Braking R2900 PDF

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CATERPILLAR ELPHINSTONE PTY. LTD.
R2900 LHD
BRAKING SYSTEM
MODULE
FORM NO. 9EL9203-00
FOR USE IN SERVICE TRAINING GUIDE:-
CEPL R2900 LHD - July 1998
Page 1
Service Training Module
R2900 Brake Module
List of Contents
Caterpillar Elphinstone Machine
List of Contents .......................................................................................................................................... 2
Important Safety Notice ............................................................................................................................. 3
R2900 Braking System Overview .............................................................................................................. 4
Introduction ................................................................................................................................................ 5
Braking System Block Schematic ............................................................................................................. 6
Braking System Component Location ........................................................................................................ 7
Location of Brake System Components ..................................................................................................... 8
Accumulator Charging Valve (Accumulator Fully Charged - Cut-Out Cycle) ............................................. 9
Accumulator Charging Valve (Accumulator Being Charged - Cut-In Cycle) ............................................ 10
Location of Brake System Components ................................................................................................... 11
Service Brake Control Valve (Released Position) .................................................................................... 13
Service Brake Accumulator ...................................................................................................................... 15
Wheel Brake (Parking Brake Released) ................................................................................................... 16
Wheel Brake (Parking Brake Released - Service Brake Applied) ............................................................ 17
System Operation (Parking Brake Engaged) ........................................................................................... 18
System Operation (Parking Brake Released) .......................................................................................... 20
System Operation (Service Brakes Applied) ............................................................................................ 21
Towing Brake Release System ................................................................................................................ 22
Towing Brake Release System Operation (Towing Brake Release Activated) ......................................... 23
Brake Pressure Test Points ...................................................................................................................... 25
Brake Electrical System ........................................................................................................................... 26
System Operation (Power Supply) ........................................................................................................... 28
System Operation (Relay Latched and Parking Brake Engaged) ............................................................ 29
System Operation (Parking Brake Released) .......................................................................................... 30
Parking Brake CMS Component Location ............................................................................................... 31
System Operation CMS (Parking Brake Released) ................................................................................. 33
Stop Light and Residual Brake Pressure Light Circuit Components ........................................................ 34
System Operation (Stop Light/Residual Brake Pressure Circuit) ............................................................. 35
Electric Brake Release System ................................................................................................................ 36
System Operation (Electric Brake Release) ............................................................................................ 37
Practical Tasks ......................................................................................................................................... 38
Theory Assessment ................................................................................................................................. 39
Theory Assessment Answers .................................................................................................................. 41
Theory Assessment ................................................................................................................................. 42
Theory Assessment Answers .................................................................................................................. 44
Servicemans Handouts ........................................................................................................................... 45
Page 2
R2900 Brake Module
IMPORTANT SAFETY NOTICE

The course content and subject matter is current
at the time of publication. Specifications,
torques, pressure settings, measurements,
adjustments, illustrations and other items can
change at any time. Always refer to the machine
specific service manual, parts book and updates
prior to performing repairs and adjustments.
Caterpillar Elphinstone Pty Ltd cannot anticipate
every possible circumstance that might involve
a potential hazard. The warnings in this module
are therefore not inclusive. If a procedure, tool,
device or work method not specifically
recommended by Caterpillar Elphinstone Pty Ltd
is to be used, you must satisfy yourself that it is
safe for yourself and others. You should also
ensure that the machine will not be damaged or
made unsafe by the procedures you choose.
Page 3
R2900 Brake Module
R2900 Braking System Overview
Module Description
Aims:
The aim of this training module is to provide participants with the operational knowledge and diagnostic skills necessary to
troubleshoot the R2900 Braking System.
Nominal Duration:
The module is designed so that most of the trainees will acquire the knowledge in one 4 hour session. The length of time
actually taken to complete the module will vary depending on factors such as the teaching method used, the trainees
knowledge and skills at entry, and the individual trainees ability.
Pre-Requisites:
Mechanical tradesman - should have completed a Basic Hydraulic and Electrical Training Program (preferred but not
essential).
Learning Outcomes:
As a result of studying this module, participants should be able to:
1. Demonstrate an understanding of the function and operation of the braking system and its components.
2. Use and understand the braking system schematic.
3. Trace the oil flow through the braking system during all modes of operation.
4. Apply this operational knowledge to troubleshoot a series of braking system problems.
5. Use the Service Manual and Parts Book to assist with troubleshooting.
Assessment:
Tasks:
Part A: Practical Tests.
Part B: Theory Assessment (True/False Test).
Resource Requirements:
R2900 LHD.
Fully equipped classroom with white board and overhead projector.
Training Module and handout material.
Hydraulic pressure gauges.
Service Manual.
Parts Book.
Tools for practical tasks.
Page 4
R2900 Brake Module
Introduction
This presentation discusses the system operation and adjusting

Introduction:
procedures for the R1600 LHD Braking System.
Graphical symbols and sectional view drawings will be used when

discussing systems operations. Systems will be explained by tracing
oil flow from the tank, through the system, and back to the tank.
Schematic colour code: 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
Testing & Adjusting NOTE: Always follow the procedures in the Service Manual when
procedures: testing and/or adjusting the machine braking system.
Servicemans Handouts: Give each trainee a copy of the relevant servicemans handouts,
supplied with this training module.
Page 5
R2900 Brake Module
WHEEL
BRAKE
PARKING
BRAKE CONTROL
VALVE
PILOT
RELIEF SERVICE BRAKE
VALVE ACCUMULATOR
SERVICE
BRAKE
FILTER CONTROL
ACCUMULATOR
CHARGING VALVE
VALVE
BRAKE AND
PILOT PUMP
ACCUMULATOR
CHARGE RELIEF
VALVE
TANK
2
Braking System Block Schematic
Block Schematic This block schematic of the R2900 LHD braking system shows the
- Parking brake system components and oil flow. There are two brake control systems on the
- Service brake system machine: the parking brake system and the service brake system. An
optional feature of the brake system is the towing brake release
Other Brake System Features: system.
- Towing brake release system
The brake and pilot pump oil (red) flows to the accumulator charging
The pump draws oil (green) valve. The valve divides the oil flow of the brake and pilot pump, priority
from the tank and sends flow is given to the service brake circuit. When the parking brake control
(red) to the various control valve is activated, pump oil is directed into the parking brake section of
valves the wheel brakes to release the brakes.
The parking brake is spring Brake and pilot pump oil flows through the accumulator charging valve
engaged and hydraulically to the service brake accumulator. When the service brake control valve
released is activated, accumulator oil goes to the service brake section of the
wheel brakes. The wheel brakes are dual-piston, outboard, wet-disc
The service brake is brakes located in the wheel ends. Each wheel brake has a parking
hydraulically applied brake piston and a service brake piston. The parking brake is spring
engaged and hydraulically released. The service brake is hydraulically
applied.
Page 6
R2900 Brake Module
1 2 3 4 5 6
7 8 9 10 11 12
Braking System Component Location
Identify components The hydraulic brake system consists of: hydraulic tank (1), parking
(1) Hydraulic tank brake control valve (2), service brake accumulator (3), accumulator
(2) Parking brake control charge relief valve (4), pilot oil filter (5), pilot relief valve (6), front wheel
valve brakes (7), service brake control valve (8), rear wheel brakes (9),
(3) Service brake accumulator charging valve (10), brake and pilot pump (11) and electric
accumulator brake release pump (12) .
(4) Accumulator charge
relief valve There are four wheel brakes on the machine. Each wheel brake has
(5) Pilot oil filter two sections; a parking brake section and a service brake section. The
(6) Pilot relief valve parking brake is oil pressure released and spring applied. The service
(7) Front wheel brakes brake is oil pressure applied and spring released. The service brake
(8) Service brake control can be used when the brake is released.
valve
(9) Rear wheel brakes
(10) Accumulator charging
valve
(11) Brake and pilot pump
(12) Electric brake release
pump
Page 7
R2900 Brake Module
1
3
1. Hydraulic tank.
2. Hydraulic oil filters. 3. Brake and pilot pump.
6
4
5. Pilot relief valve.

