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
Introduction:
This presentation discusses the system operation and adjusting

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

procedures:
NOTE: Always follow the procedures in the Service Manual when

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
VALVE
FILTER
SERVICE BRAKE
ACCUMULATOR
SERVICE
BRAKE
CONTROL
VALVE
ACCUMULATOR
CHARGING
VALVE
BRAKE AND
PILOT PUMP
ACCUMULATOR
CHARGE RELIEF
VALVE
TANK
Braking System Block Schematic

Block Schematic
- Parking brake system
- Service brake system
Other Brake System Features:
- Towing brake release system
The pump draws oil (green)
from the tank and sends flow
(red) to the various control
valves
The parking brake is spring
engaged and hydraulically
released
The service brake is
hydraulically applied
This block schematic of the R2900 LHD braking system shows the
components and oil flow. There are two brake control systems on the
machine: the parking brake system and the service brake system. An
optional feature of the brake system is the towing brake release
system.
The brake and pilot pump oil (red) flows to the accumulator charging
valve. The valve divides the oil flow of the brake and pilot pump, priority
is given to the service brake circuit. When the parking brake control
valve is activated, pump oil is directed into the parking brake section of
the wheel brakes to release the brakes.
Brake and pilot pump oil flows through the accumulator charging valve
to the service brake accumulator. When the service brake control valve
is activated, accumulator oil goes to the service brake section of the
wheel brakes. The wheel brakes are dual-piston, outboard, wet-disc
brakes located in the wheel ends. Each wheel brake has a parking
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
10
11
12
Braking System Component Location

Identify components
(1) Hydraulic tank
(2) Parking brake control
valve
(3) Service brake
accumulator
(4) Accumulator charge
relief valve
(5) Pilot oil filter
(6) Pilot relief valve
(7) Front wheel brakes
(8) Service brake control
valve
(9) Rear wheel brakes
(10) Accumulator charging
valve
(11) Brake and pilot pump
(12) Electric brake release
pump
The hydraulic brake system consists of: hydraulic tank (1), parking
brake control valve (2), service brake accumulator (3), accumulator
charge relief valve (4), pilot oil filter (5), pilot relief valve (6), front wheel
brakes (7), service brake control valve (8), rear wheel brakes (9),
accumulator charging valve (10), brake and pilot pump (11) and electric
brake release pump (12) .
There are four wheel brakes on the machine. Each wheel brake has
two sections; a parking brake section and a service brake section. The
parking brake is oil pressure released and spring applied. The service
brake is oil pressure applied and spring released. The service brake
can be used when the brake is released.
Page 7

R2900 Brake Module
2
1
3
1. Hydraulic tank.
2. Hydraulic oil filters.
3. Brake and pilot pump.
5
6
4
4. Accumulator charging valve.
5. Pilot relief valve.

6. Pilot oil filter.
4
Location of Brake System Components

Hydraulic filters are mounted
inside the hydraulic tank
Brake and pilot pump is part

of a two section gear type
pump
Accumulator charging valve
divides oil flow with priority
given to the braking system
Pilot relief valve controls the
pressure in the pilot system
Pilot oil filter is fitted with a
bypass valve
The hydraulic tank (1) is located on the right hand side of the machine.
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.
The brake and pilot pump (3) is part of a two section pump, which is
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
system, brake system and pilot hydraulic system. The accumulator
charging valve (4) is located on the left hand inside wall of the rear
frame. The valve divides the oil flow from the brake and pilot pump,
priority is given to the brake circuit.
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.
The pilot relief valve controls the pressure in the pilot oil system. The
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
1
4
5
6
7
9
10
8
11
5
Accumulator Charging Valve (Accumulator Fully Charged - Cut-Out Cycle)

(accumulator fully charged cut-out cycle)
(1) Pilot valve spool
(2) Upper limit check ball
(3) Pilot valve spring
(4) Lower limit check ball
(5) Check valve
(6) Orifice
(7) Passage
(8) Chamber
(9) Charging valve spool
(10) Spring
(11) Spool stop
in CUT-OUT cycle:
Accumulator does not need
oil; the ACV directs all pump
oil to the pilot circuit
With the engine running, oil from the brake pump goes into the
accumulator charging valve (ACV). If the brake accumulator does not
need oil, the ACV directs all oil from the brake pump to the pilot circuit.
When the brake accumulator needs oil, the ACV divides the pump flow.
The ACV will direct a percentage of pump oil to the accumulator. The
remainder of the pump oil will flow to the pilot circuit.
When the oil pressure in the accumulator reaches the cut out pressure
of the accumulator charging valve, the accumulator is fully charged
with oil.
Oil from the brake and pilot pump enters the ACV. This oil passes
through a drilled passage in valve spool (9) to chamber (8). Pressure
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
to the pilot circuit.
Oil pressure in the accumulator moves check valve (4) to the right
against pilot valve spool (1). Oil pressure in the accumulator is retained
by check balls (4) and (5).
Page 9

