Caterpillar_Cat_980M_Wheel_Loader__Prefix_MK2__Service_Repair_Manual__MK200001_and_up_.pdf

Transcript

1. Service Repair Manual Models 980M Wheel Loader
2. Shutdown SIS Previous Screen Product: WHEEL LOADER Model: 980M WHEEL LOADER MK2 Configuration: 980M Wheel Loader MK200001-UP (MACHINE) POWERED BY C13 Engine Disassembly and Assembly 980M T4 and 982M T4 Wheel Loader Power Train Media Number -M0075587-02 Publication Date -01/08/2012 Date Updated -17/07/2018 i06838485 Torque Converter - Assemble - Lock Up Clutch with Freewheel Stator SMCS - 3101-016 Assembly Procedure Table 1 Required Tools Tool Part Number Part Description Qty A 439-3938 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 Stud (3/8 - 16 by 8 in) 2 K - Guide Stud (1/2 - 13 by 3 in) 3 L 2P-8312 Retaining Ring Pliers 1
3. Illustration 1 g02752296 1. Install seals (64). Illustration 2 g02735387 2. Install adapter (63), hub (62), and bolts (61) onto impeller (54). Tighten bolts (61) to a torque of 105 ± 14 N·m (77 ± 10 lb ft). Illustration 3 g02735380 3. Install bearing (60).
4. Illustration 4 g02735374 4. Install carrier assembly (58) and retaining ring (59) onto impeller (54). Illustration 5 g02744677 5. Raise the temperature of bearing (57). Install bearing (57) onto hub (55). 6. Install seal ring (56). Illustration 6 g02734776
5. Illustration 7 g02735333 7. Install hub (55) and retaining ring (56) onto impeller (54). Illustration 8 g02732255 8. Attach Tooling (A) and a suitable lifting device to impeller (54). The weight of impeller (54) is approximately 27 kg (60 lb). 9. Position impeller (54) onto shaft assembly (39). Illustration 9 g02731806 10. Install retaining ring (53) (not shown) and plate (52) onto stator (46).
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7. 11. Install freewheel cam (51), freewheel rollers (50), and springs (49). Note: Springs (49) must be installed with the maximum number or loops to the outside. 12. Install plate (48) and retaining ring (47). Illustration 10 g02731802 Illustration 11 g02731732 13. Install stator assembly (46). 14. Install bearing (45) and race (44).
8. Illustration 12 g02744699 Illustration 13 g02731651 15. Install hub (43) and turbine (42). 16. Use two of bolts (36) to align the holes. 17. Use suitable blocking to support the bottom of shaft assembly (39). Install plate (41) and retaining ring (40). Illustration 14 g02731644 18. Install plate (38), coupling assembly (37), and bolts (36). Tighten bolts (36) to a torque of 60 ± 7 N·m (44 ± 5 lb ft).
9. Illustration 15 g02731623 19. Install plate (32), disk (33), races (34), and bearing (35). Illustration 16 g02731059 20. Lower the temperature of bushing (31). Install bushing (31) into housing (27).
10. Illustration 17 g02730689 21. Install seals (29) onto piston (28). Install plate (30), piston (28), and housing (27). Illustration 18 g02730012 22. Install bolts (26). Tighten bolts (26) to a torque of 60 ± 7 N·m (44 ± 5 lb ft). Illustration 19 g02735357
11. 23. Lower the temperature of race (25A). If necessary, use the driver group from Tooling (D) and a suitable press to install race (25A) into gear (25). Illustration 20 g02729366 24. Use a suitable lifting device to reposition the torque converter, as shown. The weight of the torque converter is approximately 122 kg (269 lb). 25. Install drive gear (25) and bolts (24). Tighten the bolts to a torque of 50 ± 7 N·m (37 ± 5 lb ft). Illustration 21 g00872709 26. Install studs (23) in torque converter housing assembly (2). Tighten the studs to a torque of 100 ± 15 N·m (74 ± 11 lb ft).
12. Illustration 22 g00872711 27. Install retaining ring (21) in the groove of idler gear (13). Illustration 23 g00872713 28. 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 24 g00872715 29. 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).
13. Illustration 25 g00872716 30. Use the proper equipment to handle bearing cup (19). Lower the temperature of bearing cup (19). Install bearing cup (19) in idler gear (13). Illustration 26 g00872718 31. Install bearing cone (16), bearing cone spacer (17), and bearing cone (18) in idler gear (13). Illustration 27 g01112903 32. Apply clean hydraulic oil on O-ring seal (15). Install O-ring seal (15) on shaft assembly (14).