4. Accumulator charging valve. 6. Pilot oil filter.
4
Location of Brake System Components
Hydraulic filters are mounted The hydraulic tank (1) is located on the right hand side of the machine.
inside the hydraulic tank The hydraulic oil filters (2) are mounted inside the hydraulic tank. There
is a bypass valve for the filter elements. Whenever the restriction
through the filters is too high, the bypass valve will open.
Brake and pilot pump is part
of a two section gear type The brake and pilot pump (3) is part of a two section pump, which is
pump mounted on the left hand rear of the torque converter updrive transfer
housing. The brake and pilot pump (3) supplies oil to the pilot steering
Accumulator charging valve system, brake system and pilot hydraulic system. The accumulator
divides oil flow with priority charging valve (4) is located on the left hand inside wall of the rear
given to the braking system frame. The valve divides the oil flow from the brake and pilot pump,
priority is given to the brake circuit.
Pilot relief valve controls the
pressure in the pilot system The pilot system relief valve (5) is mounted on the rear frame cross
beam. The pilot oil filter (6) is mounted behind the relief valve manifold.
Pilot oil filter is fitted with a The pilot relief valve controls the pressure in the pilot oil system. The
bypass valve pilot oil filter (6), filters the pilot oil and is fitted with a bypass valve which
will open whenever the resistance to the flow of oil through the filter is
too high.
Page 8
R2900 Brake Module
2 3
1
4
6
7
9
10
11
8
5
Accumulator Charging Valve (Accumulator Fully Charged - Cut-Out Cycle)
Accumulator charging valve With the engine running, oil from the brake pump goes into the
(accumulator fully charged - accumulator charging valve (ACV). If the brake accumulator does not
cut-out cycle) need oil, the ACV directs all oil from the brake pump to the pilot circuit.
(1) Pilot valve spool When the brake accumulator needs oil, the ACV divides the pump flow.
(2) Upper limit check ball The ACV will direct a percentage of pump oil to the accumulator. The
(3) Pilot valve spring remainder of the pump oil will flow to the pilot circuit.
(4) Lower limit check ball
(5) Check valve When the oil pressure in the accumulator reaches the cut out pressure
(6) Orifice of the accumulator charging valve, the accumulator is fully charged
(7) Passage with oil.
(8) Chamber
(9) Charging valve spool Oil from the brake and pilot pump enters the ACV. This oil passes
(10) Spring through a drilled passage in valve spool (9) to chamber (8). Pressure
(11) Spool stop will increase in chamber (8) and move valve spool (9) to the right. The
valve spool (9) is now held against spool stop (11) and pump oil will flow
Accumulator charging valve to the pilot circuit.
in CUT-OUT cycle:
Accumulator does not need Oil pressure in the accumulator moves check valve (4) to the right
oil; the ACV directs all pump against pilot valve spool (1). Oil pressure in the accumulator is retained
oil to the pilot circuit by check balls (4) and (5).
Page 9
R2900 Brake Module
3
2
1
4
6
7
9
10 11
8
6
Accumulator Charging Valve (Accumulator Being Charged - Cut-In Cycle)
Accumulator charging valve Brake application will cause the oil pressure in the accumulator to
(accumulator being charged - decrease. When the pressure decreases to the cut-in pressure, pilot
cut-in cycle) valve spring (3) will unseat check ball (4). At the same time, check ball
(1) Pilot valve spool (2) seats. Pilot valve spool (1) allows only one of these check balls to be
(2) Upper limit check ball seated at a time.
(3) Pilot valve spring
(4) Lower limit check ball When check ball (4) is unseated, pressure from the accumulator flows
(5) Check valve through passage (7). The oil enters the chamber behind valve spool (9).
(6) Orifice The spring (10) and the accumulator oil pressure balance the pump
(7) Passage pressure in chamber (8) acting on the opposite end of valve spool (9).
(8) Chamber This means that the pump pressure is always higher than the
(9) Charging valve spool accumulator pressure. Pump pressure flows through orifice (6), past
(10) Spring check valve (5), and out to the accumulator.
(11) Spool stop
When the accumulator is fully charged, the oil pressure in the
Accumulator needs oil; the accumulator will seat check ball (4). The pilot valve spool (1) will unseat
ACV divides pump flow to check ball (2) and allow pressure in the chamber behind valve spool (9)
accumulator and pilot circuit to return to tank. Valve spool (9) will now move to the right and direct
brake charge pump oil to the pilot circuit.
Accumulator will charge until
CUT-OUT pressure is reached
Page 10
R2900 Brake Module
1
1. Parking brake control valve. 2. Accumulator charge relief valve.
3 3
4
3. Brake control pedals. 4. Service brake accumulator.
7
Location of Brake System Components
Parking brake control valve The parking brake control valve (1) is located on the left hand inside wall
solenoids are energised to of the rear frame.
release the parking brake
When the parking brake control knob (in operators station) is moved to
Accumulator charge relief the released position, the solenoids of the parking brake control valve
valve protects the service are energised. Oil flows to the parking brake sections of the wheel
brake system if the brakes. Oil pressure then releases the parking brake.
accumulator charging valve
fails The accumulator charge relief valve (2) is mounted on the left hand
inside wall of the rear frame. The relief valve protects the service brake
system if the accumulator charging valve fails.
Brake pedals regulate the
pressure at the wheel brakes The brake control pedals (3) regulate the pressure at the brakes. As
the position of the pedal changes, the pressure at the brakes also
changes.
Service brake accumulator
supplies oil at a constant The service brake accumulator (4) is mounted on the inside left hand
pressure to the service wall of the rear frame. The accumulator stores hydraulic oil under
brakes pressure and supplies oil at a constant pressure range to the service
brake system.
Continued
Page 11
R2900 Brake Module
Service brake control valve The brake pedal is connected to the service brake control valve. The
modulates the pressure to the service brake control valve is supplied with oil from the service brake
wheel brakes, depending on accumulator. The service brake control valve will modulate this pressure
position of the pedals depending on the position of the pedals.
Left pedal applies the brakes N OTE

