CONFIDENTIAL

New Product
Information Release

Caterpillar is proud to introduces the NEW 966H Wheel Loader. The 966H replaces the
966G Series II and features improvements in areas of productivity, serviceability and
operator comfort. The 3176C Cat engine used to power the 966G II has been replaced by
the new EPA Tier 3 compliant Cat C11 engine with ACERT technology. Key to improved
productivity and fuel consumption will be the new load sensing implement system.
Additionally, the H-Series features sleek new styling and a number of new attachments that
will enhance performance, operator comfort, and efficiency.
The 966H builds upon the excellent reputation of the 966G Series II as a production loader
in applications ranging from truck loading in aggregate, waste, or forestry applications, to
industrial applications.

The information contained herein is intended for circulation only to employees of Caterpillar companies whose
duties require such knowledge. Under no circumstances is all or any part of this report to be reproduced or made
available to dealers or anyone outside the Caterpillar organization, or to anyone within the Caterpillar
organization whose duties do not require such information.

Table of Contents
Operator Station..................................................................................................................................................3
Entry and Exit.........................................................................................................................................3
Viewing Area/Ventilation.........................................................................................................................4
Operator Sound Level............................................................................................................................5
Seat.....................................................................................................................................................5-7
Steering Controls....................................................................................................................................8
Front Dash Panel/ Warning Indicators....................................................................................................9
Upper RH Control Panel/Transmission Controls..................................................................................10
Transmission Neutralizer/Ride Control............................................................................................11-12
Payload Control System.......................................................................................................................12
Electronic Monitoring System..........................................................................................................13-14

Do at the end...
Engine.................................................................................................................................................................15
ACERT Technology..........................................................................................................................16-17
Engine Specifications............................................................................................................................18
Cooling System.............................................................................................................................................19-22
Powertrain..........................................................................................................................................................23
Variable Shift Control/Shift Patterns.....................................................................................................26
Integrated Braking System...................................................................................................................27
Axles/Differentials and Bevel Gears.....................................................................................................28
Driveline................................................................................................................................................29
External Axle Oil Cooler/Brakes...........................................................................................................30
Free Wheel Stator.................................................................................................................................32
Rims & Tires.........................................................................................................................................34
Structures.....................................................................................................................................................35-37
Linkage..............................................................................................................................................................38
Hydraulics....................................................................................................................................................39-41
Bucket and Work Tools...............................................................................................................................42-44
Serviceability................................................................................................................................................45-51
Electronic Control Modules.............................................................................................................................52
Technical Specifications..............................................................................................................................53-54

966H Wheel Loaders

Operator Station

The 966H operator station offers all the features of the

966G II operator station, with some improvements.
Ultimately, the 966H cab offers unmatched operator
comfort and efficiency with steering and control options to
fit every operator and application. The following are
highlights of the 966G II carry-over and the 966H new
features found in the operator station.

Entry and Exit

Access to the cab has been improved on the 966H over the
966G II with a redesigned left side access ladder. The new
self-cleaning ladder, has a 5 degree incline for easier
access and egress. The 966H also features a full-length
ladder on the RH side of the machine.

As with the 966G II, rearhinged, full-length doors are

provided on both the right and
left sides of the cab. The right
side door latch, accessible from
inside the cab, allows the door
to be partially opened (10
degrees) and held in position.
By removing a pin, the door can be fully opened for exit.
Sliding windows are standard on both doors and can be
opened fully or incrementally.

966H Wheel Loaders

Operator Station

Ventilation/Air Conditioning

Viewing Area
The 966H cab continues to offer an unmatched viewing
area with a wide, flat, and distortion-free front windshield.
With bonded glass that reduces obstruction, the windshield
provides an accurate and full view of the working area.
Other features built in to aid work area visibility include: a
cab roof overhang on the front, rear, and sides to reduce
glare; a sloping hood improves the rear viewing area,
allowing the operator to see objects close to the rear of the
machine. Wet-arm, front and back wiper/washers ensure
that a clear view is maintained. Front windshield wiper
has a sweep of 914 mm (36 in) and is equipped with an
intermittent switch. Also, the roof provides water run-off
drains, directing water off the rear of the machine.

As with the 966G II, the pressurized air conditioning

system features excellent airflow and circulation. High
velocity air can be directed toward the operator utilizing 13
louvered vents. Heating, cooling and defrosting functions
are included. A three-speed fan and a variable temperature
control knob allow the operator to adjust the cab climate
for maximum comfort. All heating and air conditioning
controls are located on the upper control panel are within
easy reach of the operator. Over GII, the cab sealing is
improved, providing a cleaner, more comfortable operator
environment.

966H Wheel Loaders

Operator Station

Operator Sound Level

The 966H cab has maintained the same sound levels as
the GII series at 74dBa. The photo below shows a low
sound attachment that is avialable to customers. The
package has additional sound panels that have been added
to the hood, doors, rear of cab and front panels.
Additionally, sound insulation has been added around the
hydraulic tank. Cab "tightness" has also been increased
for better pressurization, which also contributes to the
lower sound level.
Seat
The 966H
features
the
Caterpillar
C500
Series
Comfort
air
suspension seat as standard. The automotive style lumbar
support applies pressure over a broad area and the seat
back recliner is a geared dual sided support, for improved
durability. Utilization of a cast, one-piece back and seat
pan ensures that there are no protrusions into the cushion.
The standard air suspension seat that adjusts six (6) ways,
as illustrated in the following pictures.

966H Wheel Loaders

Operator Station
Seat.
1. Vertical seat adjustment button
2. Adjustment lever for the back of the seat
3. Horizontal (fore and aft) seat adjustment lever
4. Lumbar (lower back) support adjustment lever
5. Armrests (both sides) adjustment knobs
6. Seat cushion adjustment (angle of front part of
cushion can be changed by lifting cushion and
pushing back).

Armrest.
The right side armrest also adjusts (as shown below) three
ways for optimal comfort when operating the implement
and machine.

1. Horizontal Adjustment Lever (LH side)

2. Wrist Rest Height (RH Side, Front)
3. Arm Rest Height (RH Side, middle location)
and angle (RH Side, Rear)

966H Wheel Loaders

Operator Station

11
7
6
1

12

10
9
8

2
3

Standard with E/H, in-cab programmable kick-outs,

located in the upper right panel, provide more flexibility
and improve productivity when the job requires load and
dump target heights.

13
4

Transmission Downshift
2. Aggregate Autodig trigger switch (optional)
3. Horn button
4. Forward/Neutral/Reverse toggle switch
(optional)
5. Bucket/Work Tool tilt lever
6. Bucket/Work Tool lift lever
7. 3rd Valve Hydraulics lever (optional)
8. Instructions: Do not oil the control levers.
9. Instructions: Do not grease the control levers
10. Read manual before operating
11. Lock-out switch when engaged,
disables the bucket/work tool levers.
12 Fine modulation allows for better
control in certain applications
13. Optional Joystick replaces tilt & lift levers and
incorporates the horn. Not shown, a
transmission downshift switch is located on the
joystick trigger.

1.

1. Tilt Kickout Adjustment:

To set, position the bucket/work tool at the
desired tilt angle with the lift arms to the desired
working level; press the rocker switch to the
bottom position for 1 second.
2. Lift and Return-To-Dig Kickout Adjustment:
To set the lift (top) kick-out: position the lift
arms at the desired height and press the
rocker switch to the upper position for 1
second. The lift arms must be above the
middle of the lift range to set the lift kick-out.
To set the Return-To-Dig kick-out: position
the lift arms at the desired position and press
the rocker switch to the upper position for 1
second. The lift arms must be below the
middle of the lift range to set the Return-ToDig kick-out.

966H Wheel Loaders

Operator Station

Steering Controls
As with the 966G II, the 966H offers both Conventional
Steering Wheel (standard) and Command Control Steering
(arrangment). With the availability of these two offerings,
customers can order their 966H to better fit their operator
and application.
Command Control Steering
CCS is a pilot operated, load sensing steering system that
links the steering wheel and frame angle positions to
provide the proper amount of steering control. The speed
in which the machine turns is proportional to the steering
wheel position. With CCS, full machine articulation can
be accomplished with a plus/minus 70 wheel rotation,
requiring less than 26 N (6 lb) of steering effort regardless
of conditions. This system provides precise control, quick
response and reduced operator efforts in any application,
soldifying the 966Hs position as being the easiest wheel
loader to operate in its class.
The CCS steering wheel's semicircular shape provides
excellent visibility to the front dash and gauges. The wheel
includes the left hand steering grip, with integrated
transmission shift controls. This steering grip provides
improved ergonomics and precise steering control. For
maximum comfort and control, a tilting and telescoping
steering column adjusts to match personal preferences. It is
easily moved to a nearly vertical position for easy cab
entry and exit.

