Caterpillar Cat 970F Wheel Loader (Prefix 9JK) Service Repair Manual Instant Download (9JK00001).pdf

Service Repair Manual
Models
970F WHEEL LOADER

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Product: WHEEL LOADER
Model: 970F WHEEL LOADER 9JK
Configuration: 970F Wheel Loader 9JK00001-UP (MACHINE) POWERED BY 3306 Engine
Disassembly and Assembly
970F WHEEL LOADER POWER TRAIN
Media Number -SENR6627-02 Publication Date -01/01/2005 Date Updated -22/07/2005
SENR66270025
Transmission
SMCS - 3030-015; 3030-016
Disassemble Transmission
Start By:
a. remove transmission hydraulic control valve
b. separate torque converter from transmission
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1. Fasten Tool (A) and a hoist to the reverse clutch housing as shown. Remove the bolts that hold
the transmission and case (1) to the transfer gear case. Use two 3/8" - 16 NC forcing screws to
separate the transmission from the transfer gear case. The weight of the unit is 540 kg (1200 lb).
2. Remove O-ring seals (2) and (3) from case (1).
3. Fasten Tool (A) and a hoist to case (1) as shown. Remove the bolts that hold case (1) to the
transmission manifold assembly. Use two 3/8" - 16 NC forcing screws to separate case (1) from
the manifold. Remove case (1) from the transmission. The weight of the case is 90 kg (200 lb).
4. Remove elbow (5) and the O-ring seal from the reverse clutch housing.
5. Remove the bolt, retainer (6) and gear (7) from the transmission input shaft.
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6. Turn the transmission over with a hoist, so the No. 6 (first speed) clutch housing is up. The
weight of the transmission is 450 kg (1000 lb).
7. Remove O-ring seal (10) and both O-ring seals (9) from the manifold assembly.
NOTE: Put an alignment marks across the clutch housings for the correct alignment at assembly.
8. Install Tool (C) to hold the piston in the No. 6 clutch housing.
9. Fasten Tool (B) and a hoist to clutch housing (11). Remove bolts (8). Remove the clutch piston
and clutch housing (11) from the transmission. The weight of clutch piston and clutch housing
(11) is 27 kg (60 lb).
10. Remove clutch piston (12) from clutch housing (11). Remove the seal rings from the clutch
piston.
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11. Remove reaction dowels (14), springs (15), three friction discs (13) and the two clutch plates
from the manifold.
12. Remove ring gear (16) from the carrier.
13. Use Tool (D) to remove retaining ring (17) from the transmission shaft.
14. Remove carrier assembly (18) from the manifold assembly.
15. Disassemble carrier assembly (18) as follows:
a. Remove the ring seal from the outside of the carrier assembly.
b. Use a hammer and a punch to push the spring pin through carrier (18) into planetary shaft (19).
Remove planetary shaft (19) from carrier (18).
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c. Remove thrust discs (20) and (24), bearings (21) and (23) and planetary gear (22) from carrier
(18).
d. Remove the other two planetary gears from the carrier as in Steps 15b and 15c.
16. Remove retaining ring (25) and sun gear (26) from the output shaft.
17. Use Tool (D) to remove retaining ring (27) from the housing.
18. Fasten Tool (B) and a hoist to manifold assembly (28) as shown. Remove manifold assembly
(28) from the transmission. The weight of manifold assembly (28) is 64 kg (140 lb). Remove the
large O-ring seal from the manifold assembly.
19. Use Tool (E) to remove retaining ring (29) from the manifold. Remove bearing (30) from the
manifold.
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20. Remove springs (32), two friction discs (31) and one clutch plate from the No. 3 and No. 4
clutch housing.
21. Remove retaining ring (33) and housing assembly (34) from the ring gear for the No. 4 clutch.
22. Remove seal rings (36) from ring carrier (35).
23. Do not remove ring carrier (35) from housing (34) unless it is worn or damaged. Use a
hammer and chisel to break the ring carrier, and remove it. After ring carrier (35) is removed,
remove the spring pin that holds the carrier in position on housing (34).
