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Cat Product Information

Product Bulletin
August 2011

Cat 966K and 972K


Medium Wheel Loaders

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.

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

TEJB9628 Cat 966K and 972K Medium Wheel Loaders

August 2011

Overview

When developing the new Medium Wheel Loaders Caterpillar set design specifications based
uponvoice 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/StageIIIB
emissions requirements. The new engine contains a Cat Clean Emissions Module (CEM), which
houses the Diesel Oxidation Catalyst (DOC), Diesel Particulate Filter (DPF), andCatRegeneration
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 operators preferred setting; and a new center display panel with five analoglike gauges and a large text box that displays in-language messages.

August 2011

TEJB9628 Cat 966K and 972K Medium Wheel Loaders

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 efficiency 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.

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.
Work Tool Fill Factors
Bucket Fill Factors
(as a % of ISO Rated Capacity)

Loose Material

Performance
Series
Bucket

Earth/Clay

115

Sand and Gravel

115

Aggregate:

25-76 mm
(1 to 3 in)

110

19 mm (0.75 in)
andsmaller

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 systembased approach to balance bucket shape with
the machines 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

Work Tools and Linkage


Lower Operating Costs

Forks, Rakes, and Plows

Performance Series Buckets feature a longer


floor that easily digs through the pile and
provides excellent visibility for the operators
tosee 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
frommaterial overflow.

Pallet Forks, Log and Lumber Forks


Rakes, with or without top clamps
Plows, angle or V-style
Fusion Quick Coupler System

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 machines 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.

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 machines performance.

Specialty Buckets
Multipurpose
Side Dump
Waste Handling
Woodchip

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.

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. Thats 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
wedgingmechanism creates a tight, rattle-free
fit. Thispatented 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. Tightfit gives
better tool control and increased productivity.
Coupler durability is substantially increased
over traditional couplers.

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.
Eachmachine will have its own optimal bucket
and fork recommendations. However, crossmachine 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.

Increased visibility An open coupler frame


design clears sight lines from the operators
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.

August 2011

TEJB9628 Cat 966K and 972K Medium Wheel Loaders

Work Tools and Linkage


Linkage

Bucket Positioner
The 966K and 972K use a rotary sensor,
mounted on the right side of the linkage
cross tube, which measures the angular
changebetween the tilt lever and the linkage
cross tube. The operator can adjust the work
tool detents electronically from within the cab.
ThePerformance Series Buckets incorporate
aspill 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.

The 966K and 972K linkage is a single tilt


Zbar design. Three versions of this linkage
are available: standard, high lift and extended
capacity (only 972K). The extended capacity
lift arrangement allows the machine toexcel
in normal hopper charging and truckloading
applications without compromising performance.
In addition, increased durability has been
engineered into the extended capacityliftarms
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.

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

The hydraulic implement system consists ofthe


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.
Thehydraulic implement circuit is controlled
via electronic fingertip controls that interface
with an electronic control module.

August 2011

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. TheM3PC 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.

TEJB9628 Cat 966K and 972K Medium Wheel Loaders

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.

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 atleast 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)

When either lever is moved into the soft detent,


the operator will feel an increased resistance
from the lever this is the operators 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. (Notethe
detent will not be activated if the lever isheld in
the detent positions for more than one second.)

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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.
Anitrogen 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.

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 (6mph). Whenspeed
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
usedtoset the reverse activation speed in
theinformation 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.
Thisensures the operator has full flow for
bothsteering and implement control to
guarantee flow is available when needed.

August 2011

966K/972K Oil Flow Explanation


Hydraulic
Tank
Fan Pump
Axle Oil
Cooler

Fan
Motor

Hydraulic
Filter
Fan/Brake/Pilot
Valve

Oil
Cooler

Implement
Valve

Pilot
Accumulator

Brake
Accumulators
Brakes/Quick
Coupler

Pilot
Circuit

Pilot
Accumulator

Steering
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.
Ifthe filter is clogged, the oil is permitted to
flow through the filter bypass valve. Theoil 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

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
tothe hydraulic tank.
966H/972H Oil Flow Explanation
Hydraulic Tank
Fan Pump
Fan Motor

Fan/Brake Valve

Brake
Accumulators

Oil Cooler
Hydraulic Filter

Brakes/Quick
Coupler

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

12

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
totank. On K Series, the kidney loop filter
islocated 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
ofthefan pump.
Flow to the axle oil cooler attachment differs
slightly between H and K Series.

