R1600 LHD

CATERPILLAR ELPHINSTONE PTY. LTD.

Ser
vice T
raining Guides
Service
Training

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BRAKE SYSTEM

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Contents
Introduction .................................................................3
Braking System Block Schematic ..............................4

Help

Braking System Component Location .........................5

Emergency/Parking Brake Circuit ...............................6

Index

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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CATERPILLAR ELPHINSTONE PTY. LTD.

Introduction:

Menu

Schematic colour
code:

Help

Testing &
Adjusting
procedures:

Index

Servicemans
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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CATERPILLAR ELPHINSTONE PTY. LTD.

Two Brake Control

Systems:
- Emergency/
parking brake
system
- Service brake
system

PARKING
BRAKE CONTROL
VALVE

Menu
Help
Index

PRESSURE
REDUCING
VALVE

PUMP

ACCUMULATOR

ACCUMULATOR
CHARGING
VALVE

SERVICE
BRAKE
CONTROL
VALVE

Other Brake
System Features:
- Brake towing
release system

The pump draws

oil (green) from
the tank and sends
flow (red) to the
various control
valves

TANK

Braking System Block Schematic

The emergency/
parking brake is
spring engaged
and hydraulically
released
The service brake
is hydraulically
applied

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CATERPILLAR ELPHINSTONE PTY. LTD.

Menu

There are four

wheel brakes on
the machine

Each wheel brake

provides
emergency/
parking and
service braking

Help
Index

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.

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CATERPILLAR ELPHINSTONE PTY. LTD.

The brake and

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

1
Menu
Help
Index

2
1. Hydraulic oil tank (behind guard).

2. Brake and pilot pump.

3
4

3. Pressure reducing valve.

4. Emergency/parking brake control valve.

Emergency/Parking Brake Circuit

The brake and

pilot pump
supplies oil to the:
- Parking brake
circuit
- Service brake
circuit
- Implement pilot
circuit
- Steering pilot
circuit
Pump oil flows from
the pump, through
the
pressure
reducing valve to
the emergency/
parking
brake
control valve
The pressure
reducing valve
limits maximum oil
pressure in the
parking brake
circuit

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CATERPILLAR ELPHINSTONE PTY. LTD.

The service brake

is used for normal
machine braking

Menu

The brake and

pilot pump is part
of the threesection vane-type
pump

Help

1
Index

1. Brake and pilot pump.

2. Accumulator charging valve.

4
3
6
3. Front brake accumulator.
4. Rear brake accumulator.

5. Service brake pedal.

6. Brake neutraliser pedal.

Service Brake Circuit

The accumulator
charging valve
keeps the
pressure in the
brake
accumulators in a
constant range
When the
accumulators are
fully charged with
oil, the
accumulator
charging valve
diverts its pump
oil to tank

Menu

SHUTTLE
VALVES

7
HIGH
PRESSURE
CONTROL
VALVE

Control

Control

To Tank

LOW PRESSURE
CONTROL VALVE

4
7

valve limits
maximum brake oil
pressure

Pressure

6
8
RELIEF
VALVE

FROM
PILOT
PUMP

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 accumulator
charging valve
keeps the
pressure in the
brake
accumulators in a
constant range

6 The ACV relief

TO TANK

Index

Pump

Help

CATERPILLAR ELPHINSTONE PTY. LTD.

TO PRESSURE
SWITCHES

TO REAR
BRAKE
ACCUMULATOR

TO FRONT
BRAKE
ACCUMULATOR

Exit

When the
accumulators do
not need oil the
ACV directs
excess pump oil to
tank
Each accumulator
is controlled by its
own shuttle valve
inside the charge
valve

Exit

Pressure Oil
Nitrogen Gas

Menu
Help
3

Index

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2
CATERPILLAR ELPHINSTONE PTY. LTD.

