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Bsqueda del medio - SENR1412 - 773D & 775D TRUCKS AIR SYSTEM & BRAKES Pgina 1 de 30
Cerrar SIS
Pantalla anterior
Producto: NO SE HA ESCOGIDO NINGUN EQUIPO
Modelo: NO SE HA ESCOGIDO NINGUN EQUIPO
Configuracin: NO SE HA ESCOGIDO NINGUN EQUIPO
Operacin de Sistemas
773D & 775D TRUCKS AIR SYSTEM & BRAKES
Nmero de medio -SENR1412-00
Fecha de publicacin -31/01/1996
Fecha de actualizacin -03/11/2006
SENR14120001
Systems Operation
Introduction
NOTE: For specifications with illustrations, make reference to the Specifications for 773D Trucks &
775D Trucks; Air System And Brakes; SENR1411. If the Specifications in SENR1411 are not the
same as listed in the Systems Operation, Testing & Adjusting, look at the printing date on the front
cover of each book. Use the Specifications listed in the book with the latest date.
https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw... 09-08-2013
Schematics
Air System Schematic
(1) Air compressor governor.
(2) Air compressor.
(3) Air dryer.
(4) Air pressure relief valve.
(5) One-way check valve.
(6) Service air reservoirs.
(7) Drain valve.
(10) Relay valve [for rear wheel brakes].

(11) Relay valve [for front wheel brakes].
(12) Double check valve.
(13) Double check valve.
(14) Inversion valve.
(15) Front wheel brake valve (ON-OFF).
(16) Pressure protection valve.
(17) Retarder brake control valve.
(18) Parking and secondary brake control valve.
(19) Service brake control valve.
(21) Secondary brake control valve.
(22) Front wheel brake master cylinder.
(23) Rear wheel brake master cylinder.
(24) Parking brake control valve (ON-OFF).
(25) Windshield wiper motor.
(26) Windshield wiper control valve.
(27) Horn valve.
(28) Secondary air reservoir [for parking and secondary brake].
(29) Air horn.
(30) Front brake ratio valve.
(31) Automatic Retarder Control Valve (ARC) [Attachment].
(A) Air Pressure Switch [For Retarder Brake]:
Switch is normally open, closed by air pressure.
When this switch is closed, it activates the retarder brake indicator on the instrument panel.
(C) Air Pressure Switch [Stop Lamp For Rear Brakes]:
When this switch is closed, it activates the brake lamp relay which activates the stop lamps.
(D) Air Pressure Switch [Parking and Secondary Brake Signal For Transmission Control]:
When this switch is open, it activates the Parking/Secondary Brake ON indicator on the Caterpillar
Electronic Monitoring System (CEMS) panel via Cat Datalink. This switch also allows for rapid
shifting of the transmission.
(E) Air Pressure Switch [Retarder And Service Brake Signal For Transmission Control]:
Switch is normally closed, opened by air pressure.
When this switch is open, it activates the brake retarder indicator at the transmission control. This will
signal the transmission control when a higher engine rpm is needed for upshifts or downshifts of the
transmission.
(F) Sensor [For Brake Air Pressure]:
Sensor sends a signal to the CEMS control to input for the Brake Air Pressure gauge. When air
pressure is too low, the sensor also triggers the master fault light and fault alarm.
Schematic Key:
(G) Standard Air Lines.
(H) Automatic Retarder Control Valve (ARC) (31) Air Lines [Attachment].
Hydraulic System Schematic
(18) Parking and secondary brake control valve.

(33) Lockup solenoid.
(34) Selector piston [for lockup clutch].
(35) Load piston [for lockup clutch].
(36) Pressure reduction valve.
(37) Lockup clutch and solenoid valve group.
(38) Modulation reduction valve [for lockup clutch].
(40) Relief valve [for parking brake release system].
(41) Passage [to rear wheel brakes].
(42) Inlet relief valve [for torque converter].
(43) Torque converter.
(44) Oil cooler [for torque converter and brakes].
(45) Oil pump drive.
(46) Parking brake release oil filter.
(47) Torque converter oil filter.
(48) Lockup clutch [for the torque converter].
(49) Screen.
(50) Parking brake release section [of oil pump].
(51) Torque converter charging section [of oil pump].
(52) Torque converter scavenge section [of oil pump].
(53) Scavenge screen.
(54) Left rear wheel brake.
(55) Right rear wheel brake.
(56) Hydraulic oil tank.
(57) Line [for torque converter and brake cooling return].

