SENR8324-03

May 2007

Specifications
D8R Track-Type Tractor Power Train
7XM1-Up (Machine)
9EM1-Up (Machine)
 i01658146

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. 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 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.
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. 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
the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
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. Caterpillar dealers have the most current information available.

When replacement parts are required for this

product Caterpillar recommends using Caterpil-
lar replacement parts or parts with equivalent
specifications including, but not limited to, phys-
ical dimensions, type, strength and material.

Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or
death.
SENR8324-03 3
Table of Contents

Table of Contents
Specifications Section
Torque Divider ........................................................ 4
Relief Valve (Torque Converter Outlet) ................... 5
Transmission Selector and Pressure Control Valve
............................................................................... 6
Transmission Hydraulic Control ............................. 7
Priority Valve .......................................................... 8
Transmission Oil Filter ........................................... 9
Transmission ........................................................ 10
Transmission Pump .............................................. 11
Transmission Mounting ......................................... 12
Bevel and Transfer Gears .................................... 13
Drive Shaft ........................................................... 15
Brake Control Valve ............................................. 16
Steering and Transmission Control Group ........... 17
Hand Control Group ............................................. 19
Foot Brake Control ................................................ 23
Brake and Planetary ............................................ 24
Differential Drive and Brake Group ...................... 25
Final Drive ............................................................ 26
Equalizer Bar ....................................................... 27
Recoil Group ........................................................ 28
Track Rollers ........................................................ 29
Idlers (Track) ........................................................ 31
Tracks .................................................................. 31
Fender .................................................................. 34
Rollover Protective Structure (ROPS) ................. 35
Drawbar ............................................................... 35
Frame Group ....................................................... 36
Bogie Suspension ................................................. 37
Sweep Group ....................................................... 38

Index Section
Index ..................................................................... 39
4 SENR8324-03
Specifications Section

Specifications Section
i01373149

Torque Divider
SMCS Code: 3113
Part No.: 110-3391

g00724740
Illustration 1
SENR8324-03 5
Specifications Section

Table 1 i01045497

Clearance
Between Parts
Diameter Across
the Components
Running
Clearance (1)
Relief Valve (Torque Converter
(A) 1.17 to 1.32 mm 0.58 to 0.66 mm
Outlet)
Stator New (0.046 to 0.052 (0.023 to 0.026
and inch) inch) SMCS Code: 3133
Impeller
100% 1.54 mm 0.77 mm Part No.: 9W-5596
Worn (0.061 inch) (0.030 inch)
(B) 1.76 to 1.94 mm 0.88 to 0.97 mm
Stator New (0.069 to 0.076 (0.035 to 0.038
and inch) inch)
Turbine
100% 2.15 mm 1.08 mm
Worn (0.085 inch) (0.043 inch)
(1) Half the clearance across the diameter

(1) Diameter of the planetary

shafts ................................... 26.439 ± 0.005 mm
(1.0409 ± .0002 inch)

(2) Torque for bolts that fasten the retainer to the

housing ........................ 50 ± 10 N·m (37 ± 7 lb ft) g00542348
Illustration 2
(3) Torque for nut ........ 170 ± 15 N·m (125 ± 11 lb ft)
(1) 5M-9623 Spacer
Note: Tighten the two setscrews in order to hold nut Thickness of spacer ............ 0.90 mm (.035 inch)
(3) in place. The setscrews should seat in a spline Outside diameter ..................... 20.62 ± 0.25 mm
space. If the setscrew holes are not in alignment (.812 ± .010 inch)
with a spline space, advance the holes to the next
available space. (2) 7M-1297 Spring (outer)
(4) Torque for bolts that fasten the stator to the Length under test force ....... 50.8 mm (2.00 inch)
carrier ............................ 40 ± 5 N·m (30 ± 4 lb ft) Test force .......... 175.9 ± 14.1 N (39.54 ± 3.16 lb)
Free length after test .......... 75.7 mm (2.98 inch)
(5) Torque for bolts that fasten the impeller to the Outside diameter .............. 22.35 mm (.880 inch)
housing .......................... 30 ± 5 N·m (22 ± 4 lb ft)
(3) 9W-5595 Spring (inner)
(6) Torque for bolts that fasten the carrier to the
impeller ........................ 50 ± 10 N·m (37 ± 7 lb ft) Length under test force ... 43.26 mm (1.703 inch)
Test force .......... 98.26 ± 4.9 N (22.090 ± 1.10 lb)
(7) Torque for bolt that fastens the yoke to the Free length after test ...... 56.21 mm (2.213 inch)
shaft ............................. 115 ± 7 N·m (85 ± 5 lb ft) Outside diameter .............. 15.88 mm (.625 inch)

(8) Torque for bolts that fasten the torque divider to

the housing .................... 50 ± 7 N·m (37 ± 5 lb ft)

(9) Outside diameter of the shaft in the bearing area

.......... 44.437 ± 0.013 mm (1.7495 ± .0005 inch)

Inside diameter of the bearings after installation in

the flange 44.500 ± 0.013 mm (1.7520 ± .0005 inch)

(10) Inside diameter of the planetary

gears .. 34.399 ± 0.010 mm (1.3543 ± .0004 inch)
6 SENR8324-03
Specifications Section

i01050900

Transmission Selector and

Pressure Control Valve
SMCS Code: 3073
Part No.: 6I-9896

g00544953
Illustration 3

(1) 7G-4842 Spring (outer) Second test

Color ............................................ two red stripes Length under test force ....... 85.5 mm (3.37 inch)
Test force ............ 240.3 ± 7.2 N (54.02 ± 1.62 lb)
First test Free length after test ..... 117.40 mm (4.622 inch)
Outside diameter .............. 21.21 mm (.835 inch)
Length under test force ....... 62.5 mm (2.46 inch)
Test force ................ 32.3 ± 1.6 N (7.26 ± 0.36 lb)
(3) 5M-9622 Spacer
Second test
Thickness of one spacer ... 1.60 mm (0.063 inch)
Length under test force ....... 36.3 mm (1.43 inch) Outside diameter ............. 20.62 mm (.8118 inch)
Test force ............ 142.3 ± 4.3 N (31.99 ± 0.97 lb) One spacer changes the pressure
Free length after test ...... 68.45 mm (2.695 inch) approximately: ......................... 98 kPa (14.2 psi)
Outside diameter ............ 27.79 mm (1.094 inch)
(3) 5M-9623 Spacer
(2) 9P-3041 Spring (inner)
Thickness of one spacer ... 0.90 mm (0.035 inch)
Color ............................................ two red stripes Outside diameter ..................... 20.62 ± 0.25 mm
(.812 ± .010 inch)
First test
One spacer changes the pressure
Length under test force ...... 110.0 mm (4.33 inch) approximately: ........................... 57 kPa (8.3 psi)
Test force .............. 72.6 ± 3.6 N (16.32 ± 0.81 lb)
SENR8324-03 7
Specifications Section

Outside diameter ................ 8.99 mm (.354 inch)

(10) 6D-3044 Spring Pin (Stainless Steel)

i01050908

Transmission Hydraulic
Control
SMCS Code: 3073
Part No.: 8E-5116

g00545078
Illustration 4

(3) 5M-9624 Spacer

Thickness of one spacer ..... 0.25 mm (.010 inch)
Outside diameter ..................... 20.62 ± 0.25 mm
(.812 ± .010 inch)
One spacer changes the pressure
approximately: ........................... 16 kPa (2.3 psi)

(4) Torque for three bolts ..... 28 ± 7 N·m (21 ± 5 lb ft)

