: CATERPILLAR senrerana August 1995. Specitications 988F & 988F Series Il Wheel Loader Brake System 988F 988F II 8YG1-UP 2ZR1-UPImportant Safety Information Most accidents involving product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skils and too's to perform these functions properly. Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death. Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information. Safety precautions and warnings are provided in this manual and on the product. If these hazard wamings are not heeded, bodiy injury or death could occur to you or other persons, ‘The hazards are identified by the “Safely Alert Symbof" and followed by a "Signal Word" such as "WARNING’ as shown below. The meaning of this safety alert symbol is as follows: Attention! Become Alert! Your Safety is Involved. The message that appears under the warning, explaining the hazard, can be either written or pictorally presented. ‘Operations that may cause product damage are identifiod by NOTICE labe!s on the product and inthis publication. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The ‘warnings in this publication and on the product are therefore not all inclusive, Ifa tool, procedure, work method or operating technique not specifically recommended by Caterpillar is used, you must satisy yourself that itis safe for you and others. You should also ensure that the product will not be damaged ‘or made unsafe by the operation, lubrication, maintenance or repair procedures you choose. The information, specifications, and illustrations in this publication are on the basis of information avaliable at the time it was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service given to the product. Obtain the complete and most current information before starting any job. Caterpilar dealers have the most current information available. For alist of the most current publication form numbers avaliable, see the Service Manual Contents Microfiche, REG1139F.Index ‘Accumulator ‘Accumulator Charging Valve Brake Control Linkage And Brake Pedal Travel ‘Adjustment Brake Control Valve Brake Pedal Hydrauic Pump Introduction Neutralizer Limit Switch "Neutralizer Limit Switch Adjustment Parking Brake Parking Brake Control Valve Parking Brake Control Cable Parking Brake Valve Limit Switch Parking Brake Valve Limit Switch Adjustment Service/Parking Brake Pressure Switch Assembly Service (Wheel) Brakes Stop Lamp Switch Assembly ‘Slop Lamp Switch Assembly Adjustment Transmission Neutralizer Pressure Switch Introduction \When the words "use again’ ae in the description, the specication given can be used to determine if a part can be Used again. the part is equal to or within the specication given, use the part again \When the word "permissibie” isin the description, the specication gven isthe "maximum or minimum’ tolerance permitted betore adjustment, repair andjor new parts are needed. ‘A comparison can be made between the measurements of a worn part and the specifications of a new part to find the ‘amount of wear. A part that is worn can be used again if an festimate of the remainder ofits service life is good. Ita short service ie is expected, replace the part Reference: For Systems Operation, Testing and Adjusting, make reference to SENAS733, 9B8F Wheel Loader Brake ‘System Operation Testing & Adjusting NOTE: AC" in the left margin isan indication of a change ‘om the former issue. Brake System IndexSpecifications Hydraul 2 036072 Rolation is counterclockwise when seen from dive end Test At Half Speed: Type of pump: Gear Output 68L/mn (18S. gpm) For test, use SAE 10W oil at 65°C (150°F) Ata pressure of 680 KPa (100 ps) With pump at 1064 7pm na ee aera oe With engine at 1000 pm over Sect rake And Pilot System: wo) " Output 64 L/min (17 US. gpm) Test At Full Spoed: ‘Ata pressure of £690) kPa (1000 psi) With pump at 1064 1pm Output 140 L/min (87 US. gom) ‘With engine at 1000 rpm Ata pressure of (690 kPa (100 ps) ‘with purnp at 21281pm With engine at 20001 Output 136L/min (36 US. gom) ‘Ata pressure of 6900 kPa (1000 ps) with pump at 2128 1pm With engine at 200016 Brake System SpecificationsDrive End Section (B) [Steering System] Test At Half Speed Test A Ful Speed outst 1981 