Caterpillar 980K Wheel Loader Workshop Repair Service Manual C13 Engine PDF Download - MCAT980K.zip
A full workshop service and repair guide—complete with electrical wiring schematics—for the Caterpillar 980K Wheel Loader, containing every technical detail needed to service, troubleshoot, fix, and rebuild the machine just like a trained technician.
Inside the Caterpillar 980K Wheel Loader workshop service and repair manual, you'll find:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
KENR6443 - Disassembly and Assembly (980K Wheel Loader C13 Engine Supplement).pdf
KENR6445 - Systems Operation (980K Wheel Loader Power Train).pdf
KENR6446 - Testing and Adjusting (980K Wheel Loader).pdf
KENR6446 - Troubleshooting (980K Wheel Loader).pdf
KENR6447 - Disassembly and Assembly (980K Wheel Loader Power Train).pdf
KENR6450 - Specifications (980K Wheel Loader Steering System).pdf
KENR6451 - Systems Operation (980K Wheel Loader Steering System).pdf
KENR6452 - Testing and Adjusting (980K Wheel Loader Steering System).pdf
KENR6453 - Specifications (980K Wheel Loader Braking and Hydraulic Fan System).pdf
KENR6454 - Systems Operation (980K Wheel Loader Braking and Hydraulic Fan System).pdf
KENR6455 - Testing and Adjusting (980K Wheel Loader Braking and Hydraulic Fan System).pdf
KENR6456 - Specifications (980K Wheel Loader Electrohydraulic System).pdf
KENR6457 - Systems Operation (980K Wheel Loader Electrohydraulic System).pdf
KENR6458 - Testing and Adjusting (980K Wheel Loader Electrohydraulic System).pdf
KENR6458 - Troubleshooting (980K Wheel Loader Electrohydraulic System).pdf
KENR6459 - Specifications (980K Wheel Loader Machine Systems).pdf
KENR6460 - Disassembly and Assembly (980K Wheel Loader Machine Systems).pdf
KENR6461 - Schematic (980K and 980K OEM Wheel Loader Hydraulic System).pdf
KENR6462 - Schematic (980K Wheel Loader and 980K OEM Wheel Loader Electrical System).pdf
UENR0786 - Systems Operation (980K Wheel Loader Machine Electronic Control System).pdf
UENR0786 - Testing and Adjusting (980K Wheel Loader Machine Electronic Control System).pdf
UENR0786 - Troubleshooting (980K Wheel Loader Machine Electronic Control System).pdf
UENR5486 - Schematic (980K and 980K OEM Wheel Loader Hydraulic System).pdf
PRODUCT DETAILS:
Total Pages: 4,613 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
KENR6443 - Disassembly and Assembly (980K Wheel Loader C13 Engine Supplement)....1
Steering Frame Lock - Separate and Connect....4
System Pressure - Release....7
Hydraulic Tank Oil - Retain....11
Batteries - Remove and Install....13
Hood Panels (Front and Rear) - Remove and Install....15
Hood Tilt Pump and Motor - Remove and Install....19
Hood Tilt Cylinder - Remove and Install....21
Hood - Remove and Install....22
Belt Tensioner - Remove and Install....26
Alternator - Remove and Install....29
Electric Starting Motor - Remove and Install....32
Fuel Priming Pump and Primary Filter (Water Separator) - Remove and Install....34
Fuel Transfer Pump - Remove and Install....40
Fuel Manifold (ARD) - Remove and Install - Clean Emissions Module....42
Ignition Coil - Remove and Install - Clean Emissions Module....45
Combustion Head - Remove and Install - Clean Emissions Module....47
Relay (ARD Nozzle Heater) - Remove and Install - Clean Emissions Module....51
Pressure Sensor (ARD Combustion Air) - Remove and Install - Clean Emissions Module....53
Nozzle Heater Harness - Remove and Install - Harness Assembly....56
Diesel Particulate Filter - Remove and Install - Clean Emissions Module....58
Flame Detection Temperature Sensor - Remove and Install - Clean Emissions Module....62
Soot Sensor - Remove and Install....64
Temperature Sensor (DPF) - Remove and Install - Clean Emissions Module....67
