Caterpillar 990 & 990 Series II Wheel Loader Hydraulic System Schematic Manual - PDF DOWNLOAD

2

1

4

3

6

5

RENR6262-02 June 2011

7

FLUID POWER SYMBOLS BASIC COMPONENT SYMBOLS MAIN

LINEAR PATTERNS

PUMP OR MOTOR

FLUID CONDITIONER

SPRING

CONTROL VALVES

VARIABILITY

SPRING (ADJUSTABLE)

LINE RESTRICTION (VARIABLE)

PRESSURE COMPENSATION

RESTRICTION

LINE RESTRICTION (FIXED)

AUX

PUMP (2 - SECTION)

PUMP (VARIABLE & PRESSURE COMPENSATED)

Pressure

2 1

Pilot Pressure

Components

3

ONE POSITION

TWO POSITION

AB

THREE POSITION

TWO - WAY

THREE - WAY

FOUR - WAY

CHECK VALVES

A B

P T

P T

NORMAL POSITION

SHIFTED POSITION

BASIC SYMBOL

INFINITE POSITION

4

SPRING LOADED

SHUTTLE

PILOT CONTROLLED

FLUID STORAGE RESERVOIRS

7 5

ATTACHMENT

VALVE PORTS

CONTROL VALVES

Denotes Wire Code

LINE RESTRICTION (VARIABLE & PRESSURE COMPENSATED)

VALVES

VALVE ENVELOPES

A

Return Lines

A

HYDRAULIC PNEUMATIC ENERGY TRIANGLES

6 PRESSURIZED

VENTED

990 and 990 Series II Wheel Loader Hydraulic System

B

B

RETURN ABOVE FLUID LEVEL

RETURN BELOW FLUID LEVEL

MEASUREMENT

PRESSURE

ROTATING SHAFTS

TEMPERATURE

FLOW

UNIDIRECTIONAL

BIDIRECTIONAL

COMBINATION CONTROLS

7HK1-UP 4FR1-UP BCR1-UP

SOLENOID

SOLENOID OR MANUAL

SOLENOID & PILOT

SOLENOID & PILOT OR MANUAL

SERVO

THERMAL

DETENT

MANUAL CONTROL SYMBOLS

8

9 11 PUSH - PULL LEVER

10 12

GENERAL MANUAL

MANUAL SHUTOFF

PUSH BUTTON

PEDAL

PILOT CONTROL SYMBOLS

RELEASED PRESSURE

EXTERNAL RETURN

INTERNAL RETURN

REMOTE SUPPLY PRESSURE

SIMPLIFIED

COMPLETE

CROSSING & JOINING LINES

ACCUMULATORS

SPRING

INTERNAL SUPPLY PRESSURE

HYDRAULIC & PNEUMATIC CYLINDERS

C

C

SPRING LOADED

AA

18

GAS CHARGED

LINES CROSSING

HYDRAULIC MOTORS

HYDRAULIC PUMPS FIXED DISPLACEMENT

13

SINGLE ACTING

LINES JOINING

FIXED DISPLACEMENT

VARIABLE DISPLACEMENT NON-COMPENSATED

INTERNAL PASSAGEWAYS

VARIABLE DISPLACEMENT NON-COMPENSATED

UNIDIRECTIONAL

UNIDIRECTIONAL

BIDIRECTIONAL

BIDIRECTIONAL

DOUBLE ACTING

INFINITE POSITIONING

3 POSITION

FLOW IN ONE DIRECTION

PARALLEL FLOW

CROSS FLOW

2 POSITION

FLOW IN EITHER DIRECTION

15 16

17

© 2011 Caterpillar, All Rights Reserved

14 D

Printed in U.S.A.

D

19 STOP

22

STOP

BB

Steering and Fan System

23

24

37

25 ENERGIZE TO REDUCE FAN SPEED AND POWER

E

E

36

30

35

29

Part No.

Serial No.

1

6E-1244

7HK, 4FR, BCR

Steering Cylinder (Left)

A1

2

9T-9568

7HK, 4FR, BCR

Steering Cylinder (Right)

A2

3a

6E-2925

7HK, 4FR, BCR

Steering Valve (Standard)

A3

3b

6E-2923

7HK, 4FR, BCR

Steering Valve (With Secondary Steering)

A3

4

6E-3985

7HK, 4FR, BCR

Relief Valve (Steering Cylinder Crossover)

A1

5

4T-1860

7HK, 4FR, BCR

Valve (Shuttle)

A3

6

7J-7423

7HK, 4FR, BCR

Check Valve (Secondary Steering Pump)