OTE::
first then neutralises the The brake and transmission neutraliser control pedal (left side pedal)
transmission applies the brake first then neutralises the transmission.
Page 12
R2900 Brake Module
2
1
Accumulator
Oil Pressure
Tank Oil
Regulated Oil
Pressure 3
TO WHEEL
BRAKES
FROM
4 ACCUMULATOR
ACCUMULATOR
TO WHEEL
TANK BRAKES
FROM
ACCUMULATOR
ACCUMULATOR
Service Brake Control Valve (Released Position)
Service Brake Control Valve: The service brake control valve is a dual pressure reducing valve with
(1) Service brake control two independent output pressures. The valve is directly below the
valve service brake pedal.
(2) Springs
(3) Return port The service brake control valve modulates pressurised oil from the
(4) Spool accumulator to the service brake section of the wheel brakes. The
(5) Spool position of the brake pedal causes a specific pressure at the brakes.
(6) Spring As the position of the pedal changes, the pressure at the service
brakes also change.
The service brake control
valve modulates (regulates) If one braking circuit fails, the second braking circuit remains functional
the pressure to the service due to the mechanical contact between the two spools (4) and (5).
brake
With the engine running, oil flows from the service brake accumulator
The further the pedal is to service brake control valve (1) through two inlet ports. When the
depressed, the greater the operator pushes on the brake pedal, springs (2) cause spools (4) and
pressure at the service brake (5) to overcome the force of spring (6) and move down.
Continued
Page 13
R2900 Brake Module
When the control spools When spool (4) moves down, oil from the accumulator port flows past
move down, accumulator the spool to the front brake port. The oil flows into the oil line to the
pressure oil flows to the front service brakes and applies the front brakes.
wheel brakes
Spool (4) is on top of spool (5) and as spool (4) moves down it causes
The service brake control spool (5) to also move down. As spool (5) moves down, oil from the
valve reduces (modulates) accumulator port flows past the spool to the rear brake port. The oil
the oil pressure to the wheel flows into the oil line to the rear service brakes and applies the rear
brakes brakes.
Internal metering passages reduce oil pressure to each axle. The

service brake control valve meters oil to the rear brakes at a higher
pressure than the front brakes.
When the operator releases the brake pedal, spring (6) forces spools
(4) and (5) up. Now the oil flowing from the accumulators is blocked at
the spool.
When the spools move up, the return ports are open. The oil in the
service brake ports can now flow into the return ports. Oil in the front
and rear brake oil lines is now vented back to the hydraulic tank.
Page 14
R2900 Brake Module
Pressure Oil 2
Nitrogen Gas 1
4
3
Service Brake Accumulator
Service Brake Accumulator The service brake accumulator supplies oil under pressure to the
(1) Accumulator service brake control valve. There is a nitrogen charge in the
(2) Nitrogen charging valve accumulator.
(3) Piston
(4) Nitrogen gas chamber The accumulator has a sealed piston (3) that moves up and down
(5) Pressure oil chamber inside the bore of the accumulator. The chamber (4) above the piston
(6) Oil pressure outlet has a charge of dry nitrogen gas. The charge of dry nitrogen gas is put
into the accumulator through valve (2).
The accumulator supplies
oil under pressure to the Oil from the pump and accumulator charging valve comes through port
service brakes (6) into chamber (5). When the pressure in the accumulator reaches
the cut-out pressure of the accumulator charging valve, the supply of
The gas chamber above the oil to the accumulator is stopped by the accumulator charging valve.
piston has a charge of dry
nitrogen gas
Pump oil pushes the piston
up and causes
compression of the dry
nitrogen gas
Page 15
R2900 Brake Module
1 2 3
Parking Brake 5
Oil Pressure 4
9
7 8 10
Wheel Brake (Parking Brake Released)
Wheel Brake (parking brake The outer casing (3) is bolted to the axle housing which does not turn.
released) There are splines on the inside of the outer casing (3). Splines on the
(1) Parking piston circumference of the steel plates (7) fit in the splines of the outer casing
(2) Service piston (3). This keeps the steel plates (7) stationary.
(3) Outer casing
(4) Springs The wheel hub (outer housing of the final drive) (5) has splines on its
(5) Wheel hub outer circumference. These splines fit into the splines on the inside of
(6) Annular passage friction discs (8). Both wheel hub (5) and friction discs (8) turn together.
(7) Steel plates
(8) Friction discs When the parking brake is released, oil flows through a port in the end
(9) Brake pack plate to annular passage (6). The oil pressure moves parking piston (1)
to the left, compressing springs (4), until the piston contacts the end
When the parking brake is plate. This relieves the pressure from the brake pack. Friction discs (8)
released, oil pressure and wheel hub (5) are free to rotate.
moves the parking piston
to the left away from the When the parking brake is engaged, the oil in the annular passage (6) is
brake pack dumped to tank. When the oil pressure drops, the parking piston is
moved to the right by springs (4) until it contacts service piston (2) and
When the parking brake is forces it into contact with brake pack (9). This holds the rotating discs
applied, springs move the to the stationary plates and locks wheel hub (5) to the axle housing.
parking piston to the right
against the brake pack Page 16
R2900 Brake Module
1 2 3
Parking Brake
Oil Pressure
Service
Brake Oil
Pressure
5
9
6 7 8 11
Wheel Brake (Parking Brake Released - Service Brake Applied)
Wheel Brake When the service brake pedal is depressed, oil under pressure flows
(1) Parking piston through a port in the end plate into annular passage (6). The pressure
(2) Service piston of the oil moves service piston (2) to the right against the brake pack (9).
(3) Outer casing Springs (4) are tensioned by pull rods (5) as the service piston moves.
(4) Springs
(5) Pull rods This causes friction between the steel plates (7), which are held
(6) Annular passage stationary by outer casing (3), and friction discs (8) which turn with the
(7) Steel plates rotation of the wheels. This friction causes the wheels to turn slower or
(8) Friction discs stop. The amount of brake application depends on the position of the
(9) Brake pack brake pedal.
When the service brake is Grooves cut in the faces of the friction discs (8) allow cooling oil to flow
applied, the service piston between the plates and discs. The cooling oil will constantly flow
moves to the right against the between the plates and discs in either the service brake applied or
brake pack released positions.
Cooling oil will constantly

flow between the brake pack
in both the brake applied and
brake released position
Page 17
R2900 Brake Module
FRONT WHEEL
BRAKES
SERVICE BRAKE
CONTROL VALVE
REAR WHEEL
BRAKES
SERVICE BRAKE
ACCUMULATOR
PARKING BRAKE
PILOT ACCUMULATOR CONTROL VALVE
RELIEF CHARGING VALVE
VALVE
TO PILOT
SYSTEM
ACCUMULATOR
CHARGE RELIEF
VALVE
STEERING BRAKE AND

PUMP PILOT PUMP
TANK
12
System Operation (Parking Brake Engaged)
Braking system shown with This schematic shows the braking system with the engine running, the
engine running, parking brake parking brake engaged and the service brake released.
applied and service brakes
released Oil from the brake and pilot pump flows to the accumulator charging
valve and the pilot relief valve. The accumulator charging valve keeps
The brake and pilot pump the pressure in the service brake accumulator within a constant range.
supplies oil to the The pilot relief valve controls the pilot oil pressure to the parking brake
accumulator charging valve circuit. The brake and pilot pump also supplies oil to the hydraulic
and pilot system implement and steering pilot systems.
The accumulator charging The pump oil flows through the accumulator charging valve to the
valve keeps the pressure in service brake accumulator. A piston in the service brake accumulator
the service brake is held against the oil intake end by dry nitrogen gas. The service brake
accumulator within a accumulator stores hydraulic oil pressure for operation of the service
constant range brakes. When the service brake accumulator is fully charged, the
accumulator charging valve directs its pump oil flow to tank. Oil flow is
The service brake blocked by the service brake control valve.
accumulator stores oil
pressure for operation of the Continued
service brakes
Page 18
R2900 Brake Module
Two solenoid control valves The parking brake control valve consists of two solenoid control valves.
control the operation of the When the solenoids are de-energised, pump oil is blocked at the
parking brake control valves.
The parking brake section of the wheel brakes is open to tank through
the parking brake control valve. The parking brakes are applied by
spring pressure.
Page 19
R2900 Brake Module
FRONT WHEEL
BRAKES
SERVICE BRAKE
CONTROL VALVE
REAR WHEEL
BRAKES
SERVICE BRAKE
ACCUMULATOR
PARKING BRAKE
VALVE
TO PILOT
SYSTEM
ACCUMULATOR
CHARGE RELIEF
VALVE
STEERING BRAKE AND

