Caterpillar Cat 972G WHEEL LOADER (Prefix AAW) Service Repair Manual Instant Download (AAW00197)

Service Repair Manual

Models

972G Wheel Loader

972G WHEEL LOADER /COMMAND CONTROL STEE/ AAW00197-UP (MACHI...

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Shutdown SIS Previous Screen Product: WHEEL LOADER Model: 972G WHEEL LOADER AAW Configuration: 972G WHEEL LOADER /COMMAND CONTROL STEE/ AAW00197-UP (MACHINE)

Disassembly and Assembly 966G and 972G Wheel Loaders Power Train Media Number -RENR2106-08

Publication Date -01/05/2004

Date Updated -28/05/2004

i02299775

Transmission Planetary - Disassemble SMCS - 3160-015

Disassembly Procedure Table 1 Required Tools Tool

Part Number

Part Description

Qty

A

138-7575

Link Bracket

3

B

1P-0520

Driver Gp

1

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.

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Illustration 1

g00458960

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.

Illustration 2

g00459007

3. Remove plate (5) .

Illustration 3

g00459030

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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.

Illustration 4

g00459073

6. Remove retaining ring (8) from output shaft (7) .

Illustration 5

g00459075

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.

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7. Remove bolts (9) and No. 6 clutch housing (6). Mark the location of the long bolts.

Illustration 6

g00459079

8. Remove clutch piston (10) from No. 6 clutch housing (6) .

9. Remove seal rings (11) and (12) from clutch piston (10) .

Illustration 7

g00459087

10. Remove clutch plate (14) and springs (13) .

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Illustration 8

g00459090

11. Remove clutch plates (15) and friction discs (16) .

Illustration 9

g00459103

12. Remove ring gear (17). Remove transmission speed sensors (18) .

Illustration 10

g00459133

13. Remove carrier assembly (19) .

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Illustration 11

g00459138

14. Remove metal seal ring (20) from carrier assembly (19) .

Illustration 12

g00459150

15. Use a hammer and a punch to push the spring pins through carrier assembly (19) and into planetary shafts (21) .

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Illustration 13

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g00459151

16. Use a hammer and a punch to remove planetary shafts (21) from carrier assembly (19) .

Illustration 14

g00324725

17. Remove thrust discs (22), planetary gears (23), and bearings (24) from the carrier assembly.

Remove spring pins (25) from planetary shafts (21) .

Illustration 15

g00459161

18. Remove O-ring seal (26). Remove bolts (27) from manifold (28) .

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Illustration 16

g00565113

19. Disconnect the harness assemblies which are attached to transmission modulating valves (29). Remove transmission modulating valves (29) from the transmission housing.

Illustration 17

g00459316

20. Remove retaining ring (32) and gear (30). Remove retaining ring (31) .

Illustration 18

g00459322

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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.

Illustration 19

g00459352

23. Remove retaining ring (34) and bearing (35) from manifold (28) .

Illustration 20

g00459369

24. Remove retaining ring (36) and clutch housing (37) .

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Illustration 21

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g00459372

25. Remove O-ring seal (38) from clutch housing (37) .

Illustration 22

g00459375

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.

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Illustration 23

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g00459387

27. Separate retaining ring (39), retainer plate (40), three coned disc springs (41), and clutch piston (42) .

Illustration 24

g00459393

28. Remove seal rings (43) from clutch piston (42) .

Illustration 25

g00459394

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29. Remove seal rings (44) from clutch housing (37) .

Illustration 26

g00565119

30. Remove retaining ring (45) from the output shaft. Remove hub (46) .

Illustration 27

g00565685

31. Remove friction discs (47) and clutch plates (48) .

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Illustration 28

g00565132

32. Remove clutch plate (49) and ring gear (50) .

Illustration 29

g00565193

33. Remove springs (51). Remove friction discs (52) and clutch plates (53) .

Illustration 30

g00565687

34. Remove clutch piston (54). Remove O-ring seals (55) and (56) .

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Illustration 31

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g00459506

35. Remove seal rings (57) and (58) from clutch piston (54) .

Illustration 32

g00565199

36. Use Tooling (A) and a suitable lifting device to remove housing (59). The weight of housing (59) is approximately 66 kg (145 lb).

Note: The clutch piston may be stuck in housing (59). As housing (59) is removed, the clutch piston may fall.

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Illustration 33

g00565203

37. Remove clutch piston (60) .

Illustration 34

g00459540

38. Remove seal rings (61) and (62) from clutch piston (60) .

Illustration 35

g00565255

39. Remove friction discs (63) and clutch plates (64) .

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Illustration 36

g00565689

40. Remove O-ring seals (65) and (66). Remove springs (68) and carrier assembly (69).

Remove rods (67) .

Illustration 37

g00459619

41. Remove gear (70) from carrier assembly (69) .

Illustration 38

g00459622

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42. Remove retaining ring (71) and bearing (72) .

Illustration 39

g00459634

43. Use several small steel rods (73) (3.175 mm (0.1250 inch) diameter and one pointed tip) to compress the retaining ring that holds carrier assembly (69) to ring gear (74) .

44. Remove carrier assembly (69) from ring gear (74) .

Illustration 40

g00459638

45. Remove retaining ring (75) from carrier assembly (69) .

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Illustration 41

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g00459643

46. Use a hammer and a punch to push the spring pins through carrier assembly (69) and into planetary shafts (76) .

47. Use a hammer and a punch to remove planetary shafts (76) from carrier assembly (69) .

Illustration 42

g00459646

48. Remove thrust discs (77), planetary gears (78), and bearings (79) from the carrier assembly.

Remove spring pins (80) from planetary shafts (76) .

