Installation Instructions for the 2Q-8720 Machine Performance Gp (Fuel Management System) (Kit) for the 988H{1052, 3101} Caterpillar

Wheel Loader:

988H (S/N: BXY1-1899)

Introduction

The machine performance group (fuel management system) has shown a ten to fifteen percent increase in fuel economy with a minimal loss in productivity. A three-way switch is located on the left hand overhead instrument panel. The operator selects one of the following switch positions for the desired fuel savings:

• Balanced position

• Off

• Maximum Fuel Savings

The machine is then operated as normal. The technology in the machine performance group (fuel management system) makes the operation transparent to the operator.

This publication contains the information for installation of the 2Q-8720 Machine Performance Gp (Fuel Management System) (Kit). This supplemental product support literature should be used with the appropriate Service Manual and the appropriate Parts Manual that is available for this standard machine.

Do not perform any procedure and do not order parts that are outlined in this publication until you understand the information that is contained in this document.

Note: In order to avoid electrical shock or personal injury, make sure that the key is in the off position before working on the electrical system.

Note: Cleanliness is an important factor. Before the removal of any component, the exterior of the component should be thoroughly cleaned. This will help to prevent dirt and moisture from contaminating the electrical wires and ECM.

Parts Identification

Illustration 1	g01383000
Parts for the 2Q-8720 Machine Performance Gp (Fuel Management System) (Kit)

Installation of the Harnesses in the Electronics Bay

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Illustration 2	g01342189
Outside view of the ECM that is closest to the cab (A) Cover (B) Cover (C) Cover

1. Remove the covers for the electronics bay (A), (B) and (C) .

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Illustration 3	g01342206
View of inside electronics bay (E) Connector "J2" (F) Connector "J1" (G) Ground stud

2. Connect the black wire that is marked "A272" of the 305-4209 Harness Assembly (Electronics Bay) (1) onto the ground stud that is in the electronics bay.

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Illustration 4	g01342219
End view of connector (E) and connector (F)

3. Remove plug (H) from connector (E). Install the purple wire that is marked "F846" of the 305-4209 Harness Assembly (Electronics Bay) (1) onto the socket that is marked "28".

4. Remove plug (J) from connector (F). Install the yellow wire that is marked "K884" of the 305-4209 Harness Assembly (Electronics Bay) (1) onto the socket that is marked "22".

5. Remove plug (K) from connector (F). Install the purple wire that is marked "K885" of the 305-4209 Harness Assembly (Electronics Bay) (1) onto the socket that is marked "21".

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Illustration 5	g01342248
View of inside electronics bay

6. Route the 305-4209 Harness Assembly (Electronics Bay) (1) from the ECM connectors to the CE connectors. Use 9X-6772 Cable Straps (2) and secure the 305-4209 Harness Assembly (Electronics Bay) (1) .

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Illustration 6	g01365375
View of the CE connector (L) (L) CE connector (M) Socket "32" (N) Socket "31" (P) Socket "33" (R) Socket "34"

7. Install the purple wire that is marked "F846" of the 305-4209 Harness Assembly (Electronics Bay) (1) onto the socket "R" of the CE connector.

8. Install the yellow wire that is marked "K884" of the 305-4209 Harness Assembly (Electronics Bay) (1) Into the socket "P" of the CE connector.

9. Install the purple wire that is marked "K885" of the 305-4209 Harness Assembly (Electronics Bay) (1) into the socket "M" of the CE connector.

10. Connect the black wire that is marked "A272" of the 305-4209 Harness Assembly (Electronics Bay) (1) into the socket "N" of the CE connector.

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Illustration 7	g01342271
View of the electronics bay (A) Cover (C) Cover

11. Replace covers (A) and (C) for the electronics bay .

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Illustration 8	g01342285
View of rear right hand inside of the cab (S) Panel (T) Panel (W) Panel

12. Remove panels (S), (T) and (W) .

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Illustration 9	g01342290
View of ventilation cover

13. Remove two screws (X) on each side of the ventilation cover (Y) and remove the ventilation cover (Y) .

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Illustration 10	g01342613
Overhead instrument panels (Z) Screws (AA) Right hand overhead instrument panel (BB) Left hand overhead instrument panel (CC) Autolube switch

14. Remove six screws (Z) from overhead instrument panels (AA) and (BB). Open each overhead instrument panel in order to expose the wires.