(7) 6P-9784 Spring (outer)

g00550071
Illustration 5
Color ............................................... yellow stripe
Length under test force ... 56.39 mm (2.220 inch) (1) Torque for 26 bolts ........ 30 ± 4 N·m (22 ± 3 lb ft)
Test Force ................ 130 ± 6.5 N (29.0 ± 1.50 lb)
Free length after test ...... 88.60 mm (3.488 inch) (2) Torque for four bolts ...... 48 ± 4 N·m (35 ± 3 lb ft)
Outside diameter .............. 16.26 mm (.640 inch)
(3) 3T-4403 Spring
(6) 6P-9783 Spring (inner)
Color ................................................... blue stripe
Color ............................................... yellow stripe Length under test force ....... 38.6 mm (1.52 inch)
Length under test force ... 56.39 mm (2.220 inch) Test force .......... 262.4 ± 13.1 N (59.00 ± 2.95 lb)
Test Force ....................... 62 ± 3 N (13.9 ± 0.7 lb) Free length after test ...... 52.83 mm (2.080 inch)
Free length after test ...... 88.60 mm (3.488 inch) Outside diameter ............ 32.54 mm (1.281 inch)
Outside diameter ............... 11.02 mm (.434 inch)

(5) 6P-9785 Spring

Color ............................................... yellow stripe
Length under test force ..... 19.48 mm (.767 inch)
Test Force ............... 23.5 ± 1.2 N (5.28 ± 0.27 lb)
Free length after test ...... 32.00 mm (1.260 inch)
Outside diameter .............. 14.83 mm (.584 inch)

(8) 9U-8388 Detent Assembly (four)

(9) 6I-8654 Spring

Length under test force ..... 13.36 mm (.525 inch)
Test Force ........... 36.65 ± 1.83 N (8.24 ± 0.41 lb)
Free length after test ........ 23.78 mm (.936 inch)
8 SENR8324-03
Specifications Section

i01376786 One spacer changes the pressure

approximately: ....................... 293 kPa (42.5 psi)
Priority Valve
(4) 5M-9624 Spacer (two places)
SMCS Code: 3180
Thickness of one spacer ..... 0.25 mm (.010 inch)
Part No.: 132-1231 Outside diameter ..................... 20.62 ± 0.25 mm
(.812 ± .010 inch)
One spacer changes the pressure
approximately: ......................... 81 kPa (11.7 psi)

(5) Torque for plug ............. 75 ± 10 N·m (55 ± 7 lb ft)

(6) Torque for valve body .. 75 ± 10 N·m (55 ± 7 lb ft)

(7) 4M-2381 Spring

Length under test force ......... 12.2 mm (.48 inch)
Test force .............. 2.30 ± 0.18 N (.517 ± .041 lb)
Free length after test ............ 22.6 mm (.89 inch)
Outside diameter ................ 7.62 mm (.300 inch)

(8) Torque for plug ............. 75 ± 10 N·m (55 ± 7 lb ft)

(9) Torque for nipple ....... 14 ± 4 N·m (125 ± 35 lb in)

(10) Torque for plug ........ 14 ± 4 N·m (125 ± 35 lb in)

(11) Torque for two plugs .... 50 ± 7 N·m (37 ± 5 lb ft)

(12) 8E-2749 Spring

Length under test force ........ 79.0 mm (3.11 inch)
Test force .... 364.12 ± 18.20 N (81.93 ± 4.095 lb)
Free length after test .......... 98.9 mm (3.89 inch)
Illustration 6
g00727019 Outside diameter ................ 21.5 mm (.846 inch)

(1) Torque for plug ............. 75 ± 10 N·m (55 ± 7 lb ft) (13) 132-1235 Spring

(2) Torque for plug ............... 50 ± 7 N·m (37 ± 5 lb ft) Length under test force ... 80.14 mm (3.155 inch)
Test force .............. 96.1 ± 4.8 N (21.60 ± 1.08 lb)
(3) 8J-2634 Spring Free length after test ........ 90.98 mm (3.58 inch)
Outside diameter ............ 13.31 mm (0.524 inch)
Length under test force ..... 62.48 mm (2.46 inch)
Test force ...... 114.67 ± 22.74 N (25.77 ± 5.11 lb) (14) 4M-2381 Spring
Free length after test ...... 69.85 mm (2.750 inch)
Outside diameter .............. 20.62 mm (.812 inch) Length under test force ......... 12.2 mm (.48 inch)
Test force .............. 2.30 ± 0.18 N (.517 ± .041 lb)
(4) 5M-9622 Spacer (two places) Free length after test ............ 22.6 mm (.89 inch)
Outside diameter ................ 7.62 mm (.300 inch)
Thickness of one space ...... 1.60 mm (.063 inch)
Outside diameter ..................... 20.62 ± 0.25 mm
(.812 ± .010 inch)
One spacer changes the pressure
approximately: ....................... 505 kPa (73.0 psi)

(4) 5M-9623 Spacer (two places)

Thickness of one spacer ..... 0.90 mm (.035 inch)
Outside diameter ..................... 20.62 ± 0.25 mm
(.812 ± .010 inch)
SENR8324-03 9
Specifications Section

i01373622

Transmission Oil Filter

SMCS Code: 3067
Part No.: 155-5748

g00725133
Illustration 7

Bypass valve setting ......... 262 ± 21 kPa (38 ± 3 psi)

(1) 9M-1986 Spring

Length under test force ......... 25.4 mm (1.0 inch)
Test force ................ 110.8 ± 8.9 N (24.9 ± 2.0 lb)
Free length after test .... 47.2440 mm (1.86 inch)
Outside diameter ................ 12.7 mm (0.50 inch)

(2) 3S-8652 Spring

Length under test force ....... 25.4 mm (1.00 inch)
Test force .......... 153.08 ± 12.46 N (34.4 ± 2.8 lb)
Free length after test ........ 96.52 mm (3.80 inch)
Outside diameter .............. 35.05 mm (1.38 inch)
10 SENR8324-03
Specifications Section

i01373674

Transmission
SMCS Code: 3030; 3155; 3160; 3169; 3190
Part No.: 105-2488

g00545187
Illustration 8

(1) Thickness of five disc assemblies Thickness of one 8P-2051 Plate .... 5.00 ± 0.08 mm
and four plates for the No. 1 clutch (.197 ± .003 inch)
(REVERSE) ............................. 47.95 ± 0.72 mm
(1.888 ± .028 inch) (3) Thickness of three discs and two plates for the
No. 3 clutch .............................. 26.77 ± 0.46 mm
Thickness of one 9P-7390 Disc (1.054 ± .018 inch)
Assembly ............ 5.59 ± 0.08 mm (.220 ± .003 inch)
Thickness of one 6Y-5911 Disc ..... 5.59 ± 0.10 mm
Thickness of one 8P-2051 Plate .... 5.00 ± 0.08 mm (.220 ± .004 inch)
(.197 ± .003 inch)
Thickness of one 6I-8500 Plate .... 5.00 ± 0.08 mm
(2) Thickness of five discs and four plates for the No. (.197 ± .003 inch)
2 clutch (FORWARD) .............. 47.95 ± 0.72 mm
(1.888 ± .028 inch) (4) Thickness of two discs and one plate for the No.
4 clutch ........ 16.18 ± 0.28 mm (.637 ± .011 inch)
Thickness of one 9P-7390 Disc ..... 5.59 ± 0.08 mm
(.220 ± .003 inch) Thickness of one 6Y-5911 Disc ..... 5.59 ± 0.10 mm
(.220 ± .004 inch)
SENR8324-03 11
Specifications Section

Thickness of one 6I-8500 Plate .... 5.00 ± 0.08 mm i01373761

(.197 ± .003 inch)
Transmission Pump
(5) Thickness of four discs and three plates for the
No. 5 clutch .............................. 31.80 ± 0.64 mm SMCS Code: 3066
(1.252 ± .025 inch)
Part No.: 155-3609
Thickness of one 6Y-5912 Disc ..... 4.95 ± 0.10 mm
(.195 ± .004 inch)

Thickness of one 8P-1964 Plate .... 4.00 ± 0.08 mm

(.157 ± .003 inch)

