992C - BRAKE SYSTEM Testing and Adjusting SENR 2520-00

992C Wheel Loader 49Z00001-UP (MACHINE) POWERED BY 3412 Engine(SEBP137...
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Product: WHEEL LOADER

Model: 992C WHEEL LOADER 49Z
Configuration: 992C Wheel Loader 49Z00001-UP (MACHINE) POWERED BY 3412 Engine
Testing and Adjusting

992C WHEEL LOADER BRAKE SYSTEM
Media Number -SENR2520-00 Publication Date -01/04/1982 Date Updated -11/10/2001
Testing And Adjusting
Introduction
NOTE: For Specifications with illustrations, make reference to the SPECIFICATIONS FOR 992C
WHEEL LOADER BRAKE SYSTEM, Form SENR2519. If the Specifications in Form SENR2519
are not the same as in the Systems Operation and the Testing and Adjusting, look at the printing date
on the back cover of each book. Use the Specifications in the book with the latest date.
NOTE: For Electrical and Hydraulic Systems schematics, make reference to: Schematic for 992C
Wheel Loader Hydraulic System, Form SENR2523. Schematic for 992C Wheel Loader Electrical
System, Form SENR2527.
Brake System
When making an analysis of a hydraulic system for bad operation, remember that correct oil flow and
pressure are necessary for correct operation. Oil flow is a function of the output of the pump. The
output of the pump is a function of engine speed. Restriction to the flow of oil causes oil pressure.
Sudden movement of the machine or release of oil under pressure can

cause injury to persons on or near the machine. To prevent possible
injury, do the procedure that follows before testing and adjusting the
brake system.
1. Move the machine to a smooth horizontal location. Move away from working machines and
personnel. Stop the engine.
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992C Wheel Loader 49Z00001-UP (MACHINE) POWERED BY 3412 Engine(SEBP137... Page 2 of 18
2. Permit only one operator on the machine. Keep all other personnel either away from the machine or
in view of the operator.
3. Activate the parking and emergency brakes. Lower the bucket to the ground. Put blocks in front of
and behind the wheels.
4. Push on the brake pedal many times until there is no more brake oil pressure.
5. Make sure all oil pressure is released before any fitting, hose or component is loosened, tightened,
removed or adjusted.
Visual Checks
Magnet.
1. Check the oil level in the hydraulic oil supply tank. Slowly loosen the tank filler cap. Permit the
pressure in the tank to be removed before the cap is removed.
2. Inspect all oil lines. connections and outer valves for leaks or damage.
3. Inspect the brake control linkage for any damage. Check the adjustments.
4. Remove the filter elements and check for foreign material. Use a magnet to make a separation of
material with iron (ferrous) from all other material. If any ferrous material is found, the component
with damage must be found and a repair must be made. The hydraulic system must then be flushed.
5. Check the torque of all bolts.
Instrument Checks
5P8687 Tool Group.5S5123 Hydraulic Testing Group.
Make reference to WARNING on first page of the BRAKE SYSTEM

TESTING AND ADJUSTING section.
Check or Pump Efficiency
For any pump test, the pump flow, measured in gpm (liter/min) at 100 psi (690 kPa) will be larger
than the pump flow at 1000 psi (6900 kPa) at the same rpm.
The difference between the pump flow of two operating pressures is the flow loss...
Flow loss when expressed as a percent of pump flow is used as a measure of pump performance.
Example of finding percent of flow loss...
If the percent of flow loss is more than 10%, on machine, (15% on the bench) pump performance is
not good enough.
*
Numbers in examples are for illustration and are not values for any specific pump or pump condition.
See SPECIFICATIONS for pump flow of a new pump at 100 psi and 1000 psi.
Test on The Machine
Measure pump flow at 690 kPa (100 psi) and at 6900 kPa (1000 psi) with engine at 1000 rpm.
Test On The Bench
If the test bench can not be run at 1000 psi at a high rpm, do the first part of the test with the pump
shaft rotation at 1000 rpm. Measure pump flow at 690 kPa (100 psi) and at 6900 kPa (1000 psi). Then
in order to measure the pump flow for the last part of the test, see SPECIFICATIONS for: Pump rpm
at 100 psi with the engine at 1000 rpm.
Operation Checks
Accumulator Charging Valve
0 to 20 700 kPa (0 to 3000 psi) pressure gauge.
1. Stop the engine and completely remove all oil pressure from the brake circuit by this method:
Activate the parking brake. Stop the engine. Push on the brake pedal many times until there is no
brake pressure.
ACCUMULATOR CHARGING VALVE

