Catalogo 950G-962G - Service Training

Service Training
MALAGA
950G/962G MEDIUM
WHEEL LOADERS
INTRODUCTION
INSTRUCTOR
REFERENCE Francis
BOOK March 1998
950G/962G MWL
CHAPTER : INTRODUCTION
COURSE DESCRIPTION
This course covers the major differences between the 950/960 F and 950/962 G Wheel Loader,
the Electronic and Electro-Hydraulic systems, the Steering and Brake Systems and
Transmission operation. Students will perform testing and adjusting procedures on power train,
electro/hydraulic implement, steering and brake systems. The class will discuss
how each procedure relate to the proper operation of the machine. Some diagnosis work may
be done
This course is intended for experienced dealer service personnel who are already
familiar with the existing Wheel Loader family, and is appropriate for technical
communicators, service training instructors and servicemen.
PREREQUISITES
Attendees should be thoroughly familiar with Wheel Loaders, have a sound knowledge
of electronic fundamentals, and be able to work with Electronic Technician (ET).
OBJECTIVES
On completion of this course the participants will be able to :
- State the operation of the new concept of Command Control Steering (CCS).
- State the operation of electro/hydraulic implement control and brake system in all modes
of operation.
- Trace the oil flow and state the operations of the transmission in all speeds forward and
reverse.
- Test, adjust and evaluate performances of all Electro-hydraulic system components.
- Use ET to perform all electronic system service functions, including programming,
operational and problem data accessing, interactive diagnostics, and general
troubleshooting.
NOTE : This course description is subject to change due to product design changes
and individual attendee needs and experience.
Page: 2
950G/962G MWL
ADDITIONAL INFORMATION
REFERENCES
950G/962G Wheel Loader Service Manual SENR1374
950G Parts Book SEBP2700
962G Parts Book SEBP2701
PREREQUISITES
Interactive Video Course "Fundamentals of Mobile Hydraulics" (CD ROM) TECD9001
STMG 546 "Graphic Fluid Power Symbols" SESV1546
SUPPLEMENTARY TRAINING MATERIAL

STMG 671 "980G Wheel Loader--Introduction" SESV1671
Page: 3
950G/962G MWL
TABLE OF CONTENTS
I - INTRODUCTION
II - CATERPILLAR MONITORING SYSTEM

Operator Station
Display Modules
Modes of Operation
Electrical Schematic
III - STEERING SYSTEM

Steering System Components
HMU System
CCS System
Pump Controls
Fan Drive System
Margin Pressure Check
IV - IMPLEMENT ELECTRO/HYDRAULIC SYSTEM

Main System Components
Implement Pilot System
Electro Hydraulic Pilot System
Calibration Procedures
V - TRANSMISSION
System Components
Control and Hydraulic System
Transmission Sensors
Pressure Test
Calibration
VI - BRAKING SYSTEM
System Components
Braking System
Brake Wear Indication
LAB EXERCISES
Page: 4
950G/962G MWL
COLOR CODES
Red The highest pressure in the system
Red and White Second highest pressure in the system

Stripes
Brown - Lube oil pressure
Orange Pilot pump system pressure
Green - Tank and return and case drain oil
Yellow - Moving parts and activated valve envelopes.
Blue - Blocked oil.
Electrical Schematics Color

Red - System voltage
Purple - Torque converter sensor voltage
Orange - Signal voltage
Black - Ground
Page: 5
Service Training
MALAGA
950G/962G MEDIUM
WHEEL LOADERS
BRAKING SYSTEM
Francis
March 1998
BRAKE SYSTEM COMPONENTS
ACCUMULATOR
CHARGING VALVE PARKING BRAKE
VALVE
PILOT AND BRAKE SERVICE BRAKE

PUMP VALVE
REAR WHEEL PARKING ACCUMULATORS FRONT WHEEL

BRAKES BRAKE BRAKES
Page:
950G/962G MWL
2
CHAPTER : BRAKE SYSTEM
BRAKE HYDRAULIC SYSTEM
FRONT
SERVICE
BRAKES
TANDEM
REAR
BRAKE VALVE
SERVICE
BRAKES
BRAKE
SWITCH
TO IMPLEMENT PRESSURE
PILOT SYSTEM PORT
PILOT AND BRAKE ACCUMULATOR

CHARGING VALVE BRAKE
PUMP ACCUMULATORS
TO PARKING
PARKING BRAKE
BRAKE
TANK VALVE
PARKING BRAKE
SWITCH
Page:
950G/962G MWL
3
950G/962G MWL
PUMPS LOCATION
4 2 1
1.Pilot and Brake Pump

2.Implement Pump
3.Inlet Tube
4.Steering Pump
Page: 4
BRAKE SYSTEM
ACCUMULATOR CUT-IN MODE
LEFT BRAKE RIGHT BRAKE ACCUMLATOR

PEDAL PEDAL CHARGING VALVE
BRAKE LIGHTS INVERSE

SHUTTLE
VALVE BRAKE
TANDEM PRESSURE
BRAKE PORT
VALVE
REAR SERVICE
BRAKES REAR BRAKE
CUT-IN/
BRAKE PRESSURE
CUT-OUT
ACCUMULATOR SWITCH
SPOOL
ORIFICE
CHECK UNLOADING
VALVE VALVE
FRONT SERVICE
BRAKES TO IMPLEMENT
FRONT
BRAKE PILOT SYSTEM
ACCUMULATOR
TO MAIN
PARKING RELIEF VALVE
BRAKE STEERING TRANSMISSION
PUMP PUMP
IMPLEMENT PILOT
AND BRAKE PUMP
PARKING
BRAKE PARKING
PRESSURE BRAKE
SWITCH VALVE
Page:
950G/962G MWL
5
BRAKE SYSTEM
ACCUMULATOR CUT-OUT MODE
LEFT BRAKE
RIGHT BRAKE
PEDAL
PEDAL
BRAKE LIGHTS INVERSE
SHUTTLE
VALVE BRAKE
TANDEM PRESSURE
BRAKE PORT
VALVE
REAR SERVICE
BRAKES CUT-IN/ BRAKE
CUT-OUT PRESSURE
SPOOL SWITCH
ORIFICE
UNLOADING
CHECK
VALVE
VALVE
FRONT SERVICE
BRAKES
TO IMPLEMENT
PILOT SYSTEM
TO MAIN
PARKING RELIEF VALVE
BRAKE STEERING TRANSMISSION
PUMP PUMP
PARKING IMPLEMENT PILOT

BRAKE PARKING AND BRAKE PUMP
PRESSURE BRAKE
SWITCH VALVE
Page:
950G/962G MWL
6
950G/962G MWL
COMPONENT LOCATION
PARKING PARKING
BRAKE
BRAKE
VALVE SWITCH
ACCUMULATOR
CHARGE BRAKE
VALVE OIL PRESSURE
SWITCH
FUEL TANK
Page: 7
950G/962G MWL
COMPONENT LOCATION
PARKING MACHINE
SYSTEM LEFT SIDE
ACCUMULATOR
Page: 8
950G/962G MWL
COMPONENT LOCATION
TRANSMISSION LEFT RIGHT

NEUTRALIZER BRAKE BRAKE
SWITCH PEDAL PEDAL
Page: 9
950G/962G MWL
COMPONENT LOCATION
REAR BRAKE
TEST PORT
TANDEM FRONT BRAKE

BRAKE TEST PORT
VALVE
Page: 10
950G/962G MWL
FRONT
REAR
Page: 11
SERVICE BRAKE
PISTON DISC PLATE PLANETARY
GEAR
SUN GEAR
BRAKE WEAR
INDICATOR PIN
Page:
950G/962G MWL
12
950G/962G MWL
SERVICE BRAKE WEAR INDICATOR
Page: 13
950G/962G MWL
ET RECORD MEASUREMENT
Page: 14
950G/962G MWL
PARKING BRAKE
PARKING PARKING
BRAKE BRAKE DRIVE
ACTUATOR SHAFT
Page: 15
Service Training
MALAGA
950G/962G MEDIUM
WHEEL LOADERS
CATERPILLAR MONITORING SYSTEM
Francis
March 1998
ELECTRONIC IMPLEMENT CONTROL SYSTEM
LIFT LEVER POSITION SENSOR BUCKET RACKBACK SOLENOID
TILT LEVER POSITION SENSOR BUCKET DUMP SOLENOID
PILOT ON/OFF SOLENOID

THIRD LEVER POSITION SENSOR
LIFT RAISE SOLENOID

FOURTH LEVER POSITION SENSOR
LIFT LOWER SOLENOID

LIFT ARM POSITION SENSOR
ELECTRONIC
IMPLEMENT 3rd LEVER FORWARD SOLENOID
BUCKET POSITION SWITCH
CONTROL
3rd LEVER REARWARD SOLENOID
IMPLEMENT LOCKOUT SWITCH
LIFT RAISE KICKOUT SOLENOID

