Caterpillar Cat 980H WHEEL LOADER (Prefix A8J) Service Repair Manual (A8J04000 and up)

1
Shutdown SIS
Previous Screen
Product WHEEL LOADER Model 980H WHEEL LOADER
A8J Configuration 980H WHEEL LOADER A8J04000-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
i04400940
Torque Converter - Assemble - Heavy duty SMCS -
3101-016 Assembly Procedure Table 1
Required Tools Required Tools Required Tools Required Tools
Tool Part Number Part Description Qty
A 138-7573 Link Bracket 3
B 8T-5096 Dial Indicator Test Group 1
B 5P-2390 Gauge Tool Group 1
C 1P-0520 Driver Group 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.
2
Illustration 1 g00504278 1. Use Tooling (C) to
install sleeve bearing (59) in cover assembly
(57). Sleeve bearing (59) must be even with the
outside surface of cover assembly (57).
Illustration 2 g00504279 2. Install cover
assembly (57) to rotating housing (39).
Illustration 3 g00503564 3. Install ring seal
(58) to rotating housing (39).
3
4. Install eight bolts (56) and the washers.
Tighten the bolts to a torque of 30 5 Nm (22
4 lb ft).
Illustration 4 g00504307 5. Install thrust
bearing race (54), thrust bearing (55), and
thrust bearing race (54) to cover assembly (57).
Illustration 5 g00504312 6. Install retaining
ring (53) in turbine hub (51).
Illustration 6
g00504313
4
7. Install converter turbine (50) on turbine hub
(51).
Illustration 7 g00504315 8. Install twenty bolts
(52). Tighten the bolts to a torque of 50 7 Nm
(37 5 lb ft).
Illustration 8 g00504382 9. Install turbine hub
(51) and converter turbine (50) as a unit to
rotating housing (39).
Illustration 9 g00503538 10. Install two thrust
bearing races (49) and the bearing to the hub.
5
Illustration 10 g00504436 11. Use Tooling (C) to
install sleeve bearing (48) to carrier assembly
(44). Bearing sleeve (48) must be even with the
counterbore of carrier assembly (44).
Illustration 11
g00504882
12. Install retainer ring (47) in stator (46).
Illustration 12 g00504931 13. Position carrier
assembly (44) on a wood block.
6
https//www.aservicemanualpdf.com/ My Dear
Friend! Thank you very much for visiting. Full
manual if required, please enter the following
URL into your browser. https//www.aservicemanual
pdf.com/
7

1. Use proper equipment to handle stator (46). Heat
   stator (46) to a maximum temperature of 121C
   (250F) for one hour.
2. Install stator (46) on carrier assembly (44).

Illustration 13
g00504935
16. Install snap ring (45) in stator (46).
Illustration 14 g00505049 17. Install stator
(46) and carrier assembly (44) in rotating
housing (39).
Illustration 15
g00503352
8
18. Install two thrust bearing races (43) and the
thrust bearing to the carrier assembly.

• Illustration 16 g00503351
• Position impeller hub (42) on a wood block.
• Install converter impeller (41) on impeller hub
  (42).

Illustration 17 g00503350 21. Install drive
flange (38) on converter impeller (41).
Illustration 18
g00503348
9
22. Install twelve bolts (40). Tighten the bolts
to a torque of 80 10 Nm (60 7 lb ft).

• Illustration 19 g00503345
• Install drive flange (38) on rotating housing
  (39). The weight of drive flange (38) is 23 kg
  (51 lb).
• Install 36 bolts (37) and the washers. Tighten
  the bolts to a torque of 30 5 Nm (22 4 lb
  ft).

Illustration 20 g00505183 25. Install retaining
ring (36) in the groove of drive gear (35).
10

• Illustration 21 g00505224
• Use the proper equipment to handle outer bearing
  race (60). Lower the temperature of outer
  bearing race (60).
• Install outer bearing race (60) in drive gear
  (35). Make sure that outer bearing race (60)
  makes contact with retaining ring (36).

Illustration 22 g00505319 28. Install drive gear
(35) on drive flange (38).
Illustration 23 g00505349 29. Install twelve
bolts (34) and the washers. Tighten the bolts to
a torque of 50 7 Nm (37 5 lb ft).
11
Illustration 24 g00505352 30. Use the proper
equipment to handle inner bearing (33). Heat
inner bearing (33) to a maximum temperature of
135C (275F). Install inner bearing (33) on
bearing carrier (28).
Illustration 25 g00505358 31. Install retaining
ring (32) in the groove of bearing carrier (28).
Illustration 26 g00505359 32. Use the proper
equipment to handle ring carrier (31). Heat ring
carrier (31) to a maximum temperature of 135C
(275F). Install ring carrier (31) on bearing
carrier (28).
12
Illustration 27
g00505387