R2900 Brake Module
3
2
4
5
6
7
9
10
11
8
6
Accumulator Charging Valve (Accumulator Being Charged - Cut-In Cycle)

(accumulator being charged cut-in cycle)
(1) Pilot valve spool
(2) Upper limit check ball
(3) Pilot valve spring
(4) Lower limit check ball
(5) Check valve
(6) Orifice
(7) Passage
(8) Chamber
(9) Charging valve spool
(10) Spring
(11) Spool stop
Accumulator needs oil; the
ACV divides pump flow to
accumulator and pilot circuit
Accumulator will charge until
CUT-OUT pressure is reached
Brake application will cause the oil pressure in the accumulator to

decrease. When the pressure decreases to the cut-in pressure, pilot
valve spring (3) will unseat check ball (4). At the same time, check ball
(2) seats. Pilot valve spool (1) allows only one of these check balls to be
seated at a time.
When check ball (4) is unseated, pressure from the accumulator flows
through passage (7). The oil enters the chamber behind valve spool (9).
The spring (10) and the accumulator oil pressure balance the pump
pressure in chamber (8) acting on the opposite end of valve spool (9).
This means that the pump pressure is always higher than the
accumulator pressure. Pump pressure flows through orifice (6), past
check valve (5), and out to the accumulator.
When the accumulator is fully charged, the oil pressure in the
accumulator will seat check ball (4). The pilot valve spool (1) will unseat
check ball (2) and allow pressure in the chamber behind valve spool (9)
to return to tank. Valve spool (9) will now move to the right and direct
brake charge pump oil to the pilot circuit.
Page 10

R2900 Brake Module
1
1. Parking brake control valve.
2. Accumulator charge relief valve.
3
3. Brake control pedals.
4
4. Service brake accumulator.
7
Location of Brake System Components

Parking brake control valve
solenoids are energised to
release the parking brake
Accumulator charge relief
valve protects the service
brake system if the
accumulator charging valve
fails
Brake pedals regulate the

pressure at the wheel brakes
Service brake accumulator

supplies oil at a constant
pressure to the service
brakes
The parking brake control valve (1) is located on the left hand inside wall
of the rear frame.
When the parking brake control knob (in operators station) is moved to
the released position, the solenoids of the parking brake control valve
are energised. Oil flows to the parking brake sections of the wheel
brakes. Oil pressure then releases the parking brake.
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.
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.
The service brake accumulator (4) is mounted on the inside left hand
wall of the rear frame. The accumulator stores hydraulic oil under
pressure and supplies oil at a constant pressure range to the service
brake system.
Continued
Page 11

R2900 Brake Module
Service brake control valve

modulates the pressure to the
wheel brakes, depending on
position of the pedals
The brake pedal is connected to the service brake control valve. The
service brake control valve is supplied with oil from the service brake
accumulator. The service brake control valve will modulate this pressure
depending on the position of the pedals.
Left pedal applies the brakes

first then neutralises the
transmission
N OTE
OTE::
The brake and transmission neutraliser control pedal (left side pedal)
applies the brake first then neutralises the transmission.
Page 12

R2900 Brake Module
Accumulator
Oil Pressure
Tank Oil
Regulated Oil
Pressure
3
TO WHEEL
BRAKES
4
TANK
FROM
ACCUMULA
TOR
ACCUMULATOR
TO WHEEL
BRAKES
FROM
ACCUMULA
TOR
ACCUMULATOR
5
6
8
Service Brake Control Valve (Released Position)

Service Brake Control Valve:
(1) Service brake control
valve
(2) Springs
(3) Return port
(4) Spool
(5) Spool
(6) Spring
The service brake control
valve modulates (regulates)
the pressure to the service
brake
The further the pedal is
depressed, the greater the
pressure at the service brake
The service brake control valve is a dual pressure reducing valve with
two independent output pressures. The valve is directly below the
service brake pedal.
The service brake control valve modulates pressurised oil from the
accumulator to the service brake section of the wheel brakes. The
position of the brake pedal causes a specific pressure at the brakes.
As the position of the pedal changes, the pressure at the service
brakes also change.
If one braking circuit fails, the second braking circuit remains functional
due to the mechanical contact between the two spools (4) and (5).
With the engine running, oil flows from the service brake accumulator
to service brake control valve (1) through two inlet ports. When the
operator pushes on the brake pedal, springs (2) cause spools (4) and
(5) to overcome the force of spring (6) and move down.
Continued
Page 13

