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

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
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.
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https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis...

Illustration 1 g06019861
1. Remove bolts (2).
2. Remove housing (1) from housing assembly (3).
3. Remove O-ring seals (4) from housing (1).
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4. Remove O-ring seal (5), sleeve (6), and O-ring seal (7) from housing assembly (3).
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6. Use Tooling (D) to separate housing assembly (3).
7. 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).
8. Remove dowel pins (9).
9. Remove bolt (10), retainer (12), and yoke (11).
10. Remove O-ring seal (13) from yoke (11).
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12. Remove the gasket and retainer (15).
13. Remove lip seal (15) from retainer (16).
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14. Remove O-ring seal (17) from stator carrier (18).
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).
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16. Use a suitable press to push shaft (19) out of bearing (20).
17. Remove rings (22) from carrier (21).
18. Use a suitable press to push shaft (19) out of carrier (21).
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19. Remove ring (23) from shaft (19).
20. Remove bolts (24) from the housing assembly.
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).
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22. Turn over the housing.
23. Remove retaining ring (27) from stator carrier (18).
24. Remove stator (28).
25. Remove retaining ring (29), plate (30), retaining ring (31), retaining ring (33), and splined
adapter (32).
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26. Remove retaining ring (34) from stator carrier (18).
27. Remove impeller hub (35) and the adapter assembly as a unit.
28. Remove bearing, (37), race (38), and retainer (36).
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30. Remove hub (39) from impeller (41).
31. Remove race (42) from the back of hub (39).
32. Lift impeller (41) from clutch adapter assembly (43).
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33. Remove dowel pins (44), sleeve bearing (45) from clutch adapter assembly (43).
34. Remove seal ring (46) from stator carrier (18).
35. Remove clutch plate (47).
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36. Remove clutch discs and clutch plates (48).
37. Remove lockup clutch piston (49).
38. Remove bearing (51), race (52) , and retainer (50).
39. Remove O-ring seals (53).
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40. Use Tooling (B) and a suitable lifting device to remove housing (25) from stator carrier
(18).
41. Remove bolts (54), drive gear (55), and race (56) from housing (25).
42. Use Tooling (C) and a suitable press to remove stator carrier (18) from inner bearing (57).
43. Remove O-ring seal (58).
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44. Remove rings (60) from seal ring carrier (61).
Note: To prevent damage, do not remove seal ring carrier (61) if it is not necessary.
45. Remove dowel pin (59) and seal ring carrier (61) from stator carrier (18).
46. Remove orifice plug (62) from stator carrier (18).
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47. Remove bearing (64), race (65), and retainer (63) from the housing assembly.
48. Remove converter turbine assembly (66) from housing assembly (26).
50. Remove turbine hub (68) from converter turbine (69).
51. Remove the race from the back of turbine hub (68).
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52. Remove converter turbine (69) from clutch adapter (70).
53. Remove bearing (72), race (73), and retainer (71) from the housing assembly.
54. Remove retaining ring (74) from the housing assembly.
55. Remove clutch plate (75) from the housing assembly.
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56. Remove clutch discs and clutch plates (76).
57. Remove sleeve bearing (77) from housing assembly (26).
58. Remove clutch piston (78) from housing assembly (26).
59. Remove O-ring seals (79) from clutch piston (78).
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60. Turn over housing assembly (26).
61. Put the housing assembly on suitable blocking.
62. Remove plugs (80).
63. Remove O-ring seal (81).
65. Remove cover (83).
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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
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.
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2. Install bolts (82) in cover (83). Tighten bolts (82) to a torque of 60 ± 7 N·m (45 ± 5 lb ft).
3. Install O-ring seal (81).
4. Install plugs (80) into housing assembly (26). Tighten plugs (80) to a torque of 50 ± 5 N·m
(37 ±4 lb ft).
5. Turn over housing assembly (26). Place the housing assembly on suitable blocking.
6. Install O-ring seals (79) to clutch piston (78).
7. Install clutch piston (78) to housing assembly (26).
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8. Install sleeve bearing (77) into housing assembly (26).
9. Install clutch discs and clutch plates (76) in an alternating order.
Note: Start with a clutch disc and end with a clutch disc.
10. Install clutch plate (75) into the housing assembly.
11. Install retaining ring (74) in the housing assembly.
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12. Install bearing (72), race (73), and retainer (71) in the housing assembly.
13. Install the converter turbine (69) on clutch adapter (70).
14. Install the race to the back of turbine hub (68).
15. Install bolts (67) to install turbine hub (68) to converter turbine (69). Tighten bolts (67) to a
torque of 105 ± 15 N·m (80 ± 10 lb ft).
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16. Install converter turbine assembly (66) into housing assembly (26).
17. Install bearing (64), race (65), and retainer (63) into housing assembly.
18. Install orifice plug (62) into stator carrier (18).
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19. 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.
20. Install seal ring carrier (61) onto stator carrier (18).
21. Install dowel pin (59) into seal ring carrier (61).
22. Install seal rings (60) to seal ring carrier (61).
23. Raise the temperature of inner bearing (57) to a maximum temperature of 135 °C (275 °F).
24. Install inner bearing (57) onto stator carrier (18).
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25. Install O-ring seal (58) on the stator carrier.
26. Lower the temperature of race (56).
27. Install race (56) into housing (25).
28. Install drive gear (55) and bolts (54) into housing (25). Tighten bolts (54) to a torque of
60 ± 7 N·m (45 ± 5 lb ft).
29. Use Tooling (B) and a suitable lifting device to install housing (25) onto stator carrier (18).
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30. Install O-ring seals (53) to housing (25).
31. Install Remove bearing (51), race (52) , and retainer (50) onto the stator carrier.
32. Install lockup clutch piston (49).
33. Install clutch discs and clutch plates (48) in an alternating order.
Note: Start with a clutch disc and end with a clutch disc.
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Suggest:
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Please download this document
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34. Install clutch plate (47).
35. Install seal ring (46) onto stator carrier (18).
36. Install dowel pins (44), sleeve bearing (45) to clutch adapter assembly (43).
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Caterpillar Cat 990K Wheel Loader (Prefix DJK) Service Repair Manual Instant Download.pdf

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