Caterpillar Cat 986K Wheel Loader (Prefix SWH) Service Repair Manual (SWH00001 and up).pdf

Service Repair Manual
Models
986K Wheel Loader

Shutdown SIS
Previous Screen
Product: WHEEL LOADER
Model: 986K WHEEL LOADER SWH
Configuration: 986K Wheel Loader SWH00001-UP (MACHINE) POWERED BY C15 Engine
Disassembly and Assembly
986K Wheel Loader Power Train
Media Number -M0085189-01 Publication Date -01/09/2014 Date Updated -04/06/2018
i02071477
Torque Converter (Lockup) - Disassemble
SMCS - 3101-015-L7
Disassembly Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A
138-7573 Link Bracket 1
B
5F-7366 Screw 1
3H-0465 Plate 2
1P-5546 Crossblock 1
5H-7369 Puller Leg 2
6B-6682 3/4" - 16 NF Nut 2
1P-0520 Driver Gp 1
4C-5653 Threaded Adapter 2
C 188-1456 Metric Eyebolt 1
D 138-7575 Link Bracket 2
E 138-7575 Link Bracket 3
F 5F-7366 Screw 1
3H-0465 Plate 2
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986K Wheel Loader SWH00001-UP (MACHINE) POWERED BY C15 Engine(M008...
2021/3/20
https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis...

5H-7369 Puller Leg 2
8B-7551 Bearing Puller 1
6B-6682 3/4" - 16 NF Nut 2
1P-0520 Driver Gp 1
G
5F-7366 Screw 1
3H-0465 Plate 2
8B-7549 Puller Leg 2
5F-7343 Bearing Puller 1
6B-6682 3/4" - 16 NF Nut 2
1P-0520 Driver Gp 1
5F-7342 Adapter 2
H 1P-0520 Driver Gp 1
J 138-7574 Link Bracket 2
Start By:
a. Remove the torque converter. Refer to Disassembly and Assembly, "Torque Converter -
Remove" for the machine that is being serviced.
b. Remove the transmission oil pump. Refer to Disassembly and Assembly, "Transmission Oil
Pump - Remove" for the machine that is being serviced.
c. Remove the torque converter outlet relief valve. Refer to Disassembly and Assembly,
"Relief Valve (Torque Converter Outlet) - Remove" for the machine that is being serviced.
d. Remove the modulating valve for the torque converter impeller clutch. Refer to
Disassembly and Assembly, "Modulating Valve (Torque Converter Impeller Clutch) -
Remove" for the machine that is being serviced.
e. Remove the modulating valve for the torque converter lockup clutch. Refer to Disassembly
and Assembly, "Modulating Valve (Torque Converter Lockup Clutch) - Remove" for the
machine that is being serviced.
2/27
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Illustration 1 g00673844
1. Place the torque converter assembly on cribbing. The weight of the torque converter
assembly is 545 kg (1200 lb).
2. Remove speed sensor (1).
3. Remove bolt (2) and retainer (3).
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4. Remove O-ring seal (4) and yoke (5).
5. Remove eleven bolts (6) and the washers.
6. Install Tooling (A) to housing assembly.
7. Attach a suitable lifting device and lifting chains to Tooling (A).
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8. Use M12 x 1.75 forcing screws in order to separate housing assembly from the torque
converter.
9. Use the suitable lifting device in order to remove housing assembly. The weight of the
housing assembly is 285 kg (630 lb).
10. Remove eight bolts (7) and retainer (8).
11. Remove seal (9) from retainer (8).
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12. Remove gasket (10).
13. Remove O-ring seal (11) and (12).
14. Position torque converter assembly onto the side, as shown.
15. Remove six bolts (13) and cover (14).
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16. Remove two bolts (15), retainer (16), and washer (17).
17. Use Tooling (B) in order to push the shaft out of the bearing.
18. Position torque converter assembly upright, as shown.
19. Install Tooling (C) to shaft assembly (18).
20. Attach a suitable lifting device and a sling to Tooling (C).
21. Use the suitable lifting device in order to remove shaft assembly (18). The weight of shaft
assembly (18) is 17 kg (38 lb).
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22. Use a suitable press in order to remove bearing (19) and seal carrier (20) from inner shaft
(18).
23. Remove 36 bolts (21), and washers (22). Do not remove two bolts (25) at this time.
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24. Install Tooling (D).
25. Attach a suitable lifting device and lifting slings to Tooling (D).
26. Use the suitable lifting device in order to remove carrier assembly (23). The weight of
carrier assembly (23) is 132 kg (290 lb).
27. Place carrier assembly (23), as shown.
28. Remove stator (24).
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29. Remove retaining ring (29) and plate (28) from stator (24). Remove ring (26) (not shown),
and plate (27) (not shown) from the other side of stator (24).
30. Use a suitable press in order to remove adapter (30) from stator (24).
31. Remove spacer (33).
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32. Remove bearing (34).
33. Remove the plate and the ring below bearing (34).
34. Remove retaining ring (35).
35. Use two persons in order to remove impeller (36). The weight of impeller (36) is 29 kg
(65 lb).
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36. Remove race (37) from impeller (36).
37. Remove twelve bolts (38) and the washers.
38. Remove impeller (36) from adapter assembly (39).
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41. Remove two bolts (25) and plate (41).
Note: Bolts (25) are on the underside of plate (41).
42. Remove two friction discs (42) and one wear plate.
43. Remove piston (43).
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44. Remove seal (44) from piston (43).
45. Install Tooling (E) to housing assembly (45).
46. Attach a suitable lifting device and slings to housing assembly (45).
47. Use the suitable lifting device in order to remove housing assembly (45). The weight of
housing assembly (45) is 45 kg (100 lb).
48. Remove twelve bolts (46) and gear (47) from housing assembly (45).
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49. Remove race (48) from gear (47).
50. Remove eight bolts (49) and sleeve (50).
51. Remove seal (51) from sleeve (50).
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52. Remove seal (52).
53. Remove two seals (53).
54. Remove retaining ring (54).
55. Use a hammer and a punch in order to remove pin (55).
56. Use Tooling (F) in order to remove ring carrier (56).
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57. Use Tooling (G) in order to remove bearing (57).
60. Use appropriate equipment to turn the housing onto the opposite side.
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61. Remove O-ring seal (59) and two plugs (60).
62. Use suitable cribbing in order to support the turbine and hub assembly. Place the cribbing
inside the housing assembly.
63. Use Tooling (H) in order to remove the hub from bearing (61).
18/27
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65. Remove 24 bolts (62) and hub (63) from turbine (64).
66. Remove clutch adapter (65).
67. Remove retaining ring (66) and plate (67).
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68. Remove two wear plates (68) and two friction discs (69).
69. Remove piston (70).
Note: It may be necessary to use shop air under pressure of 621 kPa (90 psi) to remove
piston (70).
70. Remove seal (71) from piston (70).
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Note: The following steps are used for the removal and disassembly of the pump drives.
71. Remove seven bolts (72).
72. Install two forcing screws and Tooling (J).
73. Attach a suitable lifting device and lifting slings to Tooling (J).
74. Use the suitable lifting device in order to remove adapter (73). The weight of adapter (73) is
30 kg (65 lb).
Note: If necessary, use forcing screws to separate adapter (73) from the housing.
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75. Remove two O-ring seals (74) from adapter (73).
76. Remove race (75) and seal (76) from adapter (73).
77. Remove gear assembly (77).
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78. Use Tooling (F) in order to remove bearing (78) from gear assembly (77).
79. Remove retaining ring (79) and adapter (80) from gear assembly (77).
80. Remove retaining ring (81) from adapter (80). Remove plate (82).
23/27
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81. Use Tooling (F) in order to remove bearing (83) from gear assembly (77).
82. Remove shim pack (84) and race (85).
83. Remove three bolts (86) and cover (87).
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84. Remove O-ring seal (88) from cover (87).
85. Remove bolt (89) and the washer.
86. Remove idler gear shaft (90).
87. Remove idler gear assembly (91).
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88. Remove two bearings (92) and ring (93) from idler gear assembly (91).
89. Remove four bolts (94) and block (95).
90. Remove five O-rings (96) and three plugs (97).
91. Repeat steps 71 through 90 in order to remove the remaining pump adapter.
26/27
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Shutdown SIS
Previous Screen
Product: WHEEL LOADER
Model: 986K WHEEL LOADER SWH
Configuration: 986K Wheel Loader SWH00001-UP (MACHINE) POWERED BY C15 Engine
Disassembly and Assembly
986K Wheel Loader Power Train
Media Number -M0085189-01 Publication Date -01/09/2014 Date Updated -04/06/2018
i02719081
Torque Converter (Lockup) - Assemble
SMCS - 3101-016-L7
Assembly Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A
B 1P-0520 Driver Gp 1
C 188-1456 Metric Eyebolt 1
D 138-7575 Link Bracket 2
E 138-7575 Link Bracket 3
F
1P-0520 Driver Gp 1
8T-5096 Dial Indicator Gp 1
G 1P-1863 Retaining Ring Pliers 1
Note: Cleanliness is an important factor. Before assembly, all parts should be thoroughly 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 which may cause later trouble. Inspect all parts. If any parts are
worn or damaged, use new parts for replacement.
Note: Apply oil to all of the bearings before assembly.
1. Check the condition of the O-ring seals that are used in the torque converter and torque
converter housing. If any of the seals are damaged, use new parts for replacement.
1/28
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2. Install five O-ring seals (96) and three plugs (97).
3. Install block (95) and four bolts (94).
4. Install ring (93) and two bearings (92) to idler gear assembly (91).
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5. Install idler gear assembly (91).
6. Install idler gear shaft (90).
7. Install bolt (89) and the washer.
8. Install O-ring seal (88) to cover (87).
3/28
2021/3/20