R2900 Brake Module
When the control spools

move down, accumulator
pressure oil flows to the
wheel brakes
The service brake control
valve reduces (modulates)
the oil pressure to the wheel
brakes
When spool (4) moves down, oil from the accumulator port flows past
the spool to the front brake port. The oil flows into the oil line to the
front service brakes and applies the front brakes.
Spool (4) is on top of spool (5) and as spool (4) moves down it causes
spool (5) to also move down. As spool (5) moves down, oil from the
accumulator port flows past the spool to the rear brake port. The oil
flows into the oil line to the rear service brakes and applies the rear
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
Nitrogen Gas
4
3
Service Brake Accumulator

Service Brake Accumulator
(1) Accumulator
(2) Nitrogen charging valve
(3) Piston
(4) Nitrogen gas chamber
(5) Pressure oil chamber
(6) Oil pressure outlet
The accumulator supplies

oil under pressure to the
service brakes
The gas chamber above the

piston has a charge of dry
nitrogen gas
Pump oil pushes the piston

up and causes
compression of the dry
nitrogen gas
The service brake accumulator supplies oil under pressure to the

service brake control valve. There is a nitrogen charge in the
accumulator.
The accumulator has a sealed piston (3) that moves up and down
inside the bore of the accumulator. The chamber (4) above the piston
has a charge of dry nitrogen gas. The charge of dry nitrogen gas is put
into the accumulator through valve (2).
Oil from the pump and accumulator charging valve comes through port
(6) into chamber (5). When the pressure in the accumulator reaches
the cut-out pressure of the accumulator charging valve, the supply of
oil to the accumulator is stopped by the accumulator charging valve.
Page 15

R2900 Brake Module
1
Parking Brake
Oil Pressure
5
4
6
9
7
10
Wheel Brake (Parking Brake Released)

Wheel Brake (parking brake
released)
(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
When the parking brake is

released, oil pressure
moves the parking piston
to the left away from the
brake pack
When the parking brake is
applied, springs move the
parking piston to the right
against the brake pack
The outer casing (3) is bolted to the axle housing which does not turn.
There are splines on the inside of the outer casing (3). Splines on the
circumference of the steel plates (7) fit in the splines of the outer casing
(3). This keeps the steel plates (7) stationary.
The wheel hub (outer housing of the final drive) (5) has splines on its
outer circumference. These splines fit into the splines on the inside of
friction discs (8). Both wheel hub (5) and friction discs (8) turn together.
When the parking brake is released, oil flows through a port in the end
plate to annular passage (6). The oil pressure moves parking piston (1)
to the left, compressing springs (4), until the piston contacts the end
plate. This relieves the pressure from the brake pack. Friction discs (8)
and wheel hub (5) are free to rotate.
When the parking brake is engaged, the oil in the annular passage (6) is
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
forces it into contact with brake pack (9). This holds the rotating discs
to the stationary plates and locks wheel hub (5) to the axle housing.
Page 16

R2900 Brake Module
Parking Brake
Oil Pressure
Service
Brake Oil
Pressure
5
9
6
11
Wheel Brake (Parking Brake Released - Service Brake Applied)

Wheel Brake
(1) Parking piston
(2) Service piston
(3) Outer casing
(4) Springs
(5) Pull rods
(6) Annular passage
(7) Steel plates
(8) Friction discs
(9) Brake pack
When the service brake pedal is depressed, oil under pressure flows
through a port in the end plate into annular passage (6). The pressure
of the oil moves service piston (2) to the right against the brake pack (9).
Springs (4) are tensioned by pull rods (5) as the service piston moves.
When the service brake is

applied, the service piston
moves to the right against the
brake pack
Grooves cut in the faces of the friction discs (8) allow cooling oil to flow
between the plates and discs. The cooling oil will constantly flow
between the plates and discs in either the service brake applied or
released positions.
This causes friction between the steel plates (7), which are held
stationary by outer casing (3), and friction discs (8) which turn with the
rotation of the wheels. This friction causes the wheels to turn slower or
stop. The amount of brake application depends on the position of the
brake pedal.
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
CONTROL VALVE
ACCUMULATOR
CHARGING VALVE
TO PILOT
SYSTEM
PILOT
RELIEF
VALVE
ACCUMULATOR
CHARGE RELIEF
VALVE
STEERING
PUMP
BRAKE AND
PILOT PUMP
TANK
12
System Operation (Parking Brake Engaged)

Braking system shown with
engine running, parking brake
applied and service brakes
released
The brake and pilot pump
supplies oil to the
accumulator charging valve
and pilot system
The accumulator charging
valve keeps the pressure in
the service brake
accumulator within a
constant range
The service brake
accumulator stores oil
pressure for operation of the
service brakes
This schematic shows the braking system with the engine running, the
parking brake engaged and the service brake 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 pressure in the service brake accumulator within a constant range.
The pilot relief valve controls the pilot oil pressure to the parking brake
circuit. The brake and pilot pump also supplies oil to the hydraulic
implement and steering pilot systems.
The pump oil flows through the accumulator charging valve to the
service brake accumulator. A piston in the service brake accumulator
is held against the oil intake end by dry nitrogen gas. The service brake
accumulator stores hydraulic oil pressure for operation of the service
brakes. When the service brake accumulator is fully charged, the
accumulator charging valve directs its pump oil flow to tank. Oil flow is
blocked by the service brake control valve.
Continued
Page 18