(6), (7) Torque for 10 bolts .. 115 ± 7 N·m (85 ± 5 lb ft)

(8) 4M-9592 Spring

Quantity .......................................................... 20
Length under test force ... 34.93 mm (1.375 inch)
Test force ................ 117 ± 6 N (26.30 ± 1.349 lb)
Free length after test ........ 44.7 mm (1.760 inch)
Outside diameter .............. 14.27 mm (.562 inch)

(9) 3K-2511 Dowel

Quantity ......................................................... ten
Length ........................... 176.23 mm (6.938 inch)
Outside diameter ................. 12.637 ± 0.013 mm
(.4975 ± .0005 inch) Illustration 9
g00565351

(10) Diameter of the shafts for the planetary

gears .. 26.439 ± 0.005 mm (1.0409 ± .0002 inch)

(11) Inside diameter of the planetary

gears ... 34.399 ± .008 mm (1.3543 ± .0003 inch)

(12) Diameter of the shafts for the planetary

gears ... 35.255 ± .006 mm (1.3880 ± .0002 inch)

(13) Inside diameter of the planetary

gears .. 43.221 ± 0.010 mm (1.7016 ± .0004 inch)

(14) 7H-7658 Spring

Quantity ......................................................... ten
Length under test force ..... 105.7 mm (4.16 inch)
Test force .................. 187 ± 15 N (42.0 ± 3.25 lb)
Free length after test ........ 140.5 mm (5.53 inch)
Outside diameter .................. 14.2 mm (.56 inch)

(15) Diameter of the shafts for the planetary

gears .. 33.523 ± 0.005 mm (1.3198 ± .0002 inch)

(16) Inside diameter of the planetary

gears .. 44.666 ± 0.008 mm (1.7585 ± .0003 inch)

g00725227
Illustration 10

Note: The pump must turn freely before assembly to

the case and after assembly to the case.
12 SENR8324-03
Specifications Section

(1) Clearance between gears and cover (section i02195788

C) .......... 0.130 ± 0.043 mm (.0051 ± .0017 inch)
Transmission Mounting
(2) Clearance between new gears and body (section
B2) ........ 0.081 ± 0.021 mm (.0032 ± .0008 inch) SMCS Code: 3030
Part No.: 6T-0009
(3) Clearance between new gears and body (section
B1) ........ 0.094 ± 0.033 mm (.0037 ± .0013 inch)

(4) Clearance between gears and cover (section

A) ........... 0.089 ± 0.028 mm (.0035 ± .0011 inch)

(5) Bore of bearings .................. 31.786 ± 0.008 mm

(1.2514 ± .0003 inch)

(6) Diameter of shafts ............... 31.742 ± 0.005 mm

(1.2497 ± .0002 inch)

Note: Use SAE 10W oil at 49 deg C (120 deg F) for

the bench test.
Table 2

Specifications
Section A B C
Transmission
Torque
Transmission and Torque
Function Converter
Charging Converter
Charging Illustration 11
g01109067
Scavenge
Rotation CCW(1) CCW(1) CCW(1) (1) Torque for four mounting bolts ....... 270 ± 40 N·m
72 L/min 96 L/min 104 L/min (200 ± 30 lb ft)
Output(1)
(19 US gpm) (25 US gpm) (27 US gpm)
(2) 5S-7008 Spring
RPM 1800 1800 1800
2900 kPa 900 kPa 200 kPa Quantity ........................................................ four
Pressure Color code ...................................... yellow stripe
(420 psi) (130 psi) (29 psi)
Length under test force ... 99.21 mm (3.906 inch)
(1) Counterclockwise
(1)
Test force ........................ 70 ± 6 N (15.7 ± 1.3 lb)
Minimum output
Free length after test ......... 211.6 mm (8.33 inch)
Outside diameter ................ 21.8 mm (.859 inch)

(3) Torque for 22 bolts ... 120 ± 20 N·m (89 ± 15 lb ft)

SENR8324-03 13
Specifications Section

i01373985

Bevel and Transfer Gears

SMCS Code: 3011; 3256; 3281
Part No.: 7T-2431

g00673307
Illustration 12

(1) Torque for six bolts ........................ 135 ± 20 N·m (8) Torque for six bolts ........................ 135 ± 20 N·m
(100 ± 15 lb ft) (100 ± 15 lb ft)

(2) Install a bolt of the appropriate size through the (9) As needed, use shims in order to achieve the
case. Tighten the bolt until there is zero end play following backlash between the pinion and the
in the pinion. Position the bevel and transfer gear bevel gear. .... 0.36 ± 0.12 mm (.014 ± .005 inch)
group so that the bevel gear shaft is in the vertical
position with the bevel gear at the bottom. (10) Torque for 12 bolts ....................... 475 ± 60 N·m
(350 ± 45 lb ft)
Install the 9P-1922 Shim Pack at location (3) and
the 9P-1921 Shim Pack at location (15). (11) Torque for four bolts ..................... 270 ± 40 N·m
(200 ± 30 lb ft)
(3), (15) As needed, use the shims in order to
achieve the following end play. .. 0.10 ± 0.05 mm (12) Torque for six bolts ...................... 135 ± 20 N·m
(.004 ± .002 inch) (100 ± 15 lb ft)

(4) Torque for six bolts ........................ 135 ± 20 N·m (13) Coat the seal bore surface in the retainer with
(100 ± 15 lb ft) gasket material and allow the gasket material dry
before you install the lip seal. Do not apply gasket
(5) Torque for 12 bolts .. 270 ± 40 N·m (200 ± 30 lb ft) material to the lip seal case. Apply a light coat of
the lubricant that is being sealed to the sealing lip.
(6) Torque for bolt ........ 270 ± 40 N·m (200 ± 30 lb ft)
NOTICE
(7) Apply 5P-3931 Anti-Seize Compound to the Be sure that the bolt that holds the pinion gear in place
face and threads of the nut. Torque for the (for backlash checks) is removed when adjustments
nut .......................... 612 ± 68 N·m (450 ± 50 lb ft) are complete.
14 SENR8324-03
Specifications Section

(14) Torque for four bolts ... 55 ± 10 N·m (40 ± 7 lb ft) The correct shim pack thickness is determined in
the following manner:
Procedure to Adjust The End Play 8. Add the two measurements from Step 7 and
of The Bevel Pinion Bearings divide by two.

1. Before assembly of the other components, make 9. Add 0.43 mm (0.017 inch) to the result from
sure that the bearing cups and cones are properly Step 8. The total sum is the correct shim pack
installed. The bearing cups and cones must be thickness.
seated against the shoulder of the housing and
the shoulder of the shaft. Use a piece of 0.038 mm 10. Assemble the shim pack to the correct thickness.
(0.0015 inch) thick shim stock or a standard feeler Use a micrometer to verify that the shim pack is
gauge in order to verify that the bearing cups and the correct thickness.
cones are properly seated.
The desired end play for the bevel pinion is
2. Place the axis of the gear or shaft in a vertical 0.10 ± 0.05 mm (0.004 ± 0.002 inch).
position. Install bearing cage without installing
shims (3) and without installing the O-ring seal (if 11. Remove the cage for the bearing cup.
equipped). Make sure that the cage does not bind Reassemble the components with the correct shim
in the housing. pack and the correct O-ring seal (if equipped).
Tighten the bolts to a torque of 270 ± 40 N·m
3. Install two bolts and two washers with (200 ± 30 lb ft).
approximately 180 degrees between the bolts.
12. Check the end play with a dial indicator.
4. Alternately tighten two bolts on each cap to
13.5 N·m (120 lb in) in 4.5 N·m (40 lb in)
increments.
Procedure to Adjust The End
Play of The Lower Transfer Gear
5. Loosen all of the bolts and then finger tighten the
bolts.
Bearings
1. Before assembly of the other components, make
6. Use the following steps to tighten the bolts :
sure that the bearing cups and cones are properly
installed. The bearing cups and cones must be
Use a 9S-7354 Torque Wrench or the equivalent. seated against the shoulder of the housing and
the shoulder of the shaft. Use a piece of 0.038 mm
a. Tighten the bolts to a torque of 4.5 N·m
(0.0015 inch) thick shim stock or a standard feeler
(40 lb in). gauge in order to verify that the bearing cups and
cones are properly seated.
b. Rotate the gear or the shaft at least three
revolutions. 2. Place the axis of the gear or shaft in a vertical
position. Install bearing cage without installing
c. Tighten the bolts to a torque of 9.0 N·m
shims (15) and without installing the O-ring Seal
(80 lb in). (if equipped). Make sure that the cage does not
bind in the housing.
d. Rotate the gear or the shaft at least three
revolutions. 3. Install two bolts and two washers with
approximately 180 degrees between the bolts.
e. Tighten the bolts again to a torque of 9.0 N·m
(80 lb in). 4. Alternately tighten two bolts on each cap to
13.5 N·m (120 lb in) in 4.5 N·m (40 lb in)
7. Use a tapered feeler gauge or another suitable
increments.
device for measuring . Measure the first gap
between the bearing cage and the housing.
5. Loosen all of the bolts and then finger tighten the
Measure the gap outward from the center of the
bolts.
bolt at the OD of the flange. Measure the second
gap near the other bolt in the same manner. The
6. Use the following steps to tighten the bolts :
two measurements should be within 0.25 mm
(0.010 inch) of each other in order to ensure that Use a 9S-7354 Torque Wrench or the equivalent.
the caps are level.
SENR8324-03 15
Specifications Section

