972 Transmission

972G Wheel Loader 4WW00001-UP (MACHINE) POWERED BY 3306 Engine(SEBP2...
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Product: WHEEL LOADER

Model: 972G WHEEL LOADER 4WW
Configuration: 972G Wheel Loader 4WW00001-UP (MACHINE) POWERED BY 3306 Engine
Testing and Adjusting

966G Wheel Loader and 972G
Wheel Loader Power Train
Media Number -RENR2105-09 Publication Date -01/12/2010 Date Updated -13/12/2010
i01495483
Power Train Troubleshooting

SMCS - 3000-035
https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/... 7/24/2017
972G Wheel Loader 4WW00001-UP (MACHINE) POWERED BY 3306 Engine(SEBP2... Page 2 of 19
Illustration 1 g00666454
Schematic for the Transmission Hydraulic System
(1) Transmission hydraulic control relief valve
(2) Torque converter
(3) Torque converter outlet relief valve
(4) Transmission oil filter
(5) Transmission clutch modulating valve for the Number 1 clutch
(11) Transmission oil pump
(12) Torque converter inlet relief valve
(13) Suction screen and magnet
(14) Oil sump
(15) Transmission lubrication
(16) Oil cooler
(A) Pump pressure tap at the transmission hydraulic control relief valve
(B) P3 Torque converter inlet pressure tap
(C) Torque converter outlet pressure tap
(D) Sampling valve for the transmission oil
(G) Pressure tap for the Number 1 clutch
(H) Pressure tap for the Number 4 clutch
(J) Pressure tap for the Number 2 clutch
(K) Pressure tap for the Number 5 clutch
(L) Pressure tap for the Number 3 clutch
(M) Pressure tap for the Number 6 clutch
(N) Transmission lubrication pressure tap
Personal injury or death can result from sudden machine movement.
Sudden movement of the machine can cause injury to persons on or

near the machine.
To prevent injury or death, make sure that the area around the
machine is clear of personnel and obstructions before operating the
machine.
Personal injury can result from hydraulic oil pressure and hot oil.
Hydraulic oil pressure can remain in the hydraulic system after the
engine has been stopped. Serious injury can be caused if this pressure is
not released before any service is done on the hydraulic system.
Make sure all of the attachments have been lowered, oil is cool before
removing any components or lines. Remove the oil filler cap only when
the engine is stopped, and the filler cap is cool enough to touch with
your bare hand.
Escaping fluid under pressure, even a pinhole size leak, can penetrate
body tissue, causing serious injury, and possible death. If fluid is
injected into your skin, it must be treated immediately by a doctor
familiar with this type of injury.
Always use a board or cardboard when checking for a leak.
NOTICE
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, "Caterpillar Tools and Shop

Products Guide" for tools and supplies suitable to collect and contain
fluids on Caterpillar products.
Dispose of all fluids according to local regulations and mandates.
Operational Checks
Operate the machine in each direction and in all speeds. Note the noises that are not normal and find
the sources of the noises. If the machine is not operating correctly, refer to the "Troubleshooting
Problem List" below.
Make sure that you check for any service codes that have been generated before troubleshooting a
problem.
Reference: For more information on checking for service codes with the Caterpillar Monitoring
System, refer to Testing and Adjusting, "Using Caterpillar Monitoring System to Determine Service
Codes".
Reference: For more information on checking for service codes with the Caterpillar Electronic
Technician (ET), refer to Testing and Adjusting, "Using Caterpillar Electronic Technician (ET) to
Determine Service Codes".
Reference: For additional information about troubleshooting service codes, refer to Testing and
Adjusting, "Troubleshooting Service Codes".
Troubleshooting Problem List

