Service Training

SERV2631-01
March 2002

TEXT REFERENCE

PART OF TECHNICAL INSTRUCTION MODULE SERV2631-01

992G WHEEL LOADER

STEERING AND BRAKE SYSTEMS

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TABLE OF CONTENTS
INTRODUCTION ..................................................................................................................3
STEERING SYSTEM ............................................................................................................4
Steering System Block Diagram.......................................................................................5
Steering Pilot System Components...................................................................................7
Main Steering System Components................................................................................12
Main System Pump Schematics......................................................................................16
Steering System Schematics ...........................................................................................19
SECONDARY STEERING SYSTEM .................................................................................24
Secondary Steering System Schematic...........................................................................25
BRAKE SYSTEM ................................................................................................................27
Brake System Components ............................................................................................28
Brake Pump Schematics ................................................................................................37
Brake System Schematics ...............................................................................................42
AXLE COOLING SYSTEMS..............................................................................................45
CONCLUSION.....................................................................................................................48
VISUAL LIST ......................................................................................................................49

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992G WHEEL LOADER

STEERING AND BRAKE SYSTEMS

2002 Caterpillar Inc.

Objective 1
Visuals 1 - 19
Objective 6
Visuals 1 - 35

INTRODUCTION
This presentation discusses the major features, component locations, and
systems operation for the steering and brake systems on the 992G Wheel
Loader.

Introduction
Distribute Lab A and B
Worksheets

When discussing systems operation, both sectional view and graphic

symbol schematics are provided. Systems are explained by tracing oil
flow from the tank, through the system and back to the tank.
The color codes for hydraulic oil used throughout this presentation are as
follows:
Red

- System or high pressure

Red and White Stripes

- Reduced pressures

Orange

- Pilot pressure

Green

- Tank or return oil

Blue

- Blocked oil

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STEERING SYSTEM
COMPONENT IDENTIFICATION
STEERING
PUMP

PILOT
PUMP

PILOT PILOT RELIEF

FILTER
VALVE

DUAL PILOT
CHECK VALVE

STEERING
CONTROL
VALVE
PILOT SYSTEM

STEERING PILOT
CONTROL VALVE

STEERING AND
BRAKE TANK

MAIN STEERING SYSTEM

NEUTRALIZER
VALVES

STEERING
CYLINDERS
COMMON TO MAIN AND PILOT SYSTEMS

2
STEERING SYSTEM
Identify components:
- Pilot system
- Main system
- Common to both
systems

Shown are the components of the steering system on the 992G Wheel
Loader. Components of the pilot system are shown in orange,
components of the main steering system are shown in red, and
components that are common to the the pilot system and main steering
system are shown in green.

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STEER
LEVER

STEERING HYDRAULIC SYSTEM

HOLD

PILOT CONTROL
VALVE
PILOT
PUMP

NEUTRALIZER
VALVE

FILTER

PILOT
RELIEF
VALVE

NEUTRALIZER
VALVE

QUAD
CHECK
VALVE

CHECK
VALVE

CHECK
VALVE

STEERING PUMP

COOLER

STEERING
CONTROL
VALVE

STEERING
CYLINDERS
TANK

3
Explain schematic

Steering System Block Diagram

This block diagram of the 992G steering system shows the components
and oil flow.
The steering pilot circuit consists of the pilot pump, the pilot filter, the
pilot relief valve, two check valves, the steer lever, the pilot control valve,
two neutralizer valves, and the quad check valve. When the steer lever is
moved to the left or right, pilot oil is sent through the respective
neutralizer valve to the steering control valve. The pilot oil moves the
steering control valve and allows steering pump oil to flow to the steering
cylinders.
The main steering circuit consists of the steering pump, the steering
control valve, and the steering cylinders. The steering control valve
houses the back-up relief valve, the pressure reducing valve, the valve
spool, the cylinder crossover relief valves, the makeup ball check valves,
and the shuttle valve.

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The steering pump draws oil (green) from the tank and sends flow (red) to
the steering control valve. The steering control valve directs oil to the
steering cylinders. The steering control valve also supplies oil (orange) to
the steering pilot circuit if a shortage of pilot system oil occurs. The
steering cylinders extend and retract to steer the machine.

