8/24/22, 4:25 PM SIS 2.

2003/09/25 Wheel Loader Hydraulic System (RENR6017-02)

SMCS - 5050 i01984888

Illustration 1 g00955525

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Hydraulic Schematic

(1) Auxiliary cylinders

(2) Tilt cylinder

(3) Lift cylinders

(4) Shuttle valve (ball resolver)

(5) Line relief valve (auxiliary)

(6) Line relief valve (auxiliary)

(7) Relief valve (dump)

(8) Relief valve (tiltback)

(9) Main control valve

(10) Load check valve

(11) Load check valve

(12) Load check valve

(13) Main relief valve

(14) Stem (auxiliary)

(15) Stem (tilt)

(16) Stem (lift)

(17) Float valve

(18) Screen group

(19) Primary reducing valve

(20) Solenoid valve (hydraulic lockout)

(21) Solenoid valve (dump)

(22) Solenoid valve (lower)

(23) Solenoid valve (open)

(24) Pilot valve (oil manifold)

(25) Ball valve (dead engine lower)

(26) Secondary reducing valve

(27) Shuttle valve

(28) Solenoid valve (tilt back)

(29) Solenoid valve (raise)

(30) Solenoid valve (close)

(31) Screen group

(32) Pump group

(33) Pilot/brake pump

(34) Transmission pump

(35) Breaker relief valve

(36) Steering pump

(37) Filter group

(38) Implement pump

(39) Hydraulic tank

(40) Implement ECM

(A) Hydraulic oil to the brakes

(B) Return for Ride Control

(C) Pilot supply to the Ride Control

(D) Return for steering

(E) Line to the modulating valves (transmission clutch)

(F) Steering supply

Note: Illustration 1 shows a machine with an auxiliary function. Machines without an auxiliary function (logging fork, side dump bucket,
multipurpose bucket, etc) will not be equipped with auxiliary cylinders (1), the three-section valve (10) or the pilot valve for three functions.
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Illustration 1 does not include the following systems: ride control system, braking system, hydraulic fan system and steering system. In order to
troubleshoot these systems, refer to the Schematic, RENR6019 for the 980G Series II Wheel Loader.

Reference: For additional information about the ride control system, refer to the Service Manual module Systems Operation, RENR6017, "Ride
Control System".

Reference: For additional information about the hydraulic fan system, refer to the Service Manual module Systems Operation, RENR6017,
"Hydraulic Fan System".

Reference: For additional information about the steering system, refer to the Service Manual module Systems Operation, RENR6011, "Steering
System".

Reference: For additional information about the braking system, refer to the Service Manual module Systems Operation, RENR6014, "Braking
System".

The implement system is composed of the following systems: pilot control system and main hydraulic system. Hydraulic oil tank (39) is common to
the systems.

The pilot control system is made up of the following components: pilot valve (24), pilot/brake section (33), implement ECM (40) and the lever
position sensors.

The main hydraulic system is made up of the following components: main control valve (9), auxiliary cylinders (1), tilt cylinder (2), lift cylinders (3),
main relief valve (13) and implement pump (38) .

Pilot System
The pilot system is a combination of pilot oil flow and electrical commands.

When the engine is running, pilot/brake section (32) draws oil from hydraulic tank (39). Then, the pilot pump provides pilot oil to the pilot valve (oil
manifold).

When the pilot oil enters the pilot valve, the oil passes through screen group (18). Screen group (18) is installed in the pilot valve (24).

From screen group (18), the pilot oil flows into the primary reducing valve (19). Primary reducing valve (19) will reduce the pressure of the pilot oil
to approximately 3450 ± 200 kPa (500 ± 30 psi) at a flow of 21 ± 3 L/min (5.5 ± 0.8 US gpm). When the pressure adjustment of the primary
reducing valve is greater than the pressure adjustment of the secondary reducing valve, the pilot oil from the primary reducing valve (19) will shift
shuttle valve (27) to the DOWN position. From the output of shuttle valve (27), the pilot oil flows to the solenoid valve (hydraulic lockout) (20). When
the engine start switch is placed in the ON position and as one of the control levers is moved, the solenoid valve becomes energized. Then, the
solenoid valve will open and pilot oil can flow to solenoid valves (21, 22, 23, 28, 29, 30). At this point, the electrical commands will control the
movement of the implements.

