Miting Guide

SERV1807-01
February 2006
GLOBAL SERVICE LEARNING
TECHNICAL PRESENTATION
988H WHEEL LOADER

C18 ENGINE CONTROLS
Service Training Meeting Guide

(Text Reference)
988H WHEEL LOADER -
C18 ENGINE CONTROLS
AUDIENCE
Level II–Service personnel who understand the principles of machine systems operation,
diagnostic equipment, and procedures for testing and adjusting.
CONTENT
This presentation provides technical information on and 988H Wheel Loader engine controls.
This presentation may be used for self paced and self directed training.
OBJECTIVES
After learning the information in this meeting guide, the serviceman will be able to:
1. Locate and identify the major components of the C18 ACERT™ engine;
2. Trace the flow of fuel through the C18 engine fuel delivery system;
3. Identify engine derates; and
4. Trace the flow of oil through the hydraulic fan system;
GLOBAL REFERENCES
Specalog:
988H Wheel Loader AEHQ5618
Service Manual:
988H Wheel Loader RENR6200
Engine
System Operation/Testing and Adjusting SENR9832
Troubleshooting C15 and C18 Engines for Caterpillar Built Machines RENR5033
Hydraulic System
System Operations (Hydraulic Fan System) RENR6217
Testing and Adjusting (Hydraulic Fan System) RENR6218
Parts Manuals:
988H PIN BXY SEBP3906
Training Materials:
T.I.M. "988G Wheel Loader with 3456 Engine Controls" SERV2675
Estimated Time: 3 Hours

Illustrations: 40
Form: SERV1807-01-01
Date: 02/06
© 2006 Caterpillar Inc.
SERV1807-01 -3- Text Reference
02/06
TABLE OF CONTENTS
INTRODUCTION ........................................................................................................................5
ENGINE MOUNTED ELECTRICAL COMPONENTS .............................................................7
FUEL SYSTEM............................................................................................................................9
Power Derate.........................................................................................................................20
Fuel Temperature Derate ......................................................................................................21
High Fuel filter REstriction Derates.....................................................................................22
Virtual Exhaust Temperature Derate ....................................................................................23
High Coolant Temperature Derate........................................................................................26
Engine Oil Pressure Sensor ..................................................................................................27
Low Oil Pressure ..................................................................................................................28
MACHINE MOUNTED ELECTRICAL COMPONENTS .......................................................29
HYDRAULIC FAN SYSTEM ...................................................................................................36

Maximum Fan Speed............................................................................................................40
Minimum Fan Speed.............................................................................................................41
CONCLUSION...........................................................................................................................46
HYDRAULIC SCHEMATIC COLOR CODES ........................................................................47
HANDOUTS...............................................................................................................................49
ANSWERS .................................................................................................................................52
02/06
NOTES
02/06
988H WHEEL LOADER

C18 ENGINE CONTROLS
© 2006 Caterpillar Inc.
INTRODUCTION
This presentation discusses the C18 ACERT™ electronic engine equipped with a Mechanical
Electronic Unit Injection (MEUI) fuel system used in the 988H Wheel Loader.
02/06
The C18 utilizes the A4 Electronic Control Module (ECM) engine control and is equipped with
an Air To Air After Cooler (ATAAC) intake air cooling system. The C18 is rated at 396 kW
(531 horsepower) at 1900 rpm.
The Engine ECM utilizes the Advanced Diesel Engine Management (ADEM IV) to control the
fuel injector solenoids and to monitor fuel injection.
The C18 ACERT™ engine is an in-line six-cylinder arrangement, with a displacement of 18.1
liters. Most of the service points for the C18 are located on the left side of the engine.
The C18 ACERT™ engine meets U.S. Environmental Protection Agency (EPA) Tier III
Emissions Regulations for North America and Stage III European Emissions Regulations.
NOTE: For additional information in troubleshooting the engine, refer to the Service
Manual module Troubleshooting "C15 and C18 Engines for Caterpillar Built Machines
(RENR5033).
02/06
C18 ACERT ENGINE SYSTEM BLOCK DIAGRAM (988H)

ENGINE MOUNTED COMPONENTS
6 Drivers
Injector
Connector
3 Returns
Mechanical Electronic A4E4

Unit Injectors (MEUI) ECM
Crankshaft Speed / Timing Sensor

To Machine Wiring
Harness
Camshaft Speed / Timing Sensor
Ground Bolt
Coolant Temperature Sensor
Fuel Temperature Sensor Fuel Pressure Sensor
Timing
Intake Manifold Air Temperature Sensor Calibration Sensor
Atmospheric Pressure Sensor Fuel Differential Pressure Switch
Intake Manifold Air Pressure Sensor Oil Pressure Sensor
ENGINE MOUNTED ELECTRICAL COMPONENTS
The electrical components mounted on the C18 engine in the 988H are:
- Injectors
- Crankshaft speed/timing sensor
- Camshaft speed/timing sensor
- Coolant temperature sensor
- Fuel temperature sensor
- Intake manifold air temperature sensor
- Atmospheric (barometric) pressure sensor
- Intake manifold air pressure sensor
- A4E4 Engine ECM
02/06
- Fuel pressure sensor

