Caterpillar Cat 992K Wheel Loader (Prefix 880) Service Repair Manual (88000001 and up).pdf

Service Repair Manual
Models
992K Wheel Loader

Shutdown SIS
Previous Screen
Product: WHEEL LOADER
Model: 992K WHEEL LOADER 880
Configuration: 992K Wheel Loader 88000001-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
1/18
992K Wheel Loader 88000001-UP (MACHINE) POWERED BY C32 Engine(SEBP5...
2021/6/13
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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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3. Remove O-ring seal (4) from yoke (1).
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).
3/18
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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).
9. Remove lip seal (13), bearing cup (12), and O-ring seals (14) from pump adapter (5).
10. Use two people in order to remove idler gear (15). The weight of idler gear (15) is
approximately 36 kg (80 lb).
4/18
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11. Remove bearing cones (16) from idler gear (15).
12. Remove bearing cup (17) from housing assembly (11).
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).
5/18
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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).
16. Position housing assembly (11) onto the opposite side and remove O-ring seal (18).
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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20. Attach Tooling (B) and a suitable lifting device to pump adapter (23). The weight of pump
adapter (23) is approximately 50 kg (110 lb). Use Tooling (B) and the suitable lifting device
in order to remove pump adapter (23). Remove shims (24).
21. Remove bearing cup (25) and O-ring seal (26) from pump adapter (23).
22. Use two people in order to remove pump drive gear (27) from housing assembly (11). The
weight of pump drive gear (27) is approximately 27 kg (60 lb).
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23. Remove retaining ring (29), spline adapter (30), and the O-ring seal from pump drive gear
(27). Remove bearing cones (28).
24. Repeat Steps 18 through 23 in order to remove the remaining pump adapter.
25. Position torque converter assembly (33), as shown. The weight of torque converter
assembly (33) is approximately 590 kg (1300 lb). Remove bolts (31). Install Tooling (E).
Use Tooling (E) in order to separate pilot guide (32) from torque converter assembly (33).
Remove pilot guide (32).
8/18
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26. Position torque converter assembly (33), as shown.
27. Remove bolts (34), retainer (35), and washer (36) (not shown).
28. Remove bolts (37).
29. Attach Tooling (C) to clutch housing assembly (38). The weight of clutch housing assembly
(38) is approximately 168 kg (370 lb). Install Tooling (F) in order to prevent the turbine
assembly from separating from the bearing. Remove clutch housing assembly (38).
9/18
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30. Position clutch housing assembly (38), as shown.
31. Remove bearing race (41), sleeve (40), and pins (39).
32. Remove bolts (42) and clamping plate (43). Remove turbine (44).
33. Remove bolts (45) and retainer plates (46). Remove backing plate (47).
10/18
992K Wheel Loader 88000001-UP (MACHINE) POWERED BY C32 Engine(SEB...
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34. Remove discs (48) and the plate.
35. Remove Tooling (F) from the turbine hub. Remove turbine hub assembly (49).
36. Remove race (51). Remove seal carrier (52) and seal (53). Remove sleeve bearing (50).
37. Remove piston (54) and the seals. Remove sleeve (55). Remove bearing (56) and race (57)
from clutch housing assembly (38).
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38. Remove retaining ring (60) and thrust bearing (59). Remove the carrier and stator assembly
(58).
39. Remove retaining ring (63).
40. If necessary, position stator assembly (58) and carrier (62) onto a suitable press. Use
Tooling (K) and the suitable press in order to remove carrier (62) from stator assembly (58).
Remove plate (61). Remove plate (65) (not shown).
41. Remove retaining ring (64) (not shown).
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42. Install Tooling (G) in order to hold housing assembly (68) to the backing plate. Attach
Tooling (H) and a suitable lifting device to the backing plate. The combined weight of
housing assembly (68), impeller clutch (67), and the backing plate is approximately 181 kg
(400 lb). Remove housing assembly (68), impeller clutch (67), and the backing plate from
shaft assembly (66).
43. Remove thrust bearing (71), sleeve (72), and pins (73).
44. Attach Tooling (C) and a suitable lifting device to impeller hub (70). The combined weight
of impeller (69) and impeller hub (70) is approximately 57 kg (125 lb). Remove impeller
(69) and impeller hub (70) from housing assembly (68).
13/18
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45. Remove plate (74). If necessary, remove four dowel pins (75) (not shown). Remove twelve
bolts (76) (not shown). Remove sleeve bearing (77). Use two people in order to remove
adapter (78). The weight of adapter (78) is approximately 25 kg (55 lb).
46. Remove impeller hub (70) from impeller (69).
47. Remove Tooling (G).
48. Attach Tooling (C) and a suitable lifting device to backing plate (79). The weight of backing
plate (79) is approximately 25 kg (55 lb). Remove backing plate (79) from housing
assembly (68).
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49. Remove discs (80) and plates (81).
50. Remove piston (82).
51. Remove seals (83).
15/18
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52. Remove thrust washer (84). Remove plate (85) (not shown) and two dowel pins (86) (not
shown) that are located under thrust washer (84).
53. Remove bolts (87). Use two people in order to remove gear (88) and gear (89) as one unit.
The combined weight of gear (88) and gear (89) is approximately 36 kg (80 lb). Remove
bearing race (90) from gears (88) and (89).
54. Remove seals (91) and seals (94).
16/18
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55. Drive in locator pin (93) in order to remove seal carrier (94). Remove bearing (95) from
carrier assembly (96).
56. Reposition carrier assembly (96), as shown. The weight of carrier assembly (96) is
approximately 79 kg (175 lb).
57. Remove bolts (97) and bearing cage (98) from carrier assembly (96).
58. Remove lip seal (99) from bearing cage (98).
59. Attach Tooling (J) and a suitable lifting device to shaft assembly (66). The weight of shaft
assembly (66) is approximately 26 kg (57 lb). Remove shaft assembly (66) from carrier
assembly (96). Remove gasket (100).
17/18
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60. Remove seals (105) and seal carrier (104). Remove bearing (103) from shaft (106). Remove
seal (102) and seal carrier (101).
Copyright 1993 - 2021 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Sun Jun 13 14:32:55 UTC+0800 2021
18/18
2021/6/13

