KENR8738 - Service Brake Discs - Check - Extended Life

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Testing and Adjusting

793F and 793F CMD Off-Highway Truck Braking System
Media Number -KENR8738-10 Publication Date -01/05/2015 Date Updated -30/05/2019
i03636704
Service Brake Discs - Check - Extended Life

SMCS - 4251-535; 4255-535
Checking the Brake Wear with Gauges

Table 1
Required Tools
Qty Part Number Description
1 160-1726 Brake Wear Gauge As
1 1U-7425 Brake Wear Gauge
Note: This procedure should be performed at the initial delivery in order to establish a baseline. Also, perform
this procedure again after any of the brakes are rebuilt. Rebuilding the brakes will change the piston travel. This
will create a new benchmark for the piston travel. Record the measurements in the Testing and Adjusting,
"Worksheets" that are located in the back of this book.
https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/mediasearch/mediaheaderinfoframeset.jsp&calledpage=… 1/13
Illustration 1 g01979959
Front brake housing
(S) Purge valve for service brake
(P) Purge valve for parking brake
Rear brake housing on right hand side
Note: Identification letters are embossed on the purge valves at the top of the brake housing. The purge valve for
the parking brake is labelled with a "P". The purge valve for the service brake is labelled with an "S".
Note: Before checking for wear, perform the Systems Operation/Testing and Adjusting, "Service Brakes and
Retarder System Pressure - Test".
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.
Personal injury can result from hydraulic oil under pressure.
Hydraulic oil under pressure can cause injury to persons on or near the
machine when the pressure is suddenly released.
At operating temperature, the hydraulic oil tank is hot and under

pressure. Hot oil can cause burns.
Remove the fill plug only when the engine is stopped, and the fill plug is
cool enough to touch with your bare hand.
Do not allow hot oil or components to contact skin.
NOTICE
Care must be taken to ensure that fluids are contained during
performance of inspection, maintenance, testing, adjusting, and repair
of the product. Be prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any component
containing fluids.
Refer to Special Publication, NENG2500, "Dealer Service Tool

Catalog" for tools and supplies suitable to collect and contain fluids on
Cat® products.
Dispose of all fluids according to local regulations and mandates.
Make sure that the transmission is in NEUTRAL.
Note: Do not activate the service brakes or the retarder while the gauge plug is installed.
1. While the engine is off and the parking brake is engaged, remove the top plug that is labelled with an "S".
2. Install the 160-1726 Brake Wear Gauge As.
Brake wear gauge
(1) Service brake piston
(2) Pin
(3) Brake wear gauge assembly
(4) Brake wear gauge
(A) Distance with the parking brake engaged
(B) Distance with the parking brake disengaged
(C) Distance of stroke
3. Push pin (2) until pin (2) contacts service brake piston (1), as shown above.
4. Hold brake wear gauge (4) in position on brake wear gauge assembly (3). Push down on the plunger until
contact is felt on pin (2) in brake wear gauge assembly (3). Available space permits the use of only one
arm to perform this task.
5. Remove brake wear gauge (4) from brake wear gauge assembly (3). Measure distance (A). Distance (A) is
the measurement of the extension of the plunger beyond the tube. Record this measurement. You may also
use a micrometer to take this measurement, if this is a more convenient method.
6. Start the engine. Operate the engine at high idle so that cooling oil is sent to the service brake piston.
7. Move the parking brake lever to the OFF position. Brake cooling oil flow and pressure ensure that the
parking brake piston is completely released.
8. Again, push in pin (2) until pin (2) contacts service brake piston (1).
9. With one hand, hold brake wear gauge (4) over brake wear gauge assembly (3). Push down on the plunger
until the plunger makes contact with pin (2) in brake wear gauge assembly (3).
10. Remove brake wear gauge (4) from brake wear gauge assembly (3). Measure distance (B). Distance (B) is
the measurement of the extension of the plunger beyond the tube. Record this measurement in a secure
place in order to use for future measurements of the piston stroke. You may also use a micrometer to take
this measurement, if this is a more convenient method.
11. Subtract measurement (A) from measurement (B). Distance (C) is the total movement of the brake piston.
This measurement represents the piston stroke.
Note: Refer to Table 2 and Table 3 in order to determine the percentage of brake wear. Refer to Guideline
for Reusable Parts and Salvage Operations, SEBF8095, "Service Brakes for Off-Highway Trucks and
Tractors" in order to determine the service intervals.
Table 2
Baseline Value for the Piston Stroke(1)
Front Wheels Rear Wheels
4.8 mm (0.189 inch) 5.1 mm (0.201 inch)