REVERSE FAN PRESS SWITCH
LIFT KICKOUT SET SWITCH TILT LOWER KICKOUT SOLENOID
FUNCTION SELECTION SWITCH LIFT LOWER KICKOUT SOLENOID

SYSTEM
950G/962G MWL
CAT DATA LINK (ET/MONITOR
Page:
OPTION CODE CONNECTOR TRANSMISSION)
2
CHAPTER : CATERPILLAR MONITORING
950G/962G MWL
SYSTEM
MONITORING SYSTEM
3 4
1. Digital Display Window

2. Operator Switch
3. Tachometer/Speedometer
4. Gauge Cluster
Page: 3
950G/962G MWL
SYSTEM
Sales Model Machine Code

938F, IT38F 03
953C 09
950G 13
962G 14 MACHINE CODE LIST
D10R 27
D11R 28
769D, 771D, 773D, 775D, 777D 34
5110 35
950F 39
960F 40
966F 43
970F 45
980G 46
824G 47
825G 48
826G 49
525 1DN1-374 51
24H 53
814F, 815F, 816F 58
515, 525 1DN375-UP 60
HARNESS CODE TROUBLESHOOTING

Main Display Module
31 3 12 22 16 6
Connector Contact
Wire Identification 270-BK 271-BK 272-BK 273-BK 274-BK 275-BK
Harness Code Plug Contact 1 2 3 4 5 6
Machine Code Specified Status
03 O O G G G G
09 O G G O G G
13 O G O O G G
14 G O O O G G
27 O O G O O G
28 G G O O O G
34 G O G G G O
35 O O G G G O
39 O O O G G O
40 G G G O G O
43 O O G O G O
45 O O O O O O
46 G O O O G O
47 O O O O G O
48 G G G G O O
49 O G G G O O
51 O O G G O O
53 O G O G O O
58 G O G O O O
60 G G O O O O
Page: 4
MESSAGE CENTER
VARIOUS MODULE
SWITCHES
ACTION LAMP
VARIOUS
SENSORS
P
VARIOUS GAUGE CLUSTER
SENDERS MODULE
SERVICE
CONNECTORS SPEEDO/TACH
MODULE
°C kPa MILES KM RPM LITER SERV
CODE
HARNESS CODE x10
CONNECTOR
ACTION
CAT DATA LINK ALARM
TO OTHER
CONTROLS
SYSTEM
950G/962G MWL
Page:
5
950G/962G MWL
SYSTEM
SPEEDOMETER/TACHOMETER MODULE
15
10 20
5 25
X100
0 MPH
30
km/h
TACHOMETER
SPEED READOUT GEAR READOUT
Page: 6
950G/962G MWL
SYSTEM
GAUGE CLUSTER MODULE
Page: 7
950G/962G MWL
SYSTEM
MESSAGE CENTER MODULE
Page: 8
950G/962G MWL
SYSTEM

MODE 3
SERV
CODE
SERV SERV
CODE CODE
MID CID/FMI
Page: 9
950G/962G MWL
SYSTEM

MODE 7
SERV
CODE
SERV SERV
CODE CODE
SERV
CODE
SERV
CODE
Page: 10
950G/962G MWL
SYSTEM

MODE 8
SERV
CODE
SERV SERV
CODE CODE
SERV
CODE
SERV
CODE
Page: 11
950G/962G MWL
SYSTEM
DIRECTIONS TO USE 4C8195 SERVICE TOOL
ACTIVATION OF DISPLAY OPERATIONS
Display Service Clear

Operation Contact Contact
Changing Mode :
To Scroll Ground Ground 4C8195 CMS
To Hold Open Open SERVICE TOOL
Service Mode :
To Scroll Ground Open
To Hold Open Open
To Clear Open Ground
Tattletale Mode : MODE
To Clear Open Ground
Numerical Read CLEAR SCROLL
Out Mode :
To Scroll Ground Open
To Hold Open Open
Page: 12
950G/962G MWL
SYSTEM
MODE OF OPERATION
Mode Available As Available with

Mode
Number Operator Mode Service Tool
Normal 0 Yes 0
Service Meter * Yes *
Odometer * Yes *
Tachometer * Yes *
Diagnostic Scrolling * Yes *
Harness Code 1 No Yes
Numeric Readout 2 No Yes
Service 3 No Yes
Tattletale 4 No Yes
Units 5 No Yes
(Empty) 6 No Yes
Calibration 7 No Yes
Lift Arm P.S.R. - No Yes
CAL-1 - No Yes
CAL-2 - No Yes
Prefix 1 - No Yes
Prefix 2 - No Yes
Prefix 3 - No Yes
Prefix 4 - No Yes
8 No Yes
Setup (1) No Yes
(1) : If available
Page: 13
950G/962G MWL
SYSTEM
MODULE & FEALURE MODE IDENTIFIER
Page: 14
950G/962G MWL
SYSTEM
COMPONENT IDENTIFIERS
Page: 15
950G/962G MWL
SYSTEM
ELETRICAL SHEMATIC
CATERPILLAR
MONITORING
SYSTEM
Page: 16
950G/962G MWL
SYSTEM
IMPLEMENT ELECTRONIC CONTROL

SYSTEM SCHEMATIC
Page: 17
950G/962G MWL
SYSTEM
TRANSMISSION SYSTEM ELECTRICAL SHEMATIC
Page: 18
Service Training
MALAGA
950G/962G MEDIUM
WHEEL LOADERS
IMPLEMENT HYDRAULIC SYSTEM
Francis
March 1998
IMPLEMENT HYDRAULIC SYSTEM COMPONENTS
IMPLEMENT PILOT PILOT CONTROL HYDRAULIC TILT

HYDRAULIC PUMP LEVERS TANK CYLINDER
PUMP
-
LIFT PILOT MAIN CONTROL

CYLINDER MANIFOLD VALVE
SYSTEM
950G/962G MWL
PILOT SYSTEM COMPONENTS MAIN SYSTEM COMPONENTS COMMON
Page:
2
CHAPTER : IMPLEMENT HYDRAULIC
950G/962G MWL
- SYSTEM
IMPLEMENT PILOT CONTROLS
3
1
2
4
1.Implement Pilot Control

Levers
2.Operator Seat
3.Down Shift Wire
4.Downshift Switch
Page: 3
FROM LIFT FROM FLOAT
CYLINDERS MAKEUP VALVE
TO RIDE
TO ACCUMULATOR PILOT MANIFOLD CONTROL VALVE
CHARCING VALVE
PRESSURE FLOAT PILOT CONTROL
REDUCING VALVE VALVES
VALVE
SHUTTLE TILT
TILT
LIFT
VALVE
BRAKE/PILOT ON/OFF
PUMP VALVE
PRESSURE
-
REDUCING
VALVE
MAIN
TANK CONTROL TILT LIFT
VALVE
IMPLEMENT PILOT SYSTEM
HOLD
SYSTEM
950G/962G MWL
Page:
4
950G/962G MWL
- SYSTEM
PUMPS LOCATION
5 4 2 1
1.Pilot and Brake Pump

2.Implement Pump
3.Inlet Tube
4.Steering Pump
5.Transmission Pump
Page: 5
950G/962G MWL
- SYSTEM
Page: 6
950G/962G MWL
- SYSTEM
LIFT/TILT CONTROLS
DOWNSHIFT
SWITCH PWM SENSORS
Page: 7
950G/962G MWL
- SYSTEM
LIFT SENSOR
PWM SENSOR
Page: 8
ELECTRO-HYDRAULIC PILOT SYSTEM
HOLD
EIC ECM
ON/OFF
SOLENOID SOLENOID
VALVES VALVE TILT LIFT
FLOAT TO
VALVE STEERING
SYSTEM
TEST
TO PORT
ACCUMULATOR FROM LIFT
CHARGING CYLINDER
VALVE MAKEUP VALVE
-
PUMP TO RIDE
CONTROL
VALVE IMPLEMENT
ELECTRO-HYDRAULIC
CONTROL
CONTROL VALVE SPOOLS
SHUTTLE
VALVE
SCREEN
PRESSURE
REDUCING
VALVES FROM LIFT
TANK CYLINDER
DUMP LOWER
SOLENOID
SYSTEM
VALVES
950G/962G MWL
Page:
9
ELECTRO-HYDRAULIC PILOT SYSTEM
TILT BACK
EIC ECM ON/OFF

