Custom Product Support Literature for the 303-4178 Steel Mill Ar for the 972H Wheel Loaders{0374, 7000} Caterpillar

Wheel Loader:

972H (S/N: LCC1-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.

303-4178 Steel Mill Ar

The 972H Wheel Loaders with the Steel Mill application 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.

176-2444 Axle Oscillation Limiter Block

This group adds axle oscillation limiter blocks in order to allow the machine to be equipped with chains.

362-1143 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.

242-6035 Cab Guard Gp

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.

373-7798 Cab Arrangement

The Cab Arrangement provides the following features:

• A rollover protection structure with sealed mounted windows and a metal roof

• A wiper group with motors that provide clearance to the window seals

• A window group that provides infrared windows

323-9130 Side Panel Gp

This group provides steel side panels that provide higher resistance to heat and slag than the standard plastic side panels.

374-2008 Lift Arm As

This group provides high temperature bearings at the B-pin location for the Steel Mill application.

349-8261 Pin and Bushing Gp

This group contains B-pin assemblies.

231-6181 Oil Filter Gp

This group provides a high efficiency power train oil filter.

375-5748 Support As

This support assembly improves clearance with the guard group hitch.

306-5435 Heat Insulation Ar

This group provides a protective wrap for high temperatures for the various hydraulic lines and the electrical lines that are listed below:

• Steering Lines (CCS)

• Tilt Lines

• Lift Lines

• Ride Control Lines (If Equipped)

• Hydraulic Lines for the Main Valve

• Front Wiring Harness

• Power train Oil Filler

• Lines for Manually Lowering the Lift Arm

• Parking Brake Cable and hydraulic lines

• Oil cooler lines

380-7698 Electrical Ar

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.

Transmission Override - The transmission override bypasses 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.

303-4694 Flood and Signal Lighting Ar

The Flood and Signal Lighting Ar provides protection for the front Lamp Assemblies.

303-4695 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 area

• The power train

• The non-engine end frame

• The battery box

• The Hydraulic Service Center

303-4700 Fender Gp

The Fender Group provides steel front fenders.

303-4705 Ladder Gp

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.

303-4706 Brake Control Conversion Ar

This group includes the modifications to the parking brake in order to allow the override features that are described below. Operating instructions for these overrides are included in this document.

305-4128 Lift Cylinder Gp

This group provides Tilt cylinders that are specific for the Steel Mill application which permits usage of chains on the front tires.

306-5386 Mounting Hardware Gp

This group adds the required hardware to the frame for installation of additional guards.

306-5435 Heat Insulation Gp

Insulation below the batteries and the parking brake accumulator reduce the heat transfer.

286-3807 Power Train Electronic Control Module

This group provides the software for the override features that are described below.

303-4699 Service Brake Control Ar

This group includes modifications to the parking brake in order to allow the override features that are described below. Operating instructions for the overrides are included in this manual.

• 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.

Operation of the Parking Brake Override

Illustration 1	g01459659
Rear view of machine (A) Override switch for the parking brake and auxiliary engine shutdown switch

Illustration 2	g01459672
Switch panel (B) Override for the parking brake (C) Auxiliary engine shutdown switch (D) Override indicator for the parking brake

Your 972H 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. 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 3	g01239200
Top view of cab (E) Override switches

Illustration 4	g01239199
Override switches (F) Switch for the transmission override (G) Auxiliary ignition switch (H) System power switch

System Power Switch

The system power switch (H) 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 972H Wheel Loader is equipped with an auxiliary ignition switch (G). 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 (F) .

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 972H Wheel Loader comes with a switch (F) 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.

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 5	g01324590
View of instrument panel (J) Warning light for the transmission override (K) Warning light for the parking brake override

An illuminated Warning light (J) indicates that the transmission override has lost power from the power supply. Service the machine as soon as possible.

An illuminated Indicator light (K) indicates that the parking brake override has lost power from the power supply. Remove the machine from the heat until the light turns off. The indicator will also light when the parking brake is engaged.

2Q-8381 Ecosafe Hydraulic Arrangement

The 2Q-8381 Ecosafe Hydraulic Arrangement converts the hydraulic system fluid to a water/glycol solution that is fire resistance.

Note: The hydraulic system requires thorough flushing before installation of the fire resistance 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 preventive maintenance practice is encouraged. A fluid particle count can be determined by your designated outside laboratory.

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).

Show/hide table

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