TEJB9628 Cat 966K and 972K Medium Wheel Loaders

August 2011

Operator Environment
The new four post ROPS cab provides enhanced comfort, visibility, andproductivity resulting ina more
efficient operator.
Ladder

Front Hinged Door

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.

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
thedoor 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
tothe former H Series. The entry of the door
issignificantly larger at all three locations.
Location
Switch
Striker
Shoulder

H
381 mm (15")
483 mm (19")
508 mm (20")

K
635 mm (25")
610 mm (24")
686 mm (27")

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. Leftside 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

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 261degrees
view with the six post cab. The change was
made possible due to several design changes
including:
Relocating the operators eye point further
forward in the cab relative to the front
ROPSposts
Eliminating the intermediate door posts
andside window post
Moving the ROPS posts closer together

14

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.

TEJB9628 Cat 966K and 972K Medium Wheel Loaders

August 2011

Operator Environment
Electro-Hydraulic (EH) Joystick Steering
withForce Feedback (Speed Sensitive)

Seat

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 operators 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
forthe 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

August 2011

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
angleor articulation angle of the machine.
Thejoystick 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

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.
Thiscompares to conventional steering wheels,
which can require two-and-one-half to fiveor
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.

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.
Atransmission kick down is underneath the
top of the joystick. A horn button is located
onthe 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

Implement Controls (EH)

The ignition console is new on the K Series


andcontains 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.
Tothe right of the console are the MP3 player
jack, MP3 player or cell phone holder, and
twocup holders.
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

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

foroperator convenience. Surrounding the text


box is LED warning indicators that light up
on the display screen. With the 5 large analogtype 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)

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.
Thesystem supports 27 different languages
and will display instructions or commands

August 2011

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)

TEJB9628 Cat 966K and 972K Medium Wheel Loaders

17

Operator Environment
Control Panels
Left Turn Signal
Low/High
Beam Select

Right Turn Signal


Parking Lights
and Headlights

Work Lights

Hazard Lights

Auxiliary
Work Lights
(If Equipped)

Beacon
(If Equipped)

General Operation (see OMMs for more detail):

Manual
Regeneration

Press once to see active mode (shown on


center counsel machine display)

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)

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 LEDs
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

18

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
16membrane 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.

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.
Thekeypads would then illuminate LEDs
next to the items that the customer machine
is equipped with. The operator would then
pressand release the button they are seeking
information for. The machine information
display will then describe what the function
isand how to set it (in language).

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 operators 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 mountedat 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.
Inother words, the AC compressor is never
running continuously, therefore saving fuel.

August 2011

Rearview Camera

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.
Toimprove rearview visibility at night and
lowlight conditions two rear lights are also
located on the grill and light when the auxiliary
cab lights are activated in the cab bythe
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
inreverse, and off again in forward.

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.
Usethe 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
themachine.

talking to personnel on the ground or grading


close to a curb. External rearview mirrors
aremounted 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
forimproved access to the window cleaning
platform. In addition, a non-slip step has
beenadded near the front frame lift arm pin
tohelp assist operators when stepping onto
theredesigned 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.
Theoptional 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
areturned 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

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

20

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

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
4halogen lights and a strobe beacon.
Cab Features and Options

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 12volt 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 twoare
powered when the engine start key is turned on).
The VIMS PC connector is located next tothe
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
2way radio antennas.
Operator Sound and Vibration Levels

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

August 2011

New viscous cab mounts connect the cab to


theframe 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.

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
ISO6396:2008, 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
atmaximum value.
The machine sound pressure level for a standard
machine configuration, measured according
to the procedures specified in SAEJ88:2006,
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.

22

European Sound and Vibration Levels


The dynamic operator sound pressure
levelfor a standard machine configuration,
measured according to the procedures
specified in ISO6396:2008, is 69 dB(A)
with a cooling fan speed set at 70 percent
ofthe 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
tothe test procedures and conditions that
arespecified 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 ISO6396:2008, 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
ISO6396:2008, is 108 dB(A) with the cooling
fan speed set at maximum value.

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,
andelectronic fuelpriming.
Engine

Power Dense Strategy

The new Cat C9.3 ACERT engine was


designed to optimize power density. It uses
acombination of technologies to reduce
regulated emissions while ensuring high
performance and excellent fuel efficiency.
Anupgraded ADEM 4 electronic control
module manages the combustion process and
anew 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 machines work cycle.

August 2011

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
thepower band and maximize that power.