mn 1S. gpm) tapessre of 250162 100 ps) ouput 386i (102 US. gpm) wih pup “bosom ata presse of e201 100) vit eng {om pn wan pap a 2m tot 1851 nin 8US. gon) Ata pressure of 6900 kPa (1000 psi) oupat 279 Lin 1ODUS. gen) vt pe Hoot rn ta prose ol 800¥a 100 =) vin engre 1000" Sih pam st som (1) Tite eg bots oa trae of hist 7Nm win ergo at 2000 pn s nest (8) Toten agro axa os 27 ETBNEM (meet) Brake System SpeciicatonsAccumulator Charging Valve ql FING NN a Yd Wn, | AN 36148 18600345 KPa (2700+ 50ps) 13.620 4345 170 kPa (1975 +50 -25 psi Opening pressure of relief valve Cutout pressure of charging valve (1) 54.0835 shim: Thickness of new shim 1.52 men (060 in) Use shim to adjust difference between cutout to cutin pressure of 3950 + 690 KPa (575 + 100 ps) (One new shim wil change pressure... 700 kPa (100 ps) (2) 08-1850 Spring: Length under test force 523mm 206in) Test force 58 4Nem (12 1) Free length after test 825mm (3.25in) Outside diameter 41.28 mm (1.625 in) (@) 96-6705 Spring: Length under test force 23.02 mm (906 in) Test force 10510 122N 2351027510) Free length alter test, Outside diameter 492mm (1.94 in) 12.84 mm (506 in) (4) 47-2541 Spring for cutout valve (outer Length under test force 109.2 mm (4.30 in) Test force 443+ 35N (100481) Free length after test 211 mm B3in) Outside diameter 221.59 mm (850 in) Brake System 436809 Spring for cutout valve (inne): Length under test force Test force 140.2mmm (652i) 250 20N (66.04.51) Free length ater test 1780 me (7.01 in) Outside diameter 14.86 mm (585in) Thickness of 4.6806 Shim 41.22 mm (048 in) (One shim wil change pressure 200 kPa (33ps)) Thickness of 337473 Shim 12mm (008 in) ne shim wil change pressure 280 kPa (40 psi) Thickness of 317470 Shim 1.22 mm (048 in) (One shim wil change pressure... 2685 KPa (380 ps) 47118 Spring for rei valve (red stripe} Length under test force 34.14 mm (1.344in) Test force 2220 261 N (50.1 1058.8 ib) Free length alter test 42+ 1.5mm (1.65 06 in) Outside ciameter 14.9mm (47 in) 8,.4508 Spring for flow conta valve: Length under test force 41.4 men (1.6310) Test force 708 #57 N (1592 128Ib) Free length after test 91.7 mn (361 in) Outside diameter 20.62mm (812in) SpecificationsBrake Control Valve 1 2 3 4 o AWE =3 5 6,7 8 (1) Tightening torque for nut. 47 £9Nem (357 Ib ft) C NOTE: Assemble the thinner shim next to the retainer. Use (2) 4-3303 Spring: Length under test force 37.62 mm (1.481 in) (8) 40-6802 Spring: (3) 40-3302 Spring: Length under test force 49.23 mm (1.938 in) (8) 3K:2478 Spring: (4) 91-2195 Spring: vapor eg tao lesiegraar us eh NOTE: Shim (6) is only used in earlier machines. (6) Thickness of 9.5624 Shim (0.76 mm (030in) ‘One shin will change pressure 90 KPa (13 psi) NOTE: Adaition of shims wil increase pressure, Removal of shims will decrease pressure, NOTE: Shims (6) and (7) are only used in later machines. Brake System 7 SpecificationsAccumulator (2) Lubricate threads wth clean grease and tighten head to a torque of {600 +: 130 Nem (441 3:96 bf) (@) Outside diameter of new piston... 120.18 0.03 mm (4.730 001 in) (4) Bote diameter of nen cylinder 120.7 +0.10mm (475+ 004in) Parking Brake Control Valve 36075 Install plug (1) and tighten toa torque of 504 7Nem GT=5bH) Install plug (2) and tighten toa torque of 75:£7Nem (54508) Install end cap (8) and tighten toa torque of ... 75:7 Nem (6525111) 36081 Pressure of nitrogen '5512kPa (800 psi) Internal volume of gas compartment 5.681. (6.004 at) (1) Tighten valve assembly to @ torque Of .... SO9Nem Gr+7bI Brake System SpecificationsParking Brake Tom pseoss 7 Be] (1) Lubricate piston tightly with lubricant being sealed. (2) Bote in housing for release piston... 57.163+0.013 mm (2.2505 +¢.0005in) Outside diameter of release pisION nn... 57.089 0.013 mm (2.2480: .0005in) (Thickness of one new 1V-8279 Dis¢ ... 