- Timing calibration sensor
- Differential fuel pressure switch
- Oil pressure sensor
- Engine brake solenoids (optional) (not shown)
02/06
C18 ACERT ENGINE FUEL DELIVERY SYSTEM
Electric Fuel
Priming Pump
Fuel
(Optional) Shutoff Valve
Fuel Heater
Fuel Pressure
Regulator
Fuel Gallery
Primary
Fuel Filter / Secondary
Water Separator Fuel Filter
Fuel
Transfer
Pump
Fuel Tank
FUEL SYSTEM
Fuel is drawn from the fuel tank through the primary fuel filter (10-micron) and water separator
by a gear-type fuel transfer pump. The fuel transfer pump then pushes the fuel through the
secondary fuel filter (2 micron).
The fuel then flows to the cylinder head. The fuel enters the cylinder head and flows into the
fuel gallery, where it is made available to each of the six MEUI fuel injectors. Any excess fuel
not injected leaves the cylinder head and flows back to the secondary fuel filter where it flows
past the fuel pressure regulator.
The fuel pressure regulator is a check valve that is installed in the secondary fuel filter. The
fuel pressure regulator maintains fuel system pressure between the fuel transfer pump and the
fuel pressure regulator.
From the fuel pressure regulator, the excess fuel flow returns to the fuel tank. The ratio of fuel
used for combustion and fuel returned to tank is approximately 3:1 (i.e. four times the volume
required for combustion is supplied to the system for combustion and injector cooling
purposes).
SERV1807-01 - 10 - Text Reference
02/06
A fuel differential pressure switch is installed in the secondary fuel filter base and will alert the
operator of a fuel filter restriction. The pressure differential switch compares the filter inlet
pressure to the filter outlet pressure. When the difference in the inlet and outlet pressures
causes the switch to activate, the Caterpillar Monitoring System will warn the operator that the
secondary fuel filter is clogged and that fuel flow is restricted.
02/06
2
3
1
The 10 micron primary fuel filter and water separator (5) is located on the left side of the
machine. The primary fuel filter contains a water separator which removes water from the fuel.
Water in a high pressure fuel system can cause premature failure of the fuel injectors due to
corrosion and lack of lubricity. Water should be drained from the water separator daily, using
the drain valve located at the bottom of the filter.
Fuel is drawn from the primary fuel filter by the fuel pump (not shown) and is then returned to
the secondary fuel filter (not shown). The secondary fuel filter removes all contaminants that
could damage the fuel injectors.
The electric fuel priming pump (3) is integrated into the primary fuel filter base. It is activated
by pushing the electric fuel priming pump switch (4). The fuel priming pump is used to fill the
fuel filters after they have been replaced. The fuel priming pump is capable of forcing the air
from the entire fuel system.
Also shown in illustration No. 4 are the fuel shutoff valve (1) and fuel S•O•S port (2). When
the handle is moved to a position that is perpendicular to the fuel line, this valve shuts off the
flow of fuel from the fuel tank to the primary fuel filter.
02/06
2
1
The fuel transfer pump (1) is located at the lower, left of the engine. The fuel transfer pump is
driven by the front gear train. Fuel is drawn from the primary fuel filter and water separator
through the pump inlet (2) by the fuel transfer pump and is returned to the secondary fuel filter
through the pump outlet (3).
The fuel transfer pump incorporates a check valve. The check valve allows fuel to flow around
the gears of the pump when the fuel system is primed. A relief valve (not shown) is also
installed in the fuel transfer pump. The relief valve limits the maximum fuel pressure in the
fuel system.
02/06
3
2
The 2 micron secondary fuel filter (1) is located on the right side of the machine above the
Engine ECM. Fuel is supplied by the fuel transfer pump through the filter inlet (2). The
secondary fuel filter removes all contaminants that could damage the fuel injectors. The fuel is
sent to the fuel galley in the cylinder head through the filter outlet (3).
02/06
1 2
3
The excess fuel not used by the fuel injectors is returned to the secondary fuel filter base (1)
through inlet port (3). The fuel pressure regulator (2) is a check valve that maintains the fuel
pressure in the fuel system. From the fuel pressure regulator (2), the excess fuel flow returns to
the fuel tank through outlet port (4).
02/06
2
1
The camshaft speed/timing sensor (1) is located at the top, left of the engine. It is installed in a
port at the rear of the timing gear cover.
The intake manifold air pressure sensor (2) is located near the front of the engine in the intake
manifold. The difference in pressure between atmospheric pressure and intake manifold air
pressure is referred to as "boost" pressure.
Boost pressure may be read on the status screen in Cat ET. The boost pressure is a calculation
of the difference between the signal from the atmospheric pressure sensor and the signal from
the intake manifold air pressure sensor. A failure of the intake manifold air pressure sensor can
cause the Engine ECM to perceive a "zero boost" condition and log a fault in the Caterpillar
Monitoring System.
02/06
10
The primary (crankshaft) engine speed/timing sensor (arrow) is located below the fuel transfer
pump, at the lower, left of the engine. The crankshaft speed/timing sensor provides crankshaft
speed and position information to the Engine ECM. This information is also shared with the
Power Train ECM as engine speed information. The C18 engine has no engine output speed
sensor at the flywheel housing.
02/06
4 5
3 6
2
11
The atmospheric pressure sensor (1) and the engine oil pressure sensor (2) are installed in a
manifold that is located on the lower left side of the engine, forward of the Engine ECM and
beneath the intake air tube.
The air cooled A4 Engine ECM (4) is located above the starter. Identified above is the J2/P2
connector (5) and the J1/P1 connector (6). The J1/P1 connector is a 70-pin connector and the
J2/P2 connector is a 120-pin connector.
The timing calibration probe connector (3) is fastened to the wiring harness from the J2/P2
connector (5). A cable (7X1695) is used to connect the timing calibration probe to this
connector.
02/06
NOTE: The signal from the atmospheric pressure sensor is used by the Engine ECM to
calculate a number of pressure measurements in most electronic engines. The signal from the
atmospheric pressure sensor is compared to the signal from the other engine pressure sensors
to determine the following:
- Ambient (absolute) pressure is the atmospheric pressure;
- Boost pressure is determined by comparing the atmospheric pressure (sensor) to the

intake manifold pressure sensor;
- Engine oil (gauge) pressure is determined by comparing the atmospheric pressure