(1) This is the piston stroke that is measured through the service port. This value can float by 2 to 3 mm (0.0787 to 0.1181 inch)
due to tolerances.
Table 3
Additional Piston Stroke (Compared to the Baseline Value for the Piston Stroke from Table 2)
Percent of Brake Wear Front Brake Piston Travel Rear Brake Piston Travel
10 percent 0.7 mm (0.0276 inch) 0.8 mm (0.0315 inch)


Note: Record the baseline value for the piston stroke. Compare the baseline value for the piston stroke to
the measured stroke throughout the life of the brake. The brake is completely worn when the measured
stroke is equal to the baseline value of the piston stroke plus the "100 percent" value that is shown in Table
3.
Note: The brake assembly should be rebuilt when wear reaches 75 percent of the baseline value. Refer to
the Testing and Adjusting, "Worksheets" that are located in the back of this book.
12. Remove brake wear gauge assembly (3). Install the plug.
13. Repeat Steps 1 through 12 for the other side.
Personal injury or death can result from air in the oil for the brake
hydraulic system.
Air in the system can prevent complete brake application and it is

possible that the wheels on the machine can not be stopped.
Air must not be in the oil for the brake hydraulic system to function
properly.
14. Make sure that you remove all air from the hydraulic brake system. See the Testing and Adjusting, "Brake
System Air - Purge" for the procedure.
Brake Disc Wear Check And Plate Wear Check
Note: See Specifications, "Air System and Brakes" for new dimensions.
Friction Discs
Check for the thickness of the discs. Determine if friction material needs to be removed. (This is material that
has flaked off.) Check for shallow oil grooves.
Table 4
Table For Determining The Wear Of Friction Disc
Percentage Of Disc Wear Disc Thickness

0 percent 5.08 mm (0.200 inch)




Table 5
Table For Determining The Wear Of The Grooves In The Friction Disc(1)
Percentage Of Disc Wear Disc Groove Depth





(1) This measurement is based on three measurements per side and the measurements are taken at 25.4 mm (1.00 inch) from the outside
of the disc.
Replace the discs if any of the following conditions exist.
The remaining brake disc life does not last until the next rebuild of a major component.
The disc has more than 20 percent of a wear difference when you compare the disc to the other discs that
are in the same assembly.
10 percent or more of the friction material is flaked off or the discs have a flaking tendency. (Flaking
tendency means that the friction material easily flakes off with only light force.)
Oil grooves average less than 0.46 mm (0.018 inch) in depth per each side.
The brake assembly should be rebuilt when wear reaches 75 percent of the baseline value. Refer to the
Testing and Adjusting, "Worksheets" that are located in the back of this book.
Steel Plates
Check the plate for thickness, for scored surfaces, for radial grooves, and for warpage. Replace the plates if any
of the following conditions exist.
The plate thickness is less than 2.16 mm (0.085 inch).
More than 10 percent of the surface area is scored.
The plate has deep radial grooves that would act as a cutting edge on the friction material on the discs.
The plate is warped and the plate cannot be flattened with a force of 90 N (20 lb).
Damper Plate Assemblies
Always use new dampers when you repair the oil cooled multi-disc brakes. Permanent shrinkage of the damper
material and deterioration of the damper material will reduce the brake's usable life after the rebuild.
Checking the Brake Wear with Permanently Mounted Indicators

Table 6
Required Tooling
Qty Part Number Description
2 348-6962 Brake Wear Indicator(1)
2 348-6963 Brake Wear Indicator(2)

(1) Front brakes only
(2) Rear brakes only
Note: This procedure should be performed at the initial delivery in order to establish a baseline. Also, perform
this procedure again after any of the brakes are rebuilt. Rebuilding the brakes will change the piston travel. This
will create a new benchmark for the piston travel.
Front brake housing
Rear brake housing on right hand side
Note: Identification letters are embossed on the purge valves at the top of the brake housing. The purge valve for
the parking brake is labelled with a "P". The purge valve for the service brake is labelled with an "S".
Note: Before checking for wear, perform the Systems Operation/Testing and Adjusting, "Service Brakes and
Retarder System Pressure - Test".
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.
Personal injury can result from hydraulic oil under pressure.
Hydraulic oil under pressure can cause injury to persons on or near the
machine when the pressure is suddenly released.
https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/mediasearch/mediaheaderinfoframeset.jsp&calledpage… 10/13
At operating temperature, the hydraulic oil tank is hot and under

pressure. Hot oil can cause burns.
Remove the fill plug only when the engine is stopped, and the fill plug is
cool enough to touch with your bare hand.
Do not allow hot oil or components to contact skin.
NOTICE
Care must be taken to ensure that fluids are contained during
performance of inspection, maintenance, testing, adjusting, and repair
of the product. Be prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any component
containing fluids.
Refer to Special Publication, NENG2500, "Dealer Service Tool

