Service Training

Instructor Module SERV2631-01 March 2002

TECHNICAL INSTRUCTION MODULE

992G WHEEL LOADER

STEERING AND BRAKE SYSTEMS

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Table of Contents

TABLE OF CONTENTS

MODULE DESCRIPTION PREPARATION CHECKLIST MODULE PREREQUISITES MODULE OBJECTIVES LESSON PLAN TEXT REFERENCE Introduction Steering System Secondary Steering System Brake System Axle Cooling Systems Conclusion LABORATORY EXERCISES CASE STUDY POSTTEST STUDENT MATERIALS

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Module Description

MODULE DESCRIPTION
CONTENT

This module is designed to prepare the serviceman to explain the systems operation and perform testing and adjusting procedures on the 992G Wheel Loader Steering and Brake Systems.

AUDIENCE

Level II--Service mechanics and technicians with the responsibility for servicing and repairing the 992G Wheel Loader.

REFERENCES

Service Manual Modules 992G Wheel Loader Steering System Specifications 992G Wheel Loader Steering System Operation 992G Wheel Loader Steering System Testing and Adjusting 992G Wheel Loader Hydraulic System Schematic 992G Wheel Loader Brake System Specifications 992G Wheel Loader Brake System Operation 992G Wheel Loader Brake System Testing and Adjusting

Form No. SENR1348 SENR1349 SENR1373 SENR1368 SENR1351 SENR1352 SENR1353

Parts Book 992G Wheel Loader SEBP2415

Video Tape 992G Wheel Loader--Introduction SEVN4030

Specalog 992G Wheel Loader AEHQ5182

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Preparation Checklist

PREPARATION CHECKLIST
MODULE PREPARATION

Prior to conducting the training session, gather the following materials: Instructor Materials "992G Wheel Loader--Steering and Brake Systems" [Form SERV2631-01 (included on the CD ROM)] Text Reference "992G Wheel Loader--Steering and Brake Systems" [Form SERV2631-01 (included on the CD Rom)] Service Manual "992G Wheel Loader" (Form SENR1344)

A copy of the following forms for each student in the training session: Service Manual Module "992G Wheel Loader Steering System Specifications" (Form SENR1348) Service Manual Module "992G Wheel Loader Steering System Operation" (Form SENR1349) Service Manual Module "992G Wheel Loader Steering System Testing and Adjusting" (Form SENR1373) Service Manual Module "992G Wheel Loader Hydraulic System Schematic" (Form SENR1368) Service Manual Module "992G Wheel Loader Brake System Specifications" (Form SENR1351) Service Manual Module "992G Wheel Loader Brake System Operation" (Form SENR1352) Service Manual Module "992G Wheel Loader Brake System Testing and Adjusting" (Form SENR1353)
CLASSROOM PREPARATION

Prior to delivering the classroom training session, perform the following steps: Review the Text Reference to become familiar with the topic. Duplicate enough Student Materials (Form SERV2631) for each participant in the training session. Review the Posttest questions and answers. Review the Case Study and the solution.

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Preparation Checklist

Check for applicable Service Magazine articles, Service Letters, and Technical Information Bulletins related to the topic.

LABORATORY PREPARATION

Prior to conducting the lab exercises, perform the following steps: Select the 992G Wheel Loader to be used in the lab exercises. Make tags for Laboratory Exercises A, C and E. Review the lab exercises to ensure that students have the materials and equipment needed to accomplish the objectives.

Gather the following tools and material:

1 - 1U5481 Pressure Test Gauge Group 1 - 1U5482 Hose and Fitting Group 1 - 4C4890 Fittings Group 1 - Stop Watch 1 - 1U5796 Differential Pressure Group 2 - 6V3965 Nipple 2 - 3J1907 Seal 2 - 6V0852 Cap 2 - 6V8397 Seal 2 - 8T8902 Tee 1 - 9S4180 Plug 1 - 2M9780 O-ring Seal 1 - 5P8687 Tee Test Tool Group 1 - 7S5437 Nitrogen Charging Group 1 - 8T5320 Hydraulic Test Group 1 - Mechanic's tool box with hand tools

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Module Prerequisites

MODULE PREREQUISITES
PREREQUISITE COURSES

Prerequisite courses should be completed prior to participating in this course. Interactive Video Course "Fundamentals of Mobile Hydraulics" STMG 546 "Graphic Fluid Power Symbols"

TEMV9001 SESV1546

PREREQUISITE TESTS

Prerequisite tests should be administered at least one to two weeks before participants take the course. Participants should pass the following pretests with 90% or better. Basic Hydraulics Pretest Graphic Fluid Power Symbols Pretest SEBV0557 SEBV0556

If a participant does not accomplish 90% or better, identify the area of deficiency and recommend courses or publications for the student to review. After ample review time, the student should re-take the test.

