Service Training

SEEV2629
July 1997

STUDENT MATERIALS

BRAKE VALVE

PARKING/SECONDARY
SOLENOID VALVE

REDUCING
SPOOL
ACCUMULATOR
PISTON

PROPORTIONAL
SOLENOID PILOT SHUTOFF
VALVE VALVE

PART OF TECHNICAL INSTRUCTION MODULE SEGV2629

ELECTRONICALLY CONTROLLED
BRAKE SYSTEM
D6R/D7R TRACK-TYPE TRACTORS
WITH DIFFERENTIAL STEERING
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MODULE OBJECTIVES

• Slides: 7 - 11 1. Given class notes, the Lab A Worksheet, and a Track-type Tractor
• Lab: A equipped with the electronically controlled brake system, locate and
identify the following components: brake valve, parking brake
switch, service brake sensor, service brake switch, electronic control
module, brake pressure taps, and parking brake and secondary brake
solenoid valves.

• Slide: 12 2. Given class notes, all reference material and a hydraulic schematic,
• Posttest: Section I identify the following components during a posttest: brake valve
proportional solenoids, pilot valve, accumulator piston, reducing
spool, shutoff valve, and parking brake and secondary brake solenoid
valves.
• Slide: 12 3. Given class notes and all reference material, explain the function of
• Posttest: Section II the following components during a posttest: brake valve proportional
solenoids, pilot valve, accumulator piston, reducing spool, shutoff
valve, and parking brake and secondary brake solenoid valves.

• Slides: 12 - 18 4. Given class notes, the Lab B Worksheet, and a brake valve, locate and
• Lab: B identify the following components: brake valve proportional
solenoids, pilot valve, accumulator piston, reducing spool, shutoff
valve, valve body, manifold, and parking brake and secondary brake
solenoid valves.

• Slides: 19 - 21 5. Given class notes and all reference material, explain the operation of
• Posttest: Section III the brake valve during a posttest.

• Slides: 20 - 21 6. Given a brake valve hydraulic system schematic, trace the flow of oil
• Posttest: Section IV through the system during a posttest for the following conditions:
service brakes released and service brakes engaged.

• Lab: C 7. Given the appropriate service manuals, the appropriate test equipment
and the Lab C Worksheet, test the brake valve pressures and calibrate
the brake valve.

• Lab: D 8. Given class notes, all reference material, the appropriate test
equipment, and the Lab D Worksheet, diagnose and repair a reported
complaint in the brake system during a lab exercise.
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Lab A: Brake System Component Identification

BACKGROUND This lab will help you gain familiarity with the machine and locate
INFORMATION components and service points.

MATERIALS NEEDED One of the following Operation and Maintenance Manuals:

D6R Operation and Maintenance Manual SEBU6887

D7R Operation and Maintenance Manual SEBU6890

D6R or D7R Track-type Tractor

Lab A Worksheet
Mechanic’s Tool Box with hand tools

Before operating the machine, perform a 10 hour or daily inspection,

which includes checking fluid levels as specified in the Operation and
Maintenance Manual.

EXERCISE Remove the side panels and/or cab floor plates as needed.

Locate the brake system components on the machine and complete the
Worksheet.

Operate the machine.

Allow the machine to reach normal operating temperatures.

Operate the steering controls noticing the machine reaction when

stopping.

Demonstrate the correct machine shutdown procedures.

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Lab A: Brake System Component Identification Worksheet

D6R/D7R Track-type Tractors

Directions: Use this worksheet during the slide presentation to take notes on the function and location
of each component. During the lab exercise, match the tag attached to the component with the correct
name.

_____ Brake valve

Location:
Function:

_____ Brake pressure taps

Location:
Function:

_____ Parking brake switch

Location:
Function:

_____ Service brake sensor

Location:
Function:

_____ Service brake switch

Location:
Function:

_____ Electronic control module

Location:
Function:

_____ Parking brake and secondary brake solenoid valves

Location:
Function:
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Lab B: Brake Valve Component Identification

BACKGROUND This lab allows you to gain hands on experience with the brake valve
INFORMATION components.

MATERIALS NEEDED Brake Valve

Mechanic’s Tool Box with hand tools
Lab B Worksheet
Class Notes

GROUP EXERCISE Disassemble the brake valve.

Lay out all components.

Identify and state the function of the following components using the Lab
B Worksheet:

- proportional solenoids
- pilot valve
- accumulator piston
- reducing spool assembly
- shutoff valve assembly
- manifold and valve body
- parking brake and secondary brake solenoid valves

Assemble the brake valve.

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Lab B: Brake Valve Component Identification Worksheet

Directions: Use this worksheet during the slide presentation to take notes on the function and location
of each component. During the lab exercise, match the tag attached to the component with the correct
name.

