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CATERPILLAR ELPHINSTONE PTY. LTD.
R2900 LHD
BRAKING SYSTEM
MODULE
FORM NO. 9EL9203-00
FOR USE IN SERVICE TRAINING GUIDE:CEPL R2900 LHD - July 1998
Page 1
List of Contents
Caterpillar Elphinstone Machine
List of Contents .......................................................................................................................................... 2
Important Safety Notice ............................................................................................................................. 3
R2900 Braking System Overview .............................................................................................................. 4
Introduction ................................................................................................................................................ 5
Braking System Block Schematic ............................................................................................................. 6
Braking System Component Location ........................................................................................................ 7
Location of Brake System Components ..................................................................................................... 8
Accumulator Charging Valve (Accumulator Fully Charged - Cut-Out Cycle) ............................................. 9
Accumulator Charging Valve (Accumulator Being Charged - Cut-In Cycle) ............................................ 10
Location of Brake System Components ................................................................................................... 11
Service Brake Control Valve (Released Position) .................................................................................... 13
Service Brake Accumulator ...................................................................................................................... 15
Wheel Brake (Parking Brake Released) ................................................................................................... 16
Wheel Brake (Parking Brake Released - Service Brake Applied) ............................................................ 17
System Operation (Parking Brake Engaged) ........................................................................................... 18
System Operation (Parking Brake Released) .......................................................................................... 20
System Operation (Service Brakes Applied) ............................................................................................ 21
Towing Brake Release System ................................................................................................................ 22
Towing Brake Release System Operation (Towing Brake Release Activated) ......................................... 23
Brake Pressure Test Points ...................................................................................................................... 25
Brake Electrical System ........................................................................................................................... 26
System Operation (Power Supply) ........................................................................................................... 28
System Operation (Relay Latched and Parking Brake Engaged) ............................................................ 29
System Operation (Parking Brake Released) .......................................................................................... 30
Parking Brake CMS Component Location ............................................................................................... 31
System Operation CMS (Parking Brake Released) ................................................................................. 33
Stop Light and Residual Brake Pressure Light Circuit Components ........................................................ 34
System Operation (Stop Light/Residual Brake Pressure Circuit) ............................................................. 35
Electric Brake Release System ................................................................................................................ 36
System Operation (Electric Brake Release) ............................................................................................ 37
Practical Tasks ......................................................................................................................................... 38
Theory Assessment ................................................................................................................................. 39
Theory Assessment Answers .................................................................................................................. 41
Theory Assessment ................................................................................................................................. 42
Theory Assessment Answers .................................................................................................................. 44
Servicemans Handouts ........................................................................................................................... 45
Page 2
Page 3
Assessment:
Tasks:
Part A: Practical Tests.
Part B: Theory Assessment (True/False Test).
Resource Requirements:
R2900 LHD.
Fully equipped classroom with white board and overhead projector.
Training Module and handout material.
Hydraulic pressure gauges.
Service Manual.
Parts Book.
Tools for practical tasks.
Page 4
Introduction
Introduction:
The colour codes for hydraulic oil used throughout this presentation are
as follows:
Red - System or high pressure.
Orange - Pilot pressure.
Blue - Blocked or trapped oil.
Green - Tank or return oil
Servicemans Handouts:
Page 5
WHEEL
BRAKE
PARKING
BRAKE CONTROL
VALVE
PILOT
RELIEF
VALVE
FILTER
SERVICE BRAKE
ACCUMULATOR
SERVICE
BRAKE
CONTROL
VALVE
ACCUMULATOR
CHARGING
VALVE
BRAKE AND
PILOT PUMP
ACCUMULATOR
CHARGE RELIEF
VALVE
TANK
This block schematic of the R2900 LHD braking system shows the
components and oil flow. There are two brake control systems on the
machine: the parking brake system and the service brake system. An
optional feature of the brake system is the towing brake release
system.
The brake and pilot pump oil (red) flows to the accumulator charging
valve. The valve divides the oil flow of the brake and pilot pump, priority
is given to the service brake circuit. When the parking brake control
valve is activated, pump oil is directed into the parking brake section of
the wheel brakes to release the brakes.
