Wright LHD 356 Owners Manual-Revision L BRAKES

Caterpillar Wright LHD 356 Coal Machine: Brake System Owner’s Manual
OWNERS MANUAL
BRAKE SYSTEM
Document No: 0023.D30
NCS Engineering Revision L, 16 MARCH 2005
Page 1
TABLE OF CONTENTS:
1 PARTS CATALOGUE..................................................................................................................................................................... 3
1.1 Brake components...................................................................................................................................................................... 3
1.2 Hydraulic system ....................................................................................................................................................................... 6
2. OPERATION................................................................................................................................................................................. 27
2.1 Brake system description:........................................................................................................................................................ 27
2.2 Operating guidelines ................................................................................................................................................................ 27
2.3 Towing..................................................................................................................................................................................... 28
3. MAINTENANCE .......................................................................................................................................................................... 29
3.1 Maintenance schedules ............................................................................................................................................................ 29
3.2 Maintenance procedures .......................................................................................................................................................... 29
3.2.1 Disassembly instructions .................................................................................................................................................. 29
3.2.2 Re-Assembly instructions ................................................................................................................................................. 31
3.2.3 Testing .............................................................................................................................................................................. 33
3.2.4 Wear pin indicator replacement ........................................................................................................................................ 33
3.2.5 Seal Replacement.............................................................................................................................................................. 34
3.2.6 Spring Pack Replacement ................................................................................................................................................. 34
3.3 Re-ordering information .......................................................................................................................................................... 35
4. TROUBLESHOOTING................................................................................................................................................................ 36
4.1 Engine starter does not operate ................................................................................................................................................ 36
4.2 Brakes do not release ............................................................................................................................................................... 37
4.2.1 Scenario A: Hold-off pressure low ................................................................................................................................... 37
4.2.2 Scenario B: Adequate hold-off pressure ........................................................................................................................... 38
4.3 Brakes do not apply ................................................................................................................................................................. 39
4.3.1 Emergency brakes............................................................................................................................................................. 39
4.3.2 Service brakes ................................................................................................................................................................... 39
4.4 Gears cannot be selected.......................................................................................................................................................... 40
4.5 Hydraulic system overheats ..................................................................................................................................................... 40
Page 2
1 PARTS CATALOGUE
1.1 Brake components
Brake housing (103076 or 103084)
O-rings for sealing the hydraulic ports (540300920262)
Piston backup ring (54051450160025)

Piston O-ring (540313430057)
Wear indicator pin (102821)
Wear indicator O-ring (540300870178)
Retainer O-ring (540314410084)
Retainer backup ring
Guide pin (103052)

Guide ring (103079)
Disc spring pack (25pcs)
Retainer (103078)
Piston (102818)
Washer (102976)
Bolt (103082)
Brake disc assembly
Figure 1: Exploded view of one brake housing with associated components.
Page 3
Caterpillar
Item no. Description Part no. Part no.
1 Brake housing (rear) LHD 0030
2 Brake disc pack assembly 6Y7915
3 Disc spring 100234
4 Piston 102818
5 Retainer 102819
6 Guide Pin 103052
7 Wear indicator pin 102821
8 O-ring (wear indicator pin) 8.73 ID x 1.78 sec 540300870178
9 O-ring (retainer) 144.1 ID x 8.4 sec 540314410084
10 O-ring (piston) 134.3 ID x 5.7 sec 540313430057
11 Back-up ring (retainer) 135 ID x 145 OD x 1.7 sec 54051350145017
12 Back-up ring (piston) 145 ID x 160 OD x 2.5 sec 54051450160025
13 O-ring (hydraulic port seal) 9.2 ID x 2.62 sec 540300920262
14 Bolt hex head 7/16” UNC x 4”long 103082
15 Nordloc Washer 7/16” 102976
16 Guide ring 103079
Table 1: Item list for Figure 1
Figure 2: A spring pack with 25 discs springs back-to-back.
Page 4
1.2 Hydraulic system
Page 6
Hydraulic components list:
Barlows Wright LHD 356

