SERV7105-09 September 2005 Vol. 9, No.

GLOBAL SERVICE LEARNING

TECHNICAL PRESENTATION

966H AND 972H WHEEL LOADERS INTRODUCTION

New Product Introduction (NPI)

966H AND 972H WHEEL LOADERS INTRODUCTION

AUDIENCE
Level II - Service personnel who understands the principles of machine system operation, diagnostic equipment, and procedures for testing and adjusting.

CONTENT
This presentation provides new and different New Product Introduction (NPI) information for the 966H and 972H Wheel Loaders. This presentation may be used for self-paced and selfdirected training.

OBJECTIVES
After learning the information in this presentation, the technician will be able to: 1. locate and identify the new components on the 966H and 972H Wheel Loaders; and 2. explain the operation of the new components in the systems.

REFERENCES
TIM "966G/972G Wheel Loaders - Power Train" TIM "966G/972G Wheel Loaders - Steering and Brake Systems" TIM "966G/972G Wheel Loaders - Command Control Steering System" SERV2658 SERV2659 SERV2660

Estimated Time: 2 Hours Illustrations: 38 Handouts: 5 Form: SERV7105-09 Date: 09/05

2005 Caterpillar Inc.

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TABLE OF CONTENTS
INTRODUCTION ........................................................................................................................5 SIMILARITIES AND DIFFERENCES .......................................................................................6 MACHINE APPEARANCE.........................................................................................................7 ENGINE......................................................................................................................................13 IMPLEMENT HYDRAULIC SYSTEM....................................................................................19 Implement Hydraulic System - HOLD.................................................................................19 Pump Control Valve - Engine OFF ......................................................................................22 Pump Control Valve - STANDBY........................................................................................24 Pump Control Group - Upstroke ..........................................................................................25 Pump Control Valve - Constant Flow Demand ....................................................................26 Pump Control Valve - Maximum System Pressure ..............................................................27 Pump Control Valve - Maximum System Pressure with Added Flow Demand ..................28 Tilt Control Valve - HOLD...................................................................................................32 Implement Hydraulic System - DUMP ................................................................................33 Implement Hydraulic System - DUMP ................................................................................37 Implement Hydraulic System - RAISE ................................................................................39 Implement Hydraulic System - FLOAT ...............................................................................41 Implement Hydraulic System -TILT BACK AND RAISE ..................................................43 Implement Hydraulic System - RIDE CONTROL AUTO...................................................45 Calibrations and Adjustments for Implement Hydraulic System.........................................47 STEERING SYSTEM ................................................................................................................49 FAN AND BRAKE HYDRAULIC SYSTEM ...........................................................................50 Calibrations and Adjustments for Fan and Brake System....................................................54 NEW TOOLING/SKILLS REQUIRED FOR SERVICE ..........................................................55 CONCLUSION...........................................................................................................................56 HYDRAULIC SCHEMATIC COLOR CODE...........................................................................57 HANDOUTS...............................................................................................................................58 POSTTEST .................................................................................................................................61 POSTTEST ANSWERS .............................................................................................................63

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NOTES

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966H AND 972H WHEEL LOADERS INTRODUCTION

2005 Caterpillar Inc.

INTRODUCTION The 966H and 972H Wheel Loaders have been updated to enhance performance and to meet the Tier III emissions regulations. The serial number prefixes of the "H" Series Medium Wheel Loaders are as follows: 966H Wheel Loader Aurora Gosselies Sagami 972H Wheel Loader Aurora Gosselies Sagami A7D A7G A7J A6D A6G A6J

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SIMILARITIES AND DIFFERENCES

FEATURES Configuration/Attachments Engine Hydraulic System Machine Appearance Cooling Package Operator's Station Power Train Monitoring System DIFFERENT X X X X X X X X SIMILAR SAME

2 SIMILARITIES AND DIFFERENCES The most significant change to the H Series Medium Wheel Loaders is the machine configuration. Conventional (Hand Metering Unit (HMU)) steering with electrohydraulic implement controls is the standard configuration. Command Control Steering (CCS) will be offered as an attachment. The engines in the "H" Series Medium Wheel Loaders are changing to Tier III emissions compliant Caterpillar engines with ACERT technology. The implement hydraulic system is changing to a Proportional Priority, Pressure Compensated (3PC) system. The brake and fan systems are now combined, utilizing a single pump. Machine appearance has changed with the hydraulic tank being mounted behind the cab and two service centers located under the cab on the both sides of the machine. The operators station features new style switches.

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MACHINE APPEARANCE The top of the cooling package (1) is lower and the entire cooling package is wider on the 966H and 972H Wheel Loaders. Two service centers, right side (2) and left side (not shown), have been added to the machine. The service centers provide a central location for diagnostic tests, filters, and other components used to service the machine.

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2 3 4

5 6 7

The following components are located on the left side of the machine below the cab: - Battery disconnect switch (1) - Hood actuator switch (2) - Breaker panel (3) - Battery box (4) - Ground level shutdown switch (5) - Power train oil fill cap (6) - Power train oil level sight gauge (6) The following breakers are located in the breaker panel: - 105 ampere for the alternator - 30 ampere for the unswitched buss - 20 ampere for the hood actuator - 50 ampere for the starter - 80 ampere main for the system

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The hydraulic tank (1), the hydraulic tank breaker relief valve (2), and the hydraulic tank fill cap (3) are now located behind the cab.

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2 1 3

6 4 5 7

The service center is located on the right side of the machine below the cab. The following components are located in the service center: - Case drain filter (1) - Hydraulic oil fluid sampling valve (2) - Hydraulic systems kidney loop filter (3) - Brake system accumulators (4) - Power train oil fluid sampling valve (5) - Power train oil filter (6) - Ecology drain for the hydraulic tank (7)

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13 14

5 4 3 10 11 12

The following remote pressure taps are located inside the panel on the front side of the service center: - Transmission reverse clutch (1) - Transmission forward clutch (2) - Transmission fourth speed clutch (3) - Transmission third speed clutch (4) - Transmission second speed clutch (5) - Transmission first speed clutch (6) - Steering pump outlet pressure (7) - Torque converter inlet pressure (8) - Brake system accumulator pressure (9) - Transmission lubrication pressure (10) - Transmission pump outlet pressure (11) - Torque converter outlet pressure (12) - Steering cylinder rod end grease zerks (13) - Rear axle oscillation bearing grease zerks (14)

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The automatic lubrication reservoir (arrow) is located on the platform on the right side of the machine. NOTE: The automatic lubrication system will NOT be available at first ship of the machine.

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ENGINE The 966H Wheel Loader is equipped with the Caterpillar C11 ACERT engine, serial number prefix RSX. The displacement of the C11 ACERT engine is 11.1 liters with a rated gross power of 283 hp. The performance test specification for the C11 ACERT engine in the 966H Wheel Loader is 0K4835. The 972H Wheel Loader is equipped with the Caterpillar C13 ACERT engine, serial number prefix MHX. The displacement of the C13 ACERT engine is 13.1 liters with a rated gross power of 307 hp. The performance test specification for the C13 ACERT engine in the 972H Wheel Loader is 0K4841.

