CAT + Caterpillar 966G Wheel Loader Operation & Maintenance Manual

Product:WHEELLOADER

Model:966GWHEELLOADER3ZS

Configuration:966GWheelLoader3ZS00001-UP(MACHINE)POWEREDBY3306Engine

OperationandMaintenanceManual (Custom)367-7349andQuickCouplerForWheelLoaders

MediaNumber-GEBU0024-00PublicationDate-01/10/2010DateUpdated-12/10/2010

Foreword

LiteratureInformation

Thismanualshouldbestoredintheoperator'scompartmentintheliteratureholderorseatback literaturestoragearea.

Thismanualcontainssafetyinformation,operationinstructions,transportationinformation, lubricationinformationandmaintenanceinformation.

Somephotographsorillustrationsinthispublicationshowdetailsthatcanbedifferentfromyour worktool.Guardsandcoversmighthavebeenremovedforillustrativepurposes.

Continuingimprovementandadvancementofproductdesignmighthavecausedchangestoyour worktoolwhicharenotincludedinthispublication.Read,studyandkeepthismanualwiththe machinethatyourworktoolisinstalledon.

Wheneveraquestionarisesregardingyourworktool,orthispublication,pleaseconsultyour Caterpillardealerforthelatestavailableinformation.

Safety

Thesafetysectionlistsbasicsafetyprecautions.Inaddition,thissectionidentifiesthetextand locationsofsafetysignsandlabelsusedontheworktool.

Readandunderstandthebasicprecautionslistedinthesafetysectionbeforeoperatingorperforming lubrication,maintenanceandrepaironthisworktool.

Operation

Theoperationsectionisareferenceforthenewoperatorandarefresherfortheexperiencedoperator. Thissectionincludesadiscussionofgauges,switches,machinecontrols,worktoolcontrols, transportationandtowinginformation.

Photographsandillustrationsguidetheoperatorthroughcorrectproceduresofchecking,starting, operatingandstoppingtheworktool.

Operatingtechniquesoutlinedinthispublicationarebasic.Skillandtechniquesdevelopasthe operatorgainsknowledgeoftheworktoolanditscapabilities.

Maintenance

Themaintenancesectionisaguidetoequipmentcare.Theillustrated,step-by-stepinstructionsare groupedbyserviceintervals.Itemswithoutspecificintervalsarelistedunderthewhenrequired interval.Itemsinthemaintenanceintervalsschedulearereferencedtodetailedinstructionsthat follow.

MaintenanceIntervals

Calendarintervalsshown(daily,weekly,monthly,etc)canbeusedinsteadofservicehourmeter intervalsiftheyprovidemoreconvenientservicingschedulesandapproximatetheindicatedservice hourmeterreading.Recommendedserviceshouldalwaysbeperformedattheintervalthatoccurs first.

Underextremelysevere,dustyorwetoperatingconditions,morefrequentlubricationthanisspecified inthemaintenanceintervalsschedulemightbenecessary.

Performserviceonitemsatmultiplesoftheoriginalrequirement.Forexample,atevery500service hoursor3months,alsoservicethoseitemslistedunderevery250servicehoursormonthlyandevery 10servicehoursordaily.

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Product:WHEELLOADER

Model:966GWHEELLOADER3ZS

Configuration:966GWheelLoader3ZS00001-UP(MACHINE)POWEREDBY3306Engine

OperationandMaintenanceManual (Custom)367-7349andQuickCouplerForWheelLoaders

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MaintenanceIntervalSchedule

SMCS-6700

WhenRequired

QuickCoupler-Clean/Inspect

Every250ServiceHoursor3Months

QuickCoupler-Clean/Inspect/Replace

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Product:WHEELLOADER

Model:966GWHEELLOADER3ZS

Configuration:966GWheelLoader3ZS00001-UP(MACHINE)POWEREDBY3306Engine

OperationandMaintenanceManual (Custom)367-7349andQuickCouplerForWheelLoaders

MediaNumber-GEBU0024-00PublicationDate-01/10/2010DateUpdated-12/10/2010

QuickCoupler-Clean/Inspect

SMCS-6129-040;6129-070

Personalinjuryordeathcanresultfromimproperlycheckingfora leak.

Alwaysuseaboardorcardboardwhencheckingforaleak.Escaping airorfluidunderpressure,evenapin-holesizeleak,canpenetrate bodytissuecausingseriousinjury,andpossibledeath.

Iffluidisinjectedintoyourskin,itmustbetreatedimmediatelybya doctorfamiliarwiththistypeofinjury.

Note:DonotweldonthequickcouplerwithoutconsultingyourCaterpillardealer.

