KIT-CYL HEAD (Kit) 5049108 - Caterpillar

Adjusting the Brake Pedal Linkage
Introduction
It will be necessary to take up any free play in the brake pedal linkage in order to maintain the performance of the service brake.Test Procedure
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.
Park the machine on level ground and stop the engine.
Block the wheels and engage the parking brake.
Remove the trim panel from the cab in order to gain access to the brake pedal linkage. Disconnect the heater hose.
Illustration 1 g00887280
Brake cylinder (1) Pushrod
Carefully attempt to move the pushrod (1) forward and backward. A small amount of end play should be detected.
Slowly press the brake pedal. The end play at the pushrod should be taken up when the brake pedal has travelled approximately 5 1 mm (0.19 0.03 inch).
If there is no end play at the pushrod, the brake linkage must be adjusted. If there is more than 5 1 mm (0.19 0.03 inch) of pedal travel, the brake linkage must be also adjusted in order to eliminate any excessive free play.Procedure for Adjusting the Free Play in the Brake Linkage
Illustration 2 g00872948
Brake cylinder (1) Pushrod (2) Locknut
Loosen locknut (2) on pushrod (1) .
Illustration 3 g00871487
Brake pedal linkage (3) Locknut (4) Adjustment bolt (5) Locknut (6) Adjustment bolt (7) Dust cover
Loosen locknuts (3) and (5) on adjustment bolts (4) and (6). Turn adjusting bolts (4) and (6) in a counterclockwise direction. The adjusting bolts must not contact the brake pedal linkage during adjustment of the pushrod.
Remove dust cover (7) on the brake cylinder in order to allow access to the plunger. Rotate pushrod (1) clockwise until the pushrod bottoms out in the plunger. There should be 0.9 0.3 mm (0.03 0.01 inch) of axial play between the pushrod and the plunger. Tighten locknut (2) .
Turn adjustment bolt (6) clockwise until the bolt makes contact with the pedal linkage. Turn the adjustment bolt clockwise by half a turn. Secure the adjustment bolt with locknut (5) .
Apply force to the brake pedal until the plunger in the brake cylinder is fully displaced. If the pedal makes contact with the floor of the cab then adjust the height of the pedal with adjustment bolt (4). Do not raise the pedal more than 5 mm (0.2 inch) off the floor of the cab. Use locknut (3) to secure the adjustment bolt (4) in place. If the pedal does not contact the floor, secure the adjustment bolt (4) with locknut (3) in position. Ensure that the adjustment bolt does not interfere with the pedal linkage.
When the adjustment is complete, check that the plunger in the brake cylinder is flush with the body of the brake cylinder and that the required axial play is available.
Install the dust cover onto the brake cylinder and reconnect the heater hose. Install the trim in the cab.
Remove the wheel blocks.
Prepare the machine for operation.