Training for Brake System of DW90A Off-

Road Wide-Body Dumper

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CONTENTS

Table of Contents
I. Introduction of braking system

II. Schematic diagram of braking system

III. Introduction of brake system parts

IV. Service and maintenance of brake system

INTRODUCTION TO THE BRAKE SYSTEM
1. Definition and function of brake system
Definition: A set of devices that can generate and control the braking force of a vehicle is
called a braking system.

Function:
Ø Stop or slow down the running vehicle;
Ø Park the stopped vehicle;
Ø Keep the speed stable when the vehicle goes downhill.
INTRODUCTION TO THE BRAKE SYSTEM
2. Brake system classification

The brake system includes service brake, parking brake and auxiliary brake

(1) Service braking: dual-circuit air-operated brake system

The so-called dual-circuit brake system divides the front axle and the intermediate and
rear axle into two related and independent circuits. When any one circuit fails, it will not
affect the normal work of the other circuit to ensure the reliability of braking.

(2) Parking brake: spring brake system

When the air source is disconnected, the compressed air in the spring chamber of the
brake chamber is discharged through the exhaust port of the relay valve, and the spring
releases energy can push the brake lever for mechanical braking. After inflation, the
braking is released, which is commonly known as "air brake".
INTRODUCTION TO THE BRAKE SYSTEM
(3) Auxiliary braking: it includes the engine cylinder braking, exhaust braking, eddy-current retarder
and hydrodynamic retarder.
① Engine cylinder braking: The engine cylinder brake is the retarder of the diesel engine. After
starting, by changing the operation of the engine exhaust valve, the engine becomes air
compression to absorb kinetic energy. Its essence is to turn the diesel engine that generates
energy into an air compressor to absorb energy;
② Exhaust brake: By closing the exhaust pipe of the engine, the back pressure is established in
the engine as an auxiliary braking device, so that the engine absorbs the kinetic energy of the
automobile and achieves the purpose of continuous braking.
③ Eddy-current retarder: it uses the electromagnetic principle for braking without mechanical
friction. The computer automatic control gradually increases the braking torque and braking
force, which is combined with the service braking to greatly shorten the braking distance.
④ The hydrodynamic retarder uses gasoline and engine oil as the actuating medium, which is
driven by the rotor to act on the stator. The braking torque is generated due to the impact and
damping of the oil, and the kinetic energy of the automobile is also converted into heat energy
due to the damping of the oil, which is dissipated by the heat dissipation system of the complete
vehicle.
INTRODUCTION TO THE BRAKE SYSTEM
Auxiliary braking can bear nearly 60% of braking energy when the vehicle decelerates, and
reduce the tire bursts caused by high temperature.

Engine cylinder braking

Electric turbine retarder

Hydrodynamic
Exhaust brake retarder
CONTENTS

Table of Contents
I. Introduction of braking system

II. Schematic diagram of braking system

III. Introduction of brake system parts

IV. Service and maintenance of brake system

WORKING PRINCIPLE OF AIR BRAKE SYSTEM
1. Three-dimensional schematic diagram (20Y0604):

60L front
axle air tank 60L Intermediate and Auxiliary
rear axle air tank air tank
 WORKING PRINCIPLE OF AIR BRAKE SYSTEM
1. Three-dimensional schematic diagram (20Y1039):
Rear axle relay valve

Intermediate 30L Rear axle

axle relay valve air tank Differential relay valve

30L Secondary air tank

To Rear axle brake
To Air chamber
Radiating
Filter
To air spiral tube
compressor

Differential lock solenoid valve

To front axle
brake
30L Rear axle air tank

To Hand Front axle 60L intermediate-

Brake relay valve axle air tank

To foot brake 60L front axle air

valve Dryer + four tank
To air horn protection valve
WORKING PRINCIPLE OF AIR BRAKE SYSTEM
2. The working principle of the braking system:

The engine is started up to drive the air compressor to operate; the high-temperature
air from the compressor, being subjected to heat-sink cooling via the first air pipe,
passes through the dryer for removing moisture, and reaches the four-circuit protection
valve; when pressure is up to opening pressure as specified by the four-circuit
protection valve, air flows to each air storage cylinder and the relay valve sequentially,
and then, flows to the brake chamber to achieve braking.

