Caterpillar Cat 980K Wheel Loader (Prefix W7K) Service Repair Manual (W7K00001 and up).pdf

Service Repair Manual
Models
980K Wheel Loader

Shutdown SIS
Previous Screen
Product: WHEEL LOADER
Model: 980K WHEEL LOADER W7K
Configuration: 980K Wheel Loader W7K00001-UP (MACHINE) POWERED BY C13 Engine
Disassembly and Assembly
980K Wheel Loader Power Train
Media Number -KENR6447-03 Publication Date -01/08/2012 Date Updated -21/08/2012
i06838048
Torque Converter - Disassemble - Lock Up Clutch With
Freewheel Stator
SMCS - 3101-015
Disassembly Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 439-3938 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
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https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw...

F 6L-7283 Forcing Bolt
3/8 - 16 by 3 in
7
G 417-1324 Adjust Stand 1
Start By:
a. Separate the torque converter from the transmission and from the output transfer gears.
Illustration 1 g02712129
1. Use Tooling (A) and a suitable lifting device to position the torque converter onto Tooling
(G) and suitable blocking. The weight of the torque converter is approximately 260 kg
(573 lb). Support the torque converter, as shown.
2. Remove bolts (1).
3. Remove relief valve assembly (2A).
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4. Use Tooling (F) to loosen housing assembly (2) from the torque converter.
5. Use the suitable lifting device and Tooling (A) to remove torque converter housing
assembly (2). The weight of torque converter housing assembly (2) is approximately 144 kg
(317 lb).
6. Remove O-ring seal (3) from torque converter housing assembly (2).
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7. Remove bolts (4) from pump adapter (5) and torque converter housing assembly (2).
8. Use Tooling (F) to remove pump adapter (5) from torque converter housing assembly (2).
9. Use Tooling (B) to remove bearing cup (6). Remove bearing cup (6), O-ring seal (8), and
shims (7) from pump adapter (5). See illustration 14 for Tooling (C).
10. Remove pump drive gear (9) from torque converter housing assembly (2).
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11. Use Tooling (C) to remove bearing cones (10) from each side of pump drive gear (9).
Remove bearing cones (10).
12. Use Tooling (C) to remove bearing cup (11) from torque converter housing assembly (2).
See illustration 14 for Tooling (C).
13. Remove bolt (12) and the washer from torque converter housing assembly (2).
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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).
16. Remove O-ring seal (15) from shaft assembly (14).
17. Remove bearing cone (16), bearing cone spacer (17), and bearing cone (18) from idler gear
(13).
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18. Use Tooling (C) to remove bearing cup (19) from idler gear (13). Remove bearing cup (19).
19. Remove bearing cup spacer (20) from idler gear (13).
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20. Remove retaining ring (21) from idler gear (13).
21. Use Tooling (C) to remove bearing cup (22) from idler gear (13). Remove bearing cup (22).
22. Remove studs (23) from torque converter housing assembly (2).
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23. Remove bolts (24) and gear (25).
24. Use the driver group from Tooling (D) and a suitable press to remove race (25A) from gear
(25).
25. Use a suitable lifting device to reposition the torque converter, as shown. The weight of the
torque converter is approximately 122 kg (269 lb). Remove bolts (26).
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26. Use Tooling (F) to separate housing (27) from the torque converter.
27. Use two people to remove housing (27). The weight of housing (27) is approximately 26 kg
(57 lb). Remove housing (27), piston (28), and plate (30). Remove seals (29) from piston
(28).
28. Remove bushing (31) from housing (27).
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29. Remove plate (32), disk (33), races (34), and bearing (35).
Note: Note the orientation of the bearing and races for assembly purposes.
30. Remove bolts (36), coupling assembly (37), and plate (38).
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31. Use suitable blocking to support the bottom of shaft assembly (39). Remove retaining ring
(40) and plate (41). Shaft assembly (39) can be lowered to the work bench.
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32. Install two of bolts (36) and remove turbine (42).
33. Remove bolts (36) and remove hub (43) from turbine (42).
34. Remove race (44) and bearing (45).
Note: Note the orientation of the race and bearing for assembly purposes.
35. Remove stator assembly (46).
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36. Remove retaining ring (47), plate (48), freewheel springs (49), freewheel rollers (50), and
freewheel cam (51). Remove plate (52) and retaining ring (53) (not shown) from stator (46).
37. Attach Tooling (A) and a suitable lifting device to impeller (54). The weightof impeller (54)
is approximately 27 kg (60 lb).
38. Remove impeller (54) from shaft assembly (39).
39. Position impeller (54) onto suitable blocking, as shown.
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40. Remove retaining ring (56) and hub (55).
41. Remove seal ring (56).
42. Use Tooling (D) and a suitable press to remove bearing (57).
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43. Remove retaining ring (59) and carrier assembly (58) from impeller (54).
44. Remove bearing (60).
Note: Note the orientation of the bearing (60) for assembly purposes.
45. Remove bolts (61), hub (62), and adapter (63) from impeller (54).
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46. Remove seals (64).
