Caterpillar 980G
Maintenance schedule, common problems & OEM parts breakdown
The Caterpillar 980G is a medium-to-large wheel-type loader built roughly 1996 to 2002, the direct successor to the 980F and 980F II. It runs a Cat 3406C DITA inline-six diesel, turbocharged and jacket-water aftercooled, displacing 14.6 L (891 cu in) and rated at 224 kW (300 hp) flywheel power with a gross output near 241 kW (323 hp). Operating weight runs about 29,500-29,800 kg (65,000-65,600 lb) depending on bucket, tire, and counterweight selection, with heaped bucket capacity spanning roughly 4.2-5.8 m³ (5.5-7.5 yd³) across general-purpose and rock-bucket options. It carries an articulated frame with Z-bar loader linkage on a four-plate loader tower, a powershift transmission with torque converter, and options including a limited-slip front axle and an axle oil cooler for high-energy load-and-carry work. Recognized serial prefixes for this generation include 2KR, 2SR, and 9CM.
Within the G-series run, Caterpillar kept the mechanically injected 3406C DITA architecture but added a dedicated 980G monitoring system: digital gauges, a multi-level warning display, dual-pedal braking, electronic autoshift, transmission neutralizer lockout, and a ride-control switch, giving the operator more electronic feedback without a full engine control module. The 980G was then replaced by the 980G Series II, which moved to the electronically controlled 3406E engine with air-to-air aftercooling on the same basic chassis, ahead of the 980H. That makes the plain 980G a middle point in the line: more cab electronics and operator aids than the 980F it replaced, but still a mechanically governed engine simple enough to diagnose without a laptop. In the used and parts market it holds steady demand in quarry, aggregate, and scrapyard fleets, with active engine, torque converter, and axle remanufacturing supporting units well past their original service life.
Below: full specifications, fluids & capacities, the factory service schedule, common service parts, verified fault codes, what owners discuss, attachment guidance, the complete assembly directory, and a serial-number reference. Complete parts lists with full OEM part numbers, exploded diagrams, quantities, and fitment data are available free in Heavy Parts AI.
Caterpillar 980G specifications
Engine
| Engine model | Cat 3406C DITA — turbocharged, aftercooled diesel, inline-6 |
| Cylinders | 6, inline |
| Displacement | 14.6 L (891 cu in) |
| Gross power | 241 kW (323 hp) |
| Net (flywheel) power | 224 kW (300 hp), rated |
Weights
| Operating weight | 29,519–29,773 kg (65,078–65,638 lb); figure varies slightly by bucket/tire configuration and source |
Dimensions
| Overall length (bucket on ground) | 9.48 m (31.1 ft) |
| Width over tires | 3.25–3.26 m (10.67–10.7 ft) |
| Height to top of cab | 3.75–3.78 m (12.3–12.4 ft) |
| Ground clearance | 0.47–0.49 m (1.54–1.6 ft) |
| Dump clearance at max raise | 3.27 m (10.74–10.8 ft); optional high-lift arrangement adds 221 mm (9 in) |
| Reach at max lift and dump | approx. 1.5 m (5.1 ft), general-purpose bucket |
Performance
| Max forward travel speed | 37.4 km/h (23.3 mph) |
| Max reverse travel speed | 42.8 km/h (26.6 mph) |
| Breakout force | 210 kN (47,277 lbf) |
| Static tipping load, full turn | 18,146 kg (40,005 lb) |
| Bucket capacity range | 4.2–5.7 m³ (5.5–7.5 yd³) heaped, general-purpose buckets |
Service capacities (summary)
| Fuel tank | 470 L (124.2 gal US) |
| Hydraulic system | 208 L (55 gal US) |
| Engine oil | 38 L (10 gal US) |
| Cooling system | 79 L (20.9 gal US) |
Values vary by configuration, region, and serial range — confirm against your machine before planning transport or lifts.