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Lesson Plan

MODULE LESSON PLAN

Time Estimates Student Introduction and Module Objectives Instructor and students introduce themselves. Discuss objectives, class agenda, and hand out student materials
Visuals: 1 - 18 Distribute Lab A and B Worksheets

15 min

Visual Presentation: 992G Wheel Loader Steering Hydraulic System Students take notes on the location and function of each component discussed in the presentation on the Lab A Worksheet Lab A: Steering System Component Identification Quiz Students locate and identify steering system components on class machine Lab B: Steering System Tests Students conduct steering system testing and adjusting exercises Visual Presentation: 992G Wheel Loader Brake System Students take notes on the location and function of each component discussed in the presentation on the Lab C Worksheet Lab C: Brake System Component Identification Quiz Students locate and identify brake system components on class machine Visual Presentation: 992G Wheel Loader Brake System Hydraulic Schematics Instructor and students discuss the operation of the brake hydraulic system Lab D: Brake System Tests Students conduct brake system testing and adjusting exercises

60 min

Conduct Lab A

20 min

Conduct Lab B

40 min

Visuals: 19 - 26 Distribute Lab C Worksheet

45 min

Conduct Lab C

20 min

Visuals: 27 - 31 Distribute Lab D Worksheet

45 min

Conduct Lab D

40 min

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Lesson Plan

Visual Presentation: 992G Wheel Loader Axle Cooling Systems Students take notes on the location and function of each component discussed in the presentation on the Lab E Worksheet Lab E: Axle Cooling System Component Identification Quiz Students locate and identify axle cooling system components on class machine Lab F: Steering Pump and Compensator Valve Oil Flow Students use color pencils to trace the oil flow on a steering pump and compensator valve schematic Case Study Posttest Administer posttest Review correct answers with class Restore Machine Total Estimated Time

15 min

Conduct Lab E

20 min

Conduct Lab F

25 min

Hand Out Case Study Administer Posttest

30 min

20 min 10 min 30 min 7 hrs, 15 min

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Module Objectives

MODULE OBJECTIVES
After completing this module, the student will be able to:
Visuals: 1 - 18 Lab: A

1. Given a lab worksheet listing the following components of the 992G Wheel Loader and a 992G Wheel Loader with numbers attached to the steering system components, match the numbers on the machine with the components on the worksheet during a lab quiz: steering and brake tank, steering pump, steering pilot pump, dual check valve, main control valve, neutralizer valves, pressure reducing valve, steer cylinders, pilot control valve, and secondary pump. 2. Given a lab worksheet, a 992G Wheel Loader Steering System Testing and Adjusting Module, and the correct tools, perform the following tasks on the steering system: 1. Steering time test 2. Back-up relief valve test 3. Pressure compensator test and adjustment 4. Margin pressure test and adjustment 5. Steering neutralizer valve adjustment procedure 3. Given a lab worksheet listing the following components of a 992G Wheel Loader and a 992G Wheel Loader with numbers attached to the brake system components, match the numbers on the machine with the components on the worksheet during a lab quiz: brake pump, brake accumulators, brake manifold, parking brake valve, service brake valve, parking brake lever, brake pedals, service brakes and parking brake. 4. Given a lab worksheet, a 992G Wheel Loader Brake System Testing and Adjusting Module and the correct tools, perform the following tasks on the brake system: 1. Service brake control valve pressure test 2. Parking brake control valve pressure test 3. Service brake test 5. Given a lab worksheet listing the following components of the 992G Wheel Loader and a 992G Wheel Loader with numbers attached to the axle cooling system components, match the numbers on the machine with the components on the worksheet during a lab quiz: front axle cooling pump, rear axle cooling pump, brake manifold, front axle cooler, rear axle cooler, front axle and rear axle.