1. Install seal ring (30) on ring carrier (31).
2. Install O-ring seal (29) on bearing carrier (28).

Illustration 28 g00505395 35. Install bearing
carrier (28) in drive flange (38).
Illustration 29 g00505423 36. Install retaining
ring (27) in carrier assembly (44) in order to
hold bearing carrier (28) in place.
13
Illustration 30 g00503312 37. Install two studs
(26) in torque converter housing assembly (2).
Tighten the studs to a torque of 100 15 Nm
(74 11 lb ft).
Illustration 31 g00505444 38. Install retaining
ring (24) in the groove of idler gear (15).
Illustration 32 g00505465 39. Use the proper
equipment to handle bearing cup (25). Lower the
temperature of bearing cup (25). Install bearing
cup (25) in idler gear (15).
14
Illustration 33 g00505470 40. Flip idler gear
(15) to the opposite side. Install bearing cup
spacer (23) in idler gear (15). The notch in
bearing cup spacer (23) must be aligned with
retaining ring (24).
Illustration 34 g00505479 41. Use the proper
equipment to handle bearing cup (22). Lower the
temperature of bearing cup (22). Install bearing
cup (22) in idler gear (15).
Illustration 35 g00505480 42. Install bearing
cone (21), bearing cone spacer (20) and bearing
cone (19) in idler gear (15).
15
Illustration 36 g00505482 43. Apply clean
hydraulic oil on O-ring seal (17). Install O-ring
seal (17) on shaft assembly (18).

• Illustration 37 g00505508
• Install 1/2" - 13 NC guide pin (61) in shaft
  assembly (18).
• Hold transfer gear (15) in position in torque
  converter housing assembly (2). Install shaft
  assembly (18).
• Remove guide pin (61) from shaft assembly (18).

Illustration 38
g00505517
16
47. Install bolt (14) that holds shaft assembly
(18) in place in torque converter housing
assembly (2). Tighten the bolt to a torque of 120
20 Nm (90 15 lb ft).
Illustration 39 g00505572 48. Use the proper
equipment to handle bearing cones (12). Heat
bearing cones to a maximum temperature of 135C
(275F). Install a bearing cone (12) on each side
of pump drive gear (11).
Illustration 40 g00505585 49. Use the proper
equipment to handle bearing cup (13). Lower the
temperature of bearing cup (13). Install bearing
cup (13) in torque converter housing assembly (2).
17
Illustration 41 g00505591 50. Install pump drive
gear (11) in torque converter housing assembly
(2).
Illustration 42 g00505594 51. Use the proper
equipment to handle bearing cup (8). Lower the
temperature of bearing cup (8). Install bearing
cup (8) in pump adapter (6).
Illustration 43
g00505623

1. Install shims (9) on pump adapter (6).
2. Apply clean hydraulic oil on O-ring seal (10).
   Install O-ring seal (10) on pump adapter (6).

18

• Illustration 44 g00505666
• Install two 3/8" - 16 NC guide pins (62) in
  torque converter housing assembly (2).
• Install pump adapter (6) on torque converter
  housing assembly (2).

Illustration 45
g00505669

• Install thirteen bolts (5) and the washers.
• Use Tooling (B) to check bearing end play. The
  bearing end play must be 0.15 0.05 mm (.006
  .002 inch). Add or remove shims in order to get
  the correct bearing end play.
• Note If end play is less than 0.10 mm (.004
  inch) add additional shims. If end play is
  greater than 0.20 mm (.008 inch) remove shims.

Illustration 46 g00505670 58. Apply clean
hydraulic oil on O-ring seal (4). Install O-ring
seal (4) on torque converter housing assembly
(2).
19

• Illustration 47 g01022823
• Install two 1/2" - 13 NC guide pins (63) in the
  carrier assembly.
• Install Tooling (A) to torque converter housing
  assembly (2), as shown. Attach a hoist and
  suitable lifting chains to Tooling (A). Use the
  hoist to carefully install torque converter
  housing assembly (2) on the torque converter.

• Illustration 48 g00503225
• Install eight bolts (1) and the washers to torque
  converter housing assembly (2). Tighten the
  bolts to a torque of 120 20 Nm (90 15 lb
  ft).
• End By
• a. Connect the torque converter to the
  transmission and to the output transfer gears.
  Refer to Disassembly and Assembly, "Torque
  Converter to Transmission, Output Transfer Gears
  - Connect" for the machine that is being
  serviced.

Copyright 1993 - 2021 Caterpillar Inc. All
Rights Reserved. Private Network For SIS
Licensees.
Sat Mar 27 144545 UTC0800 2021
20
Shutdown SIS
Previous Screen
Product WHEEL LOADER Model 980H WHEEL LOADER
A8J Configuration 980H WHEEL LOADER A8J04000-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
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
8B-7548 Push-Puller 1
8B-7550 Leg 2
B 8H-0684 Ratchet Wrench 1
8B-7560 Step Plate 1
8H-0663 Bearing Puller Attachment 1
8B-7548 Push-Puller 1
8H-0684 Ratchet Wrench 1
C 8B-7549 Leg 2
5P-4808 Cap 2
8B-7554 Bearing Cup Puller Attachment 1
5F-7343 5F-7343 Bearing Puller Attachment 1
1P-0520 1P-0520 Driver Group 1
D
E 1P-0510 Driver Group 1
F 7
21
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) .

• Illustration 2 g01111329
• 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).
• Use Tooling (F) to loosen housing assembly (2)
  from the torque converter.

