328-3305 Machine Ar (Underground Mine){7000} Caterpillar

Wheel Loader:

980H (S/N: MHG1-UP)

Introduction

This machine is equipped with an engine shutdown system that monitors eight main machine parameters. If one of these parameters is incorrect, the system will automatically activate a warning (light and sound). After a delay, the engine shutdown system will derate the engine. After another delay, the engine shutdown system may stop the engine. The engine might be restarted twice in order to move the machine into a secured area. The machine will stop again if the problem remains. The alert indicators for the engine shutdown are located on the controller. The controller is located just under the Caterpillar monitoring system panel .

Warning Indicators for the Engine Shutdown System

Location of the Alert Indicators for the Engine Shutdown System

Illustration 1	g01160628

(A) Caterpillar monitoring system

(B) Controller for the engine shutdown system

Illustration 2	g01929634

(1) Transmission oil level

(2) Torque converter temperature

(3) Engine coolant flow

(4) Engine coolant level

(5) Engine coolant temperature

(6) Engine oil level

(7) Engine oil pressure

(8) Hydraulic oil temperature

(9) Hydraulic oil level

(10) The Starter and the engine are now disabled after the third restart attempt.

The Engine Shutdown System Controlled Parameters

Table 1

Function	Parameters
Transmission oil level	Warning	Derate	Engine shutdown
Torque converter temperature	Warning	Derate
Engine coolant flow	Warning	Derate	Engine shutdown
Engine coolant level	Warning	Derate	Engine shutdown
Engine coolant temperature	Warning	Derate	Engine shutdown
Engine oil level	Warning	Derate	Engine shutdown
Engine oil pressure	Warning	Derate	Engine shutdown
Hydraulic oil temperature	Warning
Hydraulic oil level	Warning

Functions

Alert operator - Engine operation will not be altered if abnormal conditions are detected. The indicator that corresponds to the abnormal condition will be flashing red and the alarm will beep at two times the rate of the alarm of the Electronic Monitoring System (EMS III). This configuration is the default. An event will be logged with warning level 1 for the respective warnings.

Alert operator and derate - The indicator that corresponds to the abnormal condition will be flashing red and the action alarm (horn) will beep immediately. The engine controller will cause the engine to be derated by 25%. This deration will exist while the abnormal condition exists. A 25% deration of torque reduces engine speed to 1950 rpm. An event will be logged with warning level 2 for the respective derates.

Alert operator, Derate and Shutdown - The indicator that corresponds to the abnormal condition will be flashing red and the action alarm (horn) will beep. The engine controller will cause the engine to be derated by 25%. This deration will exist while the abnormal condition exists or until a shutdown occurs. A 25% deration of torque reduces engine speed to 1950 rpm. After some specified time, the engine control will be commanded to shut down the engine. The shutdown will remain until the engine control has been cycled. An event will be logged with warning level 3 for the respective warnings. After a shutdown, the machine can be started twice. In order to start the engine again, connect a service tool to the EMS III. If the problem has been corrected the machine will continue working normally. If the problem still exists, the machine will go through the shutdown again. After a shutdown, the machine can be restarted twice. The starter will be disabled after the third attempt to start without success.

• Adding support will inhibit the crank from turning after the shutdown command has been sent from the module of the EMS III. Once the message for a shutdown is transmitted from the EMS III, the secondary starter will be disabled until a cycle of the key occurs.

• Once three shutdowns have occurred, the starter will be disabled until the number is reset manually, through the use of the clicker box. The number of shutdowns are broadcast from the module of the EMS III at the initialization. The number of shutdowns is broadcast to the module of the transmission in order to determine the operation of the starter at initialization.

Additions and Changes to the 980H Operation and Maintenance Manual

Do Not Weld on the ROPS

The cab has "FOPS" certification.

