Milton CAT 962H User Manual

962H ®

Wheel Loader

Engine			Weights
Engine Model	Cat® C7 ACERT™		Operating Weight				19 365 kg	42,700 lb
Gross Power - SAE J1995	172 kW	230 hp	• For 3.5 m3 (4.5 yd3) general purpose bucket with BOCE
Net Power - ISO 9249	158 kW	211 hp	Operating Specifications
• Caterpillar engine with ACERT™ Technology - EPA Tier			Static Tipping Load,				12 098 kg	26,676 lb
III, EU Stage III Compliant			Full Turn
Buckets			• For 3.5 m	3	3	) general purpose bucket with BOCE
Bucket Capacities	2.7-3.8 m3	3.5-5.0 yd3			(4.5 yd

962H Wheel Loader

H-Series Wheel Loaders - The New Standard For Midsize Loaders

RELIABILITY	DURABILITY	PRODUCTIVITY
• Proven Components And Technology	• ACERT™ Technology Maintains	• Improved Cycle Times With Load-
Equal Proven Reliability	Performance, Efficiency And Durability	Sensing Hydraulic System
• Diagnostic Systems Monitor Product	While Meeting Emissions Regulations	• Constant Net Horsepower Through
Health To Ensure Reliability	• Heavy Duty Components Stand Up To	The Operating Range
• Unmatched Parts Availability And	All Operating Conditions	• Aggregate Autodig Automates The
Dealer Support pg. 4	• Strong, Solid Structures Built To Last	Loading Process pg. 8
	pg. 6

SERVICEABILITY

•Service Centers For Convenient Maintenance

•Exceptional Access To Service Points

•Monitoring Systems And Dealer Support Reduce Unexpected Downtime pg. 16

Performance you can feel with the capability to work in the most demanding applications. Unmatched operator comfort and efficiency in a world class cab. Revolutionary electronics and hydraulics for low-effort operation. Increased productivity with lower owning and operating costs.

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VERSATILITY

•Special Machine Arrangements For Specialized Applications

•Quick Coupler And Large Variety Of Cat® Work Tools pg. 10

OPERATOR COMFORT	OWNING AND OPERATING COSTS
• Easy Entry And Exit	• Proven Fuel Efficiency
• Excellent Visibility	• Superior Maintenance
• Comfortable Environment With	• Electronic Systems Monitor Product
Controlled Vibration	Health And Performance
• Choice Of Steering And Implement	• Complete Dealer Support pg. 14
Control Systems pg. 12

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RELIABILITY

The Cat® 962H - Tested And Proven - Ready To Work

•Proven components and technology provide proven reliability

•Electronic systems monitor vital machine components

•Excellent uptime from the best dealer support network in the industry

•Unmatched genuine Cat parts availability

PROVEN RELIABILITY. The 962H features many of the components designed and proven in previous 962 models - all contribute to the reliability of the 962H:

•Frames

•Axles

•Planetary powershift transmission

•Free wheel stator torque converter

•Separated cooling system

•Cab

ACERT™ TECHNOLOGY. Since March 2003, ACERT Technology has been proving itself in on-highway trucks. More recently it has proven itself again in field tests of off-highway equipment.

This technology allows Cat engines to meet durability and reliability expectations without sacrificing fuel economy or performance.

CATERPILLAR DESIGNED COMPONENTS. Components used to build Cat Wheel Loaders are designed and manufactured to Caterpillar quality standards to ensure maximum performance even in extreme operating conditions.

Engine electronic control modules and sensors are completely sealed against moisture and dust. Deutsche connectors and electrical wire braiding ensure that electrical connections resist corrosion and premature wear.

Hoses are engineered and manufactured for high resistance to abrasion, excellent flexibility and easy installation and replacement.

Caterpillar® couplings use o-ring face seals to provide positive sealing for durable leak-free connections.

Heavy duty components reduce the risk of leaks, corrosion and premature wear increasing uptime and helping to protect the environment.

MONITORING PROGRAMS. Monitoring product health is key to maintaining reliability of any equipment. Many programs are available on the 962H - both as standard and optional features - to help you track machine condition.

Caterpillar Monitoring System. The 962H is equipped with the Cat Monitoring System (CMS) that keeps watch over the health of your loader. CMS monitors critical engine system functions and will derate the engine to protect itself from damage if needed. Depending on which of the following six critical conditions arise, the CMS monitor or front panel will display warning lights and sound audible alarms.

