- Wheel Loader:
- 980H (S/N: JMS1-3999)
- 980H (S/N: MHG1-3999)
- 980H (S/N: A8J1-3999)
- 980H (S/N: MHG1-3999)
Introduction
This service publication contains the information that is needed in order to install the 318-8496 Engine Kit for Power Optimization. A complete listing of the parts that are contained in this kit are listed in the Parts Manual, SEBC1501.
This supplemental product support literature should be used with the appropriate Service Manual that is available for the standard machine.
Do not perform any procedure that is outlined in this publication until you understand the information that is contained in this document.
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Personal injury or death can result from improper assembly procedures. Do not attempt any assembly until you have read and understand the assembly instructions. |
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Personal injury or death can result from improper lifting or blocking. When a hoist or jack is used to lift any part or component, stand clear of the area. Be sure the hoist or jack has the correct capacity to lift a component. Install blocks or stands before performance of any work under a heavy component. Approximate weights of the components are shown. Clean all surfaces where parts are to be installed. |
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| NOTICE |
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Do not allow any dirt or foreign material to get into the hydraulic system during assembly, connection of lines, when components are filled with fluid, or during any maintenance operation. |
| NOTICE |
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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 you open any compartment or disassemble 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. |
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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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Installation "A"
Note: Use the following instructions when installing the kit without new battery cables and a new oil pan.
Installation of the 318-8496 Engine Kit (Power Optimization) without new Battery Cables or Oil Pan for the 980H Wheel Loader
Machine Preparation
- Refer to Service Manual, RENR8667, "980H Wheel Loader-Power Train-D&A", "Crankcase Guard - Remove and Install" and remove the crankcase guard.
- Refer to Service Manual, RENR8667, "980H Wheel Loader-Power Train-D&A", "Power Train Guard (transmission) - Remove and Install" and remove the power train guard.
- Clean the machine completely. Pay special attention to the engine and transmission components.
- Move the machine to a service bay. Raise the lift arms with the bucket in the full dump position. Allow the bucket to rest on the cutting edge.
Note: Access to the main control valve is needed if the machine is not equipped with the payload control system or the aggregate autodig system in order to install the sensor.
Release System Pressure
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Personal injury or death can result from machine articulation or movement. Machine frames can move and a person can be crushed. Connect the steering frame lock link between the front and rear frames before working on machine. Secure clevis pin with locking pin. Before operating the machine, fasten the steering frame lock link into the stored position and secure the clevis pin with locking pin. Failure to lock into the stored position before operating can result in loss of steering. |
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- Park the machine with the bucket in the full dump position and resting on the cutting edge.
- The machine must be on a hard, level surface.
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| Illustration 1 | g00497283 |
- Engage the parking brake.
- Remove the locking pins (3) from pins (1) and (2) .
- Slide the steering frame lock link into the front frame. Align the bores in the lock link with the bores in the front and rear loader frames. Install pins (1) and (2) and locking pins (3) .
Note: To align the pin bores, move the front loader frame.
 | |
| Illustration 2 | g00497286 |
- Engage the parking brake.
- Stop the engine.
- Turn the engine start switch to the ON position after the engine stops.
- Place the implement lockout switch in the UNLOCKED position.
- Move the control levers repeatedly through the full range of travel. This will relieve any pressure that may be present in the implement hydraulic system.
- Turn the engine start switch to the OFF position.
- Depress the brake pedal repeatedly. This will relieve any pressure that may be present in the braking system.
- Press the button on the breaker relief valve that is located on the hydraulic oil tank.
Fluid removal
Drain Coolant
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Pressurized system: Hot coolant can cause serious burn. To open cap, stop engine, wait until radiator is cool. Then loosen cap slowly to relieve the pressure. |
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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, "Caterpillar Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates. |
| NOTICE |
|---|
Topping off or mixing Cat ELC with other products that do not meet Caterpillar EC-1 specifications reduces the effectiveness of the coolant, shortens coolant service life, and may cause premature wear to components. Use only Caterpillar products or commercial products that have passed the Caterpillar EC-1 specification for pre-mixed or concentrate coolants. Use only Extender with Cat ELC. Failure to follow these recommendations can result in shortened cooling system component life. |
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| Illustration 3 | g00759585 |
The cooling system pressure cap is located under the engine hood at the rear of the machine.
- Slowly loosen the cooling system pressure cap (1) in order to relieve system pressure. Remove the cooling system pressure cap.
- Open the drain valve. The drain valve is located near the rear axle of the machine. Allow the coolant to drain into a suitable container.
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| Illustration 4 | g00879754 |
- Flush the cooling system with clean water until the draining water is clean. Close the drain valve.
Turbocharger
| 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, "Caterpillar Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates. |
| NOTICE |
|---|
Keep all parts clean from contaminants. Contamination of the hydraulic system with foreign material will reduce the service life of the hydraulic system components. To prevent contaminants from entering the hydraulic system, always plug or cap the lines, fittings, or hoses as they are disconnected. Cover any disassembled components and clean them properly before assembly. Clean the hydraulic system properly after any major component exchange or especially after a component failure, to remove any contamination. |
Remove the Original Turbocharger
- Remove clamp (A) and remove clamp (M) from the ends of tube (L) .
