Service Training

MALAGA

992G WHEEL LOADER

4. SISTEMA DE FRENOS
1. Components Layout
2. Operation
3. Testing & Adjusting

Adolfo
OCTOBER 1997
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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
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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

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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
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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
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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
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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
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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 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