Global Service Training

R1600H Underground Loader

Brake System
Module 7 - Text Reference

SERV2052

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SERV2052 - 03/15 -2- Module 7 - Brake System

TABLE OF CONTENTS
Safety Briefing��������������������������������������������������������������������������������������������������������������������� 3
Purpose����������������������������������������������������������������������������������������������������������������������������������� 4
Reason������������������������������������������������������������������������������������������������������������������������������������� 5
Competency statement����������������������������������������������������������������������������������������������������� 6
Learning outcomes������������������������������������������������������������������������������������������������������������ 7
INTRODUCTION������������������������������������������������������������������������������������������������������������������������� 8
PILOT AND BRAKING PUMP����������������������������������������������������������������������������������������������������� 9
BRAKE ACCUMULATOR CHARGING VALVE�������������������������������������������������������������������������� 10
BRAKE ACCUMULATOR CHARGING VALVE - CUT-IN�����������������������������������������������������������11
BRAKE ACCUMULATOR CHARGING VALVE - CUT-OUT������������������������������������������������������� 13
BRAKE ACCUMULATORS�������������������������������������������������������������������������������������������������������� 14
SERVICE BRAKE PEDALS������������������������������������������������������������������������������������������������������ 15
SERVICE BRAKE CONTROL VALVE��������������������������������������������������������������������������������������� 16
Parking Brake CONTROL VALVE��������������������������������������������������������������������������������������� 17
PARKING BRAKE CONTROL VALVE - PARKING BRAKES ENGAGED��������������������������������� 18
PARKING BRAKE CONTROL VALVE - PARKING BRAKES RELEASED�������������������������������� 19
BRAKE HYDRAULIC SYSTEM - SERVICE BRAKES RELEASED/
PARKING BRAKES ENGAGED������������������������������������������������������������������������������������������������ 20
BRAKE HYDRAULIC SYSTEM - SERVICE BRAKES APPLIED/
PARKING BRAKES RELEASED����������������������������������������������������������������������������������������������� 21
Brake Release System����������������������������������������������������������������������������������������������������� 22
BRAKE RELEASE SYSTEM - PARKING BRAKE RELEASED������������������������������������������������ 23
Purpose review������������������������������������������������������������������������������������������������������������������ 25
Reason review�������������������������������������������������������������������������������������������������������������������� 26
Competency Statement review������������������������������������������������������������������������������������ 27
Learning Outcomes Review������������������������������������������������������������������������������������������� 28
Module Conclusion���������������������������������������������������������������������������������������������������������� 29

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SERV2052 - 03/15 -3- Module 7 - Brake System

Safety Briefing
• Emergency Phone Numbers
• First Aid Responders
• Location of Exits
• Location of Fire Extinguisher
• Room Alerts or Hazards
• Designated Location for Evacuation
• Storm Shelter
• Hazardous Material

Safely Home. Everyone. Every Day.™

3
Safety Briefing

Before beginning this module, the following topics will be reviewed:

• Emergency Phone Numbers
• First Aid Responders
• Location of Exits
• Location of Fire Extinguisher
• Room Alerts or Hazards
• Designated Location for Evacuation
• Storm Shelter
• Hazardous Material

Safely Home. Everyone. Every Day.™

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SERV2052 - 03/15 -4- Module 7 - Brake System

PURPOSE

This module is designed to ensure participants can

locate and identify the function of the brake system
components and test and adjust the brake system.

4
Purpose

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SERV2052 - 03/15 -5- Module 7 - Brake System

REASON

This training is necessary for participants to identify

the brake system components and test and adjust the
brake system in order to diagnose and repair the brake
system. This will ensure the customers will experience
quick and accurate resolution of brake system issues.

5
Reason

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SERV2052 - 03/15 -6- Module 7 - Brake System

COMPETENCY Statement

At the completion of this module, participants will

be able to locate and identify the brake system
components and test and adjust the brake system
during lab exercises. Participants will also be able to
identify the function of the brake system components
during a post-assessment.