(sensor) to the engine oil pressure sensor;
- Fuel pressure is determined the fuel pressure sensor.
Also, when the engine is started, the Engine ECM uses the signal from the atmospheric
pressure sensor as a reference point for calibration of the other pressure sensors on the engine
(if the key start switch is turned to ON for at least five seconds before the engine starts).
02/06
3
2
4
1
12
The intake air temperature sensor (1) is located on the left side of the engine, rearward from the
intake air tube and above the Engine ECM.
The secondary fuel filter base (5) contains the fuel pressure differential switch (2), fuel pressure
sensor (3) and a fuel temperature sensor (4).
The fuel differential pressure switch compares the filter inlet pressure to the filter outlet
pressure. This switch is normally closed. When the difference in the inlet pressure and the
outlet pressure causes the switch to open, a fault will be logged in the Engine ECM.
When this event occurs, engine performance may be degraded when the fuel flow is restricted,
and the fuel injectors are starved of fuel. This condition, if ignored, could cause damage to the
fuel injectors.
The status of the sensors and the fuel differential pressure switch may be viewed through Cat
ET.
02/06
POWER DERATE
Highest Rated Torque Map
50% Derate
Derate
Power
100% Derate
Default Torque Map
Engine Speed
13
Power Derates
The illustration above defines the power derate in relation to the rated torque map and the
default torque map. The power derate is a percentage reduction from the rated power at a given
engine speed toward the default map at the same rpm.
Power is unchanged until the requested power exceeds the derated level. The maximum power
during a derate is calculated as:
Maximum Power Output = Rated Power - (Rated Power - Default Power) * Derate Percentage
For example, if the engine has a maximum rated power of 500 hp and a 100 hp default torque
map with a 50% derate, the engine will have 300 hp output power. If 250 hp was needed, then
the operator will not notice any change. If however, 400 hp was needed, there would be only
300 hp available due to derates.
300 hp = 500 hp - (500 hp - 100 hp) X 50% (.50)

02/06
FUEL TEMPERATURE DERATE

30%
25%
20%
% Derate
15%
10%
5%
0%
89.8 90.0 90.2 90.4 90.6 90.8 91.0 91.2 91.4 91.6 91.8 92.0 92.2
Fuel Temperature C
Level 1 Warning Level 2 Warning / Derat es
14
Fuel Temperature Derate
This illustration shows the graph for the warning and derates map for the fuel temperature.
When the fuel temperature exceeds 90° C (194° F), the Engine ECM will activate a Level 1
Warning. Also, the graph shows, as the fuel temperature increases to 91.0° C (196° F) a Level
2 Warning will be initiated by the Engine ECM. At the same time, the engine will derate to
12.5%. If the fuel temperature exceeds 92° C (198° F), the engine will be derated to 25%.
A fuel temperature sensor open circuit will derate the engine to 12.5%.
Excessive fuel temperature will cause injector wear.

02/06
FUEL FILTER RESTRICTION DERATE

FUEL TEMP ABOVE 30 C (86 F)
PRESSURE ABOVE 110 kPa (15 psi)
60%
50%
40%
% Derate
30%
20%
10%
0%
0 3 min 1 hr 2 hr 3 hr 4 hr 4hr 5 hr
1 sec
Time
Level 1 Warning Level 2 Warning / Derat es
15
High Fuel Filter Restriction Derates
When the differential pressure switch recognizes a fuel pressure of 103 kPa (15 psi) for 3
minutes, the Engine ECM will initiate a Level 1 Warning.
When the differential pressure switch recognizes 15 psi across the filter for 4 hours, the Engine
ECM will initiate a Level 2 Warning. With the Level 2 Warning initiated a 17.5% derate is
applied to the engine. After 1 second, the Engine ECM will initiate a second derate of 17.5%.
The total derate will be 35%.
The high fuel filter restriction derate will be disabled when the fuel temperature is below 30° C
(86 ° F).
02/06
VIRTUAL EXHAUST TEMPERATURE DERATE
Engine Derate
Barometric Pressure Percentage
Inlet Manifold Temperature
Engine Speed
Fuel Injection Highest Derate Other Engine

