Milton CAT 966H User Manual

Engine

Engine Model Cat®C11 ACERT™
Gross Power – SAE J1995 213 kW 286 hp
Net Power – ISO 9249 195 kW 262 hp

• Caterpillar engine with ACERT™ Technology –
EPA Tier III, EU Stage III Compliant

Buckets

Bucket Capacities 3.4-4.2 m

3

4.5-5.5 yd

3

Weights

Operating Weight 23 698 kg 52,254 lb

• For 4.25 m3(5.5 yd3) general purpose bucket with BOCE

Operating Specifications

Static Tipping Load, Full Turn 15 474 kg 34,120 lb

• For 4.25 m3(5.5 yd3) general purpose bucket with BOCE

966H

Wheel Loader

®

®

2

966H Wheel Loader

Cat®H-Series Wheel Loaders – The New Standard For Midsize Loaders

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.

SERVICEABILITY

• Service Centers For Convenient
Maintenance

• Exceptional Access To Service Points

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

PRODUCTIVITY

• Improved Cycle Times With Load­Sensing Hydraulic System

• Constant Net Horsepower Through
The Operating Range

• Aggregate Autodig Automates The
Loading Process pg. 8

DURABILITY

• ACERT™ Technology Maintains
Performance, Efficiency And Durability
While Meeting Emissions Regulations

• Heavy Duty Components Stand Up To
All Operating Conditions

• Strong, Solid Structures Built To Last

pg. 6

RELIABILITY

• Proven Components And Technology
Equal Proven Reliability

• Diagnostic Systems Monitor Product
Health To Ensure Reliability

• Unmatched Parts Availability And
Dealer Support pg. 4

3

OWNING AND OPERATING COSTS

• Proven Fuel Efficiency

• Superior Maintenance

• Electronic Systems Monitor Product
Health And Performance

• Complete Dealer Support pg. 14

OPERATOR COMFORT

• Easy Entry And Exit

• Excellent Visibility

• Comfortable Environment With
Controlled Vibration

• Choice Of Steering And Implement
Control Systems pg. 12

VERSATILITY

• Special Machine Arrangements For
Specialized Applications

• Large Variety Of Cat®Work Tools

pg. 10

• 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 966H
features many of the components designed
and proven in previous 966 models – all
contribute to the reliability of the 966H:

• 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 966H –
both as standard and optional features –
to help you track machine condition.

Caterpillar Monitoring System. The 966H
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-of­the-art satellite technology based product
that provides two-way information flow
between machine on-board 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.

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.

4

The Cat®966H – Tested And Proven – Ready To Work

RELIABILITY

S•O•SSMServices. 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.

REMANUFACTURED PARTS. Cat engines
and major components are designed to be
remanufactured and provide multiple life
cycles. The Cat Reman program is more
extensive than most rebuild programs.
Components are actually remanufactured
in the factory to original specifications
with necessary product updates.

Strict reuse guidelines and unparalleled
quality control ensure that reman products
provide the reliability and durability that
you expect from Caterpillar. Reman
products are stocked in distribution
centers around the world and are ready
to install to minimize downtime,
maintain productivity and profitability.

5

• 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
C11 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 C11 with ACERT Technology
is an 11.1 L displacement, 6-cylinder,
electronically governed engine.
Electronic fuel injection is provided
through the well-proven Caterpillar
mechanically actuated, electronically
controlled unit injection (MEUI) 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 an electronic control module
designated the A4:E4V2. The controller
continually adjusts engine output based
on load demand using a series of sensors
located on the machine and engine.

Mechanically Actuated Electronic Unit
Injectors (MEUI). The MEUI 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, heat-treated
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, square-wave
core design decreases the chance of
blockage and plugging.

POWERSHIFT TRANSMISSION. The 966H
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.
Built-in electronic controls enhance
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 966H 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.

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.

6

Built Strong And Tough

DURABILITY

STRUCTURES. The articulated frame

design of the 966H 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 966H
design and styling. This 2,517 lb (1142 kg)
counterweight incorporates the rear
lights into the top of the structure.

Linkage. The 966H 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 on- and 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.

7

• 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 966H
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 966H 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 C11 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 966H cooling system is isolated
from the engine compartment by a non­metallic 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, full­power 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.

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 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.

8

Work Smart And Move More

PRODUCTIVITY

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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