Inlet Manifold - Remove and Install - Clean Emissions Module....69
Exhaust Elbow - Remove and Install....72
Exhaust Pipe - Remove and Install - Clean Emissions Module....76
Exhaust Sensor Lines - Remove and Install - Venturi....77
Exhaust Cooler (NRS) - Remove and Install....79
Exhaust Gas Valve (NRS) - Remove and Install....81
Exhaust Manifold - Remove and Install....84
Clean Emissions Module - Remove and Install....87
Fumes Disposal Filter - Remove and Install....93
Air Control Valve - Remove and Install - ARD Combustion; Clean Emissions Module....95
Air Control Valve - Remove and Install - Control Module; Clean Emissions Module....98
Fuel Filter (Secondary) and Fuel Filter Base - Remove and Install....100
Water Temperature Regulator - Remove and Install....102
Water Pump - Remove and Install....105
Water Pump - Disassemble....108
Water Pump - Assemble....110
Expansion Tank - Remove and Install....112
Radiator Core - Remove and Install....114
Cooling System Package (Radiator; Fan Group; Fuel Cooler; Aftercooler; Hydraulic Oil Cooler; Refrigerant Condenser) - Remove and Install....117
Fan Group (Includes Fan; Fan Guard; Fan Shroud; and Hydraulic Fan Motor) - Remove and Install....123
Piston Motor (Hydraulic Fan) - Disassemble....127
Piston Motor (Hydraulic Fan) - Assemble....134
Aftercooler - Remove and Install....141
Hydraulic Oil Cooler - Remove and Install....144
Power Train Oil Cooler (Transmission) - Remove and Install....146
Engine Oil Cooler - Remove and Install....149
Engine Oil Filter and Oil Filter Base - Remove and Install....151
Turbocharger - Remove and Install....155
Air Cleaner - Remove and Install....158
Refrigerant Compressor - Remove and Install....161
Refrigerant Condenser - Remove and Install....163
Engine Oil Pan - Remove and Install....165
Engine Oil Pump - Remove and Install....167
Engine; Torque Converter; Transmission and Output Transfer Gears - Remove....171
Engine; Torque Converter; Transmission and Output Transfer Gears - Install....185
KENR6445 - Systems Operation (980K Wheel Loader Power Train)....197
General Information....198
Power Train Electronic Control System....201
Autoshift Control....214
Variable Shift Control....219
Integrated Braking System....220
Ground Speed Limiter....230
Electronic Control Module (Power Train)....231
Electrical Input Components....236
Electrical Output Components....249
Data Link....255
Monitoring System (Power Train Functions)....257
Power Train Torque Strategy....260
Torque Converter and Pump Drive Housing....261
Torque Converter....264
Torque Converter (Freewheel Stator) (Lockup)....268
Transmission Hydraulic System....272
Transmission Oil Pump....276
Oil Filter (Power Train)....279
Transmission Oil Cooler....282
Transmission Lubrication....284
Transmission Hydraulic Control....287
Modulating Valve (Transmission Clutch)....290
Transmission Hydraulic Control Operation....297
Transmission Planetary....306
Output Transfer Gears....315
Differential....319
Limited Slip Differential....322
NoSPIN Differential....328
Final Drive and Wheel....336
Oil Coolers and Cooling System Operation....338
KENR6446 - Testing and Adjusting (980K Wheel Loader)....346
Wiring Harness (Open Circuit) - Test....347
Wiring Harness (Short Circuit) - Test....348
Electrical Connector - Inspect....349
Electronic Control Module (ECM) - Replace....357
Electronic Control Module (ECM) - Flash Program....358
Electronic Control Module (ECM) - Configure....359
Transmission Clutch Hold Level (Electronic Technician) - Calibrate....365
Transmission Clutch Ramp Level (Electronic Technician) - Calibrate....371
Fill Time for the Transmission Clutch (Electronic Technician) - Calibrate....376
