SERV2633 - Monitor & Implement - Text - 992G

Service Training
SERV2633-01
April 2002
TEXT REFERENCE
PART OF TECHNICAL INSTRUCTION MODULE SERV2633
992G WHEEL LOADER

MONITORING AND IMPLEMENT SYSTEMS
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TABLE OF CONTENTS
INTRODUCTION ..................................................................................................................3
MONITORING SYSTEM ......................................................................................................4
VIDS/VIMS Major Components ......................................................................................7
Warning Operation..........................................................................................................20
Onboard Applications .....................................................................................................22
Data Events .....................................................................................................................24
Maintenance Events ........................................................................................................27
Hardware and Software Requirements ...........................................................................29
ELECTRO-HYDRAULIC IMPLEMENT SYSTEM...........................................................31
Implement Electronic Control System............................................................................33
Implement Electronic Control System Components.......................................................35
Pilot Hydraulic System ...................................................................................................44
Main Hydraulic System ..................................................................................................55
Variable Implement Pump Control Schematics ..............................................................60
Implement Control Valve Operation...............................................................................65
Electro-Hydraulic Implement System Schematics .........................................................67
Implement Hydraulic Schematics ...................................................................................75
FAN DRIVE SYSTEM.........................................................................................................91
Fan Drive System Components ......................................................................................93
Fan Drive System Schematics ........................................................................................96
CONCLUSION...................................................................................................................101
VISUAL LIST ....................................................................................................................102
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992G WHEEL LOADER

M O N I TO R I N G A N D I M P L E M E N T S Y S T E M S
2002 Caterpillar Inc.
INTRODUCTION
Introduce course
This presentation discusses the component locations, systems operation,

and testing and adjusting procedures for the Monitoring and Implement
Systems on the 992G Wheel Loaders. When discussing the monitoring
system, block diagrams and component illustrations will be used to
describe the system operation and features. When discussing the
hydraulic systems operation, both sectional view and graphic symbol
schematics will be used. The hydraulic systems will be explained by
tracing oil flow from the tank, through the system and back to the tank.
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SERVICE
LAMP
SPEEDOMETER/
TACHOMETER
MODULE
QUAD GAUGE
MODULE
MESSAGE CENTER
MODULE
KEYPAD
MODULE
OK
0
ABC
SERVICE
KEYSWITCH
VIMS
VIMS
RS-232
PORT
MAIN MODULE
GHI
4
PRS
12
VIMS
SERVICE TOOL
AND
SOFTWARE
INTERFACE
MODULE
MPH
km/h
3F
P1
2
JKL
5
TUV
8
P2
ID
DEF
3
MNO
6
WXY
9
P3
ELECTRONIC
TECHNICIAN
DISPLAY
DATA LINK
KEYPAD
DATA LINK
CAT DATA LINK
INTERFACE
MODULE
ENGINE
ECM
VIMS
ONLY
ACTION
ALARM
ACTION
LAMP
CAT DATA LINK

SENSORS
SENSORS
VITAL INFORMATION
DISPLAY/MANAGEMENT
SYSTEM
(VIDS/VIMS)
SENSORS
IMPLEMENT ECM
POWER TRAIN ECM
2
MONITORING SYSTEM
Objective 1
Visuals 2 - 15
Distribute Lab A
Worksheets
Explain operation
The 992G Wheel Loader is equipped with the Vital Information Display
System (VIDS) or the optional Vital Information Management System
(VIMS). The VIDS and VIMS are composed of modular onboard
electronics which have the ability to acquire data, perform analysis, store
information, and display data. When discussing characteristics that relate
to both the VIDS and VIMS, the system will be called VIDS/VIMS.
When equipped with source code software, the VIDS/VIMS main module
recognizes (through configuration software) the machine on which it is
installed and knows which components are present.
The various electronic modules communicate with each other in addition
to receiving information from other machine electronic control modules
(such as the Engine ECM, Power Train ECM, etc.).
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The optional VIMS uses both onboard and offboard hardware and
software to display information to the machine operator in addition to
supplying information on machine systems to dealer and customer
technical staff. This information will assist in minimizing downtime and
operating costs.
To successfully service machines equipped with the VIDS, the service
technician needs to become proficient in accessing the information
through the onboard keypad and message center. To successfully service
machines equipped with the VIMS, the service technician must also be
able to use a service tool (PC) to perform other required tasks.
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VIDS/VIMS
3
VIDS/VIMS alerts
operator of abnormal
conditions
Two types of events
stored by VIDS/VIMS:
- Data event
- Maintenance event
The VIDS/VIMS is designed to alert the operator of an immediate or

impending abnormal condition in one or more of the machine systems that
are being monitored. These abnormal conditions are called "events."
Two types of events are recognized and stored by the VIDS/VIMS. One
event is called a "data" event and alerts the operator to an abnormal
machine condition (such as hydraulic oil temperature too high). The other
event is called a "maintenance" event, which alerts the operator to a fault
condition which is caused by a malfunction (fault) in one of the electronic
devices (such as a hydraulic temperature sensor being used to monitor a
machine system). A more detailed explanation of "events" will be
covered later in the module.
In addition to alerting the operator of an abnormal condition, a service
lamp is installed externally on the machine to alert service or maintenance
personnel that an "event" is present, and diagnostic information regarding
the event is available in the VIDS/VIMS.
The major modules that comprise the VIDS/VIMS will now be covered in
detail.
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VIDS/VIMS Major Components

Quad gauge module
- Four measured
machine parameters
The quad gauge module contains four gauges which provide information
on measured machine parameters (such as temperature, pressure, and fuel
level). Consult the 992G Wheel Loader Operation and Maintenance
Manual (Form SEBU7009) for the specific machine parameters.
The VIDS/VIMS uses electronic input devices (sensors) to measure the
parameter, calculates an output signal, and sends the signal to the gauge
cluster where the parameter is displayed.
The quad gauge is configured for a specific machine (shovel, off-highway
truck, or wheel loader) and the actual machine parameter is represented
on the gauge by a graphic symbol.
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15
10
20
25
X100
30
5
Speedometer/
tachometer module
displays ground
speed, engine speed,
and transmission gear
and direction
The speedometer/tachometer module displays ground speed in km/h

(mph), engine speed, and transmission gear and direction. The electronic
input devices used for this information will be discussed later.
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ALERT
INDICATOR
UNIVERSAL
GAUGE
DATA
LOGGER
INDICATOR
ENGINE TEMP
60 Deg F
[110]
GAUGE
WARNING
AREA
MESSAGE
AREA
6
Message center
module contains:
The message center module contains a Data Logger indicator, alert

indicator, universal gauge, gauge warning area, and message area.
- Data logger indicator

- Alert Indicator
- Universal gauge
- Gauge warning area
- Message center
The Data Logger indicator (series of four dots) in the upper right corner
scrolls when the Data Logger is turned on. The dots are not present when
the Data Logger is stopped or when the Data Logger is initiated with the
offboard service tool (PC).
The alert indicator notifies the operator of an abnormal machine
condition. The condition could be caused by the VIDS/VIMS detecting a
"data" or "maintenance" event. The alert indicator receives a signal from
the main module causing the indicator to flash. The alert indicator will be
discussed in detail in the warning operation section of this presentation.
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The message area shows the value for the parameter shown on the
universal gauge. For sensor-type parameters (non switch-type inputs), the
gauge shows the actual value for the parameter being measured. The
gauge can also be used to observe any of the machine parameters by
entering the parameter number on the keypad and pressing the "gauge" on
the keypad. The universal gauge allows the operator or service technician
to select their "favorite" parameter or to monitor a troublesome parameter
which has not exceeded its limit.
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LOW ENGINE OIL PRESSURE

SHUT DOWN SAFELY
DATA EVENT
OIL PRESSURE
ERROR
CALL SHOP
MAINTENANCE EVENT
0745
267
DEFAULT SCREEN
7
Message area
displays machine
information
The message area displays information regarding the condition of the

machine. The display of information is prioritized and includes data
events, maintenance events, operator or service technician requested data,
and default information.
The message area provides two lines of text (twenty characters per line) to
display information to the operator or service technician. When an event
(data or maintenance) occurs, information relating to the out-ofspecification parameter is displayed on the first line to identify the nature
of the abnormal condition. The following is an example of information
that may appear in the message area if an abnormal data event occurs:
LOW ENGINE OIL PRESSURE
SHUT DOWN SAFELY
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Information on the second line displays the desired operator response to

the condition.
If a maintenance event occurs, the message area will display the
parameter followed by the word ERROR. The second line will give the
operator instructions regarding the condition. The following is an
example of information that may appear if a maintenance event is active:
OIL PRESSURE ERROR
CALL SHOP
Events displayed
according to priority
If more than one event is present, the event information will be displayed
according to priority. The priority process will be discussed in the
warning operation section of this module.
The message area can also display requested data such as event lists or
active system events in Module Identification (MID), Component
Identification (CID), and Failure Mode Identifier (FMI) formats.
Default information
includes time of day
and machine service
hours
If no data has been requested by the operator and no event messages are
active, default information will be presented in the message area. The
default information includes time of day and machine service hours. The
following is an example of default information displayed in the message
area:
0745
267
If a problem exists in either the source code or configuration software, the

time of day and service meter hours will not be displayed after start-up.
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OK
ID
ABC
2
DEF
3
GHI
4
JKL
5
MNO
6
PRS
7
TUV
8
WXY
9
F1
F2
F3
8
Keypad used to
communicate with
VIDS/VIMS
Six additional input

keys:
The keypad allows the operator or service technician to communicate with

the VIDS/VIMS by entering numeric information. The numeric section of
the keypad (keys 0 to 9) can be used to initiate service procedures, enter
operator identification codes, acknowledge events, and respond to
VIDS/VIMS inquiries (such as Data Logging information).
An indicator (upper right corner of keypad) flashes each time a key is
pressed to inform the operator or service technician that the keystroke was
accepted.
- OK key
- ID key
Eight additional keys are available for inputting information. They are:
- Universal gauge key

OK
- Left and right arrow

keys
- F1 key
- F2 and F3 keys
Used to complete keypad entries and to acknowledge

events.
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ID
Used by the operator to enter his or her identification or

badge number into the VIDS/VIMS memory.
Used to display the value of any measured parameter.
When the gauge key is pressed, line one of the message
area displays the parameter name and parameter
number, and line two displays the parameter value and
unit of measure.
This information is presented for one parameter at a
time. To scroll through the remaining parameters
requires using the Forward and Backward arrow keys.
A specific parameter can be displayed without using
the Forward or Backward keys by entering the number
of the parameter and then pressing the Gauge key. The
requested information will remain displayed until the
OK key is pressed, which returns the message center
module to the default mode.
If an event occurs while a parameter is being displayed,
the parameter information will be overwritten with the
event information.
Allows the operator or service technician to scroll
forward or backward through the information shown in
the message area.
F1
Allows the operator or service technician to request

additional information regarding data and maintenance
events. If a data event is displayed, pressing the F1 key
will replace the information shown on line two of the
message area with the event value and units.
If a maintenance event is displayed, pressing the F1
key will replace the information shown on line two
with MID, CID and FMI information (example: MID
049, CID 0168, FMI 04).
F2
F3
Allows the operator to clear the last non stored bucket

load from memory.
Allows the operator to select a new loader delay code.
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VIDS/VIMS
MAIN MODULE
9
Main module is
"heart" of VIDS/VIMS
The main module is the "heart" of the VIDS/VIMS and, as such, makes
decisions based upon input signals received from various other electronic
control modules on the machine. A 37 pin connector on the module
connects the necessary harness wiring to the input and output devices.
Four sections of
module functions
The overall function of the main module can be described in four sections.
The four sections are labeled: Data Links, Inputs, Outputs, and Display
Components.
- Data links
- Inputs
- Outputs
- Display
Data Links
The main modules incorporate four different

data links. One is the CAT Data Link which
is a bi-directional link allowing the VIDS/VIMS to
communicate with other onboard electronic
controls. The CAT Data Link uses two
communication paths to ensure uninterrupted
communications in the event of an open in one
path.
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The second and third data links are RS-232 data

links. These two communication links are separate.
One of the links has two communication ports, one
in the cab and the other mounted outside the cab to
allow easy access for the service technician.
The second RS-232 Data Link allows the
VIDS/VIMS to communicate with an offboard
service tool (PC).
The third RS-232 Data Link allows the VIMS to
communicate through two-way radio
communications with other offboard systems.
The fourth Data Link is an instrumentation link that
connects the various display components to the
main module.
Inputs
Inputs to the VIDS/VIMS main module include a

switch-type input from the key start switch, open or
grounded switch-type inputs from switches used to
monitor machine events, a lighting sensor to inform
the main module when the dash panel lamps are
turned ON, a keypad input to receive information
from the keypad, and an input that measures system
voltage at the VIDS/VIMS circuit breaker.
Outputs
The main module sends an output signal to the

action lamp if a Category 2 or 3 warning is present.
The module also sends a signal to the action alarm
to sound an alarm if a Category 3 warning is
present. The main module provides power for all
the display components, and turns a service light
ON (steady) to alert maintenance personnel if an
active system event is present. The light will flash
if an abuse related event is present.
Display
The main module supplies information to all the

display components (gauge cluster,
speedometer/tachometer, message center and
keypad). The display components alert the
operator to machine conditions.
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VIDS/VIMS
INTERFACE
MODULE
10
Interface modules:
- One with VIDS
- Two with VIMS
- Send output
information to
VIDS/VIMS main
module
The exact number of interface modules installed on a Caterpillar machine

will be determined by the configuration software. A 992G with VIDS has
one interface module. The same machine with VIMS has two modules.
Although each module functions in the same manner, each module will be
assigned its own individual MID. The MID number associated with each
module is determined by the machine harness code connections on each
module.
The interface modules receive inputs from the sensors and switches,
process the information, and then send an output over the CAT Data Link
to the main VIDS/VIMS module where the information is processed and
sent to the various display components.
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Interface module
inputs:
- Sensor inputs
- 18 -
The following is a brief description of the interface module inputs:

Sensor Inputs
The VIDS/VIMS uses sensors to provide

information on the various measured parameters.
The sensors used by the VIDS/VIMS are either pulse
width modulation or frequency type. The operation
of the sensors will be discussed later in this module.
Switch Inputs
Each module is capable of processing information

from thirteen switches. Eight of the switch inputs
are uncommitted and provide the module with
machine system status information (open or
grounded). The information is received from
pressure switches, temperature switches, flow and
level switches, and position switches.
- Switch inputs
- CAT Data Link
One switch input is a committed input received from

the key start switch and provides the module with
battery voltage on contact No. 1 of the 40 pin
connector when the key switch is in the ON position.
The remaining four inputs are programming type
inputs and, as such, are harness code inputs that tell
the main VIDS/VIMS module which interface
module it is communicating with. A combination of
grounded and open harness code inputs determines
the unique MID code for each module installed on
the machine.
CAT Data Link
This Data Link provides the VIDS/VIMS with both

an input and output. Its primary purpose is to
provide a high speed ring that allows data to be
shared by all electronic controls used on the
machine.
Each VIDS/VIMS module has two identical Data
Links that work independently. The two
communication paths allow the VIDS/VIMS to
continue operating even if one of the Data Links
becomes damaged. The CAT Data Link system is
bi-directional (input/output) and also performs as
an output device.
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The interface module(s), in addition to receiving and processing

information from individual electronic devices (sensors and switches),
provide outputs. The primary outputs are delivered through the CAT Data
Link to the main VIDS/VIMS module. The interface module provides
two solenoid outputs which can be used to energize solenoids or relay
coils, and also provides two regulated voltage outputs that are used to
power the sensors. The regulated outputs are +8 and +5 DCV.
Additional modules
may communicate
with VIDS/VIMS
Depending on the machine configuration and software, numerous other

modules can be connected to the VIDS/VIMS. Some of the additional
electronic control modules that may be installed are:
- Engine ECM
- Implement ECM
- Power Train ECM
Engine ECM
Implement ECM
Power Train ECM
Each additional control module processes its own input devices and uses
the CAT Data Link to communicate with the VIDS/VIMS.
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WARNING OPERATION
Category 1
Category 2
Category 3
11
Warning operation
- Warning Category 1
Warning Operation
The VIDS/VIMS monitors designated machine systems and notifies the
operator of immediate or impending problems. The warning categories of
the VIDS/VIMS are the same as those used with the Computerized
Monitoring System (CMS). The inputs and internal operation of the
controls differ, but the outputs of the system remain unchanged.
The operator receives the following types of warning:
Warning Category 1
Alert indicator flashes. No

immediate action required by the
operator. (Requires servicing by the
end of the shift.)
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VIDS/VIMS triggers
warning when a data
or maintenance event
occurs
- 21 -
Warning Category 2
Alert indicator flashes and the

action lamp flashes. Machine
operation should be changed or
maintenance performed.
Warning Category 3
Alert indicator flashes, action lamp

flashes and action alarm sounds.
Operator should perform an
immediate safe engine shutdown.
The VIDS/VIMS triggers the warning operation when a data or

maintenance event occurs. The abnormal condition is sensed by the
interface module, processed, and then sent to the main module where the
appropriate warning category is determined and relayed to the operator
through the alert indicator (flashing), action lamp (flashing), or the action
alarm (sounding).
Warning inputs are provided by switches and sensors. In some cases,
more than one input is needed to trigger a specific warning category. The
VIDS/VIMS identifies the warning category displayed according to active
events. If more than one event is active, each event will be scrolled on
the message area in five second intervals. If a Category 3 (most severe)
event is active, Category 1 and 2 events cannot be scrolled.
Although the VIMS warning categories are the same as those used on
other systems (EMS and CMS), some changes have been made in the area
of operator awareness. The VIMS documents when the operator
acknowledges the fault. When a Category 1 or 2 event becomes active,
the operator can acknowledge the event by pressing the OK key on the
keypad. Depending on the nature of the event, the warning category may
be cancelled for a specific period of time. After the time interval is
exceeded, the warning category will again be displayed. Category 3
events cannot be cancelled by the operator.
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VIDS/VIMS ONBOARD APPLICATIONS
12
Onboard Applications
Two categories of
events:
The VIDS/VIMS onboard components not only display information

relating to machine parameters but, as stated earlier, also alert the operator
of an impending event (abnormal condition) in one or more of the
machine systems being monitored. These abnormal conditions are called
"events." Two categories of events can occur: data events and
maintenance events.
- Data events
- Maintenance events
Data events indicate that the machine is operating outside of normal

limits. A data event may occur because a specific parameter detects an
abnormal condition. An example of a data event could be low hydraulic
oil level or low fuel level.
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VIDS/VIMS alerts
operator of events
- 23 -
The VIDS/VIMS will alert the operator with the appropriate warning
category. The operator must acknowledge the event and then take the
appropriate action required. If more than one event is present of the same
category, the message center will alternate between each event.
Maintenance events reflect the VIDS/VIMS self-diagnostic capabilities.
If the VIDS/VIMS detects an event condition in one or more of its
electronic monitoring devices (switches, sensors, etc.), a maintenance
event will be immediately displayed on the message center and the
operator will be alerted by the appropriate warning. The service
technician can retrieve additional diagnostic information on the detected
fault by pressing the F1 key on the keypad or by accessing the
VIDS/VIMS through the use of a service tool (PC).
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VOLTAGE TOO LOW

SHUT DOWN SAFELY
13
Data Events
Data events
The message area provides two lines (twenty characters per line) to
display information to the operator or service technician. When a data
event occurs, a message is displayed on the first line to identify the type of
abnormal condition. The second line indicates the required operator
action.
VOLTAGE TOO LOW
SHUT DOWN SAFELY
In the above example, the operator is alerted to a Category 3 warning.

The alert indicator and action lamp will flash and the action alarm will
sound. The message center directs the operator to shut the machine down
safely.
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The VIDS/VIMS detected a critically low system voltage (less than 23.0
Volts). Continued machine operation with low system voltage could
possibly cause the electronic controls installed on the machine to shut
down.
The service technician can easily investigate the data event using the
universal gauge as a service tool. Entering the parameter number of 140
and pressing the Gauge key on the keypad will display the parameter
name and number on the first line and the parameter value and units on
the second line. Example:
VOLTAGE
22.5 VOLTS
Troubleshooting data
events
[140]
When a data event occurs and the service technician is requested to

diagnose the malfunction, it is important that all the facts concerning the
reported complaint are gathered. The advanced capabilities of the
VIDS/VIMS allow the system to distinguish between actual problems
with the machine or its components and conditions caused by
inappropriate operation (abuse). The VIDS/VIMS will distinguish
between the types of problems and maintain a count of occurrences in
memory.
To effectively diagnose data events may require the service technician to
use all available VIDS/VIMS resources. The message center and keypad
may be used to display event information such as event statistics, event
list and acknowledge events. To observe the above information, the
service technician must initiate the appropriate service operation.
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On the VIMS, the event information can be downloaded using a service

tool (PC). Downloading an event list will provide the service technician
with the following types of event information:
Machine serial number
Service Meter Units (SMU)
Description (event name)
Date of event
Time event started
Minimum or maximum limits (value where a warning occurs)
Units of measurement
Actual event value
Event duration
Acknowledgment time
It may also be necessary to use other types of stored information in
solving machine abnormalities.
INSTRUCTOR NOTE: For a more detailed explanation of other
available resources, consult the Technical Instruction Module "Vital
Information Management System--Introduction" (Form SEGV2597).
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OIL PRESSURE
CALL SHOP
ERROR
14
Maintenance Events
Maintenance events
The message area provides two lines (twenty characters per line) to
display information to the operator or service technician. When a
maintenance event occurs, information identifying a specific parameter
has "error" displayed on the first line and information giving the operator
instructions appears on the second line. Example:
OIL PRESSURE
CALL SHOP
ERROR
With the above information displayed in the message area, additional

diagnostic information can be displayed on the second line by pressing the
F1 key on the keypad.
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The display will now show the MID, CID and FMI codes for the active
maintenance event. Example:
OIL PRESSURE
MID036
CID0100
Diagnostic codes
displayed on second
line
ERROR
FMI03
The diagnostic codes displayed on the second line provide valuable

information to the service technician. The MID identifies which
electronic control has diagnosed the event. Since the VIMS has the
ability to receive maintenance event information from other controls over
the CAT Data Link, it is necessary to establish the source of the event.
Each electronic control module installed on the machine has its own
unique identifier. Always refer to the appropriate service manual for the
proper MID identifier codes.
To successfully diagnose, troubleshoot, and repair VIDS/VIMS
malfunctions will require the service technician to use all resources
available (service manuals, wiring schematics, handouts etc.).
Additionally, the service technician needs to be able to use the diagnostic
tooling that is available for all electronic control systems. To diagnose
VIDS/VIMS related faults, the service technician needs to be totally
proficient in reading and interpreting the electrical wiring schematics and
in the use of a digital multimeter.
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HARDWARE
SOFTWARE
15
Hardware and Software Requirements
To successfully run the VIMS, the following computer hardware and
software is needed.
The recommended service tool and software configurations are:
Computer with a Pentium II, 266 MHz processor
32 Mb of RAM
2 Gb hard drive space available
12X speed CD-ROM
3.5" 1.44 Mb diskette drive
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Super VGA color monitor or display

RS232 port with 16550AF UART
Built in pointing device or mouse
Microsoft Windows NT, 2000, 98, or 95 operating system
NOTE: Caterpillar provides a well trained Technical Support

Hotline for assistance. Help can be reached on the PC Software
Hotline Monday through Friday, between the hours of 8:00 AM and
4:00 PM Central Standard Time (CST). Call 1-800-THE-PCDR
(within in the U.S. and parts of Canada), and 309-674-5290 (from all
other locations). Use 309-673-1403 for FAX and, if connected to the
Caterpillar Network, the User ID is: THEPCDR, Address:
ADCCHOST.
Introduce Lab A
INSTRUCTOR NOTE: At this time, introduce and perform "Lab A:

VIDS/VIMS Monitoring System Information Access." This lab will
reinforce the material discussed in the preceding visual presentation.
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ELECTRO-HYDRAULIC IMPLEMENT SYSTEM
IMPLEMENT
HYDRAULIC
PUMPS
VARIABLE PUMP PILOT

SOLENOID VALVE RELIEF
VALVE
PILOT
PUMP
HYDRAULIC
TANK
IMPLEMENT
ELECTRONIC
CONTROL
MODULE
PILOT CONTROL
LEVER MODULE
MAIN CONTROL
VALVE ASSEMBLY
LIFT LINKAGE
POSITION SENSOR
TILT
CYLINDER
LIFT
TILT LINKAGE
CYLINDER POSITION SENSOR
ELECTRONIC SYSTEM
MAIN HYDRAULIC SYSTEM
PILOT HYDRAULIC SYSTEM
COMMON TO BOTH SYSTEMS
16
Objective 2
Visuals 16 - 25
Objective 11
Visuals 16 - 35
Distribute Lab B
Worksheet
Identify components:
- Electronic system
- Pilot hydraulic
system
- Main hydraulic
system
- Common to both
systems
ELECTRO-HYDRAULIC IMPLEMENT SYSTEM

Shown are the major components of the electro-hydraulic implement
system. The electro-hydraulic implement system is pilot operated. The
pilot system controls the functions of the main control valve. The pilot
system consists of the electronic system and the pilot hydraulic system.
The electronic system components (brown) are the pilot control lever
module, the Implement Electronic Control Module (ECM), the variable
pump solenoid valve, the tilt linkage position sensor, and the lift linkage
position sensor.
SERV2633-01
4/02
Electronic system
components
Pilot hydraulic system
- 32 -
Electronic system components not shown are the tilt lever, lift lever, tilt
sensor, lift sensor, bucket kickout detent solenoid, lift kickout detent
solenoid, lower kickout detent solenoid, the implement lockout switch,
the pilot on/off solenoid valve, and the pilot control actuator solenoids.
The pilot hydraulic system (orange) consists of the pilot pump, the
manual lower valve, the pilot relief valve, the pilot on/off valve (part of
the main control valve assembly), and the pilot control actuators (part of
the main control valve assembly).
Main hydraulic system
The main hydraulic system (red) consists of the fixed pump, the variable
pump, the fixed pump relief valve (part of the main control valve
assembly), the variable pump relief valve (part of the main control valve
assembly), the main control valve assembly, two lift cylinders, and the tilt
cylinder.
Tank common to both

hydraulic systems
The hydraulic tank (green) is common to both hydraulic systems.
INSTRUCTOR NOTE: The color codes used for hydraulic oil

throughout this presentation are:
Red
- System or high pressure
Red and White Stripes
- Reduced pressure
Orange
- Pilot pressure
Blue
- Blocked oil
Green
- Tank or return oil
SERV2633-01
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IMPLEMENT ELECTRONIC
CONTROL SYSTEM
IMPLEMENT ELECTRONIC
CONTROL MODULE (ECM)
CAT DATA LINK
INPUT COMPONENTS
OUTPUT COMPONENTS
LIFT LEVER
SENSOR
PILOT ON/OFF SOLENOID

VARIABLE PUMP SOLENOID
TILT LEVER
SENSOR
TILT BACK SOLENOID NO. 1
IMPLEMENT
LOCKOUT SWITCH
TILT BACK SOLENOID NO. 2

TILT DUMP SOLENOID NO. 1
LIFT/LOWER/TILT
KICKOUT SWITCH
TILT DUMP SOLENOID NO. 2
LIFT LINKAGE
SENSOR
LIFT LOWER SOLENOID NO. 1

LIFT LOWER SOLENOID NO. 2
TILT LINKAGE
SENSOR
LIFT RAISE SOLENOID NO. 1

VARIABLE
IMPLEMENT PUMP
PRESSURE SENSOR
LIFT RAISE SOLENOID NO. 2
ANALOG TO DIGITAL
CONVERTER
LIFT LOWER KICKOUT DETENT COIL

LIFT RAISE KICKOUT DETENT COIL
BUCKET KICKOUT DETENT COIL
17
Implement Electronic Control System
Explain component
functions
Shown is a block diagram of the Implement Electronic Control System.

