Unit 2: 950G Wheel Loader

UNIT 2
Intermediate Hydraulics--
950G Wheel Loader

Unit Objectives:
Upon completion of this unit, the student will be able to:
1. Identify all components in the 950G Wheel Loader electro-
hydraulic implement system and command control steering
system.
2. State the function of all components in the 950G Wheel Loader
electro-hydraulic implement system and command control
steering system.
3. Trace the oil flow through various schematics of both the 950G
Wheel Loader electro-hydraulic implement system and command
control steering system.
4. Using the procedures in the Service Manual, test and adjust the
950G Wheel Loader electro-hydraulic implement system and
command control steering system.
Unit 2 2-1-2 Machine Hydraulic Systems
Lesson 1

Introduction
This unit covers the components nomenclature, functions, locations,
systems operation and testing and adjusting procedures for the
Electro-Hydraulic Implement System and the Command Control
Steering System.
The Electro-Hydraulic Implement System is a replacement for the
Pilot Operated Hydraulic System and the Command Control Steering
System is a replacement for the Conventional Steering System. Both
systems are available on the Caterpillar G-Series Medium Wheel
Loaders.
The information in this unit covers the 950G, 962G, 966G, 972G and
980G Wheel Loaders. However, specifications may not be the same.
When performing the testing and adjusting procedures, use the
Service Manual for the machine being tested.
 Lesson 1: Electro-Hydraulic Implement System
Lesson 1: Electro-Hydraulic Implement
System

950G Wheel Loader

• Electro-Hydraulic Implement System
• Command Control Steering System

Introduction
On machines equipped with the electro-hydraulic implement system,
the operator's lever is attached to the appropriate lever position
sender. When the operator moves the lever, the lever position sender
sends a pulse width modulation (PWM) signal to the Electronic
Control Module (ECM). The ECM analyzes the input signal and
sends a proportional signal to energize the appropriate pilot valve
solenoid. The pilot valve solenoid opens the pilot valve which sends
pilot oil to move the implement control valve spool. The implement
control valve spool directs the main pump oil to move the
implement.
Objectives
Upon completion of this lesson, the student will be able to:
1. Identify components of the 950G Wheel Loader electro-hydraulic
implement system.
2. State the function of the 950G Wheel Loader electro-hydraulic
implement system in all positions (tiltback, lower, float etc...).
3. Trace the oil flow through the 950G Wheel Loader electro-
hydraulic implement system in all positions (tiltback, lower, float
etc.)
4. Perform the testing and adjusting procedures as stated in the
950G and 962G Wheel Loaders Electro-Hydraulic System,
Testing and Adjusting Module (Form RENR2146).
Unit 2 2-1-2 Machine Hydraulic Systems
Lesson 1

Fig. 2.1.1

When discussing the hydraulic system operation, both sectional view

and graphic symbol schematics will be used. The system will be
explained by tracing oil flow from the tank, through the system and
back to the tank.
Unit 2 2-1-3 Machine Hydraulic Systems
Lesson 1

ELECTRO-HYDRAULIC IMPLEMENT SYSTEM COMPONENTS

IMPLEMENT IMPLEMENT PILOT ELECTRO-HYDRAULIC HYDRAULIC TILT

HYDRAULIC ELECTRONIC PUMP CONTROL TANK CYLINDER
PUMP CONTROL LEVERS
MODULE

LIFT PILOT MAIN CONTROL

CYLINDER VALVE VALVE

IMPLEMENT ELECTRONIC MAIN SYSTEM COMPONENTS COMMON

CONTROL
SYSTEM COMPONENTS

Fig. 2.1.2

ELECTRO-HYDRAULIC IMPLEMENT SYSTEM

Figure 2.1.2 shows the major components of the electro-hydraulic

implement system.

The implement hydraulic system is composed of the following

systems:

Implement Electronic Control System: Pilot valve (oil

manifold), pilot and brake pump, implement electronic control
module, the control levers, and the implement lockout switch.

Main Hydraulic System: Main control valve, auxiliary

cylinders (if equipped), tilt cylinder, lift cylinders, main relief
valve and the implement pump.

Ride Control System: Tilt cylinder, lift cylinders, ride control

diverter valve, and the ride control accumulator.

Kickout System: Pilot valve (oil manifold), lift position sensor,

bucket positioner switch, implement control levers, and the
implement Electronic Control Module (ECM).

Fan Drive System: Oil cooler bypass valve, hydraulic oil cooler,
hydraulic oil filter, fan drive pump, and the fan drive motor.
Unit 2 2-1-4 Machine Hydraulic Systems
Lesson 1

2
5

Fig. 2.1.3

Common Hydraulic System Components

The hydraulic tank (1) is located on the right side of the machine. A
sight glass (2) indicates the level of the hydraulic oil in the tank.

The tank has a vent valve (3) that protects the tank from excessive
pressure and/or vacuum and an ecology-type drain valve (not shown)
for changing the oil.

The hydraulic oil filter (4) is located above the tank. The hydraulic
oil filter is in the return line for the fan drive system.

Also shown is the fill cap (5).

INSTRUCTOR NOTE: Oil change intervals and procedures are

provided in the 950G/962G Wheel Loaders Operation and
Maintenance Manual (Form SEBU7018).
Unit 2 2-1-5 Machine Hydraulic Systems
Lesson 1

5 4 2 1

Fig. 2.1.4

Implement Electronic Control System

The pilot and brake pump (1) is the rear section of a two-section vane
pump located below the cab of the machine. The implement pump
(2) is the front section of the pump group. Oil from the tank flows
through the common inlet tube (3) to both pump sections. The pump
sections have separate outlets (not visible in this view).

