SERV7105-11

November 2005
Vol. 11, No. 4

GLOBAL SERVICE LEARNING

TECHNICAL PRESENTATION

950H WHEEL LOADER,

962H WHEEL LOADER, AND
IT62H INTEGRATED TOOLCARRIER
INTRODUCTION

New Product Introduction

(NPI)
950H WHEEL LOADER,
962H WHEEL LOADER, AND
IT62H INTEGRATED TOOLCARRIER
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 950H Wheel Loader, 962H Wheel Loader, and IT62H Integrated Toolcarrier. This
presentation may be used for self-paced and self-directed training.

OBJECTIVES
After learning the information in this presentation, the technician will be able to:
1. locate and identify the new components on the 950H Wheel Loader, 962H Wheel
Loader, and IT62H Integrated Toolcarrier; and
2. explain the operation of the new components in the systems.

REFERENCES

TIM "950G/962G Wheel Loaders - Command Control Steering System" SERV2644

Estimated Time: 2 Hours

Illustrations: 43
Handouts: 5
Form: SERV7105-11
Date: 11/05

© 2005 Caterpillar Inc.

SERV7105-11 -3- NPI
Vol. 11, No. 4, 2005

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 - STAND BY.......................................................................................24
Pump Control Valve - 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
Tilt Control Valve - 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

SERV7105-11 -4- NPI
Vol. 11, No. 4, 2005

NOTES
SERV7105-11 -5- NPI
Vol. 11, No. 4, 2005

950H WHEEL LOADER,

962H WHEEL LOADER, AND
I T 6 2 H I N T E G R AT E D T O O L C A R R I E R
INTRODUCTION

© 2005 Caterpillar Inc.

INTRODUCTION

The 950H Wheel Loader, 962H Wheel Loader, and IT62H Integrated Toolcarrier 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:

950H Wheel Loader

Aurora K5K
Gosselies N1A
Sagami J5J
Piracicaba M1G

962H Wheel Loader

Aurora K6K
Gosselies N4A
Sagami J6J
Piracicaba M3G

IT62H Integrated Toolcarrier

Piracicaba M5G
SERV7105-11 -6- NPI
Vol. 11, No. 4, 2005

SIMILARITIES AND DIFFERENCES

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

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

(PPPC) 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 operator’s
station features new style switches.
SERV7105-11 -7- NPI
Vol. 11, No. 4, 2005

MACHINE APPEARANCE

The top of the cooling package (1) is lower and the entire cooling package is wider on the
950H Wheel Loader, 962H Wheel Loader, and IT62H Integrated Toolcarrier. 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.
SERV7105-11 -8- NPI
Vol. 11, No. 4, 2005

1 2
3

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
SERV7105-11 -9- NPI
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1 2

The hydraulic tank (1), the hydraulic tank breaker relief valve (2), and the hydraulic tank fill
cap (3) are now located behind the cab.
SERV7105-11 - 10 - NPI
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2
1 3

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) Drenaje de caja

- Hydraulic oil fluid sampling valve (2)
- Hydraulic systems kidney loop filter (3) Filtro de sistema hidraulico
- Brake system accumulators (4) Acumulador sistema de freno
- Power train oil fluid sampling valve (5) Valvula de mostreo de aceite tren de fuerza.
- Power train oil filter (6) Filtro aceite de tren de fuerza
- Ecology drain for the hydraulic tank (7) Drenaje ecologico para el tanque hidrulico
SERV7105-11 - 11 - NPI
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1 2 7 8 9

6 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 fittings (13)
- Rear axle oscillation bearing grease fittings (14)
SERV7105-11 - 12 - NPI
Vol. 11, No. 4, 2005

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.
SERV7105-11 - 13 - NPI
Vol. 11, No. 4, 2005

ENGINE

The 950H Wheel Loader is equipped with the Caterpillar C7 ACERT™ engine, serial number
prefix C7C. The displacement of the C7 ACERT™ engine is 7.2 liters with a rated gross power
of 218 hp. The performance test specification for the C7 ACERT™ engine in the 950H Wheel
Loader is 0K6730.

