BRAKES

21 C Series Wheel Loaders

21C Series Wheel Loaders

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CASE CORPORATION

700 STATE STREET RACINE, WI 53404 U.S.A.

CASE CANADA CORPORATION

2002 Case Corporation All Rights Reserved

450 SHERMAN AVENUE HAMILTON, ON L8N 4C4 CANADA

Printed in U.S.A.

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Table of Contents
NOTES......................................................................................................................6 BRAKE CIRCUIT FROM PUMP TO TREADLE VALVE..........................................7 BRAKE CIRCUIT TO AXLES...................................................................................8 PARKING BRAKE ...................................................................................................9 PRESSURE TEST POINTS FOR THE ACCUMULATORS AND PILOT CONTROL...............................................................................................................10 BRAKE CIRCUIT....................................................................................................11
ALL "C" SERIES........................................................................................................................ 11 General description ............................................................................................................... 11 Circuit Description ................................................................................................................ 11

BRAKE PUMP........................................................................................................12
ALL "C" SERIES........................................................................................................................ 12 Brake pump description ........................................................................................................ 12

DUAL ACCUMULATOR CHARGING VALVE ASSEMBLY..................................14

ALL "C" SERIES........................................................................................................................ 14 General description ............................................................................................................... 14 Circuit description ................................................................................................................. 14 Description of the Relief Valve.............................................................................................. 14 Description of Cut In and Cut out Spool Function.................................................................14 Cut-in spool............................................................................................................................ 14

DUAL ACCUMULATOR CHARGING VALVE ASSEMBLY..................................15

Cut-out spool......................................................................................................................... 15 Description of the Filter, Orifice and Check Valve.................................................................15 Description of Accumulator Isolation Poppet.........................................................................15

DUAL ACCUMULATOR CHARGING VALVE ASSEMBLY..................................15

Description of the Accumulator Charging Pressure Switch...................................................16

NOTES....................................................................................................................19 HYDRAULIC MULIT-FUNCTION VALVE..............................................................20 (COMBINATION VALVE).......................................................................................20

ALL "C" SERIES........................................................................................................................ 20 General Description............................................................................................................... 20 Operation Description............................................................................................................ 20 Operation Description (Pressure Switches)...........................................................................20 Flow to the Accumulators and Pressure Switches.................................................................20

HYDRAULIC MULIT-FUNCTION VALVE..............................................................21 (COMBINATION VALVE).......................................................................................21

Operation Description (Parking Brake)..................................................................................21

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HYDRAULIC MULIT-FUNCTION VALVE..............................................................22 (COMBINATION VALVE).......................................................................................22
Flow to the Parking Brake Solenoid Valve............................................................................22 Parking Brake Description..................................................................................................... 22 Operation Description (Pressure Reducing Valve)................................................................22

HYDRAULIC MULIT-FUNCTION VALVE..............................................................23 (COMBINATION VALVE).......................................................................................23

Flow to the Pressure Reducing Valve....................................................................................23 Pressure Reducing Description..............................................................................................23 Auxiliary Hydraulics Description............................................................................................23 Operation Description (Pilot Lockout Solenoid) ....................................................................23

HYDRAULIC MULIT-FUNCTION VALVE..............................................................23 (COMBINATION VALVE).......................................................................................23

Flow to the Pilot Lockout Solenoid........................................................................................ 24 Pilot Lockout Solenoid Description........................................................................................ 24

PARKING BRAKE .................................................................................................32

GENERAL DESCRIPTION............................................................................................................. 32 TESTING THE PARK BRAKE........................................................................................................ 32

TOWING THE WHEEL LOADER...........................................................................33 TROUBLESHOOTING THE PARKING BRAKE....................................................34

PARK BRAKE INFORMATION CENTER OUTPUT CHECK...................................................................34 PARK BRAKE SWITCH CHECK..................................................................................................... 35 REDUNDANT BRAKE PRESSURE SWITCH CHECK..........................................................................36 SERVICE BRAKE FOOT SWITCH CHECK.......................................................................................37 REQUESTED GEAR CHECK......................................................................................................... 38 ACTUAL GEAR STATUS.............................................................................................................. 39

ACCUMULATORS.................................................................................................40
ALL "C" SERIES........................................................................................................................ 40 General description ............................................................................................................... 40 Circuit description ................................................................................................................. 40

BRAKE TREADLE VALVE.....................................................................................42

ALL "C" SERIES..................................................................................................................... 42 General Description .............................................................................................................. 42 Operation Description............................................................................................................ 42 Flow to the Brake Pedal......................................................................................................... 42

NOTES....................................................................................................................45 DISK BRAKE ASSEMBLIES..................................................................................46

621C, 721C, AND 821C............................................................................................................ 46 General Description............................................................................................................... 46 Operation Description............................................................................................................ 46

DISK BRAKE ASSEMBLIES..................................................................................47

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DISK BRAKE ASSEMBLIES..................................................................................48
921C....................................................................................................................................... 48 General Description............................................................................................................... 48 Operation Description............................................................................................................ 48

DISK BRAKE ASSEMBLIES..................................................................................49

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NOTES

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Brake Circuit from Pump to Treadle Valve

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Brake Circuit to Axles

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Parking Brake

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Pressure Test Points for the Accumulators and Pilot Control

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Brake Circuit
All "C" Series General description On all "C" Series Wheel Loaders, the brake pump provides hydraulic oil for the brakes, the pilot valve(s), and the optional ride control and/or coupler locking valve. The hydraulic oil is drawn through a suction hose from the tube that feeds the main pumps. Circuit Description The pump which is mounted to the auxiliary drive on the front cover on the left side of the engine, is operational whenever the engine is running. The hydraulic oil is drawn through a suction hose connected to the tube that feeds the main pump. It then flows through the main components of the brake circuit. The dual accumulator charging valve assembly controls the maximum pressure and unloads when the maximum pressure is obtained. As the stand-by oil is used up, the low-pressure side of the dual accumulator charging valve assembly will cut back in and replenish the system pressure. The accumulators are used to provide a surplus of oil under pressure. The accumulators will provide oil for the brakes and pilot valve(s) when the pump is unloaded and dumping oil to the sump or if the engine is dead. The Hydraulic Mulit-function valve controls the flow of oil to the parking brake and the pilot valve(s) while at the same time controlling the pressure to the pilot valve(s). The brake pedal valve regulates the flow of oil to the brake piston in the axle ends. The brakes used on the "C" SERIES are internal wet disk brakes that are located inside the axle.

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Brake Pump
All "C" Series Brake pump description The brake pump is a Commercial Intertech gear pump. The pump delivers 7.6 GPM (28.8 LPM) at a rated engine speed of 2200 RPM. The pump rotates in a counter-clockwise direction as seen from the shaft end. Because the pump is a positive displacement pump, the flow output varies with the engine speed. The pump is operational whenever the engine is running, and is either charging the accumulators or returning flow to the reservoir. The performance of the pump can be determined by installing a flow meter between the outlet of the pump and the hydraulic reservoir. The flow rate with and without pressure can then be determined.

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621C 721C

821C921C Brake Pump

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Dual Accumulator Charging Valve Assembly
All "C" Series General description The Dual Accumulator Charging Valve Assembly is mounted on the right side plate of the rear chassis. It is designed to control the oil pressure from the brake pump and to maintain a supply of oil for the accumulators, brakes, and pilot valve circuits. Circuit description The oil from the brake pump enters Dual Accumulator Charging Valve Assembly. It passes the pressure relief valve; then through the valve cut-in spool, the filter, the orifice, the check valve, the cut-out spool, and the accumulator isolation poppet spool. Upon leaving the Dual Accumulator Charging Valve Assembly, the oil flows to the Hydraulic Mulit-function Valve . Description of the Relief Valve A relief valve at the inlet of the Dual Accumulator Charging Valve Assembly protects the system from excessive pressures. In the event something fails in the brake circuit and the pressure builds to 3000 PSI (20684 kPa), the relief valve will shift and divert all output from the brake pump through the return port. This oil flows through the two 10-micron filters and back to the reservoir. Description of Cut In and Cut out Spool Function Cut-in spool The oil from the brake pump flows through the cut-in spool. It also provides pilot pressure to the cut-in spool on the side opposite of the spring. The oil that flows through the cut-in spool also flows through the cut-out spool and provides pilot pressure on the spring side of the cut-in spool. This equalizes the pressure on the cut-in spool so the spring pressure will hold the spool in a shifted position; therefore, allowing the oil to pass through the spool. When the pilot pressure on the spring side is allowed to return to the reservoir, because of the cut-out spool shifting, the cut-in spool will shift and allow the brake pump flow to return to the reservoir.

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Dual Accumulator Charging Valve Assembly (Cont.)
Cut-out spool The oil from the brake pump flows through the cut-in spool and provides pilot pressure on the end of the cut-out spool opposite the spring. When this pressure reaches 2800 PSI, the spool will shift and allow the pilot pressure on the spring side of the cut-in spool to return to the reservoir. While both the cut-in and cut-out spools are shifted. The oil is allowed to flow through the cut-in spool, but it is blocked from flowing through the cut-out spool. The oil is also blocked from going to the accumulators by the check valve; there is 2800 PSI of pressure holding the check valve closed. The cut-out spool remains shifted until the pilot pressure is reduced to approximately 2000 PSI (13790 kPa); this will occur by applying the brakes or through system leakage. When the pressure falls to 2000 PSI (13790 kPa), the spring shifts the cut-out spool and allows oil to flow through to again, providing pilot pressure on the spring side of the cut-in spool. This equalizes the pressure on the cut-in spool, allowing the spring to shift the spool; therefore, preventing the oil from passing through the return port. Description of the Filter, Orifice and Check Valve Between the cut-in spool and the cut-out spool, the oil passes through the 54micron filter, the orifice, and the check valve. The 54-micron filter protects the braking circuit from impurities contained in the oil. The orifice slows the oil and reduces the shock pressure on the accumulator when they are refilled. The check valve blocks oil from the accumulators from flowing back through the cut-in spool, after it shifts, and returning to the reservoir. Description of Accumulator Isolation Poppet The poppet has pilot pressure and a centering spring on one end, and pilot pressure only on the other end. An accumulator provides the spring end pilot pressure. Pilot pressure on the opposite end, is provided by the brake pump. The poppet does not completely block off the passageway nor does it completely open the passageway. Their purpose is to isolate one brake circuit if the other fails. When both brake circuits are working, the poppet will be centered in the passageway and allow oil to flow between the accumulators. As the pressure in an accumulator falls it reduces the pilot pressure in that solenoid, this will cause the

Dual Accumulator Charging Valve Assembly (Cont.)

poppet to be moved by the pump pressure, open the passageway, and allow more oil to the low accumulator. If one brake circuit would fail the pressure and spring

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on the opposite circuit would shift the poppet and act as a check valve; keeping pressure in the working circuit. Description of the Accumulator Charging Pressure Switch The accumulator charging pressure switch is set at 1700 PSI (11721 kPa). If the accumulator charging pressure drops down to this point, the Stop Master Indicator (Red) illuminates and the alarm sounds continuously, indicating a brake system problem. This condition will be written into diagnostic memory if the engine is running at 700 RPM or above for 15 seconds

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Dual Accumulator Charging Valve Assembly

1. 2000 psi Cut-in Spool 2. Outlets to accumulators 3. Check Valve Assembly 4. Bronze Filter 5. 1700 psi Pressure switch Port

6. Brake Pump Inlet 7. Accumulator Isolation Poppet Spool 8. 3000 psi Relief Valve 9. 2800 psi Cut-out Spool 10. Brake Pressure Adjustment

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1. 2000 psi Cut-in Spool 2. Outlets to accumulators 3. Check Valve Assembly 4. Bronze Filter 5. 1700 psi Pressure switch Port

6. Brake Pump Inlet 7. Accumulator Isolation Poppet Spool 8. 3000 psi Relief Valve 9. 2800 psi Cut-out Spool 10. Brake Pressure Adjustment

