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Caterpillar 775D

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1595294 CONTROL GROUP-SERVICE BRAKE -CHASSIS

OFF-HIGHWAY TRUCK Caterpillar 775D
775D Quarry Truck 8AS00001-UP (MACHINE) POWERED BY 3412E Engine BRAKING SYSTEM
1595294 CONTROL GROUP-SERVICE BRAKE -CHASSIS

159-5294 CONTROL GP-SERVICE BRAKE -CHASSIS
S/N 8AS325-UP
PART OF 136-1816 CHASSIS AR

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1595294CONTROL GROUP-SERVICE BRAKE -CHASSIS 

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#Part NoPart NameQty.
INSTALLATION OF HARDWARE
1) INSTALL SERVICE VALVE
14***94VALVE GROUP-AIR CONTROL -SERVICE BRAKE PEDAL1
SERVICE BRAKE VALVE (W/PEDAL)
4M***61BOLT-TO ASSEMBLE VALVE AS AND PLATES 3
MOUNT VALVE
8T***24WASHER-TO ASSEMBLE VALVE AS AND PLATES 3
MOUNT VALVE
8T***62PLUG-PIPE (1/4-14 NPTF THD)(9.52 CF SQ HOLE)2
TOP FRONT, TOP LEFT
3D***70ELBOW-EXTERNAL PIPE THREAD 1
TOP RIGHT, ACCEPTS HOSE K
3S***75ELBOW-EXTERNAL PIPE THREAD 1
BOTTOM LEFT, HOSE M
6B***72REDUCER BUSHING 1/2" x 1/4" N.P.T. (1/4-18 NPT EXTERNAL THREAD)1
BOTTOM RIGHT
5P***24ELBOW (to J.B. Port No. 6) 1
INTO 6B-5072, TUBE J
2) INSTALL SECONDARY VALVE
15***38VALVE GROUP-AIR CONTROL -SECONDARY BRAKE PEDAL1
SECONDARY BRAKE VALVE (W/PEDAL)
14***07PLATE AS 1
TO ACCEPT SECONDARY VALVE
15***39GASKET 1
UNDER PLATE AS
5M***62BOLT (3/8-16X0.75-IN)4
TO ATTACH PLATE AS
8T***96WASHER-HARD- LINE FROM PIPE AS. TO GEAR 4
TO ATTACH PLATE AS
4M***61BOLT-TO ASSEMBLE VALVE AS AND PLATES 3
TO MOUNT VALVE
8T***24WASHER-TO ASSEMBLE VALVE AS AND PLATES 3
TO MOUNT VALVE
8T***62PLUG-PIPE (1/4-14 NPTF THD)(9.52 CF SQ HOLE)3
TOP FRONT, 2 RIGHT PORTS
7D***03ADAPTER (PIPE)1
TOP LEFT
3D***70ELBOW-EXTERNAL PIPE THREAD 1
INTO 7D-4903, ORIENTED REAR, HOSE G
3D***70ELBOW-EXTERNAL PIPE THREAD 1
BOTTOM LEFT, ORIENTED REAR, HOSE H
3) INSTALL FRONT BRAKE SWITCH
12***72VALVE GROUP-AIR CONTROL (FRONT BRAKE/ON-OFF)1
8T***94CAPSCREW (BUTTON HD) (10X1/2) (STAINLESS)2
ATTACH 128-4972 VALVE TO DASH
12***01FILM-INFORMATION (INDICATOR LIGHTS)1
COVERS SCREWS
5H***78ELBOW-EXTERNAL PIPE THREAD (EXTENSION PIPE)1
INTO TOP PORT, HOSE F
8T***63PLUG-PIPE (1/4-18 NPTF THD)1
INTO REMAINING TOP PORT
4H***47UNION - USE WHEN RELOCATING AIR OVERRIDE VALVE TO R.H. SIDE PANEL if equipped with attachment parking brake control1
INTO BOTTOM PORT, HOSE C