1. Plug.
2. Remove plug (1) on the accumulator charging valve. Install 0 to 20 700 kPa (0 to 3000 psi)
pressure gauge.
3. Look at the pressure gauge. Before the engine is started, the oil pressure must be 0 kPa (0 psi).
4. Start the engine. Look for a stop (pause) in the increase of oil pressure. Make a record of the oil
pressure at this point. This is the approximate nitrogen charge (pre-charge) pressure in the
accumulator.
5. A second pause must follow the first. This is the cut-in pressure of the accumulator charging valve.
6. The oil pressure must increase to a maximum. Make a record of this pressure also. This is the
cutout pressure of the accumulator charging valve. Cutout pressure is 13 300 ± 690 kPa (1925 ± 100
psi). If the cutout pressure is not in this range, make an adjustment as follows: Stop the engine.
Remove the oil pressure in the brake circuit. Remove the cover for springs (8) and install or remove
shims (9) as needed. One shim will change the pressure 230 kPa (33 psi).
7. When the cutout pressure is correct, start the engine, push the brake pedal many times. Look at the
test gauge and check at what pressure the accumulator charging valve starts charging (cut-in
pressure).
ACCUMULATOR CHARGING VALVE IN CUT-IN POSITION

1. Passage. 2. Spring. 3. Retainer. 4. Detent balls (nine). 5. Check valve. 6. Outlet passage to accumulator. 7. Charging
valve spool. 8. Springs. 9. Shims. 10. Shims. 11. Piston. 12. Passage. 13. Relief valve. 14. Orifice. 15. Orifice. 16.
Passage. 17. Inlet passage from pump. 18. Shims. 19. Flow control valve spool. 20. Spring. 21. Outlet passage to hydraulic
tank. 22. Spring. 23. Chamber. 24. Radial holes. 25. Outlet passage to hydraulic tank. 26. Radial holes.
8. If the pressure differential from cut-in to cutout is not in the range of 3950 ± 690 kPa (575 ± 100
psi), stop the engine and remove the oil pressure in the brake circuit. Add or remove shims to make an
adjustment to the pressure differential. More shims will cause a decrease in the cut-in pressure.
9. The first pause in oil pressure must be about 5500 to 6000 kPa (775 to 825 psi) if the precharge
pressure in the accumulator is correct.
NOTE: Make reference to TEST AND CHARGE THE ACCUMULATOR for a test with more
accuracy or if this test shows an indication of a low charge.
NOTE: If the relief valve is to be checked, leave the test equipment installed. If the relief valve is not
to be checked, remove the test equipment.
Relief Valve Test And Adjustment
With the test equipment installed as described in Accumulator Charging Valve, use this procedure to
test the relief valve:
To the test the operation of the relief valve, it is necessary to keep charging valve spool (7) in the
charging position. Make a brass or aluminum spacer as shown. Remove the plug behind piston (11).
Remove the piston and put the spacer on the piston. Install the piston and spacer. Install the plug.
Tighten the plug to 70 ± 4 N·m (50 ± 3 lb. ft.).
SPACER (Brass or Aluminum)

A. 9.7 mm (.380 in.). B. 9.2 mm (.360 in.). C. 16.5 mm (.650 in.).
Start the engine and permit the oil pressure to go up. The relief valve opens at 18 600 ± 345 kPa (2700
± 50 psi). If the relief valve setting is not correct, add or remove shims (18) as needed.
NOTICE
After the relief valve test, stop the engine, remove the oil pressure from
the brake circuit. Remove the spacer.
Brake Control Valve
0 to 6900 kPa (0 to 1000 psi) Gauge.

1. Remove plug (7) in the end of the brake control valve. Install a 0 to 6900 kPa (0 to 1000 psi) gauge.
2. Start the engine and permit the oil pressure to go up to the accumulator cutout pressure.
3. Fully push the brake pedal and check the reading on the test gauge. The correct gauge reading is
5500 ± 170 kPa (800 ± 25 psi).
4. If the pressure is not in the correct range, install or remove shims (11) as needed. One shim will
change the pressure by 90 kPa (13 psi).
BRAKE CONTROL VALVE