A5

7

2U-7345

7HK, 4FR, BCR

Diverter Valve (Secondary Steering)

A5

8

4B-9782

7HK, 4FR, BCR

Ball (Steering Cylinder Makeup Valve)

B2

28 26

DD 27

F

F

B4

9

6E-3780

7HK, 4FR, BCR

Valve (Primary Steering Pump Check)

6E-3776

7HK, 4FR, BCR

Stem (Steering Valve)

B1

11

100-4335

7HK, 4FR, BCR

Relief Valve (Pump Backup)

B3

12

6E-3986

7HK, 4FR, BCR

Relief Valve (Secondary Steering)

C5

13

176-9369

7HK, 4FR, BCR

Check Valve (Steering)

C2

14

6E-4286

7HK, 4FR, BCR

Pressure Reducing Valve (Steering)

C4

15

101-4007

7HK, 4FR, BCR

Secondary Steering Pump

C4

16

159-7166

7HK, 4FR, BCR

Piston Motor (Hydraulic Fan)

D4

193-0629

BCR

101-9012

7HK, 4FR

Makeup Check Valve (Hydraulic Fan)

C6

18

4T-4207

7HK, 4FR, BCR

Cushion Orifice (1.2mm)

D2

19

176-9371

7HK, 4FR, BCR

Check Valve (Steering)

D2

20

9T-7426

7HK, 4FR, BCR

Steering Neutralizer Valve (Right)

D1

21

9T-7426

7HK, 4FR, BCR

Steering Neutralizer Valve (Left)

D2

22

6E-5566

7HK, 4FR, BCR

Selelector and Pressure Control Valve

D3

23

148-8978

7HK, 4FR, BCR

Hydraulic Oil Cooler (Hydraulic Fan)

D6

24

6E-1454

7HK, 4FR, BCR

Check Valve (Hydraulic Oil Cooler Bypass)

D6

Pressure Switch (Primary Steering Oil)

E3

Piston Pump (Steering)

E4

Piston Pump (Standard Hydraulic Fan)

E6

25

33

26

31

G

HYDRAULIC STEERING AND FAN SYSTEM SCHEMATIC 1

2

3

4

5

BCR

6E-1542

7HK, 4FR BCR 7HK, 4FR

196-7765

BCR

6E-4469

7HK, 4FR

143-2855

29 30 31 32

Piston Pump (High Ambient Hydraulic Fan)

E6

7HK, 4FR, BCR

Pilot Valve

E2

6E-5566

7HK, 4FR, BCR

Selector and Pressure Control Valve

E3

104-7108

7HK, 4FR, BCR

Check Valve

E4

6E-3528

7HK, 4FR, BCR

Breaker Relief Valve

F6

6E-4683

7HK, 4FR, BCR

Hydraulic Tank

F6

33

152-7202

7HK, 4FR, BCR

Thermostatic Valve

F7

34

4T-3134

7HK, 4FR, BCR

Filter

F6

35

6E-4679

7HK, 4FR

Fan Control Valve

36

6E-4680

7HK, 4FR

Pressure Reducing Valve

37

3E-8574

7HK, 4FR

Solenoid Valve

28

G

7HK, 4FR, BCR

109-4197

27b

34

3E-6450 196-6098 194-6800

27a

32

Location

10

17

CC

Description

HYDRAULIC SYMBOLS (ELECTRICAL)

G TRANSDUCER (FLUID)

TRANSDUCER (GAS / AIR)

GENERATOR

ELECTRIC MOTOR

PRESSURE SWITCH

PRESSURE SWITCH (ADJUSTABLE)

TEMPERATURE SWITCH

ELECTRICAL WIRE

ELECTRICAL SYMBOLS (ELECTRICAL)

T

PRESSURE SWITCH

7

21 20

19 13

28

15

HYDRAULIC SCHEMATIC EXAMPLE

CURRENT STANDARD

CURRENT STANDARD

WIRE

CIRCUIT NUMBER IDENTIFICATION

26 27

24 23

SEBP3340

RENR6250 RENR6251 RENR6252 RENR6264

Testing and Adjusting (Braking) Specifications (Hydraulics) Systems Operation (Hydraulics) Testing and Adjusting (Hydraulics) System Schematic (Hydraulics) Specifications (Machine Systems)

Chart B Pressure Tap and Sampling Port Locations Tap

Description

Part No.

