Caterpillar Cat 980F II WHEEL LOADER (Prefix 8JN) Service Repair Manual (8JN00001 and up)

1
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Product WHEEL LOADER Model 980F II WHEEL LOADER
8JN Configuration 980F SERIES II WHEEL LOADER
8JN00001-UP (MACHINE) POWERED BY 3406C DI ENGINE
Disassembly and Assembly 3406C DIESEL ENGINES FOR
CATERPILLAR BUILT MACHINES Media Number
-SENR6409-02 Publication Date -01/07/2006
Date Updated -19/05/2015
SENR64090008
Governor SMCS - 1264-015 1264-016 Disassemble
Governor

• Part of 6V4095 Pump and Governor Reconditioning
  Tool Group.
• IN
• Start By
• remove fuel injection pump housing and governor
• remove fuel transfer pump
• NOTE If it is desired to only remove the
  governor so the fuel injection pump housing can
  be disassembled, do only steps 1, 2, 3, 16, 22,
  25, 26, 27, 28, 32, 34 and 37.

2

1. Put the fuel injection pump housing and governor
   in position on Tool (A).
2. Remove the bolts, fuel ratio control (1) and
   shutoff solenoid (2) from rear governor housing
   (3).
3. Remove the bolts, rear governor housing (3) and
   the gasket from the front governor housing.

4. Remove governor spring (4), the two wave
washers, one flat washer and the seat from the
guide in the rear governor housing.

• Remove bolt (5) that holds lever assembly (6) to
  the shaft assembly.
• NOTE There is a key in the slot groove of the
  shaft assembly that must be removed before the
  shaft assembly is removed from the rear governor
  housing.
• Remove shaft assembly (7), lever (6) and lever
  (8) from the rear governor housing.

NOTE Put an alignment mark on lever (9) for
correct assembly purposes. 7. Remove bolt (10),
lever assembly (9) and spring (11) from shaft
assembly (7).
3
8. Remove plug (12) and lip-type seal (13) from
the housing.
NOTE Spacers (14) and (16) are different sizes.
Make sure they are assembled in the correct
position. 9. Use needle nose pliers, and remove
the shaft. Remove spacer (14), lever (15) and
spacer (16) from the governor housing.
10. Remove two setscrews and locknuts (17) if
necessary.
11. Release spring (18) from the notch in the
housing. Remove snap ring (19), and remove
shaft (20) from the housing. Remove lever (21)
and spring (18).
4
12. Remove liptype seal (22) from the housing.
13. If necessary, remove the screws, cover (23)
and the gasket from the governor housing.
14. Remove high idle cover (24) and three O-ring
seals (25).
15. Remove liptype seal (26), dashpot valve (27),
fitting (25), insulator and high idle
adjustment (28) from the rear housing.
5
16. Remove two bolts (29), housing (30) and the
gasket from the fuel pump housing.
17. Remove bolts (31), and remove torque control
group (32) from the block. NOTICE Depending on
the different engine applications, torque control
groups will vary. Inspect all parts for wear and
damage, and make a note of the correct sequence
of the parts for assembly purposes.
NOTE For additional information, see
Specifications Manual SENR6470.
18. Remove the bolts and block (33) for the full
load stop from the housing.

1. Remove the bolt that holds collar (35) to bolt
   (36).
2. Remove collar (35) and spring (34) from bolt
   (36). Remove bolt (36) from the block.
3. If necessary, remove the stop screw and the power
   setting screw from collar (35).

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NOTE It may be necessary to turn the piston to
remove the servo from the rack. 22. Remove the
three bolts and governor servo (37) from the fuel
injection pump housing.
23. Remove lockring (43), seat (42), spring (41)
and sleeve (40) from valve (39). Remove
lockring (38) from the groove in the center of
valve (39).
24. Remove sleeve (44), valve (45) and piston
(46) from the governor servo. Remove O-ring
seal (50) from sleeve (44). Do not remove pin
(47). If pin (47) and lever (48) or cylinder (49)
are worn or damaged replace the assembly.