The 962H Wheel Loader and IT62H Integrated Toolcarrier are equipped with the Caterpillar C7
ACERT™ engine, serial number prefix C7C. The displacement of the C7 ACERT™ engine is
7.2 liters with a rated gross power of 233 hp. The performance test specification for the C7
ACERT™ engine in the 962H Wheel Loader and IT62H Integrated Toolcarrier is 0K6731.
SERV7105-11 - 14 - NPI
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1 2

10

The following electrical components are located on the right side of the machine on the engine:
- Secondary fuel filter (1) Filtro secundario
- Electric fuel priming pump (2) Cebador de combustible electrico
- A4E4 Engine ECM (3)
- Primary fuel filter with water separator (4) Filtro separador de agua
- Fan and brake pump (5) Ventilador y Bomba de brake

The A4E4 Engine ECM features a 120 pin connector and a 70 pin connector.
SERV7105-11 - 15 - NPI
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2 3

11

The following components are found on the secondary fuel filter base on the right side of the
machine:

- Air purge valves (1)

- Differential fuel pressure switch (2)
- Fuel pressure sensor (3)
- Secondary fuel filter (4)
SERV7105-11 - 16 - NPI
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4
3

12

The following components are located on the left side of the machine on the engine:
- Muffler (1)
- Turbocharger with wastegate (2)
- Engine oil fluid sampling valve (3)
- Engine oil filter (4)
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3 4

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.
SERV7105-11 - 18 - NPI
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1
3

14

The following components are located on the front of the engine:

- Alternator drive pulley (1)

- Air conditioning compressor drive pulley (2)
- Serpentine drive belt (3)
- Automatic belt tensioner (4)
- Water pump drive pulley (5)
SERV7105-11 - 19 - NPI
Vol. 11, No. 4, 2005

"H" SERIES MEDIUM WHEEL LOADER IMPLEMENT HYDRAULIC SYSTEM

HOLD

Tilt Ride Auxiliary

Inlet Cylinder Control Function
Manifold Lift Accumulator Cover
Cylinders Manifold
Tilt Anti-drift Head End Hydraulic Lockout
Manual Solenoid valve
Lower Valve Valve
Valve Line
Relief Lift Ant i-drift
Valves Valve
Pilot
Rod Accumulator
Auxiliary
Raise Pilot End Head End
Solenoid Valve Solenoid Solenoid Valve
Valve

Tilt Back Pilot

Solenoid Valve
Lift Spool Ride Control
Relief Valve

Tilt Spool Auxiliary Spool

Pressure
Steering
Compensator
Pilot
Valve
Resolver Supply
Screen (CCS only)
Valve Resolver Pilot
Pressure Balance Pressure
Resolver Pressure
Check Valve Valve
Valve Compensat or Compensator Reducing
Valve Valve Valve
Valve

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

Case
Drain Choke Check
Valve Pump
Filter
and
Pump
Cont rol
Valve
Min Angle

Tank

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.
SERV7105-11 - 20 - NPI
Vol. 11, No. 4, 2005

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.
SERV7105-11 - 21 - NPI
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1 2

16

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.

The maximum angle stop adjustment screw (2) is used to adjust the maximum upstroke position
of the actuator piston in the pump control valve (1).
SERV7105-11 - 22 - NPI
Vol. 11, No. 4, 2005

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
Swashplate Pin
Load Sensing Piston

Actuator Piston
Signal Relief
Valve Load
Sensing
Adjustment Bias Spring
Screw
LS Signal from
Work Port Pump Upstroke

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 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.
SERV7105-11 - 23 - NPI
Vol. 11, No. 4, 2005

The adjustment screw at the top of the actuator piston is used to adjust the 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.
SERV7105-11 - 24 - NPI
Vol. 11, No. 4, 2005

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

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

18

Pump Control Valve - STAND BY

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 sufficiently 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.
SERV7105-11 - 25 - NPI
Vol. 11, No. 4, 2005

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 Swashplate Pin

Load Sensing Piston

Signal Relief Actuator Piston

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

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.
SERV7105-11 - 26 - NPI
Vol. 11, No. 4, 2005

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 Actuator Piston

Valve Load
Sensing
Bias Spring
Adjustment
Screw
LS Signal from
Work Port

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.
SERV7105-11 - 27 - NPI
Vol. 11, No. 4, 2005

