- 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.
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)     |
( 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".
- Remove three dash covers (2) and three covers (1) .
Illustration 1 | g01129920 |
- Remove cover (3) .
Illustration 2 | g01129931 |
- Remove skirt (4) to gain access to the service brake control valve.
Illustration 3 | g01129942 |
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.
- Remove 9S-4191 Plug (1) from the existing tee. Discard 9S-4191 Plug (1) .
Illustration 4 | g01129945 |
View of the Control Gp-Service Brake |
- Install 3J-1907 O-Ring Seal (3) on 183-5035 Pressure Switch (2). Install 183-5035 Pressure Switch (2) into the existing tee.
Illustration 5 | g01129946 |
View of the Control Gp-Service Brake with the 183-5035 Pressure Switch installed |
Machines with Pressure Switches (Residual Brake Oil) Installed Only
Note: The additional pressure switch is installed into the front service brake circuit.
- Remove existing 3E-7891 Pressure Switch (1) from the existing tee.
Illustration 6 | g01129949 |
View of the Switch Gp-Brake Pressure |
- 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.
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 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.
- Remove 9S-4191 Plug (1) from the existing tee. Discard 9S-4191 Plug (1) .
Illustration 8 | g01130208 |
View of the Gauge and Lines Gp-Brake Pressure |
- Install 3J-1907 O-Ring Seal (3) on 183-5035 Pressure Switch (2). Install 183-5035 Pressure Switch (2) into the existing tee.
Illustration 9 | g01130216 |
View of the Gauge and Lines Gp-Brake Pressure with the 183-5035 Pressure Switch installed |
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.
- Remove existing 3E-7891 Pressure Switch (1) .
Illustration 10 | g01129950 |
View of the service brake control valve |
- Install 3J-1907 O-Ring Seal (3) on 3E-7410 O-Ring Tee (4). Install 3E-7410 O-Ring Tee (4) .
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 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".
- Install wire EL709-YL from 264-9892 Harness (2) into pin 11 of Electronic Transmission Control J2 plug (1) .
Illustration 12 | g01130238 |
View of the electronic transmission control with the 264-9892 Harness installed |
Illustration 13 | g01130239 |
View of the cab harness and front cab harness bulkhead connector |
- Route 264-9892 Harness (2) from Electronic Transmission Control J2 plug (1) following existing cab harness (3) .
Note: Secure excess 264-9892 Harness (2) to existing cab harness (3) .
- Route 264-9893 Harness (4) following existing front cab harness (5) .
- Temporarily remove wire EL709YL from the two pin plug of 264-9893 Harness (4) .
Illustration 14 | g01130240 |
Illustration 15 | g01130241 |
- Route 264-9893 Harness (4) following existing front cab harness (5) under bracket (6) and through grommet (7) .
- Install wire EL709YL removed in Step 5 into the two pin plug.
Illustration 16 | g01130248 |
- 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
Illustration 17 | g01130236 |
View of the automatic parking brake system electrical schematic (dashed lines indicate existing machine system) |
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 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.
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 will 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, 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:
- Parking brake disengaged
- Maintain the engine rpm above 750 rpm