3192 MARINE GEAR Caterpillar


Ahead and Astern Clutches and Clutch Shafts

Usage:

The clutches and clutch shafts can be removed from the marine gear as a unit for servicing. This can be accomplished without removing the marine gear from the diesel engine. The upper housing, oil manifold and oil cooler must be removed in order for the clutches and clutch shafts to be removed.

Upper Housing Removal And Installation

1. Remove the engine aftercooler. See the covering topic, in the Engine Service Manual.


1-Cover. 2-Plug. 3-Upper housing. 4-Oil cooler. 5-Oil manifold.

2. Remove the oil cooler (4) and oil manifold (5), see the covering topics.

3. Remove the bolts securing the upper housing (3) to the lower housing and flywheel housing.


6-Saddle bolt (four). 7-Rear retainers.

NOTE: To facilitate removal of the upper housing, it may be necessary to remove the plug (2).

4. With the aid of four forcing screws, separate the upper housing from the lower housing and lift the upper housing off as shown.


REMOVING UPPER HOUSING

5. Before replacing the two bearing retainers (7), be sure the front bearing retainers are tight.

6. Install in the reverse order of removal.

NOTE: Tighten the four saddle bolts in an A-D-B-C sequence first at 150 lbs. ft. Retighten in the same order at 230 ± 20 lbs. ft.


PLACING CORRECT TORQUE ON UPPER HOUSING SADDLE BOLTS
A-B-C-D Sequence Marks.

Removal And Installation Of Upper Shaft Group

NOTE: The shaft group weighs approximately 1100 pounds.

1. Remove the upper housing. See the covering topic.

2. Loosen the two rear bearing retainers (1) and (2).

3. Rotate flywheel and remove all but two of the bolts (3) holding the spider drive ring (5) to the flywheel. Leave the two bolts, one on each side of the threaded hole for the eyebolt, at 90° from the eyebolt.


PREPARING TO REMOVE UPPER SHAFT GROUP.
1-Rear retainer. 2-Rear retainer. 3-Drive ring bolt. 4-Lifting eye. 5-Drive ring. 6-Front retainer. 7-Front retainer.


NOTICE

Install a 1/2" lifting eye and attach the hoist to the shaft group before removing the last bolts from the drive ring. The clutch end of the shaft is over-balanced and will drop down into the lower housing unless it is supported.


4. Slide the drive ring (5) to the rear out of its pilot and raise the shaft group while holding the outer races of the tapered bearing assemblies in place as illustrated.


REMOVING UPPER SHAFT GROUP

5. Install in reverse order of removal.

NOTE: Before installing the shaft group in the lower housing, be sure the front bearing retainers (6) and (7) are tight and the rear bearing retainers (1) and (2) are loose. This will allow the shaft assembly to be lowered into its correct position.

Clutch Disassembly And Assembly

1. Place the upper shaft group in a vertical position by blocking up under the ahead drive gear as illustrated.


PREPARING TO REMOVE CLUTCHES FROM CLUTCH SHAFTS
1-Bearing retainer nut and lock. 2-Ahead drive gear.

2. Remove all but two of the bearing retainer nuts (1) leaving the remaining two accessible to a wrench.

3. Use four blocks (4) 45/8" long to support the clutch assembly as illustrated before removing the stud nuts (3) and the remaining two retainer nuts (1).


REMOVING CLUTCH STUD NUTS
3-Stud nut. 4-Block (four).

4. Remove the stud nuts (3), retainer nuts (1) and remove the clutch spider (5) as shown, being careful not to damage the clutch studs.


REMOVING CLUTCH SPIDER
5-Clutch spider.


REMOVING ASTERN CLUTCH DRIVE RING

NOTE: If the old plates are to be reused, mark the clutch plates in a manner so they will be assembled in the same order. This will accommodate any wear pattern.


6-Driven plate. 7-Drive plate. 8-Cylinder assembly.


8-Cylinder assembly. 9-Ahead clutch drive ring. 10-Plate assembly.

5. Remove the ahead clutch drive rings (9) and the ahead clutch plates in the same manner as in the astern clutch.

6. Inspect the ahead and astern clutch plates and replace if worn or damaged. The clutch plates are installed alternately, beginning with a sintered bronze plate.


REMOVING PLATE ASSEMBLY


11-Retainer rings. 12-Ahead piston. 13-Astern piston.

NOTE: The astern piston can also be removed by lifting the cylinder assembly off of the piston after the retaining rings (11) have been removed. The cylinder assembly will then have to be turned over in order to remove the retainer rings on the ahead piston.


12-Ahead piston. 13-Astern piston. 14-Springs. 15-Washers. 16-Pins. 17-Retainer rings. 18-Washers. 19-Springs.

7. After the retainer rings (11) have been removed, turn the cylinder over so that the astern piston (13) is on top.


NOTICE

Use care in turning over cylinder assembly as the astern piston may fall out if not held in place.