Brake
Accumulator

The accumulator
supplies oil under
pressure to the
service brake
The gas chamber
above the piston
has a charge of
dry nitrogen gas

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

Pump oil pushes

the piston up and
causes
compression of
the dry nitrogen
gas

Exit

Accumulator
Oil Pressure

2
CATERPILLAR ELPHINSTONE PTY. LTD.

Tank Oil

Menu

Service Brake
Control Valve:

Regulated Oil
Pressure

Help

TO WHEEL
BRAKES

Index

FROM
ACCUMULATOR

TO WHEEL
BRAKES

TANK

FROM
ACCUMULATOR

5
6

Service Brake Control Valve (Released Position)

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

The brake control

valve modulates
(regulates) the
pressure to the
wheel brakes
The further the
pedal is
depressed, the
greater the
pressure at the
wheel brake
When the brake
pedal is pushed,
the springs move
the control spools
down
When the control
spools move
down, accumulator
pressure oil flows
to the wheel
brakes
The brake control
valve reduces
(modulates) the oil
pressure

Exit

Parking Brake

CATERPILLAR ELPHINSTONE PTY. LTD.

Wheel Brake

Tank Oil

Menu

Each brake group

has a service
brake piston and a
parking brake
piston

Help
3

3
5

Index

The brakes are

cooled and
lubricated by the
oil in the
differential and
axle housing

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.

When the parking

brake is released,
oil pressure
moves the parking
piston right, away
from the brake
disc
When the parking
brake is applied,
springs move the
parking piston to
the right, against
the brake disc

Exit

Parking Brake

4
CATERPILLAR ELPHINSTONE PTY. LTD.

Wheel Brake
When the service
brake is applied,
oil pressure
moves the service
piston to the right,
against the brake
discs

Tank Oil

Menu

Service Brake

Help
3

Index

When the service

brake is released,
springs move the
service piston to
the left, away from
the brake discs

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.

Exit

FRONT BRAKE
ACCUMULATOR

REAR BRAKE
ACCUMULATOR

BRAKE TREADLE
VALVE

FRONT WHEEL BRAKES

CATERPILLAR ELPHINSTONE PTY. LTD.

Menu
BRAKE OIL
PRESSURE
SWITCHES
PARKING BRAKE
CONTROL VALVE

Help
TO PILOT
SYSTEM

REAR WHEEL BRAKES

Index
PRESSURE
REDUCING
VALVE

PARK BRAKE
PRESSURE
SWITCHES

ACCUMULATOR
CHARGING VALVE

STEERING

IMPLEMENT

PILOT
TANK

System Operation (Emergency/Park Brake Applied)

Braking system
shown with engine
running,
emergency/
parking brake
applied and
service brakes
released
The brake and
pilot pump
supplies oil to the
pressure reducing
valve, accumulator
charging valve and
pilot system
The accumulator
charging valve
keeps the
pressure in the
accumulators in a
constant range
The accumulators
store oil pressure
for operation of
the service brakes

Exit

FRONT BRAKE
ACCUMULATOR

REAR BRAKE
ACCUMULATOR

BRAKE TREADLE
VALVE

FRONT WHEEL BRAKES

CATERPILLAR ELPHINSTONE PTY. LTD.

Menu
BRAKE OIL
PRESSURE
SWITCHES
PARKING BRAKE
CONTROL VALVE

Help
TO PILOT
SYSTEM

REAR WHEEL BRAKES

Index
PRESSURE
REDUCING
VALVE

PARK BRAKE
PRESSURE
SWITCHES

ACCUMULATOR
CHARGING VALVE

STEERING

IMPLEMENT

PILOT
TANK

System Operation (Emergency/Park Brake Released)

Braking system
shown with engine
running,
emergency/
parking brake
released and
service brakes
released
The pressure
reducing valve
controls the pilot
oil pressure in the
emergency/
parking brake
circuit
When the park
brake switch is
moved to the
RELEASED
position, the
emergency/
parking brake
solenoid control
valves are
energised
Pressure oil is
sent to the
emergency/
parking brake
section

Exit

FRONT BRAKE
ACCUMULATOR

REAR BRAKE
ACCUMULATOR

BRAKE TREADLE
VALVE

Menu
BRAKE OIL
PRESSURE
SWITCHES
PARKING BRAKE
CONTROL VALVE

Help

, ,
, ,
, ,
FRONT WHEEL BRAKES

TO PILOT
SYSTEM

REAR WHEEL BRAKES

Index
PRESSURE
REDUCING
VALVE

PARK BRAKE
PRESSURE
SWITCHES

ACCUMULATOR
CHARGING VALVE

STEERING

IMPLEMENT

PILOT
TANK

System Operation (Service Brakes Applied)

CATERPILLAR ELPHINSTONE PTY. LTD.