Also shown are the steering pump (4) and the transmission pump (5).
All the pumps are mounted in line to the torque converter.
Unit 2 2-1-6 Machine Hydraulic Systems
Lesson 1

5
5
4
2
6
3

1 7

Fig. 2.1.5

The pilot valve (1) is located between the lift arms behind the
implement control valve on the front frame of the machine. Oil from
the pump enters the pilot valve through the supply port (2). The pilot
manifold contains nine valves: the shuttle valve (3), the pressure
reducing valves (4), the four proportional solenoid valves (5) for the
implement functions, and the pilot on/off solenoid valve (6).

Also shown is the ride control pressure tap (7).

Unit 2 2-1-7 Machine Hydraulic Systems
Lesson 1

3
2

Fig. 2.1.6

The implement Electronic Control Module (ECM) is located at the

right rear of the cab. The ECM (1) is accessed by removing the floor
panel.

The diagnostic connector for electronic service tool use is located on

the fuse panel (2).

Also shown is the transmission ECM (3).

Unit 2 2-1-8 Machine Hydraulic Systems
Lesson 1

Fig. 2.1.7

Main Hydraulic System

The implement control levers (1) are located at the front of the right
armrest on the operator's seat. The control levers move with the seat
for operator comfort. The control levers move the lever position
sensors which send a Pulse Width Modulated (PWM) signal to the
implement ECM. The implement ECM sends a modulated signal to
the corresponding proportional solenoid valve on the pilot valve. The
signal regulates the amount of pilot oil flow through the proportional
solenoid valve. The pilot oil flows to the main control valve spool,
which directs main implement pump oil to the cylinder to move the
implement.

The implement lockout switch (2) is located forward and to the left of
the tilt control lever. If the implement lockout switch is in the OFF
position, the pilot on/off solenoid valve will not move to the ON
position when the control levers are moved. No oil will flow from
the pilot valve to the main control valve, and the implements will not
move.

NOTE: The key start switch and the implement lockout switch
must be in the ON position to move any implements with the
implement control levers.
Unit 2 2-1-9 Machine Hydraulic Systems
Lesson 1

Fig. 2.1.8

The main implement pump (1) is located below the cab on the right
side of the machine. The pump is mounted in line with the steering
and transmission pumps. The pumps are driven by a gear in the
torque converter housing.

The implement pump and the pilot and brake pump form a two-
section vane pump group using one common inlet (2) from the
hydraulic tank. The pump sections rotate on a common shaft.
Unit 2 2-1-10 Machine Hydraulic Systems
Lesson 1

1
2 3

Fig. 2.1.9

The main control valve (1) is located between the lift arms on the
front of the machine. The valve houses the lift valve spool (2), the
tilt valve spool (3), the main system relief valve (4), and the tilt line
relief valves (5).

Fig. 2.1.10

When an implement is activated, oil from the implement control

valve is directed to the tilt cylinder (1) and/or the lift cylinders (2).

Like most Caterpillar Wheel Loaders, the 950G/962G Wheel Loaders

are equipped with a Z-Bar linkage (3).
Unit 2 2-1-11 Machine Hydraulic Systems
Lesson 1

Fig. 2.1.11

Ride Control System

The ride control system consists of the tilt cylinder, lift cylinders, ride
control accumulator and the ride control diverter valve. Only the
components not previously shown will be discussed in this section of
the presentation.

The optional ride control system dampens the bucket forces which
produce a pitching motion as the machine travels over rough terrain.

The ride control accumulator (arrow) is located in front of the

articulation joint on the right side of the front frame. The
accumulator contains a precharge of nitrogen gas. Oil from the lift
cylinders pushes a piston in the accumulator against the nitrogen gas
which absorbs the forces rather than transferring the forces to the
machine. The system provides a dampening effect while traveling
over rough terrain.
Unit 2 2-1-12 Machine Hydraulic Systems
Lesson 1

Fig. 2.1.12

The ride control diverter valve (1) is located at the front end of the
main control valve. The ride control diverter valve controls oil flow
to the ride control accumulator. Located on the ride control diverter
valve are the ride control relief valve (2) and the ride control on/off
solenoid valve (3).
Unit 2 2-1-13 Machine Hydraulic Systems
Lesson 1

Fig. 2.1.13

Kickout System

The kickout system consists of the lift position sensor (arrow), the
bucket positioner switch, the lift kickout switch, the implement ECM
and the control lever detent coils. Only the components not
previously shown will be discussed in this section of the presentation.

The lift position sensor is located on the right side of the loader frame
in front of the cab.

When the operator moves the lift control lever to the FULL RAISE
position, the detent coil holds the lever in the detent position. As the
bucket raises, the lift position sensor sends a pulse width modulated
signal to the implement ECM. The signal tells the ECM the position
of the lift arm.

When the lift arm reaches the preset kickout height, the implement
ECM stops the flow of current to the lift control lever detent coil.
The control lever returns to the HOLD position, and the implement
stops moving.

The operation is the same for the LOWER kickout.

Unit 2 2-1-14 Machine Hydraulic Systems
Lesson 1

3
2

Fig. 2.1.14

The bucket positioner consists of two components: a magnet (1)

mounted on the pin that connects the Z-Bar linkage to the rod end of
the tilt cylinder and a bucket positioner switch (2) mounted on the
end of the tube (3) extending from the tilt cylinder.

When the operator moves the tilt control lever to the TILT BACK
position, the detent coil for the tilt control lever holds the lever in the
detent position.

As the bucket tilts back, the magnet assembly moves toward the
bucket positioner switch. The switch opens and the implement ECM
stops the flow of current to the lever detent coil. The lever returns to
the HOLD position, and the bucket stops moving.

