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Producto: TRUCK ENGINE

Modelo: C-12 TRUCK ENGINE 1YN
Configuración: C-12 Truck Engine 1YN00001-UP

Operación de Sistemas
C-10 and C-12 Truck Engines
Número de medio -SENR6593-04 Fecha de publicación -05/01/2004 Fecha de actualización -06/03/2004

i01797547

Compression Brake
SMCS - 1119; 1129

The compression brake is powered from the ECM. The compression brake helps the operator to slow
the vehicle on grades, in curves, or for a necessary speed reduction. The service brakes should not be
used continuously on long descending grades. The service brakes are assisted by the compression
brake. The engine crankshaft is turned by the rear wheels during downhill operation or during any
slow down condition. The engine crankshaft is turned through the differential, through the drive
shaft, through the transmission, and through the clutch. An application of a braking force can be
made to the engine piston in order to reduce the speed of the vehicle.

When the compression brake is activated, braking power is accomplished by opening the engine's
exhaust valves. The exhaust valves are opened near the top of the compression stroke in order to
release the highly compressed air into the exhaust system. The compression brake can only be
activated when the engine is in the no-fuel position. Thus, combustion does not occur and no positive
force is produced on the piston. The compressed air pressure that is released to the atmosphere
prevents the energy from returning to the engine piston on the power stroke. The result is a loss of
energy since the work that is done by the compression of the cylinder charge is not returned by the
expansion process. This loss of energy is taken from the rear wheels. The rear wheels provide the
braking action for the vehicle.

Illustration 1 g00501265

Compression brake

(1) Control valve

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(2) Lead wire

(3) Bolt assembly

(4) Slave piston

(5) Solenoid valve

(6) Master piston

(7) Stud and nut

The compression brake consists of three identical housing assemblies. A housing assembly is
installed in each of the valve mechanism compartments above the rocker arms and above the rocker
arm shaft. Each housing assembly is positioned over two cylinders. The housing assembly is
mounted to the supports for the rocker arm shaft with studs and nuts (7). The housing assemblies are
supported on the cylinder head with bolt assembly (3). The exhaust bridge assembly is used to
transfer force from slave piston (4) to the exhaust valve. The brake logic signal for the compression
brake is carried to solenoid valve (5) by lead wire (2). This is done in order to activate the
compression brake on the two cylinders of the engine.

A spacer is used on the top of the valve cover base in order to provide space for the installation of
the compression brake and of the valve cover. When the compression brake is installed, the height
increases approximately 63.5 mm (2.50 inch).

The control circuit for the compression brake permits the operation of either one, two, or all three of
the compression brake housing assemblies. This provides progressive braking capabilities with the
retarding effect of two cylinders, of four cylinders, or of all six cylinders in the engine.

Performance of the Compression Brake

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Illustration 2 g00427859
Performance of the compression brake

The performance of the compression brake, which is shown in the graph, represents an engine with
the three housing assemblies that are activated in order to stop the vehicle. The compression brake
should not be activated when the engine rpm is above 2300. The maximum engine power rating is
2100 rpm. At this level, the amount of braking that is produced by the compression brake is
approximately 315 to 325 horsepower.

Operation of the Compression Brake

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Illustration 3 g

Schematic for master-slave circuit

(1) Rocker arm shaft oil passage

(2) Solenoid valve

(3) Lead wire

(4) Spring

(5) Control valve

(6) High pressure oil passage

(7) Slave piston adjustment screw

(8) Master piston

(9) Engine oil pump

(10) Spring

(11) Engine oil pan

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(12) Fuel injector rocker arm

(13) Fuel injector pushrod

(14) Slave piston

(15) Oil drain passage

(16) Low pressure oil passage

(17) Ball check valve

(18) Exhaust valve rocker arm

(19) Exhaust valve

(20) Exhaust bridge assembly

The compression brake is operated by engine oil that is distributed around the studs. This oil is
supplied through the supports for the rocker arm shaft. Solenoid valve (2) controls the oil flow in the
compression brake housing.

When the solenoid is activated by a signal from the logic for the compression brake, solenoid valve
(2) moves downward. This causes oil drain passage (15) to engine oil pan (11) to be closed. At the
same time, low pressure oil passage (16) to control valve (5) is opened. As low pressure oil passage
(16) is filled with engine oil, the control valve is pushed upward in the chamber against the force of
spring (4). At this position, a groove in control valve (5) is in alignment with high pressure oil
passage (6). Slave piston (14) and master piston (8) are supplied by the high pressure oil passage.
Engine oil pressure will now lift ball check valve (17). High pressure oil passage (6) and the
chambers behind the slave pistons and behind the master pistons will be filled with engine oil
pressure. This pressure moves the master piston downward until contact is made with fuel injector
rocker arm (12). When upward motion is initiated on the master piston, the pressure increases above
the current level of the engine supply pressure. This causes ball check valve (17) to seat. The system
is now operating in conjunction with the exhaust valve and with the injector rocker mechanism.
When the solenoid is activated, the compression brake could be operable within 1/5 of a second.

Fuel injector pushrod (13) will begin to move upward on the pumping stroke of the electronically
controlled unit injector. When this occurs, fuel injector rocker arm (12) makes contact with
extending master piston (8). As the master piston begins to move upward, the oil pressure increases
in high pressure oil passage (6). This happens because ball check valve (17) will not allow oil to exit.
The upward movement of the fuel injector rocker arm creates a constant increase in pressure. This
forces the slave piston downward against the screw assembly in exhaust bridge assembly (20). The
slave piston moves downward with enough force to open exhaust valve (19) .

Note: Only one of the two exhaust valves for each cylinder on this engine is used in the operation of
the compression brake.

This master-slave circuit is designed to move the master piston (8). The master piston is moved
when the engine is on the compression stroke. The master-slave circuit is designed so that slave
piston (14) opens one exhaust valve of the same cylinder only on the compression stroke. This
occurs slightly before the piston reaches the top center position. The braking force is constant. The
operation of the compression brake of a cylinder is caused by the motion of the valve mechanism of
that cylinder. This causes the firing sequence of the valves to be identical to the firing order of the
engine.

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When solenoid valve (2) is in the Off position, the engine oil supply passage is closed and oil drain
passage (15) is opened. This allows oil to drain from underneath control valve (5). This also allows
spring (4) to push the control valve to the bottom of the chamber. This position allows oil from high
pressure oil passage (6) to drain into the chamber above the control valve's piston. This chamber
vents to the outside of the compression brake housing. Spring (10) now moves master piston (8) to
the retracted position away from fuel injector rocker arm (12). The time that is necessary for the
system to stop operation is approximately 1/10 of a second. The compression brake will not be able
to operate until solenoid (2) is activated again.

Copyright 1993 - 2006 Caterpillar Inc. Thu Jul 20 10:30:17 CDT 2006
Todos los derechos reservados.
Red privada para licenciados del SIS.

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