992G WH EEL LOADER

IN TROD U CT ION

1997 Caterpillar Inc.

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3508B ENGINE CONTROLS

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CYLINDER HEADS
MUI AND EUI MUI EUI

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3508B FUEL SUPPLY CIRCUIT

RETURN FUEL FUEL PRESSURE REGULATOR CYLINDER HEAD PRIMING PUMP SUPPLY

DIFFERENTIAL PRESSURE SWITCH

SECONDARY FUEL FILTERS

FUEL TANK

PRIMARY FUEL FILTER

FUEL TRANSFER PUMP

ECM

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ENGINE ECM FEATURES Throttle Lock Fan Control Ether Injection System

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THROTTLE LOCK CIRCUIT

RIGHT BRAKE PEDAL SWITCH 998-BR 998-BR
J3 P3 P1 J1

ECM Throttle Lock RH Brake (NO) Throttle Lock RH Brake (NC) Digital Return Throttle Lock ON Lamp Throttle Lock Set/Declerate Throttle Lock Resume/Accelerate Throttle Lock ON/OFF

F722-OR F721-GY 998-BR F706-PU F717-YL F718-BU F719-BR

THROTTLE LOCK LAMP 998-BR

2 113-OR BATT+

13 19 29 27 14 20 24

THROTTLE LOCK SET/DECLERATION SW 998-BR THROTTLE LOCK RESUME/ACCLERATION SW 998-BR THROTTLE LOCK SW

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HYDRAULIC ENGINE FAN CONTROL CIRCUIT

HYDRAULIC FAN SOLENOID VALVE

P86 J86 2 1 F700-BU E799-BR P2 J2 19 07

CONTROL GROUP (3408E/E3412E)

HYDRAULIC FAN PWM DRIVE AND SOL RETURN

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ETHER INJECTION SYSTEM

ETHER SWITCH

P2 J2

CONTROL GROUP (3408E/E3412E)

J3

P3 F708-YL 998-BR 721-GY 710-BR

P1 J1

23 9 39 21
200-BK 200-BK + 308-YL 310-PK

28 29 19 40

ETHER SW LAMP DIGITAL RETURN ETHER REQUEST ETHER CONTROL

P37 J37 1 2

FROM CYLINDER

+24V

RELAY

ETHER START VALVE

TO ENGINE

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MODULES CONNECTED BY CAT DATA LINK Engine ECM Power Train ECM Implement ECM VIDS/VIMS Caterpillar Electronic Technician or ECAP

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- 26 SERVICE LAMP VIMS RS-232 PORT GAUGE CLUSTER MODULE SPEEDOMETER/ TACHOMETER MODULE MESSAGE CENTER MODULE KEYPAD MODULE
OK 0
ABC

ID
DEF

1
GHI

2
JKL

3
MNO

4
PRS

5
TUV

6
WXY

SERVICE KEYSWITCH

3F VIMS SERVICE TOOL AND SOFTWARE DISPLAY DATA LINK KEYPAD DATA LINK CAT DATA LINK

7
P1

8
P2

9
P3

ELECTRONIC TECHNICIAN/ECAP

VIMS

MAIN MODULE

VIMS INTERFACE MODULE

VIMS INTERFACE MODULE

ENGINE CONTROL

ACTION ALARM ACTION LAMP CAT DATA LINK SENSORS SENSORS SENSORS

VITAL INFORMATION MANAGEMENT SYSTEM (VIMS)

IMPLEMENT CONTROL TRANSMISSION CONTROL

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VIDS/VIMS

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15 10 5 20 25 X100

MPH km/h

30

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ALERT INDICATOR

DATA LOGGER INDICATOR

UNIVERSAL GAUGE

ENGINE TEMP 60 Deg F

[135]

GAUGE WARNING AREA

MESSAGE AREA

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LOW ENGINE OIL LEVEL SHUT DOWN SAFELY

[130]

MACHINE EVENT
OIL PRESSURE CALL SHOP ERROR

SYSTEM EVENT
0745 267

DEFAULT SCREEN

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OK

ID DEF 3 MNO 6 WXY 9 F3

1 GHI 4 PRS 7 F1

ABC 2 JKL 5 TUV 8 F2

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VIDS/VIMS
MAIN MODULE

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VIDS/VIMS INTERFACE MODULE

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WARNING OPERATION Category 1 Category 2 Category 3