INSTRUCTOR NOTE: At this time, introduce and perform

"Lab A: Electro-Hydraulic Implement System Component
Identification." This lab will reinforce the material discussed in
the preceding slide presentation.
Unit 2 2-1-15 Machine Hydraulic Systems
Lesson 1

ELECTRO-HYDRAULIC PILOT SYSTEM

HOLD

IMPLEMENT
CONTROL LEVERS
ON/OFF
SOLENOID VALVE
ECM
ECM
TILT LIFT
FLOAT BACK
VALVE LIFT TILT
BACK

TEST
PORT

FROM LIFT
PILOT AND CYLINDER
BRAKE PUMP MAKEUP VALVE TO RIDE
CONTROL
VALVE MAIN
CONTROL
PILOT VALVE VALVE

SHUTTLE
VALVE

TANK LOWER DUMP

PRESSURE
REDUCING FROM LIFT
VALVES CYLINDERS DUMP LOWER

Fig. 2.1.15

ELECTRO-HYDRAULIC SYSTEM OPERATION

Implement Pilot System

Figure 2.1.15 shows the implement pilot system electro-hydraulic

pilot valve (oil manifold) in the HOLD position.

The pilot system is a closed-center design. The pilot pump pulls oil
from the tank and sends pilot oil to the electro-hydraulic control
valve. Pilot pump oil enters the electro-hydraulic control valve and
flows through the pump oil pressure reducing valve.

When the engine is at high idle and the oil is at normal operating
temperature, the pump oil pressure reducing valve reduces the pilot
pump pressure to 3450 ± 200 kPa (500 ± 30 psi).

The pilot pump oil moves the shuttle valve. The shuttle valve blocks
the lower pressure oil from the lift cylinder pressure reducing valve.
The lift cylinder pressure reducing valve reduces oil pressure from
the lift cylinders to approximately 2070 ± 200 kPa (300 ± 30 psi).
Pilot pump oil flows past the shuttle valve to the on/off solenoid
valve. When the on/off solenoid is DE-ENERGIZED (implement
lockout switch in the LOCKED position), pilot oil is blocked at the
on/off solenoid valve. When the on/off solenoid is ENERGIZED by
the ECM (implement lockout switch in the UNLOCKED position and
a lever is moved), pilot oil flows past the on/off solenoid valve to the
proportional solenoid valves.
Unit 2 2-1-16 Machine Hydraulic Systems
Lesson 1

In the HOLD position, pilot oil is blocked at the on/off solenoid valve
until the pilot control levers signal the ECM to energize the on/off
solenoid and one or more proportional solenoids.

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

Unit 2 2-1-17 Machine Hydraulic Systems
Lesson 1

ELECTRO-HYDRAULIC PILOT SYSTEM

TILT BACK

IMPLEMENT
CONTROL LEVERS
ON/OFF
SOLENOID VALVE
ECM
ECM
TILT LIFT
FLOAT BACK
VALVE LIFT TILT
BACK

TEST
PORT

FROM LIFT
CYLINDER
MAKEUP VALVE
PUMP TO RIDE
CONTROL
VALVE MAIN
CONTROL
PILOT VALVE
VALVE

SHUTTLE
VALVE

TANK LOWER DUMP

PRESSURE
REDUCING FROM LIFT
VALVES CYLINDERS DUMP LOWER

Fig. 2.1.16

Figure 2.1.16 shows the implement pilot system electro-hydraulic

control valve in the TILT BACK position.

When the tilt control lever is moved to the TILT BACK position, the
tilt lever position sensor sends an electrical signal input to the
implement Electronic Control Module. The implement ECM
analyzes the input signal and sends an electrical output to energize
the on/off solenoid valve and the tilt back solenoid valve. The tilt
back solenoid valve controls the flow of pilot oil to the main control
valve tilt spool. The implement ECM electrical output is
proportional to the input signal from the tilt lever position sensor.
The tilt back solenoid valve output pressure is proportional to the
implement ECM output signal. The main control valve tilt spool
movement is proportional to the pressure from the tilt back solenoid
valve.
Unit 2 2-1-18 Machine Hydraulic Systems
Lesson 1

TO/FROM ELECTRO-
HYDRAULIC CONTROLS

TILT LIFT
MAIN HYDRAULIC BACK TILT
CYLINDER
SYSTEM
HOLD

LIFT
CYLINDERS

SYSTEM MAIN
RELIEF VALVE CONTROL
PUMP
VALVE

DUMP LOWER

TANK TO/FROM ELECTRO-

HYDRAULIC CONTROLS

Fig. 2.1.17

Main Hydraulic System

Figure 2.1.17 shows a sectional view of the main hydraulic system

with the control levers in the HOLD position.

The pump draws oil from the hydraulic tank and sends supply oil to
the main implement control valve. Supply oil entering the control
valve flows past the system relief valve. The system relief valve
constantly senses system pressure and opens to the tank when the
pressure reaches the maximum setting of the valve. When no oil
flow is sent from the electro-hydraulic pilot valve (not shown), the
main control valve spools are in the HOLD position. Supply oil
flows through the main control valve and returns to the tank.

When the operator moves a pilot control lever, a PWM signal is sent
to the implement ECM. The implement ECM sends a signal current
to the electro-hydraulic pilot valve. The electro-hydraulic pilot valve
sends pilot oil to move the respective spool in the main implement
control valve. The main implement control valve spool directs
supply oil to the respective cylinder.
Unit 2 2-1-19 Machine Hydraulic Systems
Lesson 1

