Download - 992 G Wheel Loader 5IMPLEM

Transcript

Service TrainingMALAGA

992G WHEEL LOADER

AdolfoOCTOBER 1997

5. IMPLEMENT SYSTEM

1. Components Layout2. Operation3. Testing & Adjusting

CH

AP

TE

R : IM

PL

EM

EN

T S

YS

TE

M

992G W

HE

EL

LO

AD

ER

5-2P

age:

IMPLEMENTHYDRAULIC

PUMPS

PILOTPUMP

VARIABLE PUMPSOLENOID VALVE

PILOTRELIEFVALVE

ELECTRONICCONTROLMODULE

PILOT CONTROLLEVER MODULE

MAIN CONTROLVALVE ASSEMBLY

TILTCYLINDER

HYDRAULICTANK

LIFT LINKAGEPOSITION SENSOR

LIFTCYLINDER

TILT LINKAGEPOSITION SENSOR

ELECTRONIC SYSTEM

HYDRAULIC PILOT SYSTEM COMMON TO BOTH SYSTEMS

MAIN HYDRAULIC SYSTEM

ELECTRO-HYDRAULIC IMPLEMENT SYSTEM

CH

AP

TE

R : IM

PL

EM

EN

T S

YS

TE

M

992G W

HE

EL

LO

AD

ER

5-3P

age:

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

CH

AP

TE

R : IM

PL

EM

EN

T S

YS

TE

M

992G W

HE

EL

LO

AD

ER

5-4P

age:

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

CH

AP

TE

R : IM

PL

EM

EN

T S

YS

TE

M

992G W

HE

EL

LO

AD

ER

5-11P

age:

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

CH

AP

TE

R : IM

PL

EM

EN

T S

YS

TE

M

992G W

HE

EL

LO

AD

ER

5-12P

age:

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

CH

AP

TE

R : IM

PL

EM

EN

T S

YS

TE

M

992G W

HE

EL

LO

AD

ER

5-13P

age:

FLUIDSAMPLING

PORT

PILOTPUMP

PILOTRELIEFVALVE

PILOTFILTER

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

VARIABLE PUMPSOLENOID VALVE

LARGEACTUATOR

SMALLACTUATOR

TO TANK

TO IMPLEMENTCONTROL 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<P<28900 kPa)

VARIABLE PUMPSOLENOID VALVE

IMPLEMENTPILOT RELIEF

CH

AP

TE

R : IM

PL

EM

EN

T S

YS

TE

M

992G W

HE

EL

LO

AD

ER

5-15P

age:

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

CH

AP

TE

R : IM

PL

EM

EN

T S

YS

TE

M

992G W

HE

EL

LO

AD

ER

5-16P

age:

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

CH

AP

TE

R : IM

PL

EM

EN

T S

YS

TE

M

992G W

HE

EL

LO

AD

ER

5-17P

age:

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

CH

AP

TE

R : IM

PL

EM

EN

T S

YS

TE

M

992G W

HE

EL

LO

AD

ER

5-18P

age:

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

CH

AP

TE

R : IM

PL

EM

EN

T S

YS

TE

M

992G W

HE

EL

LO

AD

ER

5-19P

age:

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

SLOW LIFT

IMPLEMENTCONTROL

VALVE

FIXEDPUMP

VARIABLEPUMP

SOLENOIDVALVE

VARIABLEPUMP

RELIEFVALVE

PILOTRELIEFVALVE

PILOTPUMP

RELIEFVALVE

CHECKVALVE

FILTER

CH

AP

TE

R : IM

PL

EM

EN

T S

YS

TE

M

992G W

HE

EL

LO

AD

ER

5-20P

age:

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 LIFT

IMPLEMENTCONTROL

VALVE

FIXEDPUMP

VARIABLEPUMP

SOLENOIDVALVE

VARIABLEPUMP

RELIEFVALVE

PILOTRELIEFVALVE

PILOTPUMP

RELIEFVALVE

CHECKVALVE

FILTER

CH

AP

TE

R : IM

PL

EM

EN

T S

YS

TE

M

992G W

HE

EL

LO

AD

ER

5-21P

age:

LOWERLOWER TILT TILT RIDECONTROL

FAN SPEED

RAISEDUMPDUMPRAISE

FLUIDSAMPLING

PORT

LIFTCYLINDER

LIFTCYLINDERTILT CYLINDER

FIXEDPUMP

PILOTPUMP

PILOTRELIEFVALVE

PILOTON/OFFVALVE

PRESSUREREDUCING

VALVE SHUTTLEVALVE

VARIABLEPUMP

LOAD LIMITCONTROL

PRESSURECUTOFF

SMALLACTUATOR

LARGEACTUATOR

SHUTTLEVALVE

VARIABLE PUMPSOLENOID VALVE

IMPLEMENT HYDRAULIC SYSTEMHOLD

FANDRIVEPUMP

FANMOTOR

COOLER

FLOATVALVE

FLOATVALVE

FLOATSEQUENCE

VALVE

CH

AP

TE

R : IM

PL

EM

EN

T S

YS

TE

M

992G W

HE

EL

LO

AD

ER

5-22P

age:

FANDRIVEPUMP

FANMOTOR

LOWERLOWER TILT TILT RIDECONTROL

FAN SPEED

RAISEDUMPDUMPRAISE

FLUIDSAMPLING

PORT

LIFTCYLINDER

LIFTCYLINDERTILT CYLINDER

IMPLEMENT HYDRAULIC SYSTEMSLOW TILT

FIXEDPUMP

VARIABLEPUMP

PILOTPUMP

PILOTRELIEFVALVE

PILOTON/OFFVALVE

PRESSUREREDUCING

VALVE SHUTTLEVALVE

LOAD LIMITCONTROL

PRESSURECUTOFF

SMALLACTUATOR

LARGEACTUATOR

SHUTTLEVALVE

VARIABLE PUMPSOLENOID VALVE

COOLER

FLOATVALVE

FLOATVALVE

FLOATSEQUENCE

VALVE

CH

AP

TE

R : IM

PL

EM

EN

T S

YS

TE

M

992G W

HE

EL

LO

AD

ER

5-23P

age:

FANDRIVEPUMP

FANMOTOR

COOLER

LOWERLOWER TILT TILT RIDECONTROL

FAN SPEED

RAISEDUMPDUMPRAISE

FLUIDSAMPLING

PORT

LIFTCYLINDER

LIFTCYLINDERTILT CYLINDER

IMPLEMENT HYDRAULIC SYSTEMFAST TILT

FIXEDPUMP

PILOTPUMP

PILOTRELIEFVALVE

PILOTON/OFFVALVE

PRESSUREREDUCING

VALVE SHUTTLEVALVE

VARIABLEPUMP

LOAD LIMITCONTROL

PRESSURECUTOFF

SMALLACTUATOR

LARGEACTUATOR

SHUTTLEVALVE

VARIABLE PUMPSOLENOID VALVE

FLOATVALVE

FLOATVALVE

FLOATSEQUENCE

VALVE

CH

AP

TE

R : IM

PL

EM

EN

T S

YS

TE

M

992G W

HE

EL

LO

AD

ER

5-24P

age:

LOWERLOWER TILT TILT RIDECONTROL

FAN SPEED

RAISEDUMPDUMPRAISE

FLUIDSAMPLING

PORT

VARIABLE PUMPSOLENOID VALVE

LIFTCYLINDER

LIFTCYLINDERTILT CYLINDER

IMPLEMENT HYDRAULIC SYSTEMSLOW LOWER

FIXEDPUMP

PILOTPUMP

PILOTRELIEFVALVE

PILOTON/OFFVALVE

PRESSUREREDUCING

VALVE SHUTTLEVALVE

VARIABLEPUMP

LOAD LIMITCONTROL

PRESSURECUTOFF

SMALLACTUATOR

LARGEACTUATOR

SHUTTLEVALVE

FANDRIVEPUMP

FANMOTOR

COOLER

FLOATVALVE

FLOATVALVE

FLOATSEQUENCE

VALVE

CH

AP

TE

R : IM

PL

EM

EN

T S

YS

TE

M

992G W

HE

EL

LO

AD

ER

5-25P

age:

