Вы находитесь на странице: 1из 64

Cat Product Information

Product Bulletin

Cat Product Information Product Bulletin August 2011 Cat ® 966K and 972K Medium Wheel Loaders For
Cat Product Information Product Bulletin August 2011 Cat ® 966K and 972K Medium Wheel Loaders For

August 2011

Cat ® 966K and 972K Medium Wheel Loaders

August 2011 Cat ® 966K and 972K Medium Wheel Loaders For Dealer Sales Personnel This document
August 2011 Cat ® 966K and 972K Medium Wheel Loaders For Dealer Sales Personnel This document

For Dealer Sales Personnel

This document supplements information in the Specalog. Marketing content will be available only on secured dealer extranets and by accessing the PDF in the Electronic Sales Library.

content will be available only on secured dealer extranets and by accessing the PDF in the

Table of Contents

Overview

3

Work Tools and Linkage

5

Hydraulic System

9

Operator Environment

13

Engine

23

Cooling System

31

Powertrain

34

Structures

40

Safety

41

Monitoring Systems

43

Serviceability

45

Customer Support

50

Sustainability

51

Comparison of 966K/972K vs. 966H/972H

52

Comparison of 966K vs. 966H

54

Comparison of 972K vs. 972H

55

Technical Specifications – 966K

59

Technical Specifications – 972K

61

2

TEJB9628

Cat 966K and 972K Medium Wheel Loaders

August 2011

Overview

Overview When developing the new Medium Wheel Loaders Caterpillar set design specifications based upon voice of

When developing the new Medium Wheel Loaders Caterpillar set design specifications based upon voice of the customers and dealers. These design specifications came from many research projects and customer touch points. To develop a simple design that is intuitive and easy to learn for new operators and maintains the durability and reliability that Cat ® machines are known for creating. They also wanted a machine, which would improve productivity, fuel efficiency, performance, and meet job site safety/regulatory requirements.

Enter the 966K and 972K powered by the innovative Cat C9.3 ACERT™ engine optimized for maximum fuel efficiency and increased power density while meeting Tier 4 Interim/Stage IIIB emissions requirements. The new engine contains a Cat Clean Emissions Module (CEM), which houses the Diesel Oxidation Catalyst (DOC), Diesel Particulate Filter (DPF), and Cat Regeneration System (Cat RS) all working together to improve power and efficiency.

The unmatched, revolutionary world-class cab found in both machines creates a comfortable, efficient, safe, and productive operator environment. The operator station features an ergonomic electro-hydraulic (EH) joystick steering system with force feedback (speed sensitive); new viscous cab mounts that reduce noise and vibration; automatic climate control that adjusts temperature and fan speed to the operator’s preferred setting; and a new center display panel with five analog- like gauges and a large text box that displays in-language messages.

August 2011

TEJB9628

Cat 966K and 972K Medium Wheel Loaders

3

Overview

With the addition of Performance Series Buckets, which are now standard, operators benefit from reduced dig times and better material retention; ultimately translating into significant productivity and fuel effi ciency improvements. To enhance versatility, the 966K and 972K can be equipped with the Cat Fusion™ coupler system, a common interface for 924-972 wheel loaders. The Fusion coupler not only allows one machine to use a wide range of work tools, but also permits one work tool to be used by machines of different sizes. This cross-machine capability gives equipment owners additional flexibility and fleet options.

The K Series transmissions incorporate a new shifting strategy that delivers smoother shifts, faster acceleration, and increased travel speed when climbing a grade.

The wheel loaders have been optimized as a system; from the linkage and work tool carrying the payload, to the engine, transmission and torque converter moving the machine, the system has been optimized to achieve the lowest cost per ton.

The reliability, durability, and versatility of the 966K and 972K result in machines that are better built to meet your needs. All Day. Every Day.

are better built to meet your needs. All Day. Every Day. 4 TEJB9628 Cat 966K and

4

TEJB9628

Cat 966K and 972K Medium Wheel Loaders

August 2011

Work Tools and Linkage

An extensive range of work tools and bucket styles are available with either pin on or quick coupler interface for the 966K and 972K to customize these machines for your operation.

and 972K to customize these machines for your operation. Work Tool Fill Factors Bucket Fill Factors

Work Tool Fill Factors

Bucket Fill Factors

 

(as a % of ISO Rated Capacity)

 
 

Performance

Series

Loose Material

Bucket

Earth/Clay

115

Sand and Gravel

115

Aggregate:

25-76 mm (1 to 3 in)

110

19 mm (0.75 in) and smaller

105

Rock

100

Fill Factors achieved will also depend on whether the product is washed or not washed.

Performance Series Buckets:

Load Easy, Fuel Efficient, Carry More

Performance Series Buckets utilize a system- based approach to balance bucket shape with the machine’s linkage, weight, lift and tilt capacities. Operators benefit from reduced dig times and better material retention; ultimately translating into significant productivity and fuel efficiency improvements.

August 2011

TEJB9628

Cat 966K and 972K Medium Wheel Loaders

5

Work Tools and Linkage

Lower Operating Costs

Performance Series Buckets feature a longer floor that easily digs through the pile and provides excellent visibility for the operators to see when the bucket is full. Less time digging in the pile results in lower fuel consumption and improved tire life. A unique spill guard protects the cab and linkage components from material overflow.

Higher Productivity

Performance Series Buckets achieve higher fill factors – ranging from 100% to 115% depending on the machine application and material type. The buckets feature optimized geometry with a bucket opening matched to the machine’s linkage and incorporate a curved side profile to maximize material retention. The optimized design results in unsurpassed production capabilities.

Performance Series Bucket Styles

Performance Series Buckets are available for General Purpose, Material Handling, Rock, Heavy Duty Rock and Coal style buckets.

Specialty Buckets

Forks, Rakes, and Plows

• Pallet Forks, Log and Lumber Forks

• Rakes, with or without top clamps

• Plows, angle or V-style

Fusion™ Quick Coupler System

• Plows, angle or V-style Fusion™ Quick Coupler System Fusion™ is the patented wheel loader coupler

Fusion™ is the patented wheel loader coupler system from Caterpillar. The Fusion Coupler System provides performance virtually identical to pin on – with all the flexibility of a quick coupler system. The Fusion Coupler sits back, close-in to the loader arms – minimizing offset and increasing the machine’s performance.

Multipurpose

Side Dump

Waste Handling

Woodchip

6

TEJB9628

Cat 966K and 972K Medium Wheel Loaders

August 2011

Work Tools and Linkage

Fusion™ eliminates coupler offset with substantial improvements in center of gravity.
Fusion™ eliminates
coupler offset
with
substantial
improvements in
center of gravity.
with substantial improvements in center of gravity. No loss of performance – Imagine lifting a hundred

No loss of performance – Imagine lifting a hundred pound box with your arms fully extended. Now imagine lifting that same load close to your body. That’s the genius of Fusion: designed to integrate the work tool and the machine by pulling the coupler and tool closer in to the loader. As a result, the center of gravity is moved inward, towards the machine. This translates to increased lifting ability when compared to machines equipped with other coupler systems.

Unsurpassed durability – An advanced wedging mechanism creates a tight, rattle-free fit. This patented lock up system eliminates play and wear – resulting in a long service life. Wedges pull the attachment tight to the machine in two directions – in and down. Constant hydraulic pressure on the coupler wedges compensate for wear, assuring a tight fit through the life of the coupler. Tight fit gives better tool control and increased productivity. Coupler durability is substantially increased over traditional couplers.

Increased visibility – An open coupler frame design clears sight lines from the operator’s seat, making it easier than ever before to engage and disengage attachments with certainty. Offset tines and other design changes to Fusion Pallet Forks, working in conjunction with the Fusion Coupler, increase visibility substantially at ground level and truck bed height when compared to traditional coupler and fork combinations.

when compared to traditional coupler and fork combinations. The Fusion Coupler System gives Caterpillar customers one

The Fusion Coupler System gives Caterpillar customers one common interface – eliminating the need for many different couplers across the entire range of small and medium wheel loaders. This expanded machine compatibility not only allows one machine to use a range of work tools, but also allows one work tool to be picked up by machines of many different sizes. The Fusion coupler interface is designed to work on 924 through 972 machines. Each machine will have its own optimal bucket and fork recommendations. However, cross- machine compatibility gives you additional flexibility and fleet options not found with any other wheel loader coupler. The Fusion Coupler System and work tool assortment gives many abilities and options to a single machine – or a whole fleet of wheel loaders – increasing production on the job site.

August 2011

TEJB9628

Cat 966K and 972K Medium Wheel Loaders

7

Work Tools and Linkage

Linkage

Work Tools and Linkage Linkage The 966K and 972K linkage is a single tilt Z bar

The 966K and 972K linkage is a single tilt

Z bar design. Three versions of this linkage

are available: standard, high lift and extended

capacity (only 972K). The extended capacity

lift arrangement allows the machine to excel

in normal hopper charging and truck loading

applications without compromising performance. In addition, increased durability has been engineered into the extended capacity lift arms by stress relieving the structures and optimizing the side plate profile.

Lift arms are solid steel, providing superior strength with an excellent front end viewing area. The proven design offers excellent dump clearance and reach for exceptional matching to various truck loading and yard applications. The cast steel cross tube utilizes a quenched and tempered design and is heat-treated for maximum resistance to torsion and impact loads. The Z bar linkage generates excellent breakout forces and good roll back angles for better bucket loading and material retention.

Bucket Positioner

The 966K and 972K use a rotary sensor, mounted on the right side of the linkage cross tube, which measures the angular change between the tilt lever and the linkage cross tube. The operator can adjust the work tool detents electronically from within the cab. The Performance Series Buckets incorporate a spill guard protecting the linkage and sensor components. A guard also covers the sensor further protecting it from damage by material happening to flow over the bucket spill guard.

8

TEJB9628

Cat 966K and 972K Medium Wheel Loaders

August 2011

Hydraulic System

The hydraulic system in the 966K and 972K has been optimized to improve productivity, fuel efficiency, and rimpull.

Load Sensing Hydraulics

Load Sensing Hydraulics produce a flow for the implement system upon demand, and only in amounts necessary to perform the needed work functions. The result is a system that wastes little energy, making it more productive and fuel efficient. Another benefit of load sensing hydraulics is improved implement controllability through simultaneous implement operation and repeatable fine modulation, enabling greater operator comfort through ease of operation. The load sensing implement system also results in more rimpull into the pile since less energy is needed to drive the implement system in most situations.

Hydraulic Implement System

system in most situations. Hydraulic Implement System The hydraulic implement system consists of the hydraulic

The hydraulic implement system consists of the hydraulic reservoir, pump, valves, and cylinders to control the bucket lift/lower and dump/rack functions as well as standard attachments such as auxiliary 3rd functions and ride control. The hydraulic implement circuit is controlled via electronic fingertip controls that interface with an electronic control module.

The hydraulic implement system uses a variable displacement piston pump that is load sensing and pressure compensated. A load-sensing pump generates flow proportional to the operator input instead of by engine speed. Therefore, the load-sensing pump generates just enough flow to meet the application needs. Flow from the hydraulic pump is routed to a closed center M3PC implement control valve that utilizes electro hydraulic actuation. Based on electrical commands originating from electronic controls mounted in the cab, proportional solenoids direct pilot oil to shift the spools within the control valve, for control of one or more loader functions. The M3PC implement valve operates on PPPC (proportional priority pressure compensated) principle and uses the pressure compensator between the main spool and the actuator ports. All the pressure compensators of individual circuits involved are interconnected and operate with different pressure differentials. The individual highest load pressure is applied to all pressure compensators. During simultaneous operation, when the pump flow is no longer sufficient to operate all actuators at the requested velocity, the velocity of all functions is evenly reduced. This results from the reduced pressure differential across all pressure compensators. No hydraulic cylinders will come to a standstill. Double acting hydraulic cylinders will receive the hydraulic oil and convert the oil pressure and flow into the operator desired loader movement.

August 2011

TEJB9628

Cat 966K and 972K Medium Wheel Loaders

9

Hydraulic System

Implement Valve

The M3PC Priority Proportional Pressure Compensation Valve is a sectional designed valve, which can be configured from two to three sections allowing greater versatility. Customers can specify a valve that matches the demand of their application. Additionally, system functions, like ride control, anti-drift, and pilot supply, are incorporated into the valve allowing a reduction in the number of hydraulic lines within the system. Integration of function reduces the need for add-on valve while improving reliability.

Implement Controls

The EH bucket implement controls provide the operator with precise control of the work tools using soft dents and automatic cylinder snubbing.

work tools using soft dents and automatic cylinder snubbing. When either lever is moved into the

When either lever is moved into the soft detent, the operator will feel an increased resistance from the lever – this is the operator’s indication that the detent has been activated. Once the detent is activated, the operator should release the lever and allow it to automatically return to center position. In doing this, the work tool will continue to move until it reaches the kick-out position, as set by the operator. (Note – the detent will not be activated if the lever is held in the detent positions for more than one second.)

If the operator was to manually override the

detent (and prevent the work tool from traveling automatically to the kick-out position), the lever must be moved at least six degrees from the center position. Prior to H Series, machines had detents with magnets that held the lever in the detent position until the kickout position was reached by the implement.

