KENR5631-05 (en-us)

February 2016

Specifications
Systems Operation
Testing and Adjusting
D10T2 Track-Type Tractor Systems
JJW 1-UP (Machine)
RAB 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.
KENR5631-05 3
Table of Contents

Table of Contents Cutting Edges and End Bits .................................93

Ripper Frame......................................................94
Ripper Frame......................................................96
Specifications Section Ripper Mounting .................................................98
Ripper Mounting .................................................99
Window Wiper and Wiper Motor .............................5 Ripper Mounting ............................................... 100
Hydraulic Tank and Filter .....................................13 Torque Converter ............................................. 101
Expansion Tank ..................................................14 Torque Converter and Housing........................... 103
Breaker Relief Valve ...........................................15 Torque Divider .................................................. 104
Hydraulic Oil Cooler ............................................16 Power Train Oil Pump........................................ 105
Pump Lines ........................................................17 Power Train Oil Pump (Mounting) ....................... 108
Implement Hydraulic Pump .................................19 Relief Valve (Torque Converter Outlet) ................ 109
Gear Pump (Power Train) ....................................20 Relief Valve (Torque Converter Inlet)................... 110
Charge Pump .....................................................26 Transmission Hydraulic Control ......................... 111
Fan Motor...........................................................27 Transmission Oil Lines ...................................... 112
Control Manifold (Pilot Oil) ...................................28 Power Train Oil Lines ........................................ 113
Valve Manifold (Inlet) ...........................................29 Filters (Torque Converter and Transmission) ...... 114
Bank Valve (Five) ................................................30 Transmission (Mounting) ................................... 115
Bank Valve (Six)..................................................32 Transmission (Planetary) ................................... 116
Bypass Valve (Implement, Hydraulic Fan) .............33 Planetary Case and Parts .................................. 125
Lines (Hydraulic Fan) ..........................................34 Solenoid Valve (Steering Clutch, Brake).............. 126
Bulldozer Tilt Control Valve .................................35 Solenoid Valve (Transmission Clutch) ................. 127
Bulldozer Lift Control Valve .................................37 Speed Sensor (Transmission Output) ................. 128
Ripper Lift Control Valve .....................................40 Bevel and Transfer Gears ................................. 129
Ripper Tip Control Valve ......................................42 Drive Shaft ....................................................... 132
Solenoid Valve (Bulldozer, Ripper)........................44 Steering and Brake Control Valve ...................... 133
Pressure Control Valve .......................................45 Steering Clutches and Brakes ........................... 134
Control Valve .....................................................46 Final Drive ....................................................... 136
Pump Control Valve (Implement) ..........................47 Final Drive ....................................................... 138
Accumulator (Uncharged) ....................................48 Final Drive Mounting ......................................... 141
Accumulator (Charged) .......................................49 Final Drive Mounting ......................................... 142
Pin Puller Control Valve ......................................50 Equalizer Bar ................................................... 143
Check Valve .......................................................51 Telescoping Recoil Frame.................................. 144
Filter (Power Train)..............................................52 Roller Frame Mounting ...................................... 146
Pilot Oil Filter .....................................................53 Recoil Group .................................................... 148
Bulldozer Lift Cylinder..........................................54 Track Carrier Roller .......................................... 151
Bulldozer Lift Cylinder..........................................55 Track Roller (Single Flange)............................... 153
Lines (Lift Cylinder) .............................................57 Track Roller (Double Flange) ............................. 155
Tilt Cylinder (Ripper)............................................59 Idlers (Track) .................................................... 157
Bulldozer Dual Tilt Cylinder ..................................61 Idlers (Track) .................................................... 159
Lines (Tilt Cylinder) .............................................62 Idlers (Track) .................................................... 161
Relief Valve (Bulldozer) .......................................64 Idlers (Track) .................................................... 163
Ripper Lift Cylinder..............................................65 Tracks ............................................................. 165
Relief Valve (Ripper)............................................67 Tracks ............................................................. 167
Pin Puller Cylinder ..............................................68 Sprocket Segment............................................. 169
Pin Puller............................................................69 Case and Frame ............................................... 170
Pin Puller............................................................70 Case and Frame ............................................... 172
Electronic Control and Mounting (Ripper) ..............71 Bogie Suspension ............................................. 173
Ripper Control ....................................................72 Bogie Suspension ............................................. 175
Joystick Control and Mounting .............................74 Refrigerant Compressor .................................... 177
Joystick Control and Mounting .............................75 Refrigerant Compressor .................................... 179
Joystick Control and Mounting .............................77 Refrigerant Condenser ...................................... 180
Joystick Control (Bulldozer) .................................79 Heater and Air Conditioner................................. 182
Joystick Control (Bulldozer) .................................80 Operator Console ............................................. 185
Steering and Transmission Control Group ............82 Cab Air Filter..................................................... 186
Push Arm ...........................................................83 Cab ................................................................. 187
Stabilizer Link .....................................................85 Cover (Cab)...................................................... 189
Bulldozer Installation ...........................................86 ROPS Mounting ............................................... 190
Bulldozer Brace ..................................................87 Operator Platform (Remote)............................... 191
Bulldozer Trunnion ..............................................88 Counterweight Group ....................................... 192
Cutting Edges and End Bits .................................89 Fuel Tank ......................................................... 193
Cutting Edges and End Bits .................................90 Fuel Tank ......................................................... 194
Cutting Edges and End Bits .................................91 Electric Drive Pump (Ladder) ............................. 195
Cutting Edges and End Bits .................................92 Toggle Switch (Ladder) ...................................... 197
Toggle Switch (Ground Level Shutdown)............. 198
4 KENR5631-05
Table of Contents

Ether Starting Aid .............................................. 199 HVAC System

Air Cleaner ...................................................... 201 General Information (HVAC System) .................. 374
Dust Ejector ..................................................... 202 Location of Components (HVAC System) ............ 376
Electronic Control (HVAC System)...................... 379
HVAC System ................................................... 387
Systems Operation Section
Additional Information
Hydraulic System Access Ladder System ...................................... 390
General Information (Hydraulic System).............. 203 Fast Fill Fuel Adapter ........................................ 392
Location of Components (Hydraulic System) ....... 205 Additional Electrical Components ....................... 395
Electronic Control (Hydraulic System)................. 209
Hydraulic Tank and Filter ................................... 220 Reference
Piston Pump (Implement) .................................. 223 Graphic Color Codes ......................................... 399
Control Valve (Implement).................................. 234
Control Manifold (Implement Lockout)................. 255
Accumulator (Pilot)............................................ 257 Testing and Adjusting Section
Inlet Manifold .................................................... 258
Signal Resolver Network ................................... 261 General Information
Check Valve (Implement Back Pressure) ............ 262 Machine Preparation ......................................... 400
Hydraulic Oil Cooler .......................................... 264 Calibrations (Cat ET) ......................................... 402
Calibration Error Codes ..................................... 404
Fan Hydraulic System
General Information (Fan Hydraulic System) ....... 265 Testing and Adjusting
Location of Components (Fan Hydraulic System) 267 Operational Checks........................................... 424
Electronic Control (Fan Hydraulic System) .......... 269 Piston Pump (Implement) - Test and Adjust ......... 426
Modes of Operation (Fan Hydraulic System) ....... 272 Pilot System Pressure - Test and Adjust .............. 432
Piston Pump (Fan Drive).................................... 279 Accumulator (Pilot) - Test and Charge................. 434
Piston Motor (Fan Drive) .................................... 280 Relief Valve (Main) - Test ................................... 437
Bypass Valve (Flushing) .................................... 282 Hydraulic Fan Speed (On Demand) - Test and
Adjust ............................................................ 439
Power Train System Resolver Network - Test..................................... 443
General Information (Power Train System).......... 283 Relief Valve (Transmission) - Test....................... 444
Location of Components (Power Train System) ... 285 Relief Valve (Torque Converter Inlet) Pressure -
Electronic Control (Power Train System) ............. 296 Test ................................................................ 445
Steering Clutch and Brake Control Valve............. 308 Relief Valve (Torque Converter Outlet) Pressure -
Torque Divider .................................................. 319 Test and Adjust................................................ 447
Power Train Oil Pump........................................ 326 Accumulator (Power Train) - Test and Charge ..... 450
Transmission ................................................... 327 Transmission Lubrication Oil Pressure - Test ...... 451
Transmission Hydraulic Control ......................... 335 Steering Clutch and Brake Pressure - Test .......... 453
Transfer and Bevel Gears ................................. 338 Engagement Pressure for Transmission Clutch -
Accumulator (Power Train)................................. 339 Test ................................................................ 456
Oil Filter (Power Train)....................................... 340 Ladder System Pressure - Test and Adjust .......... 458
Oil Cooler (Power Train) .................................... 342
Final Drive ....................................................... 344
Pin Puller Hydraulic System .............................. 346 Index Section
Cooling System Index................................................................ 461
General Information (Cooling System) ................ 349
Location of Components (Cooling System).......... 350
Engine Cooling System ..................................... 353
Engine Oil Cooling System ................................ 357
Power Train Oil Cooling System ......................... 358
Cooling System (Aftercooler, ATAAC) ................. 358
Hydraulic Oil Cooling System ............................. 360

Undercarriage
General Information (Undercarriage) .................. 361
Location of Components (Undercarriage)............ 363
Track Roller Frame ........................................... 366
Equalizer Bar ................................................... 368
Pivot Shaft ....................................................... 369
Track Idler ....................................................... 370
Track Roller ..................................................... 371
Tracks ............................................................. 372
KENR5631-05 5
Specifications Section

Specifications Section

i05703730

Window Wiper and Wiper Motor

SMCS Code: 7305-MQ; 7305; 7306

Part No.: 337-8254

6 KENR5631-05
Specifications Section

Front

Illustration 1 g02683636

Table 1

Specification for 337-8254 Window Wiper Gp

Item Qty Part Specification Description

Tension of the window wiper arm group in the loaded position is

1 1 175-3761 Window Wiper Arm Gp
6.6 ± 0.4 N (1.5 ± 0.1 lb).

Angle for the window wiper arm group from the automatic park position is
B - -
60 degrees.

2 1 9X-2046 Screw Torque to 7.5 ± 0.5 N·m (66.4 ± 4.4 lb in).

(continued)
KENR5631-05 7
Specifications Section

(Table 1, contd)
Use the following torque for the window wiper motor group nut:
1. Torque the nut for the window wiper motor group when mounted on
3 - - glass to 5.5 ± 0.5 N·m (48.7 ± 4.4 lb in).
2. Torque the nut for the window wiper motor group when mounted on
steel to 9 ± 1 N·m (80 ± 9 lb in).

Use the following procedure in order to install the window wiper arm
group:
1. Torque the nut for the window wiper arm group to 21 ± 1 N·m
(186 ± 9 lb in).
4 - -
2. After a minimum of 0.5 hours to a maximum of 4 hours, tighten the nut
of the window wiper arm group again to 21 ± 1 N·m (186 ± 9 lb in).
Note: Ensure the minimum field torque for the nut (4) of the window wiper
arm group is 12 N·m (106 lb in).

Distance of the wiper blade from the glass edge of the window in the park
C - -
position is 60 ± 3 mm (2.4 ± 0.1 inch).
8 KENR5631-05
Specifications Section

Rear

Illustration 2 g02684479

Table 2
Item Qty Part Specification Description

Tension of the window wiper arm group is 6.0 ± 0.7 N·m (53.1 ± 6.2 lb in)
5 1 8Y-6343 Window Wiper Arm Gp
.
Distance of the wiper blade from the glass edge of the window in the park
E - -
position is 75 ± 3 mm (3.0 ± 0.1 inch).

Angle for the window wiper arm group from the automatic park position is
F - -
120 degrees.

Note: By using a wire with the diameter of 0.5 mm (0.02 inch), adjust the
jets of the nozzle assembly to direct spray onto the glass directly in front
of the rear wiper blade.
Use the following torque for the window wiper motor group nut:
6 - -
1. Torque the nut for the window wiper motor group when mounted on
glass to 5.5 ± 0.5 N·m (48.7 ± 4.47 lb in).
2. Torque the nut for the window wiper motor group when mounted on
steel to 9 ± 1 N·m (80 ± 9 lb in).

(continued)
KENR5631-05 9
Specifications Section

(Table 2, contd)
Use the following torque for the window wiper motor group nut:
1. Torque the nut for the window wiper motor group when mounted on
7 - - glass to 6.5 ± 0.5 N·m (57.5 ± 4.4 lb in).
2. Torque the nut for the window wiper motor group when mounted on
steel to 7.5 ± 0.5 N·m (66.4 ± 4.4 lb in).

Use the following procedure in order to install the nut of the window wiper
arm group:
1. Tighten the nut of the window wiper arm group to 21 ± 1 N·m
(186 ± 9 lb in).
8 - - 2. After a minimum of 0.5 hours to a maximum of 4 hours, tighten the nut
of the window wiper arm group again to a torque of 21 ± 1 N·m
(186 ± 9 lb in).
Note: Ensure the minimum field torque for the nut (8) of the window wiper
arm group is 12 N·m (106 lb in).
10 KENR5631-05
Specifications Section

Door

Illustration 3 g02684499

Table 3
Item Qty Part Specification Description

Distance of the wiper blades from the glass edges of the windows in the
G - -
park position is 20 ± 3 mm (0.8 ± 0.1 inch).

9 2 222-5374 Window Wiper Arm Gp Tension of the window wiper arm is 4.3 ± 0.5 N·m (38.1 ± 4.4 lb in).

Angle for the window wiper arm group from the automatic park position is
H - -
105 degrees.

Angle for the window wiper arm group from the automatic park position is
110 degrees.
J - - Note: By using a wire with the diameter of 0.5 mm (0.02 inch), adjust the
jets of the nozzle assembly to direct spray on to the glass directly in front
of the left wiper blade and right wiper blade.
KENR5631-05 11
Specifications Section

Illustration 4 g02684517
Section K-K

Table 4
Item Qty Part Specification Description

10 - - Torque to 38 ± 2 N·m (28 ± 1 lb ft).

Use the following procedure in order to install the window wiper arm
group:
1. Tighten the nut of the window wiper arm group to 24 ± 1 N·m
(212 ± 9 lb in).
11 - - 2. After a minimum of 0.5 hours to a maximum of 4 hours, tighten the nut
of the window wiper arm group again to a torque of 24 ± 1 N·m
(212 ± 9 lb in).
Note: Ensure the minimum field torque for the nut (11) of the window
wiper arm group is 12 N·m (106 lb in).
12 KENR5631-05
Specifications Section

Illustration 5 g02684527
Section L-L

Table 5
Item Qty Part Specification Description

12 2 344-5674 Nut Torque to 20 ± 2 N·m (177 ± 18 lb in).

KENR5631-05 13
Specifications Section

i05700259

Hydraulic Tank and Filter

SMCS Code: 5056; 5068

Part No.: 374-7146

Illustration 6 g03620362

Table 6
Specification for 374-7146 Hydraulic Tank and Filter Gp

Item Qty Part Specification Description

Length under test force is 66.8 mm (2.63 inch).

1 1 243-0781 Spring Test force is 260.0 ± 18.2 N (58.5 ± 4.1 lb).
Free length after test is 99.7 mm (3.93 inch).

2 1 260-8636 Liquid Level Gauge Tighten two bolts to 10 ± 1 N·m (89 ± 9 lb in).

3 1 8T-0389 Locknut Torque to 10.0 ± 1.5 N·m (88.5 ± 13.3 lb in).

During the assembly, lubricate the O-Ring Seal.

4 1 380-8484 Screen As
Torque to 325 ± 45 N·m (240 ± 33 lb ft).

5 1 164-4180 Plug As Torque to 55 ± 8 N·m (41 ± 6 lb ft).

14 KENR5631-05
Specifications Section

i05703630

Expansion Tank
SMCS Code: 1354

Part No.: 397-9341

Illustration 7 g03622736

Table 7
Specification for 397-9341 Expansion Tank Gp

Item Qty Part Specification Description

1 1 358-9477 Breaker Relief Valve As Torque to 20 ± 3 N·m (177 ± 27 lb in).

2 1 358-9566 Relief Valve As Torque to 20 ± 3 N·m (177 ± 27 lb in).

KENR5631-05 15
Specifications Section

i05696030

Breaker Relief Valve

SMCS Code: 5057; 5076; 5118

Part No.: 397-9340

Illustration 8 g03616596

Table 8
Specification for 397-9340 Breaker Relief Valve

Item Qty Part Specification Description

1 1 358-9566 Relief Valve As Torque to 20 ± 3 N·m (177 ± 27 lb in).

16 KENR5631-05
Specifications Section

i05703491

Hydraulic Oil Cooler

SMCS Code: 1374

Part No.: 359-6465

Illustration 9 g03622538

Table 9
Specification for 359-6465 Hydraulic Oil Cooler Gp

Item Qty Part Specification Description

1 1 384-8436 Control Valve As Torque to 88 ± 7 N·m (65 ± 5 lb ft).

KENR5631-05 17
Specifications Section

i05703675

Pump Lines
SMCS Code: 5057

Part No.: 359-6443

18 KENR5631-05
Specifications Section

Illustration 10 g03622798

Table 10
Specification for 359-6443 Pump Lines Gp

Item Qty Part Specification Description

1 1 245-1737 Bolt Torque to 47 ± 9 N·m (35 ± 7 lb ft).

KENR5631-05 19
Specifications Section

i05696609

Implement Hydraulic Pump

SMCS Code: 5070

Part No.: 373-6629, 373-6630

Illustration 11 g03617076

Table 11
Specification for 373-6629 Piston Pump Gp and 373-6630 Piston Pump Gp

Item Qty Part Specification Description

1 1 105-1635 Spring Free length is 171.4 mm (6.75 inch).

2 1 105-1651 Spring Free length is 102.7 mm (4.04 inch).

Grind the spacer to required thickness with face parallel within 0.05 mm (0.002 inch)
to achieve dimension (B).
3 1 105-1638 Spacer
Dimension (B) is 0.00 to 0.05 mm (0.000 to 0.002 inch).

Thickness is 3.0 mm (0.12 inch).

20 KENR5631-05
Specifications Section

i05703609

Gear Pump (Power Train)

SMCS Code: 3066; 3115; 5073-PWT; 5073-T3

Part No.: 374-9555

Illustration 12 g03622722

Table 12
Specification for 374-9555 Gear Pump Gp

Item Qty Part Specification Description

B 1 377-7472 Pump Shaft Diameter is 31.742 ± 0.005 mm (1.2497 ± 0.0002 inch).

C 1 377-7474 Pump Shaft Diameter is 31.742 ± 0.005 mm (1.2497 ± 0.0002 inch).

1 1 2K-0337 Locknut Torque to 110 ± 13 N·m (81 ± 10 lb ft).

KENR5631-05 21
Specifications Section

Illustration 13 g03622916
449-3151 Oil Pump Body As

Table 13
Specification for 374-9555 Gear Pump Gp

Item Qty Part Specification Description

2 1 365-1496 Bushing Bore of the bushing after installation is 31.814 ± 0.042 mm (1.2525 ± 0.0017 inch).

D 4 5M-4987 Dowel Protrusion of the dowel is 5.0 ± 0.5 mm (0.20 ± 0.02 inch).

E - - Location of the joints of two bushings from the vertical centerline is 30 ± 15 degrees.

3 Bore of the bushing before installation is 35.014 ± 0.013 mm (1.3785 ± 0.0005 inch).
1 209-0792 Bushing
G Installation depth is 1.5 ± 0.5 mm (0.06 ± 0.02 inch).

4 Bore of the bushing after installation is 31.798 ± 0.039 mm (1.2519 ± 0.0015 inch).
1 1M-3780 Bushing
G Installation depth is 1.5 ± 0.5 mm (0.06 ± 0.02 inch).
22 KENR5631-05
Specifications Section

Illustration 14 g03622896
422-4925 Manifold

Table 14
Specification for 374-9555 Gear Pump Gp

Item Qty Part Specification Description

H 2 5M-4987 Dowel Protrusion of the dowel is 5.0 ± 0.5 mm (0.20 ± 0.02 inch).

5 Bore of the bushing after installation is 31.786 ± 0.008 mm (1.2514 ± 0.0003 inch).
4 5M-1995 Bushing
J Installation depth is 1.5 ± 0.5 mm (0.06 ± 0.02 inch).

K - - Location of the joints of two bushings from the vertical centerline is 30 ± 15 degrees.
KENR5631-05 23
Specifications Section

Illustration 15 g03622877
386-4907 Pump Cover

Table 15
Specification for 374-9555 Gear Pump Gp

Item Qty Part Specification Description

6 Bore of the bushing after installation is 31.814 ± 0.042 mm (1.2525 ± 0.0017 inch).
2 379-5808 Bushing
L Installation depth is 1.5 ± 0.5 mm (0.06 ± 0.02 inch).

M - - Location of the joints of two bushings from the vertical centerline is 30 ± 15 degrees.
24 KENR5631-05
Specifications Section

Illustration 16 g03622918
377-7469 Oil Pump Body As

Table 16
Specification for 374-9555 Gear Pump Gp

Item Qty Part Specification Description

N 2 5M-4987 Dowel Protrusion of the dowel is 5.0 ± 0.5 mm (0.20 ± 0.02 inch).

7 Bore of the bushing after installation is 31.798 ± 0.039 mm (1.2520 ± 0.0015 inch).
2 1M-3909 Bushing
P Installation depth is 1.5 ± 0.5 mm (0.06 ± 0.02 inch).

R - - Location of the joints of two bushings from the vertical centerline is 30 ± 15 degrees.
KENR5631-05 25
Specifications Section

Illustration 17 g03622936
2S-0189 Oil Pump Body As

Table 17
Specification for 374-9555 Gear Pump Gp

Item Qty Part Specification Description

S 2 5M-3605 Dowel Protrusion of the dowel is 5.0 ± 0.5 mm (0.20 ± 0.02 inch).
26 KENR5631-05
Specifications Section

i05699609

Charge Pump
SMCS Code: 3204-GT; 5073

Part No.: 289-4027

Illustration 18 g03619736

Table 18
Specification for 289-4027 Piston Pump Gp

Item Qty Part Specification Description

1 4 8T-8442 Bolt Torque to 10.6 N·m (93.8 lb in).

2 1 333-7843 Spring Free length is 46 mm (1.8 inch).

3 1 198-5351 Plug Torque to 190 N·m (140 lb ft).

Grind the spacer to required thickness with face parallel within 0.05 mm (0.002 inch)
to achieve dimension (B).
4 1 189-4716 Shim
Dimension (B) is 0.00 to 0.05 mm (0.000 to 0.002 inch).

Thickness is 2.5 mm (0.10 inch).

5 3 9S-8005 O-Ring Plug Torque to 72 N·m (53 lb ft).

6 4 6V-8337 Bolt Torque to 37 N·m (27 lb ft).

KENR5631-05 27
Specifications Section

i05699911

Fan Motor
SMCS Code: 1386; 5058

Part No.: 373-6632

Illustration 19 g03620019

Table 19
Specification for 373-6632 Piston Motor Gp

Item Qty Part Specification Description

1 1 185-0292 Spring Free length is 66.3 mm (2.61 inch).

Grind the spacer to required thickness with face parallel within 0.05 mm (0.002 inch)
to achieve dimension (B).
2 1 168-2203 Shaft Shim
Dimension (B) is 0.00 to 0.05 mm (0.000 to 0.002 inch).

Thickness is 3.0 mm (0.12 inch).

28 KENR5631-05
Specifications Section

i04608790

Control Manifold (Pilot Oil)

SMCS Code: 5059-M9; 5264

Part No.: 341-9000

Illustration 20 g02759516

Table 20
Specification for 341-9000 Control Manifold Gp

Item Qty Part Specification Description

Torque to 27.2 ± 1.4 N·m (240.7 ± 12.4 lb in).

Tighten the coil nut to 6.1 ± 0.7 N·m (54.0 ± 6.2 lb in).
1 1 333-8242 Solenoid Valve Gp
Operating voltage is 24 VDC.
Coil resistance at 20 °C (68 °F) is 33.8 ohms.

2 1 177-3868 Check Valve Gp Torque to 25.8 ± 1.4 N·m (228.3 ± 12.4 lb in).
KENR5631-05 29
Specifications Section

i05703649

Valve Manifold (Inlet)

SMCS Code: 5264

Part No.: 420-4712

Illustration 21 g03622797

Table 21
Specification for 420-4712 Inlet Manifold Gp

Item Qty Part Specification Description

1 1 434-2475 Relief Valve Gp Torque to 203 ± 8 N·m (150 ± 6 lb ft).

2 1 - Torque to 15 to 20 N·m (133 to 177 lb in).

3 1 - Torque to 15 to 20 N·m (133 to 177 lb in).

30 KENR5631-05
Specifications Section

i05699832

Bank Valve (Five)

SMCS Code: 5051-B05

Part No.: 415-9402

S/N: JJW1–Up
KENR5631-05 31
Specifications Section

Illustration 22 g03619916

Table 22
Specification for 415-9402 Bank Valve (FIVE)

Item Qty Part Specification Description

1 6 6V-8188 Nut Torque to 105 ± 10 N·m (77 ± 7 lb ft).

32 KENR5631-05
Specifications Section

i05699509

Bank Valve (Six)

SMCS Code: 5051

Part No.: 377-3673

S/N: RAB1–Up

Illustration 23 g03619658

Table 23
Specification for 377-3673 Bank Valve Gp (SIX)

Item Qty Part Specification description

1 6 6V-8188 Nut Torque to 105 ± 10 N·m (77 ± 7 lb ft).

KENR5631-05 33
Specifications Section

i05703590

Bypass Valve (Implement,

Hydraulic Fan)
SMCS Code: 5076

Part No.: 417-4160

Illustration 24 g03622696

Table 24
Specification for 417-4160 Bypass Valve Gp

Item Qty Part Specification Description

1 1 384-8436 Control Valve As Torque to 160 ± 20 N·m (118 ± 15 lb ft).

34 KENR5631-05
Specifications Section

i05699670

Lines (Hydraulic Fan)

SMCS Code: 1386-LI; 5057-HFN

Part No.: 359-6440

Illustration 25 g03619768

Table 25
Specification for 359-6440 Hydraulic Fan Lines Gp

Item Qty Part Specification Description

1 2 310-1945 Taperlock Stud Torque to 65 ± 10 N·m (48 ± 7 lb ft).

KENR5631-05 35
Specifications Section

i05699209

Bulldozer Tilt Control Valve

SMCS Code: 5051; 5115; 5123

Part No.: 377-3675

Illustration 26 g03619336

Table 26
Specification for 377-3675 Control Valve Gp

Item Qty Part Specification Description

1 2 085-8091 Bolt Torque to 60 ± 7 N·m (44 ± 5 lb ft).

2 1 399-5792 Relief Valve Gp Torque to 35 ± 5 N·m (26 ± 4 lb ft).

(continued)
36 KENR5631-05
Specifications Section

(Table 26, contd)

3 1 260-8590 Shuttle Valve Gp Torque to 16 ± 3 N·m (142 ± 27 lb in).

Torque to 35 ± 3 N·m (26 ± 2 lb ft).

4 2 313-7668 Solenoid Valve Gp Nominal voltage is 24 VDC.
Coil resistance at 25 °C (77 ° F) is 5.0 ± 0.3 ohms.

As required, use the shims:

5 4 6E-1637 Shim
Thickness of one shim is 1.0 mm (0.04 inch).

6 2 198-2914 Nut Torque to 20 ± 3 N·m (177 ± 27 lb in).

Length under test force is 57.0 mm (2.24 inch).

7 1 123-9624 Spring Test force is 145.5 ± 7.3 N (32.7 ± 1.6 lb).
Free length after test is 64.70 mm (2.547 inch).

8 2 4T-1108 Plug Torque to 145 ± 15 N·m (107 ± 11 lb ft).

9 1 9J-8126 Orifice Plug Torque to 9 to 14 N·m (80 to 124 lb in).

Length under first test force is 39.4 mm (1.55 inch).

First test force is 304.2 ± 24.0 N (68.4 ± 5.4 lb).
10 2 352-9954 Spring Length under second test force is 35.5 mm (1.40 inch).
Second test force is 655.2 ± 52.0 N (147.3 ± 11.7 lb).
Free length after test is 42.78 mm (1.68 inch).

Length under test force is 7.9 mm (0.31 inch).

11 1 2S-2596 Spring Test force is 4.226 ± 0.339 N (0.950 ± 0.076 lb).
Free length after test is 33.3 mm (1.31 inch).

12 1 100-8011 Plug Torque to 300 ± 40 N·m (221 ± 30 lb ft).

KENR5631-05 37
Specifications Section

i05699309

Bulldozer Lift Control Valve

SMCS Code: 5115; 5136

Part No.: 377-3674

38 KENR5631-05
Specifications Section

Illustration 27 g03619436

Table 27
Specification for 377-3674 Control Valve Gp

Item Qty Part Specification Description

(continued)
KENR5631-05 39
Specifications Section

(Table 27, contd)

Length under first test force is 47.03 mm (1.852 inch).
First test force is 266 ± 20 N (60 ± 4 lb).
1 1 350-2762 Spring Length under second test force is 41.5 mm (1.63 inch).
Second test force is 575 ± 82 N (129 ± 18 lb).
Free length after test is 51.79 mm (2.039 inch).

As required, use the following shims to obtain a load of 380 ± 10 N (85 ± 2 lb) with retainers and spring at a length of 55.0 ± 0.5 mm
(2.17 ± 0.02 inch).
Install the thick shim to contact the end of the spring.
2
4 351-2840 Shim Thickness of one shim is 0.12 mm (0.005 inch).

3 350-3145 Shim Thickness of one shim is 0.50 mm (0.020 inch).

3 2 198-2914 Nut Torque to 20 ± 3 N·m (177 ± 27 lb in).

Torque to 35 ± 3 N·m (26 ± 2 lb ft).

4 2 313-7668 Solenoid Valve Gp Nominal voltage is 24 VDC.
Coil resistance at 25 °C (77 ° F) is 5.0 ± 0.3 ohms.

Length under test force is 7.9 mm (0.31 inch).

5 2 2S-2596 Spring Test force is 4.226 ± 0.338 N (0.950 ± 0.076 lb).
Free length after test is 33.3 mm (1.31 inch).

6 1 100-8012 Body Torque to 145 ± 15 N·m (107 ± 11 lb ft).

7 1 260-8590 Shuttle Valve Gp Torque to 16 ± 3 N·m (142 ± 27 lb in).

Length under test force is 59 mm (2.3 inch).

8 1 4T-1701 Spring Test force is 108 ± 5 N (24 ± 1 lb).
Free length after test is 64.70 mm (2.547 inch).

9 1 9J-8126 Orifice Plug Torque to 9 to 14 N·m (80 to 124 lb in).

As required, use the washer in order to adjust the pressure setting. Maximum five
10 5 4B-4278 Washer washers can be used for the adjustment of pressure setting.
Thickness of one washer is 1.6 mm (0.06 inch).

Length under first test force is 39.4 mm (1.55 inch).

First test force is 304.2 ± 24.0 N (68.4 ± 5.4 lb).
11 1 352-9954 Spring Length under second test force is 35.5 mm (1.40 inch).
Second test force is 655.2 ± 52.0 N (147.3 ± 11.7 lb).
Free length after test is 42.78 mm (1.684 inch).

12 1 4T-1108 Plug Torque to 145 ± 15 N·m (107 ± 11 lb ft).

13 1 100-8011 Plug Torque to 300 ± 40 N·m (221 ± 30 lb ft).

40 KENR5631-05
Specifications Section

i05699410

Ripper Lift Control Valve

SMCS Code: 5351

Part No.: 377-3676

Illustration 28 g03619556

Table 28
Specification for 377-3676 Control Valve Gp

Item Qty Part Specification Description

1 2 198-2914 Nut Torque to 20 ± 3 N·m (177 ± 27 lb in).

(continued)
KENR5631-05 41
Specifications Section

(Table 28, contd)

Torque to 35 ± 3 N·m (26 ± 2 lb ft).
2 2 313-7668 Solenoid Valve Gp Nominal voltage is 24 VDC.
Coil resistance at 25 °C (77 ° F) is 5.0 ± 0.3 ohms.

Length under first test force is 39.4 mm (1.55 inch).

First test force is 304.2 ± 24.0 N (68.4 ± 5.4 lb).
3 2 352-9954 Spring Length under second test force is 35.5 mm (1.40 inch).
Second test force is 655.2 ± 52.0 N (147.3 ± 11.7 lb).
Free length after test is 42.78 mm (1.684 inch).

Length under test force is 7.9 mm (0.31 inch).

4 3 2S-2596 Spring Test force is 4.226 ± 0.338 N (0.950 ± 0.076 lb).
Free length after test is 33.3 mm (1.31 inch).

5 2 100-8012 Body Torque to 145 ± 15 N·m (107 ± 11 lb ft).

6 1 4D-0514 Pipe Plug Torque to 9 to 14 N·m (80 to 124 lb in).

42 KENR5631-05
Specifications Section

i05699530

Ripper Tip Control Valve

SMCS Code: 5351

Part No.: 377-3677

Illustration 29 g03619678

Table 29
Specification for 377-3677 Control Valve Gp

Item Qty Part Specification Description

1 2 198-2914 Nut Torque to 20 ± 3 N·m (177 ± 27 lb in).

(continued)
KENR5631-05 43
Specifications Section

(Table 29, contd)

Torque to 35 ± 3 N·m (26 ± 2 lb ft).
2 2 313-7668 Solenoid Valve Gp Nominal voltage is 24 VDC.
Coil resistance at 25 °C (77 ° F) is 5.0 ± 0.3 ohms.

Length under test force is 7.9 mm (0.31 inch).

3 2 2S-2596 Spring Test force is 4.226 ± 0.338 N (0.950 ± 0.076 lb).
Free length after test is 33.3 mm (1.31 inch).

4 1 100-8012 Body Torque to 145 ± 15 N·m (107 ± 11 lb ft).

Length under first test force is 39.4 mm (1.55 inch).

First test force is 304.2 ± 24.0 N (68.4 ± 5.4 lb).
5 2 352-9954 Spring Length under second test force is 35.5 mm (1.40 inch).
Second test force is 655.2 ± 52.0 N (147.3 ± 11.7 lb).
Free length after test is 42.78 mm (1.684 inch).

6 1 116-1895 Relief Valve Gp Torque to 145 ± 15 N·m (107 ± 11 lb ft).

7 1 100-8011 Plug Torque to 300 ± 40 N·m (221 ± 30 lb ft).

8 1 4D-0514 Pipe Plug Torque to 9 to 14 N·m (80 to 124 lb in).

9 1 260-8590 Shuttle Valve Gp Torque to 16 ± 3 N·m (142 ± 27 lb in).

44 KENR5631-05
Specifications Section

i05703669

Solenoid Valve (Bulldozer,

Ripper)
SMCS Code: 5479

Part No.: 313-7668

Illustration 30 g03622801

Table 30
Specification for 313-7668 Solenoid Valve Gp

Item Qty Part Specification Description

1 1 198-2914 Nut Torque to 20 ± 3 N·m (177 ± 27 lb in).

2 1 316-1438 Cartridge As Torque to 35 ± 3 N·m (26 ± 2 lb ft).

Nominal voltage is 24 VDC.

3 1 312-8629 Coil
Resistance at 25 °C (77 °F) is 5.0 ± 0.3 ohms.
KENR5631-05 45
Specifications Section

i05700468

Pressure Control Valve

SMCS Code: 5051

Part No.: 382-0936

Illustration 31 g03622476

Table 31
Specification for 382-0936 Pressure Reducing Valve

Item Qty Part Specification Description

382-0936 Pressure Reduc-

1 1 Torque to 47.0 ± 2.8 N·m (34.7 ± 2.1 lb ft).
ing Valve
46 KENR5631-05
Specifications Section

i05703290

Control Valve
SMCS Code: 5051; 5051-JI; 5117; 5136

Part No.: 382-0938

Illustration 32 g03622338

Table 32
Specification for 382-0938 Control Valve Gp

Item Qty Part Specification Description

1 1 382-0938 Control Valve Gp Torque to 34.0 ± 1.5 N·m (300.9 ± 13.3 lb in).
KENR5631-05 47
Specifications Section

i05351091

Pump Control Valve (Implement)

SMCS Code: 5455-II

Part No.: 347-0612

Illustration 33 g03389513

Table 33
Specification for 347-0612 Pump Control Valve Gp

Item Qty Part Specification Description

1 2 6E-6527 Plug Torque to 12 ± 1 N·m (106 ± 9 lb in).

2 2 - Tighten the nuts to 21.0 ± 2.1 N·m (185.7 ± 18.6 lb in).

48 KENR5631-05
Specifications Section

i04891752

Accumulator
(Uncharged)
SMCS Code: 5077

Part No.: 331-7021

Illustration 34 g02848859

Table 34
Specification for 331-7021 Accumulator Gp

Item Qty Part Specification Description

1 1 224-5132 Cap Torque to 1.6 ± 0.1 N·m (14.2 ± 0.9 lb in).

2 1 224-5152 Gas Valve Torque to 35.0 ± 1.5 N·m (25.8 ± 1.1 lb ft).

- - - Charging medium is dry nitrogen.

KENR5631-05 49
Specifications Section

i06001254

Accumulator
(Charged)
SMCS Code: 5077

Part No.: 331-7020

Illustration 35 g03761196

Table 35
Specification for 331-7020 Accumulator Gp

Item Qty Part Specification Description

1 - - Torque to 203 ± 20 N·m (150 ± 15 lb ft).

2 1 224-5132 Cap Torque to 1.6 ± 0.1 N·m (14.2 ± 0.9 lb in).

3 1 224-5152 Gas Valve Torque to 35.0 ± 1.5 N·m (25.8 ± 1.1 lb ft).

- - - Charging medium is dry nitrogen.

50 KENR5631-05
Specifications Section

i04494329

Pin Puller Control Valve

SMCS Code: 5353

Part No.: 188-6140

Illustration 36 g02673896

Table 36
Specification for 188-6140 Control Valve and Mounting Gp

Item Qty Part Specification Description

1 1 157-2284 Special Locknut Torque to 14 ± 2 N·m (124 ± 18 lb in).

Nominal voltage is 24 VDC.

2 1 3E-8575 Solenoid Valve Gp Coil resistance at 25 ± 5 °C (77 ± 9 °F) is 24.9 ± 0.4 Ohms.

Torque to 30.5 ± 3.5 N·m (269.9 ± 31.0 lb in).

KENR5631-05 51
Specifications Section

i05703309

Check Valve
SMCS Code: 5067

Part No.: 332-5911

Illustration 37 g03622436

Table 37
Specification for 332-5911 Check Valve Gp

Item Qty Part Specification Description

1 1 332-5911 Check Valve Gp Torque to 33.9 N·m (300.0 lb in).

52 KENR5631-05
Specifications Section

i06013742

Filter (Power Train)

SMCS Code: 5068

Part No.: 346-5574

Illustration 38 g03772631

Table 38
Specification for 346-5574 Oil Filter Gp

Item Qty Part Specification Description

1 4 099-0169 Bolt Torque to 125 ± 20 N·m (92 ± 15 lb ft).

2 1 440-0257 Pressure Switch Gp Torque to 30 ± 3 N·m (266 ± 27 lb in).

Before assemble, apply red Loctite 263 to threads.

3 1 096-4833 Bolt
Torque to 7.5 ± 1.5 N·m (66.4 ± 13.3 lb in).

4 1 365-3465 Filter Housing As Torque to 200 ± 10 N·m (148 ± 7 lb ft).

5 - - Tighten the drain plug to 45 ± 3 N·m (33 ± 2 lb ft).

KENR5631-05 53
Specifications Section

i05699533

Pilot Oil Filter

SMCS Code: 5068

Part No.: 341-1330

Illustration 39 g03619697

Table 39
Specification for 341-1330 Oil Filter Gp

Item Qty Part Specification Description

1 1 227-6744 Pressure Switch Gp Torque to 6.18 ± 1.41 N·m (54.70 ± 12.48 lb in).

A - - Minimum distance that is required for removing the oil filter is 23.4 mm (0.92 inch).
54 KENR5631-05
Specifications Section

i05696172

Bulldozer Lift Cylinder

SMCS Code: 5102

Part No.: 372-4283

Illustration 40 g03616916

Table 40
Specification for 372-4283 Bulldozer Lift Cylinder Gp

Item Qty Part Specification Description

1 1 377-6020 Buffer Seal Before assembly, lubricate lightly with lubricant that is being sealed.

2 1 377-6017 U-Cup Seal Before assembly, lubricate lightly with lubricant that is being sealed.

3 1 165-9287 Lip Type Seal Before assembly, lubricate lightly with lubricant that is being sealed.

4 - - Before assembly, apply green Loctite 620 to the wiper seal groove.

Before assembly, lubricate the threads.

5 1 2J-0564 Locknut
Torque to 3400 ± 340 N·m (2508 ± 251 lb ft).

A 1 372-7088 Cylinder As Bore is 140.05 ± 0.05 mm (5.514 ± 0.002 inch).

B 1 372-7094 Rod As Diameter is 89.930 ± 0.038 mm (3.5405 ± 0.0015 inch).

C 1 372-7056 Head Bore over two lands is 90.63 ± 0.03 mm (3.568 ± 0.001 inch).

6 1 1J-2192 Bushing Bore before assembly is 57.53 ± 0.07 mm (2.265 ± 0.003 inch).
KENR5631-05 55
Specifications Section

i05696429

Bulldozer Lift Cylinder

SMCS Code: 5102

Part No.: 374-6601

Illustration 41 g03616918

Table 41
Specification for 374-6601 Bulldozer Lift Cylinder Gp

Item Qty Part Specification Description

1 1 377-6020 Buffer Seal Before assembly, lubricate lightly with lubricant that is being sealed.

2 1 377-6017 U-Cup Seal Before assembly, lubricate lightly with lubricant that is being sealed.

3 1 165-9287 Lip Type Seal Before assembly, lubricate lightly with lubricant that is being sealed.

