ThyssenKrupp reports on recent stockyard and mine developments 

As a major supplier of materials handling equipment, ThyssenKrupp Industrial Solutions AG Business Unit Resource Technologies (TKRT) has developed a complete range of products for stockyards, mines, bulk terminals and fertilizer, steel and cement plants. With more than 100 years’ experience,TKRT today supplies a complete range of products for bulk materials handling, including:

Stockyard equipment

  • slew type or bridge type bucket-wheel machines of different designs;  
  • drum (barrel) type reclaimers;
  • longitudinal and circular stockyards with stackers and scraper reclaimers;
  • homogenization/blending beds with stacker and bridge type scraper reclaimers, both as circular or longitudinal stockyards; and
  • combined portal scraper reclaimer with both stacking and reclaiming functions.

Ship unloading and loading equipment
  • grab type ship unloaders of different designs;
  • continuous ship unloaders;
  • shiploaders of different designs for bulks and bagged goods; 
  • combined shiploaders and unloaders; and 
  • pontoon based floating transshipment.
Other materials handling equipment
  • railway car tipplers;
  • truck dumpers and unloading stations; and
  • belt conveyors, curved conveyors and pipe conveyors.
  • TKRT’s new development of full-line materials handling equipment has focused on:
  • being a global supplier with its own subsidiaries throughout the world;
  • a full range of products and designs;
  • multi-purpose applications;
  • suitability of machines for diverse materials with significantly different characteristics; and
  • design suitable for upgrading to either fully automatic operation or unmanned remote controlled operation.

Recent technical achievements and contracts highlight TKRT’s development work for the coal handling in terminals and stockyards.

Recently TKRT was awarded a milestone contract from Shougang Hierro Peru for its iron ore mine expansion project.

Shougang Hierro Peru, the Chinese mining and steel company, will begin to expand the production capacity of its iron ore smelter at San Juan de Marcona, on Peru’s south coast.

The expansion will allow the refinery to increase production to additional 10 million tons per year. The iron ore of the company’s mineral exports is mainly for shipment to China.

The contract awarded by Shougang Peru consists of the following packages:

  • one semi-mobile primary crusher plant with a high capacity gyratory crusher;
  • one curved overland belt conveyor system, in total 6km long;
  • one downhill overland belt conveyor system, in total 6km long;
  • one ROM (run of mine) ore blending yard plant with stacker, drum reclaimer and belt conveyors; and
  • one product stockyard plant with stacker, bucketwheel reclaimer and conveyors.


Back in the 1960s, Krupp built one downhill conveyor system for the Marcona Mine, which since then has been in operation to transport the iron ore from the open pit crusher plant down to the beneficiation plant. It has handled 10mt (million tonnes) per year for more than 50 years and is still in very good condition. This is one of the reasons that the client decided to opt once more for TKRT.

The primary crusher plant equipped with a TKRT’s gyratory crusher of compact design is the key item of equipment for the expansion project, which will produce 10mt crushed ROM ore annually for the further process of the whole mining and beneficiation plant.

In front of the beneficiation plant the ROM ores should be blended on a storage and blending yard. This is equipped with a slewing and luffing stacker and a blending drum reclaimer.

The blending yard stacker is designed to stockpile ROM iron ores in layers with a capacity of 4,500tph (tonnes per hour), while the drum reclaimer, having a design capacity of 3,000tph, will feed the beneficiation plant continuously with controlled mixtures of raw materials.

The drum reclaimer is designed for bi-directional reclaiming operation, which is a specialized design to meet Shougang’s requirements, which is that a very high grade of blending of materials (sorts, sizes, etc) should be achieved. This is the first installation of a bi-directional reclaiming drum reclaimer in Peru.

From 2014 up to now, most equipment and structures have been manufactured, shipped and received at the Shougang Hierro Mine at Marcona, Peru. Construction has been taking place throughout 2015 and will continue into 2016. Commissioning is anticipated in 2016.