6
Competency statement

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SERV2052 - 03/15 -7- Module 7 - Brake System

LEARNING OUTCOMES

You will meet the following learning outcomes during

this R1600H Underground Loader Brake System
module:
• Locate and identify the brake system components.
• Test and adjust the brake system.
• Identify the function of the brake system components.

7
Learning outcomes

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SERV2052 - 03/15 -8- Module 7 - Brake System

BRAKING SYSTEM
COMPONENT IDENTIFICATION

Parking Brake
Brake Accumulator Pilot and
Control Charging Braking
Hydraulic Valve (2) Valve (3) Pump (4)
Tank (1)

Brake
Front Wheel Service Brake Service Brake Pilot Oil Rear Wheel Rear Brake
Release
Brakes and Pedal and Pressure Brakes Accumulator
Cylinder
(12) Transmission Service Brake Reducing (8) Front Brake (6)
Accumulator (5)
Neutralizer Pedal Control Valve Valve
(11) (10) (9) (7)

8
INTRODUCTION

• Identify the main components of
the braking system.
The braking system includes a service brake circuit and a parking brake circuit that
operates four wheel brakes on the machine. The brake system is similar to the
R1600G, but the parking brake control valve (2) has been redesigned. The service
brakes are applied by oil pressure and released by spring force. The parking
brakes are spring engaged and disengaged by pilot oil pressure. The oil for the
braking circuit is stored in the hydraulic tank (1).

The main components of the service brake circuit are the pilot and braking
pump (4), the brake accumulator charging valve (3), the rear and front brake
accumulators (6) and (7), the service brake pedal and service brake control
valve (10), the service brake and transmission neutralizer pedal (11), the front
wheel brakes (12), and the rear wheel brakes (8).

The main components of the parking brake circuit are the pilot and braking pump,
the pilot oil pressure reducing valve (9), the parking brake control valve, the front
wheel brakes, and the rear wheel brakes.

The optional brake release system can be used to release the machine brakes for
towing. The components of the brake release system are the brake release
cylinder (5), brake release sequence valve, and towing release sequence valves.
The brake release and towing release sequence valves are located in the parking
brake control valve.

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SERV2052 - 03/15 -9- Module 7 - Brake System

9
PILOT AND BRAKING PUMP

• Identify the pilot and braking
pump.
The pilot and braking pump (arrow) is part of a three-section vane pump mounted
to the torque converter updrive housing. The pump group also includes an
implement pump section and a steering pump section. The pilot and braking pump
section is attached to the steering pump section and sends oil to the brake
accumulator charging valve and the pilot pressure reducing valve.

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SERV2052 - 03/15 -10- Module 7 - Brake System

3 4

10
BRAKE ACCUMULATOR CHARGING VALVE

• Identify the brake accumulator The brake accumulator charging valve (1) is located on the left side of the rear
charging valve. frame.

The pilot and braking pump supplies hydraulic oil to the brake accumulator
charging valve and the pilot oil pressure reducing valve (2). The brake accumulator
charging valve maintains the pressure in the brake accumulator at a constant range
while the engine is running. Also, the brake accumulator charging valve divides
pump flow between the brake accumulator circuit and the pilot circuit. When the
engine is started, brake accumulator oil pressure increases to cut-out pressure.

The brake accumulator charging circuit pressure can be checked at the pressure
tap (3) located above the charging valve.

The brake accumulator oil pressure sensor (4), installed in the brake accumulator
charging valve, sends a signal to the Power Train Electronic Control Module (ECM)
indicating brake accumulator oil pressure. If a machine service brake system
failure occurs and the brake accumulator hydraulic oil pressure is too low, the low
brake accumulator oil pressure indicator on the monitor display will illuminate. If
the accumulator hydraulic oil pressure continues to decrease, the machine parking
brake will automatically engage.

