Caterpillar Cat 992G Wheel Loader (Prefix 7HR) Service Repair Manual Instant Download.pdf

Service Repair Manual
Models
992G Wheel Loader

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Product: WHEEL LOADER
Model: 992G WHEEL LOADER 7HR
Configuration: 992G Wheel Loader 7HR00001-UP (MACHINE) POWERED BY 3508B Engine
Disassembly and Assembly
854G Wheel Tractor and 992G Wheel Loader Power Train
Media Number -SENR5894-13 Publication Date -01/11/2008 Date Updated -24/11/2008
i01270892
Transmission Planetary - Disassemble
SMCS - 3160-015
Disassembly Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 1P-2420 Transmission Stand 1
B 138-7575 Link Bracket 2
C 138-7573 Link Bracket 2
D 1P-1863 Pliers 1
E 1P-0520 Driver Group 1
F FT-0833 Clamp 2
G 1P-1861 Pliers 1
Start By:
A. Separate the input transfer gears and the output transfer gears from the transmission. Refer
to Disassembly and Assembly, "Transmission from Input Transfer Gears and Output
Transfer Gears - Separate".
Note: When the transmission is disassembled, keep the clutch plates and the clutch discs in the
original sequence.
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Illustration 1 g00392140
1. Remove bolts (1), cover (2) and the gasket from the transmission case assembly.
2. Remove bolts (4) and the washers.
3. Remove manifold (5) from transmission case assembly (3) .
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4. Remove two O-ring seals (6) from manifold (5) .
5. Remove bolt (7) and the washer. Remove two sleeves (8) from transmission hydraulic
control valve (9) .
6. Remove two O-ring seals (10) from each sleeve (8) .
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7. Remove nut (11) from wiring harness connector plug (12) .
8. Remove bolts (13) from transmission hydraulic control valve (9) .
9. Slide transmission hydraulic control valve (9) to the side. Pull wiring harness connector
plug (12) from transmission case assembly (3) .
10. Use a hoist and a suitable lifting sling to remove transmission hydraulic control valve (9)
from the transmission. The weight of the transmission hydraulic control valve is 55 kg (120
lb).
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11. Mount the transmission on Tooling (A), as shown.
12. Fasten Tooling (B), a hoist and a suitable lifting chain to transmission case assembly (3) .
13. Remove bolts (14) and the washers from transmission case assembly (3) .
14. Use two 3/8-16 NC forcing screws to separate transmission case assembly (3) from housing
assembly (15). Remove transmission case assembly (3) from housing assembly (15). The
weight of the transmission case assembly is 211 kg (465 lb).
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15. Remove bolts (16) and the washers. Remove pilot plate (17) .
16. Put wood blocks under the shaft assembly in order to prevent the shaft assembly from
dropping out of the transmission.
17. Remove retaining ring (18) .
18. Remove bolts (19) and the washers.
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19. Use Tooling (B), a hoist and a suitable lifting chain to remove end plate (20). The weight of
the end plate is 57 kg (125 lb).
20. Remove bearing (21) from end plate (20) .
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21. Remove twelve springs (22) .
22. Remove six pins (23), five clutch discs (24), and four clutch plates (25) from the No. 1
clutch housing.
Typical Example
23. Remove retaining ring (26) from input shaft (27) .
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Typical Example
24. Use Tooling (C), a hoist and a suitable lifting sling to remove carrier assembly (28) and
coupling gear (29) as a unit. The combined weight of the carrier assembly and of the
coupling gear is 68 kg (150 lb).
Typical Example
25. Use 3.18 mm (0.125 inch) pins (30) in order to compress retainer ring (31) and separate
coupling gear (29) from the carrier assembly.
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Typical Example
26. Remove retaining ring (32) and bearing (33) .
Typical Example
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992G Wheel Loader 7HR00001-UP (MACHINE) POWERED BY 3508B Engine(S...
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27. Remove pin (34) from carrier assembly (28), if necessary. Use a punch to push spring pin
(35) inside shaft assembly (36). Tap shaft assembly (36) out of carrier assembly (28) .
28. Remove two thrust discs (37), two roller bearing assemblies (38) and planetary gear (39)
from carrier assembly (28) .
29. Repeat Steps 27 and 28 for the other three planetary gears in carrier assembly (28) .
30. Remove pin (40) and ring carrier (41) from shaft (27). Rotate the ring carrier in order to
provide clearance for the dowel on shaft (27) .
31. Remove two metal seal rings (42) from ring carrier (41) .
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32. Remove sun gear (43) from input shaft assembly (27) .
33. Remove seal ring (44) from sun gear (43) .
34. Install Tooling (B) on No. 1 clutch housing.
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35. Attach a hoist and suitable lifting chains to Tooling (B) .
36. Use a hoist to remove clutch piston (45) and No. 1 clutch housing (46) as a unit. The
combined weight of the clutch piston and of the No. 1 clutch housing is 77 kg (170 lb).
37. Remove clutch piston (45) from No. 1 clutch housing (46) .
38. Remove two seal rings (47) from clutch piston (45) .
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39. Remove four dowels (48) from No. 1 clutch housing (46). The weight of the No. 1 clutch
housing is 59 kg (129 lb).
40. Remove six pins (49), twelve springs (51), five clutch discs (50) and four clutch plates (52)