(58) Oil pump [for hoist hydraulics and rear brake cooling].
(59) Suction screen.
(60) Oil cooler relief valve [for rear brakes].
(61) Control valve [for hoist hydraulics].
(62) Return oil screen [for hoist hydraulics].
(63) Suction screen.
(P) Pressure tap [for pilot oil].
(R) Pressure tap [for parking brake release oil].
(S) Pressure tap [for torque converter lockup clutch].
(T) Pressure tap [for torque converter outlet].
(U) Pressure tap [for brake cooler outlet].
(V) Pressure tap [for parking brake release oil].
(W) Pressure tap [for torque converter inlet].
(X) Pressure tap [for brake cooler inlet].
(Y) Pressure tap [for left rear brake oil cooling inlet].
(Z) Pressure tap [for right rear brake oil cooling outlet].
(AA) Pressure tap [for left rear brake oil cooling outlet].
(BB) Pressure tap [for right rear brake oil cooling inlet].
Brake System Schematic
(22) Front wheel brake master cylinder.

(23) Rear wheel brake master cylinder.
(40) Relief valve [for parking brake].
(54) Left rear wheel brake assembly.
(55) Right rear wheel brake assembly.
(64) Front wheel brake assemblies.
(65) Line [to makeup oil tank].
(66) Air chamber of the front wheel brake master cylinder.
(67) Air line [from the front brake relay valve].
(68) Line [to the makeup oil tank].
(69) Air line [from the rear brake relay valve].
Bsqueda del medio - SENR1412 - 773D & 775D TRUCKS AIR SYSTEM & BRA...
Pgina 10 de 30
(70) Air chamber of the rear wheel brake master cylinder.

(71) Hot oil from the brake housing going to hydraulic tank.
(72) Slack adjuster [for the service brakes].
(73) Oil line [from the oil cooler for the left and right rear brake].
(74) Hot oil from the brake housing going to hydraulic tank.
(75) Oil line [from park brake release section of the oil pump].
(76) Air line [to the parking brake control valve].
(77) Check valve.
Location Of Components
Cab Brake Control Group
Pgina 11 de 30
Top View
(15) Front wheel brake valve (ON-OFF). (16) Pressure protection valve. (17) Retarder brake control valve. (9) Service
brake control valve. (21) Secondary brake control valve. (28) Secondary air reservoir. (30) Front brake ratio valve.
Side View
(15) Front wheel brake valve (ON-OFF). (16) Pressure protection valve. (19) Service brake control valve. (21) Secondary
brake control valve. (28) Secondary air reservoir. (30) Front brake ratio valve.
Pgina 12 de 30
Chassis Brake Control Group
Top View
(1) Air compressor governor. (2) Air compressor. (3) Air dryer. (6) Service air reservoirs. (10) Relay valve [for rear wheel
brakes]. (11) Relay valve [for front wheel brakes]. (14) Inversion valve. (18) Parking and secondary brake control valve.
(22) Front wheel brake master cylinder. (23) Rear wheel brake master cylinder. (56) Hydraulic oil tank.
Pgina 13 de 30
Side View
(1) Air compressor governor. (3) Air dryer. (6) Service air reservoirs. (10) Relay valve [for rear wheel brakes]. (11) Relay
valve [for front wheel brakes]. (14) Inversion valve. (22) Front wheel brake master cylinder. (23) Rear wheel brake master
cylinder. (56) Hydraulic oil tank.
Pgina 14 de 30
Front Service Brake Lines Group
Top View
(22) Front wheel brake master cylinder. (56) Hydraulic oil tank. (78) Brake make-up oil tank.
Pgina 15 de 30
Side View
(22) Front wheel brake master cylinder. (56) Hydraulic oil tank. (78) Brake make-up oil tank.
Rear Service Brake Lines Group
Top View
(18) Parking and secondary brake control valve. (23) Rear wheel brake master cylinder. (46) Parking brake release oil
Pgina 16 de 30
filter. (50) Parking brake release section [of oil pump]. (56) Hydraulic oil tank. (72) Slack adjuster. (78) Brake make-up
oil tank. (79) Diverter valve.
Side View
(18) Parking and secondary brake control valve. (23) Rear wheel brake master cylinder. (46) Parking brake release oil
filter. (50) Parking brake release section [of oil pump]. (56) Hydraulic oil tank. (72) Slack adjuster. (78) Brake make-up
oil tank. (79) Diverter valve.
Brake Cooling Lines
Pgina 17 de 30
Top View
(44) Oil cooler [for torque converter and brakes]. (49) Screen. (50) Parking and secondary brake release section [of oil
pump]. (51) Torque converter charging section [of oil pump]. (52) Torque converter scavenge section [of oil pump]. (56)
Hydraulic oil tank. (57) Line [for torque converter and brake cooling return]. (59) Suction screen [inside hydraulic oil
tank]. (60) Oil cooler relief valve [for rear brakes (inside hydraulic oil tank)]. (61) Control valve [for hoist hydraulics
(inside hydraulic oil tank)]. (63) Suction screen [inside hydraulic oil tank]. (U) Pressure tap [for brake cooler outlet]. (X)
Pressure tap [for brake cooler inlet]. (Y) Pressure tap [for left rear brake oil cooling inlet]. (Z) Pressure tap [for right rear
brake oil cooling outlet]. (AA) Pressure tap [for left rear brake oil cooling outlet]. (BB) Pressure tap [for right rear brake
oil cooling inlet].
Caterpillar Electronic Monitoring System