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3
4

1
2

Identify components:
1. Steering pilot
pump
2. Main steering
pump
3. Steering pilot
system pressure
tap
4. Implement fixed
displacement
pump

Steering Pilot System Components

The steering pilot pump (1) is located on the rear of the main steering
pump (2). The steering pilot pump pulls oil from the tank and sends pilot
oil to the pilot filter.
Also shown are the steering pilot system pressure tap (3) and the
implement fixed displacement pump (4).

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1
2

5
3

Identify components:
1. Pilot filter
2. Left frame

The steering system pilot filter (1) is located on the inside of the left
frame (2) below the deck access panel (behind the operator's station).
From the filter, pilot oil flows to the pilot relief valve (3) and to the pilot
control valve (not shown).

3. Pilot relief valve

4. Pressure tap
5. Steering control
valve

The pilot relief valve maintains the pilot pressure at 2400 100 kPa
(350 15 psi) with the engine at LOW IDLE. Pilot pressure is tested at
the pressure tap (4).
Also shown is the steering control valve (5).

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Identify components:
1. Control lever
2. Transmission
direction control
3. Up and down shift
switches
4. Pilot control valve
cover
5. STIC lock lever

The control lever (1) is located at the left front of the operator's seat. The
control lever is part of the Steering/Transmission Integrated Control
(STIC). Other components of the STIC are the transmission directional
control (2) and the transmission upshift and downshift switches (3).
The pilot control valve is located below the control lever and behind the
cover (4). When the control lever is moved left or right, the control lever
moves the respective valve spool in the pilot control valve. The pilot oil
flows past the pilot control valve spools to the steering control valve.
Also visible is the STIC lock lever (5).

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Identify components:
1. Neutralizer valves
2. Adjustable strikers
3. Parking brake valve

The two neutralizer valves (1) are mounted on the rear frame. Each
neutralizer valve has an adjustable striker (2) mounted on the front frame.
When the machine makes a maximum turn (either left or right), the
respective striker will contact the neutralizer valve at the end of the turn.
The striker moves the neutralizer valve and blocks oil flow to the
directional control valve. With the oil flow stopped, the directional
control valve centering spring centers the valve and stops the machine
from turning.
Also shown is the parking brake valve (3).

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Quad check valve

(arrow)

The quad check valve (arrow) is located on the rear frame to the rear of
the left neutralizer valve. The check valves in the steering pilot lines have
different cracking pressures. The supply side to the control valve opens at
15 psi while the return side opens at 145 psi. The supply side check
valves prevent pilot oil from flowing backwards when the STIC is moved
to the hold position. This ensures the main control valve spool shifts to
the hold position in a smooth, relatively quick, predictable manner.
If the operator wants the machine to behave more aggressively, he can
move the STIC from steering in one direction, through the hold position,
and steer in the opposite direction. The 145 psi check valve on the return
side will then open and the main control valve spool shifts more
aggressively.
The orifice to tank from the pilot lines should handle the flow of oil
exiting the pilot cavity on the control valve during normal spool
movement. If the flow is greater than can pass through the orifice during
rapid spool movement and the pressure increases to greater than 145 psi,
the check valve will open and allow the pilot oil to return to tank through
the pilot control valve.

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2
1

Identify components:

Main Steering System Components

1. Main steering pump

The main steering pump (1) is located on the left front of the pump drive.
The variable displacement piston pump senses both pressure and flow
requirements for the system. The steering system pump draws oil from
the hydraulic tank and sends flow to the steering control valve.

2. Steering pilot pump

3. Steering pilot system
pressure tap
4. Implement fixed
displacement pump

Also shown are the steering pilot pump (2), the steering pilot system
pressure tap (3), and the implement fixed displacement pump (4).

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10

Case drain filter (arrow)

The case drain filter (arrow) for the main steering pump is located in the
pump bay, just above and forward of the main steering pump. The filter
removes contaminants from the case drain oil before the oil enters the
steering and brake tank.

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11

Identify components:
1. Steering control
valve

The steering control valve (1) is located behind the cab on the inside of
the right frame below the deck access panel. The control valve sends
system oil to the steering cylinders and sends signal oil to the margin
spool spring chamber in the compensator valve group on the pump.

2. Selector valve
3. Crossover relief
valve
4. Secondary steering
relief valve

Also shown are the selector valve (2), the crossover relief valve (3), and
the secondary steering relief valve (4).

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12

Identify components:
1. Right steering
cylinder
2. Steering cylinder
head end
3. Steering cylinder
rod end

Shown is the right steering cylinder (1). The steering cylinder head end
(2) is pinned to the front frame and the rod end (3) is pinned to the rear
frame.

