980G Wheel Loader Power Train Caterpillar

Disassembly Procedure

Start By:

1. Remove the transmission hydraulic control valve. Refer to Disassembly and Assembly, "Transmission Hydraulic Control Valve - Remove" for the machine that is being serviced.

Note: Put identification marks on all sections of the transmission hydraulic control valve for assembly purposes.

Show/hide table



Illustration 1	g00500258

Show/hide table



Illustration 2	g00500280

Note: Put identification marks on all electrical connectors (4) for assembly purposes. Electrical connectors (4) must be positioned on the correct support clip after assembly.

1. Use the following procedure to check the O-ring seals of the solenoid valves:

   1. Remove electrical connector (4) from the support clip.

   2. Remove locknut (1), the washer and coil assembly (2) from cartridge (5) .

   3. Remove cartridge (5) from manifold (3) .
   Show/hide table
   
   

   Illustration 3	g00500281

   4. Check three O-ring seals (6) on cartridge (5). Replace any O-ring seal that is worn or damaged.

   5. Install cartridge (5) on manifold (3). Tighten cartridge (5) to a torque of 50 ± 5 N·m (37 ± 4 lb ft).

   6. Install coil assembly (2), the washer and locknut (1) to cartridge (5). Tighten locknut (1) to a torque of 5.0 ± 0.5 N·m (44 ± 4 lb in).

   7. Install electrical connector (4) to the support clip.

   8. Repeat steps 1.a through 1.g for the remaining solenoid valves.

Show/hide table



Illustration 4	g00500283

2. Remove bolts from the clamps that are holding wiring harness (9) .

3. Remove bolts (8) from manifold (3) .

4. Remove manifold (3) and wiring harness (9) from manifold (10) .

5. Remove connector (7) from manifold (3). Check the condition of the O-ring seal on connector (7). Replace a damaged seal with a new part.

Show/hide table



Illustration 5	g00500285

6. Remove 21 bolts (11) from manifold (10) .

7. Remove manifold (10) from upper valve body (12) .

Show/hide table



Illustration 6	g00500291

8. Remove upper valve body (12) from plate (13) .

Show/hide table



Illustration 7	g00500292

9. Remove bolts (14) and cover (15) from upper valve body (12) .

10. Check the condition of the O-ring seals beneath cover (15). Replace any O-ring seal that is worn or damaged.

Show/hide table



Illustration 8	g00500294

Show/hide table



Illustration 9	g00500296

11. Remove stop (16) and spool (17) from upper valve body (12) .

Show/hide table



Illustration 10	g00500298

Show/hide table

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.

Note: There is spring force against retaining ring (18). Hold retainers (20) and spring (19) while you are removing retaining ring (18) .

12. Remove retaining ring (18), two retainers (20) and spring (19) from spool (17) .

Show/hide table



Illustration 11	g00500299

Show/hide table



Illustration 12	g00500322

13. Remove spring (21) and spool (22) from upper valve body (12) .

Show/hide table



Illustration 13	g00500327

Show/hide table

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.

Note: There is spring force against retainer (25) and against retaining ring (26). Hold retainer (25) and spool (22) while you are removing retaining ring (26) .

14. Remove retaining ring (26), retainer (25), spring (24) and spring (23) from spool (22) .

Show/hide table



Illustration 14	g00500328

Show/hide table



Illustration 15	g00500329

Note: Spool (27) and spool (22) are located in the same bore of upper valve body (12). Spool (27) must be removed from the end opposite spool (22).

Show/hide table

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.

Note: There is spring force against pin (28) and against spool (27) .

15. Use the following procedure to remove spool (27) from upper valve body (12) :

    1. Turn upper valve body (12) to the opposite side and position upper valve body (12) on wood blocks, as shown.

    2. Use a hammer and a punch to push pin (28) into upper valve body (12) until pin (28) is clear of spool (27). Do not remove the punch at this time.

    3. Use a screwdriver to slightly depress spool (27) .

    4. Remove the punch from the hole for pin (28) .

    5. Slowly remove the screwdriver in order to relieve the spring force against spool (27) .

    6. Remove spool (27) from upper valve body (12) .

Show/hide table



Illustration 16	g00500330

16. Remove spring (29) from upper valve body (12) .

17. Remove slug (30) from upper valve body (12) .

Show/hide table



Illustration 17	g00500333

18. Reposition upper valve body (12) on a bench, as shown.

19. Remove piston (31) from upper valve body (12) .

Show/hide table



Illustration 18	g00500336

20. Remove spacers (32) from the inside diameter of piston (31) .

21. Remove springs (33) and (34) from upper valve body (12) .

Note: When you remove spool (35), use a punch or a screwdriver to keep the outside diameters of the spool and the bore of upper valve body (12) aligned. Avoid scratching the highly finished surfaces of spool (35) and the bore of upper valve body (12) .

22. Remove spool (35) from upper valve body (12) .

23. Remove slug (36) from spool (35) .

Show/hide table



Illustration 19	g00500337

Show/hide table

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.

Note: There is spring force against retaining ring (40) .

24. Carefully remove retaining ring (40), retainer (39), spring (38) and ball (37) from spool (35) .

Show/hide table



Illustration 20	g00500339

Show/hide table



Illustration 21	g00500340

25. Remove stop (41) and spool (42) from upper valve body (12) .

Show/hide table



Illustration 22	g00500342

Show/hide table

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.

Note: There is spring force against retaining ring (43). Hold retainers (45) and spring (44) while you are removing retaining ring (43) .

26. Remove retaining ring (43), two retainers (45) and spring (44) from spool (42) .

Show/hide table



Illustration 23	g00500343

27. Remove plate (13) from lower valve body (46) .

28. Remove two plugs (47) from plate (13) .

29. Check the condition of the O-ring seals on each plug (47). Replace any O-ring seal that is worn or damaged.

Show/hide table



Illustration 24	g00500345

Show/hide table



Illustration 25	g00500346

30. Remove two bolts (48), cover (49) and O-ring seal (50) from lower valve body (46) .

31. Remove stop (51) from lower valve body (46) .

32. Remove spool (55) from lower valve body (46) .

Show/hide table

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.

Note: There is spring force against retaining ring (52). Hold retainers (53) and spring (54) while you are removing retaining ring (52) .

33. Remove retaining ring (52), two retainers (53) and spring (54) from spool (55) .