FANDRIVEPUMP

FANMOTOR

COOLER

LOWERLOWER TILT TILT RIDECONTROL

FAN SPEED

RAISEDUMPDUMPRAISE

FLUIDSAMPLING

PORT

LIFTCYLINDER

LIFTCYLINDERTILT CYLINDER

IMPLEMENT HYDRAULIC SYSTEMFAST LOWER

FIXEDPUMP

PILOTPUMP

PILOTRELIEFVALVE

PILOTON/OFFVALVE

PRESSUREREDUCING

VALVE SHUTTLEVALVE

VARIABLEPUMP

SMALLACTUATOR

LARGEACTUATOR

SHUTTLEVALVE

LOAD LIMITCONTROL

PRESSURECUTOFF

VARIABLE PUMPSOLENOID VALVE

FLOATVALVE

FLOATVALVE

FLOATSEQUENCE

VALVE

CH

AP

TE

R : IM

PL

EM

EN

T S

YS

TE

M

992G W

HE

EL

LO

AD

ER

5-26P

age:

FANDRIVEPUMP

FANMOTOR

COOLER

LOWERLOWER TILT TILT RIDECONTROL

FAN SPEED

RAISEDUMPDUMPRAISE

FLUIDSAMPLING

PORT

LIFTCYLINDER

LIFTCYLINDERTILT CYLINDER

IMPLEMENT HYDRAULIC SYSTEMFLOAT

FIXEDPUMP

PILOTPUMP

PILOTRELIEFVALVE

PILOTON/OFFVALVE

PRESSUREREDUCING

VALVE SHUTTLEVALVE

VARIABLEPUMP

SMALLACTUATOR

LARGEACTUATOR

SHUTTLEVALVE

LOAD LIMITCONTROL

PRESSURECUTOFF

VARIABLE PUMPSOLENOID VALVE

FLOATVALVE

FLOATVALVE

FLOATSEQUENCE

VALVE

CH

AP

TE

R : IM

PL

EM

EN

T S

YS

TE

M

992G W

HE

EL

LO

AD

ER

5-27P

age:

FLOAT VALVE

PLUGPASSAGE TO

SEQUENCE VALVE

ORIFICE

TO LIFT CYLINDERROD END

FLOAT OFF FLOAT ON

CH

AP

TE

R : IM

PL

EM

EN

T S

YS

TE

M

992G W

HE

EL

LO

AD

ER

5-28P

age:

FANDRIVEPUMP

FANMOTOR

COOLER

LOWERLOWER TILT TILT RIDECONTROL

FAN SPEED

RAISEDUMPDUMPRAISE

FLUIDSAMPLING

PORT

LIFTCYLINDER

LIFTCYLINDERTILT CYLINDER

IMPLEMENT HYDRAULIC SYSTEMLOWER ENGINE OFF

FIXEDPUMP

PILOTPUMP

PILOTRELIEFVALVE

PILOTON/OFFVALVE

PRESSUREREDUCING

VALVE SHUTTLEVALVE

VARIABLEPUMP

SMALLACTUATOR

LARGEACTUATOR

SHUTTLEVALVE

LOAD LIMITCONTROL

PRESSURECUTOFF

VARIABLE PUMPSOLENOID VALVE

FLOATVALVE

FLOATVALVE

FLOATSEQUENCE

VALVE

CH

AP

TE

R : IM

PL

EM

EN

T S

YS

TE

M

992G W

HE

EL

LO

AD

ER

5-29P

age:

FANDRIVEPUMP

FANMOTOR

COOLER

LOWERLOWER TILT TILT RIDECONTROL

FAN SPEED

RAISEDUMPDUMPRAISE

FLUIDSAMPLING

PORT

LIFTCYLINDER

LIFTCYLINDERTILT CYLINDER

IMPLEMENT HYDRAULIC SYSTEMRIDE CONTROL ON

FIXEDPUMP

PILOTPUMP

PILOTRELIEFVALVE

PILOTON/OFFVALVE

PRESSUREREDUCING

VALVE SHUTTLEVALVE

VARIABLEPUMP

SMALLACTUATOR

LARGEACTUATOR

SHUTTLEVALVE

LOAD LIMITCONTROL

PRESSURECUTOFF

VARIABLE PUMPSOLENOID VALVE

FLOATVALVE

FLOATVALVE

FLOATSEQUENCE

VALVE

CH

AP

TE

R : IM

PL

EM

EN

T S

YS

TE

M

992G W

HE

EL

LO

AD

ER

5-30P

age:

FAN

FANMOTOR

FANDRIVEPUMP

TANK

SCREEN

MAKEUPVALVE

OILCOOLERBYPASSVALVE

IMPLEMENTHYDRAULIC

COOLER

COMPENSATORVALVE

PROPORTIONALVALVE

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

ENGINEECM

FAN DRIVE SYSTEMENGINE OFF

CHAPTER : IMPLEMENT SYSTEM

992G WHEEL LOADER

5-31Page:

FAN DRIVE COMPONENTS

SIGNALPRESSURE

OUTLET

PROPORTIONALVALVE

SOLENOID

MARGIN SPOOLADJUSTMENT

PRESSURECOMPENSATORADJUSTMENT

COMPENSATORVALVE

ELECTRO-HYDRAULICPROPORTIONAL VALVE

SIGNALPRESSURE TEST

PORT

SYSTEMPRESSURETEST PORT

FAN DRIVEPUMP

CHAPTER : IMPLEMENT SYSTEM

992G WHEEL LOADER

5-32Page:

FAN DRIVEMOTOR

CASE DRAINHOSE

INTAKE HOSE OUTLET HOSE

CHAPTER : IMPLEMENT SYSTEM

992G WHEEL LOADER

5-33Page:

ENGINE

992G COOLER LOCATION

CH

AP

TE

R : IM

PL

EM

EN

T S

YS

TE

M

992G W

HE

EL

LO

AD

ER

5-34P

age:

FAN

FANMOTOR

FANDRIVEPUMP

FAN DRIVE SYSTEMSOLENOID DE-ENERGIZED

TANK

SCREEN

MAKEUPVALVE

OILCOOLERBYPASSVALVE

IMPLEMENTHYDRAULIC

COOLER

COMPENSATORVALVE

PROPORTIONALVALVE

PUMP UPSTROKES

CH

AP

TE

R : IM

PL

EM

EN

T S

YS

TE

M

992G W

HE

EL

LO

AD

ER

5-35P

age:

FAN

FANMOTOR

FANDRIVEPUMP

FAN DRIVE SYSTEMSOLENOID ENERGIZED

TANK

SCREEN

MAKEUPVALVE

OILCOOLERBYPASSVALVE

IMPLEMENTHYDRAULIC

COOLER

COMPENSATORVALVE

PROPORTIONALVALVE

CH

AP

TE

R : IM

PL

EM

EN

T S

YS

TE

M

992G W

HE

EL

LO

AD

ER

5-36P

age:

FAN

FANMOTOR

FANDRIVEPUMP

FAN DRIVE SYSTEMRAPID ENGINE DECELERATION

TANK

SCREEN

MAKEUPVALVE

OILCOOLERBYPASSVALVE

IMPLEMENTHYDRAULIC

COOLER

COMPENSATORVALVE

PROPORTIONALVALVE

CHAPTER : IMPLEMENT SYSTEM

992G WHEEL LOADER

5-37Page:

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)

1

3

2

6

5 7

48

CHAPTER : IMPLEMENT SYSTEM

992G WHEEL LOADER

5-38Page:

UPPER KICK-OUT(above mid point)

LOWER KICK-OUT

X

X / 2 GOES TO KICK-OUT

GOES TO FLOAT(hits ground)

SETTING BUCKET KICKOUTS

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

CHAPTER : IMPLEMENT SYSTEM

992G WHEEL LOADER

5-39Page:

LINKAGE POSITION SENSOR REPLACE1- REPLACE AND INSTALL SENSOR AS INDICATED IN T&A2- DIAL “SERV” IN KEYPAD3- SCROLL (>) TO SET SENSORS, LIFT SENSORS ONLY4- 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 CAM7 - DUTY CYCLE CAN BE READ ON DISPLAY OR CONNECTING FLUKE TO SENSOR8- PERFORM CALIBRATION BEFORE PUTTING MACHINE BACK IN SERVICELINKAGE POSITION SENSOR CALIBRATION1- PARKING BRAKE ON2- RIDE CONTROL SWITCH OFF3- LOW IDLE4- HYD OIL TEMP > 30 C5- PRESS OK UNTIL ALL EVENTS ACKNOWLEDGED6- ENTER SERV7- PRESS SCROLL (>) UNTIL LFT LINK SNSR - CAL8- FOLLOW INSTRUCTIONS

CHAPTER : IMPLEMENT SYSTEM

992G WHEEL LOADER

5-40Page:

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

PROCEDURE1) PKNG BRAKE ON2) LOW IDLE3) MACHINE IN WIDE OPEN SPACE4) HYDRAULIC OIL > 30°C5) “OK” UNTIL ALL EVENTS ACKNOWLEDGED6) “SERV” AND SCROLL (>) UNTIL