Hoses & Fittings 103741
ITEM DESCRIPTION PART NO WHERE USED QTY

1 R2AT - 16 JIC STR FEM SW - 16 PUMP TO CHARGE VALVE 1
90° SAE FLANGE 1200 O/L
2 R2AT -,16 JIC STR FEM SW - 20 CHARGE VALVE TO STEERING VALVE 1
90° SAE FLANGE 3000 O/L
3 R2AT - 8 JIC STR FEM SW BOTH ENDS 4500 O/L HAND PUMP SUCTION TO TANK 1
4 R2AT - 8 JIC STR FEM SW - 8 JIC 90° FEM SW 600 O/L ACC,ON CHARGE VALVE TO ACCUMULATOR 1
5 R2AT - 6 JIC STR FEM SW BOTH ENDS 400 O/L HAND PUMP TO RELIEF VALVE 1
6 R2AT - 6 JIC STR FEM SW 6 JIC 90° FEM SW 2600 O/L DR ON CHARGE VALVE TO TANK
7 R2AT - 6 JIC STR FEM SW BOTH ENDS 1900 O/L BR ON CHARGE VALVE TO P ON PILOT INTERLOCK VALVE 1
8 R2AT - 6 JIC STR FEM SW - 6 JIC 90°FEM SW 1600 O/L BR ON CHARGE VALVE TO RELIEF VALVE 1
9 R2AT - 6 JIC STR FEM SW BOTH ENDS 2200 O/L T ON FOOT BRAKE VALVE TO TANK 1
10 R2AT- 6 JIC STR FEM SW BOTH ENDS 2800 O/L FOOT BRAKE MANIFOLD TO FRONT AXLE MANIFOLD 1
11 R2AT - 6 JIC STR FEM SW BOTH ENDS 1200 O/L FOOT BRAKE MANIFOLD TO REAR AXLE MANIFOLD 1
12 R2AT - 6 JIC STR FEM SW BOTH ENDS 2300 O/L RELIEF VALVE TO A ON PILOT INTERLOCK VALVE 1
13 R2AT - 6 JIC STR FEM SW BOTH ENDS 4000 O/L T ON RELIEF VALVE TO TANK 1
14 R2AT - 6 JIC STR FEM SW BOTH ENDS 1400 O/L R ON PILOT INTERLOCK VALVE TO TANK 1
15 R2AT -6 JIC ST FEM SW BOTH ENDS 1000 O/L BR ON FOOT BRAKE VALVE TO FOOT BRAKE MANIFOLD 1
16 R2AT - 6 JIC STR FEM SW BOTH ENDS 2000 O/L A ON PILOT INTERLOCK VALVE TO P ON FOOT BRAKE VALVE 1
17 R2AT - 6 JIC STR FEM SW - 6 JIC 90 600 O/L MANIFOLD ON AXLES TO BRAKES 4
18 STRAIGHT THREAD ELBOW 16C5OX - S CHARGE VALVE 2
19 STRAIGHT THREAD ELBOW 0608 C5OX - S TANK 3
20 MALE ADAPTOR 06FTX-S HYDRAULIC MANIFOLD 5
21 MALE ELBOW 0806 CTX HAND PUMP 1
22 STRAIGHT THREAD ELBOW MCJB 0604 FOOT BRAKE VALVE , PILOT INTERLOCK VALVE 8
23 MALE ELBOW 0606CTX-S HAND PUMP 1
24 MALE ELBOW 0604 CTX - S RELIEF VALVE, HYDRAULIC MANIFOLD 6
25 MALE ELBOW 0402 CTX - S PNEUMATIC VALVES, PNEUMATIC MANIFOLD 8
26 STRAIGHT THREAD ELBOW MCJB 04 PILOT INTERLOCK VALVE 1
27 MALE ELBOW 0608 CTX - S RELIEF VALVE 2
28 MALE CONNECTOR 0608 FTX - S RELIEF VALVE 2
29 MALE CONNECTOR 0402 FTX - S PNEUMATIC MANIFOLD 4
30 STRAIGHT THREAD CONNECTOR + DOWTY WASHER MCJB 0604 FOOT BRAKE VALVE 1
31 MALE CONNECTOR 0404 FTX - S PNEUMATIC VALVES, BRAKE MANIFOLD 4
Page 7
32 STRAIGHT THREAD ELBOW 0606 C5OX BRAKES 4

33 SWIVEL NUT RUN TEE 6 - R60X -S FOOT BRAKE VALVE PILOT INTERLOCK 4
34 MINIMESS BULK HEAD ADAPTOR CSHO - R¼" PRESSURE GAUGE IN COCK PIT 1
35 NUT 06 BTX FOOT BRAKE VALVES 4
36 METRIC SLEEVES 10 MM TX FOOT BRAKE VALVES 4

37 6 JIC FEM - ¼" NPT FEM ADAPTOR ACCUMULATOR CHARGE VALVE 1
38 MALE RUN TEE 06 MRO - S HAND PUMP SUCTION TANK 1
39 MALE CONNECTOR MCJN - 0806 HAND PUMP SUCTION TANK 1
40 STRAIGHT THREAD CONNECTORS MCJS -06 DR ON CHARGE VALVE 1
41 STRAIGHT THREAD CONNECTOR MCJS -08 ACC ON CHARGE VALVE 1
42 MALE CONNECTOR MCJN -0812 ACCUMULATOR 1
43 PLUG 04 - HHP - S MANIFOLDS ON AXLES, HAND PUMP 3
44 PIPE THREAD REDUCER RBN - 0804 RELIEF VALVE 1
45 PIPE NIPPLE HNN - 04 RELIEF VALVE 1
46 BALL VALVE BKHR - 04 MOD RELIEF VALVE 1
47 MINIMESS HOSE 16 X 2 - ¼ " BSPP 3000 O/L CHARGE VALVE TO GAUGE IN PANEL 1
48 MINIMESS HOSE 16 X 2 - BOTH ENDS 800 O/L FOOTBRAKE MANIFOLD TO GAUGE IN COCKPIT 1
49 MINIMESS POINT CSH - ¼" NPT FOOT BRAKE MANIFOLD 2
50 PRESSURE GAUGE REAR ENTRY WITH FLANGE PANEL IN COCKPIT 1
NCS LOGO
51 PRESSURE GAUGE BOTTOM ENTRY NO FLANGE HANDPUMP , COCKPIT 2
52 PUSHLOCK HOSE FLAME RETARDANT ¼" 801 -04 PNEUMATIC CONNECTIONS 15M
53 PUSHLOCK TAILS 04 JIC 30682-0404 PNEUMATIC CONNECTIONS 22
54 MANIFOLD PNEUMATIC PORTS 2x ¼ " 4 X ⅛ " NPT NPT 3311 -10-13-14 PNEUMATIC CONNECTIONS 1
55 10 MM STEEL TUBE HLT - 10 x 1,5 FOOT BRAKE VALVES 500mm
56 MALE ELBOW 0404 CTX -S PNEUMATIC MANIFOLD 2
57 STRAIGHT THREAD CONNECTOR MCJS - 0608 BR ON ACC. CHARGE VALVE 1
58 SWIVEL NUT ELBOW 06 - C60X - S BR ON FOOT BRAKE VALVE TANK 2
59 UNION TEE 4 JTX PNEUMATIC START BUTTON / DOOR SWITCH 1
Page 8
BARLOWS WRIGHT LHD 356 103744