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SERV2052 - 03/15 -11- Module 7 - Brake System

BRAKE ACCUMULATOR CHARGING VALVE

CUT-IN

Rear Brake Accumulator and Front Brake Accumulator and

Service Brake Control Valve Service Brake Control Valve
Inverse
Shuttle
Valve (1)
Brake Accumulator Oil
Pressure Sensor (7)
Cut-in/Cut-out
Spool (2)

Flow Control
Valve (3)
Flow Control
Orifice (5) Pressure Relief
Valve (4)

Pilot and Braking

Pump (6)
11
BRAKE ACCUMULATOR CHARGING VALVE - CUT-IN

• Explain the operation of the The brake accumulator charging valve contains the following internal components:
brake accumulator charging a pressure relief valve (4), flow control orifice (5), cut-in/cut-out spool (2), flow
valve during CUT-IN. control valve (3), and an inverse shuttle valve (1).

Oil from the pilot and braking pump (6) flows into the brake accumulator charging
valve to the flow control valve. The pressure relief valve limits the oil pressure that
flows from the pilot and braking pump to the braking circuit.

The flow control valve regulates oil flow to the braking circuit. Any excess oil that is
not required by the pilot circuit or the braking circuit is diverted back to the hydraulic
tank.

NOTE: The flow control valve contains shims that set the standby pressure
of the pilot and braking pump. When the pump is at standby pressure, the
brake accumulators do not require charging.

The check valve prevents oil from flowing through the accumulator charging valve,
and back to the pilot and braking pump.

The cut-in/cut-out spool controls the cut in and the cut out pressures for the
accumulator charging valve. When the oil pressure in the braking circuits reaches
the cut in pressure, the cut-in/cut-out spool shifts left. Oil flows to the right side of
the flow control valve.

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SERV2052 - 03/15 -12- Module 7 - Brake System

When the oil pressure in the brake accumulator reaches the cut in pressure, spring
force moves the cut-in/cut-out spool to the left. Oil from the brake accumulator
circuit flows to the left side of the flow control valve. The flow control valve moves
right and divides the oil flow between the brake accumulator circuit and the tank.
Oil flow to the tank is restricted by the flow control valve and the brake circuit
receives priority. The flow control orifice controls the rate of oil charge to the
brake accumulator circuit. The check valve prevents oil from flowing through the
accumulator charging valve, and back to the pilot and braking pump.

Oil flows through the inverse shuttle valve to charge the brake accumulators.
Pressure oil from the inverse shuttle valve flows to the oil end of the two brake
accumulators. However, the oil flow between the two brake accumulators is kept
separate.

The inverse shuttle valve is designed to charge each brake accumulator when the
pressure reaches the cut-in pressure.

The inverse shuttle valve connects to the brake accumulator oil pressure
sensor (7).

After the service brakes have been activated several times, the volume of oil in
the brake accumulator decreases. When the pressure in the brake accumulator
decreases (cut-in), the brake accumulator charging valve directs oil from the pilot
and braking pump to the brake accumulator. When the brake accumulator oil
pressure increases (cut-out), the brake accumulator charging valve directs all the
oil flow from the pilot and braking pump to the pilot circuit.

NOTE: During accumulator charging valve cut-in, priority is given to the

service brake circuit over the pilot circuit. Refer to the R1600H Load
Haul Dump Braking System, Systems Operation, Testing and Adjusting
(UENR1453) for cut-in and cut-out pressures.

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SERV2052 - 03/15
BRAKE ACCUMULATOR CHARGING VALVE
Rear Brake Accumulator and
Service Brake Control Valve
Flow Control
• Explain the operation of the
brake accumulator charging
valve during CUT-OUT.
-13- Module 7 - Brake System
CUT-OUT
Front Brake Accumulator and
Service Brake Control Valve
Inverse
Shuttle
Valve (1)
Brake Accumulator Oil
Pressure Sensor (7)
Cut-in/Cut-out
Spool (2)
Flow Control
Valve (3)
Orifice (5) Pressure Relief
Valve (4)
Pilot and Braking
Pump (6)
13
BRAKE ACCUMULATOR CHARGING VALVE - CUT-OUT
When the oil pressure in the brake accumulator circuit reaches the cut-out
pressure, oil from the brake accumulators acts on the left side of the cut-in/cut-out
spool. The cut-in/cut-out spool moves to the right, allowing oil on the left side of the
flow control valve to return to the hydraulic tank. Oil from the pilot and braking
pump acts on the left side of the cut-in/cut-out spool, causing the cut-in/cut-out
spool to move to the right and more oil flows to the tank.
NOTE: Callouts not listed in the text are shown for reference purposes only.
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SERV2052 - 03/15 -14- Module 7 - Brake System

14
BRAKE ACCUMULATORS

• Identify the brake accumulators. The brake accumulators (arrows) are located on the left side of the rear frame.

