TRACK GP 2039278 - Caterpillar

Illustration 1
Visually inspect that bolt head is contactingthe machined spotface surface on the 6G4448 Lever, by looking thru theplugholes in the housing. Note: If threads of bolt are seen at spotfaceon lever the bolt is installed backwards resulting in no clamping forceof lever to shaft. See Illustration 2 & 3 for detail.
Illustration 2 Illustration 3
If yes, the bolt head is contacting machined spotfaceon lever then go to step 5.
If No, the bolt head not contacting machinedspotface on lever then go to the Replacement Procedure.
Reinstall the 9S8006 Plugs into the 6G4661 Housing
In the comment field on Service Report, write"Yes bolt assembled correct."
Service Letter work complete
Replacement Procedure
Remove side access cover below the door.
Disconnect the 4J8922 Rod End linkage from the6G4448 Lever, remove 7V0446 Lock Pin, 1B0676 Pin
Illustration 4
Remove the Bolt and Washer holding the 6G4661Housing, Retain the hardware for reassembly. Remove the Brake Pedal andHousing from the Cab
Illustration 5Disassembly of the 7G4438 Lever and 6G8909Shaft from the 6G4661 Housing
Loosen the 5S7382 Bolt retaining the 6G4438 Pedaland remove the Pedal and 1B8706 Key from the Shaft. Retain the Pedal andhardware for reassembly
Illustration 6
Remove the 3K9042 Ring and 7S9203 Washer fromthe end of the Shaft opposite the Pedal
Note: Retain Ring and Washer for reassembly
Illustration 7
Disassemble the Shaft from the Lever and Housing
Assembly of the Brake Pedal HousingAssembly of the 7G4438 Lever and 6G8909Shaft to the 6G4661 Housing
Assemble the 2(two) 1B8706 Keys into the 6G8909Shaft
Install the 6G8909 Shaft into the large bearingof the 6G4661 and the 6G4448 Lever, align key slot in lever with key inshaft.
Install the 3K9042 Ring and 7S9203 Washer retainedduring disassembly onto the 6G8909 Shaft. Tap the shaft back into the housingso Washer is contacting Housing and center the 6G4448 Lever in Housing.
Illustration 8
Install the Pedal retained during disassemblyonto the Shaft align the key slot in Pedal with key on shaft and positionpedal for 1.5 mm clearance between pedal and housing. Install the 5S7382Bolt retained during disassembly into the 6G4438 Pedal and torque boltto 47 +/- 9 Nm.
Illustration 9
Install the 6V5782 Bolt head into the spotfaceside of 6G4448 Lever, center the lever in the housing and torque to 25+/-6 Nm
Illustration 10
Install the Pedal and Housing into the cab andsecure with hardware retained during disassembly. Torque the bolts to 47+/- 9 Nm
Illustration 11
Connect the 4J8922 Rod End linkage retained duringdisassembly to the 6G4448 Lever, with 7V0446 Lock Pin, 1B0676 Pin retainedduring disassembly Note: If the Pedals are not even loosen the jam nutand adjust the rod end to make even. Torque the jam nut to 25 +/- 6 N.m.
Illustration 12
Install the 9S8006 Plugs retained during disassemblyinto the 6G4661 Housing
Illustration 13The assembly of the lever is now complete