Caterpillar Cat 972M Wheel Loader (Prefix JPR) Service Repair Manual (JPR00001 and up).pdf

Service Repair Manual
Models
972M Wheel Loader

Shutdown SIS
Previous Screen
Product: WHEEL LOADER
Model: 972M WHEEL LOADER JPR
Configuration: 972M Wheel Loader JPR00001-UP (MACHINE) POWERED BY C9.3 Engine
Disassembly and Assembly
966M and 972M Wheel Loaders Power Train
Media Number -UENR0378-12 Publication Date -01/09/2015 Date Updated -05/10/2017
i05277906
Torque Converter (Freewheel Stator) (Lockup) - Assemble
SMCS - 3101-016-L7
Assembly Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 422-5472 Lifting Eye Assembly 3
B 1P-0520 Driver Gp 1
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
1/16
972M Wheel Loader JPR00001-UP (MACHINE) POWERED BY C9.3 Engine(SEBP...
2021/4/6
https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw...

Illustration 1 g03355787
1. Use a suitable press in order to install bearing race (61) onto shaft (58).
2. Install seals (59) onto shaft (58). Install seal (60).
3. Install bearing (57) and retaining ring (56).
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4. Install seal (55) onto stator carrier assembly (51).
5. Use Tooling (B) and a suitable press in order to install bearing (54) (not shown) into gear
(53).
6. Use Tooling (B) and a suitable press in order to install stator carrier assembly (51) into gear
(53).
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7. Install retaining ring (52) onto stator carrier assembly (51).
8. Install stator carrier assembly (51) onto shaft (58). Install retaining ring (50).
9. Install impeller hub (48) to impeller (49).
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10. Install impeller hub (48) and impeller (49). Install bolts (47). Tighten bolts (47) to a torque
of 60 ± 7 N·m (44 ± 5 lb ft).
11. Install thrust bearing (46).
12. Use Tooling (B) and a suitable press in order to install cam (45) (not shown) into stator (37).
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13. Install race (42), freewheel springs (43), and freewheel rollers (44).
Note: Be sure to install freewheel springs with the lesser number of loops going toward race
(42), as shown in Illustration 14.
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Improper assembly of parts that are spring loaded can cause bodily
injury.
To prevent possible injury, follow the established assembly procedure
and wear protective equipment.
14. Install plate (41) and retaining ring (40) into stator (37).
15. Flip the stator over and install plate (39) and retaining ring (38).
16. Install stator (37).
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17. Install thrust bearing (36).
18. Connect turbine (34) to turbine hub (35). Install two bolts (20) in order to keep turbine (34)
and turbine hub (35) together during the Step 19.
19. Install turbine (34) to turbine hub (35) as one unit. Remove bolts (20).
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20. Install washer (33) and retaining ring (32).
21. Install bearing (31).
22. Install backing plate (30).
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23. Install spline plate (29).
24. Install clutch disc (28).
25. Install plate (27).
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972M Wheel Loader JPR00001-UP (MACHINE) POWERED BY C9.3 Engine(SE...
2021/4/6

