Caterpillar Cat 980G Wheel Loader (Prefix 9CM) Service Repair Manual Instant Download

1
Product WHEEL LOADER Model 980G WHEEL LOADER
9CM Configuration 980G Wheel Loader 9CM00001-UP
(MACHINE) POWERED BY 3406C Engine
Disassembly and Assembly 980G Wheel Loader Power
Train Media Number -SENR5877-07 Publication Date
-01/09/2004
Date Updated -23/09/2004
i04400923
Torque Converter - Disassemble - Heavy Duty SMCS
- 3101-015 Disassembly Procedure Table 1
Required Tools Required Tools Required Tools Required Tools
Tool Part Number Part Description Qty
A 138-7573 Link Bracket 1
B 8B-7548 Push-Puller 1
B 8B-7550 Leg 2
B 8H-0684 Ratchet Wrench 1
B 8B-7560 Step Plate 1
B 8H-0663 Bearing Puller Attachment 1
C 8B-7548 Push-Puller 1
C 8H-0684 Ratchet Wrench 1
C 8B-7549 Leg 2
C 5P-4808 Cap 2
C 8B-7554 Bearing Cup Puller Attachment 1
D 5F-7343 Bearing Puller Attachment 1
D 1P-0520 Driver Group 1
E 1P-0520 Driver Group 1
2
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 on wood blocks.
Illustration 1 g00503225 2. Remove eight bolts
(1) and the washers from torque converter housing
assembly (2).

• Illustration 2 g00503286
• Install Tooling (A) to torque converter housing
  assembly (2), as shown. Attach a hoist and
  suitable lifting chains to Tooling (A).
• Use three 3/8" - 16 NC forcing screws (3) to
  loosen housing assembly (2) from the torque
  converter.
• Use the hoist to remove housing assembly (2) from
  the torque converter. The weight of housing
  assembly (2) is 120 kg (265 lb).

3
Illustration 3 g00503287 6. Remove O-ring seal
(4) from torque converter housing assembly (2).
Illustration 4 g00503288 7. Remove thirteen
bolts (5) and the washers from pump adapter (6)
and torque converter housing assembly (2).
Illustration 5 g00503289 8. Use three 3/8" - 16
NC forcing screws (7) to remove pump adapter (6)
from torque converter housing assembly (2).
4
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Illustration 6 g00503291 9. Remove bearing cup
(8), O-ring seal (10) and shims (9) from pump
adapter (6).
Illustration 7 g00503292 10. Remove pump drive
gear (11) from torque converter housing assembly
(2).
Illustration 8 g00503294 11. Use Tooling (B) to
remove bearing cones (12) from each side to pump
drive gear (11).
6
Illustration 9 g00503296 12. Use Tooling (C) to
remove bearing cup (13) from torque converter
housing assembly (2).

• Illustration 10 g00503297
• Remove bolt (14) and the washer from torque
  converter housing assembly (2).
• Use 3/8" - 16 NC forcing screw (16) to push the
  shaft assembly out of torque converter housing
  assembly (2).
• Remove idler gear (15) from torque converter
  housing assembly (2).

Illustration 11
g00503298
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16. Remove O-ring seal (17) from shaft assembly
(18).
Illustration 12 g00503299 17. Remove bearing
cone (19), bearing cone spacer (20) and bearing
cone (21) from idler gear (15).
Illustration 13 g00503301 18. Use Tooling (C) to
remove bearing cup (22) from idler gear (15).
8
Illustration 14 g00503302 19. Remove bearing cup
spacer (23) from idler gear (15).
Illustration 15 g00503308 20. Remove retaining
ring (24) from idler gear (15).
Illustration 16
g00503309
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21. Use Tooling (C) to remove bearing cup (25)
from idler gear (15).
Illustration 17 g00503312 22. Remove two studs
(26) from torque converter housing assembly (2).
Illustration 18 g00503314 23. Remove retaining
ring (27) and bearing carrier (28) from the
carrier assembly.
Illustration 19 g00503315 24. Remove O-ring seal
(29) from bearing carrier (28).
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25. Remove seal ring (30) from ring carrier (31).
Illustration 20 g00503316 26. Use Tooling (D)
and a press to remove ring carrier (31) from
bearing carrier (28).
Illustration 21 g00503318 27. Remove retaining
ring (32) from bearing carrier (28).
Illustration 22 g00503319 28. Use Tooling (D)
and a press to remove inner bearing (33) from
bearing carrier (28).
11

