Wheel Loader Typical Failure

Analysis Manual—Braking
System

Service Department of SDLG Import & Export Company

目录
LG918 Brake Caliper Fallen off ................................................................................................................................... 1
LG933L Engine Compressor Oil Leakage .................................................................................................................... 3
LG933L Fault analysis of holding clamp of brake caliper ........................................................................................... 4
LG936L Brake pressure is too high ............................................................................................................................. 6
LG936L Off Tracking During Brake.............................................................................................................................. 8
LG936LBrake Pressure Is Too Low ............................................................................................................................ 10
LG936L Parking Brake Failure ................................................................................................................................... 13
LG936LBrake pressure is too high ............................................................................................................................ 15
LG936L parking brake can not be released .............................................................................................................. 17
LG936L The Brake Pressure Is Too Low .................................................................................................................... 19
LG936L brake system work abnormal ...................................................................................................................... 21
LG936L parking brake cannot be released ............................................................................................................... 23
L938 cannot release the parking brake.................................................................................................................... 26
LG952H Service Brake Weakness ............................................................................................................................. 29
LG953L Weak Power In Running .............................................................................................................................. 31
LG953 Longer Braking Distance ............................................................................................................................... 33
Ḷ953F Parking Brake can’t Release Failure ............................................................................................................... 35
The brake of L953F is not released in time .............................................................................................................. 38
LG956L service brake weak ...................................................................................................................................... 41
L956F parking brake problem .................................................................................................................................. 43
L956F Loss of service brakes ............................................................................................................................. 44
The L956F loader run to one side ............................................................................................................................ 46
L956F parking break can not release ....................................................................................................................... 48
L956H brake damage and charge pump oil leakage ................................................................................................ 49
L956H Parking problem ........................................................................................................................................... 50
Not packing brake of L958F ..................................................................................................................................... 52
LG958L steering is operated heavy .......................................................................................................................... 54
LG959 Weak Brake Performance ............................................................................................................................. 56
LG959 Park Brake Problem ...................................................................................................................................... 58
The L959F parking brake cannot be released and cannot be put into gear ............................................................ 61
LG968 High Air Pressure .......................................................................................................................................... 63
L975F low brake pressure fault ................................................................................................................................ 65
No parking brake for LG978 ................................................................................................................................ 67

1
 LG918 Brake Caliper Fallen off

I．Problem description
Brazil Customer feedback: There is a LG918, SN # D9012564, working time 966h,
working condition metal mine, and its right rear brake caliper fallen off to the ground.
II．Reason analysis
SDLG wheel loader LG918 is equipped with dry disc brake axle. The boost

transfers the pressured air force into hydraulic oil force, and the pressured hydraulic oil
gets to the brake piston and presses the disc to realize the service brake.
The disc is installed with hub reduction, and the brake calipers is with the axle
body, so the brake can be realized. Normally, the brake calipers cannot be taken off
easily, and it is very dangerous if this problem happened, because the machine could
not be stopped when you need to brake.

III. Field inspection

Check the fallen bolts, and didn’t find any defects, so it’s not the bolt’s problem.
The bolts for fixing the brake calipers need to smear some lock glue----like

Loctite 262. When we inspected the fallen calipers area, we didn’t find any

trace for the glue, so we confirm this is the reason why the lock bolts was

1
 fallen, and so the brake calipers.

IV. Solution
Replace the brake calipers and bolts, and smear the lock glue on the bolts.

V. Tips
This malfunction is an accidental case, but in our routine maintenance and
inspection, we need to pay attention to the brake system device specially, in case some
problem happens. If the brake system is down, it will be very dangerous in our normal
working.

2
 LG933L Engine Compressor Oil Leakage

Ⅰ.Basic information:
One LG933L wheel loader, oil was leakage form the compressor
shaft ,work hour was 112h.
Ⅱ.Reasons analyses：
Possible reasons：

1、The sealing is failure ;

2、The cylinder body is failure ；
Ⅲ.Check process:
Disassembled the compressor and check ,the sealing was failure .

Ⅳ. Solution:
Replace a new compressor ,the failure was solved.

Ⅴ.Register:
We’d better to analysis all the reasons that can cause the issues for our
machine and to choose the right way to solve the problems one by one.

(Central Asia region offer)

3
LG933L Fault analysis of holding clamp of brake caliper

Ⅰ. Problem Description:
A lg933 loader in Russia has a working time of 1218h. It is found that
there is a phenomenon of holding clamp during the working, so it is unable
to move forward, affecting the work.

Ⅱ. Cause analysis:

There may be many reasons for the brake caliper holding clamp fault.
It is necessary to check from the beginning and remove the fault in
sequence.

1. The brake valve may be faulty.

2. The booster pump is faulty.
3. If the brake fluid is normal after changing, it means the brake fluid

is deteriorated.
4. Brake caliper and brake pad failure due to long-term wear.
Ⅲ. On site inspection:

1. First, check the whole machine in a comprehensive way according

to the sequence, and observe whether the brake tongs of the front and rear
axles are locked at the same time. If the tongs are held at the same time, it
is likely that the brake valve is broken, the pedal cannot be pressed back or
the exhaust is not smooth.
4
 2. It is still abnormal after changing the brake fluid. It is not the

problem of the brake fluid. It may be the fault of the booster pump or the
brake caliper.
3. After observation, the brake caliper is seriously worn.
Ⅳ. Treatment measures:
Replace the original brake caliper and brake pad, and retest for
troubleshooting. Improper maintenance and excessive wear are the causes
of this fault.。
Ⅴ. Warm tips:
The brake caliper is a key component in the service brake system. In

addition to providing support for the smooth braking of the equipment, this
time also reflects that only according to the specified maintenance can it
be unobstructed.

(From Eastern Europe)

5
 LG936L Brake pressure is too high

Ⅰ Failure Description:
Sudan customer feedback: One stock LG936L with working time is
5h, The failure phenomenon is brake pressure is too high（9 bar）.