4) INSTALL FRONT DCV (FRONT COMPARTMENT)
6D***81VALVE GROUP-CHECK -SERVICE BRAKE DIVERTER-RETARDER CONTROL1
5S***79HEX HEAD CAPSCREW, 3/8 NC x 7/8 in. (22 mm) 1
ATTACH DCV
8T***96WASHER-HARD- LINE FROM PIPE AS. TO GEAR 1
ATTACH DCV
2D***25TEE-TO SHUT-OFF CONTROL GROUP 3
INTO EACH DCV PORT (2 INPUT, I OUTPUT)
5H***78ELBOW-EXTERNAL PIPE THREAD (EXTENSION PIPE)1
RIGHT TEE, RIGHT END, ORIENTED REAR, HOSE K
4H***47UNION - USE WHEN RELOCATING AIR OVERRIDE VALVE TO R.H. SIDE PANEL if equipped with attachment parking brake control1
RIGHT TEE, VERTICAL PORT, HOSE C
5P***24ELBOW (to J.B. Port No. 6) 1
LEFT TEE, VERTICAL PORT, TUBE R
(REMAINING PORT IN LEFT TEE FOR RETARDER SWITCH)
5H***78ELBOW-EXTERNAL PIPE THREAD (EXTENSION PIPE)1
OUTPUT TEE, HORIZONTAL PORT, HOSE D
5H***78ELBOW-EXTERNAL PIPE THREAD (EXTENSION PIPE)1
OUTPUT TEE, HORIZONTAL PORT, HOSE O
5) INSTALL RETARDER
16***36VALVE GROUP-AIR CONTROL -MANUAL RETARDER1
16***38CONNECTOR (PUSH-IN ADAPTERS)3
5P***07TUBE 7.23 dm(28.50 in.)
5P***07TUBE 7.23 dm(28.50 in.)
5P***07TUBE 7.23 dm(28.50 in.)
4D***39BOLT-12 POINT HEAD (3/8-16X1.625-IN)2
ATTACH VALVE TO STEERING COLUMN
4D***43LOCKWASHER 2
ATTACH VALVE TO STEERING COLUMN
6) INSTALL SECONDARY RESERVOIR FITTINGS
00***99TEE TO BUSHING 1
INTO LEFT END OF TANK, HORIZONTAL
4J***14ELBOW TO TEE FOR R.H. SUPPLY LINE 1
INTO REAR PORT OF TEE, HOSE CC
4J***14ELBOW TO TEE FOR R.H. SUPPLY LINE 1
INTO FRONT PORT OF TEE, HOSE H
3B***22BUSHING-- HOSE ASSEMBLY TO QUICK RELEASE VALVE -- HOSE ASSEMBLY TO QUICK RELEASE VALVE1
INTO CENTER PORT, RIGHT END
3D***84ELBOW-- 90 DEGREES-- HIGH PRESSURE TO GAUGE 1
INTO 3B-7722 BUSHING
6D***32VALVE ASSEMBLY --TEE UNION TO SYNCHRO VALVE1
INTO 3D-8884 ELBOW
4H***47UNION - USE WHEN RELOCATING AIR OVERRIDE VALVE TO R.H. SIDE PANEL if equipped with attachment parking brake control1
INTO 6D-1432 CHECK VALVE, HOSE Q
2H***40UNION 90 degrees (.50" ext. thd.) 1
INTO REAR HOLE, RIGHT END, HOLE P
7) INSTALL INVERSION VALVE
17***32VALVE GROUP-INVERTER (SERVICE BRAKE CONTROL)1
8T***43CAPSCREW (HEX HEAD) (3/8-16X 7/8 GD 8 Z)2
TO MOUNT VALVE
8T***24WASHER-TO ASSEMBLE VALVE AS AND PLATES 2
TO MOUNT VALVE
4D***24UNION (90 degrees-2.9062" Long) 1
CONTROL PORT, HOSE G
3D***84ELBOW-- 90 DEGREES-- HIGH PRESSURE TO GAUGE 1
SUPPLY PORT, HOSE CC
5H***78ELBOW-EXTERNAL PIPE THREAD (EXTENSION PIPE)1
DELIVER PORT, HOSE DD
8) INSTALL HORN SOLENOID
9M***62COUPLING (165 in. long) 1