Location

AA

6V-3965

Steering Pump Cutoff

D4

BB

8C-3446

Fluid Sampling Port

D6

CC

6V-3965

Hydraulic Fan Pump Cutoff

E7

DD

6V-3965

Pilot Supply (Steering)

F3

Electrical System Schematic

RENR6263

2

1

32 31

3

4

5

6

WIRE GAUGE

325-PK

7

8

9 10

11 12 14 18 22 25 29 30

WIRE COLOR

B

325-PK-14

16 17

Media Number

RENR6253 RENR6254 RENR6255 RENR6256 RENR6257 RENR6258 RENR6259 RENR6260 RENR6261 RENR6262 RENR6045

WIRE COLOR

WIRE COLOR

PREVIOUS STANDARD

Systems Specifications (Steering) Systems Operation (Steering) Testing and Adjusting (Steering) Specification (Braking) System Operation (Braking)

CIRCUIT NUMBER IDENTIFICATION

325-AG135 PK-14

Power Train Specifications Systems Operation Testing and Adjusting Disassembly and Assembly Supplement

FLOW SWITCH

HARNESS IDENTIFICATION CODE THIS EXAMPLE INDICATES WIRE 135 IN HARNESS “AG”

Parts Manual Parts Book

LEVEL SWITCH

ELECTRICAL SCHEMATIC EXAMPLE

CIRCUIT NUMBER IDENTIFICATION

990 SERIES II (BCR) MEDIA REFERENCES

TEMPERATURE SWITCH

WIRE NUMBER IDENTIFICATION CODES

WIRE

6

M

33

WIRE GAUGE

A

(EXAMPLE VALVE)

(Dimensions: 39 inches x 28 inches)

21

Item

30 Page,

20

ELECTRICAL SYMBOLS TABLE

(417-GY)

RENR6262-02

(201-BK)

2

1

4

3

6

5

8

7

9

10

IMPLEMENT AND BRAKING SYSTEM SCHEMATIC

LINEAR PATTERNS Pressure

Braking and Implement System

Return Lines

7

6

(202-BK)

A

4

(202-BK)

(419-YL)

(G764-PK)

Pilot Pressure

Components

5

2

1

Denotes Wire Code

9

8

A

3 10 11

11

B

B 16

15

(201-BK)

(G756-YL)

(C491-PU)

AA

12 14 17 13

BB

19

(102-RD) (604-OR)

CC

C

C

DD 18

20

27 45 D

D 23 24 25

22

II

26 28 21

(F701-BR)

(E799-BR)

FF 30

29

31

32

40

(Dimensions: 39 inches x 28 inches)

30 Page,

RENR6262-02

36

EE

E

GG

38 E

34 33

Item

Part No.

Serial No.

Description

Location

1

101-7034

7HK, 4FR, BCR

Actuator (Parking Brake)

A2

2

101-7034

7HK, 4FR, BCR

Valve (Parking Brake)

A2

3

N/A

7HK, 4FR, BCR

Valve (On/Off Manual)

A3

4

171-7085

7HK, 4FR, BCR

Switch (Parking Brake)

A3

5

177-4104

7HK, 4FR, BCR

Pilot Valve

A4

6

108-0221

7HK, 4FR, BCR

Pilot Valve (Tilt)

A5

7

108-0222

7HK, 4FR, BCR

Pilot Valve (Lift)

A5

8

145-9897

7HK, 4FR, BCR

Tilt Cylinder

A7

9

9T-9569

7HK, 4FR, BCR

Lift cylinders

A8

10

N/A

7HK, 4FR, BCR

Shuttle valve (Parking Brake Valve)

A4

11

116-3045

7HK, 4FR, BCR

Orifice (Pilot Valve Cartridge)

12

116-3045

7HK, 4FR, BCR

Check Valve (Dead Engine Lower)

B8

13

6E-3078

7HK, 4FR, BCR

Selector and Pressure Control Valve

B8

14

4F-1860

7HK, 4FR, BCR

Shuttle Valve (Ball Resolver)

B8

15

112-2273

7HK, 4FR, BCR

Foot Pedal (Service Brakes)

B1

16

174-4312

7HK, 4FR, BCR

Pressure Switch (Parking Brake Oil)

B3

17

164-5633

7HK, 4FR, BCR

Adapter Assembly (Orifice 1.6mm)

B5

18

196-3821

7HK, 4FR, BCR

Main Control Valve

B6

19

129-7673

7HK, 4FR, BCR

Valve (Service Brake Control)

C1

20

100-4866

7HK, 4FR, BCR

Track Stem

C6

21

9U-2856

7HK, 4FR, BCR

Service Brakes (Front)

D3

22

100-4866

7HK, 4FR, BCR

Stem (Tilt)

D6

23

102-4156

7HK, 4FR, BCR

Check Valve (Load)

