Caterpillar Cat 992D Wheel Loader (Prefix 7MJ) Service Repair Manual (7MJ00001 and up)

1
Service Repair Manual
Models 992D Wheel Loader
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Product WHEEL LOADER Model 992D WHEEL LOADER
7MJ Configuration 992D Wheel Loader 7MJ00001-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
i02184090
Cylinder Head - Remove SMCS - 1100-011 Removal
Procedure Table 1
Required Tools Required Tools Required Tools Required Tools
Tool Part Number Part Description Qty
A 138-7573 Link Bracket 2
B 5P-8700 Lifting Bracket 2

• Start By
• Remove the unit injector sleeves. Refer to
  Disassembly and Assembly, "Unit Injector Sleeve
• - Remove".
• Remove the exhaust manifold. Refer to Disassembly
  and Assembly, "Exhaust Manifold - Remove and
  Install".
• NOTICE
• Keep all parts clean from contaminants.
• Contaminants may cause rapid wear and shortened
  component life.

NOTICE
3
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.
Illustration 1 g00570914 1. Remove hose assembly
(1) from the front of the fuel manifold.
Illustration 2 g00570923 2. Remove hose assembly
(2) from the rear of the fuel manifold.
4
Illustration 3
g00582732
3. Remove tube assembly (3).
Illustration 4 g00570979 4. Remove cylinder head
bolts (5). Remove bolts (4).
Illustration 5 g00570983 5. Attach Tooling (A)
and a suitable lifting device to fuel manifold
(6). The weight of the fuel manifold for the
3412E is approximately 60 kg (131 lb). The weight
of the fuel manifold for the 3408E is
approximately 39 kg (86 lb). Remove bolts (7).
Remove fuel manifold (6).
5
vO
Illustration 6 g01105094 6. Attach Tooling (B)
and a suitable lifting device to the cylinder
head. The weight of the cylinder head for the
3412E is approximately 172 kg (380 lb). The
weight of the cylinder head for the 3408E is
approximately 90 kg (200 lb). Remove cylinder
head nuts (8).
Illustration 7
g01105075
7. Remove cylinder head (9) and the gasket.
Illustration 8
g01105076
6
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1. Remove seals (10).
2. Remove spacer plate (11).

Illustration 9 g01105072 10. Remove O-ring seals
(12) and gasket (13).
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Product WHEEL LOADER Model 992D WHEEL LOADER
7MJ Configuration 992D Wheel Loader 7MJ00001-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
i02184092
Cylinder Head - Install SMCS - 1100-012 Installati
on Procedure Table 1
Required Tools Required Tools Required Tools Required Tools
Tool Part Number Part Description Qty
A 138-7573 Link Bracket 2
B 5P-8700 Lifting Bracket 2
C 8C-8422 Sealant 2
NOTICE Keep all parts clean from
contaminants. Contaminants may cause rapid wear
and shortened component life.
Note Thoroughly clean the spacer plate and the
bottom surface of the cylinder head. A new spacer
plate gasket must be installed when the cylinder
head is removed. Note Apply a thin film of clean
engine oil on the seals and the O-ring seals
prior to installation.
9
Illustration 1
g01105072
1. Install O-ring seals (12) and gasket (13).
Illustration 2
g01105076

1. Install spacer plate (11).
2. Install seals (10).

Illustration 3 g01105075 4. Position the gasket
on the engine. Attach Tooling (B) and a suitable
lifting device to the cylinder head. The weight
of the cylinder head for the 3412E is
approximately 172 kg
10
(380 lb). The weight of the cylinder head for the
3408E is approximately 90 kg (200 lb). Install
cylinder head (9).
Illustration 4 g01105094 5. Install cylinder
head nuts (8). Remove Tooling (B).
Illustration 5
g00570607
11
Illustration 6 g00582780 6. Apply Tooling (C) to
the shaded area of the fuel manifold. Tooling (C)
is applied to the bottom portion of the fuel
manifold. Tooling (C) is permitted on the entire
face of the fuel manifold.
Illustration 7 g00570983 7. Attach Tooling (A)
and a suitable lifting device to fuel manifold
(6). The weight of the fuel manifold for the
3412E is approximately 60 kg (131 lb). The weight
of the fuel manifold for the 3408E is
approximately 39 kg (86 lb). Install fuel
manifold (6). Install bolts (7).
12
Illustration 8
g00570979
Illustration 9
g00570761
13
Illustration 10
g00582808

