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63R03639 950B WHEEL LOADER Testing & Adjusting

Media Number SENR2262-02 Publication Date 1988/05/01 Update Date 1995/12/06

Air System And Brakes

Before making any tests or adjustments on the brake system,

stop the machine on level ground. Move the control knob for the
parking brake to the ON position. Put blocks in front of and
behind the wheels. Permit only one man on the machine. Keep
all other personnel away from the machine. Never disconnect
any air or brake fluid lines in the brake system until all pressure
is removed. Failure to remove this pressure will have a sudden
release of air or brake fluid under high pressure. This can cause
injury to personnel. To remove the pressure from the brake
system: Engage the parking brake. Stop the engine. Push on
either brake pedal many times until there is no more brake air
pressure. When the pressure has been removed from the air
circuit, there will be no pressure in the brake hydraulic circuit.

NOTE: Before any operation checks are made, open the drain valve to release any water in the air
reservoir. Water lowers the capacity in the reservoir and can cause the air compressor to run
constantly. Close the drain valve.

Visual Checks

Before any operation checks are made to the air system and brakes, visually inspect the complete
system as follows:

1. Check for cracks or wear in hoses and lines.

2. Check for restriction of flow; like sharp bends, clamps that are not installed correctly, and damage
to hoses and lines.

3. Check for loose connections.

4. Check for damage to components.

Air Relief Valve

The relief valve opens at 1030 kPa (150 psi) and has no adjustment.

Checks for Leakage in Air Circuit

Tools Needed:

0 to 1380 kPa (0 to 200 psi) Gauge.

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Make reference to WARNING on first page of AIR SYSTEM

AND BRAKES TESTING AND ADJUSTING section.

NOTE: It is possible to hear the sound of air leakage. Air leakage can be seen when water with soap
(soapy water) is put on the connections, valves and hoses.

Location to Install Gauge

(1) Drain valve for the air reservoir.

1. Install a 0 to 1380 kPa (0 to 200 psi) gauge in drain valve (1) for the air reservoir.

2. Start the engine and let the air pressure go up to the cutout pressure. Stop the engine.

NOTE: See chart for correct governor cutout pressure. If cutout pressure is not correct, see the
subject, AIR COMPRESSOR GOVERNOR.

3. Push and hold either brake pedal in a down position.

4. Put soapy water on all connections and valves in the air circuit. Check for leakage.

NOTE: If air pressure in the reservoir gets below cut-in pressure (see chart), start and run the engine
until the air pressure goes up to the cutout pressure.

5. Release the brake pedal.

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6. Put soapy water on the exhaust diaphragm of each brake control valve. Check for leakage.

7. Correct any leakage that is found.

8. Remove the gauge.

NOTE: During the time the valves are checked for leakage, check the exhaust passages for
restriction, like mud or dirt. A restriction in an exhaust passage will prevent or slow the release of
pressure air during normal operation.

Air Compressor Governor

Tools Needed:

0 to 1380 kPa (0 to 200 psi) Gauge.

Make reference to WARNING on first page of AIR SYSTEM

AND BRAKES TESTING AND ADJUSTING section.

Location to Install Gauge

(1) Drain valve of the air reservoir.

1. Install a 0 to 1380 kPa (0 to 200 psi) gauge on drain valve (1) for the air reservoir.

2. Start the engine and let the pressure go up to the cutout pressure. Stop the engine.

Air Compressor Governor

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(1) Adjustment screw. (2) Locknut.

3. Read the cutout pressure on the gauge.

4. Push one of the brake pedals rapidly several times, until air compressor cuts-in (starts).

5. Read the cut-in pressure on the gauge.

6. See chart for correct governor pressures. If the pressures are not correct, adjust the governor.

7. Use this procedure to adjust the governor:

a. Loosen locknut (2) adjustment screw (1).

b. Turn the adjustment screw counterclockwise to make the cutout pressure lower (clockwise
to raise). One turn of the screw changes the pressure 140 kPa (20 psi). The cut-in pressure will
change the same amount.

8. If the adjustment screw does not change the cutout pressure, the unloading valves in the air
compressor are not working correctly.

9. If the cut-in to cutout pressure difference is not correct, the governor is not working correctly.

10. Remove the gauge.

Control Valve for Secondary and Parking Brake

Tools Needed:

0 to 1380 kPa (0 to 200 psi) Gauge.