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SWASHPLATE

STEERING PUMP AND

COMPENSATOR VALVE
ENGINE OFF

MAXIMUM ANGLE
STOP

MINIMUM ANGLE
STOP

SMALL
ACTUATOR PISTON
LARGE
ACTUATOR
PISTON
FROM STEERING
CONTROL VALVE

FLOW
COMPENSATOR
SPOOL

CHARGE PUMP

PRESSURE
COMPENSATOR
SPOOL

COMPENSATOR
VALVE

13
Objective 2
Visuals 13 - 19
Explain schematic

Main System Pump Schematics

Shown is a sectional view of the steering pump and compensator valve
group.
The pump has two control pistons which work together to continually
adjust the angle of the swashplate. The small actuator piston, assisted by
the small actuator spring, is used to upstroke the pump. The large actuator
piston is used to destroke the pump.
The compensator valve group consists of a flow compensator (margin)
spool and a pressure compensator (cutoff) spool. The valve group keeps
the pump flow and pressure at a level needed to fulfill the demands of the
steering system.

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The margin compensator spring maintains the pump supply pressure a t

2100 105 kPa (305 15 psi) above the signal pressure. The pressure
compensator spring limits the system pressure to 31000 kPa (4500 psi).
When the engine is OFF, the small actuator spring moves the swashplate
to maximum angle.

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SWASHPLATE

STEERING PUMP AND

COMPENSATOR VALVE

MAXIMUM ANGLE
STOP

MINIMUM ANGLE
STOP

LOW PRESSURE STANDBY

SMALL
ACTUATOR PISTON
LARGE
ACTUATOR
PISTON
FROM STEERING
CONTROL VALVE

FLOW
COMPENSATOR
SPOOL

CHARGE PUMP

PRESSURE
COMPENSATOR
SPOOL

COMPENSATOR
VALVE

14
Objective 7
Visual 14
Explain schematic

At machine start-up, the small actuator spring holds the swashplate at

maximum angle. When the steering control valve is in the HOLD
position, pump flow is blocked at the steering control valve and no signal
pressure is generated. As the pump produces flow, the system pressure
begins to increase. This pressure is felt at the lower end of both the flow
compensator spool and the pressure compensator spool. The flow
compensator spool moves up against the low spring force and permits
system oil to go to the large actuator piston. The oil pressure at the large
actuator piston overcomes the combined force of the small actuator spring
and system oil pressure at the small actuator piston.
The large actuator piston moves the swashplate (destroke) to the LOW
PRESSURE STANDBY position. In LOW PRESSURE STANDBY, the
pump produces enough flow to compensate for system leakage at
sufficient pressure to provide instantaneous response when the steering
control valve is moved.

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STEERING
CYLINDERS
STEERING CONTROL VALVE

LINE
RELIEF
VALVE

CONTROL
SPOOL

STEERING SYSTEM

DIVERTER
VALVE

SHUTTLE
VALVE

HOLD

SECONDARY
RELIEF
VALVE

BACK-UP
RELIEF
VALVE

PRESSURE
REDUCING
VALVE

COMPENSATOR
VALVE

SECONDARY
PUMP

QUAD
CHECK
VALVE
PILOT
CONTROL
VALVE

PILOT
RELIEF
VALVE

STEER
LEVER

BYPASS
SWITCH

SELECTOR
VALVE

COOLER

FILTER
BYPASS
SWITCH

FLUID
SAMPLING
PORT

STEERING
PUMP

LEFT
RIGHT
NEUTRALIZER NEUTRALIZER

TANK

PILOT
PUMP

15
Explain schematic

Steering System Schematics

When the engine is running and the steering system is in HOLD, pilot
pump oil is blocked at the pilot control valve. Oil from the main steering
pump flows to the steering control valve. The steering control valve spool
blocks oil flow to the steering cylinders and no signal pressure is generated.
System pressure is sensed at the pump margin spool and pressure
compensator spool, and at the small actuator piston (rod end symbol). As
system pressure increases, the margin spool moves against the spring force
and opens a passage for pump oil to flow to the large actuator piston
(head end symbol).

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The pressure in the large actuator piston overcomes the combined force of
the actuator spring and the pressure in the small piston and moves the
swashplate to the LOW PRESSURE STANDBY position.
In LOW PRESSURE STANDBY, the pump produces enough flow to
compensate for system leakage and sufficient pressure to provide for
instantaneous response when the steering control valve is moved.
INSTRUCTOR NOTE: System pressure specifications are found in
the 992G Wheel Loader Steering Testing and Adjusting Module
(Form SENR1373).

