Caterpillar Cat 992C WHEEL LOADER (Prefix 42X) Service Repair Manual (42X00001 and up).pdf

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Product: WHEEL LOADER
Model: 992C WHEEL LOADER 42X
Configuration: 992C WHEEL LOADER 42X00001-UP (MACHINE) POWERED BY 3412 ENGINE
Disassembly and Assembly
3408E and 3412E Engines for Caterpillar Built Machines
Media Number -SENR1013-11 Publication Date -01/07/2015 Date Updated -22/08/2016
i02160179
Gear Group (Front) - Remove
SMCS - 1206-011
Removal Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 1P-0510 Driver Group 1
Start By:
a. Remove the camshaft. Refer to Disassembly and Assembly, "Camshaft - Remove".
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
NOTICE
Care must be taken to ensure that fluids are contained during
performance of inspection, maintenance, testing, adjusting, and repair
of the product. Be prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any component
containing fluids.
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992C WHEEL LOADER 42X00001-UP (MACHINE) POWERED BY 3412 ENGINE...
2021/6/24
https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis...

Refer to Special Publication, NENG2500, "Dealer Service Tool
Catalog" for tools and supplies suitable to collect and contain fluids on
Cat products.
Dispose of all fluids according to local regulations and mandates.
Illustration 1 g00577213
1. Align the timing mark on the idler gear with the timing mark on the crankshaft gear.
2. Remove bolts (1) and plate (2).
3. Remove idler gear (3).
4. Remove the bearing from idler gear (3) with Tooling (A) and a suitable press.
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5. Remove thrust washer (6). Remove bolts (4) and shaft (5).
6. Drilled passage (7) and drilled passage (8) in the shaft must be free of obstructions.
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All Rights Reserved.
Private Network For SIS Licensees.
Thu Jun 24 09:41:18 UTC+0800 2021
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i02151029
Gear Group (Front) - Install
SMCS - 1206-012
Installation Procedure
Table 1
Required Tools
A 1P-0510 Driver Group 1
NOTICE
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1. Place shaft (5) in position on the cylinder block and install bolts (4). Tighten bolts (4) to a
torque of 55 ± 10 N·m (41 ± 7 lb ft).
Tighten bolts (4) for the shaft in the following sequence. See Illustration 2 for the
numbering of the bolts. ... 1,3,4,5,2,1,2,3,4,5,1
2. Install thrust washer (6) with the oil groove side toward the idler gear.
3. Lower the temperature of the bearing. Install the bearing in idler gear (3) with Tooling (A)
and a suitable press. Install the bearing to a depth of 0.38 ± 0.25 mm (0.015 ± 0.010 inch).
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4. Apply clean engine oil to the shaft and to the inside diameter of idler gear (3). Install idler
gear (3) on the shaft. Install plate (2) and bolts (1).
End By:
a. Install the camshaft. Refer to Disassembly and Assembly, "Camshaft - Install".
Thu Jun 24 09:42:15 UTC+0800 2021
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i02389879
Housing (Front) - Remove
SMCS - 1151-011
Removal Procedure
Table 1
Required Tools
A 138-7573 Link Bracket 1
Start By:
a. Remove the engine oil pan. Refer to Disassembly and Assembly, "Engine Oil Pan - Remove
and Install".
b. Remove the water pump. Refer to Disassembly and Assembly, "Water Pump - Remove".
c. Remove the crankshaft front seal. Refer to Disassembly and Assembly, "Crankshaft Front
Seal - Remove".
d. Remove the front cover. Refer to Disassembly and Assembly, "Front Cover - Remove".
e. Remove the speed/timing sensors. Refer to Disassembly and Assembly, "Speed/Timing
Sensor - Remove and Install".
NOTICE
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1. Remove bolts (2) and retainer plate (3).
2. Remove gear (1).
3. Attach Tooling (A) and a suitable lifting device to front housing (4). The weight of front
housing (4) is approximately 34 kg (75 lb).
4. Remove nut (6).
5. Remove bolts (5).
6. Remove front housing (4) and the gasket.
Thu Jun 24 09:43:11 UTC+0800 2021
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i02389888
Housing (Front) - Install
SMCS - 1151-012
Table 1
Required Tools
B 8T-9022 Silicone Gasket -
NOTICE
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1. The rear of front housing (4) and the front of the cylinder block should be thoroughly
cleaned before you install the front housing.
2. Install a new gasket on the cylinder block.
3. Apply Tooling (B) to the common junction of the cylinder block, the front housing and the
oil pan.
4. Attach Tooling (A) and a suitable lifting device to front housing (4). The weight of front
housing (4) is approximately 34 kg (75 lb).
5. Install front housing (4) on the cylinder block.
6. Install bolts (5).
7. Install nut (6).
8. Remove Tooling (A) from front housing (4).
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Note: With the number one piston of the engine at top center, the timing marks on the front
gear group can be aligned. Align the timing marks on gear (1) with the marks on the
camshaft gear. The alignment of the timing marks is shown in Illustration 3.
9. Install gear (1) and retainer plate (3).
10. Install bolts (2). Tighten the bolts to a torque of 135 ± 20 N·m (100 ± 15 lb ft).
End By:
a. Install the speed/timing sensors. Refer to Disassembly and Assembly, "Speed/Timing
Sensor - Remove and Install".
b. Install the front cover. Refer to Disassembly and Assembly, "Front Cover - Install".