INTO REAR WALL OF CAB
00***33TEE-PIPE 1
INTO COUPLING, HORIZONTAL, HOSE Z
5P***98COUPLING, STRAIGHT, 1/4IN. N.P.T. 1
LEFT END OF TEE
7T***74VALVE GROUP-SOLENOID -AIR HORN1
ONTO 5P-8998 NIPPLE
3D***87FITTING - USE WHEN RELOCATING AIR OVERRIDE VALVE TO R.H. SIDE PANEL if equipped with attachment parking brake control1
INTO LEFT END OF SOLENOID, HOSE L
9M***62COUPLING (165 in. long) 1
INTO CAB FLOOR IN FRONT COMPARTMENT
3D***87FITTING - USE WHEN RELOCATING AIR OVERRIDE VALVE TO R.H. SIDE PANEL if equipped with attachment parking brake control1
INTO COUPLING, UNDERSIDE OF CAB
5H***78ELBOW-EXTERNAL PIPE THREAD (EXTENSION PIPE)1
INTO COUPLING, HOSE L
9) INSTALL DOUBLE CHECK VALVE ONTO REAR FLOOR
6D***81VALVE GROUP-CHECK -SERVICE BRAKE DIVERTER-RETARDER CONTROL1
5S***79HEX HEAD CAPSCREW, 3/8 NC x 7/8 in. (22 mm) 1
TO MOUNT DCV
8T***96WASHER-HARD- LINE FROM PIPE AS. TO GEAR 1
TO MOUNT DCV
4H***47UNION - USE WHEN RELOCATING AIR OVERRIDE VALVE TO R.H. SIDE PANEL if equipped with attachment parking brake control1
INTO FRONT INPUT, HOSE D
4H***12BREATHER (TORQUE CONVERTER)1
INTO REAR INPUT
00***33TEE-PIPE 1
FOR STOPLAMP & BRAKE SWITCHES
10) INSTALL FITTINGS ONTO INSIDE AND OUTSIDE OF JUNCTION PLATE
-PORT 1-
2G***15VALVE GROUP-PRESSURE PROTECTION (SERVICE BRAKE CONTROL)1
7X***64CAPSCREW, HEX HEAD 1/4 - 20 X 1 1/2 G8) 2
TO ATTACH PPV TO JUNCTION PLATE
8T***05WASHER, FLAT-THIN(1/4) w/o Freespool Qty is 122
TO ATTACH PPV TO JUNCTION PLATE
3D***87FITTING - USE WHEN RELOCATING AIR OVERRIDE VALVE TO R.H. SIDE PANEL if equipped with attachment parking brake control1
INTO TOP PORT OF PPV, HOSE E
00***33TEE-PIPE 1
INTO BOTTOM PORT OF PPV (ONE END OUT OF PORT 1)
2D***25TEE-TO SHUT-OFF CONTROL GROUP 1
INSIDE PORT OF 004-5933, VERTICLE IS HOSE G
5H***78ELBOW-EXTERNAL PIPE THREAD (EXTENSION PIPE)1
END OF 2D-7325, HOSE Z
8T***65PLUG-PIPE (DIESEL PARTICULATE FILTER)1
END OF 004-5933 (OUTSIDE)
-PORT 2-
8D***23COUPLING 1
INTO PORT HOLE, HOSE P
3D***13ELBOW-EXTENSION PIPE (EXTERNAL PIPE)1
INTO COUPLING, CHASSIS HOSE A (OUTSIDE)
-PORT 3-
8D***23COUPLING 1
INTO PORT HOLE
9D***51ELBOW-EXTERNAL PIPE THREAD 1
INTO COUPLING, ACCEPTS 004-5933 & HOSE M
00***33TEE-PIPE 1
LEFT END OF 9D-3351, SWITCH & HOSE E
9D***52ELBOW (EXTERNAL PIPE)1
INTO COUPLING, ACCEPTS 5H-4778 & CHASSIS HOSE (OUTSIDE)
5H***78ELBOW-EXTERNAL PIPE THREAD (EXTENSION PIPE)1
INTO 9D-3352, ACCEPTS CHASSIS HOSE C
