Caterpillar Cat 990K Wheel Loader (Prefix K9X) Service Repair Manual Instant Download.pdf

Service Repair Manual
Models
990K Wheel Loader

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Product: WHEEL LOADER
Model: 990K WHEEL LOADER K9X
Configuration: 990K Wheel Loader K9X00001-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
i06541228
Transmission Planetary - Disassemble
SMCS - 3160-015
Disassembly Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 1P-2420 Transmission Repair Stand 1
B 439-3940 Link Bracket 2
C 439-3938 Link Bracket 2
D 1P-1863 Retaining Ring Pliers 1
E 1P-0520 Driver Gp 1
F FT-0833 Clamp 2
G 1P-1861 Retaining Ring Pliers 1
H 6L-7283 Bolt 3
J 5B-4274 Forcing Bolt 2
Start by:
Separate the Transmission from Input Transfer Gears and Output Transfer Gears.
Remove the Relief Valve (Transmission Hydraulic Control).
Note: Put orientation and location marks for installation purposes.
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990K Wheel Loader K9X00001-UP (MACHINE) POWERED BY C27 Engine(M008...
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Note: When the transmission is disassembled, keep the clutch plates and the clutch discs in the
original sequence.
Illustration 1 g06014463
1. Position the transmission onto Tooling (A), as shown. The weight of the transmission is
approximately 1100 kg (2425 lb).
2. Attach Tooling (B) and a suitable lifting device to transmission case assembly (1).
3. Remove bolts (2).
4. Use Tooling (J) to separate transmission case assembly (1) from the housing assembly. Use
Tooling (B) and a suitable lifting device to remove transmission case assembly (1). The
weight of transmission case assembly (4) is approximately 210 kg (463 lb). Remove
transmission case assembly (1).
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5. Remove bolts (3) and pilot plate (4).
6. Position suitable cribbing under the shaft assembly to prevent the shaft assembly from
dropping out of the transmission.
Personal injury can result from being struck by parts propelled by a
released spring force.
Make sure to wear all necessary protective equipment.
Follow the recommended procedure and use all recommended tooling to
release the spring force.
7. Remove retaining ring (6) and bolts (5).
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8. Use Tooling (B) and a suitable lifting device to remove end plate (7). The weight of end
plate (7) is approximately 59 kg (130 lb).
9. Remove bearing (8).
10. Remove springs (9) and pins (10).
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11. Remove clutch discs (11) and clutch plates (12).
12. Remove retaining ring (14) from input shaft (13).
13. Use Tooling (C) and a suitable lifting device to remove carrier assembly (15) and coupling
gear (16) as a unit. The combined weight of carrier assembly (15) and of coupling gear (16)
is approximately 68 kg (150 lb).
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Typical example
14. Compress retaining ring (17) (not shown) to separate coupling gear (16) from carrier
assembly (15).
15. Remove retaining ring (18) and bearing (19).
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16. Remove dowel (21), if necessary. Use a suitable punch to push spring pin (20) inside shaft
(22). Remove shaft (22) out of carrier assembly (15).
17. Remove thrust discs (23), roller bearing assemblies (24), and planetary gear (25).
18. Repeat Steps 16 and 17 to remove the remaining planetary gears in carrier assembly (15).
19. Remove pin (26) and ring carrier (27) from shaft (13).
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20. Remove metal seal rings (28).
21. Remove sun gear (29).
22. Remove seal ring (30) from sun gear (29).
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23. Attach Tooling (B) and a suitable lifting device to clutch housing (32). Use Tooling (B) and
the suitable lifting device to remove clutch piston (31) and clutch housing (32) as a unit.
The combined weight of clutch piston (31) and clutch housing (32) is approximately 77 kg
(170 lb). Remove clutch piston (31) and clutch housing (32).
24. Remove clutch piston (31) and dowels (33).
25. Remove seal rings (34) from clutch piston (31).
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26. Remove pins (35), springs (37), clutch discs (36), and clutch plates (38).
27. Remove bolts (39), locks (40), and bearing cage (41).
28. Remove sun gear assembly (42) from bearing cage (41).
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Note: Replace sun gear assembly (42) if dowel (43) is worn or damaged.
29. Remove dowel (43) from gear assembly (42).
Typical example
30. Remove retaining ring (44) from bearing cage (41).
31. Place bearing cage (41) on a suitable cribbing. Use Tooling (E) to remove bearing (45).
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32. Remove coupling gear (46).
33. Remove retaining ring (47) from coupling gear (60).
34. Remove ring gear (48).