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VIDS/VIMS ONBOARD APPLICATIONS

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VOLTAGE TOO LOW SHUT DOWN SAFELY

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OIL PRESSURE CALL SHOP

ERROR

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HARDWARE

SOFTWARE

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ELECTRO-HYDRAULIC IMPLEMENT SYSTEM

- 41 ELECTRO-HYDRAULIC IMPLEMENT SYSTEM

VARIABLE PUMP PILOT SOLENOID VALVE RELIEF VALVE PILOT PUMP ELECTRONIC CONTROL MODULE PILOT CONTROL LEVER MODULE MAIN CONTROL VALVE ASSEMBLY TILT CYLINDER

IMPLEMENT HYDRAULIC PUMPS

HYDRAULIC TANK

LIFT LINKAGE POSITION SENSOR

LIFT TILT LINKAGE CYLINDER POSITION SENSOR

ELECTRONIC SYSTEM HYDRAULIC PILOT SYSTEM

MAIN HYDRAULIC SYSTEM COMMON TO BOTH SYSTEMS

- 42 ELECTRONIC IMPLEMENT CONTROL SYSTEM

IMPLEMENT ELECTRONIC CONTROL MODULE (MAC-14)

CAT DATA LINK INPUT COMPONENTS OUTPUT COMPONENTS

PILOT ON/OFF SOLENOID VARIABLE PUMP SOLENOID TILT RACKBACK SOLENOID NO. 1 IMPLEMENT LOCKOUT SWITCH TILT RACKBACK SOLENOID NO. 2 TILT DUMP SOLENOID NO. 1 TILT DUMP SOLENOID NO. 2 LIFT LINKAGE SENSOR

LIFT LEVER SENSOR

TILT LEVER SENSOR

LIFT/LOWER/TILT KICKOUT SWITCH

LIFT LOWER SOLENOID NO. 1 LIFT LOWER SOLENOID NO. 2 LIFT RAISE SOLENOID NO. 1 LIFT RAISE SOLENOID NO. 2 LIFT LOWER KICKOUT DETENT SOLENOID LIFT RAISE KICKOUT DETENT SOLENOID BUCKET KICKOUT DETENT SOLENOID

TILT LINKAGE SENSOR

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ELECTRO-HYDRAULIC IMPLEMENT SYSTEM

ELECTRONIC SYSTEM COMPONENTS
RIGHT LIFT CYLINDER

TILT CYLINDER

LEFT LIFT CYLINDER

SHUTTLE VALVE IMPLEMENT LOCKOUT SWITCH RAISE/LOW/TILT KICKOUT SET SWITCH

PRESSURE REDUCING VALVE IMPLEMENT CONTROL VALVE IMPLEMENT CONTROL VALVE

TILT LINKAGE POSITION SENSOR

CAT DATA LINK

ELECTRONIC CONTROL MODULE

LIFT LINKAGE POSITION SENSOR

PILOT ON/OFF VALVE

CHECK VALVE

BUCKET KICKOUT DETENT SOLENOID TILT LEVER SENSOR

LIFT KICKOUT DETENT SOLENOID

LOWER KICKOUT DETENT SOLENOID LIFT LEVER SENSOR FIXED PUMP

RELIEF VALVE

PILOT RELIEF VALVE VARIABLE PUMP SOLENOID VALVE

RELIEF VALVE

PILOT PUMP

VARIABLE PUMP

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ELECTRO-HYDRAULIC IMPLEMENT SYSTEM

PILOT SYSTEM COMPONENTS
RIGHT LIFT CYLINDER TILT CYLINDER LEFT LIFT CYLINDER

SHUTTLE VALVE IMPLEMENT LOCKOUT SWITCH RAISE/LOW/TILT KICKOUT SET SWITCH

PRESSURE REDUCING VALVE IMPLEMENT CONTROL VALVE IMPLEMENT CONTROL VALVE

TILT LINKAGE POSITION SENSOR

CAT DATA LINK

ELECTRONIC CONTROL MODULE

LIFT LINKAGE POSITION SENSOR

PILOT ON/OFF VALVE

CHECK VALVE

BUCKET KICKOUT DETENT SOLENOID TILT LEVER SENSOR

LIFT KICKOUT DETENT SOLENOID

LOWER KICKOUT DETENT SOLENOID LIFT LEVER SENSOR

CHECK VALVE RELIEF VALVE

RELIEF VALVE

PILOT RELIEF VALVE

FILTER VARIABLE PUMP SOLENOID VALVE

FIXED PUMP

PILOT PUMP

VARIABLE PUMP

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- 57 ELECTRO-HYDRAULIC IMPLEMENT SYSTEM