In July 2012,ThyssenKrupp Industrial Solutions AG, Business Unit Resource Technologies, Mining – Materials Handling was contracted by OCP S.A. (Office Che´rifien des Phosphates, S.A.), the leading phosphate producer of Morocco, to supply eight full portal reclaimers to be operated within the Morocco Phosphorous III & IV Complex at Jorf Lasfar, Morocco. There, as part of its strategic development plan, OCP S.A. will establish four new ODI (owner direct investment) integrated DAP granular fertilizer manufacturing plants on greenfield plots. These machines will be delivered and erected in sequences within two to three years from the beginning of 2014.

The eight identical A-frame full portal reclaimers are running on a 45.50m rail gauge and designed for a nominal reclaiming rate of 2,000tph.

The principal challenge was proving, during a fiercely contested tendering process, that TKRT offers a technical lead by presenting an innovative and different reclaimer design to achieve the requested high throughput. TKRT succeeded in promoting its meanwhile proven new technology of high speed/high rate portal reclaimers for which the weak element — the roller chain — has been replaced by a track link chain which allows for higher chain speed.

Thanks to that, it was possible to design the portal reclaimer itself with only two scraper booms; i.e. an arrangement of one main and one auxiliary scraper boom mounted laterally to the portal structure and connected together by a knuckle arrangement, instead of three scraper booms which are normally required for such a high handling rate.

ThyssenKrupp Industrial Solutions’ innovative approach for the design of high capacity portal reclaimers, backed up by the numerous references and the company’s excellent track record, were deciding factors in the contract being awarded to TKRT. With this prestigious and challenging contract, ThyssenKrupp Industrial Solutions AG will consolidate its position in the supply of high-capacity portal reclaimers working in fertilizer plants, and demonstrate once again its technological excellence.

With these achievements in the development and construction for the mining and materials handling technology TKRT is convinced that it will keep its prominent position in the world market. 

STM: offering innovative bulk material handling solutions  

Italian company STM is well-known for its expertise in the engineering and supply of belt conveyor systems for bulk material handling facilities. Since it was set up as family business in 1975, it has provided innovative integrated solutions worldwide that increase efficiency, reliability and cost savings for the customers production processes.

STM offers its customers a full range of project services:

engineering, fabrication and commissioning. At each stage of the process, STM develops flexible, individual and effective solutions. The whole supply process, from feasibility study to final delivery and commissioning, is completely implemented in STM’s factory which is located at the company’s headquarters in Tito Scalo (Potenza). This allows STM to support the customer in every stage of the project up to full implementation.  

Over the years, STM has developed a deep knowledge operating in many fields, with specific cutting-edge solutions for each applications: tunnelling conveyors, crushing plants conveyors, batching plants conveyors, waste to energy plants conveyors. Thanks to its expertise, STM has developed even more innovative solutions for bulk materials handling in order to meet the needs of all of its customers. This is why, over the past few years, STM’s portfolio has become even more challenging and specialized.

STM has gained great experience in concrete placing systems, particularly in the placement of roller-compacted concrete

(RCC) used in gravity dam construction. Indeed STM staff are often required to supply conveyor lines able to follow the dam as it grows, and to guarantee continuous feeding with flexible use, with special devices such as elevation tools for conveyors and distribution devices like swingers, crawler placers and tripper conveyors.

At the moment, STM is working to supply the belt conveyor package at Neckartal Dam, in the Karas region, Namibia. The Neckartal dam will be made from RCC concrete and will stand around 80 metres high. For this, STM will provide a cutting edge and complex plant able to lift in order to follow the growing dam wall.

To meet the needs of the contractors which want equipment able to assure uninterrupted feeding, STM developed the new swinger conveyor: a special conveyor with main features of rotating (even up to 360°) and self-elevation. Undoubtedly the swinger is an effective solution to follow the elevation of the dam but it is necessary to modify the height of the conveyor which feeds the swinger as well. To reach this goal the conveyor, with another upper conveyor which discharges the material in it, is located on a tower which is provided with a lifting system. The tower is composed of an internal tower supported by an external one during the lifting phase. In the internal tower there is a one-metre base on which additional modules are added and a last fixed module. This module is the place where the two conveyors are located: the upper one discharges the RCC in a lower conveyor which reaches the swinger.


