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Bienvenido: underground
Producto: WHEEL LOADER
Modelo: 950 WHEEL LOADER 81J
Configuracin: 950 WHEEL LOADER 81J07846-UP (MACHINE) POWERED BY
3304 ENGINE

Pruebas y Ajustes
950 WHEEL LOADER HYDRAULIC SYSTEM
Nmero de medio -REG00565-04 Fecha de publicacin -01/06/1979 Fecha de actualizacin -10/10/2001

Testing And Adjusting

Loader Hydraulic System


NOTE: For Specifications with illustrations, make reference to SPECIFICATIONS FOR 950 LOADER
HYDRAULIC SYSTEM, Form No. REG01266. If the Specifications given in Form REG01266 are not the
same as given in the Systems Operation and the Testing and Adjusting, look at the printing date on the back
cover of each book. Use the Specifications given in the book with the latest date.

Hydraulic oil, under pressures that can be higher than 3000 psi (20 700
kPa) can remain in the hydraulic systems on this machine after the
engine and pump have been stopped. Serious injury can be caused if this
pressure is not released before any service is done on the hydraulic
systems. To prevent possible injury, be sure that the pressure is released
before any fitting, hose or component is loosened, tightened, removed or
adjusted.

When possible, the bucket must always be flat on the ground before
service is started. When it is necessary for the bucket to be raised while
tests or adjustments are done, be sure that the lift arms have correct
support and the bucket is in the full dump position.

Always move the machine to a location away from the travel of other
machines. Be sure that other personnel are not near the machine when
the engine is running and tests or adjustments are being made.

During a diagnosis of the hydraulic system, remember that correct oil flow and pressure are necessary for

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correct operation. Pump output (oil flow) is a function of engine speed (rpm). Oil pressure is caused by
resistance to the flow of oil.

Visual Checks and measurements are the first step when troubleshooting a possible problem. Then do the
Operation Checks and last the Instrument Tests.

Use the 5S5123 Hydraulic Test Group, a stop watch, a magnet, a thermometer and an inch (mm) ruler for
basic tests to measure:

1. Opening pressure of the main pressure relief valve and the tilt circuit relief valves. Low relief valve
pressure makes a reduction in the ability of the machine to dig and lift a load. Too high opening
pressures can reduce hose and component life.
2. Lift and tilt circuit drift rates. Circuit drift results from leakage past cylinder piston seals, control
valve O-ring seals, poorly seated check or make-up valves and/or excessive spool to valve bore
clearances.
3. Lift and tilt circuit cycle times. Excessive circuit cycle times results from leakage, pump wear and/or
pump speed.

If basic testing reveals internal circuit leakage, install a 9S2000 Flow Meter and follow the FLOW METER
TEE TEST PROCEDURE-II to isolate the probable leakage source.

To adjust components located in the tank, it is necessary to drain the tank and remove the tank side cover.

The tilt circuit and lift circuit are arranged in a series circuit. (In bucket dump, pressure oil is not available to
the lift circuit.) The hydraulic pump and main pressure relief valve are common to both the lift and tilt
circuits. Each circuit has a check valve to prevent cylinder drift during valve spool movement. Each circuit
also has make-up valves to supplement pump flow.

Relief valves in the tilt circuit, limit the external pressure imposed on the circuit when the tilt control valve is
in the HOLD position.

Visual Checks
A visual inspection of the system with the engine stopped should be the first step when troubleshooting a
problem. Make the inspection with the bucket lowered to the ground.

1. Check the oil level. Slowly loosen the tank filler cap. If oil comes out the bleed hole when the filler cap is
loosened, allow tank pressure to bleed off before the filler cap is removed.

2. Remove the filter elements and check for presence of foreign material. A magnet will separate ferrous
metal material from non-ferrous metal and non-metallic sealing material (piston rings, O-ring seals, etc.).

3. Inspect all lines and connections for damage or leaks.

4. Inspect control linkage for bent, broken or damaged components.

Operation Checks
The operation checks can be used to find leakage in the system. They can also be used to find a valve or

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pump that is not working correctly. The speed of rod movement when the cylinders are at work can be used
to check the condition of the cylinders and the pump.

