994K WHLLDR M05 BrkSys en TXT-Participant

Global Service Training
994K Wheel Loader

Brake System
Module 5 - Text Reference
SERV2070
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SERV2070 - 10/15 -2- Module 5 - Brake System
TABLE OF CONTENTS
Safety Briefing�� 3
Purpose�� 4
Reason�� 5
Competency statement�� 6
Learning outcomes�� 7
Hydraulic Brake System Control�� 8
BRAKE HYDRAULIC SCHEMATIC - CUT-IN CYCLE/PARKING
BRAKES ENGAGED/SERVICE BRAKES ENGAGED�� 13
Service Brake Valve OFF�� 16
Service Brake Valve ON�� 17
Service Brake Valve Balanced�� 18
Brake Pump�� 19
parking brake�� 22
Purpose review�� 25
Reason review�� 26
Competency Statement review�� 27
Learning Outcomes Review�� 28
Module Conclusion�� 29

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.™

PURPOSE
This module is designed to ensure you are able to

locate, identify, and describe the function of all major
components and service points of the Brake System.
4
Purpose

REASON
This training is necessary to properly locate and identify

all major components and service points as well as
describe the operation of the Brake System to be able
to diagnose and correct system problems.
5
Reason

COMPETENCY Statement
At the completion of this module, you will be able to

successfully complete the following exercises:
• Lab 1 Exercise
• Post-Assessment
6
Competency statement

LEARNING OUTCOMES
You will meet the following learning outcomes during

this Brake System module of the 994K Wheel Loader
course:
• Locate, identify, and describe the function of all major
components and service points of the 994K Wheel
Loader.
• Test and adjust the Brake System.
7
Learning outcomes

5 8
1
4
3 2
8
Hydraulic Brake System Control
The brake pump (1), mounted on the front pump drive, provides oil to the parking
brake valve (2), accumulator charging valve (3), brake pressure relief valve (4),
high pressure screen (5), brake accumulators (6), and the service brake valve (not
shown).
The parking brake valve contains the parking brake pressure switch and parking
brake solenoid valve. The parking brake pressure switch sends an input to the
Power Train ECM giving the ON/OFF position of the parking brake.
The brake pump is a pressure compensated piston pump that is adjusted to supply
17,020 kPa (2500 psi) pressure. A check valve between the brake pump and the
accumulators has a cracking pressure of 500 kPa (72 psi). The brake pressure
relief valve has a cracking pressure of 18,000 kPa (2600 psi)
The steering and brake hydraulic tank (7) stores oil for the steering and brake
systems.
Also shown is the case drain manifold (8) for the brake pump. Each individual case
drain port contains an in-line magnet, located in the manifold, that can be used for
diagnosing performance issues.

3
1
9
Installed on the steering and brake hydraulic tank are the temperature
sensor (1) and the oil level switches (2). The temperature sensor and the oil level
switch communicate with the Implement ECM.
The steering and brake oil level sight gauge (not shown) is located on the left side
of the machine and is visible from ground level.
Also shown is the brake/steering case drain bypass switch (3).

10
This image shows the service brake valve (1) and the parking brake switch (2).
Also shown is the service brake pedal (3).

1 2
3 4 5 6
11
The image shows the remote pressure taps and switches for the service brake
system located in the pump compartment
• Rear service brake pressure switch (1)
• Front service brake pressure switch (2)
• Rear service brake pressure tap (3)
• Front service brake pressure tap (4)
• Rear brake accumulator pressure tap (5)
• Front brake accumulator pressure tap (6)

12
This image shows the service brake accumulators (arrows) located in the pump
compartment. The front accumulator controls the front service brakes. The rear
accumulator controls the rear service brakes.
The accumulators are piston type that are charged with dry nitrogen. The charge
pressure for the accumulators at 21°C (70°F) is approximately 5,520 ± 280 kPa
(800 ± 40 psi).

