5brake System Englisg-G9165
5brake System Englisg-G9165
5brake System Englisg-G9165
SERVICE MANUAL
5 Brake System
CONTENTS
5 Brake System ....................................................................................................... 5-1
51 Service Brake System .......................................................................................... 5-1
511 System Composition and Working Principle .............................................. 5-1
512 Specification and Technical Description of Main Components ................. 5-3
513 Disassembly and Assembly Single-Circuit Foot Brake Valve ................... 5-9
514 Disassembly and Assembly of Accumulator............................................. 5-11
515 Disassembly and Assembly of Prefill Valve ............................................. 5-13
516 Replacement of Brake Shoe ...................................................................... 5-15
52 Parking Brake System ....................................................................................... 5-19
521 Working Principle of Parking Brake ......................................................... 5-19
522 Disassembly and Assembly of Parking Brake Control Mechanism ......... 5-20
53 Diagnosis and Solutions for Common Faults of Brake System ........................ 5-22
523 Common Fault of Service Brake System .................................................. 5-22
524 Common Fault of Parking Brake System .................................................. 5-24
Brake System
The brake system of this grader consists of service brake system and parking brake system. The
function of service brake system is to realize speed reduction and stop when the vehicle is running
according to the operators requirements. The parking brake is used for grader to brake under
emergency conditions during operation or to keep loader stay at original position after stop,
avoiding movement in the effect of inclined road or other external forces.
is
designed
with
drum-type
brake.
511 System
Composition
and
Working Principle
The service brake system is supplied by gear pump.
During driving, the oil from the pump flows into the
accumulator through prefill valve. When the
operator steps on the brake pedal, high pressure oil
stored in accumulator (or from the prefill valve)
splits into two parts, flows into the wheel side
brake cylinders respectively to engage braking.
Meanwhile, the brake lamp switch will be trigged
by pressure oil to turn on the brake lamp. Release
the brake pedal, the pressure oil circuit to the brake
valve will be cut off, and the hydraulic oil in the
5-1
2 Filter
4 Joint
7 Brake valve
8 Accumulator
9 Pressure switch
5-2
5 Prefill valve
512 Specification
and
Technical
1 2
3
4
Fig. 5-2 Prefill valve
1 Port O
2 Port T
3 Port A
4 Port P
1
2 3 4
5 6
Fig. 5-3 Prefill valve
1 Low-pressure alarm switch
2 Port A1
3 Port P
4 Port A2
5 Port O
6 Port T
5-3
Brake valve
The hydraulic brake valve is composed of valve
body, oil channels and moveable valve block. Step
the brake pedal, the corresponding oil channels will
open to connect the inlet port and outlet port.
Release the brake pedal, the inlet port and outlet
port will be disconnected and the braking will be
relieved.
1 2
3 4
Fig. 5-4 Foot brake valve
1 Port A1
2 Port A2
3 Port T
4 Port P
1 23 4 56
Fig. 5-5 Foot brake valve
1 Port T1
2 Port T2
3 Port A1
4 Port A2
5 Port P1
6 Port P2
5-4
1
Fig. 5-7
1 Lo-pressure alarm switch
5-5
2.
3.
4.
5.
7.
8.
5-6
Brake assembly
The brake assembly comprises brake and brake
drum.
When the operator steps on the brake pedal, high
pressure oil stored in accumulator (or from the
prefill valve) splits into two parts, flows into the
wheel side brake cylinders respectively. Brake
1
Fig. 5-9
1 Brake
2 Brake drum
5-7
the
pipeline,
which
will
affect
brake
1.
2.
3.
ATTENTION
The overflowing oil could be transient, so
you need to perform the air bleeding
operation coordinately and cooperatively.
1
Fig. 5-12
1 Container
4.
2 Rubber hose
5-8
513 Disassembly
and
Assembly
2.
ATTENTION
When dismantling the hydraulic pipes, do
not screw off the nut connecting to the oil
1
2
Fig. 5-13
1 Port T
3 Straight joint
2 Port P
4 Port A
4.
5.
1
Fig. 5-14
1 Bolt
5-9
1
Fig. 5-15
1 Bolt
2.
3.
1
2
Fig. 5-16
1 Port T
3 Straight joint
2 Port P
4 Port A
5-10
Remove
the
six
connecting
bolts
of
1
Fig. 5-17
1 Periphery board
2
2 Bolt
2.
ATTENTION
When dismantling the hydraulic pipes, do
not screw off the nut connecting to the oil
port rashly. Loosen the nut gradually until
the oil spills out so as to prevent the oil
1
2
Fig. 5-18
1 Accumulator
2 Oil pipe
5-11
ATTENTION
The accumulator may still contain pressure
even removed from the machine, and that is
1
Fig. 5-19
1 U-shape bolt
3 Accumulator
2 Rubber mat
Assembly of accumulator
1.