The transmission does not operate in any speed or the transmission slips in all speeds.
The transmission overheats.
There is pump noise that is not normal.
There is noise in the transmission that is not normal.
The transmission operates in FORWARD only.
The transmission operates in REVERSE only.
The transmission does not operate in FIRST SPEED FORWARD or in FIRST SPEED
REVERSE.
The transmission does not operate in SECOND SPEED FORWARD or in SECOND SPEED
REVERSE.
The transmission does not operate in THIRD SPEED FORWARD or in THIRD SPEED
REVERSE.
The transmission does not operate in FOURTH SPEED FORWARD or in FOURTH SPEED
REVERSE.
The transmission does not disengage when the transmission direction and speed control lever (if
equipped) is in the NEUTRAL position.
The transmission does not disengage when the transmission direction control switch (if
equipped) is in the NEUTRAL position.
Pressure is low at direction clutch pressure tap (J) when the machine is operated in FORWARD
speeds.
Pressure is low at direction clutch pressure tap (G) when the machine is operated in REVERSE
speeds.
Pressure is low at speed clutch pressure tap (M) when the machine is operated in FIRST speed.
Pressure is low at speed clutch pressure tap (K) when the machine is operated in SECOND
speed.
Pressure is low at speed clutch pressure tap (H) when the machine is operated in THIRD speed.
Pressure is low at speed clutch pressure tap (L) when the machine is operated in FOURTH
speed.
Pressure is high at direction clutch pressure tap (J) when the machine is operated in
FORWARD speeds.
Pressure is high at direction clutch pressure tap (G) when the machine is operated in REVERSE
speeds.
Pressure is high at speed clutch pressure tap (M) when the machine is operated in FIRST speed.
Pressure is high at speed clutch pressure tap (K) when the machine is operated in SECOND
speed.
Pressure is high at speed clutch pressure tap (H) when the machine is operated in THIRD speed.
Pressure is high at speed clutch pressure tap (L) when the machine is operated in FOURTH
speed.
Clutch engagement is sudden. (This causes jerky shifting.)
Clutch engagement is slow. (This causes slow shifting in all gears.)
Clutch engagement is slow in all FORWARD speeds, in all REVERSE speeds, or in any one
speed (FORWARD and REVERSE).
The transmission neutralizer is actuated and the transmission remains engaged.
The machine does not move and the engine lugs when the transmission is engaged.
The engine is running and the parking brake is engaged. However, the action alarm does not
sound when the transmission is shifted into the FORWARD direction or into the REVERSE
direction.
The backup alarm does not sound when the transmission is shifted into the REVERSE
direction.
Stall speed is low.
Stall speed is high when the machine is operated in both directions.
Stall speed is high when the machine is operated in one direction or in one speed.
The lubrication pressure is low.
The lubrication pressure is high.
Torque converter pressure is low.
Torque converter pressure is high.
The torque converter overheats.
There is constant noise in the differential.
Noise occurs in the differential at different intervals.
Noise only occurs during turns.
Lubricant is leaking.
The drive wheels do not turn but the universal joint turns.
Troubleshooting
Note: In the following section, when components are referenced with a number, refer to the schematic
in Illustration 1.
Reference: For additional information about troubleshooting the power train electronic control
module (ECM), refer to Testing and Adjusting, "Troubleshooting Service Codes".
Probable Causes of Power Train Problems

