R1600G Load Haul Dump Braking System Brake Disc Wear - Check Caterpillar


Brake Disc Wear - Check
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1.1. With Axle Oil Cooler
2.1. Without Axle Oil Cooler

Table 1
Required Tools    
Part Number     Part Description     Qty    
186-9411     Brake Wear Tool     1    

------ WARNING! ------

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

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------ WARNING! ------

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.

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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, "AVSpare Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on AVSpare 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:

  • 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.

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

  • 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.

  1. Engage the parking brake and stop the engine.



    Illustration 1g00915687

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

  1. 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) .



    Illustration 2g00915688

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

  1. Drain the differential oil.

    ReferenceRefer to Operation and Maintenance Manual, "Differential and Final Drive Oil (With Axle Oil Cooler) - Change".

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



    Illustration 3g00906463

    (5) Plug

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



    Illustration 4g01014757

    Brake wear tool (installed)

    (6) Parking brake piston

    (7) Axle housing

    (8) 186-9411 Brake Wear Tool

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

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

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

  1. Stop the engine.

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

  1. 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    
    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.

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

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

  1. 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.

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

  1. Fill the differential.

    ReferenceRefer to Operation and Maintenance Manual, "Differential and Final Drive Oil (With Axle Oil Cooler) - Change".

Without Axle Oil Cooler

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

  1. Engage the parking brake and stop the engine.

  1. Drain the differential oil.

    ReferenceRefer to Operation and Maintenance Manual, "Differential and Final Drive Oil (Without Axle Oil Cooler) - Change".

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



    Illustration 5g00906837

    (1) Plug

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



    Illustration 6g01014759

    Brake wear tool (installed)

    (2) Parking brake piston

    (3) Axle housing

    (4) 186-9411 Brake Wear Tool

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

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

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

  1. Stop the engine.

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

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

    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.

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

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

  1. Fill the differential.

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

Information System:

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R1600G Load Haul Dump Machine Systems Main Control Valve - Remove
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140H and 160H Motor Graders Changing Direction and Speed
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3176C Engine for the R1600G and the R1700G Load Haul Dumps Power Is Intermittently Low or Power Cutout Is Intermittent
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