AUXILIARY TILT LIFT ACCUMULATOR

MAIN CONTROL VALVE

MAIN
RELIEF
VALVE

TO RIDE
SERVICE CONTROL
BRAKES VALVE

ELECTRO-
HYDRAULIC
CONTROL
VALVE

TO STEERING PILOT SYSTEM

FROM STEERING PUMP SIGNAL LINE

SUPPLY
MAIN LINE TO STEERING SYSTEM
IMPLEMENT
PUMP

FAN
DRIVE
PUMP
IMPLEMENT HYDRAULIC SYSTEM
HOLD

Fig. 2.1.18
Implement Hydraulic Schematics

The schematic in Figure 2.1.18, shows the oil flow in the electro-
hydraulic pilot system and the main hydraulic system when the
engine is running and the proportional solenoid valves are in the
HOLD position.
In the pilot system, the pilot pump pulls oil from the tank and sends
oil flow to the electro-hydraulic control valve. Pilot pump oil enters
the electro-hydraulic control valve and flows through the pilot pump
pressure reducing valve. The pressure reducing valve reduces the
pilot pump pressure to 3450 ± 200 kPa (500 ± 30 psi). The pilot
pump oil moves the shuttle valve. The shuttle valve blocks the lower
pressure oil from the lift cylinder pressure reducing valve. Pilot
pump oil flows through the shuttle valve to the on/off solenoid valve.
When the on/off solenoid is ENERGIZED by the ECM (implement
lockout switch in the UNLOCKED position and a lever is moved),
pilot oil flows past the on/off solenoid valve to the proportional
solenoid valves.
When the on/off solenoid is DE-ENERGIZED (implement lockout
switch in the LOCKED position), pilot oil is blocked at the on/off
solenoid valve.
In the main hydraulic system, the implement pump pulls oil from the
tank and sends oil flow to the main control valve. When the control
spools are in the HOLD position, oil flows past the system relief
valve and through the open-center control spools to the tank. The
system relief valve constantly senses system pressure and opens to
the tank when the pressure reaches the maximum setting of the relief
valve.
Unit 2 2-1-20 Machine Hydraulic Systems
Lesson 1

AUXILIARY TILT LIFT ACCUMULATOR

MAIN CONTROL VALVE

MAIN
RELIEF
VALVE

TO RIDE
SERVICE CONTROL
BRAKES VALVE

ELECTRO-
HYDRAULIC
CONTROL
VALVE

TO STEERING PILOT SYSTEM

FROM STEERING PUMP SIGNAL LINE

SUPPLY
MAIN LINE TO STEERING SYSTEM
IMPLEMENT
PUMP

FAN
DRIVE
PUMP
IMPLEMENT HYDRAULIC SYSTEM
TILT BACK

Fig. 2.1.19

When the tilt control lever is moved to the TILT BACK position, as
shown in Figure 2.1.19, the tilt lever position sensor sends an
electrical signal input to the implement ECM. The ECM analyzes the
input signal and sends an electrical output to energize the on/off
solenoid valve and the tilt back proportional solenoid valve on the
electro-hydraulic control valve. The electro-hydraulic control valve
sends pilot oil to move the tilt spool in the main control valve. The
tilt spool moves against the centering springs. Tilt spool movement
closes the passage to the tank and opens the passages to the tilt
cylinder.
Implement pump oil flows through the load check valve and tilt spool
to the head end of the tilt cylinder. Oil from the rod end of the tilt
cylinder flows back through the tilt control spool to the tank.
Check valves block oil flow from the cylinder to prevent the bucket
from drifting when the operator moves the tilt control lever from the
HOLD to the TILT BACK position.
The rod end makeup valve permits oil to flow directly from the return
circuit or the tank to the rod end of the tilt cylinder when the rod end
pressure decreases to approximately 14 kPa (2 psi) less than the tank
oil pressure. The makeup oil prevents cavitation in the cylinder and
lines.
When the tilt control spool is in the HOLD position, the tilt line relief
valves protect the tilt circuit from pressure caused by external forces.
The line relief valves are usually set at a higher pressure than the
main relief valve. However, the tilt cylinder rod end line relief valve
is set at a lower pressure than the main relief valve.
Unit 2 2-1-21 Machine Hydraulic Systems
Lesson 1

When the lift arms are raised and the bucket is in the DUMP position,
the lift arms cannot reach their maximum height until the lift linkage
extends the tilt cylinder rod. The rod end line relief valve must open
to allow the tilt cylinder rod to extend. Therefore, the rod end relief
valve is set at a lower pressure than the main relief valve.
If the rod end line relief valve was set at a higher pressure than the
main relief valve, the main relief valve would open before the tilt
cylinder rod extends. Therefore, the lift arms could not reach their
maximum height.

AUXILIARY TILT LIFT ACCUMULATOR

MAIN CONTROL VALVE

MAIN
RELIEF
VALVE

TO RIDE
SERVICE CONTROL
BRAKES VALVE

ELECTRO-
HYDRAULIC
CONTROL
VALVE

TO STEERING PILOT SYSTEM

FROM STEERING PUMP SIGNAL LINE

SUPPLY
MAIN LINE TO STEERING SYSTEM
IMPLEMENT
PUMP

FAN
DRIVE
PUMP
IMPLEMENT HYDRAULIC SYSTEM
LOWER

Fig. 2.1.20
Figure 2.1.20 shows a schematic of the hydraulic flow during the
LOWER operation.
When the lift control lever is moved to the LOWER position, the lift
lever position sensor sends a PWM signal input to the implement
ECM. The implement ECM analyzes the input signal and sends a
PWM output signal to energize the on/off solenoid valve and the
lower solenoid valve on the electro-hydraulic control valve. The
implement ECM output signal is proportional to the input signal from
the lift lever position sensor.
The electro-hydraulic control valve sends pilot oil to move the lift
spool in the main control valve. The lift spool moves against the
centering springs. The lift spool movement blocks the flow of
implement pump oil to the tank and opens a passage to the rod end of
the lift cylinders. Implement pump oil flows through the check valve
and lift spool to the rod end of the lift cylinders. The lift spool also
opens a passage for oil from the head end of the lift cylinders to
return to the tank.
Unit 2 2-1-22 Machine Hydraulic Systems
Lesson 1

AUXILIARY TILT LIFT ACCUMULATOR

MAIN CONTROL VALVE

MAIN
RELIEF
VALVE

TO RIDE
SERVICE CONTROL
BRAKES VALVE

ELECTRO-
HYDRAULIC
CONTROL
VALVE

TO STEERING PILOT SYSTEM

FROM STEERING PUMP SIGNAL LINE

SUPPLY
MAIN LINE TO STEERING SYSTEM
IMPLEMENT
PUMP

FAN
DRIVE
PUMP IMPLEMENT HYDRAULIC SYSTEM
FLOAT

Fig. 2.1.21

Figure 2.1.21 shows the hydraulic flow when the control lever is
moved to the FLOAT position. When the lift control lever is in the
FLOAT position, the lift control spool is in the same position as when
the lift control lever is in the LOWER position.

