Caterpillar Cat 980M Wheel Loader (Prefix WW3) Service Repair Manual (WW300001 and up).pdf

Service Repair Manual
Models
980M Wheel Loader

Shutdown SIS
Previous Screen
Product: WHEEL LOADER
Model: 980M WHEEL LOADER WW3
Configuration: 980M Wheel Loader WW300001-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
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980M Wheel Loader WW300001-UP (MACHINE) POWERED BY C13 Engine(M00...
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https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis...

Illustration 1 g02752296
1. Install seals (64).
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).
3. Install bearing (60).
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4. Install carrier assembly (58) and retaining ring (59) onto impeller (54).
5. Raise the temperature of bearing (57). Install bearing (57) onto hub (55).
6. Install seal ring (56).
3/17
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7. Install hub (55) and retaining ring (56) onto impeller (54).
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).
10. Install retaining ring (53) (not shown) and plate (52) onto stator (46).
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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).
13. Install stator assembly (46).
14. Install bearing (45) and race (44).
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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).
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).
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19. Install plate (32), disk (33), races (34), and bearing (35).
20. Lower the temperature of bushing (31). Install bushing (31) into housing (27).
7/17
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21. Install seals (29) onto piston (28). Install plate (30), piston (28), and housing (27).
22. Install bolts (26). Tighten bolts (26) to a torque of 60 ± 7 N·m (44 ± 5 lb ft).
8/17
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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).
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).
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).
9/17
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27. Install retaining ring (21) in the groove of idler gear (13).
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).
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).
10/17
980M Wheel Loader WW300001-UP (MACHINE) POWERED BY C13 Engine(M...
2021/3/14

(19). Install bearing cup (19) in idler gear (13).
31. Install bearing cone (16), bearing cone spacer (17), and bearing cone (18) in idler gear (13).
32. Apply clean hydraulic oil on O-ring seal (15). Install O-ring seal (15) on shaft assembly
(14).
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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).
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).
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).
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(11). Install bearing cup (11) in torque converter housing assembly (2).
39. Install pump drive gear (9) in torque converter housing assembly (2).
(6).
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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).
43. Install Tooling (J) in torque converter housing assembly (2).
44. Install pump adapter (5) on torque converter housing assembly (2).
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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.
47. Apply clean hydraulic oil on O-ring seal (3). Install O-ring seal (3) on torque converter
housing assembly (2).
48. Install relief valve assembly (2A).
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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).
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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.
Sun Mar 14 18:33:43 UTC+0800 2021
17/17
2021/3/14

Shutdown SIS
Previous Screen
i06838249
Transmission from Output Transfer Gears - Separate
SMCS - 3002-076
Separation Procedure
Table 1
Required Tools
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.
1/4
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Note: Typical example
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).
2/4
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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.
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6. Remove housing (4).
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).
8. Place transmission (12) on Tooling (D).
Copyright 1993 - 2021 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Sun Mar 14 18:34:40 UTC+0800 2021
4/4
2021/3/14

Shutdown SIS
Previous Screen
i06839284
Output Transfer Gears - Disassemble
SMCS - 3075-015-OJ
Disassembly Procedure
Table 1
Required Tools
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.
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1. Remove speed sensors (1).
2. Remove hose assembly (2).
3. Remove bolt (3) and retainer (4) from the input side of the output transfer gear case.
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4. Remove O-ring seal (5).
5. Remove yoke (6).
6. Remove bolts (7) and the washers from bearing cage (8).
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7. Use Tooling (D) to remove bearing cage (8). Remove bearing cage (8).
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).
9. Remove O-ring seal (11) from bearing cage (8).
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10. Remove spacer (12) from transfer shaft (13).
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).
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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.
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).
16. Remove spacer (17) from output gear (16).
6/16
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17. Use Tooling (B) to remove bearing (18) from transfer shaft (13). Remove bearing (18).
18. Remove O-ring seal (21), bolts (19), the washers, and retainer (20) from bearing cage (15).
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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).
21. Mark bolts (25) for installation purposes. Remove nine bolts (25) and the washers.
22. Remove cover assembly (26) and O-ring seal (27).
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23. Remove shaft (26A).
24. Remove bolt (26E). Remove the speed sensor and O-ring seal (26D). Remove bolts (26B).
Remove cage assembly (26C).
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Caterpillar Cat 980M Wheel Loader (Prefix WW3) Service Repair Manual (WW300001 and up).pdf

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Caterpillar Cat 980M Wheel Loader (Prefix WW3) Service Repair Manual (WW300001 and up).pdf