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STEERING
CYLINDERS
STEERING CONTROL VALVE

STEERING SYSTEM

SHUTTLE
VALVE
LINE
RELIEF
VALVE

CONTROL
SPOOL

GRADUAL RIGHT TURN

DIVERTER
VALVE

SECONDARY
RELIEF
VALVE

BACK-UP
RELIEF
VALVE

PRESSURE
REDUCING
VALVE

COMPENSATOR
VALVE

SECONDARY
PUMP

QUAD
CHECK
VALVE
PILOT
CONTROL
VALVE

PILOT
RELIEF
VALVE

STEER
LEVER

BYPASS
SWITCH

SELECTOR
VALVE

FILTER

COOLER
BYPASS
SWITCH

FLUID
SAMPLING
PORT

STEERING
PUMP

LEFT
RIGHT
NEUTRALIZER NEUTRALIZER

TANK

PILOT
PUMP

16
Explain schematic

When the operator moves the steering lever to the right, pilot oil flows
through the pilot control valve and the right neutralizer valve to the left
end of the steering control spool. Pilot oil pressure moves the steering
control spool to the right. System oil from the steering pump flows
through the check valve and the control spool to the steering cylinders.
As pressure increases in the steering cylinders, the pressure (signal
pressure) is sensed in the flow compensator valve spring chamber at the
pump. The signal pressure combines with the force of the flow
compensator spool spring and moves the flow compensator spool down.
The flow compensator spool restricts the flow of oil to the large actuator
piston (head end). The spring and pressure in the small actuator piston
overcome the pressure in the large piston to move the swashplate toward
maximum angle. The increase in swashplate angle increases pump oil
flow.

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The increase in oil flow through the control spool increases the system
pressure. The system pressure is sensed at the flow compensator spool.
The increased pressure moves the flow compensator spool against the
combined forces of the spring and signal pressure and sends oil to the
large actuator piston. The actuator piston moves the swashplate to a
reduced angle that produces flow relative to the position of the control
spool.

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STEERING
CYLINDERS

STEERING SYSTEM

STEERING CONTROL VALVE

SHARP RIGHT TURN

DIVERTER
VALVE

SHUTTLE
VALVE
LINE
RELIEF
VALVE

CONTROL
SPOOL

SECONDARY
RELIEF
VALVE

BACK-UP
RELIEF
VALVE

PRESSURE
REDUCING
VALVE

COMPENSATOR
VALVE

SECONDARY
PUMP

QUAD
CHECK
VALVE
PILOT
CONTROL
VALVE

PILOT
RELIEF
VALVE

STEER
LEVER

BYPASS
SWITCH

SELECTOR
VALVE

COOLER

FILTER
BYPASS
SWITCH

FLUID
SAMPLING
PORT

STEERING
PUMP

LEFT
RIGHT
NEUTRALIZER NEUTRALIZER

TANK

PILOT
PUMP

17
Explain schematic

When making a SHARP RIGHT TURN, the right striker (not shown)
contacts the right neutralizer valve. Oil flow from the pilot control valve
to the steering control valve is blocked by the movement of the neutralizer
valve. The steering control spool returns to the center position. Flow to
the steering cylinders is blocked and the machine stops turning. The
steering pump returns to the LOW PRESSURE STANDBY condition.
The neutralizer valves prevent the machine front frame from contacting
the machine rear frame when making a SHARP RIGHT or SHARP LEFT
turn.
INSTRUCTOR NOTE: Check the 992G Wheel Loader Steering
System Testing and Adjusting Module (Form SENR1373) for the
correct adjustment procedures.

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3
1

18

Identify components:

SECONDARY STEERING SYSTEM

1. Secondary pump

The secondary pump (1) is splined to the transmission output transfer gear
(2). The pump is ground driven and turns when the machine is moving.

2. Transmission
output transfer gear
3. Supply hose
4. Case drain hose

When the machine is moving, the pump pulls oil from the tank through a
suction hose (not shown). Pump oil flows through the supply hose (3) to
the diverter valve (not shown) in the steering control valve.
When the engine is running, the diverter valve sends the secondary pump
oil to the tank. When the engine is not running, the diverter valve sends
secondary pump oil to the steering control valve.
Also shown is the case drain hose (4).

