CAT + Caterpillar 966G Wheel Loader Operation & Maintenance Manual by Heavy Equipment Manual

966G WHEEL LOADER

S/N 3ZS00001-UP

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Product: WHEEL LOADER

Model: 966G WHEEL LOADER 3ZS

Configuration: 966G Wheel Loader 3ZS00001-UP (MACHINE) POWERED BY 3306 Engine

Operation and Maintenance Manual (Custom) 367-7349 and Quick Coupler For Wheel Loaders

Foreword

Literature Information

s00272057

This manual should be stored in the operator's compartment in the literature holder or seat back literature storage area.

This manual contains safety information, operation instructions, transportation information, lubrication information and maintenance information.

Some photographs or illustrations in this publication show details that can be different from your work tool. Guards and covers might have been removed for illustrative purposes.

Continuing improvement and advancement of product design might have caused changes to your work tool which are not included in this publication. Read, study and keep this manual with the machine that your work tool is installed on.

Whenever a question arises regarding your work tool, or this publication, please consult your Caterpillar dealer for the latest available information.

Safety

The safety section lists basic safety precautions. In addition, this section identifies the text and locations of safety signs and labels used on the work tool.

Read and understand the basic precautions listed in the safety section before operating or performing lubrication, maintenance and repair on this work tool.

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, machine controls, work tool controls, transportation and towing information.

Photographs and illustrations guide the operator through correct procedures of checking, starting, operating and stopping the work tool.

Operating techniques outlined in this publication are basic. Skill and techniques develop as the operator gains knowledge of the work tool and its capabilities.

Maintenance

The maintenance section is a guide to equipment care. The illustrated, step-by-step instructions are grouped by service intervals. Items without specific intervals are listed under the when required interval. Items in the maintenance intervals schedule are referenced to detailed instructions that follow.

Maintenance Intervals

Calendar intervals shown (daily, weekly, monthly, etc) can be used instead of service hour meter intervals if they provide more convenient servicing schedules and approximate the indicated service hour meter reading. Recommended service should always be performed at the interval that occurs first.

Under extremely severe, dusty or wet operating conditions, more frequent lubrication than is specified in the maintenance intervals schedule might be necessary.

Perform service on items at multiples of the original requirement. For example, at every 500 service hours or 3 months, also service those items listed under every 250 service hours or monthly and every 10 service hours or daily.

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Product: WHEEL LOADER

Model: 966G WHEEL LOADER 3ZS

Configuration: 966G Wheel Loader 3ZS00001-UP (MACHINE) POWERED BY 3306 Engine

Operation and Maintenance Manual (Custom) 367-7349 and Quick Coupler For Wheel Loaders

Media Number -GEBU0024-00 Publication Date -01/10/2010 Date Updated -12/10/2010

i04090229

Maintenance Interval Schedule

SMCS - 6700

When Required

Quick Coupler - Clean/Inspect

Every 250 Service Hours or 3 Months

Quick Coupler - Clean/Inspect/Replace

Product: WHEEL LOADER

Model: 966G WHEEL LOADER 3ZS

Configuration: 966G Wheel Loader 3ZS00001-UP (MACHINE) POWERED BY 3306 Engine

Operation and Maintenance Manual (Custom) 367-7349 and Quick Coupler For Wheel Loaders

Quick Coupler - Clean/Inspect

SMCS - 6129-040; 6129-070

Personal injury or death can result from improperly checking for a leak.

Always use a board or cardboard when checking for a leak. Escaping air or fluid under pressure, even a pin-hole size leak, can penetrate body tissue causing serious injury, and possible death.

If fluid is injected into your skin, it must be treated immediately by a doctor familiar with this type of injury.

Note: Do not weld on the quick coupler without consulting your Caterpillar dealer.

Note: Clean the quick coupler prior to inspection in order to properly inspect the quick coupler.

1. Inspect the hydraulic lines and the hydraulic fittings for damage or for wear. Repair any worn components or replace any worn components. Repair any leaking components.

2. Inspect the locking pins that secure the quick coupler to the wheel loader.

3. Inspect the steel material of the quick coupler for cracks.

4. Inspect the warning signs and labels. Replace warning signs or labels that are missing. Replace warning signs or labels when you cannot read the warning signs or labels. Refer to the Operation and Maintenance Manual, "Safety Messages"for additional information.

Rights Reserved.

Network For SIS Licensees. Fri Apr 4 02:46:24 UTC+0530 2025

Product: WHEEL LOADER

Model: 966G WHEEL LOADER 3ZS

Configuration: 966G Wheel Loader 3ZS00001-UP (MACHINE) POWERED BY 3306 Engine

Operation and Maintenance Manual (Custom) 367-7349 and Quick Coupler For Wheel Loaders

Quick Coupler - Clean/Inspect/Replace

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

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Personal injury or death can result from improperly checking for a leak.

