SERV7105-01January 2005Vol. 1, No. 1

TECHNICAL PRESENTATION

834H WHEEL DOZER AND836H LANDFILL COMPACTOR

INTRODUCTION

New Product Introduction(NPI)

SERVICE TRAINING

834H WHEEL DOZER AND 836H LANDFILL COMPACTORINTRODUCTION

AUDIENCE

Level II - Service personnel who understands the principles of machine system operation,diagnostic equipment, and procedures for testing and adjusting.

CONTENT

This self-paced, self-directed presentation provides new and different New Product Introduction(NPI) information for the 834H Wheel Dozer and 836H Landfill Compactor.

OBJECTIVESAfter learning the information in this presentation, the technician will be able to:

1. locate and identify the new components on the 834H Wheel Dozer and 836H Landfill Compactor; and

2. explain the operation of the new components in the systems.

Estimated Time: 1 HourIllustrations: 18Handouts: 6Form: SERV7105-01Date: 1/05

2005 Caterpillar Inc.

TABLE OF CONTENTS

INTRODUCTION ........................................................................................................................5

SIMILARITIES AND DIFFERENCES .......................................................................................6

ENGINE........................................................................................................................................7

AUTOMATIC BLADE POSITIONING (ABP) SYSTEM........................................................11

ATTACHMENTS .......................................................................................................................12

COOLING PACKAGE...............................................................................................................13

CONCLUSION...........................................................................................................................14

HYDRAULIC SCHEMATIC COLOR CODE...........................................................................15

HANDOUTS...............................................................................................................................17

POSTTEST .................................................................................................................................19

POSTTEST ANSWERS .............................................................................................................21

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NOTES

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INTRODUCTION

The 834H Wheel Dozer and 836H Landfill Compactor have been updated to enhanceperformance and to meet the Tier III EPA regulations. The serial number prefix of the 834HWheel Dozer is BTX. The serial number prefix for the 836H Landfill Compactor is BXD. The834H Wheel Dozer and the 836H Landfill Compactor are direct replacements for the 834G and836G machines.

1

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2SIMILARITIES AND DIFFERENCES

The most significant changes to the 834H and 836H are the engine, the hydraulic fan system,and the attachments. The engine is changing from the Caterpillar 3456 to the Caterpillar C18ACERT. The most significant change to the hydraulic system is the fan control. The fancontrol is changing from a thermostatic, wax capsule control to an electronic control.

The Automatic Blade Positioning (ABP) is standard on the 834H and 836H. ABP is a systemthat adjusts the blade to set points as the machine is shifted between forward and reverse.

The diagnostic lines group is standard on the 834H and 836H. The diagnostic lines groupprovides remote pressure taps for the power train hydraulic system.

The cooling package is changed on the 834H and 836H. The 834G and 836G are equippedwith the Advanced Modular radiator Cores (AMOCS). The 834H and 836H are equipped withthe Next Generation Modular Radiator (NGMR) cores.

A new 10.13 m3 (13.25 yd3) SU blade is available for the 834H Wheel Dozer. A new 21 m3

(27 yd3) SU blade is available for the 836H Landfill Compactor.

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ENGINE

The 834H and 836H are equipped with the Caterpillar C18 ACERT engine, serial number prefixRHX. The displacement of the C18 ACERT engine is 18.1 liters with a rated power of 498 hpat 1800 rpm. The performance test specification for the C18 ACERT engine in the 834H and836H are 0K4827 (direct drive) and 0K4828 (converter drive).

The C18 ACERT engine is equipped with a wastegated turbocharger (1) and an electric fuelpriming pump (2). The turbocharger is cooled with engine coolant. Also shown are theprimary fuel filter and water separator (3) and the engine oil filter (4).

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1

2

34

The C18 ACERT engine is equipped with a larger muffler (1) and an A4E4 Engine ElectronicControl Module (ECM) (not shown).

The brake/pilot pump (2) is also located on the right side of the machine. The secondary fuelfilter (not shown) can be accessed from the right side of the machine.

4

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1

2

5The above illustration shows the engine mounted electrical components on the 834H and 836H.

The differential fuel pressure switch monitors the condition of the secondary fuel filter.