Copyright 1993 - 2022 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Sun Feb 13 14:22:42 UTC+0800 2022
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Shutdown SIS
Previous Screen
Product: WHEEL LOADER
Model: 980K WHEEL LOADER W7K
Configuration: 980K Wheel Loader W7K00001-UP (MACHINE) POWERED BY C13 Engine
Disassembly and Assembly
980K Wheel Loader Power Train
Media Number -KENR6447-03 Publication Date -01/08/2012 Date Updated -21/08/2012
i06806533
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 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 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
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.
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1. Install adapter (63), hub (62), and bolts (61) onto impeller (54). Tighten bolts (61) to a
torque or 105 ± 14 N·m (77 ± 10 lb ft).
2. Install bearing (60).
3. Install carrier assembly (58) and retaining ring (59) onto impeller (54).
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4. Raise the temperature of bearing (57). Install bearing (57) onto hub (55).
5. Install retaining ring (56A) and seal ring (56).
6. Install hub (55) and retaining ring (56) onto impeller (54).
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7. Install seals (64).
8. Attach Tooling (A) and a suitable lifting device to impeller (54). The weightof impeller (54)
is approximately 27 kg (60 lb).
9. Position impeller (54) onto shaft assembly (39).
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Typical Example
10. Install retaining ring (53) (not shown) and plate (52) onto stator (46).
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).
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13. Install stator assembly (46).
14. Install bearing (45) race (44), and outer race (44A).
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),retaining ring (40), and ring seal (39A).
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18. Install springs (36A) and (36B) inside of springs (36). Install springs (36) in an alternating
pattern. An example would be to install a spring (36) with a spring (36A) inside. The next
one would be to install a spring (36) with a spring (36B) inside.
19. Install plate (38), coupling assembly (37), and bolts (36). Tighten bolts (36) to a torque of
60 ± 7 N·m (44 ± 5 lb ft).
Note: Plate (38) has an O-ring groove that is not used.
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20. Install disk (33), races (34), and bearing (35).
21. Lower the temperature of bushing (31). Install bushing (31) into housing (27).
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22. Install seals (29) onto piston (28). Install plate (30), piston (28), and housing (27).
Note: Plate (30) has an O-ring groove that is not used.
23. Tighten bolts (26). Tighten bolts (36) to a torque of 60 ± 7 N·m (44 ± 5 lb ft).
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24. 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).
25. Use a suitable lifting devise to reposition the torque converter, as shown. The weight of the
torque converter is approximately 1157 N (260 lb).
26. Install drive gear (25) and bolts (24). Tighten the bolts to a torque of 50 ± 7 N·m
(37 ± 5 lb ft).
27. Install studs (23) in torque converter housing assembly (2). Tighten the studs to a torque of
100 ± 15 N·m (74 ± 11 lb ft).
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28. Install retaining ring (21) in the groove of idler gear (13).
29. Use the proper equipment to handle bearing cup (22). Lower the temperature of bearing cup
(22). Install bearing cup (22) in idler gear (13).
30. 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).
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(19). Install bearing cup (19) in idler gear (13).
32. Install bearing cone (16), bearing cone spacer (17), and bearing cone (18) in idler gear (13).
33. Apply clean hydraulic oil on O-ring seal (15). Install O-ring seal (15) on shaft assembly
(14).
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34. Install Tooling (K) in shaft assembly (14).
35. Hold idler gear (13) in position in torque converter housing assembly (2). Install shaft
assembly (15).
36. Remove Tooling (K) from shaft assembly (14).
37. 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).
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38. 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).
(11). Install bearing cup (11) in torque converter housing assembly (2).
40. Install pump drive gear (9) in torque converter housing assembly (2).
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(6).
42. Apply clean hydraulic oil on O-ring seal (8).
43. Install bearing cup (6), O-ring seal (8), and shims (7) on pump adapter (5).
44. Install Tooling (J) in torque converter housing assembly (2).
45. Install pump adapter (5) on torque converter housing assembly (2).
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46. Install bolts (4) and the washers on pump adapter (5) and torque converter housing assembly
(2).
47. 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 additional shims. If end play is
greater than 0.20 mm (0.008 inch) remove shims.
48. If equipped apply clean hydraulic oil on O-ring seal (3). Install O-ring seal (3) on torque
converter housing assembly (2).
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49. Install relief valve assembly (2A).
50. Install Tooling (J) in the carrier assembly.
51. 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 is approximately 144 kg (317 lb). Install
the bearing flange (not shown), plate (not shown), and two of bolts (1).
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Caterpillar Cat 980K Wheel Loader (Prefix W7K) Service Repair Manual (W7K00001 and up).pdf

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