sistema electrohidraulico[1]..pdf
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Service Training
SERV2682-01
December 2002
TEXT REFERENCE
PART OF TECHNICAL INSTRUCTION MODULE SERV2682-01
988G WHEEL LOADER
IMPLEMENT HYDRAULIC SYSTEM
SUPPLEMENTAL INFORMATION
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TABLE OF CONTENTS
Visuals PageIntroduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 . . . . . . . . . . . . 3
Electro-Hydraulic Implement System Block Diagram . . . . . . . . . . . . . . . . . . . . . . . .2 . . . . . . . . . . . . 4
Electro-Hydraulic Implement System Components . . . . . . . . . . . . . . . . . . . . . . . . . . .3 . . . . . . . . . . . . 5
Electro-Hydraulic Implement System Block Diagram . . . . . . . . . . . . . . . . . . . . . . .14 . . . . . . . . . . . . 6
Implement Electronic Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 . . . . . . . . . . . . 7
Implement Pump Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34-36 . . . . . . . . . . . . 8
Radiator and Hydraulic oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50 . . . . . . . . . . . 11
Air-to-Air Aftercooler (ATAAC) and Air Conditioning Condenser . . . . . . . . . . . . .51 . . . . . . . . . . . 12
Fan Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57 . . . . . . . . . . . 13
Implement Control Strategy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58 . . . . . . . . . . . 14
Implement System Calibrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59-72 . . . . . . . . . . . 16
Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73 . . . . . . . . . . . 31
Visual List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
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Introduce course
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INTRODUCTION
This presentation and the "988G Wheel Loader Hydraulic Systems
Operation" Service Manual module (Form RENR2170) discuss the
component locations, systems operation, and calibration procedures for
the Implement Hydraulic System and Fan Drive System on the 988G
Wheel Loader.
This presentation includes implement hydraulic system supplemental
information not included in the Systems Operation Service Manual
module. This information and the Service Manual module should be used
for preparation and self study.
The visuals in the Text Reference have numbers that correspond to the
visuals in the presentation. The visuals in SENR2170 are in order.
However, the visuals in SENR2170 have numbers that are different thanthose in the presentation. The instructor should refer to the visual itself
and not just the visual number when locating the information for a
particular visual.
998888GGWWHHEEEELLLLOOAADDEERR
IIMMPPLLEEMMEENNTTHHYYDDRRAAUULLIICCSSYYSSTTEEMM
2002 Caterpillar Inc.
Objectives 1 and 2
Visuals 1 - 23
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Brake charging valve
LIFTLEVER
SENSOR
TILTLEVER
SENSOR
LEFTLIFT
CYLINDER
RIGHTLIFT
CYLINDER
TILTCYLINDER
SHUTTLEVALVE
PRESSUREREDUCING
VALVE
PILOTPRESSURE
SUPPLYVALVE CHECK
VALVE
BUCKETKICKOUTDETENT
SOLENOID
IMPLEMENTLOCKOUTSWITCH
RAISE/LOWER/TILTKICKOUT SET
SWITCH
TILT LINKAGEPOSITION SENSOR
LIFT LINKAGEPOSITION SENSOR
ELECTRONICCONTROLMODULE
RAISEKICKOUTDETENT
SOLENOID
LOWERKICKOUTDETENT
SOLENOID
CATDATALINK
ELECTRO-HYDRAULICIMPLEMENT SYSTEM
IMPLEMENTCONTROL
VALVE
IMPLEMENTPUMP
PILOTRELIEFVALVE
RELIEFVALVE
CHECK VALVE
FILTER
BRAKE/PILOTPUMP
ELECTRONIC SYSTEM PILOT HYDRAULIC SYSTEM MAIN HYDRAULIC SYSTEM
LOOSEMATERIAL
SWITCH
BALLVALVE
BRAKECHARGING
VALVE
Electro-Hydraulic Implement System Block Diagram
This schematic has been updated to include the brake charging valve,
which provides oil from the brake/pilot pump to the implement pilot
hydraulic system.
