Caterpillar Cat 980H Wheel Loader (Prefix KZL) Service Repair Manual (KZL00001 and up).pdf

Service Repair Manual
Models
980H WHEEL LOADER

Shutdown SIS
Previous Screen
Product: WHEEL LOADER
Model: 980H WHEEL LOADER KZL
Configuration: 980H Wheel Loader KZL00001-UP (MACHINE) POWERED BY C15 Engine
Disassembly and Assembly
980H Wheel Loader Power Train
Media Number -RENR8667-08 Publication Date -01/09/2018 Date Updated -04/09/2018
i07522010
Output Transfer Gears - Assemble
SMCS - 3075-016-OJ
Assembly Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 1P-0520 Driver Group 1
C 138-7575 Link Bracket 2
E 6V-6640 Sealant 1
F -
Guide stud
1/2" - 13 by 2 in
2
G 7M-7260 Liquid Gasket 1
Illustration 1 g01108955
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980H Wheel Loader KZL00001-UP (MACHINE) POWERED BY C15 Engine(SEBP...
2021/3/23
https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis...

1. Install bearing cup (47) and bearing cup (48) to the transfer case.
2. Install two bearing cones (46) onto input gear (44).
3. Install two bearing cones (45) onto idler gear (43).
4. Install idler gear (43) into the transfer case. The weight of idler gear (43) is approximately
41 kg (90 lb).
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5. Install input gear (44). The weight of input gear (44) is approximately 34 kg (75 lb).
6. Apply Tooling (E) to the machined surface of the transfer case.
7. Install Tooling (C) to cover (41), as shown. Attach a suitable lifting device to Tooling (C).
The weight of cover (41) is approximately 44 kg (97 lb).
8. Install cover (41) onto the transfer case.
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9. Use Tooling (A) and a suitable press to install dowels (42).
10. Install bolts (40) and the washers for cover (41).
11. Install Tooling (F) into cover (41).
12. Lower the temperature of bearing cup (31). Install bearing cup (31) into input bearing cage
(28).
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13. Install only two of bolts (25) that will later be used to hold on the cover (26) (not shown).
Install bearing cage (28). DO NOT add the shim pack at this time. Make sure that the
bearing cage does not bind with the cover.
14. Install only two bolts (29) and the washers on input bearing cage (28). Bolts (29) must be
separated by 180 degrees. Tighten the bolts finger tight until the input bearing cage contacts
the cover.
15. Tighten two bolts (29) to a torque of 2.25 N·m (20 lb in).
16. Rotate the input gear for at least three revolutions to seat the bearings.
18. Rotate the input gear for at least three revolutions to seat the bearings.
19. Tighten two bolts (29) again to a torque of 4.5 N·m (40 lb in).
20. Use a tapered feeler gauge to measure the gap between input bearing cage (28) and the
cover for the transfer case. Take the measurement next to each bolt (29) at the edge of input
bearing cage (32).
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21. Average the two measurements from Step 20. Add 0.18 mm (.007 inch) to the average. This
result is the required thickness of the shims.
22. End play should be 0.08 ± 0.03 mm (0.003 ± 0.001 inch).
23. Remove two bolts (29) and input bearing cage (28).
24. Install shim pack (30).
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25. Install input bearing cage (28). Remove Tooling (F). Install all of bolts (29) and the
washers . Remove bolts (25). Tighten bolts (29) to a torque of 136 ± 20 N·m
(100 ± 15 lb ft).
26. Install Tooling (F).
27. Lower the temperature of bearing cup (38). Install bearing cup (38) into idler bearing cage
(35).
28. Install O-ring seal (39).
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29. Install idler bearing cage (35). DO NOT add the shim pack at this time. Make sure that the
idler bearing cage does not bind with the cover.
30. Install two bolts (36) and the washers on idler bearing cage (35). Bolts (36) must be
separated by 180 degrees. Tighten the bolts finger tight until the idler bearing cage contacts
the cover.
32. Rotate the idler gear for at least three revolutions to seat the bearings.
34. Rotate the idler gear for at least three revolutions to seat the bearings.
35. Tighten two bolts (36) again to a torque of 4.5 N·m (40 lb in).
36. Use a tapered feeler gauge to measure the gap between idler bearing cage (35) and cover
(45). Take the measure next to each bolt (36) at the edge of idler bearing cage (35).
37. Average the two measurements from step 36. Add 0.18 mm (.007 inch) to the average. This