Braking system
shown with engine
running,
emergency/
parking brake
released and
service brakes
applied
The accumulator
charging
valve
charges
the
accumulators with
pressure oil
When the brake
pedal is
depressed,
pressure oil
moves the service
brake piston to
apply the brakes
The further the
pedal is
depressed, the
greater the
pressure at the
wheel brakes

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CATERPILLAR ELPHINSTONE PTY. LTD.

Menu
Help
Index

2
1. Brake release cylinder.

2. Brake release sequence valve.

The towing brake

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

3. Shuttle valve.

Towing Brake
Release System
Components:
(1) Brake release
cylinder
(2) Towing brake
release
sequence valve
(3) Shuttle valve
(4) Towing hook

4. Towing hook.

Towing Brake Release System

The towing brake

release system is
activated when the
towing brake
release cylinder
piston is moved
up

Exit

FRONT BRAKE
ACCUMULATOR

REAR BRAKE
ACCUMULATOR

, ,
, ,
, ,

BRAKE TREADLE
VALVE

FRONT WHEEL BRAKES

Menu
BRAKE OIL
PRESSURE
SWITCHES
PARKING BRAKE
CONTROL VALVE

Help

CATERPILLAR ELPHINSTONE PTY. LTD.

The towing brake

release system is
activated by the
towing brake
release cylinder
piston

TO PILOT
SYSTEM

REAR WHEEL BRAKES

Index
PRESSURE
REDUCING
VALVE

PARK BRAKE
PRESSURE
SWITCHES

ACCUMULATOR
CHARGING VALVE

The piston creates

SHUTTLE
oil pressure as it
VALVE
moves up - the
pressure releases
TOW BRAKE
the emergency/
RELEASE
CYLINDER
parking brake
section of the
wheel brakes
BRAKE RELEASE

STEERING

IMPLEMENT

,
EXTERNAL
FORCE

SEQUENCE VALVE

PILOT
TANK

Towing Brake Release System Operation

When the towing

brake piston
moves down, the
emergency/
parking brakes
apply

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CATERPILLAR ELPHINSTONE PTY. LTD.

Menu
Help
Index

Identify
components
(1) Pilot pressure
test point
(2) Service brake
test point

1
1. Pilot pressure test piont.

2. Service brake pressure test point.

1
2

Brake Pressure Test Points

Testing & adjusting

procedures

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CATERPILLAR ELPHINSTONE PTY. LTD.

The emergency/
parking brake is
applied and
released by the
parking brake
control switch

Menu

3
Help
Index

1. Park brake control switch.

2. Brake oil pressure switch.

3. Brake oil pressure switch.

When the brake oil

pressure is in the
operating range,
the emergency/
parking brake can
be released

5
6
4
4. Park brake relay.

5. Solenoids.
6. Switch.
7. Switch.

Brake Electrical System

If brake oil
pressure falls
below the
operating range,
the emergency/
parking brake will
apply
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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CATERPILLAR ELPHINSTONE PTY. LTD.

VOLTAGE KEY SWITCH ON

Emergency/
parking brake
release schematic

Menu
REMOTE CONTROL
OPERATION

Help

CIRCUIT BREAKER
No 10
+24v SUPPLY

5
6
4
2
3
1

Wire shown as red

have + battery
voltage with the
key start switch in
the on position

15A

TO ELECTRONIC
TRANSMISSION CONTROL

Index

C
B
A

B
C
A
85

PARK BRAKE
PRESSURE SWITCH

PARK BRAKE
SOLENOID

PARK BRAKE
SOLENOID

2
1

1
2
3
4

1
2

1
2
3
4

30

86
87

PARK BRAKE
RELAY

Emergency/
parking brake
control switch in
the pull to apply
configuration

+24v WHEN REMOTES

NOT IN USE

A
B
C

BRAKE OIL PRESSURE

SWITCH

Brake Electrical Schematic

The brake oil

pressure switch
provides an earth
for the park brake
relay
Park brake control
switch in the
released position,
power is supplied
from a separate 24
volt supply to keep
relay latched

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CATERPILLAR ELPHINSTONE PTY. LTD.

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.