The Implement Electronic Control Module (ECM) receives input signals
from the various sensors and switches. The Implement ECM processes
the input signals, makes decisions and provides a corresponding output
signal to the pilot solenoid valves and kickout solenoids. The Implement
ECM also communicates with other electronic control systems through
the CAT Data Link.
The Implement Electronic Control System consists of the following
components:
Lift lever sensor: Signals the Implement ECM the position of the lift
pilot control lever.
SERV2633-01
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- 34 -
Tilt lever sensor: Signals the Implement ECM the position of the tilt pilot
control lever.
Implement lockout switch: Signals the Implement ECM that the operator
wants the pilot control levers disabled.
Lift/lower/tilt kickout switch: Used to set the bucket tilt, lift raise and
lift lower kickout positions.
Lift linkage sensor: Signals the Implement ECM the position of the lift
arm relative to the machine.
Tilt linkage sensor: Signals the Implement ECM the position of the
bucket relative to the lift arm.
Pilot on/off solenoid: Controls the pilot on/off solenoid valve. The on/off
solenoid valve enables or disables the pilot hydraulic system.
Variable pump solenoid: Controls the variable pump solenoid valve.
The variable pump solenoid valve directs pilot oil from the main control
valve to the tank.
Tilt back solenoid: Controls the tilt back actuator. The tilt back actuator
directs pilot oil from the tilt back end of the main control valve spool to
the tank.
Tilt dump solenoid: Controls the tilt dump actuator. The tilt dump
actuator directs pilot oil from the tilt dump end of the main control valve
spool to the tank.
Lift lower solenoid: Controls the lift lower actuator. The lift lower
actuator directs pilot oil from the lift lower end of the main control valve
spool to the tank.
Lift raise solenoid: Controls the lift raise actuator. The lift raise actuator
directs pilot oil from the lift raise end of the main control valve spool to
the tank.
Lift lower kickout detent solenoid: Holds the lift lever in the LOWER
position.
Lift raise kickout detent solenoid: Holds the lift lever in the RAISE
position.
Bucket kickout detent solenoid: Holds the tilt lever in the TILT BACK
position.
CAT Data Link: Communication path to and from other electronic
control modules.
SERV2633-01
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- 35 -
ELECTRO-HYDRAULIC
IMPLEMENT SYSTEM
IMPLEMENT
LOCKOUT
SWITCH
TILT
CYLINDER
LEFT
LIFT
CYLINDER
ELECTRONIC SYSTEM COMPONENTS
SHUTTLE
VALVE
RAISE/LOWER/TILT
KICKOUT SET
SWITCH
HYDRAULIC
ACTUATOR
PRESSURE
REDUCING
VALVE
TILT LINKAGE
POSITION SENSOR
ELECTRONIC
CONTROL
MODULE
CAT
DATA
LINK
BUCKET
KICKOUT
DETENT
SOLENOID
IMPLEMENT
CONTROL
VALVE
LIFT LINKAGE
POSITION SENSOR
LIFT
KICKOUT
DETENT
SOLENOID
TILT
LEVER
SENSOR
RIGHT
LIFT
CYLINDER
PILOT
ON/OFF
VALVE
LOWER
KICKOUT
DETENT
SOLENOID
LIFT
LEVER
SENSOR
IMPLEMENT
CONTROL
VALVE
RELIEF
VALVE
FIXED
PUMP
CHECK
VALVE
RELIEF
VALVE
PILOT
RELIEF VALVE
BYPASS
SWITCH
MANUAL
LOWER
VALVE
BYPASS
SWITCH
VARIABLE
PUMP
SOLENOID
VALVE
BYPASS
SWITCH
VARIABLE
PUMP
PILOT
PUMP
18
Implement Electronic Control System Components
Identify components
The electronic system components (brown) are the implement lockout

switch, the raise/lower/tilt kickout set switch, the Implement ECM, the
tilt linkage position sensor, the lift linkage position sensor, the tilt lever
sensor, the bucket kickout detent solenoid, the lift lever sensor, the lift
kickout detent solenoid, the lower kickout detent solenoid, the hydraulic
actuators (on the implement control valves), the pilot on/off valve, and
the variable pump solenoid valve.
SERV2633-01
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1
1
3
4
2
19
1. Implement hydraulic
control levers
2. Tilt lever sensor
The implement hydraulic control levers (1) are attached to the right
armrest assembly and move forward and rearward with the right armrest.
When the operator moves the tilt control lever, the tilt lever sensor (2)
sends a Pulse Width Modulated (PWM) signal to the Implement ECM.
3. Horn
4. Right armrest
control lever
5. Control lever cover
Also shown are the horn (3) and the right armrest control lever (4).
Located below the control lever cover (5) are the lift lever sensor, the
bucket kickout detent solenoid, the lift kickout detent solenoid, and the
lower kickout detent solenoid.
SERV2633-01
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11
10
12
13
6
16
14
17
15
20
1. Raise, lower and tilt
kickout set switch
2. Dash light switch
3. Stairway light switch
4. Keypad
5. +12V connector
6. Electronic diagnostic
connector
The raise, lower and tilt kickout switch (1) is located in the right side
panel. Depress the top of the switch to set the TILT kickout. Depress the
bottom of the switch to set the RAISE and LOWER kickouts.
When setting the bucket TILT kickout, move the bucket to the desired
position. Return the tilt lever to the HOLD position. Depress the top of
the kickout set switch for approximately one second and release.
When setting the RAISE kickout, raise the lift arm to the desired position.
Return the lift lever to the HOLD position. Depress the bottom of the
kickout switch for approximately one second and release.
7. Rimpull selector
8. Floodlight switch
9. Ride control switch
10. Quick-shift switch
11. Torque converter
lockup switch
12. Heater and A/C fan
switch
13. Windshield wiper
switches
14. Key start switch
When setting the LOWER kickout, lower the lift arm to the desired
position. Return the lift lever to the HOLD position. Depress the bottom
of the kickout switch for approximately one second and release.
SERV2633-01
4/02
15. Heater and A/C
control switch
16. Start aid switch
17. Throttle lock switch
- 38 -
Also shown are the dash light switch (2), the stairway light switch (3), the
keypad (4), the +12V connector (5), the electronic diagnostic connector
(6), the rimpull selector (7), the flood light switch (8), the ride control
switch (9), the quick shift switch (10), the torque converter lockup switch
(11), the heater and air conditioner fan switch (12), the windshield wiper
switches (13), the key start switch (14), the heater and air conditioner
control (15), the start aid switch (16), and the throttle lock switch (17).
SERV2633-01
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- 39 -
1
2
21
1. Lift linkage
position sensor
2. Tilt linkage
position sensor
The lift linkage position sensor (1) is bolted to the left side of the front
frame near the left side lift cylinder attachment pin. The lift linkage
position sensor constantly monitors the position of the lift linkage and
sends the lift linkage position information to the Implement ECM.
The tilt linkage position sensor (2) is bolted to the right side of the lift arm
near the tilt linkage attachment pin. The tilt linkage position sensor
constantly monitors the position of the tilt linkage and sends the tilt linkage
position information to the Implement ECM.
When the operator moves the lift lever or the tilt lever, the Implement
ECM analyzes the signal from the respective lever position sensor, the
signal from the lift linkage position sensor, and the signal from the tilt
linkage position sensor. The Implement ECM then sends a proportional
signal to the respective control valve solenoid.
SERV2633-01
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- 40 -
5
6
7
4
3
2
1
22
The Implement ECM (1) is located below the platform on the right side of
the cab.
1. Implement ECM
2. Fuse panel
3. Key start relay
4. Main relay
5. VIDS interlock
module
6. VIDS/VIMS main
module
7. Power Train ECM
Also shown are the fuse panel (2), the key start relay (3), the main relay
(4), the VIDS interface module (5), the VIDS/VIMS main module (6),
and the Power Train ECM (7).
SERV2633-01
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23
1. Pilot on/off
solenoid valve
2. Pilot control
actuators
3. Float valve
4. Fixed pump relief
valve
5. Pressure reducing
valve
The pilot on/off solenoid valve (1) is located in the front bottom section
of the main control valve center manifold.
When the pilot on/off solenoid is DE-ENERGIZED, pilot oil is blocked at
the pilot on/off solenoid valve.
When the pilot on/off solenoid is ENERGIZED, pilot oil flows to the pilot
control actuators.
Also shown are the pilot control actuators (2), the float valve (3), the
fixed pump relief valve (4), and the pressure reducing valve (5).
SERV2633-01
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- 42 -
24
1. Hydraulic actuator
solenoids
2. Lift cylinder head
end line relief valve
3. Tilt cylinder head
end line relief valve
The hydraulic actuator solenoids (1) control the movement of the

hydraulic actuators.
When the operator moves a control lever, the control lever sensor sends a
pulse width modulated (PWM) signal to the Implement ECM. The
Implement ECM analyzes the signals from the control lever sensor, the
lift linkage position sensor, and the tilt linkage position sensor. The
Implement ECM then sends a proportional signal to ENERGIZE the
respective pilot control actuator solenoid.
Also shown are the lift cylinder head end line relief valve (2) and the tilt
cylinder head end line relief valve (3).
SERV2633-01
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1
3
2
4
25
1. Variable pump
solenoid valve
2. Variable pump
valve solenoid
3. Implement pilot
relief valve
4. Implement pilot oil
pressure tap
The variable pump solenoid valve (1) is located on the inside left frame
and to the rear of the implement pilot relief valve (3). The variable pump
solenoid valve controls pilot pressure to the load limiting control valve on
the variable pump control. The Implement ECM energizes the variable
pump valve solenoid (2) when the key start switch is ON. The Implement
ECM signal to the variable pump solenoid valve controls the pressure in
the load limit control valve. When the variable pump pressure increases
to 80% of maximum pressure, the load limit control valve moves and
sends oil pressure to the large actuator to destroke the pump.
Also shown is the implement pilot oil pressure tap (4).
Introduce Lab B
INSTRUCTOR NOTE: At this time, introduce and perform "Lab B:

Electronic Implement Control System Component Identification
Quiz." This lab will reinforce the material discussed in the preceding
visual presentation.
SERV2633-01
4/02
- 44 -
ELECTRO-HYDRAULIC
IMPLEMENT SYSTEM
IMPLEMENT
LOCKOUT
SWITCH
TILT
CYLINDER
LEFT
LIFT
CYLINDER
PILOT SYSTEM COMPONENTS
SHUTTLE
VALVE
RAISE/LOWER/TILT
KICKOUT SET
SWITCH
HYDRAULIC
ACTUATOR
PRESSURE
REDUCING
VALVE
TILT LINKAGE
POSITION SENSOR
ELECTRONIC
CONTROL
MODULE
CAT
DATA
LINK
RIGHT
LIFT
CYLINDER
IMPLEMENT
CONTROL
VALVE
LIFT LINKAGE
POSITION SENSOR
IMPLEMENT
CONTROL
VALVE
PILOT
ON/OFF
VALVE
CHECK
VALVES
BUCKET
KICKOUT
DETENT
SOLENOID
RAISE
KICKOUT
DETENT
SOLENOID
TILT
LEVER
SENSOR
LOWER
KICKOUT
DETENT
SOLENOID
LIFT
LEVER
SENSOR
RELIEF
VALVE
FIXED
PUMP
RELIEF
VALVE
PILOT
RELIEF VALVE
BYPASS
SWITCH
MANUAL
LOWER
VALVE
BYPASS
SWITCH
VARIABLE
PUMP
SOLENOID
VALVE
BYPASS
SWITCH
VARIABLE
PUMP
PILOT
PUMP
26
Objectives 3 and 5
Visuals 26 - 35
Distribute Lab C, D, E, F
and G Worksheets
- Tank
- Pilot pump
- Pilot relief valve
- Pilot on/off valve
- Check valves
- Manual lower valve
- Pressure reducing
valve
- Hydraulic actuators
Pilot Hydraulic System

The pilot hydraulic system components (orange) are the tank, the pilot
pump, the pilot relief valve, the pilot on/off valve, the check valves, the
manual lower valve, the pressure reducing valve, and the hydraulic
actuators. The hydraulic actuators are located on the implement control
valves.
SERV2633-01
4/02
- 45 -
10
5
2
27
1. Hydraulic tank
2. Deck plate
3. Fill cap
4. Vent valve
The implement hydraulic tank (1) is below the forward hinged deck plate
(2) on the right side of the machine. The tank has a fill cap (3) for filling
and adding oil and a vent valve (4) that protects the tank from excessive
pressure and/or vacuum.
The tank also has three screens for return oil, an ecology-type drain valve,
and a sight glass for checking the oil level.
5. Alternator breaker
6. Main circuit breaker
7. Starting/charging
analyzer connector
8. Service tool
connector
9. Running lamp
breaker
10. Key breaker
Also shown are the alternator breaker (5), the main circuit breaker (6), the
starting/charging analyzer connector (7), the service tool connector (8),
the running lamp breaker (9), and the key breaker (10).
NOTE: Oil change intervals and procedures are covered in the 992G
Operation and Maintenance Manual (Form SEBU7009).
SERV2633-01
4/02
- 46 -
2
1
4
5
28
1. Implement pilot
pump
2. Implement variable
displacement piston
pump
3. Pilot pump inlet
hose
4. Pilot pump outlet
hose
5. Pilot pump pressure
tap
The implement pilot pump (1) is a gear-type pump mounted on the front
of the implement variable displacement piston pump (2). Tank oil flows
through the pilot pump inlet hose (3) to the implement pilot pump. Pump
supply oil flows through the outlet hose (4) to the implement pilot filter.
Also shown is the pilot pump pressure tap (5).
SERV2633-01
4/02
- 47 -
2
6
1
4
5
29
1. Implement pilot oil
filter
This view shows the implement pilot oil filter (1). The oil filter bracket
(2) is bolted to the right ROPS mounting plate (3). Supply oil from the
pilot pump flows through the oil filter inlet hose (4), the pilot filter and
the oil filter outlet hose (5), to the pilot relief valve (not shown).
2. Oil filter bracket