•High coolant temperature

•High air inlet temperature

•Low engine oil pressure

•High fuel pressure

•Low fuel pressure

•Engine over-speed

Product Link. Product Link is a state-of- the-art satellite technology based product that provides two-way information flow between machine onboard systems and the Caterpillar network operations center. Multiple types of information can be collected and tracked - from machine location and service meter hours, to health and productivity information.

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EquipmentManager. With a subscription to EquipmentManager through the Cat Dealer Storefront the information collected through Product Link can be transmitted to a computer. With fast, easy-to-access machine information, you can optimize asset utilization, reduce security risks, improve maintenance management and implement before-failure repair strategies. The result is more uptime, lower operating costs and a higher overall return on equipment investment.

S•O•SSM Services. Keep minor repairs from becoming major ones and avoid complete failures. By regularly taking samples from the ports provided, your Cat dealer tracks wear of components and parts, oil performance, and oil condition and uses that data to predict wear-related problems before they happen. Often a simple adjustment or replacement of a part, based on S•O•S reports, can keep a small problem from turning into a major repair - allowing your machine to be running when you need it, not waiting in the shop for service.

DEALER SUPPORT. The Caterpillar global network of independently-owned dealers is the best in the world at providing support to keep your loader up and running. Known for parts availability and technical expertise, Cat dealers are partners in your business.

Service Capabilities. Cat field service technicians have the experience and tools necessary to service your loader on site. Field service trucks are fully loaded with state-of-the-art tools and diagnostic equipment as well as specifications and schematics for every Cat machine. Technical experts at the dealership and at Caterpillar are available to provide assistance to field service technicians when needed.

When on-site repair isn’t enough, Cat dealerships are fully-equipped to service your loader quickly.

PARTS AVAILABILITY. Caterpillar provides an unsurpassed level of personalized service for your wheel loader. With parts distribution centers throughout the world, most parts can be delivered in 24 hours.

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DURABILITY

Built Strong And Tough

•ACERT™ Technology maintains engine performance, efficiency and durability while reducing emissions

•Heavy duty components withstand all operating conditions

•Strong, solid structures built to last

EPA TIER III, EU STAGE III COMPLIANT C7 ENGINE. ACERT Technology combines proven systems with innovative new technologies to precisely deliver fuel to the combustion chamber. It maintains engine performance, efficiency and durability while dramatically reducing emissions.

The Cat C7 with ACERT Technology is a 7.2 L displacement, 6-cylinder, electronically governed engine. Electronic fuel injection is provided through the well-proven Caterpillar hydraulically actuated, electronically controlled unit injection (HEUI) system. A wastegate turbocharger, equipped with a titanium wheel for improved durability, combined with air-to-air aftercooling (ATAAC) provides consistent high horsepower with increased altitude capability.

Electronic Controller. The engine is governed by the ADEM™ A4 electronic control module. The controller continually adjusts engine output based on load demand using a series of sensors located on the machine and engine.

Hydraulically Actuated Electronic Unit Injectors (HEUI). The HEUI™ system has been at work in Cat engines across the product line with a proven track record of consistent, durable, reliable performance.

Engine Block and Pistons. The gray, cast iron engine block is made of the same material as the cylinder heads. Wall diameters are thicker than in previous designs while adjustments have been made to reduce sound levels and increase rigidity. One-piece all-steel pistons are housed within a wet, replaceable cast iron cylinder liner constructed of high-strength, heattreated castings. Steel-forged connecting rods are larger in diameter and are connected to the crankshaft with two bolts.

Cylinder Head. The cylinder head is a one-piece design that incorporates cross-flow design to facilitate air movement. This allows the engine to breathe cooler, cleaner air with less effort.

RADIATOR. Brazed aluminum construction provides a stronger joint for maximum durability and resistance to leaks. The 6-fins-per-inch, squarewave core design decreases the chance of blockage and plugging.

POWERSHIFT TRANSMISSION. The 962H continues to use heavy-duty powershift transmission technology proven on previous models and currently used up through the largest wheel loader built by Caterpillar - the 994F.

The planetary powershift transmission features heavy-duty components to handle the toughest applications. Builtin electronic controls enhance shift quality, productivity and durability.

Control Throttle Shifting. Control Throttle Shifting regulates engine speed during high-energy directional changes for smoother shifting and longer component life.

Electronic Clutch Pressure Control.