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| Illustration 5 | g01523693 |
View of turbocharger (A) Clamp (B) Hose (C) Clamp (D) Clamp (E) Clamp (F) Tube (G) Bracket (H) Tube (J) Tube (K) Turbocharger (L) Tube (M) Clamp | |
- Remove tube (L) .
- Remove clamp (D) and remove clamp (E) from the ends of tube (F) .
- Remove bracket (G) and then remove tube (F) .
- Remove clamp (C) and remove hose (B) .
- Disconnect tube (H) and disconnect tube (J) .
- Attach a suitable lifting device to turbocharger (K). The weight of turbocharger (K) is approximately 34 kg (75 lb).
- Remove four locknuts from the turbocharger. Remove turbocharger (K) and the gasket from the exhaust manifold.
Install the New Turbocharger
| Required Tools | |||
| Tool | Part Number | Part Description | Qty |
| A | 5P-3931 | Anti-Seize Compound | 1 |
| NOTICE |
|---|
Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. |
- Position the 1S-4295 Gasket on the exhaust manifold.
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| Illustration 6 | g01524202 |
View of turbocharger (A) Clamp (B) Hose (C) Clamp (D) Clamp (E) Clamp (F) Tube (G) Bracket (H) Tube (J) Tube (L) Tube (M) Clamp | |
- Apply Tooling (A) to the threads of the exhaust manifold studs.
- Attach a suitable lifting device to 302-7449 Turbocharger Gp (1). The weight of the 302-7449 Turbocharger Gp (1) is approximately 34 kg (75 lb).
- Position the 302-7449 Turbocharger Gp (1) on the exhaust manifold.
- Use the following hardware and mount the 302-7449 Turbocharger Gp (1) onto the exhaust manifold. Tighten the bolts finger tight.
- Use clamp (D) and clamp (E) and install tube (F) .
- Use bracket (G) to secure tube (F) .
- Use clamps (C) and install hose (B) .
- Use clamp (A) and clamp (M) and install tube (L) .
- Connect tube (H) and connect tube (J) .
- Tighten the four 2N-2766 Locknuts (5) to a torque of 55 ± 5 N·m (41 ± 4 lb ft).
Muffler
Remove the Old Muffler
- Loosen clamp (2) in order to disconnect tube (1). Attach a suitable lifting device to muffler (4). The weight of muffler (4) is approximately 23 kg (50 lb).
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| Illustration 7 | g01097435 |
- Remove the dust ejector hose if the dust ejector hose is present.
- Remove bolts (3) and the spacers.
- Remove muffler (4) .
Install the New Muffler
- Attach a suitable lifting device to new muffler 285-4494 Muffler As (1). The weight of the new muffler 285-4494 Muffler As (1) is approximately 23 kg (50 lb).
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| Illustration 8 | g01469948 |
View of muffler from end by the turbocharger | |
- Set the 285-4494 Muffler As (1) onto the muffler mounting bracket.
- Use the four original bolts (4) and the four original spacers (5) in order to secure the 285-4494 Muffler As (1). Tighten the four original bolts (4) .
- Connect the original tube 247-8202 Tube As (6) onto the 285-4494 Muffler As (1). Tighten the original 8T-4988 Hose Clamp (2) .
- If the machine is equipped with a turbine precleaner you will need to install a 5S-0385 Cup Plug (not shown) in the dust ejector tube on the muffler. Reconnect dust ejector hose onto the dust ejector tube that is on the muffler.
Rework the Transmission
Remove the Cab
- Refer to Disassembly and Assembly, RENR8681, "Cab-Remove" and remove the cab.
Remove the Transmission Oil Pump
- Refer to Disassembly and Assembly, RENR8667, "Transmission Oil Pump-Remove" and remove the transmission oil pump.
Remove the suction tubes for transmission.
- Remove clamps (B) .
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| Illustration 9 | g01419885 |
- Remove hose (C) .
- Remove tube (A) .
- Remove tube (D) .
Note: You may need to cut tube (D) in half, in order to remove tube (D) .
Install New suction tubes for the Transmission
- Use the following parts and install the 309-8486 Tube Assembly (2) and the 310-3651 Tube Assembly (5) :
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| Illustration 10 | g01565454 |
Install the New Transmission Oil Pump
- Refer to Disassembly and Assembly, RENR8667, "Transmission Oil Pump-Install". Use the following new O-Ring Seals and install the 307-9674 Transmission Oil Pump Gp :
Remove the Transmission Control Module
- Remove the insulation that is for sound suppression (A) .
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| Illustration 11 | g01420129 |
- Refer to Disassembly and Assembly, RENR8667, "Relief Valve (Transmission Hydraulic Control) - Remove". Remove the relief valve (transmission hydraulic control).
- Refer to Disassembly and Assembly, RENR8667, "Relief Valve (Transmission Hydraulic Control) - Assemble". Exchange the following parts with the original parts and reassemble the relief valve (transmission hydraulic control):
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| Illustration 12 | g01470033 |
Relief valve | |
- Reinstall the relief valve (transmission hydraulic control).
- Remove existing plug (B).
Note: You may need to apply heat to plug (B) in order to remove plug (B) .
