SENR8326-04

September 2013

Testing and Adjusting

D8R Track-Type Tractor
Power Train
7XM 1-Up (Machine)
9EM 1-Up (Machine)

SAFETY.CAT.COM
 i05296198

Important Safety Information

Most accidents that involve product operation, maintenance and repair are caused by failure to observe
basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous
situations before an accident occurs. A person must be alert to potential hazards, including human factors
that can affect safety. This person should also have the necessary training, skills and tools to perform these
functions properly.
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 verify
that you are authorized to perform this work, and have read and understood the operation,
lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings
are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or pictorially
presented.
A non-exhaustive list of operations that may cause product damage are identified by “NOTICE” labels on
the product and in this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
The warnings in this publication and on the product are, therefore, not all inclusive. You must not
use this product in any manner different from that considered by this manual without first satisfying
yourself that you have considered all safety rules and precautions applicable to the operation of the
product in the location of use, including site-specific rules and precautions applicable to the
worksite. If a tool, procedure, work method or operating technique that is not specifically
recommended by Caterpillar is used, you must satisfy yourself that it is safe for you and for others.
You should also ensure that you are authorized to perform this work, and that the product will not be
damaged or become unsafe by the operation, lubrication, maintenance or repair procedures that
you intend to use.
The information, specifications, and illustrations in this publication are on the basis of information that was
available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before you
start any job. Cat dealers have the most current information available.

When replacement parts are required for this

product Caterpillar recommends using Cat re-
placement parts.
Failure to follow this warning may lead to pre-
mature failures, product damage, personal in-
jury or death.

In the United States, the maintenance, replacement, or repair of the emission control devices and
systems may be performed by any repair establishment or individual of the owner's choosing.
SENR8326 3
Table of Contents

Table of Contents
Testing and Adjusting Section

Testing and Adjusting

Testing and Adjusting .................... ................... 4

Index Section

Index................................ ............................... 26
4 SENR8326
Testing and Adjusting

Testing And Adjusting Procedure

Section When you are defining a power train hydraulic system
problem, the following procedure should be used.
First, do visual checks. If the problem has not been
Testing and Adjusting identified, do the operation checks. If the problem is
not fully understood, do the instrument tests.
The procedures help to identify the power train
hydraulic system problems. When the problem is
defined, go to the troubleshooting.
i05426766
The troubleshooting section lists the probable causes
Testing and Adjusting of a known problem. Since there may be more than
one cause for a problem, the troubleshooting section
SMCS Code: 3000-036; 4000-036 may suggest specific instructions or instrument tests
be done.
The tests will help to identify the most probable
cause.
Personal injury or death can result from sudden
machine movement. This list cannot give all possible problems and
corrections. The service personnel must find the
Sudden movement of the machine can cause in- problem and the service personnel must locate the
jury to persons on or near the machine. source of the problem. Then make the necessary
repairs.
Prevent possible injury by performing the proce-
dure that follows before working on the machine. During a diagnosis of the power train hydraulic
system, remember that correct oil flow and pressure
Move the machine to a smooth horizontal loca- are necessary for correct operation.
tion. Move away from working machines and per-
sonnel and lower the buckets or implements The output of the pump increases with an increase in
(loader and backhoe) and stabilizers to the engine speed and decreases when the engine speed
ground. is decreased. Oil pressure is caused by resistance to
the flow of oil.
Permit only one operator on the machine. Keep all
other personnel away from machine or in view of When more checks are necessary use the following
the operator. tools: 8t-5320 Hydraulic Test Group, 4c-4890
Hydraulic Test Group, 4c-4892 ORFS Fittings
Engage the parking brake. Stop the engine. Group, stop watch, magnet, thermometer and ruler.
Move the hydraulic control levers to all positions Visual Checks
to release the pressure in the hydraulic system.

Note: All tests and adjustments must be made with

the oil in the power train hydraulic system at operating Personal injury or death can result from improp-
temperature. Be sure that the linkage adjustments are erly checking for a leak.
correct before the tests are made.
Always use a board or cardboard when checking
1. Move the machine to a smooth horizontal location. for a leak. Escaping air or fluid under pressure,
Move away from working machines and personnel. even a pin-hole size leak, can penetrate body tis-
Lower all implements to the ground. sue causing serious injury, and possible death.
If fluid is injected into your skin, it must be treated
2. Permit only one operator on the machine. Keep all immediately by a doctor familiar with this type of
personnel away from the machine or in the viewing injury.
area of the operator.