Always use a board or cardboard when checking for a leak. Escaping air or fluid under pressure, even a pin-hole size leak, can penetrate body tissue causing serious injury, and possible death.

If fluid is injected into your skin, it must be treated immediately by a doctor familiar with this type of injury.

Note: Do not weld on the quick coupler without consulting your Caterpillar dealer.

Note: Clean the quick coupler prior to inspection in order to properly inspect the quick coupler.

1. Remove the cover assemblies from the back of the quick coupler.

2. Clean the inside of the quick coupler in order to properly inspect the inside of the quick coupler.

3. Inspect the components inside the quick coupler for the following problems:loose bolts, oil leaks, broken parts, missing parts and cracked components

4. Inspect the hydraulic lines and the hydraulic fittings for damage or for wear. Repair any worn components or replace any worn components. Repair any leaking components.

5. Inspect the steel material of the quick coupler for cracks.

6. Reattach the cover assemblies to the back of the quick coupler.

7. Inspect the warning signs and labels. Replace warning signs or labels that are missing. Replace warning signs or labels when you cannot read the warning signs or labels. Refer to the Operation and Maintenance Manual, "Safety Messages"for additional information.

Note: Perform all repairs before placing the quick coupler back into operation.

Product: WHEEL LOADER

Model: 966G WHEEL LOADER 3ZS

Configuration: 966G Wheel Loader 3ZS00001-UP (MACHINE) POWERED BY 3306 Engine

Operation and Maintenance Manual (Custom) 367-7349 and Quick Coupler For Wheel Loaders

i01828834

Welding on Machines and Engines with Electronic Controls

SMCS - 6700

Proper welding procedures are necessary in order to avoid damage to the electronic controls and to the bearings. The following steps should be followed in order to weld on a machine or an engine with electronic controls.

Note: If you are welding on a work tool, remove the work tool from the host machine before welding.

1. Turn off the engine.

2. Turn the battery disconnect switch to the OFF position. If there is no battery disconnect switch, remove the negative battery cable at the battery.

3. Clamp the ground cable from the welder to the component that will be welded. Place the clamp as close as possible to the weld. Make sure that the electrical path from the ground cable to the component does not go through any bearing. Use this procedure in order to reduce the possibility of damage to the following components:

Bearings of the drive train

Hydraulic components

Electrical components

Other components of the machine

NOTICE

Do NOT use electrical components (ECM or sensors) or electronic component grounding points for grounding the welder.

4. Protect any wiring harnesses from the debris which is created from welding. Protect any wiring harnesses from the splatter which is created from welding.

Product: WHEEL LOADER

Model: 966G WHEEL LOADER 3ZS

Configuration: 966G Wheel Loader 3ZS00001-UP (MACHINE) POWERED BY 3306 Engine

Operation and Maintenance Manual (Custom) 367-7349 and Quick Coupler For Wheel Loaders

Media Number -GEBU0024-00 Publication Date -01/10/2010 Date Updated -12/10/2010

i02044488

Storage

SMCS - 0355

Place the quick coupler on a pallet. Store the pallet on level, solid ground.

Coat the wedges or the pins with grease. Coat the surfaces that contact the work tools with grease. Coat the bores for the mounting pins with grease. Plug the hoses or cap the hoses. Copyright 1993 - 2025 Caterpillar Inc.

Product: WHEEL LOADER

Model: 966G WHEEL LOADER 3ZS

Configuration: 966G Wheel Loader 3ZS00001-UP (MACHINE) POWERED BY 3306 Engine

Operation and Maintenance Manual (Custom) 367-7349 and Quick Coupler For Wheel Loaders

Media Number -GEBU0024-00 Publication Date -01/10/2010 Date Updated -12/10/2010

i02060887

Shipping

SMCS - 7500

If the quick coupler has been removed from the host machine, lay the quick coupler on a pallet. Secure the quick coupler to the pallet.

If the quick coupler is mounted on the host machine, raise the quick coupler slightly away from the ground.

Product: WHEEL LOADER

Model: 966G WHEEL LOADER 3ZS

Configuration: 966G Wheel Loader 3ZS00001-UP (MACHINE) POWERED BY 3306 Engine

Operation and Maintenance Manual (Custom) 367-7349 and Quick Coupler For Wheel Loaders Media Number -GEBU0024-00

Lifting and Tying Down

SMCS - 7500

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NOTICE

Improper lifting or tie-downs can allow the load to shift and cause injury or damage.