STM has great experience in the handling of coal. Indeed, the company designed and realized conveyor systems to process coal both in mines and in power stations. The conveyor systems that will be used in mines need to have a specific configuration 

because they have to follow the development of the excavation site. STM’s systems can expedite, optimize and economize the process of overburden removal, redistribution and stacking. The conveyors for this application are designed for a long lifetime and for minimizing extraordinary maintenance and downtime risk. Thanks to its flexibility and the long experience in this field, STM is able to create and manage equipment of any size and complexity, including mobile plants. This configuration satisfies the plant owner who wants to have freedom to move the plant after limited time usage in determined area.

It is necessary to have an efficient coal handling system in thermal power generation plants as well, the most conventional source of electric power. Handling
those kind of materials in a complex power plant makes it essential to design a system with exceptional reliability in order to avoid any kind of decades-long
shutdown. STM is able to provide a complete engineering service, including specific back-up solutions, limited maintenance devices, best-in-class components manufacturers. A valuable example of the long experience of STM in coal handling is the supply of seven conveyor belts to ENEL’s Federico II power plant, in the territory of Brindisi (Italy). This thermal power plant, with a total capacity of 2,640MW installed and with an area of about 270 hectares, is the second-largest thermal power plant in Italy and one of the largest in Europe. The whole line of belt conveyors, provided by STM to this power plant, comprises seven conveyors, with one of them reversible, two distributors, four tank feeders, two transfer towers and all the support steel structures for the conveyors and mixers. The material that the 
conveyor system has to transport is the result of coal combustion so it appears as light humidified ash. For this reason, the STM team created conveyor belts able to handle a very hot material with a high level of moisture and abrasiveness. Moreover, the conveyors are situated outdoors so they are equipped with a rainproof roofing and they are treated to face different atmospheric conditions like temperature leap and a saline and industrial atmosphere.

Thanks to its strong expertise, its attention to the quality, the focus on the customer and the uninterrupted improvement of industrial standards and practices, STM is globally recognized as a trusted partner in developing custom made solutions.

Bucking the trend: RAM Spreaders unveils revolutionary railcar emptying system  

RAM Spreaders has introduced a new pit-to-port rail system that usestopliftRevolverstohandleore. Thisisarevolutionary alternative to expensive bottom dump or rotary railcar dumpers, which are expensive and involve long lead times.

The system includes a large gantry that straddles the rail tracks at the receiving stockyard, and the crane across the gantry literally picks up a 20ft or 40ft container that is carried by the railcar, lifts it across to the required part of the stockpile, and empties the contents of the container onto the stockpile before returning it to the train. The gantry then moves along and collects the container from the next railcar and repeats the process. Each cycle takes only two minutes, and a capacity of 800–1,500tph (tonnes per hour) can be achieved with each gantry. The system is modular, so capacities can be increased with the addition of more gantries.  

The containers themselves are fitted with lids, to prevent the escape of fugitive dust at any part of the process, as well as while travelling to the receiving stockyard. The containers can be transported by both trains and lorries, so the system works equally well with road and rail.

Traditionally dry bulk is offloaded from rail wagons by rotary railcar dumpers or bottom dump wagons. Both of these solutions require extensive capital investment and long lead times as well as being fixed in place allowing limited flexibility.

An additional benefit of the systrem is that it can be fitted with dust suppression equipment, making it even more environmentally friendly. The dust-suppression mist forms a light ‘crust’ on the stockpiled material, preventing the escape of dust.

Customers so far include a West African iron ore operator; an Egyptian coal-fired power station; a South African coal-fired power station; and an exporter of copper conns (inside a shed) from Chile. It is also being used to stockpile iron ore in the Congo. The new system was developed for clients who needed a solution in place quickly but at a reduced capital cost. It is also ideal for use where there is available container rail equipment, but less equipment for handling bulk wagons.

All of the equipment used is standard off-the-shelf container handling equipment, and each gantry crane is capable of handling 1,000tph. Customers requiring faster rates can add further equipment. The system is <10% of the cost of conventional rotary rail car dumpers.  
CASE launches eco- and operator-friendly wheel loaders at Intermat 2015  

In April this year, at the Intermat 2015 show, CASE Construction Equipment launched its new range of wheel loaders. These new loaders generate fewer emissions in six months than a 1996 loader in a single day. The F Series features four owner friendly solutions unique to CASE for quarrying, waste handling and contracting: the Hi-eSCR in-house technology, the rear mounted engine, the Proshift 5-speed transmission and the heavy duty cooling cube. In addition, CASE customers will enjoy excellent visibility also after dark with the highly effective LED lighting and exceptional comfort for long working days.