3. Put blocks in the front of the tracks and behind the A visual inspection of the power train hydraulic
tracks. system and the components of the system is the first
step when a diagnosis of a problem is made.
4. The testing must be done in a closed area. If the
Stop the engine. Lower the blade and the ripper to the
test requires the parking brake to be disengaged, ground.
engage the service brakes.
Make the following inspections:
5. Stop the engine.
SENR8326 5
Testing and Adjusting

1. Check all oil line connections for damage and

leaks. 12. The transmission gets hot.
2. Follow all power train hydraulic system oil lines 13. The pump noise is not normal.
from the power train connections to the valve
connections. Transmission
Check the lines and connections for damage and Problem 1: The transmission does not operate in
leaks. any speed. The transmission does not engage in
all speeds.
3. Check the power train control valves for leaks.
Probable Cause:
4. Follow the power train pump lines to the
transmission sump and the main sump. 1. There is low oil pressure that is caused by the
following causes:
Check the lines, the transmission sump and the
main sump for damage or leaks. a. The oil level is low.
5. Check the transmission sump and the main sump b. The control linkage is loose or the adjustment
oil level. is not correct.
6. Remove the filter element. Check for particles that c. Failure of the oil pump or pump drive.
were removed from the oil by the filter element. A
magnet separates ferrous particles from d. Air leaks on the inlet side of the pump.
nonferrous particles.
e. Priority valve adjustment is not correct.
7. Inspect the control linkages for damaged
components. f. There is leakage inside the transmission.

g. Adjustment of the modulation relief valve is not

Troubleshooting correct, or the valve does not close.
Problem Checklist
h. The load piston or the differential valve
operation is not correct.
Transmission Problem List
2. There is a mechanical failure in the transmission.
1. The transmission does not operate in any speed.
The transmission does not engage in all speeds. 3. There is a failure of the torque converter.

2. The transmission does not make a shift. 4. There is a failure of the transfer gears or the bevel
gears.
3. Slow shifts
5. There is a failure in the final drives.
4. The transmission engages very suddenly. There is
rough shifting. Problem 2: The transmission does not make a
shift.
5. The transmission operates in FORWARD speeds Probable Cause:
only.
1. The control linkage is loose or the adjustment is not
6. The transmission operates in REVERSE speeds correct.
only.
2. The oil level is low.
7. The transmission does not operate in First speed
FORWARD or REVERSE. 3. The clutch pressures are low.

8. The transmission does not operate in Second Problem 3: Slow shifts.

speed FORWARD or REVERSE. Probable Cause:
9. The transmission does not operate in Third speed 1. Low oil pressure.
FORWARD or REVERSE.
2. The adjustment of the control linkage is not correct.
10. The transmission does not disengage when the
selection lever is in NEUTRAL. 3. Air leaks on the inlet side of the pump.
11. The transmission engages but the machine does 4. The load piston or the differential valve does not
not move. move.
6 SENR8326
Testing and Adjusting

Problem 4: The transmission engages very 1. The No. 4 clutch is not engaged. The clutch slips
suddenly. There is rough shifting. due to the following causes:
Probable Cause: a. Low oil pressure or oil leakage.
1. The Initial setting of the modulation relief valve is
b. Discs and plates have too much wear.
not correct.
2. The load piston or the differential valve does not c. The clutch has parts that are broken.
move. Problem 9: The transmission does not operate in
Third speed FORWARD or REVERSE.
3. The valve springs are weak or the springs are
damaged. Probable Cause:
Problem 5: The transmission operates in 1. The No. 3 clutch is not engaged. The clutch slips
FORWARD speeds only. due to the following causes:
Probable Cause: a. Low oil pressure or oil leakage.
1. The control linkage is loose or the adjustment is not
b. Discs and plates have too much wear.
correct.
2. The No. 1 clutch is not engaged. The clutch slips c. The clutch has parts that are broken.
due to the following causes: Problem 10: The transmission does not
disengage when the selection lever is in
a. Low oil pressure, or oil leakage. NEUTRAL.
b. Discs and plates have too much wear. Probable Cause:

c. The clutch has parts that are broken. 1. The control linkage is loose or the adjustment is not
correct.
Problem 6: The transmission operates in
REVERSE speeds only. 2. The direction clutch is engaged, and the clutch
does not release.
Probable Cause:
Problem 11: The transmission engages but the
1. The control linkage is loose or the adjustment is not machine does not move.
correct.
Probable Cause:
2. The No. 2 clutch is not engaged. The clutch slips
1. There is a failure in the final drives.
due to the following causes:
2. There is a failure in the steering clutches.
a. Low oil pressure, or oil leakage.
3. There is a failure in the transfer gears or the bevel
b. Discs and plates have too much wear. gears.
c. The clutch has parts that are broken. 4. Gears in the transmission will not move due to the
Problem 7: The transmission does not operate in following causes:
First speed FORWARD or REVERSE.
a. Too many clutches are engaged.
Probable Cause:
b. There is a mechanical failure in the
1. The No. 5 clutch is not engaged. The clutch slips transmission.
due to the following causes:
c. There is a mechanical failure in the torque
a. Low oil pressure or oil leakage. divider or the torque converter.
b. Discs and plates have too much wear. Problem 12: The transmission gets hot.

c. The clutch has parts that are broken. Probable Cause:

Problem 8: The transmission does not operate in 1. The oil level is low.
Second speed FORWARD or REVERSE.
2. The oil level is high.
Probable Cause:
3. Cores of oil cooler not completely open.
SENR8326 7
Testing and Adjusting

4. Low oil flow as a result of pump wear.

5. Long periods of operation with converter at stall

speed or near stall speed.

6. There is too much resistance between the plates

and discs of the clutches.
Problem 13: There is a pump noise that is not
normal.
Probable Cause:
1. There is loud sounds at short intervals. The sounds
indicate that particles are going through the pump.
The sounds can be caused by pump cavitation.

2. A constant loud noise is an indication of pump

failure.
3. There is air at the inlet side of the pump.
8 SENR8326
Testing and Adjusting

Schematic for the Power Train Hydraulic System

Illustration 1 g00507741
Schematic for the Power Train Hydraulic System
(1) Selector and pressure control valve (13) Transmission (A) Torque converter inlet pressure tap(P3)
(2) Torque converter (14) Sump (B) Speed clutch pressure tap (P1)
(3) Pump drive (15) Sump (transmission) (C) Direction clutch pressure tap(P2)
(4) Torque converter outlet relief valve (16) Brake control valve (E) Brake pressure tap
(5) Cooler (17) Service brake spool (F) Low pump pressure tap (torque converter
(6) Breather (18) Regulating relief valve charging pump)
(7) Sump in torque converter housing (19) Priority and makeup valve group (G) Priority valve pressure tap
(8) Parking brake valve spool (20) Priority valve. (H) High pump pressure tap (transmission
(9) Service brakes with shuttle valves. (21) Check valve charging pump)
(10) Left brake lube section (22) Power train oil pump (J) Outlet from torque converter pressure tap
(11) Right brake lube section (23) Transmission oil filter
(12) Transmission lube (24) Load piston
SENR8326 9
Testing and Adjusting

Illustration 2 g00507745
(A) Torque converter inlet (P3)
(B) Speed clutch (P1)
(C) Direction clutch (P2)
(D) Transmission lubrication

Illustration 4 g00507808
(H) Transmission charging pump

Pressure Tap Locations

Many of the pressure taps have quick disconnect
couplings that are installed. In order to prevent
damage to the seal in the coupling, do not connect or
disconnect the couplings when there is pressure in
the system.

Illustration 3 g03425379
(E) Brake
(F) Torque converter charging pump
(G) Priority valve

Illustration 5 g00507811
(J) Outlet from torque converter
10 SENR8326
Testing and Adjusting

Illustration 6 g00507816
(K) Brake lubrication

Illustration 7 g00507821
(L) Pump drive lubrication

Illustration 8 g00507846
(LP) Load piston plug
SENR8326 11
Testing and Adjusting

Transmission Pressure Chart

Table 1
Transmission Pressure Chart

Pressure Pressure Tap Low Idle High Idle Adjustment

None
Converter Inlet Pressure 860 ± 140 kPa With cold oil the value
(A)
(P3) (125 ± 20 psi) should be 1000 kPa
(145 psi) maximum.

Add or remove spacers (25)

530 ± 35 kPa (77 ± 5 psi)
in load piston (24) in selec-
Speed Clutch (P1) (Initial with the transmission selec-
(B) tor and pressure control
Pressure) tor lever in NEUTRAL Load
valve (1). See the Spacer
piston plug (LP) removed.
Chart.
Maximum of 345 kPa
2620 ± 140 kPa
(50 psi) less than the pres-
(380 ± 20 psi) with the se- None
sure at HIGH IDLE. Selec-
lector lever in any FOR- Final pressure is controlled
Speed Clutch (P1) (B) tion lever in any
WARD or REVERSE by the initial pressure
FORWARD or REVERSE
speed. Load piston plug setting.
speed. Load piston plug
(LP) installed
(LP) installed

380 ± 55 kPa (55 ± 8 psi) 380 ± 55 kPa (55 ± 8 psi)

less than the speed clutch less than the speed clutch None
pressure at tap (B). The se- pressure at tap (B). The se- Direction clutch pressure is
Direction Clutch (P2) (C) lector lever in any FOR- lector lever in any FOR- controlled by the spring rate
WARD or REVERSE WARD or REVERSE for the pressure differential
speed. Load piston plug speed. Load piston plug valve spring.
(LP) installed. (LP) installed.

Transmission Lubrication With brakes on 12 ± 11 kPa With brakes on.

(D) None
Oil (1.7 ± 1.6 psi) 160 ± 35 kPa (23 ± 5 psi)

3170 ± 140 kPa

(460 ± 20 psi) with brakes
Brake Pressure (E) None
off. Less than 70 kPa
(10 psi) with brakes on.

Add or remove spacers (26)

Low pressure (torque con- 965 ± 140 kPa
(F) in regulating relief valve
verter charging) pump (140 ± 20 psi)
(18). See the spacer chart.

Add or remove spacers (27)

2760 kPa (400 psi) 3275 ± 140 kPa
Priority Valve Setting (G) in priority valve (20). See
minimum. (475 ± 20 psi)
the spacer chart.

2840 kPa (410 psi) 3170 ± 175 kPa

Transmission Oil Pump (H) Priority valve
minimum. (460 ± 25 psi)

415 ± 70 kPa (60 ± 10 psi)

Add or remove spacers (28)
with the brakes on, selector
in converter outlet relief
Converter Outlet Pressure (J) in THIRD SPEED FOR-
valve (4). See the spacer
WARD, and the converter
chart.
in a stall condition.
200 ± 75 kPa (29 ± 11 psi)
with brakes off. Brakes off (priority valve)
Brake Lubrication (K)
140 ± 70 kPa (20 ± 10 psi) Brakes on (Check linkage)
with brakes on.
With brakes on
With brakes on
Pump drive lubrication (L) 620 ± 140 kPa None
310 ± 70 kPa (45 ± 10 psi)
(90 ± 20 psi)

Specifications for the Transmission Oil

Pump Bench Test
For the bench test, use SAE 10W oil at 49°C (120°F).
12 SENR8326
Testing and Adjusting

Type .................................................................... Gear Table 3

Transmission Selection Clutches Engaged In
Number of sections ............................................Three Transmission

Rotation (from drive end) ................Counterclockwise Neutral 3

First Speed Forward 2 and 5
Output of transmission charging section:
Second Speed Forward 2 and 4
Minimum.............................72 L/min (19 US gpm)
Third Speed Forward 2 and 3
Pump speed .......................................... 1800 rpm
Pressure..................................2900 kPa (420 psi) First Speed Reverse 1 and 5

Output of torque converter charging section: Second Speed Reverse 1 and 4

Third Speed Reverse 1 and 3

Minimum.............................96 L/min (25 US gpm)
Pump speed .......................................... 1800 rpm
Pressure....................................900 kPa (130 psi)

Output of transmission and torque converter

scavenge section:

Minimum...........................104 L/min (27 US gpm)

Pump speed ............................................ 900 rpm
Pressure......................................200 kPa (29 psi)

Spacer Chart
Table 2
Spacer Chart
Pressure Change To The Valves By Removal Or Addition Of
One Spacer Illustration 9 g00508580
Pt. No. For Change in Component Converter Outlet Relief Valve
Thickness
Spacer Pressure Used (4) Converter outlet relief valve
(28) Spacers
(27) 1.6 mm 208 kPa
5m9622 (0.063 inch) (30.2 psi)

.9 mm 116 kPa Priority Valve

(27)5m9623
(0.035 inch) (16.8 psi) (20)

.25 mm 33 kPa
(27)5m9624
(0.01 inch) (4.8 psi)

1.6 mm 127 kPa

(26)5m9622
(0.063 inch) (18 psi)

.9 mm 71 kPa Regulating Re-

(26)5m9623
(0.035 inch) (10.3 psi) lief Valve (18)

.25 mm 20 kPa
(26)5m9624
(0.01 inch) (2.9 psi)

1.6 mm 98 kPa
(25)5m9622
(0.063 inch) (14.2 psi)

.9 mm 57 kPa Load Piston

(25)5m9623
(0.035 inch) (8.3 psi) (24)

.25 mm 16 kPa
(25)5m9624
(0.01 inch) (2.3 psi)

Converter Out-
.9 mm 16.5 kPa
(28)5m9623 let Relief Valve Illustration 10 g00508583
(0.035 inch) (2.4 psi)
(4)
Transmission Hydraulic Control Valve
(1) Body of selector and pressure control valve
(24) Load piston
(25) Spacers
SENR8326 13
Testing and Adjusting