PUMP PILOT PUMP
TANK
13
System Operation (Parking Brake Released)
Braking system shown with When the parking brake control in the cab is moved to the released
engine running, parking position, power is sent to energise the parking brake solenoid control
brake released and service valves.
brakes released
Oil from the brake and pilot pump flows through the pilot relief valve to
the parking brake control valve. The pilot relief valve controls the
The pilot relief valve maximum pressure in the parking brake circuit.
controls the oil pressure in
the parking brake circuit Oil flows to the parking brake section of the wheel brakes. The oil
pressure causes the parking brake piston to retract, releasing the
When the parking brake parking brake.
control is moved to the
released position, the
parking brake solenoid
control valves are
energised
Pressure oil is sent to the

parking brake section of
the wheel brakes
Page 20
R2900 Brake Module
,, ,,
FRONT WHEEL
BRAKES
SERVICE BRAKE
CONTROL VALVE
, ,
REAR WHEEL
BRAKES
SERVICE BRAKE
ACCUMULATOR
PARKING BRAKE
VALVE
TO PILOT
SYSTEM
ACCUMULATOR
CHARGE RELIEF
VALVE
STEERING BRAKE AND

PUMP PILOT PUMP
TANK
14
System Operation (Service Brakes Applied)
Braking system shown with Oil from the brake and pilot pump flows through the accumulator
engine running, parking brake charging valve to the service brake accumulator. The service brake
released and service brakes accumulator stores hydraulic oil pressure for the operation of the
applied service brakes. When the service brake accumulator is fully charged
with oil, the accumulator charging valve sends the pump oil flow to
The accumulator charging tank.
valve charges the service
brake accumulator with The service brake control valve is in the circuit from the service brake
pressure oil accumulator to the service brakes. When the brake pedal is pushed,
oil from the service brake accumulator goes to the service brake
When the brake pedal is section of the wheel brakes. The service brake control valve is a
depressed, pressure oil tandem type valve providing split system braking. In the event of a
moves the service brake failure in either the front or rear brake system, the other portion of the
piston to apply the brakes valve will continue to function.
The further the pedal is After the service brakes have been activated several times, the volume
depressed, the greater the of oil in the service brake accumulator is reduced. The piston in the
pressure at the wheel brakes service brake accumulator moves down towards the oil end until there
is a decrease in pressure. The accumulator charging valve cuts in
sending oil from the brake and pilot pump to the accumulator.
Page 21
R2900 Brake Module
1
2
3
2. Brake release sequence valve.
1. Brake release cylinder. 3. Shuttle valves.
4. Check valve. 5. Towing hook.

15
Towing Brake Release System
Towing brake release system The towing brake release system allows the operator to release the
components: parking brakes if the brakes are applied due to a machine fault. When
(1) Brake release cylinder the brakes are released, the machine can be towed to a service area.
(2) Towing brake release The system is activated by a towing hook (5) compressing the towing
sequence valve brake release piston in the machine towing bar.
(3) Shuttle valves
(4) Check valve
(5) Towing hook
The towing brake release system must only be activated by a
The towing brake release towing hook securely attached to the recovery machine. The
system allows release of the towing hook must be securely attached to the towing bar of the
parking brake in the event of inoperative machine prior to activating the release system. Failure
a machine fault to do so may result in the towed machine moving, causing serious
personal injury or death.
The towing brake release When the machine has been towed to a safe place, ensure that it is
system is activated when the parked on a level surface and that the wheels are blocked securely
towing brake release cylinder so the machine can not move prior to any service work being
piston is moved up performed on the machine.
Ensure the inoperative machine can not move before disconnecting
the towing hook.
Page 22
R2900 Brake Module
, ,
FRONT WHEEL BRAKES
, ,
SERVICE BRAKE
CONTROL VALVE
, ,
SERVICE BRAKE
ACCUMULATOR
REAR WHEEL BRAKES

PILOT PARKING BRAKE
RELIEF ACCUMULATOR CONTROL VALVE
VALVE CHARGING VALVE
TO PILOT
SYSTEM
,,
SHUTTLE
VALVE
,,
TOW BRAKE
RELEASE
CYLINDER
ACCUMULATOR
CHARGE RELIEF
VALVE
BRAKE RELEASE
SEQUENCE VALVE
STEERING BRAKE AND
EXTERNAL
FORCE
PUMP PILOT PUMP
TANK
16
System Operation (Towing Brake Release Activated)
The towing brake release The towing brake release system is an attachment of the parking brake
system is activated by the circuit.
towing brake release
cylinder piston When the towing brake release system is activated, the piston in the
towing brake release cylinder is compressed against spring pressure.
The piston moves up and covers the tank port. Movement of the piston
The piston creates oil now creates oil pressure which is directed, via a shuttle valve, to the
pressure as it moves up parking brake section of the wheel brakes to release the brakes.
and this pressure releases
the parking brake section When the towing brake release cylinder piston is released, the spring
of the wheel brakes moves the piston down. The oil pressure in the wheel brakes decreases
and the parking brakes apply.
When the towing brake
piston moves down, the During normal operation, when the operator releases the parking
parking brakes apply brake, the parking brake control valve sends oil pressure to the wheel
brakes. The oil pressure also activates the brake release sequence
valve. The sequence valve opens the towing brake release cylinder to
tank.
Continued
Page 23
R2900 Brake Module
Brake release sequence valve With the brake release sequence valve open to tank the towing brake
disables towing release release system is disabled during normal machine operation.
system during normal
machine operation The check valve replenishes oil in the brake release system when
required.
Check valve replenishes oil in
the brake system when When the towing brake release cylinder is in the deactivated position,
required the spring chamber is connected to the hydraulic tank port. This
prevents a pressure increase (hydraulic lock) behind the shuttle valves
Tank port prevents hydraulic so the parking brakes can be released.
lock between shuttles and
deactivated piston
Page 24
R2900 Brake Module
1 3
2
2. Accumulator charging valve pressure test point.