4 - - Before assembly, apply green Loctite 620 to the wiper seal groove.

Before assembly, apply red Loctite 271 to the threads.

5 1 243-3177 Retainer
Torque to 35 ± 5 N·m (26 ± 4 lb ft).

(continued)
56 KENR5631-05
Specifications Section

(Table 41, contd)

Before assembly, lubricate the threads.
6 1 2J-0564 Locknut
Torque to 3400 ± 340 N·m (2508 ± 251 lb ft).

A 1 376-2254 Cylinder As Bore is 140.05 ± 0.05 mm (5.514 ± 0.002 inch).

B 1 376-2255 Rod As Diameter is 89.930 ± 0.038 mm (3.5405 ± 0.0015 inch).

7 1 O-Ring Seal Before assembly, lubricate lightly with lubricant that is being sealed.

D 1 372-7056 Head Bore over two lands is 90.63 ± 0.03 mm (3.568 ± 0.001 inch).

Before assembly, apply blue Loctite 242 to the threads.

8 1 8T-9102 Socket Setscrew
Torque to 3.3 ± 0.7 N·m (29.2 ± 6.2 lb in).

9 3 1J-2192 Bushing Bore before assembly is 2.265 ± 0.003 mm (0.0892 ± 0.0001 inch).
KENR5631-05 57
Specifications Section

i05703510

Lines (Lift Cylinder)

SMCS Code: 5057; 5102

Part No.: 359-6441

58 KENR5631-05
Specifications Section

Illustration 42 g03622578

Table 42
Specification for 359-6441 Lift Cylinder Lines Gp

Item Qty Part Specification Description

1 4 180-3998 Stud Torque to 35 ± 5 N·m (26 ± 4 lb ft).

2 6 109-3001 Taperlock Stud Torque to 35 ± 5 N·m (26 ± 4 lb ft).

3 4 9U-8047 Grommet As required, lubricate the grommet lightly with clean lubricant.

4 1 374-9972 Grommet As required, lubricate the grommet lightly with clean lubricant.
KENR5631-05 59
Specifications Section

i05699910

Tilt Cylinder
(Ripper)
SMCS Code: 7562

Part No.: 374-2285

Illustration 43 g03620016

Table 43
Specification for 374-2285 Ripper Cylinder Gp

Item Qty Part Specification Description

Bore before assembly is 76.708 ± 0.013 mm (3.0200 ± 0.0005 inch).

1 2 3J-6484 Bushing
Installation depth is 10.4 ± 0.5 mm (0.41 ± 0.02 inch).

Before assembly, lubricate the threads.

2 1 2J-7686 Locknut
Torque to 6500 ± 650 N·m (4794 ± 479 lb ft).

A 1 376-3085 Cylinder As Bore is 180.00 ± 0.10 mm (7.087 ± 0.004 inch).

B 1 376-3089 Rod As Diameter is 89.930 ± 0.038 mm (3.5405 ± 0.0015 inch).

C 1 380-1600 Head Bore over four lands is 90.28 ± 0.03 mm (3.554 ± 0.001 inch).

3 8 8T-0667 Bolt Torque to 900 ± 100 N·m (664 ± 74 lb ft).

Bore before assembly is 76.708 ± 0.013 mm (3.0200 ± 0.0005 inch).

4 2 3J-6484 Bushing
Installation depth is 9.6 ± 0.5 mm (0.38 ± 0.02 inch).

5 1 186-5397 Wear Ring Bore before assembly is 90.0 mm (3.54 inch).

(continued)
60 KENR5631-05
Specifications Section

(Table 43, contd)

6 1 167-2212 Buffer Seal As Lubricate the sealing lip lightly with the lubricant that is being sealed.

7 1 167-2325 U-Cup Seal Lubricate the sealing lip lightly with the lubricant that is being sealed.

8 1 282-9598 Wiper Seal Lubricate the sealing lip lightly with the lubricant that is being sealed.

9 - - Before assembly, apply green Loctite 609 to the wiper seal groove.
KENR5631-05 61
Specifications Section

i05703494

Bulldozer Dual Tilt Cylinder

SMCS Code: 5104

Part No.: 374-2278, 374-2279

Illustration 44 g03622557

Table 44
Specification for 374-2278 Dual Tilt Cylinder and 374-2279 Dual Tilt Cylinder

Item Qty Part Specification Description

1 2 4J-2379 Bushing Bore before assembly is 89.408 ± 0.020 mm (3.5200 ± 0.0008 inch).

Before assembly, lubricate the threads.

2 1 4J-8734 Locknut
Torque to 7500 ± 750 N·m (5532 ± 553 lb ft).

Before assembly, lubricate the threads.

3 1 376-3138 Piston
Torque to 700 ± 70 N·m (516 ± 52 lb ft).

A 1 Cylinder As Bore is 235.00 ± 0.10 mm (9.252 ± 0.004 inch).

B 1 9T-9682 Rod As Diameter is 101.550 ± 0.038 mm (3.9980 ± 0.0015 inch).

C 1 6E-3667 Head Bore over four lands is 101.88 ± 0.03 mm (4.011 ± 0.001 inch).

4 1 5M-0544 Bolt Torque to 1450 ± 150 N·m (1069 ± 111 lb ft).

5 1 311-9319 Buffer Seal As Before assembly, lubricate lightly with lubricant that is being sealed.

6 1 311-9320 U-Cup Seal Before assembly, lubricate lightly with lubricant that is being sealed.

7 1 311-9321 Wiper Seal Before assembly, lubricate lightly with lubricant that is being sealed.

Before assembly, apply green Loctite Retaining Compound 620 to the wiper seal
8 - -
groove.
62 KENR5631-05
Specifications Section

i05699749

Lines (Tilt Cylinder)

SMCS Code: 5057; 5104

Part No.: 359-6445

KENR5631-05 63
Specifications Section

Illustration 45 g03619838

Table 45
Specification for 359-6445 Tilt Cylinder Lines Gp

Item Qty Part Specification Description

1 2 7G-3832 Grommet Lubricate lightly with 5P-3975 Rubber Lubricant when required.

2 2 310-1945 Taperlock Stud Torque to 65 ± 10 N·m (48 ± 7 lb ft).

64 KENR5631-05
Specifications Section

i05700049

Relief Valve (Bulldozer)

SMCS Code: 5117

Part No.: 399-5792

Illustration 46 g03620138

Table 46
Specification for 399-5792 Relief Valve Gp

Item Qty Part Specification Description

1 1 6V-5556 O-Ring Seal Lubricate the seal lightly with the lubricant that is being sealed.

2 1 366-4972 Backup Ring Lubricate the bore lightly with the lubricant that is being sealed.

3 1 9X-6395 Nut Torque to 35 ± 5 N·m (26 ± 4 lb ft).

Length under test force 35.0 mm (1.38 inch).

4 1 125-1393 Spring Test force is 80.0 ± 6.4 N (18.0 ± 1.4 lb).
Free length after test is 40.25 mm (1.585 inch).

5 1 4T-4509 Seat Torque to 22 ± 2 N·m (195 ± 18 lb in).

KENR5631-05 65
Specifications Section

i05699229

Ripper Lift Cylinder

SMCS Code: 5352

Part No.: 374-2276, 374-2277

Illustration 47 g03619396
Typical example

Table 47
Specification for 374-2276 Ripper Cylinder Gp, and 374-2277 Ripper Cylinder Gp

Item Qty Part Specification Description

(continued)
66 KENR5631-05
Specifications Section

(Table 47, contd)

Bore before assembly is 89.225 ± 0.020 mm (3.5128 ± 0.0008 inch).
1 1 3G-7624 Bushing
Installation depth is 9.5 ± 0.5 mm (0.37 ± 0.02 inch).

2 1 4J-6888 Locknut Lubricate threads and torque to 8000 ± 800 N·m (5900 ± 590 lb ft).

A 1 376-3100 Cylinder As Bore is 209.45 mm (8.246 inch).

B 1 377-0924 Rod As Diameter is 101.550 ± 0.038 mm (3.9980 ± 0.0015 inch).

C 1 379-3509 Head Bore over two lands is 106.68 ± 0.03 mm (4.200 ± 0.001 inch).

Bore before assembly is 89.225 ± 0.020 mm (3.5128 ± 0.0008 inch).

3 1 9J-6549 Bushing
Installation depth is 8.9 ± 0.5 mm (0.35 ± 0.02 inch).

4 1 311-9319 Buffer Seal As Lubricate the sealing lip lightly with the fluid that is being sealed.

5 1 311-9320 U-Cup Seal Lubricate the sealing lip lightly with the fluid that is being sealed.

6 1 311-9321 Wiper Seal Lubricate the sealing lip lightly with the fluid that is being sealed.

7 - - Before assembly, apply green Loctite 609 to wiper seal groove.

8 2 8T-0667 Bolt Torque to 900 ± 100 N·m (664 ± 74 lb ft).

9 9 8T-0666 Bolt Torque to 900 ± 100 N·m (664 ± 74 lb ft).

KENR5631-05 67
Specifications Section

i04608638

Relief Valve (Ripper)

SMCS Code: 5117

Part No.: 116-1895

Illustration 48 g02759379

Table 48
Specification for 116-1895 Relief Valve Gp

Item Qty Part Specification Description

Use the following procedure to adjust the relief valve setting:

Loose the nut (2).
1 1 6E-2140 Retainer As
Reposition the retained assembly (1).
Tighten the nut (2) to 65 ± 7 N·m (48 ± 5 lb ft).

2 1 6V-8371 Hex Nut Torque to 65 ± 7 N·m (48 ± 5 lb ft).

3 1 116-1895 Relief Valve Gp Torque to 145 ± 15 N·m (107 ± 11 lb ft).

Length under test force is 41.04 mm (1.616 inch).

4 1 9T-6960 Spring Test force is 467 ± 37 N (105 ± 8 lb).
Free length after test is 44.93 mm (1.769 inch).

5 1 4T-5073 Backup Ring Lubricate the bore lightly with the lubricant that is being sealed.

6 1 7J-9933 O-Ring Seal Lubricate the bore lightly with the lubricant that is being sealed.

7 1 8U-2685 O-Ring Seal Lubricate the bore lightly with the lubricant that is being sealed.

8 1 4T-5072 Backup Ring Lubricate the bore lightly with the lubricant that is being sealed.
68 KENR5631-05
Specifications Section

i04523798

Pin Puller Cylinder

SMCS Code: 5354

Part No.: 6E-3113

Illustration 49 g02709436

Table 49
Specification for 6E-3113 Ripper Pin Puller Cylinder Gp

Item Qty Part Specification Description

Before assembly, lubricate the threads.

1 1 173-9779 Bolt
Torque to 900 ± 100 N·m (664 ± 74 lb ft).

A 1 6E-3976 Cylinder As Bore is 101.60 ± 0.08 mm (4.000 ± 0.003 inch).

B 1 6E-3980 Rod As Diameter is 44.400 ± 0.038 mm (1.7480 ± 0.0015 inch).

C 1 6E-4976 Head Bore of the head over four lands is 44.78 ± 0.03 mm (1.763 ± 0.001 inch).

Before assembly, lubricate the threads with clean grease.

2 1 6E-4976 Head
Torque to 600 ± 130 N·m (443 ± 96 lb ft).

Inside diameter before assembly is 44.45 mm (1.750 inch).

3 1 4T-6907 Wear Ring
Thickness is 1.50 ± 0.03 mm (0.059 ± 0.001 inch).

4 1 167-2190 Buffer Seal As Lubricate lightly with the lubricant that is being sealed.

5 1 167-2300 U-Cup Seal Lubricate lightly with the lubricant that is being sealed.

6 1 231-3539 Wiper Seal Lubricate lightly with the lubricant that is being sealed.

7 - - Before assembly, apply green Loctite 609 to the wiper seal groove.
KENR5631-05 69
Specifications Section

i05699430

Pin Puller
SMCS Code: 6313

Part No.: 372-8795

Illustration 50 g03619596
Left side view

Table 50
Specification for 372-8795 Pin Puller

Item Qty Part Specification description

1 4 6K-0138 Locking Bolt Torque to 240 ± 40 N·m (177 ± 30 lb ft).

70 KENR5631-05
Specifications Section

i05699461

Pin Puller
SMCS Code: 6313

Part No.: 4Z-8946

S/N: RAB1–Up

Illustration 51 g03619621

Table 51
Specification for 4Z-8946 Pin Puller

Item Qty Part Specification description

1 4 6K-0138 Locking Bolt Torque to 240 ± 40 N·m (177 ± 30 lb ft).

KENR5631-05 71
Specifications Section

i05699389

Electronic Control and Mounting

(Ripper)
SMCS Code: 5357

Part No.: 341-3241

S/N: JJW1–Up

Illustration 52 g03619536

Table 52
Specification for 341-3241 Electronic Control and Mounting Gp

Item Qty Part Specification Description

1 4 5W-8591 Bolt Torque to 15 ± 3 N·m (133 ± 27 lb in).

72 KENR5631-05
Specifications Section

i05699631

Ripper Control
SMCS Code: 5063

Part No.: 352-5146

Illustration 53 g03619759

Table 53
Specification for 352-5146 Ripper Control Gp

Item Qty Part Specification Description

Before assembly, apply Lubriplate liberally to the mating surfaces.

1 2 112-0858 Bearing
Bore before assembly is 14.313 ± 0.013 mm (0.5635 ± 0.0005 inch).

Before assembly, apply Lubriplate liberally to the mating surfaces.

2 2 112-0858 Bearing Bore before assembly is 14.313 ± 0.013 mm (0.5635 ± 0.0005 inch).
Bearing to be installed to 0.0 to 0.5 mm (0.00 to 0.02 inch).

3 4 295-4155 Bolt Before assembly, apply blue Loctite 242 to the threads.
KENR5631-05 73
Specifications Section

Illustration 54 g03619772
Detailed view of area A

Table 54
Item Qty Part Specification Description

As required, use the following shims:

1 195-7871 Shim Thickness is 0.25 mm (0.010 inch).

4
1 195-7872 Shim Thickness is 0.41 mm (0.016 inch).

1 195-7869 Shim Thickness is 0.15 mm (0.006 inch).

5
1 195-7870 Shim Thickness is 0.51 mm (0.020 inch).
74 KENR5631-05
Specifications Section

i05703652

Joystick Control and Mounting

SMCS Code: 5063; 5705

Part No.: 439-0391

Illustration 55 g03622776
Top view

Table 55
Specification for 439-0391 Joystick Control and Mounting Gp

Item Qty Part Specification Description

1 2 6V-2317 Bolt Torque to 15 ± 3 N·m (133 ± 27 lb in).

2 2 6V-3940 Bolt Torque to 15 ± 3 N·m (133 ± 27 lb in).

KENR5631-05 75
Specifications Section

i05707151

Joystick Control and Mounting

SMCS Code: 5063; 5705

Part No.: 339-0509

Illustration 56 g03625296

Table 56
Specification for 346-0020 Joystick Control and Mounting Gp

Item Qty Part Specification Description

1 4 112-6646 Locknut Torque to 7 ± 1 N·m (62 ± 9 lb in).

Apply blue Loctite 242 to the threads.

2 1 6V-1820 Bolt
Torque to 30 ± 7 N·m (266 ± 62 lb in).
76 KENR5631-05
Specifications Section

Illustration 57 g03625297

Table 57
Specification for 351-7690 Joystick Control Gp

Item Qty Part Specification Description

Torque to 7 ± 1 N·m (62 ± 9 lb in).

3 2 4B-9808 Setscrew
Apply blue Loctite 242 to the threads.
KENR5631-05 77
Specifications Section

i05707169

Joystick Control and Mounting

SMCS Code: 5063; 5705

Part No.: 346-0020

Illustration 58 g03625317

Table 58
Specification for 346-0020 Joystick Control and Mounting Gp

Item Qty Part Specification Description

1 4 112-6646 Locknut Torque to 7 ± 1 N·m (62 ± 9 lb in).

Apply blue Loctite 242 to the threads.

2 1 6V-1820 Bolt
Torque to 30 ± 7 N·m (266 ± 62 lb in).
78 KENR5631-05
Specifications Section

Illustration 59 g02720485

Table 59
Specification for 342-8944 Joystick Control Gp

Item Qty Part Specification Description

Torque to 7 ± 1 N·m (62 ± 9 lb in).

3 2 4B-9808 Setscrew
Apply blue Loctite 242 to the threads.
KENR5631-05 79
Specifications Section

i05707175

Joystick Control (Bulldozer)

SMCS Code: 5705

Part No.: 351-7690

Illustration 60 g02723459

Table 60
Specifications for 351-7690 Joystick Control Gp

Item Qty Part Specification Description

1 - - As required, apply PLEXUS MA330 ACRYLIC adhesive to the surfaces.

Before assembly, apply sealant to the threads.

2 2 4B-9808 Setscrew
Torque to 7 ± 1 N·m (62 ± 9 lb in).

3 2 175-4165 Screw Torque to 1.53 ± 0.15 N·m (13.54 ± 1.33 lb in).

4 4 112-6646 Locknut Torque to 7 ± 1 N·m (62 ± 9 lb in).

80 KENR5631-05
Specifications Section

i05707189

Joystick Control (Bulldozer)

SMCS Code: 5705

Part No.: 351-7690

Illustration 61 g02723455

Table 61
Specifications for 342-8944 Joystick Control Gp

Item Qty Part Specification Description

1 2 4B-9808 Setscrew Torque to 7 ± 1 N·m (62 ± 9 lb in).

KENR5631-05 81
Specifications Section

Illustration 62 g02723456

Table 62
Specifications for 342-8944 Joystick Control Gp

Item Qty Part Specification Description

2 2 175-4170 Screw Torque to 1.69 ± 0.23 N·m (14.96 ± 2.04 lb in).

Before assembly, apply sealant to the threads.

3 1 175-4168 Screw
Torque to 0.92 ± 0.10 N·m (8.14 ± 0.89 lb in).

4 2 175-4165 Screw Torque to 1.53 ± 0.15 N·m (13.54 ± 1.33 lb in).

82 KENR5631-05
Specifications Section

i05703691

Steering and Transmission

Control Group
SMCS Code: 3033

Part No.: 379-0333

Illustration 63 g03622817

Table 63
Specification for 379-0333 Steering and Transmission Control Gp

Item Qty Part Specification Description

1 4 8T-4137 Bolt Torque to 28 ± 6 N·m (248 ± 53 lb in).

KENR5631-05 83
Specifications Section

i05699249

Push Arm
SMCS Code: 6061

Part No.: 346-6918, 422-0251

Illustration 64 g03619357

Table 64
Specification for 346-6918 Push Arm Gp and 422-0251 Stabilizer Push Arm Gp

Item Qty Part Specification Description

Use as required in order to obtain the clearance of 0.2 to 1.0 mm (0.01 to 0.04 inch) with
1 52 4T-9707 Shim the trunnion ball.
Thickness of one new shim is 0.8 mm (0.03 inch).

2 - - Orient the rod of the cylinder such that, the lubrication fitting is facing down.

3 8 7X-0379 Bolt Torque to 700 ± 90 N·m (516 ± 66 lb ft).

Use as required in order to obtain the clearance of 0.2 to 1.0 mm (0.01 to 0.04 inch) be-
4 52 8E-1378 Shim tween the bearings and the tractor and dozer trunnion ball.
Thickness of one new shim is 0.8 mm (0.03 inch).

(continued)
84 KENR5631-05
Specifications Section

(Table 64, contd)

5 8 7X-0449 Full Nut Torque to 700 ± 90 N·m (516 ± 66 lb ft).

6 2 3G-8053 Pin Diameter is 79.12 ± 0.02 mm (3.115 ± 0.001 inch).

Use minimum of one spacer per side of each connector assembly and maximum of three
7 6 137-8479 Spacer spacers per pin joint.
Thickness of one new spacer is 2 mm (0.1 inch).

8 2 9J-6662 Pin Diameter is 88.65 ± 0.02 mm (3.490 ± 0.001 inch).

KENR5631-05 85
Specifications Section

i05700389

Stabilizer Link
SMCS Code: 6071

Part No.: 346-6916

Illustration 65 g03620366

Table 65
Specification for 346-6916 Stabilizer Link Gp

Item Qty Part Specification Description

1 8 7X-0396 Bolt Torque to 700 ± 90 N·m (516 ± 66 lb ft).

As required, use the shims to obtain a clearance of 0.2 to 1.0 mm (0.01 to 0.04 inch)
2 52 8E-1378 Shim with the bearings, tractor, and dozer trunnion balls:
Thickness is 0.8 mm (0.03 inch).
86 KENR5631-05
Specifications Section

i05703710

Bulldozer Installation
SMCS Code: 6050

Part No.: 346-6924, 422-0255, 422-0256

, 422-0257

Illustration 66 g03622836

Table 66
Specification for 346-6924 Bulldozer Installation Ar,422-0255 Bulldozer Installation Ar, 422-0256 (Bulldozer Installation Ar)and
422-0257 (Bulldozer Installation Ar)

Item Qty Part Specification description

1 2 7T-4810 Pin Diameter is 95.00 ± 0.02 mm (3.740 ± 0.001 inch).

2 8 7X-0379 Bolt Torque to 700 ± 90 N·m (516 ± 66 lb ft).

3 2 3G-8053 Pin Diameter is 79.12 ± 0.02 mm (3.115 ± 0.001 inch).

4 2 9W-2939 Pin Diameter is 57.25 ± 0.10 mm (2.254 ± 0.004 inch).

5 8 8T-8917 Bolt Torque to 120 ± 20 N·m (89 ± 15 lb ft).

6 2 6J-5985 Pin Diameter is 57.09 ± 0.06 mm (2.248 ± 0.002 inch).

KENR5631-05 87
Specifications Section

i05700249

Bulldozer Brace
SMCS Code: 6060; 6074

Part No.: 7T-7577

Illustration 67 g03620558

Table 67
Specification for 7T-7577 Bulldozer Brace

Item Qty Part Specification Description

1 2 7X-0379 Bolt Torque to 750 ± 90 N·m (553 ± 66 lb ft).

2 1 7X-0403 Bolt Torque to 1150 ± 150 N·m (848 ± 111 lb ft).

88 KENR5631-05
Specifications Section

i05703209

Bulldozer Trunnion
SMCS Code: 6069

Part No.: 9J-6073

Illustration 68 g03622256

Table 68
Specification for 9J-6073 Bulldozer Trunnion Gp

Item Qty Part Specification Description

1 28 7X-0405 Bolt Torque to 1050 ± 150 N·m (774 ± 111 lb ft).

KENR5631-05 89
Specifications Section

i05696290

Cutting Edges and End Bits

SMCS Code: 6801; 6804

Part No.: 346-6930

Illustration 69 g03616799

Table 69
Specification for 346-6930 Universal Blade and Edge Gp

Item Qty Part Specification Description

1 39 5P-8823 Bolt Torque to 2300 ± 300 N·m (1696 ± 221 lb ft).

90 KENR5631-05
Specifications Section

i05696309

Cutting Edges and End Bits

SMCS Code: 6801; 6804

Part No.: 346-6933

Illustration 70 g03616818

Table 70
Specification for 346-6933 Semi-Universal Blade and Edge

Item Qty Part Specification Description

1 36 5P-8823 Bolt Torque to 2300 ± 300 N·m (1696 ± 221 lb ft).

KENR5631-05 91
Specifications Section

i05696329

Cutting Edges and End Bits

SMCS Code: 6801; 6804

Part No.: 422-0248

S/N: RAB1–Up

Illustration 71 g03616837

Table 71
Specification for 422-0248 Universal Blade and Edge Gp

Item Qty Part Specification Description

1 39 5P-8823 Bolt Torque to 2300 ± 300 N·m (1696 ± 221 lb ft).

92 KENR5631-05
Specifications Section

i05696349

Cutting Edges and End Bits

SMCS Code: 6801; 6804

Part No.: 422-0246

S/N: RAB1–Up

Illustration 72 g03616841

Table 72
Specification for 422-0246 Universal Blade and Edge Gp

Item Qty Part Specification Description

1 39 5P-8823 Bolt Torque to 2300 ± 300 N·m (1696 ± 221 lb ft).

KENR5631-05 93
Specifications Section

i05696372

Cutting Edges and End Bits

SMCS Code: 6801; 6804

Part No.: 422-0250

S/N: RAB1–Up

Illustration 73 g03616848

Table 73
Specification for 422-0245 Universal Blade As

Item Qty Part Specification Description

1 36 5P-8823 Bolt Torque to 2300 ± 300 N·m (1696 ± 221 lb ft).

94 KENR5631-05
Specifications Section

i05699370

Ripper Frame
SMCS Code: 6310; 7067

Part No.: 378-9332

Illustration 74 g03619496

Table 74
Specification for 378-9332 Ripper Frame

Item Qty Part Specification Description

1 2 9J-9055 Pin As Diameter is 76.17 ± 0.05 mm (2.999 ± 0.002 inch).

2 2 111-2106 Pin As Diameter is 101.45 to 101.60 mm (3.994 to 4.000 inch).

(continued)
KENR5631-05 95
Specifications Section

(Table 74, contd)

Coat bore with 5P-0960 Grease Cartridge after cleaning and before painting.
3 4 2V-0447 Bushing After assembly, bore for the pin assembly (2) is 102.510 ± 0.046 mm
(4.0358 ± 0.0018 inch).

4 2 132-7994 Pin As Diameter is 76.15 ± 0.05 mm (2.998 ± 0.002 inch).

5 2 105-5448 Pin As Diameter is 88.85 ± 0.05 mm (3.498 ± 0.002 inch).

Coat bore with 5P-0960 Grease Cartridge after cleaning and before painting.
6 4 133-2015 Bushing After assembly, bore for the pin assembly (5) is 89.110 ± 0.043 mm
(3.5083 ± 0.0017 inch).

7 2 9J-6689 Pin As Diameter is 101.55 ± 0.05 mm (3.998 ± 0.002 inch).

Coat bore with 5P-0960 Grease Cartridge after cleaning and before painting.
After assembly, bore for the pin assembly (7) is 101.976 ± 0.101 mm
8 2 4T-1422 Bushing
(4.0148 ± 0.0040 inch).
Installation depth is 15.00 ± 0.50 mm (0.590 ± 0.020 inch).

Use the spacers as required.

9 26 9W-6371 Spacer
Thickness of one new spacer is 3 mm (0.1 inch).
96 KENR5631-05
Specifications Section

i05699459

Ripper Frame
SMCS Code: 6310; 7067

Part No.: 378-9331

Illustration 75 g03619618

Table 75
Specification for 378-9331 Ripper Frame

Item Qty Part Specification Description

1 2 9J-9055 Pin As Diameter of pin is 76.17 ± 0.05 mm (2.999 ± 0.002 inch).

2 2 111-2106 Pin As Diameter of pin is 101.45 to 101.60 mm (3.994 to 4.000 inch).

Use spacers as required.

3 24 9W-6371 Spacer
Thickness of one new spacer is 3 mm (0.1 inch).

4 2 9W-6343 Pin As Diameter of pin is 76.15 ± 0.05 mm (2.998 ± 0.002 inch).

5 2 105-5448 Pin As Diameter of pin is 88.85 ± 0.05 mm (3.498 ± 0.002 inch).

(continued)
KENR5631-05 97
Specifications Section

(Table 75, contd)

6 2 7T-7303 Pin As Diameter of pin is 101.55 ± 0.05 mm (3.998 ± 0.002 inch).

Before assembly, coat bores with 5P-0960 Grease Cartridge.

After assembly, bore for the pin assembly (6) is 101.976 ± 0.101 mm
7 4 7T-7190 Bushing
(4.0148 ± 0.0040 inch).
Installation depth is 16.0 ± 1.0 mm (0.63 ± 0.04 inch).
98 KENR5631-05
Specifications Section

i05700866

Ripper Mounting
SMCS Code: 6324

Part No.: 378-9150

Illustration 76 g03620516

Table 76
Specification for 378-9150 Ripper Mounting Gp

Item Qty Part Specification Description

All surface must be clean and free of paint. Coat all the bores with 5P-0960 Grease Cartridge after cleaning and before painting.
Bushings to be flushed with the face of the boss.

1 2 2V-1256 Bushing Bore after assembly is 76.420 ± 0.046 mm (3.0087 ± 0.0018 inch).

2 2 3T-8459 Bushing Bore after assembly is 89.160 ± 0.046 mm (3.5102 ± 0.0018 inch).

3 2 7T-7222 Pin As Diameter is 88.85 ± 0.05 mm (3.498 ± 0.002 inch).

KENR5631-05 99
Specifications Section

i05703469

Ripper Mounting
SMCS Code: 6324

Part No.: 383-9098

Illustration 77 g03622518

Table 77
Specification for 383-9098 Ripper Mounting Gp

Item Qty Part Specification Description

All surface must be clean and free of paint. Coat all the bores with 5P-0960 Grease Cartridge after cleaning and before painting.
Bushings to be flushed with the face of the boss.

1 2 2V-1256 Bushing Bore after assembly is 76.420 ± 0.046 mm (3.0087 ± 0.0018 inch).

2 2 3T-8459 Bushing Bore after assembly is 89.160 ± 0.046 mm (3.5102 ± 0.0018 inch).

3 2 9J-2290 Pin As Diameter is 88.85 ± 0.05 mm (3.498 ± 0.002 inch).

100 KENR5631-05
Specifications Section

i05703569

Ripper Mounting
SMCS Code: 6324

Part No.: 378-9144

Illustration 78 g03622656
Rear view

Table 78
Specification for 378-9144 Ripper Mounting Gp

Item Qty Part Specification Description

1 4 8C-8843 Bolt Torque to 1050 ± 150 N·m (774 ± 111 lb ft).

2 12 7X-0405 Bolt Torque to 1050 ± 150 N·m (774 ± 111 lb ft).

3 20 7X-0439 Bolt Torque to 3600 ± 400 N·m (2655 ± 295 lb ft).

4 2 8T-2502 Bolt Torque to 50 ± 10 N·m (37 ± 7 lb ft).

KENR5631-05 101
Specifications Section

i05699349

Torque Converter
SMCS Code: 3101

Part No.: 374-5783

102 KENR5631-05
Specifications Section

Illustration 79 g03619477

Table 79
Specification for 374-5783 Torque Converter Gp

Item Qty Part Specification Description

1 8 1A-2029 Bolt Torque to 50 ± 7 N·m (37 ± 5 lb ft).

Before assembly, lubricate lock plate surface, thread, and output flange thread.
2 1 1T-0229 Bearing Locknut
Torque to 935 ± 35 N·m (690 ± 26 lb ft).

3 24 3B-1915 Bolt Torque to 50 ± 7 N·m (37 ± 5 lb ft).

4 12 6H-1717 Bolt Torque to 120 ± 15 N·m (89 ± 11 lb ft).

KENR5631-05 103
Specifications Section

i05703493

Torque Converter and Housing

SMCS Code: 3101

Part No.: 359-6482

Illustration 80 g03622556

Table 80
Specification for 359-6482 Torque Converter and Housing Gp

Item Qty Part Specification Description

1 1 3D-8241 O-Ring Seal Before assembly, lubricate the bore lightly with the fluid that is being sealed.

Before assembly, lubricate the sealing lip lightly with the lubricant being
2 1 117-7127 Lip Type Seal
sealed.

3 1 1B-4367 Bolt Torque to 240 ± 25 N·m (177 ± 18 lb ft).

4 2 165-4854 O-Ring Seal Before assembly, lubricate the bore lightly with the fluid that is being sealed.
104 KENR5631-05
Specifications Section

i05699460

Torque Divider
SMCS Code: 3113

Part No.: 374-5784

Illustration 81 g03619617

Table 81
Specification for 374-5784 Torque Converter Gp

Item Qty Part Specification Description

1 8 1A-2029 Bolt Torque to 50 ± 7 N·m (37 ± 5 lb ft).

KENR5631-05 105
Specifications Section

i05699470

Power Train Oil Pump

SMCS Code: 3066

Part No.: 374-9554

106 KENR5631-05
Specifications Section

Illustration 82 g03619641

Table 82
Specification for 374-9554 Gear Pump Gp

Item Qty Part Specification Description

1 4 8T-4196 Bolt Torque to 35 ± 5 N·m (26 ± 4 lb ft).

2 1 2K-0337 Locknut Torque to 110 ± 13 N·m (81 ± 10 lb ft).

3 - - Surface must be free of oil and grease.

(continued)
KENR5631-05 107
Specifications Section

(Table 82, contd)

Lubricate sealing lip lightly with the lubricant that is being sealed.
4 1 111-4919 Lip Type Seal
Apply high strength/high temperature anaerobic flange sealant to seal.

5 1 5H-4279 Cup Plug Apply high strength/high temperature anaerobic flange sealant to plug bore.
108 KENR5631-05
Specifications Section

i05703409

Power Train Oil Pump

(Mounting)
SMCS Code: 3066

Part No.: 374-1212

Illustration 83 g03622477

Table 83
Specification for 374-1212 Power Train Pump and Mounting Gp

Item Qty Part Specification Description

1 2 180-3998 Stud Torque to 35 ± 5 N·m (26 ± 4 lb ft).

2 2 112-1574 O-Ring Seal Lubricate the bore lightly with the lubricant that is being sealed.

3 1 9M-7539 O-Ring Seal Lubricate the bore lightly with the lubricant that is being sealed.
KENR5631-05 109
Specifications Section

i05703611

Relief Valve (Torque Converter

Outlet)
SMCS Code: 3133-OL

Part No.: 381-0180

Illustration 84 g03622721

Table 84
Specification for 378-9150 Ripper Mounting Gp

Item Qty Part Specification Description

1 4 0S-1594 Bolt Torque to 48 ± 7 N·m (35 ± 5 lb ft).

As required, use the following shims:

3 5M-9624 Shim Thickness of one shim is 0.25 mm (0.010 inch).

2
1 5M-9623 Shim Thickness is 0.9 mm (0.04 inch).

1 5M-9622 Shim Thickness is 1.6 mm (0.06 inch).

Length under test force is 59.94 mm (2.360 inch).

3 1 1W-9860 Spring Test force is 231 ± 14 N (52 ± 3 lb).
Free length after test is 73.41 mm (2.890 inch).

4 2 164-5567 Quick Disconnect Coupler As Torque to 14 ± 4 N·m (124 ± 35 lb in).

110 KENR5631-05
Specifications Section

i04483389

Relief Valve (Torque Converter

Inlet)
SMCS Code: 3133-IL

Part No.: 148-1928

Illustration 85 g02663196

Table 85
Specification for 148-1928 Relief Valve (TORQUE CONVERTER INLET)

Item Qty Part Specification Description

- - - Use SAE 10 oil that is 50 °C (122 °F) to test the relief valve.

- - - Cracking pressure is 900 ± 70 kPa (130 ± 10 psi).

- - - Maximum Override pressure at 120 L/min (32 US gpm) is 1100 kPa (160 psi).

- - - Minimum Reset pressure is 760 kPa (110 psi).

KENR5631-05 111
Specifications Section

i05794889

Transmission Hydraulic Control

SMCS Code: 3073

Part No.: 378-2003

Illustration 86 g03619718

Table 86
Specification for 378-2003 Transmission Hydraulic Control Gp

Item Qty Part Specification Description

1 4 451-1493 O-Ring Seal Lubricate the seal with oil that is being sealed.

2 10 113-0920 Bolt Torque to 3.7 ± 0.8 N·m (32.7 ± 7.1 lb in).

3 1 421-8199 Solenoid Valve Gp Torque to 100 ± 10 N·m (74 ± 7 lb ft).

4 1 450-1004 Special Nut Torque to 6.1 ± 0.7 N·m (54.0 ± 6.2 lb in).

Length under test force is 12.70 mm (0.500 inch).

5 2 3J-6956 Spring Test force is 1.69 ± 0.09 N (0.38 ± 0.02 lb).
Free length after test is 19.1 mm (0.75 inch).

6 18 6V-4249 Bolt Torque to 55 ± 10 N·m (41 ± 7 lb ft).

112 KENR5631-05
Specifications Section

i05703592

Transmission Oil Lines

SMCS Code: 3154

Part No.: 374-1209

Illustration 87 g03622698

Table 87
Specification for 374-1209 Transmission Oil Lines Gp

Item Qty Part Specification Description

1 1 357-4903 Flow Control Valve Gp Torque to 27.2 ± 1.4 N·m (240.7 ± 12.4 lb in).
KENR5631-05 113
Specifications Section

i05703629

Power Train Oil Lines

SMCS Code: 3016

Part No.: 374-1210

Illustration 88 g03622723

Table 88
Specification for 374-1210 Power Train Oil Lines Gp

Item Qty Part Specification Description

1 4 180-3998 Stud Torque to 35 ± 5 N·m (26 ± 4 lb ft).

114 KENR5631-05
Specifications Section

i05703651

Filters (Torque Converter and

Transmission)
SMCS Code: 3067

Part No.: 338-9802

Illustration 89 g03622759

Table 89
Specification for 338-9802 Oil Filter Gp

Item Qty Part Specification Description

A - - Minimum distance that is required for removing the oil filter is 25.0 mm (0.98 inch).
KENR5631-05 115
Specifications Section

i05703489

Transmission
(Mounting)
SMCS Code: 3030; 3063; 3155; 3160; 3169; 3190

Part No.: 416-6550

Illustration 90 g03622536

Table 90
Specifications for 416-6550 Transmission Mounting Gp

Item Qty Part Specification Description

1 2 5J-5793 Bolt Torque to 50 ± 10 N·m (37 ± 7 lb ft).

2 3 2A-1531 Bolt Torque to 120 ± 20 N·m (89 ± 15 lb ft).

3 4 0S-1591 Bolt Torque to 50 ± 10 N·m (37 ± 7 lb ft).

4 17 1B-2886 Bolt Torque to 120 ± 20 N·m (89 ± 15 lb ft).

116 KENR5631-05
Specifications Section

i05703731

Transmission
(Planetary)
SMCS Code: 3030; 3063; 3155; 3160; 3169; 3190

Part No.: 372-6095

Illustration 91 g03622879

Table 91
Specification for 372-6095 Transmission Planetary Gp

Item Qty Part Specification Description

1 27 1M-8657 Bolt Torque to 115 ± 7 N·m (85 ± 5 lb ft).

Before assembly of each bearing, lubricate each groove and seal with clean oil that is
2 2 8M-4395 O-Ring Seal
being sealed.

3 1 355-9687 Seal As Lubricate the sealing lip lightly with the lubricant that is being sealed.
KENR5631-05 117
Specifications Section

Illustration 92 g03622996
View of area A

Table 92
Item Qty Part Specification Description

Total thickness of six new friction discs, and six new plates is 73.54 ± 1.01 mm (2.895 ± 0.040 inch):

6 8E-2729 Friction Disc Thickness of one new friction disc is 5.59 ± 0.08 mm (0.220 ± 0.003 inch).
4
1 232-7575 Plate Thickness of one plate is 6.35 ± 0.13 mm (0.250 ± 0.005 inch).

5 3P-7447 Plate Thickness of one plate is 6.73 ± 0.08 mm (0.265 ± 0.003 inch).
118 KENR5631-05
Specifications Section

Illustration 93 g03622997
View of area B

Table 93
Item Qty Part Specification Description

Length under test force is 187.32 mm (7.375 inch).

5 12 114-4652 Spring Test force is 147 ± 12 N (33 ± 3 lb).
Free length after test is 212.7 mm (8.37 inch).

Total thickness of six new friction discs, and six new plates is 73.54 ± 1.01 mm (2.895 ± 0.040 inch):

6 9W-9856 Friction Disc Thickness of one new friction disc is 5.59 ± 0.08 mm (0.220 ± 0.003 inch).
6
1 232-7575 Plate Thickness of one plate is 6.35 ± 0.13 mm (0.250 ± 0.005 inch).

5 3P-7447 Plate Thickness of one plate is 6.73 ± 0.08 mm (0.265 ± 0.003 inch).
KENR5631-05 119
Specifications Section

Illustration 94 g03622998
View of area C

Table 94
Item Qty Part Specification Description

Total thickness of four new friction discs, and three new plates is 42.63 ± 0.56 mm (1.678 ± 0.022 inch):

7 4 233-9748 Friction Disc Thickness of one new friction disc is 5.61 ± 0.08 mm (0.221 ± 0.003 inch).

3 370-8590 Plate Thickness of one plate is 6.73 ± 0.08 mm (0.265 ± 0.003 inch).

Length under test force is 50.8 mm (2.00 inch).

8 12 379-6624 Spring Test force is 304.63 ± 45.70 N (68.48 ± 10.27 lb).
Free length after test is 60.1 mm (2.37 inch).
120 KENR5631-05
Specifications Section

Illustration 95 g03623000
View of area D

Table 95
Item Qty Part Specification Description

Total thickness of three new friction discs, and two new plates is 30.29 ± 0.40 mm (1.193 ± 0.016 inch):

9 3 233-9748 Friction Disc Thickness of one new friction disc is 5.61 ± 0.08 mm (0.221 ± 0.003 inch).

2 370-8590 Plate Thickness of one plate is 6.73 ± 0.08 mm (0.265 ± 0.003 inch).
KENR5631-05 121
Specifications Section

Illustration 96 g03623001
View of area E

Table 96
Item Qty Part Specification Description

Total thickness of six new friction discs, and five new plates is 45.78 ± 1.00 mm (1.802 ± 0.039 inch):

10 6 234-6707 Friction Disc Thickness of one new friction disc is 4.98 ± 0.10 mm (0.196 ± 0.004 inch).

5 370-8592 Plate Thickness of one plate is 3.18 ± 0.08 mm (0.125 ± 0.003 inch).
122 KENR5631-05
Specifications Section

Illustration 97 g03623002
View of area F

Table 97
Item Qty Part Specification Description

11 5 8P-4047 Planetary Shaft Diameter is 42.395 ± 0.006 mm (1.6691 ± 0.0002 inch).

12 5 9G-1919 Planetary Gear Inside diameter is 58.298 ± 0.010 mm (2.295 ± 0.0004 inch).
KENR5631-05 123
Specifications Section

Illustration 98 g03623003
View of area G

Table 98
Item Qty Part Specification Description

13 5 110-9287 Planetary Shaft Diameter is 42.395 ± 0.006 mm (1.6691 ± 0.0002 inch).

