KENR5824

March 2008

Systems Operation
993K Wheel Loader
Braking System
LWA1-Up (Machine)
Z9K1-Up (Machine)

SAFETY.CAT.COM
 i01658146

Important Safety Information

Most accidents that involve product operation, maintenance and repair are caused by failure to observe
basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous
situations before an accident occurs. A person must be alert to potential hazards. This person should also
have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings
are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the Safety Alert Symbol and followed by a Signal Word such as
DANGER, WARNING or CAUTION. The Safety Alert WARNING label is shown below.

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or pictorially
presented.
Operations that may cause product damage are identified by NOTICE labels on the product and in
this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
The warnings in this publication and on the product are, therefore, not all inclusive. If a tool,
procedure, work method or operating technique that is not specifically recommended by Caterpillar
is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that
the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
The information, specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before you
start any job. Caterpillar dealers have the most current information available.

When replacement parts are required for this

product Caterpillar recommends using Caterpil-
lar replacement parts or parts with equivalent
specifications including, but not limited to, phys-
ical dimensions, type, strength and material.

Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or
death.
KENR5824 3
Braking System
Table of Contents

Table of Contents
Systems Operation Section
General Information (Brake) ................................. 4
Electronic System Components ............................ 12
Piston Pump (Brake) ............................................. 14
High Pressure Screen Group (Deluxe Filtration) .. 16
Brake Accumulator .............................................. 17
Brake Control Valve (Service) ............................... 18
Torque Converter Impeller Clutch Operation ........ 20
Brake Control Valve (Parking) .............................. 21
Service Brakes ..................................................... 23
Parking Brake ...................................................... 24
Parking Brake Interlock ......................................... 25

Index Section
Index ..................................................................... 26
4 KENR5824
Braking System
Systems Operation Section

Systems Operation Section

i02826505

General Information (Brake)

SMCS Code: 4250
KENR5824 5
Braking System
Systems Operation Section

g01410185
Illustration 1
Main Hydraulic Schematic for the Braking System
6 KENR5824
Braking System
Systems Operation Section

(1) Rear service brakes (10) Breaker relief valve (20) Accumulator pressure switch for the
(2) Front service brakes (11) Oil pressure sensor for the rear service rear service brakes
(3) Brake pedals brakes (VIMS) (21) Accumulator for the rear service brakes
(4) Hydraulic oil temperature sensor for the (12) Oil pressure sensor for the front service (A) Pressure port for the rear service brakes
rear service brakes brakes (VIMS) (B) Pressure port for the front service brakes
(5) Service brake control valve (13) Parking brake limit switch (C) Pressure port for the rear service brakes
(6) Hydraulic oil temperature sensor for the (14) Parking brake (D) Pressure port for the front service brakes
front service brakes (15) Accumulator for the front service brakes (E) Pressure port for accumulator (9)
(7) Hydraulic oil tank for the steering system (16) Check valve for the brake manifold (F) Pressure port for accumulator (10)
and for the braking system (17) Parking brake control valve
(8) Brake manifold (18) Parking brake pressure switch
(9) Brake pump (19) Manifold

Note: To determine the general location of a main

brake system component, refer to the section for the
appropriate components description.

g01410981
Illustration 3
(9) Brake pump.

Brake pump (9) is a variable displacement piston

pump. The brake pump draws oil from hydraulic
oil tank (7). A pressure control valve on the pump
senses the load requirements of the brake circuit. The
pressure control valve then maintains the pressure
by upstroking the pump or by destroking the pump.
g01410982
Illustration 2
The check valve for the pump pressure line is part
(22) High Pressure Screen. of manifold (19). This check valve helps to reduce
pressure spikes that may occur in the brake circuit.
High pressure screen (22) (if equipped) is located by
the accumulators on the right side of the machine.
High pressure screen (22) contains a screen that
protects the hydraulic system in case of a component
failure. The high pressure screen may be removed
and cleaned.

Breaker relief valve (10) is part of hydraulic oil tank

(7) for the steering system and for the braking
system. Breaker relief valve (10) controls the amount
of vacuum and the amount of pressure buildup in
hydraulic oil tank (22).

g01410985
Illustration 4
(19) Manifold
KENR5824 7
Braking System
Systems Operation Section

g01410986 g01411370
Illustration 5 Illustration 7
(15) Accumulator for the front service brakes Location of the Service Brake Control Valve
(21) Accumulator for the rear service brakes (5) Service brake control valve

The oil then flows through manifold (19). The oil then
flows to accumulator (15) and to accumulator (21).

If pressure output from brake pump (9) decreases,

the check valve in manifold (19) prevents pressure
oil from flowing back to the brake pump from the
accumulators.

