Lesson 3: Brake Actuation Systems

Lesson 3: Brake Engagement Systems

Fig. 3.3.1 Brake Engagement Methods

Introduction
This lesson discussed different methods of brake engagement.

Objectives
1. Troubleshoot the brakes with a brake system schematic.
Unit 3 3-3-2 Power Train II
Lesson 3

Fig. 3.3.2 Shoe Type Brakes

Shoe Type Brakes

Shoe type brakes cause the machine to stop when the brake linings
are mechanically pushed out against the brake drum.. Engagement
systems for shoe type brakes can consist of air, a combination of air
and hydraulic or of hydraulic components.
In Figure 3.3.2, when the rod is pushed out of the air chamber, the
cam is rotated, and the lobes of the cam push the shoes outward.
Unit 3 3-3-3 Power Train II
Lesson 3

Fig. 3.3.3 Shoe Type Service Brake - Air Systems

Shoe Type Service Brake - Air System

In Figure 3.3.3, the shoe type brakes are applied with air.
The air compressor and governor generate and regulate the air in the
system. A supply of air is held in the air tank. The input from the
pedal is transmitted by the brake pedal valve
Double check valve two inputs share one output line with the use of
the quick release valve reduces the time required to release the
service brakes.
The air chamber changes the air signal into mechanical energy
When the brake pedal is depressed, the brake pedal valve routes air to
the top of the air chamber. The air chamber pushes the rod down to
apply the mechanical linkage.
The double check valve allows two types of inputs to actuate the
same output. The system can use a foot pedal or a hand lever to
control the same air chamber.
Unit 3 3-3-4 Power Train II
Lesson 3

PARKING BRAKE AIR CIRCUIT

TO TRANSMISSION
NEUTRALIZER
VALVE

JUNCTION
BLOCKS

PARKING BRAKE
VALVE
AIR CHAMBER

SECONDARY/PARKING
AIR PRESSURE
BRAKE
SWITCH

Fig. 3.3.4 Parking Brake Air Circuit

Parking Brake Air Circuit

In Figure 3.3.4, the parking brake valve has been used to apply the
parking brakes by blocking the flow of air to the air chamber. The
spring in the air chamber pushes the rod downward to apply the
mechanical linkage. Air is used to release the parking brakes.
The parking brake valve blocks air supply to the air chamber when
the operator has the parking brake on.
The junction block allows one input to control to two outputs.
The air pressure switch alerts the operator when the air pressure in
the parking brake circuit drops below a specified amount.
Unit 3 3-3-5
Lesson 3

Fig. 3.3.5 Slack Adjuster

Slack Adjuster
The air system sends a signal to the chamber and the rod moves a
proportional amount or the parking brake chamber is drained and the
spring pushes the rod down a specific amount. As the brake linings
wear, the rod movement is no longer sufficient to engage the brakes.
A slack adjuster adjusts for brake wear. The slack adjuster consists of
a worm gear in mesh with a gear splined to the end of the cam shaft.
To adjust for brake wear, turn the worm gear manually. The cam
rotates so proper clearance can be maintained between the brake
linings and drum.

Fig. 3.3.6 Shoe Brakes

Shoe Type Brakes

In Figure 3.3.6, a hydraulically actuated wheel cylinder pushes the
brake linings out against the brake drum. When the brakes are
engaged with a wheel cylinder, the brake engagement system consists
of hydraulic components or a combination of air and hydraulic
components.
Shoe type brakes engaged with wheel cylinders are only used as
service brakes.
Unit 3 3-3-6 Power Train II
Lesson 3

Fig. 3.3.7 Shoe Type Service Brake - Air Over Hydraulic System

Shoe Type Service Brake - Air Over Hydraulic System

In Figure 3.3.7, the brakes are engaged with air and hydraulic
components. The air system is shown in blue, the hydraulic lines are
shown in red and the mechanical components are shown in yellow.
The two section air tank directs air through two lines to the brake
pedal valve
When the brake pedal is depressed, pressure air from both sides of
the two-section air tank is routed to the two combined air chamber
and master cylinder units.
The combined air chamber and master cylinder changes the air signal
into a hydraulic signal and the wheel cylinders change the hydraulic
signal into mechanical brake engagement.
The master cylinder uses oil from a reservoir to engage the brakes.
No external hydraulic source is required.
Unit 3 3-3-7 Power Train II
Lesson 3

