GUSSET 0300439 - Caterpillar

Make sure all pressure is released from the air system before disconnecting any of the air lines. Failure to release the pressure can cause the air to release rapidly when the lines are disconnected and could cause personal injury.
1. Lower the crankcase guard plate directly under the operators compartment. 2. Disconnect electrical wiring harness (1), two electrical wires (2) and three tube assemblies (4) from brake valve (3). 3. Remove the retainers and pins (5) and (6) and brake pedal (7). 4. Loosen nut (8), and remove the adjustment assembly. Remove bolts (9) and the washer. When bolt (9) and the washer is removed brake control valve will fall. The following steps are for the installation of the brake control valves. 5. Position the brake control valve, and install bolt (9) and the washer. Install the adjustment assembly and nut (8). 6. Position brake pedal (7), and install pins (5), (6) and the retainers. 7. Connect electrical wiring harness (1), two electrical wires (2) and three tube assemblies (4) to brake valve (3).8. Install the crankcase guard.Disassemble & Assemble Brake Control Valve
Start By:a. remove brake control valve 1. Remove boot (1) and the component parts from valve (2). 2. Remove plunger (8), spring (7), spring (6), rubber spacer (5) and slug (4).3. Remove retaining ring (3) using Tool (A), and disassemble the components. 4. Retaining ring (3), retainer (11), piston assembly (10) and spring (9).5. Using Tool (B), remove retaining ring (11), and disassemble piston assembly (10). 6. Piston assembly (10), rubber washer (13), retainer (14) and retaining ring (11). 7. Remove two bolts (15) and a cartridge assembly (16), and disassemble. 9. Remove O-ring seals (17) and (19) from cartridge housing (18).10. Remove retaining screw (25) and rubber diaphragm (24). Remove O-ring seal (22) from retainer (23). Remove spring (21) and plunger (20). The following steps are for the assembly of the brake control valves. 11. Install plunger (20) and (21).12. Install O-ring (22) on retainer (23).13. Position rubber diaphragm (24), and install retaining screw (25).14. Install O-rings (17) and (19) on a cartridge housing (18). 15. Install cartridge assembly (16) and two bolts (15). 16. Using Tool (B), and install retainer (14), rubber washer (13) and retaining ring (11) to piston assembly (10). 17. Put piston assembly (10) in position, and use Tool (A), install retainer ring (3). 18. Install slug (4), rubber spacer (5), spring (6), spring (7), and plunger (8). 19. Install the component parts and boot (1) to valve (2).End By:a. install brake control valve