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MALAGA
5. IMPLEMENT SYSTEM
1. Components Layout
2. Operation
3. Testing & Adjusting
Adolfo
OCTOBER 1997
Page:
IMPLEMENT ELECTRONIC
CONTROL MODULE
(MAC-14)
CAT
DATA LINK
INPUT COMPONENTS OUTPUT COMPONENTS
PILOT ON/OFF
TILT LEVER SOLENOID
SENSOR
VARIABLE PUMP
SOLENOID
LIFT LEVER
SENSOR
TILT RACKBACK
SOLENOID NO. 1
LIFT RAISE
SOLENOID NO. 1
LIFT RAISE
SOLENOID NO. 2
BUCKET KICKOUT
DETENT SOLENOID
Page:
5-4
ELECTRO-HYDRAULIC
IMPLEMENT SYSTEM
TILT
PILOT SYSTEM COMPONENTS RIGHT
CYLINDER
LEFT
LIFT LIFT
CYLINDER CYLINDER
SHUTTLE
VALVE
IMPLEMENT RAISE/LOW/TILT
LOCKOUT KICKOUT SET
SWITCH SWITCH PRESSURE
REDUCING
VALVE
CHECK
BUCKET LIFT LOWER VALVE
KICKOUT KICKOUT KICKOUT
DETENT DETENT DETENT
SOLENOID SOLENOID RELIEF
SOLENOID VALVE
RELIEF PILOT FILTER
TILT LIFT VALVE RELIEF
LEVER LEVER VALVE
SENSOR SENSOR VARIABLE
PUMP
SOLENOID VARIABLE
FIXED PILOT VALVE PUMP
PUMP PUMP
992G WHEEL LOADER
CHAPTER : IMPLEMENT SYSTEM
COMPONENTS
Page: 5-5
992G WHEEL LOADER
CHAPTER : IMPLEMENT SYSTEM
Page: 5-6
992G WHEEL LOADER
CHAPTER : IMPLEMENT SYSTEM
Page: 5-7
992G WHEEL LOADER
CHAPTER : IMPLEMENT SYSTEM
Page: 5-8
992G WHEEL LOADER
CHAPTER : IMPLEMENT SYSTEM
Page: 5-9
992G WHEEL LOADER
CHAPTER : IMPLEMENT SYSTEM
IMPLEMENT PUMPS
VARIABLE PUMP
CASE DRAIN
FIXED PUMP
Page: 5-10
Page:
5-11
ELECTRO-HYDRAULIC
IMPLEMENT SYSTEM
TILT
MAIN HYDRAULIC SYSTEM COMPONENTS RIGHT
CYLINDER
LEFT
LIFT LIFT
CYLINDER CYLINDER
SHUTTLE
VALVE
IMPLEMENT RAISE/LOW/TILT
LOCKOUT KICKOUT SET
SWITCH SWITCH PRESSURE
REDUCING
VALVE
TILT LINKAGE
POSITION SENSOR
CHECK
BUCKET LIFT LOWER VALVE
KICKOUT KICKOUT KICKOUT
DETENT DETENT DETENT
SOLENOID SOLENOID RELIEF
SOLENOID VALVE
RELIEF PILOT
RELIEF FILTER
TILT LIFT VALVE
LEVER LEVER VALVE
SENSOR SENSOR VARIABLE
PUMP
SOLENOID VARIABLE
FIXED PILOT VALVE
PUMP PUMP
PUMP
Page:
VARIABLE PUMP
5-12
SOLENOID VALVE
TO PILOT
SYSTEM
VARIABLE IMPLEMENT PUMP
LESS THAN 2400kPa (350 psi)
TO TANK
PILOT TO IMPLEMENT
RELIEF CONTROL VALVE
VALVE
PRESSURE
LOAD
PILOT
FLUID
SAMPLING
PORT SMALL
ACTUATOR
PILOT
PUMP PUMP
LARGE
ACTUATOR
Page:
VARIABLE PUMP
SOLENOID VALVE
TO PILOT
5-13
SYSTEM
TO TANK
PILOT TO IMPLEMENT
RELIEF CONTROL VALVE
VALVE
PRESSURE
CUTOFF
FLUID
SAMPLING
PORT SMALL
ACTUATOR
PILOT
PUMP
LARGE PUMP
ACTUATOR
992G WHEEL LOADER
CHAPTER : IMPLEMENT SYSTEM
VARIABLE PUMP
SOLENOID VALVE
IMPLEMENT
PILOT RELIEF
Page: 5-14
Page:
VARIABLE PUMP
SOLENOID VALVE
5-15
TO PILOT
SYSTEM
VARIABLE IMPLEMENT PUMP
MORE THAN 28,940 kPa (4200 psi)
TO TANK
PILOT TO IMPLEMENT
RELIEF CONTROL VALVE
VALVE
PRESSURE
LOAD
PILOT
FLUID
SAMPLING
PORT SMALL
ACTUATOR
PILOT
PUMP PUMP
LARGE
ACTUATOR
Page:
5-16
ELECTRO-HYDRAULIC TILT
CYLINDER