The 966K and 972K have a redesigned steering neutralizer valve which is important in reducing the stress on the frame when the operator articulates the machine fully. The steering neutralizer valves were removed from the hitch area and replaced with sensors in the steering cylinders. Hydraulic snubbing in the steering control eliminates metal on metal contact at full articulation that induces stress on the hitch pins and frames.

Ride Control (Standard)

Ride control provides the operator with a smoother ride over rough terrain, enabling a more comfortable ride at higher speeds. The benefit is reduced cycle times; higher

productivity and better fuel efficiency while performing load and carry applications.

A nitrogen gas accumulator in the hydraulic

lift circuit acts as a shock absorber, dampening forces from the bucket or other work tools. When the machine travels over rough ground, Ride Control reduces machine pitching by allowing the bucket and lift arms to compress the nitrogen in the accumulator, improving machine stability and providing a smoother, more comfortable ride. Ride Control gives operators more confidence to travel at higher speeds during load and carry, improving cycle times and load retention for higher productivity. Ride Control also contributes to increased frame and machine life by reducing shock loads into the structures.

10

TEJB9628

Cat 966K and 972K Medium Wheel Loaders

August 2011

Hydraulic System

By using a switch in the cab, an operator can choose between three modes: Ride Control Off, Ride Control On or Automatic Ride Control.

• In automatic mode, the Ride Control system will automatically become active if the ground speed exceeds 9.7 km/h (6 mph). When speed decreases below 9.7 km/h (6 mph), the system will automatically deactivate. When deactivated, automatic mode offers a rigid hydraulic system for the lift arms to provide more efficient loading and lifting. The system will also deactivate if the bucket is operated. The speed at which Ride Control activates/deactivates can be adjusted using the Rd Ctrl Fwd Act Spd function in the information display the operator can set the forward activation speed for the system. Rd Ctrl Rev Act Spd function is used to set the reverse activation speed in the information display.

• In the Ride Control On mode, the system is always active. Operators should not load in the On mode because this will cause the lift cylinders to compress the nitrogen in the accumulator, providing a spongy feel and reduced hydraulic force. An application where this mode is useful would be when working with pallet forks or loading heavy objects at low speed such as loading concrete pipe on rough underfoot.

Hydraulic Tank

The hydraulic tank is located behind the cab above the pump inlets to improve inlet conditions with the help of gravity, for increased pump reliability and durability.

Heavy Duty Piston Pump

The heavy-duty pump is part of a two-pump system, with one dedicated to the implement system and one to the steering system. This ensures the operator has full flow for both steering and implement control to guarantee flow is available when needed.

966K/972K Oil Flow Explanation

Hydraulic Tank Fan Pump Axle Oil Cooler Hydraulic Filter Fan Fan/Brake/Pilot Brake Motor Valve Accumulators
Hydraulic
Tank
Fan Pump
Axle Oil
Cooler
Hydraulic
Filter
Fan
Fan/Brake/Pilot
Brake
Motor
Valve
Accumulators
Oil
Brakes/Quick
Cooler
Coupler
Implement
Pilot
Pilot
Pilot
Steering
Valve
Accumulator
Circuit
Accumulator
Valve

The main oil flow for the fan circuit originates from the hydraulic tank that is shared by all hydraulic circuits. The oil flows into the suction port of the fan pump and continues through the discharge side into the fan circuit. The oil then flows through an anti-drainback check valve before entering the kidney loop filter.

If the filter is clogged, the oil is permitted to

flow through the filter bypass valve. The oil then flows into the fan/brake/pilot valve. Inside the valve block the oil is split into three separate functions. Oil will be supplied to the fan drive and pilot circuit continuously, and when needed the brake system.

A load sensing line connects the fan/brake/pilot

valve with the fan pump. Depending on the system that takes priority, a resolved signal is sent to

the fan pump to control the required flow.

The pilot circuit takes priority. Oil flows from the park/brake/pilot valve into two circuits. The first is the primary steering pilot supply, which charges the primary steering pilot accumulator and then flows to the steering valve. The other circuit is the implement and redundant steering pilot supply which charges the implement and redundant steering pilot accumulator before flowing to the implement valve. From the steering and implement valve, oil is returned to the hydraulic tank through the valve drains. The brake circuit takes

August 2011

TEJB9628

Cat 966K and 972K Medium Wheel Loaders

11

Hydraulic System

priority over the fan when the pressure in the accumulators drops below a set limit. The oil then travels through the brake circuit as needed and returns to tank.

Flow that is not used to charge the accumulators, exits the fan/brake/pilot valve and enters the fan motor. The flow is regulated by a solenoid valve inside the fan/brake/pilot valve. From the fan motor the oil flows through the oil cooler or if necessary through the oil cooler bypass valve. If equipped, the oil will split off between the axle oil cooler attachment and the return line to tank. If the machine is not equipped with axle oil cooling, the oil returns directly to the hydraulic tank.

966H/972H Oil Flow Explanation Hydraulic Tank Fan Pump Fan Motor Fan/Brake Valve Brake Accumulators Oil
966H/972H Oil Flow Explanation
Hydraulic Tank
Fan Pump
Fan Motor
Fan/Brake Valve
Brake
Accumulators
Oil Cooler
Brakes/Quick
Coupler
Hydraulic Filter
Axle Oil Cooler

The main oil flow for the fan circuit originates from the hydraulic tank that is shared by all hydraulic circuits. The oil flows into the suction port of the fan pump and continues through the discharge side into the fan circuit. The oil then flows directly into the fan/brake valve. Inside the valve block the oil is split into two separate functions. Oil will be supplied to the fan drive continuously and when needed the brake system. A priority valve inside the block determines the ratio of oil between the circuits. If the pressure inside the accumulators drops to a set minimum value, priority is shifted to the brakes and full flow is supplied to the accumulators. For the fan circuit, a solenoid

valve regulates the flow going to the fan, ultimately controlling the fan speed.

A load sensing line connects the fan/brake valve with the fan pump. Depending on the system that takes priority, a resolved signal is sent to the fan pump to control the required flow. Flow that is not used to charge the accumulators, exits the fan/brake valve and enters the fan motor. From the fan motor the oil enters the oil cooler. Flow is also able to bypass the oil cooler if necessary. The oil then travels through an anti-drainback check valve which blocks the oil when the filter is being serviced. Oil then travels through the kidney loop filter or through the filter bypass in the event that the filter is clogged. If equipped, the oil travels through the axle oil cooler attachment before returning to tank. If the machine does not have the axle oil cooler attachment, the oil returns directly to tank after filtration.

System Differences:

• On H Series, the kidney loop filter is located after the fan/brake valve, fan motor and oil cooler. The oil is filtered before returning to tank. On K Series, the kidney loop filter is located between the fan pump and the fan/brake/charge valve. The oil is filtered before entering the fan circuit.

• On K Series the pilot circuit is driven off of the fan pump.

• Flow to the axle oil cooler attachment differs slightly between H and K Series.

12

TEJB9628

Cat 966K and 972K Medium Wheel Loaders

August 2011

Operator Environment

The new four post ROPS cab provides enhanced comfort, visibility, and productivity resulting in a more efficient operator.

Ladder

productivity resulting in a more efficient operator. Ladder Access to the operator station has been improved

Access to the operator station has been improved with a redesigned left side access ladder. The new ladder is built at a 10-degree incline compared to a 5 degree on the H Series. When further comfort is needed, an optional retractable ladder which provides an inclination of 18-degrees is offered for the European market. The idea behind this change in angle is to make climbing the ladder into the cab feel more like walking up stairs. The steps are four bar self-cleaning steps that are wide enough spaced to allow debris to fall between the bars. The spacing between the steps meets ISO standards along with the distance from the ground to the ladder. The first step is flexible with a very substantial rubber belting to help make it resistant to damage if the operator were to run over something.

Front Hinged Door

the operator were to run over something. Front Hinged Door New front hinged, full length door

New front hinged, full length door is provided on the left side of the cab. By eliminating the intermediate door posts, the door opening is much wider. Additionally this change eliminates the side blind spot caused by the extra posts that were previously used to hinge the rear opening door. The pull type door handle has been relocated on the lower right hand corner of the door for easy access when standing on the ground or first step of the ladder. A gas strut opens the door automatically once the door handle/ latch is pulled. Once in the cab the operator now has the ability to open or close the door from a seated position. The cab features sliding windows on both sides that can be opened incrementally with one hand operation to facilitate easy communication to personnel on

August 2011

TEJB9628

Cat 966K and 972K Medium Wheel Loaders

13

Operator Environment

the ground. This will help encourage operators to work with the door closed, contributing to a cleaner, and quieter cab environment.

Notice on the chart the dimensions of the door opening on the K Series cab compared to the former H Series. The entry of the door is significantly larger at all three locations.

Location

 

H

 

K

Switch

381

mm (15")

635

mm (25")

Striker

483

mm (19")

610

mm (24")

Shoulder

508

mm (20")

686

mm (27")

Four Post ROPS

To help simplify the cab and enhance visibility the cab was converted from a six post design on the H Series to a new four post cab design. By making several design changes to the cab, visibility has been enhanced to include 54 more degrees of view around the cab. Meaning out of a possible 360 degrees view the operator can now see 315 degrees compared to the 261 degrees view with the six post cab. The change was made possible due to several design changes including:

• Relocating the operator’s eye point further forward in the cab relative to the front ROPS posts

• Eliminating the intermediate door posts and side window post

• Moving the ROPS posts closer together

Spot mirrors have been added to the left and right side of the cab to enhance visibility towards the ground near the center of the machine. Left side visibility is important when talking to personnel on the ground or grading close to a curb, therefore the increase of visibility to the left will help create a safe working environment.

Convex Windshield

help create a safe working environment. Convex Windshield The front glass panel has been changed from

The front glass panel has been changed from a flat glass to a convex glass which helps enhance visibility, increase cab space, decrease sound levels in the cab, and is more durable than flat glass. The convex windshield provides a clean and clear panoramic view for safe operation of the machine. Optional with the convex windshield are window guards to help protect the glass in applications such as waste handling, scrap handling, forestry, land clearing, etc.

14

TEJB9628

Cat 966K and 972K Medium Wheel Loaders

August 2011

Operator Environment

Seat

Operator Environment Seat The Cat Optimized Seating System is 6-way adjustable to accommodate all-sized operators. The

The Cat Optimized Seating System is 6-way adjustable to accommodate all-sized operators. The seat has a one piece high back and supports the lumbar area of the back up to the shoulders. Both armrests are large and can be adjusted up or down to improve comfort and convenience. Armrests are attached to the seat so they stay with the operator’s body as the machine rides over rough ground. The armrests also adjust fore and aft to accommodate arm lengths of different size operators. An optional feature for the cab seat is a heated backrest and cushion.

• Raise seat height up and down

• Slide seat fore and aft

• Recline seat back fore and aft

• Seat cushion tilt up, mid and down

• Lumbar adjustment

• Headrest height adjustment

Electro-Hydraulic (EH) Joystick Steering with Force Feedback (Speed Sensitive)

(EH) Joystick Steering with Force Feedback (Speed Sensitive) The industry leading EH joystick steering system combines

The industry leading EH joystick steering system combines operator comfort and precision control to provide a sustainable work environment for the operator. The system incorporates a force feedback motor that automatically adjusts the effort needed to tilt the ergonomic joystick based on ground speed, resulting in superior control in all applications and climates. The joystick has 80 degrees of total movement that is 40 degrees either side of the center. The movement and position of the joystick mirrors the articulation angle of the machine making operation of the steering system intuitive. When the engine is off the joystick is very loose and can move easily. Once the machine is powered on, the joystick automatically aligns itself to the steering angle or articulation angle of the machine. The joystick then becomes active and will mirror the articulation angle of the machine. In addition the joystick is equipped with a yellow forward/neutral/reverse finger switch and a thumb wheel used for up and downshifting.

The EH Joystick Steering System has numerous redundancies; combined with superior control at all speeds, the redundancies enabled Caterpillar to completely remove the steering wheel from the cab (opening up leg room and a clear line of sight to the work area). The EH joystick input angle is triple redundant, providing three position inputs to the system: dual ECMs, dual electrical

August 2011

TEJB9628

Cat 966K and 972K Medium Wheel Loaders

15

Operator Environment

harnesses, and dual valve units that communicate and work with each other in the event a primary component has a malfunction. Only one set of ECMs, electrical harnesses, and valve units is used for normal operation and components from the primary and secondary system cross communicate with one another.

Electro-hydraulic Steering Wheel

An optional electro-hydraulic steering wheel system will be available from the factory several months after the wheel loaders go into production. It too senses ground speed and automatically adjusts steering effort to improve controllability and comfort at higher speeds. Full machine articulation can be accomplished by rotating the wheel approximately 330˚. This compares to conventional steering wheels, which can require two-and-one-half to five or more full turns to achieve full articulation. Retrofit kits will be available for the joystick and steering wheel systems, so dealers and equipment owners can change systems as required.

Implement Controls (EH)

can change systems as required. Implement Controls (EH) Seat mounted single axis implement control levers provide

Seat mounted single axis implement control levers provide the operator with precise control of the work tool, all while moving with the seat for maximum comfort. In cab programmable kick-outs and automatic cylinder snubbing maximize operator comfort and productivity

throughout their shift. Optional auxiliary hydraulics are available for these machines.

