Caterpillar Cat 980G Wheel Loader (Prefix 2KR) Service Repair Manual (2KR00001 and up)

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Product: WHEEL LOADER

WHEEL

980G Wheel Loader 2KR00001-UP

Disassembly and Assembly

980G Wheel Loader Power Train

Number -SENR5877-07

Date -01/09/2004

Updated -23/09/2004

Torque Converter - Assemble - Heavy duty

-

Assembly Procedure

Required Tools

Part Number Part Description Qty

138-7573 Link Bracket

Dial Indicator Test Group 1

Gauge Tool Group

1P-0520 Driver Group 1

Note: Cleanliness is an important factor. Before assembly, all parts should be 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.

1. Use Tooling (C) to install sleeve bearing (59) in cover assembly (57). Sleeve bearing (59) must be even with the outside surface of cover assembly (57).

Install cover assembly (57) to rotating housing (39).

Install ring seal (58) to rotating housing (39).

Use Tooling (C) to install sleeve bearing (48) to carrier assembly (44). Bearing sleeve (48) must be even with the counterbore of carrier assembly (44).

Install retainer ring (47) in stator (46).

Position carrier assembly (44) on a wood

14. Use proper equipment to handle stator (46). Heat stator (46) to a maximum temperature of 121°C (250°F) for one hour.

15. Install stator (46) on carrier assembly (44).

16. Install snap ring (45) in stator (46).

17. Install stator (46) and carrier assembly (44) in rotating housing (39).

18. Install two thrust bearing races (43) and the thrust bearing to the carrier assembly.

Illustration 16

19. Position impeller hub (42) on a wood block.

20. Install converter impeller (41) on impeller hub (42).

17

21. Install drive flange (38) on converter impeller (41).

18

22. Install twelve bolts (40). Tighten the bolts to a torque of 80 ± 10 N·m (60 ± 7 lb ft).

23. Install drive flange (38) on rotating housing (39). The weight of drive flange (38) is 23 kg (51 lb).

24. Install 36 bolts (37) and the washers. Tighten the bolts to a torque of 30 ± 5 N·m (22 ± 4 lb ft).

25. Install retaining ring (36) in the groove of drive gear (35).

26. Use the proper equipment to handle outer bearing race (60). Lower the temperature of outer bearing race (60).

27. Install outer bearing race (60) in drive gear (35). Make sure that outer bearing race (60) makes contact with retaining ring (36).

28. Install drive gear (35) on drive flange (38).

29. Install twelve bolts (34) and the washers. Tighten the bolts to a torque of 50 ± 7 N·m (37 ± 5 lb ft).

Illustration 24

30. Use the proper equipment to handle inner bearing (33). Heat inner bearing (33) to a maximum temperature of 135°C (275°F). Install inner bearing (33) on bearing carrier (28).

25

31. Install retaining ring (32) in the groove of bearing carrier (28).

Illustration 26

32. Use the proper equipment to handle ring carrier (31). Heat ring carrier (31) to a maximum temperature of 135°C (275°F). Install ring carrier (31) on bearing carrier (28).

seal ring (30) on ring

O-ring

(29) on bearing

bearing carrier (28) in drive flange

retaining ring (27) in carrier assembly (44) in order to hold bearing carrier (28) in

Install two studs (26) in torque converter housing assembly (2). Tighten the studs to a torque of 100 ± 15 N·m (74 ± 11 lb ft).

Install retaining ring (24) in the groove of idler gear (15).

Use the proper equipment to handle bearing cup (25). Lower the temperature of bearing cup (25). Install bearing cup (25) in idler gear (15).

40. Flip idler gear (15) to the opposite side. Install bearing cup spacer (23) in idler gear (15). The notch in bearing cup spacer (23) must be aligned with retaining ring (24).

41. Use the proper equipment to handle bearing cup (22). Lower the temperature of bearing cup (22). Install bearing cup (22) in idler gear (15).

42. Install bearing cone (21), bearing cone spacer (20) and bearing cone (19) in idler gear (15).

47. Install bolt (14) that holds shaft assembly (18) in place in torque converter housing assembly (2). Tighten the bolt to a torque of 120 ± 20 N·m (90 ± 15 lb ft).

48. Use the proper equipment to handle bearing cones (12). Heat bearing cones to a maximum temperature of 135°C (275°F). Install a bearing cone (12) on each side of pump drive gear (11).

49. Use the proper equipment to handle bearing cup (13). Lower the temperature of bearing cup (13). Install bearing cup (13) in torque converter housing assembly (2).