D6

24

6E-3185

7HK, 4FR, BCR

Line Relief Valve (Dump)

D7

25

9T-9552

7HK, 4FR, BCR

Diverter Valve (Ride Contol)

D9

26

6E-3303

7HK, 4FR, BCR

Stem (Diverter Valve Ride Control)

D9

27

6E-4185

7HK, 4FR, BCR

Accumulators (Ride Control)

D10

28

9D-2632

7HK, 4FR, BCR

Accumulator (Pilot)

D4

A4-A6

29

9T-9551

7HK, 4FR, BCR

Combination Valve (Parking)

E5

30

102-4156

7HK, 4FR, BCR

Check Valve (Load)

D6

31

9T-6720

7HK, 4FR, BCR

Line Relief Valve (Tilt Back)

D6

32

100-7001

7HK, 4FR, BCR

Valve (Check/Flow Control)

E8

33

142-4281

7HK, 4FR, BCR

Line Relief Valve (Raise)

E4

34

158-9956

7HK, 4FR, BCR

Check Valve

E4

35

6R-0442

7HK, 4FR, BCR

Shuttle Valve

E4

36

6E-6293

7HK, 4FR, BCR

Relief Valve (Pilot)

E5

37

117-7761

7HK, 4FR, BCR

Unloading Valve (Pilot)

E5

38

152-8340

7HK, 4FR, BCR

Solenoid Valve (Ride Contol)

E9

39

100-6731

7HK, 4FR, BCR

Stem (Float Valve)

F5

40

100-4867

7HK, 4FR, BCR

Stem (Raise)

E6

41

6E-1291

7HK, 4FR, BCR

Valve (Pilot Operated Check)

E6

42

196-3822

7HK, 4FR, BCR

Main Relief Valve

E7

43

4Z-6240

7HK, 4FR, BCR

Relief Valve (Main)

F7

44

6E-5842

7HK, 4FR, BCR

Check Valve (Main Relief)

F8

45

9U-2856

7HK, 4FR, BCR

Service Brakes (Rear)

E2

46

148-8977

7HK, 4FR, BCR

Hydraulic Oil Cooler

F7

47

6E-3528

7HK, 4FR, BCR

Breaker Relief Valve

F7

48

100-6909

7HK, 4FR, BCR

Accumulators (Service Brakes)

F4

49

158-9956

7HK, 4FR, BCR

Check Valves

F5

50

108-1176

7HK, 4FR, BCR

Plug (Orifice)

F5

51

116-6399

7HK, 4FR, BCR

Relief Valve (Service Brake Backup)

F5

52

9T-9554

7HK, 4FR, BCR

Hydraulic Tank

53

6E-4657

7HK, 4FR, BCR

Pump (Pilot/Braking)

G5

54

6E-3321

7HK, 4FR, BCR

Piston Pump (Implement)

C2

F7-G7

HH

BRAKING SYSTEM

41

37

Pressure Tap and Fluid Sampling Port Locations

35

JJ

39 42

KK 49

48

50 F

F 44

43 46

47

LL 51 53 52

Description

Tap

Part No.

AA

6V-3965

Head End (Lift Cylinder)

B9

BB

6V-3965

Rod End (Lift Cylinder)

C9

CC

6V-3965

Head End (Tilt Cylinder)

C7

DD

6V-3965

Rod End (Tilt Cylinder)

C7

EE

6V-3965

Service Brakes (Front)

D2

FF

6V-3965

Pilot Oil (Implement)

E4

GG

6V-3965

Pilot Oil (Ride Control)

E9

HH

8C-3446

Fluid Sampling Port

E4

II

6V-3965

E2

JJ

6V-3965

Service Brakes (Rear) Parking Brake Oil

KK

6V-3965

Main Relief Valve (Implement)

F9

LL

6V-3965

Main Relief Valve (Implement)

F9

Location

E4

54

G

G

1

2

3

51 50 49 48 37

4

5

36 35 34 29 28

6

7 11 17

5

6

25 26 38 12 13 14

53

16 10 4

9

8

7

3

10

AA BB

2

8

21

45

52 47 46

48

1

27

9

42 43 44

54

19 15

DD CC

18 20 22 23 24 30 31 32 33 39 40 41

THIS SCHEMATIC IS FOR THE 990 AND 990 SERIES II WHEEL LOADER HYDRAULIC SYSTEM MEDIA NUMBER: RENR6262-02 Components are shown installed on a fully operable machine with the key and engine off, transmission shifter in neutral and with parking brake set.

Refer to the appropriate Service Manual for Troubleshooting, Specifications and Systems Operations.