1. Pilot pressure test point. 3. Accumulator charge relief valve.
1
2
17
Brake Pressure Test Points
Identify components The pilot pressure test point (1) is located on the pilot oil filter. The test
(1) Pilot pressure test point point is used for checking the pilot pressure in the parking brake,
(2) Accumulator charging steering and implement hydraulic system.
valve pressure test point
(3) Accumulator charge relief The pressure point (2) located in the pressure manifold, below the
valve brake accumulator is for checking the CUT- IN, CUT- OUT pressures of
the accumulator charging valve.
The accumulator charge relief valve (3) can only be tested and set on a
test bench.
Testing & adjusting

procedures
Always follow the procedures in the Service Manual when testing and
adjusting the machine
Page 25
R2900 Brake Module
1 3
2
2. Service brake oil low pressure switch (CMS).
1. Parking brake control switch. 3. Service brake oil low pressure switch (B.A).
4 5
5
6
7
5. Solenoids.
6. Parking brake low oil pressure switch.
4. Parking brake relay. 7. Parking brake pressure switch (remotes).
18
Brake Electrical System
The parking brake is engaged The parking brake system is controlled by parking brake control switch
and released by the parking (1) in the cab. The standard parking brake control switch is a pull-to-
brake control switch apply type. When the switch is pulled out, the brakes will apply.
Certain mining regulations require machines to be equipped with a
When the service brake oil push-to-apply parking brake control switch. When the switch is pushed
pressure is in the operating in, the brakes are applied.
range, the parking brake can
be released When the service brake oil pressure is in the operating range, service
brake low oil pressure switches (2) and (3) will close. Switch (3) will
If service brake oil pressure provide an earth for parking brake relay (4). If the park brake control
falls below the operating switch is in the engaged position, the relay (4) will energise and latch.
range, the parking brake will
apply If the engine is started with parking brake control switch (1) in the
release position, the brakes will not release as the parking brake relay
will not be latched. The switch must be moved to the engaged position
to latch the relay.
When the parking brake control switch is moved to the release position,
power is supplied to park brake solenoid control valves (5) toContinued
release
Page 26
R2900 Brake Module
The Caterpillar Monitoring If service brake oil pressure falls below the operating range, switch (3)
System monitors the service will open. The parking brake relay will open and interrupt power to
brake oil pressure solenoids (5). The parking brake will apply.
If the service brake oil Service brake low oil pressure switch (2) is for the Caterpillar Monitoring
pressure falls below the System. When brake oil pressure falls below the normal operating
normal operating range, the range, the switch will open, causing a category three warning. The
Caterpillar Monitoring System Caterpillar Monitoring System alert indicator will come on, the fault light
will initiate a category 3 will flash and the fault alarm will sound.
warning
The parking brake low oil pressure switch (6) is an input of the electronic
The parking brake low oil transmission control. When the parking brake is engaged, the switch
pressure switch is an input of sends a signal to the transmission control. The control shifts the
the transmission electronic transmission to neutral. The transmission control also sends the
control - the signal tells the parking brake status to the Caterpillar Monitoring System over the data
control when the parking link. When the parking brake is engaged, the alert indicator for the
brake is engaged parking brake flashes on the Caterpillar Monitoring System. If the
operator selects FORWARD or REVERSE while the parking brake is
The transmission electronic engaged, the Caterpillar Monitoring System initiates a category 3
control sends the parking warning.
brake low oil pressure switch
signal to the Caterpillar Parking brake pressure switch (7) is part of the optional remote control
Monitoring System over the system.
Cat data link
Page 27
R2900 Brake Module
PARKING BRAKE
RELAY
87 30 B
C
A
PARKING BRAKE
CONTROL SWITCH
BRAKE CONTROL
10 A
+ 24v REMOTE CONTROL
10 A
10
1
2 REMOTE CONTROL
PARKING BRAKE SWITCH
SOLENOIDS
1 27
2 22
28
18
8 37
1
14 38
2
13
3
POWER SUPPLY FROM

SERVICE BRAKE LOW BRAKE CONTROL CIRCUIT BREAKER
OIL PRESSURE SWITCH
1 1
2 2 POWER SUPPLY FROM REMOTE
CONTROL CIRCUIT BREAKER
3 3
TRANSMISSION PRESSURE
GROUND CIRCUIT
SWITCH ABA
19
System Operation (Power Supply)
Key on engine not running This schematic shows the wires that have battery voltage with the key
switch in the on position, and the parking brake control switch in the
brake engaged position (engine off).
Power is then supplied from the brake control circuit breaker to the
Power is supplied from brake parking brake control switch. With the switch in the engaged position
control circuit breaker to power is available at the parking brake relay which cannot be energised
parking brake relay because with the engine off there is no system pressure. The service
brake low oil pressure switch and the ABA switch (Automatic Brake
Application) contacts are therefore open, interrupting the ground circuit
for the parking brake relay.
NOTE:
If the ABA transmission oil pressure switch (optional) is not fitted a loop
Loop wire fitted when wire is fitted to the three pin plug to complete the circuit to the brake
optional impending brake charge pressure switch (as shown).
application is not required
Power is supplied to terminal 30 on the parking brake relay through the
remote control switch (optional) from the remote control system circuit
Power supplied to terminal 30 breaker.
on brake relay from remote
control circuit breaker Page 28
R2900 Brake Module
PARKING
BRAKE RELAY
87 30 B
C
A
PARKING BRAKE
CONTROL SWITCH
BRAKE CONTROL
10 A
10 A
10
1
2 REMOTE CONTROL
SOLENOIDS
1 27
2 22
28
18
8 37
1
14 38
2
13
3
POWER SUPPLY FROM

OIL PRESSURE SWITCH
1 1
3 3
SWITCH ABA GROUND CIRCUIT
20
System Operation (Relay Latched and Parking Brake Engaged)
With engine running With the engine running the transmission oil pressure will rise. The
transmission and brake oil transmission pressure (ABA) switch (if fitted) will close.
pressure will increase
At the same time the brake oil pressure will increase. The service brake
With both switches closed low oil pressure switch will close. With both switches in the closed
the parking brake relay will position the parking brake relay circuit is completed to ground and the
latch parking brake relay will latch.
Page 29
R2900 Brake Module
PARKING BRAKE
RELAY
87 30 B
C
A
PARKING BRAKE
CONTROL SWITCH
BRAKE CONTROL
10 A
10 A
10
1
2 REMOTE CONTROL
SOLENOIDS
1 27
2 22
28
18
8 37
1
14 38
2
13
3
POWER SUPPLY TO ENERGISE

SERVICE BRAKE LOW PARK BRAKE SOLENOIDS
OIL PRESSURE SWITCH
1 1
3 3
GROUND CIRCUIT
SWITCH ABA
21
Parking brake relay is Power is supplied from the remote circuit breaker to latch the parking
latched by power from brake relay.
remote circuit breaker
Once the parking brake relay is latched and the parking brake switch is
Once relay is latched, moved to the released position, power is directed to parking brake
parking brake can be solenoids. The parking brake solenoids are energised and the parking
released brakes are released.
Page 30
R2900 Brake Module
1 2
1. Parking brake low oil pressure switch. 2. Impending brake application switch.
6
3
4
5
4. Parking brake low oil pressure alert indicator.
5. Service brake low oil pressure alert indicator.
6. Impending brake application alert indicator. 3. Service brake low oil pressure switch (C.M.S).
22
Parking Brake CMS Component Location
The display area of the CMS shows the operator the condition of the
CMS display area alerts the machine systems and alerts the operator to any abnormal machine
operator to any abnormal conditions that may exist.
machine conditions
In the CMS electrical brake system three switches and alert indicators
Brake system uses three are used.
switches and alert indicators a. Parking brake low oil pressure switch.
b. Service brake low oil pressure switch.
c. Impending brake application.
The parking brake pressure switch (1) is located below the brake
release control valve on the left hand inside wall of the rear frame.
The parking brake pressure switch via the electronic transmission

control module, activates the alert indicator (4) on the CMS panel when
Parking brake pressure the parking brake is engaged.
switch activates the parking
brake alert indicator on the When the parking brake is released the park brake pressure switch will
CMS dash when parking open. The parking brake light on the CMS panel will then go out.
brakes are applied. Continued
Page 31
R2900 Brake Module
Park/ing brake released, The parking brake pressure switch sends a signal to the transmission
switch will open and park control module. When the emergency /parking brake is applied, this
brake alert indicator will switch will close, causing the transmission to neutralise. When the
deactivate parking brake is released, the transmission will resume normal
operation.
The parking brake pressure
switch sends a signal to the The service brake low oil pressure switch (3) is located on the left hand
transmission control module. inside wall of the rear frame.
When the machine is started the brake system oil pressure increases.
When the pressure reaches the setting of switch (3) its contacts will
Service brake low oil close causing the low brake oil pressure light (5) on the CMS panel to
pressure switch. go out. The parking brake can now be released.
If the service brake oil pressure decreases to below the setting of

switch (3) its contacts will open and the service brake low oil pressure
light on the CMS panel will come on, warning the operator of low
service brake oil pressure.
Switch for impending brake The impending brake application switch (2) (optional) is located on
application light. (IBA) back of the hydraulic pilot filter housing above the torque converter.
If the transmission oil pressure falls below the setting of switch (2), the
impending brake application light (6) on the dash will illuminate warning
the operator of the abnormal condition.
Page 32
R2900 Brake Module
PARKING BRAKE LOW