As an option the implement control levers can be replaced with one implement control joystick. This joystick provides third valve hydraulic functions through the yellow roller knobs/tabs on the front of the control. A transmission kick down is underneath the top of the joystick. A horn button is located on the left side of the joystick as well.

• For 2V hydraulics, the yellow roller knobs/ tabs are not included.

• For 3V hydraulics, one yellow roller knob/tab is included.

Ignition Console

one yellow roller knob/tab is included. Ignition Console The ignition console is new on the K

The ignition console is new on the K Series and contains the ignition controls, EH parking brake and implement lock out rocker switches, a 12-volt port, and the controls for the optional heated/remote controlled external mirrors. To the right of the console are the MP3 player jack, MP3 player or cell phone holder, and two cup holders.

16

TEJB9628

Cat 966K and 972K Medium Wheel Loaders

August 2011

Operator Environment

Electro-hydraulic Park Brake Control

The operator can activate the electro-hydraulic parking brake by using a two position maintained rocker switch in the cab. Once the machine has been shut down the parking brake will activate automatically. It is a spring-applied, oil released, dry drum brake. The 966K and 972K monitoring system alerts the operator if the transmission is engaged while the parking brake is applied. If necessary, when the brake is applied, the operator can drive through the parking brake. If the transmission is in gear when the parking is applied, the transmission is neutralized. To reactivate the transmission, the operator must first shift into neutral and then back into gear.

Information Display

into neutral and then back into gear. Information Display The central display panel has a large

The central display panel has a large 51 by 102 mm (2 by 4 in) text box, five analog-like gauges, and LED warning indicators. The large text box provides in-language information about machine operation, feature activation and system troubleshooting and calibration. The system supports 27 different languages and will display instructions or commands

for operator convenience. Surrounding the text box is LED warning indicators that light up on the display screen. With the 5 large analog- type gauges the operator can easily identify if key systems are within normal operating range. The navigation buttons are located on the side of the screen and help assist with set up and other various functions.

Resettable trip totals and lifetime totals functions have been incorporated into the monitor to display information.

Trip Totals Functionality (resettable “trip” meter, like on your car):

• Page 1 (Average Fuel Consumption Rate, Total Fuel Consumed, Total Idle Time, Engine Idle Time)

• Page 2 (Total Operating Hours, Neutral Gear Operating Hours, Total Hydraulic Oil Filter Bypass Hours, Odometer)

• Page 3 requires PCS (Total Payload Weight, Total Load Count, Total Pass Count, Machine Loaded Travel Hours)

Lifetime Totals Functionality:

• Page 1 (Total Fuel Consumed, Total Idle Fuel, Engine Idle Time)

• Page 2 (Total Operating Hours, Neutral Gear Operating Hours, Total Hydraulic Oil Filter Bypass Hours, Odometer)

• Page 3 requires PCS (Total Payload Weight, Total Load Count, Total Pass Count, Machine Loaded Travel Hours)

August 2011

TEJB9628

Cat 966K and 972K Medium Wheel Loaders

17

Operator Environment

Control Panels

Left Turn Signal

Low/High

Beam Select

Work Lights

Auxiliary

Work Lights

(If Equipped)

Heated Mirror

(If Equipped)

Ride Control

Implement Tilt

Kickout

Auto/Manual

Transmission Select

Keypad Help

Autodig Operation Mode (If Equipped)

Autodig Material Mode Increase (If Equipped)

Autodig Material Mode Decrease (If Equipped)

(If Equipped) Autodig Material Mode Decrease (If Equipped) Right Turn Signal Parking Lights and Headlights Hazard
(If Equipped) Autodig Material Mode Decrease (If Equipped) Right Turn Signal Parking Lights and Headlights Hazard

Right Turn Signal

Parking Lights

and Headlights

Hazard Lights

Beacon

(If Equipped)

Manual

Regeneration

Auto Regeneration

Disable

Implement Lift

Kickout

Transmission

Neutralizer

Quick Coupler

(If Equipped)

Work Tool Control (If Equipped)

PCS Reweigh

(If Equipped)

PCS Clear/Zero

(If Equipped)

Two control panels located on the front right ROPS post consist of large membrane switches making them easy to activate while wearing gloves. The membrane switches contain LED’s to denote activation/mode and have a positive feel and “click” to signal activation. The ISO symbols located on each membrane switch are molded all the way through to ensure the

image will not wear off over time. Each switch is sealed to improve reliability and life of the controls. The top control panel consists of 16 membrane switches while the bottom switch pad is much smaller and contains 8 of the most frequently used switches. Both of the control panels are connected to the cab using only two wires, which give power to the entire pad.

General Operation (see OMMs for more detail):

• Press once to see active mode (shown on center counsel machine display)

• Press again and again to scroll through alternate settings

• Press and hold button for 2 seconds to select setting (to select, operator could also press the OK button next to the machine display, but this is not as ergonomic)

On the eight switch control panel one new switch is represented by an ISO symbol of a question mark and is being denoted as the “what” switch. This switch has the ability to tell the operator the functions of all the ISO switches on either control panel to assist new operators in identifying the operation coinciding with each switch. To use the switch the operator would press and release the “what” switch. The keypads would then illuminate LEDs next to the items that the customer machine is equipped with. The operator would then press and release the button they are seeking information for. The machine information display will then describe what the function is and how to set it (in language).

18

TEJB9628

Cat 966K and 972K Medium Wheel Loaders

August 2011

Operator Environment

Automatic Climate Control and Air Quality

The new climate control system automatically adjusts the air temperature and fan speed to maintain the operator’s preferred climate setting. A conventional rotary switch along with adjustable temperature and fan knobs allow the operator to set the cab climate for maximum comfort. All heating and air conditioning controls are located on the upper control panel within easy reach of the operator and can be adjusted easily while wearing gloves.

The cab air filtration system is now serviced from outside the cab, enabling maximum air quality and cab cleanliness. A tube brings air from near the top of the cab roof down to the air filters on the right side of the cab where the filters are housed, drawing air in from the cleanest possible location, away from the dirty tires. In the air filter box the primary (external air which is about 5-10% of the air flow) filter element is mounted in a steel frame to provide a great seal and make the filter easier to secure in the proper place. The primary filter is conveniently mounted at an angle that will allow the dust to fall outside the housing when cleaning. The secondary (recirculation air which is about 90 to 95% of the airflow) filter is located on a panel inside the box and used prior to the evaporator. An optional charcoal filter is available for odorous environments and directly replaces the standard secondary filter. The improved filtration of the cab allows for better air flow through and across the evaporator therefore making the air conditioning much more reliable and effective. Regardless of the climate control system setting in the cab (manual or auto) the AC compressor always cycles if there is demand for AC. In other words, the AC compressor is never running continuously, therefore saving fuel.

is never running continuously, therefore saving fuel. Rearview Camera With the new standard rearview camera,

Rearview Camera

running continuously, therefore saving fuel. Rearview Camera With the new standard rearview camera, visibility is greatly

With the new standard rearview camera, visibility is greatly enhanced. The camera is in a small eye pocket just below the Cat logo on the grill and is able to view objects down to the rear counterweight. The rearview camera has an eyebrow across the top to protect the convex lens from debris and moisture. It is also heated to remove fog and ice. A 178 mm (7 in) diagonal color display screen in the cab shows the operator what is being seen by the camera. The panoramic view enables operators to see trucks coming behind loader or people on the ground. To improve rearview visibility at night and low light conditions two rear lights are also located on the grill and light when the auxiliary cab lights are activated in the cab by the membrane switch.

The rearview camera has three operating modes: off, always on, or only on in reverse. Selecting the “standby” mode on the rearview camera monitor enables the ‘only on in reverse’ mode. The transmission ECM sends a signal to the rearview camera system to turn it on in reverse, and off again in forward.

August 2011

TEJB9628

Cat 966K and 972K Medium Wheel Loaders

19

Operator Environment

The rearview camera can be set to display markers on the monitor display screen using the controls located across the bottom of the monitor. The markers include the following:

Horizontal Marker – Enable this option to display a horizontal reference line. The marker will be displayed as a horizontal green line. Use the Marker Position under Horizontal marker to adjust the horizontal position of the marker. Use the plus and minus buttons located on the bottom of the monitor to adjust the marker position.

Vertical Marker – Enable this option to display a vertical reference line. The marker will be displayed as a vertical green line. Use the Marker Position under Vertical marker to adjust the vertical position of the marker. Use the plus and minus buttons located on the bottom of the monitor to adjust the marker position.

Graticule – Enable this option to display a series of points on each side of the machine projecting backward. The points represent a straight projection from the back of the machine.

a straight projection from the back of the machine. External Mirrors and Window Cleaning Access External

External Mirrors and Window Cleaning Access

External mirrors help enhance visibility around the machine in several areas. Standard mirrors have dimensions of 305 by 229 mm (12 by 9 ft). Left and right hand mirrors come equipped with a spot mirror to enhance the view when

talking to personnel on the ground or grading close to a curb. External rearview mirrors are mounted on the cab door and emergency exit to improve all around visibility. To make cleaning the windshield easier, the external mirrors on the side of the cab fold vertically for improved access to the window cleaning platform. In addition, a non-slip step has been added near the front frame lift arm pin to help assist operators when stepping onto the redesigned window cleaning platform. These two items along with grab bars located on all sides of the cab make cleaning the windshield and servicing of the windshield wipers or lights safe and efficient. Optional heated and powered mirrors are available to further improve visibility in cold climates. The optional heated mirrors are enabled by a membrane switch located on the control panel. Once enabled a pop-up on the information display will signify that the heated mirrors are turned on. Additionally, the LED on the membrane switch will remain on while the heated mirrors are activated. The heated mirrors will automatically turn off after 10 minutes or if needed the membrane switch can be used to disable them sooner.

Lights

membrane switch can be used to disable them sooner. Lights The 966K and 972K standard lighting
membrane switch can be used to disable them sooner. Lights The 966K and 972K standard lighting
membrane switch can be used to disable them sooner. Lights The 966K and 972K standard lighting
membrane switch can be used to disable them sooner. Lights The 966K and 972K standard lighting

The 966K and 972K standard lighting package now includes roading lights, which have a high and low beam as well as turn signals (LED front

20

TEJB9628

Cat 966K and 972K Medium Wheel Loaders

August 2011

Operator Environment

signals are optional). The standard package also comes with four work lights located at the four corners of the cab, two facing forward and two facing back. The stop, tail, and turn signals are located in the counterweight in the rear of the machine. All rear signal lights are mounted in a pocket for extra protection and are LED lights to improve the durability and reliability. Optional lights include the HID lighting package that includes 4 high intensity discharge lights and a strobe beacon (mounted to the outside of the standard work lights). A halogen work light package is also available that includes 4 halogen lights and a strobe beacon.

Cab Features and Options

halogen lights and a strobe beacon. Cab Features and Options Additional features in the cab to
halogen lights and a strobe beacon. Cab Features and Options Additional features in the cab to

Additional features in the cab to help improve operator comfort and convenience are traditional AM/FM/CD/MP3 radios, MP3 player jack, cell phone or MP3 holder, and a12-volt outlet. The cab also comes radio ready meaning the den

slot where the radio mounts, the power source, speakers, and the antenna are all pre-wired in the cab for the operator. Satellite radios equipped with Blue Tooth technology are available, enabling hands free use of a mobile phone. Again the MP3 jack and 12 volt outlet is part of the new cab. In addition there are two new 12 volt outlets, one on the front right ROPS post near the floor and the other near the floor by the rear left ROPS post lunch box tie down area (this one is powered any time the main disconnect switch is on, the other two are powered when the engine start key is turned on). The VIMS PC connector is located next to the outlet on the rear left ROPS post, which is convenient for a customer/technician wanting to download data or for an operator who has an electronically heated or cooled lunch box that needs to be heated or cooled (can do so at this location). A CB radio ready option, which provides an additional 20 amp DC/DC converter which is enough power to run any CB or 2 way radio provided by the company. Also supplied in this package is the CB and 2 way radio antennas.

Operator Sound and Vibration Levels

2 way radio antennas. Operator Sound and Vibration Levels New viscous cab mounts connect the cab

New viscous cab mounts connect the cab to the frame of the machine, decreasing noise and vibration the operator is subjected to. The result is a sustainable work environment and well-rested operator, remaining efficient and productive.

August 2011

TEJB9628

Cat 966K and 972K Medium Wheel Loaders

21

Operator Environment

The sound values indicated below are for specific operating conditions only. Machine and operator sound levels will vary at different engine and/ or cooling fan speeds. Hearing protection may be needed when the machine is operated with

a cabin that is not properly maintained, or

when the doors and/or windows are open for extended periods or in a noisy environment.

North America Sound and Vibration Levels

• The operator sound pressure level for a standard machine configuration, measured according to the procedures specified in ISO 6396:2008, is 71 dB(A) with the cooling fan speed set at maximum value.

• The machine sound power level for a standard machine configuration, measured according to the procedures specified in ISO 6395:2008, is 111 dB(A) with the cooling fan speed set at maximum value.