The CCS steering column adjustments and the integrated

transmission controls are shown below:

1. CCS telescope adjustment lever

2. CCS column tilt adjustment control
3. Forward / Neutral / Reverse rocker
toggle switch
4. Up-shift / down-shift rocker control
Note: Once the CCS column is positioned, test the
position by turning the wheel fully left and right. A good
steering column and seat adjustment combination will
allow you to turn the steering wheel without leaning
forward on the seat.

966H Wheel Loaders

Operator Station
The conventional steering tilt steering column adjustments
and the integrated transmission controls are shown below:

Conventional Steering Wheel

With the standard steering wheel configuration, Cat offers
a low effort hand metering unit hydraulic steering system.
Load sensing steering directs power through the steering
system only when needed. When not steering, more
engine power is available to generate rimpull, breakout
force, lift force, and ultimately reduced fuel consumption.
With a standard hand-grip feature, the steering column can
be tilted to maximum operator comfort.

1. Conventional Steering Tilt Adjustment Control

2. The transmission is controlled by the shift lever
(2) that is located on left side of the steering
column.
For up-shift/down-shift rotate the knob on the
end of the shift lever forward or backwards
For directional shifts, move the lever away from
the operator (forward), toward the operator
(reverse), and middle (neutral).

966H Wheel Loaders

Operator Station

Front Dash Panel. The front dash panel is conveniently

laid out for easy operation. Following are the features of
the front dash:

1. Tachometer
2. Speedometer & Gear
Indicator
3. Coolant Temperature
Gauge
4. Transmission Oil Temp
Gauge
5. Hydraulic Oil Temp Gauge
6. Fuel Tank Gauge
7. Left Warning & Indicators
8. Right Warning &
Indicators
9. Cigar Lighter (12 Volt)
10. Flood Lamp (attachment)
11. Blank

10

12. Lighting Switch 4

Position (left to right): Off,
Parking Lights, Roading
Lights Front only (attach),
Roading Lights Front &
Rear (attach)
13. Parking Brake Handle
14. Radio (attachment)
15. Rotating Beacon
(attachment)
16. Hazard Switch
(attachment)
17. 12V Power Port
18. Electronic Technician
(E.T.)
Connector
19. Key/Engine Start Switch

Warning/Indicator LED's. The front dash panel contains 20

different warning and/or indictor LED's for easy machine
operation and problem detection. The following are the
locations, descriptions, and symbols for these LED's:

1. Directional Signals ON (attachment)

2. Hazard Lights ON (attachment)
3. Parking Brake ON
4. Transmission Override (attachment)
5. Neutralizer Override/Disable ON
6. Fuel Level LOW
7. Engine Air Filter Restricted
8. Flood Lamp ON
9. Fuel Pressure Indicator HIGH/LOW
10. Roading Lights ON
11. Master Action Lamp Indicator
12. Machine Security System ON (attachment)
13. Ride Control ON (attachment)
14. Ether Aid ON
15. Blank
16. High Beam ON
17. Transmission Oil Filter Restricted
18. Autodig Pile Detect ON (attachment)
19. Autodig Operator Trigger ON (attachment)
20. Autodig Record ON (attachment)

966H Wheel Loaders

Operator Station
To Upper Right Control Panel.. As with the 966G II, many
of the operator controls are conveniently integrated into the
upper right control panel for easy access and readability.
The following describes the type of controls and location
of these upper right panel features:

1. Electronic Monitoring System

2. Display Monitor Selector
3. HVAC Selector Switch (att)
4. HVAC Fan Speed Control (att)
5. HVAC Temperature Control (att)
6. Windshield Wiper (front)
7. Windshield Wiper (rear)
8. Variable Shift Control
9. Transmission Mode Selection
10. Ride Control Switch (att)

11. Neutralizer Override Switch

12. Secondary Steering Test (att)
13. Blank
14. Heated Mirrors (att)
15. Autodig Selection (att)
16. Autodig Mode (att)
17. Autodig Kickout (att)
18. Blank
19. Quick Coupler (att)
20. Lift / Tilt Kickout

Conventional Steering
Transmission
Controls. As with the
966G II, the
transmission is
controlled by the shift
lever located on the
left side of the steering column. To up-shift/downshift, the
operator rotates the knob on the end of the shift lever
forward or backwards. For directional shifts, the operator
moves the lever towards the bucket from for forward,
toward the seat for reverse and in the middle for neutral.

CCS Transmission
Controls. As with the
966G II, transmission
controls are integrated
into the left hand
steering grip on the CCS
wheel. With CCS and
its +/- 70 steering
feature, the operator can
keep one hand on the transmission controls in all steering
positions. The operator selects forward, neutral or reverse
with a three-position rocker switch mounted on the
forward face of the steering grip. The grip rotates on the
wheel, like a spinner knob, to maintain an optimum control
angle for the operator, in turn providing a smooth, constant
steering effort.

966H Wheel Loaders

11

Operator Station

Transmission
Mode with
Conventional
Steering
Wheel.
With the
conventional
steering wheel,
the
Transmission
Mode switch
is conveniently located in the upper right panel, and
replaces a traditional lever on the steering column.
1. Manual mode:
When the switch is positioned on the hand symbol, the
operator is required to up-shift and down-shift manually.
2. Automatic mode:
The number (4, 3, 2) indicates the highest gear the machine
will up-shift.
Modes 1-4 or 2-4 represent the highest gear in which the
machine will automatically shift. The maximum gear is
delected by rotating the transmission speed selector to the
appropriate gear with in that range.

12

Transmission Mode
with Command Control
Steering.
On CCS, the
Transmission Mode
switch is conveniently
located in the upper
right panel, and
replaces a traditional
lever on the steering
column. For transmission shifting, the operator has a
choice of manual or automatic shift modes.
1. Manual mode:
When the switch is positioned on the hand symbol, the
operator is required to upshift and down-shift
manually. Manual shifting is controlled by thumb
operated up-shift and downshift buttons, located on
the rear face of the steering grip.
2. Automatic mode:
The number (4, 3, 2) indicates the highest gear to which
the machine will up-shift.
3. Fully - Automatic mode:
When the switch is positioned on "1-4" symbol, the
machine will upshift and down shift through all 4 gears,
forward and reverse, at factory pre-set shift points.

966H Wheel Loaders

Operator Station
Transmission Neutralizer Override Switch. Like the 966G
II, the transmission neutralizer override switch on the
966H is a momentary switch, located in the upper right
control panel. Pressing the upper position of the toggle
switch will activate the override. With this selection, the
left pedal will not neutralize (disengage) the transmission,
but will function only as a service brake, in conjunction
with the transmission downshift function. (See the
Integrated Braking System functional description in the
Power Train section for more detail.) The normal, default
position of the switch is the lower (released) position.
Upon engine start-up, the neutralizer will default to the
active position. Note: The transmission neutralizer switch
defaults to the on position. This is the correct setting for
nearly all applications. Turning it off can adversely affect
brake life.

Ride Control. Available as an option on

both the 966G II and 966H, ride control can improve an
operator's performance and machine control. A nitrogen oil
accumulator in the hydraulic lift circuit acts as a shock
absorber, dampening forces from the bucket. 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.

Ride Control
System Accumulator

966H Wheel Loaders

13

Operator Station
Ride Control. By using a switch located in the upper
right panel of the cab, an operator can choose between
three modes:
A. AUTOMATIC:
In the top position, ride control will
automatically activate if the ground speed
exceeds 9.7 km/h (6 mph). When speed
decreases below 9.7 km/h (6 mph), the system
will automatically deactivate. When deactivated,
automatic mode offers a rigid hydraulic
system for the lift arms to provide more
efficient loading and lifting. The system will
also deactivate if the bucket is operated. The
speed that ride control activates/deactivates
can be adjusted by a qualified Caterpillar
service technician utilizing Electronic
Technician (ET).

