Caterpillar Cat 980C Wheel Loader (Prefix 63X) Service Repair Manual Instant Download

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Product WHEEL LOADER Model 980C WHEEL LOADER
63X Configuration 980C Wheel Loader 63X06575-UP
(MACHINE) POWERED BY 3406 Engine
Disassembly and Assembly 980C WHEEL LOADER POWER
TRAIN Media Number -SENR7757-02 Publication Date
-01/04/1984
Date Updated -02/10/2009
SENR77570008
Front Drive Shaft SMCS - 3253-11 3253-12 Remove
Front Drive Shaft
1. Remove four bolts (1) that hold the center
drive shaft to the yoke. Pull drive shaft (2)
clear of the yoke.
2. Remove six bolts and nuts (3) that hold the
bearing cage and retainer to the frame.
2

1. Remove bolt (7) and retainer (6). Remove yoke (4)
   from the drive shaft.
2. Remove two bolts (8), and remove retainer (5)
   from the bearing cage.

5. Remove lip seal (9) from the retainer.
6. Install two 3/8"-16 NC forcing screws (11) in
the bearing cage. Remove bearing cage (10) and
bearing from the machine.
7. Remove O-ring seal (12) from the bearing cage.
3
8. Use tooling (A) and a press to remove the
bearing from the cage.

1. Remove four bolts and nuts (13) that hold the
   universal joint to the yoke.
2. Remove front drive shaft (15) from the machine.
   The weight of the front drive shaft is 29 kg (64
   lb.).
3. Remove universal joint (14) from the drive shaft.

Install Front Drive Shaft

1. Install universal joint (1) on the front drive
   shaft. Tighten the bolts to a torque of 135 15
   Nm (100 11 lb.ft.).
2. Put front drive shaft (2) in position on the yoke
   of the front differential.
3. Install the bolts that hold the universal joint
   to the yoke. Tighten the bolts to a torque of 135
   15 Nm (100 11 lb.ft.).

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4. Use tooling (A) and a press to install the
bearing in the cage.
5. Install O-ring seal (3) on the bearing cage.
Put a small amount of 1P808 General Purpose
Lubricant on the O-ring seal.
6. Put bearing cage (4) in position in the frame.
Make sure the opening (slot) (5) in the bearing
cage is toward the top as shown.
7. Install the lip seal in the retainer with
tooling (A). Install the seal with the lip toward
the front of the retainer. Put a small amount of
1P808 General Purpose Lubricant on the lip of the
seal.
6
8. Install retainer (7) on the bearing cage. Make
sure grease fitting (6) is in alignment with the
opening (slot) in the bearing cage.

1. Put yoke (9) in position on the drive shaft.
2. Put a small amount of 1P808 General Purpose
   Lubricant on the O-ring seal. Install seal (8),
   retainer (10) and the bolt. Tighten the bolt to a
   torque of 470 50 Nm (347 37 lb.ft.).
3. Install the center drive shaft on the yoke.
   Tighten the bolts to a torque of 135 15 Nm
   (100 11 lb.ft.).

Remove Center Drive Shaft
1. Remove four bolts (3). Disconnect center drive
shaft (2) and universal joint (1) from the yoke.
7

1. Remove four bolts (4). Remove center drive shaft
   group (2) from the machine. The weight of the
   center drive shaft group is 32 kg (71 lb.).
2. Remove universal joints (1) and (5) from the
   center drive shaft group.

Install Center Drive Shaft Group
1. Install universal joints (1) on the center
drive shaft group. Tighten the bolts to a torque
of 135 15 Nm (100 11 lb.ft.).

1. Put center drive shaft group (2) in position on
   the transfer gear yoke. Install the bolts that
   hold it. Tighten the bolts to a torque of 135
   15 Nm (100 11 lb.ft.).
2. Connect center drive shaft group (2) to the yoke
   of the front drive shaft. Install the bolts that
   hold it. Tighten the bolts to a torque of 135
   15 Nm (100 11 lb.ft.).

Copyright 1993 - 2022 Caterpillar Inc. All
Rights Reserved. Private Network For SIS
Licensees.
Thu Jan 6 021501 UTC0800 2022
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Product WHEEL LOADER Model 980C WHEEL LOADER
63X Configuration 980C Wheel Loader 63X06575-UP
(MACHINE) POWERED BY 3406 Engine
Disassembly and Assembly 980C WHEEL LOADER POWER
TRAIN Media Number -SENR7757-02 Publication Date
-01/04/1984
Date Updated -02/10/2009
SENR77570009
Rear Drive Shaft SMCS - 3253-11 3253-12 Remove
Rear Drive Shaft START BY a. remove power train
guard

1. Remove eight bolts and nuts (1). Remove rear
   drive shaft (3) from the machine.
2. Remove universal joints (2) from the drive shaft.