MAIN HYDRAULIC SYSTEM COMPONENTS
RIGHT LIFT CYLINDER TILT CYLINDER LEFT LIFT CYLINDER

SHUTTLE VALVE IMPLEMENT LOCKOUT SWITCH RAISE/LOW/TILT KICKOUT SET SWITCH

PRESSURE REDUCING VALVE IMPLEMENT CONTROL VALVE IMPLEMENT CONTROL VALVE

TILT LINKAGE POSITION SENSOR

CAT DATA LINK

ELECTRONIC CONTROL MODULE

LIFT LINKAGE POSITION SENSOR

PILOT ON/OFF VALVE

CHECK VALVE

BUCKET KICKOUT DETENT SOLENOID TILT LEVER SENSOR

LIFT KICKOUT DETENT SOLENOID

LOWER KICKOUT DETENT SOLENOID LIFT LEVER SENSOR

CHECK VALVE RELIEF VALVE

RELIEF VALVE

PILOT RELIEF VALVE

FILTER VARIABLE PUMP SOLENOID VALVE

FIXED PUMP

PILOT PUMP

VARIABLE PUMP

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- 59 VARIABLE PUMP SOLENOID VALVE TO PILOT SYSTEM

VARIABLE IMPLEMENT PUMP

LESS THAN 2400kPa (350 psi)

TO TANK PILOT RELIEF VALVE PRESSURE CUTOFF PILOT FILTER LOAD LIMIT CONTROL SHUTTLE VALVE TO IMPLEMENT CONTROL VALVE

FLUID SAMPLING PORT PILOT PUMP

SMALL ACTUATOR LARGE ACTUATOR PUMP

- 60 VARIABLE PUMP SOLENOID VALVE TO PILOT SYSTEM

VARIABLE IMPLEMENT PUMP

LESS THAN 28,940 kPa (4200 psi)

TO TANK PILOT RELIEF VALVE PRESSURE CUTOFF PILOT FILTER LOAD LIMIT CONTROL SHUTTLE VALVE TO IMPLEMENT CONTROL VALVE

FLUID SAMPLING PORT PILOT PUMP

SMALL ACTUATOR LARGE ACTUATOR PUMP

- 61 VARIABLE PUMP SOLENOID VALVE TO PILOT SYSTEM

VARIABLE IMPLEMENT PUMP

MORE THAN 28,940 kPa (4200 psi)

TO TANK PILOT RELIEF VALVE TO IMPLEMENT CONTROL VALVE PRESSURE CUTOFF LOAD LIMIT CONTROL SHUTTLE VALVE

PILOT FILTER

FLUID SAMPLING PORT PILOT PUMP

SMALL ACTUATOR LARGE ACTUATOR PUMP

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ELECTRO-HYDRAULIC IMPLEMENT SYSTEM

HOLD

RIGHT LIFT CYLINDER

TILT CYLINDER

LEFT LIFT CYLINDER

SHUTTLE VALVE IMPLEMENT LOCKOUT SWITCH RAISE/LOW/TILT KICKOUT SET SWITCH

PRESSURE REDUCING VALVE IMPLEMENT CONTROL VALVE IMPLEMENT CONTROL VALVE

TILT LINKAGE POSITION SENSOR

CAT DATA LINK

ELECTRONIC CONTROL MODULE

LIFT LINKAGE POSITION SENSOR

PILOT ON/OFF VALVE

CHECK VALVE

BUCKET KICKOUT DETENT SOLENOID TILT LEVER SENSOR

LIFT KICKOUT DETENT SOLENOID

LOWER KICKOUT DETENT SOLENOID LIFT LEVER SENSOR FIXED PUMP

CHECK VALVE PILOT RELIEF VALVE RELIEF VALVE FILTER VARIABLE PUMP SOLENOID VALVE

RELIEF VALVE

PILOT PUMP

VARIABLE PUMP

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ELECTRO-HYDRAULIC IMPLEMENT SYSTEM