Illustration 11 g00508585
Priority and Makeup Valve Group
(18) Regulating relief valve
(19) Priority and makeup valve group
(20) Priority valve
(26) Shims
(27) Shims

Linkage For Service Brake Pedal

Personal injury or death can result from sudden

machine movement.
Accidental disengagement of the parking brake or
transmission engagement while the engine is run-
ning can cause sudden machine movement.
Do not make any adjustments to the control link-
age with the engine running.
14 SENR8326
Testing and Adjusting

Illustration 12 g00508629
Brake Pedal Linkage
(1) Brake valve spool (4) Rod end (7) Rod
(2) Brake control valve (5) Spring (B) Rod assembly
(3) Pin (6) Locknuts (C) Rod assembly

Torque for all of the locknuts that hold the rod ends in Procedure To Adjust The Brake Pedal
place on the rod. ...................60 ± 12 N·m (44 ± 9 lb ft) Linkage
Note: All rod assembly measurements must be made
in a straight line between the centerlines of the rod
end mounting holes.

(B) Assembled length of rod assembly (midrange

reference) ..................................... 935 mm (36.8 inch)

(C) Assembled length of rod assembly

................................ 410 ± 1.5 mm (16.14 ± 0.06 inch)

(D) Dimension (maximum)................ 37 mm (1.5 inch)

(E) Dimension (midrange reference) ................ 41 mm

(1.6 inch)

(F) Dimension .......... 308 ± 17 mm (12.13 ± 0.67 inch)

Illustration 13 g00508803
Brake Pedal Linkage
(8) Adjusting bolt (upper stop)
(9) Locknut

1. Adjust rod assembly (C) to the specified length.

2. Remove pin (3) in order to disconnect rod

assembly (B) from brake spool (1).
SENR8326 15
Testing and Adjusting

3. Adjust the position of the upper brake stop.

e. Check maximum dimension (D) in two places
a. Adjust bolt (8) until spring (5) is extended in order to make sure that the dimension has
3 ± 1 mm (0.12 ± 0.04 inch). Turning bolt (8) not been exceeded.
clockwise into the support stretched spring (5).
f. Tighten two locknuts (6) and assemble the
b. Tighten locknut (9). cotter into pin (3).

4. Adjust the brake pedal position. 6. Adjust the lower stop for the brake pedal.

a. Release brake pedal (10) against the upper a. Depress brake pedal (10) until brake valve
stop. spool (1) reaches the maximum extension
from brake control valve (2). Bolt (12) must be
b. Index the pedal on the shaft spline and turned far enough into the support so that the
position the pedal to dimension (F). brake pedal will not contact bolt (12) at this
time.
c. Tighten bolt (11).
b. Turn the bolt counterclockwise until the bolt
5. Adjust rod assembly (B). head contacts brake pedal (10). Make sure
a. Release brake pedal (10) against the upper that brake valve spool (1) is at the maximum
stop. extension.
c. Release brake pedal (10). Turn bolt (12)
b. Loosen two locknuts (6).
counterclockwise by an additional one-half
c. Push brake valve spool (1) all the way into turn.
brake control valve (2). Hold the valve spool in d. Tighten locknut (13).
place.

Illustration 14 g00508950
Brake Pedal Linkage
(10) Brake pedal
(11) Bolt
(12) Adjusting bolt (lower stop)
(13) Locknut

d. To adjust the length of rod assembly (B), turn

rod (7) while both rod ends are held from
turning. Adjust the rod assembly length in
order to obtain a free fit of pin (3) with rod end
(4) and brake valve spool (1). Then assemble
pin (3). If the rod assembly (B) is adjusted
properly, then the brake valve spool (1) will
remain in the brake control valve (2) while the
brake pedal is against the upper stop.
16 SENR8326
Testing and Adjusting

Linkage For Parking Brake

Illustration 15 g00509047

(1) Parking brake lever (7) Locknut (13) Rod

(2) Brake control valve (8) Rod (A) Rod assembly
(3) Parking brake valve spool (9) Rod end (C) Dimension
(4) Spring pin assembly (10) Spring pin assembly (D) Dimension
(5) Rod end (11) Rod end (E) Dimension
(6) Locknut (12) Locknut

Torque for all the locknuts that hold the rod ends in (E) Dimension (maximum).............. 34 mm (1.34 inch)
place on the rods. ...................25 ± 6 N·m (19 ± 4 lb ft)
Procedure To Adjust The Parking Brake
Note: All rod assembly measurements must be made
in a straight line between the centerlines of the rod Linkage
end mounting holes.
1. Engage the parking brake.
(1)Testing and Adjusting, “Hand Control Group”

(C) Dimension............. 15 ± 1.5 mm (0.59 ± 0.06 inch)

(D) Assembled length of rod assembly (midrange

reference) ..................................... 450 mm (17.7 inch)
SENR8326 17
Testing and Adjusting

2. Adjust rod end (9) in order to obtain dimension (C). Transmission Control Adjustments
The dimension is measured on rod (8) from the
end of the threads to the nut face on rod end (9).
Tighten locknut (7) and install spring pin assembly
(10).