980G fluids & capacities
| System | Capacity | Recommended fluid |
|---|---|---|
| Engine crankcase (with filter) | 38 L (10.1 US gal) | Cat DEO (Diesel Engine Oil), multigrade diesel engine oil meeting Cat's engine oil spec for this era. Viscosity by ambient temperature: SAE 10W-30 in cold conditions down to roughly -20°C, SAE 15W-40 as the year-round standard grade, straight SAE 30 acceptable in consistently warm climates. Cat Arctic/cold-weather DEO grade recommended for sustained sub-zero operation. |
| Cooling system | 79 L (20.9 US gal) | Cat ELC (Extended Life Coolant), full-strength premix, or Cat DEAC (Diesel Engine Antifreeze/Coolant) mixed 50/50 with water. ELC and DEAC must not be mixed in the same system; DEAC requires periodic supplemental coolant additive treatment, ELC does not. |
| Fuel tank | 469-470 L (124 US gal) | No. 2-D diesel fuel meeting ASTM D975 (or equivalent), low-sulfur. Use an arctic/winter-blend diesel fuel in cold climates to prevent gelling; avoid biodiesel blends above the OEM-approved percentage. |
| Transmission (powershift) | 62 L (16.4 US gal) | Cat TDTO (Transmission/Drive Train Oil). Viscosity by ambient temperature: SAE 10W for cold starts below 0°C, SAE 30 as the standard year-round grade, SAE 50 for sustained hot-climate operation. Cat TDTO-TMS (multi-season, synthetic-blend) approved as an all-season alternate. |
| Front axle (differential and final drives) | 87 L (23 US gal) | Cat TDTO, same viscosity grading as the transmission (SAE 10W cold / SAE 30 standard / SAE 50 hot climate). |
| Rear axle (differential and final drives) | 81-87 L (21.4-23 US gal) - varies by source/configuration | Cat TDTO, same viscosity grading as the transmission (SAE 10W cold / SAE 30 standard / SAE 50 hot climate). |
| Hydraulic system, total (implement + steering circuits, including tank) | 208 L (55 US gal) | Cat TDTO is the standard fill for this machine's combined hydraulic/implement circuit; Cat HYDO Advanced 10 hydraulic oil listed as an acceptable alternate. Viscosity by ambient temperature follows the same TDTO grading: SAE 10W cold, SAE 30 standard. |
| Hydraulic tank | 125 L (33.1 US gal) | Same fluid as the hydraulic system: Cat TDTO (standard fill) or Cat HYDO Advanced 10 (alternate), graded by ambient temperature as above. |
| Grease (chassis and linkage lubrication points) | Spec only - no refill volume | Cat Multipurpose Grease (MPGM), NLGI 2, lithium-complex base, effective roughly -30°C to 40°C for general chassis and pin points. For heavy-load bucket/loader-linkage pins or high-temperature service, Cat Extreme Application (XA) or Cat Ultra 5Moly grease is the upgrade option; Cat Arctic Platinum grease for sustained service below -30°C. |
Capacities are refill values from factory literature — always fill to the dipstick/sight gauge, not the number.
Caterpillar 980G maintenance schedule
| Service interval | Tasks |
|---|---|
| Every 10 h |
|
| Every 250 h |
|
| Every 500 h |
|
| Every 1,000 h |
|
| Every 2,000 h |
|
| Every 4,000 h |
|
Servicing the 980G beyond the schedule
Predictive Maintenance and Fluid Analysis
The 980G's 3406C DITA runs mechanical unit injection with no engine ECM, so S·O·S oil sampling on the engine, powershift transmission, and front and rear axle oil is the main way to catch wear before failure, since there are no fault codes to read. Watch for hydraulic oil turning up in transmission samples or the reverse: 980G units are known to develop hydraulic pump seal leaks that cross-contaminate the transmission case, so any sudden foam or additive-package shift in either sample is worth chasing immediately, not at the next interval.
Corrective and Common Repairs
Z-bar loader-linkage pins and the four-plate loader-tower mount wear fastest on the 980G in load-and-carry cycles, showing up as bucket-pivot slop before hydraulics show any symptom. The known cross-contamination fault, hydraulic oil migrating into the transmission case through a worn pump seal, shows up as milky or additive-heavy transmission oil; catch it by checking pump seals and the transmission case at every fluid check. Torque converter overheating under prolonged stall work is the other repeat complaint; confirm the axle oil cooler is functioning on high-energy routes.
Overhaul and Rebuild Points
Top overhaul on the 3406C DITA centers on cylinder liners, mechanical unit injectors, and valve guides once compression and injector return volumes drift out of spec; with no ECM, declining power or smoke is the trigger, not a stored code. The powershift transmission and torque converter come next, with clutch-pack slippage under load the first sign a rebuild is due. Front and rear axle differential, final-drive gearsets, and wet-disc brake packs wear together on load-and-carry duty, so plan axle overhaul as one job rather than chasing each side separately.
Seasonal and Environment Servicing
Cold-weather starts are the 980G's weak point: the mechanically injected 3406C DITA has no electronic cold-start assist, so a working ether system or block heater, plus winter-grade fuel and hydraulic oil, matter more here than on later ECM engines. In hot, dusty quarry and aggregate work, keep the radiator, jacket-water aftercooler, and hydraulic oil cooler cores clear of packed fines, since sustained heat load is what shortens torque converter and axle wet-disc brake life on this model. Check tire pressure more often through temperature swings.