26. Install springs (26) and (25) inside of springs (24). Install springs (24) in an alternating
pattern. An example would be to install a spring (24) and with a spring (25) inside. The next
one would be to install a spring (24) with a spring (26) inside.
Improper assembly of parts that are spring loaded can cause bodily
injury.
To prevent possible injury, follow the established assembly procedure
and wear protective equipment.
27. Install plate (23) to coupling assembly (21). Install bolts (22). Tighten bolts (22) to a torque
of 50 ± 10 N·m (37 ± 7 lb ft).
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28. Install coupling assembly (21). Install bolts (20). Tighten bolts (20) to a torque of
60 ± 7 N·m (44 ± 5 lb ft).
29. Install seal ring (19) into piston (18).
30. Install piston (18).
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31. Install O-ring seal (17). Install bushing (16) into housing assembly (15).
32. Install housing assembly (15) into the torque converter.
33. Install bolts (13). Tighten bolts (13) to a torque of 60 ± 7 N·m (44 ± 5 lb ft). Install seal
(14).
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34. Position torque converter (12) as shown.
35. Use Tooling (B) in order to install bearing (11) in pump drive gear (9).
36. Attach Tooling (A) and a suitable lifting device to torque converter housing (10). The
weight of torque converter housing (10) is approximately 100 kg (220 lb). Use Tooling (A)
and the suitable lifting device in order to install torque converter housing (10) over the
torque converter.
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37. Install pump drive gear (9) and drive gear shaft (8).
38. Install bolt (7) and the washer that holds drive gear shaft (8) to the torque converter housing.
Tighten bolt (7) to a torque of 240 ± 40 N·m (180 ± 30 lb ft).
39. Install pump drive flange (6) and bolts (62). Tighten bolts (62) to a torque of 60 ± 12 N·m
(44 ± 9 lb ft).
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40. Install bolts (4) and the washers that hold the torque converter to the torque converter
housing. Tighten bolts (4) to a torque 50 ± 10 N·m (37 ± 7 lb ft).
41. Install O-ring seal (5).
42. Install gear (3). Tighten bolt (63) to a torque of 120 ± 20 N·m (90 ± 15 lb ft).
43. Install torque converter speed sensor (2), the seal, and the washer. Tighten torque converter
speed sensor (2) to a torque of 25 ± 5 N·m (18 ± 4 lb ft).
End By:
a. Connect the torque converter to the transmission and the output transfer gears.
Copyright 1993 - 2021 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Tue Apr 6 17:06:57 UTC+0800 2021
16/16
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Shutdown SIS
Previous Screen
i06909789
Transmission from Output Transfer Gears - Separate
SMCS - 3002-076
Separation Procedure
Table 1
Required Tools
A 439-3938 Link Bracket 3
B 154-6181 Forcing Screw 3
Start By:
a. Separate the torque converter from the transmission.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
1/4
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1. Remove bolts (1) and tube assembly (2).
2. Disconnect harness assemblies (3).
3. Attach Tooling (A) and a suitable lifting device to transmission (4). The weight of
transmission (4) is approximately 425 kg (936 lb).
2/4
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4. Remove bolts (5) and (6) that connect transmission (4) with output transfer gears (7).
5. Use Tooling (B) to separate transmission (4) from output transfer gears (7).
6. Remove transmission (4).
Copyright 1993 - 2021 Caterpillar Inc.
All Rights Reserved.
Tue Apr 6 17:07:54 UTC+0800 2021
3/4
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Shutdown SIS
Previous Screen
i06909951
Transmission Planetary - Disassemble
SMCS - 3160-015
Disassembly Procedure
Table 1
Required Tools
A 1P-2420 Transmission Repair Stand 1
B 439-3940 Bracket As 3
C 1P-0520 Driver Gp 1
D 8B-7551 Bearing Puller 1
Start By:
a. Separate the transmission from the output transfer gears.
Note: Cleanliness is an important factor. Before the disassembly procedure, clean the exterior of
the component . Cleaning will help to prevent dirt from entering the internal mechanism.
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1. Remove O-ring seal (1) from the housing.
2. Remove bolt (2). Remove drive gear (3) from the end of the input shaft.
3. Remove plate (4).
4. Attach Tooling (B) and a suitable lifting device to the transmission, as shown. The weight
of the transmission is approximately 425 kg (936 lb).
2/21
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5. Carefully position the transmission on the opposite end so that No. 6 clutch housing (5) is
facing upward, as shown.
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.
6. Remove retaining ring (6) from output shaft assembly (7). Remove bolts (8) and No. 6
clutch housing (5). Mark the location of the long bolts.
7. Remove clutch piston (9) from No. 6 clutch housing (5).
8. Remove seal rings (10) and (11) from clutch piston (9).
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9. Remove clutch plate (12), springs (13), and the pins.
10. Remove clutch plates (12) and friction discs (14). Remove dowels (15).
11. Remove ring gear (16).
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12. Remove carrier assembly (17). Remove bolts (18).
13. Remove metal seal ring (19) from carrier assembly (17).
14. Push the spring pins (20) through carrier assembly (17) and into planetary shafts (21).
Remove planetary shafts (21) from carrier assembly (17).
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15. Remove thrust discs (22), planetary gears (23), and bearings (24) from the carrier assembly.