Weights and instructions are listed herein. This information is applicable to units that are manufactured by Caterpillar.

Table 1 Part

Lifting the Quick Coupler

Note: Do not use steel cables, chains, or hooks in the mounting holes in order to lift the quick coupler. Damage to the mounting holes of the quick coupler would be a result.

For lifting the quick coupler, use properly rated lifting slings. Position the lifting device for level lifting. Position any hydraulic hoses in order to prevent any damage to the hoses.

Illustration 1 g02297639

Tying Down the Quick Coupler

Note: Do not tie the quick coupler down using the pin bores. Damage may occur to the pin bores.

Tie down the quick coupler. Use cables, restraining bands, or straps that are strong enough to secure the load and strong enough to prevent the load from shifting. Secure any hydraulic hoses in order to prevent damage to the hoses.

Product: WHEEL LOADER

Model: 966G WHEEL LOADER 3ZS

Configuration: 966G Wheel Loader 3ZS00001-UP (MACHINE) POWERED BY 3306 Engine

Operation and Maintenance Manual (Custom) 367-7349 and Quick Coupler For Wheel Loaders

Media Number -GEBU0024-00 Publication Date -01/10/2010 Date Updated -12/10/2010

i03700900

Transport Position

SMCS - 7500

NOTICE

For specific information on your host machine, refer to the Operation and Maintenance Manual of your host machine.

In order to transport the quick coupler, lay the quick coupler on a pallet. Secure the quick coupler to the pallet.

Private Network For SIS Licensees. Fri Apr 4 02:45:05 UTC+0530 2025

Product: WHEEL LOADER

Model: 966G WHEEL LOADER 3ZS

Configuration: 966G Wheel Loader 3ZS00001-UP (MACHINE) POWERED BY 3306 Engine

Operation and Maintenance Manual (Custom) 367-7349 and Quick Coupler For Wheel Loaders

Hydraulic System Air Purge

SMCS - 5050-542-AI

NOTICE

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.

Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide", for tools and supplies suitable to collect and contain fluids.

Dispose of all fluids according to local regulations and mandates.

1. Check the valves on the host machine. The valves must be in the OPEN position. Refer to the Operation and Maintenance Manual of the host machine for the different positions of the valves.

2. If a work tool is connected to the quick coupler, disengage the work tool. Remove the work tool from the quick coupler.

3. Start the host machine. Run the host machine until the hydraulic oil temperature reaches the normal operating temperature for the hydraulic oil.

4. Engage the quick coupler and disengage the quick coupler for three times in order to purge the air from the hydraulic system.

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Rights Reserved.

Network For SIS Licensees. Fri Apr 4 02:44:55 UTC+0530 2025

Product: WHEEL LOADER

Model: 966G WHEEL LOADER 3ZS

Configuration: 966G Wheel Loader 3ZS00001-UP (MACHINE) POWERED BY 3306 Engine

Operation and Maintenance Manual (Custom) 367-7349 and Quick Coupler For Wheel Loaders Media Number -GEBU0024-00

Operation

SMCS - 6129; 7000

Operating the Quick Coupler

Improper attachment of work tools could result in injury or death.

Do not operate this machine until you have positive indication that the coupler pins are fully engaged. Check for engagement by:

1. Tilt the work tool down.

2. Put downward pressure on the work tool.

3. Back the machine up and make sure there is not any movement between the work tool and the quick coupler assembly.

NOTICE

Auxiliary hoses for work tools must be removed before the quick coupler pins are disengaged.

Pulling the work tools with the auxiliary hoses could result in machine damage.

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Note: Some machines may have a device that is used to lock the third function valve. Refer to the Operation and Maintenance Manual of the host machine for additional information.

In order to operate the quick coupler, use the control for the third function valve.

In order to engage the quick coupler, move the control for the third function valve in a forward direction.

In order to disengage the quick coupler, move the control for the third function valve in a rearward direction.

1 g02297033

When you engage the quick coupler, Verify that the quick coupler is fully engaged with the work tool. Visually check the indicators (1) for each of the wedges.

Illustration

Product: WHEEL LOADER

Model: 966G WHEEL LOADER 3ZS

Configuration: 966G Wheel Loader 3ZS00001-UP (MACHINE) POWERED BY 3306 Engine

Operation and Maintenance Manual (Custom) 367-7349 and Quick Coupler For Wheel Loaders

Daily Inspection

SMCS - 6700-040

Personal injury or death can result from improperly checking for a leak.

Always use a board or cardboard when checking for a leak. Escaping air or fluid under pressure, even a pin-hole size leak, can penetrate body tissue causing serious injury, and possible death.

