Caterpillar Cat 986H Wheel Loader (Prefix 986) Service Repair Manual (98600001 and up).pdf

Service Repair Manual
Models
986 and 986H Wheel Loader

Shutdown SIS
Previous Screen
Product: WHEEL LOADER
Model: 986H WHEEL LOADER 986
Configuration: 986 Wheel Loader 98600001-UP (MACHINE) POWERED BY C15 Engine
Disassembly and Assembly
986H Wheel Loader
Media Number -UENR0367-03 Publication Date -01/09/2014 Date Updated -07/03/2017
i05844522
Transmission Planetary - Disassemble - Heavy Duty
SMCS - 3160-015
Disassembly Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 1P-2420 Transmission Repair Stand 1
B 439-3939 Link Bracket As 3
C 1P-7407 Eyebolt 1
D FT-0833 Clamp 3
E 1P-1863 Retaining Ring Pliers 1
F 5P-5197 External Pliers 1
G 1P-0520 Driver Group 1
H 1P-0510 Drive Group 1
L 1P-0074 Slide Hammer Puller Gp 1
Start By:
a. Separate the transmission and the output transfer gears.
Note: Cleanliness is an important factor. Before the disassembly procedure, thoroughly clean the
exterior of the component to prevent dirt from entering the internal mechanism.
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986 Wheel Loader 98600001-UP (MACHINE) POWERED BY C15 Engine(M007400...
2021/3/22
https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis...

Illustration 1 g01915213
1. Place the transmission assembly onto Tooling (A).
2. Remove tube assembly (1).
3. Install Tooling (B) and a suitable lifting device to modulating valve assembly (2). The
weight of modulating valve assembly (2) is approximately 43 kg (95 lb).
4. Remove bolts (3). Remove modulating valve assembly (2).
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5. Remove tubes (4) and the O-ring seals.
6. Remove bolts (5).
7. Attach Tooling (B) and a suitable lifting device to planetary group (5). The weight of
planetary group (5) is approximately 565 kg (1250 lb). Remove planetary group (5) from
the transmission case.
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8. Place planetary group (5) on suitable blocks.
Note: Put alignment marks across the clutch housings for assembly purposes.
9. Remove bolts (7) and the washers.
Personal injury can result from being struck by parts propelled by a
released spring force.
Make sure to wear all necessary protective equipment.
Follow the recommended procedure and use all recommended tooling to
release the spring force.
10. Use Tooling (D) to secure the clutch piston in clutch housing (9).
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11. Install Tooling (B) and a suitable lifting device on clutch housing (9). The weight of clutch
housing (9) is approximately 32 kg (70 lb).
12. Carefully remove clutch housing (9) from manifold assembly. Remove springs (8).
13. Remove clutch piston (11) from clutch housing (9). Remove seals (10) from the piston.
14. Remove friction discs (12), clutch plates (12), and dowels (14) from manifold assembly.
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15. Remove gear (15) from the carrier assembly.
16. Use Tooling (E) to remove retaining ring (16) from shaft assembly. Remove the spacer
under the retaining ring.
17. Remove carrier assembly (17).
18. Use a drift to bend locks (18) from bolts (19). Remove bolts (19), locks (18), and slinger
(20) from carrier assembly.
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19. Remove spring pin (22) from the carrier and shaft (21). Remove spring pin (22) from shaft
(21).
20. Remove thrust discs (23) and (27) and gear (25).
21. Remove bearings (24) and (26) from gear (25).
22. Repeat Steps 19 through 21 for the removal of the remaining planetary gears.
23. Use Tooling (F) to remove retaining ring (29) from the housing assembly.
24. Remove gear (28).
25. Remove O-ring seal (30) from the manifold assembly.
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26. Remove bolts (31) that hold the manifold assembly to the clutch housing.
27. Attach Tooling (B) and a suitable lifting device to manifold assembly (32). The weight of
manifold assembly (32) is approximately 72 kg (160 lb).
28. Carefully remove manifold assembly (32) from the clutch housing. Remove O-ring seal
(33).
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29. Remove retaining ring (34) and bearing (35) from the manifold assembly.
30. Remove bolts (36) from the clutch housing.
31. Use Tooling (D) to hold the piston in the clutch housing (37). Attach Tooling (B) and a
suitable lifting device to the clutch housing (37). The weight of clutch housing (37) is
approximately 25 kg (55 lb).
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32. Carefully remove clutch housing (37).
33. Remove springs (38).
34. Remove clutch piston (39) from the clutch housing.
35. Remove seals (40) and (41) from the clutch piston.
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36. Remove friction discs (43), clutch plate (42), and dowels (44).