(CEMS)
The Caterpillar Electronic Monitoring System (CEMS) consists of an action alarm, an action light and
a monitoring panel with individual alert indicators for each machine system listed on the CEMS
panel.
The CEMS is designed to alert the operator of an immediate or impending problem in one or more of
the machine systems.
Instrument Panel
(1) Brake Air Pressure gauge. (2) Parking/Secondary Brake ON indicator.
Brake Air Pressure gauge (1) and Parking/Secondary Brake ON indicator (2) are part of the
instrument panel. Brake Air Pressure gauge (1) is controlled by a sensor. Parking/Secondary Brake
ON indicator (2) is controlled by a pressure switch.
Brake Air Pressure gauge (1) displays the air pressure in the system. When the needle on Brake Air
Pressure gauge (1) is in the red area, the CEMS action light will come on and the master alarm will
Pgina 18 de 30
sound. This warning comes on when the air pressure from the service reservoirs is below 483 kPa (70
psi).
Parking/Secondary Brake ON indicator (2) flashes while the parking brakes or the secondary brakes
are engaged or a brake master cylinder has over stroked. When the parking brake or the secondary
brake is engaged and the transmission is moved into gear, the CEMS action light will come on and the
master alarm will sound.
When the cut-out air pressure is at 830 kPa (120 psi) and the lever on the parking brake control valve
is in the OFF position, Parking/Secondary Brake ON indicator (2) will stop flashing and the parking
and secondary brakes will release.
Air Compressor Governor
Air Compressor Governor

