980L Tier 3 Wheel Loader Machine System Caterpillar

Disassembly Procedure

Start By:

1. Remove the main control valve.

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Illustration 1	g06130482

1. Remove pressure sensors (1) and (1A).
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   Illustration 2	g03642221

2. Remove plug (2) and the O-ring seal. Mark the orientation of fittings (3). Remove fittings (3) and the O-ring seals.
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   Illustration 3	g06130486

3. Mark the orientation of coil (5). Remove nut (4) and coil (5).
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   Illustration 4	g06130488

4. Remove cartridge assembly (6).
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   Illustration 5	g03642234

5. Remove O-ring seal (9) and backup rings (11) from cartridge assembly (6).

6. Remove O-ring seal (8) and backup rings (10). Remove O-ring seal (7).
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   Illustration 6	g06130490

7. Remove relief valve (12).
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   Illustration 7	g03642259

8. Remove O-ring seal (15) and backup rings (17) from relief valve (12).

9. Remove O-ring seal (14) and backup rings (16). Remove O-ring seal (13).
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   Illustration 8	g06130510

10. Remove relief valve (18).
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    Illustration 9	g03642305

11. Remove O-ring seal (19) from relief valve (18).
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    Illustration 10	g03642327

12. Remove hose assembly (22).

13. Remove fittings (20) and the O-ring seals.

14. Mark the orientation of fitting (21). Remove fitting (21) and the O-ring seal.
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    Illustration 11	g03642356

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    Pressurized System! Hydraulic accumulators contain gas and oil under high pressure. DO NOT disconnect lines or disassemble any component of a pressurized accumulator. All gas pre-charge must be removed from the accumulator as instructed by the service manual before servicing or disposing of the accumulator or any accumulator component. Failure to follow the instructions and warnings could result in personal injury or death. Only use dry nitrogen gas to recharge accumulators. See your Cat dealer for special equipment and detailed information for accumulator service and charging.

15. Remove accumulator (23).
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    Illustration 12	g03642358

16. Remove O-ring seal (24) from accumulator (23).
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    Illustration 13	g03642361

17. Remove plugs (25) and the O-ring seals.
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    Illustration 14	g03642364

18. Remove hose assembly (27). Remove fitting (26) and the O-ring seal.
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    Illustration 15	g03642368

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    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.

19. Remove bolts (28) and housing (29).
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    Illustration 16	g03642372

20. Remove O-ring seal (32), O-ring seals (31), and O-ring seal (30) from housing (29).
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    Illustration 17	g03642376

21. Mark the orientation of coil (34). Remove nut (33) and coil (34).
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    Illustration 18	g03642379

22. Remove cartridge assembly (35).
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    Illustration 19	g03642381

23. Remove O-ring seals (36) from cartridge assembly (35).

24. Repeat Steps 21 through 23 for the remaining coil and cartridge assembly.
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    Illustration 20	g03642382

25. Remove plugs (37) and the O-ring seals.
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    Illustration 21	g03642606

26. Remove valve stems (38).
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    Illustration 22	g03642647

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    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.

27. Remove valve (39).
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    Illustration 23	g03642654

28. Remove O-ring seal (40) from valve (39).
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    Illustration 24	g03642656

29. Remove spring (41).
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    Illustration 25	g03642666

30. Remove washer (42).
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    Illustration 26	g03642701

31. Remove bolts (43) and cover (44).
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    Illustration 27	g03642704

32. Remove O-ring seal (45) from cover (44).
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    Illustration 28	g03642707

33. Remove plug (46) and the O-ring seal from cover (44).
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    Illustration 29	g03642709

34. Remove retainer (47).
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    Illustration 30	g03642712

35. Remove O-ring seal (48) from retainer (47).
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    Illustration 31	g03642716

36. Remove valve stem (49).
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    Illustration 32	g03642720

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    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.

37. Remove valves (50) and (51).
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    Illustration 33	g03642725

38. Remove O-ring seals (52) from valve (50). Remove O-ring seals (53) from valve (51).
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    Illustration 34	g03642727

39. Remove springs (54) and (55).
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    Illustration 35	g03642771

40. Remove stem (56). Repeat this step for the remaining stem.
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    Illustration 36	g03642804

41. Remove relief valve (57).
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    Illustration 37	g03642805

42. Remove O-ring seal (59) and backup ring (60) from relief valve (57). Remove O-ring seal (58).
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    Illustration 38	g03642819

43. Remove valve (61).
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    Illustration 39	g03642822

44. Remove O-ring seal (63) and backup ring (64) from valve (61). Remove O-ring seal (62).
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    Illustration 40	g03642827

45. Remove the bolts and housing (65).
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    Illustration 41	g03642829

46. Remove O-ring seals (66) from housing (65).
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    Illustration 42	g03642833

47. Remove nut (67) and coil (68) from housing (65).
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    Illustration 43	g03642837