The F Series complies with EU Stage IV/Tier 4 Final with the Hi-eSCR technology developed by FPT Industrial, CASE’s sister company. It uses the well-proven SCR introduced by FPT on  trucks in 2004 and on CASE wheel loaders in 2011, and doesn’t require a particulate filter or EGR valve. This unique design, which uses only built-for-life-components, is maintenance-free and fuel efficient. With this system, fewer components are involved, engine oil is not compromised and, since there is no need for a diesel particulate filter (DPF) or extra cooling, the engine hood is more compact, providing better rear visibility. An additional advantage is the wheel loader’s safety near flammable materials, as the exhaust’s maximum temperature is 200°C, lower than it would be with a DPF. This is particularly valuable when doing jobs such as handling materials in wood recycling centres, for example.

The unique design, with five radiators mounted to form a cube instead of overlapping ensures a constant flow of fresh, clean air from the sides and the top. This cube structure also provides easy access for effective cleaning.

Models up to 20 tonnes feature the high efficiency Proshift five- speed transmission that enables the operator to take better advantage of the outstanding torque. The lock-up results in fuel savings of up to two litres per hour and faster cycles compared with conventional transmissions. Productivity of these models is further improved by the rear mounted engine, which results in a better weight distribution, increasing the bucket payload by up to 15% compared to other loaders of the same weight.

Effective lighting is a key requirement for customers, who need their wheel loaders to work in low light situations, for example during the winter months in northern countries when night falls 

early, or when they are running their units up to three shifts per day finishing well after dark. The new F Series offers a highly efficient lighting package with 6 LED lights providing a far- reaching spread of light – over 21,000

lumen of lighting power.

Wheel loader operators work long hours on a fast and powerful machine, so comfort is a key concern. CASE teamed up with top range seat experts Grammer for the F Series’ new Premium leather seat, which provides outstanding protection from repetitive shocks and vibrations. The low frequency absorber provides a smooth ride at all speeds, the fore and aft isolator ensures a comfortable ride on rough terrain, and the best-in-class active seat suspension with electronic automatic weight adjustment and dynamic dampening system delivers ultimate comfort. The adjustable armrests, extra-wide cushion, high and adjustable backrest, adjustable headrest and 80mm height adjustment enables the operator to personalize the seat set-up to create the perfect working position.


CASE Construction Equipment sells and supports a full line of construction equipment around the world, including loader/backhoes, excavators, motor graders, wheel loaders, vibratory compaction rollers, crawler dozers, skid steers, compact track loaders and rough-terrain forklifts. Through CASE dealers, customers have access to a true professional partner with world- class equipment and aftermarket support, industry-leading warranties and flexible financing.

CASE Construction Equipment is a brand of CNH Industrial N.V., a major supplier of capital goods listed on the New York Stock Exchange and on the Mercato Telematico Azionario of the Borsa Italiana. 

Simulation modellling — a key to successful stockyard design  

South African-based DemcoTECH Engineering completed a simulation and modelling study for a major iron ore distribution centre for Brazilian miner, Vale, in Malaysia, underpinning its successful global track record of capabilities in stockyard design and layout.

DemcoTECH was appointed the materials handling engineering contractor for the Teluk Rubiah Maritime Terminal in Malaysia and was involved in the entire project from concept to completion of the implementation phase, FEL4.

DemcoTECH with ZAA Engineering Projects and Naval Architects completed the simulation study for the project. The study simulated operational processes such as import of materials from bulk carriers via the ship-unloaders and transport on the import conveyor system to the stockpiles, including blending and export of iron ore from the process stockpiles to the bulk export carriers.

The modelling of the import, blending and export operations was carried out using a combination of static spreadsheet models and dynamic Monte Carlo based simulations of operations.

“The dynamic simulation techniques are very powerful tools to simulate events such as unloading and loading operations as a time series. particularly as these processes consist of a large number of individual events that occur randomly in space and time,” says Paul van de Vyver, DemcoTECH Engineering GM.