IMPLEMENT SYSTEM RIGHT
LIFT
LEFT
LIFT
CYLINDER CYLINDER
HOLD
SHUTTLE
VALVE
IMPLEMENT RAISE/LOW/TILT
LOCKOUT KICKOUT SET
SWITCH SWITCH PRESSURE
REDUCING
VALVE
CHECK
BUCKET LIFT LOWER VALVE
KICKOUT KICKOUT KICKOUT
DETENT DETENT DETENT
SOLENOID SOLENOID RELIEF
SOLENOID PILOT VALVE
RELIEF RELIEF
TILT LIFT FIXED VALVE VALVE FILTER
LEVER LEVER PUMP
SENSOR SENSOR VARIABLE
PUMP
SOLENOID VARIABLE
PILOT VALVE PUMP
PUMP
Page:
5-17
ELECTRO-HYDRAULIC TILT
CYLINDER
IMPLEMENT SYSTEM RIGHT
LIFT
LEFT
LIFT
CYLINDER CYLINDER
SLOW TILT
SHUTTLE
VALVE
IMPLEMENT RAISE/LOW/TILT
LOCKOUT KICKOUT SET
SWITCH SWITCH PRESSURE
REDUCING
VALVE
TILT LINKAGE
POSITION SENSOR
CHECK
BUCKET LIFT LOWER VALVE
KICKOUT KICKOUT KICKOUT
DETENT DETENT DETENT
SOLENOID SOLENOID RELIEF
SOLENOID PILOT VALVE
RELIEF RELIEF
TILT LIFT FIXED VALVE VALVE FILTER
LEVER LEVER PUMP
SENSOR SENSOR VARIABLE
PUMP
SOLENOID VARIABLE
PILOT VALVE PUMP
PUMP
Page:
5-18
ELECTRO-HYDRAULIC TILT
CYLINDER
IMPLEMENT SYSTEM RIGHT
LIFT
LEFT
LIFT
CYLINDER CYLINDER
FAST TILT
SHUTTLE
VALVE
IMPLEMENT RAISE/LOW/TILT
LOCKOUT KICKOUT SET
SWITCH SWITCH PRESSURE
REDUCING
VALVE
TILT LINKAGE
POSITION SENSOR
CHECK
BUCKET LIFT LOWER VALVE
KICKOUT KICKOUT
DETENT KICKOUT
DETENT DETENT
SOLENOID SOLENOID RELIEF
SOLENOID PILOT VALVE
RELIEF RELIEF
TILT LIFT FIXED VALVE VALVE FILTER
LEVER LEVER PUMP
SENSOR SENSOR VARIABLE
PUMP
SOLENOID VARIABLE
PILOT VALVE PUMP
PUMP
Page:
5-19
ELECTRO-HYDRAULIC TILT
CYLINDER
IMPLEMENT SYSTEM RIGHT
LIFT
LEFT
LIFT
CYLINDER CYLINDER
SLOW LIFT
SHUTTLE
VALVE
IMPLEMENT RAISE/LOW/TILT
LOCKOUT KICKOUT SET
SWITCH SWITCH PRESSURE
REDUCING
VALVE
TILT LINKAGE
POSITION SENSOR
IMPLEMENT IMPLEMENT
CHECK
BUCKET LIFT LOWER VALVE
KICKOUT KICKOUT KICKOUT
DETENT DETENT
SOLENOID DETENT RELIEF
SOLENOID SOLENOID PILOT VALVE
RELIEF RELIEF
TILT LIFT FIXED VALVE VALVE FILTER
LEVER LEVER PUMP
SENSOR SENSOR VARIABLE
PUMP
SOLENOID VARIABLE
PILOT VALVE PUMP
PUMP
Page:
5-20
ELECTRO-HYDRAULIC
IMPLEMENT SYSTEM TILT
RIGHT CYLINDER
LEFT
FAST LIFT LIFT LIFT
CYLINDER CYLINDER
SHUTTLE
VALVE
IMPLEMENT RAISE/LOW/TILT
LOCKOUT KICKOUT SET
SWITCH SWITCH PRESSURE
REDUCING
VALVE
TILT LINKAGE
POSITION SENSOR
IMPLEMENT IMPLEMENT
CHECK
BUCKET LOWER VALVE
KICKOUT LIFT
DETENT KICKOUT KICKOUT
SOLENOID DETENT DETENT RELIEF
SOLENOID SOLENOID PILOT VALVE
RELIEF RELIEF
TILT LIFT FIXED VALVE VALVE FILTER
LEVER LEVER PUMP
SENSOR SENSOR VARIABLE
PUMP
SOLENOID VARIABLE
PILOT VALVE PUMP
PUMP
Page:
PRESSURE
REDUCING
VALVE SHUTTLE
VALVE
PILOT
ON/OFF
VALVE
FLOAT FLOAT
SEQUENCE VALVE
VARIABLE PUMP VALVE FLOAT
SOLENOID VALVE VALVE
LOAD LIMIT
CONTROL FAN
FLUID DRIVE
SAMPLING SMALL PUMP
PORT ACTUATOR
VARIABLE
LARGE PUMP
ACTUATOR
PILOT
PUMP
Page:
LIFT LIFT
