Caterpillar_Cat_980H_Wheel_Loader__Prefix_KZL__Service_Repair_Manual__KZL00001_and_up_.pdf

Transcript

1. Service Repair Manual Models 980H WHEEL LOADER
2. Shutdown SIS Previous Screen Product: WHEEL LOADER Model: 980H WHEEL LOADER KZL Configuration: 980H Wheel Loader KZL00001-UP (MACHINE) POWERED BY C15 Engine Disassembly and Assembly 980H Wheel Loader Power Train Media Number -RENR8667-08 Publication Date -01/09/2018 Date Updated -04/09/2018 i07522010 Output Transfer Gears - Assemble SMCS - 3075-016-OJ Assembly Procedure Table 1 Required Tools Tool Part Number Part Description Qty A 1P-0520 Driver Group 1 C 138-7575 Link Bracket 2 E 6V-6640 Sealant 1 F - Guide stud 1/2" - 13 by 2 in 2 G 7M-7260 Liquid Gasket 1 Illustration 1 g01108955
3. 1. Install bearing cup (47) and bearing cup (48) to the transfer case. Illustration 2 g01108951 2. Install two bearing cones (46) onto input gear (44). Illustration 3 g01108939 3. Install two bearing cones (45) onto idler gear (43). Illustration 4 g01108936 4. Install idler gear (43) into the transfer case. The weight of idler gear (43) is approximately 41 kg (90 lb).
4. 5. Install input gear (44). The weight of input gear (44) is approximately 34 kg (75 lb). Illustration 5 g01109391 6. Apply Tooling (E) to the machined surface of the transfer case. Illustration 6 g06247304 7. Install Tooling (C) to cover (41), as shown. Attach a suitable lifting device to Tooling (C). The weight of cover (41) is approximately 44 kg (97 lb). 8. Install cover (41) onto the transfer case. Illustration 7 g01109245
5. 9. Use Tooling (A) and a suitable press to install dowels (42). Illustration 8 g01108903 10. Install bolts (40) and the washers for cover (41). Illustration 9 g01109256 11. Install Tooling (F) into cover (41). Illustration 10 g01108790 12. Lower the temperature of bearing cup (31). Install bearing cup (31) into input bearing cage (28).
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7. Illustration 11 g01111373 Illustration 12 g01111376 13. Install only two of bolts (25) that will later be used to hold on the cover (26) (not shown). Install bearing cage (28). DO NOT add the shim pack at this time. Make sure that the bearing cage does not bind with the cover. 14. Install only two bolts (29) and the washers on input bearing cage (28). Bolts (29) must be separated by 180 degrees. Tighten the bolts finger tight until the input bearing cage contacts the cover. 15. Tighten two bolts (29) to a torque of 2.25 N·m (20 lb in). 16. Rotate the input gear for at least three revolutions to seat the bearings. 17. Tighten two bolts (29) to a torque of 4.5 N·m (40 lb in). 18. Rotate the input gear for at least three revolutions to seat the bearings. 19. Tighten two bolts (29) again to a torque of 4.5 N·m (40 lb in). 20. Use a tapered feeler gauge to measure the gap between input bearing cage (28) and the cover for the transfer case. Take the measurement next to each bolt (29) at the edge of input bearing cage (32).
8. 21. Average the two measurements from Step 20. Add 0.18 mm (.007 inch) to the average. This result is the required thickness of the shims. 22. End play should be 0.08 ± 0.03 mm (0.003 ± 0.001 inch). 23. Remove two bolts (29) and input bearing cage (28). Illustration 13 g01108788 24. Install shim pack (30). Illustration 14 g01109292 Illustration 15 g01108784
9. 25. Install input bearing cage (28). Remove Tooling (F). Install all of bolts (29) and the washers . Remove bolts (25). Tighten bolts (29) to a torque of 136 ± 20 N·m (100 ± 15 lb ft). Illustration 16 g01109317 26. Install Tooling (F). Illustration 17 g01108900 27. Lower the temperature of bearing cup (38). Install bearing cup (38) into idler bearing cage (35). 28. Install O-ring seal (39).