994K BRAKE HYDRAULIC SCHEMATIC

CUT-IN CYCLE
PARKING BRAKE ENGAGED / SERVICE BRAKES ENGAGED
Front Axle (16)
Left Brake Parking

Right Brake (1)
Pedal
Brake
(11)
Pedal
Stop (14)
Lamp Throttle Lock Parking Brake Control Valve (9)
Switch Switch (15)
(12)
Torque Parking Brake
Converter Solenoid Valve
Pedal (10)
Position
Sensor
(13)
Service Brake
Control Valve (8)
Front Brake Rear Brake
Accumulator Accumulator
(4) (5)
Check
Relief Valve (6)
Valve
(7) Inverse
Shuttle
Valve (3)
Brake
Pump
(2)
Rear Axle (17) Pump
Actuator (19)
Steering and
Brake Tank (18)
13
BRAKE HYDRAULIC SCHEMATIC - CUT-IN CYCLE/PARKING BRAKES
ENGAGED/SERVICE BRAKES ENGAGED
This schematic shows the brake system during the CUT-IN cycle with the service
brakes engaged and the parking brake (1) released.
When the accumulator oil pressure decreases below 16,000 ± 345 kPa
(2320 ± 50 psi), the brake pump (2) begins to upstroke and the inverse shuttle
valve (3) enters the CUT-IN mode. In the CUT-IN mode, the accumulator pressure
keeps the inverse shuttle valve centered and oil flows from the brake pump to the
front brake and rear brake accumulators (4-5).
When the brake pump is connected to the accumulators, the pressure decreases
between the inverse shuttle valve and the check valve (6). Pump oil flows to the
accumulators until the accumulator pressure and the pressure at the inverse shuttle
valve reach the 16,000 ± 345 kPa (2320 ± 50 psi) CUT-OUT pressure. When the
CUT-OUT pressure is reached, the pump destrokes.
When either brake pedal is depressed, the service brakes are engaged. The
movement of the brake pedal is mechanically transmitted to the service brake
control valve (8), which permits oil to flow through the service brake valve to the
front and rear service brakes.

If the machine loses power or if the brake pump fails, the service brakes can still
be engaged. The pressure in the accumulators permits several applications of the
service brakes to stop the machine or slow the machine enough to engage the
parking brake.
The rear brake accumulator also supplies oil to the parking brake control valve (9).
When the parking brake solenoid (10) is de-energized by the Power Train ECM,
oil is blocked from the parking brake and the parking brake is engaged by spring
force.
When the left brake pedal (11) is depressed the stop lamp switch (12) is closed,
which illuminates the brake lights. Also, when the left brake pedal is depressed,
a Pulse Width Modulated (PWM) signal is sent from the torque converter pedal
position sensor (13) to the Power Train ECM. The ECM processes the signal and
sends an output signal to the impeller clutch solenoid, which decreases impeller
clutch pressure. As the pedal is depressed farther, oil pressure to the impeller
clutch continues to decrease. When the pedal has been depressed approximately
10 degrees, a mechanical linkage from the right brake pedal to the tandem brake
valve causes the service brakes to engage.
When the right brake pedal (14) is depressed, the throttle lock switch (15) signals
the Engine ECM to disable the throttle lock function.
NOTE: Callouts not listed in the text are shown for reference purposes only.

994K BRAKE HYDRAULIC SCHEMATIC

CUT-OUT CYCLE
PARKING BRAKE RELEASED / SERVICE BRAKES RELEASED
Front Axle (16)
Left Brake Parking

Right Brake (1)
Pedal
Brake
(11)
Pedal
Stop (14)
Lamp Throttle Lock Parking Brake Control Valve (9)
Switch Switch (15)
(12)
Torque Parking Brake
Converter Solenoid Valve
Pedal (10)
Position
Sensor
(13)
Service Brake
Control Valve (8)
Front Brake Rear Brake
Accumulator Accumulator
(4) (5)
Check
Relief
Valve (6)
Valve
(7) Inverse
Shuttle
Valve (3)
Brake
Pump
(2)
Rear Axle (17) Pump
Actuator (19)
Steering and
Brake Tank (18)
15
BRAKE HYDRAULIC SCHEMATIC - CUT-OUT CYCLE/PARKING BRAKES
RELEASED/SERVICE BRAKES RELEASED
When the pressure in the accumulators (4-5) increases to the CUT-OUT pressure
of 16,000 ± 345 kPa (2320 ± 50 psi), the accumulator oil pressure closes the
check valve (6) and oil from the brake pump (2) to the accumulators is blocked. Oil
pressure increases, which causes the brake pump compensator spool to direct oil
to the pump control piston and destroke the brake pump.
The check valve prevents the high pressure oil in the passages to the inverse
shuttle valve from flowing back to the brake pump. The inverse shuttle valve
will remain in the CUT-OUT mode until the pressure in one of the accumulators
decreases to the CUT-IN pressure of 16,000 ± 345 kPa (2320 ± 50 psi).
When the brake pedals are not depressed, the service brakes are released. The
movement of the brake pedal is mechanically transmitted to the service brake
control valve (8), which blocks oil flow to the front and rear service brakes. The
service brakes are released by spring force.
When the parking brake solenoid (10) is energized by the Power Train ECM, oil is
directed to the parking brake and the parking brake is released by accumulator oil
pressure.