Brake and pilot pump oil flows through the accumulator charging valve
to the service brake accumulator. When the service brake control valve
is activated, accumulator oil goes to the service brake section of the
wheel brakes. The wheel brakes are dual-piston, outboard, wet-disc
brakes located in the wheel ends. Each wheel brake has a parking
brake piston and a service brake piston. The parking brake is spring
engaged and hydraulically released. The service brake is hydraulically
applied.
Page 6
10
11
12
The hydraulic brake system consists of: hydraulic tank (1), parking
brake control valve (2), service brake accumulator (3), accumulator
charge relief valve (4), pilot oil filter (5), pilot relief valve (6), front wheel
brakes (7), service brake control valve (8), rear wheel brakes (9),
accumulator charging valve (10), brake and pilot pump (11) and electric
brake release pump (12) .
There are four wheel brakes on the machine. Each wheel brake has
two sections; a parking brake section and a service brake section. The
parking brake is oil pressure released and spring applied. The service
brake is oil pressure applied and spring released. The service brake
can be used when the brake is released.
Page 7
2
1
3
1. Hydraulic tank.
2. Hydraulic oil filters.
5
6
4
The hydraulic tank (1) is located on the right hand side of the machine.
The hydraulic oil filters (2) are mounted inside the hydraulic tank. There
is a bypass valve for the filter elements. Whenever the restriction
through the filters is too high, the bypass valve will open.
The brake and pilot pump (3) is part of a two section pump, which is
mounted on the left hand rear of the torque converter updrive transfer
housing. The brake and pilot pump (3) supplies oil to the pilot steering
system, brake system and pilot hydraulic system. The accumulator
charging valve (4) is located on the left hand inside wall of the rear
frame. The valve divides the oil flow from the brake and pilot pump,
priority is given to the brake circuit.
The pilot system relief valve (5) is mounted on the rear frame cross
beam. The pilot oil filter (6) is mounted behind the relief valve manifold.
The pilot relief valve controls the pressure in the pilot oil system. The
pilot oil filter (6), filters the pilot oil and is fitted with a bypass valve which
will open whenever the resistance to the flow of oil through the filter is
too high.
Page 8
2
1
4
5
6
7
9
10
8
11
5
With the engine running, oil from the brake pump goes into the
accumulator charging valve (ACV). If the brake accumulator does not
need oil, the ACV directs all oil from the brake pump to the pilot circuit.
When the brake accumulator needs oil, the ACV divides the pump flow.
The ACV will direct a percentage of pump oil to the accumulator. The
remainder of the pump oil will flow to the pilot circuit.
When the oil pressure in the accumulator reaches the cut out pressure
of the accumulator charging valve, the accumulator is fully charged
with oil.
Oil from the brake and pilot pump enters the ACV. This oil passes
through a drilled passage in valve spool (9) to chamber (8). Pressure
will increase in chamber (8) and move valve spool (9) to the right. The
valve spool (9) is now held against spool stop (11) and pump oil will flow
to the pilot circuit.
Oil pressure in the accumulator moves check valve (4) to the right
against pilot valve spool (1). Oil pressure in the accumulator is retained
by check balls (4) and (5).
Page 9
3
2
4
5
6
7
9
10
11
8
6
Page 10
1
1. Parking brake control valve.
3
3. Brake control pedals.
4
4. Service brake accumulator.
7
The parking brake control valve (1) is located on the left hand inside wall
of the rear frame.
When the parking brake control knob (in operators station) is moved to
the released position, the solenoids of the parking brake control valve
are energised. Oil flows to the parking brake sections of the wheel
brakes. Oil pressure then releases the parking brake.
The accumulator charge relief valve (2) is mounted on the left hand
inside wall of the rear frame. The relief valve protects the service brake
system if the accumulator charging valve fails.
The brake control pedals (3) regulate the pressure at the brakes. As
the position of the pedal changes, the pressure at the brakes also
changes.
The service brake accumulator (4) is mounted on the inside left hand
wall of the rear frame. The accumulator stores hydraulic oil under
pressure and supplies oil at a constant pressure range to the service
brake system.