37. Remove retaining ring (45) from the shaft assembly.
38. Attach Tooling (B) and a suitable lifting device to clutch housing assembly (46). The weight
of clutch housing (46) is approximately 45 kg (100 lb).
39. Carefully remove clutch housing (46).
40. Remove seal rings (48) from the ring carrier (47).
41. Check the condition of the ring carrier (47). If ring carrier (47) is worn or damaged, use new
parts for replacement. If the ring carrier is not worn or damaged, DO NOT remove ring
carrier (47). Use a hammer and a chisel in order to break the ring carrier. Remove the ring
carrier and pin (49) from housing assembly.
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42. Remove bolts (52) from the housing.
43. Remove ring gear (50) and gear (51).
44. Remove friction discs (53) and clutch plates (54) from the housing assembly.
45. Remove reaction plate (56) from housing assembly (55).
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Personal injury can result from being struck by parts propelled by a
released spring force.
Make sure to wear all necessary protective equipment.
Follow the recommended procedure and use all recommended tooling to
release the spring force.
46. Use Tooling (H) and a suitable press in order to put force on plate (57) until spiral lockring
(58) can be removed. Release the force. Remove the plate and three springs (59) from the
housing.
47. Remove piston (60) from reaction plate (56).
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48. Remove seals (61) and (62) from piston (60).
49. Use Tooling (D) to hold the piston clutch housing (63). Attach Tooling (B) and a suitable
lifting device to clutch housing (63). The weight of clutch housing (63) is approximately
39 kg (85 lb). Remove clutch housing (63).
50. Remove springs (64).
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51. Remove piston (65) from housing assembly.
52. Remove seals (66) and (67) from the piston.
53. Remove friction discs (68) and clutch plates (69).
54. Use Tooling (E) in order to remove retaining ring (70) from the shaft assembly.
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55. Attach Tooling (B) and a suitable lifting device to carrier (71). The weight of carrier (71) is
56. Use Tooling (E) to remove retaining ring (72) from hub (73). Remove hub (73) from the
carrier.
57. Remove gear (74) from the carrier.
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58. Remove retaining ring (75). Remove bearing (76) from the carrier.
59. Remove spring pin (87) from the carrier.
60. Remove shaft (82), thrust discs (78) and (81), and gear (79). Remove bearing (80) from the
gear (79). Remove pin (77) from shaft (82).
61. Repeat Steps 59 through 60 for the removal of the remaining gears.
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62. Remove gear (83) from the shaft assembly.
63. Remove bolts (86) from clutch housing (84).
64. Use Tooling (D) to hold the piston in clutch housing (84). Attach Tooling (B) and a suitable
lifting device to clutch housing (84). The weight of clutch housing (84) is approximately
44 kg (97 lb).
65. Remove clutch housing (84), springs (85), and dowels (87).
66. Remove piston (88) from the clutch housing.
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67. Remove seals (89) and (90) from the clutch piston.
68. Remove friction discs (91) and clutch plates (92).
69. Remove gear assembly (93) and plate assembly (94) from the clutch housing.
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70. Remove friction plates (95) and clutch plates (96).
71. Attach Tooling (C) and a suitable lifting device to output shaft assembly (97). The weight of
output shaft assembly (97) and the carrier is approximately 90 kg (200 lb).
72. Remove the retaining ring that holds output shaft assembly (97) in the bearing on the
bottom of the clutch housing.
73. Remove output shaft assembly (97) and the carrier from the clutch housing.
74. Place output shaft assembly (97) on suitable blocks.
75. Use Tooling (E) to remove retaining ring (98).
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76. Use a soft hammer to remove shaft assembly (99) from the bearing in the carrier.
77. Remove carrier assembly (100) from the shaft assembly.
78. Remove seals (103) and (104) from the carrier assembly.
79. Remove spiral lockring (101).
80. Use Tooling (G) to remove bearing (102).
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81. Use a hammer and a punch to push spring pin (105) from the carrier assembly.
82. Remove shaft (110), thrust discs (106) and (109), and gear (107). Remove bearing (108)
from gear (107). Remove pin (105) from shaft (110).
83. Repeat Steps 81 and 82 for the remaining gears.
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84. Remove spacer (112) and gear (111) from the shaft assembly.
85. Put the shaft assembly on suitable blocks, as shown. Use two people to remove carrier
assembly (113) from the shaft assembly. The weight of carrier assembly (113) is
86. Put the carrier assembly on a suitable block, as shown. Use a screwdriver to compress the
retainer ring. Remove gear (114) from the carrier assembly. Remove retaining ring (115).