3. ROPS mounting
plate
4. Oil filter inlet hose
5. Oil filter outlet
hose
6. Oil filter bypass
switch
The oil filter bypass switch (6) alerts the VIDS when oil is bypassing the
filter.
SERV2633-01
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- 48 -
1
2
30
1. Pilot relief valve
2. Variable pump
solenoid valve
3. Inlet hose
4. Outlet hose
5. Outlet hose
6. Return hose
7. Pilot relief valve
pressure sensor
The pilot relief valve (1) is bolted to the inside left frame forward of the
variable pump solenoid valve (2). Pilot oil from the pilot filter flows
through the inlet hose (3) to the pilot relief valve. The pilot relief valve
limits the pilot oil pressure to 2400 kPa (350 psi). Pilot pressure oil flows
through the outlet hose (4) to the on/off solenoid valve. Pilot pressure oil
also flows through the outlet hose (5) to the variable pump solenoid valve.
Pilot relief valve return oil flows through the return hose (6) to the tank.
The pilot relief valve pressure sensor (7) supplies pilot oil pressure
information to the VIDS/VIMS.
SERV2633-01
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- 49 -
31
Manual lower valve

(arrow)
The manual lower valve (arrow) is located at the articulation joint on the
front frame. The manual lower valve is used to lower the implement
when the engine and the machine electrical system are dead. The manual
lower valve sends oil from the pressure reducing valve to the hydraulic
tank, allowing the implement lift cylinders to retract.
SERV2633-01
4/02
- 50 -
7
6
3
2
32
1. Pilot control
actuators
2. Pilot on/off
solenoid valve
3. Lift rod end line
relief valve
4. Lift head end line
relief valve
5. Tilt rod end line
relief valve
6. Tilt head end line
relief valve
7. Fixed pump relief
valve
8. Float valve
The pilot control actuators (1) control pilot oil flow from the ends of the
main control valve spools to the tank.
Also shown are the pilot on/off solenoid valve (2), the lift rod end line
relief valve (3), the lift head end line relief valve (4), the tilt rod end line
relief valve (5), the tilt head end line relief valve (6), the fixed pump relief
valve (7), and the float valve (8).
SERV2633-01
4/02
- 51 -
MAIN CONTROL SPOOLS

HOLD
CENTERING
SPRINGS
STABILIZING
SPRING
SNAP
RING
TANK OIL
PORT
ACTUATOR
SOLENOID
ACTUATOR
SOLENOID
PILOT
SPOOL
FEEDBACK
SPRING
SPRING
RETAINER
MAIN
SPOOL
PILOT OIL
PORT
33
Explain the operation of
the pilot control
actuators.
In the HOLD position, both solenoids for the pilot control actuators are
de-energized. When both solenoids are de-energized, the pilot spool
spools direct pilot oil to the ends of the main spool. The pilot pressure at
each end of the main spool and the force of the centering springs keep the
main spool centered in the control valve.
The centering springs and retainers help stabilize the movement of the
main spool. The stabilizing springs dampen the movement of the pilot
spools by holding the pilot spools in contact with the feedback springs.
SERV2633-01
4/02
- 52 -
MAIN CONTROL SPOOLS

LEFT SOLENOID ENERGIZED
STABILIZING
SPRING
CENTERING
SPRINGS
SNAP
RING
TANK OIL
PORT
ACTUATOR
SOLENOID
ACTUATOR
SOLENOID
PILOT
SPOOL
FEEDBACK
SPRING
SPRING
RETAINER
MAIN
SPOOL
PILOT OIL PORT
34
the pilot control
actuators.
When the left solenoid is energized, the solenoid moves the pilot spool to
the right. The pilot spool directs the pilot oil on the left side of the main
spool to tank. This decreases the pilot oil pressure at the left end of the
main spool.
The right actuator solenoid is de-energized. When the solenoid is deenergized, the feedback spring holds the pilot spool to the right. The pilot
spool directs pilot oil to the right end of the main spool. The pilot oil
pressure at the right end of the main spool moves the main spool to the
left. As the main spool moves to the left toward the left pilot spool, the
centering springs and the feedback spring are compressed.
SERV2633-01
4/02
- 53 -
MAIN CONTROL SPOOLS

LEFT ACTUATOR BALANCED
STABILIZING
SPRING
CENTERING
SPRINGS
TANK OIL
PORT
SNAP
RING
ACTUATOR
SOLENOID
ACTUATOR
SOLENOID
PILOT FEEDBACK
SPRING
SPOOL
SPRING
RETAINER
MAIN
SPOOL
PILOT OIL
PORT
35
the pilot control
actuators.
When the left solenoid is energized, the main spool moves to the left
which compresses the centering springs and the feedback spring. The
force of the feedback spring is equal to the force of the actuator solenoid
and the stabilizing spring. When the pilot spool moves far enough to the
left, the pilot oil port and the tank oil port are blocked. When the oil in
the actuator is blocked the main spool stops moving. The main spool will
stay in this balanced position until the current to the actuator solenoid
changes.
If the operator moves the implement control lever further in the same
direction, the Implement ECM will increase the duty cycle of the signal to
the actuator solenoid. This increases the current which increases the force
on the pilot spool. The pilot spool will move to the right which opens the
tank oil port. The decreased oil pressure inside the left actuator will allow
the main spool to move further to the left due to the pilot oil pressure on
the right end of the main spool. As the main spool moves to the left the
feedback spring will be compressed more and the feedback sequence
begins again.
SERV2633-01
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- 54 -
If the operator moves the implement control lever toward the centered
position, the Implement ECM will decrease the duty cycle of the PWM
signal to the actuator solenoid. This decreases the current which
decreases the force on the pilot spool. The pilot spool will move to the
left which opens the pilot oil port and blocks the tank oil port.
The combined force of the pilot oil and the compressed centering springs
on the left side of the main spool will move the main spool to the right.
This will decrease the flow of oil to the implements. The force on the
pilot spool from the feedback spring decreases as the main spool moves to
the right. As the main spool moves to the right the force of the feedback
spring continues to decrease. The pilot spool continues to move to the
right until the pilot oil port and the tank oil port are blocked. When the
force of the feedback spring equals the combined force of the stabilizing
spring and the actuator solenoid, the spools will be balanced. The spools
will remain balanced until the current to the actuator solenoid increases or
decreases.
SERV2633-01
4/02
- 55 -
ELECTRO-HYDRAULIC
IMPLEMENT SYSTEM
IMPLEMENT
LOCKOUT
SWITCH
TILT
CYLINDER
LEFT
LIFT
CYLINDER
MAIN HYDRAULIC SYSTEM COMPONENTS
SHUTTLE
VALVE
RAISE/LOWER/TILT
KICKOUT SET
SWITCH
HYDRAULIC
ACTUATOR
PRESSURE
REDUCING
VALVE
TILT LINKAGE
POSITION SENSOR
ELECTRONIC
CONTROL
MODULE
CAT
DATA
LINK
BUCKET
KICKOUT
DETENT
SOLENOID
IMPLEMENT
CONTROL
VALVE
LIFT LINKAGE
POSITION SENSOR
RAISE
KICKOUT
DETENT
SOLENOID
TILT
LEVER
SENSOR
RIGHT
LIFT
CYLINDER
PILOT
ON/OFF
VALVE
LOWER
KICKOUT
DETENT
SOLENOID
LIFT
LEVER
SENSOR
IMPLEMENT
CONTROL
VALVE
RELIEF
VALVE
FIXED
PUMP
CHECK
VALVE
RELIEF
VALVE
PILOT
RELIEF VALVE
BYPASS
SWITCH
MANUAL
LOWER
VALVE
BYPASS
SWITCH
VARIABLE
PUMP
SOLENOID
VALVE
BYPASS
SWITCH
VARIABLE
PUMP
PILOT
PUMP
36
Objective 4
Visuals 34 - 41
- Fixed pump
- Fixed pump relief
valve
- Fixed pump
implement control
valve
- Variable pump
- Variable pump relief
valve
- Variable pump
implement control
valve
- Shuttle valve
- Lift cylinders
- Tilt cylinder
Main Hydraulic System

The main hydraulic system components (red) are the fixed pump, the
fixed pump relief valve, the fixed pump implement control valve, the
variable pump, the variable pump relief valve, the variable pump
implement control valve, the left and right lift cylinders, and the tilt
cylinder.
SERV2633-01
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1
2
37
The main hydraulic system contains a fixed displacement, piston-type

pump (1) and a variable displacement piston-type pump (5).
1. Fixed pump
2. Supply hose
3. Suction hose
4. Implement pilot
pump
5. Variable pump
6. Supply hose
7. Case drain hose
8. Pump drive
housing
Oil flows from the tank through a suction hose (3) to the fixed
displacement pump. The fixed displacement pump oil flows through the
supply hose (2) to the fixed pump implement control valve.
Oil flows from the tank through a suction hose (not shown) to the variable
displacement pump. The variable displacement pump supply oil flows
through the supply hose (6) to the variable pump implement control valve.
Also shown are the implement pilot pump (4), the case drain hose (7), and
the pump drive housing (8).
SERV2633-01
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- 57 -
38
1. Case drain filter for
the fixed pump
2. Case drain filter for
the variable pump
Shown is the case drain filter for the fixed pump (1) and the case drain
filter for the variable pump (2). The case drain filters remove
contaminants from the case drain oil before the oil enters the implement
hydraulic tank.
SERV2633-01
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- 58 -
1
2
4
5
39
1. Main control valve
assembly
2. Right side control
valve
3. Tilt cylinder rod end
hose
4. Lift cylinder rod end
hose
5. Lift cylinder head
end hose
6. Tilt cylinder head
end hose
The main control valve assembly (1) is located in the front frame below
the boom.
The right side control valve (2) receives oil from the variable
displacement pump.
Also shown are the hose (3) to the rod end of the tilt cylinder, the hose (4)
to the rod end of the lift cylinders, the hose (5) to the head end of the lift
cylinders, and the hose (6) to the head end of the tilt cylinder.
SERV2633-01
4/02
- 59 -
2
3
5
4
40
When an implement is activated, oil from the implement control valve is

directed to the lift cylinders (1) and/or tilt cylinder (2).
1. Lift cylinder
2. Tilt cylinder
3. Tilt linkage
position sensor
4. Right front brake
housing
5. Right front final
drive housing
Also shown are the tilt linkage position sensor (3), the right front brake
housing (4), and the right front final drive housing (5).
SERV2633-01
4/02
- 60 -
VARIABLE IMPLEMENT PUMP

SOLENOID VALVE
TO PILOT
SYSTEM
PILOT
FILTER
LESS THAN 28940 kPa (4200 psi)

ENGINE SPEED MORE THAN 1400 rpm
PILOT
RELIEF
VALVE
TO TANK
TO IMPLEMENT
CONTROL VALVE
PRESSURE
CUTOFF
LOAD
LIMIT
CONTROL
CONTROL VALVE
BYPASS
SWITCH
FLUID
SAMPLING
PORT
SMALL
ACTUATOR
PILOT
PUMP
PUMP
LARGE
ACTUATOR
41
Variable Implement Pump Control Schematics
Explain schematic
This schematic shows the oil flow in the variable implement pump control
valve when the system pressure is less than 28940 kPa (4200 psi) and the
engine speed is more than 1400 rpm.
The pilot pump pulls oil from the tank and sends oil flow through the pilot
filter to the pilot system. The pilot relief valve limits the pilot system oil
pressure to 2400 205 kPa (350 30 psi). When the key start switch is in
the ON position, the variable pump solenoid valve is activated. Pilot oil
flows through the variable implement pump solenoid valve to the load limit
control. The combined force of the system oil and the small actuator
spring holds the variable implement pump swashplate at maximum angle.
SERV2633-01
4/02
- 61 -

SOLENOID VALVE
TO PILOT
SYSTEM
PILOT
FILTER
MORE THAN 28940 kPa (4200 psi)

ENGINE SPEED MORE THAN 1400 rpm
PILOT
RELIEF
VALVE
TO TANK
TO IMPLEMENT
CONTROL VALVE
PRESSURE
CUTOFF
LOAD
LIMIT
CONTROL
BYPASS
SWITCH

CONTROL VALVE
FLUID
SAMPLING
PORT
SMALL
ACTUATOR
PILOT
PUMP
PUMP
LARGE
ACTUATOR
42
Explain schematic
When the system pressure increases to 28940 kPa (4200 psi) and the
engine speed is more than 1400 rpm, the variable implement pump oil
becomes signal oil for the variable implement pump control valve. The
signal pressure moves the pressure cutoff valve against the spring. The
signal oil at the bottom of the pressure cutoff valve flows past the pressure
cutoff valve to the large actuator piston and destrokes the pump. The
variable pump pressure will not exceed 28940 kPa (4200 psi).
SERV2633-01
4/02
- 62 -

SOLENOID VALVE
TO PILOT
SYSTEM
PILOT
FILTER

ENGINE SPEED LESS THAN 1400 rpm
PILOT
RELIEF
VALVE
TO TANK
TO IMPLEMENT
CONTROL VALVE
PRESSURE
CUTOFF
LOAD
LIMIT
CONTROL
BYPASS
SWITCH