Note:Cleanthequickcouplerpriortoinspectioninordertoproperlyinspectthequickcoupler.

1.Inspectthehydrauliclinesandthehydraulicfittingsfordamageorforwear.Repairanyworn componentsorreplaceanyworncomponents.Repairanyleakingcomponents.

2.Inspectthelockingpinsthatsecurethequickcouplertothewheelloader.

3.Inspectthesteelmaterialofthequickcouplerforcracks.

4.Inspectthewarningsignsandlabels.Replacewarningsignsorlabelsthataremissing.Replace warningsignsorlabelswhenyoucannotreadthewarningsignsorlabels.Refertothe OperationandMaintenanceManual,"SafetyMessages"foradditionalinformation.

Product:WHEELLOADER

Model:966GWHEELLOADER3ZS

Configuration:966GWheelLoader3ZS00001-UP(MACHINE)POWEREDBY3306Engine

OperationandMaintenanceManual (Custom)367-7349andQuickCouplerForWheelLoaders

MediaNumber-GEBU0024-00PublicationDate-01/10/2010DateUpdated-12/10/2010

QuickCoupler-Clean/Inspect/Replace

SMCS-6129-040;6129-070;6129-510

Personalinjuryordeathcanresultfromimproperlycheckingfora leak.

Alwaysuseaboardorcardboardwhencheckingforaleak.Escaping airorfluidunderpressure,evenapin-holesizeleak,canpenetrate bodytissuecausingseriousinjury,andpossibledeath.

Iffluidisinjectedintoyourskin,itmustbetreatedimmediatelybya doctorfamiliarwiththistypeofinjury.

Note:DonotweldonthequickcouplerwithoutconsultingyourCaterpillardealer.

Note:Cleanthequickcouplerpriortoinspectioninordertoproperlyinspectthequickcoupler.

1.Removethecoverassembliesfromthebackofthequickcoupler.

2.Cleantheinsideofthequickcouplerinordertoproperlyinspecttheinsideofthequickcoupler.

3.Inspectthecomponentsinsidethequickcouplerforthefollowingproblems:loosebolts,oil leaks,brokenparts,missingpartsandcrackedcomponents

4.Inspectthehydrauliclinesandthehydraulicfittingsfordamageorforwear.Repairanyworn componentsorreplaceanyworncomponents.Repairanyleakingcomponents.

5.Inspectthesteelmaterialofthequickcouplerforcracks.

6.Reattachthecoverassembliestothebackofthequickcoupler.

7.Inspectthewarningsignsandlabels.Replacewarningsignsorlabelsthataremissing.Replace warningsignsorlabelswhenyoucannotreadthewarningsignsorlabels.Refertothe OperationandMaintenanceManual,"SafetyMessages"foradditionalinformation.

Note:Performallrepairsbeforeplacingthequickcouplerbackintooperation.

FriApr402:46:35UTC+05302025

Product:WHEELLOADER

Model:966GWHEELLOADER3ZS

Configuration:966GWheelLoader3ZS00001-UP(MACHINE)POWEREDBY3306Engine

OperationandMaintenanceManual (Custom)367-7349andQuickCouplerForWheelLoaders

MediaNumber-GEBU0024-00PublicationDate-01/10/2010DateUpdated-12/10/2010 i01828834

WeldingonMachinesandEngineswithElectronicControls

SMCS-6700

Properweldingproceduresarenecessaryinordertoavoiddamagetotheelectroniccontrolsandtothe bearings.Thefollowingstepsshouldbefollowedinordertoweldonamachineoranenginewith electroniccontrols.

Note:Ifyouareweldingonaworktool,removetheworktoolfromthehostmachinebeforewelding.

1.Turnofftheengine.

2.TurnthebatterydisconnectswitchtotheOFFposition.Ifthereisnobatterydisconnectswitch, removethenegativebatterycableatthebattery.

3.Clampthegroundcablefromtheweldertothecomponentthatwillbewelded.Placetheclamp ascloseaspossibletotheweld.Makesurethattheelectricalpathfromthegroundcabletothe componentdoesnotgothroughanybearing.Usethisprocedureinordertoreducethe possibilityofdamagetothefollowingcomponents:

Bearingsofthedrivetrain

Hydrauliccomponents

Electricalcomponents

Othercomponentsofthemachine

DoNOTuseelectricalcomponents(ECMorsensors)orelectronic componentgroundingpointsforgroundingthewelder.

4.Protectanywiringharnessesfromthedebriswhichiscreatedfromwelding.Protectanywiring harnessesfromthesplatterwhichiscreatedfromwelding.