TEJB9628 Cat 966K and 972K Medium Wheel Loaders

23

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

Emissions

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
onall 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
andtraveling 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 doneto 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.
24

The 966K and 972K feature a Cat C9.3 ACERT


engine and a Cat Clean Emissions Module to
deliver the performance and efficiency that
customers 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.
Thesystem 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.

TEJB9628 Cat 966K and 972K Medium Wheel Loaders

August 2011

Engine
Cat Clean Emissions Module

Cat Regeneration System

The Cat Clean Emissions Module is thehardware


required to meet Tier 4 Interim/StageIIIB
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. Theseare
actually located in series inside the silver canister.
The Tier 4 Interim/StageIIIB engines more
thoroughly control the generation of NOx.
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,
itneeds to be removed using a special service
tool at 5,000 hours. An alternate method is
tosimply swap the current ash loaded DPF
foranempty DPF through Cat Reman.

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. Thesystem will
automatically activate and will not interrupt
the customers work cycle. The regeneration
strategy has been designed and optimized to
provide an acceptable maintenance interval,
while having no impact on the operation
orproductivity of the machine.
Four Position Key Switch
The four position key switch is new on all
KSeries models. The fourth position of the
key switch is necessary as part of twonew
KSeries features, Key Off Regen and
DelayedEngine 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 Clean Emissions Module is mounted


onits 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.

August 2011

The K Series machines are shipped with


KeyOff 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.

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.

Engine Durability

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 operators 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
and972K have an elevated low idle speed of
1,100rpm. The fluctuation takes place once
theoperator commands an engine speed
above1,100rpm. The low idle engine speed
will remain elevated at 1,100rpm 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.

26

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
tomaintain engine and aftertreatment
durability and performance.

TEJB9628 Cat 966K and 972K Medium Wheel Loaders

August 2011

Engine
Tier 4 Interim/Stage IIIB Engines require
CatDEO-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.
Ashtakes up useful volume of the DPF to
store soot between each regeneration cycle.
IfCat 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. CatDEO-ULS or
APICJ-4 help to enhance the service life
oftheDPF.

Engine Air Filtration System


Rain Cap
Inlet stack
Sealing plate
Bellows and band clamp
Strata tube precleaner

Cat DEO-ULS benefits:

Check valve and plenum

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

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

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).

28

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

Bellows and Band Clamp Provides flexible


seal between hood and plenum, clamp secures
the bellows to the plenum.

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

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:

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 900-1,400rpm
toallow for DPF regeneration.

Work Mode: Typical low idle speeds are


usedto 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 10seconds,
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 = NotWorking
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).

August 2011

Engine Idle Shutdown


The engine idle shutdown feature saves fuel, saves
warranty hours, and helps customers meet
California regulation of idling only 5minutes
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
isreset.

TEJB9628 Cat 966K and 972K Medium Wheel Loaders

29

Engine
Conditions for EIS to occur:

Cold Start/High Altitude Package

Engine coolant temperature must have been


warm after the last start.

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.

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.

The transmission and fan pump bypass solenoids


activate on each start when the transmission
oiltemperature is less than 0C (32F) at
10,000feet linearly until the transmission oil
temperature is less than 26C (14.8 F) at sea
level (see below graph). Thetransmission pump
bypass deactivates after the engine speed is
greater than 600rpm 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

Altitude (ft)

The left service brake is released.

8,000
6,000
4,000
Bypass not required

2,000
0
32

26

18
Temperature C

Engine RPM at Start Up


At start up the engine is at a minimum of
800rpm for 10 seconds before the machine
returns to the hibernate setting. A transmission
fluid level check is performed at 950 rpm for
5minutes. 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

August 2011

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 machines 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 pumps pressure compensator.
The flow compensator on the variable hydraulic
pump controls the fans 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.

TEJB9628 Cat 966K and 972K Medium Wheel Loaders

31

Cooling System
Compartmental Design

Variable Pitch Fan

The cooling system is isolated from the


enginecompartment by a non-metallic shield.
Ahydraulically 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. Thisairflow
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
9fins per inch cooling cores.

32

A variable pitch fan is optional on the 966K


and 972K helps clean the cooler cores from
thebackside. The variable pitch fan acts
like anairplane 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.
Thepurge can also be activated manually
through the display and uses the configuration
shown in the ET.

TEJB9628 Cat 966K and 972K Medium Wheel Loaders

August 2011

Cooling System
AC System

Serviceability

The AC condenser has a parallel flow to provide


a more efficient flow of coolant throughthe
AC condenser. The new AC fittings anddual
seals help improve the efficiency of thecooling
system through better containment of refrigerant
within the system.