The accumulators store energy for the front service

brakes and for the rear service brakes. Also,
the accumulators supply oil for the front service
brakes and for the rear service brakes. Additionally,
accumulator (21) stores energy for the parking brake
circuit. Accumulator (21) also supplies oil for the
parking brake circuit.

g01410988
Illustration 8
(3) Brake pedals

The oil then flows to brake manifold (8). Brake

manifold (8) routes the oil to service brake control
valve (5). When either brake pedal (3) is depressed,
the pressure oil flows through service brake control
valve (5). When service brake control valve (5)
actuates, pressure oil flows to front service brakes
g01410987
Illustration 6 (2) and to rear service brakes (1).
(8) Brake manifold
Depressing either brake pedal causes spool
movement in service brake control valve (5). This
allows oil from the accumulators to flow to front
service brakes (2) and to rear service brakes (1).

However, depressing the left brake pedal first limits

the amount of power that is available through the
drive train by limiting the amount of impeller clutch
pressure. This provides more engine power for the
rest of the hydraulic system. Depressing the left
pedal assembly even farther actuates the service
brakes at each wheel.
8 KENR5824
Braking System
Systems Operation Section

When the oil pressure increases to approximately

8270 kPa (1200 psi), parking brake pressure switch
(18) closes. This stops the Warning Category 3 alarm
if the transmission was in a forward speed position
or in a reverse speed position. However, if the
transmission was in neutral, the Warning Category 1
would stop.

Pressure Tap and Pressure Switch

Locations

g01412406
Illustration 9
(17) Parking brake control valve
(18) Parking brake pressure switch

Check valve (16) is in the drain line from the parking

brake line. The oil also flows into parking brake
control valve (17). Accumulator (21) also provides
pressure oil for parking brake control valve (17).
Pressure oil also flows to parking brake pressure
switch (18).
g01411012
When parking brake control valve (17) moves to the Illustration 11
disengaged position, oil from the accumulator flows (B) Pressure port for the front service brakes
through parking brake control valve (17). The oil then
flows to the parking brake. This causes parking brake
(14) to disengage.

g01411367
Illustration 10
Location of the Parking Brake
(14) Parking brake.
g01411015
Illustration 12
Parking brake (14) engages automatically when the
(A) Pressure port for the rear service brakes
supply pressure from the accumulators drops below
6890 345 kPa (999 50 psi). This causes parking
brake pressure switch (18) to open.
KENR5824 9
Braking System
Systems Operation Section

There are several pressure taps on this machine.

Pressure tap (B) is for the front service brakes.
Pressure tap (A) is for the rear service brakes.

g01411813
Illustration 14
Right side of the machine
(20) Accumulator pressure switch for the service brakes
g01411016
Illustration 13
(8) Brake manifold Pressure switch (20) is for the accumulator for the
(16) Check valve for the brake manifold service brakes. The pressure switch is located on
(C) Pressure port for the rear service brakes manifold (19).
(D) Pressure port for the front service brakes
(E) Pressure port for the accumulator for the front service brakes
(F) Pressure port for the accumulator for the rear service brakes

Brake manifold (8) contains the following pressure

taps:

(C) Pressure port for the rear service brakes

(D) Pressure port for the front service brakes
(E) Pressure port for the accumulator for the front
service brakes

(F) Pressure port for the accumulator for the rear

service brakes g01411019
Illustration 15
(11) Oil pressure sensor for the rear service brakes
(12) Oil pressure sensor for the front service brakes
(8) Brake manifold

If the machine is equipped with the Vital Information

Management System (VIMS), two oil pressure
sensors will be located on brake manifold (8). Oil
pressure sensor (12) is for the front service brakes.
Oil pressure sensor (11) is for the rear service brakes.
10 KENR5824
Braking System
Systems Operation Section

g01411365
Illustration 16
(13) Parking brake limit switch
(17) Parking brake control valve
(18) Parking brake pressure switch

Parking brake limit switch (13) and parking brake

pressure switch (18) are located on the side of
parking brake control valve (17).

