Caterpillar Cat 992K Wheel Loader (Prefix H4C) Service Repair Manual (H4C00001 and up).pdf

Service Repair Manual
Models
992K Wheel Loader

Shutdown SIS
Previous Screen
Product: WHEEL LOADER
Model: 992K WHEEL LOADER H4C
Configuration: 992K Wheel Loader H4C00001-UP (MACHINE) POWERED BY C32 Engine
Disassembly and Assembly
992K Wheel Loader and 854K Wheel Dozer Power Train
Media Number -RENR8912-03 Publication Date -01/02/2008 Date Updated -16/08/2018
i02926664
Torque Converter - Disassemble
SMCS - 3101-015
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
Start By:
a. Remove the torque converter. Refer to Disassembly and Assembly, "Torque Converter -
Remove".
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b. Remove the modulating valve. Refer to Disassembly and Assembly, "Modulating Valve
(Torque Converter Lockup Clutch) - Remove and Install".
c. Remove the modulating valve. Refer to Disassembly and Assembly, "Modulating Valve
(Torque Converter Impeller Clutch) - Remove and Install".
d. Remove the outlet relief valve. Refer to Disassembly and Assembly, "Relief Valve (Torque
Converter Outlet) - Remove".
e. Remove the torque converter priority valve. Refer to Disassembly and Assembly, "Torque
Converter Priority Valve - Remove".
f. Remove the transmission pump. Refer to Disassembly and Assembly, "Transmission Pump
- Remove".
g. Remove the steering piston pump. Refer to Disassembly and Assembly, "Piston Pump
(Steering) - Remove".
h. Remove the brake piston pump. Refer to Disassembly and Assembly, "Piston Pump (Brake)
- Remove".
i. Remove the implement piston pump. Refer to Disassembly and Assembly, "Piston Pump
(Implememt, RH) - Remove".
j. Remove the implement piston pump. Refer to Disassembly and Assembly, "Piston Pump
(Implememt, Center) - Remove".
k. Remove the piston pump. Refer to Disassembly and Assembly, "Piston Pump (Hydraulic
Fan) - Remove".
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
Note: Cleanliness is an important factor. Before you begin the disassembly procedure, the exterior
of the components should be thoroughly cleaned. This will help to prevent dirt from entering the
internal mechanism. Precision components can be damaged by contaminants or by dirt. Perform
disassembly procedures on a clean work surface. Keep components covered and protected at all
times.
1. Position the torque converter housing assembly onto suitable cribbing. The weight of the
torque converter housing assembly is approximately 1250 kg (2850 lb).
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Illustration 1 g01450165
2. Remove bolt (2), retainer (3) and yoke (1).
3. Remove O-ring seal (4) from yoke (1).
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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).
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).
4/18
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10. Use two people in order to remove idler gear (15). The weight of idler gear (15) is
approximately 36 kg (80 lb).
11. Remove bearing cones (16) from idler gear (15).
12. Remove bearing cup (17) from housing assembly (11).
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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).
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).
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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).
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).
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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).
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.
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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).
26. Position torque converter assembly (33), as shown.
27. Remove bolts (34), retainer (35), and washer (36) (not shown).
28. Remove bolts (37).
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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).
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).
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992K Wheel Loader H4C00001-UP (MACHINE) POWERED BY C32 Engine(SEB...
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33. Remove Tooling (F) from turbine hub (45). Remove turbine hub assembly (45) from clutch
housing assembly (38).
34. Remove race (47) from hub assembly (45). Remove seal carrier (48) and seal (49). Remove
sleeve bearing (46).
35. Remove sleeve (50). Remove bearing (51) and race (52) from clutch housing assembly (38).
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36. Remove retaining ring (55) and thrust bearing (54). Remove the carrier and stator assembly
(53).
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37. Remove retaining ring (58).
38. If necessary, position stator assembly (53) and carrier (57) onto a suitable press. Use
Tooling (K) and the suitable press in order to remove carrier (57) from stator assembly (53).
Remove plate (56). Remove plate (60) (not shown).
39. Remove retaining ring (59) (not shown).
40. 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). Remove housing assembly (63), impeller clutch (62), and the backing plate from
shaft assembly (61).
41. Remove thrust bearing (66), sleeve (67), and pins (68).
42. 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). Remove impeller
(64) and impeller hub (65) from housing assembly (63).
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43. Remove plate (69). If necessary, remove four dowel pins (70) (not shown). Remove twelve
bolts (71) (not shown). Remove sleeve bearing (72). Use two people in order to remove
adapter (73). The weight of adapter (73) is approximately 25 kg (55 lb).
44. Remove impeller hub (65) from impeller (64).
45. Remove Tooling (G).
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46. Attach Tooling (C) and a suitable lifting device to backing plate (74). The weight of backing
plate (74) is approximately 25 kg (55 lb). Remove backing plate (74) from housing
assembly (63).
47. Remove discs (75) and plates (76).
48. Remove piston (77).
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49. Remove seals (78).
50. Remove thrust washer (79). Remove plate (80) (not shown) and two dowel pins (81) (not
shown) that are located under thrust washer (79).
51. Remove bolts (82). Use two people in order to remove gear (83) and gear (84) as one unit.
The combined weight of gear (83) and gear (84) is approximately 36 kg (80 lb). Remove
bearing race (85) from gears (83) and (84).
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52. Remove seals (86) and seals (89).
53. Drive in locator pin (88) in order to remove seal carrier (89). Remove bearing (90) from
carrier assembly (91).
54. Reposition carrier assembly (91), as shown. The weight of carrier assembly (91) is
55. Remove bolts (92) and bearing cage (93) from carrier assembly (91).
56. Remove lip seal (95) from bearing cage (93). Remove spacer (94) from the shaft assembly.
57. Attach Tooling (J) and a suitable lifting device to shaft assembly (61). The weight of shaft
assembly (61) is approximately 26 kg (57 lb). Remove shaft assembly (61) from carrier
assembly (91). Remove gasket (96).
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58. Remove seals (101) and seal carrier (100). Remove bearing (99) from shaft (102). Remove
seal (98) and seal carrier (97).
Copyright 1993 - 2021 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Sat Feb 27 17:55:34 UTC+0800 2021
18/18
2021/2/27

