Field Installation Instructions for the Variable Pitch Fan System on 980K Wheel Loaders{1071, 107P, 1356, 1386, 138R, 7620} Caterpillar

Field Installation Instructions for the Variable Pitch Fan System on 980K Wheel Loaders{1071, 107P, 1356, 1386, 138R, 7620}

Usage:

980K GTZ

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

Introduction

This Special Instruction will provide information on the installation of 387-1357 Fan Reversing Kit .

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

Safety Section

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NOTICE

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat products. Dispose of all fluids according to local regulations and mandates.

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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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Personal injury or death can result from improperly checking for a leak.
Always use a board or cardboard when checking for a leak. Escaping air or fluid under pressure, even a pin-hole size leak, can penetrate body tissue causing serious injury, and possible death.

If fluid is injected into your skin, it must be treated immediately by a doctor familiar with this type of injury.

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Shut off engine and remove key before performing maintenance or repair work. Failure to do so may result in personal injury due to inadvertant machine operation.

Do not start the engine or move any of the controls if there is a "Do Not Operate" or similar warning tag attached to the start switch or controls.

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Personal injury or death can result from the work tool falling.

Fully lower the loader arms before you release the hydraulic system pressure.

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DO NOT OPERATE OR WORK ON THIS MACHINE UNLESS YOU HAVE READ AND UNDERSTAND THE INSTRUCTIONS AND WARNINGS IN THE OPERATION AND MAINTENANCE MANUALS. FAILURE TO FOLLOW THE INSTRUCTIONS OR HEED THE WARNINGS COULD RESULT IN INJURY OR DEATH. CONTACT ANY CATERPILLAR DEALER FOR REPLACEMENT MANUALS. PROPER CARE IS YOUR RESPONSIBILITY.

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Use an appropriate lifting device that is rated for the specific load. Failure to do so can result in serious injury or death.

Required Parts

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Table 1
Required Parts
Item	Qty	Group	Part Number	Description
1	1	⁽¹⁾	325-9619	Baffle As
2	1	⁽¹⁾	325-9620	Baffle As
3	1	⁽¹⁾	334-4637	Motor Support As
4	1	⁽¹⁾	308-1190	Adapter
5	1	⁽¹⁾	8T-4908 ⁽²⁾	Bolt
6	1	⁽¹⁾	8T-4224	Hard Washer
7	1	⁽¹⁾	7X-0515	Hard Washer
8	9	⁽¹⁾	8T-4132 ⁽³⁾	Nut
9	9	⁽¹⁾	307-7312	Fan
10	12 cm	⁽¹⁾	312-6458	Reflective Tape
11	1	⁽⁴⁾	399-8897	Hydraulic Fan Pump and Lines Gp
12	1	⁽²⁾	377-9581	Elbow As
13	3	⁽²⁾	377-9564	Elbow As
14	12	⁽²⁾	8T-4136	Bolt
15	1	⁽²⁾	132-5789	Clip
16	1	⁽²⁾	7K-1181	Cable Strap
17	17	⁽²⁾	8T-4121	Hard Washer
18	1	⁽²⁾	6D-4246	Clip
19	9	⁽²⁾	202-2762	Clip
20	1	⁽²⁾	387-0311	Hose As
21	1	⁽²⁾	2Y-5429	Grommet
22	1	⁽²⁾	387-0276	Hose As
23	1	⁽²⁾	211-8071	Protective Cap
24	1	⁽²⁾	1P-4278	Hose Clamp
25	1	⁽²⁾	4H-6112	Breather
26	1	⁽²⁾	377-9582	Elbow Adapter
27	2	⁽²⁾	7X-7729	Washer
28	1	⁽²⁾	387-0295	Bracket As
29	1	⁽²⁾	130-5300	Clip
30	1	⁽²⁾	8T-4137	Bolt
31	1	⁽²⁾	117-9409	Grommet
32	3	⁽²⁾	099-3649	Bolt
33	3	⁽²⁾	7X-0579	Hard Washer
34	2	⁽²⁾	8T-3016	Washer
35	2	⁽²⁾	170-5632	Bolt
36	1	⁽²⁾	188-2461	Solenoid Valve Gp
37	1	⁽²⁾	338-3647 ⁽⁵⁾	Tube As
38	1	⁽²⁾	148-8368	Elbow As (Adapter assembly)
39	1	⁽²⁾	325-9624	Hose As
40	1	⁽²⁾	338-2743 ⁽⁶⁾	Hose As
41	1	⁽²⁾	148-8315 ⁽⁷⁾	Connector
42	6	⁽²⁾	9X-8250	Clip (Adapter assembly)
43	7	⁽²⁾	8T-4133	Nut
44	2		346-1067	Relay Gp
45	2		225-4130	International Film Gp
46	2		225-4131	Film

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^( 1 )	325-9618 Fan Control Ar
^( 2 )	Apply a high strength adhesive/sealant for locking and sealing studs and screws in place. Not recommended for use on fasteners 6.5 mm (0.26inch) and smaller if easy removal is required.
^( 3 )	200 ± 30 N·m (148 ± 22 lb ft)
^( 4 )	387-0267 Air Lines Gp
^( 5 )	This component will replace existing component 324-8126 Tube .. Refer to Illustration 11
^( 6 )	This hose assembly will replace the existing 323-4559 Hose As . Refer to Illustration 11
^( 7 )	Replaces the existing connector. Refer to Illustration 11

Rework Procedure

Standard Removal

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Illustration 1	g03267757

Remove the cooling system from the machine for improved access to the fan components. Refer to Disassembly and Assembly, KENR6443, "Fan Group" for removal and installation instructions.

