Product:WHEELLOADER
Model:966GCWHEELLOADERSGW
Configuration:966GCWheelLoaderSGW00001-UP(MACHINE)POWEREDBYC9.3Engine
OperationandMaintenanceManual
966GCMediumWheelLoader
MediaNumber-M0094019-03PublicationDate-01/10/2020DateUpdated-30/10/2020
Foreword
CaliforniaProposition65Warning
DieselengineexhaustandsomeofitsconstituentsareknowntotheStateofCaliforniato causecancer,birthdefects,andotherreproductiveharm.
WARNING-Thisproductcanexpose youtochemicalsincludingethylene glycol,whichisknowntotheStateof Californiatocausebirthdefectsorother reproductiveharm.Formoreinformation goto:
www.P65Warnings.ca.gov
Donotingestthischemical.Washhandsafterhandlingtoavoidincidentalingestion.
WARNING-Thisproductcanexpose youtochemicalsincludingleadandlead compounds,whichareknowntothe StateofCaliforniatocausecancer,birth defects,orotherreproductiveharm.For moreinformationgoto:
www.P65Warnings.ca.gov
Washhandsafterhandlingcomponentsthatmaycontainlead.
LiteratureInformation
Thismanualshouldbestoredintheoperator'scompartmentintheliteratureholderorseatback literaturestoragearea.
Thismanualcontainssafetyinformation,operationinstructions,transportationinformation, lubricationinformation,andmaintenanceinformation.
Somephotographsorillustrationsinthispublicationshowdetailsorattachmentsthatcanbe differentfromyourmachine.Guardsandcoversmighthavebeenremovedforillustrative purposes.
Continuingimprovementandadvancementofproductdesignmighthavecausedchangestoyour machinewhicharenotincludedinthispublication.Read,study,andkeepthismanualwiththe machine.
Wheneveraquestionarisesregardingyourmachine,orthispublication,pleaseconsultyourCat dealerforthelatestavailableinformation.
Safety
Thesafetysectionlistsbasicsafetyprecautions.Inaddition,thissectionidentifiesthetextand locationsofwarningsignsandlabelsusedonthemachine.
Readandunderstandthebasicprecautionslistedinthesafetysectionbeforeoperatingor performinglubrication,maintenance,andrepaironthismachine.
Operation
Theoperationsectionisareferenceforthenewoperatorandarefresherfortheexperienced operator.Thissectionincludesadiscussionofgauges,switches,machinecontrols,attachment controls,transportation,andtowinginformation.
Photographsandillustrationsguidetheoperatorthroughcorrectproceduresofchecking,starting, operating,andstoppingthemachine.
Operatingtechniquesoutlinedinthispublicationarebasic.Skillandtechniquesdevelopasthe operatorgainsknowledgeofthemachineanditscapabilities.
Maintenance
Themaintenancesectionisaguidetoequipmentcare.TheMaintenanceIntervalSchedule(MIS) liststheitemstobemaintainedataspecificserviceinterval.Itemswithoutspecificintervalsare listedunderthe"WhenRequired"serviceinterval.TheMaintenanceIntervalScheduleliststhe pagenumberforthestep-by-stepinstructionsrequiredtoaccomplishthescheduledmaintenance. UsetheMaintenanceIntervalScheduleasanindexor"onesafesource"forallmaintenance procedures.
MaintenanceIntervals
Usetheservicehourmetertodetermineservicingintervals.Calendarintervalsshown(daily, weekly,monthly,etc.)canbeusedinsteadofservicehourmeterintervalsifthecalendarintervals
providemoreconvenientservicingschedulesandapproximatetheindicatedservicehourmeter reading.Performtherecommendedserviceattheintervalthatoccursfirst.
Undersevere,dusty,orwetoperatingconditions,morefrequentlubricationthanisspecifiedinthe maintenanceintervalschartmightbenecessary.
Performserviceonitemsatmultiplesoftheoriginalrequirement.Forexample,atevery500 servicehoursor3months,alsoservicethoseitemslistedunderevery250servicehoursor monthlyandevery10servicehoursordaily.
CertifiedEngineMaintenance
Propermaintenanceandrepairareessentialtokeeptheengineandmachinesystemsoperating correctly.Astheheavy-dutyoff-roaddieselengineowner,youareresponsibleforthe performanceoftherequiredmaintenancelistedintheOwnerManual,OperationandMaintenance Manual,andServiceManual.