The schematic diagram is as follows:

WORKING PRINCIPLE OF AIR BRAKE SYSTEM
2. Schematic diagram of braking system
Lifting gas Exhaust
brake valve
Air-taking Solenoid
block valve
Differential
lock
Auxiliary
Air dryer air tank Hand-
Four-circuit brake Solenoid
protection valve valve valve

Clutch booster
Air compressor Brake
master Transmission
valve

Rear-axle brake air

Foot brake valve tank Rear axle
brake
Intermedi
Intermediate chamber
Front axle brake Intermediate ate axle
axle brake brake
chamber axle relay
air tank chamber
valve
Front axle brake Rear axle
air tank relay valve
Front axle
relay valve
Intermedi
ate axle
brake
chamber
Front axle
brake chamber
Rear axle
brake
chamber
WORKING PRINCIPLE OF AIR BRAKE SYSTEM
3. Schematic diagram of braking system-service braking circuit
Four-circuit protection
Air dryer valve

Intermediate/Rear axle braking air circuit

Air compressor Intermediate/Rear axle control air circuit

Front axle braking air circuit

Front axle control air circuit

Rear-axle
brake air tank
Foot brake valve Rear axle
Front axle brake Intermediate axle
brake chamber brake chamber
chamber

Intermediate
axle brake
air tank
Front axle brake
air tank
Front axle relay valve
Rear axle
relay valve

Intermediate
axle relay
valve

Intermediate axle Rear axle brake

Front axle brake brake chamber chamber
chamber
WORKING PRINCIPLE OF AIR BRAKE SYSTEM
4. Schematic diagram of brake system - parking brake circuit
Auxiliary
Air dryer air tank
Four-circuit protection
valve

Air compressor
Brake master
valve

Rear axle
brake
Intermediate chamber
Front axle brake axle brake
chamber chamber

Foot brake valve

Intermediate
axle brake
Front axle chamber
brake
chamber
Rear axle brake
chamber
CONTENTS

Table of Contents
I. Introduction of braking system

II. Schematic diagram of braking system

III. Introduction of brake system parts

IV. Service and maintenance of brake system

INTRODUCTION OF BRAKE SYSTEM PARTS
1. Air compressor

Ø The air compressor is installed on the engine

as an engine accessory, driven by the engine,
and provides compressed air to the braking
system and other auxiliary air systems.
Ø The cylinder head is cooled by engine coolant.
INTRODUCTION OF BRAKE SYSTEM PARTS
2. Dryer-Function
Dryer is an air treatment unit, which not only integrates the functions of unloading valve, but also dries the air from air
compressor to a certain extent. Its intermediate port is reflux port. Its specific function is to use the high-pressure gas in the air
reservoir to bring the water vapor and oil gas in the dryer to the atmosphere when the dryer functions as unloading valve, so
that the dryer can achieve the purpose of regeneration.

Four-circuit
Air dryer
protection valve
INTRODUCTION OF BRAKE SYSTEM PARTS
2. Dryer - technical requirements
① Working medium: air
② Working temperature:-40 ℃ to + 65 ℃
③ Maximum working pressure: 13 bar
④ Cut-off pressure: 8.5 ± 0.2 bar
⑤ Restore air supply pressure drop: 0.7-1.2 bar
⑥ Reflux pressure drop: 0.4 ± 0.05 bar
⑦ Rated power/working voltage of electric
heater: 100W/24VDC
Heater starting temperature: 7℃ ± 6℃
Heater disconnect temperature: 29.5℃±3℃
INTRODUCTION OF BRAKE SYSTEM PARTS
2. Dryer - working principle

• When the air flows through

the particle dryer, the water
is removed and retained in Body
the upper layer of the
particle dryer.