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Illustration 2	g03267662
(A) 8T-4956 Bolt (B) 5P-1076 Hard Washer (C) 321-8440 Motor Support As (D) 242-1283 Bracket (E) 8T-4136 Bolt (F) 7X-7729 Washer (G) 326-3578 Cover (H) 350-2445 Fan Guard

Use appropriate lifting device and strap to remove bracket (C). Secure component prior to removal.

Remove eight bolts (A) and eight washers (B) from support (C).

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Illustration 3	g03269800
(J) 8T-4132 Nut (K) 7X-0515 Hard Washer

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Illustration 4	g03269465
This view has been exploded to enhance component location (P) 350-7075 Piston Motor Gp (R) 192-7356 Adapter (Z) 8T-4196 Bolt (AA) 8T-7934 Hard Washer (AB) 262-6813 Fan Spider As (AC) 312-6458 Reflective Tape

Remove and discard nut (J) and washer (K). Use a M16 wrench to loosen nut (J). Counter torque on the fan may be required to prevent the fan assembly from turning.

Remove and discard adapter (R) and fan assembly (AB) .

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Illustration 5	g03268077
(L) 8T-4956 Bolt (M) 8T-4223 Hard Washer

Loosen and remove bolt (L) and washer (M). These parts will be used in the reassembly process.

Remove eight bolts (E) and eight washers (F) from bracket (D). Remove fan guard (H) (this component will be used in reassembly). Remove motor support assembly (C) and piston motor group (P) (this component will be used in reassembly).

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Illustration 6	g03272018
(S) 323-9518 Baffle (T) 8T-4136 Bolt (U) 7X-7729 Washer (V) 8T-4195 Bolt (W) 7X-7729 Washer (X) 8T-3490 Weld Nut (Y) 323-9528 Baffle As

Loosen and remove bolt (T ) and washer (U) ( (these components will be used in reassembly). Remove and discard baffle (S).

Loosen and remove bolt (V), washer (W), and weld nut (X). Remove and discard baffle (Y) .

Installation of 387-1357 Fan Reversing Kit

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Illustration 7	g03336473
View of 334-4635 Suction Fan Gp

Install 350-7075 Piston Motor Gp (P) with 8T-4956 Bolt (L) and 8T-4223 Hard Washer (M) .

Install 308-1190 Adapter (4) to the motor shaft with 8T-4132 Nut (8), 7X-0515 Hard Washer (7), and adhesive sealer.

Install 307-7312 Fan (9) to 308-1190 Adapter (4) with 8T-4908 Bolts (5) and 8T-4224 Hard Washers (6) .

Apply 312-6458 Reflective Tape (10) to the fan blade.

Reassemble the 350-2445 Fan Guard (H) with 8T-4136 Bolts (E), and 7X-7729 Washers (F) .

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Illustration 8	g03579576
Location and torque for 387-0276 Hose As and 1P-4278 Hose Clamp (22) 387-0276 Hose As (24) 1P-4278 Hose Clamp (L1) Center line of fan (R1) 117.5 ± 5 mm (4.63± 0.2 inch) (R2) 187 ± 5 mm (7.36 ± 0.2 inch)

Install 387-0276 Hose As (22) with 1P-4278 Hose Clamp (24) and 211-8071 Protective Cap (23) to the 301-7312 Fan (9). Orient clamp as shown and torque 1P-4278 Hose Clamp (24) to 2.5 N·m (22 lb in)

Install the 325-9620 Baffle As (2) with 8T-4195 Bolt (V) and 7X-7729 Washer (W) .

Install the 334-4637 Motor Support As (3) to the cooling system. Install 387-0276 Hose As (22) with 2Y-5429 Grommet (21.)

Install 325-9619 Baffle As (1)

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Illustration 9	g03337152
View of 387-0267 Air Lines Gp .

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Illustration 10	g03338237

Refer to Special Instruction, REHS7738, "Procedure to Replace the Air Control Valve on Certain 950K through 980K Wheel Loaders " for information to install the components in Illustration 10.

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Illustration 11	g03336964
(CA) 372-4149 Hose As (CA)

Use the following steps to Install components in Illustration 11.

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Illustration 12	g03389684

Attach the 338-3647 Tube As (37). This tube assembly will replace the existing 324-8126 Tube in that location.

Connect 325-9624 Hose As (39) to 148-8368 Elbow As (38). Connect elbow assembly (38) to 338-3647 Tube As (37) .

Install 325-9624 Hose As (39) to existing 372-4149 Hose As (CA) with 202-2762 Clips (19), 9X-8250 Clips (42), 8T-4136 Bolts (14), 8T-4121 Hard Washers (17), and 8T-4133 Nuts (43) .

Attach 338-2743 Hose As (40) and 148-8315 Connector (41). This hose assembly will replace the existing 323-4559 Hose As and connector in that location.

Install the 346-1067 Relay Gp (44). Assemble the relays in position 6. Attach 338-3647 Tube As (37) .

Install the 225-4130 Film (45) on machines that are located in North America. Install the 225-4131 Film (46) on machines located outside North America. Install the film over the previous film located on the sides of the radiator group.