254-0348 Control Gp-Parking Brake (Automatic) Custom Product Support Literature for the R1700G <B>S/N:</B>8XZ1-UP Load Haul Dump{1408, 4250} Caterpillar


254-0348 Control Gp-Parking Brake (Automatic) Custom Product Support Literature for the R1700G S/N:8XZ1-UP Load Haul Dump{1408, 4250}

Usage:

R1700G 8XZ


Load Haul Dump:
R1700G (S/N: 8XZ1-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 that are outlined in this publication 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, RENR4666 (9EP5396), "R1700G L.H.D Braking System", "Braking System Pressure - Release". This module is part of Service Manual, RENR4656 (9EP5386) Volume II.

ReferenceDisassembly and Assembly, RENR4675 (9EP5405), "R1700G L.H.D. Machine Systems", "Seat - Remove and Install". This module is part of Service Manual, RENR4656 (9EP5386) Volume II.

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

ReferenceSystems Operation Testing and Adjusting, RENR4666 (9EP5396), "R1700 L.H.D. Braking System", "Brake System Air-Purge". This module is part of Service Manual, RENR4656 (9EP5386) Volume 2.

ReferenceOperation and Maintenance Manual, SEBU7323, "R1700G Load Haul Dump", "Towing Information". This manual is part of Service Manual, RENR4656 (9EP5386) Volume 2.

Table 1
Required Tools    
Tool     Part Number     Part Description     Qty    
A     151-6320     Wire Removal Tool     2    

Table 2
Parts that are Required in Order to Install the Automatic Parking Brake Application System    
Qty     Part Number     Description    
1     254-0344     Harness    
1     254-0345     Harness    
1     258-6270     Harness    
1     254-7396     Harness    
1     254-0347     Harness    
1     3E-7410     O-Ring Tee    
2     3J-1907     O-Ring Seal    
1     183-5035     Pressure Switch    
1     155-2270     Connecting Plug Kit    
1     102-8802     Receptacle Kit    
3     8T-8737     Seal Plug    
1     254-7397     Relay As    
25     6K-0806     Cable Strap    
25     163-5531     Cable Tie    
2     2N-0402     Bolt    
2     4B-4274     Washer    
1     4M-0061     Bolt    
1     8T-4224     Hard Washer    
1     130-5300     Clip    
1     180-9364     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, REHS0685 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.

  1. Install the steering frame lock.

  1. Lower the bucket to the ground.

  1. Engage the parking brake.

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

  1. Release the brake system pressure. Refer to Systems Operation Testing and Adjusting, RENR4666 (9EP5396), "R1700G L.H.D Braking System", "Braking System Pressure - Release".



    Illustration 1g01217619

    View of the instrument panels inside the operator station

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

  1. Remove the operator seat from the operator station. Refer to Disassembly and Assembly, RENR4675 (9EP5405), "R1700G L.H.D. Machine Systems", "Seat - Remove and Install".

Machines with Brake Pressure Gauges and a Residual Brake Light Installed




    Illustration 2g01217613

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

  1. 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 - Park Brake Pressure Switch . Refer to ""Installation of the Relay and Wiring Harnesses" " Step 15

  1. 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) .

  1. 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) .

  1. 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 4g01217616

    View of the 180-9364 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) 0DE4140 Hose As

    (C) Location for the 183-5035 Pressure Switch

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

  1. Install 180-9364 Lines Gp-Brake . Refer to Illustration 4.



    Illustration 5g01069961

    Typical Example

  1. 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) .

  1. 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) .

  1. 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 16. Install all harnesses securely by using the cable ties listed in Table 2. For information on servicing Deutsch DT Style connectors refer to 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.

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

  1. Install 4M-0061 Bolt (4), 8T-4224 Hard Washer (5), 130-5300 Clip (2) and earth wire 202-BK (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

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

  1. Install wire 164-WH from the new 258-6270 Harness into pin one of Electronic Transmission Control J1 plug (13) .

  1. Install wire 164-WH removed in Step 4 into pin A of the three pin plug from the new 258-6270 Harness .

  1. Install wire EL709-YL from the new 258-6270 Harness into pin 39 of Electronic Transmission Control J1 plug (13) .

  1. Install wire C880-BR from the new 258-6270 Harness into pin 28 of Electronic Transmission Control J2 plug (12) .

  1. Connect the three pin receptacle from the new 258-6270 Harness to the three pin plug from new 254-7396 Harness (10). Secure to the existing harness at location (F) .

  1. Connect the two pin receptacle (11) from new 254-7396 Harness (10) to the two pin plug from the new 254-0354 Harness .



    Illustration 11g01073950

  1. Route the new 254-0345 Harness from under the operator seat base following existing cab part A harness (18). Install wire EL709-YL into pin 63 of connector (14). Continue wire C880-BR following along existing cab part A harness (15) .



    Illustration 12g01076285

  1. Install wire C880-BR into pin 28 of 70 pin connector (19) located at the inside bulkhead.

  1. Connect the two pin plug from the new 258-6270 Harness to the new 183-5035 Pressure Switch .

  1. Route the new 254-0347 Harness from the pressure switch following existing cab part B harness (16). Install wire EL709-YL into pin 63 of connector (17) .

  1. Connect earth wire 202-BK from the new 254-0347 Harness , at location (A). Refer to ""Installation of the Pressure Switch" ", Illustration 3.



    Illustration 13g01073213

  1. Install the new 254-0344 Harness through rubber boot (20) into pin 28 of 70 pin connector (19) located at the outside bulkhead.



    Illustration 14g01217617

    View of the rear main harness

  1. Route the other end of new 254-0344 Harness (22) following existing harness (21) to the service brake pressure switches.

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

  1. Install wire C880-BR from new 254-0344 Harness (22) into pin A from where wire 200-BK was removed.



    Illustration 15g01073606

  1. Install wire 200-BK removed in Step 18 into pin one of the 155-2270 Connecting Plug Kit listed in Table 2.

  1. 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 (23) to the existing harness. Refer to Illustration 15.

  1. Install the seat removed in Step 8 of ""Installation of the Pressure Switch" ". Refer to Disassembly and Assembly, RENR4675 (9EP5405), "R1700G L.H.D. Machine Systems", "Seat - Remove and Install".

  1. 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.

  1. Use Caterpillar Winflash(Electronic Technician) to flash the Power Train 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, REHS0685 in the service request.

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

  1. Purge the air from the braking system. Refer to Systems Operation Testing and Adjusting, RENR4666 (9EP5396), "R1700 L.H.D. Braking System", "Brake System Air-Purge".

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

Electrical System Schematic




Illustration 16g03192417

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, SEBU7323, "R1700G 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:

  • Parking brake disengaged

  • Maintain the engine rpm above 800 rpm

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