Supplemental Service Information for the USAF 980H Rough Terrain Forklift {0374, 7000} Caterpillar

Wheel Loader

980H (S/N: PF81-UP)

Introduction

Table 1

Revision History
Revision	Summary of Changes
01	Changes were made to the introduction.

This Special Instruction contains supplemental information for the USAF 980H 25K (25,000 lbs) Capacity Rough Terrain Forklift. This special instruction is a supplement to the service manual for your machine.

Operation Section

The operation section is a reference for the new operator and a refresher for the experienced operator. This section includes descriptions of gauges, switches, machine controls, attachment controls, transportation, and towing information.

Operator Controls

Illustrations guide the operator through correct procedures of checking, starting, operating, and stopping the machine. Operating techniques that are outlined in this publication are basic. Skill and techniques develop as the operator gains knowledge of the machine and the capabilities of the machine.

Illustration 1	g03415565
(1) Steering control (2) Horn (3) Seat (4) Transmission control (5) Tilt control for the steering wheel (6) Service brake controls (7) Governor control (8) Telescopic control for the steering wheel (9) Hydraulic control support

Illustration 2	g03409694
(10) Lighter (11) Light switch (12) Display module (13) Parking brake control (14) Implement function (15) Beacon switch (if equipped) (16) Hazard switch (17) Engine start switch (18) 12 V power receptacle

Illustration 3	g03735022
(18A) Temperature control for the heating and air conditioning (18B) Heating and air conditioning (18C) Fan control (19) Front window wiper/washer switch (20) HID lights (if equipped) (21) Autoshift control (22) Autodig control (if equipped) (23) Autodig mode select switch (if equipped) (24) Autodig kickout set switch (if equipped) (25) Auto reverse fan (26) Carriage sideshift/fork positioning mode select switch (27) Lift and tilt kickout switch (28) Heated mirror (if equipped) (29) Bucket/fork selector control (if equipped) (30) Secondary steering (if equipped) (31) Transmission neutralizer override switch (32) Ride control (if equipped) (33) Rear window wiper/washer switch (34) Low/High beam lights

Illustration 4	g03410777
(1) Transmission control (if equipped) (2) Horn button (35) Transmission downshift (36) Autodig trigger switch (if equipped) (37) Hydraulic lockout (38) PCS store button (if equipped) (39) Auxiliary control (if equipped) (40) Lift control (41) Tilt control (42) Fine modulation

Auxiliary Control (39)

If equipped, this lever is used for fork carriage sideshift/fork repositioning.

Illustration 5	g03411126
Machines that are not equipped with a joystick.

Fork Positioning Control

WIDEN - Move the lever to position 1 in order to widen the fork tine spacing.

HOLD - The lever will return to position 2 when the lever is released from position 1 or from position 3. The fork tine spacing will remain the same.

NARROW - Move the lever to position 3 in order to narrow the fork spacing.

Fork Carriage Sideshift Control

LEFT - Move the lever to position 1 in order to shift the fork carriage to the left.

HOLD - The lever will return to position 2 when the lever is released from position 1 or from position 3. The fork carriage will remain in the selected position.

RIGHT - Move the lever to position 3 in order to shift the fork carriage to the right.

Tilt Control (40)

Illustration 6	g03735056
Machines that are not equipped with a joystick

TILT FORWARD (1) - Push the lever forward in order to tilt the forklift forward.

HOLD (2) - When you release the lever, the lever will return the HOLD position. The forklift will remain in the selected position.

TILT BACK (3) - Pull the lever backward in order to tilt the forklift backward.

Lift Control (41)

Illustration 7	g03735245
Machines that are not equipped with a joystick

LOWER (1) - Push the lever forward in order to lower the attachment. The lever will return to the HOLD position when the lever is released.

HOLD (2) - The lever will return to the HOLD position when the lever is released from the RAISE position or from the LOWER position. The attachment will remain in the selected position.

RAISE (3) - Pull the lever backward in order to raise the attachment. The lever will return to the HOLD position when the lever is released.

Fine Modulation (42)

Machines may be equipped with a switch for fine modulation. This switch controls the shift speed of the main hydraulic spool. Activating this switch will allow better control in certain applications.

Press the front of the switch in order to enable fine modulation. Press the rear of the switch in order to disable fine modulation.

Control Gp-Lines and Mast

Installation Procedure

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Illustration 8	g03720461

1. Fasten a suitable lifting device to the tilt cylinders (1). Install both tilt cylinders (1) and valve (2).
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   Illustration 9	g03720462

2. Install both tilt cylinder lines (3) and (4).
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   Illustration 10	g03720464

3. Install hydraulic lines. (5), (6) and (7).
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   Illustration 11	g03720465

4. Install hydraulic lines (8) for mast lift cylinders.
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   Illustration 12	g03720467

5. Install hose assembly (9) on both sides of the machine.
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   Illustration 13	g03720468

6. Install hose assembly (10) onto hydraulic tank (11).
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   Illustration 14	g03720469

7. Install wiring gp (12) for the mast on the main control valve (13).
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   Illustration 15	g03720471

8. Fasten a suitable lifting device to cover assembly (14). Install cover assembly (14), bolts (15), and washers.

   The weight of cover assembly (14) is approximately 23 kg (50 lb).

