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Service Training MALAGA

992G WHEEL LOADER

5. IMPLEMENT SYSTEM
1. Components Layout 2. Operation 3. Testing & Adjusting
Adolfo OCTOBER 1997

Page:

ELECTRO-HYDRAULIC IMPLEMENT SYSTEM


5-2 IMPLEMENT HYDRAULIC PUMPS VARIABLE PUMP PILOT SOLENOID VALVE RELIEF VALVE PILOT PUMP ELECTRONIC CONTROL MODULE PILOT CONTROL LEVER MODULE MAIN CONTROL VALVE ASSEMBLY TILT CYLINDER

CHAPTER : IMPLEMENT SYSTEM

992G WHEEL LOADER

HYDRAULIC TANK

LIFT LINKAGE POSITION SENSOR

LIFT TILT LINKAGE CYLINDER POSITION SENSOR

ELECTRONIC SYSTEM HYDRAULIC PILOT SYSTEM

MAIN HYDRAULIC SYSTEM COMMON TO BOTH SYSTEMS

Page: 5-3

ELECTRONIC IMPLEMENT CONTROL SYSTEM


IMPLEMENT ELECTRONIC CONTROL MODULE (MAC-14)

CAT DATA LINK INPUT COMPONENTS OUTPUT COMPONENTS PILOT ON/OFF SOLENOID VARIABLE PUMP SOLENOID TILT RACKBACK SOLENOID NO. 1 TILT RACKBACK SOLENOID NO. 2

TILT LEVER SENSOR LIFT LEVER SENSOR

IMPLEMENT LOCKOUT SWITCH LIFT/LOWER/TILT KICKOUT SWITCH

CHAPTER : IMPLEMENT SYSTEM

TILT DUMP SOLENOID NO. 1 TILT DUMP SOLENOID NO. 2

992G WHEEL LOADER

LIFT LINKAGE SENSOR

LIFT LOWER SOLENOID NO. 1 LIFT LOWER SOLENOID NO. 2 LIFT RAISE SOLENOID NO. 1 LIFT RAISE SOLENOID NO. 2 LIFT LOWER KICKOUT DETENT SOLENOID LIFT RAISE KICKOUT DETENT SOLENOID BUCKET KICKOUT DETENT SOLENOID

TILT LINKAGE SENSOR

Page: 5-4
CAT DATA LINK

ELECTRO-HYDRAULIC IMPLEMENT SYSTEM


PILOT SYSTEM COMPONENTS
RIGHT LIFT CYLINDER TILT CYLINDER LEFT LIFT CYLINDER

SHUTTLE VALVE IMPLEMENT LOCKOUT SWITCH

RAISE/LOW/TILT KICKOUT SET SWITCH

PRESSURE REDUCING VALVE

CHAPTER : IMPLEMENT SYSTEM

TILT LINKAGE POSITION SENSOR

IMPLEMENT CONTROL VALVE

IMPLEMENT CONTROL VALVE

992G WHEEL LOADER

ELECTRONIC CONTROL MODULE

LIFT LINKAGE POSITION SENSOR

PILOT ON/OFF VALVE

CHECK VALVE

BUCKET KICKOUT DETENT SOLENOID TILT LEVER SENSOR

LIFT KICKOUT DETENT SOLENOID

LOWER KICKOUT DETENT SOLENOID LIFT LEVER SENSOR RELIEF VALVE

CHECK VALVE RELIEF VALVE

PILOT RELIEF VALVE

FILTER VARIABLE PUMP SOLENOID VALVE

FIXED PUMP

PILOT PUMP

VARIABLE PUMP

992G WHEEL LOADER


CHAPTER : IMPLEMENT SYSTEM

COMPONENTS

SERVICE TOOL CONNECTOR

FILL CAP

VENT VALVE

HYDRAULIC TANK

Page:

5-5

992G WHEEL LOADER


CHAPTER : IMPLEMENT SYSTEM

PILOT SYSTEM COMPONENTS

PILOT PUMP

IMPLEMENT VARIABLE PISTON PUMP

PUMP OUTLET

PILOT CIRCUIT PRESSURE TAP

Page:

5-6

992G WHEEL LOADER


CHAPTER : IMPLEMENT SYSTEM

PILOT CIRCUIT COMPONENTS

OIL FILTER BYPASS SWITCH

HYDRAULIC OIL FILTER

OIL OUTLET

OIL INLET

Page:

5-7

992G WHEEL LOADER


CHAPTER : IMPLEMENT SYSTEM

PILOT CIRCUIT COMPONENTS

PILOT RELIEF VALVE

SIGNAL LINE

PILOT RELIEF VALVE PRESSURE SENSOR

VARIABLE PUMP SOLENOID VALVE

Page:

5-8

992G WHEEL LOADER


CHAPTER : IMPLEMENT SYSTEM

MAIN CONTROL VALVES

TILT ROD END LINE RELIEF VALVE

TILT HEAD END LINE RELIEF VALVE

FIXED PUMP RELIEF VALVE

PILOT CONTROL SOLENOID VALVES

PILOT ON/OFF SOLENOID VALVE

LIFT HEAD END LINE RELIEF VALVE FLOAT SEQUENCE VALVE

LIFT ROD END LINE RELIEF VALVE

FLOAT VALVE

Page:

5-9

992G WHEEL LOADER


CHAPTER : IMPLEMENT SYSTEM

IMPLEMENT PUMPS

VARIABLE PUMP

CASE DRAIN

FIXED PUMP

Page:

5-10

Page: 5-11
CAT DATA LINK

ELECTRO-HYDRAULIC IMPLEMENT SYSTEM


MAIN HYDRAULIC SYSTEM COMPONENTS
RIGHT LIFT CYLINDER TILT CYLINDER LEFT LIFT CYLINDER

SHUTTLE VALVE IMPLEMENT LOCKOUT SWITCH

RAISE/LOW/TILT KICKOUT SET SWITCH

PRESSURE REDUCING VALVE

TILT LINKAGE POSITION SENSOR

CHAPTER : IMPLEMENT SYSTEM

IMPLEMENT CONTROL VALVE

IMPLEMENT CONTROL VALVE

992G WHEEL LOADER

ELECTRONIC CONTROL MODULE

LIFT LINKAGE POSITION SENSOR

PILOT ON/OFF VALVE

CHECK VALVE

BUCKET KICKOUT DETENT SOLENOID TILT LEVER SENSOR

LIFT KICKOUT DETENT SOLENOID

LOWER KICKOUT DETENT SOLENOID LIFT LEVER SENSOR RELIEF VALVE

CHECK VALVE RELIEF VALVE FILTER VARIABLE PUMP SOLENOID VALVE

PILOT RELIEF VALVE

FIXED PUMP

PILOT PUMP

VARIABLE PUMP

Page:
VARIABLE PUMP SOLENOID VALVE TO PILOT SYSTEM

5-12
FLUID SAMPLING PORT

VARIABLE IMPLEMENT PUMP


LESS THAN 2400kPa (350 psi)

TO TANK PILOT RELIEF VALVE PRESSURE CUTOFF PILOT FILTER LOAD LIMIT CONTROL SHUTTLE VALVE TO IMPLEMENT CONTROL VALVE

CHAPTER : IMPLEMENT SYSTEM

992G WHEEL LOADER

SMALL ACTUATOR PILOT PUMP PUMP

LARGE ACTUATOR

Page:
TO PILOT SYSTEM

VARIABLE PUMP SOLENOID VALVE

5-13
FLUID SAMPLING PORT

VARIABLE IMPLEMENT PUMP


LESS THAN 24,500 kPa (3550 psi)

TO TANK PILOT RELIEF VALVE PRESSURE CUTOFF PILOT FILTER LOAD LIMIT CONTROL SHUTTLE VALVE TO IMPLEMENT CONTROL VALVE

CHAPTER : IMPLEMENT SYSTEM

992G WHEEL LOADER

SMALL ACTUATOR PILOT PUMP

LARGE ACTUATOR

PUMP

992G WHEEL LOADER


CHAPTER : IMPLEMENT SYSTEM

VARIABLE PUMP SOLENOID VALVE

IMPLEMENT PILOT RELIEF

VARIABLE PUMP SOLENOID VALVE


CONTROLS PILOT PRESSURE TO LOAD LIMITING CONTROL VALVE ON VARIABLE PUMP CONTROL ECM ENERGIZES SOLENOID WHEN KEY SWITCH ON RECEIVES CONSTANT SIGNAL FROM ECM SUPPLIES PILOT OIL TO LOAD LIMIT CONTROL MAINTAINS 80% PUMP FLOW (27600<P<28900 kPa)

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5-14

Page:
VARIABLE PUMP SOLENOID VALVE TO PILOT SYSTEM

5-15
FLUID SAMPLING PORT

VARIABLE IMPLEMENT PUMP


MORE THAN 28,940 kPa (4200 psi)