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2 3 4

7 5 6

10

The following electrical components are located on the right side of the machine on the engine: - Engine oil pressure sensor (5) - Air intake pressure sensor (2) - Inlet air temperature sender (3) - A4E4 Engine ECM (4) - Atmospheric pressure sensor (1) - Crankshaft speed timing sensor (6) - Camshaft speed timing sensor (7) The A4E4 Engine ECM features a 120 pin connector and a 70 pin connector.

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11

The following components are found on the fuel filter bases on the right side of the machine: - Fuel priming pump switch (1) - Electric fuel priming pump (2) - Fuel pressure sensor (3) - Fuel temperature sender (4) - Differential fuel pressure switch (5) - Air bleed valve (6) - Primary fuel filter and water separator (7) - Secondary fuel filter (8)

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5 6 7

12

The following components are located on the left side of the machine on the engine: - Bracket for ether start aid bottle (2) - Muffler (3) - Turbocharger with wastegate (4) - Engine oil fluid sampling valve (5) - Engine oil filter (6) Also shown is the hydraulic tank and sight gauge (1) located behind the cab. The radiator top tank and sight gauge (4) are located on the left side of the machine, just above the cooling fan.

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13

The hydraulic oil cooler (1) and the air conditioner condenser coil (2) are located at the rear of the machine. These two components swing out to allow the removal of debris from the cooling package. The radiator (3) and the Air To Air AfterCooler (ATAAC) (4) are also located at the rear of the machine. The fuel tank filler cap (not shown) is also located in this area.

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14

The following components are located on the front of the engine: - Coolant temperature sender (1) - Automatic belt tensioner (2) - Alternator drive pulley (3) - Air conditioner compressor drive pulley (4) - Serpentine drive belt (5)

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"H" SERIES MEDIUM WHEEL LOADER IMPLEMENT HYDRAULIC SYSTEM

HOLD
Tilt Cylinder Lift Cylinders Tilt Anti-drift Valve Ride Control Accumulator Head End Solenoid valve Line Relief Valves Lift Ant i-drift Valve Raise Pilot Solenoid Valve Rod End Solenoid Valve Auxiliary Head End Solenoid Valve

Inlet Manifold Manual Lower Valve

Auxiliary Function

Cover Manifold Hydraulic Lockout Valve

Pilot Accumulator

Tilt Back Pilot Solenoid Valve Lift Spool Tilt Spool Pressure Compensator Valve Resolver Valve Pressure Compensat or Valve Ride Control Relief Valve Auxiliary Spool

Screen

Resolver Valve Check Valve

Balance Valve

Resolver Valve

Pressure Compensator Valve

Pilot Pressure Reducing Valve

Steering Pilot Supply (CCS only)

Signal Duplication Valve

Signal Relief Valve Lower / Float Pilot Solenoid Valve Ride Control Auxiliary Rod End Solenoid Valve Differential Pressure Relief Valve

Dump Pilot Solenoid Valve

Case Drain Filter

Choke Check Valve

Min Angle Tank

Pump and Pump Cont rol Valve

15 IMPLEMENT HYDRAULIC SYSTEM Implement Hydraulic System - HOLD The "H" Series Medium Wheel Loaders are now equipped with a Proportional Priority, Pressure Compensated (3PC) implement hydraulic system. The 3PC hydraulic system is load sensing with a signal duplication valve, signal relief valve, pressure compensator valves, pressure differential relief valve, pressure reducing valve, and a resolver network. Also, the 3PC valve has anti-drift solenoid valves for the lift and tilt functions. The implement control valve is a closed-center valve. The 3PC hydraulic system will sense a demand for a change in flow and the implement pump will upstroke or destroke to provide the flow. The machine may also be equipped with an optional auxiliary function. The auxiliary section is installed between the ride control valve and the cover manifold.

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When the engine is started and the implement control levers are in the HOLD position, the implement pump supplies standby oil flow to the 3PC valve group. The oil flows into the inlet manifold and is divided into two paths. The supply path for the implements flows through the inlet manifold into the tilt section where the flow path is divided again. One path flows to the tilt stem and is blocked. The second path flows to the lift control section, to the ride control section, to the optional auxiliary section, and to the cover manifold. Within the cover manifold, the oil flows to both the pilot pressure reducing valve (PRV) and the differential pressure relief valve. The differential pressure relief valve maintains a difference between the load sensing pressure and the pump supply oil pressure of 3000 kPa (435 psi). When all of the control valves are in the HOLD position, the implement pump is at low pressure standby. The differential pressure relief valve maintains the minimum pressure for low pressure standby. The standby pressure is directed to the pilot pressure reducing valve, and the pilot pressure reducing valve provides a regulated pilot oil pressure to activate the control valves as needed. The pilot oil flows from the PRV through the check valve to the pilot accumulator and the hydraulic lockout solenoid valve. If the wheel loader is equipped with the optional Command Control Steering (CCS), the oil flow will be shared by the implement pilot system and the steering pilot system. The hydraulic lockout solenoid valve is in the CLOSED position until the hydraulic lockout switch in the cab is activated. When the solenoid valve is energized, the solenoid valve opens and pilot oil flows to the various implement function solenoid valves. The second path of oil in the inlet manifold flows through the screen to the signal duplication valve. The signal duplication valve uses the pump supply oil to duplicate the signal from the highest pressure in the resolver network. When all implement control valves are in the HOLD position, there is no load sensing signal in the resolver network. With no load sensing pressure present, the implement pump is at low pressure standby.

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The implement pump is a variable displacement piston pump. The pump control valve (1) controls the angle of the swash plate (not shown). The implement pump supplies oil flow for the implement hydraulic system, the implement pilot system, and the optional CCS pilot system. Maximum angle stop adjustment screw (2) is used to adjust the maximum upstroke position of the actuator piston in the pump control valve (1).

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PUMP CONTROL VALVE

ENGINE OFF
Maximum Angle Stop Adjustment Screw Set Screw To Implement Control Valve

Pump System Pressure Piston Load Sensing Spool Orifice

Pump Load Sensing Sleeve Margin Spring Load Sensing Piston Swashplate Pin

Signal Relief Valve

Actuator Piston Load Sensing Adjustment Screw LS Signal from Work Port Pump Upstroke

Bias Spring

17 Pump Control Valve - Engine OFF This illustration shows the pump control group components with the engine OFF. The swashplate pin connects the actuator piston is connected to the pump swashplate (not shown). The bias spring moves the actuator piston and the pump swashplate to maximum angle. The pump control valve group consists of a load sensing spool assembly, which consists of a load sensing spool and a load sensing sleeve. The load sensing spool is moved up or down by different signal pressures pushing on the piston on each end of the spool. The pump system pressure piston receives an internal signal pressure equal to pump system pressure. The load sensing piston receives a load sensing signal from the implement hydraulic control valve, which is equal to the highest work pressure. The signal relief valve (located in the implement control valve) limits the maximum load sensing signal to the load sensing piston. Pump system pressure is directed through the orifice on the right side of the control valve group to the spring chamber in the upstroke end of the actuator piston and the center lands of the load sensing piston.