Raise, lower, tilt and tiltback the bucket several times.

1. Watch the cylinders as they are extended and retracted. Movement must be smooth and regular.

2. Listen for pump noise.

3. Listen for relief valve action. Relief valves should not open except at full cylinder extension or retraction
when bucket is empty.

4. Watch the operation of the bucket positioner and lift kickouts.

Lift control lever should lock in RAISE.

Tilt control lever should lock in TILT BACK.

Bucket positioner mechanism should return the tilt control lever from TILT BACK to HOLD at the pre-set
position.

Lift kickout should return lift control lever from RAISE to HOLD at pre-set height.

Test and check adjustment of any area where incorrect operation is evident or suspected. (See appropriate
section of LOADER SYSTEM TEST PROCEDURES.)

When or if hydraulic circuit internal leakage is determined or suspected, perform pressure checks first. If
operation is still slow or sluggish install a 9S2000 Flow Meter to isolate the suspected leakage source (See
FLOW METER TEE TEST PROCEDURE-II.)

Loader System Test Procedures


Checking Pump Efficiency

For any pump test, the pump flow, measured in gpm (litre/min) at 100 psi (7.0 kg/cm2) (690 kPa), will be
larger than the pump flow at 1000 psi (70.0 kg/cm2) (6900 kPa) at the same rpm.

The difference between the pump flow of two pressures of operation is the flow loss.

Flow loss when expressed as a percent of pump flow is used as a measure of pump performance.

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If the percent of flow loss is more than 10%, pump performance is not good enough.

*Numbers in
examples are for illustration and are not values for any specific pump or pump condition. See
SPECIFICATIONS for pump flow of a new pump at 100 psi and 1000 psi.

Test On The Machine

Install a 9S2000 or 5P3600 Flow Meter. [See FLOW METER TEE TEST PROCEDURE II, FORM NO.
REG00880]. Measure pump flow at 100 psi (7.0 kg/cm2) (690 kPa) and at 1000 psi (70.0 kg/cm2) (6900 kPa)
with engine at 2000 rpm.

Test On The Bench

If the test bench can not be run at 1000 psi at a high rpm, do the first part of the test with the pump shaft
rotation at half speed of the pump. See SPECIFICATIONS for HALF SPEED data for pump being tested.
Measure pump flow at 100 psi (7.0 kg/cm2) (690 kPa) and at 1000 psi (70.0 kg/cm2) (6900 kPa). Then in
order to measure the pump flow for the last part of the test, see SPECIFICATIONS for: Pump rpm at 100 psi
with the engine at 2000 rpm.

Lift and Tilt Circuit Speeds

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The loader filter elements should be changed, if dirty, before speed tests are done. The oil must be of the
correct viscosity and at normal temperature for operation to obtain the correct test results. The speed tests are
made with the engine at high idle.

The speeds in the charts are those of a machine equipped with a general purpose bucket.

System speeds approximate to the speeds given, is an indication that the circuits operate normally. Make a
test of the relief valves to be sure they are adjusted to specifications.

If only the lift circuit or only the tilt circuit has slow speeds, check the slow circuit for too much drift.

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Tilt Circuit Drift

Drift measurements are the maximum permissible during the time interval shown for the oil temperature in the
system.

TEST NO. 1: Dump the bucket part way to raise the front of the machine off the ground. Put the tilt control
lever in HOLD position. Shut off the engine and look to see if the tilt cylinder rods move out.

TEST NO. 2: Dump the bucket part way to raise the front of the machine off the ground. Shut off the engine
and place the tilt control lever in DUMP position. Look to see if the tilt cylinder rods move out.

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TEST NO. 3: Start the engine. Raise bucket off the ground (empty with bucket bottom parallel to ground). Put
the tilt control lever in HOLD position. Shut off the engine and look to see if tilt cylinder rods move in.

TEST NO. 4: Start the engine. Raise bucket off the ground (empty with bucket bottom parallel to ground).
Shut off the engine and place the tilt control lever in TILT BACK position. Look to see if tilt cylinder rods
move in.