(1) Spring [to set pressure]. (2) Piston. (3) Inlet and exhaust valve. (4) Spring [for inlet and exhaust valve].
The air compressor governor operates with the air compressor unloader pistons to control the air
pressure in the system. The air compressor governor has a cut-out pressure setting of 830 35 kPa
(120 5 psi). When the air system increases to the maximum setting, the air pressure from the service
air reservoirs flows through the opening of the governor. This air flow moves the governor piston (2)
against the force of spring (4). Piston (2) moves inlet and exhaust valve (3) to open the inlet opening.
The air pressure flows through the governor to operate the compressor unloader mechanism which
stops the flow of compressed air.
Pgina 19 de 30
When the air pressure in the service air reservoirs decreases to the minimum setting of 690 + 0 - 35
kPa (100 + 0 - 5 psi), the force of spring (1) is greater than the minimum pressure on piston (2). Inlet
and exhaust valve (3) moves to close the inlet opening and open the exhaust opening of the governor.
This permits the compressor to send compressed air flow to the service air reservoirs.
Air Compressor
Air Compressor
(1) Air compressor governor. (2) Air compressor.
Air compressor (2) is driven by the timing gear train on the rear of the engine and is lubricated by the
lubrication system for the engine. Air compressor (2) is cooled by the engine cooling system. Air for
air compressor (2) comes from the engine air inlet manifold.
Air compressor governor (1) is mounted on air compressor (2) and connects to the air dryer.
Air Dryer
Air Dryer
(1) Air dryer. (2) Air relief valve.
Air flows from the air compressor into air dryer (1). Air dryer (1) removes the moisture and
contaminants from the air system. Air relief valve (2) located on air dryer (1) protects the air system
from damage. Air relief valve (2) will open at 1200 kPa (175 psi). Air relief valve (2) can not be
adjusted.
Pgina 20 de 30
Air Reservoirs
Service Air Reservoirs
There are three air reservoirs in the air system. The service air reservoirs hold air under pressure for
control of the service brakes and retarder. The secondary air reservoir holds air under pressure for
control of the parking brake and secondary brakes.
(1) Service air reservoirs [for service brakes and retarder]. (2) Air pressure relief valve. (3) Drain valve.
Service air reservoirs (1) are located on top of the hydraulic and transmission tank. A cover must be
removed to access them. The two service air reservoirs (1) are connected; one has air pressure relief
valve (2) and the other has drain valve (3). Air pressure relief valve (2) is a backup to the relief valve
on the air dryer to protect the air system from damage. Air pressure relief valve (2) will open at 1030
kPa (150 psi). Moisture drains from one air reservoir to the other. By opening manual drain valve (3),
the moisture is expelled.
Secondary Air Reservoir
Location of Secondary Air Reservoir (For Parking and Secondary Brakes).
Pgina 21 de 30
Location of Drain Valve (For Secondary Air Reservoir).
The secondary air reservoir is located at the rear of the cab. A cover must be removed to access the
secondary air reservoir. The drain valve is located on the right side of the cab. By opening the manual
drain valve, moisture is expelled.
One-Way Check Valve
Components Of The Check Valve

(1) Seat. (2) Valve. (3) Spring.
The one-way check valves in the air system are used to stop the reverse flow of air from the air
reservoirs. There are one-way check valves fastened in the inlet of the first service air reservoir and in
the inlet of the secondary air reservoir.
Air from the air compressor will put spring (3) in compression and valve (2) will open. This permits
air to flow into the reservoirs.
Pgina 22 de 30
When the air pressure in the reservoir and the force of spring (3) is more than the air pressure from the
air compressor, valve (2) will move against seat (1). This prevents air from flowing into the air
compressor from the reservoirs.
Pressure Protection Valve
Pressure Protection Valve

(1) Supply passage. (2) Valve. (3) Delivery passage.
Pgina 23 de 30
A pressure protection valve in the air system prevents a complete loss of air pressure in either the
secondary air system or any accessory device.
All air flow for the accessory circuits for the brakes must flow through the pressure protection valve.
Air will not flow through valve (2) until the air pressure at supply passage (1) is 550 kPa (80 psi).
When the pressure at supply passage (1) is 550 kPa (80 psi), valve (2) moves to allow air to flow to
delivery passage (3). Valve (2) closes when the air pressure lowers below 485 kPa (70 psi).
Service Brake Control Valve

Gradual modulation of the service brake system is controlled by the use of the foot operated brake
control valve (treadle). The rate of rise (time versus psi) is called modulation.
The foot valve modulates air pressure from the service air reservoirs to the brake relay valve. In
addition, the valve body serves as a junction point for the several circuits requiring non-modulated
air/auxiliary components and the retarder brake controls.
Service Brake Control Valve (Treadle)