14 10 110-9286 Planetary Gear Inside diameter is 58.298 ± 0.008 mm (2.2952 ± 0.0003 inch).
124 KENR5631-05
Specifications Section

Illustration 99 g03623004
View of area H

Table 99
Item Qty Part Specification Description

15 5 6P-6739 Planetary Shaft Diameter is 35.255 ± 0.006 mm (1.3880 ± 0.0002 inch).

16 5 7G-2476 Planetary Gear Inside diameter is 43.221 ± 0.008 mm (1.7016 ± 0.0003 inch).
KENR5631-05 125
Specifications Section

i05703650

Planetary Case and Parts

SMCS Code: 3064

Part No.: 422-0091

Illustration 100 g03622757

Table 100
Specification for 422-0091 Planetary Case and Parts Gp

Item Qty Part Specification Description

1 3 326-0316 Plug As Torque to 135 ± 10 N·m (100 ± 7 lb ft).

126 KENR5631-05
Specifications Section

i05703932

Solenoid Valve (Steering Clutch,

Brake)
SMCS Code: 4804

Part No.: 174-4909

Illustration 101 g03623096

Table 101
Specification for 174-4909 Solenoid Valve Gp

Item Qty Part Specification Description

1 1 218-2373 Nut Torque to 13.0 ± 1.5 N·m (115.1 ± 13.3 lb in).

2 - - Torque to 50 ± 5 N·m (37 ± 4 lb ft).

KENR5631-05 127
Specifications Section

i05794870

Solenoid Valve (Transmission

Clutch)
SMCS Code: 3174; 5479-T3

Part No.: 421-8199

Illustration 102 g03672700

Table 102
Specification for 421-8199 Solenoid Valve Gp

Item Qty Part Specification Description

1 1 450-1004 Special Nut Torque to 6.1 ± 0.7 N·m (54.0 ± 6.2 lb in).

2 1 Cartridge Torque to 100 ± 10 N·m (74 ± 7 lb ft).

Operating voltage is 12 VDC.

- - -
Resistance at 20 °C (68 °F) is 5.40 ± 0.27 ohms.
128 KENR5631-05
Specifications Section

i05570794

Speed Sensor (Transmission

Output)
SMCS Code: 1408-NS; 1439-OJ; 3159-NS; 3175-OJ

Part No.: 191-8304, 191-8305

Illustration 103 g03531017

Typical example

Table 103
Specifications for 191-8304 Speed Sensor Gp and 191-8305 Speed Sensor Gp

Item Qty Part Specification Description

Before assembly, lubricate the O-ring seal lightly with the lubricant that is being sealed.
1 - -
Torque to 28 ± 7 N·m (250 ± 62 lb in).

- - - Output type of the sensor is analog signal.

- - - Minimum clearance between the sensor and the gear tooth is 0.5 mm (0.02 inch).
KENR5631-05 129
Specifications Section

i05703689

Bevel and Transfer Gears

SMCS Code: 3011; 3256; 3281

Part No.: 213-5173

Illustration 104 g03622816

Table 104
Specification for 213-5173 Bevel and Transfer Gear

Item Qty Part Specification Description

Apply red Loctite 271 to the threads.

1 15 9X-8881 Bolt
Torque to 270 ± 40 N·m (199 ± 29 lb ft).

2 41 5P-4143 Locking Bolt Torque to 135 ± 20 N·m (99 ± 15 lb ft).

Apply red Loctite 271 to the threads.

3 4 9X-8883 Bolt
Torque to 270 ± 40 N·m (199 ± 29 lb ft).

4 2 9X-8874 Bolt Torque to 135 ± 20 N·m (99 ± 15 lb ft).

130 KENR5631-05
Specifications Section

Illustration 105 g03622818

Section A-A

Illustration 106 g03622819

Section B-B
KENR5631-05 131
Specifications Section

Table 105
Item Qty Part Specification Description

6 1 032-0676 Locking Bolt Torque to 270 ± 40 N·m (199 ± 29 lb ft).

Lubricate the sealing lip of the lip type seal lightly with the lubricant that is
7 1 216-0273 Lip Type Seal
being sealed.

8 10 9S-1367 Bolt Torque to 1125 ± 100 N·m (830 ± 74 lb ft).

Apply Loctite C5A Copper Anti-Seize to the face and the threads of bearing
9 1 121-9871 Bearing Nut nut.
Torque to 2375 ± 300 N·m (1752 ± 221 lb ft).

As required, use Shim Pack in order to obtain the backlash. Use the following
procedure to obtain the backlash:

1. Install fixture (5) and tighten until there is no movement in the pinion gear.
2. Check the backlash, the backlash must be 0.36 ± 0.12 mm
(0.014 ± 0.005 inch).
3. Check the backlash on three different teeth that are evenly spaced around
the gear.
10 1 3T-4391 Shim Pack 4. The difference between the high measurement and the low measurement
must not be more than 0.15 mm (0.006 inch).
5. Install the correct quantity of shims.
6. Check the gear backlash in order to be certain that the clearance is still cor-
rect. If the clearance is not correct, add or remove shims.
7. Remove fixture (5).

Refer to Disassembly and Assembly, RENR8166, “Bevel and Transfer Gears -

Assemble”.
132 KENR5631-05
Specifications Section

i05703230

Drive Shaft
SMCS Code: 3253

Part No.: 173-0245

Illustration 107 g03622277

Table 106
Specification for 173-0245 Drive Shaft Gp

Item Qty Part Specification Description

1 8 0S-1604 Bolt Torque to 156 ± 7 N·m (115 ± 5 lb ft).

2 8 0S-1604 Bolt Torque to 135 ± 15 N·m (100 ± 11 lb ft).

KENR5631-05 133
Specifications Section

i05699750

Steering and Brake Control Valve

SMCS Code: 4101; 4102; 4120

Part No.: 345-6789

Illustration 108 g03619837

Table 107
Specification for 345-6789 Control Manifold Gp

Item Qty Part Specification Description

1 2 382-0937 Accumulator Gp Torque to 95.2 ± 6.8 N·m (70.2 ± 5.0 lb ft).

134 KENR5631-05
Specifications Section

i06148245

Steering Clutches and Brakes

SMCS Code: 4003; 4101; 4117; 4120

Part No.: 237-1017

Illustration 109 g03622376

Table 108
Specification for 237-1017 Steering Clutch and Brake Gp

Item Qty Part Specification Description

Thickness of eight new friction discs and seven new plates for the steering clutch is 59.830 ± 1.965 mm (2.3555 ± 0.0774 inch):
1
8 255-9267 Friction Disc Thickness of one new friction disc is 4.70 ± 0.18 mm (0.185 ± 0.007 inch).

(continued)
KENR5631-05 135
Specifications Section

(Table 108, contd)

7 7T-6994 Plate Thickness of one new plate is 3.175 ± 0.075 mm (0.1250 ± 0.0030 inch).

Thickness of ten new friction discs and ten new plates for the brakes is 110.30 ± 2.55 mm (4.343 ± 0.100 inch):

2 10 215-8140 Friction Disc Thickness of one new friction disc is 5.56 ± 0.18 mm (0.219 ± 0.007 inch).

10 109-0063 Plate Thickness of one new plate is 5.470 ± 0.075 mm (0.2154 ± 0.0030 inch).

Length under test force is 29.80 mm (1.173 inch).

3 1 105-3372 Spring Test force is 13.86 N (3.12 lb).
Free length after test is 38.10 mm (1.500 inch).
136 KENR5631-05
Specifications Section

i05699870

Final Drive
SMCS Code: 4003; 4050; 4059; 4084

Part No.: 110-2656

Illustration 110 g03619976

Typical example
KENR5631-05 137
Specifications Section

Table 109
Specification for 110-2656 Final Drive Gp and 110-2780 Final Drive Gp

Item Qty Part Specification Description

Gap required to ensure metal to metal clamp-up between the shaft and plate
is 0.08 ± 0.05 mm (0.003 ± 0.002 inch).
Check the gap before each plate is bolted to the shafts.
B - -
After the plates are bolted, make sure that the gears can turn freely. If the
gears cannot turn freely, then drive the plates toward the carrier with the prop-
er tooling.

1 35 8T-9400 Bolt Torque to 700 ± 90 N·m (516 ± 66 lb ft).

Rubber toric rings and all surfaces in contact with seals must be clean and
dry at assembly. Apply a thin layer of oil to the contacting surfaces of the met-
2 1 -
al seals just before installation. Seal rings must be assembled square with
the bore. Toric seals must not be bulged or twisted.

3 8 5D-0353 Locking Bolt Torque to 50 ± 10 N·m (37 ± 7 lb ft).

Gap required to ensure metal to metal clamp-up between the hub and re-
E - -
tainer is 0.08 ± 0.05 mm (0.003 ± 0.002 inch).

4 8 030-8538 Bolt Torque to 135 ± 20 N·m (100 ± 15 lb ft).

5 1 124-2375 Lip Type Seal Lubricate the sealing lip lightly with the lubricant that is being sealed.

6 16 5K-7143 Self-Locking Bolt Torque to 135 ± 20 N·m (100 ± 15 lb ft).

Illustration 111 g03619977

Table 110
Item Qty Part Specification Description

7 1 6V-3298 Magnetic Plug Torque to 225 ± 20 N·m (166 ± 15 lb ft).

8 1 9S-4185 O-Ring Plug Torque to 80 ± 8 N·m (59 ± 6 lb ft).

138 KENR5631-05
Specifications Section

i05703509

Final Drive
SMCS Code: 4003; 4050; 4059; 4084

Part No.: 192-0722

KENR5631-05 139
Specifications Section

Illustration 112 g03622576

Table 111
Specification for 192-0722 Final Drive Gp

Item Qty Part Specification Description

(continued)
140 KENR5631-05
Specifications Section

(Table 111, contd)

Gap required to ensure metal to metal clamp-up between the shaft and plate
is 0.08 ± 0.05 mm (0.003 ± 0.002 inch).
Check the gap before each plate is bolted to the shafts.
B - -
After the plates are bolted, make sure that the gears can turn freely. If the
gears cannot turn freely, then drive the plates toward the carrier with the prop-
er tooling.

1 35 8T-9400 Bolt Torque to 700 ± 90 N·m (516 ± 66 lb ft).

2 8 5D-0353 Locking Bolt Torque to 50 ± 10 N·m (37 ± 7 lb ft).

3 8 030-8538 Bolt Torque to 135 ± 20 N·m (100 ± 15 lb ft).

Gap required to ensure metal to metal clamp-up between the hub and re-
E - -
tainer is 0.08 ± 0.05 mm (0.003 ± 0.002 inch).

Rubber toric rings and all surfaces in contact with seals must be clean and
dry at assembly. Apply a thin layer of oil to the contacting surfaces of the met-
4 1 6Y-0857 Duo-Cone Seal Gp
al seals just before installation. Seal rings must be assembled square with
the bore. Toric seals must not be bulged or twisted.

Before assembly, apply a thin film of lubricant to diameter (F) of 2.0 mm

(0.08 inch). Offset the two seal joints to 180 degrees.
5 2 189-6244 Seal Gently stretch each seal as it is installed. Smooth each seal to lay flat and uni-
form all around and to have minimal gap to the ends with no bunching.

6 2 189-3063 Retainer Offset the plate joints 90 degrees to seal joints.

7 1 124-2375 Lip Type Seal Lubricate the sealing lip lightly with the lubricant that is being sealed.

8 16 5K-7143 Self-Locking Bolt Torque to 135 ± 20 N·m (100 ± 15 lb ft).

Illustration 113 g03622577

Table 112
Item Qty Part Specification Description

9 1 6V-3298 Magnetic Plug Torque to 225 ± 20 N·m (166 ± 15 lb ft).

10 1 9S-4185 O-Ring Plug Torque to 80 ± 8 N·m (59 ± 6 lb ft).

KENR5631-05 141
Specifications Section

i05758109

Final Drive Mounting

SMCS Code: 4050-MT

Part No.: 350-9316

Illustration 114 g03655097

Table 113
Specification for 350-9316 Final Drive Mounting Gp

Item Qty Part Specification Description

Use the following procedure to tighten the bolts:

Tighten the bolt to 800 ± 80 N·m (590 ± 59 lb ft).

1 60 6C-3214 Bolt
Again, tighten to an additional angle of 60 ± 5 degrees.

Note: Do not reuse the bolts.

142 KENR5631-05
Specifications Section

i05758111

Final Drive Mounting

SMCS Code: 4050-MT

Part No.: 371-6968

Illustration 115 g03655100

Table 114
Specification for 371-6968 Final Drive Mounting Gp

Item Qty Part Specification Description

Use the following procedure to tighten the bolts:

Tighten the bolt to 800 ± 80 N·m (590 ± 59 lb ft).

1 44 6C-3214 Bolt
Again, tighten to an additional angle of 60 ± 5 degrees.

Note: Do not reuse the bolts.

KENR5631-05 143
Specifications Section

i05699529

Equalizer Bar
SMCS Code: 7206; 7207

Part No.: 222-3676

Illustration 116 g03619677

Table 115
Specification for 222-3676 Equalizer Bar Gp

Item Qty Part Specification Description

1 2 380-7428 Relief Valve Torque to 50 ± 8 N·m (37 ± 6 lb ft).

1. Apply Loctite 7649 Primer N to the internal threads for setscrew.

2 8 2F-5326 Setscrew
2. Apply green Loctite 620 to threads and assemble below flush with bar.

Apply green Loctite 620 to the seating surface before assembly. Assemble the seal
3 4 207-7107 Seal As
with the part number facing towards outside of the bar.

Apply green Loctite 620 to the seating surface before assembly. Assemble the seal
4 1 8P-9142 Seal
with the part number facing towards outside of the bar.

Assemble the bushings flush with the side marked “FRONT”.

5 1 251-9905 Bushing Before assembly, outside diameter is 127.18 ± 0.05 mm (5.007 ± 0.002 inch).
Before assembly, inside diameter is 115.14 ± 0.08 mm (4.533 ± 0.003 inch).

Apply green Loctite 620 to the seating surface before assembly. Assemble the seal
6 1 9G-2398 Seal
with the part number facing towards outside of the bar.
144 KENR5631-05
Specifications Section

i05700009

Telescoping Recoil Frame

SMCS Code: 4151

Part No.: 364-3802, 364-3803, 426-3806

, 426-3807

Illustration 117 g03620116

Table 116
Specification for 364-3802 Telescoping Recoil Frame Gp, 426-3806 Telescoping Recoil Frame Gp, 426-3807 Telescoping Recoil
Frame Gp, and 364-3803 Telescoping Recoil Frame Gp

Item Qty Part Specification description

1 12 7X-0342 Bolt Torque to 115 ± 20 N·m (85 ± 15 lb ft).

2 18 9G-7516 Plug Tighten the plug to seat on chamfers.

Clean all mating surfaces with a degreaser. Wipe all mating surfaces with a clean cloth in
order to remove debris and contaminants. Apply Hi-temp flange sealant on the mating
3 1 9X-4588 Seal As
surfaces before seal installation.
Lubricate seal lightly with the lubricant that is being sealed.

(continued)
KENR5631-05 145
Specifications Section

(Table 116, contd)

4 1 7G-1952 Bearing Inside diameter before installation is 371.48 mm (14.625 inch).

5 4 7X-0420 Bolt Torque to 115 ± 20 N·m (85 ± 15 lb ft).

Outside diameter before installation is 223.491 ± 0.038 mm (8.7988 ± 0.0015 inch).

6 1 7T-4134 Bushing
Thickness is 4.00 ± 0.02 mm (0.157 ± 0.001 inch).

Outside diameter before installation is 192.400 ± 0.038 mm (7.5748 ± 0.0015 inch).

7 1 7G-9709 Bushing
Thickness is 4.00 ± 0.02 mm (0.157 ± 0.001 inch)
146 KENR5631-05
Specifications Section

i05703653

Roller Frame Mounting

SMCS Code: 4151

Part No.: 380-7422, 380-7423, 380-7424

Illustration 118 g03623017

Table 117
Specification for 380-7422 Roller Frame Mounting, 380-74223 Roller Frame Mounting, and 380-7424 Roller Frame Mounting

Item Qty Part Specification Description

1 - - Install plug (2) after assembly of cover.

3 2 Pivot Shaft Seal Before assembly, clean all mating surfaces with degreaser, wipe clean to remove debris and
4 2 7T-4145 Sleeve contaminants. Apply 5P-0960 Grease Cartridge to both mating surfaces.

5 24 6V-8849 Bolt Torque to 475 ± 60 N·m (350 ± 44 lb ft).

6 2 9M-5894 O-Ring Seal Before assembly, Lubricate lightly with the lubricant that is being sealed.

7 2 Retainer Install retainer with bolt hole aligned with tapped hole in roller frame assembly.
KENR5631-05 147
Specifications Section

Illustration 119 g03623018

View B-B

Table 118
Item Qty Part Specification Description

8 4 5P-2566 Bolt Use the following procedure to tighten the bolts (8) and (9):

1. Install bolts (8) and hand tighten the bolts.

9 4 346-0351 Bolt 2. Install the bolts (9) and tighten in the sequence of front, back, front, back. Then, tighten to
1600 ± 200 N·m (1180 ± 148 lb ft).
3. Push the guard against the track roller frame and tighten the bolts (8) to standard torque.

10 1 438-4790 Pin(1) Diameter is 82.350 ± 0.025 mm (3.2421 ± 0.0010 inch).

Before assembly, wipe pin and bore with new clean, dry disposable towel.
11 1 278-0237 Pin
Liberally apply 5P-0960 Grease Cartridge to the pin, saddle bores, and pin bore.
(1) Protect pin from paint
148 KENR5631-05
Specifications Section

i05700036

Recoil Group
SMCS Code: 4151; 4157; 4158

Part No.: 355-1296, 355-1297

KENR5631-05 149
Specifications Section

Illustration 120 g03620136

Table 119
Specification for 355-1296 Track Adjuster and Recoil Gp and 355-1297 Track Adjuster and Recoil Gp

Item Qty Part Specification Description

1 1 7I-3928 Tube Before assembly, lubricate the contact surfaces.

2 1 190-8609 Fill Valve Torque to 34 ± 7 N·m (25 ± 5 lb ft).

3 1 2S-5926 Relief Valve Torque to 34 ± 7 N·m (25 ± 5 lb ft).

(continued)
150 KENR5631-05
Specifications Section

(Table 119, contd)

4 1 8T-1981 U-Cup Seal Before assembly, lubricate the sealing lip of the U-Cup Seal.

5 2 362-3565 Wear Ring Before assembly, lubricate the sealing lip of the wear seal.

6 2 362-3564 Wear Ring Before assembly, lubricate the sealing lip of the wear seal.

Length under test force 987 mm (38.9 inch).

7 1 7T-3926 Spring Test force is 262923 N (59108 lb).
Free length after test is 1254.8 ± 20.0 mm (49.40 ± 0.79 inch).
KENR5631-05 151
Specifications Section

i05699649

Track Carrier Roller

SMCS Code: 4154

Part No.: 359-9904, 385-4710

Illustration 121 g03619763

Table 120
Specification for 359-9904 Track Carrier Roller and 385-4710 Track Carrier Roller

Item Qty Part Specification Description

During assembly, lubricate the threads with Loctite C5A Copper Anti-Seize.
1 4 6T-1139 Bolt Tighten the bolt on abutment side of the cap prior to tighten the bolt on gap side of the cap.
Torque to 1125 ± 100 N·m (830 ± 74 lb ft).
152 KENR5631-05
Specifications Section

Illustration 122 g03619765

Table 121
Item Qty Part Specification Description

2 16 241-1855 Bolt Torque to 135 ± 20 N·m (99 ± 15 lb ft).

The rubber toric seals and all the contacting surfaces must be clean and dry at assembly. Before
162-7863 Duo-Cone assembly, apply a thin film of molykote paste to the contacting surfaces of the metal seal rings.
3 2
Seal Gp The metal seal rings must be assembled square. The rubber toric seals should not bulge and the
rubber toric seals should not twist.

4 2 107-4057 O-Ring Seal Lubricate the bore lightly with lubricant that is being sealed.

Lubricate the surface lightly with lubricant that is being sealed.

154-3306 Track Roller
5 1 Dimension (C) for the extension of the shaft from the collar on both sides is 61.92 ± 0.13 mm
Shaft
(2.438 ± 0.005 inch).

The plug must not be recessed below the surface of the stopper assembly.
A - - Install the plug so that the end is even with the stopper assembly. The plug can extend up to
0 to 5 mm (0.0 to 0.2 inch) out of the stopper assembly.

Installation depth for installing the stopper assembly below the end of the track roller shaft is
B - -
11 ± 4 mm (0.4 ± 0.2 inch)

Minimum end play of track roller shaft is 0.26 mm (0.010 inch).

- - -
Maximum end play of track roller shaft is 1.26 mm (0.050 inch).
KENR5631-05 153
Specifications Section

i05703449

Track Roller (Single Flange)

SMCS Code: 4180

Part No.: 309-7679, 332-6423

S/N: RAB1–Up
Part No.: 309-7679, 332-6423, 423-1333
S/N: JJW1–Up

Illustration 123 g03622559

Typical example

Table 122
Specification for 309-7679 Track Roller Gp, 423-1333 Track Roller Gp, and 332-6423 Track Roller Gp

Item Qty Part Specification Description

1 2 9W-9499 Bushing After assembly, bore is 127.25 ± 0.04 mm (5.010 ± 0.002 inch).

2 16 241-1855 Bolt Torque to 135 ± 20 N·m (100 ± 15 lb ft).

Rubber toric seals and all surfaces that in contact with the seals must be clean
and dry at assembly. Prior to assembly apply, a thin layer of oil to the surfaces
162-7863 Duo-Cone Seal
3 2 that are in contact with the metal seals. The metal seal must be assembled
Gp
square with the bore. The rubber toric seals must not bulge. The rubber toric
seals must not be twisted.

4 2 107-4057 O-Ring Seal Lubricate the bore lightly with the lubricant that is being sealed.

(continued)
154 KENR5631-05
Specifications Section

(Table 122, contd)

Distance to the bushing from the face of the roller on each side is 21.5 ± 0.5 mm
A - -
(0.85 ± 0.02 inch).

The stopper assembly must not be recessed below the surface of the stopper
after assembly.
B 1 8E-6620 Stopper As
Dimension for installing the stopper below the end of the shaft is 11 ± 4 mm
(0.4 ± 0.2 inch).

Extension of the shaft from the surface of the collar on both side is
C 1 154-3306 Track Roller Shaft 61.92 ± 0.13 mm (2.438 ± 0.005 inch).

Minimum end play is 0.26 mm (0.010 inch).

- - -
Maximum end play is 1.26 mm (0.050 inch).
KENR5631-05 155
Specifications Section

i05703552

Track Roller (Double Flange)

SMCS Code: 4180

Part No.: 309-7678, 332-6424

Illustration 124 g03622636

Typical example

Table 123
Specification for 332-6424 Double Flange Track Roller and 309-7678 Double Flange Track Roller

Item Qty Part Specification Description

1 2 9W-9499 Bushing After assembly, bore is 127.25 ± 0.04 mm (5.010 ± 0.002 inch).

2 16 241-1855 Bolt Torque to 135 ± 20 N·m (100 ± 15 lb ft).

Rubber toric seals and all surfaces that in contact with the seals must be clean and dry
at assembly. Prior to assembly apply, a thin layer of oil to the surfaces that are in contact
3 2 162-7863 Duo-Cone Seal Gp
with the metal seals. The metal seal must be assembled square with the bore. The rub-
ber toric seals must not bulge. The rubber toric seals must not be twisted.

4 2 107-4057 O-Ring Seal Lubricate the bore lightly with the lubricant that is being sealed.

Distance to the bushing from the face of the roller on each side is 21.5 ± 0.5 mm
A - -
(0.85 ± 0.02 inch).

(continued)
156 KENR5631-05
Specifications Section

(Table 123, contd)

The stopper assembly must not be recessed below the surface of the stopper after
assembly.
B 1 8E-6620 Stopper As
Dimension for installing the stopper below the end of the shaft is 11 ± 4 mm
(0.4 ± 0.2 inch).

Extension of the shaft from the surface of the collar on both side is 61.92 ± 0.13 mm
C 1 154-3306 Track Roller Shaft (2.438 ± 0.005 inch).

Minimum end play is 0.26 mm (0.010 inch).

- - -
Maximum end play is 1.26 mm (0.050 inch).
KENR5631-05 157
Specifications Section

i05699789

Idlers (Track)
SMCS Code: 4159

Part No.: 167-1946

Illustration 125 g03619877

Table 124
Specification for 167-1946 Track Idler Gp

Item Qty Part Specification Description

Dimension above the surface of the stopper is 0 to 5 mm (0 to 0.2 inch).

A 1 6Y-0473 Clear Plug
The plug must not be recessed below the surface of the stopper.

Dimension for installing the stopper below the end of the shaft 11 ± 4 mm
B 1 9G-4872 Rubber Stopper
(0.4 ± 0.1 inch).

Lubricate with the lubricant that is being sealed.

C 1 154-3308 Track Idler Shaft Dimension for the extension of the shaft from the collar on both sides
70.08 ± 0.13 mm (2.759 ± 0.005 inch).

1 2 7R-8872 O-Ring Seal Lubricate the bore lightly with the lubricant that is being sealed.

Rubber toric seals must be clean and dry at assembly. All surfaces that contact the
toric seals must be clean and dry at assembly. At assembly, apply a thin film of oil to
the contacting surfaces of the metal seal. Seal rings must be assembled squarely
2 2 162-7864 Duo-Cone Seal Gp
with the bore. The toric ring must not bulge and the toric ring must not be twisted.
Refer to Special Instruction, SEHS8364, “Assembly and Installation of Conventional
Duo-Cone Seals”.

3 24 8T-4835 Bolt Torque to 135 ± 20 N·m (99 ± 15 lb ft).

End play (clearance) of the idler shaft:

- - - Minimum 0.33 mm (0.013 inch).
Maximum 1.19 mm (0.047 inch).
158 KENR5631-05
Specifications Section

Illustration 126 g03622716

332-6008 Idler and Bearing As

Table 125
Item Qty Part Specification Description

After assembly, bore is 136.78 ± 0.03 mm (5.385 ± 0.001 inch).

D 2 9W-4194 Bushing
Installation depth of the bushing is 13.0 ± 0.5 mm (0.51 ± 0.02 inch).
KENR5631-05 159
Specifications Section

i05699831

Idlers (Track)
SMCS Code: 4159

Part No.: 245-9947

Illustration 127 g03619900

Table 126
Specification for 245-9947 Track Idler Gp

Item Qty Part Specification Description

Dimension above the surface of the stopper is 0 to 5 mm (0 to 0.2 inch).

A 1 6Y-0473 Clear Plug
The plug must not be recessed below the surface of the stopper.

Dimension for installing the stopper below the end of the shaft 7 ± 7 mm
B 1 9G-4872 Rubber Stopper
(0.3 ± 0.3 inch).

Lubricate with the lubricant that is being sealed.

C 1 154-3308 Track Idler Shaft Dimension for the extension of the shaft from the collar on both sides
69.42 ± 0.13 mm (2.733 ± 0.005 inch).

1 2 7R-8872 O-Ring Seal Lubricate the bore lightly with the lubricant that is being sealed.

Rubber toric seals must be clean and dry at assembly. All surfaces that contact the
toric seals must be clean and dry at assembly. At assembly, apply a thin film of oil to
the contacting surfaces of the metal seal. Seal rings must be assembled squarely
2 2 162-7864 Duo-Cone Seal Gp
with the bore. The toric ring must not bulge and the toric ring must not be twisted.
Refer to Special Instruction, SEHS8364, “Assembly and Installation of Conventional
Duo-Cone Seals”.

3 24 4K-5175 Bolt Torque to 135 ± 20 N·m (99 ± 15 lb ft).

End play (clearance) of the idler shaft:

- - - Minimum 0.23 mm (0.009 inch).
Maximum 1.21 mm (0.048 inch).
160 KENR5631-05
Specifications Section

Illustration 128 g03622716

332-6008 Idler and Bearing As

Illustration 129 g03622724

Table 127
Item Qty Part Specification Description

After assembly, bore is 136.78 ± 0.03 mm (5.385 ± 0.001 inch).

D 2 9W-4194 Bushing
Installation depth of the bushing is 13.0 ± 0.5 mm (0.51 ± 0.02 inch).
KENR5631-05 161
Specifications Section

i05703492

Idlers (Track)
SMCS Code: 4159

Part No.: 125-3537

Illustration 130 g03622540

Table 128
Specification for 125-3537 Track Idler Gp

Item Qty Part Specification Description

End play (clearance) of the idler shaft:

- - - Minimum 0.23 mm (0.009 inch).
Maximum 1.29 mm (0.051 inch).

1 2 7R-8872 O-Ring Seal Lubricate lightly with the lubricant that is being sealed.

Dimension above the surface of the stopper is 0 to 5 mm (0.0 to 0.2 inch).

A 1 6Y-0473 Clear Plug
The plug must not be recessed below the surface of the stopper after assembly.

Dimension for installing the rubber stopper below the end of the shaft is 7 ± 7 mm
B 1 9G-4872 Rubber Stopper
(0.3 ± 0.3 inch).

Dimension for the extension of the shaft from the collar on both sides 69.42 ± 0.13 mm
C 1 154-3308 Track Idler Shaft (2.733 ± 0.005 inch).

(continued)
162 KENR5631-05
Specifications Section

(Table 128, contd)

Rubber toric seals must be clean and dry at assembly. All surfaces that contact the toric
seals must be clean and dry at assembly. At assembly, apply a thin film of oil to the con-
2 2 162-7864 Duo-Cone Seal Gp tacting surfaces of the 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. Refer to Special In-
struction, SEHS8364, “Assembly and Installation of Conventional Duo-Cone Seals”.

3 24 4K-5175 Bolt Torque to 135 ± 20 N·m (100 ± 15 lb ft).

4 2 9W-4194 Bushing Bore after assembly is 136.78 ± 0.03 mm (5.385 ± 0.001 inch).
KENR5631-05 163
Specifications Section

i05703550

Idlers (Track)
SMCS Code: 4159

Part No.: 198-7309

Illustration 131 g03622737

Table 129
Specification for 198-7309 Idler Gp

Item Qty Part Specification Description

End play (clearance) of the idler shaft:

- - - Minimum 0.31 mm (0.012 inch).
Maximum 1.21 mm (0.048 inch).

Dimension above the surface of the stopper is 2.5 ± 2.5 mm (0.10 ± 0.10 inch).
A 1 6Y-0473 Clear Plug
The plug must not be recessed below the surface of the stopper after assembly.

Dimension for installing the rubber stopper below the end of the shaft is 7 ± 7 mm
B 1 9G-4872 Rubber Stopper
(0.3 ± 0.3 inch).

(continued)
164 KENR5631-05
Specifications Section

(Table 129, contd)

Dimension for the extension of the shaft from the collar on both sides
C 1 154-3308 Track Idler Shaft 69.42 ± 0.13 mm (2.733 ± 0.005 inch).

1 2 7R-8872 O-Ring Seal Lubricate lightly with the lubricant that is being sealed.

Rubber toric seals must be clean and dry at assembly. All surfaces that contact the
toric seals must be clean and dry at assembly. At assembly, apply a thin film of oil to
the contacting surfaces of the metal seal. Seal rings must be assembled squarely
2 2 162-7864 Duo-Cone Seal Gp
with the bore. The toric ring must not bulge and the toric ring must not be twisted.
Refer to Special Instruction, SEHS8364, “Assembly and Installation of Conventional
Duo-Cone Seals”.

3 24 6J-2515 Bolt Torque to 135 ± 20 N·m (100 ± 15 lb ft).

4 2 9W-4194 Bushing Bore after assembly is 136.78 ± 0.03 mm (5.385 ± 0.001 inch).
KENR5631-05 165
Specifications Section

i05703329

Tracks
SMCS Code: 4170

Part No.: 398-5236

Illustration 132 g03622377

Table 130
Specification for 398-5236 Track Link As(1)

Item Qty Part Specification Description

Use the following procedure to tighten the bolts for the full inks:

1. Torque the bolts to 870 ± 90 N·m (641 ± 66 lb ft).

2. Again, tighten the bolts to an additional angle of 120 ± 5 degrees.
- - -
Use the following procedure to tighten the bolts for the master links:

1. Torque the bolts to 700 ± 70 N·m (516 ± 51 lb ft).

2. Again, tighten the bolts to an additional angle of 90 ± 5 degrees.

- - - The maximum assembly force for the track link assembly is 840000 N (188840 lb).

- - - The reference setting force is 630000 N (141630 lb).

A - - Distance between the bolt holes is 190.00 ± 0.39 mm (7.480 ± 0.015 inch).

B - - Distance between the bolt holes is 250.00 ± 0.39 mm (9.842 ± 0.015 inch).

C - - Distance between the bolt holes is 190.00 ± 0.80 mm (7.480 ± 0.031 inch).

(continued)
166 KENR5631-05
Specifications Section

(Table 130, contd)

D - - Distance between the bolt holes is 258.00 ± 0.80 mm (10.157 ± 0.031 inch).

Dimension above the surface of the stopper is 0.0 to 2.0 mm (0.00 to 0.08 inch).
E - -
The plug must not be recessed below the surface of the stopper.

F - - Protrusion at one end of the pin is 2.1 ± 0.8 mm (0.08 ± 0.03 inch).

G - - Distance from the end of the pin to the surface of the stopper is 8.0 ± 4.0 mm (0.31 ± 0.16 inch).

H - - Bushing protrusion at each end 1.66 ± 0.13 mm (0.065 ± 0.005 inch).

(1) All joints of the link assembly must have flexibility even with a measurable end play of zero. Flexibility is the ability for movement from the
weight of the link assembly.
KENR5631-05 167
Specifications Section

i05703429

Tracks
SMCS Code: 4170

Part No.: 380-5946, 398-5234

Illustration 133 g03622478

Table 131
Specification for 398-5234 Track Link As(1) and 380-5946 Track Link As(1)

Item Qty Part Specification Description

Use the following procedure to tighten the bolts for the full links:

1. Torque the bolts to 870 ± 90 N·m (641 ± 66 lb ft).

2. Again, tighten the bolts by an additional turn of 120 ± 5 degrees.
- - -
Use the following procedure to tighten the bolts for the master links:

1. Torque the bolts to 700 ± 70 N·m (516 ± 52 lb ft).

2. Again, tighten the bolts by an additional turn of 90 ± 5 degrees.

- - - The maximum assembly force for the track link assembly is 835000 N (187716 lb).

- - - The reference setting force is 630000 N (141630 lb).

A - - Distance between the bolt holes is 190.00 ± 0.39 mm (7.480 ± 0.015 inch).

B - - Distance between the bolt holes is 250.00 ± 0.39 mm (9.842 ± 0.015 inch).

C - - Distance between the bolt holes is 190.00 ± 0.80 mm (7.480 ± 0.031 inch).

(continued)
168 KENR5631-05
Specifications Section

(Table 131, contd)

D - - Distance between the bolt holes is 258.00 ± 0.80 mm (10.157 ± 0.031 inch).

Dimension above the surface of the stopper is 0.0 to 2.0 mm (0.00 to 0.08 inch).
E - -
The plug must not be recessed below the surface of the stopper.

F - - Protrusion at one end of the pin is 1.97 ± 0.13 mm (0.077 ± 0.005 inch).

G - - Distance from the end of the pin to the surface of the stopper is 8.0 ± 4.0 mm (0.31 ± 0.16 inch).

H - - Bushing protrusion at each end 1.66 ± 0.13 mm (0.065 ± 0.005 inch).

(1) All joints of the link assembly must have flexibility even with a measurable end play of zero. Flexibility is the ability for movement from the
weight of the link assembly.
KENR5631-05 169
Specifications Section

i05699629

Sprocket Segment
SMCS Code: 4155

Part No.: 160-4928, 278-2351

Illustration 134 g03619761

Table 132
Specification for 160-4928 Sprocket Segment Gp, and 278-2351 Sprocket Segment Gp

Item Qty Part Specification Description

During assembly, lubricate the bolts, hard washers, and nuts with SAE 30 or an equivalent.

Use the following procedure in order to tighten the nut:

1 30 2M-5656 Nut 1. Tighten the nut to 870 ± 70 N·m (642 ± 52 lb ft).
2. Again, tighten the nut to an additional angle of 120 degrees.
170 KENR5631-05
Specifications Section

i05696129

Case and Frame

SMCS Code: 3281; 4117

Part No.: 372-9206

Illustration 135 g03619456

Table 133
Specification for 372-9206 Case and Frame Gp

Item Qty Part Specification Description

After assembly, bore is 63.576 ± 0.061 mm (2.5030 ± 0.0024 inch).

1 4 7T-9014 Bushing
During installation flush the bushing with outside surface.

(continued)
KENR5631-05 171
Specifications Section

(Table 133, contd)

After assembly, bore is 63.576 ± 0.061 mm (2.5030 ± 0.0024 inch).
2 2 8P-7598 Bushing
During installation flush the bushing with outside surface.

3 2 8P-0420 Bearing After assembly, bore is 57.321 ± 0.061 mm (2.2567 ± 0.0024 inch).

Valve should not be assembled below flush with inside wall of the case.
4 1 106-8186 Drain Valve
Apply blue Loctite 242 to the internal threads of the drain valve.

5 2 3T-9658 Bushing Before assembly, bore is 102.08 ± 0.03 mm (4.019 ± 0.001 inch).

6 2 7T-4135 Bearing After assembly, bore is 215.23 ± 0.10 mm (8.474 ± 0.004 inch).
172 KENR5631-05
Specifications Section

i05699411

Case and Frame

SMCS Code: 3281; 4117

Part No.: 372-7045

Illustration 136 g03619558

Table 134
Specification for 372-7045 Case and Frame Gp

Item Qty Part Specification Description

After assembly, bore is 63.576 ± 0.061 mm (2.5030 ± 0.0024 inch).

1 4 7T-9014 Bushing
During installation flush the bushing with outside surface.

After assembly, bore is 63.576 ± 0.061 mm (2.5030 ± 0.0024 inch).

2 2 8P-7598 Bushing
During installation flush the bushing with outside surface.

3 2 8P-0420 Bearing After assembly, bore is 57.321 ± 0.061 mm (2.2567 ± 0.0024 inch).

Valve should not be assembled below flush with inside wall of the case.
4 1 106-8186 Drain Valve
Apply blue Loctite 242 to the internal threads of the drain valve.

5 2 3T-9658 Bushing Before assembly, bore is 102.08 ± 0.03 mm (4.019 ± 0.001 inch).

6 2 7T-4135 Bearing After assembly, bore is 215.23 ± 0.10 mm (8.474 ± 0.004 inch).
KENR5631-05 173
Specifications Section

i05699632

Bogie Suspension
SMCS Code: 7217

Part No.: 426-3810

Illustration 137 g03619760

Table 135
Specification for 426-3810 Bogie Suspension Gp

Item Qty Part Specification description

- - - Coat all bores for the pin assemblies with black 4C-5592 Anti-Seize Compound.

(continued)
174 KENR5631-05
Specifications Section

(Table 135, contd)

Apply black 4C-5592 Anti-Seize Compound to cartridge pin bores before installing the cartridge
pins.
393-1127 Cartridge Pin The end of the cartridge pin with the larger diameter must be installed next to the cover. the end of
1 2
Assembly the pin with the large diameter may be marked with a 4.8 mm (0.19 inch) hole or letter “X” . The
hole must be on top of the vertical centerline or on the bottom of the vertical centerline. This end of
the cartridge pin must be even with the outside surface of the major bogie.

2 2 6T-1382 Minor Bogie Assemble the minor bogie with words “This Side Out” toward the outside of the major bogies.

Apply black 4C-5592 Anti-Seize Compound to cartridge pin bores before installing the cartridge
pins.
251-3273 Cartridge Pin The end of the cartridge pin with the larger diameter must be installed next to the cover. the end of
3 14
Assembly the pin with the large diameter may be marked with a 4.8 mm (0.19 inch) hole or letter “X” . The
hole must be on top of the vertical centerline or on the bottom of the vertical centerline. This end of
the cartridge pin must be even with the outside surface of the major bogie.

4 16 1D-4629 Bolt Torque to 750 ± 90 N·m (553 ± 66 lb ft).

KENR5631-05 175
Specifications Section

i05703516

Bogie Suspension
SMCS Code: 7217

Part No.: 397-7285, 426-3798, 426-3799

Illustration 138 g03622596

Typical example

Table 136
Specification for 397-7285 Bogie Suspension Gp, 426-3798 Bogie Suspension Gp, and 426-3799 Bogie Suspension Gp

Item Qty Part Specification description

Coat all bores for the pin assemblies with black 4C-5592 Anti-Seize Compound.

Apply black 4C-5592 Anti-Seize Compound to cartridge pin bores before installing the cartridge
pins.
The end of the cartridge pin with the larger diameter must be installed next to the cover. The end of
1 2 - the pin with the large diameter may be marked with a 4.8 mm (0.19 inch) hole or letter “X” . The
hole or the letter must be on top of the vertical centerline or on the bottom of the vertical centerline.
This end of the cartridge pin must be even with the outside surface of the major bogie.
Diameter of 358-5256 Pin is 82.500 ± 0.025 mm (3.2480 ± 0.0010 inch).

2 8 6T-1382 Minor Bogie Assemble the minor bogie with words “This Side Out” toward the outside of the major bogies.

(continued)
176 KENR5631-05
Specifications Section

(Table 136, contd)

Apply black 4C-5592 Anti-Seize Compound to cartridge pin bores before installing the cartridge
pins.
The end of the cartridge pin with the larger diameter must be installed next to the cover. The end of
3 14 - the pin with the large diameter may be marked with a 4.8 mm (0.19 inch) hole or letter “X” . The
hole or the letter must be on top of the vertical centerline or on the bottom of the vertical centerline.
This end of the cartridge pin must be even with the outside surface of the major bogie.
Diameter of 7G-2535 Pin is 63.500 ± 0.025 mm (2.5000 ± 0.0010 inch).