The brake accumulators have a sealed piston that moves back and forth inside the
bore of the accumulator and is charged with dry nitrogen gas. The dry nitrogen gas
is added to the accumulator through the nitrogen charging valve at the top of the
accumulator.

Oil from the brake accumulator charging valve enters the accumulator and moves
a piston which causes the dry nitrogen gas to compress. When the pressure in the
accumulator reaches the cut-out pressure, the brake accumulator charging valve
stops the flow of oil to the brake accumulators.

When the operator pushes down on either brake pedal, oil in the accumulator flows
through the service brake control valve to apply the service brakes.

NOTE: Refer to the R1600H Load Haul Dump Braking System, Systems
Operation, Testing and Adjusting (UENR1453) for the brake accumulator
pressure specifications.

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SERV2052 - 03/15
5
• Identify the brake pedals and the
service brake control valve.
-15- Module 7 - Brake System
1
2
4
6 3
15
SERVICE BRAKE PEDALS
The service brake and transmission neutralizer pedal (1) and the service brake
pedal (2) are connected to the service brake control valve (3) and stop light limit
switch by a shaft assembly (4). When either of the brake pedals are depressed, the
service brake control valve will apply the service brakes and the stop light limit
switch will close. This causes the stop lights to illuminate.
The transmission neutralizer limit switch and stop light limit switch are located in a
housing (5) next to the service brake and transmission neutralizer pedal assembly.
The transmission is neutralized by de-energizing the direction clutch solenoid. At
the same time, the speed clutch is still energized, allowing full engine power to be
used in the hydraulic system.
The front service brake oil pressure sensor (6) and the rear service brake oil
pressure sensor (7) send a signal to the Power Train ECM indicating the residual
oil pressure in the front and rear service brakes.
The Power Train ECM monitors the residual brake oil pressure for the residual
brake oil pressure light function and for the operator present function to determine if
the operator is pressing the service brake pedal.
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SERV2052 - 03/15 -16- Module 7 - Brake System

SERVICE BRAKE CONTROL VALVE

BRAKE PEDAL BRAKE PEDAL
RELEASED APPLIED

Piston (1)

Spring (2) Upper Spool (3)

Lower Spool (5)

To Rear Brakes To Rear Brakes

From Accumulator

To Front Brakes To Front Brakes

From Accumulator
To Tank To Tank
Spring (4)

16_1

SERVICE BRAKE CONTROL VALVE

• Identify and explain the operation
of the service brake control
valve.
The service brake control valve is located under the floor panel in the operator
station. A mechanical link connects the two brake pedals.
When the operator depresses either brake pedal (right view), the upper
spring (2) moves the upper spool (3) and lower spool (5) down. The spools close
the passages to the tank and open the passage from the brake accumulators.
The oil from the brake accumulators flows through the spools to apply the service
brakes and to fill the chamber between the upper spool and the lower spool.

The pressure at the bottom of the lower spool and the force of the spring (4) move
the lower spool up against the pressure in the chamber between the upper spool
and the lower spool. The pressure in the chamber between the upper spool and the
lower spool moves the upper spool up against the force on the brake pedal.

The force at the bottom of each spool balances that spool against the force at the
top of the spool. Each spool acts as a pressure reducing valve to limit the pressure
in the brakes proportionally to the force at the top of the respective spool.

When the brake pedal is RELEASED (left view), the oil passage from the
accumulator to the brakes are closed, and the passages from the brakes to
the tank are opened. Oil in the rear and front service brakes flows through the
respective spools to the tank. Spring force at the bottom of the lower spool moves
the spools up.
NOTE: Callouts not listed in the text are shown for reference purposes only.