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STEERING
CYLINDERS

SECONDARY STEERING SYSTEM

STEERING CONTROL VALVE

GRADUAL RIGHT TURN

DIVERTER
VALVE

SHUTTLE
VALVE
LINE
RELIEF
VALVE

CONTROL
SPOOL

SECONDARY
RELIEF
VALVE

BACK-UP
RELIEF
VALVE

PRESSURE
REDUCING
VALVE

COMPENSATOR
VALVE

SECONDARY
PUMP

QUAD
CHECK
VALVE
PILOT
CONTROL
VALVE

PILOT
RELIEF
VALVE

STEER
LEVER

BYPASS
SWITCH

SELECTOR
VALVE

FILTER

COOLER
BYPASS
SWITCH

FLUID
SAMPLING
PORT

STEERING
PUMP

RIGHT
LEFT
NEUTRALIZER NEUTRALIZER

TANK

PILOT
PUMP

19
Explain schematic

Secondary Steering System Schematic

Shown is a schematic of the steering system with the engine off and the
machine moving.
When the engine is off, no oil flows from the pilot pump and the steering
pump. The steering system oil comes from the secondary steering system.
The secondary steering system consists of the secondary pump, secondary
relief valve, diverter valve, and check valve.
When the machine is moving, the output transfer gear turns the secondary
pump. Secondary pump oil flows through the diverter valve and the
check valve to the steering control valve.

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Secondary pump oil also flows through the pressure reducing valve and
the check valve to the pilot control valve.
When the operator moves the steer lever, secondary pump oil is used to
steer the machine.
INSTRUCTOR NOTE: At this time, introduce and perform "Lab A:
Steering System Component Identification Quiz" and "Lab B:
Steering System Tests" individually. These labs will reinforce the
material discussed in the preceding presentation.

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BRAKE SYSTEM COMPONENTS

BRAKE
PUMP

BRAKE
ACCUMULATORS

REAR SERVICE
BRAKES

PARKING BRAKE
VALVE

STEERING AND BRAKE

TANK
SERVICE BRAKE
COMPONENTS

PARKING BRAKE
LEVER

PARKING
BRAKE

MANIFOLD

PARKING BRAKE
COMPONENTS

SERVICE BRAKE
PEDALS

SERVICE BRAKE
VALVE

FRONT SERVICE
BRAKES

SERVICE AND PARKING SYSTEMS

SHARED COMPONENTS

20
Objective 3
Visuals 21 - 35
Distribute Lab C
Worksheet

BRAKE SYSTEM
Shown are the components of the brake system on the 992G Wheel
Loader. Components of the service brake system are shown in orange,
components of the parking brake system are shown in brown, and
components that are common to the service brake system and the parking
brake system are shown in red.

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BRAKE HYDRAULIC SYSTEM

TANDEM
BRAKE
VALVE

FRONT BRAKE
ACCUMULATOR

REAR BRAKE
ACCUMULATOR

MANIFOLD
PRESSURE
SWITCH

MANIFOLD

CHECK
VALVE

BRAKE
PUMP

CHECK
VALVE PARKING
BRAKE
VALVE

PARKING
BRAKE

REAR
BRAKE

FRONT
BRAKE

TANK

21
Brake System Components
Identify components
and explain function:
- Brake pump
- Check valves

Shown is a simplified schematic of the brake system. The brake system

component functions are:
Brake pump: Pulls oil from the tank and sends supply oil to the
accumulator charging valves.

- Brake accumulators

Check valves: Allows oil flow in one direction.

- Manifold
- Tandem brake valve
- Service brake
- Parking brake valve
- Parking brake
- Pressure switch

Brake accumulators: When the engine is running, the front and rear
brake accumulators supply oil within a controlled pressure range to the
tandem brake valve and to the parking brake valve. If the engine stops
running, the accumulators provide an emergency oil supply to provide
braking.

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Manifold: Serves as a junction block for oil lines, pressure taps, sensors
and other monitoring components.
Tandem brake valve: Controls brake oil flow and pressure to the front
and rear service brakes.
Service brakes: Slow or stop the machine during operation.
Parking brake valve: Controls oil pressure to the parking brake.
Parking brake: Prevents the machine from moving when parked.
Pressure switch: Sends a signal to VIMS when the case drain filter
begins to bypass.