10. Illustration 18 g01109335 29. Install idler bearing cage (35). DO NOT add the shim pack at this time. Make sure that the idler bearing cage does not bind with the cover. 30. Install two bolts (36) and the washers on idler bearing cage (35). Bolts (36) must be separated by 180 degrees. Tighten the bolts finger tight until the idler bearing cage contacts the cover. 31. Tighten two bolts (36) to a torque of 2.25 N·m (20 lb in). 32. Rotate the idler gear for at least three revolutions to seat the bearings. 33. Tighten two bolts (36) to a torque of 4.5 N·m (40 lb in). 34. Rotate the idler gear for at least three revolutions to seat the bearings. 35. Tighten two bolts (36) again to a torque of 4.5 N·m (40 lb in). 36. Use a tapered feeler gauge to measure the gap between idler bearing cage (35) and cover (45). Take the measure next to each bolt (36) at the edge of idler bearing cage (35). 37. Average the two measurements from step 36. Add 0.18 mm (.007 inch) to the average. This result is the required thickness of the shims. 38. End play should be 0.08 ± 0.03 mm (0.003 ± 0.001 inch). 39. Remove two bolts (36) and idler bearing cage (35). Illustration 19 g01109344
11. Illustration 20 g01109397 40. Install the required number of shims (37). Install idler bearing cage (35). Remove Tooling (F). Install bolts (36). Tighten bolts (36) to a torque of 135 ± 20 N·m (100 ± 15 lb ft). Install O-ring seal (34). Illustration 21 g01109400 41. Install cover (33). Install nuts (32) and the washers.
12. Illustration 22 g01778734 42. Position rotor (26J). Install bearing (26H). Install retaining ring (26K). Illustration 23 g01771938 43. Position cage (26G). Install bolts (26F). Illustration 24 g01771836 44. Position cage assembly (26C). Install bolts (26B). Position speed sensor (26D). Install bolt (26B).
13. Illustration 25 g01771954 45. Install shaft (26A). Illustration 26 g01771754 46. Install cover assembly (26) with O-ring seal (27). Install bolts (25) and the washers.
14. Illustration 27 g01109417 47. Lower the temperature of bearing cup (23). Install bearing cup (23) into bearing cage (15). Illustration 28 g01109448 48. Install bearing cone (22) into bearing cage (15). Illustration 29 g01109466 49. Lower the temperature of other bearing cup (23). Install bearing cup (23) into bearing cage (15).
15. Illustration 30 g01108777 50. Install retainer (20), the washers, and six bolts (19) onto bearing cage (15). Install O-ring seal (21). 51. Tighten bolts (19) to a torque of 55 ± 10 N·m (40 ± 7 lb ft). Illustration 31 g01109473 52. Turn bearing cage (15) to the opposite side, as shown. Apply Tooling (G) in the seal bore of bearing cage (15). DO NOT put Tooling (G) on the seal case. Allow Tooling (G) to dry. 53. Use Tooling (A) to install lip seal (24) in bearing cage (15). Make sure that the sealing lip is facing toward the inside of bearing cage (15). Install the seal until the seal is flush with the face of the bearing cage..
16. Illustration 32 g01109483 54. Use the proper equipment to handle bearing (18). Raise the temperature of bearing (18) to a maximum temperature of 135°C (275°F). Install bearing (18) on transfer shaft (13). Illustration 33 g01109488 55. Place transfer shaft (13) on a wood block (not shown). Support transfer shaft (13) with two plates in a suitable press, as shown. Illustration 34 g01109494 56. Use two people to lower output gear (16) on transfer shaft (13). The weight of output gear (16) is approximately 26 kg (57 lb). 57. Install spacer (17) on transfer shaft (13).
