966C WHEEL LOADER 30K02369-UP (MACHINE) POWERED BY 3306 ENGINE(SE...

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Producto: WHEEL LOADER

Modelo: 966C WHEEL LOADER 30K
Configuración: 966C WHEEL LOADER 30K02369-UP (MACHINE) POWERED BY 3306 ENGINE

Operación de Sistemas
966 WHEEL LOADER AIR SYSTEM AND BRAKES
Número de medio -REG01114-01 Fecha de publicación -01/05/1973 Fecha de actualización -10/10/2001

Systems Operation

Introduction
NOTE: For Specifications with illustrations, make reference to AIR SYSTEM AND BRAKES
SPECIFICATIONS FOR 966 WHEEL LOADER, Form No. REG01415. If the Specifications in Form
REG01415 are not the same as in the Systems Operation and the Testing and Adjusting, look at the
printing date on the back cover of each book. Use the Specifications in the book with the latest date.

Air System And Brakes

BRAKE ASSEMBLY
1. Brake chamber. 2. Push rod. 3. Shaft.

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BRAKE AIR SYSTEM SCHEMATIC

1. Brake chambers (four). 2. Quick release and holding valves (two). 3. Air compressor. 4. Air compressor governor. 5. Air
pressure gauge. 6. Line to transmission neutralizer valve. 7. Left brake control valve. 8. Double check valve. 9. Right brake
control valve. 10. Emergency and parking brake control valve. 11. Safety relief valve. 12. Air reservoir. 13. Horn valve. 14.
Stop light switch. 15. Double check valve.

Each wheel has an expanding-shoe type brake actuated by a brake chamber. Push rod (2), extended by air
pressure in brake chamber (1) or by force of the protective brake apply spring, rotates shaft (3). When the
shaft rotates, a cam on the hidden end of the shaft forces the brake shoes against the brake drum to apply
the brakes. Brake chamber design provides for:

1. Service Brakes. Metered air pressure from the foot control valves controls the amount of brake
application as determined by the operator.
2. Emergency Brakes. Automatic four-wheel braking is provided when system air pressure is 40 psi
(2.8 kg/cm2) or less. Spring force applies the brakes.

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3. Parking Brakes. When system air pressure is 40 to 120 psi (2.8 to 8.4 kg/cm2), a manually-
operated push-pull valve provides full brake application. Spring force applies the brakes.

Brake Air System

Pressure air for the brake system is supplied by air compressor (3). Air compressor governor (4) senses
system pressure and maintains air pressure in air reservoir (12) at 100 to 120 psi (7.0 to 8.4 kg/cm2).
Safety relief valve (11) limits system pressure to 150 psi (10.5 kg/cm2).

Air reservoir outlet provides air at system pressure to the air horn valve (13), air gauge (5), inlet ports of
foot control valves (7) and (9) and the emergency and parking control valve (10) inlet port.

As long as the knob on the emergency and parking brake control valve (10) is not pushed in, the
protective brake springs will not be compressed and the brake chambers will not release the wheel brakes.
If either brake treadle is depressed before the parking brakes are released, double check valve (15)
prevents emergency brake application plus service brake application. This prevents damage to the brake
slack adjusters and brake camshafts.

After the air reservoir is charged to operating pressure and the knob on the emergency and parking brake
control valve is pushed in, pressure air enters the protective brake chamber of each brake chamber to
release the parking brakes.

If pressure in the main supply circuit falls below approximately one third of full system pressure, the
pressure differential across the emergency and parking brake control valve will allow the spring to close
the valve, thus sealing off pressure air from the quick release and holding valves (2). This will cause the
quick release and holding valves to exhaust the air in the protective brake chambers. The brakes remain
applied until sufficient pressure is built up in the protective brake chambers to move the pistons against
the force of the brake springs.

During a service brake application (parking brake released), pressure air is directed from either brake
control valve to double check valve (8). If the left brake pedal is depressed, the transmission is neutralized
through line (6) and the service brake is applied.

NOTE: The transmission neutralizer control valve blocks the oil supply to the transmission directional
valve and dumps the oil from the engaged directional clutch, thus neutralizing the transmission.
Depressing the right brake pedal does not neutralize the transmission.

If the right brake pedal is depressed only the service brakes are applied. Pressure air travels from double
check valve (8) to the service brake air chambers of each brake chamber. (1). Pressure air from the brake
control valve is prevented from passing through double check valve (15) because full system pressure acts
on the opposite side of the shuttle.

Brake Control Valve

Two brake control valves are used in the braking system. The operation is the same for each valve.

When the brake control valve treadle is depressed, a force is exerted on seat (1). The force compresses
rubber spring (2) and moves piston assembly (3) downward. The exhaust valve seat (7) contacts and
closes exhaust port (12) in valve (9). Continued downward movement of the piston assembly pushes the
valve (9) off inlet valve seat (8). Pressure air from inlet port (13) passes around the valve and out through
outlet port (5). Air travels to the double check valve, air chamber and transmission neutralizer control

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valve when the left brake treadle is depressed, or to the double check valve and air chamber when the
right brake treadle is depressed.