Itisprohibitedforanypersonengagedinthebusinessofrepairing,servicing,selling,leasing,or tradingenginesormachinestoremove,alter,ortorenderinoperative,anyemission-relateddevice orelementofdesigninstalledonorinanengineormachinethatisincompliancewithall applicableregulationsoftheintendedcountrytowhichithasbeenshipped.Certainelementsof themachineandenginesuchastheexhaustsystem,fuelsystem,electricalsystem,intakeair system,andcoolingsystemmaybeemission-relatedandshouldnotbealteredunlessapprovedby Caterpillar.
MachineCapacity
Additionalattachmentsormodificationsmayexceedmachinedesigncapacitywhichcan adverselyaffectperformancecharacteristics.Includedwouldbestabilityandsystemcertifications suchasbrakes,steering,androlloverprotectivestructures(ROPS).ContactyourCatdealerfor furtherinformation.
ProductIdentificationNumber
EffectiveFirstQuarter2001theProductIdentificationNumber(PIN)haschangedfrom8to17 characters.Toprovideuniformequipmentidentification,constructionequipmentmanufacturers aremovingtocomplywiththelatestversionoftheproductidentificationnumberingstandard. Non-roadmachinePINsaredefinedbyISO10261.ThenewPINformatwillapplytoall machinesandgeneratorsets.ThePINplatesandframemarkingwilldisplaythe17characterPIN. Thenewformatwilllooklikethefollowing:
This is the sample of the manual if you need complete manual Click Here to download
Where:
1.WorldManufacturingCode(characters1-3)
2.MachineDescriptor(characters4-8)
3.CheckCharacter(character9)
4.MachineIndicatorSection(MIS)orProductSequenceNumber(characters10-17).Thesewere previouslyreferredtoastheSerialNumber.
MachinesandgeneratorsetsproducedbeforeFirstQuarter2001willmaintaintheir8character PINformat.
Componentssuchasengines,transmissions,axles,andworktoolswillcontinuetousean8 characterSerialNumber(S/N).
Copyright1993-2025CaterpillarInc. AllRightsReserved. PrivateNetworkForSISLicensees.
TueJul2222:08:01UTC+05302025
Product:WHEELLOADER
Model:966GCWHEELLOADERSGW
Configuration:966GCWheelLoaderSGW00001-UP(MACHINE)POWEREDBYC9.3Engine
OperationandMaintenanceManual
966GCMediumWheelLoader
MediaNumber-M0094019-03PublicationDate-01/10/2020DateUpdated-30/10/2020
ArticulationBearings-Lubricate
SMCS-7057-086-BD;7065-086-BD;7066-086-BD
CrushingHazard.Connectthesteeringframelockbetweenfrontand rearframesbeforeservicingthemachineinthearticulationarea. Disconnectthesteeringframelockandsecureitinthestoredposition beforeresumingoperation.Failuretodosocouldresultinserious injuryordeath. EnsurethatthemachineignitionswitchisintheOFFpositionandthattheparkingbrakeis engagedbeforeenteringthearticulationarea.
RefertoOperationandMaintenanceManual,"SteeringFrameLock" beforeenteringthearticulationjoint.Thehitchgreasefittingsareontherightsideofthemachine inthearticulationhitcharea.
Illustration1g06313202
Wipeallfittingsbeforeapplyinggrease.
Applygreasetoonefittingontheupperpivotbearing(1)andonefittingonthelowerpivot bearing(2).
Copyright1993-2025CaterpillarInc. AllRightsReserved. PrivateNetworkForSISLicensees.
TueJul2222:24:15UTC+05302025
Product:WHEELLOADER
Model:966GCWHEELLOADERSGW
Configuration:966GCWheelLoaderSGW00001-UP(MACHINE)POWEREDBYC9.3Engine
OperationandMaintenanceManual 966GCMediumWheelLoader
MediaNumber-M0094019-03PublicationDate-01/10/2020DateUpdated-30/10/2020
AutomaticLubricationGreaseTank-Fill-IfEquipped
SMCS-7540-544-TNK
TheAutomaticProgressiveGreasingSystem
Reference:RefertoSystemOperation,RENR6331formoreinformationontheAutomatic ProgressiveGreasingSystem.