Ⅱ Reasons analyses：
Base on the structure and working principle of LG936L braking
system, find the reason from the following several aspects.
1 Oil water separater is broken.
2 Brake air pressure gauge is broken.

3 Pressure sensor is broken.

4 Relief valve has failure..

6
Ⅲ Check process:
1 Base on the failure exclusion principle: from simple to difficult,

and from the outside to the inside.First check whether the oil-water
separator and exhaust is normal, oil water separator exhaust is abnormal by
checking, the relief valve of the oil water separator opens, oil water

separator is broken.
2 check the brake pressure gauge on the dashboard, return to normal,it
is ok.

3 by changing the pressure sensor, ruled out the faulty

4 check the air tank relief valve, it is ok.
Ⅳ Solution:
Replace the oil water separator assembly, and the problem is solved.
Ⅴ Register:
We’d better to analysis all the reasons that can cause the issues of our
machine and to choose the right way to solve the problems one by one

7
 LG936L Off Tracking During Brake

Ⅰ. Basic information:
One customer feedback LG936Lwheel loader feedback: One LG936 loader run to one
side when the operator brake loader.
Ⅱ. Reasons analyses：
The main reason of running to one side is that brake torque of left and right wheels are

different in the brake moments.

The cause:
1 The brake caliper on the side of the wheel is “jammed” and difficult to get away
during running, the cause is usually the damage of the rectangle seal ring which push the
piston reset.
2 When push the brake pedal, the caliper didn’t work, due to the internal leakage or the

oil-way is blocked, the brake fluid can’t reach brake caliper, it lead to the result.
3 Piston of the caliper is rust, it can cause the result.
Ⅲ. Check process:

The customer feedback it is more than three months the loader was in the stock.
Check the brake shoe when operator brake the loader, find the brake shoe on left side
can’t move, the technician find the caliper is heavy rust after disassembling the brake caliper

Ⅳ .Solution:
Clean the piston of brake caliper, change seals and reassemble the caliper, the loader
can work normally.

Ⅴ. Warm tips:
We should ask dealer to check and maintenance the machines at regular internal when

8
store the machines by long term.

9
 LG936LBrake Pressure Is Too Low

Ⅰ.Basic information:
Sudan customer feedback: One LG936L with working time is 1670h,The failure
phenomenon is brake pressure is too low and alarm.

Ⅱ.Reasons analyses：
Base on the structure and working principle of LG936L braking system, find the reason
from the following several aspects.
1 Air c has failure
2 Air pipe has leak;

3 Air tank leak;

4 Pressure sensor is damage;
5 The relief valve is damage;

6 The barometer is damage;

7 Air compressor parator is damage
8 The oil-water se ompressor belt is too loose;

10
Ⅲ.Check process:
1.Base on the failure exclusion principle:from simple to difficult, and from the outside

to the inside.First check the belt/Air pipe and air tanks，they are ok.
2. On-site inspection, Check the sensors/safety valve/air pressure gauge and air
compressor unit,they are ok.

3. check whether the oil-water separator and exhaust is normal, oil-water separator
exhaust is abnormal by checking, oil-water separator is broken.
Ⅳ.Solution:
Replace the oil water separator assembly, and the problem is solved.

Ⅴ.Warm tips:
We’d better to analysis all the reasons that can cause the issues for our machine and to

11
choose the right way to solve the problems one by one.

12
 LG936L Parking Brake Failure

Ⅰ. Basic information:
A LG936L has no parking brake, however, the service brake is OK, reported by
Brazilian dealer (the brake pressure is 0.7MPa).
Ⅱ . Reasons analyses：
Brake system failure should be analyzed from the brake components and brake

electrical system:
The service brake is OK, indicates that the air reservoir which supplies the service
brake and parking brake is OK;
No parking brake indicates that the brake solenoid, brake chamber, parking brake may
have failure;
Resort to electrical schematic to find possible failures.

Ⅲ .Solutions:
The hour meter is 155 hrs, observe the brake chamber and find no leakage, the brake
shoes and brake disk are also OK, indicates that the brake components are OK;

Check the fuse F6 and the fuse is not blow out;

The brake pressure is 0.7MPa, indicates the emergency brake switch is engaged (when
pressure is lower than 0.4MPa, the emergency brake switch will switch off);

When brake solenoid is powered, the solenoid will make a sound, indicates the brake
solenoid is OK;
Press down the parking brake button, as is often the case, 54# and 55# will disconnect,

the solenoid will power off, the parking brake will come into effect, however, this machine
has no parking brake, indicates that 54# and 55# are still connected, the parking brake switch
is broken, replace a new one and troubleshooting.
13
 Powered by region Americas

14
 LG936LBrake pressure is too high

Ⅰ. Failure Description:
Sudan customer feedback: One stock LG936Lwith working time is 1274h,The failure
phenomenon is brake pressure is too high（9.5 bar）.

Ⅱ.Reasons analyses：
Base on the structure and working principle of LG936L braking system, find the reason
from the following several aspects.
1.Oil water separater is broken.
2.Brake air pressure gauge is broken.
3.Pressure sensor is broken.
4.Relief valve has failure..

15
Ⅲ.Check process:
1. On-site replacement of oil-water separation assembly, the fault has not been solved,

so the oil-water separator is ok.

2.check the brake pressure gauge on the dashboard, return to normal,it is ok.
3.by changing the pressure sensor, ruled out the faulty

4. Check the relief valve and find it is not working.

Ⅳ. Solution:
Replace the relief valve of the air storage tank, and the problem is solved.

Ⅴ.Register:
We’d better to analysis all the reasons that can cause the issues of our machine and to
choose the right way to solve the problems one by one
he problems one by one.