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Illustration 43

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g00565272

49. Remove retaining ring (81) that holds output shaft (82) to the input shaft. Remove output shaft (82) .

Illustration 44

g00459776

50. Remove O-ring seal (83) from output shaft (82) .

Illustration 45

g00460029

51. Remove retaining ring (85) .

52. Remove sun gear (84) from output shaft (82) .

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Illustration 46

g00460030

53. Use a suitable press to push output shaft (82) out of bearing (86), as shown.

Illustration 47

g00460034

54. If necessary, remove bearings (87) from both ends of output shaft (82) .

Illustration 48

g00565282

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55. Use Tooling (A) and a suitable lifting device to remove housing (88). The weight of housing (88) is approximately 61 kg (135 lb).

Illustration 49

g00460042

56. Remove clutch piston (89), friction discs (90), and clutch plates (91) .

Illustration 50

g00460045

57. Remove seal rings (92) and (93) from clutch piston (89) .

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Illustration 51

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g00460067

58. Remove retaining ring (94) from the input shaft.

59. Remove springs (95) and ring gear (96). Remove O-ring seals (97) and (98) .

Illustration 52

g00460068

60. Remove carrier assembly (99) from the input shaft. The weight of the carrier assembly is approximately 29 kg (65 lb).

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Illustration 53

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g00460074

61. Remove gear (100) .

62. Place a suitable wood block under carrier assembly (99) .

63. Use several small steel rods (101) (2.36 mm (0.093 inch) diameter and one pointed tip) to compress the retaining ring that holds carrier assembly (99) to ring gear (102) together.

64. Remove ring gear (102) from carrier assembly (99) .

Illustration 54

g00460078

65. Remove retaining ring (105) from carrier assembly (99) .

66. Remove retaining ring (104). Remove sun gear (103) and the bearing. Use Tooling (B) to remove sun gear (103) and the bearing.

Illustration 55

g00460081

67. Use a hammer and a punch to push the spring pins through carrier assembly (99) and into planetary shafts (106) .

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Illustration 56

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g00460134

68. Use a hammer and a punch to remove planetary shafts (106) from carrier assembly (99) .

Illustration 57

g00460135

69. Remove thrust discs (107), bearings (109), and planetary gears (108) from the carrier assembly.

70. Remove spring pins (110) from planetary shafts (106) .

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Illustration 58

g00460138

71. Remove bearing (111) from sun gear (103) .

Illustration 59

g00460141

72. Remove O-ring seal (112) from sun gear (103) .

Illustration 60

g00460178

73. Remove plate (113) .

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Illustration 61

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g00460181

74. Remove friction discs (114) and clutch plates (117). Remove O-ring seals (115) and (116) .

Illustration 62

g00460207

75. Use several small steel rods (118) (2.36 mm (0.093 inch) diameter and one pointed tip) to compress the retaining ring that holds coupling (120) to carrier assembly (119). Remove coupling (120) from carrier assembly (119) .

Note: Coupling (120) and carrier assembly (119) may be removed together at this time. Use small steel rods (118) in order to separate coupling (120) and carrier assembly (119). See Step 43 for similar actions.

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Illustration 63

g00460208

76. Remove clutch piston (121) from the clutch housing. Remove carrier assembly (119) .

Illustration 64

g00460209

77. Remove seal rings (122) and (123) from clutch piston (121) .

Illustration 65

g00460233

78. Remove retaining ring (124). Use Tooling (B) to remove bearing (125) .

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79. Remove seal ring (126) from carrier assembly (119) .

Illustration 66

g00460237

80. Use a hammer and a punch to push the spring pins through carrier assembly (119) and into planetary shafts (127) .

81. Use a hammer and a punch to remove planetary shafts (127) from carrier assembly (119) .

Illustration 67

g00460313

82. Remove thrust discs (128), planetary gears (129), and bearings (130) from the carrier assembly. Remove spring pins (131) from planetary shafts (127) .

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Illustration 68

g00460315

83. Remove retaining ring (132) from housing (133) .

84. Use a soft hammer to remove input shaft (134) from housing (133) .

Illustration 69

g00460318

85. Remove ring seals (136) and O-ring seal (137) from input shaft (134). Remove bearing (135) .

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Illustration 70

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g00460322

86. Use a suitable press and Tooling (C) to remove race (138) from input shaft (134) .

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All Rights Reserved.

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Shutdown SIS Previous Screen Product: WHEEL LOADER Model: 972G WHEEL LOADER AAW Configuration: 972G WHEEL LOADER /COMMAND CONTROL STEE/ AAW00197-UP (MACHINE)

Disassembly and Assembly 966G and 972G Wheel Loaders Power Train Media Number -RENR2106-08

Publication Date -01/05/2004

Date Updated -28/05/2004

i06064263

Transmission Planetary - Assemble SMCS - 3160-016

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

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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) .

Illustration 2

g00460315

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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Illustration 3

g00460313

Illustration 4

g00460237

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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.

Illustration 5

g00460233

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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.

Illustration 6

g00460209

9. Install seal rings (122) and (123) on clutch piston (121) .

Illustration 7

g00460208

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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Illustration 8

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g00460207

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) .

Illustration 9

g00460934

Illustration 10

g00720054

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) .

Illustration 11

g00460178

18. Install plate (113) .

Illustration 12

g00460135

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