GLOBAL MANPOWER DEVELOPMENT

773G / 775G OFF-HIGHWAY TRUCK

BRAKE SYSTEM
MODULE 7 - TEXT REFERENCE

SERV1921

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© 2011 Caterpillar Inc.

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SERV1921 - 09/11
5 8
• Brake system components (rear
of truck):
- ARC/TCS valve
- Towing valve
- Brake cooling pump
- Secondary brake/purge valve
- Brake charging pump
- Brake accumulators
- Brake charging valve
- Front brake manifold
-2- Module 7 - Brake System
6
3
4
1
2
2_1
The hydraulic brake system on the 773G/775G trucks operates similar to the
773F/775F trucks, but many components have been redesigned.
The new Automatic Retarder Control/Traction Control System (ARC/TCS) valve (1)
controls both the ARC system and the TCS by metering oil to the rear service brakes.
On the F Series trucks, the TCS valve metered oil to the parking brakes.
The brake system also includes a redesigned towing valve (2) that does not require
tools to activate.
Brake wear indicators have been added for easy ground level inspection.
A new single piece brake has eliminated over 200 fasteners.
A brake cooling pump (3) has been added to trucks with the Tier 4 engine. The
cooling pump is not installed on LRC model trucks.
Other brake system components shown in this image are:
• Secondary brake/purge valve (4)
• Brake charging pump (5)
• Brake accumulators (6)
• Brake charging valve (7)
• Front brake manifold (8)
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SERV1921 - 09/11 -3- Module 7 - Brake System

3 4

2
3_1
• Brake components (front of The service brake valve (1) is located below the cab at the base of the service brake
truck): pedal.

- Service brake valve
- Brake system oil filter
- Towing pump
- Electric motor
- Secondary steering pump
The brake system oil filter (2) has been relocated to a compartment in front of the
left front tire.
The towing pump (3) has been relocated to the right front frame rail. The towing
pump is driven by an electric motor (4), which also drives the secondary steering
pump (5).

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SERV1921 - 09/11 -4- Module 7 - Brake System

BRAKE HYDRAULIC SYSTEM

(8) (10)
Secondary Service
Brake Valve/ Brake
Accumulator Valve
Bleed Down Valve

(15)
Parking
Brake
(13)
Front
Service
(7) Front Brake Brake
Manifold

(14)
Rear
(12) Slack Adjuster
Rear (4)
Service Service
Brake (5) Brake
Parking Accumulator
Brake
Accumulator

(6) ARC/TCS Valve

(13)
Front
Service
(3) Accumulator
Brake
Charging Valve

(11)
(9) Brake Oil Cooler
(12) Towing Valve
Rear (2)
Service (11) Brake
Brake Brake Oil Filter
(14)
Oil Cooler
(15) Rear
Slack Adjuster (18) (20) Hoist
Parking (19) Brake
Secondary Pump
Brake Cooling
M Steering
Pump Pump (1)
(16) Towing Pump (Tier 4) Brake
Charging Pump
(17)
Hoist Pilot
Valve

4_1
• Brake hydraulic system Oil from the brake charging pump (1) flows through the brake oil filter (2) to the
accumulator charging valve (3). From the accumulator charging valve, the brake
pump oil flows to the following components:

• Service brake accumulator (4)

• Parking brake accumulator (5)

• ARC/TCS valve (6)

• Front brake manifold (7)

• Secondary brake/accumulator purge valve (8)

• Towing valve (9)

• Service brake valve The brake pump oil also flows through the front brake manifold to the service brake
valve (10).

• Accumulator charging valve The accumulator charging valve controls accumulator charging. When the
accumulators are charged, the excess oil flow is sent to the brake oil cooler (11).

The service brake valve directs oil to the ARC/TCS valve when the brake pedal is
depressed.

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SERV1921 - 09/11 -5- Module 7 - Brake System

• ARC/TCS valve The ARC/TCS valve controls the rear service brake application when the brake pedal
is depressed or when the retarding system is activated. The ARC/TCS valve also
controls wheel spin by metering the oil to the rear service brakes (12).

• Front brake manifold The front brake manifold controls the front service brakes (13) application via the
Brake ECM.

• Slack adjusters The rear slack adjusters (14) compensate for brake disc wear by allowing a small
volume of oil to flow through the slack adjusters and remain between the slack
adjusters and the brake pistons under low pressure.

• Secondary brake/accumulator The secondary brake/accumulator purge valve controls parking brake application by
purge valve directing oil to the parking brakes (15). The secondary brake/accumulator purge
valve also releases pressure from the brake accumulators when the engine is shut
off.

• Towing pump The towing pump (16) provides oil to release the parking brakes, which allows the
truck to be towed. The towing pump also provides oil to the hoist pilot valve (17) if
the brake pump fails or the engine won’t run.

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SERV1921 - 09/11 -6- Module 7 - Brake System

BRAKE ELECTRONIC CONTROL SYSTEM

(1) Brake ECM

(2) Cat Data Link (3) CAN Data Link

INPUT COMPONENTS OUTPUT COMPONENTS

(4) Engine Speed Sensor

(16) Front Service Brake Solenoid
(5) Wheel Speed Sensors
(17) Rear Brake Supply Solenoid
(6) Service Brake
Accumulator Pressure Sensor
(18) Rear Brake
(7) Brake Oil Filter Bypass Switch Pressure Control Solenoids

(8) Service Brake Pedal

Position Sensor
(19) Parking Brake Solenoid
(9) Secondary Brake Pedal
Position Sensor (20) Brake Light Relay
(10) Steering Cylinder
Position Sensor

(11) TCS Test Switch

(12) ARC Switch

(13) Compression Brake Switch

(14) Front Brake Disable Switch

(15) Retarder Lever

Position Sensor
6_1
• Brake ECS components The 773G/775G Trucks are equipped with a Brake ECM (1) for controlling the parking
brake and front service brake applications, the ARC system, and the TCS.

• Brake ECM The Brake ECM also controls the A/C compressor clutch and the brake light via the
brake light relay (20). This image shows only the brake system input and output
components.

• Input components The Brake ECM receives information from various input components such as the
engine speed sensor (4), the service brake pedal position sensor (8), the ARC
switch (12), the retarder lever position sensor (15), and the rear wheel speed
sensors (5). Based on the input information, the Brake ECM controls the front service
brake application when the service brake pedal is depressed or the rear service
brake application when the ARC system is activated. The Brake ECM also controls
when the service brakes should engage for the TCS and the parking brake application
when the parking brake is manually activated.

