Caterpillar Cat 980G II WHEEL LOADER (Prefix AYT) Service Repair Manual (AYT00001 and up).pdf

Shutdown SIS
Previous Screen
Product: WHEEL LOADER
Model: 980G II WHEEL LOADER AYT
Configuration: 980G SERIES II WHEEL LOADER AYT00001-UP (MACHINE) POWERED BY 3406E
Disassembly and Assembly
980G Series II Wheel Loader Power Train
Media Number -RENR4378-05 Publication Date -01/01/2004 Date Updated -14/01/2004
i05903287
Torque Converter (Freewheel Stator) - Disassemble
SMCS - 3101-015
Disassembly Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 138-7573 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
F 7
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Forcing Screw
3/8 - 16 x 3 in
Start By:
A. Separate the torque converter from the transmission and from the output transfer gears.
Refer to Disassembly and Assembly, "Torque Converter from Transmission, Output
Transfer Gears - Separate" for the machine that is being serviced.
1. Place the torque converter housing assembly (2) on wood blocks.
Illustration 1 g00503225
2. Remove bolts (1) and the washers from torque converter housing assembly (2) .
3. Install Tooling (A) to torque converter housing assembly (2) , as shown. Attach a suitable
lifting device to Tooling (A) . The weight of housing assembly (2) is approximately 120 kg
(265 lb).
4. Use Tooling (F) to loosen housing assembly (2) from the torque converter.
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5. Remove housing assembly (2) from the torque converter.
6. Remove O-ring seal (3) from torque converter housing assembly (2) .
7. Remove bolts (4) and the washers from pump adapter (5) and torque converter housing
assembly (2) .
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8. Use Tooling (F) to remove pump adapter (5) from torque converter housing assembly (2) .
9. Use tooling (C) to remove bearing cup (6) , O-ring seal (8) , and shims (7) from pump
adapter (5) . See illustration 13 for Tooling (C) .
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10. Remove pump drive gear (9) from torque converter housing assembly (2) .
11. Use Tooling (B) to remove bearing cones (10) from each side to pump drive gear (9) .
12. Use Tooling (C) to remove bearing cup (11) from torque converter housing assembly (2) .
See illustration 13 for Tooling (C) .
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13. Remove bolt (12) and the washer from torque converter housing assembly (2) .
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) .
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17. Remove bearing cone (16) , bearing cone spacer (17) , and bearing cone (18) from idler gear
(13) .
18. Use Tooling (C) to remove bearing cup (19) from idler gear (13) .
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 cups (22) from idler gear (13) .
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22. Remove studs (23) from torque converter housing assembly (2) .
23. Remove retaining ring (24) and bearing carrier (25) from the carrier assembly.
24. Remove bearing carrier (25) .
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25. Remove O-ring seal (26) from bearing carrier (25) .
26. Remove seal ring (27) from ring carrier (28) .
27. Use Tooling (D) and a press to remove ring carrier (28) from bearing carrier (25) .
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28. Remove retaining ring (29) from bearing carrier (25) .
29. Use Tooling (D) and a press to remove inner bearing (30) from bearing carrier (25) .
30. Remove bolts (31) and the washers from drive gear (32) .
31. Remove drive gear (32) .
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32. Use Tooling (E) and a press to remove the outer bearing race (32A) (not shown) from drive
gear (32) .
33. Remove retaining ring (33) from drive gear (32) .
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34. Remove bolts (34) and the washers from drive flange (35) and rotating housing (36) .
35. Use bolts (34) as forcing screws to remove drive flange (35) from rotating housing (36) .
The weight of drive flange (35) is 23 kg (51 lb).
36. Remove bolts (37) from drive flange (35) .
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37. Remove drive flange (35) from impeller (38) .
38. Position impeller hub (39) on wood blocks.
39. Remove impeller (38) from impeller hub (39) .
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40. Remove thrust bearing (40) and race (40A) (not shown) from carrier assembly (41) .
41. Remove carrier assembly (41) and stator (42) as a unit from rotating housing (36) .
42. Remove snap ring (43) from stator (42) . Remove plate (44) from stator (42) .
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43. Remove 11 freewheel rollers (45) and 11 freewheel springs (46) from freewheel cam (47) .
Remove stator (42) from carrier assembly (41) .
44. Remove retaining ring (48) . Remove plate (49) .
45. Use Tooling (E) and a hydraulic press in order to remove freewheel cam (47) from stator
(42) .
Note: If necessary, heat the stator to a maximum temperature of 135 °C (275 °F) for
approximately 15 minutes.
46. Remove thrust bearing (50) from carrier assembly (41) . Remove sleeve bearing (51) from
carrier assembly (41) .
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47. Remove thrust bearing race (52) and the thrust bearing.
48. Remove turbine (53) and turbine hub (54) as a unit from rotating housing (36) .
49. Remove bolts (55) and the washers that hold turbine (53) to hub (54) .
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50. Remove hub (54) from turbine (53) .
51. Remove retaining ring (56) from turbine hub (54) .
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52. Remove two races (57) and thrust bearing (58) .
