- Wheel Loader:
- 980K (S/N: W7K1-UP)
Introduction
The supplemental product support literature should be used with the appropriate Service Manual and the appropriate Parts Manual that is available for each standard machine. This supplement is used to determine the difference between the custom modifications and a standard machine.
The Service and Parts Manual available for the standard machine should be used if the service information is not in this supplementary product support literature.
358-1557 Axle Oscillation Limiter Block
The group adds oscillation limiter blocks in order to allow the machine to be equipped with chains.
286-3807 Power Train Electronic Control Module
This group provides the software for the parking brake and transmission override systems that are installed on the machine at the factory.
378-6431 Service Brake Gp
This group includes parts for modifications to the parking brake.
372-7797 Cab Guard Gp
The group provides a metallic cab shroud to protect the front and bottom portion of the cab.
379-3644 Heat Protection Ar
A protective wrap for high temperatures is called out for the various hydraulic lines and the electrical lines that are listed below:
- Steering Lines
- Tilt Lines
- Lift Lines
- Ride Control Lines
- Brake Control Lines
- Oil Cooler Lines
- Hydraulic Tank Lines
- Hydraulic Lines for the Main Valve
- Fuel Lines
- Grease Lines
- Power Train Oil Filler
- Power Train Oil Lines
- Diagnostic Lines
- Torque Converter Cooler Lines
379-6438 Steel Mill Guard Ar
This protection is designed to sustain higher temperature than the standard machine. This group includes protection for the following:
- The hitch and steering area
- The power train
- The non-engine end frame
- The tilt cylinders
- The hydraulic service center
379-6437 Electrical Ar
This arrangement provides the electrical components unique to the override systems along with thermal protection.
This group includes the wiring modifications that are required in order to include the override features that are described below. Operating instructions for the override features are included in this document.
Parking Brake Override - The Parking Brake Override allows the operator to release the parking brake from the rear of the machine. An auxiliary parking brake release is also provided in the cab.
Transmission Override - The transmission override bypasses the standard transmission control module. The transmission override provides a secondary means of shifting the machine into first gear forward or first gear reverse within the cab.
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.
373-9582 Configuration Ar (CAB)
This arrangement provides metallic guarding for the cab lights, replacing the standard plastic HVAC cover with a metallic design. The arrangement also replaces the front curved glass with straight rubber mounted glass.
379-6436 Lift Arm and Bearing As
This group provides high temperature bearings at the B-pin location for the Steel Mill application.
379-6435 Fluid and Film Gp
The 379-6435 Fluid and Film Gp consist of a film, tag, and EcoSafe FR-46 hydraulic fluid that is fire resistant and biodegradable. The hydraulic fluid is used in the steering, fan drive, implement system, and brake system.
385-6759 Flood and Signal Lighting Gp
This group provides light guards for the front frame and counterweight.
349-8260 Bucket Pin
This group provides the B-pins for the Steel Mill application.
379-6444 Film Gp
This group provides the Steel Mill machine films.
Operation of the Parking Brake Override
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| Illustration 1 | g02951739 |
Rear view of machine Switch panel (1) Auxiliary engine shutdown switch (2) Override indicator for the parking brake (3) Override for the parking brake | |
Your 980K 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 downward 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 upward in order to enter the test mode. The green indicator should light indicating that the system is working correctly. The switch is a momentary switch, which means the switch will return to the middle position when released. 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. When the switch guard is closed, the override switch must be in the middle position. The switch can be in the override position (down) and closing the cover will allow the switch to remain in the down position. The override switch should be in the middle 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.
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| Illustration 2 | g03466757 |
Override switches inside the cab (4) Transmission override switch (5 and 5A) Auxiliary ignition switch and Auxiliary parking brake release (6) System power switch (7) System power lamp | |
System Power Switch
The system power switch (6) 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 980K Wheel Loader is equipped with an auxiliary ignition switch (5). 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. A buzzer will sound to indicate that the override system is activated. 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 override can be utilized.
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 Parking Brake Release Switch
Your 980K is equipped with an auxiliary parking brake release switch (5A). This switch should only be activated if the standard release switch does not function.