• Output components Output components include the rear brake supply solenoid (17), the rear brake
pressure control solenoids (18), the front service brake solenoid (16), and the parking
brake solenoid (19).

• Steering cylinder position sensor The steering cylinder position sensor (10) sends a signal to the Brake ECM indicating
the position of the left steering cylinder. The ECM uses the steering cylinder position
information when activating the TCS.

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SERV1921 - 09/11 -7- Module 7 - Brake System

• Secondary brake pedal position The Brake ECM uses the secondary brake pedal position sensor (9) signal to apply
sensor the secondary/parking brakes when the secondary brake pedal is depressed.

• Compression brake switch The compression brake switch (13) is also an input to the Brake ECM. When the
compression brake switch is activated, the Brake ECM sends a signal over the Cat
Data Link (2) to the Engine ECM. The Engine ECM controls the engine compression
brake.

NOTE: For information on the engine compression brake, refer to the “Engine
Module” of this course.

• Front brake disable switch When the front brake disable switch (14) is activated, the Brake ECM de-energizes
the front brake solenoid and only the rear brakes are engaged when the service
brake pedal is depressed.

This module will cover the brake system components controlled by the Brake ECM.
Other Brake ECM input and output components are shown during the discussion of
other machine systems.

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SERV1921 - 09/11 -8- Module 7 - Brake System

8_1

BRAKE SYSTEM COMPONENTS

• Brake ECM The Brake ECM (arrow) is located in the compartment at the rear of the cab. The
Brake ECM performs the brake control functions, and controls the ARC system and
TCS.

The Brake ECM is an A4:M1 module with two 70-pin connectors. The Brake ECM
communicates with the Engine ECM, Transmission/Chassis ECM, and monitoring
system over the Cat Data Link and can communicate with some attachments over
the CAN Data Link.

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SERV1921 - 09/11 -9- Module 7 - Brake System

1
2

9_1
• Oil cooled rear brake The rear brakes on the 773G/775G trucks are oil cooled. The brakes are
components: environmentally sealed and adjustment free. Oil continually flows through the brake
discs for cooling. Duo-Cone seals prevent the cooling oil from leaking to the ground
- Smaller piston or transferring into the axle housing. The wheel bearing adjustment must be
- Larger piston maintained to keep the Duo-Cone seals from leaking.

The smaller piston (1) is used to engage the secondary and parking brakes. The
parking brakes are spring engaged and hydraulically released.

The larger piston (2) is used to engage the service brakes. The service brakes are
engaged hydraulically and released by spring force.

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SERV1921 - 09/11 -10- Module 7 - Brake System

3 4 1

4 2
5

10_1
• Disc and caliper front brake The front brakes are a disc and caliper design. The brake caliper (1) is fastened to
components: the spindle and does not rotate. The brake disc (2) is fastened to the wheel and
rotates with the wheel. Air can be bled from the front brakes through the bleed
- Brake caliper valve (3).
- Brake disc
- Bleed valve During brake application, hydraulic oil from the front brake manifold forces the brake
pistons (4) against the brake pads (5). The brake pads are forced against the disc
- Brake pistons to stop the rotation of the wheel.
- Brake pads

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SERV1921 - 09/11 -11- Module 7 - Brake System

2
1
3

11_1
• Rear of engine: The brake charging pump (1) and hoist pump (2) are mounted to the pump drive at
the left rear of the engine. The brake system accumulators are charged by the brake
- Brake charging pump charging pump, which supplies oil to the accumulator charging valve though the
- Hoist pump brake oil filter.
- Brake oil cooling pump (Tier 4
only) The brake oil cooling pump (3) is mounted to the brake charging pump on machines
with the Tier 4 engine. A brake cooling pump is not installed on LRC model trucks.
The cooling pump sends oil to the brake oil cooler before the oil flows to the rear
brakes for cooling.

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SERV1921 - 09/11
• Left frame rail in front of left front
tire:
- Brake system oil filter
- Filter bypass switch
- Brake system pressure port
- Steering return oil filter
-12- Module 7 - Brake System
12_1
The brake system oil filter (1) is located inside the filter compartment on the left frame
rail in front of the left front tire. The brake filter includes a filter bypass switch (2),
which informs the Brake ECM if the filter is restricted. The Brake ECM sends a signal
to the monitoring system, which illuminates the brake system check indicator lamp.
Brake system pressure can be checked at the port (3) located in the hydraulic line to
the accumulator charging valve.
The steering return oil filter (4) is also located in the filter compartment.
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SERV1921 - 09/11 -13- Module 7 - Brake System

2 5
1
4

• Inboard side of brake accumulator
bracket:
- Accumulator charging valve
- Bracket
- Line to parking brake
accumulator
- Service brake relief valve
- Secondary/parking brake relief
valve
13_1
The accumulator charging valve (1) is bolted to a bracket (2) that houses the brake
accumulators in front of the hydraulic tank on the right side of the machine. The
accumulator charging valve directs oil to the brake accumulators and the following
components:
• ARC/TCS valve
• Front brake manifold
• Secondary brake valve
• Towing valve

Once the accumulators are charged, the excess oil flow is sent to the brake oil
cooler.

The Brake ECM monitors the pressure in the service brake accumulator with the
brake accumulator pressure sensor (not visible), which is installed in the line (3) to the
parking brake accumulator. If the pressure in the service brake accumulators is low,
the Brake ECM will signal the monitoring system to turn on the brake system check
indicator lamp. The service brake relief valve (4) limits the pressure in the brake
charging circuit. The secondary/parking brake relief valve (5) limits the pressure in
the secondary/parking brake circuit.

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SERV1921 - 09/11 -14- Module 7 - Brake System

ACCUMULATOR CHARGING VALVE

CUT-IN
(10)
Front Brake Manifold
(2)
(1) Service Brake
Cut-in/
Accumulator
Cut-out
Spool

(3)
Unloading
(5) Accumulator Valve
Oil Pressure Sensor

(9)
Parking Brake
Accumulator
(8) (4)
Parking Brake Brake Cooling
Relief Valve System
(7)
Brake System
Relief Valve

• Accumulator charging valve -
CUT-IN
(6)
Brake Charging Pump 14_1
The accumulator charging valve maintains the pressure in the service brake
accumulator (1) at a constant rate while the engine is running. If the truck has lost
power or the brake pump has failed, the pressure in the accumulators will permit
several applications of the service brakes.