53. Remove bolts (59) and the washers from cover assembly (60) .
54. Remove cover assembly (60) from rotating housing (36) .
55. Remove ring seal (61) from rotating housing (36) .
56. Remove sleeve bearing (62) from cover assembly (60) .
Copyright 1993 - 2022 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Sat Feb 19 10:18:51 UTC+0800 2022
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Shutdown SIS
Previous Screen
Product: WHEEL LOADER
Model: 980G II WHEEL LOADER AYT
Configuration: 980G SERIES II WHEEL LOADER AYT00001-UP (MACHINE) POWERED BY 3406E
Disassembly and Assembly
980G Series II Wheel Loader Power Train
Media Number -RENR4378-05 Publication Date -01/01/2004 Date Updated -14/01/2004
i05903427
Torque Converter (Freewheel Stator) - Assemble
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 Pin
(3/8 - 16 by 8 in)
2
K -
Guide Pin
(1/2 - 13 by 3 in)
3
L 2P-8312 Retaining Ring Pliers 1
Note: Cleanliness is an important factor. Before assembly, 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. Use Tooling (H) to install sleeve bearing (62) in cover assembly (60) . Sleeve bearing (62)
must be even with the outside surface of cover assembly (60) .
2. Install ring seal (61) to rotating housing (36) .
3. Install cover assembly (60) to rotating housing (36) .
4. Install bolts (59) and the washers to cover assembly (60) . Tighten the bolts to a torque of 30
± 5 N·m (22 ± 4 lb ft).
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5. Install races (57) and thrust bearing (58) to cover assembly (60) .
6. Install retaining ring (56) in turbine hub (54) .
7. Install turbine (53) on hub (54) .
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8. Install bolts (55) and the washers to turbine (53) . Tighten the bolts to a torque of 50 ± 7
N·m (37 ± 5 lb ft).
9. Install hub (54) and turbine (53) as a unit to rotating housing (36) .
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10. Install thrust bearing race (52) and the bearing to the turbine hub (54) .
11. Use Tooling (H) and a hydraulic press in order to install sleeve bearing (51) to carrier
assembly (41) . Install thrust bearing (50) to carrier assembly (41) .
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12. Use Tooling (H) and a hydraulic press in order to install freewheel cam (47) to stator (42) .
13. Install plate (49) to stator (42) . Install retaining ring (48) to stator (42) .
Note: If necessary, heat stator (42) to a maximum temperature of 135 °C (275 °F). Install
the cam with the IMPELLER SIDE facing downward. Continue with the installation until
freewheel cam (47) contacts the retaining ring (not shown).
14. Install stator (42) to carrier assembly (41) . Install freewheel springs (46) and freewheel
rollers (45) to freewheel cam (47) . Always install new freewheel springs (46) and
freewheel rollers (45) . Install freewheel springs (46) with the maximum number of loops in
freewheel springs (46) to the outside of freewheel cam (47) . Use the orientation of stator
(42) in Illustration 11 in reference to the following statement: Stator (42) should turn freely
in the clockwise direction. Stator (42) should not turn freely in the counterclockwise
direction.
15. Install plate (44) to stator (42) . Install snap ring (43) to stator (42) .
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16. Install carrier assembly (41) and stator (42) as a unit to rotating housing (36) .
17. Install thrust bearing (40) and race (40A) (not shown) to the carrier assembly (41) .
18. Position impeller hub (39) on a wood block.
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19. Install impeller (38) on impeller hub (39) .
20. Install drive flange (35) on impeller (38) .
21. Install bolts (37) on drive flange (35) . Tighten the bolts to a torque of 80 ± 10 N·m (60 ± 7
lb ft).
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22. Install drive flange (35) on rotating housing (36) . The weight of drive flange (35) is
approximately 23 kg (51 lb).
23. Install bolts (34) and the washers to drive flange (35) . Tighten the bolts to a torque of 30 ±
5 N·m (22 ± 4 lb ft).
24. Install retaining ring (33) in the groove of drive gear (32) .
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25. Use the proper equipment to handle outer bearing race (32A) . Lower the temperature of
outer bearing race (32A) .
26. Install outer bearing race (32A) in drive gear (32) . Make sure that outer bearing race (32A)
contact retaining ring (33) .
27. Install drive gear (32) on drive flange (35) .
28. Install bolts (31) and the washers on drive gear (32) . Tighten the bolts to a torque of 50 ± 7
N·m (37 ± 5 lb ft).
29. Use the proper equipment to handle inner bearing (30) . Heat inner bearing (30) to a
maximum temperature of 135 °C (275 °F). Install inner bearing (30) on bearing carrier
(25) .
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30. Install retaining ring (29) in the groove of bearing carrier (25) .
31. Use the proper equipment to handle ring carrier (28) . Heat ring carrier (28) to a maximum
temperature of 135 °C (275 °F). Install ring carrier (28) on bearing carrier (25) .
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32. Install seal ring (27) on ring carrier (28) .
33. Install O-ring seal (26) on bearing carrier (25) .
34. Install bearing carrier (25) in drive flange (35) .
35. Install retaining ring (24) and bearing carrier (25) on carrier assembly (28) .
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36. Install studs (23) in torque converter housing assembly (2) . Tighten the studs to a torque of
100 ± 15 N·m (74 ± 11 lb ft).
37. Install retaining ring (21) in the groove of idler gear (13) .
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38. Use the proper equipment to handle bearing cup (22) . Lower the temperature of bearing cup
(22) . Install bearing cup (22) in idler gear (13) .
39. 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) .
(19) . Install bearing cup (19) in idler gear (13) .
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41. Install bearing cone (16) , bearing cone spacer (17) , and bearing cone (18) in idler gear
(13) .
42. Apply clean hydraulic oil on O-ring seal (15) . Install O-ring seal (15) on shaft assembly
(14) .
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43. Install Tooling (K) in shaft assembly (14) .
44. Hold idler gear (13) in position in torque converter housing assembly (2) . Install shaft
assembly (15) .
45. Remove Tooling (K) from shaft assembly (14) .
46. 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).
47. 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) .
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(11) . Install bearing cup (11) in torque converter housing assembly (2) .
49. Install pump drive gear (9) in torque converter housing assembly (2) .
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