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2
3
1

22

Identify components:
1. Brake pump
2. Pump drive
3. Pressure
compensator valve
4. Pump supply port

The brake pump (1) is located on the left rear of the pump drive (2).
The brake pump supplies oil flow to charge the two accumulators.
Also shown are the pressure compensator valve (3) and the pump supply
port (4).

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23

Case drain filter (arrow)

The case drain filter (arrow) for the brake pump is located on the left side
of the pump bay, just above the pump drive. The filter removes
contaminants from the case drain oil before the oil enters the steering and
brake tank.

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24

Identify components:
1. Accumulators
2. Deck frame
3. Deck plate

The accumulators (1) are bolted to the deck frame (2) below the deck
plate (3) on the left side of the cab.
The accumulators supply oil at a constant pressure range to the brake
system. The accumulators also supply pressure oil to the brake system to
stop the machine if the engine stops running while the machine is moving.

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2
1

25

Identify components:
1. Manifold
2. Service brake valve

Oil from the rear brake accumulator flows through the manifold (1) to the
top section of the service brake valve (2) and to the parking brake valve
(3). Oil from the front brake accumulator flows through the manifold to
the bottom section of the service brake valve.

3. Parking brake valve

When the parking brake valve is in the BRAKE RELEASED position,

accumulator oil pressure is sent through the parking brake valve to the
brake chamber. Oil pressure compresses the spring in the brake chamber
and releases the parking brake. When the parking brake valve is moved
to the BRAKE ENGAGED position, accumulator oil pressure is blocked
at the parking brake valve. Oil in the parking brake chamber flows
through the parking brake valve to drain. The spring in the brake
chamber engages the brake.

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26

Identify components:

The oil activated disc brake (1) is the same at all four wheels.

1. Oil activated disc

brake

Also shown are the service brake supply line (2), the brake cooling supply
line (3), and the final drive housing (4).

2. Service brake
supply line
3. Brake cooling oil
line
4. Final drive housing

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27

Parking brake control

lever (arrow)

The parking brake control lever (arrow) controls the valve spool in the
parking brake valve.

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28

Identify components:
1. Parking brake

The parking brake (1) is located on the output transfer gear case above the
secondary steering pump (2). The parking brake is spring engaged and
hydraulically released.

2. Secondary steering
pump

INSTRUCTOR NOTE: At this time, introduce and perform "Lab C:

Brake System Component Identification Quiz." This lab will
reinforce the material discussed in the preceding presentation.

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BRAKE PUMP
LOW PRESSURE
CONTROL PISTON

SPRING

PRESSURE
COMPENSATOR VALVE
BARREL

CONTROL PISTON
PASSAGE

OUTLET PASSAGE

DRIVE SHAFT
INLET PASSAGE
PISTON ASSEMBLY

SWASHPLATE

29
Distribute Lab D
Worksheet
Identify components and
explain function:
- Pressure
compensator valve

Brake Pump Schematics

Shown in this illustration are the main components of the brake pump.
The components are:
- Pressure compensator valve
- Control piston

- Control piston

- Spring
- Spring
- Swashplate

- Swashplate

- Piston assembly

- Piston assembly

- Barrel

- Barrel

- Drive shaft

- Drive shaft

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When pressure in the brake system is less than 16000 345 kPa
(2300 50 psi), the spring keeps the swashplate at maximum angle. The
pump piston stroke is longest and pump displacement is maximum. A
small amount of pressure oil from the outlet passage flows to the pressure
compensator. A spool in the pressure compensator blocks the flow of oil
to the control piston passage.

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PUMP COMPENSATOR VALVE

LOW BRAKE SYSTEM PRESSURE

HIGH BRAKE SYSTEM PRESSURE

TO CONTROL FROM PUMP
OUTLET
PISTON

TO CONTROL FROM PUMP

OUTLET
PISTON
ADJUSTMENT
BOLT

ADJUSTMENT
BOLT

LOCKNUT

SPRING

LOCKNUT

PRESSURE
COMPENSATOR SPOOL

SPRING

PRESSURE
COMPENSATOR SPOOL

30
Identify components
and explain function:
- Adjustment bolt
- Locknut

This illustration shows the main components and the operation of the
pressure compensator valve. The components are:
- Adjustment bolt
- Locknut

- Spring

- Spring
- Spool

- Pressure compensator pool

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The left illustration shows the operation of the pressure compensator valve
when the brake system pressure is less than 16000 345 kPa (2300 50
psi). Pump output oil flows around the right land of the pressure
compensator spool and into the chamber at the right end of the spool.
When the brake system pressure increases to 16000 345 kPa
(2300 50 psi), the pressure of the oil in the chamber is high enough to
move the spool against the spring. Movement of the spool permits oil to
flow past the spool to the control piston in the pump.
INSTRUCTOR NOTE: Check the 992G Wheel Loader Brake System
Testing and Adjusting Module (Form SENR1353) for the correct
pressure compensator spool adjustment procedure.

