980G Caterpillar Wheel Loader Operation and Maintenance Manual by quality service repair manual

Product:WHEELLOADER

Model:980GWHEELLOADER2SR

Configuration:980GWHEELLOADER2SR00651-UP(MACHINE)POWEREDBY3406ENGINE

OperationandMaintenanceManual

980GWheelLoader

MediaNumber-SEBU6946-11PublicationDate-01/09/2012DateUpdated-07/02/2019

Foreword

CaliforniaProposition65Warning

s03548206

DieselengineexhaustandsomeofitsconstituentsareknowntotheStateofCaliforniatocause cancer,birthdefects,andotherreproductiveharm.

WARNING-Thisproductcanexpose youtochemicalsincludingethylene glycol,whichisknowntotheStateof Californiatocausebirthdefectsorother reproductiveharm.Formoreinformation goto:

www.P65Warnings.ca.gov

Donotingestthischemical.Washhandsafterhandlingtoavoidincidentalingestion.

WARNING-Thisproductcanexpose youtochemicalsincludingleadandlead compounds,whichareknowntotheState ofCaliforniatocausecancer,birthdefects, orotherreproductiveharm.Formore informationgoto:

www.P65Warnings.ca.gov

Washhandsafterhandlingcomponentsthatmaycontainlead.

Product:WHEELLOADER

Model:980GWHEELLOADER2SR

Configuration:980GWHEELLOADER2SR00651-UP(MACHINE)POWEREDBY3406ENGINE

OperationandMaintenanceManual

980GWheelLoader

MediaNumber-SEBU6946-11PublicationDate-01/09/2012DateUpdated-07/02/2019

ArticulationBearings-Lubricate

SMCS-7057-086-BD;7065-086-BD;7066-086-BD

Wipeoffthefittingsbeforeanylubricantisapplied.

Illustration1g00123326

Applylubricantthroughonefittingontheupperpivotbearing.

Illustration2g00123328

Applylubricantthroughonefittingonthelowerpivotbearing.

TueMar2612:12:21UTC+05302024

Product:WHEELLOADER

Model:980GWHEELLOADER2SR

Configuration:980GWHEELLOADER2SR00651-UP(MACHINE)POWEREDBY3406ENGINE

OperationandMaintenanceManual

980GWheelLoader

MediaNumber-SEBU6946-11PublicationDate-01/09/2012DateUpdated-07/02/2019

AxleOscillationBearings-Lubricate

SMCS-3268-086-BD;3278-086-BD

Wipeoffthefittingsbeforeanylubricantisapplied. Illustration1g00519370

Opentheaccessdoorontherightsideofthemachine.Applylubricantthroughtworemotefittings(1) and(2).

Product:WHEELLOADER

Model:980GWHEELLOADER2SR

Configuration:980GWHEELLOADER2SR00651-UP(MACHINE)POWEREDBY3406ENGINE

OperationandMaintenanceManual

980GWheelLoader

MediaNumber-SEBU6946-11PublicationDate-01/09/2012DateUpdated-07/02/2019 i01082723

BackupAlarm-Test

SMCS-7406-081

TurntheenginestartswitchkeytotheONpositioninordertoperformthetest. Applytheservicebrake.

MovethetransmissiondirectioncontrollevertotheREVERSEposition.

Thealarmshouldstarttosoundimmediately.Thealarmwillcontinuetosounduntilthetransmission directioncontrolleverismovedtotheNEUTRALpositionortotheFORWARDposition.

Thebackupalarmislocatedbehindthegrillontherearofthemachine.

Athree-positionswitchattherearofthebackupalarmregulatesthesoundofthealarm(high,low, andmedium).

Thealarmissetatthemaximumsoundlevelwhenthemachineisshippedfromthefactory.The settingshouldremainonhigh,unlessthejobsiterequiresalowersoundlevel.