NOTICE

Set the lift kickout so the lift cylinder piston rods stop .12 in. (3.05 mm)
from end of their strokes.

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Lift Circuit Drift

Drift measurements are the maximum permissible during the time interval shown for the oil temperature in the
system.

TEST NO. 1: Put down pressure on the bucket to raise the front of the machine off the ground. Put the lift
control lever in HOLD position. Shut off the engine and look to see if lift cylinder rods move out.

TEST NO. 2: Put down pressure on the bucket to raise the front of the machine off the ground. Shut off the
engine and place the lift control lever in LOWER position. Look to see if the lift cylinder rods move out.

TEST NO. 3: Raise the empty bucket off the ground. Place the lift control lever in HOLD position. Shut off
the engine and look to see if the lift cylinder rods move in.

TEST NO. 4: Raise the empty bucket off the ground. Shut off the engine and place the lift control lever in
RAISE position. Look to see if the lift cylinder rods move in.

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Main Pressure Relief Valve And Tilt Circuit Relief Valves


5S5123 Hydraulic Testing GroupFT584 Lift Arm Supports (two), (Fabricated Tool).

NOTICE

Use only high pressure testing equipment; pressure can exceed 2550 psi
(179.3 kg/cm2) (17 580 kPa).

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The oil must be at normal temperature of operation during testing.

HYDRAULIC TANK
1. Bucket positioner slave cylinder. 2. Make-up valve (for rod end tilt). 3. Lever and cam (for tilt control). 4. Tilt valve. 5. Main
pressure relief valve. 6. Lift valve. 7. Tilt relief valve (rod end). 8. Lever and cam (for lift control). 9. Tilt relief valve (head end).
10. Lift kickout slave cylinder. 11. Bucket positioner and lift kickout make-up valves.

The tilt circuit relief valves and the main pressure relief valve can be tested while installed on the machine or
they can be removed and tested on a hydraulic test bench. The test procedures are illustrated on the machine
using the 5S5123 Hydraulic Testing Group.

The pressure at which the relief valves opens should be tested regularly and reset, if necessary, to the correct
operating pressure. The hydraulic tank or control valve need not be disturbed to check the pressure settings.

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NOTE: The main pressure relief valve opens at a lower pressure than the tilt circuit relief valves. Since the
tilt circuit relief valves sense the same pressure as the main pressure relief valve when the tilt control valve
spool is in operating position, it is necessary to have the tilt circuit relief valve (rod ends) at the correct
pressure adjustment before the test is made on the main pressure relief valve in the testing sequence that
follows.

Tilt Circuit Relief Valve Adjustment (Rod Ends)

1. Place the bucket flat on the ground. With the engine shut off, move the tilt control lever to all positions.
This will release pressure in the hydraulic lines. Return the control lever to HOLD position.

2. Attach pressure gauge (5) and pressure plate assembly (3) to hose (2). Install the pressure plate between
hose (2) and tube assembly (4). Or, remove the tank guard and tap into the line, using the plug on the tilt rod
end line.

PRESSURE PLATE ASSEMBLY


1. Hose assembly (rod end). 2. Hose. 3. Pressure plate assembly. 4. Tube assembly (rod end).

NOTE: Do not hold relief valve pressure for more than 10 seconds. If more time is needed, wait 1 minute
before testing the relief valve again.

3. Start the engine, and raise the lift arm until it is parallel to the ground. Place the bucket in a full dumped
position. Then, with the lift control lever in RAISE position look at the pressure reading on the gauge as rod
(7) is pulled out of cylinder (6). The tilt control lever must be in HOLD position during this test.

TILT RELIEF VALVE TEST (ROD END)


2. Hose. 5. Pressure gauge. 6. Tilt cylinder. 7. Piston rod.

4. The correct pressure setting for the tilt circuit relief valve is 2475 25 psi (173.3 1.8 kg/cm2) (17 080
172 kPa). If the pressure reading is not correct, record the reading and do the test again.