HYDRAULIC VALVES
ITEM DESCRIPTION NCS p/n OEM p/n WHERE USED QTY

A SINGLE ACCUMULATOR CHARGE VALVE 101279 LHD 7712 1
B RELIEF VALVE AND SUB PLATE 103735 LHD 7713 1
C HAND PUMP 101272 LHD 0663 1
D ACCUMALATOR 5 LITRES 9.5 MPA 103736 LHD 4739 1
E FOOT BRAKE VALVE (TRAMMING) 103737 LHD 7711 1
F FOOT BRAKE VALVE (SERVICE BRAKE) 103738 LHD 8035 1
G PNEUMATIC OPERATED DIRECTIONAL CONTROL 103739 LHD 7714 1
VALVE
H DOOR LATCH VALVE 103740 LHD 7716 1

MOUNTING BRACKETS AND SUB PLATES
ITEM DESCRIPTION NCS p/n OEM p/n WHERE USED QTY

1 INTERLOCK VALVE MOUNTING BRACKET 103637 1
2 PHEUMATIC MANIFOLD MOUNTING BRACKET 103638 1
3 FOOT BRAKE VALVES MOUNTING BRACKET 103656 1
4 DOOR SWITCH MOUNTING BRACKET 103653 1
5 PRESSURE GAUGE MOUNTING BRACKET 103641 1
6 SUB PLATE FOR ABOVE 103644 1
7 SUB PLATE FOR HANDPUMP 103646 1
8 SUB PLATE FOR RELIEF VALVE 103645 1
9 HYDRAULIC MANIFOLD MOUNTING BRACKET 103636 1
10 SUB PLATE FOR ACCUMULATOR 103726
CHARGE VALVE 1
11 MOUNTING BRACKETS FOR ACCUMULATOR 101262 2
12 ACCUMULATOR MOUNTING BRACKET 103728 1
13 HYDRAULIC MANIFOLD 103635 3
14 CHANGE OVER MANIFOLD 104902 1
15 SUB-PLATE FOR CHANGE OVER MANIFOLD 104903 1
Page 9

FASTENERS
QT
ITEM DESCRIPTION PART NO WHERE USED Y
PNEUMATIC MANIFOLD DOOR
1 M5 x 25 CAP SET SCREWS HT 510105025 SWITCH 4
2 M6 x 16 SET SCREW HT 510306016 INTERLOCK VALVE 4
3 M8 x 20 SET SCREW HT 510308020 PRESSURE GAUGE 2
4 M8 x 25 CAP SCREW HT 510108025 HAND PUMP 4
5 M10 X 25 SET SCREW HT 510310025 FOOT BRAKE VALVE 8
6 M10 X 35 SET SCREW HT 510310035 ACCUMULATOR MNTG BKT 4
7 M10 x 60 CAP SCREWS HT CAP 510110060 HAND PUMP RELIEF VALVE 2
8 M10 x 80 CAP SCREWS HT 510110080 ACC CHARGE VALVE 2
9 M5 FLAT WASHERS 51210510 4
12 MI0 FLAT WASHERS 51211020 16
13 M5 NUTS 51110600 4
14 M10 NUTS 51111000 4
15 M8 x 30 SET SCREW HT 510308030 CHANGE OVER MANIFOLD 2
Page 10
1.2.1 Hydraulic valve description:

(The letter indicated next to valve description corresponds to letters on parts list 103744.)
A SINGLE ACCUMULATOR CHARGE VALVE; NCS P/N 101279

OEM P/N LHD 7712
OPERATION:
Since the brake circuit interfaces to the machine from the steering system hydraulic circuit, the flow and pressure must
be interrupted as little as possible. For this reason the brake hydraulic system is fitted with an Accumulator.
The accumulator is charged off the steering circuit by the accumulator charge valve, where after the flow to the
steering system is restored.
Note: The Accumulator charge valve also contains an orifice. This is between the check valve and accumulator its purpose is to prevent pressure
spikes when charging as well as reducing the flow rate to the accumulator so that not all of the flow is diverted from the steering system while the
accumulator is being charged.
Page 11
1) Cartridge sensing valve MODDPS2-16VF080
The sensing valve ensures that the steering circuit is not starved of oil flow when the brake circuit
is being charged.
2) Seal kit for sensing valve SK3-16-3S

ITEM DESCRIPTION PART No. QTY
1 Large Backup Seal for DPS2-16 BUPDPS216-LAR 1
2 Small Backup Seal for DPS2-16 BUPDPS216-SM 1
3 O Ring 2-117 ORI 117 1
4 O Ring 2-119 ORI 119 1
5 O Ring 3-916 ORI 916 1
Note: Seal kits are only supplied as complete kits
Page 12
3) Cartridge unloader relief valve 1PUL60
The accumulator unloader valve cartridge is responsible for keeping the accumulator pressure
above the minimum required to operate the failsafe brakes.
4) Seal kit for unloader relief valve SK10-3P

