- Integrated Toolcarrier:
- IT14G (S/N: FWL1-UP; 8ZM1-UP; KZN1-UP; 1WN1-UP)
- IT28G (S/N: WAC1-UP; 8CR1-UP; 9AR1-UP; DBT1-UP)
- IT38G Series II (S/N: JAN1-UP; CSX1-UP)
- IT38G (S/N: 7BS1-UP; 1CW1-UP)
- IT28G (S/N: WAC1-UP; 8CR1-UP; 9AR1-UP; DBT1-UP)
- Compact Wheel Loader:
- 914G (S/N: PDF1-UP; 7ZM1-UP; 9WM1-UP)
- 914G2 (S/N: KNP1-UP)
- IT14G2 (S/N: ERP1-UP)
- 914G2 (S/N: KNP1-UP)
- Wheel Loader:
- 924G (S/N: DDA1-UP; RBB1-UP; WMB1-UP; AAN1-UP; 9SW1-UP; 3PZ1-UP)
- 924GZ (S/N: RTA1-UP; AAB1-UP; KTC1-UP; 6YW1-UP; WGX1-UP; DFZ1-UP; 3DZ1-UP)
- 928G (S/N: GMB1-UP; DJD1-UP; WLG1-UP; 6XR1-UP; 7SR1-UP)
- 930G (S/N: TWR1-UP; TFW1-UP)
- 938G Series II (S/N: RTB1-UP; MSC1-UP; CRD1-UP; PHN1-UP; B9Y1-UP)
- 938G (S/N: 4YS1-UP; 6WS1-UP; 8RS1-UP; 9HS1-UP)
- 924GZ (S/N: RTA1-UP; AAB1-UP; KTC1-UP; 6YW1-UP; WGX1-UP; DFZ1-UP; 3DZ1-UP)
Introduction
This Special Instruction includes the information needed to install the new parking brake lever.
The 9U-3439 Park Brake Lever As has been discontinued and is service replaced by the 323-4077 Lever As used in the 441-5758 Brake Control Gp .
To make this replacement on 924G, 928G, and 938G machines you will also need to change out the bracket assembly and cover assembly so the new 323-4077 Lever As can be used.
Safety
Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death. Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information. |
Parts List
Required Parts     | |||
---|---|---|---|
Item     | Qty     | Part Number     |
Description     |
1     | 1     | 6S-6646     | Cotter Pin     |
2     | 1     | 125-0965     | Retaining Ring     |
3     | 1     | 323-4077     | Lever As     |
4     | 1     | 425-8286     | Block     |
5     | 1     | 447-2227     | Boss     |
6     | 1     | 163-6408     | Bracket As     |
7     | 2     | 032-8870     | Spring Pin     |
8     | 1     | 3H-8538     | Pin     |
9     | 1     | 8K-1433     | Grommet     |
10     | 4     | 8T-4189     | Bolt     |
11     | 4     | 8T-4224     | Hard Washer     |
12     | 1     | 8T-4742     | Yoke Rod End     |
13     | 1     | 8T-4744     | Spring Pin Assembly     |
14     | 1     | 136-2109     | Cover As     |
15     | 1     | 273-9436     | Cable As     |
Existing Parts to be Reused     | |||
Item     | Qty     | Part Number     |
Description     |
16     | 1     | 6G-4195     | Limit Switch As     |
17     | 2     | 2N-3477     | Screw     |
18     | 4     | 4B-5324     | Washer     |
19     | 2     | 7D-6922     | Locknut     |
20     | 2     | 9X-2042     | Screw     |
21     | 2     | 9X-2045     | Screw     |
Removal of Existing Brake Control Group
- This cover assembly will need to be removed to gain access to the park brake mounting bracket.
Illustration 1 | g03828453 |
- Remove the cover first by removing screws (20). Retain the screws to use for installation of the new lever.
