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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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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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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
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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
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 Released)
Braking systemshown with enginerunning,emergency/parking brake
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
VALVEFRONT WHEEL BRAKES
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)
Braking systemshown with enginerunning,emergency/parking brake
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
VALVEFRONT WHEEL BRAKES
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
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,
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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
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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.