Service Training

MALAGA

992G WHEEL LOADER

6. STEERING & BRAKES

1. Components Layout
2. Operation
3. Testing & Adjusting

Adolfo
OCTOBER 1997
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6-2

STEERING SYSTEM COMPONENTS

STEERING PILOT PILOT PILOT RELIEF DUAL PILOT STEERING PILOT

PUMP PUMP FILTER VALVE CHECK VALVE CONTROL VALVE

NEUTRALIZER
VALVES

CHAPTER : STEERING & BRAKES

992G WHEEL LOADER

STEERING
CONTROL STEERING AND STEERING
VALVE BRAKE TANK CYLINDERS

PILOT SYSTEM MAIN HYDRAULIC SYSTEM COMMON TO MAIN AND PILOT SYSTEMS
Page:
CONTROL
LEVER
STEERING HYDRAULIC SYSTEM
6-3

HOLD
PILOT CONTROL
VALVE

PILOT NEUTRALIZER NEUTRALIZER

PUMP VALVE VALVE
FILTER

PILOT DUAL
RELIEF CHECK CHECK
VALVE VALVE VALVE

CHAPTER : STEERING & BRAKES

992G WHEEL LOADER

STEERING PUMP CHECK
COOLER VALVE

CONTROL
VALVE

STEERING
CYLINDERS

TANK
 992G WHEEL LOADER
CHAPTER : STEERING & BRAKES

COMPONENTS

STEERING PILOT PUMP IMPLEMENT FIXED PUMP

STEERING PUMP MAIN STEERING PUMP

COMPENSATOR VALVE

Page: 6-4
 992G WHEEL LOADER
CHAPTER : STEERING & BRAKES

COMPONENTS

LEFT FRAME STEERING PILOT FILTER

PILOT RELIEF VALVE STEERING CONTROL VALVE

Page: 6-5
 992G WHEEL LOADER
CHAPTER : STEERING & BRAKES

COMPONENTS

STICK CONTROL LEVER

STIC STEERING AND STEERING PILOT

TRANSMISSION LOCK LEVER CONTROL VALVE

Page: 6-6
 992G WHEEL LOADER
CHAPTER : STEERING & BRAKES

COMPONENTS

NEUTRALIZER VALVES PARKING BRAKE VALVE

ADJUSTABLE STRIKERS

Page: 6-7
Page:

STEERING PUMP AND

COMPENSATOR VALVE
6-8

LOW PRESSURE STANDBY

SWASHPLATE

MINIMUM ANGLE
STOP
MAXIMUM ANGLE
STOP

CHAPTER : STEERING & BRAKES

SMALL
ACTUATOR PISTON

992G WHEEL LOADER

CONPENSATOR VALVE LARGE
ACTUATOR
PISTON
CHARGE
FROM STEERING PUMP
CONTROL VALVE

FLOW PRESSURE
COMPENSATOR COMPENSATOR
SPOOL SPOOL
Page:

STEERING PUMP AND

COMPENSATOR VALVE
6-9

UPSTROKE

SWASHPLATE

MINIMUM ANGLE
STOP
MAXIMUM ANGLE
STOP

SMALL

CHAPTER : STEERING & BRAKES

ACTUATOR PISTON

992G WHEEL LOADER

CONPENSATOR VALVE LARGE
ACTUATOR
PISTON
FROM STEERING CHARGE
CONTROL VALVE PUMP

FLOW PRESSURE
COMPENSATOR COMPENSATOR
SPOOL SPOOL
 992G WHEEL LOADER
CHAPTER : STEERING & BRAKES

COMPONENTS

SELECTOR VALVE

CROSSOVER RELEF VALVE STEERING CONTROL

VALVE

Page: 6-10
Page:
6-11

STEERING
CYLINDERS STEERING SYSTEM
STEERING CONTROL VALVE
HOLD
DIVERTER
SHUTTLE VALVE
VALVE

LINE
RELIEF SECONDARY
VALVE CONTROL BACK-UP
SPOOL RELIEF
RELIEF VALVE
VALVE

PRESSURE COMPENSATOR
REDUCING VALVE

CHAPTER : STEERING & BRAKES

VALVE SECONDARY
PUMP
DUAL
CHECK PILOT
RELIEF

992G WHEEL LOADER

VALVE
VALVE
STEER STEER
CONTROL LEVER
VALVE

FILTER
COOLER
SELECTOR STEERING
VALVE PUMP FLUID
SAMPLING
PORT
RIGHT LEFT
NEUTRALIZER NEUTRALIZER

PILOT
TANK PUMP
Page:
6-12

STEERING
CYLINDERS STEERING SYSTEM
STEERING CONTROL VALVE
GRADUAL RIGHT TURN
DIVERTER
SHUTTLE VALVE
VALVE

LINE
RELIEF SECONDARY
VALVE CONTROL BACK-UP
SPOOL RELIEF
RELIEF VALVE
VALVE

PRESSURE COMPENSATOR
REDUCING VALVE
VALVE SECONDARY
PUMP

CHAPTER : STEERING & BRAKES

DUAL
CHECK PILOT
VALVE RELIEF

992G WHEEL LOADER

VALVE
STEER STEER
CONTROL LEVER
VALVE

FILTER
COOLER
SELECTOR STEERING
VALVE FLUID
PUMP SAMPLING
PORT
RIGHT LEFT
NEUTRALIZER NEUTRALIZER

PILOT
TANK PUMP
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6-13

STEERING
CYLINDERS STEERING SYSTEM
STEERING CONTROL VALVE
SHARP RIGHT TURN
DIVERTER
SHUTTLE VALVE
VALVE

LINE
RELIEF SECONDARY
VALVE CONTROL BACK-UP
SPOOL RELIEF
RELIEF VALVE
VALVE

PRESSURE COMPENSATOR
REDUCING VALVE
VALVE SECONDARY

CHAPTER : STEERING & BRAKES

PUMP
DUAL
CHECK PILOT
VALVE RELIEF

992G WHEEL LOADER

VALVE
STEER STEER
CONTROL LEVER
VALVE

FILTER
COOLER
SELECTOR STEERING
VALVE PUMP FLUID
SAMPLING
PORT
RIGHT LEFT
NEUTRALIZER NEUTRALIZER

PILOT
TANK PUMP
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6-14

STEERING
CYLINDERS STEERING SYSTEM
STEERING CONTROL VALVE
GRADUAL RIGHT TURN
SECONDARY STEER
DIVERTER
SHUTTLE VALVE
VALVE

LINE
RELIEF SECONDARY
VALVE CONTROL BACK-UP
SPOOL RELIEF
RELIEF VALVE
VALVE

PRESSURE COMPENSATOR
REDUCING VALVE
VALVE SECONDARY
PUMP

CHAPTER : STEERING & BRAKES

DUAL
CHECK PILOT
VALVE RELIEF
VALVE

992G WHEEL LOADER

STEER STEER
CONTROL LEVER
VALVE

FILTER
COOLER
SELECTOR
VALVE STEERING FLUID
PUMP SAMPLING
PORT
RIGHT LEFT
NEUTRALIZER NEUTRALIZER

PILOT
TANK PUMP
Page:
6-15

BRAKE SYSTEM COMPONENTS

BRAKE BRAKE PARKING BRAKE PARKING BRAKE SERVICE BRAKE

PUMP ACCUMULATORS VALVE LEVER PEDALS

CHAPTER : STEERING & BRAKES

992G WHEEL LOADER

REAR SERVICE STEERING AND BRAKE PARKING MANIFOLD SERVICE BRAKE FRONT SERVICE
BRAKES TANK BRAKE VALVE BRAKES

Service Brake Components Parking Brake Components Shared by Service and Parking Systems
Page:
6-16

BRAKE HYDRAULIC SYSTEM

BRAKE
VALVE

REAR BRAKE
ACCUMULATOR

FRONT BRAKE
ACCUMULATOR

CHAPTER : STEERING & BRAKES

MANIFOLD MANIFOLD

992G WHEEL LOADER

CHECK
VALVE

PUMP
CHECK REAR FRONT
VALVE PARKING BRAKE BRAKE
BRAKE PARKING
VALVE BRAKE
TANK
 992G WHEEL LOADER
CHAPTER : STEERING & BRAKES