3. Remove spring assembly (4).

4. Pull out parking brake valve spool (3) from brake

control valve (2) to the stop for the spool.

5. Adjust the length of rod assembly (A) in order to

obtain a free fit of spring pin assembly (4) with rod
end (5) and parking brake valve spool (3). If rod
assembly (A) is properly adjusted, the parking
brake valve spool must remain out from the brake
valve against the stops for the spool while lever (1)
is up in the ENGAGED position.

6. Check dimension (E) from the end of the threads

on rod (13) to the nut face on rod ends (5) and (11).
Make sure that the dimension has not been
exceeded. Tighten locknuts (6) and (12). Illustration 16 g00509103

Illustration 17 g00509104

(1)Testing and Adjusting, “Hand Control Group”

Torque for all locknuts on cable assembly that hold

the rod ends in place. ..............6 ± 1 N·m (53 ± 9 lb in)

Torque for all locknuts that fasten the cable

assemblies to cover (17) and cover (20).
................................................38 ± 7 N·m (28 ± 5 lb ft)

(7) Dimension .................12 ± 2 mm (0.47 ± 0.08 inch)

(8) Dimension .................12 ± 2 mm (0.47 ± 0.08 inch)

18 SENR8326
Testing and Adjusting

Forward/Reverse Assembly Procedure

1. Engage the parking brake.

2. At the transmission, move the transmission rotary

selector spool to the NEUTRAL position.

3. Assemble cable (4) to the dimensions that are

shown in View B-B.
4. Adjust cable (4) in order to allow the free fit of pin
assembly (9) into the transmission bellcrank. To
adjust the cable, remove the bolts that hold cover
(5) to the housing. Loosen the locknut that is on
cable (4). Turn cover (5), as required.

Speed Control Assembly Procedure

1. Assemble cable (3) to the dimensions that are

shown in View B-B.
2. At the transmission, move the transmission speed
selector spool to the SECOND GEAR position.

3. Turn handle (2) to the SECOND GEAR position.

4. Adjust cable (3) in order to allow the free fit of pin

assembly (10) into the transmission bellcrank. To
adjust the cable, remove the bolts that hold cover
(6) to the housing. Loosen the locknut on cable (3)
and turn cover (6), as required.

Hand Control Group

SENR8326 19
Testing and Adjusting

Illustration 18 g00509241

Torque for all locknuts on cable assembly that hold (1) Apply 4c-4030 Thread Lock Compound to the
the rod ends in place. ..............6 ± 1 N·m (53 ± 9 lb in) threads on the parking brake lever.

Torque for the locknut that holds the swivel end (2) Apply lubricant to the inside of the handle.
................................................25 ± 6 N·m (18 ± 4 lb ft)
(4) Dimension (two places)..........................15 ± 2 mm
Torque for all locknuts on the cable assemblies (0.6 ± 0.08 inch)
................................................38 ± 7 N·m (28 ± 5 lb ft)
Ball joint assemblies:
20 SENR8326
Testing and Adjusting

Torque for both ball joint assemblies......8 ± 2 N·m

(6 ± 1.5 lb ft)

(5) Dimension (two places)..........................16 ± 2 mm

(0.63 ± 0.08 inch)

(6) Torque for rod end ..............8 ± 2 N·m (6 ± 1.5 lb ft)

(7) Torque for nut .....................8 ± 2 N·m (6 ± 1.5 lb ft)

(10) Torque for the screws that fasten the neutral start
switch to the plate ...................................0.5 ± .05 N·m
(4.425 ± 0.442 lb in)
Attach the green wire number 306 to the common
post of the switch assembly. Attach the orange wire
number 307 to the normally open post of the switch
assembly.

(11) Torque for the pin with 4c-4030 Thread Lock

Compound ..............................8 ± 2 N·m (6 ± 1.5 lb ft)
Apply lubricant to the rod assembly.
(12) Install the seal with the lip downward.