This illustration shows the accumulator charging valve in the CUT-IN position. When
the accumulator oil pressure decreases below a certain point, the accumulator
charging valve reaches the cut-in pressure setting. The pressure decrease allows
spring force to move the cut-in/cut-out spool (2) to the left and oil flows to the left end
of the unloading valve (3). The orifice in the unloading valve restricts the pump flow
to the brake cooling system (4). Oil flow to the brake accumulators increases and
the accumulators are charged.

The accumulator oil pressure sensor (5) sends a signal to the Brake ECM to alert the
operator when the brake oil pressure drops below the minimum operating pressure.

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SERV1921 - 09/11
ACCUMULATOR CHARGING VALVE
(10)
Front Brake Manifold
(01) Service Brake
Accumulator
(05) Accumulator
Oil Pressure Switch
(12) Check Valve
(09)
Parking Brake
Accumulator
Parking Brake
Relief Valve
• Accumulator charging valve -
CUT-OUT
-15- Module 7 - Brake System
CUT-OUT
(02)
Cut-in/
Cut-out
Spool
(03)
Unloading
Valve
(11)
Check
Valve
(08) (04)
Brake Cooling
System
(07)
Brake System
Relief Valve
(06)
Brake Charging Pump 15_1
This illustration shows the accumulator charging valve in the CUT-OUT position.
When the accumulator oil pressure increases to the cut-out pressure setting, the
increased pressure causes the cut-in/cut-out spool (2) to move right against spring
force. Oil at the left end of the unloading valve (3) flows to the tank. Oil pressure on
the right end of the unloading spool overcomes the decreased oil pressure on the left
end of the spool and spring force. Most of the brake charging pump oil now flows to
the brake cooling system (4).
The check valve (11) prevents high accumulator oil pressure from flowing to the
brake cooling system.
The accumulator charging valve remains in the CUT-OUT position until the pressure
in the accumulators decreases to the cut-in pressure setting. When the brake
pump pressure is checked at the brake pump, at low idle with the accumulators fully
charged, the brake pressure should be less than 1380 kPa (200 psi).
The brake system relief valve (7) regulates the oil pressure in the brake circuit. Any
excess oil that is not required by the brake circuit or the brake cooling system is
diverted back to the hydraulic oil tank.
The secondary/parking brake relief valve (8) limits oil pressure in the secondary/
parking brake circuit. A check valve (12) prevents oil in the secondary/parking brake
circuit from flowing to the service brake circuit.
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SERV1921 - 09/11
1 2
• Right side of frame:
- Service brake accumulator
- Parking brake accumulator
-16- Module 7 - Brake System
16_1
The service brake accumulator (1) and the parking brake accumulator (2) are located
on the right side of the frame in front of the hydraulic tank. The accumulators are
charged by the brake charging valve and supply the required oil flow to engage the
front and rear service brakes and release the rear parking brakes.
A check valve in the circuit between the parking brake accumulator and the service
brake accumulator allows only the parking brake accumulator to be charged when
using the towing pump.
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SERV1921 - 09/11
• Service brake valve and front
brake manifold:
- Front brake manifold
- Front service brake solenoid
- Service brake pedal position
sensor
- Service brake valve
- Service brake pedal
-17- Module 7 - Brake System
17_1
3
4
17_2
The front brake manifold (1) is mounted below the cab on the left upper frame. The
front brake manifold contains the front service brake solenoid (2), which controls oil
to the front brakes. The amount of oil flow to the front service brakes is determined
by the Brake ECM based on a signal from the service brake pedal position
sensor (3). The Brake ECM allows some oil from the brake accumulators to flow to
the front brakes by energizing the front brake solenoid.
When the front brake disable switch in the cab is activated, the Brake ECM de-
energizes the front brake solenoid and only the rear brakes are engaged to stop the
truck.
The Brake ECM also uses the service brake pedal position sensor to energize the
brake light relay (located in cab) and turn on the brake lights.
The service brake valve (4) is mounted below the floor of the operator’s cab. When
the service brake pedal (5) is depressed, an internal spool directs oil flow from the
service brake accumulators to the ARC/TCS valve and then to the rear service
brakes.
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SERV1921 - 09/11
• Slack adjusters:
- Rear brake slack adjusters
- Service brake oil pressure ports
-18- Module 7 - Brake System
18_1
The 773G/775G trucks have two rear brake slack adjusters (1) mounted to a bracket
above the rear axle.
The rear slack adjusters are a new design, but operate the same as the 773F/775F
slack adjusters.
The slack adjusters compensate for brake disc wear by allowing a small volume of
oil to flow through the slack adjuster and remain between the slack adjuster and the
brake piston under low pressure. The slack adjusters maintain a slight pressure on
the brake piston at all times.
Brake cooling oil pressure maintains a small clearance between the brake discs.
The service brake oil pressure can be tested at the pressure ports (2) located on the
slack adjusters.
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SERV1921 - 09/11
4
3 6
• Inboard side of rear brake
housing:
- Service brake supply line
- Parking brake supply line
- Service brake bleed screw
- Parking brake bleed screw
- Brake cooling ports
- Brake wear indicator
-19- Module 7 - Brake System
1
19_1
This image shows the inboard side of the right front brake housing. Oil from the front
slack adjuster flows to the service brake piston through the service brake supply
line (1). Oil from the secondary brake/accumulator purge valve flows to the parking
brake piston through the parking brake supply line (2).
The service brake bleed screw (3) is identified by an “S” on the brake anchor plate
casting next to the screw. The parking brake bleed screw (4) is identified by a “P”
on the casting.
Another check to verify correct slack adjuster operation is to connect a gauge to the
pressure port on top of the slack adjuster and another gauge at the service brake
bleed screw location on the brake anchor plate casting.
With the service brake pedal depressed, the pressure reading on both gauges
should be approximately the same. When the brakes are RELEASED, the pressure
at the slack adjuster should return to zero. The pressure at the service brake bleed
screw location should return to the residual pressure held on the brakes by the slack
adjuster piston.
If the slack adjuster residual pressure is too low, it could indicate a failed slack
adjuster. High residual pressure may indicate a failed slack adjuster or warped brake
discs. To check for warped brake discs, rotate the wheel to see if the pressure
fluctuates. If the pressure fluctuates while rotating the wheel, the brake discs are
probably warped and should be replaced.
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SERV1921 - 09/11 -20- Module 7 - Brake System

To check for brake cooling oil leakage, block the brake cooling ports (5) and pressurize
each brake assembly to a maximum of 138 kPa (20 psi). Close off the air supply
source and observe the pressure trapped in the brake assembly for five minutes.
The trapped pressure should not decrease.