24. Use steel spacers, as necessary, and a press to push on retainer plate (38) to put three disc
springs (40) under compression.
NOTE: Prior to removing three disc springs (40) from housing (34), note their installed positions
for assembly purposes.
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25. Use Tool (F) to remove retaining ring (39) from housing (34). Release the pressure on plate
(38), and remove the retainer plate, three disc springs (40) and No. 5 piston (37) from housing
(34).
26. Remove the two seal rings from piston (37).
27. Remove ring gear (42) from the No. 3 and 4 clutch housing. Remove three friction discs (41)
and two clutch plates from ring gear (42). Remove the clutch plate from the ring gear.
28. Remove No. 4 (third speed) clutch piston (43) and reaction dowels (44) from the clutch
housing.
29. Remove seal rings (45) and (46) from clutch piston (43).
30. Install Tool (G) to hold No. 3 (fourth speed) clutch piston in clutch housing assembly (47).
Install two 5/8" - 11 NC forged eyebolts in clutch housing assembly (47) as shown. Fasten a hoist
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to the eyebolts. Remove clutch housing assembly (47) and the clutch piston. The weight of the
unit is 41 kg (90 lb).
31. Remove clutch piston (48) from clutch housing assembly (47). Remove the seal rings from
clutch piston (48).
32. Remove springs (49), three friction discs (50) and the two clutch plates from the No. 2
(forward) clutch housing.
33. Use Tool (D) to remove retaining ring (52). Remove clutch hub (51).
34. Lift sun gear (53), carrier assembly (54) and ring gear (55) from the transmission shaft as a
unit.
35. Remove sun gear (53) from carrier assembly (54).
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a. Put the lock ring under compression, and remove carrier assembly (54) from ring gear (55).
Several short lengths of 3.175 mm (.125 in) rod (56) with a point ground on one end can be used
to put the ring under compression.
b. Use a hammer and a punch to push the spring pin through carrier (54) into planetary shaft (57).
Remove planetary shaft (57) from carrier (54).
c. Remove thrust discs (58) and (61), bearing (60) and planetary gear (59) from carrier (54).
d. Remove the other two planetary gears from the carrier as in Steps 36b and 36c.
e. Remove retaining ring (62) that holds bearing (63) in carrier (54).
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f. Use Tool (H) and a press to push bearing (63) out of carrier (54).
37. Install Tool (C) to hold the forward clutch piston in the clutch housing.
38. Fasten Tool (B) and a hoist to the No. 2 (forward) clutch housing. Remove the bolts and the
clutch housing with the clutch piston. The weight of the unit is 27 kg (60 lb).
39. Remove clutch piston (64) from the No. 2 (forward) clutch housing (65). Remove the seal
rings from clutch piston (64).
40. Remove springs (68) and reaction dowels (67).
41. Remove three friction discs (66) and the two clutch plates.
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42. Remove ring gear (69) from the carrier assembly and shaft.
43. Remove retaining ring (71) that holds the bearing in the carrier assembly. Remove shaft (70)
from the carrier assembly and the inner shaft.
44. Use Tool (D) to remove retaining ring (73) from the end of shaft (70). Remove gear (72) from
shaft (70).
45. Use Tool (H) and a press to push shaft (70) out of bearing (74) as shown.
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46. Remove bearings (75) and (76) from the ends of shaft (70).
47. Remove plate assembly (77) from the reverse clutch housing.
48. Use Tool (J) to remove retaining ring (79) that holds sun gear (78).
49. Remove carrier assembly (80) and ring gear (81) from the shaft.
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a. Remove the sun gear from carrier assembly (80).
b. Remove seal ring (82) from carrier assembly (80).
c. Put the retaining ring under compression, and remove carrier assembly (80) from ring gear (81).
Several short lengths of 3.175 mm (.125 in) rod (83) with a point ground on one end can be used
to put the ring under compression.
d. Use a hammer and a punch to push the spring pins through carrier (80) and into planetary shafts
(84). Remove planetary shafts (84) from carrier (80).
e. Remove thrust disc (85), bearing (86), planetary gear (87), thrust disc (88), thrust disc (89),
bearing (90), planetary gear (91) and thrust disc (92) from the carrier.