If the engine is not running and the lift cylinders are in a RAISED position, oil in the head end of the lift cylinders will be pressurized. That oil will
flow around the ball resolver (4) and into the pilot valve (oil manifold). Screen group (31) will filter the oil as the oil flows into pilot valve (24). The oil
pressure will flow through secondary reducing valve (29). The pressure in primary reducing valve (20) will be less than the pressure in secondary
reducing valve (26). Shuttle valve (27) will shift to the UP position and the oil that is coming from the head end of the lift cylinders will supply the oil
to the pilot system. The oil will be blocked at solenoid valve (20). When the key start switch is placed in the ON position, the operator can lower the
lift arms.

In a case of a battery failure with the lift arms in the RAISED position, the lift arms can be lowered by the ball valve (dead battery) (25). The oil
flows from the shuttle valve (ball resolver) (4) through secondary reducing valve (26). Then, the oil flows out of pilot valve (24) to ball valve (25). As
ball valve (25) is opened the oil from the head end of lift cylinders (3) can flow to hydraulic tank (39).

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Illustration 2 g00916699
Electrohydraulic Control

Illustration 3 g01028603
Joystick Control

The electronic control is located on the panel at the right side of the operator's seat. The electronic control can be either an electrohydraulic control
or a joystick control. The electrohydraulic control consists of control levers, position sensors, and detent coils. The joystick control consists of one
handle, position sensors and detents.

As one of the control levers or the joystick handle is moved, the position sensor is rotated about the axis. As the position sensor is rotated, an
electronic signal is sent to implement ECM (40). The implement ECM interprets the amount of rotation of the position sensor. Then, the ECM sends
a proportional current to the proper solenoid valve. The solenoid valve is energized proportionally by the amount of current that is sent by
implement ECM (40). Pilot oil flows from the solenoid valve to the end cap of the stem in main control valve (9) .

The electronic control is equipped with detent coils. When the control lever is placed at the end of travel, the control lever is held in position until the
current to the coils is interrupted. Then, the control lever returns to the HOLD position.

The detents in the joystick control are soft detents. The soft detents are controlled by the software within the ECM. As the joystick control is moved
into the detent position, the linkage will travel to the kickout position that is preprogrammed. The joystick control should be released in order to
automatically return to the HOLD position. The linkage movement will continue until the kickout is reached. Any 6° movement of the joystick control

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from the HOLD position will disable the detent. The soft detents will not be activated if the joystick control is held in the detent position for more
than 1 second.

Reference: For information about the solenoid valves, refer to the Service Manual module Systems Operation, "Solenoid Valves (Implement)" for
the machine that is being serviced.

Reference: For information about calibrating the control levers, refer to the Service Manual module Testing and Adjusting, RENR6018, "Position
Sensor for the Control Lever (Electronic Technican)" for the machine that is being serviced.

Reference: For information about calibrating the control levers, refer to the Service Manual module Testing and Adjusting, RENR6018, "Position
Sensor for the Control Lever (Caterpillar Monitoring System)" for the machine that is being serviced.

Main Hydraulic System

Implement pump (38) sends pump supply oil to main control valve (9). Main relief valve (13) is installed into main control valve (9). Main relief valve
(13) regulates the pressure in the main hydraulic system. Main relief valve (13) opens when the oil pressure in the hydraulic system rises above the
relief valve setting. The relief valve setting is 20700 ± 340 kPa (3000 ± 50 psi) at approximately 480 L/min (127 US gpm).

Reference: For more information about the main relief valve, refer to the Service Manual module Systems Operation, "Relief Valve" for the
machine that is being serviced.