(1) Seat. (2) Rubber spring. (3) Piston assembly. (4) Retainer. (5) Outlet passage. (6) Spring. (7) Valve seat. (8) Valve
seat. (9) Valve. (10) Valve body. (11) Valve spring. (12) Exhaust passage. (13) Inlet passage. (14) Exhaust diaphragm.
When the brake pedal is pushed, a force is put on seat (1). This force pushes rubber spring (2) and
piston assembly (3) down. Valve seat (7) closes exhaust passage (12) in valve (9). Piston assembly (3)
moves valve (9) off valve seat (8). Pressure air from inlet passage (13) flows around valve (9) to
outlet passage (5). The air then flows to the relay valve for the air chambers in the brake master
cylinders.
Pgina 24 de 30
When the air pressure below piston assembly (3) becomes more than the force above the piston, the
piston lifts enough to allow valve (9) to move up to valve seat (8). This stops the supply of pressure
air. Piston assembly (3) is still in contact with valve (9), so exhaust passage (12) is also closed. The
service brake control valve is now in balance. Air pressure is held in the lines and in the air chambers
in the brake master cylinders.
When the pedal is lifted a small amount, the force above piston assembly (3) is less. The pressure air
below piston assembly (3) and the force of spring (6) lifts the piston off valve (9). Pressure air in the
lines and in the air chambers in the brake master cylinders flows around piston assembly (3), through
exhaust passage (12) and out exhaust diaphragm (14) until the forces above and below the piston are
in balance.
When the pedal is completely released, piston assembly (3) moves off valve (9). Air pressure opens
exhaust diaphragm (14). Valve (9) is held against valve seat (8) by spring (11).
Parking And Secondary Brake Control Valve

The parking and secondary brake control valve is located on the right side of the truck frame across
from the hydraulic oil tank. The parking and secondary brake control valve controls the flow of oil to
the rear parking brakes.
The parking brakes are spring applied and pressure released.
Location of Parking and Secondary Brake Control Valve.
Pgina 25 de 30
Parking And Secondary Brake Control Valve In ON Position

(1) Passage [from parking brake release section of the oil pump]. (2) Relief valve. (4) Piston. (5) Air inlet passage. (6)
Stem. (7) Chamber [connected to torque converter inlet relief valve]. (8) Drain passage [to hydraulic oil tank]. (9) Check
valve. (10) Spring. (11) Oil outlet passage [to release parking brakes].
When the parking brake control valve in the cab is in the Parking Brake ON position, air flow to air
inlet passage (5) will be blocked. When there is no air flow at air inlet passage (5), spring (10) will
keep stem (6) pushed up and stop the flow of oil from passage (1) to oil outlet passage (11). The
engine must be in operation to have brake oil pressure to passage (1).
Parking And Secondary Brake Control Valve In OFF Position

(1) Passage [from parking brake release section of the oil pump]. (2) Relief valve. (4) Piston. (5) Air inlet passage. (6)
Pgina 26 de 30
Stem. (7) Chamber [connected to torque converter inlet relief valve]. (8) Drain passage [to hydraulic oil tank]. (9) Check
valve. (10) Spring. (11) Oil outlet passage [to release parking brakes].
Move the parking brake control valve in the cab to the Parking Brake OFF position. Air pressure will
be allowed to flow into passage (5). Air pressure will force piston (4) and stem (6) down. When stem
(6) moves down, the pressure oil from passage (1) enters oil outlet passage (11). The oil pressure will
increase in the brake housing and release the parking brakes. Relief valve (2) limits system pressure to
4690 200 kPa (681 29 psi).
Front Wheel Brake Valve (On-Off) And

Parking Brake Control Valve (On-Off)
The front brakes are caliper disc brakes. An ON-OFF valve on the left side of the instrument panel, in
the cab, permits the operator to turn OFF the air to the front brakes when they are not needed.
When the front wheel brake valve is in the ON position, modulated air from the service brake control
valve activates the front and rear brakes. When the front wheel brake valve is in the OFF position, air
from the service brake control valve will only flow to the rear brakes.
The front wheel brake valve should be ON except when operating conditions are such that all wheel
brakes are not needed. Move the lever to the OFF position when only rear wheel brakes are needed.
The parking brake control valve (ON-OFF) for the rear brakes is not modulated. It is located on the
transmission control console in the cab. The rear brakes are oil cooled multi-disc brakes.
When the parking brake control valve is in ON position, no air flows to the parking and secondary
brake control valve. This causes parking brake application. When the parking brake control valve is in
the OFF position, full air system pressure flows to the parking and secondary brake control valve.
This causes parking brake release.
Pgina 27 de 30
Control Valve Components