TO TANK PILOT RELIEF VALVE PRESSURE CUTOFF PILOT FILTER LOAD LIMIT CONTROL SHUTTLE VALVE TO IMPLEMENT CONTROL VALVE

CHAPTER : IMPLEMENT SYSTEM

992G WHEEL LOADER

SMALL ACTUATOR PILOT PUMP PUMP

LARGE ACTUATOR

Page: 5-16

ELECTRO-HYDRAULIC IMPLEMENT SYSTEM


HOLD

RIGHT LIFT CYLINDER

TILT CYLINDER

LEFT LIFT CYLINDER

SHUTTLE VALVE IMPLEMENT LOCKOUT SWITCH

RAISE/LOW/TILT KICKOUT SET SWITCH

PRESSURE REDUCING VALVE

CHAPTER : IMPLEMENT SYSTEM

TILT LINKAGE POSITION SENSOR

IMPLEMENT CONTROL VALVE

IMPLEMENT CONTROL VALVE

992G WHEEL LOADER

CAT DATA LINK

ELECTRONIC CONTROL MODULE

LIFT LINKAGE POSITION SENSOR

PILOT ON/OFF VALVE

CHECK VALVE

BUCKET KICKOUT DETENT SOLENOID TILT LEVER SENSOR

LIFT KICKOUT DETENT SOLENOID

LOWER KICKOUT DETENT SOLENOID LIFT LEVER SENSOR FIXED PUMP RELIEF VALVE

CHECK VALVE RELIEF VALVE FILTER VARIABLE PUMP SOLENOID VALVE

PILOT RELIEF VALVE

PILOT PUMP

VARIABLE PUMP

Page: 5-17

ELECTRO-HYDRAULIC IMPLEMENT SYSTEM


SLOW TILT

RIGHT LIFT CYLINDER

TILT CYLINDER

LEFT LIFT CYLINDER

SHUTTLE VALVE IMPLEMENT LOCKOUT SWITCH

RAISE/LOW/TILT KICKOUT SET SWITCH

PRESSURE REDUCING VALVE

TILT LINKAGE POSITION SENSOR

CHAPTER : IMPLEMENT SYSTEM

IMPLEMENT CONTROL VALVE

IMPLEMENT CONTROL VALVE

992G WHEEL LOADER

CAT DATA LINK

ELECTRONIC CONTROL MODULE

LIFT LINKAGE POSITION SENSOR

PILOT ON/OFF VALVE

CHECK VALVE

BUCKET KICKOUT DETENT SOLENOID TILT LEVER SENSOR

LIFT KICKOUT DETENT SOLENOID

LOWER KICKOUT DETENT SOLENOID LIFT LEVER SENSOR FIXED PUMP RELIEF VALVE

CHECK VALVE RELIEF VALVE FILTER VARIABLE PUMP SOLENOID VALVE

PILOT RELIEF VALVE

PILOT PUMP

VARIABLE PUMP

Page: 5-18

ELECTRO-HYDRAULIC IMPLEMENT SYSTEM


FAST TILT

RIGHT LIFT CYLINDER

TILT CYLINDER

LEFT LIFT CYLINDER

SHUTTLE VALVE IMPLEMENT LOCKOUT SWITCH

RAISE/LOW/TILT KICKOUT SET SWITCH

PRESSURE REDUCING VALVE

TILT LINKAGE POSITION SENSOR

CHAPTER : IMPLEMENT SYSTEM

IMPLEMENT CONTROL VALVE

IMPLEMENT CONTROL VALVE

992G WHEEL LOADER

CAT DATA LINK

ELECTRONIC CONTROL MODULE

LIFT LINKAGE POSITION SENSOR

PILOT ON/OFF VALVE

CHECK VALVE

BUCKET KICKOUT DETENT SOLENOID TILT LEVER SENSOR

LIFT KICKOUT DETENT SOLENOID

LOWER KICKOUT DETENT SOLENOID LIFT LEVER SENSOR FIXED PUMP RELIEF VALVE

CHECK VALVE RELIEF VALVE FILTER VARIABLE PUMP SOLENOID VALVE

PILOT RELIEF VALVE

PILOT PUMP

VARIABLE PUMP

Page: 5-19
CAT DATA LINK BUCKET KICKOUT DETENT SOLENOID TILT LEVER SENSOR

ELECTRO-HYDRAULIC IMPLEMENT SYSTEM


SLOW LIFT

RIGHT LIFT CYLINDER

TILT CYLINDER

LEFT LIFT CYLINDER

SHUTTLE VALVE IMPLEMENT LOCKOUT SWITCH

RAISE/LOW/TILT KICKOUT SET SWITCH