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Illustration 11	g01342632
End view of connector for the autolube switch

15. Refer to Illustration 10. If the machine has the autolube system, Locate the autolube switch (CC) .

16. If the machine does not have the autolube system, locate the connector that would have been used for the autolube. Use the wire numbers and locations in Table 2 in order to identify the connector.
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    Table 2

    Connector for the Autolube Switch
    Color and Gauge	WIRE NAME	POS	Terminal
    		1
    WH-18	164-U141	2	3E-7790
    YL-18	L919-U313	3	3E-7790
    		4
    		5
    		6
    PU-18	614-U262	A	065-5071
    PU-18	614-U269	A	065-5071
    BK-18	200-U213	B	065-5071
    BK-18	200-U7	B	065-5071
    		C
    		D
    ACCESSORY TABLE
    QTY	PART NAME	PART NUMBER
    1	Plug or Connector	3E-7996

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Illustration 12	g01342651
View of the back side of the left hand overhead instrument panel with the 293-9130 Rocker switch assembly (3) (DD) Connector for the autolube switch

17. Remove the plug from the third slot in the Left hand overhead instrument panel. Install the 293-9130 Rocker switch assembly (3) into the third slot.

18. Connect the 305-4210 Harness to the 293-9130 Rocker switch assembly (3) .

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Illustration 13	g01342665
Connector for the autolube switch (EE) Pin "2" (FF) Pin "A"

19. Remove the white "164" wire from pin location (EE) of the connector for the autolube switch. Remove the purple "614" wires from pin location (FF) of the connector for the autolube switch.

20. Remove the terminals from all three of the wires. Strip wires and crimp a 8T-8730 Connector Socket onto each wire.

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Illustration 14	g01342809
End view of the 155-2267 Connector Plug As (GG) Socket location "A" (HH) Socket location "B" (JJ) Socket location "C"

21. Install the white wire number "164" that has the new 8T-8730 Connector Socket into socket (JJ) of the 155-2267 Connector Plug As .

22. Install the two purple wires that are numbered "614" that have the new 8T-8730 Connector Socket into socket locations (GG) and (HH) of the 155-2267 Connector Plug As .

23. Install the 155-2276 Plug Lock Wedge into the 155-2267 Connector Plug As in order to secure the sockets.

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Illustration 15	g01342816
View of the 2Q-8720 Machine Performance Gp (Fuel Management System) switch and wiring

24. Connect the 155-2267 Connector Plug As (4) with the 305-4210 Harness (2) .

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Illustration 16	g01342837
View of the autolube switch and wiring (LL) White wire number "164" (KK) Purple wires numbered "614". (MM) Connector for the switch for the autolube system (NN) Blade terminal "A" on the connector for the autolube switch (PP) Blade terminal "2" on the connector for the autolube switch

25. Connect the two purple wires that are numbered "614" (KK) onto blade terminal (NN) on connector (MM) .

26. Connect the white wire number "164" (LL) onto the blade terminal (PP) on the connector for the autolube switch (MM) .

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Illustration 17	g01342871

27. Route the 305-4210 Harness (2) around the headliner to the right hand post. Secure the 305-4210 Harness (2) to the existing harness with 9X-6772 Cable Strap . (7). Route the 305-4210 Harness (2) down the right hand post. Secure the 305-4210 Harness (2) with 9X-6772 Cable Straps . (7) .

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Illustration 18	g01342889
View of the bottom of the right hand post and under the right hand post

28. Pass the 305-4210 Harness (2) through the cab floor.

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Illustration 19	g01342930
View of the CE connectors in the electronics bay (RR) CE connector

29. Route the 305-4210 Harness (2) along the existing cab harness to the electronics bay. Secure the 305-4210 Harness (2) to the existing harness with 9X-6772 Cable Straps . (7) .

