Caterpillar Cat 990K Wheel Loader (Prefix DJK) Service Repair Manual Instant Download

1
Product WHEEL LOADER Model 990K WHEEL LOADER
DJK Configuration 990K Wheel Loader DJK00001-UP
(MACHINE) POWERED BY C27 Engine
Disassembly and Assembly 844K Wheel Dozer and
990K Wheel Loader Power Train Media Number
-UENR6577-01 Publication Date -01/07/2017
Date Updated -05/07/2017
i06551679
Torque Converter (Lockup) - Disassemble SMCS -
3101-015-L7 Disassembly Procedure Table 1
Required Tools Required Tools Required Tools Required Tools
Tool Part Number Part Description Qty
A 3E-3879 Eyebolt 1
B 138-7573 Link Bracket 2
C 1H-3110 Bearing Puller Attachment 1
D 154-6182 Forcing Bolt 2
Start by a. Remove the torque converter.
2
Illustration 1
g06019861

1. Remove bolts (2).
2. Remove housing (1) from housing assembly (3).

Illustration 2 g06019862 3. Remove O-ring seals
(4) from housing (1).
3
Illustration 3 g06019864 4. Remove O-ring seal
(5), sleeve (6), and O-ring seal (7) from housing
assembly (3).
Illustration 4
g06019869
5. Remove bolts (8).
Illustration 5
g06019868
4
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1. Use Tooling (D) to separate housing assembly (3).
2. Use Tooling (B) and a suitable lifting device to
   remove housing assembly (3) from the torque
   converter. The weight of housing assembly (3) is
   approximately 110 kg (243 lb).
3. Remove dowel pins (9).

Illustration 6 g06019874 9. Remove bolt (10),
retainer (12), and yoke (11).
Illustration 7
g06019876
10. Remove O-ring seal (13) from yoke (11).
6
Illustration 8
g06019877

1. Remove bolts (14).
2. Remove the gasket and retainer (15).

Illustration 9
g06019878
13. Remove lip seal (15) from retainer (16).
7
Illustration 10 g06019879 14. Remove O-ring seal
(17) from stator carrier (18).
Illustration 11 g06019882 15. Use Tooling (A)
and a suitable lifting device to remove shaft
(19) from the torque converter. The weight of
shaft (19) is approximately 15 kg (33 lb).
8
Illustration 12 g06019916 16. Use a suitable
press to push shaft (19) out of bearing (20).
Illustration 13
g06019918

1. Remove rings (22) from carrier (21).
2. Use a suitable press to push shaft (19) out of
   carrier (21).

9
Illustration 14
g06019922
19. Remove ring (23) from shaft (19).
Illustration 15 g06019924 20. Remove bolts (24)
from the housing assembly.
Illustration 16 g06019925 21. Use Tooling (B)
and a suitable lifting device to separate housing
(25) from housing assembly (26). The weight of
housing (25) and the components is 133 kg (295
lb). The weight of housing assembly (26) and the
components is approximately 68 kg (150 lb).
10
Illustration 17
g06019939

1. Turn over the housing.
2. Remove retaining ring (27) from stator carrier
   (18).

Illustration 18
g06019942
24. Remove stator (28).
Illustration 19 g06019971 25. Remove retaining
ring (29), plate (30), retaining ring (31),
retaining ring (33), and splined adapter (32).
11
Illustration 20 g06020015 26. Remove retaining
ring (34) from stator carrier (18).
Illustration 21 g06020016 27. Remove impeller
hub (35) and the adapter assembly as a unit.
Illustration 22 g06020020 28. Remove bearing,
(37), race (38), and retainer (36).
12
Illustration 23
g06020022

1. Remove bolts (40).
2. Remove hub (39) from impeller (41).

Illustration 24 g06020025 31. Remove race (42)
from the back of hub (39).
Illustration 25 g06020027 32. Lift impeller (41)
from clutch adapter assembly (43).
13
Illustration 26 g06020030 33. Remove dowel pins
(44), sleeve bearing (45) from clutch adapter
assembly (43).
Illustration 27 g06020032 34. Remove seal ring
(46) from stator carrier (18).
Illustration 28
g06020034
35. Remove clutch plate (47).
14
Illustration 29 g06020037 36. Remove clutch
discs and clutch plates (48).
Illustration 30
g06020041
37. Remove lockup clutch piston (49).

• Illustration 31 g06020050
• Remove bearing (51), race (52) , and retainer
  (50).
• Remove O-ring seals (53).

15
Illustration 32 g06020052 40. Use Tooling (B)
and a suitable lifting device to remove housing
(25) from stator carrier (18).
Illustration 33 g06020060 41. Remove bolts (54),
drive gear (55), and race (56) from housing (25).

• Illustration 34 g06020062
• Use Tooling (C) and a suitable press to remove
  stator carrier (18) from inner bearing (57).
• Remove O-ring seal (58).

16

• Illustration 35 g06020068
• Remove rings (60) from seal ring carrier (61).
• Note To prevent damage, do not remove seal ring
  carrier (61) if it is not necessary.
• Remove dowel pin (59) and seal ring carrier (61)
  from stator carrier (18).

Illustration 36 g06020069 46. Remove orifice
plug (62) from stator carrier (18).
17
Illustration 37 g06020151 47. Remove bearing
(64), race (65), and retainer (63) from the
housing assembly.
Illustration 38 g06020154 48. Remove converter
turbine assembly (66) from housing assembly (26).
Illustration 39
g06020160

1. Remove bolts (67).
2. Remove turbine hub (68) from converter turbine
   (69).
3. Remove the race from the back of turbine hub (68).

