SERV7105-01 January 2005 Vol. 1, No.

SERVICE TRAINING
TECHNICAL PRESENTATION

980H WHEEL LOADER INTRODUCTION

New Product Introduction (NPI)

980H WHEEL LOADER INTRODUCTION

AUDIENCE
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.

OBJECTIVES
After learning the information in this presentation, the technician will be able to: 1. locate and identify the new components on the 980H Wheel Loader; and 2. explain the operation of the new components in the systems.

REFERENCES
TIM "980G Series II Wheel Loader - 3406E Engine Controls" TIM "980G Series II Wheel Loader - Steering and Brake Systems" TIM "980G Series II Wheel Loader - Electro-hydraulic Implement System" SERV2742 SERV2746 SERV2745

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

2005 Caterpillar Inc.

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TABLE OF CONTENTS
INTRODUCTION ........................................................................................................................5 SIMILARITIES AND DIFFERENCES .......................................................................................6 OPERATOR'S STATION..............................................................................................................7 ENGINE........................................................................................................................................8 POWER TRAIN .........................................................................................................................13 Electronic 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

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NOTES

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980H WHEEL LOADER

2005 Caterpillar Inc.

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

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SIMILARITIES AND DIFFERENCES

FEATURES Engine Power Train Attachments Cooling Package Machine Appearance Monitoring System Hydraulic System Operators Station DIFFERENT X X X X X X X X SIMILAR SAME

2 SIMILARITIES AND DIFFERENCES The two most significant changes to the 980H Wheel Loader are the engine and the power train. The engine is changing from the Caterpillar 3406E to the Caterpillar C15 ACERT. The most significant change to the power train is the transmission hydraulic control. The transmission hydraulic control has changed from the Powershift Transmission control to the Electronic Clutch Pressure Control (ECPC). The diagnostic lines group is standard on the 980H Wheel Loader. The diagnostic lines group is an attachment on the 980G Series II Wheel Loader. The appearance of the 980H Wheel Loader is changed slightly. Changes to the machines appearance 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 Loader is equipped with the Advanced Modular Cooling System (AMOCS). The 980H Wheel Loader is equipped with the Next Generation Modular Radiator (NGMR) cores.

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

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ENGINE The 980H Wheel Loader is equipped with the Caterpillar C15 ACERT engine, serial number prefix LHX. The displacement of the C15 ACERT engine is 15.2 liters with a rated power of 343 hp at 2000 rpm. The performance test specification for the C15 ACERT engine in the 980H Wheel Loader is 0K5301. The C15 ACERT engine is equipped with a larger muffler (1) and an A4E4 Engine Electronic Control Module (ECM) (not visible). The fuel manifold (2) is located higher on the engine.

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3 2

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

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C15 ACERT ENGINE SYSTEM BLOCK DIAGRAM (980H)

ENGINE MOUNTED COMPONENTS
6 Drivers Injector Connector

3 Returns Electronic Unit Injectors Crankshaft Speed / Timing Sensor To Machine Wiring Harness Ground Bolt Coolant Temperature Sender Fuel Temperature Sender Fuel Pressure Sensor Timing Calibration Connector Differential Fuel Pressure Switch Oil Pressure Sensor A4E4 ECM

Camshaft Speed / Timing Sensor

Inlet Air Temperature Sender Atmospheric Pressure Sensor Turbo Outlet Pressure Sensor

6 The above illustration shows the engine mounted electrical components on the 980H Wheel Loader.

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A4E4 Electronic Control Module (ECM)

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C15 ACERT EUI SYSTEM (980H)

MACHINE MOUNTED COMPONENTS
Disconnect Switch 24 V

Ground Bolt 15 Amp Breaker Tachometer Output

Main Power Relay

Key Start Switch

Fuel Filter Restriction Indicator Lamp Air Filter Restriction Indicator Lamp Ether Start Aid Indicator Lamp Turbo Inlet Pressure Sensor Transmission Lube Temperature Sender

Throttle Sensor

Accelerator Pedal

Ground Level Shutdown

Fan Control Valve + Battery Relay Ether Start Valve Cylinder

Caterpillar Monitoring System

15 10 5 20 25
X100
Mph Km/h

Engine Service Tool Connector

30

44

Cat Data Link

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

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

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1 1 2

POWER TRAIN Electronic Clutch Pressure Control (ECPC) Transmission The transmission hydraulic control on the 980H Wheel Loader is an ECPC. Six externally mounted solenoid valves (1) are located on top of the transmission case (2). The solenoid valves are controlled by the Machine ECM. The Machine ECM controls the fill and the engagement modulation of the six transmission clutches.

