Caterpillar Cat 990K Wheel Loader (Prefix M9P) Service Repair Manual Instant Download.pdf

Product: WHEEL LOADER
Model: 990K WHEEL LOADER M9P
Configuration: 990K Wheel Loader M9P00001-UP (MACHINE) POWERED BY C27 Engine
Disassembly and Assembly
990K Wheel Loader and 844K Wheel Dozer Machine Systems
Media Number -UENR6576-05 Publication Date -01/01/2018 Date Updated -26/01/2018
i07100617
Piston Pump (Brake, Steering) - Disassemble
SMCS - 5070
Disassembly Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A
437-3776 Fixture As. 1
1U-9127(1)
Adapter Plate 1
1U-5750 Engine Stand 1
B
1P-0510 Driver Gp 1
5P-8244 Hard Washer 2
C 8H-0663 Bearing Puller Gp 1
(1)
Part of the Hydraulic Test Bench Tooling.
Start By:
a. Remove the piston pump.
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990K Wheel Loader M9P00001-UP (MACHINE) POWERED BY C27 Engine(M008...
2021/8/23
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Illustration 1 g06224966
1. Secure pump body (1) to Tooling (A) or a suitable workbench.
2. Remove bolts (2) and valve assembly (3).
3. Remove gasket (4), plug (5), and the seal.
4. Remove plug (6) from valve assembly (3).
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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.
5. Remove O-ring seal (7) from plug (6).
6. Measure height of adjustment screw (8) from plug (6) for assembly purposes.
7. Remove nut (9).
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8. Remove plate (10) from plug (6).
9. Remove adjustment screw (8) in the direction shown.
10. Remove O-ring seal (12) and backup ring (11) from adjustment screw (8).
11. Remove O-ring seal (13) and coupler (14) from the piston pump.
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12. Remove bolts (15) and pump flange (16) from pump body (1).
13. Remove O-ring seal (17) and control plate (18) from pump flange (16).
14. Remove bearing cup (19) from pump flange (16).
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15. Remove bearing cone (20) from shaft assembly (21).
16. Remove shim (22) from shaft assembly (21).
17. Remove O-ring seal (23) from pump body (1).
18. Rotate pump body (1) and remove barrel assembly (24).
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19. Remove pistons (25), piston retainer (27), and guide (26) from barrel assembly (24).
20. Use Tooling (B), Tooling (C), and a suitable press to compress the barrel spring.
21. Remove retaining ring (28) from barrel assembly (24).
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22. Remove spring (31), spacer (30), and pins (29) from barrel assembly (24).
23. Remove plugs (33) and the O-ring seals from pump body (1).
24. Remove plug (32) and the O-ring seal.
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25. Remove plug (34) from pump body (1).
26. Remove swashplate (35) from pump body (1) by lifting from the side marked (X).
27. Remove shaft assembly (21) and spring (37) from pump body (1).
28. Remove screws (36) and bearings (38) from the pump body.
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29. Use Tooling (C) and a suitable press to remove bearing cone (39) from shaft assembly (21).
30. Remove retaining ring (40) and lip seal (41) from pump body (1).
31. Remove bearing cup (42) from pump body (1).
10/10
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i07100670
Piston Pump (Brake, Steering) - Assemble
SMCS - 5070
Assembly Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A
437-3776 Fixture As. 1
1U-9127(1)
Adapter Plate 1
1U-5750 Engine Stand 1
B
1P-0510 Driver Gp 1
5P-8244 Hard Washer 2
C 8H-0663 Bearing Puller Gp 1
D - Loctite 243 -
E 6V-2055 Grease 1
(1)
Part of the Hydraulic Test Bench Tooling.
Note: Lubricate all parts with clean hydraulic oil during assembly.
1/14
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1. Lower the temperature of bearing cup (42). Install bearing cup (42) into pump body (1).
2. Install lip seal (41) and retaining ring (40).
3. Raise the temperature of bearing cone (39). Install bearing cone (39) onto shaft assembly
(21). Make sure that the bearing cone is seated properly.
4. Refer to "Setting Bearing Preload" before continuing with assembly.
2/14
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5. Install bearings (38). Install new screws (36). Tighten screws (36) to a torque of
5 ± 0.5 N·m (44 ± 4 lb in).
Note: New screws (36) must have a threadlocker, if not apply Tooling (D) to the threads.
6. Install shaft assembly (21) and spring (37) into pump body (1).
7. Install swashplate (35) into pump body (1) by lowering the side marked (X) last.
Note: Caution must be used when you install the swashplate. Swashplate (35) must be
properly engaged onto the spring.
8. Install plug (34) into pump body (1).
3/14
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Improper assembly of parts that are spring loaded can cause bodily
injury.
To prevent possible injury, follow the established assembly procedure
and wear protective equipment.
9. Install plugs (33) and the O-ring seals into pump body (1).
10. Apply Tooling (D) onto the threads of plug (32). and the O-ring seal. Install plug (32) and
the O-ring seal.
11. Apply Tooling (E) onto pins (29). Install pins (29), spacer (30), and spring (31) into barrel
assembly (24).
4/14
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injury.