R2900 Brake Module
Two solenoid control valves

control the operation of the
parking brake
The parking brake control valve consists of two solenoid control valves.
When the solenoids are de-energised, pump oil is blocked at the
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
CONTROL VALVE
ACCUMULATOR
CHARGING VALVE
TO PILOT
SYSTEM
PILOT
RELIEF
VALVE
ACCUMULATOR
CHARGE RELIEF
VALVE
STEERING
PUMP
BRAKE AND
PILOT PUMP
TANK
13
System Operation (Parking Brake Released)

engine running, parking
brake released and service
brakes released
The pilot relief valve
controls the oil pressure in
the parking brake circuit
When the 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
When the parking brake control in the cab is moved to the released
position, power is sent to energise the parking brake solenoid control
valves.
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
maximum 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
parking brake.
Page 20

R2900 Brake Module
,, ,,
, ,
FRONT WHEEL
BRAKES
SERVICE BRAKE
CONTROL VALVE
REAR WHEEL
BRAKES
SERVICE BRAKE
ACCUMULATOR
PARKING BRAKE
CONTROL VALVE
ACCUMULATOR
CHARGING VALVE
TO PILOT
SYSTEM
PILOT
RELIEF
VALVE
ACCUMULATOR
CHARGE RELIEF
VALVE
STEERING
PUMP
BRAKE AND
PILOT PUMP
TANK
14
System Operation (Service Brakes Applied)

engine running, parking brake
released and service brakes
applied
The accumulator charging
valve charges the service
brake accumulator with
pressure oil
When the brake pedal is
depressed, pressure oil
moves the service brake
piston to apply the brakes
The further the pedal is
depressed, the greater the
pressure at the wheel brakes
Oil from the brake and pilot pump flows through the accumulator
charging valve to the service brake accumulator. The service brake
accumulator stores hydraulic oil pressure for the operation of the
service brakes. When the service brake accumulator is fully charged
with oil, the accumulator charging valve sends the pump oil flow to
tank.
The service brake control valve is in the circuit from the service brake
accumulator to the service brakes. When the brake pedal is pushed,
oil from the service brake accumulator goes to the service brake
section of the wheel brakes. The service brake control valve is a
tandem type valve providing split system braking. In the event of a
failure in either the front or rear brake system, the other portion of the
valve will continue to function.
After the service brakes have been activated several times, the volume
of oil in the service brake accumulator is reduced. The piston in the
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
3
2. Brake release sequence valve.
3. Shuttle valves.
1. Brake release cylinder.
4
4. Check valve.
5. Towing hook.
15
Towing Brake Release System

Towing brake release system
components:
(1) Brake release cylinder
(2) Towing brake release
sequence valve
(3) Shuttle valves
(4) Check valve
(5) Towing hook
The towing brake release
system allows release of the
parking brake in the event of
a machine fault
system is activated when the
towing brake release cylinder
piston is moved up
The towing brake release system allows the operator to release the
parking brakes if the brakes are applied due to a machine fault. When
the brakes are released, the machine can be towed to a service area.
The system is activated by a towing hook (5) compressing the towing
brake release piston in the machine towing bar.
The towing brake release system must only be activated by a

towing hook securely attached to the recovery machine. The
towing hook must be securely attached to the towing bar of the
inoperative machine prior to activating the release system. Failure
to do so may result in the towed machine moving, causing serious
personal injury or death.
When the machine has been towed to a safe place, ensure that it is
parked on a level surface and that the wheels are blocked securely
so the machine can not move prior to any service work being
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
RELIEF
VALVE
PARKING BRAKE
CONTROL VALVE
TO PILOT
SYSTEM
ACCUMULATOR
CHARGING VALVE
SHUTTLE
VALVE
,,
,,
TOW BRAKE
RELEASE
CYLINDER
ACCUMULATOR
CHARGE RELIEF
VALVE
BRAKE RELEASE
SEQUENCE VALVE
BRAKE AND
PILOT PUMP
EXTERNAL
FORCE
STEERING
PUMP
TANK
16
System Operation (Towing Brake Release Activated)

system is activated by the
towing brake release
cylinder piston
The piston creates oil
pressure as it moves up
and this pressure releases
the parking brake section
of the wheel brakes
When the towing brake
piston moves down, the
parking brakes apply
The towing brake release system is an attachment of the parking brake

circuit.
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
now creates oil pressure which is directed, via a shuttle valve, to the
parking brake section of the wheel brakes to release the brakes.
When the towing brake release cylinder piston is released, the spring
moves the piston down. The oil pressure in the wheel brakes decreases
and the parking brakes apply.
During normal operation, when the operator releases the parking
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

disables towing release
system during normal
machine operation
Check valve replenishes oil in
the brake system when
required
Tank port prevents hydraulic
lock between shuttles and
deactivated piston
With the brake release sequence valve open to tank the towing brake
release system is disabled during normal machine operation.
The check valve replenishes oil in the brake release system when
required.
When the towing brake release cylinder is in the deactivated position,
the spring chamber is connected to the hydraulic tank port. This
prevents a pressure increase (hydraulic lock) behind the shuttle valves
so the parking brakes can be released.
Page 24

R2900 Brake Module
1. Pilot pressure test point.
2. Accumulator charging valve pressure test point.