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| Illustration 13 | g01420159 |
Note: The following steps 5 through 7 are only necessary on standard transmissions. These steps are not required on a heavy-duty transmission.
- Install a 313-7626 Orifice Plug .
- Refer to Disassembly and Assembly, RENR8667, "Relief Valve (Transmission Hydraulic Control) - Install". Reinstall the transmission control module.
Refill all fluids
- Refer to Operation and Maintenance Manual, SEBU7879, "Transmission Oil Filter - Replace" and replace the transmission oil filter.
- Refer to Operation and Maintenance Manual, SEBU7879, "Capacities (Refill)" and refill any fluids that have been drained.
Temporary Cab Installation
Note: VERIFY THAT ALL FLUID LEVELS ARE CORRECT.
- Temporarily set the cab on the machine and connect the electrical system. Turn on the battery disconnect switch.
- Turn off air conditioner
- Position the cab and install the front mounting bolts loosely.
- Connect the ground strap to the frame at the left rear of cab.
- Manually engage the parking brake in order to warm the transmission oil.
- Connect a pressure gauge to the top remote pressure port for the Transmission Pump.
- The pressure should be 2344 ± 69 kPa (340 ± 10 psi) at high idle.
- If the pressure is low, remove the cab in order to gain access to the pressure relief screw that is for the transmission.
- Turn the pressure relief screw clockwise in order to increase the relief pressure.
- Temporarily install the cab. Start the machine and check the pressure.
- Repeat steps 3 through 10 until the pressure meets the specification of 2344 ± 69 kPa (340 ± 10 psi) at high idle.
- Refer to Disassembly and Assembly, RENR8681, "Cab-Install" and reinstall the cab.
Pressure Sensor Installation
Note: This section is not required if the machine is configured with the aggregate autodig system or the Payload Control System (PCS).
- Use a 3J-1907 O-Ring Seal (1) and install the 126-6872 Tee (2) into the 265-2834 Block (3) .
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| Illustration 14 | g01470837 |
- Use a 3J-1907 O-Ring Seal (1) and install the 6V-3965 Quick Disconnect Coupler (Test) (4) into the 126-6872 Tee (2) .
- Use a 3J-1907 O-Ring Seal (1) and install the 221-3416 Pressure Sensor Gp (Head End Oil for the Lift Cylinder) (6) into the 265-2834 Block (36) .
- Use the following hardware and install the sensor assembly (A) on the right hand side of the front frame:
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| Illustration 15 | g01420255 |
- Remove the plug. Use a 6V-8397 O-Ring Seal (9) and install a 122-2222 Adapter (10) into the head end of the oil tube that is for the lift cylinder.
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| Illustration 16 | g01471228 |
Note: Make sure that the pressure is relieved before removing the plug in order to install the upper end of the 3T-6856 Hose As (1) .
- Use a 6V-8397 O-Ring Seal (9) and connect one end of the 3T-6856 Hose As (12) onto the 6V-8724 Elbow (11) .
- Use a 6V-8397 O-Ring Seal (9) and connect the other end of the 3T-6856 Hose As (12) onto the 126-6872 Tee (2) .
- Use the following parts and install the 263-4169 Monitor Harness As (14) :
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| Illustration 17 | g01573041 |
- Secure the balance of the 263-4169 Monitor Harness As (14) at point (B) .
- Connect the other end of the 263-4169 Monitor Harness As (15) to the front wiring group (C) .
Install the labels for the Software
Note: You will receive new labels for the engine in a separate shipment. You will need to install all these labels before you install the software.
- Replace serial number plate (A) .
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| Illustration 18 | g01532293 |
- Replace emissions label (B). This label is not required on machines with a existing emissions Label for 2007 or 2008 .
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| Illustration 19 | g01532296 |
- Replace the information plate (C) .
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| Illustration 20 | g01532298 |
- Attach the rework label in location (D) .
Flash New Software
- Refer to Testing an Adjusting, RENR8666, "Electronic Control Module (ECM) - Flash Program". Use the following steps and Flash the software that was provided by Service Engineering.
- Connect the data link cable between the communication adapter and the electronic technician.
- Connect the data link cable between the communication adapter and the diagnostic connector of the machine.
- Turn the disconnect switch to the ON position.
- Turn the key start switch to the ON position.
- Set the implement lockout to the LOCKED position.
- Ensure that the transmission direction switch is in the Neutral position.
- Ensure that the engine is not running.
- Use WinFlash in order to load the software.
- The following software will need to be flashed:
- You will get a pop up for the factory password. You must call the Dealer Solution Network. Request support for the tier II engine from Caterpillar Engine Components in order to obtain the factory password.
- Configure the electronic control modules for the Implement and the transmission.
- Calibrate the electronic control modules for the Implement and the transmission.
Note: Calibration of the pressures for clutch engagement is unnecessary. Clutches will engage at pump pressure, which has now been set to 2344 ± 69 kPa (340 ± 10 psi). The calibration will still be available in electronic technician, but the calibration will not be functional. The calibration should not be performed.
Note: Completion of the calibration for the transmission clutch fill is required. Completing this calibration will eliminate transmission diagnostic codes.
Adjust Hydraulic Fan Speed
- Refer to Testing and Adjusting, RENR8678, "Hydraulic Fan Speed - Test and Adjust".
