WIRING DIAGRAM 6L5824 - Caterpillar

Installing and Setting the Brake Wear Indicator
Note: This procedure is preset at the factory in order to establish a baseline. Perform this procedure again after any of the rear and front brakes are rebuilt. Rebuilding the brakes will change the piston travel. Performing the procedure after rebuilding the brakes will create a benchmark for the piston travel.
While the engine is off and the parking brake is engaged, remove the top plug that has the label "S".
Install the brake wear indicator into the open port at one of the locations shown in Illustration 1. Tighten the brake wear indicator to a torque of 140 14 N m (105 10 lb ft).
Illustration 2 g01979773
Typical view of an installed brake wear indicator
(A) Cap
Remove cap (A) from the brake wear indicator.
Illustration 3 g01979775
Typical view of newly installed brake discs
(B) Indicator rod
(C) Brake piston
Apply forward pressure to indicator rod (B) so that the indicator rod contacts brake piston (C).
Illustration 4 g02797842
New install position for break wear indicator
(B) Indicator rod
(D) Dowel bushing
Push dowel bushing (D) into the body until the end of dowel bushing (D) is flush with the notched shoulder that is on indicator rod (B).
Table 2
Nominal Indicator Length Extending from Black Dowel Bushing for 770G (On New Brakes) Nominal Indicator Length Extending from Black Dowel Bushing for 772G (On New Brakes
6.1 0.25 mm (0.240 0.010 inch) 7.6 0.25 mm (0.299 0.010 inch)
Reinstall cap (A) that was removed in Step 3. Tighten cap (A) to a torque of 34 4 N m (300 35 lb in). Checking the Brake Wear
Illustration 5 g01979795
Typical view of an installed brake wear indicator
(A) Cap
While the engine is off and the parking brake is engaged, remove cap (A) from the brake wear indicator.
Illustration 6 g01979777
Typical view of brake wear indicator in service
(B) Indicator rod
(C) Brake piston
(D) Dowel bushing
Push indicator rod (B) until the indicator rod contacts brake piston (C).
Illustration 7 g02797926
Sections X, Y, and Z show different levels of brake wear
(B) Indicator rod
(D) Dowel bushing
If the end of indicator rod (B) is flush with dowel bushing (D) as shown in section "X" of Illustration 7, then the brake material has exceeded the service life. If the brake material has exceeded the service life, replace the brake discs.
If the end of indicator rod (B) goes below the end of dowel bushing (D) as shown in section "Y" of Illustration 7, then the brake material has exceeded the service life. If the brake material has exceeded the service life, replace the brake discs.
If the end of indicator rod (B) protrudes from dowel bushing (D) as shown section "Z" of Illustration 7, then the brake material has not exceeded the service life. Note: The measurement in the table below is taken from the forward edge dowel bushing (D) to the end of indicator rod (B). Values are estimated.
Table 3
Approximate 770G and 772G Off-Highway Truck Brake Life Remaining
Measured Brake Indicator
Remaining Brake Life 770G 772G
100% 6.1 0.25 mm (0.240 0.010 inch) 7.6 0.25 mm (0.299