3. Accumulator charge relief valve.
17
Brake Pressure Test Points

Identify components
(1) Pilot pressure test point
(2) Accumulator charging
valve pressure test point
(3) Accumulator charge relief
valve
The pilot pressure test point (1) is located on the pilot oil filter. The test
point is used for checking the pilot pressure in the parking brake,
steering and implement hydraulic system.
The pressure point (2) located in the pressure manifold, below the
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
2
1. Parking brake control switch.
2. Service brake oil low pressure switch (CMS).

3. Service brake oil low pressure switch (B.A).
4
6
4. Parking brake relay.
5
7
5. Solenoids.
6. Parking brake low oil pressure switch.
7. Parking brake pressure switch (remotes).
18
Brake Electrical System

The parking brake is engaged
and released by the parking
brake control switch
When the service brake oil
pressure is in the operating
range, the parking brake can
be released
If service brake oil pressure
falls below the operating
range, the parking brake will
apply
The parking brake system is controlled by parking brake control switch

(1) in the cab. The standard parking brake control switch is a pull-toapply type. When the switch is pulled out, the brakes will apply.
Certain mining regulations require machines to be equipped with a
push-to-apply parking brake control switch. When the switch is pushed
in, the brakes are applied.
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
provide an earth for parking brake relay (4). If the park brake control
switch is in the engaged position, the relay (4) will energise and latch.
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

System monitors the service
brake oil pressure
If service brake oil pressure falls below the operating range, switch (3)
will open. The parking brake relay will open and interrupt power to
solenoids (5). The parking brake will apply.
If the service brake oil

pressure falls below the
normal operating range, the
Caterpillar Monitoring System
will initiate a category 3
warning
Service brake low oil pressure switch (2) is for the Caterpillar Monitoring
System. When brake oil pressure falls below the normal operating
range, the switch will open, causing a category three warning. The
Caterpillar Monitoring System alert indicator will come on, the fault light
will flash and the fault alarm will sound.
The parking brake low oil

pressure switch is an input of
the transmission electronic
control - the signal tells the
control when the parking
brake is engaged
The transmission electronic
control sends the parking
brake low oil pressure switch
signal to the Caterpillar
Monitoring System over the
Cat data link
The parking brake low oil pressure switch (6) is an input of the electronic
transmission control. When the parking brake is engaged, the switch
sends a signal to the transmission control. The control shifts the
transmission to neutral. The transmission control also sends the
parking brake status to the Caterpillar Monitoring System over the data
link. When the parking brake is engaged, the alert indicator for the
parking brake flashes on the Caterpillar Monitoring System. If the
operator selects FORWARD or REVERSE while the parking brake is
engaged, the Caterpillar Monitoring System initiates a category 3
warning.
Parking brake pressure switch (7) is part of the optional remote control
system.
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
1
2
REMOTE CONTROL
SWITCH
PARKING BRAKE
SOLENOIDS
1
2
8
14
13
1
2
3
27
22
28
18
37
38
POWER SUPPLY FROM

BRAKE CONTROL CIRCUIT BREAKER
SERVICE BRAKE LOW

OIL PRESSURE SWITCH
1
2
3
1
2
3
TRANSMISSION PRESSURE
SWITCH ABA
POWER SUPPLY FROM REMOTE

CONTROL CIRCUIT BREAKER
GROUND CIRCUIT
19
System Operation (Power Supply)

Key on engine not running
Power is supplied from brake

control circuit breaker to
parking brake relay
Loop wire fitted when

optional impending brake
application is not required
Power supplied to terminal 30

on brake relay from remote
control circuit breaker
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
parking brake control switch. With the switch in the engaged position
power is available at the parking brake relay which cannot be energised
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
wire is fitted to the three pin plug to complete the circuit to the brake
charge pressure switch (as shown).
Power is supplied to terminal 30 on the parking brake relay through the
remote control switch (optional) from the remote control system circuit
breaker.
Page 28

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
1
2
REMOTE CONTROL
SWITCH
PARKING BRAKE
SOLENOIDS
1
2
8
14
13
1
2
3
27
22
28
18
37
38
POWER SUPPLY FROM