Parking brake limit switch (13) functions as an

override switch for the transmission.
KENR5824
Axle Oil Cooler
Illustration 17
Hydraulic Schematic for the Axle Oil Cooler
(25) Axle oil cooler for the rear axle
(26) Thermal bypass for the rear axle
(27) Brake lube oil switch for the rear axle
(28) Rear service brakes
(29) Screen group for the rear axle
(30) Filter bypass for the rear axle
(31) Axle oil cooler pump and motor for the
rear axle
Pump (32) circulates hydraulic oil to both axle oil
cooler pumps and motors (35) and (36).
Axle oil cooler pumps and motors (35) and (36)
circulate the oil which flows through both axle
housings.
11
Braking System
Systems Operation Section
g01411510
(32) Pump for the pilot oil and the axle (39) Screen group for the front axle
cooling oil (40) Axle oil cooler pump and motor for the
(33) Axle oil coolers for the front axle front axle
(34) Thermal bypass for the front axle (41) Front service brakes
(35) Brake lube oil switch for the front axle
(36) Filter bypass for the front axle
(37) Flow of pilot oil
(38) Flow to implement oil coolers
12 KENR5824
Braking System
Systems Operation Section

Axle oil cooler pump (35) circulates the oil through

axle oil cooler (32). When the engine is started and
the axle oil is cold, the oil from axle oil cooler pump
(35) can not easily flow through axle oil cooler (32).
The oil pressure will increase in axle oil cooler (32)
and thermal bypass (37) will open. Thermal bypass
(37) limits the maximum oil pressure in axle oil cooler
(32). When the temperature of the oil increases, the
pressure of the oil decreases. When the spring force
is greater than the force of the oil pressure, thermal
bypass (37) will close. The axle oil flows through axle
oil cooler (32). From axle oil cooler (32), oil circulates
through screen group (26) and rear brake manifold
(29) and through both brake housings of rear axle
(28). g01411022
Illustration 19
Axle oil cooler pump (36) circulates the oil through (4) Hydraulic oil temperature sensor for the rear service brakes.
axle oil cooler (33). When the engine is started and
the axle oil is cold, the oil from axle oil cooler pump Hydraulic oil temperature sensor (6) for the front
(36) can not easily flow through axle oil cooler (33). service brakes is located on the front axle housing.
The oil pressure will increase in axle oil cooler (33) Hydraulic oil temperature sensor (4) for the rear
and thermal bypass(40) will open. Thermal bypass service brakes is located on the rear axle housing.
(40) limits the maximum oil pressure in axle oil cooler
(33). When the temperature of the oil increases, the The hydraulic oil temperature sensors activate a
pressure of the oil decreases. When the spring force warning in the cab when the temperature of the oil
is greater than the force of the oil pressure, thermal reaches approximately 90C (194F). When the
bypass (40) will close. The axle oil flows through temperature of the oil cools to approximately 85C
axle oil coolers (33). From axle oil coolers (33), oil (185F), the warning stops.
circulates through screen group (25) and front brake
manifold (30) and through both brake housings of
i02977711
front axle (31).
Electronic System
Components
SMCS Code: 1400; 4250

Features
Parking Brake Interlock
The interlock prevents the machine from accidental
movement. The feature also prevents the operator
from accidentally driving through the parking brake.
The transmission will not shift to first gear forward
Illustration 18
g01411369 or the transmission will not shift to first gear reverse
when the parking brake is engaged. The ECM shifts
(6) Hydraulic oil temperature sensor for the front service brakes.
the transmission to the NEUTRAL position when the
transmission is in a gear and the parking brake is
set. The transmission will not shift to a gear when
the parking brake is released. The transmission must
first be shifted to NEUTRAL in order to shift to a gear.
KENR5824 13
Braking System
Systems Operation Section

Driving through the Parking Brake

This feature provides the capability to shift to first
gear when the parking brake is engaged. The parking
brake is engaged and the plunger that is in the cab
pops out if the pressure for releasing the parking
brake is not available. The operator can drive through
the parking brake for a short distance. Hold the
parking brake switch that is located in the cab in the
OFF position. The switch contains a spring in order to
resist this effort. This switch will automatically move
to the ON position when the switch is released. Move
the direction switch in the forward position or the
reverse position. Do not release the parking brake
switch. The transmission will shift to the respective
gear. See table1 for more information.

Table 1
State STIC Parking Brake Parking Brake Transmission Display
control Switch Gear
Initial 1F OFF OFF 1F 1F
Brake ON failure 1F ON ON 1N 1N
Direction to Neutral 1F ON ON 1N 1N
Switch in OFF 1N OFF ON 1N 1N
Direction to Forward
1F or 1R OFF ON 1F or 1R 1F or 1R
or Reverse

Parking Brake Table 2

Switch Status
Switch Position Normally Open Normally Closed
Out Closed Open
In Open Closed

Parking Brake Pressure

g01478277
Illustration 21

The parking brake pressure switch provides the

ECM with information about the hydraulic portion of
g01478268 the parking brake assembly. The parking brake is
Illustration 20
applied by a spring. The parking brake is released by
hydraulic pressure. The parking brake is on when the
The operator uses the parking brake switch in order
pressure switch is not actuated. The parking brake is
to set the brake. The ECM sets the brake if the
off when the pressure switch is actuated. The ECM
operating conditions of the machine are appropriate.
will log a diagnostic code of CID 0627 for the switch.
The ECM will log a diagnostic code of CID 0070 for
the switch.
14 KENR5824
Braking System
Systems Operation Section