Continued
Page 11
The brake pedal is connected to the service brake control valve. The
service brake control valve is supplied with oil from the service brake
accumulator. The service brake control valve will modulate this pressure
depending on the position of the pedals.
N OTE
OTE::
The brake and transmission neutraliser control pedal (left side pedal)
applies the brake first then neutralises the transmission.
Page 12
Accumulator
Oil Pressure
Tank Oil
Regulated Oil
Pressure
3
TO WHEEL
BRAKES
4
TANK
FROM
ACCUMULA
TOR
ACCUMULATOR
TO WHEEL
BRAKES
FROM
ACCUMULA
TOR
ACCUMULATOR
5
6
8
The service brake control valve is a dual pressure reducing valve with
two independent output pressures. The valve is directly below the
service brake pedal.
The service brake control valve modulates pressurised oil from the
accumulator to the service brake section of the wheel brakes. The
position of the brake pedal causes a specific pressure at the brakes.
As the position of the pedal changes, the pressure at the service
brakes also change.
If one braking circuit fails, the second braking circuit remains functional
due to the mechanical contact between the two spools (4) and (5).
With the engine running, oil flows from the service brake accumulator
to service brake control valve (1) through two inlet ports. When the
operator pushes on the brake pedal, springs (2) cause spools (4) and
(5) to overcome the force of spring (6) and move down.
Continued
Page 13
When spool (4) moves down, oil from the accumulator port flows past
the spool to the front brake port. The oil flows into the oil line to the
front service brakes and applies the front brakes.
Spool (4) is on top of spool (5) and as spool (4) moves down it causes
spool (5) to also move down. As spool (5) moves down, oil from the
accumulator port flows past the spool to the rear brake port. The oil
flows into the oil line to the rear service brakes and applies the rear
brakes.
Internal metering passages reduce oil pressure to each axle. The
service brake control valve meters oil to the rear brakes at a higher
pressure than the front brakes.
When the operator releases the brake pedal, spring (6) forces spools
(4) and (5) up. Now the oil flowing from the accumulators is blocked at
the spool.
When the spools move up, the return ports are open. The oil in the
service brake ports can now flow into the return ports. Oil in the front
and rear brake oil lines is now vented back to the hydraulic tank.
Page 14
Pressure Oil
Nitrogen Gas
4
3
Page 15
1
Parking Brake
Oil Pressure
5
4
6
9
7
10
The outer casing (3) is bolted to the axle housing which does not turn.
There are splines on the inside of the outer casing (3). Splines on the
circumference of the steel plates (7) fit in the splines of the outer casing
(3). This keeps the steel plates (7) stationary.
The wheel hub (outer housing of the final drive) (5) has splines on its
outer circumference. These splines fit into the splines on the inside of
friction discs (8). Both wheel hub (5) and friction discs (8) turn together.
When the parking brake is released, oil flows through a port in the end
plate to annular passage (6). The oil pressure moves parking piston (1)
to the left, compressing springs (4), until the piston contacts the end
plate. This relieves the pressure from the brake pack. Friction discs (8)
and wheel hub (5) are free to rotate.
When the parking brake is engaged, the oil in the annular passage (6) is
dumped to tank. When the oil pressure drops, the parking piston is
moved to the right by springs (4) until it contacts service piston (2) and
forces it into contact with brake pack (9). This holds the rotating discs
to the stationary plates and locks wheel hub (5) to the axle housing.
Page 16
Parking Brake
Oil Pressure
Service
Brake Oil
Pressure
5
9
6
11
When the service brake pedal is depressed, oil under pressure flows
through a port in the end plate into annular passage (6). The pressure
of the oil moves service piston (2) to the right against the brake pack (9).
Springs (4) are tensioned by pull rods (5) as the service piston moves.
Grooves cut in the faces of the friction discs (8) allow cooling oil to flow
between the plates and discs. The cooling oil will constantly flow
between the plates and discs in either the service brake applied or
released positions.
This causes friction between the steel plates (7), which are held
stationary by outer casing (3), and friction discs (8) which turn with the
rotation of the wheels. This friction causes the wheels to turn slower or
stop. The amount of brake application depends on the position of the
brake pedal.