Electronic Clutch Pressure Control (ECPC) system modulates clutches individually to improve shift quality, component life and operator comfort. Adjustment is simplified with all solenoid valves externally mounted on top of the transmission housing.

AXLES. The 962H axles are designed by Caterpillar for durability in all operating conditions. The front axle is rigidly mounted to the frame to support the weight of the wheel loader and withstand internal torque loads as well as external forces encountered throughout operation.

The rear axle is designed to allow ± 13° oscillation. All four wheels remain on the ground over uneven terrain providing excellent stability and traction.

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Integrated Braking System. The Cat exclusive Integrated Braking System reduces axle oil temperatures and improves transmission neutralizer smoothness. IBS has a direct impact on durability of the axles and brakes especially in applications involving long distances and/or heavy braking.

STRUCTURES. The articulated frame design of the 962H features a durable box-section engine frame and rigid four-plate loader tower that is robotically welded. Robotic welding creates frame joints with deep plate penetration welds and excellent fusion for maximum strength and durability.

Engine End Frame (EEF). A full boxsection engine end frame with hitch plates at the front end provides a strong, rigid structure that resists twisting and impact loads. The result is an extremely solid mounting platform for the engine, transmission, axle, ROPS and other accessories.

Spread Hitch. The distance between the upper and lower hitch plates is an important contributor to machine performance and component life. The Caterpillar spread hitch design provides excellent load distribution and bearing life. Both the upper and lower hitch pins pivot on double tapered roller bearings - improving durability by distributing both vertical and horizontal loads over a larger surface area. The wide opening also provides excellent service access.

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. The fabricated, four-plate loader tower absorbs the forces associated with loading, twisting and penetration.

Counterweight. The one-piece counterweight is integrated into the 962H design and styling. This 3084 lb (1399 kg) counterweight incorporates the rear lights into the top of the structure.

Linkage. The 962H linkage is a singletilt Z-bar design. Z-bar linkage generates excellent breakout force and good rack back angle for better bucket loading and load retention.

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 both onand off-highway trucks.

Rotary sensors, for the tilt lever and lift circuit allow the operator to electronically set detent positions from the cab. A guard covers the sensor to protect it from damage.

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PRODUCTIVITY

Work Smart And Move More

•Hydraulics are easy to control with low effort

•Maximum fuel efficiency and flexibility in idle speeds

•Consistent horsepower regardless of conditions

•Standard and optional features that maximize productivity

LOAD SENSING HYDRAULICS. The 962H features a load sensing hydraulic system that automatically adjusts to operating conditions to provide only the hydraulic flow required by the implement for improved fuel efficiency.

With the new M3PC Priority Proportional Pressure Compensation Valve, implement control is improved over the previous system - raise/lower and rack back/dump can be operated simultaneously and fine modulation is repeatable for improved productivity.

Operators will notice enhanced ease of operation, more rimpull into the pile and a 20% increase in lift force.

Electrohydraulic Implement Controls.

Electrohydraulic implement controls on the 962H provide the operator with incab programmable kickouts to prevent material spillage - improving productivity. The implement control console features an optional Forward/Neutral/Reverse switch allowing fast, easy directional changes to reduce cycle times.

CONSTANT NET HORSEPOWER. On many competitive machines, gross horsepower is constant, meaning that net engine power available for actual work will vary based on demands made from parasitic sources, such as air conditioning or cooling fans.

The Cat C7 engine is electronically configured to provide constant net horsepower at full parasitic load enhancing productivity and improving fuel efficiency.

On-Demand Fan. With electronic control of the variable speed on-demand fan, temperature levels of the engine coolant, transmission oil, hydraulic oil and air inlet manifold are constantly monitored. This data is used to control and maintain fan speed at the level necessary to maintain normal system temperatures. Controlled fan speed improves fuel efficiency, lowers noise levels and reduces radiator plugging.

Separated Cooling System. Many competitive loaders use cooling systems that pull air in from the sides, through the engine compartment and exhaust it out the rear of the machine. The 962H cooling system is isolated from the engine compartment by a non-metallic shield. The hydraulically driven, variable speed fan draws in clean air from the rear of the machine and exhausts it out the sides and top of the hood. The end results are optimal cooling efficiency, increased fuel efficiency, less radiator plugging and reduced operator sound levels.

PLANETARY POWERSHIFT TRANSMISSION. The electronic planetary powershift transmission with automatic shift capability is designed and built by Caterpillar. The very responsive, full-power speed and directional changes provide excellent cycle times and productivity.

