Caterpillar Cat 980L Wheel Loader (Prefix D8Z) Service Repair Manual Instant Download.pdf

Service Repair Manual
Models
980L Wheel Loader

Shutdown SIS
Previous Screen
Product: WHEEL LOADER
Model: 980L WHEEL LOADER D8Z
Configuration: 980L Wheel Loader D8Z00001-UP (MACHINE) POWERED BY C13 Engine
Disassembly and Assembly
980L T3 Wheel Loader Machine System
Media Number -M0075594-01 Publication Date -01/05/2018 Date Updated -24/05/2018
i06826791
Piston Pump (Implement) - Assemble
SMCS - 5070-016-FD; 5070-016-II; 5070-016; 5084-016; 5084-016-QP
S/N - D8Z1-20200
Assembly Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 439-3940 Link Bracket 2
B 1U-5449 Bearing Puller Gp 1
C 1P-0510 Driver Gp 1
D 192-5092 Removal Tool 1
E - Loctite 648 -
F - Loctite 263 -
G 8T-0372 Bolt 2
H 8T-5096 Dial Indicator 1
J 9U-5719 Tubing 1
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https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis...

Illustration 1 g03687208
1. Use Tooling (C) to install shims (62) and bearing cups (61) into center section (3).
2. Use Tooling (C) and a suitable press to install bearing cup (59). Install bearing cup (59).
3. Install bearings (58) into front pump housing (27).
Note: There are two (2) Brass Pins (which are used to hold the bearings in place) in the front pump
housing.
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4. Apply Tooling (E) to the outer diameter of lip seal (57). Use Tooling (C) and a suitable press to
install lip seal (57) into retainer (55). Install lip seal (57)
5. Install O-ring seal (56) onto retainer (55).
6. Install retainer (55) and bolts (54) onto front pump housing (27). Tighten bolts (54) to a torque of
9.5 ± 0.2 N·m (84.1 ± 1.8 lb in).
7. Install sleeves (53) into the swashplate.
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8. Use the following procedure to determine the shim requirements needed between the retainers and
the swashplate :
a. Install piston (52) and retaining ring (51) onto actuator (47).
Improper assembly of parts that are spring loaded can cause bodily
injury.
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To prevent possible injury, follow the established assembly procedure
and wear protective equipment.
b. Use Tooling (D) and a suitable press to install retainer (50), spring (49), and retainer (48) onto
actuator (47).
c. Install ring (42) onto shaft (43). Install shaft (43), actuator assembly (44), plate (45), and shims
(46) onto swashplate (37).
d. Install pistons (40) into plate (41).
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e. Install pistons (40) and plate (41) onto swashplate (37).
f. Use a feeler gauge to measure the gap between retainer (38) and plate (41). Add shims (39) to
achieve a clearance of 0.010 to 0.030 mm (0.0004 to 0.0012 inch).
g. Apply Tooling (F) to bolts (36). Install shims (39), retainer (38), and bolts (36).
h. Repeat Steps 8.f and 8.g for the remaining rotating group.
Front pump shaft assembly
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Rear pump shaft assembly
9. Raise temperature of bearing cone (30) to 121 °C (250 °F). Install bearing cone (30) onto shaft
assembly (29).
10. Apply Tooling (E) to the outer diameter of guide (31). Install guide (31) with the tapered edge facing
away from bearing cone (30).
11. Use the following procedure to determine the end play for the shaft:
a. Install shaft assembly (29) into the housing.
b. Raise the temperature of bearing (24) to 121 °C (250 °F). Install ring (25) and bearing (24)
onto the shaft.
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c. Install the shims (61) and bearing cups (60) into center section (3).
d. Install center section (3) and Tooling (G). Tighten Tooling (G) to a torque of 110 N·m
(80 lb ft).
e. Use a rubber mallet to seat the shaft into the bearing cup.
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f. Install a suitable bolt into the end of the shaft. Install Tooling (H), as shown. Use a lever to
measure the amount of end play in the shaft. Add the appropriate thickness of shims to achieve
an end play of 0.020 to 0.070 mm (0.0008 to 0.0028 inch).