5.Usestandardweldingproceduresinordertoweldthematerialstogether.

Product:WHEELLOADER

Model:966GWHEELLOADER3ZS

Configuration:966GWheelLoader3ZS00001-UP(MACHINE)POWEREDBY3306Engine

OperationandMaintenanceManual (Custom)367-7349andQuickCouplerForWheelLoaders

MediaNumber-GEBU0024-00PublicationDate-01/10/2010DateUpdated-12/10/2010

Storage

SMCS-0355

i02044488

Placethequickcoupleronapallet.Storethepalletonlevel,solidground. Coatthewedgesorthepinswithgrease.Coatthesurfacesthatcontacttheworktoolswithgrease. Coattheboresforthemountingpinswithgrease.Plugthehosesorcapthehoses.

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Product:WHEELLOADER

Model:966GWHEELLOADER3ZS

Configuration:966GWheelLoader3ZS00001-UP(MACHINE)POWEREDBY3306Engine

OperationandMaintenanceManual (Custom)367-7349andQuickCouplerForWheelLoaders

MediaNumber-GEBU0024-00PublicationDate-01/10/2010DateUpdated-12/10/2010

Shipping

SMCS-7500

Ifthequickcouplerhasbeenremovedfromthehostmachine,laythequickcoupleronapallet. Securethequickcouplertothepallet.

Ifthequickcouplerismountedonthehostmachine,raisethequickcouplerslightlyawayfromthe ground.

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Product:WHEELLOADER

Model:966GWHEELLOADER3ZS

Configuration:966GWheelLoader3ZS00001-UP(MACHINE)POWEREDBY3306Engine

OperationandMaintenanceManual (Custom)367-7349andQuickCouplerForWheelLoaders

MediaNumber-GEBU0024-00PublicationDate-01/10/2010DateUpdated-12/10/2010

LiftingandTyingDown

SMCS-7500

NOTICE

Improperliftingortie-downscanallowtheloadtoshiftandcause injuryordamage.

Weightsandinstructionsarelistedherein.Thisinformationisapplicabletounitsthatare manufacturedbyCaterpillar.

i04090130

Note:Donotusesteelcables,chains,orhooksinthemountingholesinordertoliftthequickcoupler. Damagetothemountingholesofthequickcouplerwouldbearesult.

Forliftingthequickcoupler,useproperlyratedliftingslings.Positiontheliftingdeviceforlevel lifting.Positionanyhydraulichosesinordertopreventanydamagetothehoses.

Illustration1g02297639

TyingDowntheQuickCoupler

Note:Donottiethequickcouplerdownusingthepinbores.Damagemayoccurtothepinbores.

Tiedownthequickcoupler.Usecables,restrainingbands,orstrapsthatarestrongenoughtosecure theloadandstrongenoughtopreventtheloadfromshifting.Secureanyhydraulichosesinorderto preventdamagetothehoses.

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Product:WHEELLOADER

Model:966GWHEELLOADER3ZS

Configuration:966GWheelLoader3ZS00001-UP(MACHINE)POWEREDBY3306Engine

OperationandMaintenanceManual (Custom)367-7349andQuickCouplerForWheelLoaders

MediaNumber-GEBU0024-00PublicationDate-01/10/2010DateUpdated-12/10/2010

i03700900

TransportPosition

SMCS-7500

NOTICE

Forspecificinformationonyourhostmachine,refertotheOperation andMaintenanceManualofyourhostmachine.

Inordertotransportthequickcoupler,laythequickcoupleronapallet.Securethequickcouplerto thepallet.

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Product:WHEELLOADER

Model:966GWHEELLOADER3ZS

Configuration:966GWheelLoader3ZS00001-UP(MACHINE)POWEREDBY3306Engine

OperationandMaintenanceManual (Custom)367-7349andQuickCouplerForWheelLoaders

MediaNumber-GEBU0024-00PublicationDate-01/10/2010DateUpdated-12/10/2010

HydraulicSystemAirPurge

SMCS-5050-542-AI

NOTICE

Caremustbetakentoensurethatfluidsarecontainedduring performanceofinspection,maintenance,testing,adjustingandrepair ofthemachine.Bepreparedtocollectthefluidwithsuitablecontainers beforeopeninganycompartmentordisassemblinganycomponent containingfluids.

RefertoSpecialPublication,NENG2500,"CaterpillarToolsandShop ProductsGuide",fortoolsandsuppliessuitabletocollectandcontain fluids.

Disposeofallfluidsaccordingtolocalregulationsandmandates.

i02055845

1.Checkthevalvesonthehostmachine.ThevalvesmustbeintheOPENposition.Refertothe OperationandMaintenanceManualofthehostmachineforthedifferentpositionsofthe valves.

