Caterpillar Cat 972G II Wheel Loader (Prefix AWP) Service Repair Manual (AWP00001 and up).pdf

Service Repair Manual
Models
972G II Wheel Loader

Shutdown SIS
Previous Screen
Product: WHEEL LOADER
Model: 972G II WHEEL LOADER AWP
Configuration: 972G II Wheel Loader AWP00001-UP (MACHINE) POWERED BY 3196 Engine
Disassembly and Assembly
966G Series II and 972G Series II
Wheel Loaders Power Train
Media Number -RENR4365-07 Publication Date -01/08/2008 Date Updated -14/08/2008
i02299289
Torque Converter (Freewheel Stator) - Disassemble
SMCS - 3101-015
Disassembly Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 138-7575 Link Bracket 2
B 1P-0510 Driver Gp 1
C 2P-8312 Retaining Ring Pliers 1
Start By:
A. Separate the torque converter from the transmission and from the output transfer gears.
Refer to Disassembly and Assembly, "Torque Converter from Transmission, Output
Transfer Gears - Separate".
Note: Cleanliness is an important factor. Before the disassembly procedure, the exterior of the
component should be thoroughly cleaned. This will help to prevent dirt from entering the internal
mechanism.
NOTICE
Care must be taken to ensure that fluids are contained during
performance of inspection, maintenance, testing, adjusting and repair
of the product. Be prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any component
containing fluids.
1/11
972G II Wheel Loader AWP00001-UP (MACHINE) POWERED BY 3196 Engine(SE...
2021/5/12
https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis...

Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop
Products Guide" for tools and supplies suitable to collect and contain
fluids on Caterpillar products.
Dispose of all fluids according to local regulations and mandates.
Illustration 1 g00456063
1. Use Tooling (A) and a suitable lifting device to position the torque converter assembly on
suitable blocking, as shown. The weight of the torque converter assembly is approximately
191 kg (420 lb).
2. Remove torque converter speed sensor (4) , the seal, and the washer.
3. Remove bolt (1) and retainer (2) . Remove gear (3) from the torque converter housing.
2/11
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4. Remove bolts (6) and the washers that hold the torque converter to the torque converter
housing.
5. Remove O-ring seal (5) .
6. Remove bolts (7) and pump drive flange (8) .
3/11
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7. Remove bolt (9) and the washer that holds drive gear shaft (10) to the torque converter
housing.
8. Remove pump drive gear (11) and drive gear shaft (10) .
9. Remove drive gear shaft (10) from pump drive gear (11) .
10. Use Tooling (A) and a suitable lifting device to remove the torque converter housing. The
weight of the torque converter housing is approximately 113 kg (250 lb).
11. Remove bearing (12) from pump drive gear (11) . Use Tooling (B) in order to remove the
bearing.
4/11
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Note: For the disassembly of carrier shaft (17) , refer to Steps 30 through 34.
12. Remove bolts (13) and the washers. Use a suitable lifting device to remove impeller (14)
from rotating housing (15) . The weight of the impeller assembly is approximately 36 kg (80
lb).
Note: If the torque converter is equipped with a freewheel stator, continue with Steps 13
through 19.
13. Turn impeller (14) to the opposite side.
14. Remove retaining ring (16) and spacer (18) from carrier shaft (17) .
15. Remove stator (19) .
5/11
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16. Remove retaining ring (20) and washer (21) from stator (19) . Repeat the procedure for the
opposite side of stator (19) .
Note: If necessary, raise the temperature of the stator to a maximum temperature of 135 °C
(275 °F) for approximately fifteen minutes.
17. Remove bearing race (22) , freewheel rollers (23) , freewheel springs (24) , and freewheel
cam (25) from stator (19) .
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18. Remove spacer (26) from impeller (14) .
19. Use a suitable press to remove carrier shaft (17) from impeller (14) .
20. Remove bolts (27) and drive gear (28) .
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21. Remove bearing (29) from impeller (14) .
22. Remove retaining ring (30) and end cover (31) from rotating housing (15) .
8/11
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24. Use Tooling (C) to remove retaining ring (33) .
25. Remove bearing spacer (34) from rotating housing (15) .
26. Turn rotating housing (15) onto the opposite side. Remove turbine (35) .
27. Remove bolts (36) and the washers. Separate turbine (35) from turbine hub assembly (37) .
28. If necessary, remove locating dowel (38) .
9/11
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29. Remove bearing (39) and ring (40) from rotating housing (15) .
30. Remove retaining ring (46) and plate (45) .
31. Use a soft faced hammer to remove shaft assembly (41) from carrier shaft (17) .
32. Remove outer bearing (44) .
33. Use a suitable press to remove inner race (43) from shaft (41) .
10/11
972G II Wheel Loader AWP00001-UP (MACHINE) POWERED BY 3196 Engine(...
2021/5/12

34. Remove ring (42 ) from shaft (41) .
Copyright 1993 - 2021 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Wed May 12 08:50:39 UTC+0800 2021
11/11
2021/5/12