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NOTES

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Hydraulic Mulit-function Valve (Combination Valve)
All "C" Series General Description This valve is mounted on the right rear frame near the articulation joint. It controls the Parking Brake, the Pilot Valve Lock Out, and the pressure for the Pilot Valves. At the same time, it provides a passage for filling the brake accumulators and monitoring the pressure to warn the operator if there is a failure in the brake system. Operation Description Because this is a dual braking system, the oil going to the Front Brakes flows directly from the Dual Accumulator Charging Valve Assembly into one each of the Brake Accumulators, the Redundant Brake Pressure Switches then the Brake Treadle Valve. Oil going to the Rear Brakes flows directly to the other Brake Accumulator, the Redundant Brake Pressure Switch, and then the Brake Treadle Valve. Oil for the Rear Brakes also supplies oil for the Parking Brake, and after passing through the Pilot Pressure Reduction Valve, supplies oil to the Pilot Valves and the options Ride Control and/or Coupler Locking Valve. Operation Description (Pressure Switches) The Brake Pressure Switch for the front and rear brakes is set for 900 PSI (6205 kPa). If both of the accumulators drop below this pressure, a severe brake malfunction has occurred. The Transmission ECM (Electronic Control Module) will disconnect the transmission from the engine, and the drive train will be neutralized. At this point, the Parking Brake will be applied, and the Parking Brake Lamp on the Instrument Cluster will illuminate. Flow to the Accumulators and Pressure Switches Oil flows from the Dual Accumulator Charging Valve Assembly into the Hydraulic Mulit-function Valve through port FB for the front brake circuit and RB for the rear brake circuit. Port FB (front brake) is connected directly to ports ACF for the accumulator and PS1F for the pressure switch. Hydraulic tubing connects the accumulator to port ACF. The Redundant Brake Pressure Switch is threaded directly into the PS1F port.

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Hydraulic Mulit-function Valve (Combination Valve) (Cont.)
Port RB (rear brake) is connected directly to ports ACR for the accumulator and PS1R for the pressure switch. Hydraulic tubing connects the accumulator to port ACR. The Redundant Brake Pressure Switch is threaded directly into the PS1R port. Port RB is also connected internally to the other valves and through them to the other outlet ports. Operation Description (Parking Brake) The parking brake is spring applied and hydraulically released. When the machine is turned off, the parking brake is automatically applied. When the machine is started, the parking brake stays on, and the parking brake lamp on the Instrument Cluster will illuminate. The operator must press the service brake pedals and put the machine in gear before the parking brake will release. If the operator puts the machine in gear before pressing the service brake pedals, the Caution Master Indicator (Yellow) will flash and the alarm will sound for three (3) seconds. If the machine loses electrical power, the parking brake activates automatically. If the machine loses hydraulic pressure, the parking brake will not apply because the internal check valve will keep the parking brake canister pressurized until the solenoid valve is shifted.

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Hydraulic Mulit-function Valve (Combination Valve) (Cont.)
Flow to the Parking Brake Solenoid Valve Oil flows into port RB, past the internal Check Valve (cartridge type), to the Parking Brake Solenoid Valve.

Parking Brake Description The Parking Brake circuit consists of two Solenoid Valves, both are two way, two position cartridge valves. One contains a check valve, which controls the disengagement of the parking brake, and the second one controls the flow direction during engagement and disengagement. These screw-in hydraulic cartridge valves are installed in the PB port of the valve block body. When the electrical current is removed, the solenoid's magnetic field collapses, and the spring on the opposite side shifts the valve. When the valve shifts, the oil trapped in the parking brake canister flows to reservoir, and the spring then sets the parking brake. When the electrical current is applied, the solenoid's magnetic field energizes, and the solenoid overcomes the spring pressure and shifts the valve. When the valve shifts, the oil flows through the valve and out of port PB (parking brake) into the brake canister, depressing the spring and releasing the parking brake. Operation Description (Pressure Reducing Valve) The Pressure Reducing Valve controls the pressure for the auxiliary hydraulic options and the Pilot Valves. The valve senses circuit pressure, and when it reaches 550 PSI, the valve shifts and blocks the flow until it senses the pressure has dropped. The spring shifts the spool, allowing flow to the auxiliary and pilot hydraulics. In the cavity beneath the pressure reducing valve there is a flowlimiting orifice disc with a .063 diameter drilled pilot opening. This opening provides a minimum pressure drop between the Pressure Reducing Valve and the hydraulic down stream. This difference in pressure allows the pilot valve to operate without jerking.