9. Fill the implement hydraulic system. Refer to Operation and Maintenance Manual, "Hydraulic System Oil - Change" for the correct procedure.
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   Illustration 16	g03720472

10. Use a suitable lifting device (16) to install mast (17) to the front of the machine.
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    Illustration 17	g03720473

11. Position mast (18) in front of the machine. Align tilt cylinder clevis ends (20) to mast tilt mount (19). Align frame mount (22) to mast mounting eyes (21).
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    Illustration 18	g03720474

12. Insert two pins (23) into two sleeves (24) of mast.
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    Illustration 19	g03720476

13. Use a suitable lifting device to position mast (25) between the front frame hooks (26). The mast pin (23) should rest on the front frame hooks (26).
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    Illustration 20	g03720477

14. Use a suitable lifting device (27) to lift the tilt cylinders (1). Align the cylinder rod end (28) close to the cylinder clevis mount hole (29).

15. Start the engine.
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    Illustration 21	g03720479

16. Extend the tilt cylinder rod (28) in order to align the holes (30).

17. Stop the engine.
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    Illustration 22	g03720480

18. Insert pin (31) into tilt cylinder clevis.
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    Illustration 23	g03720481

19. Install pin retainer (32) and pin retainer bolts (33).
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    Illustration 24	g03720482

20. Install pin retainers (34) on the pin (23) on each side of the hook (26). Use bolts (35) to fasten bar (36) to the pin retainers (34).
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    Illustration 25	g03720483

21. Attach hydraulic lines. (37), (38), (39) and (40).
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    Illustration 26	g03720485

22. Install NATO plug (41).

Lubrication

Mast Lubrication Points

Wipe off all fittings before any lubricant is applied.

Illustration 27	g01194262

Apply lubricant through the remote grease fitting (1).

Illustration 28	g01194332

Apply lubricant through fitting (2) on each side of the mast.

Illustration 29	g01194342

Apply lubricant through fitting (3) on each tilt cylinder pin.

Illustration 30	g01194382

Apply lubricant through fittings (4) located on each side of the mast.

Illustration 31	g01194472

Apply lubricant through fitting (5) on the fork carriage assembly.

Illustration 32	g01194514

Apply lubricant through fittings (6) on the fork carriage assembly.

Hydraulic Schematic

980H Hydraulic Schematic

Illustration 33	g01224836
(1) Tank Gp (2) Pump Gp-Gear (3) Pump Gp-Gear (4) Pump Gp-Gear (5) Pump Gp-Gear (6) Motor Gp-Piston (7) Pump Gp-Piston (8) Valve Gp-Mounting (9) Strainer (10) Oil Cooler Core As. (11) Valve Gp-Check (12) Filter Gp (13) Pump Gp-Piston (14) Valve Gp-Pilot (15) Valve Gp.-Steering (16) Valve Gp-Pressure Reducing (17) Valve Gp-Shuttle (18) Valve Gp-Relief (19) Valve Gp-Relief (20) Valve Gp-Check (21) Valve Gp-Check (22) Valve Gp-Check (23) Screen Gp (24) Valve Gp-Neutralizer (25) Cylinder Gp (26) Valve Gp-Control (27) Valve Gp-Relief (28) Valve Gp-Relief (29) Valve Gp-Relief (30) Choke (31) Valve Gp-Relief (32) Cylinder Gp (33) Valve Gp (34) Strainer (35) Connector (36) Connector (37) Valve Gp-Pilot (38) Valve Gp-Sequence (39) Valve Gp-Solenoid (40) Valve Gp-Pressure Reducing (41) Valve Gp-Pressure Reducing (42) Valve Gp-Solenoid (43) Valve Gp-Shuttle (44) Valve Gp-Diverter (45) Valve Gp-Pressure Reducing (46) Valve Gp-Relief (47) Mast Ar. Lift

Test and Adjust Information

Flash File

The 980H 25K Rough Terrain Forklift requires 465-6572 Implement Software Gp.

Pump Flow

At high idle with an implement system pressure of 20700 kPa (3000 psi), the pump flow for the 980H 25K Rough Terrain Forklift is 116 cc/rev or 292 L/min (77 US gpm).

Cycle Time-Mast

Table 2

FUNCTION	DIRECTION	TIME(S)(1) (in seconds)
Lift	Up	17.0
	Down	30.7
Tilt	Forward	2.7
	Back	1.9
Carriage Side	Left	5.7
	Right	3.2
Positioning	Together	5.5
	Apart	4.0

(1)	Times are recorded with no load, high idle, and warm oil.

Mast Contact Information

USAF Cat 980H Rough Terrain Forklift (25K Capacity) Mast Contact is:

Greenfield Products
3920 Greenfield Dr.
Union City, TN 38261
Phone (731) 886-1500
Fax (731) 886-1598
Email (Equipment Information) TMihal@greenfieldpi.com
Email (Parts Orders) parts@greenfieldpi.com