Visuals: 12 - 18 Lab: B

Visuals: 19 - 31 Lab: C

Visual: 30 - 31 Lab: D

Visual: 32 Lab: E

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Module Objectives

MODULE OBJECTIVES (continued)

Visual: 13 Lab F

6. Given a schematic of the 992G Wheel Loader steering pump and compensator valve and a set of color pencils, trace the oil flow when the steering pump is in the LOW PRESSURE STANDBY condition. 7. Given the steering system case study, develop a logical plan to troubleshoot, diagnose, and solve the operator complaint. 8. Given a list of steering and brake system components and a list of component functions, match the component with the function during a posttest.

Case Study

Visuals: 1 - 32 Posttest

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Laboratory Exercises

LABORATORY EXERCISES
INSTRUCTOR NOTE

The following section provides directions to set up, facilitate and assist during the student lab exercises Some lab exercises are the written type with worksheets, while other labs are the traditional "on the iron" labs. Answers are provided for the worksheet exercises. The actual student lab sheets along with accompanying materials are located in the Student Materials section. At the beginning of each lab, review the lab description. NOTE: Discuss safety procedures with the students for each shop lab (i.e. safety glasses, clothing).

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Laboratory Exercises

Lab A: Steering System Component Identification Quiz

INSTRUCTOR NOTE

Shop Exercise: Instructor attaches tags containing letters or numbers on the Steering System components. Students will identify the Steering System components by matching the lettered or numbered tags on the components with the names on the worksheet. NOTE: Tags containing letters or numbers should be attached to the Steering System components in advance. Record the tag information under "Tag No." on the instructor's copy of "Lab A: Steering System Component Identification Quiz Worksheet."

INDIVIDUAL EXERCISE

Procedure: Explain the process for filling out the worksheet (distributed during the presentation). Inform students that they may refer to the Service Manual or class notes while taking the quiz. Inform students that they may not confer among themselves. Discuss completed quiz with class.

MATERIALS NEEDED

___ Lettered or numbered tags ___ Lab A Worksheet ___ Pen or pencil ___ 992G Wheel Loader ___ Mechanic's tool box with hand tools

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Laboratory Exercises

Lab A: Steering System Component Identification Quiz Worksheet Answers

Directions: Use this worksheet during the presentation to take notes on the function and location of each component. During the lab exercise, match the tag attached to the component with the correct name. (Each correct match is worth 10 points.) Tag No. ___ Component Quad check valve Function: Provide a smooth return of the control valve to the HOLD position Location: On the EEF, to the rear of the left neutralizer valve Steering pump Function: Supplies oil to steering system when engine is ON Location: On the left front of the pump drive Steering and brake tank Function: Holds hydraulic oil Location: On the left side of the machine, near the cab Pilot control valve Function: Hydraulic control of main control valve Location: In the cab, below the STIC Steering control valve Function: Directs oil to steering cylinders Location: Behind the cab, on the right frame, below the deck access panel Steering pilot pump Function: Supplies oil flow to the pilot system Location: On the rear of the steering pump Steer cylinders Function: Turn machine Location: At the articulation joint Neutralizer valve Function: Stops pilot oil flow to the main control valve at full turn Location: On the EEF, below the front of the cab Pressure reducing valve Function: Reduces main steering pump pressure to pilot pressure if the steering pilot pump fails Location: On the steering control valve Secondary pump Function: Supplies steering system flow while the machine is moving if the primary system fails Location: On the output transfer gear case

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Laboratory Exercises

Lab B: Steering System Tests

INSTRUCTOR NOTE

Shop Exercise: When testing and adjusting the steering system, use the 992G Wheel Loader Steering Testing and Adjusting Module (Form SENR1373).

GROUP EXERCISE

Procedure: Distribute Lab B Worksheets. Have students demonstrate the Steering System tests.