a. Tighten the bolts to a torque of 4.5 N·m i01051006

(40 lb in).
Drive Shaft
b. Rotate the gear or the shaft at least three
revolutions. SMCS Code: 3253
Part No.: 3T-4457
c. Tighten the bolts to a torque of 9.0 N·m
(80 lb in).

d. Rotate the gear or the shaft at least three

revolutions.

e. Tighten the bolts again to a torque of 9.0 N·m

(80 lb in).

7. Use a tapered feeler gauge or another suitable

device for measuring . Measure the first gap
between the bearing cage and the housing.
Measure the gap outward from the center of the
bolt at the OD of the flange. Measure the second
gap near the other bolt in the same manner. The
two measurements should be within 0.25 mm Illustration 13
g00545672
(0.010 inch) of each other in order to ensure that
the caps are level. (1) Torque for eight bolts that hold the bearing to the
flange ..................... 135 ± 15 N·m (100 ± 11 lb ft)
The correct shim pack thickness is determined in
the following manner: (2) Torque for eight bolts that hold the bearing to the
yokes ..................... 135 ± 15 N·m (100 ± 11 lb ft)
8. Add the two measurements from Step 7 and
divide by two.

9. Add 0.36 mm (0.014 inch) to the result from

Step 8. The total sum is the correct shim pack
thickness.

10. Assemble the shim pack to the correct thickness.

Use a micrometer to verify that the shim pack is
the correct thickness.

The desired end play is 0.10 ± 0.05 mm

(0.004 ± 0.002 inch).

11. Remove the cage for the bearing cup.

Reassemble the components with the correct shim
pack and the correct O-ring seal (if equipped).
Tighten the bolts to a torque of 270 ± 40 N·m
(200 ± 30 lb ft).

12. Check the end play with a dial indicator.

16 SENR8324-03
Specifications Section

i01373578 Outside diameter ................ 15.0 mm (0.59 inch)

Brake Control Valve (3) Torque for adapter and nipple ............ 37 ± 7 N·m
(27 ± 5 lb ft)
SMCS Code: 4265; 4269
(4) Torque for two plugs .... 75 ± 10 N·m (55 ± 7 lb ft)
Part No.: 172-1240
(5) Torque for plug ............... 37 ± 7 N·m (27 ± 5 lb ft)

(6) 6Y-7264 Spacer

Thickness of one spacer ..... 0.1 mm (.0039 inch)
Outside diameter ..................... 15.50 ± 0.25 mm
(.610 ± .0098 inch)

(6) 6Y-7265 Spacer

Thickness of one spacer ... 0.25 mm (.0098 inch)
Outside diameter ..................... 15.50 ± 0.25 mm
(.610 ± .0098 inch)

(6) 6Y-7266 Spacer

Thickness of one spacer ..... 0.5 mm (.0196 inch)
Outside diameter ..................... 15.50 ± 0.25 mm
(.610 ± .0098 inch)

g00544950
Illustration 14

(1) 4M-2381 Spring

Length under test force ......... 12.2 mm (.48 inch)
Test force .............. 2.30 ± 0.18 N (.517 ± .041 lb)
Free length after test ............ 22.6 mm (.89 inch)
Outside diameter ................ 7.62 mm (.300 inch)

(2) 8E-2715 Spring

Length under test force ....... 41.0 mm (1.61 inch)
Test force .......... 205.3 ± 10.3 N (46.15 ± 2.32 lb)
Free length after test ...... 53.04 mm (2.088 inch)
SENR8324-03 17
Specifications Section

i01061122

Steering and Transmission

Control Group
SMCS Code: 3033
Part No.: 6Y-3590

g00551731
Illustration 15

Torque for all 1/4 inch locknuts on cable assembly (16) Dimension ............... 12 ± 2 mm (.47 ± .08 inch)
that hold the rod ends in place ................... 6 ± 1 N·m
(53 ± 9 lb in) (17) Dimension ............... 12 ± 2 mm (.47 ± .08 inch)

Torque for all 5/8 inch locknuts that fasten the cable
assemblies to covers (17) and (20) ......... 38 ± 7 N·m
(28 ± 5 lb ft)

Torque for all 3/8 inch locknuts that hold the rod ends
in place on rods ................... 25 ± 6 N·m (18 ± 4 lb ft)

Note: All rod assembly measurements must be made

in a straight line between the centerlines of the rod
end mounting holes.

(1) Consult the Steering and Transmission Hand

Control Group for adjustment procedures.

(2) Length to assemble rod. ...... 450 mm (17.7 inch)

(6) Torque for two bolts (if present) ......... 25 ± 6 N·m

(18 ± 4 lb ft)

(9) Dimension ........... 15.0 ± 1.5 mm (.59 ± .06 inch)

18 SENR8324-03
Specifications Section

g00551619
Illustration 17

Speed Control Assembly Procedure

1. Assemble cable (12) to the dimensions shown in
View B-B.

2. At the transmission, move the transmission speed

selector spool to the SECOND GEAR position
(middle detent).

3. Turn handle (5) to the SECOND GEAR position

(white mark on handle aligned with the number
g00551615
Illustration 16 2 on speed collar).

Forward/Reverse Assembly Procedure 4. Adjust cable (12) to allow free fit of pin assembly
(18) into the transmission bellcrank. To adjust the
1. Engage the parking brake. cable, remove bolts that hold cover (15) to the
housing. Loosen the locknut on cable (12) and
2. Move the spool of the transmission direction turn cover (15) as necessary.
selector into the NEUTRAL position.
Parking Brake Adjustment Procedure
3. Assemble cable (13) to the dimensions shown in
View B-B. 1. Engage the parking brake.

4. Adjust cable (13) in order to allow free fit of pin 2. Assemble rod end (10) to rod (7) to the dimension
assembly (19) into the transmission bellcrank. To shown in View A-A.
adjust the cable, remove the bolts that hold cover
(14) to the housing. Loosen the locknut on cable 3. Assemble rod end (10) to bellcrank (11).
(13). Turn cover (14), as necessary.
4. Pull the parking brake valve spool (4) out against
the stop.

5. Assemble rod (2) to the specified dimension.

Assemble rod end (8) to bellcrank (11).

