File Under Loaders

FLUID ANALYSIS GUIDE

Machine Profiles
992G Wheel Loaders
Description 3. If the machine is under a “close follow” to monitor wear
These are articulated wheel loaders with planetary power shift levels to ascertain whether a failure mode is in
transmission and four wheel multiple disc wet brakes within the progress.
final drive housing. 4. If an oil change interval has been altered from the
interval recommended in the Operation & Maintenance
Guide.
Serial Number Range O&MM:
7HR SEBU7009-02
10-98

Lubrication Recommendations
For complete information concerning lubrication
recommendations, refer to Caterpillar Machine Lubricant
Recommendations. Form SEBU6250.

Oil Sampling Procedures

The engine, transmission and hydraulic systems are equipped
with oil sampling valves on this model. The final drives and
differentials must be sampled using a hand held vacuum pump.

Oil Sampling Intervals:

Engine: 250 hours - Oil Sampling Valve
Transmission: 500 hours - Oil Sampling Valve
Final Drives: 500 hours
Implement and Engine Cooling Fan Hydraulics:
500 hours - Oil Sampling Valve
Steering and Brake Actuation Hydraulics:
500 hours - Oil Sampling Valve

Filter Inspection
Recommend that filters be saved for inspection. Plastic bags
are convenient for retaining the filters until they can be cut open
for inspection. The 4C5084 Filter Cutting Tool is available for
this purpose. Be alert for visible pieces of synthetic friction
material or metal which may indicate a problem.

Recommended Oil Sampling Intervals:

The recommended oil sampling intervals for this machine model
is 250 hours for the engine and 500 hours for all other systems.
Caterpillar dealers or users may wish to consider a 250 hour
sampling interval for all systems, particularly under the following
circumstances:
1. If the machine is under a Customer Support
Agreement (CSA).
2. If the machine application is more severe than normal.
 CONFIDENTIAL
This document contains unpublished confidential proprietary,
and trade secret information of Caterpillar Inc., and is intended
for distribution only to parties specifically authorized by
Caterpillar. Unauthorized copying, distribution, or use is
specifically prohibited.

 2002 CATERPILLAR INC. ALL RIGHTS RESERVED

NOTICE
Information supplied by this document is intended to be
used only as a general guideline for interpretation.

Model-specific information supplied by this document is

subject to change and may vary on a machine-by-machine
basis. Most often, changes to major components changes
are delineated by specific serial number breaks and/or
prefix changes. Equipment may need to consult current
Operations & Maintenance Manuals, Parts Manuals, Service
Manuals or other reference materials for details for a
specific serial number machine.

Wear tables, provided elsewhere by Caterpillar, were

developed for average conditions and are intended to
reflect expected values at normal oil change periods. They
may be too high or too low for some specific machine
applications. Interpretations should be based on the trend
of wear values in each compartment whenever possible.

2 Printed in U.S.A. 04/09/02

ENGINE
Machine Model: 992G Wheel Loader
Machine Model S/N: 7HR
Chromium
Piston rings
Engine Model: 3508B EUI
Horsepower Rating: 597 kW, 800 FWHP
Oil Change Interval: 500 Hrs.
Recommended Oil Sampling Interval: 250 hours Lead
Recommended Coolant Analysis: Main and rod bearings
Level 1: As determined by customer requirements. Front gear train bushings
Level 2: After 500 hours of initial use, and annually or as
determined by Level 1 analysis.
Oil Sampling: 500 hours Aluminum
Filter Change Interval: 500 Hrs. Main and rod bearing
Sump Capacity: 102 Liters (26.9 Gal.) Piston skirts
Engine Oil Cooler: Water Dirt entry (clay soils)
Cooling System: 268 Liters (70.8 Gal.) Anti-seize compounds (no failure)
Cooling System: Advanced Modular Cooling System Front gear train bushings
(AMOCS) which utilizes a two-pass coolant flow and increases
cooling surface.
Oil Transfer Possibilities: None Silicon
After-cooler: Separate circuit water-to-air Dirt entry
Silicon grease (no failure)
Silicon additives (no failure)
Notes:
1. Recommend Caterpillar Diesel Engine Oil (DEO).
Molybdenum
2. Two turbochargers Top piston ring

