Caterpillar Cat 962G Wheel Loader (Prefix 4PW) Service Repair Manual (4PW00001 and up).pdf

Service Repair Manual
Models
962G Wheel Loader

Shutdown SIS
Previous Screen
Product: WHEEL LOADER
Model: 962G WHEEL LOADER 4PW
Configuration: 962G Wheel Loader 4PW00001-UP (MACHINE) POWERED BY 3126 Engine
Disassembly and Assembly
950G and 962G Wheel Loaders and IT62G Integrated Toolcarrier Power Train
Media Number -SENR1381-10 Publication Date -01/10/2007 Date Updated -25/10/2007
i00734834
Output Transfer Gears - Disassemble
SMCS - 3075-015
Disassembly Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A
1P-0520 Driver Group 1
1P-2322 Puller Assembly 1
B
8B-7556 Adapter 2
8B-7548 Push-Puller 1
8B-7560 Step Plate 1
8H-0684 Ratchet Box Wrench 1
C 8B-7551 Bearing Puller Attachment 1
Start By:
A. Separate the output transfer gears from the transmission planetary group. Refer to
Disassembly and Assembly, "Transmission from Output Transfer Gears - Separate".
Note: Cleanliness is an important factor. Before disassembly, the exterior of the case should be
thoroughly cleaned in order to prevent dirt and debris from entering the internal mechanism.
During disassembly, all parts should be thoroughly cleaned in cleaning fluid. Then allow the parts
to air dry. Wiping cloths or rags should not be used to dry the parts. Lint may be deposited on the
parts. This may cause later trouble.
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Illustration 1 g00332214
1. Remove speed sensors (1) .
Note: Keep the shim pack together for assembly purposes.
2. Remove bolts (2). Use two forcing screws of a suitable size to remove bearing cage
assembly (3) and the shim pack.
3. Remove the lip seal, the O-ring seal and the bearing cup from bearing cage assembly (3) .
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4. Put the output transfer gear group on wood blocks, as shown. The weight of the output
transfer gear group is 231 kg (510 lb).
5. Remove lifting eye bracket (4) .
6. Remove bolts (5) that hold bearing cage assembly (6) to the housing.
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7. Use two 3/8" - 16 NC forcing screws (7) to remove bearing cage assembly (6) from the
housing.
Note: Keep the shim pack together for assembly purposes.
8. Remove shim pack (8) .
9. Remove bearing cup (9) and O-ring seal (10) from bearing cage assembly (6) .
10. Fasten a suitable lifting sling and a hoist to input transfer gear (11). Use a hoist to remove
input transfer gear (11). The weight of the input transfer gear is 23 kg (50 lb).
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11. Use Tooling (A) to remove bearing cone (12). Repeat this step for the opposite side of the
input transfer gear.
12. Remove bearing cup (13) from the output transfer gear housing.
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13. Remove spacer (14) from the output shaft.
14. Put the output transfer gear group in a vertical position, as shown.
15. Remove bolt (15) and yoke retainer (16) from the output shaft.
16. Remove yoke assembly (17) from the output shaft.
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17. Remove bolts (18) .
18. Use two 3/8" - 16 NC forcing screws to remove bearing cage assembly (19) from the output
transfer gear housing.
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19. Remove bearing cage assembly (19) .
20. Remove lip seal (20) from the bearing cage assembly.
21. Remove bearing cup (21) and O-ring seal (22) from the bearing cage assembly.
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22. Use a hoist and a suitable lifting sling to hold output transfer gear (23) in position.
23. Use Tooling (B) to push output shaft (25) from transfer gear (23) and from bearing cone
(24) .
24. Remove transfer gear (23) from output shaft (25) .
25. Remove output shaft (25) and bearing cone (24) from the output transfer gear housing.
Note: The output shaft is free to fall when the bearing cone is removed.
26. Use a press and Tooling (C) to push the output shaft from bearing cone (24) .
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27. Remove transfer gear (23) from the output transfer gear housing.
28. Remove bolts (26) and cover (27) from the output transfer gear housing.
29. Remove O-ring seal (28) from cover (27) .
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962G Wheel Loader 4PW00001-UP (MACHINE) POWERED BY 3126 Engine(SE...
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30. Remove suction screen (30) and screen tube assembly (29) .
31. Separate suction screen (30) from screen tube assembly (29) .
32. Remove magnet assembly (31) from screen tube assembly (29) .
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All Rights Reserved.