Also visible in this image is the brake wear indicator (6).

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SERV1921 - 09/11
4 6
• Inside right frame rail:
- Secondary brake/purge valve
- Parking brake solenoid valve
- Purge solenoid valve
- Secondary brake pressure
switch
- Towing valve
- Towing valve knob
-21- Module 7 - Brake System
3 1
5
2
21_1
The secondary brake/purge valve (1) is located on the inside right frame rail to the
rear of the center cross member. The secondary brake/purge valve receives oil flow
from the parking brake accumulator. Contained within the valve is a parking brake
solenoid valve (2) and a purge solenoid valve (3).
When the parking brake solenoid is energized by the Brake ECM, the parking
brake valve directs oil flow to the rear parking brakes. When the transmission shift
lever is moved to PARK, a signal is sent to the Brake ECM to engage the parking
brakes. There is not a separate parking brake control switch. The secondary brake
pressure switch (4) sends a signal to inform the Transmission/Chassis ECM that the
secondary/parking brake is engaged.
When the machine is shut down, the purge solenoid is energized by the Transmission/
Chassis ECM and the purge valve drains the brake accumulators to the tank.
The towing valve (5) is used to release the parking brakes for towing and must be
manually shifted using the knob (6) located on the bottom of the towing valve.
Once the valve is shifted, oil flow from the electric secondary steering/brake retract
pump is directed to the secondary brake/purge solenoid valve to release the parking
brake.
To release the parking brakes for service work or towing, the electric motor on the
pump is energized by the brake release switch located in the cab.
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SERV1921 - 09/11 -22- Module 7 - Brake System

When the key start switch is turned ON, the secondary steering system is energized
for three seconds to check the system. Since the towing pump is driven by the same
electric motor as the secondary steering pump, the towing valve allows the towing
pump oil to flow directly to the hydraulic tank during the secondary steering test.

When the electric motor is energized and the towing valve has been shifted, supply
oil can flow from the towing pump, through the towing valve, to the parking brake
valve. The brake release pump is also used to provide pilot oil to lower the body
when the engine is off.

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SERV1921 - 09/11
2 3
• Front inside of right frame rail:
- Brake retract pump
- Secondary steering pump
- Electric motor
-23- Module 7 - Brake System
1
23_1
The brake retract pump (1), the secondary steering pump (2), and the electric
motor (3) are mounted to a bracket, which is attached to the inside of the left front
frame rail. The brake retract pump provides oil to release the parking brakes and
hoist pilot oil for lowering the body on trucks with a dead engine.
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SERV1921 - 09/11 -24- Module 7 - Brake System

• Floor of cab:
- Secondary brake pedal position
sensor
- Secondary brake pedal
24_1
The secondary brake pedal position sensor (1) is located on the back of the secondary
brake pedal (2). The position sensor sends a signal to the Brake ECM indicating the
position of the secondary brake pedal. The Brake ECM sends a signal to the parking
brake solenoid, which controls the secondary brake application at the rear brakes.

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SERV1921 - 09/11 -25- Module 7 - Brake System

BRAKE HYDRAULIC SYSTEM

(32) PARKING BRAKES ENGAGED/SERVICE BRAKES RELEASED
Secondary Brake
Accumulator
Pressure Sensor
(2) (13) (28)
(30) Secondary Brake
(1) Parking Brake ECM Service Brake (29)
Pedal Position Sensor
Parking Brake Brake Solenoid Control Valve Service Brake
Relay Valve Pedal Position
(3) Sensor
Accumulator
Purge Solenoid

(27)
(4) Front
Rear Brake
Service Solenoid
Brake (7) ARC/TCS
Valve (31)
(14) Front
(26)
Service Service
Directional
(5) Brake Brake
Spool
Rear Accumulator
(8) (25) Front Brake
Parking Brake (15)
Brake Manifold
Reducing Parking
(6) Valve (9) Brake (24) Accumulator
Rear Brake Pressure Accumulator Charging Valve
Slack Adjuster Control
Solenoid
(10)
Resolver
(31)
Valves
Front
(9) Service
(11) Rear Brake
Pressure Brake
Supply Solenoid
Control (16)
(8) Solenoid Towing Valve
Brake (33)
Reducing Service Brake
Valve Accumulator
(6) Pressure Sensor (23)
Rear Brake Brake Oil
Slack Adjuster Cooler
(5) (19)
Rear Brake
Parking Filter
Brake (17)
Brake (21)
Retract (18) Hoist
Pump Secondary Pump
M (22) Brake
Steering Cooling
(4) (20) Brake
Pump Pump
Rear Charge Pump
Service (12)
Brake Hoist Pilot Valves

25_1
• Brake hydraulic system - This image shows the brake hydraulic system with the parking brakes ENGAGED,
PARKING BRAKES ENGAGED/ the service brakes RELEASED, and the accumulators charged.
SERVICE BRAKES RELEASED
• Accumulator charging valve Oil from the brake charging pump (20) flows through the brake oil filter (19) to the
accumulator charging valve (24). The accumulator charging valve directs supply oil
to the service brake accumulator (14), to the parking brake accumulator (15), to the
front brake manifold (25), and to the ARC/TCS valve (7). With the accumulators
charged, the charging valve will direct excess pump oil flow to the brake oil
cooler (23).

• Parking brake operation When the shift lever in the cab is in the PARK position, a signal is sent to the Brake
ECM (13). The Brake ECM de-energizes the parking brake solenoid (2). With the
parking brake solenoid de-energized, oil from the parking brake accumulator is
blocked by the parking brake solenoid valve. Oil at the top of the parking brake relay
valve (1) flows to the drain, and spring force moves the relay valve up. The parking
brake relay valve directs oil from the parking brakes (5) to the tank. The parking
brakes are engaged by spring force.