_____ Proportional solenoids

Location:
Function:

_____ Pilot valve

Location:
Function:

_____ Accumulator piston

Location:
Function:

_____ Reducing spool assembly

Location:
Function:

_____ Shutoff valve

Location:
Function:

_____ Manifold

Location:
Function:

_____ Valve body

Location:
Function:

_____ Parking brake and secondary brake solenoid valves

Location:
Function:
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Lab C: Testing and Adjusting

BACKGROUND This lab will allow you to gain familiarity performing system tests, to
INFORMATION determine if the machine is operating within specifications, and adjust
system pressures using the service manual.

MATERIALS NEEDED Power Train Electronic Control System Service

Manual SENR8367
Caterpillar Monitoring System SENR6717

One each of the following service manual modules depending on the

machine model used:

D6R Power Train Specifications SENR8354

D6R Power Train Systems Operation SENR8355
D6R Power Train Testing and Adjusting SENR8356
D6R Electrical System Schematic SENR8362
D7R Power Train Specifications SENR8339
D7R Power Train Systems Operation SENR8340
D7R Power Train Testing and Adjusting SENR8341
D7R Electrical System Schematic SENR8362

Lab C Testing and Adjusting Worksheets

D6R or D7R Track-type Tractor
6V7830 Tetragauge
4C8195 Control Service Tool
Mechanic's Tool Box with hand tools

EXERCISE • Record the pressure specifications from the appropriate service

manual module.

• Remove the side panels and/or cab floor plates as needed.

• Perform all brake pressure tests.

• Test the right and left brake low pressure and adjust the right and left
brake using the procedures in the Power Train Electronic Control
System Service Manual (Form SENR8367). Enter the correct
calibration specifications from the service manual on the worksheet.
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Lab C: Testing and Adjusting Worksheet

Machine Model Dealer

Name/Code Customer
Machine PIN (S/N)+Config Job
Transmission S/N Application
Engine S/N Date
S.M.H Service Mechanic

SYSTEM CHECK

Visual Checks: Oil Level OK Oil Type OK

Air/Water in oil Oil Leaks
Abrasives in oil

PARKING BRAKE ON

PRESSURE TEST TAP XMSN GEAR ENGINE SPEED

LOW IDLE HIGH IDLE
SPEC ACTUAL SPEC ACTUAL
Left Brake B1 N N/A N/A
Right Brake B2 N N/A N/A

BRAKES OFF

PRESSURE TEST TAP XMSN GEAR ENGINE SPEED

LOW IDLE HIGH IDLE
SPEC ACTUAL SPEC ACTUAL
Left Brake B1 N
Right Brake B2 N

SERVICE BRAKE ON

PRESSURE TEST TAP ENG SPEED XMSN GEAR

NEUTRAL 3F STALL
SPEC ACTUAL SPEC ACTUAL
Left Brake B2 High Idle
Right Brake B2 High Idle

CALIBRATION SPECIFICATIONS

PRESSURE TEST TAP ENG SPEED XMSN GEAR PARKING SPEC ACTUAL
BRAKE
Left Brake C1 High Idle N OFF
Right Brake C2 High Idle N OFF
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Lab D: System Troubleshooting

BACKGROUND This lab will help reinforce the operation of the brake system, the power
INFORMATION train oil system, the electrical system and introduce you to
troubleshooting.
MATERIALS NEEDED
Power Train Electronic Control System Service
Manual SENR8367
Caterpillar Monitoring System SENR6717

One each of the following service manual modules depending on the

machine model used:

D6R Power Train Specifications SENR8354

D6R Power Train Systems Operation SENR8355
D6R Power Train Testing and Adjusting SENR8356
D6R Electrical System Schematic SENR8362
D7R Power Train Specifications SENR8339
D7R Power Train Systems Operation SENR8340
D7R Power Train Testing and Adjusting SENR8341
D7R Electrical System Schematic SENR8362

Lab D Troubleshooting Analysis Worksheet

D6R or D7R Track-type Tractor
6V7830 Tetragauge
4C8195 Service Tool
Mechanic's Tool Box with hand tools
EXERCISE
Review the reference materials and list the possible problems that could
be occurring in the brake electrical and hydraulic systems.

Determine the tests required to identify problems in the system.

Troubleshoot the system problems.

Discuss the troubleshooting results at the end of the lab and be prepared
to answer the following questions:
What symptoms were identified?
What tests were made?
What was the problem?
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Lab D: Troubleshooting Analysis Worksheet

STEP 1: Verify problem

STEP 2: State the problem

STEP 3: Visual inspection

STEP 4: List all possible causes

1.

2.

3.

4.

STEP 5: Devise and run checks/record data

1.

Result:

2.

Result:

3.

Result:

4.

