Service Manual of RS8160 Road Roller

SERVICE MANUAL

5 Brake System

Service Manual for G9165 Grader

CONTENTS
5 Brake System ....................................................................................................... 5-1
51 Service Brake System .......................................................................................... 5-1
511 System Composition and Working Principle .............................................. 5-1
512 Specification and Technical Description of Main Components ................. 5-3
513 Disassembly and Assembly Single-Circuit Foot Brake Valve ................... 5-9
514 Disassembly and Assembly of Accumulator............................................. 5-11
515 Disassembly and Assembly of Prefill Valve ............................................. 5-13
516 Replacement of Brake Shoe ...................................................................... 5-15
52 Parking Brake System ....................................................................................... 5-19
521 Working Principle of Parking Brake ......................................................... 5-19
522 Disassembly and Assembly of Parking Brake Control Mechanism ......... 5-20
53 Diagnosis and Solutions for Common Faults of Brake System ........................ 5-22
523 Common Fault of Service Brake System .................................................. 5-22
524 Common Fault of Parking Brake System .................................................. 5-24

Service Manual for G9165 Grader

Brake System

The brake system of this grader consists of service brake system and parking brake system. The
function of service brake system is to realize speed reduction and stop when the vehicle is running
according to the operators requirements. The parking brake is used for grader to brake under
emergency conditions during operation or to keep loader stay at original position after stop,
avoiding movement in the effect of inclined road or other external forces.

51 Service Brake System

This machine adopts full hydraulic brake system. It
has advantages of smooth braking, safe and reliable,
simple structure, and convenient maintenance. The
system

is

designed

with

drum-type

brake.

(Double-circuit service brake system is optional,

when a circuit fails, the other brake circuit can still
carry out braking, which improves the vehicle's
safety).

511 System

Composition

and

Working Principle
The service brake system is supplied by gear pump.
During driving, the oil from the pump flows into the
accumulator through prefill valve. When the
operator steps on the brake pedal, high pressure oil
stored in accumulator (or from the prefill valve)
splits into two parts, flows into the wheel side
brake cylinders respectively to engage braking.
Meanwhile, the brake lamp switch will be trigged
by pressure oil to turn on the brake lamp. Release
the brake pedal, the pressure oil circuit to the brake
valve will be cut off, and the hydraulic oil in the
5-1

Service Manual for G9165 Grader

wheel side brake cylinders will return to oil tank
through valve, then the brake will be released and
the brake lamp will be off.
The prefill valve always takes supplying oil to the
accumulator as first priority. The two accumulators
will be charged to set pressure as long as the
engine is running, to guarantee reliable braking.
The brake valve controls the four rear wheel side
brakes through hydraulic circuits, and braking
pressure is determined by the pressure acted on
brake valve.

Fig. 5-1 Composition of service brake system

1 Brake pump

2 Filter

3 Hydraulic oil tank

4 Joint

6 Oil return block

7 Brake valve

8 Accumulator

9 Pressure switch

10 Brake joint block

11 Right wheel side brake

5-2

5 Prefill valve

12 Left wheel side brake

Service Manual for G9165 Grader

512 Specification

and

Technical

Description of Main Components

Prefill valve
The prefill can keep the two accumulators at right
pressure. When the pressure of oil in the
accumulators drops to 12.4MPa or below, the
prefill valve will charge them immediately. When
the pressure of oil in the accumulators is charged to
16MPa, the prefill will stop charging.

1 2
3
4
Fig. 5-2 Prefill valve
1 Port O
2 Port T
3 Port A
4 Port P

Prefill valve for double-circuit brake system.

1
2 3 4
5 6
Fig. 5-3 Prefill valve
1 Low-pressure alarm switch
2 Port A1
3 Port P
4 Port A2
5 Port O
6 Port T

5-3

Service Manual for G9165 Grader

Brake valve
The hydraulic brake valve is composed of valve
body, oil channels and moveable valve block. Step
the brake pedal, the corresponding oil channels will
open to connect the inlet port and outlet port.
Release the brake pedal, the inlet port and outlet
port will be disconnected and the braking will be
relieved.

1 2
3 4
Fig. 5-4 Foot brake valve
1 Port A1
2 Port A2
3 Port T
4 Port P

Foot brake valve for double-circuit brake system.

