CAT 980G Boom Replacement Problems: Troubleshooting and Solutions

[MikePhua]

The CAT 980G is a reliable wheel loader used in construction and mining applications. However, operators may encounter issues when changing the boom or dealing with related components. This article outlines the common problems experienced during boom changes on the CAT 980G and offers solutions and troubleshooting tips to help resolve these issues effectively.
Common Problems During CAT 980G Boom Changes

1. Hydraulic Cylinder Malfunctions:
   • Symptoms: When changing the boom, the hydraulic cylinders responsible for lifting and lowering the boom may not function properly. This can result in sluggish movements or a complete failure to raise the boom.
     
   • Potential Causes: Issues with hydraulic fluid levels, air in the hydraulic lines, or damaged seals within the hydraulic cylinders can all cause the boom to operate improperly.
     
   • Solution: Begin by checking the hydraulic fluid levels. If fluid is low, top it off with the appropriate type of hydraulic fluid. Inspect the hydraulic lines for leaks and any signs of contamination. Bleed the system to remove trapped air. If the hydraulic cylinders are worn or leaking, they may need to be rebuilt or replaced.
     
2. Boom Pin and Bushing Wear:
   • Symptoms: Worn boom pins or bushings can cause excessive play in the boom, leading to poor stability and potentially damaging the boom and related components.
     
   • Potential Causes: Continuous heavy usage or lack of proper maintenance can lead to wear in the boom pins and bushings.
     
   • Solution: Inspect the boom pins and bushings for excessive wear. If significant wear is present, replace the worn-out pins or bushings. Regular lubrication of these components can help extend their lifespan and prevent premature wear.
     
3. Alignment Issues:
   • Symptoms: If the boom is not aligned properly during replacement or adjustment, it may not fit correctly, causing stress on the hydraulic system and other components. This can also result in uneven lifting or difficulty in achieving full boom extension.
     
   • Potential Causes: Improper boom removal or installation techniques, or failing to ensure correct alignment during the replacement process, can cause alignment problems.
     
   • Solution: Before reassembling the boom, ensure that all mounting points and attachment areas are properly aligned. Carefully follow the manufacturer’s instructions during installation to avoid alignment issues. If necessary, consult a professional technician for assistance with proper alignment.
     
4. Electrical and Control System Issues:
   • Symptoms: During the boom change process, operators may experience electrical malfunctions or problems with the boom control system. This could manifest as unresponsive controls or an inability to activate certain functions.
     
   • Potential Causes: Damaged wiring, faulty sensors, or issues with the control panel can disrupt the electrical signals required to control the boom.
     
   • Solution: Inspect the wiring and connections for any visible damage or corrosion. Check the control panel for any error codes or malfunction indicators. Replace any damaged electrical components or sensors. In some cases, recalibrating the control system may be required.
     
5. Pressure Problems in the Hydraulic System:
   • Symptoms: If the boom does not lift or lower smoothly or the movement is jerky, there could be pressure issues in the hydraulic system. This may also cause the boom to operate slower than usual.
     
   • Potential Causes: A malfunctioning hydraulic pump, clogged filters, or an issue with the hydraulic pressure relief valve can lead to these problems.
     
   • Solution: Check the hydraulic pressure readings using a gauge to ensure that the system is operating within the recommended pressure range. Inspect and replace any clogged filters. If the hydraulic pump or pressure relief valve is malfunctioning, repair or replace the components.
     

Step-by-Step Troubleshooting Process

1. Check Hydraulic Fluid Levels and Quality:
   • Start by ensuring that the hydraulic fluid levels are adequate. Low or contaminated fluid can affect hydraulic system performance. Replace any dirty or old fluid, and top off the system as needed.
     
2. Inspect Hydraulic Components:
   • Examine the hydraulic cylinders for leaks or signs of wear. Check the hydraulic lines for cracks or leaks, and replace any damaged parts. Ensure that the pump is functioning properly and that the pressure relief valve is set correctly.
     
3. Inspect Boom Pins and Bushings:
   • Check the boom pins and bushings for wear. If they are excessively worn, replace them to prevent further damage to the boom. Regular lubrication can help reduce wear and extend the lifespan of these components.
     
4. Align the Boom Properly:
   • Ensure the boom is aligned correctly during installation. Misalignment can lead to poor performance and damage to the machine. Follow the manufacturer’s instructions carefully and make sure all mounting points are aligned.
     
5. Check Electrical Components:
   • If you encounter issues with the boom control system, inspect the wiring for any signs of wear or damage. Ensure that sensors and the control panel are functioning correctly. Replace any faulty components and test the system after repairs.
     
6. Test the System:
   • After performing all necessary checks and repairs, test the boom operation. Raise and lower the boom several times to ensure smooth operation. Monitor for any unusual sounds, slow movements, or jerky behavior.
     

Preventative Maintenance Tips

1. Regularly Check Hydraulic Fluid: Ensure that hydraulic fluid is checked frequently and topped off as needed. Also, replace hydraulic fluid at regular intervals to prevent contamination and ensure smooth operation.
   
2. Lubricate Boom Pins and Bushings: Regular lubrication of the boom pins and bushings can prevent excessive wear and reduce the risk of damage to these components.
   
3. Perform Routine Inspections: Schedule routine inspections of the hydraulic system, boom components, and electrical systems. Early detection of wear or issues can prevent major breakdowns and costly repairs.
   
4. Ensure Proper Alignment: When replacing or adjusting the boom, always ensure that it is aligned properly. Misalignment can cause stress on the machine and reduce its operational efficiency.
   
5. Check Electrical System Regularly: Periodically inspect the wiring, sensors, and control panels to ensure that the electrical system is functioning correctly. Recalibrate the control system if necessary.
   

Conclusion
The CAT 980G is a powerful and reliable wheel loader, but issues with the boom and hydraulic system can occur, especially during boom replacements. By understanding the common causes of boom-related problems, such as hydraulic issues, alignment problems, and electrical malfunctions, operators can troubleshoot and resolve these issues effectively. Regular maintenance, proper lubrication, and timely inspections are key to keeping the boom system functioning optimally and ensuring the longevity of the machine.