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Sat Mar 28 16:50:36 UTC+0800 2020
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Shutdown SIS
Previous Screen
i06502801
Output Transfer Gears - Assemble
SMCS - 3075-016
Assembly Procedure
Table 1
Required Tools
A 1P-0520 Driver Group 1
B 8T-5096 Dial Indicator Gp 1
Note: Cleanliness is an important factor. Before assembly, all parts should be thoroughly
cleaned in cleaning fluid. Allow the parts to air dry. Wiping cloths or rags should not be
used to dry parts. Lint may be deposited on the parts. This may cause later trouble. Inspect
all parts. If any parts are worn or damaged, use new parts for replacement.
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1. Make sure that magnet assembly (31) is in position on the screen tube assembly (29).
2. Install screen tube assembly (29) in suction screen (30).
3. Install screen tube assembly (29) and suction screen (30) in the output transfer gear housing.
4. Install O-ring seal (28) on cover (27). Apply clean oil on O-ring seal (28).
2/11
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5. Install cover (27) and bolts (26).
6. Install output transfer gear (23) in the output transfer gear housing, as shown.
7. Heat bearing cone (24) to a maximum temperature of 135°C (275°F). Install bearing cone
(24) on output shaft (25). Make sure that the bearing cone contacts the mating surface.
8. Lift transfer gear (23) in order to align the bore with the output shaft. Install output shaft
(25).
9. Heat bearing cone (24) to a maximum temperature of 135°C (275°F). Install bearing cone
(24) on the opposite end of output shaft (25). Make sure that the bearing cone contacts the
mating surface.
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10. Lower the temperature of bearing cup (21). Install bearing cup (21) in bearing cage
assembly (19).
11. Install O-ring seal (22) on bearing cage assembly (19).
12. Apply 7M-7260 Liquid Gasket to the seal bore. Allow the liquid gasket to dry. Use Tooling
(A) to install the lip seal in bearing cage assembly (19).
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13. Apply clean transmission oil to O-ring seal (22). Install bearing cage assembly (19). Install
bolts (18). The torque for bolts (18) is 60 ± 12 N·m (44 ± 9 lb ft).
14. Repeat Steps 10 through 12 in order to assemble bearing cage assembly (3).
15. Install spacer (14) on the output shaft.
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Note: The bearing axis must be vertical for correct end play adjustment.
16. Use a 0.038 mm (0.0015 inch) shim or a standard feeler gauge to ensure that the bearing
cups and the bearing cones are seated in the housing.
Note: Do not install the O-ring seal or the shims at this time.
17. Use two cage bolts (2) in order to install bearing cage assembly (3). The cage bolts are
separated by 180 degrees.
18. Tighten two cage bolts (2) to a torque of 1.7 N·m (15 lb in).
19. Turn output shaft (25) for at least three revolutions in order to seat the bearings.
21. Turn output shaft (25) for at least three revolutions in order to seat the bearings.
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22. Tighten two cage bolts (2) again to a torque of 3.4 N·m (30 lb in).
23. Measure the gap between the case and bearing cage assembly (3) at two cage bolts (2).
Perform the measurement between the outside diameter of the flange and the cage bolts.
24. Average the two measurements from Step 23. Add 0.23 mm (0.009 inch) to the average.
This result is the required thickness of the shims.
25. Remove bearing cage assembly (3). Install the O-ring seal on bearing cage assembly (3).
Apply clean transmission oil to the O-ring seal. Install bearing cage assembly (3) with the
required shims from Step 24. Install cage bolts (2). The torque for cage bolts (2) is
60 ± 12 N·m (44 ± 9 lb ft).
26. Use Tooling (B) to measure the bearing end play. If the bearing end play is less than
0.05 mm (0.002 inch), add shims. If the bearing end play is more than .11 mm (0.004 inch),
remove shims.
27. Install yoke assembly (17).
28. Install yoke retainer (16) and bolt (15) on the output shaft. The torque for bolt (15) is
240 ± 40 N·m (177 ± 30 lb ft).
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29. Lower the temperature of bearing cup (13). Install bearing cup (13) in the output transfer
gear housing.
30. Heat bearing cones (12) to a maximum temperature of 135°C (275°F). Install one bearing
cone (12) on each side of input transfer gear (11).