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87. Remove spiral lockring (116). Use Tooling (G) to remove bearing (117) from the carrier.
Remove seal rings (118).
88. Use a hammer and a punch to push spring pin (119) from the carrier assembly.
89. Remove shaft (128), thrust discs (120), (123), (124) and (127), and gears (122) and (126).
Remove bearings (121) and (125) from the gears. Remove pin (119) from shaft (128).
90. Repeat Steps 88 and 89 for the remaining gears.
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91. Remove O-ring seals (129).
92. Remove gear (130) from the shaft assembly and remove seals (131) from the seal carrier.
93. Remove spiral lockring (132) from the shaft assembly.
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94. Put shaft assembly on suitable blocks, as shown. Use a soft hammer to strike shaft assembly
(134) until the bearing is removed from shaft assembly (133).
95. Remove retaining ring (135) from the shaft assembly. Remove bearing (136).
96. Remove O-ring seal (137).
97. Use Tooling (H) and a suitable press to remove seal carrier (138) from the shaft assembly.
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98. Use Tooling (L) to remove bearing (139) from the shaft assembly.
99. Remove gear (140) from the clutch housing.
100. Remove piston (141) from the clutch housing.
101. Remove seals (142) and (143) from the piston (141).
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102. Remove spiral lockring (144). Use Tooling (G) to remove bearing (145) from the housing.
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All Rights Reserved.
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Shutdown SIS
Previous Screen
Product: WHEEL LOADER
Model: 986H WHEEL LOADER 986
Configuration: 986 Wheel Loader 98600001-UP (MACHINE) POWERED BY C15 Engine
Disassembly and Assembly
986H Wheel Loader
Media Number -UENR0367-03 Publication Date -01/09/2014 Date Updated -07/03/2017
i05866210
Transmission Planetary - Assemble - Heavy Duty
SMCS - 3160-016
Specifications
Table 1
1/31
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Specification for 366-9917 Transmission Planetary Gp
Item Qty Part Specification Description
1 12 7H-7658 Spring
Length under test force is 105.570 mm (4.1563 inch).
Test force is 186.83 ± 14.46 N (42.00 ± 3.25 lb).
Free length after test is 140.495 mm (5.5313 inch).
2 36 9H-5537 Spring
Length under test force is 46.7 mm (1.84 inch).
Test force is 127.89 ± 10.23 N (28.75 ± 2.30 lb).
Free length after test is 62.7 mm (2.47 inch).
Section A-A
Table 2
Item Qty Part Specification Description
3 5 3P-2793 Ring Seal
Lubricate the bore lightly with the lubricant that is being
sealed.
4 Thickness of four new friction discs and three new plates is 54.87 ± 0.72 mm
(2.160 ± 0.028 inch):
4
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9W-9856 Friction
Disc
Thickness of one new friction disc is 5.59 ± 0.08 mm
(0.220 ± 0.003 inch).
3 3P-7447 Plate
Thickness of one new plate is 6.73 ± 0.08 mm
(0.265 ± 0.003 inch).
5
Thickness of four new friction discs and three new plates is 54.87 ± 0.72 mm
(2.160 ± 0.028 inch):
4
9W-9856 Friction
Disc
(0.220 ± 0.003 inch).
3 3P-7447 Plate
(0.265 ± 0.003 inch).
6 1 7G-4817 Seal Ring
sealed.
7
Thickness of five new friction discs and three new plates is 30.29 ± 0.40 mm
(1.193 ± 0.016 inch):
5
233-9748 Friction
Disc
(0.220 ± 0.003 inch).
3 370-8590 Plate
(0.265 ± 0.003 inch).
sealed.
9
Thickness of five new friction discs and four new plates is 37.62 ± 0.82 mm
(1.481 ± 0.032 inch):
5
234-6707 Friction
Disc
(0.196 ± 0.004 inch).
4 370-8592 Plate
(0.125 ± 0.003 inch).
sealed.
11
Thickness of three new friction discs and two new plates is 30.29 ± 0.40 mm
(1.193 ± 0.016 inch):
3
233-9748 Friction
Disc
(0.220 ± 0.003 inch).
2 370-8590 Plate
(0.265 ± 0.003 inch).
12 1 7G-4818 Seal Ring
sealed.
13 1 136-4841 Gasket Assemble with rubber surface against the slinger.
14 2
8M-5661 O-Ring
Seal
Before assembly of each bearing, lubricate with oil
immediately.
15 2
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Caterpillar Cat 986H Wheel Loader (Prefix 986) Service Repair Manual (98600001 and up).pdf

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