Payload Control System. An optional feature available as

a factory or dealer installed attachment on both the 966G
II and the 966H, Payload Control System (PCS) provides
on-the-go weighing and tracking of material. The PCS
display and keypad are mounted within easy operator
reach and out of the forward line of sight, just below the
upper control console. PCS offers easy calibration and
accuracy within 1 to 1 % when following recommended
weighing procedure. PCS provides additional features,
including material flow management, which enables
tracking of the type and quantity of materials loaded by
individual trucks.

B. OFF:
In the middle position, ride control is
deactivated.
C. ON:
In the bottom position, ride control is
activated for all ground speeds. This is used
as a service mode. 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 and poor pile
penetration.

14

PCS stores operating data for later download and retrieval

with a personal computer. There are twelve different
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, weight and number of passes
Material identification
Up to 21 different materials
Truck identification numbers (up to five
digits)
Up to 2,639 truck loads

966H Wheel Loaders

Operator Station
Electronic Monitoring System (EMS). As with the 980GII,
the 966H is equipped standard with EMS. EMS
continuously monitors critical machine systems and
provides the operator with four warning categories,
depending on the severity of the situation. The picture
below shows the features of the EMS display panel,
conveniently located in the upper right control panel of the
cab for easy visibility and identification:

1.
2.
3.
4.
5.
6.

Monitor Display Switch

Engine Oil Pressure -Low
Parking Brake -Engaged
Brake Oil Pressure -Low
Electrical System -Malfunction
Axle Oil Temperature -High

7. Hydraulic Oil Filter - Plugged

8. Hydraulic Oil Level -Low
9. Engine Air Inlet Temp. -High
10. Primary Steering Oil Press -Low
11. Secondary Strg. Oil Press -Low (att)
12. Monitor Display Window

The EMS display contains 10 alert indicators and a digital

display window. A switch is used to scroll between
different categories in the display window. Front dash
mounted gauges and display modules provide system
performance information to the operator.

A. Self-Test
Upon start-up (when the key switch is turned from off to on), the
monitoring system will perform an automatic internal self-test.
This test will verify proper operation of the outputs (displays,
indicator lamps and audible alarms). The operator must observe
the outputs in order to determine whether the displays are
operating properly. The test lasts approximately three seconds.
During the test, all alert indicators flash and the display unit will
show some information as well. The tachometer and gauge
needles will all ramp straight up, then go to the right and to the
left most extreme positions before settling in normal mode.
Other indicators the operator will notice during this test cycle
include an asterisk in the gear/direction readout, 303 km/h (188
mph) in the speedometer readout, the indicator lamp is on and an
audible alarm will sound once.
B. Category 1 Warning
The first category of warning is designed only to make the
operator aware of a machine condition by having the alert
indicator flash. The warning identifies a system in need of
operator attention. This can include mechanical malfunction or
performance parameters where the operator may need to alter
his/her technique. Examples include high or low electrical
voltage, high axle oil temperature, engine over-speed or a fault in
the secondary steering system.

966H Wheel Loaders

15

Operator Station
C. Category 2 Warning
Category 2 warnings require a change in machine operation to
reduce excessive temperature in one or more systems. Examples
of these warnings are excessive engine coolant temperature,
excessive transmission temperature or excessive hydraulic oil
temperature.

Cab Convenience Features - Overview. The attention to

detail is evident in the cab where numerous features
enhance operator comfort and machine productivity. The
following highlights some of those features:

D. Category 2-S Warning

When a Category 2-S warning occurs, a constant alarm will
sound. This warning level indicates a severe condition in one or
more of the systems included in Category 2. Immediate
corrective action is needed to prevent damage to the machine.
E. Category 3 Warning
In the event of a Category 3 warning, the alert indicator and the
action light will flash and the action alarm will sound. Category
3 faults require that the operator immediately shutdown the
machine to prevent damage to a system and/or the entire
machine. The machine must not be operated until the
malfunction has been corrected. Category 3 faults include low
engine oil pressure, an engaged parking brake when the
transmission is not in neutral, low brake oil pressure, low
steering oil pressure, low hydraulic oil pressure or oil level and
serious electrical malfunctions. The fault code display located
in the lower portion of the alert display provides information.

16

966H Wheel Loaders

In addition to standard air conditioning, a

heater/defroster provides for comfort in cold,
humid conditions.
A 12-volt cigar/cigarette lighter is provided,
along with a 12-volt accessory power outlet.
The steering column features both tilt and
telescoping functions.
The bucket control module has three different
adjustment modes.
Standard six way adjustable C500 comfort seat
A storage area holds a lunch box and/or other
items. A beverage holder is also placed within
easy reach.
Two hooks with straps provide convenient
storage locations for items such as coats and
hats.
There are right and left side sliding windows for
controlled cross ventilation.

Engine

Engine
The Caterpillar C11 is an 11.1 Litre, displacement, in-line,
6 cylinder engine which is electronically governed using
the Cat ADEM A4 controller. Electronic fuel injection is
through the Caterpillar designed, mechanically actuated,
electronic fuel injection system (MEUI). The C11 uses
ACERT Technology, a series of Caterpillar engineered
innovations, which provides advanced electronic control,
precision fuel delivery and refined air management for
outstanding engine performance and certified emissions
compliance. The 966Hs waste gate turbo charger is
equipped with a titanium wheel that provides better wear at
higher speeds. Turbocharging combined with air-to-air
aftercooling (ATAAC) provide consistent, high horsepower
with increased altitude capability.

A4:E4V2 Electronic Controller. The engine is governed by

an electronic control module designated the A4:E4V2.
This 32 bit computer continually adjusts engine output
based on load demand. The adjustments are completed
through a series of sensors located on the machine and
engine.
Mechanical Electric Unit Injectors(MEUI). The C11
features the Mechanically Actuated Electronic Unit
Injector (MEUI) fuel delivery system. MEUI facilitates
the more sophisticated fuel injection delivery of ACERT
Technology and is comprised of four major components:
injectors, low pressure fuel transfer pump, sensors and
electronic control. It is a system that has been at work in
Cat engines for millions of miles, and has a proven track
record of consistent, reliable performance.
Constant Net Horsepower. The 966Hs C11 is
electronically configured to provide constant net
horsepower throughout the operating range. Constant net
horsepower automatically compensates for parasitic loads
(like the on-demand cooling fan), allowing operators to
maintain a constant level of productivity regardless of
parasitic loads.

966H Wheel Loaders

17

Engine
Engine Block & Pistons. The C11 is a popular engine in
the on-highway truck market with millions of miles to its
credit, and a history of reliability and durability. As a
testament to the C11s robust design, only slight changes
have been made to the C11 in order to allow for higher
peak cylinder pressures. Some of the most noteworthy
changes have been made to the block. The block is a gray,
cast iron design with the material upgraded to the same
iron used in cylinder heads. Its metallurgy has been made
stronger in order to manage the greater stresses associated
with elevated peak cylinder pressures. In addition to the
metallurgy changes, wall diameters have been made thicker
while design adjustments have been incorporated to reduce
sound levels and increase rigidity. Also new on the block
are straight-thread, o-ring ports (STOR) which replace the
pipe thread ports used previously. This leak-free
technology minimizes the loss of engine oil and other
fluids inherent with the higher internal pressures realized
with ACERT Technology. All paper gaskets have been
replaced with press in place seals, and the head gasket is
now comprised of layered steel. The C11 features onepiece, all steel pistons. The new pistons are housed within
a wet, replaceable cast iron cylinder liner constructed of
high-strength, heat-treated castings. These new pistons
offer longer life in the higher peak cylinder pressures.
Connecting rods have been made larger in diameter and are
connected to the crankshaft using two bolts.
Cylinder Head. The cylinder head is a one-piece design
that has been improved to incorporate a cross flow air
design as opposed to the uni-flow design of previous
models. Cross flow facilitates air movement, allowing the
engine to breath cleaner, cooler air with less effort. As
with other engine components, the cylinder head has been
made thicker to account for increased cylinder pressures
realized through ACERT Technology.
ACERT Technology.
Cat engines are exceeding performance and emission
targets with the help of ACERT Technology. ACERT
Technology builds on the decades of Caterpillar experience
in diesel engine design and manufacturing.
ACERT Technology is a series of Caterpillar innovations
that work at the point of combustion to optimize engine
performance. It is sometimes easier to think of ACERT as
a series of building blocks or tools used by Caterpillar to
optimize engine performance while meeting U.S. EPA Tier
18

3 and European Union Stage 111a

regulations. The four building
blocks of ACERT are:
Fuel Delivery
Electronic Control
Air Management
After Treatment
Off-road applications only require three of these building
blocks to meet engine performance targets and emissions
compliance. The three building blocks incorporated in the
C11 are fuel delivery through MEUI, Electronic control,
and air management through cross flow design and
turbocharging. After treatment, the fourth building block,
is not needed for off-road applications at this time.
ACERT Technology has been proving itself in on-highway
trucks since March of 2003. ACERT is technology that
allows Cat engines to meet durability and reliability
expectations without sacrificing performance. Competitive
technologies, like exhaust gas recirculation (EGR),
reintroduce corrosive exhaust gases back into the
combustion chamber, leaving too many questions
unanswered about engine life and shortened service
intervals. Instead, Caterpillar chose a path of research and
development on its existing technologies to arrive at a
solution that uses fuel mapping, electronic control and
multiple injection fuel delivery to manage emissions. The
result is an engine with technology that positions
Caterpillar to meet future
emission regulations.