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Hydraulic Mulit-function Valve (Combination Valve) (Cont.)
Flow to the Pressure Reducing Valve Oil flows into port RB and flows through the Pressure Reducing Valve as long as the pressure in the circuit is less than 550 PSI. Pressure Reducing Description This valve is a spool-type direct acting, hydraulic Pressure Reducing Valve with an internal spring chamber drain. It is a pressure-regulating device for secondary circuits. This valve is installed in port PR of the valve block body Auxiliary Hydraulics Description The auxiliary port (AUX) in the valve block body is blocked unless auxiliary hydraulics are installed (ride control, coupler locking). If installed, they will have their own control valves added between the pressure reducing valve and the option. Operation Description (Pilot Lockout Solenoid) The Pilot Lockout Switch is located on the top left-hand side of the Front Console. Press the left side of the toggle switch disables the Pilot Controls. The Pilot Control Lamp, which is located on the left side of the Instrument Panel, will illuminate. When activated, the Pilot Lockout Switch disconnects the electrical current to the Pilot Lockout Solenoid Valve. The magnetic field in the coil collapses and the spring on the opposite side of the valve shifts the spool blocking all oil flow to the Pilot Valves. When the Pilot Valves are disabled, the loader linkage is locked in the position they were in when the switched was pressed. Pressing the right side of the toggle switch enables the Pilot Controls. The Pilot Control Lamp, which is located on the left side of the Instrument Panel, will not illuminate. When the Pilot Lockout Switch is activated, it connects the electrical current to the Pilot Lockout Solenoid Valve. The magnetic field in the coil energizes and over

Hydraulic Mulit-function Valve (Combination Valve) (Cont.) 21C Series Wheel Loaders
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comes the spring on the opposite side of the valve. The spool shifts, allowing the oil to flow to the Pilot Valves. When the Pilot Valves are enabled, the loader linkage will operate when the control levers are moved. Flow to the Pilot Lockout Solenoid Oil flows in port RB, through the Pressure Reducing Valve and orifice disc, to the blocked port on the Pilot Lockout Valve. Pilot Lockout Solenoid Description This is a solenoid-operated, normally closed, two-way, direct-acting spool valve. This valve is installed in port SV1 of the valve block body.

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Parking Brake
General Description The park brake is activated as soon as the electrical current is turned off. To release the park brake the operator must; start the machine, step on the service brake, and shift into either forward or reverse. Testing the Park Brake The operator can test the park brake by using the diagnostics built into the information center. The transmission must be in 3 rd gear manual mode to perform the test. If the transmission is left in any other gear during the test the transmission will be disconnected from the engine. To perform the test use the following procedure: 1. Start the machine. 2. Make sure the transmission selector switch is in 3 rd neutral, the automatic switch is in the manual position, and the park brake switch is on. 3. Select the display field number 011 using the programming entry procedure listed previously. 4. Press the up count switch once so the display reads 1. 5. Shift the transmission selector into 3 rd forward and slowly increase the engine RPM's. The park brake should hold the machine at full throttle. 6. Shift the transmission selector into 3 rd reverse and slowly increase the engine RPM's. The park brake should hold the machine at full throttle. 7. Reduce the engine RPMs and shift the machine into neutral. 8. Press the reset switch to exit the test mode. 9. Turn off the machine. If the park brake does not hold the machine at full throttle refer to the brakes section of the service manual for troubleshooting procedures.

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Towing the Wheel Loader
If you must tow the Wheel Loader, read the following recommendations and use caution. NEVER Tow the Wheel Loader from the Front. If the Wheel Loader cannot be started to release the parking brake, do the following: 1. Put blocks in front of and behind each tire. 2. Remove the Parking brake cap (6). 3. Loosen the lock nut (9). 4. Turn the adjusting screw COUNTERCLOCKWISE until the parking brake is released (10). If the Wheel Loader is to be towed more than 1/2 mile (0.8 km) you must disconnect the front and rear drive shafts.

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Troubleshooting The Parking Brake
If the park brake does not release, perform the following checks. Park Brake Information Center Output Check This check will check the wiring from the information center to the park brake relay to make sure that it is functioning properly. This same check will also check to see that the park brake indicator light is functioning. 1. Start the machine. 2. Press the Program/Reset switch to the program position, advance to display field number 019, the park brake light will flash intermittently. 3. Press the Program/Reset switch back to the center position. You should see a 01 in the display if the information center is not activating the park brake relay and the park brake is in the on position. 4. Turn the park brake switch in the cab to the off position, place or foot on the service brake and shift the FNR lever to either forward or reverse. You should see the display read 00 when the park brake releases. 5. Place the FNR lever back in neutral, place the park brake switch in the on position. 6. Press the Program/Reset switch to the Reset position to exit the monitoring mode. 7. Turn the key switch to the off position.