(13) 6y-2846 Spring

Length under test force ..... 74.64 mm (2.939 inch)

Test force......................................626 N (140.7 lb)
Free length after test ......... 79.92 mm (3.146 inch)
Outside diameter...................... 20 mm (0.79 inch)

(14) 5n-6096 Spring

Length under test force ..... 25.50 mm (1.004 inch)

Test force...................................19.57 N (4.400 lb)
Free length after test ......... 48.77 mm (1.920 inch)
Outside diameter............... 13.82 mm (0.544 inch)

(15) Torque for the screws that fasten the backup

switch to the plate ...................................0.5 ± .05 N·m
(4.425 ± 0.442 lb in)
Attach brown wire number 321 to the common post of
the switch assembly and black wire number 200 to
the normally open post.
(16) Apply lubricant to the rod assembly.
(17) Apply 4c-4030 Thread Lock Compound to the
threads on the rod assembly.

(18) Dimension ...............16 ± 2 mm (0.63 ± 0.08 inch)

(19) Drive the bearing on the stamped end.
SENR8326 21
Testing and Adjusting

Illustration 19 g00509550

(1A) The handle is in ENGAGED position. (23) Depth for the bearing...........................4.5 ± 1 mm
(0.18 ± 0.04 inch)
(1B) The handle is in DISENGAGED position.
(24) Apply 4c-4030 Thread Lock Compound to the
(21) Torque for four screws......6 ± 1 N·m (53 ± 9 lb in) shaft.
(22) Torque for three screws...................1.7 ± .25 N·m (25) Drive the bearing on the stamped end only.
(15.05 ± 2.21 lb in)
(26) Torque for nut ..................25 ± 6 N·m (18 ± 4 lb ft)
22 SENR8326
Testing and Adjusting

(27) Depth for the bearing...........................1.5 ± 1 mm 1. Engage the parking brake ((1A) position).
(0.06 ± 0.04 inch) Disengage the parking brake ((1B) position).
Rotate handle (2) by 15 degrees toward reverse.
(28) Dimension for the washers on the end of the
shaft .........................0.10 to 2.0 mm (.004 to .08 inch) 2. Check continuity through switch (15). If there is no
continuity within 1 degree of the 15 degree angle,
(29) Torque for the bolt on the collar.........1.7 ± .2 N·m adjust the position of switch (15).
(15.05 ± 1.77 lb in)
3. To adjust the position of switch (15), remove three
(33) Torque for two screws .....................0.8 ± 0.1 N·m screws (31) and remove cover assembly (30).
(7.08 ± 0.89 lb in)
4. Loosen the screws for the switch and slide switch
Speed Control Adjustment Procedure (15) to the correct position. Tighten the screws.
Check the continuity through the switch. Readjust
1. Rotate collar (32) until the number 2 is 30 ± 1 the switch, if necessary.
degrees counterclockwise from vertical. Vertical is
5. Install cover assembly (30) and three screws (31).
viewed from the end of handle (2).

Torque for the bolt that holds collar (29)

.................................1.7 ± 0.2 N·m (15.05 ± 1.77 lb in)

2. Remove plate (20). Rotate lever (9) until the plate

is parallel with the top of housing (8).

3. Install handle assembly (3) with the white mark in

line with the number 2 on collar (29).

Forward/Reverse Adjustment Procedure

1. Rotate ring (32) so screw (31) is in the center of the

slot.

Torque for two screws (33) ....................0.8 ± 0.1 N·m

(7.08 ± 0.89 lb in)

2. With parking brake lever (1) in the ENGAGED

position (1A), rotate handle (2) until the white mark
on the handle lines up with N (neutral) on ring (32).

Torque for three screws (22) ................1.7 ± 0.25 N·m

(15.05 ± 2.21 lb in)

Parking Brake Lever and Neutral Start

Switch Adjustment Procedure

1. With parking brake lever (1) in ENGAGED position

(1A), loosen the screw for parking brake lever (1)
and remove the lever.
2. Install parking brake lever (1) on splined shaft (19)
so the hole in lever (1) is in line with the hole in
plate (20).

3. Check continuity through neutral start switch (10).

If there is no continuity, adjust the position of
switch (10).

Backup Alarm Adjustment Procedure

SENR8326 23
Testing and Adjusting

Governor and Decelerator Control Group

Illustration 20 g00509626

Note: Apply 1p-0808 Multipurpose Grease to all (16) Assembled length of the rod assembly (midrange
bearings and bearing cavities. reference) .....................................769 mm (30.3 inch)
(4) Drive the bearing on the stamped end only. (24) Torque for rod end nut .....14 ± 4 N·m (10 ± 3 lb ft)
(6) Lubricate all of the parts in the decelerator with (25) Assembled length of rod assembly ....376 ± 3 mm
SAE (30W) oil.
(14.8 ± 0.1 inch)
(8) Lubricate the seal lip with SAE (30W) oil.
(11) Align the timing mark with the centerline of the
saw cut.

