Caterpillar Cat 992K Wheel Loader (Prefix KK2) Service Repair Manual (KK200001 and up).pdf

Service Repair Manual
Models
992K Wheel Loader

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Product: WHEEL LOADER
Model: 992K WHEEL LOADER KK2
Configuration: 992K Wheel Loader KK200001-UP (MACHINE) POWERED BY C32 Engine
Disassembly and Assembly
C27 and C32 Engines for Caterpillar Built Machines
Media Number -KENR8148-13 Publication Date -01/09/2018 Date Updated -05/09/2018
i07416060
Crankshaft Rear Seal - Remove and Install
SMCS - 1161-010
Removal Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 1U-7600 Slide Hammer Puller 1
B - Pry Bar 1
C 5P-7312 Seal Distorter 1
D 5P-7314 Distorter Ring 1
E
249-2937(1)
Seal Locator As 1
5P-7310(1)
Bolt 3
9S-8858(1)
Nut (Seal Installer) 1
6V-6143(1)
Seal Installer 1
5P-1733(2)
Seal Locator As 1
5P-7309(2)
Bolt 3
9S-8858(2)
Nut (Seal Installer) 1
6V-6143(2)
Seal Installer 1
(1)
Large pilot for crankshaft gear (approximately 85 mm (3.3 inch) diameter)
(2)
Small pilot for crankshaft gear (approximately 52 mm (2.0 inch) diameter)
Start By:
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992K Wheel Loader KK200001-UP (MACHINE) POWERED BY C32 Engine(M007...
2020/4/5
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a. Remove the flywheel.
Note: Ensure that the rear gear remains in place when the crankshaft rear seal and
crankshaft wear sleeve are removed.
1. Install two bolts from the flywheel and suitable washers through the rear gear in the
crankshaft.
Illustration 1 g01146630
Note: Ensure that you do not damage the flywheel housing with Tooling (B).
Note: If the crankshaft wear sleeve starts to slide off the crankshaft, go to Step 3.
2. Use Tooling (B) to pry around the lip of crankshaft wear sleeve (2).
3. Use Tooling (A) or a punch and hammer in order to puncture three or more holes in
crankshaft rear seal (1).
4. Use Tooling (A) to remove crankshaft rear seal (1).
5. If necessary, use Tooling (C) and Tooling (D) to remove crankshaft wear sleeve (2).
Installation Procedure
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1. Clean the outside diameter of the crankshaft.
Note: Install the crankshaft rear seal with the arrow that shows the direction of crankshaft
rotation toward the rear of the engine.
2. Use Tooling (E) to install crankshaft wear sleeve (2) and crankshaft rear seal (1) as a unit.
End By:
a. Install the flywheel.
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Sun Apr 5 11:05:44 UTC+0800 2020
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i04591909
Rear Power Take-Off (RPTO) - Remove and Install
SMCS - 1165-RE
Removal Procedure
Table 1
Required Tools
A 138-7575 Link Bracket 2
B 5J-0490 Bolt 4
C 1P-0510 Driver Gp 1
D
5P-6190 Wear Sleeve 1
5P-6209 Sleeve Driver 1
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1. Remove cover (1) and the O-ring seal. Upon installation, use the opening to aid in aligning
the teeth of the gears.
2. If necessary, remove the shipping covers from rear power take-off (2) and (3).
3. Attach Tooling (A) to rear power take-off (2). The weight of rear power take-off (2) is
approximately 25 kg (55 lb).
4. Remove the bolts from rear power take-off (2) and use Tooling (B) to remove rear power
take-off (2).
5. Attach Tooling (A) to rear power take-off (3). The weight of rear power take-off (3) is
Note: Use the holes where the shipping covers are located for installing Tooling (A).
6. Remove the bolts from rear power take-off (3) and use Tooling (B) to remove rear power
take-off (3).
Rear Power Take-Off (2)
7. Remove the O-ring seal from rear power take-off (2).
8. Remove the bolts from pump gear (8). Remove bolts (7) and retaining ring (6).
9. Use a suitable press to remove bearing (5) and shaft (4) from rear power take-off (2).
10. Use Tooling (C) and a suitable press to remove bearing (5) from shaft (4).
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Rear Power Take-Off (3)
11. Remove the O-ring seal from rear power take-off (3).
12. Remove the bolts from pump gear (14). Remove bolts (13) and retaining ring (12).
13. Remove lip seal (9).
14. Use a suitable press to remove bearing (11) and shaft (10) from rear power take-off (3).
15. Use Tooling (C) and a suitable press to remove bearing (11) from shaft (10).
1. Install rear power take-off (2) and (3) in the reverse order of removal.
a. Lubricate the O-ring seals for rear power take-off (2) and (3) and the bore lightly with
the lubricant that is being sealed.
b. Lubricate the shafts, bearings, and bores with clean engine oil.
