SERV7105-01 January 2005 Vol. 1, No. 1
SERVICE TRAINING TECHNICAL PRESENT PRESENTA ATION
834H WHEEL 834H WHEEL DOZ DOZER ER AND 836H LANDFIL LANDFILL L COMP COMPACT ACTOR OR INTRODUCTION
New Product Introduction (NPI)
834H WHEEL 834H WHEEL DOZ DOZER ER AND 836H LANDFIL LANDFILL L COMP COMPACT ACTOR OR 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 834H Wheel Dozer and 836H Landfill Compactor.
OBJECTIVES After learning the information in this presentation, the technician will be able to: 1. locate and identif identify y the new components components on the 834H Wheel Wheel Dozer and and 836H Landfill Compactor; and 2. explai explain n the operation operation of the new components components in the the systems. systems.
Estimated Time: 1 Hour Illustrations: 18 Handouts: 6 Form: SERV7105-01 Date: 1/05 © 2005 Caterpilla Caterpillarr Inc.
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TABLE OF CONTENTS INTRODUCTION .................................................. ......................................................................5 SIMILARITIES AND DIFFERENCES .......................................................................................6 ENGINE........................................................................................................................................7 AUTOMATIC BLADE POSITIONING (ABP) SYSTEM........................................................11 ATTACHMENTS ................................................... ....................................................................12 COOLING PACKAGE...............................................................................................................13 CONCLUSION...........................................................................................................................14 HYDRAULIC SCHEMATIC COLOR CODE...........................................................................15 HANDOUTS...............................................................................................................................17 POSTTEST .................................................................................................................................19 POSTTEST ANSWERS .................................................. ...........................................................21
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834H WHEEL DOZER AND 836H LANDFILL COMPACTOR INTRODUCTION
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INTRODUCTION
The 834H Wheel Dozer and 836H Landfill Compactor have been updated to enhance performance and to meet the Tier III EPA regulations. The serial number prefix of the 834H Wheel Dozer is BTX. The serial number prefix for the 836H Landfill Compactor is BXD. The 834H Wheel Dozer and the 836H Landfill Compactor are direct replacements for the 834G and 836G machines.
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SIMILARITIES AND DIFFERENCES
The most significant changes to the 834H and 836H are the engine, the hydraulic fan 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 Automatic Blade Positioning (ABP) is standard on the 834H and 836H. ABP is a system that adjusts the blade to set points as the machine is shifted between forward and reverse. The diagnostic lines group is standard on the 834H and 836H. The diagnostic lines group provides remote pressure taps for the power train hydraulic system. The cooling package is changed on the 834H and 836H. The 834G and 836G are equipped with the Advanced Modular radiator Cores (AMOCS). The 834H and 836H are equipped with the Next Generation Modular Radiator (NGMR) cores. A new 10.13 m3 (13.25 yd3) SU blade is available for the 834H Wheel Dozer. A new 21 m3 (27 yd3) SU blade is available for the 836H Landfill Compactor.
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ENGINE
The 834H and 836H are 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 498 hp at 1800 rpm. The performance test specification for the C18 ACERT engine in the 834H and 836H are 0K4827 (direct drive) and 0K4828 (converter drive). The C18 ACERT engine is equipped with a wastegated turbocharger (1) and an electric fuel priming pump (2). The turbocharger is cooled with engine coolant. Also shown are the primary fuel filter and water separator (3) and the engine oil filter (4).
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The C18 ACERT engine is equipped with a larger muffler (1) and an A4E4 Engine Electronic Control Module (ECM) (not shown). The brake/pilot pump (2) is also located on the right side of the machine. The secondary fuel filter (not shown) can be accessed from the right side of the machine.
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C18 ACERT ENGINE SYSTEM BLOCK DIAGRAM 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 Temperature Sender
Fuel Pressure Sensor
Inlet Air Temperature Sender
Timing Calibration Sensor
Atmospheric Pressure Sensor
Differential Fuel Pressure Switch
Turbo Outlet Pressure Sensor
Oil Pressure Sensor
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The above illustration shows the engine mounted electrical components on the 834H and 836H. The differential fuel pressure switch monitors the condition of the secondary fuel filter.
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C18 ACERT EUI SYSTEM
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
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Service Tool Connector
25 X100
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MPH km/h
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CAT Data Link
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The above illustration shows the machine mounted electrical components that are inputs and outputs of the Engine ECM on the 834H and 836H.
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AUTOMATIC BLADE POSITIONING (ABP) SYSTEM
ABP is standard equipment on the 834H and 836H. ABP is a system that automates much of the repetitive work of positioning the blade on the machine. ABP uses the cylinder position sensor (arrow) of the kickout system and the transmission directional switch to determine the blade position. Once the blade heights are set by the operator, ABP will position the blade to those determined height without the operator moving the joystick. When the operator selects REVERSE, the blade is automatically positioned to the raise height that was set by the operator. The operation of the system is same when the operator selects FORWARD with the transmission direction switch. The calibration of the cylinder position sensor follows the lift linkage strategy. The cylinder position cylinder can be calibrated with Caterpillar Electronic Technician (Cat ET) or with the 4C8195 service tool and Caterpillar Monitoring System (CMS).
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ATTACHMENTS
The diagnostic lines group is standard equipment on the 834H and 836H. 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 inlet pressure
8.
Torque converter outlet pressure
9.
Impeller clutch pressure
10. Lockup clutch pressure
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COOLING PACKAGE
The cooling package on the 834H and 836H is equipped with ten NGMR cores (arrow) 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 834H Wheel Dozer and 836H Landfill Compactor. All new components and their locations were identified and discussed.
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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
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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
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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 ____ Neutralizer disabled indicator light ____ Turn signal indicator lights (2) ____ Horn ____ Front and rear work lights ____ Windshield wipers (if equipped) ____ Heating and air conditioner controls (if equipped) ____ Backup 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 ____ 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 ____ Blade serial number
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Machine Posttest Directions: Answer each question with the best possible answer.
1. The 834H and 836H are equipped with which engine? a. 3406E b. C18 ACERT c. C15 ACERT d. 3456 2. The 834H and 836H are equipped with a water cooled turbocharger. a. True b. False 3. The diagnostic lines group is an attachment on 834H and 836H. a. True b. False 4. The 834H and 836H are equipped with which style radiator core? a. AMOCS b. Folded c. Single Panel d. NGMR 5. The 834H and 836H are equipped with Automatic Blade Positioning. a. True b. False
NPI Handout No. 3
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NPI Handout No. 4
Machine Posttest - Continued 6. The Next Generation Modular Radiator (NGMR) cores have six fins per inch and utilize two pass cooling a. True b. False 7. The 834H and 836H are equipped with what type Engine ECM? a. ADEM III b. A4E4 c. ADEM IV d. A4M1 8. Where is the diagnostics line group located on the 834H and 836H? 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. What does the Automatic Blade Positioning system use to determine blade position? a. Machine kickout set points and engine rpm b. Directional control level and cylinder position sensor c. Joystick lever position and machine speed d. Cylinder position sensor and Machine ECM 10. The Automatic Blade Positioning system calibrations must be done using the 4C-8195 Control Service Tool. a. True b. False
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Machine Posttest Answers Quiz Answers: 1. b 2. a 3. b 4. d 5. a 6. a 7. b 8. b 9. b 10. b
NPI Posttest Answers