Supplemental Service Information for the U.S. Navy 980H Rough Terrain Forklift {0374, 6405, 6700, 7000} Caterpillar


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Supplemental Service Information for the U.S. Navy 980H Rough Terrain Forklift {0374, 6405, 6700, 7000} [REHS8257]
WORK TOOLS
FORK GP
1.1. Introduction
2.1. Operation Section
3.2. Operator Controls
4.2. Auxiliary Control (39)
5.3. Fork Positioning Control
6.3. Fork Carriage Sideshift Control
7.2. Tilt Control (40)
8.2. Lift Control (41)
9.2. Fine Modulation (42)
10.1. Control Gp-Lines and Mast
11.2. Installation Procedure
12.1. Lubrication
13.2. Mast Lubrication Points
14.1. Hydraulic Schematic
15.2. 980H Hydraulic Schematic
16.1. Test and Adjust Information
17.2. Flash File
18.2. Pump Flow
19.2. Cycle Time-Mast
20.1. Mast Contact Information
21.1. Top Handler Contact Information
Wheel Loader
980H (S/N: PF81-UP)

Introduction

Table 1
Revision History 
Revision  Summary of Changes 
02  Changes were made to the introduction. 

This Special Instruction contains supplemental information for the U.S. Navy 980H 25K (25,000 lbs) Capacity Rough Terrain Forklift. This special instruction is a supplement to the service manual for your machine.

Operation Section

The operation section is a reference for the new operator and a refresher for the experienced operator. This section includes descriptions of gauges, switches, machine controls, attachment controls, transportation, and towing information.

Operator Controls

Illustrations guide the operator through correct procedures of checking, starting, operating, and stopping the machine. Operating techniques that are outlined in this publication are basic. Skill and techniques develop as the operator gains knowledge of the machine and the capabilities of the machine.



Illustration 1g03415565
(1) Steering control
(2) Horn
(3) Seat
(4) Transmission control
(5) Tilt control for the steering wheel
(6) Service brake controls
(7) Governor control
(8) Telescopic control for the steering wheel
(9) Hydraulic control support


Illustration 2g03409694
(10) Lighter
(11) Light switch
(12) Display module
(13) Parking brake control
(14) Implement function
(15) Beacon switch (if equipped)
(16) Hazard switch
(17) Engine start switch
(18) 12 V power receptacle


Illustration 3g03735022
(18A) Temperature control for the heating and air conditioning
(18B) Heating and air conditioning
(18C) Fan control
(19) Front window wiper/washer switch
(20) HID lights (if equipped)
(21) Autoshift control
(22) Autodig control (if equipped)
(23) Autodig mode select switch (if equipped)
(24) Autodig kickout set switch (if equipped)
(25) Auto reverse fan
(26) Carriage sideshift/fork positioning mode select switch
(27) Lift and tilt kickout switch
(28) Heated mirror (if equipped)
(29) Bucket/fork selector control (if equipped)
(30) Secondary steering (if equipped)
(31) Transmission neutralizer override switch
(32) Ride control (if equipped)
(33) Rear window wiper/washer switch
(34) Low/High beam lights


Illustration 4g03410777
(1) Transmission control (if equipped)
(2) Horn button
(35) Transmission downshift
(36) Autodig trigger switch (if equipped)
(37) Hydraulic lockout
(38) PCS store button (if equipped)
(39) Auxiliary control (if equipped)
(40) Lift control
(41) Tilt control
(42) Fine modulation

Auxiliary Control (39)

If equipped, this lever is used for fork carriage sideshift/fork repositioning.



Illustration 5g03411126
Machines that are not equipped with a joystick

Fork Positioning Control

WIDEN - Move the lever to position 1 in order to widen the fork tine spacing.

HOLD - The lever will return to position 2 when the lever is released from position 1 or from position 3. The fork tine spacing will remain the same.

