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5. IMPLEMENT SYSTEM
1. Components Layout 2. Operation 3. Testing & Adjusting
Adolfo OCTOBER 1997
Page:
HYDRAULIC TANK
Page: 5-3
CAT DATA LINK INPUT COMPONENTS OUTPUT COMPONENTS PILOT ON/OFF SOLENOID VARIABLE PUMP SOLENOID TILT RACKBACK SOLENOID NO. 1 TILT RACKBACK SOLENOID NO. 2
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
Page: 5-4
CAT DATA LINK
CHECK VALVE
FIXED PUMP
PILOT PUMP
VARIABLE PUMP
COMPONENTS
FILL CAP
VENT VALVE
HYDRAULIC TANK
Page:
5-5
PILOT PUMP
PUMP OUTLET
Page:
5-6
OIL OUTLET
OIL INLET
Page:
5-7
SIGNAL LINE
Page:
5-8
FLOAT VALVE
Page:
5-9
IMPLEMENT PUMPS
VARIABLE PUMP
CASE DRAIN
FIXED PUMP
Page:
5-10
Page: 5-11
CAT DATA LINK
CHECK VALVE
FIXED PUMP
PILOT PUMP
VARIABLE PUMP
Page:
VARIABLE PUMP SOLENOID VALVE TO PILOT SYSTEM
5-12
FLUID SAMPLING PORT
TO TANK PILOT RELIEF VALVE PRESSURE CUTOFF PILOT FILTER LOAD LIMIT CONTROL SHUTTLE VALVE TO IMPLEMENT CONTROL VALVE
LARGE ACTUATOR
Page:
TO PILOT SYSTEM
5-13
FLUID SAMPLING PORT
TO TANK PILOT RELIEF VALVE PRESSURE CUTOFF PILOT FILTER LOAD LIMIT CONTROL SHUTTLE VALVE TO IMPLEMENT CONTROL VALVE
LARGE ACTUATOR
PUMP
Page:
5-14
Page:
VARIABLE PUMP SOLENOID VALVE TO PILOT SYSTEM
5-15
FLUID SAMPLING PORT
TO TANK PILOT RELIEF VALVE PRESSURE CUTOFF PILOT FILTER LOAD LIMIT CONTROL SHUTTLE VALVE TO IMPLEMENT CONTROL VALVE
LARGE ACTUATOR
Page: 5-16
TILT CYLINDER
CHECK VALVE
LOWER KICKOUT DETENT SOLENOID LIFT LEVER SENSOR FIXED PUMP RELIEF VALVE
PILOT PUMP
VARIABLE PUMP
Page: 5-17
TILT CYLINDER
CHECK VALVE
LOWER KICKOUT DETENT SOLENOID LIFT LEVER SENSOR FIXED PUMP RELIEF VALVE
PILOT PUMP
VARIABLE PUMP
Page: 5-18
TILT CYLINDER
CHECK VALVE
LOWER KICKOUT DETENT SOLENOID LIFT LEVER SENSOR FIXED PUMP RELIEF VALVE
PILOT PUMP
VARIABLE PUMP
Page: 5-19
CAT DATA LINK BUCKET KICKOUT DETENT SOLENOID TILT LEVER SENSOR
TILT CYLINDER
CHECK VALVE
LOWER KICKOUT DETENT SOLENOID LIFT LEVER SENSOR FIXED PUMP RELIEF VALVE
PILOT PUMP
VARIABLE PUMP
Page: 5-20
BUCKET KICKOUT DETENT SOLENOID TILT LEVER SENSOR
TILT CYLINDER
CHECK VALVE
LOWER KICKOUT DETENT SOLENOID LIFT LEVER SENSOR FIXED PUMP 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
DUMP
DUMP
RAISE
FAN MOTOR PRESSURE CUTOFF SHUTTLE VALVE LOAD LIMIT CONTROL SMALL ACTUATOR LARGE ACTUATOR VARIABLE PUMP
FAN SPEED
COOLER
FIXED 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
DUMP
DUMP
RAISE
FAN MOTOR
PRESSURE CUTOFF
COOLER
FAN SPEED
SHUTTLE VALVE
FIXED PUMP
Page: 5-23
FLUID SAMPLING PORT
LIFT CYLINDER
SHUTTLE VALVE
LOWER
TILT
TILT
LOWER
RIDE CONTROL
DUMP
DUMP
RAISE
FAN MOTOR
FAN SPEED
COOLER
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
DUMP
DUMP
RAISE
FAN MOTOR PRESSURE CUTOFF SHUTTLE VALVE LOAD LIMIT CONTROL SMALL ACTUATOR LARGE ACTUATOR VARIABLE PUMP FIXED PUMP
FAN SPEED
COOLER
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
DUMP
DUMP
RAISE
FAN SPEED
COOLER
Page: 5-26
FLUID SAMPLING PORT
SHUTTLE VALVE
LOWER
TILT
TILT
LOWER
RIDE CONTROL
DUMP
DUMP
RAISE
FAN SPEED
PILOT PUMP
FLOAT VALVE
FLOAT OFF
FLOAT ON
Page: 5-28
FLUID SAMPLING PORT
SHUTTLE VALVE
LOWER
TILT
TILT
LOWER
RIDE CONTROL
DUMP
DUMP
RAISE
PILOT RELIEF VALVE PRESSURE CUTOFF SHUTTLE VALVE FIXED PUMP COOLER
FAN MOTOR
FAN SPEED
PILOT PUMP
Page:
IMPLEMENT HYDRAULIC SYSTEM
RIDE CONTROL ON
LIFT CYLINDER TILT CYLINDER LIFT CYLINDER
5-29
SHUTTLE VALVE
LOWER
TILT
TILT
LOWER
RIDE CONTROL
DUMP
DUMP
RAISE
PILOT RELIEF VALVE PRESSURE CUTOFF SHUTTLE VALVE FIXED PUMP COOLER
FAN MOTOR
FAN SPEED
PILOT PUMP
Page: 5-30
SCREEN
MAKEUP VALVE FAN DRIVE PUMP COMPENSATOR VALVE PROPORTIONAL VALVE IMPLEMENT HYDRAULIC COOLER OIL COOLER BYPASS VALVE
TANK
INPUTS TO PROPORTIONAL VALVE: --COOLANT TEMPERATURE SENSOR --STEERING TANK TEMPERATURE SENSOR --IMPLEMENT TANK TEMPERATURE SENSOR --AIR CONDITIONER ON/OFF SWITCH
COMPENSATOR VALVE
Page:
5-31
INTAKE HOSE
OUTLET HOSE
Page:
5-32
ENGINE
Page:
5-33
Page: 5-34
MAKEUP VALVE
TANK
Page: 5-35
SCREEN
MAKEUP VALVE
TANK
Page: 5-36
SCREEN
MAKEUP VALVE
TANK
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
X/2
GOES TO KICK-OUT
LOWER KICK-OUT
Page:
5-38
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
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
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
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
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
Page:
5-44
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
Page:
5-45