992C Caterpillar Wheel Loader Operation and Maintenance Manual by quality service repair manual

Product:WHEELLOADER

Model:992CWHEELLOADER49Z

Configuration:992CWheelLoader49Z00001-UP(MACHINE)POWEREDBY3412Engine

OperationandMaintenanceManual

992CWHEELLOADER

MediaNumber-SEBU6282-01PublicationDate-01/02/1992DateUpdated-15/06/2006

ProductIdentificationandSerialNumberLocations

TheProductIdentificationNumber(PIN)willbeusedtoidentifyapoweredmachinethatisdesigned foranoperatortoride.

Caterpillarproductssuchasearthmovingequipmentnotdesignedforanoperatortoride(engines, transmissions,etc.)areidentifiedbySerialNumbers.Also,mostmajorCaterpillarattachmentsare identifiedbySerialNumbers.

Forquickreference,recordtheidentificationnumbersinthespacesprovidedbelowtheillustration photographs.

TransmissionSerialNumber____________________

EngineSerialNumber____________________

BucketSerialNumber____________________

WedMay1022:16:30UTC+05302023

Product:WHEELLOADER

Model:992CWHEELLOADER49Z

Configuration:992CWheelLoader49Z00001-UP(MACHINE)POWEREDBY3412Engine

OperationandMaintenanceManual

992CWHEELLOADER

MediaNumber-SEBU6282-01PublicationDate-01/02/1992DateUpdated-15/06/2006

SpecificationsandModelViews

Engine(1),fueltank(2),bucket(3),andcab(4).

Operator'scompartment(5),hydraulictank(6),radiator(7),transmission(8),andbattery(9).

Keydisconnectswitch(10).

Basicmachineshippingspecificationsarelistedbelow.

WedMay1022:16:03UTC+05302023

Product:WHEELLOADER

Model:992CWHEELLOADER49Z

Configuration:992CWheelLoader49Z00001-UP(MACHINE)POWEREDBY3412Engine

OperationandMaintenanceManual

992CWHEELLOADER

MediaNumber-SEBU6282-01PublicationDate-01/02/1992DateUpdated-15/06/2006

Foreword

Thismanualcontainssafety,operation,transportation,lubricationandmaintenanceinformation.

Somephotographsorillustrationsinthispublicationshowdetailsorattachmentsthatmaybedifferent fromyourmachine.Guardsandcoversmayhavebeenremovedforillustrativepurposes.

Continuingimprovementandadvancementofproductdesignmayhavecausedchangestoyour machinewhicharenotincludedinthispublication.Read-study-andkeepitwiththemachine.

Wheneveraquestionarisesregardingyourmachine,orthispublication,pleaseconsultyour Caterpillardealerforthelatestavailableinformation.

Safety

Thesafetysectionlistsbasicsafetyprecautions.Inaddition,thissectionidentifiesthetextand locationsofwarninglabelsusedonthemachine.

Readandunderstandthebasicprecautionslistedinthesafetysectionbeforeoperatingorperforming lubrication,maintenanceandrepaironthisproduct.

Operation

Theoperationsectionisareferenceforthenewoperatorandarefresherfortheexperiencedone.This sectionincludesadiscussionofgauges,switches,machinecontrols,attachmentcontrols, transportationandtowinginformation.

Photographsandillustrationsguidetheoperatorthroughcorrectproceduresofchecking,starting, operatingandstoppingthemachine.

Operatingtechniquesoutlinedinthispublicationarebasic.Skillandtechniquesdevelopasthe operatorgainsknowledgeofthemachineanditscapabilities.

Maintenance

Themaintenancesectionisaguidetoequipmentcare.Theillustrated,step-by-stepinstructionsare groupedbyservicingintervals.Itemswithoutspecificintervalsarelistedunder"WhenRequired" topics.Itemsinthe"MaintenanceIntervals"chartarereferencedtodetailedinstructionsthatfollow.

MaintenanceIntervals

Usetheservicehourmetertodetermineservicingintervals.Calendarintervalsshown(daily,weekly, monthly,etc.)maybeusedinsteadofservicehourmeterintervalsiftheyprovidemoreconvenient servicingschedulesandapproximatetheindicatedservicehourmeterreading.Recommendedservice shouldalwaysbeperformedattheintervalthatoccursfirst.

Underextremelysevere,dustyorwetoperatingconditions,morefrequentlubricationthanisspecified inthe"MaintenanceInterval"chartmaybenecessary.