1. Use Tool (C) to hold spring (51) under
   compression so the ring on the governor shaft can
   be removed.
2. Remove the ring, and carefully remove Tool (C).
3. Remove bearing (52), the sleeve and spring (51)
   from the governor shaft.

8
28. Remove ring (53) and dashpot assembly (54)
from the governor shaft.

1. Use Tool (B), and remove ring (60) from seat
   (57).
2. Remove ring (59) and spool (58) from seat (57).
3. Remove seat (57), and spring (56) from shield
   (55).

32. Remove spring (62), if equipped, and riser
(61) from the governor shaft.
33. Remove ring (63), races (64) and bearing (65)
from the riser.
9
34. Remove the bolts and carrier assembly (66)
from the fuel injection pump housing.

1. Remove dowels (68) and flyweights (69) from the
   carrier assembly.
2. Remove dowel (67) from the governor shaft, and
   remove the governor shaft from the carrier
   assembly.

37. Remove races (70) and (72) and bearing (71)
from the camshaft in the fuel injection pump
housing.
10
Assemble Governor
Pump and Governor Reconditioning Tool Group
11
1. Put the fuel injection pump housing in
position on Tool (A). Install race (3), bearing
(2) and race (1) on the end of the camshaft in
the fuel injection pump housing.
2. Put flyweights (5) in position on carrier
assembly (4), and install dowels (6) to hold the
flyweights in place. The flyweights must move
freely on the dowels and have 0.010 to 0.230 mm
(.0004 to .0090 in) end play.
3. Install governor shaft (7) on carrier assembly
(4).

1. Install dowel (8) in governor shaft (7), and
   slide carrier assembly (4) down on the governor
   shaft until dowel (8) fits into the slot in the
   carrier assembly.
2. Install carrier assembly (4) on the end of the
   camshaft.

6. Install race (12), bearing (11), race (10) and
ring (9) on riser (13).
12
7. Install riser (13) and spring (14), if
equipped, on the governor shaft.

1. Install spool (18) and ring (19) on seat (17),
   and use Tool (B) to install ring (20) to hold
   them in position.
2. Install seat (17) on spring (16) and spring (16)
   on shield (15).

10. Install dashpot assembly (21) on the governor
shaft.
11. Install ring (22) in the groove on the
governor shaft. Install sleeve (23), spring (25),
the sleeve and bearing (24) on the governor shaft.
13
12. Use Tool (C) to hold spring (25) under
compression, and install the ring in the groove
on the governor shaft.

1. Install O-ring seal (26) on sleeve (27). Install
   piston (29) and sleeve (27) in the governor servo
   as shown.
2. Install valve (28) in the governor servo as shown.

15. Install lockring (33) in the groove near the
center of valve (28). Put sleeve (34), spring
broken link spring (35) and seat (36) in position
on valve (28), and install lockring (37) to hold
them in place.
16. Put governor servo (30) in position on the
fuel injection pump housing with piston (29)
engaged over the rack. Make sure the lever is
engaged in the slot groove of riser (13).
14

1. If dowel (43) was removed, install it in block
   (44) 31 0.5 mm (1.22 .02 in) above the
   outside surface of the block.
2. Install bolt (45) in block (44) and spring (38)
   on bolt (45).
3. Install stop screw (40) and the locknut on collar
   (42). Install power setting screw (41) and the
   locknut on the collar.
4. Install collar (42) on bolt (45). Make an
   alignment of the hole in the collar with the
   notch in bolt (45), and install bolt (39).

21. If the dowels that align block (44) with the
front governor housing were removed, install
them 4.0 0.5 mm (.16 .02 in) above the
outside surface of the front governor
housing. 22. Put block (44) in position on the
front governor housing with the holes in the
block in alignment with dowels in the front
governor housing.