OIL PRESSURE SWITCH
C
B
A
10 27 PARK BRAKE SWITCH N.C
11 36 PARKBRAKE SWITCH N.O
3 CAT DATA LINK -
1 9 CAT DATA LINK +
2 5 GROUND
3
ELECTRONIC TRANSMISSION
CONTROL
SERVICE BRAKE LOW OIL 1 23 CAT DATA LINK +
PRESSURE SWITCH CMS
2 24 CAT DATA LINK -
3 35 BRAKE OIL PRESSURE
1 1 4 33 IMPENDING BRAKE APP.
2 2 2 GROUND
3 3
COMPUTERISED MONITORING
SYSTEM
IBA CMS
SWITCH CAT DATA LINK CIRCUIT IMPENDING BRAKE
APPLICATION CIRCUIT
SERVICE BRAKE LOW OIL

PARKING BRAKE LOW OIL
PRESSURE SWITCH CMS
PRESSURE SWITCH CIRCUIT
CIRCUIT
23
System Operation CMS (Parking Brake Released)
Parking brake can not be The parking brake cannot be released until the brake and transmission
released until brake and oil pressure increases. This increase in pressure will cause the service
transmission have system brake low oil pressure switch and impending brake application (I.B.A.)
pressure switch (if fitted) to close, causing the alert indicators on the CMS dash
to go out.
When the parking brakes are released the parking brake low oil pressure
CAT Data Link allows the switch closes sending a signal to the electronic transmission control.
transmission control to This signal is then communicated to the CMS on the CAT control data
receive and send information link causing the parking brake light to go out.
to the computerised
monitoring system The CAT data link is bidirectional, allowing the transmission control to
receive and send information. The purpose of the data link is to enable
Loop wire fitted when the transmission control to communicate with the Computerised
optional impending brake Monitoring System (CMS). The data link is not a single visible
application is not fitted component as it consists of internal control circuits and connecting
wiring harness.
NOTE:
When the impending brake application is not fitted a loop wire is fitted
to complete the circuit to ground (as shown above).
Page 33
R2900 Brake Module
1 2
1. Stop light switch. 2. Stop light.
4
3. Rear brake pressure switch. 4. Residual brake pressure light.
24
Stop Light and Residual Brake Pressure Light Circuit Components
Identify components: The components of this circuit are; stop light switch (1), stop light (2),
(1) Stop light switch rear brake pressure switch (3) and residual brake pressure light (4).
(2) Stop light
(3) Residual brake pressure The stop light switch (1) is mounted in the front brake circuit at the
switch outlet of the brake control valve.
(4) Residual brake pressure
light If the machine is equipped with a residual brake pressure option a rear
brake pressure switch (3) is also fitted.
Operating the machine with
the residual pressure will When the service brakes are applied the stop light (2) will illuminate.
cause overheating of the
brakes and may severely NOTE:
shorten the service life of Operating the machine with residual pressure will cause overheating of
brake components the brakes and may severely shorten the service life of brake
components.
Page 34
R2900 Brake Module
STOP/TAIL
LAMP
CAB
T
+24V 9 S
15A
FRONT BRAKE
PRESSURE SWITCH
3
1
2
1
2 3
1 TO FRONT
2 LIGHT SWITCH
POWER SUPPLY
REAR BRAKE
PRESSURE SWITCH RESIDUAL BRAKE
PRESSURE LIGHT STOP LIGHT CIRCUIT
25
System Operation (Stop Light/Residual Brake Pressure Circuit)
When the service brakes are When the service brakes are applied oil pressure will close the brake
applied will close the brake pressure switches and completes the circuit to the stop/tail lamp
pressure switches and Power will now be supplied to illuminate the stop light.
completes the circuit to the If the machine is equipped with a residual brake pressure circuit a rear
stop/tail light brake pressure switch is also fitted (as shown).
Machine equipped with a When the service brake is applied the brake oil pressure rises above
residual brake pressure the setting of residual brake pressure switches. The switches will close
circuit are fitted with a rear completing the circuit to the residual brake pressure light. Power will
brake pressure switch and now be supplied to illuminate residual brake pressure light.
light
If the residual brake oil pressure remains in the wheel brakes above the
setting of the switches after the brakes have been released, the light
will remain illuminated. Also the rear brake light will illuminate.
Page 35
R2900 Brake Module
2
1. Brake release pump. 2. Brake release pump solenoid.
3
4
3. Brake release pump switch. 4. Park brake control switch.

26
Electric Brake Release System
Brake Release Circuit The electric brake release circuit allows the operator to release the
Components: parking brake if the brake is applied due to a machine fault. When the
(1) Brake release pump brakes are released, the machine can be towed to a service area.
(2) Brake release pump
relay The electric brake release circuit is controlled by a switch located on
(3) Brake release switch the circuit breaker board in the operators station.
(4) Park brake control
switch The electric brake release circuit uses an electric hydraulic pump to
supply oil to the parking brake circuit and the service brake circuit.
The brake release circuit
allows the operator to release When the brake system is fully charged, the operator must use the
the parking brake parking brake control switch to release the brakes.
The pump is activated by a Because the service brake circuit is charged with oil, the service brake
switch located on the circuit can be used to stop the machine during towing, etc.
breaker board.
An electric hydraulic pump

charges the parking brake
circuit and service brake
circuit
Page 36
R2900 Brake Module
BRAKE RELEASE
SWITCH BRAKE RELEASE
RELAY
+24V 6
15A
BRAKE
CONTROL MOTOR
BRAKE RELEASE
S G MOTOR
FUSE
BAT MTR
675A
MOTOR
POS NEG POS NEG
12 VOLT
BATTERIES
DISCONNECT
SWITCH
BRAKE RELEASE MOTOR CIRCUIT RELAY POWER SUPPLY
27
System Operation (Electric Brake Release)
Explain operation The above electrical schematic shows the brake release pump
activated.
When the brake release toggle switch is held in the on position, power
from the brake control circuit breaker energises the brake release relay.
Then power is supplied from the 675 amp fuse to activate the brake
release pumps electrical motor.
Page 37
R2900 Brake Module
1. Electrical faults. 1. Bleed down oil pressure.