-PORT 4-
9M***62COUPLING (165 in. long) 1
INTO PORT HOLE
3D***84ELBOW-- 90 DEGREES-- HIGH PRESSURE TO GAUGE 1
INTO COUPLING, HOSE N
8W***08VALVE-AIR RATIO (FRONT BRAKE)1
FRONT BRAKE RATIO VALVE, ABOVE PORT 3
4M***61BOLT-TO ASSEMBLE VALVE AS AND PLATES 2
TO ATTACH RATIO VALVE
8T***24WASHER-TO ASSEMBLE VALVE AS AND PLATES 2
TO ATTACH RATIO VALVE
4J***14ELBOW TO TEE FOR R.H. SUPPLY LINE 1
TOP PORT ON RATIO VALVE, HOSE N
2D***93ELBOW- RELAY EMERGENCY VALVE TO HOSE ASSEMBLIES 1
BOTTOM PORT ON RATIO VALVE, HOSE F
5H***78ELBOW-EXTERNAL PIPE THREAD (EXTENSION PIPE)1
INTO COUPLING, ACCEPTS CHASSIS HOSE D (OUTSIDE)
-PORT 5-
9M***62COUPLING (165 in. long) 1
INTO PORT HOLE
3D***87FITTING - USE WHEN RELOCATING AIR OVERRIDE VALVE TO R.H. SIDE PANEL if equipped with attachment parking brake control1
INTO COUPLING, HOSE O
5H***78ELBOW-EXTERNAL PIPE THREAD (EXTENSION PIPE)1
INTO COUPLING, ACCEPTS CHASSIS HOSE E (OUTSIDE)
-PORT 7-
9M***62COUPLING (165 in. long) 1
INTO PORT HOLE
2D***25TEE-TO SHUT-OFF CONTROL GROUP 1
INTO COUPLING, VERTICLE PORT, SECONDARY SWITCH
3D***87FITTING - USE WHEN RELOCATING AIR OVERRIDE VALVE TO R.H. SIDE PANEL if equipped with attachment parking brake control1
HORIZONTAL END OF TEE, HOSE AA
5H***78ELBOW-EXTERNAL PIPE THREAD (EXTENSION PIPE)1
INTO COUPLING, CHASSIS HOSE F (OUTSIDE)
-PORT 8-
9M***62COUPLING (165 in. long) 1
INTO PORT HOLE
3D***87FITTING - USE WHEN RELOCATING AIR OVERRIDE VALVE TO R.H. SIDE PANEL if equipped with attachment parking brake control1
INTO COUPLING HOSE BB
5H***78ELBOW-EXTERNAL PIPE THREAD (EXTENSION PIPE)1
INTO COUPLING, CHASSIS HOSE G (OUTSIDE)
----HOSE ROUTINGS----
-FRONT COMPARTMENT-
5M***62BOLT (3/8-16X0.75-IN)1
8T***96WASHER-HARD- LINE FROM PIPE AS. TO GEAR 1
9M***06CLIP-TO 8X7433 HARNESS AS ON FORE-AFT 1
FOR HOSE K
6V***65CLIP (CLIP UNDER HYDRAULIC TANK) 1
FOR TUBE J (3/8IN OD TUBE)
5M***62BOLT (3/8-16X0.75-IN)1
8T***96WASHER-HARD- LINE FROM PIPE AS. TO GEAR 1
7S***44CLIP (9.52MM ID) 1
FOR TUBES J AND R (3/8IN OD TUBE)
7K***81STRAP-PRESSURE & RETURN HOSES TO 1
HOSE BUNDLE AT SECONDARY VALVE
7K***81STRAP-PRESSURE & RETURN HOSES TO 3
HOSE BUNDLE IN TUNNEL-3 PLACES
-REAR COMPARTMENT-
7K***81STRAP-PRESSURE & RETURN HOSES TO 2
HOSE BUNDLE-2 PLACES
5M***62BOLT (3/8-16X0.75-IN)1
8T***96WASHER-HARD- LINE FROM PIPE AS. TO GEAR 1
4D***63CLIP 1
FOR HOSES AA, BB, F, M, O, Z
----HOSES/TUBES----
