PIPE 2D7957 - Caterpillar

Assembly Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 1P-0510 Driver Gp 1
Inspect all parts and clean all parts. If any parts are worn or damaged, use new Caterpillar parts for replacement. Note: Lubricate all pistons and all seals with clean hydraulic oil prior to installation. Check that all the grooves for the O-rings are clean.
Illustration 1 g00801480
Install the small O-ring (12) on the piston.
Illustration 2 g00801481
Install the large O-ring (11) on the piston.
Illustration 3 g00801484
Align the marks on piston (10) and the marks on brake cylinder (14) and install the piston into the brake cylinder.
Illustration 4 g00801486
Use a suitable press to ensure that an overall pressure is applied to the piston. The use of a press will avoid any distortion of the piston when the piston is installed into the brake cylinder. Apply a pressure of 30 bar (435 psi) to the piston.
Illustration 5 g00801054
Install spacers (4) and bushings (3) into the piston. Secure the spacers and the bushings to the brake cylinder with washers (2) and bolts (1).
Illustration 6 g00801053
Install the components for the automatic brake adjusters into the piston: three retainers (6), three outer springs (7), three inner springs (8) and three bushings (9). Apply a downward force on bolts (5) in order to engage the threads in the brake cylinder.
Illustration 7 g00801491
Tighten bolts (1) and (5) to a torque of 10 N m (88.5 lb in).
Illustration 8 g00801728
Install purge screw (18) in the brake cylinder. Tighten the purge screw to a torque of 12 N m (9 lb ft).
Illustration 9 g00801492
After you have assembled the piston into the brake cylinder it will be necessary to run a pressure test. The pressure test will ensure that the piston is correctly seated in the brake cylinder. Connect a suitable air supply to the adapter that is located in the brake cylinder. Apply a pressure of 6 bar (87 psi) on the piston. If there is a pressure reduction within a minute, inspect the O-rings. If necessary, replace the O-rings .
Illustration 10 g00801065
Use Tool (A) in order to install bearing cup (13) into the piston.