• The machine sound pressure level for a standard machine configuration, measured according to the procedures specified in SAE J88:2006, is 76 dB(A). The measurement was conducted under the following conditions: distance of 15 m (49.2 ft), moving forward in an intermediate gear ratio, static hydraulic cycle (with no payload) and with the cooling fan speed set at maximum value.

European Sound and Vibration Levels

• The dynamic operator sound pressure level for a standard machine configuration, measured according to the procedures specified in “ISO 6396:2008,” is 69 dB(A) with a cooling fan speed set at 70 percent of the maximum value.

• The sound power level that is labeled on the machine is 108 LWA. The measurement of the sound power level was made according to the test procedures and conditions that are specified in the European Union Directive “2000/14/EC” as amended by “2005/88/EC.”

• The operator sound pressure level for a machine installed with a Low Sound package, measured according to the procedures specified in ISO 6396:2008, is 69 dB(A) with the cooling fan speed set at maximum value.

• The machine sound power level for a machine installed with a Low Sound package, measured according to the procedures specified in ISO 6396:2008, is 108 dB(A) with the cooling fan speed set at maximum value.

22

TEJB9628

Cat 966K and 972K Medium Wheel Loaders

August 2011

Engine

The 966K and 972K have redesigned power dense engines that meet Tier 4 Interim/Stage IIIB emissions requirements. Along with the power dense engines several changes have been made to ensure durability in different areas including the use of Cat DEO-ULS™ or CJ-4 oils, ultra low sulfur diesel fuel, enhanced air filtration, engine idle management, auto idle shutdown, emissions equipment, and electronic fuel priming.

Engine

emissions equipment, and electronic fuel priming. Engine The new Cat C9.3 ACERT engine was designed to

The new Cat C9.3 ACERT engine was

designed to optimize power density. It uses

a combination of technologies to reduce

regulated emissions while ensuring high

performance and excellent fuel efficiency. An upgraded ADEM™ 4 electronic control module manages the combustion process and

a new high-pressure common rail fuel system

allows precise injection timing for a clean, efficient fuel burn. The rugged Cat Clean Emissions Module is securely rubber mounted on its own platform above the engine and contains a Diesel Oxidation Catalyst, Diesel Particulate Filter and Cat Regeneration System. Regeneration, the process by which soot is removed from the Diesel Particulate Filter, is completely automatic and does not interrupt the machine’s work cycle.

Power Dense Strategy

interrupt the machine’s work cycle. Power Dense Strategy Power density means achieving higher horsepower output with

Power density means achieving higher horsepower output with smaller displacement engines. With the K Series, Caterpillar looked at lowering the owning and operating costs by using smaller engines. The machines have improved response while achieving better fuel economy by utilizing smaller engines.

The main reason for this change in displacement was in regards to meeting the emission standards in the most fuel-efficient manner. A small engine helps to meet emissions requirements because it is able to work in the optimal portion of the power band and maximize that power.

August 2011

TEJB9628

Cat 966K and 972K Medium Wheel Loaders

23

Engine

On average, this results in higher exhaust temperatures throughout the day, which are needed to improve the efficiency of the diesel particulate filter. Smaller engines enable a more fuel-efficient method to meet emissions regulations when compared to larger displacement engines.

Operators are noticing a better performance overall with the engine. This is likely due to engine response. Engine response is the ability of the engine to go from low rpm to high rpm quickly and still have the power to do the task at hand. Operators universally equate the engine response to greater power. The operators relate the smaller engine to the higher power.

Explanations as to why going to power dense engines are the right thing for our customers.

Lower Fuel Consumption: More flexibility to meet emissions targets when using the full capabilities of engines, so engines are better optimized for fuel consumption while meeting emissions targets (we were under utilizing the larger engine power potential on our previous machines, now we are utilizing a higher percentage of the engine potential on all of our engines).

Less Weight: Smaller engines are lighter. We have made a focused effort to reduce machine weight (while maintaining durability targets) as much as possible so that less power (and fuel) is used in accelerating and traveling as well as grade climbing.

Lower Owning & Operating Cost: The smaller engines will cost less than the larger engines from an initial purchase price and require less oil (smaller oil sump than larger engine) and fuel (better fuel consumption).

The main point is that this was all done to meet the customer needs of reducing fuel consumption as much as possible while enhancing the machine performance, maintaining durability that our customers demand, and meeting the stricter emissions requirements.

Emissions

and meeting the stricter emissions requirements. Emissions The 966K and 972K feature a Cat C9.3 ACERT

The 966K and 972K feature a Cat C9.3 ACERT engine and a Cat Clean Emissions Module to deliver the performance and efficiency that customer’s demand, while meeting Tier 4 Interim/ Stage IIIB emissions standards. The six-cylinder electronic engine is turbocharged and aftercooled. The displacement produces better lugging capability, lower internal stresses and longer component life. ACERT™ Technology is a combination of building blocks that includes electronics, fuel systems, air management systems and aftertreatment components. The system is optimized based on engine size, the type of application and the geographic location in which it will work. The technologies are applied systematically and strategically to meet high customer expectations for productivity, fuel efficiency, reliability and service life.

24

TEJB9628

Cat 966K and 972K Medium Wheel Loaders

August 2011

Engine

Cat Clean Emissions Module

The Cat Clean Emissions Module is the hardware required to meet Tier 4 Interim/Stage IIIB emission standards in North America and Europe. The silver canister located above the engine is the diesel particulate filter, which also contains a diesel oxidation catalyst. These are actually located in series inside the silver canister. The Tier 4 Interim/Stage IIIB engines more thoroughly control the generation of NO x . Soot is a byproduct of incomplete combustion in the cylinder. Soot is then collected in the DPF and burned off using elevated temperatures (regeneration) and turned into carbon dioxide and water. Ash is a noncombustible residue of lubricating oil or fuel. The ash is also collected in the DPF, but since it is not combustible, it needs to be removed using a special service tool at 5,000 hours. An alternate method is to simply swap the current ash loaded DPF for an empty DPF through Cat Reman.

current ash loaded DPF for an empty DPF through Cat Reman. The Clean Emissions Module is

The Clean Emissions Module is mounted on its own steel frame which is then mounted to the rear machine frame. This means the module is mounted above the engine and is in no way attached to the engine reducing stress on the engine. The module is also mounted above the engine to allow access to valve lash adjustment and injector replacement.

Cat Regeneration System

The Diesel Particulate Filter (DPF), part

of

the engine aftertreatment system, must

be

regenerated periodically using the Cat

Regeneration System. Regeneration consists

of heating up the filter using a spark-ignited

burner until the filter reaches operating

temperature. A closed-loop controller maintains the appropriate temperature in order to convert soot built up in the filter into carbon dioxide and water that are flushed out by the gasses passing through the filter. The system will automatically activate and will not interrupt the customer’s work cycle. The regeneration strategy has been designed and optimized to provide an acceptable maintenance interval, while having no impact on the operation

or productivity of the machine.

Four Position Key Switch

The four position key switch is new on all

K Series models. The fourth position of the

key switch is necessary as part of two new

K Series features, Key Off Regen and

Delayed Engine Shutdown.

Key Off Regen

• Key off regen allows for regeneration when the engine start switch key has been removed.

• Key Off Regen can be overridden by holding the 4th position of key switch for 2 seconds or pressing “Disable Regen” button.

• The K Series machines are shipped with Key Off Regen disabled. This is configurable by the dealer based on customer preference.

Delayed Engine Shutdown

• Delayed Engine Shutdown allows the engine to run for a time after the engine start switch has been turned to off to cool the engine and the machine system components.

August 2011

TEJB9628

Cat 966K and 972K Medium Wheel Loaders

25

Engine

• Delayed Engine Shutdown can be overridden by rotating the key to the 4th position of the key switch.

• The K Series machines are shipped with Delayed Engine Shutdown enabled.

Elevated Low Idle Strategy

To ensure smooth operation of the machine when a high speed regeneration cycle initiates, the regeneration system has safeguards preventing unintended increases to low idle engine speeds while the machine is in gear. The regeneration system will never increase the engine speed above the operator’s throttle command while the machine is in gear. The low idle engine speed fluctuates between the value set through Engine Idle Management System (EIMS) and an elevated low idle engine speed required to complete the regeneration cycle. The 966K and 972K have an elevated low idle speed of 1,100 rpm. The fluctuation takes place once the operator commands an engine speed above 1,100 rpm. The low idle engine speed will remain elevated at 1,100 rpm until the regeneration cycle and cool down period has completed. The only time the regeneration system will increase engine speed irrespective of an operator command is during a low speed regeneration cycle with the machine parked.

The operator is notified of this elevated low idle condition through the main display by use of the Active Regen lamp, also known as the HEST lamp (high exhaust system temperature). The Active Regen lamp illuminates once the operator commands an engine speed above the elevated low idle speed. The lamp will remain illuminated until the regeneration cycle and cool down period has completed and the elevated idle condition is no longer required.

Engine Durability

idle condition is no longer required. Engine Durability The K Series engines were designed, tested and

The K Series engines were designed, tested and validated using the same rigorous Caterpillar criteria for reliability and durability. K Series customers can expect similar time to first engine overhaul as experienced with their current H Series wheel loaders.

Ultra Low Sulfur Diesel (ULSD) fuel is required on all Tier 4 equipped machines to maintain engine and aftertreatment durability and performance.

26

TEJB9628

Cat 966K and 972K Medium Wheel Loaders

August 2011

Engine

Tier 4 Interim/Stage IIIB Engines require Cat DEO-ULS or API CJ-4 oils, which result in less engine wear since the soot particles are suspended by the oil (suspended soot particles do not adhere to the engine components, therefore engine wear is minimized). These oils also reduce the ash loading of the DPF. Ash takes up useful volume of the DPF to store soot between each regeneration cycle. If Cat DEO-ULS or API CJ-4 are not used, the DPF will fill up with ash faster, reducing the service life of the DPF. Cat DPF maintenance intervals is 5,000 hrs. Cat DEO-ULS or API CJ-4 help to enhance the service life of the DPF.

Cat DEO-ULS benefits:

Enhanced dispersants – provides better soot-related viscosity control, prevents viscosity loss from shearing and reduces oil consumption (reduced oil consumption = reduced ash loading of DPF)

Better detergents – protects against piston and ring groove deposits

Advanced additive package – improves protection of the engine and DPF

Improved protection from thermal and oxidative breakdown – withstands higher sump temperatures while offering low- temperature pumpability

Exceeds performance requirements of Cat ECF-3 (Engine Crankcase Fluid Specification). Developed and tested to provide superior protection and life for Cat engines

Engine Air Filtration System

and life for Cat engines Engine Air Filtration System Rain Cap Inlet stack Sealing plate Bellows

Rain Cap

Inlet stack

Sealing plate

Bellows and band clamp

Strata tube precleaner

Check valve and plenum

The engine air filtration system is mounted under the hood just forward of the exhaust stack and cleans air before sending it into the turbo. Dirty air comes in through the rain cap and is filtered through the system using various components. Here are the air filtration system components:

Rain Cap – Prevents rain, snow, large debris etc. from entering the air inlet system (similar to H Series). An optional trash precleaner is offered if the application calls for it.

Inlet Stack – Elevates and supports the rain cap off the hood and directs airflow to the air cleaner system.

Sealing Plate – Provides the contact surface for the flexible bellow between hood and the precleaner assembly.

August 2011

TEJB9628

Cat 966K and 972K Medium Wheel Loaders

27

Engine

Bellows and Band Clamp – Provides flexible seal between hood and plenum, clamp secures the bellows to the plenum.

Strata Precleaner – The Strata Precleaner takes dust particles out of the air flowing into the engine prior to the air flowing through the initial primary filter. As air enters the precleaner, stationary vanes cause the incoming air to spin. A centrifugal force spins dust and dirt to the outer walls where they are ejected out into the exhaust stream. The clean air enters the center of the tube and continues on into the primary air filter. The strata precleaner removes 93% of dust particles before the air has reached the primary filter.

Check Valve – Attached to DPF outlet line. The vacuum from the exhaust from the DPF removes particles (sometimes referred to as “scavenging” – 10 % scavenging improves air filter life). The check valve also prevents recirculation of exhaust gases.

Plenum – Supports the bellows and strata precleaner. It transitions airflow from hood to air cleaner inlet.

Primary and Secondary Filters – PowerCore element is the primary filter and provides the same function as other “primary filters” on previous models, it filters out dust which has gotten past the rain cap and strata precleaner. The secondary filter is pleated and protects the system from dust that leaks past the primary filter while operating. It also protects the air intake system from dust when the primary filter is being serviced. The primary filter can be cleaned with low pressure air 3 times, resulting in 4 life cycles. The secondary filter is not cleanable and is replaced when the primary filter is replaced (after 4 life cycles). See the O&MM for details (SEBU8551).

Fuel Management System (FMS)

The fuel management system strategy provides two operator selectable power modes, configurable through the display (machine set to FMS Off from factory). With FMS turned On, available power is optimized for maximum fuel savings with minimal productivity impact. With FMS turned Off, full power is available to the machine for maximum productivity. When FMS is on, it provides engine torque and speed limits based on gear and torque converter ratio. If FMS is turned on during a torque converter stall test, the resultant engine speed will be lower than the value obtained with FMS turned off. FMS On should only be used in free flowing material (loose aggregates).