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Manual lower ball
valve
IMPLEMENT
PUMP
BRAKE/PILOT
PUMP
IMPLEMENT PUMP
CONTROL VALVE
PILOT
RELIEF
VALVE
ELECTRONIC
CONTROL MODULE
IMPLEMENT CONTROL
LEVER MODULE
IMPLEMENT
CONTROL
VALVE
TILT
CYLINDER
HYDRAULIC
TANK
LIFT LINKAGE
POSITION SENSOR
LIFT
CYLINDER
TILT LINKAGE
POSITION SENSOR
PILOT
PRESSURE
SUPPLY
VALVE
PILOT
FILTER
ELECTRONIC SYSTEM
PILOT HYDRAULIC SYSTEM
MAIN HYDRAULIC SYSTEM
HYDRAULIC TANK
MANUAL
LOWER
BALL
VALVE
ELECTRO-HYDRAULIC IMPLEMENT SYSTEM COMPONENTS
Electro-Hydraulic Implement System Components
This profile of the 988G Wheel Loader implement system components
has been updated to include the manual lower ball valve location.
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Implement pump
pressure sensor
LIFT/LOWER/TILTKICKOUT SET SWITCH
IMPLEMENTLOCKOUT SWITCH
LIFT LINKAGEPOSITION SENSOR
TILT LEVERSENSOR
LIFT LEVERSENSOR
PILOT PRESSURE SUPPLYSOLENOID VALVE
BUCKET KICKOUT DETENT COIL
RAISE KICKOUT DETENT COIL
LOWER KICKOUT DETENT COIL
IMPLEMENT PUMP SOLENOID
TILT RACK BACK SOLENOID
TILT DUMP SOLENOID
LIFT LOWER SOLENOID
LIFT RAISE SOLENOID
CAT DATA LINK
IMPLEMENT ELECTRONICCONTROL MODULE (ECM)
IMPLEMENT ELECTRONICCONTROL SYSTEM
INPUT COMPONENTS OUTPUT COMPONENTS
LOOSE MATERIALMODE SWITCH
TILT LINKAGEPOSITION SENSOR
IMPLEMENT PUMPPRESSURE SENSOR
AXLE COOLINGBYPASS SOLENOID
LOOSE MATERIALMODE INDICATOR
ANALOG TO DIGITALCONVERTER
Implement Electronic Control System
This diagram has been updated to include the following components:
Implement pump pressure sensor: This sensor sends an implement
pump output pressure analog signal to the analog to digital converter. The
signal is converted to digital and sent to the Implement ECM.
Axle cooling bypass solenoid: This solenoid allows axle oil to bypass
the fan motor and rear oil cooler when the axle oil is below a certaintemperature.
Loose material mode indicator: Illuminates to indicate that the loose
material mode is ON.
INSTRUCTOR NOTE: This visual is illustration No. 23 in the "988G
Wheel Loader Hydraulic System Operation" Service Manual module
(From RENR2170).
Loose material mode
indicator
Axle cooling bypass
solenoid
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UPSTROKE
IMPLEMENT PUMP CONTROL VALVEUPSTROKE
CASEDRAIN
FLOW CONTROLVALVE SPOOL
FLOW CONTROLVALVE SLEEVE
TO LARGE ENDOF ACTUATOR
FEEDBACKLEVER
HIGH PRESSURECUTOFF SPOOL
SIGNAL OILFROM RESOLVER
FROM PUMPSOLENOID
Implement Pump Control Valve
This view shows the oil flow in the implement pump control valve during
implement pump UPSTROKE. When the machine is started and system
pressure increases, signal oil from the ball resolver flows to the small end
of the actuator (in the pump) to upstroke the pump.