16
 LG936L parking brake can not be released

Ⅰ. Basic Information:
The whole machine works for 500 hours, and the customer feedback that the parking
brake of the whole machine cannot be released.
Ⅱ. Reason Analyses:
The main reasons why parking brake cannot be released are as follows:

Parking brake switch problem

Parking brake solenoid valve
Parking brake air chamber problem
Ⅲ. Checking Process:
Step 1：Cut off the gas pipe of parking gas chamber on site, remove parking brake, and
eliminate parking brake gas chamber fault.

Step 2：Check parking brake switch, remove and brake power is normal, troubleshoot
brake switch fault.
Step 3: Disassemble and check parking brake solenoid valve, power detection found

that the solenoid valve does not work, so it is judged that parking solenoid valve fault caused.

Ⅳ. Solution:
17
 After replacing parking solenoid valve, troubleshoot.
Ⅴ .Warm tips:

Straighten out electrical schematic diagram and exclude item by item.

（Eastern Europe Region）

18
 LG936L The Brake Pressure Is Too Low

Ⅰ. Basic information:
Customer feedback: LG936L (E3623115A29) models, The brake pressure is too low,
the braking effect is poor.

Ⅱ. Reasons analyses：
The cause of the brake pressure is too low:
1 Air compressor belt is too loose;
2 Air pipe has leak;
3 Air tank leak;

4 Pressure sensor is damage;

5 The relief valve is damage;
6 The barometer is damage;

7 Air compressor has failure;

8 The oil-water separator is damage.
Ⅲ. Check process:

1 On-site inspection, the belt/Air pipe and air tanks are ok;
2 On-site inspection, sensors/safety valve/the barometer and oil-water separator are ok;
3 Disassemble inlet pipe of the oil-water separator, and then start the machine. The air

19
pressure is too low, so there is the failure in air compressor.

Ⅳ .Solution:

Replaced the air compressor assembly, it is ok.

Ⅴ. Warm tips:
We’d better to analysis all the reasons that can cause the issues for our machine and to
choose the right way to solve the problems one by one.

20
 LG936L brake system work abnormal

Ⅰ. Failure Description:
Customer feedback: The working time of one LG936L is 407h, brake system work
abnormal.

Ⅱ.Reasons analyses：
According to the structure and working principle of the brake system, the following
reasons may exist:
1. Low brake air pressure;
2. The pipeline behind the air tank leaks;
3. Foot brake valve failure;
4. Shuttle valve failure;
5. The brake caliper is faulty;
6. The booster pump is faulty;
Ⅲ.Check process:
1. Start the whole machine and check whether the air pressure is normal;
2. Check the pipeline, no leakage is found;
3. Check the on-off performance of foot brake, no abnormality found;
4. The shuttle valve was disassembled and inspected, and no abnormality was found.
5. The friction plate and other problems of the brake caliper were removed and

21
inspected, and no abnormality was found.
6. Check the booster pump and find that there is a fault in the booster pump.

Ⅳ. Solution:
Replace the booster pump, test run, troubleshooting.

Ⅴ.Register:

Based on the analysis of the phenomenon, the fault cause is speculated, and the possible
fault cause is preliminarily found.

22
 LG936L parking brake cannot be released

I. Basic information：
One LG936L （Intent No.:E3623115A29）working for 545 hours,can not release the
parking brake.

Ⅱ. Reasons analysis：
LG936L adopts electro pneumatic parking brake. When the parking brake switch is

pressed, the brake solenoid valve is powered off, and the parking brake chamber
immediately exhausts and relieves pressure. Under the action of internal spring, the brake
lever is pulled up to block the transmission output flange.

The parking brake cannot be released for the following reasons:

1.The parking brake fuse (F6, 10A) is blown, resulting in the power failure of the brake
solenoid valve, and the whole vehicle is in the constant braking state;
23
 2.Brake solenoid valve fault, always in power-off exhaust state;

3.The hand brake switch (parking brake button) is faulty. It cannot be powered on no

matter it is pressed or turned up;

4.When the emergency brake switch (pressure switch, installed on the air tank to detect
the pressure of the air tank) fails, or the pressure of the air tank is low, lower than 0.4MPa,

the pressure switch will be automatically disconnected, both of which will cause the circuit
to be disconnected and the brake solenoid valve to be in the braking state;

24
 5.Circuit problem, open circuit;
III. Check process:

After examination:
1.The fuse is not blown ;
2.Use a multimeter to check the circuit, the circuit is powered off, remove the brake

solenoid valve and check it separately, it can be turned on and off normally;

3.Check the pressure switch of the air tank. By using the replacement method, it is
found that the pressure switch has been disconnected and the gas pressure in the gas storage
tank is normal;
4.It is judged that the pressure switch is faulty.

IV. Solution：

Change a new pressure switch，problem solved.

V. Warm tips：
Fault diagnosis and accurate diagnosis according to the fault phenomenon.

（Asia region provided）

25
 L938 cannot release the parking brake

I. Basic information：
One L938 only have 8 working hours, and the parking brake cannot be released.

II. Reasons analysis：

This L938(Indent No. L0380W3225A36E0 ) uses full hydraulic braking system.

According to the working principle of full hydraulic braking, the possible reasons of

the parking brake cannot be released are as below:

1、 Brake solenoid valve fault, internal open circuit or leakage;
2、 Brake valve block internal fault, leakage or damage of one way valve;
3、 Oil leakage of the parking brake cylinder;
26
 4、 The pressure of parking brake accumulator is insufficient, nitrogen leaks or
nitrogen is not charged for a long time;

5、 Parking brake switch failure, internal open circuit;

6、 The emergency brake switch fails, the brake pressure value cannot be accurately
sensed, or there is an internal open circuit;

7、 Harness connection problem, loose connector or worn circuit.

III. Check process:
The inspection was carried out from easy to difficult. Because it is only a parking brake

problem and the service brake is well, can except the dual charging valve block problem and
the pilot pump problem.