14. Illustration 28 g01112954 33. Install Tooling (K) in shaft assembly (14). 34. Hold idler gear (13) in position in torque converter housing assembly (2). Install shaft assembly (14). 35. Remove Tooling (K) from shaft assembly (14). Illustration 29 g01112970 36. Install bolt (12) that holds shaft assembly (14) in place in torque converter housing assembly (2). Tighten bolt (12) to a torque of 120 ± 20 N·m (90 ± 15 lb ft). Illustration 30 g00872724 37. Use the proper equipment to handle bearing cones (10). Heat bearing cones to a maximum temperature of 135 °C (275 °F). Install bearing cone (10) on each side of pump drive gear (9).
15. Illustration 31 g00872801 38. 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 32 g00872727 39. Install pump drive gear (9) in torque converter housing assembly (2). Illustration 33 g00872729 40. Use the proper equipment to handle bearing cup (6). Lower the temperature of bearing cup (6).
16. Illustration 34 g00871319 41. Apply clean hydraulic oil on O-ring seal (8). 42. Install bearing cup (6), O-ring seal (8), and shims (7) on pump adapter (5). Illustration 35 g01112978 43. Install Tooling (J) in torque converter housing assembly (2). 44. Install pump adapter (5) on torque converter housing assembly (2). Illustration 36 g01112982
17. 45. Install bolts (4) and the washers on pump adapter (5) and torque converter housing assembly (2). 46. Use Tooling (G) to check bearing end play. The bearing end play must be 0.15 ± 0.05 mm (0.006 ± 0.002 inch). Add or remove shims to get the correct bearing end play. Note: If end play is less than 0.10 mm (0.004 inch) add extra shims. If end play is greater than 0.20 mm (0.008 inch) remove shims. Illustration 37 g00872732 47. Apply clean hydraulic oil on O-ring seal (3). Install O-ring seal (3) on torque converter housing assembly (2). Illustration 38 g02730506 48. Install relief valve assembly (2A).
18. Illustration 39 g02752336 Illustration 40 g02752337 49. Install Tooling (J) in the carrier assembly. 50. Use Tooling (A) and a suitable lifting devise to position torque converter housing assembly (2) to position torque converter housing assembly (2) on the torque converter, as shown. The weight of torque converter housing assembly (2) is approximately 144 kg (317 lb). Install two bolts (1). Illustration 41 g00503225
19. 51. Install remaining bolts (1) for torque converter housing assembly (2). Tighten bolts (1) to a torque of 120 ± 20 N·m (90 ± 15 lb ft). End By: a. Connect the torque converter to the transmission and to the output transfer gears. Copyright 1993 - 2021 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees. Tue Mar 16 11:29:10 UTC+0800 2021
20. Shutdown SIS Previous Screen Product: WHEEL LOADER Model: 980M WHEEL LOADER MK2 Configuration: 980M Wheel Loader MK200001-UP (MACHINE) POWERED BY C13 Engine Disassembly and Assembly 980M T4 and 982M T4 Wheel Loader Power Train Media Number -M0075587-02 Publication Date -01/08/2012 Date Updated -17/07/2018 i06838249 Transmission from Output Transfer Gears - Separate SMCS - 3002-076 Separation Procedure Table 1 Required Tools Tool Part Number Part Description Qty A 1U-9200 Lever Puller Hoist 1 B 439-3940 Link Bracket 1 C 395-1094 Link Bracket 3 D 1P-2420 Transmission Repair Stand 1 Start By: a. Separate the torque converter from the transmission.
21. Illustration 1 g01105945 Note: Typical example Illustration 2 g03662427 1. Use Tooling (A), Tooling (B), and a suitable lifting device to reposition the transmission and output transfer gears (1) onto suitable cribbing. The weight of the transmission and output transfer gears (1) is approximately 1406 kg (3100 lb). 2. Disconnect harness assembly (2). Disconnect tube assembly (3).
22. Illustration 3 g03728546 Illustration 4 g06136933 Illustration 5 g06136941 3. Attach Tooling (C) and a suitable lifting device to housing (4). The weight of housing (4) is approximately 108 kg (240 lb). Remove all bolts (5). 4. Remove three bolts (7). 5. Remove bolts (6) and solenoid (9). Remove sleeve (8). Remove and inspect O-rings (10) and (11). Repeat for remaining solenoids and sleeves.