Catalog" for tools and supplies suitable to collect and contain fluids on
Cat® products.
Dispose of all fluids according to local regulations and mandates.
Installing and Setting the Brake Wear Indicator

1. While the engine is off and the parking brake is engaged, remove the top plug that has the label "S".
2. Install the brake wear indicator into the open port. Tighten the brake wear indicator to a torque of
140 ± 14 N·m (105 ± 10 lb ft).
Note: The 348-6962 Brake Wear Indicator Gp is for the front wheels, and the 348-6963 Brake Wear
Indicator Gp is for the rear wheels.
Typical view of an installed brake wear indicator
3. Remove cap (A) from the brake wear indicator.
Typical view of newly installed brake discs
4. Apply forward pressure to indicator rod (B) so that the indicator rod contacts brake piston (C).
5. 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).
6. 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
Typical view of an installed brake wear indicator
1. While the engine is off and the parking brake is engaged, remove cap (A) from the brake wear indicator.
Typical view of worn brake discs
2. Push indicator rod (B) until the indicator rod contacts brake piston (C).
Note: If the end of rod (B) is flush with dowel bushing (D), or if the end of rod (B) goes below the end of
dowel bushing (D), then the brake material has exceeded the service life. If the brake material has
exceeded the service life, replace the brake discs.
3. After the brake wear has been checked, pull back rod (B).
4. Reinstall cap (A) that was removed in Step 1. Tighten cap (A) to a torque of 34 ± 4 N·m (300 ± 35 lb in).
Copyright 1993 - 2019 Caterpillar Inc. Mon Jun 24 2019 13:48:32 GMT-0300 (Horário Padrão de Brasília)
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24/06/2019 Media Search - KENR8738 - 793F and 793F CMD Off-Highway Truck Braking System

Testing and Adjusting

Service Brake Discs - Check - Extended Life

Checking the Brake Wear with Gauges

Personal injury or death can result from machine movement.

Personal injury can result from hydraulic oil under pressure.

At operating temperature, the hydraulic oil tank is hot and under

Do not allow hot oil or components to contact skin.

Refer to Special Publication, NENG2500, "Dealer Service Tool

Dispose of all fluids according to local regulations and mandates.

Make sure that the transmission is in NEUTRAL.

2. Install the 160-1726 Brake Wear Gauge As.

Front Wheels Rear Wheels

4.8 mm (0.189 inch) 5.1 mm (0.201 inch)

10 percent 0.7 mm (0.0276 inch) 0.8 mm (0.0315 inch)

20 percent 1.3 mm (0.0512 inch) 1.5 mm (0.0591 inch)

30 percent 2.0 mm (0.0787 inch) 2.3 mm (0.0905 inch)

40 percent 2.6 mm (0.1024 inch) 3.0 mm (0.1181 inch)

50 percent 3.3 mm (0.1299 inch) 3.8 mm (0.1496 inch)

70 percent 4.6 mm (0.1811 inch) 5.3 mm (0.2087 inch)

80 percent 5.3 mm (0.2087 inch) 6.1 mm (0.2402 inch)

90 percent 5.9 mm (0.2323 inch) 6.8 mm (0.2677 inch)

13. Repeat Steps 1 through 12 for the other side.

Air in the system can prevent complete brake application and it is

Brake Disc Wear Check And Plate Wear Check

Percentage Of Disc Wear Disc Thickness

20 percent 4.98 mm (0.196 inch)

40 percent 4.88 mm (0.192 inch)

70 percent 4.72 mm (0.186 inch)

90 percent 4.63 mm (0.182 inch)

Percentage Of Disc Wear Disc Groove Depth

10 percent 0.62 mm (0.024 inch)

40 percent 0.57 mm (0.022 inch)

60 percent 0.53 mm (0.021 inch)

90 percent 0.48 mm (0.019 inch)

Replace the discs if any of the following conditions exist.

The plate thickness is less than 2.16 mm (0.085 inch).

More than 10 percent of the surface area is scored.

Damper Plate Assemblies

Checking the Brake Wear with Permanently Mounted Indicators

2 348-6962 Brake Wear Indicator(1)

2 348-6963 Brake Wear Indicator(2)

Personal injury or death can result from machine movement.

Personal injury can result from hydraulic oil under pressure.

At operating temperature, the hydraulic oil tank is hot and under

Do not allow hot oil or components to contact skin.

Refer to Special Publication, NENG2500, "Dealer Service Tool

Dispose of all fluids according to local regulations and mandates.

Installing and Setting the Brake Wear Indicator

3. Remove cap (A) from the brake wear indicator.

Checking the Brake Wear

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