12. Use Tooling (B), Tooling (C), and a suitable press to compress the barrel spring.
13. Install retaining ring (28) into barrel assembly (24).
14. Ensure that pins (29) are at the same height, if not repeat Steps 11 through 13.
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15. Install guide (26), piston retainer (27), and pistons (25) into barrel assembly (24).
16. Rotate pump body (1) and install barrel assembly (24).
17. Install shim (22) onto shaft assembly (21).
18. Install O-ring seal (23) onto pump body (1).
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19. Install bearing cone (20) onto shaft assembly (21).
20. Lower the temperature of bearing cup (19). Install bearing cup (19) into pump flange (16).
21. Install O-ring seal (17) and control plate (18) onto pump flange (16).
7/14
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injury.
22. Install pump flange (16) and bolts (15) onto pump body (1). Tighten bolts (15) to a torque of
37 ± 3 N·m (327 ± 26 lb in).
23. Install O-ring seal (13) and coupler (14) onto the piston pump.
24. Install O-ring seal (12) and backup ring (11) onto adjustment screw (8).
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25. Install adjustment screw (8) in the direction shown.
26. Install plate (10) into plug (6).
27. Install nut (9).
28. Set adjustment screw (8) to the height from plug (6) before disassembly.
29. Install O-ring seal (7) onto plug (6).
9/14
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injury.
30. Install plug (6) into valve assembly (3).
31. Install gasket (4), plug (5), and the seal.
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32. Install valve assembly (3) and bolts (2). Tighten bolts (2) to a torque of 15.5 ± 1.5 N·m
(135 ± 10 lb in).
33. Remove pump body (1) from Tooling (A) or a suitable workbench.
End By:
a. Install the piston pump.
Setting Bearing Preload
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1. Set bearing preload before you install the rotating group. The bearing preload should be
0.00 to 0.05 mm (0.000 to 0.002 inch) .
Note: The bearing cup must be installed to check the bearing preload.
a. Do not install shim (10). Install bearing cone (7) onto shaft (8). Assemble the pump
without shim (10) to check the preload of bearing cone (7).
b. Install port block (2) on pump housing (1). Install bolts (3).
c. Install Tooling (D) onto the pump housing. Use the dial indicator to determine the end
play of shaft (8). Be sure that you move shaft (8) completely in both directions. Use
appropriate tools to move shaft (8).
d. The thickness of shim (10) found in Step 17 should equal the end play measurement
plus 0.0508 mm (0.00200 inch). For example, if the end play is 2.1590 mm
(0.08500 inch) then the shim thickness should be 2.2098 mm (0.08700 inch).
e. Record the measurement.
f. If necessary, grind the shim to the determined measurement.
2. Do not install shim (10). Install bearing cone (7) onto shaft (8). Assemble the pump without
shim (10) to check the preload of bearing cone (7).
3. Install port block (2) on pump housing (1). Install bolts (3).
4. Install Tooling (D) onto the pump housing. Use the dial indicator to determine the end play
of shaft (8). Be sure that you move shaft (8) completely in both directions. Use appropriate
tools to move shaft (8).
5. The thickness of shim (10) found in Step 17 should equal the end play measurement plus
0.0508 mm (0.00200 inch). For example, if the end play is 2.1590 mm (0.08500 inch) then
the shim thickness should be 2.2098 mm (0.08700 inch).
6. Record the measurement.
7. If necessary, grind the shim to the determined measurement.
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i06542606
Brake Accumulator - Remove and Install
SMCS - 4263-010
Removal Procedure
Start By:
a. Release the system pressure
Pressurized System!
Hydraulic accumulators contain gas and oil under high pressure. DO
NOT disconnect lines or disassemble any component of a pressurized
accumulator. All gas pre-charge must be removed from the accumulator
as instructed by the service manual before servicing or disposing of the
accumulator or any accumulator component.
Failure to follow the instructions and warnings could result in personal
injury or death.
Only use dry nitrogen gas to recharge accumulators. See your Cat
dealer for special equipment and detailed information for accumulator
service and charging.
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1. Remove cover (1).
2. Disconnect tube assemblies (2).
3. Use two people to remove brake accumulator (4). The weight of brake accumulator (4) is
approximately 30 kg (66 lb). Loosen clamps (3) and remove brake accumulator (4). Repeat
for the other brake accumulator (5).
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Installation Procedure
1. Install brake accumulators (4) and (5) in the reverse order of removal.
a. Tighten clamps (3) to a torque of 17 ± 2 N·m (151 ± 18 lb in).
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i06551968
Accumulator Charging Valve (Brake) - Remove and Install
SMCS - 4264-010
Removal Procedure
Start By:
a. Release the system pressure.
1. Remove cover (1).
1/2
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2. Remove the straps and disconnect harness assembly (2). Remove pressure sensor (3).
3. Disconnect tube assemblies (4).
4. Remove bolts (6) and brake accumulator charging valve (5).
Installation Procedure
1. Install brake accumulator charging valve (5) in the reverse order of removal.
a. Tighten pressure sensor (3) to a torque of 30 ± 3 N·m (266 ± 27 lb in).
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Caterpillar Cat 990K Wheel Loader (Prefix M9P) Service Repair Manual Instant Download.pdf

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