Calibration Priority Derate
Selector Conditions
Engine ECM
16
Virtual Exhaust Temperature Derate
An engine derate can occur due to a estimated (virtual) high exhaust gas temperature. The
Engine ECM monitors barometric pressure, intake manifold temperature, and engine speed to
estimate exhaust gas temperature. Certain conditions (high altitude, high ambient temperatures,
high load and full accelerator pedal throttle, barometric pressure, intake manifold temperature,
and engine speed) are monitored to determine if the engine derate should be enabled. The
Engine ECM determines a maximum fuel delivery percentage to maintain safe maximum power
output under load. This calculation is new to the off-road Tier III engines and is used in place
of the previous altitude compensation derate strategy.
This event is to inform the mechanic that a derate has occurred because of operating conditions.
Generally, this is normal and requires no service action.
The Engine ECM will process all derate inputs in the highest derate priority selector. The most
critical derate condition input will be used to adjust fuel system delivery limiting engine power
to a safe level for the conditions in which the product is being operated, thereby prevent
elevated exhaust temperatures.
02/06
The virtual exhaust temperature derate will log a 194 event code. The derate will enable a
Level 1 Warning and eventually a Level 2 Warning. The level of the warning will depend on
the conditions that are sent to the Engine ECM.
The following conditions must be met in order to initiate a virtual exhaust temperature derate.
-.No CID 168 01 FMI (low battery voltage to the Engine ECM) are active.
- No active intake manifold pressure sensor faults.
- No active atmospheric pressure (barometric) sensor faults
- No +5 V sensor voltage codes active.
- The virtual exhaust temp derate must be the highest derate.
- More fuel is being requested than the virtual exhaust temp derate will allow.
This derate is triggered by the information inferred by the Engine ECM, rather than an
individual sensor as with the previous single derate strategies. If you think this derate is
possibly being imposed incorrectly check for event codes on high intake manifold temperature
and correct those first. Also, make sure the aftercooler is unobstructed. For additional
information about troubleshooting, refer to the troubleshooting for the particular engine that is
being serviced.
02/06
17
18
The coolant temperature sensor (1) is installed at the right front corner of the engine, above the
jacket water pump.
The lower illustration shows the fluid sampling port (2) for the engine coolant with the bracket
removed.
02/06
HIGH COOLANT TEMPERATURE DERATE

120%
100%
80%
% Derate
60%
40%
20%
0%
110 111 111.5 112 112.5 113 113.5 114 114.5
Coolant Temperature C
Level 1 Warning Level 2 Warning/ Derat es
19
High Coolant Temperature Derate
The coolant temperature sensor measures the temperature of the coolant.
When the temperature of the coolant exceeds 110° C (230° F), the Engine ECM will initiate a
Level 1 Warning.
When the temperature of the coolant exceeds 111° C (231° F), the Engine ECM will initiate a
Level 2 Warning. At 111° C (231° F) the Engine ECM will initiate a 25% derate. Refer to the
Illustration for the remainder of the high engine coolant temperature derates. At 100% derate,
the engine available power will be approximately 50%.
02/06
20
Engine Oil Pressure Sensor
The engine oil pressure sensor (1) is located on the left side of the engine and the right side of
the machine near the Engine ECM (3). The sensor monitors the pressure of the engine oil.
The engine oil pressure sensor is one of the many sensors that require a regulated 5.0 VDC for
the sensor supply voltage. The sensor outputs a variable DC voltage signal.
The Engine ECM will use the information supplied by the oil pressure sensor to output warning
levels to the Caterpillar Monitoring System and engine derates.
Also shown is the atmospheric (barometric) pressure sensor (2).

02/06
LOW OIL PRESSURE WARNING LEVELS

180
160
140
120
100
kPa
80
60
40
20
0
0 500 1000 1500 2000 2500 3000 3500
kPa Shut down Level 3 rpm

kPa Warning Level 1
21
Low Oil Pressure
This illustration shows a graph with the two different warning levels for low oil pressure.
When the oil pressure is below (154 kPa @ 1600 rpm) the blue line, the Cat Monitoring System
will enable the low oil pressure Level 1 Warning. If a Level 1 Warning occurs, the operator
should change machine operation or perform maintenance to the system.
When the oil pressure is below (104 kPa @ 1600 rpm) the red line, the Cat Monitoring System
will enable the low oil pressure Level 3 Warning. The operator should immediately perform a
safe engine shutdown.
Also, along with the Level 3 Warning, the Engine ECM initiates a 35% engine derate.
If the signal between the Engine ECM and the oil pressure sensor is lost or disabled, the Engine
ECM will initiate a low engine oil pressure Level 1 Warning.
02/06
A4E4
Electronic C18 ACERT MEUI SYSTEM (988H)
Control Module MACHINE MOUNTED COMPONENTS
(ECM)
Ground Disconnect
Bolt Switch
24 V
Main Power Key Start
15 Amp Relay Switch
Breaker
Tachometer Output
Right Brake Switch

Throttle Accelerator
Throttle Lock Sensor Pedal
Resume / Accelerate Switch
Throttle Lock Manual Ether

Set / Decelerate Switch Aid Switch
Throttle Lock Ground Level Shutdown Switch

Enable Switch
Fan Proportional
Throttle Lock Lamp Solenoid Valve
+ Battery Relay Ether Start Valve

Transmission Lubrication
Temperature Sender Cylinder
Caterpillar Monitoring System

Engine
15
10 20
Service Tool Connector

5 25
X100
44
CAT Data Link
MPH
0 km/h
22
MACHINE MOUNTED ELECTRICAL COMPONENTS
The electrical components mounted on the machine for the C18 engine are:
- right brake switch

- throttle lock resume/accelerate switch
- throttle lock set/decelerate switch
- throttle lock enable switch
- throttle lock lamp
- transmission lubrication temperature sensor
- disconnect switch
- main power relay
- key start switch
- throttle position sensor
02/06
- manual ether start aid switch

- ground level shutdown switch
- fan proportional solenoid valve
- ether start aid relay
- Caterpillar Monitoring System
02/06
2
1
23
The right brake switch (1) is located next to the right brake pedal. When the right brake switch
is activated, the engine rpm will return to low idle if the throttle lock is enabled.
The throttle pedal (2) is located on the right side of the operators station. The throttle pedal
enables the operator to operate the machine at the desired engine rpm.
Also shown is the engine brake pedal (3).