3 16 1D-4629 Bolt Torque to 750 ± 90 N·m (553 ± 66 lb ft).

KENR5631-05 177
Specifications Section

i05653988

Refrigerant Compressor
SMCS Code: 1802

Part No.: 324-9711

Illustration 139 g03563816

Typical view

Table 137
Specification for 320-1291 Refrigerant Compressor Gp, and 324-9711 Refrigerant Compressor Gp

Item Qty Part Specification description

Plug assembly is under pressure when the system is pressurized.

1 1 7T-4532 Plug As
Toque to 19.6 ± 4.9 N·m (173.5 ± 43.4 lb in).

314-4018 Pressure Relief Valve Opening pressure is 3800 ± 300 kPa (550 ± 44 psi).
2 1
Assembly Sealing pressure is 3010 kPa (435 psi).

- - - Maximum belt tension force is 1176 N (264 lb).

- - - Displacement per revolution is 154.9 cc (9.5 cubic inch).

- - - Recommended Compressor speed is 2700 ± 200 rpm.

Refrigerant Oil
- - -
Oil capacity is 180 mL (6 oz).

- - - Poly Alkaline Glycol Oil (PAG).

- - - Cat 4C-2959 Air Conditioner Lubricant (250 mL (8.45 Oz)).

R-134a Refrigerant
- - - DuPont is SUVA TRANS A/C HFC134a.
ICI is KLEA 134a.
Magnetic Clutch
Clutch 24 DCV coil resistance (BK(Black) wire) at 20° C (68° F) is 17.6 ± 0.6 ohms.
- - -
Minimum voltage for engagement is 16 DCV.
Maximum Current at 20° C (68° F) 1.42 amp.
178 KENR5631-05
Specifications Section

Note: Refer to Systems Operation, “Identifying the

Air Conditioning System”.
KENR5631-05 179
Specifications Section

i06213325

Refrigerant Compressor
SMCS Code: 1802

Part No.: 324-9711

Illustration 140 g03631017

Table 138
Specification for 324-9711 Refrigerant Compressor Gp

Item Qty Part Specification description

Plug assembly is under pressure when the system is pressurized.
1 1 7T-4532 Plug As
Toque to 19.6 ± 4.9 N·m (173.5 ± 43.4 lb in).

314-4018 Pressure Relief Valve Opening pressure is 3800 ± 300 kPa (550 ± 44 psi).
2 1
Assembly Sealing pressure is 3010 kPa (435 psi).

- - - Displacement per revolution is 154.9 cc (9.5 cubic inch).

- - - Poly Alkaline Glycol Oil (PAG).

Magnetic Clutch
Clutch 24 DCV coil resistance at 20° C (68° F) is 14.6 ± 0.6 ohms.
- - -
Minimum voltage for engagement is 16 DCV.
Maximum current at 20° C (68° F) is 1.7 amp.

Note: Refer to Systems Operation, “Location of

Components (HVAC System)”.
180 KENR5631-05
Specifications Section

i04556067

Refrigerant Condenser
SMCS Code: 1805

Part No.: 329-4025

Illustration 141 g02724025

Table 139
Specification for 329-4025 Refrigerant Condenser Gp

Item Qty Part Specification Description

1 12 8T-4192 Bolt Torque to 50 ± 10 N·m (37 ± 7 lb ft).

KENR5631-05 181
Specifications Section

Illustration 142 g02724027

View of area A without case

Table 140
Specification for 329-4025 Refrigerant Condenser Gp

Item Qty Part Specification Description

Apply 4C-5592 Anti-Seize Compound to the motor shaft to prevent seizing of fan to
2 2 308-6335 Electric Motor Gp
motor shaft.

3 2 5C-2890 Nut Torque to 6 ± 1 N·m (53 ± 9 lb in).

4 4 8T-6685 Bolt Before assembly, apply blue Loctite 242 to the threads.

5 2 325-4416 Stud Torque to 7 ± 2 N·m (62 ± 18 lb in).

Extension of spring pin from condenser coil assembly block is 6.0 ± 2.0 mm
6 1 2D-6403 Spring Pin
(0.24 ± 0.08 inch).

7 2 3H-7180 Setscrew Torque to 6 ± 1 N·m (53 ± 9 lb in).

182 KENR5631-05
Specifications Section

i05703610

Heater and Air Conditioner

SMCS Code: 7304; 7309; 7320

Part No.: 418-6840

KENR5631-05 183
Specifications Section

Illustration 143 g03622719

184 KENR5631-05
Specifications Section

Table 141
Specification for 418-6840 Heater and Air Conditioner Gp

Item Qty Part Specification Description

1 4 6V-7357 Bolt Torque to 6 ± 1 N·m (53 ± 9 lb in).

2 4 248-6772 Screw Torque to 2.30 ± 0.25 N·m (20.36 ± 2.21 lb in).

3 3 311-3520 Screw Torque to 1.2 ± 0.2 N·m (10.6 ± 1.8 lb in).

4 15 3E-8020 Screw Torque to 6 ± 1 N·m (53 ± 9 lb in).

5 4 5C-9553 Bolt Torque to 6 ± 1 N·m (53 ± 9 lb in).

6 1 8T-4189 Bolt Torque to 15 ± 3 N·m (133 ± 27 lb in).

Illustration 144 g03622760

View of area A

Table 142
Specification for 418-6840 Heater and Air Conditioner Gp

Item Qty Part Specification Description

7 1 8C-7581 Screw Torque to 1.40 ± 0.25 N·m (12.39 ± 2.21 lb in).

8 2 119-3859 Screw Torque to 2.30 ± 0.25 N·m (20.36 ± 2.21 lb in).

9 2 9X-2044 Screw Torque to 6 ± 1 N·m (53 ± 9 lb in).

KENR5631-05 185
Specifications Section

i05699531

Operator Console
SMCS Code: 5258; 7300; 7451

Part No.: 421-1044

Illustration 145 g03619696

Table 143
Specification for 421-1044 Operator Console Gp

Item Qty Part Specification Description

1 5 9X-2044 Screw Torque to 6 ± 1 N·m (53 ± 9 lb in).

2 7 3E-8020 Screw Torque to 6 ± 1 N·m (53 ± 9 lb in).

3 8 9X-2045 Screw Torque to 6 ± 1 N·m (53 ± 9 lb in).

4 4 9X-2042 Screw Torque to 6 ± 1 N·m (53 ± 9 lb in).

5 2 233-9161 Screw Torque to 1.7 ± 0.4 N·m (15.0 ± 3.5 lb in).

6 3 127-2170 Screw Torque to 6 ± 1 N·m (53 ± 9 lb in).

186 KENR5631-05
Specifications Section

i05699429

Cab Air Filter

SMCS Code: 7342

Part No.: 357-4272

Illustration 146 g03619577

Table 144
Specification for 357-4272 Cab Air Filter Gp

Item Qty Part Specification Description

1 1 333-2108 Rain Cap As Tighten 3E-7404 Hose Clamp to maximum 2 N·m (18 lb in).
KENR5631-05 187
Specifications Section

i05703269

Cab
SMCS Code: 7301; 7325; 7335

Part No.: 379-6562

S/N: RAB1–Up

Illustration 147 g03622336

Table 145
Specification for 379-6562 Cab Gp

Item Qty Part Specification description

1 1 4H-3001 Button Plug Apply, clear Loctite RTV Silicone Clear.

(continued)
188 KENR5631-05
Specifications Section

(Table 145, contd)

Apply dow corning 732 RTV sealant to all at splice.
2 2 364-1427 Seal
Apply clear Loctite RTV Silicone Clear.

3 2 9R-5616 Plug Apply clear Loctite RTV Silicone Clear.

4 1 285-3985 Button Plug Apply, clear Loctite RTV Silicone Clear.

5 8 8T-4138 Bolt Torque to 5.1 ± 0.3 N·m (45.1 ± 2.7 lb in).

6 2 5M-8500 Knob Apply, blue Loctite 242.

7 2 9M-5884 Bumper Apply clear Loctite 411 to the surface.

Apply dow corning 732 RTV sealant to all at splice.

8 - -
Apply clear Loctite RTV Silicone Clear.
KENR5631-05 189
Specifications Section

i05699709

Cover (Cab)
SMCS Code: 7301-CH

Part No.: 445-6234

Illustration 148 g03619779

Table 146
Specification for 445-6234 Cab Cover Gp

Item Qty Part Specification description

1 36 9X-2045 Screw Torque to 6 ± 1 N·m (53 ± 9 lb in).

2 3 9X-2044 Screw Torque to 6 ± 1 N·m (53 ± 9 lb in).

3 2 9X-2046 Screw Torque to 6 ± 1 N·m (53 ± 9 lb in).

4 8 104-2091 Flat Head Screw Torque to 0.9 ± 0.2 N·m (8.0 ± 1.8 lb in).
190 KENR5631-05
Specifications Section

i05699650

ROPS Mounting
SMCS Code: 7266; 7323-MT; 7325-MT

Part No.: 420-6205

Illustration 149 g03619764

Table 147
Specification for 420-6205 Rollover Protective Structure (ROPS) Mounting Gp

Item Qty Part Specification Description

1 16 288-8101 Bolt Torque to 2000 ± 250 N·m (1475 ± 184 lb ft).

KENR5631-05 191
Specifications Section

i05703729

Operator Platform (Remote)

SMCS Code: 7253-ZM

Part No.: 436-6515

Illustration 150 g03622876

Table 148
Specification for 436-6515 Operator Platform Gp

Item Qty Part Specification Description

2 5C-9553 Bolt Torque to 6 ± 1 N·m (53 ± 9 lb in).

192 KENR5631-05
Specifications Section

i05703589

Counterweight Group
SMCS Code: 7056

Part No.: 248-6690, 248-6727

Illustration 151 g03622697

Table 149
Specification for 248-6690 Counterweight Gp and 248-6727 (Counterweight Gp)

Item Qty Part Specification Description

1 2 7T-7222 Pin As Diameter is 88.85 ± 0.05 mm (3.498 ± 0.002 inch).

2 2 4T-1389 Pin As Diameter is 88.85 ± 0.05 mm (3.498 ± 0.002 inch).

3 2 9J-6689 Pin As Diameter is 101.55 ± 0.05 mm (3.998 ± 0.002 inch).

KENR5631-05 193
Specifications Section

i05699458

Fuel Tank
SMCS Code: 1273

Part No.: 373-3188

Illustration 152 g03619620

Table 150
Specification for 373-3188 Fuel Tank Gp

Item Qty Part Specification Description

Apply blue Loctite 242 to threads.

1 5 6V-2314 Bolt
Torque to 3.3 ± 0.7 N·m (29.2 ± 6.2 lb in).

328-9050 Liquid Level Sensor

2 1 Operating voltage is 9 to 36 VDC.
As

3 2 5P-2618 Connector Torque to 3.4 ± 1 N·m (30 ± 9 lb in).

194 KENR5631-05
Specifications Section

i05699570

Fuel Tank
SMCS Code: 1273

Part No.: 373-3189

Illustration 153 g03619717

Table 151
Specification for 373-3189 Fuel Tank Gp

Item Qty Part Specification Description

Apply blue Loctite 242 to threads.

1 5 6V-2314 Bolt
Torque to 3.3 ± 0.7 N·m (29.2 ± 6.2 lb in).

328-9050 Liquid Level Sensor

2 1 Operating voltage is 9 to 36 VDC.
As

3 2 5P-2618 Connector Torque to 3.4 ± 1 N·m (30 ± 9 lb in).

KENR5631-05 195
Specifications Section

i05703393

Electric Drive Pump (Ladder)

SMCS Code: 5057; 5713

Part No.: 379-6545

Illustration 154 g03622456

Table 152
Specifications for 379-6545 Electric Drive Pump Gp

Item Qty Part Specification Description

1 1 Nut Torque to 3.4 N·m (30.1 lb in).

2 - - Tighten the terminal to 3.4 to 4.5 N·m (30.1 to 39.8 lb in).

3 1 Bolt Torque to 7.3 to 8.5 N·m (64.6 to 75.2 lb in).

4 1 Nut Torque to 6.8 to 9.5 N·m (60.2 to 84.1 lb in).

5 1 Nut Torque to 4.5 N·m (39.8 lb in).

6 1 Nut Torque to 9.5 N·m (84.1 lb in).

7 - - Tighten to 12.9 to 16.9 N·m (114.2 to 149.6 lb in).

8 1 Nut Torque to 5.4 to 6.8 N·m (47.8 to 60.2 lb in).

9 - - Tighten the bolt to 24.4 to 27.1 N·m (215.9 to 239.9 lb in).

10 8 Bolt Torque to 12.9 to 16.9 N·m (114.2 to 149.6 lb in).

(continued)
196 KENR5631-05
Specifications Section

(Table 152, contd)

11 2 Bolt Torque to 7.9 to 9.0 N·m (69.9 to 79.7 lb in).

12 1 Check Valve Cap Torque to 17.5 to 19.7 N·m (154.9 to 174.4 lb in).

13 1 Plug Torque to 23.7 to 26.0 N·m (209.8 to 230.1 lb in).

14 1 Check Valve Cap Torque to 17.5 to 19.7 N·m (154.9 to 174.4 lb in).

15 1 Plug Torque to 23.7 to 26.0 N·m (209.8 to 230.1 lb in).

16 - Cartridge Torque to 24.4 to 27.1 N·m (215.9 to 239.9 lb in).

KENR5631-05 197
Specifications Section

i05706369

Toggle Switch (Ladder)

SMCS Code: 1408; 7254; 7332

Part No.: 301-2980

Illustration 155 g03624736

Table 153
Specification for 301-2980 Toggle Switch

Item Qty Part Specification Description

1 1 266-7191 Toggle Switch Final installation torque to 3.8 N·m (33.6 lb in).

2 2 6T-3631 Hex Nut Torque to 2.2 ± 0.1 N·m (19.5 ± 0.9 lb in).

Position of the contacts when the handle is in the center position is nor-
- - -
mally open.
198 KENR5631-05
Specifications Section

i05699630

Toggle Switch (Ground Level

Shutdown)
SMCS Code: 1408; 7332

Part No.: 301-2979

Illustration 156 g03363476

Table 154
Specification for 301-2979 Toggle Switch Gp

Item Qty Part Specification Description

1 1 271-2178 Toggle Switch Torque to 3.8 N·m (33.6 lb in).

2 2 6T-3631 Hex Nut Torque to 2.2 ± 0.1 N·m (19.5 ± 0.9 lb in).
KENR5631-05 199
Specifications Section

i05703291

Ether Starting Aid

SMCS Code: 1456

Part No.: 359-6462

200 KENR5631-05
Specifications Section

Illustration 157 g03622356

Table 155
Specification for 359-6462 Ether Starting Aid Gp

Item Qty Part Specification Description

1 2 Bolt Torque to 11.3 ± 1.1 N·m (100.0 ± 9.7 lb in).

2 1 101-3129 Stud Torque to 35 ± 5 N·m (26 ± 4 lb ft).

Position the final installation such that the orifice spray indication mark is directed
3 2 427-6302 Atomizer As
against the incoming air stream.
KENR5631-05 201
Specifications Section

i05703349

Air Cleaner
SMCS Code: 1051; 1054

Part No.: 359-6463

Illustration 158 g03622397

Table 156
Specification for 359-6463 Air Cleaner Gp

Item Qty Part Specification Description

1 20 8T-4195 Bolt Torque to 27 ± 4 N·m (239 ± 35 lb in).

202 KENR5631-05
Specifications Section

i05703532

Dust Ejector
SMCS Code: 1068

Part No.: 359-6469

Illustration 159 g03622616

Table 157
Specification for 359-6469 Dust Ejector Gp

Item Qty Part Specification Description

Gap in the clamps should not align with the tube slots.
1 2 176-8234 Clamp
Torque to 10 to 13 N·m (89 to 115 lb in).
KENR5631-05 203
Hydraulic System

Systems Operation Section

Hydraulic System

i05142116

General Information (Hydraulic

System)
SMCS Code: 5050; 7000
204 KENR5631-05
Hydraulic System

Illustration 160 g03304216

KENR5631-05 205
Hydraulic System

(1) Hydraulic oil cooler (5) Charge filter by-pass switch (9) Implement valve stack
(2) Implement pumps (6) Implement control lever (10) Implement relief valve
(3) Accumulator (7) Ripper control lever
(4) Charge filter (8) Hydraulic oil tank

The implement hydraulic system is a load sensing Implement Controls

system that controls the operation of the bulldozer
blade and the operation of the ripper or winch (if
equipped). Both Implement pumps are variable
displacement pumps that supply oil to the implement
valve. flow varies to match the load sense demand of
the system while keeping the hydraulic pressure
constant. The pump work together to meet the full
command flow of oil to the hydraulic system. The
implement hydraulic system is controlled by the
machine ECM, implement ECM, and various
operator controls.

i05668755

Location of Components
(Hydraulic System)
SMCS Code: 3000; 3100; 4000; 5050

Implement Pumps

Illustration 162 g03319643

The blade control lever is located on the right console

of the operator station. For additional information on
the sensors and switches on the control lever, refer to
System Operation, “Electronic Control (Hydraulic
System)”.

Illustration 161 g03319178

Both hydraulic Implement pumps are located under

the floor plate in the cab.

Reference: Refer to System Operation, KENR5631,

“Piston Pump (Implement)”.
206 KENR5631-05
Hydraulic System

Implement Control Valves

Illustration 163 g03319750

The ripper control lever (If equipped) is located to the Illustration 165 g03320980
rear of the blade control lever on the right console of Implement Control Valves
the operator station. For additional information on the (A) Blade Lift Control Valve (Right)
sensors and switches on the ripper control lever, (B) Blade Tilt control Valve (Right)
refer to System Operation, “Electronic Control (C) Ripper Tip Control Valve
(Hydraulic System)”. (D) Inlet Manifold
(E) Implement Relief Valve
(AA) Blade Lift Control Valve (Left))
(BB) Blade Tilt control Valve (Left)
(CC) Ripper Lift Control Valve

The hydraulic Implement valves and solenoids are

located under the floor plate in the cab. For additional
information on the solenoids controlling the
implement control valves, refer to System Operation,
“Electronic Control (Hydraulic System)”.

Illustration 164 g03319832

The Implement Lockout Switch is located on the

panel above the right console of the operator station.
For additional information refer to System Operation,
“Electronic Control (Hydraulic System)”.
KENR5631-05 207
Hydraulic System

Hydraulic Tank Hydraulic Oil Cooler

Illustration 166 g03320648 Illustration 168 g03326901

The hydraulic oil tank is located on the rear of the The hydraulic oil cooler is located at the front of the
machine, mounted on the right fender just in front of machine behind the radiator.
the fuel tank.
Accumulator
Hydraulic Oil Filter

Illustration 169 g03323116

There are two identical accumulators on the right-

hand fender the one closer to the front of the
machine is for the fan charging system. The
accumulator closer to the rear of the tractor is the
pilot accumulator.

Illustration 167 g03323074 Pin Puller Cylinder and Valve

The charge filter is mounted to the inside of the right Reference: Refer to SysOp, KENR5631, “Location of
fender inside a compartment. The compartment is to Components (Power Train)”.
the right of the step.
208 KENR5631-05
Hydraulic System

Hydraulic Oil Temperature Sensor Hydraulic Tank Filter Bypass

Switch

Illustration 170 g03595256

Illustration 172 g03595377

The hydraulic oil temperature sensor is located on
the inside facing side of the hydraulic oil tank. For The hydraulic tank filter bypass switch is located on
additional information refer to System Operation,
the inside side of the hydraulic tank. For additional
“Electronic Control (Hydraulic System)”.

Charge Filter Bypass Switch

Illustration 171 g03595319

The charge filter bypass switch is located on the right

side of the machine on the charge filter. For
additional information refer to System Operation,
“Electronic Control (Hydraulic System)”.
KENR5631-05 209
Hydraulic System

information refer to System Operation, “Electronic

Control (Hydraulic System)”.

i05293436

Electronic Control (Hydraulic

System)
SMCS Code: 1400; 5050; 7610

Electronic Control Modules

Implement ECM

Illustration 173 g03307257

(1) Implement ECM
(2) J1 machine harness connector
(3) J2 machine harness connector

Illustration 174 g01309473

ECM Connectors and Contacts
The Implement ECM determines actions that are
based on input information and memory information.
After the Implement ECM receives the input
information, the ECM sends a corresponding
response to the outputs. The inputs and outputs of
the Implement ECM are connected to the machine
harness by two 70 contact connectors (J1 and J2).
The ECM sends the information to the Caterpillar
Electronic Technician (Cat ET) on the Cat Data Link.
Note: The ECM is not serviceable. The ECM must be
replaced if the ECM is damaged. Replace the ECM if
a failure is diagnosed.
210 KENR5631-05
Hydraulic System

ECM Pull Up Voltage (Table 158, contd)

Implement ECM Contact Description J1 Contact De-
In order to aid in diagnostics of certain types of scriptions(1)
electrical circuits that are controlled by the ECM, an
internal “pull up voltage” is connected to ECM switch No.(2) Type Function
and sensor signal input contacts. An above normal
voltage is internally connected to the ECM signal 13 Battery Return Battery -
input circuit through a resister.
20 CAN C Data Link + CAN C Data Link +
During normal operation, the switch or sensor signal 21 Sensor Power Return 5V Sensor Return
will hold the circuit low or at a certain signal
amplitude, however, circuit conditions such as a loss Hydraulic Oil Temperature
22 Analog Input
of power to the component, a disconnection, or an Sensor
open circuit will allow the circuit to be pulled high by 23 Battery Return Battery -
the ECM pull up voltage. This condition will result in
an above normal voltage condition at the ECM Switch to Battery
Implement Shutoff Switch
24
contact. As a result, the ECM will activate an FMI 03 Input
(voltage above normal) diagnostic code for the
affected circuit. Switch to Ground
27 ECM Location 1
Input
The types of ECM input circuits that have pull up
voltage present are: 31 Battery Power Input Battery +

Switch to Ground
• Pulse Width Modulated (PWM) sensor input 32
Input
ECM Location Enable
circuits
Switch to Ground Single/Dual Tilt Trigger Switch
33
• Switch to Ground Input switch input circuits Input (N/C)

• Active analog (voltage) input signal circuits Switch to Ground Single/Dual Tilt Trigger Switch
34
Input (N/O)
• Passive analog (resistance) input signal circuits Blade Manual Select Switch (N/
Switch to Ground
35
Input C)
ECM Pull Down Voltage
Main Implement Pump Pressure
36 Analog Input
Sensor
In order to aid in diagnostics of electrical circuits that
are controlled by the ECM, an internal “pull down 38 Battery Power Input Battery +
voltage” is connected to ECM switch to battery type
input circuits. 39 Battery Power Input Battery +

During normal operation, the switch contacts that are Switch to Ground Blade Manual Select Switch (N/
40
Input O)
allowing the connection to a voltage source will hold
the circuit high. When circuit conditions such as a Switch to Ground
loss of power to the switch supply voltage, a 41 Blade Mode Select Switch (N/C)
Input
disconnection in the switch circuit or an open circuit
will allow the circuit to be pulled low by the ECM pull Switch to Ground
Blade Mode Select Switch (N/O)
42
down voltage. This condition will result in a below Input
normal voltage condition at the ECM contact. As a
47 Battery Power Input Battery +
result, the ECM will activate an FMI 04 (voltage
below normal) diagnostic code for the affected circuit. Sourcing Driver
48 Blade Raise Solenoid
Output
Pin Locations
Sourcing Driver
Table 158 49 Blade Lower Solenoid
Output
Implement ECM Contact Description J1 Contact De-
scriptions(1) 50 Souring Driver Return PWM Drivers 1 - 4 Return

Type Sourcing Driver Right Tilt Cylinder Extend

No.(2) Function 51
Output Solenoid
1 Key Switch Input Key Switch Run
Sourcing Driver Right Tilt Cylinder Retract
52
10 CAN C Data Link - CAN C Data Link - Output Solenoid

11 Sensor Power +5V Sensor Supply 55 Souring Driver Return PWM Driver 9-12 Return

(continued) (continued)
KENR5631-05 211
Hydraulic System

(Table 158, contd) (Table 159, contd)

Implement ECM Contact Description J1 Contact De- Implement ECM Contact Description J2(1)
scriptions(1)
No.(2) Type Function
No.(2) Type Function
Ripper Raise/Lower Position
27 PWM Input
56 Sensor Power Return 10V Return Sensor

57 Battery Return Battery - Switch to Ground

28 Right Front Charge Filter Switch
Input
Sourcing Driver
58 Ripper Raise
Output 32 PWM Input Ripper In/Out Position Sensor

Sourcing Driver Switch to Ground

59 Ripper Lower 38 Auto Ripper Switch (N/C)
Output Input

Sourcing Driver Switch to Ground

60 PWM Driver 5-8 Return 39 Auto Ripper Switch (N/O)
Return Input
Sourcing Driver Switch to Ground Proportional Solenoid Return
61 Ripper Shank In 46
Output Input Feedback 1
Sourcing Driver Switch to Ground Proportional Solenoid Return
62 Ripper Shank Out 47
Output Input Feedback 2
Switch to Ground Right Cylinder Lift Position
63 Ripper Auto Stow Switch (N/C) 48 PWM Input
Input Sensor
Switch to Ground 49 PWM Input Left Cylinder Lift Position Sensor
64 Ripper Auto Stow Switch (N/O)
Input
Switch to Ground
52 Hydraulic Tank Oil Filter
Sourcing Driver Input
65 Blade Raise Solenoid 2
Output
Switch To Ground
61 Remote Control Enable
Sourcing Driver Input
66 Blade Lower Solenoid 2
Output
64 CAN Data Link + CAN B Data Link +
Sourcing Driver
67 Left Tilt Cylinder Extend Solenoid 65 CAN Data Link - CAN B Data Link -
Output
67 CAN Data Link + CAN A Data Link +
Sourcing Driver Left Tilt Cylinder Retract
68
Output Solenoid 68 CAN Data Link - CAN A Data Link -
(1) The ECM responds to an active input only when all of the nec-
Sensory Power
69 10V Sensor Supply essary conditions are satisfied.
Output (2) The connector contacts that are not listed are not used.
70 Battery Return Battery -
(1) Contacts that are not listed are not used. Inputs
(2) The connector contacts that are not listed are not used.
The machine has several different types of input
Table 159 devices. The ECM receives machine status
information from the input devices and determines
Implement ECM Contact Description J2(1) the correct output action that is needed in order to
control machine operations based on memory and
No.(2) Type Function software parameters. The machine utilizes the
Sourcing Driver following types of inputs: switch type and sensor
2 Implement Shutoff Switch type.
Output

Sourcing Driver Switches provide signals to the switch inputs of the

4 Load Return 1 ECM. The possible outputs of a switch are listed: an
Return
open signal, a grounded signal and + battery signal.
22 Return Sensor / Driver Return
Blade Raise/Lower Position Sensors provide an electrical signal to the ECM that
24 PWM Input constantly changes. The sensor input to the ECM
Sensor
can be one of several different types of electrical
25 PWM Input Blade Tilt Position Sensor signals such as: pulse width modulated (PWM)
signals, voltage signals and frequency input signals.
26 PWM Input Blade Pitch Position Sensor
Each possible input to the ECM is listed in the tables
for the 70-pin connectors.
(continued)
212 KENR5631-05
Hydraulic System

Inputs provide information to the ECM in the form of Main Implement Pump Sensor
sensors or switches.

Sensors
Sensors provide information to the ECM about the
intent of the operator or changing conditions. The
sensor signal changes proportionally to the changing
of operator input or changing conditions. The
following types of sensor signals are used by the
ECM.
Frequency – The sensor produces a signal and the
frequency (Hz) varies as the condition changes.
Pulse width modulated – The sensor produces a
signal. The duty cycle of the signal varies as the
condition changes. The frequency of this signal is
constant.

Analog – The ECM measures the voltage that is

associated to a specific condition of the control.

Hydraulic Oil Temperature Sensor Illustration 176 g03346558

The main implement pump sensor is an active analog

sensor. The sensor sends an output voltage that is
proportional to the pressure of the main implement
pump sensor.

Illustration 175 g03345886

The hydraulic oil temperature sensor is a passive

analog sensor. The resistance of the sensor changes
proportionally to temperature changes. The ECM
measures the resistance of the sensor and
determines the temperature of the hydraulic oil. If the
ECM detects that the hydraulic oil has exceeded a
preset temperature, The ECM sends a signal to the
engine ECM to engage the hydraulic fan.
KENR5631-05 213
Hydraulic System

Blade Control Handle Blade Pitch Sensor

Illustration 177 g03347829

The ECM receives signals from the blade control

handle as pulse width modulated signals. These
signals are operator requests for blade movement
such as RAISE, LOWER, TILT LEFT, and TILT
RIGHT. In most cases, the ECM will respond to the
duty cycle of the pulse width modulated signal by
sending a corresponding pulse width modulated
signal to the related solenoids. The ECM relates a
specific sensor duty cycle value to a specific control
handle position. The ECM determines the correct
solenoid output based on a “software map” that is
contained in the programmable memory of the ECM.
The ECM receives signals from a position sensor on Illustration 178 g03346395
the X-axis and a position sensor on the Y-axis.
The blade pitch sensor is the proportional thumb
rocker located on the blade control handle. The
sensor is an active pulse width modulated position
sensor. The ECM interprets the pulse width
modulated signal as a specific position on the thumb
rocker. The thumb rocker controls the blade pitch. A
thumb rocker position to the left corresponds with a
blade pitch back movement. The ECM sends a
corresponding pulse width modulated signal one set
of tilt solenoids to cause the blade to pitch forward or
back.
214 KENR5631-05
Hydraulic System

Ripper Control Handle Implement Shutoff Switch

Illustration 179 g03348012 Illustration 180 g03346014

The ripper control handle has two active pulse width The implement shutoff switch is a two pole switch.
modulated position sensors. One sensor detects The switch has a normally connected and a normally
ripper raise/lower and one sensor detects ripper open contact. When the switch is not depressed the
shank in/out. The ECM interprets the pulse width normally connected contact is connected to the
modulated signals as specific positions on the raise/ return, and the normally open contact floats to a high
lower and shank in/out controls. The ECM sends a voltage state. When the switch is depressed, the
corresponding pulse width modulated signal to the normally open contact is connected to the return and
ripper raise/lower and shank in/out solenoids. the normally connected contact floats to a high
voltage state. Based on the voltage state of the two
Switches ECM contacts, the ECM determines if the switch is
depressed. The second pole on the switch allows the
Switches provide an open signal, a ground signal, or path of power from an ECM driver to flow through the
a +battery signal to the inputs of the ECM. Switches switch to the shutoff solenoid.
are open or closed.
• When a switch is open, no signal is provided to the
corresponding input of the ECM. This “no signal”
condition is also called “floating”.
• When a switch is closed, a ground signal or a
+battery signal is provided to the corresponding
input of the ECM.
KENR5631-05 215
Hydraulic System

Single / Dual Tilt Trigger Switch Blade Manual Select Switch

Illustration 181 g03346395 Illustration 182 g03346395

The trigger switch is a single pole switch. The switch The blade manual select switch is a single pole
has a normally connected and a normally open switch. The switch has a normally connected and a
contact. When the trigger is not depressed the normally open contact. When the right pushbutton is
normally connected contact is connected to the not depressed the normally connected contact is
return, and the normally open contact floats to a high connected to the return, and the normally open
voltage state. When the trigger is depressed, the contact floats to a high voltage state. When the right
normally open contact is connected to the return and pushbutton is depressed, the normally open contact
the normally connected contact floats to a high is connected to the return and the normally
voltage state. Based on the voltage state of the two connected contact floats to a high voltage state.
ECM contacts, the ECM determines if the trigger is Based on the voltage state of the two ECM contacts,
depressed. The trigger engages single tilt the ECM determines if the right pushbutton is
functionality if dual tilt is equipped. depressed. The button selects the blade mode.
216 KENR5631-05
Hydraulic System

Blade Mode Select Switch Ripper Autostow Switch

Illustration 184 g03347739

The ripper autostow switch is a single pole switch.

The switch has a normally connected and a normally
open contact. When the pushbutton on the ripper
handle is not depressed, the normally connected
contact is connected to the return and the normally
open contact floats to a high voltage state. When the
pushbutton is depressed, the normally open contact
is connected to the return and the normally
connected contact floats to a high voltage state.
Based on the voltage state of the two ECM contacts,
the ECM determines if the autostow switch
pushbutton has been depressed. The button
Illustration 183 g03346395 engages the autostow feature for the ripper.

The blade mode select switch is a single pole switch.

The switch has a normally connected and a normally
open contact. When the left pushbutton is not
depressed the normally connected contact is
connected to the return, and the normally open
contact floats to a high voltage state. When the left
pushbutton is depressed, the normally open contact
is connected to the return and the normally
connected contact floats to a high voltage state.
Based on the voltage state of the two ECM contacts,
the ECM determines if the left pushbutton is
depressed. The button controls auto carry and cat
grade control features.
KENR5631-05 217
Hydraulic System

Auto Ripper Control Switch Hydraulic Oil Tank Filter Bypass Switch

Illustration 185 g03347739 Illustration 186 g03348326

The auto ripper control switch is a single pole switch. The hydraulic oil tank filter bypass switch is a single
The switch has a normally connected and a normally pole pressure switch. When the switch is closed
open contact. When the pushbutton on the ripper under normal operation, the ECM contact is
handle is not depressed, the normally connected connected to a return contact. When the hydraulic
contact is connected to the return and the normally pressure exceeds a set point, the switch opens.
open contact floats to a high voltage state. When the When the switch opens, the ECM contact floats to a
pushbutton is depressed, the normally open contact high voltage from the ECM pull-up voltage. When the
is connected to the return and the normally switch opens, the ECM alerts the operator that the
connected contact floats to a high voltage state. hydraulic oil tank filter is being bypassed.
Based on the voltage state of the two ECM contacts,
the ECM determines if the auto ripper control switch Outputs
pushbutton has been depressed. The button
engages the automatic control feature for the ripper. The ECM responds to decisions by sending electrical
signals to the outputs. The outputs can create an
action or the outputs can provide information to the
operator or the service technician.
218 KENR5631-05
Hydraulic System

Proportional Solenoids Blade Tilt Solenoids

There are four solenoids controlling blade tilt. There
is a left extend and retract tilt, and right extend and
retract solenoid. The solenoids are identical in
construction, and each set controls the operation of a
blade tilt valve spool. The solenoids are proportional
solenoids and depending on the duty cycle of the
ECM outputs the left and right tilt spools will shift
depending upon input. The tilt spools may act
simultaneously in dual tilt mode, or independently in
single tilt mode.

Ripper Raise/Lower Solenoids

There are two solenoids controlling ripper height.
There is a ripper raise and lower solenoid. The two
solenoids are identical in construction, and together
control the operation of the ripper raise/lower spool.
The solenoids are proportional solenoids, and if the
ECM sends a higher duty cycle signal to the ripper
raise solenoid, that solenoid shifts the spool further in
the RAISE position. If the ECM sends a higher duty
cycle signal to the ripper lower solenoid, that solenoid
shifts the spool further in the LOWER position. The
Illustration 187 g03347475 two solenoids operate together to control the
movement of the ripper raise/lower spool.
All proportional solenoids in the implement system
are identical in construction, however function
differently. Illustration 187 shows an example of a Ripper Shank In/Out Solenoids
proportional solenoid in the implement system.
There are two solenoids controlling ripper shank
Note: The solenoid coils are not designed to operate movement. There is a ripper shank in and out
using 24 DCV directly. The ECM sends a PWM signal solenoid. The two solenoids are identical in
of 24 V at a duty cycle that will provide the necessary construction, and together control the operation of
current to the solenoid coils. Do NOT activate the the ripper shank in/out spool. The solenoids are
coils by using 24 DCV (+battery). The life of the coils proportional solenoids, and if the ECM sends a
higher duty cycle signal to the ripper shank in
will be reduced drastically. A source of 12 DCV solenoid, that solenoid shifts the spool further in the
should be used, if the coils must be activated by not SHANK IN position. If the ECM sends a higher duty
using the ECM. cycle signal to the ripper shank out solenoid, that
solenoid shifts the spool further in the SHANK OUT
Blade Raise/Lower Solenoids position. The two solenoids operate together to
control the movement of the ripper shank in/out
There are four solenoids controlling blade height. spool.
There are two blade raise solenoids and two blade
lower solenoids. The four solenoids are identical in
construction, and control the operation of the two
blade height valve spools. The solenoids are
proportional solenoids, and if the ECM sends a
higher duty cycle signal to a blade raise solenoid, that
solenoid shifts the spool further in the direction of the
RAISE position. If the ECM sends a higher duty cycle
signal to the blade lower solenoid, that solenoid shifts
the spool further in the direction of the LOWER
position. The two raise and two lower solenoids are
linked and the ECM will send signals to both
solenoids to provide an identical spool movement.
KENR5631-05 219
Hydraulic System

On/Off Solenoids

Ripper Pin Puller Solenoid

Illustration 189 g03349583

The implement shutoff solenoid is activated by the

implement shutoff switch. When the switch is
activated, a circuit is completed allowing energy to
Illustration 188 g03349477 flow to the implement lockout solenoid. The solenoid
is an on/off type solenoid. When the solenoid is
The ripper pin puller solenoid is an on/off solenoid. activated, the solenoid prevents the implement
The solenoid is directly activated by a switch in the system from operating.
cab. The solenoid controls the movement of the pin
that locks a ripper tooth in place. Data Link
Electronic communication between the Implement
Implement Shutoff Solenoid ECM, Power train ECM, Engine ECM, and the other
control modules on the machine is conducted over
329-5064 data link circuits. The data link circuits allow the
sharing of information with other electronic control
modules. The data link circuits are bidirectional. The
data link circuit allows the ECM to send information
and to receive information.
The electronic communication system consists of
multiple CAN datalink systems.
220 KENR5631-05
Hydraulic System

The SAE J1939 CAN Data Link circuit is separated Caterpillar Electronic Technician (CAT ET). The other
into different groups. “CAN A” is connected to all of data link systems are high speed data links used for
the ECMs on the machine, and is used primarily for machine control purposes.
information and service purposes, such as the
i05235709

Hydraulic Tank and Filter

SMCS Code: 5056; 5068

Hydraulic Tank

Illustration 190 g03341413

(1) Vacuum breaker (7) Fan charge and kidney loop suction port (12) Kidney loop return, fan pump, fan motor,
(2) Hydraulic oil tank (8) Implement # 2 suction port and charge pump case drains
(3) Screen (9) Implement #1 suction port (13) Filter bypass switch port
(4) Implement case drain return (10) Ecology drain port (14) Filter element
(5) Implement return (11) Oil sample port (15) Oil temperature sensor port
(6) Pilot drain
KENR5631-05 221
Hydraulic System

Hydraulic oil tank (2) is located on the right fender of

the machine.
Hydraulic oil tank (2) is sealed in order to prevent
contamination to the hydraulic oil. Suction port (8)
and suction port (9) supplies oil to the implement
pumps. Suction port (7) is the fan charge and kidney
loop suction port.
Oil flows from the hydraulic components into
hydraulic oil tank (2) through the following passages:
• Implement return (5)
• Implement case drain return (4)

• Kidney loop return, fan pump, fan motor, and

charge pump case drains (12)

• Pilot drain (6)

222 KENR5631-05
Hydraulic System

Charge Filter

Illustration 191 g03341076

Steering Charge Filter
(1) Charge pump pressure port (K) (4) Bypass valve (7) Passage to implement pumps
(2) Passage from charge pump (5) Bypass pressure switch
(3) Filter element (6) “S.O.S.” sampling port

Hydraulic oil is forced through high efficiency filter When the bypass valve opens, bypass pressure
element (3). Bypass valve (4) will open if filter switch (5) opens. Bypass pressure switch (5) sends a
element (3) is plugged, and bypass sensor (5) signal to the implement ECM. Advisor will display this
indicates the bypass to the operator. After the filter event on the display screen. The “Action Lamp” will
some of the oil is diverted to the implement pilot activate in order to notify the operator that the charge
system, the rest of the oil is directed to the fan pump. filter is being bypassed. If this action occurs and the
oil is at normal operating temperature, inspect the
Oil enters the charge filter through passage (2) from filter element for restrictions.
the charge pump.
Correct maintenance must be used in order to make
Charge oil fills filter element (3). During normal sure that the filter element does not become full of
operation, the oil flows through filter element (3). debris.
Filter element (3) stops any debris that is in the oil.
The oil then flows to the rest of the implement
system.
If the filter element is full of debris, the restriction to
the flow causes a pressure increase on the outside of
the filter. The pressure causes bypass valve (4) to
open. The oil flows through the open bypass valve
directly to the implement pilot system and fan
system. The debris in the oil can damage the other
components in the hydraulic system when the oil
does not go through the filter element.
KENR5631-05 223
Hydraulic System

i05238253

Piston Pump (Implement)

SMCS Code: 5070-VD; 5070-II; 5070; 5084-QP;
5084; 5455-II; 5455

Illustration 192 g02141329

Implement Pump and Compensator (Engine Off)
(1) Pressure Compensator Spool (7) Pump Output (13) Signal Passage to Large Actuator
(2) Flow Compensator Spool (8) Large Actuator (BB) Cutaway Section
(3) Load Sensing Signal (9) Swashplate (CC) Component Surface
(4) Margin Spring (10) Drive Shaft (FF) Activated Component
(5) Cutoff Spring (11) Small Actuator and Bias Spring (GG) Tank Pressure
(6) Case Drain Passage (12) Piston and Barrel Assembly

These pumps are variable displacement pumps. The is great enough to overcome the force of the cutoff
pumps supply flow to the implement valve. Flow spring, the pressure compensator spool shifts
varies to match the load sense demand of the system upward. This action allows oil into the large actuator
while keeping pressure constant. The pumps will in order to destroke the pump.
work in tandem with a second implement load
sensing pump to meet the full command flow. Flow Compensator Spool (2) – The load sensing
signal and the margin spring apply pressure on the
The pump compensator valve has the following top of the spool. The pump output pressure acts on
components: the bottom of the spool. The flow compensator spool
shifts upward in order to regulate pressure in the
Pressure Compensator Spool (1) and Cutoff large actuator.
Spring (5) – When the output pressure of the pump
224 KENR5631-05
Hydraulic System

Margin Spring (4) – When the engine is OFF, the

flow compensator spool does not have oil pressure
on either end. The margin spring pushes the flow
compensator spool downward in order to keep the
large actuator open to the case drain line. When the
engine is started, the swashplate will be held at the
maximum angle by the bias spring.

