This document provides assembly instructions for a torque converter used in a 992K wheel loader. It lists over 60 steps and accompanying illustrations to assemble the various components of the torque converter in the proper order. Key components include seals, bearings, gears, plates, pistons, discs, sleeves, and housings. Special tools and lifting devices are required due to the large size and weights of components, which range from 25-680 kg. Proper temperatures and torques are specified for a safe and accurate reassembly of the torque converter.
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2. 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
F
0S-1614 Bolt 1
5P-0537 Hard Washer 1
G
9X-8876 Bolt 2
1F-7958 Nut 2
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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3. Illustration 1 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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4. 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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5. 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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6. 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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7. Illustration 11 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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8. 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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9. 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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10. 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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11. 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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12. Illustration 23 g00357638
Illustration 24 g01450614
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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13. Illustration 26 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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14. 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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15. Illustration 31 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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16. Illustration 34 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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17. Illustration 36 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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18. Illustration 39 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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19. 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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20. 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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21. Illustration 47 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.
All Rights Reserved.
Private Network For SIS Licensees.
Mon Mar 30 14:56:55 UTC+0800 2020
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22. 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
F
0S-1614 Bolt 1
5P-0537 Hard Washer 1
G
9X-8876 Bolt 2
1F-7958 Nut 2
H 138-7575 Link Bracket 3
J 2D-1201 Eyebolt 1
K 1P-0520 Driver Gp
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23. 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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24. 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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25. Illustration 4 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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26. Thank you very much for
your reading. Please Click
Here. Then Get COMPLETE
MANUAL. NO WAITING
NOTE:
If there is no response to
click on the link above,
please download the PDF
document first and then
click on it.
27. Illustration 7 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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28. 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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