Caterpillar Cat 992K Wheel Loader (Prefix ZMX) Service Repair Manual (ZMX00001 and up)

Service Repair Manual

Models

992K Wheel Loader

992K Wheel Loader ZMX00001-UP (MACHINE) POWERED BY C32 Engine(SEBP...

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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

0S-1614

Bolt

1

5P-0537

Hard Washer

1

9X-8876

Bolt

2

1F-7958

Nut

2

F

G 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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Illustration 1

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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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992K Wheel Loader ZMX00001-UP (MACHINE) POWERED BY C32 Engine(SEBP...

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

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Illustration 5

g01127577

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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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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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Illustration 11

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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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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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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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Illustration 18

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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

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32. Install sleeve bearing (46).

33. Install seal carrier (48) and seal (49).

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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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992K Wheel Loader ZMX00001-UP (MACHINE) POWERED BY C32 Engine(SE...

Illustration 23

g00357638

Illustration 24

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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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Illustration 26

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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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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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Illustration 31

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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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Illustration 34

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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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Illustration 36

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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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Illustration 39

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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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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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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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Illustration 47

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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.

Mon Mar 30 14:56:55 UTC+0800 2020

All Rights Reserved.

Private Network For SIS Licensees.

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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

0S-1614

Bolt

1

5P-0537

Hard Washer

1

9X-8876

Bolt

2

1F-7958

Nut

2

F

G H

138-7575

Link Bracket

3

J

2D-1201

Eyebolt

1

K

1P-0520

Driver Gp

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992K Wheel Loader ZMX00001-UP (MACHINE) POWERED BY C32 Engine(SEBP...

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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992K Wheel Loader ZMX00001-UP (MACHINE) POWERED BY C32 Engine(SEBP...

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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Illustration 4

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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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992K Wheel Loader ZMX00001-UP (MACHINE) POWERED BY C32 Engine(SEBP...

Illustration 7

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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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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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