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BRAKE PUMP
HIGH PRESSURE
PRESSURE
COMPENSATOR VALVE

CONTROL PISTON

SPRING

BARREL

CONTROL PISTON
PASSAGE

OUTLET PASSAGE

DRIVE SHAFT
INLET PASSAGE
PISTON ASSEMBLY

SWASHPLATE

31
Explain schematic

When the brake system pressure reaches 16000 345 kPa (2300 50 psi),
oil from the pressure compensator valve fills the chamber in the control
piston. As the brake system pressure increases above 16000 345 kPa
(2300 50 psi), the oil pressure from the pressure compensator valve
moves the control piston against the control spring. This movement
decreases the angle of the swashplate, the stroke of the pistons, and the
displacement of the pump. The amount of oil per pump revolution is
decreased to the amount needed to maintain the system pressure at 16000
345 kPa (2300 50 psi).

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BRAKE HYDRAULIC SYSTEM

SERVICE BRAKES OFF / PARKING BRAKE OFF

TANDEM
BRAKE
VALVE

REAR BRAKE
ACCUMULATOR

FRONT BRAKE
ACCUMULATOR

MANIFOLD

PRESSURE
SWITCH

CHECK
VALVE

MANIFOLD

CHECK
VALVE

PARKING
BRAKE
VALVE

PUMP

PARKING
BRAKE

REAR
BRAKE

FRONT
BRAKE

TANK

32
Objective 4
Visuals 32 - 33
Explain schematic

Brake System Schematics

The brake pump draws oil from the tank and directs the flow through the
check valves to the accumulators. When the engine is running, the brake
pump maintains the oil pressure in the front and rear brake accumulators
at 16000 345 kPa (2300 50 psi).
The tandem brake valve controls brake oil flow and pressure to the front
and rear service brakes. When the brakes are released, oil from the
accumulators is blocked at the tandem brake valve. Oil in the service
brakes drains through the tandem brake valve to the tank.

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BRAKE HYDRAULIC SYSTEM

SERVICE BRAKE ON / PARKING BRAKE OFF

TANDEM
BRAKE
VALVE

REAR BRAKE
ACCUMULATOR
FRONT BRAKE
ACCUMULATOR

MANIFOLD

MANIFOLD

CHECK
VALVE

PUMP

CHECK
VALVE PARKING
BRAKE
VALVE

PARKING
BRAKE

REAR
BRAKE

FRONT
BRAKE

TANK

33
Explain schematic

When the operator moves the parking brake control knob to the BRAKE
OFF position, a cable moves the spool in the parking brake valve.
Pressure oil from the rear brake accumulator flows around the valve spool
and RELEASES the parking brake.
When the operator depresses either brake pedal, the tandem brake valve
spools move down against the spring at the bottom of the brake valve.
The tandem brake valve spools close the passages to the tank and open the
passages to the front and rear brake accumulators. The rear brake
accumulator oil flows through the spool for the rear brakes in the tandem
brake valve and ENGAGES the rear brakes. The rear brake accumulator
oil also fills the chamber between the tandem brake valve spools. The
front brake accumulator oil flows through the spool for the front brakes in
the tandem brake valve and ENGAGES the front brakes.

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The front brake accumulator oil also fills the chamber at the bottom of the
valve spool for the front brakes in the tandem brake valve.
The combined force of the oil pressure and the spring at the bottom of the
valve spool for the front brakes moves the valve spool for the front brakes
up against the oil pressure in the chamber between the front and rear
brake spools in the tandem brake valve. This movement increases the oil
pressure in the chamber. The increased oil pressure moves the valve
spool for the rear brakes up against the force on the brake pedal.
The force at the bottom of each brake spool in the tandem brake valve
balances the brake spool against the force at the top of the brake spool.
Each brake spool acts as a pressure reducing valve to limit the pressure in
the brakes proportionally to the force at the top of the respective brake
spool.
When the brake pedal is RELEASED, the oil passages from the
accumulators to the brakes are closed and the passages from the brakes to
the tank are opened. Oil in the rear and front service brakes flows
through the tandem brake valve to the tank. The force at the bottom of
each brake spool in the tandem brake valve moves the respective brake
spool up.
INSTRUCTOR NOTE: At this time, introduce and perform "Lab D:
Brake System Tests." This lab will reinforce the material discussed in
the proceeding presentation.