“IMPL VALVE SOL - CAL” APPEARS7) “OK” TO START.....FOLLOW INSTRUCTIONS

ERRORS

1 - SOLENOID ERRORCHECK SOL/CAL/WIRNG

4 - LFT LINK SNSR ERRCHECK SNSR/CAL/WIRNG

2 - CURRENT ABOVE RANGE

3- CURRENT BELOW RANGE

CHECK FOR CODES, CORRECT ANDRECALIBRATE

HYDRAULIC PROBLEMS. CHECKIMPLEMENT AND PILOT PUMPPRESSURES. MAKE SURE BUCKET IS

HYDRAULIC PROBLEMS. CHECKFOR EXCESSIVE CYLINDER DRIFT

CHECK FOR CODES, CORRECT ANDRECALIBRATE

CHAPTER : IMPLEMENT SYSTEM

992G WHEEL LOADER

5-41Page:

VARIABLE DISPLACEMENT PUMP TESTS

DISSABLES LEFT SIDE OF IMPLEMENT CONTROL VALVE

ISOLATES VARIABLE DISPLACEMENT PUMP

PROCEDURE1) PKNG BRAKE ON2) XMS NEUTRAL3) START ENGINE4) WARM OIL TO 49°C5) “OK” UNTIL ALL EVENTS ACKNOWLEDGED6) “SERV” AND SCROLL (>) UNTIL

“IMPL RLF - VAR PUMP” APPEARS7) “OK” TO START.....FOLLOW INSTRUCTIONS8) EVERY 5 SEC

PRESS [<] OR [>] TO SEE SPEC LIST

SPECIFICATIONS INDICATED ON MESSAGE DISPLAY AREUPDATED 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

CHAPTER : IMPLEMENT SYSTEM

992G WHEEL LOADER

5-42Page:

FIXED DISPLACEMENT PUMP TESTS

DISSABLES RIGHT SIDE OF IMPLEMENT CONTROL VALVE

ISOLATES FIXED DISPLACEMENT PUMP

PROCEDURE1) PKNG BRAKE ON2) XMS NEUTRAL3) START ENGINE4) WARM OIL TO 49°C5) “OK” UNTIL ALL EVENTS ACKNOWLEDGED6) “SERV” AND SCROLL (>) UNTIL

IMPL RLF - FIX PUMP APPEARS7) “OK” TO START.....FOLLOW INSTRUCTIONS8) EVERY 5 SEC

PRESS [<] OR [>] TO SEE SPEC LIST

SPECIFICATIONS INDICATED ON MESSAGE DISPLAY AREUPDATED 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

LAB EXERCISES

CHAPTER : IMPLEMENT SYSTEM

992G WHEEL LOADER

5-43Page:

Lab A: Implement Hydraulic Component Identification QuizWorksheet

Directions: Use this worksheet and the notes during the presentation to locate the components on the machine.

Component Location on the Machine

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

LAB EXERCISES

CHAPTER : IMPLEMENT SYSTEM

992G WHEEL LOADER

5-44Page:

Lab B: Implement Hydraulic System Tests Worksheet 1

Following the procedures in the 992G Wheel Loader Hydraulic SystemsTesting and Adjusting Module (Form SENR1367), perform the followingtests:

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

SENR1367

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

LAB EXERCISES

CHAPTER : IMPLEMENT SYSTEM

992G WHEEL LOADER

5-45Page:

Lab B: Implement Hydraulic System Tests Worksheet

Pilot ReliefValve

Pilot Pressure EngineOFF

Pilot Control ValveChamber Pressure

Specifications

Machine Pressure

FIXED DISPLACEMENT PUMP

Main Relief Valve Case Drain Flow

Specifications

Machine Pressure

PILOT SYSTEM PRESSURE TEST

VARIABLE DISPLACEMENT PUMP

Cutoff Valve Back up Relief Valve

Specifications

Machine Pressure

RIGHT VALVE GROUP TORQUE CONVERTOR

Dump Line Relief Valve Stall Double Stall

Specifications

Machine Pressure

LEFT VALVE GROUP

Dump Line Relief Valve Tilt Back Line Relief Valve

Raise Line Relief Valve Lower Line Relief Valve

Specifications

Machine Pressure

Specifications

Machine Pressure