1. Install dowels (46) in the front governor housing
   6.0 0.5 mm (.24 .02 in) above the outside
   surface of the front governor housing.
2. Assemble torque spring group (47) in the correct
   sequence, and install it on the block.

15
To avoid possible personal injury and damage to
the engine when front governor housing (48) is
installed on the fuel injection pump housing,
make sure the flange on bolt (45) is behind the
shield of the dashpot. If the flange on the bolt
is installed on the wrong side of the shield, the
riser in the governor will be held in the maximum
fuel delivery position.
25. Install the gasket and front governor housing
(48) on the fuel injection pump housing. Make
sure the flange on bolt (45) is behind the shield
of dashpot (21).

1. Check the seal on dashpot valve (51) for damage
   or wear, and make a replacement if necessary.
2. Install dashpot valve (51), insulator (49),
   fitting (50) high idle screw (52) and the locknut
   in rear governor housing (53). Tighten insulator
   (49) to a torque of 4.5 0.5 Nm (40 4.4 lb
   in).

28. Use Tool (D), and install seal (54) with the
lip of the seal down as shown. Put clean engine
oil on the lip of the seal. Install high idle
screw cover (55) and O-ring seal (56).
16
29. Install the liptype seals in housing (53)
with Tool (D) as shown.
30. Install the gasket and cover (57) in the
governor housing.
31. Put clip (60) in position on shaft (61), and
install shaft (61) into the housing through
spring (59) and lever (58). Put the key in the
lever in alignment with the keyway in the shaft.
32. Install clip (62) on the shaft, and install
screw (63) and the locknut on the lever. Put the
end of the spring in position in the notch in the
housing as shown.
17
33. Install screws (64) and locknuts (65) on
lever assembly (66). Tighten locknuts (65) to a
torque of 1.70 0.25 Nm (15 3 lb in).

1. Install shaft (68) in the housing. Install long
   spacer (67), lever assembly (66) and the short
   spacer on shaft (68).
2. Check the condition of the O-ring seal on the
   plug. Lubricate the O-ring seal with clean engine
   oil, and install the plug to hold shaft (68) in
   position.

1. Install lever assembly (72) on shaft assembly
   (73). Be sure the alignment marks on the
   components are in alignment with each other.
2. Install shaft assembly (73) into the housing. Put
   washer (71) and lever (74) in position on the
   shaft assembly. Put key (70) in the key slot on
   shaft assembly (73), and install lever (69) over
   the key on the shaft assembly. Align the bolt
   hole in lever (69) with groove (75) in the shaft
   assembly, and install the bolt.

38. Install seat (76), wave washer (78), washer
(79), wave washer (80) and spring (81) on
guide (77).
To avoid possible personal injury and damage to
the engine when rear governor housing (53) in
installed on the fuel injection pump housing,
18
make sure the flyweights are toward the fuel
injection pump housing. If the flyweights are
extended out too far, the riser in the governor
will be held in the maximum fuel delivery
position.

1. Install gasket (82) and rear governor housing
   (53) on the front governor housing.
2. Make the governor adjustments. See the topic
   "Fuel Ratio Control Governor Check" in the
   System Operation Testing Adjusting Manual, Form
   No. SENR6471.

41. Put fuel ratio control (83) in position. Make
sure the flange on the end of the fuel ratio
control is behind the slot in lever assembly
(66). See Illustration B88652P1.

