Caterpillar Cat 980K Wheel Loader (Prefix W7K) Service Repair Manual (W7K00001 and up)

1
Service Repair Manual
Models 980K Wheel Loader
2
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Product WHEEL LOADER Model 980K WHEEL LOADER
W7K Configuration 980K Wheel Loader W7K00001-UP
(MACHINE) POWERED BY C13 Engine
Disassembly and Assembly 980K Wheel Loader Power
Train Media Number -KENR6447-03 Publication Date
-01/08/2012
Date Updated -21/08/2012
i06838048
Torque Converter - Disassemble - Lock Up Clutch
With Freewheel Stator SMCS - 3101-015 Disassembly
Procedure Table 1 Required Tools
Tool Part Number Part Description Qty
A 439-3938 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
3
F 6L-7283 Forcing Bolt 3/8 - 16 by 3 in 7
G 417-1324 Adjust Stand 1
Start By a. Separate the torque converter from
the transmission and from the output transfer
gears.

• Illustration 1 g02712129
• Use Tooling (A) and a suitable lifting device to
  position the torque converter onto Tooling
• (G) and suitable blocking. The weight of the
  torque converter is approximately 260 kg (573
  lb). Support the torque converter, as shown.
• Remove bolts (1).

Illustration 2
g02730506
3. Remove relief valve assembly (2A).
4

• Illustration 3 g02711758
• Use Tooling (F) to loosen housing assembly (2)
  from the torque converter.
• Use the suitable lifting device and Tooling (A)
  to remove torque converter housing assembly (2).
  The weight of torque converter housing assembly
  (2) is approximately 144 kg (317 lb).

Illustration 4 g00871317 6. Remove O-ring seal
(3) from torque converter housing assembly (2).
Illustration 5
g00871318
5
7. Remove bolts (4) from pump adapter (5) and
torque converter housing assembly (2).
Illustration 6 g00871264 8. Use Tooling (F) to
remove pump adapter (5) from torque converter
housing assembly (2).
Illustration 7 g00871319 9. Use Tooling (B) to
remove bearing cup (6). Remove bearing cup (6),
O-ring seal (8), and shims (7) from pump adapter
(5). See illustration 14 for Tooling (C).
Illustration 8 g00871326 10. Remove pump drive
gear (9) from torque converter housing assembly
(2).
6
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Illustration 9 g00871451 11. Use Tooling (C) to
remove bearing cones (10) from each side of pump
drive gear (9). Remove bearing cones (10).
Illustration 10 g00871333 12. Use Tooling (C) to
remove bearing cup (11) from torque converter
housing assembly (2). See illustration 14 for
Tooling (C).
Illustration 11 g01112900 13. Remove bolt (12)
and the washer from torque converter housing
assembly (2).
8

1. Use Tooling (F) to push shaft assembly (14) out
   of torque converter housing assembly (2).
2. Remove idler gear (13) from torque converter
   housing assembly (2).

Illustration 12 g01112903 16. Remove O-ring seal
(15) from shaft assembly (14).
Illustration 13 g00871365 17. Remove bearing
cone (16), bearing cone spacer (17), and bearing
cone (18) from idler gear (13).
9
Illustration 14 g00871366 18. Use Tooling (C) to
remove bearing cup (19) from idler gear (13).
Remove bearing cup (19).
Illustration 15 g00871367 19. Remove bearing cup
spacer (20) from idler gear (13).
Illustration 16
g00871368
10
20. Remove retaining ring (21) from idler gear
(13).
Illustration 17 g00871369 21. Use Tooling (C) to
remove bearing cup (22) from idler gear (13).
Remove bearing cup (22).
Illustration 18 g00871370 22. Remove studs (23)
from torque converter housing assembly (2).
11
Illustration 19
g02729366
23. Remove bolts (24) and gear (25).
Illustration 20 g02735357 24. Use the driver
group from Tooling (D) and a suitable press to
remove race (25A) from gear (25).
Illustration 21 g02730012 25. Use a suitable
lifting device to reposition the torque
converter, as shown. The weight of the torque
converter is approximately 122 kg (269 lb).
Remove bolts (26).
12
Illustration 22 g02730687 26. Use Tooling (F) to
separate housing (27) from the torque converter.
Illustration 23 g02730689 27. Use two people to
remove housing (27). The weight of housing (27)
is approximately 26 kg (57 lb). Remove housing
(27), piston (28), and plate (30). Remove seals
(29) from piston (28).
Illustration 24
g02731059
28. Remove bushing (31) from housing (27).
13
Illustration 25 g02731623 29. Remove plate (32),
disk (33), races (34), and bearing (35). Note
Note the orientation of the bearing and races for
assembly purposes.
Illustration 26 g02731644 30. Remove bolts (36),
coupling assembly (37), and plate (38).
14
Illustration 27 g02731651 31. Use suitable
blocking to support the bottom of shaft assembly
(39). Remove retaining ring (40) and plate (41).
Shaft assembly (39) can be lowered to the work
bench.
Illustration 28
g02731711
Illustration 29
g02732048
15

