PS-110, PS-130 & PS180 PNUEMATIC COMPACTORS LOWER DRIVE ASSE Caterpillar


Service Brake

Usage:

Disassemble Service Brake

NOTE: Before starting disassembly, obtain the wheel cylinder seal kit for the brake. The part number for the kit is located in the Parts Book for the machine.

1. Do steps 1 through 6 of Remove Lower Drive Assemblies, located in this module. This will remove the wheel and tire assemblies and brake lines for the brakes to be serviced.

2. Do steps 1 through 8 of Disassemble Lower Drive Assemblies, located in this module. This will remove the brake drums and brake assemblies to be serviced.

NOTE: Brake assemblies may be serviced while installed on the machine, if desired. However, make sure the machine is securely blocked and supported before working on or around the machine.

NOTE: Illustrations in these instructions show a left-hand brake. Some components are installed oppposite for a right-hand brake.

3. Pull the bottom of brake shoes (1) and (6) away from the center of the brake. Automatic adjuster (3) will drop away from the brake.

4. Remove lower spring (2), lever (4), and lower link (5) from the brake by hand.

NOTE: Check the positions of shoe retaining springs (7) and (9), and upper link (10) before removing. These parts must be installed in their original positions during brake assembly.

NOTE: If the brake assembly has been removed from the machine, shoe retaining springs (7) and (9), wheel cylinder bolt (8), and upper link (10) have already been removed from the brake. Steps 5, 6, and 7 will not be needed.

5. Remove left shoe retaining spring (7) and right shoe retaining spring (9) using a suitable brake spring tool.

6. Unhook upper link (10) from wheel cylinder bolt (8). Disassemble pivot (11) from the brake, if necessary to remove.

7. Pull wheel cylinder bolt (8) out of the brake assembly.

8. Press down on retainer (12) and turn to remove. Remove retainer (12), spring (13), cup (14), and shoe hold down pin (15) from the brake.

9. Repeat step 8 to remove components of the remaining shoe hold down pin (16).

10. Lift the two brake shoes (1) and (6) away from the brake.

11. Remove two 12-point head bolts (18) and two star socket bolts (20) securing wheel cylinder (17) to backing plate (19).

12. Remove wheel cylinder (17).

13. Remove rubber boots (21) and pistons (22) from the wheel cylinder.

14. Remove rubber cups (23) and springs (24) from inside the wheel cylinder.

15. Discard rubber boots (21) and rubber cups (23). These will be replaced with new parts during assembly.

16. Check all springs for loss of tension or damage. Replace any weak or damaged springs.

17. Inspect the wheel cylinder and pistons as follows:

a. Check the bore of the wheel cylinder for scoring, pitting, or corrosion. Use crocus cloth to remove light roughness or deposits. If the bore does not clean up readily, the wheel cylinder must be replaced.

b. Flush the inside of the wheel cylinder with alcohol or brake fluid. Wipe dry with a lint-free cloth.

c. Check the clearance between the pistons and the wheel cylinder wall with a narrow feeler gauge. If clearance exceeds .13 mm (.005 in.), the wheel cylinder or pistons will have to be replaced.

18. Inspect the automatic adjuster for broken teeth or damaged threads. Make sure all parts turn freely.

19. Clean the backing plate. Make sure that shoe support points are smooth and free of rough edges.

20. Inspect the brake linings and measure their thickness. If linings appear damaged or are worn to 1.60 mm (.063 in.), they must be replaced with new parts. Linings must always be replaced in sets of two.

21. Check all other parts for damage or excessive wear. Replace parts as necessary.

Assemble Service Brake


NOTICE

Keep oil, grease and other petroleum products away from wheel cylinder components. Oil or grease may cause damage to the rubber parts of the wheel cylinder.


1. Coat the wheel cylinder bore and two pistons (22) with clean brake fluid.

2. Install springs (24) and new rubber cups (23) into the wheel cylinder. Make sure the springs fit into the open end of the cups.