Shutdown SIS
Previous Screen
Product: WHEEL LOADER
Model: 992K WHEEL LOADER 880
Configuration: 992K Wheel Loader 88000001-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
i04351631
Torque Converter (Lockup) - Assemble
SMCS - 3101-016-L7
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
1. Apply oil to all of the bearings before assembly.
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2. Raise the temperature of seal carrier (101). Install seal carrier (101) onto shaft (106).
3. Lubricate seal (102) with the oil that is being sealed. Install seal (102) on seal carrier (101).
4. Raise the temperature of bearing (103). Install bearing (103) onto shaft (106).
5. Raise the temperature of seal carrier (104). Install seal carrier (104) onto shaft (106).
6. Lubricate seals (105) with the lubricant that is being sealed. Install seals (105) onto seal
carrier (104).
7. Attach Tooling (J) and a suitable lifting device to shaft assembly (66). The weight of shaft
assembly (66) is approximately 26 kg (57 lb). Use Tooling (J) and the suitable lifting device
in order to install shaft assembly (66) onto carrier assembly (96). Install gasket (100).
2/21
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8. Reposition carrier assembly (96). The combined weight of carrier assembly (96) and the
shaft assembly is approximately 34 kg (75 lb).
9. Install lip seal (99) into bearing cage (98). Position bearing cage (98). Install bolts (97).
Tighten bolts (97) to a torque of 50 ± 7 N·m (37 ± 5 lb ft).
3/21
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10. Reposition carrier assembly (96). The weight of carrier assembly (96) is approximately
79 kg (175 lb). Raise the temperature of bearing (95). Install bearing (95) onto carrier
assembly (96).
11. Raise the temperature of seal carrier (92). Install seal carrier (92).
Note: Make sure that the Holes (X) in seal carrier (92) are in alignment with Holes (Y) in
the shaft.
12. Install locator pin (93).
13. Install seals (91) and (94).
14. Install bearing race (90) in gear (88) and gear (89). Use two people in order to install gears
(89) and (88). The combined weight of gear (88) and gear (89) is approximately 36 kg
(80 lb). Install bolts (87). Tighten bolts (87) to a torque of 240 ± 25 N·m (175 ± 18 lb ft).
15. Install two dowel pins (86) (not shown). Install plate (85) (not shown). Install thrust washer
(84).
4/21
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16. Lubricate seals (83) with oil that is being sealed. Install seals (83).
17. Install piston (82).
18. Install discs (80) and plates (81).
5/21
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19. Attach Tooling (C) and a suitable lifting device to backing plate (79). The weight of backing
plate (79) is approximately 25 kg (55 lb). Install backing plate (79) onto housing assembly
(68).
20. Install impeller hub (70) on impeller (69).
21. Install sleeve bearing (77).
6/21
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22. Use two people in order to install adapter (78). The weight of adapter (78) is approximately
25 kg (55 lb). Install twelve bolts (76) (not shown). Tighten bolts (76) to a torque of
120 ± 15 N·m (89 ± 11 lb ft).
23. Install four dowel pins (75) (not shown) that are located under plate (74). The correct height
for dowel pins (75) is 3.10 ± 0.13 mm (0.122 ± 0.005 inch). Install plate (74).
24. Install pins (73) and sleeve (72). Install thrust bearing (71).
25. Attach Tooling (C) and a suitable lifting device to impeller hub (70). The combined weight
of impeller (69) and impeller hub (70) is approximately 57 kg (125 lb). Align the splines
and install impeller (69) and impeller hub (70) on housing assembly (68).
26. Install Tooling (G) in order to hold housing assembly (68) to the backing plate. Attach
Tooling (H) and a suitable lifting device to the backing plate. The combined weight of
housing assembly (68), impeller clutch (67), and the backing plate is approximately 181 kg