Model Views

Illustration 3	g01948576
Left side view of machine (A) Bucket (B) Fuel tank (C) Engine (DDDD) Air Cleaner Group

Illustration 4	g01948485
Right side view of machine (D) Battery (E) Radiator (F) Operator's compartment (G) Hydraulic tank (H) Transmission

Table 2

980H Wheel Loader with Underground Mining Arrangement
Approximate weight	33000 kg
Maximum length	10277 mm
Width across tires	3000 mm
Height to top of FOPS	3111 mm
Counterweight	3110.5 kg

Illustration 5	g01830795
Right side view of machine (J) 3111 mm (122.48 inch) (K) 2923 mm (115.08 inch) (L) 2511 mm (98.86 inch) (M) 2744 mm (108.03 inch) (N) 740 mm (29.13 inch) (P) 3700 mm (145.67 inch) (R) 357 mm (14.06 inch) (T) 3834 mm (150.94 inch) (U) 2700 mm (106.30 inch) (V) 3492 mm (137.48 inch)

Operator Controls

Illustration 6	g01830796
Operator controls (W) Governor control (X) Steering column tilt control (Y) Transmission control (Z) Horn (AA) Steering control (BB) Lift control (CC) Tilt control (DD) Seat (EE) Steering column telescope control (FF) Transmission control and service (GG) Service brake control

Fuse Panel

Illustration 7	g01930153

Instrument Panels

Illustration 8	g01948489
(HH) Indicators (JJ) Engine start switch (KK) Diagnostic connector (LL) Hazard lamp (MM) Parking brake control (NN) 12 volt power receptacle (PP) Indicators (RR) CMS display (TT) CMS display

Illustration 9	g01948493
(VV) Kickout and positioner control (WW) Transmission neutralizer override switch (XX) Autoshift (YY) Window wiper (ZZ) Light switches (AAA) Lateral light switches (BBB) Lamp (CCC) CMS display (DDD) Heating and air conditioning controls (EEE) "MIS" connector (FFF) CMS Warning categories

Implement Controls

Illustration 10	g01948507
(GGG) Tilt control (HHH) Lift control (JJJ) Horn (KKK) Ashtray (LLL) 12 V Lighter (MMM) Safety Valve

Battery Disconnect Switch

Illustration 11	g01171566
Battery disconnect switch in the OFF position

Illustration 12	g01171567
Battery disconnect switch in the ON position

Diagnostic Codes for CMS

Illustration 13	g01948509
(NNN) Switch (PPP) Display

Control for the Window Wiper and the Window Washer

Illustration 14	g01948514
(RRR) Front window wiper/washer switch

Note: There is no rear wiper with the underground mining arrangement.

Directional Turn Signal and Hazard Flasher Control

Illustration 15	g01830802
View of turn signal and hazard flasher control (TTT) Directional turn signal (UUU) Hazard switch

1. Push on the left hand side of switch (TTT) in order to activate the left turn signal. Push on the right hand side of switch (TTT) in order to activate the right turn signal.

Heating and Air Conditioning Control

Illustration 16	g01948517
(VVV) Temperature control (WWW) Heating and air conditioning switch (XXX) Fan speed control

• "O" Stop

• "I" Low speed

• "II" Medium speed

• "III" High speed

• "IIII" Very high speed.

Seat

Illustration 17	g01830804
(YYY) Backrest (ZZZ) Seat backrest angle adjustment (AAAA) Fore and aft adjustment (BBBB) Angle adjustment for the armrest (CCCC) Adjustment for seat height

• Lift up backrest (YYY) in order to remove the back extension.

• Pull adjustment (ZZZ) in order to adjust the angle of the backrest.

• Pull fore and aft adjustment (AAAA) in order to adjust the Fore and aft position of seat.

• Rotate the knob (BBBB) in order to adjust the angle of the armrest.

• Use adjustment for seat height (CCCC) in order to adjust seat height.

Hydraulic Control Support

Illustration 18	g01948523
(1) Control lever

• Use control lever (1) in order to adjust the height of the armrest.

Alternate Exit

Illustration 19	g01948527
(2) Ring

1. Pull out the string of the seal by using the ring (2) that is located on the right of the cab. This will unlock the window in the seal.

2. Push the window out of the cab.

Parking Brake Control

Illustration 20	g01948533
(3) Parking brake control knob

Transmission Neutralizer Override Switch

Illustration 21	g01948536
(4) Transmission neutralizer override switch

Autoshift Control

Illustration 22	g01948542
Autoshift control switch

Ride Control

Illustration 23	g01948546
Autoshift control switch (5) Ride control switch

Note: A connector for the ride control is available on the harness inside the switch panel. If the customer wants this function, the customer will need to order the correct switch. The customer will need to place the switch in the unused slot.