1. Orifice for check valve. 2. Spring. 3. Delivery passage. 4. Spool. 5. Springs. 6. Plunger. 7. Plug. 8. Piston. 9. Supply
passage. 10. Return oil passage. 11. Shims.
Test and Charge The Accumulator
7S5437 Nitrogen Charging Group
Do not use oxygen. Dry nitrogen is the only gas approved for use in the
accumulators. A charge of oxygen gas put into the accumulator, will
cause an explosion. This danger will not happen if nitrogen cylinders
with standard CGA (Compressed Gas Association, Inc.) Number 580
Connections are used. When you order nitrogen gas be sure that the
cylinders are equipped with CGA No. 580 Connections. Do not use 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 the nitrogen charging equipment to a valve that can be used
interchangeably on nitrogen, oxygen or other gas cylinders. BE SURE
YOU ARE USING DRY NITROGEN.
Stop the engine. Push on the brake pedal many times until there is no brake pressure. The accumulator
piston must be on the bottom of the cylinder to be sure that the pressure of the nitrogen charge is
correct.
Gas pressure is variable with temperature. The accumulator must be at the same temperature as the air
around it before it can be checked or a charge put into it. Use the chart for the correct nitrogen
charging pressure.
NITROGEN CHARGING GROUP

1. Pressure gauge. 2. Connection to nitrogen cylinder valve. 3. Regulator assembly. 4. Valve. 5. Pressure gauge. 6.
Pressure regulating screw. 7. Valve handle. 8. Chuck.
Check For Nitrogen Charge In The Accumulator
1. Remove the cap from the valve assembly on the accumulator.
2. Use the 0 to 13 800 kPa (0 to 2000 psi) gauge (5) to check the nitrogen charge in the accumulator.
TYPICAL EXAMPLE OF TEST EQUIPMENT INSTALLED

4. Valve. 5. Pressure gauge. 7. Valve handle. 8. Chuck.
3. Install chuck (8) on the valve of the accumulator.
4. Turn valve (7) on chuck (8) completely in (clockwise). Check the temperature of the air around the
accumulator. The pressure on the gauge must be inside the tolerances shown on the chart.
5. If the pressure on the gauge is too high, slowly open valve (4) to lower the pressure.
6. If the pressure on the gauge is too low, charge the accumulator as follows:
Charge Procedure For The Accumulator
7. Connect the hose from the nitrogen cylinder to valve (4).
8. Close valve (4) and open the valve on the nitrogen cylinder. Make an adjustment to screw (6) on
the regulator assembly until gauge (1) is at the pressure needed to correctly put a charge into the
accumulator. Use the chart as a reference for the correct charging pressure.
9. Open valve (4) and put a charge into the accumulator. Turn valve (4) off. If the pressure on gauge
(5) is the same as gauge (1) and does not change, the accumulator has the correct charge. If there is a
decrease in pressure on gauge (5), open valve (4) and let more nitrogen go to the accumulator. Do this
procedure as many times as necessary until the pressure on gauge (5) is the same as gauge (1) and
does not change when valve (4) is turned off.
10. Turn off valve (4). Turn the valve on the nitrogen cylinder off.
11. Turn valve (7) on chuck (8) completely out (counterclockwise).
12. Remove the test equipment.
Charge Procedure For A Rebuilt Accumulator
It is necessary to remove all air from the nitrogen end of the accumulator. When the accumulator is
rebuilt, put approximately 1.9 liters (2 quarts) of SAE 10W hydraulic oil in the nitrogen end of the
accumulator. This oil will be used to help get the air out of the nitrogen end of the accumulator and
also to put a lubricant at the top seal of the accumulator piston. After the accumulator is installed on
the machine, charge it as follows:
NOTICE
Low nitrogen charge can cause early pump failure because of short
cycle times between the cut-in and cutout operations of the
accumulator charging valve.
1. Use the same equipment as used to check the nitrogen charge in the accumulator.
2. Valve (7) on chuck (8) must be turned in completely (clockwise). Open valve (4).
3. Start the engine and let it run until it is warm. As oil goes into the bottom of the accumulator, the
air and then the oil will be pushed out of the top through the test equipment. When the oil flow stops,
the top of the accumulator will be free of air.
4. Close valve (4) completely.
5. Stop the engine and push the brake pedal several times. This will permit the oil pressure in the
brake system to be removed. The piston in the accumulator will be at the top of the accumulator.
6. Put a charge of nitrogen in the accumulator. Follow the procedure in Steps 7 through 12 in
CHARGE PROCEDURE FOR THE ACCUMULATOR. The charging cycle will take longer because
the piston will have to be moved to the bottom and the oil will have to be moved out of the
accumulator.
Transmission Neutralizer Control Valve
0 to 6900 kPa (0 to 1000 psi) Gauge.