980G fault codes & troubleshooting
| Code | Meaning | Likely cause | What to do |
|---|---|---|---|
| 352.00 (CID 352, FMI 00) | Lift lever position sensor circuit - signal reading above normal operating range | Sensor out of calibration, internal sensor fault, or a wiring/connector fault at the loader control lever cluster | Inspect lift lever sensor wiring and connector for corrosion or damage, run the implement lever calibration procedure with Cat ET, replace the sensor if it will not hold calibration |
| 353.13 (CID 353, FMI 13) | Tilt lever position sensor out of calibration | Lever sensor calibration lost after a battery disconnect, ECM replacement, or lever linkage adjustment | Check lever linkage for looseness, then run the implement lever calibration procedure in Cat ET before returning the machine to service |
| 490.05 (CID 490, FMI 05) | Implement (work tool) lockout switch circuit - open circuit or current below normal | Open wiring, a blown fuse, or a faulty lockout switch or relay in the loader control circuit | Check the lockout switch fuse, wiring, and connector; test switch continuity and replace the switch if it reads open |
| 638.05 (CID 638, FMI 05) | Starter solenoid circuit - open circuit or current below normal | Open wiring to the starter solenoid, a blown fuse, a worn solenoid coil, or a corroded connector at the starter | Check the starting circuit fuse and relay, inspect wiring to the solenoid, test solenoid coil resistance, repair or replace as needed |
| 177.08 (CID 177, FMI 08) | Transmission (torque converter) oil temperature sensor signal abnormal - erratic frequency or pulse-width reading | Damaged sensor, chafed or shorted harness wiring, or moisture intrusion at the connector | Inspect the transmission oil temperature sensor wiring and connector for damage or moisture, test the sensor against service manual values, replace if out of spec |
| 671.01 (CID 671, FMI 01) | Drivetrain-related sensor circuit reading below normal operating range - reference sources disagree on whether this circuit is a transmission output speed sensor or a pedal position sensor on this control system | Sensor signal loss, an open or grounded wire, or a corroded connector on the affected circuit | Confirm the exact CID mapping for this machine's ECM software with Cat ET, then inspect that sensor's wiring and connector and retest |
| 149.05 (CID 149, FMI 05) | Ride control solenoid circuit - open circuit or current below normal | Open wiring to the ride control solenoid valve, a blown fuse, or a failed solenoid coil | Check the ride control fuse and wiring, test solenoid coil resistance, replace the solenoid if it reads open |
Codes and remedies are general guidance for this model family — always confirm with diagnostic tooling and your dealer before major repairs.
980G attachments & work tools
General purpose buckets
Standard GP buckets for this loader class run roughly 3.8-5.7 m³ (5.0-7.5 yd³) heaped, sized to the machine's lift/tilt and static-tip capacity. Several width/profile options are offered for stockpiling, bank loading and re-handling, with contoured profiles aimed at higher fill factor and material retention.
Heavy-duty rock and quarry buckets
Rock buckets use spade-nose construction with corner guards and extra wear plating for high-impact, abrasive loading; a heavier quarry version adds further protection for severe rock-face work. Capacity runs lower than a GP bucket of similar size because of denser material.
Flat floor / multi-purpose buckets
Flat-floor buckets, up to about 5.5 m³ (7.2 yd³), carry an extended cutting edge for improved back-dragging and grading. A hinged multi-purpose (clamshell) bucket variant adds clamp, dozing and scraping functions but needs the optional third-function auxiliary hydraulic circuit to open and close.
Coal / light-material buckets
Oversized, low-density buckets for coal and light material can reach roughly 8 m³ (10+ yd³) class capacity on this size of loader, trading depth for width and volume since the payload is light. Bolt-on cutting edges are typical rather than individual penetration teeth.
Forks (pallet, construction, log/lumber)
Pallet and construction forks mount on the standard loader linkage for general material handling. Log and lumber forks use flat tines with a raised back for loading, sorting and decking logs or stacked lumber, and are offered as part of the forestry work-tool lineup for this loader class.
Grapples (log and root)
Log/timber grapples and root or brush grapple-rakes pair with the forestry machine arrangement for sorting, decking and mill-feed work. Grapple clamp action runs off the auxiliary hydraulic circuit rather than the base lift/tilt system.
Coupler and mounting system
Base mounting is a pin-on lift-arm/bucket linkage. An optional hydraulic quick coupler shared across this loader family lets buckets and other pin-on tools be swapped from the cab without leaving the seat. Electrohydraulic single-lever implement control handles lift and tilt, and the optional third-function circuit when fitted.