Check that the voltage resistance of the parking brake switch is normal;
The pressure of parking brake accumulator is normal;
The voltage resistance of brake solenoid valve is normal;
Check the urgent brake switch. It is found that the resistance is 0 ohm under standard
atmospheric pressure and the internal short. It is determined that the urgent brake switch is
faulty.

27
 The urgent brake switch is a pressure switch that checking the parking brake pressure.
Under normal conditions, when the pressure is higher than 60bar, it will automatically turn

on. And lower than 60bar, it will automatically turn off. And when the machine braking
system fails, resulting the pressure suddenly drops and cannot be stopped effectively, the
internal automatic disconnection will cause the parking brake system to power off , Realize

urgent braking to ensure the safety of machine and personnel. In this case, unplug the urgent
brake switch and place it under normal atmospheric pressure, the pressure is lower than
60bar, the internal should be in an open state, and the measuring resistance finds that the

internal is connected, indicating that the switch is malfunctioning.

IV. Solution：
Replace urgent brake switch and solve the problem.

V. Warm tips：
Fault diagnosis and accurate diagnosis according to the fault phenomenon.
（Asia region provided）

28
 LG952H Service Brake Weakness

Ⅰ. Basic information:
A LG952H occurred service brake weakness and long distance when braking. But
parking brake was normal.

Ⅱ. Reasons analyses：
According with LG952H braking system drawing analyze all relative parts, from

engine air compressor to brake disc.

1)Engine air compressor failure.

2)Air dryer leak cause braking system pressure lower..
3) Air tank leak cause braking system pressure lower.
4) Brake valve failure cause leak.
29
 5) Air booster failure cause leak.
6) Brake disc failure cause leak

7) Connection hose or pipe leak.

Ⅲ. Check process:
Checked and found that service brake weakness, but parking brake was well.

Checked and found brake lower pressure warming light was not working, it meaning
from engine air compressor to air tank was well.
Checked and fount all brake disc were well.

Disconnected front air booster oil hose and tested, then found that service brake
weakness.

Ⅳ. Solution:

Replace a new air booster, test machine, issue was gone.

Ⅴ. Warm tips:
We’d better to analysis all the reasons that can cause the issues for our machine and to

choose the right way to solve the problems one by one follow below regulation: from outer
to inner; from simple to complex.
（APAC Region）

30
 LG953L Weak Power In Running

Ⅰ. Basic information:
A LG953L with 2000hrs became weaker power in running suddenly, machine running
speed was not increase according with engine accelerator. Meanwhile, front booster brake
fluid injected from booster reservoir. Checked and found the brake calipers of front axle
were locking and brake disc temperature was high.

Ⅱ. Reasons analyses：
Analyze the reason follow brake system drawing:

1－brake caliper; 2—brake valve; 3—booster; 4—air dryer; 5—compressor; 6—air reservoir; 7—gauge.

1）Impurities in brake fluid and caused blocking

2）Brake valve inner parts blocked and can’t return, so the high pressure air push
booster working always
3）Booster rod or spring broken and can’t return
4）Piston of brake caliper blocked and can’t return
5）The clearance of brake shoes and brake disc is less or no
6）Foreign materials were blocked in brake caliper and brake disc

Ⅲ. Check process:
As only front booster brake fluid reservoir injected, so brake valve is in good condition,
then judged the reason as principle: from easy section to difficult section, from outside to
31
inside:
1) Checked brake fluid level and quality, normal

2) Checked front axle clearance of brake shoes and brake disc is less
3) Checked brake caliper and brake disc dock area, no foreign materials were
blocked

4) Dismantled booster hose to T joint and found much impurities

5) Dismantled brake caliper and found piston rusty seriously
Ⅳ. Solution:

Clean brake system oil circle and replace new brake caliper piston and relative seals,
then test machine, the issues was gone.
Ⅴ. Warm tips:
We’d better to analysis all the reasons that can cause the issues for our machine and to
choose the right way to solve the problems one by one follow below regulation: from outer
to inner; from simple to complex.
（Africa Region）

32
 LG953 Longer Braking Distance

Ⅰ.Basic information:
One LG953 is braking longer distance, and the temperature of braking plate is rises
quickly, the working time is 3004 hours

Ⅱ Reasons analyses：
The possible reasons is as following according to working principle:
1) Braking fluid is not enough;
2) Air is inside braking pipe
3) Braking pressure is low

4) Fraction plate worn seriously

5) Brake caliper failures
6) Booster pump failures

33
Ⅲ Check process:
Checking braking fluid level and normal

Push down braking pedal and loose air bleeds screw of brake caliper to let out air , to
find no normal air in pipe , but to feel that pressure is a litter low
Checking thickness of brake caliper and friction plate and which is normal

Push down brake caliper and piston could move trend, which should be failure
To analysis which should be failure of booster pump, to disassemble working pump
and find rusting of piston and inner cylinder and sealing worn seriously, resulting in brake

distance is longer, To check that they changed braking fluids before , so maybe it is relation
of changing air fluids
Ⅳ Solution:
To change booster pump and brake fluid, testing the machine, the failures was settling.
Ⅴ Warm tips:
It is harm seriously for inferior brake fluids, in order to be safety for machine and driver,
please to choose original brake fluids.

34
 Ḷ953F Parking Brake can’t Release Failure

Ⅰ. Basic Information:
New L953F only worked for 1.6 hour, after delivered to dealer yard, can’t release the
parking brake when driving it off the trail car.

Ⅱ. Reason Analyses:
L953F adopted the traditional park braking system, which is controlled via electrical

and action through air pressure, so this failure we should analysis at the two aspect.
Electrical failure reason:
Electric supply line is broken, leading to no electric supplied.

Parking brake switch working abnormal.

Parking brake solenoid is failure.

L953F Electrical Control System diagram

Air pressure action system failure reason:

35
 Air pressure is too low to push down the piston releasing the parking brake.
Parking brake booster is clamping stagnation.