4.95.08 mm (198 +008 in) (4) Thickness of one new 18-0087 Plat... 6:35-+.08 mm (250% (003 in) (6) Tightening torque for six bolts 140+ 14Nem (105 1016 ft) (©) Tightening torque for bolt... 118+ 7 Nem (85 +: 5 ft (7) 78:3987 Spring for engaging brake: Length under test force Test force 69.34 mm (2730in) ‘3694 4 312N (875: 7016) Free length after test {82.75 mm (3.258) (Outside diameter 42.88 mm (1.688 in) (®) Thickness of four new discs and three new plates ‘38.29 0:39.41 mm (1.507 to 1.652in) 35.41 mm (1.384in) (®) Lubricate seal ightly with lubricant being sealed ‘Minimum thickness (worn plates and discs) Brake System ‘SpecificationsService (Wheel) Brakes c 8YG1-Up Ly | 036156 NOTE: Because of the wear characteristic onthe outside faces of the two outer most 70-7504 Plates, they must be installed in exacly the same position as they were before assembly. Lubricate the pies and discs with the lubricant being used in the final dive prior to assemoly (1), 70-7504 Piate thickness: New 2.413 0.064 mm (0950 + 0025 in) Minium worn 2.29 mm (090 in) (2) 9W-7018 Disc thickness: New 5.08 0.13 mm (200+ 005in) Minimum worn, 470mm (.185in) (@) Thickness of eight new plates and seven new discs ‘54.86 + 1.42 mm (2.160 +.056 in) Minimum thickness (worn plates and discs) 51.22 mm 2016) {6M-8252 Spring piston return Length under test force Test force Free length after test Outside diameter “ 635mm (250in) 370 20N (85+ 51) 714mm (281 in) 49.71 mm (776in) NOTE: To obtain the minimum permissible thickness, measure the thickness of each plate and disc, then add all of these measurements. When a disc is checked for thickness, measure the depth of each groove inthe disc. The depth of a groove must be greater than 0.46 mm (018 in). For additional information on measuring disk and groove thickness, refer to SENRS733, 988F Whee! Loader Brake System Operation, Testing And Adjusting Brake System 10 c 22R1-Up 1 2 34 —t —| Eom te | / 8 a 035950 (1) Tighten bieeder screw to a torque of 11E4Nem G+3bf) (2) Lubricate seals lightly with the lubricant being sealed. NOTE: Lubricate the plates and discs withthe lubricant ‘boing used in the brake compartment pri to assemby. Bo sure to assemble the plates and discs So thal a steel pate is at each end of the pack @) 118-6606 Plate thickness: New {6:35 0.13 mm (.250 + 006 in) Minimum worn 6.00 mm (236 in} (4), 105-8750 Disc thickness: New 7.10 £0.13 (280 +005 in) Minimum worn 570mm (224in) (6) 8V:2609 Spring, four piston return: Length under test force 86.4 mm (2.40in) Test force 715.0 (16067 1b) Free length after test 407.7 mm (4.24in) Outside diameter £20.42 mm (604 in) Specifications(6) Thickness o five new plates and four new discs 60.15+ 1.17 mm (2368+ 046 in) Minimum thekness (worn plates and discs) .... 528mm (2.0 in) NOTE: To obtan the minimum permissible thickness, ‘measure the thickness of each plate and isc, then add all of| these measurerrents. When a disc is checkad for thickness, ‘measure the depth of each groove in the disc. The depth of a {groove must be greater than 0.48 rn (018 i). For additional in‘ormation on measuring disk and groove thickness, refer 'o SENRB733, 986F Whee! Loader Brake ‘System Oneratien, Testing And Adjusting Parking Brake Control Cable 036088 (2) Tighten twonuts toa torque of... 8+ Nem (6+ 2b) (6) Tighten twonuts toa torque of 38: 7Nem (28511) 1. Install cable assembly (3) in column and attach knob (1). 2. Pull knob (1) out to engage the parking and secondary brake. 3. Atach yoke 1) to cable assembly (3) and connect to lever ‘assembly Service/Parking Brake Pressure Switch Assembly 3E-6452 == = 025097 ‘Actuation pressure at ~40° to +1219 (~40° to 250°) 8270 kPa (1200 psi) maximum Deactuation pressure at ~40° to +121%C (~40 to +4250°F) {6890 + 345 kPa (1000 + 50 ps) Contacts A & C normally closed below deactuation pressure (1) Installation tightening torque .... 40 § Nem (29-4 Ib) Brake System 1 ‘Specifications.Parking Brake Valve Limit Switch 3E-5181 ean] 36096 ‘Actuating force Over travel fore Contact operation 245++89N (551 +2001) {89 (201b) maximum normaly open (1 & 2), normally closed a4) C Parking Brake Valve Limit Switch Adjustment 36100 ‘Assemble block (8) and block assembly (4) with bolts (2) and rut (5) onto shat (1)-Insal nuts (5) unt thee is mirrmum 0F 0.10. (004i) fae play between shat (1), block @), and block assembly (8). Keep nuts (6) fom tightening any further, and install us (7). Tighten nuts (7) up against rts (5) Make sure there isa mirimum of 0.10 mm (004i) free play betwoon shaft (1), block (3), and block assembly (4) 1. Stop the engine and extend the parking brake cable assembly to the maximum engaged positon 2, Thread switch assembly (2) ito bracket (10) unti the wool of switch assembly (8) just makes contact with the fat spot on Bock 6). Rotate switch assembly (9) an addtional one and one halt {um and align the wheel so that can rol down the ramp ‘on block () Keep as cose to the one and one hal tun ‘igure as possibe. 