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NOTE: The relief valves are in the hydraulic tank. When an adjustment is needed for a relief valve, the top
of the tank must be removed. Either all of the oil must be removed or enough oil removed from the tank until
the level of the oil is below the valve.

NOTICE

Plug (10) is spring loaded.

5. Add to shims (8) for a decrease or remove shims (8) for an increase in the pressure setting of the relief
valve.

6. Tighten plug (10) to 100 5 lb. ft. (135 7 Nm).

TILT CIRCUIT RELIEF VALVE


8. Shims. 9. Springs. 10. Plug.

NOTE: Machines with the 7J3972 Relief Valve, the relief setting is 2500 25 psi (175 1.8 kg/cm2) (17 200
172 kPa).

7. Temporarily install the top cover and check the pressure again.

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NOTE: On early machines with a 4J8675 Relief Valve the relief setting is 2200 25 psi (154 1.8 kg/cm2)
(15 180 172 kPa).

NOTICE

The retainer on the 7J3972 and 4J8675 Relief Valve is spring loaded.
The torque for the bolts that hold the retainer is 27 2 lb. ft. (37 3
Nm).

Tilt Circuit Relief Valve Adjustment (Head Ends):

PRESSURE PLATE ASSEMBLY INSTALLED


3. Pressure plate. 11. Hose assembly (head end). 12. Elbow.

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8. Place the bucket flat on the ground. With the engine shut off, move the tilt control lever to all positions.
This will release pressure in the hydraulic lines. Return the control lever to HOLD position.

9. Install pressure plate (3) between hose assembly (11) and elbow (12).

10. Start the engine. Raise the lift arms and install the FT584 Lift Arm Supports.

11. Move the lever for the lift control valve to the LOWER position, and look at the pressure reading on
gauge (5). The tilt control lever must be in HOLD position during this test.

TESTING TILT RELIEF VALVE (HEAD END)


2. Hose. 13. Lift arms supports.

NOTE: Do not hold relief valve pressure for more than 10 seconds. If more time is needed, wait 1 minute
before testing the relief valve again.

12. The correct pressure setting for the tilt circuit relief valve is 2475 25 psi (173.3 1.8 kg/cm2) (17 800
172 kPa). If the pressure reading is not correct, record the reading and do the test again.

TILT CIRCUIT RELIEF VALVE


8. Shims. 9. Springs. 10. Plug.

13. Add shims (8) under plug (10) for a decrease or remove shims (8) for an increase in the pressure setting of
the tilt circuit relief valve.

NOTICE

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Plug (10) is spring loaded.

14. Tighten plug (10) to 100 5 lb. ft. (135 7 Nm).

NOTE: Machines with the 7J4878 Relief Valve, the relief setting is 2500 25 psi (175 1.8 kg/cm2) (17 200
172 kPa).

NOTE: On early machines with a 4J8675 Relief Valve the relief setting is 2200 25 psi (154 1.8 kg/cm2)
(15 180 172 kPa).

NOTICE

The retainer on the 7J4878 and 4J8675 Relief Valve is spring loaded.
The torque for the bolts that hold the retainer is 27 2 lb. ft. (37 3
Nm).

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15. Temporarily install the tank top cover and check the relief valve pressure setting.

Main Pressure Relief Valve Adjustment

16. Move the control lever to raise the lift arms parallel to the ground.

17. Move the tilt lever to DUMP position until arm (14) makes contact with stop (15).

18. Run the engine at high idle speed. Look at the test gauge and move the control lever to DUMP position
and hold it in that position.

NOTE: Do not hold relief valve open for more than 10 seconds. If more time is needed, wait 1 minute before
testing the relief pressure again.

19. The correct pressure setting for the main relief valve is 2225 25 psi (155 1.8 kg/cm2) (15 340 172
kPa). If the pressure reading is not correct, record the reading and do the test again.

TESTING THE MAIN PRESSURE RELIEF VALVE


2. Hose to pressure gauge. 14. Arm. 15. Stop.

NOTE: On early machines with a 4J8131 relief valve the relief setting is 2000 25 psi (140 1.8 kg/cm2)
(13 800 172 kPa).