- Adjust the fan speed to 1400 RPM ±25 RPM maximum speed.
Rework Completion
- Start the machine and check the machine for leaks.
- Wash the machine.
- Exercise the machine for at least an hour.
- Recheck the machine for leaks.
Installation "B"
Note: Use the following instructions when installing the kit that includes new battery cables and a new oil pan.
Installation of the 318-8496 Engine Kit (Power Optimization) with new Battery Cables and Oil Pan for the 980H Wheel Loader
Machine Preparation
- Refer to Service Manual, RENR8667, "980H Wheel Loader-Power Train-D&A", "Crankcase Guard - Remove and Install" and remove the crankcase guard.
- Refer to Service Manual, RENR8667, "980H Wheel Loader-Power Train-D&A", "Power Train Guard (transmission) - Remove and Install" and remove the power train guard.
- Clean the machine completely. Pay special attention to the engine and transmission components.
- Move the machine to a service bay. Raise the lift arms with the bucket in the full dump position. Allow the bucket to rest on the cutting edge.
Note: Access to the main control valve is needed if the machine is not equipped with the payload control system or the aggregate autodig system in order to install the sensor.
Release System Pressure
|
Personal injury or death can result from machine articulation or movement. Machine frames can move and a person can be crushed. Connect the steering frame lock link between the front and rear frames before working on machine. Secure clevis pin with locking pin. Before operating the machine, fasten the steering frame lock link into the stored position and secure the clevis pin with locking pin. Failure to lock into the stored position before operating can result in loss of steering. |
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- Park the machine with the bucket in the full dump position and resting on the cutting edge.
- The machine must be on a hard, level surface.
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| Illustration 21 | g00497283 |
- Engage the parking brake.
- Remove the locking pins (3) from pins (1) and (2) .
- Slide the steering frame lock link into the front frame. Align the bores in the lock link with the bores in the front and rear loader frames. Install pins (1) and (2) and locking pins (3) .
Note: To align the pin bores, move the front loader frame.
| | |
| Illustration 22 | g00497286 |
- Engage the parking brake.
- Stop the engine.
- Turn the engine start switch to the ON position after the engine stops.
- Place the implement lockout switch in the UNLOCKED position.
- Move the control levers repeatedly through the full range of travel. This will relieve any pressure that may be present in the implement hydraulic system.
- Turn the engine start switch to the OFF position.
- Depress the brake pedal repeatedly. This will relieve any pressure that may be present in the braking system.
- Press the button on the breaker relief valve that is located on the hydraulic oil tank.
Fluid removal
Drain Engine Oil
| 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 you open any compartment or disassemble 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. |
- Tilt the hood and remove the side panels.
- Open the crankcase drain valve (1). Allow the oil to drain into a suitable container. Close the crankcase drain valve.
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| Illustration 23 | g01030594 |
- Remove the filter element (2) with a strap type wrench.
- Clean the filter mounting base with a clean cloth. Make sure that the used filter gasket has been completely removed.
- Apply a thin coat of clean engine oil to the seal of the new filter. Install a new engine oil filter hand tight until the seal of the engine oil filter contacts the base. Note the position of the index marks on the filter in relation to a fixed point on the filter base.
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| Illustration 24 | g00101318 |
- Tighten the filter according to the instructions that are printed on the filter. Use the index marks as a guide. For non-Caterpillar filters, use the instructions that are provided with the filter.
Note: You may need to use a Caterpillar strap wrench, or another suitable tool, in order to turn the filter to the amount that is required for final installation.
Note: There are rotation index marks on the engine oil filter that are spaced 90 degrees or 1/4 or a turn away from each other. When you tighten the engine oil filter, use the rotation index marks as a guide.
- Clean the oil filler plug and install the oil filler plug.
Drain Coolant
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Pressurized system: Hot coolant can cause serious burn. To open cap, stop engine, wait until radiator is cool. Then loosen cap slowly to relieve the pressure. |
|
| 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, "Caterpillar Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates. |
| NOTICE |
|---|
Topping off or mixing Cat ELC with other products that do not meet Caterpillar EC-1 specifications reduces the effectiveness of the coolant, shortens coolant service life, and may cause premature wear to components. Use only Caterpillar products or commercial products that have passed the Caterpillar EC-1 specification for pre-mixed or concentrate coolants. Use only Extender with Cat ELC. Failure to follow these recommendations can result in shortened cooling system component life. |
| | |
| Illustration 25 | g00759585 |
The cooling system pressure cap is located under the engine hood at the rear of the machine.
- Slowly loosen the cooling system pressure cap (1) in order to relieve system pressure. Remove the cooling system pressure cap.
- Open the drain valve. The drain valve is located near the rear axle of the machine. Allow the coolant to drain into a suitable container.
| | |
| Illustration 26 | g00879754 |
- Flush the cooling system with clean water until the draining water is clean. Close the drain valve.
Optional Removal of Rear Tires
The rear tires may be removed for better access to the underside of the machine. Refer to Service Manual, RENR8667, "980H Wheel Loader-Power Train-D&A", "Tire and Rim (Rear) - Remove and Install".