• Note Apply clean engine oil to the bolts for the
  cylinder head.
• Install cylinder head bolts (5). Install bolts
  (4).
• Tighten the bolts in the following sequence
• In a numerical sequence, tighten the bolts 1
  through 26 for the 3412E. In a numerical
  sequence, tighten the bolts 1 through 18 for the
  3408E.
• In a numerical sequence, tighten the bolts to a
  torque of 270 15 Nm (200 11 lb ft).
• In a numerical sequence, tighten the bolts to a
  torque of 450 15 Nm (330 11 lb ft).
• In a numerical sequence, again tighten the bolts
  to a torque of 450 15 Nm (330 11 lb ft).
• Tighten the upper row of nuts that are on the
  cylinder head in the following sequence In a
  numerical sequence, tighten nuts 27 through 39
  for the 3412E to a torque of
• 45 7 Nm (33 5 lb ft).
• In a numerical sequence, tighten nuts 19 through
  27 for the 3408E to a torque of 45 7 Nm (33
  5 lb ft).

Illustration 11
g00582732
10. Install tube assembly (3).
14
Illustration 12 g00570923 11. Install hose
assembly (2) on the rear of the fuel manifold.

• Illustration 13 g00570914
• Install hose assembly (1) on the front of the
  fuel manifold.
• End By
• Install the exhaust manifold. Refer to
  Disassembly and Assembly, "Exhaust Manifold -
  Remove and Install".
• Install the unit injector sleeves. Refer to
  Disassembly and Assembly, "Unit Injector Sleeve -
  Install".

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Product WHEEL LOADER Model 992D WHEEL LOADER
7MJ Configuration 992D Wheel Loader 7MJ00001-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
i05933135
Lifter Group - Remove and Install SMCS -
1209-010 Removal Procedure Table 1
Required Tools Required Tools Required Tools Required Tools
Tool Part Number Part Description Qty
A 5P-7433 Valve Lifter Tool Group 1
Start By A. Remove the cylinder head. Refer to
Disassembly and Assembly, "Cylinder Head -
Remove". NOTICE Keep all parts clean from
contaminants. Contaminants may cause rapid wear
and shortened component life.
16
Illustration 1
g00571490
Illustration 2
g00571491

1. Install Tooling (A) in lifter assembly (1) .
2. Remove lifter assembly (1) from the lifter bore.

Illustration 3 g00571492 3. Remove lifter guide
spring (2) from the lifter assembly.
17
Installation Procedure Table 2
Required Tools Required Tools Required Tools Required Tools
Tool Part Number Part Description Qty
A 5P-7433 Valve Lifter Tool Group 1
Note Install new valve lifter guide springs on
the valve lifter when the valve lifters are
removed from the engine. Note Apply clean engine
oil to the ball socket for the pushrod and the
bore for the valve lifter assembly.
Illustration 4 g00571513 1. Make an alignment of
the new lifter guide spring (2) in Tooling (A) .
Illustration 5 g01104989 2. Install lifter
assembly (1) in the cylinder block with Tooling
(A) .
18
End By Install the cylinder head. Refer to
Disassembly and Assembly, "Cylinder Head -
Install".
Copyright 1993 - 2021 Caterpillar Inc. All Rights
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Mon Jun 21 002931 UTC0800 2021
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Product WHEEL LOADER Model 992D WHEEL LOADER
7MJ Configuration 992D Wheel Loader 7MJ00001-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
i06177964
Camshaft - Remove and Install SMCS -
1210-010 Removal Procedure Table 1
Required Tools Required Tools Required Tools Required Tools
Tool Part Number Part Description Qty
A 1P-0510 Driver Group 1

• Start By
• Remove the front housing. Refer to Disassembly
  and Assembly, "Housing (Front) - Remove".
• Remove the lifter group. Refer to Disassembly and
  Assembly, "Lifter Group - Remove and Install".
• Remove the flywheel housing. Refer to Disassembly
  and Assembly, " Flywheel Housing - Remove and
  Install".
• NOTICE
• Keep all parts clean from contaminants.
• Contaminants may cause rapid wear and shortened
  component life.

NOTICE
20
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.
Illustration 1 g00572086 1. Remove four bolts
(1) and plate (2) from the rear of the camshaft.
Remove gear (3) from the camshaft.
Illustration 2 g00572090 2. Rotate the engine
until the V marks on the front of the timing
gears are in alignment.
21
Illustration 3 g00572095 3. Remove two bolts (5)
and plate (4) from the camshaft.
Illustration 4 g00572105 4. Remove camshaft (6)
from the cylinder block.
Illustration 5 g00572214 5. If necessary, remove
camshaft gear (7) with Tool (A) and press.
Installation Procedure
22
NOTICE Keep all parts clean from
contaminants. Contaminants may cause rapid wear
and shortened component life.

