brake systems r1600

8/10/2019 Brake Systems r1600

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CATERPILLAR ELPHINSTONE PTY. LTD.

R1600 LHDR1600 LHDR1600 LHDR1600 LHDR1600 LHDSerSerSerSerService Tvice Tvice Tvice Tvice Training Guidesraining Guidesraining Guidesraining Guidesraining Guides

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BRAKE SYSTEMBRAKE SYSTEM
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C ontentsC ontentsC ontentsC ontentsC ontents

Introduction .................................................................3

Braking System Block Schematic ..............................4

Braking System Component Location.........................5Emergency/Parking Brake Circuit ...............................6

Service Brake Circuit ...................................................7

Accumulator Charging Valve .......................................8

Brake Accumulator ......................................................9

Service Brake Control Valve (Released Position) .....10

Wheel Brake (Parking Brake Released)....................11

Wheel Brake (Parking Brake Released - Service Brake- Applied) ..............................................................12

System Operation (Emergency/Park Brake Applied) 13

System Operation (Emergency/Park Brake Released) -..............................................................................14

System Operation (Service Brakes Applied).............15

Towing Brake Release System .................................16

Towing Brake Release System Operation .................17

Brake Pressure Test Points .......................................18

Brake Electrical System ............................................19

Brake Electrical Schematic .......................................20

Bleed Down the Oil Pressure in the Brake System -(Practical Task) .....................................................21

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Introduction

The colour codes for hydraulic oil used throughout this presentation are as follow s:

R edR edR edR edR ed - System or high pressure.

O rangeO rangeO rangeO rangeO range - Pilot pressure.

B lueB lueB lueB lueB lue - B locked or trapped oil.

G reenG reenG reenG reenG reen - Tank or return oil

Introduction:

Schematic colourcode:

Testing &

Adjustingprocedures:

ServicemansHandouts:


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PUMP

ACCUMULATOR

CHARGING

VALVE

PARKING

BRAKE CONTROL

VALVE

PRESSURE

REDUCING

VALVE

SERVICE

BRAKE

CONTROL

VALVE

TANK

ACCUMULATOR

WHEEL

BRAKE

Braking System Block Schematic

Two Brake ControlSystems:- Emergency/

parking brakesystem

- Service brakesystem

Other BrakeSystem Features:- Brake towing

release system

The pump drawsoil (green) fromthe tank and sendsflow (red) to thevarious controlvalves

The emergency/parking brake is

spring engagedand hydraulicallyreleased

The service brakeis hydraulicallyapplied


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8

1 654

3297 7

Braking System Component Location

(1) Hydraulic tank, (2) Front brake accumulator, (3) Rear brake accumulator,(4) Pressure reducing valve, (5) Accumulator charging valve, (6) Brake and pilot pump,(7) Wheel brakes, (8) Service brake treadle valve,(9) Emergency/parking brake control valve.

There are fourwheel brakes onthe machine

Each wheel brake

providesemergency/parking andservice braking


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1. Hydraulic oil tank (behind guard).

1

2. Brake and pilot pump.

2

3. Pressure reducing valve.

4

4. Emergency/parking brake control valve.

3

Emergency/Parking Brake Circuit

The brake andpilot pump is partof three-sectionvane-type pump

The brake andpilot pumpsupplies oil to the:- Parking brake

circuit- Service brake

circuit- Implement pilot

circuit- Steering pilot

circuit

Pump oil flows fromthe pump, throughthe pressurereducing valve tothe emergency/

parking brakecontrol valve

The pressurereducing valvelimits maximum oilpressure in theparking brake

circuit


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1

1. Brake and pilot pump.

2

2. Accumulator charging valve.

4

3

3. Front brake accumulator.

4. Rear brake accumulator.

6 5

5. Service brake pedal.

6. Brake neutraliser pedal.

Service Brake Circuit

The service brakeis used for normalmachine braking

The brake and

pilot pump is partof the three-section vane-typepump

The accumulatorcharging valvekeeps thepressure in thebrakeaccumulators in aconstant range

When theaccumulators arefully charged withoil, the

accumulatorcharging valvediverts its pumpoil to tank

RR


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7

3

5

46

9

1

To Tank

PressureControl

Control

8

Pump

FROM

PILOT

PUMP

RELIEF

VALVE

SHUTTLE

VALVES

TO

PRESSURE

SW

ITCHES

TOTANK

LOW PRESSURE

CONTROL VALVE

HIGH

PRESSURE

CONTROL

VALVE

TOREAR

BRAKE

ACCUMULATOR

TOFRONT

BRAKE

ACCUMULATOR

3

8

9

52

6

41

7

Accumulator Charging Valve

(1) Outlet port, (2) Relief valve, (3) Inlet port, (4) Outlet port, (5) Return port,(6) Oil pressure switch port, (7) Shuttle valve, (8) Low pressure control valve,(9) High pressure control valve.