Optional Removal of Rear Axle
The rear axle may be removed for better access to the underside of the machine. Refer to Service Manual, RENR8667, "980H Wheel Loader-Power Train-D&A", "Oscillating Axle (Rear) - Remove" and refer to Service Manual, RENR8667, "980H Wheel Loader-Power Train-D&A", "Oscillating Axle (Rear) - Install".
Remove the Counterweight
- Position the forks of a lift truck under counterweight (2) .
 | |
| Illustration 27 | g01101393 |
- Remove bolts (1). Lower counterweight (2) to the ground. The weight of counterweight (2) is approximately 1633 kg (3600 lb).
Remove the Axle Oil Cooler (if Equipped)
- Disconnect the hoses and place a plug in each hose (A) .
 | |
| Illustration 28 | g01413583 |
Bottom view of the axle oil cooler (A) Hoses (B) Mounting bolts (C) Axle oil cooler | |
- Support the axle oil cooler (C) and remove mounting bolts (B) .
- Remove the axle oil cooler.
Removal of Old Oil Pan
- Refer to Disassembly and Assembly, RENR8261, "Engine Oil Pan - Remove and Install". Remove all oil pan bolts and remove the oil pan (A) and the gasket. Oil pan weighs approximately 16.16 kg (35.63 lb).
Note: Oil pan may be removed by lowering the rear of the oil pan and sliding the oil pan to the rear.
 | |
| Illustration 29 | g01414957 |
Oil pan (A) Original oil pan | |
- Remove the tube (B) and the bracket. Discard tube (B), but keep all other parts removed for later use.
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| Illustration 30 | g01414975 |
Bottom of engine block (B) Tube (C) Tube assembly (D) Plate | |
- Remove tube assembly (C). Keep all parts removed for later use.
- Remove plate (D). Discard the plate. (D) .
Battery Cables
Disconnect Batteries
|
Personal injury may occur from failure to properly service the batteries. Batteries give off flammable fumes that can explode. Electrolyte is an acid and can cause personal injury if it contacts the skin or eyes. Prevent sparks near the batteries. Sparks could cause vapors to explode. Do not allow jumper cable ends to contact each other or the engine. Improper jumper cable connections can cause an explosion. Always wear protective glasses when working with batteries. |
|
- Turn the engine start switch key OFF. Turn all of the switches OFF.
 | |
| Illustration 31 | g01472272 |
- Turn the battery disconnect switch (A) to the OFF position. Remove the key that is for the battery disconnect switch.
- Disconnect the negative battery cable (B) from the disconnect switch.
Note: Do not allow the disconnected battery cable to contact the disconnect switch.
- Disconnect both negative battery cables (C) at the battery.
- Disconnect both positive battery cables (D) at the battery.
- Inspect the battery terminals for corrosion. Clean the battery terminals if the battery cables are corroded. Inspect the battery cables for wear or damage.
Installation of the 307-3119 Cable Assembly
- Connect the end with the boot of 307-3119 Battery Cable (1) onto the alternator. Tighten the nut to 18.2 ± 2.4 N·m (13.42 ± 1.77 lb ft).
 | |
| Illustration 32 | g01532854 |
- Route the 307-3119 Battery Cable (1) per Illustration 32 and Illustration 32.
- Secure the 307-3119 Battery Cable (1) with the following hardware:
- Connect the other end of the 307-3119 Battery Cable (1) onto the starter with the existing wire. Tighten the nut to 30.5 ± 3.5 N·m (22.50 ± 2.58 lb ft).
Installation of the 321-3764 Cable as
- Connect one end of the 321-3764 Cable As (14) onto the lower stud of the terminal block. Tighten the nut to 70 ± 15 N·m (51.63 ± 11.06 lb ft).
 | |
| Illustration 33 | g01532954 |
- Route the 321-3764 Cable As (14) per the illustration. Secure the 321-3764 Cable As (14) with the following hardware:
- Route the 321-3764 Cable As (14) per the illustration. Secure the 321-3764 Cable As (14) with the following hardware:
 | |
| Illustration 34 | g01533194 |
- Continue to route the 321-3764 Cable As (14) around the frame. Secure the 321-3764 Cable As (14) with the following hardware:
 | |
| Illustration 35 | g01533213 |
- Continue to route the 321-3764 Cable As (14) past the engine mount to the circuit breaker panel. Secure the 321-3764 Cable As (14) with the following hardware:
- Connect the 321-3764 Cable As (14) onto the circuit breaker assembly that is for the alternator. Tighten the nut (C) to 7 ± 1 N·m (5.16 ± 0.74 lb ft).
 | |
| Illustration 36 | g01533256 |
- Secure the 321-3764 Cable As (14) with existing hardware.
- Remove battery cables (E) and (F) from the crossmember for the engine mount.
 | |
| Illustration 37 | g01525105 |
Top view of rear battery cables (E) Red battery cable (F) Red battery cable | |
- Use the original hardware (H) and reroute the remaining black battery cable (G) to the other side of the crossmember for the engine mount.
 | |
| Illustration 38 | g01523577 |
Battery cables (G) Black battery cable (H) Original hardware | |
Reconnect Batteries
- Reconnect the negative battery cable (B) to the disconnect switch (A) .