50. Install pump drive gear (11) in torque converter housing assembly (2).

51. Use the proper equipment to handle bearing cup (8). Lower the temperature of bearing cup (8). Install bearing cup (8) in pump adapter (6).

Install shims (9) on pump adapter (6).

Apply clean hydraulic oil on O-ring seal (10). Install O-ring seal (10) on pump adapter (6).

54. Install two 3/8" - 16 NC guide pins (62) in torque converter housing assembly (2).

55. Install pump adapter (6) on torque converter housing assembly (2).

56. Install thirteen bolts (5) and the washers.

57. Use Tooling (B) to check bearing end play. The bearing end play must be 0.15 ± 0.05 mm (.006 ± .002 inch). Add or remove shims in order to get the correct bearing end play.

Note: If end play is less than 0.10 mm (.004 inch) add additional shims. If end play is greater than 0.20 mm (.008 inch) remove shims.

58. Apply clean hydraulic oil on O-ring seal (4). Install O-ring seal (4) on torque converter housing assembly (2).

59. Install two 1/2" - 13 NC guide pins (63) in the carrier assembly.

60. Install Tooling (A) to torque converter housing assembly (2), as shown. Attach a hoist and suitable lifting chains to Tooling (A). Use the hoist to carefully install torque converter housing assembly (2) on the torque converter.

61. Install eight bolts (1) and the washers to torque converter housing assembly (2). Tighten the bolts 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. Refer to Disassembly and Assembly, "Torque Converter to Transmission, Output Transfer GearsConnect" for the machine that is being serviced.

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1. Use a hoist and suitable lifting chains to carefully position the transmission and the output transfer gears on Tooling (A) and on wood blocks, as shown. The weight of the transmission and the transfer gears as a unit is 1160 kg (2560 lb).

Note: Check the condition of all O-ring seals and of all parts. If any components are worn or damaged, use new parts for replacement.

2. Check output shaft (20) for wear or damage. If necessary, replace output shaft (20)

3. Install output shaft (20) in torque converter (3)

4. Install O-ring seal (19) on torque converter (3). Apply clean power train oil on O-ring seal (19)

5. Use a hoist and suitable lifting chains to carefully install torque converter (3) to transmission (14). The weight of torque converter (3) is 240 kg (530 lb). Use the output shaft to align torque converter (3) with transmission (14) .

6. Install two brackets (17), eleven bolts (18) and the washers to torque converter (3) and transmission (14) .

10. Use a hoist and a suitable lifting sling to carefully install steering pump (7), transmission pump (8) and brake pump (9) to the torque converter. The weight of the three pumps as a unit is 80 kg (176 lb).

11. Install three bolts (13) and the washers.

12. Install hose assembly (12) and bolt (11) to torque converter (3) .

two

tube

as a

to transmission

Install four bolts (5) and the washers that secure tube assembly (6) to transmission magnetic screen (4)

16. Install relief valve (2) and three bolts (1) on torque converter (3) .

17. Fill the transmission with oil. For the correct procedure, refer to Operation and Maintenance Manual for the machine that is being serviced.

End By: Connect the engine to the torque converter, to the transmission and to the output transfer gears. Refer to Disassembly and Assembly, "Engine to Torque Converter, Transmission, Output Transfer Gears - Connect" for the machine that is being serviced.

Copyright 1993 - 2022 Caterpillar Inc. All Rights Reserved.

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Previous

980G

Disassembly and Assembly

Wheel Loader

Number

Separation Procedure

Date

Tools

Part Number Part Description Qty

Load Leveler

138-7574 Link Bracket

Stand

Tube

Pin

1U-9759 Stand

138-7574 Link Bracket

Start By:

Remove the engine, the torque converter, the transmission and the output transfer gears. Refer to Disassembly and Assembly, "Engine, Torque Converter, Transmission and Output Transfer Gears - Remove" for the machine that is being serviced.

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1. Remove two tube assemblies (1) as a unit from the engine and the output transfer gears.

2. Attach Tooling (A) to the engine and the output transfer gears, as shown. Attach a hoist and suitable lifting chains to Tooling (A) .

3. Use the hoist to carefully lower the engine, the torque converter, the transmission and the output transfer gears on Tooling (B), as shown.

Place two wood blocks (2) under the output transfer gears. The weight of the engine, torque converter, transmission and output transfer gears as a unit is 3630 kg (8000

Place Tooling (C) under the transmission,