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Park Brake Switch Check This check will check operation of the park brake switch to make sure that it is functioning properly. This same check will also check to see that the park brake indicator light is functioning. This check does not check the wiring from the information center to the park brake pressure switch. 1. Turn the key switch to the on position, do not start the machine. 2. Press the Program/Reset switch to the program position, advance to display field number 043, the park brake light will flash intermittently. 3. Press the Program/Reset switch back to the center position. You should see a 01 in the display if the park brake switch is in the on position . 4. Toggle the park brake switch to the off position. You should see the display read 00 when the park brake releases . 5. Press the Program/Reset switch to the Reset position to exit the monitoring mode. 6. Turn the key switch to the off position.

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Redundant Brake Pressure Switch Check This check will check operation of the redundant brake pressure switch (900 psi) and the wiring from the switch to information center to make sure that it is functioning properly. This same check will also check to see that the park brake indicator light is functioning. This check does not check the wiring from the information center to the park brake switch located in the cab. 1. Start the machine. 2. Press the Program/Reset switch to the program position, advance to display field number 044, the park brake light will flash intermittently. 3. Press the Program/Reset switch back to the center position. You should see a 00 in the display if the brake pressure is in the normal operating range. The display will show 01 if the brake pressure is out of the normal operating range. 4. Press the Program/Reset switch to the Reset position to exit the monitoring mode. 5. Turn the key switch to the off position.

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Service Brake Foot Switch Check This test will check operation of the service brake foot switch to make sure that it is functioning properly. This same check will also check to see that the park brake indicator light is functioning. 1. Turn the key switch to the on position, do not start the machine. 2. Press the Program/Reset switch to the program position, advance to display field number 045, the park brake light will flash intermittently. 3. Press the Program/Reset switch back to the center position. You should see a 00 in the display if the service brake pedals are not activated. 4. Step on the service brake pedal. You should see a 01 in the display when the switch is activated. 5. Press the Program/Reset switch to the Reset position to exit the monitoring mode. 6. Turn the key switch to the off position.

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Requested Gear Check This test is designed to test the FNR/Shifting lever to see that it is functioning normally. It tests to see that the information center is reading the same gear that the lever is requesting. 1. Turn the key switch to the on position, do not start the machine. 2. Press the Program/Reset switch to the program position, advance to display field number 028 3. Press the Program/Reset switch back to the center position. You should see the appropriate code in the table below for the requested gear. The display should also flash the appropriate direction selected and gear number in the transmission display window. 4. Cycle through all gears in all directions (FNR) using the shifter lever and make sure the appropriate code is shown on the display for each gear requested. The correct codes are listed in the table below. Forward 1 - Code 101 Forward 2- Code 102 Forward 3- Code 103 Forward 4- Code 104 Neutral Neutral Neutral Neutral 1 Code 200 2 Code 200 3 Code 200 4 Code 200 Reverse 1 Code 301 Reverse 2 Code 302 Reverse 3 Code 303

1. Press the Program/Reset switch to the Reset position to exit the monitoring mode. 2. Turn the key switch to the off position.

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Actual Gear Status This test will check to determine that the actual gear the transmission is in, is the same as the gear that the information center is reading. It does not test the readings that the information center is receiving from the FNR/Shifter lever. To perform this test the operator must have the transmission in the manual mode, the declutch and park brake switch off, and apply the service brake. 1. Start the machine. 2. Press the Program/Reset switch to the program position, advance to display field number 030 using the programming entry procedure listed previously. 3. Press the Program/Reset switch back to the center position. You should see the appropriate code in the table below for the requested gear the transmission is in. The display should also flash the appropriate direction selected and gear number in the transmission display window. 4. Cycle through all gears in all directions (FNR) using the shifter lever and make sure the appropriate code is shown on the display for each gear requested. The correct codes are listed in the table below. Forward 1 - Code 101 Forward 2- Code 102 Forward 3- Code 103 Forward 4- Code 104 Limp Home Mode 115 Neutral 1 Code 200 Neutral 2 Code 200 Neutral 3 Code 200 Neutral 4 Code 200 Limp Home Mode 215 Reverse 1 Code 301 Reverse 2 Code 302 Reverse 3 Code 303 Limp Home Mode - 315

5. Press the Program/Reset switch to the Reset position to exit the monitoring mode. 6. Stop the machine, place it in neutral and apply the park brake. 7. Turn the key switch to the off position.

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Accumulators
All "C" Series General description Two accumulators are used in the brake system. One serves the front axle brakes; the other is used for the rear axle brakes. The accumulators on the brake system hold the pressure required to operate the brakes. In addition, they hold reserve pressure to operate the brakes and pilot control valve(s) in the event the brake system or the engine has a malfunction.

