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 SYSTEM
1. Components Layout2. Operation3. Testing & Adjusting
CH
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992G W
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LO
AD
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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
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992G W
HE
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LO
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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
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992G W
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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
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992G W
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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
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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
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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
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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
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992G W
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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
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992G W
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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
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992G W
HE
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LO
AD
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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
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992G W
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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
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992G W
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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
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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
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992G W
HE
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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
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EN
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TE
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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
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992G W
HE
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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
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EN
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YS
TE
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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
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EN
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TE
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992G W
HE
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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
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R : IM
PL
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TE
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992G W
HE
EL
LO
AD
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5-27P
age:
FLOAT VALVE
PLUGPASSAGE TO
SEQUENCE VALVE
ORIFICE
TO LIFT CYLINDERROD END
FLOAT OFF FLOAT ON
CH
AP
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R : IM
PL
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TE
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992G W
HE
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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
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EN
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YS
TE
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992G W
HE
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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
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EN
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TE
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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
CH
AP
TE
R : IM
PL
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EN
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YS
TE
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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
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EN
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TE
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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
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EN
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YS
TE
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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
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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
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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
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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
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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
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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
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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