Caterpillar_Cat_980G_II_WHEEL_LOADER__Prefix_AYT__Service_Repair_Manual__AYT00001_and_up_.pdf

Transcript

1. Shutdown SIS Previous Screen Product: WHEEL LOADER Model: 980G II WHEEL LOADER AYT Configuration: 980G SERIES II WHEEL LOADER AYT00001-UP (MACHINE) POWERED BY 3406E Disassembly and Assembly 980G Series II Wheel Loader Power Train Media Number -RENR4378-05 Publication Date -01/01/2004 Date Updated -14/01/2004 i05903287 Torque Converter (Freewheel Stator) - Disassemble SMCS - 3101-015 Disassembly Procedure Table 1 Required Tools Tool Part Number Part Description Qty A 138-7573 Link Bracket 3 B 8B-7548 Push-Puller 1 8B-7550 Leg 2 8H-0684 Ratchet Wrench 1 8B-7560 Step Plate 1 8H-0663 Bearing Puller Attachment 1 C 8B-7548 Push-Puller 1 8H-0684 Ratchet Wrench 1 8B-7549 Leg 2 5P-4808 Cap 2 8B-7554 Bearing Cup Puller Attachment 1 D 5F-7343 Bearing Puller Attachment 1 1P-0520 Driver Group 1 E 1P-0510 Driver Group 1 F 7
2. Forcing Screw 3/8 - 16 x 3 in Start By: A. Separate the torque converter from the transmission and from the output transfer gears. Refer to Disassembly and Assembly, "Torque Converter from Transmission, Output Transfer Gears - Separate" for the machine that is being serviced. 1. Place the torque converter housing assembly (2) on wood blocks. Illustration 1 g00503225 2. Remove bolts (1) and the washers from torque converter housing assembly (2) . Illustration 2 g01111329 3. Install Tooling (A) to torque converter housing assembly (2) , as shown. Attach a suitable lifting device to Tooling (A) . The weight of housing assembly (2) is approximately 120 kg (265 lb). 4. Use Tooling (F) to loosen housing assembly (2) from the torque converter.
3. 5. Remove housing assembly (2) from the torque converter. Illustration 3 g00871317 6. Remove O-ring seal (3) from torque converter housing assembly (2) . Illustration 4 g00871318 7. Remove bolts (4) and the washers from pump adapter (5) and torque converter housing assembly (2) .
4. Illustration 5 g00871264 8. Use Tooling (F) to remove pump adapter (5) from torque converter housing assembly (2) . Illustration 6 g00871319 9. Use tooling (C) to remove bearing cup (6) , O-ring seal (8) , and shims (7) from pump adapter (5) . See illustration 13 for Tooling (C) . Illustration 7 g00871326
5. 10. Remove pump drive gear (9) from torque converter housing assembly (2) . Illustration 8 g00871451 11. Use Tooling (B) to remove bearing cones (10) from each side to pump drive gear (9) . Illustration 9 g00871333 12. Use Tooling (C) to remove bearing cup (11) from torque converter housing assembly (2) . See illustration 13 for Tooling (C) .
6. https://www.aservicemanualpdf.com/ My Dear Friend! Thank you very much for visiting. Full manual if required, please enter the following URL into your browser. https://www.aservicemanualpdf.com/
7. Illustration 10 g01112900 13. Remove bolt (12) and the washer from torque converter housing assembly (2) . 14. Use Tooling (F) to push shaft assembly (14) out of torque converter housing assembly (2) . 15. Remove idler gear (13) from torque converter housing assembly (2) . Illustration 11 g01112903 16. Remove O-ring seal (15) from shaft assembly (14) .
8. Illustration 12 g00871365 17. Remove bearing cone (16) , bearing cone spacer (17) , and bearing cone (18) from idler gear (13) . Illustration 13 g00871366 18. Use Tooling (C) to remove bearing cup (19) from idler gear (13) . Illustration 14 g00871367 19. Remove bearing cup spacer (20) from idler gear (13) .
9. Illustration 15 g00871368 20. Remove retaining ring (21) from idler gear (13) . Illustration 16 g00871369 21. Use Tooling (C) to remove bearing cups (22) from idler gear (13) .
