Caterpillar Cat 992K Wheel Loader (Prefix KK4) Service Repair Manual (KK400001 and up).pdf

Service Repair Manual
Models
992K Wheel Loader

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Product: WHEEL LOADER
Model: 992K WHEEL LOADER KK4
Configuration: 992K Wheel Loader KK400001-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
i04593412
Crankshaft Front Seal - Remove and Install
SMCS - 1160-010
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
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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992K Wheel Loader KK400001-UP (MACHINE) POWERED BY C32 Engine(M008...
2020/4/3
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Illustration 1 g01098057
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).
Installation Procedure
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.
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All Rights Reserved.
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Fri Apr 3 20:01:47 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.
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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.
Fri Apr 3 20:02:43 UTC+0800 2020
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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
approximately 68 kg (150 lb).
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.
Fri Apr 3 20:03:40 UTC+0800 2020
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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.
Fri Apr 3 20:04:37 UTC+0800 2020
4/4
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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).
Fri Apr 3 20:05:34 UTC+0800 2020
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i03424280
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. Remove tube assemblies (1).
2. Disconnect harness assemblies (5) and harness assembly (2).
3. Remove bolts (4).
4. Remove valve mechanism cover base (3) and the seal from the cylinder head.
NOTICE
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1. Install the seal on valve mechanism cover base (3).
2. Position valve mechanism cover base (3) on the cylinder head and install bolts (4).
3. Position harness assemblies (5) on the electronic unit injectors. Tighten the cap nuts to a
torque of 2.5 ± 0.25 N·m (22 ± 2 lb in).
4. Connect harness assembly (2).
5. Install tube assemblies (1).
End By:
a. Install the valve mechanism cover. Refer to Disassembly and Assembly, "Valve Mechanism
Cover - Remove and Install".
Fri Apr 3 20:06:30 UTC+0800 2020
3/3
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i04597917
Valve Actuator (Variable) - Remove and Install
SMCS - 1105-010
Removal Procedure
Start By:
A. Remove the valve mechanism cover.
Note: Do not disassemble the variable valve actuator after the component has been removed. Any
attempt to disassemble the variable valve actuator will void the warranty of the component.
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.
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.
NOTICE
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1. Disconnect harness assembly (4). Disconnect harness assembly (5) .
2. Remove bolt (2). Remove four nuts (3) and two nuts (6) .
3. Remove variable valve actuator (1) .
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4. Remove support (11) and stud (10) .
5. Remove two studs (9) and three studs (7) .
6. Remove rocker arm (8) .
NOTICE
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1. Install two studs (9) at location 5 and location 7. Tighten studs (9) to a torque of 47 ± 9 N·m
(35 ± 7 lb ft).
2. Install stud (10) at location 6. Tighten stud (10) to a torque of 65 ± 10 N·m (48 ± 7 lb ft).
Install support (11) .
3. Position rocker arm (8). Install three studs (7) at location 1, location 2, and location 4.
Tighten studs (7) to a torque of 50 ± 5 N·m (37 ± 4 lb ft) plus a 45 ± 5 degree turn.
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4. Install variable valve actuator (1) .
5. Install bolt (2). Tighten bolt (2) to a torque of 105 ± 20 N·m (77 ± 15 lb ft). Install four nuts
(3). Tighten nuts (3) to a torque of 105 ± 20 N·m (77 ± 15 lb ft). Refer to the tightening
sequence.
6. Install two nuts (6). Tighten nuts (6) to a torque of 47 ± 9 N·m (35 ± 7 lb ft). Refer to the
tightening sequence.
7. Connect harness assembly (5). Connect harness assembly (4) to variable valve actuator (1) .
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8. First adjust the lash on the exhaust and then adjust the compression brake on variable valve
actuator (1). Refer to Testing and Adjusting, "Slave Piston Lash - Adjust" for more
information on adjusting the lash for the compression brake. Tighten jam nut (12) to a
torque of 15 ± 3 N·m (11 ± 2 lb ft).
End By: Install the valve mechanism cover.
Fri Apr 3 20:07:27 UTC+0800 2020
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