NARROW - Move the lever to position 3 in order to narrow the fork spacing.

Fork Carriage Sideshift Control

LEFT - Move the lever to position 1 in order to shift the fork carriage to the left.

HOLD - The lever will return to position 2 when the lever is released from position 1 or from position 3. The fork carriage will remain in the selected position.

RIGHT - Move the lever to position 3 in order to shift the fork carriage to the right.

Tilt Control (40)



Illustration 6g03735056
Machines that are not equipped with a joystick

TILT FORWARD (1) - Push the lever forward in order to tilt the forklift forward.

HOLD (2) - When you release the lever, the lever will return the HOLD position. The forklift will remain in the selected position.

TILT BACK (3) - Pull the lever backward in order to tilt the forklift backward.

Lift Control (41)



Illustration 7g03735245
Machines that are not equipped with a joystick

LOWER (1) - Push the lever forward in order to lower the attachment. The lever will return to the HOLD position when the lever is released.

HOLD (2) - The lever will return to the HOLD position when the lever is released from the RAISE position or from the LOWER position. The attachment will remain in the selected position.

RAISE (3) - Pull the lever backward in order to raise the attachment. The lever will return to the HOLD position when the lever is released.

Fine Modulation (42)

Machines may be equipped with a switch for fine modulation. This switch controls the shift speed of the main hydraulic spool. Activating this switch will allow better control in certain applications.

Press the front of the switch in order to enable fine modulation. Press the rear of the switch in order to disable fine modulation.

Control Gp-Lines and Mast

Installation Procedure



    Illustration 8g03720461

  1. Fasten a suitable lifting device to the tilt cylinders (1). Install both tilt cylinders (1) and valve (2).


    Illustration 9g03720462

  2. Install both tilt cylinder lines (3) and (4).


    Illustration 10g03720464

  3. Install hydraulic lines. (5), (6) and (7).


    Illustration 11g03720465

  4. Install hydraulic lines (8) for mast lift cylinders.


    Illustration 12g03720467

  5. Install hose assembly (9) on both sides of the machine.


    Illustration 13g03720468

  6. Install hose assembly (10) onto hydraulic tank (11).


    Illustration 14g03720469

  7. Install wiring gp (12) for the mast on the main control valve (13).


    Illustration 15g03720471

  8. Fasten a suitable lifting device to cover assembly (14). Install cover assembly (14), bolts (15), and washers.

    The weight of cover assembly (14) is approximately 23 kg (50 lb).

  9. Fill the implement hydraulic system. Refer to Operation and Maintenance Manual, "Hydraulic System Oil - Change" for the correct procedure.


    Illustration 16g03720472

  10. Use a suitable lifting device (16) to install mast (17) to the front of the machine.


    Illustration 17g03720473

  11. Position mast (18) in front of the machine. Align tilt cylinder clevis ends (20) to mast tilt mount (19). Align frame mount (22) to mast mounting eyes (21).


    Illustration 18g03720474

  12. Insert two pins (23) into two sleeves (24) of mast.


    Illustration 19g03720476

  13. Use a suitable lifting device to position mast (25) between the front frame hooks (26). The mast pin (23) should rest on the front frame hooks (26).


    Illustration 20g03720477

  14. Use a suitable lifting device (27) to lift the tilt cylinders (1). Align the cylinder rod end (28) close to the cylinder clevis mount hole (29).

  15. Start the engine.


    Illustration 21g03720479

  16. Extend the tilt cylinder rod (28) in order to align the holes (30).

  17. Stop the engine.


    Illustration 22g03720480

  18. Insert pin (31) into tilt cylinder clevis.


    Illustration 23g03720481

  19. Install pin retainer (32) and pin retainer bolts (33).


    Illustration 24g03720482

  20. Install pin retainers (34) on the pin (23) on each side of the hook (26). Use bolts (35) to fasten bar (36) to the pin retainers (34).