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SERV1921 - 09/11
• Secondary brake pedal
• Service brake operation
• Service brake control valve
• Front brake solenoid
-26- Module 7 - Brake System
The secondary brake pedal is used to modulate the pressure to engage the parking
brake. When the secondary brake pedal is depressed, the secondary brake pedal
position sensor (30), located at the base of the pedal, sends a PWM signal to the
Brake ECM. The Brake ECM sends a current to the parking brake solenoid, which
drains oil from the parking brake relay valve. Spring force moves the parking brake
relay valve up. The parking brake relay valve directs oil from the parking brake
pistons to the tank and the parking brakes begin to engage to slow truck
movement.
NOTE: If the shift lever is in the PARK position, the parking brake is commanded
to be engaged and the Brake ECM will not recognize the secondary brake pedal
position sensor signal.
When the service brake pedal is released, the front service brakes (31) and the rear
service brakes (4) are released. The front brakes are controlled by the Brake ECM
via the front brake solenoid (27), and the rear brakes are controlled by the service
brake control valve (28).
Oil flows through the front brake manifold to the service brake control valve. Oil
flowing into the front brake manifold also flows to the front brake solenoid and to the
directional spool (26). When the service brake pedal is released, oil from the front
brake manifold is blocked at the service brake control valve. Oil on the right end of
the brake reducing valves (8) is directed to the tank through the service brake control
valve. Spring force shifts the brake reducing valves to the right and oil from the rear
service brakes flows to the tank through the brake reducing valves. The rear service
brakes are released by spring force.
The front brakes are also released when the Brake ECM de-energizes the front
brake solenoid. When the service brake pedal is released, the service brake pedal
position sensor (29) sends a signal to the Brake ECM. The Brake ECM sends a
corresponding signal to de-energize the front brake solenoid. Spring force shifts the
front brake solenoid to the left, which drains oil from the left side of the directional
spool. Spring force shifts the directional spool to the left and oil from the front service
brakes flows to the tank. The front service brakes are released.
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SERV1921 - 09/11 -27- Module 7 - Brake System

BRAKE HYDRAULIC SYSTEM

(32) PARKING BRAKES RELEASED/SERVICE BRAKES ENGAGED
Secondary Brake
Accumulator
Pressure Sensor
(2) (13) (28)
(30) Secondary Brake
(1) Parking Brake ECM Service Brake (29)
Pedal Position Sensor
Parking Brake Brake Solenoid Control Valve Service Brake
Relay Valve Pedal Position
(3) Sensor
Accumulator
Purge Solenoid

(27)
(4) Front
Rear Brake
Service Solenoid
Brake (7) ARC/TCS
Valve (31)
(14) Front
(26)
Service Service
Directional
(5) Brake Brake
Spool
Rear Accumulator
(8) (25) Front Brake
Parking Brake (15) Manifold
Brake Reducing Parking
(6) Valve (9) Brake (24) Accumulator
Rear Brake Pressure Accumulator Charging Valve
Slack Adjuster Control
Solenoid
(10)
Resolver
(31)
Valves
Front
(9) Service
(11) Rear Brake
Pressure Brake
Supply Solenoid
Control (16)
(8) Solenoid Towing Valve
Brake (33)
Reducing Service Brake
Valve Accumulator
(6) Pressure Sensor (23)
Rear Brake Brake Oil
Slack Adjuster Cooler
(5) (19)
Rear Brake
Parking Filter
Brake (17)
Brake (21)
Retract (18) Hoist
Pump Secondary Pump
M (22) Brake
Steering Cooling
(4) (20) Brake
Pump Pump
Rear Charge Pump
Service (12)
Brake Hoist Pilot Valves

27_1
• Brake hydraulic system - This image shows the brake hydraulic system with the parking brakes RELEASED,
PARKING BRAKES RELEASED/ the service brakes ENGAGED by depressing the brake pedal, and the accumulators
SERVICE BRAKES ENGAGED charged.

• Accumulator charging valve Oil from the brake charging pump (20) flows through the brake oil filter (19) to the
accumulator charging valve (24). The accumulator charging valve directs supply oil
to the service brake accumulator (14), to the parking brake accumulator (15), to the
front brake manifold (25), and to the ARC/TCS valve (7). With the accumulators
charged, the charging valve will direct excess pump oil flow to the brake oil
cooler (23).

• Parking brake operation When the shift lever in the cab is moved from the PARK position, a signal is sent to
the Brake ECM (13). The Brake ECM sends current to energize the parking brake
solenoid (2). With the parking brake solenoid energized, parking brake accumulator
oil is directed to the top of the parking brake relay valve (1), which moves down. The
parking brake relay valve directs oil from the parking brake accumulator to the
parking brake pistons. The parking brakes (5) are released.

• Service brake operation When the service brake pedal is depressed, the front service brakes (31) and the
rear service brakes (4) are engaged. The front brakes are controlled by the Brake
ECM and the rear brakes are controlled by the service brake control valve (28).

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SERV1921 - 09/11
• Service brake control valve
• Front brake solenoid
• Front brake disable switch
-28- Module 7 - Brake System
Oil flows through the front brake manifold to the service brake control valve. Oil
flowing into the front brake manifold also flows to the front brake solenoid (27) and to
the directional spool (26). When the service brake pedal is depressed, the service
brake control valve directs oil to the resolver valves (10) in the ARC/TCS valve. The
resolver valves shift and oil flows to the right side of the brake reducing valves (8).
The brake reducing valves shift to the left and oil from the service brake accumulator
flows through the rear slack adjusters (6). The rear service brakes are engaged.
The front brakes are also engaged when the Brake ECM energizes the front brake
solenoid. When the service brake pedal is depressed, the service brake pedal
position sensor (29) sends a signal to the Brake ECM. The Brake ECM sends a
corresponding signal to energize the front brake solenoid. The front brake solenoid
shifts to the right, which directs brake charging pump oil to the left side of the
directional spool. The directional spool shifts to the right and brake pump oil is
directed to the front brake pistons. The front service brakes are engaged.
When the front brake disable switch in the cab is activated, the Brake ECM de-
energizes the front brake solenoid and only the rear brakes are engaged to stop the
truck.
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SERV1921 - 09/11 -29- Module 7 - Brake System

BRAKE HYDRAULIC SYSTEM

(32) PARKING BRAKES RELEASED WITH TOW PUMP
Secondary Brake
Accumulator
Pressure Sensor
(2) (13) (28)
(30) Secondary Brake
(1) Parking Brake ECM Service Brake (29)
Pedal Position Sensor
Parking Brake Brake Solenoid Control Valve Service Brake
Relay Valve Pedal Position
(3) Sensor
Accumulator
Purge Solenoid

