R1600 LHD

CATERPILLAR ELPHINSTONE PTY. LTD.

Ser vice T
Service raining Guides
Training
Exit

Menu

Help

BRAKE SYSTEM
Exit
Contents
Menu
Introduction .................................................................3
Braking System Block Schematic ..............................4
Help Braking System Component Location .........................5
Emergency/Parking Brake Circuit ...............................6
Service Brake Circuit...................................................7
Index
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:

Menu • Schematic colour

code:
• Testing &
Help Adjusting
procedures:

Index • Serviceman’s
Handouts:

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
 WHEEL
BRAKE
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• Two Brake Control

PARKING Systems:
Menu BRAKE CONTROL - Emergency/
VALVE parking brake
system
Help - Service brake
PRESSURE system
REDUCING
VALVE ACCUMULATOR
Index • Other Brake
SERVICE
BRAKE
System Features:
CONTROL - Brake towing
ACCUMULATOR
CHARGING VALVE release system
PUMP VALVE
• The pump draws
oil (green) from
the tank and sends
flow (red) to the
various control
valves

• The emergency/
TANK parking brake is
Braking System Block Schematic spring engaged
and hydraulically
released

• The service brake

is hydraulically
applied
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• There are four

1 4 5 6 wheel brakes on
Menu the machine

• Each wheel brake

Help provides
emergency/
parking and
Index service braking

7 8 9 7 2 3

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.
Exit CATERPILLAR ELPHINSTONE PTY. LTD.

• The brake and

1 pilot pump is part
Menu of three-section
vane-type pump

Help • The brake and

2
pilot pump
supplies oil to the:
Index 1. Hydraulic oil tank (behind guard). 2. Brake and pilot pump. - Parking brake
circuit
- Service brake
circuit
- Implement pilot
3 circuit
- Steering pilot
circuit
4
• Pump oil flows from
the pump, through
the pressure
reducing valve to
3. Pressure reducing valve. 4. Emergency/parking brake control valve. the emergency/
Emergency/Parking Brake Circuit parking brake
control valve

• The pressure
reducing valve
limits maximum oil
pressure in the
parking brake
circuit
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• The service brake

is used for normal
Menu machine braking

• The brake and

Help pilot pump is part
1 2 of the three-
section vane-type
Index 1. Brake and pilot pump. 2. Accumulator charging valve. pump

• The accumulator
4 charging valve
keeps the
3 pressure in the
brake
accumulators in a
constant range
6 5
• When the
accumulators are
3. Front brake accumulator. 5. Service brake pedal. fully charged with
4. Rear brake accumulator. 6. Brake neutraliser pedal. oil, the
Service Brake Circuit accumulator
charging valve
diverts its pump
oil to tank
 ACCUMULATOR

ACCUMULATOR
Exit

TO FRONT
CATERPILLAR ELPHINSTONE PTY. LTD.
2

TO REAR
BRAKE

BRAKE
1 4 • The accumulator
charging valve
Menu keeps the

TO PRESSURE
3 SHUTTLE pressure in the

SWITCHES
VALVES
brake
Help accumulators in a
1 5
7 constant range
HIGH
Index Control PRESSURE
6 • The ACV relief
CONTROL
To Tank VALVE valve limits
Pump
maximum brake oil
9
Pressure pressure
Control
LOW PRESSURE
CONTROL VALVE • When the

TO TANK
accumulators do
6 not need oil the
4 8 ACV directs
RELIEF
9 excess pump oil to
7 VALVE

FROM
tank
PILOT
8 3 PUMP 2 5 • Each accumulator
is controlled by its
Accumulator Charging Valve own shuttle valve
inside the charge
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.
 |


z
y


| |

z


,
y

{

{
z 
,



y
z
|
Pressure Oil 2
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Nitrogen Gas 1 • Brake

Accumulator


z
| ,




y
z
{
|
Menu
4 • The accumulator
supplies oil under
Help pressure to the


z
| ,




y
z
{
|
3 service brake

Index • The gas chamber

above the piston

{

z
| ,

y



z
|
has a charge of
dry nitrogen gas

• Pump oil pushes

|
z{
y


,
z

|

z


{
y

the piston up and
5 causes
compression of
the dry nitrogen
gas
6

Brake Accumulator

(1) Accumulator, (2) Nitrogen charging valve, (3) Piston, (4) Nitrogen gas chamber,
(5) Pressure oil chamber, (6) Oil pressure outlet.
 Accumulator 2
Oil Pressure 1
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Tank Oil
• Service Brake
Regulated Oil Control Valve:
Menu Pressure
• The brake control
3 valve modulates
Help (regulates) the
TO WHEEL
BRAKES pressure to the
wheel brakes
Index
FROM
4 ACCUMULATOR
• The further the
pedal is
TO WHEEL
BRAKES depressed, the
TANK
greater the
pressure at the
FROM wheel brake
ACCUMULATOR

