980 B Wheel Loader S/n 89P1 & Up Volume 1 of 2

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Caterpillar Service Manual 980 B Wheel Loader S/n 89P1 & Up Volume 1 of 2

WITHOUT THE AUTHORIZATION OF CATERPILLAR OR IT S SUCCESSORS.

1 Caterpillar Service Manual 980 B Wheel Loader S/n 89P1 & Up Volume 1 of 2 Service Manual THIS IS A MANUAL PRODUCED BY JENSALES INC. WITHOUT THE AUTHORIZATION OF CATERPILLAR OR IT S SUCCESSORS. CATERPILLAR AND IT S SUCCESSORS ARE NOT RESPONSIBLE FOR THE QUALITY OR ACCURACY OF THIS MANUAL. TRADE MARKS AND TRADE NAMES CONTAINED AND USED HEREIN ARE THOSE OF OTHERS, AND ARE USED HERE IN A DESCRIPTIVE SENSE TO REFER TO THE PRODUCTS OF OTHERS. CT-S-980BWL89P

2 .;'" J)... ",. ~', SERVICE MANUAL

3 4.75" BORE, SIX CYLINDER TWO VALVE VEHICLE ENGINE INDEX SYSTEMS OPERATION Air Induction and Exhaust Systems Alternators Circuit Breaker..., Cooling System '"..., 10 Fuel Injection Pump Operation..., 5 Fuel Injection Valve... 6 Fuel System... 5 Generator Generator Regulator Governor Operation... " Lubrication System Solenoid Starting Motor Starting and Charging Systems Valves and Valve Mechanism..., TESTING AND ADJUSTING,~. "~;,,'J...,...;::,.. ;;.. Air Induction and Exhaust System Checking Inlet Manifold Pressure at Torque Converter Stall Speed Compression Crankcase Pressure Cylinder Head Measuring Inlet Manifold Pressure Precombustion Chamber Position Restriction of Air Inlet and Exhaust Valve Clearance Setting Basic Block Connecting Rods and Pistons... '.' Crankshaft Cylinder Liner Projection Flywheel Cooling System Testing Cooling System Visual Inspection Flexible Drive Coupling Fuel System Accessory Drive Shaft Timing Check Fuel Injection Pump Lifter Washer and Pump Plunger Checking Fuel Injection Pump Timing-On Engine Fuel Injection Pump Timing Dimension Setting--Off Engine 27 Fuel Injection Service Fuel Injection Valve Fuel Injection Pump Installation Fuel Rack Setting Fuel Ratio Control Setting......, 31 Governor Adjustments Governor Control and Deceleration Linkage Adjustments Locating Top Center Position for No.1 Cylinder Testing Fuel Injection Equipment Visual Inspection... : Lubrication System Excessive Oil Consumption High Oil Pressure Low Oil Pressure Unusual Bearing Wear Problem Solving Starting and Charging System Battery Charging System Starting System SPECIFICATIONS Alternators... 64, 65 Connecting Rod Crankshaft Cylinder Block... : Cylinder Head Cylinder Liner Flexible Drive Coupling Fuel Bypass Valve... " 51 Fuel Injection Equipment Fuel Transfer Pump Generators , 66 Generator Regulators , 68 Governor Governor and Decelerator <;:ontrol Oil Filter Oil Pump Piston and Rings Power Take-off and Hydraulic Pump Drive Radiator Shutoff Solenoid Starter Solenoids , 73 Starting Motors... 69,70,71 Temperature Regulator Timing Gears..., 53 Turbocharger (AiResearch TI210 and T1224) Turbocharger (Schwitzer F444, 4LF504 and E Models) Valves... 54, 55 Valve Cover Valve Rocker Arms and Lifters... " Water Pump... 60'.. ~~~~. ~~._. ':'-"'*" '~'''~~,.K,.~s:;a.~,~.''''''~:~;t{';*''';~~~~~~''~~~~~~~~~~'::'.~:~~:~~.. :,~:<",.'~;."':."7... ~~"C :f?-_...", ~'-."'"... 'i.....,..,...':"".~"":..:,:.~,~::;:;;,~~....,:.,-,.,;...",.,;:,.:~"" ;c ~..:..~... "... ::~:~~... ':~~~~.. :~~~:~...