If fluid is injected into your skin, it must be treated immediately by a doctor familiar with this type of injury.

NOTICE

Accumulated grease and oil on a work tool is a fire hazard.

Remove debris with steam cleaning or high pressure water at any time a significant quantity of oil is spilled on the work tool.

Note: If major repairs to the quick coupler are required, consult your Caterpillar dealer.

Note: Clean the quick coupler prior to daily inspection in order to properly inspect the quick coupler.

i02055801

1. For the maximum service life of the quick coupler, make a thorough daily inspection before you mount a work tool to the host machine.

2. Inspect the quick coupler for the following conditions: loose bolts, oil leaks, broken parts, missing parts and cracked components. Check the overall condition of the quick coupler. Check the overall condition of the hydraulic system.

3. Inspect the warning signs and labels. Replace warning signs or labels that are missing. Replace warning signs or labels when you cannot read the warning signs or labels. Refer to the Operation and Maintenance Manual, "Safety Messages"for additional information.

4. Inspect the condition of the hydraulic lines and the hydraulic fittings.

5. Check the mounting pins for the quick coupler.

6. Check the lifting device, if equipped. If damage is present do not use the lifting device. Contact your Caterpillar dealer for repairs.

7. Perform all repairs before you put the quick coupler into operation.

8. Lubricate the fittings for the wedges. Refer to Operation and Maintenance Manual, "Quick Coupler-Lubricate" for additional information.

Product: WHEEL LOADER

Model: 966G WHEEL LOADER 3ZS

Configuration: 966G Wheel Loader 3ZS00001-UP (MACHINE) POWERED BY 3306 Engine

Operation and Maintenance Manual (Custom) 367-7349 and Quick Coupler For Wheel Loaders

Quick Coupler Installation and Removal

SMCS - 6129-010

Installation Procedure

i04089271

Note: Before you install the quick coupler, verify that the hydraulic system of the host machine meets the following requirements:

• The control of the quick coupler must be protected against inadvertent operation.

• When the quick coupler is engaged, there must be no buildup of pressure on the side of the cylinder that disengages the pins of the quick coupler.

• When the pins of the quick coupler are disengaged, the pins will be held in the disengaged position by the hydraulic system.

1. Clean all of the pins. Clean all of the bores for the pins.

2. Align the lower bores of the quick coupler with the bores of the lift arms of the host machine.

3. Install the pins into the lower bores. Lock the pins.

4. Move the tilt linkage until the bores of the tilt linkage are aligned with the upper bores of the quick coupler.

5. Install the pins into the upper bores. Lock the pins.

6. Check the position of the stops on the quick coupler. The usage of stops is determined by the requirements of the host machine. Refer to the Operation and Maintenance Manual of the host machine for additional information.

7. Connect the hydraulic lines from the quick coupler to the hydraulic fittings on the host machine. Refer to the Operation and Maintenance Manual of the host machine for additional information.

8. Open the valves on the host machine (if equipped). Valves are not always equipped on the host machine.

9. Before you operate the quick coupler, Purge the air from the hydraulic system. Refer to the Operation and Maintenance Manual, "Hydraulic System Air Purge" for additional information.

Removal Procedure

1. Place the quick coupler on a surface that is solid and level.

2. Stop the engine of the host machine.

3. Release the pressure in the hydraulic system. In order to release the pressure in the hydraulic system, turn the engine start key to the ON position. Do not start the engine. Cycle the hydraulic controls. Activate the third function of the hydraulic system. Cycle the control for the third function.

4. Turn the engine start key to the OFF position.

5. Close the valves on the host machine (if equipped). Valves are not always equipped on the host machine.

Personal injury or death can result from improperly checking for a leak.

Always use a board or cardboard when checking for a leak. Escaping air or fluid under pressure, even a pin-hole size leak, can penetrate body tissue causing serious injury, and possible death.

If fluid is injected into your skin, it must be treated immediately by a doctor familiar with this type of injury.

NOTICE

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.

Refer to Special Publication, NENG2500, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat products.

Dispose of all fluids according to local regulations and mandates.

6. Place a suitable container below the hydraulic fittings in order to catch any hydraulic oil that may escape. Slowly disconnect the hydraulic lines. Plug the ends of the hydraulic lines or connect the hydraulic lines.

7. Dispose of the hydraulic oil in a suitable manner.

8. Remove the pins from the upper bores of the quick coupler.

9. Remove the pins from the lower bores of the quick coupler.

10. Start the engine of the host machine. Carefully move the host machine away from the quick coupler.

Note: If the quick coupler is stored for an extended period of time, place grease in the bores of the quick coupler and coat all of the surfaces of the pins with grease.