Illustration 2 | g03828464 |
(20) 9X-2042 Screw |
- Then remove two screws (21) in the rear. Unbuckle strap assembly (A) and pull up to remove cover assembly, letting the straps pull through slots in the cover. Retain the screws to use for installation of the new lever.
Illustration 3 | g03828505 |
(A) Strap (21) 9X-2045 Screw |
- Remove current park brake system by first removing two nuts and washer (B) from top of cable (D). Remove cable (D) from the lever assembly. Remove clip (C) from cable (D) inside the bracket assembly. Remove cable (D) from inside the cab by pulling down from underneath the cab.
Illustration 4 | g03828559 |
(B) Two nuts and washer (C) Clip (D) Cable |
- Remove the three wires from switch assembly (16) .
Illustration 5 | g03828578 |
(16) 6G-4195 Limit Switch As |
- Remove the two washers and bolts (E) to remove the bracket assembly from the cab.
Illustration 6 | g03828649 |
(E) Washer and bolt |
- Remove switch assembly (16) from the bracket assembly, by removing two screws (17), four washers (18), and two nuts (19). Retain switch assembly (16) and the hardware to use for installation of the new lever.
Illustration 7 | g03828681 |
(16) 6G-4195 Limit Switch As (17) 2N-3477 Screw (18) 4B-5324 Washer (19) 7D-6922 Locknut |
Installation of the Brake Control Group
- Install park brake lever assembly (3) onto bracket assembly (6) with two bolts (10) and washers (11) .
Illustration 8 | g03829107 |
(3) 323-4077 Lever As (6) 163-6408 Bracket As (10) 8T-4189 Bolt (11) 8T-4224 Hard Washer |
- Install switch assembly (16) onto bracket assembly (6) with two screws (17), four washers (18), and two nuts (19) .
Illustration 9 | g03829160 |
(16) 6G-4195 Limit Switch As (17) 2N-3477 Screw (18) 4B-5324 Washer (19) 7D-6922 Locknut |
- Adjusting switch (16) so lever is pushed down when lever (3) is down.
- Enlarge rear hole (F) in bracket assembly (6) to 22 mm (0.87 inch) diameter.
Note: Drill 22 mm (0.87 inch) diameter hole through floor of cab if no hole is present.
Illustration 10 | g03829255 |
(F) Hole (6) 163-6408 Bracket As (10) 8T-4189 Bolt (11) 8T-4224 Hard Washer |
- Install bracket assembly (6) into cab with two bolts (10) and two washers (11) .
- Install block (4) into park brake lever assembly (3) by removing pin (8) and inserting pin (8) from the opposite side. Locking into place with pin (1) .
Illustration 11 | g03829566 |
(1) 6S-6646 Cotter Pin (4) 425-8286 Block (8) 3H-8538 Pin |
- Install boss (5) up from the under side of the cab through the hole in cab floor and bracket assembly (6). Lock boss into place with retaining ring (2) .
Illustration 12 | g03829691 |
(2) 125-0965 Retaining Ring (3) 323-4077 Lever As (4) 425-8286 Block (5) 447-2227 Boss (6) 163-6408 Bracket As (12) 8T-4742 Yoke Rod End (13) 8T-4744 Spring Pin Assembly (15) 273-9436 Cable As |
- Install park brake cable assembly (15) from underneath the cab, through boss (5) and up to park brake lever assembly (3) .
- Screw rod end (12) onto cable end and lock to block (4) with spring pin assembly (13) .
- Install three wires to switch assembly (16) .
Illustration 13 | g03829757 |
(A) Common (B) Norm open (C) Norm closed (16) 6G-4195 Limit Switch As |
- Finish routing cable assembly (15) and adjust parking brake cable per instructions in service manual.
- Install cover assembly (14) .
Illustration 14 | g03830128 |
(A) Strap (21) 9X-2045 Screw |
- Put two halves of strap assembly (A) through slots in cover assembly (14) and push cover down to install. Install two screws (21) in the rear.
- Install two screws (20) in front.
Illustration 15 | g03830140 |
(20) 9X-2042 Screw |