• Illustration 6 g00572220
• Note The key for gear (7) must be in position on
  the camshaft (6) before gear (7) is installed.
• Do not use a torch to heat camshaft gear (7).
  Raise the temperature of camshaft gear (7) by one
  of the following methods.
• Use a suitable oven to raise the temperature of
  camshaft gear (7). Do not exceed 150 C (302 F)
  for more than four hours.
• Use a suitable induction heater to raise the
  temperature of the hub of camshaft gear
• (7). Do not exceed 150 C (302 F) at bottom of
  gear teeth root radius.
• Install camshaft gear (7) to camshaft (6).
• Put 8T-2998 Lubricant on the camshaft lobes and
  the rollers for the valve lifter. Put clean
  engine oil on the bearing journals of the
  camshaft.

23
Illustration 7 g00572105 4. Install camshaft (6)
until the rear of the camshaft is even with the
rear of the cylinder block.
Illustration 8 g00572090 5. Make an alignment of
the V marks on the camshaft gear and the idler
gear.
Illustration 9
g00572221
6. Install plate (4) on the cylinder block.
Illustration 10
g00572086
24

• Install gear (3) and plate (2) on the rear of the
  camshaft.
• End By
• Install the flywheel housing. Refer to
  Disassembly and Assembly, "Flywheel Housing -
  Remove and Install".
• Install the lifter group. Refer to Disassembly
  and Assembly, "Lifter Group - Remove and
  Install".
• Install the front housing. Refer to Disassembly
  and Assembly, "Housing (Front) - Install".

Copyright 1993 - 2021 Caterpillar Inc. All Rights
Reserved. Private Network For SIS Licensees.
Mon Jun 21 003028 UTC0800 2021
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Product WHEEL LOADER Model 992D WHEEL LOADER
7MJ Configuration 992D Wheel Loader 7MJ00001-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
i01519738
Camshaft Bearings - Remove and Install SMCS -
1211-010 Removal Procedure Table 1
Required Tools Required Tools Required Tools Required Tools
Tool Part Number Part Description Qty
A 8S-2241 Camshaft Bearing Tool Group 1
A 8S-8293 Extension 1
A 5P-1667 Tube 1

• Start By
• Remove the flywheel housing. Refer to Disassembly
  and Assembly, "Flywheel Housing - Remove and
  Install".
• Remove the camshaft. Refer to Disassembly and
  Assembly, "Camshaft - Remove and Install".
• Remove the pistons and connecting rods. Refer to
  Disassembly and Assembly, "Pistons and Connecting
  Rods - Remove".
• NOTICE
• Keep all parts clean from contaminants.
• Contaminants may cause rapid wear and shortened
  component life.

26
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, "Caterpillar Tools and Shop Products
Guide" for tools and supplies suitable to collect
and contain fluids on Caterpillar
products. Dispose of all fluids according to
local regulations and mandates.

• Illustration 1 g00569925
• Remove the rear camshaft bearing with Tool (A) .
• Remove the remainder of the camshaft bearings
  with Tool (A) through the rear of the engine
  block. Start from the rear of the cylinder block
  and move toward the front.
• Installation Procedure
• Table 2

Required Tools Required Tools Required Tools Required Tools
Tool Part Number Part Description Qty
A 8S-2241 Camshaft Bearing Tool Group 1
A 8S-8293 Extension 1
A 5P-1667 Tube 1
27
NOTICE Keep all parts clean from
contaminants. Contaminants may cause rapid wear
and shortened component life.
Note Ensure that the inside of the cylinder
block is clean. Inspect the camshaft bore for
metal burrs. Put a thin film of clean engine oil
on the inside of the camshaft bearing bores and
on each camshaft bearing prior to
installation. Note Two different camshaft
bearings are used. Install the wider camshaft
bearings in the front and rear camshaft bores.
Install the narrow camshaft bearings in the inner
bores.

• Illustration 2 g00570127
• Install all the camshaft bearings with Tool (A)
  so that the oil hole in the camshaft bearing is
  in a horizontal position. Installation angle (1)
  is 90 15.
• Install the camshaft bearings with Tool (A) on
  the front side of the engine. Start the bearing
  that is being installed from the rear of each
  bore. Pull the bearing into the bore with Tool
• (A). Use the following procedure for achieving
  the proper installation depth for the
• bearings.

