992K Wheel Loader Electrohydraulic System Caterpillar

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Personal injury can result from hydraulic oil pressure and hot oil. Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic system. Make sure all of the attachments have been lowered, oil is cool before removing any components or lines. Remove the oil filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand.

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Dry nitrogen is the only gas approved for use in the accumulators. The charging of oxygen gas in an accumulator will cause an explosion. An explosion can be eliminated by using nitrogen gas cylinders with standard CGA (Compressed Gas Association, Inc.) No. 580 connectors. When nitrogen gas is ordered, make sure to order the cylinders with CGA No. 580 connectors. Do not rely on color codes or other methods of identification to tell the difference between nitrogen and oxygen cylinders. In any application, never use an adapter to connect your nitrogen charging group to a valve outlet used on both nitrogen, oxygen, or other gas cylinders. BE SURE YOU USE DRY NITROGEN (99.8% purity).

Illustration 1	g02714940
Location of ride control switch

Machine Preparation

Prepare the machine for testing by completing the procedure that is specified in the Service Manual module Testing and Adjusting, "Machine Preparation for Troubleshooting" for the machine that is being serviced.

Discharging the Accumulator

Illustration 2	g06220436
Accumulator Valve (1) Guard (2) Charging Valve (A) Protective Cap

1. Remove Guard (1) which protects the nitrogen charging valve (2).

2. Remove the protective cap (A) on the nitrogen charging valve (2)

Accumulator equipped with 158-2336 Gas Valve

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Illustration 3	g06220439
158-2336 Gas Valve (A) Cap (B) Nut (C) nut

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Illustration 4	g06220444
158-2336 Gas Valve (A) Cap (B) Nut (C) Nut

1. Hold the hex nut at location (C) of the nitrogen charging valve with one wrench. Turn the hex nut at location (B) with a second wrench in a counterclockwise direction. Loosening the nut opens the nitrogen charging valve (2). Three turns will fully open the valve. The compressed gas will be released from the ride control accumulator. Now, the ride control accumulator can be removed from the machine.

Accumulator equipped with 222-2367 Gas Valve Assembly

Illustration 5	g02614762
222-2367 Gas Valve Assembly

Illustration 6	g00282185
(3) Nipple (4) Coupling assembly (5) Pressure gauge (6) Hose assembly (7) Coupling assembly (8) Nipple (9) Valve (10) Pressure gauge (11) Regulator assembly (12) Pressure regulating screw (13) Chuck for the nitrogen cylinder valve (14) Valve handle (15) Chuck (16) Hose assembly (17) Tee

1. Identify the correct nitrogen charging chuck.

2. Attach hose assembly (16) to nitrogen charging chuck (15)

3. Turn on the valve handle (14) of the nitrogen charging chuck (15) all the way in the counterclockwise direction.

   Note: Turning the valve handle will ensure that nitrogen charging valve (2) will not be opened when nitrogen charging chuck (15) is attached to nitrogen charging valve (2).

4. Attach nitrogen charging chuck (15) and hose assembly (16) to nitrogen charging valve (2)

5. Place the open end of hose assembly (16) away from the work area and away from other personnel.

6. Turn on the valve handle (14) of the nitrogen charging chuck (15) all the way in the clockwise direction to open nitrogen charging valve (2), Turning the valve handle will release all the nitrogen from the accumulator through hose assembly (16). Remove the hydraulic lines from the accumulator. Now, the accumulator can be removed from the machine.

Testing Procedure for the Accumulator Precharge Pressure

Illustration 7	g00282185
(3) Nipple (4) Coupling assembly (5) Pressure gauge (6) Hose assembly (7) Coupling assembly (8) Nipple (9) Valve (10) Pressure gauge (11) Regulator assembly (12) Pressure regulating screw (13) Chuck for the nitrogen cylinder valve (14) Valve handle (15) Chuck (16) Hose assembly (17) Tee

Note: Test the accumulator precharge pressure when the machine is not running and the work tool is flat on the ground. The pressure in the hydraulic system must be released. The released pressure will ensure that the accumulator piston has shifted to the oil end of the accumulator.

1. Remove guard (1) which protects nitrogen charging valve (2).

2. Remove the protective cap on nitrogen charging valve (2).

3. Identify the correct nitrogen charging chuck.

4. Turn the handle for valve (14) of the nitrogen charging chuck (15) all the way in the counterclockwise direction.

5. Attach nitrogen charging chuck (15) and hose assembly (16) to nitrogen charging valve (2).

6. Attach hose assembly (16) between nitrogen charging chuck (15) and tee (17). Install needle valve (9) on tee (17), as shown. Install an 8T-0858 Pressure Gauge in the remaining open port on the tee. The pressure gauge is rated at 0 to 16000 kPa (0 to 2300 psi).

