Caterpillar Cat 972H Wheel Loader (Prefix GTA) Service Repair Manual (GTA00001 and up).pdf

Service Repair Manual
Models
972H Wheel Loader

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Product: WHEEL LOADER
Model: 972H WHEEL LOADER GTA
Configuration: 972H Wheel Loader GTA00001-UP (MACHINE) POWERED BY C13 Engine
Disassembly and Assembly
966H and 972H Wheel Loaders Power Train
Media Number -RENR8847-07 Publication Date -01/03/2013 Date Updated -04/03/2013
i06064263
Transmission Planetary - Assemble
SMCS - 3160-016
S/N - A7D1-UP
S/N - A7G1-UP
S/N - A7J1-UP
S/N - GTA1-UP
S/N - LCC1-UP
Assembly Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 138-7575 Link Bracket 3
B 1P-0520 Driver Gp 1
D FT-2746 Guide Pin 2
E 1P-0510 Driver Gp 1
F - Loctite 5127 1
Note: Cleanliness is an important factor. Before assembly, all parts should be 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.
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Illustration 1 g00460318
Note: O-ring seal (137) is not installed at this time. The O-ring seal is shown in order to
clarify the installation in Step 11.
1. Raise the temperature of bearing (135) and the race. Install bearing (135) and the race onto
input shaft (134) , as shown.
2. Apply clean transmission oil to ring seals (136) . Install two ring seals (136) on input shaft
(134) .
3. Carefully install input shaft (134) in housing (133) .
4. Install retaining ring (132) in order to hold the input shaft and the bearing in place.
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5. Install bearings (130) in planetary gears (129) . Install the gear assemblies, thrust discs
(128) , and planetary shafts (127) in carrier assembly (119) .
6. Use a hammer and a punch to install spring pins (131) that hold planetary shafts (127) in
carrier assembly (119) . Make sure that the spring pins are flush with the counterbore in the
carrier.
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7. Install seal ring (126) on carrier assembly (119) .
8. Use Tooling (B) to install bearing (125) . Install retaining ring (124) .
Note: Coupling (120) may be installed on carrier assembly (119) at this time. Refer to Step
13 for the procedure.
9. Install seal rings (122) and (123) on clutch piston (121) .
10. Place suitable cribbing under the housing. Install clutch piston (121) in the clutch housing.
Make sure that the lips of the seals are facing downward.
11. Install O-ring seal (137) . Apply clean transmission oil to O-ring seal (137) and the O-ring
seal groove on the shaft. Refer to Illustration 1 for the location of the O-ring seal.
12. Install carrier assembly (119) .
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13. If necessary, install coupling (120) on carrier assembly (119) . Use small steel rods (118) to
compress the retaining ring that holds coupling (120) to carrier assembly (119) .
Note: For assembly purposes, use Tooling (D) to hold the clutch plates in place. Do not
remove Tooling (D) until Step 85 is completed.
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14. Install one clutch plate (117) in the housing so that the small hole in the clutch plate is
aligned with the small hole in the housing, as shown.
15. Install Tooling (D) in two of the five threaded holes in the housing through clutch plate
(117) , as shown. Do not remove Tooling (D) until Step 85 is completed.
16. Install friction discs (114) and clutch plates (117) in alternating order. Start with a friction
disc. Install clutch plates (117) so that Tooling (D) passes through the bolt holes in the
clutch plates. Install the clutch plates with the small holes on the opposite side of Tooling
(D) in comparison to the first clutch plate (117) that was installed in Step 14.
17. Install O-ring seals (115) and (116) .
18. Install plate (113) .
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19. Install bearings (109) in planetary gears (108) . Install the gear assemblies, thrust discs
(107) , and planetary shafts (106) in carrier assembly (99) .
carrier.
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21. Use Tooling (B) and a press to install bearing (111) . Install retaining ring (104) .
22. Install O-ring seal (112) on sun gear (103) . Apply clean transmission oil to O-ring seal
(112) and the O-ring seal groove on sun gear (103) .
23. Install sun gear (103) in carrier assembly (99) .
24. Install retaining ring (105) on carrier assembly (99) .
Note: Gear (100) is not installed at this time. The gear is shown in order to clarify the
installation in Step 27.
25. Use small steel rods (101) to compress the retaining ring. Install carrier assembly (99) in
ring gear (102) until the retaining ring fits into the groove in the ring gear.