28

• Illustration 3 g00583232
• Install the rear camshaft bearing. Pull the
  bearing into the bore until the front face of
  the bearing is flush with the front face of bore
  (2).
• Install the narrow internal camshaft bearings.
  Start at the rear of the engine and work forward.
  Pull each bearing into the bore until the front
  face of the bearing is flush with the front face
  of the bore.

Illustration 4
g00569930
Measure the depth of the front camshaft
bearing. c. Install the front camshaft bearing
with Tool (A) until the bearing is at the
specified depth. the depth is measured from the
front of the engine block. The front camshaft
bearing for the 3412E should be 7.4 0.5 mm
(0.29 0.02 inch) from the front face of the
engine block. The front camshaft bearing for the
3408E should be 4.6 0.5 mm (0.18 0.02 inch)
from the front face of the engine block. Note
Refer to Specifications, "Camshaft Bearings" for
more information about camshaft bearings.
29

• End By
• Install the camshaft. Refer to Disassembly and
  Assembly, "Camshaft - Remove and Install".
• Install the flywheel housing. Refer to
  Disassembly and Assembly, "Flywheel Housing -
  Remove and Install".
• Install the pistons and connecting rods. Refer to
  Disassembly and Assembly, "Pistons and
  Connecting Rods - Install".

Copyright 1993 - 2021 Caterpillar Inc. All Rights
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Mon Jun 21 003124 UTC0800 2021
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Product WHEEL LOADER Model 992D WHEEL LOADER
7MJ Configuration 992D Wheel Loader 7MJ00001-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
i01057286
Engine Oil Pan - Remove and Install SMCS -
1302-010 Removal Procedure 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,
"Caterpillar Dealer Service Tool Catalog" for
tools and supplies suitable to collect and
contain fluids on Caterpillar products. Dispose
of all fluids according to local regulations and
mandates.
NOTICE Keep all parts clean from
contaminants. Contaminants may cause rapid wear
and shortened component life.
31
Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
contact the skin.
1. Drain the oil from the engine oil pan into a
suitable container for storage or disposal.
Illustration 1 Typical example
g00552331
2. Remove tube assembly (1). Remove the gaskets.
Illustration 2 Typical example
g00552333

• Remove bolts (2) from engine oil pan (3).
• Use two technicians in order to remove engine oil
  pan (3).
• The weight of the engine oil pan for the 3408E is
  approximately 14 kg (31 lb). The weight of the
  engine oil pan for the 3412E is approximately 27
  kg (60 lb).
• Thoroughly remove gasket (4) from the engine oil
  pan and the cylinder block.

32
Make sure that all of the old gasket material has
been removed from the mating surfaces of the
engine oil pan and the cylinder block. Make sure
that all surfaces are clean and free of dirt and
debris.
Installation Procedure NOTICE Keep all parts
clean from contaminants. Contaminants may cause
rapid wear and shortened component life.
1. Use 5H-2471 Adhesive to install a new gasket
on the engine oil pan.
Illustration 3 Typical example
g00552333

• Put new gasket (4) into position on engine oil
  pan (3).
• Use two technicians in order to put engine oil
  pan (4) in position on the engine.
• The weight of the engine oil pan for the 3408E is
  approximately 14 kg (31 lb). The weight of the
  engine oil pan for the 3412E is approximately 27
  kg (60 lb).
• Install bolts (2) that hold engine oil pan (3) to
  the cylinder block.

33
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Illustration 4 Typical example
g00552331

1. Install tube assembly (1).
2. Fill the engine to the correct level with the
   recommended oil. Refer to the Operation and
   Maintenance Manual.

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Product WHEEL LOADER Model 992D WHEEL LOADER
7MJ Configuration 992D Wheel Loader 7MJ00001-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
i05661411
Cylinder Liner - Remove SMCS - 1216-011 Removal
Procedure Table 1
Required Tools Required Tools Required Tools Required Tools
Tool Part Number Part Description Qty
A 5P-8665 Cylinder Liner Puller Gp 1
A 6V-9448(1) Cylinder Pack Puller Gp 1
A 373-1438(2) Cylinder Pack Puller Gp 1
(1) Alternative option to remove liner, piston,
and connecting rod as an assembly for 137 mm (5.4
inch) and 140 mm (5.5 inch) bore diameters. (2)
Alternative option to remove liner, piston, and
connecting rod as an assembly for 145 mm (5.7
inch) bore diameter. Start By a. Remove the
pistons and connecting rods. Refer to Disassembly
and Assembly, "Pistons and Connecting Rods -
Remove". NOTICE Keep all parts clean from
contaminants. Contaminants may cause rapid wear
and shortened component life.
36
Illustration 1
g01005579
1. Remove cylinder liner (1) with Tooling (A).
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