FUEL SYSTEM TESTING AND ADJUSTING shaped to prevent the screws from turning, after the adjustment has been made. Mter setting the idle RPM, move the governor control lever to change the engine RPM.

4 FUEL SYSTEM TESTING AND ADJUSTING shaped to prevent the screws from turning, after the adjustment has been made. Mter setting the idle RPM, move the governor control lever to change the engine RPM. Return it to the idle position and recheck the idle RPM. Repeat the adjustment procedure until the specified idle RPM is obtained. position. Hold the lever in the FULL LOAD position while making the adjustment. 7. Turn adjusting bolt out with cover (4) until the proper dial indicator reading is obtained. The proper reading is listed in the RACK SETTING INFORMATION. Fuel Ratio Control Setting Tools Required: 9S240 Rack Positioning Tool Group, Wrench. The fuel rack must be set correctly before setting the fuel ratio control. 1. Remove the rack cover from the front of the fuel injection pump housing, and cover (4) from the rear of the fuel ratio control. 2. Engage slot in cover (4) with cross-dowel in adjusting bolt and turn the adjusting bolt in as far as possible. This prevents the head of the bolt from limiting the travel of the fuel rack. 3. Install 9S238 Rack Positioning Bracket Group over the front end of the fuel rack and 9S215 Dial Indicator in the bracket. 4. Remove the plug from the bottom of the governor and install plug (2). Through opening in plug (2) use rod (3) to push in (retract) the speed limiter plunger. SETTING FUEL RATIO CONTROL 4-Cover. 8. Turn cover (4) clockwise the amount necessary to align the bolt holes and install cover (4). 9. Remove the 9S238 Rack Positioning Bracket Group, 9S215 Dial Indicator and install the rack cover. 10. Install the standard plug in place of plug (2). NOTE-Before starting the engine, make certain the governor control lever will move the governor to the SHUTOFF position and that all parts operate freely. With the above initial adjustment made, a further adjustment while the engine is running can be made if necessary to improve engine performance. To reduce exhaust smoke during acceleration, turn cover (4) out (less fuel) 1/2 turn at a time until satisfactory. When exhaust smoke is acceptable but acceleration is sluggish, turn cover (4) in (more fuel) 1/2 turn at a time until sati.sfactory. RETRACTING SPEED LIMITER PLUNGER 1-Governor control lever. 2-9S8518 Plug Rod. 5. Center the rack and set the dial indicator on zero. Remove the spacer..6. With the speed limiter plunger held in, move governor control lever (1) to FULL LOAD NOTE-Some exhaust smoke is likely to appear at maximum acceleration. NOTE-If acceleration is sluggish and full engine power seems to be lost, inspect the air line to the cover and the cover gasket for air leaks. If no air leaks are apparent, inspect the diaphragm. A damaged diaphragm will not allow the fuel rack to open completely, acceleration will be sluggish and full engine power cannot be obtained. 31.

;:, I CCnllllU ;:,,;:, I CIVI ~ I.;) I &;IVI.;) V..-l;.nM IIVI" the machine, the cylinder port with highest pressure (6 or 8) forces oil into the cavity at the left or right end of shuttle valve (14).