02/06
24
25
Throttle Lock Control
The throttle lock switch (1) is located in the front console underneath the quad gauges. Press
the top of the throttle lock switch in order to enable the throttle lock function. The throttle lock
indicator (2) in the lower illustration will illuminate when the throttle lock has been enabled.
02/06
26
The set/deceleration switch (1) is located toward the top of the operator controls. The switch
can be used to set the engine speed with the throttle pedal. The switch can also reduce the
engine rpm by pressing and holding the button momentarily.
The resume/acceleration switch (2) is located toward the bottom of the operator controls. The
switch can be used to resume the set engine speed. The switch can also increase the engine
rpm by pressing and holding the button momentarily.
02/06
27
The disconnect switch (arrow) is located inside the right, rear storage compartment of the
bumper. The disconnect switch allows service personnel to turn off battery supply to the
machine for service purposes.
02/06
28
The ground level shutdown switch (arrow) is located in the left rear of the bumper. The switch
enables the engine to be shutdown externally for safety reasons. The switch can also be used to
disable the injectors during cranking for service purposes.
To operate the switch, lift the cover and move the switch to the upper position. To reset the
switch, the key start switch must be cycled to the OFF position for a few seconds, and then to
the ON position after the ground level shutdown switch has been returned to the down position.
02/06
HYDRAULIC FAN SYSTEM COMPONENTS
Coolant Pump Control Air Intake Implement

Temperature Valve Temperature Sensor ECM Hydraulic Oil
Sensor Temperature Sensor
Hydraulic Hydraulic Solenoid Hydraulic Hydraulic

Fan Motor Oil Cooler Valve Fan Pump Tank
29
HYDRAULIC FAN SYSTEM
The 988H Wheel Loader is equipped with an on demand hydraulic fan system. The
components of the hydraulic fan system are the following
- Hydraulic tank
- Hydraulic fan pump
- Hydraulic fan motor
- Hydraulic oil cooler
- Engine Electronic Control Module (ECM)
- Solenoid valve
- Pump control valve
- Inlet air temperature sensor
- Coolant temperature sensor
- Hydraulic oil temperature sensor
02/06
30
The 988H Wheel Loader is equipped with an on demand hydraulic fan system. The on demand
control fan system uses a variable displacement hydraulic fan pump (1) in order to provide oil
flow to the hydraulic fan motor (not shown). The hydraulic fan motor rotates the fan blades to
move the air through the radiator package. Then, the oil from the hydraulic fan motor flows
through the oil cooler (not shown) and back to the hydraulic tank.
In an on demand fan system, the fan speed will increase or decrease in order to provide the
required amount of cooling. During light usage, the fan system will maintain a minimum fan
speed. During heavy usage or high ambient temperatures, the fan system will supply the fan
speed that is required to cool the machine fluids (hydraulic oil, engine coolant). Also, the fan
system cools the air that is flowing through the Air To Air Aftercooler.
In the on demand fan system, the Engine ECM, located on the engine, receives signals from
three temperatures sensors that are located on the machine. As the temperature sensors reach
the key target temperature, data is sent to the Engine ECM. Then, the Engine ECM interprets
the data and sends a proportional current to the solenoid valve (2).
02/06
The following temperatures must be met in order to maintain the fan system at minimum fan
speed.
- The inlet air manifold temperature is below 52° C (126° F)
- The hydraulic oil temperature is below 87° C (189° F)
- The coolant temperature is below 92° C (198° F)
As one of the sensors reads a temperature that is above the key target temperature, the Engine
ECM interprets a demand for additional cooling. The Engine ECM starts sending a reduced
amount of current to the solenoid valve and the pump starts to upstroke.
The hydraulic fan pump is a variable displacement piston pump that is controlled by the pump
control valve. The pump control valve senses any change in pressure in the signal line. When
the current to the solenoid valve is at maximum current, the pressure through the signal line
will decrease and the fan pump will destroke. The supply of oil to the fan motor will decrease.
When the current to the solenoid valve starts to decrease, the oil in the signal line will drain
back to the hydraulic tank. Then, the fan pump will upstroke. The supply of oil to the fan
motor will increase.
The fan motor (not shown) is a fixed displacement piston motor that is equipped with a makeup
valve. The make up valve allows the hydraulic oil to flow from the motor outlet through the
makeup valve and back to the motor inlet. This will allow the motor to gradually shut down
and prevent motor cavitation.
The maximum and minimum fan speed must be calibrated through Caterpillar Electronic
Technician.
Calibration procedure for the Hydraulic Fan System can be found in the Troubleshooting
Testing and Adjusting Service Manual 988H Electrohydraulic System (RENR6218).
02/06
Engine ECM J2
DEMAND FAN CIRCUIT
Analog Temperature
90
Sensor Return
Bu 18 1 Signal
Pk 18 2 Ground
Coolant
71 Engine Coolant
Caterpillar Temperature Signal
Temperature Sensor
Monitoring System
Intake Manifold 35 1
24 +8 VDC Bu 18 Signal
Air Temperature
Pk 18 2 Ground
Cat Data
2 Ground Link Intake Manifold Air
J1 Temperature Sensor
10 Hyd Oil Temp Sensor Variable Speed

43
Fan Control
Yl 18 1
Br 18 2
BU 18 VS Variable Speed 51 Hydraulic Fan
Fan Control Speed Solenoid
BK 18 Ground
GY 18 Signal
Hydraulic Oil
Temperature
Sensor
31
The Engine ECM receives input signals from the engine coolant temperature sensor, and intake
manifold air temperature sensor.
Hydraulic oil temperature sensor signals are sent to the Caterpillar Monitoring System main
display module and transmitted over the Cat Data Link to the Engine ECM.
The Engine ECM processes the input signals and sends corresponding output signals to the
variable speed fan solenoid valve in order to control fan speed.
NOTE: The variable speed fan control feature can be enabled, disabled, and calibrated
using the ET Service Tool. The variable speed fan default setting is enabled.
02/06