CONTROL VALVE
FLUID
SAMPLING
PORT
SMALL
ACTUATOR
PILOT
PUMP
PUMP
LARGE
ACTUATOR
43
Explain schematic
When the system pressure is less than 11590 kPa (1700 psi) and the engine
speed is less than 1400 rpm, the variable implement pump solenoid valve
begins to modulate the pressure to the load limit control. Below 11590 kPa
(1700 psi) system pressure is not adequate to destroke the pump, and the
pump continues to deliver full flow.
SERV2633-01
4/02
- 63 -

SOLENOID VALVE
TO PILOT
SYSTEM
PILOT
FILTER

PILOT
RELIEF
VALVE
TO TANK
TO IMPLEMENT
CONTROL VALVE
PRESSURE
CUTOFF
LOAD
LIMIT
CONTROL
CONTROL VALVE
BYPASS
SWITCH
FLUID
SAMPLING
PORT
SMALL
ACTUATOR
PILOT
PUMP
PUMP
LARGE
ACTUATOR
44
Explain schematic
When system pressure is between 11590 kPa (1700 psi) and 28940 kPa
(4200 psi) and the engine speed is less than 1400 rpm, the variable
implement pump solenoid valve modulates the pressure of the pilot oil to
the load limit control cylinder. The signal oil acting on the vertical piston
in the small actuator assembly moves the pivot lever on the load limit
control. The pivot lever moves the load limit control valve against the
spring and load limit control cylinder pressure. The oil at the bottom of
the load limit control valve flows through the load limit control valve and
through the pressure cutoff valve to the large actuator piston. The large
actuator piston reduces the angle of the swashplate and limits the load on
the engine to approximately 40%.
SERV2633-01
4/02
- 64 -

SOLENOID VALVE
TO PILOT
SYSTEM
PILOT
FILTER

PILOT
RELIEF
VALVE
TO TANK
TO IMPLEMENT
CONTROL VALVE
PRESSURE
CUTOFF
LOAD
LIMIT
CONTROL
BYPASS
SWITCH

CONTROL VALVE
FLUID
SAMPLING
PORT
SMALL
ACTUATOR
PILOT
PUMP
PUMP
LARGE
ACTUATOR
45
Explain schematic
When the system pressure reaches 28940 kPa (4200 psi) and the engine
speed is less than 1400 rpm, the variable implement pump solenoid valve
modulates the pressure of the pilot oil to the load limit control cylinder.
The load limit control attempts to destroke the pump to 40% load.
However, because the system pressure is at high pressure cutoff, signal oil
acting on the end of the pressure cutoff valve shifts the valve. Signal oil
from the load limit control is blocked and the signal oil from the pressure
cutoff valve flows to the large actuator and destrokes the pump.
SERV2633-01
4/02
- 65 -
IMPLEMENT CONTROL VALVE

HOLD
ROD
END
LOAD
CHECK
VALVE
HEAD
END
RAISE
LINE RELIEF
PILOT CONTROL
MAKEUP
ACTUATOR
VALVE
RAISE
ACTUATOR
SOLENOID
LINE RELIEF
MAKEUP
VALVE
LIFT
SPOOL
TO
TANK
SUPPLY
PASSAGE
PASSAGE TO
NEXT VALVE
TO
TANK
LOWER
PILOT CONTROL
ACTUATOR
PILOT
PASSAGE
LOWER
ACTUATOR
SOLENOID
INTERNAL
PASSAGE
46
Explain the implement
control valve operation
Implement Control Valve Operation

In the HOLD position, pilot oil pressure is present at both ends of the
control valve lift spool. The pilot oil and the centering springs keep the
lift spool in the centered position. The control valve lift spool blocks oil
flow to the lift cylinders, and oil from the lift cylinders is blocked by the
lift spool. The oil is trapped and the cylinders will remain in the HOLD
position.
Oil from the fixed implement pump enters the supply passage, flows
around the lift spool, and flows to the tank. The flow of oil through the
lift control valve for the variable implement pump is the same as the flow
of oil through the lift control valve for the fixed implement pump.
The flow of oil through the tilt control valve is similar to the flow of oil
through the lift control valve. However, the tilt control valve has priority
over the lift control valve.
SERV2633-01
4/02
- 66 -
IMPLEMENT CONTROL VALVE

LOWER
ROD
END
LOAD CHECK
VALVE
HEAD
END
RAISE
LINE RELIEF
PILOT CONTROL
MAKEUP
ACTUATOR
VALVE
RAISE
ACTUATOR
SOLENOID
LINE RELIEF
MAKEUP
VALVE
LIFT
SPOOL
TO
TANK
SUPPLY
PASSAGE
PASSAGE TO
NEXT VALVE
TO
TANK
LOWER
PILOT CONTROL
ACTUATOR
PILOT
PASSAGE
LOWER
ACTUATOR
SOLENOID
INTERNAL
PASSAGE
47
Explain the implement
control valve operation
When the operator moves the implement control valve to the LOWER
position, the lift lever sensor sends a PWM signal to the Implement ECM.
Then the Implement ECM sends a proportional signal that energizes the
lower actuator solenoid.
The solenoid moves the spool for the pilot control actuator and the pilot
oil at the right end of the lift spool is drained to the tank. The pilot oil
pressure on the left end of the lift spool moves the lift spool to the
LOWER position.
The lift spool directs oil from the implement pump to the load check
valve. Oil flows through the load check valve and through the lift spool to
the rod end of the lift cylinders. The lift spool also opens the tank
passages to allow the oil from the head end of the lift cylinders to return to
the tank.
The tilt control valve is similar to the lift control valve. The variable
implement control valves are similar to the fixed implement control
valves.
SERV2633-01
4/02
- 67 -
ELECTRO-HYDRAULIC
IMPLEMENT SYSTEM
TILT
CYLINDER
LEFT
LIFT
CYLINDER
HOLD
IMPLEMENT
LOCKOUT
SWITCH
SHUTTLE
VALVE
RAISE/LOWER/TILT
KICKOUT SET
SWITCH
HYDRAULIC
ACTUATOR
PRESSURE
REDUCING
VALVE
TILT LINKAGE
POSITION SENSOR
ELECTRONIC
CONTROL
MODULE
CAT
DATA
LINK
BUCKET
KICKOUT
DETENT
SOLENOID
TILT
LEVER
SENSOR
RIGHT
LIFT
CYLINDER
IMPLEMENT
CONTROL
VALVE
IMPLEMENT
CONTROL
VALVE
LIFT LINKAGE
POSITION SENSOR
RAISE
KICKOUT
DETENT
SOLENOID
PILOT
ON/OFF
VALVE
LOWER
KICKOUT
DETENT
SOLENOID
LIFT
LEVER
SENSOR
RELIEF
VALVE
FIXED
PUMP
CHECK
VALVE
RELIEF
VALVE
PILOT
RELIEF VALVE
BYPASS
SWITCH
MANUAL
LOWER
VALVE
BYPASS
SWITCH
VARIABLE
PUMP
SOLENOID
VALVE
BYPASS
SWITCH
VARIABLE
PUMP
PILOT
PUMP
48
Objective 6
Visuals 42 - 46
Explain schematic
Electro-Hydraulic Implement System Schematics

When the implement lockout switch is in the ON position, the Implement
ECM energizes the pilot on/off solenoid. The pilot on/off solenoid opens
the pilot on/off valve.
The pilot pump pulls oil from the hydraulic tank and sends oil flow
through the pilot on/off valve to the hydraulic actuators at each end of the
control valve spools. Pilot oil pressure increases to the relief valve
pressure setting. The relief valve opens and maintains a constant pressure
in the pilot system of 2400 kPa (350 psi). The control valve spools are
hydraulically locked in the HOLD position.
In the HOLD position, the control valve spools block oil flow to the lift
and tilt cylinders. Oil from the fixed pump and the variable pump flows
past the respective control valve spools to the tank.
SERV2633-01
4/02
- 68 -
ELECTRO-HYDRAULIC
IMPLEMENT SYSTEM
IMPLEMENT
LOCKOUT
SWITCH
TILT
CYLINDER
LEFT
LIFT
CYLINDER
SLOW TILT BACK
SHUTTLE
VALVE
RAISE/LOWER/TILT
KICKOUT SET
SWITCH
HYDRAULIC
ACTUATOR
PRESSURE
REDUCING
VALVE
TILT LINKAGE
POSITION SENSOR
ELECTRONIC
CONTROL
MODULE
CAT
DATA
LINK
BUCKET
KICKOUT
DETENT
SOLENOID
IMPLEMENT
CONTROL
VALVE
LIFT LINKAGE
POSITION SENSOR
RAISE
KICKOUT
DETENT
SOLENOID
TILT
LEVER
SENSOR
RIGHT
LIFT
CYLINDER
PILOT
ON/OFF
VALVE
LOWER
KICKOUT
DETENT
SOLENOID
LIFT
LEVER
SENSOR
IMPLEMENT
CONTROL
VALVE
RELIEF
VALVE
FIXED
PUMP
CHECK
VALVE
RELIEF
VALVE
PILOT
RELIEF VALVE
BYPASS
SWITCH
MANUAL
LOWER
VALVE
BYPASS
SWITCH
VARIABLE
PUMP
SOLENOID
VALVE
BYPASS
SWITCH
VARIABLE
PUMP
PILOT
PUMP
49
Slow tilt back uses