1 Backup Seal BUP014 1
2 Backup Seal BUP015 1
3 O Ring 2-014 ORI 014 1
4 O Ring 2-015 ORI 015 1
5 O Ring 3-910 ORI 910 1

Page 13
5) Cartridge check valve MOD CV3-10P010
The check valve cartridge prevents the charged accumulator from discharging back into the
steering system. This valve is a non-return valve.
6) Seal kit cartridge check valve SK10-2

1 Small Backup Seal BUP13x1.3x1.3 1
2 O Ring 2-014 ORI 014 1
3 O Ring 3-910 ORI 910 1

Page 14
B RELIEF VALVE AND SUB PLATE; NCS p/n 103735

OEM p/n LHD 7713
The purpose of the relief valve is to prevent over pressurization of the brake circuit when using the
Hand pump.
Page 15
1) Cartridge relief valve MOD RV1-10-1036
The relief valve cartridge pressure is set at 15Mpa, when this pressure is exceeded the valve
opens allowing the flow to divert back to tank preventing over pressurization of the brakes.
1 2
2) Seal kit for relief valve SK10-2

1 Small Backup Seal BUP13x1.3x1.3 1
2 O Ring 2-014 ORI 014 1
3 O Ring 3-910 ORI 910 1
Page 16
C HAND PUMP ; NCS p/n 101272

OEM p/n LHD 0663
The hand pump is used to release the brakes when there is not pressure in the main hydraulic
system.
Page 17
D ACCUMULATOR; NCS p/n 103736

OEM p/n LHD 4739
The accumulator which is pressurized from the steering system is used to provide release
pressure for the four spring applied brakes.
1) Accumulator 5.5 liters ACC-A-5.5C
The accumulator is pre-charged with nitrogen to a pressure of 9 Mpa.
Note: Accumulators should only be opened and serviced by the manufacturer.
Page 18
E FOOT BRAKE VALVE (TRAMMING); NCS p/n 103737

OEM p/n LHD 7711
This foot brake pedal is used to prevent the machine from moving during loading operations, it is
also fitted with a pneumatic switch which moves the transmission into neutral to allow more
hydraulic pressure to be diverted to the bucket lift system.
Page 19
1) Cartridge foot brake valve BRCIPD20SP105
When the foot brake pedal is depressed this cartridge valve opens allowing hydraulic pressure to
flow out of the brakes back to tank and for the springs to apply the brakes.
Note: Cartridge parts as per above list can be supplied separately.
2) Seal kit foot brake valve 1SK339

1 Small Backup Seal 2
2 Medium Backup Seal 1
3 Large O Ring 2-014 1
4 Medium O Ring 2-015 1
5 Small O Ring 3-910 1
Note: Seal kits are only supplied as complete kits.
3) Pneumatic switch for foot brake valve VM430-01-075
When the foot brake pedal is depressed it also actuates this pneumatic switch allowing air
pressure to flow into a piston (located in the transmission), selecting neutral.
Page 20
F FOOT BRAKE VALVE (SERVICE BRAKES): NCS p/n 103738

OEM p/n LHD 8035
This foot brake pedal is used to stop the machine during normal tramming operations.
Page 21
29 PEDAL REF ONLY 1

28 SCREW SKT HD CAP M10 X 30 510110030 1
27 CLEVIS PIN REF ONLY 1
26 NUT HEX M10 51111000 1
25 CLEVIS REF ONLY 1
26 27 16 29 13 12 28
24 SPLIT PIN DIA 3 X 20 4
25 23 PIN PSP42 1
22 PIN PSP87 1
21 CLACIER BUSH GLBMB 10 X 10 4
20
20 SCERW SKT HD CAP M8 X 20 510108020 4
19 HEX HD. CAP SCREW M8 X 70 510308070 3
17 18 NUT NYLOCK M8 51120800 3
17 WASHER SPRING M8 51220820 7
15 16 NUT NYLOCK M10 51121000 1
14 15 SCREW HEX HD M8 X 25 510308025 1
9 14 NUT HEX M8 51111600 1

13 LINK REF ONLY 1
8
12 BEARING REF ONLY 2
7 11 BASE PLATE REF ONLY 1
6 10 WASHER FLAT M10 51211020 8

9 END CAP REF ONLY 1
8 WIPER SEAL MCWP7-10 1
4 5 24 10 22 3 21 23 11 19 18 2 1 7 STOPPER RING PSR1 1
6 BELLVILLE SPRING V08-20-316 12
5 RETAINER PISTON PRP1 1
4 LIFTING SCREW ACS-M10 X 110 1
3 RETAINER SLEEVE PRS1 1
2 RUBBER BOOT DUC4-02-105 1
1 FOOT BRAKE VALVE BRV4-02-105 1
ITEM DESCRIPTION SIZE/REF QTY
Page 22
1) Seal kit foot brake valve 1SK339

1 Small Backup Seal 2
2 Medium Backup Seal 1
3 Large O Ring 2-014 1
4 Medium O Ring 2-015 1
5 Small O Ring 3-910 1
2) Cartridge foot brake valve BRCIPD20SP105 (Same as tramming valve cartridge)
When the foot brake pedal is depressed this cartridge valve opens allowing pressure to flow out of
the brake back to tank and for the springs to apply the brake.
Page 24
G PNEUMATIC OPERATED DIRECTIONAL CONTROL VALVE; NCS p/n 103739