SLOW TILT

RIGHT LIFT CYLINDER

TILT CYLINDER

LEFT LIFT CYLINDER

SHUTTLE VALVE IMPLEMENT LOCKOUT SWITCH RAISE/LOW/TILT KICKOUT SET SWITCH

PRESSURE REDUCING VALVE IMPLEMENT CONTROL VALVE IMPLEMENT CONTROL VALVE

TILT LINKAGE POSITION SENSOR

CAT DATA LINK

ELECTRONIC CONTROL MODULE

LIFT LINKAGE POSITION SENSOR

PILOT ON/OFF VALVE

CHECK VALVE

BUCKET KICKOUT DETENT SOLENOID TILT LEVER SENSOR

LIFT KICKOUT DETENT SOLENOID

LOWER KICKOUT DETENT SOLENOID LIFT LEVER SENSOR FIXED PUMP

CHECK VALVE PILOT RELIEF VALVE RELIEF VALVE FILTER VARIABLE PUMP SOLENOID VALVE

RELIEF VALVE

PILOT PUMP

VARIABLE PUMP

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ELECTRO-HYDRAULIC IMPLEMENT SYSTEM

FAST TILT

RIGHT LIFT CYLINDER

TILT CYLINDER

LEFT LIFT CYLINDER

SHUTTLE VALVE IMPLEMENT LOCKOUT SWITCH RAISE/LOW/TILT KICKOUT SET SWITCH

PRESSURE REDUCING VALVE IMPLEMENT CONTROL VALVE IMPLEMENT CONTROL VALVE

TILT LINKAGE POSITION SENSOR

CAT DATA LINK

ELECTRONIC CONTROL MODULE

LIFT LINKAGE POSITION SENSOR

PILOT ON/OFF VALVE

CHECK VALVE

BUCKET KICKOUT DETENT SOLENOID TILT LEVER SENSOR

LIFT KICKOUT DETENT SOLENOID

LOWER KICKOUT DETENT SOLENOID LIFT LEVER SENSOR FIXED PUMP

CHECK VALVE PILOT RELIEF VALVE RELIEF VALVE FILTER VARIABLE PUMP SOLENOID VALVE

RELIEF VALVE

PILOT PUMP

VARIABLE PUMP

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ELECTRO-HYDRAULIC IMPLEMENT SYSTEM

SLOW LIFT

RIGHT LIFT CYLINDER

TILT CYLINDER

LEFT LIFT CYLINDER

SHUTTLE VALVE IMPLEMENT LOCKOUT SWITCH RAISE/LOW/TILT KICKOUT SET SWITCH

PRESSURE REDUCING VALVE IMPLEMENT CONTROL VALVE IMPLEMENT CONTROL VALVE

TILT LINKAGE POSITION SENSOR

CAT DATA LINK

ELECTRONIC CONTROL MODULE

LIFT LINKAGE POSITION SENSOR

PILOT ON/OFF VALVE

CHECK VALVE

BUCKET KICKOUT DETENT SOLENOID TILT LEVER SENSOR

LIFT KICKOUT DETENT SOLENOID

LOWER KICKOUT DETENT SOLENOID LIFT LEVER SENSOR FIXED PUMP

CHECK VALVE PILOT RELIEF VALVE RELIEF VALVE FILTER VARIABLE PUMP SOLENOID VALVE

RELIEF VALVE

PILOT PUMP

VARIABLE PUMP

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ELECTRO-HYDRAULIC IMPLEMENT SYSTEM