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The adjustment screw at the top of the actuator piston is used to the adjust maximum angle of the swashplate. The set screw at the top of the load sensing spool is used to hold the load sensing sleeve in position. The adjustment screw at the bottom of the load sensing spool is used to adjust the load sensing margin pressure for the pump. The spring at the bottom of the load sensing spool is the margin pressure spring.

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PUMP CONTROL VALVE

STANDBY
Maximum Angle Stop Adjustment Screw Set Screw To Implement Control Valve

Pump System Pressure Piston Load Sensing Spool Orifice

Pump Load Sensing Sleeve Margin Spring Load Sensing Piston Swashplate Pin

Signal Relief Valve

Actuator Piston Load Sensing Adjustment Screw LS Signal from Work Port Pump Destroke Bias Spring

18 Pump Control Valve - STANDBY When the engine is started, pump flow goes to the closed-center control valves in the implement control valve group. The flow is blocked in the implement control valve. Pressure in the system increases, and the pump system pressure is directed to the top end of the actuator piston. Pump system pressure on top of the pump system pressure piston moves the piston and load sensing spool down against the force of the margin spring. The spool moves down until the upper opening of the spool opens a path around the load sensing spool to drain. The opening to drain must open sufficient to provide a pressure differential across the orifice. With reduced pressure on the lower end and full pressure on the top of the actuator piston, the actuator piston moves the swashplate pin toward minimum angle. In STANDBY, the pump is delivering minimum flow to compensate for leakage in the pump, for leakage in the implement control valve, and for the operation of the pump control valve.

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PUMP CONTROL VALVE

UPSTROKE
Maximum Angle Stop Adjustment Screw Set Screw To Implement Control Valve

Pump System Pressure Piston Load Sensing Spool Orifice

Pump Load Sensing Sleeve Margin Spring Load Sensing Piston Swashplate Pin

Signal Relief Valve

Actuator Piston Load Sensing Adjustment Screw LS Signal From Work Port Pump Upstroke Bias Spring

19 Pump Control Group - Upstroke When the control lever or levers are moved to activate one or more implements, a load sensing signal, equal to the highest work port pressure, is directed to the lower end of the load sensing piston. The combined forces of the load sensing piston and the margin spring push the load sensing spool up until the center land on the load sensing spool closes the drain passage. The upward movement of the load sensing spool continues until the lower opening of the spool opens a path to the two metering ports. Pump system oil flows through the lower opening of the load sensing spool to the spring chamber of the actuator piston. The combined force on the the larger diameter of the actuator piston and the spring pushes the actuator piston and the swashplate pin up, increasing the swashplate angle to increase pump flow.

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PUMP CONTROL VALVE

CONSTANT FLOW DEMAND
Maximum Angle Stop Adjustment Screw Set Screw To Implement Control Valve

Pump System Pressure Piston Load Sensing Spool Orifice

Pump Load Sensing Sleeve Margin Spring Load Sensing Piston Swashplate Pin

Signal Relief Valve

Actuator Piston Load Sensing Adjustment Screw LS Signal from Work Port Bias Spring

20 Pump Control Valve - Constant Flow Demand When the flow demand is met, the force developed by the pump system pressure on top of the pump system pressure piston is equal to the force developed by the load sensing signal on the load sensing piston plus margin spring. When the forces are equal, the pump flow is constant and the load sensing spool is in the CENTER position. The pump flow remains constant until a change in the flow demand occurs.

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PUMP CONTROL VALVE

Maximum Angle Stop Adjustment Screw Set Screw

MAXIMUM SYSTEM PRESSURE

To Implement Control Valve

Pump System Pressure Piston Load Sensing Spool Orifice

Pump Load Sensing Sleeve Margin Spring Load Sensing Piston Swashplate Pin

Signal Relief Valve

Actuator Piston Load Sensing Adjustment Screw LS Signal from Work Port Pump Destroke Bias Spring

21 Pump Control Valve - Maximum System Pressure This illustration shows the pump control valve with the load sense pressure at signal relief with one function activated. When the work port pressure increases to the setting of the signal relief valve, the valve opens to limit the signal pressure to the bottom of the load sensing piston. Pump system pressure will increase to overcome the combination of forces on the bottom of the load sensing piston. The load sensing spool moves down to open the actuator piston spring cavity to drain. The pump system pressure moves the actuator piston and swashplate pin towards minimum angle. The pump destrokes to minimum flow.

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MAXIMUM SYSTEM PRESSURE WITH ADDED FLOW DEMAND

Maximum Angle Stop Adjustment Screw Set Screw To Implement Control Valve

PUMP CONTROL VALVE

Pump System Pressure Piston Load Sensing Spool Orifice

Pump Load Sensing Sleeve Margin Spring Load Sensing Piston Swashplate Pin

Signal Relief Valve

Actuator Piston Load Sensing Adjustment Screw LS Signal From Work Port Pump Destroke

Bias Spring

22 Pump Control Valve - Maximum System Pressure With Added Flow Demand This illustration shows the pump control valve with the load sense pressure at signal relief. When an additional function is activated, the pump system pressure slightly decreases. With less pressure on top of the pump system pressure piston, the force on the bottom of the load sensing piston moves the load sensing spool up. The load sensing spool restricts the flow through the upper opening to drain. The increased pressure on the larger area of the actuator piston plus the bias spring pushes the actuator piston up. The pump upstrokes to meet the added flow demand.

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1 12

3 4 5

11 6 7 10 9 8

23

This photo shows a front view of the implement control valve in the loader frame. The following components can be seen in this view: - Pressure differential relief valve (1) - Head end solenoid valve (ride control) (2) - Signal relief valve (3) - Tilt anti-drift valve (4) - Rod end solenoid valve (ride control) (5) - Ride control balance solenoid valve (6) - Pilot pressure reducing valve (7) - Pilot accumulator (8) - Pilot supply pressure tap (9) - Lift cylinder head end pressure tap (10) - Lift cylinder head end pressure sensor for Payload Control System and Autodig (10) - Hydraulic lockout solenoid valve (12)

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13

12 11

10 9 8 6

5 7

24

The following components can be seen from the left rear of the control valve: - Tilt anti-drift valve (1) - Signal relief valve (2) - Signal duplication valve (3) - Return to tank port (4) - Supply port from pump (5) - Signal line to pump (6) - Tank line (7) - Screen (8) - Tilt back pilot solenoid valve (9) - Tilt back pilot (10) - Tilt cylinder rod end line relief (11) - Ride control balance solenoid valve (12) - Rod end solenoid valve (ride control) (13)

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The following components are located on the right side of the implement control valve: - Tilt cylinder rod end line relief (1) - Lift anti-drift valve (2) - Line to manual lower valve (3) - Tank line (4) - Ride control relief valve (5) - Line to ride control accumulator (6) - Raise pilot solenoid valve (7) - Dump pilot solenoid valve (8)

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"H" SERIES MEDIUM WHEEL LOADER TILT CONTROL VALVE

HOLD
From Signal Duplication Valve To / From Head End of Cylinder Tilt Anti-drift Valve To / From Rod End of Cylinder Pressure Compensator Valve Bridge Passage Line Relief and Makeup Valve Internal Passage Control Spool Line Relief and Makeup Valve Feeder Passage To Signal Duplication Valve From Resolver Valves

Rackback Pilot Solenoid Valve

Dump Pilot Solenoid Valve

Supply Passage

26 Tilt Control Valve - HOLD With the tilt control valve in the HOLD position, the springs on each end of the control spool keep the spool centered. The control spool blocks the flow of pump supply oil to the pressure compensator valve. The bridge passage is open to tank through the internal passage in the control spool and there is no oil flow to the resolver valve. With no oil flow to the resolver network, there is no signal to the signal duplication valve and the signal pressure to the pump control valve is matching the oil pressure in the resolver network. The implement pump is supplying low pressure standby.