Ⅲ. Checking Process:
Step 1：Start engine, check the low air alarm indicator is lighting, after engine ideal
for half an hour, check the low air alarm indicator is out of lamp, showing the air pressure
is in normal condition.

Step 2: press down the parking brake, no action of solenoid, then measure the connector
of solenoid, there is no electric. Firstly, check the electrical control box, finding the fuse is
intact. Secondly, disassemble the parking switch, find the switch no connected with electric

line. Therefore, connected line with switch.

Step 3：press down the parking switch again, still no action of solenoid, measure the
connector of solenoid, which has been supplied electric. So dismount the solenoid to test,

find it is abnormal.
Ⅳ. Solution:
Replaced new solenoid, the parking brake can be released normal.

Ⅴ. Warm tips:
Electrical control and air action type parking brake system, is the major type brake
system of China brand wheel loader parking brake system. Any failure should be separated
into two group, electrical failure or air system failure, then check each parts according to

36
from easy to complicated princepal.
（Vietnam Region）

37
 The brake of L953F is not released in time

Ⅰ.Problem Description:
There is an l953f in Chulachi, Russia, with the complete machine number of
vlgl953fcj0620098. The equipment works for 1000 hours and will be sold in February 2019.
According to user feedback, after working for about two hours, when braking, it will be
found that it is not timely to release the brake. What is the problem that the agent asked for

feedback.

Ⅱ.Cause analysis:
There are many reasons for untimely release of brake, which may be due to:

1. Air enters into the brake system, and the pipeline is mixed with air. When braking,
due to the air. The volume becomes smaller after being compressed, resulting in untimely
release of braking effect, and compression in the pipeline during release of braking.The

increase of air volume leads to the incomplete backflow of brake fluid.

2. The brake caliper is faulty, the rectangular oil seal is damaged, and the brake caliper
piston cannot return smoothly .Position or internal piston rusted.

3. Foot brake valve is faulty, internal piston movement is stuck.

4. The booster pump is faulty, the piston of the booster chamber of the booster pump is
worn abnormally, and the return card is stuck Stagnation
5. There are foreign matters in the transmission that cause blockage, and the brake oil
38
return is not smooth.

Ⅲ.On site inspection:

1. Check the oil suction pump to see if it is damaged.

2. Disassemble the transmission oil pan and check whether the suction screen is
blocked and fallen off and whether there is any foreign matter at the bottom of the oil pan.

3. Check whether the oil suction pipe is blocked by foreign matters.

4. Check whether the torque converter suction filter element is blocked.
5. Check the transmission valve, which may be due to foreign matters.

6. If the seal group of the booster pump is damaged, there is a large amount of air in
the brake fluid, resulting in the brake performance degradation.
7. Whether the brake fluid fails or does not meet the requirements.

8. Check whether the brake piston is stuck.

9. Check whether the respirator on the booster pump is blocked, causing the piston to
39
recover slowly.

Ⅳ.Treatment measures:

During the inspection, it was found that the return spring of the booster pump was
broken. After the replacement of the new booster pump, it was checked after 30 minutes of
normal operation again. The brake and release brake were very timely. Explain to the
customer that this machine is completely normal. If you have any problem, please contact
the agent at any time. Please feel free to use it.
Ⅴ.Warm tips:
The afterburner pump is an important component of the brake system on the equipment.
It should be carefully maintained. Do not keep the brake status for a long time to avoid wear.
(from Eastern Europe)

40
 LG956L service brake weak

I. Basic information：
A LG956L in Malaysia has weak service brake, normal foot brake resistance, sufficient
brake bleeding sound, but long braking distance.
II.Reasons analysis：
LG956L adopts air roof oil caliper disc service brake. The poor braking effect can be

analyzed from the following routes:

1. Air compressor failure, air leakage or poor compression;
2. Air source manager failure, air leakage or blockage;
3. The air tank leaks and the air pressure is insufficient;
5. Air leakage or blockage of foot brake valve;
6. Air leakage due to seal failure of booster pump;

7. Brake fluid deteriorates or enters air;

8. The brake caliper piston leaks oil or is stuck;
9. The brake disc and friction plate are seriously worn;

10. Brake system pipeline leakage;

III. Check process:

Due to the customer's feedback, the foot brake feedback is normal, and the bleeding
41
sound is normal, which means that the pressure before the foot brake valve is normal. The
problem is that after the foot brake valve, check whether the booster pump, pipeline and

brake caliper friction plate are normal, so let the customer check the brake oil and bleed the
oil circuit again. After re bleeding, the brake system returns to normal. The reason is that
when the customer deflated last time, the gas was not completely discharged, and the brake

fluid mixed with gas resulted in delayed braking and poor braking effect.

IV. Solution：
Bleed the brake fluid again and solve the problem.

V. Warm tips：
First, locat the fault parts according to the fault phenomenon, so as to reduce the
troubleshooting time.

（Asia region provided）

42
 L956F parking brake problem

Ⅰ.Basic information:
One customer complain that his L956F have parking brake problem. The working
hours is 3000h. And the machine cannot parking brake when the machine parking on the
slope. The service brake is ok.
Ⅱ.Reasons analyses：

1. The service brake is OK, indicates that the air reservoir which supplies the service
brake and parking brake is OK;
2. No parking brake indicates that the brake solenoid, brake chamber, parking brake
may have failure;
3. Operating problem
4. The braking torque is not enough

Ⅲ Check process:
We checked the brake solenoid, brake chamber, parking brake, everything was well. At
last, we get the information that the customer parking the machine on the slope with full

load.
Ⅳ Solution:
Told the customer the correct method to parking on the slope. When parking the

machine on the slope, we should put down the bucket on the ground and with no load.
Ⅴ Warm tips:
We’d better to analysis all the reasons that can cause the issues for our machine and to

choose the right way to solve the problems one by one follow below regulation: from outer
to inner; from simple to complex.
（APAC Region）
43
 L956F Loss of service brakes

Ⅰ. Failure Description:
Customer feedback: The working time of one L956F is 1150h, Loss of service brakes.