“Through repeat simulations, we were able to statistically evaluate all possible outcomes of the process and the probability of achieving the required outputs given the randomness of the events.

“In addition, we could also test the influence of assumptions regarding individual events through sensitivity analysis.“

The simulations were repeated over the full import/export period, taking cognizance of all influencing factors ranging from weather and sea conditions, equipment capacities, rates and efficiencies, through to vessel arrival and departure schedules, all materials handling operations, power supply and potential failures and operating times.  
“For each scenario, the typical output generated include  import/export volumes achieved, berth occupancies and demurrage, results which could then be utilized to optimize/adapt the plant layout, equipment selection or operational parameters,” adds van de Vyver.

“As undoubtedly one of the most important maritime terminal developments in this region,Teluk Rubiah, which initially handles 30mt (million metric tonnes) of iron ore per year and serves as a strategic distribution hub to Vale’s customers in Asia, highlights DemcoTECH’s ability to handle major terminal and stockyard projects.”

Detailed engineering of the bulk materials handling on stockyards is an integral component of an import terminal project DemcoTECH is presently executing for the Port of Ploce in Croatia.

“The multi-product terminal will offload and handle mainly coal, but also iron ore for distribution to the region’s coal-fired power stations and steel mills. The project scope includes the entire materials handling system, starting with coal offloaded from the ship-unloaders through to the coal stockyards and the train rapid rail load-out system.

“The vastly different material properties of coal and iron ore have design implications for the system, particularly the chutes and train rapid rail load-out system, as well as the fact that the main stockpile is served by only one rail-mounted bucketwheel 

stacker reclaimer, after being offloaded by grab type ship- unloaders,” notes van de Vyver.

A standby stockpile facility is also being designed, utilizing mobile plant feeding into mobile hoppers, which discharge onto the yard conveyor via dual vibratory feeders. The mobile hoppers can be positioned along the entire length of the new yard conveyor.

Earlier this year, DemcoTECH successfully commissioned the upgrade to Lesotho’s Le?tseng Diamond Mine’s run-of-mine (ROM) stacking conveyor. The turnkey contract comprised mechanically and structurally redesigning out the original design items that were compromising the performance of the conveyor. This included installing a new rake trestle as well as relocating the 160kW drive from the head end of the 33m-high boom and relocating it at ground level for ease of maintenance. This entailed the entire conveyor structure having to be reviewed and then redesigned. In addition, the head arrangement was redesigned to cater for a new head chute.

A new WEBA head chute was installed allowing even material particle size distribution across the stockpile. This ensures consistent feed of fines and lumpy materials being distributed evenly over both reclaim feeders reclaiming for Le?tseng’s Plants No 1 and No 2.

The implementation contract followed a design audit performed for Le?tseng by DemcoTECH.

“We worked to a very tight schedule to minimize any 

disruption to production, with the improvements to the ROM stacker being implemented during the mine’s annual shut down period of seven days in February this year,” says van de Vyver.

The boom stacker conveyor feeds from the primary crusher to the stockpile, where the material is reclaimed to feed Le?tseng Plants No 1 and No 2.

DemcoTECH was also appointed in 2014 to carry out the conveyor design and layout for the expansion to the tailings dump for Phase 3 of the Le?tseng Mine expansion and is currently upgrading the tailings dump. This involves the installation of additional conveyor equipment as well as relocating the main extendable boom stacker conveyor and transfer towers. This current work is aimed at enabling the tailings system to handle higher capacities resulting from Le?tseng’s Project Kholo, which, amongst other objectives, is aimed at increasing ore throughput.

Previous stockyard projects include the design, engineering, procurement and construction management for the materials handling portion of the expansion to Grindrod’s multi product terminal at the port of Richards Bay in South Africa. The scope of the contract was to provide the bulk materials handling system conveying various materials, but mainly coal and rock phosphate, from three Richards Bay terminal sites. The system provided, which has been operating successfully since commissioning, included receiving the coal from a tippler discharging onto three belt conveyors, one of which fed an open stockpile. The stockpile was equipped with mobile plant reclaiming material via a Buffalo feeder.

