Caterpillar Cat 972K Wheel Loader (Prefix Z4W) Service Repair Manual (Z4W00001 and up).pdf

Service Repair Manual
Models
972K Wheel Loader

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Product: WHEEL LOADER
Model: 972K WHEEL LOADER Z4W
Configuration: 972K Wheel Loader Z4W00001-UP (MACHINE) POWERED BY C9.3 Engine
Disassembly and Assembly
C9.3
Engines for Caterpillar Built Machines
Media Number -KENR8149-07 Publication Date -01/05/2014 Date Updated -29/05/2014
i05295978
Cylinder Block Cover - Remove and Install
SMCS - 1201-010-CH
Removal Procedure
Start By:
a. Remove the engine control module.
Illustration 1 g02157630
1. Disconnect tube assembly (1). Disconnect hose assemblies (3). Disconnect harness
assemblies (4) and (5). Remove nut (2) and position the harness assembly out of the way.
Remove three nuts (6) and remove bracket (7).
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2. Remove bolt (8). Remove stud bolt (9) and remove stud bolt (12).
3. Remove bolts (10) and remove the cylinder block cover (11).
Installation Procedure
NOTICE
Cleanliness is an important factor. Before assembly, clean all parts
thoroughly with 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.
NOTICE
Check the O-ring seals, the gaskets, and the seals for wear or for
damage. Replace the components, if necessary.
1. Install cylinder block cover (11) in the reverse order of removal.
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Tightening sequence
a. Tighten the bolts and the stud bolts in the above sequence.
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All Rights Reserved.
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Thu Apr 15 09:52:31 UTC+0800 2021
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C9.3
i05296037
Valve Mechanism Cover - Remove and Install
SMCS - 1107-010
Removal Procedure
1. Disconnect harness assembly (1) and remove the NRS Intake Pressure Sensor (2).
2. Disconnect harness assembly (5) and remove bolts (4). Remove the NRS Differential
Pressure Sensor (3) and remove the two rectangular seals (not shown).
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3. Disconnect clamp assemblies (7) and remove hose (6).
4. Disconnect harness assembly (8). Remove nuts (9) and the washers (not shown). Position
the harness assembly (8) and bracket assembly (10) out of the way.
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5. Remove two studs (11). Remove washers (12) and springs (13).
6. Remove eight bolts (14). Remove washers (12) and springs (13).
Note: Ensure that all stud bolts, bolts, washers, and springs have been fully removed from
the valve mechanism cover prior to the removal of the cover. This action will help prevent
any foreign material from being lost in the engine compartment, or in the engine.
7. Remove valve mechanism cover (15).
8. Remove cap (16) and the O-ring seal.
9. Remove clamp assembly (18) and remove breather assembly (17).
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10. Remove adapter (19) and remove both O-ring seals (not shown).
1. Install valve mechanism cover (15) in the reverse order of removal.
Tightening sequence for the valve mechanism cover
a. Tighten bolts (14) and stud bolts (11) in the above sequence.
b. Hand tighten cap (16).
c. Tighten adapter (19) to a torque of 15 ± 3 N·m (132 ± 26 lb in).
d. Tighten clamp (18) to a torque of 4.5 ± 0.5 N·m (40 ± 5 lb in).
e. Tighten the NRS Intake Pressure Sensor (2) to a torque of 10 N·m (89 lb in).
Thu Apr 15 09:53:28 UTC+0800 2021
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C9.3
i04371980
Compression Brake - Remove
SMCS - 1129-011
Removal Procedure
Start By:
A. Remove the valve mechanism cover. Refer to Disassembly and Assembly, "Valve
Mechanism Cover - Remove and Install".
1. Disconnect harness assembly (3) .
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2. Remove bolts (1) and remove compression brake (2) .
Thu Apr 15 09:54:24 UTC+0800 2021
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C9.3
i04372729
Compression Brake - Disassemble - Valve Assembly
SMCS - 1129-015
Disassembly Procedure
Start By:
A. Remove the compression brake. Refer to Disassembly and Assembly, "Compression Brake -
Remove".
1. Remove bolts (2) .
2. Remove valve (3) from compression brake (1) .
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3. Remove O-rings (4) from valve (3) .