FRONT WHEEL
BRAKES
SERVICE BRAKE
CONTROL VALVE
REAR WHEEL
BRAKES
SERVICE BRAKE
ACCUMULATOR
PARKING BRAKE
CONTROL VALVE
ACCUMULATOR
CHARGING VALVE
TO PILOT
SYSTEM
PILOT
RELIEF
VALVE
ACCUMULATOR
CHARGE RELIEF
VALVE
STEERING
PUMP
BRAKE AND
PILOT PUMP
TANK
12
This schematic shows the braking system with the engine running, the
parking brake engaged and the service brake released.
Oil from the brake and pilot pump flows to the accumulator charging
valve and the pilot relief valve. The accumulator charging valve keeps
the pressure in the service brake accumulator within a constant range.
The pilot relief valve controls the pilot oil pressure to the parking brake
circuit. The brake and pilot pump also supplies oil to the hydraulic
implement and steering pilot systems.
The pump oil flows through the accumulator charging valve to the
service brake accumulator. A piston in the service brake accumulator
is held against the oil intake end by dry nitrogen gas. The service brake
accumulator stores hydraulic oil pressure for operation of the service
brakes. When the service brake accumulator is fully charged, the
accumulator charging valve directs its pump oil flow to tank. Oil flow is
blocked by the service brake control valve.
Continued
Page 18
The parking brake control valve consists of two solenoid control valves.
When the solenoids are de-energised, pump oil is blocked at the
control valves.
The parking brake section of the wheel brakes is open to tank through
the parking brake control valve. The parking brakes are applied by
spring pressure.
Page 19
FRONT WHEEL
BRAKES
SERVICE BRAKE
CONTROL VALVE
REAR WHEEL
BRAKES
SERVICE BRAKE
ACCUMULATOR
PARKING BRAKE
CONTROL VALVE
ACCUMULATOR
CHARGING VALVE
TO PILOT
SYSTEM
PILOT
RELIEF
VALVE
ACCUMULATOR
CHARGE RELIEF
VALVE
STEERING
PUMP
BRAKE AND
PILOT PUMP
TANK
13
When the parking brake control in the cab is moved to the released
position, power is sent to energise the parking brake solenoid control
valves.
Oil from the brake and pilot pump flows through the pilot relief valve to
the parking brake control valve. The pilot relief valve controls the
maximum pressure in the parking brake circuit.
Oil flows to the parking brake section of the wheel brakes. The oil
pressure causes the parking brake piston to retract, releasing the
parking brake.
Page 20
,, ,,
, ,
FRONT WHEEL
BRAKES
SERVICE BRAKE
CONTROL VALVE
REAR WHEEL
BRAKES
SERVICE BRAKE
ACCUMULATOR
PARKING BRAKE
CONTROL VALVE
ACCUMULATOR
CHARGING VALVE
TO PILOT
SYSTEM
PILOT
RELIEF
VALVE
ACCUMULATOR
CHARGE RELIEF
VALVE
STEERING
PUMP
BRAKE AND
PILOT PUMP
TANK
14
Oil from the brake and pilot pump flows through the accumulator
charging valve to the service brake accumulator. The service brake
accumulator stores hydraulic oil pressure for the operation of the
service brakes. When the service brake accumulator is fully charged
with oil, the accumulator charging valve sends the pump oil flow to
tank.
The service brake control valve is in the circuit from the service brake
accumulator to the service brakes. When the brake pedal is pushed,
oil from the service brake accumulator goes to the service brake
section of the wheel brakes. The service brake control valve is a
tandem type valve providing split system braking. In the event of a
failure in either the front or rear brake system, the other portion of the
valve will continue to function.
After the service brakes have been activated several times, the volume
of oil in the service brake accumulator is reduced. The piston in the
service brake accumulator moves down towards the oil end until there
is a decrease in pressure. The accumulator charging valve cuts in
sending oil from the brake and pilot pump to the accumulator.
Page 21
3
2. Brake release sequence valve.
3. Shuttle valves.
4
4. Check valve.
5. Towing hook.
15
The towing brake release system allows the operator to release the
parking brakes if the brakes are applied due to a machine fault. When
the brakes are released, the machine can be towed to a service area.