• Hold the control lever in the fuel off position,
  and install shutoff solenoid (84).
• Make an adjustment to the fuel ratio control. See
  the topic "Fuel Ratio Control And Governor Check"
  in the System Operation Testing Adjusting
  Manual, Form No. SENR6471.
• End By
• install fuel transfer pump
• install fuel injection pump housing and governor

Thu Dec 23 191033 UTC0800 2021
19
Shutdown SIS
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Product WHEEL LOADER Model 980F II WHEEL LOADER
8JN Configuration 980F SERIES II WHEEL LOADER
8JN00001-UP (MACHINE) POWERED BY 3406C DI ENGINE
Disassembly and Assembly 3406C DIESEL ENGINES FOR
CATERPILLAR BUILT MACHINES Media Number
-SENR6409-02 Publication Date -01/07/2006
Date Updated -19/05/2015
SENR64090009
Fuel Injection Pumps SMCS - 1251-011 1251-012
1251-017 Remove Fuel Injection Pumps
Start By a. remove fuel injection lines
1. Remove the plug, and move the race until Tool
(A) can be installed to hold the rack in the
center position. The rack must be in the center
position to remove the fuel injection pumps.
To prevent possible personal injury carefully
follow the steps below.
20

1. Put Tool (B), except for the 8T5287 Wrench, in
   position on the fuel pump housing as shown. Lower
   the handle to center the adjusting screw with the
   fuel line seat. With the handle down in the
   locked position, the adjusting screw must just be
   in contact with fuel line seat (1). If force is
   needed to lower the handle or there is a gap,
   remove the tooling, and make an adjustment to the
   screw.
2. Loosen bushing (2) 1/4 of a turn.
3. Put Tool (B) in position on the pump housing with
   the handle down in the locked position as shown.
4. Remove bushing (2) from the pump housing.
5. Carefully and slowly lift the handle to release
   the spring force. Remove the tooling.

1. Install Tool (C) on fuel pump (4) as shown.
2. Remove seal (3) and fuel pump (4) from the fuel
   pump housing.

9. Remove spacers (5) from the pump
housing. NOTE There must be a pump installed on
either side of the pump to be removed to install
Tool (B). If there is no pump, take a pump
already removed, and remove the spring so there
will be no spring force, and install it in the
pump housing. See Install Fuel Pump. NOTE
Spacers (5) are the same thickness for each fuel
injection pump so they can be mixed. The fuel
injection pump plungers and barrels are sets and
cannot be mixed.
Install Fuel Injection Pumps
21

1. Install spacers (5) in the fuel pump housing.
2. Move the rack until Tool (A) can be installed to
   hold the rack in the center position. The rack
   must be in the center position to install the
   fuel injection pumps.
3. Install a fuel pump without its spring so that
   Tool (B) can be installed. See Step 5 for correct
   fuel pump installation.

1. Install Tool (C) on the bonnet of the fuel pump
   as shown.
2. Install the fuel pump in the pump housing with
   the saw cut (slot) (9) in the gear in alignment
   with small pin (6) in the lifter assembly and
   groove (8) in the barrel in alignment with large
   pin (7) in the pump housing.

22

1. Install the seal and bushing (2) on the fuel
   pump.
2. Put Tool (B) in position on the fuel pump housing
   as shown.
3. Lower the handle slowly and carefully. If the
   fuel pump is not installed correctly, the handle
   will not go all the way down. Do not try to use
   force on it. Remove and install the tooling and
   the fuel pump again.
4. Make sure the seal is in its correct position,
   and start to tighten bushing (2). Remove the
   tooling, and tighten the bushing to a torque of
   260 15 Nm (190 10 lb ft). Back off 180
   degrees and tighten the bushing again to a torque
   of 260 15 Nm (190 10 lb ft).