Install Rear Drive Shaft
9

• Install universal joints (2) on the drive shaft.
  Tighten the bolts to a torque of 135 15 Nm
  (100
• 11 lb.ft.).
• Put rear drive shaft (1) in position between the
  transfer gears and the rear differential. Install
  the bolts that hold it. Tighten the bolts to a
  torque of 135 15 Nm (100 11 lb.ft.).
• END BY
• a. install power train guard

Copyright 1993 - 2022 Caterpillar Inc. All
Rights Reserved. Private Network For SIS
Licensees.
Thu Jan 6 021558 UTC0800 2022
10
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Previous Screen
Product WHEEL LOADER Model 980C WHEEL LOADER
63X Configuration 980C Wheel Loader 63X06575-UP
(MACHINE) POWERED BY 3406 Engine
Disassembly and Assembly 980C WHEEL LOADER POWER
TRAIN Media Number -SENR7757-02 Publication Date
-01/04/1984
Date Updated -02/10/2009
SENR77570010

• Front Axle Housing
• SMCS - 3260-11 3260-12
• Remove Front Axle Housing
• START BY
• remove front tires and rims
• remove front drive shaft

1. Disconnect hose assembly (1) from the block
assembly.
2. Fasten a hoist to each wheel brake assembly as
shown.
11
3. Remove eight nuts (2) and the washers that
hold the axle housing to the frame. Remove front
axle housing (3) from the machine. The weight of
the front axle housing is 1783 kg (3930 lb.).
Install Front Axle Housing

1. Fasten a hoist to each wheel brake assembly as
   shown.
2. Put front axle housing (1) in position under the
   machine. Install the washers and nuts on the
   bolts that hold it to the frame.

• Connect hose assembly (2) to the block assembly.
• Remove the air (bleed) from the brake system. See
  980C Wheel Loader Air Systems And Brakes,
  Systems Operation Testing And Adjusting, Form No.
  SENR7762.
• END BY
• install front drive shaft
• install front tires and rims

Copyright 1993 - 2022 Caterpillar Inc. All
Rights Reserved. Private Network For SIS
Licensees.
Thu Jan 6 021654 UTC0800 2022
12
Shutdown SIS
Previous Screen
Product WHEEL LOADER Model 980C WHEEL LOADER
63X Configuration 980C Wheel Loader 63X06575-UP
(MACHINE) POWERED BY 3406 Engine
Disassembly and Assembly 980C WHEEL LOADER POWER
TRAIN Media Number -SENR7757-02 Publication Date
-01/04/1984
Date Updated -02/10/2009
SENR77570011

• Rear Axle Housing
• SMCS - 3260-11 3260-12
• Remove Rear Axle Housing
• START BY
• remove rear tires and rims
• remove crankcase guards (front section only)
• remove rear drive shaft
• This operation is in the 3406 Vehicular Engine
  For 980C Wheel Loader, Disassembly And Assembly
  section.

1. Disconnect hose (1) from the block on top of
the axle housing.
13
2. Disconnect grease line (2) from the top of the
rear support. Disconnect the grease line from the
top of the front support.
3. Remove two bolts (3) that hold bracket (4) to
the front support. Push the bracket and hoses
clear of the support.
4. Fasten a hoist to each wheel brake assembly as
shown.
5. Remove eight bolts and nuts (5) that hold the
front and rear supports to the frame. Remove rear
axle housing (6) from the machine. The weight of
the rear axle housing is 1980 kg (4365 lb.).
Install Rear Axle Housing
14

1. Fasten a hoist to each wheel brake assembly as
   shown.
2. Put rear axle housing (1) in position under the
   machine. Install the bolts and nuts that hold the
   front and rear supports to the frame. Tighten
   the bolts to a torque of 1140 100 Nm (840 74
   lb.ft.).

3. Put bracket (2) in position on the front
support. Install the bolts that hold it.
4. Connect grease line (3) to the fitting on top
of the rear support. Connect the grease line to
the fitting on top of the front support.