Circuit description The accumulators are charged to 800 PSI (5516 kPa) with nitrogen. When hydraulic oil is applied to the opposite side of the accumulator piston at pressures in excess of 800 PSI (5516 kPa), the accumulator piston moves, compressing the nitrogen while accumulating a supply of oil. The Dual Accumulator Charging Valve Assembly charges the accumulators to 2800 PSI (19305 kPa) when the machine is started or when the accumulator pressures are reduced because of brake usage or system leakage. When the brakes are applied, hydraulic pressure in the accumulator is and, the volume of oil in the accumulator is also reduced. As the pressure nears 2000 PSI (13790 kPa), the accumulators are resupplied with Brake Pump flow from the Dual Accumulator Charging Valve Assembly. If the front brakes malfunction in the dual brake system, the rear brakes will still be operational. Conversely, if the rear brakes malfunction, the front brakes will still be operational.

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Brake Treadle Valve
ALL "C" SERIES General Description The Brake Treadle Valve consists of two pressure regulating valves that control the flow of oil from the accumulators to the brake actuators. Each valve assembly controls the brakes on one axle, yet a single pedal actuates both, resulting in the application of all four brakes from the single pedal. Operation Description The Brake Treadle Valve is actuated as the operator depresses the pedal. The harder the operator depresses the pedal, the more the brake treadle valve moves. The further the Brake Treadle Valve moves, the higher the brake pressure is at the wheel. As the pressure in the brake actuators begins build, it is sensed between and beneath the spools in the valve. This creates an increase in pedal effort that provides pedal "feel." The left brake pedal contains the Brake Treadle Valve and electrical switches for the brake lamp and the transmission declutch. The right brake pedal is a tagalong. The two brake pedals are attached with a cross shaft. This solid connection allows the operator to depress either pedal to operate the brakes. It also allows the operator to declutch the transmission with either pedal after activating the declutch switch. Flow to the Brake Pedal The oil flows from the Dual Accumulator Valve Assembly to the Brake Treadle Valve. The accumulators are attached to this circuit also and provide oil pressure as needed when the brakes are applied.

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NOTES

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BRAKES
Disk Brake Assemblies
621C, 721C, and 821C General Description The 621C, 721C, and 821C use a ZF limited slip axle. This axle was adopted as upgrade to the wet disc brakes on the "B" Series. The ZF axle model numbers are as follows: 621C Rear 407 Front 407 721C Rear 407 Front 409 821C Rear 409 Front 411

Each of the four brake assemblies is mounted in the planetary assembly. The brake pressure can be checked at the quick disconnect fitting. The quick disconnect fittings are located on the right side of the unit near the pivot connection of the front and rear chassis. There is one fitting for the front brake and one fitting for the rear brake. Operation Description Hydraulic oil, under pressure from the Brake Treadle Valve, is applied to the piston, forcing it to move. The movement of the piston compresses the friction and metal brake disks together, creating the braking force needed by the machine. Return springs force the piston to retract, which returns the oil from behind the piston to the tank and provides clearance between the friction and metal disks. Disassembly of the brake requires the removal of the planetary cover assembly first. Special tools are required for the removal and reassembly of the brakes.

46

21C Series Wheel Loaders

rev. 02

BRAKES
Disk Brake Assemblies
621C, 721C, and 821C

47

21C Series Wheel Loaders

rev. 02

BRAKES
Disk Brake Assemblies
921C General Description The 921C are the only 21C Series machine using the GKN limited slip axles. This same axle has been used since the machines introduction. Each of the four brake assemblies is mounted in the planetary assembly. The brake pressure can be checked at the quick disconnect fitting. The quick disconnect fittings are located on the right side of the unit near the pivot connection of the front and rear chassis. There is one fitting for the front brake and one fitting for the rear brake. Operation Description Hydraulic oil, under pressure from the Brake Treadle Valve, is applied to the piston, forcing it to move. The movement of the piston compresses the friction and metal brake disks together creating the braking force needed by the machine. Return springs force the piston to retract, returns the oil from behind the piston to the tank, and allows clearance between the friction and metal disks. Disassembly of the brake first requires the removal of the planetary cover assembly. Special tools are required for the removal and reassembly of the brakes.

48

21C Series Wheel Loaders

rev. 02

BRAKES
Disk Brake Assemblies
921C

49

21C Series Wheel Loaders

rev. 02