Remove spring pins (20) from planetary shafts (21).
16. Disconnect the harness assemblies (26) which are attached to transmission modulating
valves (25). Remove transmission modulating valves (25) from the transmission housing.
17. Remove retaining ring (27) and (28).
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18. Use Tooling (B) and a suitable lifting device to remove housing assembly (29). The weight
of housing assembly (29) is approximately 88 kg (195 lb).
19. Remove bearing (30) from housing assembly (29).
20. Remove retaining ring (33) and clutch assembly (31). Remove springs (32) and rods (34)
(not shown).
7/21
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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.
21. Use steel spacers and a suitable press to install retainer plate (35). Remove retaining ring
(36) from the clutch assembly (31).
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22. Separate retaining ring (36), retainer plate (35), and five coned disc springs (37). Remove
seal rings (39) from clutch piston (38). Remove seal rings (41) from clutch housing (40).
23. Remove friction discs (42) and clutch plates (43). Remove dowels (44).
24. Remove retaining ring (45) from output shaft assembly (7). Remove sun gear (46).
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25. Remove friction discs (47) and clutch plates (48).
26. Remove ring gear (49).
27. Remove retaining ring (50). Remove plate (51) from ring gear (49).
10/21
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28. Remove clutch piston (53). Remove O-ring seal (52). Use Tooling (B) and a suitable lifting
device to remove housing (54). The weight of housing (54) is approximately 54 kg (119 lb).
Note: Remove the clutch piston in the bottom of housing (54). The clutch piston may be
stuck in housing (54). As housing (54) is removed, the other clutch piston may fall.
29. Remove seal rings (55) and (56) from clutch pistons (53).
11/21
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30. Remove dowels (57). Remove O-ring seal (58). Remove clutch plate (59). Remove springs
(60).
31. Remove friction discs (61) and clutch plates (59).
32. Remove carrier assembly (62).
33. Use several small steel rods (64) ( 3.175 mm (0.1250 inch) diameter and one pointed tip) to
compress the retaining ring that holds carrier assembly (62) to ring gear (65).
34. Remove carrier assembly (62) from ring gear (65). Remove ring seal (63).
12/21
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35. Remove retaining ring (66) from carrier assembly (62).
36. Use a suitable punch to push spring pins (67) (not shown) through carrier assembly (62) and
into planetary shafts (68).
Remove spring pins (67) from planetary shafts (68).
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38. Remove retaining ring (72). Remove output shaft assembly (7).
39. Remove retaining ring (75). Remove sun gear (74). Remove bearing (73). Remove bearings
(76) from each end of output shaft assembly (7).
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40. Remove bolts (78). Use Tooling (B) and a suitable lifting device to remove housing (77).
The weight of housing (77) is approximately 61 kg (135 lb).
Note: Remove clutch piston (79) in the bottom of housing (77). Clutch piston (79) may be
stuck in housing (77). As housing (77) is removed, clutch piston (79) may fall.
41. Remove seal rings (80) from clutch piston (79).
42. Remove plate (81). Remove springs (82). Remove dowels (83). Remove friction discs (84)
and clutch plates (85).
43. Remove retaining ring (87). Use two people to remove carrier assembly (86). The weight of
carrier assembly (86) is approximately 29 kg (65 lb)
15/21
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44. Remove ring gear (88) from carrier assembly (86).
45. Use several small steel rods (89) ( 2.36 mm (0.093 inch) diameter and one pointed tip) to
compress the retaining ring that holds carrier assembly (86) to ring gear (90) together.
46. Remove ring gear (90) from carrier assembly (86).
16/21
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47. Use a suitable punch to push spring pins (91) through carrier assembly (86) and into
planetary shafts (92).
48. Use a suitable punch to remove planetary shafts (92) from carrier assembly (86).
49. Open retaining ring (93) into slots in the planetary shaft holes. Use Tooling (C) to remove
bearing (94) and sun gear (95) from carrier assembly (86). Remove thrust disc (96).
17/21
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51. Remove spring pins (91) from planetary shafts (92).
52. Remove O-ring seal (100). Remove plate (101).
53. Remove O-ring seal (102). Remove friction discs (103) and clutch plates (104).
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54. Remove ring carrier (105) and carrier assembly (106).
55. Use a suitable punch to push spring pins (107) through carrier assembly (106) and into
planetary shafts (108).
56. Remove thrust discs (109), planetary gears (110), and bearings (111) from the carrier
assembly. Remove spring pins (107) from planetary shafts (108).
19/21
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57. Remove coupling (112). Remove sun gear (113).
58. Remove clutch piston (114).
59. Remove seal rings (115) and (116) from clutch piston (114).
60. Remove retaining ring (117) to remove input shaft (119) from housing (118).
20/21
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Caterpillar Cat 972M Wheel Loader (Prefix JPR) Service Repair Manual (JPR00001 and up).pdf

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