When the lift control lever is in the FLOAT position, the ECM
increases the electrical output to the lower proportional solenoid
valve on the electro-hydraulic pilot valve. The lower proportional
solenoid valve increases the pilot oil pressure to the control spool.
The increase in pilot oil pressure is also sensed at the float valve.
The increased pilot oil pressure overcomes the float valve spring and
moves the float valve to the open position. Oil behind the lift
cylinder makeup valve flows through the float valve to the tank.

The small orifices in the makeup valve cause a restriction to the

implement pump oil when filling the cavity behind the makeup valve.
With oil flowing from behind the makeup valve faster than oil flows
in, the pressure difference between the oil around the makeup valve
and the oil behind the makeup valve becomes high enough to lift the
makeup valve off its seat. The oil from the implement pump flows
past the makeup valve to the tank.
Unit 2 2-1-23 Machine Hydraulic Systems
Lesson 1

AUXILIARY TILT LIFT ACCUMULATOR

MAIN CONTROL VALVE

MAIN
RELIEF
VALVE

TO RIDE
SERVICE CONTROL
BRAKES VALVE

ELECTRO-
HYDRAULIC
CONTROL
VALVE

TO STEERING PILOT SYSTEM

FROM STEERING PUMP SIGNAL LINE

SUPPLY
MAIN LINE TO STEERING SYSTEM
IMPLEMENT
PUMP

FAN
DRIVE
PUMP
IMPLEMENT HYDRAULIC SYSTEM
LOWER ENGINE OFF

Fig. 2.1.22

In Figure 2.1.22 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 pressure oil flows
through the hose to the lift cylinder pressure reducing valve. The lift
cylinder pressure reducing valve reduces the oil pressure from the lift
cylinder to approximately 2070 kPa (300 psi). With the engine off
and no pressure on the pilot pump side of the shuttle valve, the lift
cylinder oil shifts and flows past the shuttle valve to the on/off
solenoid valve. When the on/off solenoid is de-energized, lift
cylinder oil is blocked at the on/off solenoid valve. When the on/off
solenoid is energized (key on, implement lockout switch unlocked, as
shown) and the lift control lever in the LOWER position, lift cylinder
oil flows through the on/off solenoid valve to the proportional
solenoid valves.

With the lift control lever in the LOWER position, lift cylinder oil is
sent to move the lift control spool. 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 valve into the rod end of
the lift cylinders and prevents cylinder cavitation.
Unit 2 2-1-24 Machine Hydraulic Systems
Lesson 1

AUXILIARY TILT LIFT ACCUMULATOR

MAIN CONTROL VALVE

MAIN
RELIEF
VALVE

TO RIDE
SERVICE CONTROL
BRAKES VALVE

ELECTRO-
HYDRAULIC
CONTROL
VALVE

TO STEERING PILOT SYSTEM

FROM STEERING PUMP SIGNAL LINE

SUPPLY
MAIN LINE TO STEERING SYSTEM
IMPLEMENT
PUMP

FAN
DRIVE
PUMP IMPLEMENT HYDRAULIC SYSTEM
RIDE CONTROL

Fig. 2.1.23

Figure 2.1.23 schematic shows the hydraulic flow when the ride
control solenoid valve is ENERGIZED. The ride control solenoid
valve is controlled by the transmission ECM.
The ride control switch (not shown) allows the operator to select
between the ride control ON, ride control OFF and ride control
AUTO positions.
When the ride control switch is in the ON position, the transmission
ECM will continually ENERGIZE the ride control solenoid.
When the ride control switch is in the AUTO position, the
transmission ECM will ENERGIZE the ride control solenoid when
the machine ground speed is above 9.7 km/h (6 mph) and will DE-
ENERGIZE the ride control solenoid when the ground speed is below
8.8 km/h (5.5 mph).
When the ride control solenoid valve is ENERGIZED, pilot pressure
shifts the selector spool to connect the head end of the lift cylinders
with the accumulator. A floating piston in the accumulator separates
the oil from the nitrogen gas. Since nitrogen gas is compressible, the
gas serves 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
accumulator. The force in 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.
Unit 2 2-1-25 Machine Hydraulic Systems
Lesson 1

When the ride control solenoid valve is DE-ENERGIZED, the orifice

passage in the control valve allows the pressure in the head end of the
lift cylinders and the pressure in the accumulator to equalize.