A nonmetallic shunt tank is now being usedto


give the operator a better visual of the coolant
level of the engine and provides a more efficient
clean than a steel tank.

Regardless of the climate control system setting


in the cab (manual or auto) the ACcompressor
always cycles if there is demand for AC.
Inother words, the AC compressor is never
running continuously, therefore saving fuel.

At key on, a number of things are checked


including the low level coolant switch to make
sure the coolant level is within range.

The AC compressor also incorporates a


protection strategy to keep the compressor
from running under damaging conditions.
Ahigh/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.
Alow 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 0C (32F).
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).

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 Caterpillars proven durability.
Torque Converter

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.

34

Fixed Stator vs. Free Wheel Stator The engine


output shaft drives the torque converters
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 fluids momentum as it returns
to the impeller, increasing the units 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 stators ability to redirect and
increase the oils 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

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.

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.
Inputthrottle command or directional shift
will exit transmission fluid level check and
return to hibernate setting.

Transmission

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
only2 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

August 2011

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.

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 its 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
newerclutch 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
optimalmachine performance.

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.

Driveline
The driveline consists of three driveshafts;
oneto 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.
Themidship bearing is a spherical roller bearing.
Axles

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).
Ifan 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).
Thismode is not recommended due to the
higher fuel burn.

36

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. Eachaxle
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.
Therear axle includes a trunnion, two trunnion
supports and the associated bearings that allow
oscillation of plus or minus 13degrees.

TEJB9628 Cat 966K and 972K Medium Wheel Loaders

August 2011

Powertrain
Thisallows 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
thehigh loads encountered in the demanding
applications the 966K and 972K typically
perform. Use of ride control and autoshift
inload 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 afactory 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.

development during braking. This higher energy


is converted to heat, which is detrimental to
thebrake disc, oil and axle life.
When the brake pedal is applied the transmission
downshifts to absorb the energy throughthe
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 efficiency
the engine is not fueled while the integrated
braking system is active. During this time the
machines motion is used to spin the pumps
and engine.
Brake

Integrated Braking System

Integrated Braking System (IBS) is a Caterpillar


exclusive feature developed to reduce axle
oiltemperatures and improve transmission
neutralizer smoothness. Improvements in
machine capabilities and modern features
suchas automatic powershift transmission
andRide Control have resulted in higher energy

August 2011

Braking can occur using either of the cab


floor-mounted pedals. Brake pedals are
clipped so the heel leaves clearance to the
floor. Somecompetitors have little clearance
to the floor causing dirt buildup which results
in the pedal remaining partially engaged.
Thisburns 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.

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).

38

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. Eachtire
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.

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
ofrubber and wheel, which makes it quick
andeasy 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
ofproduct design.
Spread Hitch Design

Engine End Frame (EEF)

The distance between the upper and lower


hitch plates is an important contributor to
machine performance and life. Caterpillars
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.

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.

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.

Non Engine End Frame (NEEF)

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.
Ingress/Egress

Visibility

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.

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
aladder. When further comfort is needed,
anoptional 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
Ground Level Maintenance Points
and Service Centers

Window Cleaning Platform

Key maintenance points and service centers


arelocated 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
FallingObjects Protection Structure (FOPS)
An integrated ROPS and FOPS structure is
designed to carry loads directly into the tractor
main frame and protect the operator.

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.

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 customers machine health quick and easy. These programs
include Product Link, VisionLink, and SOS Services.
Product Link

Payload Control System 3.0

Cat Product Link allows remote monitoringof


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
andmore.
SOSSM Services
SOS 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 customers schedule, resulting in increased
uptime and flexibility in maintenance repairs
before failure.

August 2011

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
ofmaterials loaded by individual trucks.

TEJB9628 Cat 966K and 972K Medium Wheel Loaders

43

Monitoring Systems
PCS stores operating data for later download
and retrieval with personal computerand
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
ofpasses
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

Clamshell Hood

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

The K Series retains the Cat sloped one-piece


non-metallic tilting hood, which has become
one of our brands 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 toraise the
hood is approximately 48seconds. If necessary,
the entire hood enclosure can beremoved
utilizing built-in liftpoints.

August 2011

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
theengine area.

TEJB9628 Cat 966K and 972K Medium Wheel Loaders

45

Serviceability
Site Gauges

Hydraulics Service Center

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 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.

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 systems capacity is 65 L (17.2gal).
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).

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.

Electrical Service Center

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.

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,
andthe jump start receptacle.

August 2011

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).