In the pump control valve, the signal oil is blocked at the high pressure
cutoff spool. The signal oil also flows to the flow control valve. Spring
force holds the flow control valve spool to the right, which blocks thesignal oil from flowing to the large end of the actuator (in the pump).
Oil from the large end of the actuator is directed through the flow control
valve to case drain.
When the actuator (in the pump) upstrokes the pump, the feedback lever
causes the flow control valve sleeve to move to the right against spring
force and in the same direction as the flow control valve spool. The
sleeve and valve spool meter oil flow to and from the large end of the
actuator to limit actuator movement.
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Mechanical/hydraulic
DESTROKE
IMPLEMENT PUMP CONTROL VALVEMECHANICAL/HYDRAULIC DESTROKE
TO LARGE ENDOF ACTUATOR
FEEDBACKLEVER
HIGH PRESSURECUTOFF SPOOL
CASEDRAIN
FLOW CONTROLVALVE SPOOL
FLOW CONTROLVALVE SLEEVE
SIGNAL OILFROM RESOLVER
FROM PUMPSOLENOID
The implement pump control valve also provides a mechanical/hydraulic
pump DESTROKE.
When the pump UPSTROKES, the feedback lever moves the flow control
valve sleeve to the right. When the pump upstrokes to the maximum flow
position, signal oil from the resolver is directed past the flow control valve
to the stationary high pressure cutoff spool. The signal oil is sent through
another passage to the large end of the actuator (in the pump), which
causes the pump to DESTROKE.
The sleeve and valve spool meter oil flow to and from the large end of the
actuator to maintain the actuator position.
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Electronic DESTROKE
IMPLEMENT PUMP CONTROL VALVEELECTRONIC DESTROKE
TO LARGE ENDOF ACTUATOR
FEEDBACKLEVER
HIGH PRESSURECUTOFF SPOOL
CASEDRAIN
FLOW CONTROLVALVE SPOOL
FLOW CONTROLVALVE SLEEVE
SIGNAL OILFROM RESOLVER
FROM PUMPSOLENOID
During certain machine conditions, which will be explained later, the
Implement ECM will electronically destroke the pump to decrease the
pump flow and the load on the engine. The pump solenoid valve is
ENERGIZED by the Implement ECM. The pump solenoid valve directs
pilot oil to the right end of the slug which presses against the flow control
spool and the spool moves to the left against spring force. The pump
solenoid can be modulated by the Implement ECM to vary the pressure
against the slug.
Signal oil at the flow control valve is directed to the large end of the
actuator (in the pump), which causes the pump to DESTROKE.
When the actuator destrokes the pump, the feedback lever causes the flow
control valve sleeve to move to the left in the same direction as the flow
control valve spool. The sleeve and valve spool meter oil flow to and
from the large end of the actuator to maintain the actuator position. The
pump solenoid valve controls the amount of destroke by controlling the
pressure to the right end of the slug.
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1. AMOCS radiator
2. Hydraulic oil cooler
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Radiator and Hydraulic Oil Cooler
This view shows the AMOCS radiator (1) and hydraulic oil cooler (2)
installed in the radiator housing.
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Air-to-Air Aftercooler and Air Conditioning Condenser
This view shows the air-to-air after cooler ATAAC (1) and air
conditioning condenser (2) installed in the radiator housing.1. ATAAC
2. Air conditioning
condenser
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Fan drive hydraulic
system:
- HIGH PRESSURE
CUTOFF
WAXCAPSULE
BYPASS VALVE
FANPUMP
FANMOTOR
CHECKVALVEFAN
OILCOOLERBYPASS
VALVEFAN DRIVE SYSTEMHIGH PRESSURE CUTOFF
DESTROKE
ACTUATOR
FLOWCONTROL
SPOOL
PRESSURECUTOFFSPOOL
FLOW/PRESSURECOMPENSATOR VALVE
Fan Drive System
The pressure cutoff spool limits the maximum system pressure for any
given pump displacement. The pressure cutoff spool is held in the left
position during normal operation by spring force.