Air
compressor Open the Four-way
check valve protection valve

Channel

As the temperature
drops, condensed water
will be generated, and
the condensed water will
pass through the
channel to the valve at
the outlet.
INTRODUCTION OF BRAKE SYSTEM PARTS
2. Dryer - working principle Four-circuit
protection
valve

Air
compressor

5L
regenerative
air reservoir
INTRODUCTION OF BRAKE SYSTEM PARTS
3. Four-circuit protection valve - action

Ø It divides the front axle brake system, intermediate and

rear axle brake system, parking brake system, and
auxiliary gas system into four completely independent
circuits.
Ø It is used in multi circuit air braking system. When one
circuit fails, it can still ensure that there is a certain safe
braking air pressure in other circuits.
Ø The four air outlets are independent and can control the
rear axle, front axle, parking and auxiliary circuits
respectively. The opening pressure of the first and
second circuits and the third and fourth circuits can be
the same or different, but the opening pressure of
former cannot be less than that of the latter, which can
be adjusted by the pressure regulating spring.
INTRODUCTION OF BRAKE SYSTEM PARTS
3. Four-circuit protection valve - parameters

Circuit
21 22 23 24
Item

Opening pressure
0.47 0.47 0.5 0.5
(MPa)
Safety pressure
(MPa) ≧0.4
(port 1 maintains
air supply)

0 ≧0.34 # ≧0.34
When a circuit fails
( air pressure of ≧0.34 0 ≧0.34 ≧0.34
port 1 is 0), close
pressure statically ≧0.34 >0.34 0 ≧0.34
(MPa)
≧0.34 ≧0.34 ≧0.34 0
INTRODUCTION OF BRAKE SYSTEM PARTS
3. Four-circuit protection valve - working principle

There are "21", "22", "23" and "24"

digital signs at the four output ports
of the four-circuit protection valve.
During installation, connect the
corresponding pipelines according
to the digital signs (port 21 is
connected to the rear axle brake
circuit, port 22 is connected to the
front axle brake circuit, port 23 is
connected to the auxiliary air circuit,
and port 24 is not connected). Do
not install them wrongly, otherwise
abnormal braking will occur.
INTRODUCTION OF BRAKE SYSTEM PARTS
3. Four-way protection valve - schematic diagram
Four-circuit To auxiliary gas
protection valve storage tank

To the front
axle air tank

From air
compressor

To intermediate-rear axle air tank

 INTRODUCTION OF BRAKE SYSTEM PARTS
4. Brake master valve and its principle
Ø The master brake valve, commonly known as foot brake valve, is mainly used for service
braking. It adopts dual-circuit control to control the braking of front axle and rear axle at the
same time.
Ø The built-in valve core can increase the braking force with the increase of pedal stroke.

From the
To the Intermediate
Intermediate and rear axle
and rear axle Air reservoir
Relay valve
To front axle From front axle
Relay valve Air reservoir
INTRODUCTION OF BRAKE SYSTEM PARTS
4. Brake master valve-working principle
The upper circuit, that is, the first circuit, outputs the brake signal air pressure to the (intermediate) rear axle relay valve,
opens the control relay valve, so that the compressed air from the (intermediate) rear axle brake air reservoir enters the
(intermediate) rear brake chamber through the relay valve, pushes the (intermediate) rear brake camshaft to rotate, and
opens the leading shoe of the drum brake to realize the (intermediate) rear axle wheel braking. The lower circuit, that is,
the second circuit, outputs the brake signal air pressure to the relay valve, opens the relay valve, makes the compressed
air of the front axle brake air reservoir enter the left and right front brake chambers through the relay valve, pushes the
front brake camshaft to rotate, and opens the collar and slave shoes of the drum brake to realize the braking of the front
wheels.
Service brake, when the pedal Release the service
is depressed. brake and release
the pedal.

Roller

The ejector rod moves

downward under the action of
the roller.

Close the valve ports of

chambers 11 and 12,
open the exhaust valve at
Open the valve ports of the same time, and control
chambers 11 and 12, and the return gas to exhaust
close the exhaust valve at
into the atmosphere
the same time
through the exhaust port

Port 11 Port 11
Port 21

Port 22 Port 12 Port 12

INTRODUCTION OF BRAKE SYSTEM PARTS
5. Relay valve - function
Ø During braking, the compressed air in the reservoir is quickly filled into the brake chamber to shorten the braking
reaction time;
Ø When the brake is released, the compressed air in the brake chamber is quickly emptied to avoid brake drag.
There are three relay valves on the complete vehicle, namely the front axle relay valve, the intermediate axle relay valve
and the rear axle relay valve
INTRODUCTION OF BRAKE SYSTEM PARTS
5. Relay valve - working principle
In general, the air inlet is connected to the air reservoir, and the air outlet is connected to the brake chamber. When the
brake pedal is depressed, the output air pressure of the brake valve is input as the pilot control pressure of the relay
valve. Under the action of the pilot control pressure, the air inlet valve is pushed open, so the compressed air enters the
brake chamber directly from the air reservoir through the inlet instead of flowing through the brake valve, which greatly
shortens the inflation pipeline of the brake chamber and accelerates the inflation process of the chamber.