The implement hydraulic pump has the following

components:
Large Actuator (8) – When oil pressure increases
behind the large actuator piston, the piston will
overcome the force of the small actuator and bias
spring. This action causes the angle of the
swashplate to be reduced.
Swashplate (9) – The displacement of the pump is
controlled by the angle of the swashplate. When the
swashplate is at a maximum angle, the pistons move
the maximum volume of oil in and out of the rotating
barrel.
Drive Shaft (10) – The rotation of the pump is
clockwise when the pump is viewed from the drive
end. The piston and barrel assembly is splined to the
drive shaft.
Small Actuator and Bias Spring (11) – When oil
pressure is behind the small actuator piston, the
angle of the swashplate will be increased. If there is
no pressure behind the large actuator piston, the bias
spring will hold the swashplate at the maximum
angle.
Piston and Barrel Assembly (12) – The barrel
contains nine pistons. The piston and barrel
assembly rotates whenever the engine is running.
The pistons move oil into the barrel and out of the
barrel.
KENR5631-05 225
Hydraulic System

Illustration 193 g02141376

Compensator Valve (Engine Off)
(1) Pressure Compensator Spool (6) Case Drain Passage (BB) Cutaway Section
(2) Flow Compensator Spool (7) Pump Output (CC) Component Surface
(3) Load Sensing Signal (13) Signal Passage to Large Actuator (FF) Activated Component
(4) Margin Spring (14) Adjustment Screw (GG) Tank Pressure
(5) Cutoff Spring (15) Orifice

The compensator valve is bolted to the implement Margin pressure is equal to the spring force value of
pump. The compensator valve contains two spools: margin spring (4). Margin pressure is adjusted by
pressure compensator spool (1) and flow turning adjustment screw (14), on the flow
compensator spool (2). compensator spool (2). See the Testing and
Adjusting section in this manual for the correct
Load sensing signal (3) is sent from the signal procedure and pressures.
resolver network. This signal is the highest signal that
is commanded by any of the control valves. The Pressure compensator spool (1) limits the maximum
signal is not the sum of the signals that are system pressure. When the pressure of pump output
commanded by all of the control valves. This signal (7) is high enough to overcome the force of cutoff
represents the single greatest load that is being spring (5), pressure compensator spool (1) shifts to
placed on the hydraulic system. the right. As a result, the cutoff pressure is equal to
the forces of spring (5). High-pressure oil is allowed
The flow that is supplied by the hydraulic pump is the into signal passage (13) to the large actuator. The
amount that is required in order to keep the supply angle of the swashplate is reduced and the pump
pressure at the pressure of load sensing signal (3) destrokes.
plus the margin pressure.
226 KENR5631-05
Hydraulic System

Orifice (15) is in the signal passage to the large

actuator piston. Orifice (15) regulates the response
rate of the large actuator piston by creating a
consistent leak path.

Note: Orifice (15) must be installed with the slot for

the screwdriver parallel to the spool bores.

Low Pressure Standby

Illustration 194 g02141655

Implement Pump and Compensator (Low Pressure Standby)
(1) Pressure Compensator Spool (7) Pump Output (13) Signal Passage to Large Actuator
(2) Flow Compensator Spool (8) Large Actuator (BB) Cutaway Section
(3) Load Sensing Signal (9) Swashplate (CC) Component Surface
(4) Margin Spring (10) Drive Shaft (FF) Activated Component
(5) Cutoff Spring (11) Small Actuator and Bias Spring (GG) Tank Pressure
(6) Case Drain Passage (12) Piston and Barrel Assembly (LL) First Pressure Reduction

Low-pressure standby occurs when the engine is As pump output pressure increases, flow
running and the control levers are in HOLD. The only compensator spool (2) is pushed upward against the
flow demands on the system are compensation for force of margin spring (4). When the pump supply
leakage and the production of pilot oil. Bias spring pressure becomes greater than the force of the
(11) holds swashplate (9) at the maximum angle margin spring, flow compensator spool (2) moves up.
before the engine is started. The pump output Pump output oil flows into large actuator (8). The
pressure is felt at the bottoms of both spools of the force of small actuator and bias spring (11) is
compensator valve. overcome and swashplate (9) moves toward the
minimum angle until equilibrium is reached.
KENR5631-05 227
Hydraulic System

The pump is at low-pressure standby. Flow

compensator spool (2) continues to meter oil to large
actuator (8) in order to balance the forces at the top
and at the bottom of the spool.

Note: Low-pressure standby is not adjustable. Low-

pressure standby will vary between machines. Low-
pressure standby will also vary in the same pump as
leakage increases. As leakage increases, the pump
will upstroke slightly in order to compensate for the
leakage.
228 KENR5631-05
Hydraulic System

Upstroke

Illustration 195 g02142167

Implement Pump and Compensator (Upstroke)
(1) Pressure Compensator Spool (8) Large Actuator (BB) Cutaway Section
(2) Flow Compensator Spool (9) Swashplate (CC) Component Surface
(3) Load Sensing Signal (10) Drive Shaft (FF) Activated Component
(4) Margin Spring (11) Small Actuator and Bias Spring (GG) Tank Pressure
(5) Cutoff Spring (12) Piston and Barrel Assembly (KK) High Pressure
(6) Case Drain Passage (13) Signal Passage to Large Actuator (RR) Signal Pressure
(7) Pump Output (16) Reduced Pressure

When an implement hydraulic circuit is activated and The pump may upstroke under the following
that circuit requires flow, pump output pressure (7) conditions:
falls. The force of margin spring (4) and load sensing
signal (3) becomes greater than the pump output • An implement is initially activated from low
pressure. Flow compensator spool (2) shifts pressure standby or multiple implements are
downward. activated.
When the spool shifts downward, the flow of oil to • A main control spool in a hydraulic control valve is
large actuator (8) is blocked. Oil that is in the in a position that requires the pump to compensate
chamber of large actuator (8) is vented to the case for system leakage.
drain across flow compensator spool (2). The small
actuator and bias spring (11) moves swashplate (9) • A main control spool in a hydraulic control valve is
to a greater angle. moved to a position that increases system
The pump now produces more flow. This condition is demand.
known as “upstroking”.
KENR5631-05 229
Hydraulic System

• The demand from the implements remains

constant but the engine speed decreases.

Note: The pressure of the load sensing signal is the

highest signal that is commanded by any of the
control valves. The signal pressure is not the sum of
the signals that are commanded by all of the control
valves.
Load sensing signal (3) does not need to increase in
order to upstroke the implement pump. If pump
supply pressure falls due to increased demand, the
pump will upstroke even though load sensing signal
(3) has not changed.
For example, if one implement is activated at an
operating pressure of 13800 kPa (2000 psi), the load
sensing signal pressure is 13800 kPa (2000 psi).
If a second implement is activated at an initial
operating pressure of 6900 kPa (1000 psi), the load
sensing signal will still be 13800 kPa (2000 psi). The
pressure of the supply oil will decrease momentarily
as more flow is now demanded by the additional
circuit.
The pressure of load sensing signal (3) plus the force
of margin spring (4) is now higher than the output
pressure of the pump at the bottom end of the spool.
Flow compensator spool (2) is pushed to the bottom.
Oil from large actuator (8) is vented to the case drain.
The angle of swashplate (9) increases and the
hydraulic pump provides more flow.
230 KENR5631-05
Hydraulic System

Destroke

Illustration 196 g02142192

Implement Pump and Compensator (Destroke)
(1) Pressure Compensator Spool (8) Large Actuator (BB) Cutaway Section
(2) Flow Compensator Spool (9) Swashplate (CC) Component Surface
(3) Load Sensing Signal (10) Drive Shaft (FF) Activated Component
(4) Margin Spring (11) Small Actuator and Bias Spring (GG) Tank Pressure
(5) Cutoff Spring (12) Piston and Barrel Assembly (KK) High Pressure
(6) Case Drain Passage (13) Signal Passage to Large Actuator (SS) Reduced Signal Pressure
(7) Pump Output (17) Increased Pressure

When less flow is required, the pressure of pump • An implement is moved to the HOLD position.
output (7) increases due to the greater restriction in
the system. Pump output pressure becomes greater • System leakage is reduced.
than the force of margin spring (4) and reduced load
sensing signal (3). Flow compensator spool (2) shifts • A main control spool for a hydraulic control valve
upward. is moved to a position that decreases system
demand.
When the spool shifts upward, oil flows to large
actuator (8). Large actuator (8) overcomes the force • The demand for the implements remains constant,
of the small actuator and bias spring (11). The angle but the engine speed increases.
of swashplate (9) is reduced.
Note: The pressure of the load sensing signal is the
The pump now produces less flow. This condition is highest signal that is commanded by any of the
known as “destroking”. control valves. The signal pressure is not the sum of
the signals that are commanded by all of the control
The pump may destroke under the following
conditions: valves.
KENR5631-05 231
Hydraulic System

Load sensing signal (3) does not need to decrease in

order to destroke the implement pump. If pump
supply pressure increases due to decreased
demand, the pump will destroke even though load
sensing signal (3) has not changed.
For example, if two implements are activated at
operating pressures of 13800 kPa (2000 psi) and
6900 kPa (1000 psi), the load sensing signal
pressure is 13800 kPa (2000 psi).
If the implement which is activated at 6900 kPa
(1000 psi) is returned to the HOLD position, the
pressure of load sensing signal (3) will still be
13800 kPa (2000 psi). However, the pressure of
pump output (7) is momentarily increased due to the
reduced oil flow that is required in the implement
hydraulic circuits.
The output pressure of the pump is now greater than
the pressure of load sensing signal (3) and margin
spring (4). Flow compensator spool (2) shifts to the
top. Oil flows to large actuator (8). The angle of
swashplate (9) decreases and the hydraulic pump
provides less flow.
232 KENR5631-05
Hydraulic System

Constant Flow

Illustration 197 g02142296

Implement Pump and Compensator (Constant Flow)
(1) Pressure Compensator Spool (8) Large Actuator (BB) Cutaway Section
(2) Flow Compensator Spool (9) Swashplate (CC) Component Surface
(3) Load Sensing Signal (10) Drive Shaft (FF) Activated Component
(4) Margin Spring (11) Small Actuator and Bias Spring (GG) Tank Pressure
(5) Cutoff Spring (12) Piston and Barrel Assembly (KK) High Pressure
(6) Case Drain Passage (13) Signal Passage to Large Actuator (LL) First Pressure Reduction
(7) Pump Output (18) Reduced Pressure (RR) Signal Pressure

The production of constant oil flow by the implement Flow compensator spool (2) constantly meters oil to
pump is a combination of upstroking and destroking. large actuator (8) in order to equalize the pressures
Due to fluctuations in the system during operation, on the top and the bottom of the spool. The system
the pump upstrokes, or the pump destrokes until the stabilizes and swashplate (9) is held at a relative
system stabilizes. constant angle in order to maintain the required flow.
When constant flow of oil is demanded by an
implement hydraulic circuit, load sensing signal (3)
acts on the top end of flow compensator spool (2).
The pressure of pump output (7) acts on the bottom
of flow compensator spool (2).
KENR5631-05 233
Hydraulic System

High Pressure Stall

Illustration 198 g02142323

Implement Pump and Compensator (High Pressure Stall)
(1) Pressure Compensator Spool (8) Large Actuator (BB) Cutaway Section
(2) Flow Compensator Spool (9) Swashplate (CC) Component Surface
(3) Load Sensing Signal (10) Drive Shaft (FF) Activated Component
(4) Margin Spring (11) Small Actuator and Bias Spring (GG) Tank Pressure
(5) Cutoff Spring (12) Piston and Barrel Assembly (KK) High Pressure
(6) Case Drain Passage (13) Signal Passage to Large Actuator (RR) Signal Pressure
(7) Pump Output (17) Increased Pressure

Pressure compensator spool (1) is in parallel with When the spool shifts, pump oil is allowed to flow to
flow compensator spool (2). Pressure compensator large actuator (8). The increase in pressure in large
spool (1) limits the maximum system pressure at any actuator (8) overcomes the force of the small
pump displacement. actuator and bias spring (11). The angle of
swashplate (9) decreases and the hydraulic pump
Pressure compensator spool (1) is forced downward destrokes.
during normal operation by cutoff spring (5). If pump
output pressure is enough to overcome the force of Note: When the pump is in the HIGH PRESSURE
cutoff spring (5), pressure compensator spool (1) STALL condition, the activation of a second
shifts upward. implement will cause the pressure of pump output (7)
to drop. When pump output pressure drops, pressure
compensator spool (1) shifts downward. Large
actuator (8) is opened to the drain. The pump
upstrokes until the pressure of pump output (7)
increases to the HIGH PRESSURE STALL condition.
234 KENR5631-05
Hydraulic System

i05241895

Control Valve (Implement)

SMCS Code: 5051-CD; 5051; 5063; 5115; 5123;
5136; 5811-FCD; 5811-BCD; 5811-CTC; 5811-SCY

Illustration 199 g03344313

Control Valve Stack
(1) Inlet Manifold (3) Blade Tilt Control Valve (5) Ripper Tip Control Valve
(2) Blade Lift Control Valve (4) Ripper Lift Control Valve (6) Solenoid

Four implement control valves are mounted together The implement control valves are activated by
in the valve stack: blade lift control valve (2), blade tilt proportional solenoids (6). A solenoid is located at
control valve (3) and ripper lift control valve (4), and both ends of each control valve. The solenoids
ripper tip control valve (5). control the pilot oil that shifts the valve spools. The
solenoids are activated by electrical signals from the
Inlet manifold (1) is mounted in the center of the implement ECM. The electrical signals are
valve stack. The inlet manifold contains the main proportional to the direction and the amount of
relief valve. movement of the implement control levers.
The flow from each pump will enter at opposite ends
of the implement valve stack and the supply oil will
converge in inlet manifold (1).
KENR5631-05 235
Hydraulic System

The ripper lift valve in the stack does not have a Energized
resolver valve, all other control valves have a
resolver valve. The resolvers work together in order
to ensure that the highest pressure that is
commanded by a single control valve is sent as the
signal to the pump compensator valve.

Control Valve Solenoids

The spools of the implement control valves are
shifted by pilot oil. The flow of pilot oil to the end of
the control valve spools is controlled by a
proportional solenoid. Every control valve has a
solenoid on each end of the spool.

De-energized

Illustration 201 g03339667

Solenoid valve (energized solenoid)
(1) Spring
(2) Valve spool
(3) Passage to hydraulic oil tank
(4) Passage from pilot supply oil
(5) Passage to pilot chamber
(BB) Cutaway section
(CC) Component surface
(FF) Activated component
(GG) Tank pressure
(RR) First pilot pressure reduction

When an implement is activated, the solenoid on one

end of the implement control valve is energized. The
solenoid forces valve spool (2) downward. In this
Illustration 200 g03339665
position, passage (3) to passage (5) is blocked.
Solenoid valve (de-energized solenoid)
(1) Spring Passage (4) is open and pilot supply oil flows around
(2) Valve spool valve spool (2) to passage (5). Pilot oil from passage
(3) Passage to hydraulic oil tank (5) exerts pressure on the end of the control valve
(4) Passage from pilot supply oil spool and the spool shifts.
(5) Passage from pilot chamber
(BB) Cutaway section The solenoid is a proportional solenoid. The solenoid
(CC) Component surface
(FF) Activated component
moves valve spool (2) downward by an amount that
(GG) Tank pressure is proportional to the amount of movement of the
(RR) First pilot pressure reduction implement control lever. When valve spool (2) is
pushed down further, passage (4) is opened more.
When an implement is in the HOLD position, both More pilot oil is allowed into passage (5). The
solenoids on the implement control valve are de- implement control spool shifts proportionally to the
energized. When the solenoid is de-energized, spring pilot oil pressure.
(1) forces valve spool (2) upward. In this position,
pilot supply oil in passage (4) is blocked. The oil that Blade Control Valve HOLD Position
is from the end of the control valve spool drains
through passage (5). The oil flows around valve The following Illustrations show the implement
spool (2) and the oil returns to the hydraulic tank hydraulic system when all of the implements are in
through passage (3). BLADE HOLD.
236 KENR5631-05
Hydraulic System

Illustration 202 g03346296

(1) End cover (9) Implement control handle (15) Passage to hydraulic oil tank
(2) Blade lift control valve (10) Implement pump (18) Load sense passage from previous
(6A) Blade raise solenoid (11) Passage to head end valve
(6B) Blade lower solenoid (12) Passage to rod end (23) Resolver
(8) Machine electronic control module (13) Pilot oil passage (28) Lift cylinder
(ECM) (14) Lift valve spool
KENR5631-05 237
Hydraulic System

Illustration 203 g03343216

Blade lift control valve (HOLD)
(6A) Blade raise solenoid (18) Load sense passage from previous (32) Makeup valve
(6B) Blade lower solenoid valve (BB) Cutaway section
(16) Passage from the implement pump (19) Load check valve (CC) Surface of the part
(11) Passage to head end (20) Chamber (FF) Activated component
(12) Passage to rod end (21) Pilot chamber (GG) Tank pressure
(13) Pilot oil passage (22) Spring (KK) High-pressure oil
(14) Lift valve spool (23) Resolver (RR) Charge pressure
(15) Passage to hydraulic oil tank (25) Spring chamber (UU) Trapped oil
(17) Load sensing passage to pump (26) Flow control valve spool

When the blade lift control valve is in the HOLD Implement pump oil enters the lift control valve from
position, implement control handle (9) sends a pulse the inlet manifold through the passage from
width modulated signal to ECM (8). implement pump (16). Oil flows through the throttling
slots in lift valve spool (14).
ECM (8) interprets the signal as an operator request
to hold the blade position. ECM (8) sends a signal to Blade Control Valve RAISE
solenoid (6B) and solenoid (6A). The solenoids are
de-energized, causing pilot chambers (21) to open to Position
the hydraulic tank. Lift valve spool (14) is held in the The following Illustrations show the implement
center position by centering springs (22). hydraulic system when all of the implements are in
BLADE RAISE.
In the center position, lift valve spool (14) blocks
pump supply oil. Also, the lift valve spool blocks the
oil from flowing to passage to rod end (12) and
passage to head end (11) of the blade lift cylinders.
The oil in these passages is trapped and the blade
does not move.
238 KENR5631-05
Hydraulic System

Illustration 204 g03343219

(1) End cover (9) Implement control handle (18) Load sense passage from previous
(2) Blade lift control valve (10) Implement pump oil passage valve
(6A) Blade raise solenoid (13) Pilot oil passage (23) Resolver
(6B) Blade lower solenoid (14) Lift valve spool (28) Blade lift cylinders
(8) ECM (15) Passage to hydraulic oil tank (58) Poppet valve
KENR5631-05 239
Hydraulic System

Illustration 205 g03345136

Blade lift control valve (BLADE RAISE)
(6A) Blade raise solenoid (19) Load check valve (BB) Cutaway section
(6B) Blade lower solenoid (20) Chamber (CC) Component surface
(11) Passage to head end (21) Pilot chamber (FF) Activated component
(12) Passage to rod end (22) Spring (GG) Tank pressure
(13) Passage from pilot manifold (23) Resolver (KK) High pressure
(14) Lift valve spool (25) Spring chamber (LL) First pressure reduction
(15) Passage to hydraulic oil tank (26) Flow control valve spool (RR) Pilot pressure
(16) Passage from implement pump (29) Left orifice (SS) First pilot pressure reduction
(17) Load sensing passage to pump (30) Signal chamber (UU) Trapped oil
(18) Load sense passage from previous (32) Makeup valve
valve (33) Return passage

When the operator moves dozer control handle (9) Blade raise solenoid (6A) is energized. The solenoid
into the RAISE position an electronic PWM signal is valve opens in order to allow pilot supply oil in the
sent from handle (9) t o ECM (8). ECM (8) translates passage from pilot manifold passage (13) into pilot
that signal in to a current which is then driven to two chamber (21) on the right end of lift valve spool (14).
raise solenoids (6A) located on two implement lift The pressure of the pilot oil shifts lift valve spool (14)
valves (2) on the implement valve stack. to the left.
ECM (8) interprets the signal as an operator request When lift valve spool (14) shifts, left orifice (29) is
to raise the blade. As the joystick is pulled further exposed to the pressure in the passage to rod end
back, a lower duty cycle percentage is sent to the (12). The oil that enters orifice (29) becomes signal
ECM (8). oil. The signal oil flows through an internal passage in
the middle of lift valve spool (14) to signal chamber
(30). From signal chamber (30), the oil flows to
resolver (23) and to spring chamber (25).
240 KENR5631-05
Hydraulic System

The signal oil is at the same pressure as the oil in the In this situation, the pressure in passage to head end
rod end of the blade lift cylinders. If this pressure is (11) becomes less than the tank pressure in return
the highest pressure of all the implements, the ball in passage (33). When the pressure in return passage
resolver (23) shifts to the right. The signal is sent (33) is enough to overcome the force of the spring
through the inlet manifold to the compensator valve behind makeup valve (32), the valve shifts to the
of the implement pump. The implement pump right.
upstrokes in order to meet the demand.
The difference in pressure causes tank oil to be
When the increased flow of pump supply oil builds drawn past makeup valve (32) into passage to head
enough pressure to overcome the existing pressure end (11). This makeup oil supplements the pump
plus the spring force behind load check valve (19), supply oil and the cylinders do not cavitate.
the load check valve shifts to the left. Pump supply oil
flows through chamber (20), around lift valve spool When the blade comes in contact with the ground,
(14), and into passage to rod end (12). After the the blade stops falling and the implement pump can
pump oil exits through passage to rod end (12), the now supply enough flow. The pressure rises in
oil flows to the rod end of the blade lift cylinders. The passage to head end (11). When the pressure in
blade will begin to raise. The cylinder will continue to passage to head end (11) is high enough, the force of
raise until the cylinder reaches the end of travel in the the spring behind makeup valve (32) forces the valve
raise direction. When the cylinder reaches the end of to shift back to the left.
travel in the raise direction, poppet valves (58)
located in the cylinder piston will open. This allows oil Blade Control Valve FLOAT
on the rod side of the cylinder to bypass the cylinder
head and return to tank via the head side of the Position
cylinder. This limits the pressure and thereby cylinder The following Illustrations show the implement
force at end of stroke. When the resistance on the hydraulic system when all of the implements are in
cylinder is significant , the load sense pressure will FLOAT.
reach the pump cutoff setting. This causes the pump
to de-stroke while maintaining the pressure at cutoff
until the command is released.
Oil from the head end of the blade lift cylinders
returns to passage (11). The oil returns to the
hydraulic tank through return passage (33).
At the same time, the signal pressure in spring
chamber (25) plus the force of spring (22) moves flow
control valve (26) to the left. This movement allows
the throttling slots in flow control valve (26) to meter
the flow of pump supply oil.
All of the pressures and forces within the control
valve equalize in order to provide smooth operation
for the blade lift cylinders. In the dual lift valve
system, the work ports of the valves are connected
near the front of the machine so that equal pressure
is maintained for both cylinders.

BLADE LOWER Condition

The operation of the blade lift control valve in the
LOWER position is similar to the operation of the
blade lift control valve in the RAISE position.

Makeup Operation
If the blade is in a position above the ground,
pressure in the rod end of the lift cylinders may
exceed the pressure in the head end of the lift
cylinders until the blade comes in contact with the
ground. This action could occur because the weight
of the blade causes the blade to drop quickly. If the
pump is not able to supply enough oil, cavitation in
the head end of the lift cylinders can occur.
KENR5631-05 241
Hydraulic System

Illustration 206 g03343573

(1) End cover (9) Implement control handle (18) Load sense passage from previous
(2) Blade lift control valve (10) Implement pump oil passage valve
(6A) Blade raise solenoid (11) Pilot oil passage (23) Resolver
(6B) Blade lower solenoid (14) Lift valve spool (28) Blade lift cylinders
(8) ECM (15) Passage to hydraulic oil tank
242 KENR5631-05
Hydraulic System

Illustration 207 g03345296

Blade Lift Control Valve (BLADE FLOAT)
(6A) Blade raise solenoid (18) Load sense passage from previous (33) Return passage
(6B) Blade lower solenoid valve (BB) Cutaway section
(11) Passage to head end (21) Pilot chamber (CC) Component surface
(12) Passage to rod end (22) Springs (FF) Activated component
(13) Passage from pilot manifold (23) Resolver (GG) Tank pressure
(14) Lift valve spool (29) Left orifice (KK) High pressure
(15) Passage to hydraulic oil tank (30) Signal chamber (RR) Pilot pressure
(16) Passage from implement pump (31) Right Orifice (SS) First pilot pressure reduction
(17) Passage to pump (32) Makeup valve (UU) Trapped oil

When the operator moves the blade control lever into When lift valve spool (14) shifts to the right into the
FLOAT position, implement control handle (9) sends FLOAT position, pump supply oil is blocked from
a pulse width modulated signal to ECM (8). entering passage to rod end (12) and passage to
head end (11). Passage to head end (11) is open to
ECM (8) interprets the signal as an operator request return passage (33). Passage to rod end (12) is open
to hold the blade position. ECM (8) sends signal to to return passage (33). When both ends of the lift
blade lower solenoid (6B). Blade lower solenoid (6B) cylinders are open to the tank, the blade is free to
is energized. The solenoid valve opens in order to “float” in order to follow the contour of the ground.
allow pilot supply oil from the passage from pilot
manifold (13) into pilot chamber (21) on the left end When lift valve spool (14) shifts, right orifice (31) is
of lift valve spool (14). The pressure of the pilot oil in exposed to tank pressure in passage to head end
pilot chamber (21) shifts the lift valve spool (14) to the (11) and left orifice (29) is blocked. No signal is sent
right. to the implement pump. The pump destrokes to the
LOW PRESSURE STANDBY condition.
KENR5631-05 243
Hydraulic System

Pilot pressure, provided by the fan charge pressure

pump, maintains the lift valve spool (14) in the shifted
position.
244 KENR5631-05
Hydraulic System

Blade Control Valve TILT RIGHT

Position (Dual Tilt)

Illustration 208 g03343598

Dual tilt equipped machine in the tilt right position, right-hand cylinder retracts and the left-hand cylinder extends
(3) Blade tilt control valve (9A) Trigger (18) Load sense passage from previous
(6A) Blade tilt solenoid (extend) (9B) Implement control handle valve
(6B) Blade tilt solenoid (retract) (10) Implement pump oil passage (23) Resolver
(6C) Blade tilt solenoid (extend) (14) Tilt valve spool (43) Left tilt cylinder
(6D) Blade tilt solenoid (retract) (15) Passage to hydraulic oil tank (44) Right tilt cylinder
(8) ECM
KENR5631-05 245
Hydraulic System

Illustration 209 g03344213

Blade tilt left-hand cylinder control valve (extend)
(6C) Blade tilt solenoid (extend) (19) Load check valve (34) Signal limiter valve
(6D) Blade tilt solenoid (retract) (20) Chamber (BB) Cutaway section
(11) Passage to the head end (21) Pilot chamber (CC) Component surface
(12) Passage to the rod end (22) Spring (FF) Activated component
(13) Passage from the pilot manifold (23) Resolver (GG) Tank pressure
(14) Tilt valve spool (25) Spring chamber (KK) High pressure
(15) Passage to the hydraulic oil tank (26) Flow control valve spool (LL) First pressure reduction
(16) Passage from the implement pump (29) Left orifice (SS) First pilot pressure reduction
(17) Load sensing passage to pump (30) Signal chamber
(18) Load sense passage from previous (31) Right orifice
valve (33) Return passage

When the machine is in DUAL TILT, neither of the When the operator moves implement control lever
coils in the solenoid valve are energized.. Tilt valve (9B) to the TILT RIGHT position, implement pump oil
spool (14) is centered by the spring force of centering is sent from the left blade tilt control valve to the head
springs (22). end of left tilt cylinder (43) through passage (11).
When the operator moves implement control handle The pressure forces cylinder (43) to extend and oil is
(9B) into the tilt right position, an electronic PWM forced out of the rod end.
signal is sent from implement control handle (9B) to
ECM (8). ECM (8) translates that signal in to a In the right blade tilt control valve, implement pump
current which is then driven to two solenoids (6C) oil is sent to the rod end of right tilt cylinder (44). The
and (6B) located on two implement dozer tilt valves pressure forces cylinder (44) to retract and oil is
(3) on the implement valve stack. forced out of the head end of cylinder (44).
Tilt cylinders (43) and (44) move in opposite
directions and the blade tilts to the right.
246 KENR5631-05
Hydraulic System

When implement control lever (9B) is released, the

oil is blocked at the blade tilt control valves. The
blade remains tilted to the right until implement
control lever (9B) is moved again.
As tilt cylinders (43) and (44) encounter resistance,
the oil under pressure is directed to the implement
pump in the form of load sense signal (17). This
signal causes the pump to upstroke sending more oil
to the tilt control valves which provides more
pressure to tilt cylinders (43) and (44).
When tilt cylinders (43) and (44) reach the end of
travel (or significant resistance), signal limiting valve
(34) will open bleeding off the load sense pressure.
This prevents the load sense signal from
commanding the implement pump to a higher
displacement. This maintains the pressure at the
desired setting until the command is released

BLADE TILT LEFT Condition

The operation in DUAL TILT LEFT is similar to DUAL
TILT RIGHT. The oil follows the opposite path as
DUAL TILT RIGHT position.
Left tilt cylinder (44) retracts and right tilt cylinder (43)
extends the blade tilts to the left.

Blade Control Valve PITCH

Position
BLADE PITCH has priority over DUAL TILT. When
the thumb switch on the blade control lever is pushed
to the right or the left, the dual tilt circuit operates in
the BLADE PITCH mode. The thumb switch is used
to adjust the vertical angle of the blade. BLADE
PITCH can be activated by moving the thumb switch
to the right. RACK BACK can be activated by moving
the thumb switch to the left.
In BLADE PITCH, both cylinders act together to
change the vertical angle of the blade.
KENR5631-05 247
Hydraulic System

Blade Pitch (Forward)

Illustration 210 g03344007

(3) Blade tilt control valve (9) Implement control handle (23) Resolver
(6A) Blade tilt solenoid (extend) (10) Implement pump oil passage (42) Centering Springs
(6B) Blade tilt solenoid (retract) (18) Load sense passage from previous (43) Right Tilt Cylinder
(6C) Blade tilt solenoid (extend) valve (44) Left Tilt Cylinder
(6D) Blade tilt solenoid (retract) (14) Tilt valve spool
(8) ECM (15) Passage to hydraulic oil tank
248 KENR5631-05
Hydraulic System

When the operator moves the thumb switch on the

blade control lever to the right, implement control
handle (9) sends a pulse width modulated signal to
ECM (8).

Note: In BLADE PITCH, the solenoid (6A) and (6C)

are energized on the blade tilt control valves (3).
Implement pump oil is sent from the blade tilt control
valve spool (14) through passage (11) to the head
end of tilt cylinders (43) and (44).The pressure forces
the cylinders to extend and oil is forced out of the rod
end. Tilt cylinders (43) and (44) extend and the blade
pitches forward.
When the thumb switch is released, the oil is blocked
at the blade tilt control valves (3). The blade remains
angled forward until the thumb switch-on implement
control handle (9) is moved again.
As tilt cylinders (43) and (44) encounter resistance,
the oil under pressure is directed to the implement
pump in the form of load sense signal (17). This
signal causes the pump to upstroke sending more oil
to the tilt control valves which provides more
pressure to tilt cylinders (43) and (44).
When tilt cylinders (43) and (44) reach the end of
travel (or significant resistance), signal limiting valve
(34) will open bleeding off the load sense pressure.
This prevents the load sense signal from
commanding the implement pump to a higher
displacement. This maintains the pressure at the
desired setting until the command is released

Rack Back
Note: In RACK BACK, solenoid (6B) and (6D) are
energized on the blade tilt control valves (3).
The operation in RACK BACK is similar to BLADE
PITCH. RACK BACK is activated when the operator
moves the thumb switch-on implement control lever
(9) to the left.
Both tilt cylinders retract and the blade racks back.
KENR5631-05 249
Hydraulic System

Ripper Control Valve RAISE Position

Illustration 211 g03344021

(4) Ripper lift control valve (10) Implement pump (48) Ripper lift cylinders
(6E) Ripper lower solenoid (13) Passage from pilot manifold (57) Ripper control lever
(6F) Ripper raise solenoid (14) Lift valve spool
(8) ECM (15) Passage to hydraulic oil tank
250 KENR5631-05
Hydraulic System

Illustration 212 g03344048

Ripper Lift Control Valve (RIPPER RAISE)
(6E) Ripper lower solenoid (19) Load check valve (33) Return passage
(6F) Ripper raise solenoid (20) Chamber (BB) Cutaway section
(16) Passage from implement pump (21) Pilot chamber (CC) Component surface
(11) Passage to rod end (22) Spring (FF) Activated component
(12) Passage to head end (25) Spring chamber (GG) Tank pressure
(13) Passage from pilot manifold (26) Flow control valve spool (KK) High pressure
(14) Ripper lift valve spool (29) Left orifice (LL) First pressure reduction
(15) Passage to hydraulic oil tank (31) Right orifice (RR) Charge or pilot pressure
(18) Load sense passage to the next valve (30) Signal chamber (SS) First pilot pressure reduction
section (32) Makeup valve (UU) Trapped oil

When the operator moves ripper control handle (57) ECM (8) interprets the signal as an operator request
to the raise position, an electronic PWM signal is sent to raise the ripper. Right orifice (31) is exposed to the
form the handle to ECM (8). ECM (8) translates that pressure in passage to rod end (11). The oil that
signal in to a current which is then driven to solenoid enters right orifice (31) becomes signal oil. The signal
(6F) located on ripper lift control valve (4). oil flows through an internal passage in the middle of
lift valve spool (14) to signal chamber (30). From
Ripper raise solenoid (6F) is energized which opens signal chamber (30), the signal oil flows to the next
to allow the pilot supply oil (13) into pilot chamber valve section through passage (18).
(21) on the left end of lift valve spool (14). The
pressure of pilot oil (13) shifts the lift valve spool (14)
to the right.
KENR5631-05 251
Hydraulic System

When the increased flow of pump supply oil builds

enough pressure to overcome the existing pressure
plus the spring force behind load check valve (19),
the load check valve shifts to the left. Pump supply oil
flows through chamber (20), around lift valve spool
(14), and into passage to rod end (11). After the
pump oil exits through passage to rod end (11), the
oil flows to the rod end of the ripper lift cylinders. The
ripper raises.
Oil from the head end of the ripper lift cylinders
returns through passage to head end (12). The oil
then flows around lift valve spool (14) and to the
hydraulic tank through the inlet manifold.
All of the pressures and forces within the control
valve equalize in order to provide smooth operation
for the ripper lift cylinders.

RIPPER LOWER Condition

The operation of the ripper lift control valve in
LOWER is similar to the operation of the ripper lift
control valve in RAISE.

Makeup Operation
If the ripper is in a position above the ground,
pressure in the rod end of the lift cylinders exceeds
the pressure in the head end of the lift cylinders until
the ripper comes in contact with the ground. This
contact occurs because the weight of the ripper
causes the ripper to drop quickly. If the pump is not
able to supply enough oil, cavitation in the head end
of the ripper lift cylinders can occur.
In this situation, the pressure in passage to head end
(12) becomes less than the tank pressure in return
passage (33). When the pressure in return passage
(33) is enough to overcome the force of the spring
behind left makeup valve (32), valve (32) shifts to the
left.
The difference in pressure causes tank oil to be
drawn past makeup valve (32) into passage to head
end (12). This makeup oil supplements the pump
supply oil and the cylinders do not cavitate.
When the ripper comes in contact with the ground,
the ripper stops falling and the implement pump can
now supply enough flow. The pressure rises in
passage to head end (12). When the pressure in
passage to head end (12) is high enough, the force of
the spring behind makeup valve (32) forces the valve
to shift back to the right.
252 KENR5631-05
Hydraulic System

Ripper Control Valve SHANK IN

Position

Illustration 213 g03344065

(5) Ripper tip control valve (10) Implement pump (49) Ripper tip cylinders
(6G) Ripper shank out solenoid (13) Passage from pilot manifold (57) Ripper control lever
(6H) Ripper shank in solenoid (14) Tip valve spool (58) Line relief valve
(8) ECM (15) Passage to hydraulic oil tank
KENR5631-05 253
Hydraulic System

Illustration 214 g03344108

Ripper Tip Control Valve (SHANK IN)
(6G) Ripper shank out solenoid (19) Load check valve (33) Return passage
(6H) Ripper shank in solenoid (20) Chamber (58) Line relief valve
(11) Passage to head end (21) Pilot chamber (BB) Cutaway section
(12) Passage to rod end (22) Spring (CC) Component surface
(13) Passage from pilot manifold (23) Resolver (FF) Activated component
(14) Tip valve spool (25) Spring chamber (GG) Tank pressure
(15) Passage to hydraulic oil tank (26) Flow control valve spool (KK) High pressure
(16) Passage from implement pump (29) Left orifice (LL) First pressure reduction
(17) Load sensing passage (30) Signal chamber (RR) Charge or pilot pressure
(18) Load sense passage to the next valve (31) Right orifice (TT) First pilot pressure reduction
section (32) Makeup valve

When the operator moves ripper control lever (57) When tip valve spool (14) shifts, right orifice (31) is
from HOLD to SHANK IN, ripper control lever (57) exposed to the pressure in the passage to head end
sends a pulse width modulated signal to ECM (8). (11). The oil that enters orifice (31) becomes signal
oil. The signal oil flows through an internal passage in
ECM (8) sends a signal to energize solenoid (6H). the middle of tip valve spool (14) to signal chamber
Solenoid (6H) opens in order to allow pilot supply oil (30). From signal chamber (30), the oil flows to
in the passage from pilot manifold (13) into pilot resolver (23).
chamber (21) on the left end of tip valve spool (14).
The pressure of the pilot oil shifts the tip valve spool
to the right.
254 KENR5631-05
Hydraulic System

When the increased flow of pump supply oil builds

enough pressure to overcome the existing pressure
plus the spring force behind load check valve (19),
the load check valve shifts to the left. Pump supply oil
flows through chamber (20), around tip valve spool
(14), and into the passage to head end (11). After the
pump oil exits through the passage to head end (11),
the oil flows to the head end of the ripper tip
cylinders. The shank of the ripper tips inward.
Oil from the rod end of ripper tip cylinders (49)
returns through the passage to rod end (12). The oil
then flows around tip valve spool (14) and returns to
the hydraulic tank through passage (33).
All of the pressures and forces within the control
valve equalize in order to provide smooth operation Illustration 215 g03351771
for the ripper tip cylinders. Line Relief Valve
(52) Return passage
SHANK OUT Condition (53) Adjustment screw
(54) Passage
The operation of the ripper tip control valve in (55) Spring
SHANK OUT is similar to the operation of the ripper (56) Valve
(58) Line relief valve
tip control valve in SHANK IN. For the ripper SHANK
OUT position solenoid (6G) is activated.
Line relief valve (58) is used in order to relieve
pressure spikes in the cylinder head end passage .
Relief/Makeup Operation The pressure in the cylinder head end passage
enters line relief valve (58) through passage (54).
The operator may tip the shank of the ripper outward When the pressure in passage (54) is enough to
while the shank of the ripper is in the ground and the overcome the force of spring (55), valve (56) shifts to
tractor is moving forward. In this case, the ground will the right.
force the shank rapidly outward. This causes the
pressure in the rod end of the tip cylinders to become When valve (56) shifts to the right, oil from passage
very low while the pressure spikes in the head end of (54) flows out of the line relief valve through return
the tip cylinders. If the pump is not able to supply passages (52). The pressure in the cylinder head end
enough oil, cavitation in the rod end of the ripper tip passage is reduced.
cylinders can occur. If the pressure is not relieved in
the head end of the tip cylinders, damage may occur Note: The setting of the line relief valve can be
to the hydraulic components. adjusted with screw (53).

Makeup valve (32) is used in order to avoid cavitation

of the rod end of ripper tip cylinders (49). The
pressure in cylinder rod end passage becomes less
than the tank pressure in return passage (33). When
the pressure in return passage (33) is enough to
overcome the force of the spring behind makeup
valve (32), makeup valve (32) shifts to the left.
The difference in pressure causes tank oil to be
drawn past makeup valve (32) into cylinder rod end
passage. This makeup oil supplements the pump
supply oil and the cylinders do not cavitate.
KENR5631-05 255
Hydraulic System

i05239565

Control Manifold (Implement

Lockout)
SMCS Code: 5264

Illustration 216 g03342285

Pilot Manifold
(1) Implement Lockout Valve (6) Tank or Pilot Drain (RR) Reduced Pilot Pressure
(2) Pilot Manifold (EE) Pneumatic Pressure (AP) Accumulator Pressure
(3) Accumulator (FF) Activated Component (HPS) Pilot Supply Pressure
(4) Pump Supply (GG) Tank Pressure
(5) Hydraulic Pilot Supply (PP) First Pressure Reduction
256 KENR5631-05
Hydraulic System

The primary purpose of pilot lockout valve (1) is to

provide a method for disabling the implement system
pilot controls. Solenoid (7) in pilot lockout valve (1)
does this by both blocking the pilot supply passage
(4) and draining downstream pilot oil (6) to tank. The
secondary function of lockout valve (1) is to provide a
connection point and method for attaching pilot
accumulator (3) on the correct side of pilot lockout
valve (1). Pilot lockout valve (1) includes a check
valve that prevents accumulator (3) from draining
immediately at machine shutdown. Pilot lockout valve
(1) also provides a location to attach the charge
pressure sensor.
Implement lockout valve (1) is located in pilot
manifold (2).
When the machine is on and the implement lockout
switch is in the OFF (unlocked) position, solenoid (7)
is energized. Solenoid (87) is de-energized when the
engine speed is below 800 rpm and no implement is
commanded to move. When solenoid (8) is
energized, the valve directs the pilot oil to passage
Illustration 217 g03342357 (6). Pilot supply now flows through the center
manifold of the implement control valve bank. The
pilot supply rail distributes the pilot supply oil to either
end of each implement control valve.
If the operator moves the implement lockout switch in
the cab to the ON locked position, solenoid (7) is de-
energized. Implement lockout valve (1) closes. Pilot
supply from the implement control valves returns to
the hydraulic tank through passage (6).

