Service Repair Manual
Models
992K Wheel Loader
992K Wheel Loader ZMX00001-UP (MACHINE) POWERED BY C32 Engine(SEBP...
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Shutdown SIS Previous Screen Product: WHEEL LOADER Model: 992K WHEEL LOADER ZMX Configuration: 992K Wheel Loader ZMX00001-UP (MACHINE) POWERED BY C32 Engine
Disassembly and Assembly 854K Wheel Dozer and 992K Wheel Loader Power Train Media Number -KENR7587-01
Publication Date -01/09/2011
Date Updated -30/05/2018
i04350650
Torque Converter - Assemble SMCS - 3101-016 S/N - 8801-UP S/N - ZMX1-UP
Assembly Procedure Table 1 Required Tools Tool
Part Number
Part Description
Qty
B
138-7574
Link Bracket
2
C
138-7573
Link Bracket
3
0S-1614
Bolt
1
5P-0537
Hard Washer
1
9X-8876
Bolt
2
1F-7958
Nut
2
F
G H
138-7575
Link Bracket
3
J
2D-1201
Eyebolt
1
K
1P-0520
Driver Gp
1
L
8T-5096
Dial Indicator Gp
1
M
5P-2390
Gauge Tool Gp
1
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992K Wheel Loader ZMX00001-UP (MACHINE) POWERED BY C32 Engine(SEBP...
Illustration 1
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g02505824
1. Raise the temperature of seal carrier (96). Install seal carrier (96) onto shaft (101). 2. Lubricate seal (97) with the oil that is being sealed. Install seal (97) on seal carrier (96). 3. Raise the temperature of bearing (98). Install bearing (98) onto shaft (101). 4. Raise the temperature of seal carrier (99). Install seal carrier (99) onto shaft (101). 5. Lubricate seals (100) with the lubricant that is being sealed. Install seals (100) onto seal carrier (99).
Illustration 2
g02505817
6. Attach Tooling (J) and a suitable lifting device to shaft assembly (61). The weight of shaft assembly (61) is approximately 26 kg (57 lb). Use Tooling (J) and the suitable lifting device in order to install shaft assembly (61) onto carrier assembly (91). Install gasket (95).
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992K Wheel Loader ZMX00001-UP (MACHINE) POWERED BY C32 Engine(SEBP...
Illustration 3
g02505797
7. Reposition carrier assembly (91). The combined weight of carrier assembly (91) and the shaft assembly is approximately 34 kg (75 lb). 8. Install lip seal (94) into bearing cage (93). Position bearing cage (93). Install bolts (92). Tighten bolts (92) to a torque of 50 ± 7 N·m (37 ± 5 lb ft).
Illustration 4
g01452833
Illustration 5
g01127577
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9. Reposition carrier assembly (91). The weight of carrier assembly (91) is approximately 79 kg (175 lb). Raise the temperature of bearing (90). Install bearing (90) onto carrier assembly (91). 10. Raise the temperature of seal carrier (87). Install seal carrier (87). Note: Make sure that the Holes (X) in seal carrier (87) are in alignment with Holes (Y) in the shaft. 11. Install locator pin (88). 12. Install seals (86) and (89).
Illustration 6
g01452827
13. Install bearing race (85) in gear (83) and gear (84). Use two people in order to install gears (84) and (83). The combined weight of gear (83) and gear (84) is approximately 36 kg (80 lb). Install bolts (82). Tighten bolts (82) to a torque of 240 ± 25 N·m (175 ± 18 lb ft).
Illustration 7
g01452822
14. Install two dowel pins (81) (not shown). Install plate (80) (not shown). Install thrust washer (79).
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992K Wheel Loader ZMX00001-UP (MACHINE) POWERED BY C32 Engine(SEBP...
Illustration 8
g01452817
15. Lubricate seals (78) with oil that is being sealed. Install seals (78).
Illustration 9
g01452810
16. Install piston (77).
Illustration 10
g01452805
17. Install discs (75) and plates (76).
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992K Wheel Loader ZMX00001-UP (MACHINE) POWERED BY C32 Engine(SEBP...
Illustration 11
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g01452792
18. Attach Tooling (C) and a suitable lifting device to backing plate (74). The weight of backing plate (74) is approximately 25 kg (55 lb). Install backing plate (74) onto housing assembly (63).