c. Install the crankshaft front seal. Refer to Disassembly and Assembly, "Crankshaft Front
Seal - Install".
d. Install the water pump. Refer to Disassembly and Assembly, "Water Pump - Install".
e. Install the engine oil pan. Refer to Disassembly and Assembly, "Engine Oil Pan - Remove
and Install".
Thu Jun 24 09:44:08 UTC+0800 2021
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i02389917
Valve Mechanism Cover - Remove and Install
SMCS - 1107-010
Removal Procedure
NOTICE
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2. Remove cover (1).
NOTICE
1. Install cover (1).
Thu Jun 24 09:45:05 UTC+0800 2021
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i02160475
Valve Mechanism Cover Base - Remove and Install
SMCS - 1120-010
Removal Procedure
Start By:
a. Remove the valve mechanism cover. Refer to Disassembly and Assembly, "Valve
Mechanism Cover - Remove and Install".
NOTICE
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1. Disconnect harness assembly (3).
2. Disconnect harness assemblies (5).
3. Remove bolt (4).
5. Remove base (2).
NOTICE
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1. Install base (2).
3. Install bolt (4).
Note: Each harness assembly has a white connector that is marked "F" (front) and a black
connector that is marked "R" (rear). The white connector must be installed on the injector
toward the front of the engine. The black connector must be installed on the injector toward
the rear of the engine.
Note: The black connector is marked "R" (rear). Assemble the black connector to the
injector on the rear cylinder. The rear cylinders are 3, 7, and 11 on the left side of the
engine. The rear cylinders are 4, 8, and 12 on the right side of the engine.
4. Place harness assemblies (5) on the connectors. Tighten the nuts on harness assemblies (5)
to the following torque.
Torque for nuts ... 1.70 ± 0.25 N·m (15.046 ± 2.213 lb in)
5. Connect harness assembly (3).
End By:
a. Install the valve mechanism cover. Refer to Disassembly and Assembly, "Valve Mechanism
Cover - Remove and Install".
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i02160605
Rocker Arm and Shaft - Remove
SMCS - 1102-011
Removal Procedure
Start By:
a. Remove the unit injector. Refer to Disassembly and Assembly, "Unit Injector - Remove".
NOTICE
1. Remove bolt (2) and cylinder head bolt (1).
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2. Remove rocker arm assembly (3) and the O-ring seal.
3. Remove the pushrods.
4. Remove valve bridges (4).
Thu Jun 24 09:46:58 UTC+0800 2021
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i02160625
Rocker Arm - Disassemble
SMCS - 1123-015
Disassembly Procedure
Start By:
a. Remove the rocker arm and shaft. Refer to Disassembly and Assembly, "Rocker Arm and
Shaft - Remove".
NOTICE
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1. Remove retaining rings (1), washers (2), and arm assemblies (3) from shaft (4).
Thu Jun 24 09:47:55 UTC+0800 2021
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i02161072
Rocker Arm - Assemble
SMCS - 1123-016
Assembly Procedure
NOTICE
1. Lubricate shaft (4) with clean engine oil and install arm assemblies (3).
2. Install washers (2).
3. Install retaining rings (1).
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End By:
a. Install the rocker arm and shaft. Refer to Disassembly and Assembly, "Rocker Arm and
Shaft - Install".
Thu Jun 24 09:48:52 UTC+0800 2021
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i02161082
Rocker Arm and Shaft - Install
SMCS - 1102-012
NOTICE
1. Lubricate the wear pad on top of valve bridges (4) with clean engine oil. Install valve
bridges (4).
2. Install the pushrods.
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3. Install the O-ring seal and rocker arm assembly (3).
4. Install cylinder head bolt (1) and bolt (2). Do not tighten bolt (2) at this time.
5. Tighten cylinder head bolt (1) to a torque of 270 ± 15 N·m (199 ± 11 lb ft). Tighten cylinder
head bolt (1) again to a torque of 450 ± 15 N·m (332 ± 11 lb ft). Tighten cylinder head bolt
(1) again to a torque of 450 ± 15 N·m (332 ± 11 lb ft). Tighten bolt (2) to the standard
torque value.
End By:
a. Install the unit injector. Refer to Disassembly and Assembly, "Unit Injector - Install".
Thu Jun 24 09:49:49 UTC+0800 2021
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i02184090
Cylinder Head - Remove
SMCS - 1100-011
Removal Procedure
Table 1
Required Tools
B 5P-8700 Lifting Bracket 2
Start By:
a. Remove the unit injector sleeves. Refer to Disassembly and Assembly, "Unit Injector Sleeve
- Remove".
b. Remove the exhaust manifold. Refer to Disassembly and Assembly, "Exhaust Manifold -
Remove and Install".
NOTICE
NOTICE
1/5
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Care must be taken to ensure that fluids are contained during
performance of inspection, maintenance, testing, adjusting, and repair
of the product. Be prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any component
containing fluids.
Refer to Special Publication, NENG2500, "Dealer Service Tool
Catalog" for tools and supplies suitable to collect and contain fluids on
Cat products.
Dispose of all fluids according to local regulations and mandates.
1. Remove hose assembly (1) from the front of the fuel manifold.
2. Remove hose assembly (2) from the rear of the fuel manifold.
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Caterpillar Cat 992C WHEEL LOADER (Prefix 42X) Service Repair Manual (42X00001 and up).pdf

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Caterpillar Cat 992C WHEEL LOADER (Prefix 42X) Service Repair Manual (42X00001 and up).pdf