1. Connect hose (4) to the block on top of the rear
   support.
2. Remove (bleed) the air from the brake system. See
   980C Wheel Loader Air Systems And Brakes,
   Systems Operation Testing And Adjusting, Form No.
   SENR7762.

15

• END BY
• install rear drive shaft
• install crankcase guards (front section only)
• install rear tires and rims
• This operation is in the 3406 Vehicular Engine
  For 980C Wheel Loader, Disassembly And Assembly
  section.

Copyright 1993 - 2022 Caterpillar Inc. All
Rights Reserved. Private Network For SIS
Licensees.
Thu Jan 6 021751 UTC0800 2022
16
Shutdown SIS
Previous Screen
Product WHEEL LOADER Model 980C WHEEL LOADER
63X Configuration 980C Wheel Loader 63X06575-UP
(MACHINE) POWERED BY 3406 Engine
Disassembly and Assembly 980C WHEEL LOADER POWER
TRAIN Media Number -SENR7757-02 Publication Date
-01/04/1984
Date Updated -02/10/2009
SENR77570012
Front Support SMCS - 3268-11 3268-12 Remove
Front Support

• START BY
• remove rear drive shaft
• remove crankcase guards (front section only)
• connection of anti-pivot link
• This operation is in the 3406 Vehicular Engine
  For 980C Wheel Loader, Disassembly And Assembly
  section.

1. Put two 50 ton screw jacks (1) under the rear
of the machine as shown.
17
2. Remove bolt (2) and retainer (4). Remove yoke
(3) and O-ring seals from the rear differential.

1. Disconnect grease line (7) from the top of the
   support.
2. Remove bolts (6) from the retainer. Push bracket
   (5) clear of the support.

5. Install two 3/8"-16 NC forcing screws (8) in
the retainer as shown. Remove retainer (9) from
the support.
6. Remove seal (10) and the gasket from the
retainer.
18

1. Remove two bolts, nuts and washers (11) from each
   side of the front support.
2. Loosen the nuts that hold the rear support to the
   frame approximately 12.7 mm (.50 in.).

9. Fasten tool (A) to the front support as shown.
Lift the rear of the machine with the 50 ton
screw jacks to a height of approximately 939.8
mm (37 in.). Remove front support (12) from the
machine. The weight of the front support is 53 kg
(118 lb.).
10. Remove bearing (14) and seal (13) from the
support.
Install Front Support
19
1. Use tool (A) and a press to install the
bearing in the front support.
2. Install seal (1). Put a small amount of 5P960
Multipurpose Type Grease on the seal.
3. Fasten tooling (B) to the front support as
shown. Put 5P960 Multipurpose Type Grease on the
trunnion. Put front support (2) in position on
the trunnion. Lower the machine with the 50 ton
screw jacks until the front support makes contact
with the frame. Install the bolts and nuts that
hold the front support to the frame. Tighten the
bolts to a torque of 1140 100 Nm (840 74
lb.ft.). Tighten the bolts that hold the rear
support to a torque of 1140 100 Nm (840 74
lb.ft.). Remove the 50 ton screw jacks from
under the machine.
4. Install a new gasket and seal (3) on the
retainer. Put a small amount of 5P960
Multipurpose Type Grease on the seal.
20
5. Install retainer (5) on the front support. Put
bracket (4) in position on the retainer. Install
the bolts that hold the retainer.

• Install yoke (6) on the pinion shaft. Install the
  retainer and bolt that hold it. Tighten the bolt
  to a torque of 360 45 Nm (265 33 lb.ft.).
• END BY
• install crankcase guards (front section only)
• install rear drive shaft
• separation of anti-pivot link
• This operation is in the 3406 Vehicular Engine
  For 980C Wheel Loader, Disassembly And Assembly
  section.

Copyright 1993 - 2022 Caterpillar Inc. All
Rights Reserved. Private Network For SIS
Licensees.
Thu Jan 6 021848 UTC0800 2022
21
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Previous Screen
Product WHEEL LOADER Model 980C WHEEL LOADER
63X Configuration 980C Wheel Loader 63X06575-UP
(MACHINE) POWERED BY 3406 Engine
Disassembly and Assembly 980C WHEEL LOADER POWER
TRAIN Media Number -SENR7757-02 Publication Date
-01/04/1984
Date Updated -02/10/2009
SENR77570013
Rear Support SMCS - 3268-11 3268-12 Remove Rear
Support

• START BY
• remove crankcase guards (front section only)
• connection of anti-pivot link
• This operation is in the 3406 Vehicular Engine
  For 980C Wheel Loader, Disassembly And Assembly
  section.
• Drain the oil from the rear differential.