SERVICE BRAKE LOW

OIL PRESSURE SWITCH
1
2
3
SWITCH ABA
1
2
3

GROUND CIRCUIT
20
System Operation (Relay Latched and Parking Brake Engaged)

With engine running
transmission and brake oil
pressure will increase
With both switches closed
the parking brake relay will
latch
With the engine running the transmission oil pressure will rise. The
transmission pressure (ABA) switch (if fitted) will close.
At the same time the brake oil pressure will increase. The service brake
low oil pressure switch will close. With both switches in the closed
position the parking brake relay circuit is completed to ground and the
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
+ 24v
REMOTE CONTROL
10 A
10
1
1
2
REMOTE CONTROL
SWITCH
PARKING BRAKE
SOLENOIDS
1
2
8
14
13
1
2
3
27
22
28
18
37
38
POWER SUPPLY TO ENERGISE

PARK BRAKE SOLENOIDS
SERVICE BRAKE LOW

OIL PRESSURE SWITCH
1
2
3
SWITCH ABA
1
2
3

GROUND CIRCUIT
21
Parking brake relay is

latched by power from
remote circuit breaker
Once relay is latched,

parking brake can be
released
Power is supplied from the remote circuit breaker to latch the parking
brake relay.
Once the parking brake relay is latched and the parking brake switch is
moved to the released position, power is directed to parking brake
solenoids. The parking brake solenoids are energised and the parking
brakes are released.
Page 30

R2900 Brake Module
1. Parking brake low oil pressure switch.
2. Impending brake application switch.
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
CMS display area alerts the

operator to any abnormal
machine conditions
Brake system uses three
switches and alert indicators
Parking brake pressure

switch activates the parking
brake alert indicator on the
CMS dash when parking
brakes are applied.
The display area of the CMS shows the operator the condition of the
machine systems and alerts the operator to any abnormal machine
conditions that may exist.
In the CMS electrical brake system three switches and alert indicators
are used.
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
the parking brake is engaged.
When the parking brake is released the park brake pressure switch will
open. The parking brake light on the CMS panel will then go out.
Continued
Page 31

R2900 Brake Module
Park/ing brake released,

switch will open and park
brake alert indicator will
deactivate
The parking brake pressure switch sends a signal to the transmission

control module. When the emergency /parking brake is applied, this
switch will close, causing the transmission to neutralise. When the
parking brake is released, the transmission will resume normal
operation.
The parking brake pressure

switch sends a signal to the
transmission control module.
The service brake low oil pressure switch (3) is located on the left hand
inside wall of the rear frame.
Service brake low oil

pressure switch.
When the machine is started the brake system oil pressure increases.
When the pressure reaches the setting of switch (3) its contacts will
close causing the low brake oil pressure light (5) on the CMS panel to
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

application light. (IBA)
The impending brake application switch (2) (optional) is located on

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
11
1
2
3
27
36
3
9
5
PARK BRAKE SWITCH N.C

PARKBRAKE SWITCH N.O
CAT DATA LINK CAT DATA LINK +
GROUND
ELECTRONIC TRANSMISSION
CONTROL
SERVICE BRAKE LOW OIL

PRESSURE SWITCH CMS
1
2
3
1
2
3
1
2
3
4
23
24
35
33
2
CAT DATA LINK +

CAT DATA LINK BRAKE OIL PRESSURE
IMPENDING BRAKE APP.
GROUND
COMPUTERISED MONITORING
SYSTEM
IBA CMS
SWITCH
CAT DATA LINK CIRCUIT

PRESSURE SWITCH CMS
CIRCUIT
IMPENDING BRAKE
APPLICATION CIRCUIT
PARKING BRAKE LOW OIL

PRESSURE SWITCH CIRCUIT
23
System Operation CMS (Parking Brake Released)

Parking brake can not be
released until brake and
transmission have system
pressure
CAT Data Link allows the

transmission control to
receive and send information
to the computerised
monitoring system
Loop wire fitted when
optional impending brake
application is not fitted
The parking brake cannot be released until the brake and transmission
oil pressure increases. This increase in pressure will cause the service
brake low oil pressure switch and impending brake application (I.B.A.)
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
switch closes sending a signal to the electronic transmission control.
This signal is then communicated to the CMS on the CAT control data
link causing the parking brake light to go out.
The CAT data link is bidirectional, allowing the transmission control to
receive and send information. The purpose of the data link is to enable
the transmission control to communicate with the Computerised
Monitoring System (CMS). The data link is not a single visible
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. 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:
(1) Stop light switch
(2) Stop light
(3) Residual brake pressure
switch
(4) Residual brake pressure
light
Operating the machine with
the residual pressure will
cause overheating of the
brakes and may severely
shorten the service life of
brake components
The components of this circuit are; stop light switch (1), stop light (2),
rear brake pressure switch (3) and residual brake pressure light (4).
The stop light switch (1) is mounted in the front brake circuit at the
outlet of the brake control valve.
If the machine is equipped with a residual brake pressure option a rear
brake pressure switch (3) is also fitted.
When the service brakes are applied the stop light (2) will illuminate.
NOTE:
Operating the machine with residual pressure will cause overheating of
the brakes and may severely shorten the service life of brake
components.
Page 34

