001_Brake Pedal Troubleshooting Guide

April 2020

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 Use of this Document

• Purpose
− This document is intended to assist with troubleshooting brake pedal issues found through normal
troubleshooting process’ or the CAT® ET Hystat Troubleshooting Test.
• Common Issues Associated with Brake Pedal Issues
− ET Hystat Troubleshooting Test fails with $0104 code – Brake pedal not calibrated.
− Machine will not achieve max speed.
− Machine speed or response is erratic when brake pedal is applied.

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 Troubleshooting Steps

• Step 1 : Run brake pedal calibration through ET.

− Reference SMCS - 1439-524; 4269-524 in SIS Web for calibration process
− If calibration fails, move to Step 2
• Step 2 : Inspect pedal roller area for debris. Ensure there is no debris trapped between the roller and the brake valve or
between the heel of the pedal and the base of the pedal. Clean any debris that is present and run a brake pedal calibration in
ET.
− If calibration fails, move to Step 3
• Step 3 : Inspect pedal shaft & bushing areas for debris. If pedal feels “gritty” when applied or does not smoothly return back to
initial position, there is debris between the shaft and bushings. Clean shaft/bushing area as best as possible, dis-assembling
the pedal if possible, to gain access.
− Re-run the pedal calibration after cleaning.
− If calibration fails, move to Step 4
• Step 4 : Attempt to adjust pedal sensor and re-run the calibration. If it still fails, replace pedal sensor.
− Follow sensor adjustment process detailed on next slide if necessary.

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 Brake Pedal Sensor Adjustment Process

• Replacing the sensor only

− Remove cover on the side of the pedal facing outboard
(toward cab ingress).
− Remove the two bolts holding the sensor in place.
− Remove and replace the sensor in the reverse sequence.
− Run ET calibration. If it fails out of range, sensor will need
to be adjusted.
• Adjusting the pedal sensor
− Adjustment screws are labeled as “Adjustment 2” on the
diagram.
− Loosen the two screws, but do not fully remove them.
− Adjust the sensor CW or CCW to adjust the sensor duty
cycle to be within range based on ET fault indication.
▪ Clockwise rotation will INCREASE the DC%
▪ Counterclockwise will DECREASE the DC%
− Run ET calibration.

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 Brake Pedal Brake Light Switch & Sensor Adjustment
• Brake Light Switch Replacement
− Loosen the set screws holding the treadle to the shaft and remove.
− Clean set screws, apply semi-permanent Loctite to each and re-install by only
installing a few turns such that pedal can still rotate freely.
− Replace the switch by removing all necessary components shown on drawing
exploded view.
− If the brake lights are not off with the pedal in the neutral position, or do not
come one with slight depressing of the pedal, the switch will need to be reset.
− The switch is set and adjusted using the internal hex on the end of the treadle
shaft – labeled as “Adjustment 1” in diagram.
− With the pedal in the fully released position, slowly rotate the shaft so that the
brake lights turn ON. Once the lights turn on, slowly turn the shaft until the lights
turn OFF. Tighten the screws in this position holding the shaft stationary and not
touching the treadle.
− Before fully torqueing the set screws, slightly depress the pedal to ensure that
the brake lights come on with a small amount of pedal movement & remain off
with the pedal fully released.
− Torque set screws to correct torque.
− If the switch was replaced and the pedal was adjusted, the sensor adjustment
process will need to be repeated, and the pedal will need to be re-calibrated.

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