(27)
(4) Front
Rear Brake
Service Solenoid
Brake (7) ARC/TCS
Valve (31)
(14) Front
(26)
Service Service
Directional
(5) Brake Brake
Spool
Rear Accumulator
(8) (25) Front Brake
Parking Brake (15)
Brake Manifold
Reducing Parking
(6) Valve (9) Brake (24) Accumulator
Rear Brake Pressure Accumulator Charging Valve
Slack Adjuster Control
Solenoid
(10)
Resolver
(31)
Valves
Front
(9) Service
(11) Rear Brake
Pressure Brake
Supply Solenoid
Control (16)
(8) Solenoid Towing Valve
Brake (33)
Reducing Service Brake
Valve Accumulator
(6) Pressure Sensor (23)
Rear Brake Brake Oil
Slack Adjuster Cooler
(5) (34)
(19)
Rear (35) Relief
Brake
Parking Pressure Valve
Filter
Brake Reducing
Valve (21)
(18) Hoist
M Secondary (22) Brake Pump
Steering Cooling
(4) (17) Brake Retract Pump (20) Brake
Pump Pump
Rear Charge Pump
Service (12)
Brake Hoist Pilot Valves

29_1
• Brake hydraulic system - The brake system is also equipped with a brake retract pump (17). In the case of a
PARKING BRAKES RELEASED loss of oil flow from the brake charging pump (20), the brake retract pump can be
WITH TOW PUMP used to release the parking brakes. The brake retract pump is driven by a motor,
which is enabled through the brake release switch in the cab.

• Brake release switch activated When the brake release switch is activated, the motor is energized, which drives the
brake retract pump. The brake retract pump provides oil flow through the towing
valve (16) to the parking brake accumulator (15), the parking brake solenoid (2), and
the parking brake relay valve (1). The parking brake relay valve directs oil to release
the parking brakes as previously described.

• Towing valve The towing valve, under normal operation, is closed and connects the brake retract
pump to the tank. If the truck is to be towed with a dead engine, the towing valve
must be shifted manually. When manually shifted, the towing valve directs oil flow
from the electric driven brake retract pump to the parking brake valve to release the
parking brakes. The towing valve also contains a relief valve (34) and a pressure
reducing valve (35). The relief valve limits pressure in the towing valve circuit. The
pressure reducing valve controls the parking brake accumulator pressure oil that is
supplied to the hoist pilot valves (12).

• Brake retract pump provides oil to The brake retract pump also provides oil to the hoist pilot valves so that the body can
hoist valve be lowered if the engine won’t run or the brake charging pump won’t operate.

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SERV1921 - 09/11
6
• Retarding and traction control
systems components:
- ARC/TCS valve
- Rear slack adjusters
- Rear brake supply solenoid
- Pressure control solenoids
- Supply hose from service brake
accumulator to ARC/TCS valve
- Return hose to tank
- Hose from service brake valve
to ARC/TCS valve
-30- Module 7 - Brake System
1
7
4
5
2
30_1
RETARDING AND TRACTION CONTROL SYSTEM
The Brake ECM controls truck retarding and the TCS. The ARC/TCS valve (1) is a
new design in the 773G/775G trucks.
The main component in the retarding system is the ARC/TCS valve, which is
mounted to the inside of the rear frame rail. The ARC/TCS valve contains three
solenoids, which control oil flow from the service brake accumulator to the rear slack
adjusters (2) and the rear brakes. The front brakes are not used with the ARC or
the TCS.
The rear brake supply solenoid (3) directs oil from the service brake accumulator to
the pressure control solenoids (4) when the retarding system or TCS is active. The
pressure control solenoids control oil flow to the brake reducing valves inside the
ARC/TCS valve, which controls the oil flow to the rear slack adjusters and the rear
brakes. Oil from the service brake accumulator enters the ARC/TCS valve through
the supply hose (5) and returns to the tank through the return hose (6). Oil from the
service brake valve enters the ARC/TCS valve through the hose (7) at the top of the
ARC/TCS valve.
When the service brake pedal is depressed, the service brake valve directs oil to the
brake reducing valves inside the ARC/TCS valve, which controls the oil flow to the
rear slack adjusters and the rear brakes as previously described.
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SERV1921 - 09/11 -31- Module 7 - Brake System
BRAKE HYDRAULIC SYSTEM
RETARDER ENABLED/REAR SERVICE BRAKES ENGAGED

(1) (5) Service Brake

Brake ECM Control Valve
(3) Retarder Lever
(2) ARC Switch (4) Engine
Speed Sensor

(6) Front
Brake
Solenoid
(9)
(12) ARC/TCS Accumulator
Valve Charging Valve (10)
(11)
Rear (7) Front
Service Directional Service
Brake Spool Brake
(14) (8) Front Brake
Brake Manifold
Reducing
(17) Valve (13)
Rear Brake Pressure
Slack Adjuster Control
Solenoid
(15) (10)
Resolver Front
Valves Service
(13) Brake
(16) Rear Brake
Pressure
Supply Solenoid
Control
(14) Solenoid
Brake
Reducing
Valve
(17)
Rear Brake
Slack Adjuster

(11)
Rear
Service
Brake

31_1
• Brake hydraulic system - This schematic shows the retarding system components in the brake hydraulic
RETARDER ENABLED/SERVICE system with the service brakes engaged by the retarding function. Retarding control
BRAKES ENGAGED is a feature of the 773G/775G trucks, which is used to control the truck downhill
speed. The feature consists of manual retarding and Automatic Retarding Control
(ARC). The manual retarder lever is used for retarding when ARC is not desired by
the operator, such as a speed slower than the speed that initiates the ARC.

• Manual retarder lever activated When the manual retarder lever (3) is activated, the lever sends a proportional signal
to the Brake ECM (1). The Brake ECM sends a current to the rear brake supply
• ARC activated solenoid (16) and the pressure control solenoids (13). When the ARC is activated,
by pressing the ARC switch (2) in the cab, and the engine speed sensor (4) senses
an increase above the desired engine speed, the Brake ECM sends a current to the
rear brake supply solenoid and the pressure control solenoids.

• Rear supply solenoid and
pressure control solenoids
energized
Oil from the accumulator charging valve also flows into the ARC/TCS valve (12).
With the rear supply solenoid and the pressure control solenoids energized, oil from
the accumulator charging valve is directed to the resolver valves (15). The resolver
valves shift and oil flows to the right end of the brake reducing valves (14). The brake
reducing valves shift to the left and oil from the accumulator charging valve flows
through the rear slack adjusters (17). The rear service brakes (11) are engaged.

NOTE: If the manual retarder lever and the ARC are ENGAGED at the same
time, the pressure control solenoids will receive a current that corresponds to
the system that is requiring the most braking.