fixed pump only
When the tilt lever is moved to the SLOW TILT BACK position, the tilt
lever sensor sends a PWM signal to the Implement ECM. The Implement
ECM analyzes the input signals from the tilt lever sensor, the lift linkage
position sensor, and the tilt linkage position sensor. The Implement ECM
then sends a proportional signal to ENERGIZE the tilt back hydraulic
actuator solenoid on the fixed pump implement control valve. The tilt
back solenoid moves the hydraulic actuator valve and sends pilot oil at the
tilt back end of the tilt/dump control valve spool to drain. This condition
reduces the oil pressure at the tilt back end of the tilt/dump control valve
spool. The oil pressure on the dump end of the tilt/dump control valve
spool moves the valve spool to the TILT BACK position.
SERV2633-01
4/02
- 69 -
The fixed pump oil flows past the tilt/dump control valve spool to the rod
end of the tilt cylinder. Tilt cylinder head end oil flows past the tilt/dump
control valve spool to the tank.
Variable pump oil is
not needed for slow
implement operation
The variable pump oil is not needed for SLOW TILT BACK operation.
The Implement ECM does not energize the variable pump tilt back
hydraulic actuator solenoid. The variable pump oil flows through the
variable pump implement control valve to the tank.
With the exception of the FLOAT position, the Implement ECM uses the
oil from the fixed pump for all implement operations until the operational
demand for oil is greater than the fixed pump can supply. The Implement
ECM will then use oil from the variable pump to satisfy the demand.
SERV2633-01
4/02
- 70 -
ELECTRO-HYDRAULIC
IMPLEMENT SYSTEM
IMPLEMENT
LOCKOUT
SWITCH
TILT
CYLINDER
LEFT
LIFT
CYLINDER
FAST TILT BACK
SHUTTLE
VALVE
RAISE/LOWER/TILT
KICKOUT SET
SWITCH
HYDRAULIC
ACTUATOR
PRESSURE
REDUCING
VALVE
TILT LINKAGE
POSITION SENSOR
ELECTRONIC
CONTROL
MODULE
CAT
DATA
LINK
BUCKET
KICKOUT
DETENT
SOLENOID
IMPLEMENT
CONTROL
VALVE
LIFT LINKAGE
POSITION SENSOR
RAISE
KICKOUT
DETENT
SOLENOID
TILT
LEVER
SENSOR
RIGHT
LIFT
CYLINDER
PILOT
ON/OFF
VALVE
LOWER
KICKOUT
DETENT
SOLENOID
LIFT
LEVER
SENSOR
IMPLEMENT
CONTROL
VALVE
RELIEF
VALVE
FIXED
PUMP
CHECK
VALVE
RELIEF
VALVE
PILOT
RELIEF VALVE
BYPASS
SWITCH
MANUAL
LOWER
VALVE
BYPASS
SWITCH
VARIABLE
PUMP
SOLENOID
VALVE
BYPASS
SWITCH
VARIABLE
PUMP
PILOT
PUMP
50
Both pumps used
during fast implement
operation
When the tilt lever is moved to the FAST TILT BACK position, the tilt
sends a signal to ENERGIZE the tilt back hydraulic actuator solenoid on
the fixed pump implement control valve and a signal to ENERGIZE the
tilt back hydraulic actuator solenoid on the variable pump implement
control valve. The signals may be of different values. Each solenoid
moves the respective hydraulic actuator valve and sends pilot oil at the tilt
back end of the respective tilt/dump control valve spool to drain. This
condition reduces the pilot oil pressure at the tilt back end of the control
valve spool. The oil pressure on the dump end of the respective tilt/dump
control valve spool moves the control valve spool to the TILT BACK
position.
SERV2633-01
4/02
- 71 -
The fixed pump oil flows around the tilt/dump control valve spool in the
fixed pump implement control valve to the rod end of the tilt cylinder.
The variable pump oil flows around the tilt/dump control valve spool in
the variable pump implement control valve to the rod end of the tilt
cylinder. The tilt cylinder head end oil flows past both tilt/dump control
valve spools to the tank. The return oil flow past each valve spool is
proportional to the supply oil flow past the valve spool.
The desired tilt cylinder speed determines the difference in oil flow
between the fixed pump and the variable pump. A slow tilt cylinder
speed will cause a larger difference in oil flow between the two pumps
than a fast tilt cylinder speed.
SERV2633-01
4/02
- 72 -
ELECTRO-HYDRAULIC
IMPLEMENT SYSTEM
TILT
CYLINDER
LEFT
LIFT
CYLINDER
SLOW RAISE
IMPLEMENT
LOCKOUT
SWITCH
SHUTTLE
VALVE
RAISE/LOWER/TILT
KICKOUT SET
SWITCH
HYDRAULIC
ACTUATOR
PRESSURE
REDUCING
VALVE
TILT LINKAGE
POSITION SENSOR
ELECTRONIC
CONTROL
MODULE
CAT
DATA
LINK
BUCKET
KICKOUT
DETENT
SOLENOID
IMPLEMENT
CONTROL
VALVE
LIFT LINKAGE
POSITION SENSOR
RAISE
KICKOUT
DETENT
SOLENOID
TILT
LEVER
SENSOR
RIGHT
LIFT
CYLINDER
PILOT
ON/OFF
VALVE
LOWER
KICKOUT
DETENT
SOLENOID
LIFT
LEVER
SENSOR
IMPLEMENT
CONTROL
VALVE
RELIEF
VALVE
FIXED
PUMP
CHECK
VALVE
RELIEF
VALVE
PILOT
RELIEF VALVE
BYPASS
SWITCH
MANUAL
LOWER
VALVE
BYPASS
SWITCH
VARIABLE
PUMP
SOLENOID
VALVE
BYPASS
SWITCH
VARIABLE
PUMP
PILOT
PUMP
51
Slow lift uses fixed
pump only
When the operator moves the lift lever to the SLOW RAISE position, the
lift lever sensor sends a PWM signal to the Implement ECM. The
Implement ECM analyzes the input signals from the lift lever sensor, the
Implement ECM then sends a proportional signal to ENERGIZE the lift
hydraulic actuator solenoid on the fixed pump implement control valve.
The solenoid moves the hydraulic actuator valve and sends pilot oil at the
lift end of the lift/lower control valve spool to drain. This condition
reduces the pilot oil pressure at the lift end of the control valve spool. The
oil pressure on the lower end of the control valve spool moves the valve
spool to the RAISE position.
The fixed pump oil flows past the lift/lower control valve spool to the
head end of the lift cylinders. Lift cylinder rod end oil flows past the
lift/lower control valve spools to the tank.
The variable pump oil is not needed for slow lift operation. The
Implement ECM does not energize the variable pump hydraulic actuator.
The variable pump oil flows through the variable pump implement control
valve to the tank.
SERV2633-01
4/02
- 73 -
ELECTRO-HYDRAULIC
IMPLEMENT SYSTEM
TILT
CYLINDER
LEFT
LIFT
CYLINDER
FAST RAISE
IMPLEMENT
LOCKOUT
SWITCH
SHUTTLE
VALVE
RAISE/LOWER/TILT
KICKOUT SET
SWITCH
HYDRAULIC
ACTUATOR
PRESSURE
REDUCING
VALVE
TILT LINKAGE
POSITION SENSOR
ELECTRONIC
CONTROL
MODULE
CAT
DATA
LINK
BUCKET
KICKOUT
DETENT
SOLENOID
IMPLEMENT
CONTROL
VALVE
LIFT LINKAGE
POSITION SENSOR
RAISE
KICKOUT
DETENT
SOLENOID
TILT
LEVER
SENSOR
RIGHT
LIFT
CYLINDER
PILOT
ON/OFF
VALVE
LOWER
KICKOUT
DETENT
SOLENOID
LIFT
LEVER
SENSOR
IMPLEMENT
CONTROL
VALVE
RELIEF
VALVE
FIXED
PUMP
CHECK
VALVE
RELIEF
VALVE
PILOT
RELIEF VALVE
BYPASS
SWITCH
MANUAL
LOWER
VALVE
BYPASS
SWITCH
VARIABLE
PUMP
SOLENOID
VALVE
BYPASS
SWITCH
VARIABLE
PUMP
PILOT
PUMP
52
Both pumps used for
fast lift operation
When the lift lever is moved to the FAST RAISE position, the lift lever
sensor sends a proportional PWM signal to the Implement ECM. The
Implement ECM analyzes the input signals from the lift lever sensor, the
Implement ECM sends a signal to the lift actuator solenoid on the fixed
pump implement control valve and to the lift actuator solenoid on the
variable pump implement control valve. The signals may be of different
values. The solenoids move the hydraulic actuators and send pilot oil at
the lift ends of the lift/lower control valve spools to drain. This condition
reduces the pilot pressure at the lift ends of the lift/lower control valve
spools. The oil pressure on the lower ends of the control valve spools
move the control valve spools to the RAISE position.
The fixed pump oil flows around the lift/lower control valve spool in the
fixed pump implement control valve to the head end of the lift cylinders.
SERV2633-01
4/02
- 74 -
The variable pump oil flows around the lift/lower control valve spool in
the variable pump implement control valve to the head end of the lift
cylinders. The lift cylinder rod end oil flows past both lift/lower control
valve spools to the tank. The return oil flow past each control valve spool
is proportional to the supply oil flow past the control valve spool.
The desired lift cylinder speed determines the difference in oil flow
between the fixed pump and the variable pump. A slow lift cylinder
speed will cause a larger difference in oil flow between the two pumps
than a fast lift cylinder speed.
SERV2633-01
4/02
- 75 -
IMPLEMENT HYDRAULIC SYSTEM

HOLD
PRESSURE
REDUCING
VALVE
LIFT
CYLINDER
SHUTTLE
VALVE
TILT
BACK
LOWER
PILOT
ON/OFF
VALVE
VARIABLE PUMP
SOLENOID VALVE
TILT
BACK
FLOAT
CHECK
VALVE
FLOAT
SEQUENCE
VALVE
RAISE
LOWER
RIDE
CONTROL
FLOAT
CHECK
VALVE
DUMP
DUMP
PILOT
RELIEF
VALVE
RAISE
FAN
COOLER MOTOR
PRESSURE
CUTOFF
VARIABLE PUMP
CONTROL
BYPASS
SWITCH
LIFT
CYLINDER
TILT CYLINDER
FIXED
PUMP
BYPASS
SWITCH
LOAD LIMIT
CONTROL
FLUID
SAMPLING
PORT
FAN
DRIVE PUMP
SMALL
ACTUATOR
LARGE
ACTUATOR
FAN SPEED
BYPASS
SWITCH
VARIABLE
PUMP
BYPASS
SWITCH
BYPASS
SWITCH
PILOT
PUMP
53
Objective 7
Visuals 47 - 54
Implement Hydraulic Schematics

The electrical system is not shown in this schematic and the schematics
that follow.
Implements in HOLD
This schematic shows the oil flow in the implement pilot system and the
implement hydraulic system when the engine is running and the control
valves are in the HOLD position.
In the pilot system, the pilot pump pulls oil from the tank and sends oil
flow to the pilot relief valve, the variable pump control, the variable pump
solenoid valve, the ride control valve (optional), and the pilot on/off valve.
The pilot relief valve limits the pilot system pressure to 2400 205 kPa
(350 30 psi).
SERV2633-01
4/02
- 76 -
When the Implement ECM activates the variable pump solenoid valve,
pilot oil flows from the variable pump solenoid valve to the load limit
control valve cylinder in the variable pump control. Pilot oil pressure
joins with the load limit valve spring and moves the load limit control
valve against the control valve pivot lever.
When the variable pump is in the HOLD position, signal oil flows in
several directions inside the variable pump control valve. Signal oil flows
through the orifice to the end of the pressure cutoff valve. Signal oil also
flows to the bottom of the pressure cutoff valve, to the bottom of the load
limit valve, and to the small actuator. Signal oil is blocked at the bottom
of the pressure cutoff valve when the spring force is greater than the
signal oil pressure. Signal oil is blocked at the bottom of the load limit
control valve when the combined force of the load limit cylinder and the
load limit control valve spring is greater than the force of the control
valve pivot lever. Signal oil pressure in the small actuator assists the
small actuator spring in moving the swashplate to maximum angle.
Signal oil also flows through the small actuator assembly and orifice to
the area behind the piston in the small actuator assembly.
Pilot on/off solenoid
controlled by
implement lockout
switch
The pilot on/off valve solenoid is controlled by the implement lockout

switch. When the implement lockout switch is in the OFF position, the
Implement ECM de-energizes the pilot on/off solenoid valve. Pilot oil is
then blocked at the pilot on/off solenoid valve. When the implement
lockout switch is in the ON position, the Implement ECM energizes the
pilot on/off solenoid valve. Pilot oil flows past the pilot on/off solenoid
valve to the hydraulic actuator on each end of the control valve spools.
Open-center control
valves
In the implement fixed pump hydraulic system, the fixed pump pulls oil
from the tank and sends oil flow to the left side main control valve. When
the control valve spools are in the HOLD position, oil flows past the fixed
pump relief valve and through the open-center control valves to the tank.
The fixed pump relief valve constantly senses pressure at the fixed pump
and opens to the tank when the pressure reaches the maximum setting of
31000 kPa (4500 psi).
SERV2633-01
4/02
- 77 -
In the implement variable pump hydraulic system, the variable pump

pulls oil from the tank and sends oil flow to the right side main control
valve. When the main control valve spools are in the HOLD position, oil
flows past the variable pump relief valve and through the open-center
control valves to the tank. Variable pump pressure is controlled at a
maximum of 28940 kPa (4200 psi) by the variable pump compensator
valve. The variable pump relief valve serves as a back-up if a
compensator valve failure occurs. The variable pump relief valve is set at
32800 kPa (4760 psi)
In HOLD oil flow is
blocked
In the HOLD position, oil flow to and from the cylinders is blocked at the
control valve spools.
SERV2633-01
4/02
- 78 -

SLOW TILT BACK
PRESSURE
REDUCING
VALVE
LIFT
CYLINDER
SHUTTLE
VALVE
PILOT
ON/OFF
VALVE
FLOAT
CHECK
VALVE
FLOAT
SEQUENCE
VALVE
VARIABLE PUMP
SOLENOID VALVE
TILT
BACK
TILT
BACK
LOWER
RAISE
DUMP
RIDE
CONTROL
DUMP
RAISE
FAN
COOLER MOTOR
PRESSURE
CUTOFF
FIXED
PUMP
VARIABLE PUMP
CONTROL
BYPASS
SWITCH
LOWER
FLOAT
CHECK
VALVE
PILOT
RELIEF
VALVE
FLUID
SAMPLING
PORT
LIFT
CYLINDER
TILT CYLINDER
BYPASS
SWITCH
LOAD LIMIT
CONTROL
FAN
DRIVE PUMP
SMALL
ACTUATOR
LARGE
ACTUATOR
FAN SPEED
BYPASS
SWITCH
VARIABLE
PUMP
BYPASS
SWITCH
BYPASS
SWITCH
PILOT
PUMP
54
Slow tilt back uses
fixed pump only
When the tilt lever is moved to the SLOW TILT BACK position, the tilt
then sends a PWM signal to energize the tilt back hydraulic actuator
solenoid on the fixed pump implement control valve. The Implement
ECM electrical output is proportional to the signal inputs from the tilt
lever sensor, the lift linkage position sensor, and the tilt linkage position
sensor.
The tilt back hydraulic actuator valve sends pilot oil to the tank and
reduces the oil pressure at the tilt back end of the control valve spool. The
pilot oil pressure at the dump end of the control valve spool moves the
control valve spool to the TILT BACK position.
SERV2633-01
4/02
- 79 -
The tilt spool blocks the flow of fixed pump oil to the tank and opens a
passage to the rod end of the tilt cylinder. The fixed pump oil flows
through the load check valve and tilt spool to the rod end of the tilt
cylinder. The tilt spool also opens a passage for oil in the head end of the
tilt cylinder to return to the tank.
The variable pump oil flows through the right side implement control
valve to the tank.
SERV2633-01
4/02
- 80 -

FAST TILT BACK
PRESSURE
REDUCING
VALVE
LIFT
CYLINDER
SHUTTLE
VALVE
PILOT
ON/OFF
VALVE
FLOAT
CHECK
VALVE
FLOAT
SEQUENCE
VALVE
VARIABLE PUMP
SOLENOID VALVE
TILT
BACK
TILT
BACK
LOWER
RAISE
RIDE
CONTROL
DUMP
DUMP
RAISE
FAN
COOLER MOTOR
PRESSURE
CUTOFF
BYPASS
SWITCH
LOWER
FLOAT
CHECK
VALVE
PILOT
RELIEF
VALVE
FLUID
SAMPLING
PORT
LIFT
CYLINDER
TILT CYLINDER
VARIABLE PUMP
CONTROL
FIXED
PUMP
BYPASS
SWITCH
LOAD LIMIT
CONTROL
FAN
DRIVE PUMP
SMALL
ACTUATOR
LARGE
ACTUATOR
FAN SPEED
BYPASS
SWITCH
VARIABLE
PUMP
BYPASS
SWITCH
BYPASS
SWITCH
PILOT
PUMP
55
Fast tilt back uses
both pumps
When the tilt lever is moved to the FAST TILT BACK position, the tilt
sends a PWM signal to activate the tilt back hydraulic actuator solenoid
on the fixed pump implement control valve. The Implement ECM also
sends a PWM signal to activate the tilt back hydraulic actuator solenoid
on the variable pump implement control valve. The Implement ECMs
electrical output is proportional to the input signals from the tilt lever
sensor, the lift linkage position sensor, and the tilt linkage position sensor.
However, the PWM signal to the two valves may be different.
On the fixed pump implement control valve, the tilt back hydraulic
actuator valve sends pilot oil to the tank and reduces the oil pressure at the
tilt back end of the control valve spool.
SERV2633-01
4/02
- 81 -
The pilot oil pressure at the dump end of the control valve spool moves
the control valve spool to the TILT BACK position. The tilt spool blocks
the flow of fixed pump oil to the tank and opens a passage to the rod end
of the tilt cylinder. The fixed pump oil flows through the load check
valve and tilt spool to the rod end of the tilt cylinder.
On the variable pump implement control valve, the tilt back hydraulic
tilt end of the control valve spool. The pilot oil pressure at the dump end
of the control valve spool moves the control valve spool to the TILT
BACK position. The tilt spool blocks the flow of variable pump oil to the
tank and opens a passage to the rod end of the tilt cylinder. The variable
pump oil flows through the load check valve and tilt spool and joins with
the oil flow from the fixed pump. The combined oil flows to the rod end
of the lift cylinders.
Increased oil flow
increases implement
speed
The increased oil flow increases the implement speed.