1 23 4 56
Fig. 5-5 Foot brake valve
1 Port T1
2 Port T2
3 Port A1
4 Port A2
5 Port P1
6 Port P2

5-4

Service Manual for G9165 Grader

Bladder type accumulator

Accumulator is used to store pressure oil for braking.
Its principle is to store the pressure liquid and
capsule with pressure in a sealed housing and it is
used to brake by absorbing and releasing the liquid
due to the changing pressure. When brake pump is
working, it injects the pressure fluid into
accumulator through prefill valve to store energy.
Then, the gas is compressed in the capsule, so that
1
Fig. 5-6
1 Accumulator

the pressure of liquid is the same with that of

capsule, to obtain energy reserves. The air in
capsules is nitrogen.
The accumulator can store sufficient pressure oil.
In case of system failure (the prefill valve is not
able to charge), the pressure oil stored in the
accumulator can conduct 6 times braking.

When the pressure of oil in accumulator is lower

than 11.5MPa, low-pressure alarm switch will be
trigged and the alarm indicator on instrument panel
will be on. You should stop the vehicle for
inspection immediately.

1
Fig. 5-7
1 Lo-pressure alarm switch

5-5

Service Manual for G9165 Grader

Method to inflate the accumulator
1.

Firstly park the machine on flat ground,

continuously operate the service brake and
parking brake several times, and drain the high
pressure oil in accumulators as far as possible.
Then slowly loosen the oil pipe on the bottom
of accumulator and drain the residual pressure
out of the accumulator.

2.

Remove the protective cap of inflation valve

from top of the accumulator.

3.

Connect the end with pressure gauge of

inflation tool to the inflation valve on top of
accumulator, and the other end should be
connected with nitrogen cylinder.

4.

Open the switch of nitrogen cylinder. After the

inflation pressure of inflation tools is stable,
slowly open the switch on the inflation tools,
i.e., open the inflation valve in the accumulator
and fill air into the accumulator.

5.

Pressure may be instantly achieved, then switch

off the nitrogen cylinders, and see whether the
pressure value still indicates the specified value
after the gauge of inflation tools come to stable.
If not, then refill it. If the pressure is high, drain
the air through the inflation plug through

Fig. 5-8 Working principle of accumulator

inflation tools, and reduce the pressure to the

appropriate value.
6.

After air is filled to required pressure, firstly

switch off nitrogen cylinders, and then close the
switch on inflation tools.

7.

Remove the air inflation tool.

8.

If accumulator leaks (Wipe accumulator head

with oil, and if there is leakage, bubbles will
come out. Hit the inflation valve inside the

5-6

Service Manual for G9165 Grader

accumulator with a hammer and a screwdriver.
Pull it down, and then quickly reset it until the
sealing surface can be connected.
9.

Install protection cap of accumulator inflation

valve.

Brake assembly
The brake assembly comprises brake and brake
drum.
When the operator steps on the brake pedal, high
pressure oil stored in accumulator (or from the
prefill valve) splits into two parts, flows into the
wheel side brake cylinders respectively. Brake
1
Fig. 5-9
1 Brake

cylinder pushes the brake shoe to expand outside,

to produce friction resistance between the brake

2 Brake drum

and brake drum inner wall, so as to realize braking.

The brake mainly consists of brake carrier, brake

cylinder, brake shoe assembly and accessories.
The brake assembly is equipped with brake parts
clearance automatically adjustable cylinder. When
the friction plate is worn off, the clearance between
the friction plate and brake drum can be adjusted
automatically to offset the wear loss.
1
2
3
4
Fig. 5-10 Brake assembly
1 Brake cylinder
2 Brake shoe assembly
3 Brake carrier
4 Return spring

5-7

Service Manual for G9165 Grader

Deflation of brake system

After overhauling of brake system, there will be air
in

the

pipeline,

which

will

affect

brake

performance. So air bleeding must be done after

the overhaul.
The air bleeding should be performed by two men
cooperatively. Each wheel side brake is designed
with deflating valve (air bleeding valve), do the air
bleeding according to the following instructions:
1
Fig. 5-11
1 Plastic cap

1.

Remove the plastic cap of air bleeding bolt.

2.

Connect a hose to the air bleeding bolt, and put

the other end of the hose into a container.

3.

Loosen the air bleeding bolt about half a turn,

and tread down the brake pedal. Once there is
oil overflowing, tighten the bolts immediately,
and release the brake pedal.

ATTENTION
The overflowing oil could be transient, so
you need to perform the air bleeding
operation coordinately and cooperatively.
1
Fig. 5-12
1 Container

4.
2 Rubber hose

The air in other brakes should be drained out

according to related requirements as well.