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9. Install three bolts (86) and cover 87.
10. Use the proper equipment in order to handle bearing cup (85).
11. Lower the temperature of bearing cup (85).
12. Install bearing cup (85) into the housing.
13. Use the proper equipment to handle bearing (83).
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14. Heat bearing (83) to a maximum temperature of 135 °C (275 °F).
15. Install bearing (83) onto gear assembly (77).
16. Install plate (82) onto adapter (80).
17. Install retaining ring (81).
18. Install adapter assembly (80) into gear assembly (77).
19. Install retaining ring (79).
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20. Use the proper equipment in order to handle bearing (78).
21. Heat bearing (78) to a maximum temperature of 135 °C (275 °F).
22. Install bearing (78) onto gear assembly (77).
Note: Allow the bearing and the gear assembly to reach a uniform temperature.
23. Use a hammer and a suitable punch in order to reset the bearing around the inside race of
the bearing. This will ensure that the bearing is seated correctly.
24. Install gear assembly (77) and entire shim pack (84).
25. If both pump drives were removed, repeat Steps 10 through 24 for the remaining pump
drive.
26. Lower temperature of bearing cup (75). Install bearing cup (75) into adapter (73). Ensure
that the bearing cup (75) is seated.
6/28
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Caterpillar Cat 986K Wheel Loader (Prefix SWH) Service Repair Manual (SWH00001 and up).pdf

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Caterpillar Cat 986K Wheel Loader (Prefix SWH) Service Repair Manual (SWH00001 and up).pdf