FAST LIFT
RIGHT LIFT CYLINDER

TILT CYLINDER

LEFT LIFT CYLINDER

SHUTTLE VALVE IMPLEMENT LOCKOUT SWITCH RAISE/LOW/TILT KICKOUT SET SWITCH

PRESSURE REDUCING VALVE IMPLEMENT CONTROL VALVE IMPLEMENT CONTROL VALVE

TILT LINKAGE POSITION SENSOR

CAT DATA LINK

ELECTRONIC CONTROL MODULE

LIFT LINKAGE POSITION SENSOR

PILOT ON/OFF VALVE

CHECK VALVE

BUCKET KICKOUT DETENT SOLENOID TILT LEVER SENSOR

LIFT KICKOUT DETENT SOLENOID

LOWER KICKOUT DETENT SOLENOID LIFT LEVER SENSOR FIXED PUMP

CHECK VALVE PILOT RELIEF VALVE RELIEF VALVE FILTER VARIABLE PUMP SOLENOID VALVE

RELIEF VALVE

PILOT PUMP

VARIABLE PUMP

- 69 IMPLEMENT HYDRAULIC SYSTEM

SLOW TILT
LIFT CYLINDER TILT CYLINDER LIFT CYLINDER

PRESSURE REDUCING VALVE

SHUTTLE VALVE

LOWER

TILT

TILT

LOWER

RIDE CONTROL

PILOT ON/OFF VALVE

VARIABLE PUMP SOLENOID VALVE RAISE DUMP DUMP RAISE

PILOT RELIEF VALVE PRESSURE CUTOFF

FAN MOTOR

FAN SPEED

COOLER SHUTTLE VALVE FIXED PUMP

FLUID SAMPLING PORT

LOAD LIMIT CONTROL SMALL ACTUATOR LARGE ACTUATOR

FAN DRIVE PUMP VARIABLE PUMP

PILOT PUMP

- 70 IMPLEMENT HYDRAULIC SYSTEM

SLOW TILT
LIFT CYLINDER TILT CYLINDER LIFT CYLINDER

PRESSURE REDUCING VALVE

SHUTTLE VALVE

LOWER

TILT

TILT

LOWER

RIDE CONTROL

PILOT ON/OFF VALVE

VARIABLE PUMP SOLENOID VALVE RAISE DUMP DUMP RAISE

PILOT RELIEF VALVE PRESSURE CUTOFF SHUTTLE VALVE FIXED PUMP

FAN SPEED

FLUID SAMPLING PORT

LOAD LIMIT CONTROL SMALL ACTUATOR LARGE ACTUATOR

VARIABLE PUMP

PILOT PUMP

- 71 IMPLEMENT HYDRAULIC SYSTEM

FAST TILT
LIFT CYLINDER TILT CYLINDER LIFT CYLINDER

PRESSURE REDUCING VALVE

SHUTTLE VALVE

LOWER

TILT

TILT

LOWER

RIDE CONTROL

PILOT ON/OFF VALVE

VARIABLE PUMP SOLENOID VALVE

RAISE

DUMP

DUMP

RAISE

PILOT RELIEF VALVE PRESSURE CUTOFF SHUTTLE VALVE FIXED PUMP

FAN MOTOR

FAN SPEED

COOLER

FLUID SAMPLING PORT

LOAD LIMIT CONTROL SMALL ACTUATOR LARGE ACTUATOR

FAN DRIVE PUMP VARIABLE PUMP

PILOT PUMP

- 72 IMPLEMENT HYDRAULIC SYSTEM

SLOW LOWER
LIFT CYLINDER TILT CYLINDER LIFT CYLINDER

PRESSURE REDUCING VALVE

SHUTTLE VALVE

LOWER

TILT

TILT

LOWER

RIDE CONTROL

PILOT ON/OFF VALVE

VARIABLE PUMP SOLENOID VALVE

RAISE

DUMP

DUMP

RAISE

PILOT RELIEF VALVE PRESSURE CUTOFF SHUTTLE VALVE LOAD LIMIT CONTROL SMALL ACTUATOR LARGE ACTUATOR PILOT PUMP VARIABLE PUMP FIXED PUMP