WEAR ELEMENT SOURCES

Copper
Front and rear idler gear thrust bearing
Oil cooler core tubes
Wrist pin bushing
Timing gear thrust washers
Piston pin bushings
Fuel transfer pump bushings
Camshaft bushings
Oil pump drive thrust washer
Rocker arm bushings
Gear thrust washers
Rear idler gear bushings
Rear cluster gear bushings
Crankshaft thrust bearing
Turbocharger bearings
Camshaft lifter roller pins
Rear accessory drive thrust washer
Oil additives (no failure)
Anti-seize compounds (no failure)

Iron
Crankshaft
Camshaft
Valves
Cylinder liners
Valve seats, guides
Oil pump
Piston rings

3 Printed in U.S.A. 04/09/02

TRANSMISSION
Machine Model: 992G Wheel Loader
Machine Model S/N: 7HR
Tin
Bearings
Type: 21” and Planetary Power Shift
Speeds: 3F 3R
Oil Change Interval: 1000 Hrs.
Filter Change Interval: 500 Hrs. Aluminum
Oil Sampling Interval: 500 hours Torque converter impeller
Sump Capacity: 169 Liters (44.6 Gal.) Torque converter turbine
Transmission Pump Type: Gear Dirt entry (clay soils)
Oil Cooler Type: Water Anti-seize compounds (no failure)
Disc Material:
Transmission Discs: F37 and Rayflex
VCTC: Gylon Silicon
Common Sump: Transmission, VCTC, transmission input Dirt entry
planetary and output transfer gears share a common sump. Silicon grease (no failure)
Oil Transfer Possibilities: Silicon additives (no failure)
1. Oil may transfer between the engine and transmission
through the rear crankshaft seal.
Sodium
2. Hydraulic oil could transfer to the transmission through Coolant leak
damaged seals in the pump drive. Condensation
Water entry
Oil Additives (no failure)
Notes:
1. Recommend Caterpillar Transmission / Drive Train Oil
(TDTO).
2. Magnetic strainer in gear case sump. Drain oil in sump
before removing to inspect if failure is suspected.
3. Machine is equipped with Variable Capacity Torque
Converter (VCTC) which has a split impeller with a
lock-up clutch.

WEAR ELEMENT SOURCES

Copper
Torque converter bushings
Cooler core leaching (no failure)
Oil additives (no failure)
Anti-seize compounds (no failure)

Iron
Pump housing
Gears
Bearings
Clutch plates
Splines
Shafts
Pump wear
Housing

Chromium
Bearings

4 Printed in U.S.A. 04/09/02

IMPLEMENT, AND BRAKE
ACTUATION HYDRAULICS Aluminum
Machine Model: 992G Wheel Loader Dirt entry (clay soils)
Machine Model S/N: 7HR Pump body wear (gear pump)
Oil Change Interval: 2000 Hrs. Isolation plate (gear pump)
Filter Change Interval: 500 Hrs. Anti-seize compounds (no failure)
Sump Capacity:
Hydraulic System (Implement System and Fan Drive Motor)
326 Liters (86 Gal.) Silicon
Oil Sampling Interval: 500 hours Dirt entry
Oil Cooler Type: Air Silicon grease (no failure)
Pump Type(s): Silicon additives (no failure)
Vickers Gear Pump controls flow to: Pilot Controls
Variable displacement Piston Pumps control flow
to: Implements and brake actuation Sodium
Lift and tilt system consists of two piston pumps mounted on a Condensation
single pump drive. Water entry
Variable displacement pump is controlled by Electronic Control Oil additives (no failure)
Module. A solenoid valve controls the torque setting which
allows the Electronic Control Module to vary the hydraulic load
felt by the engine - optimizing performance. The implement
circuit has increased system pressure and optimized system
flow for faster hydraulics and greater lift forces.
Fixed displacement hydraulic pump performs with high
efficiency and great reliability.
Common Sump: Separate Sump
Oil Transfer Possibilities:
Oil may transfer between the transmission and hydraulic
compartments through damaged pump seals in the pump drive.