Fuel Management System Example

Engine Torque
Engine Torque

Engine Speed

Lug Curve – FMS Off Variable Lug Curve – FMS On Variable Engine Speed Limit
Lug Curve –
FMS Off
Variable Lug
Curve – FMS On
Variable Engine
Speed Limit –
FMS On

28

TEJB9628

Cat 966K and 972K Medium Wheel Loaders

August 2011

Engine

Engine Idle Management System (EIMS)

The Engine Idle Management System (EIMS) maximizes fuel efficiency and provides flexibility in managing idle speeds for specific application requirements. It was available on the H Series with the same functionality with the exception of the DPF regen mode which was added as part of meeting Tier 4 Interim/Stage IIIB emissions regulations.

Five idle control speeds are available:

Work Mode: Typical low idle speeds are used to meet working machine performance, according to customer preference and operating conditions. The customer can configure the Work Mode engine speed within a predefined range through the Cat ET service tool (650-1,100 rpm for 966-980K, 700-1,200 rpm for 950-962K).

Hibernate Mode: Reduces low idle from the working low idle to the hibernate low idle when all of the conditions are met for 10 seconds, to provide lower fuel consumption, reduced sound levels and lower emissions:

No data link, coolant temperature sensor, fan solenoid, or throttle faults

Fan bypass > 23%

Throttle Position < 25%

Coolant Temp > 50° C (122° F)

Implement Operation Status = Not Working

Park Brake = On

Gear = Neutral

The customer can configure the Hibernate Mode engine speed within a predefined range through the Cat ET service tool (650-800 rpm for 966-980K, 700-800 rpm for 950-962K).

Warm-Up Mode: This mode elevates idle after start up in cold conditions.

Low Voltage Mode: This mode elevates idle after start up to prevent battery drain due to high electrical loads from attachments and accessories.

DPF Regeneration Mode: This mode elevates and holds engine speed between 900-1,400 rpm to allow for DPF regeneration.

speed between 900-1,400 rpm to allow for DPF regeneration. Engine Idle Shutdown The engine idle shutdown

Engine Idle Shutdown

The engine idle shutdown feature saves fuel, saves warranty hours, and helps customers meet California regulation of idling only 5 minutes for off-highway machines. When the feature is enabled through Cat ET (disabled by default), the engine will shut down after the machine has been idling for a specified amount of time (5-60 minutes, configurable through ET).

In addition to the machine idling for the appropriate period of time, there are several conditions that need to be met for the shutdown to occur. Several operator inputs are monitored to determine if the machine is in use. As long as the inputs are active, the shutdown timer is reset.

August 2011

TEJB9628

Cat 966K and 972K Medium Wheel Loaders

29

Engine

Conditions for EIS to occur:

• Engine coolant temperature must have been warm after the last start.

• The left service brake is released.

• Gear is in neutral.

• Ground speed is 0.

• The implement is not active.

• The throttle pedal is released.

Additionally, the shutdown will not occur if the idle is elevated to warm the engine or charge the batteries, and the engine will not shut down if a DPF regeneration cycle is immanent or active. New on the K Series with the engine idle shutdown is the shutdown of the electronic system (to preserve battery life) that was not possible on H Series due to hardware limitations.

Twenty seconds before the shutdown is initiated, the display will provide instructions indicating how to cancel the shutdown, and the level 3 action alarm in the cab will sound. Once the timer runs out, the parking brake will be automatically applied, fuel will be cut to the engine, the display will show a message indicating the shutdown has occurred, and several electrical systems automatically will be powered down on the machine. Once the machine is finally keyed off, VIMS will store the shutdown duration.

Cold Start/High Altitude Package

A new optional cold start/high altitude package includes a fan pump bypass, transmission pump bypass, additional battery capacity, and the engine heater plug/cord. The bypass systems reduce the parasitic load on the engine, while the additional battery capacity increases the cold cranking revolutions during startup. With the new optional cold start/high altitude package available on K Series, starting capability has been dramatically improved in cold weather conditions and at higher altitudes.

The transmission and fan pump bypass solenoids activate on each start when the transmission oil temperature is less than 0° C (32° F) at 10,000 feet linearly until the transmission oil temperature is less than –26° C (–14.8° F) at sea level (see below graph). The transmission pump bypass deactivates after the engine speed is greater than 600 rpm for 5 seconds or the engine speed is greater than 1,100 rpm. The fan pump bypass deactivates after the engine speed is greater than 800 rpm for 10 seconds or the engine speed is greater than 1,100 rpm.

Agree 8/5/10 MWL Cold Start Bypass Map Values

12,000 10,000 8,000 6,000 4,000 Bypass not required 2,000 0 –32 –26 –18 –9 0
12,000
10,000
8,000
6,000
4,000
Bypass not required
2,000
0
–32
–26
–18
–9
0
Altitude (ft)

Temperature °C

Engine RPM at Start Up

At start up the engine is at a minimum of 800 rpm for 10 seconds before the machine returns to the hibernate setting. A transmission fluid level check is performed at 950 rpm for 5 minutes. Input throttle command or directional shift will exit transmission fluid level check and return to hibernate setting.

30

TEJB9628

Cat 966K and 972K Medium Wheel Loaders

August 2011

Cooling System

The 966K and 972K is equipped with an electronically controlled, hydraulically driven, on demand fan cooling system. The system offers numerous benefits, including reduced sound levels, reduced plugging, enhanced cold weather operation and increased fuel economy. Fan efficiency is also higher than an engine-mounted fan due to the tighter clearance between fan tip and the shroud. This is made possible with the non-engine mounted fan. Fan speed is varied utilizing an electro-hydraulically controlled, variable displacement hydraulic piston pump, which drives a fixed displacement hydraulic motor.

Fan Speed

which drives a fixed displacement hydraulic motor. Fan Speed Fan speed is controlled to meet the

Fan speed is controlled to meet the varying cooling requirements of the machine. In cooler conditions or during light duty cycles, less cooling is required and fan speed is minimized. As cooling requirements increase, oil flow to the hydraulic motor is increased, providing the additional airflow necessary to maintain system temperatures within the machine’s normal operating range. In addition to engine coolant, the system also monitors and responds to changes in charge air (ATAAC out) and hydraulic sump temperatures. This provides for a much more efficient cooling system. As a system temperature reaches the target level, fan speed is increased to provide additional airflow and system cooling. If the temperature continues to rise, the fan speed will continue to increase and maintain a higher speed until the system temperature returns to its respective target level. Maximum cooling fan speed is limited to a speed set by the variable displacement piston pump’s pressure compensator. The flow compensator on the variable hydraulic pump controls the fan’s minimum speed. The fan pump is sized to provide required oil flow to achieve maximum fan speed at or above an engine speed. This means that during an aggressive truck loading cycle, in high ambient conditions, there is maximum airflow through the cooling package. Fan speed is not reduced when the engine lugs down.

August 2011

TEJB9628

Cat 966K and 972K Medium Wheel Loaders

31

Cooling System

Compartmental Design

The cooling system is isolated from the

engine compartment by a non-metallic shield.

A hydraulically driven, variable speed fan draws

air in from the rear of the machine, through the cooling system and is exhausted out the

sides and top of the hood. This provides air that

is cleaner and cooler than what can be drawn

through the engine compartment. This airflow pattern, combined with the variable speed fan, reduces the amount of air needed to pass through the system. The end results are faster machine warm up in cold weather, increased fuel efficiency, less radiator plugging and lower sound levels. The shield also serves as a sound barrier and helps reduce operator sound levels.

Unit Core Design

The unit cores are constructed of brazed aluminum with high strength plastic tanks and square wave design. Each core is 5 rows deep. The brazed aluminum construction provides a stronger joint, in turn, reducing the chance of leaks while the square wave cores decrease the likelihood of blockage and plugging. The standard unit core is 6 fins per inch and provides for easier cleaning as well as greater resistance to plugging.

A

fuel cooling core has been added to the system

to

extend injector life and improve durability.

High Ambient Cooling

Replaces 6 fins per inch cooling cores with 9 fins per inch cooling cores.

Variable Pitch Fan

cores with 9 fins per inch cooling cores. Variable Pitch Fan A variable pitch fan is

A variable pitch fan is optional on the 966K

and 972K helps clean the cooler cores from the backside. The variable pitch fan acts

like an airplane propeller in that the pitch of the blade is actually changed to switch the direction flow of cooling air. This fan is beneficial in providing more airflow in the reverse direction (when compared to a system that simply reverses the fan rotation), which more thoroughly expels any debris build up

in the cooling cores. The variable pitch fan

eliminates the need for an air wand used to clean the backside of the cooler cores.

The purge cycle on the variable pitch fan is configured through ET. The default setting for the time between purge and length of purge are 300 seconds and 40 seconds, respectfully. The purge can also be activated manually through the display and uses the configuration shown in the ET.

32

TEJB9628

Cat 966K and 972K Medium Wheel Loaders

August 2011

Cooling System

AC System

The AC condenser has a parallel flow to provide a more efficient flow of coolant through the AC condenser. The new AC fittings and dual seals help improve the efficiency of the cooling system through better containment of refrigerant within the system.

Regardless of the climate control system setting

in the cab (manual or auto) the AC compressor

always cycles if there is demand for AC. In other words, the AC compressor is never running continuously, therefore saving fuel.

The AC compressor also incorporates a

protection strategy to keep the compressor from running under “damaging” conditions.

A high/low pressure switch on the discharge

coupling prevents the compressor clutch from

engaging if the pressure on the high side is too high or too low, protecting the compressor.

A low pressure switch on the suction coupling

which prevents the compressor clutch from engaging if the pressure on the low side is too low, protecting the compressor. A thermocouple on the evaporator that will disengage the compressor clutch if it reaches 0° C (32° F).

In cold climates the AC compressor will cycle automatically which helps to keep the bearings and seals lubricated, prolonging the life of the AC system. The only time the AC compressor system will not engage is due to the protection strategy specified above (combination of high/ low pressure switches and thermocouple).

Serviceability

A nonmetallic shunt tank is now being used to give the operator a better visual of the coolant level of the engine and provides a more efficient clean than a steel tank.

At key on, a number of things are checked including the low level coolant switch to make sure the coolant level is within range.

August 2011

TEJB9628

Cat 966K and 972K Medium Wheel Loaders

33

Powertrain

Integrated powertrain components ensure a robust design that provides customers with optimal performance and enhanced fuel efficiency, all while maintaining Caterpillar’s proven durability.

Torque Converter

Caterpillar’s proven durability. Torque Converter A torque converter gives larger output load potential than

A torque converter gives larger output load

potential than the engine provides alone. The need for very low speed gears and the number of gears required from a direct drive configuration is reduced.

Free Wheel Stator Torque Converter – The 966K and 972K feature a Free Wheel Stator Torque Converter (FWSTC). A FWSTC improves machine powertrain efficiency in certain

applications and contributes to fuel efficiency.

A torque converter provides a larger/broader

output load potential than the engine can provide alone, reducing the need for very low speed gears and the number of gears required

from a direct drive configuration.

Fixed Stator vs. Free Wheel Stator – The engine output shaft drives the torque converter’s impeller. The impeller accelerates the torque converter fluid from low to high velocity, adding kinetic energy to the fluid. This energy is given up to a turbine causing the fluid to lose speed. The force of the oil that hits the turbine blades causes the turbine to rotate, driving the output shaft (input to transmission). The stator is a stationary reaction member between the turbine and impeller. The stator redirects the flow of oil as it leaves the turbine to increase the fluid’s momentum as it returns to the impeller, increasing the unit’s torque capacity. In conditions where demand placed on the torque converter is not extreme (output torque requirements equal to or less than input torque) such as when ground speed is high and resistance is low (machine slowing from high speed), turbine speed will be high relative to impeller speed. Oil passing through the turbine may then strike the back of the stator blades, eliminating the stator’s ability to redirect and increase the oil’s momentum. As a result, the stator actually lowers the efficiency of the system by increasing drag. Free wheel stator allows the stator to turn in the same direction as the turbine in this condition, minimizing drag on the converter and increasing efficiency.

How A Free Wheel Stator Works –The free wheel assembly is a one-way clutch consisting of a cam, rollers, springs and a carrier. The cam is a spline connected to the stator so that when the stator tries to move in the opposite direction to the turbine, the rollers are forced into the narrow end of the tapered grooves, preventing the cam and the stator assembly around the carrier from spinning. Since the carrier is held stationary, the stator cannot turn and the free wheel assembly is locked. As the speed of the turbine approaches 85 percent of the

34

TEJB9628

Cat 966K and 972K Medium Wheel Loaders

August 2011

Powertrain

impeller speed, oil passing through the turbine strikes the back of the stator blades so that the stator starts to turn in the same direction of the turbine. The cam then rotates so that the rollers occupy the wide end of the tapered grooves. The cam and stator assembly are then free to rotate around the carrier (freewheel), thereby reducing drag and increasing efficiency.

Transmission

reducing drag and increasing efficiency. Transmission Transmissions on the K Series are planetary power shift,

Transmissions on the K Series are planetary power shift, which has been our design in one form or another for the past 30 years on medium wheel loaders. This design is time proven, tested and bullet proof. A planetary design means you have a sun gear with planet gears around it. It has either 3 or 4 tooth engagements compared to a countershaft gear that has only 2 gears opposing one another. The nature of the planetary design allows for a higher load capacity, increased life, and is the overall premium design for Cat medium wheel loaders.