Performserviceonitemsatmultiplesoftheoriginalrequirement.Forexample,at"Every500Service Hoursor3Months",alsoservicethoseitemslistedunder"Every250ServiceHoursorMonthly", "Every50ServiceHoursorWeekly"and"Every10ServiceHoursorDaily."

MachineDescription

ThisrubbertiredbucketmachineisequippedwithaCaterpillar3412dieselengine.Theprimaryuse ofthismachineisformovingmaterial.

MachineStorage

ForcompletestorageinformationrefertoSpecialInstructionSEHS9031,"StorageProcedurefor CaterpillarProducts".

WedMay1022:14:05UTC+05302023

Product:WHEELLOADER

Model:992CWHEELLOADER49Z

Configuration:992CWheelLoader49Z00001-UP(MACHINE)POWEREDBY3412Engine

OperationandMaintenanceManual

992CWHEELLOADER

MediaNumber-SEBU6282-01PublicationDate-01/02/1992DateUpdated-15/06/2006

LiteratureReferenceMaterials

CaterpillarReferenceMaterial

ThefollowingliteraturecanbeobtainedthroughanyCaterpillardealer.

SEBD0518,"KnowYourCoolingSystem"

SEBD0970,"CoolantandYourEngine"

SEBD0717,"DieselFuelsandYourEngine"

SEHS7067,"FuelsRecommendationsforCaterpillarDieselEngines"

SEBU5898,"ColdWeatherRecommendationsOperationandMaintenanceManual"

SEBU6310,"EMALubricatingOilsDataBook"forengines

SEBD0640,"OilandYourEngine"

SENR2507,ServiceManual

SEBP1377,PartsManual

SEHS9031,"StorageProcedureforCaterpillarProducts"

SEBF8029,"GuidelineForReusablePartsandSalvageOperations"(Anindexofpublicationson reusabilityorsalvageofusedparts.)

SEBU5407,SafetyManual

AdditionalReferenceMaterial

ASTMD2896TBNMeasurements(Cannormallybeobtainedfromyourlocaltechnologicalsociety, libraryorcollege.)

SAEJ313DieselFuels(FoundintheSAEhandbookorcanbeobtainedfromanylocallibrary, collegeortechnologicalsociety.)

SAEJ754Nomenclature(NormallyfoundintheSAEhandbook.)

SAEJ183Classification(NormallyfoundintheSAEhandbook.)

WedMay1022:14:54UTC+05302023

Product:WHEELLOADER

Model:992CWHEELLOADER49Z

Configuration:992CWheelLoader49Z00001-UP(MACHINE)POWEREDBY3412Engine

OperationandMaintenanceManual

992CWHEELLOADER

MediaNumber-SEBU6282-01PublicationDate-01/02/1992DateUpdated-15/06/2006

CoolingSystemSpecifications

CoolantInformation

Dieselengineoperatingtemperatureshaveincreasedtoimproveengineefficiency.Thismeans propercoolingsystemmaintenanceisespeciallyimportant.Overheating,overcooling,pitting, cavitationerosion,crackedheads,pistonseizures,andpluggedradiatorsareclassiccoolingsystem failures.Infact,coolantisasimportantasthequalityoffuelandlubricatingoil.

NOTICE

Caterpillarrecommendsthatthecoolantmixturecontainaminimum of30%CaterpillarAntifreeze,orequivalent.Liquidsupplemental coolantadditivemustbeadded,whennotusingCaterpillarAntifreeze, whichcontainstheproperadditive.

Neveraddcoolanttoanoverheatedengine,enginedamagecanresult. Allowtheenginetocoolfirst.

Allwateriscorrosiveatengineoperatingtemperature.Thecooling systemshouldbeprotectedwitha3%to6%concentrationofliquid supplementalcoolantadditiveatalltimes,regardlessofthe concentrationofantifreeze.

Excessivesupplementalcoolantadditivegreaterthanthe recommended6%,togetherwithconcentrationsofantifreezegreater than65%cancausedepositstoformandcanresultinradiatortube blockage,overheating,and/orwaterpumpsealdamage.

Donotuseliquidsupplementalcoolantadditiveorelementsor antifreezewithDowtherm209Full-Fillcoolant.Dowtherm209FullFillcoolantisnotcompatiblewithotherantifreezeandcoolant mixtures.

