Field Installation of Decelerator Pedal{1276} Caterpillar

Field Installation of Decelerator Pedal{1276}

Usage:

Track-Type Tractors:: D3C Series III (PIN: 4KS1-386; 4TS1-337; 5GS1-269); D4C Series III (PIN: 4LS1-256; 6BS1-317; 8CS1-461); D5C Series III (PIN: 5HS1-324; 6CS1-362; 7PS1-494)

Introduction

Decelerator pedals may be used to slow machine movement. This instruction provides installation information for decelerator pedals.

The information in this instruction should be read and understood before proceeding with any modifications.

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Attach a "Do Not Operate" tag to the start switch or controls before beginning any maintenance procedure. Failure to attach this tag could result in injury or death. Contact your Caterpillar dealer to purchase these tags. The form number is SEHS7332.

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NOTICE

The decelerator pedal assembly described in this instruction is not compatible with the 933C Track Loader or 939C Track Loader. Misadjustment and poor machine performance may result if the parts described in this instruction are used on a 933C Track Loader or 939C Track Loader.

Read the following safety information which is provided in the appropriate Operation and Maintenance Manual: General Hazard Information, Crushing Prevention and Cutting Prevention, Burn Prevention, Fire Prevention and Explosion Prevention and Machine Parking.

Reference: Service Manual SENR1245, Service Manual Module SENR1257, "Power Train Testing and Adjusting D3C, D4C, and D5C Series III Hystat Track-Type Tractors", "Initial Pressure Tests".

Required Parts

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Table 1
Required Parts
Qty	Part Number	Description
1	2A-4133	Pin
1	2M-4036	Rod End
1	3B-4607	Cotter
1	4B-6493	Spring
1	4H-2558	Grommet
1	5P-4116	Washer
2	5P-6261	Retaining Rings
1	6V-3338	Yoke Rod End
3	6V-8187	Nuts
1	7B-7210	Pin
2	8T-1172	Lip Seals
2	8T-1176	Roller Bearings
5	8T-4121	Washers
2	8T-4122	Washers
1	8T-4133	Nut
4	8T-4137	Bolts
1	8T-4186	Bolt
1	8Y-0102	Governor Control Shaft
1	8Y-5353	Pedal Assembly
1	176-2457	Spring
2	9S-1354	Nuts
1	9X-1147	Cable
1	033-8248	Clip
1	104-4707	Rod End
1	153-5077	Bracket
1	153-5524	Plate
1	154-8681	Bracket
1	REHS0289	Special Instruction

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Table 2
Required Tools
Qty	Part Number	Description
1	1U-8165	Drill Bit (8.70MM)
1	8T-0855	Pressure Gauge ⁽¹⁾
1	8T-3087	Hand Tap (M10 X 1.50)
1	9U-7400	Multitach ⁽²⁾

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^( 1 )	The pressure gauge is used during the test procedures.
^( 2 )	The multitach is used during the test procedures.

Preparation for Installation

Turn the battery disconnect switch to the OFF Position.

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Illustration 1	g00404063
119-0785 Panel

Remove four bolts (1). Move the 119-0785 Panel (2). Disconnect the electrical connectors. Remove the 119-0785 Panel (2). See Illustration 1.

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Illustration 2	g00406938

Remove plate (3). See Illustration 2.

Remove the foot rest (4). See Illustration 2.

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Illustration 3	g00749863

Remove the following items: 3B-4607 Cotter (5), 2A-4133 Pin (6) and 176-2457 Spring (22). The parts will be used during the assembly procedure. Remove the cable end (7) and the cable end (9) from plate (12). See Illustration 3.

Remove the 5C-9553 Bolts (11). Remove the 9X-8256 Washers (10). Remove the plate (12). Discard the plate (12). Save the bolts (11) and the washers (10) for the assembly procedure. See Illustration 3.

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Illustration 4	g00426842

Loosen two 6V-8187 Nuts (13). Remove the two 8B-3768 Yoke Rod Ends (14). Remove two nuts (13). See Illustration 4. One 6V-8187 Nut (13) and one 8B-3768 Yoke Rod End will be used during the assembly procedure. See Illustration 4.

Remove the two nuts (15) and the two washers (18). The four parts will be used during the assembly procedure. See Illustration 4.

Remove the 5G-3518 Cable Group (19). Remove the 9C-6601 Cable (20). The parts will be used during the assembly procedure. See Illustration 4.