SOLENOID SOLENOID
VALVES VALVE TILT LIFT
FLOAT TO
VALVE STEERING
SYSTEM
TEST
TO PORT
ACCUMULATOR FROM LIFT
CHARGING CYLINDER
VALVE MAKEUP VALVE
PUMP TO RIDE
-
CONTROL
VALVE
IMPLEMENT
ELECTRO-HYDRAULIC CONTROL
CONTROL VALVE SPOOLS
SHUTTLE
VALVE
SCREEN
PRESSURE
REDUCING FROM LIFT
VALVES CYLINDER
TANK DUMP LOWER
SOLENOID
VALVES
SYSTEM
950G/962G MWL
Page:
10
950G/962G MWL
- SYSTEM
MAIN HYDRAULIC
SYSTEM
HOLD
TILT
CYLINDER
TILT LIFT
BACK
PUMP LIFT
CYLINDER
MAIN
SYSTEM CONTROL
RELIEF VALVE VALVE
DUMP LOWER
SCREEN
TANK
Page: 11
HOLD
ACCUMULATOR
TILT LIFT
AUXILIARY
MAIN CONTROL VALVE
MAIN
RELIEF
VALVE
RIDE
CONTROL
VALVE
-
TO STEERING
PILOT SYSTEM
TO
HYDRAULIC
BRAKES
ELECTRO-HYDRAULIC
CONTROL VALVE
STEERING
PUMP
IMPL PUMP
BRAKE AND
SYSTEM
PILOT PUMP
950G/962G MWL
Page:
12
TANK
TILT BACK
ACCUMULATOR
TILT LIFT
AUXILIARY
MAIN CONTROL VALVE
MAIN
RELIEF
VALVE
RIDE
CONTROL
VALVE
TO STEERING
-
PILOT SYSTEM
TO
HYDRAULIC
BRAKES
ELECTRO-HYDRAULIC
CONTROL VALVE
STEERING
PUMP
IMPL PUMP
BRAKE AND
PILOT PUMP
SYSTEM
950G/962G MWL
Page:
TANK
13
FLOAT
ACCUMULATOR
TILT LIFT
AUXILIARY
MAIN CONTROL VALVE
MAIN
RELIEF
VALVE
RIDE
CONTROL
VALVE
TO STEERING
-
PILOT SYSTEM
TO
HYDRAULIC
BRAKES 2140 kPa
ELECTRO-HYDRAULIC
CONTROL VALVE
STEERING
PUMP
IMPL PUMP
BRAKE AND
PILOT PUMP
SYSTEM
950G/962G MWL
Page:
TANK
14
ACCUMULATOR
TILT LIFT
AUXILIARY
MAIN CONTROL VALVE
MAIN
RELIEF
VALVE
RIDE
CONTROL
VALVE
-
TO STEERING
PILOT SYSTEM TO
HYDRAULIC
BRAKES
ELECTRO-HYDRAULIC
CONTROL VALVE
STEERING
PUMP
IMPL PUMP
BRAKE AND
SYSTEM
PILOT PUMP
950G/962G MWL
Page:
15
TANK
RIDE CONTROL
ACCUMULATOR
TILT LIFT
AUXILIARY
MAIN CONTROL VALVE
MAIN
RELIEF
VALVE
RIDE
CONTROL
VALVE
TO STEERING
-
PILOT SYSTEM
TO
HYDRAULIC
BRAKES
ELECTRO-HYDRAULIC
CONTROL VALVE
STEERING
PUMP
IMPL PUMP
BRAKE AND
PILOT PUMP
SYSTEM
950G/962G MWL
Page:
TANK
16
950G/962G MWL
- SYSTEM
CALIBRATION PROCEDURE
ELECTRONIC IMPLEMENT CONTROL
To start the calibration procedure the machine monitoring system should be put in the implement control
calibration mode. The mode is identified by a - 7 - on the Monitoring System Display. The implement
control calibration mode is arranged into 9 "sub modes."
1 - Lift Arm Position Sensor Reading.
2 - CAL 1 - Lift/Lower Function Automatic Calibration.
3 - CAL 2 - Tilt/Dump/3rd Function Start of Modulation.
4 - Modulation Current Adjustment
- Prefix 1 - Lift Function Maximum Modulation Current Adjustment.
- Prefix 2 - Lower Function Maximum Modulation Current Adjustment.
- Prefix 3 - Tilt Back Function Maximum Modulation Current Adjustment.
- Prefix 4 - Dump Function Maximum Modulation Current Adjustment.
- Prefix 5 - 3rd Function Maximum Modulation Current Adjustment.
- Prefix 6 - 3rd Function Maximum Modulation Current Adjustment.
Sub mode calibration functions are described below.
WITH MONITORING DISPLAY MODE ON - 7 -.

1. LIFT ARM POSITION SENSOR READING.
- Minimum reading, between 160 and 190 (% Duty Cycle), with bucket fully tilt back and the Lift arms
fully lowered.
- Maximum reading, between 680 and 950 (% Duty Cycle), with the lift arms fully up. If the values are
not on whithin specs adjust the lift senser linkage.
a. Set the lower kick out for the bucket to be about 30 cm off the ground.
Set the the upper kick out position to about 30 cm before the top of the lift arms range.
b. While in monitoring display mode - 7 -, with the engine at High Idle, perform 3 or 4
lift and lower kick outs. The control is recording the lift cylinder velocity.
2. WITH MONITORING DISPLAY MODE ON SUB MODE - CAL 1 -

With the engine at high idle, pull the lift lever all the way back and hold it. After few seconds
the lift arms will start to move up. Continue holding the lever until the lift arms stop, release the
lift lever. Wait for the machine to stop rocking, then push the lift lever all the way forward,
again after about 2/3 seconds, the lift arms will begin moving downward. When this calibration
is completed, the display should be alternating between "CAL 1" and "donE".
3. WITH THE MONITORING DISPLAY MODE ON SUB MODE - CAL 2 -
With the engine at high idle, very slowly push the tilt lever forward to dump the bucket. As soon
as initial bucket movement is detected, press the "clear" switch to record the current that causes
the initial bucket movement, after the "clear" switch is released keep pushing the tilt lever for one
additional second for the ECM to memorize new setting. Repeat this procedure for the tilt back
function and any auxiliary function that may be present. When this calibration is completed, the
display should be alternating between "CAL 2" and "donE".
4. WITH THE MONITORING DISPLAY MODE ON SUB MODE Prefix "1"
(Prefix "1 " to "6" are available)
With the engine at high idle, smoothly modulate the lift lever up to the detent position and then move
the lever into de tent. If a sudden increase in function speed is felt when the lever moves into detent,
the maximum modulation current should be increased. Use the "clear" switch to increase
or decrease the current. Repeat this procedure for each of the 4 function speeds for all functions (6 on
machines with auxiliary functions).
Page: 17
Service Training
MALAGA
950G/962G MEDIUM
WHEEL LOADERS
SECONDARY STEERING SYSTEM
Francis
March 1998
STEERING
CYLINDERS STEERING SYSTEM
HOLD, LOW PRESSURE STANDBY
STEERING
CONTROL
VALVE BIAS SPRING
HYDRAULIC
PUMP
FLOW COMPENSATOR
(MARGIN) SPOOL
HAND PRESSURE
METERING COMPENSATOR
UNIT (HMU) VALVE
950G/962G MWL
PRESSURE
SYSTEM
COMPENSATOR SPOOL
Page:
2
CHAPTER : SECONDARY STEERING
STEERING STEERING SYSTEM
CYLINDERS
LEFT TURN, CONSTANT FLOW
STEERING
CONTROL
VALVE
BIAS SPRING
HYDRAULIC
FLOW COMPENSATOR PUMP
(MARGIN) SPOOL
HAND PRESSURE
UNIT (HMU) VALVE
PRESSURE
COMPENSATOR SPOOL
950G/962G MWL
SYSTEM
Page:
3
STEERING STEERING SYSTEM
CYLINDERS
LEFT TURN, CONSTANT FLOW
STEERING
CONTROL
VALVE
BIAS SPRING
SECONDARY
STEERING
VALVE
1200 kPa
700 kPa
HYDRAULIC
PUMP
FLOW COMPENSATOR
(MARGIN) SPOOL
HAND PRESSURE
UNIT (HMU) VALVE
SECONDARY STEERING
PUMP AND ELECTRIC MOTOR
PRESSURE
950G/962G MWL
COMPENSATOR SPOOL
SYSTEM
Page:
4
Service Training
MALAGA
950G/962G MEDIUM
WHEEL LOADERS
STEERING SYSTEM
Francis
March 1998
STEERING SYSTEM COMPONENTS
STEERING HYDRAULIC TANK HAND
CONTROL VALVE METERING UNIT PILOT SYSTEM
MAIN SYSTEM
NEUTRALIZER SECONDARY SYSTEM
STEERING VALVES
PUMP COMMON TO
ALL SYSTEMS
STEERING SECONDARY STEERING SECONDARY