Note: The shims are located in the center section under the bearing cup.
g. Remove the center section.
h. Remove shaft assembly (29) from the housing.
i. Use Tooling (B) to remove ring (25) and bearing (24) from shaft (29).
j. Repeat Steps 11.a through 11.i for the driven end of the pump.
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injury.
12. Install washers (34), spring (35), and inner and outer bushings (33) into barrel assembly (16).
13. Use a suitable press to compress spring (35).
14. Install retaining ring (32) into barrel assembly (16).
15. Repeat Steps 12 through 14 for the remaining barrel assembly.
16. Use the following procedure to determine the sliding block play:
a. Install the pins and bearings (58).
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980L Wheel Loader D8Z00001-UP (MACHINE) POWERED BY C13 Engine(SEB...
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Note: The pins must be installed to a depth below the bearings.
Dimension (A)
b. Install the swashplate assembly into the pump housing.
c. Use a depth gauge to level the swashplate assembly inside the pump housing. Take several
measurements to make sure that the swashplate is level.
d. Install a 5.0 mm (0.02 ft) ball bearing into each spherical hole on the swashplate assembly.
e. Use the depth gauge to measure the distance from the face of the pump housing to the top of
the ball bearings. This measurement will be referred to as Dimension (A).
Dimension (B)
f. Measure the length of lubrication tubes (17). This measurement will be referred to as
Dimension (B).
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Dimension (C)
g. Remove the shims from the holes in the head assembly. Use the depth gauge to measure the
depth of the holes. This measurement will be referred to as Dimension (C).
h. Use the following formula to determine the number of shims needed:
A + C + 5 mm (0.19685 inch) = B + 0.01 to 0.15 mm (0.00039 to 0.00590 inch)
17. Install pistons (40) into barrel assembly (16).
18. Install shaft (29) into barrel assembly (16).
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19. Install Tooling (J) on the shaft. Tooling (J) is used to prevent damage to the lip seal.
20. Raise the temperature of Tooling (J) to shrink into place.
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21. Install spacer (25) and bearing cone (24).
22. Repeat Steps 16 through 21 for the other rotating group.
23. Apply a paint mark on one drive shaft spline that aligns with the center of one of the kidney slots on
the cylinder barrel.
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24. On the coupling, select any spline and apply a paint mark along the root of the spline. Apply a paint
mark on each end of the coupling as well.
Use the rotating group for the rear pump for this step.
25. Install the coupling onto the drive shaft at various positions, until the paint mark on the coupling
aligns between two kidney slots on the cylinder barrel.
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26. Slightly lift the Coupling, and then apply a paint mark on the drive shaft spline that aligns with the
paint mark on the Coupling.
27. The cylinder barrels for the front pump and rear pump must be properly “timed” to insure smooth,
quiet operation of the pump. Illustration 39 shows how the two cylinder barrels are set in properly
“timed” positions. Use the paint marks to ensure that the front pump and rear pump must be properly
“timed” during final assembly.
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28. Install the O-ring seals and the back-up rings on lubrication tubes (20).
29. Install lube tubes (20) and the shims determined in Step 16.h.
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30. Install port plate (21).
31. Install rotating group (26) for the front pump onto center section (3).
32. Make sure that both actuator pistons and lube tubes (20) are in the appropriate cavities on center
section (3).
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33. Install front pump housing (27).
34. With the pump still oriented as shown in Step 33, install Tooling (G). Do not clamp firmly - you only
need to hold them together to reposition the pump. Reposition pump as shown.
35. Remove Tooling (G).
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36. Install coupling (22) onto the tail-splines of the front pump drive shaft. Orient the coupling so that
the paint marks on the coupling and the drive shaft align with each other.
Note: Install the lubrication tubes and the shims determined in Step 16.h.
37. Install lube tubes (17) and the shims.
38. Install port plate (18) onto center section (3).
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39. Install rotating group (11) onto center section (3). Orient the rotating group so that the paint marks
on the coupling and the drive shaft align with each other.