(400 lb). Install housing assembly (68), impeller clutch (67), and the backing plate onto
shaft assembly (66).
27. Remove Tooling (G) that held housing (68) to the backing plate.
7/21
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28. Install retaining ring (64) (not shown).
29. Lower the temperature of carrier (62). Use Tooling (K) and a suitable press in order to
install carrier (62) into stator assembly (58).
30. Install plate (65) (not shown). Install plate (61). Install retaining ring (63).
8/21
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31. Install the carrier and stator assembly (58). Install thrust bearing (59) and retaining ring
(60).
32. Install sleeve (55).
33. Install race (57) and bearing (56).
34. Install the seals and piston (54) from the bottom side of clutch housing assembly (38).
9/21
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35. Install sleeve bearing (50).
36. Install seal carrier (52) and seal (53).
37. Install race (51).
38. Install turbine hub assembly (49). Install Tooling (F) in order to hold the turbine assembly
together. Refer to Illustration 25 below.
39. Install discs (48) and the plate.
40. Install backing plate (47). Install retainer plates (46) and bolts (45). Tighten bolts (45) to a
torque of 50 ± 7 N·m (37 ± 5 lb ft).
10/21
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41. 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).
42. Install pins (39), sleeve (40) and bearing race (41). Reposition clutch assembly (38) onto the
opposite side for assembly purposes. The weight of clutch assembly (38) is approximately
168 kg (370 lb).
11/21
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43. Attach Tooling (C) and a suitable lifting device to clutch assembly (38). Install clutch
assembly (38). Remove Tooling (F) that is used to prevent the turbine assembly from
separating away from the bearing.
44. Install bolts (37). Tighten bolts (37) to a torque of 120 ± 15 N·m (89 ± 11 lb ft).
45. 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).
12/21
2021/6/13

46. 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).
47. Install spline adapter (30), the O-ring seal, bearing cones (28) and retaining ring (29) onto
pump drive gear (27).
48. 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.
13/21
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49. 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.
50. 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).
51. When possible, rotate either the torque converter or the outer housing in order to ensure that
the bearings are properly seated.
52. 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
48 in order to obtain the correct bearing end play, as needed.
53. Remove the pump adapter from the housing assembly.
14/21
2021/6/13

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54. Install O-ring seals (26) onto pump adapter (23).
55. Install the correct number of shims (24) onto the housing assembly. The correct number of
shims (24) were determined in Step 52.
56. 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).
57. 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.
58. Repeat Steps 48 through 56 in order to install the remaining pump adapter.
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59. 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).
60. Lower the temperature of bearing cup (17). Install bearing cup (17) in the housing assembly.
61. 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).
16/21
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62. Lubricate bearing cones (16) with the oil that is being sealed. Install bearing cones (16) onto
idler gear (15).
63. 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).
64. Lower the temperature of bearing cup (12). Install bearing cup (12) into pump adapter (5).
17/21
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Caterpillar Cat 992K Wheel Loader (Prefix 880) Service Repair Manual (88000001 and up).pdf

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