Procedure to Rework the Governor and Brake Pedal for Certain D3K2, D4K2, and D5K2 Small Track Type Tractors {4122} Caterpillar

Track-Type Tractor

D3K2 (S/N: KF21-2155; KL21-2210; FT31-2099; LT31-2109; JPJ1-2169)

D4K2 (S/N: KM21-2171; KR21-2199; MT31-2123; RT31-2129)

D5K2 (S/N: KW21-2199; KY21-2247; WT31-2147; YT31-2149; RRE1-2191)

Introduction

This Special Instruction describes the rework procedure for the governor and brake pedal. This procedure inserts two stainless steel shims to sandwich the nylon friction pack.

Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.

Safety Section

Illustration 1	g00104545

Prevent the machine from movement. Park the machine on a level surface.

Attach a "Do Not Operate" warning tag or a similar warning tag to the start switch or to the controls before you service the equipment. These warning tags (Special Instruction, SEHS7332) are available from your Caterpillar dealer.

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Do not operate or work on this machine unless you have read and understand the instructions and warnings in the Operation and Maintenance Manuals. Failure to follow the instructions or heed the warnings could result in injury or death. Contact your Cat dealer for replacement manuals. Proper care is your responsibility.

Required Parts

Required Tools

Installation Procedure

1. Pull up the floor mat. Use Tool (A) to remove foot rests.
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   Illustration 2	g06103095
   Panel bolts

2. Use Tool (B) to remove the bolts and the panel.
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   Illustration 3	g06103108
   Dash foot bolts

3. Use Tool (B) to remove the bolts at the dash foot.
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   Illustration 4	g06103123
   Dash box nuts

4. Remove the 10 mm nuts in the dash box using Tool (C). Pull the dash back enough to get both sides of panel, disconnect harness as needed.
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   Illustration 5	g06103158
   Left-hand sensor

5. Use Tool (D), 8 mm wrench, to remove the left-hand sensor
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   Illustration 6	g06103157
   Right-hand side nut

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   Illustration 7	g06104574
   Pedal right-hand assembly (1) 446-4857 Needle Bearing (4) 6S-3859 Washer (5) 5D-0998 Disc Spring (6) 6S-3900 Seat (7) 8T-7971 Hard Washer (8) 6V-7687 Locknut

6. Use Tool (E), 19 mm wrench, to loosen the lock nut (8) on the right-hand side. Remove hardware and save washer (7), seat (6), disc springs (5), and washer (4).
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   Illustration 8	g06103176
   The pin of the drive pedal and punch

7. Use Tool (F), a punch, to drive out the pin.
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   Illustration 9	g06103214
   Drive shaft of pedal

8. Drive the shaft out.

   Note: Do not damage the end of the shaft.

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   Illustration 10	g06103217
   Inspect shaft and replace bearings

9. Check the pedal shaft for brinelling, bearing marks, at bearing area.

   Remove all paint from static bore of bearing at Locations A and B. Replace the two needle bearings (1) at Locations A and B.

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   Illustration 11	g06103240
   Shim installed

10. Place the larger ID shim (2), over the tube in pedal arm.
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    Illustration 12	g06103249
    Friction pad placed

11. Place the friction pad.
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    Illustration 13	g06103263
    Both shims installed

12. Add the smaller ID shim (3) on other side of friction pad and put the shaft back into the pedal.

    Note: Make sure that both shims are correctly positioned on each side of the friction pad.

13. Reposition the shaft.

14. Reinstall the pin in the pedal arm tube and shaft.

15. Reinstall the sensor on the left-hand side of pedal
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    Illustration 14	g06104551
    Pedal right-hand assembly and correct orientation of disc spring washers (1) 446-4857 Needle Bearing (4) 6S-3859 Washer (5) 5D-0998 Disc Spring (6) 6S-3900 Seat (7) 8T-7971 Hard Washer (8) 6V-7687 Locknut

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    Illustration 15	g06103268
    Fully assembled pedal

16. Reinstall the washer (4) and the six disc spring washers (5). Orient disc spring washers (5) as shown in Illustration 14. Reinstall seat (6), washer (7), and locknut (8). Apply thread sealant. Refer to Illustration 15 for a fully assembled pedal.

17. Adjust the locknut torque to the preference of the operator.

    Note: Be sure that the pedal operating force meets the operator expectations.

    Note: Be sure that the pedal will return to top position at rest to ensure that high idle is reached.

18. Reassemble dash in place with cover plate in reverse order of disassembly. Replace floor mat, and foot rests.