1. Install two of bolts (36) and remove turbine
   (42).
2. Remove bolts (36) and remove hub (43) from
   turbine (42).

Illustration 30
g02731732
Illustration 31
g02731802

• Remove race (44) and bearing (45).
• Note Note the orientation of the race and
  bearing for assembly purposes.
• Remove stator assembly (46).

16
Illustration 32 g02731806 36. Remove retaining
ring (47), plate (48), freewheel springs (49),
freewheel rollers (50), and freewheel cam (51).
Remove plate (52) and retaining ring (53) (not
shown) from stator (46).

• Illustration 33 g02732255
• Attach Tooling (A) and a suitable lifting device
  to impeller (54). The weightof impeller (54) is
  approximately 27 kg (60 lb).
• Remove impeller (54) from shaft assembly (39).

Illustration 34 g02735333 39. Position impeller
(54) onto suitable blocking, as shown.
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Illustration 35
g02734776
40. Remove retaining ring (56) and hub (55).
Illustration 36
g02735372
41. Remove seal ring (56).
Illustration 37 g02734816 42. Use Tooling (D)
and a suitable press to remove bearing (57).
Illustration 38
g02735374
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43. Remove retaining ring (59) and carrier
assembly (58) from impeller (54).
Illustration 39
g02735380
44. Remove bearing (60). Note Note the
orientation of the bearing (60) for assembly
purposes.
Illustration 40 g02735387 45. Remove bolts (61),
hub (62), and adapter (63) from impeller (54).
19
Illustration 41
g02752296
46. Remove seals (64).
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20
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Previous Screen
Product WHEEL LOADER Model 980K WHEEL LOADER
W7K Configuration 980K Wheel Loader W7K00001-UP
(MACHINE) POWERED BY C13 Engine
Disassembly and Assembly 980K Wheel Loader Power
Train Media Number -KENR6447-03 Publication Date
-01/08/2012
Date Updated -21/08/2012
i06806533
Torque Converter - Assemble - Lock Up Clutch with
Freewheel Stator 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
G 8T-5096 Dial Indicator Test Group 1
G 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
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.
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Illustration 1 g02735387 1. Install adapter
(63), hub (62), and bolts (61) onto impeller
(54). Tighten bolts (61) to a torque or 105 14
Nm (77 10 lb ft).
Illustration 2
g02735380
2. Install bearing (60).
Illustration 3 g02735374 3. Install carrier
assembly (58) and retaining ring (59) onto
impeller (54).
22

• Illustration 4 g06122365
• Raise the temperature of bearing (57). Install
  bearing (57) onto hub (55).
• Install retaining ring (56A) and seal ring (56).

Illustration 5
g02734776
Illustration 6 g02735333 6. Install hub (55) and
retaining ring (56) onto impeller (54).
23
Illustration 7
g02752296
7. Install seals (64).

• Illustration 8 g02732255
• Attach Tooling (A) and a suitable lifting device
  to impeller (54). The weightof impeller (54) is
  approximately 27 kg (60 lb).
• Position impeller (54) onto shaft assembly (39).

Illustration 9
g02731806
24
Illustration 10 Typical Example
g06122374

• Install retaining ring (53) (not shown) and plate
  (52) onto stator (46).
• 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.
• Install plate (48) and retaining ring (47).

Illustration 11
g02731802
Illustration 12
g06122399
25

1. Install stator assembly (46).
2. Install bearing (45) race (44), and outer race
   (44A).

Illustration 13
g02744699
Illustration 14
g06122404

1. Install hub (43) and turbine (42).
2. Use two of bolts (36) to align the holes.
3. Use suitable blocking to support the bottom of
   shaft assembly (39). Install plate (41),retaining
   ring (40), and ring seal (39A).