Apressurehazardispresent.Severepersonalinjuryordeathcanresult fromremovinghosesorfittingsthatareunderpressure.Relievethe pressureinthesystembeforeyouremovehosesorfittings.
(1)Reservoir (2)Dustcap (3)Filllocation
Greasereservoir(1)isneartherearfenderontheleftsideofthemachine.
FillingtheReservoir
1.Removedustcap(2)fromgreasereservoir(1).
2.Cleanthefittingbeforefilling.
3.Fillgreasereservoir(1)withgreasetothemaximumlevelwhichisindicatedonthegrease reservoir(1).
Note:Avoidfullyemptyingthereservoircausingairtoenterthesystem.Airmaybe pumpedintothereservoir.Thisaircanaccumulateunderthepiston.Theaircanberemoved ifthereservoirisrefilledtoalevelslightlyabovethemaximumlevelmark.Excessairand excessgreasewillbereleasedfromthepumpattheoverflowpassage.
Reference:Forthecorrecttypeofgrease,refertoOperationandMaintenanceManual, "LubricantViscosities".
Note:Ifadifferentbrandofgreaseisused,checkforcompatibility.Ifthenewgreaseisnot compatiblewiththegreaseinthereservoir,thesystemmustbepurged.RefertoSystem Operation,RENR6331formoreinformationaboutpurgingthesystem.
4.Installdustcap(2).
Copyright1993-2025CaterpillarInc. AllRightsReserved. PrivateNetworkForSISLicensees.
TueJul2222:24:27UTC+05302025
Product:WHEELLOADER
Model:966GCWHEELLOADERSGW
Configuration:966GCWheelLoaderSGW00001-UP(MACHINE)POWEREDBYC9.3Engine
OperationandMaintenanceManual
966GCMediumWheelLoader
MediaNumber-M0094019-03PublicationDate-01/10/2020DateUpdated-30/10/2020
AxleOscillationBearings-Lubricate
SMCS-3268-086-BD;3278-086-BD
CrushingHazard.Connectthesteeringframelockbetweenfrontand rearframesbeforeservicingthemachineinthearticulationarea. Disconnectthesteeringframelockandsecureitinthestoredposition beforeresumingoperation.Failuretodosocouldresultinserious injuryordeath.
EnsurethatthemachineignitionswitchisintheOFFpositionandthattheparkingbrakeis engagedbeforeenteringthearticulationarea.
RefertoOperationandMaintenanceManual,"SteeringFrameLock"beforeenteringthe articulationjoint.
Illustration1g06489744
Theremotegreasefittingsareontherightsideofthemachineinthearticulationjoint
Wipeallfittingsbeforelubricating.
Greasefitting(1)willlubricatetheaxlepivotbearingthatisontherearoftherearaxle.Grease fitting(2)willlubricatetheaxlepivotbearingthatisonthefrontoftherearaxle.
Note:RefertoOperationandMaintenanceManual,"LubricantViscosities"forthepropergrease.
Copyright1993-2025CaterpillarInc. AllRightsReserved. PrivateNetworkForSISLicensees.
TueJul2222:24:44UTC+05302025
Product:WHEELLOADER
Model:966GCWHEELLOADERSGW
Configuration:966GCWheelLoaderSGW00001-UP(MACHINE)POWEREDBYC9.3Engine
OperationandMaintenanceManual
966GCMediumWheelLoader
MediaNumber-M0094019-03PublicationDate-01/10/2020DateUpdated-30/10/2020 i07409293
BackupAlarm-Test
SMCS-7406-081
Thebackupalarmisontherearofthemachine.
Illustration1g06313263
TurntheenginestartswitchtotheONpositiontoperformthetest. Applytheservicebrake.PlacethetransmissionintoREVERSE.
Thebackupalarmshouldsoundimmediately.Thebackupalarmwillcontinuetosounduntilthe transmissionisplacedintoNEUTRALorintoFORWARD.
Copyright1993-2025CaterpillarInc.
TueJul2222:25:00UTC+05302025
Product:WHEELLOADER
Model:966GCWHEELLOADERSGW
Configuration:966GCWheelLoaderSGW00001-UP(MACHINE)POWEREDBYC9.3Engine
OperationandMaintenanceManual
966GCMediumWheelLoader
MediaNumber-M0094019-03PublicationDate-01/10/2020DateUpdated-30/10/2020
BatteryorBatteryCable-Clean/Inspect/Replace
SMCS-1401-040;1401-070;1401-510;1402-070;1402-510;1402-040
Personalinjurymayoccurfromfailuretoproperlyservicethebatteries.