Some major improvements have been made using the planetary design. One of these improvements which started with H Series is controlled throttle shifting. This basically protects the transmission in high speed forward

to reverse shifts or reverse to forward shifts by modulating the engagements to prevent the slamming together of the clutches, extending the machine life. The new series of machines continues to use the electronic clutch pressure controller (ECPC). The ECPC provides control over each individual clutch pack to improve the shift modulation of the transmission.

The transmission still has external valves for

improved serviceability. The transmission filter

is located in the hydraulic service center for

the 966K and 972K. The oil change intervals remains at 1,000 hours. The site gauge has also been retained but slightly tilted to improve visibility. The transmission fluid level check is performed at 950 rpm for 5 minutes. Input throttle command or directional shift will exit transmission fluid level check and return to hibernate setting.

All speed sensors were changed on K Series to

a Fixed Gap speed sensor design. The Fixed

Gap speed sensor design means the sensor requires no adjustment when it’s installed.

The gap between the sensor and the gear it

is reading, is fixed based on the machining

to the housing relative to the fixed position of the gears. This greatly improves assembly consistency and accuracy. The H Series Adjustable Gap speed sensors required a process to set the gap between the sensor and the gear it is reading which, if not set properly, could damage the sensor tip and require the sensor be replaced.

The K Series transmissions incorporate a newer clutch disc material, which enables a new shifting strategy that delivers smoother shifts, faster acceleration, and better performance climbing a grade. With the further enhancement to a torque based 2 to 1 downshift, owners and operators will fully benefit from utilizing the automatic 1-4 transmission mode; which results in lower fuel consumption and optimal machine performance.

August 2011

TEJB9628

Cat 966K and 972K Medium Wheel Loaders

35

Powertrain

Single Clutch Speed Shifting on K Series only disengages the speed clutches during shifts, reducing torque interruption. On H Series both the speed and directional clutches were disengaged during shifts resulting in more torque interruption. By reducing torque interruption on K Series with Single Clutch Speed Shifting delivers smoother shifts, faster acceleration, and better performance climbing a grade.

Again the new speed shifting is now torque based (2 to 1 downshift) rather than speed based meaning if the transmission needs to downshift due to a torque requirement it will do so automatically. On the H Series the transmission downshifted from 2 to 1 based on ground speed. The torque based system optimizes when the downshift occurs, enabling a smooth penetration into the pile. Overall the new torque based downshift and single clutch speed shift logic provides greater acceleration, faster ramp speeds, and better shift quality.

Variable Shift Control (VSC)

The K Series VSC strategy only has two settings, enabled and disabled and is configurable through the information display. It is enabled from the factory.

When VSC is enabled, the machine control software uses a partial throttle shifting strategy, meaning the transmission will shift at lower engine RPMs (burning less fuel). If an operator would like more aggressive shift points, simply depressing the throttle pedal to the floor will result in full throttle shift points, meaning the transmission will shift at higher engine RPMs (burning more fuel).

When VSC is disabled, the machine control software uses the full throttle shifting strategy only, meaning the transmission will shift at higher engine RPMs (burning more fuel). This mode is not recommended due to the higher fuel burn.

Driveline

The driveline consists of three driveshafts; one to the rear axle, one through the hitch to the midship bearing and one from the midship bearing to the front axle. All five universal joints are relubable while triple lip seals keep grease in and dirt out. The midship bearing, slip joint, and all universal joints require lubrication. The midship bearing is a spherical roller bearing.

Axles

The midship bearing is a spherical roller bearing. Axles The 966K and 972K axles are designed
The midship bearing is a spherical roller bearing. Axles The 966K and 972K axles are designed

The 966K and 972K axles are designed to handle extreme applications resulting in reliable performance and extended life. The axle design is known as a 4 piece axle and contains inboard brakes and inboard final drives. Each axle contains two axle shaft housings, the center housing and the intermediate housing. The front axle is rigidly mounted to the front frame in order to withstand internal torque loads and still maintain support for the wheel loader. The rear axle includes a trunnion, two trunnion supports and the associated bearings that allow oscillation of plus or minus 13 degrees.

36

TEJB9628

Cat 966K and 972K Medium Wheel Loaders

August 2011

Powertrain

This allows all four wheels to remain on the ground over uneven terrain, which in turn equates to excellent stability and traction. Rotating axle components are designed for the high loads encountered in the demanding applications the 966K and 972K typically perform. Use of ride control and autoshift in load and carry applications often result in higher speed operation where brake actuation can be severe. Axle oil cooler attachments are available for aggressive applications.

External Axle Oil Cooler

External axle oil cooler (AOC) is available as a factory installed attachment for the 966K and 972K. The axle oil cooler is for use in “high energy” applications, such as long distance load and carry in high ambient temperature conditions. However, with the availability of IBS, it is estimated that very few applications and conditions will require AOC. In order to provide flexibility for the installation of AOC after delivery, Caterpillar offers an AOC ready package.

Integrated Braking System

offers an AOC ready package. Integrated Braking System Integrated Braking System (IBS) is a Caterpillar exclusive

Integrated Braking System (IBS) is a Caterpillar exclusive feature developed to reduce axle oil temperatures and improve transmission neutralizer smoothness. Improvements in machine capabilities and modern features such as automatic powershift transmission and Ride Control have resulted in higher energy

development during braking. This higher energy is converted to heat, which is detrimental to the brake disc, oil and axle life.

When the brake pedal is applied the transmission downshifts to absorb the energy through the drivetrain, which minimizes brake wear and heat build up. When compared to the auto downshift that occurs while the machine is coasting, the IBS downshift initiates at a higher ground speed. This results in reduced brake wear because the drivetrain is being used to slow the machine. To further enhance fuel effi ciency the engine is not fueled while the integrated braking system is active. During this time the machine’s motion is used to spin the pumps and engine.

Brake

motion is used to spin the pumps and engine. Brake Braking can occur using either of

Braking can occur using either of the cab floor-mounted pedals. Brake pedals are “clipped” so the heel leaves clearance to the floor. Some competitors have little clearance to the floor causing dirt buildup which results in the pedal remaining partially engaged. This burns up the brakes and can lead to expensive replacement costs. The left hand pedal also serves as the neutralizer and activates the IBS. Eight friction disks, two per wheel, are enclosed in oil and mounted on the low torque side of the final drive, requiring less braking force. Axle oil circulation provides cooling to the brake discs for better heat dissipation.

August 2011

TEJB9628

Cat 966K and 972K Medium Wheel Loaders

37

Powertrain

Brake accumulators are charged through a variable displacement pump instead of a fixed displacement pump, meaning oil flow is “on demand.” Thus power and fuel are not wasted creating flow when it is not needed. This on demand feature equates to greater fuel savings and lower owning and operating costs.

Parking Brake

The parking brake can be manually released. (See OMM for instructions.) (SEBU8551)

Rims and Tires

The 966K and 972K utilize a 635 mm (25 in) three-piece rims featuring 20 M24 fasteners (bolts) to attach each to the axle. Several bias and radial tire options are available from Bridgestone, Firestone, and Michelin, offering tread types for a wide range of conditions and applications. Radial tires are preferred overall because they result in longer tread life, better steering control, and lower rolling resistance (lower fuel burn) when compared to bias ply tires. Bias ply tires do provide a smoother ride at low speeds on rough terrain, but are less controllable at higher speeds due to the additional flex in the tires and they also result in higher rolling resistance (higher fuel burn). The basic tread type is an L-3, a rock tire with good traction, adhesion, and vibration reduction technology. The 966K and 972K can also be fitted with L-4 or L-5 tread type tires for more severe conditions where additional tread thickness or resistance to cuts is necessary (load and carry and face loading applications, respectively).

and carry and face loading applications, respectively). Flexport tires will be an option offered on the

Flexport tires will be an option offered on the 966K and 972K. Cat ® Flexport™ Tires are a solid, ported design for flat-proof operation in severe applications such as demolition, scrap handling and waste transfer stations. Each tire features elliptical holes (ports) molded through the outer ring of the sidewall for more flexibility and stability. The flexible sidewall delivers a more cushioned and comfortable ride compared to other solid tires. The result is less operator fatigue and less stress on the machine.

38

TEJB9628

Cat 966K and 972K Medium Wheel Loaders

August 2011

Powertrain

The next generation of Flexport tires for wheel loaders feature improved, high quality rubber compounds for longer wear. A smooth tread design with rounded tire edges is available for enhanced durability in severe applications. The Flexport design is a complete assembly of rubber and wheel, which makes it quick and easy to install a new set of Flexport tires.

Unlike other solid tires, Flexport tires can be used on surfaces that are not maintained (scrap yards, waste transfer stations, etc.) as well as in severe applications. Regardless of the application, the suppleness of Flexport tires absorbs much of the shock that the standard solid tire passes on to the operator and machine.

Options include:

• 26.5R25 VLT BS E3 Radial

• 26.5R25 VJT BS E3/L3 Radial

• 26.5R25 VMT BS L3 Radial

• 26.5-25 SRG LD FS L3 Bias

• 750/65R25 XLD L3T MX L3 Radial

• 26.5R25 XHA2 MX L3 Radial

• 26.5R25 XLD D1 MX L4 Radial

• 26.5R25 VSNT BS E4/L4 Radial

• 26.5-25 SDT LD FS L5 Bias

• 26.5R25 VSDL BS L5 Radial

• 26.5R25 XLDD2 MX L5 Radial

• 26.5R25 X MINE D2 MX L5 Radial

August 2011

TEJB9628

Cat 966K and 972K Medium Wheel Loaders

39

Structures

The K Series features many of the components designed and proven reliable over generations of product design.

Spread Hitch Design

The distance between the upper and lower hitch plates is an important contributor to machine performance and life. Caterpillar’s spread-hitch design provides excellent load distribution and bearing life. Both the upper and lower hitch pins pivot on double tapered roller bearings, neutralizing and distributing vertical and horizontal loads over a larger surface area. Thick hitch plates and a butterfly plate that supports the hitch increase torsional stiffness for improved durability and life, while the thick lower plate directs thrust loads through the frame. The wide opening also provided for improved service access. This provides excellent frame rigidity, which contributes to high product quality.

Counterweight

The 966K counterweight is a two piece design while the 972K counterweight utilizes a one piece design. The mass of the counterweights are 991 kg (2,185 lb) and 2482 kg (5,472 lb) for the 966K and 972K respectively. Both designs incorporate the rear LED lights into the casting structure to enhance reliability and durability.

Engine End Frame (EEF)

enhance reliability and durability. Engine End Frame (EEF) The 966K and 972K utilize a full box

The 966K and 972K utilize a full box section engine end frame with hitch plates at the front end. The box section frame provides a strong, rigid structure that resists twisting and impact loads. The result is an extremely solid mounting platform for the engine, transmission, axle, roll over protection structure (ROPS) and other accessories.

Non Engine End Frame (NEEF)

(ROPS) and other accessories. Non Engine End Frame (NEEF) The non-engine end frame provides a solid

The non-engine end frame provides a solid mounting base for the front axle, lift arms, lift cylinders and tilt cylinders. It is a fabricated four-plate loader tower that absorbs all the forces associated with loading, twisting, and penetration.

40

TEJB9628

Cat 966K and 972K Medium Wheel Loaders

August 2011

Safety

Caterpillar continues to be proactive in developing machines that meet or exceed safety standards. Safety is an integral part of all machines and system designs, and can be seen throughout the K Series models.

Visibility

and can be seen throughout the K Series models. Visibility The streamlined four post ROPS enhances

The streamlined four post ROPS enhances visibility by eliminating two posts, adding a convex windshield, and removing the steering wheel. The cab has a clean and clear panoramic view for safe operation of the machine. External rearview mirrors are mounted on the cab door and emergency exit to further contribute to all around visibility. The standard rearview camera with integral hood lights enhances visibility to the rear in all lighting conditions.

Ingress/Egress

to the rear in all lighting conditions. Ingress/Egress Well-placed grab bars and a ladder inclination angle

Well-placed grab bars and a ladder inclination angle of 10-degrees forward makes the walk into the cab feel more like a staircase than a ladder. When further comfort is needed, an optional retractable ladder which provides an inclination of 18-degrees is offered for the European market. The new wider front-hinged door can be opened and closed while seated, allowing easy ingress and egress.

August 2011

TEJB9628

Cat 966K and 972K Medium Wheel Loaders

41

Safety

Window Cleaning Platform

Safety Window Cleaning Platform To help provide a safe means for cleaning the windshield, a new

To help provide a safe means for cleaning the windshield, a new window cleaning platform is standard on all K Series machines. In addition the external mirrors on the side of the cab fold vertically and a non-slip step has been added near the front frame lift arm pin to help assist operators when stepping onto the platform. These items along with grab bars located on all sides of the cab make cleaning the windshield and servicing of the windshield wipers or lights safe and efficient.

Ground Level Maintenance Points and Service Centers

Key maintenance points and service centers are located at ground level for improved safety and efficiency while servicing machines.

