Curso Cat 980h Stmg

SERV7105-01January 2005Vol. 1, No. 5

TECHNICAL PRESENTATION

980H WHEEL LOADERINTRODUCTION

New Product Introduction(NPI)

SERVICE TRAINING

980H WHEEL LOADER INTRODUCTIONAUDIENCE

Level II - Service personnel who understands the principles of machine system operation,diagnostic equipment, and procedures for testing and adjusting.

CONTENT

This self-paced, self-directed presentation provides new and different New Product Introduction(NPI) information for the 980H Wheel Loader.

OBJECTIVESAfter learning the information in this presentation, the technician will be able to:

1. locate and identify the new components on the 980H Wheel Loader; and2. explain the operation of the new components in the systems.

REFERENCES

TIM "980G Series II Wheel Loader - 3406E Engine Controls" SERV2742TIM "980G Series II Wheel Loader - Steering and Brake Systems" SERV2746TIM "980G Series II Wheel Loader - Electro-hydraulic Implement System" SERV2745

Estimated Time: 1 HourIllustrations: 18Handouts: 6Form: SERV7105-01Date: 1/05

© 2005 Caterpillar Inc.

TABLE OF CONTENTS

INTRODUCTION ........................................................................................................................5

SIMILARITIES AND DIFFERENCES .......................................................................................6

OPERATOR'S STATION..............................................................................................................7

ENGINE........................................................................................................................................8

POWER TRAIN .........................................................................................................................13Electronic Clutch Pressure Control (ECPC) Transmission ..................................................13

ATTACHMENTS .......................................................................................................................18

COOLING PACKAGE...............................................................................................................19

MACHINE APPEARANCE.......................................................................................................20

CONCLUSION...........................................................................................................................23

HYDRAULIC SCHEMATIC COLOR CODE...........................................................................24

HANDOUTS...............................................................................................................................26

POSTTEST .................................................................................................................................28

POSTTEST ANSWERS .............................................................................................................30

SERV7105-01 - 3 - NPIVol. 1, No. 5, 2005

NOTES

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INTRODUCTION

The 980H Wheel Loader has been updated to enhance performance and to meet the Tier IIIEPA regulations. The serial number prefix of the 980H Wheel Loader is JMS. The 980HWheel Loader retains most of the features of the 980G Series II Wheel Loader. The 980HWheel Loader is a direct replacement for the 980G Series II Wheel Loader.

1

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980H WHEEL LOADER

© 2005 Caterpillar Inc.

2

SIMILARITIES AND DIFFERENCES

The two most significant changes to the 980H Wheel Loader are the engine and the powertrain. The engine is changing from the Caterpillar 3406E to the Caterpillar C15 ACERT. Themost significant change to the power train is the transmission hydraulic control. Thetransmission hydraulic control has changed from the Powershift Transmission control to theElectronic Clutch Pressure Control (ECPC).

The diagnostic lines group is standard on the 980H Wheel Loader. The diagnostic lines groupis an attachment on the 980G Series II Wheel Loader.

The appearance of the 980H Wheel Loader is changed slightly. Changes to the machine’sappearance include the hood, the fuel tank, and the battery boxes.

The cooling package is changed on the 980H Wheel Loader. The 980G Series II Wheel Loaderis equipped with the Advanced Modular Cooling System (AMOCS). The 980H Wheel Loaderis equipped with the Next Generation Modular Radiator (NGMR) cores.

SERV7105-01 - 6 - NPIVol. 1, No. 5, 2005

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OPERATOR'S STATION

The 980H can be equipped with a multi-function joystick instead of two levers. Calibration forthe joystick is similar to the levers. The calibration can be performed with CaterpillarElectronic Technician (Cat ET) and Caterpillar Monitoring System (CMS).

3

SERV7105-01 - 7 - NPIVol. 1, No. 5, 2005

ENGINE

The 980H Wheel Loader is equipped with the Caterpillar C15 ACERT engine, serial numberprefix LHX. The displacement of the C15 ACERT engine is 15.2 liters with a rated power of343 hp at 2000 rpm. The performance test specification for the C15 ACERT engine in the980H Wheel Loader is 0K5301.

The C15 ACERT engine is equipped with a larger muffler (1) and an A4E4 Engine ElectronicControl Module (ECM) (not visible). The fuel manifold (2) is located higher on the engine.

4

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1

2

The A4E4 Engine ECM (1) is equipped with one 120 pin connector (2), one 70 pin connector (3), and 26 output drivers.

5

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1

2

3

6

The above illustration shows the engine mounted electrical components on the 980H WheelLoader.