• Illustration 23 g00503321
• Remove twelve bolts (34) and the washers from
  drive gear (35).
• Remove drive gear (35) from the drive flange.

Illustration 24 g00503322 31. Use Tooling (E)
and a press to remove the outer bearing race from
drive gear (35).
Illustration 25 g00503344 32. Remove retaining
ring (36) from drive gear (35).
12
Illustration 26 g00503345 33. Remove 36 bolts
(37) from drive flange (38) and rotating housing
(39).
Illustration 27 g00503347 34. Use two bolts (37)
as forcing screws to remove drive flange (38)
from rotating housing (39). The weight of drive
flange (38) is 23 kg (51 lb).
Illustration 28
g00503348

1. Place the impeller hub on wood blocks.
2. Remove twelve bolts (40) from drive flange (38).

13
Illustration 29 g00503350 37. Remove drive
flange (38) from the impeller hub and converter
impeller (41).
Illustration 30 g00503351 38. Remove converter
impeller (41) from impeller hub (42).
Illustration 31 g00503352 39. Remove two thrust
bearing races (43) and the thrust bearing from
the carrier assembly.
14
Illustration 32 g00503533 40. Remove carrier
assembly (44) and the stator as a unit from
rotating housing (39).
Illustration 33
g00503534
41. Remove snap ring (45).

• Illustration 34 g00503535
• Heat stator (46) and carrier assembly (44) as a
  unit to a minimum temperature of 121C (250F)
  for one hour. This will expand stator (46).
• Remove stator (46) from carrier assembly (44).

15
Illustration 35 g00503536 44. Remove retainer
ring (47) from stator (46).
Illustration 36 g00503537 45. Remove sleeve
bearing (48) from carrier assembly (44).
Illustration 37 g00503538 46. Remove two thrust
bearing races (49) and the thrust bearing from
the hub.
16
Illustration 38 g00503539 47. Remove converter
turbine (50) and turbine hub (51) as a unit from
rotating housing (39).

• Illustration 39 g00503540
• Remove twenty bolts (52) and the washers from
  converter turbine (50).
• Remove converter turbine (50) from turbine hub
  (51).

Illustration 40 g00503541 50. Remove retaining
ring (53) from turbine hub (51).
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Illustration 41 g00503542 51. Remove two thrust
bearing races (54) and thrust bearing (55) from
the cover assembly.

• Illustration 42 g00503564
• Remove eight bolts (56) and the washers from
  cover assembly (57).
• Remove cover assembly (57) from rotating housing
  (39).
• Remove ring seal (58) from rotating housing (39).

Illustration 43 g00503567 55. Remove sleeve
bearing (59) from cover assembly (57).
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Product WHEEL LOADER Model 980G WHEEL LOADER
9CM Configuration 980G Wheel Loader 9CM00001-UP
(MACHINE) POWERED BY 3406C Engine
Disassembly and Assembly 980G Wheel Loader Power
Train Media Number -SENR5877-07 Publication Date
-01/09/2004
Date Updated -23/09/2004
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.
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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).
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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
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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.
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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.
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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
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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
25
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).
26

• 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).
27
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).
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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.
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30
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).
31
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friend! Thank you very much for reading. Enter
the link into your browser. The full manual is
available for immediate download. https//www.ebo
oklibonline.com