ACERT Technology (Fuel

Delivery). One of the
breakthroughs of ACERT
Technology is the concept of
multiple injection fuel delivery. This process involves a
high degree of precision as the combustion process grows
in complexity due to changing engine speeds and load
demands. One key benefit of multiple injection technology
is lower combustion chamber temperatures which in turn
generate fewer emissions. By precisely shaping the
combustion cycle, Caterpillar is optimizing thorough
combustion of the fuel, further reducing emissions output
while giving customers more work for their fuel expense.

966H Wheel Loaders

Engine

ACERT Technology (Electronic

Control). Caterpillar has been
electronically controlling its engines
since the mid 1980s. The
culmination of this pioneering spirit
is the ADEM A4 controller. ADEM
A4 is a 32 bit computer that uses
sensors located throughout the
engine to regulate fuel delivery and all other engine
systems that require input to manage load and
performance. ADEM A4 is the muscle behind engine
responsiveness, self-diagnosis, controlling emissions and
fuel economy.
ACERT Technology (Air Management). Air management is
a key concept in optimizing engine performance and
controlling emissions. Engines must breath clean, cool air
in order to perform. The new cross flow design
incorporated in the cylinder head facilitates air movement,
while tighter tolerances between the piston and cylinder
liner reduce blow by gases. The C11s waste gate turbo
charging helps ensure that the right amount of compressed
air is being introduced into the combustion chamber.

Engine Idle Management.

Caterpillars Engine
Idle Management
System (EIMS) was
designed to maximize
fuel efficiency and
allow customers
flexibility in
managing idle speeds
given specific
application
requirements. EIMS
comes with four idle
control settings:
hibernate, work, low voltage and warm-up.

Hibernate Mode:
Engaged when the transmission is in neutral, the
parking brake is set, throttle pedal is depressed 5%
or less and fan current is greater than .8 amps.
Once these conditions have been met and 10 seconds
have elapsed, engine idle will drop to the
programmed low idle speed of 600 rpm
(factory setting)
Hibernate low idle speeds can be set between 600
and 950 through Electronic Technician.
Work Mode:
Allows flexibility in setting the working idle
speed according to the customers preference and
application requirements
Factory setting is 800 rpm
Working idle speeds can be programmed between 650
to 1000 rpms
Warm Up Mode:
This mode is Enabled & Disabled in transmission
configuration screen with ET (factory fault is
disabled).
Engaged when the transmission is in neutral, the
parking brake is set and throttle pedal is depressed 5%
or less.
Once these conditions are met and 10 minutes have
elapsed, the engine software will monitor
coolant and
inlet manifold temperature.
Idle speed will increase to 1100 rpm once coolant
temperature drops below 70 degrees C and inlet
manifold temperature is less than 5 degrees C.
Once the coolant temperature reaches 80 degrees C
and inlet manifold temperature is above 15 degrees C,
the idle speed will return to normal.
Low Voltage Mode:
Engaged when the transmission is in neutral, the
parking brake is set and the throttle pedal is
depressed 5% or less.
Once these conditions are met and 5 minutes elapse,
the engine software will monitor battery voltage.
As the battery drops below 24.5 volts, the engine s
speed will ramp up to 1100 rpm until the battery is
charged. Once the battery reaches 24.5 volts, engine
idle speed will return to normal

966H Wheel Loaders

19

Cooling System

Cooling System.
The 966H is equipped with an electronically controlled,
hydraulically driven, on demand fan cooling system. The
system offers numerous benefits, including lower 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 (4.9mm (.2 in)). 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.

20

Fan Speed.
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 inlet manifold temperature and
hydraulic sump temperatures. This consistent monitoring
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 (1200 rpm) is limited to a
speed set by the variable displacement piston pumps
pressure compensator. The fans minimum speed (500
rpm) is controlled by the flow compensator on the variable
hydraulic pump. The fan pump is sized to provide required
oil flow to achieve maximum fan speed at or above an
engine speed of 1560 rpm. 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.

966H Wheel Loaders

Cooling System

Separate System.
The cooling system is isolated from the engine
compartment by a non-metallic shield. A hydraulically
driven, variable speed fan draws air in from the rear of the
machine, through the cooling system and exhaustit out the
sides and top of the hood. This flow provides cleaner and
cooler air than what can be drawn through the engine
compartment. In addition, this airflow pattern, combined
with the variable speed fan, reduces the amount of air
needed to pass through the system. The end results are
faster machine warm up in cold weather, increased fuel
efficiency, less radiator plugging and lower sound levels.
The shield also serves as a sound barrier and helps reduce
operator sound levels.

Access.
The reverse flow cooling package also provides excellent
access for service. A new corrugated and perforated swing
out rear grill will minimize entry of debris into the cooling
cores while providing easy access to the hydraulic oil
cooler and air conditioner condensers. These cores swing
out for easy cleaning and also allow access to the rear face
of the radiator and Air-to-Air Aftercooler (ATAAC) cores.
Hinged side panels in the support structure provide access
to the cooling fan, front face of the radiator and ATAAC
cores for cleaning.

966H Wheel Loaders

21

Cooling System

The standard oil cooler core has 6 fins per inch and is 48
mm (1.98)thick while the high ambient attachment core
utilizes a 9 fins per inch design and is 48 (1.98) mm thick.
Serviceability.
A shunt tank located site gage provides for quick service
checks.
Auto Reversing Fan. An auto reversing fan will be available
as an attachment for the 966H. This feature is intended for
use in extreme conditions, such as recycling, waste transfer
stations and wood chip processing. Depending on operator
preference and application, the fan can be set to
automatically reverse ever 30 minutes for 30 seconds or
every 20 minutes for 12 seconds. Once the reversing takes
place, the fan will return to the normal airflow direction. A
switch in the cab provides a manual override that initiates
the purge cycle and then resets the control timer.
Unit Core Design.
The unit cores are constructed of brazed aluminum with
high strength plastic tanks and square wave design. Each
core is 4 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. An optional high ambient
aluminum core (9 fins per inch) will be available as part of
the high ambient attachment package.
Swing out air conditioning condenser and oil cooler cores
on the 966H are full width design, which provides for
more efficient airflow through the cooling package. The
air conditioner condenser has 6 fins per inch and is
constructed of steel. The 6 fins per inch allow debris to
pass through the core with less plugging, which equates to
greater up time. An optional high ambient package is
available that utilizes 9 fins per inch instead of the standard
offering of 6 fins per inch.

22

966H Wheel Loaders

Cooling System
Cooling System Specifications:
Individual Unit Cores
4 row, 6 fins per inch (FPI) construction
1180 mm tall, 650 mm wide modules
43 degrees C (110 degrees F) ambient temperature
capability
Optional High Ambient Cooling Package:
50 degrees C (122 decrees F) ambient
temperature capability
4 row, 9 fins per inch (FPI)
Suction Fan
Hydraulically driven
965.2mm (38.0 in) diameter
1200 rpm max fan speed @ 1500 through high idle
rpm
Bellmouth shroud
4.9mm (.2 in) tip clearance
Non-metallic construction

966H Wheel Loaders

23

Powertrain
Planetary Powershift Transmission
The 966H continues to use a proven, heavyduty powershift
transmission. The
transmission is comprised
of an 11 in (280 mm)
planetary drive. The
forward direction, reverse
direction as well as first
and fourth gear planetary
sections feature 4 planet
gears. The third gear
planetary features 3
planet gears. The 966H
utilizes Control Throttle
Shifting and the Electronic Clutch Pressure Control
(ECPC) system to improve shift quality as well as
component life. ECPC continuously monitors related
machine conditions and serves as a diagnostic test point.
In addition to smoother shifting, operators will realize
5.9% more rimpull in first gear and up to a 4.6% increase
in 3F travel speed.