10. Illustration 17 g00871370 22. Remove studs (23) from torque converter housing assembly (2) . Illustration 18 g00871267 23. Remove retaining ring (24) and bearing carrier (25) from the carrier assembly. Illustration 19 g01112906 24. Remove bearing carrier (25) .
11. Illustration 20 g00871269 25. Remove O-ring seal (26) from bearing carrier (25) . 26. Remove seal ring (27) from ring carrier (28) . Illustration 21 g00871273 27. Use Tooling (D) and a press to remove ring carrier (28) from bearing carrier (25) .
12. Illustration 22 g00871274 28. Remove retaining ring (29) from bearing carrier (25) . Illustration 23 g00871275 29. Use Tooling (D) and a press to remove inner bearing (30) from bearing carrier (25) . Illustration 24 g01112907 30. Remove bolts (31) and the washers from drive gear (32) . 31. Remove drive gear (32) .
13. Illustration 25 g01112910 32. Use Tooling (E) and a press to remove the outer bearing race (32A) (not shown) from drive gear (32) . Illustration 26 g00871278 33. Remove retaining ring (33) from drive gear (32) . Illustration 27 g00871279
14. 34. Remove bolts (34) and the washers from drive flange (35) and rotating housing (36) . Illustration 28 g00871281 35. Use bolts (34) as forcing screws to remove drive flange (35) from rotating housing (36) . The weight of drive flange (35) is 23 kg (51 lb). Illustration 29 g00871282 36. Remove bolts (37) from drive flange (35) .
15. Illustration 30 g00871283 37. Remove drive flange (35) from impeller (38) . Illustration 31 g00871284 38. Position impeller hub (39) on wood blocks. 39. Remove impeller (38) from impeller hub (39) . Illustration 32 g00870210
16. 40. Remove thrust bearing (40) and race (40A) (not shown) from carrier assembly (41) . Illustration 33 g00870211 41. Remove carrier assembly (41) and stator (42) as a unit from rotating housing (36) . Illustration 34 g00870212 42. Remove snap ring (43) from stator (42) . Remove plate (44) from stator (42) .
17. Illustration 35 g01112913 43. Remove 11 freewheel rollers (45) and 11 freewheel springs (46) from freewheel cam (47) . Remove stator (42) from carrier assembly (41) . Illustration 36 g01112915 44. Remove retaining ring (48) . Remove plate (49) . 45. Use Tooling (E) and a hydraulic press in order to remove freewheel cam (47) from stator (42) . Note: If necessary, heat the stator to a maximum temperature of 135 °C (275 °F) for approximately 15 minutes. Illustration 37 g01112917 46. Remove thrust bearing (50) from carrier assembly (41) . Remove sleeve bearing (51) from carrier assembly (41) .
18. Illustration 38 g01112919 47. Remove thrust bearing race (52) and the thrust bearing. Illustration 39 g00870286 48. Remove turbine (53) and turbine hub (54) as a unit from rotating housing (36) . Illustration 40 g01112920 49. Remove bolts (55) and the washers that hold turbine (53) to hub (54) .
19. Illustration 41 g00870755 50. Remove hub (54) from turbine (53) . Illustration 42 g00870288 51. Remove retaining ring (56) from turbine hub (54) .
20. Illustration 43 g01112924 52. Remove two races (57) and thrust bearing (58) . Illustration 44 g00870291 53. Remove bolts (59) and the washers from cover assembly (60) . 54. Remove cover assembly (60) from rotating housing (36) . 55. Remove ring seal (61) from rotating housing (36) . Illustration 45 g00870294 56. Remove sleeve bearing (62) from cover assembly (60) . Copyright 1993 - 2022 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees. Sat Feb 19 10:18:51 UTC+0800 2022
21. Shutdown SIS Previous Screen Product: WHEEL LOADER Model: 980G II WHEEL LOADER AYT Configuration: 980G SERIES II WHEEL LOADER AYT00001-UP (MACHINE) POWERED BY 3406E Disassembly and Assembly 980G Series II Wheel Loader Power Train Media Number -RENR4378-05 Publication Date -01/01/2004 Date Updated -14/01/2004 i05903427 Torque Converter (Freewheel Stator) - Assemble SMCS - 3101-016 Assembly Procedure Table 1 Required Tools Tool Part Number Part Description Qty A 138-7573 Link Bracket 3 G 8T-5096 Dial Indicator Test Group 1 5P-2390 Gauge Tool Group 1 H 1P-0520 Driver Group 1 J - Guide Pin (3/8 - 16 by 8 in) 2 K - Guide Pin (1/2 - 13 by 3 in) 3 L 2P-8312 Retaining Ring Pliers 1 Note: Cleanliness is an important factor. Before assembly, thoroughly cleaned 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 of the bearings before assembly.