The accumulatorcharging valvekeeps thepressure in thebrake

accumulators in aconstant range

The ACV reliefvalve limitsmaximum brake oilpressure

When theaccumulators donot need oil theACV directsexcess pump oil totank

Each accumulatoris controlled by its

own shuttle valveinside the chargevalve


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z

z

z

z

z

z

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zz|

, yz |

,

yz

|

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1

3

6

2

4

5

Pressure Oil

Nitrogen Gas

Brake Accumulator

(1) Accumulator, (2) Nitrogen charging valve, (3) Piston, (4) Nitrogen gas chamber,(5) Pressure oil chamber, (6) Oil pressure outlet.

BrakeAccumulator

The accumulatorsupplies oil under

pressure to theservice brake

The gas chamberabove the pistonhas a charge ofdry nitrogen gas

Pump oil pushesthe piston up andcausescompression ofthe dry nitrogengas

2Accumulator


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TO WHEELBRAKES

FROMACCUMULATOR

FROMACCUMULATOR

TANK

TO WHEELBRAKES

1

3

4

5

2

6

Accumulator

Oil Pressure

Tank Oil

Regulated OilPressure

Service Brake Control Valve (Released Position)

(1) Brake control valve, (2) Springs, (3) Return port, (4) Spool, (5) Spool, (6) Spring.

Service BrakeControl Valve:

The brake controlvalve modulates

(regulates) thepressure to thewheel brakes

The further thepedal isdepressed, thegreater thepressure at thewheel brake

When the brakepedal is pushed,the springs movethe control spoolsdown

When the controlspools movedown, accumulatorpressure oil flowsto the wheelbrakes

The brake controlvalve reduces(modulates) the oilpressure

1 8


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2

1 84

3

5

6

7

9

3

Parking Brake

Tank Oil

Wheel Brake (Parking Brake Released)

(1) Service brake piston, (2) Service brake oil passage, (3) Disc, (4) Axle housing,(5) Axle, (6) Parking brake piston, (7) Spring, (8) Spring, (9) Parking brake oil passage.

Wheel Brake

Each brake grouphas a servicebrake piston and a

parking brakepiston

The brakes arecooled andlubricated by theoil in thedifferential andaxle housing

When the parkingbrake is released,oil pressuremoves the parkingpiston right, awayfrom the brakedisc

When the parkingbrake is applied,springs move the

parking piston tothe right, againstthe brake disc


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REAR BRAKE

BRAKE TREADLE

VALVEFRONT WHEEL BRAKES

FRONT BRAKE


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PARK BRAKE

PRESSURE

SWITCHES

TANK

IMPLEMENT

STEERING

REAR BRAKE

ACCUMULATOR

BRAKE OIL

PRESSURE

SWITCHES

VALVE

PRESSURE

REDUCING

VALVE

ACCUMULATOR

CHARGING VALVE

PARKING BRAKE

CONTROL VALVE

REAR WHEEL BRAKES

FRONT BRAKE

ACCUMULATOR

PILOT

TOPILOT

SYSTEM

System Operation (Emergency/Park Brake Applied)

Braking systemshown with enginerunning,emergency/parking brake

applied andservice brakesreleased

The brake andpilot pumpsupplies oil to thepressure reducingvalve, accumulatorcharging valve andpilot system

The accumulatorcharging valvekeeps thepressure in theaccumulators in a

constant range

The accumulatorsstore oil pressurefor operation ofthe service brakes

REAR BRAKE

BRAKE TREADLE


FRONT BRAKE


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PARK BRAKE

PRESSURE

SWITCHES

TANK

IMPLEMENT

STEERING

REAR BRAKE

ACCUMULATOR

BRAKE OIL

PRESSURE

SWITCHES

VALVE

PRESSURE

REDUCING

VALVE

ACCUMULATOR

CHARGING VALVE

PARKING BRAKE

CONTROL VALVE

REAR WHEEL BRAKES

FRONT BRAKE

ACCUMULATOR

PILOT

TOPILOT

SYSTEM

System Operation (Emergency/Park Brake Released)