• When the brake

pedal is pushed,
5
the springs move
the control spools
down
6
Service Brake Control Valve (Released Position) • When the control
spools move
down, accumulator
(1) Brake control valve, (2) Springs, (3) Return port, (4) Spool, (5) Spool, (6) Spring. pressure oil flows
to the wheel
brakes

• The brake control

valve reduces
(modulates) the oil
pressure
 1 8
Parking Brake 4
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Tank Oil • Wheel Brake

Menu • Each brake group

has a service
brake piston and a
Help parking brake
3 piston
3
Index 5 • The brakes are
cooled and
lubricated by the
oil in the
6 differential and
axle housing

• When the parking

brake is released,
7
oil pressure
moves the parking
piston right, away
9 from the brake
2 disc
Wheel Brake (Parking Brake Released) • When the parking
brake is applied,
(1) Service brake piston, (2) Service brake oil passage, (3) Disc, (4) Axle housing, springs move the
(5) Axle, (6) Parking brake piston, (7) Spring, (8) Spring, (9) Parking brake oil passage. parking piston to
the right, against
the brake disc
 1 8 4
Parking Brake
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Tank Oil • Wheel Brake

• When the service
Menu Service Brake
brake is applied,
oil pressure
moves the service
Help 3 piston to the right,
3 against the brake
5 discs
Index
• When the service
brake is released,
6 springs move the
service piston to
the left, away from
the brake discs

2 9

Wheel Brake (Parking Brake Released - Service Brake Applied)

(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.
 BRAKE TREADLE
FRONT WHEEL BRAKES
FRONT BRAKE REAR BRAKE VALVE
ACCUMULATOR ACCUMULATOR
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• Braking system
shown with engine
Menu running,
BRAKE OIL
PRESSURE emergency/
SWITCHES
PARKING BRAKE parking brake
Help CONTROL VALVE
applied and
REAR WHEEL BRAKES
service brakes
released

TO PILOT
SYSTEM
Index
PRESSURE
REDUCING • The brake and
VALVE
PARK BRAKE
PRESSURE
pilot pump
SWITCHES supplies oil to the
pressure reducing
ACCUMULATOR
CHARGING VALVE valve, accumulator
charging valve and
pilot system

STEERING • The accumulator

charging valve
keeps the
IMPLEMENT PILOT pressure in the
TANK accumulators in a
System Operation (Emergency/Park Brake Applied) constant range

• The accumulators
store oil pressure
for operation of
the service brakes
 BRAKE TREADLE
FRONT WHEEL BRAKES
FRONT BRAKE REAR BRAKE VALVE
ACCUMULATOR ACCUMULATOR
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• Braking system
shown with engine
Menu running,
BRAKE OIL
PRESSURE emergency/
SWITCHES
PARKING BRAKE parking brake
Help CONTROL VALVE
released and
REAR WHEEL BRAKES
service brakes
released

TO PILOT
SYSTEM
Index
PRESSURE
REDUCING • The pressure
VALVE
PARK BRAKE
PRESSURE
reducing valve
SWITCHES controls the pilot
oil pressure in the
ACCUMULATOR
CHARGING VALVE emergency/
parking brake
circuit

STEERING • When the park

brake switch is
moved to the
IMPLEMENT PILOT RELEASED
TANK position, the
emergency/
System Operation (Emergency/Park Brake Released) parking brake
solenoid control
valves are
energised

• Pressure oil is
sent to the
emergency/
parking brake
section
 , ,
BRAKE TREADLE
FRONT WHEEL BRAKES
FRONT BRAKE REAR BRAKE VALVE
ACCUMULATOR ACCUMULATOR
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• Braking system

, ,
shown with engine
Menu running,

, ,
BRAKE OIL
PRESSURE emergency/
SWITCHES
PARKING BRAKE parking brake
Help CONTROL VALVE
released and
REAR WHEEL BRAKES
service brakes
applied

TO PILOT
SYSTEM
Index
PRESSURE
REDUCING • The accumulator
VALVE
PARK BRAKE
PRESSURE
charging valve
SWITCHES ‘charges’ the
accumulators with
ACCUMULATOR
CHARGING VALVE pressure oil

• When the brake

pedal is
STEERING depressed,
pressure oil
moves the service
IMPLEMENT PILOT brake piston to
TANK apply the brakes
System Operation (Service Brakes Applied)
• The further the
pedal is
depressed, the
greater the
pressure at the
wheel brakes
Exit 1
CATERPILLAR ELPHINSTONE PTY. LTD.

