SERV7105-01 January 2005 Vol. 1, No. 3
SERVICE TRAINING TECHNICAL PRESENTA PRESENTATION
988H 988H WHEE WHEEL L LO LOAD ADER ER
New Product Introduction (NPI)
988H 988H WHEE WHEEL L LO LOAD ADER ER AUDIENCE Level II - Service personnel who understands the principles of machine system operation, diagnostic equipment, and procedures for testing and adjusting.
CONTENT This presentation provides new and different New Product Introduction (NPI) information on the 988H Wheel Loader. Loader. This presentation may be used for self-paced and self-directed training.
OBJECTIVES After learning the information in this presentation, the technician will be able to: 1. locate and and identify identify the new components components on the 988H Wheel Wheel Loader; Loader; and 2. explain explain the operation operation of the new components components in the the systems. systems.
REFERENCES TIM "988G Wheel Loader - 3456 Engine Controls" TIM "988G Wheel Loader - Power Train" TIM "988G Wheel Loader - Steering and Brake Systems" TIM "988G Wheel Loader - Implement Hydraulic System" TIM "988G Wheel Loader - Caterpillar Monitoring System"
Estimated Time: 1 Hour Illustrations: 17 Handouts: 6 Form: SERV7105-01 Date: 1/05 © 2005 Caterpilla Caterpillarr Inc.
SERV2675 SERV2680 SERV2681 SERV2682 SERV2683
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TABLE OF CONTENTS CONTENTS INTRODUCTION .................................................. ........................................................ ......................................................................5 ..............5 SIMILARITIES AND DIFFERENCES ....................................................... .......................................................................................6 ................................6 ENGINE........................................................................................................................................7 FAN HYDRAULIC SYSTEM ................................................ ...................................................11 IMPLEMENT HYDRAULIC SYSTEM............................................................... SYSTEM....... .............................................................................14 .....................14 ATTACHMENTS TTACHMENTS ................................................... ........................................................ ....................................................................16 ............16 POWER TRAIN ..................................................... ............................................................................................................. ....................................................................17 ............17 COOLING PACKAGE...............................................................................................................23 CONCLUSION...........................................................................................................................24 HYDRAULIC SCHEMATIC COLOR CODE...........................................................................25 HANDOUTS...............................................................................................................................27 POSTTEST .................................................... ........................................................................................................... .............................................................................29 ......................29 POSTTEST ANSWERS .................................................. ........................................................ ...........................................................31 ...31
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NOTES
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988H WHEEL LOADER
© 2005 Caterpillar Inc.
1
INTRODUCTION
The 988H Wheel Loader has been updated to enhance performance and to meet the Tier III EPA regulations. The serial number prefix of the 988H Wheel Loader is BXY. The 988H Wheel Loader retains most of the features of the 988G Wheel Loader. The 988H Wheel Loader is a direct replacement for the 988G Wheel Loader.
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2
SIMILARITIES AND DIFFERENCES
The most significant changes to the 988H Wheel Loader are the engine, the hydraulic fan system, the power train system, and the attachments. The engine is changing from the Caterpillar 3456 to the Caterpillar C18 ACERT. The most significant change to the hydraulic system is the fan control. The fan control is changing from a thermostatic, wax capsule control to an electronic control. The Lincoln Automatic Lubrication System (Autolube) is an attachment. The Autolube control will be integrated in the Power Train Electronic Control Module (ECM). The priority valve has been removed from the power train hydraulic system. The diagnostic lines group is standard on the 988H Wheel Loader. The diagnostic lines group provides remote pressure taps for the power train hydraulic system. The cooling package is changed on the 988H Wheel Loader. The 988G Wheel Loader is equipped with the Advanced Modular radiator Cores (AMOCS). The 988H Wheel Loader is equipped with the Next Generation Modular Radiator (NGMR) cores.
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3 4 2
1
5
3
ENGINE
The 988H Wheel Loader is equipped with the Caterpillar C18 ACERT engine, serial number prefix RHX. The displacement of the C18 ACERT engine is 18.1 liters with a rated power of 555 hp at 1800 rpm. The performance test specification for the C18 ACERT engine in the 988H Wheel Loader is 0K4826. The C18 ACERT engine is equipped with an A4E4 Engine Electronic Control Module (ECM) (1). The A4E4 Engine ECM is equipped with one 120 pin connector, one 70 pin connector, and 26 output drivers. Also visible in this illustration are the fuel filter bypass switch (2), the differential fuel pressure switch (3), the fuel temperature sender (4), and the secondary fuel filter (5).