Table 3 i02090271

Switch Status Piston Pump (Brake)

Switch Position Normally Open Normally Closed
SMCS Code: 4268-QP; 5070-BRK
High Pressure Closed Open
Low Pressure Open Closed

Position of Torque Converter Pedal

g01478288
Illustration 22
The pedal position sensor determines the position of
the torque converter pedal. The sensor sends a PWM
signal to the ECM. The ECM monitors the signal.
Then, the ECM calculates the position of the pedal
from the signal. Information about the transmission
output speed is broadcast on the Cat data link. The
ECM will log a diagnostic code of CID 1712 for the
torque converter pedal position sensor.
Torque Converter Lockup Clutch
Solenoid (Attachment)
g00103376
Illustration 24
Location of the Brake Pump
(1) Torque converter housing. (2) Brake Pump. (3) Pressure
compensator valve.
The braking system uses an automatically controlled
variable displacement piston pump. The pump has
the capability to detect pressure requirements and
flow requirements. The pump is mounted on the
engine side of the torque converter housing. The
pump supplies oil flow in order to charge the two
accumulators.

g01478292
Illustration 23

The solenoid functions as a proportional valve. The

solenoid modulates hydraulic pressure to the lockup
clutch. The ECM increases the current to the solenoid
valve and the hydraulic pressure at the lockup clutch
is increased. The ECM decreases the current to the
solenoid valve and the hydraulic pressure at the
lockup clutch is at a minimum. The ECM will log a
diagnostic code of CID 0679 for the lockup clutch
solenoid.
KENR5824 15
Braking System
Systems Operation Section

g00103377
Illustration 25
Component Locations for the Brake Pump
(3) Pressure compensator valve. (4) Actuator piston. (5) Swashplate control spring. (6) Swashplate. (7) Pump drive shaft. (8) Pump outlet
passage. (9) Pump inlet passage. (10) Piston. (11) Cylinder barrel. (12) Shoe plate. (13) Piston shoe.

When pump drive shaft (7) is rotated, cylinder barrel

(11) also turns. Nine pistons (10) and cylinder barrel
(11) turn together. Each piston has an attached piston
shoe. Piston shoes (13) are held against nonrotating
swashplate (6) by shoe plate (12).

When the pistons are almost out of cylinder barrel

(11), the swashplate is at the maximum angle. This
draws oil from pump inlet passage (9) and into the
piston bore in cylinder barrel (11). As this barrel
rotates, the angled swashplate pushes the pistons
back into the cylinder barrel. This pushes oil out of
the piston bore and through pump outlet passage (8)
to the hydraulic system.
g00103379
Pressure compensator valve (3) keeps the pump Illustration 26
pressure and the pump flow at the necessary level Pressure Compensator Valve
in order to fulfill the load requirements and the flow (3) Pressure compensator valve. (14) Pressure compensator
requirements. spool. (15) Spring. (16) Screw. (17) Pump outlet passage. (18)
Passage. (19) Drain passage to pump case.
Maximum pump output is available when the engine
is on and the oil pressure is less than the pressure When the pressure of the oil is less than the pressure
of pressure compensator valve (3). of pressure compensator valve (3), oil from pump
outlet passage (8) flows to passage (17). The oil is
then stopped by pressure compensator spool (14).

When the service brakes are not applied, the

pressure of the oil through pump outlet passage (8)
increases until the oil in pump outlet passages (8) and
(17) has more force on spool (14) than spring (15).
16 KENR5824
Braking System
Systems Operation Section

The oil in pump outlet passage (17) then moves i02832171

pressure compensator spool (14). In order to move
pressure compensator spool (14), the pressure must High Pressure Screen Group
be at least 13790 345 kPa (2000 50 psi). This is (Deluxe Filtration)
the pressure setting of pressure compensator valve
(3). SMCS Code: 4295
With the movement of pressure compensator spool
(14), the oil in pump outlet passage (17) can flow
through passage (18). The oil that flows through
passage (18) controls actuator piston (4) in the
pump. The force of the oil from passage (18) moves
actuator piston (4) and the piston moves swashplate
(6) toward the minimum angle (approximate zero
degree angle).

When pump drive shaft (7) and cylinder barrel (11)

turn with swashplate (6) at the minimum angle
position, pistons (10) have very little movement in
cylinder barrel (11). This movement occurs when
the reaction plate and piston shoes (13) follow the
approximate zero degree angle of swashplate (6).

