972G Caterpillar Wheel Loader Operation and Maintenance Manual by quality service repair manual

Product:WHEELLOADER

Model:972GWHEELLOADER4WW

Configuration:972GWheelLoader4WW00001-UP(MACHINE)POWEREDBY3306Engine

OperationandMaintenanceManual 966Gand972GWheelLoaders

MediaNumber-SEBU7035-05PublicationDate-01/09/2002DateUpdated-01/03/2002

Foreword

SMCS-7494

LiteratureInformation

s00037320

Thismanualshouldbestoredintheoperator'scompartmentintheliteratureholderorseatback literaturestoragearea.

Thismanualcontainssafetyinformation,operationinstructions,transportationinformation, lubricationinformationandmaintenanceinformation.

Somephotographsorillustrationsinthispublicationshowdetailsorattachmentsthatcanbedifferent fromyourmachine.Guardsandcoversmighthavebeenremovedforillustrativepurposes.

Continuingimprovementandadvancementofproductdesignmighthavecausedchangestoyour machinewhicharenotincludedinthispublication.Read,studyandkeepthismanualwiththe machine.

Wheneveraquestionarisesregardingyourmachine,orthispublication,pleaseconsultyourCat dealerforthelatestavailableinformation.

Safety

Thesafetysectionlistsbasicsafetyprecautions.Inaddition,thissectionidentifiesthetextand locationsofwarningsignsandlabelsusedonthemachine.

Readandunderstandthebasicprecautionslistedinthesafetysectionbeforeoperatingorperforming lubrication,maintenanceandrepaironthismachine.

Operation

Theoperationsectionisareferenceforthenewoperatorandarefresherfortheexperiencedoperator. Thissectionincludesadiscussionofgauges,switches,machinecontrols,attachmentcontrols, transportationandtowinginformation.

Photographsandillustrationsguidetheoperatorthroughcorrectproceduresofchecking,starting, operatingandstoppingthemachine.

Operatingtechniquesoutlinedinthispublicationarebasic.Skillandtechniquesdevelopasthe operatorgainsknowledgeofthemachineanditscapabilities.

Maintenance

Themaintenancesectionisaguidetoequipmentcare.TheMaintenanceIntervalSchedule(MIS)lists theitemstobemaintainedataspecificserviceinterval.Itemswithoutspecificintervalsarelisted underthe"WhenRequired"serviceinterval.TheMaintenanceIntervalScheduleliststhepage numberforthestep-by-stepinstructionsrequiredtoaccomplishthescheduledmaintenance.Usethe MaintenanceIntervalScheduleasanindexor"onesafesource"forallmaintenanceprocedures.

MaintenanceIntervals

Usetheservicehourmetertodetermineservicingintervals.Calendarintervalsshown(daily,weekly, monthly,etc.)canbeusedinsteadofservicehourmeterintervalsiftheyprovidemoreconvenient servicingschedulesandapproximatetheindicatedservicehourmeterreading.Recommendedservice shouldalwaysbeperformedattheintervalthatoccursfirst.

Underextremelysevere,dustyorwetoperatingconditions,morefrequentlubricationthanisspecified inthemaintenanceintervalschartmightbenecessary.

Performserviceonitemsatmultiplesoftheoriginalrequirement.Forexample,atevery500service hoursor3months,alsoservicethoseitemslistedunderevery250servicehoursormonthlyandevery 10servicehoursordaily.

CaliforniaProposition65Warning

DieselengineexhaustandsomeofitsconstituentsareknowntotheStateofCaliforniatocause cancer,birthdefects,andotherreproductiveharm.

Batteryposts,terminalsandrelatedaccessoriescontainleadandleadcompounds.Washhandsafter handling.

CertifiedEngineMaintenance

Propermaintenanceandrepairisessentialtokeeptheengineandmachinesystemsoperating correctly.Astheheavydutyoff-roaddieselengineowner,youareresponsiblefortheperformanceof therequiredmaintenancelistedintheOwnerManual,OperationandMaintenanceManual,and ServiceManual.