20. Remove the top cover from the oil supply tank. Carefully remove plug (16) from the relief valve.

NOTICE

Plug (16) is spring loaded.

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21. Add shims (17) under plug (16) for a decrease or remove shims (17) for an increase in the pressure
setting.

22. Torque plug (16) to 80 5 lb. ft. (109 7 Nm).

MAIN RELIEF VALVE


16. Plug. 17. Shims. 18. Spring.

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Bucket Positioner And Lift Kickout Circuits

SCHEMATIC OF THE BUCKET POSITIONER AND LIFT KICKOUT


1. Cam. 2. Lift kickout master cylinder. 3. Bucket positioner slave cylinder. 4. Roller. 5. Roller spring. 6. Tilt valve spool. 7. Piston.
8. Cam lever. 9. Rod assembly. 10. Lift valve spool. 11. Cam. 12. Bucket positioner master cylinder. 13. Piston. 14. Cam lever. 15.
Rod assembly. 16. Lift kickout slave cylinder. 17. Roller. 18. Bucket positioner circuit make-up valve. 19. Lift kickout circuit make-
up valve.

Bucket Positioner Circuit

The length of rod assembly (9) controls the relationship between cam lever (8) and roller (4). The tilt valve
spool (6) will not lock in the TILT BACK position if rod assembly (9) is set too long. If the rod assembly is set
too short, the valve spool will not return automatically from the TILT BACK (locked) position to the HOLD
position.

Piston (13) must have a stroke of .72 in. (18.3 mm). A longer stroke can result in damage to master cylinder

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(12); a shorter stroke can result in failure of the circuit to return valve spool (6) from the TILT BACK
(locked) position to the HOLD position.

Cam (11) can be moved to adjust the bucket digging angle.

Lift Kickout Circuit

The length of rod assembly (15) controls the relationship between cam lever (14) and roller (17). The lift
valve spool (10) will not lock in RAISE position if rod assembly (15) is set too short. If rod assembly (15) is
set too long, valve spool (10) will not return automatically from RAISE (locked) position to HOLD position.

Piston (7) must have a stroke of .72 in. (18.3 mm). A longer stroke can result in damage to master cylinder
(2); a shorter stroke can result in failure of the circuit to return the valve spool (10) from the RAISE (locked)
position to the HOLD position.

Cam (1) should be adjusted so the lift valve spool (10) is returned to HOLD position when the lift cylinder
piston rods are .12 in. (3.0 mm) from the ends of their strokes.

Adjustment For Tilt Linkage In Tank


Move the control lever to the TILT BACK position. Approximately 20 lbs. (89 N) force is needed to move the
control lever from the TILT BACK position. If much less force is needed to move the lever from TILT BACK
position, an adjustment is needed.

1. Remove the oil from the hydraulic tank.

2. Remove the cover from the top of the hydraulic tank.

3. Disconnect spring (4) from plate (3). Connect the spring in a hole in plate (3) which puts more tension on
spring (4). If there is no hole in the plate to make an increase to the tension of spring (4), install a new spring.

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TILT LINKAGE
1. Lever and cam. 2. Roller. 3. Plate. 4. Spring. 5. Rod assembly. 6. Pin. 7. Valve spool (for tilt control). X. .24 in. (6.1 mm)
measurement.

TILT LINKAGE IN TANK


1. Cam. 2. Roller. 3. Plate. 4. Roller spring. 5. Rod assembly.

4. When the linkage in the tank is being assembled, it is necessary to make an adjustment for the length of rod
assembly (5). Connect one end of rod assembly (5) to lever and cam (1).

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5. With the control lever in TILT BACK position, the distance between roller (2) and lever and cam (1) is .24
in. (6.1 mm), measurement (X).

6. Make an adjustment for the length of rod assembly (5). When the control lever and valve spool (7) are in
TILT BACK position, pin (6) must be installed with no movement to valve spool (7).

NOTE: Pin (6) must be installed horizontal with the bottom of the tank.