1
Fig. 5-20
1 U-shape bolt
3 Accumulator
2 Rubber mat
2.
1
2
Fig. 5-21
1 Accumulator
2 Oil pipe
5-12
1
Fig. 5-22
1 Periphery board
2
2 Bolt
Remove
the
six
connecting
bolts
of
1
Fig. 5-23
1 Periphery board
2
2 Bolt
2.
3.
4.
5.
1
4
Fig. 5-24
1 Oil pipe (Port O)
3 T-junction (Port T)
4 T-junction (Port A)
3
2 Port P
5-13
1
Fig. 5-25
1 Bolt
1
Fig. 5-26
1 Bolt
2.
3.
4.
1
4
Fig. 5-27
1 Oil pipe (Port O)
3 T-junction (Port T)
4 T-junction (Port A)
11010Nm
3
2 Port P
5-14
1
Fig. 5-28
1 Periphery board
2
2 Bolt
1
Fig. 5-29
1 Tire
2.
1
Fig. 5-30
1 Brake drum
5-15
4.
5.
1
Fig. 5-31
1 End cover
1
Fig. 5-32
1 Splined hub
ATTENTION
Be careful when disassembling the spring,
and protective measures shall be taken.
1
Fig. 5-33
1 Return spring
5-16
7.
1
Fig. 5-34
1 Brake shoe
ATTENTION
The new brake shoe must be grinded and
repaired to ensure necessary contact area
between the brake shoe and brake drum.
Besides, to avoid unbalanced braking force,
the two brake shoes should be replaced
together.
1
Fig. 5-35
1 Return spring
8.
1
Fig. 5-36
1 Splined hub
5-17
1
Fig. 5-37
1 End cover
1
Fig. 5-38
1 Brake drum
1
Fig. 5-39
1 Tire
5-18
the end of the pull rod will rotate to expand the two
brake shoes (friction plates), the brake shoes will
press against the inner wall of rotating brake drum
to realize braking, and the hand brake indicator
light will be on.
Generally, the failure rate of parking (hand) brake
system is very small. But if basic maintenance
tasks are not being carefully addressed, phenomena
like brake slide, wear of friction plates, crack of
brake drum and brake dray (the grader is not able
to move after reliving the brake) may occur. The
brake slide is caused by severe worn friction plates.
The main causes of premature wear of friction
plate are: there is oil on friction plate, or swell of
1
Fig. 5-41
1 Hand brake indicator light
5-19
Brake
Control
Mechanism
Disassembly
of
parking
brake
control
mechanism
1.
Fig. 5-42
1 Screw
2 Parking brake control handle
Fig. 5-43
1 Adjusting nut
2 Connecting pin, cotter pin
5-20
Fig. 5-44
1 Screw
2 Parking brake control handle
2.
1
2
Fig. 5-45
1 Adjusting nut
2 Connecting pin, cotter pin
5-21
53
Common faults of full hydraulic brake system are: Insufficient foot brake force, parking brake cant
be released normally, insufficient parking brake force, accumulator charging failure or too long
charging time, no inching braking, low service brake pressure alarm indicator light is on, and the
brake lamp doesnt work.
Problems
Diagnosis
Solutions
1.
2.
1.
2.
3.
Insufficient
foot brake
force
4.
5.
6.
7.
8.
3.
4.
5.
6.
7.
8.
Charging
frequency of
prefill valve
is too fast
1.
2.
1.
Accumulator
charging
failure
2.
3.
4.
Pressure of accumulator
capsules is too low.
Prefill valve does not work.
There is no oil or oil level
is too low in hydraulic
tank.
Pump is too old to work
There is air in accumulator.
Prefill valve does not work
5-22
1.
2.
1.
2.
3.
4.
Accumulator
charging
time is too
long
2.
3.
1.
5
The brake
lamp doesnt
work
Low service
brake
pressure
alarm
indicator
light is on
2.
1.
2.
1.
2.
3.
is
in
of
is
System
pressure
is
inadequate, in the short
time of starting grader.
System failure, the oil
pressure is decreased.
1.
2.
1.
2.
1.
Low service
brake
pressure
alarm
indicator
light is on
when service
brake
is
engaged
1.
2.
2.
No inching
braking
Off tracking
when
braking
5-23
Problems
Diagnosis
1.
Parking
brake failure
2.
3.
Parking
brake
control
handle
cannot
fixed
Solutions
control
be
5-24
1.
2.
3.
Readjust it as required.
Clean brake shoe.
Adjust the stroke of parking brake
control mechanism.