Batteriesgiveoffflammablefumesthatcanexplode.Electrolyteisan acidandcancausepersonalinjuryifitcontactstheskinoreyes.
Preventsparksnearthebatteries.Sparkscouldcausevaporstoexplode. Donotallowjumpercableendstocontacteachotherortheengine. Improperjumpercableconnectionscancauseanexplosion.
Alwayswearprotectiveglasseswhenworkingwithbatteries.
Illustration1g06313272
1.TurntheenginestartswitchkeyOFF.TurnalltheswitchesOFF.
2.TurnthebatterydisconnectswitchOFF.Removethekey.
3.Removetheaccesscoversfromthebatterycompartments.
Illustration2g02161433
4.Removethebatteryhold-down.
5.Disconnectthenegativebatterycablefromthedisconnectswitch.
Note:Donotallowthedisconnectedbatterycabletocontactthedisconnectswitch.
6.Disconnectthenegativebatterycableatthebattery.
7.Disconnectthepositivebatterycableatthebattery.
8.Inspectthebatteryterminalsforcorrosion.Inspectthebatterycablesforwearordamage.
9.Makeanynecessaryrepairs.Ifnecessary,replacethebatterycablesorthebattery.
10.Cleanthebatteryterminalsandthesurfacesofthebatterieswithacleancloth.
11.Connectthepositivebatterycableatthebattery.
12.Connectthenegativebatterycableatthebattery.
13.Coatthebatteryterminalswithpetroleumjellytopreventcorrosion.
14.Reinstallthebatteryhold-down
15.Torquethelocknutsinthecenterofthehold-downto14±1N·m(10±2lbft)
16.Connectthebatterycableatthebatterydisconnectswitch.
17.InstallthekeyandturnthebatterydisconnectswitchON.
18.Reinstallbatterycompartmentcoverplates.
RecycletheBattery
Alwaysrecycleabattery.Neverdiscardabattery.
Alwaysreturnusedbatteriestooneofthefollowinglocations:
•Abatterysupplier
•Anauthorizedbatterycollectionfacility
•Recyclingfacility
Copyright1993-2025CaterpillarInc. AllRightsReserved. PrivateNetworkForSISLicensees.
TueJul2222:25:13UTC+05302025
Product:WHEELLOADER
Model:966GCWHEELLOADERSGW
Configuration:966GCWheelLoaderSGW00001-UP(MACHINE)POWEREDBYC9.3Engine
OperationandMaintenanceManual
966GCMediumWheelLoader
MediaNumber-M0094019-03PublicationDate-01/10/2020DateUpdated-30/10/2020
Belt-Inspect/Adjust/Replace
SMCS-1397-025;1397-040;1397-510
Yourmachineisequippedwithasingleserpentinebelt.Stoptheengine.Opentherearhood.The beltisonthefrontoftheengine.
(1)Alternator (2)Compressor (3)Idler (4)Tensioner (5)WaterPump (6)CrankshaftPulley (7)SerpentineBelt
Illustration2g06114636 (A)Newbelt (B)Wornbelt
1.Inspecttheconditionoftheserpentinebelt.Overtimethebeltribswilllosematerial(C). Thespacebetweentheribswillincrease(D).Thelossofmaterialwillcausethepulley sheavetocontactthebeltvalley.Thiswillleadtobeltslippageandacceleratedwear(E). Replacethebeltifthebeltiswornorfrayed.
Tensionerkeepsthecorrecttensiononthebelt.Insertaratchetwithasquaredriveintotensioner. Rotatethetensionercounterclockwisetorelievetensiononthebelt.Removethebelt.
Installthenewbelt.Besurethatthenewbeltisroutedcorrectly,asshown.Rotatethetensioner counterclockwisetoinstallthenewbelt.Releasethetensionerwhenthenewbeltisinstalled.The correcttensionwillautomaticallybeapplied.
Copyright1993-2025CaterpillarInc. AllRightsReserved. PrivateNetworkForSISLicensees.