Fig. 3.3.8 Shoe Type Service Brake - Hydraulic System

Shoe Type Service Brake - Hydraulic System

In Figure 3.3.8, the brakes are applied hydraulically. The brake pedal
is mechanically connected to the master cylinder. The master
cylinder sends oil directly to the wheel cylinder.
When the brake pedal is depressed, the master cylinder sends oil to
the wheel cylinders. The wheel cylinders mechanically engage the
service brake.
The master cylinder uses oil from a reservoir to apply the brakes. No
external hydraulic source is required.
Some machines use hydraulically assisted master cylinders to reduce
the amount of pedal effort. External hydraulic oil is used to assist the
operator. It is still possible to apply the brakes if this oil source is
lost.
Unit 3 3-3-8 Power Train II
Lesson 3

OIL INLET BLEEDER

PISTON

HYDRAULIC
WHEEL BRAKE ACTUATOR
ACTUATOR
PLUNGER ADJUSTING
SCREW

PAWL

Fig. 3.3.9 Hydraulic Wheel Brake Actuator

Hydraulic Wheel Brake Actuator

A specific amount of hydraulic oil is sent to the wheel cylinder. As
the brake linings wear, the amount of wheel cylinder movement may
no longer be sufficient to apply the brakes.

Fig. 3.3.10 External Self-Adjusting Mechanism

External Self-Adjusting Mechanism

The external self adjusting mechanism operates each time the brakes
are enganed while the machine is traveling in reverse. It does not
adjust the brakes while the machine is traveling in forward.
Unit 3 3-3-9 Power Train II
Lesson 3

Fig. 3.3.11 External Self-Adjusting Mechanism - Machine in Reverse

External Self-Adjusting Mechanism

The bellcrank lever, spring and cable are the key components. When
the brakes are engaged when machine is traveling in reverse and the
brake shoes are properly adjusted, the cable tension and the spring
force are equal, the forces hold the bellcrank lever in a stationary
position.
As the brake linings wear, travel of the upper cable increases and the
tension decreases. When the brake linings have worn, the cable
tension will be lower than the spring force. The spring force pulls the
bellcrank back (to the left) and down and turns the starwheel on the
end of the adjusting screw. As the screw is turned the brake shoes
moves out.
This continues until the spring force and cable tension are equal.
The cable prevents the spring from moving the bellcrank. The
bellcrank cannot move the starwheel and the brakes cannot be over
adjusted.
Unit 3 3-3-10 Power Train II
Lesson 3

CALIPER DISC BRAKE

ENGAGED

PISTON
BLEED VALVE

CALIPER

CARRIER LINING
FROM BRAKE CYLINDER

DISC

Fig. 3.3.12 Caliper Disc Brake

Fig. 3.3.13 Multiple Disc Service Brake

Hydraulically Engaged Brakes

Caliper and multiple disc brakes are hydraulically engaged.
In a service brake application, the clutches will be hydraulically
engaged. When oil is sent to the brake chamber, the oil will cause the
brake piston to engage the clutch.
In a parking brake application, the clutches are mechanically engaged
by parking brake springs. Oil is sent to the brake chamber, and
pushes the brake piston back in order to release the clutch.
Unit 3 3-3-11 Power Train II
Lesson 3

FROM AIR TANK

LEFT BRAKE
TO PARKING BRAKE
CONTROL
CONTROL VALVE TO TRANSMISSION
VALVE
NEUTRALIZER VALVE
AIR HORN
VALVE LEFT
HORN BRAKE
PEDAL

STOP LIGHT AIR PRESSURE SWITCH DOUBLE

CHECK
VALVE
QUICK RELEASE
VALVE RIGHT
BRAKE
PEDAL
RIGHT BRAKE
CONTROL VALVE
REAR BRAKE FRONT BRAKE
AIR/HYDRAULIC AIR/HYDRAULIC
CYLINDER CYLINDER

Fig. 3.3.14 Service Brake Air Components - Air Over Hydraulic System

Service Brake Air Components - Air Over Hydraulic System

In Figure 3.3.14, the air components of an air over hydraulic service
brake system are shown. The right brake pedal is pressed, and the
purple color indicates air pressure.
Both of the brake pedals are supplied with air. When one brake pedal
is depressed, pressure air from the air tank is routed through the
double check valve and the quick release valve to the two combined
air chamber and master cylinder units. The air signal is converted to
a hydraulic signal. The hydraulic oil is sent to the brake chambers.
The clutches mechanically apply the service brakes.
The double check valve allows the left pedal and the right pedal to
actuate the same output.
The stop light air pressure switch is used to turn on the stop lights on
the rear of the machine.
Unit 3 3-3-12 Power Train II
Lesson 3