PRESSURE REDUCING VALVE

TILT LINKAGE POSITION SENSOR

IMPLEMENT CONTROL VALVE

IMPLEMENT CONTROL VALVE

CHAPTER : IMPLEMENT SYSTEM

992G WHEEL LOADER

ELECTRONIC CONTROL MODULE

LIFT LINKAGE POSITION SENSOR

PILOT ON/OFF VALVE

CHECK VALVE

LIFT KICKOUT DETENT SOLENOID

LOWER KICKOUT DETENT SOLENOID LIFT LEVER SENSOR FIXED PUMP RELIEF VALVE

CHECK VALVE RELIEF VALVE FILTER VARIABLE PUMP SOLENOID VALVE

PILOT RELIEF VALVE

PILOT PUMP

VARIABLE PUMP

Page: 5-20
BUCKET KICKOUT DETENT SOLENOID TILT LEVER SENSOR

ELECTRO-HYDRAULIC IMPLEMENT SYSTEM


FAST LIFT
RIGHT LIFT CYLINDER

TILT CYLINDER

LEFT LIFT CYLINDER

SHUTTLE VALVE IMPLEMENT LOCKOUT SWITCH

RAISE/LOW/TILT KICKOUT SET SWITCH

PRESSURE REDUCING VALVE

TILT LINKAGE POSITION SENSOR

IMPLEMENT CONTROL VALVE

IMPLEMENT CONTROL VALVE

CHAPTER : IMPLEMENT SYSTEM

992G WHEEL LOADER

CAT DATA LINK

ELECTRONIC CONTROL MODULE

LIFT LINKAGE POSITION SENSOR

PILOT ON/OFF VALVE

CHECK VALVE

LIFT KICKOUT DETENT SOLENOID

LOWER KICKOUT DETENT SOLENOID LIFT LEVER SENSOR FIXED PUMP RELIEF VALVE

CHECK VALVE RELIEF VALVE FILTER VARIABLE PUMP SOLENOID VALVE

PILOT RELIEF VALVE

PILOT PUMP

VARIABLE PUMP

Page:
IMPLEMENT HYDRAULIC SYSTEM
HOLD
LIFT CYLINDER
TILT CYLINDER

LIFT CYLINDER

5-21
PRESSURE REDUCING VALVE
PILOT ON/OFF VALVE PILOT RELIEF VALVE

SHUTTLE VALVE

LOWER

TILT

TILT

LOWER

RIDE CONTROL

VARIABLE PUMP SOLENOID VALVE

FLOAT SEQUENCE VALVE


RAISE

FLOAT VALVE FLOAT VALVE

CHAPTER : IMPLEMENT SYSTEM

DUMP

DUMP

RAISE

992G WHEEL LOADER

FAN MOTOR PRESSURE CUTOFF SHUTTLE VALVE LOAD LIMIT CONTROL SMALL ACTUATOR LARGE ACTUATOR VARIABLE PUMP

FAN SPEED

COOLER

FIXED PUMP

FLUID SAMPLING PORT

FAN DRIVE PUMP

PILOT PUMP

Page:
IMPLEMENT HYDRAULIC SYSTEM
SLOW TILT

5-22
PRESSURE REDUCING VALVE PILOT RELIEF VALVE FLUID SAMPLING PORT
PILOT PUMP

LIFT CYLINDER

TILT CYLINDER

LIFT CYLINDER

SHUTTLE VALVE

LOWER

TILT

TILT

LOWER

RIDE CONTROL

PILOT ON/OFF VALVE

VARIABLE PUMP SOLENOID VALVE

FLOAT SEQUENCE VALVE


RAISE

FLOAT VALVE FLOAT VALVE

CHAPTER : IMPLEMENT SYSTEM

DUMP

DUMP

RAISE

992G WHEEL LOADER

FAN MOTOR
PRESSURE CUTOFF
COOLER

FAN SPEED

SHUTTLE VALVE

FIXED PUMP

LOAD LIMIT CONTROL SMALL ACTUATOR LARGE ACTUATOR VARIABLE PUMP

FAN DRIVE PUMP

Page: 5-23
FLUID SAMPLING PORT

IMPLEMENT HYDRAULIC SYSTEM


FAST TILT
LIFT CYLINDER
TILT CYLINDER

LIFT CYLINDER

PRESSURE REDUCING VALVE

SHUTTLE VALVE

LOWER

TILT

TILT

LOWER

RIDE CONTROL

PILOT ON/OFF VALVE

VARIABLE PUMP SOLENOID VALVE

FLOAT SEQUENCE VALVE


RAISE

FLOAT VALVE FLOAT VALVE