Note: Do not allow the disconnected battery cable to contact the disconnect switch.
 | |
| Illustration 39 | g01532596 |
- Reconnect both negative battery cables (C) at the battery.
- Reconnect both positive battery cables (D) at the battery.
- Do not turn the disconnect switch to the ON position.
Install New Oil Pan
Installation of the 9N-3167 Plate
- Apply 5H-2471 Adhesive around the perimeter of the top of the 9N-3167 Plate (2) in order to retain the 188-0210 Gasket (1) .
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| Illustration 40 | g01523599 |
Plate and gasket | |
- Refer to Illustration 41 for the bolt location. Use the following hardware and install the 9N-3167 Plate (5) onto the bottom of the engine block:
- Four 2P-3205 Bolts (6)
- Four 2P-3205 Bolts (6)
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| Illustration 41 | g01523587 |
Bottom of engine block (V) Bracket (W) Bolts (X) Washers (Y) Locknuts (Z) Washers | |
- Use a new 109-0078 O-Ring Seal (12) and install the original Tube As (13) .
- Use the following original hardware and install the original Tube Bracket (V) onto the 9N-3167 Plate (5) :
- One bracket (V)
- Two bolts (W)
- Two washers (X)
- Two locknuts (Y)
- Two washers (Z)
- One bracket (V)
Installation of the New Oil Pan
- Apply 5H-2471 Adhesive around the perimeter of the 275-4261 Oil Pan (3) in order to retain the 188-0210 Gasket (1) .
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| Illustration 42 | g01525110 |
- Install the 188-0210 Gasket (1) onto the 275-4261 Oil Pan (3). Make sure that the holes are aligned.
- Refer to Illustration 43. Use four 2P-3205 Bolts (4) and install the 275-4261 Oil Pan (3) .
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| Illustration 43 | g01504253 |
- Refer to Illustration 44. Use 28 2P-3205 Bolts (4) and complete the installation of the 275-4261 Oil Pan (3) .
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| Illustration 44 | g01504420 |
- Use a lubricating spray such as WD40 and install the 283-7180 Panel (10) .
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| Illustration 45 | g01419426 |
- Install two 5M-2894 Hard Washers (6) and two 170-0612 Studs (8) through the 283-7180 Panel (10) and into the block.
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| Illustration 46 | g01504474 |
- Install six 5M-2894 Hard Washers (6) and six 0S-1619 Bolts (5) through the 283-7180 Panel (10) and into the block.
- Secure the fumes disposal tube onto the 170-0612 Stud (8) that is located on the left hand side of the 275-4261 Oil Pan .
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| Illustration 47 | g01419509 |
- Use a 2K-4973 Locknut (11) and install a 132-5789 Clip (12) onto the 170-0612 Stud (8) that is located on the right hand side of the 275-4261 Oil Pan .
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| Illustration 48 | g01512453 |
- Use a 7K-1181 Cable Strap (13) in order to secure the existing harness onto the 132-5789 Clip (12) .
Install the Oil Pan Drain and the Plugs
- Use a 5P-7701 O-Ring Seal (4) and install a 122-0957 Adapter (1) into the 275-4261 Oil Pan (9) .
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| Illustration 49 | g01477137 |
- Use a 8L-2786 O-Ring Seal (5) and install a 6V-7238 Shutoff Valve (2) into the 122-0957 Adapter (1). .
Reinstall the Axle Oil Cooler
- Use the original bolts (B) and reinstall the axle oil cooler (C) .
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| Illustration 50 | g01413583 |
- Reconnect all of the hoses for the axle oil cooler.
Turbocharger
| 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, "Caterpillar Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates. |
| NOTICE |
|---|
Keep all parts clean from contaminants. Contamination of the hydraulic system with foreign material will reduce the service life of the hydraulic system components. To prevent contaminants from entering the hydraulic system, always plug or cap the lines, fittings, or hoses as they are disconnected. Cover any disassembled components and clean them properly before assembly. Clean the hydraulic system properly after any major component exchange or especially after a component failure, to remove any contamination. |
Remove the Original Turbocharger
- Remove clamp (A) and remove clamp (M) from the ends of tube (L) .
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| Illustration 51 | g01523693 |
View of turbocharger (A) Clamp (B) Hose (C) Clamp (D) Clamp (E) Clamp (F) Tube (G) Bracket (H) Tube (J) Tube (K) Turbocharger (L) Tube (M) Clamp | |
- Remove tube (L) .
- Remove clamp (D) and remove clamp (E) from the ends of tube (F) .
- Remove bracket (G) and then remove tube (F) .
- Remove clamp (C) and remove hose (B) .
- Disconnect tube (H) and disconnect tube (J) .
- Attach a suitable lifting device to turbocharger (K). The weight of turbocharger (K) is approximately 34 kg (75 lb).
- Remove four locknuts from the turbocharger. Remove turbocharger (K) and the gasket from the exhaust manifold.
Install the New Turbocharger
| Required Tools | |||
| Tool | Part Number | Part Description | Qty |
| A | 5P-3931 | Anti-Seize Compound | 1 |
| NOTICE |
|---|
Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. |
- Position the 1S-4295 Gasket on the exhaust manifold.