Itisprohibitedforanypersonengagedinthebusinessofrepairing,servicing,selling,leasing,or tradingenginesormachinestoremove,alter,orrenderinoperativeanyemissionrelateddeviceor elementofdesigninstalledonorinanengineormachinethatisincompliancewiththeregulations (40CFRPart89).Certainelementsofthemachineandenginesuchastheexhaustsystem,fuel system,electricalsystem,intakeairsystemandcoolingsystemmaybeemissionrelatedandshould notbealteredunlessapprovedbyCaterpillar.

MachineCapacity

Additionalattachmentsormodificationsmayexceedmachinedesigncapacitywhichcanadversely affectperformancecharacteristics.Includedwouldbestabilityandsystemcertificationssuchas brakes,steering,androlloverprotectivestructures(ROPS).ContactyourCatdealerforfurther information.

CatProductIdentificationNumber

EffectiveFirstQuarter2001theCatProductIdentificationNumber(PIN)haschangedfrom8to17 characters.Inanefforttoprovideuniformequipmentidentification,Caterpillarandotherconstruction equipmentmanufacturersaremovingtocomplywiththelatestversionoftheproductidentification numberingstandard.Non-roadmachinePINsaredefinedbyISO10261.ThenewPINformatwill applytoallCatmachinesandgeneratorsets.ThePINplatesandframemarkingwilldisplaythe17 characterPIN.Thenewformatwilllooklikethefollowing:

2.MachineDescriptor(characters4-8)

3.CheckCharacter(character9)

4.MachineIndicatorSection(MIS)orProductSequenceNumber(characters10-17).Thesewere previouslyreferredtoastheSerialNumber.

MachinesandgeneratorsetsproducedbeforeFirstQuarter2001willmaintaintheir8characterPIN format.

Componentssuchasengines,transmissions,axles,etc.andworktoolswillcontinuetousean8 characterSerialNumber(S/N).

TueJan722:48:28UTC+05302025

Product:WHEELLOADER

Model:972GWHEELLOADER4WW

Configuration:972GWheelLoader4WW00001-UP(MACHINE)POWEREDBY3306Engine

OperationandMaintenanceManual 966Gand972GWheelLoaders

MediaNumber-SEBU7035-06PublicationDate-01/09/2002DateUpdated-11/02/2019 i01722752

ArticulationBearings-Lubricate

SMCS-7057-086-BD;7065-086-BD;7066-086-BD

Wipeoffthefittingsbeforeanylubricantisapplied.

Illustration1g00885520

Applylubricantthroughonefittingontheupperhitch.

Applylubricantthroughonefittingonthelowerhitch.

TueJan722:35:14UTC+05302025

Product:WHEELLOADER

Model:972GWHEELLOADER4WW

Configuration:972GWheelLoader4WW00001-UP(MACHINE)POWEREDBY3306Engine

OperationandMaintenanceManual 966Gand972GWheelLoaders

MediaNumber-SEBU7035-06PublicationDate-01/09/2002DateUpdated-11/02/2019

AxleOscillationBearings-Lubricate

SMCS-3268-086-BD;3278-086-BD

CrushingHazard.InsurethatthemachineignitionswitchisintheOFF positionandthattheparkingbrakeisengagedbeforeenteringthe articulationarea.Failuretodosocouldresultinseriousinjuryordeath.

Opentherearaccesspanelthatislocatedontheleftsideofthemachineinordertogainaccessto theremotegreasefittings.

i02405745

Illustration2g00881949

Wipeallfittingsbeforelubricating.

Thetopremotegreasefittingwilllubricatetheaxlepivotbearingthatisonthefrontoftherear axle.Thebottomremotegreasefittingwilllubricatetheaxlepivotbearingthatisontherearof therearaxle.

Note:5P-0960MolybdenumGreaseispreferred.1P-0808MultipurposeGreasegreasemaybe used.

TueJan722:35:28UTC+05302025

This is the sample of the manual Click on the download link for complete Manual

Product:WHEELLOADER

Model:972GWHEELLOADER4WW

Configuration:972GWheelLoader4WW00001-UP(MACHINE)POWEREDBY3306Engine

OperationandMaintenanceManual 966Gand972GWheelLoaders

MediaNumber-SEBU7035-06PublicationDate-01/09/2002DateUpdated-11/02/2019

BackupAlarm-Test-IfEquipped

SMCS-7406-081

TurntheenginestartswitchtotheONpositioninordertoperformthetest.

i01897507

Applytheservicebrake.PlacethetransmissionintoREVERSE. Thebackupalarmshouldsoundimmediately.Thebackupalarmwillcontinuetosounduntilthe transmissionisplacedintoNEUTRALorintoFORWARD.