(1) Plunger. (2) Lever. (3) Passage [in plunger]. (4) Exhaust passage. (5) Delivery passage. (6) Spring. (7) Inlet valve. (8)
Seat. (9) Spring. (10) Supply passage.
The operation of the front wheel brake valve (ON-OFF) and the operation of the parking brake control
valve (ON-OFF) are the same. When air is needed to flow through the valve, lever (2) depresses
plunger (1). Plunger (1) moves inlet valve (7) off of seat (8) and exhaust passage (4) is closed.
Pressure air flows into supply passage (10) and flows around inlet valve (7), which is off seat (8). Air
flows out through delivery passage (5).
When air is not needed to flow through the valve, lever (2) releases plunger (1). Spring (6) moves
plunger (1) up and inlet valve (7) is pushed up to seat (8) by spring (9). Air from delivery passage (5)
flows through passage (3) in plunger (1) to exhaust passage (4).
Pgina 28 de 30
Front Brake Ratio Valve
Location Of Front Brake Ratio Valve
The front brake ratio valve controls the air pressure to the front brakes when the front wheel brake
valve (ON-OFF) is in the ON position.
When the service brake pedal is partially depressed and the supply air pressure is below 448 kPa (65
psi), only 50% of the supply air pressure is allowed to the front wheel brake master cylinder. When
the supply pressure to the front brake ratio valve reaches 448 kPa (65 psi) and above, the delivery
pressure to the front wheel brake master cylinder equals the supply pressure.
With the air flow restricted during partial engagement, the rear brakes will engage first and provide
more control to the operator. During full supply air pressure, the operator will receive maximum
braking capacity.
Retarder Brake Control Valve
Location Of Retarder "ON" Light On The Instrument Panel
Pgina 29 de 30
A hand control valve on the right side of the steering column provides modulated application of the
service brakes for the rear wheels when machine retarding is needed. There is a retarder "ON" light on
the instrument panel.
Location Of Retarder Brake Control Valve
The retarder brake control valve is under the dash. The handle is connected to the retarder brake
control valve by a shaft assembly.
Retarder Brake Control Valve

(1) Cam. (2) Piston. (3) Valve seat [for exhaust air]. (4) Spring. (5) Valve seat [for inlet air]. (6) Supply passage. (7)
Delivery passage. (8) Exhaust passage.
The hand operated retarder brake control valve modulates air pressure, up to a maximum of 550 kPa
(80 psi), to the rear brake relay valve. When the handle is in the OFF position, air at system pressure
at supply passage (6) is stopped by the inlet valve.
Pgina 30 de 30
When the handle is moved to the ON position, spring (4) is put in compression by cam (1). Spring (4)
puts pressure on piston (2) and the piston is moved down against the exhaust end of the valve
assembly. The exhaust end of the valve assembly is held on seat (3) and the inlet end of the valve
assembly is off seat (5). Supply air flows past the inlet end of the valve assembly to delivery passage

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Bsqueda del medio - SENR1412 - 773D & 775D TRUCKS AIR SYSTEM & BRAKES Pgina 1 de 30

Fecha de publicacin -31/01/1996

Fecha de actualizacin -03/11/2006

(10) Relay valve [for rear wheel brakes].

Hydraulic System Schematic

(18) Parking and secondary brake control valve.

(57) Line [for torque converter and brake cooling return].

Brake System Schematic

(22) Front wheel brake master cylinder.

(70) Air chamber of the rear wheel brake master cylinder.

Chassis Brake Control Group

Front Service Brake Lines Group

Rear Service Brake Lines Group

Brake Cooling Lines

Caterpillar Electronic Monitoring System

Air Compressor Governor

Air Compressor Governor

Secondary Air Reservoir

Location of Secondary Air Reservoir (For Parking and Secondary Brakes).

Location of Drain Valve (For Secondary Air Reservoir).

One-Way Check Valve

Components Of The Check Valve

Pressure Protection Valve

Pressure Protection Valve

Service Brake Control Valve

Service Brake Control Valve (Treadle)

Parking And Secondary Brake Control Valve

Location of Parking and Secondary Brake Control Valve.

Parking And Secondary Brake Control Valve In ON Position

Parking And Secondary Brake Control Valve In OFF Position

Front Wheel Brake Valve (On-Off) And

Control Valve Components

Front Brake Ratio Valve

Location Of Front Brake Ratio Valve

Retarder Brake Control Valve

Location Of Retarder "ON" Light On The Instrument Panel

Location Of Retarder Brake Control Valve

Retarder Brake Control Valve

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