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1
2
6 3
4 5
4
The engine on the 988H Wheel Loader is equipped with an electric fuel priming pump (1) and a turbocharger (2) that is cooled with engine coolant. Also shown are the primary fuel filter and water separator (3), the engine oil filter (4), the engine oil cooler (5), and the transmission oil cooler (6).
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C18 ACERT ENGINE SYSTEM BLOCK DIAGRAM (988H) ENGINE MOUNTED COMPONENTS 6 Drivers
Injector Connector
3 Returns A4E4 ECM
Electronic Unit Injectors Crankshaft Speed / Timing Sensor
To Machine Wiring Harness
Camshaft Speed / Timing Sensor
Ground Bolt Coolant Temperature Sender Fuel Pressure Sensor
Fuel Temperature Sender
Timing Calibration Sensor
Inlet Air Temperature Sender
Atmospheric Pressure Sensor
Differential Fuel Pressure Switch
Turbo Outlet Pressure Sensor
Oil Pressure Sensor
5
The above illustration shows the engine mounted electrical components on the 988H Wheel Loader. The differential fuel pressure switch monitors the condition of the secondary fuel filter.
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C18 ACERT EUI SYSTEM (988H)
A4E4 Electronic Control Module (ECM)
MACHINE MOUNTED COMPONENTS Ground Bolt
Disconnect Switch 24 V
15 Amp Breaker
Tachometer Output
Main Power Relay
Key Start Switch
Right Brake Switch Throttle Sensor
Throttle Lock Resume / Accelerate Switch
Accelerator Pedal Manual Ether Aid Switch
Throttle Lock Set / Decelerate Switch Throttle Lock Enable Switch
Ground Level Shutdown Switch Fan Proportional Solenoid Valve
Throttle Lock Lamp + Battery
Relay
Ether Start Valve
Transmission Lubrication Temperature Sender
Cylinder
Caterpillar Monitoring System
Engine
15 10
20
5
Service Tool Connector
25 X100
0
MPH km/h
44
CAT Data Link
6
The above illustration shows the machine mounted input electrical components and output electrical components of the Engine ECM on the 988H Wheel Loader. The fan proportional solenoid valve controls the fan speed.
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3
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1
2
7
HYDRAULIC FAN SYSTEM
The hydraulic fan system on the 988H Wheel Loader now includes an electronically controlled hydraulic demand fan. The Engine ECM (1) sends a current to the fan proportional solenoid valve (2) to control the demand fan speed. The inlet air temperature, the engine coolant temperature, and the hydraulic oil temperature are inputs to the Engine ECM. The Engine ECM then determines the desired fan speed based on the temperatures. Also shown is the hydraulic fan pump (3). For more detailed information on the electronically controlled hydraulic demand fan system refer to Service Training Meeting Guide "938G Series II Wheel Loader/IT38G Series II Integrated Tool Carrier with Tier II Emissions Engines " (Form SERV1787). NOTE:
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HYDRAULIC FAN SYSTEM MINIMUM FAN SPEED
Fan Motor
Solenoid Valve
Fan
Pump Control Valve Flow Control Spool
Oil Cooler
Pressure Cutoff Spool
Fan Pump
Actuator Min Angle
Filter
Hydraulic Tank
8
The above illustration is a hydraulic schematic of the 988H Wheel Loader hydraulic fan system at MINIMUM FAN SPEED. As the current from the Engine ECM to the fan proportional solenoid valve increases, the speed of the fan decreases. If there is a failure in the electronic control of the fan drive system, the fan will go to maximum speed.
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9
The hydraulic fan system must be calibrated on the 988H Wheel Loader using Caterpillar Electronic Technician (Cat ET). The above illustration shows the Engine ECM Service drop down menu and the Engine Cooling Fan Calibration line item.
