1990/11/01 Testing And Adjusting (SENR3256-02)

SMCS - SENR32560001

Important Information

When tests and adjustments are made to the transmission or the

torque converter, the parking brake must be OFF. To prevent
movement of the machine and personal injury do the procedure
thatfollows.

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1. Lower the bulldozer and ripper to the ground.

2. Put blocks in front of and behind the tracks.

3. Let only approved personnel on the machine and keep all other personnel off the machine and in clear view of the operator.

4. When testing must be done in a closed area and whenever possible, activate the service brakes if the parking brake can not be used.

NOTE: All tests and adjustments must be made with the oil in the power train hydraulic system at normal temperature of operation. Be sure the
linkage adjustments are correct before tests are made.

Power Train Hydraulic System Schematic

Transmission Hydraulic Controls

(1) Priority valve [part of oil filter(4)]. (2) Oil pump. (3) Steering and brake control valve. (4) Oil filter. (5) Body of selector and pressure control valve. (6) No. 5 clutch. (7) No. 4 clutch.
(9) Torque converter. (10) Sump (in case of case and frame). (11) Steering clutch and brake lubrication. (12) Speed selection spool. (13) Load piston. (14) Relief valve for converter
outlet. (15) Modulation relief valve. (16) Pressure differential valve. (17) Direction selection spool. (18) Ratio valve for torque converter. (19) Transmission lubrication. (20) No. 3
clutch. (21) No. 2 clutch. (22) No. 1 clutch. (23) Oil cooler. (A) Pressure tap for pump. (B) Pressure tap for converter inlet (P3). (C) Pressure tap for converter outlet. (D) Pressure tap
for speed clutch (P1). (E) Pressure tap for direction clutch (P2).

Location Of The Pressure Taps

Right Side Of Steering Clutch And Brake Control Valve
(3) Steering clutch and brake control valve. (A) Pump (priority valve).
NOTE: A port on the left side of the valve at the same location may also be used to check pump/priority valve pressure.

(14) Torque converter outlet relief valve. (C) Torque converter outlet pressure tap.

(G)Left steering clutch. (H) Left brake. (J) Right brake. (K) Right steering clutch.

(B) Converter inlet (P3). (D) Speed clutch (P1). (E) Direction clutch (P2). (F) Transmission lube.

(L) Steering clutch and brake lubrication (right side-front tap) (left side-rear tap).
(LP) Load piston plug.

Transmission Pressure Chart

NOTE: If the vehicle is equipped with a neutral start switch, the transmission control lever must be in NEUTRAL before the starter can be engaged
to start the engine.

Transmission Oil Pump Bench Test Specifications

Type ... Gear

Number of sections ... Three

Rotation (seen from drive end) ... Counterclockwise

Output of transmission and torque converte rsection:

[use SAE 10W oil at 49°C (120°F)](minimum) ... 57 liter/min(15 U.S. gpm)

At a pump speed of ... 1800 rpm

At a pressure of ... 3100 kPa (450 psi)

Output of steering clutch and brake lubrication section:

[use SAE 10W oil at 49°C (120°F)] (minimum) ... 152 liter/min(40 U.S. gpm)

At a pump speed of ... 1800 rpm

At a pressure of ... 345 kPa (50 psi)

Output of torque converter scavenge section:

[use SAE 10W oil at 49°C (120°F)] (minimum) ... 53 liter/min(14 U.S. gpm)

At a pump speed of ... 1800 rpm

At a pressure of ... 70 kPa (10 psi)

NOTE: Before an adjustment is made, make sure that the valve spring is not weak or broken.
Transmission Hydraulic Control Valve
(5) Body of selector and pressure control valve. (13) Load piston. (26) Spacers.

Outlet Relief Valve For Torque Converter

(14) Relief valve for converter outlet. (25) Spacers.

Location Of Priority Valve

(1) Priority valve (under cover). (4) Oil filter.
Priority Valve (Located in Oil Filter Housing)
(1) Priority valve. (24) Spacers.

Steering And Brakes

Steering And Brake Pressure Chart

Note A: Make sure the steering and brake control and parking brake linkages and the clutch lever and spring assemblies are correctly adjusted before any system pessures are
adjusted.
Note B: Use shims (27) for steering clutches and shims (28) for brakes to adjust the 2750 kPa (400 psi) pressure. use shims (29) to djust the 225 kPa (33 psi) brake residual
pressure. The "Less than 70 kPa (10 psi)" pressure is not adjustable.
NOTE: Pressure values are with engine at maximum rpm and transmission in Neutral.

Steering And Brake Pressure Taps

(G) Left steering clutch. (H) Left brake. (K) Right steering clutch. (J) Right brake.
Steering And Brake Control Valve
(27) Shims to adjust clutch pressures. (28) Shims to adjust brake pressures. (29) Shims to adjust brake residual pressure.

NOTE: Before an adjustment is made, make sure that the valve spring is not weak orbroken.