7. Turn the valve handle for needle valve (9) all the way in the clockwise direction. Completely turning the valve handle will ensure that the needle valve (9) is closed.

8. Open nitrogen charging valve (2)
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   Illustration 8	g06220439
   158-2336 Gas Valve (A) Cap (B) Nut (C) Nut

   1. Accumulators equipped with a 158-2336 Gas Valve, hold the hex nut at location (C) of the nitrogen charging valve with one wrench. Turn the hex nut location (B) with a second wrench in a counterclockwise direction. Loosening the nut opens the nitrogen charging valve (2). Three turns will fully open the valve.
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      Illustration 9	g02614762
      222-2367 Gas Valve Assembly

   2. Accumulators equipped with a 222-2367 Gas Valve Assembly, turn valve handle (14) in the clockwise direction to open accumulator valve (2).

9. Read pressure gauge (10) to determine the charge pressure in the accumulator. The pressure reading should be 5000 kPa (725 psi) at 21 °C (70 °F).

   Note: If the machine has been running for some time, the ambient temperature of the accumulator may be different from the outside air temperature. Refer to Table 2 for the proper pressure.

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   Table 2

   Accumulator Precharge Pressure/Temperature Relationship for a Typical Accumulator with a Precharge of 5000 kPa (725 psi)
   Temperature	Pressure
   −7 °C (20 °F)	4530 kPa (657 psi)
   −1 °C (30 °F)	4624 kPa (671 psi)
   4 °C (40 °F)	4717 kPa (684 psi)
   10 °C (50 °F)	4810 kPa (698 psi)
   16 °C (60 °F)	4905 kPa (711 psi)
   21 °C (70 °F)	5000 kPa (725 psi)
   27 °C (80 °F)	5092 kPa (739 psi)
   32 °C (90 °F)	5185 kPa (752 psi)
   38 °C (100 °F)	5198 kPa (754 psi)
   43 °C (110 °F)	5270 kPa (764 psi)
   49 °C (120 °F)	5364 kPa (778 psi)

10. Proceed to Step 11 if the accumulator precharge pressure is within the specification.

    You will need to charge the accumulator if the pressure is not within the specification. Proceed to the "Charging Procedure" for instructions to charge the accumulator.

11. Close nitrogen charging valve (2).
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    Illustration 10	g06220446
    158-2336 Gas Valve (B) Nut

    1. Accumulators equipped with a 158-2336 Gas Valve , with a wrench, tighten hex nut at location (B) of the nitrogen charging valve in a clockwise direction to close the nitrogen charging valve (2). Tighten the hex nut at to a torque of 8.8 ± 2 N·m (6.5 ± 1.5 lb ft)
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       Illustration 11	g02614762
       222-2367 Gas Valve Assembly

    2. Accumulators equipped with a 222-2367 Gas Valve Assembly, turn valve handle (14) in a counterclockwise direction to close nitrogen charging valve (2).

12. Turn on the handle for needle valve (9) in a counterclockwise direction. Turning the handle will allow the pressure in hose (16) to vent.

13. Remove Tool (A) from the machine.

14. Install the protective cap on nitrogen charging valve (2).

15. Install guard (1) on the accumulator.

Charging Procedure

Illustration 12	g06220436
Accumulator Valve (1) Guard (2) Charging Valve (A) Protective Cap. (1) Guard (2) Charging Valve (A) Protective Cap

Illustration 13	g00282185
(3) Nipple (4) Coupling assembly (5) Pressure gauge (6) Hose assembly (7) Coupling assembly (8) Nipple (9) Valve (10) Pressure gauge (11) Regulator assembly (12) Pressure regulating screw (13) Chuck for the nitrogen cylinder valve (14) Valve handle (15) Chuck (16) Hose assembly (17) Tee

Before proceeding to the test procedure that follows, complete the procedure:

• Testing and Adjusting, "Machine Preparation for Troubleshooting"

1. Perform Step 1 through Step 9 of the "Testing Procedure for the Accumulator Precharge Pressure" for instructions on the installation of the nitrogen charging group.

2. Turn the ride control ON and place into "SERVICE" mode.

   1. Set the parking brake.

   2. Press and hold the ride control button for 10 seconds. The keypad will indicate that the ride control is in service mode by flashing all three ride control indicator lights. The indicator light will turn to an amber color while in the service mode.

3. Open needle valve (9).

4. Start the engine.

5. Pull back on the lift control lever to raise the boom to full lift.

6. Recenter the lift control lever.

7. Pull back on the lift control lever again. Pulling back on the control lever will cause the lift circuit to reach relief pressure.