WHEEL BRAKE WHEEL BRAKES HYDRAULIC SYSTEM WHEEL BRAKE

SLACK ADJUSTER SLACK ADJUSTER

JUNCTION BLOCK JUNCTION BLOCK

REAR AIR FRONT AIR
CYLINDER CYLINDER

REAR FRONT MASTER

FRONT MASTER CYLINDER
RESERVOIR CYLINDER
REAR OIL
SLACK
ADJUSTER RESERVOIR PRESSURE SLACK ADJUSTER
SWITCHES

WHEEL BRAKE WHEEL BRAKE

Fig. 3.3.15 Service Brake Hydraulic Components - Air Over Hydraulic System

Service Brake Hydraulic Components - Air Over Hydraulic

System
In Figure 3.3.15, the hydraulic components of an air over hydraulic
service brake system are shown.
When the brake pedal is depressed, pressure air is routed to the two
combined air chamber and master cylinder units. The air signal is
converted to a hydraulic signal. The hydraulic oil is sent to the brake
chambers. The clutches mechanically apply the service brakes.
The master cylinder uses oil from a reservoir to apply the brakes. No
external hydraulic source is required.
Unit 3 3-3-13 Power Train II
Lesson 3

RETARDER AND SERVICE BRAKE SYSTEM AIR RESERVOIR

RELIEF
VALVE
(SERVICE)
ONE WAY
CHECK VALVE

AIR RESERVOIR
(SERVICE)

CAB ENCLOSURE DRAIN VALVE

RETARDER
FRONT BRAKE VALVE
ON/OFF DOUBLE
VALVE CHECK
VALVE

FRONT BRAKE
RATIO VALVE RELAY RELAY
DOUBLE VALVE VALVE
CHECK (REAR) (FRONT)
SERVICE
BRAKE VALVE
CONTROL
VALVE

BRAKE
CYLINDER
( FRONT )

BRAKE
CYLINDER
( REAR )

Fig. 3.3.16 Service Brake Air Components - Air Over Hydraulic System

Service Brake Air Components - Air Over Hydraulic System

There are two service brake inputs. Both of the brake inputs are
supplied with air. When the brakes are needed, air is routed through
the double check valve to the relay valve. The relay valve allows air
from the air tank to flow to the combined air chamber and master
cylinder unit. The air signal is converted to a hydraulic signal. The
hydraulic oil is sent to the brake chambers. The clutches
mechanically apply the service brakes. The retarder hand lever and
the service brake foot pedal send oil to the same brake chamber even
though the purpose and amount of pressure is different.
The front brakes can be turned on or off. If the front brakes are on,
the front brake ratio valve reduces the amount of pressure that
engages the front brakes.
The pressure of the signal air from the brake input is not sent directly
to the air chamber. The signal air is sent to the control passage of the
relay valve. The relay valve opens to allow pressurized air from the
air tanks to flow to the air chamber.
Unit 3 3-3-14 Power Train II
Lesson 3

PARKING/SECONDARY BRAKES AND ACCESSORIES

CAB ENCLOSURE

PRESSURE
PROTECTION VALVE
RELAY DOUBLE
VALVE CHECK
(FRONT) VALVE

PARKING
BRAKE INVERSION
CONTROL VALVE
SECONDARY BRAKE VALVE
CONTROL VALVE

WIPER
MOTOR WINDSHIELD BRAKE
WIPER CYLINDER
VALVE ( FRONT )

HORN
VALVE
AIR HORN AIR RESERVOIR PARK/SECONDARY BRAKE
( SECONDARY ) RELEASE VALVE

Fig. 3.3.17 Parking Brake Air Components - Air Over Hydraulic System

Parking Brake Air Components - Air Over Hydraulic System

In Figure 3.3.17, the parking brake switch applies the parking brakes
by blocking the flow of air to the parking brake release valve. The
air over hydraulic system is used to release the parking brakes.
When the parking brake is turned on or when the secondary brakes
are applied, air does not flow to the parking brake release valve. The
parking brake release valve blocks the flow of oil to the brake
chamber. The parking brake springs apply the parking brakes.
The inversion valve allows air from the air tanks to flow to the air
chamber when the secondary brake is applied. The inversion valve is
similar to a relay valve, except the inversion valve allows air to flow
through when pressure is not present in the control passage.
AIR AND BRAKE SYSTEMS

AIR HYDRAULIC ELECTRICAL

Fig. 3.3.18 Air and Brake Systems

Air and Brake Systems

In a brake actuation system the air charging system is shared, and
many inputs are monitored by the electrical system.
Unit 3 3-3-15 Power Train II
Lesson 3