2.Ifaworktoolisconnectedtothequickcoupler,disengagetheworktool.Removetheworktool fromthequickcoupler.

3.Startthehostmachine.Runthehostmachineuntilthehydraulicoiltemperaturereachesthe normaloperatingtemperatureforthehydraulicoil.

4.Engagethequickcoupleranddisengagethequickcouplerforthreetimesinordertopurgethe airfromthehydraulicsystem.

Product:WHEELLOADER

Model:966GWHEELLOADER3ZS

Configuration:966GWheelLoader3ZS00001-UP(MACHINE)POWEREDBY3306Engine

OperationandMaintenanceManual (Custom)367-7349andQuickCouplerForWheelLoaders

MediaNumber-GEBU0024-00PublicationDate-01/10/2010DateUpdated-12/10/2010

Operation

SMCS-6129;7000

OperatingtheQuickCoupler

Improperattachmentofworktoolscouldresultininjuryordeath.

Donotoperatethismachineuntilyouhavepositiveindicationthatthe couplerpinsarefullyengaged.Checkforengagementby:

1.Tilttheworktooldown.

2.Putdownwardpressureontheworktool.

3.Backthemachineupandmakesurethereisnotanymovement betweentheworktoolandthequickcouplerassembly.

NOTICE

Auxiliaryhosesforworktoolsmustberemovedbeforethequick couplerpinsaredisengaged.

Pullingtheworktoolswiththeauxiliaryhosescouldresultinmachine damage.

Note:Somemachinesmayhaveadevicethatisusedtolockthethirdfunctionvalve.Refertothe OperationandMaintenanceManualofthehostmachineforadditionalinformation.

Inordertooperatethequickcoupler,usethecontrolforthethirdfunctionvalve.

Inordertoengagethequickcoupler,movethecontrolforthethirdfunctionvalveinaforward direction.

Inordertodisengagethequickcoupler,movethecontrolforthethirdfunctionvalveinarearward direction.

Illustration1g02297033

Whenyouengagethequickcoupler,Verifythatthequickcouplerisfullyengagedwiththeworktool. Visuallychecktheindicators(1)foreachofthewedges.

Copyright1993-2025CaterpillarInc. AllRightsReserved.

FriApr402:44:44UTC+05302025

Product:WHEELLOADER

Model:966GWHEELLOADER3ZS

Configuration:966GWheelLoader3ZS00001-UP(MACHINE)POWEREDBY3306Engine

OperationandMaintenanceManual (Custom)367-7349andQuickCouplerForWheelLoaders

MediaNumber-GEBU0024-00PublicationDate-01/10/2010DateUpdated-12/10/2010 i02055801

DailyInspection

SMCS-6700-040

Personalinjuryordeathcanresultfromimproperlycheckingfora leak.

Alwaysuseaboardorcardboardwhencheckingforaleak.Escaping airorfluidunderpressure,evenapin-holesizeleak,canpenetrate bodytissuecausingseriousinjury,andpossibledeath.

Iffluidisinjectedintoyourskin,itmustbetreatedimmediatelybya doctorfamiliarwiththistypeofinjury.

NOTICE

Accumulatedgreaseandoilonaworktoolisafirehazard.

Removedebriswithsteamcleaningorhighpressurewateratanytime asignificantquantityofoilisspilledontheworktool.

Note:Ifmajorrepairstothequickcouplerarerequired,consultyourCaterpillardealer.

Note:Cleanthequickcouplerpriortodailyinspectioninordertoproperlyinspectthequickcoupler.

1.Forthemaximumservicelifeofthequickcoupler,makeathoroughdailyinspectionbeforeyou mountaworktooltothehostmachine.

2.Inspectthequickcouplerforthefollowingconditions:loosebolts,oilleaks,brokenparts, missingpartsandcrackedcomponents.Checktheoverallconditionofthequickcoupler.Check theoverallconditionofthehydraulicsystem.

3.Inspectthewarningsignsandlabels.Replacewarningsignsorlabelsthataremissing.Replace warningsignsorlabelswhenyoucannotreadthewarningsignsorlabels.Refertothe OperationandMaintenanceManual,"SafetyMessages"foradditionalinformation.

4.Inspecttheconditionofthehydrauliclinesandthehydraulicfittings.

5.Checkthemountingpinsforthequickcoupler.

6.Checktheliftingdevice,ifequipped.Ifdamageispresentdonotusetheliftingdevice.Contact yourCaterpillardealerforrepairs.

7.Performallrepairsbeforeyouputthequickcouplerintooperation.