Notes:
1. Recommend Caterpillar Hydraulic Oil (HYDO).

WEAR ELEMENT SOURCES

Copper
Cooler core leaching (no failure)
Oil additives (no failure)
Pressure plate wear (gear pump)
Slipper and port plate wear (piston pump)
Anti-seize compounds (no failure)

Iron
Pump housing
Cylinder wear
Pump wear
Housing

Chromium
Cylinder rods

Tin
Bearings

5 Printed in U.S.A. 04/09/02

STEERING, AND BRAKE ACTUATION
HYDRAULICS Silicon
Machine Model: 992G Wheel Loader Dirt entry_Silicon grease (no failure)_Silicon additives (no
Machine Model S/N: 7HR failure)
Steering System: Load sensing steering with STIC Control
System integrates steering and transmission into a single
controller. Sodium
Oil Change Interval: 2000 Hrs. Condensation_Water entry_Oil additives (no failure)
Filter Change Interval: 500 Hrs.
Sump Capacity:
Hydraulic System (Steering System and Braking System) 159
Liters (42 Gal.)
Oil Sampling Interval: 500 hours
Oil Cooler Type: Air
Pump Type(s):
Variable Displacement Piston Pump
Common Sump: Separate Sump
Oil Transfer Possibilities:
Oil may transfer between the transmission and hydraulic
compartments through damaged pump seals in the pump drive.

Notes:
1. Recommend Caterpillar Hydraulic Oil (HYDO).

WEAR ELEMENT SOURCES

Copper
Cooler core leaching (no failure)
Oil additives (no failure)
Pressure plate wear (gear pump)
Slipper and port plate wear (piston pump)
Anti-seize compounds (no failure)

Iron
Pump housing
Cylinder wear
Pump wear
Housing

Chromium
Cylinder rods

Tin
Bearings

Aluminum
Dirt entry (clay soils)
Pump body wear (gear pump)
Isolation plate (gear pump)
Anti-seize compounds (no failure)

6 Printed in U.S.A. 04/09/02

 Brake plates
DIFFERENTIAL, BEVEL GEAR, Thrust washers - Differential
BRAKES AND FINAL DRIVES
Machine Model: 992G Wheel Loader
Machine Model S/N: 7HR Chromium
Oil Change Interval: 2000 Hrs. Bearings
Sump Capacity:
360 Liters (95 Gal.)/Front
345 Liters (91 Gal.)/Rear Tin
Oil Sampling Interval: 500 hours Bearings
Final Drive Type: Outboard Single Planetary Reduction
Brakes: Four-wheel, fully hydraulic, fully enclosed, oil-disc type.
Brake Disc Friction Material: Cellulose Fiber Aluminum
Common Sump: Differential, bevel gear, final drives and Dirt entry (clay soils)
brakes share a common sump. Anti-seize compounds (no failure)
Oil Transfer Possibilities:
1. Brake actuating oil (hydraulic oil) may leak past the
piston seal and transfer to the final drive. Silicon
2. Wear metals, silicon, or water within either final drive Dirt entry
or the differential will be transferred to the oil within the Silicon grease (no failure)
Silicon additives (no failure)
other compartments.

Sodium
Notes: Condensation
1. Recommend Caterpillar Transmission / Drive Train Oil Water entry
(TDTO). Oil additives (no failure)
2. When operating in water, check for water/silicon entry.
3. Recommend sampling both right and left final drives as
well as the differential.
4. Tire spinning causes rapid differential wear. Spinout
occurs more on rear axle than front.
5. A through flushing of the entire axle housing is
necessary after a failure or major contamination.
6. A magnetic plug is in each final drive cover for
inspection if high iron readings are found. Some
magnetic fuzz is normal.
7. Brake discs are cellulose fiber, however brake plate
wear can show as high iron.

WEAR ELEMENT SOURCES

Copper
Thrust washer - Differential
Sleeve bearing - Differential
Sleeve bearing – Planetary
Oil additives (no failure)
Anti-seize compounds (no failure)

Iron
Gears
Bearings
Splines
Final drive housing
Shafts

7 Printed in U.S.A. 04/09/02