Athree-positionswitchonthebackupalarmregulatesthevolumeofthealarm. Thebackupalarmissetforthehighestsoundlevelwhenthemachineisshippedfromthefactory. ThesettingshouldremainonHIGHunlessthejobsiterequiresalowersoundlevel.

TueJan722:35:42UTC+05302025

Product:WHEELLOADER

Model:972GWHEELLOADER4WW

Configuration:972GWheelLoader4WW00001-UP(MACHINE)POWEREDBY3306Engine

OperationandMaintenanceManual 966Gand972GWheelLoaders

MediaNumber-SEBU7035-06PublicationDate-01/09/2002DateUpdated-11/02/2019 i01897517

Battery-Clean

SMCS-1401-070

Illustration1g00987179

Openthebatterycompartmentontheleftrearsideofthemachine.Removethebatteryhold-down.

Cleanthebatteryterminalsandthesurfacesofthebatterieswithacleancloth.Coatthebattery terminalswithpetroleumjelly.Makesurethatthebatterycablesareinstalledsecurely.

Replacethebatteryhold-down.RefertoOperationandMaintenanceManual,"BatteryHoldDown-Tighten"forthecorrecttorque.Closethebatterycompartment.

TueJan722:35:57UTC+05302025

Product:WHEELLOADER

Model:972GWHEELLOADER4WW

Configuration:972GWheelLoader4WW00001-UP(MACHINE)POWEREDBY3306Engine

OperationandMaintenanceManual 966Gand972GWheelLoaders

MediaNumber-SEBU7035-06PublicationDate-01/09/2002DateUpdated-11/02/2019

Battery-Recycle

SMCS-1401-561

Alwaysrecycleabattery.Neverdiscardabattery.

Alwaysreturnusedbatteriestooneofthefollowinglocations:

•Abatterysupplier

•Anauthorizedbatterycollectionfacility

•Recyclingfacility

i07746330

TueJan722:36:11UTC+05302025

Product:WHEELLOADER

Model:972GWHEELLOADER4WW

Configuration:972GWheelLoader4WW00001-UP(MACHINE)POWEREDBY3306Engine

OperationandMaintenanceManual 966Gand972GWheelLoaders

MediaNumber-SEBU7035-06PublicationDate-01/09/2002DateUpdated-11/02/2019 i01897534

BatteryHold-Down-Tighten

SMCS-7257-527

Illustration1g00882014

Openthebatterycompartmentontheleftrearsideofthemachine.

Overtime,thevibrationofanoperatingmachinecancausethebatteryhold-downtoloosen.To helptopreventloosebatteriesandthepossibilityofloosecableconnections,tightenthelocknutin thecenterofthehold-downtoatorqueof14±3N·m(10±2lbft).

TueJan722:36:26UTC+05302025

Product:WHEELLOADER

Model:972GWHEELLOADER4WW

Configuration:972GWheelLoader4WW00001-UP(MACHINE)POWEREDBY3306Engine

OperationandMaintenanceManual

966Gand972GWheelLoaders

MediaNumber-SEBU7035-06PublicationDate-01/09/2002DateUpdated-11/02/2019 i08185587

BatteryorBatteryCable-Inspect/Replace

SMCS-1401-510;1401-040;1402-040;1402-510

Personalinjurymayoccurfromfailuretoproperlyservicethebatteries.

Batteriesgiveoffflammablefumesthatcanexplode.Electrolyteisan acidandcancausepersonalinjuryifitcontactstheskinoreyes.

Preventsparksnearthebatteries.Sparkscouldcausevaporstoexplode. Donotallowjumpercableendstocontacteachotherortheengine. Improperjumpercableconnectionscancauseanexplosion. Alwayswearprotectiveglasseswhenworkingwithbatteries.

1.Preparethemachineformaintenance.RefertoOperationandMaintenanceManual,Prepare theMachineforMaintenance.