MATERIALS NEEDED

___ Lab B Worksheets ___ 992G Wheel Loader ___ 992G Wheel Loader Steering System Testing and Adjusting Module (Form SENR1373) ___ 1U5481 Pressure Test Gauge Group ___ 1U5482 Hose and Fitting Group ___ 4C4890 Fittings Group ___ Stop Watch ___1U5796 Differential Pressure Group ___ 6V3965 Nipple (2) ___ 3J1907 Seal (2) ___ 6V0852 Cap (2) ___ 9S4180 Plug ___ 2M9780 O-ring Seal ___ 5P8687 Tee Test Tool Group ___ 6V8397 Seal (2) ___ 8T8902 Tee (2) ___ Putty ___ Mechanic's tool box with hand tools

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Laboratory Exercises

Lab B: Steering System Tests Worksheet 1

Following the procedures in the 992G Wheel Loader Steering System Testing and Adjusting Module (Form SENR1373) and the 992G Wheel Loader Steering System Specification Module (Form SENR1348), perform the following tasks:

1. Steering Time Test 2. Back-up Relief Valve Test and Adjust 3. Pressure Compensator Test and Adjust 4. Margin Pressure Test and Adjust 5. Steering Neutralizer Valve Adjustment Procedure
WARNING

To avoid possible personal injury, follow all warnings listed in the "992G Wheel Loader Hydraulic System Testing and Adjusting Module" (Form SENR1367).

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Laboratory Exercises

Lab B: Steering System Tests Worksheet 2

Steering Time Test:

1. Run the test three times. 2. Compare the average time to the Service Manual specification. Oil Temp ____F Cycle Time Specification Is the average time within machine specification? ___Yes ___No 1st Test 2nd Test 3rd Test Average

STEERING SYSTEM PRESSURES ACTUAL Back-up Relief Valve Pressure Compensator Margin Pressure Are the actual machine pressures within specification? Yes No SPECIFICATION

STEERING NEUTRALIZER VALVE ADJUSTMENT ACTUAL PUTTY THICKNESS SPECIFICATION

Is the neutralizer valve striker adjusted properly?

Yes

No

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Laboratory Exercises

Lab C: Brake System Component Identification Quiz

INSTRUCTOR NOTE

Shop Exercise: Instructor attaches tags containing letters or numbers on the Brake System components. Students will identify the Brake System components by matching the lettered or numbered tags on the components with the names on the worksheet. NOTE: Tags containing letters or numbers should be attached to the Brake System components in advance. Record the tag information under "Tag No." on the instructor's copy of "Lab C: Brake System Component Identification Quiz Worksheet."

INDIVIDUAL EXERCISE

Procedure: Explain the process for filling out the worksheet (distributed during the visual presentation). Inform students that they may refer to the Service Manual or class notes while taking the quiz. Inform students that they may not confer among themselves. Discuss completed quiz with class.

MATERIALS NEEDED

___ Lettered or numbered tags ___ Lab C Worksheet ___ Pen or pencil ___ 992G Wheel Loader ___ Mechanic's tool box with hand tools

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Laboratory Exercises

Lab C: Brake System Component Identification Quiz Worksheet Answers

Directions: Use this worksheet during the spresentation to take notes on the function and location of each component. During the lab exercise, match the tag attached to the component with the correct name. (Each correct match is worth 10 points.) Tag No. ___ Component Brake pump Function: Supplies oil to brake system when engine is ON Location: On the front rear of the pump drive Parking brake valve Function: Controls oil flow to release parking brake Location: On the EEF, under the cab, left side of the machine Tandem brake valve Function: Controls oil flow and pressure to service brakes Location: Under the front of the cab Brake accumulators Function: Supply oil to brake system when engine is OFF Location: On the left side of the machine, under the platform, beside the cab Service brakes Function: Primary brakes for stopping the machine Location: On each axle shaft, before the final drives Parking brake Function: Prevents movement of parked machine Location: On the output transfer gear case Brake manifold Function: Junction block for brake hydraulic lines Location: On the left side of the machine, under the cab Parking brake lever Function: Actuates parking brake Location: In the cab, on the left side of the dash Left brake pedal Function: Operates impeller clutch and actuates service brake valve Location: On the floor in the cab Right brake pedal Function: Applies service brakes by actuating service brake valve Location: On the floor in the cab

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Laboratory Exercises

Lab D: Brake System Tests

INSTRUCTOR NOTE

Shop Exercise:

When testing and adjusting the brake system, use the 992G Wheel Loader Brake System Testing and Adjusting Module (Form SENR1353).

INDIVIDUAL EXERCISE

Procedure: Distribute the Lab D Worksheets. Have students demonstrate the Brake System tests.