The
transmission is
controlled by an
A4M1
electronic
control module.
The A4M1
receives input
from various
sensors located
throughout the
966H, processes
the data and then sends current to each ECPC value, in
turn, setting the required pressure. The result is very fine
clutch control as well as increased component life.

The primary benefit of ECPC is the increased level of

control enabled by using Electronic Clutch Pressure
Control solenoids. Another benefit is enhanced
serviceability resulting from all solenoid valves being
externally located, on top of the transmission housing.
With the development of ECPC valve technology, better
modulation of each individual transmission valve is
possible. This transmission uses a total of six ECPC
valves. Each valve has its own pressure port for increased
serviceability. In addition to fine modulation, Caterpillar
ECPC system provides:
Smoother shifts, both speed and directional
Less energy transferred into the clutches
Possible longer life on the rotating seals

24

966H Wheel Loaders

Powertrain
Electronic Controls. Electronic controls provide the
operator with a choice between automatic and manual
transmission shift modes.
Command Control. The manual/autoshift select switch is
located on the switch panel above and to the operators
right. In the manual position (hand), the transmission
speed selector thumb switch located on the Command
Control wheel must be used to change transmission speeds.
Rotating the auto-shift switch to the right allows the
operator to select between four different autoshift modes.
In modes four, three and two, the numbers represent the
highest gear to which the machine will automatically shift.
The 966H also features a fully automatic 1-4 mode,
designed for operations such as load and carry. Even in
automatic modes, the manual downshift button, located on
the left hand steering grip of the Command Control wheel,
can be activated when desired.
HMU (Steering Wheel). The manual/autoshift select switch
located on the switch panel above the operators right. In
the manual position (hand), the transmission speed selector
located on the direction selection lever must be used to
change transmission speeds. Rotating the auto-shift switch
to the right allows the operator to select between two
different autoshift modes. Mode 2-4 represents the highest
gear in which the machine will automatically shift. The
maximum gear is selected by rotating the transmission
speed selector to second, third or fourth gear. When the
electronic control is switched to 1-4, the machine will
automatically upshift and downshift through all four gears,
forward and reverse. As with mode 2-4, the maximum
gear is selected by rotating the transmission speed selector
to one of the three gears. Similar to machines equipped
with Command Control, the manual downshift button,
located on the right hand armrest, can be actuated when
desired.

Autoshift Select Switch

(CCS)

Variable Shift Control Switch

Variable Shift Control (VSC). Variable Shift Control is

standard on the 966H. VSC allows the operator to better
match application requirements, providing three different
transmission shifting patterns. Selection is made utilizing
a rotary switch, located in the overhead switch panel.
The left most position provides an aggressive shift pattern.
In this position, the transmission upshifts at higher engine
rpm (1900-2100 rpm), approaching high idle. This
position is suitable for dedicated truck loading or cycles
where the operator desires the most aggressive shift pattern
to address high rimpull requirements such as going up
slopes and over soft ground conditions. The middle
position allows the transmission to upshift at lower engine
rpm (1600-1800), and provides the best combination of
shift smoothness, productivity and fuel economy for most
applications. The far right position (gas pump symbol) is
the economy mode. This mode allows the transmission to
upshift at even lower engine speeds (1300 1500 rpm).
This mode is probably the best choice for application
where the operator would normally work at part throttle
and hourly productivity is not critical. In addition to lower
sound levels and smoother shifts, the economy mode can
provided improved fuel efficiency. Field testing has
demonstrated that most operators prefer this position when
performing a variety of operations due to improved
transmission shift quality and reduced sound levels.

Autoshift Select Switch

(HMU)

966H Wheel Loaders

25

Powertrain

Integrated Braking System (IBS) Integrated

Braking System (IBS) is a Caterpillar exclusive feature
developed to reduce axle oil temperatures and improve
transmission neutralizer smoothness. Improvements in
machine capabilities and modern features such as
automatic powershift transmission and Ride Control have
resulted in higher energy development during braking.
This higher energy is converted to heat, which is
detrimental to brake disc, oil and axle life. In the past, the
most common method employed by wheel loader
manufactures to dissipate this heat load has been through
the use of axle oil coolers (AOC).
IBS Operation. With IBS, the first few degrees of
neutralization pedal travel initiate a transmission
downshift, which passes some of the breaking energy to
the torque converter in turn increasing power train drag and
retarding the machine. This transfer of energy greatly
reduces axle oil temperatures. Further depressing the left
pedal begins to pressurize the service brakes, continues
transmission downshifting, and eventually neutralizes the
transmission once 2nd or 1st gear is achieved. The
transmission will downshift to second gear for all autoshift modes, except in the 1-4 transmission mode, where
the machine will downshift to first gear.

26

Pressurization/Neutralization. IBS also improves control

of the overlap between brake system pressurization and
neutralization, which results in smoother disengagement
and reengagement of the transmission clutches. This
overlap is intuitive to the operator through the use of the
left pedal. If the operator prefers a different brake overlap
than the standard factory setting, a Caterpillar technician
can easily and accurately change the setting.
IBS - Neutralization/Re-engagement IBS also provides the
capability to stop the machine on a slope, neutralize the
transmission and re-engage the transmission with no
unwanted machine movement. This is accomplished by
depressing the left brake pedal beyond the neutralization
set point to apply full machine service brake holding
capability, and then releasing the left pedal 4 degrees,
waiting 1 second to allow the transmission clutches to fill,
and increasing engine speed while releasing the service
brake pedal fully.
IBS Axle Oil Coolers (AOC). AOC have a significant
impact on machine cost. While AOC can be very effective
in reducing operating cost through longer axle and brake
life, they are costly to purchase or add in the field. IBS,
standard on all 966H loaders, reduces the need for AOC in
all but the most severe applications by integrating the left
brake/neutralizer control pedal with other machine
systems, greatly improving energy management.

966H Wheel Loaders

Powertrain

Axles. The 966GII four piece axle design has been

maintained for the 966H. Designed to last in all operating
conditions, each axle contains two axle shaft housings, the
center housing and the intermediate housing. The front
axle is rigidly mounted to the front frame. It provides the
structure to support the weight of the wheel loader, internal
torque loads and external loads applied during breakout
force. The rear axle includes a trunnion, two trunnion
supports and the associated bearings that allow oscillation
of plus or minus 13 degrees. This allows all four wheels to
remain on the ground over uneven terrain, which in turn
equates to excellent stability and traction. Rotating axle
components are designed for the high loads encountered in
the demanding applications the 966H typically performs.
Use of ride control and autoshift in load and carry
applications often result in higher speed operation where
brake actuation can be severe. Serviceability has not been
compromised with the launch of the H Series as
reassembly and disassembly of the brakes and duo-cone
seals will remain the same as that of the GII. Extreme
service axles are available for aggressive applications.

Differentials and Bevel Gears. The differential and bevel

gear groups used in the 966H are the same as those used in
the 966GII.
Differential Choices. The 966H is available with either
conventional (Open), limited slip (LSD) or no-spin (NS)
differentials.
Conventional (Open) Differentials. Application Range
Good and dry underfoot conditions.
Advantages:
No steering or tracking interference
No tire scuffing/wear
Lowest initial cost and operating cost
Disadvantages:
None in dry, firm underfoot conditions
Wheel slip and loss of traction in slippery or poor
underfoot conditions
Limited Slip Differentials. Application Range Optimum 4
wheel drive in good or poor underfoot conditions
Advantages:
Provides more tractive effort, in adverse
conditions, than an open style differential
Disadvantage:
Maneuverability is diminished in slippery
conditions, but still has better traction than
the open differentials
Tire scuffing and plowing

966H Wheel Loaders

27

Powertrain
No Spin (NS) Differentials Rear Only. Application Range
Mainly used in uphill load and carry applications
Advantages:
Provides improved tractive effort in poor
underfoot conditions
Disadvantages:
Maneuverability is less than that realized
through the use of a rear LSD differential
Tire scuffing and plowing

Driveline
The driveline consists of three driveshafts one to the rear
axle, one through the hitch to the midship bearing and one
from the midship bearing to the front axle. All five
universal joints are permanently lubricated while triple lip
seals keep grease in and dirt out. The only points requiring
lubrication are the midship bearing and the slip joint on the
driveshaft. The midship bearing is a spherical roller
bearing.