5 ;:, I CCnllllU ;:,,;:, I CIVI ~ I.;) I &;IVI.;) V..-l;.nM IIVI" the machine, the cylinder port with highest pressure (6 or 8) forces oil into the cavity at the left or right end of shuttle valve (14). This moves the shuttle valve which directs the high pressure oil through passage (13), orifice (12) and into chamber (3). The pilot valve (1) will then open and relieve the high pressure in the system. STEERING GEAR AND VALVE 3. Oil line (pressurized during right hand turn). 6. Oil line from pump to control valve. 7. Oil line (pressurized during left hand turn). 8. Steering control valve. 10. Return line to tank. 14. Follow-up linkage. fastened to front frame. 15. Spring-loaded linkage. 16. Steering gear. STEERING CONTROL VALVE IN NEUTRAL POSITION (Later Machines) 1. Main relief pilot valve. 2. Springs. 3. Chamber. 4. Return port to hydraulic tank. 5. Flow control valve. 6. Cylinder port (R.H. turn). 7. Inlet port from pump. 8. Cylinder port (L.H. turn). 9. Passage connected to port (4). return to hydraulic tank. 10. Spool. 11. Spool centering spring. 12. Orifice. 13. Passage. 14. Shuttle valve. 15. Throttling slots. 16. Bridge slots. LOCATION OF HYDRAULIC PUMPS STEERING CONTROL VALVE Oil Flow-Neutral Pump flow enters the steering control valve at port (7). With the spool (10) in NEUTRAL position, oil flow to the cylinder ports (6 and 8) is restricted. Bridge slots (16) in the spool allow a small flow of oil to the hydraulic tank and each cylinder port. The flow restriction causes a pressure increase in pump inlet port (7). As the pressure increases, flow control valve (5) moves to the left, compressing springs (2). Oil flows through openings in valve (5) and out port (4) to the hydraulic tank. Oil pressure in the steering cylinders is equal because of bridge slots (16). The equal pressure in both cylinders eliminates erratic steering cylinder operation. STEERING CONTROL VALVE IN NEUTRAL POSITION (Earlier Machines) 1. Main relief pilot valve. 2. Springs. 3. Chamber. 4. Return port to hydraulic tank. 5. Flow control valve. 6. Cylinder port (R.H. turn). 7. Inlet port from pump. 8. Cylinder port (L.H. turn). 9. Passage connected to port (4). return to hydraulic tank. 10. Spool. 11. Spool centering spring. 12. Orifice. 13. Passage. 14. Shuttle valve. 15. Throttling slots. 16. Bridge slots. A steering shock can be absorbed by relieving the cylinders high pressure oil through the main pilot relief valve. If an external force tends to steer 6

$:;Ut"t"Lt:IVIt:I" 11-\1..., I ~~nll"u ""'1"""_"'_'.' ' ""',._,...,,... 3. Lift seals (6) and rings (7)from around shafts. 4.$

6 :;Ut"t"Lt:IVIt:I" 11-\1..., I ~~nll"u ""'1"""_"'_'.' ' ""',._,...,, Lift seals (6) and rings (7)from around shafts. 4. Lift drive shaft and gear assembly (11) part of the way out of the body of the pump. If the shaft assembly is not free, turn the shaft assembly and use small radial movements until it is free. Lift bushings (4) from around the shafts. Remove spring pin (5) and ball (14) from each bushing. 5. Lift the drive shaft and gear assembly (11) and the idler gear and shaft assembly (3) out of the body of the pump. 6. Remove body of pump (2) from vise. Turn the open end down. Let the body fall against a block of wood until bushings (16) fall from the body. Be careful so there is no damage to the face of the body that fits against the flange (8). Bushings (16) are the same as bushings (4). BUSHINGS 2. Body of pump. 4. Bushing (twol. 11. Drive shaft and gear assembly. 7. Check the bores (15) and (17) in body for wear. Do not use a new body (2) unless a gear has worn more than.015 in. (0,38 mm) of metal from the bore in any area of (17). 8. Remove snap ring (10) from flange (8). REMOVING SNAP RING BUSHINGS AND SEALS 8. Flange. 10. Snap ring. 4. Bushing (twol. 5. Spring pin {two I. 6. Seal (twol. 7. Back up ring (twol. 13. Dowel (twol. 14. Ball (twol. SEAL REMOVED 8. Flange. 9. Lip type seal. 18. O-ring seal. REMOVING BUSHINGS 2. Body of pump. 15. Bore for drive shaft and gear assembly ( Bushings. 17. Bore for idler gear. 9. Put flange (8) on bench with the face that has the seat for seal (18) on top. Drive the lip-type seal (9) from the flange. 12