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"H" SERIES MEDIUM WHEEL LOADER TILT CONTROL VALVE

DUMP
From Signal Duplication Valve From Head End of Cylinder Tilt Anti-drift Valve To Signal Duplication Valve From Resolver Valves To Rod End of Cylinder

Pressure Compensator Valve Bridge Passage

Line Relief and Makeup Valve Internal Passage Control Spool

Line Relief and Makeup Valve Feeder Passage

Tilt Back Pilot Solenoid Valve

Dump Pilot Solenoid Valve

Supply Passage

27 Implement Hydraulic System - DUMP When the tilt lever is moved to the DUMP position, the Implement ECM energizes the dump proportional solenoid and the tilt anti-drift valve. As the control valve initially shifts to the left, and there is pressure in the rod end of the tilt cylinder, the pressure goes around the control spool to the bridge passage. The pressure in the bridge passage goes to the resolver network and to the signal duplication valve to upstroke the implement pump. The pressure also goes to the spring chamber in the center of the pressure compensator valve. The lower half of the pressure compensator valve shifts down to block the oil flow from the bridge passage to the feeder passage. As the tilt control spool continues shifting to the left, pump supply oil flows around the center land on the control spool to the feeder passage. Oil pressure in the feeder passage lift the pressure compensator valve up. Pump flow goes through the opening in the lower end of the compensator valve to the bridge passage. From the bridge passage the pump flow goes around the right end of the control spool into the work port to the rod end of the tilt cylinder. Return oil from the head end of the tilt cylinder flows around the tilt anti-drift valve and the left end of the control spool to the tank port.

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From Signal Duplication Valve To Pump, Signal Limiter, and Signal Drain Valve

PRESSURE COMPENSATOR OPERATION

Signal Pressure Differential Relief Valve

To Signal Duplication Valve

Resolver Valve Valve A Valve B Valve C

Spool Pump Supply Bridged Passage Pump Supply Feeder Passage Pump Supply

HOLD

LOW PRESSURE

HIGH PRESSURE

28 Three compensators are shown in various states in this illustration. The pressure compensator valve for valve "A" is in HOLD. The circuit with the highest workport pressure keeps the resolver valve closed. The circuit with the highest work port pressure regulates the oil flow through all activated control valves. The highest work port pressure is directed through the ball resolver network to the pump control valve as the load sensing pressure. When a high pressure circuit is activated as shown for valve "C", the control spool is shifted and pump supply oil enters the feeder passage below the pressure compensator valve. Pressure increases and the pressure compensator valve moves up. When the valve moves up, supply oil enters the bridged passage of the control valve. Supply oil in the bridged passage enters the signal network sending the work port pressure to the signal duplication valve.

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The work port oil pressure goes to the signal duplication valve. The signal duplication valve is a shock absorber. The valve uses the work port pressure signal and the pump system pressure signal to generate a stabilized load sensing signal which is sent to the pump control valve. The pump control valve directs a pressure signal to the actuator piston to UPSTROKE the pump. The increased flow lifts the pressure compensator spool up. The flow goes through the bridge passage, around the control spool, and out to the work port. The signal oil also flows to the chamber above the compensator. The signal oil on the top of the pressure compensator valve works against the forces working below the pressure compensator. When the forces are in balance, the supply oil is metered through the crossdrilled holes in the pressure compensator to provide work port oil. The pressure of the signal oil is limited by the signal relief valve. When more than one circuit is activated at the same time, the highest work port pressure is directed to the signal duplication valve. The signal duplication valve sends the signal oil to the chamber at the top of all pressure compensators valves. With the same circuit pressure working on all pressure compensators, the pressure differential across all shifted control stems is the same, as shown in the illustration for the pressure compensator for valve "C" and for valve "B." The pressure differential across the control stems will be the same value whether the pump can supply the flow demand for all activated circuits or not. For example, if the margin pressure is 2100 kPa (300 psi) the pressure differential between the pump supply passage and the feeder passage is approximately 2100 kPa (300 psi) regardless of what the circuit pressure is. With multiple valves activated, the individual circuit pressures will vary. When the pump cannot meet the flow needs of all activated circuits, the pressure compensators will move down to proportion the pump flow in relation to the amount of control spool travel and pressure for each circuit. The pressure differential will be less than described in the example, but the pressure differential will be the same for all spools. Valve "B" pressure compensator shows what occurs when an additional circuit is activated with a lower circuit pressure than the first activated valve. The pressure compensator valve will respond to changes in the circuit pressure by opening and closing off the passage between the feeder passage and the bridged passage to maintain a constant flow rate for a given control stem displacement. As the compensator opens and closes, the pressure differential across the compensator will vary in order to maintain a constant flow rate to the implement. The pressure differential across the main control spool is the same for all activated main control spools.

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The load signal from the valve "C" pressure compensator is directed to the top of the valve "B" pressure compensator valve with the lower circuit pressure. When the control spool is moved, pressure oil in the feeder passage moves the pressure compensator valve up. The pressure compensator valve does not move up enough to open the resolver valve to the signal network due to the higher forces working on the resolver valve. The pressure compensator valve will respond to changes in the circuit pressure by opening and closing off the passage between the feeder passage and the bridged passage to maintain a constant flow rate for a given control spool displacement. As the compensator opens and closes, the pressure differential across the compensator will vary in order to maintain a constant flow rate to the implement, while the pressure differential across the main control spool is the same for all activated main control spools.