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f. Remove the other planetary gears (87) and (91) from carrier (80) as in Step 50e.
g. Remove retaining ring (93) that holds bearing (94) in carrier (80).
h. Use Tool (H) and a press to push bearing (94) out of carrier (80).
51. Remove sun gear (95) from the shaft and carrier.
52. Remove three friction discs (96) and two clutch plates (97) from the No. 6 (reverse) clutch
housing.
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53. Remove ring gear (98).
54. Use a hoist to remove shaft (99) and carrier assembly (100) from the clutch housing. The
weight of the shaft and carrier assembly is 25 kg (55 lb).
55. Remove seal ring (103) from carrier assembly (100). Remove seal rings (101) and (102) from
the seal carrier.
56. Use a soft faced hammer to push shaft (99) out of the bearing in carrier assembly (100) as
shown.
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57. Do not remove inner bearing race (104) from shaft (99) unless it is necessary. Use a hammer
and chisel to break the seal carrier, and remove it fromshaft (99). Remove the pin that holds the
seal carrier on shaft (99).
58. Use a press and Tool (K) to push shaft (99) out of bearing race (104).
a. Use a hammer and a punch to push the spring pins through carrier (100) and into planetary shaft
(105). Remove planetary shaft (105) from carrier (100).
b. Remove thrust disc (106), bearing (107), planetary gear (108) and thrust disc (109) from the
carrier.
c. Remove the other two planetary gears (108) from carrier (100) as in Step 59b.
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d. Use Tool (L) to remove retaining ring (110) that holds bearing (111) in carrier (100).
e. Use Tool (H) and a press to push bearing (111) out of carrier (100) as shown.
60. Remove clutch piston (112) from No. 6 (reverse) clutch housing (113). Remove the seal rings
from clutch piston (112).
61. Use a hoist to turn housing (113) over. The weight of housing (113) is 43 kg (95 lb).
62. Use Tool (E) to remove retaining ring (114) that holds bearing (115) in housing (113).
63. Use a press and Tool (H) to push the bearing out of housing (113) as shown.
Assemble Transmission
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NOTE: Check all parts of the transmission for wear or damage. If any parts are worn or damaged,
use new parts for replacement. During assembly, put clean transmission oil on all parts.
1. Be sure the small plug in the bottom of the bearing bore in No. 6 (reverse) clutch housing (113)
is installed 1.25 ± 0.25 mm (.049 ± .010 in) below the surface of the bearing bore.
2. Use Tool (A) and a press to install the bearing in No. 6 (reverse) clutch housing (113) as shown.
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3. Use Tool (B) to install retaining ring (114) in clutch housing (113).
4. Install the seal rings on clutch piston (112). Be sure the lips on the seal rings are facing toward
the clutch housing as shown.
5. Put clean transmission oil on the seal rings, and install clutch piston (112) in clutch housing
(113).
6. Assemble carrier assembly (100) as follows:
a. Put bearing (111) in position on carrier (100) with notch in the inner race up (toward the
outside). Use Tool (A) and a press to install the bearing in carrier (100).
b. Use Tool (C) to install retaining ring (110) in carrier (100).
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NOTICE
Be sure the rubber in the spring pins that hold planetary shafts (105) in
carrier (100) is not damaged. If the rubber is damaged, replace the
spring pins with new parts.
c. Install the bearing in planetary gear (108). Install planetary gear (108) in carrier (100) with a
thrust disc on each side of the planetary gear as shown. Install planetary shaft (105) in carrier
(100) and through the bearing and planetary gear (108). Be sure the spring pin hole in the carrier is
in alignment with the spring pin hole in the planetary shaft. Install the spring pin to hold the
planetary shaft in position.
d. Install the other two planetary gears (108) in carrier (100) as in Step 6c.
7. Install shaft (99) in carrier assembly (100) as shown. Be sure the dowel in shaft (99) engages in
the notch of the carrier bearing.