The system is activated by a towing hook (5) compressing the towing
brake release piston in the machine towing bar.
,
,
, ,
, ,
FRONT WHEEL BRAKES
SERVICE BRAKE
CONTROL VALVE
SERVICE BRAKE
ACCUMULATOR
PILOT
RELIEF
VALVE
PARKING BRAKE
CONTROL VALVE
TO PILOT
SYSTEM
ACCUMULATOR
CHARGING VALVE
SHUTTLE
VALVE
,,
,,
TOW BRAKE
RELEASE
CYLINDER
ACCUMULATOR
CHARGE RELIEF
VALVE
BRAKE RELEASE
SEQUENCE VALVE
BRAKE AND
PILOT PUMP
EXTERNAL
FORCE
STEERING
PUMP
TANK
16
Page 23
With the brake release sequence valve open to tank the towing brake
release system is disabled during normal machine operation.
The check valve replenishes oil in the brake release system when
required.
When the towing brake release cylinder is in the deactivated position,
the spring chamber is connected to the hydraulic tank port. This
prevents a pressure increase (hydraulic lock) behind the shuttle valves
so the parking brakes can be released.
Page 24
17
The pilot pressure test point (1) is located on the pilot oil filter. The test
point is used for checking the pilot pressure in the parking brake,
steering and implement hydraulic system.
The pressure point (2) located in the pressure manifold, below the
brake accumulator is for checking the CUT- IN, CUT- OUT pressures of
the accumulator charging valve.
The accumulator charge relief valve (3) can only be tested and set on a
test bench.
Page 25
2
1. Parking brake control switch.
4
6
4. Parking brake relay.
5
7
5. Solenoids.
6. Parking brake low oil pressure switch.
7. Parking brake pressure switch (remotes).
18
If service brake oil pressure falls below the operating range, switch (3)
will open. The parking brake relay will open and interrupt power to
solenoids (5). The parking brake will apply.
Service brake low oil pressure switch (2) is for the Caterpillar Monitoring
System. When brake oil pressure falls below the normal operating
range, the switch will open, causing a category three warning. The
Caterpillar Monitoring System alert indicator will come on, the fault light
will flash and the fault alarm will sound.
The parking brake low oil pressure switch (6) is an input of the electronic
transmission control. When the parking brake is engaged, the switch
sends a signal to the transmission control. The control shifts the
transmission to neutral. The transmission control also sends the
parking brake status to the Caterpillar Monitoring System over the data
link. When the parking brake is engaged, the alert indicator for the
parking brake flashes on the Caterpillar Monitoring System. If the
operator selects FORWARD or REVERSE while the parking brake is
engaged, the Caterpillar Monitoring System initiates a category 3
warning.
Parking brake pressure switch (7) is part of the optional remote control
system.
Page 27
PARKING BRAKE
RELAY
87
30
B
C
A
PARKING BRAKE
CONTROL SWITCH
BRAKE CONTROL
10 A
+ 24v
REMOTE CONTROL
10 A
10
1
1
2
REMOTE CONTROL
SWITCH
PARKING BRAKE
SOLENOIDS
1
2
8
14
13
1
2
3
27
22
28
18
37
38
1
2
3
TRANSMISSION PRESSURE
SWITCH ABA
GROUND CIRCUIT
19
This schematic shows the wires that have battery voltage with the key
switch in the on position, and the parking brake control switch in the
brake engaged position (engine off).
Power is then supplied from the brake control circuit breaker to the
parking brake control switch. With the switch in the engaged position
power is available at the parking brake relay which cannot be energised
because with the engine off there is no system pressure. The service
brake low oil pressure switch and the ABA switch (Automatic Brake
Application) contacts are therefore open, interrupting the ground circuit
for the parking brake relay.
NOTE:
If the ABA transmission oil pressure switch (optional) is not fitted a loop
wire is fitted to the three pin plug to complete the circuit to the brake
charge pressure switch (as shown).
Power is supplied to terminal 30 on the parking brake relay through the
remote control switch (optional) from the remote control system circuit
breaker.
