176-6235 Protection Ar-Corrosion Custom Product Support Literature for 966G and 972...

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Product:  WHEEL LOADER 
Model:  966G WHEEL LOADER 3PW00549 
Configuration: 176-6235 Protection Ar-Corrosion Custom Product Support Literature for 966G and 972G Wheel Loaders 3PW00001-UP (MACHINE) 

Testing and Adjusting

966G Wheel Loader and 972G
Wheel Loader Braking System
Media Number -RENR2112-04 Publication Date -01/02/2009 Date Updated -11/02/2009

i01768718

Braking System Troubleshooting

SMCS - 4250-035

Escaping fluid under pressure, even a pinhole size leak, can penetrate
body tissue, causing serious injury, and possible death. If fluid is
injected into your skin, it must be treated immediately by a doctor
familiar with this type of injury.

Always use a board or cardboard when checking for a leak.

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.

This section provides probable causes to known problems. Since there may be several probable causes, specific
inspections or instrument tests may be recommended. These inspections and tests will help to identify the causes
that are most probable.
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Note: Make sure that you use an oil with the correct viscosity for the operating conditions.

Reference: For additional information about the various lubricant viscosities, refer to Operation And Maintenance
Manual, "Lubricant Specifications" for your machine.

Problem List

• Problem List for the Service Brakes

1. The accumulator pressure will not reach cut-out pressure at low idle. This typically causes a Warning
Category 3 to occur. This may also engage the parking brake.

Probable Cause

a. When the hydraulic oil is hot and the engine is running at low idle, the output of the pump is not
sufficient to overcome the pump's own internal losses.

2. The front service brakes do not operate, and the warning system is not activated.

Probable causes

a. The brake group within the axle housing is damaged.

b. The lines to the front service brakes are obstructed.

c. The front circuit of the service brake control valve is faulty.

3. The rear service brakes do not operate, and the warning system is not activated.

Probable causes

a. The brake group within the axle housing is damaged.

b. The lines to the rear service brakes are obstructed.

c. The rear circuit of the service brake control valve is faulty.

4. Service brakes slip, and the warning system is not activated.

Probable causes

a. One or both axles contain an incorrect hydraulic oil additive.

b. The brake disc in the axle housing is worn.

5. The service brakes are not applied evenly.

Probable causes

a. The brake disc and associated components in the axle housing are excessively worn.

b. The brake valve is sticking because of contaminated oil.

c. The service brake valve is not delivering the correct amount of pressure.

6. Too much force needed to push the brake pedals, and the warning system is not activated.

Probable causes
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a. The brake pedals and/or brake pedal linkages are damaged.

b. The brake valve is sticking because of contaminated oil.

• Problem List for the Parking Brake

1. The parking brake does not hold the machine stationary.

Probable causes

a. The parking brake must be adjusted.

b. The brake linings are excessively worn.

c. There is grease or oil on the brake drum and/or on the brake lining.

2. The parking brake does not engage when the parking brake control knob is pulled out.

Probable causes

a. The parking brake cable is disconnected.

b. The parking brake cable has stretched until the cable will not actuate the parking brake.

c. The parking brake is out of adjustment.

• Problem List for the Charging System for the Service Brakes

1. The low oil pressure warning will not turn off.

Probable causes

a. There is inadequate pump pressure for the brake system.

Note: If you can turn off the warning by increasing the rpm of the engine, the cause of the problem is
the brake pump.

b. The hydraulic oil is too hot.

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