Problem: The transmission does not operate in any speed or the transmission slips in all speeds.
Probable causes:
1. The transmission fuse is missing or broken.
2. There is a problem in the electrical circuit for the transmission.
3. The system voltage is low.
4. The transmission direction and speed control (if equipped) is faulty.
5. The transmission direction control switch (if equipped) is faulty.
6. The upshift switch (if equipped) or the downshift switch (if equipped) is faulty.
7. The oil pressure is low. This may be caused by any of the following conditions:
a. The oil level is low.
b. There is a restriction in the oil flow circuit or a dirty oil strainer.
c. The oil pump has failed.
d. Air leaks on the inlet side of the pump.
e. There is oil leakage inside the transmission (worn seals around the clutch piston).
f. The transmission hydraulic control relief valve (1) is not adjusted correctly. The
transmission hydraulic control relief valve is stuck open.
8. There is a torque converter failure.
9. There is a mechanical failure in the transmission.
10. Clutch discs and clutch plates are excessively worn.
11. The transmission neutralizer limit switch is not operating.
Problem: The transmission overheats.
Probable causes:
1. The coolant level in the radiator is low.
2. The machine is being used for the wrong application. There is too much torque converter slip,
which is caused by too much load.
3. An incorrect transmission gear is being used for the load that is on the machine. Shift to a lower
gear.
4. The temperature gauge is faulty.
5. The oil level is too high or too low.
6. The oil cooler or oil lines are restricted.
7. The clutch slips too much. This may be caused by any of the following conditions:
a. Low oil pressure. Refer to "Problem: The transmission does not operate in any speed
or the transmission slips in all speeds."
b. A clutch is damaged.
8. Oil flow is low. This may be caused by pump wear or by leakage in the hydraulic system.
9. There is air in the oil. This may be caused by air leaks on the intake side of the pump.
10. Torque converter inlet relief valve (12) is stuck open. This causes low oil flow through the
torque converter.
11. The clutch or clutches are not fully released. (This is called clutch drag.) This may be caused by
any of the following conditions:
a. Clutch plates or clutch discs are warped.
b. A return spring is broken or weak.
c. A transmission clutch modulating valve is stuck at a partial pressure.
Problem: There is pump noise that is not normal.
Probable causes:
1. A loud noise at short intervals indicates foreign material in the transmission hydraulic system.
2. A constant loud noise indicates pump failure.
3. There is air at the inlet side of the pump.
Problem: Noise in the transmission that is not normal
Probable causes:
1. Gears are damaged.
2. The teeth of the clutch plates are worn and/or the teeth of the clutch discs are worn.
3. Clutch plates are slipping and the clutch discs are making noise.
4. Other transmission components may be worn or damaged.
Problem: The transmission operates in FORWARD only.
Probable causes:
1. Number 1 REVERSE transmission clutch modulating valve (5) is inoperative.
2. There is a problem in the electrical circuit.
3. The REVERSE clutch is not engaged or the REVERSE clutch slips. This may be caused by any
of the following conditions:
a. There is low oil pressure due to leaking piston seals.
b. The clutch discs and clutch plates have too much wear.
c. Clutch components are broken.
Problem: The transmission operates in REVERSE only.
Probable causes:
1. Number 2 FORWARD transmission clutch modulating valve (7) is inoperative.
3. The FORWARD clutch is not engaged or the FORWARD clutch slips. This may be caused by
any of the following conditions:
972G Wheel Loader 4WW00001-UP (MACHINE) POWERED BY 3306 Engine(SEB... Page 10 of 19
Problem: The transmission does not operate in FIRST SPEED FORWARD position or in
FIRST SPEED REVERSE position.
Probable causes:
1. Number 6 FIRST SPEED transmission clutch modulating valve (10) is inoperative.
3. The FIRST SPEED clutch is not engaged or the FIRST SPEED clutch slips. This may be
caused by any of the following conditions:
Problem: The transmission does not operate in SECOND SPEED FORWARD position or in
SECOND SPEED REVERSE position.
1. Number 5 SECOND SPEED transmission clutch modulating valve (8) is inoperative.
3. The SECOND SPEED clutch is not engaged or the SECOND SPEED clutch slips. This may be
Problem: The transmission does not operate in THIRD SPEED FORWARD position or in
THIRD SPEED REVERSE position.
Probable causes:
1. Number 4 THIRD SPEED transmission clutch modulating valve (6) is inoperative.
3. The THIRD SPEED clutch is not engaged or the THIRD SPEED clutch slips. This may be
Problem: The transmission does not operate in FOURTH SPEED FORWARD position or in
FOURTH SPEED REVERSE position.
Probable causes:
1. Number 3 FOURTH SPEED transmission clutch modulating valve (9) is inoperative.
3. The FOURTH SPEED clutch is not engaged or the FOURTH SPEED clutch slips. This may be
Problem: Transmission clutches do not disengage when the transmission direction and speed
control lever (if equipped) is in the NEUTRAL position.
Probable causes:
2. A direction clutch is engaged. There is an electrical problem or a mechanical problem with a

transmission clutch modulating valve.
Problem: Transmission clutches do not disengage when the transmission direction control
switch (if equipped) is in the NEUTRAL position.
Probable causes:
2. A direction clutch is engaged. There is an electrical problem or a mechanical problem with a