The tilt cylinder rod end oil flows past each control valve spool in
proportion to the respective pump oil flow past the control valve spool.
SERV2633-01
4/02
- 82 -

SLOW LOWER
PRESSURE
REDUCING
VALVE
LIFT
CYLINDER
SHUTTLE
VALVE
PILOT
ON/OFF
VALVE
FLOAT
CHECK
VALVE
FLOAT
SEQUENCE
VALVE
VARIABLE PUMP
SOLENOID VALVE
TILT
BACK
TILT
BACK
LOWER
RAISE
RIDE
CONTROL
DUMP
DUMP
RAISE
FAN
COOLER MOTOR
PRESSURE
CUTOFF
BYPASS
SWITCH
LOWER
FLOAT
CHECK
VALVE
PILOT
RELIEF
VALVE
FLUID
SAMPLING
PORT
LIFT
CYLINDER
TILT CYLINDER
VARIABLE PUMP
CONTROL
FIXED
PUMP
BYPASS
SWITCH
LOAD LIMIT
CONTROL
FAN
DRIVE PUMP
SMALL
ACTUATOR
LARGE
ACTUATOR
FAN SPEED
BYPASS
SWITCH
VARIABLE
PUMP
BYPASS
SWITCH
BYPASS
SWITCH
PILOT
PUMP
56
Slow lower uses fixed
pump only
When the lift lever is moved to the SLOW LOWER position, the lift lever
sensor sends a PWM signal to the Implement ECM. The Implement ECM
analyzes the input signals from the lift lever sensor, the lift linkage
then sends a PWM signal to energize the lower hydraulic actuator
solenoid valve on the fixed pump implement control valve. The
Implement ECMs electrical output is proportional to the input signals
from the tilt lever sensor, the lift linkage position sensor, and the tilt
linkage position sensor.
The lift hydraulic actuator valve sends pilot oil to the tank and reduces the
oil pressure at the lower end of the control valve spool.
The pilot oil pressure at the raise end of the control valve spool moves the
control valve spool to the LOWER position.
SERV2633-01
4/02
- 83 -
The lower spool blocks the flow of fixed pump oil to the tank and opens a
passage to the rod end of the lift cylinders. The fixed pump oil flows
through the load check valve and lift spool to the rod end of the lift
cylinders. The lift spool also opens a passage for oil in the head end of
the lift cylinders to return to the tank.
The variable pump oil flows through the right side implement control
valve to the tank.
SERV2633-01
4/02
- 84 -

FAST LOWER
PRESSURE
REDUCING
VALVE
LIFT
CYLINDER
SHUTTLE
VALVE
TILT
BACK
LOWER
PILOT
ON/OFF
VALVE
VARIABLE PUMP
SOLENOID VALVE
TILT
BACK
FLOAT
CHECK
VALVE
FLOAT
SEQUENCE
VALVE
RAISE
RIDE
CONTROL
DUMP
DUMP
RAISE
FAN
COOLER MOTOR
PRESSURE
CUTOFF
BYPASS
SWITCH
LOWER
FLOAT
CHECK
VALVE
PILOT
RELIEF
VALVE
FLUID
SAMPLING
PORT
LIFT
CYLINDER
TILT CYLINDER
VARIABLE PUMP
CONTROL
FIXED
PUMP
BYPASS
SWITCH
LOAD LIMIT
CONTROL
FAN
DRIVE PUMP
SMALL
ACTUATOR
LARGE
ACTUATOR
FAN SPEED
BYPASS
SWITCH
VARIABLE
PUMP
BYPASS
SWITCH
BYPASS
SWITCH
PILOT
PUMP
57
Fast lower uses both
pumps
When the lift lever is moved to the FAST LOWER position, the lift lever
sensor increases the PWM signal to the Implement ECM. The Implement
ECM analyzes the input signals from the lift lever sensor, the lift linkage
sends a PWM signal to activate the lower hydraulic actuator solenoid on
the fixed pump implement control valve. The Implement ECM also sends
a PWM signal to activate the lower hydraulic actuator solenoid on the
variable pump implement control valve. The Implement ECMs output
signal is proportional to the input signals from the lift lever sensor, the lift
linkage position sensor, and the tilt linkage position sensor. However, the
PWM signal to the two valves may be different.
SERV2633-01
4/02
- 85 -
On the fixed pump implement control valve, the lower hydraulic actuator
valve sends pilot oil to the tank and reduces the oil pressure at the lower
end of the control valve spool. The pilot oil pressure at the raise end of
the control valve spool moves the control valve spool to the LOWER
position. The lift spool blocks the flow of fixed pump oil to the tank and
opens a passage to the rod end of the lift cylinders. The fixed pump oil
flows through the load check valve and lift spool to the rod end of the lift
cylinders.
On the variable pump implement control valve, the lower hydraulic
lower end of the control valve spool. The pilot oil pressure at the raise
end of the control valve spool moves the control valve spool to the
LOWER position. The lift spool blocks the flow of variable pump oil to
the tank and opens a passage to the rod end of the lift cylinders. The
variable pump oil flows through the load check valve and lift spool and
joins the oil flow from the fixed pump. The combined oil flows to the rod
end of the lift cylinders.
Increased oil flow
increases implement
speed
The increased oil flow increases the implement speed.

The lift cylinder head end oil that flows past each control valve spool is
proportional to the respective pump oil flow past the control valve spool.
SERV2633-01
4/02
- 86 -

FLOAT
PRESSURE
REDUCING
VALVE
LIFT
CYLINDER
SHUTTLE
VALVE
PILOT
ON/OFF
VALVE
FLOAT
CHECK
VALVE
FLOAT
SEQUENCE
VALVE
VARIABLE PUMP
SOLENOID VALVE
TILT
BACK
TILT
BACK
LOWER
RAISE
DUMP
RIDE
CONTROL
DUMP
RAISE
FAN
COOLER MOTOR
PRESSURE
CUTOFF
FIXED
PUMP
VARIABLE PUMP
CONTROL
BYPASS
SWITCH
LOWER
FLOAT
CHECK
VALVE
PILOT
RELIEF
VALVE
FLUID
SAMPLING
PORT
LIFT
CYLINDER
TILT CYLINDER
BYPASS
SWITCH
LOAD LIMIT
CONTROL
FAN
DRIVE PUMP
SMALL
ACTUATOR
LARGE
ACTUATOR
FAN SPEED
BYPASS
SWITCH
VARIABLE
PUMP
BYPASS
SWITCH
BYPASS
SWITCH
PILOT
PUMP
58
Objective 10
Visual 52
During float, the

Implement ECM
energizes lower
actuator solenoid on
both control valves
During float, the

Implement ECM also
energizes float
solenoid
To enter the FLOAT position, the wheel loader bucket must be below the
mid (center) position.
When the lift lever is in the FLOAT position, the movement of the lift
control spools are the same as when the lift control lever is in the FAST
LOWER position. However, the Implement ECM increases the electrical
signal to energize the lower hydraulic actuator solenoid on the fixed pump
implement control valve. The Implement ECM also increases the
electrical signal to activate the lower hydraulic actuator solenoid on the
variable pump implement control valve. The increased electrical signal
fully opens the hydraulic actuator solenoid valves to the tank.
The Implement ECM also energizes the electromagnetic float solenoid on
the lift control lever assembly. The solenoid holds the lift lever in the
FLOAT position.
SERV2633-01
4/02
- 87 -
When the fixed pump hydraulic actuator solenoid valve is fully opened to
the tank, oil is also drained from the spring chamber in the float sequence
valve. The pilot oil pressure at the opposite end of the float sequence
valve overcomes the spring and opens the float sequence valve to the
tank.
During float, pump oil

flows to tank
When the float sequence valve is open, the oil behind the float valve
flows through the float sequence valve to the tank. The pressure in the
float valve spring chamber is reduced to approximately tank pressure.
The small orifices in the float valve cause a restriction to the implement
pump oil when filling the cavity behind the float valve. With oil flowing
from behind the float valve faster than oil flows in, the pressure difference
between the oil around the float valve and the oil behind the float valve
becomes high enough to lift the float valve off its seat. The oil from the
implement pump flows past the float valve to the tank.
SERV2633-01
4/02
- 88 -

LOWER ENGINE OFF
PRESSURE
REDUCING
VALVE
LIFT
CYLINDER
SHUTTLE
VALVE
TILT
BACK
LOWER
PILOT
ON/OFF
VALVE
VARIABLE PUMP
SOLENOID VALVE
TILT
BACK
FLOAT
CHECK
VALVE
FLOAT
SEQUENCE
VALVE
RAISE
DUMP
RIDE
CONTROL
DUMP
RAISE
FAN
COOLER MOTOR
PRESSURE
CUTOFF
VARIABLE PUMP
CONTROL
BYPASS
SWITCH
LOWER
FLOAT
CHECK
VALVE
PILOT
RELIEF
VALVE
FLUID
SAMPLING
PORT
LIFT
CYLINDER
TILT CYLINDER
FIXED
PUMP
BYPASS
SWITCH
LOAD LIMIT
CONTROL
FAN
DRIVE PUMP
SMALL
ACTUATOR
LARGE
ACTUATOR
FAN SPEED
BYPASS
SWITCH
VARIABLE
PUMP
BYPASS
SWITCH
BYPASS
SWITCH
PILOT
PUMP
59
Lower with engine off
Lift cylinder oil

becomes supply oil
for pilot system
In this schematic, the bucket is being LOWERED with the ENGINE OFF.
The weight of the implement creates a high pressure in the head end of the
lift cylinders. The high lift cylinder pressure oil flows through the hose
and shuttle valve to the pressure reducing valve. The pressure reducing
valve decreases the lift cylinder oil pressure to approximately 2070 kPa
(300 psi). The reduced pressure oil flows past the check valve to the pilot
on/off solenoid valve and becomes the oil supply for the pilot system.
When the on/off solenoid valve is de-energized, pilot oil is blocked at the
on/off solenoid valve. When the on/off solenoid valve is energized (as
shown), pilot oil flows through the on/off solenoid valve and pressurizes
the pilot solenoid valves.
When the lift control lever is moved to the LOWER position, the
Implement ECM operation is the same as when the engine is running.
The lift control spool directs oil in the head end of the lift cylinders to the
tank.
Tank oil flows through the rod end makeup valves into the rod end of the
lift cylinders and prevents cylinder cavitation.
SERV2633-01
4/02
- 89 -

RIDE CONTROL ON
PRESSURE
REDUCING
VALVE
LIFT
CYLINDER
SHUTTLE
VALVE
TILT
BACK
LOWER
PILOT
ON/OFF
VALVE
VARIABLE PUMP
SOLENOID VALVE
TILT
BACK
FLOAT
CHECK
VALVE
FLOAT
SEQUENCE
VALVE
RAISE
DUMP
RIDE
CONTROL
DUMP
RAISE
FAN
COOLER MOTOR
PRESSURE
CUTOFF
VARIABLE PUMP
CONTROL
BYPASS
SWITCH
LOWER
FLOAT
CHECK
VALVE
PILOT
RELIEF
VALVE
FLUID
SAMPLING
PORT
LIFT
CYLINDER
TILT CYLINDER
FIXED
PUMP
BYPASS
SWITCH
LOAD LIMIT
CONTROL
FAN
DRIVE PUMP
SMALL
ACTUATOR
LARGE
ACTUATOR
FAN SPEED
BYPASS
SWITCH
VARIABLE
PUMP
BYPASS
SWITCH
BYPASS
SWITCH
PILOT
PUMP
60
Ride control solenoid
controlled by Power
Train ECM
This schematic shows the hydraulic flow when the ride control solenoid
valve is energized. The ride control solenoid valve is controlled by the
Power Train ECM.
The ride control switch (not shown) allows the operator to select between
the ride control ON, ride control OFF, and the ride control AUTO
positions.
When the ride control switch is in the ON position, the Power Train ECM
continually energizes the ride control solenoid valve.
SERV2633-01
4/02
- 90 -
When the ride control switch is in the AUTO position, the Power Train
ECM energizes the ride control solenoid when the machine ground speed
is above 9.7 km/hr (6 mph) and will de-energize the ride control solenoid
when the ground speed is below 8.8 km/hr (5.5 mph).
When the Power Train ECM energizes the ride control solenoid valve,
pilot pressure at the selector spool flows to the tank. The spring shifts the
selector spool to connect the head end of the lift cylinders with the
accumulators. A floating piston in the accumulators separates the oil
from the nitrogen gas. Since nitrogen gas is compressible, the gas
functions as a spring. Any downward force on the lift arms is transferred
through the oil at the head end of the lift cylinders to the accumulators.
The pressure of the oil is transmitted to the accumulator piston, which
compresses the nitrogen gas. Compressing the nitrogen gas absorbs the
pressure spike and the oil displacement caused by the downward force on
the lift arms. This operation results in less ground induced shocks on
structures and components, reduced tire flexing and a greater payload
retention.
Introduce and perform
Labs C, D, E, F and G
INSTRUCTOR NOTE: At this time, introduce and perform the

following lab excercises:
Lab C: Implement Hydraulic System Component
Identification Quiz
Lab D: Implement System Speed Checks
Lab E: Implement Pilot System Tests
Lab F: Main Hydraulic System Tests
Lab G: Implement System Keypad Procedures
Summarize labs by
asking questions
Take time between each lab to discuss the findings of the students.
These labs will reinforce the material discussed in the preceding
SERV2633-01
4/02
- 91 -
FAN DRIVE SYSTEM

ENGINE OFF
OIL
COOLER
BYPASS
VALVE
IMPLEMENT
HYDRAULIC
OIL COOLER
COOLING
FAN
BYPASS
SWITCH
FAN
MOTOR
MAKEUP
VALVE
ELECTRO-HYDRAULI
PROPORTIONAL
VALVE
REVERSE
SENSOR
CASE DRAIN
FILTERS
FAN
DRIVE
PUMP
FROM
IMPLEMENT
CASE DRAIN
FILTER
COMPENSATOR
VALVE
BYPASS
SWITCH
61
Objective 8
Visuals 53 - 61
FAN DRIVE SYSTEM
Distribute Lab H and I

Worksheets
Shown is a schematic of the fan drive system. The fan drive system is
controlled by the Engine ECM. Components of the fan drive system are:
Hydraulic tank: Reservoir for the hydraulic oil supply.
- Hydraulic tank
- Fan drive pump
- Proportional valve
Fan drive pump: Pulls oil from the tank and supplies oil to the fan drive
motor.
Electro-hydraulic proportional valve: Controls the signal to the pump.
- Fan drive motor

- Makeup valve
Compensator valve: Controls fan speed by controlling pump flow.
- Fan
Fan motor: Works with the fan drive pump to turn the fan.
- Oil cooler
- Oil cooler bypass
valve
SERV2633-01
4/02
- 92 -
Makeup valve: Prevents cavitation of the fan drive motor.