23. 6. Remove housing (4). Illustration 6 g06136944 7. Remove bolts (14) from manifold (13). Attach Tooling (C) and a suitable lifting device to transmission (12). The weight of transmission (12) is approximately 450 kg (992 lb). Illustration 7 g06136950 8. Place transmission (12) on Tooling (D). Copyright 1993 - 2021 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees. Tue Mar 16 11:30:06 UTC+0800 2021
24. Shutdown SIS Previous Screen Product: WHEEL LOADER Model: 980M WHEEL LOADER MK2 Configuration: 980M Wheel Loader MK200001-UP (MACHINE) POWERED BY C13 Engine Disassembly and Assembly 980M T4 and 982M T4 Wheel Loader Power Train Media Number -M0075587-02 Publication Date -01/08/2012 Date Updated -17/07/2018 i06839284 Output Transfer Gears - Disassemble SMCS - 3075-015-OJ Disassembly Procedure Table 1 Required Tools Tool Part Number Part Description Qty A 1P-0520 Driver Group 1 B 8B-7548 Push-puller 1 8B-7551 Bearing Puller Assembly 1 9S-9154 Step Plate 1 C 439-3940 Link Bracket 2 D 6L-7283 Bolt 2 Start By: a. Remove the transmission from the output transfer gears.
25. Illustration 1 g01108584 1. Remove speed sensors (1). Illustration 2 g01108586 2. Remove hose assembly (2). Illustration 3 g01108605 3. Remove bolt (3) and retainer (4) from the input side of the output transfer gear case.
26. Illustration 4 g01108617 4. Remove O-ring seal (5). Illustration 5 g01108628 5. Remove yoke (6). Illustration 6 g01108630 6. Remove bolts (7) and the washers from bearing cage (8).
27. Illustration 7 g01108631 7. Use Tooling (D) to remove bearing cage (8). Remove bearing cage (8). Illustration 8 g01108635 8. Use Tooling (A) (not shown) to remove lip seal (9) and outer bearing race (10) from bearing cage (8). Remove lip seal (9) and outer bearing race (10). Illustration 9 g01108639 9. Remove O-ring seal (11) from bearing cage (8).
28. Illustration 10 g01108665 10. Remove spacer (12) from transfer shaft (13). Illustration 11 g01108680 11. Position the transfer case with the output side upward, as shown. The weight of the output transfer gear group is 545 kg (1202 lb). 12. Mark bolts (14) for installation purposes. Remove bolts (14) and the washers from bearing cage (15). 13. Use Tooling (D) to loosen bearing cage (15) from the transfer case. Remove bearing cage (15).
29. Illustration 12 g01108700 14. Place bearing cage (15) in a suitable press, as shown. Press transfer shaft (13) out of bearing cage (15). The weight of transfer shaft (13) is approximately 27 kg (60 lb). Note: Place a suitable block (not shown) under transfer shaft (13) to prevent transfer shaft (13) from falling to the ground. Illustration 13 g01108710 15. Use two people to remove bearing cage (15) from output gear (16). The weight of bearing cage (15) is approximately 33 kg (73 lb). Remove bearing cage (15). Illustration 14 g01108772 16. Remove spacer (17) from output gear (16).
30. Illustration 15 g01108776 17. Use Tooling (B) to remove bearing (18) from transfer shaft (13). Remove bearing (18). Illustration 16 g01108777 18. Remove O-ring seal (21), bolts (19), the washers, and retainer (20) from bearing cage (15). Illustration 17 g01108778
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32. Illustration 18 g01108779 19. Use Tooling (A) and a suitable press to remove two bearing cones (22) and two bearing cups (23) from bearing cage (15). Remove two bearing cones (22) and two bearing cups (23). 20. Remove lip seal (24) from bearing cage (15). Illustration 19 g01771754 21. Mark bolts (25) for installation purposes. Remove nine bolts (25) and the washers. 22. Remove cover assembly (26) and O-ring seal (27).
33. Illustration 20 g01771954 23. Remove shaft (26A). Illustration 21 g01771836 24. Remove bolt (26E). Remove the speed sensor and O-ring seal (26D). Remove bolts (26B). Remove cage assembly (26C).
34. Illustration 22 g06137100 25. Remove bolts (26F). Remove cage (26G). Illustration 23 g01778734 26. Remove retaining ring (26K). Remove bearing (26H). Remove rotor (26J). Illustration 24 g01108784
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