5-8

Service Manual for G9165 Grader

513 Disassembly

and

Assembly

Single-Circuit Foot Brake Valve

Disassembly of single-circuit foot brake valve
1.

Tread down the brake pedal repeatedly to

unload the brake system.

2.

Disconnect the oil pipes from port A, port T

and port T of foot brake valve.

ATTENTION
When dismantling the hydraulic pipes, do
not screw off the nut connecting to the oil
1
2
Fig. 5-13
1 Port T
3 Straight joint

port rashly. Loosen the nut gradually until

the oil spills out so as to prevent the oil

2 Port P
4 Port A

splashing due to incomplete pressure relief.

When dismantling the hydraulic pipeline,
necessary protective measures shall be
taken for each pipeline and oil port to
prevent debris like dust from entering the
brake system.
3.

Remove the four straight joints.

4.

Remove the three connecting bolts of foot

brake valve and cab.

5.

1
Fig. 5-14
1 Bolt

5-9

Take the brake valve out of cab.

Service Manual for G9165 Grader

Assembly of single-circuit foot brake valve
1.

Fix the foot brake valve on cab with three

bolts.

1
Fig. 5-15
1 Bolt
2.

Install the four straight joints to the valve.

583Nm

3.

Connect the oil pipes to port A, port T and port

T of foot brake valve accordingly.
454.5Nm

1
2
Fig. 5-16
1 Port T
3 Straight joint

2 Port P
4 Port A

5-10

Service Manual for G9165 Grader

514 Disassembly and Assembly of

Accumulator
Disassembly of accumulator
1.

Remove

the

six

connecting

bolts

of

accumulator periphery board and frame.

1
Fig. 5-17
1 Periphery board

2
2 Bolt

2.

Tread down the brake pedal repeatedly to

unload the brake system. Remove the oil pipe
from the bottom of accumulator.

ATTENTION
When dismantling the hydraulic pipes, do
not screw off the nut connecting to the oil
port rashly. Loosen the nut gradually until
the oil spills out so as to prevent the oil
1
2
Fig. 5-18
1 Accumulator

splashing due to incomplete pressure relief.

When dismantling the hydraulic pipeline,

2 Oil pipe

necessary protective measures shall be

taken for each pipeline and oil port to
prevent debris like dust from entering the
brake system.

5-11

Service Manual for G9165 Grader

3.

Loosen the U-shape fixing bolt of accumulator

and take down the bolts, nuts and gaskets, and
then take out the accumulator and remove the
straight joint.

ATTENTION
The accumulator may still contain pressure
even removed from the machine, and that is
1
Fig. 5-19
1 U-shape bolt
3 Accumulator

so-called preload pressure. You must be

very careful when handling or operating on

the accumulator.

2 Rubber mat

Assembly of accumulator
1.

Fix the accumulator on the support with

U-shape bolt, rubber mat, nuts and gaskets.

1
Fig. 5-20
1 U-shape bolt
3 Accumulator

2 Rubber mat

2.

Install the straight joint and connect the oil

pipe.
Pipe joint: 31031Nm
Oil pipe: 707Nm

1
2
Fig. 5-21
1 Accumulator

2 Oil pipe
5-12

Service Manual for G9165 Grader

3.

Install the accumulator periphery board to rear

frame with bolts.

1
Fig. 5-22
1 Periphery board

2
2 Bolt

515 Disassembly and Assembly of

Prefill Valve
Disassembly of prefill valve
1.

Remove

the

six

connecting

bolts

of

accumulator periphery board and frame.

1
Fig. 5-23
1 Periphery board

2
2 Bolt
2.

Disconnect the oil pipe (to oil tank) from port

O of prefill valve.

3.

Disconnect the oil pipe (to high-pressure filter

oil outlet) from port P of prefill valve.

4.

Remove the T-junction from port A of prefill

valve.

5.

Remove the T-junction from port T of prefill

valve.

1
4
Fig. 5-24
1 Oil pipe (Port O)
3 T-junction (Port T)
4 T-junction (Port A)

3
2 Port P

5-13

Service Manual for G9165 Grader

6.

Remove the fixing bolts of prefill valve

periphery. Take down the valve.

1
Fig. 5-25
1 Bolt

Assembly of prefill valve

1.

Install the fixing bolts of prefill valve

periphery.

1
Fig. 5-26
1 Bolt

2.

Install the T-junction to port A of prefill valve.

Install the T-junction to port T of prefill valve.
707Nm

3.

