Caterpillar Cat 992K Wheel Loader (Prefix RM5) Service Repair Manual (RM500001 and up).pdf

Service Repair Manual
Models
992K Wheel Loader

Shutdown SIS
Previous Screen
Product: WHEEL LOADER
Model: 992K WHEEL LOADER RM5
Configuration: 992K Wheel Loader RM500001-UP (MACHINE) POWERED BY C32 Engine
Disassembly and Assembly
854K Wheel Dozer and 992K Wheel Loader Machine Systems
Media Number -KENR5573-03 Publication Date -01/01/2014 Date Updated -05/07/2017
i02875102
Piston Pump (Hydraulic Fan) - Disassemble
SMCS - 1387-015-QP; 5070-015-HFN
Disassembly Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 1P-1856 Pliers 1
B 9S-9151 Bearing Puller 1
C Bar stock(1)
1
D 1P-1861 Retaining Ring Pliers 1
(1)
Make a piece that is 9.50 mm (0.375 inch) thick 19.00 mm (0.750 inch) wide and 50.8 mm (2.00 inch) long.
Start By:
a. Remove the steering pump. Refer to Disassembly and Assembly, "Piston Pump (Hydraulic
Fan) - Remove".
Note: Cleanliness is an important factor. Before the disassembly procedure, the exterior of the
component should be thoroughly cleaned. This will help to prevent dirt from entering the internal
mechanism.
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
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992K Wheel Loader RM500001-UP (MACHINE) POWERED BY C32 Engine(M008...
2020/3/31
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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.
Illustration 1 g01431185
1. Place steering pump assembly (1) on a suitable bench, as shown.
2. Remove bolts (2) and actuator assemblies (3) from steering pump (1).
Sudden release of spring force can cause injury.
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To prevent the possibility of injury, follow the procedure to relieve the
spring pressure.
Note: There is slight spring pressure between the head assembly and the pump housing.
3. Remove bolts (4) that secure head assembly (5) to steering pump housing (6).
4. Remove O-ring seal (7) and O-ring seals (8) from head assembly (5).
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5. Remove piston guides (9) and (10) from head assembly (5), if necessary.
6. Remove bearing cup (11) from head assembly (5).
7. Remove spring (12), piston (13), and port plate (14) from pump housing (6).
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8. Remove piston assembly (15) from the pump housing.
9. Remove spacer (16) from piston assembly (15).
10. Remove bearing cone (17) from pump shaft (18).
11. Remove adjustment shim (19) from pump shaft (18).
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12. Remove rotating group (20) from pump housing (6).
13. Place rotating group (20) on suitable blocks, as shown.
14. Remove pump shaft (18) from rotating group (20).
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15. Use a suitable press and Tooling (B) in order to remove bearing cone (21) from pump shaft
(18).
16. Remove swashplate (22) from barrel assembly (23).
17. Remove piston assembly (24) from barrel assembly (23).
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18. Remove piston assemblies (24) from retaining plate (25), as shown.
19. Remove retaining ball (26) from barrel assembly (23).
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spring pressure.
20. Install Tooling (C), as shown.
Note: There is spring force against retaining ring (27). When retaining ring (27) is removed,
the spring force will be released. Removal of the internal components in barrel assembly
(23) should be performed in a press. This is done in order to retain spring (28) and retaining
ring (27).
21. Use a suitable press and Tooling (C) in order to compress spring (28) in barrel assembly
(23).
22. Use Tooling (A) in order to remove retaining ring (27) from the barrel assembly.
23. Remove spring (28), guide (29), and pins (30) from the barrel assembly.
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24. If necessary, remove stops (31) from swashplate (22).
25. Remove bearing races (32) from pump housing (6).
26. Use Tooling (D) in order to remove retaining ring (33) from pump housing (6).
27. Remove lip seal (34) from pump housing (6).
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28. Remove bearing cup (35) from pump housing (6).
29. Remove ring (36) from pump housing (6).
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30. Remove O-ring seals (37) from valve assembly (38).
spring pressure.
31. Remove O-ring seals (41) and locking nut (40) from valve assembly (39).
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32. Remove O-ring seal (48) from stem assembly (49).
33. Remove spring (47), spring (46), and plunger (45) from valve assembly (39).
34. Remove plug (42), O-ring seal (43), and spool (44) from valve assembly (39).
35. Repeat Steps 32 through 34 for the remaining valve assembly (38).
Copyright 1993 - 2020 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Tue Mar 31 17:51:42 UTC+0800 2020
13/13
2020/3/31