FAN MOTOR

FAN SPEED

COOLER

FLUID SAMPLING PORT

FAN DRIVE PUMP

- 73 IMPLEMENT HYDRAULIC SYSTEM

FAST LOWER
LIFT CYLINDER TILT CYLINDER LIFT CYLINDER

PRESSURE REDUCING VALVE

SHUTTLE VALVE

LOWER

TILT

TILT

LOWER

RIDE CONTROL

PILOT ON/OFF VALVE

VARIABLE PUMP SOLENOID VALVE

RAISE

DUMP

DUMP

RAISE

PILOT RELIEF VALVE PRESSURE CUTOFF SHUTTLE VALVE FIXED PUMP

FAN MOTOR

FAN SPEED

COOLER

FLUID SAMPLING PORT

LOAD LIMIT CONTROL SMALL ACTUATOR LARGE ACTUATOR

FAN DRIVE PUMP VARIABLE PUMP

PILOT PUMP

- 74 IMPLEMENT HYDRAULIC SYSTEM

FLOAT
LIFT CYLINDER TILT CYLINDER LIFT CYLINDER

PRESSURE REDUCING VALVE

SHUTTLE VALVE

LOWER

TILT

TILT

LOWER

RIDE CONTROL

PILOT ON/OFF VALVE

VARIABLE PUMP SOLENOID VALVE

RAISE

DUMP

DUMP

RAISE

PILOT RELIEF VALVE

FAN MOTOR PRESSURE CUTOFF SHUTTLE VALVE COOLER FIXED PUMP

FAN SPEED

FLUID SAMPLING PORT

LOAD LIMIT CONTROL SMALL ACTUATOR LARGE ACTUATOR VARIABLE PUMP

FAN DRIVE PUMP

PILOT PUMP

- 75 IMPLEMENT HYDRAULIC SYSTEM

LOWER ENGINE OFF
LIFT CYLINDER TILT CYLINDER LIFT CYLINDER

PRESSURE REDUCING VALVE

SHUTTLE VALVE

LOWER

TILT

TILT

LOWER

RIDE CONTROL

PILOT ON/OFF VALVE

VARIABLE PUMP SOLENOID VALVE

RAISE

DUMP

DUMP

RAISE

PILOT RELIEF VALVE PRESSURE CUTOFF SHUTTLE VALVE FIXED PUMP

FAN MOTOR

FAN SPEED

COOLER

FLUID SAMPLING PORT

LOAD LIMIT CONTROL SMALL ACTUATOR LARGE ACTUATOR VARIABLE PUMP

FAN DRIVE PUMP

PILOT PUMP

- 76 IMPLEMENT HYDRAULIC SYSTEM

RIDE CONTROL ON
LIFT CYLINDER TILT CYLINDER LIFT CYLINDER

PRESSURE REDUCING VALVE

SHUTTLE VALVE

LOWER

TILT

TILT

LOWER

RIDE CONTROL

PILOT ON/OFF VALVE

VARIABLE PUMP SOLENOID VALVE

RAISE

DUMP

DUMP

RAISE

PILOT RELIEF VALVE PRESSURE CUTOFF SHUTTLE VALVE FIXED PUMP

FAN MOTOR

FAN SPEED

COOLER

FLUID SAMPLING PORT

LOAD LIMIT CONTROL SMALL ACTUATOR LARGE ACTUATOR VARIABLE PUMP

FAN DRIVE PUMP

PILOT PUMP

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FAN DRIVE SYSTEM

ENGINE OFF

FAN FAN MOTOR

SCREEN

MAKEUP VALVE FAN DRIVE PUMP PROPORTIONAL VALVE COMPENSATOR VALVE IMPLEMENT HYDRAULIC COOLER

OIL COOLER BYPASS VALVE

TANK

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FAN DRIVE SYSTEM

SOLENOID DE-ENERGIZED

FAN FAN MOTOR

SCREEN

MAKEUP VALVE FAN DRIVE PUMP PROPORTIONAL VALVE COMPENSATOR VALVE IMPLEMENT HYDRAULIC COOLER OIL COOLER BYPASS VALVE

TANK

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FAN DRIVE SYSTEM

SOLENOID ENERGIZED

FAN FAN MOTOR

SCREEN

MAKEUP VALVE FAN DRIVE PUMP PROPORTIONAL VALVE COMPENSATOR VALVE IMPLEMENT HYDRAULIC COOLER OIL COOLER BYPASS VALVE

TANK

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FAN DRIVE SYSTEM

RAPID ENGINE DECELERATION

FAN FAN MOTOR

SCREEN

MAKEUP VALVE FAN DRIVE PUMP PROPORTIONAL VALVE COMPENSATOR VALVE IMPLEMENT HYDRAULIC COOLER OIL COOLER BYPASS VALVE

TANK