Page 28
PARKING
BRAKE RELAY
87
30
B
C
A
PARKING BRAKE
CONTROL SWITCH
BRAKE CONTROL
10 A
+ 24v
REMOTE CONTROL
10 A
10
1
1
2
REMOTE CONTROL
SWITCH
PARKING BRAKE
SOLENOIDS
1
2
8
14
13
1
2
3
27
22
28
18
37
38
1
2
3
GROUND CIRCUIT
20
With the engine running the transmission oil pressure will rise. The
transmission pressure (ABA) switch (if fitted) will close.
At the same time the brake oil pressure will increase. The service brake
low oil pressure switch will close. With both switches in the closed
position the parking brake relay circuit is completed to ground and the
parking brake relay will latch.
Page 29
PARKING BRAKE
RELAY
87
30
B
C
A
PARKING BRAKE
CONTROL SWITCH
BRAKE CONTROL
10 A
+ 24v
REMOTE CONTROL
10 A
10
1
1
2
REMOTE CONTROL
SWITCH
PARKING BRAKE
SOLENOIDS
1
2
8
14
13
1
2
3
27
22
28
18
37
38
TRANSMISSION PRESSURE
SWITCH ABA
1
2
3
GROUND CIRCUIT
21
Power is supplied from the remote circuit breaker to latch the parking
brake relay.
Once the parking brake relay is latched and the parking brake switch is
moved to the released position, power is directed to parking brake
solenoids. The parking brake solenoids are energised and the parking
brakes are released.
Page 30
4
5
4. Parking brake low oil pressure alert indicator.
5. Service brake low oil pressure alert indicator.
6. Impending brake application alert indicator.
The display area of the CMS shows the operator the condition of the
machine systems and alerts the operator to any abnormal machine
conditions that may exist.
In the CMS electrical brake system three switches and alert indicators
are used.
a. Parking brake low oil pressure switch.
b. Service brake low oil pressure switch.
c. Impending brake application.
The parking brake pressure switch (1) is located below the brake
release control valve on the left hand inside wall of the rear frame.
The parking brake pressure switch via the electronic transmission
control module, activates the alert indicator (4) on the CMS panel when
the parking brake is engaged.
When the parking brake is released the park brake pressure switch will
open. The parking brake light on the CMS panel will then go out.
Continued
Page 31
The service brake low oil pressure switch (3) is located on the left hand
inside wall of the rear frame.
When the machine is started the brake system oil pressure increases.
When the pressure reaches the setting of switch (3) its contacts will
close causing the low brake oil pressure light (5) on the CMS panel to
go out. The parking brake can now be released.
If the service brake oil pressure decreases to below the setting of
switch (3) its contacts will open and the service brake low oil pressure
light on the CMS panel will come on, warning the operator of low
service brake oil pressure.
Page 32
27
36
3
9
5
1
2
3
1
2
3
4
23
24
35
33
2
IBA CMS
SWITCH
IMPENDING BRAKE
APPLICATION CIRCUIT
23
The parking brake cannot be released until the brake and transmission
oil pressure increases. This increase in pressure will cause the service
brake low oil pressure switch and impending brake application (I.B.A.)
switch (if fitted) to close, causing the alert indicators on the CMS dash
to go out.
When the parking brakes are released the parking brake low oil pressure
switch closes sending a signal to the electronic transmission control.
This signal is then communicated to the CMS on the CAT control data
link causing the parking brake light to go out.
The CAT data link is bidirectional, allowing the transmission control to
receive and send information. The purpose of the data link is to enable
the transmission control to communicate with the Computerised
Monitoring System (CMS). The data link is not a single visible
component as it consists of internal control circuits and connecting
wiring harness.
NOTE:
When the impending brake application is not fitted a loop wire is fitted
to complete the circuit to ground (as shown above).
Page 33
2. Stop light.
4
3. Rear brake pressure switch.
The components of this circuit are; stop light switch (1), stop light (2),
rear brake pressure switch (3) and residual brake pressure light (4).
The stop light switch (1) is mounted in the front brake circuit at the
outlet of the brake control valve.
If the machine is equipped with a residual brake pressure option a rear
brake pressure switch (3) is also fitted.