10 A

15 A IMPLEMENT ELECTRONIC
15 A IMPLEMENT CONTROL SYSTEM
10 A ECM
10 A
10 A
CAT DATA LINK
10 A OPERATOR IMPLEMENT CONTROLS

FUSE IMPLEMENT FUNCTION

HOLDER SELECT SWITCH OPTIONS CODE PLUG
NO. 2 (ATTACHMENT)

IMPLEMENT
LOCKOUT SWITCH KICKOUT SET SWITCH

LIFT LEVER RAISE

DETENT COIL
LIFT LEVER LOWER ON/OFF PILOT SOLENOID
DETENT COIL
TILT LEVER LIFT LINKAGE
DETENT COIL RAISE PROPORTIONAL SOLENOID

LIFT LEVER LIFT LINKAGE

POSITION SENSOR LOWER PROPORTIONAL SOLENOID

TILT LEVER TILT LINKAGE TILT BACK

POSITION SENSOR PROPORTIONAL SOLENOID

AUXILIARY LEVER TILT LINKAGE

POSITION SENSOR DUMP PROPORTIONAL SOLENOID
(ATTACHMENT)
AUXILIARY LEVER REARWARD
BUCKET PROPORTIONAL SOLENOID
POSITIONER SWITCH AUXILIARY LEVER FORWARD
PROPORTIONAL SOLENOID
(ATTACHMENT)
LIFT POSITION
WLPCS ECM SENSOR
(ATTACHMENT)

Fig. 2.1.24

IMPLEMENT ELECTRONIC CONTROL SYSTEM

Figure 2.1.24 shows a block diagram of the Implement Electronic

Control System.
The implement ECM receives input signals from the various sensors
and switches. The ECM processes the input signals, makes decisions
and provides a corresponding output signal to the proportional
solenoid valves, detent coils, and auxiliary attachments (if equipped).
The ECM also communicates with other electronic control systems
through the CAT Data Link.
The Electronic Implement Control System consists of the following
components:
Lift lever position sensor: Signals the ECM the position of the lift
control lever.
Tilt lever position sensor: Signals the ECM the position of the tilt
control lever.
Auxiliary lever position sensor: Signals the ECM the position of
the auxiliary control lever.
Lift position sensor: Signals the ECM the position of the lift arms.
Unit 2 2-1-26 Machine Hydraulic Systems
Lesson 1

Bucket positioner switch: Signals the ECM the position of the

bucket.
Implement lockout switch: Signals the ECM that the operator
wants the control levers disabled.
Kickout set switch: Used to set the kickout positions.
Implement function select switch: Provides a third hydraulic
function to be controlled when a machine is equipped with a two-axis
joystick.
Options code plug: Signals the ECM what implement options are
installed on the machine.
Pilot on/off solenoid valve: Used to disable and enable the pilot
hydraulic system.
Tilt linkage dump proportional solenoid valve: Directs pilot oil to
the main control valve.
Tilt linkage tilt back proportional solenoid valve: Directs pilot oil
to the main control valve.
Lift linkage raise proportional solenoid valve: Directs pilot oil to
the main control valve.
Lift linkage lower proportional solenoid valve: Directs pilot oil to
the main control valve.
Auxiliary lever rearward proportional solenoid valve: Directs
pilot oil to the main control valve.
Auxiliary lever forward proportional solenoid valve: Directs pilot
oil to the main control valve.
Lift lever raise detent coil: Holds the raise/lower lever in the raise
position.
Lift lever lower detent coil: Holds the raise/lower lever in the lower
position.
Tilt lever detent coil: Holds the tilt/dump lever in the tilt back
position.
CAT Data Link: Communication path to and from other electronic
control modules.
Wheel loader payload control system: Signals the operator various
payload information.
Unit 2 2-1-27 Machine Hydraulic Systems
Lesson 1

Fig. 2.1.25

Implement Electronic Control System Components

The implement ECM receives input signals from the implement
lockout switch (1), the lever position sensors located on each side of
the pilot control levers (2) below the cover, the lift kickout set switch
(3), the lift arm position sensor (4), and the bucket position switch
(5).

Fig. 2.1.26

The implement ECM energizes the pilot on/off solenoid (1) and the
proportional solenoid valves (2). Only two proportional solenoid
valves are visible in this view. The other two valves are located on
the opposite side of the pilot valve.
Unit 2 2-1-28 Machine Hydraulic Systems
Lesson 1

Fig. 2.1.27

The implement ECM energizes and de-energizes the tilt lever detent
coil (1), the lift lever raise detent coil (2) and the lift lever lower
detent coil (3) as needed to perform the implement kickout functions.

The implement ECM also sends information over the CAT Data Link.
Unit 2 2-1-29 Machine Hydraulic Systems
Lesson 1

Fig. 2.1.28

Kickout Set Switch

The lift kickout set switch (arrow) is a momentary push button switch
used to set the lift raise and lift lower kickout positions.

To set the raise kickout position, raise the lift arms above the midway
point to the desired position, and release the control lever. PRESS
the lift kickout switch. The implement ECM records the lift arm
position sensor PWM signal. The implement ECM DE-ENERGIZES
the lift lever raise detent coil each time the lift arm position sensor
PWM signal is equal to or above the recorded signal.

To set the lower kickout position, lower the lift arms below the
midway point to the desired position, and release the control lever.
PRESS the lift kickout switch. The implement ECM records the lift
arm position sensor PWM signal. The implement ECM uses the
recorded PWM signal to determine when to DE-ENERGIZE the lift
lever lower detent coil.
Unit 2 2-1-30 Machine Hydraulic Systems
Lesson 1

3
2

Fig. 2.1.29

Bucket Positioner

The bucket positioner consists of two components: a magnet (1)

mounted on the pin that connects the Z-Bar linkage to the rod end of
the tilt cylinder and a bucket positioner switch (2) mounted on the
end of the tube (3) extending from the tilt cylinder (4).

Adjustment for the bucket kickout is made by rotating and aligning

the magnet assembly with the solid state switch on the end of the
tube assembly. Always refer to the appropriate service literature
before any adjustments are made.

Each time the magnet and switch align, the switch sends a signal to
the implement ECM to de-energize the tilt lever detent coil.
Unit 2 2-1-31 Machine Hydraulic Systems
Lesson 1

Fig. 2.1.30

ELECTRONIC CONTROL SYSTEM DIAGNOSTICS

The implement ECM is capable of detecting most electrical faults

associated with the implement electronic control system. When a
fault is detected, the fault is stored in the implement ECM memory.
Diagnostic information is shown on the Caterpillar Monitoring
System Message Center Module display (arrow) when using the
operator's switch (not shown) and the Diagnostic Scrolling Mode or
the 9U6665 or 4C8195 Service Tool to enter the Service Mode
(Mode 3).