Depress the foot

pedal, input the Relay valve
brake signal air
pressure, and the
relay valve opens

Main valve Braking

process

Transmissi
on air
supply port
Brake chamber

When braking, the compressed air from the brake valve

enters chamber a from port 4, moves the piston 7
downward and closes the exhaust valve 6. At this time,
the inlet valve 5 is opened, and the compressed air will
be transmitted from port 1 to the brake air chamber
through port 2. When the balance is reached, the inlet
and exhaust valves will be closed at the same time.
INTRODUCTION OF BRAKE SYSTEM PARTS
5. Relay valve - ports

From the gas tank

Pilot control air

valve (from
brake master
valve)

Service brake
chamber to brake
chamber
INTRODUCTION OF BRAKE SYSTEM PARTS
6. Differential relay valve
The differential relay valve prevents the overlapping of the combined spring brake
cylinder and the force in the brake chamber (spring brake chamber) when the service
and parking brake systems operate at the same time, so as to avoid the overload of
mechanical transmission elements. In addition, it can also make the spring brake
cylinder charge and exhaust quickly.
INTRODUCTION OF BRAKE SYSTEM PARTS
6. Differential relay valve-working principle
Hand-brake
Differential relay
valve
valve

Air pressure
without brake
signal

Piston 1

Piston 2 Main valve

Spring chamber
leading to spring
air chamber

Transmission Brake chamber

air supply port
INTRODUCTION OF BRAKE SYSTEM PARTS
6. Differential relay valve-working principle (continued)

When parking braking, if the service brake

system is activated, the pressure is
established through the port 41 and
chamber (C) . If the pressure is finally
large enough to push the piston (5) down,
the exhaust valve (8) is closed and the
inlet valve (6) is opened. The pressure of
the air reservoir at port 1 enters the spring
chamber of the spring brake chamber
through port 2. As the braking force of the
service brake system increases, this will
partially or completely alleviate the braking
effect of the parking brake system.
 INTRODUCTION OF BRAKE SYSTEM PARTS
6. Differential relay valve-port

Control gas Control gas

circuit from foot circuit from hand
brake valve brake valve

From Parking brake

auxiliary gas chamber to all
storage tank brake
chambers
INTRODUCTION OF BRAKE SYSTEM PARTS
7. Hand brake valve
Function: It can follow the emergency brake and parking brake of the car. Between the
driving position and the parking position, the joystick can automatically return to the driving
position, and it can be locked when in the parking position.

Working principle
(continued When the handle 1 is turned a=42.5°,
the handle is in the thrust position at
this time, and the vehicle is in a fully
braked state. The remaining air from
the control port is discharged from port
3.
When the handle
is at the rightmost
end, the vehicle
is in the fully
released braking
state.

Port 2 Port 2
Port 1 Port 3 Port 1
INTRODUCTION OF BRAKE SYSTEM PARTS
8. Air reservoir - action
Stores the compressed air from the air compressor, and uses it in
automobile braking, honking and other systems.
INTRODUCTION OF BRAKE SYSTEM PARTS
8. Air reservoir - purpose and action
The air reservoir is divided into front axle braking, intermediate and rear axle
braking, auxiliary air and regenerative air reservoir according to different air
consuming parts.
Auxiliary air. In addition to braking, the parts of the vehicle that need air:
Ø Exhaust brake;
Ø Air horn;
Ø PTO;
Ø Tire inflation; Auxiliary air
Ø Damping seat;
Ø Intermediate and rear axle differentials.
Functions:
Ø Energy storage
Ø Filter
Ø Pressure stabilization Gas for
intermediate
Ø Cooling Front axle air and rear axles
INTRODUCTION OF BRAKE SYSTEM PARTS
8. Air reservoir-drain valve
The drain valve is installed in the lower part of the gas storage cylinder to discharge the
oil, water, and impurities accumulated in the air reservoir. If necessary, it can also be
used to release the air pressure in the air reservoir. For example, when repairing air
pipelines.
INTRODUCTION OF BRAKE SYSTEM PARTS
9. Brake chamber - action
The front, intermediate, and rear brake chambers of this car all use composite
brake chambers, which are used to not only act on the service brake of the
intermediate and rear axles, but also implement emergency braking.
INTRODUCTION OF BRAKE SYSTEM PARTS
9. Brake chamber - working principle
The diaphragm spring brake chamber provides braking force for the wheels. The
diaphragm chamber of the combined spring brake chamber is used for service
braking, and the spring chamber is used for parking braking and emergency braking,
and the two chambers are completely independent of each other.
INTRODUCTION OF BRAKE SYSTEM PARTS
9. Brake chamber - service brake
During service braking, the compressed air operated by the foot brake valve enters chamber
a through port 11, acts on diaphragm d, pushes tray a, compresses return spring c, and
pushes push rod b out. The force acting on diaphragm d acts on the brake arm through tray
a → push rod b, generating braking torque for the wheel.

