Custom Product Support Literature for the 980H Wheel Loaders that are equipped with 284-2174 Steel Mill Arrangement {7000} Caterpillar


Custom Product Support Literature for the 980H Wheel Loaders that are equipped with 284-2174 Steel Mill Arrangement {7000}

Usage:

980H MHG
Wheel Loader:
980H (S/N: MHG1-UP)

Introduction

This supplemental product support literature should be used with the appropriate service manual and the appropriate parts manual that is available for this machine. This supplement shows the custom modifications that have been made to the standard machine configuration.

The service manual and the parts manual that is available for the standard machine should be used if the service information is not in this supplementary product support literature.

284-2174 Steel Mill Arrangment

The 980H Wheel Loaders with the Steel Mill Arrangment are designed to reduce the effects of the heat of handling hot slag. Caterpillar wants the customer and the end user to be aware that this arrangement does not make the machine fireproof!

The part numbers that are listed below are assemblies and groups within the top level steel mill arrangements.

222-1738 Brake Accumulator Group

The brake accumulator is a 3.79 L (231.28 in3) hydraulic brake accumulator with piston seals that have a higher temperature rating.

Note: Contact your dealer for service repair. Replacement accumulators should consist of the high temperature piston seals.

303-4010 Brake Control Conversion Arrangment

This arrangement provides new bearings in order to avoid the lever from locking in the brake control group.

153-7786 Loader Frame Guard

The guards for the Loader frame provide added protection for the main valve and for the lift lines.

189-7109 Steering Shaft

Standard steering shaft assembly is replaced by a steering shaft that consists of a steel cover. This steel cover provides higher resistance to heat and slag than the standard plastic cover for the steering shaft.

189-8281 Insulator

Heat insulation between the batteries and the battery box. This insulation helps to reduce the heat transfer from the steel battery box to the batteries.

233-9688 Transmission Arrangement (Heavy-Duty)

The heavy-duty transmission utilizes 432 mm (17 inch) planetary drives for all of the gears. This transmission arrangement is beneficial for extreme operating conditions that include heavy loads and many directional changes.

240-8591 Fuel Tank and Hydraulic Tank Guard

This group provides sheet metal guards for the fuel tank, the hydraulic tank, the brake accumulators, and the hydraulic oil filter. These guards provide protection from the slag and these guards also act as deflectors from the radiant heat.

242-6035 Cab Guard Group

This shroud assembly provides protection in the lower front portion of the cab. Both the brake lines and the steering lines are guarded from the hot slag. This shroud also acts as a deflector from the radiant heat.

247-3027 Transmission Support

This group provides added support for the transmission, which is beneficial for applications that include a high number of directional changes.

249-2679 Tilt Cylinder Guard Group

The tilt cylinder guard is a sheet metal guard above the tilt cylinder that provides protection from falling slag.

289-8295 Step Group

This group replaces the rear standard rubber supports for the steps with steel cable supports. The steps provide longer life in a high temperature environment.

265-6753 Enclosed ROPS Cab Arrangment

This arrangement includes rubber mounted glass for quick replacement.

284-8613 Lines Guard Group

This group provides steel guards for the main implement valves and for the steering cylinders. A protective wrap for high temperatures is also called out for the various hydraulic lines and the electrical lines that are listed below:

  • Steering Lines

  • Tilt Lines

  • Ride Control Lines (If Equipped)

  • Hydraulic Tank Lines

  • Hydraulic Lines for the Main Valve

  • Fuel Lines

  • Power train Oil Filler

  • Lines for Manually Lowering the Lift Arrangement

  • Parking Brake Cable

201-8253 Lift Cylinder Lines Gp

This lift cylinder lines Gp provides protection for the lift cylinder lines.

298-6395 Protection Wiring Group

This protection wiring group provides protection for the front wiring harness .

293-3793 Flood Lighting Arrangement

This flood lighting arrangement provides protection for the lighting group.