26. Install carrier assembly (99) on the input shaft. The weight of the carrier assembly is
approximately29 kg (65 lb).
27. Install gear (100) .
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Typical Example
Do Not Remove Tooling (D) Until Step 85 is Completed.
28. Install retaining ring (94) on the input shaft.
29. Install ring gear (96) .
30. Install O-ring seals (97) and (98) . Install springs (95) .
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disc. Start with a friction disc. Install clutch plates (91) so that Tooling (D) passes through
the bolt holes in the clutch plates. Install the last clutch plate so that the small holes in the
clutch plate are over springs (95) , as shown. Install rods (67) .
33. Install clutch piston (89) . Make sure that the lips of the seals are facing upward.
Typical Example
34. Use Tooling (A) and a suitable lifting device to install housing (88) . The weight of housing
(88) is approximately 61 kg (135 lb).
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35. If bearings (87) were removed, lower the temperature of the two bearings. Then, put the
bearings in position in both ends of output shaft (82) .
36. Use Tooling (E) to install bearings (87) .
Note: For the 966F, install the bearing to a depth of 12.0 ± 0.5 mm (0.47 ± 0.02 inch) on the
gear end of the output shaft. After assembly, the inside diameter of bearing (87) must be
34.988 ± 0.039 mm (1.3775 ± 0.0015 inch). Repeat for the opposite end of the output shaft.
Note: For the 972F, install the bearing to a depth of 13.00 ± 0.25 mm (0.512 ± 0.010 inch)
on the gear end of the output shaft. After assembly, the inside diameter of bearing (87) must
be 56.650 ± 0.061 mm (2.2303 ± 0.0024 inch). Install the bearing on the other end of the
output shaft to a depth of 25.50 ± 0.25 mm (1.004 ± 0.010 inch). After assembly, the inside
diameter of bearing must be 35.629 ± 0.039 mm (1.4028 ± 0.0016 inch).
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Note: Make sure that the locating dowel fits into the notch in the bearing. Also, the groove
in the bearing must face the top of the output shaft.
37. Raise the temperature of bearing (86) and install the bearing on output shaft (82) .
38. Install sun gear (84) on output shaft (82) .
39. Install retaining ring (85) .
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40. Install O-ring seal (83) on output shaft (82) .
41. Install output shaft (82) over the input shaft.
42. Install retaining ring (81) that holds output shaft (82) to the carrier assembly.
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43. Install bearings (79) in planetary gears (78) . Install the gear assemblies, thrust discs (77) ,
and planetary shafts (76) in carrier assembly (69) .
carrier.
45. Install retaining ring (75) on carrier assembly (69) .
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46. Use steel rods (73) to compress the retaining ring. Install carrier assembly (69) in ring gear
(74) until the retaining ring fits into the groove in the ring gear.
47. Install bearing (72) and retaining ring (71) .
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48. Install gear (70) in carrier assembly (69) .
49. Install carrier assembly (69) . Make sure that all of the gear teeth are correctly engaged.
50. Install springs (68) . Install O-ring seals (65) and (66) .
51. Install friction discs (63) and clutch plates (64) in alternating order. Install clutch plates (64)
so that Tooling (D) passes through the bolt holes in the clutch plates. Install the last clutch
plate so that the small holes in the clutch plate are over springs (68) , as shown. Start with a
friction disc.
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53. Install clutch piston (60) . Make sure that the lips of the seals are facing upward.
Note: Clutch piston (60) may be installed in housing (59) before the housing is placed in
position.
Typical Example
54. Use Tooling (A) and a suitable lifting device to install housing (59) . The weight of housing
(59) is approximately 66 kg (145 lb).
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56. Install clutch piston (54) . Make sure that the lips of the seals are facing downward.
57. Install hub (46) . Install retaining ring (45) on the output shaft.
58. Install O-ring seals (55) and (56) .
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59. Install friction discs (52) and clutch plates (53) in alternating order. Install clutch plates (53)
so that Tooling (D) passes through the bolt holes in clutch plates (53) . Install the first clutch
plate so that the pins pass through the small holes in the clutch plate, as shown. Start with a
clutch plate.
60. Install ring gear (50) and clutch plate (49) .
disc.
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62. Install seal rings (43) on clutch piston (42) .
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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.
63. Stack clutch piston (42) , coned disc springs (41) , and retainer plate (40) on the clutch
housing. Make sure that the outside edges of the coned disc springs contact each other first.
