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

Product:WHEELLOADER

Model:972KWHEELLOADERZ4W

Configuration:972KWheelLoaderZ4W00001-UP(MACHINE)POWEREDBYC9.3Engine

OperationandMaintenanceManual 966Kand972KWheelLoaders

MediaNumber-SEBU8551-10PublicationDate-01/07/2014DateUpdated-24/07/2014

Foreword

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).

WedAug920:15:16UTC+05302023

Product:WHEELLOADER

Model:972KWHEELLOADERZ4W

Configuration:972KWheelLoaderZ4W00001-UP(MACHINE)POWEREDBYC9.3Engine

OperationandMaintenanceManual 966Kand972KWheelLoaders

MediaNumber-SEBU8551-10PublicationDate-01/07/2014DateUpdated-24/07/2014

ARDSparkPlug-Clean

SMCS-1555-070

NOTICE

IftheengineisrunningorthekeyisintheONposition,theARDplug willcontinuetofire.TurnthekeytotheOFFpositionbeforeservicing theARDplug.

i05374672

Illustration1g02140195

1.Removethewireharnessfromthesparkplug.

2.Useadeepwellsocketandabreakerbartoloosenthesparkplug.Ifnecessary,consultyour Caterpillardealerforthepartnumberofthesocket.Afterthesparkplughasbeenloosened,use thesockettoremovethesparkplugbyhandinordertodetectproblemswiththethreads.

3.Afterremovingsparkplug,cleanthegroundprobeinsidetheARDcombustionheadbyrunning a305-2389PlugBoreBrushthroughtheholeintheARDcombustionhead.Runthebrush throughtheholeseveraltimes.

4.Carefullycleanthesparkplugusinganonmetalliccleaningpad.Iftheprobeappearstobebent, replacethesparkplug.Otherwise,installtheoriginalsparkplug.RefertotheSpecifications manualforthecorrecttorquevalue.

Note:Thesparkplugmaybedamagedifthesparkplugisdropped.Donotinstallasparkplug thathasbeendropped.

Donotovertightenthesparkplug.Theshellcanbecrackedandthe gasketcanbedeformed.Themetalcandeformandthegasketcanbe damaged.Theshellcanbestretched.Thiswillloosenthesealthatis betweentheshellandtheinsulator,allowingcombustionpressureto blowpasttheseal.Seriousdamagetotheenginecanoccur.

Usethepropertorque.

5.InstallthesparkplugbyhanduntilthesparkplugcontactstheARD.Torquethesparkplugto theproperspecification.

6.Connectthewiringharness.

WedAug920:42:00UTC+05302023

Product:WHEELLOADER

Model:972KWHEELLOADERZ4W

Configuration:972KWheelLoaderZ4W00001-UP(MACHINE)POWEREDBYC9.3Engine

OperationandMaintenanceManual 966Kand972KWheelLoaders

MediaNumber-SEBU8551-10PublicationDate-01/07/2014DateUpdated-24/07/2014

ArticulationBearings-Lubricate

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

CrushingHazard.Connectthesteeringframelockbetweenfrontand rearframesbeforeservicingthemachineinthearticulationarea. Disconnectthesteeringframelockandsecureitinthestoredposition beforeresumingoperation.Failuretodosocouldresultinserious injuryordeath.

i04538150

EnsurethatthemachineignitionswitchisintheOFFpositionandthattheparkingbrakeis engagedbeforeenteringthearticulationarea.

RefertoOperationandMaintenanceManual,"SteeringFrameLock"beforeenteringthearticulation joint.

Wipeallfittingsbeforeapplyinggrease.

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

Illustration1g02109577

Applygreasetoonefittingontheupperpivotbearing(1)andonefittingonthelowerpivotbearing (2).

WedAug920:42:18UTC+05302023

Product:WHEELLOADER

Model:972KWHEELLOADERZ4W

Configuration:972KWheelLoaderZ4W00001-UP(MACHINE)POWEREDBYC9.3Engine

Illustration1g02494037

(1)Reservoir (2)DustCap (3)FillerTubeAssembly

1.Removedustcap(2)fromreservoir(1).

2.Cleanfillertubeassembly(3)andthecouplingonthefillertubeassembly.

3.Removefillertubeassembly(3)andthecoupling.

4.Removethegreasefittingfromthefilterandcleanthefilter.

5.Cleanthefilterwithsolventandcompressedair.Checkthefilterforcracks.Ifanycracksexist, replacethefilter.

6.Replacethegreasefittinginthefilter.

7.Fillthefilterwithgrease.

8.Installthefilter.

9.Installthefilterassemblyontofillertubeassembly(3).

10.Installfillertubeassembly(3)anddustcap(2).

WedAug920:42:33UTC+05302023

Product:WHEELLOADER

Model:972KWHEELLOADERZ4W

Configuration:972KWheelLoaderZ4W00001-UP(MACHINE)POWEREDBYC9.3Engine

OperationandMaintenanceManual 966Kand972KWheelLoaders

MediaNumber-SEBU8551-10PublicationDate-01/07/2014DateUpdated-24/07/2014 i04284393 AutomaticLubricationGreaseTank-Fill-Autolube-If Equipped

SMCS-7540-544-TNK

TheAutomaticTWINGreasingSystem

Reference:RefertoSystemOperation,RENR6331formoreinformationontheAutomaticTWIN GreasingSystem.