When the service brakes are applied the stop light (2) will illuminate.
NOTE:
Operating the machine with residual pressure will cause overheating of
the brakes and may severely shorten the service life of brake
components.
Page 34
STOP/TAIL
LAMP
CAB
+24V
T
S
15A
3
1
2
FRONT BRAKE
PRESSURE SWITCH
1
2
1
2
REAR BRAKE
PRESSURE SWITCH
3
TO FRONT
LIGHT SWITCH
POWER SUPPLY
RESIDUAL BRAKE
PRESSURE LIGHT
When the service brakes are applied oil pressure will close the brake
pressure switches and completes the circuit to the stop/tail lamp
Power will now be supplied to illuminate the stop light.
If the machine is equipped with a residual brake pressure circuit a rear
brake pressure switch is also fitted (as shown).
When the service brake is applied the brake oil pressure rises above
the setting of residual brake pressure switches. The switches will close
completing the circuit to the residual brake pressure light. Power will
now be supplied to illuminate residual brake pressure light.
If the residual brake oil pressure remains in the wheel brakes above the
setting of the switches after the brakes have been released, the light
will remain illuminated. Also the rear brake light will illuminate.
Page 35
2
1. Brake release pump.
The electric brake release circuit allows the operator to release the
parking brake if the brake is applied due to a machine fault. When the
brakes are released, the machine can be towed to a service area.
The electric brake release circuit is controlled by a switch located on
the circuit breaker board in the operators station.
The electric brake release circuit uses an electric hydraulic pump to
supply oil to the parking brake circuit and the service brake circuit.
When the brake system is fully charged, the operator must use the
parking brake control switch to release the brakes.
Because the service brake circuit is charged with oil, the service brake
can be used to stop the machine during towing, etc.
BRAKE RELEASE
SWITCH
+24V
BRAKE RELEASE
RELAY
6
15A
BRAKE
CONTROL
MOTOR
BRAKE RELEASE
MOTOR
FUSE
675A
POS NEG
BAT MTR
MOTOR
POS NEG
12 VOLT
BATTERIES
DISCONNECT
SWITCH
BRAKE RELEASE MOTOR CIRCUIT
27
Page 37
1. Electrical faults.
Practical Tasks
Bleed down oil pressure in
the brake system
Task 1
1: Each trainee will be required to successfully bleed down the oil
pressure in the brake system.
1. Find the procedure in Service Manual.
2. Follow the procedure and successfully complete the task.
Electrical Faults.
Task 2
2: Trainer to place a series of electrical faults on the machine.
1. Place a faulty parking brake relay in the circuit.
2. Remove wire EL332-BR from parking brake control switch.
Each trainee will be required to successfully
1. Fault find the electrical faults, using the electrical schematic
and service manual.
2. Rectify the faults, test and start machine.
Service manual.
Always check the Service Manual for the correct adjusting procedure
and specifications.
Always follow the procedures contained in the Service Manual when
testing and/or adjusting the machine.
Page 38
Q.4. The accumulator charging valve divides the oil flow between the:
A. Pilot and transmission systems
B. Brake and pilot systems
C. Brake and hydraulic systems
D. Pilot and oil cooling systems
Page 39
Q.9. The accumulator charging valve gives priority oil flow to:
A. The brake system
B. The brake and pilot systems
C. The hydraulic system
D. The transmission control valve
Page 40
Page 41
Q.2. When the parking brake switch is moved to the engaged position:
A. The front wheel brakes release
B. The rear parking brakes release
C. The service brakes apply
D. All the wheel brakes are activated
Continued
Page 42
Q.10.
The electric brake rrelease
elease pump is activated by:
Q.10.The
A.
B.
C.
D.
Page 43
Page 44
,,,
,,,
3
?