The minimal movement of pistons (10) keeps the

pressure of the oil in pump outlet passage (8) at the
pressure setting of pressure compensator valve (3).
The extra oil from pump outlet passage (8) flows into
the pump body for pump lubrication. The oil in the g01412504
Illustration 27
pump body flows through a drain line to the hydraulic
tank. Right side of machine near the brake accumulators
(1) High Pressure Screen for the Brake Pump.
When the pressure of the oil in the braking system
decreases, there is a decrease in the pressure of the
oil in pump outlet passage (17). Spring (15) moves
pressure compensator spool (14). This causes a lack
of oil pressure in passage (18) to control actuator
piston (4) in the pump. The lack of oil pressure
for actuator piston (4) allows spring (5) to move
swashplate (6). Swashplate (6) is able to move to the
maximum angle position. This will cause the pump
to upstroke again.
KENR5824 17
Braking System
Systems Operation Section

i02832214

Brake Accumulator
SMCS Code: 4263

g01412539
Illustration 29
Location of the Two Brake Accumulators

g00669209
Illustration 28
High Pressure Screen
(2) Oil outlet passage. (3) Passage. (4) Passage. (5) Oil inlet
passage. (6) Screen housing. (7) Screen assembly. (8) Drain Plug.

The screens for the hydraulic system filter any debris

that is in the hydraulic oil. The screens prevent a
debris generating failure from contaminating the oil
that is in the hydraulic system.

During normal operation, the oil flows through screen

assembly (7) to oil outlet passage (2).

Correct maintenance recommendations must be

followed in order to ensure that the screen assembly
does not become plugged with debris. If the screen
assembly is plugged, the flow of oil to the high
pressure system stops. The oil will not bypass the
screen if the screen assembly is plugged.
18 KENR5824
Braking System
Systems Operation Section

When the pressure in the accumulators reaches

approximately 16000 345 kPa (2320 50 psi), the
supply of oil is stopped. When either brake pedal is
pushed, oil from pressure oil chamber (5) flows out
of port (6) to the service brake control valve. This
applies the service brakes.

i02832297

Brake Control Valve (Service)

SMCS Code: 4265

The service brake control valve is connected to the

right pedal assembly. The control valve is mounted
beneath the cab platform.

g01438465
Illustration 31
(1) Brake port for the rear service brakes
(2) Accumulator port for the rear service brakes
(3) Tank port for the rear axle
(4) Brake port for the front service brakes
(5) Accumulator port for the front service brakes
(6) Tank port for the front axle

g00428660
Illustration 30
Brake Accumulator
(1) Nitrogen charging valve. (2) Accumulator. (3) Nitrogen gas
charge. (4) Piston. (5) Pressure oil chamber. (6) Outlet to the
service brake control valve.

Piston (4) moves up and down inside the bore of

each accumulator (2). Chamber (3) has a charge of
approximately 4826 kPa (700 psi) of dry nitrogen gas.
Each accumulator is charged with nitrogen through
charging valve (1).

Oil enters pressure oil chamber (5) from the brake

pump. The oil reaches the pressure oil chamber
through outlet port (6). The oil pushes piston (4)
upward. The pressure of the oil compresses the
nitrogen gas.
KENR5824 19
Braking System
Systems Operation Section

g01412559 g01412560
Illustration 32 Illustration 33
Service Brake Control Valve View A-A
(1) Brake port for the rear service brakes (1) Brake port for the rear service brakes
(2) Accumulator port for the rear service brakes (3) Tank port for the rear axle
(4) Brake port for the front service brakes (4) Brake port for the front service brakes
(5) Accumulator port for the front service brakes (6) Tank port for the front axle
(7) Modulating spring
(8) Piston
(9) Modulating spring
(10) Brake pedal return spring
(11) Upper spool
(12) Retainer assembly
(13) Pilot oil passage
(14) Passage
(15) Accumulator port for the rear axle
(16) Cavity
(17) Lower spool
(18) Pilot oil passage
(19) Cavity
(20) Accumulator port for the front axle
(21) Spring
20 KENR5824
Braking System
Systems Operation Section