Dowtherm209full-fillcoolantwilllowerthewaterpumpcavitation temperatureandcoolantboilingpoint.Theseloweredtemperatures willcauseoverheatingatalowerambienttemperaturethanan ethyleneglycolandwatermix.IfDowthermisused,followthe

instructionsprovidedanduseonlytheinhibitorpackagerecommended bythesupplier.

Ifthemachineistobestoredin,orshippedto,anareawithfreezing temperatures,thecoolingsystemmustbeprotectedtothelowest expectedoutside(ambient)temperature.

Theenginecoolingsystemisnormallyprotectedto-28°C(-20°F)with CaterpillarAntifreeze,whenshippedfromthefactoryunlessspecial requirementsaredefined.

Checkthespecificgravityofthecoolantsolutionfrequentlyincoldweathertoensureadequate protection.

Cleanthecoolingsystemifitiscontaminated,iftheengineoverheatsoriffoamingisobservedin theradiator.

Coolantshouldbedrained,thesystemcleanedandnewcoolantaddedevery3000servicehoursor twoyears.WhennotusingCaterpillarAntifreezeandsupplementalcoolantadditiveas recommended,thedrainperiodmustbeshortenedto1500servicehoursoroneyear.

Fillingatover20liters(5U.S.gallons)perminutecancauseairpocketsinthecoolingsystem.

Afterdrainingandrefillingthecoolingsystem,operatetheenginewiththeradiatorcapremoved untilthecoolantreachesnormaloperatingtemperatureandthecoolantlevelstabilizes.Add coolantasnecessarytofillthesystemtotheproperlevel.

Neveroperatewithoutathermostatinthecoolingsystem.Coolingsystemproblemscanarise withoutathermostat.

Referto"KnowYourCoolingSystem,"formSEBD0518and"CoolantandYourEngine"form SEBD0970,formoredetailedspecifications.

CoolantWater

Hardwater,orwaterwithhighlevelsofcalciumandmagnesiumions,encouragestheformation ofinsolublechemicalcompoundsbycombiningwithcoolingsystemadditivessuchassilicates andphosphates.

Thetendencyofsilicatesandphosphatestoprecipitateout-of-solutionincreaseswithincreasing waterhardness.Hardwater,orwaterwithhighlevelsofcalciumandmagnesiumionsencourages theformationofinsolublechemicals,especiallyafteranumberofheatingandcoolingcycles.

Caterpillarpreferstheuseofdistilledwaterordeionizedwatertoreducethepotentialandseverity ofchemicalinsolubility.

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Usingwaterthatmeetstheminimumacceptablewaterrequirementmaynotpreventdrop-outof thesechemicalcompoundstotally,butshouldminimizetheratetoacceptablelevels.

Antifreeze

NOTICE

Caterpillarrecommendsthatthecoolantmixcontainaminimumof 30%CaterpillarAntifreeze,orequivalentandacceptablewaterto maintainanadequatewaterpumpcavitationtemperatureforefficient waterpumpperformance.

Premixcoolantsolutiontoprovideprotectiontothelowestexpected outside(ambient)temperature.Pureundilutedantifreezewillfreezeat -23°C(-10°F).

Onlyuseagreaterconcentration(above30%)ofCaterpillar Antifreezeasneededforanticipatedoutside(ambient)temperatures. Donotexceedacoolantmixtureof60%antifreezetowatersincea concentrationabove60%antifreezewillreducetheengine'sfreeze protectionandincreasethepossibilityofdepositformationinthe coolingsystem.

UseCaterpillarAntifreezeorGMSpecification6038-MAntifreeze.CaterpillarAntifreezeis availablethroughyourCaterpillardealerinquantitiesthatfollow.

Mostcommercialantifreezesareformulatedforgasolineengineapplicationsandwill,therefore, havehighsilicatecontent.CaterpillarAntifreezeisformulatedwithalowsilicatecontentandthe propercoolantadditivesforheavydutydieselengines.

GMSpecification6038-Misalowsilicateantifreeze,butsupplementalcoolantadditivemustbe added.

ThemajoradvantagesofCaterpillarAntifreezeare:

*Significantlyreduceswaterpumpsealleakageproblemscausedbyexcessive concentrationofchemicaladditives.

*Thereisnoneedtoaddsupplementalcoolantadditiveoninitialfillwhichmustbedone withcurrentcommerciallyavailableantifreezes.

*Highsilicateantifreezesusedwithasupplementalcoolantadditivecancauseabuildupof solidsoveraperiodoftimewhichcancauseplugging,lossofheattransfer,andwaterpump sealdamage.