3. Install pistons (22) into the wheel cylinder on top of cups.

4. Install new rubber boots (21) over the ends of the wheel cylinder.

5. Secure wheel cylinder (17) to backing plate (19) with two 12-point head bolts (18) and two star-socket bolts (20).

6. Apply a light coat of high-temperature lubricant to backing plate (19) where it contacts shoes (1) and (6).

7. Install pivot (11) and upper link (10) to brake shoe (6), if these parts were removed during disassembly.

8. Set shoes (1) and (6) in place on the backing plate. Secure with hold down pins (15) and (16), cups (14), springs (13), and retainers (12).

NOTE: If the brake assembly is removed from the machine, steps 9, 10, and 11 should not be done at this time. These components will be installed when the brake is installed on the machine.

9. Install wheel cylinder bolt (8).

10. Install shoe retaining spring (7), upper link (10), and shoe retaining spring (9) onto wheel cylinder bolt (8) in the order listed. Use a suitable brake spring tool.

11. Install lever (4) into shoe (6). Connect lower spring (2), and lower link (5), as shown.

12. Apply a light coat of high-temperature lubricant to the threads of automatic adjuster (3). Turn the end of the automatic adjuster to fully shorten its length.

13. Pull the bottom of brake shoes (1) and (6) away from the center of the brake. Install automatic adjuster (3) between the shoes.

14. Check the inside rubbing surface of the brake drum for the following conditions before installation:

a. Scored or bellmouthed drum. If the rubbing surface of the drum is scored or otherwise rough, the drum must be rebored or replaced. If the inside diameter of the drum at the open end exceeds the inside diameter at the closed end by more than .25 mm (.010 in.), the drum must be rebored or replaced.

b. Concave or convex drum. Rebore or replace the drum if the surface variance exceeds .12 mm (.005 in.) on the side.

c. Hard spots or heat checks. Rebore or replace the drum if the spots cause noticeable effects such as pedal pulsation or brake roughness. If heat checks are plainly visible or can be felt with a fingernail, the drum must be rebored or replaced.

d. Out of round drum. Rebore or replace the drum if the out of round condition exceeds .15 mm (.006 in.) total indicator reading.

15. The inside diameter of a new brake drum is 260.35 ± .12 mm (10.250 ± .005 in.). The maximum rebore diameter of the drum is 260.62 mm (10.315 in.). If the drum diameter exceeds the maximum rebore specification, the drum must be replaced with a new part.

NOTE: Record the measured diameter of each brake drum on the machine. The difference in the diameter of the drums must not exceed .51 mm (.020 in.).

16. Adjust the service brake as follows, before installing the brake drum:

a. Set a brake shoe gauge to the inside diameter of brake drum (25), as shown.

b. Set the other end of the brake shoe gauge over the brake shoes, as shown.

c. Turn star wheel (26) of the automatic adjuster to expand the brake shoes until the gauge just slides over the linings.

d. Rotate the gauge around the brake shoes to ensure proper clearance.

17. Do steps 17 and 18 of Assemble Lower Drive Assemblies, located in this module. This will install the brake to the lower drive assembly. Make sure shims are installed correctly behind the brake.

18. Do step 26, and steps 30 through 34 of Assemble Lower Drive Assemblies, located in this module. This will complete assembly of the brake and installation of the brake drum.

19. Do steps 11 through 16 of install Lower Drive Assemblies, located in this module. These steps will install the brake line, bleed the brake system, and install the wheel and tire assemblies.

NOTE: After installing the service brakes, check the brake pedal to make sure the brake system is working. Start the machine and make several forward and reverse stops. This will activate the automatic adjusters and provide final adjustment to the brakes.

Caterpillar Information System:

PS-110, PS-130 & PS180 PNUEMATIC COMPACTORS LOWER DRIVE ASSE Lower Drive Assemblies
PS-110, PS-130 & PS180 PNUEMATIC COMPACTORS LOWER DRIVE ASSE Drive Chains
PS-110, PS-130 & PS0180 PNEUMATIC COMPACTORS TIRE WETTING & Testing And Adjusting
PS-110, PS-130 & PS0180 PNEUMATIC COMPACTORS TIRE WETTING & Systems Operation
PS-110, PS-130 & PS-180 PNEUMATIC COMPACTORS SERVICE BRAKE & Testing and Adjusting
PS-110, PS-130 & PS-180 PNEUMATIC COMPACTORS SERVICE BRAKE & Systems Operation
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