254-0328 Control Gp-Parking Brake (Automatic) For R1600G Load Haul Dump Machines {1408, 4250} Caterpillar


254-0328 Control Gp-Parking Brake (Automatic) For R1600G Load Haul Dump Machines {1408, 4250}

Usage:

R1600G 9PP
Load Haul Dump
R1600G (S/N: 9PP1-UP; 9YZ1-UP)

Introduction

This publication contains the information for the installation of an automatic parking brake application system. This supplemental product support literature should be used with the appropriate Service Manual and the appropriate Parts Manual that is available for this standard machine.

Do not perform any procedure or order parts until you understand the information that is contained in this document.

Note: The optional ABA Transmission Switch Group must be installed with the Automatic Parking Brake system if not already installed on the machine. If the optional ABA Transmission Switch Group is not installed, stopping the engine or stalling the engine would not engage the parking brake automatically.

Reference: Systems Operation, Testing and Adjusting, "System Pressure - Release" for the machine being serviced.

Reference: Disassembly and Assembly, "Seat - Remove" for the machine being serviced.

Reference: Special Instruction, SEHS9615, "Servicing deutsch connector HD and DT Style Connectors".

Reference: Disassembly and Assembly, "Seat - Install" for the machine being serviced.

Reference: Systems Operation Testing and Adjusting, "Braking System Air - Purge" for the machine being serviced

Reference: Operation and Maintenance Manual for the machine being serviced.

Table 1
Required Tools 
Tool  Part Number  Part Description  Qty 
151-6320  Wire Removal Tool 

Table 2
Parts that are Required in Order to Install the Automatic Parking Brake Application System 
Qty  Part Number  Description 
254-0324  Harness 
254-0325  Harness 
254-7395  Harness 
254-7396  Harness 
254-0327  Harness 
3E-7410  O-Ring Tee 
3J-1907  O-Ring Seal 
183-5035  Pressure Switch 
155-2270  Connecting Plug Kit 
102-8802  Receptacle Kit 
8T-8737  Seal Plug 
254-7397  Relay 
27  163-5808  Medium Cable Ties 
25  163-5531  Large Cable Ties 
2N-0402  Bolt 
4B-4274  Washer 
4M-0061  Bolt 
8T-4224  Hard Washer 
130-5300  Clip 
160-4397  Lines Gp - Brake(1) 
Software Gp - Power Train(2) 
(1) Only required if machine does not have brake pressure gauges or residual brake light installed.
(2) The new software is available in the form of a flash file from Cat Underground Mining through the "Dealer Solution Network" (DSN). Reference Custom Service Information, REHS0692 in the service request.

Installation of the Pressure Switch

  1. Move the machine to a hard, level location, that is away from operating machines and away from personnel.

  2. Install the steering frame lock.

  3. Lower the bucket to the ground.

  4. Engage the parking brake.

  5. Turn the battery disconnect switch to the OFF position.

  6. Release the brake system pressure. Refer to Systems Operation Testing and Adjusting, "System Pressure - Release".


    Illustration 1g01069959
    View of the instrument panels inside the operator station

  7. Remove three instrument panels (1), (2), and (3) from the operator station.

  8. Remove the operator seat from the operator station.

Machines with Brake Pressure Gauges and a Residual Brake Light Installed



    Illustration 2g01093258

  1. Disconnect 225-8056 Hose As (2) from 2P-1314 Connector (1).

  2. Remove 2P-1314 Connector (1). Retain the connector for installation purposes.


    Illustration 3g01069511
    (A) Typical location for the earth connection when installing the 254-0347 Harness. Refer to "Installation of the Relay and Wiring Harnesses", Step 14.

  3. Install 3J-1907 O-Ring Seal (4) on 3E-7410 O-Ring Tee (3). Install 3E-7410 O-Ring Tee (3) into existing fitting (6).

  4. Install 3J-1907 O-Ring Seal (4) on 183-5035 Pressure Switch (5). Install 183-5035 Pressure Switch (5) into 3E-7410 O-Ring Tee (3).

