Caterpillar Cat 992 WHEEL LOADER (Prefix 25K) Service Repair Manual (25K01170 and up).pdf

Service Repair Manual
Models
992 and 992B WHEEL LOADER

Shutdown SIS
Previous Screen
Product: WHEEL LOADER
Model: 992 WHEEL LOADER 25K
Configuration: 992B WHEEL LOADER 25K01170-UP (MACHINE) POWERED BY D348 ENGINE
Disassembly and Assembly
992B WHEEL LOADER POWER TRAIN
Media Number -SENR7195-00 Publication Date -01/11/1975 Date Updated -12/10/2001
Axles
SMCS - 3259-12; 3259-11
Remove Axles
1. Remove the oil from the final drive compartment.
2. Install a 1/2"-13NC forged eyebolt in the top of the cover and fasten a hoist.
3. Remove the bolts from the cover. Install two 1/2"-13NC forcing screws (2) and remove cover
(1). Weight of cover is 65 lb. (29.5 kg).
4. Install a 1/2"-13NC forged eyebolt (3) in end of axle and pull axle (4) out far enough to fasten a
hoist.
NOTE: If axle is difficult to remove, turn machine a little in either direction to remove torque
from axles.
5. Remove axle. Weight is 165 lb. (75 kg).
1/2
992B WHEEL LOADER 25K01170-UP (MACHINE) POWERED BY D348 ENGIN...
2021/11/20
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6. Remove ring, sun gear and spacer from axle.
Install Axles
1. Install spacer (3), sun gear (2) and ring (1) on axle.
2. Fasten a hoist and put the axle in position in the axle housing.
NOTE: If the axle does not go into position easily, turn the machine a little to the left or right to
get splines in alignment.
3. If the axles can not be lifted high enough to give alignment for splines into the differential,
remove ring (1) and slide the sun gear (2) half way off the axle. Use a piece of pipe (5) to lift the
axle and push it in position in the differential. Install ring.
4. Turn the flat sides of the three shafts (4) as shown to make clearance for counterbore in cover.
5. Fasten a hoist and put cover in position on wheel and install nuts. Tighten nuts.
NOTICE
If the cover does not fit flat up against the final drive without force,
remove the cover and repeat Step 4.
Copyright 1993 - 2021 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Sat Nov 20 23:54:12 UTC+0800 2021
2/2
2021/11/20

Shutdown SIS
Previous Screen
Final Drive Carriers
SMCS - 4092-15; 4092-16; 4092-11; 4092-12
Remove Final Drive Carriers
start by:
a) remove tires and rims
b) remove axles
1. Remove three bolts that hold the final drive carrier in place. Install two 1/2"-13NC forcing
screws (1) in carrier. Move the carrier out far enough to install tool (A) and a 1/2"-13NC X 1 3/4
in. long bolt, flat washer and nut.
2. Fasten a hoist and remove final drive carrier. Weight is 515 lb. (234 kg).
Install Final Drive Carriers
1. Fasten a hoist and put the final drive carrier in position on wheel.
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2. Remove tool (A) and install the three bolts (1) to hold the carrier in place.
end by:
a) install axles
b) install tire and rim
Disassemble Final Drive Carriers
start by:
a) remove fuel drive carrier
1. Lift the three shafts (1) out of carrier or remove snap ring and remove shaft from bottom.
2. Remove the three gears (2), six steel washers (4) and six brass (3) washers from carrier.
3. Remove two bearings (6) and spacer (5) from each of the gears.
Assemble Final Drive Carriers
1. Install two bearings and spacer in each gear with the spacer between the bearings.
2/3
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2. Put the gears, steel washers and brass washers in position in carrier with a steel washer (2) next
to each side of the gear and brass washer (1) next to carrier.
3. Install the three shafts and snap rings. Turn the flat sides of the three shafts toward the outside
of carrier.
end by:
a) install final drive carrier
Sat Nov 20 23:55:08 UTC+0800 2021
3/3
2021/11/20