Ⅱ.Reasons analyses：
According to the structure and working principle of the brake system, the following
reasons may exist:
1. Low brake air pressure;
2. The pipeline behind the air tank leaks;
3. Foot brake valve failure;
4. Shuttle valve failure;
5. The brake caliper is faulty;
6. The booster pump is faulty;
7、The oil-water separator is in fault;
Ⅲ.Check process:
1. Start the whole machine and check whether the air pressure is normal;
2. Check the pipeline, no leakage is found;
3. Check the on-off performance of foot brake, no abnormality found;
4. The shuttle valve was disassembled and inspected, and no abnormality was found.
5. The friction plate and other problems of the brake caliper were removed and

44
inspected, and no abnormality was found.
6. Check the booster pump and find that there is a fault in the booster pump.

Ⅳ. Solution:
Replace the booster pump, test run, troubleshooting.

Ⅴ.Register:

Based on the analysis of the phenomenon, the fault cause is speculated, and the possible
fault cause is preliminarily found.

45
 The L956F loader run to one side

Ⅰ Basic information:
The dealer fed back that one L956F （VLGL956FHL0622194）, working hours is 570
hours, the loader run to one side, check but can’t find the failure reason.
Ⅱ Reasons analyses：
1. The air pressure of one side tire is too low;

2. The axle exist failure on one side, example, the gears are jammed because of the
failure;
3. The loader was braked because of the caliper piston are blocked;
4. Mechanical failure, example, the articulation bearings or pins were damaged;
5. The steering system reason:
1) The pipe leak oil;

2) Steering cylinder leak inside on one side;

3) The spool of steering gear was blocked, can’t be in neutral position;
4) The overload valve was blocked on low pressure position;

5) The air is in steering hydraulic system

6) The hydraulic pressure of steering system is too low.

Ⅲ Check process:
46
 Consulted the failure with customer, the loader was put in machine store before two
months, the loader run to one side when drive the loader; dealer check if the machine

occurred pipe leak or mechanical failure, didn’t find abnormal;

Dealer found the two pistons of right front caliper are in brake position, open the caliper
and found the caliper pistons were rusty.

Ⅳ Solution:
Clean the pistons and change the seals, reinstall the calipers, the loader run well.
Ⅴ Warm tips:
Check the machine carefully in according to the possible reason, then find the failure
cause.
(EMEA region supply)

47
 L956F parking break can not release

Ⅰ Basic information:
One L956F, working hours 1300h ,the parking break can not release.
Ⅱ Reasons analyses：
The break solenoid valve was broken .
The wire harness of the parking break system was broken .

The parking break housing was broken.

The parking break switch was broken.
Ⅲ Check process:
Checked the break solenoid valve , it is in good condition.
Checked the parking break switch , it was cut off.

Ⅳ Solution:
Replaced the parking break switch , the problem is ok.
Ⅴ Analysis:
We shall analysis what kinds of reasons can caused the issues. So, we check the reasons

one by one until to solve the issues.

(By Asian)

48
 L956H brake damage and charge pump oil leakage

Ⅰ Basic information:
Oman customer feedback a L956H, machine number VLGL956HTP0620215, after
432 hours of work, the parking brake is damaged, the oil leakage phenomenon of the oil cup
of the booster pump.

Ⅱ Reasons analyses：

Parking brake pads worn inconsistently at top and bottom, upper part not worn lower
part completely worn;
Clogged oil cup breather holes.

Ⅲ Solution and suggestion

Replace the brake with a new one. The oil cup ventilation holes are small and easily
clogged, so it is recommended to improve the ventilation method.

49
 L956H Parking problem

Ⅰ.Problem description：
Dealer feedback on a L956H has no parking brake, working time 2405 hours.

Ⅱ.Cause analysis：
According to the principle analysis, the possible fault causes are as follows:
1, the fuse is broken;
2. Parking brake switch failure;
3. The parking brake line or connector is disconnected;
4, parking brake solenoid valve coil break or short circuit;

5, parking brake valve block spool hair card;

6. Parking brake block；
Ⅲ.Field inspection：

1. Check that the fuse is not broken;

2. Use a multimeter to measure the parking brake switch, can be normally on and off,
and there is electricity;

3. Use a multimeter to measure the parking brake solenoid valve is electric;

4. The measurement solenoid coil resistance value is infinite, prove that the coil is open.

50
Ⅳ.Treatment measure：
Replacement of new solenoid coil, field test, troubleshooting.

Ⅴ.Note：
Diagnosing faults requires a step-by-step process from simple to complex.
(Provided by Saudi Arabia region)

51
 Not packing brake of L958F

Ⅰ Basic information:
One L958F is not packing brake, the working time is 699 hours

Ⅱ Reasons analyses：
The possible reasons is as following according to working principle:
Fuse is broken;
The switch of packing brake failure;
Wire or connector of packing brake is broken;
Packing brake solenoid valve wire is broken or short circuit;

Packing brake valve code is block;

Packing brake plate is block;
Ⅲ Check process:
Checking fuse but not broken;
Testing packing brake switch by using meter and it could be on and off normally and
52
it is 24V;
Testing packing brake solenoid valve and it is 24V;

Testing solenoid valve resistance and it is infinity, which proves that wire of solenoid
valve is broken;
Ⅳ Solution:

To change solenoid valve , testing the machine, the failures was settling.
Ⅴ Warm tips:
To diagnose failures should be checking step by step from simple to complex.

53
 LG958L steering is operated heavy

Ⅰ.Basic information:
Heavy steering was found when 800h operating time on one LG958L unit.
Ⅱ.Reasons analyses：
Possible reasons：
1、Hydraulic oil level is short for require.

2、The hydraulic oil quality become to worse.