result is the required thickness of the shims.
38. End play should be 0.08 ± 0.03 mm (0.003 ± 0.001 inch).
39. Remove two bolts (36) and idler bearing cage (35).
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40. Install the required number of shims (37). Install idler bearing cage (35). Remove Tooling
(F). Install bolts (36). Tighten bolts (36) to a torque of 135 ± 20 N·m (100 ± 15 lb ft). Install
O-ring seal (34).
41. Install cover (33). Install nuts (32) and the washers.
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42. Position rotor (26J). Install bearing (26H). Install retaining ring (26K).
43. Position cage (26G). Install bolts (26F).
44. Position cage assembly (26C). Install bolts (26B). Position speed sensor (26D). Install bolt
(26B).
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45. Install shaft (26A).
46. Install cover assembly (26) with O-ring seal (27). Install bolts (25) and the washers.
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47. Lower the temperature of bearing cup (23). Install bearing cup (23) into bearing cage (15).
48. Install bearing cone (22) into bearing cage (15).
49. Lower the temperature of other bearing cup (23). Install bearing cup (23) into bearing cage
(15).
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50. Install retainer (20), the washers, and six bolts (19) onto bearing cage (15). Install O-ring
seal (21).
51. Tighten bolts (19) to a torque of 55 ± 10 N·m (40 ± 7 lb ft).
52. Turn bearing cage (15) to the opposite side, as shown. Apply Tooling (G) in the seal bore of
bearing cage (15). DO NOT put Tooling (G) on the seal case. Allow Tooling (G) to dry.
53. Use Tooling (A) to install lip seal (24) in bearing cage (15). Make sure that the sealing lip is
facing toward the inside of bearing cage (15). Install the seal until the seal is flush with the
face of the bearing cage..
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54. Use the proper equipment to handle bearing (18). Raise the temperature of bearing (18) to a
maximum temperature of 135°C (275°F). Install bearing (18) on transfer shaft (13).
55. Place transfer shaft (13) on a wood block (not shown). Support transfer shaft (13) with two
plates in a suitable press, as shown.
56. Use two people to lower output gear (16) on transfer shaft (13). The weight of output gear
(16) is approximately 26 kg (57 lb).
57. Install spacer (17) on transfer shaft (13).
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58. Use Tooling (A) and a suitable press to install bearing cage (15) on transfer shaft (13). The
weight of bearing cage (15) is approximately 33 kg (73 lb).
59. Use a suitable lifting device to install bearing cage assembly (15) into the transfer case.
Install bolts (14). The weight of bearing cage assembly is approximately 106 kg (235 lb).
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60. Use a suitable lifting device to turn the transfer case assembly onto the other side. The
weight of the transfer case assembly is approximately 525 kg (1160 lb). Install spacer (12)
onto shaft (13).
61. Install O-ring seal (11) onto bearing cage (8).
62. Turn bearing cage (8) to the opposite side, as shown. Apply Tooling (G) in the seal bore of
bearing cage (8). DO NOT put Tooling (G) on the seal case. Allow Tooling (G) to dry.
63. Use Tooling (A) to install lip seal (9) in bearing cage (8). Make sure that the sealing lip is
facing toward the inside of bearing cage (8). Install the seal until the seal is flush with the
face of the bearing cage.
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64. Install bearing cage (8). Install bolts (7) and the washers for bearing cage (8). Tighten the
bolts to a torque of 55 ± 10 N·m (40 ± 7 lb ft).
65. Install yoke (6).
66. Install O-ring seal (5).
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67. Install bolt (3) and retainer (4) to the input side of the output transfer gear case. Tighten bolt
(3) to a torque of 475 ± 60 N·m (350 ± 44 lb ft).
68. Install hose assembly (2).
69. Install speed sensors (1). Install the speed sensors until firm contact is made with the tooth
of input gear. Unscrew the speed sensors for 1/2 ± 1/8 of a turn.
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End By:
a. Install the transmission from the output transfer gears. Refer to Disassembly and Assembly,
"Transmission from Output Transfer Gears - Connect".
Copyright 1993 - 2021 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Tue Mar 23 10:41:27 UTC+0800 2021
19/19
2021/3/23