22. Illustration 1 g01112937 1. Use Tooling (H) to install sleeve bearing (62) in cover assembly (60) . Sleeve bearing (62) must be even with the outside surface of cover assembly (60) . Illustration 2 g03337064 2. Install ring seal (61) to rotating housing (36) . 3. Install cover assembly (60) to rotating housing (36) . 4. Install bolts (59) and the washers to cover assembly (60) . Tighten the bolts to a torque of 30 ± 5 N·m (22 ± 4 lb ft).
23. Illustration 3 g00870744 5. Install races (57) and thrust bearing (58) to cover assembly (60) . Illustration 4 g00870748 6. Install retaining ring (56) in turbine hub (54) . Illustration 5 g00870755 7. Install turbine (53) on hub (54) .
24. Illustration 6 g00870757 8. Install bolts (55) and the washers to turbine (53) . Tighten the bolts to a torque of 50 ± 7 N·m (37 ± 5 lb ft). Illustration 7 g00870759 9. Install hub (54) and turbine (53) as a unit to rotating housing (36) .
25. Illustration 8 g00870760 10. Install thrust bearing race (52) and the bearing to the turbine hub (54) . Illustration 9 g01112941 11. Use Tooling (H) and a hydraulic press in order to install sleeve bearing (51) to carrier assembly (41) . Install thrust bearing (50) to carrier assembly (41) . Illustration 10 g01112915
26. Illustration 11 g01112913 12. Use Tooling (H) and a hydraulic press in order to install freewheel cam (47) to stator (42) . 13. Install plate (49) to stator (42) . Install retaining ring (48) to stator (42) . Note: If necessary, heat stator (42) to a maximum temperature of 135 °C (275 °F). Install the cam with the IMPELLER SIDE facing downward. Continue with the installation until freewheel cam (47) contacts the retaining ring (not shown). 14. Install stator (42) to carrier assembly (41) . Install freewheel springs (46) and freewheel rollers (45) to freewheel cam (47) . Always install new freewheel springs (46) and freewheel rollers (45) . Install freewheel springs (46) with the maximum number of loops in freewheel springs (46) to the outside of freewheel cam (47) . Use the orientation of stator (42) in Illustration 11 in reference to the following statement: Stator (42) should turn freely in the clockwise direction. Stator (42) should not turn freely in the counterclockwise direction. Illustration 12 g00870421 15. Install plate (44) to stator (42) . Install snap ring (43) to stator (42) .
27. Illustration 13 g00870422 16. Install carrier assembly (41) and stator (42) as a unit to rotating housing (36) . Illustration 14 g00870762 17. Install thrust bearing (40) and race (40A) (not shown) to the carrier assembly (41) . Illustration 15 g00870994 18. Position impeller hub (39) on a wood block.
28. 19. Install impeller (38) on impeller hub (39) . Illustration 16 g00870995 20. Install drive flange (35) on impeller (38) . Illustration 17 g00871000 21. Install bolts (37) on drive flange (35) . Tighten the bolts to a torque of 80 ± 10 N·m (60 ± 7 lb ft).
29. Illustration 18 g00871001 22. Install drive flange (35) on rotating housing (36) . The weight of drive flange (35) is approximately 23 kg (51 lb). 23. Install bolts (34) and the washers to drive flange (35) . Tighten the bolts to a torque of 30 ± 5 N·m (22 ± 4 lb ft). Illustration 19 g00871003 24. Install retaining ring (33) in the groove of drive gear (32) .
