777D Testing and Adjusting - Brake System Air - Purge

777D Off-Highway Truck AGC00001-UP (MACHINE) POWERED BY 3508B Engi...
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Product: TRUCK
Model: 777D TRUCK AGC
Configuration: 777D Off-Highway Truck AGC00001-UP (MACHINE) POWERED BY 3508B Engine
Testing and Adjusting

776D, 777D and 777D HAA Off-Highway Truck/Tractors Air System and Brakes
Media Number -RENR3324-07 Publication Date -01/03/2007 Date Updated -23/03/2007
i01961827
Brake System Air - Purge
SMCS - 4250-542-AI
S/N - AFS81-UP
S/N - AGC991-UP
S/N - AGY1-UP
Table 1
Required Tools
Part Number Description Required Amount
6V-4143 Coupler 2
177-7860 Hose As 1
There are purge valves for the hydraulic brakes on each wheel. Before you use the purge
valves to remove air from the oil in the system, the makeup oil tank for the hydraulic brakes
must be full. Also, the air system pressure must be more than 550 kPa (80 psi).
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777D Off-Highway Truck AGC00001-UP (MACHINE) POWERED BY 3508B Engi... Page 2 of 7
Personal injury or death can result from air in the oil for the brake
hydraulic system.
Air in the system can prevent complete brake application and it is

possible that the wheels on the machine can not be stopped.
Air must not be in the oil for the brake hydraulic system to function
properly.
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.
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.
Note: Purge only one wheel at a time.
Service Brakes and Retarder
Rear Brakes
1. Assemble two 6V-4143 Coupler on the 177-7860 Hose As in order to construct a jumper
hose.
2. Apply the parking brake. This will release the pressure in the lines.
Illustration 1 g00645567
(1) Pressure tap on the rear slack adjuster
(2) Pressure tap for parking brake release pressure
3. Connect one end of the jumper hose to pressure tap (1) .
4. Connect the other end of the jumper hose to a pressure tap (2) .
(P) Purge valve for the parking brake
(S) Purge valve for the service brake
Note: Identification letters are embossed on the purge valves at the top of the brake
housing. The purge valve for the parking brake is labelled with a "P". The purge valve for
the service brake is labelled with an "S".
5. Connect a drain hose from the "S" port to the hydraulic tank or to a suitable container.
6. Run the engine at low idle. Move the parking brake lever to the OFF position.
7. Pull down the retarder control.
8. Open the purge valve "S" on a rear wheel brake housing and purge the brake system.
Leave the purge valve open until there is a constant flow of oil.
9. Close the purge valve. Repeat Steps 5 through 8 for the other rear wheel brake.
10. Close the purge valve. Move the retarder control to the OFF position. Activate the parking
brake in order to release the pressure. Remove the jumper hose.
Note: In order to verify that all of the air was removed from the service brake lines for
the rear brakes, perform the following steps.
Note: In order to make sure that the makeup oil tank is full, operate the engine at high
idle for 20 seconds before each brake application.
Note: Make sure that the parking brake reset valve is depressed.
11. Move the parking brake lever to the OFF position in order to allow full travel of the
service brake piston.
12. Push down on the brake pedal or pull down the retarder control.
13. Open the purge valve "S" on a rear wheel brake housing and purge the brake system.
14. Repeat Steps 12 through 13 until there is a continuous flow of oil.
15. Close the purge valve. Release the brake pedal or move the retarder control to the OFF
position.
16. Complete Steps 12 through 15 on the other rear brake.
17. Remove the drain hose.
Note: After you purge the brakes, you may need to reset the actuating pins for the overstroke
switch. The actuating pins for the overstroke switch are on the master cylinders. A brake
overstroke condition is a Level III warning.
When you need to reset the actuating pin, you will push the actuating pin into the housing.
Push the actuating pin into the housing until the bottom of the pin is flush with the bottom of
the housing.
Front Brakes
Note: In order to make sure that the makeup oil tank is full, operate the engine at high
idle for 20 seconds before each brake application.
1. Move the parking brake lever to the OFF position in order to allow full travel of the
service brake piston.
2. Depress the service brake pedal. Run the engine at high idle.
View of service brake (front oil cooled)
(3) Purge valve
View of service brake (front caliper) (if equipped)
(3) Purge valve
3. Connect a drain hose from purge valve (3) to the hydraulic tank or to a suitable
container.
4. Open purge valve (3) on a front wheel brake housing and purge the brake system.
5. Repeat Steps 2 through 4 until there is a continuous flow of oil.
6. Close the purge valve. Release the brake pedal or move the retarder control to the OFF
position.
7. Complete Steps 2 through 6 on the other front wheel brake.
Note: After you purge the brakes, you may need to reset the actuating pins for the overstroke
switch. The actuating pins for the overstroke switch are on the master cylinders. A brake
overstroke condition is a Level III warning.
When you need to reset the actuating pin, you will push the actuating pin into the housing.
Push the actuating pin into the housing until the bottom of the pin is flush with the bottom of
the housing.
Parking Brake
(P) Purge valve for the parking brake
(S) Purge valve for the service brake
Though the parking brake application is mechanical, it is very important to remove the air from
the parking brake release system.
1. Connect a drain hose from the "P" port to the hydraulic tank or to a suitable container.
2. While the engine is operating, move the lever for the parking brake to the OFF position.
3. Open the purge valve "P" on a rear wheel brake housing. Close the purge valve when
there is a constant flow of oil.
4. Repeat this procedure for the other rear wheel brake housing.
Copyright 1993 - 2019 Caterpillar Inc. Wed Aug 28 13:22:27 UTC+0630 2019
All Rights Reserved.
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777D Off-Highway Truck AGC00001-UP (MACHINE) POWERED BY 3508B Engi...

Testing and Adjusting

Brake System Air - Purge

Part Number Description Required Amount

Air in the system can prevent complete brake application and it is

Personal injury or death can result from machine movement.

Care must be taken to ensure that fluids are contained during

Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop

Dispose of all fluids according to local regulations and mandates.

Note: Purge only one wheel at a time.

Service Brakes and Retarder

(1) Pressure tap on the rear slack adjuster

(2) Pressure tap for parking brake release pressure

3. Connect one end of the jumper hose to pressure tap (1) .

(P) Purge valve for the parking brake

(S) Purge valve for the service brake

7. Pull down the retarder control.

14. Repeat Steps 12 through 13 until there is a continuous flow of oil.

16. Complete Steps 12 through 15 on the other rear brake.

17. Remove the drain hose.

View of service brake (front oil cooled)

(3) Purge valve

View of service brake (front caliper) (if equipped)

(3) Purge valve

5. Repeat Steps 2 through 4 until there is a continuous flow of oil.

7. Complete Steps 2 through 6 on the other front wheel brake.

8. Remove the drain hose.

(P) Purge valve for the parking brake

(S) Purge valve for the service brake

5. Remove the drain hose.

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