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"H" SERIES MEDIUM WHEEL LOADER IMPLEMENT HYDRAULIC SYSTEM

DUMP
Tilt Cylinder Lift Cylinders Manual Lower Valve Tilt Anti-drift Valve

Ride Control

Auxiliary Function

Line Relief Valves

Lift Anti-drift Valve Auxiliary Head End Solenoid Valve

Pilot Shutoff Valve

Load Check Valve Tilt Back Pilot Solenoid Valve

Raise Pilot Solenoid Valve

Pilot Accumulator

Lift Spool Tilt Spool Pressure Compensator Valve Resolver Valve Pressure Compensator Valve

Ride Control Relief Valve Pilot Pressure Reducing Valve Resolver Valve

Screen

Balance Valve

Resolver Valve

Signal Duplication Valve

Signal Relief Valve Lower / Float Pilot Solenoid Valve

Dump Pilot Solenoid Valve

Auxiliary Rod End Solenoid Valve

Pressure Differential Relief Valve

Case Drain Filter

Choke Check Valve

Pump Tank

29 Implement Hydraulic System - DUMP When the tilt control lever is moved into the DUMP position, a load sensing signal pressure equal to work port pressure is directed to the resolver network. The signal oil goes through the resolver to the top of the signal duplication valve. The signal duplication valve shifts down. Pump flow goes through the signal duplication valve to the bottom of the duplication valve and the orifice. The duplication valve and the orifice stabilizes the load sensing signal pressure to the pump control, the spring chamber on each compensator valve, and to the pressure differential relief valve. The load sensing pressure acting on the bottom of the pressure differential relief valve causes the pressure setting to increase. The pilot pressure reducing valve limits maximum pilot pressure to 3450 170 kPa (500 25 psi). The implement pump oil flows through the cover manifold and regulated pilot oil is directed to the various implement function solenoid valves. The load sensing signal moves the pump load sensing spool in the pump control valve to upstroke the pump. The signal circuit is also equipped with a choke check valve. The valve will allow free flow to the pump control valve. Also, the choke check valve will slow the signal flow return back to the hydraulic tank.

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With the control lever moved to DUMP direction, current proportional to the movement of the control lever is directed to the coil on the dump pilot solenoid valve. The solenoid valve sends a proportional amount of pilot oil to the dump end of the tilt stem. The tilt spool begins to shift upward. The lower end of the tilt spool is active. Supply oil flowing through the inlet manifold is directed around the lands of the tilt spool to the load check valve. The check valve unseats. Supply oil flows to the tilt pressure compensator valve. The oil flow through the compensator valve is blocked. As the pressure at the top of the compensator valve increases, the oil pressure shifts the compensator spool downward. The supply oil flows through the compensator valve and back around the tilt spool to the rod end of the tilt cylinder. The supply oil is directed to rod end of the tilt cylinder. Also, as the tilt lever is moved, the solenoid for the tilt anti-drift valve is energized. The oil from the head end of the tilt cylinder flows around the load check valve, through the tilt spool, and back to tank. Oil directed to the rod end of the tilt cylinder through the bridge passage is also directed to the tilt ball resolver in the resolver network. As the work port pressure increases the pressure in the resolver network, the resolver ball shifts and blocks oil from any other resolvers in the network. The oil at the tilt ball resolver is directed to the top of the signal duplication valve. The dump operation is also equipped with a makeup and line relief valve. The line relief valve regulates the pressure spikes caused by outside forces acting on the work tool. This allows the pressure spike to return to the hydraulic tank. This will prevent high pressure from damaging any components in the work tool or actuators. The line relief valve acts like a makeup valve, when the pump can not supply the amount of oil needed to fill the void in the cylinder. When the negative pressure occurs in the tilt cylinder, the valves moves off the seat and tank oil flows around the valve to fill the void in the cylinder. NOTE: The pilot line used on the optional Command Control Steering has been removed from the illustration.

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"H" SERIES MEDIUM WHEEL LOADER IMPLEMENT HYDRAULIC SYSTEM

RAISE
Tilt Cylinder Lift Cylinders Tilt Anti-drift Valve Ride Control Accumulator

Inlet Manifold Manual Lower Valve

Auxiliary Function

Cover Manifold Hydraulic Lockout Valve Pilot Accumulator

Head End Solenoid Valve Line Relief Valves Lift Anti-drift Valve Raise Pilot Solenoid Valve Auxiliary Head End Solenoid Valve

Rod End Solenoid Valve

Tilt Back Pilot Solenoid Valve Lift Spool Tilt Spool Pressure Compensator Valve Resolver Valve

Pressure Compensator Valve

Ride Control Relief Valve Balance Solenoid Valve

Auxiliary Spool

Pilot Pressure Reducing Valve

Screen

Resolver Valve

Check Valve

Balance Valve

Resolver Valve

Signal Duplication Valve

Signal Relief Valve Lower / Float Pilot Solenoid Valve

Ride Control Dump Pilot Solenoid Valve Auxiliary Rod End Solenoid Valve Pressure Differential Relief Valve

Case Drain Filter

Choke Check Valve

Min Angle Tank

Pump and Pump Control Valve

30 Implement Hydraulic System - RAISE When the lift control lever is moved to the RAISE position, the lift lever position sensor sends a proportional electronic signal to the Implement ECM. The Implement ECM sends a corresponding proportional signal to the raise pilot solenoid valve. The Implement ECM also sends a fixed signal to the lift anti-drift valve. A proportional amount of pilot oil is directed from the raise pilot solenoid valve to the top of the lift spool. The lift spool shifts downward. Initially, as the lift spool begins to shift, any work port pressure will enter the control valve and is directed around the spool to the feeder passage. The work port oil pressure goes through the holes in the pressure compensator valve to the area between the compensator valve and the load check spool. The oil pressure helps the spring force hold the pressure compensator valve down to function as a load check valve. As the control spool shifts down, supply oil flows through the throttling slots into the supply passage. The pressure compensator valve will move up to the load check spool as the pump discharge pressure increases above the work port pressure. The pump system oil pressure flows through the orifices in the pressure compensator valve to the feeder passage, around the lift anti-drift valve, and to the head end of the lift cylinder.

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The pressure at the work port begin to increase which increases the pressure in the lift resolver network. The ball resolver moves downward and oil flows through the resolver network to the top of the signal duplication valve. The signal duplication valve shifts and sends a matching resolver network pressure out of the duplication valve over the choke check valve to the pump control valve. The implement pump upstrokes to supply the flow demand. Also, matching oil from the signal duplication valve flows to the pressure compensator valve working on the bottom of the compensator valve. As the pressure changes in the head end of the lift cylinders, the pressure compensator valve opens and closes to maintain a constant flow for a given control spool displacement. If the machine is equipped with the optional ride control, the balance valve solenoid will be energized, allowing oil on the right side of the balance valve to go to the hydraulic tank. As the pressure in the head end of the lift cylinders increases to raise, the oil pressure on the left side of the balance valve will force the balance valve to shift to the right. Supply oil flows over the check valve, through the balance valve to the ride control accumulator, charging the accumulator. With ride control not enabled, the head end solenoid valve is de-energized and the accumulator charge oil will block the flow of oil between the head end of the lift cylinders and the accumulator. NOTE: The pilot line used on the optional Command Control Steering has been removed from the illustration.