28
Practical Tasks
Bleed down oil pressure in Task 1

1: Each trainee will be required to successfully bleed down the oil
the brake system pressure in the brake system.
1. Find the procedure in Service Manual.
2. Follow the procedure and successfully complete the task.
Electrical Faults. Task 22: Trainer to place a series of electrical faults on the machine.
1. Place a faulty parking brake relay in the circuit.
2. Remove wire EL332-BR from parking brake control switch.
Each trainee will be required to successfully
1. Fault find the electrical faults, using the electrical schematic
and service manual.
2. Rectify the faults, test and start machine.
Service manual. Always check the Service Manual for the correct adjusting procedure
and specifications.
Always follow the procedures contained in the Service Manual when
testing and/or adjusting the machine.
Page 38
R2900 Brake Module
R2900 LHD Braking System

Theory Assessment
Directions: Multiple Choice.

Read each statement carefully and circle the letter(s) of the correct answer(s)
* Reference to notes and other literature is allowed.
Q.1. Each wheel brake has:

A. One section
B. Two sections
C. Four sections
D. Nine sections
Q.2. The parking brake is:

A. Oil applied and spring released
B. Oil applied and released
C. Oil released and spring applied
D. Pedal controlled
Q.3. The brake and pilot pump is a:

A. Centrifugal pump
B. Piston pump
C. Vane pump
D. Gear pump
Q.4. The accumulator charging valve divides the oil flow between the:
A. Pilot and transmission systems
B. Brake and pilot systems
C. Brake and hydraulic systems
D. Pilot and oil cooling systems
Q.5. The accumulator charge rrelief

elief valve limits maximum oil pr essur
pressur
essuree in the :
A. Pilot system
B. Parking brake system
C. Accumulator charging circuit
D. Main hydraulic circuit
Continued
Page 39
R2900 Brake Module
Q.6. The service brake accumulator supplies oil under pr essur

pressur
essuree to:
A. The parking brake control valve
B. The service brake control valve
C. The accumulator charging valve
D. The pilot relief valve
Q.7. The service brake contr ol valve is operated by a:

control
A. Lever
B. Switch
C. Pedal
D. Solenoid
Q.8. The service brakes ar e:

are:
A. Electronically applied
B. Spring applied and oil released
C. Oil applied and released
D. Oil applied and spring released
Q.9. The accumulator charging valve gives priority oil flow to:
A. The brake system
B. The brake and pilot systems
C. The hydraulic system
D. The transmission control valve
Q.10. The service brake accumulator is charged with:

A. Compressed air
B. Oxygen
C. Hydrogen
D. Dry nitrogen
Page 40
R2900 Brake Module
R2900 Braking System

Theory Assessment Answers
Q.1. B.
Q.2. C.
Q.3. D.
Q.4. B.
Q.5. C.
Q.6. B.
Q.7. C.
Q.8. D.
Q.9. A.
Q.10. D.
Page 41
R2900 Brake Module
R2900 LHD Brake Electrical System

Theory Assessment
Directions: Multiple Choice.

Read each statement carefully and circle the letter(s) of the correct answer(s)
* Reference to notes and other literature is allowed.
Q.1. The parking brake is controlled by:

controlled
A. A switch on the pilot control valve
B. A switch on the main dash panel
C. A switch on the circuit breaker board
D. The transmission electronic control module
Q.2. When the parking brake switch is moved to the engaged position:
A. The front wheel brakes release
B. The rear parking brakes release
C. The service brakes apply
D. All the wheel brakes are activated
Q.3. The brake oil pr essur

pressur
essuree switches ar
aree located on:
A. The inside left wall of the rear frame
B. The inside right wall of the rear frame
C. The radiator guard
D. The right wall of the front frame
Q.4. The parking brake rrelay

elay is located:
A. Behind the pilot control valve
B. Under the STIC steer control valve
C. Behind the CMS dash
D. Under the operators seat
Q.5. The parking brake rrelay

elay contr ols the:
controls
A. Service brake application
B. Release of the parking brake
C. Release of the service brakes
D. Transmission gear selection
Continued
Page 42
R2900 Brake Module
Q.6. The parking brake solenoids ar

aree mounted on the:
A. Main implement control valve
B. Brake system relief valve
C. Transmission hydraulic controls
D. Hydraulic brake release control valve
Q.7. When rremote

emote contr ol is fitted to the machine:
control
A. Two extra solenoid control valves are fitted
B. One extra solenoid control valve is fitted
C. Three extra solenoid control valves are fitted
D. Five extra solenoid control valves are fitted
Q.8. When the transmission oil pr essur

pressur
essuree rises the:
A. Parking brake switch will open
B. ABA switch (if fitted) will open
C. ABA switch (if fitted) will close
D. Parking brake switch will close
Q.9. When the service brake oil pr essur

pressur
essuree incr eases to working pr
increases essur
pressur e:
essure:
A. The brake charge pressure switch will close
B. The parking brake relay will unlatch
C. The brake charge pressure switch will open
D. The service brakes will apply
Q.10. The electric brake rrelease

Q.10.The elease pump is activated by:
A. The remote controls
B. The parking brake switch
C. A toggle switch mounted on the dash
D. A toggle switch mounted on the circuit breaker board
Page 43
R2900 Brake Module
R2900 Brake Electrical System

Theory Assessment Answers
Q.1. B.
Q.2. D.
Q.3. A.
Q.4. C.
Q.5. B.
Q.6. D.
Q.7. B.
Q.8. C.
Q.9. A.
Q.10. D.
Page 44
R2900 Brake Module
,,,
,,,
3
?
Servicemans Handout No. 1

Braking System Component Location
(1) Brake and pilot pump

(2) Accumulator charging valve
(3) Pilot oil filter
(4) Pilot relief valve
(5) Brake system relief valve
(6) Accumulator
(7) Service brake control valve
(8) Wheel brakes
(9) Parking brake release solenoid
(10) Hydraulic tank
(11) Electric pump
Page 45
R2900 Brake Module
2 3
1
4
6
7
10
11
8
5

Accumulator Charging Valve (Component Location)
(1) Spring
(2) Check valve
(3) Spool stop
(4) Pilot valve spool
(5) Pilot valve spring
(6) Chamber
(7) Charging valve spool
(8) Orifice
(9) Upper limit check ball
(10) Lower limit check ball
(11) Passage
Page 46
R2900 Brake Module
Park Brake
Oil Pressure
10
Wheel Brake (Parking Brake Released)

Servicemans Handout No.3
(1) Parking piston

(2) Service piston
(3) Outer casing
(4) Springs
(5) Wheel hub
(6) Annular passage
(7) Steel plates
(8) Friction discs
(9) Brake pack
Page 47
R2900 Brake Module
FRONT WHEEL
BRAKES
SERVICE BRAKE
CONTROL VALVE
REAR WHEEL
BRAKES
SERVICE BRAKE
ACCUMULATOR
PARKING BRAKE
VALVE
TO PILOT
SYSTEM
ACCUMULATOR
CHARGE RELIEF
VALVE
STEERING BRAKE AND

PUMP PILOT PUMP
TANK
12

System Operation (Parkimg Brake Engaged)
(1) Pressure oil

(2) Pilot oil
(3) Tank oil
Page 48
R2900 Brake Module
FRONT WHEEL
BRAKES
SERVICE BRAKE
CONTROL VALVE
REAR WHEEL
BRAKES
SERVICE BRAKE
ACCUMULATOR
PARKING BRAKE
VALVE
TO PILOT
SYSTEM
ACCUMULATOR
CHARGE RELIEF
VALVE
STEERING BRAKE AND