7 -._,..,."''''_... "".,..., """''''... tlll. Assem~ly 3. Install a ball (14) and a spring pin (5) in bushings (16). Put a little clean grease in the holes for the spring pins to keep the pins from falling out. 4. Put a little clean grease on the two O-ring seals (6) and install in bushings (16). 5. Put a little clean grease on two back-up rings (7) and install them on bushings (16). INSTALLING SEAL 8. Flange P529 Handle P463 Drive Plate. 1. Install a new O-ring seal (18). INSTALLING O-RING SEAL 2. Use a handle (19) and a drive plate (20) to install lip-type seal (9) in flange (8). 6. O-ring seal. INSTALLING BALL 14. Ball. INSTALLING BACK-UP RING 7. Back-up ring Xl! INSTALLING SPRING PIN 5. Spring pin. INSTALLING DOWEL 13. Dowel. 13

8 CLEANING AND INSPECTION OF PARTS CLEANING All parts should be cleaned thoroughly in a good cleaning solvent before inspection. CYLINDER HEAD ASSEMBLY Remove all carbon deposits from discharge cavities and all rust and scale from cooling cavities of cylinder head body. Scrape all foreign matter from body surfaces and use air pressure to blow dirt particles from all cavities. Discharge valves can be dressed by lapping them on a piece of fine crocus cloth on a flat surface, provided they are not excessively worn. CYLINDER BLOCK Clean carbon and dirt from inlet and unloader passages. Use air pressure to blow carbon and dirt deposits from unloader passages. Inlet valves, as in the case of discharge valves, not worn excessively can be cleaned by lapping them on a piece of fine crocus cloth on a flat surface. OIL PASSAGE Clean thoroughly all oil passages through crankshaft, connecting rods, crankcase, end covers and base plate. If necessary inspect passages with a wire and blow foreign matter out with air pressure. AIR STRAINER Thoroughly clean strainer element, then saturate it in clean oil and squeeze out excess oil before replacing it in air strainer. CRANKCASE - SELF-LUBRICATED TYPE The breather should be thoroughly washed and deaned. The oil pump check valve in the base should be removed and replaced. It is important when' th~ oil pump check valve is replaced that it be installed correctly with the ball stop pin end pressed in first. When installed the ball and its seat should be visible from the crankcase base. INSPECTION OF PARTS CYLINDER HEAD BODY Inspect cylinder head body for cracks or damage. WATER-COOLED TYPE Use air pressure to test water jackets of cylinder head and block for leakage. Replace unit if leakage is found. DISCHARGE VALVES AND SEATS If discharge valves are worn and grooved where they contact the seats, they should be replaced. If the discharge valve seats are worn excessively so that there is no longer enough metal left to reclaim them by lapping, the seats should be replaced. DISCHARGE VALVE SPRING AND CAP NUTS Replace all used discharge valve springs and cap nuts. CRANKCASE AND END COVERS Check for cracks or broken lugs in crankcase and end covers. Also check their oil passages to make sure they are open and clean. If an oil seal ring is used in the end cover, check fit of ring in ring groove. There should be 0.008" to 0.015" clearance at the gap when placed in the end bore of the crankshaft. If the oil ring is worn thin or is damaged, it should be replaced. Inspect oil ring groove in end cover; if groove is worn excessively replace end cover or machine groove for next oversize oil seal ring. CRANKCASE BEARING BORES With cylinder block installed on crankcase, check fit of ball bearings in bearing bores. They must be a tight press fit. The crankcase should be replaced if bores are worn or damaged. CYLINDER BLOCK Check for cracks or broken lugs on cylinder block. Also check unloader bore bushings to be sure they are not worn, rusted or damaged. If these bushings are to be replaced they can be removed by running a yg" pipe thread tap inside the bushing, then inserting a Ys" pipe threaded rod and pulling the bushing straight up and out. Do not use an easy-out for removing these bushings. INLET VALVES AND SEATS If inlet valves are grooved or worn where they contact the se<ft, they should be replaced. If the inlet valve seats are worn or damaged so they cannot be reclaimed by facing, they should be replaced. CYLINDER BORES Cylinder bores wl1ich are scored or out of round by more than 0.002" or tapered more than 0.003" should be rebored or honed oversize. Oversize pistons are available in 0.010, 0.020, and oversizes. Cylinder bores must be smooth, straight, and round. Clearance between cast iron pistons and cylinder bores should be between 0.002" minimum and 0.004" maximum (Fig. 17). Aluminum pistons are cam ground. FIGURE 17 - MEASURING CYLINDER BORES PISTONS Check pistons for scores, cracks,or enlarged ring grooves; replace pistons if any of the,se conditions are found. Measure each piston with a micrometer in relation to the cylinder bore diameter to be sure the clearance is between 0.002" minimum and 0.004" maximum. 21