Switch for the Transmission Override
Your 980K Wheel Loader comes with a switch (4) 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 momentary switch for the transmission override should be in the center neutral position.
Note: If use of the steering system is required while in override mode, power the override switch panel and place the standard ignition in Key-on 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.
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.
Steel Mill Electrical Test
Note: If the test fails any of the following procedures, perform the entire test again after the problem is repaired.
Cab Overrides (Pretest conditions)
- Machine in NEUTRAL.
- Parking brake engaged.
- Battery disconnect switch ON.
- Ignition switch OFF.
- Auxiliary Power Override switch OFF.
- Green light should be off.
- The 10 Amp fuse should be in terminal 1 of the fuse panel.
Perform Electrical Test
- Ensure that this test is completed in a safe area.
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To prevent personal injury when checks are made while the machine is in operation, make sure only approved personnel are on the machine. Keep other personnel off the machine and in view of the operator. Make sure checks are done in an open area. |
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Personal injury or death can result from sudden machine movement. Sudden movement of the machine can cause injury to persons on or near the machine. To prevent injury or death, make sure that the area around the machine is clear of personnel and obstructions before operating the machine. |
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- Turn the ignition key to the ON position. Do not start the machine.
- Verity the green light is ON. This light indicates power to the override system.
- Start the machine with the ignition key.
- Verify that the green light is ON.
- Turn the ignition key to the OFF position.
- Verify that the green light is OFF.
- Attempt to start the machine with the override start switch. The machine should not start.
Note: The override power switch is off.
- Turn the override power switch to the ON position.
- Verify that the green light is ON.
- Start the machine with the override ignition start switch. The machine should start.
- Disengage the parking brake.
- Move the transmission override switch to the forward position. The machine should move forward.
- Move the transmission override switch to the reverse position. The machine should move in reverse.
- Engage the parking brake.
- Turn off the machine by turning off the override power switch.
The cab override testing is complete.
Ground Level Override Shutdown Test
- Ensure that the parking brake is applied.
- Start the machine.
- Toggle the standard ground level shutdown switch.
- Verify that the machine has shutdown.
- Close the shutdown switch guard.
Parking Brake Override Test
- The test requires two persons. Ensure that this test is completed in a safe area.
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Personal injury or death can result from sudden machine movement. Sudden movement of the machine can cause injury to persons on or near the machine. To prevent injury or death, make sure that the area around the machine is clear of personnel and obstructions before operating the machine. |
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- Park the machine on a slight incline.
- Position the machine so that the machine is facing down the incline.
- Engage the parking brake.
- Shut down the engine.
- One person should remain in the cab.
- The other person is position behind the machine. This person should toggle the override switch up (test position).
- This person should verify that the green light next to the switch is on.
- Return the switch to the neutral position (momentary switch).
- The person in the cab should pump the brakes until all of the hydraulic fluid has left the main accumulator.
- Stop pumping the brakes, when the parking brake level feels spongy and the machine does not roll when attempting to disengage the parking brake.
- The person behind the machine should flip the parking brake override switch down to release the parking brake.
- Verify that the parking brake has released, the machine should start rolling.
- Immediately return the parking brake override switch to the neutral position. The parking brake will engage. The machine should stop rolling.
EcoSafe FR-46 Fire Resistance Hydraulic Fluid 168-8249 Hydraulic Oil
Use EcoSafe FR-46 hydraulic fluid in the steering, fan drive, implement system, and brake system.
The EcoSafe FR-46 is a fully synthetic, non-aqueous hydraulic fluid. The fluid has excellent low temperature properties and is resistant to oxidating and thermal degradation. Additions features include:
- non-sludge and varnish forming
- high viscosity index
- low pour point
- excellent heat transfer
- complete compatibility with commonly used seals, hoses, and metals
| Physical Properties of EcoSafe FR-46 | |
| Viscosity at 38° C (100° F) Viscosity at 98° C (210° F) |
230 53.3 |
| Viscosity Index | 185 |
| Pour Point | −48° C (−55° F) |
| Flash Point | 273° C (525° F) |