An external core style axle oil cooler (AOC) is

available as a factory installed attachment for the
966H. 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.
This factory available option provides pre-drilled and
tapped axle housings, along with pre-routed internal
steel lines, which are required for internal oil transfer.
The AOC ready package greatly reduces the time and
expense of field installing an axle oil cooler kit.

External Axle Oil Cooler

28

966H Wheel Loaders

Powertrain

Brakes
Braking can occur using either of the cab floormounted pedals. 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. With the
introduction of the 966H, brakes are now charged on
demand through a load sensing pump compared to the
fixed displacement pump used on the 966GII. This
improvement should equate to greater fuel savings and
lower owning and operating costs.

Parking Brake. The parking brake is mounted on the

machine driveshaft and can be manually applied by the
operator. It is a spring-applied, oil released, dry drum
brake. The 966H 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 to first gear.
Brake Wear Indicators. See information in
serviceability section.

966H Wheel Loaders

29

Powertrain
Free Wheel Stator
A free wheel stator 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 966H features a

Free Wheel Stator Torque Converter (FWSTC). A FWSTC
improves machine power train efficiency in certain
applications and contributes to the improved fuel efficiency
of the 966H. 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.

30

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.

966H Wheel Loaders

Powertrain

How 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. 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 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.

Free Wheel Stator Benefits. The graph represents the

efficiency of a fixed stator torque converter relative to an
equivalent converter with a free wheel stator. When the
turbine/impeller speed ratio of the two converter types is
below .85, they perform virtually the same. The benefit of
a free wheel stator is realized through reducing drag in the
torque converter. This reduction in drag results in
increased fuel efficiency.

966H Wheel Loaders

31

Powertrain
Bridgestone/Firestone:
26.5-25 20PR SRG FS L3
26.5 R25 * VMT BS L3
Continential:
26.5R25 * CN L3
26.5R25 * CN L3
Goodyear:
26.5-25 20PR SHRL GY L3
26.5 R25 * RT3B GY L3
Michelin:
26.5 R25 * XHA MX L3
750/65 R25 * MX L3
26.5 R25 * MINED2 MX L5

The 966H can also be ordered less tires or less tires and
rims.

Rims and Tires. The 966H utilizes a 25 in (635 mm) threepiece rim featuring 20 M24 fasteners (bolts) to attach each
to the axle. Several bias & radial tire options are available
from Bridgestone / Firestone, Goodyear and Michelin,
offering tread types for a wide range of conditions and
applications. Bias ply tires are preferable in truck loading
applications where short runs keep heat build-up low.
Radial tires are especially suited for load and carry
applications where machines cover longer distances and
travel at higher speeds. The basic tread type is an L-3 rock
tire with good traction and adhesion. The 966H can also
be fitted with L-4 or L-5 tread -type tires for more severe
conditions where additional resistance to cuts is necessary.

Price List Tire Offerings.

32

966H Wheel Loaders

Structures

Structures. The 966H retains the same basic structures as

used on the 966GII. Minor changes have been made to
accommodate powertrain, cooling and hydraulic system
mountings. The articulated frame design features a durable
box section engine frame and rigid four-plate loader tower.
Over 80 percent robotically welded, frame joints feature
welds with deep plate penetration and excellent fusion for
maximum durability and fatigue strength.

Spread Hitch Design. 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. The lower hitch plate on the engine frame is
constructed with a 2 in (50 mm) thick plate. This provides
excellent frame rigidity, which contributes to high product
quality.

Engine End Frame(EEF). The 966H utilizes 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, ROPs and other accessories.

966H Wheel Loaders

33

Structures

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. The picture window plate, located in the
front of the tower, is 1 in (25 mm) thick, producing
minimum yield strength of 42,000 psi (290 MPa).

34

Counterweight. The 966H uses a one-piece counterweight

that is integrated into the machines design and styling. The
rear bumper counterweight has been redesigned to
incorporate the rear lights into the top of the structure. Two
counterweight packages are available for the 966H. The
standard counterweight package weighs 2517 lbs (1142 kg)
while the heavy duty counterweight used in logging and
highlift arrangements weighs 5849 lbs (2653 kg).

966H Wheel Loaders

Linkage

Linkage. The 966H linkage is a single tilt Z bar design.

Two versions of this linkage are available, standard and
high lift. The standard linkage is designed with a
maximum B-pin height of 166.6 in (4.23 m) while the
high lift version has 22 in (0.56 m) more dump
clearance. This extra clearance allows the 966H to
solidly perform in a number of unique applications.

Bucket Positioner. The 966H uses a rotary sensor,

mounted on the right side of the linkage cross tube,
which measures the angular change between the tilt lever
and the linkage cross tube. The operator can adjust the
bucket positioner electronically from within the cab. A
guard covering the sensor protects it from damage by
material falling over the rear of the bucket.

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 is heat-treated for
maximum resistance to torsion and impact loads. Z bar
linkage generates excellent breakout forces and good
rack back angle for better bucket loading and material
retention.

966H Wheel Loaders

35

Hydraulics

NEW Load Sensing Hydraulic System

New with the 966H is a closed center, load sensing,
hydraulic implement system. This replaces the open
center, fixed displacement system used by the 966G II.
With Caterpillars new load sensing system, the operator
will realize more controllability with less effort, resulting
in a more productive and fuel efficient loader.
Benefits of the New Load Sensing System. The driver
behind the new load sensing system is to produce flow and
pressure for the implements only upon demand, and only
in amounts necessary to perform the needed work
functions. The result is a system that wastes little energy,
in turn, making it more productive and fuel-efficient.
Another benefit of a load sensing system is improved
implement controllability through simultaneous operation
and repeatable fine modulation. This allows for greater
operator comfort through ease of operation. From a
performance standpoint, with the new load sensing
implement system, operators will realize more rimpull into
the pile and will see a lift force increase of approximately
20%.
System
Description. The
hydraulic
implement system
consists of the
hydraulic
reservoir, pump,
valves, and
cylinders to
control the bucket
lift/lower and
dump/rack
functions as well as standard attachments such as auxiliary
3rd & 4th functions and ride control. The hydraulic
implement circuit will be controlled via an electronic
fingertip controls that interfaces with an electronic control
module.

36

The hydraulic implement system will use a variable

displacement piston-type pump that is load sensing and
pressure compensated. A load-sensing pump generates
flow proportionate to the implement speed (e.g. lift/tilt
cylinder velocity) instead of engine speed, unlike a fixed
displacement pump found in the 966G II. Therefore,
regardless of the engine speed, the load-sensing pump will
generate just enough flow to meet the application needs
and not any more. Flow from the hydraulic pump will be
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, the implement control valve will direct pump oil
to one or more loader functions, simultaneously by shifting
the spool valve through proportional solenoids. The M3PC
implement valve operates on PPPC (proportional priority
pressure compensated) principle and uses the pressure
compensator between the main spool and the actuator
ports. All the pressure compensators of individual circuits
involved are interconnected and operate with the same
pressure differential. 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 actuator 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.

966H Wheel Loaders

Hydraulics

Major Features to
the System (NEW!
Implement Valve).
The M3PC Priority
Proportional Pressure
Compensation Valve
is new to the Cat
Valve line up. The
M3PC is a sectional
designed valve,
which can be
configured from two
to nine 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, can be incorporated into the valve allowing a
reduction in the number of hydraulic lines within the
system. Integration of function reduces the need for addon valve while improving response. Two major benefits to
the new valve are its ability to assign priority to one
function over another and proportionality, where operators
can work both lift and tilt at the same time.
Relocated Hydraulic Tank. The hydraulic tank has now
been moved behind the cab to a location higher than the
implement pump. With the new location, pump flow to
and from the tank is improved, eliminating cavitation
issues and improving pump life.
High Efficiency Filtration. Rich getting information Sent
an email to Art
Heavy Duty Piston Pump. The heavy duty pump is part of
a two pump system, with one dedicated for the hydraulic
system and one to the steering system. This ensures the
operator has full flow for both steering and implement
control without potential flow sharing issues.

