BLOCK AS-CYL 7E4667 - Caterpillar

Do not perform any procedure in this Special Instruction until the information has been read and understood.Note: Brake wear indicators should only be installed and calibrated when all friction discs are at 100% remaining life.Reference Section
ReferenceTesting and Adjusting, KENR8738, "793F Off-Highway Truck Braking System ", "Installing and Setting the Brake Wear Indicator"Required Parts
Table 1
Service Repair Kit    
Part Number     Part Name     Qty    
363-8596     Kit-Indicator     As Applicable (1)    
( 1 ) The kit will provide the needed seals and dowel bushing to rebuild one indicator.Machine Coverage
Illustration 1 g03045156
(-) Original version of model before letter designations (R) Represents the applicable indicator part number to use on Rear brakes for specific truck serial number (F) Represents the applicable indicator part number to use on Front brakes for specific truck serial number
Note 1: 773F, 775F, 777F require machining the brake port into brake anchor. Brake port machining is required for the following Off-Highway Trucks 773F (S/N: EED1-1249), 773F (S/N: EXD1-126), 775F (S/N: DLS1-1252), and 777F (S/N: JRP1-2541).
Note 2: Brake wear indicators not available for 777F and earlier wet front brake option.
Note 3: Extended life wheel option.
Note 4: For the 795F and 797F the rear indicator is electronic and requires sensors, wires and mounting hardware. 795 requires two 286-1876 Position Sensor Gp and 339-5020 Integrated Brake Wiring Gp . 797 requires two 286-1876 Position Sensor Gp and 324-3351 Integrated Brake Wiring Gp .
Note 5: 789, 789B, and 789C machines require machining a chamfer into the inside corner of the rear wheels to prevent interference with the indicator.
Illustration 2 g02451657
Typical view of 286-1876 Position Sensor Gp (1) Sensor box (2) Spring (3) Loose rodMachining of the Brake Anchor For Use With Brake Wear Indicators on 773F, 775F, and 777F Machines
Note: Brake port machining is required for the following Off-Highway Trucks 773F (S/N: EED1-1249), 773F (S/N: EXD1-126), 775F (S/N: DLS1-1252), and 777F (S/N: JRP1-2541).Use the appropriate tooling for the following steps. Tooling that is misused may cause unsafe conditions.
Illustration 3 g02156446
Typical example of brake anchor without port for brake wear indicator. (A) Brake Anchor
Illustration 4 g02155760
(A) Brake Anchor (B) 16 degree from center of brake anchor center to start point of hole (C) Radius of 316 mm (12.45 inch) (D) Location of hole to be drilled
Measure from the center of the brake anchor to radius (C) .
Mark this location for further reference.
Measure from center to the right of center 16 degrees to find the center of the hole to be drilled and tapped.
Mark this location for further reference.Note: The measurements from Step 1 and Step 2 make up hole location (D) .
Drill a hole of 19.75 mm (0.80 inch) in diameter with a depth of 27 mm (1.10 inch). Refer to Step 2.a for the reference location of the hole to be drilled.
Drill a 12.5 mm (0.50 inch) through hole at the reference location in Step 2.a.
Use suitable tooling in order to create a "NO. 10 port" in the created hole location.
Tap the hole with a "7/8-14-2B"