Shutdown SIS
Previous Screen
Product: WHEEL LOADER
Model: 992K WHEEL LOADER RM5
Configuration: 992K Wheel Loader RM500001-UP (MACHINE) POWERED BY C32 Engine
Disassembly and Assembly
854K Wheel Dozer and 992K Wheel Loader Machine Systems
Media Number -KENR5573-03 Publication Date -01/01/2014 Date Updated -05/07/2017
i02875105
Piston Pump (Hydraulic Fan) - Assemble
SMCS - 1387-016-QP; 5070-016-HFN
Assembly Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 1P-1856 Pliers 1
C Bar stock(1)
1
D 1P-1861 Retaining Ring Pliers 1
E 1S-0256 Pliers 1
F 1U-7978 Screwdriver 1
G 8H-8581 Feeler Gauge 1
H 8T-5096 Indicator 1
(1)
Make a piece that is 9.50 mm (0.375 inch) thick, 19.00 mm (0.750 inch) wide and 50.8 mm (2.0 inch) long.
Note: Cleanliness is an important factor. Before assembly, all parts should be thoroughly cleaned
in cleaning fluid. Allow the parts to air dry. Wiping cloths or rags should not be used to dry parts.
Lint may be deposited on the parts which may cause later trouble. Inspect all parts. If any parts are
worn or damaged, use new parts for replacement.
Note: Apply a light film of hydraulic oil to all internal components prior to assembly. Check the
condition of all O-ring seals. If any O-ring seals are worn or damaged, use new parts for
replacement.
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Improper assembly of parts that are spring loaded can cause bodily
injury.
To prevent possible injury, follow the established assembly procedure
and wear protective equipment.
1. Install O-ring seal (43) to plug (42). Install spool (44) and plug (42) in valve assembly (39).
Tighten plug (42) to a torque of 31 ± 2 N·m (23 ± 1 lb ft).
2. Install O-ring seal (48) to stem assembly (49). Install plunger (45), spring (46), and spring
(47) into valve assembly (39). Tighten plug (40) to a torque of 100 ± 5 N·m (75 ± 3 lb ft).
3. Repeat Steps 1 and 2 for the remaining valve assembly.
4. Install O-ring seals (41) to valve assembly (39).
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5. Install O-ring seals (37) to valve assembly (38).
6. Install ring (36) in pump housing (6).
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7. Lower the temperature of bearing cup (35). Use the proper equipment in order to install the
bearing cup in pump housing (6).
8. Install lip seal (34) in pump housing (6).
9. Use Tooling (D) in order to install retaining ring (33) in pump housing (6).
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10. Install bearing races (32) into pump housing (6).
11. Raise the temperature of bearing cone (21) to a temperature of 121 °C (250 °F). Install
bearing cone (21) onto pump shaft (18).
12. Install pump shaft (18) in pump housing (6).
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13. Use the following steps in order to determine the proper preload on bearings of the pump
assembly.
a. Install adjustment shim (19) and bearing cone (17) on shaft assembly (18).
b. Lower the temperature of bearing cup (11). Install the bearing cup in head assembly
(5).
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c. Position head assembly (5) on pump housing (6).
d. Use Tooling (G) in order to measure the distance between the head assembly and the
pump housing.
e. Take measurements at three equal intervals on the surface between the head assembly
and the pump housing.
f. The average of the three dimensions should be between zero and 0.05 mm (0.002
inch).
g. If necessary, grind adjustment shim (17) in order to obtain the correct dimension
between the head assembly and the pump housing. It may be necessary to replace the
shim with a new part.
14. Install bolts (4) and head assembly (5) to pump housing (6). Tighten the bolts to a torque of
240 ± 40 N·m (175 ± 30 lb ft).
15. Use the following steps in order to check the end play in pump shaft (18).
a. Use Tooling (H), Tooling (E), and Tooling (F) in order to check for end play in pump
shaft (18). If end play exists in the shaft assembly, repeat Step 13 until the correct
dimension between the head assembly and the pump housing is reached.
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b. Remove bolts (4) and head assembly (5) from the pump housing. Remove bearing
cone (17), and adjustment shim (19) from the pump shaft (18). Remove the pump
shaft from pump housing (6).
c. Proceed with the assembly of the pump assembly.
16. Install stops (31) into swashplate (22).
8/15
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Improper assembly of parts that are spring loaded can cause bodily
injury.
To prevent possible injury, follow the established assembly procedure
and wear protective equipment.
Note: There is spring force against retaining ring (27). When retaining ring (27) is not
seated properly, the spring force will be released. Installation of the internal components in
barrel assembly (23) should be performed in a press. This is done in order to retain spring
(28) and retaining ring (27).
17. Install pins (30), guide (29) and spring (28) in barrel assembly (23).
18. Use a suitable press and Tooling (C) in order to compress the spring (28) in barrel assembly
(23).
19. Use Tooling (B) in order to install retaining ring (27).
20. Slowly release compression on spring (28). Make sure that the retaining ring (27) is seated
properly.
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21. Install retaining ball (26) on barrel assembly (23).
22. Install pistons (24) into retaining plate (25).
23. Install piston assembly (24) into barrel assembly (23).
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24. Install swashplate (22) onto barrel assembly (23).
25. Install pump shaft (18) into rotating group (20).
26. Install bearing races (32) for the swashplate into pump housing (6).
11/15
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Caterpillar Cat 992K Wheel Loader (Prefix RM5) Service Repair Manual (RM500001 and up).pdf

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Caterpillar Cat 992K Wheel Loader (Prefix RM5) Service Repair Manual (RM500001 and up).pdf