MAXIMUM FAN SPEED
Fan
Motor
Fan Pump
Control Valve
Flow
Control Solenoid
Spool Valve
Oil
Cooler
Pressure
Cutoff
Spool
Actuator
Fan Max Angle
Pump
Filter
Hydraulic
Tank
32
Maximum Fan Speed

As one of the sensors reads a temperature that is above the key target temperature, the Engine
ECM sends a reduced current to the solenoid valve for additional cooling. The solenoid valve
shifts downward. The oil flow to the tank port becomes blocked and the pressure against the
right side of the flow control spool will increase and the flow control spool shifts to the left.
Oil that is behind the piston in the actuator flows back to the hydraulic tank. The piston within
the actuator moves to the right. The angle of the swashplate increases. The flow of oil from
the fan pump discharge will increase.
As one or more of the key target temperatures continues to increase, the Engine ECM will
continue to reduce the current that is sent to the solenoid valve. The movement of the flow
control spool to the left continues and an additional amount of oil flows from behind the
actuator. Then, the swashplate moves more toward the maximum angle.
Calibrating the maximum fan speed in the Engine ECM is performed with Caterpillar
Electronic Technician (ET) through the "Service" mode.
02/06

MINIMUM FAN SPEED
Fan
Motor
Fan Pump
Control Valve
Flow
Control Solenoid
Spool Valve
Oil
Cooler
Pressure
Cutoff
Spool
Actuator
Fan Min Angle
Pump
Filter
Hydraulic
Tank
33
Minimum Fan Speed

As all of the sensors sense a reduction in temperature, the Engine ECM starts increasing the
current to the solenoid valve. The solenoid begins to shifts upward. The oil flow to the tank
port on the solenoid valve increases and the pressure against the right side of the flow control
spool decreases and the flow control spool shifts to the right. Oil pressure behind the actuator
increases and the piston in the actuator moves to the left. The angle of the swashplate
decreases. The flow of oil from the discharge of the fan pump will decrease proportionally
compared to the temperature change of all three sensors.
As all the key target temperatures continue to decrease, the Engine ECM will continue to
increase the current that is sent to the solenoid valve. The movement of the flow control spool
to the left continues and an additional amount of oil flows behind the actuator. Then, the
swashplate continues to move toward the minimum angle.
Calibrating the minimum fan speed is performed in the Engine ECM with Caterpillar Electronic
Technician (ET) through the "Service" mode.
02/06
34
1
2
35
5
The upper illustration shows the location of the engine coolant temperature sensor (1). The
sensor is located on the right side of the engine and the left side of the machine. The sensor
sends an analog voltage signal to the Engine ECM.
Also shown is the fluid sampling port (2)
The lower illustration shows the location of the intake manifold air temperature sensor (3). The
sensor is located on the left side of the engine and the right side of the machine. Also, the
sensor sends an analog voltage signal to the Engine ECM.
Also shown is the fuel filter (4) and the Engine ECM (5).
02/06
36
This illustration shows the location of the hydraulic oil temperature sensor (arrow). The sensor
is located between the engine end frame and the hydraulic tank. The sensor sends a PWM
signal to the Caterpillar Monitoring System. Then, the information is sent to the Engine ECM
through the Cat Data Link.
02/06
1
3
4
5 6
37
The hydraulic oil cooler (2) and the hydraulic oil cooler bypass valve (5) are located on the rear
frame (6). The hydraulic oil cooler is built into the radiator group (1). The bypass valve is
installed in the lines group to the cross beam of the frame. The bypass valve opens when the
oil pressure is above 345 ± 45 (50 ± 7 psi) due to cold oil.
Also shown are the air conditioning condenser (3) and hydraulic fan system solenoid valve (4).
02/06
38
39
The hydraulic fan system calibration is performed using the ET Service Tool. In the upper
illustration, the ET service tool is connected to the machine.
To perform hydraulic fan system calibrations, select the item "Engine 988H" that is shown in
the lower illustration. Proceed to Service, Calibrations, and Engine Cooling Fan Calibration.
02/06
40
CONCLUSION
This presentation has provided information for the C18 ACERT™ engine used in the 988H
Wheel Loader.
This presentation supports the service manual. When used in conjunction with the service
manual, the information in this package should permit the technician to do a thorough job of
analyzing a problem in these systems.
For service repairs, adjustments and maintenance, always refer to the Owner and Operator
Manual, Service Manuals, and other related service publications.
02/06
HYDRAULIC SCHEMATIC COLOR CODE
Black - Mechanical Connection. Seal Red - High Pressure Oil
Dark Gray - Cutaway Section Red / White Stripes - 1st Pressure Reduction
Light Gray - Surface Color Red Crosshatch - 2nd Reduction in Pressure
White - Atmosphere Or Air (No Pressure) Pink - 3rd Reduction in Pressure
Purple - Pneumatic Pressure Red / Pink Stripes - Secondary Source Oil Pressure
Yellow - Moving or Activated Components Orange - Pilot, Signal or Torque Converter Oil
Cat Yellow - (Restricted Usage) Orange / White Stripes -