Apressurehazardispresent.Severepersonalinjuryordeathcanresult fromremovinghosesorfittingsthatareunderpressure.Relievethe pressureinthesystembeforeyouremovehosesorfittings.

Illustration1g02494037

(1)Reservoir

(2)DustCap

(3)FillerTubeAssembly

Greasereservoir(1)islocatedneartherearfenderontherightsideofthemachine.

FillingtheReservoir

1.Removedustcap(2)fromgreasereservoir(1).

2.Cleanthefittingbeforefilling.

3.Fillgreasereservoir(1)withgreasetothemaximumlevelwhichisindicatedonthegrease reservoir(1).

Note:Avoidfullyemptyingthereservoircausingairtoenterthesystem.Airmaybepumped intothereservoir.Thisaircanaccumulateunderthepiston.Theaircanberemovedifthe reservoirisrefilledtoalevelslightlyabovethemaximumlevelmark.Excessairandexcess greasewillbereleasedfromthepumpattheoverflowpassage.

Reference:Forthecorrecttypeofgrease,refertoOperationandMaintenanceManual, "LubricantViscosities".

Note:Ifadifferentbrandofgreaseisused,checkforcompatibility.Ifthenewgreaseisnot compatiblewiththegreaseinthereservoir,thesystemmustbepurged.RefertoSystem Operation,RENR6331formoreinformationaboutpurgingthesystem.

4.Installdustcap(2).

WedAug920:42:48UTC+05302023

Product:WHEELLOADER

Model:972KWHEELLOADERZ4W

Configuration:972KWheelLoaderZ4W00001-UP(MACHINE)POWEREDBYC9.3Engine

OperationandMaintenanceManual 966Kand972KWheelLoaders

MediaNumber-SEBU8551-10PublicationDate-01/07/2014DateUpdated-24/07/2014

AxleOscillationBearings-Lubricate

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

i05615077

EnsurethatthemachineignitionswitchisintheOFFpositionandthattheparkingbrakeis engagedbeforeenteringthearticulationarea.

RefertoOperationandMaintenanceManual,"SteeringFrameLock"beforeenteringthearticulation joint.

Illustration1g02109740 Theremotegreasefittingsareontherightsideofthemachineinthearticulationjoint.

Illustration2g03565889

Wipeallfittingsbeforelubricating.

Greasefitting(1)willlubricatetheaxlepivotbearingthatisontherearoftherearaxle.Greasefitting (2)willlubricatetheaxlepivotbearingthatisonthefrontoftherearaxle.

Note:RefertoOperationandMaintenanceManual,"LubricantViscosities"forthepropergrease.

WedAug920:43:02UTC+05302023

Product:WHEELLOADER

Model:972KWHEELLOADERZ4W

Configuration:972KWheelLoaderZ4W00001-UP(MACHINE)POWEREDBYC9.3Engine

OperationandMaintenanceManual 966Kand972KWheelLoaders

MediaNumber-SEBU8551-10PublicationDate-01/07/2014DateUpdated-24/07/2014

BackupAlarm-Test-IfEquipped

SMCS-7406-081

Thebackupalarmisontherearofthemachine.

Illustration1g01043892

TurntheenginestartswitchtotheONpositioninordertoperformthetest.

Applytheservicebrake.PlacethetransmissionintoREVERSE.

Thebackupalarmshouldsoundimmediately.Thebackupalarmwillcontinuetosounduntilthe transmissionisplacedintoNEUTRALorintoFORWARD.

i04404608

Product:WHEELLOADER

Model:972KWHEELLOADERZ4W

Configuration:972KWheelLoaderZ4W00001-UP(MACHINE)POWEREDBYC9.3Engine

Illustration2g02161419

Openbothbatterycompartmentsontheleftsideofthemachineundertheplatform.Removethe batteryhold-down.

Cleanthebatteryterminalsandthesurfacesofthebatterieswithacleancloth.Coatthebattery terminalswithpetroleumjelly.Makesurethatthebatterycablesareinstalledsecurely.

Replacethebatteryhold-down.RefertoOperationandMaintenanceManual,"BatteryHold-DownTighten"forthecorrecttorque.Closethebatterycompartment.

WedAug921:26:38UTC+05302023

Product:WHEELLOADER

Model:972KWHEELLOADERZ4W

Configuration:972KWheelLoaderZ4W00001-UP(MACHINE)POWEREDBYC9.3Engine

BatteryHold-Down-Tighten

SMCS-7257-527

Illustration1g02161433

Openbothbatterycompartmentsontheleftsideofthemachineundertheplatform.

Overtime,thevibrationofanoperatingmachinecancausethebatteryhold-downtoloosen.Tohelp topreventloosebatteriesandthepossibilityofloosecableconnections,tightenthelocknutinthe centerofthehold-downtoatorqueof14±3N·m(10±2lbft).

WedAug921:26:58UTC+05302023

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