When fan hydraulic system pressure is at maximum, pump supply
pressure increases and the pressure cutoff spool moves right against spring
force. The pressure cutoff spool directs supply oil to the destroke actuator
piston.
The increase in pressure allows the destroke actuator piston to overcome
the combined force of the upstroke actuator piston and spring to destroke
the pump. The pump is now at minimum flow and pump supply pressure
is at maximum. This condition is maintained to control maximum fan
speed.
This feature eliminates the need for a main relief valve in the fan
hydraulic system. Maximum system pressure is adjusted by turning the
pressure compensator adjustment screw.
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Implement control
strategy features:
- Dig trigger
- Loose material mode
- Tilt back structural
protection
- Tilt dump structural
protection
- FRAC
- Lower feather catch
- Float
- Lift snubbing
- Raise inversion with
FDLAC
IMPLEMENT CONTROL STRATEGY Dig Trigger Loose Material Mode Tilt Rack Structural Protection Tilt Dump Structural Protection FRAC Lower Feather Catch
Float Lift Snubbing Raise Inversion With FDLAC
Implement Control Strategy
The 988G Wheel Loader implement control strategy consists of the
following features:
Dig Trigger: The pump is destroked to 60% and the Power train Torque
Strategy is active when the machine is in first gear forward and the boom
is below horizontal.
Loose Material Mode: When the loose material mode is activated andthe machine goes into Dig Trigger, the pump produces maximum flow and
the Power Train Torque Strategy is still active.
Tilt Back and Tilt Dump Structural Protection: The spool command is
limited when the linkage is close to contacting the tilt back or dump stops,
or bottoming out the cylinder.
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Full Rack Angle Control (FRAC): During lifting, the Implement ECM
automatically adjusts the bucket angle in the dump direction when the
boom is slightly above horizontal to prevent spillage and maintain a level
bucket.
Lower Feather Catch: Brings the linkage to a smooth stop when a
lower command is abruptly stopped.
Float: Occurs when the boom is below horizontal and the lever is moved
into lower detent. (used for dozing and cleanup).
Lift Snubbing: When the boom is at the maximum lift position and the
lift lever is moved to hold and back to raise, lift snubbing is cancelled
resulting in main relief pressure in the head end of the lift cylinders. This
procedure can be used for checking main relief pressure and implement
stall conditions. The implement hydraulic service mode eliminatessnubbing.
Raise Inversion with Full Dump Lift Angle Control (FDLAC): The
raise command is limited when the bucket is against the dump stops to
prevent excessive stress on the dump stops and linkage pins.
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IMPLEMENT SYSTEM CALIBRATIONS
Lever Sensors Linkage Sensors
Implement Valve Solenoids
Implement System Calibrations
Implement system calibrations consists of lift and tilt lever sensor
calibrations, lift and tilt linkage sensor calibrations, and implement pilot
valve solenoid calibrations. Calibrations must be performed in the order
listed in this visual.
The sensor calibrations determine the minimum and maximum sensor
duty cycles associated with the respective minimum and maximum
linkage and lever angles.
A sensor calibration must be performed for any of the following reasons:
Sensor replaced
ECM replaced
Required by a service code
Sensor calibration
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The solenoid calibration determines the current required to initiate
movement of the pilot valve spool to allow oil flow and initiate movement
of the main control spool. The main spool shifts until pressure increases
enough to initiate the movement of the implement in a desired direction.
When the operator moves the implement lever during normal operation,
the Implement ECM begins energizing the corresponding solenoid with
the calibrated current level. Using the calibrated current level to initiate
movement results in consistent implement movement and helps to
eliminate the deadband (free travel) in the implement control levers.