Identification of Components Reduced Pilot, Signal or TC Oil Pressure
Within a Moving Group
Orange / Crosshatch - 2nd Reduction In
Brown - Lubricating Oil Pilot, Signal or TC Oil Pressure
Green - Tank, Sump, o r Return Oil Blue - Trapped Oil
Green / White Stripes -

Scavenge / Suction Oil or Hydraulic Void
HYDRAULIC SCHEMATIC COLOR CODES
The colors on the hydraulic schematics and cross-sectional views shown throughout this
presentation denote specific meanings. This illustration identifies the meaning of each color.
02/06
HYDRAULIC SCHEMATIC COLOR CODE

SERV1807-01
Black - Mechanical Connection. Seal Red - High Pressure Oil
Dark Gray - Cutaway Section Red / White Stripes - 1st Pressure Reduction
Light Gray - Surface Color Red Crosshatch - 2nd Reduction in Pressure
White - Atmosphere or Air (No Pressure) Pink - 3rd Reduction in Pressure
Purple - Pneumatic Pressure Red / Pink Stripes - Secondary Source Oil Pressure
- 48 -
Yellow - Moving or Activated Components Orange - Pilot, Charge or Torque Converter Oil
Cat Yellow - (Restricted Usage) Orange / White Stripes - Reduced Pilot, Charge, or
Identification of Components TC Oil Pressure
within a Moving Group
Orange / Crosshatch - 2nd Reduction in Pilot,
Brown - Lubricating Oil Charge, or TC Oil Pressure
Green - Tank, Sump, or Return Oil Blue - Trapped Oil
Green / White Stripes -

Scavenge / Suction Oil or Hydraulic Void
Text Reference
SERV1807-01 - 49 - Laboratory Exercise
02/06 Handout No. 1
Lab A Worksheet
C18 ACERT™ Engine Component Identification Worksheet
Directions: Place the correct letter or number next to the component. During the visual
presentation, use these worksheets to take notes as the function of each component is explained.
Example: _____Pilot Pump
Location: The single section gear pump mounted on left main implement pump.
Function: Supplies pilot system oil flow to the pilot filter, pilot manifold and pilot systems.
_____ Engine ECM
Function:
Location:
_____ Primary Fuel Filter

Function:
Location:
_____ Fuel Transfer Pump

Function:
Location:
_____ Electronic Priming Pump

Function:
Location:
_____ Secondary Fuel Filters

Function:
Location:
_____ Electronic Unit Injector

Function:
Location:
_____ Fuel Pressure Regulating Valve

Function:
Location:
_____ Fuel Temperature Sensor

Function:
Location:
02/06 Handout No. 2
Lab A Worksheet
C18 ACERT™ Engine Component Identification Worksheet (continued)
_____ Fuel Pressure Sensor

Function:
Location:
_____ Differential Fuel Pressure Switch

Function:
Location:
_____ Crankshaft Speed Sensor

Function:
Location:
_____ Camshaft Speed Sensor

Function:
Location:
_____ Timing Calibration Connector

Function:
Location:
_____ Engine Jacket Water Temperature Sensor

Function:
Location:
_____ Engine Oil Pressure Sensor

Function:
Location:
_____ Intake Manifold Air Pressure Sensor

Function:
Location:
_____ Intake Air Temperature Sensor

Function:
Location:
02/06 Handout No. 3
Lab A Worksheet
_____ Atmospheric Pressure Sensor

Function:
Location:
_____ Throttle Position Sensor

Function:
Location:
_____ Throttle Lock Enable Switch

Function:
Location:
_____ Throttle Set/Decelerate Switch

Function:
Location:
_____ Throttle Resume/Accelerate Switch

Function:
Location:
02/06 Handout No. 1
Lab A Worksheet Answers

C18 ACERT™ Engine Component Identification Worksheet
Directions: Place the correct letter or number next to the component. During the visual
presentation, use these worksheets to take notes as the function of each component is explained.
Example: _____Pilot Pump
Location: The single section gear pump mounted on left main implement pump.
Function: Supplies pilot system oil flow to the pilot filter, pilot manifold and pilot systems.
_____ Engine ECM

Function: Electronic Control Module, governor, electronic fuel system control.
Location: Mounted on the engine, right side of engine compartment.
_____ Primary Fuel Filter

Function: 10 micron filter, removes large debris which could damage the injectors.
Location: Between the tank and the transfer pump, left rear of engine compartment, on engine.
_____ Fuel Transfer Pump

Function: Low pressure fuel pump.
Location: On engine, right rear side of the engine compartment.
_____ Electronic Priming Pump

Function: Primes fuel system from the tank through the filters to the injectors.
Location: Mounted on the primary filter housing.
_____ Secondary Fuel Filters

Function: Two micron filter, removes small debris which could damage the injectors.
Location: Downstream of the transfer pump, right side of the engine compartment.
_____ Electronic Unit Injector

Function: Controlled by the Engine ECM, delivers fuel to the cylinder.
Location: In the cylinder head below valve cover.
_____ Fuel Pressure Regulating Valve

Function: Maintains fuel system pressure.
Location: Mounted in the secondary fuel filter base, right side of engine compartment.
_____ Fuel Temperature Sensor

Function: Fuel temperature measurement for the Engine ECM and high temperature warnings.
Location: Mounted in the secondary fuel filter base, right side of engine compartment.
02/06 Handout No. 2

_____ Fuel Pressure Sensor

Function: Fuel pressure measurement for the Engine ECM, and high and low pressure
warnings.
Location: Mounted on the secondary fuel filter base.
_____ Differential Fuel Pressure Switch