SAE and ISO Standards

The all-new 966K and 972K have been designed to many national and international standards.

Roll Over Protection Structure (ROPS) and Falling Objects Protection Structure (FOPS)

An integrated ROPS and FOPS structure is designed to carry loads directly into the tractor main frame and protect the operator.

42

TEJB9628

Cat 966K and 972K Medium Wheel Loaders

August 2011

Monitoring Systems

Monitoring product health is key to maintaining reliability of any equipment. Many programs offered by Caterpillar make the tracking of the customer’s machine health quick and easy. These programs include Product Link, VisionLink, and S·O·S Services.

Product Link

Cat Product Link allows remote monitoring of equipment to improve overall fleet-management effectiveness. Product Link is deeply integrated into machine systems. Events and diagnostic codes, as well as hours, fuel, idle time and other detailed information are transmitted to a secure web based application, VisionLink™. VisionLink includes powerful tools to convey information to users and dealers, including mapping, working and idle time, fuel level and more.

S·O·S SM Services

S·O·S services can help the customer manage component life and machine availability decreases downtime while improving productivity and efficiency. Regular fluid sampling can help track what is going on inside the equipment. Wear related problems are predictable and easily repairable. Maintenance can be done according to the customer’s schedule, resulting in increased uptime and flexibility in maintenance repairs before failure.

Payload Control System 3.0

repairs before failure. Payload Control System 3.0 Designed specifically for Cat Wheel Loaders, the Payload

Designed specifically for Cat Wheel Loaders, the Payload Control System (PCS) provides on-the-go weighing and tracking of material. Available as a factory or dealer installed attachment, PCS is easily installed on the 966K and 972K. The PCS now displays the payload information on the center display panel rather than a separate display screen. Besides simple installation, PCS offers easy calibration and high accuracy. PCS provides additional features, including material flow management, which enables tracking of the type and quantity of materials loaded by individual trucks.

August 2011

TEJB9628

Cat 966K and 972K Medium Wheel Loaders

43

Monitoring Systems

PCS stores operating data for later download and retrieval with personal computer and VIMSPC software. There are three customizable reports provided to help improve various aspects of the operation, including production measurement, inventory control and machine and personnel scheduling. With the addition of a printer, tickets can be printed for driver records. The system can record the following information:

• Loader identification number

• Date, time, ticket number, and number of passes

• Material, truck, and operator identification

• Up to 20 different material descriptions

• Up to 50 truck descriptions and target weights

• Up to 2,200 truck loads, including data about each individual bucket loaded

44

TEJB9628

Cat 966K and 972K Medium Wheel Loaders

August 2011

Serviceability

Ground level maintenance points and service centers along with other key serviceability features make servicing customer machines and in-field component exchange quick, easy, and efficient.

Ground Level Maintenance Points

Grease fittings have been grouped on the right side of the machine in two convenient locations: within a service compartment just below the platform, and in a bank located just off the front-end frame. Remote grease lines facilitate the lubrication of vital components located throughout the EEF and NEEF.

Engine Enclosure

located throughout the EEF and NEEF. Engine Enclosure The K Series retains the Cat sloped “one-piece”

The K Series retains the Cat sloped “one-piece” non-metallic tilting hood, which has become one of our brand’s hallmarks and provides industry-leading access to the engine, Cat Clean Emissions Module (Cat CEM) and other components but with fresh new styling clearly distinct from the H Series. Lift time to raise the hood is approximately 48 seconds. If necessary, the entire hood enclosure can be removed utilizing built-in lift points.

Clamshell Hood

be removed utilizing built-in lift points. Clamshell Hood New to the loaders is a rear clamshell

New to the loaders is a rear clamshell hood design that allows quick access to the engine oil dipstick and fill, fuel fill port, and cooler cores. With the hood lowered the operator can raise the clamshell hood easily with the assistance of spring struts that provide an ergonomic opening and closing effort for the operator in all weather conditions. The new clamshell hood will also provide improved access to the cooler cores including the hydraulic oil cooler, air conditioning condenser, jacket water, fuel cooler, and the air to air after cooler (ATAAC).

Fenders

Steel fenders remain part of the 966K and 972K standard package. Full coverage, metallic rear roading fenders are optional and only require 60 degrees of swing to fully access the engine area.

August 2011

TEJB9628

Cat 966K and 972K Medium Wheel Loaders

45

Serviceability

Hydraulics Service Center

Serviceability Hydraulics Service Center The hydraulic components are all conveniently located behind the hinged right

The hydraulic components are all conveniently located behind the hinged right side access ladder at a single ground level service center improving safety and reducing service time. Accessible from the service center are the transmission and hydraulic oil filters, brake accumulators, pressure test ports, etc.

Site Gauges

brake accumulators, pressure test ports, etc. Site Gauges The 966K and 972K provide well protected, sight
brake accumulators, pressure test ports, etc. Site Gauges The 966K and 972K provide well protected, sight

The 966K and 972K provide well protected, sight gauges for the transmission and hydraulic oil levels. Both are readily visible and eliminate the risk of contaminants entering the system during daily checks. The engine coolant level is now clearly visible through the new plastic shunt tank.

Cooling System

The cooling system is readily accessible for clean out and maintenance by raising the new clamshell hood feature. With six cooling fins per inch and a perforated grill, most airborne debris entering the system passes through the cooler cores. The cooler cores swing out providing easy access for cleaning; an option variable pitch fan is available to automatically purge the cooler cores by periodically reversing the airflow.

Radiator Cleaning

The cooler cores swing out providing easy access for cleaning and are accessible once the clamshell hood is opened. The engine side of the cooler cores is accessible for clean out through lockable panels on both sides of the

46

TEJB9628

Cat 966K and 972K Medium Wheel Loaders

August 2011

Serviceability

radiator support structure. Note: The machine must be shut down prior to opening the side panels, and the panels must be closed before lowering the hood. An optional variable pitch fan is available to automatically purge the cooler cores by periodically reversing the airflow.

Coolant

The cooling system’s capacity is 65 L (17.2 gal). The system is factory filled with a premixed Extended Life Coolant. ELC can provide up to 12,000 hours between change intervals, but periodic checks are still suggested (using premixed ELC for topping off prior to 12,000 hours).

Electrical Service Center

off prior to 12,000 hours). Electrical Service Center The electrical service center provides grouped ground level

The electrical service center provides grouped ground level access to numerous electrical features, enhancing safety and convenience for operators and service technicians. It is conveniently located beneath the left platform for access before entering the cab and contains the maintenance free batteries, a fuse relay panel, main disconnect switch, ground level engine shutdown switch, hood tilt switch, and the jump start receptacle.

Brake Wear Indicators

Axles on the 966K and 972K are equipped with brake wear indicators, allowing a technician to determine when it is necessary to service the brakes. The check can be made by simply removing the plug from the inspection port and taking precise measurements to estimate the percentage of remaining brake life, with the brakes applied. The amount of friction material worn from disc and the oil groove depth are measured using the following steps.

the oil groove depth are measured using the following steps. 1. Start the engine. Run the

1. Start the engine. Run the engine until the brake accumulators reach the cutout pressure (less than 30 seconds).

2. Stop the engine. Engage the parking brake.

3. Thoroughly clean the area around plug (4). Remove any excess paint that may be present on the flange face for the axle housing (7). Plug (4) is held in place by screw (5).

4. Remove screw (5) and plug (4).

5. Apply light pressure to pin (3) in order to ensure that pin (3) is seated against cup (6).

August 2011

TEJB9628

Cat 966K and 972K Medium Wheel Loaders

47

Serviceability

6. Measure dimension (C) with the service brakes in the APPLIED position. Dimension (C) equals the distance from the flange face for axle housing (7) to the end of pin (3). Use a depth micrometer and the tools in Table 1 to measure dimension (C).

a. Use a caliper or a similar tool to determine the exact thickness (D) of gauge block (8).

b. Gauge block (8) is in the shape of the letter “U.” Position gauge block (8) so that the slot straddles the hole in flange face (7). Firmly hold gauge block (8) against flange face (7).

c. Measure dimension (E).

d. To determine the value of dimension (C), subtract the value of dimension (D) from the value of dimension (E).

7. In order to retrieve the baseline values, perform the steps that follow.

a. Stop the engine.

b. Connect the Cat Electronic Technician (ET) to diagnostic connector.

c. Turn the engine start switch key to the ON position, but do not start the engine.

d. Start the Cat Electronic Technician (ET) and select “Transmission 966” under the heading “Available ECM’s.”

e. Select the “Configuration Tool” icon.

f. Exit from the ET.

g. Turn the engine start switch key to the OFF position.

h. Disconnect the ET from diagnostic connector.

8.

Determine the amount of service life that is available for the left front service brake disc. Write down the value of dimension (C) for the left front service brake. This value was measured in Step 6. Write down the baseline value for the left front service brake that is stored in the powertrain ECM.

9.

Subtract the value of dimension (C) from the baseline value. An example of the baseline value is shown in illustration 7. The baseline value for the left front service brake equals 46.05 mm (1.813 inch). The difference indicates the amount of wear that has occurred to the service brake discs.

10.

Repeat Steps 8 and 9 for the other service brakes.

11.

To provide an estimate on the amount of service life for the brake discs, refer to the table below.

Disc Thickness Wear Chart

 

Estimated Percentage of Remaining Brake Disc Life

Amount of Friction Material that is Worn from the Disc

Oil Groove

Depth

 

0.00

mm

1.05

mm

100

(0.000 in)

(0.041 in)

 

0.29

mm

0.90

mm

80

(0.011 in)

(0.036 in)

 

0.58

mm

0.76

mm

60

(0.023 in)

(0.030 in)

 

0.88

mm

0.61

mm

40

(0.034 in)

(0.024 in)

 

1.17

mm

0.47

mm

20

(0.046 in)

(0.018 in)

 

1.46

mm

0.32

mm

0

(0.058 in)

(0.013 in)

48

TEJB9628

Cat 966K and 972K Medium Wheel Loaders

August 2011

Serviceability

Ecology Drains

Ecology drains are provided for the engine, transmission, and hydraulics.

Engine Oil Change Intervals

With 500 hour oil change intervals, downtime

is reduced so more work can be completed.

Electronic Priming Pump and Fuel/Water Separator

An electronic fuel-priming pump located on the primary fuel filter base reduces the need to prefill or manually prime filters after a change has occurred. In addition, a water separator

is located on the primary fuel filter. When you

turn the key switch to the ON position, wait momentarily. The sensor in the bottom of the water separator will check for water presence.

Window Cleaning Platform

A new window cleaning platform extends

along the front of the convex windshield for fast, safe, and more convenient cleaning access. To make accessing the platform easier, the external mirrors on the side of the cab folds horizontally rather than vertically. A non-slip step has also been added near the front frame lift arm pin to help assist operators when stepping onto the cleaning platform.

Grab Bars

when stepping onto the cleaning platform. Grab Bars Grab bars on the interior and exterior of

Grab bars on the interior and exterior of the cab have been strategically located to improve safety and serviceability when maneuvering around the cab. A new full length grab bar goes around the entire roof cap of the cab to assist when on the new window cleaning platform or servicing other areas of the cab. Grab bars are also located on either side of the ladder and on the interior of the door to assist with entry and exit.

Autolube (optional)

The Caterpillar designed Groeneveld Autolube system will be available as a price list attachment for the 966K and 972K. This system incorporates

a 24V pump with a 4-liter grease reservoir and

integrated timer that allows the operator to select the grease interval through the information

display. Three available settings can be selected; light (45 minutes), medium (30 minutes), and heavy (15 minutes). Once each lubrication cycle

is initiated, the pump dispenses grease under

pressure through timer intervals adjustable via the monitor. This system will reduce overall operating costs and improve serviceability by providing precise lubrication of pins and bushings while the machine is in operation.

August 2011

TEJB9628

Cat 966K and 972K Medium Wheel Loaders

49

Customer Support

Cat dealers are with customers every step of the way to provide unsurpassed worldwide parts support, trained technicians, training assistance, financing options, and customer support agreements.

financing options, and customer support agreements. Machine Selection Cat dealers are ready to help evaluate

Machine Selection

Cat dealers are ready to help evaluate machine options; from new or used machine sales, to rental or rebuild options, Cat dealers can provide an optimal solution to meet customer business needs.

Product Support

Cat dealers are with customers every step of the way to maximize machine uptime by providing unsurpassed worldwide parts support, trained technicians and customer support agreements.

Operation

To help maximize the return on your investment, Cat dealers offer various training resources to improve operating techniques to maximize fuel efficiency.

Financing

Cat dealers offer financing options to meet a variety of customer needs.

50

TEJB9628

Cat 966K and 972K Medium Wheel Loaders

August 2011

Sustainability

The 966K and 972K are designed to compliment your business plan, reduce emissions and minimize the consumption of natural resources.

emissions and minimize the consumption of natural resources. Key Sustainability Enhancements • Improved fuel efficiency

Key Sustainability Enhancements

• Improved fuel efficiency – less fuel consumed results in lower emissions.

• Engine air filter life doubled to reduce cost and waste.

• Machine is built with a 96% recyclability rate (ISO 16714) to conserve valuable natural resources and further enhance machine End-of-Life value.