transmission clutch modulating valve.
Problem: Pressure is low at direction clutch pressure tap (J) when the machine is operated in
FORWARD speeds.
Probable causes:
2. There is too much leakage in the piston seals of the FORWARD clutch.
3. Number 2 FORWARD transmission clutch modulating valve (7) is not correctly calibrated.
4. Number 2 FORWARD transmission clutch modulating valve (7) is contaminated.
Problem: Pressure is low at direction clutch pressure tap (G) when the machine is operated in
REVERSE speeds.
Probable causes:
2. There is too much leakage in the piston seals of the REVERSE clutch.
3. Number 1 REVERSE transmission clutch modulating valve (5) is not correctly calibrated.
4. Number 1 REVERSE transmission clutch modulating valve (5) is contaminated.
Problem: Pressure is low at speed clutch pressure tap (M) when the machine is operated in
FIRST speed.
Probable causes:
2. There is too much leakage in the piston seals of the FIRST SPEED clutch.
3. Number 6 FIRST SPEED transmission clutch modulating valve (10) is not correctly calibrated.
4. Number 6 FIRST SPEED transmission clutch modulating valve (10) is contaminated.
Problem: Pressure is low at speed clutch pressure tap (K) when the machine is operated in
SECOND speed.
Probable causes:
2. There is too much leakage in the piston seals of the SECOND SPEED clutch.
3. Number 5 SECOND SPEED transmission clutch modulating valve (8) is not correctly
calibrated.
4. Number 5 SECOND SPEED transmission clutch modulating valve (8) is contaminated.
Problem: Pressure is low at speed clutch pressure tap (H) when the machine is operated in
THIRD speed.
Probable causes:
2. There is too much leakage in the piston seals of the THIRD SPEED clutch.
3. Number 4 THIRD SPEED transmission clutch modulating valve (6) is not correctly calibrated.
4. Number 4 THIRD SPEED transmission clutch modulating valve (6) is contaminated.
Problem: Pressure is low at speed clutch pressure tap (L) when the machine is operated in
FOURTH speed.
Probable causes:
2. There is too much leakage in the piston seals of the FOURTH SPEED clutch.
3. Number 3 FOURTH SPEED transmission clutch modulating valve (9) is not correctly
calibrated.
4. Number 3 FOURTH SPEED transmission clutch modulating valve (9) is contaminated.
Problem: Pressure is high at direction clutch pressure tap (J) when the machine is operated in
FORWARD speeds.
Probable causes:
2. Number 2 FORWARD transmission clutch modulating valve (7) is not correctly calibrated.
Problem: Pressure is high at direction clutch pressure tap (G) when the machine is operated in
REVERSE speeds.
Probable causes:
2. Number 1 REVERSE transmission clutch modulating valve (5) is not correctly calibrated.
Problem: Pressure is high at speed clutch pressure tap (M) when the machine is operated in
FIRST speed.
Probable causes:
2. Number 6 FIRST SPEED transmission clutch modulating valve (10) is not correctly calibrated.
Problem: Pressure is high at speed clutch pressure tap (K) when the machine is operated in
SECOND speed.
Probable causes:
2. Number 5 SECOND SPEED transmission clutch modulating valve (8) is not correctly
calibrated.
Problem: Pressure is high at speed clutch pressure tap (H) when the machine is operated in
THIRD speed.
Probable causes:
2. Number 4 THIRD SPEED transmission clutch modulating valve (6) is not correctly calibrated.
Problem: Pressure is high at speed clutch pressure tap (L) when the machine is operated in
FOURTH speed.
Probable causes:
2. Number 3 FOURTH SPEED transmission clutch modulating valve (9) is not correctly
calibrated.
Problem: Clutch engagement is sudden. (This causes jerky shifting.)
Probable causes:
1. Transmission clutch modulating valves (5), (6), (7), (8), (9), (10) need to be calibrated.
Reference: For additional information about calibrating the transmission clutch modulating
valves, refer to Testing and Adjusting, "Calibration and Programming".
valves, refer to Testing and Adjusting, "Engagement Pressure for the Transmission Clutch -
Calibrate".
valves, refer to Testing and Adjusting, "Fill Time for the Transmission Clutch - Calibrate".
2. Transmission clutch modulating valves are unstable.
3. A speed sensor has malfunctioned.
Problem: Clutch engagement is slow. (This causes slow shifting in all gears.)
Probable causes:
1. Oil pressure is low. Refer to "Problem: The transmission does not operate in any speed or
the transmission slips in all speeds."
Problem: Clutch engagement is slow in all FORWARD speeds, in all REVERSE speeds, or in
any one speed (FORWARD and REVERSE).
Probable causes:
1. The clutch pressure is low because of leaking seals on the piston for the affected speed.
2. The corresponding transmission clutch modulating valve is contaminated.
Problem: The transmission neutralizer is actuated and the transmission remains engaged.
Probable causes:
1. The transmission neutralizer limit switch must be adjusted to the proper specification.
2. The transmission neutralizer limit switch has failed.
Problem: The machine does not move and the engine lugs when the transmission is engaged.
Probable causes:
1. The service brakes are locked up.
2. The parking brake is not released or the parking brake may be locked up.
3. There is a mechanical failure in the front differential or in the rear differential.