TueMar2612:12:46UTC+05302024

Product:WHEELLOADER

Model:980GWHEELLOADER2SR

Configuration:980GWHEELLOADER2SR00651-UP(MACHINE)POWEREDBY3406ENGINE

OperationandMaintenanceManual 980GWheelLoader

MediaNumber-SEBU6946-11PublicationDate-01/09/2012DateUpdated-07/02/2019

Battery-Clean

SMCS-1401-070

1.Preparethemachineformaintenance.RefertoOperationandMaintenanceManual,"Prepare theMachineforMaintenance".RefertostepsforlockoutcontrolsthatDOESNOTrequirethe enginetoberunning.

2.Openthebatterycompartmentontherightrearsideofthemachine. Illustration1g01093084 Batteries

3.Cleanthebatteryterminalsandthesurfacesofthebatterieswithacleancloth.Coatthebattery terminalswithpetroleumjelly.Makesurethatthebatterycablesareinstalledsecurely.

i08193197

TueMar2612:13:01UTC+05302024

This is the sample of the manual Click on the download link for complete Manual

Product:WHEELLOADER

Model:980GWHEELLOADER2SR

Configuration:980GWHEELLOADER2SR00651-UP(MACHINE)POWEREDBY3406ENGINE

OperationandMaintenanceManual

980GWheelLoader

MediaNumber-SEBU6946-11PublicationDate-01/09/2012DateUpdated-07/02/2019

Battery-Recycle

SMCS-1401-561

Alwaysrecycleabattery.Neverdiscardabattery.

Alwaysreturnusedbatteriestooneofthefollowinglocations:

•Abatterysupplier

•Anauthorizedbatterycollectionfacility

•Recyclingfacility

i07746330

TueMar2612:13:13UTC+05302024

Product:WHEELLOADER

Model:980GWHEELLOADER2SR

Configuration:980GWHEELLOADER2SR00651-UP(MACHINE)POWEREDBY3406ENGINE

OperationandMaintenanceManual 980GWheelLoader

MediaNumber-SEBU6946-11PublicationDate-01/09/2012DateUpdated-07/02/2019

BatteryHold-Down-Tighten

SMCS-7257-527

1.Preparethemachineformaintenance.RefertoOperationandMaintenanceManual,"Prepare theMachineforMaintenance".RefertostepsforlockoutcontrolsthatDOESNOTrequirethe enginetoberunning.

2.Openthebatterycompartmentontherightrearsideofthemachine.

Illustration1g01093110 Batterynuts

i08193200

3.Overtime,thevibrationofanoperatingmachinecancausethebatteryhold-downstoloosen. Tohelptopreventloosebatteriesandthepossibilityofloosecableconnections,tightenthe eightnutsonthetwohold-downstoatorqueof2.50±0.25N·m(22±2lbin).

TueMar2612:13:26UTC+05302024

Product:WHEELLOADER

Model:980GWHEELLOADER2SR

Configuration:980GWHEELLOADER2SR00651-UP(MACHINE)POWEREDBY3406ENGINE

OperationandMaintenanceManual

980GWheelLoader

MediaNumber-SEBU6946-11PublicationDate-01/09/2012DateUpdated-07/02/2019 i08185587

BatteryorBatteryCable-Inspect/Replace

SMCS-1401-040;1401-510;1402-040;1402-510

Personalinjurymayoccurfromfailuretoproperlyservicethebatteries.

Batteriesgiveoffflammablefumesthatcanexplode.Electrolyteisan acidandcancausepersonalinjuryifitcontactstheskinoreyes.

Preventsparksnearthebatteries.Sparkscouldcausevaporstoexplode. Donotallowjumpercableendstocontacteachotherortheengine. Improperjumpercableconnectionscancauseanexplosion.

Alwayswearprotectiveglasseswhenworkingwithbatteries.

1.Preparethemachineformaintenance.RefertoOperationandMaintenanceManual,Preparethe MachineforMaintenance.

2.TurntheenginestartswitchkeyOFF.TurnalloftheswitchesOFF.