8. Close needle valve (9).

9. Lower the boom to place the work tool on the ground.

10. Move the lift control lever into the FLOAT position (past detent) and release.

11. Attach the open end of hose assembly (6) to needle valve (9) by using coupling (7) and nipple (8).

12. Attach regulator assembly (11) to a nitrogen tank.

13. Adjust pressure regulating screw (12) to obtain a pressure reading of 5000 ± 70 kPa (725 ± 10 psi) on gauge (5).

    Note: 5000 ± 70 kPa (725 ± 10 psi) is the appropriate pressure for the accumulator when the ambient temperature is 21 °C (70 °F). If the machine has been running for some time, the temperature of the accumulator may be different from the ambient temperature of the outside air. Refer to Table 2 for the proper pressure.

14. Open needle valve (9). Measure the amount of time that is required for gauge (10) to obtain the charge pressure. Charging time should take 10 to 20 seconds.

    Note: If the charging time is less than 10 seconds, repeat Step 1 through Step 8 to exhaust the nitrogen gas from the accumulator. Repeat Steps 9 through 14 to charge the accumulator.

15. Once the accumulator is charged, close the nitrogen charging valve.
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    Illustration 14	g06220447
    158-2336 Gas Valve (A) Cap (B) Nut

    1. Accumulators equipped with a 158-2336 Gas Valve, with a wrench, tighten hex nut at location (B) of the nitrogen charging valve in a clockwise direction to close the nitrogen charging valve (2). Tighten the hex nut to a torque of 8.8 ± 2 N·m (6.5 ± 1.5 lb ft)
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    Illustration 15	g02614762
    222-2367 Gas Valve Assembly

16. Accumulators equipped with a 222-2367 Gas Valve Assembly, turn valve handle (14) in a counterclockwise direction to close nitrogen charging valve (2).

17. Close the valve on the nitrogen cylinder.

18. Slowly loosen chuck (15) from accumulator valve (2) and allow the pressure to vent from hose (16). Observe gauge (10) to determine when the pressure has been released from hose (16).

19. Remove chuck (15) from accumulator valve (2).

20. Install the protective cap (A) on accumulator valve (2).

21. Install guard (1).

22. Use the ride control button.

    1. Press the ride control button once and the ride control system will turn off. The indicator light will turn off.

    2. Press and release the ride control button. The ride control system will now be in "AUTO" mode.

    3. The middle indicator light will be illuminated while the ride control is in this position.

    4. The LED on the indication module will also become illuminated green.

Diverter Valve Test

Note: The following steps are used to determine if the diverter valve is operating correctly. This test should be performed to verify that the ride control is being activated.

1. Lift the front wheels off the ground by moving the bucket to the full LOWER position. With the front wheels off the ground, place the lift control lever in the HOLD position.

2. Turn the ride control ON and place into "SERVICE" mode.

   1. Set the parking brake.

   2. Press and hold the ride control button for 10 seconds. The keypad will indicate that the ride control is in service mode by flashing all three ride control indicator lights. The indicator light will turn to an amber color while in the service mode.

      Note: The front wheels should lower to the ground. If the wheels do not lower to the ground, the diverter spool has not shifted to the ON position. The following causes could be the reason that the diverter spool does not move to the ON position:

      • a failure of the solenoid coil on the diverter valve

      • a failure of the cartridge valve in diverter valve

      • a failure of the spool valve in the diverter valve

      • a blockage in pilot circuit to the diverter valve

Road Test

Note: The pressure of the procedure in Step 9 of the "Testing Procedure for the Accumulator Precharge Pressure" is the recommended pressure for machines with a bucket of typical weight and average payload.

Machines with heavy buckets and large payloads may need an increase in the nitrogen charge pressure. With the ride control switch in the ON position, The increase in nitrogen charge pressure will keep the piston in the accumulator from contacting the stop during normal roading.

Note: Raising the nitrogen charge pressure will result in a stiffer ride.

1. Place a typical payload in the bucket.

2. Use the ride control button.

   1. Press the ride control button once and the ride control system will turn off. The indicator light will turn off.

   2. Press and release the ride control button. The ride control system will now be in "AUTO" mode.

   3. The middle indicator light will be illuminated while the ride control is in this position.

   4. The LED on the indication module will also become illuminated green.

3. Drive the machine over a fairly rough road surface.

4. If the ride is too soft or a noise is heard from contact between the piston and the stop, the nitrogen charge pressure must be increased.

   Note: The ride control accumulators are rated up to 34500 kPa (5004 psi).

5. If the ride is too soft return to Step 9 of the "Testing Procedure for the Accumulator Precharge Pressure" procedure and increase the accumulator charge pressure by 345 kPa (50 psi). Perform the road test again. Add sufficient nitrogen to obtain a suitable ride for the payload of the machine.