30. Illustration 20 g00870829 25. Use the proper equipment to handle outer bearing race (32A) . Lower the temperature of outer bearing race (32A) . 26. Install outer bearing race (32A) in drive gear (32) . Make sure that outer bearing race (32A) contact retaining ring (33) . Illustration 21 g00870763 27. Install drive gear (32) on drive flange (35) . 28. Install bolts (31) and the washers on drive gear (32) . Tighten the bolts to a torque of 50 ± 7 N·m (37 ± 5 lb ft). Illustration 22 g00871006 29. Use the proper equipment to handle inner bearing (30) . Heat inner bearing (30) to a maximum temperature of 135 °C (275 °F). Install inner bearing (30) on bearing carrier (25) .
31. Illustration 23 g00871007 30. Install retaining ring (29) in the groove of bearing carrier (25) . Illustration 24 g00871009 31. Use the proper equipment to handle ring carrier (28) . Heat ring carrier (28) to a maximum temperature of 135 °C (275 °F). Install ring carrier (28) on bearing carrier (25) . Illustration 25 g00871012
32. 32. Install seal ring (27) on ring carrier (28) . 33. Install O-ring seal (26) on bearing carrier (25) . Illustration 26 g00871014 34. Install bearing carrier (25) in drive flange (35) . Illustration 27 g00871015 35. Install retaining ring (24) and bearing carrier (25) on carrier assembly (28) .
33. Illustration 28 g00872709 36. Install studs (23) in torque converter housing assembly (2) . Tighten the studs to a torque of 100 ± 15 N·m (74 ± 11 lb ft). Illustration 29 g00872711 37. Install retaining ring (21) in the groove of idler gear (13) . Illustration 30 g00872713
34. 38. Use the proper equipment to handle bearing cup (22) . Lower the temperature of bearing cup (22) . Install bearing cup (22) in idler gear (13) . Illustration 31 g00872715 39. Flip idler gear (13) to the opposite side. Install bearing cup spacer (20) in idler gear (13) . The notch in bearing cup spacer (20) must be aligned with retaining ring (21) . Illustration 32 g00872716 40. Use the proper equipment to handle bearing cup (19) . Lower the temperature of bearing cup (19) . Install bearing cup (19) in idler gear (13) .
35. Please write to us. Our email: aservicemanualpdf@yahoo.com Please go to the homepage to get the full manual, or other brand PDF manuals. Home Site: aservicemanualpdf.com
36. Thank you very much for your reading. Please Click Here. Then Get COMPLETE MANUAL. NO WAITING NOTE: If there is no response to click on the link above, please download the PDF document first and then click on it.
37. Illustration 33 g00872718 41. Install bearing cone (16) , bearing cone spacer (17) , and bearing cone (18) in idler gear (13) . Illustration 34 g01112903 42. Apply clean hydraulic oil on O-ring seal (15) . Install O-ring seal (15) on shaft assembly (14) . Illustration 35 g01112954
38. 43. Install Tooling (K) in shaft assembly (14) . 44. Hold idler gear (13) in position in torque converter housing assembly (2) . Install shaft assembly (15) . 45. Remove Tooling (K) from shaft assembly (14) . Illustration 36 g01112970 46. Install bolt (12) that holds shaft assembly (14) in place in torque converter housing assembly (2) . Tighten the bolt to a torque of 120 ± 20 N·m (90 ± 15 lb ft). Illustration 37 g00872724 47. Use the proper equipment to handle bearing cones (10) . Heat bearing cones to a maximum temperature of 135 °C (275 °F). Install a bearing cone (10) on each side of pump drive gear (9) .
39. Illustration 38 g00872801 48. Use the proper equipment to handle bearing cup (11) . Lower the temperature of bearing cup (11) . Install bearing cup (11) in torque converter housing assembly (2) . Illustration 39 g00872727 49. Install pump drive gear (9) in torque converter housing assembly (2) . Illustration 40 g00872729
40. https://www.aservicemanualpdf.com/ My Dear Friend! Thank you very much for visiting. Full manual if required, please enter the following URL into your browser. https://www.aservicemanualpdf.com/