Make reference to WARNING on first page of AIR SYSTEM

AND BRAKES TESTING AND ADJUSTING section.

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Location to Install Gauge

(1) Drain valve of the air reservoir.

1. Install a 0 to 1380 kPa (0 to 200 psi) gauge in drain valve (1) of the air reservoir.

2. Start the engine and let the pressure go up to the cutout pressure (see chart under Air Compressor
Governor for correct setting).

3. With the control knob for the secondary and parking brake in the OFF position (pushed in), stop
the engine.

4. Push one of the brake pedals rapidly several times, until the control knob automatically moves to
the ON position.

5. Read the pressure on the gauge.

6. The correct pressure to automatically engage the parking brake is 275 ± 35 kPa (40 ± 5 psi). If the
pressure on the gauge is not correct, the operation of the control valve for the secondary and parking
brake is not correct.

7. Disassemble the control valve and check for worn or damaged parts.

8. If this does not correct the problem, install a new valve.

9. Remove the gauge.

Brake Control Valves

The application of the wheel brakes must be the same when either of the brake pedals are pushed.
When the left pedal is pushed, the transmission is disengaged and the brakes are activated. When the
right pedal is pushed, only the brakes are activated. This is the only difference between the operation
of these pedals.

If the operation of the wheel brakes is not the same between the two pedals, there is a failure in one
of the control valves. Repair or replace the brake control valve that has failed.

Leakage in Hydraulic Circuit

Tools Needed:

9S7692 Inverted Flare Connector.

1/8 in. Pipe Plug

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Tape Measure.

Make reference to WARNING on first page of AIR SYSTEM

AND BRAKES TESTING AND ADJUSTING section.

Problem

Loss of brake fluid from the reservoirs can be caused by one or more of the following reasons.

1. Leakage at hose or tube connections or leakage through damaged hoses or tubes.

2. Leakage around seals (1), (2) or (3) of the master cylinder. This leakage can be caused by
incorrect installation or a cut or damaged seal.

Master Cylinder

(1) Seal. (2) Seal. (3) Seals.

3. Leakage around seals (4) and (5) in the wheel brake head assembly. This leakage can be caused by
incorrect installation or a cut or damaged seal.

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Head Assembly of Wheel Brake

(4) Seal. (5) Seal.

Test

Use the tests that follow to find the cause for brake fluid leakage.

1. For large amounts of brake fluid leakage, inspect all hoses, tubes and fittings in the brake system
for an indication of leakage. If any leakage is found, it must be corrected before going to the next
step.

2. Check the brake fluid level in the reservoirs. Measure the distance from top edge (6) to the fluid
level. The correct distance is 13 mm (.5 in.). If the reservoir is too full, remove fluid until it is at the
correct level. If the fluid level is too low, add fluid until it is at the correct level. Install the
diaphragm and cover on the reservoir.

Use only DOT 3 brake fluid.

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Check of Brake Fluid Level in Reservoir

(6) Top edge of reservoir. (7) Reservoir for rear axle (rear wheel brakes). (8) Reservoir for front axle
(front wheel brakes).

3. Put a clean metal oil pan under the master cylinders to catch brake fluid drops from the master
cylinders.

4. Start the engine and let the air pressure and oil temperature go up to normal pressure and
temperature for operation. Keep the engine in operation during this procedure to make sure of correct
air pressure. Make 100 complete brake applications and releases. Stop (pause) ten seconds between
applications.

NOTE: Do not move the machine for this test.

5. Check the brake fluid level in the reservoirs again. If a loss of brake fluid can be measured, check
the oil pan for drops of brake fluid. Make a comparison of the amount of fluid in the metal oil pan
with the amount of fluid loss from the reservoir. If the amounts of fluid are approximately the same,
the problem is in the master cylinder. If the amounts are different, go to the next step.

6. If brake fluid loss from the reservoir is more than the leakage from the master cylinder, the
probable location of the leakage is at seals (4) and (5) in the wheel brake head assembly. The leakage
can be from either or both wheel brakes on the axle. To find the location of the leakage (if only one
brake is leaking), do the procedure that follows:

NOTE: Reservoir (7) is for the rear axle (rear wheel brakes). Reservoir (8) is for the front axle (front
wheel brakes).

a. Find which axle has the problem (leakage).

b. On this axle, disconnect tube (9) from the head assembly on one of the wheel brakes.