8. Lift off astern piston (13) being careful not to damage the pins (16).

9. Remove retainer rings (17), washers (18), springs (19) and lift off cylinder assembly from ahead piston (12).

Dump Valve Removal And Installation


1-Retainer ring.

The clutches contain two dump valves. For dump valve function, see the topic, ACTUATING OIL TO CLUTCHES.


REMOVING VALVE BODY

1. Remove the valve body using a 5F7334 Block, two 1D419 Nuts, two L1329 Bolts, two 8B2377 Bolts, two 4B4280 Washers and two 4B4276 Washers.


REMOVING DUMP PISTON FROM BODY
2-Dump piston. 3-Valve body.

NOTE: When assembling, be sure the arrow on the dump valve is pointing outward from the clutch cylinder as illustrated. The solid end of the dump piston marked "OUT" must also be positioned as illustrated.

Disassembling Clutch Drive Spider And Oil Pump Drive Shaft

NOTE: The oil pump drive shaft (1) is splined to the spider and can be removed by lifting it straight up from the spider after the retainer (2), cover (4), and coupling (3) are removed.

1. Using an 8B7551 Bearing Pulling Attachment, an 8B7548 Push Puller, 8B7550 Legs, an 8B7560 Step Plate and an 8H684 Wrench, pull the top bearing assembly (5) from the clutch spider as illustrated. To remove the bearing assembly (7), invert the Bearing Pulling Attachment 8B7551, attach 91/2" legs and pull the bearing assembly (7) in the same manner as the bearing assembly (5).


1-Oil pump drive shaft. 2-Retainer. 3-Coupling. 4-Cover.


REMOVING BEARING ASSEMBLY FROM CLUTCH DRIVE SPIDER
5-Bearing assembly. 6-Spacer. 7-Bearing assembly.

2. Remove the spacer (6) which is located between the two bearings.

3. Using the same pulling tools as on the first bearing (5), remove the second bearing (7) from the clutch drive spider.

4. Inspect the bearings (5) and (7) and replace if worn or damaged.

5. Install in reverse order of disassembly.

NOTE: When installing the bearing assemblies (5) and (7), heat them in oil (220° - 240° F. Max.) and slip them over the clutch spider with the grease seal on bearing assembly (5) facing away from the spider.

Main Shaft Disassembly


REMOVING ASTERN DRIVING GEAR AND REAR THRUST BEARING
1-Rear thrust bearing assembly. 2-Astern driving gear.

1. Using a 1H3107 Push Puller, 1H3108 Puller Legs, 1H3110 Bearing Pulling Attachment, 7F9540 Hydraulic Puller, 6F25 Hydraulic Pump Group and a 5F9886 Adapter, pull the rear thrust bearing assembly (1) and the astern driving gear (2) off the astern driving shaft as shown.


REMOVING AHEAD DRIVE SHAFT ASSEMBLY

2. Using a 1H3107 Push Puller, 1H3109 Puller Legs, 1H3110 Bearing Pulling Attachment, 7F9540 Hydraulic Puller and a 6F25 Hydraulic Pump Group, remove the inner bearing race (3) from the astern drive shaft as shown.


REMOVING BEARING INNER RACE FROM ASTERN DRIVE SHAFT
3-Inner race.

3. Using a 1H3107 Push Puller, 1H3110 Bearing Pulling Attachment, 7F9540 Hydraulic Puller, 6F25 Hydraulic Pump Group, and 5F7694 Plug, remove the double tapered thrust bearing (4) from the ahead drive shaft as shown.


REMOVING DOUBLE TAPERED THRUST BEARING FROM AHEAD DRIVE SHAFT
4-Double tapered thrust bearing.

4. Using a 1H3107 Push Puller with 1H3108 Puller Legs, 7F9540 Puller Attachment, 6F25 Hydraulic Pump Group and 5F7694 Plug, remove the ahead driving gear from the ahead drive shaft as shown.


REMOVING AHEAD DRIVING GEAR
5-Outer race of front support bearing.

5. Remove the outer race (5).


REMOVING FRONT SUPPORT BEARING FROM AHEAD DRIVE SHAFT
6-Front support bearing. 7-Inner race.


8-Retainer.

6. Using a 1H3107 Push Puller with 1H3108 Puller Legs, 7F9540 Hydraulic Puller, 6F25 Hydraulic Pump Group, 1H3110 Bearing Pulling Attachment and 5F7694 Plug, remove the bearing (7) and inner race (6) as shown.


REMOVING INNER BEARING AND SHIELD
9-Bearing. 10-Shield.

7. Inspect all bearings and replace if worn or damaged.

8. Assemble in reverse order of disassembly.

NOTE: Bearings can be assembled to their shafts by first heating them in oil (220° - 240° F. Max.) and then quickly slipping them on the proper shafts, seating them with a plastic hammer.

Caterpillar Information System:

3192 MARINE GEAR Lubrication Components
3192 MARINE GEAR Lubrication, Hydraulic System and Operation
3192 MARINE GEAR Introduction and Application
3192 MARINE GEAR Cutaway
3192 MARINE GEAR Specifications
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