LOCATION TO INSTALL GAUGE

1. Cap.
1. Remove cap (1) and install a 0 to 6900 kPa (0 to 1000 psi) gauge.
2. Start the engine and push the brake pedal several times to remove the air from the brake system.
3. When the accumulator is fully charged, push the left brake pedal all the way and look at the gauge.
The pressure must be 5500 ± 170 kPa (800 ± 25 psi). If the pressure is not within this range, make
adjustments given in BRAKE CONTROL VALVE.
4. Look at the gauge and release the left brake pedal. The pressure must go down to 690 kPa (100 psi)
in .2 to .5 seconds. This delay causes the transmission to engage again before the wheel brakes
completely release.
TRANSMISSION NEUTRALIZER CONTROL VALVE

2. Shims.
5. Shims (2), in the transmission neutralizer control valve, control this delay time setting. Install shims
(2) to cause a decrease in the delay time setting. Remove shims (2) to cause an increase in the delay
time setting.
Emergency And Parking Brake
0 to 27 500 kPa (0 to 4000 psi) Gauge.
Test for Parking Brake (Brake Fully Activated).
1. Start the engine and permit the oil pressure in the accumulator to get to cutout pressure.
2. Pull the emergency and parking brake control valve out to activate the brake.
3. Put the power shift transmission into second speed forward.
EMERGENCY AND PARKING BRAKE

1. Springs. 2. Plate. 3. Guide bolts. 4. Disc. 5. Plate. 6. Oil chamber. 7. Release piston. 8. Shaft.
4. Push the governor control pedal. The machine must not move. If it does, check the wear on the
plates and discs. The minimum thickness of eight plates (2) and nine discs (4) is 91.54 mm (3.604
in.). Check the force of springs (1).
Electric Warning System
For electric Warning System information, see Form SENR2526 in the OPERATOR'S STATION
section.
Remove Air From Brake System (Bleed The Brakes)

Air must not be in the oil for the brake hydraulic system. Air in the system can prevent complete
brake application and it is possible that the wheels on the vehicle can not be stopped.
Wheel Brakes
1. Check the level of the oil in the hydraulic tank. Keep the tank full all through the air removal
procedure. Use the correct oil in the hydraulic system (SAE 10W).
2. Remove air from the oil in the accumulator as follows: Start the engine and permit the oil pressure
to go up to cutout pressure. Stop the engine. Open plug (1) on the brake control valve. Push the brake
pedal and hold until no air is in the oil from plug (1). Close the plug, then release the brake pedal.
BRAKE CONTROL VALVE

1. Plug for removal of air.
3. Connect a hose to bleeder screw (2) at each wheel brake.
4. Start and run the engine at low idle. Open bleeder screw (2) to permit a flow of oil through the
hose. Push the brake pedal and hold until the flow of oil from the hose is free of air. Close the bleeder
screw. Do this procedure for each wheel brake, but do only one wheel brake at a time.
BLEEDER SCREW FOR WHEEL BRAKES

2. Bleeder screw.
5. Fill the hydraulic oil tank.
6. If the brakes feel soft during application in the first few hours of operation, do the air removal
procedure again.
Emergency and Parking Brake
Parking brake application is mechanical, but it is just as important to remove the air from the brake
release system for the parking brake as it is to remove the air from the wheel brakes. Use the
procedure that follows to remove the air from the emergency and parking brake.
1. Start the engine and permit the oil pressure to go up to the cutout pressure. Stop the engine.

2. Put the parking brake control valve in the RELEASE position (push the control valve spool IN).
3. Connect a hose to bleeder screw (3) on top of the emergency and parking brake housing. Slowly
open bleeder screw (3) to permit a flow of oil through the hose. Permit the flow of oil until there is no
air in the oil. Close the bleeder screw.
BLEEDER SCREW FOR EMERGENCY AND PARKING BRAKE

3. Bleeder screw.
Adjustment Of Brake Control Linkage And Brake Pedal Travel

1. Adjust length of rod (3) and rod end (5) until the distance from the center of pin (1) to the center of
the pin in rod (3) is 108.0 mm (4.25 in.). Tighten nut (2).
BRAKE CONTROL LINKAGE

1. Pin. 2. Nut. 3. Rod. 4. Lever. 5. Rod end. 6. Screw. 7. Lever.
2. Adjust length of rod (9) and rod end (11) until the distance from the center of pin (8) to the center
of pin (17) is 137.2 mm (5.40 in.). Tighten nut (10).