CHAPTER : IMPLEMENT SYSTEM

DUMP

DUMP

RAISE

992G WHEEL LOADER

PILOT RELIEF VALVE PRESSURE CUTOFF SHUTTLE VALVE FIXED PUMP

FAN MOTOR

FAN SPEED

COOLER

LOAD LIMIT CONTROL SMALL ACTUATOR LARGE ACTUATOR VARIABLE PUMP

FAN DRIVE PUMP

PILOT PUMP

Page:
IMPLEMENT HYDRAULIC SYSTEM
SLOW LOWER

5-24
PRESSURE REDUCING VALVE PILOT RELIEF VALVE FLUID SAMPLING PORT PILOT PUMP

LIFT CYLINDER

TILT CYLINDER

LIFT CYLINDER

SHUTTLE VALVE

LOWER

TILT

TILT

LOWER

RIDE CONTROL

PILOT ON/OFF VALVE

VARIABLE PUMP SOLENOID VALVE

FLOAT SEQUENCE VALVE RAISE

FLOAT VALVE FLOAT VALVE

CHAPTER : IMPLEMENT SYSTEM

DUMP

DUMP

RAISE

992G WHEEL LOADER

FAN MOTOR PRESSURE CUTOFF SHUTTLE VALVE LOAD LIMIT CONTROL SMALL ACTUATOR LARGE ACTUATOR VARIABLE PUMP FIXED PUMP

FAN SPEED

COOLER

FAN DRIVE PUMP

Page:
IMPLEMENT HYDRAULIC SYSTEM

5-25
PRESSURE REDUCING VALVE PILOT RELIEF VALVE FLUID SAMPLING PORT PILOT PUMP

FAST LOWER

LIFT CYLINDER

TILT CYLINDER

LIFT CYLINDER

SHUTTLE VALVE

LOWER

TILT

TILT

LOWER

RIDE CONTROL

PILOT ON/OFF VALVE

VARIABLE PUMP SOLENOID VALVE

FLOAT SEQUENCE VALVE RAISE

FLOAT VALVE FLOAT VALVE

CHAPTER : IMPLEMENT SYSTEM

DUMP

DUMP

RAISE

992G WHEEL LOADER

FAN MOTOR PRESSURE CUTOFF SHUTTLE VALVE FIXED PUMP

FAN SPEED

COOLER

LOAD LIMIT CONTROL SMALL ACTUATOR LARGE ACTUATOR VARIABLE PUMP

FAN DRIVE PUMP

Page: 5-26
FLUID SAMPLING PORT

IMPLEMENT HYDRAULIC SYSTEM


FLOAT
LIFT CYLINDER TILT CYLINDER LIFT CYLINDER

PRESSURE REDUCING VALVE

SHUTTLE VALVE

LOWER

TILT

TILT

LOWER

RIDE CONTROL

PILOT ON/OFF VALVE

VARIABLE PUMP SOLENOID VALVE

FLOAT SEQUENCE VALVE RAISE

FLOAT VALVE FLOAT VALVE

CHAPTER : IMPLEMENT SYSTEM

DUMP

DUMP

RAISE

992G WHEEL LOADER

PILOT RELIEF VALVE

FAN MOTOR PRESSURE CUTOFF COOLER SHUTTLE VALVE FIXED PUMP

FAN SPEED

LOAD LIMIT CONTROL SMALL ACTUATOR LARGE ACTUATOR VARIABLE PUMP

FAN DRIVE PUMP

PILOT PUMP

Page: 5-27 PLUG PASSAGE TO SEQUENCE VALVE ORIFICE

FLOAT VALVE

CHAPTER : IMPLEMENT SYSTEM

992G WHEEL LOADER

TO LIFT CYLINDER ROD END

FLOAT OFF

FLOAT ON

Page: 5-28
FLUID SAMPLING PORT

IMPLEMENT HYDRAULIC SYSTEM


LOWER ENGINE OFF
LIFT CYLINDER TILT CYLINDER LIFT CYLINDER

PRESSURE REDUCING VALVE

SHUTTLE VALVE

LOWER

TILT

TILT

LOWER

RIDE CONTROL

PILOT ON/OFF VALVE

VARIABLE PUMP SOLENOID VALVE

FLOAT SEQUENCE VALVE RAISE

FLOAT VALVE FLOAT VALVE

CHAPTER : IMPLEMENT SYSTEM

DUMP

DUMP

RAISE

992G WHEEL LOADER

PILOT RELIEF VALVE PRESSURE CUTOFF SHUTTLE VALVE FIXED PUMP COOLER

FAN MOTOR

FAN SPEED

LOAD LIMIT CONTROL SMALL ACTUATOR LARGE ACTUATOR VARIABLE PUMP

FAN DRIVE PUMP

PILOT PUMP