Auxiliary / third-function hydraulics
Work tools beyond a plain pin-on bucket, such as multi-purpose buckets and grapples, need the optional third-function auxiliary hydraulic circuit with electrohydraulic controls to actuate their clamp or grapple function. This is a factory- or dealer-installed option, not standard equipment.
High lift arrangement
An optional high-lift linkage arrangement increases dump clearance and reach beyond the standard configuration, used for loading over truck sideboards or into taller hoppers.
Waste Handling Arrangement (WHA)
Factory WHA package adds special guarding, a trash-resistant radiator and a cooling system suited to waste-transfer and recycling duty, aimed at fast-cycle, high-production loading in debris-heavy environments.
Forestry machine arrangement
Forestry-specific factory arrangement supports the guarding and hydraulic provisions needed to run log/lumber forks and grapples in logging-yard and mill-feed applications.
Steel mill / custom guarding arrangement
A custom steel-mill arrangement adds heat- and debris-oriented protection across the frame, tanks, driveline and counterweight areas for extended component life in steel-mill and similarly rugged environments.
Ride control
Optional automatic ride control uses a nitrogen-charged oil accumulator in the lift circuit to dampen bucket/load shock during travel, improving stability and ride and reducing structural fatigue, useful when carrying loaded buckets or forks over rough haul roads.
Ground engaging tools (GET)
Buckets are offered with bolt-on or weld-on tooth and adapter systems plus cutting edges and wear plates matched to material and abrasion level. GET choice follows bucket type, with GP, rock and coal/light-material buckets each using a different edge/tooth combination.
All 980G assemblies by section
Every catalogued assembly group for the Caterpillar 980G. Open an assembly to preview the parts inside — full OEM part numbers are available in Heavy Parts AI.
Operator Station
265-3936 Guard Ar-Window -Custom
264-3559 Guard Ar-Window -Custom
| 0S***75 | Pin-To Arm Assembly And Retainer | 4 |
| 24***57 | Tube | 1 |
| 24***58 | Block | 2 |
980G serial number reference
The PIN plate on a 980G is riveted to the machine frame near the operator's station, generally on the left front frame rail close to the articulation joint; check the frame near the cab steps if it isn't immediately visible. The plate reads as a 3-character prefix identifying the production block, followed by a sequential serial number, so a plate reading 2KR01234 is unit 01234 of that block; some plates on these years show just the prefix plus sequence rather than a full 17-character PIN.
| Prefix | Identifies | Notes |
|---|---|---|
| 2KR | 980G (Series I) wheel loader | Cat 3406C diesel. Serials run 2KR00001-UP, spanning the 980G production window. Plant of origin not confirmed - confirm with dealer. |
| 2SR | 980G (Series I) wheel loader | Cat 3406/3406C diesel, same base machine as the 2KR block. Serials run 2SR00001-UP (some listings cite an in-block break around 2SR00651-UP). Appears to be a parallel production sequence rather than a distinct configuration. Plant of origin not confirmed - confirm with dealer. |
| 9CM | 980G (Series I) wheel loader | Cat 3406C diesel. Serials run 9CM00001-UP, documented across the full production window. Associated with European-sourced production - treat as a general trend, verify plant specifics with your dealer. |
Frequently asked questions
What engine does the Caterpillar 980G use?
The 980G runs a Cat 3406C DITA inline-six diesel, turbocharged and jacket-water aftercooled, displacing 14.6 L (891 cu in). It is rated at 224 kW (300 hp) flywheel power, with a gross output near 241 kW (323 hp), and is mechanically governed with no engine control module. The following 980G Series II switched to the electronically controlled 3406E engine with air-to-air aftercooling.
What is the operating weight of the Caterpillar 980G?
Operating weight runs roughly 29,500-29,800 kg (65,000-65,600 lb), varying with bucket size and type, tire selection, and counterweight or axle options.
What replaced the Caterpillar 980G?
The 980G was followed by the 980G Series II, which kept the same basic chassis but switched to the electronically controlled 3406E engine with air-to-air aftercooling. Caterpillar later replaced that line with the 980H.
What 980G owners discuss
What do owners say about the 980G's hydraulic lift and tilt response?
What steering complaints come up most often on the 980G?
What quirks show up on the 980G's 3406C engine?
What electrical and sensor issues are commonly reported?
What wear patterns should you watch for on the frame, articulation joint, and tires?
What is the overall consensus on 980G reliability?
What should you check when buying a used 980G?
Compiled from owner and technician discussions across the industry — experiences vary by serial range and machine history.
Need a specific 980G part?
Search live OEM part data, check fitment, and cross-reference alternatives with Heavy Parts AI.