Right Front Wheel Brake

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(9) Tube.

c. Connect a 9S7692 Inverted Flare Connector to the fitting on tube (9). Install a 1/8 in. pipe plug in
the connector. One wheel brake has now been removed from the system so that the other wheel
brake on the axle can be checked for leakage.

d. Do Steps 2 through 5 again. If brake fluid loss from the reservoir is the same as before, there is no
leakage in the brake that has been removed from the system (blocked).

e. Do Steps 6b through 6e again for the other brake on the same axle. This gives added proof to the
location of the problem.

Correction

After the location of the leakage is found, use the procedure that follows to correct brake problems.

1. For hose, tube or fitting leaks; tighten, repair or replace connections as needed.

2. If the leakage is in a master cylinder, replace seals (1), (2) and (3) of the master cylinder. It is also
possible that some other defect, that can be easily seen, will need correction. Also, rippling
(roughness) may be found in the bore of the master cylinder. This condition is not desired. Correct
any damage or problem that can be easily found.

3. If the leakage is in a wheel brake head assembly, replace seals (4) and (5) of the head assembly or
replace the complete head assembly.

Remove Air From the Wheel Brake Hydraulic Circuit (bleed the brakes)

Make reference to WARNING on first page of AIR SYSTEM

AND BRAKES TESTING AND ADJUSTING section.

Bleeder Screws for the Master Cylinders

(1) Bleeder screws.

Air must not be in the hydraulic circuit. Air in the system can prevent complete brake application
and it is possible that the wheels on the machine can not be stopped.

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NOTE: Keep both brake fluid reservoirs full of brake fluid during the air removal procedure.

1. Start the engine and let the air pressure go up to normal pressure for operation. Keep the engine in
operation during this procedure to make sure of correct air pressure.

2. Push and hold the right brake pedal down.

3. Loosen (open) bleeder screws (1) on the master cylinders.

4. Tighten (close) bleeder screws (1) and release the right brake pedal.

5. Do Steps 2 thru 4 again until there is a constant flow of brake fluid (all of the air is removed) from
each bleeder screw on the master cylinders.

Bleeder Screws for the Wheel Brake

(2) Bleeder screws.

6. Push and hold the right brake pedal down.

NOTE: Bleed only one wheel at a time.

7. Open bleeder screws (2) at wheel brake.

8. Close bleeder screws (2) and release the right brake pedal.

9. Do Steps 6 thru 8 again until there is a constant flow of brake fluid from bleeder screws (2).

10. Do Steps 6 thru 9 again at each wheel brake until all of the air is removed from the system.

Hot or Dragging Brakes

Tools Needed:

0 to 1380 kPa (0 to 200 psi) Gauge.

6.4 mm (.25 in.) diameter by 150 mm (6 in.) Long Bolt.

Hot or dragging brakes are caused when the brakes do not release correctly. When the stroke of the
master cylinder is too much, the brake fluid pressure indicator, master fault light and fault alarm will
come ON. Brake hydraulic pressure is 16 times the amount of air pressure.

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Make reference to WARNING on first page of AIR SYSTEM

AND BRAKES TESTING AND ADJUSTING section.

Use the procedure that follows to correct a problem of hot or dragging brakes:

Location to Install Gauge

(1) Drain valve for the air reservoir.

NOTE: If the brake fluid pressure indicator is on, go to Step 9b.

1. Install a 0 to 1380 kPa (0 to 200 psi) gauge in drain valve (1) of the air reservoir.

2. Remove brake fluid pressure switch (2) and the indicator rod from the air/hydraulic cylinder. Use
a 6.4 mm (.25 in.) diameter bolt that is 150 mm (6 in.) long, in place of the indicator rod.

NOTE: Two bolts can be used to check both master cylinders at the same time.

Air/Hydraulic Cylinders

(2) Brake fluid pressure switch for rear wheel brakes. (3) Brake fluid pressure switch for front wheel
brakes (under bracket).

3. Start the engine and let the air pressure go up to cutout pressure (see chart). Stop the engine.

NOTE: Make sure air pressure is above the cut-in pressure (see chart) when the master cylinder
stroke is checked.