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AXLE COOLING SYSTEMS

BRAKE
REAR
AXLE

BRAKE

AXLE
MANIFOLD

AXLE
MANIFOLD

FRONT
AXLE

COOLER
BRAKE

BRAKE

RELIEF
VALVE
COOLER
RELIEF
VALVE

REAR
PUMP

FRONT
PUMP

34
Objective 5
Visual 34
Explain schematic

AXLE COOLING SYSTEMS

Shown is a schematic of the front and rear axle cooling systems. Each
axle cooling system cools the oil in the respective axle. The operation of
both systems is the same.
When the operator applies the service brakes, friction generates heat in the
brake plates and discs. Also, heavy loads generate heat in the differential.
The front and rear pumps pull the high temperature oil from the
differential cases and send the flow to the oil cooler. The oil cooler
removes the heat and returns the oil to the axle manifold. The cooler oil
flows from the manifold and enters the axles at each brake chamber and at
the differential housing.

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When the brakes are ENGAGED or RELEASED, the cooler oil passes
between the brake discs and plates. The cooler oil flows through grooves
in the face of the brake discs and absorbs the heat from the brake discs
and plates. The high temperature oil collects in the bottom of the brake
chamber and returns internally to the bottom of the differential housing.
In the differential, the cooler oil flows over the gears and removes the
heat. The high temperature oil flows to the bottom of the differential
housing and joins with the oil from the brakes. The oil is again pulled
into the pump and the cycle continues.
When the oil is cold, the high resistance to flow through the cooler causes
the pump pressure to increase. When the pump pressure increases to
345 kPa (50 psi), the relief valve opens allowing cold oil to flow to the
pump inlet.
INSTRUCTOR NOTE: At this time, introduce and perform "Lab E:
Axle Cooling System Component Identification Quiz." This lab will
reinforce the material discussed in the preceding presentation.

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35

Identify components:
1. Rear axle cooling
pump
2. Front axle cooling
pump
3. Relief valve for the
rear axle cooling
pump
4. Relief valve for the
front axle cooling
pump

The front and rear axle cooling pumps (1) and (2) are located on the front
accessory drive on the front of the engine. The axle cooling pumps draw
oil from the differential cases and pump the oil through the axle oil cooler.
The oil then returns to the brake and differential housings.
The relief valves (3) and (4) are located on the axle cooling pumps. The
relief valves prevent cold oil from flowing to the axle oil cooler and limit
the maximum pressure in the axle cooling system.

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36

CONCLUSION
This concludes this presentation on the 992G Wheel Loader Steering and
Brake Systems.
Always check the Service Manual for the latest service information and
specifications when servicing, testing and adjusting, and/or making
repairs.

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VISUAL LIST
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.

Title
Steering component location graphic
Steering system block diagram - HOLD
Steering pilot pump
Steering pilot filter
Steering transmission integrated control
(STIC)
Neutralizer valves
Dual check valve
Main steering pump
Case drain filter - main steering pump
Steering control valve
Steering cylinder
Main steering pump schematic ENGINE OFF
Main steering pump schematic - LOW
PRESSURE STANDBY
Steering system schematic - HOLD
Steering system schematic - GRADUAL
RIGHT TURN
Steering system schematic - SHARP
RIGHT TURN
Secondary steering pump

19. Secondary steering system schematic GRADUAL RIGHT TURN

20. Brake component location graphic
21. Brake hydraulic system schematic
22. Brake pump
23. Case drain filter - brake pump
24. Brake accumulators
25. Service brake valve
26. Service brake
27. Parking brake control lever
28. Parking brake
29. Brake pump graphic - LOW PRESSURE
30. Brake pump servo valve
31. Brake pump graphic - HIGH
PRESSURE
32. Brake hydraulic schematic - SERVICE
BRAKE OFF, PARKING BRAKE ON
33. Brake hydraulic schematic - SERVICE
BRAKE ON, PARKING BRAKE OFF
34. Axle cooling system schematic
35. Axle cooling pumps
36. Model view