Cooling fan: Circulates air through the radiator, the hydraulic system oil
cooler, the steering and brake systems oil cooler, the brake and axle oil
cooler, and the air conditioner condenser.
Implement hydraulic oil cooler: Cools the oil used in the fan drive and
hydraulic systems.
Oil cooler bypass valve: Allows cold oil to bypass the cooler, normally
at engine start-up.
SERV2633-01
4/02
- 93 -
13
4
5
6
10
11
7
12
62
Fan Drive System Components
1 Fan drive pump

2. Pump drive
housing
The fan drive pump (1) is a variable displacement piston pump. The
pump is mounted to the right front of the pump drive housing (2) opposite
the variable displacement implement pump (not shown).
3. Pump outlet tube

4. Signal pressure
outlet
5. Electro-hydraulic
proportional valve
6. Proportional valve
solenoid
7. Drain tube
8. Signal hose
9. Margin spool
adjustment
10.Compensator valve
11.Pressure
compensator
adjustment
12.Signal pressure tap
13.System pressure
tap
Other components of the fan drive pump are the outlet tube (3), the signal
pressure outlet (4), the electro-hydraulic proportional valve (5), the
proportional valve solenoid (6), the proportional valve drain tube (7), the
proportional valve signal hose (8), the margin spool adjustment (9), the
compensator valve (10), the pressure compensator valve adjustment (11),
the signal pressure tap (12), and the system pressure tap (13).
SERV2633-01
4/02
- 94 -
63
Case drain filter for

the fan drive pump
(arrow)
The case drain filter for the fan drive pump (arrow) is located in the pump
bay, above the fan drive pump. The case drain filter removes
contaminants from the case drain oil before the oil enters the hydraulic
tank.
SERV2633-01
4/02
- 95 -
2
1
3
64
The fan drive motor (1) is located at the rear of the machine in front of the
engine radiator assembly.
1. Fan drive motor

2. Intake hose
3. Outlet hose
4. Case drain hose
5. Case drain filter
Also shown are the motor intake hose (2), the motor outlet hose (3), the
case drain hose (4), and the case drain filter (5).
SERV2633-01
4/02
- 96 -
FAN DRIVE SYSTEM

SOLENOID DE-ENERGIZED
OIL
COOLER
BYPASS
VALVE
IMPLEMENT
HYDRAULIC
OIL COOLER
COOLING
FAN
BYPASS
SWITCH
FAN
MOTOR
MAKEUP
VALVE
ELECTRO-HYDRAUL
PROPORTIONAL
VALVE
REVERSE
SENSOR
CASE DRAIN
FILTERS
FAN
DRIVE
PUMP
FROM
IMPLEMENT
CASE DRAIN
FILTER
COMPENSATOR
VALVE
BYPASS
SWITCH
65
Objective 9
Visuals 59 - 61
Fan Drive System Schematics

When the engine is running, the fan drive pump pulls oil from the
implement hydraulic tank and sends oil flow to the fan motor. The fan
motor turns the cooling fan. Oil from the fan motor flows through the
implement hydraulic cooler to the implement hydraulic tank.
The cooling fan sends air flow through the engine radiator, the implement
hydraulic cooler, the steering and brake oil cooler, the front and rear axle
coolers, and the air conditioner condenser.
The fan drive pump also sends oil flow through the screen to the electrohydraulic proportional valve.
SERV2633-01
4/02
Proportional valve
controls signal oil to
pump compensator
valve
- 97 -
The electro-hydraulic proportional valve controls the signal oil to the

pump compensator valve. When the Engine ECM de-energizes the
electro-hydraulic proportional valve (as shown), the proportional valve
closes the passage for signal oil flow to the tank. The signal oil flows
through the two orifices to the pump compensator valve. The signal oil
causes the compensator valve to upstroke the pump.
SERV2633-01
4/02
- 98 -
FAN DRIVE SYSTEM

SOLENOID ENERGIZED
OIL
COOLER
BYPASS
VALVE
IMPLEMENT
HYDRAULIC
OIL COOLER
COOLING
FAN
BYPASS
SWITCH
MAKEUP
VALVE
FAN
MOTOR
ELECTRO-HYDRAULIC
PROPORTIONAL
VALVE
REVERSE
SENSOR
CASE DRAIN
FILTERS
FAN
DRIVE
PUMP
FROM
IMPLEMENT
CASE DRAIN
FILTER
COMPENSATOR
VALVE
BYPASS
SWITCH
66
Engine ECM uses
various temperature
sensor signals to
control fan speed
The Engine ECM receives input signals from the engine coolant
temperature sensor, the steering hydraulic tank temperature sensor, the
implement hydraulic tank temperature sensor, and the air conditioner
on/off switch. The Engine ECM analyzes the signals and energizes the
electro-hydraulic proportional valve when needed.
When the Engine ECM energizes the electro-hydraulic proportional valve,
the proportional valve opens the passage for signal oil flow to the tank.
The size of the opening is proportional to the signal from the Engine
ECM.
SERV2633-01
4/02
- 99 -
Signal oil flows through the open passage to the tank. This condition
decreases the signal pressure at the compensator valve and destrokes the
pump. Destroking the pump decreases pump flow and decreases the fan
speed. Decreasing the pump flow also decreases the horsepower needed
to turn the pump.
When the engine is operating below 88C (190F), the fan will operate at
a minimum speed of 375 50 rpm. Above 98C (208F), the fan will
operate at a maximum speed of 885 rpm.
When the air conditioner is ON, the fan will operate at a minimum speed
of 621 rpm.
If an electrical system failure occurs, the fan goes to maximum (100%)
speed.
SERV2633-01
4/02
- 100 -
FAN DRIVE SYSTEM

RAPID ENGINE DECELERATION
OIL
COOLER
BYPASS
VALVE
IMPLEMENT
HYDRAULIC
OIL COOLER
COOLING
FAN
BYPASS
SWITCH
FAN
MOTOR
MAKEUP
VALVE
ELECTRO-HYDRAUL
PROPORTIONAL
VALVE
REVERSE
SENSOR
CASE DRAIN
FILTER
FAN
DRIVE
PUMP
FROM
IMPLEMENT
CASE DRAIN
FILTER
COMPENSATOR
VALVE
BYPASS
SWITCH
67
Flow through motor
check valve and pump
flow prevent
cavitation during rapid
deceleration
In this illustration, the fan motor is being driven by the cooling fan.
During normal operation, oil pressure at the fan motor inlet is higher than
oil pressure at the fan motor outlet. The higher inlet pressure seats the
makeup valve.
When the engine is decelerated rapidly from HIGH IDLE, the inertia of
the fan keeps the fan drive motor turning faster than the fan drive pump
can supply oil. The oil pressure at the fan motor inlet becomes lower than
the oil pressure at the fan motor outlet. The higher outlet pressure opens
the makeup valve and allows oil from the motor outlet to flow to the inlet.
The combination of oil flow through the makeup valve and the pump oil
flow prevents cavitation of the fan motor.
When pump output matches the fan speed, the motor inlet oil pressure
increases above the motor outlet oil pressure. The higher inlet pressure
closes the makeup valve.
SERV2633-01
4/02
- 101 -
68
CONCLUSION
This concludes the presentation on the 992G Wheel Loader Monitoring
System and Electro-Hydraulic Implement System.
Always check the Service Manual for the latest service information and
specifications when servicing, testing and adjusting, and/or making
repairs.
Introduce and perform

Labs H and I
INSTRUCTOR NOTE: At this time, introduce and perform the

following lab exercises:
Lab H: Fan Drive System Component Identification Quiz
Lab I: Fan Drive System Tests
Summarize labs by
asking questions
These labs will reinforce the material discussed in the preceding

SERV2633-01
4/02
- 102 -
VISUAL LIST
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
Title visual
Vital Information Management System
VIDS/VIMS main module
Four gauge cluster module
Speedometer/tachometer module
Message center module
Message area
Keypad
VIDS/VIMS main module
VIDS/VIMS interface module
Subtitle visual--warning operation
Machine side view graphic
Machine event display
System event display
Subtitle visual--hardware/software
Component location graphic
Electronic input and output components
Electronic components
Implement control levers
Operator switch panel
Linkage position sensors
Control module compartment
Main control valve
Pilot control actuator solenoids
Variable pump solenoid valve
Pilot system components
Hydraulic tank
Pilot system pump
Pilot system filter
Pilot system relief valve
Manual lower valve
Pilot control actuators
Pilot control actuators cutaway
Pilot control actuators cutaway, left
solenoid energized
Pilot control actuators cutaway, left
solenoid energized, balanced
Main hydraulic system components
Implement system hydraulic pumps
Implement pump case drain filters
Main control valve
40. Lift and tilt cylinders

41. Variable pump control schematic less
than 28940 kPa (4200 psi), high idle
42. Variable pump control schematic more
than 28940 kPa (4200 psi), high idle
43. Variable pump control schematic less
than 11590 kPa (1700 psi)
than 11590 kPa (1700 psi), less than
28940 kPa (4200 psi)
than 28940 kPa (4200 psi)
46. Implement control valve (HOLD)
47. Implement control valve (LOWER)
48. Electro-hydraulic implement system
schematic (HOLD)
schematic (SLOW TILT)
schematic (FAST TILT)
schematic (SLOW LIFT)
schematic (FAST LIFT)
53. Implement hydraulic system schematic
(HOLD)
(SLOW TILT)
(FAST TILT)
(SLOW LOWER)
(FAST LOWER)
(FLOAT)
(LOWER--ENGINE OFF)
(RIDE CONTROL ON)
61. Fan drive system schematic
(ENGINE OFF)
SERV2633-01
4/02
- 103 -
VISUAL LIST
62.
63.
64.
65.
Fan drive system components

Fan drive pump case drain filter
Fan drive motor
Fan drive system schematic
(SOLENOID DE-ENERGIZED)

(SOLENOID ENERGIZED)
(RAPID ENGINE DECELERATION)
68. Model view

SERV2633 - Monitor & Implement - Text - 992G

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Service Training

PART OF TECHNICAL INSTRUCTION MODULE SERV2633

992G WHEEL LOADER

992G WHEEL LOADER

2002 Caterpillar Inc.

This presentation discusses the component locations, systems operation,

CAT DATA LINK

POWER TRAIN ECM

The VIDS/VIMS is designed to alert the operator of an immediate or

VIDS/VIMS Major Components

The speedometer/tachometer module displays ground speed in km/h

The message center module contains a Data Logger indicator, alert

- Data logger indicator

LOW ENGINE OIL PRESSURE

The message area displays information regarding the condition of the

Information on the second line displays the desired operator response to

If a problem exists in either the source code or configuration software, the

Six additional input

The keypad allows the operator or service technician to communicate with

- Universal gauge key

- Left and right arrow

Used to complete keypad entries and to acknowledge

Used by the operator to enter his or her identification or

Allows the operator or service technician to request

Allows the operator to clear the last non stored bucket

The main modules incorporate four different

The second and third data links are RS-232 data

Inputs to the VIDS/VIMS main module include a

The main module sends an output signal to the

The main module supplies information to all the

The exact number of interface modules installed on a Caterpillar machine

The following is a brief description of the interface module inputs:

The VIDS/VIMS uses sensors to provide

Each module is capable of processing information

One switch input is a committed input received from

This Data Link provides the VIDS/VIMS with both

The interface module(s), in addition to receiving and processing

Depending on the machine configuration and software, numerous other

Alert indicator flashes. No

Alert indicator flashes and the

Alert indicator flashes, action lamp

The VIDS/VIMS triggers the warning operation when a data or

VIDS/VIMS ONBOARD APPLICATIONS

The VIDS/VIMS onboard components not only display information

Data events indicate that the machine is operating outside of normal

VOLTAGE TOO LOW

In the above example, the operator is alerted to a Category 3 warning.

When a data event occurs and the service technician is requested to

On the VIMS, the event information can be downloaded using a service

With the above information displayed in the message area, additional

The diagnostic codes displayed on the second line provide valuable

Super VGA color monitor or display

NOTE: Caterpillar provides a well trained Technical Support

INSTRUCTOR NOTE: At this time, introduce and perform "Lab A:

ELECTRO-HYDRAULIC IMPLEMENT SYSTEM

VARIABLE PUMP PILOT

MAIN HYDRAULIC SYSTEM

PILOT HYDRAULIC SYSTEM

COMMON TO BOTH SYSTEMS

ELECTRO-HYDRAULIC IMPLEMENT SYSTEM

Pilot hydraulic system

Main hydraulic system

Tank common to both