PUMP CONTROL VALVE

MAXIMUM SYSTEM PRESSURE

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 Actuator Piston

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

21

Pump Control Valve - MAXIMUM SYSTEM PRESSURE

This illustration shows the pump control valve with the load sensing 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.
SERV7105-11 - 28 - NPI
Vol. 11, No. 4, 2005

PUMP CONTROL VALVE

MAXIMUM SYSTEM PRESSURE WITH ADDED 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

Actuator Piston
Signal Relief
Valve Load
Sensing
Adjustment Bias Spring
Screw
LS Signal From
Work Port Pump Destroke

22

Pump Control Valve - MAXIMUM SYSTEM PRESSURE with Added Flow Demand

This illustration shows the pump control valve with the load sensing 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 2
3
4
12

5
11

6
7

10
8
9

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)
SERV7105-11 - 30 - NPI
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13
1 2 4
3

12

11

10
5

9 8 6
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)
SERV7105-11 - 31 - NPI
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1 2 3 4

8 6 5
7

25

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)
SERV7105-11 - 32 - NPI
Vol. 11, No. 4, 2005

"H" SERIES MEDIUM WHEEL LOADER TILT CONTROL VALVE

HOLD
To Signal Duplication Valve
From Signal Duplication Valve
From Resolver Valves

To / From Head End To / From Rod End

of Cylinder of Cylinder
Pressure
Compensat or
Tilt Anti-drift
Valve
Valve

Bridge Passage

Line Relief
and Line Relief
Makeup Valve and
Makeup Valve
Internal Passage
Feeder
Control Spool Passage

Rackback Pilot Dump Pilot

Solenoid Valve 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.
SERV7105-11 - 33 - NPI
Vol. 11, No. 4, 2005

"H" SERIES MEDIUM WHEEL LOADER TILT CONTROL VALVE

DUMP
To Signal Duplication Valve
From Signal Duplication Valve
From Resolver Valves

From Head End To Rod End

of Cylinder of Cylinder
Pressure
Compensat or
Tilt Anti-drift
Valve
Valve

Bridge Passage

Line Relief
and Line Relief
Makeup Valve and
Makeup Valve
Internal Passage
Feeder
Control Spool Passage

Tilt Back Pilot Dump Pilot

Solenoid Valve Solenoid Valve

Supply
Passage

27

Tilt Control Valve - 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 lifts 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.
SERV7105-11 - 34 - NPI
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From Signal
Duplication Valve PRESSURE COMPENSATOR OPERATION

To Pump, Signal Limiter, Signal Pressure Differential

and Relief Valve
Signal Drain Valve

To Resolver
Signal Valve
Duplication Valve Valve A Valve B Valve C

Spool
Bridged Feeder
Pump Passage Pump Pump
Supply Supply Passage 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.
SERV7105-11 - 35 - NPI
Vol. 11, No. 4, 2005

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 cross-
drilled 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.
SERV7105-11 - 36 - NPI
Vol. 11, No. 4, 2005

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.
SERV7105-11 - 37 - NPI
Vol. 11, No. 4, 2005

"H" SERIES MEDIUM WHEEL LOADER IMPLEMENT HYDRAULIC SYSTEM

DUMP

Tilt Auxiliary
Cylinder Ride Function
Lift Control
Cylinders

Manual Tilt Anti-drift Pilot Shutoff

Lower Valve Valve
Valve Line Lift Anti-drift
Relief Valve
Valves

Auxiliary
Raise Pilot
Head End
Load Solenoid Valve
Solenoid Valve
Check
Valve
Pilot
Accumulator
Tilt Back Pilot
Solenoid Valve
Lift Spool Ride Control
Relief Valve

Tilt Spool Pilot

Pressure
Reducing
Pressure
Valve
Compensator
Valve
Screen Resolver
Valve Balance Resolver
Resolver Pressure Valve
Valve
Valve Compensator
Valve

Signal
Relief
Signal Valve
Duplication
Valve
Lower / Float
Dump Pilot Pilot
Solenoid Valve Solenoid Valve Auxiliary Rod End Pressure Differential
Solenoid Valve Relief Valve