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SERV2052 - 03/15 -17- Module 7 - Brake System

2
5 3
1

17
Parking Brake CONTROL VALVE

• Identify the parking brake control
valve components.
The parking brake control valve (1) is located on the left side of the rear frame.
The parking brake control valve has two parking brake solenoid valves (2)
controlled by a parking brake switch in the operator’s station. The operation of
the parking brake solenoid valves are identical. The parking brake switch sends a
signal to the Power Train ECM, which sends a corresponding signal to the parking
brake solenoids.

The parking brake oil pressure sensor (3) sends a signal to the Power Train
ECM indicating parking brake circuit pressure. Parking brake oil pressure can be
measured at the parking brake system oil pressure test port (4).

When the parking brake switch is moved to the OFF position, the parking brake
solenoid valves are energized, allowing oil pressure to flow from the parking brake
control valve to the parking brake sequence valve (5) and parking brake dump
valve (6). The pressure of the oil moves the parking brake piston, compressing the
springs and allowing the discs and axle to rotate freely.

If the parking brake switch is moved to the ON position, the parking brake solenoid
valves are DE-ENERGIZED, allowing oil behind the parking brake piston to return
to the hydraulic tank. With no oil pressure behind the parking brake piston, the
force of the springs in the parking brake prevents the discs and axle from rotating.
The parking brake oil pressure switch (not visible) for remote control light is located
at the rear of the parking brake control valve.
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SERV2052 - 03/15 -18- Module 7 - Brake System

R1600H BRAKE CONTROL VALVE Tow Release

PARKING BRAKES ENGAGED Sequence Valves (3)
Front Parking Brakes (8)
Brake Release
Cylinder (2) Rear Parking Brakes (9)

Brake Release
Steering Release
Sequence
Diverter Valve
Valve (1)
(12)
Pilot Oil Pressure
Reducing Valve
(10) Parking Brake
Dump Valve (4)

Parking Brake Parking Brake

Pressure Sensor Sequence
(13) Valve (5)

Parking Brake
Solenoid
Valves (7)

Implement and Steering

Solenoid Valve (6)

STIC Steering Pilot Valve (11)

Pilot Oil Pressure

Reducing Valve (10)
18
PARKING BRAKE CONTROL VALVE - PARKING BRAKES ENGAGED

• Explain the operation of the
parking brake control valve
when the parking brakes are
ENGAGED.
Pilot oil from the pilot oil pressure reducing valve (10) flows to the parking brake
solenoids (7) and parking brake sequence valve (5). When the parking brake
switch in the cab is moved to the ON position, a signal is sent to the Power Train
ECM, The Power Train ECM de-energizes the parking brake solenoids and pilot oil
is blocked from flowing to the left end of the parking brake sequence valve and to
the bottom of the parking brake dump valve (4).

Oil in the front parking brakes (8) and rear parking brakes (9) flows through the tow
release sequence valves (3) and moves the parking brake dump valve down. With
the parking brake dump valve shifted down, the oil from the parking brakes returns
to the tank and spring force engages the parking brakes.

NOTE: Callouts not listed in the text are shown for reference purposes only.

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SERV2052 - 03/15 -19- Module 7 - Brake System

R1600H BRAKE CONTROL VALVE Tow Release

PARKING BRAKES RELEASED Sequence Valves (3)
Front Parking Brakes (8)
Brake Release
Cylinder (2) Rear Parking Brakes (9)

Steering Release Brake Release

Diverter Valve (12) Sequence
Valve (1)
Pilot Oil Pressure
Reducing Valve
(10)
Parking Brake
Dump Valve (4)

Parking Brake Parking Brake

Pressure Sensor Sequence
(13) Valve (5)
Parking Brake
Solenoid
Valves (7)

Implement and
Steering Solenoid
Valve (6)

Steering Pilot Valve (11)

Pilot Oil Pressure

Reducing Valve (10)
19
PARKING BRAKE CONTROL VALVE - PARKING BRAKES RELEASED

• Explain the operation of the
parking brake control valve
when the parking brakes are
RELEASED.
When the parking brake switch in the cab is moved to the OFF position, a signal is
sent to the Power Train ECM. The Power Train ECM energizes the parking brake
solenoid valves (7) and pilot oil is directed to the left end of the parking brake
sequence valve (5) and the bottom of the parking brake dump valve (4). The pilot
oil moves the parking brake sequence valve to the right and moves the dump valve
up. The dump valve blocks the pilot oil from flowing to the tank and the parking
brake sequence valve directs the pilot oil to the tow release sequence valves.

