980L Tier 3 Wheel Loader Machine System Caterpillar

Assembly Procedure

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Illustration 1	g03643545

1. Install orifice (147) into relief manifold assembly (121).
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   Illustration 2	g03643542

2. Install the O-ring seal and plug (146).
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   Illustration 3	g03643540

3. Install the O-ring seal and fitting (145).
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   Illustration 4	g03643537

4. Install the O-ring seal and plug (144).
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   Illustration 5	g03643534

5. Install the O-ring seal and plug (143).
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   Illustration 6	g03643533

6. Install orifice (142).
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   Illustration 7	g03643529

7. Install the O-ring seal and plug (141).
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   Illustration 8	g03643527

8. Install the O-ring seal and plug (140).
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   Illustration 9	g03643525

9. Install valve spool (139).
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   Illustration 10	g03643522

10. Install the O-ring seal and plug (138).
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    Illustration 11	g03643515

11. Install the O-ring seal and plug (137).
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    Illustration 12	g03643512

12. Install O-ring seal (132) onto cartridge (131). Install O-ring seal (133) and backup rings (135). Install O-ring seal (134) and backup rings (136).
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    Illustration 13	g03643508

13. Install cartridge (131). Tighten cartridge (131) to a torque of 27.5 ± 2.5 N·m (243.4 ± 22.1 lb in).
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    Illustration 14	g03643501

14. Install coil (130) and nut (129). Tighten nut (129) to a torque of 5 ± 1 N·m (44 ± 9 lb in).
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    Illustration 15	g03643497

15. Install valve spool assembly (128).
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    Illustration 16	g03643493

16. Install the O-ring seal and plug (127).
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    Illustration 17	g03643489

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    Improper assembly of parts that are spring loaded can cause bodily injury. To prevent possible injury, follow the established assembly procedure and wear protective equipment.

17. Install spring (123) and spacer (124). Install O-ring seal (125) onto plug (126). Install plug (126).
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    Illustration 18	g03643488

18. Install O-ring seals (122) onto relief manifold assembly (121).
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    Illustration 19	g03643485

19. Install relief manifold assembly (121) and bolts (120).
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    Illustration 20	g03643470

20. Install O-ring seal (117) onto valve (116). Install backup ring (118) and O-ring seal (119).
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    Illustration 21	g03643461

21. Install valve (116). Tighten valve (116) to a torque of 50 ± 5 N·m (37 ± 4 lb ft).
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    Illustration 22	g03643458

22. Install O-ring seal (113) onto relief valve (112). Install backup ring (114) and O-ring seal (115).
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    Illustration 23	g03643456

23. Install relief valve (112). Tighten relief valve (112) to a torque of 37.5 ± 3.5 N·m (27.7 ± 2.6 lb ft).
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    Illustration 24	g03643455

24. Install the O-ring seal and valve (111). Tighten valve (111) to a torque of 30 to to 33 N·m (266 to 292 lb in).
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    Illustration 25	g03643452

25. Install the O-ring seals and tube assembly (110). Install the O-ring seals and fitting (109).
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    Illustration 26	g03643446

26. Install the O-ring seals and plugs (108).
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    Illustration 27	g03643444

27. Install O-ring seal (105) onto check valve (104). Install O-ring seal (106) and backup ring (107).
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    Illustration 28	g03643441

28. Install check valve (104). Tighten check valve (104) to a torque of 24 ± 3 N·m (212 ± 27 lb in).
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    Illustration 29	g03643438

29. Install O-ring seal (101) onto check valve (100). Install O-ring seal (102) and backup ring (103).
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    Illustration 30	g03643433

30. Install check valve (100). Tighten check valve (100) to a torque of 24 ± 3 N·m (212 ± 27 lb in).
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    Illustration 31	g03643430

31. Install hose assembly (99).
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    Illustration 32	g03643428

32. Install the O-ring seal and plug (98).
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    Illustration 33	g03643425

33. Install spool (97).
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    Illustration 34	g03643418

34. Install spring (96).
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    Illustration 35	g03643379

35. Install spool (95).
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    Illustration 36	g03643352

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    Improper assembly of parts that are spring loaded can cause bodily injury. To prevent possible injury, follow the established assembly procedure and wear protective equipment.