BRAKE CONTROL VALVE

1. Seat. 2. Rubber spring. 3. Piston assembly. 4. Retainer. 5. Outlet port. 6. Spring. 7. Exhaust valve seat. 8. Inlet valve seat. 9.
Valve. 10. Valve body. 11. Valve spring. 12. Exhaust port. 13. Inlet port. 14. Exhaust diaphragm.

When the air pressure below piston assembly (3) becomes greater than the force exerted above the piston,
the piston lifts sufficiently to permit valve (9) to move upward and seat. This blocks off further supply of
pressure air. Piston assembly (3) remains seated against valve (9), preventing any loss of air pressure
through exhaust port (12). Thus, the brake control valve is in a balanced position and air pressure is held
in the lines and air chambers.

If the treadle is partially raised, mechanical force above piston assembly (3) is decreased. The greater
force below the piston assembly, exerted by pressure air and spring (6), lifts the piston assembly,
unseating it from valve (9). Pressure air in the lines and air chambers is permitted to escape past exhaust
diaphragm (14) until forces above and below the piston are balanced. When the treadle is completely
raised, piston assembly (3) will remain unseated from valve (9), exhausting all pressure air to atmosphere
and releasing the brakes. Valve (9) is held in its seat by valve spring (11).

Emergency And Parking Brake Control Valve

With the air reservoir discharged, the emergency and parking brake control valve will be in the released
position. [knob (1) pulled out]. Valve (8) will be seated against upper face of valve body (2) sealing off
pressure air supply to outlet port (5), and exhaust port (7). Air pressure in the reservoir is allowed to build
to the operating range.

When the air pressure gauge registers in the operating range, the operator must push in and hold knob (1)
on the emergency and parking brake control valve to release the parking brakes. Pressure air from the

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reservoir enters the valve through inlet port (6), passes through orifice (4), and outlet port (5) to the
protective brake chambers, releasing the parking brakes. Air pressure then holds valve (8) seated over
exhaust port (7).

FLOW OF AIR (BRAKES APPLIED)

1. Knob and pin assembly. 2. Valve body. 3. Spring. 4. Orifice. 5. Outlet port (to protective brake chambers). 6. Inlet port
(from air reservoir). 7. Exhaust port (to atmosphere). 8. Valve assembly.

The emergency and parking brake control valve can be actuated either manually or by a pressure
reduction in the air system. To actuate the valve manually, the operator pulls knob (1) out to exhaust the
pressure air and apply the emergency and parking brakes.

FLOW OF AIR (BRAKES RELEASED)

1. Knob and pin assembly. 2. Valve body. 3. Spring. 4. Orifice. 5. Outlet port (to protective brake chambers). 6. Inlet port
(from reservoir). 7. Exhaust port (to atmosphere). 8. Valve assembly.

In the event of an air system failure or the pressure drops below 40 ± 5 psi (2.8 ± 0.4 kg/cm2), spring (3)
will unseat valve (8) exhausting pressure air to the atmosphere and will apply the emergency and parking
brakes.

Air Brake Chamber

Each brake chamber has two air chambers (1) and (5). Both chambers are supplied by the brake air system
supply. The illustration shows the protective chamber (5) pressurized and the service brake chamber (1)
unpressurized. When the air system is discharged (empty), the air in chamber (5) is exhausted. Spring (3)
moves piston (4) and extends the push rod (7) to apply the brakes.

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BRAKE CHAMBER
1. Service brake chamber. 2. Diaphragm. 3. Protective brake apply spring. 4. Protective brake piston. 5. Protective brake
chamber. 6. Brake return spring. 7. Push rod.

The brakes stay applied until the air system is charged and the emergency and parking brake control knob
(8) is pushed in. The protective brake air chamber (5) then fills at system pressure, compresses the spring
(3) and retracts the push rod (7) to release the brakes.

BRAKE CHAMBER
1. Service brake chamber. 5. Protective brake chamber.

When the foot control valve treadle is depressed, modulated air pressure from the foot control valve outlet
port pressurizes air chamber (1), extends the push rod and applies the brakes. System air pressure in
chamber (5) keeps spring (3) compressed.

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DASH MOUNTED PARKING BRAKE CONTROL

8. Emergency and parking brake control knob.

If air system pressure falls to approximately 40 psi (2.8 kg/cm2), the emergency and parking brake control
valve automatically closes and blocks air flow to chamber (5). The air in chamber (5) exhausts to the
atmosphere and spring (3) extends the pushrod to apply the brakes. The brakes stay applied until system
air pressure is recharged and the emergency and parking brake control knob is pushed in.

The brakes are always applied when air system pressure is below 40 psi (2.8 kg/cm2). For PARK, when
the air system pressure is above 40 psi (2.8 kg/cm2), pull the emergency and parking brake control knob
out. This exhausts the air in chamber (5) and spring (3) force applies the brakes. To release the brakes
from PARK, push the control knob in and hold until air pressure in chamber (5) compresses spring (3)
and releases the brakes.