Page:
IMPLEMENT HYDRAULIC SYSTEM
RIDE CONTROL ON
LIFT CYLINDER TILT CYLINDER LIFT CYLINDER

5-29

PRESSURE REDUCING VALVE

SHUTTLE VALVE

LOWER

TILT

TILT

LOWER

RIDE CONTROL

PILOT ON/OFF VALVE

VARIABLE PUMP SOLENOID VALVE

FLOAT SEQUENCE VALVE RAISE

FLOAT VALVE FLOAT VALVE

CHAPTER : IMPLEMENT SYSTEM

DUMP

DUMP

RAISE

992G WHEEL LOADER

PILOT RELIEF VALVE PRESSURE CUTOFF SHUTTLE VALVE FIXED PUMP COOLER

FAN MOTOR

FAN SPEED

FLUID SAMPLING PORT

LOAD LIMIT CONTROL SMALL ACTUATOR LARGE ACTUATOR VARIABLE PUMP

FAN DRIVE PUMP

PILOT PUMP

Page: 5-30

FAN DRIVE SYSTEM


ENGINE OFF
ENGINE ECM FAN FAN MOTOR

SCREEN

MAKEUP VALVE FAN DRIVE PUMP COMPENSATOR VALVE PROPORTIONAL VALVE IMPLEMENT HYDRAULIC COOLER OIL COOLER BYPASS VALVE

CHAPTER : IMPLEMENT SYSTEM

992G WHEEL LOADER

TANK

INPUTS TO PROPORTIONAL VALVE: --COOLANT TEMPERATURE SENSOR --STEERING TANK TEMPERATURE SENSOR --IMPLEMENT TANK TEMPERATURE SENSOR --AIR CONDITIONER ON/OFF SWITCH

992G WHEEL LOADER


CHAPTER : IMPLEMENT SYSTEM

FAN DRIVE COMPONENTS

SYSTEM PRESSURE TEST PORT

FAN DRIVE PUMP

SIGNAL PRESSURE OUTLET

PROPORTIONAL VALVE SOLENOID

MARGIN SPOOL ADJUSTMENT

COMPENSATOR VALVE

SIGNAL PRESSURE TEST PORT

PRESSURE COMPENSATOR ADJUSTMENT

ELECTRO-HYDRAULIC PROPORTIONAL VALVE

Page:

5-31

992G WHEEL LOADER


CHAPTER : IMPLEMENT SYSTEM

INTAKE HOSE

OUTLET HOSE

FAN DRIVE MOTOR

CASE DRAIN HOSE

Page:

5-32

992G WHEEL LOADER


CHAPTER : IMPLEMENT SYSTEM

992G COOLER LOCATION

ENGINE

Page:

5-33

Page: 5-34

FAN DRIVE SYSTEM


SOLENOID DE-ENERGIZED PUMP UPSTROKES
SCREEN

FAN FAN MOTOR

MAKEUP VALVE

CHAPTER : IMPLEMENT SYSTEM

FAN DRIVE PUMP COMPENSATOR VALVE

PROPORTIONAL VALVE IMPLEMENT HYDRAULIC COOLER OIL COOLER BYPASS VALVE

992G WHEEL LOADER

TANK

Page: 5-35

FAN DRIVE SYSTEM


SOLENOID ENERGIZED

FAN FAN MOTOR

SCREEN

MAKEUP VALVE

CHAPTER : IMPLEMENT SYSTEM

FAN DRIVE PUMP COMPENSATOR VALVE

PROPORTIONAL VALVE IMPLEMENT HYDRAULIC COOLER OIL COOLER BYPASS VALVE

992G WHEEL LOADER

TANK

Page: 5-36

FAN DRIVE SYSTEM


RAPID ENGINE DECELERATION

FAN FAN MOTOR

SCREEN

MAKEUP VALVE

CHAPTER : IMPLEMENT SYSTEM

FAN DRIVE PUMP COMPENSATOR VALVE

PROPORTIONAL VALVE IMPLEMENT HYDRAULIC COOLER OIL COOLER BYPASS VALVE

992G WHEEL LOADER

TANK

992G WHEEL LOADER


CHAPTER : IMPLEMENT SYSTEM

6 5 7

1 3 8 2 4

1- HYDRAULIC CONTROL LEVERS 2- TILT LEVER POSITION SENSOR 3- HORN 4- RIGHT ARMREST CONTROL LEVER 5- REDUCED RIMPULL SWITCH 6- THROTTLE LOCK SET SWITCH 7- IMPLEMENT HYDRAULIC LOCK SWITCH 8- CONTROL LEVER COVER - DETENT SOLENOIDS (UNDER COVER)

Page:

5-37

992G WHEEL LOADER


CHAPTER : IMPLEMENT SYSTEM

SETTING BUCKET KICKOUTS


TO SET KICK-OUTS PRESS & HOLD UPPER, LOWER OR TILT KICK-OUTS FOR APROXIMATELY ONE SECOND

UPPER KICK-OUT (above mid point)

X/2

GOES TO KICK-OUT

GOES TO FLOAT (hits ground)

LOWER KICK-OUT

Page:

5-38

992G WHEEL LOADER


CHAPTER : IMPLEMENT SYSTEM

LINKAGE POSITION SENSOR REPLACE


1- REPLACE AND INSTALL SENSOR AS INDICATED IN T&A 2- DIAL SERV IN KEYPAD 3- SCROLL (>) TO SET SENSORS, LIFT SENSORS ONLY 4- FOLLOW INSTRUCTION UNTIL TARGET NUMBER APPEARS (%) 5- OK WILL SHUTOFF ENGINE (LEAVE KEY SWITCH ON) 6- ADJUST SENSOR ROTATING SHAFT WITH ROLLER IN CENTRE OF CAM 7 - DUTY CYCLE CAN BE READ ON DISPLAY OR CONNECTING FLUKE TO SENSOR 8- PERFORM CALIBRATION BEFORE PUTTING MACHINE BACK IN SERVICE

LINKAGE POSITION SENSOR CALIBRATION


1- PARKING BRAKE ON 2- RIDE CONTROL SWITCH OFF 3- LOW IDLE 4- HYD OIL TEMP > 30 C 5- PRESS OK UNTIL ALL EVENTS ACKNOWLEDGED 6- ENTER SERV 7- PRESS SCROLL (>) UNTIL LFT LINK SNSR - CAL 8- FOLLOW INSTRUCTIONS Page: 5-39

992G WHEEL LOADER


CHAPTER : IMPLEMENT SYSTEM

IMPLEMENT VALVE CALIBRATION


CALIBRATES EIGHT PROPORTIONAL SOLENOIDS PERFORM IF FOLLOWING CONDITIONS APPLY: - ONE OR MORE SOLENOIDS REPLACED - SERVICE CODE INDICATES CALIBRATION NEEDED - IMPLEMENT ELECTRONIC MODULE REPLACED

PROCEDURE
1) PKNG BRAKE ON 2) LOW IDLE 3) MACHINE IN WIDE OPEN SPACE 4) HYDRAULIC OIL > 30C 5) OK UNTIL ALL EVENTS ACKNOWLEDGED 6) SERV AND SCROLL (>) UNTIL IMPL VALVE SOL - CAL APPEARS 7) OK TO START.....FOLLOW INSTRUCTIONS ERRORS 1 - SOLENOID ERROR
CHECK SOL/CAL/WIRNG CHECK FOR CODES, CORRECT AND RECALIBRATE HYDRAULIC PROBLEMS. CHECK IMPLEMENT AND PILOT PUMP PRESSURES. MAKE SURE BUCKET IS HYDRAULIC PROBLEMS. CHECK FOR EXCESSIVE CYLINDER DRIFT CHECK FOR CODES, CORRECT AND RECALIBRATE

2 - CURRENT ABOVE RANGE 3- CURRENT BELOW RANGE 4 - LFT LINK SNSR ERR
CHECK SNSR/CAL/WIRNG

Page:

5-40

992G WHEEL LOADER


CHAPTER : IMPLEMENT SYSTEM

VARIABLE DISPLACEMENT PUMP TESTS


DISSABLES LEFT SIDE OF IMPLEMENT CONTROL VALVE ISOLATES VARIABLE DISPLACEMENT PUMP

PROCEDURE
1) PKNG BRAKE ON 2) XMS NEUTRAL 3) START ENGINE 4) WARM OIL TO 49C 5) OK UNTIL ALL EVENTS ACKNOWLEDGED 6) SERV AND SCROLL (>) UNTIL IMPL RLF - VAR PUMP APPEARS 7) OK TO START.....FOLLOW INSTRUCTIONS 8) EVERY 5 SEC PRESS [<] OR [>] TO SEE SPEC LIST SPECIFICATIONS INDICATED ON MESSAGE DISPLAY ARE UPDATED THROUGH SOFTWARE FILES. COULD BE DIFFERENT TO SPECS IN SERVICE MANUAL. SPECS LISTED: - VARIABLE DISPLACEMENT PUMP CUTOFF - RIGHT VALVE DUMP LINE RELIEF PRESSURE - BUCKET LIFT TIME WITH VARIABLE PUMP ONLY - DOUBLE STALL RPM WITH VARIABLE PUMP ONLY - RIGHT VALVE BACK UP RELIEF SETTING

Page:

5-41

992G WHEEL LOADER


CHAPTER : IMPLEMENT SYSTEM

FIXED DISPLACEMENT PUMP TESTS


DISSABLES RIGHT SIDE OF IMPLEMENT CONTROL VALVE ISOLATES FIXED DISPLACEMENT PUMP

PROCEDURE
1) PKNG BRAKE ON 2) XMS NEUTRAL 3) START ENGINE 4) WARM OIL TO 49C 5) OK UNTIL ALL EVENTS ACKNOWLEDGED 6) SERV AND SCROLL (>) UNTIL IMPL RLF - FIX PUMP APPEARS 7) OK TO START.....FOLLOW INSTRUCTIONS 8) EVERY 5 SEC PRESS [<] OR [>] TO SEE SPEC LIST SPECIFICATIONS INDICATED ON MESSAGE DISPLAY ARE UPDATED THROUGH SOFTWARE FILES. COULD BE DIFFERENT TO SPECS IN SERVICE MANUAL. SPECS LISTED:
- FIXED DISPLACEMENT PUMP MAIN RELIEF - LEFT VALVE DUMP LINE RELIEF PRESSURE - BUCKET LIFT TIME WITH FIXED PUMP ONLY - DOUBLE STALL RPM WITH FIXED PUMP ONLY - LEFT VALVE TILT LINE RELIEF SETTING - LEFT VALVE LOWER LINE RELIEF SETTING - LEFT VALVE RAISE LINE RELIEF SETTING
Page: 5-42

992G WHEEL LOADER


CHAPTER : IMPLEMENT SYSTEM

LAB EXERCISES
Lab A: Implement Hydraulic Component Identification Quiz Worksheet
Directions: Use this worksheet and the notes during the presentation to locate the components on the machine. Component Pilot pump Fan drive pump Pilot relief valve Pilot control lever module Pilot oil filter Pressure reducing valve Main implement pumps Main control valves Main relief valve Variable pump backup relief valve Pilot ON/OFF solenoid valve Hydraulic tank Variable pump torque control solenoid valve Fan drive motor Fan drive speed control valve Lift linkage position sensor Tilt linkage position sensor Location on the Machine

Page:

5-43

992G WHEEL LOADER


CHAPTER : IMPLEMENT SYSTEM

LAB EXERCISES
Lab B: Implement Hydraulic System Tests Worksheet 1 SENR1367
Following the procedures in the 992G Wheel Loader Hydraulic Systems Testing and Adjusting Module (Form SENR1367), perform the following tests: 1. Operational Checks 2. Release of Pressure in Implement Hydraulic System 3. Fixed Displacement Pump Test 4. Variable Displacement Pump Test 5. Pilot System Pressure Test - Pilot Relief Valve Adjustment - Pilot Pressure Supply with Engine OFF - Pilot Control Valve Chamber Pressure Check 6. Main System Pressure Tests - Fixed Displacement Pump Main Relief Valve Pressure Test - Left Valve Dump Line Relief Valve Test - Left Valve Tilt Back Line Relief Valve Test - Left Valve Raise Line Relief Valve Test - Left Valve Lower Line Relief Valve Test - Variable Displacement Pump Cutoff Valve Pressure Test - Torque Convertor Stall and Double Stall Test - Variable Displacement Pump Backup Relief Valve Pressure Test - Right Valve Dump Line Relief Valve Test - Fan Drive Pump Cutoff Pressure Test - Fan Drive Pump Margin Pressure Test

1. Page 43 2. Page 44 3. Page 45 4. Page 46 5. Pilot System - Page 55 - Page 56 - Page 56 6. Main System - Page 58 - Page 61 - Page 63 - Page 65 - Page 68 - Page 70 - Page 72, 89 - Page 73 - Page 77 - Page 91 - Page 92

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992G WHEEL LOADER


CHAPTER : IMPLEMENT SYSTEM

LAB EXERCISES
Lab B: Implement Hydraulic System Tests Worksheet PILOT SYSTEM PRESSURE TEST Pilot Relief Valve Specifications Machine Pressure FIXED DISPLACEMENT PUMP Main Relief Valve Specifications Machine Pressure LEFT VALVE GROUP Dump Line Relief Valve Specifications Machine Pressure Raise Line Relief Valve Specifications Machine Pressure VARIABLE DISPLACEMENT PUMP Cutoff Valve Specifications Machine Pressure RIGHT VALVE GROUP Dump Line Relief Valve Specifications Machine Pressure TORQUE CONVERTOR Stall Double Stall Back up Relief Valve Lower Line Relief Valve Tilt Back Line Relief Valve Case Drain Flow Pilot Pressure Engine Pilot Control Valve OFF Chamber Pressure

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