8. Put seal carrier (102) in position on shaft (99), and install the pin to hold the seal carrier in
place.
9. Heat inner bearing race (104) to a maximum temperature of 135°C (275°F). Install it on shaft
(99).
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10. Install seal ring (103) on the carrier assembly (100).
11. Install seal rings (101) in the grooves of seal carrier (102).
12. Use a hoist to install carrier assembly (100) and shaft (99) in the No. 6 (reverse) clutch
housing as shown. The weight of the unit is 25 kg (55 lb).
13. Install ring gear (98) in the No. 6 (reverse) clutch housing.
14. Install three friction discs (96) and the two clutch plates in the clutch housing in alternating
order. Start with a friction disc, and end with a friction disc.
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15. Install sun gear (95) in the carrier assembly as shown.
a. Put bearing (94) in position on carrier (80) with the notch in the inner race up (toward the
outside). Use Tool (A) and a press to install the bearing in the carrier.
b. Install retaining ring (93) to hold the bearing in carrier (80).
NOTICE
Be sure the rubber in spring pins (115) is not damaged. If the rubber is
damaged, replace the spring pins with new parts.
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c. Install bearings (86) in planetary gears (87). Install planetary gears (87) in carrier (80) with a
thrust disc (89) on each side of the planetary gear as shown. Install planetary shaft (84) in carrier
(80) and through the bearings and planetary gears (87) as shown. Be sure the spring pin hole in the
planetary shaft is in alignment with the spring pin hole in the carrier. Install spring pin (115) to
hold planetary shaft (84) in position.
d. Install the remainder of the planetary gears in carrier (80) as in Step 16c.
17. Install retaining ring (116) in the groove of carrier (80). Install carrier assembly (80) in ring
gear (81) until retaining ring (116) fits in the groove of ring gear (81) to hold the unit together.
18. Install seal ring (82) in the groove of carrier assembly (80).
19. Install ring gear (81) and carrier assembly (80) over the transmission shaft as shown. Be sure
the notch in the carrier engages with the dowel in the gear assembly on the shaft.
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20. Install sun gear (78) on the transmission shaft. Be sure the gear teeth are correctly engaged
with the lower set of planetary gears in carrier assembly (80).
21. Use Tool (D) to install retaining ring (79) on the shaft to hold the sun gear in position.
22. Install plate assembly (77) on No. 6 (reverse) clutch housing (113). Be sure the pins in plate
assembly (77) are correctly fitted into their bores in clutch housing (113). Also one of the two oil
passages (117) for the clutch piston must be in alignment with the passage in clutch housing (113).
23. Lower the temperature of the small bearing, and put it in position in the end of output shaft
(70). Use Tool (E) to install the bearing until it is 25.50 ± 0.25mm (1.004 ± .010 in) below the end
of the shaft. The inside diameter of the bearing must be 35.629 ± 0.039 mm (1.4027 ± .0015 in)
after assembly.
24. Lower the temperature of the large bearing, and put it in position in the end of output shaft
(70). Use Tool (A) to install the bearing until it is 13.00 ± 0.25 mm (.512 ± .010 in) from the end
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of the shaft. The inside diameter of the bearing must be 56.650 ± 0.061 mm (2.2303 ± .0024 in)
after assembly.
25. Heat bearing (74) to a maximum temperature of 135°C (275°F), and install it on shaft (70). Be
sure the shoulder is toward the end of the shaft as shown.
26. Install gear (72) on shaft (70) next to the bearing.
27. Use Tool (F) to install retaining ring (73) in the groove of shaft (70).
28. Install output shaft (70) over the input shaft.
29. Install retaining ring (71) to hold the bearing in the carrier assembly.
30. Install ring gear (69) over the transmission shafts and carrier assembly.
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31. Install springs (68) and reaction dowels (67) through the plate assembly and into the No. 6
(reverse) clutch housing.
32. Install three friction discs (66) and the two clutch plates on top of the plate assembly in
alternating order. Start with a friction disc and stop with a friction disc.