DemcoTECH also completed an expansion to the manganese export facility at Assmang Limited’s Cato Ridge Alloys plant in KwaZulu-Natal, South Africa, working jointly with Kantey & Templer Engineers. Part of the project focused on the supply of a greenfields stockpile and reclaim facility and included an automatic truck loading system.

The stockpile has a new elevated tripper feeding the stockpile with a dust suppression system to provide a safe and environmentally friendly operation. The wagon tippler was supplied with a new side arm charger to eliminate the positioning of rail wagons using a locomotive.

DemcoTECH Engineering is a specialist bulk materials handling and niche process plant company, offering services from concept design through to project completion to the power generation, cement, mining, metallurgical, manufacturing and port handling industries. 


Phoenix Terminal Solutions: a new level

Founded in 1892, Phoenix Products Company Inc. designs and manufactures lighting fixtures for some of the world’s harshest environments, including bulk handling stockyards. One of its key markets is the bulk handling industry a critical link in the world’s supply chain. How a terminal utilizes the ever-changing technology available in this competitive industry can have a direct effect on the operator’s bottom line. For this reason, having integrated systems and concise information about them is crucial.


For years, Phoenix has been observing the many unique characteristics of the terminal industry from the long buying cycles to the amount of capital investment required to remain competitive. The distribution channels are also unique. In many cases, the manufacturer, OEM and specifier are all located on separate continents, which often complicates the management of these projects.

Phoenix has responded to these distinguishing factors with an innovative new business model — Phoenix Terminal Solutions. It sells Phoenix’s lighting fixtures in addition to other industry- leading manufacturers’ of specialty equipment.


Prior to doing anything, Phoenix researched, interviewed and judged key market professionals’ reactions to its concept. The response was positive, and it was convinced it was the right thing to do for two predominant reasons:


  • Trust: Phoenix is more than 123 years old. With its rich history and the credibility built over the decades, customers were confident they’d be presented with top-quality products from trusted suppliers.
  • Efficiency: there was also a consensus that, with PTS bringing more products from more manufacturers, customers would learn more from a single sales call than they would by meeting with four or more separate vendors.


Phoenix has aggressively grown its presence in the terminal market for lights installed on equipment worldwide. Scott Fredrick, CEO of PTS and Phoenix explains, “A good deal of our

growth has been in LED technology and was leveraged when we established a specialized port sales team within Phoenix. Until then, we weren’t able to identify an alternate sales channel that would focus exclusively on the port market, be adaptable to the long buying cycle or have a multi-national presence required by the industry.”


In addition to Phoenix, PTS currently represents two premium manufacturers — LASE and Bright Light Systems. But this is only the beginning. Fredrick states that they plan to add
others possibly organizations based overseas that are looking to grow in the North American market. Plans also exists to partner with American companies looking to expand into international markets because its port sales team already has a strong presence in Europe, Latin America, and Asia.

In reference to LASE’s new partnership with PTS, Lars Ambrosy, CEO of the Germany-based manufacturer says, “LASE strengthens its presence by this partnership. Phoenix stands for quality as well as high-value products and services, which also reflects the philosophy of LASE.”

This increased presence means more information for port operators who may not have the exposure to these manufacturers due to time or geographical constraints.


Fredrick further explains,“PTS’ sales team had proven to be very effective. It includes credible, port industry veterans with a wealth of applicable knowledge.” This brings a wealth of resources and a new level of service to terminals worldwide.

PTS has been fully operational since January 2015. Thus far, the market response and overall performance of the newly formed, specialized company has exceeded expectations. The project opportunities are abundant, and appointments have been incredibly productive.

All in all, it’s been a very promising start for a company that is challenging the status quo and working to optimize distribution in the port industry.  
Cat® M Series 966 and 972 wheel loaders offered with XE advanced powertrain  

he 966M, 966M XE, 972M and 972M XE wheel loaders have EU Stage IV C9.3 ACERTTM engines equipped with a combination of proven electronic, fuel, air and aftertreatment components. Applying proven technologies systematically and strategically lets Caterpillar meet its customers’ high expectations for productivity, fuel efficiency, reliability and service life. Deep system integration results in reduced emissions, improved performance and improved fuel economy without interrupting machine performance making it seamless to operators.