Adjustment For Lift Linkage In Tank


Move the control lever to the RAISE position. Approximately 20 lbs. (89 N) force is needed to move the
control lever from the RAISE position. If much less force is needed to move the lever from RAISE position,
an adjustment is needed.

LIFT LINKAGE
1. Lever and cam. 2. Roller. 3. Pin. 4. Rod assembly. 5. Valve spool (for lift control). 6. Plate. 7. Spring. Y. .29 in. (7.3 mm)
measurement.

1. Remove the oil from the hydraulic tank.

2. Remove the bottom of the hydraulic tank.

3. Disconnect spring (7) from plate (6). Connect the spring in a hole in plate (6) which puts more tension on
spring (7). If there is no hole in plate (6) to make an increase to the tension of spring (7), install a new spring.

4. When the linkage in the tank is being assembled, it is necessary to make an adjustment for the length of rod
assembly (4). Connect one end of rod assembly (4) to lever and cam (1).

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5. With the control lever in RAISE position, the distance between roller (2) and lever and cam (1) is .29 in.
(7.3 mm) measurement (Y).

6. Make an adjustment for the length of rod assembly (4). When the control lever and valve spool (5) are in
the HOLD position, pin (3) must be installed with no movement to valve spool (5).

NOTE: Pin (3) must be installed horizontal with the cover on top of the tank.

LIFT LINKAGE IN TANK


1. Lever and cam. 2. Roller. 3. Pin. 4. Rod assembly. 5. Valve spool (for lift control). 7. Spring.

Adjustment For Master Cylinder Of Bucket Positioner


1. The correct location of master cylinder (3) is when cam (7) is moved so that roller (8) is on the flat surface
(A) of cam (7) and the maximum stroke of piston (9), into the master cylinder, is .72 in. (18.3 mm).

POSITIONER FOR THE BUCKET


1. Strip. 2. Plate assembly. 3. Master cylinder. 4. Bolts (two). 5. Oil cup. 6. Bolts (two). 7. Cam. 8. Roller (on piston). 9. Piston. 10.
Bolts (two). A. Flat surface on cam. B. .72 in. (18.3 mm) measurement between mark (C) put on cam and flat surface of the cam.

2. With the bucket tilted forward, loosen bolts (6). Move cam (7) farther away from the master cylinder.

3. Start and run the engine at slow speed. Move the control levers and put the bucket on the ground in the
position necessary to dig.

4. Stop the engine. Move the control lever to TILT BACK position.

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5. Move cam (7) to push piston (9) into the master cylinder. When the action of cam (7) on piston (9) moves
the control lever to the HOLD position tighten bolts (6).

6. Start and run the engine at high idle speed. Test the action of the bucket positioner. If the positioner does
not stop the bucket in the position to dig a small movement to cam (7), either nearer or farther away from
roller (8), is necessary.

POSITIONER FOR THE BUCKET


1. Strip. 2. Plate assembly. 3. Master cylinder. 4. Bolts (two). 5. Oil cup. 6. Bolt (two). 7. Cam. 8. Roller (on piston). 9. Piston.

7. When the adjustments for cam (7) and master cylinder (3) correctly position the bucket to dig, stop the
engine.

8. Loosen bolts (4) and move strip (1) to a position where strip (1) and plate assembly (2) are in alignment.
Tighten bolts (4) when the alignment is correct.

Adjustment For Master Cylinder Of Lift Kickout


1. The approximate location of master cylinder (4) is when the center of bolt (2), through cam (1), and the
outer diameter (surface) of roller (6), on piston (7), is 1.50 in. (38.1 mm), measurement (D).

2. The correct location of master cylinder (4) is when bolt (2) is loose and cam (1) is turned to move roller (2)
and piston (7), into master cylinder (4), to get a maximum piston stroke of .72 in. (18.3 mm).

3. Start the engine and run it at slow speed. Move the control lever to RAISE position until the bucket is lifted
as far as it will go.

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MASTER CYLINDER AND CAM FOR LIFT KICKOUT


1. Cam. 2. Bolt (through cam). 3. Bolts (two). 4. Master cylinder. 5. Outer surface of cam. 6. Roller. 7. Piston. D. 1.50 in. (38.1 mm)
measurement.