33. Install the seal rings on clutch piston (64). Be sure the lips of the seal rings are toward the
housing as shown.
34. Put clean transmission oil on the seal rings, and install clutch piston (64) in the No. 5
(forward) clutch housing (65).
35. Use Tool (G) to hold the clutch piston in clutch housing (65). Fasten Tool (H) and a hoist to
clutch housing (65). Put the clutch housing in position on the plate assembly as shown.
36. Be sure springs (68) fit correctly in the clutch pistons, and remove Tool (G) and Tool (H).
Install the two bolts that hold the clutch housings and plate assembly together.
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a. Put the bearing in position in carrier (54) with the notch in the inner race up (toward the
outside). Use Tool (A) and a press to install the bearing in carrier (54).
b. Install retaining ring (62) to hold the bearing in carrier (54).
NOTICE
Be sure the rubber in spring pins (118) is not damaged. If the rubber is
c. Install the bearing in planetary gear (59). Install planetary gear (59) in carrier (54) with a thrust
disc (58) on each side of the planetary gear as shown. Install planetary shaft (57) in carrier (54)
through the bearing and planetary gear (59) as shown. Be sure the spring pin hole in the carrier is
in alignment with the spring pin hole in the planetary shaft. Install spring pin (118) to hold
planetary shaft (57) in position.
d. Install the other two planetary gears in carrier (54) as in Step 37c.
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38. Install the retaining ring in the groove of carrier assembly (54). Install carrier assembly (54) in
ring gear (55) until the retaining ring fits in the groove of ring gear (55) to hold the unit together.
39. Install carrier assembly (54) and ring gear (55) over the transmission shafts and planet carrier
as shown. Be sure the notch in the carrier bearing engages with the dowel in the output shaft.
40. Install sun gear (53) in carrier assembly (54).
41. Install clutch hub (57). Use Tool (F) to install retaining ring (52) to hold the clutch hub in
position.
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42. Install three friction discs (50) and the two clutch plates in alternating order. Start with a
friction disc, and stop with a friction disc.
43. Install the ten dampers in bolt holes (119) of the No. 3 (fourth speed) clutch housing (47).
Install the two dampers in bolt holes (120) on the No. 4 (third speed) clutch side of clutch housing
(47).
44. Be sure four dowels (121) extend 11.0 ± 0.5 mm (.43 ± .02 in) above the surface of clutch
housing (47).
45. Install the seal rings on No. 3 (fourth speed) clutch piston (48). Be sure the lips of the seal
rings are toward the housing as shown.
46. Put clean transmission oil on the seal rings, and install clutch piston (48) in the No. 3 and 4
clutch housing (47).
47. Install Tool (J) to hold the No. 3 (fourth speed) clutch piston in clutch housing (47). Install two
5/8" - 11 NC forged eyebolts in clutch housing (47), and fasten a hoist to it.
48. Put springs (49) in position, and install the clutch piston and clutch housing (47) as shown. Be
sure the springs are engaged correctly with the clutch piston and forward clutch housing. Remove
Tool (J) and the hoist.
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49. Install reaction dowels (44) in clutch housing (47).
50. Install the seal rings on No. 4 (third speed) clutch piston (43). Be sure the lips of the seals are
toward the housing as shown.
51. Put clean transmission oil on the seal rings, and install clutch piston (43) in clutch housing
(47).
52. Install ring gear (42) in the clutch housing.
53. Install the clutch plate in ring gear (42).
54. Install three friction discs (41) and the clutch two plates in the ring gear in alternating order.
Start with a friction disc and stop with a friction disc.
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55. Install the two seal rings on piston (37). Be sure the lips of the seal ring are toward housing
(34). Put clean transmission oil on the seal rings. Install piston (37) in housing (34).
56. Install three disc springs (40) on housing (34) in their original positions. Put plate (38) in
position on the disc springs with the shoulder for the retaining ring up as shown.
57. Use steel spacers and a press to put the plate and three disc springs under compression. Use
Tool (K) to install retaining ring (39).