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980H POWER TRAIN ELECTRICAL SYSTEM

Input Components Upshift, Downshift, Forward, Neutral, Reverse Key Start Switch Auto/Manual Shift Switch Variable Shift Control Switch Ride Control Auto/Off Switch Primary Steering Pressure Switch Parking Brake Pressure Switch Neutralizer Disable Switch Left Brake Pedal Position Sensor Transmission Output Speed Sensor No.1 Transmission Output Speed Sensor No. 2 Transmission Input Speed Sensor

Cat Data Link Power Train ECM

Control and Monitor Systems

Output Components Start Relay Power Train Filter Bypass Indicator Lamp Low Fuel Level Indicator Lamp Ride Control Solenoid No. 1 Ride Control Solenoid No. 2 Clutch 1 (Reverse)

Clutch 2 (Forward) Clutch 3 (4th Gear)

Clutch 4 (3rd Gear)

Clutch 5 (2nd Gear) Clutch 6 (1st Gear) Backup Alarm

Engine RPM From Engine ECM

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

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POWER TRAIN HYDRAULIC SYSTEM

NEUTRAL
Transmission Relief Valve

Torque Convert er Inlet Relief Valve

Power Train Pump

Torque Converter Outlet Relief Valve REV 3rd Speed

FWD Power Train Oil Cooler

2nd Speed

4th Speed To Transmission Lube Transmission Housing

1st Speed

Solenoid Valves

11 This illustration along with illustration No. 10 shows the relationship between the input and output components that makeup the transmission electronic control system. All the maximum clutch pressures are determined by the transmission relief valve; therefore, all clutch pressures readings should be the same. Maximum clutch pressures no longer have to be individually calibrated to various pressure levels. The operation of the transmission is controlled by the programming stored in the Machine ECM. Actions taken to shift the transmission are based on information received by the Machine ECM. The transmission electronic control system provides improved flexibility and response over the mechanical and hydraulic controls used in earlier machines. The Machine ECM improves shift quality by reducing shift harshness and shift hesitation. Shift harshness is reduced by improved control over the clutch piston at TOUCHUP and by using a feedback signal to adjust the modulation time to the shift load. Shift hesitation is reduced by overlapping the currents to the proportional solenoid valves for the off-going (releasing) clutch and on-coming (engaging) clutch.

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2 5

3 1 4

12

The power train oil filter (1) on the 980H Wheel Loader is located on the left side of the machine, behind the fuel tank (2). Also visible are the power train oil fill tube (3), the power train oil sight glass (4), the power train oil fluid sampling valve (5), and the power train pump outlet pressure tap (6).

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13 The above graphic shows the calibrations that can be selected using Caterpillar Electronic Technician (Cat ET). The Transmission Clutch Engagement Pressure Calibration, the Transmission Fill Calibration, the Neutralization Setpoint, and the Neutralization Setpoint Adjustment can be performed using Cat ET. The Power Train Electronic Control Module (ECM) configuration screen has line items to program both the Ride Control Reverse Activation Speed and the Ride Control Forward Activation Speed.

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1 6 5 4 2 3 8 10 12 13 7 9 11

14

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

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1 3

15

COOLING PACKAGE The cooling package on the 980H Wheel Loader is equipped with four NGMR cores (1) to cool the 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 conditioning condenser coil and hydraulic oil cooler (3).

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3 4

16

MACHINE APPEARANCE The top of the cooling package (1) is lower and the entire cooling package is wider on the 980H Wheel Loader. This allows the operator better vision to the rear while maintaining cooling capacity. 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 of the machine. Each battery box contains two 12V batteries connected in series. The positive battery lead connects to the batteries on the right side of the machine, and the negative battery connects to the batteries on left side of the machine. The 980H Wheel Loader utilizes a 24V electrical system.