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"H" SERIES MEDIUM WHEEL LOADER IMPLEMENT HYDRAULIC SYSTEM

FLOAT
Tilt Cylinder Lift Cylinders Tilt Anti-drift Valve Ride Control Accumulator

Inlet Manifold Manual Lower Valve

Auxiliary Function

Cover Manifold Hydraulic Lockout Valve Pilot Accumulator

Head End Solenoid valve Line Relief Valves Lift Anti-drift Valve Raise Pilot Solenoid Valve Rod End Solenoid Valve Auxiliary Head End Solenoid Valve

Tilt Back Pilot Solenoid Valve Lift Spool Tilt Spool Pressure Compensator Valve Screen Resolver Valve

Pressure Compensator Valve

Ride Control Relief Valve

Auxiliary Spool

Pilot Pressure Reducing Valve

Resolver Valve

Check Valve

Balance Valve

Resolver Valve

Signal Duplication Valve

Signal Relief Valve Lower / Float Pilot Solenoid Valve Ride Control Auxiliary Rod End Solenoid Valve Pressure Differential Relief Valve

Dump Pilot Solenoid Valve

Case Drain Filter

Choke Check Valve

Min Angle Tank

Pump and Pump Control Valve

31 Implement Hydraulic System - FLOAT When the lift lever is moved to the FLOAT position, the lift lever position sensor sends a proportional electronic signal to the Implement ECM. The Implement ECM sends a corresponding proportional electronic signal to the lower/float pilot solenoid valve. The Implement ECM also sends a fixed electronic signal to the lift load check valve. Pilot oil flows from the lower/float pilot solenoid valve to the bottom of the lift spool and the lift spool shifts up fully. System oil pressure is blocked. Also, oil flow through the pressure compensator loop is blocked. Oil from the head end and rod end of the lift cylinders along with the oil to the resolver network is open to tank. In the FLOAT position, the pilot oil also flows to the resolver valve in the ride control section, through the resolver network to the signal duplication valve. A matching signal (pilot pressure) is directed to the pump control valve from the signal duplication valve. The pump is upstroked to meet the demand required by the pilot pressure.

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As the machine moves, the lift cylinders move up and down with the contour of the ground. The check valve allows oil to flow to the lift cylinders when the pressure in the lift cylinders drops below tank pressure.

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"H" SERIES MEDIUM WHEEL LOADER IMPLEMENT HYDRAULIC SYSTEM

TILT BACK AND RAISE
Tilt Cylinder Lift Cylinders Tilt Anti-drift Valve Ride Control Accumulator

Inlet Manifold Manual Lower Valve

Auxiliary Function

Cover Manifold Hydraulic Lockout Valve

Line Relief Valves

Lift Ant i-drift Valve Raise Pilot Solenoid Valve Auxiliary Head End Solenoid Valve

Pilot Accumulator

Tilt Back Pilot Solenoid Valve Lift Spool Tilt Spool Pressure Compensator Valve Resolver Valve

Pressure Compensat or Valve

Ride Control Relief Valve Auxiliary Spool Pilot Pressure Reducing Valve

Screen

Resolver Valve

Check Valve

Balance Valve

Resolver Valve

Signal Duplication Valve

Signal Relief Valve Lower / Float Pilot Solenoid Valve Ride Control Auxiliary Rod End Solenoid Valve Pressure Differential Relief Valve

Dump Pilot Solenoid Valve

Case Drain Filter

Choke Check Valve

Pump Tank

32 Implement Hydraulic System - TILT BACK AND RAISE When the lift control lever is moved to the RAISE position and the tilt control lever is moved to the TILT BACK position, the lift lever position sensor and tilt lever position sensor sends an individual proportional electronic signal to the Implement ECM. The Implement ECM sends a corresponding proportional signal to the raise pilot solenoid valve and the tilt back pilot solenoid valve. The Implement ECM also sends a fixed signal to the lift and tilt anti-drift valve. A proportional amount of pilot oil is directed from the raise pilot solenoid valve to the top of the lift spool and a proportional amount of pilot oil is directed from the tilt back pilot solenoid valve to the top of the tilt spool. The lift spool shifts downward. Initially, as the lift spool begins to shift, any work port pressure will enter the control valve and is directed around the spool to the feeder passage. The work port oil pressure goes through the orifices in the pressure compensator valve in between the compensator valve and the load check spool. The oil pressure helps the spring force hold the pressure compensator valve down. Identically, as the tilt spool begins to shift, any work port pressure will enter the control valve and is directed around the spool to the feeder passage.

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The work port oil pressure goes through the holes in the pressure compensator valve to the area between the compensator valve and the load check spool. The oil pressure helps the spring force hold the pressure compensator valve down to function as a load check valve. As the cylinders start to move, the pressure at the work ports increases which increases the pressure in the resolver network. The ball resolver with the highest work port pressure moves seats and blocks oil flow back through the resolver network. The highest work port pressure flows through the resolver network to the top of the signal duplication valve. The signal duplication valve shifts and sends the matching resolver network pressure out of the duplication valve over the choke check valve to the pump control valve. The implement pump recognizes a demand for increased oil flow and the pump upstrokes to supply the flow demand. Also, matching oil from the signal duplication valve flows to the pressure compensator valve working on the bottom of the load check spool. As the pressure changes in the head end of the lift cylinders, the pressure compensator valve opens and closes to maintain a constant flow for a given control spool displacement. If the machine is equipped with the optional ride control, the balance valve solenoid will be energized, allowing oil on the right side of the balance valve to go to the hydraulic tank. As the pressure in the head end of the lift cylinders begins to raise, the oil pressure on the left side of the balance valve will force the balance valve to shift to the right. Supply oil flows over the check valve, through the balance valve to the ride control accumulator, charging the accumulator. With ride control not enabled, the head end solenoid valve is de-energized and the accumulator charge oil will block the flow of oil between the head end of the lift cylinders and the accumulator. NOTE: The pilot line used on the optional Command Control Steering has been removed from the illustration.

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"H" SERIES MEDIUM WHEEL LOADER IMPLEMENT HYDRAULIC SYSTEM

HOLD / AUTO TRAVEL MORE THAN 9.7 KM/H (6 MPH)
Ride Control Accumulator Head End Solenoid Valve Line Relief Valves Lift Ant i-drift Valve Raise Pilot Solenoid Valve Rod End Solenoid Valve Auxiliary Head End Solenoid Valve Tilt Cylinder Lift Cylinders Tilt Anti-drift Valve

Inlet Manifold

Auxiliary Function

Manual Lower Valve

Pilot Shutoff Valve Pilot Accumulator

Tilt Back Pilot Solenoid Valve Lift Spool Tilt Spool Pressure Compensator And Load Sense Spool Resolver Valve

Pressure Compensator And Load Sense Spool

Ride Control Relief Valve

Pressure Compensator And Load Sense Valve Pilot Pressure Reducing Valve

Screen

Resolver Valve

Check Valve

Balance Valve

Resolver Valve

Auxiliary Spool

Signal Duplication Valve

Signal Relief Valve Lower / Float Pilot Solenoid Valve

Ride Control Dump Pilot Solenoid Valve

Auxiliary Rod End Solenoid Valve

Pressure Differential Relief Valve

Case Drain Filter

Choke Check Valve

Pump Tank

33 Implement Hydraulic System - RIDE CONTROL AUTO When the ride control system is in AUTO and the machine reaches the configured ride control ground speed, the ride control balance solenoid valve is de-energized by the Power Train ECM. After the ride control equalization time has expired, the Power Train ECM energizes both the ride control head end solenoid valve and the ride control rod end solenoid valve. The head end solenoid valve connects the head end of the lift cylinders to the ride control accumulator. The ride control accumulator dampens the motion of the lift arms which makes the machine more stable. The rod end solenoid valve allows oil from the tank passage to flow into the rod ends of the lift cylinders when the lift cylinders move down. When the machine is in ride control AUTO, the control levers are in the HOLD position, and the ground speed is more than the 9.7 km/h (6 mph), the control spools are in the HOLD position blocking all oil flow through the implement control valve to the cylinders. The resolver network is at tank pressure and the pump is at low pressure standby.

