Installation Procedure for the 980K Wheel Loader Inclined Ladder Field Install Kit{0679, 0680, 1273, 5057, 5147, 7000, 7254, 7960} Caterpillar

Wheel Loader:

980K (S/N: W7K1-UP; GTZ1-UP)

Introduction

ReferenceDisassembly and Assembly, KENR6460, "980K Wheel Loader Machine Systems", "Fuel Tank Remove and Install"

ReferenceSpecial Instruction, REHS1841, "General Welding Procedures"

This procedure details the field installation of the 392-7759 Ladder Ar on the 980K Wheel Loader.

Do not perform any procedure in this publication or order any parts until you understand the information that is contained in this publication.

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Personal injury or death can result from sudden machine movement. Sudden movement of the machine can cause injury to persons on or near the machine. To prevent injury or death, make sure that the area around the machine is clear of personnel and obstructions before operating the machine.

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Do not attempt to assemble this machine until you read and you understand the assembly instructions. Improper assembly procedures could result in injury or death.

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Personal injury can result from hydraulic oil pressure and hot oil. Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic system. Make sure all of the work tools have been lowered to the ground, and the oil is cool before removing any components or lines. Remove the oil filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand.

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Sudden movement or accidental starting of the machine can cause personal injury or death to persons on or near the machine. To prevent personal injury or death, perform the following: Park the machine on a smooth, level surface. Lower the work tool to the ground and engage the parking brake. Stop the engine and remove the key. Block the wheels and install the steering frame lock.

Important Safety Information

Do not perform any procedure in this special instruction until you have read this special instruction and you understand this information. Use only proper tools and observe all precautions that pertain to the use of those tools. Failure to follow these procedures can result in personal injury. The following procedures should also be observed.

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs.

A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools in order to perform these functions properly.

Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.

Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. If tools, procedure, work method, or your actions are not recommended by Caterpillar, ensure that tools, and your actions are safe.

Ensure that the product will not be damaged or the product will be made unsafe by the operation, lubrication, maintenance, or the repair procedures.

Weld Specifications and Qualifications

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Protect yourself and others; read and understand this warning. Fumes and gases can be dangerous to your health. Ultraviolet rays from the weld arc can injure eyes and burn skin. Electric shock can kill. Read and understand the manufacturer's instruction and your employer's safety practices. Keep your head out of the fumes. Use ventilation, exhaust at the arc, or both, to keep fumes and gases from your breathing zone and the general area. Wear correct eye, ear and body protection. Do not touch live electric parts. Refer to the American National Standard Z49.1, "Safety in Welding and Cutting" published by the American Welding Society, 2501 N.W. 7th Street, Miami, Florida 33125: OSHA Safety and Health Standards, 29 CFR 1910, available from U.S. Dept. of Labor, Washington D.C. 20210.

Note: Personal breathing protection should be worn by the personnel that are welding. Personal breathing protection will prevent fumes from entering the lungs of the person that is welding. Use a 237-5181 Respirator for breathing protection.

Qualifications

Welders must be qualified for the appropriate type of weld that is being performed. Welders must be qualified for the appropriate position of weld that is being performed. Welders must be qualified for the welding process that is being utilized: Shielded Metal Arc Welding (SMAW), Flux Cored Arc Welding (FCAW) and Gas Metal Arc Welding (GMAW). Refer to Caterpillar Specification 1E99 for information that regards qualification requirements. The welders must have used the process at some time within the last 6 months. The welders must complete the process of certification if the welders have not used the welding processes for 6 months.

Proper Welding Procedure on Machines and Engines with Electronic Controls

Proper precautions are necessary to prevent damage to electronic controls. When you weld on a machine with electronic controls, use the steps that follow:

1. Turn off the engine. Put the key start switch in the OFF position.

2. If the machine has a battery disconnect switch, open the switch. If the machine does not have a battery disconnect switch, disconnect the negative battery cable at the battery.

3. Connect the ground cable for the welder directly to the actual machine component that will be welded. Attach the clamp for the ground cable as close as possible to the area that is being welded. This process will reduce the chance of damage from welding current to the components that follow: bearings, hydraulic components and electrical components.

   Note: Do NOT use electrical components as a ground point for the welder. Do NOT use ground points for electronic components as a ground point for the welder.

4. Protect the wiring harnesses from the welding spatter.

Area Preparation

The area to be welded shall be clean, dry, and free of the following contaminants:

• Oil

• Grease

• Paint

• Dirt

• Rust

• Any fluids or moisture

All welding shall be conducted on base material heated and maintained at a minimum temperature of 15.6° C (60° F).