MATERIALS NEEDED

___ Lab D Worksheets ___ 992G Wheel Loader ___ 992G Wheel Loader Brake System Testing and Adjusting Module (Form SENR1353) ___ 1U5481 Pressure Test Gauge Group ___ 1U5482 Hose and Fitting Group ___ 7S5437 Nitrogen Charging Group ___ 8T5320 Hydraulic Test Group ___ Mechanics tool box with hand tools

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Laboratory Exercises

Lab D: Brake System Tests Worksheet 1

Following the procedures in the 992G Wheel Loader Brake System Testing and Adjusting Module (Form SENR1353), perform the following tasks: 1. Service Brake Control Valve Pressure Test 2. Parking Brake Control Valve Pressure Test 3. Service Brake Test

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Laboratory Exercises

Lab D: Brake System Tests Worksheet 2

BRAKE SYSTEM PRESSURE TEST ACTUAL Service Brake Control Valve Pressure Parking Brake Control Valve Pressure SPECIFICATION

Do the service brakes appear to be working properly?

Yes

No

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Laboratory Exercises

Lab E: Axle Cooling System Component Identification Quiz

INSTRUCTOR NOTE

Shop Exercise: Instructor attaches tags containing letters or numbers on the Axle Cooling System components. Students will identify the Axle Cooling System components by matching the lettered or numbered tags on the components with the names on the worksheet. NOTE: Tags containing letters or numbers should be attached to the Axle Cooling System components in advance. Record the tag information under "Tag No." on the instructor's copy of "Lab E: Axle Cooling System Component Identification Quiz Worksheet."

INDIVIDUAL EXERCISE

Procedure: Explain the process for filling out the worksheet (distributed during the visual presentation). Inform students that they may refer to the Service Manual or class notes while taking the quiz. Inform students that they may not confer among themselves. Discuss completed quiz with class.

MATERIALS NEEDED

___ Lettered or numbered tags ___ Lab E Worksheet ___ Pen or pencil ___ 992G Wheel Loader ___ Mechanic's tool box with hand tools

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Laboratory Exercises

Lab E: Axle Cooling System Component Identification Quiz Worksheet Answers

Directions: Use this worksheet during the presentation to take notes on the function and location of each component. During the lab exercise, match the tag attached to the component with the correct name. (Each correct match is worth 12.5 points.) Tag No. ___ Component Front axle cooling pump Function: Circulates the oil from the front axle through the cooler Location: On the front of the engine Rear axle cooling pump Function: Circulates the oil from the rear axle through the cooler Location: On the front of the engine Brake manifold Function: Junction block for hydraulic brake lines and provides access to the brake system pressure taps Location: On the left side of the machine, under the cab Front axle cooler Function: Cools the oil from the front axle Location: On the front of the cooling package, in the lower right corner Rear axle cooler Function: Cools the oil from the rear axle Location: On the front of the cooling package, in the lower right corner Front axle Function: Houses the service brakes and differential Location: Front of the machine Rear axle Function: Houses the service brakes and differential Location: Front of the machine

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Laboratory Exercises

Lab F: Steering Pump and Compensator Valve Oil Flow

INSTRUCTOR NOTE

Classroom Exercise: Students may refer to their course materials and class notes when performing the lab. Trace the oil flow through the steering pump when the steering pump is in the Low Pressure Standby condition. Steering system oil color codes: Red Red and White Stripes Blue Green System or high pressure Reduced pressure Blocked oil Tank or return oil

INDIVIDUAL EXERCISE

Procedure: Give students a copy of the "992G Wheel Loader Steering Pump (Low Pressure Standby) Schematic" and a set of color pencils. Explain the lab. Refer to Visual No. 13 in the Text Reference to check the lab.

MATERIALS NEEDED

___ 992G Wheel Loader Steering System (Low Pressure Standby) Schematic ___ Set of color pencils

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SWASHPLATE MINIMUM ANGLE STOP

STEERING PUMP AND COMPENSATOR VALVE

MAXIMUM ANGLE STOP

LOW PRESSURE STANDBY

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SMALL ACTUATOR PISTON LARGE ACTUATOR PISTON

FROM STEERING CONTROL VALVE

CHARGE PUMP

FLOW COMPENSATOR SPOOL

PRESSURE COMPENSATOR SPOOL

Laboratory Exercises

CONPENSATOR VALVE

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Case Study

CASE STUDY

INSTRUCTOR NOTE

The following section provides a case study and possible solutions. You may want to work through the case study and make your own notes. The actual student case study, without the solution, is located in the Student Materials Section. The case study is designed to promote logical troubleshooting procedures. To do this, the students can complete the case study in either of the following ways: A. Each student may complete the case study individually and then discuss the solution as a class. B. Students may complete the case study in small groups and then discuss the solution as a class. You may want to copy the solutions and hand them out after the discussion. Students may use their class notes and other reference materials.