6. Adjust rod end (3) to allow free fit of the pin into
parking brake valve spool (4).
SENR8324-03 19
Specifications Section

i01374051

Hand Control Group

SMCS Code: 3030
Part No.: 6Y-3589

g00725401
Illustration 18

Torque for all 1/4 inch locknuts (jam nuts) on Torque for all 5/8 inch locknuts (jam nuts) on the
cable assemblies that hold the rod ends in cable assemblies ................. 38 ± 7 N·m (28 ± 5 lb ft)
place ..................................... 6 ± 1 N·m (53 ± 9 lb in)
(1) Apply 4C-4030 Thread Lock Compound to the
Torque for the 3/8 inch locknut (jam nut) that threads on the parking brake lever.
holds the swivel rod end in place on the center
rod ........................................ 25 ± 6 N·m (18 ± 4 lb ft) (2) Apply lubriplate to the inside of handle.
20 SENR8324-03
Specifications Section

(4) Dimension (two places) ............... 15.0 ± 2.0 mm

(.60 ± .08 inch)

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

(6 ± 1 lb ft)

(5) Dimension (two places) ............... 16.0 ± 2.0 mm

(.63 ± .08 inch)

(6) Torque for rod end ............. 8 ± 2 N·m (6 ± 1 lb ft)

(7) Torque for nut .................... 8 ± 2 N·m (6 ± 1 lb ft)

(10) Torque for screws that fasten the neutral start

switch to the plate ...................... 0.50 ± 0.05 N·m
(4.425 ± .442 lb in)

Attach the No. 306 green wire to the wire terminal

post of the switch assembly that is marked “COM”.
Attach the No. 307 orange wire to the post that is
marked “NO”.

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

Compound ......................... 8 ± 2 N·m (6 ± 1 lb ft)

Apply lubriplate to the rod assembly.

(12) The lip of the seal should face downward when

the seal is installed.

(13) 6Y-2846 Spring

Length under test force ... 74.64 mm (2.939 inch)
Test force .................................. 626 N (140.8 lb)
Free Length after test ..... 79.92 mm (3.146 inch)
Outside diameter ..................... 20 mm (.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 (.544 inch)

(15) Torque for screws that fasten the backup switch

to the plate .. 0.50 ± 0.05 N·m (4.425 ± .442 lb in)

Attach the No. 321 brown wire to the wire terminal

post of the switch assembly that is marked “COM”.
Attach the No. 200 blackwire number 200 to the post
that is marked “NO”.

(23) Apply lubriplate to the rod assembly.

(24) Apply 4C-4030 Thread Lock Compound to

threads on rod assembly.

(25) Dimension ......... 16.0 ± 2.0 mm (.63 ± .08 inch)

(28) Drive the bearing (both ends of shaft) on the

stamped end only.
SENR8324-03 21
Specifications Section

g00725402
Illustration 19
(1A) Brake ENGAGED position
(1B) Brake DISENGAGED position

(28) Torque for four screws .. 6 ± 1 N·m (53 ± 9 lb in) (32) Drive the bearing on the stamped end only.

(29) Torque for three screws ............. 1.7 ± 0.25 N·m (33) Torque for nut .............. 25 ± 6 N·m (18 ± 4 lb ft)
(15.04 ± 2.21 lb in)
(34) Install the bearing to the following
(30) Install the bearing to the following depth. .................... 1.5 ± 1.0 mm (.06 ± .04 inch)
depth. .................... 4.5 ± 1.0 mm (.18 ± .04 inch)
(35) Use the necessary washers on the end of
(31) Apply 4C-4030 Thread Lock Compound to the the shaft in order to achieve the following
shaft. dimension. ........ 0.10 ± 2.0 mm (.004 ± .08 inch)
22 SENR8324-03
Specifications Section

(36) Torque for the bolt that tightens the Backup Alarm (Adjustment
collar ............... 1.7 ± 0.2 N·m (15.04 ± 1.77 lb in)
Procedure)
(40) Torque for two screws .................. 0.8 ± 0.1 N·m
1. Engage the parking brake ( (1A) position).
(7.08 ± .88 lb in)
Disengage the parking brake ( (1B) position).
Rotate handle (2) counterclockwise by 15 degrees
Speed Control (Adjustment toward the reverse.
Procedure) Check for continuity through switch (15).
1. Rotate collar (39) until the number “2” is 30 ± 1
degrees counterclockwise from vertical. View the 2. In order to adjust the position of switch (15),
position from the end of handle (2). remove three screws (38) and remove cover
assembly (37).
Torque for the bolt that holds collar (36) in
place ................ 1.7 ± 0.2 N·m (15.04 ± 1.77 lb in) 3. Loosen the screws for the switch. Slide switch
(15) to the correct position and tighten screws.
2. Remove plate (27). Rotate lever (9) until the lever
is parallel with the top of housing (8). Recheck continuity, as shown. See Step 1.
Readjust switch (15), if necessary.
3. Install handle assembly (3) with the white mark in
line with the number “2” on collar (36). 4. Install cover assembly (37) and three screws (38).

Forward/Reverse Adjustment Steering Control Assembly and

Procedure Adjustment Procedure
1. Rotate ring (39) so that screw (38) is in the center Note: Before you install the valve hoses do the
of the slot. following procedure:

(40) torque for two screws .............. 0.8 ± 0.1 N·m 1. Install plate assembly (20) to housing (22) and
(7.08 ± .88 lb in) tighten bolts (21).

2. With parking brake lever (1) in the ENGAGED (1A) 2. Install valve group (19) to plate assembly (20).
position, rotate handle (2) until the white mark on Assemble bolts (18) finger tight.
the handle lines up with “N” (neutral) on ring (39).
3. Move parking brake lever (1) to the ENGAGED
(29) Torque for three screws ......... 1.7 ± 0.25 N·m (1A) position.
(15.04 ± 2.21 lb in)
4. Install a pin 3.0 mm (.12 inch) in diameter to the
timing hole in lever (17) and in the hole in housing
Parking Brake Lever and Neutral (16).
Start Switch (Adjustment
5. Tighten bolts (18) and remove the pin from lever
Procedure) (17) and housing (16).
1. With parking brake lever (1) in the ENGAGED
(1A) position, loosen the screw for parking brake
lever (1) and remove the lever.

2. Install parking brake lever (1) on splined shaft (26)

so that the hole in lever (1) is in line with the hole
in plate (27).

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

If there is no continuity, adjust the position of
switch (10).
SENR8324-03 23
Specifications Section

i01061181

Foot Brake Control

SMCS Code: 4269-FU
Part No.: 6Y-3516

g00551739
Illustration 20

(C) Assembled length of rod assembly ....... 935 mm

(36.8 inch)

(D) Maximum .............................. 41 mm (1.61 inch)

(E) Minimum ................................ 37 mm (1.46 inch)

(1) Torque for 14 bolts ......... 47 ± 4 N·m (35 ± 3 lb ft)

(2) Torque for bolt ........ 135 ± 20 N·m (100 ± 15 lb ft)

(3) Torque for bolts .............. 45 ± 7 N·m (33 ± 5 lb ft)

Brake Pedal Linkage Adjustment

Illustration 21
g00551761 Procedure
Torque for all 1/2 inch locknuts (jam nuts) and 1. Install adjusted rod assemblies (B) and (C).
studs that hold the rod ends in place on the
rod ...................................... 60 ± 12 N·m (45 ± 9 lb ft) 2. Adjust the head end of bolt (6) away from the
support until spring (4) has extended (stretched)
Note: All rod assembly measurements must be made 3 ± 1 mm (.12 ± .04 inch). Bolt (6) is the upper
in a straight line between the centerlines of the rod stop for the brake pedal.
end mounting holes.

(B) Assembled length of rod

assembly ...... 410.0 ± 1.5 mm (16.14 ± .06 inch)
24 SENR8324-03
Specifications Section

3. Hold the brake pedal against the upper stop. Push i01061236
the brake spool all the way into the valve. Then
adjust the rod end so that the pin which connects Brake and Planetary
the rod end to the valve spool has a free fit.
SMCS Code: 4132
4. Push the brake pedal down until the valve spool
Part No.: 6Y-3588
stops.