  5. Install 2P-1314 Connector (1) retained from Step 2. Connect 225-8056 Hose As (2).

Machines without a Residual Brake Light or Brake Pressure Gauges Installed



    Illustration 4g01093266
    View of the 160-4397 Lines Gp-Brake
    (1) 5P-5008 Reducer
    (2) 2P-1279 Locknut
    (3) 2P-1278 Union
    (4) 9S-4191 Plug
    (5) 3J-1907 O-Ring Seal
    (6) 5I-3190 Fitting
    (7) Existing 9L-8493 Cap
    (8) 225-8059 Hose As
    (C) Location for the 183-5035 Pressure Switch

  1. Remove existing 9L-8493 Caps (7) from the brake valve.

  2. Install 160-4397 Lines Gp-Brake. Refer to Illustration 4.


    Illustration 5g01069961
    Typical example

  3. Install 3J-1907 O-Ring Seal (5) on 183-5035 Pressure Switch (9). Install 183-5035 Pressure Switch (9) in the end of 5I-3190 Fitting (6).

Machines with a Residual Brake Light Installed Only



    Illustration 6g01071990
    Typical example

  1. Install 3J-1907 O-Ring Seal (1) on 183-5035 Pressure Switch (2).

  2. Remove the 9S-4191 Plug from 5I-3190 Fitting (3) and install 183-5035 Pressure Switch (2).

Machines with Brake Pressure Gauges Installed only



    Illustration 7g01072739

  1. Install 3J-1907 O-Ring Seal (2) on 183-5035 Pressure Switch (3).

  2. Remove the 9S-4191 Plug from 5I-3190 Fitting (1) and install 183-5035 Pressure Switch (3).

Installation of the Relay and Wiring Harnesses

Note: Install the wiring with the electrical schematic. Refer to Illustration 15. Install all harnesses securely by using the cable ties listed in Table 2. For information on servicing Deutsch DT Type connectors, see Special Instruction, SEHS9615, "Servicing Deutsch HD and DT Style Connectors".



    Illustration 8g01072765
    Top view of the operator seat base
    (A) 115 mm (4.53 inch)
    (B) 53 mm (2.09 inch)
    (C) 35 mm (1.38 inch)
    (D) 38 mm (1.50 inch)
    (E) Drill 3.6 mm (0.14 inch) through holes two places. Tap threads to 3/16 UNC


    Illustration 9g01073207

  1. Drill and tap two holes and position 254-7397 Relay (9) below the operator seat base. Install 2N-0402 Bolts (7) and 4B-4274 Washers (8). Refer to Illustration 8 and Illustration 9.

  2. Connect the six-pin plug from new 254-7396 Harness (10) to the relay receptacle. Refer to Illustration 9.

  3. Install 4M-0061 Bolt (4), 8T-4224 Hard Washer (5), 130-5300 Clip (2), and earth wire 202-BK(Black) (3) to tapping block (1). Position connector (6) on 130-5300 Clip (2). Refer to Illustration 9.


    Illustration 10g01073212
    View of the Electronic Transmission Control located under the operator seat base.

  4. Remove wire 164-WH(White)from pin one of Electronic Transmission Control J1 plug (13) (not shown).

  5. Install wire 164-WH(White)from the new 254-7395 Harness into pin one of Electronic Transmission Control J1 plug (13).

  6. Install wire 164-WH(White)removed in Step 4 into pin A of the three-pin plug from the new 254-7395 Harness.

  7. Install wire EL709-YL(Yellow)from the new 254-7395 Harness into pin 10 of Electronic Transmission Control J2 plug (12).

  8. Install wire C880-BR(Brown)from the new 254-7395 Harness into pin 40 of Electronic Transmission Control J2 plug (12).

  9. Connect the three-pin receptacle from 254-7395 Harness to the three-pin plug from new 254-7396 Harness (10). Secure to the existing harness at location (F).

  10. Connect the two-pin receptacle (11) from new 254-7396 Harness (10) to the two-pin plug from the new 254-0325 Harness.


    Illustration 11g03328397
    View of the 237-4992 Cab Wiring-Gp (Lower) with the new wiring harnesses installed

  11. Route new 254-0325 Harness (21) from under the operator seat base following existing cab part A harness (23). Install wire EL709-YL(Yellow) (18) from new 254-0325 Harness (21) into pin one of 102-8802 Receptacle Kit (16).

  12. Continue wire C880-BR(Brown)from new 254-0325 Harness (21) following existing cab part A harness (15). Install wire C880-BR(Brown)into pin 38 of 70-pin connector (14), at the inside bulkhead.

  13. Connect the two-pin plug from new 254-0327 Harness (19) to the 183-5035 Pressure Switch. Refer to "Installation of the Pressure Switch".