Function: Compares the filter inlet pressure to the filter outlet pressure for the Engine ECM
and filter bypass warning.
Location: Mounted on the secondary fuel filter base.
_____ Crankshaft Speed Sensor

Function: Engine speed/timing measurement, TDC, and cylinder identification.
Location: Timing gear housing, bottom of engine.
_____ Camshaft Speed Sensor

Function: Engine speed/timing measurement, TDC, and cylinder identification.
Location: Timing gear housing, right side of engine compartment.
_____ Timing Calibration Connector

Function: Connects the timing probe when installed in the rear housing, to the Engine ECM.
Location: In the engine wiring harness, above the Engine ECM.
_____ Engine Jacket Water Temperature Sensor

Function: Coolant temperature measurement for Engine ECM, instrument panel, temperature
warning.
Location: Below thermostat housing, at the front of the engine.
_____ Engine Oil Pressure Sensor

Function: Oil pressure measurement for the Engine ECM, instrument panel, and low pressure
warning.
Location: On right side of engine in the oil gallery next to the atmospheric pressure sensor.
_____ Intake Manifold Air Pressure Sensor

Function: Calculates the difference between atmospheric pressure and intake manifold air
pressure, referred to as "boost" pressure.
Location: Located near the front of the engine in the intake manifold.
_____ Intake Air Temperature Sensor

Function: Intake air temperature measurement for Engine ECM and temperature warning.
Location: Located on the left side of the engine, rearward from the intake air tube and above
the Engine ECM.
02/06 Handout No. 3

_____ Atmospheric Pressure Sensor

Function: Ambient pressure for gauge pressure measurements, altitude compensation.
Location: In the engine block, next to the oil pressure sensor.
_____ Throttle Position Sensor

Function: Engine speed control.
Location: In the cab, on the throttle pedal assembly.
_____ Throttle Lock Enable Switch

Function: Engine speed control.
Location: In the cab, on the front console.
_____ Throttle Set/Decelerate Switch

Function: Engine speed control, set engine rpm or decrease engine rpm.
Location: In the cab, on the right side operator controls.
_____ Throttle Resume/Accelerate Switch

Function: Engine speed control, resume previous engine rpm setting or increase engine rpm.
Location: In the cab, on the right side operator controls.

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SERV1807-01

GLOBAL SERVICE LEARNING

988H WHEEL LOADER

Service Training Meeting Guide

Estimated Time: 3 Hours

ENGINE MOUNTED ELECTRICAL COMPONENTS .............................................................7

MACHINE MOUNTED ELECTRICAL COMPONENTS .......................................................29

HYDRAULIC FAN SYSTEM ...................................................................................................36

HYDRAULIC SCHEMATIC COLOR CODES ........................................................................47

988H WHEEL LOADER

© 2006 Caterpillar Inc.

C18 ACERT ENGINE SYSTEM BLOCK DIAGRAM (988H)

Mechanical Electronic A4E4

Crankshaft Speed / Timing Sensor

Fuel Temperature Sensor Fuel Pressure Sensor

Atmospheric Pressure Sensor Fuel Differential Pressure Switch

Intake Manifold Air Pressure Sensor Oil Pressure Sensor

ENGINE MOUNTED ELECTRICAL COMPONENTS

- Fuel pressure sensor

C18 ACERT ENGINE FUEL DELIVERY SYSTEM

- Boost pressure is determined by comparing the atmospheric pressure (sensor) to the

- Engine oil (gauge) pressure is determined by comparing the atmospheric pressure

- Fuel pressure is determined the fuel pressure sensor.

Highest Rated Torque Map

Default Torque Map

300 hp = 500 hp - (500 hp - 100 hp) X 50% (.50)

FUEL TEMPERATURE DERATE

Fuel Temperature Derate

Excessive fuel temperature will cause injector wear.

FUEL FILTER RESTRICTION DERATE

High Fuel Filter Restriction Derates

VIRTUAL EXHAUST TEMPERATURE DERATE

Inlet Manifold Temperature

Fuel Injection Highest Derate Other Engine

Virtual Exhaust Temperature Derate

HIGH COOLANT TEMPERATURE DERATE

Level 1 Warning Level 2 Warning/ Derat es

High Coolant Temperature Derate

The coolant temperature sensor measures the temperature of the coolant.

Engine Oil Pressure Sensor

Also shown is the atmospheric (barometric) pressure sensor (2).

LOW OIL PRESSURE WARNING LEVELS

kPa Shut down Level 3 rpm

Low Oil Pressure

Right Brake Switch

Throttle Lock Manual Ether

Throttle Lock Ground Level Shutdown Switch

+ Battery Relay Ether Start Valve

Caterpillar Monitoring System

Service Tool Connector

MACHINE MOUNTED ELECTRICAL COMPONENTS

- right brake switch

- manual ether start aid switch

Also shown is the engine brake pedal (3).

Throttle Lock Control

HYDRAULIC FAN SYSTEM COMPONENTS

Coolant Pump Control Air Intake Implement

Hydraulic Hydraulic Solenoid Hydraulic Hydraulic

HYDRAULIC FAN SYSTEM

- The inlet air manifold temperature is below 52° C (126° F)

- The hydraulic oil temperature is below 87° C (189° F)

- The coolant temperature is below 92° C (198° F)

10 Hyd Oil Temp Sensor Variable Speed

HYDRAULIC FAN SYSTEM

C18 ACERT ENGINE SYSTEM BLOCK DIAGRAM (988H)

C18 ACERT ENGINE FUEL DELIVERY SYSTEM