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Oil Pressure Sensor

6 Drivers

3 Returns

InjectorConnector

A4E4ECM

Ground Bolt

Turbo Outlet Pressure Sensor

Atmospheric Pressure Sensor

Inlet Air Temperature Sender

Fuel Temperature Sender

Coolant Temperature Sender

Camshaft Speed / Timing Sensor

Timing Calibration Connector

Crankshaft Speed / Timing Sensor

C15 ACERT ENGINE SYSTEM BLOCK DIAGRAM (980H)ENGINE MOUNTED COMPONENTS

To Machine WiringHarness

Fuel Pressure Sensor

Electronic UnitInjectors

Differential FuelPressure Switch

7

The above illustration shows the machine mounted electrical components that are inputs andoutputs of the Engine ECM on the 980H Wheel Loader.

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A4E4Electronic

ControlModule(ECM)

GroundBolt

15 AmpBreaker

MainPower Relay

Key StartSwitch

24 V

Service Tool ConnectorCat Data Link

Fan Control Valve

Turbo Inlet Pressure Sensor Ground Level Shutdown

ThrottleSensor

AcceleratorPedal

Disconnect Switch

C15 ACERT EUI SYSTEM (980H)MACHINE MOUNTED COMPONENTS

Caterpillar Monitoring System

0

5

1015

20

25

30

X100

MphKm/h

P

44

Relay+ Battery

Cylinder

Engine

Ether Start Valve

Transmission LubeTemperature Sender

Tachometer Output

Air Filter Restriction IndicatorLamp

Fuel Filter RestrictionIndicator Lamp

Ether Start AidIndicator Lamp

The C15 ACERT engine on the 980H Wheel Loader is equipped with a wastegatedturbocharger (1). The turbocharger is cooled with engine coolant that is supplied by tube (2).

8

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1

2

POWER TRAIN

Electronic Clutch Pressure Control (ECPC) Transmission

The transmission hydraulic control on the 980H Wheel Loader is an ECPC. Six externallymounted solenoid valves (1) are located on top of the transmission case (2). The solenoidvalves are controlled by the Machine ECM. The Machine ECM controls the fill and theengagement modulation of the six transmission clutches.

9

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1

11

2

10

The above graphic shows the inputs and outputs of the Power Train ECM on the 980H WheelLoader. The 980H Wheel Loader is equipped with two transmission output speed sensors andthe six proportional solenoid valves.

SERV7105-01 - 14 - NPIVol. 1, No. 5, 2005

Variable ShiftControl Switch

Parking BrakePressure Switch

NeutralizerDisable Switch

Primary SteeringPressure Switch

Left Brake Pedal Position Sensor

Transmission InputSpeed Sensor

Ride ControlAuto/Off Switch

Power Train Filter Bypass Indicator Lamp

Backup Alarm

Start Relay

Clutch 3 (4th Gear)

Clutch 4 (3rd Gear)

Clutch 5 (2nd Gear)

Clutch 2 (Forward)

Clutch 1 (Reverse)

Control and MonitorSystemsPower

TrainECM

Upshift, Downshift,Forward, Neutral,

Reverse

Key Start Switch

Cat Data Link

Input Components Output Components

980H POWER TRAINELECTRICAL SYSTEM

Clutch 6 (1st Gear)

Ride ControlSolenoid No. 2

Auto/ManualShift Switch Low Fuel Level

Indicator Lamp

Engine RPMFrom Engine ECM

Ride ControlSolenoid No. 1

Transmission OutputSpeed Sensor No.1

Transmission OutputSpeed Sensor No. 2

11

This illustration along with illustration No. 10 shows the relationship between the input andoutput components that makeup the transmission electronic control system.

All the maximum clutch pressures are determined by the transmission relief valve; therefore, allclutch pressures readings should be the same. Maximum clutch pressures no longer have to beindividually calibrated to various pressure levels.

The operation of the transmission is controlled by the programming stored in the MachineECM. Actions taken to shift the transmission are based on information received by theMachine ECM. The transmission electronic control system provides improved flexibility andresponse over the mechanical and hydraulic controls used in earlier machines.

The Machine ECM improves shift quality by reducing shift harshness and shift hesitation. Shiftharshness is reduced by improved control over the clutch piston at TOUCHUP and by using afeedback signal to adjust the modulation time to the shift load. Shift hesitation is reduced byoverlapping the currents to the proportional solenoid valves for the off-going (releasing) clutch and on-coming (engaging) clutch.