CYLINDER PUMP AND MOTOR STEERING VALVE
Page:
950G/962G MWL
2
CHAPTER : STEERING SYSTEM
950G/962G MWL
COMPONENTS IDENTIFICATION
4 3
1
2
5
1. HMU.
2. Signal Hose
3. Signal Pressure Port
4 Brake Valve
5. Accelerator Pedal Cable
Page: 3
STEERING SYSTEM
HAND HOLD
METERING
UNIT NEUTRALIZER
VALVE
CHECK VALVE
SECONDARY NEUTRALIZER
STEERING VALVE
VALVE
STEERING
STEERING CYLINDERS
CONTROL
PUMP VALVE
SECONDARY
STEERING
PUMP AND MOTOR
TANK
Page:
950G/962G MWL
4
950G/962G MWL
STEERING CONTROL VALVE
8 1
9 2
3
7
4
6
5
1. Steering Control Valve 6.Drain Hose

2.Left Turn Hose 7.Pressure Port Line
3.Back-Up Relief Valve 8.Supply Hose
4.Return Hose 9.Right Turn Hose
5.Supply Hose
Page: 5
950G/962G MWL
Page: 6
STEERING HYDRAULIC SYSTEM
FROM IMPLEMENT
PILOT SUPPLY
PILOT
CONTROL
VALVE
DOUBLE DOUBLE
CHECK SHUTTLE
CHECK
VALVE VALVE
VALVE
CONTROL
VALVE
STEERING PUMP
SCREEN
TANK STEERING
CYLINDERS
Page:
950G/962G MWL
7
HOLD
STEERING
CYLINDERS
FROM
IMPLEMENT
PILOT SYSTEM
PILOT CONTROL
VALVE
SHUTTLE
VALVE
TO
IMPLEMENT DOUBLE
PILOT MAKEUP BALL
CHECK VALVE CHECK VALVES
AND
BRAKE SYSTEM CYLINDER CROSSOVER
RELIEF VALVE
PILOT / BRAKE
PUMP CONTROL SPOOL
DOUBLE
CHECK VALVE
FROM PILOT
RETURN
IMPLEMENT
PUMP SHUTTLE VALVE
PRESSURE
REDUCING
TO IMPLEMENT VALVE
PUMP
BACK-UP
RELIEF
STEERING VALVE
PUMP
STEERING CONTROL
VALVE
Page:
950G/962G MWL
8
950G/962G MWL
STEERING PILOT CONTROL VALVE
Page: 9
950G/962G MWL
STEERING PILOT CONTROL VALVE

(Engine running)
Page: 10
950G/962G MWL
STEERING PILOT COTROL VALVE

(In process)
Page: 11
950G/962G MWL
OUTPUT PRESSURE VS INPUT POSITION
"ZERO" INPUT POSITION

1800 kPa
1600 kPa
MINIMUM
OUTPUT DI FF
PRESSURE
550 +/-
10 kPa
0 kPa
- 35 2 +
- 1 0 2 +
- 1 35
(CCW DEGREES) (CW DEGREES)
Page: 12
PUMP AND COMPENSATOR OPERATION
ENGINE OFF
SIGNAL PASSAGE PUMP OUTPUT
YOKE PAD
LARGE ACTUATOR
SWASHPLATE
DRIVE
SHAFT
FLOW COMPENSATOR
(MARGIN SPOOL) PRESSURE
SMALL ACTUATOR
COMPENSATOR
AND BIAS SPRING
(PRESSURE CUTOFF)
Page:
PISTON AND
950G/962G MWL
BARREL ASSEMBLY
13
LOW PRESSURE STANDBY
SIGNAL PASSAGE
PUMP OUTPUT
LARGE ACTUATOR YOKE PAD
SWASHPLATE
DRIVE
SHAFT
FLOW COMPENSATOR PRESSURE
(MARGIN SPOOL) COMPENSATOR
(PRESSURE CUTOFF)
SMALL ACTUATOR PISTON AND

AND BIAS SPRING BARREL ASSEMBLY
Page:
950G/962G MWL
14
UPSTROKING
SIGNAL PUMP OUTPUT
REDUCED PRESSURE LARGE ACTUATOR YOKE PAD
SWASHPLATE
DRIVE
FLOW COMPENSATOR SHAFT
PRESSURE
(MARGIN SPOOL) COMPENSATOR SMALL ACTUATOR
(PRESSURE CUTOFF) AND BIAS SPRING
PISTON AND
BARREL ASSEMBLY
Page:
950G/962G MWL
15
DESTROKING
SIGNAL PUMP OUTPUT

SWASHPLATE
DRIVE
SHAFT
FLOW COMPENSATOR PRESSURE

(PRESSURE CUTOFF) PISTON AND
BARREL ASSEMBLY
SMALL ACTUATOR
AND BIAS SPRING
Page:
950G/962G MWL
16
HIGH PRESSURE STALL
PUMP OUTPUT
SIGNAL AT
AT MAX. PRESSURE
MAX. PRESSURE
SWASHPLATE
DRIVE
PRESSURE SHAFT
FLOW COMPENSATOR
(PRESSURE CUTOFF) SMALL ACTUATOR
AND BIAS SPRING
PISTON AND
Page:
BARREL ASSEMBLY
950G/962G MWL
17
RIGH TURN
STEERING
CYLINDERS
FROM 1 m/m
IMPLEMENT
PILOT SYSTEM
3450 kPa PILOT CONTROL
VALVE 25600 kPa
SHUTTLE
VALVE
TO
IMPLEMENT DOUBLE MAKEUP BALL
CHECK VALVE CHECK VALVES
PILOT AND
RELIEF VALVE
PILOT / BRAKE
PUMP
CONTROL SPOOL
158 l/min DOUBLE
CHECK VALVE
FROM PILOT
RETURN
292 l/min 23500 kPa
IMPLEMENT
PUMP SHUTTLE VALVE
PRESSURE
REDUCING
TO IMPLEMENT VALVE
138 kPa
- 2 kPa
PUMP
BACK-UP
IMPLEMENT RETURN RELIEF
STEERING VALVE
PUMP 2070 kPa
37 l/min STEERING CONTROL
VALVE
Page:
950G/962G MWL
18
SUPPLEMENTAL STEER - LEFT TURN ENGINE OFF
STEERING
CYLINDERS
FROM
IMPLEMENT
PILOT SYSTEM
PILOT CONTROL 1 m/m
3450 kPa
VALVE 25600 kPa
SHUTTLE
VALVE
TO
IMPLEMENT DOUBLE MAKEUP BALL
PILOT AND CHECK VALVE CHECK VALVES
RELIEF VALVE
PILOT / BRAKE
PUMP
CONTROL SPOOL
DOUBLE
158 l/min CHECK VALVE
FROM PILOT
RETURN 23500 kPa
IMPLEMENT 292 l/min
PUMP SHUTTLE VALVE
PRESSURE
REDUCING
TO IMPLEMENT VALVE
138 kPa
- 2 kPa
IMPLEMENT RETURN 2070 kPa PUMP
1200 kPa BACK-UP
700 kPa RELIEF
STEERING VALVE
PUMP
37 l/min STEERING CONTROL
SECONDARY VALVE
STEER
32 l/min
6500 kPa
Page:
950G/962G MWL
19
950G/962G MWL
FAN DRIVE SYSTEM
4 1
5
1. Fan Motor Intake Hose

2. Hydraulic Fan Motor
3. Fan
4. Return Hose
5. Drain Hose
Page: 20
FAN DRIVE SYSTEM
ENGINE ON
TO IMPLEMENT
HYDRAULIC
SYSTEM
42 l/min
FAN
STEER OIL COOLER (1385 rpm)
PUMP BY-PASS VALVE
170 kPa 450 kPa
FAN
IMPLEMENT MOTOR
PUMP
PILOT/
BRAKE
PUMP FILTER OIL COOLER MAKEUP
VALVE
17000 kPa
TANK RELIEF
VALVE
Page:
950G/962G MWL
21
FAN DRIVE SYSTEM
ENGINE OFF
TO IMPLEMENT
HYDRAULIC
SYSTEM
42 l/min
FAN
FAN
STEER PUMP OIL COOLER (1385 rpm)
PUMP BY-PASS VALVE
170 kPa 450 kPa
FAN
MOTOR
IMPLEMENT
PUMP
PILOT/
BRAKE
PUMP FILTER OIL COOLER MAKEUP
VALVE
17000 kPa
TANK RELIEF
VALVE
Page:
950G/962G MWL
22
950G/962G MWL
STEERING PRESSURE TEST PORT
FROM
IMPLEMENT
PILOT SYSTEM
PILOT SIGNAL INPUT