A solenoid calibration must be performed for any of the following
reasons:
Solenoid replaced
ECM replaced
Required by a service code
The implement system calibrations can be performed using the Caterpillar
Monitoring System and the 4C-8195 Control Service Tool or the
Caterpillar Electronic Technician (ET) Service Tool.
INSTRUCTOR NOTE: For more information on implement system
calibrations, refer to the Service Manual module "988G Wheel
Loader Hydraulic System Troubleshooting Testing and Adjusting"
(Form RENR2171).
Solenoid calibration
Calibration methods
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Interior of cab:
1. 4C-8195 Control
Service Tool
2. Service connector
3. Display window
4. Machine service
connector
Implement system calibrations can be performed by entering the
Caterpillar Monitoring System Calibration mode. The 4C-8195 Control
Service Tool (1) allows the proper electrical connection at the service
connector (2) to perform the calibration procedures.
The display window (3) of the Caterpillar Monitoring System main
display module shows the calibration codes.
Also visible in this view is the machine service connector (4), which
provides the connection point for the ET Service Tool.
INSTRUCTOR NOTE: The Caterpillar Monitoring System access
procedures are found in the Service Manual module "Caterpillar
Monitoring System Operation, Testing and Adjusting"
(Form SENR1394).
1
2
4
3
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Calibration codes:
- Calibration submode
number
- Calibration step
number
- Calibration error
codes
CALIBRATIONSUBMODE
CALIBRATIONSTEP NUMBER
CALIBRATIONERROR CODES
CALIBRATION CODES
The calibration codes displayed in the Caterpillar Monitoring System
display window are six digit codes. The six digits are divided into three
two-digit fields.
The first two digits provide the calibration submode number. In this view,
"61" indicates tilt linkage position sensor calibration mode.
The center two digits are the calibration step number. In this view, step
number five is displayed.
The last two digits are used for calibration error codes. When no error
codes are present, the last two digits are blank.
NOTE: For more information on calibrations codes, refer to the
Service Manual module "988G Wheel Loader Hydraulic System
Troubleshooting Testing and Adjusting" (Form RENR2171).
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Calibrations using the
ET Service Tool
Implement system calibrations can also be performed using the ET
Service Tool. In this view of the the ET Service Tool screen, the ET
Service tool is connected with the machine.
To perform implement system calibrations, select the bottom menu item
"Implement 988G."
The menu shown is the ECM selection menu, which is displayed when ET
first establishes connection to the various ECMs on the machine. Thismenu can be accessed using the "Data Link" pull down menu and clicking
on "Select ECM", if ET is already in use.
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Calibrations menu:
- Lift linkage sensor
calibration
- Tilt linkage sensor
calibration
- Implement valve
solenoid calibration
- Lever calibrations
Once the Implement ECM has been selected, select the "Service" menu
and then the calibrations menu. The following items can be found under
the "Calibrations" menu:
Lift linkage sensor calibration
Tilt linkage sensor calibration
Implement valve solenoid calibration
Lever calibrations
This view also displays the available ECMs on the machine, information
about the machine components and the ET software version.
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Calibration successful This view shows successful calibration of the lift linkage sensor. The ET
Service Tool checks each step after the technician successfully performs
the step. The check marks indicate that all the steps were performed.
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Implement valve
solenoid calibration
An implement valve solenoid calibration can be selected. This calibration
is performed to determine the amount of current required to initiate
movement of the implement for each solenoid. The Implement ECM uses
the current value obtained during this calibration as a starting point when
the implements are used. Using the preset value to begin movement
ensures smooth movement from the HOLD position.
NOTE: Performing the implement valve solenoid calibration is
similar to setting the pilot initiation pressure on a pilot operated (nonelectro-hydraulic) implement system.
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Lift lever calibrations From this screen, the lift lever calibrations can be selected. This view
shows that the lift lever calibration has been selected.
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Tilt lever calibration This screen shows the tilt lever calibration in process. The
"ATTENTION" message on the screen provides information to the
technician before completing the next step.