Note: Heating instructions (preheat, interpass, and postheat) for any specific repair shall override the minimum 15.6° C (60° F) requirement.

Note: Heat distortion of the base metal is possible when you weld. Avoid excessive heating of the base metal.

Attach the welding ground cable directly to the base metal. Protect machined surfaces from sparks. Protect the machined surfaces from the welding spatter.

Machine Preparation

1. Park the machine on a smooth, level surface. Move away from other operating machines and away from personnel. Lower the implements to the ground. turn the engine start switch to the OFF position.

2. Permit only one operator on the machine. Keep other personnel away from the machine or in sight of the operator.

3. Engage the parking brake. Put blocks in front of the wheels and behind the wheels.

4. Install the steering frame lock in the LOCKED position so the machine cannot articulate.

Required Parts

Removal and Preparation of Fuel Tank

1. Remove the fuel tank from the machine. For the proper procedure, refer to Disassembly and Assembly, KENR6460, "Fuel Tank Remove and Install".

2. Remove the ladder group.

3. Stem clean the inside of the tank in order to remove any residual fuel.

4. fill the tank with carbon dioxide. For the proper procedure, refer to Special Instruction, REHS1841, "General Welding Procedures".

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Illustration 1	g03266442

5. Use an air arc gouge on the existing welds in order to remove the four plates (A) .

Installation Procedure

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Illustration 2	g03266959
(B) 125 mm (5 inch) (C) 275 mm (11 inch) (D) 332 mm (13 inch) (E) 343 mm (13.5 inch) (F) 412.3 mm (16 inch) (G) 1024.7 mm (40 inch) (H) 1118.6 mm (44 inch) (J) 383.5 mm (15 inch) (K) 23.5 mm (0.9 inch) (W1) 3 mm (0.1 inch) fillet weld

1. Use a 3 mm (0.1 inch) fillet weld to attach four 9U-1793 Blocks (1) and two 378-5307 Blocks (2). Refer to Illustration 2.

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Illustration 3	g03269416
(M) 352.9 mm (14 inch) (N) 633.1 mm (25 inch) (P) 913.3 mm (36 inch) (R) 1193.5 mm (47 inch) (S) 673.8 mm (27 inch) (T) 631.9 mm (25 inch) (U) 590.1 mm (23 inch) (V) 548.2 mm (22 inch) (X) 511.9 mm (20 inch) (Y) 405.1 mm (16 inch) (Z) 286.9 mm (11 inch) (AA) 221.9 mm (9 inch) (AB) 211.9 mm (8 inch) (AC) 175.6 mm (7 inch) (AD) 237.6 mm (9 inch) (AE) 262.6 mm (10 inch) (AF) 292.6 mm (12 inch)

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Illustration 4	g03269536

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Illustration 5	g03269656
(W1) 3 mm (0.1 inch) fillet weld

2. Weld the following hardware onto the side of the tank. Refer to Illustrations 3, 4, and 5 for placement and welding information.
   • Three 7X-0752 Weld Bosses (3)

   • One 381-0753 Bracket (4)

   • Two 8T-4935 Weld Bosses (5)

   • Four 8T-4219 Weld Studs (6)

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Illustration 6	g03269937

3. Attach 378-3499 Bracket As (7) with four 368-5078 Bolts (9) and four 279-6632 Washers (8) .

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Illustration 7	g03269996

4. Attach 224-1277 Film (10) and 259-4506 Film (11) to 378-3499 Bracket As (7) .

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Illustration 8	g03271336

5. Insert one 316-0393 Bearing (35) into each 315-2038 Blocks (15). Install two 315-2038 Blocks (15) and one 315-2037 Hook (14). Secure with two 344-1190 Bolts (12) and two 368-5090 Hard Washers (13) .

6. Attach the 3B-8489 Grease Fitting (36) to each 315-2038 Block (15) .

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Illustration 9	g03272116

7. Attach 378-3512 Arm As (16). Secure with one 2S-1654 Washer (18) and one 352-4457 Bolt (17),

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Illustration 10	g03272176

8. Install one 254-4152 Cylinder (21) .

9. Install two 254-4151 Rollers (19) and two 5L-4035 Retaining Rings (20) .

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Illustration 11	g03272417

10. install 378-3502 Ladder As (23). Secure with the following hardware.
    • Two 254-4187 Pins (24)

    • Two 344-1203 Bolts (25)

    • Two 370-8026 Hard Washers (26)

11. Install 254-4171 Pin (22) and 095-0917 Retaining Ring (33) .

12. Install 254-4189 Block (34) and 254-4190 Plate (29). Secure with one 7X-7729 Washer (28) and one 8T-4137 Bolt (27) .

13. Attach 315-2036 Cable As (30) onto 315-2037 Hook (14). Secure with one 344-1202 Bolt (31) and one 370-8026 Hard Washer (26) .