290-0018 Window Group

This window group provides heat resistant glass for the cab.

269-9086 Window Wiper Guard Group

This window wiper guard group provides protection from heat for the window wipers.

273-5629 Override Control Group

Multiple overrides can be found in this group. These systems are designed to provide the operator with alternate controls in an emergency situation.

  • Parking Brake Override The Parking Brake Override allows the operator to release the parking brake from the rear of the machine.

  • Transmission Override The Transmission Override allows the operator to bypass the standard transmission control module. The Transmission Override also allows the operator to shift the machine into first gear forward or first gear reverse.

  • Auxiliary Ignition The Auxiliary Ignition provides the operator with the option of bypassing the standard ignition switch.

Note: These overrides cannot possibly address every failure mode. The overrides simply give the operator an alternative option.

Operating instructions for these overrides are included in this document.

282-1794 Signal Lighting Group

This group mounts the front flood lamps and signals closer into the frame which is beneficial for operating the machine in narrow places.

283-2173 Rear Frame Hardware Group

Blocks are added to the frame in order to support the heavy-duty transmission mounts.

301-2932 Front Fender Group

These narrow steel fenders replace the standard fenders. All rubber components that could deteriorate with high temperatures are removed.

284-2176 Loader Frame Group

This group adds the weld studs for the Guard group to the loader frame.

286-3807 Power Train Electronic Control Module

This is software for the Control module that is used on the Steel Mill Arrangment.

Operation of the Parking Brake Override




Illustration 1g01459659

Rear view of machine

(A) Override switch for the parking brake and auxiliary engine shutdown switch




Illustration 2g01459672

Switch panel

(B) Override for the parking brake

(C) Auxiliary engine shutdown switch

(D) Override indicator for the parking brake

Your 980H Wheel Loader comes with a parking brake system that is activated by a spring and released hydraulically. If the machine stalls the switch for the parking brake release can be activated so the machine can be towed. The switch for the parking brake release is located in the rear grill of the machine. In order to access the switch, flip up the switch guard. Move the switch upward in order to release the parking brake. An auxiliary accumulator stores hydraulic pressure which releases the parking brake when the switch is activated.

The parking brake override also has a test mode. Move the switch downward in order to enter the test mode. The green indicator should light indicating that the system is working correctly. Test the parking brake override daily. If the green indicator lamp does not light, contact your local dealer for service. The machine should not be put back into operation until this issue is resolved. When the test is completed, make sure that the toggle switch is put back into the center position. Make sure that the guard for the switch is closed in order to protect the switch.

Note: Make sure that the parking brake override is not activated when you park the machine. Close the switch guard in order to deactivate the switch. When the switch guard is closed, the override switch is placed back into the center neutral position. The override switch should be in the center neutral position during normal operation.

Override Switches

The steel mill arrangement includes three override switches that are located in the cab. These switches are located on the right hand side of the cab toward the rear of the machine.




Illustration 3g01460307

Top view of cab

(E) Override switches




Illustration 4g01460327

Override switches

(G) System power switch

(H) Auxiliary ignition switch

(J) Switch for the transmission override

System Power Switch

The system power switch (G) should be activated in the forward position if the override feature is needed and the green indicator is not on. If the green indicator is on, leave the switch in the back position.

Note: If this switch needs to be activated contact your local dealer immediately for service. The machine should not be placed back into operation until the dealer has inspected the machine.

Auxiliary Ignition Switch

Your 980H Wheel Loader is equipped with an auxiliary ignition switch (H). This switch should only be used if the standard ignition switch fails. In order to activate, make sure that the green indicator lamp is on. If the lamp is not on, move the system power switch into the activated forward position. When the indicator lamp is on, the auxiliary ignition switch can be put into the momentary forward position in order to start the machine. Hold the switch forward until the machine starts. Once the machine is started, the transmission can be put into first gear forward, neutral, or first gear reverse by using the override switch (J) .

Note: If this switch needs to be activated, contact your local dealer immediately for service. The machine should not be placed back into operation until the dealer has inspected the machine.