VARIABLE SHIFT CONTROL. Match transmission shifting patterns to machine application requirements. Variable Shift Control (VSC) improves shift quality and fuel efficiency in certain applications by allowing the transmission to upshift at lower engine RPMs.

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RIDE CONTROL. The optional Ride Control System improves ride, performance and load retention when traveling over rough terrain. Operators gain confidence moving at higher speeds in load and carry operations decreasing cycle times and increasing productivity.

PAYLOAD CONTROL SYSTEM. Scales, designed specifically for Cat machines allow on-the-go weighing of material in the bucket. Operators load trucks more accurately and efficiently. Loading trucks right the first time equates to quicker cycles for the operator and more productivity and controllability for your operation.

Payload Control is offered as a factoryinstalled option. Driver tickets and a variety of reports can be printed with the addition of the optional printer.

AUTOLUBE. The optional Caterpillar Autolube System provides precise, automatic lubrication of pins and bushings - during loader operation. Automatic lubrication reduces time spent on daily maintenance and downtime for unplanned repairs due to inadequate greasing - improving productivity.

AGGREGATE AUTODIG. Well-received by both experienced and novice operators, the optional Aggregate Autodig automates the loading process.

Aggregate Autodig provides smoother loading cycles, consistently full payloads and eliminates tire spin - all without touching the controls.

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VERSATILITY

Built For Your Operation

•Special machine arrangements provided from the factory

•A quick coupler and variety of buckets and work tools for many applications

SPECIAL MACHINE ARRANGEMENTS.

When you have a specialized operation, you need a specialized wheel loader to be productive. The following machine arrangements are available for the 962H:

Aggregate Yard Loaders. The Yard Loader Value Package provides the ultimate in productivity and convenience. Options such as Autolube, Aggregate Autodig, Payload Control and Ride Control reduce operator fatigue and make your wheel loader the most productive yard loader available.

Forestry Applications. The Forest Machine Arrangement provides Ride Control, a heavy-duty tilt cylinder and an additional counterweight for use in forestry and logging applications. Specially-designed work tools for forestry applications can be factoryinstalled.

Industrial Loader. Heavy duty guarding and special features designed specifically for industrial applications, such as waste and scrap handling, allow the 962H to withstand the harshest of conditions. Work tools designed specifically for these applications can be added to

the machine.

Lift Arrangements. High lift arrangements are available for applications requiring additional dump clearance. Both 2-valve and 3-valve packages can be factory installed for conventional steering and Command Control machines.

WORK TOOLS AND QUICK COUPLERS.

A variety of buckets, work tools and couplers are available from the factory or from your Caterpillar dealer to customize the 962H for your operation.

Quick Couplers. Quick couplers provide unmatched versatility for wheel loaders. The hydraulic model allows an operator to change attachments in seconds without leaving the cab. On the manual model, the operator must lock the pins.

Buckets. Various types and sizes of buckets are available to match Cat wheel loaders to any job, anywhere, any time.

General Purpose Buckets. General purpose buckets provide good allaround performance for stockpiling, rehandling, excavating and bank loading. A heavy duty general purpose bucket can be used for more aggressive applications.

Material Handling Buckets. The material handling bucket is a flat-floor bucket used for handling stockpiled materials such as aggregates or other easy-to-load materials requiring moderate breakout force.

Multi-Purpose Buckets. Multi-Purpose Buckets have a unique four-way action that can load, strip topsoil, bulldoze, clamp pipe or large chunks of concrete, clean up debris, and many other tasks.

Rock Buckets. These buckets are designed to work primarily in the mining and quarry industries, either in straightor spade-edge configurations. The straight edge has higher breakout force and increased dump clearance; the spade edge offers better penetration.

Side Dump Buckets. Side dump buckets dump both to the front and to the side of the machine, an advantage when working in tight quarters, such as street work, tunnel construction and building levees.

Waste Buckets. Waste buckets are designed for long life in the harsh world of refuse applications. This highcapacity bucket is well-suited for loading, sorting and other transfer station work.

Woodchip and Clean-Up Buckets.

Woodchip and high-capacity clean-up buckets are available for forestry and millyard applications.

Ground Engaging Tools (GET). Several GET options are available from Caterpillar for the IT62H buckets. A cast corner adapter is incorporated into the design of the buckets that allows a tooth to be placed on the extreme corner for protection against base bucket wear.

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