OEM p/n LHD 7714
This valve is opened by pneumatic pilot pressure from the emergency stop button to allow
hydraulic pressure to flow to the foot brake valves
Page 25
G DOOR LATCH VALVE; NCS p/n 103740

OEM p/n LHD 7716
This valve acts as a fail-safe system switch, if the drivers door is opened when the machine is
running, pneumatic pilot pressure from the brake release system closes the pneumatic directional
control valve which dumps hydraulic pressure from the brakes back to tank allowing the spring
applied fail-safe brakes to apply.
The brake system can only be recharged and the brakes released when the drivers door is closed.
Page 26
2. OPERATION
2.1 Brake system description:

The brake system is a spring applied hydraulically released system. It consists of inboard mounted
wet brakes on each axle wheel end. The spring applied hydraulically released brakes operate in
both the service and fail-safe/park mode. This implies that the spring-loaded fail-safe will instantly
apply in the event of hydraulic pressure loss.
Service braking:
The proportional foot brake valve is used to activate the service brake function. When the foot
brake valve is released, the pressure is allowed to flow through the brake system to the brake,
thus compressing the springs releasing the brakes. When the foot brake pedal is depressed the
brake pressure decreases proportionally, allowing the springs to apply the brake.
Emergency braking:
The emergency brakes will apply under the following conditions:
1. When the emergency/park brake valve is actuated.
2. When either the steering or brake system pressure drops below the minimum pressure, e.g.
when the pump is worn out or when a pipe bursts.
3. When the cabin door is opened.
When the emergency brakes are applied, the transmission is shifted to neutral.
Tramming braking:
The tramming brake will operate when the second foot brake pedal is depressed. This brake
functions like the service brake, with the exception that the transmission is shifted to neutral.
2.2 Operating guidelines
Starting:
a. The machine will not start unless neutral gear is selected. Make sure that the emergency/park
brake valve knob is out (towards the operator).
b. To release the emergency/park brakes the operator needs to push the emergency/park brake
valve knob inwards.
Normal operation:
c. The cabin door needs to be closed before the brakes will release.
d. Service brakes operate as normal.
e. Tramming brakes operate as normal, except that the gear is automatically locked when the
tramming brake pedal is depressed.
Emergency brakes:
f. To apply emergency brakes manually, pull the emergency park brake valve knob outwards.
WARNING:
In the failsafe mode of operation the brakes apply instantaneously and can cause severe
deceleration of the machine.
Page 27
2.3 Towing
A hand pump is provided to allow the brakes to be released when there is no system pressure.
The hand pump is connected via a relief valve which prevents over pressurisation of the brakes.
It is connected into the system after the pneumatic pilot interlock valve, through a change over
manifold (item 104902 as indicated in the hydraulic schematic). To pressurise the brake system
the pipe from the hand pump is swopped with the pipe from the system, then the hand pump is
operated until the pressure guage in front of the driver/operator shows 11 Mpa. The machine can
then be towed. In an emergency, the brakes can still be applied by depressing the foot brake
valve.
It is furthermore required that the valve on top of the hand pump is closed before using the hand
pump.
Page 28
3. MAINTENANCE
3.1 Maintenance schedules
The following must be done as part of routine maintenance:
Description Replace Criteria

O-rings (piston and Every 10000 hours or when brake
retainer.) disc packs are replaced
Disc spring packs. Every 20000 hours or when brake Replace if the free height
disc packs are replaced of a 25 disc spring stack
< 74.8 mm
Brake hydraulic As per Caterpillar service intervals
fluid
3.2 Maintenance procedures
IMPORTANT NOTE:
1. Measure the thickness of each complete disc brake pack when assembling it to the axle. This
dimension is required when testing the brakes. (See section 3.2.3)
2. When replacing the disc brake packs, the wear indicator pin also needs to be replaced
according to section 3.2.4.
3.2.1 Disassembly instructions

(For the following discussion, please also refer to figure 1)
a. Disconnect the hydraulic hoses to the brake housing, remove the brake housing from the axle
and place the housing upright on a clean surface. The brake housing is now ready for
dismantling.
b. Make sure that all of the steel and friction discs from the disc brake pack have been removed.
Remove the six retainer bolts (7/16” UNC x 4”) by unscrewing each bolt only one turn (anti-
clockwise) before proceeding to the next bolt. This is necessary to release the forces in the
disc spring stacks evenly. (See figure 9, where the 6 bolts have been unscrewed.)
Page 29
Figure 9: Showing the 6 bolts in the retainer.
c. Remove the retainer from the piston. Although it will make removal easier by inserting a small
wedge between the retainer and brake housing, the retainer should come out of the piston
relatively easy, and no presses are needed for this operation.
d. Remove the piston by hand from the brake housing. Take care not to bend or force the wear
indicator pin, as it may damage the wear indicator pin hole in the brake housing (The wear
indicator pin hole is a sealing surface). The housing should now appear as indicated in figure
10.
Figure 10: Brake housing with spring packs assembled on guide pins.
e. The wear indicator pin can now be removed from the piston.
Page 30
f. Remove the spring packs from the guide pins in the brake housing. To test if they are still
acceptable, keep the springs in stacks of 25 and measure the free height when these stacks
have been placed on a level flat surface. See section 3.1 for acceptance criteria for the disc
springs.
g. If necessary, remove the 9 guide pins from the brake housing.
h. Remember to remove the 2 O-rings that seal the hydraulic ports between the brake housing
and the retainer. See figure 11 for an illustration of the O-rings.
O-ring sealing
hydraulic port
Figure 11: Showing the O-ring in position on the hydraulic port
3.2.2 Re-Assembly instructions