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Indicator Rod Removed and 6.4 mm (.25 in.) Bolt installed.

(4) 150 mm (6 in.) Bolt.

4. With the brake fully released, push bolt (4) down until it comes in contact with the piston in the air
chamber.

5. Measure the length of the bolt.

6. Push and hold the right brake pedal down.

7. Push bolt (4) down again, until it comes in contact with the piston.

8. Measure the length of the bolt at this point.

9. The difference in the two lengths is the stroke of the master cylinder.

a. If the master cylinder stroke is less than 79.0 mm (3.11 in.), see the subject TOO LITTLE
MASTER CYLINDER STROKE.

b. If the master cylinder stroke is at its maximum, the brake fluid pressure indicator will come
on. See the subject TOO MUCH MASTER CYLINDER STROKE.

10. Do Steps 1 thru 9 again for the other master cylinder.

Too Little Master Cylinder Stroke

The steps that follow are probable causes of too little master cylinder stroke. With each step is a
correction for the problem. Too little master cylinder stroke can be caused by:

(1) A failure in the master cylinder.

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a. Remove and disassemble the master cylinder.

b. Check for a stuck piston (a piston that will not move).

c. Check for a loose locknut on the air cylinder rod.

(2) A failure in the head assembly of the wheel brake.

a. Remove and disassemble the head assembly.

b. Check for a stuck piston (a piston that will not move).

Too Much Master Cylinder Stroke

When the master cylinder stroke is at its maximum, one pair (front or rear) of wheel brakes will do
all of the work (braking). This condition will cause hot (overheating) wheel brakes and axle
components. When this condition exists, the brake fluid pressure indicator will come on.

Too much master cylinder stroke can be caused by:

1. Low brake fluid level in the reservoirs.

a. See the LUBRICATION AND MAINTENANCE GUIDE.

2. Air in the hydraulic circuit.

a. See REMOVE AIR FROM WHEEL BRAKE HYDRAULIC CIRCUIT (BLEED THE BRAKES).

3. Leakage in the brake fluid lines.

a. See CHECK FOR LEAKAGE IN HYDRAULIC CIRCUIT.

4. Brakes out of adjustment.

5. Failure of the seal on the master cylinder piston.

Secondary And Parking Brake Adjustment

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SECONDARY AND PARKING BRAKE

(1) Rod. (2) Nut. (3) Rod end. (4) Cotter. (5) Nut. (6) Pin. (7) Lever. (8) Drum. (9) Shoe (two). (10)
Starwheel. (A) Dimension from face of mounting bracket to center of pin (6). (B) Stroke of lever (7).

Make reference to WARNING on first page of AIR SYSTEM

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AND BRAKES TESTING AND ADJUSTING section.

1. Start the engine and let the air pressure go up to operating range.

2. Move the control knob for the parking brake to OFF (brake released) position. Stop the engine.

3. Remove cotter (4) and pin (6). Remove lever (7) from its shaft.

4. Turn starwheel (10) to get a clearance, between shoes (9) and drum (8), of . . . 0.50 mm (.020 in.)

5. Pressurize the air chamber to 655 kPa (95 psi) minimum.

6. Loosen nut (2) and turn rod end (3) to get dimension (A), . . . 100.0 mm (3.94 in.)

7. Install lever (7), pin (6) and cotter (4).

8. Use nut (5) to turn rod (1) until free movement between rod end (3) and lever (7) is removed.

9. Tighten nut (2).

10. Move the control knob for the parking brake to ON (brake engaged) position and check the
stroke [distance (B)]. Do Steps 1 through 8 again if distance (B) is more than . . . 19.0 mm (.75 in.)

11. Make three successive stops in the third forward at maximum speed, using the secondary parking
brake.

12. Let the brake cool, then apply brake and check movement of the air chamber rod (3). The rod
should not move more than 19mm (.75 in.) at distance (B)

NOTE: The secondary/parking brake is adjusted correctly if the machine can not be moved in first
2
speed reverse. The brake must also provide a minimum vehicle deceleration rate of 2.45m/sec
(0.25G) during actual braking of the vehicle from maximum speed in fourth forward or reverse.

Copyright 1991, 2022 Caterpillar Inc.

All Rights Reserved.

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