• Towing Brake
Release System
Menu Components:
(1) Brake release
cylinder
Help 2 (2) Towing brake
release
sequence valve
Index 1. Brake release cylinder. 2. Brake release sequence valve. (3) Shuttle valve
(4) Towing hook

• The towing brake

release system
allows release of
the emergency/
3 parking brake in
the event of a
machine fault

• The towing brake

3. Shuttle valve. 4. Towing hook. release system is
Towing Brake Release System activated when the
towing brake
release cylinder
piston is moved
up
 , ,
BRAKE TREADLE
FRONT WHEEL BRAKES
FRONT BRAKE REAR BRAKE VALVE
ACCUMULATOR ACCUMULATOR
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• The towing brake

, ,
release system is
Menu activated by the

, ,
BRAKE OIL
PRESSURE towing brake
SWITCHES
PARKING BRAKE release cylinder
Help CONTROL VALVE
piston
REAR WHEEL BRAKES
• The piston creates

TO PILOT
SYSTEM
Index PARK BRAKE
SHUTTLE
VALVE
oil pressure as it
PRESSURE
REDUCING
PRESSURE
SWITCHES
moves up - the
VALVE
pressure releases

,
TOW BRAKE
RELEASE
the emergency/
CYLINDER parking brake
ACCUMULATOR
CHARGING VALVE section of the
BRAKE RELEASE wheel brakes
SEQUENCE VALVE

• When the towing

brake piston

EXTERNAL
FORCE
STEERING

moves down, the

emergency/
IMPLEMENT PILOT parking brakes
TANK apply
Towing Brake Release System Operation
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• Identify
2 components
Menu (1) Pilot pressure
test point
(2) Service brake
Help test point
1
• Testing & adjusting
Index 1. Pilot pressure test piont. 2. Service brake pressure test point. procedures

Brake Pressure Test Points

Exit 2 CATERPILLAR ELPHINSTONE PTY. LTD.

1 • The emergency/
parking brake is
Menu applied and
released by the
3 parking brake
Help control switch

2. Brake oil pressure switch. • When the brake oil

Index 1. Park brake control switch. 3. Brake oil pressure switch. pressure is in the
operating range,
the emergency/
parking brake can
be released
5
• If brake oil
pressure falls
6 below the
operating range,
4 the emergency/
5. Solenoids. parking brake will
6. Switch. 7 5 apply
4. Park brake relay. 7. Switch.

Brake Electrical System • The transmission

electronic control
sends the park
brake switch signal
to the Caterpillar
Monitoring System
over the Cat data
link
 PARK BRAKE
SWITCH

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VOLTAGE KEY SWITCH ON

• Emergency/
parking brake
Menu release schematic
REMOTE CONTROL 5
OPERATION 6
4
2
• Wire shown as red
Help CIRCUIT BREAKER
No 10 3 have + battery
1
+24v SUPPLY
15A
voltage with the
key start switch in
TO ELECTRONIC
Index TRANSMISSION CONTROL the on position
C B
B C
A A • Emergency/
85 86 parking brake
PARK BRAKE 87 PARK BRAKE
PRESSURE SWITCH 30 RELAY control switch in
the pull to apply
1
PARK BRAKE 2 2
configuration
SOLENOID 1 3 +24v WHEN REMOTES
NOT IN USE
4
• The brake oil
1 A pressure switch
PARK BRAKE 1 2 B
SOLENOID 2 3 C provides an earth
4
for the park brake
BRAKE OIL PRESSURE
relay
SWITCH

• Park brake control

Brake Electrical Schematic switch in the
released position,
power is supplied
from a separate 24
volt supply to keep
relay latched
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• Identify
components:
Menu
• Explain task.

Help • Service manual.

Index

Bleed Down the Oil Pressure in the Brake System

(Practical Task)

Task – 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.