Shutdown SIS
Previous Screen
Final Drive Ring Gears, Hubs And Wheels
SMCS - 4054-11; 4054-12; 4055-11; 4055-12; 4208-11; 4208-12
Remove Final Drive Ring Gears, Hubs And Wheel
start by:
a) remove tires and rims
b) remove final drive carriers
1. Install a strap (1) or chain around the wheel.
2. Put the forks of a lift truck or stand under wheel as a support.
1/5
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3. Remove two bolts, lock and retainer from the ring gear hub. Fasten tool (A) to the hub with a
1/2"-13NC X 1 3/4 in. long bolt and flat washer.
4. Remove bolts (2) and retainer (3) from spindle housing.
5. Remove ring gear and hub (4) from wheel. Weight is 320 lb. (145 kg).
6. Fasten a hoist to the hub. Remove the bolts, locks and bolts from ring gear. Remove hub (5)
from ring gear. Weight of hub is 143 lb. (65 kg).
7. Remove the outside bearing (6) from the spindle housing.
2/5
2021/11/20

8. Fasten a hoist to the wheel. Carefully push the wheel away from the brake with a bar (7) to
release the snap ring. Do not push against the Duo-Cone seal. Remove the wheel. Weight of wheel
is 730 lb. (331 kg).
9. Remove the Duo-Cone seal from the wheel and brake plate with tool (B).
10. Remove snap ring on spline from inside of wheel.
11. Remove the bearing cups from the wheel with tooling (C).
12. Remove bearing cone and spacer from axle housing.
Install Final Drive Ring Gears, Hub And Wheel
1. Install spacer (2) and bearing cone (1) on axle housing.
2. Lower the temperature of the bearing cups (3) and install in wheel.
3. Install snap ring (4) on the wheel.
4. Install the Duo-Cone seal in the wheel and brake plate with tool (A).
NOTE: Put a small amount of lubricant to be sealed on the mating surface of the Duo-Cone seal.
3/5
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5. Fasten a hoist to the wheel and put it in position on the axle housing. Push the wheel in until the
snap ring (4) makes contact with the brake hub. Push snap ring (4) up from the bottom to get the
snap ring started into the brake hub (5). Push the wheel in to get the snap ring into the correct
place in the brake hub.
NOTE: The snap ring must be pushed up from the bottom to get the wheel into the brake hub.
6. Fasten a hoist and install ring gear and hub (6) on the spindle housing.
7. Install retainer and four bolts (8) evenly spaced without shims. Tighten the bolts evenly to a
torque of 100 ± 10 lb.ft. (13.8 ± 1.4 mkg) while slowly turning the wheel to get the bearings in
their correct position (seated).
8. Measure the distance between the retainer (7) and end of the spindle housing through the two
tapped holes (9).
9. Check the thickness of the retainer with a micrometer (10) on each side in line with the tapped
holes as shown.
10. Subtract the average thickness of retainer from the average distance between the retainer and
end of the spindle housing. Install shims behind the retainer that are the same thickness plus .010
in. (0.25 mm).
4/5
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11. Remove retainer and four bolts. Install correct shims, retainer and bolts. Tighten bolts to a
torque of 200 ± 20 lb.ft. (27.2 ± 2.8 mkg). Install the lockwire (11) in the bolts. Be sure wire does
not pass over the bolt heads.
end by:
a) install final drive carriers
b) remove tires and rims
Sat Nov 20 23:56:05 UTC+0800 2021
5/5
2021/11/20