The service brake control valve is a fully split i02089560

modulating valve with two independent output
pressures. The valve is actuated by a camshaft which
can be actuated by either brake pedal.
The service brake control valve controls the
modulation of high pressure oil flow from the
accumulators to the service brakes. The position of
either brake pedal causes a specific pressure at the
service brakes. As the position of the pedal changes,
the pressure at the service brakes also changes.
When piston (8) is pushed downward by the linkage
of the camshaft, pedal force acts to compress
modulating spring (7), modulating spring (9), and
brake pedal return spring (10). The compression of
these springs forces spools (11) and (17) to move
downward.
The flow of oil through passages (14) to the hydraulic
tank is blocked when the spools move downward.
When the spools move down farther, the accumulator
oil pressure is applied to the service brakes. Passage
(14) connects the accumulator oil pressure from
accumulator ports (15) and (20) to the service brakes
through brake ports (1) and (4).
Torque Converter Impeller
Clutch Operation
SMCS Code: 3134-CL
The left brake pedal controls the amount of brake oil
pressure that is used to apply the service brakes. The
left brake pedal also controls the amount of pressure
that actuates the impeller clutch. The impeller clutch
is positioned between the engine and the torque
converter.
By using the left brake pedal, the operator may divert
engine power to the implement hydraulic circuit
without putting the transmission in neutral.
As the operator depresses the pedal, the impeller
clutch pressure drops quickly to a working pressure.
The pressure is then modulated to a reduced
pressure. This sequence occurs during the next ten
degrees of pedal travel. Depressing the left brake
pedal past this point applies the service brakes.

As oil flows from the accumulators to the service

brakes, oil also flows through passages (13) and (18)
to cavities (16) and (19). The service brakes and the
respective cavity have the same oil pressure.

The oil pressure in cavity (19) and the force of spring

(21) act to balance lower valve spool (17) against the
force that is created by the oil pressure in cavity (16).
In the same manner, pressure in cavity (18) creates
a force against the bottom of upper valve spool (11).
This force is balanced by the force of modulation
springs (7) and (9) at the top of the spool.

The force of springs (7), (9), and (10) act to balance

the force that is applied to the brake pedal. Upward
movement of valve spools (11) and (17) causes
accumulator ports (15) and (20) to be covered. The
level of pressure in the independent valve sections
create a force. This force is a type of feedback that g00103246
allows the operator to modulate pressure to the Illustration 34
service brakes. Typical Torque Converter Impeller Clutch
(X) Approximate pedal position in degrees. (Y) Approximate
percent of impeller clutch pressure.

Range (A) indicates the released position. In this

range, the brake pedal does not apply the service
brakes.

Range (B) indicates the first two degrees of pedal

movement. In this range, the impeller clutch pressure
is reduced to the maximum working pressure level.
Range (B) is the approximate pressure range for
preventing slippage of the impeller clutch.
KENR5824 21
Braking System
Systems Operation Section

Range (C) occurs approximately within the next ten

degrees of pedal travel. The impeller clutch pressure
is modulated from the maximum working pressure to
the minimum impeller clutch pressure.

Range (D) indicates the percent of service brake

pressure.

Range (E) indicates the impeller clutch pressure.

Note: For more information about the torque

converter impeller clutch, refer to Systems Operation,
SENR1346, 992G Wheel Loader and 854G Wheel
Dozer Power Train, Torque Converter.

i02832498

Brake Control Valve (Parking)

SMCS Code: 4282
g00537843
Illustration 36
Parking Brake Control Valve

The parking brake control valve is located under the

cab on the left side of the machine.

The parking brake control valve controls the flow of

pressure oil for the parking brake actuator.