TueJul2222:26:33UTC+05302025
Product:WHEELLOADER
Model:966GCWHEELLOADERSGW
Configuration:966GCWheelLoaderSGW00001-UP(MACHINE)POWEREDBYC9.3Engine
OperationandMaintenanceManual
966GCMediumWheelLoader
MediaNumber-M0094019-03PublicationDate-01/10/2020DateUpdated-30/10/2020 i05823698
BrakeAccumulator-Check
SMCS-4263-535
PressurizedSystem!
Hydraulicaccumulatorscontaingasandoilunderhighpressure.DO NOTdisconnectlinesordisassembleanycomponentofapressurized accumulator.Allgaspre-chargemustberemovedfromtheaccumulator asinstructedbytheservicemanualbeforeservicingordisposingofthe accumulatororanyaccumulatorcomponent.
Failuretofollowtheinstructionsandwarningscouldresultinpersonal injuryordeath.
Onlyusedrynitrogengastorechargeaccumulators.SeeyourCat dealerforspecialequipmentanddetailedinformationforaccumulator serviceandcharging.
1.TurntheenginestartswitchtotheONposition.Thealertindicatorforthebrakeshould comeonifthebrakingsystemisnotatnormaloperatingpressure.
2.Starttheengine.Runtheengineatlowidlespeeduntiltheengineiswarminorderto increasetheaccumulatorpressure.Thealertindicatorshouldgooff.
3.Atlowidleenginespeed,fullydepressthebrakepedalandrelease.Repeatthisprocessuntil hearingthebrakechargingsystemrechargetheaccumulators.Whencharging,youwillhear aslightdipinenginerpm.
4.Whenchargingiscompleted,stoptheengineandturnthekeytotheONpositionwithout startingtheengine.Fullyapplythebrakepedalandfullyreleaseoffthebrakepedalatarate
of1secondonand1secondoff.Countthenumberofcyclesuntilthealertindicatorfor brakeoilpressurecomeson.Aminimumofthreeapplicationsofthebrakepedalare required.
5.Ifthealertindicatorcomesonbeforethenumberofcycleslistedinstep4,measurethe accumulatorpre-chargepressures.OnlyanauthorizedCatdealercanmeasurethenitrogen gaspressureintheaccumulator.Useonlydrynitrogenforrecharging.
Copyright1993-2025CaterpillarInc. AllRightsReserved. PrivateNetworkForSISLicensees.
TueJul2222:26:47UTC+05302025
Product:WHEELLOADER
Model:966GCWHEELLOADERSGW
Configuration:966GCWheelLoaderSGW00001-UP(MACHINE)POWEREDBYC9.3Engine
OperationandMaintenanceManual
966GCMediumWheelLoader
MediaNumber-M0094019-03PublicationDate-01/10/2020DateUpdated-30/10/2020
BrakingSystem-Test
SMCS-4251-081;4267-081
•Fastentheseatbeltbeforeyoutestthebrakes.
•Parkthemachineonadry,levelsurface.
i07409318
•Checktheareaaroundthemachine.Makesurethatthemachineisclearofpersonneland clearofobstacles.
•Makesurethatthesteeringframelockisintheunlockedposition.
Thefollowingtestsareusedtodeterminewhetherthebrakingsystemisfunctional.Thesetestsare notintendedtomeasurethemaximumbrakeholdingeffort.Therequiredbrakeholdingeffortfor sustainingamachineataspecificenginerpmvariesfromonemachinetoanothermachine.The variationsincludedifferencesintheenginesetting,thepowertrainefficiency,thebrakeholding ability,andothers.
ServiceBrakeHoldingAbilityTest
Personalinjurycanresultifthemachinemoveswhiletesting.
Ifthemachinebeginstomoveduringtest,reducetheenginespeed immediatelyandengagetheparkingbrake.
1.Starttheengine.Raisetheimplementslightly.Applytheservicebrake.Releasetheparking brake.
2.MakesuretheAuto/ManualTransmissionSelectisintheMANUALmode.Putthe transmissioncontrolinSECONDGEARFORWARDwhiletheservicebrakesareapplied.
3.Graduallyincreasetheenginespeedtohighidle.Themachineshouldnotmove.
4.Reducetheenginespeedtolowidle.Movethetransmissiondirectioncontroltothe NEUTRALposition.Engagetheparkingbrake.Lowertheimplementtotheground.Stop theengine.
Ifthemachinemovedduringthetest,consultyourCaterpillardealerforabrakeinspection.Make anynecessaryrepairsbeforethemachineisreturnedtooperation.