8. Pin. 9. Rod. 10. Nut. 11. Rod end. 12. Screw. 13. Cable assembly. 14. Lever. 15. End. 16. Nut.
3. Connect cable assembly (19) to lever (7) and cable assembly (13) to lever (14).
4. Adjust screw (6) on lever (4) to get about 0.5 mm (.02 in.) clearance between lever (4) and screw
(6).

17. Pin. 18. Lever. 19. Cable assembly. 20. End. 21. Nut.
5. Adjust screw (12) on lever (18) to get about 0.5 mm (.02 in.) clearance between lever (14) and
screw (12).
6. Adjust angle assembly (24) against lever (22) to hold pedal (26) above stop (28) at dimension (C)
of 82.6 mm (3.25 in.). Do this for both pedals.
BRAKE PEDAL
22. Lever. 23. Shaft. 24. Angle assembly. 25. End. 26. Pedal. 27. Nut. 28. Pedal stop. C. Distance between pedal and pedal
stop.
NOTE: If additional adjustment is needed, remove lever (22) from shaft (23). Install lever (22) in a
different location (rotate it) on the splines of the shaft. Then, use the angle assembly for a final
adjustment of the pedal.
7. Loosen nut (27) and adjust end (25) of the cable assembly until the hole in end (25) is in alignment
with the hole in lever (22).
8. Connect cable assembly to lever.
9. Do Steps 7 and 8 again for the other pedal.
10. Make a final adjustment to the clearance, between levers (7) and (14) and screws (6) and (12), to
get a clearance of 0.5 ± 0.2 mm (.02 ± .01 in.). Tighten the lock nuts on screws (6) and (12).
11. Any addition to the adjustment of cable assemblies (13) and (19) can be made with ends (15) and
(20). Make sure nuts (16) and (21) are tight.
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992C Wheel Loader 49Z00001-UP (MACHINE) POWERED BY 3412 Engine(SEBP137...

Product: WHEEL LOADER

Testing and Adjusting

Testing And Adjusting

Sudden movement of the machine or release of oil under pressure can

5. Check the torque of all bolts.

Make reference to WARNING on first page of the BRAKE SYSTEM

Check or Pump Efficiency

Example of finding percent of flow loss...

Test on The Machine

Test On The Bench

0 to 20 700 kPa (0 to 3000 psi) pressure gauge.

ACCUMULATOR CHARGING VALVE

ACCUMULATOR CHARGING VALVE IN CUT-IN POSITION

Relief Valve Test And Adjustment

SPACER (Brass or Aluminum)

Brake Control Valve

0 to 6900 kPa (0 to 1000 psi) Gauge.

Make reference to WARNING on first page of the BRAKE SYSTEM

BRAKE CONTROL VALVE

Test and Charge The Accumulator

7S5437 Nitrogen Charging Group

NITROGEN CHARGING GROUP

Check For Nitrogen Charge In The Accumulator

1. Remove the cap from the valve assembly on the accumulator.

TYPICAL EXAMPLE OF TEST EQUIPMENT INSTALLED

3. Install chuck (8) on the valve of the accumulator.

Charge Procedure For The Accumulator

7. Connect the hose from the nitrogen cylinder to valve (4).

11. Turn valve (7) on chuck (8) completely out (counterclockwise).

12. Remove the test equipment.

Charge Procedure For A Rebuilt Accumulator

4. Close valve (4) completely.

Transmission Neutralizer Control Valve

0 to 6900 kPa (0 to 1000 psi) Gauge.

Make reference to WARNING on first page of the BRAKE SYSTEM

LOCATION TO INSTALL GAUGE

TRANSMISSION NEUTRALIZER CONTROL VALVE

Emergency And Parking Brake

0 to 27 500 kPa (0 to 4000 psi) Gauge.

Test for Parking Brake (Brake Fully Activated).

3. Put the power shift transmission into second speed forward.

EMERGENCY AND PARKING BRAKE

Electric Warning System

Remove Air From Brake System (Bleed The Brakes)

BRAKE CONTROL VALVE

3. Connect a hose to bleeder screw (2) at each wheel brake.

BLEEDER SCREW FOR WHEEL BRAKES

5. Fill the hydraulic oil tank.

Emergency and Parking Brake

Make reference to WARNING on first page of the BRAKE SYSTEM

BLEEDER SCREW FOR EMERGENCY AND PARKING BRAKE

Adjustment Of Brake Control Linkage And Brake Pedal Travel

BRAKE CONTROL LINKAGE

BRAKE CONTROL LINKAGE

BRAKE CONTROL LINKAGE

8. Connect cable assembly to lever.

9. Do Steps 7 and 8 again for the other pedal.

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