18
Illustration 40 g06020162 52. Remove converter
turbine (69) from clutch adapter (70).
Illustration 41 g06020166 53. Remove bearing
(72), race (73), and retainer (71) from the
housing assembly.

• Illustration 42 g06020168
• Remove retaining ring (74) from the housing
  assembly.
• Remove clutch plate (75) from the housing
  assembly.

19

• Illustration 43 g06020173
• Remove clutch discs and clutch plates (76).
• Remove sleeve bearing (77) from housing assembly
  (26).

• Illustration 44 g06020211
• Remove clutch piston (78) from housing assembly
  (26).
• Remove O-ring seals (79) from clutch piston (78).

20
Illustration 45
g06020183

1. Turn over housing assembly (26).
2. Put the housing assembly on suitable blocking.
3. Remove plugs (80).
4. Remove O-ring seal (81).
5. Remove bolts (82).
6. Remove cover (83).

21
Product WHEEL LOADER Model 990K WHEEL LOADER
DJK Configuration 990K Wheel Loader DJK00001-UP
(MACHINE) POWERED BY C27 Engine
Disassembly and Assembly 844K Wheel Dozer and
990K Wheel Loader Power Train Media Number
-UENR6577-01 Publication Date -01/07/2017
Date Updated -05/07/2017
i06552005
Torque Converter (Lockup) - Assemble SMCS -
3101-016-L7 Assembly Procedure Table 1
Required Tools Required Tools Required Tools Required Tools
Tool Part Number Part Description Qty
A 3E-3879 Eyebolt 1
B 138-7573 Link Bracket 2
C 1P-0520 Driver Group 1
E 1P-0808 Multipurpose Grease 1
Note Cleanliness is an important factor. Before
assembly, thoroughly all parts 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 oil to all the bearings before
assembly. 1. Check the condition of the O-ring
seals that are used in the torque converter and
torque converter housing. If any of the seals
are damaged, use new parts for replacement.
22

• Illustration 1 g06020183
• Install bolts (82) in cover (83). Tighten bolts
  (82) to a torque of 60 7 Nm (45 5 lb ft).
• Install O-ring seal (81).
• Install plugs (80) into housing assembly (26).
  Tighten plugs (80) to a torque of 50 5 Nm (37
  4 lb ft).

• Illustration 2 g06020211
• Turn over housing assembly (26). Place the
  housing assembly on suitable blocking.
• Install O-ring seals (79) to clutch piston (78).
• Install clutch piston (78) to housing assembly
  (26).

23

• Illustration 3 g06020173
• Install sleeve bearing (77) into housing assembly
  (26).
• Install clutch discs and clutch plates (76) in an
  alternating order.
• Note Start with a clutch disc and end with a
  clutch disc.

• Illustration 4 g06020168
• Install clutch plate (75) into the housing
  assembly.
• Install retaining ring (74) in the housing
  assembly.

24
Illustration 5 g06020166 12. Install bearing
(72), race (73), and retainer (71) in the housing
assembly.
Illustration 6 g06020162 13. Install the
converter turbine (69) on clutch adapter (70).

• Illustration 7 g06020160
• Install the race to the back of turbine hub (68).
• Install bolts (67) to install turbine hub (68) to
  converter turbine (69). Tighten bolts (67) to a
  torque of 105 15 Nm (80 10 lb ft).

25
Illustration 8 g06020154 16. Install converter
turbine assembly (66) into housing assembly (26).
Illustration 9 g06020151 17. Install bearing
(64), race (65), and retainer (63) into housing
assembly.
Illustration 10 g06020069 18. Install orifice
plug (62) into stator carrier (18).
26

• Illustration 11 g06020068
• Raise the temperature of seal ring carrier (61)
  to a maximum temperature of 135 C (275 F).
• Note Note the location of the two holes in the
  side of seal ring carrier (61). Make sure that
  one hole is aligned with the oil passage on
  stator carrier (18). Make sure that the remaining
  hole is in alignment with the hole that is
  provided for the installation of dowel pin (59).
• Failure to align the oil passages in seal ring
  carrier (61) and stator carrier (18) will result
  in failure of the components.
• Install seal ring carrier (61) onto stator
  carrier (18).
• Install dowel pin (59) into seal ring carrier
  (61).
• Install seal rings (60) to seal ring carrier (61).

• Illustration 12 g06020216
• Raise the temperature of inner bearing (57) to a
  maximum temperature of 135 C (275 F).
• Install inner bearing (57) onto stator carrier
  (18).

27
25. Install O-ring seal (58) on the stator
carrier.
Illustration 13
g06020060

1. Lower the temperature of race (56).
2. Install race (56) into housing (25).
3. Install drive gear (55) and bolts (54) into
   housing (25). Tighten bolts (54) to a torque of
   60 7 Nm (45 5 lb ft).

Illustration 14 g06020052 29. Use Tooling (B)
and a suitable lifting device to install housing
(25) onto stator carrier (18).
28
Illustration 15
g06020050

1. Install O-ring seals (53) to housing (25).
2. Install Remove bearing (51), race (52) , and
   retainer (50) onto the stator carrier.

Illustration 16
g06020041
32. Install lockup clutch piston (49).
Illustration 17 g06020037 33. Install clutch
discs and clutch plates (48) in an alternating
order. Note Start with a clutch disc and end
with a clutch disc.
29
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Illustration 18
g06020034
34. Install clutch plate (47).
Illustration 19 g06020032 35. Install seal ring
(46) onto stator carrier (18).
Illustration 20 g06020030 36. Install dowel pins
(44), sleeve bearing (45) to clutch adapter
assembly (43).
31
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friend! Thank you very much for reading. Enter
the link into your browser. The full manual is
available for immediate download. https//www.eb
ooklibonline.com