4. Remove O-ring (5) from compression brake (1) .
Thu Apr 15 09:55:21 UTC+0800 2021
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C9.3
i04372734
Compression Brake - Assemble - Valve Assembly
SMCS - 1129-016
Assembly Procedure
Note: Check the O-ring seals for wear or for damage. Replace the components, if necessary.
Note: Lubricate the O-ring seals sparingly with clean engine oil.
1. Install O-ring seal (5) onto compression brake (1) .
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Note: Lubricate the O-ring seals sparingly with clean engine oil.
2. Install O-rings (4) onto valve (3) .
3. Install valve assembly (3) into compression brake (1) .
4. Install bolts (2). Tighten bolts (2) to a torque of 6 ± 1 N·m (53 ± 9 lb in).
End By: Install the compression brake. Refer to Disassembly and Assembly, "Compression Brake
- Install".
Thu Apr 15 09:56:18 UTC+0800 2021
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C9.3
i04372741
Compression Brake - Install
SMCS - 1129-012
Table 1
Required Tools
Tool Part Number Part Description Qty
A 1U-7234 Feeler Gauge 1
1. Adjust the engine valve lash. Refer to Testing and Adjusting, "Engine Valve Lash -
Inspect/Adjust".
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2. Loosen mounting nuts (4) that hold down the harness assembly. This will give the
compression brake more clearance during installation.
3. Lubricate the O-ring seal (5) that is found on compression brake (2) sparingly with clean
engine oil.
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Torque Sequence
4. Position compression brake (2) .
5. Connect harness assembly (3) and install bolts (1) finger tight.
6. Tighten bolts (1) to a torque of 55 ± 10 N·m (41 ± 7 lb ft) in the above sequence.
7. Tighten mounting nuts (4) that hold down the harness assembly.
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Note: Failure to adjust lash properly could result in engine damage.
8. Set the brake lash for the compression brake on cylinders one, three and five. Position the
number one piston to the top center position of compression stroke. Refer to Testing and
Adjusting, "Finding Top Center Position for No. 1 Piston".
9. Thread adjuster (7) clockwise until the brake piston (8) touches valve bridge (9) .
10. Turn adjuster (7) counterclockwise until the adjuster has turned one full rotation.
11. Use Tooling (A) in order to verify the brake lash of 0.9 ± 0.2 mm (0.035 ± 0.008 inch). The
brake lash is measured between brake piston (8) and valve bridge (9) .
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12. Tighten the locknut (6) to a torque of 50 ± 10 N·m (37 ± 7 lb ft). Do not allow the
adjustment screw to turn while you are tightening the adjustment locknut. Recheck the valve
lash after tightening the adjustment locknut.
Note: Failure to adjust lash properly could result in engine damage.
13. On cylinders two, four, and six, set the lash on the compression brake. Position the number
six piston to the top center position of compression stroke.
14. Thread adjuster (7) clockwise until the brake piston (8) touches valve bridge (9) .
15. Turn adjuster (7) counterclockwise until the adjuster has turned one full rotation.
16. Use Tooling (A) in order to verify the brake lash of 0.9 ± 0.2 mm (0.035 ± 0.008 inch). The
brake lash is measured between brake piston (8) and valve bridge (9) .
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17. Tighten locknuts (6) to a torque of 50 ± 10 N·m (37 ± 7 lb ft). Do not allow adjuster (7) to
turn while you are tightening locknut (6). Recheck the valve lash after tightening the
locknut.
End By: Install the valve mechanism cover. Refer to Disassembly and Assembly, "Valve
Thu Apr 15 09:57:15 UTC+0800 2021
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C9.3
i06789860
Rocker Arm and Shaft - Remove
SMCS - 1102-011
Removal Procedure
Start By:
a. Remove the valve mechanism cover. Refer to Disassembly and Assembly, "Valve
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
NOTICE
Put identification marks on each of the rocker arms and push rods in
order to identify the proper location for installation.
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1. Disconnect harness assemblies (4).
Note: Failure to hold stud bolt (2) stationary during the removal of nut (1) could result in
damage to the harness assembly (3).
2. Hold stud bolts (2) with a wrench in order to keep the stud bolts from rotating. Remove nuts
(1). Position harness assembly (3) out of the way.
