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Product: TRUCK
Model: 777D TRUCK AGC01605
Configuration: 777D Off-Highway Truck AGC00001-UP (MACHINE) POWERED BY 3508B Engine

Testing and Adjusting

776D, 777D and 777D HAA Off-Highway Truck/Tractors Air System and Brakes
Media Number -RENR3324-07 Publication Date -01/03/2007 Date Updated -23/03/2007

i05909512

Service Brake Discs - Check

SMCS - 4255-535

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.

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 benchmark for the piston travel. Record the measurements in the
Testing and Adjusting, "Worksheets" located in the back of this book.

Rear Brakes
Table 1
Required Tools
Part Number Description Required Amount
5P-9726 Gauge Plug 2
1U-7425 Brake Wear Gauge 2

Illustration 1 g00645569
Rear brake housing

(S) Purge valve for service brake

(P) Purge valve for parking brake

Note: Identification letters are embossed on the purge valves at the top of the brake housing. The
purge valve for the parking brake is Labeled with a "P". The purge valve for the service brake is
Labeled with an "S".

Note: Before checking for wear, perform the Systems Operation/Testing and Adjusting, "Service
Brakes and Retarder System Pressure - Test". There must be a fixed ratio between the hydraulic
pressure at the wheels and the air pressure at the master cylinders.

Make sure that the transmission is in NEUTRAL.

Note: Do not activate the service brakes or the retarder while the 5P-9726 Gauge Plug is installed.

1. While the engine is off and the parking brake is engaged, remove the top plug that is Labeled
with an "S".

2. Install the 5P-9726 Gauge Plug .

Illustration 2 g00282837

Brake wear gauge

(1) Service brake piston

(2) Pin
 (3) Gauge plug

(4) Brake wear gauge

(A) Distance with the parking brake disengaged

(B) Distance of stroke

(C) Distance with the parking brake engaged

NOTICE

Do not allow the brake piston to retract while the pin is installed in the
plug hole. This could cause the pin to break off when the brake piston
retracts. It is possible for broken pieces of the tool to fall into the brake
housing and cause damage.

3. Push pin (2) until pin (2) contacts service brake piston (1) , as shown above.

4. Hold brake wear gauge (4) in position on gauge plug (3) . Push down on the plunger until the
plunger contacts pin (2) in gauge plug (3) . Available space permits the use of only one arm to
perform this task.

5. Remove brake wear gauge (4) from gauge plug (3) . Measure distance (C) . Distance (C) 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.

6. Pull pin (2) away from piston (1) and against plug (3) to ensure that pin (2) does not break
when piston (1) is retracted.

7. Start the engine. Operate the engine at high idle so that cooling oil is sent to the service brake
piston.

8. Move the parking brake lever to the OFF position. Brake cooling oil flow and pressure ensure
that the parking brake piston is released.

9. Again, push in pin (2) until pin (2) contacts service brake piston (1) .

10. With one hand, hold brake wear gauge (4) over gauge plug (3) . Push down on the plunger until
the plunger contacts pin (2) in gauge plug (3) .

11. Remove brake wear gauge (4) from gauge plug (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.

12. Subtract measurement (A) from measurement (C) . Distance (B) is the total movement of the
brake piston. This measurement represents the stacked height of the brake discs.
Note: Refer to Tables 2 and 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
Table For Determining The Wear Of Brake Disc Pack
Percent of Brake Wear Rear Brake Piston Travel
0 percent 7.4 mm (0.29 inch)

10 percent
8.1 mm (0.32 inch)

20 percent
8.9 mm (0.35 inch)

30 percent
9.7 mm (0.38 inch)

40 percent
10.4 mm (0.41 inch)

50 percent
10.9 mm (0.43 inch)

60 percent
11.7 mm (0.46 inch)

70 percent
12.4 mm (0.49 inch)

75 percent
12.8 mm (0.50 inch)

80 percent
13.2 mm (0.52 inch)

90 percent
14.0 mm (0.55 inch)

100 percent
14.7 mm (0.58 inch)

Note: The brake assembly should be rebuilt when wear reaches 75 percent of the baseline
value. Refer to the Testing and Adjusting, "Worksheets" located in the back of this book.

Table 3
Table For Determining The Wear Of Brake Disc Pack
Percent of Brake Wear Front Brake Piston Travel
 0 percent
3.41 mm (0.134 inch)

20 percent
4.63 mm (0.182 inch)

40 percent
5.85 mm (0.230 inch)

60 percent
7.07 mm (0.278 inch)

75 percent
7.99 mm (0.315 inch)

80 percent
8.29 mm (0.326 inch)

100 percent
9.51 mm (0.374 inch)

Note: The brake assembly should be rebuilt when wear reaches 75 percent of the baseline
value. Refer to the Testing and Adjusting, "Worksheets" located in the back of this book.