4S***63HOSE ASSEM. (29.50" long overall) 1
FRONT BRAKE SWITCH (BOTTOM PORT) TO TEE ON FRONT DCV, RIGHT SIDE
4S***62HOSE ASSEM. (76" long overall) 1
TEE ON FRONT DCV-OUTPUT TO REAR DVC-INPUT
7D***96HOSE ASSEM. (13" long overall) 1
TOP PORT OF PPV (JUNCTION PLATE) TO PORT 3
6D***79HOSE ASSEMBLY -- UNION IN CROSS TO UNION IN QUICK RELEASE VALVE1
FRONT BRAKE SWITCH (SIDE PORT) TO FRONT BRAKE RATIO VALVE (JUNCTION PLATE) (BOTTOM PORT)
4D***43HOSE ASSEMBLY-- UNION DASH JUNCTION BLOCK -- UNION DASH JUNCTION BLOCK1
DELIVERY OF SECONDARY TO CONTROL PORT ON INVERSION VALVE
4S***61HOSE ASSEM. (93" long overall) 1
SECONDARY SUPPLY (BOTTOM PORT) TO LEFT END OF SECONDARY AIR RESERVOIR
5P***07TUBE 7.23 dm(28.50 in.)
SUPPLY OF FOOT BRAKE VALVE (BOTTOM PORT) TO SUPPLY PORT OF RETARDER
4S***60HOSE ASSEMBLY -- RESERVOIR TO TEE UNION IN PRESSURE PROTECTION VALVE1
DELIVERY OF FOOT BRAKE VALVE TO TEE ON FRONT DCV-INPUT, RIGHT SIDE
4S***59HOSE ASSEM. (85" long overall) 1
HORN SOLENOID TO ELBOW ON FRONT COMPARTMENT FLOOR
8W***03HOSE AS 1
SUPPLY OF FOOT BRAKE VALVE (BOTTOM PORT) TO 9D-3351 ELBOW AT PORT 3
7D***96HOSE ASSEM. (13" long overall) 1
TOP PORT OF FRONT BRAKE RATIO VALVE
7D***22HOSE ASSEM. (118" Long Overall) 1
TEE ON FRONT DCV-OUTPUT TO PORT 5
2D***26HOSE ASSEM. (20.50" long overall) 1
RIGHT REAR PORT ON AIR RESERVOIR (2H-3940 ELBOW) TO COUPLING IN PORT 2
6D***55HOSE ASSEM. (16" long overall) 1
RIGHT CENTER PORT ON AIR RESERVOIR (4H-6147 CONNECTOR) TO 2D-7325 TEE IN PORT 1
5P***07TUBE 7.23 dm(28.50 in.)
RETARDER DELIVERY TO TEE ON FRONT DCV-INPUT, LEFT SIDE
8X***21HOSE AS 1
TEE AT HORN SOLENOID TO TEE IN PORT 1
4D***47HOSE ASSEMBLY -- EMERGENCY CONTROL VALVE TO QUICK RELEASE VALVE1
LEFT END OF SECONDARY AIR RESERVOIR TO INVERSION SUPPLY
5P***07TUBE 7.23 dm(28.50 in.)
AVAILABLE REPAIR KIT(S):
19***84KIT-VALVE (BRAKE)(SECONDARY BRAKE INVERTER VALVE)1
(INCLUDES O-RINGS, DIAPHRAGM, LUBRICANT, INSTRUCTIONS, DIAPHRAGM SCREW & WASHER, CHECK VALVE, INLET & EXHAUST VALVE,
EXHAUST COVERS, RETAINING RING)
USE AS REQUIRED
ORDER BY THE METER
REFER TO HYDRAULIC INFORMATION SYSTEM
KIT MARKED J SERVICES PART MARKED J
SEPARATE ILLUSTRATION

1595294 CONTROL GROUP-SERVICE BRAKE -CHASSIS - OFF-HIGHWAY TRUCK Caterpillar 775D - 775D Quarry Truck 8AS00001-UP (MACHINE) POWERED BY 3412E Engine BRAKING SYSTEM | 777parts

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