Position Sensor (Left Brake Pedal) (Electronic Technician) - Calibrate....382
Torque Converter Stall - Test....390
Transmission Pressures - Test and Adjust....396
Output Transfer Gears - Adjust....415
Differential Pinion Preload - Adjust....419
Differential Backlash and Bearings - Adjust....423
Limited Slip Differential Disc End Play - Check....429
Wheel Bearings - Adjust....430
Glossary of Electrical Terms....433
System Schematic....437
KENR6446 - Troubleshooting (980K Wheel Loader)....440
General Information....444
Service Tools....446
Connector Locations....448
Diagnostic Capabilities....452
Machine Preparation for Troubleshooting....458
Visual Inspection....460
Symptom Troubleshooting....463
Emerging Symptom Information....465
Torque Converter Troubleshooting....466
Transmission Troubleshooting....469
Differential and Final Drive Troubleshooting....483
Event Code List....487
Diagnostic Code List....494
Using the Operator Monitor to Determine Diagnostic Codes....504
Using Caterpillar Electronic Technician to Determine Diagnostic Codes....507
KENR6447 - Disassembly and Assembly (980K Wheel Loader Power Train)....879
Steering Frame Lock - Separate and Connect....882
System Pressure - Release....885
Crankcase Guard - Remove and Install....889
Power Train Guard (Transmission) - Remove and Install....891
Fender (Front) - Remove and Install....893
Relief Valve (Torque Converter Outlet) - Remove....895
Relief Valve (Torque Converter Outlet) - Disassemble....896
Relief Valve (Torque Converter Outlet) - Assemble....900
Relief Valve (Torque Converter Outlet) - Install....904
Transmission Oil Pump - Remove....905
Transmission Oil Pump - Disassemble....908
Transmission Oil Pump - Assemble....912
Transmission Oil Pump - Install....919
Relief Valve (Transmission Hydraulic Control) - Remove....922
Relief Valve (Transmission Hydraulic Control) - Disassemble....927
Relief Valve (Transmission Hydraulic Control) - Assemble....929
Relief Valve (Transmission Hydraulic Control) - Install....932
Modulating Valve (Transmission Clutch) - Remove....936
Modulating Valve (Transmission Clutch) - Disassemble....938
Modulating Valve (Transmission Clutch) - Assemble....940
Modulating Valve (Transmission Clutch) - Install....942
Steering Frame Lock - Separate and Connect 01_08_2012....944
Torque Converter; Transmission and Output Transfer Gears - Remove....950
Torque Converter from Transmission; Output Transfer Gears - Separate....958
Torque Converter - Disassemble - Heavy Duty....964
Torque Converter - Disassemble - Lock Up Clutch With Freewheel Stator....980
Torque Converter - Assemble - Lock Up Clutch with Freewheel Stator....996
Torque Converter - Assemble - Heavy duty....1014
Torque Converter (Freewheel Stator) - Disassemble....1031
Torque Converter (Freewheel Stator) - Assemble....1050
Transmission from Output Transfer Gears - Separate....1070
Output Transfer Gears - Disassemble....1074
Output Transfer Gears - Assemble....1089
Transmission Planetary - Disassemble - Heavy Duty....1107
Transmission Planetary - Disassemble....1138
Transmission Planetary - Assemble....1177
Transmission Planetary - Assemble - Heavy Duty....1217
Transmission to Output Transfer Gears - Connect....1248
Torque Converter to Transmission; Output Transfer Gears - Connect....1252
Torque Converter; Transmission and Output Transfer Gears - Install....1257
Parking Brake Actuator - Remove and Install....1264
Parking Brake - Remove....1269
Parking Brake - Install....1274
Drive Shaft (Front) - Remove and Install....1278
Carrier Bearing (Drive Shaft) - Remove and Install....1280
Drive Shaft (Center) - Remove and Install....1286
Drive Shaft (Rear) - Remove and Install....1288