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SERV1921 - 09/11
• ARC allows truck to maintain
constant engine speed
• Engine overspeed protection
• Enhanced diagnostic capabilities
-32- Module 7 - Brake System
ARC allows the truck to maintain a constant machine speed during a long downgrade.
The ARC ON/OFF switch activates the ARC and the operator must select the correct
gear for the grade, load, and ground conditions. ARC is set at the factory to maintain
a constant engine speed of 1938 rpm (engine speed is programmable from 1838 to
1938 rpm). When the ARC initially takes control of retarding, the engine speed may
oscillate out of the ± 50 rpm target, but the engine speed should stabilize within a few
seconds.
The ARC system is designed to allow the transmission to upshift to the gear selected
by the shift lever. After the transmission shifts to the gear selected by the operator,
and the engine speed exceeds 2285 rpm, the ARC system will apply the retarder as
needed to maintain a constant engine speed.
The ARC system also provides engine overspeed protection. If an unsafe engine
speed is reached, the ARC will engage the rear brakes, even if the ARC switch is in
the OFF position and the throttle is depressed.
Trucks approaching an overspeed condition will sound a horn and activate a light.
If the operator ignores the light and horn, the ARC will engage the retarder. If the
engine speed continues to increase, the Transmission/Chassis ECM will either
upshift (only one gear above the shift lever position) or unlock the torque converter
(if the shift lever is in the top gear position).
The ARC also provides service personnel with enhanced diagnostic capabilities
through the use of onboard memory, which stores possible faults, solenoid cycle
counts, and other service information for retrieval at the time of service.
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SERV1921 - 09/11 -33- Module 7 - Brake System

TRACTION CONTROL SYSTEM

(1) Brake ECM

INPUT COMPONENTS OUTPUT COMPONENTS

(2) TCS Test Switch
(8) Rear Brake
(3) Left Wheel Supply Solenoid
Speed Sensor

(4) Right Wheel (9) Pressure

Speed Sensor Control Solenoids

(5) Service Brake Pedal

Position Sensor

(6) Transmission Output

Speed Sensors

(7) Steering Cylinder

Position Sensor

33_1

Traction Control System (TCS)

• Traction control system (TCS)
The Traction Control System (TCS) uses the rear service brakes to decrease the
revolutions of a spinning wheel. The TCS allows the tire with better underfoot
conditions to receive an increased amount of torque. The system is controlled by the
Brake ECM (1) and operates similar to the 773F/775F TCS but uses the rear service
brakes rather than the rear parking brakes to slow the wheels.

• Brake ECM monitors speed and
steering angle
The Brake ECM monitors the drive wheels and the steering angle. The drive wheels
are monitored through four input signals: the left rear wheel speed sensor (3), the
right rear wheel speed sensor (4), and the transmission output speed sensors (6)
(via the Transmission ECM). The steering angle is monitored through the steering
cylinder position sensor (7).

When a spinning drive wheel is detected, the Brake ECM sends a signal to the rear
brake supply solenoid (8) and the pressure control solenoids (9), which ENGAGE the
rear service brake of the affected wheel. When the condition has improved and the
ratio between the right and left axles returns to 1:1, the Brake ECM sends a signal
to RELEASE the brake.

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SERV1921 - 09/11 -34- Module 7 - Brake System

• Service brake pedal position The service brake pedal position sensor (5) provides an input signal to the Brake
sensor ECM and performs the following two functions:

• When the service brakes or retarder are ENGAGED, the TCS function
is stopped.

• The service brake pedal position sensor provides the input signal
needed to perform a diagnostic test. When the TCS test switch (2) and
the retarder lever are ENGAGED simultaneously, the TCS will engage
each rear brake independently. Install two pressure gauges on the
ARC/TCS valve, and observe the pressure readings during the test
cycle. The left brake pressure will decrease and increase. After a short
pause, the right brake pressure will decrease and increase. The test
will repeat as long as the TCS test switch and the retarder lever are
ENGAGED.

• ARC/TCS valve pressure ports Pressure ports can be installed on the ARC/TCS valve to check the left and right
brake release pressure. When the proportional solenoid is ENERGIZED, Cat ET will
show 68% when the brake is FULLY ENGAGED.

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SERV1921 - 09/11 -35- Module 7 - Brake System

TCS WHEEL SPIN RATIO VS. STEERING ANGLE

2.2
2.1 2.1

2.0
1.875 1.875
TCS Wheel Spin Ratio

1.8

1.65 1.65
1.6

1.425 1.425
1.4

1.2
1.2

1
-40 -30 -20 -10 0 +10 +20 +30 +40

Steering Angle - Degrees

35_1
• Explain TCS wheel spin ratio vs. When the front wheels are straight, the TCS is active when one rear wheel is spinning
steering angle approximately 1.2 times as fast as the other (spin ratio). The TCS provides more
traction when the truck is traveling straight.

The cut-in wheel speed ratio of the TCS will vary with the steering angle of the truck,
so if the wheels are turned at a larger angle with respect to straight-line motion, the
cut-in ratio for TCS engagement increases.

In simple terms, when the truck is performing a tight turn, the ratio between the rear
wheels is expected to be larger and thus a larger cut-in ratio is required so that the
TCS is not as sensitive while the machine is performing a tight circle. If the wheels
are not turned at all, the ratio of the wheel speed will be closer to one and the cut-in
ratio of the wheel speed is lower.

NOTE: This graph is an example of the steering angle versus the spin ratio
and is only for explanation purposes. The graph does not depict the actual TCS
software map in the Brake ECM.

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SERV1921 - 09/11
• Speed and steering cylinder
sensors:
- Rear wheel speed sensor
- Steering cylinder position
sensor connector cover
-36- Module 7 - Brake System
36_1
36_2
The top image shows the left rear wheel speed sensor (1) looking toward the rear of
the truck. The TCS monitors the drive wheels through four input speed signals: one
at each drive axle, and two at the transmission output shaft.
The transmission output speed sensors monitor the ground speed of the machine
and provide input signals to the Brake ECM through the Cat Data Link. The TCS
uses the transmission output speed sensors to disable the TCS when ground speed
is above 19.3 km/h (12 mph).
The steering cylinder position sensor is located inside the left steering cylinder and
the sensor connector can be accessed by removing a cover (2) on the head end of
the steering cylinder.
NOTE: Module 6 “Steering System” provides an explanation of the steering
cylinder position sensor.
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SERV1921 - 09/11 -37- Module 7 - Brake System
(02) (01) Accumulator Charging Valve
Left Rear
Service Brake ARC/TCS VALVE
ENGINE RUNNING/BRAKES RELEASED

(07)
Brake (04)
Reducing Brake ECM
Valve (05)
Pressure
Control
Solenoid (09)
(06) Service Brake
Resolver Control Valve
Valves (05)
(08) Rear Brake Pressure
Supply Solenoid Control
Solenoid
(07)
Brake
Reducing
Valve

(03)
Right Rear
Service Brake 37_1
• ARC/TCS valve - ENGINE This illustration shows the ARC/TCS valve with the engine running and the brakes
RUNNING/BRAKES RELEASED RELEASED.