PRESSURE SHAFT
TEST PORT
STEERING PILOT
CONTROL VALVE
PILOT
SIGNAL
PRESSURE
ADJ
REDUCED PILOT
SIGNAL PRESSURE
TEST PORT
CONTROL SPOOL
Page: 23
950G/962G MWL
STEERING SYSTEM
MARGIN PRESSURE ADJUSTMENT
SIGNAL
PRESSURE
AP
1U5796
DIFFERENTIAL
FLOW COMPENSATOR PRESSURE GROUP
(MARGIN SPOOL)
MARGIN PRESSURE \
ADJUSTMENT SCREW
PRESSURE
COMPENSATOR
(PRESSURE CUTOFF)
PUMP
OUTPUT
PUMP OUTPUT
PRESSURE TAP
1. Install the steering frame lock link so the machine can not turn.
2. Using the load sensing signal pressure tap and the pump outlet pressure tap,
install the Pressure Differential Gauge (1U5796). Connect a 60000 kPa pressure
gauge in the differential pressure gauge, pump outlet side.
3. Loosen jam nut on the crossover line relief valve, and turn adjuster screw three
full turns counterclockwise.
4. Start the engine , allow the hydraulic oil to reach normal operating temperature.
5. While operating at the high idle, turn slowly the steering wheel against the frame
link lock until the pressure gauge installed on the pump outlet pressure tap
shows 20000 kPa approximately. Then slowly unturn the steering wheel so that
the pressure gradually decreases.
7. Between 20000 kPa and 12000 kPa approximately, the Margin pressure should
remain constant at 2400 +/- 150 kPa
8. If the reading is not with in specs, screw in or out the Margin pressure adjustment
screw.
Page: 24
Service Training
MALAGA
950G/962G MEDIUM
WHEEL LOADERS
TRANSMISSION
Francis
March 1998
POWER TRAIN COMPONENTS
DIESEL TORQUE TRANSMISSION OUTPUT
ENGINE CONVERTER TRANSFER GEAR
REAR REAR PARKING FRONT FRONT

FINAL DRIVE DRIVE SHAFT BRAKE DRIVE SHAFT FINAL DRIVE
Page:
950G/962G MWL
2
CHAPTER : TRANSMISSION
Page:
3
TRANSMISSION HYDRAULIC SYSTEM
TRANSMISSION RELIEF OIL PUMP TRANSMISSION SOLENOID

AND TORQUE CONVERTER CONTROL VALVES
INLET RELIEF VALVES
TORQUE CONVERTER CASE
TORQUE CONVERTER
FLYWHEEL HOUSING
OIL
OIL COOLER
FILTER
TRANSFER
GEAR CASE
TORQUE CONVERTER PUMP SUPPLY
OUTLET RELIEF LINE
OIL RETURN MAGNET
LINE SCREEN
950G/962G MWL
ECM TRANSMISSION CONTROL AND
OPERATOR STATION INPUTS MACHINE INPUTS HYDRAULIC SYSTEMS
SHIFT
LEVER SECONDARY STEERING PRIMARY STEERING NEUTRAL
PRESSURE SWITCH
TEST SWITCH (OPTION) ENGINE SPEED SENSOR (OPTION)
NEUTRALIZER
SWITCH
P
DOWNSHIFT SWITCH MESSAGE
CENTER
SECONDARY STEERING °C kPa MILES K M R P M LITER SERV
CODE
x10 MODULE
PRESSURE SWITCH TORQUE
NEUTRALIZER CONVERTER
OVERRIDE SWITCH PARKING BRAKE SWITCH (OPTION)
TRANSMISSION
RELIEF VALVE T/C
MANUAL/AUTO SWITCH KEY SWITCH OUTLET
RELIEF TO
ECM OUTPUTS VALVE TRANSMISSION
AIR INLET HEATER SWITCH COOLER
TRANSMISSION INPUTS T/C

INLET
RELIEF SOLENOID SOLENOID
VALVE VALVE VALVE
TRANSMISSION OIL
R 3
TRANSMISSION INTERMEDIATE TEMPERATURE SENSOR
SPEED SENSOR NO. 2
TORQUE CONVERTER 1
4
TRANSMISSION OUTPUT OUTPUT SPEED SENSOR
SPEED SENSOR NO. 1 SOLENOID SOLENOID
VALVE VALVE
TRANSMISSION INTERMEDIATE F 2
TRANSMISSION OUTPUT SPEED SENSOR NO. 1
SPEED SENSOR NO. 2 FILTER
2 5
SOLENOID SOLENOID
PUMP VALVE VALVE
4 1
TANK
Page:
3 6
950G/962G MWL
4
950G/962G MWL
TRANSMISSION HYDRAULIC SYSTEM COMPONENETS
Transmission Steering Implement Brake/Oilot

Pump Pump Pump Pump
Output Transfer
Gear housing
Page: 5
950G/962G MWL
POWER TRAIN COMPONENTS
Solenoid
Valves
Transmission
Filter
Page: 6
ELECTRONIC TRANSMISSION
PRIMARY STEERING
PRESSURE SWITCH CONTROL SYSTEM
OPTION
SECONDARY STEERING
PRESSURE SWITCH TRANSMISSION
OPTION ACTUATORS
SECONDARY STEERING
SOLENOID
TEST SWITCH
OPTION
RIDE CONTROL SWITCH SOLENOID
OPTION
SOLENOID
SHIFT LEVER
PARK BRAKE SOLENOID

SWITCH
SOLENOID
TRANSMISSION NEUTRALIZER
SWITCH
SOLENOID
TRANSMISSION NEUTRALIZER
SWITCH OVERRIDE TRANSMISSION
ELECTRONIC
CONTROL
AUTO/MANUAL SWITCH MODULE
AIR INLET
HEATER RELAY
KEY SWITCH
RIDE CONTROL
DOWNSHIFT SWITCH SOLENOID
AIR INLET
HEATER SWITCH
BACK-UP ALARM
ENGINE SPEED SENSOR
CAT DATA LINK

TRANSMISSION OIL
TEMPERATURE SENSOR
TRANSMISSION INPUT
SPEED SENSOR ENGINE START
SOLENOID
TRANSMISSION INTERMEDIATE
SPEED SENSOR NO. 1
TRANSMISSION INTERMEDIATE SECONDARY STEER

SPEED SENSOR NO. 2 RELAY
TRANSMISSION OUTPUT
Page:
SPEED SENSOR NO. 1
950G/962G MWL
TRANSMISSION OUTPUT
7
SPEED SENSOR NO. 2
950G/962G MWL
ELECTRONIC SYSTEM COMPONENTS
Page: 8
950G/962G MWL
TRANSMISSION SHIFT LEVER
Shift Lever
Control Group
Neutralizer Left Brake

Switch Box Pedal
Page: 9
950G/962G MWL
Parking Brake Downshift

Key Start
Knob Switch
Switch
Page: 10
950G/962G MWL
NEW TRANSMISSION SHIFT CONTROL
Page: 11
950G/962G MWL
Optional Ride Auto/Manual

Control Switch Transmission Switch
Page: 12
950G/962G MWL
TRANSMISSION SENSORS
Engine Speed
Sensor
Torque Converter
Output Sensor
Page: 13
950G/962G MWL
TRANSMISSION SENSORS
Transmission Oil
Temperature
Sensor
Intermediate
Speed Sensor 1
Intermediate
Speed Sensor 2
Output Speed
Sensor 2 Output Speed
Sensor 1
Page: 14
950G/962G MWL
TRANSMISSION TEST PORTS
Pump Pressure
Test Port
Transmission
Pressure Test Port
Torque Converter
Inlet Test Port
Page: 15
950G/962G MWL
TRANSMISSION TEST PORTS
Clutch Pressure
Test Port
Torque
Converter
Outlet
Test Port
Lubrication
Pressure
Test Port
Page: 16
950G/962G MWL
COMBINATION SHIFT
ONCOMING SPEED CLUTCH
Pulse Level Full ON Level
Ramp Level Hold ON Level
Modulation Curve
Hold Level
Full OFF Level

Pulse Time Ramp Time HoldTime Full ON Time
Desired
Modulation Enable Time Slip Time
Release Rate 1
Release Rate 2 OFFGOING SPEED CLUTCH
Release Rate 3
Full OFF Level

Release Release
Ramp Release Ramp Time 3
Time 2 Margin Time
ONCOMING DIRECTION CLUTCH Full ON Level

