980L Tier 3 Wheel Loader Machine System Caterpillar

Removal Procedure

Start By:

1. Remove the bucket.

2. Remove the tilt lever and the tilt link.

3. Remove the front fenders.

4. Remove the lift position control.

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When you are using hydraulic cylinders and puller studs, always ensure that the rated capacity of the puller stud meets or exceeds the rated capacity of the hydraulic cylinder. If the puller stud does not meet or exceed the rated capacity of the hydraulic cylinder, a sudden failure of the puller stud could occur. The sudden failure of the puller stud could result in personal injury or death.

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Illustration 1	g06396435

1. Attach a suitable lifting device to tilt cylinder (1). The weight of tilt cylinder (1) is approximately 228 kg (503 lb). Raise tilt cylinder (1) until tilt cylinder (1) is clear of the lift arm.

2. Use a suitable lifting sling to secure tilt cylinder (1) to the cab as shown in Illustration 1.

3. Repeat Step 1 and Step 2 for the other tilt cylinder.
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   Illustration 2	g06396437

4. Start the machine and raise lift arm (2).

5. Place Tooling (A) in position under lift arm (2). Lower lift arm (2) on Tooling (A) as shown in Illustration 2. The weight of lift arm (2) is approximately 2310 kg (5093 lb)

6. Shut off the Machine. Release the pressure in the hydraulic system. Refer to Disassembly and Assembly, "System Pressure - Release".
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   Illustration 3	g06396447

7. Disconnect harness assembly (5) and remove the cable straps. Remove bolts (4) and clamps (3). Reposition harness assembly (5) away from the frame assembly.
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   Illustration 4	g06396477

8. Disconnect hose assemblies (6).
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   Illustration 5	g06396478

9. Remove cable strap (9) and disconnect hose assembly (7).

10. Remove bolt (8) and reposition hose assembly (7) away from the lift arm.

    Note: If any of the hose assemblies, the tube assemblies, and the harness assemblies attached to the lift arm could get damage during the removal of the lift arm, then remove the hose assemblies, the tube assemblies, and the harness assemblies from the lift arm.

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    Illustration 6	g06396484

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    Illustration 7	g06396989

11. Place suitable blocks between the frame and lift cylinder rod as shown in the Illustration 6. The weight of the lift cylinder is approximately 260 kg (573 lb).

12. Remove bolt (10) and the washer.

13. Attach Tooling (G) and a suitable lifting device to remove pin assembly (11). The combined weight of Tooling (G) and pin assembly (11) is approximately 50 kg (110 lb). Remove pin assembly (11).

14. Repeat Step 11 through Step 13 for the other side.
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    Illustration 8	g06396491

15. Disconnect tube assemblies (13) and remove adapter assemblies (12).
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    Illustration 9	g06396494

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    Illustration 10	g06396508

16. Attach a suitable lifting device to lift arm (2). The weight of lift arm (2) is approximately 2310 kg (5093 lb).

17. Remove bolt (15) and the washer.

18. Attach Tooling (B) and a suitable lifting device to remove pin assembly (14). The combined weight of Tooling (B) and pin assembly (14) is approximately 96 kg (212 lb). Remove pin assembly (14) and the shims.

19. Repeat Step 17 and Step 18 for the other side.

20. Remove lift arm (2) and place lift arm (2) on suitable blocks or on a suitable work place.
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    Illustration 11	g06396525

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    Illustration 12	g06396536

21. Remove lip seals (16) from the bucket pin bore.

22. Use Tooling (C) and a suitable lifting device to remove bearing (17). The weight of Tooling (C) is approximately 33 kg (73 lb). Remove bearing (17).

23. Repeat Step 21 and Step 22 for the other side.
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    Illustration 13	g06396541

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    Illustration 14	g06396543

24. Remove lip seals (18) from the lift cylinder pin bore.

25. Use Tooling (D) and a suitable lifting device to remove bearing (19). The weight of Tooling (D) is approximately 33 kg (73 lb). Remove bearing (19).

26. Repeat Step 24 and Step 25 for the other side.
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    Illustration 15	g06396550

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    Illustration 16	g06396552

27. Remove lip seals (20) from the pivot pin bore.

28. Use Tooling (E) and a suitable lifting device to remove bearing (21). The weight of Tooling (E) is approximately 35 kg (77 lb). Remove bearing (21).

29. Repeat Step 27 and Step 28 for the other side.

Installation Procedure

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Illustration 17	g06396552

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Illustration 18	g06396913
Dimension (M) is 20.0 ± 1.0 mm (0.79 ± 0.04 inch)

1. Use Tooling (E) and a suitable lifting device to install bearing (21). The weight of Tooling (E) is approximately 35 kg (77 lb). Install bearing (21) in the pivot pin bore. Install bearing (21) to a depth of Dimension (M) below the surface of the lift arm. Repeat for the other side.