2.TurntheenginestartswitchkeyOFF.TurnalloftheswitchesOFF.

3.TurnthebatterydisconnectswitchOFF.Removethekey.

4.Disconnectthenegativebatterycablefromthedisconnectswitch.

Note:Donotallowthedisconnectedbatterycabletocontactthedisconnectswitch.

5.Disconnectthenegativebatterycableatthebattery.

6.Disconnectthepositivebatterycableatthebattery.

7.Inspectthebatteryterminalsforcorrosion.Inspectthebatterycablesforwearordamage.

8.Makeanynecessaryrepairs.Ifnecessary,replacethebatterycablesorthebattery.

9.Connectthepositivebatterycableatthebattery.

10.Connectthenegativebatterycableatthebattery.

11.Connectthebatterycableatthebatterydisconnectswitch.

12.InstallthekeyandturnthebatterydisconnectswitchON.

RecycletheBattery

Alwaysrecycleabattery.Neverdiscardabattery.

Alwaysreturnusedbatteriestooneofthefollowinglocations:

•Abatterysupplier

•Anauthorizedbatterycollectionfacility

•Recyclingfacility

TueJan722:36:40UTC+05302025

Product:WHEELLOADER

Model:972GWHEELLOADER4WW

Configuration:972GWheelLoader4WW00001-UP(MACHINE)POWEREDBY3306Engine

OperationandMaintenanceManual 966Gand972GWheelLoaders

MediaNumber-SEBU7035-06PublicationDate-01/09/2002DateUpdated-11/02/2019 i01488615

Belts-Inspect/Adjust/Replace

SMCS-1357-040;1357-510;1357-025

AlternatorBelt

1.Stoptheengine.Opentheenginehood.Thealternatorisontheleftsideofthemachine.

2.Inspecttheconditionofthealternatorbelt.Ifthebeltiscrackedorfrayed,replacethebelt.

3.UseaBT-33-72CBorroughsGaugetocheckthetensionofthealternatorbelt.

Thetensionofausedalternatorbeltwithmorethan30minutesofoperationatratedspeed shouldbe400±44N(90±10lb).Thetensionofanewalternatorbeltwith30minutesof operationorlessatratedspeedshouldbe534±22N(120±5lb).

AdjustingtheTensionoftheAlternatorBelt

Illustration2g00284980

1.Loosenonemountingbolt(1)andadjustingnuts(3)and(4).

2.Turnadjustingnuts(3)and(4)counterclockwiseinordertorotatealternator(2)outward untilthecorrectbelttensionisreached.Tightentheadjustingnuts.

3.Tightenmountingbolt(1).

4.Recheckthetensionofbelt(5).Ifthetensionofthebeltisincorrect,repeattheadjustment procedure.

AirConditionerBelt

Illustration3g00285119

1.Stoptheengine.Opentheenginehood.Theairconditionercompressorisontheleftsideof themachine.

2.Inspecttheconditionoftheairconditionerbelt.Ifthebeltiscrackedorfrayed,replacethe belt.

3.UseaBT-33-72CBorroughsGaugetocheckthetensionoftheairconditionerbelt.

Thetensionofausedairconditionerbeltwithmorethan30minutesofoperationatrated speedshouldbe400±44N(90±10lb).Thetensionofanewairconditionerbeltwith30 minutesofoperationorlessatratedspeedshouldbe534±22N(120±5lb).

AdjustingtheTensionoftheAirConditionerBelt

Illustration4g00284981

1.Loosencompressorbracketmountingbolt(1)andadjustmentbolt(4).

2.Insertaratchetwithasquaredriveintothesquareholeinmountingbracket(3).Usethe ratchetasaleverinordertorotatecompressor(2)outward.Rotatethecompressoruntilthe correctbelttensionisreached.

3.Tightencompressorbracketmountingbolt(1)andadjustmentbolt(4).

4.Recheckthetensionofbelt(5).Ifthetensionofthebeltisincorrect,repeattheadjustment procedure.