2. Reference the following for installing lip seal (9):
a. Leave the installation sleeve in place to install the lip seal. The lip seal must be
installed dry.
b. The cases, the seal group, and the sleeve are not serviceable separately. If the seal and
the installation sleeve are separated, these components cannot be used again.
c. Use Tooling (D) to install the lip seal wear sleeve. Push the lip seal in place. Doing so
will dislodge the installation sleeve.
Sun Apr 5 11:06:41 UTC+0800 2020
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i04593310
Vibration Damper and Pulley - Remove and Install
SMCS - 1205-010
Removal Procedure
Table 1
Required Tools
A -
Guide Stud
1/2 - 13 NC by 6 inch
2
1. If necessary, remove the belt from the engine. Refer to Operation and Maintenance Manual,
"Belts - Inspect/Adjust/Replace".
2. Remove bolts (1) at Location (X) and install Tooling (A).
3. Remove remaining bolts (1) and the spacer.
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4. Attach a suitable lifting device onto damper (2). The weight of damper (2) is approximately
34 kg (75 lb).
5. Slide damper (2) forward and remove.
6. Attach a suitable lifting device onto damper (3). The weight of vibration damper (3) is
7. Remove the spacer and slide damper (3) forward and remove.
8. Remove bolts (5) and adapter (4).
1. Install dampers (2) and (3) in the reverse order of removal.
a. Tighten bolts (1) to a torque of 135 ± 20 N·m (100 ± 15 lb ft).
Sun Apr 5 11:07:38 UTC+0800 2020
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i04593412
Crankshaft Front Seal - Remove and Install
SMCS - 1160-010
Removal Procedure
Table 1
Required Tools
A 1U-7600 Slide Hammer Puller 1
B - Pry Bar 1
C 5P-7312 Seal Distorter 1
D 5P-7314 Distorter Ring 1
E
5P-1733 Seal Locator 1
5P-1737 Bolt 3
9S-8858 Nut (Seal Installer) 1
6V-6142 Seal Installer 1
Start By:
a. Remove the crankshaft vibration damper and pulley.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
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1. Remove bolts (1) and adapter (2).
Note: Ensure that you do not damage the front housing with Tooling (B).
Note: If the crankshaft wear sleeve starts to slide off the crankshaft, go to Step 3.
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2. Use Tooling (B) to pry around the lip of crankshaft wear sleeve (3).
3. Use Tooling (A) to puncture three or more holes in crankshaft front seal (4).
4. Use Tooling (A) to remove crankshaft front seal (4).
5. If necessary, use Tooling (C) and Tooling (D) to remove crankshaft wear sleeve (3).
1. Clean the outside diameter of the crankshaft.
2. Use Tooling (E) to install crankshaft front seal (4) and crankshaft wear sleeve (3) as a unit.
Note: Install the crankshaft front seal with the arrow that shows the direction of crankshaft
rotation toward the front of the engine.
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3. Install adapter (2) and bolts (1).
End By:
a. Install the crankshaft vibration damper and pulley.
Sun Apr 5 11:08:35 UTC+0800 2020
4/4
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i04593610
Gear Group (Front) - Remove and Install
SMCS - 1206-010
Removal Procedure
Start By:
a. Remove the front housing.
1/2
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1. Remove bolts (5) and gear assembly (4).
2. Remove bolts (3) and plate (2). Remove gear assembly (1).
3. Remove bolts (6), the thrust washer, and shaft (7).
1. Install gear assemblies (1) and (4) in the reverse order of removal.
a. Apply clean engine oil to shaft (7), the bearing bore, and the thrust faces prior to
installation.
b. Tighten bolts (6) to a torque of 55 ± 10 N·m (41 ± 7 lb ft).
c. Install plate (2) oil groove side toward the gear assembly.
Sun Apr 5 11:09:31 UTC+0800 2020
2/2
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i04600330
Housing (Front) - Remove and Install
SMCS - 1151-010
Removal Procedure
Table 1
Required Tools
A - LOCTITE 5900 Flange Sealant 1
B - LOCTITE 11358 Cup Plug Sealant 1
Start By:
A. Remove the water pump.
B. Remove the crankshaft front seal.
C. Remove the water temperature regulator housing.
D. Remove the front engine support.
1. Remove the necessary bolts from the oil pan. Refer to Disassembly and Assembly, "Oil Pan
- Remove and Install".