Shutdown SIS
Previous Screen
i07399197
Torque Converter (Freewheel Stator) - Assemble
SMCS - 3101-016
Assembly Procedure
Table 1
Required Tools
C 2P-8312 Retaining Ring Pliers 1
D 7F-6068 Sleeve 1
Note: Cleanliness is an important factor. Before assembly, all parts should be thoroughly cleaned
in cleaning fluid. Allow the parts to air dry. Wiping cloths or rags should not be used to dry parts.
Lint may be deposited on the parts which may cause later trouble. Inspect all parts. If any parts are
worn or damaged, use new parts for replacement.
1/9
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1. Install bearing (39) and ring (40) on rotating housing (15).
1. Install locating dowel (38) in turbine hub assembly (37).
2. Install turbine hub assembly (37) to turbine (35). Install bolts (36) and the washers. The
torque for bolts (36) is 60 ± 7 N·m (44 ± 5 lb ft).
3. Turn rotating housing (15) onto opposite side. Install turbine (35).
2/9
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4. Install bearing spacer (34).
5. Use Tooling (C) to install retaining ring (33) on turbine hub assembly (37). Retaining ring
(33) must be securely seated in the groove.
6. Install O-ring seal (32).
7. Install end cover (31) and retaining ring (30) in rotating housing (15).
3/9
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8. Lower the temperature of bearing (29).
9. Install bearing (29) in impeller (14).
Note: The notch in bearing (29) must face downward, as shown.
10. Install drive gear (28) and bolts (27). The torque for bolts (27) is 105 ± 15 N·m
(75 ± 11 lb ft).
Note: If the torque converter is equipped with a freewheel stator, continue with Steps 11
through 16.
11. Install the seal ring (not shown) onto carrier shaft (17). Use a suitable press to install carrier
shaft (17) in impeller (14).
12. Install spacer (26) over shaft (17).
4/9
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13. Install freewheel cam (25), freewheel springs (24), freewheel rollers (23), and bearing race
(22) in stator (19).
Note: If necessary, raise the temperature of stator (19) to a maximum temperature of 135 °C
(275 °F). Install the cam with the IMPELLER SIDE facing downward. Continue with the
installation until freewheel cam (25) contacts the retaining ring (not shown).
Note: Install freewheel springs (24) with the maximum number of loops toward the outside
diameter of freewheel cam (25).
14. Install washer (21) and retaining ring (20) on stator (19). Repeat the procedure for the
opposite side of stator (19).
5/9
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15. Install stator (19) on impeller (14).
16. Install plate (18) and retaining ring (16) on carrier shaft (17).
17. Assemble carrier shaft (17), as follows.
18. Install ring (42) on shaft (41).
19. Use a suitable press to install inner race (43) onto shaft (41).
20. Install outer bearing (44).
6/9
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21. Use Tooling (B), Tooling (D), and a suitable press to install shaft assembly (41) and outer
bearing (44) into carrier shaft (17).
22. Install plate (45) and retaining ring (46).
23. Install impeller (14) on rotating housing (15). The weight of the impeller assembly is
approximately 36 kg (80 lb).
24. Install bolts (13) and the washers. The torque for bolts (13) is 60 ± 7 N·m (44 ± 5 lb ft).
25. Use Tooling (B) to install bearing (12) in pump drive gear (11).
7/9
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26. Install pump drive gear (11) and drive gear shaft (10).
27. Use Tooling (A) and a suitable lifting device to install the torque converter housing over the
torque converter. The weight of the torque converter housing is approximately 113 kg
(250 lb).
28. Install bolt (9) and the washer that holds drive gear shaft (10) to the torque converter
housing. The torque for bolt (9) is 240 ± 40 N·m (180 ± 30 lb ft).
29. Install pump drive flange (8) and bolts (7). The torque for bolts (7) is 60 ± 12 N·m
(44 ± 9 lb ft).
8/9
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30. Install bolts (6) and the washers that hold the torque converter to the torque converter
housing. The torque for bolts (6) is 50 ± 10 N·m (37 ± 7 lb ft).
31. Install O-ring seal (5).
32. Install gear (3), retainer (2), and bolt (1). The torque for bolt (1) is 120 ± 20 N·m
(90 ± 15 lb ft).
33. Install torque converter speed sensor (4), the seal, and the washer. Adjust torque converter
speed sensor (4) to maintain an air gap of 0.71 ± 0.18 mm (0.028 ± 0.007 inch). The torque
for torque converter speed sensor (4) is 25 ± 5 N·m (18 ± 4 lb ft).
End By:
a. Connect the torque converter to the transmission and to the output transfer gears. Refer to
Disassembly and Assembly, "Torque Converter to Transmission, Output Transfer Gears -
Connect".
Wed May 12 08:51:36 UTC+0800 2021
9/9
2021/5/12