Shutdown SIS
Previous Screen
Wheel Brakes
SMCS - 4255-15; 4255-16
Disassemble Wheel Brakes
start by:
a) remove final drive ring gears, hubs and wheels
1. Install tooling (A) with three 5/8"-18NF X 3 1/2 in. long bolts (1) between the hub and spindle
housing in three locations. Put enough force on the bolts to hold the hub in the center and keep it
from moving during disassembly.
1/6
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2. Install a 1/2"-13NC forged eyebolt in the brake cover. Fasten a hoist to the eyebolt. Remove the
bolts that hold the cover in place. Install three 1/2"-13NC forging screws and remove the brake
cover (2). Weight of cover is 120 lb. (54 kg).
3. Remove the plate and discs (3) from the brake with tool (B).
4. Fasten a hoist to lifting bracket (C). Put the bracket under the brake hub (4). Remove tool (A)
and brake hub. Weight of hub is 60 lb. (27 kg).
5. Disconnect the brake hose from back of the brake anchor housing to permit oil to drain from
piston.
6. Install three 1/2"-13NC forcing screws (5) in the brake piston. Tighten the forcing screws and
push the piston out until cotter pins (7) can be installed in return pins. Install a cotter pin in all of
the return pins.
7. Remove the three forcing screws and slowly push the piston back into the housing.
8. Remove the retaining pins (6) from the return pins.
2/6
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9. Remove piston (8) from the housing with lifting bracket (C) and a hoist. Weight of piston is 50
lb. (23 kg).
10. Remove the two seals (9) from piston.
11. Remove bolts and locks (10) from the inner housing.
12. Remove the inner housing with lifting bracket (C) and a hoist. Weight of inner housing is 50
lb. (23 kg).
13. Put the springs on the return pins under compression with tool (D) and a 5/8" nut. Remove the
cotter pins (7) from the return pins. Slowly release the tension on the springs. Remove the springs
and return pins from the inner housing.
14. Remove the seal from the inner housing.
3/6
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Assemble Wheel Brakes
1. Install the springs on the return pins. Install the pins and springs in the inner housing with the
spring in the counterbore (1). Put the springs under compression with tool (A) and a 5/8" nut.
Install cotter pins in the return pins to hold them in place and remove tool (A).
2. Put the inner housing (2) in position into the brake anchor housing with tool (B) and a hoist.
Install the bolts and locks to hold it in place.
NOTE: The inner housing can only be installed in one position in the anchor housing. Two of the
return pins are closer together than the others.
3. Install the two seals on the piston. Put hydraulic oil on the seals.
4/6
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4. Install the piston in the housing with tool (B) and a hoist. Push the piston into the housing and
install the retaining pins (3) in the return pins (4). Install three 1/2"-13NC forcing screws (5).
Tighten the forcing screws to push the piston out until cotter pins (6) can be removed. Remove the
cotter pins and forcing screws.
5. Connect the brake hose (7) to the brake anchor housing.
6. Put the hub (8) in position in the housing with tool (B) and a hoist. Install tooling (C) and three
5/8"-18NF X 3 1/2 in. long bolts (10) between the hub and spindle housing in three locations. Put
enough force on the bolts to hold the hub in the center and keep it from moving during assembly.
5/6
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7. Put oil on the discs and plates. Use the same oil that is used in the final drive. Install the plates
and discs (10) in the housing so a steel plate is on the inside and outside when assembled. There
must be seven plates and six discs.
8. Install a 1/2"-13NC forged eyebolt in brake cover plate. Fasten a hoist and install brake cover
plate (11) on housing. Install bolts (12) to hold it in place.
end by:
a) install final drive ring gears, hubs and wheels
b) remove air from brake system (See REMOVE AIR FROM BRAKE SYSTEM in TESTING
AND ADJUSTING)
Sat Nov 20 23:57:02 UTC+0800 2021
6/6
2021/11/20