5. Adjust bolt (5) until the head contacts the brake

pedal.

6. Release the brake pedal. Turn bolt (5) an

additional 1/2 turn out. Tighten the locknut.

g00551787
Illustration 22

(1) Thickness of four new disc assemblies and three

new plates .. 28.34 ± 0.96 mm (1.116 ± .038 inch)

Thickness of one new 6Y-9373 Friction Disc

Assembly ............ 4.70 ± 0.18 mm (.185 ± .007 inch)

Thickness of one new 7T-6994

Plate ............ 3.175 ± 0.075 mm (.1250 ± .0030 inch)

(2) Torque for 12 bolts .. 135 ± 20 N·m (100 ± 15 lb ft)

SENR8324-03 25
Specifications Section

(3) Diameter of new shafts for planetary i01062165

gears .. 42.395 ± 0.008 mm (1.6691 ± .0003 inch)
Differential Drive and Brake
(4) Inside diameter of new planetary Group
gears .. 51.948 ± 0.010 mm (2.0452 ± .0004 inch)
SMCS Code: 4131
Apply 6V-6640 RTV Silicone Sealant to the flange
of the slinger in the area that makes contact with Part No.: 6Y-3587
the carrier.

g00551791
Illustration 23
Belleville spring position during installation.

g00552226
Illustration 24

(1) Thickness of four new disc assemblies and three

new plates for brake ................ 28.34 ± 0.96 mm
(1.116 ± .038 inch)

Thickness of one new 6Y-9373 Friction Disc

Assembly ............ 4.70 ± 0.18 mm (.185 ± .007 inch)

Thickness of one new 7T-6994

Plate .................... 3.18 ± 0.08 mm (.125 ± .003 inch)

(2) Apply 5P-3413 Pipe Sealant to four plugs before

installing.

(3) Use shims in order to obtain the following

backlash between the bevel gear and the pinion
shaft. ..... 0.210 ± 0.075 mm (.0083 ± .0030 inch)

(4) Tighten the nut until the rolling torque needed to

rotate pinion shaft is as follows ... 0.3 to 1.35 N·m
(3 to 12 lb in)

Bend the tab on the lock washer into the slot in the
nut.
26 SENR8324-03
Specifications Section

Note: Tighten the nut before the bevel gear is i02188299

installed.
Final Drive
(6) Apply 6V-6640 RTV Silicone Sealant to the
flange of the slinger in the area that it makes SMCS Code: 4003; 4050; 4059; 4084
contact with the carrier.
Part No.: 157-5072
(7) Inside diameter of new planetary
gears .. 58.298 ± 0.010 mm (2.2952 ± .0004 inch)

(8) Diameter of new shafts for planetary

gears .. 42.395 ± 0.008 mm (1.6691 ± .0003 inch)

(9) Diameter of new shafts for planetary

gears .. 42.395 ± 0.008 mm (1.6691 ± .0003 inch)

(10) Inside diameter of new planetary

gears .. 51.948 ± 0.010 mm (2.0452 ± .0004 inch)

(11) Make sure that the three washers are equally

spaced.

(14) Torque for three bolts ..................... 50 ± 10 N·m

(37 ± 7 lb ft)

Housing (13) Bearing Preload

Procedure
1. Install the rotating housing (13) with bearings into
the brake housing.

2. Install plate (12) with three equally spaced bolts.

3. Tighten the bolts until the rolling torque needed to Illustration 26

g00550389
rotate housing (13) is 2.25 to 4 N·m (20 to 35 lb in)
(1) Rubber toric seals must be clean and dry at
4. Measure the gap between plate (12) and housing assembly. All surfaces that contact toric seals
(13). Install shims (5) equal to the measured gap. must be clean and dry at assembly. Apply a thin
film of oil to the contacting surfaces of the metal
5. Recheck rotating torque. seal rings before you assemble the rings. The
seal rings must be assembled square with the
bore. The rings must be assembled square with
the bore. The rings must be square with the toric
seal. The rings must not bulge. The rings must
not be twisted. Put lubricant on all other seals at
assembly.

(2) Torque for bolts ............ 50 ± 10 N·m (37 ± 7 lb ft)

(3) Torque for bolts ...... 135 ± 20 N·m (100 ± 15 lb ft)

Note: Make sure that there is metal to metal contact

between the retainer and the hub before the bolts
are tightened.
g00552140
Illustration 25
(4) Torque for bolts ...... 430 ± 60 N·m (318 ± 45 lb ft)
Belleville Spring position for installation.
(5) Torque for bolts ............ 50 ± 10 N·m (37 ± 7 lb ft)
SENR8324-03 27
Specifications Section

Note: Make sure that there is metal to metal contact

between the plate and the shaft before the bolts are
tightened. Then make sure that the plate is flush with
the carrier. Make sure that the gears can be rotated
by hand. If the gears can not be rotated by hand,
guide the covers toward the carrier with the proper
tooling.

(6) Torque for plug ........... 105 ± 10 N·m (78 ± 7 lb ft)

(7) Torque for the sprocket bolts:

Put SAE 30W oil on the treads. Tighten the bolts
to the following torque. .................. 300 ± 50 N·m
(220 ± 37 lb ft)
Then rotate the bolts for the following additional
degrees. .......................................... 120 degrees
Minimum torque after turn .... 570 N·m (420 lb ft)

(8) Torque for bolts ...... 800 ± 90 N·m (590 ± 66 lb ft)

i01374351

Equalizer Bar
SMCS Code: 7206; 7207
Part No.: 127-8779

g00725653
Illustration 27
28 SENR8324-03
Specifications Section

(1) Use 90W gear oil to fill the end pin joints through
the fitting. Add oil until the oil covers the hex on
the fitting.

(2) Torque for four bolts ................... 1600 ± 200 N·m

(1180 ± 150 lb ft)

(3) Install the equalizer bar with the word “FRONT”

toward the front of the machine.

(4) Apply 4C-4032 Bearing Mount Compound to the

threads of the plugs. Install the plugs below the
surface of the face of the equalizer bar.

(5) Apply a light coating of the oil that is being sealed

to the inside diameter of the seal before installing
the pin.

(6) Install the pin even with the roller frame at the
rear.

(7) Apply 5P-3931 Anti-Seize Compound to the front

bore of the equalizer bar saddle. Apply 5P-3931
Anti-Seize Compound to the rear surface of pin
before installation. The pin should be flush on
the back side of the equalizer bar saddle. Do not
apply Anti-Seize Compound in the bearing area.

i01377000

Recoil Group
SMCS Code: 4151; 4157; 4158
Part No.: 101-4193

g00727126
Illustration 28

(1) Torque for two valves ..... 34 ± 7 N·m (25 ± 5 lb ft) (2), (3) Lubricate these parts with SAE 30W oil prior
to assembly.
SENR8324-03 29
Specifications Section

(4) Turn retainer nut (5) so that the retainer nut Note: Rubber toric seals must be clean and dry at
is below front roller frame (4). The following assembly. All surfaces that contact the toric seals
dimension (6) should be obtained: must be clean and dry at assembly. At assembly,
apply a thin film of oil to the contacting surfaces of the
(6) Dimension ............. 2.0 ± 1.5 mm (.08 ± .06 inch) metal seal. Seal rings must be assembled squarely
with the bore. The toric ring must not bulge and the
toric ring must not be twisted.
i02765769

Track Rollers Roller Placement

SMCS Code: 4180 Suspended Undercarriage, Sealed and
Part No.: 9W-8705, 9W-8706 Lubricated Track (SALT)
Start at the front of the machine:
Single Flange and Double Flange
No. 1 track roller is a single flange. 246-0775

