PLUG-STOP 2012377 - Caterpillar

Before making any tests or adjustments to the brake system, stop the machine on level surface. Permit only one person on the machine. Keep all other personnel away from the machine. Never disconnect oil lines or remove plugs in the brake circuit until the oil pressure is removed. Failure to remove this pressure will have a result of a sudden release of oil under pressure of as high as 18,600 kPa (2700 psi). To remove the oil pressure from the brake circuit: activate the parking brake. Stop the engine. Push on the brake pedal many times until there is no brake oil pressure.
1. Release the pressure in the brake circuit. Open the cover behind the operator's compartment. Put identification on all lines, hoses and tubes before disconnection. Cap and plug all lines and fittings as they are removed to prevent excess fluid loss and contamination.
Typical Example2. Remove tube assemblies (1), (2) and (3) from the brake control valve.
Typical Example3. Remove tubes (4). Disconnect tubes (5).
Typical Example4. Put identification on wires (6) and then disconnect them.
Typical Example5. Remove pin (8) and cotter pin to disconnect linkage (9). Remove bolts (7) and then remove brake control valve (10). The following steps are for the installation of the brake control valve.6. Put the brake control valve (10) in position and install the bolts (7) that hold it. Connect rod end of linkage (9) with pin (8) and cotter pin.7. Connect wires (6) to their respective positions.8. Connect tubes (4). Install tubes (5).9. Install tube assemblies (1), (2) and (3) on the brake control valve.10. Close the cover behind the operator's compartment.Disassemble Brake Control Valve
Start By:a. Remove brake control valve 1. Remove manifold (1) from the brake control valve. 2. Remove four bolts (2) and retainer (3) from the valve. 3. Remove shims (6) from the retainer.4. Remove nut (7), retainer (5) and valve stem (4) from the retainer.5. Remove seal (8) from the retainer. 6. Remove seal (9) from retainer (3). 7. Remove springs (11) and (12) from the valve body. Remove retainer (10) from the valve body.8. Remove cover (13) from the valve body. 9. Remove piston (14) from the cover.10. Remove spring (16) and orifice (15) from the cover. 11. Remove spring (19), retainer (18) and stem (17).Assemble Brake Control Valve
1. Make sure all of the parts of the brake control are clean. Inspect all seals for damage and make replacement if needed.2. Put clean hydraulic oil on all of the parts of the valve. 3. Install stem (1), retainer (2) and spring (3) in the valve body. 4. Install piston (4) in the cover.5. Install spring (5) and orifice (6) in the cover as shown. 6. Put cover (7) in position on the valve body and install the four bolts that hold it. 7. Install retainer (8), large spring (9) and small spring (10) in the valve body. 8. Install the lip-type seal in the retainer with tooling (A). Install the seal with the lip toward the inside