The tow release sequence valves are held up by spring force and pilot oil is
allowed to flow to the front parking brakes (8) and the rear parking brakes (9). The
brakes are released.

NOTE: Callouts not listed in the text are shown for reference purposes only.

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SERV2052 - 03/15 -20- Module 7 - Brake System

R1600H BRAKE HYDRAULIC SYSTEM Front Brakes (9)

SERVICE BRAKES RELEASED / PARKING BRAKES ENGAGED

Brake Release
Cylinder (6)

Brake Release
Sequence
Valve (5)
Steering Release
Diverter Valve (15)
Parking Brake
Control Valve (7)

Brake
Accumulators
(8)

STIC Steering Pilot Valve (14)

Service Brake
Control Valve
(1)
Selector and
Pressure
Control Valve (4)
Steering Implement
System Lift Circuit
(12) (13)

Rear Brakes (10)

Pilot Oil Pressure

Reducing Valve (2) Brake Accumulator
Charging Valve (3)

Pilot and Braking Pump (11)

20
BRAKE HYDRAULIC SYSTEM - SERVICE BRAKES RELEASED/PARKING
BRAKES ENGAGED

• Explain the operation of the brake This illustration of the brake hydraulic system shows the oil flow with the service
hydraulic system with SERVICE brakes RELEASED and the parking brakes ENGAGED. The parking brakes are
BRAKES RELEASED and engaged by spring force as previously described.
PARKING BRAKES ENGAGED.
With the engine running, oil flows from the pilot and braking pump (11) to the brake
accumulator charging valve (3). The accumulator charging valve directs oil to the
brake accumulators (8) and service brake control valve (1) as previously described.

When the service brakes are released as shown in this illustration, the service
brake control valve blocks oil flow to the service brakes. Oil from the service brakes
returns to the tank through the service brake valve and spring force releases the
service brakes.

NOTE: Callouts not listed in the text are shown for reference purposes only.

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SERV2052 - 03/15 -21- Module 7 - Brake System

R1600H BRAKE HYDRAULIC SYSTEM Front Brakes (9)

SERVICE BRAKES APPLIED / PARKING BRAKES RELEASED

Brake Release
Cylinder (6)

Brake Release
Sequence
Steering Release Valve (5)
Diverter Valve (15)
Parking Brake
Control Valve (7)

Brake
Accumulators
(8)

STIC Steering Pilot Valve (14)

Service Brake
Control Valve
(1)
Selector and
Pressure
Control Valve (4)
Steering Implement
System Lift Circuit
(12) (13)

Rear Brakes (10)

Pilot Oil Pressure

Reducing Valve (2) Brake Accumulator
Charging Valve (3)

Pilot and Braking Pump (11)

21
BRAKE HYDRAULIC SYSTEM - SERVICE BRAKES APPLIED/PARKING
BRAKES RELEASED

• Explain the operation of the brake This illustration of the brake hydraulic system shows the oil flow with the service
hydraulic system with SERVICE brakes APPLIED and the parking brakes RELEASED. The parking brakes are
BRAKES APPLIED and PARKING released by pilot pressure as previously described.
BRAKES RELEASED.
With the engine running, oil flows from the pilot and braking pump (11) to the brake
accumulator charging valve (3). The accumulator charging valve directs oil to the
brake accumulators (8) and service brake control valve (1) as previously described.

When the service brakes are applied as shown in this illustration, the service brake
control valve directs oil from the brake accumulator charging valve to the service
brakes. The service brake control valve modulates the oil to the brake pistons to
apply the brakes.

NOTE: Callouts not listed in the text are shown for reference purposes only.

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SERV2052 - 03/15 -22- Module 7 - Brake System

1
2

6 3

4
22
Brake Release System

• Identify the brake release system If the parking brake is engaged due to a machine fault and the machine must be
components. towed, the optional brake release system can be used to disengage the parking
brake.