4, Tighton nut (8) toa torque of 95 Nem (71. NOTE: Do not evertighten nut (8) or damage tothe threads (on switch assembly (9) can result. Brake System 2 SpecificationsTransmission Neutralizer Pressure Switch 4E-4456 036105 Actuation pressure at ~40° to +1219C (40° to *$250°F) 790 + 140 KPa (115 +20 ps) Deactuation pressure at ~40°C to + 121°C (40°F to + 250°) (690+ 105kPa (100+ 15s) C Contacts normally closed below deactuation pressure Stop Lamp Switch Assembly ‘9X-0023 bp 36108 Momentary on, normaly closed contacts Actuating force (pretravel) 23+5N +11) ‘Actuating force (maximum over travel)... 45.5N (10.2216) Tighten to @ torque of 18541.5Nem (1441 bt) Stop Lamp Switch Assembly Adjustment 1 © 1 ossw2 4 5 6 (9) lastaaton tightening torque 19521.5Nem Giaeae vow") (4) Tghtening torque for two bots 80 4Nem rae") 1. With the brake valve in the OFF postion [stem (1) fly Cut], adjust switch assemily 6) by bringing its roller into light contact with the surlace of ramp (2) 2. Move bracket (5) 2.75 mm (.108 in) toward the brake Panel, depressing the switch into the OFF postion. Brake System 13 ‘Specificationsit Switch Neutralizer Limit Switch Adjustment 9X-4232 036107 Actuating force 22N (4910) Contact operation... normally open (1 & 2), normally closed (183) Operating position equals distance (A).....285 mm (1.16in) Free movement positon equals distance (B) 363mm (143i) 1. Adjust angle assembiy (4) against lever (5) to hod pedal 826 + 1.5 mm (825 = 06 i) [dimension (X)] above pedal stop on the floor plate, 2. Adjust the postion of plate (1) until lever assemiby (3) activates satch assembly (2) when the let brake pedal is depressed 3 to 6 mrn (12 to 24 in). Brake System 14 " SpeeificationsBrake Control Linkage And Brake Pedal Travel Adjustment 036103, a pssi09 ew AoA (6) 8V-8494 Spring: 8 9, Length under test focce 189.mm (7.4 in) Test force 187 + 10N 285+ 2.21) Free length after test 1654 1mm (65+ O4in) ‘Outside diameter 196mm (77 in) 10, 1 \ oseioe G1 2 5 NOTE: Lubricate shatt (12) prior to assembly adjustment procedure. 1. Loosen nut (4) and adjust the length of rod end (6) which ‘connects to lever (6), tc distance (A). Distance (A), from center of pin (1) to center of pin (2) equals 107.8 mm (4.241n), Tighten nut (4! against rod end (3). Brake System - a Specifications2 Connect the brake cable assemblies to levers (10) and an, 3. Aujust screw (6) in lover (7) f0 obtain @ 0.5 + 0.3m (02 £01 in) gap between two upper levers (7) and (10). Tighten nut (9) against lever (7), 4. Adjust screw (6) in ever (6) to obtain a 0.5 + 0.3mm (02 + 01 in) gap between two lower lovers (6) and (11) Tighten wut (@) against lever (6), 1. 14 15 16 p3en0 5. Adjust angle assembly (15) against lever (14) to hold ‘pedal (16) above stop (19) at dimension (B) of 82.6 mm (8.25 in), Complete this step for both pedal. NOTE: I additional adjustment is needed, remove lever (14) ‘rom shaft (13). Install lever (14) in a diferent location (rotate 't) on the splines of the shat. Use the angle assembly for a final adjustment of the pedal 6. Loosen nut (18) and adjust end (17) ofthe cable assembly Lunt the hole in end (17) isn alignment with the hole in lever (14). ©1996 Caterpilar Al Fights Reserved 7. Connect the cable assembly tothe lever assembly and ‘ihten rut (18). 18. Repeat Steps 5 and 6 forthe other pea 9. Make a final clearance adjustment between levers (10) ‘and (11) and screws (8) unt clearance of 0.5 + 0.2mm (02 3 .01in)is obtained. Any addition to the adjustment Of the cable assembles can be made on the ends of the ‘cable assemblies at levers (10) and (11). Brake Pedal osm 4 2 » > 41. Assemble both pedal assemblies on brackets to get distance (A), from end of retainer (2) to side of bracket (3), of 15.75 mm (620in) Tighten nuts (1) toa torque of 195+ 15Nem QE 1T BM (4) Lubricate seating lip lightly wth the lubricant being sealed (four places) Printed in US.A