• Typical Example
• After each fuel pump has been installed, follow
  the steps below to check total race travel to
  make sure each pump has been installed correctly.
• Install Tool (D) on the fuel pump housing as
  shown and zero the dial indicator.
• Remove Tool (A) from the fuel pump housing.
• Move rack (10) in and out of the fuel pump
  housing to measure rack travel. Rack travel is
  approximately 9.62 mm (.379 in) in the plus (full
  fuel) direction and 10.40 mm (.410 in) in the
  minus (shutoff) direction. If this measurement is
  not obtained, center the rack, install Tool (A),
  and remove and install the fuel pump again.
• NOTE One tooth off and rack travel is
  approximately 6.35 to 6.82 mm (.250 to .269 in)
  in the plus direction and 7.02 to 7.05 mm (.276
  to .278 in) in the minus direction.
• End By
• install fuel injection lines

Disassemble Assemble Fuel Injection Pumps
See SMHS8378 for the correct tool usage. Start
By
23
a. remove fuel injection pumps NOTICE Be
careful when the injection pumps are
disassembled. Do not damage the surfaces of the
plungers, barrels and bonnets. Any scratches will
cause leakage inside the fuel injection pump. The
plunger and barrel for each pump are made as a
set. Do not put the plunger of one pump in the
barrel of another pump. If one part has wear,
install a complete new pump assembly. Be careful
when the plunger is put into the bore of the
barrel.

• NOTE Do not remove the gear from the plunger.
  The gear and plunger are assembled and adjusted
  at the factory.
• Pull plunger (4) and washer (3) out of barrel (1)
  and spring (2).
• Remove spring (2) from barrel (1).

• Use the following procedure to put the fuel pump
  in position on Tool (A)
• Select the correct turret position.
• Place a barrel assembly into the turret.

24

• Loosen the nut on the clamp.
• Adjust clamp end (6) until the bonnet is almost
  touching the barrel when the clamp handle is in
  the locked position.
• Tighten the nut on the clamp.
• Use Tool (B) to expand ring (5), and carefully
  lift it off the fuel pump.
• Slowly release the clamp handle of Tool (A), and
  remove the lockring.
• Remove bonnet (7), spring (8) and valve (9) from
  barrel (1).
• NOTE The following steps are for assembly of the
  fuel injection pumps.
• NOTICE
• Put clean fuel on all parts during assembly.

• Put spring (8) and valve (9) in bonnet (7).
• Put bonnet (7) barrel (1) and ring (5) in
  position on Tool (A).
• Put the barrel assembly in position on Tool (A).
  Lower the handle on Tool group (A) to hold the
  fuel pump together.
• Use Tool (B), and lower ring (5) on to the barrel
  and the bonnet to hold them together.
• Remove the barrel assembly from Tool (B).
• Install spring (2) on barrel (1).
• Install washer (3) on plunger (4). Make sure the
  spring seat on the washer is away from the gear
  on the plunger.
• Install plunger (4) in barrel (1). Make sure
  spring (2) is engaged in the spring seat on
  washer (3). End By
• install fuel injection pumps

Copyright 1993 - 2021 Caterpillar Inc. All Rights
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Thu Dec 23 191121 UTC0800 2021
25
Shutdown SIS
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Product WHEEL LOADER Model 980F II WHEEL LOADER
8JN Configuration 980F SERIES II WHEEL LOADER
8JN00001-UP (MACHINE) POWERED BY 3406C DI ENGINE
Disassembly and Assembly 3406C DIESEL ENGINES FOR
CATERPILLAR BUILT MACHINES Media Number
-SENR6409-02 Publication Date -01/07/2006
Date Updated -19/05/2015
SENR64090010
Fuel Injection Pump Housing SMCS - 1253-016
1253-015 Disassemble Fuel Injection Pump Housing

• Start By
• disassemble governor
• remove fuel injection pumps

1. Remove the six lifters from the fuel pump
   housing.
2. Remove rack (1) and camshaft (2) from the fuel
   pump housing. If necessary, use a soft hammer to
   push the camshaft out the governor end.

26
3. Use Tool (A) and remove the three camshaft
bearings from the fuel pump housing.

1. Remove rack bearing (4) and the other rack
   bearing from the fuel pump housing.
2. Remove dowel (3) from the fuel pump housing.

6. Remove bolts (6), cover (5) and the gasket
from the fuel pump housing.
Assemble Fuel Injection Pump Housing
27
1. Install gasket (7) and cover (5) on the side
of the fuel pump housing.