Illustration 218 g03342796

Implement Control valve
(7) Solenoid
(8) Passage to Implement Control Valves
(9) Passage to Hydraulic Oil Tank
KENR5631-05 257
Hydraulic System

i05239458 Accumulator

Accumulator (Pilot) The accumulator is located on the top of the pilot

manifold.
SMCS Code: 5077-PS The accumulator contains a bladder that separates
oil and dry nitrogen gas. The accumulator stores
potential energy by accumulating a quantity of
pressurized hydraulic oil. The oil that is stored is
available to the pilot circuit when additional pressure
is needed.

Illustration 219 g03342233

258 KENR5631-05
Hydraulic System

The accumulator provides two functions to the releases oil in the pilot circuit to maintain pressure
machine. First, the accumulator stores hydraulic oil at during rapid flow change events in the pilot circuit. An
a set pressure so that when the machine is shut identical accumulator is used in the fan circuit to
down the implements can be lowered to the ground maintain pilot pressure in the fan controller during
or shaken out releasing stored energy in the rapid engine speed changes.
cylinders. Second, the accumulator stores and
i05257662

Inlet Manifold
SMCS Code: 1058; 5264

Operation of the Inlet Manifold

Illustration 220 g03347428

(1) Inlet manifold (5) (LS1) Load sense pressure to (9) Pump supply pressure ( “HA” )
(2) Passage to hydraulic oil tank implement pump 1 (10) Passage from resolvers in valve stack
(3) Check valve (6) Main relief valve (GG) Tank pressure
(4) (LS) Load sense pressure to implement (7) Passage from Implement pump (pump (KK) High pressure
pump 2 supply) (LL) Signal oil
(8) Implement pressure sensor
KENR5631-05 259
Hydraulic System

Illustration 221 g03348005

(1) Inlet manifold (6) Main Relief Valve (9) Pump Supply Pressure ( “HA” )
(3) Check valve (8) Implement pressure sensor port

The hydraulic inlet manifold is located in the center of The flow of hydraulic oil from each implement pump
the valve stack between the ripper lift valve and the will enter at opposite ends of the implement control
ripper tip valve. valve stack and converge in inlet manifold (1) through
oil passages (7). This oil supplies the implement
The following two lines are connected to the inlet circuits whenever the implements are activated. Main
manifold: relief valve (6) protects the implement system from
pressure spikes.
• Pump supply lines (7)
Signal oil from the resolver network in the implement
• Signal resolver network line (10) control valves enters inlet manifold (1) through
passage (10).
The inlet manifold contains the following valves:
Return oil from the implement control valves enters
• Check Valve (3) inlet manifold (1) and returns to the hydraulic oil tank
through passage (2).
• Main Relief Valve (6)
Check valve (3) is located in the signal resolver
• Implement pressure sensor port (8) circuit and prevents rapid de-stroke of the implement
pump.
260 KENR5631-05
Hydraulic System

Main Relief Valve

Illustration 222 g03348385

Main Relief Valve
(11) Spring
(12) Outlet to Tank
(13) Valve Spool
(14) Inlet from Pump
(GG) Tank pressure
(KK) High pressure

The main relief valve protects the implement

hydraulic system from pressure spikes. This pressure
setting is higher than all of the operating pressures in
the implement hydraulic system.
Pump supply oil flows into inlet passage (14). The
force of spring (11) holds valve spool (13) closed
when the pressure of the pump supply oil is less than
the pressure setting of the relief valve.
When the pressure in inlet passage (14) is enough to
overcome the force of spring (11), valve spool (13)
opens to the left. Pump oil is allowed to return to the
hydraulic oil tank through passages (12).
When pump pressure is not enough to overcome the
force of spring (11), valve spool (13) shifts back to the
right.
KENR5631-05 261
Hydraulic System

i05243970

Signal Resolver Network

SMCS Code: 5079

S/N: JJW1–Up

Illustration 223 g03344064

Signal resolver network
(1) Passage from Ripper Lift Control Valve (6) Passage from Ripper Shank Control (E) Ripper Lift Control Valve
(2) Passage from Blade Tilt (Right) Control Valve (F) Blade Tilt (Right) Control Valve
Valve (7) Passage to Pump Compensator (G) Blade Lift Control Valve
(3) Passage from Blade Lift Control Valve (A) Blade Lift Control Valve (GG) Tank pressure
(4) Passage from Blade Lift Control Valve (B) Blade Tilt (Left) Control Valve (FF) Activated components
(5) Passage from Blade Tilt (Left) Control (C) Ripper Shank Control Valve (RR) Pilot pressure
Valve (D) Inlet Manifold

The resolver network consists of a resolver (ball

check valve) in each implement control valve, except
the first control valve section in the signal resolver
network. Each resolver compares the signal pressure
from the previous control valve and the signal
pressure from the current control valve. The resolver
ball shifts in order to allow the higher signal to flow to
the next resolver.
262 KENR5631-05
Hydraulic System

For example, Illustration 223 shows the resolver i05259712

network when the ripper lift control valve is activated.
Ripper lift control valve (E) starts the signal flow to
blade tilt (right) control valve (F). The ball in the
Check Valve (Implement Back
resolver for the blade tilt (right) control valve shifts Pressure)
downward. This shift allows the signal to flow through
the blade tilt (right) resolver to blade lift control valve SMCS Code: 5067
(G). The ball in this resolver shifts downward. This
shift allows the signal to flow through the blade lift
resolver to the other blade lift control valve (A). The
ball in this resolver shifts downward. This shift allows
the signal to flow through the blade lift resolver to
blade tilt (left) control valve (B). The ball in this
resolver shifts downward. This shift allows the signal
to flow through the blade tilt resolver to ripper shank
control valve (C). The ball in this resolver shifts
downward. The highest signal is sent to the pump
compensator valves. In this case, the signal from the
ripper lift control valve is sent to the pump
compensator valves through passage (7).

Note: The first control valve section in the signal

resolver network will not have a resolver.
The signal instructs the dual load sensing pumps to
vary output in order to meet the highest load
requirement. Also, the pump compensator valves
add margin pressure to the load requirement.
Note: The resolver network does not add various
loads together. Instead, the single highest resolved
load governs the pump output.
When all of the implements are in HOLD, the
pressure in the resolver network is at tank pressure.
The pump compensator valves keep the implement
pumps at LOW PRESSURE STANDBY until an
implement is activated.
Illustration 224 g03348660
(1) Implement back pressure check valve
KENR5631-05 263
Hydraulic System

Illustration 225 g03348847

(1) Implement back pressure check valve
(2) Check valve
(3) Return oil to tank
(4) Return oil from the implement inlet manifold

The purpose of this valve is to provide back pressure

to the implement valve. The back pressure will allow
the make-up valves within the implement valve stack
to perform the proper function during drop
commands. Without the back pressure valve the
make-ups will not open effectively limiting
regeneration flow on several circuits.
264 KENR5631-05
Hydraulic System

i05239009

Hydraulic Oil Cooler

SMCS Code: 1374

Illustration 226 g03341995

(1) Hydraulic oil cooler (3) Vertical hose (5) Thermal bypass valve
(2) Cooler inlet (4) Cooler outlet (6) Thermal bypass valve inlet

Hydraulic oil cooler (1) cools the oil from the fan
pump and motor case drain, and kidney loop flushing
circuit. In order to prevent overcooling, thermal
bypass valve (5) allows oil to bypass the hydraulic oil
cooler until the oil warms.
Return oil from the demand fan and kidney loop
flushing circuit enters thermal bypass valve inlet (6).
The oil is directed through horizontal hose (3). When
the oil is cold, thermal bypass valve (5) remains
open. The oil passes through cooler outlet (4) and
returns to the tank. When the oil is warm, thermal
bypass valve (5) closes against the seat. This forces
the oil through the hydraulic oil cooler. The oil then
flows through cooler outlet (4).
The hydraulic oil cooler receives oil from the demand
fan and kidney loop flushing circuit through inlet (2).
The oil flows through hydraulic oil cooler (1) and the
oil exits through outlet (4). The oil then flows to the
hydraulic tank.

Illustration 227 g03342151

(5) Thermal bypass valve
(6) Thermal bypass valve inlet
(7) Poppet
(8) Outlet passage
(9) Spring
(10) Passage from cooler tubes
(11) Passage to cooler tubes
KENR5631-05 265
Fan Hydraulic System

Fan Hydraulic System

i05669270

General Information (Fan

Hydraulic System)
SMCS Code: 1350; 1356; 1386; 1387

S/N: JJW1–Up
266 KENR5631-05
Fan Hydraulic System

Illustration 228 g03595258

(1) Reversible fan motor with internal (5) Accumulator (10) Variable displacement charge pump
flushing valve (6) Flushing bypass valve (11) Hydraulic tank
(2) Radiator (7) Implement pump (12) Hydraulic oil temperature sensor
(3) Hydraulic oil cooler with integrated (8) Variable displacement, bi-directional, fan
bypass valve pump
(4) High efficiency filter (9) Boost pump
KENR5631-05 267
Fan Hydraulic System

The fan hydraulic system consists of several Fan Pump

integrated circuits. The primary circuit is a closed
loop circuit consisting of variable displacement, bi-
directional, fan pump (8) and reversible fan motor
with internal flushing valve (1). The fan system also
consists of the following components.

• Boost Pump
• Flushing Bypass valve

• Variable Displacement Charge Pump

• High efficiency filter
• Accumulator

i05669469
Illustration 230 g03340276

Location of Components (Fan The fan pump is mounted on the rear of the right-
Hydraulic System) hand implement pump.

SMCS Code: 1356; 1386 Reference: Refer to System Operation, KENR5631,

“Piston Pump (Fan Drive)”
S/N: JJW1–Up
Boost Pump
Fan Motor

Illustration 231 g03340366

Illustration 229 g03340273

The boost pump is a fixed displacement gear pump
The fan motor is located at the front of the machine in that is inside the rear of the fan pump.
front of the radiator and in the middle of the radiator
guard. Reference: Refer to System Operation, KENR5631,
“Modes of Operation (Fan Hydraulic System)”
Reference: Refer to System Operation, KENR5631,
“Piston Motor (Fan Drive)”
268 KENR5631-05
Fan Hydraulic System

Charge Pump Fan Charging System Accumulator

Illustration 232 g03340377 Illustration 234 g03340398

The variable displacement axial piston charge pump The fan charging system accumulator is located
is mounted on the rear of the fan pump. below the floor plate on the inside of the right-hand
fender just to the rear of the filter.
Reference: Refer to System Operation, KENR5631,
“Modes of Operation (Fan Hydraulic System)” There are two identical accumulators on the right-
hand fender the one closer to the front of the
High Efficiency Filter machine is for the fan charging system. The
accumulator closer to the rear of the tractor is the
pilot accumulator.

Reference: Refer to System Operation, KENR5631,

“Modes of Operation (Fan Hydraulic System)”

Flushing Bypass Valve

Illustration 233 g03340396

The high efficiency filter is located below the floor

plate on the inside of the right-hand fender near the
front of the fender.

Illustration 235 g03340403

The flushing bypass valve is located below the floor

plate on the inside of the right-hand fender just to the
rear of the fan charging system accumulator.
Reference: Refer to System Operation, KENR5631,
“Bypass Valve (Flushing)”
KENR5631-05 269
Fan Hydraulic System

Hydraulic Oil Temperature Sensor Reference: Refer to System Operation, KENR5631,

“Electronic Control (Fan Hydraulic System)”

i05293459

Electronic Control (Fan

Hydraulic System)
SMCS Code: 1386; 1387; 1400; 7610

Electronic Control Modules

Implement ECM

Illustration 236 g03595256

The hydraulic oil temperature sensor is located in the

inboard side of the hydraulic oil tank, near the front of
the tank.

Illustration 237 g03307257

270 KENR5631-05
Fan Hydraulic System

ECM Pull Up Voltage

In order to aid in diagnostics of certain types of
electrical circuits that are controlled by the ECM, an
internal “pull up voltage” is connected to ECM switch
and sensor signal input contacts. An above normal
voltage is internally connected to the ECM signal
input circuit through a resister.
During normal operation, the switch or sensor signal
will hold the circuit low or at a certain signal
amplitude, however, circuit conditions such as a loss
of power to the component, a disconnection, or an
open circuit will allow the circuit to be pulled high by
the ECM pull up voltage. This condition will result in
an above normal voltage condition at the ECM
contact. As a result, the ECM will activate an FMI 03
(voltage above normal) diagnostic code for the
affected circuit.
The types of ECM input circuits that have pull up
voltage present are:
• Pulse Width Modulated (PWM) sensor input
circuits
• Switch to Ground Input switch input circuits

• Active analog (voltage) input signal circuits

• Passive analog (resistance) input signal circuits

ECM Pull Down Voltage

In order to aid in diagnostics of electrical circuits that
are controlled by the ECM, an internal “pull down
voltage” is connected to ECM switch to battery type
input circuits.
During normal operation, the switch contacts that are
allowing the connection to a voltage source will hold
the circuit high. When circuit conditions such as a
loss of power to the switch supply voltage, a
disconnection in the switch circuit or an open circuit
Illustration 238 g01309473 will allow the circuit to be pulled low by the ECM pull
ECM Connectors and Contacts down voltage. This condition will result in a below
normal voltage condition at the ECM contact. As a
The Implement ECM determines actions that are result, the ECM will activate an FMI 04 (voltage
based on input information and memory information. below normal) diagnostic code for the affected circuit.
After the Implement ECM receives the input
information, the ECM sends a corresponding Pin Locations
response to the outputs. The inputs and outputs of Table 160
the Implement ECM are connected to the machine
harness by two 70 contact connectors (J1 and J2). Implement ECM Contact Description J1 Contact De-
The ECM sends the information to the Caterpillar scriptions(1)
Electronic Technician (Cat ET) on the Cat Data Link. No.(2) Type Function
Note: The ECM is not serviceable. The ECM must be 10 CAN C Data Link - CAN C Data Link -
replaced if the ECM is damaged. Replace the ECM if
a failure is diagnosed. 13 Battery Return Battery -

20 CAN C Data Link + CAN C Data Link +

(continued)
KENR5631-05 271
Fan Hydraulic System

(Table 160, contd) Sensors

Implement ECM Contact Description J1 Contact De-
Sensors provide information to the ECM about the
scriptions(1)
intent of the operator or changing conditions. The
No.(2) Type Function sensor signal changes proportionally to the changing
of operator input or changing conditions. The
22 Analog Input
Hydraulic Oil Temperature following types of sensor signals are used by the
Sensor ECM.
23 Battery Return Battery - Frequency – The sensor produces a signal and the
Battery Power Input Battery +
frequency (Hz) varies as the condition changes.
31

38 Battery Power Input Battery + Pulse width modulated – The sensor produces a
signal. The duty cycle of the signal varies as the
39 Battery Power Input Battery + condition changes. The frequency of this signal is
constant.
47 Battery Power Input Battery +

57 Battery Return Battery - Analog – The ECM measures the voltage that is
associated to a specific condition of the control.
70 Battery Return Battery -
(1) Contacts that are not listed are not used.
(2) The connector contacts that are not listed are not used.
Hydraulic Oil Temperature Sensor
Table 161
Implement ECM Contact Description J2(1)

No.(2) Type Function

22 Return Sensor / Driver Return
64 CAN Data Link + CAN B Data Link +
65 CAN Data Link - CAN B Data Link -
67 CAN Data Link + CAN A Data Link +
68 CAN Data Link - CAN A Data Link -
(1) The ECM responds to an active input only when all of the nec-
essary conditions are satisfied.
(2) The connector contacts that are not listed are not used.

Inputs
The machine has several different types of input
devices. The ECM receives machine status
information from the input devices and determines
the correct output action that is needed in order to
control machine operations based on memory and
software parameters. The machine utilizes the Illustration 239 g03345886
following types of inputs: switch type and sensor
type. The hydraulic oil temperature sensor is a passive
analog sensor. The resistance of the sensor changes
Switches provide signals to the switch inputs of the proportionally to temperature changes. The ECM
ECM. The possible outputs of a switch are listed: an measures the resistance of the sensor and
open signal, a grounded signal and + battery signal. determines the temperature of the hydraulic oil. If the
ECM detects that the hydraulic oil has exceeded a
Sensors provide an electrical signal to the ECM that preset temperature, the ECM sends a signal to the
constantly changes. The sensor input to the ECM engine ECM to engage the hydraulic fan.
can be one of several different types of electrical
signals such as: pulse width modulated (PWM)
signals, voltage signals and frequency input signals.
Each possible input to the ECM is listed in the tables
for the 70-pin connectors.
Inputs provide information to the ECM in the form of
sensors or switches.
272 KENR5631-05
Fan Hydraulic System

Data Link Note: If the engine is in the overspeed condition, the

Electronic communication between the Implement engine ECM will regulate the fan to minimum speed.
ECM, Power Train ECM, Engine ECM, and the other This action will help to protect the fan hydraulic
control modules on the machine is conducted over system.
data link circuits. The data link circuits allow the
sharing of information with other electronic control
modules. The data link circuits are bidirectional. The
data link circuit allows the ECM to send information
and to receive information.
The electronic communication system consists of
multiple CAN datalink systems.
The SAE J1939 CAN Data Link circuit is separated
into different groups. “CAN A” is connected to all of
the ECMs on the machine, and is used primarily for
information and service purposes, such as the
Caterpillar Electronic Technician (CAT ET). The other
data link systems are high speed data links used for
machine control purposes.

i05669610

Modes of Operation (Fan

Hydraulic System)
SMCS Code: 1356; 5050; 7000

S/N: JJW1–Up
The purpose of the fan system is to drive the engine
cooling fan as required by the demand fan logic
software. The fan hydraulic system consists primarily
of a closed loop fan pump and motor combination.
The fan pump receives charge oil from a variable
displacement charge pump. The charge pump also
provides pilot oil to the implement sub system and
circulates hydraulic oil through the high efficiency
filter. The fan hydraulic system also includes a small
boost pump. The boost pump provides oil flow for the
flushing circuit. The boost pump oil is directed to the
flushing bypass valve. If the oil is cold, the flushing
bypass valve allows the oil to return directly to the
tank through the case drain filter. If the oil is hot, the
flushing bypass valve directs oil through the fan
pump flushing circuit , the hydraulic oil cooler, and
through the case drain filter as the oil returns to the
hydraulic tank.
The following sensors send information to the
engine ECM:
• Hydraulic oil temperature sensor

• Engine coolant temperature sensor

• Engine intake air temperature sensor

• Engine Speed
The engine ECM uses the information from the four
sensors in order to adjust the current signal that is
sent to the fan control solenoid.
KENR5631-05 273
Fan Hydraulic System

Hydraulic Fan System (Minimum Fan

Speed)

Illustration 240 g03346553

(1) Charge oil filter (7) Hydraulic oil tank (13) Variable displacement, bi-directional,
(K) Charge oil pressure and SOS port (8) Flushing bypass valve fan pump
(2) Reversing fan solenoid (9) Variable displacement charge pump (14) Fan motor internal flushing valve
(3) Pressure control spool (10) Fan main relief valve (15) Reversible fan motor
(4) Pressure control solenoid (11) Crossover relief valves (16) Pilot oil to the implement lockout
(5) Accumulator (12) Hydraulic oil cooler with integrated manifold
(6) Boost pump bypass valve

The fan motor in Illustration 240 is shown rotating at Note: The hydraulic oil temperature is detected on
the minimum speed. the implement ECM and is communicated to the
engine ECM through the data link.
This condition may occur in the following
situations: The current that is sent to pressure control solenoid
(4) by the engine ECM is at the maximum current.
• Initial start-up of the machine (cold engine coolant) This current causes pressure control spool (3) to shift
to the OPEN position. The pump swashplate moves
• Low ambient temperature to the minimum angle position. At the same time, the
engine ECM sends maximum current to reversing fan
• The engine is in the overspeed condition solenoid (2). When reversing fan solenoid (2) is sent
maximum current, the valve spool is shifted to the
• Hydraulic oil is not at operating temperature right. When the spool is shifted to the right, the fan
spins in the forward direction.
274 KENR5631-05
Fan Hydraulic System

Fan pump (13) produces minimum flow. Fan motor

(15) rotates at the slowest speed.
KENR5631-05 275
Fan Hydraulic System

Hydraulic Fan System (Maximum Fan

Clip Speed in the Forward Direction)

Illustration 241 g03345292

(1) Charge oil filter (7) Hydraulic oil tank (13) Variable displacement, bi-directional,
(K) Charge oil pressure and SOS port (8) Flushing bypass valve fan pump
(2) Reversing fan solenoid (9) Variable displacement charge pump (14) Fan motor internal flushing valve
(3) Pressure control spool (10) Fan main relief valve (15) Reversible fan motor
(4) Pressure control solenoid (11) Crossover relief valves (16) Pilot oil to the implement lockout
(5) Accumulator (12) Hydraulic oil cooler with integrated manifold
(6) Boost pump bypass valve

Fan motor (15) is rotating at the maximum calibrated Maximum fan speed is created when, minimum
clip speed in Illustration 241 . current is sent to solenoid (4) by the engine ECM.
The reduced current allows the spring to shift
This condition may occur in the following pressure control spool (3) to the CLOSED position.
situations: The pump swashplate moves to the maximum angle.
At the same time, the engine ECM sends maximum
• Maximum cooling needed for engine coolant. current to reversing fan solenoid (2). When reversing
fan solenoid (2) is sent maximum current, the valve
• High engine intake temperature spool is shifted to the right. When the spool is shifted
to the right, the fan spins in the forward direction.
• Maximum cooling needed for hydraulic oil.
Fan pump (13) produces maximum controlled flow.
Fan motor (15) rotates at the maximum controlled
speed.
276 KENR5631-05
Fan Hydraulic System

Hydraulic Fan System (Maximum Fan

Clip Speed in the Reverse Direction)

Illustration 242 g03342410

(1) Charge oil filter (7) Hydraulic oil tank (13) Variable displacement, bi-directional,
(K) Charge oil pressure and SOS port (8) Flushing bypass valve fan pump
(2) Reversing fan solenoid (9) Variable displacement charge pump (14) Fan motor internal flushing valve
(3) Pressure control spool (10) Fan main relief valve (15) Reversible fan motor
(4) Pressure control solenoid (11) Crossover relief valves (16) Pilot oil to the implement lockout
(5) Accumulator (12) Hydraulic oil cooler with integrated manifold
(6) Boost pump bypass valve

The engine ECM will automatically activate the When the engine ECM activates the reversing mode,
reversing fan solenoid at predetermined intervals. minimum current is sent to reversing fan solenoid (2).
The fan reversing valve will only engage when the The reduced current allows the spring to shift the
machine is in REVERSE gear, also in NEUTRAL with spool of the reversing valve to the left. When the
the park brake released. This function ensures that spool is shifted to the left, the fan spins in the reverse
the fan does not suck in the debris that comes over direction.
the top of the bulldozer blade. The reversing fan
intervals and duration of the intervals are Crossover relief valves (11) will momentarily open
programmable by using electronic technician. The when fan pump (13) reverses direction.
fan can also be reversed by using the manual
reversing fan switch.
KENR5631-05 277
Fan Hydraulic System

Fan Motor Internal Flushing Valve

Illustration 243 g03352930

(14) Fan motor internal flushing valve
(15) Reversible fan motor
(17) Flushing relief valve

The fan pump and motor form a closed loop system.

This closed loop system is similar to many other
closed loop systems found on Cat products. But the
loops are not really closed. Oil needs to be
continually flushed from the system for cooling or to
remove debris from the oil. All pumps and motors
have a certain amount of internal leakage that
increases as the pump or motor ages. This oil leaks
into the housing of the pump and is allowed to exit
the pump through the case drain. In this case, fan
motor (15) also has an internal flushing valve (14)
that allows hot oil and dirty oil to exit the closed loop
system. Illustration 243 shows the high-pressure side
of the loop (A) as red in color. It is important to
understand that the low-pressure side of the loop (B)
still has a significant amount of pressure.
Under normal operating conditions, the fan system is
designed to flush oil from the low-pressure side (B)
as long as a minimum pressure is still maintained.
The minimum pressure is maintained by flushing
relief valve (17). The pressure from the high-pressure
side of the loop (A), forces the flushing valve UP.
When the flushing valve is UP, oil from the low-
pressure side of the loop (B) can act against flushing
relief valve (17). If the pressure exceeds the preset
value, relief valve (17) will open and allow some oil to
be flushed from the closed loop. The oil that is
flushed from the closed loop in this manner joins the
oil from the boost circuit which passes through the
hydraulic oil cooler before returning to the case drain
filter in the hydraulic tank. Any oil that is lost from the
closed loop system in any manner, is replaced by oil
from charge pump (9).
278 KENR5631-05
Fan Hydraulic System

Boost Pump and Cooler Bypass

Illustration 244 g03353425

(1) Charge oil filter (7) Hydraulic oil tank (13) Variable displacement, bi-directional,
(K) Charge oil pressure and SOS port (8) Flushing bypass valve fan pump
(2) Reversing fan solenoid (9) Variable displacement charge pump (14) Fan motor internal flushing valve
(3) Pressure control spool (10) Fan main relief valve (15) Reversible fan motor
(4) Pressure control solenoid (11) Crossover relief valves (16) Pilot oil to the implement lockout
(5) Accumulator (12) Hydraulic oil cooler with integrated manifold
(6) Boost pump bypass valve
KENR5631-05 279
Fan Hydraulic System

Fixed displacement boost pump (6) is located inside Fan Pump Components
the rear of fan pump (13). All of the oil from boost
pump (6) returns to the hydraulic tank through the The hydraulic fan pump is a bidirectional variable
case drain filter. The case drain filter is located inside displacement axial piston pump. The displacement of
the hydraulic tank. The oil from the boost pump can the pump and the direction of oil flow is controlled by
follow two different paths. When the oil leaves the the engine ECM.
boost pump, the oil travels to flushing bypass valve
(8). If the oil is cold, flushing bypass valve (8) is open The fan hydraulic pump has the following
and the oil returns directly to the case drain filter in components:
the hydraulic tank. When the oil is warmer, flushing
Pressure override valve (POR) valve (4) – When
bypass valve (8) will be closed. The oil will be
the pressure of the oil in the drive loop exceeds the
directed to the case of fan pump (13). The oil passes pressure setting of the POR valve, the pressure will
through the case of fan pump (13) flushing any debris cause the pump to destroke.
from the case and cooling the internal parts of the
pump. Then this oil joins the oil from the case drain of Crossover relief and makeup valves (3) – The
fan motor (15). The combination of the two case crossover relief valves relieve high-pressure spikes
drains, then passes through the hydraulic oil cooler in the fan loop. Each valve also contains a makeup
before returning to the case drain filter in the valve. The makeup valve allows charge oil to
hydraulic tank. replenish the closed fan loop.
When cooler bypass valve (12) is open, the
combined oil flow from the case drain of the fan
motor and the boost circuit will bypass the cooler and POR Valve
return directly to the hydraulic oil tank through the
case drain filter. When cooler bypass valve (12) is
closed, the oil will flow through the cooler and then
return to the hydraulic oil tank through the case drain
filter.

i05232630

Piston Pump (Fan Drive)

SMCS Code: 1387-QP; 5070-HFN

S/N: JJW1–Up

Piston Pump
Illustration 246 g06000314
(5) Spring
(6) Passage from the actuator piston
(7) Passage to pump case
(8) Passage from the drive loop
(9) Passage from the drive loop
(10) Slug
(11) Chamber
(12) Piston
(13) Valve

The POR valve limits the maximum pressure in both

sides of the closed drive loop. When the valve opens,
the valve drains oil from the actuator piston in the fan
pump. As the actuator piston is drained, the centering
springs in the actuator piston move the swashplate to
Illustration 245 g06000267
reduce pump output.
(1) Reversing valve solenoid Slug (10) serves as a resolver. Oil from the high-
(2) Pressure reducing valve pressure side of the closed loop enters the POR
(3) Crossover relief valves
(4) Pressure override valve
valve through either passage (8) or passage (9). Slug
(10) is moved left if the high pressure is in passage
(9). Slug (10) is moved right if the high pressure is in
passage (6). The high-pressure oil is sent to chamber
(11).
280 KENR5631-05
Fan Hydraulic System

When the pressure in chamber (11) is high enough to The valve also acts as a makeup valve for the closed
overcome spring (5), piston (12) and valve (13) move drive loop. When the pressure of the low-pressure
to the left against spring (5). The valve connects side of the closed loop drops below charge pressure,
passage (6) to passage (7). The oil from the actuator charge oil in passage (15) opens valve (20). Oil from
piston is then allowed to drain to the pump case. the charge circuit flows into the low-pressure side of
the drive loop through passage (14). When the
The pressure setting of the POR valve is adjustable. pressure in passage (14) and chamber (19) reaches
charge pressure, the force of spring (16) closes valve
Crossover Relief and Makeup Valve (20).

i05236872

Piston Motor (Fan Drive)

SMCS Code: 1386-QP; 5058-HFN

S/N: JJW1–Up
The hydraulic fan motor is a piston motor that is
located at the front of the machine in front of the
radiator and in the middle of the radiator guard. The
hydraulic fan motor turns a fan that cools the radiator
cores of the machine.

Illustration 247 g06000322

(14) Passage from the drive loop
(15) Passage to charge the circuit
(16) Spring
(17) Spring
(18) Valve
(19) Chamber
(20) Valve

A crossover relief and makeup valve is placed in

each side of the closed drive loop. The crossover
relief valves are designed to remove high-pressure
spikes in the drive loops. Some charge oil is lost in
the closed drive loop from leakage and flushing. The
makeup valves allow charge oil to replenish the low-
pressure side of the drive loop.
Oil from the drive loop enters the valve through
passage (14). The oil flows into chamber (19). Valve
(20) is held closed by spring (16).
The pressure of the oil in chamber (19) acts against
valve (18). The force of spring (17) keeps valve (18)
closed until oil pressure in the drive loop reaches the
relief pressure.
When the force of the pressure of the oil in chamber
(19) against valve (18) becomes greater than the
force of spring (17), valve (18) opens to the right. The
oil in chamber (19) flows around valve (18) to the
drain.
When the pressure drops in chamber (19), only the
force of spring (16) is acting against valve (20). The
high pressure on the left side of valve (20) is greater
than the force of spring (16). Valve (20) opens to the
right. Oil from the drive loop can now go through
passage (15) into the charge circuit.
KENR5631-05 281
Fan Hydraulic System

Illustration 248 g01949676

(1) Inlet port (5) Piston (9) Swashplate

(2) Outlet port (6) Spring (10) Case drain port
(3) Inlet passage (7) Rotating group (11) Outlet passage
(4) Valve plate (8) Slipper
282 KENR5631-05
Fan Hydraulic System

Pump supply oil enters the hydraulic motor through i05233252

inlet port (1). The pump supply oil flows from inlet
port (1) through the passage in valve plate (4). The Bypass Valve
pump supply oil flows through inlet passage (3). The
high-pressure oil initiates a force against the piston (Flushing)
(5). The force against piston (5) pushes the piston out
of rotating group (7). The piston that is pushing out of SMCS Code: 5076
rotating group (7) will push slipper (8) against
swashplate (9). The force of the piston causes the S/N: JJW1–Up
slipper to slide on swashplate (9) which will initiate
the rotation of rotating group (7). As rotating group (7)
turns, spring (6) holds rotating group (7) against
swashplate (9).
As the slippers follow the angle of swashplate (9), the
pistons start to move back into the rotating group.
When rotating group (7) rotates over outlet passage
(11), the oil will be pushed out of the rotating group.
The low-pressure oil will flow out of the motor through
the passage in valve plate (4) to fan motor outlet (2).
Oil that has leaked within the motor lubricates the
components of the motor. The oil then flows out of
the motor through case drain (10).

Illustration 250 g03340576

Hydraulic oil flushing bypass valve
(1) Relief valve
(2) Return to the case drain filter inside the hydraulic oil tank
(3) From the boost pump
(4) To the flushing port on the fan pump
(5) From the hydraulic oil cooler
Illustration 249 g03341450 (6) Case drain from the right side implement pump
(12) Shuttle-relief valve
(13) Pressure limiter valve The hydraulic oil flushing bypass valve is installed in
the lines that connect the hydraulic oil cooler to the
The piston motor is equipped with a shuttle-relief type flushing circuit of the hydraulic fan system. The
flushing valve (12) and a pressure limiter valve (13). bypass valve regulates the temperature of the oil in
Shuttle-relief valve (12) allows oil to be flushed from order to ensure that the fan pump is properly cooled.
the low-pressure side of the closed loop fan circuit
but only when the pressure is above a preset limit If the oil is cold, the flushing bypass valve allows the
that is set by pressure limiter valve (13). oil to return directly to the tank through the case drain
filter. When the oil is hot, the flushing bypass valve
directs oil through the fan pump flushing circuit , the
hydraulic oil cooler, and through the case drain filter.
The oil then returns to the hydraulic oil tank.
Whether the flushing bypass valve is open or closed,
all of the oil that passes through the boost pump is
filtered by the case drain filter before returning to the
hydraulic oil tank.
KENR5631-05 283
Power Train System

Power Train System

i05594053

General Information (Power Train

System)
SMCS Code: 3000; 3100; 3282; 4000
284 KENR5631-05
Power Train System

Illustration 251 g03552060

(1) Diesel engine (9) Transmission (17) Kidney loop filter

(2) Power train ECM (10) Bevel gears (18) Service brake
(3) Service brake pedal (11) Final drive (19) Power train oil pump
(4) Decelerator pedal (12) Transmission hydraulic control valve (20) Torque converter outlet relief valve
(5) Rotary speed sensor (13) Pin puller (if equipped) (21) Tracks
(6) Torque converter housing (14) Power train accumulator (22) Power train oil cooler
(7) Torque converter outlet speed sensor (15) Steering clutch and brake control valve
(8) Torque converter inlet relief valve (16) Power train oil filter
KENR5631-05 285
Power Train System

The planetary transmission has three FORWARD Transmission direction selector (2) is located at the
and three REVERSE speeds. The speed and top of finger tip control (1).
direction of the planetary transmission are
electronically controlled by the power train ECM with Transmission upshift switch (3) is the upper switch on
inputs from the operator. Power is directed to the the front of finger tip control (1).
planetary transmission. Power is then directed to the
transfer and bevel gears. The transfer and bevel Transmission downshift switch (4) is the lower switch
gears turn two inner axle shafts that send power to on the front of finger tip control (1).
the steering clutches and brakes.
Parking brake switch (5) is located at the bottom of
Steering clutches turn the machine. The brakes stop finger tip control (1).
the machine and work with the steering clutches in
turning the machine. The steering clutches and the For more information on the control sensors, refer to
brakes are electronically controlled by the power train System Operation, “Electronic Control (Power Train
ECM with inputs from the operator. System)”.

Power from the steering clutches and brakes is used Reference: Refer to Operation and Maintenance
to turn two sun gear shafts that turn the final drives. Manual, SEBU8708 for more information on the
The final drives are single reduction planetary gear operator controls.
sets that send the power to the sprockets.
The sprockets drive the tracks.

i05602790

Location of Components
(Power Train System)
SMCS Code: 3000; 3100; 3282; 4000

Operator Controls

Illustration 253 g03559372

(6) Brake Pedal
(7) Decelerator Pedal

Service brake pedal (6) is the pedal on the left near

the floor of the operator station.
Decelerator pedal (7) is the pedal on the right near
the floor of the operator station.
Reference: Refer to Operation and Maintenance
Manual, SEBU8708 for more information on the
operator controls.

Illustration 252 g03559216

(1) Finger Tip Control (FTC)
(2) Transmission direction selector
(3) Transmission Upshift Switch
(4) Transmission Downshift Switch
(5) Parking Brake Switch

Finger Tip Control (FTC) (1) is located in the cab on

the left console.
286 KENR5631-05
Power Train System

Power Train Oil Pump

Illustration 254 g03561138

The low/high idle switch is located on the right Illustration 256 g03561681
console of the operator station.
The power train oil pump is mounted to the front of
Reference: Refer to Operation and Maintenance the bevel gear case and inside the left frame.
Manual, SEBU8708 for more information on the
operator controls. Reference: Refer to System Operation, KENR5631,
“Power Train Oil Pump”.
Power Train Oil Fill Tube and
Dipstick

Illustration 255 g03561263

The power train oil fill tube and dipstick are located in
a compartment on the left side of the cab below the
cab fresh air filter.
KENR5631-05 287
Power Train System

Torque Divider Torque Converter Outlet Relief

Valve

Illustration 258 g03569403

The torque converter outlet relief valve is mounted to

the upper right rear of the torque converter housing.
Reference: Refer to System Operation, KENR5631,
Illustration 257 g03569295
“Torque Divider”.
The housing for the torque divider is located behind
the engine between the flywheel housing and the Torque Converter Inlet Relief Valve
main drive shaft.
Reference: Refer to System Operation, KENR5631,
“Torque Divider”.

Illustration 259 g03570323

The torque converter inlet relief valve is mounted to

the front of the main case inside the right frame.
Reference: Refer to System Operation, KENR5631,
“Torque Divider”.
288 KENR5631-05
Power Train System

Power Train Oil Coolers Transmission

Illustration 260 g03570438

The power train oil cooler is mounted to the bottom of

the tractor in front of the engine.
Reference: Refer to System Operation, KENR5631,
“Oil Cooler (Power Train)”.
Illustration 261 g03570456

The planetary transmission is located inside the

transmission case, that is inside the main case.

Reference: Refer to System Operation, KENR5631,

“Transmission”.
KENR5631-05 289
Power Train System

Transmission Hydraulic Control

Illustration 262 g03570676

(8) Main Relief Valve (10) Transmission

(9) Transmission Hydraulic Control (11) Transmission Modulating Valves

Transmission hydraulic control (9) is located on top of Transfer and Bevel Gears
planetary transmission (10). Main relief valve (8), and
transmission modulating valves (11) are contained in
transmission hydraulic control valve (9). For
additional information about the solenoids controlling
the modulating valves and main relief valve, refer to
System Operation, “Electronic Control (Power Train
System)”.

Reference: Refer to System Operation, KENR5631,

“Transmission Hydraulic Control”.

Illustration 263 g03571131

The transfer and bevel gears are located inside the

bevel gear case in front of the planetary
transmission.
Reference: Refer to System Operation, KENR5631,
“Transfer and Bevel Gears”.
290 KENR5631-05
Power Train System

Brakes Electronic Steering Clutch and

Brake Control Valve

Illustration 265 g03578097

The steering and brake control valve is located

beneath the plate that is under the operator seat. The
steering clutch and brake control valve is mounted on
the top of the bevel gear case. For addition
Illustration 264 g03576658
information about the solenoids controlling the
The brakes are located within a housing behind the steering and brake valves, refer to System Operation,
final drives. “Electronic Control (Power Train System)”.

Reference: Refer to System Operation, KENR5631, Reference: Refer to System Operation, KENR5631,
“Electronic Steering Clutch and Brake Control Valve”. “Electronic Steering Clutch and Brake Control Valve”.
KENR5631-05 291
Power Train System

Final Drive Power Train Oil Filters

Illustration 267 g03579097

The power train oil filter is mounted to the top inside

of the left fender at the front of the machine.
Reference: Refer to System Operation, KENR5631,
“Oil Filter (Power Train)”.
Illustration 266 g03576777

The final drives are on the bottom rear of the

Kidney Loop Filter
machine.

Reference: Refer to System Operation, KENR5631,

“Final Drive”.

Illustration 268 g03581767

The kidney loop filter is mounted inside a

compartment at the top front of the left fender.

Reference: Refer to System Operation, KENR5631,

“Oil Filter (Power Train)”.
292 KENR5631-05
Power Train System

Transmission Breather for the Power Train Accumulator

Power Train

Illustration 269 g03571236

The transmission breather for the power train is

located in the compartment on the left rear of the
tractor, outside of the cab. The transmission breather
is attached to the transmission filler tube.
Illustration 271 g03582153

Power Train ECM The power train accumulator is located under the
rear left fender.
Reference: Refer to System Operation, KENR5631,
“Accumulator (Power Train)”

Pin Puller Valve

Illustration 270 g03573476

The power train ECM is located behind a panel at the

rear of the operator station behind the seat.

Illustration 272 g03573678

The pin puller valve is located on the back right side

of the transmission.
Reference: Refer to System Operation, KENR5631,
“Pin Puller Hydraulic System”
KENR5631-05 293
Power Train System

Transmission Speed Sensors Torque Converter Oil Temperature

Sensor

Illustration 273 g03590337

Illustration 275 g03590378

The transmission speed sensors are located on the
left side of the transmission, under the housing at the
rear of the machine. For more information refer to The torque converter oil temperature sensor is
System Operation, “Electronic Control (Power Train located behind and to the right of the torque
System)”. converter. For more information refer to System
Operation, “Electronic Control (Power Train
Torque Converter Speed Sensor System)”.

