264-9894 Control Gp-Parking Brake (Automatic) Custom Product Support Literature for the R2900G <B>S/N:</B>GLK1-UP Load Haul Dump{1408, 4250} Caterpillar

264-9894 Control Gp-Parking Brake (Automatic) Custom Product Support Literature for the R2900G S/N:GLK1-UP Load Haul Dump{1408, 4250}

Usage:

R2900G GLK

Load Haul Dump:: R2900G (S/N: GLK1-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.

ReferenceSystems Operation Testing and Adjusting, RENR7813, "R2900G Load Haul Dump Braking System", "System Pressure - Release". This module is part of Service Manual, RENR6948 Volume 2.

ReferenceSpecial Instruction, SEHS9615, "Servicing Deutsch HD and DT Style Connectors".

ReferenceSystems Operation Testing and Adjusting, RENR7813, "R2900G Load Haul Dump Braking System", "Braking System Air-Purge". This module is part of Service Manual, RENR6948 Volume 2.

ReferenceOperation and Maintenance Manual, SEBU7330, "R2900G Load Haul Dump", "Towing Information". This manual is part of Service Manual, RENR6948 Volume 2.

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Table 1
Parts that are Required in Order to Install the Automatic Parking Brake Application System
Qty	Part Number	Description
1	264-9892	Harness
1	264-9893	Harness
50	6K-0806	Cable Strap
1	3E-7410	O-Ring Tee ⁽¹⁾
2	3J-1907	O-Ring Seal
1	183-5035	Pressure Switch
-	-	Software Gp - Power Train ⁽²⁾

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^( 1 )	Only required for machines with pressure switches (residual brake oil) 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, REHS2163 in the service request.

Installation Procedure

Installation of the Pressure Switch

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

Engage the parking brake.

Install the steering frame lock.

Lower the bucket to the ground.

Turn the battery disconnect switch to the OFF position.

Release the braking system pressure. Refer to Systems Operation Testing and Adjusting, RENR7813, "R2900G Load Haul Dump Braking System", "System Pressure - Release".

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Illustration 1	g01129920

Remove three dash covers (2) and three covers (1) .

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Illustration 2	g01129931

Remove cover (3) .

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Illustration 3	g01129942

Remove skirt (4) to gain access to the service brake control valve.

Machines without Pressure Switches (Residual Brake Oil) or Brake Pressure Gauges Installed

Note: The additional pressure switch is installed into the front service brake circuit.

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Illustration 4	g01129945
View of the Control Gp-Service Brake

Remove 9S-4191 Plug (1) from the existing tee. Discard 9S-4191 Plug (1) .

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Illustration 5	g01129946
View of the Control Gp-Service Brake with the 183-5035 Pressure Switch installed

Install 3J-1907 O-Ring Seal (3) on 183-5035 Pressure Switch (2). Install 183-5035 Pressure Switch (2) into the existing tee.

Machines with Pressure Switches (Residual Brake Oil) Installed Only

Note: The additional pressure switch is installed into the front service brake circuit.

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Illustration 6	g01129949
View of the Switch Gp-Brake Pressure

Remove existing 3E-7891 Pressure Switch (1) from the existing tee.

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Illustration 7	g01130233
View of the Switch Gp-Brake Pressure with the 183-5035 Pressure Switch installed

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

Install 3E-7891 Pressure Switch (1) removed in Step 1 into 3E-7410 O-Ring Tee (4) .

Install 3J-1907 O-Ring Seal (3) on 183-5035 Pressure Switch (2). Install 183-5035 Pressure Switch (2) into 3E-7410 O-Ring Tee (4) .

Machines with Brake Pressure Gauges Installed Only

Note: The additional pressure switch is installed into the front service brake circuit.

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Illustration 8	g01130208
View of the Gauge and Lines Gp-Brake Pressure

Remove 9S-4191 Plug (1) from the existing tee. Discard 9S-4191 Plug (1) .

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Illustration 9	g01130216
View of the Gauge and Lines Gp-Brake Pressure with the 183-5035 Pressure Switch installed

Install 3J-1907 O-Ring Seal (3) on 183-5035 Pressure Switch (2). Install 183-5035 Pressure Switch (2) into the existing tee.

Machines with Brake Pressure Gauges and Pressure Switches (Residual Brake Oil) Installed

Note: The additional pressure switch is installed into the front service brake circuit.

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Illustration 10	g01129950
View of the service brake control valve

Remove existing 3E-7891 Pressure Switch (1) .

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Illustration 11	g01129951
View of the service brake control valve with the 183-5035 Pressure Switch installed

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

Install 3E-7891 Pressure Switch (1) removed in Step 1 into 3E-7410 O-Ring Tee (4) .

Install 3J-1907 O-Ring Seal (3) on 183-5035 Pressure Switch (2). Install 183-5035 Pressure Switch (2) into 3E-7410 O-Ring Tee (4) .

Installation of the Wiring Harnesses

Note: Install the wiring with the electrical schematic. Refer to Illustration 17. Install all harnesses securely by using the cable ties listed in Table 1. For information on servicing Deutsch DT Type connectors, see Special Instruction, SEHS9615, "Servicing Deutsch HD and DT Style Connectors".

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Illustration 12	g01130238
View of the electronic transmission control with the 264-9892 Harness installed

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Illustration 13	g01130239
View of the cab harness and front cab harness bulkhead connector

Install wire EL709-YL from 264-9892 Harness (2) into pin 11 of Electronic Transmission Control J2 plug (1) .

Note: Secure excess 264-9892 Harness (2) to existing cab harness (3) .

Route 264-9892 Harness (2) from Electronic Transmission Control J2 plug (1) following existing cab harness (3) .

Connect 264-9892 Harness (2) to 264-9893 Harness (4) at location (A) .

Route 264-9893 Harness (4) following existing front cab harness (5) .

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Illustration 14	g01130240

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Illustration 15	g01130241

Temporarily remove wire EL709YL from the two pin plug of 264-9893 Harness (4) .

Route 264-9893 Harness (4) following existing front cab harness (5) under bracket (6) and through grommet (7) .

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Illustration 16	g01130248

Install wire EL709YL removed in Step 5 into the two pin plug.

Connect 264-9893 Harness (4) to the 183-5035 Pressure Switch at location (B) .

Connect earth wire 202-BK from 264-9893 Harness (4) at a suitable location.

Installation of the Software

Turn the battery disconnect switch to the ON position.

Use Caterpillar Winflash (Electronic Technician) to flash the Software-Gp Transmission 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, REHS2163 in the service request.

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

Purge the air from the braking system. Refer to Systems Operation Testing and Adjusting, RENR7813, "R2900G Load Haul Dump Braking System", "Braking System Air-Purge".

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

Electrical System Schematic

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Illustration 17	g01130236
View of the automatic parking brake system electrical schematic (dashed lines indicate existing machine system)

Automatic Parking Brake System Operation

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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 550 RPM and 750 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.

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, SEBU7330, "R2900G Load Haul Dump", "Towing Information". 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: