PUMP GP-PISTON 7Y4009 - Caterpillar

Service Brake Control - Adjust
Adjustment Procedure
Illustration 12 g01302042
(A) 0.56 mm to 0.90 mm (0.022 inch to 0.035 inch) (B) Limit Switch (1) Stop Plate (2) Locknut (3) Set bolt (4) Right brake pedal (5) Left brake pedal (6) Lock plate
Unlock the lock plate (3) .
Illustration 13 g01515548
(A) 0.56 mm to 0.90 mm (0.022 inch to 0.035 inch) (B) Limit Switch (2) Locknut (3) Set bolt (4) Right brake pedal (5) Left brake pedal (6) Lock plate (7) Rod end (8) Locknut (9) Pushrod (10) Master cylinder (11) Boot
Illustration 14 g01302129
(C) Slot for the lock plate (6) Lock plateNote: The brakes have identical controls. Adjust one brake control at a time.
Unseat the boots (11) from the master cylinder (10) .
Pull both pedals (4) and (5) upward. Adjust the set bolt (3) so that the Lock plate (6) aligns with the slot for the lock plate (C) . Tighten locknut (2) . Ensure that the limit switches (B) engage when the pedals are against the stops.
Depress the brake pedal (4) and release the brake pedal. This process is called stroking. Fully stroke and release brake pedal (4) six times in order to obtain the nominal position of the master cylinder piston.
Loosen nut (8) .
Back off pushrod (9) . Insert a 0.76 mm (0.030 inch) shim between the brake pedal (4) and the set bolt (3) . Adjust pushrod (9) until contact is made between the pedal and the shim. Also, adjust pushrod (9) until initial resistance is felt from the master cylinder (10) . Tighten nut (8) to a torque of 20 5 N m (177 44 lb in). Pushrod (10) should not be allowed to move when nut (8) is tightened.. Remove the shim..
Move pushrod (9) and rod end (7) in order to ensure that free play exists. Measure the gap (A) that is between the brake pedal and the set bolt (3) with a feeler gauge. The measurement on the gap (A) should read a minimum of 0.56 mm (0.022 inch). .Note: Ensure that a 0.9 mm (0.04 inch) shim will not fit between the stop on the brake pedal and the plate assembly.
Adjust the brake pedal if the gap is not within allowed specifications.
Repeat the above procedure for the left brake pedal.Note: For the left pedal (5) , you will use the lock plate (1) instead of the set bolt (3) .
Ensure that the Lock plate (6) aligns with the slot for the lock plate (C) .
Ensure that boot (11) is sealed properly against the master cylinder.Checking the Wear on the Service Brake Discs
Introduction
It is necessary to check the service brake discs for wear in order to maintain the performance of the service brake.Required Tools
Use the following test equipment in order to check for wear on the service brake discs:
Table 1
Required Tools    
Tool    Part Number    Description    Qty    
A     242-0992     Brake Wear Gauge     1    Procedure for Checking the Wear
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