WASHER-SPRING 2096323 - Caterpillar

Illustration 7 g01009623
The proper alignment is shown between bumper (5) and lever (10) .
Replace bumper (5) that is located on the floor of the cab.
You must now reassemble lever (10) onto aligned shaft (13). Pull shaft (13) to the left. Replace lever (10) onto shaft (13). Ensure that you maintain the alignment marks that were placed on the locknut in Step 18.
Illustration 8 g01009582
When you reassemble lever (10) onto shaft (13), use Illustration 7 as a guide. Do not tighten bolt (15) that locks lever (10) in position at this time. Lever (10) must rest flat against bumper (5) .Note: If the alignment between bumper (5) and lever (10) cannot be achieved, lever (10) must be removed and the process repeated again until the alignment is correct. If the alignment is correct, proceed to Step 22.
Illustration 9 g01009471
Lever (10) is removed from the shaft for clarity.
You must now verify that the brake assembly will have the correct spring tension. In order to check spring tension, temporarily assemble cable (11) to lever (10) by using pin (7) and cotter pin (8) .
Illustration 10 g01009447
Assemble spring (6) onto the hook that is located on the floor. Attach the opposite end of the spring (6) onto the pedal assembly.
Spring (6) should have tension at rest. If spring (6) does not have the proper tension, lever (10) must be rotated around the shaft while you maintain the alignment of the tang that was set in Step 15. This process must be performed until spring (6) has the proper tension.
If spring (6) does not have the proper tension, lever (10) must be rotated around the shaft until you achieve the proper spring tension. Ensure that you maintain the alignment of the tang until spring (6) is assembled with tension.
When you have verified that the spring has the proper tension, remove spring (6). Remove cotter pin (8) and pin (7) in order to release cable (11) from lever (10) .
Illustration 11 g01010112
Remove plate (17) that retains bumper (5). Allow lever (10) and shaft (13) to hang away from the pedal assembly. This will allow you to properly align the edge of lever (10) with the edge of plate (15) .
Place position sensor (2) on the tang of shaft (13). Position sensor (2) must be oriented so that the wiring harness is facing upward. Use Illustration 11 as a guide, if necessary.
Secure position sensor (2) to plate (16) by using two screws (1) .
Install plate (17) that was removed in Step 27.
Illustration 12 g01009471
Lever (10) is removed from the shaft for clarity.
Install pin (7) into lever (10). Ensure that you install two washers (12) with pin (7) .
Install cotter pin (8) and washer (9) onto pin (7) .
Illustration 13 g01009447
Install spring (6) onto the floor of the cab.
Illustration 14 g01009582
Install bolt (15) that locks lever (10) onto shaft (13). Tighten the bolt to a torque of 136 14 N m (100 10 lb ft).
Illustration 15 g01013008
Assemble pedal (3) onto shaft (13). Ensure that dimension (A) is 83 mm (3.25 inch). Tighten the