Makeproperantifreezeadditions.

Addingpureantifreezeasamakeupsolutionforcoolingsystemtop-upisanunacceptable practice.Itincreasestheconcentrationofantifreezeinthecoolingsystemwhichincreasesthe concentrationofdissolvedsolidsandundissolvedchemicalinhibitorsinthecoolingsystem.Add antifreezemixedwithwatertothesamefreezeprotectionasyourcoolingsystem.

UsethechartbelowtoassistindeterminingtheconcentrationofCaterpillarAntifreezetouse.

SupplementalCoolantAdditive

Supplementalcoolantadditiveisnecessarytopreventrust,scale,pittingand/orcorrosionof enginepartsthatcoolantcomesincontactwith.MostantifreezesolutionsDONOTcontain sufficientsupplementalcoolantadditive.

NOTICE

Alwaysaddsupplementalcoolantadditiveorequivalenttothecoolant, orinstallaCaterpillarsupplementalcoolantadditiveelement(if equipped).Neverusecoolantonly,exceptifCaterpillarAntifreezeis beingusedwhichcontainstheadditive.Inthiscase,nosupplemental coolantadditiveisneededoninitialfill,butisnecessaryona maintenancebasis.

Usesupplementalcoolantadditiveorasupplementalcoolantadditive element(ifequipped).Thiswillprovidea3%to6%concentrationin thecoolingsystemtohelppreventcorrosion.

Topreventoverinhibitingtheengine'scoolingsystem,neveruseboth theliquidsupplementalcoolantadditiveandthesupplementalcoolant additiveelement(ifequipped)atthesametime.Theuseofthese additivestogethercouldresultinexcessiveconcentrationthatwould exceedtheCaterpillarrecommendedmaximumof6%.

Excessiveconcentrationofanadditivecanformdepositsonthehigher temperaturesurfacesofthecoolingsystemandcreateabarrierthat reducestheengine'sheattransfercharacteristics.Reducedheat transfercouldcausecrackingofthecylinderheadandotherhigh temperaturecomponents.Excessiveconcentrationsofadditivecould alsoacceleratewaterpumpsealwear.

SupplementalcoolantadditiveisneededwhennotusingCaterpillar Antifreezeforpremixedcoolantsolution.

LiquidsupplementalcoolantadditivecanbepurchasedfromyourCaterpillardealer.Followthe instructionsonthecontainer.

NOTICE

DoNOTaddsupplementalcoolantadditiveatinitialfillwhenusing CaterpillarAntifreeze.CaterpillarAntifreezecontainsthenecessary supplementalcoolantadditiveprecharge.Additionofsupplemental coolantadditivecouldresultinanoverconcentration.

OninitialfillofaneworreconditionedengineifCaterpillarAntifreezeisnotused,add1liter(1 quart)ofsupplementalcoolantadditive,orequivalent,foreach30liters(8U.S.gallons)sothat thecoolingsystemwillhavea3%to6%concentrationofsupplementalcoolantadditive.

Tomaintaina3%to6%concentrationofadditive,addliquidsupplementalcoolantadditiveor installamaintenancesupplementalcoolantadditiveelement(ifequipped),every250servicehours oroilchange,whicheveroccursfirst.Usethe8T5296TestKittocheckforconcentration.

Iftheengineisnotequippedwithspin-onelement,add.25liter(1/2pint)ofsupplementalcoolant additiveforeach38liters(10U.S.gallons)ofcoolantcapacitytomaintainthe3%to6% concentrationofadditive.

CoolingSystemCleaning

CaterpillarCoolingSystemCleanersaredesignedtocleanthesystemofharmfulscaleand corrosion.Itdissolvesmineralscale,corrosionproducts,lightoilcontaminationandsludge.

Cleanthesystemaccordingtothemaintenanceintervalchart,orwheneverthecoolantisdirtyor foaming.

CoolingsystemcleanersareavailablefromyourCaterpillardealerinthequantitieslistedbelow. Followthelabeldirectionsforproperusage.

WedMay1022:18:50UTC+05302023

Model:992CWHEELLOADER49Z

Configuration:992CWheelLoader49Z00001-UP(MACHINE)POWEREDBY3412Engine

YoumustreadandunderstandthewarningsandinstructionscontainedintheSafetysectionof thismanualbeforeperforminganyoperationormaintenanceprocedures.