SERVICE BRAKE VALVE

BRAKES OFF
Plunger (1)
Plunger Springs (13)
Return Spring (2)
Shims (14)
Ball (3)
Ball Retainer (4) Check Valve (15)
Upper Spool (5) Orifice (16)
Tank Port (17)
Front Brake Port (6) Upper Piston (18)
Retainer (19)
System Pressure Port (7)
Check Valve (20)
Return Spring (8)

Orifice (21)
Lower Spool (9) Tank Port (22)
Rear Brake Port (10) Lower Piston (23)
Check Valve (24)

Lower Return Spring (12)

16
Service Brake Valve OFF
The service brake valve has two individual brake ports: the front brake port (6) and
the rear brake port (10). The pressure at the service brake ports will be equal to the
pressure developed by the two plunger springs (13). Also, the spring force will be
proportional to the plunger (1) movement.
The brake control valve is equipped with check valves. The top check valve (15)
prevents spikes in the tank port from entering the cavity with the plunger springs
and acting on the plunger. The two lower check valves (20) and (24) also prevent
spikes in the tank line from acting on the upper spool (5) and lower spool (9) and
eventually transferring to the brake pedal.
The brake control valve is also equipped with shims (14) that are between the ball
retainer (4) and the springs. These shims are used to adjust the maximum pressure
that is directed to the service brakes.

SERVICE BRAKE VALVE

BRAKES ON
Plunger (1)
Return Spring (2)
Shims (14)
Ball (3)
Check Valve (15)
Ball Retainer (4)
Orifice (16)
Upper Spool (5)
Tank Port (17)
Front Brake Port (6) Upper Piston (18)
Retainer (19)
Check Valve (20)
Return Spring (8)

Orifice (21)
Lower Spool (9)
Tank Port (22)
Rear Brake Port (10) Lower Piston (23)
Check Valve (24)


17
Service Brake Valve ON
To initiate the operation of the service brake valve, the operator depresses the
brake pedal. The plunger (1) is pushed in the downward direction against the
plunger springs (13). The springs push the ball retainer (4), the ball (3), the upper
spool (5), and the upper piston (18) down against the retainer and the lower
spool (9). The front brake port (6) will be blocked from the upper tank port (17). The
front brake port will then be open to flow from the system pressure port (11). Also,
the system oil flows through the orifice into the cavity between the upper spool and
the upper piston.
The upper spool, upper piston, and retainer moves the lower spool downward
compressing the lower return spring (12) and the lower piston is bottomed out. The
rear brake port (10) will then be open to flow from the system pressure port (from
the rear brake accumulator). Also, the oil flows through the orifice into the cavity
that is between the lower spool and the lower piston (23).