40. Install connection rods (10).
41. Install new self-adhesive dampener strips to the connection rods marked (10A).
42. Install bearing (8) and bearing cup (9) into rear pump housing (7).
Note: There are two Brass Pins (which are used to hold the bearings in place) remaining in the front
pump housing. If undamaged, leave the brass pins in the front pump housing.
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43. Use Tooling (A) and a suitable lifting device to install rear pump housing (7). Install rear pump
housing (7).
injury.
44. Install the O-ring seals and nuts (6). Tighten nuts (6) to a torque of 110 N·m (81 lb ft).
45. Apply Tooling (F) to bolts (4). Install bolts (4).
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46. Install the O-ring seals, valve group (2), the washers, and bolts (1) to center section (3).
End By:
a. Install the piston pump (implement).
Copyright 1993 - 2021 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Tue Dec 7 23:59:39 UTC+0800 2021
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Shutdown SIS
Previous Screen
Product: WHEEL LOADER
Model: 980L WHEEL LOADER D8Z
Configuration: 980L Wheel Loader D8Z00001-UP (MACHINE) POWERED BY C13 Engine
Disassembly and Assembly
980L T3 Wheel Loader Machine System
Media Number -M0075594-01 Publication Date -01/05/2018 Date Updated -24/05/2018
i07322205
Piston Pump (Implement) - Assemble
SMCS - 5070-016-FD; 5070-016-II; 5070-016; 5084-016; 5084-016-QP
S/N - D8Z20201-UP
Assembly Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A
1U-9130 Stand Assembly 1
1U-9129 Plate 1
B - M20 x 2.5 threaded rod 2
C 4C-8359 Eyebolt 2
D 1P-0510 Driver Gp 1
E 6V-2012 Depth Gage 1
F 421-5660 Lifting Eye Assembly 2
G 8H-0663 Bearing Puller 1
H 153-3568 Bolt 1
1/15
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1. Install backup ring (65) and O-ring seal (64) onto stopper (63).
2. Install stopper (63) into the pump body.
3. Install plugs (62).
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4. Install setscrew (60) and nut (61) onto cover (59). Use Tooling (E) and adjust setscrew (60)
to the height recorded during the disassembly. Tighten nut (61) to a torque of 240 ± 24 N·m
(175 ± 15 lb ft).
5. Install cover (59) and bolts (58) onto pump body (23). Tighten bolts (58) to a torque of
330 ± 33 N·m (240 ± 20 lb ft).
6. Install O-ring seals (57) into pump body (23).
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7. Install the O-ring seal and adapter (56) into pump body (23).
8. Install plug (55), the O-ring seal, and plug (54) into pump body (23).
9. Install bearing (53) into pump body.
Note: Bearing (53) must align with the dowel in the pump body.
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10. Install piston (52) into pump body (23).
11. Install backup ring (51) and O-ring seal (50) onto stopper (49).
12. Install stopper (49) into the pump body.
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13. Install plate (48) onto swashplate assembly (45).
14. Install swashplate assembly (45), O-ring seals (46), and O-ring seals (47) into pump body
(23).
Note: Ensure that swashplate (45) engages the piston and the bearing properly.
15. Use Tooling (G) and a suitable press to install bearing (44) onto shaft assembly (41).
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16. Install retaining ring (43) onto shaft assembly (41).
17. Install lip seals (42) into seal carrier (40).
18. Use a soft faced hammer to install shaft assembly (41) and seal carrier (40) into pump body
(23).
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19. Install retaining ring (39) into pump body (23).
20. Install springs (38) and bearing (37) onto barrel assembly (36).
21. Install retainer (35) and pistons (34) onto barrel assembly (36).
8/15
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22. Install rotating group (33) into pump body (23).
23. Use Tooling (F) and a suitable lifting device to install pump body (23) onto Tooling (A).
Pump body (23) weighs approximately 60 kg (133 lb).
24. Install setscrew (31) and nut (32) onto head (22). Use Tooling (E) and adjust setscrew (31)
to the height recorded during the disassembly. Tighten nut (32) to a torque of 240 ± 24 N·m
(175 ± 15 lb ft).
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