Quick Release Valves (76J1157-Up & 30K814-Up)

The quick release valves hasten the exhaust of air from the brake chambers by providing a downstream
exhaust. The quick release valve assumes three normal positions during operation. These positions are the
APPLYING position, when air under pressure passes through the valve into the brake chamber; the
HOLD position, when pressure is held in the brake chamber; and the RELEASE position, when the brake
chamber exhausts.

When the brakes apply, air under pressure enters the inlet port (2) of the quick release valve, and moves
the diaphragm (4) down, closing the exhaust port (5). The outer edges of the diaphragm are deflected
downward against the resistance of the spring (6). Pressure air passes through the outlet port (1) to the
brake chamber.

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QUICK RELEASE VALVE IN APPLYING POSITION

1. Brake chamber port. 2. Inlet port. 3. Plug. 4. Diaphragm. 5. Exhaust port. 6. Spring.

As soon as the brake chamber pressure below the diaphragm equals the brake valve pressure above the
diaphragm, spring (6) forces the edge of the diaphragm (4) up against the body. The center of the
diaphragm continues to cover the exhaust port (5). This is the HOLDING position.

QUICK RELEASE VALVE IN HOLDING POSITION

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QUICK RELEASE VALVE IN EXHAUST POSITION

When the brake control valve is closed, air pressure on the top of the diaphragm is released. The brake
chamber pressure below the center of the diaphragm raises it, opening the exhaust port (5) and permitting
the brake chamber air to exhaust.

Quick Release And Holding Valve (76J1-76J1156 & 30K1-

30K813)
The quick release and holding valves are located on the front and rear axle housings. They reduce the time
required to apply the emergency and parking brakes by hastening the exhaust of air pressure from the
protective brake chambers.

When the emergency and parking brake control valve is moved to release the parking brakes, air enters
the quick release and holding valve through inlet port (6). Shuttle assembly (5) move against sealing
washer (2) to close exhaust port (3). Air enters drilled passage (7) in the shuttle expanding sealing band
(8). As the band expands, it unseats from the opening in air passage (7) sending air to the protective brake
chambers to release the brakes.

QUICK RELEASE AND HOLDING VALVE IN RELEASED POSITION

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1. Outlet port to protective brake chamber. 2. Sealing washer. 3. Exhaust port to atmosphere. 4. Outlet port to protective brake
chamber. 5. Shuttle assembly. 6. Inlet port from emergency and parking brake control valve. 7. Air passage through shuttle. 8.
Rubber sealing band.

When the valve assumes its holding position, pressures at inlet port (6) and outlet ports (1) and (4) are
equal. Sealing band (8) has contracted, closing air passage (7) through shuttle (5) blocking the return of
air from the protective brake chambers.

QUICK RELEASE AND HOLDING VALVE IN BRAKE APPLIED POSITION

1. Outlet port to protective brake chamber. 2. Sealing washer. 3. Exhaust port to atmosphere. 4. Outlet port to protective brake
chamber. 5. Shuttle assembly. 6. Inlet port from emergency and parking brake control valve. 8. Rubber sealing band.

A pressure reduction, caused either by an application of the emergency and parking brake control valve or
a failure, will actuate the quick release and holding valves.

When the pressure at port (6) is reduced, shuttle (5) unseats from exhaust port (3). This allows the air in
the protective brake chambers to exhaust and apply the brakes.

Double Check Valve

Two double check valves are used in the air brake system. One double check valve is mounted on the
right brake control valve. The other double check valve is mounted beneath the floor plate in the lines
group on the right side of the machine.

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DOUBLE CHECK VALVE OPERATION

1. Port to emergency and parking brake chamber. 2. Port from emergency and parking brake control valve. 3. Port from left
brake control valve. 4. Shuttle. 5. Right brake control valve. 6. Shuttle. 7. Port from right brake control valve. 8. Port to service
brake chambers. 9. Port to service brake chambers.

During a service brake application (parking brakes released) pressure air is directed from either brake
control valve to port (3) or (7). Shuttle (4) blocks off the passage to the opposite service brake control
valve and directs the air out port (8) to the service brake chambers.

In normal operation, full system pressure acts through passage (2) upon shuttle (6) preventing air from the
brake control valves from passing out port (1) to the protective brake system.

If the service brakes are applied before the emergency and parking brakes are released, the double check
valve, containing shuttle (6), will prevent a compound application of both braking systems. When the
emergency and parking brakes are applied, there will be no pressure in this system. When pressure air is
introduced into the service brake system, it will unseat shuttle (6) sending air out port (1) to the protective
brake chambers. The protective brake system will be releasing as the service brakes are being applied.

Copyright 1993 - 2019 Caterpillar Inc. Mon Jun 24 15:22:09 EST 2019
Todos los derechos reservados.
Red privada para licenciados del SIS.

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