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Diagnostic tests Diagnostic tests can be performed on the implement electronic control
system. At this time, only the main implement relief test can be
performed.
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Machine configuration
information
This screen displays machine configuration information and the status of
various machine functions.
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Implement lift circuit
status
The implement lift circuit electronic components preset group 2 status is
displayed as follows:
The implement lockout switch is not locked.
The lift lever is positioned completely forward (100%)
The lift cylinder is extended 354 mm
The lift link sensor has moved 38% from maximum position
The raise solenoid current is 1.953 amps
The lower solenoid current is 0 amps
The implement pump pressure is 1080 psi
The ET user can setup groups as desired.
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Logged diagnostic
codes
This screen displays the logged diagnostic codes for the 988G Wheel
Loader. The codes are listed in numeric order by machine system.
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CONCLUSION
This presentation has provided 988G Wheel Loader implement system
supplemental information. This information should be used in
conjunction with the "988G Wheel Loader Hydraulic Systems Operation"
Service Manual module.
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VISUAL LIST
1. Model view
2. Electro-Hydraulic implement system
block diagram
3. Electro-Hydraulic implement system
components
4. Pump compartment
5. Components above implement pump
6. Hydraulic oil filters
7. Pilot control actuators
8. Manual lower ball valve
9. Implement control valve
10. Hydraulic tank11. Components on front of hydraulic tank
12. Pilot on/off valve
13. Ride control valve
14. Electro-Hydraulic implement system
block diagram
15. Implement electronic control system
block diagram
16. Lift and tilt cylinders
17. Electronics bay
18. Implement control levers19. Tilt lever sensor
20. Lift lever sensor
21. Kickout detent coil
22. Left overhead console switches
23. Right overhead console switches
24. Pilot control actuator (HOLD)
25. Pilot control actuator (LEFT
SOLENOID ENERGIZED)
26. Pilot control actuator (LEFT
ACTUATOR BALANCED)
27. Implement control valve (HOLD)
28. Implement control valve (LOWER)
29. Implement pump cutaway
30. Pump control valve cutaway
31. Pump and control valve operation
32. Pump and control valve operation
(UPSTROKE)
33. Pump and control valve operation
(ELECTRONIC DESTROKE)
34. Implement pump control valve cutaway
(UPSTROKE)
36. Implement pump control valve cutaway
(MECHANICAL/HYDRAULIC
DESTROKE)
35. Implement pump control valve cutaway
(ELECTRONIC DESTROKE)
37. Implement hydraulic system (HOLD)
38. Implement hydraulic system (TILT
BACK)39. Implement hydraulic system (RAISE)
40. Implement hydraulic system (LOWER)
41. Implement hydraulic system (FLOAT)
42. Implement hydraulic system (LOWER
ENGINE OFF)
43. Implement hydraulic system (MANUAL
LOWERING)
44. Implement hydraulic system (RIDE
CONTROL ON)
45. Ride control switch46. Ride control valve
47. Ride control accumulator
48. Fan pump
49. Fan motor
50. Radiator
51. ATAAC
52. Wax capsule valve
53. Fan system case drain oil filter
54. Fan hydraulic drive system (LOW
PRESSURE)
55. Fan hydraulic drive system
(UPSTROKE)
56. Fan hydraulic drive system
(DESTROKE)
57. Fan hydraulic drive system (HIGH
PRESSURE CUTOFF)
58. Implement control strategy
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VISUAL LIST
59. Implement system calibrations
60. Service connector and 4C8195 Control
Service Tool
61. Calibration codes
62. ET Service Tool calibrations
63. Calibrations menu
64. Lift linkage sensor calibration
65. Implement valve solenoid calibration
66. Implement dump valve calibration
67. Lift lever calibrations
68. Tilt lever calibration
69. Diagnostic tests
70. Machine configuration information
71. Implement lift circuit status
72. Logged diagnostic codes
73. Model view