PUMP PILOT PUMP
TANK
13

(1) Pressure oil

(2) Pilot oil
(3) Tank oil
Page 49
R2900 Brake Module
FRONT WHEEL
BRAKES
SERVICE BRAKE
CONTROL VALVE
REAR WHEEL
BRAKES
SERVICE BRAKE
ACCUMULATOR
PARKING BRAKE
VALVE
TO PILOT
SYSTEM
ACCUMULATOR
CHARGE RELIEF
VALVE
STEERING BRAKE AND

PUMP PILOT PUMP
TANK
14

System Operation (Service Brakes Applied)
(1) Pressure oil

(2) Pilot oil
(3) Tank oil
Page 50
R2900 Brake Module
FRONT WHEEL BRAKES
SERVICE BRAKE
CONTROL VALVE
SERVICE BRAKE
ACCUMULATOR
REAR WHEEL BRAKES

PILOT PARKING BRAKE
RELIEF ACCUMULATOR CONTROL VALVE
VALVE CHARGING VALVE
TO PILOT
SYSTEM
SHUTTLE
VALVE
TOW BRAKE
RELEASE
CYLINDER
ACCUMULATOR
CHARGE RELIEF
VALVE
BRAKE RELEASE
SEQUENCE VALVE
STEERING BRAKE AND
EXTERNAL
FORCE
PUMP PILOT PUMP
TANK
16

System Operation (Towing Brake Release Activated)
(1) Pressure oil

(2) Pilot oil
(3) Tank oil
Page 51
R2900 Brake Module
PARKING BRAKE
RELAY
87 30 B
C
A
PARKING BRAKE
CONTROL SWITCH
BRAKE CONTROL
10 A
REMOTE
+ 24v CONTROL
10 A
1
10
1
2 REMOTE CONTROL
PARK BRAKE SWITCH
SOLENOIDS
1 27
2 22
28
18
8 37
1
14 38
2
13
3
POWER SUPPLY FROM

0IL PRESSURE SWITCH
1 1
2 2 POWER SUPPLY FROM
REMOTE CONTROL CIRCUIT BREAKER
3 3
19
Servicemans Handout No 9
System Operation (Power Supply)
Page 52
R2900 Brake Module
PARKING BRAKE
RELAY
87 30 B
C
A
PARKING BRAKE
CONTROL SWITCH
BRAKE CONTROL
10 A
REMOTE
+ 24v CONTROL
10 A
1
10
1
2 REMOTE CONTROL
PARK BRAKE SWITCH
SOLENOIDS
1 27
2 22
28
18
8 37
1
14 38
2
13
3
POWER SUPPLY FROM

0IL PRESSURE SWITCH
1 1
2 2 POWER SUPPLY FROM
REMOTE CONTROL CIRCUIT BREAKER
3 3
20

System Operation (Relay Latched and Parking Brake Engaged)
Page 53
R2900 Brake Module
PARKING BRAKE
PRESSURE SWITCH
C
B
A
10 27 PARK BRAKE SWITCH N.C
11 36 PARKBRAKE SWITCH N.O
3 CAT DATA LINK -
1 9 CAT DATA LINK +
2 5 GROUND
3
ELECTRONIC TRANSMISSION
CONTROL
SERVICE BRAKE LOW OIL 1 23 CAT DATA LINK +
PRESSURE SWITCH CMS
2 24 CAT DATA LINK -
3 35 BRAKE OIL PRESSURE
1 1 4 33 IMPENDING BRAKE APP.
2 2 2 GROUND
3 3
COMPUTERISED MONITORING
SYSTEM
IBA CMS
IMPENDING BRAKE
SWITCH CAT DATA LINK CIRCUIT
APP, CIRCUIT
SERVICE BRAKE LOW OIL

PARKING BRAKE LOW OIL
PRESSURE SWITCH CMS
PRESSURE SWITCH CIRCUIT
CIRCUIT
21

System Operation CMS (Parking Brake Released)
Page 54
R2900 Brake Module
STOP/TAIL
LAMP
CAB
T
+24V 9 S
15A
FRONT BRAKE
PRESSURE SWITCH
3
1
2
1
2 3
TO FRONT
1 LIGHT SWITCH
2
POWER SUPPLY
REAR BRAKE
PRESSURE SWITCH RESIDUAL BRAKE
PRESSURE LIGHT STOP LIGHT CIRCUIT
25

System Operation (Stop Light and Residual Brake Circuit)
Page 55
R2900 Brake Module
BRAKE RELEASE
SWITCH BRAKE RELEASE
RELAY
+24V 6
15A
BRAKE
CONTROL MOTOR
BRAKE RELEASE
S G MOTOR
FUSE
BAT MTR
675A
MOTOR
POS NEG POS NEG
12 VOLT
BATTERIES
DISCONNECT
SWITCH
BRAKE RELEASE MOTOR CIRCUIT RELAY POWER SUPPLY
27

System Operation (Electric Brake Release)
Page 56

Braking R2900 PDF

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USE TOOLBAR CONTROLS

CATERPILLAR ELPHINSTONE PTY. LTD.

IMPORTANT SAFETY NOTICE

R2900 Braking System Overview

This presentation discusses the system operation and adjusting

Graphical symbols and sectional view drawings will be used when

Braking System Block Schematic

Braking System Component Location

5. Pilot relief valve.

Location of Brake System Components

Accumulator Charging Valve (Accumulator Fully Charged - Cut-Out Cycle)

Accumulator Charging Valve (Accumulator Being Charged - Cut-In Cycle)

Location of Brake System Components

Left pedal applies the brakes N OTE

Service Brake Control Valve (Released Position)

Internal metering passages reduce oil pressure to each axle. The

Service Brake Accumulator

Wheel Brake (Parking Brake Released)

Wheel Brake (Parking Brake Released - Service Brake Applied)

Cooling oil will constantly

STEERING BRAKE AND

System Operation (Parking Brake Engaged)

STEERING BRAKE AND

System Operation (Parking Brake Released)

Pressure oil is sent to the

STEERING BRAKE AND

System Operation (Service Brakes Applied)

4. Check valve. 5. Towing hook.

Towing Brake Release System

REAR WHEEL BRAKES

STEERING BRAKE AND

System Operation (Towing Brake Release Activated)

2. Accumulator charging valve pressure test point.

Brake Pressure Test Points

Testing & adjusting

Brake Electrical System

+ 24v REMOTE CONTROL

POWER SUPPLY FROM

System Operation (Power Supply)

+ 24v REMOTE CONTROL

POWER SUPPLY FROM

System Operation (Relay Latched and Parking Brake Engaged)

+ 24v REMOTE CONTROL

POWER SUPPLY TO ENERGISE

System Operation (Parking Brake Released)

Parking Brake CMS Component Location

The parking brake pressure switch via the electronic transmission

If the service brake oil pressure decreases to below the setting of

PARKING BRAKE LOW

SERVICE BRAKE LOW OIL

System Operation CMS (Parking Brake Released)

1. Stop light switch. 2. Stop light.

Stop Light and Residual Brake Pressure Light Circuit Components

System Operation (Stop Light/Residual Brake Pressure Circuit)

3. Brake release pump switch. 4. Park brake control switch.

Electric Brake Release System

An electric hydraulic pump

BRAKE RELEASE MOTOR CIRCUIT RELAY POWER SUPPLY

System Operation (Electric Brake Release)

1. Electrical faults. 1. Bleed down oil pressure.

Bleed down oil pressure in Task 1

R2900 LHD Braking System