Illustration 274 g03590357

The torque converter speed sensor is located on the

top of the output of the torque converter, under the
cab. For more information refer to System Operation,
“Electronic Control (Power Train System)”.
294 KENR5631-05
Power Train System

Transmission Sump Temperature Power Train Oil Level Sensor

Sensor

Illustration 278 g03590818

Illustration 276 g03590489

The power train oil level sensor is located on the front
of the oil tank on the left side of the machine. For
The transmission sump temperature sensor is more information refer to System Operation,
located with the transmission oil filter on the left side “Electronic Control (Power Train System)”.
of the machine, under the left platform. For more
information refer to System Operation, “Electronic
Control (Power Train System)”. Parking Brake Switch
Service Brake Position Sensor

Illustration 279 g03590863

The parking brake switch is located on the left

Illustration 277 g03590683
armrest in the cab. For more information refer to
System Operation, “Electronic Control (Power Train
The service brake position sensor is located at the System)”.
top of the service brake pedal inside the cab. For
more information refer to System Operation,
“Electronic Control (Power Train System)”.
KENR5631-05 295
Power Train System

Brake Pedal Switch Power Train Filter Bypass Switch

Illustration 280 g03591265 Illustration 281 g03591597

The brake pedal switch is located in the top part of The power train filter bypass switch is located with
the brake pedal assembly in the cab. For more the transmission oil filter on the left side of the
information refer to System Operation, “Electronic machine, under the left platform. For more
Control (Power Train System)”.
296 KENR5631-05
Power Train System

information refer to System Operation, “Electronic

Control (Power Train System)”.

i05651210

Electronic Control (Power

Train System)
SMCS Code: 1400; 4000; 7610

Electronic Control Modules

Power Train ECM

Illustration 282 g03307257

Illustration 283 g01309473

ECM Connectors and Contacts
The Power Train ECM determines actions that are
based on input information and memory information.
After the Power Train ECM receives the input
information, the ECM sends a corresponding
response to the outputs. The inputs and outputs of
the Power Train ECM are connected to the machine
harness by two 70 contact connectors (J1 and J2).
The ECM sends the information to the Caterpillar
Electronic Technician (Cat ET) on the Cat Data Link.

Note: The ECM is not serviceable. The ECM must be

replaced if the ECM is damaged. Replace the ECM if
a failure is diagnosed.
KENR5631-05 297
Power Train System

ECM Pull Up Voltage (Table 162, contd)

Power Train ECM Contact Description J1 Contact De-
In order to aid in diagnostics of certain types of scriptions(1)
electrical circuits that are controlled by the ECM, an
internal “pull up voltage” is connected to ECM switch No.(2) Type Function
and sensor signal input contacts. An above normal
voltage is internally connected to the ECM signal Differential Speed In-
4 Transmission Output Speed 2 +
input circuit through a resister. put (+)

Differential Speed In-

During normal operation, the switch or sensor signal 5 Transmission Output Speed 2 -
put (-)
will hold the circuit low or at a certain signal
amplitude, however, circuit conditions such as a loss 10 CAN C Data Link - CAN C Data Link -
of power to the component, a disconnection, or an
open circuit will allow the circuit to be pulled high by 13 Battery Return Battery -
the ECM pull up voltage. This condition will result in
Differential Speed In- Torque Converter Output Speed
an above normal voltage condition at the ECM 15
put (+) 1+
contact. As a result, the ECM will activate an FMI 03
(voltage above normal) diagnostic code for the Differential Speed In- Torque Converter Output Speed
affected circuit. 16
put (-) 1-
The types of ECM input circuits that have pull up 20 CAN C Data Link + CAN C Data Link +
voltage present are:
Sensor Power
21 5V Sensor Return
• Pulse Width Modulated (PWM) sensor input Return
circuits Torque Converter Oil Tempera-
22 Analog Input
ture Sensor
• Switch to Ground Input switch input circuits
23 Battery Return Battery -
• Active analog (voltage) input signal circuits
Transmission Oil Temperature
29 Analog Input
• Passive analog (resistance) input signal circuits Sensor

31 Battery Power Input Battery +

ECM Pull Down Voltage Switch to Ground
33 Reverse Switch (N/O)
Input
In order to aid in diagnostics of electrical circuits that
are controlled by the ECM, an internal “pull down Switch to Ground
Reverse Switch (N/C)
34
voltage” is connected to ECM switch to battery type Input
input circuits.
Switch to Ground
35 Parking Brake Switch (N/O)
During normal operation, the switch contacts that are Input
allowing the connection to a voltage source will hold Battery Power Input Battery +
38
the circuit high. When circuit conditions such as a
loss of power to the switch supply voltage, a 39 Battery Power Input Battery +
disconnection in the switch circuit or an open circuit
will allow the circuit to be pulled low by the ECM pull Switch to Ground
40 Parking Brake Switch (N/C)
down voltage. This condition will result in a below Input
normal voltage condition at the ECM contact. As a Sensor Power
result, the ECM will activate an FMI 04 (voltage 44
Output
8 V Sensor Supply
below normal) diagnostic code for the affected circuit.
Sensor Power
45 8 V Sensor Return
Pin Locations Return
Table 162 47 Battery Power Input Battery +
Power Train ECM Contact Description J1 Contact De- Sourcing Driver Electronic Clutch Pressure Con-
scriptions(1) 48
Output trol 1
No.(2) Type Function Sourcing Driver Electronic Clutch Pressure Con-
49
Output trol 2
Differential Speed In-
2 Transmission Output Speed 1 +
put (+) Souring Driver
50 PWM Drivers 1 - 4 Return
Return
Differential Speed In-
3 Transmission Output Speed 1 -
put (-)

(continued)

(continued)
298 KENR5631-05
Power Train System

(Table 162, contd) (Table 163, contd)

Power Train ECM Contact Description J1 Contact De- Power Train ECM Contact Description J2(1)
scriptions(1)
No.(2) Type Function
No.(2) Type Function
Right Clutch / Brake Steering
25 PWM Input
Sourcing Driver Electronic Clutch Pressure Con- Input
51
Output trol 3
Switch to Ground
28 Upshift Switch (N/O)
Souring Driver Input
54 PWM Driver 11-12 Return
Return
Switch to Ground
Souring Driver 29 Upshift Switch (N/C)
55 PWM Driver 9-12 Return Input
Return
Switch to Ground
Sensor Power 30 Downshift Switch (N/O)
56 10V Return Input
Return
Switch to Ground
57 Battery Return Battery - 31 Downshift Switch (N/C)
Input
Sourcing Driver
58 Left Proportional Brake Solenoid Service Brake Pedal Position
Output 32 PWM Input
Sensor
Sourcing Driver Right Proportional Brake 33 PWM Input FNR Position Sensor
59
Output Solenoid
Switch to Ground
Sourcing Driver 36 Forward Switch (N/O)
60 PWM Driver 5-8 Return Input
Return
Switch to Ground
Sourcing Driver Clutch Pressure Control 37 Forward Switch (N/C)
61 Input
Output Solenoid
Switch to Ground
Switch to Ground Power Train Oil Filter Bypass 60 Power Train Oil Level Sensor
64 Input
Input Switch
67 CAN Data Link + CAN A Data Link +
Sourcing Driver
65 Transmission Reverse Clutch
Output 68 CAN Data Link - CAN A Data Link -
(1) The ECM responds to an active input only when all of the nec-
Sourcing Driver
66 Transmission Forward Clutch essary conditions are satisfied.
Output (2) The connector contacts that are not listed are not used.
Sensory Power
69 10V Sensor Supply
Output
Inputs
70 Battery Return Battery -
The machine has several different types of input
(1) Contacts that are not listed are not used. devices. The ECM receives machine status
(2) The connector contacts that are not listed are not used. information from the input devices and determines
the correct output action that is needed in order to
Table 163 control machine operations based on memory and
software parameters. The machine utilizes the
Power Train ECM Contact Description J2(1)
following types of inputs: switch type and sensor
No.(2) Type Function type.

Sourcing Driver Parking Brake Dump Valve Switches provide signals to the switch inputs of the
3 ECM. The possible outputs of a switch are listed: an
Output Solenoid
open signal, a grounded signal and + battery signal.
Sourcing Driver
4 Load Return 1
Return Sensors provide an electrical signal to the ECM that
Sourcing Driver
constantly changes. The sensor input to the ECM
6
Output
Backup Alarm can be one of several different types of electrical
signals such as: pulse width modulated (PWM)
Sourcing Driver signals, voltage signals and frequency input signals.
8 Load Return 2
Return Each possible input to the ECM is listed in the tables
for the 70-pin connectors.
22 Return Sensor / Driver Return

24 PWM Input Left Clutch / Brake Steering Input Inputs provide information to the ECM in the form of
sensors or switches.

(continued)
KENR5631-05 299
Power Train System

Sensors Torque Converter Output Speed Sensor

Sensors provide information to the ECM about the
intent of the operator or changing conditions. The
sensor signal changes proportionally to the changing
of operator input or changing conditions. The
following types of sensor signals are used by the
ECM.
Frequency – The sensor produces a signal and the
frequency (Hz) varies as the condition changes.
Pulse width modulated – The sensor produces a
signal. The duty cycle of the signal varies as the
condition changes. The frequency of this signal is
constant.

Analog – The ECM measures the voltage that is

associated to a specific condition of the control. Illustration 285 g03372298

The ECM receives signals from the torque converter

Transmission Output Speed Sensor output speed sensor as a frequency signal. The
torque converter output speed sensor is a passive
sensor. The signal indicates the rotational speed of
the connection from the output of the torque
converter to the input of the transmission. The signal
is generated by a gear passing in front of the sensor,
with one full pulse generated per tooth on the gear.
The sensor has an inductive coil that creates a
voltage pulse to the ECM when a gear tooth passes
the sensor. The ECM interprets the frequency of the
pulses as the speed of the gear.

Illustration 284 g03372196

The ECM receives signals from the transmission

output speed sensor as a frequency signal. The
transmission output speed sensor is an active
sensor. The signal indicates the rotational speed of
the connection from the output of the torque
converter to the input of the transmission. The signal
is generated by a gear passing in front of the sensor,
with one full pulse generated per tooth on the gear.
The signal is low when a gear tooth is in front of the
sensor and high when in a valley.
300 KENR5631-05
Power Train System

Torque Converter Oil Temperature Transmission Sump Temperature Sensor

Sensor

Illustration 287 g03372390

Illustration 286 g03345886

The ECM receives signals from the transmission
sump oil temperature sensor as an analog signal.
The ECM receives signals from the torque converter The sensor is a passive sensor. The voltage output of
oil temperature sensor as an analog signal. The the sensor changes proportionally to the temperature
sensor is a passive sensor. The voltage output of the of the transmission oil.
sensor changes proportionally to the temperature of
the torque converter oil.
KENR5631-05 301
Power Train System

Left and Right Steering Lever Position Service Brake Pedal Position Sensor
Sensor

Illustration 289 g03373852

Illustration 288 g03373852

The service brake pedal position sensor is an active
pulse width position sensor. The sensor sends a
The left and right steering lever position sensors are pulse width modulated signal to the ECM. The signal
active pulse width position sensors. The sensors allows the ECM to determine the position of the
send pulse width modulated signals to the ECM. The service brake pedal.
signals allow the ECM to determine the position of
the left and right steering lever.
302 KENR5631-05
Power Train System

Forward Neutral Reverse (FNR) Position Power Train Oil Level Sensor
Sensor

Illustration 291 g03374014

Illustration 290 g03589790

The Power Train oil level sensor is an active pulse
width modulated sensor. The sensor sends a pulse
The forward neutral reverse (FNR) position sensor is width modulated signal to the ECM. The duty cycle of
an active pulse width position sensor. The sensor the signal is proportional to the level of oil in the
sends a pulse width modulated signal to the ECM. Power Train oil tank.
The signal allows the ECM to determine the position
of the FNR lever.
Switches
Switches provide an open signal, a ground signal, or
a +battery signal to the inputs of the ECM. Switches
are open or closed.
• When a switch is open, no signal is provided to the
corresponding input of the ECM. This “no signal”
condition is also called “floating”.
• When a switch is closed, a ground signal or a
+battery signal is provided to the corresponding
input of the ECM.
KENR5631-05 303
Power Train System

Forward and Reverse Switches Parking Brake

Illustration 292 g03587184 Illustration 293 g03372717

The forward and reverse switches are single pole The parking brake switch is a two position switch with
limit switches. The forward and reverse switches a normally open contact and a normally closed
each have a normally open contact and a normally contact. The contacts provide switch to ground inputs
closed contact. When the switch is not activated, the to the ECM. Through these contacts, the ECM can
normally open contact floats to a high voltage state, determine if the parking brake is engaged or
and the normally closed contact is pulled to a low disengaged. The parking brake switch directly
voltage state. When the switch is activated, the controls the action of the parking brake system, by
normally open contact is pulled to a low voltage state, either opening or closing the driver side circuit on the
and the normally closed contact floats to a high brake solenoid.
voltage state. The ECM monitors the state of the two
contacts for each switch and determines the operator
request for forward or reverse movement.
304 KENR5631-05
Power Train System

Power Train Oil Filter Bypass Switch Service Brake Switch

Illustration 295 g03588356

The service brake switch is a single pole limit switch.

The service brake switch has a normally open
contact and a normally closed contact. When the
switch is not activated, the normally open contact
floats to a high voltage state, and the normally closed
Illustration 294 g03320660 contact is pulled to a low voltage state. When the
switch is activated, the normally open contact is
The Power Train oil filter bypass switch is a pressure pulled to a low voltage state, and the normally closed
switch. The switch alerts the ECM when the Power contact floats to a high voltage state. The ECM
Train oil filter is being bypassed. The contact floats to monitors the state of the two contacts for the switch
a high voltage when the switch is not closed. When and determines if the operator has fully depressed
the switch closes, the contact is pulled to a low or the service brake.
ground voltage state by the return line.
KENR5631-05 305
Power Train System

Upshift and Downshift Switches Proportional Solenoids

Transmission Clutch Control Solenoids

Illustration 296 g03588881

The upshift and downshift switches are single pole

push-button switches. Illustration 297 g03587899
Transmission speed 1 solenoid
Outputs Transmission speed 2 solenoid
The ECM responds to decisions by sending electrical Transmission speed 3 solenoid
signals to the outputs. The outputs can create an Transmission forward solenoid
action or the outputs can provide information to the
operator or the service technician. Transmission reverse solenoid
Each of these solenoid valves is designed to control
the flow of to a clutch plate. When the solenoid is not
engaged or receiving a low duty cycle signal, the
solenoid does not allow Power Train hydraulic oil to
engage a clutch plate. As the duty cycle of the signal
to the solenoid increases, the solenoid allows some
flow and the clutch begins to engage. When the duty
cycle of the signal to the solenoid is at the maximum,
the flow of Power Train hydraulic oil fully engages the
clutch. The engagement of a clutch is proportional to
the duty cycle of the signal sent by the ECM.

Note: The solenoid coils are not designed to operate

using 24 DCV directly. The ECM sends a PWM signal
of 24 V at a duty cycle that will provide the necessary
current to the solenoid coils. Do NOT activate the
coils by using 24 DCV (+battery). The life of the coils
will be reduced drastically. A source of 12 DCV
should be used, if the coils must be activated by not
using the ECM.
306 KENR5631-05
Power Train System

Brake Solenoid Clutch Pressure Solenoid

Illustration 298 g03372925 Illustration 299 g03373029

The brake solenoid is designed to control the flow of The clutch pressure control solenoid is designed to
brake oil to the brakes. The brakes are spring applied control the main relief pressure, which determines
and hydraulically released. When the solenoid is not the top pressure for the clutch engagement system.
engaged or receiving a low duty cycle signal, the The top pressure is inversely related to the
solenoid does not allow brake oil to disengage the engagement of the solenoid. The ECM sends a duty
brakes. As the duty cycle of the signal to the solenoid cycle signal to the solenoid. As the duty cycle
increases, the solenoid allows some flow and the increases, the top pressure proportionally decreases.
brakes begin to release. When the duty cycle of the
signal to the solenoid is at the maximum, the flow of Note: The solenoid coils are not designed to operate
brake oil fully releases the brakes. The engagement using 24 DCV directly. The ECM sends a PWM signal
of the brakes is inversely proportional to the duty of 24 V at a duty cycle that will provide the necessary
cycle of the signal sent by the ECM. current to the solenoid coils. Do NOT activate the
coils by using 24 DCV (+battery). The life of the coils
Note: The solenoid coils are not designed to operate will be reduced drastically. A source of 12 DCV
using 24 DCV directly. The ECM sends a PWM signal should be used, if the coils must be activated by not
of 24 V at a duty cycle that will provide the necessary using the ECM.
current to the solenoid coils. Do NOT activate the
coils by using 24 DCV (+battery). The life of the coils
will be reduced drastically. A source of 12 DCV
should be used, if the coils must be activated by not
using the ECM.
KENR5631-05 307
Power Train System

On/Off Solenoid Backup Alarm

Brake Dump Solenoid

Illustration 301 g03350044

The backup alarm is controlled by the power train

ECM. When in the REVERSE position, the backup
alarm sounds. The alarm is driven by the ECM.

Data Link
Electronic communication between the Implement
ECM, Power Train ECM, Engine ECM, and the other
Illustration 300 g03588439 control modules on the machine is conducted over
data link circuits. The data link circuits allow the
The brake dump solenoid is an on/off solenoid valve. sharing of information with other electronic control
The solenoid is activated when the limit switch on the modules. The data link circuits are bidirectional. The
brake pedal is activated. The solenoid controls if the data link circuit allows the ECM to send information
brake hydraulic oil is being directed to the tank, or and to receive information.
allowed to be distributed by the brake solenoid. The electronic communication system consists of
multiple CAN datalink systems.
308 KENR5631-05
Power Train System

The SAE J1939 CAN Data Link circuit is separated Caterpillar Electronic Technician (CAT ET). The other
into different groups. “CAN A” is connected to all of data link systems are high speed data links used for
the ECMs on the machine, and is used primarily for machine control purposes.
information and service purposes, such as the
i05979255

Steering Clutch and Brake

Control Valve
SMCS Code: 4102; 4120

General Information

Illustration 302 g03621384

(1) Electronic steering clutch and brake (B1) Left-hand brake pressure test port (C2) Right-hand steering clutch pressure
control valve (B2) Right-hand brake pressure test port test port
(2) Proportional solenoids (C1) Left-hand steering clutch pressure test
(3) Parking brake ON/OFF solenoid port
KENR5631-05 309
Power Train System

Illustration 303 g03625837

(4) Right-hand brake pressure reducing (7) Brake accumulators (11) Left-hand steering clutch port
valve (8) Left-hand steering clutch pressure (12) Tank port
(5) Right-hand steering clutch pressure reducing valve (13) Right-hand steering clutch port
reducing valve (9) Left-hand brake pressure reducing valve (14) Right-hand brake port
(6) Inlet check valve (10) Left-hand brake port (15) Supply port
310 KENR5631-05
Power Train System

Illustration 304 g03626442

(3) Parking brake ON/OFF solenoid (19) Right-hand brake restriction valve (22) Left-hand steering clutch proportional
(16) Left-hand brake restriction valve (20) Right-hand brake proportional solenoid solenoid
(17) Left-hand brake restriction check valve (21) Right-hand steering clutch proportional (23) Left-hand brake proportional solenoid
(18) Right-hand brake restriction check solenoid
valve

The power train ECM responds to the operators Electronic steering clutch and brake control valve (1)
movement of the finger tip control (FTC), parking is installed on the top of the main case below the
brake switch, and service brake pedal. operator seat. Electronic steering clutch and brake
control valve (1) can be accessed by removing the
The first movement of the FTC modulates operator seat, the seat pedestal, and the rear floor
disengagement of the steering clutch and the plate in the cab. The valve body contains four
machine will make a gradual turn. Further movement proportional solenoids (2) and ON/OFF parking brake
of the FTC modulates engagement of the brake and solenoid (3). Proportional solenoids (2) are controlled
the machine will make a sharper turn. by the Power Train ECM. Proportional solenoids (2)
control oil to the steering clutches and brakes. The
The service brake pedal modulates the engagement status of brake solenoids (20) and (23), and steering
of both of the brakes to stop the machine. The clutch solenoids (21) and (22) may be viewed
parking brake switch engages both of the brakes to through the information display panel (Service/
prevent the machine from moving when parking System Status/Power Train Screens), or by using Cat
brake ON/OFF solenoid (4) is energized. ET. All four pressures for the steering clutches and
the brakes may be tested at pressure test ports (B1),
(B2), (C1), and (C2). The pressure ports are located
below proportional solenoids (2) on electronic
steering and brake control valve (1). Pressure test
ports (B1), (B2), (C1), and (C2) correspond to the
respective solenoids.
KENR5631-05 311
Power Train System

Gradual Right Turn

Illustration 305 g03617222

(1) Left brake proportional solenoid (5) Restriction valve (9) Left brake pressure reducing valve
(2) Left clutch proportional solenoid (6) Restriction valve (10) Left clutch pressure reducing valve
(3) Right clutch proportional solenoid (7) Left accumulator (11) Right clutch pressure reducing valve
(4) Right brake proportional solenoid (8) Right accumulator (12) Right brake pressure reducing valve
312 KENR5631-05
Power Train System

(13) Pump supply oil (17) From right clutch (21) Left Finger Tip Control (FTC)
(14) From left brake (18) Parking brake solenoid (22) Right Finger Tip Control (FTC)
(15) From right brake (19) Check valves
(16) From left clutch (20) Power Train ECM

When the operator pulls the lever for right Finger Tip
Control (FTC) (22) rearward, the right steering lever
position sensor sends a signal to power train
Electronic Control Module (ECM) (20). Power train
ECM (20) then decreases the current to right steering
clutch proportional solenoid (3). The amount of
current sent to right steering clutch proportional
solenoid (3) is directly proportional to the position of
the right-hand FTC steering control lever.
The decreased current begins to de-energize right
steering clutch proportional solenoid (3). This action
also decreases the flow of pilot oil to pressure
reducing valve (11), which opens the flow of pump
supply oil (13) and pilot oil to drain. This decreased
pressure allows the spring in pressure reducing valve
(11) to move the spool in pressure reducing valve
(11) to the right.
As the spool in pressure reducing valve (11) moves
to the right, the high-pressure supply passage to the
right steering clutch is closed off and the passage to
the drain is opened. The spool movement in pressure
reducing valve (11) begins decreasing the pressure
in the right steering clutch circuit. The decreased
pressure in the right steering clutch circuit allows the
right steering clutch to begin disengaging.
When the operator pulls the lever for right FTC (22)
all the way to the detent, right clutch proportional
solenoid (3) is de-energized. The pilot oil to right
clutch proportional solenoid (3) is drained to tank,
which allows the spring in right clutch pressure
reducing valve (11) to move right clutch pressure
reducing valve (11) all the way to the right.
KENR5631-05 313
Power Train System

Sharp Right Turn

Illustration 306 g03620607

(1) Left brake proportional solenoid (5) Restriction valve (9) Left brake pressure reducing valve
(2) Left clutch proportional solenoid (6) Restriction valve (10) Left clutch pressure reducing valve
(3) Right clutch proportional solenoid (7) Left accumulator (11) Right clutch pressure reducing valve
(4) Right brake proportional solenoid (8) Right accumulator (12) Right brake pressure reducing valve
314 KENR5631-05
Power Train System

(13) Pump supply oil (17) From right clutch (21) Left Finger Tip Control (FTC)
(14) From left brake (18) Parking brake solenoid (22) Right Finger Tip Control (FTC)
(15) From right brake (19) Check valves
(16) From left clutch (20) Power Train ECM

When the operator pulls the lever for Right Finger Tip
Control (FTC) (22) rearward , past the halfway
position, the right steering lever position sensor
sends an increased signal to Power Train ECM (20).
Power Train ECM (20) then decreases the current to
right brake proportional solenoid (4). The amount of
current sent to right brake solenoid (4) is directly
proportional to the position of the lever on right FTC
(20).
The decreased current de-energizes right brake
proportional solenoid (4), which opens the flow of
pump supply oil (13) and pilot oil to drain. The result
is decreased pilot pressure to the spool in right brake
pressure reducing valve (12). This decreased
pressure allows the spring to move the reducing
spool to the right in right brake pressure reducing
valve (12). As the spool moves to the right, high-
pressure pump supply passage to the right brake
(17) is closed and the passage from the right brake
circuit is opened to drain. This spool movement
begins decreasing the pressure to the right brake.
The decreased pressure allows the springs to begin
engaging the right brake.
When the operator moves the right FTC steering
lever all the way to the rear, right brake proportional
solenoid (4) is de-energized. The pilot oil to right
brake proportional solenoid (4) is drained to tank,
which allows the spring in right brake pressure
reducing valve (12) to move right brake pressure
reducing valve (12) all the way to the right.
KENR5631-05 315
Power Train System

Service Brakes Engaged

Illustration 307 g03620638

(1) Left brake proportional solenoid (5) Restriction valve (9) Left brake pressure reducing valve
(2) Left clutch proportional solenoid (6) Restriction valve (10) Left clutch pressure reducing valve
(3) Right clutch proportional solenoid (7) Left accumulator (11) Right clutch pressure reducing valve
(4) Right brake proportional solenoid (8) Right accumulator (12) Right brake pressure reducing valve
316 KENR5631-05
Power Train System

(13) Pump supply oil (17) From right clutch (21) Left Finger Tip Control (FTC)
(14) From left brake (18) Parking brake solenoid (22) Right Finger Tip Control (FTC)
(15) From right brake (19) Check valves
(16) From left clutch (20) Power Train ECM

When the operator depresses the service brake

pedal, the brake pedal position sensor sends a signal
to Power Train ECM (20). Power Train ECM (20) then
decreases the current to both left brake proportional
solenoid (1) and right brake proportional solenoid (4).
The amount of current sent to left brake proportional
solenoid (1) and right brake proportional solenoid (4)
is directly proportional to the position of the service
brake pedal.
The decreased current de-energizes left brake
proportional solenoid (1) and right brake proportional
solenoid (4) , which reduces flow to the end of left
brake pressure reducing valve (9) and right brake
pressure reducing valve (12). This action allows the
flow of pump supply oil (13) and pilot oil to drain. The
result is decreased pilot pressure to both brake
pressure reducing valves (9) and (12). This
decreased pressure allows the springs to move the
valve spools to the right in brake pressure reducing
valves (9) and (12).
As the spools move to the right in both brake
pressure reducing valves (9) and (12), the passages
from the brake circuits are connected to the drain
passages and the high-pressure supply passages
are closed. This action decreases the oil pressure to
both left brake (14) and right brake (17). The
decreased pressure allows the brake springs to begin
engaging the brake.
When the service brake pedal is partly depressed,
the pilot pressure will partially decrease. Only a
portion of the brake oil will be exhausted. This action
will result in light operation of the brakes as the
spring applied brakes begin to engage.
When the service brake pedal is fully depressed, pilot
pressure will decrease to zero. All of the brake oil in
both of the brake circuits will be exhausted to the
drain. This operation will give full braking action.
When the service brake pedal is pushed to the floor,
the service brake switch (end of travel) opens. This
action energizes parking brake solenoid (18). The
parking brake valve opens and the valve exhausts
any remaining pilot pressure oil to the drain through
check valves (19). This operation results in the
maximum application of the brakes.
KENR5631-05 317
Power Train System

Parking Brake Engaged

Illustration 308 g03620642

(1) Left brake proportional solenoid (5) Restriction valve (9) Left brake pressure reducing valve
(2) Left clutch proportional solenoid (6) Restriction valve (10) Left clutch pressure reducing valve
(3) Right clutch proportional solenoid (7) Left accumulator (11) Right clutch pressure reducing valve
(4) Right brake proportional solenoid (8) Right accumulator (12) Right brake pressure reducing valve
318 KENR5631-05
Power Train System

(13) Pump supply oil (17) From right clutch (21) Left Finger Tip Control (FTC)
(14) From left brake (18) Parking brake solenoid (22) Right Finger Tip Control (FTC)
(15) From right brake (19) Check valves
(16) From left clutch (20) Power Train ECM
KENR5631-05 319
Power Train System

When the operator sets the parking brake switch to high-pressure supply passages are closed and
the ON position, parking brake solenoid (18) is passages from left brake (14) and right brake (17) are
energized. Left brake proportional solenoid (1) and connected to the drain passages. This operation
right brake proportional solenoid (4) are also de- decreases the pressure to the brakes. This
energized by Power Train ECM (20) when the decreased pressure allows the brake springs to
parking brake switch is set to the ON position. The engage the brakes fully. At the same time, both
pilot oil from left brake pressure reducing valve (9) steering clutch proportional solenoids (2) and (3) are
and right brake pressure reducing valve (12) is de-energized. With both steering clutch proportional
drained to tank through check valves (19). This solenoids (2) and (3) de-energized, high-pressure
action causes the pilot pressure in the brake circuits supply passages to both steering clutch pressure
to decrease, and the spools in brake reducing valve reducing valves (10) and (11) are drained to tank.
(9) and (12) move to the right. As the spools in brake This operation allows both steering clutch springs to
reducing valves (9) and (12) move to the right, the disengage the steering clutches.
i05645955

Torque Divider
SMCS Code: 3113; 3114

Components

Illustration 309 g03582982

(1) Flywheel (6) Carrier (11) Turbine

(2) Ring Gear (7) Yoke (12) Planetary Carrier
(3) Housing (8) Output Shaft (13) Planetary Gears
(4) Impeller (9) Outlet Passage (14) Sun Gear
(5) Inlet Passage (10) Stator

The torque divider consists of a torque converter and The torque converter uses the planetary gear set and
of a planetary gear set. the stator in order to multiply the torque to the
transmission. When the machine works against a low
The torque divider transmits engine power to the load, the torque multiplication is low. When the
planetary transmission. The hydraulic connection is machine works against a high load, the torque
through the torque converter. The mechanical multiplication is higher. A higher torque can then be
connection is through a planetary gear group. sent to the transmission during high load conditions.
320 KENR5631-05
Power Train System

The planetary gear group multiplies the torque from

the engine by increasing the mechanical advantage
through the gears. The torque multiplication
increases as the load on the machine increases.
During no-load conditions, neither the torque
converter nor the planetary gear group can multiply
the torque from the engine.
The torque converter is connected to the flywheel (1).
The torque converter housing is installed on the
engine flywheel housing. Output shaft (8) is
connected to yoke (7). Yoke (7) is connected to the
planetary transmission through a drive shaft.
These components are the main components of the
planetary gear group: sun gear (14), planetary carrier
(12), planetary gears (13) and ring gear (2).
Sun gear (14) is connected to the flywheel by splines.
Planetary gears (13) are mounted in planetary carrier
(12). Planetary carrier (12) is connected to output
shaft (8) by splines. The planetary gears are
engaged with sun gear (14) and with ring gear (2).
These components are the main components of the
torque converter: housing (3), impeller (4), turbine
(11) and stator (10).
Housing (3) is connected to flywheel (1) by splines.
Impeller (4) is connected to housing (3). Turbine (11)
is connected to ring gear (2) by splines. Stator (10) is
connected to carrier (6). The stator cannot turn.
KENR5631-05 321
Power Train System

Torque Converter Operation

Illustration 310 g03583038

Torque Converter
(1) Flywheel (7) Yoke (13) Planetary Gears
(2) Ring Gear (8) Output Shaft (14) Sun Gear
(3) Housing (9) Outlet Passage (A) Drive Assembly
(4) Impeller (10) Stator (B) Driven Assembly
(5) Inlet Passage (11) Turbine (C) Stationary Assembly
(6) Carrier (12) Planetary Carrier

Oil for the operation of the torque converter flows The force of the oil from the stator can now add to the
through inlet passage (5) in carrier (6) to impeller (4). torque output from the engine to the impeller. The
The rotation of the impeller gives force to the oil. The extra force adds to the torque output of the engine to
impeller sends the oil toward the outside of the the turbine. The force of the oil that is coming from
impeller, around the inside of housing (3), and to the stator is determined by the difference in speed
turbine (11). between the turbine and the impeller. The amount of
force of the oil increases as the difference in the
The force of the oil against the blades of the turbine speed of the two components increases.
turns the turbine. Since the turbine is connected to
ring gear (2), torque is sent to planetary gears (13). The load on the machine changes the speed of the
The torque that is sent to the turbine by the force of turbine. When the load is higher, the difference in
the oil from the impeller cannot be more than the speed between the turbine and the impeller
torque output of the engine to the impeller. increases. The different loads on the machine control
the amount of torque multiplication that can be added
The oil that is flowing from the turbine moves in a by the force of the oil from the stator.
direction that is opposite to the rotation of impeller
(4). Stator (10) changes the direction of the oil. The
stator is connected to carrier (6) and the stator
cannot turn. Therefore, most of the oil is sent back to
impeller (4). The remainder of the oil flows from the
stator, through outlet passage (9), and to the oil
cooler.
322 KENR5631-05
Power Train System

Torque Divider Operation

Illustration 311 g03583206

Torque Converter
(1) Flywheel (7) Yoke (13) Planetary Gears
(2) Ring Gear (8) Output Shaft (14) Sun Gear
(3) Housing (9) Outlet Passage (A) Drive Assembly
(4) Impeller (10) Stator (B) Driven Assembly
(5) Inlet Passage (11) Turbine (C) Stationary Assembly
(6) Carrier (12) Planetary Carrier

The torque converter is driven by the engine through When the machine operates under a load, planetary
housing (3). The planetary gear group is driven by carrier (12) has a resistance to rotation. Since sun
the engine through sun gear (14). These connections gear (14) turns at the speed of the engine, the
allow the torque output of the engine to go in two resistance to rotation turns planetary gears (13). The
separate directions. rotation is opposite to the rotation of ring gear (2).
The opposite rotation of planetary gears (13)
Because of the larger radius of ring gear (2), most of decreases the speed of the ring gear.
the torque is sent by the torque converter through the
ring gear to planetary gears (13). The remainder of Since turbine (11) is connected to the ring gear, a
the torque is sent by sun gear (14) to planetary gears decrease in speed causes the torque converter to
(13). Planetary carrier (12), sun gear (14), planetary multiply the torque of the engine from housing (3).
gears (13), and ring gear (2) turn at the speed of the The torque multiplication is sent to planetary carrier
engine. The planetary carrier (12) has no resistance (12) and to the output shaft through the ring gear.
to rotation.
As the speed of the ring gear decreases, the torque
The torque from the torque converter turbine and of the engine is multiplied through sun gear (14) and
from the planetary gear group is sent through the through the planetary gear group. The torque
planetary carrier to output shaft (8) and to the multiplication is sent to planetary carrier (12) and to
planetary transmission. When the torque converter the output shaft.
and the planetary gear group turn at the same speed,
torque from the engine cannot be multiplied.
KENR5631-05 323
Power Train System

When the machine operates under higher load, the

resistance to rotation of planetary carrier (12)
increases. Then, the speed of the ring gear
decreases. The slower speed allows higher torque
multiplication through the torque converter turbine
and through the sun gear.
If the resistance to rotation of the planetary carrier
becomes high enough, the ring gear stops. During
some very high load conditions, the rotation of the
planetary carrier and the rotation of the output shaft
also stop. The stopped output shaft causes the ring
gear to turn slowly in the opposite direction. The
torque multiplication of the torque converter turbine
and of the sun gear is at the maximum.

Torque Divider Lubrication

Lubrication oil for the torque divider bearings and the
planetary gears comes from the supply that is used
for the operation of the torque converter. The
bearings constantly run in oil. Bearings and gears in
the planetary gear group receive lubrication through
the flange that connects the turbine (11) to ring gear
(2). The pilot bearings receive lubrication through
passages in the output shaft.

Torque Converter Inlet Relief Valve

Illustration 313 g03583646

Lubrication distribution manifold cover removed
(1) Torque converter inlet relief valves

Illustration 312 g03583536

The torque converter inlet relief valve consists of two
poppets installed in the main case behind the
lubrication distribution manifold
324 KENR5631-05
Power Train System

Illustration 314 g03583521

Torque converter inlet relief valve
(1) Torque converter inlet relief valve (5) Passage (FF) Moving parts or activated components
(2) Face of the main case (6) Spring (GG) Tank oil, suction oil, return oil, and
(3) Lubrication distribution manifold (7) Passage to main sump case drain oil
(4) Passage to torque converter inlet (BB) Cutaway section (RR) Pilot, charge, or torque converter oil

There are two torque converter inlet relief valves (1).

Torque converter inlet relief valves (1) are located in
passages on the right font of the main case, behind
the lubrication distribution manifold.
Torque converter inlet relief valves (1) limit the
maximum pressure to the torque converter. Torque
converter inlet relief valves (1) also prevent damage
to the torque converter when the engine is started
and the oil is cold. The setting for torque converter
relief valves (1) is not adjustable.
When the pressure in passage (4) is enough to
overcome the force of spring (6), the oil will flow
through torque converter inlet relief valves (1) to the
main sump through passage (7).
KENR5631-05 325
Power Train System

Torque Converter Outlet Relief

Valve

Illustration 315 g03583976

Torque Converter Outlet Relief Valve
(1) Passage from Torque Converter
(2) Orifice
(3) Holes
(4) Outlet Passage to Power Train Oil Coolers
(5) Spring
(6) Shim
(7) Spool

The torque converter outlet relief valve is mounted to

the right side of the torque converter housing. The
torque converter outlet relief valve maintains a
constant minimum pressure inside the torque
converter. The pressure setting of the outlet relief
valve may be adjusted by removing or adding shims
(6) behind spring (5).
Oil flows into the valve from the torque converter
through inlet passage from torque converter (1). The
pressure of the oil acts against spool (7). When the
pressure of the oil becomes greater than the force of
spring (5), spool (7) shifts to the right. Oil is allowed
to flow through holes (3) in valve spool (7) and into
the outlet passage to the power train oil coolers (4).
326 KENR5631-05
Power Train System

i05654011

Power Train Oil Pump

SMCS Code: 3066

Illustration 316 g03585829

Power Train Oil Pump
(1) Input Shaft (5) Inlet for Section A (C) Torque Converter Charging Section
(2) Outlet for Section C (6) Outlet for Section A (D) Transmission and Torque Converter
(3) Outlet for Section B (A) Transmission Scavenge Section Charging Section
(4) Outlet for Section D (B) Torque Converter Scavenge Section

The power train oil pump is a four-section gear type Section (B) is the torque converter scavenge section.
pump. The pump is driven by input shaft (1). Input Section (B) draws oil from the torque converter
shaft (1) is coupled to the hydraulic steering pump. housing. The oil passes through a screen before the
The hydraulic steering pump is driven by the engine oil leaves the torque converter housing. This oil is
flywheel. sent to the oil reservoir in the main case.
During operation, oil enters each section of the pump Sections (C) and (D) draw oil from the oil reservoir in
through inlet passages in the pump body. The oil fills the main case. The oil passes through a screen
the space between the gear teeth. When the gears before the oil leaves the main case. The screen
turn, oil is sent through outlet passages in the pump catches large debris in the power train oil. The screen
body. prevents debris in the power train oil from damaging
the power train components.
Section (A) is the transmission scavenge section.
Section (A) draws oil from the transmission case. The Section (C) is the torque converter charging section.
oil passes through a screen before the oil leaves the Section (C) sends oil from the main case to the
transmission case. This oil is sent to the oil reservoir torque converter charge filter for the torque converter
in the main case. charging. Output oil from the torque converter
charging filter for torque converter charging passes
through the torque converter inlet relief valve to the
torque converter.
KENR5631-05 327
Power Train System

Section (D) is the transmission charging section. The clutch is now engaged. The discs keep ring gear
Section (D) draws filtered oil from the main case. (C) from rotation. The clutch is released when the
Output oil from Section (D) passes through the pressure in the area behind piston (D) decreases and
transmission charge filter before the oil flows to the the force of spring (E) moves piston (D) to the right.
transmission and to the valve for the steering Discs (A ) and plates (B) now move apart and the
clutches and the brakes. clutch is not engaged.
Table 164
i05656394
Transmission Clutch Engagement

Transmission Engaged Clutches

Speed Direction
SMCS Code: 3006; 3030; 3063; 3064; 3155; 3160;
First Speed FORWARD 2 and 5
3169; 3187; 3190
Second Speed FORWARD 2 and 4
Introduction Third Speed FORWARD 2 and 3
The transmission has five hydraulically activated
NEUTRAL 3
clutches. The clutches give three speeds FORWARD
and three speeds REVERSE. Speed and direction First Speed REVERSE 1 and 5
are electrically controlled.
Second Speed REVERSE 1 and 4

Third Speed REVERSE 1 and 3

Both a speed clutch and a direction clutch must be

engaged in order to send power through the
transmission. Table 164 lists the combination of the
clutches that are engaged for the different
FORWARD and REVERSE speeds.