8.Lubricatethefittingsforthewedges.RefertoOperationandMaintenanceManual,"Quick Coupler-Lubricate"foradditionalinformation.

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Product:WHEELLOADER

Model:966GWHEELLOADER3ZS

Configuration:966GWheelLoader3ZS00001-UP(MACHINE)POWEREDBY3306Engine

OperationandMaintenanceManual (Custom)367-7349andQuickCouplerForWheelLoaders

MediaNumber-GEBU0024-00PublicationDate-01/10/2010DateUpdated-12/10/2010

QuickCouplerInstallationandRemoval

SMCS-6129-010

InstallationProcedure

i04089271

Note:Beforeyouinstallthequickcoupler,verifythatthehydraulicsystemofthehostmachinemeets thefollowingrequirements:

•Thecontrolofthequickcouplermustbeprotectedagainstinadvertentoperation.

•Whenthequickcouplerisengaged,theremustbenobuildupofpressureonthesideofthe cylinderthatdisengagesthepinsofthequickcoupler.

•Whenthepinsofthequickcoupleraredisengaged,thepinswillbeheldinthedisengaged positionbythehydraulicsystem.

1.Cleanallofthepins.Cleanalloftheboresforthepins.

2.Alignthelowerboresofthequickcouplerwiththeboresoftheliftarmsofthehostmachine.

3.Installthepinsintothelowerbores.Lockthepins.

4.Movethetiltlinkageuntiltheboresofthetiltlinkagearealignedwiththeupperboresofthe quickcoupler.

5.Installthepinsintotheupperbores.Lockthepins.

6.Checkthepositionofthestopsonthequickcoupler.Theusageofstopsisdeterminedbythe requirementsofthehostmachine.RefertotheOperationandMaintenanceManualofthehost machineforadditionalinformation.

7.Connectthehydrauliclinesfromthequickcouplertothehydraulicfittingsonthehostmachine. RefertotheOperationandMaintenanceManualofthehostmachineforadditionalinformation.

8.Openthevalvesonthehostmachine(ifequipped).Valvesarenotalwaysequippedonthehost machine.

9.Beforeyouoperatethequickcoupler,Purgetheairfromthehydraulicsystem.Refertothe OperationandMaintenanceManual,"HydraulicSystemAirPurge"foradditionalinformation.

RemovalProcedure

1.Placethequickcoupleronasurfacethatissolidandlevel.

2.Stoptheengineofthehostmachine.

3.Releasethepressureinthehydraulicsystem.Inordertoreleasethepressureinthehydraulic system,turntheenginestartkeytotheONposition.Donotstarttheengine.Cyclethe hydrauliccontrols.Activatethethirdfunctionofthehydraulicsystem.Cyclethecontrolforthe thirdfunction.

4.TurntheenginestartkeytotheOFFposition.

5.Closethevalvesonthehostmachine(ifequipped).Valvesarenotalwaysequippedonthehost machine.

Personalinjuryordeathcanresultfromimproperlycheckingfora leak.

Alwaysuseaboardorcardboardwhencheckingforaleak.Escaping airorfluidunderpressure,evenapin-holesizeleak,canpenetrate bodytissuecausingseriousinjury,andpossibledeath.

Iffluidisinjectedintoyourskin,itmustbetreatedimmediatelybya doctorfamiliarwiththistypeofinjury.

NOTICE

Caremustbetakentoensurethatfluidsarecontainedduring performanceofinspection,maintenance,testing,adjusting,andrepair oftheproduct.Bepreparedtocollectthefluidwithsuitablecontainers beforeopeninganycompartmentordisassemblinganycomponent containingfluids.

RefertoSpecialPublication,NENG2500,"DealerServiceTool Catalog"fortoolsandsuppliessuitabletocollectandcontainfluidson Catproducts.

Disposeofallfluidsaccordingtolocalregulationsandmandates.

6.Placeasuitablecontainerbelowthehydraulicfittingsinordertocatchanyhydraulicoilthat mayescape.Slowlydisconnectthehydrauliclines.Plugtheendsofthehydrauliclinesor connectthehydrauliclines.

7.Disposeofthehydraulicoilinasuitablemanner.

8.Removethepinsfromtheupperboresofthequickcoupler.

9.Removethepinsfromthelowerboresofthequickcoupler.

10.Starttheengineofthehostmachine.Carefullymovethehostmachineawayfromthequick coupler.

Note:Ifthequickcouplerisstoredforanextendedperiodoftime,placegreaseintheboresofthe quickcouplerandcoatallofthesurfacesofthepinswithgrease.

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This is the sample of the manual if you need complete manual Click Here to download