TILT CYLINDER CYLINDER
CYLINDER
PRESSURE
REDUCING
VALVE SHUTTLE
VALVE
PILOT
ON/OFF
VALVE
FLOAT FLOAT
SEQUENCE VALVE
VARIABLE PUMP VALVE FLOAT
PRESSURE
REDUCING SHUTTLE
VALVE VALVE
PILOT
ON/OFF
VALVE
FLOAT FLOAT
SEQUENCE VALVE
VARIABLE PUMP VALVE FLOAT
LIFT LIFT
TILT CYLINDER CYLINDER
CYLINDER
PRESSURE
REDUCING
SHUTTLE
VALVE VALVE
PILOT
ON/OFF
VALVE
FLOAT FLOAT
SEQUENCE VALVE
VALVE FLOAT
VARIABLE PUMP
SOLENOID VALVE VALVE
LOAD LIMIT
CONTROL FAN
FLUID DRIVE
SAMPLING SMALL PUMP
PORT ACTUATOR
VARIABLE
LARGE PUMP
ACTUATOR
PILOT
PUMP
Page:
PRESSURE
REDUCING
SHUTTLE
VALVE VALVE
PILOT
ON/OFF
VALVE
FLOAT FLOAT
SEQUENCE VALVE
VARIABLE PUMP VALVE FLOAT
PILOT
PUMP
Page:
PRESSURE
REDUCING
SHUTTLE
VALVE VALVE
PILOT
ON/OFF
VALVE
FLOAT FLOAT
SEQUENCE VALVE
VARIABLE PUMP VALVE FLOAT
SOLENOID VALVE VALVE
PILOT
PUMP
Page:
5-27
FLOAT VALVE
PLUG
PASSAGE TO
SEQUENCE VALVE
ORIFICE
FLOAT OFF FLOAT ON
Page:
PRESSURE
REDUCING
SHUTTLE
VALVE VALVE
PILOT
ON/OFF
VALVE
FLOAT FLOAT
SEQUENCE VALVE
VARIABLE PUMP VALVE FLOAT
SOLENOID VALVE VALVE
PRESSURE
CUTOFF COOLER
SHUTTLE
VALVE FIXED
PUMP
PILOT
PUMP
Page:
PRESSURE
REDUCING
SHUTTLE
VALVE VALVE
PILOT
ON/OFF
VALVE
FLOAT FLOAT
SEQUENCE VALVE
VARIABLE PUMP VALVE FLOAT
PILOT
PUMP
Page:
5-30
SCREEN
MAKEUP
VALVE
PROPORTIONAL
Page: 5-31
992G WHEEL LOADER
CHAPTER : IMPLEMENT SYSTEM
CASE DRAIN
FAN DRIVE HOSE
MOTOR
Page: 5-32
992G WHEEL LOADER
CHAPTER : IMPLEMENT SYSTEM
ENGINE
Page: 5-33
Page:
5-34
SCREEN
MAKEUP
VALVE
TANK
Page:
5-35
SCREEN
MAKEUP
VALVE
TANK
Page:
5-36
SCREEN
MAKEUP
VALVE
TANK
992G WHEEL LOADER
CHAPTER : IMPLEMENT SYSTEM
6
5 7
1
3
8
4
3- HORN
Page: 5-37
992G WHEEL LOADER
CHAPTER : IMPLEMENT SYSTEM
UPPER KICK-OUT
(above mid point)
GOES TO FLOAT
X (hits ground)
LOWER KICK-OUT
Page: 5-38
992G WHEEL LOADER
CHAPTER : IMPLEMENT SYSTEM
PROCEDURE
1) PKNG BRAKE ON
2) LOW IDLE
3) MACHINE IN WIDE OPEN SPACE
4) HYDRAULIC OIL > 30°C
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 FOR CODES, CORRECT AND
CHECK SOL/CAL/WIRNG RECALIBRATE
Page: 5-40
992G WHEEL LOADER
CHAPTER : IMPLEMENT SYSTEM
PROCEDURE
1) PKNG BRAKE ON
2) XMS NEUTRAL
3) START ENGINE
4) WARM OIL TO 49°C
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
PROCEDURE
1) PKNG BRAKE ON
2) XMS NEUTRAL
3) START ENGINE
4) WARM OIL TO 49°C
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.
Pilot pump
Hydraulic tank
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:
Page: 5-44
992G WHEEL LOADER
CHAPTER : IMPLEMENT SYSTEM
LAB EXERCISES
Lab B: Implement Hydraulic System Tests Worksheet
PILOT SYSTEM PRESSURE TEST
Pilot Relief Pilot Pressure Engine Pilot Control Valve
Valve OFF Chamber Pressure
Specifications
Machine Pressure
Specifications
Machine Pressure
Page: 5-45