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Illustration 12	g03274296

14. Install 426-5227 Gas Spring (32) .

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Illustration 13	g03274878

15. Attach 378-3506 Plate (37). Secure with one 8T-4896 Hard Washer (38) and one 344-1192 Bolt (39) .

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Illustration 14	g03275277

16. Install two 381-4633 Plates (40). Secure with four 368-5080 Bolts (42) and 368-5090 Hard Washers (44) .

17. Attach 378-3517 Step Gp (43). Secure with the following hardware:
    • Four 9X-2842 Bolts (41)

    • Four 3L-0594 Spacers (45)

    • Four 370-8026 Hard Washers (26)

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Illustration 15	g03275376

18. Install 254-5258 Breather (46) .

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Illustration 16	g03303016

19. Attach 387-1591 Hose As (47) to 254-4152 Cylinder (21) with one 254-5257 Elbow (48) and two 6V-8397 O-Ring Seal (49) .

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Illustration 17	g03303036

20. Route 387-1591 Hose As (47) to 381-0753 Bracket (4). Attach one 150-4052 Union As (53) and one 2P-1279 Locknut (52). Secure 387-1591 Hose As (47) with the following hardware:
    • One 6D-3479 Clip (51)

    • One 8T-4121 Hard Washer (50)

    • One 8T-4137 Bolt (27)

21. Attach 387-1592 Hose As (54). Secure with the following hardware:
    • One 6D-3479 Clip (51)

    • One 8T-4121 Hard Washer (50)

    • One 8T-4137 Bolt (27)

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Illustration 18	g03303193

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Illustration 19	g03306777

22. Route 387-1592 Hose As (54) as shown in Illustration 18 and Illustration 19. Secure with the following hardware:
    • Four 6D-3479 Clip (51)

    • Two 8T-4121 Hard Washers (50)

    • Two 124-3019 Bracket As (55)

    • Two 8T-4136 Bolt (56)

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Illustration 20	g03307517

23. Attach 244-1542 Orifice Plug (62) inside 143-7685 Special Adapter (63). Install 4J-5477 O-Ring Seal (64) .

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Illustration 21	g03309257

24. Attach 112-1817 Manual Valve Gp (57) to 387-1592 Hose As (54) .

25. Attach 150-4050 Elbow As (58) to 112-1817 Manual Valve Gp (57) .

26. Attach 148-8433 Tee As (59) and 3J-1907 O-Ring Seal (60) to 150-4050 Elbow As (58) .

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Illustration 22	g03306899

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Personal injury can result from hydraulic oil pressure and hot oil. Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic system. Make sure all of the work tools have been lowered to the ground, and the oil is cool before removing any components or lines. Remove the oil filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand.

Note: Refer to Disassembly and Assembly, KENR6460, "System Pressure - Release" before opening any hydraulic circuit.

27. Attach the 148-8433 Tee As (59) to the parking brake actuator assembly. Attach the O-ring face seal fitting from the parking brake hose assembly to the 148-8433 Tee As (59) .

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Illustration 23	g03307576

28. Install 7I-1024 Hose Guard (61) and (61A). Use 59 cm (23 inch) coupling to clip (61). Use 76 cm (30 inch) clip to clip (61A) .

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Illustration 24	g03307859

29. Install 378-5309 Cover As (68). Secure with one 179-1732 Bolt (66) and one 9X-2038 Washer (65) .

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Illustration 25	g03307818

30. Finish securing the 378-5309 Cover As (68) with one 186-0815 Bolt (67) and one 9X-2038 Washer (65) .

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Illustration 26	g03309339

31. Install 381-1456 Plate (69). Secure with three 8T-4137 Bolts (70) and three 8T-4121 Hard Washers (71) .

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Illustration 27	g03309578

32. Install 387-0767 Plate As (72). Secure with four 8T-4133 Nuts (73) and 368-5090 Hard Washers (13) .

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Illustration 28	g03309616

33. Attach 378-3510 Flap (76) and 378-4762 Strip (77). Secure with four 368-5080 Bolts (74) and four 368-5090 Hard Washers (13) .

34. Attach 318-2970 Strip (75). Secure with two 368-5080 Bolts (74) and two 368-5090 Hard Washers (13) .