31. Install input transfer gear (11), as shown.
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32. Lower the temperature of bearing cup (9). Install bearing cup (9) in bearing cage assembly
(6). Do not install O-ring seal (10) at this time.
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Note: The bearing axis must be vertical for correct end play adjustment.
33. Use a 0.038 mm (0.0015 inch) shim or a standard feeler gauge to ensure that the bearing
cups and the bearing cones are seated in the housing.
Note: Do not install the O-ring seal or the shims at this time.
34. Use two cage bolts (5) in order to install bearing cage assembly (6). The cage bolts are
separated by 180 degrees.
36. Turn input transfer gear (11) for at least three revolutions in order to seat the bearings.
38. Turn input transfer gear (11) for at least three revolutions in order to seat the bearings.
39. Tighten two cage bolts (5) again to a torque of 3.4 N·m (30 lb in).
40. Measure the gap between the case and bearing cage assembly (6) at two cage bolts (5).
Perform the measurement between the outside diameter of the flange and the cage bolts.
41. Average the two measurements from Step 40. Add 0.23 mm (0.009 inch) to the average.
This result is the required thickness of the shims.
42. Remove bearing cage assembly (6). Install the O-ring seal on bearing cage assembly (5).
Apply clean transmission oil to the O-ring seal. Install bearing cage assembly (6) with the
required shims from Step 41. Install cage bolts (5). The torque for cage bolts (5) is
60 ± 12 N·m (44 ± 9 lb ft).
43. Use Tooling (B) to measure the bearing end play. If the bearing end play is less than
0.05 mm (0.002 inch), add shims. If the bearing end play is more than 0.15 mm
(0.006 inch), remove shims.
44. Install lifting eye bracket (4).
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45. Use the following procedure to install speed sensors (1):
a. Align the gear tooth with the center of the hole for the transmission speed sensor.
b. Apply 5P-3413 Pipe Sealant to the threads of the sensor. Install the sensor. Screw the
sensor inward until the sensor contacts the gear tooth.
c. Back off the sensor by 1/2 turn. Tighten the adjustment locknut. The torque for the
adjustment locknut is 25 ± 5 N·m (18 ± 4 lb ft).
Note: Do not allow the sensor to turn as the adjustment locknut is tightened.
End By:
a. Connect the output transfer gears to the transmission planetary group. Refer to Disassembly
and Assembly, "Transmission to Output Transfer Gears - Connect".
Sat Mar 28 16:51:35 UTC+0800 2020
11/11
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Shutdown SIS
Previous Screen
i00732414
Transmission to Output Transfer Gears - Connect
SMCS - 3002-077
Connection Procedure
Table 1
Required Tools
A 138-7575 Link Bracket 1
1. Use a hoist to install the transmission planetary group on the output transfer gear case. The
weight of the transmission planetary group is 545 kg (1200 lb).
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2. Install O-ring seal (3) .
3. Remove Tooling (A) from the transmission planetary group.
4. Install drain tube assembly (2) and bolts (1) .
End By: Connect the torque converter to the transmission. Refer to Disassembly and Assembly,
"Torque Converter to Transmission, Output Transfer Gears - Connect".
Sat Mar 28 16:52:34 UTC+0800 2020
2/2
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Shutdown SIS
Previous Screen
i01624201
Torque Converter to Transmission, Output Transfer Gears -
Connect
SMCS - 3003-077
Connection Procedure
Table 1
Required Tools
A 138-7575 Link Bracket 3
Note: Check the condition of all parts. If any parts are worn or damaged, use new parts for
replacement.
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1. Install the O-ring seal on the transmission housing. Apply clean power train oil on the O-
ring seal.
2. Use a suitable hoist in order to install torque converter assembly (12) on the transmission
planetary group. The weight of the torque converter assembly is 159 kg (350 lb).
3. Install bolts (14) that hold torque converter assembly (12) to the transmission planetary
group. The torque for bolts (14) is 120 ± 20 N·m (90 ± 15 lb ft).
4. Put the torque converter, the transmission and the output gears in a horizontal position on
wood blocks.
5. Remove bolts (13) that hold torque converter assembly (12) to the transmission planetary
group. The torque for bolts (13) is 120 ± 20 N·m (90 ± 15 lb ft).
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Caterpillar Cat 962G Wheel Loader (Prefix 4PW) Service Repair Manual (4PW00001 and up).pdf

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