26
Illustration 15 g06122416 18. Install springs
(36A) and (36B) inside of springs (36). Install
springs (36) in an alternating pattern. An
example would be to install a spring (36) with a
spring (36A) inside. The next one would be to
install a spring (36) with a spring (36B) inside.
Illustration 16 g06122422 19. Install plate
(38), coupling assembly (37), and bolts (36).
Tighten bolts (36) to a torque of 60 7 Nm (44
5 lb ft). Note Plate (38) has an O-ring groove
that is not used.
27
Illustration 17 g06122434 20. Install disk (33),
races (34), and bearing (35).
Illustration 18 g02731059 21. Lower the
temperature of bushing (31). Install bushing (31)
into housing (27).
28
Illustration 19 g02730689 22. Install seals (29)
onto piston (28). Install plate (30), piston
(28), and housing (27). Note Plate (30) has an
O-ring groove that is not used.
Illustration 20 g02730012 23. Tighten bolts
(26). Tighten bolts (36) to a torque of 60 7
Nm (44 5 lb ft).
29
Illustration 21 g02735357 24. 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).

• Illustration 22 g02729366
• Use a suitable lifting devise to reposition the
  torque converter, as shown. The weight of the
  torque converter is approximately 1157 N (260
  lb).
• Install drive gear (25) and bolts (24). Tighten
  the bolts to a torque of 50 7 Nm (37 5 lb
  ft).

Illustration 23 g00872709 27. Install studs (23)
in torque converter housing assembly (2). Tighten
the studs to a torque of 100 15 Nm (74 11 lb
ft).
30
Illustration 24 g00872711 28. Install retaining
ring (21) in the groove of idler gear (13).
Illustration 25 g00872713 29. Use the proper
equipment to handle bearing cup (22). Lower the
temperature of bearing cup (22). Install bearing
cup (22) in idler gear (13).
Illustration 26 g00872715 30. 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).
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Illustration 27 g00872716 31. Use the proper
equipment to handle bearing cup (19). Lower the
temperature of bearing cup (19). Install bearing
cup (19) in idler gear (13).
Illustration 28 g00872718 32. Install bearing
cone (16), bearing cone spacer (17), and bearing
cone (18) in idler gear (13).
Illustration 29 g01112903 33. Apply clean
hydraulic oil on O-ring seal (15). Install O-ring
seal (15) on shaft assembly (14).
32

• Illustration 30 g01112954
• Install Tooling (K) in shaft assembly (14).
• Hold idler gear (13) in position in torque
  converter housing assembly (2). Install shaft
  assembly (15).
• Remove Tooling (K) from shaft assembly (14).

Illustration 31 g01112970 37. 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 Nm (90 15 lb ft).
Illustration 32
g00872724
33
38. 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).
Illustration 33 g00872801 39. Use the proper
equipment to handle bearing cup (11). Lower the
temperature of bearing cup (11). Install bearing
cup (11) in torque converter housing assembly (2).
Illustration 34 g00872727 40. Install pump drive
gear (9) in torque converter housing assembly (2).
34
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35
Illustration 35 g00872729 41. Use the proper
equipment to handle bearing cup (6). Lower the
temperature of bearing cup (6).

• Illustration 36 g00871319
• Apply clean hydraulic oil on O-ring seal (8).
• Install bearing cup (6), O-ring seal (8), and
  shims (7) on pump adapter (5).

• Illustration 37 g01112978
• Install Tooling (J) in torque converter housing
  assembly (2).
• Install pump adapter (5) on torque converter
  housing assembly (2).

36

• Illustration 38 g01112982
• Install bolts (4) and the washers on pump adapter
  (5) and torque converter housing assembly (2).
• 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 additional shims. If end play is
  greater than 0.20 mm (0.008 inch) remove shims.

Illustration 39 g00872732 48. If equipped apply
clean hydraulic oil on O-ring seal (3). Install
O-ring seal (3) on torque converter housing
assembly (2).
37
Illustration 40
g02730506
49. Install relief valve assembly (2A).
Illustration 41
g02752336

• Illustration 42 g02752337
• Install Tooling (J) in the carrier assembly.
• 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 is
  approximately 144 kg (317 lb). Install the
  bearing flange (not shown), plate (not shown),
  and two of bolts (1).

38
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