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Oil Pressure Sensor

6 Drivers

3 Returns

InjectorConnector

A4E4ECM

Ground Bolt

Turbo Outlet Pressure Sensor

Atmospheric Pressure Sensor

Inlet Air Temperature Sender

Fuel Temperature Sender

Coolant Temperature Sender

Camshaft Speed / Timing Sensor

TimingCalibration

Sensor

Crankshaft Speed / Timing Sensor

To Machine WiringHarness

Fuel Pressure Sensor

Electronic UnitInjectors

Differential FuelPressure Switch

C18 ACERT ENGINE SYSTEM BLOCK DIAGRAMENGINE MOUNTED COMPONENTS

6The above illustration shows the machine mounted electrical components that are inputs andoutputs of the Engine ECM on the 834H and 836H.

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A4E4Electronic

Control Module(ECM)

GroundBolt

15 AmpBreaker

Main PowerRelay

Key StartSwitch

24 V

Service Tool ConnectorCAT Data Link

Fan ProportionalSolenoid Valve

Ground Level Shutdown Switch

ThrottleSensor

AcceleratorPedal

DisconnectSwitch

C18 ACERT EUI SYSTEMMACHINE MOUNTED COMPONENTS

Caterpillar Monitoring System

0

5

1015

20

25X100

MPHkm/h 44

Relay+ Battery

Cylinder

Engine

Ether Start ValveTransmission Lubrication

Temperature Sender

Tachometer Output

Right Brake Switch

Throttle LockResume / Accelerate Switch

Throttle LockSet / Decelerate Switch

Throttle LockEnable Switch

Throttle Lock Lamp

Manual EtherAid Switch

AUTOMATIC BLADE POSITIONING (ABP) SYSTEM

ABP is standard equipment on the 834H and 836H. ABP is a system that automates much ofthe repetitive work of positioning the blade on the machine. ABP uses the cylinder positionsensor (arrow) of the kickout system and the transmission directional switch to determine theblade position. Once the blade heights are set by the operator, ABP will position the blade tothose determined height without the operator moving the joystick.

When the operator selects REVERSE, the blade is automatically positioned to the raise heightthat was set by the operator. The operation of the system is same when the operator selectsFORWARD with the transmission direction switch.

The calibration of the cylinder position sensor follows the lift linkage strategy. The cylinderposition cylinder can be calibrated with Caterpillar Electronic Technician (Cat ET) or with the4C8195 service tool and Caterpillar Monitoring System (CMS).

7

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ATTACHMENTS

The diagnostic lines group is standard equipment on the 834H and 836H. The diagnostic linesgroup remote pressure taps are located behind the cab on the left side of the machine. Theremote pressure taps include:

1. Transmission reverse clutch pressure

2. Transmission forward clutch pressure

3. Transmission fourth speed clutch pressure

4. Transmission third speed clutch pressure

5. Transmission second speed clutch pressure

6. Transmission first speed clutch pressure

7. Torque converter inlet pressure

8. Torque converter outlet pressure

9. Impeller clutch pressure

10. Lockup clutch pressure

8

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7

8

9

10

1 2

34

5

6

COOLING PACKAGE

The cooling package on the 834H and 836H is equipped with ten NGMR cores (arrow) to coolthe engine coolant. The NGMR cores have six fins per inch and utilize two pass cooling.

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CONCLUSION

This presentation has provided New Product Introduction (NPI) information for the Caterpillar834H Wheel Dozer and 836H Landfill Compactor. All new components and their locations wereidentified and discussed.

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HYDRAULIC SCHEMATIC COLOR CODE

This illustration identifies the meanings of the colors used in the hydraulic schematics and cross-sectional views shown throughout this presentation.

