69D and 769D Off-Highway Trucks and 771D Quarry Truck Machine Systems Caterpillar

Service and Parking Brake (Rear) - Assemble

Usage:

769D 5SS

Assembly Procedure

Show/hide table

Table 1
Required Tools
Tool	Part Number	Part Description	Qty
A	FT-0120	Lifting Bracket	1
B	FT-0797	Lifting Hook Bracket	1
C	164-4622	Clamp Assembly	1
D	1P-7405	Eyebolts	2
E	8S-1378	Stud Remover and Resetter Tool Set	2

Check all of the O-ring seals and the components for wear or damage. Replace the components, if necessary.

Lubricate all of the O-ring seals lightly with the lubricant that is being sealed.

Show/hide table




Illustration 1	g00484266

Show/hide table




Illustration 2	g00515724
Example (A) illustrates incorrectly installed ring seals.

Show/hide table




Illustration 3	g00515714
Example (B) illustrates correctly installed ring seals.

Install the two rubber ring seals into housing (18) .
Note: Be sure that yellow side (A) of the rubber ring seal (B) is facing outward.

Install two plastic ring seals (21) into housing (18) .

Show/hide table




Illustration 4	g00484264

Lubricate the bore of piston (20) with the lubricant that is being sealed. Use a soft faced hammer to push housing (18) into piston (20) . Use the identification marks to ensure alignment during the installation of the housing.

Show/hide table




Illustration 5	g00484263

Install three O-ring seals (19) onto the housing support.

Show/hide table




Illustration 6	g00484239

Use two people to position housing (18) onto housing support (16) . Install 12 bolts (17) and the washers into housing (18) . The weight of housing (18) is 30 kg (66 lb). Tighten bolts (17) to a torque of 55 ± 10 N·m (41 ± 7 lb ft).

Show/hide table




Illustration 7	g00484236

Install Tooling (D) to housing support (16) , as shown. Attach a suitable lifting device to Tooling (D) . Attach the lifting device to a suitable hoist.

Install the three seals into housing support (16) . Install housing support (16) and the housing into cylinder (13) . The weight of housing support (16) and the housing is 52 kg (115 lb).

Show/hide table




Illustration 8	g00484234

Install four bolts (15) and the washers that fasten housing support (16) to cylinder (13) . Tighten bolts (15) to a torque of 55 ± 10 N·m (41 ± 7 lb ft).

Show/hide table




Illustration 9	g00484231

Show/hide table




Illustration 10	g00515724
Example (A) illustrates incorrectly installed ring seals.

Show/hide table




Illustration 11	g00515714
Example (B) illustrates correctly installed ring seals.

Install the two rubber ring seals into piston (11) .
Note: Be sure that yellow side (A) of rubber seal ring (B) is facing outward.

Install two plastic ring seals (14) into piston (11) .

Lubricate the bore of the cylinder with the lubricant that is being sealed. Install piston (11) into the cylinder.

Show/hide table




Illustration 12	g00484228

Show/hide table

Improper assembly of parts that are spring loaded can cause bodily injury.

To prevent possible injury, follow the established assembly procedure and wear protective equipment.

Install spring (9) on guide (10) . Position spring (9) and guide (10) in the housing support.

Use Tooling (C) to compress spring (9) . Install the pin in guide (10) in order to secure spring (9) .

Show/hide table




Illustration 13	g00484009

Install O-ring seal (8) on brake housing (2) .

Show/hide table




Illustration 14	g00484008

Use Tool (E) to install the studs. Tighten the studs to a torque of 65 ± 10 N·m (48 ± 7 lb ft). Position Tool (B) on backup plate (7) , as shown. Attach Tool (B) to a suitable hoist. The weight of backup plate (7) is 64 kg (141 lb).

Install four nuts (6) . Tighten the nuts evenly. Tighten each of the nuts by one revolution before proceeding to the next nut. Tighten to a final torque in a star pattern.

Show/hide table




Illustration 15	g00484007

Show/hide table




Illustration 16	g00515724
Example (A) illustrates incorrectly installed ring seals.

Show/hide table




Illustration 17	g00515714
Example (B) illustrates correctly installed ring seals.

Install the two rubber ring seals into brake hub (3) .
Note: Be sure that yellow side (A) of rubber ring seal (B) is facing outward.

Install two plastic ring seals (5) into brake hub (3) .

Show/hide table




Illustration 18	g00484006

Install 16 bolts (4) and the washers that fasten the backup plate to brake housing (2) . Tighten bolts (4) to a torque of 135 ± 20 N·m (100 ± 15 lb ft).

Position Tool (A) , as shown. Attach Tool (A) to a suitable hoist. Use Tool (A) to position brake hub (3) into brake housing (2) , as shown. The weight of the brake hub is 33 kg (72.8 lb).

Show/hide table




Illustration 19	g02965742

Note: Lubricate the friction discs with 8T-9568 Hydraulic Oil during assembly.

Start with damper assembly (1) . Install damper assembly (1) with the facing material facing toward the backup plate. Install a friction disc and an outer plate into brake housing (2) in alternating order. Ensure that an outer plate is on the end of the stack.