The XE advanced powertrain first introduced with the 966K XE continues with the 966M XE and the 972M XE. The XE technology results in 25% higher fuel efficiency on average compared with machines with traditional torque converters, and simplifies operation with a two pedal design while providing seemingly endless power.

The 966M and 972M powertrains have also been improved with the addition of lock-up clutch torque converters as standard. These new torque converters have also been matched with the engine power and hydraulics to improve performance and fuel efficiency and are another example of deep system integration. These rugged planetary transmissions also have a split-flow oil system and use new multi-viscosity oil which improves fuel economy. The deep system integration of the above features and further axle and hydraulic improvements below result in ten percent lower fuel consumption on average compared to the 966K and 972K. The new 966M and 972M are second only to the 966M XE and 972M XE which are the class leaders in fuel efficiency.

These models are used in dry bulk handling and where poor underfoot conditions make traction difficult slowing production and challenging job deadlines. By their ability to engage on-the-

go and to transfer 100% of the torque to the wheel with traction, the disc-type differential locks improve tractive ability in these applications thereby increasing productivity. All four models come standard with front axle differential locks which are manually activated by a switch on the floor. Optional fully automatic front and rear axle differential locks operate by measuring differences in axle speeds and require no operator intervention to activate. These disc-type differential locks will reduce tyre scuffing compared with other traction aids further reducing operating costs for customers.

The axles contribute to lower fuel consumption due to lower oil levels and bevel gear shrouds which reduce churning losses from rotating components. They also have external caliper disc parking brakes mounted to the input shaft of the front axles. Caliper parking brakes have higher capacity than the drum brakes used on the 966K and 972K. Since they are external, they do not have the inefficiencies of enclosed wet parking brakes due to brake discs running in oil nor is there any oil to change reducing fuel and maintenance costs. External caliper parking brakes are easily accessible for inspection and service.

The main hydraulic valve is a mono-block with an integrated ride control section. The mono-block design reduces weight, has forty percent fewer leak points and is common across all
M Series models. The ride control system now has two accumulators enabling it to be more effective over a greater payload range, increasing productivity and operator efficiency due to a better ride. Auxiliary third and fourth hydraulic functions can be easily added at the factory or in the field with the addition of a second remote valve.

Hydraulic implement pumps continuously and automatically balance hydraulic loads with the machine performance desired by the operator. The pumps have larger displacements for increased hydraulic flow at lower engine rpm thereby saving fuel.  

A new ‘aggregate handler’ version of these models allows to increase payload by approximately 700kg in free-flowing material applications.


Improving operator efficiency remains a key design goal for the 966M, 966M XE, 972M and 972M XE. Ensuring operators are safe, confident in the control of their machines, have a clean, comfortable and quiet operating environment with controls that are intuitive and low effort, all contribute to reduced operator fatigue and better performance.

In the cab, the new door securely seals against the new roll formed ROPS posts and the lower glass panel has been extended several centimetres to improve visibility to the left side of the machine. Large convex mirrors improve visibility to the rear and integrated spot mirrors provide visibility close to both sides of the machine.

A new multipurpose colour touch screen display dramatically simplifies the operator interface; with machine controls, rear view camera and new fully integrated Cat Production Measurement

system. Intuitive navigation with in-language text enables operators to modify certain machine operating parameters and monitor machine conditions literally at the touch of their fingers. Some controls have been relocated to this new display eliminating the need for the second membrane switch pad further reducing cab clutter.

Operator sound pressure level & exterior sound power level remain unchanged for the 966M and 972M at respectively 69 dB(A) and 108 dB(A).The 966M XE & 972M XE operating at lower engine speed, benefit from reduced noise levels at respectively 67 dB(A) and 105 dB(A).

Cat Connect enables operators and managers to access machine operating data including total fuel consumption, average fuel rate, total idle time and fuel consumed at idle, total operating hours and several other machine data. The Caterpillar Production Measurement app option is integrated in the touch screen display providing payload information. These technologies and services provide an increasing ability for customers to monitor, manage and enhance operations, gain more control of their jobsites and reduce costs and increase profits.