BRAKE SYSTEM
SELECTOR TRANSMISSION
VALVE BOOST NEUTRALIZER
MANIFOLD CYLINDER PRESSURE SWITCH RESERVOIR

FRONT AXLE

BRAKE UNIT MASTER

CYLINDER

PARKING REAR AXLE

BRAKE
SLAVE
CYLINDER

PARKING BRAKE PARKING TRANSMISSION

CABLE BRAKE LEVER NEUTRALIZER SWITCH

Fig. 3.3.19 Service Brakes - Hydraulic System

Service Brake - Hydraulic System

In Figure 3.3.19, the master cylinder sends oil directly to the brake
chambers. The brake pedal is mechanically connected to the master
cylinder.
When the brake pedal is depressed, the master cylinder sends oil to
the brake chambers and the clutches apply the service brake.
A hydraulically assisted master and slave cylinder is used to reduce
the amount of pedal effort required by the operator.
When external hydraulic oil is used to assist the operato, it is still
possible to apply the brakes if this oil source is lost.
Unit 3 3-3-16 Power Train II
Lesson 3

BRAKE HYDRAULIC SYSTEM

FRONT SERVICE
BRAKES

REAR SERVICE TANDEM BRAKE

BRAKES VALVE
BRAKE
TO IMPLEMENT SWITCH
PRESSURE
PILOT SYSTEM PORT

PILOT AND BRAKE ACCUMULATOR

PUMP CHARGING VALVE BRAKE
ACCUMULATORS

TO PARKING
PARKING BRAKE
BRAKE
VALVE
TANK PARKING BRAKE
SWITCH

Fig. 3.3.20 Service Brakes - Hydraulic System

Service Brake - Hydraulic System

When the brake pedal is depressed, passages are opened up through
the brake pedal valve to the brake chambers. The clutches
mechanically apply the service brake.
The accumulators store oil to allow for a brake applications in the
event of an engine failure. The accumulator charging valve monitors
the pressure of the accumulators. When the pressure in the
accumulators is low, the accumulator charging valve allows oil to
flow to the accumulators. When the accumulators are full, the
accumulator charging valve routes the oil flow to the tank.

PARKING BRAKE CIRCUIT

BRAKE ENGAGED

PARKING PRESSURE
BRAKE SWITCH

SUPPLY
FROM SOLENOID
TRANSMISSION VALVE
PUMP
ACCUMULATOR

Fig. 3.3.21 Parking Brake - Hydraulic System

Parking Brake - Hydraulic System

In Figure 3.3.21, the parking brake switch has been used to apply the
parking brakes by energizing the parking brake solenoid valve. The
parking brake solenoid valve blocks the flow of oil to the brake
chamber. The hydraulic system is used to release the parking brakes.
When the parking brake is turned on, the parking brake solenoid is
not energized. Oil flow into the brake chamber is blocked The
parking brake springs apply the parking brakes
Unit 3 3-3-17 Power Train II
Lesson 3

BRAKE RELEASE EXTERNAL

AIR SUPPLY
DURING TOWING
PARKING
RELIEF VALVE BRAKE
RELEASE
PARKING BRAKE HOIST VALVE VALVE
RELEASE PUMP PILOT SUPPLY
AND FILTER

CHECK VALVE

DIVERTER
VALVE TOWING
PUMP

DIVERTER VALVE
CLAMP BOLTS SECONDARY
STEERING
PUMP

Fig. 3.3.22 Brake Release During Towing

Brake Release During Towing

In Figure 3.3.22, the parking brakes are automatically applied by
springs when the engine is not running. To tow the machine, the
parking brakes must be released, an electric drive pump supplies the
oil needed for parking brake release. This pump is turned on with a
switch in the cab. The position of the spool in the diverter valve must
be manually shifted to release the parking brakes. This prevents
accidental parking brake release.
Some machines do not have a component to supply towing oil and an
external service tool is needed to pump oil into the parking brake
chamber.
Unit 3 3-3-18 Power Train II
Lesson 3

BRAKE COOLING SYSTEM

MAKEUP TANK AIR/HYDRAULIC CYLINDERS

TORQUE
CONVERTER
PUMP HOUSING
DRIVE

OIL COOLER

RIGHT
REAR
BRAKE

PARKING
BRAKE
VALVE
LEFT
REAR
BRAKE HOIST
VALVE
AETA
VALVE M
RIGHT
FRONT
BRAKE
BRAKE
BRAKE HOIST
COOLING
TOWING PUMP PUMP
PUMP
LEFT
FRONT
BRAKE DIVERTER
VALVE

Fig. 3.3.23 Brake Cooling System

Brake Cooling System

When multi-disc brakes are used, cooling oil is continually passed
through the clutch pack. This oil carries away debris and cools the
discs and plates.
In addition to dedicated pumps that provide cooling oil flow, some
relief valves and other valves dump excess oil into the brake cooling
oil flow instead of routing the excess oil to the tank.