13. Remove gauge plug (3) . Install the plug.

14. Repeat Steps 1 through 13 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.

15. 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 (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)

10 percent
5.03 mm (0.198 inch)

20 percent
4.98 mm (0.196 inch)

30 percent
4.93 mm (0.194 inch)

40 percent
4.88 mm (0.192 inch)

50 percent
4.83 mm (0.190 inch)

60 percent
4.78 mm (0.188 inch)

70 percent
4.72 mm (0.186 inch)

80 percent
4.67 mm (0.184 inch)

90 percent
4.63 mm (0.182 inch)

100 percent
4.57 mm (0.180 inch)

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

0 percent
0.64 mm (0.025 inch)

10 percent
0.62 mm (0.024 inch)
 20 percent
0.60 mm (0.024 inch)

30 percent
0.59 mm (0.023 inch)

40 percent
0.57 mm (0.022 inch)

50 percent
0.55 mm (0.022 inch)

60 percent
0.53 mm (0.021 inch)

70 percent
0.51 mm (0.020 inch)

80 percent
0.50 mm (0.020 inch)

90 percent
0.48 mm (0.019 inch)

100 percent
0.46 mm (0.018 inch)
(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 side.

• The brake assembly should be rebuilt when wear reaches 75 percent of the baseline value. Refer
to the Testing and Adjusting, "Worksheets" 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 2.29 mm (0.090 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 brakes usable life after
the rebuild.

Front Brakes
Front Caliper Service Brakes

Illustration 3 g00540364

(1) Disc
(2) Caliper

(3) Linings

(4) Thickness of the disc

(5) Thickness of the lining

Linings (3) are part of caliper (2) . There are two linings (3) for each caliper (2) . Disc (1) rotates
between the two linings (3) . This causes linings (3) to wear. The thickness (5) can be visually
checked. Linings (3) must be replaced when thickness (5) is less than 3.15 mm (0.124 inch).

Disc (1) should be checked for damage or for wear. Disc (1) should be replaced when thickness (4) is
less than 15.87 mm (0.625 inch).

Illustration 4 g00645613

View of the Service Brakes (Front Caliper)

(6) Pins

(7) Bolts

Linings (3) are held in position by pins (6) . Pins (6) are locked in position with bolts (7) .

Refer to Specifications, "Service Brake (Front Caliper)" for the clearance for pins (6) . When the
proper clearance has been made, tighten bolt (7) to the appropriate torque.

Note: Make sure that bolt (7) fully engages the groove in pin (6) before bolt (7) is tightened.

Front Oil Cooled Service Brakes

Table 6
Required Tools
Part Number Description Required Amount
8S-9191 Bolt 2

Illustration 5 g00652897

View of Service Brake Assembly (Front Oil Cooled) from the Outside of the Machine

(S) Purge valve for service brake

Illustration 6 g01013368

View from the Inside of the Machine of the Inside of the Service Brakes (Front Oil Cooled)

(2) Port
 Illustration 7 g01013369

Section A-A

(2) Port

1. Remove the plugs from ports (2) .

2. Install a 8S-9191 Bolt in each open port (2) . Tighten the bolts finger tight.

3. Engage the service brakes.

4. Tighten the 8S-9191 Bolts to 27 N·m (20 lb ft) while the service brakes are engaged.

5. Measure the distance from the top of a 8S-9191 Bolt to the spot face around port (1) . Record
this measurement.

Note: Use the same bolt for all of the measurements.

6. Release the service brake.

7. Loosen purge screw (1) .

8. Tighten the 8S-9191 Bolts evenly to 27 N·m (20 lb ft).

 9. Tighten purge screw (1) .

10. Measure the distance from the top of the 8S-9191 Bolt that was used in Step 5 to the spot face
around port (1) . Record this measurement.

11. Find the difference between the measurement in Step 5 and the measurement in Step 10. The
difference is the amount of wear on the clutch pack. Refer to Table 7 for the percentage of wear
on the clutch pack.

Table 7
Table for the Wear of Front Service Brakes (Oil Cooled)
Percent of Remaining Service Life Measured Difference

0 percent
9.51 mm (0.374 inch)

20 percent
8.29 mm (0.326 inch)

25 percent
7.99 mm (0.315 inch)

40 percent
7.07 mm (0.278 inch)

60 percent
5.85 mm (0.230 inch)

80 percent
4.63 mm (0.182 inch)

100 percent
3.41 mm (0.134 inch)

Note: 25 percent of remaining service life refers to 75 percent wear of the brake assembly. The
brake assembly should be rebuilt when wear reaches 75 percent of the baseline value. Refer to
the Testing and Adjusting, "Worksheets" located in the back of this book.

12. Remove all test equipment.

13. Install the plugs in ports (2) .

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