Illustration 12
g01452783
19. Install impeller hub (65) on impeller (64).
Illustration 13
g01452774
20. Install sleeve bearing (72).
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21. Use two people in order to install adapter (73). The weight of adapter (73) is approximately 25 kg (55 lb). Install twelve bolts (71) (not shown). Tighten bolts (71) to a torque of 120 ± 15 N·m (89 ± 11 lb ft). 22. Install four dowel pins (70) (not shown) that are located under plate (69). The correct height for dowel pins (70) is 3.10 ± 0.13 mm (0.122 ± 0.005 inch). Install plate (69).
Illustration 14
g01452764
23. Install pins (68) and sleeve (67). Install thrust bearing (66). 24. Attach Tooling (C) and a suitable lifting device to impeller hub (65). The combined weight of impeller (64) and impeller hub (65) is approximately 57 kg (125 lb). Align the splines and install impeller (64) and impeller hub (65) on housing assembly (63).
Illustration 15
g01452758
25. Install Tooling (G) in order to hold housing assembly (63) to the backing plate. Attach Tooling (H) and a suitable lifting device to the backing plate. The combined weight of housing assembly (63), impeller clutch (62), and the backing plate is approximately 181 kg (400 lb). Install housing assembly (63), impeller clutch (62), and the backing plate onto shaft assembly (61). 26. Remove Tooling (G) that held housing (63) to the backing plate.
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992K Wheel Loader ZMX00001-UP (MACHINE) POWERED BY C32 Engine(SEBP...
Illustration 16
g01452868
Illustration 17
g01452743
27. Install retaining ring (59) (not shown). 28. Lower the temperature of carrier (57). Use Tooling (K) and a suitable press in order to install carrier (57) into stator assembly (53). 29. Install plate (60) (not shown). Install plate (56). Install retaining ring (58).
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992K Wheel Loader ZMX00001-UP (MACHINE) POWERED BY C32 Engine(SEBP...
Illustration 18
g01452734
30. Install the carrier and stator assembly (53). Install thrust bearing (54) and retaining ring (55).
Illustration 19
g01452703
31. Install sleeve (50) into clutch housing assembly (38). Install race (52) and bearing (51).
Illustration 20
g01452696
32. Install sleeve bearing (46). 33. Install seal carrier (48) and seal (49).
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34. Install race (47).
Illustration 21
g01452691
35. Install turbine hub assembly (45) into clutch housing assembly (38). 36. Install Tooling (F) in order to hold the turbine assembly together. Refer to Illustration 24 below.
Illustration 22
g01450685
37. Install turbine (44). Install clamping plate (43) and bolts (42). Tighten bolts (42) to a torque of 120 ± 15 N·m (89 ± 11 lb ft).
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992K Wheel Loader ZMX00001-UP (MACHINE) POWERED BY C32 Engine(SE...
Illustration 23
g00357638
Illustration 24
g01450614
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38. Install pins (39), sleeve (40) and bearing race (41). Reposition clutch housing assembly (38) onto the opposite side for assembly purposes. The weight of clutch housing assembly (38) is approximately 168 kg (370 lb). 39. Attach Tooling (C) and a suitable lifting device to clutch housing assembly (38). Install clutch housing assembly (38). Remove Tooling (F) that is used to prevent the turbine assembly from separating away from the bearing.
Illustration 25
g00357633
40. Install bolts (37). Tighten bolts (37) to a torque of 120 ± 15 N·m (89 ± 11 lb ft).
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992K Wheel Loader ZMX00001-UP (MACHINE) POWERED BY C32 Engine(SE...
Illustration 26
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g00357612
41. Install washer (36) (not shown), retainer (35), and bolts (34) onto torque converter assembly (33). Tighten bolts (34) to a torque of 120 ± 15 N·m (89 ± 11 lb ft).
Illustration 27
g01451779
42. Position torque converter assembly (33), as shown. The weight of torque converter assembly (33) is approximately 590 kg (1300 lb). Install pilot guide (32) on torque converter assembly (33). Install bolts (31). Tighten bolts (31) to a torque of 120 ± 15 N·m (89 ± 11 lb ft).
Illustration 28
g01450567
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43. Install spline adapter (30), the O-ring seal, bearing cones (28) and retaining ring (29) onto pump drive gear (27).
Illustration 29
g01450430
44. Use two people in order to install pump drive gear (27). The weight of pump drive gear (27) is approximately 27 kg (60 lb). Install all of the shims.