released andservice brakesreleased

The pressurereducing valvecontrols the pilotoil pressure in theemergency/

parking brakecircuit

When the parkbrake switch ismoved to theRELEASEDposition, the

emergency/parking brakesolenoid controlvalves areenergised

Pressure oil issent to the

emergency/

parking brakesection

REAR BRAKE

BRAKE TREADLE


FRONT BRAKE


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PARK BRAKE

PRESSURE

SWITCHES

TANK

IMPLEMENT

STEERING

REAR BRAKE

ACCUMULATOR

BRAKE OIL

PRESSURE

SWITCHES

PRESSURE

REDUCING

VALVE

ACCUMULATOR

CHARGING VALVE

PARKING BRAKE

CONTROL VALVE

REAR WHEEL BRAKES

FRONT BRAKE

ACCUMULATOR

PILOT

TOPILOT

SYSTEM

, ,

,

,

,

,

System Operation (Service Brakes Applied)


released andservice brakesapplied

The accumulatorcharging valve

charges the

accumulators with

pressure oil

When the brakepedal isdepressed,pressure oilmoves the servicebrake piston toapply the brakes

The further thepedal isdepressed, thegreater thepressure at thewheel brakes


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4. Towing hook.

3

3. Shuttle valve.

1

1. Brake release cylinder.

2

2. Brake release sequence valve.

Towing Brake Release System

Towing BrakeRelease SystemComponents:(1) Brake release

cylinder

(2) Towing brakereleasesequence valve

(3) Shuttle valve(4) Towing hook

The towing brakerelease system

allows release ofthe emergency/parking brake inthe event of amachine fault

The towing brakerelease system is

activated when thetowing brakerelease cylinderpiston is movedup

REAR BRAKE

BRAKE TREADLE


FRONT BRAKE


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TOW BRAKE

RELEASE

CYLINDER

PARK BRAKE

PRESSURE

SWITCHES

BRAKE RELEASE

SEQUENCE VALVE

SHUTTLE

VALVE

EXTERNAL

FORCE

TANK

IMPLEMENT

STEERING

ACCUMULATOR

BRAKE OIL

PRESSURE

SWITCHES

PRESSURE

REDUCING

VALVE

ACCUMULATOR

CHARGING VALVE

PARKING BRAKE

CONTROL VALVE

REAR WHEEL BRAKES

ACCUMULATOR

PILOT

TOPILOT

SYSTEM

, ,

,

,

,

,

,

Towing Brake Release System Operation

The towing brakerelease system isactivated by thetowing brakerelease cylinder

piston

The piston createsoil pressure as itmoves up - thepressure releasesthe emergency/parking brakesection of the

wheel brakes

When the towingbrake pistonmoves down, theemergency/parking brakesapply


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1

2

1. Pilot pressure test piont.

1

2. Service brake pressure test point.

2

Brake Pressure Test Points

Identifycomponents(1) Pilot pressure

test point(2) Service brake

test point

Testing & adjustingprocedures

2


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1. Park brake control switch.

1

2. Brake oil pressure switch.3. Brake oil pressure switch.

3

2

4. Park brake relay.

4

6

5. Solenoids.

6. Switch.7. Switch.

7

5

5

Brake Electrical System

The emergency/parking brake isapplied andreleased by theparking brake

control switch

When the brake oilpressure is in theoperating range,the emergency/parking brake canbe released

If brake oilpressure fallsbelow theoperating range,the emergency/parking brake willapply

The transmissionelectronic controlsends the parkbrake switch signalto the CaterpillarMonitoring Systemover the Cat datalink

PARK BRAKE

SWITCH


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15A

5

6

4

2

3

1

1

2

2

1

C

B

A

A

B

C

B

C

A

CIRCUIT BREAKER

No 10

REMOTE CONTROL

OPERATION

+24v SUPPLY

TO ELECTRONIC

TRANSMISSION CONTROL

BRAKE OIL PRESSURE

SWITCH

PARK BRAKE

PRESSURE SWITCH

PARK BRAKE

SOLENOID

PARK BRAKE

SOLENOID

PARK BRAKE

RELAY

VOLTAGE KEY SWITCH ON

+24v WHEN REMOTES

NOT IN USE

30

85 86

87

12

3

4

1

2

3

4

Brake Electrical Schematic

Emergency/parking brakerelease schematic

Wire shown as red

have + batteryvoltage with thekey start switch inthe on position

Emergency/parking brakecontrol switch inthe pull to apply

configuration

The brake oilpressure switchprovides an earthfor the park brakerelay

Park brake controlswitch in thereleased position,power is suppliedfrom a separate 24volt supply to keeprelay latched

E i


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Bleed Down the Oil Pressure in the Brake System(Practical Task)

Task Each trainee w ill be required to successfully bleed dow n the oil pressure in the brake system .

1. Find the procedure in S ervice M anual.

2. Follow the procedure and successfully com plete the task.

Identifycomponents:

Explain task.

Service manual.

brake systems r1600

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