R2900 Brake Module
STOP/TAIL
LAMP
CAB
+24V
T
S
15A
3
1
2
FRONT BRAKE
PRESSURE SWITCH
1
2
1
2
REAR BRAKE
PRESSURE SWITCH
3
TO FRONT
LIGHT SWITCH
POWER SUPPLY
RESIDUAL BRAKE
PRESSURE LIGHT
STOP LIGHT CIRCUIT

25
System Operation (Stop Light/Residual Brake Pressure Circuit)

When the service brakes are
applied will close the brake
pressure switches and
completes the circuit to the
stop/tail light
When the service brakes are applied oil pressure will close the brake
pressure switches and completes the circuit to the stop/tail lamp
Power will now be supplied to illuminate the stop light.
If the machine is equipped with a residual brake pressure circuit a rear
brake pressure switch is also fitted (as shown).
When the service brake is applied the brake oil pressure rises above
the setting of residual brake pressure switches. The switches will close
completing the circuit to the residual brake pressure light. Power will
now be supplied to illuminate residual brake pressure light.
Machine equipped with a

residual brake pressure
circuit are fitted with a rear
brake pressure switch and
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.
3. Brake release pump switch.
2. Brake release pump solenoid.
4. Park brake control switch.

26
Electric Brake Release System

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

charges the parking brake
circuit and service brake
circuit
Page 36

R2900 Brake Module
BRAKE RELEASE
SWITCH
+24V
BRAKE RELEASE
RELAY
6
15A
BRAKE
CONTROL
MOTOR
BRAKE RELEASE
MOTOR
FUSE
675A
POS NEG
BAT MTR
MOTOR
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
the brake system
Task 1
1: Each trainee will be required to successfully bleed down the oil
pressure in the brake system.
1. Find the procedure in Service Manual.
2. Follow the procedure and successfully complete the task.
Electrical Faults.
Task 2
2: 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
e in the :
pressur
essure
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
e to:
pressur
essure
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 contr

olled 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
e switches ar
e located on:
pressur
essure
are
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.
B.
C.
D.
Service brake application

Release of the parking brake
Release of the service brakes
Transmission gear selection
Continued
Page 42

R2900 Brake Module
Q.6. The parking brake solenoids ar

e mounted on the:
are
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
e rises the:
pressur
essure
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
e incr
eases to working pr
essur
e:
pressur
essure
increases
pressur
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
elease pump is activated by:
Q.10.The
A.
B.
C.
D.
The remote controls

The parking brake switch
A toggle switch mounted on the dash
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)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
Brake and pilot pump

Pilot oil filter
Pilot relief valve
Brake system relief valve
Accumulator
Service brake control valve
Wheel brakes
Parking brake release solenoid
Hydraulic tank
Electric pump
Page 45

R2900 Brake Module
2
1
4
5
6
7
10
8
11
5

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

R2900 Brake Module
Park Brake
Oil Pressure
10
Wheel Brake (Parking Brake Released)

Servicemans Handout No.3
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
Parking piston
Service piston
Outer casing
Springs
Wheel hub
Annular passage
Steel plates
Friction discs
Brake pack
Page 47

R2900 Brake Module
FRONT WHEEL
BRAKES
SERVICE BRAKE
CONTROL VALVE
REAR WHEEL
BRAKES
SERVICE BRAKE
ACCUMULATOR
PARKING BRAKE
CONTROL VALVE
ACCUMULATOR
CHARGING VALVE
TO PILOT
SYSTEM
PILOT
RELIEF
VALVE
ACCUMULATOR
CHARGE RELIEF
VALVE
STEERING
PUMP
BRAKE AND
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
CONTROL VALVE
ACCUMULATOR
CHARGING VALVE
TO PILOT
SYSTEM
PILOT
RELIEF
VALVE
ACCUMULATOR
CHARGE RELIEF
VALVE
STEERING
PUMP
BRAKE AND
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
CONTROL VALVE
ACCUMULATOR
CHARGING VALVE
TO PILOT
SYSTEM
PILOT
RELIEF
VALVE
ACCUMULATOR
CHARGE RELIEF
VALVE
STEERING
PUMP
BRAKE AND
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