Case
Drain Choke Check
Filter 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. When the load sensing pressure is acting on the bottom of the pressure
differential relief valve, the pressure setting is increased. The pilot pressure reducing valve
limits maximum pilot pressure to 3450 ± 170 kPa (500 ± 25 psi). Then, 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.
SERV7105-11 - 38 - NPI
Vol. 11, No. 4, 2005

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. When the work port pressure goes above 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 valve 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 form
the illustration.
SERV7105-11 - 39 - NPI
Vol. 11, No. 4, 2005

"H" SERIES MEDIUM WHEEL LOADER IMPLEMENT HYDRAULIC SYSTEM

RAISE

Ride
Tilt Control Auxiliary
Inlet Cylinder Accumulator Function
Manifold Lift Cover
Cylinders Manifold

Tilt Anti-drift Head End

Manual Solenoid Valve Hydraulic Lockout
Lower Valve Valve
Valve Line
Relief Lift Anti-drift
Valves Valve Pilot
Accumulator
Auxiliary
Raise Pilot
Rod Head End
Solenoid Valve
End Solenoid Valve
Solenoid
Valve

Tilt Back Pilot

Solenoid Valve Pressure
Lift Spool Compensator Ride Control
Valve Relief Valve
Auxiliary
Tilt Spool Spool
Pilot
Balance Pressure
Solenoid Reducing
Pressure Valve Valve
Compensator
Valve
Screen
Resolver Balance Resolver
Resolver Valve Valve Valve
Valve Check Valve

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

Case
Drain Choke Check
Filter Valve Pump
and
Pump
Control
Min Angle Valve

Tank

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. 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.
SERV7105-11 - 40 - NPI
Vol. 11, No. 4, 2005

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 form
the illustration.
SERV7105-11 - 41 - NPI
Vol. 11, No. 4, 2005

"H" SERIES MEDIUM WHEEL LOADER IMPLEMENT HYDRAULIC SYSTEM

FLOAT

Ride
Tilt Control Auxiliary
Inlet Cylinder Accumulator Function
Manifold Lift Cover
Cylinders Manifold
Head End
Manual Tilt Anti-drift Hydraulic Lockout
Solenoid valve
Lower Valve Valve
Valve Line
Relief Lift Anti-drift
Valves Valve Pilot
Accumulator
Rod Auxiliary
Raise Pilot End Head End
Solenoid Valve Solenoid Solenoid Valve
Valve

Tilt Back Pilot

Solenoid Valve Pressure
Lift Spool Compensator Ride Control
Valve Relief Valve
Auxiliary
Tilt Spool Spool
Pilot
Pressure Pressure
Compensator Reducing
Valve Valve

Screen
Resolver Balance Resolver
Resolver Valve Check Valve Valve
Valve Valve

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

Case
Drain Choke Check
Valve Pump
Filter and
Pump
Control
Valve
Min Angle

Tank

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 the 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.
SERV7105-11 - 42 - NPI
Vol. 11, No. 4, 2005

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.
SERV7105-11 - 43 - NPI
Vol. 11, No. 4, 2005

"H" SERIES MEDIUM WHEEL LOADER IMPLEMENT HYDRAULIC SYSTEM

TILT BACK AND RAISE

Ride
Tilt Control Auxiliary
Inlet Cylinder Accumulator Function
Manifold Lift Cover
Cylinders Manifold

Manual Tilt Anti-drift Hydraulic Lockout

Lower Valve Valve
Valve Line
Relief Lift Ant i-drift Pilot
Valves Valve Accumulator

Auxiliary
Raise Pilot
Head End
Solenoid Valve
Solenoid Valve

Tilt Back Pilot Pressure

Solenoid Valve Compensat or
Lift Spool Valve Ride Control
Relief Valve

Tilt Spool Auxiliary Spool Pilot

Pressure
Reducing
Pressure
Valve
Compensator
Valve
Screen
Resolver
Balance Resolver
Valve
Resolver Check Valve Valve
Valve Valve

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

Case
Drain Choke Check
Filter 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. 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. Then, 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.
SERV7105-11 - 44 - NPI
Vol. 11, No. 4, 2005

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 increase 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 form
the illustration.
SERV7105-11 - 45 - NPI
Vol. 11, No. 4, 2005

"H" SERIES MEDIUM WHEEL LOADER IMPLEMENT HYDRAULIC SYSTEM

HOLD / AUTO TRAVEL MORE THAN 9.7 KM/H (6 MPH)