With the engine running, oil flows from the accumulator charging valve (1) into the
ARC/TCS valve.

In the ARC/TCS valve, oil flows through a screen to the rear brake supply
solenoid (8) and to the brake reducing valves (7). When the TCS is not activated, the
rear brake supply solenoid and the pressure control solenoids (5) are de-energized
by the Brake ECM (4). Oil from the accumulator charging valve is blocked at the
rear brake supply solenoid. Spring force moves the brake reducing valves to the
right, and oil from the left rear service brake (2) and right rear service brake (3) is
directed to the tank through the brake reducing valves. The rear service brakes are
RELEASED.

Caterpillar: Confidential Yellow

SERV1921 - 09/11 -38- Module 7 - Brake System
(02) (01) Accumulator Charging Valve
Left Rear
Service Brake ARC/TCS VALVE
ENGINE RUNNING/LEFT BRAKE ENGAGED

(12)
Wheel Speed
Sensors
(07)
Left Brake (04)
Reducing Brake ECM
Valve (05)
Left
Pressure
Control (11)
(09) Solenoid Service Brake
Resolver Control Valve
Valves (06)
(10) Rear Brake Right
Supply Solenoid Pressure
Control
(08) Solenoid
Right Brake
Reducing
Valve

(03)
Right Rear
Service Brake 38_1
• ARC/TCS valve - ENGINE This illustration shows the ARC/TCS valve with the engine running and the left brake
RUNNING/LEFT BRAKE ENGAGED.
ENGAGED
When signals from the wheel speed sensors (12) indicate that the left wheel is
spinning 60% faster than the right wheel, the Brake ECM (4) sends a signal to the
rear brake supply solenoid (10) and the left pressure control solenoid (5). The rear
brake supply solenoid shifts down and directs oil to the pressure control solenoids.
The left pressure control solenoid shifts to the left and oil is directed to the top resolver
valve (9). The resolver shifts and oil flows to the right end of the left brake reducing
valve (7). The left brake reducing valve shifts to the left and oil is directed to the left
rear service brake (2). The pressure control solenoids control the rate at which the
oil is allowed to flow to the service brakes.

The left rear service brake begins to ENGAGE. The left brake orifice restricts the
flow of oil to the service brake.

When the signals from the sensors indicate that the left wheel is no longer spinning,
the Brake ECM stops sending signals to the rear brake supply solenoid and the left
pressure control solenoid. Oil from the accumulator charging valve is blocked at the
rear brake supply solenoid. Spring force moves the left brake reducing valve to the
right and oil from the left rear service brake is directed to the tank through the left
brake reducing valve. The left rear service brake is RELEASED.

Caterpillar: Confidential Yellow

SERV1921 - 09/11 -39- Module 7 - Brake System

BRAKE COOLING SYSTEM

(3)
Accumulator
Charging Valve

(5)
Rear Brake (2) Hoist Valve
(1) Brake
Oil Cooler

(4) Brake
Cooling
Pump

(6) Brake Charge Pump

(5)
(7) Hoist Pump
Rear Brake

39_1

BRAKE COOLING SYSTEM

• Brake cooling system oil flow
This schematic shows the oil flow through the brake cooling system on the 773G/775G
trucks. The brake oil cooler (1) receives oil from the hoist valve (2) (in the HOLD,
FLOAT, and SNUB positions) and the accumulator charging valve (3). The brake oil
cooler also receives oil from the brake cooling pump on trucks with the Tier 4
engine.

Oil from the brake cooler flows to the rear brakes to cool the brakes. The cool oil
returns to the hoist and brake hydraulic tank.

• Pressure relief valve The pressure in the brake cooling system is limited by a relief valve located in the
hoist valve. The relief valve is usually needed only when the brake cooling oil is cold.
When brake cooling oil is at operating temperature, the brake cooling oil pressure is
usually much lower than the setting of the oil cooling relief valve.

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SERV1921 - 09/11 -40- Module 7 - Brake System

1 2

4
5

40_1
• Brake cooling system The brake cooling pump (1), on models with the Tier 4 engine, is a gear-type pump
components: mounted to the brake charging pump (2) at the rear of the engine.

- Brake cooling pump Oil flow from the brake cooling pump (Tier 4 engine) combines with oil from the hoist
- Brake charging pump valve (3) and flows to the brake oil cooler (4) located on the right side of the engine.
- Hoist valve The oil from the cooler flows to the rear brakes through the brake cooling lines (5).
- Brake oil cooler
Engine coolant from the water pump flows around the brake oil cooler and back to
- Brake cooling lines the cylinder block. The engine coolant transfers the heat from the brake oil system
to the engine coolant.

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SERV1921 - 09/11
• Rear brake cooling lines:
- Inlet line test ports
- Outlet line test ports
- Rear brake oil temperature
sensor.
-41- Module 7 - Brake System
41_1
This image shows the brake cooling lines to the rear brakes. Brake cooling inlet oil
pressure can be tested at the inlet line test ports (1) and the brake cooling outlet oil
pressure can be tested at the outlet line test ports (2).
The pressure measured at the brake inlet tube (from the oil cooler) will always be
higher than the pressure measured at the brake outlet tube.
The rear brake oil temperature sensor (3) is located in the right brake oil return line.
The brake oil temperature sensor sends a signal to the Brake ECM indicating brake
oil temperature. The Brake ECM will send a signal over the Cat Data Link, which
informs the monitoring system to display the temperature on the brake temperature
gauge.
The most common cause of high brake cooling oil temperature is operating the truck
in a gear range, which is too high for the grade and not maintaining a high enough
engine speed. The engine speed should be maintained at approximately 1900 rpm
during long downhill hauls. Make sure the oil cooling relief valve is not stuck open.
Make sure the pistons in the slack adjuster are not stuck and holding too much
pressure on the brakes.
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