1.Opentheaccesscoverontherightsideofthemachine. 2.MaintaintheoillevelbetweentheADDandFULLmarksonthedipstick(1)withtheengine running.

MaintaintheoillevelbetweentheLOWandFULLmarksontheenginestoppedsideofthe dipstickwiththeenginestopped.

3.Removetheoilfillplug(2)andaddoilifnecessary.

4.Cleanandinstallthefillplug.

5.Closetheaccesscover.

1.Opentheaccesscoverlocatedontheplatformbehindtheoperator'scompartment.

2.MaintaintheoilbetweentheLOWandFULLmarksonthedipstick(1)atLOWIDLE.

3.Removetheoilfillcap(2)andaddoilifnecessary.

4.Cleanandinstallthefillcap.

Replacethefilterelementifthecabtransmissionoilfilterindicatorcomesonduringoperation. Refertotopic"TransmissionFilter"inthe"Every500ServiceHoursor3Months"sectionofthis manual.

Thehydraulicoiltankislocatedontherightsideofthemachine.

1.MaintaintheoillevelabovetheADDCOLDmarkonthesightgauge(1).

2.Removetheoilfillcap(2)andaddoil,ifnecessary,throughthefilltube.

3.Cleanandinstallthefillcap.

Buckettobelevelandonthegroundduringfilling.

CoolingSystem LookattheCoolantLevel

Theradiatorcapislocatedinthetophoodofthemachineattheleftrear.

1.Removetheradiatorcapslowlytorelievepressure.

2.Maintainthecoolantleveltowithin1cm(1/2in)ofthebottomofthefillpipe.Ifitisnecessary toaddcoolantdaily,checkforleaks.

3.Inspectthecapseal.Replacethecapifitisdamaged.

4.Installthecap.

DraintheWaterandSediment

Drainvalveislocatedattheleftsideofthemachineunderthefueltank.

1.Openthedrainvalveandallowthewaterandsedimenttodrain.

2.Closethedrainvalve.

BucketCylinderandLinkageBearings

LubricateFittings

Wipeallfittingsbeforelubricating.

FuelTank

Lubricatefourremotefittingsfortherightliftcylinder,liftarmandtheheadendoftherighttilt cylinder.

Lubricatefourremotefittingsfortheleftliftcylinder,liftarmandtheheadendofthelefttilt cylinder.

Lubricatefourfittingsforthetiltcylinderrodendsandtiltleverpivots,twooneachsideofthe machine.

Lubricatetwofittings,oneoneachsideofthemachine.

Totalof14fittings.

SteeringCylinderBearings

LubricateFittings

Wipeallfittingsbeforelubricating.

1.Lubricateonefittingineacheyeofthetwosteeringcylinders.Totaloftwofittings.

2.Lubricatetworemotefittingsfortheheadendofthesteeringcylinders.

Totaloffourfittings.

Walk-AroundInspection

InspectMachine

NOTICE

Accumulatedgreaseandoilonamachineisafirehazard.Removethis debriswithsteamcleaningorhighpressurewater,atleastevery1000 hoursoreachtimeanysignificantquantityofoilisspilledona machine.

NOTE:Keepaclosewatchforleaks.Ifleakingisobserved,findthesourceandcorrecttheleak. Checkthefluidlevelsmorefrequentlythantherecommendedperiodsifleakingissuspectedor observed.

1.Inspecttheengineprecleanerbowlfordirtbuild-up.Removedirtfrombowlwhenanydirthas accumulatedclosetothefulllineonbowl.

2.Checktheairfilterelementindicators.Servicethefiltersifthefilterelementindicatorhas movedintotheredzone.

3.Inspectthebucketandlinkagefordamageorexcessivewear.Repairifdamaged.

4.Inspectthelightsforbrokenbulbsandlenses.Replaceifbroken.

5.Inspectandremoveanytrashbuild-upintheenginecompartment.

6.Inspectthecoolingsystemforleaks,faultyhosesandtrashbuild-up.Correctanyleaksand removeanytrashfromradiator.

7.Inspectthehydraulicsystemforleaks.Inspectthetank,hoses,tubes,plugs,jointsandfittings. Correctanyleaks.

8.Inspectdifferentials(frontandrear)undermachineforleaks.

9.Inspectthefinaldrives(frontandrear)forleaks.

10.Inspecttires(frontandrear)fordamageandproperinflation.Replaceanymissingvalvecaps.

11.Inspecttransmissionforleaks.

This is the sample of the manual Click on the download link for complete Manual