3、As the cubage efficiency of steering pump was reduced, heavy steering would be
Found while the engine working in a low rotate speed.
4、The steering system pressure is lower than standard pressure.
5、The core in priority valve is blocked.
6、The feedback oil passage was not circular, which caused by jam and internal

desquamation in LS feedback hose.

7、The steering rod was distortion, blocked, and bearing shattered.
8、The break clamp on drivel axle is lock-break.

9、The failure of steering cylinder.

Ⅲ.Check process:
1、checked the hydraulic oil ,it was standard level and good quality.

2、Tested the steering pressure ,it was fit the standard .

3、Checked the hose and connectors for LS hose,found the connector port of priority
valve was blocked.

Ⅳ. Solution:
Clean the priority valve ,test the machine ,the loader work normal.

54
Ⅴ.Register:
We’d better to analysis all the reasons that can cause the issues for our machine and to

choose the right way to solve the problems one by one.

(Asia region offer)

55
 LG959 Weak Brake Performance

Ⅰ. Basic information:
Customer feedback: LG959, total operating time was 986h, and the brake performance
was weak, the specific phenomenon including long brake distance and felt powerless when
trying to brake.

Ⅱ. Reasons analyses：
LG959 adopted air booster type brake system, it is consisted of air compressor, oil-air
separator, air reservoir, brake valve, booster and the pipes.

Attention: The LG959 is equipped with ZF wet axle, not the dry disc in picture above,
the picture is just for your reference.
We can separate the circuit into two parts by the air reservoir, the normal brake air

56
pressure of the brake system is 0.784Mpa, if the pressure is lower than standard, that means
the first part from the compressor to the air reservoir has problems; if the air pressure is

normal, that indicates the malfunction occurred in the second part, form the air reservoir to
the discs.
Ⅲ. Check process:

Started the machine, and made it run at idle speed for a few minutes, then checked the
air pressure gauge in the cab to see whether the air pressure was normal. We found that the
pressure was normal. If there was no gauge in the cab or the gauge was broken, we could

connect air pressure gauge on the air reservoir, then we can read the value from it.
Checked the brake valve to see if it had some air leakage, and it was proved working
normally.
Then checked the booster, during the inspection process, we found out that there were
some oil leakage happened on the surface of the oil cylinder, and the booster air inlet also
leaking air.

Ⅳ.Solution:
Changing the boosters and the malfunction has been solved.
Ⅴ. Warm tips:

Pinpoint the malfunction cause according to the malfunction phenomenon and solve
the problems quickly.

57
 LG959 Park Brake Problem

Ⅰ. Basic information:
Dealer in Alaska feedback,there is an LG959 has park brake problem, Sometimes it
will not disengage, and then sometimes it will not engage.They have replaced the park brake
valve with new solenoid, and all three of the sending units. When the brake will not engage,
they can loosen the line returning to the hydraulic oil tank, relieve the pressure and the brake

will then engage by spring pressure. The SN of this machine is VLG0958LLD9022531.

Ⅱ. Reasons analyses：
This NA LG959 adopts full hydraulic brake system, the components are brake pump,
oil filling valve, accumulator for service brake and park brake, service brake valve, park
brake valve, park brake cylinder and oil pipes.

Brake pump absorb the oil from the oil pan, and the oil goes to the oil filling valve after
an oil filter, the oil filling valve’s function is to keep a certain pressure in the brake system.
When the pressure is up to 179 bar, the oil will go out from port O to pilot control system,
58
when pressure is lower than 148 bar, the oil filling process will be active again.
For park brake system, its accumulator get oil supply from port SW of oil filling valve,

the brake status was controlled by the park brake valve.

SW1: When the pressure in the brake circuit is lower than a set value, this switch (1)
cuts power to the transmission which puts it in neutral, (2) cuts power to the park brake

solenoid which engages the parking brake.

SW2: When the pressure in the brake circuit is lower than a set value, the low brake
pressure alarm indicator in the display panel will be blinking and the alarm buzzer will sound.

This should cause the operator to stop the machine and report the problem to service .
SW3: This switch causes the parking brake indicator to be lit. it reflects the status of
park brake,it will be lit when press the park brake switch,it will be went out conversely.

Ⅲ .Check process:
Start the machine, and make it run at idle for a few minutes, then check the service
59
brake performance, cause some components in the brake system are common for service
brake and park brake, so if the service brake is normal, that indicates the brake pump and

oil filling valve are good.

Then check the park brake accumulator pressure, connect a test pipe to test port M1,
and read the value, and found that the pressure complied with the requirements.

The last one that needs to check is the park brake valve, the three pressure switches
have little influence on the oil circuit. According to the phenomenon, this problem is mostly
like to be caused by the park brake solenoid valve, if the spool can’t change position

smoothly, it will cause such problem. When we changed a new park brake solenoid valve,
the problem was solved.
Ⅳ. Solution:
Change the park brake solenoid valve, and the malfunction is solved.
Ⅴ. Warm tips:
Pinpoint the malfunction cause according to the malfunction phenomenon and solve
the problems quickly.

60
 The L959F parking brake cannot be released and cannot be put into gear

Ⅰ Basic information:
Agent feedback: an L959F could not be mounted after the brake switch was replaced,
and the parking brake could not be removed, and the parking brake light on the dashboard
kept flashing.

Ⅱ Reasons analyses：

Possible problems are as follows:

1. Parking brake is not applied before parking, so parking brake cannot be removed
2. Parking brake shift switch or brake relay is damaged.

3. Parking brake indication switch is damaged

4. Parking brake solenoid valve stuck and damaged.
5. The wiring harness of parking brake indication switch and emergency brake switch

is inversely connected.
4120008846-55bar emergency brake switch, 4120008845-75bar parking brake
indication switch, 4120004312-50bar, parking brake low pressure alarm switch
Ⅲ Check process:

61
 The check procedure is as follows:
1. Parking will be implemented when starting the whole machine, and then try to

remove it, but the brake still cannot be removed after repeated operation
2. Measuring the braking relay and replacing the new relay have not been solved yet.
3. Replace the parking brake indication switch again, which has not been solved.