INSTRUCTOR NOTE: The Caterpillar Monitoring System

access procedures are found in the Service Manual module
"Caterpillar Monitoring System Operation, Testing and
Adjusting" (Form SENR1394).
Unit 2 2-1-32 Machine Hydraulic Systems
Lesson 1

MESSAGE CENTER MODULE

MODE 3

SERV
CODE

SERV
CODE

Fig. 2.1.31

Figure 2.1.31 shows the Caterpillar Monitoring System Message

Center Module display in the Service Mode (Mode 3). When no fault
is detected, the display shows three continuous dashes (- - -).

INSTRUCTOR NOTE: Suggested troubleshooting procedures

are found in the Service Manual module "950G/962G Wheel
Loaders Electro-Hydraulic System Testing and Adjusting" (Form
SENR2146).
Unit 2 2-1-33 Machine Hydraulic Systems
Lesson 1

MESSAGE CENTER MODULE

MODE 3

SERV
CODE

SERV SERV
CODE CODE

MID CID/FMI

Fig. 2.1.32

When the Caterpillar Monitoring System is in the Service Mode

(Figure 2.1.32), the Message Center shows the fault code.

The fault code consists of the Module Identifier (MID) followed by

the Component Identifier (CID) and Failure Mode Identifier (FMI).

The MID tells which electronic control module diagnosed the fault.
An MID of 082 means the fault was diagnosed in the implement
electronic control system. MID's are listed on the machine electrical
schematic in the Service Manual.

The CID tells which component is faulty. CID 356 means the fault
was diagnosed in the bucket dump solenoid circuit.

The FMI tells the type of failure. FMI F05 means the failure is
"current below normal" or "open circuit."

When the SERV CODE indicator is ON, the fault is PRESENT in the
machine. When the SERV CODE indicator is OFF, the fault is NOT
PRESENT in the machine.

INSTRUCTOR NOTE: At this time, introduce and perform

"Lab B: Electro-Hydraulic Implement System Operation" and
"Lab C: Electro-Hydraulic System Testing and Adjusting."
These labs will reinforce the material discussed in the preceding
slide presentation.
Unit 2 2-1-34 Machine Hydraulic Systems
Lesson 1

Fig. 2.1.33

CONCLUSION

This concludes the presentation on the 950G/962G Wheel Loaders

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.

INSTRUCTOR NOTE: At this time, introduce and perform

"Lab D: Fan Drive System Component Identification" and "Lab
E: Fan Drive System Testing and Adjusting." These labs will
reinforce the material discussed in the preceding slide
presentation.
Unit 2 -1- Machine Hydraulic Systems
Instructor Copy Lab 2.1.1

Instructor Copy: Lab 2.1.1

Lab 2.1.1: Implement Hydraulic System Component
Identification

Shop Lab Exercise

Instructor attaches tags containing letters or numbers to the Implement

Hydraulic System components.

Students will identify Implement Hydraulic System components by

matching the lettered or numbered tags on the components with the
names on the worksheets.

NOTE: Tags containing letters or numbers should be attached to the

Implement Hydraulic System components in advance. Record the
tag information in the space provided on the instructor's copy of the
"Lab 2.1.1: Implement Hydraulic System Component Identification
Worksheet."

Procedure:
Explain the process for filling out the worksheets

Inform the students that they may refer to the Service Manual or class
notes during the lab.

Discuss the completed lab worksheets with the class.

Materials Needed
Lettered or numbered tags

Lab 2.1.1 Worksheet

Pen or pencil

950G Wheel Loader

Mechanic's tool box with hand tools

Service Manual module "950G and 962G Wheel Loaders Electro-

Hydraulic System, Testing and Adjusting Module" (Form RENR2146)
Unit 2 -2- Machine Hydraulic Systems
Instructor Copy Quiz 2.1.1

Instructor Copy: Quiz 2.1.1

Lab 2.1.1: Implement Hydraulic System Component Identificatio

Directions: Use this worksheet during the slide presentation to take notes on the function and
location of each component. During the lab exercise, match the tag attached to the
component with the correct name. (Each correct match is worth 10 points.)

Component Tag No.

Brake/pilot pump ___

Implement pilot control levers ___

Pilot valve ___

Implement hydraulic pump ___

Main control valve ___

Main relief valve ___

Lift cylinders ___

Tilt cylinders ___

Hydraulic tank ___

Ride control accumulator ___

Unit 2 -1- Machine Hydraulic Systems
Student Copy Quiz 2.1.1

Student Copy: Quiz 2.1.1

Lab 2.1.1: Implement Hydraulic System Component Identification

Directions: Use this worksheet during the slide presentation to take notes on the function and
location of each component. During the lab exercise, match the tag attached to the
component with the correct name. (Each correct match is worth 10 points.)

Component Tag No.

Brake/pilot pump ___

Implement pilot control levers ___

Pilot valve ___

Implement hydraulic pump ___

Main control valve ___

Main relief valve ___

Lift cylinders ___

Tilt cylinders ___

Hydraulic tank ___

Ride control accumulator ___

Unit 2 -1- Machine Hydraulic Systems
Lab 2.1.1 Instructor Copy

Instructor Copy: Lab 2.1.2

Lab 2.1.2: Implement Hydraulic System Tests

This lab measures the students ability to perform the implement

hydraulic system tests.

Materials Needed

The materials listed is the amount needed per machine used.