3.TurnthebatterydisconnectswitchOFF.Removethekey.

4.Disconnectthenegativebatterycablefromthedisconnectswitch.

Note:Donotallowthedisconnectedbatterycabletocontactthedisconnectswitch.

5.Disconnectthenegativebatterycableatthebattery.

6.Disconnectthepositivebatterycableatthebattery.

7.Inspectthebatteryterminalsforcorrosion.Inspectthebatterycablesforwearordamage.

8.Makeanynecessaryrepairs.Ifnecessary,replacethebatterycablesorthebattery.

9.Connectthepositivebatterycableatthebattery.

10.Connectthenegativebatterycableatthebattery.

11.Connectthebatterycableatthebatterydisconnectswitch.

12.InstallthekeyandturnthebatterydisconnectswitchON.

RecycletheBattery

Alwaysrecycleabattery.Neverdiscardabattery.

Alwaysreturnusedbatteriestooneofthefollowinglocations:

•Abatterysupplier

•Anauthorizedbatterycollectionfacility

•Recyclingfacility

AllRightsReserved. PrivateNetworkForSISLicensees.

TueMar2612:13:41UTC+05302024

Product:WHEELLOADER

Model:980GWHEELLOADER2SR

Configuration:980GWHEELLOADER2SR00651-UP(MACHINE)POWEREDBY3406ENGINE

OperationandMaintenanceManual

980GWheelLoader

MediaNumber-SEBU6946-11PublicationDate-01/09/2012DateUpdated-07/02/2019 i01488907

Belts-Inspect/Adjust/Replace

SMCS-1357-025;1357-040;1357-510

AdjustingtheCompressorDriveBelt

1.Stoptheengineinordertoinspecttheairconditionerbelt.

2.Opentheenginehood.

3.Inspecttheconditionofthecompressordrivebeltandtheadjustmentofthecompressordrive belt.Ausedcompressordrivebeltshouldmeasure400±44N(90±10lb).Measurethe tensionbyusingaBoroughsGaugeBT-33-97.Ausedbelthasbeeninserviceforthirty minutes.Anewcompressordrivebeltshouldmeasure534±22N(120±5lb).Measurethe tensiononaBorroughsGaugeBT-33-97.Ifthetensionofthecompressordrivebeltis acceptable,thenproceedtoStep8.Iftheaircompressorbeltneedsadjustment,thencontinueto thenextstep.

4.Loosenthecompressorlocknut(2).Loosenthemountingbolts(3)and(4).

5.Turntheadjustingnut(1)untilthecorrectbelttensionisreached.

6.Tightenthecompressorlocknut(2)to150±20N·m(110±15lbft).Tightenthemounting bolts(3)and(4).

7.Recheckthemeasurementofthebelt.

8.Closetheenginehood.Starttheengine.Ifpoorcoolingisstillexperienced,turnofftheair conditioner.Stoptheengine.NotifyyourCaterpillardealerforairconditionersystemservice,if necessary.

AdjustingtheAlternatorBelt

Illustration3g00536060

1.Opentheenginehood.Thealternatorisontherightsideofthemachine.Pullthecableinorder toopentheengineaccessdoorontherightsideofthemachine.

Illustration4g00536037

2.Inspecttheconditionofthealternatorbelt(5)andtheadjustmentofthealternatorbelt.Aused alternatorbeltshouldmeasure400±44N(90±10lb).MeasurethetensiononaBorroughs GaugeBT-33-72C.Ausedbelthasbeenusedforthirtyminutes.Anewalternatorbeltshould measure534±22N(120±5lb)onaBorroughsGaugeBT-33-72C.Ifthetensionofthe alternatorbeltisacceptable,thenproceedtoStep7.Ifthealternatorbeltneedsadjustment,then continuetothenextstep.

3.Loosenthebolts(3)thatmountthealternator(4).Loosenthelocknut(2).

4.Turntheadjustinglocknut(1)untilthecorrecttensionisreached.