(For the following discussion, please also refer to figure 1)
a. Put the brake housing (item 1, figure 1) on a suitable dry, clean surface with the side where the
brake disc assembly mounts, in the upward direction.
b. Apply Loctite 270 on the thread of each guide pin (item 6, figure1) and screw into the 9 holes in
the brake housing. Torque to 20 N.m.
c. Assemble a spring stack with 25 disc springs (item 3, figure 1) on each guide pin. The springs
must be positioned back to back as indicated in figures 2 and 10.
d. Carefully assemble the piston O-ring and backup ring in the groove on the piston. Ensure that
the sequence of the O-ring and backup ring is as indicated in figure 1. Mount the O-ring and
backup ring on the retainer as well. Ensure that the sequence of the O-ring and backup ring is
correct. Lubricate the O-rings with oil.
Page 31
e. Two small O-rings (item 13 and another one not shown in figure 1) ensure a tight seal between
the hydraulic ports on the brake housing and the bottom of the retainer. Wet the two O-rings
with oil and assemble them into the brake housing as shown in figure 11.
f. Without putting Loctite on the thread of the wear indicator pin, screw it into the rear of the
piston in the threaded hole provided for it. The wear indicator pin is only used for alignment
now, and will be removed again.
g. Apply a small quantity of copper based grease to the 9 holes in the piston and position the
piston on the disc spring stacks so that the wear indicator pin lines up with the hole provided in
the brake housing.
h. Take the retainer (with the O-ring and backup ring mounted) and position it so that the two
holes on the bottom of the retainer line up with the two hydraulic ports and O-rings on the brake
housing. Press it down by hand or tap it lightly with a rubber hammer. The brake assembly
should now look like figure 12.
Figure 12: Brake housing with the piston and retainer assembled.
i. Apply Loctite 270 on the threads of the bolts and again ensure that the hydraulic ports are
properly lined up. As can be seen in figure 9, there is enough thread on the bolts to start taking
up the disc spring forces. Screw the 6 bolts with Nordloc® washers in until each bolt head
touches the retainer. Now, rotate each bolt one turn before proceeding to the next bolt. This is
to evenly pull up the retainer to the brake housing against the force of the springs. Proceed
until the retainer is against the brake housing and torque the 6 bolts (7/16” UNC x 4”) long bolts
to 60 N.m.
Page 32
j. Plug the two air supply holes on the brake housing, as they will not be used on the new brake
design. Also plug the two hydraulic ports on the brake housing to keep dust and dirt out. The
brake assembly is now ready for assembly onto an axle.
3.2.3 Testing
The operation of the brakes in the brake housing can be tested after assembly or repair. The hand
pump provided for towing the vehicle can be used for this.
After the disc brake pack is fitted to the vehicle, and a pressure of 8.5 MPa applied to the brake
circuit, the brakes should be fully released.
The travel between brakes applied and brakes fully released can easily be measured between the
brake housing and wear indicator pin. This distance should approximately be:
TRAVEL = (42.26mm – brake pack thickness in mm) + 2.0 mm
As shown, the travel depends on the thickness tolerance and the amount of wear on the brake disc
pack.
3.2.4 Wear pin indicator replacement
IMPORTANT NOTE:
The amount of wear on the disc brake pack can only be determined with the emergency/park
brakes fully applied!
If the wear indicator pin is flush with the surface on the brake housing, the disc brake pack has
worn 4.83 mm and needs replacement. For instructions on how to replace the disc brake pack,
please see the appropriate Barlows/Caterpillar manual.
When the disc brake pack has been replaced, and the brake housings fitted to the machine, the
brakes must be released. To do this, chock the wheels and either use the hand pump (for towing)
or start and idle the machine. When the brakes are released, enough material from the old wear
indicator pin will be protruding from the brake housing to remove the pin.
Page 33
Wear indicator setting tool

(It can also be in the shape
of a round disc ring 4.83
mm thick)
Figure 13: Showing the wear indicator setting tool in position.
Remove the old wear indicator pin and screw in a new wear indicator pin without applying Loctite
to the threads. Apply the emergency/park brakes and mark the position (with the supplied wear
indicator setting tool) where the wear indicator pin must be cut off. Please see figure 13.
Remove the wear indicator pin and cut or grind it off as marked. Now, apply Loctite 270 to the
thread of the wear indicator pin and screw it into the piston. Remember to oil the O-ring when
inserting the wear indicator pin. The tip of the wear indicator pin should protrude approximately
4.83 mm from the brake housing. (Measured with the emergency/park brakes applied)
3.2.5 Seal Replacement

A seal kit, NCS item no. 103081 was created with the following items:
O-ring (retainer), NCS part no. 540314410084

O-ring (piston), NCS part no. 540313430057
Backup ring (piston), NCS part no. 54051450160025
Backup ring (retainer), NCS part no. 54051350145017
2 off hydraulic port O-ring seals, NCS part no. 540300920262
1 off wear indicator pin o-ring seal, NCS part no. 540300870178
Wear indicator pin, part no. 102821
Wear indicator setting tool, part no. 102935
Piston guide ring, part no. 103079
Apart from the indicator pin, all of the seals in the kit must be replaced at the same time.
Disassembly is described in section 3.2.1. Take care to ensure that the sequence of O-ring and
backup ring is as indicated in Figure 1.
3.2.6 Spring Pack Replacement
Page 34
If the free height of the disc spring packs is less than 74.8 mm, permanent deformation has
occurred and the springs need replacement.
If the disc springs (NCS item no. 100234) needs replacement, all of the springs in a brake housing
must be renewed at the same time. The amount of disc springs in a housing is 9 x 25 = 225.
To disassemble, follow the procedure described in 3.2.1.
3.3 Re-ordering information