36. Install the O-ring seals and plug (94). Tighten plug (94) to a torque of 300 ± 45 N·m (221 ± 33 lb ft).
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    Illustration 37	g03643342

37. Install spool (93).
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    Illustration 38	g03643346

38. Install spring (92).
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    Illustration 39	g03643339

39. Install spool (91).
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    Illustration 40	g03643337

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    Improper assembly of parts that are spring loaded can cause bodily injury. To prevent possible injury, follow the established assembly procedure and wear protective equipment.

40. Install the O-ring seal and plug (90). Tighten plug (90) to a torque of 300 ± 45 N·m (221 ± 33 lb ft).
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    Illustration 41	g03643336

41. Install the O-ring seal and fitting (89).
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    Illustration 42	g03642860

42. Install O-ring seal (86) onto relief valve (85). Install O-ring seal (87) and backup rings (88).
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    Illustration 43	g03642855

43. Install relief valve (85). Tighten relief valve (85) to a torque of 53 ± 3 N·m (39 ± 2 lb ft).
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    Illustration 44	g03642852

44. Install the O-ring seal and plug (83) into housing (65). Install the O-ring seal and plug (84).
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    Illustration 45	g03642851

45. Install O-ring seals (82) onto cartridge (81).
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    Illustration 46	g03642850

46. Install cartridge (81). Tighten cartridge (81) to a torque of 35 ± 3 N·m (26 ± 2 lb ft).
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    Illustration 47	g03642848

47. Install coil (80) and nut (79). Tighten nut (79) to a torque of 20 ± 3 N·m (177 ± 27 lb in).
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    Illustration 48	g03642847

48. Install O-ring seals (78) onto cartridge (77).
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    Illustration 49	g03642846

49. Install cartridge (77). Tighten cartridge (77) to a torque of 35 ± 3 N·m (26 ± 2 lb ft).
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    Illustration 50	g03642842

50. Install coil (76) and nut (75) onto housing (65). Tighten nut (75) to a torque of 20 ± 3 N·m (177 ± 27 lb in).
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    Illustration 51	g03642840

51. Install O-ring seal (70) onto cartridge (69). Install O-ring seal (71) and backup rings (73). Install O-ring seal (72) and backup rings (74).
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    Illustration 52	g03642837

52. Install cartridge (69) onto housing (65). Tighten cartridge (69) to a torque of 27.2 ± 1.4 N·m (240.7 ± 12.4 lb in).
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    Illustration 53	g03642833

53. Install coil (68) and nut (67) onto housing (65). Tighten nut (67) to a torque of 6.1 ± 0.7 N·m (54.0 ± 6.2 lb in).
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    Illustration 54	g03642829

54. Install O-ring seals (66) onto housing (65).
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    Illustration 55	g03642827

55. Install housing (65) and the bolts.
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    Illustration 56	g03642822

56. Install O-ring seal (62) onto valve (61). Install backup ring (64) and O-ring seal (63).
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    Illustration 57	g03642819

57. Install valve (61). Tighten valve (61) to a torque of 185 ± 18 N·m (136 ± 13 lb ft).
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    Illustration 58	g03642805

58. Install O-ring seal (58) onto relief valve (57). Install backup ring (60) and O-ring seal (59).
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    Illustration 59	g03642804

59. Install relief valve (57). Tighten relief valve (57) to a torque of 203 ± 8 N·m (150 ± 6 lb ft).
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    Illustration 60	g03642771

60. Install spool (56). Repeat this step for the remaining spool.
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    Illustration 61	g03642727

61. Install springs (55) and (54).
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    Illustration 62	g03642725

62. Install O-ring seals (53) onto valve (51). Install O-ring seals (52) onto valve (50).
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    Illustration 63	g03642720

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    Improper assembly of parts that are spring loaded can cause bodily injury. To prevent possible injury, follow the established assembly procedure and wear protective equipment.