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)
ofgauge 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 ECMs.
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.

48

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. Thisvalue
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). Thedifference
indicates the amount of wear that has
occurred to the service brake discs.
10. Repeat Steps 8 and 9 for the other
servicebrakes.
11. To provide an estimate on the amount
ofservice life for the brake discs, refer
tothe table below.
Disc Thickness Wear Chart
Amount of
Estimated
Friction
Percentage
Material that
of Remaining
isWorn from
Oil Groove
Brake DiscLife
the Disc
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)

TEJB9628 Cat 966K and 972K Medium Wheel Loaders

August 2011

Serviceability
Ecology Drains

Grab Bars

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.

August 2011

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
andexit.
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). Onceeach lubrication cycle
isinitiated, the pump dispenses grease under
pressure through timer intervals adjustable via
the monitor. This system will reduce overall
operating costs and improve serviceability
byproviding precise lubrication of pins and
bushings while the machine is in operation.

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.
Operation
To help maximize the return on your investment,
Cat dealers offer various training resources
to improve operating techniques to maximize
fuelefficiency.
Financing
Cat dealers offer financing options to meet
avariety of customer needs.

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.

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
theconsumption of natural resources.
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.
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.

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
(massfraction in percent) of the new machine
potentially able to be recycled, reused or both

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.

August 2011

TEJB9628 Cat 966K and 972K Medium Wheel Loaders

51

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


K Series

H Series

Performance Series Buckets

Standard

Optional, 972H only

Fusion Coupler

Optional

Optional

Rated 31,026 kPa (4,500 psi)

Rated 31,026 kPa (4,500 psi)

Standard

Standard

Filtered before entering the fan circuit

Filtered before returning to tank

Standard

EH implement standard

with in-cylinder sensors

with steering neutralizer valves

Standard Steering System

Electro-hydraulic joystick

Conventional steering wheel

Optional Steering System

Electro-hydraulic steering wheel

Command control steering wheel

10 degree angle

5 degree angle

Minimum width of 610 mm (24")

Minimum width of 381 mm (15")

Front hinged

Rear hinged

Cab Design

Four post

Six post

Windshield

Convex glass

Flat glass

Standard

Standard

Implement Joystick

Optional, fingertip roller design

Optional, thumbwheel design

Information Display

Center console, in language text

Cat monitoring system

Analog

Analog

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)

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

Heated and remotely adjustable

Heated

LED, stop/tail/turn

Incandescent, stop/tail/turn

Work Tools

Hydraulics
Implement System
Load Sense Hydraulics
Kidney Loop Oil Filtration
E-H Implement and Steering Controls
Steering Cylinder Snubbing
Steering

Operator Station
Ingress/Egress Incline
Cab Door Opening
Cab Door

Seat Mounted Implement Controls

Gauges
Control Panel

Cab Mounts

Optional External Mirrors


Counterweight Lights

52

TEJB9628 Cat 966K and 972K Medium Wheel Loaders

August 2011

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


K Series

H Series

C9.3

C11

Tier 4 Interim

Tier 3

Cat Clean Emissions Module

Standard

Not available

Cat Regeneration System

Standard

Not available

Standard, strata tube

Optional, turbine

Electrical Fuel Priming System

Standard

Standard

Fuel Management System

Standard

Not available

Engine Idle Management System (EIMS)

Standard

Standard

Standard, including electronics

Standard, engine only

Optional, fan pump and trans pump


bypass, additional batteries, heater cord

Optional, ether aid and heater cord

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

Optional, 9 fins per inch

Optional, 9 fins per inch

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

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

Speed clutches only

Speed and directional clutches

Torque/load based

Speed based

Open Front and Rear Differentials

Standard

Standard

Limited Slip Front/Rear Differentials

Optional

Optional

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

Engine
Model
Emissions

Precleaner

Engine Idle Shutdown


Cold Start/High Altitude Package
Cooling
Cooler Core Access

High Ambient Cooling


Cooling Shunt Tank

Powertrain
Park Brake

Shifting Strategy
2 to 1 Downshift Strategy

Serviceability

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
10%

1000
800

9%
600
4%
400
200
0

Moderate
Truck
Loading

Moderate
Truck
Loading

Batch Plant
Load and
Carry

Batch Plant
Load and
Carry

Roading

Roading

Mix

Mix

Productivity (Tonnes/Hour)
1200
1000

10%

800
9%
600
4%
400
200
0

Moderate
Truck
Loading

Moderate
Truck
Loading

Batch Plant
Load and
Carry

Batch Plant
Load and
Carry

Roading

Roading

Mix

Mix

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%

10%

6
4
2
0

Moderate
Truck
Loading

Moderate
Truck
Loading

Batch Plant
Load and
Carry

Batch Plant
Load and
Carry

Roading

Roading

Mix

Mix

Fuel Rate (Liters/Hour)