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Case Study

992G Wheel Loader Steering System Case Study

DIRECTIONS

Students may use the service manual and class notes to complete the case study. The solution to the case study can be distributed during the classroom discussion. The following case study is based on a possible field complaint. The customer called the dealer and complained that his 992G Wheel Loader steering was unusually slow. At the job site, the mechanic talked with the operator and found that the machine seemed to turn equally slow in both directions. The mechanic decided to move the machine to a level place away from the work area and perform the tests in the Service Manual steering system testing and adjusting procedure. Was the correct decision made? Whether or not the right decision was made, on a sheet of paper list the conditions that could cause slow steering in both directions. Describe the tests and/or inspections that would allow the mechanic to identify those conditions.

SITUATION

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Case Study

When performing the "margin pressure test," the mechanic found that the margin pressure was well below specifications. When the mechanic tried to adjust the pressure, the pressure became erratic. The mechanic removed the flow compensator valve and found a broken spring. The mechanic replaced the broken spring, adjusted the valve and corrected the problem. Function of the flow compensator valve: The flow compensator valve establishes the pressure difference between the signal pressure and the pump supply pressure. When the steering control valve is moved, the steering pump must produce enough flow to move the steering cylinder piston at the desired speed before the pressure becomes high enough to overcome the flow compensator valve spring and destroke the pump. If the flow compensator valve setting is too low, the flow needed to produce enough pressure to overcome the flow compensator valve spring and destroke the pump is not enough to move the cylinder piston at the desired speed.

SOLUTION

SUPPLEMENTAL INFORMATION

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Posttest

POSTTEST

INSTRUCTOR NOTE

The following posttest is a paper test designed to measure the student's understanding of the 992G Wheel Loader Steering and Brake Systems. The answers are provided on the following page. The actual student posttest are provided in the Student Materials section. The module posttest may be used as a pretest. This posttest only addresses Objective 8. Objective 1 was accomplished by Lab A, Objective 2 was accomplished by the tests in Lab B, Objective 3 was accomplished by Lab C, Objective 4 was accomplished by the tests in Lab D, Objective 5 was accomplished by Lab E, Objective 6 was accomplished by Lab F, and Objective 7 was accomplished by the case study. However, all labs may be used to supplement the posttest.

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Posttest

992G Wheel Loader Steering System and Brake System Components and Functions Posttest

INSTRUCTOR NOTE

Classroom Posttest Students may refer to their course materials and class notes when taking the posttest. Students may not consult with others during the posttest. Students will match the correct Steering or Brake System component with the correct function.

INDIVIDUAL EXERCISE

Procedure: Give students a copy of the "992G Wheel Loader Steering and Brake System Components and Functions Posttest." Explain the process for filling out the posttest. Inform students that they may refer to class notes or any other materials while taking the test. Inform students that they may not confer among themselves. Discuss completed test with class.

MATERIALS NEEDED

___ 992G Wheel Loader Steering and Brake System Components and Functions Posttest ___ Pen or pencil

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Posttest

992G Wheel Loader Steering System and Brake System Components and Functions Posttest
Directions: Match each component to the correct function. (Each correct match is worth 10 points.) Function C Component Front axle cooling pump Function Definition A. Supplies oil to steering system when the engine is ON

Steering pump

B. Supply oil to the brake system when the engine is OFF

Brake pump

C. Supplies oil to the front differential and service brakes

Pressure reducing valve

D. Supplies oil to the brake system when the engine is ON

Rear brake manifold

E. Controls oil flow and pressure to service brakes

Parking brake valve

F. Supplies pilot oil from the main steering pump in case of pilot pump failure

Tandem brake valve

G. Directs pilot oil to the main control valve

Quad check valve

H. Provides a smooth return of the control valve to the HOLD position

Brake accumulators

I. Directs main pump oil to the service brakes and the parking brake

Pilot control valve

J. Controls oil flow to release parking brake