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When the ground speed reaches the ECM configured value of 9.7 km/h (6 mph), the balance solenoid valve will be de-energized and the balance spool will move in the direction needed to equalize the pressures on each end of the balance spool. During the balancing operation, when the pressure at the right side of the balance spool is lowest, the spool shifts to the right and the implement pump supplies oil flow to equalize the pressure on both ends of the spool. During the balancing operation, when the pressure at the left side of the balance spool is lowest, the spool shifts to the left and the pressure in the oil pressure in the accumulator flows to tank until the pressures on both ends of the spool are equal. The Power Train ECM limits the time to equalize to one second (default). Then, the ECM energizes the balance solenoid valve. The oil pressure on the right end of the balance spool flows through the orifice to the hydraulic tank. The balance spool shifts to the right. Oil in the accumulator is trapped at the check valve. After the one second balancing time, the rod end solenoid and the head end solenoid valves are energized. The oil pressure that holds the check valves locked is released to tank. The oil in the head end of the lift cylinders flows to the ride control accumulator. The accumulator cushions the forward and backward pitching motions of the machine. At a ground speed below the ECM configured valve of 9.7 km/h (6 mph), the rod end solenoid and the head end solenoid valves are de-energized. The check valves close and the spring force and the oil pressure hold the check valves closed. NOTE: The one second balance default time can be reconfigured in Caterpillar Electronic Technician (ET).

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34 Calibrations and Adjustments for Implement Hydraulic System The implement system calibrations for the "H" Series Medium Wheel Loaders are the same as they are for the "G" Series II Medium Wheel Loaders. The calibrations should be performed in the order in which they appear, lever position sensors, linkage position sensors, and the implement valve calibrations. The "H" Series Medium Wheel Loaders feature soft detents. When the lever position sensors are calibrated the levers must be held in the full travel positions.

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35 This screen shot taken from ET shows the ride control configuration line items. The ride control reverse and forward activation speed can be configured. The ride control pressure equalization time can also be configured. If the operator is complaining about lift arm movement when the ride control engages, two adjustments can be made. The ride control reverse activation speed can be changed to a very low value, so that the ride control system engages as the operator backs out of the loading area. The ride control equalization time can be increased to allow more time for the balance valve to equalize the pressure between the head ends of the lift cylinders and the ride control accumulator.

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2 3 5 1

36

STEERING SYSTEM The steering systems on the "H" Series Medium Wheel Loaders remain virtually the same. As mentioned previously, the standard machines are equipped with Hand Metering Unit (HMU) steering. Command Control Steering (CCS) is available as an option. The location of the steering control valve for both systems has changed. The steering control valve is located on the output transfer gear (1) of the transmission. This location offers improved access to the adjustable valves on the steering control valve. This photograph shows the CCS control valve (2), the crossover relief valve (3), the remote tap line for the steering pump output pressure (4), and the pressure reducing valve (5) for the steering pilot oil.

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2 1

37

FAN AND BRAKE HYDRAULIC SYSTEM The fan and brake pump (1) is located on the front gear train of the engine, on the right side of the machine. The fan and brake pump provides oil flow for the electronic demand fan system and the brake hydraulic system. The signal pressure tap (2) and the outlet pressure tap (3) are located on the fan and brake pump. Also located on the engine on the right side of the machine is the fan control and brake accumulator charging valve (4).

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1 12 11

2 3 4 5

10

38

The following components are located on the fan control and brake accumulator charging valve: - Signal line to the fan and brake pump (1) - Fan solenoid valve, an electronic output of the Engine ECM which controls the speed of the cooling fan (2) - Relief valve, limits the maximum pressure in the brake system (3) - Cut-in valve, maintains minimum brake accumulator pressure (4) - Return hose to the hydraulic tank (5) - Cut-out valve, maintains maximum brake accumulator pressure (6) - Brake pressure switch, warns the operator when brake accumulator pressure is low (7) - Inverse shuttle valve, maintains equal charge pressure in both accumulators (8) - Accumulator ports (9) - Pump inlet port (10) - Fan motor outlet port (11) - Priority valve, blocks flow to the fan motor when the brake accumulators are charging (12)

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FAN AND BRAKE HYDRAULIC SYSTEM
ACCUMULATORS CUT- IN Pressure Switch Fan Solenoid Valve Fan Control / Brake Charging Valve

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Brake Accumulators To Service Brake Valve

Inverse Shuttle Valve Cut In Valve

Relief Valve

Cut Out Valve

Resolver Valve Fan Motor Screen Priority Valve

Flow Control Spool Pressure Cutoff Spool

Pump Control Valve

Oil Cooler

Fan / Brake Pump

Actuator Min Angle

Filter Case Drain Filter Hydraulic Tank

39 When the fan and brake system is in the ACCUMULATORS CUT-IN condition, the brake accumulator pressure has dropped to 11720 kPa (1700 psi) and the cut-in valve is shifted to the left. Oil flows from the fan/brake pump through the cut-in valve to the resolver valve. The resolver valve allows the higher of two pressures between the signal from the fan solenoid valve and from the cut-in valve to flow to the flow control spool of the pump control valve. In this instance the oil from the cut-in valve is higher in pressure. The flow control spool sends oil to the actuator to control the displacement of the fan/brake pump. Oil also flows to the priority valve which shifts the priority valve up and partially blocks the flow of oil to the fan motor. Oil also flows past the screen, the check valve, and the orifice to the inverse shuttle valve. The inverse shuttle valve maintains equal pressure in both brake accumulators. The relief valve protects the brake system from high pressure.

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FAN AND BRAKE HYDRAULIC SYSTEM
ACCUMULATORS CUT-OUT

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Brake Accumulators To Service Brake Valve

Pressure Switch

Inverse Shuttle Valve Fan Solenoid Valve Cut In Valve

Relief Valve

Fan Control / Brake Charging Valve

Cut Out Valve

Resolver Valve Fan Motor Screen Priority Valve Oil Cooler Fan / Brake Pump Filter

Pump Control Valve Flow Control Spool Pressure Cutoff Spool

Actuator Min Angle

Case Drain Filter Hydraulic Tank

40 The above illustration shows the fan and brake hydraulic system with the brake accumulators in the ACCUMULATORS CUT-OUT condition. The brake accumulator pressure has increased to 14500 kPa (2100 psi) and the cut-out valve momentarily shifted down, allowing the oil on the right side of the cut-in valve to drain to tank. The cut-in valve shifts to the right and blocks the flow of oil to the pump signal system and drains the signal oil from the resolver valve and the priority valve. The signal oil from the fan solenoid valve flows to the resolver valve and to the flow control spool on the pump control valve. The fan solenoid valve now controls the position of the swash plate on the fan/brake valve. Pump oil flows through the screen and is blocked from entering the brake system by the check valve. The priority valve is fully shifted down and directs the majority of the pump flow to the fan motor. The fan motor drives the cooling fan, which cools the machine systems.