Switch for the Transmission Override

Your 980H Wheel Loader comes with a switch (J) for the transmission override. If the transmission does not shift properly with the standard controls, the transmission override can be used. The switch for the transmission override has three positions :first gear forward (toggle switch in the forward position), neutral (toggle switch in the middle position) and first gear reverse (toggle switch in the back position).

Note: The transmission override should only be used in an emergency situation. During normal operation, the switch for the transmission override should be in the center neutral position.

Note: If this switch needs to be activated, contact your local dealer immediately for service. The machine should not be placed back into operation until the dealer has inspected the machine.

It is important to maintain the machine according to all routine scheduled service. The override functions should be tested on a daily basis. Contact your local dealer for more information.

Override Warning Lights




Illustration 5g01460348

View of instrument panel

(K) Warning light for the parking brake override

(L) Warning light for the transmission override

Warning light (K) will light when there is a problem with the accumulator for the parking brake override.

Warning light (L) will light when there is a problem with the transmission override.

2Q-7734 Glycol Hydraulic Arrangement

The 2Q-7734 Glycol Hydraulic Arrangement converts the hydraulic system fluid to the fire resistant water/glycol solution Ecosafe 68.

Note: The hydraulic system requires thorough flushing before installation of the fire resistant fluid.

Fire Resistance Hydraulic Fluid

Water/glycol solutions from different suppliers will vary in properties. Avoid mixing different brands of fluids. Your fluid supplier can furnish information regarding the necessary tests for proper maintenance.

The hydraulic system should be checked in accordance with the instructions in the Operation and Maintenance Manual.

Water will evaporate during normal operation of the hydraulic system. The fluid should contain a water content of 40 percent. Maximum fire resistance is obtained at this level. The fluid should be tested for water content weekly. Temperatures above 65°C (149°F) will require testing two or three times each week. The water content can be measured easily with a hand-held refractometer. The water content should be measured alternate months at a minimum. Only deionized water or distilled water should be added to the water/glycol solution.

Optimum protection of equipment against rusting and corrosion can be ensured by maintaining the proper level of reserve alkalinity in the solution. The loss of reserve alkalinity can be expected to accompany the loss of water that occurs through evaporation under normal operating conditions. The reserve alkalinity should be measured alternate months, when the sample is sent for water analysis.

A particle count analysis should be performed alternate months. A particle count analysis informs you if the hydraulic system is contaminated. Examples of contamination are dirt, sludge, and other debris. This is a preventive maintenance practice that is strongly encouraged. A fluid particle count can be determined by your designated outside laboratory.


NOTICE

Never mix glycol type fluids with petroleum base oil. If the fluid becomes contaminated with petroleum base products, shut down the machine immediately. Oil contamination mixed with water-glycol will cause a sludge that can plug orifices and filters.


The water/glycol solution should have the following viscosities:

  • The solution should be between 150 Saybolt Universal Seconds to 225 Saybolt Universal Seconds viscosity at 37.8°C (100°F).

  • The solution should be no more than 5000 Saybolt Universal Seconds maximum viscosity at 17.8°C (64°F).

------ WARNING! ------

Accidental machine starting can cause injury or death to personnel working on the machine.

To avoid accidental machine starting, turn the battery disconnect switch to the OFF position and remove the key. If the machine is not equipped with a battery disconnect switch, disconnect the battery cables from the battery and tape the battery clamps.

Place a do not operate tag at the battery disconnect switch location to inform personnel that the machine is being worked on.

----------------------

Weekly Interval (Minimum)

A sample should be drawn from the reservoir. Use a hand-held refractometer in order to measure the water content.

Two Month Interval

A sample should be drawn from the reservoir. Send the sample to a qualified laboratory that is familiar with the chemistry of water/glycol solution. The following information should be collected during testing:

  • Karl Fischer Water Analysis

  • Alkaline Reserve content

  • Fluid particle count

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