g01412655
Illustration 35
(1) Parking brake control knob
g00291888
Illustration 37
Parking Brake Control Valve
(2) Port for the hydraulic oil tank
(3) Port for the parking brake actuator
(4) Pressure port that is connected to the accumulator for the rear
service brakes
22
Braking System
Systems Operation Section
g00291889
Illustration 38
View A-A
(2) Port for the hydraulic oil tank
(3) Port for the parking brake actuator
(4) Pressure port that is connected to the accumulator for the front
service brakes
(5) Stem for the brake control valve (parking)
(6) Detent springs
(7) Detent balls
(8) Spool
(9) Retainer
(10) Spring
When parking brake control knob (1) is pushed in,
the parking brake disengages. This causes spool
(8) and retainer (9) to move right. This movement
compresses spring (10).
This allows pressure oil to flow into the pressure
port from the brake accumulator for the rear service
brakes. The oil then flows out of the port for parking
brake actuator (3). The oil then flows into a cavity in
the actuator assembly for the parking brake.
When the oil pressure in the cavity for the parking
brake actuator is high enough to compress the
actuator springs, the parking brake disengages. The
pressure of the oil keeps the parking brake in the
DISENGAGED position.
Pull out parking brake control knob (1) in order to
engage the parking brake. Pulling out on parking
brake control knob (1) causes stem (5) to move spool
(8) to the left. This stops the flow of pressure oil to
the parking brake actuator. This allows the oil in the
cavity of the parking brake actuator to flow back to
the hydraulic oil tank.
With a decrease in oil pressure for the parking brake
circuit, the force of the springs in the parking brake
actuator is greater than the pressure of the oil in the
cavity of the parking brake actuator. This allows the
springs to engage the parking brake.
KENR5824
If there is a decrease of hydraulic oil pressure in the
service brake circuit during machine operation, the
parking brake control valve will automatically engage
the parking brake. If the machine is in either first
speed forward or first speed reverse, the transmission
will also shift into the NEUTRAL position.
With a loss of hydraulic oil pressure, the force of
spring (10) moves spool (8) to the left. This blocks
any flow of oil that would normally help keep spring
(10) compressed. This causes spring (10), retainer
(9) and spool (8) to move left. At the same time, stem
(5) also moves to the left.
Detent springs (6) and detent balls (7) move in and
out of grooves that are machined into spool (8).
This allows the operator to feel the internal locking
mechanism of the parking brake control valve.
When the oil pressure for the parking brake actuator
decreases below a preset value, the Caterpillar
Monitoring System indicates a Warning Category 3
alarm.
The following warning indications will notify the
operator:
The alert indicator will flash approximately nine
times per second.
The action lamp will flash ON for one second and
OFF for two seconds.
The action alarm will sound ON for one second
and OFF for two seconds.
The transmission returns to the NEUTRAL position
if the transmission is in either first speed forward or
first speed reverse. This will occur when the parking
brake engages.
Note: The parking brake can be manually engaged
and disengaged when the pressure in the system is
above 10300 kPa (1495 psi). However, if the system
pressure is below 10300 kPa (1495 psi), actuation
force increases.
Note: If the parking brake control knob is in the
DISENGAGED position, the parking brake control
valve will move to the ENGAGED position when the
pressure difference between the pressure port and
the tank port is approximately 2400 kPa (350 psi).
Note: Hydraulic tank pressure above 690 kPa
(100 psi) may cause stem (5) to extend to the
ENGAGED position.
Reference: For additional information on the
Caterpillar Monitoring System, refer to Service
Manual, SENR1394, Caterpillar Monitoring System.
KENR5824 23
Braking System
Systems Operation Section

i02833169 Brake housing (3) is fastened between the spindle

and the axle housing. The brake housing does
Service Brakes not turn. The splines on the outside circumference
of plates (2) engage with the splines which are
SMCS Code: 4251 positioned on the inside of the brake housing.

There are splines on the outside circumference of

brake hub (8). These splines engage with the splines
on the inside circumference of discs (1). This causes
both the brake hub and the discs to turn together.

Oil pressure flows from the brake control valve into

chamber (4) when a brake pedal is pushed. The oil in
chamber (4) pushes piston (5) against plates (2) and
against discs (1). This causes friction between plates
(2). The plates are held stationary by housing (3) and
by discs (1), which turn with the rotation of the axle
shafts. This friction causes the wheels to turn at a
slower rate or to stop.

The discs have grooves which allow cooling oil

to pass between the plates and the discs. These
grooves allow the oil to flow in either the activated
position or the released position. If the depth of the
grooves in the friction discs is adequate, the cooling
oil constantly flows between the discs and the plates.
This happens even when the service brakes are
applied.

The oil from chamber (4) flows back to the service

brake control valve, and to the hydraulic tank when
the brake pedal is released. Springs (6) pull piston
(5) away from the plates. The flow of oil between the
plates and the discs helps to separate the stack as
the brake is released.

g01412890
Illustration 39
Components of the Service Brake
(1) Discs (six)
(2) Plates (six)
(3) Brake housing
(4) Chamber
(5) Piston
(6) Springs (six)
(7) Guides (six)
(8) Brake hub

The oil activated disc brakes are positioned at all

four of the interfaces between the spindles and axle
housings. The heat from the friction of the brakes is
removed by the oil in the compartment for the service
brake.
24 KENR5824
Braking System
Systems Operation Section

i02833694 Plates (13) react against four pins (10) that are
anchored in bearing cage (11). Discs (3) have splines
Parking Brake on the inside diameter which engage with hub (6).
The hub is splined to shaft (7). The shaft is driven
SMCS Code: 4267 by one of the transfer gears. The discs turn with the
transfer gear shaft.

g01412995
Illustration 41
Location of the Parking Brake Control Knob
(14) Parking brake control knob

Parking brake control knob (14) is positioned on the

right side of the dashboard. This knob operates the
parking brake control valve.