2. Put two 50 ton screw jacks (1) in position
under the rear of the machine as shown.
22
3. Remove bolts (2). Remove cover (3) from the
support. Remove the gasket from the back of the
cover.

1. Remove washer (4). Remove bolts (5), and remove
   plate (6). Remove the washer from behind the
   plate.
2. Remove bolts and nuts (7) from each side of the
   rear support. Loosen the bolts and nuts that
   hold the front support to the frame approximately
   12.7 mm (.50 in.).

6. Disconnect grease line (8) from the top of the
rear support.
7. Fasten tool (A) to the rear support as shown.
Lift the rear of the machine with the two 50 ton
screw jacks to a height of approximately 939.8 mm
(37 in.). Remove rear support (9) with tool (A).
23
8. Remove seal (10) and bearing (11) from the
rear support.

1. Remove bolts (12) that hold the block to the
   bracket.
2. Remove all bolts (13) that hold the trunnion to
   the axle housing except for two that are 180
   apart.
3. Remove bracket (14).

12. Fasten tool (A) to the trunnion as shown.
Remove the remainder of the bolts that hold the
trunnion. Remove trunnion (15) with tool (A). The
weight of the trunnion is 34 kg (75 lb.).
13. Remove seal (16) from the trunnion.
24
Install Rear Support
1. Install seal (1) on the trunnion. Put a small
amount of clean SAE 90 oil on the seal.
2. Fasten tool (B) to the trunnion. Install
trunnion (2) in the axle housing with tool (B).
3. Use tool (A) and a press to install the
bearing in the rear support.
25
4. Install seal (3) in the rear support. Put a
small amount of 5P960 Multipurpose Type Grease on
the seal.
5. Put 5P960 Multipurpose Type Grease on the
trunnion. Fasten tool (B) to the rear support.
Install rear support (4) on the trunnion with
tool (B). Use the two 50 ton screw jacks to lower
the machine until the rear support makes contact
with the frame. Install the bolts and nuts that
hold the rear support. Tighten the bolts to a
torque of 1140 100 Nm (840 74 lb.ft.).
Tighten the bolts that hold the front support to
a torque of 1140 100 Nm (840 74 lb.ft.).
Remove the 50 ton screw jacks.
6. Connect grease line (5) to the top of the rear
support.

• Install washer, plate (6) and washer (7) in the
  rear support. Tighten the bolts that hold the
  plate to a torque of 260 25 Nm (190 18
  lb.ft.).
• Install the O-ring seal on the cover for the rear
  support. Install the cover on the rear support.
• Fill the rear differential with SAE 90 oil to the
  correct level. See the Maintenance Guide. END
  BY
• install crankcase guards (front section only)
• separation of anti-pivot link

26
This operation is in the 3406 Vehicular Engine
For 980C Wheel Loader Engine, Disassembly And
Assembly section.
Copyright 1993 - 2022 Caterpillar Inc. All
Rights Reserved. Private Network For SIS
Licensees.
Thu Jan 6 021945 UTC0800 2022
27
Shutdown SIS
Previous Screen
Product WHEEL LOADER Model 980C WHEEL LOADER
63X Configuration 980C Wheel Loader 63X06575-UP
(MACHINE) POWERED BY 3406 Engine
Disassembly and Assembly 980C WHEEL LOADER POWER
TRAIN Media Number -SENR7757-02 Publication Date
-01/04/1984
Date Updated -02/10/2009
SENR77570014
Front Differential And Bevel Gear SMCS - 3256-11
3256-12 3258
28
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29
Remove Front Differential And Bevel Gear
START BY
30

• remove drive axles (front only)
• remove front drive shaft
• Drain the oil from the front axle housing.

Connect the anti-pivot link to the main frames of
the machine before the machine is lifted.
Keep clear of the machine when tooling (A) is
installed under the machine, and when the
machine is lowered on to tooling (A).
2. Put wood blocks behind the rear wheels. Use
the bucket of the machine to lift the front to a
height of approximately 1143 mm (45 in.). Install
tooling (A) under the front of the machine as
shown.

1. Remove brackets (3) and (4) from the axle
   housing.
2. Remove tube assemblies (1) and (2).

31
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the link into your browser. The full manual is
available for immediate download. https//www.eb
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