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PUMP AND PUMP CONTROL VALVE MINIMUM DISPLACEMENT - DIG TRIGGER MODE Pressure Sensor To Implement Control Valve Pressure Tap Actuator Pump Solenoid Valve
Swashplate Lever Arm
From Tank Super Charger
From Brake / Pilot Pump
Pump
Pump Case Fill
Pump Case Air Bleed
Pump Case Drain Filter
To Tank
10
IMPLEMENT HYDRAULIC SYSTEM
The 988H Wheel Loader implement hydraulic system is equipped with the current implement pump. The implement pump was effective with the 988G Wheel Loader BNH01062. The pump is controlled directly by the pump solenoid valve. The pump solenoid valve directs brake/pilot pump oil flow to and from the actuator. The actuator upstrokes and destrokes the pump. When the 988H Wheel Loader is in DIG TRIGGER, the Implement ECM sends the minimum current to the pump solenoid valve and the implement pump is at MINIMUM DISPLACEMENT.
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IMPLEMENT HYDRAULIC SYSTEM
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Tilt Cylinder
Lift Cylinder
Lift Cylinder
HOLD
Ride Control Auxiliary Valve
Pressure Reducing Valve
Shuttle Valve
Lower
Tilt Back
Manual Lower Valve Pilot Supply Valve
Balance Valve
Float Sequence Valve
Tilt Stem
Lift Stem
Auxiliary Stem
Main Relief Valve
Dump
Raise
Float Check Valve
Implement Pump
From Brake/Pilot Pump
11
The ride control system for the 988H Wheel Loader has been updated. The ride control system for the 988H has a balance valve and two accumulators compared to a single accumulator and no balance valve on the 988G. The balance valve in the ride control system equalizes the pressure between the lift cylinders and the ride control accumulators. If the pressure in the lift cylinders circuit is higher than the pressure in the accumulators, the balance valve will shift to the left allowing supply oil to charge the accumulators. The implement pump can charge the accumulators up to the main relief valve setting of the implement system.
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ATTACHMENTS
The most significant change to the mandatory attachment list for the 988H Wheel Loader is the addition of the 3.88 meter lift linkage. The 3.88 meter lift linkage is designed for loading trucks in the 27 000 kg to 36 000 kg (30 ton to 40 ton) payload range. The 4.25 meter lift linkage is designed for loading trucks in the 45 000 kg to 64 000 kg (50 ton to 70 ton) payload range.
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7
1 2
6
8 3
5
9
4
10
13
POWER TRAIN
The power train hydraulic system on the 988H Wheel Loader is equipped with remote pressure taps. The remote pressure taps are located in the pump bay, behind the cab. The remote pressure taps are: 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 inlet pressure 8. Torque converter outlet pressure 9. Impeller clutch pressure 10. Lockup clutch pressure
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POWER TRAIN HYDRAULIC SYSTEM NEUTRAL Transmission Relief Valve Lockup Clutch Solenoid Valve
Torque Converter Inlet Relief Valve
Impeller Clutch Solenoid Valve
Torque Converter Outlet Relief Valve Scavenge Pump
R
3
1
4
F
Power Train Oil Cooler
2
2
5
To Transmission Lube
1
4
Transmission Housing
3
Solenoid Valves
6
14
The priority valve has been removed from the power train hydraulic system on the 988H Wheel Loader. The priority valve was removed due to the power train pump providing an adequate flow rate for the power train hydraulic system. The torque converter no longer features a free wheel stator when the machine is equipped with the lockup clutch attachment. With the removal of the free wheel stator, the durability of the torque converter on the 988H has increased.
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15
The power train system calibrations can be selected by using Caterpillar Electronic Technician (Cat ET) on the 988H Wheel Loader. The Power Train Electronic Control Module (ECM) configuration screen has line items to program both the Autolube interval and the minimum Autolube pressure. Autolube is now controlled by the Power Train ECM. The default settings for reduced rimpull on the 988H Wheel Loader are 60%, 70%, 80%, and 90%. The default settings for reduced rimpull on the 988G Wheel Loader are 35%, 50%, 65%, and 80%.