Lift Control

Illustration 24	g01948550
Lift control lever (6) The lift control lever has no fine modulation for the 980H with the underground mining arrangement.

Tilt Control

Illustration 25	g01948552
Tilt control lever (7) The tilt control lever has no fine modulation for the 980H with the underground mining arrangement.

Kickout and Positioner Control

Illustration 26	g01948553
Kickout and positioned control switch (8) Control switch for the kickout and positioner

Hood

Note: The hood does not tilt on the 980H with the underground mining arrangement.

Service the Cab Air Filter

Illustration 27	g01948558
Cab air filter (9) Bolts (10) Filter

1. Remove the two bolts (9) and remove the filter cover that is on the right side of the seat.

2. Remove the filter element (10) .

3. Clean the filter element with air pressure or wash the filter element in warm water with a nonsudsing household detergent.

4. If water and detergent are used in order to clean the filter element, rinse the filter element in clean water and allow the filter element to air dry thoroughly.

5. Inspect and replace the filter if the filter is damaged.

6. Reinstall the filter element.

7. Reinstall the filter cover.

Circuit Breaker Reset

Illustration 28	g01910816
Circuit breakers

Circuit Breaker Reset - Depress the button in order to reset the circuit breakers. If the circuit is functioning properly, the button will remain depressed. If the button will not remain depressed, check the appropriate electrical circuit.

The circuit breakers are located in the engine compartment on the left side of the machine.

Engine Shutdown (11) - 50 amp

Electrical Circuits in Cab (12) - 20 amp

Main Circuit (14) - 80 amp

Alternator (15) - 105 amp

Illustration 29	g01810673

Two circuit breakers are also located in the cab behind the operator seat. These breakers are both 15 amperes.

Pressure Taps

Illustration 30	g01910898
Access cover for the pressure taps

Illustration 31	g01910934
Pressure Taps

Hydraulic Tank

Illustration 32	g01910966

Right Hand bottom access to the hydraulic tank drain

Cooling Tank

Illustration 33	g01911373

Access to the shunt tank is located at the rear of the machine on the top left hand side.

Guard Groups

Illustration 34	g01911294
Guard Group for the Fuel Tank

Illustration 35	g01911335
Guard Group for the Loader Frame

Replace the Biodegradable Hydraulic Oil Filter Element

Illustration 36	g01910819
(16) Bolts (17) Cover

1. Remove the four bolts (16) .

2. Remove the cover (17) in order to gain access to the oil filter element.

Replace the Transmission Oil Filter

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NOTICE
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates.

1. Open the engine hood. The transmission oil filter is located on the right side of the machine.

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Illustration 37	g01811997

2. Remove the plug (19) and allow the oil to drain into a suitable container.

3. Use a strap type wrench in order to remove the transmission filter housing (18) .

4. Remove the used transmission oil filter element. Dispose of the used filter element properly.

5. Clean the transmission filter housing in a clean, nonflammable solvent. Clean the filter housing base.

6. Inspect the filter housing seal. Replace the seal if the seal is damaged.

7. Insert a new transmission oil filter element into the transmission filter housing.

8. Install the transmission filter housing into the filter housing base. Tighten the transmission filter housing by hand. Install plug (19) .

9. Start the engine. Apply the service brakes.

10. Slowly operate the transmission controls in order to circulate the transmission oil. Return the transmission to NEUTRAL.

11. Engage the parking brake. Inspect the transmission oil filter for leaks.

12. Stop the engine.

13. Check the transmission oil level.

    ReferenceRefer to Operation and Maintenance Manual, "Transmission Oil Level - Check" for the correct procedure.

Lubrication of the Drive Shaft

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NOTICE
To prevent damage to the seal, fully articulate the machine to the right or to the left, before lubricating the spline.

Illustration 38	g01910878

Wipe all fittings before applying lubricant. Apply lubricant through one fitting on the drive shaft spline.