Tire and Rim (Front) - Remove and Install....1290
Tire and Rim (Rear) - Remove and Install....1293
Fixed Axle (Front) - Remove....1297
Fixed Axle (Front) - Install....1300
Oscillating Axle (Rear) - Remove....1303
Trunnion Support (Oscillating Axle; Front) - Remove and Install....1308
Trunnion Support (Oscillating Axle; Rear) - Remove and Install....1313
Axle Shaft - Remove and Install....1320
Final Drive; Brake and Wheel - Remove....1325
Final Drive Planetary Carrier - Disassemble....1329
Final Drive Planetary Carrier - Assemble....1333
Final Drive and Wheel - Disassemble....1336
Final Drive Spindle and Service Brake - Disassemble....1343
Final Drive Spindle and Service Brake - Assemble....1348
Final Drive and Wheel - Assemble....1356
Duo-Cone Conventional Seals - Install....1365
Final Drive; Brake and Wheel - Install....1372
Differential and Bevel Gear - Remove....1376
Differential and Bevel Gear - Disassemble....1379
Differential and Bevel Gear - Assemble....1391
Differential and Bevel Gear - Install....1410
Limited Slip Differential - Disassemble....1413
Limited Slip Differential - Assemble....1421
NoSPIN Differential - Disassemble....1430
NoSPIN Differential - Assemble....1433
Oscillating Axle (Rear) - Install....1436
KENR6450 - Specifications (980K Wheel Loader Steering System)....1441
Hydraulic Tank....1443
Temperature Sensor (Hydraulic Oil)....1447
Piston Pump (Steering)....1448
Piston Pump (Brake; Pilot; Fan)....1454
Control Manifold (Brake; Pilot; Fan)....1456
Gear Pump (Secondary Steering)....1458
Steering Control....1460
Solenoid Valve (Steering)....1462
Steering Control Valve....1463
Solenoid Valve (Pilot Proportioning)....1465
Pressure Sensor (Steering) - Secondary Steering....1466
Relief Valve....1467
Diverter Valve (Secondary Steering)....1468
Steering Cylinder....1470
Accumulator (Steering) - Uncharged....1472
Articulated Hitch....1474
Torque Converter and Transmission Pressures....1476
Torque Converter and Pump Drive Housing....1478
Torque Converter....1481
Torque Converter (Freewheel Stator)....1484
Torque Converter (Lockup)....1487
Relief Valve (Torque Converter Outlet)....1490
Temperature Sensor (Torque Converter Oil) (Transmission Oil)....1492
Temperature Sensor (Torque Converter Oil)....1493
Transmission Oil Pump....1494
Oil Filter (Power Train)....1497
Engine and Transmission Support Group....1499
Left Hand Steering Control - Includes Transmission Controls....1501
Transmission Hydraulic Control....1507
Transmission Control Valve....1509
Modulating Valve (Transmission Clutch)....1511
Transmission Planetary....1513
Output Transfer Gears....1516
Speed Sensor (Transmission Input)....1520
Speed Sensor (Transmission Output)....1521
Drive Shaft....1522
Differential and Bevel Gear....1524
Limited Slip Differential....1526
Fixed Axle (Front)....1528
Oscillating Axle (Rear)....1530
Final Drive and Wheel....1533
Rim Mounting....1535
Axle Oil Cooler Pump and Clutch....1536
Check Valve (Axle Oil Cooler Bypass)....1537
Temperature Sensor (Axle Oil)....1538
KENR6451 - Systems Operation (980K Wheel Loader Steering System)....1539
General Information (Steering)....1540
General Information (Electrical System)....1551
Steering System (Electrical)....1554
Monitoring System (Steering Functions)....1580
Piston Pump (Steering)....1582
Piston Pump (Brake; Pilot; Fan)....1590
Control Manifold (Brake; Pilot; Fan)....1599
Steering Control Valve....1606
Secondary Steering System....1610
Secondary Steering System (Electrical)....1615
Gear Pump (Secondary Steering)....1623
Diverter Valve (Secondary Steering)....1626
KENR6452 - Testing and Adjusting (980K Wheel Loader Steering System)....1628
Machine Preparation for Troubleshooting....1629
Visual Inspection....1631