2. Position the oil filter and base out of the way. Position the fuel filter and base out of the
way.
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3. Position fuel line assembly (1) out of the way.
4. Remove covers (3) and remove tube assembly (4) .
5. Remove oil filler tube (5). Remove any clips or straps that may be attached to the front
housing.
6. Remove speed sensors (2) and (6) .
7. Remove bolts (8) and remove damper (7). Repeat for the other damper.
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8. Remove stud (9) and studs (10) .
9. Remove sealing plate (11) and the adapters. Repeat for the other side.
10. Attach a suitable lifting device to front housing (14). The weight of front housing (14) is
11. Remove nut (12) and remove bolts (13) .
12. Remove front housing (14) and the gasket.
1. Install front housing (14) in the reverse order of removal.
Note: The rear face of front housing (14) and the front face of the block must be free
containments prior to and during installation.
a. Apply a continuous bead of Tooling (A) to the end of the gasket for front housing
(14) prior to installation. Strike excess sealant with a straight edge.
b. Apply Tooling (A) to the oil pan gasket, where the gasket for front housing (14) will
make contact. Ensure that Tooling (A) spans the entire width of the T-Joint.
c. Trim the gasket for front housing (14) flush with the face after installation.
d. Tighten studs (10) to a torque of 35 ± 5 N·m (26 ± 4 lb ft).
e. Apply Tooling (B) to the threads of stud (9) .
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f. Tighten the bolts on gear assemblies (4) to a torque of 240 ± 40 N·m (177 ± 30 lb ft).
Tighten using the above illustrated sequence. Tighten bolts illustrated as 1 and 2 an
additional 240 ± 40 N·m (177 ± 30 lb ft).
g. Lubricate speed sensors (2) and (6) lightly with the lubricant being sealed.
h. Seat speed sensors (2) and (6) before tightening.
Sun Apr 5 11:10:28 UTC+0800 2020
4/4
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i04596172
Housing (Rear) - Remove and Install
SMCS - 1157-010
Removal Procedure
Table 1
Required Tools
A 138-7575 Link Bracket 1
B 1P-0520 Driver Group 1
C 230-6262 Sealant 1
Start By:
a. Remove the rear gears.
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1. Remove plug (1) and disconnect hose assembly (2).
2. Attach Tooling (A) to Location (X). The weight of rear housing (3) is 84 kg (185 lb).
3. Remove bolts (4) and remove rear housing (3).
4. Remove gasket (5).
5. Remove dowels (6). Remove bearing sleeve (7) and the dowels.
1. Install rear housing (3) in the reverse order of removal.
Note: Make sure that the housing and the face of the block are free of contaminants prior to
installation.
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Note: Apply clean engine oil to the bearings and the shaft assemblies prior to installation on
the engine.
a. Use Tooling (B) to install bearing sleeve (25).
b. Install gasket (23). Apply a continuous bead of Tooling (C) to Areas (Y). The sealant should
span the entire width of the T-Joint .
c. Attach Tooling (B) to Location (X). The weight of rear housing (21) is 84 kg (185 lb).
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d. Position rear housing (3). Install bolts (4). Tighten bolts (4) to a torque of 55 ± 10 N·m
(41 ± 7 lb ft) using the sequence in Illustration 5.
Sun Apr 5 11:11:25 UTC+0800 2020
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i04597754
Valve Mechanism Cover - Remove and Install
SMCS - 1107-010
Removal Procedure
Start By:
A. If necessary, remove the electronic control module
1. Remove bolts (1) and valve mechanism cover (2). Remove the seals from valve mechanism
covers (2) .
2. Repeat for the other valve mechanism covers. Position any hoses, tubes, or harnesses out of
the way.
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Note: Note the location of breather (4) for installation purposes.
3. Loosen clamp (4) and remove breather (3). Remove elbow (5) and the O-ring seal. Repeat
for the other breather.
1. Install valve mechanism cover (2) in the reverse order of removal.
a. Lubricate the bore for the O-ring seal with fluid that is being sealed.
b. Tighten clamp (4) to a torque of 4.5 ± 0.5 N·m (40 ± 4 lb in).
c. Use the torque sequence in Illustration 3 to tighten bolts (1).
Sun Apr 5 11:12:21 UTC+0800 2020
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Caterpillar Cat 992K Wheel Loader (Prefix KK2) Service Repair Manual (KK200001 and up).pdf

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