980G Caterpillar Wheel Loader Service Repair Manual

980G WHEEL LOADER

Product: WHEEL LOADER

Model: 980G WHEEL LOADER 2SR

Configuration: 980G WHEEL LOADER 2SR00651-UP (MACHINE) POWERED BY 3406 ENGINE

Disassembly and Assembly

980G Wheel Loader Engine Supplement

-SENR5873-03

Aftercooler - Install

SMCS - 1063-012

Installation Procedure

Table 1 Required Tools

A 138-7573 Link Bracket 2

Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

1. Clean all parts and inspect all parts. If any parts are worn or damaged, use new Caterpillar parts for replacement.

1

2. Install O-ring seal (26) to core assembly (25). Repeat the procedure for the other end of the core assembly.

Note: Lubricate the O-ring seals with a suitable lubricant.

2

3. Install the gasket and core assembly (25) to aftercooler housing (24) .

3

4. Install the gasket and cover (22) to aftercooler housing (24) .

Illustration 4

5. Install 22 bolts (22) in order to secure cover (23) to aftercooler housing (24) .

Illustration 5

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6. Install the gasket and adapter (20) and (21) to the aftercooler. Repeat the procedure for the other end of the aftercooler.

Illustration 6

7. Install six gaskets (19) to the engine.

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Illustration 7

Typical Example

8. Attach Tooling (A), as shown.

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9. Install the aftercooler with a hoist and suitable lifting slings. Weight of the aftercooler is 34 kg (75 lb).

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Illustration 8

Typical Example

This is a view under the machine.

Illustration 9

Typical Example

This is a view of the front of the aftercooler.

10. Install 12 bolts (18) in order to secure aftercooler (6) to the engine.

11. Remove the hoist and the suitable lifting sling.

Illustration 10

Typical Example

12. Connect tube (16) to aftercooler (6) and tighten retaining nut (17) .

Illustration 11

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13. Position the gasket and elbow (14) to aftercooler (6). Install four bolts (13) in order to secure elbow (14) to aftercooler (6) .

14. Install the bolt and clip (15) to elbow (14) .

12

15. Position the gasket and elbow (12) to the aftercooler (6). Install four bolts (11) in order to secure elbow (12) to aftercooler (6) .

Illustration 13

Typical Example

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16. Install the gasket and plate (10) to aftercooler (6) .

Illustration 14

Typical Example

17. Position gasket (9) to aftercooler (6) .

Illustration 15

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18. Install four bolts and nuts (7) in order to secure tube assembly (8) to aftercooler (6) .

16

19. Position the fuel filters on the aftercooler and install two bolts (5) .

20. Position the air conditioner hose in place and install the bolt to secure clip (1) .

21. Position the ether aid engine line (3) in place. Secure the clip with bolt (4) .

22. Connect the ether aid engine line (3) and tighten retaining nut (2) .

23. Fill the cooling system. Refer to Operations and Maintenance Manual, "Cooling System Coolant - Change" for the machine that is being serviced.

End By:

a. Install the side panel on the right side of the machine. Refer to Disassembly and Assembly, "Side Panels - Remove and Install" for the machine that is being serviced.

b. Disconnect the steering frame lock. Refer to Disassembly and Assembly, "Steering Frame Lock - Separate and Connect" for the machine that is being serviced. Copyright 1993 - 2023 Caterpillar Inc.

Product: WHEEL LOADER

Model: 980G WHEEL LOADER 2SR

Configuration: 980G WHEEL LOADER 2SR00651-UP (MACHINE) POWERED BY 3406 ENGINE

Disassembly and Assembly

980G Wheel Loader Engine Supplement

Aftercooler - Remove

SMCS - 1063-011

Removal Procedure

Table 1 Required Tools

A 138-7573 Link Bracket 2

Start By:

A. Connect the steering frame lock. Refer to Disassembly and Assembly, "Steering Frame LockSeparate and Connect" for the machine that is being serviced.

B. Remove the side panel on the right side of the machine. Refer to Disassembly and Assembly, "Side Panels - Remove and Install" for the machine that is being serviced.

NOTICE

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.

Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide", for tools and supplies suitable to collect and contain fluids in Caterpillar machines.

Dispose of all fluids according to local regulations and mandates.

At operating temperature, the engine coolant is hot and under pressure.

Steam can cause personal injury.

Check the coolant level only after the engine has been stopped and the fill cap is cool enough to touch with your bare hand.