No. 2 track roller is a single flange. 246-0775

No. 3 track roller is a double flange. 246-0779

No. 4 track roller is a double flange. 246-0779

No. 5 track roller is a double flange. 246-0779

No. 6 track roller is a double flange. 246-0779

No. 7 track roller is a single flange. 246-0775

No. 8 track roller is a single flange. 246-0775

Non-Suspended (Hardbottom)
Undercarriage Sealed and Lubricated
Track (SALT)

Illustration 29
g01364855 Start at the front of the machine:

End play (clearance) of the roller shaft: No. 1 track roller is a double flange. 246-0779

Minimum ........................... 0.26 mm (0.010 inch) No. 2 track roller is a double flange. 246-0779
Maximum .......................... 1.26 mm (0.050 inch) No. 3 track roller is a double flange. 246-0779
(1) Diameter of double flange roller tread .. 241.0 mm No. 4 track roller is a double flange. 246-0779
(9.48 inch)
No. 5 track roller is a double flange. 246-0779
(1) Diameter of single flange roller tread .. 247.0 mm
(9.72 inch) No. 6 track roller is a double flange. 246-0779
(2) Torque for 12 bolts .. 135 ± 20 N·m (100 ± 15 lb ft) No. 7 track roller is a double flange. 246-0779
(3) Protrusion of the plug from the No. 8 track roller is a double flange. 246-0779
stopper ....................... 0 to 5 mm (0 to 0.20 inch)

Note: The plug must NOT be recessed below the

surface of the stopper after the roller is assembled.

(4) Torque for bolts that hold the rollers to the

bogies .................... 750 ± 70 N·m (553 ± 51 lb ft)

(5) Bearing depth ..... 19.0 ± 0.5 mm (.75 ± .02 inch)

30 SENR8324-03
Specifications Section

Non-Suspended Undercarriage Sealed

and Lubricated Track (SALT)
Table 3
Prime Attachments
Machine Part Number Description
206-6783 Track-Type Tractor D8T
Standard Arrangement. Includes
Suspension-type Undercarriage and
8 roller tubular track roller frames,
carrier roller ready

D8T 192-2599 Carrier Rollers for use with

Suspension-type Undercarriage
209-3418 Non-Suspended Undercarriage that
does not include carrier rollers
209-3419 Non-Suspended Undercarriage that
includes carrier rollers
103-0127 Track-Type Tractor D8R
Standard Arrangement. Includes
Suspension-type Undercarriage and
8 roller tubular track roller frames,
carrier roller ready

D8R 192-2599 Carrier Rollers for use with

Suspension-type Undercarriage
209-3418 Non-Suspended Undercarriage that
does not include carrier rollers
209-3419 Non-Suspended Undercarriage that
includes carrier rollers
SENR8324-03 31
Specifications Section

i02425203 Note: Rubber toric seals must be clean and dry at

assembly. All surfaces that contact the toric seals
Idlers (Track) must be clean and dry at assembly. At assembly,
apply a thin film of oil to the contacting surfaces of the
SMCS Code: 4159 metal seal. Seal rings must be assembled squarely
with the bore. The toric ring must not bulge and the
Part No.: 111-1729, 111-1730
toric ring must not be twisted.

(6) Torque for bolts .......... 85 ± 15 N·m (65 ± 11 lb ft)

(7) Torque for bolts that hold the idler to the track
roller frame .... 1600 ± 200 N·m (1180 ± 150 lb ft)

i01063605

Tracks
SMCS Code: 4170
Part No.: 8E-7696, 8E-7697, 8E-7698, 8E-7699

Specifications

g01212163
Illustration 30

End play (clearance) of the idler shaft

g00553339
Illustration 31
Minimum ........................... 0.33 mm (0.013 inch)
Maximum .......................... 1.19 mm (0.047 inch) For instructions on reusability, refer to Guideline For
Reusable Parts, SEBU8022, “Sealed And Lubricated
(1) Depth of the stopper below the Track”.
chamfer ............... 7 ± 7 mm (0.275 ± 0.275 inch)
Maximum track press assembly force ........... 660 kN
(2) Dimension of the plug above the surface of the (148,500 lb)
stopper ..................... 0 to 5 mm (0 to 0.197 inch)
(1) Torque for bolts (1) that hold the half links
Note: The plug must NOT be recessed below the together ................. 650 ± 70 N·m (480 ± 50 lb ft)
surface of the stopper after assembly.
Note: Tighten the bolts by an additional 120 degree
(3) Bearing depth from the end of the turn.
idler ..................... 13.0 ± 0.5 mm (.51 ± .02 inch)
Note: Apply 2P-2506 Thread Compound to the
(4) Extension of the shaft on both sides of the threads, to the body, and to the washer face of each
idler ......... 61.92 ± 0.13 mm (2.438 ± 0.005 inch) bolt that holds the half links together.

(5) Rubber toric seals (2) Torque for bolts (2) that hold track shoes to
links ....................... 650 ± 70 N·m (480 ± 50 lb ft)

Note: Apply SAE 30W oil to the bolt threads and the
washer faces of each bolt before installation.
32 SENR8324-03
Specifications Section

Note: Tighten the bolts by an additional 120 degree Minimum diameter of the bushing before the
turn. bushing is turned:
Operations under little shock loads or no shock
(3) Grouser Height loads ................................... 71.4 mm (2.81 inch)
New grouser height (extreme service) .. 71.5 mm Operations under average shock loads or heavy
(2.81 inch) shock loads ......................... 73.9 mm (2.91 inch)

Minimum Grouser Heights (9) Maximum permissible end clearance (end

Operations under little shock loads or no shock play) .................................... 0.20 mm (.008 inch)
loads ................................... 25.5 mm (1.00 inch)
(10) Extension of pin for each side of link
Operations under average shock loads or heavy
shock loads ......................... 38.0 mm (1.50 inch) ............................... 2.9 ± 0.8 mm (.11 ± .03 inch)

(4) Link Height Check and Adjust the Track

Height of an unused link ........ 150.00 ± 0.25 mm
(5.906 ± 0.010 inch)
Minimum Link Heights
Operations under little shock loads or no shock
loads ............................. 134.00 mm (5.276 inch)
Operations under average shock loads or heavy
shock loads ................... 138.00 mm (5.433 inch)

(5) Distance from the center of one pin to the center

of the next pin (pitch) ............. 215.90 ± 0.13 mm
(8.500 ± .005 inch)

g00479439
Illustration 33

Check the track adjustment. Check the track for wear

and for excessive dirt buildup.

Grease is under high pressure.

Grease coming out of the relief valve under pres-

sure can penetrate the body causing injury or
death.

Do not watch the relief valve to see if grease is es-

caping. Watch the track or track adjustment cylin-
der to see if the track is being loosened.

Loosen the relief valve only one turn.

g00561478
Illustration 32
Move the machine forward. Allow the machine to
(6) Thickness of an unused thrust ring coast to a stop without the use of the service brakes.
.................... 10.70 ± 0.08 mm (.421 ± .003 inch) Adjust the tracks while you are in the machine’s
typical operating conditions. If packing conditions
(7) Distance from the face of the link to the end of prevail on the workplace, the tracks should be
the bushing ... 1.76 ± 0.13 mm (.069 ± .005 inch) adjusted with packing material.

(8) Bushings
Diameter of an unused
bushing ..... 81.65 ± 0.25 mm (3.215 ± .010 inch)
SENR8324-03 33
Specifications Section

Loose Track Adjustment

g00040329
Illustration 34
g00040335
Illustration 36
To measure the sag in the track, stretch a string over
the grousers that are between the sprocket and the
NOTICE
front idler. Take the measurement from the string to
Do not attempt to tighten track when dimension (1) is
the top of the grouser at the maximum measurement.
142 mm (5.60 inch) or more. Contact your Caterpillar
Dimension (2) is the maximum distance between the
dealer for track service or instructions.
string and the grouser.