64. Use steel spacers and a press to push on retainer plate (40) . Install retaining ring (39) on the
clutch housing.
65. Install seal rings (44) on clutch housing (37) .
Note: Each seal ring has a small gap. The gaps on the different seal rings should not be in
line with each other.
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66. Install O-ring seal (38) on clutch housing (37) .
67. Install clutch housing (37) in the ring gear. Install retaining ring (36) . Install springs (51) .
68. Lower the temperature of bearing (35) . Install bearing (35) in manifold (28) . Install
retaining ring (34) .
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Typical Example
69. Use Tooling (A) and a suitable lifting device to install manifold (28) . The weight of
manifold (28) is approximately 85 kg (190 lb).
Note: When installing manifold (28) ensure proper alignment of dowel on output shaft (82)
in notch of bearing (35) .
70. Install bolt (33) which holds the harness assembly in place.
Typical Example
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71. Install retaining ring (32) on the output shaft.
72. Install gear (30) . Use two screwdrivers to lift the clutch housing. Install retaining ring (31) .
Typical example
73. Apply Tooling (F) to both sides of the washers for bolts (27) . Install bolts (27) in manifold
(28) . Tighten bolts (27) to a torque of 280 ± 20 N·m (207 ± 15 lb ft).
74. Install O-ring seal (26) .
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75. Install bearings (24) in planetary gears (23) . Install the gear assemblies, thrust discs (22)
and planetary shafts (21) in carrier assembly (19) .
carrier.
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77. Install metal seal ring (20) in carrier assembly (19) .
78. Install carrier assembly (19) .
79. Install ring gear (17) .
80. Install transmission speed sensors (18) , the seals, and the washers. Refer to Testing and
Adjusting, RENR4387, "Speed Sensor (Transmission) - Adjust". Tighten the locknuts. The
torque for the locknuts is 25 ± 5 N·m (220 ± 45 lb in).
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81. Install clutch plates (15) and friction discs (16) in alternating order. Install clutch plates (15)
so that the guide pins pass through the bolt holes in the clutch plates. Start with a friction
disc.
82. Install springs (13) and clutch plate (14) . Make sure that clutch plate (14) is installed so that
the small holes are over springs (13) , as shown.
84. Install clutch piston (10) in No. 6 clutch housing (6) . Make sure that the lips of the seals are
facing downward.
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85. Install No. 6 clutch housing (6) and five new bolts (9) . Tighten bolts (9) until bolts (9) are
snug. Remove Tooling (D) .
86. Install the two remaining bolts (9) . Tighten bolts (9) to a torque of 110 ± 10 N·m (80 ± 7 lb
ft).
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87. Install retaining ring (8) on output shaft (7) .
Typical Example
88. Apply 690 to 1030 kPa (100 to 150 psi) of shop air pressure into each oil passage (140)
(total of six).
If the clutch pistons do not move, apply a small amount of clean transmission oil in each oil
passage and check for movement again. If the clutch pistons do not move, the transmission
must be disassembled again so that the clutch pistons and the seal rings can be checked.
Note: The mounting surfaces for the transmission modulating valves must be completely
clean. Clean the surfaces before installation of the transmission modulating valves.
89. Install transmission modulating valves (29) on the transmission housing. The torque for the
mounting bolts is 30 ± 4 N·m (265 ± 35 lb in).
90. Connect the harness assemblies which attach to the transmission modulating valves.
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91. The No. 6 clutch housing (6) is facing upward. Use Tooling (A) and a suitable lifting device
to position the transmission onto the opposite end so that the No. 1 clutch housing is facing
upward. The weight of the transmission is approximately 544 kg (1200 lb).
92. Install plate (5) .
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93. Install drive gear (4) on the end of the input shaft, as shown.
94. Install retainer (2) and bolt (3) . Tighten bolt (3) to a torque of 100 ± 20 N·m (75 ± 15 lb ft).
95. Apply clean transmission oil on O-ring seal (1) . Install O-ring seal (1) on the housing.
End By: Connect the transmission to the output transfer gears. Refer to Disassembly and
Assembly, "Transmission to Output Transfer Gears - Connect".
Copyright 1993 - 2021 Caterpillar Inc.
All Rights Reserved.
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Caterpillar Cat 972H Wheel Loader (Prefix GTA) Service Repair Manual (GTA00001 and up).pdf

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