Illustration 30
g01452988
45. Lower the temperature of bearing cup (25). Install bearing cup (25) into pump adapter (23). Note: Do not install the seals for the pump adapters at this time.
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992K Wheel Loader ZMX00001-UP (MACHINE) POWERED BY C32 Engine(SE...
Illustration 31
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g01451567
46. Attach Tooling (B) and a suitable lifting device to pump adapter (23). Install pump adapter (23) and bolts (22). Tighten bolts (22) to a torque of 240 ± 40 N·m (177 ± 30 lb ft). 47. When possible, rotate either the torque converter or the outer housing in order to ensure that the bearings are properly seated.
Illustration 32
g01452534
48. Use Tooling (L) and Tooling (M) in order to check bearing end play. The bearing end play must be 0.10 ± 0.05 mm (0.004 ± 0.002 inch). Remove the shims that were installed in Step 44 in order to obtain the correct bearing end play, as needed. 49. Remove the pump adapter from the housing assembly.
Illustration 33
g01451591
50. Install O-ring seals (26) onto pump adapter (23).
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992K Wheel Loader ZMX00001-UP (MACHINE) POWERED BY C32 Engine(SE...
Illustration 34
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g01451609
51. Install the correct number of shims (24) onto the housing assembly. The correct number of shims (24) were determined in Step 48. 52. Use Tooling (B) and a suitable lifting device in order to install pump adapter (23) on the housing assembly. Install bolts (22). Tighten bolts (22) to a torque of 240 ± 40 N·m (177 ± 30 lb ft). 53. When possible, rotate either the torque converter housing or the outer housing in order to ensure that the bearings are properly seated. Use Tooling (L) and Tooling (M) in order to recheck the bearing end play. Repeat the above procedures, if necessary. 54. Repeat Steps 44 through 52 in order to install the remaining pump adapter.
Illustration 35
g00357394
55. Install O-ring seal (18). Turn housing assembly (11) onto the opposite side. The weight of housing assembly (11) is approximately 680 kg (1500 lb).
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Illustration 36
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g00357392
56. Lower the temperature of bearing cup (17). Install bearing cup (17) in the housing assembly.
Illustration 37
g01451665
57. Attach Tooling (B), Tooling (C), and a suitable lifting device to housing assembly (11). The weight of housing assembly (11) is approximately 680 kg (1500 lb). Install housing assembly (11) onto the torque converter. Install bolts (10).
Illustration 38
g01450330
58. Lubricate bearing cones (16) with the oil that is being sealed. Install bearing cones (16) onto idler gear (15).
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Illustration 39
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g01450328
59. Use two people in order to install idler gear (15) and the shim pack. The weight of idler gear (15) is approximately 36 kg (80 lb).
Illustration 40
g01451687
60. Lower the temperature of bearing cup (12). Install bearing cup (12) into pump adapter (5).
Illustration 41
g01451688
61. Attach Tooling (B) and a suitable lifting device to pump adapter (5). The weight of pump adapter (5) is approximately 50 kg (110 lb). Install pump adapter (5) and bolts (6) onto housing assembly (11).
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62. Repeat Steps 47 through 53 in order to adjust bearing end play.
Illustration 42
g01452994
Illustration 43
g01451688
63. Use Tooling (B) and the suitable lifting device in order to remove pump adapter (5) from housing assembly (11). 64. Install lip seal (13) and O-ring seals (14) to pump adapter (5). Use Tooling (B) and the suitable lifting device in order to install pump adapter (5) onto housing assembly (11). Install bolts (6).
Illustration 44
g02513136
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65. Install the O-ring seals and manifold (8). Install bolts (7). 66. Install the O-ring seal and orifice plug (9) (not shown) on housing assembly (11).
Illustration 45
g02505758
67. Install seal (4) on yoke (1).
Illustration 46
g02505643
68. Install yoke (1), retainer (3), and bolt (2). Tighten bolt (2) to a torque of 240 ± 25 N·m (177 ± 18 lb ft). Note: The following Step will verify the proper assembly of the torque converter. This Step should be done before the torque converter is installed into the machine.
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992K Wheel Loader ZMX00001-UP (MACHINE) POWERED BY C32 Engine(SE...
Illustration 47
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g02505917
69. Apply air pressure to port (102). The air should flow freely through the torque converter. A blockage exists when the air nozzle is pushed backward. The torque converter will need to be repaired before installation into the machine. End By: a. Install the hydraulic fan piston pump. b. Install the center implement piston pump. c. Install the right-hand implement piston pump. d. Install the brake piston pump. e. Install the steering piston pump. f. Install the transmission pump. g. Install the torque converter priority valve. h. Install the outlet relief valve. i. Install the impeller clutch modulating valve. j. Install the torque converter. Copyright 1993 - 2020 Caterpillar Inc.