17. Illustration 35 g01109496 58. Use Tooling (A) and a suitable press to install bearing cage (15) on transfer shaft (13). The weight of bearing cage (15) is approximately 33 kg (73 lb). Illustration 36 g01109498 59. Use a suitable lifting device to install bearing cage assembly (15) into the transfer case. Install bolts (14). The weight of bearing cage assembly is approximately 106 kg (235 lb). Illustration 37 g01108665
18. 60. Use a suitable lifting device to turn the transfer case assembly onto the other side. The weight of the transfer case assembly is approximately 525 kg (1160 lb). Install spacer (12) onto shaft (13). Illustration 38 g01108639 61. Install O-ring seal (11) onto bearing cage (8). Illustration 39 g01108635 62. Turn bearing cage (8) to the opposite side, as shown. Apply Tooling (G) in the seal bore of bearing cage (8). DO NOT put Tooling (G) on the seal case. Allow Tooling (G) to dry. 63. Use Tooling (A) to install lip seal (9) in bearing cage (8). Make sure that the sealing lip is facing toward the inside of bearing cage (8). Install the seal until the seal is flush with the face of the bearing cage.
19. Illustration 40 g01108630 64. Install bearing cage (8). Install bolts (7) and the washers for bearing cage (8). Tighten the bolts to a torque of 55 ± 10 N·m (40 ± 7 lb ft). Illustration 41 g01108628 65. Install yoke (6). Illustration 42 g01108617 66. Install O-ring seal (5).
20. Illustration 43 g01108605 67. Install bolt (3) and retainer (4) to the input side of the output transfer gear case. Tighten bolt (3) to a torque of 475 ± 60 N·m (350 ± 44 lb ft). Illustration 44 g01108586 68. Install hose assembly (2). Illustration 45 g01108584 69. Install speed sensors (1). Install the speed sensors until firm contact is made with the tooth of input gear. Unscrew the speed sensors for 1/2 ± 1/8 of a turn.
21. End By: a. Install the transmission from the output transfer gears. Refer to Disassembly and Assembly, "Transmission from Output Transfer Gears - Connect". Copyright 1993 - 2021 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees. Tue Mar 23 10:41:27 UTC+0800 2021
22. Shutdown SIS Previous Screen Product: WHEEL LOADER Model: 980H WHEEL LOADER KZL Configuration: 980H Wheel Loader KZL00001-UP (MACHINE) POWERED BY C15 Engine Disassembly and Assembly 980H Wheel Loader Power Train Media Number -RENR8667-08 Publication Date -01/09/2018 Date Updated -04/09/2018 i03565130 Transmission Planetary - Disassemble - Heavy Duty SMCS - 3160-015 Disassembly Procedure Table 1 Required Tools Tool Part Number Part Description Qty A 1P-2420 Transmission Repair Stand 1 B 138-7575 Link Bracket 3 C 1P-7407 Eyebolt 1 D FT-0833 Clamp 3 E 1P-1863 Retaining Ring Pliers 1 F 5P-5197 External Pliers 1 G 1P-0520 Driver Group 1 H 1P-0510 Drive Group 1 L 1P-0074 Slide Hammer Puller Gp 1 Start By: a. Separate the transmission and the output transfer gears. Refer to Disassembly and Assembly, "Transmission to Output Transfer Gears - Separate". Note: Cleanliness is an important factor. Before the disassembly procedure, the exterior of the component should be thoroughly cleaned. This will help to prevent dirt from entering the internal mechanism.
23. Illustration 1 g01915213 1. Place the transmission assembly onto Tooling (A). Illustration 2 g01915234 2. Disconnect tube assembly (1). Illustration 3 g01915255 3. Install Tooling (B) and a suitable lifting device to modulating valve assembly (2). The weight of modulating valve assembly (2) is approximately 43 kg (95 lb). 4. Remove bolts (3). Remove modulating valve assembly (2).
24. Illustration 4 g01915279 5. Remove tubes (4) and the O-ring seals. Illustration 5 g01915294 6. Attach Tooling (B) and a suitable lifting device to planetary group (5). The weight of planetary group (5) is approximately 565 kg (1250 lb). Remove planetary group (5) from transmission case (6). 7. Place planetary group (5) on suitable blocks. Note: Put alignment marks across the clutch housings for assembly purposes.