BRAKE SYSTEM COMPONENTS

BRAKE PUMP PUMP SERVO VALVE

DECK PLATE ACCUMULATORS

Page: 6-17
Page:
6-18

BRAKE PUMP
LOW PRESSURE

CONTROL PISTON SPRING

PUMP SERVO VALVE

BARREL

CONTROL PISTON

CHAPTER : STEERING & BRAKES

PASSAGE

992G WHEEL LOADER

OUTLET PASSAGE

DRIVE SHAFT

INLET PASSAGE

PISTON ASSEMBLY SWASHPLATE

Page:
6-19

PUMP SERVO VALVE

LOW BRAKE SYSTEM PRESSURE HIGH BRAKE SYSTEM PRESSURE

TO CONTROL FROM PUMP TO CONTROL FROM PUMP

PISTON OUTLET PISTON OUTLET

ADJUSTMENT ADJUSTMENT

CHAPTER : STEERING & BRAKES

BOLT BOLT

992G WHEEL LOADER

LOCKNUT PRESSURE COMPENSATOR SPOOL LOCKNUT PRESSURE COMPENSATOR SPOOL
Page:
6-20

BRAKE PUMP
HIGH PRESSURE

CONTROL PISTON SPRING

PUMP SERVO VALVE

BARREL

CONTROL PISTON

CHAPTER : STEERING & BRAKES

PASSAGE

992G WHEEL LOADER

OUTLET PASSAGE

DRIVE SHAFT

INLET PASSAGE
PISTON ASSEMBLY SWASHPLATE
 992G WHEEL LOADER
CHAPTER : STEERING & BRAKES

BRAKE SYSTEM COMPONENTS

SERVICE BRAKE VALVE PARKING BRAKE VALVE

Page: 6-21
 992G WHEEL LOADER
CHAPTER : STEERING & BRAKES

BRAKE OIL LINE BRAKE SYSTEM COMPONENTS

BRAKE COOLING OIL LINE SERVICE BRAKE HOUSING

PARKING BRAKE SECONDARY STEERING

PUMP

Page: 6-22
Page:
6-23

BRAKE HYDRAULIC SYSTEM

SERVICE BRAKE OFF / PARKING BRAKE ON BRAKE
VALVE

REAR BRAKE
ACCUMULATOR

FRONT BRAKE
ACCUMULATOR

CHAPTER : STEERING & BRAKES

MANIFOLD MANIFOLD

992G WHEEL LOADER

CHECK
VALVE

PUMP
CHECK REAR FRONT
VALVE PARKING BRAKE BRAKE
BRAKE PARKING
VALVE BRAKE
TANK
Page:
6-24

BRAKE HYDRAULIC SYSTEM

SERVICE BRAKE ON / PARKING BRAKE OFF BRAKE
VALVE

REAR BRAKE
ACCUMULATOR

FRONT BRAKE
ACCUMULATOR

CHAPTER : STEERING & BRAKES

MANIFOLD MANIFOLD

992G WHEEL LOADER

CHECK
VALVE

PUMP
CHECK REAR FRONT
VALVE PARKING BRAKE BRAKE
BRAKE PARKING
VALVE BRAKE
TANK
Page:

AXLE COOLING SYSTEMS

6-25

BRAKE BRAKE

REAR AXLE AXLE FRONT

AXLE MANIFOLD MANIFOLD AXLE

COOLER
BRAKE BRAKE

CHAPTER : STEERING & BRAKES

COOLER

992G WHEEL LOADER

RELIEF
VALVE

RELIEF
VALVE

REAR FRONT
PUMP PUMP
 992G WHEEL LOADER
CHAPTER : STEERING & BRAKES

LAB EXERCISES

Lab A: Steering System Component Identification Quiz

Worksheet

Directions: Use this worksheet during the presentation to take notes on the function and
location of each component. During the lab exercise locate the components.

Component Location on the Machine

Dual check valves ___________________________________

Steering pump ___________________________________

Steering and brake oil tank ___________________________________

Steering pilot pump ___________________________________

Steering pilot relief valve ___________________________________

Steering pilot control valve ___________________________________

Steering pilot and brake filter ___________________________________

Main control valve ___________________________________

Oil cooler ___________________________________

Steer cylinders ___________________________________

Neutralizer valve ___________________________________

Pressure reducing valve ___________________________________

Secondary pump ___________________________________

Selector and pressure control valve ___________________________________

Page: 6-26
 992G WHEEL LOADER
CHAPTER : STEERING & BRAKES

LAB EXERCISES
Lab B: Steering System Operational Tests Worksheet

Steering Time Check:

1. Run the test three times.

2. Compare the average time to the Service Manual specification.
Oil Temp ____C 1st Test 2nd Test 3rd Test Average

Cycle Time

Specification

STEERING SYSTEM PRESSURE

SPECIFICATION ACTUAL

Pilot Oil Pressure

Back up Relief Valve Left Turn

Back up Relief Valve Right Turn

Pressure Compensator Valve

Margin Pressure

NEUTRALIZER STRIKER ADJUSTMENT

SPECIFICATION ACTUAL ADJUSTMENT

Right Stop

Left Stop

Lab C: Brake System Operational Tests Worksheet

BRAKE SYSTEM PRESSURE

SPECIFICATION ACTUAL

Brake Pump Compensator Valve

Service Brake Control Valve

Parking Brake Control Valve

Page: 6-27
 992G WHEEL LOADER
CHAPTER : STEERING & BRAKES

LAB EXERCISES
Lab D: Brake System and Brake Cooling System Component Identification Quiz
Worksheet

Directions: Use this worksheet during the presentation to take notes on the function and
location of each component. During the lab exercise locate the components.

Component Location on the Machine

Brake pump ___________________________________

Parking brake valve ___________________________________

Service brake valve ___________________________________

Brake accumulators ___________________________________

Service brakes ___________________________________

Parking brake ___________________________________

Brake manifold ___________________________________

Parking brake lever ___________________________________

Brake pedals ___________________________________

Front brake cooling pump ___________________________________

Rear brake cooling pump ___________________________________

Front brake cooler ___________________________________

Rear brake cooler ___________________________________

Front axle ___________________________________

Rear axle ___________________________________

Front axle manifold ___________________________________

Rear axle manifold ___________________________________

Page: 6-28