Connect the oil pipe (to high-pressure filter oil

outlet) to port P of prefill valve.
707Nm

4.

Connect the oil pipe (to oil tank) to port O of

prefill valve.

1
4
Fig. 5-27
1 Oil pipe (Port O)
3 T-junction (Port T)
4 T-junction (Port A)

11010Nm

3
2 Port P

5-14

Service Manual for G9165 Grader

5.

Install the six connecting bolts of accumulator

periphery board and frame.

1
Fig. 5-28
1 Periphery board

2
2 Bolt

516 Replacement of Brake Shoe

1.

Remove the rear wheels. Refer to 7 Frame,

Wheels & Working Device for details.

1
Fig. 5-29
1 Tire

2.

1
Fig. 5-30
1 Brake drum

5-15

Remove the brake drum.

Service Manual for G9165 Grader

3.

Remove the end cover.

4.

Remove the splined hub.

5.

Remove the return spring.

1
Fig. 5-31
1 End cover

1
Fig. 5-32
1 Splined hub

ATTENTION
Be careful when disassembling the spring,
and protective measures shall be taken.

1
Fig. 5-33
1 Return spring

5-16

Service Manual for G9165 Grader

6.

Replace the brake shoes.

7.

Install the return spring.

1
Fig. 5-34
1 Brake shoe

ATTENTION
The new brake shoe must be grinded and
repaired to ensure necessary contact area
between the brake shoe and brake drum.
Besides, to avoid unbalanced braking force,
the two brake shoes should be replaced
together.
1
Fig. 5-35
1 Return spring

8.

1
Fig. 5-36
1 Splined hub

5-17

Install the splined hub.

Service Manual for G9165 Grader

9.

Install the end cover.

1
Fig. 5-37
1 End cover

10. Install the brake drum.

1
Fig. 5-38
1 Brake drum

11. Install the rear wheels.

700~800Nm
12. Recover the machine.

1
Fig. 5-39
1 Tire

5-18

Service Manual for G9165 Grader

52 Parking Brake System

521 Working Principle of Parking
Brake
The parking brake system is used to keep loader
stay at original position after stop, to avoid
unexpected movement due to inclined road or
external forces. The system consists of brake
handle, parking brake and fixed plate.
Hand brake operating mechanism comprises hand
brake, control handle, and control wire (flexible
shaft). When pulling up the brake control handle,
the pull rod will swing and the cylindrical can at
1 2
3
Fig. 5-40 Schematic diagram of parking
brake system
1 Parking brake is relieved
2 Parking brake is engaged
3 Parking brake assembly

the end of the pull rod will rotate to expand the two
brake shoes (friction plates), the brake shoes will
press against the inner wall of rotating brake drum
to realize braking, and the hand brake indicator
light will be on.
Generally, the failure rate of parking (hand) brake
system is very small. But if basic maintenance
tasks are not being carefully addressed, phenomena
like brake slide, wear of friction plates, crack of
brake drum and brake dray (the grader is not able
to move after reliving the brake) may occur. The
brake slide is caused by severe worn friction plates.
The main causes of premature wear of friction
plate are: there is oil on friction plate, or swell of

1
Fig. 5-41
1 Hand brake indicator light

friction plates (exposed to moisture). The brake

drag is mainly caused by swell of friction plate.
Thereby, you should clean the friction plates
periodically to keep them clean and dry.

5-19

Service Manual for G9165 Grader

522 Disassembly and Assembly of

Parking

Brake

Control

Mechanism
Disassembly

of

parking

brake

control

mechanism
1.

Remove the fixing screws of parking brake

control handle shield.

Fig. 5-42
1 Screw
2 Parking brake control handle

2. Screw off the adjusting nut of flexible control

shaft.
3. Use a plier to remove the cotter pin and
connecting pin.
4. Take down parking brake assembly.

Fig. 5-43
1 Adjusting nut
2 Connecting pin, cotter pin

5-20

Service Manual for G9165 Grader

Assembly of parking brake control mechanism
1.

Fix the parking brake control handle shield on

cab floor with screws. Then set the brake
handle in the lowest position (non-braking
state). Connect the flexible control shaft and
the hand brake.

Fig. 5-44
1 Screw
2 Parking brake control handle

2.

Connecting the parking brake control shaft to

the parking brake with pin and cotter pin, and
fix the shaft on the support.