Linkage Adjustments

To prevent possible personal injury do not make any

adjustments to the control linkage with the engine running
unless necessary and then let only approved personnel on the
machine. Keep other personnel off the machine and in clear
view of the service personnel.

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Linkage For Transmission Controls And Parking Brake

Transmission Control Linkage (Type 1shown)
(1) Rod assembly. (2) Rod. (3) Rod assembly. (4) Parking brake lever. (5) Rod assembly. (6) Rod assembly. (7) Rod end. (8) Rod assembly. (9) Lever. (10) Lever. (11) Rod assembly.
(12) Rod assembly. (13) Lever.

Type 1: 8PB-8PB2080; 9DB1-9DB962; Type 2: 8PB2081-Up;9DB963-Up

NOTE: While the Type 1 and Type 2 linkages look somewhat different, the adjustment procedures are the same.

Torque for all 3/8 in. locknuts (jam nuts) that hold the rod ends in place on the rods ... 14 ± 4 Nꞏm (10 ± 3 lbft)

Torque for all 3/8 in. locknuts on rod end ball studs ... 25 ± 7 Nꞏm (18 ± 5 lb ft)

NOTE: All rod assembly measurements must be made in a straight line between the centerlines of the rod end mounting holes.

(1) Assembled length of rod assembly (Type 1) ... 481 ± 1 mm (18.94 ± .04 in)

Assembled length of rod assembly (Type 2) ... 471 ± 1 mm (18.54 ± .04 in)

(3) Assembled length of rod assembly ... 113 ± 1 mm (4.45 ± .04 in)

(5) Assembled length of rod assembly (Type 1) ... 252.5 ± 1.5 mm (9.94 ± .06 in)

Assembled length of rod assembly ... 240 ± 1.5 mm (9.45 ± .06 in)

(6) Assembled length of rod assembly ... 367 ± 1 mm (14.45 ± .04 in)

(11) Assembled length of rod assembly ... 435 ± 1 mm (17.13 ± .04 in)

(12) Assembled length of rod assembly ... 554 ± 1 mm (21.81 ± .04 in)
Procedure For Adjustment Of Transmission Control Linkage
1. Position shift lever (14) as shown in View A-A (centered in slot)

2. Position lever (9) at transmission valve for speed control in neutral (shown in detail C) and adjust rod (16) for free fit of bolt in lever(18).

3. Position lever (10) at transmission valve for direction control in forward (shown in detail C) and adjust rod (15) to obtain a free fit of bolt in
lever(17).

Transmission Control Linkage

(9) Speed control lever. (10) Direction control lever. (14) Shift lever.

Procedure For Adjustment Of Parking Brake

NOTE: While the Type 1 and Type 2 linkages look somewhat different, the adjustment procedures are the same.

1. With parking brake lever (4) located as shown in the brake ON position (lever down), adjust rod (2) until end fits freely in lever(4).

2. Tighten locknut on rod (2) to a torque of ... 5 ± 0.5 Nꞏm (4 ± .5 lb ft).

3. Adjust rod assembly (5) to the specified length. Install the adjusted rod assembly.

NOTE: Do not change the length of rod assembly (5) in further adjustments.

4. Disconnect rod assembly (8) at its upper end.

5. Pull up on lever (13) until lever (13) is at its highest point (detents fully depressed). Do not stretch spring can on rod (8) if so equipped. Adjust the
length of rod assembly (8) until pin fits freely through upper rod end (7). Then turn upper rod end (7) down two full turns (shorten) and install rod
assembly (8).

6. To check parking brake adjustment, install a 0 to 4000 kPa (0 to 600 psi) pressure gauge on either the right or left brake pressure tap.

7. Start the engine and run it at low idle.

8. With parking brake lever (4) in the brake ON position (lever down), the pressure gauge must read less than 300 kPa (44 psi). If the pressure is
not less than 300 kPa (44 psi), make rod assembly (8) shorter and check the pressure again.

9. Rotate parking brake lever (4) to the brake OFF position (lever up). The pressure gauge must read 2750 ± 150 kPa (400 ± 22 psi). If the
pressure reading is low, make rod assembly (8) longer and check the pressure again.
10. After adjusting the linkage in Steps 7 and 8, attach a 0 to 4000 kPa (0 to 600 psi) gauge to the P1 pressure tap on the transmission. With the
engine running at low idle, move parking brake lever from brake ON to brake OFF (full lever travel each way). The P1 pressure should read exactly
the same with the parking brake ON or OFF.

11. If the P1 pressure is not the same with the parking brake ON as it is with the parking brake OFF, the parking brake valve is leaking oil and the
linkage must be adjusted further using the following instructions:

a. If P1 with the parking brake OFF is less than P1 with the parking brake ON, lengthen rod assembly (8).

b. If P1 with the parking brake ON is less than P1 with the parking brake OFF, shorten rod assembly (8).

