Webasto Caterpillar 980K Installation Manual

Engine off hydraulic fluid / engine coolant / cab warmer

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Engine OFF Hydraulic Fluid / Engine Coolant / Cab Warmer

Caterpillar 980K

INSTALLATION MANUAL

4/2014

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Summary of Contents for Webasto Caterpillar 980K

Page 1 Engine OFF Hydraulic Fluid / Engine Coolant / Cab Warmer Caterpillar 980K INSTALLATION MANUAL 4/2014...
Page 3: Table Of Contents
Caterpillar 980K / Thermo 90ST Installation CONTENTS INTRODUCTION ..............................4 1.1. Scope ................................4 1.2. Applicability of Manual ..........................4 1.3. Meaning of Warnings, Cautions and Notes ....................4 1.4. Safety ................................4 1.5. Legal Provisions for Installation ........................4 PARTS LIST ................................5 PREPARATION..............................6 3.1. Heater Preparation............................6 3.2.
Page 4: Introduction
The general safety regulations for the prevention of accidents and the relevant operating safety instructions must be observed at all times. 1.5. Legal Provisions for Installation Machine operation must not be impaired due to any Webasto installed components. All power circuits must be fused with appropriate fuse or circuit breaker.
Page 5: Parts List
Caterpillar 980K / Thermo 90ST Installation 2. PARTS LIST Machine Make Model Caterpillar 980K Included in Box Item Product # Description Source Qty. 5010808A Thermo 90ST Off Hwy HD Kit 24V Diesel Webasto Optional Add-on Accessories Hydraulic Heating Item Product #...
Page 6: Preparation
Obtain fuse box access by removing interior panels shown. Fig. 2 IMPORTANT The CAT 980K Series is designed with a negative (Ground) master disconnect switch. The proceeding steps will describe a necessary Webasto harness ground modification required for this installation. Fig. 3...
Page 7 Caterpillar 980K / Thermo 90ST Installation Remove the heater electrical connector from its current mounting location. This will be relocated in proceeding steps. Fig. 3 Remove ground portion of the harness from the location shown. Fig. 4 Reconfigure all heater harness ground leads into one spliced ground circuit.
Page 8: Hydra Liner Preparation
Caterpillar 980K / Thermo 90ST Installation During the heater dry fit mounting process; mark and drill a new hole to mount the electrical connector bracket facing the front of the machine. Rear heater mounting bracket. Fig. 6 3.2. Hydra Liner Preparation Drain the hydraulic tank per the manufacturer’s...
Page 9 Caterpillar 980K / Thermo 90ST Installation Remove the hydraulic tank from the machine per the manufacturer’s recommendations. Fig. 8...
Page 10: Installation
Caterpillar 980K / Thermo 90ST Installation 4. INSTALLATION 4.1. General References Bare body parts, for example around any drilled holes must be treated with anti-corrosive coating. Secure hoses, cables and wiring harnesses with cable ties and clamps provided. Fit protective hoses around any chaffing points.
Page 11: Electrical
Make sure to turn off master disconnect switch before performing this step! Locate the starter motor on the right side of the engine. Cut the positive lead of the Webasto heater harness to proper length, install supplied eyelet and connect to starter stud as shown in fig. 20.
Page 12 In this installation, pins 8-11 were empty. Fig. 22 Locate the same connector from the inside of the cab (left rear corner) and pin the remainder of the Webasto controller harness to match the wire colors from the previous step.
Page 13: Fuel
Caterpillar 980K / Thermo 90ST Installation 4.2.3. Fuel Remove the left side step panel per manufacturer’s recommendations to access the top of the fuel tank. Fig. 25 Thoroughly clean all debris around fuel tank access cover. Remove for fuel standpipe installation in proceeding steps.
Page 14 Caterpillar 980K / Thermo 90ST Installation In the CAT 980K installation no cutting of the standpipe was necessary. However; with different tank options always ensure the standpipe is approximately 4” from the bottom of the tank. This ensures the heater cannot run the tank empty of fuel and less chance of picking debris or sediment from the bottom of the tank.
Page 15: Exhaust
Caterpillar 980K / Thermo 90ST Installation Note the direction of the fuel dampener towards the rear of the machine. Fig. 31 Install the supplied protective loom over the fuel line and route along the existing wires harnesses securing it with cable ties where necessary.
Page 16 Caterpillar 980K / Thermo 90ST Installation For this installation the muffler was installed and mounted to the engine skid plate horizontally using an “L” bracket. Note: When mounting a muffler horizontally, be sure the moisture weep hole (fig. 36) is clear of any obstructions.
Page 17: Intake
Caterpillar 980K / Thermo 90ST Installation 4.2.5. Intake The air intake is routed towards the rear of the machine and mounted as shown in figures 37 and 38. Fig. 37 An intake tube clamp was used to secure tube to the rear engine shroud.
Page 18: Hydra Liner (Hydraulic Fluid Warmer)
Caterpillar 980K / Thermo 90ST Installation 4.3. Hydra liner (Hydraulic Fluid Warmer) Remove The hydraulic tank per manufacturer’s recommendations. Fig. 39 Locate the rearmost lower left corner of the hydraulic tank. Using the proper safety equipment, carefully remove the retaining bracket with a grinding wheel.
Page 19 Caterpillar 980K / Thermo 90ST Installation Using the dimensions in fig. 42, locate the center point and clearly mark. Using the proper safety equipment, drill a 3” O.D. hole using a hole saw. Fig. 42 Install the coupler so that the Hydra Liner is a minimum of 1”...
Page 20: Various Plumbing Configurations
Caterpillar 980K / Thermo 90ST Installation 4.4. Various Plumbing Configurations Coolant plumbing is dependent on the options that are installed. When routing always make sure to fully tighten all hose clamps and secure in a manner that’s prevent hose chaffing.
Page 21: Initial Start-Up
Caterpillar 980K / Thermo 90ST Installation 5. INITIAL START-UP IMPORTANT Refer to the safety instructions in the operating and maintenance instructions supplied with the heater kit. The operating and maintenance instructions must be read thoroughly before starting the heater. After you have installed the heater, bleed the water system and the fuel supply system carefully. Follow the instructions supplied by the vehicle manufacturer for this purpose.
Page 22: Mounting Bracket Drawings
Caterpillar 980K / Thermo 90ST Installation 6. MOUNTING BRACKET DRAWINGS Fig. 47...
Page 23 Caterpillar 980K / Thermo 90ST Installation Fig. 48...
Page 24: Limited Warranty
Original Equipment installations (OE). This warranty period may not exceed three (3) years from the original date of sale by Webasto. This warranty period may be superseded by a contractual agreement.
Page 25 Caterpillar 980K / Thermo 90ST Installation NOTES...
Page 26 Caterpillar 980K / Thermo 90ST Installation NOTES...
Page 27 Caterpillar 980K / Thermo 90ST Installation NOTES...
Page 28 Webasto Thermo & Comfort N.A., Inc. 15083 North Road Fenton, MI 48430 USA Phone: 810-593-6000 Fax: 810-593-6001 Email: info-us@webasto.com Internet: http://www.webasto.us http://www.techwebasto.com Org. 4/2014 Rev. N/A P/N: 5010837A...