   Note: Make sure that the lubrication holes are aligned during the installation of the bearings.

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   Illustration 19	g06396941

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   Illustration 20	g06396940
   Orientation of lip seal (20).

2. Apply Tooling (J) to the lip seal bore. Use Tooling (F) to install lip seals (20). Install lip seals (20). Repeat for the other side.

   Note: Make sure that the lip of the lip seal is facing outward. The lip seals should not protrude beyond bore face.

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   Illustration 21	g06396543

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   Illustration 22	g06396910
   Dimension (N) is 8.5 ± 1.0 mm (0.33 ± 0.04 inch)

3. Use Tooling (D) and a suitable lifting device to install bearing (19). The weight of Tooling (D) is approximately 33 kg (73 lb). Install bearing (19) in the lift cylinder pin bore. Install bearing (21) to a depth of Dimension (N) below the surface of the lift arm. Repeat for the other side.

   Note: Make sure that the lubrication holes are aligned during the installation of the bearings.

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   Illustration 23	g06396939

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   Illustration 24	g06396936
   Orientation of lip seal (18).

4. Apply Tooling (J) to the lip seal bore. Use Tooling (F) to install lip seals (18). Install lip seals (18). Repeat for the other side.

   Note: Make sure that the lip of the lip seal is facing outward. The lip seals should not protrude beyond bore face.

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   Illustration 25	g06396536

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   Illustration 26	g06396908
   Dimension (P) is 10.0 ± 1.0 mm (0.39 ± 0.04 inch)

5. Use Tooling (C) and a suitable lifting device to install bearing (17). The weight of Tooling (C) is approximately 33 kg (73 lb). Install bearing (17) in the bucket pin bore. Install bearing (17) to a depth of Dimension (P) below the surface of the lift arm. Repeat for the other side.

   Note: Make sure that the lubrication holes are aligned during the installation of the bearings.

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   Illustration 27	g06396933

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   Illustration 28	g06396935
   Orientation of lip seal (16).

6. Apply Tooling (J) to the lip seal bore. Use Tooling (F) to install lip seals (16). Install lip seals (16). Repeat for the other side.

   Note: Make sure that the lip of the lip seal is facing outward. The lip seals should not protrude beyond bore face.

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   Illustration 29	g06396962

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   Illustration 30	g06397041

7. Attach a suitable lifting device to lift arm (2). The weight of lift arm (2) is approximately 2310 kg (5093 lb).

8. Lubricate the pin bores of lift arm (2) with Tooling (H). Lubricate the pin bores of the front loader frame with Tooling (K).

   Note: Make sure that the Tooling (A) is in position.

9. Position lift arm (2) in alignment with the pin bores of the front loader frame and Tooling (A).

   Note: Do not damage the lip seals when installing the pin assemblies.

10. Use two people to install pin assembly (14). The weight of pin assembly (14) is approximately 34 kg (75 lb). Install the shims, pin assembly (14), the washer, and bolt (15). Repeat for the other side.
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    Illustration 31	g06396491

11. Apply Tooling (L) to the threads of adapter assemblies (12) and tube assemblies (13). Install adapter assemblies (12) and connect tube assemblies (13).
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    Illustration 32	g06397079

12. Attach a suitable lifting device to position the rod end of the lift cylinders in alignment with the pin bores of the lift arm. The weight of the lift cylinder is approximately 260 kg (573 lb).

    Note: Do not damage the lip seals when installing the pin assemblies.

13. Apply Tooling (K) to the pin bores of the lift cylinder. Install pin assembly (11), the washer, and bolt (10).

14. Repeat Step 12 and Step 13 for the other side.
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    Illustration 33	g06396478

15. Position hose assembly (7) and install bolt (8).

16. Connect hose assembly (7) and install cable strap (9).
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    Illustration 34	g06396477

17. Connect hose assemblies (6).
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    Illustration 35	g06396447

18. Position harness assembly (5). Install clamps (3) and bolts (4). Tighten bolts (4) to a torque of 6 ± 1 N.m (53 ± 9 lb in).

19. Connect harness assembly (5) and install the cable straps.

20. Start the machine. Raise the lift arms and remove the blocks from the frame and the lift cylinder rods. Remove Tooling (B) and lower the lift arm to the floor.
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    Illustration 36	g06396435

21. Attach a suitable lifting device to lower tilt cylinder (1). The weight of tilt cylinder (1) is approximately 228 kg (503 lb). Lower tilt cylinder (1) on the lift arm. Repeat for the other tilt cylinder.

End By:

1. Install the lift position sensor.

2. Install the front fenders.

3. Install the tilt lever and the tilt link.

4. Install the bucket.