL NO.
SUPPORTED
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, require-
ments 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 Sq Centimeter = 100 Sq Millimeters = 0.155 Sq Inches
1 Meter = 100 Centimeters = 1000 Millimeters = 39.37 Inches 1 Sq Meter = 10,000 Sq Centimeters = 10.76 Sq Feet
1 Kilometer = 1000 Meters = 0.621 Miles 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 Cu Centimeter = 1,000 Cu Millimeters = 0.06 Cu Inches
1 Kilogram = 1000 Grams = 2.2 Pounds 1 Cu Meter = 1,000,000 Cu Centimeters = 35.31 Cu Feet
1 Metric Ton = 1000 Kilograms = 1 Megagram = 1.1 Short Tons
Temperature
Liquid Measure
5/9 ( F - 32) = C
1 Milliliter = 0.001 Liters = 0.0338 Fluid Ounces 212 Fahrenheit is equivalent to 100 Celsius
1 Liter = 1000 Milliliters = 33.82 Fluid Ounces 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 Kilopascals 6.895 Kilopascals Pounds per Sq 0.145

Inch Inch
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

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

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TM 5-3805-291-10

LOADER, HEAVY, SCOOP:

4.5 CUBIC YARD ROCK BUCKET

5.0 CUBIC YARD GENERAL PURPOSE BUCKET

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

HEADQUARTERS, DEPARTMENT OF THE ARMY

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

CARBON MONOXIDE (EXHAUST GASES) CAN KILL!

The Best Defense Against Carbon Monoxide Poisoning Is Good Ventilation!

BLACKOUT LIGHTING SYSTEM

ENGINE COOLANT (ARCTIC) HEATER (ARCTIC MACHINE ONLY)

ETHER COLD START SYSTEM

FRAME ARTICULATION AREA/STEERING FRAME LOCK

HAZARDOUS WASTE DISPOSAL

HIGH PRESSURE ACCUMULATOR

HYDRAULIC SYSTEM PRESSURE

LOWERING LOADER ARM WITH ENGINE STOPPED

MANUAL RELEASE OF PARKING BRAKE

To order this NBC decal use:

PRESSURIZED COOLING SYSTEM

SOLVENT CLEANING COMPOUND

LIST OF EFFECTIVE PAGES/WORK PACKAGES

Date of issue for original manual is:

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

TECHNICAL MANUAL HEADQUARTERS

LOADER, HEAVY, SCOOP:

4.5 CUBIC YARD ROCK BUCKET

REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS

INTRODUCTORY INFORMATION, EQUIPMENT

PMCS MAINTENANCE INSTRUCTIONS 1

Table of Contents - Continued

WP 0022 00 Marine Transport (RO/RO Procedures) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0022 00-1

HOW TO USE THIS MANUAL

CONTENTS OF THIS MANUAL

FEATURES OF THIS MANUAL

INTRODUCTORY INFORMATION, EQUIPMENT

GENERAL INFORMATION 0001 00

MAINTENANCE FORMS, RECORDS, AND REPORTS 0001 00

REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIR) 0001 00

CORROSION PREVENTION AND CONTROL (CPC) 0001 00

DESTRUCTION OF ARMY MATERIEL TO PREVENT ENEMY USE 0001 00

PREPARATION FOR STORAGE OR SHIPMENT 0001 00

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

GENERAL INFORMATION - CONTINUED 0001 00

NOMENCLATURE CROSS-REFERENCE LIST 0001 00

GENERAL INFORMATION - CONTINUED 0001 00

LIST OF ABBREVIATIONS/ACRONYMS - CONTINUED 0001 00

END OF WORK PACKAGE

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

EQUIPMENT DESCRIPTION AND DATA 0002 00

EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES 0002 00

EQUIPMENT DESCRIPTION AND DATA - CONTINUED 0002 00

EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES - CONTINUED

EQUIPMENT DESCRIPTION AND DATA - CONTINUED 0002 00

LOCATION AND DESCRIPTION OF MAJOR COMPONENTS 0002 00

KEY COMPONENT DESCRIPTION

EQUIPMENT DESCRIPTION AND DATA - CONTINUED 0002 00

LOCATION AND DESCRIPTION OF MAJOR COMPONENTS - CONTINUED

KEY COMPONENT DESCRIPTION

EQUIPMENT DESCRIPTION AND DATA - CONTINUED 0002 00

LOCATION AND DESCRIPTION OF MAJOR COMPONENTS - CONTINUED

KEY COMPONENT DESCRIPTION