Pulse Level
Modulation Curve Hold ON Level

Ramp Level
Hold Level
Full OFF Level
RampTime HoldTime Desired SlipTime

Pulse Delay Time
Desired EngagementTime
Release Rate 1
Release Rate 2
Release Rate 3 OFFGOING DIRECTION CLUTCH
Full OFF Level
Release RampTime 3
Release Shift Start Time
Ramp
Time 2
Page: 17
CLUTCH PRESSURE
SHIFT - 1 FWD to 2 FWD
1 Pressure - Clutch 1 3 Pressure - Clutch 5

2 Pressure - Clutch 2 4 Pressure - Clutch 6
4
2
Page:
950G/962G MWL
18
950G/962G MWL
Transmission Clutch Pressure Test

Use the following procedure to check the
pressure of the direction oil and the speed
clutch oil.
Shift the transmission direction and speed

B D control lever from the NEUTRAL position to
the FORWARD position (if equipped). Shift the
transmission direction control switch from the
NEUTRAL position to the FORWARD position (if
equipped). Increase the engine speed to high
idle. Make sure that the transmission oil is at
A normal operating temperature. The needle on the
C E F pressure gauge for the Number 2 clutch should
rise. The needle on the pressure gauge for the
Number 6 clutch should rise. The pressure
readings must be within the values that are found
in ÒTransmission PressuresÓ, Table 3 that follows.
With the transmission in the FORWARD position,
shift through the remaining forward speeds and
return to the FIRST SPEED position. Use the
Modulating Solenoid Valves for the Transmission transmission direction and speed control lever
(if equipped) or transmission upshift gear speed
(A) Pressure tap for the Number 6 clutch. (B) Pressure tap for switch (if equipped) to change speeds. The
the Number 5 clutch.(C)) Pressure tap for the Number 4 clutch. pressure reading for each energized clutch must
(D) Pressure tap for the Number 3.clutch. (E) Pressure tap for
the Number 2 clutch. (F) Pressure tap for the Number 1 clutch. be within the values found in ÒTransmission
PressuresÓ, Table 3 that follows. This checks the
pressure of all the speed clutches.
I. Install the correct hose assembly from 1 U-5482 5. Perform Step 4 for all reverse speeds. The same
Pressure Adapter Group on the following pressure levels should be noted in all reverse
pressure taps: (A), (B), (C), (D), (E), and (F). speeds.
Attach the opposite end of the hose assembly to
the 0 to 3400 kPa (0 to 580 psi) pressure gauge
in the lU-5481 Pressure Gauge Group.
Transmission Clutch Pressure Adjust
2. Engage the parking brake. Shift the transmission Reference: If the pressure reading for each
direction and speed control lever to the NEUTRAL energized clutch is not within the values found in
position (if equipped). Shift the transmission direction ÒTransmission PressuresÓ, Table 3, the transmission
control switch to the NEUTRAL position (if equipped). modulating solenoid valve may need to be
Start the engine and operate the engine at low idle. calibrated. For more information on this topic
refer to the Service Manual module for Testing
and Adjusting, SENR1380, ÒModulating Valve
3. Place the transmission neutralizer override switch (Transmission) - Calibrate.Ó
in the OFF position by depressing the top of the
switch.
4. Depress the right service brake pedal and

hold the right service brake pedal. Release the
parking brake. Watch the pressure gauges.
Page: 19
950G/962G MWL
Torque Converter Inlet Oil Pressure
I. Install the correct hose assembly from 1 U-5482

Pressure Adapter Group on pressure tap (H).
in the l U- 5481 Pressure Gauge Group.
2. Start the engine and operate the engine at high
idle. Observe the pressure gauge. With the oil
at normal operating temperature, the torque
converter outlet oil pressure reading must be
M within values found in ÒTransmission PressuresÓ,
Table 3 that follows.
L
(L) Pressure tap for the transmission oil pump.

Lubrication Oil Pressure Test
(M) Pressure tap for P3 torque converter inlet oil
pressure. Use the following procedure to check the pressure
of the transmission lubrication oil.
1. Install the correct hose assembly from 1 U-5482
Pressure Adapter Group on pressure tap (M).
in the lU-5481 Pressure Gauge Group.
2. Start the engine and operate the engine at high G

idle. Observe the pressure gauge. With the oil
at normal operating temperature, the torque
converter inlet oil pressure reading must be
within values found in ÒTransmission PressuresÓ,
Table 3 that follows.
Torque Converter Outlet Pressure Test

Use the following procedure to check oil pressure Inlet for Transmission Lubrication Oil
at the torque converter outlet. The inlet for the transmission lubrication oil is located on
the right side of the machine.
(G) Transmission lubrication pressure tap.
1. Install the correct hose assembly from lU-5482

Pressure Adapter Group on pressure tap (G).
the 0 to 400 kPa (0 to 58 psi) pressure gauge in
the 1 U-5481 Pressure Gauge Group.
idle. Observe the pressure gauge. With the oil at
normal operating temperature, the lubrication oil
H pressure reading must be within values found in
ÒTransmission PressuresÓ, Table 3 that follows.
The torque converter outlet is located on the right side of

the machine on the torque converter housing.
(H) Torque converter outlet pressure tap.
Page: 20
950G/962G MWL
Transmission Oil Pump Pressure Test Transmission Oil Pump Pressure Adjust
Use the following procedure to check transmission If the transmission oil pump pressure at pressure tap
oil pump pressure. (L) is not within the values found in ÒTransmission
PressuresÓ, Table 3, adjust the spring of the
transmission hydraulic control relief valve. Use the
M procedure that follows.
1.Remove adjustment cover.

2.Turn adjustment screw (P) in the proper direction.
L Turning the adjustment screw clockwise

increases pump pressure. Turning the adjustment
screw counterclockwise decreases pump
pressure. One full turn of the adjustment screw
changes pump pressure 160 kPa (23 psi).
P
3.Install adjustment cover.
Transmission Hydraulic Control Relief Valve 4.Perform ÒTransmission Oil Pump Pressure TestÓ
to ensure that the oil pump pressure is now within
The transmission hydraulic control relief valve is located the value found in ÒTransmission PressuresÓ,
on the left side of the machine on the torque converter
housing. Table 3.
(L) Pressure tap for the transmission oil pump.(M) Pres-
sure tap for P3 torque converter inlet oil pressure.
1. Install the correct hose assembly from 1 U-5482

Pressure Adapter Group on pressure tap (K).
in the 1 U - 5481 Pressure Gauge Group. J
2. Install the correct hose assembly from 1 U- 5482 K

Pressure Adapter Group on pressure tap (L).
in the 1 U-5481 Pressure Gauge Group.

idle. Observe the pressure gauges. With the oil at
normal operating temperature, the transmission
oil pump pressure reading must be within values
found in ÒTransmission PressuresÓ, Table 3 that
follows.
Transmission Oil Filter

The transmission oil filter is located above the
parking brake on the left side of the machine.
(J) Oil sampling valve for the transmission. (K)
Pressure tap for the transmission oil pump.
Page: 21
950G/962G MWL
Table 3
TRANSMISSION PRESSURES 1
Actual
Pressure Tap Specification Pressure
2690 +
_ 70 kPa
(A) Number 6
clutch pressure (390 +
_ 10) psi
(B) Number 5 + 70 kPa

2210 _
_ 10) psi
(C) Number 4 2690 +

_ 70 kPa
clutch pressure +
(390 _ 10) psi
(D) Number 3 2690 +
_ 70 kPa
_ 10) psi
(E) Number 2 + 70 kPa

2760 _
_ 10) psi
(F) Number 1 2760 +

_ 70 kPa
_ 10) psi
(G) Transmission 105kPa (15 psi)

lubrication pressure (minimum)
415 _+ 135 kPa

(H) Torque converter
outlet pressure (60 +
_ 20) psi
(K) Transmission 2860 +

_ 70 kPa
oil pump pressure (415 +
_ 10) psi
(L) Transmission 2860 +

_ 70 kPa
oil pump pressure (415 +
_ 10) psi
(M) Torque converter 550kPa (80psi)

inlet pressure
1
Oil pressure at high idle
Page: 22
950G/962G MWL
SYSTEM CALIBRATIONS
CALIBRATION SUBMODES
SUBMODE SUBMODE ON AVAILABLE

NUMBER DESCRIPTION DISPLAY WITH
20 Set Forward High Speed Lockout F1/F2/F3/F4

21 Set Reverse High Speed Lockout R1/R2/R3/R4 ET
&
RD0 (off) SWITCH
22 Set Ride Control Configuration RD1 (1solnd) BOX
RD2 (2 solnd)
23 Set Secondary Steering Selection SS0/SSI
24 Set Shift Input Selection SF0/SFI
31 Clutch 1 Engagement Calibration
33 Clutch 3 Engagement Calibration SWITCH
BOX
(1) (2) ONLY
40 Clutch Fill Calibration
(1) Specified engagement pressure