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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. The switch 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.

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The ground level shutdown switch (1) is located just above the fuel tank (2) on the 980H Wheel Loader. The ground level shutdown switch allows personnel to shutdown the engine in the event of an emergency. The ground level shutdown switch disables fuel injection, however the engine can still be rotated using the starter motor for maintenance purposes.

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CONCLUSION This presentation has provided New Product Introduction (NPI) information for the Caterpillar 980H 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 the serviceman to analyze problems in any of the major systems on this machine.

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HYDRAULIC SCHEMATIC COLOR CODE

Black - Mechanical Connection. Seal Dark Gray - Cutaway Section Light Gray - Surface Color Red - High Pressure Oil

Red / White Stripes - 1st Pressure Reduction

Red Crosshatch - 2nd Reduction in Pressure Pink - 3rd Reduction in Pressure

White - Atmosphere or Air (No Pressure) Purple - Pneumatic Pressure

Red / Pink Stripes - Secondary Source Oil Pressure

Yellow - Moving or Activated Components Cat Yellow - (Restricted Usage) Identification of Components Within a Moving Group Brown - Lubricating Oil Green - Tank, Sump, o r Return Oil Green / White Stripes Scavenge / Suction Oil or Hydraulic Void

Orange - Pilot, Signal or Torque Converter Oil Orange / White Stripes Reduced Pilot, Signal or TC Oil Pressure Orange / Crosshatch - 2nd Reduction in Pilot, Signal or TC Oil Pressure Blue - Trapped Oil

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.

HYDRAULIC SCHEMATIC COLOR CODE

Red - High Pressure Oil

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

Black - Mechanical Connection. Seal

Dark Gray - Cutaway Section

Red / White Stripes - 1st Pressure Reduction

Light Gray - Surface Color

Red Crosshatch - 2nd Reduction in Pressure Pink - 3rd Reduction in Pressure

White - Atmosphere or Air (No Pressure)

Purple - Pneumatic Pressure

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Red / Pink Stripes - Secondary Source Oil Pressure

Yellow - Moving or Activated Components

Orange - Pilot, Signal or Torque Converter Oil Orange / White Stripes Reduced Pilot, Signal or TC Oil Pressure Orange / Crosshatch - 2nd Reduction in Pilot, Signal or TC Oil Pressure Blue - Trapped Oil

Cat Yellow - (Restricted Usage) Identification of Components Within a Moving Group

Brown - Lubricating Oil

Green - Tank, Sump, o r Return Oil

Green / White Stripes Scavenge / Suction Oil or Hydraulic Void

NPI

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NPI 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

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NPI Handout No. 2

Machine Orientation Checklist - continued

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

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NPI Handout No. 3

Machine Posttest
Directions: Answer each question with the best possible answer. 1. The 980H Wheel Loader is equipped with which engine? a. 3406E b. C18 ACERT c. C15 ACERT d. 3456 2. The 980H Wheel Loader is equipped with which transmission hydraulic control? a. ECPC b. ELRT c. ICM d. EPTC II 3. The diagnostic lines group is an attachment on 980H Wheel Loader. a. True b. False 4. The 980H Wheel Loader is equipped with which style radiator core? a. AMOCS b. Folded c. Single Panel d. NGMR 5. The 980H Wheel Loader utilizes what type hood actuator? a. Two jack screws b. No hood, side panels for engine access c. Manual crank d. Self contained hydraulic

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NPI Handout No. 4

Machine Posttest - Continued

6. The 980H Wheel Loader has how many batteries in the main electrical system a. One 24V battery b. Two 12V batteries c. Two 12V batteries with a third kicker 24V battery d. Four 12V batteries 7. The 980H Wheel Loader is equipped with what type Engine ECM? a. ADEM III b. A4E4 c. ADEM IV d. A4M1 8. Where is the power train oil filter located on the 980H Wheel Loader? a. Left side of the machine, by the fuel tank b. Behind the cab c. In the return line, near the power train oil cooler d. 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 machine b. On the rear bumper, right side of the machine c. Above the fuel tank d. Next to the battery disconnect switch 10. All the power train system calibrations must be done using the 4C-8195 Control Service Tool on the 980H Wheel Loader. a. True b. False

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NPI 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