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41 Calibrations and Adjustments for Fan/Brake Hydraulic System The fan system requires a calibration. The calibration is done using Caterpillar Electronic Technician (ET). After selecting the Engine ECM, the Engine Cooling Fan Calibration is found in the Service drop down menu and under Calibrations. The technician uses ET to adjust the electrical signal to the fan solenoid valve to obtain a minimum fan speed and a maximum fan speed. After the calibration is complete the Engine ECM will control fan speed between the minimum and maximum based on inlet manifold temperature, hydraulic oil temperature, and coolant temperature. The Engine Cooling Fan Calibration should be performed after any component of the fan and brake hydraulic system is replaced, the Engine ECM is replaced, or the Engine ECM software is flashed. If the minimum and maximum speeds can not be obtained during the calibration there may be a problem with the fan/brake pump or elsewhere in the system.

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NEW TOOLING - Caterpillar Electronic Technician

42

NEW TOOLING/SKILLS REQUIRED FOR SERVICE The 966H and 972H Wheel Loaders have many electronically controlled components. A strong knowledge of Caterpillar Electronic Technician (Cat ET) is required for many service activities.

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43

CONCLUSION This presentation has provided New Product Introduction (NPI) information for the Caterpillar 966H and 972H Wheel Loaders. Always use the latest Service Information to ensure that the most current specifications and test procedures are used.

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HYDRAULIC SCHEMATIC COLOR CODE

Black - Mechanical connection. Seal Dark Gray - Cutaway section Light Gray - Surface color White - Atmosphere or Air (No pressure) Purple - Pneumatic pressure Yellow - Moving or activated components Cat Yellow - (Restricted usage) Identification of components within a moving group Brown - Lubricating oil Green - Tank, sump, or return oil Green / White Stripes Scavenge Oil or Hydraulic Void Red - High pressure oil Red/White Stripes - 1st pressure reduction Red Crosshatch - 2nd reduction in pressure Pink - 3rd reduction in pressure Red/Pink Stripes - Secondary source oil pressure Orange - Pilot, charge, or Torque Converter oil Orange / White Stripes Reduced pilot, charge, or TC oil pressure Orange Crosshatch - 2nd reduction in pilot, charge, or TC oil pressure. Blue - Trapped oil

HYDRAULIC SCHEMATIC COLOR CODE This illustration identifies the meanings of the colors used in the hydraulic schematics and cross-sectional views shown throughout this presentation.

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HYDRAULIC SCHEMATIC COLOR CODE

Red - High pressure oil Red/White Stripes - 1st pressure reduction Red Crosshatch - 2nd reduction in pressure Pink - 3rd reduction in pressure

Black - Mechanical connection. Seal

Dark Gray - Cutaway section

Light Gray - Surface color

White - Atmosphere or Air (No pressure)

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Purple - Pneumatic pressure

Red/Pink Stripes - Secondary source oil pressure Orange - Pilot, charge, or Torque Converter oil Orange / White Stripes Reduced pilot, charge, or TC oil pressure Orange Crosshatch - 2nd reduction in pilot, charge, or TC oil pressure. Blue - Trapped oil

Yellow - Moving or activated components

Cat Yellow - (Restricted usage) Identification of components within a moving group

Brown - Lubricating oil

Green - Tank, sump, or return oil

Green / White Stripes Scavenge Oil or Hydraulic Void

NPI

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NPI Handout No. 1

Machine Orientation Checklist

Directions: Use this sheet when performing the machine orientation lab exercise. Place a check in the blank if the fluid level is acceptable. ____ ____ ____ ____ ____ ____ Engine oil level Hydraulic system oil level Autolube lubrication system grease level (if equipped) Final drive and differential oil level Cooling system fluid level Fuel level

Place a check in the blank if acceptable or after task was performed. ____ Check the Caterpillar Monitoring System for abnormal machine conditions ____ Check seat belt ____ Check the air filter precleaners Place a check in the blank if the indicator, switch, or control is working correctly. ____ ____ ____ ____ ____ ____ ____ ____ ____ ____ ____ ____ Key start switch Engine coolant temperature gauge Fuel level gauge Power train oil temperature gauge Hydraulic oil temperature gauge Ride control indicator light (if equipped) Autoshift indicator light Front and rear work lights Front and rear work lights Windshield wipers (if equipped) Heating and air conditioner controls (if equipped) Back-up alarm

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NPI Handout No. 2

Machine Orientation Checklist - continued

Place a check in the blank after locating and reading the following warnings label on the machine. ____ ____ ____ ____ ____ ____ ____ ROPS Parking brake No clearance (articulation joint) Radiator Batteries Unit injectors Do not operate

Place a check in the blank after locating each of the following controls. ____ ____ ____ ____ ____ ____ ____ ____ ____ Throttle pedal Left brake pedal Right brake pedal Tilt lever Lift lever Parking brake knob Steering Wheel Ground level shutdown switch Battery disconnect switch

Place a check in the blank after locating each of the following identification plates. ____ ____ ____ ____ Product Identification Number (PIN) Engine serial number Transmission serial number Bucket serial number

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NPI Handout No. 3

Machine Posttest
Directions: Answer each question with the best possible answer. 1. The 972H Wheel Loader is equipped with which engine? a. 3196 b. C13 ACERT c. C15 ACERT d. 3176 2. The 966H/972H Wheel Loaders are equipped with combination fan and brake valve. a. True b. False 3. The diagnostic lines group is an attachment on 966H/972H Wheel Loader. a. True b. False 4. The 966H/972H Wheel Loader are equipped with which style implement hydraulic system? a. AMOCS b. LS/PC c. Open center d. 3PC 5. The 966H/972H Wheel Loaders require service personnel to use Cat ET to calibrate the fan hydraulic system. a. True b. False

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NPI Handout No. 4

Machine Posttest - Continued

6. The 966H/972H Wheel Loaders ride control system utilizes: a. Two solenoid valves b. A balance valve c. Four accumulators d. Both a and b 7. The 966H/972H Wheel Loader are equipped with what type Engine ECM? a. ADEM III b. A4M1 c. ADEM IV d. A4E4 8. The hydraulic tank on the 966H/972H is located: a. On the right side of the machine b. Behind the cab c. On the left side of the machine d. On the rear of the machine 9. Where are the remote pressure taps located on the 966H/972H Wheel Loaders? a. On the service center, left side of the machine b. On the service center, right side of the machine c. Behind the cab, in the pump bay d. Next to the battery disconnect switch 10. The 966H/972H Wheel Loaders are equipped with an implement electrohydraulic system. a. True b. False 11. The 966H Wheel Loader is equipped with which engine? a. 3196 b. C11 ACERT c. C13 ACERT d. 3176

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NPI Posttest Answers

Machine Posttest Answers

Quiz Answers: 1. b 2. a 3. b 4. d 5. a 6. b 7. d 8. b 9. b 10. a 11. b