58. Heat ring carrier (35) to a temperature of 127°C to 166°C (260°F to 330°F) for a maximum of
ten minutes. Install the ring carrier on housing (34) so the part number can be seen. Install the pin
to hold ring carrier (35).
59. Install seal rings (36) on carrier (35).
60. Install housing assembly (34) in the ring gear as shown.
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61. Install retaining ring (33) to hold housing assembly (34) in the ring gear.
62. Install two friction discs (31) and the clutch plate on the No. 4 (third speed) clutch piston. Be
sure the clutch plate is between the two friction discs.
63. Use a press to install the bearing in manifold assembly (28). Be sure the notch in the inner
bearing race is down (toward the inside) before the bearing is installed.
64. Use Tool (B) to install retaining ring (29) that holds the bearing in manifold assembly (28).
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65. Put springs (32) in position on the No. 4 (third speed) piston.
66. Fasten Tool (H) and a hoist to manifold assembly (28). Put the manifold assembly in position
on the clutch housing. Be sure the springs are fitted correctly in the manifold assembly and clutch
piston. Also, be sure the notch in the bearing engages with the dowel in the No. 5 (second speed)
clutch housing. Install the two bolts that hold manifold assembly (28). Remove the hoist and Tool
(H) from the manifold assembly.
67. Put sun gear (26) in position, and install retaining ring (27) to hold it on the transmission
output shaft.
68. Pull up on sun gear (26) to move the No. 5 (second speed) piston housing, and use Tool (F) to
install retaining ring (25).
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NOTICE
Be sure the rubber in the spring pins is not damaged. If the rubber is
a. Install the bearing in planetary gear (22). Install planetary gear (22) in carrier (18) with a thrust
disc (20) on each side of the planetary gear as shown. Install planetary shaft (19) in carrier (18)
through the bearing and planetary gear (22) as shown. Be sure the spring pin hole in the carrier is
in alignment with the spring pin hole in the planetary shaft. Install spring pin (118) to hold
planetary shaft (19) in position.
b. Install the other two planetary gears in carrier (18) as in Step 69a.
c. Install the ring seal on carrier assembly (18).
70. Install carrier assembly (18).
71. Use Tool (F) to install retaining ring (17).
72. Install ring gear (16).
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73. Install reaction dowels (14). Install three friction discs (13) and the two clutch plates in
alternating order. Start with a friction disc and end with a friction disc.
74. Install the seal rings on clutch piston (12). Be sure the lips of the seal rings are toward the
housing as shown.
75. Put clean transmission oil on the seal rings, and install clutch piston (12) in No. 6 (first speed)
clutch housing (11).
76. Install Tool (G) to hold the clutch piston in position in clutch housing (11). Fasten Tool (L)
and a hoist to clutch housing (11). Install springs (15) in the manifold assembly, and put clutch
housing (11) in position. Be sure the springs are engaged correctly in the manifold assembly and
the clutch piston. Remove Tool (G), the hoist and Tool (L). Install the bolts to hold the clutch
housings together. Tighten the bolts to a torque of 115 ± 7 N·m (85 ± 5 lb ft).
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77. Check to be sure the clutch pistons are free in their clutch housings with Nozzle (M), as
follows:
a. Put air free of water under a pressure of 690 kPa to 1030 kPa (100 psi to 150 psi) into each of
the six oil passages.
b. If the clutch pistons do not move, put a small amount of clean SAE 30 oil into each passage.
Check for movement again. If the clutch pistons still do not move, the transmission must be
disassembled to check the clutch pistons and seal rings.
78. Install O-ring seals (9) and (10) on the manifold assembly.
79. Use a hoist to turn the transmission over. Install the O-ring seal and elbow (5). Install gear (7),
retainer (6) and the bolt on the transmission input shaft.
80. Install O-ring seal (122) on the manifold assembly. Fasten Tool (A) and a hoist to case (1).
Install the case on the transmission. Install the bolts that hold case (1) to the manifold assembly.
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Caterpillar Cat 970F Wheel Loader (Prefix 9JK) Service Repair Manual Instant Download (9JK00001).pdf

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