Note: Apply 1u-8801 Rust Preventive Oil to all rod

ends, pins, locknuts, adjusting threads, and pin holes.

(15) Torque for rod end nut .....14 ± 4 N·m (10 ± 3 lb ft)
24 SENR8326
Testing and Adjusting

Illustration 21 g00509649

Adjustment For The Governor Control Adjustment Of The Governor Control

Lever Effort Linkage

1. Disconnect rod end (14) from lever (13). 1. Disconnect rod end (14) from lever (13).
Disconnect spring (17). Disconnect spring (17).
2. Housing nut (7) adjusts the force that is needed to 2. Move governor control lever (2) to the vertical
move handle (1). Measure the lever effort by the position.
force on handle (1) or by the torque of shaft
assembly (3). 3. Turn lever (13) counterclockwise until the governor
control shaft enters the shut off detent position (J).
Force on handle (1) .................60 ± 4 N (13.5 ± 0.9 lb)
4. Loosen bolt (12). Position lever (13) on splined
Torque on shaft assembly (3) ..............24.5 ± 1.6 N·m governor shaft (27) at angle (H). Angle (H) is 55 ±
(217 ± 14 lb in) 5 degrees from vertical position (G). Tighten bolt
(12).
SENR8326 25
Testing and Adjusting

5. Loosen bolt (10) and position lever (9) on splined 4. When decelerator pedal (20) is depressed against
shaft (5). Align the timing mark on the shaft with the stop bolt, adjust decelerator stop bolt (19) until
the centerline of the lever saw cut. Tighten bolt the engine speed is 1000 ± 50 RPM .
(10).
5. Tighten locknut (18) in order to lock the stop bolt in
6. Loosen nuts (24) and adjust rod assembly (25) to position.
the correct assembled length. Tighten nuts (24).
6. Recheck decelerated engine speed by depressing
7. Loosen locknut (15). Adjust rod end (14) in order to pedal (20) against stop bolt (19).
allow the free fit with pin (26) and lever (13).
Tighten locknut (15). If the adjustment is correct, 7. Disconnect the tachometer.
the governor control shaft (27) will be in the shut off
detent when governor control lever(2) is vertical.
Reference dimension (F) is 15 degrees from
vertical position (G).

Adjustment For The High Idle Stop Bolt

1. Connect a tachometer in order to measure the

engine speed.

2. Loosen locknut (21) and back high idle stop bolt

(22) away from governor control lever (2).

3. Start the engine. Move governor control lever (2),

until the engine speed does not increase. The
governor control shaft (27) should be rotated
clockwise to HIGH IDLE position (E).

4. Adjust high idle stop bolt (22) so that the bolt

contacts governor control lever (2). Back off the
bolt away from the lever by one turn. Tighten
locknut (21) in order to lock high idle stop bolt (22)
in position.

5. Check the high idle rpm by pulling governor control

lever (2) against stop bolt (22). High idle stop bolt
(22) is not an adjustment for high idle.
When the bolt allows the governor shaft to rotate to
the HIGH IDLE position (E), stop bolt (22) is
correctly adjusted and the bolt is protecting the
governor and the governor control linkage from
damage.
If HIGH IDLE RPM is not 2240 ± 50 rpm, System
Operations, Testing & Adjusting Manual for 3406C
Engine, senr1028, “Governor Adjustments”

6. Disconnect the tachometer.

Decelerator Adjustment

1. Connect a tachometer in order to measure the

engine speed.

2. Loosen locknut (18).

3. Start the engine. Move governor control lever (2)

until the engine speed is at least 1200 RPM.
26 SENR8326
Index Section

Index
I
Important Safety Information ............................. 2

T
Table of Contents............................................... 3
Testing and Adjusting ........................................ 4
Governor and Decelerator Control Group.... 23
Hand Control Group..................................... 18
Linkage For Parking Brake .......................... 16
Linkage For Service Brake Pedal ................ 13
Pressure Tap Locations ................................. 9
Procedure ...................................................... 4
Schematic for the Power Train Hydraulic
System ......................................................... 8
Transmission Control Adjustments .............. 17
Troubleshooting ............................................. 5
Visual Checks ................................................ 4
Testing and Adjusting Section ........................... 4
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