SERVICE BRAKE VALVE

BRAKE PORTS BALANCED
Plunger (1)
Return Spring (2) Shims (14)
Ball (3) Check Valve (15)
Ball Retainer (4) Orifice (16)
Upper Spool (5) Tank Port (17)
Upper Piston (18)

Front Brake Port (6)
Retainer (19)
Check Valve (20)
Return Spring (8)

Orifice (21)
Lower Spool (9)
Tank Port (22)
Lower Piston (23)
Rear Brake Port (10)
Check Valve (24)

18
Service Brake Valve Balanced
In the upper section, the oil pressure in the cavity is equal to the pressure at the
service brake port. Due to the area of the upper piston (18), the upper spool (5) is
shifted upward compressing the plunger springs (13). The upper spool moves up
to block the flow of oil between the upper pressure port and the front brake port (6).
This creates a balance between the force of the plunger springs and the front brake
port pressure.
At the same time, the pressure in the lower cavity is equal to the pressure at the
rear brake port (10). Due to the area of the lower piston (23), the lower spool (9)
is pushed up and the lower spool blocks the flow of oil between the lower system
pressure port and the rear brake port. This creates a balance between the upper
piston force and the lower brake port pressure.
Increasing the downward movement of the plunger (1) will increase the spring force
and cause pressure at the service brake ports to increase until maximum pressure
is reached.
Decreasing the downward movement of the plunger will decrease spring force and
cause pressure at the service brake ports to decrease. The return springs move
the upper and lower spools up when the pedal is fully released, opening the service
brake ports up to the tank ports.

BRAKE PUMP
LOW PRESSURE
Control Piston (5) Spring (6)

Pump Control
Valve (1)
Barrel (7)
Control Piston
Passage (2)
Outlet Passage (3)
Drive
Shaft (8)
Inlet Passage (4)

Piston Assembly (9) Swashplate (10)
19
Brake Pump
Shown in this illustration are the main components of the brake pump. The
components are:
• Pump control valve (1)
• Control piston (5)
• Spring (6)
• Barrel (7)
• Drive shaft (8)
• Piston assembly (9)
• Swashplate (10)
When pressure in the brake system is less than 16000 ± 345 kPa (2300 ± 50 psi),
the spring keeps the swashplate at maximum angle. The pump piston stroke is
longest and pump displacement is maximum. A small amount of pressure oil from
the outlet passage (3) flows to the pump control valve. A spool in the pump control
valve blocks the flow of oil to the control piston passage (2).

PUMP CONTROL VALVE

LOW BRAKE SYSTEM PRESSURE HIGH BRAKE SYSTEM PRESSURE
Spring Spring
(6) From Pump (6) From Pump
Adjustment To Control Adjustment To Control
Outlet (5) Outlet (5)
Bolt (1) Piston (4) Bolt (1) Piston (4)
Locking Pressure Compensator Locking Pressure Compensator

Nut (2) Spool (3) Nut (2) Spool (3)
20
This illustration shows the main components and the operation of the pump control
valve. The components are:
• Adjustment bolt (1)
• Locknut (2)
• Pressure compensator spool (3)
• Spring (6)
The left illustration shows the operation of the pump control valve when the brake
system pressure is less than 16000 ± 345 kPa (2300 ± 50 psi). Pump output
oil flows around the right land of the pressure compensator spool and into the
chamber at the right end of the spool.
When the brake system pressure increases to 16000 ± 345 kPa (2300 ± 50 psi),
the pressure of the oil in the chamber is high enough to move the spool against the
spring. Movement of the spool permits oil to flow past the spool to the control
piston (4) in the pump.
For the correct adjustment procedure for the pump control valve, refer to the Brake
System Testing and Adjusting Module.

BRAKE PUMP
HIGH PRESSURE
Pump Control Control Piston (5) Spring (6)
Valve (1)
Barrel (7)
Control Piston
Passage (2)
Outlet Passage (3)
Drive
Shaft (8)
Inlet Passage (4)

Piston Assembly (9) Swashplate (10)
21
When the brake system pressure reaches 16000 ± 345 kPa (2300 ± 50 psi), oil
from the pump control valve (1) fills the chamber in the control piston (5). As the
brake system pressure increases above 16000 ± 345 kPa (2300 ± 50 psi), the oil
pressure from the pump control valve moves the control piston against the control
spring (6). This movement decreases the angle of the swashplate (10), the stroke
of the pistons, and the displacement of the pump. The amount of oil per pump
revolution is decreased to the amount that is required to maintain the system
pressure at 16000 ± 345 kPa (2300 ± 50 psi).

3
2
22
parking brake
The parking brake assembly is located at the articulation hitch on the loader frame.
The parking brake is spring activated and hydraulic oil pressure released through
the cylinders (1). The cylinders are equipped with air purge screws (2).
Parking brake pressure can be checked at the remote pressure tap in front of the
cab. A hose (3) connects the parking brake pressure tap to the parking brake
cylinder.