Result:

STEP 6: Isolate and eliminate

STEP 7: Repair machine

STEP 8: Verify fix

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BRAKE SYSTEM CASE STUDY

DIRECTIONS Use your class notes, the provided reference material and a
Troubleshooting Analysis Worksheet to complete this case study.

The following case study is based on a possible field problem.

SITUATION The operator of a D7R Track-type Tractor with an electronically

controlled brake system reported to his supervisor that the machine was
veering to the left during straight travel. He told the supervisor that when
he applied the brakes, the machine would turn sharply to the left before
stopping.

The maintenance supervisor knew that the tractor was equipped with the
Caterpillar Monitoring System which would reveal some diagnostic
information. The supervisor connected the 4C8195 Control Service Tool
to the monitor service connector at the fuse panel. He put the monitoring
system in Service Mode (Mode 3). The monitoring system display read
"- - -" indicating no service codes were logged.

The supervisor told the technician to perform the left brake adjustment
procedure using the Power Train Electronic Control System Service
Manual. After completing the brake adjustment and driving the machine,
machine operation appeared normal. The problem returned shortly after
the operator began working.

The maintenance supervisor decided to call his Caterpillar dealer service

department to inform the dealer of the situation. The dealer field
supervisor relayed the information to a field serviceman and sent him to
the job site to investigate the problem.

QUESTIONS Could the customer contact in the dealer service department make any
suggestions to the customer before sending a serviceman to the job site?

Could the dealer field supervisor make any suggestions to the field
serviceman before sending him to the job site?

What additional checks could have been performed before adjusting the
brake?

What problems can cause the machine to steer left during straight travel?
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Electronically Controlled Brake System Posttest

I. Directions: Match the components with the associated numbers.

Identify Components

Proportional Solenoid

Pilot Valve

Accumulator Piston

Reducing Spool Assembly

Shutoff Valve Assembly

Parking Brake/Secondary Brake Solenoid

BRAKE VALVE
1

2 3

5 6
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II. Directions: Match the component to its primary function.

Regulates the flow of oil to the brake 1. Proportional Solenoid

Controls the pilot pressure in the brake valve 2. Pilot Valve

Direct oil to drain to fully engage the brakes when 3. Accumulator Piston
the parking brake switch is energized or when the
brake pedal reaches 75% of its travel. 4. Reducing Spool Assembly

Regulates pilot pressure in the pilot pressure chamber 5. Shutoff Valve Assembly

Allows brake pressure to drain gradually if pilot 6. Parking and Secondary Brake Valves
valve pressure drops suddenly

Helps modulate pressure in the brake

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III. Directions: Circle or underline the correct answer.

1. When the operator calls for increased brake engagement, the ECM__________________________.

a. raises current to the solenoid

b. lowers current to the solenoid
c. de-energizes the solenoid
d. energizes the solenoid

2. What separates the pilot pressure from the supply pressure in the brake valve?

a. Screened orifice
b. Poppet
c. Filter
d. Check valve

3. When the brake pressure set by the pilot pressure is achieved, the reducing spool assembly lets only
enough oil go into the __________________ to make up for leakage and keep pressure on the brake
constant.

a. pilot pressure chamber

b. supply oil chamber
c. brake chamber
d. pressure feedback chamber

4. Pressure in the pilot pressure chamber increases until it can force open a ___________ in the pilot
valve.

a. screened orifice
b. poppet
c. filter
d. check valve

5. The reducing spool assembly directs oil into the brake when the pilot pressure in the pilot pressure
chamber is _____________ the brake pressure in the pressure feedback chamber.

a. equal to
b. greater than
c. less than

6. Which of the following components connects the secondary brake solenoid directly to the battery
when the brake pedal reaches near full travel?

a. Service brake switch

b. Service brake sensor
c. Parking brake switch
d. ECM
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IV. Directions: Using the two schematics which follow, trace the oil flow through the brake valve
when the service brakes are RELEASED and when the service brakes are ENGAGED.

The color codes are:

Red - Pump supply pressure

Red and White Stripes - Reduced pressure

Orange - Torque converter oil

Green - Open to drain

Yellow - Activated valve envelopes or moving parts

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SEEV2629

BRAKE VALVE
BRAKES RELEASED

BRAKE ACCUMULATOR
SOLENOIDS PISTON
- 16 -

TO TO
LEFT RIGHT
BRAKE BRAKE

PARKING SECONDARY
SUPPLY OIL REDUCING BRAKE BRAKE
SPOOL SOLENOID SOLENOID
Student Materials
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SEEV2629

BRAKE VALVE
BRAKES ENGAGED

BRAKE ACCUMULATOR
SOLENOIDS PISTON
- 17 -

TO TO
LEFT RIGHT
BRAKE BRAKE

PARKING SECONDARY
SUPPLY OIL REDUCING BRAKE BRAKE
SPOOL SOLENOID SOLENOID
Student Materials