If a machine does not have carrier rollers, the sag in 1. Remove the access cover.
the track is measured between the sprocket and the
front idler. The correct adjustment of dimension (2) is
115 ± 10 mm (4.5 ± .40 inch).

g00104001
Illustration 37

2. Add multipurpose grease (MPGM) through

Illustration 35
g00104000 track adjustment valve (5). Add the MPGM until
dimension (2) is correct.
If the machine is equipped with a carrier roller, the
correct adjustment of dimension (3) and dimension 3. Operate the machine back and forth in order to
(4) is 65 ± 10 mm (2.6 ± .4 inch). equalize the pressure. Allow the machine to coast
to a complete stop. Do not use the brakes.

4. Remeasure dimension (2).

34 SENR8324-03
Specifications Section

Tight Track Adjustment i01067663

Fender
SMCS Code: 7252
Part No.: 9N-4205

g00104002
Illustration 38

1. Loosen relief valve (6) by one turn of 360 degrees.

Allow the grease to escape.

2. Close the relief valve.

3. Add MPGM through track adjustment valve (5).

Add grease until dimension (2) is correct.

4. Install the access cover.

Bolt Torque for Track Shoes

The torque requirement for track shoe bolts is
650 ± 70 N·m (480 ± 50 lb ft). Tighten the bolts for
an additional 120 degrees. If you are using bolts
with a master link, tighten the bolts to a torque of
650 ± 70 N·m (480 ± 50 lb ft). Then, tighten the bolts Illustration 39
g00556518

for an additional 120 degrees.

(1) Torque for six bolts ........................ 240 ± 40 N·m
(177 ± 30 lb ft)

(2) Torque for eight bolts ..................... 240 ± 40 N·m

(177 ± 30 lb ft)

(3) Torque for eight bolts ..................... 240 ± 40 N·m

(177 ± 30 lb ft)

(4) Torque for eight bolts ..................... 430 ± 60 N·m

(317 ± 44 lb ft)
SENR8324-03 35
Specifications Section

i01059320 (2) Torque for two bolts .. 136 ± 10 N·m (100 ± 7 lb ft)
Rollover Protective Structure (3) Torque for twelve bolts that hold the ROPS to the
(ROPS) supports ............... 900 ± 100 N·m (660 ± 75 lb ft)

SMCS Code: 7122; 7264; 7266; 7323; 7325 i02194061

Part No.: 113-4260, 118-5244 Drawbar

SMCS Code: 7105; 7119
Part No.: 7T-2512

g00551232
Illustration 40

Note: Mating surfaces must be clean and free of

paint before installation.
g00556544
Illustration 42
(1) Torque for 20 bolts that hold the supports to the
case ............... 1800 ± 200 N·m (1320 ± 150 lb ft) (1) Torque for eight mounting studs .. 1800 ± 200 N·m
(1330 ± 150 lb ft)

g00551261
Illustration 41

Note: Mating surfaces must be clean and free of

paint before installation.
36 SENR8324-03
Specifications Section

i01062515

Frame Group
SMCS Code: 7050
Part No.: 119-6057

g00552246
Illustration 43

g00552254
Illustration 45

(1) Torque for bolts that hold the

guide ...................... 475 ± 50 N·m (350 ± 37 lb ft)

(2) Put 6V-1541 Quick Cure Primer on retainers,

g00552334 seals and frame assembly. Permit the Primer to
Illustration 44
dry. Apply 7M-7456 Compound on the retainer
bore. Apply the same compound to the outside
diameter of sleeve and frame assembly bore
before seal installation.

(3) Torque for bolts that hold the idler to

bogie .............. 1850 ± 150 N·m (1360 ± 110 lb ft)

(4) Torque for bolts that hold the rollers to the

bogies .................... 750 ± 70 N·m (550 ± 50 lb ft)
SENR8324-03 37
Specifications Section

(5) Install the plate.

(6) Install the plug after assembly of plate (5).

(7) Torque for bolts in plate ................. 270 ± 40 N·m

(200 ± 30 lb ft)

(8) Install the plugs into the retainer. See view C-C
for the position of the retainer and plugs.

Note: Both retainers have notches in order to align

retainers.

Procedure to Fill the Pivot Shaft with Oil

1. Remove the plug (1) from both roller frames.
The hose from the pivot shaft oil bottle must be
connected to the cross-tube.

2. Fill the pivot shaft bearing compartments with

SAE 30W oil. The oil level is at the bottom of the
filler hole.

3. Fill the center oil compartment of the pivot shaft

through the pivot shaft oil bottle. Fill with oil to
capacity of compartment.

4. Install plugs (1).

5. Check the oil level in the pivot shaft oil bottle

again. If necessary, add more oil.

6. The oil level should be checked and maintained

daily.

i02189569

Bogie Suspension
SMCS Code: 7217
Part No.: 7T-2540

g01106904
Illustration 46
38 SENR8324-03
Specifications Section

i02194065

Sweep Group
SMCS Code: 7162
Part No.: 111-3264

g00553103
Illustration 47

(1) Assemble the minor bogie with words “This Side

Out” toward the outside of the major bogies.

(2) Apply 2P-2506 Thread Compound to cartridge

pin bores before installing the cartridge pins. g00556967
Illustration 48

(3) Torque for the bolts that hold the

(1) Torque for two bolts ....................... 430 ± 60 N·m
guide ...................... 475 ± 50 N·m (350 ± 37 lb ft)
(317 ± 44 lb ft)
Note: The end of the cartridge pin with a larger hole
(2) Torque for two bolts ....................... 430 ± 60 N·m
must be installed next to the cap. This end may be
(317 ± 44 lb ft)
marked with an “X”. The hole or “X” mark must be on
top of the vertical centerline or on the bottom of the
(3) Torque for two locknuts ................ 900 ± 100 N·m
vertical centerline. This end must be even with the
(665 ± 74 lb ft)
outside surface of the major bogie.
SENR8324-03 39
Index Section

Index
B Rollover Protective Structure (ROPS) ................... 35

Bevel and Transfer Gears ..................................... 13

Procedure to Adjust The End Play of The Bevel S
Pinion Bearings ................................................ 14
Procedure to Adjust The End Play of The Lower Specifications Section ............................................. 4
Transfer Gear Bearings.................................... 14 Steering and Transmission Control Group ............ 17
Bogie Suspension.................................................. 37 Sweep Group......................................................... 38
Brake and Planetary .............................................. 24
Brake Control Valve............................................... 16
T

D Table of Contents..................................................... 3
Torque Divider ......................................................... 4
Differential Drive and Brake Group........................ 25 Track Rollers ......................................................... 29
Housing (13) Bearing Preload Procedure .......... 26 Roller Placement................................................ 29
Drawbar ................................................................. 35 Single Flange and Double Flange...................... 29
Drive Shaft............................................................. 15 Tracks .................................................................... 31
Check and Adjust the Track ............................... 32
Specifications..................................................... 31
E Transmission ......................................................... 10
Transmission Hydraulic Control............................... 7
Equalizer Bar ......................................................... 27 Transmission Mounting ......................................... 12
Transmission Oil Filter ............................................. 9
Transmission Pump................................................ 11
F Transmission Selector and Pressure Control
Valve ...................................................................... 6
Fender ................................................................... 34
Final Drive ............................................................. 26
Foot Brake Control ................................................ 23
Frame Group ......................................................... 36

Hand Control Group .............................................. 19

Backup Alarm (Adjustment Procedure).............. 22
Forward/Reverse Adjustment Procedure........... 22
Parking Brake Lever and Neutral Start Switch
(Adjustment Procedure) ................................... 22
Speed Control (Adjustment Procedure) ............. 22
Steering Control Assembly and Adjustment
Procedure......................................................... 22

Idlers (Track) ......................................................... 31

Important Safety Information ................................... 2

Priority Valve............................................................ 8

Recoil Group.......................................................... 28
Relief Valve (Torque Converter Outlet).................... 5
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