Electro Hydraulic
(EH) Bucket
Controls. The EH
bucket controls have
been improved over
the 966GII and
include a new
feature called soft
detents. This
means the lever
returns to the center
position after a
detent is actuated
rather than being
held in the full
travel position by a magnet.
How do soft detents work? 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. (Note the detent
will not be activated if the lever is held in the detent
positions for more than one second.) If the operator was to
manually override the detent (and prevent the work tool
from traveling automatically to the kick-out position), the
lever must be moved at least six degrees from the center
position.
NOTE: Optional joystick implement control also has soft
detents and will function in a similar manner. However,
the optional joystick implement controls will have the
dump and lift kick outs turned off..

966H Wheel Loaders

37

Hydraulics

Hydraulic Specifications.
Implement Pump:
Heavy duty piston type, variable displacement
Load Sensing Control Type
145cc displacement
320 L/min (85gpm) @ 10000 kPa (1450 psi)
Steering Pump:
Medium duty piston type, variable displacement
Load sensing with pressure cut-off
190 L/min (50 gpm) @ 4000 kPa (580 psi)
Fan Drive Pump:
Variable displacement, piston pump
50 L/min (13 gpm) @ 1600 rpm
Supplemental Steering Pump:
Gear type, fixed displacement
37.9 L/min (10 gpm) @ 6000 kPa (870 psi)
Implement Valve:
Priority Proportional Pressure Compensation Type
Electro Hydraulic Sectional Valve
Maximum flow to pump 320 lpm (85 gpm) @ 34500 kPa (5000 psi)

38

966H Wheel Loaders

Bucket and Work Tools

Buckets and Work Tool Controls. Choose from a variety of

Caterpillar Buckets and Work Tools to match your job
conditions.

Quick Coupler General Purpose Buckets. The 966H can

also utilize general purpose buckets with a quick coupler
arrangement. When equipped with a quick coupler, bucket
capacity can range between 4.75 yd3 (3.63 m3) and 5.50
yd (4.21 m3).
Material Handling Buckets. The 966H can also utilize
general purpose buckets with a quick coupler arrangement.
When equipped with a quick coupler, bucket capacity can
range between 4.75 yd3 (3.63 m3) and 5.50 yd (4.21 m3).

General Purpose Buckets. As the name implies, general

purpose buckets provide all around performance. They are
useful in stockpiling and rehandling applications and can
also be used for excavating and bank loading where
breakout force is required. A wedge floor design increases
floor strength to accommodate the increased breakout force
of Z-bar linkage loaders such as the 966H. General
purpose buckets accept standard Caterpillar bolt-on-cutting
edges, and base edges are pre-drilled for the GET Corner
Guard System.
Several general purpose bucket combinations are available,
ranging in capacity from 4.50 yd3 (3.44 m3) to 5.50 yd3
(4.21 m3). The capacity range is based on four basic
bucket sizes: 4.50 yd3 (3.44 m3), 4.75 yd3 (3.63 m3), 5.00
yd3 (3.82 m3) and 5.25 yd3 (4.01 m3) in combination with
various GET, segments and cutting edges.

Rock Buckets. Designed for use in face or bank loading,

rock buckets feature a high penetration spade edge for
greater impact loads and/or increased material penetration.
Added wear strips reduce the need for costly bucket
rebuilds. Rock bucket base edges are drilled to accept
bolt-on segments between adapters or a bolt-on cutting
edge. Each sidebar will accept (2) sets of protectors. One
size is available with a capacity of 4.50 yd3 (3.44 m3).

966H Wheel Loaders

39

Bucket and Work Tools

Ground Engaging Tools (GET). Several GET options are

offered by Caterpillar to suit the wide range of machine
and application needs. Selection of the correct GET is
essential for obtaining maximum performance and lowest
cost per ton operating costs. The corners of 966H buckets,
like their predecessors, incorporate a cast corner adapter
for teeth that allow the tooth to be placed on the extreme
corner for protection against wear on the base bucket.
Caterpillar continues to offer abrasion resistant material
(ARM) for GET, which helps prolong the lift of
components three to four times. This is achieved using a
special material consisting of carbide particles embedded
in a weld puddle on contact surfaces.
Heavy Duty Rock Buckets. This bucket type is
recommended for use in face loading where high abrasion
and high impacts are encountered. Caterpillar heavy duty
rock buckets deliver strength and durability while reducing
downtime and operating costs. The buckets are enhanced
with a liner, as well as inner, outer, upper and lower side
wear plates. These plates are combined with skid plates to
shield higher wear areas and add strength while holding
weight gain to a minimum. Heavy duty rock buckets are
only available with a capacity of 4.50 yd3 (3.44 m3).

In addition to the
reversible bolt-on
cutting edge, a bolton half arrow cutting
edge is also available
for 966H buckets.
This cutting edge is made from through-hardened DH-2
steel and will protect the full length of the bottom and
leading edge of the base edge from wear. This hole pattern
in the base edge permits switching the end edges to
maximize wear.

Waste Handler Buckets. Waste handling buckets are also

available through Caterpillar for use in refuse applications.
These straight edge buckets are available with a capacity of
8.50 yd3 (3.44 m3).

40

966H Wheel Loaders

Bucket and Work Tools

966H
buckets are
also
available
with the
new Cat K
Series tooth
system.
This system
features a
tip that is easier to install and has more secure retention
than the former system. Tips install with a slight twist and
are secured with a one piece vertical retainer, that is fast
and easy to install and remove, requiring no special tools.

Bucket and Attachment Specifications. The operating

specifications provide the information required to select the
correct bucket for the application. When using Full Turn
Static Tipping Load (FTSTL) to determine payloads for
each bucket, use these guidelines. For general purpose
buckets, use a stability ratio of 2.0, which equates to 50%
of FTSTL as a maximum payload. For rock buckets, use a
stability ratio of 2.3, or 43.5% of FTSTL as a maximum
payload.

966H Wheel Loaders

41

Serviceability
Serviceability
The 966H offers superior serviceability by locating routine
maintenance points in designated ground level service
centers. Ground level access to maintenance points has
several benefits: reduction of daily start-up time, helps
ensure that daily maintenance gets done, reduces operator
fatigue and the need to climb on the machine.

Ground Level Maintenance Points. Grease fittings have

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

Remote
Pressure
Taps.
Pressure
ports for the
steering and
hydraulic
systems,
transmission
and brakes
are grouped
behind a lockable access panel just below the right side
service platform. This is the same compartment that holds
four of the remote grease fittings.

42

Hydraulic Service Center.

The transmission oil and
hydraulic filters are
conveniently located behind
a swing out door just below
the right side access
platform. In addition to
making filters easily
accessible, the hydraulic oil
tank can also be drained
using a port located in the
same compartment. Each
filter carries a 500-hour
service interval, in turn, reducing operating costs and
improving productivity

Electric Service Center.

Batteries, relay panel and an
optional toolbox are
conveniently located below the left side access platform.
To the left of the battery box is the relay panel, which also
houses the engine shutdown switch. Above the relay
panel, and integrated into the platform, is a compartment
containing the hood tilt actuator switch, master switch and
optional jump-start receptacle.

966H Wheel Loaders

Serviceability

Coolant
Hydraulic

Transmission

Site Gauges. The 966H provides well protected, sight

gauges for the transmission, hydraulic oil and radiator
coolant. All are ready visible and eliminate the risk of
contaminants entering the system during daily checks.

Air Cleaner. The

966Hs air
cleaner is
accessible
underneath the
hood on the right
hand side
platform. The
new air cleaner
eliminates the
need for the
standard precleaner.

Non Metallic
Hood. A redesigned and
restyled nonmetallic hood is
used on the
966H. The side
panels have been
strengthened
through the use
of more robust
reinforcement
ribs while the
change in
contour also adds to the hoods rigidity. As with the
966GII, the H Series utilizes a single, mechanical lift
cylinder with a manual back up. Lift time to raise the
hood is approximately 48 seconds. If necessary, the entire
hood enclosure can be removed utilizing built-in lift
points.

Engine Compartment. On
the right side of the engine
compartment, the service
door provides access to the
engine oil fill and dipstick
while the coolant site gauge
can be viewed by opening
the left side service door.
Rear panels, located behind
the rear tires, can be easily
removed for improved
serviceability.