23
The image above shows location of the parking brake pressure tap (arrow) in front
of the cab.

1
2
3
4
7
24
This image is showing a transparency view of the parking brake. The parking brake
is spring applied and hydraulically released. When the parking brake switch (not
shown) is released, the parking brake valve blocks the flow of oil to the parking
brake. The springs (1) force the plates and discs (2) together. Since the discs are
splined to the drive shaft and the plates are held in place by the rods (7), the spring
force stops the drive shaft.
When the parking brake switch is pressed, the parking brake valve directs oil to the
parking brake cylinders (3). The oil pressure develops a force on the piston (4) in
the cylinders and moves the piston to the left. The piston pushes pin (6) against the
plate (5) and the force compresses the springs. The plate is disengaged from both
the plates and discs. The discs and the drive shaft are free to rotate.

PURPOSE
This module was designed to ensure you are able to

locate, identify, and describe the function of all major
components and service points of the Brake System.
25
Purpose review

REASON
This training was necessary to properly locate and

identify all major components and service points as well
as describe the operation of the Brake System to be
able to diagnose and correct system problems.
26
Reason review

COMPETENCY Statement
You have successfully completed the following

exercises:
• Lab 1 Exercise
• Post-Assessment
27
Competency Statement review

LEARNING OUTCOMES
You have met the following learning outcomes during

this Brake System module of the 994K Wheel Loader
course:
• Located, identified, and described the function of all
major components and service points of the 994K Wheel
Loader.
• Tested and adjusted the Brake System.
28
Learning Outcomes Review

Module Conclusion
This concludes the Brake System module for the 994K

Wheel Loader course.
29
Module Conclusion

994K WHLLDR M05 BrkSys en TXT-Participant

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Global Service Training

994K Wheel Loader

Caterpillar: Confidential Yellow

Safely Home. Everyone. Every Day.™

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

Safely Home. Everyone. Every Day.™

Caterpillar: Confidential Yellow

This module is designed to ensure you are able to

Caterpillar: Confidential Yellow

This training is necessary to properly locate and identify

Caterpillar: Confidential Yellow

At the completion of this module, you will be able to

Caterpillar: Confidential Yellow

You will meet the following learning outcomes during

Caterpillar: Confidential Yellow

Caterpillar: Confidential Yellow

Also shown is the brake/steering case drain bypass switch (3).

Caterpillar: Confidential Yellow

Caterpillar: Confidential Yellow

Caterpillar: Confidential Yellow

Caterpillar: Confidential Yellow

994K BRAKE HYDRAULIC SCHEMATIC

Front Axle (16)

Left Brake Parking

Caterpillar: Confidential Yellow

Caterpillar: Confidential Yellow

994K BRAKE HYDRAULIC SCHEMATIC

Front Axle (16)

Left Brake Parking

Caterpillar: Confidential Yellow

SERVICE BRAKE VALVE

Upper Spool (5) Orifice (16)

Tank Port (17)

Front Brake Port (6) Upper Piston (18)

Return Spring (8)

Rear Brake Port (10) Lower Piston (23)

Check Valve (24)

Lower Return Spring (12)

Caterpillar: Confidential Yellow

SERVICE BRAKE VALVE

Front Brake Port (6) Upper Piston (18)

Return Spring (8)

Rear Brake Port (10) Lower Piston (23)

Check Valve (24)

Lower Return Spring (12)

Caterpillar: Confidential Yellow

SERVICE BRAKE VALVE

Return Spring (2) Shims (14)

Ball (3) Check Valve (15)

Ball Retainer (4) Orifice (16)

Upper Spool (5) Tank Port (17)

Upper Piston (18)

Return Spring (8)

System Pressure Port (11)

Lower Return Spring (12)

Caterpillar: Confidential Yellow

Control Piston (5) Spring (6)

Outlet Passage (3)

Inlet Passage (4)

Caterpillar: Confidential Yellow

PUMP CONTROL VALVE

Locking Pressure Compensator Locking Pressure Compensator

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