(2) Solenoid valve electrical current value
The ECM uses the main display module on the To access calibration mode 8 for the power train
Caterpillar Monitoring System for showing diagnos- ECM do the following:
tic information to service personnel. Diagnostic
information concerning the ECM is sent on the CAT 1. Attach the 4C-8195 service tool to the service
data link to the Caterpillar Monitoring System. Ser- mode connector.
vice personnel must be familiar with the Caterpillar
Monitoring System in order to troubleshoot the 2. Depress the service mode switch on the service
power train ECM. tool. The Caterpillar Monitoring System will scroll to
different display modes in the display area while the
The Caterpillar Monitoring System has several dif- switch is depressed. Display mode 8 is used by the
ferent modes of operation. For troubleshooting and power train ECM. The switch should be held until
calibrating the power train ECM, service personnel the Caterpillar Monitor System display area shows
must place the Caterpillar Monitoring System in "-8 -".
certain modes of operation.
3. Hold down on the SET switch until the display
The 4C.8195 Service Tool allows personnel access area is in the desired submode. The submodes
to information that is related lo service. The service available are as seen in the table.
tool attache to the 4 pin service mode connector
which is located in the compartment behind the
fuse panel access cover in the right rear interior
panel of the cab.
Page: 23
950G/962G MWL
Submode 20 - Set Forward High Speed Submode 23 - Secondary Steering

Lockout Selection
This submode is used to set the highest speed This submode is used to enable/disable the second-
obtainable when in forward. The procedure for this ary steering option in the power train ECM. The pro-
submode is as follows: cedure for this submode is as follows:
1.Using the 4C8195 service tool, enter Transmission
Calibration Mode (8) via MODE switch and then 1.Using the 4C8195 service tool, enter Transmission
enter submode 20 using the Scroll switch. Calibration Mode (8) via MODE switch and then
enter submode 23 using the Scroll switch.
2. Use the INCREMENT (+) and DECREMENT (-)
positions of the CLEAR swatch to select the 2.Use the INCREMENT (+) position of the CLEAR
desired maximum speed; Fl , F2, F3 or F4. switch to change the selection. Press and release
the switch to change between SSO (disabled) and
3. Exit submode 20 by scrolling to the next submode SSl (enabled). There is external hardware for
using the SCROLL switch or by exiting the secondary steering function, if it is enabled and the
Transmission Calibration Mode using the MODE external hardware does not exist, then fault codes
switch. may be logged,
Submode 21 - Set Reverse High Speed 3.Exit submode 23 by scrolling to the next submode
Lockout using the SCROLL switch or by exiting the
Transmission Calibration Mode using the MODE
This submode is used to set the highest speed switch.
obtainable when in reverse. The procedure for this
submode IS as follows:
1.Using the 4C8195 service tool, enter Transmission
Calibration Mode (8) via MODE switch and then
enter submode 21 using the Scroll switch. Submode 24 - Shift Input Selection
2.Use the INCREMENT (+) and DECREMENT (-) This submode is used to select the shift control
positions of the CLEAR switch to select the input selection in the power train ECM. This selec-
desired maximum speed, R 1, R2, R3 or R4. tion is controlled by the setup of the machine. if
the machine is a standard type with twist grip
3.Exit submode 21 by scrolling to the next submode selector, then this is a standard machine. if the
using the SCROLL switch or by exiting the machine is a type with the shift switches in steer-
Transmission Calibration Mode using the MODE ing wheel, then this is an optional type. The proce-
switch. dure for this submode is as follows:
1. Using the 4C8195 service tool, enter Transmis-
sion
Submode 22 - Set Ride Control sion Calibration Mode (8) via MODE switch and
Configuration the enter submode 24 using the Scroll switch.
This submode is used to set the ride control 2. This display will show current shift input, type
configuration of the machIne. The procedure for selection. SF0 is standard type with twist grip
this shifter and SF1 is optional type with shaft
submode is as follows: switches in the steering wheel. Use the INCRE
MENT (+) position of the CLEAR switch to
1. Using the 4C8195 service tool, enter Transmis- change the selection. Press and release switch
sion to change between SF0 (standard twist grip
sion Calibration Mode (8) via MODE switch and shifter machine) and SF1 (optional steering
then enter submode 22 using the Scroll switch. wheel with switches).
2. Use the INCREMENT (+) and DECREMENT (-) 3. Exit submode 24 by scrolling to the next sub
positions of the CLEAR switch to change the mode using the SCROLL switch or by exiting
selection. Press and release the switch to the Transmission Calibration Mode using the
change between RdO (off), Rdl (standard - 1 MODE switch.
solenoid) and Rd2 (improved - 2 solenoid).
3. Exit submode 22 by scrolling to the next sub
mode using the SCROLL switch or by exiting the
Transmission Calibration Mode using the
MODE switch.
Page: 24
950G/962G MWL
TRANSMISSION CLUTCH ENGAGEMENT CALIBRATION
Engagement Pressure Specifications For Transmission Clutches
Clutch 1 Clutch 2 Clutch 3 Clutch 4 Clutch 5 Clutch 6

kPa (psi) kPa (psi) kPa (psi) kPa (psi) kPa (psi) kPa (psi)
+
2760 _ 70 2760 +_ 70 2690 +_ 70 +
2690 _ 70 2210 +_ 70 2690 +_ 70
+
(400 _ 10) (400 +_ 10) (390 +_ 10) +
(390 _ 10) (320 +_ 10) (390 +_ 10)
Correct engagement pressure can greatly effect the

Tools Needed life of the transmission. These submodes are used
4C-8195 Control Service Tool 1 to set the engagement pressure of each clutch. In
this process, the mechanic adjusts the electrical cur-
8T-0855 4150 kPa (600 psi) Pressure Gauge 1 rent that is sent to each clutch solenoid valve in
order to obtain the specified clutch engagement
pressure. This clutch engagement calibration should
be performed prior to performing the clutch fill cali-
bration (submode 40).
5 The Transmission System needs to be calibrated if

any of the following has occurred:
6
- A clutch solenoid valve(s) has been replaced,
swapped, or cleaned.
- A different power train ECM has been installed.
- A transmission clutch has been rebuilt.
- Shift harshness exists (clutch fill calibration only).
2 1
3 During this calibration, error codes (EXX) can occur.
4
The error codes appear in the display area if there is
a problem with the conditions of running the calibra-
tion or if there is a problem with the calibration
results. The error codes that can appear arc:
Clutch Solenoid Valve Identification
EOl - Active Clutch Solenoid Or Speed Sensor Fault
(1) Clutch 1 solenoid- reverse. Correct the fault.
(2) Clutch 2 solenoid- forward E04 - Transmission Direction Lever Not In Neutral
(3) Clutch 3 solenoid- fourth EO5 - Transmission Oil Temp Below Threshold
(4) Clutch 4 solenoid- third 40*C (104*F)
(5) Clutch 5 solenoid- second E06 - Engine Speed Below Threshold (1800 rpm)
(6) Clutch 6 solenoid- first E07 - Parking Brake Is Not On
EO9 - Machine Speed Not Zero
Page: 25
950G/962G MWL
Procedure
NOTE: The Steps of this procedure must be STEP 9. When all conditions are met (pressure showing
performed exactly and in sequence. This procedure on the display), move the transmission direction fever
can terminate if any unspecified or unexpected to the FORWARD position. This pressurizes the clutch
functions are activated or if a fault (CID FMI) is present. being calibrated.
Without being instructed, DO NOT change any switch
positions move any levers or depress any pedals. If STEP 10. The display changes and now shows a
there is a problem with the conditions of running the number that corresponds to the electrical current of the
calibration or if there is a problem with the calibration particular solenoid valve. The INCREMENT (+) and
results, an error code (EXX) will appear in the display DECREMENT (-) positions of the CLEAR switch can
area. now be used to adjust the electrical current of the
STEP I. If a new clutch solenoid valve was installed,
solenoid valve which controls engagement pressure.
shift the transmission at least 12 times into a gear that While monitoring the pressure gauge, use the CLEAR
uses the solenoid valve. Allow sufficient time for the switch to adjust the pressure until the pressure gauge
corresponding clutch to be fully pressurized. reading matches the specified engagement pressure
from Step 8.
STEP 2. Warm the transmission oil to at least 40°C
(104°F). STEP 11. Move the transmission direction lever to the
NEUTRAL position, this completes the calibration.
STEP 3. Place a pressure gauge on the clutch to be
calibrated. A 3500 kPa (500 psi) gage is desired. STEP 12. Use the SCROLL switch to go to the
submode that corresponds to the next clutch to be
STEP 4. Place the transmission direction lever in the calibrated or to go to the Clutch FiII Calibration,
NEUTRAL position. submode 40. To exit Transmission Calibration Mode,
use the MODE switch.
STEP 5. Place the parking brake switch in the ON
positron.
STEP 6. Set the engine speed to high idle.
STEP 7. Using the 4C.8195 service tool, enter
Transmission Calibration Mode (Mode 8). Then enter
the submode that corresponds to the clutch being
calibrated (same as Step 3).
Submode 31 - Clutch 1 Engagement
Submode 33 - Clutch 3.Engagement
STEP 8. If all the conditions are correct for calibration,