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POWER TRAIN ELECTRICAL SYSTEM INPUT COMPONENTS
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CAT Data Link Power Train ECM
Control and Monitor Systems
STIC Upshift, Downshift, Forward, Neutral, Reverse
Key Start Switch
Auto/Manual Shift Switch
Transmission Oil Temperature Sensor
Reduced Rimpull Enable Switch
Impeller Clutch Pressure Sensor
Reduced Rimpull Selection Switch
Autolube Pressure Sensor
Ride Control Auto / Off Switch
Autolube Level Switch
Lockup Clutch Enable Switch
Parking Brake Pressure Switch
Steering / Transmission Lock Switch
Torque Converter Output Speed Sensor
Torque Converter Pedal Position Sensor Transmission Output Speed Sensors Engine Speed From Engine ECM
16
The above illustration shows the inputs to the Power Train ECM on the 988H Wheel Loader. On a machine equipped with the Autolube attachment, the 988H Wheel Loader is equipped with an Autolube pressure sensor and an Autolube level switch.
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POWER TRAIN ELECTRICAL SYSTEM OUTPUT COMPONENTS
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CAT Data Link
Power Train ECM
Control and Monitor Systems
Autolube Indicator Lamp
Reduced Rimpull Indicator Lamp
Primary Steering Pressure Indicator Lamp
Autoshift Indicator Lamp
Ride Control Solenoid
Clutch 1 Reverse Solenoid
Start Relay
Clutch 2 Forward Solenoid
Back-up Alarm
Clutch 3 4th Gear Solenoid
Impeller Clutch Solenoid
Clutch 4 3rd Gear Solenoid
Lockup Clutch Solenoid
Clutch 5 2nd Gear Solenoid
Autolube Solenoid
Clutch 6 1st Gear Solenoid
17
The above illustration shows the outputs of the Power Train ECM on the 988H Wheel Loader. On a machine equipped with the Autolube attachment, the 988H Wheel Loader is equipped with an Autolube solenoid and an Autolube indicator lamp.
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Return Supply
AXLE OIL COOLER HYDRAULIC CIRCUIT
Solenoid Valve
Fan Motor
Axle Oil Cooler
Rear Axle Screen Temperature Sensor Temperature Sensor
Front Axle Screen Axle Oil Pump Rear Axle Front Axle
MPH km/h
CAT Data Link
Caterpillar Monitoring System
Power Train ECM
18
The axle oil cooler circuit now has a separate pump to supply oil to fan motor. A second section was added to the brake/pilot pump (not shown) to supply oil to the fan motor. The Power Train ECM controls the solenoid valve for the axle oil cooler system. When the Power Train ECM sends current to the solenoid valve, supply oil from the pump is allowed to flow through the solenoid valve. The oil from the solenoid valve bypasses the fan motor and is sent to tank. When the Power Train ECM de-energizes the solenoid valve, the supply oil is blocked by the solenoid valve. The oil flows to the fan motor cooling causing the fan motor to rotate at maximum speed. The two-section axle oil pump circulates oil from the axle housings through the axle screens and axle oil cooler and back to the axle housings. The axle oil pump is driven off of the pump drive at the torque converter.
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COOLING PACKAGE
The cooling package on the 988H Wheel Loader is equipped with NGMR cores to cool the engine coolant. The NGMR cores have six fins per inch and utilize two pass cooling.
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CONCLUSION
This presentation has provided New Product Introduction (NPI) information for the Caterpillar 988H Wheel Loader. All new components and their locations were identified and discussed. Use this presentation with: - TIM "988G Wheel Loader - 3456 Engine Controls" (SERV2675) - TIM "988G Wheel Loader - Steering and Brake Systems" (SERV2681) - TIM "988G Wheel Loader - Power Train" (SERV2680) - TIM "988G Wheel Loader - Electro-hydraulic Implement System" (SERV2682) - TIM "988G Wheel Loader - Caterpillar Monitoring System" (SERV2683) - 988H Service Manual The information in this package should permit the serviceman to analyze problems in any of the major systems on this tractor.