3. Loosen nuts (6) and loosen rocker arm adjustment screws (5).
4. Remove bolts (8) and remove stud bolts (2). Remove the rocker arm shaft assembly.
5. Remove pushrods (7).
Thu Apr 15 09:58:11 UTC+0800 2021
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C9.3
i03630847
Rocker Arm - Disassemble
SMCS - 1123-015
Disassembly Procedure
Start By:
a. Remove the rocker arm and shaft. Refer to Disassembly and Assembly, "Rocker Arm and
Shaft - Remove".
NOTICE
Note: Place an identification mark on each of the components of the rocker shaft for installation
purposes.
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1. Remove plug (2) from rocker shaft (1).
2. Remove inlet rocker arm (4) and exhaust rocker arm (3) from rocker shaft (1).
Thu Apr 15 09:59:08 UTC+0800 2021
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C9.3
i03630849
Rocker Arm - Assemble
SMCS - 1123-016
Assembly Procedure
NOTICE
1. Lubricate all components of the rocker arm shaft with clean engine oil.
2. Install exhaust rocker arm (3) and inlet rocker arm (4) on rocker shaft (1).
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3. Install plug (2) into rocker shaft (1). Install plug (2) to a depth of 1.25 ± 0.25 mm
(0.049 ± 0.010 inch).
End By:
a. Install the rocker arm and shaft. Refer to Disassembly and Assembly, "Rocker Arm and
Shaft - Install".
Thu Apr 15 10:00:05 UTC+0800 2021
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C9.3
i07074607
Rocker Arm and Shaft - Install
SMCS - 1102-012
Table 1
Required Tools
Tool Part Number Part Description Qty
A 8T-2998 Lubricant 1
NOTICE
1. Apply Tooling (A) to both ends of the pushrods.
2. Apply Tooling (A) to each of the bottom faces of the rocker arms.
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View showing stud bolt (2) locations.
3. Install pushrods (7).
4. Align the rocker arm shaft assembly with locating dowel (X). Position the rocker arm shaft
assembly. Install bolts (8) and nuts (2). Tighten bolts (8) and nuts (2) to standard torque.
5. Position rocker arm adjustment screws (5) and tighten nuts (6). Adjust the valve lash of the
rocker arms. Refer to Testing and Adjusting, "Engine Valve Lash - Inspect/Adjust".
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6. Position harness assembly (3). Hold stud bolts (2) stationary and install nuts (1).
7. Connect harness assemblies (4) and carefully position locking spring (Z) into position.
End By:
a. Install the valve mechanism cover. Refer to Disassembly and Assembly, "Valve Mechanism
Cover - Remove and Install".
Thu Apr 15 10:01:02 UTC+0800 2021
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C9.3
i06019467
Cylinder Head - Remove
SMCS - 1100-011
Removal Procedure
Start By:
A. Remove the exhaust manifold. Refer to Disassembly and Assembly, "Exhaust Manifold -
Remove and Install".
B. Remove the fan drive mounting group. Refer to Disassembly and Assembly, "Fan Drive
Mounting Group - Remove and Install".
C. Remove the fuel rail and the fuel manifold. Refer to Disassembly and Assembly, "Fuel Rail
and Fuel Manifold - Remove".
D. Remove the fuel filter base. Refer to Disassembly and Assembly, "Fuel Filter Base -
Remove and Install".
E. Remove the inlet manifold. Refer to Disassembly and Assembly, "Inlet Manifold -
Remove".
F. Remove the rocker arm and shaft. Refer to Disassembly and Assembly, "Rocker Arm and
Shaft - Remove".
G. Remove the unit injectors. Refer to Disassembly and Assembly, "Unit Injector - Remove".
NOTICE
NOTICE
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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.
Refer to Special Publication, NENG2500, "Dealer Service Tool
Catalog" for tools and supplies suitable to collect and contain fluids on
Cat products.
Dispose of all fluids according to local regulations and mandates.
1. Remove tube assembly (1) .
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2. Remove bolts (4) .
3. Remove bolts (3) and bracket (2) .
Note: Examine bolts (5) for wear or for damage. Refer to Reuse And Salvage Guidelines,
SEBF8301, "Inspection and Reuse of Critical Fasteners Used in All Engines". Replace with
new bolts (5) , if necessary.
4. Remove bolts (5) and bolts (6) .
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Caterpillar Cat 972K Wheel Loader (Prefix Z4W) Service Repair Manual (Z4W00001 and up).pdf

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