the specified engagement pressure for the particular
clutch is shown in the display area. The units of the
value shown is one tenths kPa. For the true specified
kPa value, multiply the value showing by 10. Record
the value In the remaining Steps, adjustments are
made so that this specified engagement pressure is the
actual pressure gauge reading. The specified
engagement pressure is also listed in the preceding
Engagement Pressure Specifications chart.
NOTE: If the setup conditions are not correct the

engagement pressure IS NOT shown n the display
area. Instead an error code (EXX) appears. The
calibration will not run until all necessary conditions
(error code corrected) are met. Correct the error code
and restart these procedures.
Page: 26
950G/962G MWL
Submode 40 - Clutch Fill Procedure
Correct fill parameters can greatly effect the NOTE: The Steps of this procedure must be
transmission shift quality. In order to gain greater performed exactly and in sequence. This procedure
consistency in setting the fill parameters, the can terminate if any unspecified or unexpected
calibration procedure is automatic. The clutch functions are activaled or if a fault (CID FMI) is
engagement calibration (submodes 31 to 36) should present.
be performed prior to performing this clutch fill WIthout being instructed, DO NOT change any
calibration. switch positions, move any levers or depress any
pedals. If there is a problem with the conditions of
During this calibration, error codes (EXX) can occur. running the calibration or if there IS a problem with
The error codes appear in the display area if there is the calibration results, an error code (EXX) will
a problem with the conditions of running the calibra- appear in the display area.
tion or if there is a problem with the calibration
results. The error codes that can appear are:
STEP 1. The clutch engagement calibration
EO1 - Active Clutch Solenoid Or Speed Sensor Fault (submodes 31 to 36) should be performed prior to
Correct the fault. performing this clutch fill calibration.
E04 - Transmission Direction Lever Not in Neutral
EO5 - Transmission Oil Temp Below Threshold STEP 2. If a new clutch solenoid valve was installed,
(68*C) shift the transmission at least 12 times into a gear
E06 - Engine Speed Below Threshold (1500 rpm) that uses the solenoid valve. See table on preceding
E07 - Parking Brake Is Not On illustration. Allow sufficient time for the corresponding
EO9 - Machine Speed Not Zero clutch to be fully pressurized.
El 1 - Engagement Pressure Calibration Not
Completed STEP 3. Warm the transmission oil to at least 68*C
E21 - Clutch 1 At A Limit (154°F). Operate the machine or let the transmission
E22 - Clutch 2 At A Limit spin in neutral to ensure the transmission is fully
E23 - Clutch 3 At A Limit warmed.
E24 - Clutch 4 At A Limit
E25 - Clutch 5 At A Limit STEP 4. Place the transmission direction lever in the
E26 - Clutch 6 At A Limit NEUTRAL position.
For error codes E21, E22, E23, E24, E25 or E26, STEP 5. Place the parking brake switch in the ON
the calibration software needed to adjust one of the position. The transmission will shift to NEUTRAL and
parameters beyond the design limit. The software First Speed.
will pick values that do the best job possible, but
the error indicates something is wrong with either STEP 6. Set the engine speed to high idle.
the calibration conditions or the control system.
Things to check for E21 through E26 error codes STEP 7. Using the 4C8195 service tool, enter
are: Transmission Calibration Mode (Mode 8) and then
enter submode 40.
1. Were the oil and transmission fully warmed to
run the calibration? STEP 8. If all the conditions are correct for
2. Are the valves correctly torqued (be sure valves calibration, 0’s will move across the display area.
are torqued when cool)?
3. Are seals worn causing leakage?
4. IS clutch worn beyond allowable range?
5. Is valve damaged?
6. If a new valve was installed, shift the tractor into
a gear using that valve at least 12 times, before
beginning the procedure.
If there are no problems, or once problems are

fixed, run the clutch fill calibration (submode 40)
again.
Page: 27
950G/962G MWL
NOTE: If the setup conditions are not correct, 0Õs are

NOT shown in the display area. Instead an error
code (EXX) appears. The calibration will not run until
all necessary conditions (error code corrected) are
met. Correct the error code and restart these
procedures.
STEP 9. When all conditions are met (0Õs moving
across the display), move the transmission direction
lever to the FORWARD position. This begins the
actual clutch fill calibration.
STEP 10. The display changes and now shows the
number of the active clutch (1 to 6). The calibration
automatically changes to each clutch.
NOTE: During the calibration there are many clutch
fills occurring. Remain seated. There will be some
vibration and noise as clutches touch up. If any of the
setup conditions are violated during the calibration,
then the calibration will be stopped and a
corresponding error code (EXX) will be shown. Cor-
rect the error code and restart these procedures.
STEP 11. When the calibration successfully

completes, Ò- - -Ó will be shown on the display. An
error code may also be displayed indicating that the
calibration had a problem completing the
adjustments.
STEP 12. Operate the machine to check the shift

quality.
STEP 13. Exit submode 40 by scrolling to the anoth-
er submode using the SCROLL switch or by exiting
Transmission Calibration Mode using the MODE
switch.
Page: 28

Catalogo 950G-962G - Service Training

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Catalogo 950G-962G - Service Training

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Service Training

On completion of this course the participants will be able to :

SUPPLEMENTARY TRAINING MATERIAL

II - CATERPILLAR MONITORING SYSTEM

III - STEERING SYSTEM

IV - IMPLEMENT ELECTRO/HYDRAULIC SYSTEM

Red The highest pressure in the system

Red and White Second highest pressure in the system

Brown - Lube oil pressure

Orange Pilot pump system pressure

Green - Tank and return and case drain oil

Yellow - Moving parts and activated valve envelopes.

Blue - Blocked oil.

Electrical Schematics Color

Purple - Torque converter sensor voltage

Orange - Signal voltage

PILOT AND BRAKE SERVICE BRAKE

REAR WHEEL PARKING ACCUMULATORS FRONT WHEEL

PILOT AND BRAKE ACCUMULATOR

1.Pilot and Brake Pump

LEFT BRAKE RIGHT BRAKE ACCUMLATOR

BRAKE LIGHTS INVERSE

PARKING IMPLEMENT PILOT

TRANSMISSION LEFT RIGHT

TANDEM FRONT BRAKE

SERVICE BRAKE WEAR INDICATOR

CATERPILLAR MONITORING SYSTEM

LIFT LEVER POSITION SENSOR BUCKET RACKBACK SOLENOID

TILT LEVER POSITION SENSOR BUCKET DUMP SOLENOID

PILOT ON/OFF SOLENOID

LIFT RAISE SOLENOID

LIFT LOWER SOLENOID

LIFT RAISE KICKOUT SOLENOID

LIFT KICKOUT SET SWITCH TILT LOWER KICKOUT SOLENOID

FUNCTION SELECTION SWITCH LIFT LOWER KICKOUT SOLENOID

CAT DATA LINK (ET/MONITOR

1. Digital Display Window

Sales Model Machine Code

HARNESS CODE TROUBLESHOOTING

SPEED READOUT GEAR READOUT

GAUGE CLUSTER MODULE

MESSAGE CENTER MODULE

MESSAGE CENTER MODULE

MESSAGE CENTER MODULE

MESSAGE CENTER MODULE

DIRECTIONS TO USE 4C8195 SERVICE TOOL

ACTIVATION OF DISPLAY OPERATIONS

Display Service Clear

Mode Available As Available with

MODULE & FEALURE MODE IDENTIFIER

IMPLEMENT ELECTRONIC CONTROL

TRANSMISSION SYSTEM ELECTRICAL SHEMATIC

IMPLEMENT HYDRAULIC SYSTEM

IMPLEMENT PILOT PILOT CONTROL HYDRAULIC TILT

LIFT PILOT MAIN CONTROL

PILOT SYSTEM COMPONENTS MAIN SYSTEM COMPONENTS COMMON

IMPLEMENT PILOT CONTROLS

1.Implement Pilot Control

1.Pilot and Brake Pump

EIC ECM ON/OFF

MAIN CONTROL VALVE

MAIN CONTROL VALVE

MAIN CONTROL VALVE