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NPI Handout No. 1
HYDRAULIC SCHEMATIC COLOR CODE Black - Mechanical Connection. Seal
Red - High Pressure Oil
Dark Gray - Cutaway Section
Red / White Stripes - 1st Pressure Reduction
Light Gray - Surface Color
Red Crosshatch - 2nd Reduction in Pressure
White - Atmosphere Or Air (No Pressure)
Pink - 3rd Reduction in Pressure
Purple - Pneumatic Pressure
Red / Pink Stripes - Secondary Source Oil Pressure
Yellow - Moving or Activated Components
Orange - Pilot, Signal or Torque Converter Oil
Cat Yellow - (Restricted Usage) Identification of Components Within a Moving Group
Orange / White Stripes Reduced Pilot, Signal or TC Oil Pressure
Brown - Lubricating Oil
Orange / Crosshatch - 2nd Reduction In Pilot, Signal or TC Oil Pressure
Green - Tank, Sump, or Return Oil
Blue - Trapped Oil
Green / White Stripes Scavenge / Suction Oil or Hydraulic Void
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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E D O C R O L O C C I T A M E H C S C I L U A R D Y H
l i O e r u s s e r P h g i H d e R
l a e S . n o i t c e n n o C l a c i n a h c e M k c a l B
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n o i t c u d e R e r u s s e r P t s 1 s e p i r t S e t i h W / d e R
n o i t c e S y a w a t u C y a r G k r a D
e r u s s e r P n i n o i t c u d e R d n 2 h c t a h s s o r C d e R
r o l o C e c a f r u S y a r G t h g i L
e r u s s e r P n i n o i t c u d e R d r 3 k n i P
) e r u s s e r P o N ( r i A r O e r e h p s o m t A e t i h W
e r u s s e r P l i O e c r u o S y r a d n o c e S s e p i r t S k n i P / d e R
e r u s s e r P c i t a m u e n P e l p r u P
NPI Handout No. 2
l i O r e t r e v n o C e u q r o T r o l a n g i S , t o l i P e g n a r O
e r u s s e r P l i O C T - r o s l e a p n i r i g t S S e , t i t o h l i P W / d e e g c u n d a r e O R
s t n e n o p m o C d e t a v i t c A r o g n i v o M w o l l e Y
s t n e n o p p u o ) m o r e C G g f g a o n s i U n v o o l d i t M i e O t a a c c g i f r i n n i i t i t s n h t a e e t i i c R d ( I W r b u w L o l l n e Y w t o r a B C
n I n o i t c u d e e r R u s d s n e r 2 P - l h i c O t a C h T s r s o o r l a C n / i g e S g , n t o a r l i O P
l i O d e p p a r T e u l B
d i o V c i l l i u O a r n d r y u t H e r R o r - l i o s O , e n p p o i m r i u t t S S c u , e S k t i n h / a T W e / g n n e n e v e e e r a r c G G S
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NPI Handout No. 3
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 ____ Autolube lubrication system grease level (if equipped) ____ 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 indicator light (if equipped) ____ Autoshift indicator light ____ Autolube indicator light (if equipped) ____ Reduced rimpull indicator lights ____ Throttle lock indicator light ____ 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. 4
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 ____ STIC ____ Ground level shutdown switch ____ Engine brake (if equipped) ____ 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. 5
Machine Posttest Directions: Answer each question with the best possible answer.
1. The 988H Wheel Loader is equipped with which engine? a. 3406E b. C18 ACERT c. C15 ACERT d. 3456 2. The 988H Wheel Loader is equipped with which fan hydraulic system control? a. Electronic b. Wax capsule c. Thermostatic d. Wiggins 3. The diagnostic lines group is an attachment on 988H Wheel Loader. a. True b. False 4. The 988H Wheel Loader is equipped with which style radiator core? a. AMOCS b. Folded c. Single Panel d. NGMR 5. The 988H Wheel Loader requires service personnel to use Cat ET to calibrate the fan hydraulic system. a. True b. False
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NPI Handout No. 6
Machine Posttest - Continued 6. The 988H Wheel Loader ride control system utilizes a. Two solenoid valves b. A balance valve c. Four accumulators d. One accumulator 7. The 988H Wheel Loader is equipped with what type Engine ECM? a. ADEM III b. A4E4 c. ADEM IV d. A4M1 8. Which linkage lengths are offered as mandatory attachments for the 988H Wheel Loader? a. 3.25 meter b. 3.88 meter c. 4.25 meter d. Both b and c 9. Where are the remote pressure taps located on the 988H Wheel Loader? a. On the rear bumper, left side of the machine b. On the rear bumper, right side of the machine c. Behind the cab, in the pump bay d. Next to the battery disconnect switch 10. The 988H Wheel Loader is equipped with a priority valve in the power train hydraulic system. a. True b. False