5.Tightenadjustinglocknut(2).Tightenthemountingbolt(3).

6.Recheckthemeasurementofthebelt.

7.Closetheengineaccessdoor.Closetheenginehood.

TueMar2612:13:58UTC+05302024

Product:WHEELLOADER

Model:980GWHEELLOADER2SR

Configuration:980GWHEELLOADER2SR00651-UP(MACHINE)POWEREDBY3406ENGINE

OperationandMaintenanceManual

980GWheelLoader

MediaNumber-SEBU6946-11PublicationDate-01/09/2012DateUpdated-07/02/2019

BrakeAccumulator-Check

i05092713

SMCS-4263-535 Illustration1g00882020

1.TurntheenginestartswitchtotheONposition.Thealertindicatorforbrakeoilpressureshould comeonifthebrakingsystemisnotatnormaloperatingpressure.

2.Starttheengine.Runtheengineathalfspeedfor2minutesinordertoincreasetheaccumulator pressure.Thealertindicatorforbrakeoilpressureshouldgooff.

3.Stoptheenginebyturningthemachinestartswitchtooff.Wait5secondsthenturnmachine startswitchtoon,butdonotstarttheengine.Waitforthedisplaymonitortogothrough

startup,keyonlevelchecks,andoperatorselection.Applytheservicebrakes(fullydepressthe pedal)foradurationofonesecond.Releasethepedalforadurationofonesecond.Repeatthe applicationandreleaseprocessuntilthealertindicatorforbrakeoilpresurecomeson.Thiswill decreasetheaccumulatorpressure.Aminimumoffiveapplicationsoftheservicebrakepedal arerequired.

4.Ifthealertindicatorcomesonafterlessthanfiveapplicationsofthebrake,measurethe accumulatorprechargepressure.AnauthorizedCaterpillardealercanmeasurethenitrogengas pressureintheaccumulator.Useonlydrynitrogengasforrecharging.

TueMar2612:14:21UTC+05302024

Product:WHEELLOADER

Model:980GWHEELLOADER2SR

Configuration:980GWHEELLOADER2SR00651-UP(MACHINE)POWEREDBY3406ENGINE

OperationandMaintenanceManual

980GWheelLoader

MediaNumber-SEBU6946-11PublicationDate-01/09/2012DateUpdated-07/02/2019

BrakeDiscs-Check

SMCS-4255-082;4255-535

Reference:Forinformationaboutcheckingthethicknessofthebrakediscs,refertoTestingand Adjusting,SENR5881,"980GWheelLoaderBrakingSystem","ServiceBrakeDiscs-Check"or consultyourCaterpillardealer.

TueMar2612:14:35UTC+05302024

Product:WHEELLOADER

Model:980GWHEELLOADER2SR

Configuration:980GWHEELLOADER2SR00651-UP(MACHINE)POWEREDBY3406ENGINE

OperationandMaintenanceManual 980GWheelLoader

MediaNumber-SEBU6946-11PublicationDate-01/09/2012DateUpdated-07/02/2019

BrakingSystem-Test

SMCS-4251-081;4267-081

•Fastentheseatbeltbeforeyoutestthebrakes.

•Parkthemachineonadry,levelsurface.

i01739721

•Checktheareaaroundthemachine.Makesurethatthemachineisclearofpersonnelandclear ofobstacles.

•Makesurethatthesteeringframelockisintheunlockedposition.

Thefollowingtestsareusedtodeterminewhetherthebrakingsystemisfunctional.Thesetestsarenot intendedtomeasurethemaximumbrakeholdingeffort.Therequiredbrakeholdingeffortfor sustainingamachineataspecificenginerpmvariesfromonemachinetoanothermachine.The variationsincludedifferencesintheenginesetting,thepowertrainefficiency,thebrakeholding ability,etc.

ServiceBrakeHoldingAbilityTest

Personalinjurycanresultifthemachinemoveswhiletesting.