48. Remove cartridge (69) from housing (65).
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    Illustration 44	g03642840

49. Remove O-ring seal (72) and backup rings (74) from cartridge (69). Remove O-ring seal (71) and backup rings (73). Remove O-ring seal (70).
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    Illustration 45	g03642842

50. Remove nut (75) and coil (76) from housing (65).
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    Illustration 46	g03642846

51. Remove cartridge (77).
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    Illustration 47	g03642847

52. Remove O-ring seals (78) from cartridge (77).
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    Illustration 48	g03642848

53. Remove nut (79) and coil (80).
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    Illustration 49	g03642850

54. Remove cartridge (81).
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    Illustration 50	g03642851

55. Remove O-ring seals (82) from cartridge (81).
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    Illustration 51	g03642852

56. Remove plug (84) and the O-ring seal from housing (65). Remove plug (83) and the O-ring seal.
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    Illustration 52	g03642855

57. Remove relief valve (85).
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    Illustration 53	g03642860

58. Remove O-ring seal (87) and backup rings (88) from relief valve (85). Remove O-ring seal (86).
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    Illustration 54	g03643336

59. Remove fitting (89) and the O-ring seal.
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    Illustration 55	g03643337

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    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.

60. Remove plug (90) and the O-ring seal.
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    Illustration 56	g03643339

61. Remove spool (91).
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    Illustration 57	g03643346

62. Remove spring (92).
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    Illustration 58	g03643342

63. Remove spool (93).
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    Illustration 59	g03643352

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    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.

64. Remove plug (94) and the O-ring seal.
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    Illustration 60	g03643379

65. Remove spool (95).
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    Illustration 61	g03643418

66. Remove spring (96).
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    Illustration 62	g03643425

67. Remove spool (97).
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    Illustration 63	g03643428

68. Remove plug (98) and the O-ring seal.
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    Illustration 64	g03643430

69. Remove hose assembly (99).
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    Illustration 65	g03643433

70. Remove check valve (100).
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    Illustration 66	g03643438

71. Remove backup ring (103) and O-ring seal (102) from check valve (100). Remove O-ring seal (101).
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    Illustration 67	g03643441

72. Remove check valve (104).
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    Illustration 68	g03643444

73. Remove backup ring (107) and O-ring seal (106) from check valve (104). Remove O-ring seal (105).
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    Illustration 69	g03643446

74. Remove plugs (108) and the O-ring seals.
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    Illustration 70	g03643452

75. Remove fitting (109) and the O-ring seals. Remove tube assembly (110) and the O-ring seals.
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    Illustration 71	g03643455

76. Remove valve (111) and the O-ring seal.
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    Illustration 72	g03643456

77. Remove relief valve (112).
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    Illustration 73	g03643458

78. Remove O-ring seal (115) and backup ring (114) from relief valve (112). Remove O-ring seal (113).
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    Illustration 74	g03643461

79. Remove valve (116).
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    Illustration 75	g03643470

80. Remove O-ring seal (119) and backup ring (118) from valve (116). Remove O-ring seal (117).
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    Illustration 76	g03643485

81. Remove bolts (120) and relief manifold assembly (121).
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    Illustration 77	g03643488

82. Remove O-ring seals (122) from relief manifold (121).
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    Illustration 78	g03643489

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    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.

83. Remove plug (126) and O-ring seal (125). Remove spacer (124) and spring (123).
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    Illustration 79	g03643493

84. Remove plug (127) and the O-ring seal.
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    Illustration 80	g03643497

85. Remove valve spool assembly (128).
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    Illustration 81	g03643501

86. Mark the orientation of coil (130) for assembly purposes. Remove nut (129) and coil (130).
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    Illustration 82	g03643508

87. Remove cartridge (131).
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    Illustration 83	g03643512

88. Remove O-ring seal (134) and backup rings (136) from cartridge (131). Remove O-ring seal (133) and backup rings (135). Remove O-ring seal (132).
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    Illustration 84	g03643515

89. Remove plug (137) and the O-ring seal.
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    Illustration 85	g03643522

90. Remove plug (138) and the O-ring seal.
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    Illustration 86	g03643525

91. Remove valve spool (139).
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    Illustration 87	g03643527

92. Remove plug (140) and the O-ring seal.
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    Illustration 88	g03643529

93. Remove plug (141) and the O-ring seal.
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    Illustration 89	g03643533

94. Remove orifice (142).
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    Illustration 90	g03643534

95. Remove plug (143) and the O-ring seal.
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    Illustration 91	g03643537

96. Remove plug (144) and the O-ring seal.
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    Illustration 92	g03643540

97. Mark the orientation of fitting (145) for assembly purposes. Remove fitting (145) and the O-ring seal.
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    Illustration 93	g03643542

98. Remove plug (146) and the O-ring seal.
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    Illustration 94	g03643545

99. Remove orifice (147) from relief manifold (121).