PARKING BRAKE
CONTROL VALVE
ACCUMULATOR
CHARGING VALVE
TO PILOT
SYSTEM
PILOT
RELIEF
VALVE
SHUTTLE
VALVE
TOW BRAKE
RELEASE
CYLINDER
ACCUMULATOR
CHARGE RELIEF
VALVE
BRAKE RELEASE
SEQUENCE VALVE
BRAKE AND
PILOT PUMP
EXTERNAL
FORCE
STEERING
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
CONTROL
+ 24v
10 A
10
1
1
2
REMOTE CONTROL
SWITCH
PARK BRAKE
SOLENOIDS
1
2
8
14
13
1
2
3
27
22
28
18
37
38
POWER SUPPLY FROM

SERVICE BRAKE LOW

0IL PRESSURE SWITCH
1
2
3
SWITCH ABA
1
2
3
POWER SUPPLY FROM

REMOTE CONTROL CIRCUIT BREAKER
GROUND CIRCUIT
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
CONTROL
+ 24v
10 A
10
1
1
2
REMOTE CONTROL
SWITCH
PARK BRAKE
SOLENOIDS
1
2
8
14
13
1
2
3
27
22
28
18
37
38
POWER SUPPLY FROM

SERVICE BRAKE LOW

0IL PRESSURE SWITCH
1
2
3
SWITCH ABA
1
2
3
POWER SUPPLY FROM

REMOTE CONTROL CIRCUIT BREAKER
GROUND CIRCUIT
20

System Operation (Relay Latched and Parking Brake Engaged)
Page 53

R2900 Brake Module
PARKING BRAKE
PRESSURE SWITCH
C
B
A
10
11
1
2
3
27
36
3
9
5
PARK BRAKE SWITCH N.C

PARKBRAKE SWITCH N.O
CAT DATA LINK CAT DATA LINK +
GROUND
ELECTRONIC TRANSMISSION
CONTROL

PRESSURE SWITCH CMS
1
2
3
1
2
3
1
2
3
4
23
24
35
33
2
CAT DATA LINK +

CAT DATA LINK BRAKE OIL PRESSURE
IMPENDING BRAKE APP.
GROUND
COMPUTERISED MONITORING
SYSTEM
IBA CMS
SWITCH
CAT DATA LINK CIRCUIT
IMPENDING BRAKE
APP, CIRCUIT

PRESSURE SWITCH CMS
CIRCUIT
PARKING BRAKE LOW OIL

PRESSURE SWITCH CIRCUIT
21

System Operation CMS (Parking Brake Released)
Page 54

R2900 Brake Module
STOP/TAIL
LAMP
CAB
+24V
15A
3
1
2
FRONT BRAKE
PRESSURE SWITCH
1
2
1
2
REAR BRAKE
PRESSURE SWITCH
T
S
3
TO FRONT
LIGHT SWITCH
POWER SUPPLY
RESIDUAL BRAKE
PRESSURE LIGHT
STOP LIGHT CIRCUIT
25

System Operation (Stop Light and Residual Brake Circuit)
Page 55

R2900 Brake Module
BRAKE RELEASE
SWITCH
+24V
BRAKE RELEASE
RELAY
6
15A
BRAKE
CONTROL
MOTOR
BRAKE RELEASE
MOTOR
FUSE
675A
POS NEG
BAT MTR
MOTOR
POS NEG
12 VOLT
BATTERIES
DISCONNECT
SWITCH
BRAKE RELEASE MOTOR CIRCUIT
RELAY POWER SUPPLY
27

System Operation (Electric Brake Release)
Page 56

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Service Training Module

Service Training Module

IMPORTANT SAFETY NOTICE

Service Training Module

R2900 Braking System Overview

Service Training Module

This presentation discusses the system operation and adjusting

Schematic colour code:

Testing & Adjusting

NOTE: Always follow the procedures in the Service Manual when

Give each trainee a copy of the relevant servicemans handouts,

Service Training Module

Braking System Block Schematic

Service Training Module

Braking System Component Location

Service Training Module

3. Brake and pilot pump.

4. Accumulator charging valve.

5. Pilot relief valve.

Location of Brake System Components

Brake and pilot pump is part

Service Training Module

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

Service Training Module

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

Brake application will cause the oil pressure in the accumulator to

Service Training Module

2. Accumulator charge relief valve.

Location of Brake System Components

Brake pedals regulate the

Service brake accumulator

Service Training Module

Service brake control valve

Left pedal applies the brakes

Service Training Module

Service Brake Control Valve (Released Position)

Service Training Module

When the control spools

Service Training Module

Service Brake Accumulator

The accumulator supplies

The gas chamber above the

Pump oil pushes the piston

The service brake accumulator supplies oil under pressure to the

Service Training Module

Wheel Brake (Parking Brake Released)

When the parking brake is

Service Training Module

Wheel Brake (Parking Brake Released - Service Brake Applied)

When the service brake is

Cooling oil will constantly

Service Training Module

System Operation (Parking Brake Engaged)

Service Training Module

Two solenoid control valves

Service Training Module

System Operation (Parking Brake Released)

Braking system shown with

When the parking brake

Pressure oil is sent to the

Service Training Module