Many of the hydraulic components such as hoses, fittings and standard valves can be
ordered directly from local suppliers such as Parker, Commercial, SMC etc. Any component
can also be ordered directly from NCS Engineering.
All components can be ordered directly from NCS Engineering. Please fax the ordering
information to:
NCS Engineering
Att: Mr C Wilcock (Sales Manager)
+27 11 814 1145
Please state the part no. and product description clearly.
Page 35
4. TROUBLESHOOTING
The following troubleshooting procedures are intended as a guideline for identifying possible
problems. The possible modes of failure associated with the brakes are discussed individually.
Before any troubleshooting is undertaken, please ensure the following:

• The hydraulic oil level is adequate.
• The compressed air supply to the brake system is sufficient.
• The pressure gauge in the cab is working correctly.
• The machine is parked on a level surface in a safe area (as far as possible)
The assumptions mentioned with the discussion of each mode of failure should be confirmed
before doing further troubleshooting. Experience has taught that wrong assumptions can cause a
lot of wasted time and effort.
The letter indicated next to valve descriptions correspond to letters on parts list 103744.
SAFETY WARNING!
Take care not to disconnect hoses or pipes under pressure. When needing to disconnect as part
of the troubleshooting procedure, slowly undo the fitting until oil or air flows from the connection. It
is unnecessary to disconnect completely.
DO NOT DISCONNECT PRESSURISED AIR LINES COMPLETELY. THIS CAN CAUSE
INJURY.
4.1 Engine starter does not operate

Check that:
1. There is adequate air pressure in the pneumatic circuit.
2. Neutral is selected on the gear lever.
3. The cabin door is closed.
Possible cause: Remedy:

Airflow to the start Inspect and/or repair hoses and couplings.
interlock valve “G”
interrupted.
Start interlock valve If neutral is selected and the hose between the
“G” faulty. emergency/park brake valve and “G” is disconnected, a
clearly audible noise from the exhausting air must be heard,
otherwise the valve can be faulty.
Page 36
4.2 Brakes do not release

Two scenarios where the brakes do not release will be discussed, namely:
A. Brakes do not release while the pressure gauge in the cab indicates lower than hold-off
pressure.
B. Brakes do not release while the pressure gauge in the cab indicates normal hold-off pressure.
4.2.1 Scenario A: Hold-off pressure low

Check that:
1. The tests are done with the engine at half revs.
2. The accumulator dump valve (4) is closed.
3. The cabin door is closed.
4. The steering wheel has been turned a few times before commencing with the tests.
5. There are no leakages from any hoses.
POSSIBLE CAUSE REMEDY
4.1. Pneumatic door, switch faulty. Replace
4.2.1. Steering pump failure Check that steering system is operative.

Steering pump coupling The steering pump supplies the
Mechanical drive failure brake hold off pressure as well as
steering.
4.2.1.1. Steering pump failure worn condition The pressure gauge in the cockpit shows accumula-
tor charge pressure. If the pressure does not build
15Mpa in less than 5 seconds there is a problem
with the pump or mechanical drive from the engine.
The ACC port on valve A is connected to control

Panel guage. Use this guage for the test. Apply the brakes
4.2.1.2. Accumulator failure fully for a few times. If the pressure drops to below
12Mpa on the first brake application, the accumulator
has either lost it's gas pre charge or has failed. (SEALS)
Remove minimess hose from ACC port on valve A and connect to

GP port on the valve. If the pressure shown on the gauge in the
4.2.1.3. Accumulator charge valve A failure cockpit does not immediately drop to below 1.5MPa after
charging to 15Mpa, the valve is faulty.
IMPORTANT: Before working on the system, discharge accu-
mulator by opening ball valve 46. Remove unloader cartridge
item 2 on A and check the "o"- rings and back-up rings
.
4.2.1.4 Tramming foot brake valve faulty IMPORTANT: For this test to be carried out,
Page 37
adequate pneumatic pressure to valve G is assumed.

Remove hose from port T on valve E, if there is an
excessive amount of oil leaking through, replace
tramming foot brake valve cartridge.
4.2.1.5 Service foot brake valve faulty As above.
Valve F
After releasing the brakes manually the gauge
mounted infront of the operator will indicate low
pressure to brakes.
4.2.2 Scenario B: Adequate hold-off pressure

Assumptions:
1. The vehicle is positioned on a level surface.
2. The following tests are done at half revs.
3. The pressure reading in the cab is more than minimum hold-off pressure.
POSSIBLE CAUSE REMEDY
4.2.2.1. If pressure on gauge is indicating adequate hold off

pressure after releasing the brakes manually, then
proceed with next 2 steps.
4.2.2.2. Faulty pilot interlock valve G Release the park brake button manually. If the
brakes don't apply the valve must be replaced.
Page 38
4.3 Brakes do not apply
4.3.1 Emergency brakes
CAUTIONARY NOTE:
Check the operation of the emergency brakes before using the machine