Remove the bolts (16). Remove the washers (17). Remove the bracket (21). The parts will be used during the assembly procedure. Discard bracket (21). See Illustration 4.

Hole Location for the Firewall Panel

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Illustration 5	g00408366
The 115-2182 Plate (1) is used for the firewall panel. See Table 3.

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Table 3
Tapped Hole Location on the Firewall Panel
Dimension	Size
A	81.5 ± 1.5 mm (3.21 ± 0.06 inch)
B	149.5 ± 1.5 mm (5.89 ± 0.06 inch)
C	574.5 ± 1.5 mm (22.62 ± 0.06 inch)
D	360.7 ± 1.5 mm (14.20 ± 0.06 inch)
E	494.7 ± 1.5 mm (19.48 ± 0.06 inch)

Note: Locate the holes on the firewall panel as accurate as possible. The pedal assembly cannot block access to the fuse panel.

Drill four holes (F) with a 1U-8165 Drill . Use a 8T-3087 Hand Tap (M10 X 1.50) to tap four holes (F). See Illustration 5 and Table 3.

119-0785 Panel Modifications

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Illustration 6	g00408619
See Table 4.

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Table 4
119-0785 Panel Modifications
Dimension	Size
A	45 ± 1.5 mm (1.8 ± 0.06 inch)
B	100 ± 1.5 mm (3.9 ± 0.06 inch)
C	15 ± 1.5 mm (0.6 ± 0.06 inch)
D	5.0 ± 1.5 mm (0.18 ± 0.06 inch)

Cut a notch in the 119-0785 Panel in order to accommodate the 9X-1147 Cable . See Illustration 6. The dimensions are listed in Table 4.

Hole Location for the 120-8407 Plate

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Illustration 7	g00408839
See Table 5.

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Table 5
Hole Location for the 120-8407 Plate
Size	Dimension
A	70.0 mm (2.75 inch)
B	21.0 mm (0.83 inch)
C	21.0 mm (0.83 inch)

Cut a hole in the 120-8407 Plate in order to accommodate the 9C-6601 Cable . See Illustration 7. The dimensions are listed in Table 5.

117-4640 Plate Modifications

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Illustration 8	g00417230
See Table 6.

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Table 6
117-4640 Plate Modifications
Dimension	Size
A	30 ± 1.5 mm (1.2 ± 0.06 inch)
B	20.0 ± 1.5 mm (0.79 ± 0.06 inch)

Cut a notch in the 117-4640 Plate . See Illustration 8. The dimensions are listed in Table 6.

Installation Procedure for the Pedal

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Illustration 9	g00427960

Use three 8T-4121 Washers (1) and use three 8T-4137 Bolts (2) in order to install the 154-8681 Bracket (3). See Illustration 9.

Install one 4H-2558 Grommet (4). See Illustration 9.

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Illustration 10	g00431386

Install one 8T-4186 Bolt (5). Install one 8T-4133 Nut (6). Dimension (B) is 58 mm (2.3 inch). See Illustration 10.

Install two 8T-1176 Roller Bearings (10) into the 8Y-5353 Pedal Assembly (11). See Illustration 10.

Install two 8T-1172 Lip Seals (9) into the 8Y-5353 Pedal Assembly (11). Install the lip of the seal to the outside. See View B-B in Illustration 10.

Install one 8Y-0102 Governor Control Shaft (8) in order to connect the pedal assembly (11) to bracket (3). See Illustration 10.

Install two 5P-6261 Retaining Rings (7). See Illustration 10.

Installation Procedure for the 153-5524 Plate and 153-5077 Bracket

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Illustration 11	g00431718

Use one 5C-9553 Bolt (1) and use one 9X-8256 Washer (2) in order to install the 153-5524 Plate (3). Install the bolt and install the washer in Location (A). Use finger pressure in order to tighten the bolt (1). Bolt (1) and washer (2) are reused from disassembly. See Illustration 11.

Install one 4B-6493 Spring (4) in Location (B). See Illustration 11.

Move plate (3) counterclockwise in order to attach spring (4).

Use caution and move plate (3) clockwise. Install one 5C-9553 Bolt (1) and install one 9X-8256 Washer (2) in Location (C). Bolt (1) and washer (2) are reused from disassembly. See Illustration 11.