Remove the fill cap slowly to relieve pressure.

Cooling system conditioner contains alkali. Avoid contact with the skin and eyes to prevent personal injury.

Note: Put identification marks on all lines, on all hoses, on all wires and on all tubes for installation purposes. Plug all lines, all hoses and all tubes. This will help to prevent fluid loss and this will help to keep contaminants from entering the system.

1. Drain the cooling system. The capacity of the cooling system is 81 L (21 US gal).

Illustration 1 g00533541

2. Loosen retaining nut (2) and disconnect ether aid engine line (3) .

3. Remove bolt (4). Position ether aid engine line (3) aside.

4. Remove the bolt from clip (1). Position the air conditioner hose aside.

5. Remove two bolts (5) that secure the fuel filters. Position the fuel filters aside.

Illustration 2

Typical Example

6. Remove four nuts (7) in order to separate tube assembly (8) from aftercooler (6) .

Illustration 3

Typical Example

7. Remove gasket (9) from aftercooler (6) .

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Illustration 4

Typical Example

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8. Remove plate (10) and the gasket from aftercooler (6) .

Illustration 5

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9. Remove four bolts (11) and remove elbow (12) .

6

10. Remove the bolt and clip (15) from elbow (14) .

11. Remove four bolts (13) and remove elbow (14) .

Illustration 7

Typical Example

12. Loosen retaining nut (17) and disconnect tube (16) from aftercooler (6) .

Illustration 8

Typical Example

13. Install Tooling (A) .

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14. Attach a hoist and suitable lifting slings to Tooling (A), as shown.

Illustration 9

Typical Example

This is a view of the front of the aftercooler.

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Illustration 10

Typical Example

This is a view under the machine.

15. Remove 12 bolts (18) from aftercooler (6). Remove the aftercooler from the engine. Weight of aftercooler is 34 kg (75 lb).

Illustration 11

Typical Example

16. Remove six gaskets (19) from the engine.

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12

17. Remove adapter (20) and (21) and the O-ring seals from the aftercooler.

13

18. Remove 22 bolts (22) in order to separate cover (23) from housing (24) .

Illustration 14

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19. Remove cover (23) and the gasket from housing (24) .

Illustration 15

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20. Remove core assembly (25) and the gasket from housing (24) .

Illustration 16

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21. Remove O-ring seal (26) from core assembly (25). Repeat the procedure for the other end of the core assembly.

Copyright 1993 - 2023 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees. Sun Aug 27 16:09:51 UTC+0530 2023

Product: WHEEL LOADER

Model: 980G WHEEL LOADER 2SR

Configuration: 980G WHEEL LOADER 2SR00651-UP (MACHINE) POWERED BY 3406 ENGINE

Disassembly and Assembly 980G Wheel Loader Engine Supplement

Air Cleaner - Remove and Install

SMCS - 1051-010; 1054-010

Removal Procedure

Start By:

A. Connect the steering frame lock. Refer to Disassembly and Assembly, "Steering Frame LockSeparate and Connect" for the machine that is being serviced.

1. Open the engine hood. The air cleaner is located on the left side of the machine.

1 g00514333

2. Loosen clamp (2) and hose clamp (3). Remove precleaner (1) .

2

3. Loosen hose clamps (4) at the air cleaner and at the turbocharger. Remove hose assembly (5) .

3

4. Disconnect electrical connector (6) .

5. Disconnect line (7) from the starting aid valve assembly (8) .

Illustration 4

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6. Disconnect air conditioning dryer (10) at the quick-connect fittings (9) .

Illustration 5

7. Remove bolts (11) and (12) .

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Illustration 6

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8. Loosen hose clamps (13). Remove the hose from dust ejector tube (14) .

Illustration 7

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9. Use a hoist and a suitable lifting sling to support the air cleaner assembly, as shown.

Illustration 8

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Illustration 9

10. Remove bolts (15) from both sides of the air cleaner support.

Illustration 10

11. Remove bolt (16) .

12. Remove the air cleaner assembly. Weight of the air cleaner assembly is 93 kg (205 lb).

Note: Use the following procedure to remove the air cleaner housing.

11

13. Disconnect line (17) .

12

14. Remove bolts (18) .

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Illustration 13 g00514330

15. Remove bolts (19). Separate the two halves.

Illustration 14

16. Remove bolts (20) .

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Illustration 15

17. Remove the air cleaner housing.

Installation Procedure

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