  14. Connect earth wire 202-BK(Black)from new 254-0327 Harness (19) at location (A). Refer to "Installation of the Pressure Switch", Illustration 3.

  15. Route new 254-0327 Harness (19) from the pressure switch following existing cab part B harness (20). Install wire EL709-YL(Yellow) (22) from new 254-0327 Harness (19) into pin one of 155-2270 Connecting Plug Kit (17).

  16. Fit 8T-8737 Seal Plugs to pin two of 102-8802 Receptacle Kit (16) and pin two of 155-2270 Connecting Plug Kit (17).

  17. Use two 163-5808 Medium Cable Ties to secure 102-8802 Receptacle Kit (16) and 155-2270 Connecting Plug Kit (17) in position.


    Illustration 12g01082626

  18. Install the new 254-0324 Harness through rubber boot (25) into pin 38 of 70-pin connector (24), at the outside bulkhead.


    Illustration 13g01082635
    View of the existing 245-5449 Rear Wiring-Gp

  19. Route the other end of new 254-0324 Harness (26) following existing harness (27) to the service brake pressure switches.

  20. Locate the service brake low brake oil pressure switch (brake activation) connector. The correct connector has a 200-BK(Black)wire in pin A from the machine harness. Remove wire 200-BK(Black)from pin A on the machine harness side of the connector.

  21. Install wire C880-BR(Brown)from new 254-0324 Harness (26) into pin A from where wire 200-BK(Black)was removed.


    Illustration 14g01082645

  22. Install wire 200-BK(Black)removed in Step 20 into pin one of the 155-2270 Connecting Plug Kit listed in Table 2.

  23. Connect the 155-2270 Connecting Plug Kit into a 102-8802 Receptacle Kit. Insert two 8T-8737 Seal Plugs into the receptacle kit. Place the remaining 8T-8737 Seal Plug into pin two of the connecting plug kit. Secure connector (28) to the existing harness. Refer to Illustration 14.

  24. Install the seat removed in Step 8.

  25. Install the three instrument panels removed in Step 7 of "Installation of the Pressure Switch".

Installation of the Software

  1. Turn the battery disconnect switch to the ON position.

  2. Use Caterpillar Winflash (Electronic Technician) to flash the Software-Gp into the Electronic Transmission Control.

    Note: The new software is now available in the form of a flash file from Caterpillar Underground Mining through the Dealer Solution Network (DSN). Reference Customer Service Information, REHS0692 in the service request.

  3. Cycle the battery disconnect switch to the OFF position and back to the ON position.

  4. Purge the air from the braking system. Refer to Systems Operation Testing and Adjusting, "Braking System Air - Purge" for the machine being serviced.

  5. Check that the Automatic Parking Brake system operates correctly. Refer to "Automatic Parking Brake System Operation"

Electrical System Schematic



Illustration 15g03330131
Machines fitted with a brake accumulator oil pressure switch


Illustration 16g06433618
Machines fitted with a brake accumulator oil pressure sensor

Automatic Parking Brake System Operation


NOTICE

This system should not be used as a substitute for physically engaging the parking brake before leaving the operator station.


A Load Haul Dump machine equipped with the automatic parking brake system will automatically engage the parking brake under certain conditions. The system uses the Electronic Transmission Control to detect when all the following conditions are active for 3 seconds or more:

  • Parking brake disengaged.

  • Remote control switch is in the OFF position (if equipped).

  • Ground speed is less than 5 km/h (3.1 mph).

  • Engine RPM is between 650 RPM and 800 RPM.

  • Neutralizer pedal released (foot off pedal).

  • Service brake pedal released (foot off pedal).

When all the above conditions are continuously active, for 3 seconds or more the parking brake will automatically engage.

If the parking brake is automatically engaged, disengage the parking brake by cycling the parking brake switch from the OFF position to the ON position. Cycle back to the OFF position.

Note: The optional ABA Transmission Switch Group must be installed with the Automatic Parking Brake system if not already installed on the machine. If the optional ABA Transmission Switch Group is not installed, stopping the engine or stalling the engine would not engage the parking brake automatically.

Towing the Machine

The procedure for towing the Load Haul Dump machine is unaffected when the engine is not running. Refer to Operation and Maintenance Manual for the machine being serviced. When towing the machine with the engine running, adhere to at least two of the following conditions to prevent the parking brake from automatically engaging:

  • Parking brake disengaged

  • Maintain the engine rpm above 800 rpm

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