SERV7105-01

January 2005
Vol. 1, No. 5
TECHNICAL PRESENTATION
980H WHEEL LOADER
INTRODUCTION
New Product Introduction
(NPI)
SERVICE TRAINING
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" SERV2742
TIM "980G Series II Wheel Loader - Steering and Brake Systems" SERV2746
TIM "980G Series II Wheel Loader - Electro-hydraulic Implement System" SERV2745
Estimated Time: 1 Hour
Illustrations: 18
Handouts: 6
Form: SERV7105-01
Date: 1/05
2005 Caterpillar Inc.
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
SERV7105-01 - 3 - NPI
Vol. 1, No. 5, 2005
NOTES
SERV7105-01 - 4 - NPI
Vol. 1, No. 5, 2005
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.
1
SERV7105-01 - 5 - NPI
Vol. 1, No. 5, 2005
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 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.
SERV7105-01 - 6 - NPI
Vol. 1, No. 5, 2005
FEATURES
Attachments
HydrauIic System
Engine
Machine Appearance
Power Train
X
X
X
DIFFERENT SIMILAR SAME
X
X
X
X
SIMILARITIES AND DIFFERENCES
CooIing Package
Operator's Station
Monitoring System
X
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).
3
SERV7105-01 - 7 - NPI
Vol. 1, No. 5, 2005
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.
4
SERV7105-01 - 8 - NPI
Vol. 1, No. 5, 2005
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
SERV7105-01 - 9 - NPI
Vol. 1, No. 5, 2005
1
2
3
6
The above illustration shows the engine mounted electrical components on the 980H Wheel
Loader.
SERV7105-01 - 10 - NPI
Vol. 1, No. 5, 2005
Oil Pressure Sensor
6 Drivers
3 Returns
Injector
Connector
A4E4
ECM
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 Wiring
Harness
Fuel Pressure Sensor
Electronic Unit
Injectors
Differential Fuel
Pressure Switch
7
The above illustration shows the machine mounted electrical components that are inputs and
outputs of the Engine ECM on the 980H Wheel Loader.
SERV7105-01 - 11 - NPI
Vol. 1, No. 5, 2005
A4E4
Electronic
Control
Module
(ECM)
Ground
Bolt
15 Amp
Breaker
Main
Power Relay
Key Start
Switch
24 V
Service Tool Connector
Cat Data Link
Fan Control Valve
Turbo Inlet Pressure Sensor Ground Level Shutdown
Throttle
Sensor
Accelerator
Pedal
Disconnect Switch
C15 ACERT EUI SYSTEM (980H)
MACHINE MOUNTED COMPONENTS
Caterpillar Monitoring System
0
5
10
15
20
25
30
X100
Mph
Km/h
P
44
Relay + Battery
Cylinder
Engine
Ether Start Valve
Transmission Lube
Temperature Sender
Tachometer Output
Air Filter Restriction Indicator
Lamp
Fuel Filter Restriction
Indicator Lamp
Ether Start Aid
Indicator Lamp
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).
8
SERV7105-01 - 12 - NPI
Vol. 1, No. 5, 2005
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.
9
SERV7105-01 - 13 - NPI
Vol. 1, No. 5, 2005
1
1
1
2
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.
SERV7105-01 - 14 - NPI
Vol. 1, No. 5, 2005
Variable Shift
Control Switch
Parking Brake
Pressure Switch
Neutralizer
Disable Switch
Primary Steering
Pressure Switch
Left Brake
Pedal Position Sensor
Transmission Input
Speed Sensor
Ride Control
Auto/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 Monitor
Systems
Power
Train
ECM
Upshift, Downshift,
Forward, Neutral,
Reverse
Key Start Switch
Cat Data Link
Input Components Output Components
980H POWER TRAIN
ELECTRICAL SYSTEM
Clutch 6 (1st Gear)
Ride Control
Solenoid No. 2
Auto/Manual
Shift Switch Low Fuel Level
Indicator Lamp
Engine RPM
From Engine ECM
Ride Control
Solenoid No. 1
Transmission Output
Speed Sensor No.1
Transmission Output
Speed Sensor No. 2

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.
SERV7105-01 - 15 - NPI
Vol. 1, No. 5, 2005
To Transmission
Lube
Power Train
Oil Cooler
Transmission
Relief Valve

Torque Converter
Outlet Relief
Valve
4
5
6
4th Speed
2
1
Solenoid
Valves
3
2nd Speed
3rd Speed
POWER TRAIN HYDRAULIC SYSTEM
NEUTRAL
Transmission
Housing
Power Train
Pump
1st Speed
REV
Torque Convert er
Inlet Relief Valve

FWD
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).
12
SERV7105-01 - 16 - NPI
Vol. 1, No. 5, 2005
1
2
3
4
5
6
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.
SERV7105-01 - 17 - NPI
Vol. 1, No. 5, 2005
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
14
SERV7105-01 - 18 - NPI
Vol. 1, No. 5, 2005
1
2
3
4
5
6
7
8
9
10
11
12
13
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).
15
SERV7105-01 - 19 - NPI
Vol. 1, No. 5, 2005
1
2
3
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.
16
SERV7105-01 - 20 - NPI
Vol. 1, No. 5, 2005
1
2
3
4
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.
17
SERV7105-01 - 21 - NPI
Vol. 1, No. 5, 2005
1
2
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.
18
SERV7105-01 - 22 - NPI
Vol. 1, No. 5, 2005
1
2
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.
19
SERV7105-01 - 23 - NPI
Vol. 1, No. 5, 2005
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.
SERV7105-01 - 24 - NPI
Vol. 1, No. 5, 2005
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 Components
Within 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 in
Pilot, 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 - NPI
Vol. 1, No. 5, 2005
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SERV7105-01 - 26 - NPI
Vol. 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
SERV7105-01 - 27 - NPI
Vol. 1, No. 5, 2005 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
SERV7105-01 - 28 - NPI
Vol. 1, No. 5, 2005 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
SERV7105-01 - 29 - NPI
Vol. 1, No. 5, 2005 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
SERV7105-01 - 30 - NPI
Vol. 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