Shutdown SIS
Previous Screen
Product: WHEEL LOADER
Model: 980H WHEEL LOADER KZL
Configuration: 980H Wheel Loader KZL00001-UP (MACHINE) POWERED BY C15 Engine
Disassembly and Assembly
980H Wheel Loader Power Train
Media Number -RENR8667-08 Publication Date -01/09/2018 Date Updated -04/09/2018
i03565130
Transmission Planetary - Disassemble - Heavy Duty
SMCS - 3160-015
Disassembly Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 1P-2420 Transmission Repair Stand 1
B 138-7575 Link Bracket 3
C 1P-7407 Eyebolt 1
D FT-0833 Clamp 3
E 1P-1863 Retaining Ring Pliers 1
F 5P-5197 External Pliers 1
G 1P-0520 Driver Group 1
H 1P-0510 Drive Group 1
L 1P-0074 Slide Hammer Puller Gp 1
Start By:
a. Separate the transmission and the output transfer gears. Refer to Disassembly and
Assembly, "Transmission to Output Transfer Gears - Separate".
Note: Cleanliness is an important factor. Before the disassembly procedure, the exterior of the
component should be thoroughly cleaned. This will help to prevent dirt from entering the internal
mechanism.
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1. Place the transmission assembly onto Tooling (A).
2. Disconnect tube assembly (1).
3. Install Tooling (B) and a suitable lifting device to modulating valve assembly (2). The
weight of modulating valve assembly (2) is approximately 43 kg (95 lb).
4. Remove bolts (3). Remove modulating valve assembly (2).
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5. Remove tubes (4) and the O-ring seals.
6. Attach Tooling (B) and a suitable lifting device to planetary group (5). The weight of
planetary group (5) is approximately 565 kg (1250 lb). Remove planetary group (5) from
transmission case (6).
7. Place planetary group (5) on suitable blocks.
Note: Put alignment marks across the clutch housings for assembly purposes.
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8. Remove bolts (7) and the washers.
Personal injury can result from being struck by parts propelled by a
released spring force.
Make sure to wear all necessary protective equipment.
Follow the recommended procedure and use all recommended tooling to
release the spring force.
9. Use Tooling (D) to secure the clutch piston in clutch housing (9).
10. Install Tooling (B) and a suitable lifting device on clutch housing (9). The weight of clutch
housing (9) is approximately 32 kg (70 lb).
11. Carefully remove clutch housing (9) from manifold assembly. Remove springs (8).
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12. Remove clutch piston (11) from clutch housing (9). Remove seals (10) from the piston.
13. Remove friction discs (12), clutch plates (12), and dowels (14) from manifold assembly.
14. Remove gear (15) from the carrier assembly.
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15. Use Tooling (E) to remove retaining ring (16) from shaft assembly. Remove the spacer
under the retaining ring.
16. Remove carrier assembly (17).
17. Use a drift to bend locks (18) from bolts (19). Remove bolts (19), locks (18), and slinger
(20) from carrier assembly.
18. Remove spring pin (22) from the carrier and shaft (21). Remove spring pin (22) from shaft
(21).
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19. Remove thrust discs (23) and (27) and gear (25).
20. Remove bearings (24) and (26) from gear (25).
21. Repeat Steps 18 through 20 for the removal of the remaining planetary gears.
22. Use Tooling (F) to remove retaining ring (29) from the housing assembly.
23. Remove gear (28).
24. Remove O-ring seal (30) from the manifold assembly.
25. Remove bolts (31) that hold the manifold assembly to the clutch housing.
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26. Attach Tooling (B) and a suitable lifting device to manifold assembly (32). The weight of
manifold assembly (32) is approximately 72 kg (160 lb).
27. Carefully remove manifold assembly (32) from the clutch housing. Remove O-ring seals
(33).
28. Remove retaining ring (34) and bearing (35) from the manifold assembly.
8/27
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29. Remove bolts (36) from the clutch housing.
30. Use Tooling (D) to hold the piston in the clutch housing (37). Attach Tooling (B) and a
suitable lifting device to the clutch housing (37). The weight of clutch housing (37) is
approximately 25 kg (55 lb).
31. Carefully remove clutch housing (37).
32. Remove springs (38).
33. Remove clutch piston (39) from the clutch housing.
9/27
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34. Remove seals (40) and (41) from the clutch piston.
35. Remove friction discs (43), clutch plate (42) and dowels (44).
36. Remove retaining ring (45) from the shaft assembly.
37. Attach Tooling (B) and a suitable lifting device to clutch housing assembly (46). The weight
of clutch housing (46) is approximately 45 kg (100 lb).
38. Carefully remove clutch housing (46).
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39. Remove seal rings (48) from the ring carrier (47).
40. Check the condition of the ring carrier (47). If ring carrier (47) is worn or damaged, use new
parts for replacement. If the ring carrier is not worn or damaged, DO NOT remove ring
carrier (47). Use a hammer and a chisel in order to break the ring carrier. Remove the ring
carrier and pin (49) from housing assembly.
41. Remove bolts (52) from the housing.
42. Remove ring gear (50) and gear (51).
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43. Remove friction discs (53) and clutch plates (54) from the housing assembly.
44. Remove reaction plate (56) from housing assembly (55).
Personal injury can result from being struck by parts propelled by a
released spring force.
Make sure to wear all necessary protective equipment.
Follow the recommended procedure and use all recommended tooling to
release the spring force.
45. Use Tooling (H) and a suitable press in order to put force on plate (57) until spiral lockring
(58) can be removed. Release the force. Remove the plate and three springs (59) from the
housing.
12/27
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Caterpillar Cat 980H Wheel Loader (Prefix KZL) Service Repair Manual (KZL00001 and up).pdf

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Caterpillar Cat 980H Wheel Loader (Prefix KZL) Service Repair Manual (KZL00001 and up).pdf