Lab 2.1.2 Worksheets

950G Wheel Loader

950G and 962G Wheel Loaders Electro-Hydraulic System, Testing and

Adjusting Module (Form RENR2146)

1 - 8T-5320 Hydraulic test group

2 - 8S-7630 Stand or equivalent

2 - 8S-8048 Saddle

2 - 8S-7641 Tube

2 - 8S-7615 Pin

1 - 7S-5437 Nitrogen Charging Group

1 - 4C-4892 ORFS Fitting Group

1 - 9U-7400 Multitach

1 - Straight edge ruler 152 mm (6 in.)

1 - Stop watch

1 - Felt tip pen or marker

1 - Mechanic's tool box with hand tools

Unit 2 -2- Machine Hydraulic Systems
Lab 2.1.1 Instructor Copy

Lab 2.1.2: Implement Hydraulic System Tests Worksheet 1

Following the procedures in the 950G and 962G Wheel Loaders Electro-
Hydraulic System, Testing and Adjusting Module (Form RENR2146),
perform the following tasks:

Record all test results on "Lab 2.1.2: Implement Hydraulic System Tests
Worksheets"

1. Lift and Tilt Cylinder Drift Tests

2. Lift and Tilt Cylinder Speed Tests

3. Pilot System Pressure Test Engine OFF with Raised Bucket

4. Pilot System Pressure Test Engine ON

5. Main Relief Valve Test and Adjust

6. Line Relief Valves Test and Adjust

7. Charge Ride Control Accumulator Test and Charge

8. Ride Control Diverter Valve Test

9. Fan Drive Gear Pump Pressure Test

10. Fan Drive Gear Motor Speed Test

WARNING

To avoid possible personal injury, follow all warnings listed in the

950G Wheel Loader, 962G Wheel Loader and IT62G Integrated
Toolcarrier Hydraulic System, Testing and Adjusting Module (Form
SENR1390)
Unit 2 -3- Machine Hydraulic Systems
Instructor Copy Lab 2.1.2

Lab 2.1.2: Implement Hydraulic System Tests Worksheet 1

TILT CYLINDERS DRIFT

Maximum Drift Oil Temperature Time In Minutes

Specifications

Cylinders Drift

LIFT CYLINDERS DRIFT

Maximum Drift Oil Temperature Time In Minutes

Specifications

Cylinders Drift

PILOT AND MAIN SYSTEM PRESSURE TEST

Pilot Relief Main Relief Rod End Relief
Pressure Pressure Pressure
Specifications

Machine Pressure

TILT CYLINDER
Oil Temp ____°F 1st Test 2nd Test 3rd Test Average

Cycle Time

Specification
Is the average cycle time within machine specification? ___Yes ___No

LIFT CYLINDERS

Oil Temp ____°F 1st Test 2nd Test 3rd Test Average

Cycle Time

Specification
Is the average cycle time within machine specification? ___Yes ___No
Unit 2 -1- Machine Hydraulic Systems
Student Copy Lab 2.1.2

Student Copy: Lab 2.1.2

Lab 2.1.2: Implement Hydraulic System Tests

This lab measures your ability to perform the implement hydraulic

system tests.

Materials Needed

The materials listed is the amount needed per machine used.

Lab 2.1.2 Worksheets

950G Wheel Loader

950G and 962G Wheel Loaders Electro-Hydraulic System, Testing and

Adjusting Module (Form RENR2146)

1 - 8T-5320 Hydraulic test group

2 - 8S-7630 Stand or equivalent

2 - 8S-8048 Saddle

2 - 8S-7641 Tube

2 - 8S-7615 Pin

1 - 7S-5437 Nitrogen Charging Group

1 - 4C-4892 ORFS Fitting Group

1 - 9U-7400 Multitach

1 - Straight edge ruler 152 mm (6 in.)

1 - Stop watch

1 - Felt tip pen or marker

1 - Mechanic's tool box with hand tools

Unit 2 -2- Machine Hydraulic Systems
Student Copy Lab 2.1.2

Lab 2.1.2: Implement Hydraulic System Tests Worksheet 1

Following the procedures in the 950G and 962G Wheel Loaders Electro-
Hydraulic System, Testing and Adjusting Module (Form RENR2146),
perform the following tasks:

Record all test results on "Lab 2.1.2: Implement Hydraulic System Tests
Worksheets"

1. Lift and Tilt Cylinder Drift Tests

2. Lift and Tilt Cylinder Speed Tests

3. Pilot System Pressure Test Engine OFF with Raised Bucket

4. Pilot System Pressure Test Engine ON

5. Main Relief Valve Test and Adjust

6. Line Relief Valves Test and Adjust

7. Charge Ride Control Accumulator Test and Charge

8. Ride Control Diverter Valve Test

9. Fan Drive Gear Pump Pressure Test

10. Fan Drive Gear Motor Speed Test

WARNING

To avoid possible personal injury, follow all warnings listed in the

950G Wheel Loader, 962G Wheel Loader and IT62G Integrated
Toolcarrier Hydraulic System, Testing and Adjusting Module (Form
SENR1390)
Unit 2 -3- Machine Hydraulic Systems
Student Copy Lab 2.1.2

Lab 2.1.2: Implement Hydraulic System Tests Worksheet 1

TILT CYLINDERS DRIFT

Maximum Drift Oil Temperature Time In Minutes

Specifications

Cylinders Drift

LIFT CYLINDERS DRIFT

Maximum Drift Oil Temperature Time In Minutes

Specifications

Cylinders Drift

PILOT AND MAIN SYSTEM PRESSURE TEST

Pilot Relief Main Relief Rod End Relief
Pressure Pressure Pressure
Specifications

Machine Pressure

TILT CYLINDER
Oil Temp ____°F 1st Test 2nd Test 3rd Test Average

Cycle Time

Specification
Is the average cycle time within machine specification? ___Yes ___No

LIFT CYLINDERS

Oil Temp ____°F 1st Test 2nd Test 3rd Test Average

Cycle Time

Specification
Is the average cycle time within machine specification? ___Yes ___No