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| Illustration 52 | g01524202 |
View of turbocharger (A) Clamp (B) Hose (C) Clamp (D) Clamp (E) Clamp (F) Tube (G) Bracket (H) Tube (J) Tube (L) Tube (M) Clamp | |
- Apply Tooling (A) to the threads of the exhaust manifold studs.
- Attach a suitable lifting device to 302-7449 Turbocharger Gp (1). The weight of the 302-7449 Turbocharger Gp (1) is approximately 34 kg (75 lb).
- Position the 302-7449 Turbocharger Gp (1) on the exhaust manifold.
- Use the following hardware and mount the 302-7449 Turbocharger Gp (1) onto the exhaust manifold. Tighten the bolts finger tight.
- Use clamp (D) and clamp (E) and install tube (F) .
- Use bracket (G) to secure tube (F) .
- Use clamps (C) and install hose (B) .
- Use clamp (A) and clamp (M) and install tube (L) .
- Connect tube (H) and connect tube (J) .
- Tighten the four 2N-2766 Locknuts (5) to a torque of 55 ± 5 N·m (41 ± 4 lb ft).
Muffler
Remove the Old Muffler
- Loosen clamp (2) in order to disconnect tube (1). Attach a suitable lifting device to muffler (4). The weight of muffler (4) is approximately 23 kg (50 lb).
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| Illustration 53 | g01097435 |
- Remove the dust ejector hose if the dust ejector hose is present.
- Remove bolts (3) and the spacers.
- Remove muffler (4) .
Install the New Muffler
- Attach a suitable lifting device to new muffler 285-4494 Muffler As (1). The weight of the new muffler 285-4494 Muffler As (1) is approximately 23 kg (50 lb).
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| Illustration 54 | g01469948 |
View of muffler from end by the turbocharger | |
- Set the 285-4494 Muffler As (1) onto the muffler mounting bracket.
- Use the four original bolts (4) and the four original spacers (5) in order to secure the 285-4494 Muffler As (1). Tighten the four original bolts (4) .
- Connect the original tube 247-8202 Tube As (6) onto the 285-4494 Muffler As (1). Tighten the original 8T-4988 Hose Clamp (2) .
- If the machine is equipped with a turbine precleaner you will need to install a 5S-0385 Cup Plug (not shown) in the dust ejector tube on the muffler. Reconnect dust ejector hose onto the dust ejector tube that is on the muffler.
Oil Gauge Assembly (Dipstick)
- Remove old oil Gauge Assembly (Dipstick).
- Install the 300-7445 Oil Gauge Assembly .
Rework the Transmission
Remove the Cab
- Refer to Disassembly and Assembly, RENR8681, "Cab-Remove" and remove the cab.
Remove the Transmission Oil Pump
- Refer to Disassembly and Assembly, RENR8667, "Transmission Oil Pump-Remove" and remove the transmission oil pump.
Remove the suction tubes for transmission.
- Remove clamps (B) .
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| Illustration 55 | g01419885 |
- Remove hose (C) .
- Remove tube (A) .
- Remove tube (D) .
Note: You may need to cut tube (D) in half, in order to remove tube (D) .
Install New suction tubes for the Transmission
- Use the following parts and install the 309-8486 Tube Assembly (2) and the 310-3651 Tube Assembly (5) :
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| Illustration 56 | g01565454 |
Install the New Transmission Oil Pump
- Refer to Disassembly and Assembly, RENR8667, "Transmission Oil Pump-Install". Use the following new O-Ring Seals and install the 307-9674 Transmission Oil Pump Gp :
Remove the Transmission Control Module
- Remove the insulation that is for sound suppression (A) .
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| Illustration 57 | g01420129 |
- Refer to Disassembly and Assembly, RENR8667, "Relief Valve (Transmission Hydraulic Control) - Remove". Remove the relief valve (transmission hydraulic control).
- Refer to Disassembly and Assembly, RENR8667, "Relief Valve (Transmission Hydraulic Control) - Assemble". Exchange the following parts with the original parts and reassemble the relief valve (transmission hydraulic control):
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| Illustration 58 | g01470033 |
Relief valve | |
- Reinstall the relief valve (transmission hydraulic control).
- Remove existing plug (B).
Note: You may need to apply heat to plug (B) in order to remove plug (B) .
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| Illustration 59 | g01420159 |
Note: The following step is only necessary on standard transmissions.
- Install a 313-7626 Orifice Plug .
- Refer to Disassembly and Assembly, RENR8667, "Relief Valve (Transmission Hydraulic Control) - Install". Reinstall the transmission control module.
Refill all fluids
- Refer to Operation and Maintenance Manual, SEBU7879, "Transmission Oil Filter - Replace" and replace the transmission oil filter.
- Refer to Operation and Maintenance Manual, SEBU7879, "Capacities (Refill)" and refill any fluids that have been drained.
Temporary Cab Installation
Note: VERIFY THAT ALL FLUID LEVELS ARE CORRECT.
- Temporarily set the cab on the machine and connect the electrical system. Turn on the battery disconnect switch.
- Turn off air conditioner
- Position the cab and install the front mounting bolts loosely.
- Connect the ground strap to the frame at the left rear of cab.
- Manually engage the parking brake in order to warm the transmission oil.