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To TransmissionLube

Power TrainOil Cooler

TransmissionRelief Valve

Torque ConverterOutlet Relief

Valve

4

5

6

4th Speed 2

1

SolenoidValves

3

2nd Speed

3rd Speed

POWER TRAIN HYDRAULIC SYSTEMNEUTRAL

TransmissionHousing

Power TrainPump

1st Speed

REV

Torque ConverterInlet Relief Valve

FWD

The power train oil filter (1) on the 980H Wheel Loader is located on the left side of themachine, behind the fuel tank (2).

Also visible are the power train oil fill tube (3), the power train oil sight glass (4), the powertrain oil fluid sampling valve (5), and the power train pump outlet pressure tap (6).

12

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1

2

3

4

5

6

13

The above graphic shows the calibrations that can be selected using Caterpillar ElectronicTechnician (Cat ET). The Transmission Clutch Engagement Pressure Calibration, theTransmission Fill Calibration, the Neutralization Setpoint, and the Neutralization SetpointAdjustment can be performed using Cat ET.

The Power Train Electronic Control Module (ECM) configuration screen has line items toprogram both the Ride Control Reverse Activation Speed and the Ride Control ForwardActivation Speed.

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ATTACHMENTS

The diagnostic lines group is standard equipment on the 980H Wheel Loader. The diagnosticlines group remote pressure taps are located behind the cab on the left side of the machine. Theremote pressure taps include:

1. Transmission reverse clutch pressure

2. Transmission forward clutch pressure

3. Transmission fourth speed clutch pressure

4. Transmission third speed clutch pressure

5. Transmission second speed clutch pressure

6. Transmission first speed clutch pressure

7. Torque converter outlet pressure

8. Torque converter inlet pressure

9. Steering pump signal pressure

10. Steering pump outlet pressure

11. Brake accumulator pressure

12. Power train pump outlet pressure

13. Transmission lube pressure

14

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12

34

5

67

8

9

10

11

12 13

COOLING PACKAGE

The cooling package on the 980H Wheel Loader is equipped with four NGMR cores (1) to coolthe engine coolant. The NGMR cores have six fins per inch and utilize single pass cooling.

Also visible are the Air To Air AfterCooler (ATAAC) (2) and the swing out air conditioningcondenser coil and hydraulic oil cooler (3).

15

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1 2

3

MACHINE APPEARANCE

The top of the cooling package (1) is lower and the entire cooling package is wider on the 980HWheel Loader. This allows the operator better vision to the rear while maintaining coolingcapacity. The hood (2) features a gradual bend and bolt on integrated fenders. The fuel tank (3) features an integrated ladder.

The 980H Wheel Loader is equipped with two battery boxes (4). One is located on each side ofthe machine. Each battery box contains two 12V batteries connected in series. The positivebattery lead connects to the batteries on the right side of the machine, and the negative batteryconnects to the batteries on left side of the machine. The 980H Wheel Loader utilizes a 24Velectrical system.

16

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12

34

The hood actuator (1) on the 980H Wheel Loader is located on the left side of the machine.The hood actuator is a self contained electric motor, hydraulic pump, and hydraulic tank. Theswitch for the hood actuator is located on the right side of the machine.

The hood can be manually raised using the lever (2) located next to the hood actuator.

17

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1

2

The ground level shutdown switch (1) is located just above the fuel tank (2) on the 980H WheelLoader.

The ground level shutdown switch allows personnel to shutdown the engine in the event of anemergency. The ground level shutdown switch disables fuel injection, however the engine canstill be rotated using the starter motor for maintenance purposes.

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1

2

CONCLUSION

This presentation has provided New Product Introduction (NPI) information for the Caterpillar980H Wheel Loader. All new components and their locations were identified and discussed.When used in conjunction with TIM "980G Series II Wheel Loader - 3406E Engine Controls" (SERV2742), TIM "980G Series II Wheel Loader - Steering and Brake Systems"(SERV2746), TIM "980G Series II Wheel Loader - Electro-hydraulic Implement System"(SERV2745), and the Service Manual, the information in this package should permit theserviceman to analyze problems in any of the major systems on this machine.

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HYDRAULIC SCHEMATIC COLOR CODE

This illustration identifies the meanings of the colors used in the hydraulic schematics and cross-sectional views shown throughout this presentation.

