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Testing and Adjusting

R1600G Load Haul Dump Braking System
Media Number -RENR7838-01 Publication Date -01/02/2004 Date Updated -19/02/2004

i01949922

Brake Disc Wear - Check

SMCS - 4255-535

Table 1

Required Tools
Part Number Part Description Qty
9EL9734 Brake Wear Tool 1

Personal injury or death can result if two persons are not used in the
following procedure.

Personal injury or death can result from machine movement.

Place blocks in front of and behind the wheels to make sure the machine
does not move while the parking brakes are disengaged.

NOTICE
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, "Caterpillar Tools and Shop

Products Guide" for tools and supplies suitable to collect and contain
fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates.

Brake service life can vary greatly because of the different machine applications. The following conditions can lead
to premature brake failure:

z Check for oil leaks at the yoke and the drive axles. A leak can also allow contamination from water and debris
to occur. Water and debris can enter the axle through the lip seal at the drive yoke. The water and debris can
mix with the oil. This water and debris can lead to premature brake failure.

z The axle housing breather is plugged or damaged. Check the axle housing breather for proper operation.

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z Excessive heat can be generated if the service brakes are used as a retarder. Excessive heat can be generated if
the service brakes are used as a device to maintain a slower ground speed. This type of operation should be
avoided by using a lower transmission speed.

Grooves are cut in the faces of the friction discs. It is very important to change the friction disc as soon as possible
once the groove depth has reached the maximum wear limit. As the depth of the grooves is reduced, the flow of the
cooling oil is reduced. This causes heat to build up. The heat causes the rapid wear of the disc material. Eventually,
the friction material will wear off the disc. This will cause metal to metal contact between the disc and plates. This
problem is known as spalling.

The buildup of the friction material in the oil could cause damage to the very smooth surface finish of the plate.
Spalling will destroy the very smooth surface finish of the plate. This will make replacement of these brake
components necessary.

If the failure has progressed to metal to metal contact, the complete axle must be thoroughly cleaned. This process of
cleaning the axle must be done correctly, or the debris will continue to contaminate the oil. This will cause the
material on the brake disc to wear rapidly. This condition will cause premature failure of the service and parking
brakes.

If excessive brake wear or premature brake wear is suspected, perform a scheduled oil sampling. This report could
help establish a possible cause for failure of the service and parking brake.

With Axle Oil Cooler

Table 2

Required Tools
Part Number Part Description Qty
1W-2152 Cover 1

9L-1633 Drive Gasket 1

8T-1159 Bolts 2

1. Move the machine to a hard, level surface.

2. Engage the parking brake and stop the engine.

View Image

Illustration 1 g00915687

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Note: Axle oil cooler pump (2) must be removed from the pump drive prior to running the engine for the brake
disc wear check.

3. Remove two bolts (1) and the washers. Remove axle oil cooler pump (2) from the pump drive. Remove the O-
ring seal from axle oil cooler pump (2) .

View Image

Illustration 2 g00915688

4. Install a 9L-1633 Drive Gasket and 1W-2152 Cover (3) over the pump drive. Install two 8T-1159 Bolts (4) and
the washers.

5. Drain the differential oil.

Reference: Refer to Operation and Maintenance Manual, "Differential and Final Drive Oil (With Axle Oil
Cooler) - Change" for the machine that is being serviced.

6. Put blocks in front of the wheels and behind the wheels to ensure the machine will not move with the parking
brake disengaged.

View Image

Illustration 3 g00906463
(5) Plug

7. Remove plug (5) from the axle housing.

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View Image

Illustration 4 g01014757
Brake wear tool (installed)

(6) Parking brake piston

(7) Axle housing

(8) 9EL9734 Brake Wear Tool

8. Install brake wear tool (8) into axle housing (7). The rod on the brake wear tool must contact parking brake
piston (6) .

9. Start the engine and disengage the parking brake. Put a mark on the brake wear tool rod at this position with a
suitable marker.

10. Engage the parking brake. Put a mark on the brake wear tool rod at this position with a suitable marker.

11. Stop the engine.

12. Remove the brake wear tool. The distance between the two marks on the rod is the parking brake piston travel.

13. If the parking brake piston travel reaches 4.9 mm (0.19 inch) the wheel brakes are worn and must be
overhauled.

Table 3

Parking Brake Piston Travel

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New Brake Discs Worn Brake Discs

2.0 mm (0.079 inch) 4.9 mm (0.19 inch)

Note: If one wheel brake is found to have worn brake discs, both wheel brake assemblies on that axle must be
overhauled.

14. Install plug (5) to the axle housing.

15. Remove two 8T-1159 Bolts (4) and the washers. Remove 1W-2152 Cover (3) and the 9L-1633 Drive Gasket
from the pump drive.

16. Install a new O-ring seal to axle oil cooler pump (2). Install axle oil cooler pump (2) to the pump drive. Install
two bolts (1) and the washers.

17. Remove the blocks from in front of the wheels and behind the wheels.

18. Fill the differential.

Reference: Refer to Operation and Maintenance Manual, "Differential and Final Drive Oil (With Axle Oil
Cooler) - Change" for the machine that is being serviced.

Without Axle Oil Cooler

1. Move the machine to a hard, level surface.

2. Engage the parking brake and stop the engine.

3. Drain the differential oil.

Reference: Refer to Operation and Maintenance Manual, "Differential and Final Drive Oil (Without Axle Oil
Cooler) - Change" for the machine that is being serviced.

4. Put blocks in front of the wheels and behind the wheels to ensure the machine will not move with the parking
brake disengaged.

View Image

Illustration 5 g00906837
(1) Plug

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5. Remove plug (1) from the axle housing.

View Image

Illustration 6 g01014759
Brake wear tool (installed)

(2) Parking brake piston

(3) Axle housing

(4) 9EL9734 Brake Wear Tool

6. Install brake wear tool (4) into axle housing (3). The rod on the brake wear tool must contact parking brake
piston (2) .

7. Start the engine and disengage the parking brake. Put a mark on the brake wear tool rod at this position with a
suitable marker.

8. Engage the parking brake. Put a mark on the brake wear tool rod at this position with a suitable marker.

9. Stop the engine.

10. Remove the brake wear tool. The distance between the two marks on the rod is the parking brake piston travel.

11. If the parking brake piston travel reaches 4.9 mm (0.19 inch) the wheel brakes are worn and must be
overhauled.

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Table 4

Parking Brake Piston Travel

New Brake Discs Worn Brake Discs

2.0 mm (0.079 inch) 4.9 mm (0.19 inch)

Note: If one wheel brake is found to have worn brake discs, both wheel brake assemblies on that axle must be
overhauled.

12. Install plug (3) to the axle housing.

13. Remove the blocks from in front of the wheels and behind the wheels.

14. Fill the differential.

Reference: Refer to Operation and Maintenance Manual, "Differential and Final Drive Oil (Without Axle Oil
Cooler) - Change" for the machine that is being serviced.

Copyright 1993 - 2008 Caterpillar Inc. Tue Mar 18 19:26:51 EST 2008
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