MASTER CYLINDER AND CAM FOR LIFT KICKOUT


1. Cam. 2. Bolt. 3. Bolts (two). 4. Master cylinder. 5. Surface of cam. 6. Roller. 7. Piston.

4. Stop the engine. With bolt (2) loose, turn cam (1) until it moves piston (7) .38 in. (1.0 mm) into master
cylinder (4) and tighten bolt (2).

5. Start and run the engine at high idle speed. Move the control lever to RAISE position. If the control lever is
not moved to HOLD position, before the rods hit the cylinder heads, loosen bolt (2) and turn cam (1) to move
piston (7) more than .38 in. (1.0 mm) into the master cylinder.

6. When the action of cam (1) on piston (7) moves the control lever to HOLD position when the rods, in the
lift cylinders, are approximately .12 in. (3.0 mm) from hitting the cylinder head, the adjustment for the lift
kickout is correct.

Master Cylinders For Lift Kickout And Bucket Positioner


The master cylinders for the lift kickout and bucket positioner have the same pressure setting for the relief
valve (2). The pressure setting is 225 25 psi (15.8 1.8 kg/cm2) (1551 172 kPa).

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MASTER CYLINDER
1. Check valve. 2. Relief valve (ball).

There is no adjustment for check valve (1). A new master cylinder is installed if there is a failure. Check valve
(1) must open at .6 .5 psi (0.04 0.03 kg/cm2) (4.1 3.4 kPa) and must not leak.

Removing Air From The Hydraulic System For Lift Kickout And
Bucket Positioner
An air supply with 25 psi (1.8 kg/cm2) (172 kPa) and a 5K3921 Air Relief Valve are needed to remove the air
from the system.

NOTE: The air must be removed from the hydraulic system for the lift kickout and bucket positioner after
any line or valve in the system has been installed or when the hydraulic tank has been filled after it was
empty.

1. Move the machine to a place where the ground is level.

2. Move the control lever to RAISE position until the tilt cylinders are parallel to the ground, then move the
control lever to HOLD position.

3. Move the control lever to the TILT FORWARD position until the bucket is in full DUMP position, then
move the control lever to the HOLD position.

4. Put blocks under the bucket so it can not move down. Stop the engine.

5. Slowly loosen filler cap (5) on the hydraulic tank.

6. Move the control lever to the TILT BACK position. The control lever must not be moved from the TILT
BACK position when the air is being removed.

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LIFT KICKOUT AND BUCKET POSITIONER (Locations for Master Cylinders)


1. Master cylinder for lift kickout. 2. Oil line. 3. Oil line. 4. Master cylinder for bucket positioner.

7. Remove the guard in front of the hydraulic tank.

8. Tighten filler cap (5) on the hydraulic tank.

9. Remove plug from oil line (8) between the tank and the rod ends of the tilt cylinders. Install 5K3921 Air
Relief Valve (6) where plug was removed.

10. Loosen oil lines (2) and (3) to let air and oil go out of the lines and fittings.

11. Remove the two bolts which hold master cylinder (1) on the lift arm. Put the master cylinder in a position
which is parallel to the ground.

HYDRAULIC TANK WITH GUARD REMOVED


5. Hydraulic oil supply tank filler cap. 6. 5K3921 Air Relief Valve. 7. Bleed plug. 8. Tilt circuit oil line (rod ends).

12. Put air with 25 psi (1.8 kg/cm2) (172 kPa) through the air relief valve into the hydraulic system. It will be
necessary to put more air in the tank as most of the air will go out through the loosened lines.

13. Let the oil go out of lines (2) and (3) for 30 seconds more, after no air can be seen in the oil, then tighten
lines (2) and (3).

14. Open bleed plug (7) and let the air pressure out of the tank. Tighten bleed plug.

15. When the air is out of the hydraulic tank remove air relief valve (5) and install the plug in the line to the

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tilt cylinders.

16. Install master cylinder (1). Make an adjustment of the stroke for the master cylinder for correct lift
kickout.

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