22
5. Remove housing assembly (2) from the torque
converter.
Illustration 3 g00871317 6. Remove O-ring seal
(3) from torque converter housing assembly (2) .
Illustration 4 g00871318 7. Remove bolts (4) and
the washers from pump adapter (5) and torque
converter housing assembly (2) .
23
Illustration 5 g00871264 8. Use Tooling (F) to
remove pump adapter (5) from torque converter
housing assembly (2) .
Illustration 6 g00871319 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) .
Illustration 7
g00871326
24
10. Remove pump drive gear (9) from torque
converter housing assembly (2) .
Illustration 8 g00871451 11. Use Tooling (B) to
remove bearing cones (10) from each side to pump
drive gear (9) .
Illustration 9 g00871333 12. Use Tooling (C) to
remove bearing cup (11) from torque converter
housing assembly (2) . See illustration 13 for
Tooling (C) .
25

• Illustration 10 g01112900
• Remove bolt (12) and the washer from torque
  converter housing assembly (2) .
• Use Tooling (F) to push shaft assembly (14) out
  of torque converter housing assembly (2) .
• Remove idler gear (13) from torque converter
  housing assembly (2) .

Illustration 11 g01112903 16. Remove O-ring seal
(15) from shaft assembly (14) .
26
Illustration 12 g00871365 17. Remove bearing
cone (16) , bearing cone spacer (17) , and
bearing cone (18) from idler gear (13) .
Illustration 13 g00871366 18. Use Tooling (C) to
remove bearing cup (19) from idler gear (13) .
Illustration 14 g00871367 19. Remove bearing cup
spacer (20) from idler gear (13) .
27
Illustration 15 g00871368 20. Remove retaining
ring (21) from idler gear (13) .
Illustration 16 g00871369 21. Use Tooling (C) to
remove bearing cups (22) from idler gear (13) .
28
Illustration 17 g00871370 22. Remove studs (23)
from torque converter housing assembly (2) .
Illustration 18 g00871267 23. Remove retaining
ring (24) and bearing carrier (25) from the
carrier assembly.
Illustration 19
g01112906
24. Remove bearing carrier (25) .
29

• Illustration 20 g00871269
• Remove O-ring seal (26) from bearing carrier (25)
  .
• Remove seal ring (27) from ring carrier (28) .

Illustration 21 g00871273 27. Use Tooling (D)
and a press to remove ring carrier (28) from
bearing carrier (25) .
30
Illustration 22 g00871274 28. Remove retaining
ring (29) from bearing carrier (25) .
Illustration 23 g00871275 29. Use Tooling (D)
and a press to remove inner bearing (30) from
bearing carrier (25) .

• Illustration 24 g01112907
• Remove bolts (31) and the washers from drive gear
  (32) .
• Remove drive gear (32) .

31
Illustration 25 g01112910 32. Use Tooling (E)
and a press to remove the outer bearing race
(32A) (not shown) from drive gear (32) .
Illustration 26 g00871278 33. Remove retaining
ring (33) from drive gear (32) .
Illustration 27
g00871279
32
34. Remove bolts (34) and the washers from drive
flange (35) and rotating housing (36) .
Illustration 28 g00871281 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).
Illustration 29 g00871282 36. Remove bolts (37)
from drive flange (35) .
33
Please write to us. Our email
aservicemanualpdf_at_yahoo.com Please go to the
homepage to get the full manual, or other brand
PDF manuals. Home Site aservicemanualpdf.com
34
Thank you very much for your reading. Please
Click Here. Then Get COMPLETE MANUAL. NO WAITING
GET MORE OTHER MANUALS
https//www.aservicemanualpdf.com/
NOTE If there is no response to click on the
link above, please download the PDF document
first and then click on it.
GET MORE OTHER MANUALS
https//www.aservicemanualpdf.com/
35
Illustration 30 g00871283 37. Remove drive
flange (35) from impeller (38) .

• Illustration 31 g00871284
• Position impeller hub (39) on wood blocks.
• Remove impeller (38) from impeller hub (39) .

Illustration 32
g00870210
36
40. Remove thrust bearing (40) and race (40A)
(not shown) from carrier assembly (41) .
Illustration 33 g00870211 41. Remove carrier
assembly (41) and stator (42) as a unit from
rotating housing (36) .
Illustration 34 g00870212 42. Remove snap ring
(43) from stator (42) . Remove plate (44) from
stator (42) .
37
Illustration 35 g01112913 43. Remove 11
freewheel rollers (45) and 11 freewheel springs
(46) from freewheel cam (47) . Remove stator
(42) from carrier assembly (41) .

• Illustration 36 g01112915
• Remove retaining ring (48) . Remove plate (49) .
• 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.

Illustration 37 g01112917 46. Remove thrust
bearing (50) from carrier assembly (41) . Remove
sleeve bearing (51) from carrier assembly (41) .
38
https//www.aservicemanualpdf.com/ My Dear
Friend! Thank you very much for visiting. Full
manual if required, please enter the following
URL into your browser. https//www.aservicemanual
pdf.com/