45

5%

40

9%
8%

35
30

10%

25
20
15
10
5
0

Moderate
Truck
Loading

Moderate
Truck
Loading

Batch Plant
Load and
Carry

Batch Plant
Load and
Carry

Roading

Roading

Mix

Mix

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
21%
100
80

19%

60
8%
40
20
0

Moderate
Truck
Loading

Moderate
Truck
Loading

Batch Plant
Load and
Carry

Batch Plant
Load and
Carry

Roading

Roading

Mix

Mix

Fuel Efficiency (Tonnes/Liter)


30
21%
25
20
19%
15
8%
10
5
0

Moderate
Truck
Loading

Moderate
Truck
Loading

Batch Plant
Load and
Carry

Batch Plant
Load and
Carry

Roading

Roading

Mix

Mix

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
Max. Gross Power
(1,800 rpm)
SAEJ1995
Max. Gross Power
(1,800 rpm)
SAEJ1995 (metric)
Max. Net Power
(1,800 rpm)
ISO9249
Max. Net Power
(1,800 rpm)
ISO9249 (metric)
Max. Net Power
(1,800 rpm)
SAEJ1349
Max. Net Power
(1,800 rpm)
SAEJ1349 (metric)
Max. Net Power
(1,800 rpm)
EEC80/1269
Max. Net Power
(1,800 rpm)
EEC80/1269 (metric)
Peak Gross Torque
(1,400 rpm)
SAEJ1995
Peak Net Torque
(1,400 rpm)
SAEJ1349
Bore
Stroke
Displacement

Operating Specifications
Cat C9.3 ACERT
222 kW
296 hp

302 hp

199 kW

267 hp

271 hp

199 kW

267 hp

271 hp

Static Tipping Load 14 636 kg


Full 37 Turn
ISO14397-1*
Static Tipping Load 15 828 kg
Full 37 Turn
Rigid Tires**
Breakout Force
173 kN

Hydraulic System
32,259 lb

34,886 lb

38,984 lb

For 4.2 m3 (5.5 yd3) 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

1,006 ft-lb

Forward 1
Forward 2
Forward 3
Forward 4
Reverse 1
Reverse 2
Reverse 3
Reverse 4

1274 Nm

940 ft-lb

Maximum travel speed in standard vehicle


with empty bucket and standard L3 tires
with 826 mm (33 in) roll radius.

115 mm
149 mm
9.3 L

4.5 in
5.9 in
568 in3

199 kW

267 hp

271 hp

1364 Nm

6.7 km/h
12.6 km/h
22.4 km/h
37.4 km/h
7.8 km/h
13.7 km/h
23.5 km/h
38.5 km/h

4.2 mph
7.8 mph
13.9 mph
23.2 mph
4.9 mph
8.5 mph
14.6 mph
23.9 mph

Steering System
Pump Type
Implement System
Maximum Pump
Output (2,275 rpm)
Implement System
Maximum Operating
Pressure
Implement System
Optional 3rd Function
Maximum Flow
Implement System
Optional 3rd Function
Maximum Pressure
Hydraulic Cycle
Time Raise from
Carry Position
Hydraulic Cycle
Time Dump, at
Maximum Raise
Hydraulic Cycle
Time Lower,
Empty, Float Down
Hydraulic Cycle
Time Total

Piston
340 L/min 90 gal/min

31 000 kPa 4,496 psi

300 L/min 79.3 gal/


min
20 700 kPa 3,000 psi

5.9 Seconds

1.5 Seconds

2.4 Seconds

9.8 Seconds

Cycle time with rated payload.

Brakes
Brakes

Meet OSHA,
SAEJ1473 OCT90
and ISO 3450-1985
required standards

Cat engine with ACERT Technology


meets Tier 4 Interim/Stage IIIB emission
standards.

Weights
Operating Weight

24 189 kg

53,311 lb

For 4.2 m3 (5.5 yd3) general purpose buckets


with BOCE.

Buckets
Bucket Capacities

2.50 m39.20 m3

3.25 yd312.00 yd3

Refer to bucket selection chart.