Ifthemachinebeginstomoveduringtest,reducetheenginespeed immediatelyandengagetheparkingbrake.

1.Starttheengine.Raisetheimplementslightly.Applytheservicebrake.Releasetheparking brake.

2.MovethetransmissioncontroltoTHIRDSPEEDFORWARDwhiletheservicebrakesare applied.MakesurethattheautoshiftcontrolisintheOFFposition.

3.Graduallyincreasetheenginespeedtohighidle.Themachineshouldnotmove.

4.Reducetheenginespeedtolowidle.MovethetransmissiondirectioncontroltotheNEUTRAL position.Engagetheparkingbrake.Lowertheimplementtotheground.Stoptheengine.

Ifthemachinemovedduringthetest,consultyourCaterpillardealerforabrakeinspection.Makeany necessaryrepairsbeforethemachineisreturnedtooperation.

ParkingBrakeHoldingAbilityTest

Personalinjurycanresultifthemachinemoveswhiletesting.

Ifthemachinebeginstomove,reducetheenginespeedimmediatelyand applytheservicebrakepedal.

Thistestisperformedwhentheparkingbrakeisengaged.Ifthemachinebeginstomove,comparethe enginerpmtotheenginerpmofapriortest.Thiswillindicatetheamountofsystemdeterioration.

1.Starttheengine.Raisetheimplementslightly.Engagetheparkingbrake.

2.MovethetransmissioncontroltoTHIRDSPEEDFORWARD.Makesurethattheautoshift controlisintheOFFposition.

Theparkingbrakeindicatorlightshouldcomeon.

3.Graduallyincreasetheenginespeedtohighidle.Themachineshouldnotmove.

4.Reducetheenginespeedtolowidle.MovethetransmissiondirectioncontroltotheNEUTRAL position.Lowertheimplementtotheground.Stoptheengine.

Ifthemachinemovedduringthetest,consultyourCaterpillardealerforabrakeinspection.Makeany necessaryrepairsbeforethemachineisreturnedtooperation.

Product:WHEELLOADER

Model:980GWHEELLOADER2SR

Configuration:980GWHEELLOADER2SR00651-UP(MACHINE)POWEREDBY3406ENGINE

OperationandMaintenanceManual 980GWheelLoader

MediaNumber-SEBU6946-11PublicationDate-01/09/2012DateUpdated-07/02/2019

BucketCuttingEdges-Inspect/Replace

SMCS-6801-040;6801-510

Personalinjuryordeathcanresultfrombucketfalling. Blockthebucketbeforechangingbucketcuttingedges.

(1)BoltsforCuttingEdge (2)CuttingEdge

Checkthecuttingedgesandtheendbitsforwearandfordamage.Usethefollowingprocedureto servicethecuttingedgesandtheendbits:

1.Raisethebucketandplaceblockingunderthebucket.

2.Lowerthebucketontotheblocking.Stoptheengine.

3.Removebolts(1),cuttingedge(2)andtheendbits.

4.Cleanallcontactsurfaces.

5.Iftheoppositesideofthecuttingedgeisnotworn,usetheoppositesideofthecuttingedge. Theendbitsarenotreversible.

Ifbothsidesareworn,installanewcuttingedge.

6.Installbolts(1).Tightentheboltstothespecifiedtorque.

Reference:RefertoSpecifications,SENR3130,"GroundEngagingTool(G.E.T.)Fasteners".

7.Starttheengine.Raisethebucketandremovetheblocking.Lowerthebuckettotheground.

8.Afterafewhoursofoperation,checktheboltsforpropertorque.

BucketWearPlates

Personalinjuryordeathcanresultfromthebucketfalling. Blockthebucketbeforechangingbucketwearplates.

Inspectthewearplates.Replacethewearplatesbeforedamagetothebottomofthebucketoccurs. ConsultyourCaterpillardealerforreplacementofwearplates.

TueMar2612:15:07UTC+05302024

This is the sample of the manual Click on the download link for complete Manual