Shutdown SIS
Previous Screen
i02642179
Transmission from Output Transfer Gears - Separate
SMCS - 3002-076
Separation Procedure
Table 1
Required Tools
Start By:
A. Separate the torque converter from the transmission. Refer to Disassembly and Assembly,
"Torque Converter from Transmission, Output Transfer Gears - Separate".
Note: Put identification marks on all harness assemblies for installation purposes. Plug all tube
assemblies. This helps to prevent fluid loss, and this helps to keep contaminants from entering the
system.
1/3
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1. Remove bolts (1) and remove drain tube assembly (2) .
2. Attach Tooling (A) and a suitable lifting device to transmission planetary (4) .
2/3
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4. Disconnect harness assemblies (6). Disconnect harness assembly (8) .
5. Remove bolts (5) which hold transmission planetary (4) to output transfer gear case (7) .
Note: If necessary, use forcing screws in order to separate transmission planetary (4) from
output transfer gear case (7) .
6. Use Tooling (A) and the suitable lifting device in order to separate transmission planetary
(4) from output transfer gear case (7). The weight of transmission planetary (4) is
approximately 545 kg (1200 lb).
Wed May 12 08:52:32 UTC+0800 2021
3/3
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Shutdown SIS
Previous Screen
i02299775
Transmission Planetary - Disassemble
SMCS - 3160-015
Disassembly Procedure
Table 1
Required Tools
C 8H-0663 Bearing Puller 1
Start By:
A. Separate the transmission from the output transfer gears. Refer to Disassembly and
Assembly, "Transmission from Output Transfer Gears - Separate".
Note: Cleanliness is an important factor. Before the disassembly procedure, the exterior of the
component should be thoroughly cleaned. This will help to prevent dirt from entering the internal
mechanism.
Note: Put identification marks on all lines, on all hoses, on all wires, and on all tubes for
installation purposes. Plug all lines, hoses, and tubes. This helps to prevent fluid loss and this
helps to keep contaminants from entering the system.
1/30
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1. Remove O-ring seal (1) from the housing.
2. Remove bolt (3), retainer (2), and drive gear (4) from the end of the input shaft.
3. Remove plate (5) .
2/30
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4. Attach Tooling (A) and a suitable lifting device to the transmission, as shown. The weight
of the transmission is approximately 544 kg (1200 lb).
5. Carefully position the planetary group on the opposite end so that No. 6 clutch housing (6)
is facing upward, as shown.
6. Remove retaining ring (8) from output shaft (7) .
Personal injury can result from being struck by parts propelled by a
released spring force.
Make sure to wear all necessary protective equipment.
Follow the recommended procedure and use all recommended tooling to
release the spring force.
3/30
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7. Remove bolts (9) and No. 6 clutch housing (6). Mark the location of the long bolts.
8. Remove clutch piston (10) from No. 6 clutch housing (6) .
9. Remove seal rings (11) and (12) from clutch piston (10) .
10. Remove clutch plate (14) and springs (13) .
4/30
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11. Remove clutch plates (15) and friction discs (16) .
12. Remove ring gear (17). Remove transmission speed sensors (18) .
13. Remove carrier assembly (19) .
5/30
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14. Remove metal seal ring (20) from carrier assembly (19) .
15. Use a hammer and a punch to push the spring pins through carrier assembly (19) and into
planetary shafts (21) .
6/30
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16. Use a hammer and a punch to remove planetary shafts (21) from carrier assembly (19) .
17. Remove thrust discs (22), planetary gears (23), and bearings (24) from the carrier assembly.
Remove spring pins (25) from planetary shafts (21) .
18. Remove O-ring seal (26). Remove bolts (27) from manifold (28) .
7/30
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19. Disconnect the harness assemblies which are attached to transmission modulating valves
(29). Remove transmission modulating valves (29) from the transmission housing.
20. Remove retaining ring (32) and gear (30). Remove retaining ring (31) .
8/30
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21. Use Tooling (A) and a suitable lifting device to remove manifold (28). The weight of
manifold (28) is approximately 85 kg (190 lb).
22. Remove bolt (33) which holds the harness assembly in place.
23. Remove retaining ring (34) and bearing (35) from manifold (28) .
24. Remove retaining ring (36) and clutch housing (37) .
9/30
2021/5/12

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25. Remove O-ring seal (38) from clutch housing (37) .
Personal injury can result from being struck by parts propelled by a
released spring force.
Make sure to wear all necessary protective equipment.
Follow the recommended procedure and use all recommended tooling to
release the spring force.
26. Use steel spacers and a suitable press to push on retainer plate (40). Remove retaining ring
(39) from the clutch housing.
10/30
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27. Separate retaining ring (39), retainer plate (40), three coned disc springs (41), and clutch
piston (42) .
28. Remove seal rings (43) from clutch piston (42) .
11/30
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29. Remove seal rings (44) from clutch housing (37) .
30. Remove retaining ring (45) from the output shaft. Remove hub (46) .
31. Remove friction discs (47) and clutch plates (48) .
12/30
2021/5/12

Caterpillar Cat 972G II Wheel Loader (Prefix AWP) Service Repair Manual (AWP00001 and up).pdf

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Caterpillar Cat 972G II Wheel Loader (Prefix AWP) Service Repair Manual (AWP00001 and up).pdf