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Personal injury or death can result if two persons are not used in the following procedure. |
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Sudden movement of the machine or release of oil under pressure can cause injury to persons on or near the machine. To prevent possible injury, perform the procedure that follows before testing and adjusting the brake system. |
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Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat products. Dispose of all fluids according to local regulations and mandates. |
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Personal injury can result from improper troubleshooting and repair procedures. The following troubleshooting and repair procedures should only be performed by qualified personnel familiar with this equipment. |
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Do not attempt to disassemble or assemble this machine until you read and understand the disassembly and assembly instructions. Improper disassembly and assembly procedures could result in injury or death. |
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Personal injury can result from contact with hot hydraulic oil and from contact with hydraulic oil that is under high pressure. Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. The hydraulic oil pressure must be released before any service on the hydraulic system is performed or serious personal injury could occur. Verify that all of the work tools have been completely lowered to the ground. Release the hydraulic oil pressure at the hydraulic tank through the breaker relief valve when the breaker relief valve is cool enough to touch with your bare hand. Verify that the hydraulic oil is cool before you begin to remove any hydraulic components or hydraulic lines. |
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Before service work is begun, park the machine on a hard level surface. Block the wheels of the machine so unexpected movement will not occur. Unexpected movement of the machine can cause personal injury or death. |
This procedure will remove air from the brake system.
| Required Tooling | |||
| Item | Part Number | Description | Qty |
| F | Transparent tube |
4 | |
| Suitable containers | 4 | ||
| G | 177-7860(1) | Hose As | 1 |
| H | 6V-4143(1) | Quick Connect Coupler | 2 |
| J | 6V-3966(1) | Fitting As | 1 |
| K | 1S-8937(1) | Needle Valve | 1 |
| (1) | Assemble into a tool for purging the brakes. |
Connect each end hose assembly (G) to one quick connector coupling (H). Connect fitting assembly (J) to needle valve (K). Then connect quick connector coupling (H) to fitting assembly (J) that is attached to needle valve (K).
| Required Parts if Your Machine Has Plug (B) Installed in the Brake Housings | |||
| Callout | Part Number | Description | Quantity |
| 1 | 115-5411 | Elbow | 4 |
| 2 | 214-7568 | O-Ring Seal | 4 |
| 3 | 3K-0360 | O-Ring Seal | 4 |
| 4 | 6V-3965 | Fitting | 4 |
| 5 | 6V-0852 | Dust Cap | 4 |
- Prepare the machine for testing by completing the procedure that is specified in the Service Manual module Troubleshooting, "Machine Preparation for Troubleshooting" for the machine that is being serviced.
- Move the machine to a smooth, horizontal location. Move the machine away from other operating machines and away from personnel. Lower the bowl to the ground and move the parking brake switch to the on ON position. Place chocks in front of the wheels and behind the wheels.
- Check the hydraulic tank oil level. Make sure that you maintain the correct oil level in the hydraulic oil tank throughout the air removal procedure.
- With the engine running at low idle hold the service brake pedal in the not fully ON position.
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Illustration 1 g03896108 View if the right front wheel station.
(1) Parking brake air purge valve
(2) Service brake air purge valve - Fasten one end of a transparent tube (F) to each air purge valve. Place the other end of the tube into a suitable container for collecting the hydraulic oil.
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| Illustration 2 | g03896086 |
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View of the right rear wheel station. Service brake air purge valve (1). | |
- Hold the end of tubing (F) in a suitable container.
- With the engine running at low idle hold the service brake in PARTIALLY APPLIED position.
- Open each service brake purge valve, one at a time until the stream of hydraulic oil is visually free of air.
- Actuate the differential lock valve while the engine is at LOW IDLE. Then cycle the differential valve lock five times between the ON and the OFF. Wait 15 seconds between each cycle.
- Refill the hydraulic tank to the full mark and replace the cap onto the hydraulic tank.
- Check the hydraulic oil level and refill the hydraulic tank to the full mark as necessary. Then replace the cap onto the hydraulic tank.
Note: Failure to follow the sequence as detailed in this procedure may result in inadequate purging of the parking brake
- Verify that the parking brake control is in the ON position.
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Illustration 3 g03896103 Top view of the right front wheel station
(1) Park brake air purge valve
(2) Service brake air purge valve - Install a needle valve and hose assembly to the adapter on the parking brake port on the left front wheel.
- Start the engine. Turn the parking brake control to the OFF position.
- Open the needle valve to allow oil to flow. Drain the oil into a suitable container. Continue to purge the system until the oil is free of air. When the oil is free of air, close the needle valve, turn the parking brake control to the ON position, and shut the machine off.
- Remove the needle valve and hose assembly from the parking brake port.
- Repeat Steps 2 through 5 on the right front wheel.