from the forward clutch housing.
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41. Remove bolts (53), four locks (54) and bearing cage (55) .
42. Use a soft hammer to tap gear assembly (56) out of bearing cage (55) .
43. Remove dowel (57) from gear assembly (56) .
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44. Remove retaining ring (58) from bearing cage (55) .
45. Place bearing cage (55) on wood blocks. Use Tooling (E) to drive out bearing (59), as
shown.
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46. Remove coupling gear (60) .
47. Remove retaining ring (61) from coupling gear (60) .
48. Remove ring gear (62) .
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54. Remove six pins (66), twelve springs (67), four clutch discs (68) and three clutch plates
(69) .
55. Use Tooling (C), a hoist and a suitable lifting chain to remove planetary carrier (70). The
weight of the planetary carrier is 59 kg (130 lb).
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56. Use a punch to push spring pin (71) inside planetary shaft (72). Tap shaft (72) out of
planetary carrier (70) .
57. Remove four thrust discs (73), two planetary gears (74) and two bearing assemblies (75)
from planetary carrier (70) .
58. Repeat Steps 56 and 57 for the other three planetary gears.
59. Remove bolts (76), two locks (77), two lock plates (78) and ring gear (79) .
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64. Remove seal rings (82) from clutch piston (80) .
65. Remove four dowels (83) from No. 3 clutch housing (81). Two of the dowels are located on
the bottom of the housing. The weight of the No. 3 clutch housing is 56 kg (124 lb).
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66. Remove input shaft (27). The weight of the input shaft is 32 kg (70 lb).
67. Remove dowel (85), ring (84) and metal ring seal (86) from input shaft (27) .
68. Remove twelve springs (87), three clutch discs (88) and two clutch plates (89) .
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69. Remove ring gear (90) .
70. Install Tooling (B) on No. 4 clutch housing (92) .
73. Remove clutch piston (91) from clutch housing (92).
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75. Remove retaining ring (94) from the bottom of the transmission.
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76. Use Tooling (C), a hoist and a suitable lifting chain to remove planetary carrier (95) and the
connected components. The combined weight of the carrier and of the components is 186 kg
(410 lb).
77. Turn the carrier onto the opposite end. Put the carrier on wood blocks, as shown. Remove
twelve bolts (96) and the washers from No. 5 clutch housing (97) .
78. Use Tooling (F) to hold clutch piston (98) in clutch housing (97). Use Tooling (C) to
remove the clutch housing and the clutch piston. The combined weight of the clutch housing
and the clutch piston is 61 kg (135 lb).
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79. Remove clutch piston (98) from clutch housing (97). The weight of the clutch housing is 41
kg (90 lb).
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81. Remove two plugs (100) and two dowels (101) from clutch housing (97) .
82. Turn the clutch housing onto the opposite side. Remove dowel (103) from clutch housing
(97). Remove two seal rings (104) from ring (102). Remove ring (102) from clutch housing
(97) .
83. Remove six pins (105), twelve springs (106) and the pins.
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84. Remove five clutch discs (107) and four clutch plates (108) .
85. Turn the carrier onto the opposite end. Use Tooling (D) to remove retaining ring (110) from
the output shaft. Remove sun gear (109) from the output shaft.
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86. Remove ring seal (111) from sun gear (109) .
87. Use Tooling (C), a hoist and a suitable lifting chain to remove planetary carrier (95) from
output shaft assembly (112). The weight of the planetary carrier is 52 kg (115 lb).
88. Remove sun gear (113) from output shaft assembly (112) .
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89. Remove hub (114) from output shaft assembly (112). The weight of the hub is 20 kg (45 lb).
90. Remove dowel (115) from output shaft assembly (112). Remove one bearing sleeve (116)
from each end of output shaft assembly (112). The weight of the output shaft assembly is 27
kg (60 lb).
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91. Use Tooling (G) to remove retaining ring (117) from planetary carrier (95) .
92. Use Tooling (E) to remove ball bearing (118) from planetary carrier (95) .
93. Use a punch to push spring pin (119) inside planetary shaft assembly (120). Tap planetary
shaft assembly (120) from carrier (95) .
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94. Remove two thrust discs (121), planetary gear (122), roller bearing (123) and spring pin
(119) from planetary shaft assembly (120) .
95. Repeat Steps 93 and 94 for the other three planetary gears (122) .
96. Remove three O-ring seals (124) from housing assembly (125) .
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97. Remove three dowels (126) from housing assembly (125) .
98. Turn housing assembly (125) onto the opposite side, as shown. Remove bolts (127) from
bearing cage (128) .
99. Use three 3/8 - 16 NC forcing screws to separate bearing cage (128) from housing assembly
(125). Remove dowel (129) and plug (130). Remove bearing cage (128) from housing
assembly (125) .
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Caterpillar Cat 992G Wheel Loader (Prefix 7HR) Service Repair Manual Instant Download.pdf

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