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Illustration 20	g01342939
View of the CE connectors in the electronics bay (RR) CE connector

30. Identify CE connector (RR) and remove the endbell.

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Illustration 21	g01342947
View of CE connector and 305-4210 Harness

31. Pass the four wires of the 305-4210 Harness through the endbell of the CE connector. Disconnect the CE connector for easier access.

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Illustration 22	g01365403
View of pin locations for the CE connector (SS) Pin location "31" (TT) Pin location "32" (WW) Pin location "34" (XX) Pin location "33"

32. Remove the plugs from the following locations on the CE connector:
    • (SS)

    • (TT)

    • (WW)

    • (XX)

33. Insert the black wire number "A272" of the 305-4210 Harness into the CE connector in location (SS) .

34. Insert the purple wire number "K885" from the 305-4210 Harness into the CE connector at location (TT) .

35. Insert the purple wire number "F846" from the 305-4210 Harness into the CE connector at location (WW) .

36. Insert the yellow wire number "K884" from the 305-4210 Harness into the CE connector at location (XX) .

37. Reinstall all panels.

Flash Software

Note: Updating of the ET to the latest version is highly recommended. It is possible to install the fuel management system without the update. However, several unnecessary errors will appear. Allow an hour for The following processes: software installation and calibration.

Note: After the software is installed, the reduced rimpull switch will be disabled. The rimpull will be controlled by the dial for the rimpull only.

Note: Use the configuration screen to check the installation status of the axle oil cooler, before flashing the software.

1. Refer to Testing and Adjusting, RENR6218 and flash the following software.

   Note: An error message about software will appear. Hit "OK" whenever this happens. ET should allow the software to flash. If ET does not allow the software to flash, you must update ET to the latest version:.

   • 313-3626 Engine Ratings Electronic Software Gp

   • 315-0537 Implement Software Gp

   • 321-7263 Power train Software Gp

Calibrate

After flashing the software, several service codes will appear. In order to clear the codes, several sensors, valves, clutches and solenoids will need to be calibrated. All the calibrations can be run through the ET service tool. One service code will appear regarding the solenoid for the fan bypass for the axle oil cooler. To clear this code, the bypass solenoid for the axle oil cooler needs reconfiguration. It is impossible to clear this code without changing the configuration. .

To change the configuration, click on the "Configuration" button: Click on "Operator Settings" under the Implement ECM. Double click on "Axle Oil Cooler Fan Bypass Solenoid Installation Status". If the axle oil cooler is on the machine, change the setting to "Installed". If the axle oil cooler is NOT on the machine, change the setting to "Uninstalled". Refer to Illustration 23.

Illustration 23	g01444936

To turn on the Fuel Management System, click on "Machine Settings" under the Transmission ECM in the "Configuration" screen. Double click on "Economy Mode" and change the setting to "Installed". You will need to enter factory passwords. Get the passwords by clicking on the link at the bottom of the screen "https://fps.cat.com". There is a cost per machine, that is associated with the software.

On the "Configuration" screen, notice the delay time that is set for the idle auto kickdown. If the machine sits at high idle for 30 seconds, the machine will kick off throttle lock and the engine will return to low idle. If the machine sits at high idle for 30 seconds, the machine will kick off throttle lock and the engine will return to low idle.

The time delay for the auto kickdown can be configured with the ET service tool. The default time is 30 seconds.

Test

After flashing the software and running the calibrations, three functions should be tested:

Illustration 24	g01343692
View of the switch for the 2Q-8720 Machine Performance Gp (Fuel Management System) (A) 1800 RPM (B) OFF (C) 1700 RPM

1. Test the light: Turn the switch to position A or position C. The green light should illuminate. If the green light does not light, confirm that the switch has been properly installed and that the Machine Performance Gp fuel management system has been properly configured.

2. Test the functionality: Turn on the machine. Move the switch to position A and press the throttle lock button. Confirm that throttle lock is turned on. Engine speed should lock at about 1800 RPM. Move the switch to position C and press the throttle lock button. Confirm that throttle lock is turned on. Engine speed should lock at about 1700 RPM.