4. Reconnect the brake switch according to the circuit diagram again, and measure the
resistance of parking brake solenoid valve to be normal. Disassemble the solenoid valve
block and find that the spool is difficult to pull out.

Analysis: The parking brake logic in North America is special. The parking brake
cannot be released without parking brake before the whole machine stops. The parking brake
relay is self-powered when the braking is released and the parking brake is released. The
set pressure value of the three pressure switches of parking brake is very close. If one of
them is damaged, the action of the other switches will not be caused.
Ⅳ Solution:
Replace the solenoid valve assembly and the problem is relieved.
Ⅴ Warm tips:
Parking brake cannot be released, generally for parking brake solenoid valve failure
and parking relay failure.

62
 LG968 High Air Pressure

Ⅰ.Basic information:
One LG968，hour meter is 432h ，have brake valve problem，air is always leakage
from its small hole ，there is high brake pressure warning on the panel.

High pressure Leakage form the small hole Safety valve had working phenomenon

Ⅱ.Reasons analyses：
Possible reasons：

The pressure adjust part of brake valve have problem ,lead the air leakage and high
pressure.
Ⅲ.Check process:
Replaced a new brake valve then solve the problem,after that check ed the brake valve
found the diaphragm of the valve was broken ,so lead the problem.
Ⅳ. Solution:
Replaced a new valve ,the failure was solved.
Ⅴ.Register:
We’d better to analysis all the reasons that can cause the issues for our machine and to

choose the right way to solve the problems one by one.

(Central Asia region offer)

63
Diaphragm was broken

64
 L975F low brake pressure fault

Ⅰ Basic information:
The machine VLGL975FAK0600107 purchased by the customer which has been used
about 1482 hours. The phenomenon of low brake pressure alarm occurs during the use.

Ⅱ Reasons analyses：
1.The brake pump failure, resulting in the brake pump can not output pressure oil;
2.There is leakage on the brake pipe, resulting in insufficient brake pressure;
3.The pressure sensor on the brake valve block fails, resulting in false alarm;
4.The internal fault of the double-way liquid filling valve leads to the phenomenon of
hydraulic oil leakage and insufficient brake pressure.

65
Ⅲ Check process:
1. On-site inspection shows that the pipeline of the braking system looks good and no

leakage occurs;
2.The pressure at parking brake M1 was detected, and the gradual increase could reach
18.5mpa.It indicates that the hydraulic pump works normally and is not damaged;
3. Test the pressure at parking brake M2, the pressure is unstable, and the maximum
pressure is 5MPa.It indicates that there is internal leakage in the double-way liquid filling
valve, which leads to pressure failure.
Ⅳ Solution:
Replace the valve, restart the test run, the vehicle is normal.

Ⅴ Warm tips:

We’d better to analysis all the reasons that can cause the issues for our machine and to
choose the right way to solve the problems one by one.
Area (Asia-pacific)
66
 No parking brake for LG978

Ⅰ Basic information:
Customer feedback a LG978 has not parking brake when operating the parking brake
switch , which is working 621hrs, the alarm light on the panel is also not on .

Ⅱ Reasons analyses：
LG978 parking brake working principle is the use of pressure-released caliper disc

brake, under normal circumstances, the solenoid valve is energized, stored within the
accumulator brake A high pressure oil from the mouth into the outflow from the mouth into
the parking brake B by hydraulic overcome the spring force, the brake friction plate and the

gearbox output flange separation, then the vehicle without the parking brake. When you
press the parking brake switch or the vehicle is turned off, the solenoid valve power, oil
pressure within the parking brake into the brake B from the mouth, the outflow from the T

port back to the tank, hydraulic lift, brake friction plate in spring under the force of the
gearbox output flange snapping, friction flange reaches the braking effect.

67
 Parking Brake valve

Parking braker
Accumulator

Oil returning

Charging valve

1, Parking brake light switch

2,Solenoid valve
3,Urgent brake switch
4,Pressure testing valve
5,Braking low pressure alarm switch
6,Checking valve

The possible reasons can be divided into the electric and the hydraulic problems:
1, the parking brake switch failure.

2, the emergency brake pressure switch failure.

3, dashboard indicator failure.
4, the solenoid valve circuit failure.

5, electromagnetic valve spool stuck failure

6, parking brake oil line failure .
7, parking brake accumulator failure.

8, the parking brake cylinder failure

68
Ⅲ Check process:
1, on-site parking brake switch observe the operation, the parking brake unresponsive,

has no parking brake.

2, on-site measuring with a multimeter parking brake switch-off is normal, no fault.
3. Use a multimeter to check off solenoid valve circuit is also normal, so I ruled out

electrical problems.
4, engine idling, deflated by the parking brake deflated mouth, found normal fluid
outflow, ignorance ,Significant bubble phenomenon, the operation of the parking brake

switch does not work, there has been pressure on the oil outflow.
5, so I suspect that is a solenoid valve spool stuck in through the oil position, a check
after the demolition of the solenoid valve, found,Spool can move normally, no stuck
phenomenon, after cleaning the solenoid valve Replace, site commissioning or no The
parking brake.
6, so in the stall state, release the parking brake release pressure gas nozzle, the pressure
is completely released, After the discovery dashboard parking brake indicator light, then
start the engine, operate the parking brake switch, now Field test many times, parking brake
work, mainly due to the pressure within the parking brake has been released caused the
spring has not come out in a compressed state without the parking brake
Ⅳ. Solution:
Under flameout state, put the parking brake release pressure gas nozzle, the pressure is
completely released the parking brake is working properly
V. Tips
Symptom processed according to the situation in accordance with normal thinking or
unable to dispose of failure, we must consider abnormal and unusual measures

69
山东临工工程机械有限公司 70

SHANDONG LINOGNG CONSTRUCTION MACHINERY CO.LTD