Page 45
2
1
4
5
6
7
10
8
11
5
Spring
Check valve
Spool stop
Pilot valve spool
Pilot valve spring
Chamber
Charging valve spool
Orifice
Upper limit check ball
Lower limit check ball
Passage
Page 46
Park Brake
Oil Pressure
10
Parking piston
Service piston
Outer casing
Springs
Wheel hub
Annular passage
Steel plates
Friction discs
Brake pack
Page 47
FRONT WHEEL
BRAKES
SERVICE BRAKE
CONTROL VALVE
REAR WHEEL
BRAKES
SERVICE BRAKE
ACCUMULATOR
PARKING BRAKE
CONTROL VALVE
ACCUMULATOR
CHARGING VALVE
TO PILOT
SYSTEM
PILOT
RELIEF
VALVE
ACCUMULATOR
CHARGE RELIEF
VALVE
STEERING
PUMP
BRAKE AND
PILOT PUMP
TANK
12
Page 48
FRONT WHEEL
BRAKES
SERVICE BRAKE
CONTROL VALVE
REAR WHEEL
BRAKES
SERVICE BRAKE
ACCUMULATOR
PARKING BRAKE
CONTROL VALVE
ACCUMULATOR
CHARGING VALVE
TO PILOT
SYSTEM
PILOT
RELIEF
VALVE
ACCUMULATOR
CHARGE RELIEF
VALVE
STEERING
PUMP
BRAKE AND
PILOT PUMP
TANK
13
Page 49
FRONT WHEEL
BRAKES
SERVICE BRAKE
CONTROL VALVE
REAR WHEEL
BRAKES
SERVICE BRAKE
ACCUMULATOR
PARKING BRAKE
CONTROL VALVE
ACCUMULATOR
CHARGING VALVE
TO PILOT
SYSTEM
PILOT
RELIEF
VALVE
ACCUMULATOR
CHARGE RELIEF
VALVE
STEERING
PUMP
BRAKE AND
PILOT PUMP
TANK
14
Page 50
SERVICE BRAKE
ACCUMULATOR
ACCUMULATOR
CHARGING VALVE
TO PILOT
SYSTEM
PILOT
RELIEF
VALVE
SHUTTLE
VALVE
TOW BRAKE
RELEASE
CYLINDER
ACCUMULATOR
CHARGE RELIEF
VALVE
BRAKE RELEASE
SEQUENCE VALVE
BRAKE AND
PILOT PUMP
EXTERNAL
FORCE
STEERING
PUMP
TANK
16
Page 51
PARKING BRAKE
RELAY
87
30
B
C
A
PARKING BRAKE
CONTROL SWITCH
BRAKE CONTROL
10 A
REMOTE
CONTROL
+ 24v
10 A
10
1
1
2
REMOTE CONTROL
SWITCH
PARK BRAKE
SOLENOIDS
1
2
8
14
13
1
2
3
27
22
28
18
37
38
1
2
3
GROUND CIRCUIT
19
Servicemans Handout No 9
System Operation (Power Supply)
Page 52
PARKING BRAKE
RELAY
87
30
B
C
A
PARKING BRAKE
CONTROL SWITCH
BRAKE CONTROL
10 A
REMOTE
CONTROL
+ 24v
10 A
10
1
1
2
REMOTE CONTROL
SWITCH
PARK BRAKE
SOLENOIDS
1
2
8
14
13
1
2
3
27
22
28
18
37
38
1
2
3
GROUND CIRCUIT
20
Page 53
PARKING BRAKE
PRESSURE SWITCH
C
B
A
10
11
1
2
3
27
36
3
9
5
1
2
3
1
2
3
4
23
24
35
33
2
IBA CMS
SWITCH
IMPENDING BRAKE
APP, CIRCUIT
21
Page 54
STOP/TAIL
LAMP
CAB
+24V
15A
3
1
2
FRONT BRAKE
PRESSURE SWITCH
1
2
1
2
REAR BRAKE
PRESSURE SWITCH
T
S
3
TO FRONT
LIGHT SWITCH
POWER SUPPLY
RESIDUAL BRAKE
PRESSURE LIGHT
25
Page 55
BRAKE RELEASE
SWITCH
+24V
BRAKE RELEASE
RELAY
6
15A
BRAKE
CONTROL
MOTOR
BRAKE RELEASE
MOTOR
FUSE
675A
POS NEG
BAT MTR
MOTOR
POS NEG
12 VOLT
BATTERIES
DISCONNECT
SWITCH
BRAKE RELEASE MOTOR CIRCUIT
27
Page 56