4. There is a mechanical failure in a final drive.
5. The gears in the transmission do not turn.
a. Too many clutches are engaged.
b. There is a mechanical failure in the transmission.
Problem: The engine is running and the parking brake is engaged. However, the parking brake
alarm does not sound when the transmission is shifted into the FORWARD direction or into the
REVERSE direction.
Probable causes:
1. The parking brake alarm has failed.
Problem: The backup alarm does not sound when the transmission is shifted into REVERSE.
Probable causes:
1. The backup alarm fuse is broken.
2. The backup alarm has failed.
Problem: Stall speed is low.
Probable causes:
1. Engine performance is not correct.
2. The oil is cold.
Problem: Stall speed is high when the machine is operated in both directions.
Probable causes:
1. The oil level is low.
2. There is air in the oil.
3. Direction clutches are slipping.
4. There is a failure in the torque converter.
Problem: Stall speed is high when the machine is operated in one direction or in one speed.
Probable causes:
1. There is a leak in the clutch circuit.
2. There is a failure in the direction clutch or in the speed clutch that has high stall speed.
Problem: The lubrication pressure is low.
Probable causes:
1. Torque converter inlet relief valve (12) is bypassing too much oil flow.
2. The oil pressure is low. Refer to "Problem: The transmission does not operate in any speed
Problem: The lubrication pressure is high.
Probable causes:
There is a restriction in an oil passage inside the transmission.
Problem: The torque converter pressure is low.
Probable causes:
1. Torque converter inlet relief valve (12) is bypassing too much oil flow.
2. Adjustment of torque converter outlet relief valve (3) is not correct.
3. The valve spool in torque converter outlet relief valve (3) does not move.
4. The oil pressure is low. Refer to "Problem: The transmission does not operate in any speed
Problem: The torque converter pressure is high.
Probable causes:
1. There is a restriction inside the torque converter.
2. There is a restriction in an oil passage or in the oil cooler.
3. Torque converter inlet relief valve (12) is stuck in the closed position.
4. The oil is not at normal operating temperature.
Problem: The torque converter overheats.
Probable causes:
1. The machine is being used for the wrong application. There is too much torque converter slip,
which is caused by too much load.
2. The incorrect transmission gear is being used for the load that is on the machine. Shift to a
lower gear.
3. The oil level in the transmission is too high or too low.
4. The coolant level in the radiator is low.
5. The oil cooler or oil lines are restricted.
6. The oil flow through the torque converter is too low. This may be caused by any of the
following conditions:
a. Torque converter inlet relief valve (12) is bypassing too much oil flow.
b. Pump flow or oil pressure is low. Refer to "Problem: Torque converter pressure is
low."
Problem: There is constant noise in the differential.
Probable causes:
1. The level of lubricant is too high or too low.
2. The wrong type of lubricant is being used.
3. Wheel bearings are damaged or improperly adjusted.
4. The ring gear and the pinion do not have correct tooth contact.
5. The ring gear and the pinion are damaged or worn.
6. There is too much backlash between the pinion and the gear or too little backlash between the
pinion and the gear.
7. Pinion bearings are loose or worn.
8. Side bearings are loose or worn.
Problem: Noise occurs in the differential at different intervals.
Probable causes:
1. The ring gear does not run evenly because the bolts on the ring gear are not tight or because the
ring gear is warped.
2. Differential bearings are loose or broken.
Problem: Noise only occurs during turns.
Probable causes:
1. The differential pinion gears are too tight on the retainer pins or on the pinion shaft.
2. The side gears are too tight in the differential case.
3. Differential pinion gears or side gears are faulty.
4. Thrust washers are damaged or worn.
5. There is too much backlash between the side gears and the pinion gears.
Problem: Lubricant is leaking.
Probable causes:
1. Loss of lubricant through the axle shafts can be caused by any of the following conditions:
a. The lubricant is above the proper level.
b. The wrong type of lubricant is being used.
c. There is a restriction in the axle housing breather.
d. An oil seal on the axle shaft is worn or installed incorrectly.
2. Loss of lubricant at the pinion shaft can be caused by the following conditions:
a. The lubricant is above the proper level.
b. The wrong type of lubricant is being used.
c. There is a restriction in the axle housing breather.
d. An oil seal on the pinion shaft is worn or installed incorrectly.
e. A universal joint flange on the pinion shaft is loose.
Problem: The drive wheels do not turn but the universal joint turns.
Probable causes:
1. An axle shaft is broken.
2. Ring gear teeth are damaged.
3. The side gear or the differential pinion is broken.
4. The differential pinion shaft or the retainer pin is broken.
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972G Wheel Loader 4WW00001-UP (MACHINE) POWERED BY 3306 Engine(SEBP2...