When parking brake control knob (14) is pushed

in, oil flows from the accumulators to chamber (8)
behind piston (12). Piston (12), plate (9), and bolts
Illustration 40
g00102882 (4) are pushed to the left when the oil fills chamber
(8). Shaft (7) is able to rotate when the pressure on
Location of the Components for the Parking Brake
plates (13) and on discs (3) is released.
(1) Spring
(2) Plate
(3) Disc When parking brake control knob (14) is pulled out,
(4) Bolt the flow of oil from the accumulator stops. The flow of
(5) Bolt oil to the parking brake also stops. Oil in chamber (8)
(6) Hub drains back to the hydraulic oil tank. Springs (1) then
(7) Shaft
(8) Chamber
exert force on plate (2). Discs (3) and plates (13) are
(9) Plate clamped together. This compression of discs (3) and
(10) Pin plates (13) engage the parking brake.
(11) Bearing cage
(12) Piston When the pressure in the accumulators decreases
(13) Plate
below 6890 345 kPa (999 50 psi), the parking
brake engages. The position of the control knob
The parking brake is positioned on the output transfer
indicates the status of the parking brake.
gear case. The parking brake is a multiple disc brake
with a dry cavity which is engaged by springs (1).
KENR5824
i02833714
Parking Brake Interlock
SMCS Code: 3030; 4267; 4282
Illustration 42
g01413005
(1) Parking brake control knob
When the parking brake control knob is pushed in,
the parking brake is disengaged. The gear selection
is not affected when the parking brake control knob is
in the disengaged position.
When the parking brake control knob is pulled out,
the parking brake is engaged. The transmission will
not shift out of neutral into first speed forward or into
first speed reverse when the parking brake control
knob is in the engaged position.
The transmission can be engaged if the transmission
is in second speed forward, in third speed forward,
in second speed reverse or in third speed reverse.
However, a Warning Category 3 will occur.
When the transmission is in first speed forward or in
first speed reverse and the parking brake is engaged,
the transmission automatically shifts into neutral. In
this situation, a Warning Category 1 occurs.
After the electronic control module (ECM) has shifted
the transmission into neutral, the parking brake must
first be disengaged. The direction switch on the
STIC steering control lever must then be shifted to
NEUTRAL before the ECM will shift the transmission
into a forward speed or into a reverse speed.
25
Braking System
Systems Operation Section
If the parking brake engages and the transmission is
in first speed forward or in first speed reverse, the
ECM shifts the transmission into neutral. Before the
ECM will allow the transmission to shift into a forward
speed or into a reverse speed, push in on the parking
brake control knob in order to disengage the parking
brake. Next, shift the direction switch on the STIC
steering control lever to NEUTRAL. Then shift the
direction switch on the STIC steering control lever to
first speed forward or to first speed reverse.
To shift the transmission to second speed forward,
to third speed forward, to second speed reverse
or to third speed reverse, you must first shift the
transmission to neutral. Next, shift the transmission
to the desired gear.
Approximately 15845 kPa (2300 psi) of oil pressure
is supplied to the parking brake during normal
operation. This prevents the springs inside the
parking brake from engaging the parking brake.
Note: The following information is provided in case
of a malfunction of the parking brake interlock.
The parking brake control valve expels pressure
during a malfunction in the hydraulic system. One
type of malfunction in the hydraulic system is a loss
of system pressure. The parking brake control valve
then allows the internal springs to engage the parking
brake.
If there is a hydraulic failure and pressure oil
is not available to release the parking brake, a
drive-through mode is available. The drive-through
mode functions when the operator pushes in the
parking brake control knob.
Before the ECM will allow the transmission to shift
into a forward speed or into a reverse speed, push in
on the parking brake control knob in order to actuate
the parking brake switch. Next, shift the direction
switch on the STIC steering control lever to the
NEUTRAL position. Then shift the direction switch on
the STIC steering control lever to first speed forward
or to first speed reverse.
Note: First speed forward or first speed reverse must
be used in order to drive through a parking brake that
functions correctly.
26 KENR5824
Braking System
Index Section

Index
B

Brake Accumulator ................................................ 17

Brake Control Valve (Parking) ............................... 21
Brake Control Valve (Service) ............................... 18

Electronic System Components ............................ 12

Features............................................................. 12

General Information (Brake) .................................. 4

Axle Oil Cooler ................................................... 11
Pressure Tap and Pressure Switch Locations ... 8

High Pressure Screen Group (Deluxe Filtration) ... 16

Important Safety Information ................................. 2

Parking Brake ........................................................ 24

Parking Brake Interlock ......................................... 25
Piston Pump (Brake) ............................................. 14

Service Brakes ...................................................... 23

Systems Operation Section ................................... 4

Table of Contents................................................... 3
Torque Converter Impeller Clutch Operation ......... 20
KENR5824 27
Braking System
Index Section
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