August 2011

TEJB9628 Cat 966K and 972K Medium Wheel Loaders

59

Technical Specifications 966K


Axles
Front
Rear
Maximum SingleWheel Rise and Fall

Cab
Fixed
Oscillating
13degrees
495 mm
19.5 in

Tires
Choose from a variety of tires to match
your application.
Choices 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
Cat Flexport
NOTE: In certain applications (such as
load and carry), the loaders productive
capabilities might exceed the tires tonneskm/h (ton-mph) capabilities. Caterpillar
recommends that you consult a tire supplier
to evaluate all conditions before selecting a
tire model. Other special tires are available
on request.

ROPS/FOPS

Dimensions
Meets SAE and
ISOstandards

Cat cab with a four post integrated Rollover


Protective Structure (ROPS) are standard in
North America and Europe.
ROPS meets SAE J1040 APR88 and
ISO3471:1994 criteria.
Falling Objects Protective Structure (FOPS)
meets SAE J231 JAN81 and ISO:1992
Level II criteria.

Service Refill Capacities


Fuel Tank
Standard
Cooling System
Crankcase
Transmission
Differentials and
Final Drives Front
Differentials and
Final Drives Rear
Hydraulic Tank

381 L

101 gal

65 L
24.5 L
50 L
64 L

17.2 gal
6.5 gal
13.2 gal
16.9 gal

64 L

16.9 gal

198 L

52.3 gal

Height to Top
ofROPS

3547 mm

11'7"

Height to Top
ofExhaust Pipe
Height to Top
ofHood
Ground Clearance
with 26.5R25
(SeeTire Option
Chart for Other
Tires)
B-Pin Height
Standard
B-Pin Height
High-Lift
Center Line of
Rear Axle to Edge
of Counterweight
Lift Arm Clearance
Lift Arm Clearance
@ High Lift
Wheelbase
B-Pin Height @
Carry Standard
Center Line of
Rear Axle to Hitch
Rack Back @
Maximum Lift
Dump Angle @
Maximum Lift
Rack Back @ Carry
Rack Back @
Ground
Height to Center
Line of Axle

3518 mm

11'6"

2828 mm

9'3"

475 mm

1'6"

4234 mm

13'10"

4792 mm

15'8"

2187 mm

7'2"

2862 mm

9'3"

4153 mm

13'6"

3450 mm

11'3"

640 mm

2'1"

1725 mm

5'7"

62 degrees
49 degrees
50 degrees
42 degrees
798 mm

2'7"

NOTE: All dimensions are approximate


andbased on L3 Michelin XHA2 tires.

60

TEJB9628 Cat 966K and 972K Medium Wheel Loaders

August 2011

Technical Specifications 972K


Engine
Engine Model
Max. Gross Power
(1,800 rpm)
SAEJ1995
Max. Gross Power
(1,800 rpm)
SAEJ1995 (metric)
Max. Net Power
(1,800 rpm)
ISO9249
Max. Net Power
(1,800 rpm)
ISO9249 (metric)
Max. Net Power
(1,800 rpm)
SAEJ1349
Max. Net Power
(1,800 rpm)
SAEJ1349 (metric)
Max. Net Power
(1,800 rpm)
EEC80/1269
Max. Net Power
(1,800 rpm)
EEC80/1269 (metric)
Peak Gross Torque
(1,400 rpm)
SAEJ1995
Peak Net Torque
(1,400 rpm)
SAEJ1349
Bore
Stroke
Displacement

Operating Specifications
Cat C9.3 ACERT
237 kW
318 hp

322 hp

215 kW

288 hp

292 hp

215 kW

288 hp

Static Tipping Load 16 317 kg


Full 37 Turn
ISO14397-1*
Static Tipping Load 17 642 kg
Full 37 Turn
Rigid Tires**
Breakout Force
196 kN

Hydraulic System
35,963 lb

38,884 lb

44,075 lb

For 4.8 m3 (6.3 yd3) 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
292 hp

215 kW

288 hp

292 hp

1426 Nm

1,051 ft-lb

1335 Nm

985 ft-lb

115 mm
149 mm
9.3 L

4.5 in
5.9 in
568 in3

Forward 1
Forward 2
Forward 3
Forward 4
Reverse 1
Reverse 2
Reverse 3
Reverse 4

7.0 km/h
12.5 km/h
21.4 km/h
36.9 km/h
8.0 km/h
14.3 km/h
24.5 km/h
42.2 km/h

4.4 mph
7.8 mph
13.3 mph
22.9 mph
5.0 mph
8.9 mph
15.2 mph
26.2 mph

Maximum travel speed in standard vehicle


with empty bucket and standard L3 tires
with 826 mm (33 in) roll radius.