• Improved operator efficiency through enhanced visibility and reduced noise/ vibration levels.

• Product Link family of products and solutions that collect, communicate, store and deliver product and job-site information to maximize productivity and reduce costs.

• Major components are rebuildable, eliminating waste and saving money by giving the machine and/or major components a second – and even third – life.

Recyclability Rate Calculation Description

A machine with higher recyclability rate will

help ensure more efficient usage of valuable natural resource and enhance End-of-Life value of the product. According to ISO 16714 (Earthmoving machinery – Recyclability and recoverability – Terminology and calculation method), recyclability rate is defined as percentage by mass (mass fraction in percent) of the new machine potentially able to be recycled, reused or both.

All parts in the bill of material are first evaluated by component type based on a list of components defined by the ISO 16714 and Japan CEMA (Construction Equipment Manufacturers Association) standards. Remaining parts are further evaluated for recyclability based on material type.

Recyclable Content Definition

The amount of recyclable content in a machine

is equal to the recyclability rate of the machine.

Recyclability rate – percentage by mass (mass fraction in percent) of the new machine potentially able to be recycled, reused or both

August 2011

TEJB9628

Cat 966K and 972K Medium Wheel Loaders

51

Comparison of 966K/972K vs. 966H/972H

 

K Series

H Series

Work Tools

Performance Series Buckets

Standard

Optional, 972H only

Fusion Coupler

Optional

Optional

Hydraulics

Implement System

Rated 31,026 kPa (4,500 psi)

Rated 31,026 kPa (4,500 psi)

Load Sense Hydraulics

Standard

Standard

Kidney Loop Oil Filtration

Filtered before entering the fan circuit

Filtered before returning to tank

E-H Implement and Steering Controls

Standard

EH implement standard

Steering Cylinder Snubbing

with in-cylinder sensors

with steering neutralizer valves

Steering

Standard Steering System

Electro-hydraulic joystick

Conventional steering wheel

Optional Steering System

Electro-hydraulic steering wheel

Command control steering wheel

Operator Station

Ingress/Egress Incline

10 degree angle

5 degree angle

Cab Door Opening

Minimum width of 610 mm (24")

Minimum width of 381 mm (15")

Cab Door

Front hinged

Rear hinged

Cab Design

Four post

Six post

Windshield

Convex glass

Flat glass

Seat Mounted Implement Controls

Standard

Standard

Implement Joystick

Optional, fingertip roller design

Optional, thumbwheel design

Information Display

Center console, in language text

Cat monitoring system

Gauges

Analog

Analog

Control Panel

Membrane switches

Rocker switches

“What” Switch

Standard

Not available

Climate Control

Automatic or Manual

Manual

Air Conditioning

Standard

Standard

Cab Filtration System

External

Internal

Rearview Camera

Standard

Optional

North America Operator Sound Pressure Level

71

dB(A)

71

dB(A)

Europe Operator Sound Pressure Level

69

dB(A)

69

dB(A)

Cab Mounts

Viscous mounts

Solid mounts

Pre-wired for Strobe Beacon

Standard

Standard

Pre-wired for Radio with Standard Speakers

Standard

Standard

Bluetooth Capable

Optional

Not available

10 Amp Voltage Converter with 3-Power Ports

Standard

Standard

Product Link

Standard

Standard

Optional External Mirrors

Heated and remotely adjustable

Heated

Counterweight Lights

LED, stop/tail/turn

Incandescent, stop/tail/turn

52

TEJB9628

Cat 966K and 972K Medium Wheel Loaders

August 2011

Comparison of 966K/972K vs. 966H/972H

 

K Series

H Series

Engine

Model

C9.3

C11

Emissions

Tier 4 Interim

Tier 3

Cat Clean Emissions Module

Standard

Not available

Cat Regeneration System

Standard

Not available

Precleaner

Standard, strata tube

Optional, turbine

Electrical Fuel Priming System

Standard

Standard

Fuel Management System

Standard

Not available

Engine Idle Management System (EIMS)

Standard

Standard

Engine Idle Shutdown

Standard, including electronics

Standard, engine only

Cold Start/High Altitude Package

Optional, fan pump and trans pump bypass, additional batteries, heater cord

Optional, ether aid and heater cord

Cooling

Cooler Core Access

Rearclamshell and swing out cores

Swing out cores

Variable Pitch Fan

Optional

Optional

Cooling Capacity

5 rows of inline tubes, 6 fins per inch

4 rows of inline tubes, 6 fins per inch

High Ambient Cooling

Optional, 9 fins per inch

Optional, 9 fins per inch

Cooling Shunt Tank

Plastic

Steel

Fuel Cooling Core

Standard

Not available

On-Demand Hydraulic Fan

Standard

Standard

Pull Airflow In Rear Out Sides

Standard

Standard

AirBorne Debris Grill

Standard

Standard

Powertrain

Park Brake

EH applied with manual release

Cable applied without manual release

Inboard Brake and Final Drives

Standard

Standard

Integrated Braking System

Standard

Standard

Brake Wear Indicators

Standard

Standard

Optimized Torque Converter

Standard

Standard, 966H only

4-Speed Planetary Transmission

Standard

Standard

Shifting Strategy

Speed clutches only

Speed and directional clutches

2 to 1 Downshift Strategy

Torque/load based

Speed based

Open Front and Rear Differentials

Standard

Standard

Limited Slip Front/Rear Differentials

Optional

Optional

Serviceability

Sloped One-Piece Tilting Hood

Standard

Standard

Rear Clamshell Hood

Standard

Not available

Hydraulic Service Center

Standard

Standard

Electrical Service Center

Standard

Standard

Window Cleaning Platform

Standard

Optional

August 2011

TEJB9628

Cat 966K and 972K Medium Wheel Loaders

53

Comparison of 966K vs. 966H

966K vs. 966H Performance Comparison

A performance comparison for the 966K vs. 966H is not available at this time. However, the results from the 972K vs. 972H below should be directionally similar for the 966K. The 966K and 972K both have the new single clutch speed shifting logic which improves acceleration, speed up ramps and shift smoothness. The 966K gets the Performance Series buckets for the first time (a limited number of Performance Series buckets were available for the 972H in North America late in their production). Performance Series buckets will:

• Reduce loading time thereby saving fuel.

• Increase fill factors improving fuel efficiency (tonnes/liter or tons/gallon).

• Increase material retention due to improved strike plane angle and convex side bars.

54

TEJB9628

Cat 966K and 972K Medium Wheel Loaders

August 2011

Comparison of 972K vs. 972H

972K vs. 972H Performance Comparison

Machine/Work Tool Configurations

• 972H with Material Handling Bucket (4.78 m3/6.25 yd3)

• 972K with Material Handling Performance Series Bucket (4.78 m3/6.25 yd3)

Operations

• Moderate Truck Loading (Part throttle, ~30 second cycles)

• Batch Plant Load & Carry (3rd Gear maximum, 70 second cycles with short ramp)

Material

• Sand, density 1649-1774 kg/m3 (2,780-2,990 lb/yd3)

Environmental Conditions

• Dry, temperatures varied from 15-22° C (59-72° F); maximum temperature variation between compared runs was ~ –13° C (~8° F)

Note: Cooling Package was standard 6 fins per inch, 972K equipped with variable pitch fan.

August 2011

TEJB9628

Cat 966K and 972K Medium Wheel Loaders

55

Comparison of 972K vs. 972H

Productivity (Tons/Hour)

1200

1000

800

600

400

200

0

1200

1000

800

600

400

200

0

10% 9% 4% Moderate Moderate Batch Plant Batch Plant Roading Roading Mix Mix Truck Truck
10%
9%
4%
Moderate
Moderate
Batch Plant
Batch Plant
Roading
Roading
Mix
Mix
Truck
Truck
Load and
Load and
Loading
Loading
Carry
Carry
Productivity (Tonnes/Hour)
10%
9%
4%
Moderate
Moderate
Batch Plant
Batch Plant
Roading
Roading
Mix
Mix
Truck
Truck
Load and
Load and
Loading
Loading
Carry
Carry
H
Series
K
Series
Mix
50% moderate truck loading, 25% batch plant load and carry, and 25% roading

• Production was improved due to the Optimized Torque Converter (10% increase to rimpull in all gears)

• Production was also improved due to bucket loadability and shorter dig times … optimized ground speed to bucket tilt speed balance (slightly smaller tilt cylinder with same pump flow results in an increase to bucket tilt speed)

56

TEJB9628

Cat 966K and 972K Medium Wheel Loaders

August 2011

Comparison of 972K vs. 972H

Fuel Rate (Gallons/Hour)

12 5% 9% 10 8% 8 10% 6 4 2 0 Moderate Moderate Batch Plant
12
5%
9%
10
8%
8
10%
6
4
2
0
Moderate
Moderate
Batch Plant
Batch Plant
Roading
Roading
Mix
Mix
Truck
Truck
Load and
Load and
Loading
Loading
Carry
Carry
Fuel Rate (Liters/Hour)
45
5%
40
9%
8%
35
30
10%
25
20
15
10
5
0
Moderate
Moderate
Batch Plant
Batch Plant
Roading
Roading
Mix
Mix
Truck
Truck
Load and
Load and
Loading
Loading
Carry
Carry
H
Series
K
Series
Mix
50% moderate truck loading, 25% batch plant load and carry, and 25% roading

• Production was improved due to the Optimized Torque Converter (10% increase to rimpull in all gears)

• Production was also improved due to bucket loadability and shorter dig times … optimized ground speed to bucket tilt speed balance (slightly smaller tilt cylinder with same pump flow results in an increase to bucket tilt speed)

August 2011

TEJB9628

Cat 966K and 972K Medium Wheel Loaders

57

Comparison of 972K vs. 972H

Fuel Efficiency (Tons/Gallon)

120

100

80

60

40

20

0

30

25

20

15

10

5

0

21% 19% 8% Moderate Moderate Batch Plant Batch Plant Roading Roading Mix Mix Truck Truck
21%
19%
8%
Moderate
Moderate
Batch Plant
Batch Plant
Roading
Roading
Mix
Mix
Truck
Truck
Load and
Load and
Loading
Loading
Carry
Carry
Fuel Efficiency (Tonnes/Liter)
21%
19%
8%
Moderate
Moderate
Batch Plant
Batch Plant
Roading
Roading
Mix
Mix
Truck
Truck
Load and
Load and
Loading
Loading
Carry
Carry
H
Series
K
Series
Mix
50% moderate truck loading, 25% batch plant load and carry, and 25% roading

• Production was improved due to the Optimized Torque Converter (10% increase to rimpull in all gears)

• Production was also improved due to bucket loadability and shorter dig times … optimized ground speed to bucket tilt speed balance (slightly smaller tilt cylinder with same pump flow results in an increase to bucket tilt speed)

58

TEJB9628

Cat 966K and 972K Medium Wheel Loaders

August 2011

Technical Specifications – 966K

Engine

Engine Model

Cat ® C9.3 ACERT™

Max. Gross Power (1,800 rpm) – SAE J1995

222

kW

296 hp

Max. Gross Power (1,800 rpm) – SAE J1995 (metric)

302 hp

Max. Net Power (1,800 rpm) – ISO 9249

199

kW

267 hp

Max. Net Power (1,800 rpm) – ISO 9249 (metric)

271

hp

Max. Net Power (1,800 rpm) – SAE J1349

199

kW

267 hp

Max. Net Power (1,800 rpm) – SAE J1349 (metric)

271

hp

Max. Net Power (1,800 rpm) – EEC 80/1269

199

kW

267 hp

Max. Net Power (1,800 rpm) – EEC 80/1269 (metric)

271

hp

Peak Gross Torque (1,400 rpm) – SAE J1995

1364

N·m

1,006 ft-lb

Peak Net Torque (1,400 rpm) – SAE J1349

1274

N·m

940 ft-lb

Bore

115 mm

4.5 in

Stroke

149 mm

5.9 in

Displacement

9.3 L

568 in 3

• Cat engine with ACERT™ Technology – meets Tier 4 Interim/Stage IIIB emission standards.

Weights

Operating Weight

• For 4.2 m 3 (5.5 yd 3 ) general purpose buckets with BOCE.

24 189 kg

53,311 lb

Buckets

Bucket Capacities

2.50 m 3 - 9.20 m 3

3.25 yd 3 - 12.00 yd 3

• Refer to bucket selection chart.

Operating Specifications

Static Tipping Load

14 636 kg

32,259 lb

Full 37° Turn – ISO 14397-1*

Static Tipping Load Full 37° Turn – Rigid Tires**

15 828 kg

34,886 lb

Breakout Force

173 kN

38,984 lb

• For 4.2 m 3 (5.5 yd 3 ) general purpose buckets with BOCE. * Full compliance to ISO (2007) 14397-1

Sections 1 thru 6, which requires 2% verification between calculations and testing.

** Compliance to ISO (2007) 14397-1 Sections 1 thru 5.

Transmission

Forward 1

6.7 km/h

4.2 mph

Forward 2

12.6 km/h

7.8 mph

Forward 3

22.4 km/h

13.9 mph

Forward 4

37.4 km/h

23.2 mph

Reverse 1

7.8 km/h

4.9 mph

Reverse 2

13.7 km/h

8.5 mph

Reverse 3

23.5 km/h