- Connect a pressure gauge to the top remote pressure port for the Transmission Pump.
- The pressure should be 2344 ± 69 kPa (340 ± 10 psi) at high idle.
- If the pressure is low, remove the cab in order to gain access to the pressure relief screw that is for the transmission.
- Turn the pressure relief screw clockwise in order to increase the relief pressure.
- Temporarily install the cab. Start the machine and check the pressure.
- Repeat steps 3 through 10 until the pressure meets the specification of 2344 ± 69 kPa (340 ± 10 psi) at high idle.
- Refer to Disassembly and Assembly, RENR8681, "Cab-Install" and reinstall the cab.
Pressure Sensor Installation
Note: This section is not required if the machine is configured with the aggregate autodig system or the Payload Control System (PCS).
- Use a 3J-1907 O-Ring Seal (1) and install the 126-6872 Tee (2) into the 265-2834 Block (3) .
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| Illustration 60 | g01470837 |
- Use a 3J-1907 O-Ring Seal (1) and install the 6V-3965 Quick Disconnect Coupler (Test) (4) into the 126-6872 Tee (2) .
- Use a 3J-1907 O-Ring Seal (1) and install the 221-3416 Pressure Sensor Gp (Head End Oil for Lift Cylinder) (6) into the 265-2834 Block (36) .
- Use the following hardware and install the sensor assembly (A) on the right hand side of the front frame:
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| Illustration 61 | g01420255 |
- Remove the plug. Use a 6V-8397 O-Ring Seal (9) and install a 122-2222 Adapter (10) into the head end of the oil tube that is for the lift cylinder.
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| Illustration 62 | g01471228 |
Note: Make sure that the pressure is relieved before removing the plug in order to install the upper end of the 3T-6856 Hose As (1) .
- Use a 6V-8397 O-Ring Seal (9) and connect one end of the 3T-6856 Hose As (12) onto the 6V-8724 Elbow (11) .
- Use a 6V-8397 O-Ring Seal (9) and connect the other end of the 3T-6856 Hose As (12) onto the 126-6872 Tee (2) .
- Use the following parts and install the 263-4169 Monitor Harness As (14) :
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| Illustration 63 | g01573041 |
- Secure the balance of the 263-4169 Monitor Harness As (14) at point (B) .
- Connect the other end of the 263-4169 Monitor Harness As (15) to the front wiring group (C) .
Rework the Crankcase Guard
- In order to accommodate the new RH side engine oil drain, cut a hole (C) in the RH side of the guard for the engine crankcase. Use Dimension (A) and use the dimension (B) for the location of the hole.
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| Illustration 64 | g01511753 |
Crankcase guard (A) 300 mm (11.81 inch) (B) 465.5 mm (18.33 inch) | |
- Install the 291-5653 Insulation (1) and the 291-5667 Insulation (2) .
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| Illustration 65 | g01511655 |
Install the labels for the Software
Note: You will receive new labels for the engine in a separate shipment. You will need to install all these labels before you install the software.
- Replace serial number plate (A) .
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| Illustration 66 | g01532293 |
- Replace emissions label (B). This label is not required on machines with a existing emissions Label for 2007 or 2008 .
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| Illustration 67 | g01532296 |
- Replace the information plate (C) .
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| Illustration 68 | g01532298 |
- Attach the rework label in location (D) .
Flash New Software
- Refer to Testing an Adjusting, RENR8666, "Electronic Control Module (ECM) - Flash Program". Use the following steps and Flash the software that was provided by Service Engineering.
- Connect the data link cable between the communication adapter and the electronic technician.
- Connect the data link cable between the communication adapter and the diagnostic connector of the machine.
- Turn the disconnect switch to the ON position.
- Turn the key start switch to the ON position.
- Set the implement lockout to the LOCKED position.
- Ensure that the transmission direction switch is in the Neutral position.
- Ensure that the engine is not running.
- Use WinFlash in order to load the software.
- The following software will need to be flashed:
- You will get a pop up for the factory password. You must call the Dealer Solution Network. Request support for the tier II engine from Caterpillar Engine Components in order to obtain the factory password.
- Configure the Electronic Control Modules for the Implement and the Transmission.
- Calibrate the Electronic Control Modules for the Implement and the Transmission.
Note: Calibration of the pressures for clutch engagement is unnecessary. Clutches will engage at pump pressure, which has now been set to 2344 ± 69 kPa (340 ± 10 psi). The calibration will still be available in electronic technician, but the calibration will not be functional. The calibration should not be performed.
Note: Completion of the calibration for the transmission clutch fill is required. Completing this calibration will eliminate transmission diagnostic codes.
Adjust Hydraulic Fan Speed
- Refer to Testing and Adjusting, RENR8678, "980H Wheel Loader Electrohydraulic System ", "Hydraulic Fan Speed - Test and Adjust".
- Adjust the fan speed to 1400 RPM ±25 RPM maximum speed.
Rework Completion
- Reinstall rear tires on the machine if tires were removed.
- Reinstall rear axles on the machine if axles were removed.
- Start the machine and check the machine for leaks.
- Wash the machine.
- Exercise the machine for at least an hour.
- Recheck the machine for leaks.
- Install guards and the counterweight to the machine.