9 980B ENGINE DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP HOUSING & GOVERNOR CONNECT GOVERNOR TO FUEL INJECTION PUMP HOUSING 1. Position the cylinder and weight assemblies (1) on the fuel injection pump housing so that slot in piston is engaged with the rack (2). / Y!".,~ J " 2. Push the cylinder and weight assemblies onto the locating dowels. 3. Install the three mounting bolts (5) and lock. 4. Install the washer-type spring (4), seat assembly (3), and governor spring (8) on the cylinder assembly. The washer-type spring (4) should be installed so that the inside diameter of spring will contact the guide in governor housing (6). 5. Position the governor housing (6) on the fuel injection pump housing, and install the governor mounting bolts. 6. Install the spring (12), collar (10), and rack stop collar ( 11) on bolt (7). 7. Install and tighten the rack stop collar retaining screw (9). 8. Position the idle screw housing (13) on the governor so that dowel in housing engages slot (14) in rack stop collar (11). 9. Install the idle screw cover. concluding steps: a) install fuel ratio control b) install fuel injection pump housing and governor as a unit c) set the rack and adjust governor (See FUEL RACK SETTING AND GOV ERNOR ADJUSTMENTS in TESTING AND ADJUSTING) /5

VEHICLE SYSTEMS DISASSEMBLY AND ASSEMBLY REMOVE TANK VALVE GROUP 11-5076 1.' Let the oil out of the hydraulic tank. TANK VALVE GROUP 2. Remove floor plates. 3.

10 VEHICLE SYSTEMS DISASSEMBLY AND ASSEMBLY REMOVE TANK VALVE GROUP ' Let the oil out of the hydraulic tank. TANK VALVE GROUP 2. Remove floor plates. 3. Remove top cover (1) for the hydraulic tank with filler neck. 4. Remove bottom cover (2) for the hydraulic tank. (3) "",-./ 5. Remove lines guard for the hydraulic tank. 6. Disconnect two gauge lines (4) from filter housing. 7. Remove holding bolts from filter housing (5), filter cover and support strap (3). 8. Disconnect filter outlet line (6) from under filter. -~'!:'- Gj 9. Disconnect inlet line (8) from side of filter. 10. Remove filter housing (7) with a hoist. 12. ~...,,'..- ittfi"'q.,' ;.'-) <"~ie":" i:,'

951B Traxcavator S/n 79H, 32F, 69H & 86J Volume 1 of 2

951B Traxcavator S/n 79H, 32F, 69H & 86J Volume 1 of 2 Caterpillar Service Manual 91B Traxcavator S/n 79H, 2F, 9H & 8J Volume 1 of 2 Service Manual THIS IS A MANUAL PRODUCED BY JENSALES INC. WITHOUT THE AUTHORIZATION OF CATERPILLAR OR IT S SUCCESSORS. CATERPILLAR