Shutdown SIS
Previous Screen
Anchor Housings And Spindles
SMCS - 4205-11; 4205-12
Remove Anchor Housings And Spindles
start by:
a) disassemble brakes
1. Remove oil line between anchor housing and spindle.
2. Fasten a hoist and tool (A) to the anchor housing and spindle.
3. Remove nuts and lockwashers from spindle studs. Remove anchor housing (1) and spindle as a
unit. Weight is 620 lb. (281 kg). Remove O-ring seal from spindle.
4. Put the spindle on a block and remove the four bolts that hold anchor housing and spindle
together.
1/3
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5. Install three 1/2"-13NC forged eyebolts (2) in anchor housing. Fasten a hoist and remove
anchor housing. Weight is 300 lb. (136 kg).
Install Anchor Housings And Spindles
1. Install O-ring seal (1) on spindle. Fasten a hoist and put anchor housing in position on spindle.
2. Install the four bolts (3) to hold the spindle and anchor housing together.
3. Fasten a hoist and tool (A) to the anchor housing and spindle. Install O-ring seal (2) on spindle.
4. Put spindle in position on axle housing and install nuts and lockwashers. Tighten nuts to a
torque of 640 ± 80 lb.ft. (88.5 ± 11.1 mkg).
5. Install oil line between anchor housing and spindle.
end by:
a) assemble brakes
2/3
2021/11/20

Shutdown SIS
Previous Screen
Rear Axle Housing Support (Front And Rear)
SMCS - 3268-16; 3268-11; 3268-15
Remove Rear Axle Housing Support (Front)
1. Remove the guard (1) from under the transmission with jack (A). Weight of guard is 450 lb.
(204 kg).
1/9
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2. Put a floor jack in position under the drive shaft. Remove the bolts and remove drive shaft (2).
Weight of drive shaft is 85 lb. (38 kg).
3. Disconnect grease line (3) from top of support.
4. Remove three bolts (4), retainer (6), shims and yoke (5) from pinion shaft.
5. Remove the four bolts that hold the support to the frame.
6. Remove the two front bolts and loosen the two rear bolts in the rear support.
7. Disconnect the two grease lines from top of the rear support.
8. Remove oil filler tube from axle housing.
9. Put a transmission jack (7) in position under the support. Fasten the jack to the support.
10. Lift the rear of the machine with tooling (B) until the support is free of frame.
11. Pry the support forward and off of the differential. Lower the support from the machine.
Weight of the support is 415 lb. (188 kg).
Install Rear Axle Housing Support (Front)
2/9
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1. Lift the support (1) into position with a transmission jack and slide on to differential.
2. Lower the machine with tooling (A) and install the bolts in the supports. Tighten the bolts to a
torque of 825 ± 75 lb.ft. (114.1 ± 10.4 mkg).
3. Install yoke (5), O-ring (4), shims (3) and retainer (2). Install the three bolts in retainer and
tighten to a torque of 200 ± 20 lb.ft. (27.7 ± 2.8 mkg).
3/9
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4. Lift the drive shaft into place with a floor jack. Put grease on the bolt threads and surface under
the head. Install the bolts (6) and tighten to a torque of 225 ± 20 lb.ft. (31.1 ± 2.8 mkg).
5. Connect the grease lines on the front and rear supports.
6. Install the guard (7) under transmission with tool (A).
7. Install oil filler tube on axle housing.
Remove Rear Axle Housing Support (Rear)
1. Remove breather tube (1) from differential.
2. Remove the bolts (3) from the rear support.
3. Loosen the bolts in the front support.
4. Disconnect the grease lines (2) on top of the rear support.
4/9
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5. Lift the rear of machine with tooling (A) until the dowels (5) in rear support is clear of frame.
6. Remove bolts (4) from cover.
7. Remove cover (7), thrust bearing and oil tube (6) from support.
8. Remove all of the bolts (8) from thrust plate (9) except two.
9. Put a transmission jack in position under machine and fasten it to the support.
10. Remove the two bolts from thrust plate. Remove thrust plate and thrust bearing from support.
11. Push the support (10) away from the axle housing with two bars and remove the support.
Weight of support is 575 lb. (261 kg).
Install Rear Axle Housing Support (Rear)
5/9
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1. Lift the support into position with a transmission jack.
2. Install two bolts (1) from the plate in the axle housing with flat washers. Push the support on to
the axle housing with two bars (2) as shown.
3. Install thrust bearing (3) in support.
4. Install thrust plate (4) and bolts (5). Tighten bolts to a torque of 200 ± 25 lb.ft. (27.7 ± 3.5 mkg).
5. Remove transmission jack from support.
6/9
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6. Install oil tube (6), thrust bearing (9) and cover (8) on support. Tighten bolts in cover to a torque
of 350 ± lb.ft. (48.4 ± 4.8 mkg).
7. Lower rear of machine on to the support. Make sure the dowels (7) go into the holes in the
frame. Remove tooling (A) from machine.
8. Install the bolts that hold the support to frame. Tighten bolts in the two supports to 825 ± 75
lb.ft. (114.1 ± 10.4 mkg).
9. Install breather tube on differential tube on differential.
Disassemble Rear Axle Housing Support (Front)
start by:
a) remove rear axle housing support (front)
1. Remove the two O-ring seals (1) from support.
2. Remove the bolts from retainer (2). Remove retainer from support.
3. Remove bearing (3) from support with a hammer and chisel. Do not damage support with
chisel.
Assemble Rear Axle Housing Support (Front)
7/9
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1. Install the bearing in the support with tooling (A) and a press.
2. Install retainer and two O-ring seals.
end by:
a) install rear axle housing support (front)
Disassemble Rear Axle Housing Support (Rear)
start by:
a) remove rear axle housing support (rear)
1. Remove O-ring seal (1) from support.
2. Remove bearing (2) from support with a hammer and chisel. Do not damage support with
chisel.
Assemble Rear Axle Housing Support (Rear)
8/9
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1. Install the bearing in the rear support with tooling (A) and a press.
2. Install O-ring seal in support.
end by:
a) install rear axle housing support (rear).
Sat Nov 20 23:58:56 UTC+0800 2021
9/9
2021/11/20