966H Wheel Loaders

Fenders. Standard front fenders

have not changed with the
introduction of the 966H while the
rear fenders have been restyled.
Full, non-metallic, rear roading
fenders now hinge at the front of
the platform and only require 60
degrees swing to fully access the
engine area, compared to 90
degrees with the 966GII.

43

Serviceability

Swing Out Grill. A new

perforated and corrugated
swing out grill will
effectively trap most
airborne debris before it
is pulled into the cooling
cores. This feature will
significantly decrease
radiator plugging and
reduce cooling system
maintenance. The air
conditioner and oil cooler
cores are easily accessible through the swing out rear grill.

Radiator Cleaning. Removable panels on either side of the

radiator support structure provide access to the front face
of the radiator and ATAAC for cleaning. Note: The
machine must be shut down prior to removal of the side
panels, and the panels must be closed before lowering the
hood.

Cooling System Cores.

Full width heat exchanger
cores and air conditioning
condenser provide more
efficient airflow without
compromising
serviceability. The cores
swing out 45 degrees to
allow for easy cleaning of
the radiator rear face.

44

Coolant. The cooling systems capacity is 12.4 gal (47 L).

The system is factory filled with a glycol/water coolant
mixture and can be switched to Caterpillar Extended Life
Coolant after 3000 hours. ELC can provide up to 6,000
hours between change intervals, but periodic checks are
still suggested.
Brake Wear
Indicators.
Axles on the
966H 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 visually
checking the position of the brake wear pin, with the
brakes applied. If the pin is visible, the service brakes do
not need to be replaced.

Ecology Drains. Axle oil ecology drains are provided as

factory installed options.

Engine Oil Change Intervals. With 500 hour intervals,

downtime is reduced so more work can be completed.

966H Wheel Loaders

Serviceability

Electronic Priming Pump & Water

Separator. An electronic fuel
priming pump located on the
primary fuel filter base reduces the
need to pre-fill or manually prime
filters after a change has occurred.
In addition, a water separator is
located on the primary fuel filter
and should be drained after every 10
hours of operation.

Caterpillar Monitoring System. The CMS provides a

wealth of machine operation and performance feedback,
along with diagnostic codes. With this information, a
technician can quickly troubleshoot problems. Remote
pressure taps provide for easy hydraulic system checks.

Autolube (Optional). The

Caterpillar designed Lincoln
Quicklube Automatic
lubrication system will be
available as a price list
attachment for the 966H. This
system incorporates a 24V
pump with an 8 liter grease
reservoir and integrated timer
that allows the customer to
program a timed interval for the
systems lubrication cycle. Once each lubrication cycle is
initiated, the pump dispenses grease under pressure
through pre-set metering valves that apply the proper
amount of grease to each lubrication point. This system
will reduce overall operating costs and improve
serviceability by providing precise lubrication of pins and
bushings while the machine is in operation.
installation.

Windshield
Cleaning
Arrangement
(Optional).
An optional
windshield
cleaning
arrangement
makes it easy
to access the
full
windshield
area. The
package
consists of one step and one platform located on the loader
front frame, and two additional handrails, one at the top of
the windshield and one at the bottom. The left front
platform handrail has been modified and the left exterior
mirror is hinged to provide easy access to the front.

966H Wheel Loaders

45

Serviceability

As such, the PL121SR can be purchased alone and

offers basic asset management capabilities. For those
machines that require additional machine health and
productivity information, the PL300 ECM can be
installed to tap into that information and pass it into the
radio for transmission back to the EquipmentManager
web application. The PL121SR radio and PL300 ECM
together make up the PL321SR.
Product Link.
Caterpillar
proudly
announces the
availability of
the Product
Link PL121SR
and PL321SR,
replacing the PL151 and PL201. These state of the art
satellite technology based products provide two-way
information flow between machine on-board systems
and Caterpillar dealers/customers through the Dealer
Storefront and EquipmentManager. An
EquipmentManager subscription is necessary to set up a
machine for data collection and to view the collected
information.

PL121SR and PL321SR Features

Service Meter Hour Updates
Equipment Location
Integration with Internet or Optional PC Mapping
Software
Product Watch Monitoring
Email / Pager Alerts
Fuel Consumption Monitoring (PL321SR)

The new Product Link PL121SR and PL321SR modules

follow a new approach as compared to the previous
models by separating the radio technology (PL121SR)
from the computing technology (PL300ECM) that
connects into the on-board electronic systems.

46

966H Wheel Loaders

Electronic Control Modules

Engine.
A4:E4V2 Electronic Controller. The engine is governed
by an electronic control module designated the A4:E4V2.
This 32 bit computer continually adjusts engine output
based on load demand. The adjustments are completed
through a series of sensors located on the machine and
engine.
Transmission.
The transmission is controlled by an A4M1 electronic
control module. The A4M1 receives input from various
sensors located throughout the 966H, processes the data
and then sends current to each ECPC value, in turn, setting
the required pressure. The result is very fine clutch control
as well as increased component life.

Electro/Hydraulics.
See under Hydraulics section page 37.
Instrumentation.
The operator interface is controlled by the EMS module.
The Electronic Monitoring System (EMS) receives inputs
from various sensors and by way of the CAT data link.
EMS contains ten LEDs, which monitor critical system
functions such as low engine pressure. The EMS panel
also drives the speedotach and quad gage panels located
within the dashboard. In addition to alerting the operator
of potential problems, EMS displays hours, distance
traveled, and fault codes. When used with a service tool,
the EMS can be used to calibrate various systems on the
966H.

966H Wheel Loaders

47

Technical Specifications
Engine

Transmission

Engine Model

Caterpillar C11 with ATAAC

Forward 1

6.7 kph

4.5 mph

Gross Power @ Rated

286 hp

195 kw

Forward 2

12.6 kph

7.8 mph

Net Power

262 hp

195 kw

Forward 3

22.1 kph

13.8 mph

Gross Peak Torque

972 ft/lb

1318 Nm

Forward 4

37.4 kph

23.4 mph

Net Torque Rise

38.4%

Reverse 1

7.4 kph

4.6 mph

Bore

5.12 in

130 mm

Reverse 2

13.9 kph

8.7 mph

Stroke

5.51 in

140 mm

Reverse 3

24.3 kph

15.2 mph

Displacement

677 in3

11.1 L

Reverse 4

37.4 kph

23.4 mph

High Idle

2270 rpm

Low Idle

950 rpm

Rated Speed

1800 rpm

* Maximum Travel Speed w/29.5-R25 L-3 Tires

Weights
Operating Weight

23,602 kg

52,019 lbs

Max Empty Weight (ROPS)

24,141 kg

53,207 lbs

Bucket Capacities

3.44-4.21 m3

4.50-5.50 yd3

Max Bucket Capacity

4.21 m3

5.50 yd3

Buckets

Optimal buckets available through Cat Work Tools for light material

Operating Specifications
Static Tipping Load, Straight

16,691 kg

36,787 lb

Static Tipping Load, Full Turn

14,944 kg

32,937 lb

Breakout Force

?? kN

?? lb

48

966H Wheel Loaders

Technical Specifications
Hydraulic System
Bucket/Work Tool System
(Standard), Gear-Type Pump
Output at 2000 RPM and
6900 kPa (1000 psi)

Tires
464 L/min

123 gpm

Relief Valve Setting

20,700 kPa 3000 psi

Pilot System, Gear-Type Pump

Output at 2000 RPM and
4310 kPa (625 psi)

38 L/min

Main Pilot Valve Setting 3450 kPa

Fluid Capacities (Refill Capacities)

10 gpm

500 psi

Hydraulic Cycle Time -Raise

6 seconds

Hydraulic Cycle Time - Dump

2.06 seconds

Hydraulic Cycle Time

Lower, Empty, Float Down

3.4 seconds

Hydraulic Cycle time - Total

12.96 seconds

Standard Tire
29.5-R25 L-3 Radial
Choose from a variety of tires to match your application

Engine Oil

?? liters

Cooling System

?? liters

Hydraulic Tank

?? liters

Fuel Tank

?? liters

Brakes
Meets required standards
Meet OSHA, SAE J1473 OCT90 and ISO 3450-1985

Axles
Front

Fixed front

Rear

Oscillating +/- 13 degrees

Maximum Single-Wheel Rise

& Fall

502 mm

19.8 in

966H Wheel Loaders

49

Notes

50

966H Wheel Loaders

Notes

966H Wheel Loaders

51

Notes

52

966H Wheel Loaders