992 G Wheel Loader 5IMPLEM

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Transcript of 992 G Wheel Loader 5IMPLEM

  • Service TrainingMALAGA

    992G WHEEL LOADER

    AdolfoOCTOBER 1997

    5. IMPLEMENT SYSTEM1. Components Layout2. Operation3. Testing & Adjusting

  • CHAPTER : IMPLEM

    ENT SYSTEM

    992G W

    HEEL LOADER

    5-2Page:

    IMPLEMENTHYDRAULIC

    PUMPS

    PILOTPUMP

    VARIABLE PUMPSOLENOID VALVE

    PILOTRELIEFVALVE

    ELECTRONICCONTROLMODULE

    PILOT CONTROLLEVER MODULE

    MAIN CONTROLVALVE ASSEMBLY

    TILTCYLINDER

    HYDRAULICTANK

    LIFT LINKAGEPOSITION SENSOR

    LIFTCYLINDER

    TILT LINKAGEPOSITION SENSOR

    ELECTRONIC SYSTEMHYDRAULIC PILOT SYSTEM COMMON TO BOTH SYSTEMS

    MAIN HYDRAULIC SYSTEM

    ELECTRO-HYDRAULIC IMPLEMENT SYSTEM

  • CHAPTER : IMPLEM

    ENT SYSTEM

    992G W

    HEEL LOADER

    5-3Page:

    LIFT/LOWER/TILTKICKOUT SWITCH

    IMPLEMENTLOCKOUT SWITCH

    TILT LINKAGESENSOR

    LIFT LINKAGESENSOR

    TILT LEVERSENSOR

    LIFT LEVERSENSOR

    PILOT ON/OFFSOLENOID

    BUCKET KICKOUTDETENT SOLENOID

    LIFT RAISE KICKOUTDETENT SOLENOID

    LIFT LOWER KICKOUTDETENT SOLENOID

    VARIABLE PUMPSOLENOID

    TILT RACKBACKSOLENOID NO. 1

    TILT RACKBACKSOLENOID NO. 2

    TILT DUMPSOLENOID NO. 1

    TILT DUMPSOLENOID NO. 2

    LIFT LOWERSOLENOID NO. 1

    LIFT LOWERSOLENOID NO. 2

    LIFT RAISESOLENOID NO. 1

    LIFT RAISESOLENOID NO. 2

    CATDATA LINK

    IMPLEMENT ELECTRONICCONTROL MODULE

    (MAC-14)

    ELECTRONIC IMPLEMENT CONTROL SYSTEM

    INPUT COMPONENTS OUTPUT COMPONENTS

  • CHAPTER : IMPLEM

    ENT SYSTEM

    992G W

    HEEL LOADER

    5-4Page:

    LIFTLEVER

    SENSOR

    TILTLEVER

    SENSOR

    FIXEDPUMP

    LEFTLIFT

    CYLINDER

    RIGHTLIFT

    CYLINDER

    TILTCYLINDER

    SHUTTLEVALVE

    PRESSUREREDUCING

    VALVE

    PILOTON/OFFVALVE

    CHECKVALVE

    IMPLEMENTCONTROL

    VALVE

    BUCKETKICKOUTDETENT

    SOLENOID

    IMPLEMENTLOCKOUTSWITCH

    RAISE/LOW/TILTKICKOUT SET

    SWITCH

    TILT LINKAGEPOSITION SENSOR

    LIFT LINKAGEPOSITION SENSOR

    ELECTRONICCONTROLMODULE

    LIFTKICKOUTDETENT

    SOLENOID

    LOWERKICKOUTDETENT

    SOLENOID

    CATDATALINK

    ELECTRO-HYDRAULICIMPLEMENT SYSTEM

    PILOT SYSTEM COMPONENTS

    IMPLEMENTCONTROL

    VALVE

    VARIABLEPUMP

    SOLENOIDVALVE

    VARIABLEPUMP

    RELIEFVALVE

    PILOTRELIEFVALVE

    PILOTPUMP

    RELIEFVALVE

    CHECKVALVE

    FILTER

  • CHAPTER : IMPLEMENT SYSTEM

    992G WHEEL LOADER

    5-5Page:

    COMPONENTS

    HYDRAULIC TANK

    FILL CAP

    VENT VALVE

    SERVICE TOOL CONNECTOR

  • CHAPTER : IMPLEMENT SYSTEM

    992G WHEEL LOADER

    5-6Page:

    PILOT SYSTEM COMPONENTS

    PILOT CIRCUITPRESSURE TAP

    IMPLEMENT VARIABLEPISTON PUMP

    PUMP OUTLET

    PILOT PUMP

  • CHAPTER : IMPLEMENT SYSTEM

    992G WHEEL LOADER

    5-7Page:

    PILOT CIRCUIT COMPONENTS

    OIL INLET

    HYDRAULIC OIL FILTER

    OIL OUTLET

    OIL FILTER BYPASS SWITCH

  • CHAPTER : IMPLEMENT SYSTEM

    992G WHEEL LOADER

    5-8Page:

    PILOT CIRCUIT COMPONENTS

    VARIABLE PUMPSOLENOID VALVE

    SIGNAL LINE

    PILOT RELIEF VALVEPRESSURE SENSOR

    PILOT RELIEF VALVE

  • CHAPTER : IMPLEMENT SYSTEM

    992G WHEEL LOADER

    5-9Page:

    MAIN CONTROL VALVES

    LIFT HEAD ENDLINE RELIEF VALVE

    FLOATSEQUENCE

    VALVEFLOATVALVE

    PILOT ON/OFFSOLENOID VALVE

    FIXED PUMPRELIEF VALVE

    PILOT CONTROLSOLENOID VALVES

    LIFT ROD ENDLINE RELIEFVALVE

    TILT ROD END LINERELIEF VALVE

    TILT HEAD END LINERELIEF VALVE

  • CHAPTER : IMPLEMENT SYSTEM

    992G WHEEL LOADER

    5-10Page:

    IMPLEMENT PUMPS

    FIXED PUMPCASE DRAIN

    VARIABLE PUMP

  • CHAPTER : IMPLEM

    ENT SYSTEM

    992G W

    HEEL LOADER

    5-11Page:

    LIFTLEVER

    SENSOR

    TILTLEVER

    SENSOR

    LEFTLIFT

    CYLINDER

    RIGHTLIFT

    CYLINDER

    TILTCYLINDER

    SHUTTLEVALVE

    PRESSUREREDUCING

    VALVE

    PILOTON/OFFVALVE

    CHECKVALVE

    IMPLEMENTCONTROL

    VALVE

    BUCKETKICKOUTDETENT

    SOLENOID

    IMPLEMENTLOCKOUTSWITCH

    RAISE/LOW/TILTKICKOUT SET

    SWITCH

    TILT LINKAGEPOSITION SENSOR

    LIFT LINKAGEPOSITION SENSOR

    ELECTRONICCONTROLMODULE

    LIFTKICKOUTDETENT

    SOLENOID

    LOWERKICKOUTDETENT

    SOLENOID

    CATDATALINK

    ELECTRO-HYDRAULICIMPLEMENT SYSTEM

    MAIN HYDRAULIC SYSTEM COMPONENTS

    IMPLEMENTCONTROL

    VALVE

    VARIABLEPUMP

    SOLENOIDVALVE

    VARIABLEPUMP

    RELIEFVALVE

    PILOTRELIEFVALVE

    PILOTPUMP

    RELIEFVALVE

    FIXEDPUMP

    CHECKVALVE

    FILTER

  • CHAPTER : IMPLEM

    ENT SYSTEM

    992G W

    HEEL LOADER

    5-12Page:

    FLUIDSAMPLING

    PORT

    PILOTPUMP

    PILOTRELIEFVALVE

    PILOTFILTER

    VARIABLE IMPLEMENT PUMPLESS THAN 2400kPa (350 psi)

    VARIABLE PUMPSOLENOID VALVE

    LARGEACTUATOR

    SMALLACTUATOR

    TO TANKTO IMPLEMENT

    CONTROL VALVE

    TO PILOTSYSTEM

    PUMP

    LOADLIMIT

    CONTROL

    PRESSURECUTOFF

    SHUTTLEVALVE

  • CHAPTER : IMPLEM

    ENT SYSTEM

    992G W

    HEEL LOADER

    5-13Page:

    FLUIDSAMPLING

    PORT

    PILOTPUMP

    PILOTRELIEFVALVE

    PILOTFILTER

    VARIABLE IMPLEMENT PUMPLESS THAN 24,500 kPa (3550 psi)

    VARIABLE PUMPSOLENOID VALVE

    LARGEACTUATOR

    SMALLACTUATOR

    TO TANKTO IMPLEMENT

    CONTROL VALVE

    TO PILOTSYSTEM

    PUMP

    SHUTTLEVALVE

    LOADLIMIT

    CONTROL

    PRESSURECUTOFF

  • CHAPTER : IMPLEMENT SYSTEM

    992G WHEEL LOADER

    5-14Page:

    VARIABLE PUMP SOLENOID VALVE

    CONTROLS PILOT PRESSURE TO LOAD LIMITING CONTROL VALVE ONVARIABLE 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

  • CHAPTER : IMPLEM

    ENT SYSTEM

    992G W

    HEEL LOADER

    5-15Page:

    FLUIDSAMPLING

    PORT

    PILOTPUMP

    PILOTRELIEFVALVE

    PILOTFILTER

    VARIABLE IMPLEMENT PUMPMORE THAN 28,940 kPa (4200 psi)

    VARIABLE PUMPSOLENOID VALVE

    LARGEACTUATOR

    SMALLACTUATOR

    TO TANKTO IMPLEMENT

    CONTROL VALVE

    TO PILOTSYSTEM

    PUMP

    SHUTTLEVALVE

    LOADLIMIT

    CONTROL

    PRESSURECUTOFF

  • CHAPTER : IMPLEM

    ENT SYSTEM

    992G W

    HEEL LOADER

    5-16Page:

    LIFTLEVER

    SENSOR

    TILTLEVER

    SENSOR

    LEFTLIFT

    CYLINDER

    RIGHTLIFT

    CYLINDER

    SHUTTLEVALVE

    PRESSUREREDUCING

    VALVE

    PILOTON/OFFVALVE

    CHECKVALVE

    IMPLEMENTCONTROL

    VALVE

    BUCKETKICKOUTDETENT

    SOLENOID

    IMPLEMENTLOCKOUTSWITCH

    RAISE/LOW/TILTKICKOUT SET

    SWITCH

    TILT LINKAGEPOSITION SENSOR

    LIFT LINKAGEPOSITION SENSOR

    ELECTRONICCONTROLMODULE

    LIFTKICKOUTDETENT

    SOLENOID

    LOWERKICKOUTDETENT

    SOLENOID

    CATDATALINK

    ELECTRO-HYDRAULICIMPLEMENT SYSTEM

    HOLD

    IMPLEMENTCONTROL

    VALVE

    TILTCYLINDER

    FIXEDPUMP

    VARIABLEPUMP

    SOLENOIDVALVE

    VARIABLEPUMP

    RELIEFVALVE

    PILOTRELIEFVALVE

    PILOTPUMP

    RELIEFVALVE

    CHECKVALVE

    FILTER

  • CHAPTER : IMPLEM

    ENT SYSTEM

    992G W

    HEEL LOADER

    5-17Page:

    LIFTLEVER

    SENSOR

    TILTLEVER

    SENSOR

    LEFTLIFT

    CYLINDER

    RIGHTLIFT

    CYLINDER

    SHUTTLEVALVE

    PRESSUREREDUCING

    VALVE

    PILOTON/OFFVALVE

    CHECKVALVE

    IMPLEMENTCONTROL

    VALVE

    BUCKETKICKOUTDETENT

    SOLENOID

    IMPLEMENTLOCKOUTSWITCH

    RAISE/LOW/TILTKICKOUT SET

    SWITCH

    TILT LINKAGEPOSITION SENSOR

    LIFT LINKAGEPOSITION SENSOR

    ELECTRONICCONTROLMODULE

    LIFTKICKOUTDETENT

    SOLENOID

    LOWERKICKOUTDETENT

    SOLENOID

    CATDATALINK

    ELECTRO-HYDRAULICIMPLEMENT SYSTEM

    SLOW TILT

    IMPLEMENTCONTROL

    VALVE

    TILTCYLINDER

    FIXEDPUMP

    VARIABLEPUMP

    SOLENOIDVALVE

    VARIABLEPUMP

    RELIEFVALVE

    PILOTRELIEFVALVE

    PILOTPUMP

    RELIEFVALVE

    CHECKVALVE

    FILTER

  • CHAPTER : IMPLEM

    ENT SYSTEM

    992G W

    HEEL LOADER

    5-18Page:

    LIFTLEVER

    SENSOR

    TILTLEVER

    SENSOR

    LEFTLIFT

    CYLINDER

    RIGHTLIFT

    CYLINDER

    TILTCYLINDER

    SHUTTLEVALVE

    PRESSUREREDUCING

    VALVE

    PILOTON/OFFVALVE

    CHECKVALVE

    IMPLEMENTCONTROL

    VALVE

    BUCKETKICKOUTDETENT

    SOLENOID

    IMPLEMENTLOCKOUTSWITCH

    RAISE/LOW/TILTKICKOUT SET

    SWITCH

    TILT LINKAGEPOSITION SENSOR

    LIFT LINKAGEPOSITION SENSOR

    ELECTRONICCONTROLMODULE

    LIFTKICKOUTDETENT

    SOLENOID

    LOWERKICKOUTDETENT

    SOLENOID

    CATDATALINK

    ELECTRO-HYDRAULICIMPLEMENT SYSTEM

    FAST TILT

    IMPLEMENTCONTROL

    VALVE

    FIXEDPUMP

    VARIABLEPUMP

    SOLENOIDVALVE

    VARIABLEPUMP

    RELIEFVALVE

    PILOTRELIEFVALVE

    PILOTPUMP

    RELIEFVALVE

    CHECKVALVE

    FILTER

  • CHAPTER : IMPLEM

    ENT SYSTEM

    992G W

    HEEL LOADER

    5-19Page:

    LIFTLEVER

    SENSOR

    TILTLEVER

    SENSOR

    LEFTLIFT

    CYLINDER

    RIGHTLIFT

    CYLINDER

    TILTCYLINDER

    SHUTTLEVALVE

    PRESSUREREDUCING

    VALVE

    PILOTON/OFFVALVE

    CHECKVALVE

    IMPLEMENTCONTROL

    VALVE

    BUCKETKICKOUTDETENT

    SOLENOID

    IMPLEMENTLOCKOUTSWITCH

    RAISE/LOW/TILTKICKOUT SET

    SWITCH