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Red - High Pressure Oil

Red / White Stripes - 1st Pressure Reduction

Pink - 3rd Reduction in Pressure

Red / Pink Stripes - Secondary Source Oil Pressure

Orange - Pilot, Signal or Torque Converter Oil

Blue - Trapped Oil

Brown - Lubricating Oil

Cat Yellow - (Restricted Usage)

Green / White Stripes -Scavenge / Suction Oil or Hydraulic Void

Identification of ComponentsWithin a Moving Group

HYDRAULIC SCHEMATIC COLOR CODE

Black - Mechanical Connection. Seal

Dark Gray - Cutaway Section

Light Gray - Surface Color

White - Atmosphere Or Air (No Pressure)

Purple - Pneumatic Pressure

Yellow - Moving or Activated Components

Orange / Crosshatch - 2nd Reduction InPilot, Signal or TC Oil Pressure

Orange / White Stripes -Reduced Pilot, Signal or TC Oil Pressure

Red Crosshatch - 2nd Reduction in Pressure

Green - Tank, Sump, or Return Oil

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SERV7105-01 - 17 - NPIVol. 1, No. 1, 2005 Handout No. 1

Machine Orientation Checklist

Directions: Use this sheet when performing the machine orientation lab exercise.

Place a check in the blank if the fluid level is acceptable.

____ Engine oil level____ Hydraulic system oil level____ Hood actuator system oil level____ Power train hydraulic system oil level____ Final drive and differential oil level____ Cooling system fluid level ____ Fuel level

Place a check in the blank if acceptable or after task was performed.

____ Check the Caterpillar Monitoring System for abnormal machine conditions____ Check seat belt____ Check the air filter precleaners

Place a check in the blank if the indicator, switch, or control is working correctly.

____ Key start switch____ Engine coolant temperature gauge____ Fuel level gauge____ Power train oil temperature gauge____ Hydraulic oil temperature gauge____ Neutralizer disabled indicator light____ Turn signal indicator lights (2)____ Horn____ Front and rear work lights____ Windshield wipers (if equipped)____ Heating and air conditioner controls (if equipped)____ Backup alarm

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Machine Orientation Checklist - continued

Place a check in the blank after locating and reading the following warnings label on themachine.

____ ROPS____ Parking brake____ No clearance (articulation joint)____ Radiator____ Batteries____ Unit injectors____ Do not operate

Place a check in the blank after locating each of the following controls.

____ Throttle pedal____ Left brake pedal____ Right brake pedal____ Tilt lever____ Lift lever____ Parking brake knob____ Steering Wheel____ Battery disconnect switch

Place a check in the blank after locating each of the following identification plates.

____ Product Identification Number (PIN)____ Engine serial number____ Transmission serial number ____ Blade serial number

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Machine Posttest

Directions: Answer each question with the best possible answer.

1. The 834H and 836H are equipped with which engine?a. 3406Eb. C18 ACERTc. C15 ACERTd. 3456

2. The 834H and 836H are equipped with a water cooled turbocharger.a. Trueb. False

3. The diagnostic lines group is an attachment on 834H and 836H.a. Trueb. False

4. The 834H and 836H are equipped with which style radiator core?a. AMOCSb. Foldedc. Single Paneld. NGMR

5. The 834H and 836H are equipped with Automatic Blade Positioning.a. Trueb. False

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Machine Posttest - Continued

6. The Next Generation Modular Radiator (NGMR) cores have six fins per inch and utilizetwo pass coolinga. Trueb. False

7. The 834H and 836H are equipped with what type Engine ECM?a. ADEM IIIb. A4E4c. ADEM IVd. A4M1

8. Where is the diagnostics line group located on the 834H and 836H?a. Left side of the machine, by the fuel tankb. Behind the cabc. In the return line, near the power train oil coolerd. Just forward of the hydraulic tank

9. What does the Automatic Blade Positioning system use to determine blade position?a. Machine kickout set points and engine rpmb. Directional control level and cylinder position sensorc. Joystick lever position and machine speedd. Cylinder position sensor and Machine ECM

10. The Automatic Blade Positioning system calibrations must be done using the 4C-8195Control Service Tool.a. Trueb. False

SERV7105-01 - 21 - NPIVol. 1, No. 1, 2005 Posttest Answers

Machine Posttest Answers

Quiz Answers:

1. b

2. a

3. b

4. d

5. a

6. a

7. b

8. b

9. b

10. b

COVERPREFACETABLE OF CONTENTSNOTESINTRODUCTIONSIMILAR_DIFFENGINEAUTO BLADE POS (ABP) SYSATTACHMENTSCOOLING PACKAGECONCLUSIONCOLOR CODEHANDOUTSPOSTTESTANSWERS