Disc packs worn Check the wear on the disc packs at the indicator pin.
Replace if necessary.
Hose or pipe blocked Disconnect the hoses from the brake housings to test
or pinched whether it is a mechanical or hydraulic fault. If the brakes
apply it is a hydraulic fault.
If the pipes or hoses are blocked off in the released position,

the brakes may not apply. Check all hoses and pipes for
damage and/or blockage. Blockage can be checked by
disconnecting the hoses from the brake housing and
releasing the brakes. If oil flows from the hose there is no
blockage.
Faulty emergency Undo the air line from the pressure supply port on the
brake valve emergency brake valve. If the emergency brakes do not
apply, the valve must be replaced.
4.3.2 Service brakes

Disc packs worn Check the wear on the disc packs at the indicator pin.
Replace if necessary.
Hose or pipe blocked Disconnect the hoses from the brake housings to test
or pinched whether it is a mechanical or hydraulic fault. If the brakes
apply it is a hydraulic fault.
If the pipes or hoses are blocked off in the released position,

the brakes may not apply. Check all hoses and pipes for
damage and/or blockage. Blockage can be checked by
disconnecting the hoses from the brake housing and
releasing the brakes. If oil flows from the hose there is no
blockage.
Faulty foot brake Disconnect the hose from port “T” on the valve. Oil must flow
valve (“E” and “F”) from this line when the foot brake is depressed. If not,
replace.
Page 39
4.4 Gears cannot be selected

If the pneumatic switch (valve) on the tramming brake is faulty, problems may be experienced in
selecting gears.

Faulty pneumatic Check the operation of the valve by disconnecting the hose
valve on tramming between the valve and the transmission lock. There should
brake valve “E” be no air flowing through the valve on the tramming brake
valve when the tramming brake is not operated.
Faulty directional
control valve “G”
4.5 Hydraulic system overheats

Overheating of the hydraulic system can be caused by various faults in any of the individual
functions that are supplied from the common reservoir. The following discussion only concerns
overheating due to the brake system.

Faulty charge valve Check as per section 4.2.1
Leakage in system Leakage in the system will cause the pump to operate much
longer than normal. Although this can theoretically cause
overheating, the chances are that the loss of oil will be
noticed before this becomes a problem.
------------------------------- End of document -----------------------
Page 40

Wright LHD 356 Owners Manual-Revision L BRAKES

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What are the different types of brakes described in the manual?

What are the different types of brakes described in the manual?

What are the maintenance procedures and schedules for the brakes?

What are the maintenance procedures and schedules for the brakes?

Caterpillar Wright LHD 356 Coal Machine: Brake System Owner’s Manual

Document No: 0023.D30

NCS Engineering Revision L, 16 MARCH 2005

O-rings for sealing the hydraulic ports (540300920262)

Piston backup ring (54051450160025)

Retainer O-ring (540314410084)

Retainer backup ring

Guide pin (103052)

Brake disc assembly

Figure 1: Exploded view of one brake housing with associated components.

Table 1: Item list for Figure 1

Figure 2: A spring pack with 25 discs springs back-to-back.

Hydraulic components list:

Barlows Wright LHD 356

ITEM DESCRIPTION PART NO WHERE USED QTY

32 STRAIGHT THREAD ELBOW 0606 C5OX BRAKES 4

36 METRIC SLEEVES 10 MM TX FOOT BRAKE VALVES 4

BARLOWS WRIGHT LHD 356 103744

ITEM DESCRIPTION NCS p/n OEM p/n WHERE USED QTY

BARLOWS WRIGHT LHD 356 103743

ITEM DESCRIPTION NCS p/n OEM p/n WHERE USED QTY

BARLOWS WRIGHT LHD 356 103742

15 M8 x 30 SET SCREW HT 510308030 CHANGE OVER MANIFOLD 2

1.2.1 Hydraulic valve description:

A SINGLE ACCUMULATOR CHARGE VALVE; NCS P/N 101279

1) Cartridge sensing valve MODDPS2-16VF080

2) Seal kit for sensing valve SK3-16-3S

Note: Seal kits are only supplied as complete kits

3) Cartridge unloader relief valve 1PUL60

4) Seal kit for unloader relief valve SK10-3P

ITEM DESCRIPTION PART No. QTY

Note: Seal kits are only supplied as complete kits

5) Cartridge check valve MOD CV3-10P010

6) Seal kit cartridge check valve SK10-2

Note: Seal kits are only supplied as complete kits

B RELIEF VALVE AND SUB PLATE; NCS p/n 103735

1) Cartridge relief valve MOD RV1-10-1036

2) Seal kit for relief valve SK10-2

Note: Seal kits are only supplied as complete kits

C HAND PUMP ; NCS p/n 101272

D ACCUMULATOR; NCS p/n 103736

1) Accumulator 5.5 liters ACC-A-5.5C

The accumulator is pre-charged with nitrogen to a pressure of 9 Mpa.

Note: Accumulators should only be opened and serviced by the manufacturer.

E FOOT BRAKE VALVE (TRAMMING); NCS p/n 103737

1) Cartridge foot brake valve BRCIPD20SP105

Note: Cartridge parts as per above list can be supplied separately.

2) Seal kit foot brake valve 1SK339

ITEM DESCRIPTION PART No. QTY

Note: Seal kits are only supplied as complete kits.

3) Pneumatic switch for foot brake valve VM430-01-075

F FOOT BRAKE VALVE (SERVICE BRAKES): NCS p/n 103738

29 PEDAL REF ONLY 1

9 14 NUT HEX M8 51111600 1

6 10 WASHER FLAT M10 51211020 8