Ride
Tilt Control Auxiliary
Inlet Cylinder Accumulator Function
Manifold Lift
Cylinders
Tilt Anti-drift Head End
Manual Solenoid Valve Pilot Shutoff
Lower Valve Valve
Valve Line
Relief Lift Ant i-drift Pilot
Valves Valve Accumulator
Rod
End Auxiliary
Raise Pilot
Solenoid Head End
Solenoid Valve
Valve Solenoid Valve

Tilt Back Pilot

Solenoid Valve Pressure
Compensator Pressure
Lift Spool Ride Control
Valve Compensator
Relief Valve
Valve
Tilt Spool Pilot
Pressure
Reducing
Pressure
Valve
Compensator
Valve
Screen
Resolver Balance Resolver Auxiliary
Resolver Valve Valve Valve Spool
Check
Valve
Valve

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

Case
Drain Choke Check
Filter 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 accumulator 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.
SERV7105-11 - 46 - NPI
Vol. 11, No. 4, 2005

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 value 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).
SERV7105-11 - 47 - NPI
Vol. 11, No. 4, 2005

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.
SERV7105-11 - 48 - NPI
Vol. 11, No. 4, 2005

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.
SERV7105-11 - 49 - NPI
Vol. 11, No. 4, 2005

5 1

36

STEERING SYSTEM

The steering systems on the "H" 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.
SERV7105-11 - 50 - NPI
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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 outlet pressure tap is 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 (2).
SERV7105-11 - 51 - NPI
Vol. 11, No. 4, 2005

2
1 3

5
7 6

38

The following components are located on the fan control and brake accumulator charging valve:

- Priority valve, blocks flow to the fan motor when the brake accumulators are
charging (1)
- Signal tap to the fan and brake pump (2)
- Fan solenoid valve, an electronic output of the Engine ECM which controls the speed
of the cooling fan (3)
- Relief valve, limits the maximum pressure in the brake system (4)
- Cut-in valve, maintains minimum brake accumulator pressure (5)
- Brake pressure switch, warns the operator when brake accumulator pressure is low (6)
- Cut-out valve, maintains maximum brake accumulator pressure (7)
SERV7105-11 - 52 - NPI
Vol. 11, No. 4, 2005

Brake
FAN AND BRAKE HYDRAULIC SYSTEM Accumulators
ACCUMULATORS CUT- IN
To Service Brake Valve

Pressure
Inverse Relief
Switch
Shuttle Valve Valve

Fan Solenoid
Valve Cut In Valve
Cut Out
Fan Control / Brake Valve
Charging Valve

Pump
Resolver
Control Valve
Valve
Flow
Fan Screen Control
Motor Spool
Priority
Pressure
Valve
Cutoff
Spool

Oil
Cooler Actuator
Fan / Brake Min Angle
Pump

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.
SERV7105-11 - 53 - NPI
Vol. 11, No. 4, 2005

Brake
FAN AND BRAKE HYDRAULIC SYSTEM Accumulators
ACCUMULATORS CUT-OUT
To Service Brake Valve

Inverse Relief
Shuttle Valve Valve
Pressure
Switch
Fan Solenoid
Cut In Valve
Valve
Cut Out
Fan Control / Brake Valve
Charging Valve

Pump
Resolver
Control Valve
Valve
Flow
Fan Screen Control
Motor Spool
Priority
Pressure
Valve
Cutoff
Spool
Oil
Cooler
Actuator
Fan / Brake Min Angle
Pump

Filter
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.
SERV7105-11 - 54 - NPI
Vol. 11, No. 4, 2005

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.
SERV7105-11 - 55 - NPI
Vol. 11, No. 4, 2005

NEW TOOLING

- Caterpillar Electronic Technician

42

NEW TOOLING/SKILLS REQUIRED FOR SERVICE

The 950H Wheel Loader, 962H Wheel Loader, and IT62H Integrated Toolcarrier have many
electronically controlled components. A strong knowledge of Caterpillar Electronic Technician
(Cat ET) is required for many service activities.
SERV7105-11 - 56 - NPI
Vol. 11, No. 4, 2005