12. If linkage adjustments are made in Step 10, repeat the pressure checks in Steps 7, 8, and 9. Readjust as necessary until all pressures are met.

Transmission Control Linkage

(15) Rod assembly. (16) Rod assembly. (17) Lever. (18) Lever.

Linkage For Steering Clutch And Brake And Foot Brake Controls
 Steering clutch and brake control linkage adjustments should be
made only with the engine OFF. Accidental disengagement of
the parking brake while the engine is running could cause
sudden machine movement and personal injury.

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(1) Steering clutch control lever. (2) Platform opening. (3) Bumper. (4) Brake pedal. (5) Rod assembly. (6) Stop bolt. (7) Locknut. (8) Rod assembly. (9) Rod assembly. (10) Rod
assembly. (11) Lever. (12) Rod assembly. (13) Bolt. (B) Distance from floor plate to bottom of brake pedal. (C) Gap between clutch levers and platform opening.
NOTE: Apply 1U-8801 Rust Preventive Oil to all rod ends, pins, pin holes, locknuts, and adjusting threads.

Torque for all 9.525 mm (0.375 inch) locknuts that hold the rod ends in place ... 14 ±4 Nꞏm ... (124 ± 36 lb in)

NOTE: All rod assembly measurements must be made in a striaght line between the centerlines of the rod end mounting holes.

(5) Assembled length of rod assembly ... 266.0 ± 1.5 mm (10.50 ± 0.06 inch)

(8) Assembled length of rod assembly ... 441.0 ± 1.0 mm (17.36 ± 0.04 inch)

(13) Torque for four bolts ... 47 ± 4 Nꞏm (35 ± 3 lb ft)

Procedure For Adjustment Of Steering Clutch And Brake Linkage

(1) Steering clutch control lever. (2) Platform opening. (3) Bumper. (4) Brake pedal. (5) Rod assembly. (6) Stop bolt. (7) Locknut. (8) Rod assembly. (9) Rod assembly. (10) Rod
assembly. (11) Lever. (12) Rod assembly. (13) Bolt. (B) Distance from floor plate to bottom of brake pedal. (C) Gap between clutch levers and platform opening.
1. Install rod assembly (5) after it has been adjusted to correct length.

2. Make adjustments to rod assemblies (9) and (10) so that a gap (C) of 7.0 ± 1.0 mm (0.28 ± 0.04 inch) exists between clutch levers (1) and
platform opening (2).

3. Adjust bumpers (4) in order to obtain a gap of 1.0 mm + 1.0 mm - 0.5 mm (0.04 inch + 0.04 inch - 0.02 inch) between the bumpers and clutch
levers (1).

Procedure For Adjustment Of Brake Pedal Linkage

(1) Steering clutch control lever. (2) Platform opening. (3) Bumper. (4) Brake pedal. (5) Rod assembly. (6) Stop bolt. (7) Locknut. (8) Rod assembly. (9) Rod assembly. (10) Rod
assembly. (11) Lever. (12) Rod assembly. (13) Bolt. (B) Distance from floor plate to bottom of brake pedal. (C) Gap between clutch levers and platform opening.
1. Assemble brake pedal (4) on shaft so that front edge of pedal tread plate is 146 mm (5.75 in) above the floor plate. This will be one spline tooth
down from position where timing mark on shaft is aligned with centerline of slot in pedal.

2. Install rod assembly (8) after it has been adjusted to correct length.

3. Disconnect rod assembly (12) from lever (11).

4. Rotate lever (11) counterclockwise (toward the front of the tractor) until resistance is felt.

5. Adjust the length of rod assembly (12) to obtain a free fit in lever (11).

6. Push the brake pedal down until lever (11) stops.

7. With the brake pedal fully pushed down, adjust bolt (6) until the head contacts the brake pedal.

8. Release the brake pedal, and turn bolt (6) an additional 1/2 turn out. Tighten locknut (7).

NOTE: To bring pedal closer to operator, align timing mark on shaft with centerline of slot in pedal. This will give dimension (B) of 176 mm (6.9 in)

Adjustment Procedure For Clutch Levers And Spring Assemblies

Clutch Lever And Spring Assembly (Part of Steering and Brake Control Valve)
(1) Roller. (2) Cover. (3) Plunger. (4) Clutch lever. (5) Spring assembly. (6) Bolt.
NOTE: This adjustment should be made before any system pressures areadjusted.

1. Remove cover (2), and loosen bolt (6).

2. Move clutch lever (4) until roller (1) is in contact with, but not depressing, plunger (3).

3. Move spring assembly (5) until the pin of the spring assembly is in the front detent of the clutch lever (as shown in the illustration).

4. Tighten bolt (6).

5. Do Steps 2 through 4 for the other clutch lever.

6. Install cover (2).

1DD1-UP, 3MD1-UP, 4KD1-UP, 7EG1-UP, 8RC1-UP

PPI-0007C860
2022/09/13
11:57:31+01:00
SENR32560001
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