Air from the air brake control

The air spring chamber of the element generates the
parking or emergency braking braking force by moving the
circuit is being compressed. push rod to the right.
INTRODUCTION OF BRAKE SYSTEM PARTS
9. Brake chamber - parking brake
During parking braking and emergency braking, the hand brake valve is operated to
fully or partially release the compressed air in chamber B through port 12, and the
spring f also fully or partially releases its energy to generate braking torque to the
wheels through piston e / diaphragm d, tray a, push rod b and brake arm.
• After the gas in the parking or
emergency braking circuit is
discharged, the spring chamber
moves forward under the action It is in a dead state
of the energy storage spring
INTRODUCTION OF BRAKE SYSTEM PARTS
9. Brake chamber - precautions
Ø Loosen the bolt g counterclockwise to release the parking brake, which is used to manually
release the brake without compressed air;
Ø During normal driving, the bolt g shall be screwed to the end clockwise, otherwise it cannot
stop normally;
Ø The spring force of the return spring(f) is very large, and the spring cavity must be
disassembled by professionals under the special tooling.
INTRODUCTION OF BRAKE SYSTEM PARTS
10. Brake - action
Ø It is used for braking during driving to slow down or stop the vehicle
Ø It is used for parking braking to keep the vehicle stationary for a long time.
Ø Use drum brake.

Non-braking
Brake State
state
INTRODUCTION OF BRAKE SYSTEM PARTS
10. Brake - structure
The front, intermediate and
rear axle brake adopts the
same structural form, mainly
including dust cover, brake
base plate, brake shoe, return
spring, fixing pin, brake
camshaft, adjusting arm, etc.
INTRODUCTION OF BRAKE SYSTEM PARTS
10. Brake-clearance adjustment
With the increase of service time, the brake pads are gradually worn, and the brake will be
insensitive to travel braking and slow in response, so it is necessary to adjust the brake. The
correct brake clearance is an important prerequisite to ensure safe driving.

1. Tighten the adjusting nut

on the adjusting arm to
the end;
2. Loosen 2-3 buckles;
3. The front axle has one
more loose buckle than
the intermediate and rear
axles;
4. If the brake is still
insensitive after
adjustment, consider
replacing the brake
shoes.
INTRODUCTION OF BRAKE SYSTEM PARTS
10. Brake-clearance adjustment
After the brake clearance is adjusted in place by the adjusting arm, it is necessary to
measure the clearance between the brake pad and the brake hub with a feeler gauge.
The clearance range is 0.7 - 1.7mm, and the difference between the upper and lower
drum-shoe is less than 0.5mm.
INTRODUCTION OF BRAKE SYSTEM PARTS
11. Air-taking block
In the auxiliary brake pipeline, the compressed air in the
auxiliary air tank is divided into multiple paths.
Exhaust
brake
valve
Lifting gas

Solenoid
valve
Air-taking
block Differenti
al lock

Solenoid
valve

Clutch booster

Transmission
INTRODUCTION OF BRAKE SYSTEM PARTS
12. Brake line

Connect the relevant components in the braking system in a certain sequence.

CONTENTS

Table of Contents
I. Introduction of braking system

II. Schematic diagram of braking system

III. Introduction of brake system parts

IV. Service and maintenance of brake system

谢谢 T HANK Y O U
TOUGH WORLD. TOUGH EQUIPMENT.
极 限 工 况 强 悍 设 备