25. Illustration 6 g01886812 8. Remove bolts (7) and the washers. Illustration 7 g01886813 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. 9. Use Tooling (D) to secure the clutch piston in clutch housing (9). 10. Install Tooling (B) and a suitable lifting device on clutch housing (9). The weight of clutch housing (9) is approximately 32 kg (70 lb). 11. Carefully remove clutch housing (9) from manifold assembly. Remove springs (8).
26. Illustration 8 g01886814 12. Remove clutch piston (11) from clutch housing (9). Remove seals (10) from the piston. Illustration 9 g01886815 13. Remove friction discs (12), clutch plates (12), and dowels (14) from manifold assembly. Illustration 10 g01886816 14. Remove gear (15) from the carrier assembly. Illustration 11 g01886818
27. 15. Use Tooling (E) to remove retaining ring (16) from shaft assembly. Remove the spacer under the retaining ring. 16. Remove carrier assembly (17). Illustration 12 g01886819 17. Use a drift to bend locks (18) from bolts (19). Remove bolts (19), locks (18), and slinger (20) from carrier assembly. Illustration 13 g01886826 18. Remove spring pin (22) from the carrier and shaft (21). Remove spring pin (22) from shaft (21).
28. Illustration 14 g01886833 19. Remove thrust discs (23) and (27) and gear (25). 20. Remove bearings (24) and (26) from gear (25). 21. Repeat Steps 18 through 20 for the removal of the remaining planetary gears. Illustration 15 g01886835 22. Use Tooling (F) to remove retaining ring (29) from the housing assembly. 23. Remove gear (28). 24. Remove O-ring seal (30) from the manifold assembly. Illustration 16 g01886836 25. Remove bolts (31) that hold the manifold assembly to the clutch housing.
29. Illustration 17 g01886838 26. Attach Tooling (B) and a suitable lifting device to manifold assembly (32). The weight of manifold assembly (32) is approximately 72 kg (160 lb). 27. Carefully remove manifold assembly (32) from the clutch housing. Remove O-ring seals (33). Illustration 18 g01886839 28. Remove retaining ring (34) and bearing (35) from the manifold assembly. Illustration 19 g01886841
30. 29. Remove bolts (36) from the clutch housing. Illustration 20 g01886843 30. Use Tooling (D) to hold the piston in the clutch housing (37). Attach Tooling (B) and a suitable lifting device to the clutch housing (37). The weight of clutch housing (37) is approximately 25 kg (55 lb). 31. Carefully remove clutch housing (37). 32. Remove springs (38). Illustration 21 g01886845 33. Remove clutch piston (39) from the clutch housing.
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32. Illustration 22 g01886846 34. Remove seals (40) and (41) from the clutch piston. Illustration 23 g01886847 35. Remove friction discs (43), clutch plate (42) and dowels (44). Illustration 24 g01886848 36. Remove retaining ring (45) from the shaft assembly. 37. Attach Tooling (B) and a suitable lifting device to clutch housing assembly (46). The weight of clutch housing (46) is approximately 45 kg (100 lb). 38. Carefully remove clutch housing (46).
33. Illustration 25 g01886849 39. Remove seal rings (48) from the ring carrier (47). 40. Check the condition of the ring carrier (47). If ring carrier (47) is worn or damaged, use new parts for replacement. If the ring carrier is not worn or damaged, DO NOT remove ring carrier (47). Use a hammer and a chisel in order to break the ring carrier. Remove the ring carrier and pin (49) from housing assembly. Illustration 26 g01886850 41. Remove bolts (52) from the housing. 42. Remove ring gear (50) and gear (51).
34. Illustration 27 g01886852 43. Remove friction discs (53) and clutch plates (54) from the housing assembly. Illustration 28 g01886853 44. Remove reaction plate (56) from housing assembly (55). Illustration 29 g01886854 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. 45. Use Tooling (H) and a suitable press in order to put force on plate (57) until spiral lockring (58) can be removed. Release the force. Remove the plate and three springs (59) from the housing.
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