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Red - High Pressure Oil

Red / White Stripes - 1st Pressure Reduction

Pink - 3rd Reduction in Pressure

Red / Pink Stripes - Secondary Source Oil Pressure

Orange - Pilot, Signal or Torque Converter Oil

Blue - Trapped Oil

Brown - Lubricating Oil

Cat Yellow - (Restricted Usage)

Green / White Stripes -Scavenge / Suction Oil or Hydraulic Void

Identification of ComponentsWithin a Moving Group

HYDRAULIC SCHEMATIC COLOR CODE

Black - Mechanical Connection. Seal

Dark Gray - Cutaway Section

Light Gray - Surface Color

White - Atmosphere or Air (No Pressure)

Purple - Pneumatic Pressure

Yellow - Moving or Activated Components

Orange / Crosshatch - 2nd Reduction inPilot, Signal or TC Oil Pressure

Orange / White Stripes -Reduced Pilot, Signal or TC Oil Pressure

Red Crosshatch - 2nd Reduction in Pressure

Green - Tank, Sump, or Return Oil

SERV7105-01 - 25 - NPIVol. 1, No. 5, 2005

Red

- H

igh

Pres

sure

Oil

Red

/ W

hite

Str

ipes

- 1

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Red

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Pink

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Red

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trip

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Seco

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y So

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Oil

Pres

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Ora

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Oil

Blu

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rapp

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Bro

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ricat

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Oil

Cat

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Gre

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trip

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Com

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SERV7105-01 - 26 - NPIVol. 1, No. 5, 2005 Handout No. 1

Machine Orientation Checklist

Directions: Use this sheet when performing the machine orientation lab exercise.

Place a check in the blank if the fluid level is acceptable.

____ Engine oil level____ Hydraulic system oil level____ Hood actuator system oil level____ Power train hydraulic system oil level____ Final drive and differential oil level____ Cooling system fluid level ____ Fuel level

Place a check in the blank if acceptable or after task was performed.

____ Check the Caterpillar Monitoring System for abnormal machine conditions____ Check seat belt____ Check the air filter precleaners

Place a check in the blank if the indicator, switch, or control is working correctly.

____ Key start switch____ Engine coolant temperature gauge____ Fuel level gauge____ Power train oil temperature gauge____ Hydraulic oil temperature gauge____ Ride control automatic indicator light____ Ride control manual indicator light____ Neutralizer disabled indicator light____ Autodig indicator lights (3) (if equipped)____ Turn signal indicator lights (2)____ Horn____ Front and rear work lights____ Windshield wipers (if equipped)____ Heating and air conditioner controls (if equipped)____ Back-up alarm


Machine Orientation Checklist - continued

Place a check in the blank after locating and reading the following warnings label on themachine.

____ ROPS____ Parking brake____ No clearance (articulation joint)____ Radiator____ Batteries____ Unit injectors____ Do not operate

Place a check in the blank after locating each of the following controls.

____ Throttle pedal____ Left brake pedal____ Right brake pedal____ Tilt lever____ Lift lever____ Parking brake knob____ Steering Wheel____ Ground level shutdown switch____ Hood actuator switch____ Battery disconnect switch

Place a check in the blank after locating each of the following identification plates.

____ Product Identification Number (PIN)____ Engine serial number____ Transmission serial number ____ Bucket serial number


Machine Posttest

Directions: Answer each question with the best possible answer.

1. The 980H Wheel Loader is equipped with which engine?a. 3406Eb. C18 ACERTc. C15 ACERTd. 3456

2. The 980H Wheel Loader is equipped with which transmission hydraulic control?a. ECPCb. ELRTc. ICMd. EPTC II

3. The diagnostic lines group is an attachment on 980H Wheel Loader.a. Trueb. False

4. The 980H Wheel Loader is equipped with which style radiator core?a. AMOCSb. Foldedc. Single Paneld. NGMR

5. The 980H Wheel Loader utilizes what type hood actuator?a. Two jack screwsb. No hood, side panels for engine accessc. Manual crankd. Self contained hydraulic


Machine Posttest - Continued

6. The 980H Wheel Loader has how many batteries in the main electrical systema. One 24V batteryb. Two 12V batteriesc. Two 12V batteries with a third “kicker” 24V batteryd. Four 12V batteries

7. The 980H Wheel Loader is equipped with what type Engine ECM?a. ADEM IIIb. A4E4c. ADEM IVd. A4M1

8. Where is the power train oil filter located on the 980H Wheel Loader?a. Left side of the machine, by the fuel tankb. Behind the cabc. In the return line, near the power train oil coolerd. Just forward of the hydraulic tank

9. Where is the ground level shutdown switch located on the 980H Wheel Loader?a. On the rear bumper, left side of the machineb. On the rear bumper, right side of the machinec. Above the fuel tankd. Next to the battery disconnect switch

10. All the power train system calibrations must be done using the 4C-8195 Control ServiceTool on the 980H Wheel Loader.a. Trueb. False

SERV7105-01 - 30 - NPIVol. 1, No. 5, 2005 Posttest Answers

Machine Posttest Answers

Quiz Answers:

1. c

2. a

3. b

4. d

5. d

6. b

7. b

8. a

9. c

10. b

Curso Cat 980h Stmg

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