63. Install valve (51) and valve (50). Tighten valves (51) and (50) to a torque of 100 ± 10 N·m (74 ± 7 lb ft).
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    Illustration 64	g03642716

64. Install valve stem (49).
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    Illustration 65	g03642712

65. Install O-ring seal (48) onto retainer (47).
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    Illustration 66	g03642709

66. Install retainer (47).
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    Illustration 67	g03642707

67. Install the O-ring seal and plug (46) into cover (44).
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    Illustration 68	g03642704

68. Install O-ring seal (45) into cover (44).
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    Illustration 69	g03642701

69. Install cover (44) and bolts (43).
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    Illustration 70	g03642666

70. Install washer (42).
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    Illustration 71	g03642656

71. Install spring (41).
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    Illustration 72	g03642654

72. Install O-ring seal (40) onto valve (39).
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    Illustration 73	g03642647

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    Improper assembly of parts that are spring loaded can cause bodily injury. To prevent possible injury, follow the established assembly procedure and wear protective equipment.

73. Install valve (39).
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    Illustration 74	g03642606

74. Install valve stems (38).
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    Illustration 75	g03642382

75. Install the O-ring seals and plugs (37).
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    Illustration 76	g03642381

76. Install O-ring seals (36) onto cartridge assembly (35).
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    Illustration 77	g03643757

77. Install cartridge assembly (35) into housing (29). Tighten cartridge (35) to a torque of 35 ± 3 N·m (26 ± 2 lb ft).
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    Illustration 78	g03642376

78. Install coil (34) and nut (33). Tighten nut (33) to a torque of 20 ± 3 N·m (177 ± 27 lb in).

79. Repeat Steps 76 through 78 for the remaining coil and cartridge assembly.
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    Illustration 79	g03642372

80. Install O-ring seal (32) onto housing (29). Install O-ring seals (31) and O-ring seal (30).
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    Illustration 80	g03642368

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    Improper assembly of parts that are spring loaded can cause bodily injury. To prevent possible injury, follow the established assembly procedure and wear protective equipment.

81. Install housing (29) and bolts (28).
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    Illustration 81	g03642364

82. Install the O-ring seal and fitting (26). Install hose assembly (27).
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    Illustration 82	g03642361

83. Install the O-ring seals and plugs (25).
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    Illustration 83	g03642358

84. Install O-ring seal (24) onto accumulator (23).
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    Illustration 84	g03642356

85. Install accumulator (23). Tighten accumulator (23) to a torque of 20 ± 1 N·m (177 ± 9 lb in).
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    Illustration 85	g03642327

86. Install the O-ring seal and fitting (21).

87. Install the O-ring seals and fittings (20).

88. Install hose assembly (22).
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    Illustration 86	g03642305

89. Install O-ring seal (19) onto relief valve (18).
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    Illustration 87	g06130510

90. Install relief valve (18). Tighten relief valve (18) to a torque of 64.5 ± 3.5 N·m (47.6 ± 2.6 lb ft).
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    Illustration 88	g03642259

91. Install O-ring seal (13) onto relief valve (12). Install O-ring seal (14) and backup rings (16). Install O-ring seal (15) and backup rings (17).
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    Illustration 89	g06130490

92. Install relief valve (12). Tighten relief valve (12) to a torque of 185 ± 18 N·m (136 ± 13 lb ft).
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    Illustration 90	g03642234

93. Install O-ring seal (7) onto cartridge assembly (6). Install O-ring seal (8) and backup rings (10). Install O-ring seal (9) and backup rings (11).
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    Illustration 91	g06130488

94. Install cartridge assembly (6). Tighten cartridge assembly (6) to a torque of 27.2 ± 3.0 N·m (240.7 ± 26.6 lb in).
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    Illustration 92	g06130486

95. Install coil (5) and nut (4). Tighten nut (4) to a torque of 6.1 ± 0.7 N·m (54.0 ± 6.2 lb in).
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    Illustration 93	g03642221

96. Install the O-ring seals and fittings (3). Install the O-ring seal and plug (2).
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    Illustration 94	g06130482

97. Install pressure sensors (1) and (1A). Tighten pressure sensor (1) to a torque of 62 ± 6 N·m (46 ± 4 lb ft). Tighten pressure sensors (1A) to a torque of 65 ± 10 N·m (48 ± 7 lb ft).

End By:

1. Install the main control valve.