Product: WHEEL LOADER

Testing and Adjusting

Power Train Troubleshooting

Schematic for the Transmission Hydraulic System

(1) Transmission hydraulic control relief valve

(2) Torque converter

(3) Torque converter outlet relief valve

(4) Transmission oil filter

(5) Transmission clutch modulating valve for the Number 1 clutch

(6) Transmission clutch modulating valve for the Number 4 clutch

(7) Transmission clutch modulating valve for the Number 2 clutch

(8) Transmission clutch modulating valve for the Number 5 clutch

(9) Transmission clutch modulating valve for the Number 3 clutch

(10) Transmission clutch modulating valve for the Number 6 clutch

(11) Transmission oil pump

(12) Torque converter inlet relief valve

(13) Suction screen and magnet

(14) Oil sump

(15) Transmission lubrication

(16) Oil cooler

(B) P3 Torque converter inlet pressure tap

(C) Torque converter outlet pressure tap

(D) Sampling valve for the transmission oil

(G) Pressure tap for the Number 1 clutch

(H) Pressure tap for the Number 4 clutch

(J) Pressure tap for the Number 2 clutch

(K) Pressure tap for the Number 5 clutch

(L) Pressure tap for the Number 3 clutch

(M) Pressure tap for the Number 6 clutch

(N) Transmission lubrication pressure tap

Personal injury or death can result from sudden machine movement.

Sudden movement of the machine can cause injury to persons on or

Always use a board or cardboard when checking for a leak.

Care must be taken to ensure that fluids are contained during

Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop

Dispose of all fluids according to local regulations and mandates.

Troubleshooting Problem List

The transmission overheats.

There is pump noise that is not normal.

There is noise in the transmission that is not normal.

The transmission operates in FORWARD only.

The transmission operates in REVERSE only.

Clutch engagement is sudden. (This causes jerky shifting.)

Clutch engagement is slow. (This causes slow shifting in all gears.)

The transmission neutralizer is actuated and the transmission remains engaged.

Stall speed is low.

Stall speed is high when the machine is operated in both directions.

The lubrication pressure is low.

The lubrication pressure is high.

Torque converter pressure is low.

Torque converter pressure is high.

The torque converter overheats.

There is constant noise in the differential.

Noise occurs in the differential at different intervals.

Noise only occurs during turns.

Probable Causes of Power Train Problems

1. The transmission fuse is missing or broken.

2. There is a problem in the electrical circuit for the transmission.

3. The system voltage is low.

4. The transmission direction and speed control (if equipped) is faulty.

5. The transmission direction control switch (if equipped) is faulty.

a. The oil level is low.

b. There is a restriction in the oil flow circuit or a dirty oil strainer.