Shutdown SIS
Previous Screen
Product: WHEEL LOADER
Model: 992K WHEEL LOADER H4C
Configuration: 992K Wheel Loader H4C00001-UP (MACHINE) POWERED BY C32 Engine
Disassembly and Assembly
992K Wheel Loader and 854K Wheel Dozer Power Train
Media Number -RENR8912-03 Publication Date -01/02/2008 Date Updated -16/08/2018
i02927088
Torque Converter - Assemble
SMCS - 3101-016
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
NOTICE
Keep all parts clean from contaminants.
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Contaminants may cause rapid wear and shortened component life.
Note: Check the O-ring seals, the gaskets, and the seals for wear or for damage. Replace the
components, if necessary.
1. Raise the temperature of seal carrier (97). Install seal carrier (97) onto shaft (102).
2. Lubricate seal (98) with the oil that is being sealed. Install seal (98) on seal carrier (97).
3. Raise the temperature of bearing (99). Install bearing (99) onto shaft (102).
4. Raise the temperature of seal carrier (100). Install seal carrier (100) onto shaft (102).
5. Lubricate seals (101) with the lubricant that is being sealed. Install seals (101) onto seal
carrier (100).
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 (96).
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7. Reposition carrier assembly (91). The combined weight of carrier assembly (91) and the
shaft assembly is approximately 34 kg (75 lb).
8. Install spacer (94) onto the shaft assembly.
9. Install lip seal (95) 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).
3/21
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10. 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).
11. 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.
12. Install locator pin (88).
13. Install seals (86) and (89).
14. 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).
15. Install two dowel pins (81) (not shown). Install plate (80) (not shown). Install thrust washer
(79).
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16. Lubricate seals (78) with oil that is being sealed. Install seals (78).
17. Install piston (77).
18. Install discs (75) and plates (76).
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19. 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).
20. Install impeller hub (65) on impeller (64).
21. Install sleeve bearing (72).
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22. 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).
23. 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).
24. Install pins (68) and sleeve (67). Install thrust bearing (66).
25. 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).
26. 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).
27. Remove Tooling (G) that held housing (63) to the backing plate.
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28. Install retaining ring (59) (not shown).
29. Lower the temperature of carrier (57). Use Tooling (K) and a suitable press in order to
install carrier (57) into stator assembly (53).
30. Install plate (60) (not shown). Install plate (56). Install retaining ring (58).
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31. Install the carrier and stator assembly (53). Install thrust bearing (54) and retaining ring
(55).
32. Install sleeve (50) into clutch housing assembly (38). Install race (52) and bearing (51).
33. Install sleeve bearing (46).
34. Install seal carrier (48) and seal (49).
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35. Install race (47).
36. Install turbine hub assembly (45) into clutch housing assembly (38).
37. Install Tooling (F) in order to hold the turbine assembly together. Refer to Illustration 24
below.
38. 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).
10/21
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39. 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
40. 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.
41. Install bolts (37). Tighten bolts (37) to a torque of 120 ± 15 N·m (89 ± 11 lb ft).
11/21
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42. 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).
43. 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).
12/21
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44. Install spline adapter (30), the O-ring seal, bearing cones (28) and retaining ring (29) onto
pump drive gear (27).
45. 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.
46. 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.
13/21
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Caterpillar Cat 992K Wheel Loader (Prefix H4C) Service Repair Manual (H4C00001 and up).pdf

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Caterpillar Cat 992K Wheel Loader (Prefix H4C) Service Repair Manual (H4C00001 and up).pdf