1. Use Tool (B) and install the D shaped rack
   bearing into the governor and fuel pump drive
   side of the fuel pump housing 87.0 0.5 mm (3.42
   .02 in) from outside surface (X).
2. The inside flat diameter after assembly must be
   11.178 0.050 mm (.440 .002 in) and the inside
   large diameter must be 12.767 0.058 mm (.503
   .002 in).

• Install dowel (3) in the fuel pump housing 6.0
  0.5 (.24 .02 in) above the outside surface.
• Use Tool (C) and install the rack bearing into
  the fuel pump housing 7.16 0.13 mm (.282
• .005 in) below the surface of the pump housing.
• The inside diameter of the bearing after assembly
  must be 12.746 0.045 (.502 .002 in).

7. Use Tool (A) and install the three camshaft
bearings in the fuel pump housing with the oil
holes in the bearings 30 3 degrees from the
horizontal center line toward the plugged holes
in the fuel pump housing.
28
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8. The inside diameter of all three bearings
after assembly must be 68.399 0.038 mm
(2.6905 .0015 in).

1. Make sure bearing (8) on the governor and fuel
   pump drive is installed 1.0 0.5 mm (.04 .02
   in) below surface (Y).
2. Make sure middle bearing (9) is 218 0.3 mm (8.6
   .01 in) below surface (Y).

1. Make sure bearing (10) governor side is 1.00
   0.25 mm (.040 .010 in) below the outside
   surface.
2. Remove the plugs from the side of the fuel pump
   housing. The oil holes in the bearings must in
   alignment with holes (11) in the fuel pump
   housing. If the bearings are not in alignment,
   remove them and install again.

• Make an alignment of rack (1) and install it in
  the fuel pump housing.
• Install the six lifters in the fuel pump housing.
  Make sure the pins in the lifter are on the same
  side as the dowels in the fuel pump housing.
• End By
• install fuel injection pumps
• assemble governor

Thu Dec 23 191209 UTC0800 2021
31
Shutdown SIS
Previous Screen
Product WHEEL LOADER Model 980F II WHEEL LOADER
8JN Configuration 980F SERIES II WHEEL LOADER
8JN00001-UP (MACHINE) POWERED BY 3406C DI ENGINE
Disassembly and Assembly 3406C DIESEL ENGINES FOR
CATERPILLAR BUILT MACHINES Media Number
-SENR6409-02 Publication Date -01/07/2006
Date Updated -19/05/2015
SENR64090011
Fuel Ratio Control SMCS - 1278-017
1278-010 Remove Install Fuel Ration Control

• Disconnect air line (1) from the fuel ratio
  control.
• Remove wire seal (4) from the bolts.
• Remove bolts (3) that hold fuel ratio control
  (2).
• Remove the fuel ratio control by pulling down and
  out from the collar.
• NOTE The following steps are for the
  installation of the fuel ratio control.
• Put fuel ratio control (2) in position on the
  governor. Make sure the valve head of the fuel
  ratio control is connected in the groove of the
  collar.
• Install bolts (3) that hold the fuel ratio
  control to the governor. Connect air line (1) to
  the fuel ratio control.

32

1. To make an adjustment to the fuel ratio control,
   see the topic "Governor Adjustment For The Air
   Fuel Ratio Control" in, Testing Adjusting
   Manual SENR6471.
2. Install wire seal (4) on the bolts with Tool (A).

Disassemble Assemble Fuel Ratio Control
Start By a. remove fuel ratio control
1. Put Tool (A) in a vise so that the station
being used is not over the vise jaw. Place the
fuel ratio control over the pins in Tool (A).
Remove bolts (3) and remove cover (26) and gasket
(24). NOTICE There is spring force behind
cover (7). Hold cover (7) in position, and slowly
remove the bolts that hold it to release the
spring force.
33
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