TueJan722:36:55UTC+05302025

Product:WHEELLOADER

Model:972GWHEELLOADER4WW

Configuration:972GWheelLoader4WW00001-UP(MACHINE)POWEREDBY3306Engine

OperationandMaintenanceManual 966Gand972GWheelLoaders

MediaNumber-SEBU7035-06PublicationDate-01/09/2002DateUpdated-11/02/2019

BrakeAccumulator-Check

SMCS-4263-535

Illustration1g00882020

i05092713

1.TurntheenginestartswitchtotheONposition.Thealertindicatorforbrakeoilpressure shouldcomeonifthebrakingsystemisnotatnormaloperatingpressure.

2.Starttheengine.Runtheengineathalfspeedfor2minutesinordertoincreasethe accumulatorpressure.Thealertindicatorforbrakeoilpressureshouldgooff.

3.Stoptheenginebyturningthemachinestartswitchtooff.Wait5secondsthenturn machinestartswitchtoon,butdonotstarttheengine.Waitforthedisplaymonitortogo throughstartup,keyonlevelchecks,andoperatorselection.Applytheservicebrakes(fully depressthepedal)foradurationofonesecond.Releasethepedalforadurationofone second.Repeattheapplicationandreleaseprocessuntilthealertindicatorforbrakeoil

presurecomeson.Thiswilldecreasetheaccumulatorpressure.Aminimumoffive applicationsoftheservicebrakepedalarerequired.

4.Ifthealertindicatorcomesonafterlessthanfiveapplicationsofthebrake,measurethe accumulatorprechargepressure.AnauthorizedCaterpillardealercanmeasurethenitrogen gaspressureintheaccumulator.Useonlydrynitrogengasforrecharging.

TueJan722:37:10UTC+05302025

Product:WHEELLOADER

Model:972GWHEELLOADER4WW

Configuration:972GWheelLoader4WW00001-UP(MACHINE)POWEREDBY3306Engine

OperationandMaintenanceManual 966Gand972GWheelLoaders

MediaNumber-SEBU7035-06PublicationDate-01/09/2002DateUpdated-11/02/2019

BrakingSystem-Test

SMCS-4251-081;4267-081

i02056278

Inordertotestthebrakingsystem,refertotheTestingandAdjustingServiceManualofthe brakingsystemforyourmachineorconsultyourCaterpillardealer.

AllRightsReserved. PrivateNetworkForSISLicensees.

TueJan722:37:23UTC+05302025

Product:WHEELLOADER

Model:972GWHEELLOADER4WW

Configuration:972GWheelLoader4WW00001-UP(MACHINE)POWEREDBY3306Engine

OperationandMaintenanceManual 966Gand972GWheelLoaders

MediaNumber-SEBU7035-06PublicationDate-01/09/2002DateUpdated-11/02/2019

BucketCuttingEdges-Inspect/Replace

SMCS-6801-510;6801-040

Personalinjuryordeathcanresultfrombucketfalling. Blockthebucketbeforechangingbucketcuttingedges.

Illustration1g00764365 (1)BoltsforCuttingEdge (2)CuttingEdge

i03657238

Checkthecuttingedgesandtheendbitsforwearandfordamage.Usethefollowingprocedureto servicethecuttingedgesandtheendbits:

1.Raisethebucketandplaceblockingunderthebucket.

2.Lowerthebucketontotheblocking.Stoptheengine.

3.Removebolts(1),cuttingedge(2)andtheendbits.

4.Cleanallcontactsurfaces.

5.Iftheoppositesideofthecuttingedgeisnotworn,usetheoppositesideofthecuttingedge. Theendbitsarenotreversible.

Ifbothsidesareworn,installanewcuttingedge.

6.Installbolts(1).Tightentheboltstothespecifiedtorque.

Reference:RefertoSpecifications,SENR3130,"GroundEngagingTool(G.E.T.) Fasteners".

7.Starttheengine.Raisethebucketandremovetheblocking.Lowerthebuckettotheground.

8.Afterafewhoursofoperation,checktheboltsforpropertorque.

BucketWearPlates

Personalinjuryordeathcanresultfromthebucketfalling. Blockthebucketbeforechangingbucketwearplates.

Illustration2g00879740

Inspectthewearplates.Replacethewearplatesbeforedamagetothebottomofthebucketoccurs. ConsultyourCaterpillardealerforreplacementofwearplates.

TueJan722:37:36UTC+05302025

This is the sample of the manual Click on the download link for complete Manual