    Illustration 25g03720483

  21. Attach hydraulic lines. (37), (38), (39) and (40).


    Illustration 26g03720485

  22. Install NATO plug (41).

Lubrication

Mast Lubrication Points

Wipe off all fittings before any lubricant is applied.



Illustration 27g01194262

Apply lubricant through the remote grease fitting (1).



Illustration 28g01194332

Apply lubricant through fitting (2) on each side of the mast.



Illustration 29g01194342

Apply lubricant through fitting (3) on each tilt cylinder pin.



Illustration 30g01194382

Apply lubricant through fittings (4) located on each side of the mast.



Illustration 31g01194472

Apply lubricant through fitting (5) on the fork carriage assembly.



Illustration 32g01194514

Apply lubricant through fittings (6) on the fork carriage assembly.

Hydraulic Schematic

980H Hydraulic Schematic



Illustration 33g01224836
(1) Tank Gp
(2) Pump Gp-Gear
(3) Pump Gp-Gear
(4) Pump Gp-Gear
(5) Pump Gp-Gear
(6) Motor Gp-Piston
(7) Pump Gp-Piston
(8) Valve Gp-Mounting
(9) Strainer
(10) Core As.-Oil Cooler
(11) Valve Gp-Check
(12) Filter Gp
(13) Pump Gp-Piston
(14) Valve Gp-Pilot
(15) Valve Gp.-Steering
(16) Valve Gp-Pressure Reducing
(17) Valve Gp-Shuttle
(18) Valve Gp-Relief
(19) Valve Gp-Relief
(20) Valve Gp-Check
(21) Valve Gp-Check
(22) Valve Gp-Check
(23) Screen Gp
(24) Valve Gp-Neutralizer
(25) Cylinder Gp
(26) Valve Gp-Control
(27) Valve Gp-Relief
(28) Valve Gp-Relief
(29) Valve Gp-Relief
(30) Choke
(31) Valve Gp-Relief
(32) Cylinder Gp
(33) Valve Gp
(34) Strainer
(35) Connector
(36) Connector
(37) Valve Gp-Pilot
(38) Valve Gp-Sequence
(39) Valve Gp-Solenoid
(40) Valve Gp-Pressure Reducing
(41) Valve Gp-Pressure Reducing
(42) Valve Gp-Solenoid
(43) Valve Gp-Shuttle
(44) Valve Gp-Diverter
(45) Valve Gp-Pressure Reducing
(46) Valve Gp-Relief
(47) Mast Ar. Lift

Test and Adjust Information

Flash File

The 980H 25K Rough Terrain Forklift requires 465-6572 Implement Software Gp.

Pump Flow

At high idle with an implement system pressure of 20700 kPa (3000 psi), the pump flow for the 980H 25K Rough Terrain Forklift is 116 cc/rev or 292 L/min (77 US gpm).

Cycle Time-Mast

Table 2
FUNCTION  DIRECTION  TIME(S)(1)
(in seconds) 
Lift  Up  17.0 
Down 30.7 
Tilt  Forward  2.7 
Back 1.9 
Carriage Side  Left  5.7 
Right 3.2 
Positioning  Together  5.5 
Apart 4.0 
(1) Times are recorded with no load, high idle, and warm oil.

Mast Contact Information

U.S. Navy Cat 980H Rough Terrain Forklift (25K Capacity) Mast Contact is:

Greenfield Products
3920 Greenfield Dr.
Union City, TN 38261
Phone (731) 886-1500
Fax (731) 886-1598
Email (Equipment Information) [email protected]
Email (Parts Orders) [email protected]

Top Handler Contact Information

U.S. Navy Cat 980H Rough Terrain Forklift (25K Capacity) Top Handler Contact is:

Adcock's Machine, Welding & Fabrication
Attn: Gwen Adcock
1238 Highway 158 West
Oxford, NC 27565
Phone (919) 693-7297
Fax (919) 693-5064

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