The 980G Series II Wheel Loader can be equipped with a two-section valve or a three-section main control valve. The three sections control the lift
function, the tilt function, and the auxiliary function of the work tool. The two-section valve controls the lift function, and the tilt function of the work
tool. The stems in main control valve (9) are open centered. When the engine is running and the control levers are in the CENTER position, pump
supply oil flows through main control valve (9) and back to hydraulic tank (39).

Illustration 4 g00955653
Main Control Valve

(41) Auxiliary valve section. (42) Tilt valve section. (43) Lift valve section.

When pilot oil flows to an end cap of main control valve (9) the stem is shifted and the pump supply oil is directed to the appropriate implement
cylinder.

Stems (14, 15, 16) control the flow of supply oil to the implement cylinders. The movement of stems are controlled by pilot pressure oil from the
pilot control valve.

Tilt stem (15) has three positions: TILT BACK position, HOLD position and DUMP position. When tilt stem (15) moves to the TILT BACK position,
pump supply oil flows through the tilt valve (42) to the head end of the tilt cylinder. Oil from the rod end of tilt cylinder (2) flows through tilt valve (42)
back to the hydraulic oil tank.

When the tilt lever is in the HOLD position, all of the oil flow returns to hydraulic tank (38). When tilt stem (15) moves to the DUMP position, pump
supply oil flows through the tilt valve (42) to the rod end of tilt cylinder (2). Oil from the head end of tilt cylinder (3) will flow to the hydraulic tank.

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Lift stem (16) has three positions: RAISE position, HOLD position and LOWER position. When the lift stem 16 is moved to the RAISE position,
pump supply oil flows to the head end of the lift cylinders. As lift cylinders (3) are moving the oil that is in the rod end of the lift cylinders (3) will flow
through lift control valve (52) back to hydraulic tank (36). When the lift lever is placed in the HOLD position, stem (17) will return to the CENTER
position. The pump supply oil flows through the main control valve and returns to the hydraulic tank. When the operator moves the lift control lever
to the LOWER position, stem (17) will shift. Pump supply oil flows to the rod end of lift cylinders (4). Lift cylinder (3) will retract and the oil in the
head end of lift cylinder (3) will flow through lift control valve (43) back to the hydraulic tank.

When the lift control lever in the cab is placed in the FLOAT position the lift valve spool remains in the LOWER position. Float valve (17) vents the
pump supply oil that is in the rod end of lift cylinder (3). The pump supply oil will drain back to hydraulic tank (39) through float valve (17). The
bucket will follow the contour of the terrain with a minimal amount of downward pressure.

The flow of oil through the main control valve changes when the machine has an auxiliary circuit. The oil from implement pump (33) first flows to
auxiliary stem (13). The auxiliary stem has three positions: OPEN position, HOLD position and CLOSE position.

In the OPEN position, high pressure oil flows through auxiliary control valve (41) to the rod end of the auxiliary cylinder. In the HOLD position, all of
the oil flow returns to the hydraulic oil tank. In the CLOSE position, high pressure oil flows to the head end of the auxiliary cylinder.

The auxiliary circuit, the tilt circuit, and the lift circuit have check valves that are built inside the main control valve. Load check valves (10), (11) and
(12) prevent reverse oil flow through main control valve (9). Check valves (10, 11, 12) are built into the control valves. The check valves prevent oil
from flowing back to implement pump (28) from a load that may be developed in the one or more of the cylinders.

The tilt function and the auxiliary functions are equipped with line relief valves. If the work tool is met by an outside source, a pressure spike can be
induced into the main control valve. If the pressure spike is higher than the setting of the line relief valve, the line relief valve will allow the pressure
to dump to hydraulic tank (39) .

Reference: For more information about the operation of the main control valve, refer to the Service Manual module Systems Operation, "Main
Control Valve" for the machine that is being serviced.

AWH1-UP, AXG1-UP, AYT1-UP

PSP-0002E923
2022/08/24
14:24:03+02:00
i01877650
© 2022 Caterpillar Inc.
Caterpillar:
Confidential Green

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