The brake release system is activated by a recovery bar (not shown) compressing
the piston in the brake release cylinder (1) or by an external force being applied to
the optional recovery hook (2). The brake release cylinder is located in the machine
towing hitch at the rear of the machine.

Oil in the brake release cylinder is forced from the cylinder and directed to the
brake release sequence valve (3), which opens and prevents oil from returning to
the hydraulic tank. Oil is directed to the tow release sequence valves (4), allowing
oil from the cylinder to flow to the wheel brakes. This oil pressure disengages the
parking brake section of the wheel brakes. The brake release sequence valve also
ensures that the brake release system is disabled when the engine is running.

The brake release system pressure can be checked at the brake release pressure
tap (5) located on the front of the parking brake valve (6).

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BRAKE RELEASE SYSTEM Tow Release

PARKING BRAKES RELEASED Sequence Valves (4)
Front Parking Brakes (5)
Brake Release
Cylinder (1) Rear Parking Brakes (6)

Pilot Oil
Pressure Brake
Reducing Release
Valve (2) Sequence
Valve (3)

Steering
Cylinders (14)
Parking Brake
Dump Valve (7)

Parking Brake
Sequence
Valve (11)

Brake
Steering Release Solenoid
Diverter Valve (12) Implement Valves (8)
and Steering
Steering Control Solenoid
Valve (13) Valve
(10)

STIC Steering Pilot Valve (9)

Pilot Oil Pressure

Reducing Valve (2)
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BRAKE RELEASE SYSTEM - PARKING BRAKE RELEASED

• Explain the operation of the brake
release system.
When the brake release system is activated, the recovery bar or the recovery hook
compresses the piston rod in the brake release cylinder (1) against spring force.
The hydraulic oil in the brake release cylinder (from the hydraulic tank) is directed
to the brake release sequence valve (3) and to the tow sequence valves (4). Since
the engine is not running, there is no oil flow from the pilot oil pressure reducing
valve (2), and spring force moves the brake sequence valve to the left. Oil is
blocked from flowing to the tank.

Oil pressure from the brake release cylinder moves the tow release sequence
valves down and oil is directed to the front and rear parking brakes (5) and (6). The
oil pressure then releases the parking brakes.

When the recovery bar is removed, or the external force on the recovery hook is
removed, the brake release system is deactivated and the piston rod in the brake
release cylinder is returned by spring force. The parking brake oil is now returned
to the tank via the brake release cylinder and the parking brake is engaged by
spring force.

When the engine is running, the brake release sequence valve ensures that the
brake release system is disabled and the parking brake is disengaged.

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If the machine must be towed, the brake release system can also be used to
release the machine steering. The steering release diverter valve (12) is located
on the rear frame beside the hydraulic oil tank. When the brake release system
is activated, oil from brake release cylinder activates the steering release diverter
valve. The steering release diverter valve allows oil flow between the rod end and
the head end of the steering cylinders (14), which permits the machine to articulate
freely during towing.

NOTE: Refer to the R1600H Load Haul Dump Operation and Maintenance
Manual (SEBU8317) for the brake release procedure.
NOTE: Callouts not listed in the text are shown for reference purposes only.

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PURPOSE

This module was designed to ensure participants can

locate and identify the function of the brake system
components and test and adjust the brake system.

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Purpose review

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REASON

This training was necessary for participants to identify

the brake system components and test and adjust the
brake system in order to diagnose and repair the brake
system. This will ensure the customers will experience
quick and accurate resolution of brake system issues.

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Reason review

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COMPETENCY Statement

Participants are now able to locate and identify the

brake system components and test and adjust the
brake system during lab exercises. Participants are
also able to identify the function of the brake system
components during a post-assessment.

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Competency Statement review

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LEARNING OUTCOMES

You have met the following learning outcomes during

this R1600H Underground Loader Brake System
module:
• Located and identified the brake system components.
• Tested and adjusted the brake system.
• Identified the function of the brake system components.

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Learning Outcomes Review

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Module Conclusion

This concludes the Brake System module for the

R1600H Underground Loader course.

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Module Conclusion

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