1
2
Fig. 5-45
1 Adjusting nut
2 Connecting pin, cotter pin

5-21

Service Manual for G9165 Grader

53

Diagnosis and Solutions for Common Faults of Brake System

Common faults of full hydraulic brake system are: Insufficient foot brake force, parking brake cant
be released normally, insufficient parking brake force, accumulator charging failure or too long
charging time, no inching braking, low service brake pressure alarm indicator light is on, and the
brake lamp doesnt work.

523 Common Fault of Service Brake System

Table 5-1
S/N

Problems

Diagnosis

Solutions
1.

2.
1.
2.
3.

Insufficient
foot brake
force

4.
5.
6.
7.
8.

There is air in brake line.

Brake valve is faulty.
There is leakage in the
brake line.
Prefill valve does not work.
Accumulator is damaged.
Friction plate of wheel side
brake is worn to the limit.
The pilot pump is too old to
work.
There is oil (dirt) on brake
shoe

3.

4.
5.
6.
7.
8.

Charging
frequency of
prefill valve
is too fast

1.
2.
1.

Accumulator
charging
failure

2.
3.
4.

Pressure of accumulator
capsules is too low.
Prefill valve does not work.
There is no oil or oil level
is too low in hydraulic
tank.
Pump is too old to work
There is air in accumulator.
Prefill valve does not work

5-22

1.

Drain the air. There are deflating

valves on left and right wheel side
brakes.
Check brake valve, detect whether
the maximum braking pressure of
brake valve outlet is equal to the
brake pressure required by the
system. If the pressure is not
normal, adjust the brake pressure or
replace the brake valve.
Check whether the brake pipelines
and connectors leak. If the
connector is loose, retighten it; if
the seal is damaged, replace it.
Replace prefill valve.
Check the accumulator
Replace friction plate.
Check the pressure or flow of
pump.
Clean the brake shoe.

2.

Check the air pressure in the

accumulator capsules.
Replace prefill valve.

1.
2.
3.
4.

Check the oil level in the tank.

Check the pump pressure or flow.
Drain the air.
Replace the prefill valve.

Service Manual for G9165 Grader

1.

Accumulator
charging
time is too
long

2.
3.

1.
5

The brake
lamp doesnt
work

Low service
brake
pressure
alarm
indicator
light is on

2.

1.

2.

Pump is too old to work

and cannot deliver all flow
or pressure.
Prefill valve does not work.
Accumulator capsule is
damaged and nitrogen is
leaked.
The
brake
lamp
damaged.
There are system faults
the working process
grader and oil pressure
decreasing.

1.
2.
3.

is
in
of
is

System
pressure
is
inadequate, in the short
time of starting grader.
System failure, the oil
pressure is decreased.

1.
2.

Check the brake lamp.

Stop the machine to check it.

1.

Please wait that the alarm will stop

automatically if system oil
pressure is sufficient.
Stop the machine for inspection

2.

1.

Low service
brake
pressure
alarm
indicator
light is on
when service
brake
is
engaged

1.
2.

Check the pressure or flow of

pump.
Replace the prefill valve.
Remove, check or
replace
capsules.

There is leakage in brake

line.
Pressure of nitrogen in the
accumulator capsule is
abnormal
(caused
by
sealing failure).

2.

Check whether the brake pipes and

pipe joints have leakage problem.
If the pipe joint is loose, retighten
it; if the seal is damaged, replace
the seal.
Unload
the
brake
system
thoroughly before measuring the
nitrogen pressure. Methods: Shut
down the engine and tread down
the brake pedal repeatedly to
unload the brake system, and use
pressure gauge to measure the
nitrogen pressure.

No inching
braking

Brake valve failure.

Detect whether the maximum pressure

of brake valve outlet is normal. If the
maximum pressure of export is much
greater than required system pressure,
replace the brake valve.

Off tracking
when
braking

Inflation pressure of the tires

are not uniform.

Try to keep the tire pressure uniform as

far as possible.

5-23

Service Manual for G9165 Grader

524 Common Fault of Parking Brake System

Table 5-2
S/N

Problems

Diagnosis

1.

Parking
brake failure

2.
3.

Parking
brake
control
handle
cannot
fixed

Solutions

The clearance between

brake drum and brake shoe
is too large, the contact
area is small.
There is oil on the brake
shoe.
The expansion force of the
brake shoe is not enough.

The parking brake

handle is faulty.

control

be

5-24

1.
2.
3.

Readjust it as required.
Clean brake shoe.
Adjust the stroke of parking brake
control mechanism.

Check whether the parking brake

control handle deformed or jammed,
whether the spring is broken. If not,
check whether it is caused by screw
loose.