Tighten two bolts (1) .

Use three 8T-6870 Bolts (6) and use three 8T-4224 Hard Washers (7) to install the 153-5077 Bracket (5). Bolts (6) and washers (7) are reused from disassembly. See Illustration 11.

Installation of the Cables

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Illustration 12	g00749537

Install the 5G-3518 Cable Group (1) into the 153-5077 Bracket (2). Use the nuts and washers from the disassembly procedure. Equalize the nut threads of cable group (1) on both sides of bracket (2). Tighten nuts (5). See Illustration 12.

Install one new 6V-8187 Nut (3) on cable group (1). Install one 104-4707 Rod End (4) on cable group (1). Do not tighten nut (3) at this time. See View (A-A) in Illustration 12.

Pin (6) and cotter (5) are reused from disassembly. Move plate (6) to the high idle position. Adjust rod end (4) so the 2A-4133 Pin (7) makes light contact with the back edge of the slot in plate (6). Tighten nut (3) when the adjustments are complete. Install the 3B-4607 Cotter (8) in pin (7). See View (A-A) in Illustration 12.

Install the 9C-6601 Cable (9) into the 153-5077 Bracket (2). Use the nuts and washers from the disassembly procedure. Equalize the threads of cable (9) on both sides of bracket (2). Tighten nuts (10) to a torque of 38 ± 7 N·m (28 ± 5.2 lb ft). See Illustration 12.

Use handle (B) to move lever (A). See Illustration 12. Position lever (A) against the low idle linkage stop. See View (B-B) in Illustration 12.

The 6V-8187 Nut (3) is reused from disassembly. Install one 6V-8187 Nut (3) on the 9C-6601 Cable (9). See View (A-A) in Illustration 12.

The 8B-3768 Rod End (12) is reused from disassembly. Position plate (6) to low idle. Install the 8B-3768 Rod End (12). Adjust rod end (12) to the middle of the slot on plate (6). Tighten nut (3) to a torque of 38 ± 3 N·m (28.0 ± 2.0 lb ft). See View (A-A) in Illustration 12.

Install the 2A-4133 Pin (7). See Illustration 12.

Note: Check that two 9S-1354 Nuts (22) and two 8T-4122 Washers (27) are on the 9X-1147 Cable (14).

Install the 9X-1147 Cable (14) into the 153-5077 Bracket (2). Equalize the threads of cable (14) on both sides of bracket (2). Tighten nuts (22) to a torque of 38 ± 7 N·m (28 ± 5 lb ft). See Illustration 12.

Install one new 6V-8187 Nut (3) on cable (14). See Illustration 12.

Install one 2M-4036 Rod End (15) on the end of cable (14). Tighten nut (3) to a torque of 8 ± 3 N·m (6.0 ± 2.0 lb ft). Install one new 2A-4133 Pin (7) and install one new 3B-4607 Cotter (8). See View (A-A) in Illustration12.

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Illustration 13	g00749538

Note: Check that two 9S-1354 Nuts (21) and two 8T-4122 Washers (28) are on cable (14) .

Route cable (14) through the grommet (29) to the pedal. Equalize the threads of cable (14) on both sides of bracket (30). Tighten nuts (22) to a torque of 38 ± 7 N·m (28 ± 5 lb ft). See Illustration 13.

Place pedal (16) against bolt (17). See View (A-A) in Illustration 13.

Install one new 6V-8187 Nut (3) on cable (14). See View (A-A) in Illustration 13.

Install one 6V-3338 Yoke Rod End (23). Install the 7B-7210 Pin (19) when pedal (16) is against bolt (17). It may be necessary to adjust yoke rod end (23) or nuts (22). See Illustration 13.

Install one end of the 176-2457 Spring (20) in pin (19). Install the other end of spring (20) into Position (C). See Illustration 13.

Check that the machine controls are in the NEUTRAL Position. Use bolt (17) to adjust engine speed. Check that the engine speed is reduced to 1000 ± 50 RPM if the deceleration pedal is depressed.

Tighten nut (18) .

See Service Manual 1245, Service Manual Module SENR1257, "Power Train Testing and Adjusting D3C, D4C, and D5C Series III Hystat Track-Type Tractors", "Initial Pressure Tests". Check the low idle signal pressure and check the high idle signal pressure. If necessary, adjust the low idle signal pressure and adjust the high idle pressure.