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Shutdown SIS
Previous Screen
Front Differential And Carrier
SMCS - 3258-11; 3258-12
Remove Front Differential And Carrier
start by:
a) remove front axles
1. Lift the bucket and install the lift arm supports (A).
2. Drain the oil from the front differential.
3. Remove the bolts from the front differential cover. Install bracket (C) and fasten a hoist.
Remove cover (1) from axle housing. Weight is 150 lb. (68 kg).
1/4
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4. Loosen the locknut on bolt (2) and turn the bolt into the axle housing.
5. Fasten a hoist and tool (B) to the differential. Tighten the bolt in tool (B) to hold the differential
from turning.
6. Remove two bolts (3) from junction in brake lines.
7. Remove the bolts (5) from the front universal joint. Push the universal joint away from the
flange with a bar.
8. Remove the bolts (4) that hold the differential to the axle housing. Install two of the bolts in the
threaded holes and push the differential away from the axle housing.
9. Remove the differential from the axle housing. Weight is 1100 lb. (499 kg).
NOTICE
The differential must be kept level during removal and installation.
2/4
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Install Front Differential And Carrier
1. Fasten a hoist and tool (B) to the differential. Tighten the bolt in tool (B) to hold the differential
from turning.
2. Install two 1/2"-13NC guide pins in the carrier housing.
3. Put the differential in position in the axle housing with pin (1) in axle housing in hole in carrier
housing. Remove the two guide pins and install the bolts (3) that hold the differential to axle
housing.
4. Put multipurpose grease on the threads of the bolts for the universal joint. Install the bolts (2) in
the universal joint and tighten to a torque of 225 ± 20 lb.ft. (31.2 ± 2.8 mkg).
5. Turn bolt (4) out until it touches the differential and tighten the locknut.
3/4
2021/11/21

Caterpillar Cat 992 WHEEL LOADER (Prefix 25K) Service Repair Manual (25K01170 and up).pdf

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Caterpillar Cat 992 WHEEL LOADER (Prefix 25K) Service Repair Manual (25K01170 and up).pdf