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Shutdown SIS Previous Screen Product: WHEEL LOADER Model: 992K WHEEL LOADER ZMX Configuration: 992K Wheel Loader ZMX00001-UP (MACHINE) POWERED BY C32 Engine
Disassembly and Assembly 854K Wheel Dozer and 992K Wheel Loader Power Train Media Number -KENR7587-01
Publication Date -01/09/2011
Date Updated -30/05/2018
i04350792
Torque Converter (Lockup) - Disassemble SMCS - 3101-015-L7 S/N - 8801-UP S/N - ZMX1-UP
Disassembly Procedure Table 1 Required Tools Tool
Part Number
Part Description
Qty
A
154-6183
Forcing Bolt
2
B
138-7574
Link Bracket
2
C
138-7573
Link Bracket
3
D
154-6184
Forcing Bolt
3
E
5J-0490
Forcing Bolt
2
0S-1614
Bolt
1
5P-0537
Hard Washer
1
9X-8876
Bolt
2
1F-7958
Nut
2
F
G H
138-7575
Link Bracket
3
J
2D-1201
Eyebolt
1
K
1P-0520
Driver Gp
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992K Wheel Loader ZMX00001-UP (MACHINE) POWERED BY C32 Engine(SEBP...
Start By: a. Remove the torque converter. b. Remove the torque converter lockup clutch modulating valve. c. Remove the torque converter impeller clutch modulating valve. d. Remove the torque converter outlet relief valve. e. Remove the torque converter priority valve. f. Remove the transmission pump. g. Remove the steering piston pump. h. Remove the brake piston pump. i. Remove the right-hand implement piston pump. j. Remove the center implement piston pump. k. Remove the hydraulic fan piston pump. 1. Position the torque converter housing assembly onto suitable cribbing. The weight of the torque converter housing assembly is approximately 1250 kg (2850 lb).
Illustration 1
g02505643
2. Remove bolt (2), retainer (3), and yoke (1).
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992K Wheel Loader ZMX00001-UP (MACHINE) POWERED BY C32 Engine(SEBP...
Illustration 2
g02505758
3. Remove O-ring seal (4) from yoke (1).
Illustration 3
g01450186
4. Remove bolts (6) and bolts (10). 5. Remove bolts (7), manifold (8), and the O-ring seals. 6. Remove orifice plug (9) (not shown) and the O-ring seal. 7. Install Tooling (A). Use Tooling (A) in order to separate pump adapter (5) from housing assembly (11).
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Illustration 4
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g01450226
8. Attach Tooling (B) and a suitable lifting device to pump adapter (5). The weight of pump adapter (5) is approximately 50 kg (110 lb). Use Tooling (B) and the suitable lifting device in order to remove pump adapter (5) from housing assembly (11).
Illustration 5
g01450322
9. Remove lip seal (13), bearing cup (12), and O-ring seals (14) from pump adapter (5).
Illustration 6
g01450328
10. Use two people in order to remove idler gear (15). The weight of idler gear (15) is approximately 36 kg (80 lb).
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992K Wheel Loader ZMX00001-UP (MACHINE) POWERED BY C32 Engine(SEBP...
Illustration 7
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g01450330
11. Remove bearing cones (16) from idler gear (15).
Illustration 8
g01450331
12. Remove bearing cup (17) from housing assembly (11).
Illustration 9
g01450350
13. Attach Tooling (B), Tooling (C), and a suitable lifting device to housing assembly (11). The weight of housing assembly (11) is approximately 680 kg (1500 lb).
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14. Install Tooling (D) to housing assembly (11). Use Tooling (D) in order to separate housing assembly (11) from the torque converter assembly. 15. Use Tooling (B), Tooling (C), and the suitable lifting devices in order to remove housing assembly (11).
Illustration 10
g00357394
16. Position housing assembly (11) onto the opposite side and remove O-ring seal (18).
Illustration 11
g02513099
17. Remove bolts (19) and adapter (20) from housing assembly (11). Remove O-ring seal (21) (not shown). 18. Remove bolts (22). 19. Install Tooling (A) in order to separate pump adapter (23) from housing assembly (11).
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