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a suitable lifting device to remove clutch piston (50) and clutch housing (49) as a unit. The
combined weight of clutch piston (50) and clutch housing (49) is approximately 75 kg
36. Remove clutch piston (50) from clutch housing (49).
37. Remove seal rings (51) and (52) from clutch piston (50).
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38. Remove pins (53), springs (54), clutch discs (55), and clutch plates (56).
39. Use Tooling (C) and a suitable lifting device to remove planetary carrier (57). The weight of
planetary carrier (57) is approximately 50 kg (110 lb). Remove planetary carrier (57).
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40. Use a suitable punch to push spring pin (58) inside planetary shaft (59). Remove shaft (59)
out of planetary carrier (57). Remove spring pin (58).
41. Remove thrust discs (60), planetary gears (61), and bearing assemblies (62).
42. Repeat Steps 40 and 41 for the remaining planetary gears.
43. Remove bolts (63), locks (64), lock plates (65), and ring gear (66).
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a suitable lifting device remove clutch piston (67) and clutch housing (68) as a unit. The
combined weight of clutch piston (67) and clutch housing (68) is approximately 75 kg
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47. Remove dowels (71) from clutch housing (68).
48. Use two people to remove input shaft (13). The weight of input shaft (13) is approximately
32 kg (70 lb).
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49. Remove dowel (73), ring (72), and ring seal (74) from input shaft (13).
50. Remove springs (75), clutch discs (76), and clutch plates (77).
51. Remove ring gear (78).
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the suitable lifting device to remove clutch piston (79) and clutch housing (80) as a unit.
The combined weight of clutch piston (79) and clutch housing (80) is approximately 67 kg
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55. Remove retaining ring (83) from the bottom of the transmission.
56. Use Tooling (C), and a suitable lifting device to remove planetary carrier assembly (84).
The weight of planetary carrier assembly (84) is approximately 170 kg (375 lb).
57. Turn over carrier assembly (84). Position carrier assembly (84) on a suitable cribbing.
Remove bolts (85).
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58. Use Tooling (F) to hold clutch piston (87) in clutch housing (86).
59. Use Tooling (C) to remove clutch housing (86) and clutch piston (87). The combined
weight of clutch housing (86) and clutch piston (87) is approximately 55 kg (121 lb).
Remove clutch housing (86) and clutch piston (87).
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62. Remove plugs (90), O-ring seals (91), and dowels (92) from clutch housing (86).
63. Turn over clutch housing (86). Remove spring pin (94) and dowel (93) from clutch housing
(86).
64. Remove seal rings (96) from ring (95). Remove ring (95) from clutch housing (86).
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65. Remove pins (97), springs (99), and pins (98).
66. Remove clutch discs (100) and clutch plates (101).
67. Turn over the planetary carrier assembly.
68. Use Tooling (D) to remove retaining ring (102). Remove retaining ring (102) and sun gear
(109).
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69. Remove metal ring seal (104) from sun gear (103).
70. Use Tooling (C) and a suitable lifting device to remove planetary carrier assembly (84). The
weight of planetary carrier assembly (84) is approximately 52 kg (115 lb). Remove
planetary carrier assembly (84).
71. Remove sun gear (106) from output shaft (105).
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72. Remove hub (107) from output shaft (105). The weight of hub (107) is approximately 20 kg
(45 lb).
73. Remove dowel (109). Remove bearing sleeve (108) from each end of output shaft (105).
The weight of output shaft (105) is approximately 27 kg (60 lb).
74. Use Tooling (G) to remove retaining ring (110) from planetary carrier assembly (84).
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75. Use Tooling (E) to remove bearing (111).
76. Drive spring pin (112) into shaft (113).
77. Remove shaft (113), thrust discs (114), planetary gear (115), roller bearing (116), and spring
pin (112).
78. Repeat Steps 76 and 77 for the remaining planetary gears (115).
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79. Remove O-ring seals (118), (119), and (120) from support housing assembly (117).
80. Remove dowels (121) from support housing assembly (117).
81. Turn over support housing assembly (117). Remove bolts (122) from bearing cage (123).
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Caterpillar Cat 990K Wheel Loader (Prefix K9X) Service Repair Manual Instant Download.pdf

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