43

CONCLUSION

This presentation has provided New Product Introduction (NPI) information for the Caterpillar
950H Wheel Loader, 962H Wheel Loader, and IT62H Integrated Toolcarrier. Always use the
latest Service Information to ensure that the most current specifications and test procedures are
used.
SERV7105-11 - 57 - NPI
Vol. 11, No. 4, 2005

HYDRAULIC SCHEMATIC COLOR CODE

Black - Mechanical connection. Seal Red - High pressure oil

Dark Gray - Cutaway section Red/White Stripes - 1st pressure reduction

Light Gray - Surface color Red Crosshatch - 2nd reduction in pressure

White - Atmosphere or Pink - 3rd reduction in pressure

Air (No pressure)

Purple - Pneumatic pressure Red/Pink Stripes - Secondary source oil pressure

Yellow - Moving or activated components Orange - Pilot, charge, or Torque Converter oil

Cat Yellow - (R estricted usage) Orange / White Stripes -

Identification of components Reduced pilot, charge, or TC oil pressure
within a moving group
Orange Crosshatch - 2nd reduction in
Brown - Lubricating oil pilot, charge, or TC oil pressure.

Green - Tank, sump, or return oil Blue - Trapped oil

Green / White Stripes -

Scavenge Oil or Hydraulic Void

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.
 HYDRAULIC SCHEMATIC COLOR CODE
SERV7105-11

Black - Mechanical connection. Seal Red - High pressure oil

Vol. 11, No. 4, 2005

Dark Gray - Cutaway section Red/White Stripes - 1st pressure reduction

Light Gray - Surface color Red Crosshatch - 2nd reduction in pressure

White - Atmosphere or Pink - 3rd reduction in pressure

Air (No pressure)

Purple - Pneumatic pressure Red/Pink Stripes - Secondary source oil pressure

- 58 -

Yellow - Moving or activated components Orange - Pilot, charge, or Torque Converter oil

Cat Yellow - (R estricted usage) Orange / White Stripes -

Identification of components Reduced pilot, charge, or TC oil pressure
within a moving group
Orange Crosshatch - 2nd reduction in
Brown - Lubricating oil pilot, charge, or TC oil pressure.

Green - Tank, sump, or return oil Blue - Trapped oil

Green / White Stripes -

Scavenge Oil or Hydraulic Void
Handout No. 1
NPI
SERV7105-11 - 59 - NPI
Vol. 11, No. 4, 2005 Handout No. 2

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
SERV7105-11 - 60 - NPI
Vol. 11, No. 4, 2005 Handout No. 3

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
SERV7105-11 - 61 - NPI
Vol. 11, No. 4, 2005 Handout No. 4

Machine Posttest
Directions: Answer each question with the best possible answer.

1. The 950H Wheel Loader is equipped with which engine?

a. 3126B
b. C9 ACERT™
c. C7 ACERT™
d. 3176

2. The 950H/962H/IT62H are equipped with combination fan and brake valve.
a. True
b. False

3. The diagnostic lines group is an attachment on 950H/962H/IT62H.

a. True
b. False

4. The 950H/962H/IT62H are equipped with which style implement hydraulic system?
a. AMOCS
b. LS/PC
c. Open center
d. PPPC

5. The 950H/962/IT62H require service personnel to use Cat ET to calibrate the fan
hydraulic system.
a. True
b. False
SERV7105-11 - 62 - NPI
Vol. 11, No. 4, 2005 Handout No. 5

Machine Posttest - Continued

6. The 950H/962H/IT62H ride control system utilizes:
a. Two solenoid valves
b. A balance valve
c. Four accumulators
d. Both a and b

7. The 950H/962H/IT62H 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 950H/962H/IT62H 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 950H/962H/IT62H?

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 950H/962H/IT62H are equipped with an implement electrohydraulic system.

a. True
b. False

11. The 962H Wheel Loader and IT62H Integrated Toolcarrier are equipped with which
engine?
a. 3196
b. C9 ACERT™
c. C7 ACERT™
d. 3176
SERV7105-11 - 63 - NPI
Vol. 11, No. 4, 2005 Posttest Answers

Machine Posttest Answers

Quiz Answers:

1. b
2. a
3. a
4. d
5. a
6. b
7. d
8. b
9. b
10. a
11. c