Steering System
Piston
Pump Type
Implement System 340 L/min 90 gal/min
Maximum Pump
Output (2,275 rpm)
Implement System 31 000 kPa 4,496 psi
Maximum Operating
Pressure
Implement System 300 L/min 79.3 gal/
Optional 3rd Function
min
Maximum Flow
Implement System 20 700 kPa 3,000 psi
Optional 3rd Function
Maximum Pressure
Hydraulic Cycle
5.9 Seconds
Time Raise from
Carry Position
Hydraulic Cycle
2.0 Seconds
Time Dump at
Maximum Raise
Hydraulic Cycle
2.4 Seconds
Time Lower,
Empty, Float Down
Hydraulic Cycle
10.3 Seconds
Time Total
Cycle time with rated payload.

Brakes
Brakes

Meet OSHA,
SAEJ1473 OCT90
and ISO 3450-1985
required standards

Cat engine with ACERT Technology


meets Tier 4 Interim/Stage IIIB emission
standards.

Weights
Operating Weight

26 212 kg

57,770 lb

For 4.8 m3 (6.3 yd3) general purpose buckets


with BOCE.

Buckets
Bucket Capacities

2.90 m39.90 m3

3.75 yd313.00 yd3

Refer to bucket selection chart.

August 2011

TEJB9628 Cat 966K and 972K Medium Wheel Loaders

61

Technical Specifications 972K


Axles
Front
Rear
Maximum SingleWheel Rise and Fall

Cab
Fixed
Oscillating
13degrees
495 mm
19.5 in

Tires
Choose from a variety of tires to match
your application.
Choices 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
Cat Flexport
NOTE: In certain applications (such as
load and carry), the loaders productive
capabilities might exceed the tires tonneskm/h (ton-mph) capabilities. Caterpillar
recommends that you consult a tire supplier
to evaluate all conditions before selecting a
tire model. Other special tires are available
on request.

ROPS/FOPS

Dimensions
Meets SAE and
ISOstandards

Cat cab with a four post integrated Rollover


Protective Structure (ROPS) are standard
inNorth America and Europe.
ROPS meets SAE J1040 APR88 and
ISO3471:1994 criteria.
Falling Objects Protective Structure (FOPS)
meets SAE J231 JAN81 and ISO:1992
Level II criteria.

Service Refill Capacities


Fuel Tank
Standard
Cooling System
Crankcase
Transmission
Differentials and
Final Drives Front
Differentials and
Final Drives Rear
Hydraulic Tank

381 L

101 gal

66 L
24.5 L
50 L
64 L

17.4 gal
6.5 gal
13.2 gal
16.9 gal

64 L

16.9 gal

198 L

52.3 gal

Height to Top
ofROPS

3547 mm

Height to Top
ofExhaust Pipe
Height to Top
ofHood
Ground Clearance
with 26.5R25
(SeeTire Option
Chart for Other
Tires)
B-Pin Height
Standard
B-Pin Height
High-Lift
Center Line of
Rear Axle to Edge
of Counterweight
Lift Arm Clearance
Lift Arm Clearance
@ High Lift
Wheelbase
B-Pin Height @
Carry Standard
Center Line of
Rear Axle to Hitch
Rack Back @
Maximum Lift
Dump Angle @
Maximum Lift
Rack Back @ Carry
Rack Back @
Ground
Height to Center
Line of Axle

3518 mm 11'6"

11'7"

2828 mm 9'3"
475 mm

1'6"

4456 mm 14'7"
4792 mm 15'8"
2473 mm 8'1"

3804 mm 12'6"
4153 mm 13'6"
3450 mm 11'3"
689 mm 2'3"
1725 mm 5'7"
56 degrees
48 degrees
50 degrees
41 degrees
798 mm

2'7"

NOTE: All dimensions are approximate


andbased on L3 Michelin XHA2 tires.

62

TEJB9628 Cat 966K and 972K Medium Wheel Loaders

August 2011

Notes

August 2011

TEJB9628 Cat 966K and 972K Medium Wheel Loaders

63

For more complete information on Cat products, dealer services, and industry solutions, visit us on the
web at www.cat.com
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All rights reserved
Printed in the U.S.A.
Materials and specifications are subject to change without notice. Featured machines in photos may
include additional equipment. See your Cat dealer for available options.
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trade dress, as well as corporate and product identity used herein, are trademarks of Caterpillar and
may not be used without permission.

TEJB9628 (08-2011)