Illustration 317 g03586884

Clutch Operation (Typical Example)
(A) Discs
(B) Plates
(C) Ring Gear
(D) Piston
(E) Spring
(F) Clutch Housing

The five transmission clutches are the disc type. The

clutches are in separate housings. Each clutch has
discs (A) and plates (B). The inside teeth of discs (A)
are engaged with the outside teeth of ring gear (C).
Notches on the outside diameter of plates (B) are
engaged with pins in clutch housing (F). The pins
keep the plates from rotation.
Springs (E) are between clutch housing (F) and
piston (D), as shown above. Springs (E) keep the
clutches disengaged. The clutches are engaged
when oil is sent into the area behind piston (D). When
the pressure of the oil in the area between piston (D)
and housing (F) increases, piston (D) moves to the
left. Piston (D) moves against the force of spring (E).
Piston (D) pushes the discs and plates together.
328 KENR5631-05
Power Train System

Transmission Components

Illustration 318 g03587032

D10T2 Power Shift Transmission
Transmission Components
(1) Coupling Gear for No. 1 Clutch (10) No. 5 Clutch (First Speed) (19) No. 3 Planetary Gears
(2) No. 1 Clutch (REVERSE) (11) Hub (20) No. 2 Planetary Gears
(3) No. 2 and No. 3 Carrier (12) No. 4 Carrier (21) No. 2 Sun Gear
(4) No. 2 Clutch (FORWARD) (13) No. 4 Sun Gear (22) Ring Gear
(5) Ring Gear for No. 2 Clutch (14) Input Shaft (23) No. 1 Planetary Gears
(6) No. 3 Clutch (Third Speed) (15) Output Shaft (24) No. 1 Sun Gear
(7) Ring Gear for No. 3 Clutch (16) Rotor (25) No. 1 Carrier
(8) No. 4 Clutch (Second Speed) (17) No. 4 Planetary Gears
(9) Ring Gear for No. 4 Clutch (18) No. 3 Sun Gear

The transmission is fastened to the case at the rear The transmission has five hydraulically activated
of the machine. Power from the torque divider is sent clutches. No. 1 clutch (2) and No. 2 clutch (4) at the
to input shaft (14) by a drive shaft. Power flows from rear of the transmission are the direction clutches.
the transmission through output shaft (15). The No. 1 clutch (2) is the REVERSE direction clutch. No.
power then flows to the transfer gears. 2 clutch (4) is the FORWARD direction clutch.
KENR5631-05 329
Power Train System

No. 3 clutch (6), No. 4 clutch (8), and No. 5 clutch

(10) are the speed clutches. No. 3 clutch (6) gives
THIRD speed. No. 4 clutch (8) gives SECOND speed
and No. 5 clutch (10) gives FIRST speed.
The only clutch that rotates is No. 5 clutch (10).
330 KENR5631-05
Power Train System

Power Flow
KENR5631-05 331
Power Train System

First Speed Forward

Illustration 319 g03587222

Power Flow In First Speed Forward
(3) No. 2 and No. 3 Carrier (9) Ring Gear for No. 4 Clutch (15) Output Shaft
(4) No. 2 Clutch (FORWARD) (10) No. 5 clutch (FIRST SPEED) (17) No. 4 Planetary Gears
(5) Ring Gear for No. 2 Clutch (11) Hub (18) No. 3 Sun Gear
(6) No. 3 Clutch (THIRD SPEED) (12) No. 4 Carrier (19) No. 3 Planetary Gears
(7) Ring Gear for No. 3 Clutch (13) No. 4 Sun Gear (20) No. 2 Planetary Gears
(8) No. 4 Clutch (SECOND SPEED) (14) Input Shaft (21) No. 2 Sun Gear

When the transmission is in FIRST SPEED The movement of the planetary gears causes No. 2
FORWARD, No. 5 clutch (10) and No. 2 clutch (4) are and No. 3 carrier (3) to turn in the same direction as
engaged. input shaft (14).
No. 2 clutch (4) holds ring gear (5) stationary. No. 5 As No. 2 and No. 3 carrier (3) turns, No. 3 planetary
clutch (10) locks hub (11) to No. 4 carrier (12) and gears (19) turn. No. 3 planetary gears (19) turn ring
ring gear (7). gear (7) and No. 3 sun gear (18). No. 3 sun gear (18)
turns output shaft (15).
Input shaft (14) turns No. 2 sun gear (21). No. 2 sun
gear turns No. two planetary gears (20). Ring gear (7) turns No. 4 carrier (12). No. 4 carrier
(12) is connected to hub (11). The power is directed
Since ring gear (5) is held stationary by No. 2 clutch from No. 4 carrier (12) to No. 5 clutch (10), and then
(4), No 2 planetary gears (20) move around the through hub (11) to output shaft (15).
inside of the ring gear.
332 KENR5631-05
Power Train System

As a result, the torque to output shaft (15) is divided The movement of No. three planetary gears (19)
through No. 3 sun gear (18), hub (11), and No. 4 sun causes No. 3 sun gear (18) to turn. No. 3 sun gear
gear (13). From output shaft (15), power goes to the (18) turns output shaft (15). From output shaft (15),
transfer and bevel gears. power goes to the transfer and bevel gears.

Second Speed Forward

When the transmission is in SECOND SPEED
FORWARD, No. 4 clutch (8) and No. 2 clutch (4) are
engaged. No. 2 clutch (4) holds ring gear (5)
stationary.
No. 4 clutch (8) holds ring gear (9) stationary. Input
shaft (14) turns No. 2 sun gear (21). No. 2 sun gear
(21) turns No. two planetary gears (20).
Since ring gear (5) is held stationary by No. 2 clutch
(4), No. 2 planetary gears (20) move around the
inside of the ring gear. The movement of No. 2
planetary gears (20) causes No. 2 and No. 3 carrier
(3) to turn in the same direction as input shaft (14).
As No. 2 and No. 3 carrier (3) turns, No. 3 planetary
gears (19) turn. No. 3 planetary gears (19) turn ring
gear (7) for No. 3 clutch (6) and No. 3 sun gear (18).
No. 3 sun gear (18) turns output shaft (15). Ring gear
(7) turns No. 4 carrier (12).
Since ring gear (9) is held stationary by No. 4 clutch
(8), No. 4 planetary gears (17) move around the
inside of the ring gear.
The movement of No. 4 planetary gears (17) causes
No. 4 sun gear (13) to turn. No. 4 sun gear (13) turns
output shaft (15).
As a result, torque to output shaft (15) is divided
through No. 3 sun gear (18) and No. 4 sun gear (13).
From output shaft (15), power goes to the transfer
and bevel gears.

Third Speed Forward

When the transmission is in THIRD SPEED
FORWARD, No. 3 clutch (6) and No. 2 clutch (4) are
engaged. No. 2 clutch (4) holds ring gear (5)
stationary.
No. 3 clutch (6) holds ring gear (7) stationary. Input
shaft (14) turns No. 2 sun gear (21). No. two sun gear
(21) turns No. two planetary gears (20).
Since ring gear (5) is held stationary by No. 2 clutch
(4), No. 2 planetary gears (20) move around the
inside of the ring gear. The movement of No. 2
planetary gears (20) causes No. 2 and No. 3 carrier
(3) to turn in the same direction as input shaft (14).
Since ring gear (7) is held stationary by No. 3 clutch
(6), No. 3 planetary gears (19) move around the
inside of the ring gear.
KENR5631-05 333
Power Train System

First Speed Reverse

Illustration 320 g03587406

Power Flow In First Speed Reverse
(1) Coupling Gear for No. One Clutch (10) No. 5 Clutch (FIRST SPEED) (18) No. 3 Sun Gear
(2) No. 1 Clutch (REVERSE) (11) Hub (19) No. 3 Planetary Gears
(3) No. 2 and No. 3 Carrier (12) No. 4 Carrier (22) Ring Gear
(6) No. 3 Clutch (THIRD SPEED) (13) No. 4 Sun Gear (23) No. 1 Planetary Gears
(7) Ring Gear for No. 3 Clutch (14) Input Shaft (24) No. 1 Sun Gear
(8) No. 4 Clutch (SECOND SPEED) (15) Output Shaft (25) No. 1 Carrier
(9) Ring Gear for No. 4 Clutch (17) No. 4 Planetary Gears

When the transmission is in FIRST SPEED The rotation of No. 1 planetary gears (23) on the
REVERSE, No. 5 clutch (10) and No. 1 clutch (2) are shafts causes ring gear (22) to turn in the opposite
engaged. No. 1 clutch (2) holds coupling gear (1) direction as input shaft (14). Ring gear (22) is a direct
stationary. mechanical connection with No. 2 and No. 3 carrier
(3).
No. 5 clutch (10) locks hub (11) to No. 4 carrier (12)
and No. 3 ring gear (7). As No. 2 and No. 3 carrier (3) turns, No. 3 planetary
gears (19) turn. No. 3 planetary gears (19) turn ring
Input shaft (14) turns No. 1 sun gear (24). No. 1 sun gear (7) for No. 3 clutch (6) and No. 3 sun gear (18).
gear (24) turns No. 1 planetary gears (23). No. 1 No. 3 sun gear (18) turns output shaft (15).
carrier (25) is a direct mechanical connection with
coupling gear (1). Ring gear (7) turns No. 4 carrier (12). No. 4 carrier
(12) is connected to hub (11).
Since coupling gear (1) is held stationary by No. 1
clutch (2), No. 1 carrier (25) is held stationary.
334 KENR5631-05
Power Train System

The power is directed from No. 4 carrier (12) to No. 5 Since coupling gear (1) is held stationary by No. 1
clutch (10), and then through hub (11) to output shaft clutch (2), No. 1 carrier (25) is held. The rotation of
(15). No. 1 planetary gears (23) on the shafts causes ring
gear (22) to turn in the opposite direction as input
As a result, torque to output shaft (15) is divided shaft (14).
through No. 3 sun gear (18), hub (11), and No. 4 sun
gear (13). Ring gear (22) is a direct mechanical connection with
No. two and No. 3 carrier (3).
From output shaft (15), the power goes to the transfer
and bevel gears. Since ring gear (7) is held stationary by No. 3 clutch
(6), No. 3 planetary gears (19) move around the
Second Speed Reverse inside of the ring gear.
The movement of No. 3 planetary gears (19) causes
When the transmission is in SECOND SPEED No. 3 sun gear (18) to turn. No. 3 sun gear (18) turns
REVERSE, No. 4 clutch (8) and No. 1 clutch (2) are
output shaft (15).
engaged. No. 1 clutch (2) holds coupling gear (1)
stationary. No. 4 clutch (8) holds ring gear (9) From output shaft (15), power goes through the
stationary. Input shaft (14) turns No. 1 sun gear (24). transfer and bevel gears.
No. 1 sun gear (24) turns No. 1 planetary gears (23).
No. 1 carrier (25) is a direct mechanical connection
with coupling gear (1).
Neutral Default Strategy
Neutral default strategy is a feature that is
Since coupling gear (1) is held stationary by No. 1 programmed into the machine transmission control
clutch (2), No. 1 carrier (25) is held stationary. The module. Neutral default strategy will prevent
rotation of No. 1 planetary gears (23) on the shafts movement of the machine or damage to the
causes ring gear (22) to turn in the opposite direction transmission when the transmission is in neutral and
as input shaft (14). the transmission ECM expects that one or more
components in the transmission control are failed.
Ring gear (22) is a direct mechanical connection with The transmission ECM checks for unnecessary load
No. 2 and No. 3 carrier (3). As No. 2 and No. 3 carrier on the drive train by constantly comparing the data
(3) turns, No. 3 planetary gears (19) turn. from the torque converter output speed sensor to the
data from the engine speed sensor.
No. 3 planetary gears (19) turn ring gear (7) and No.
3 sun gear (18). No. 3 sun gear (18) turns output The neutral default strategy in the transmission ECM
shaft (15). Ring gear (7) turns No. 4 carrier (12). will disengage the No. 3 clutch if the transmission
ECM detects a machine component that has failed. If
Since ring gear (9) is held stationary by No. 4 clutch the power train oil is below 40 °C (104 °F) and the
(8), No. 4 planetary gears (17) move around the neutral default strategy is also active, the service
inside of the ring gear. The movement of No. 4 brake will automatically be applied.
planetary gears (17) causes No. 4 sun gear (13) to
turn. No. 4 sun gear (13) turns output shaft (15). Note: Neutral default strategy is only active when the
machine is in the NEUTRAL position. Neutral default
As a result, torque to output shaft (15) is divided
strategy is disengaged when a speed clutch is
through No. 3 sun gear (18) and No. 4 sun gear (13).
From the output shaft, power goes through the commanded by the operator.
transfer and bevel gear and through the service The neutral default strategy requires a stabilized
brakes to the final drives. speed of the torque converter and a temperature of
the power train oil in order to function properly.
Third Speed Reverse During start-up of the machine, the service brakes
will automatically be applied for 10 seconds in order
When the transmission is in THIRD SPEED for the power train to stabilize. During this 10 second
REVERSE, No. 3 clutch (6) and No. 1 clutch (2) are period, if the machine is shifted into gear the
engaged. transmission ECM will release the service brakes. If
the parking brake is released within the first 10
No. 1 clutch (2) holds coupling gear (1) stationary. seconds, and the tractor is not shifted into gear, the
No. 3 clutch (6) holds ring gear (7) stationary. service brakes will remain applied until the parking
brake switch is cycled after the 10 second period.
Input shaft (14) turns No. 1 sun gear (24). No. 1 sun
gear (24) turns No. 1 planetary gears (23). No. 1 The neutral default strategy will become active on
carrier (25) is a direct mechanical connection with machines that are equipped with attachments that
coupling gear (1). are driven by the PTO in neutral. If the machine is in
the NEUTRAL position and brake engagement is
undesirable, warm the power train oil above 40 °C
(104 °F).
KENR5631-05 335
Power Train System

i05660956

Transmission Hydraulic Control

SMCS Code: 3073; 3167

Illustration 321 g03589781

Transmission Hydraulic Control
(1) Modulating Valve for No. 3 Clutch (3) Modulating Valve for No. 4 Clutch (5) Modulating Valve for No. 1 Clutch
(2) Modulating Valve for No. 5 Clutch (4) Modulating Valve for No. 2 Clutch (6) Main Relief Valve

The transmission hydraulic control contains the main The five modulating valves control the flow of this oil
relief valve and the five modulating valves for the to the transmission clutches. Main relief valve (6)
transmission clutches. The transmission hydraulic controls the supply pressure to the modulating
control is mounted on the top of the transmission. valves.
Oil from the transmission charging section of the
power train oil pump passes through the transmission
charge filter to the transmission hydraulic control.
336 KENR5631-05
Power Train System

Transmission Modulating Valves As clutch pressure increases, the pressure plus the
force of the spring moves the spool back to the left.
When maximum clutch pressure is reached, a
balance is maintained between clutch pressure and
solenoid (4). The spool is in a metering position.
De-energizing solenoid (4) returns the modulating
valve to the left. Pressure on the left end of the spool
drains through passage (2). This allows the spool to
shift to the left. Clutch pressure is now directed to the
drain and the clutch is disengaged.

Illustration 322 g03382791

Transmission Modulating Valve
(1) Pump Supply Oil
(2) Drain
(3) Passage To Clutch

Each clutch is controlled by a transmission

modulating valve. Solenoid (4) is energized in order
to engage the corresponding clutch.
The modulating valve allows the respective clutch to
fill with oil to a pressure that is determined by the
amount of current going to the solenoid. The power
train ECM determines the amount of current that is
supplied to the solenoid.
All of the clutches except for the No. 5 clutch are
energized by the same current and the same
pressure. The No. 5 clutch solenoid receives less
current and the No. 5 clutch receives less pressure.
This strategy for the transmission modulating valves
is different from previous strategies.
The amount of current that is supplied to the solenoid
is determined by the response of the machine, which
includes the following indicators:

• Speed sensors
• Gear selection

• Oil temperature
As, a current is applied to solenoid (4) the modulating
valve becomes engaged. As the pressure at the left
end of the spool increases, the spool shifts to the
right. Pump oil is now directed to the clutch through
passage (3). When the clutch fills, pressure begins to
increase and the clutch engages.
KENR5631-05 337
Power Train System

Electronic Main Relief Valve

Illustration 323 g03382849

Main Relief Valve
(1) Pump Supply Oil (3) To Torque Converter Inlet
(2) To Transmission Hydraulic Control (4) To Tank

The electronic main relief valve controls system oil

pressure by bleeding off pump supply oil (1) to torque
converter inlet (3). The current signal from power
train ECM (5) will control what the system pressure
will be.
338 KENR5631-05
Power Train System

i05661934

Transfer and Bevel Gears

SMCS Code: 3011; 3256; 3281

Illustration 324 g03589800

Transfer and Bevel Gears
(1) Pinion Gear (4) Transmission Output Shaft (7) Output Shaft
(2) Yoke Assembly (5) Transfer Gear (8) Bevel Gear
(3) Transmission Input Shaft (6) Transfer Gear (9) Input Shaft

A drive shaft assembly connects the yoke on the Transfer gear (5) turns transfer gear (6). Transfer
torque converter to yoke assembly (2). Yoke gear (6) is connected to output shaft (7) by splines.
assembly (2) is connected to transmission input shaft Therefore, output shaft (7) turns.
(3) by splines.
Output shaft (7) is connected by splines to the inner
When a speed and direction are selected, the power axle shafts. The axle shafts then connect to the
is sent from the planetary transmission to steering clutch and brake groups.
transmission output shaft (4). Pinion gear (1) is
splined to transmission output shaft (4). Therefore, Lubrication oil enters through passages in the
power is transferred from transmission output shaft transfer case in order to lubricate the bevel gear, the
(4) to pinion gear (1). pinion, and the transfer gears. The lubrication oil
sprays all of the components from a tube in the
Pinion gear (1) turns bevel gear (8). Bevel gear (8) is transfer case.
bolted to transfer gear (5). Therefore, transfer gear
(5) also turns.
KENR5631-05 339
Power Train System

i05662653

Accumulator (Power Train)

SMCS Code: 5077-PWT

Illustration 325 g03590490

(14) Power Train Accumulator

Power train accumulator (14) is located under the

rear left-hand fender.
The accumulator stores potential energy by
accumulating a quantity of pressurized power train
oil. The pressurized oil is stored in an accumulator
cylinder. The accumulator is charged to 1724 kPa
(250 psi) with dry nitrogen.
As pressurized power train oil enters power train
accumulator (14), the oil creates pressure within the
accumulator. Energy is stored as the cylinder that is
inside power train accumulator (14) is compressed by
the power train oil. Power train accumulator (14)
supplements power train oil flow in low flow
conditions.
340 KENR5631-05
Power Train System

i05658319

Oil Filter (Power Train)

SMCS Code: 3004; 3067; 5068-PWT

Illustration 326 g03587938

Power Train Filter system for the D10T2
(1) Power Train Main Oil Filter (4) Inlet for the Power Train Main Filter (8) Filter Base for the Kidney Loop Filter
(2) Power Train Kidney Loop Filter (5) Outlet for the Power Train Main Filter
(3) Filter Base for the Power Train Main (6) Inlet for the Kidney Loop Filter
Filter (7) Outlet for the Kidney Loop Filter
KENR5631-05 341
Power Train System

Illustration 327 g03588086 Illustration 328 g03588359

Power Train Main Oil Filter Kidney Loop Filter
(1) Power Train Main Oil Filter (2) Kidney Loop Filter
(3) Filter Base (6) Inlet for the Kidney Loop Filter
(9) Filter Bypass Pressure Switch (7) Outlet for the Kidney Loop Filter
(10) Spring (8) Kidney Loop Filter Base
(11) Bypass Valve (14) Kidney Loop Filter Element
(12) Filter Housing
(13) Filter Element The power train oil system contains a power train
main oil filter and a kidney loop filter. The
transmission section of the power train oil pump
supplies oil to main power train filter (1). The filtered
oil then flows to the transmission control valve.
Oil enters main filter base (3) through inlet (4). The oil
goes through filter base (3) to filter housing (12). Oil
fills the space between the inside of filter housing
(12) and filter element (13). Normally, oil goes
through filter element (13) and the oil leaves the filter
base through outlet (5). Filter element (13) stops any
debris that is in the oil.
If filter element (13) becomes full of debris, the
restriction to the flow of oil causes a pressure
increase. The increase in pressure causes bypass
valve (11) to open against spring (10). Oil flows
directly from inlet passage (4) to outlet passage (5).
Filter bypass pressure switch (9) turns on an
indicator in the cab to alert the operator that the oil
filter is plugged. When the oil does not go through
filter element (13), the oil is dirty and the debris in the
oil can cause damage to components in the power
train oil system.
342 KENR5631-05
Power Train System

A portion of the oil then flows through kidney loop i05663549

filter (2) and the filtered oil returns to the transmission
case. Kidney loop filter base (8) contains a bypass Oil Cooler (Power Train)
valve.
SMCS Code: 1374-PWT; 1375
Correct maintenance procedures must be followed in
order to ensure that the filter element does not
become full of debris which will stop the flow of clean
oil to the power train oil system.

Illustration 329 g03590784

Power train oil cooler (22)

Illustration 330 g03590806

Power Train Oil Cooler
(1) Coolant Inlet
(2) Coolant Outlet
(3) Oil Inlet
(4) Oil Outlet

Power train oil cooler (22) is located under the

radiator at the front of the machine. Power train oil
cooler (22) s an oil to water type cooler.
Power train system oil with a high temperature
comes from the torque converter outlet relief valve.
The oil enters power train oil cooler (14) at oil inlet
(3). The oil flows around the many tubes inside the
cooler.
KENR5631-05 343
Power Train System

Engine coolant enters the cooler through cooler inlet

(1). As the coolant flows through the tubes inside
power train oil cooler (22), the coolant absorbs the
heat from the oil. Coolant leaves power train oil
cooler (22) through coolant outlet (2). The coolant is
then cooled by the cooling system of the engine.
After the power train oil flows around the tubes in
power train oil cooler (14), the oil flows out of oil
outlet (4). The oil has a lower temperature. The oil
then flows to the distribution manifold on the front of
the bevel gear case. The manifold divides the flow
between the transmission and the brakes for
lubrication and cooling.
344 KENR5631-05
Power Train System

i05662576

Final Drive
SMCS Code: 4003; 4011; 4050; 4059; 4084

Illustration 331 g03589911

Final Drive
(1) Outer Axle Shaft (5) Inner Sun Gear (9) Inner Carrier
(2) Sprocket Segments (6) Outer Sun Gear (10) Hub
(3) Inner Planetary Gears (7) Outer Carrier (11) Duo-Cone Seals
(4) Outer Planetary Gears (8) Ring Gear

The final drives take power from the steering clutches The power from the steering clutches is sent to the
and the final drives send the power to the tracks. The final drive by outer axle shaft (1). Inner sun gear (5) is
final drives give a double reduction by using fastened by splines to outer axle shaft (1). The
planetary gears. rotation of outer axle shaft (1) and of inner sun gear
(5) causes inner planetary gears (3) to turn. Ring
gear (8) is a stationary component. As the planetary
gears turn, the gears move around the inside of ring
gear (8). The movement of the planetary gears
around ring gear (8) causes inner carrier (9) to turn.
Inner carrier (9) is connected to outer sun gear (6) by
splines. The rotation of inner carrier (9) and outer sun
gear (6) cause outer planetary gears (4) to turn.
KENR5631-05 345
Power Train System

Outer planetary gears (4) move around the inside of

ring gear (8). This movement causes outer carrier (7)
and hub (10) to turn. This sends the power to
sprocket segments (2) and the track.
All components get splash lubrication oil as the gears
move and oil is thrown inside the final drives.
346 KENR5631-05
Power Train System

i05238298

Pin Puller Hydraulic System

SMCS Code: 6313
KENR5631-05 347
Power Train System

Illustration 332 g03341847

Illustration 333 g03342148

Pin Puller Hydraulic System
(1) Pin Puller Cylinder (2) Head End Pressure (3) Solenoid Valve
348 KENR5631-05
Power Train System

(4) Manifold (6) Return to Tank

(5) Oil from Transmission Case (7) Rod End Pressure

This circuit utilizes the power train oil circuit to drive a

cylinder that is used to pull the ripper shank pins. A
small two position valve is used to switch the position
of the cylinder
The pin puller hydraulic system consists of two main
components: solenoid valve (3) and pin puller
cylinder (1). Solenoid valve (3) is controlled by a
toggle switch that is located in the operator
compartment.
Supply oil for the pin puller hydraulic system is
supplied from the back of the transmission housing.
Supply oil enters manifold (4) through line (5).
When the pin puller switch is in the HOLD position,
the oil is blocked by solenoid valve (3). The oil in both
ends of cylinder (1) is also blocked.
When the pin puller switch is moved to the
DISENGAGE position, a signal is sent to solenoid
valve (3). Solenoid valve (3) shifts and oil pressure
from line (5) is sent to line (2). This oil travels to the
head end of cylinder (1) and the cylinder rod extends.
As the cylinder rod extends, the ripper shank pin is
removed from the ripper shank. Return oil from the
rod end of the cylinder returns to manifold (4) through
line (7). Solenoid valve (3) directs the return oil
through line (6) to the tank.
When the pin puller switch is moved to the ENGAGE
position, a signal is sent to solenoid valve (3).
Solenoid valve (3) shifts and oil pressure from line (5)
is sent to line (7). This oil travels to the rod end of
cylinder (1) and the cylinder rod retracts. As the
cylinder rod retracts, the ripper shank pin is inserted
in the ripper shank. Return oil from the head end of
the cylinder returns to manifold (4) through line (2).
Solenoid valve (3) directs the return oil through line
(6) to the tank.
KENR5631-05 349
Cooling System

Cooling System

i05644133

General Information (Cooling

System)
SMCS Code: 1350

Illustration 334 g03582194

Cooling system for a D10T Track-Type Tractor with a C27 engine
(1) Cab heater (5) Hydraulic oil cooler (9) Power train oil cooler
(2) Turbocharger (6) Hydraulic demand fan (10) Engine oil cooler
(3) Thermostat housing (7) Radiator cores (11) NOx reduction system (NRS)
(4) Shunt tank (8) Jacket water pump
350 KENR5631-05
Cooling System

The engine coolant is used to cool the following Turbocharger

components:

• C27 engine components

• Engine oil

• Power train oil

• NOx reduction system (NRS)

• Turbocharger

i05644586

Location of Components
(Cooling System)
SMCS Code: 1350; 1400

Cab Heater

Illustration 336 g03582302

The turbocharger is located on the right-hand and

left-hand side of the engine.
Reference: Refer to Systems Operation, KENR5631,
“Cooling System (Aftercooler, ATAAC)” for additional
information.

Thermostat Housing

Illustration 335 g03582297

The cab heater is located in the middle and on the left

side of the machine.

Reference: Refer to Systems Operation, KENR5631,

“Engine Cooling System” for additional information.

Illustration 337 g03582305

Thermostat housing is located on the front on the

engine.
Reference: Refer to Systems Operation, KENR5631,
“Engine Cooling System” for additional information.
KENR5631-05 351
Cooling System

Shunt Tank Hydraulic Demand Fan

Illustration 338 g03582322 Illustration 340 g03582468

Shunt tank (4) is located at the front of the machine in The hydraulic demand fan is located at the front of
the engine compartment. the machine in the engine compartment.

Reference: Refer to Systems Operation, KENR5631, Reference: Refer to Systems Operation, KENR5631,
“Engine Cooling System” for additional information. “Engine Cooling System” for additional information.

Hydraulic Oil Cooler Radiator

Illustration 339 g03582327 Illustration 341 g03582470

The hydraulic oil cooler is located behind the radiator. The radiator is located at the front of the machine in
the engine compartment.
Reference: Refer to Systems Operation, KENR5631,
“Hydraulic Oil Cooling System” for additional Reference: Refer to Systems Operation, KENR5631,
information. “Engine Cooling System” for additional information.
352 KENR5631-05
Cooling System

Water Pump Engine Oil Cooler

Illustration 342 g03582474 Illustration 344 g03615441

The water pump is located on the right side on the The engine oil cooler is located on the right-hand side
engine. of the engine.
Reference: Refer to Systems Operation, KENR5631, Reference: Refer to Systems Operation, KENR5631,
“Engine Cooling System” for additional information. “Engine Cooling System” for additional information.

Power Train Oil Cooler NOx Reduction System (NRS)

Illustration 343 g03582500 Illustration 345 g03582502

The power train oil cooler is located in the front of the The two NRS coolers are located on the right-hand
machine under the radiator. and left-hand side of the engine.
Reference: Refer to Systems Operation, KENR5631,
“Power Train Oil Cooling System” for additional
information.
KENR5631-05 353
Cooling System

Reference: Refer to Systems Operation, KENR5631,

“Engine Cooling System” for additional information.

i05635835

Engine Cooling System

SMCS Code: 1350

Components

At operating temperature, the engine coolant is

hot and under pressure. Illustration 347 g03582943
Bottom of radiator
Steam can cause personal injury.
(3) Inlet
Check the coolant level only after the engine has (4) Outlet
been stopped and the fill cap is cool enough to
touch with your bare hand. The engine radiator contains twelve cores (2). These
cores are the “two-pass” type of cores. The coolant
Remove the fill cap slowly to relieve pressure. enters the cores from the bottom. Then, the coolant
exits the bottom of the cores after the coolant has
Cooling system conditioner contains alkali. Avoid circulated through the cores. Coolant is added to the
contact with the skin and eyes to prevent person- system through shunt tank (1). Outlet (4) is
al injury. connected to the inlet side of the water pump. Inlet
(3) is connected to the top side of the temperature
regulator housing.

Illustration 346 g03582939

Illustration 348 g03583068
Engine Radiator
Right side view
(1) Shunt Tank
(2) Cores (5) Thermostat Housing
(6) Water Pump
(7) Flow Switch
354 KENR5631-05
Cooling System

Illustration 349 g03583070

Bottom of the radiator
(8) Drain Valve

Water pump (6) draws coolant from outlet (4). The

water temperature regulator is located in thermostat
housing (5). Coolant can be drained from the engine
and cores (2) through drain valve (8). Flow switch (7)
determines if the engine coolant is circulating.
Note: Outlet (4) has a smaller orifice in order for
coolant to be forced through the hydraulic oil cooler.

Illustration 350 g03583110

Right side view
(9) Sampling Valve

Use sampling valve (9) to collect a sample of the

engine coolant.
KENR5631-05 355
Cooling System

Coolant Flow

Illustration 351 g03579942

Cooling system for a D10T
S/N: JJW
Track-Type Tractor with a C27 engine
(1) Shunt Tank (6) Water Pump (12) Cab Heater
(2) Cores (10) Power Train Oil Cooler (13) NOx reduction system (NRS)
(5) Thermostat Housing (11) Engine Oil Cooler
356 KENR5631-05
Cooling System

Illustration 352 g03581468

Cooling system for a D10T
S/N: RAB
Track-Type Tractor with a C27 engine
(1) Shunt Tank (6) Water Pump (12) Cab Heater
(2) Cores (10) Power Train Oil Cooler
(5) Thermostat Housing (11) Engine Oil Cooler

The hydraulic demand fan is mounted to the radiator Engine coolant will be pumped through engine oil
guard. The hydraulic demand fan is mounted in front cooler (11) and out to power train oil coolers (10) and
of the radiator. The fan drive pump is controlled by NRS (13). This coolant will flow out of engine oil
the engine ECM. This arrangement allows the fan to cooler (11) and power train oil coolers (10) to the
draw air through the sides of the engine engine block through NRS (13). This coolant flows
compartment. Air is drawn through the radiator and through the engine block to the cylinder head. From
out of the front of the machine. This design eliminates the cylinder head, coolant flows to thermostat
the possibility that the fan will inject debris into the housing (5). This cycle will repeat until the engine
radiator. coolant warms enough to open the temperature
regulator.
When the engine is cold, the temperature regulator
will be closed. The temperature regulator is inside the
thermostat housing (5). As a result, engine coolant
will not circulate through the engine radiator. Water
pump (6) will draw engine coolant from the outlet side
of cab heater (12). The water pump will draw engine
coolant from thermostat housing (5). This engine
coolant comes from the cylinder head.
KENR5631-05 357
Cooling System

When the temperature regulator opens, coolant can (6).

then flow to cores (2). Coolant flows to water pump
i05640308

Engine Oil Cooling System

SMCS Code: 1378

Components and Engine Oil Flow

Illustration 353 g03585827

(1) Engine Oil Cooler (2) Engine Oil Filters (3) Bypass Tube

Unfiltered oil leaves the engine block and flows

through engine oil filters (2).
When the engine oil is cold, the viscosity of the oil is
enough to cause the oil to bypass the cooler cores
through cooler bypass tube (3). As a result, the
engine oil will bypass engine oil cooler (1) until the oil
warms and the oil becomes thinner.
When the oil is warm, most of the engine oil will flow
through engine oil cooler (1).
358 KENR5631-05
Cooling System

Coolant Flow Coolant Flow

Reference: See Systems Operation, “Engine Reference: See Systems Operation, “Engine
Cooling System” in this module for information about Cooling System” in this module for information about
engine coolant flow. engine coolant flow.

i05640313 i05640317

Power Train Oil Cooling Cooling System (Aftercooler,

System ATAAC)
SMCS Code: 1375 SMCS Code: 1063

Components Components

Illustration 354 g03585831 Illustration 355 g03585945

(1) Power Train Oil Coolers (1) Air-to-Air Aftercoolers (ATAAC)
(2) Inlets (2) Inlet
(3) Outlets (3) Outlet

Power train oil coolers (1) are located on the right The engine air cooling system consists of the
side of the engine. Power train oil flows from the following main components:
torque converter outlet relief valve through inlet (2) to
oil coolers (1). Engine coolant is pumped through oil • Air-to-Air Aftercoolers (ATAAC) (1)
coolers (1) in order to cool the power train oil. Outlet
(3) is connected to the lubrication distribution valve. • Inlet (2)
From the lubrication distribution valve, the oil
lubricates the power train. • Outlet (3)

Reference: Refer to Service Manual, RENR7547,

“Power Train Oil Cooler” for the flow of the power
train oil through the power train oil coolers.
KENR5631-05 359
Cooling System

Air Flow

Illustration 356 g03585996

(1) Air-to-Air Aftercooler (ATAAC) (6) Tube (9) Muffler

(4) Turbocharger (7) Tube
(5) Hydraulic Demand Fan (8) Precleaner

Turbochargers (4) draw engine intake air through

precleaner (8) and into the air inlet. The engine intake
air is compressed by turbochargers (4). Compressing
the engine intake air causes the engine intake air to
become hot. The compressed engine intake air flows
through ATAAC (1). Demand fan (5) pulls cooling air
through ATAAC (1) in order to cool the compressed
engine intake air. The cooler compressed engine
intake air helps to provide increased power output,
reduced emission levels, and lower fuel
consumption.
360 KENR5631-05
Cooling System

The cool engine intake air is forced through outlet (3) Oil Flow
and through tube (7) into the engine.

i05640335

Hydraulic Oil Cooling System

SMCS Code: 1374

Components

Illustration 357 g03586078

Bottom of radiator
(1) Hydraulic Oil Cooler
(2) Outlet
Illustration 358 g03586197
(3) Inlet
(4) Bypass Valve Maximum fan speed
(1) Hydraulic Oil Cooler
Hydraulic oil cooler (1) is an oil-to-water cooler. (4) Bypass Valve
(5) Line to hydraulic tank
(6) Fan Drive Motor
(7) Fan Drive Pump
(GG) Tank Oil
(KK) High Pressure

Return oil from fan drive motor (6) enters the

hydraulic oil cooler (1) through inlet (3). Bypass valve
(4) prevents the hydraulic oil from building up too
much pressure in hydraulic oil cooler (1). When the
oil pressure in hydraulic oil cooler (1) becomes too
high, bypass valve (4) will open. This action allows
some oil to pass through the valve and return through
line to hydraulic tank (5) through outlet (2).
The opening pressure for bypass valve (4) is 345 kPa
(50 psi).
KENR5631-05 361
Undercarriage

Undercarriage

i05664434

General Information
(Undercarriage)
SMCS Code: 4150

Illustration 359 g03591516

D10T2 Undercarriage
(1) Rear idler (4) Track (7) Minor bogie
(2) Rear track roller frame (5) Front idler (8) Track roller
(3) Front track roller frame (6) Major bogie
362 KENR5631-05
Undercarriage

The final drives and bevel gears are located on a Eight rubber pads are used in pairs on each roller
common center line. The steering and brake groups frame. A rubber pad is installed on top of each major
are located on the common center line also. Removal bogie. The four rubber pads are installed on the
and installation of the power train modules has been bottom of the roller frame. The rubber pads are
simplified. The final drives are raised above the installed in alignment with the rubber pads on the
abrasive wear and packing conditions of the major bogies. The rubber pads control the amount of
operating environment, which is another advantage. movement of the major bogies. Because the rubber
Also, there is a reduction of shock loads through pads are flexible, mud and debris will be removed
many of the power train components. When the from the rubber pads during operation. This resilient
implements are suddenly engaged, and ground undercarriage arrangement will keep more track on
impact of the tractor are forms of shock loads. In this the ground at all times. This arrangement will
elevated location, the final drives do not support any decrease wear. The arrangement also increases
of the weight of the machine. This action permits the
undercarriage and suspension to be made resilient.
Four major bogies turn on sealed, lubricated
cartridge pins. The front major bogie supports an
idler and a minor bogie. The rear major bogie
supports an idler and a minor bogie. Each of the two
major bogies in the middle of the roller frame
supports a minor bogie. Each minor bogie supports
two track rollers. The minor bogies also pivot on
sealed, lubricated cartridge pins. The idlers turn on
sealed, lubricated shafts.
KENR5631-05 363
Undercarriage

operator comfort. Sealed, lubricated tracks are The track roller frames can be separated into two
standard equipment. sections. The front section has a tube assembly. The
tube assembly telescopes into the rear track roller
i05665454 frame.

Reference: Refer to Systems Operation, KENR5631,

Location of Components “Track Roller Frame” for more information on the
(Undercarriage) track roller frames.

SMCS Code: 4150 Track Roller

Track Roller Frame

Illustration 362 g03593396

The track rollers are fastened to the minor bogies.

Illustration 360 g03592107
Each track roller frame has eight track rollers. Four of
the rollers are single flange rollers. Four of the rollers
are double flange rollers.

Note: Some machines are equipped with only single

flange rollers.
Rollers are arranged in the following sequence. Start
at the front of the machine.
No. 1 Roller – Single flange
No. 2 Roller – Single flange
No. 3 Roller – Double flange
No. 4 Roller – Double flange
No. 5 Roller – Double flange
No. 6 Roller – Double flange
No. 7 Roller – Single flange
No. 8 Roller – Single flange

Illustration 361 g03592139

Recoil spring assembly Reference: Refer to Systems Operation, KENR5631,
“Track Roller” for more information on the single
flange track rollers.
364 KENR5631-05
Undercarriage

Track Idler Reference: Refer to Systems Operation, KENR8943,

“Tracks” for more information on the tracks.

Equalizer Bar

Illustration 363 g03593622

Each track roller frame has a front idler and a rear

idler. Illustration 365 g03594099

Reference: Refer to Systems Operation, KENR5631, Front View

“Track Idler” for more information on the single flange
The track roller frames are connected together at the
track rollers.
front of the machine by the equalizer bar.
Tracks Reference: Refer to Systems Operation, KENR5631,
“Equalizer Bar” for more information on the equalizer
bar.

Illustration 364 g03593777

The machine has sealed, lubricated track. Each track

assembly has the following components: links, pins,
bushings, thrust rings, polyurethane seal assemblies,
rubber stoppers and polyurethane plugs.
KENR5631-05 365
Undercarriage

Pivot Shaft Minor Bogies

Illustration 366 g03594156 Illustration 368 g03594737

The track roller frames are connected together at the There are 16 minor bogies (8 per side of the tractor)
rear of the machine by the pivot shaft. the pivot shaft that pivot on sealed, lubricated cartridge pins. Each
is also connected to the main frame of the machine. of the minor bogies support two track rollers.

Reference: Refer to Systems Operation, KENR5631, Sprocket Segments

“Pivot Shaft” for more information on the pivot shaft.

Major Bogies

Illustration 369 g03598156

Illustration 367 g03594256

There are five sprocket segments attached to each
There are four major bogies that turn on sealed. final drive.
lubricated cartridge pins. The front and rear major
bogies support an idler and a minor bogie. The two
middle major bogies support minor bogies.
366 KENR5631-05
Undercarriage

i05673874

Track Roller Frame

SMCS Code: 4151

Illustration 370 g03598678

Track Roller Frame
(1) Rear track roller frame (3) Pivot Shaft (5) Recoil oscillation guide
(2) Front track roller frame (4) Track adjustment cover

Illustration 371 g03598736

Recoil Spring Assembly
(6) Tube assembly (9) Grease valve (12) Spring
(7) Cylinder assembly (10) Relief valve
(8) Piston (11) Retainer

The track roller frame can be separated into two Recoil oscillation guide (5) prevents any rotation of
sections. Front track roller frame (2) has a large tube tube assembly (6) inside rear track roller frame (1).
assembly that telescopes or slides into rear track Rear oscillation guide (5) allows tube assembly (6) to
roller frame (1). The recoil spring assembly is inside move back and forth in the frame section during
tube assembly (6). recoil.
Two grooves are machined in the outer diameter of
tube assembly (6). Recoil oscillation guide (5) is
installed in rear track roller frame (1). After
installation, recoil oscillation guide (5) is in alignment
with the grooves in tube assembly (6).
KENR5631-05 367
Undercarriage

The track can be adjusted by removing track

adjustment cover (4) and accessing grease valve (9)
and relief valve (10). Grease valve (9) is used for
moving front track roller frame (2) to adjust the track.
When grease is pumped into grease valve (9), piston
(8) moves in a forward direction. This movement
causes front track roller frame (2) to move out of rear
roller frame (1). The track tightens. Tension on the
track is released by loosening relief valve (10) one
turn.
368 KENR5631-05
Undercarriage

i05674916

Equalizer Bar
SMCS Code: 7206

Illustration 372 g03599477

(1) Equalizer bar (3) Rubber Pads (5) Pin

(2) Equalizer Bar Saddle (4) Track Roller Frames

Tack roller frames (4) are connected together at the

front by equalizer bar (1). Spherical bearings connect
equalizer bar (1) to track roller frames (4).
Equalizer bar (1) pivots in the center around pin (5).
Rubber pads (3) on the top of equalizer bar (1)
cushion the oscillation of equalizer bar (1).
KENR5631-05 369
Undercarriage

i05676896

Pivot Shaft
SMCS Code: 4153

Illustration 373 g03601196

Connection of Pivot shaft (1) to track roller frame (4)
(1) Pivot shaft (3) Bushing
(2) Bushing (4) Track roller frame
370 KENR5631-05
Undercarriage

i05678009

Track Idler
SMCS Code: 4159

Illustration 375 g03604897

Illustration 374 g03601560
Track Idler
Connection of Pivot shaft (1) to track roller frame (4)
(1) Thrust washer
(1) Pivot shaft (2) Retainer assembly
(2) Bushing (3) Shaft
(3) Bushing (4) Rubber stopper
(4) Track roller frame (5) Neoprene plug
(6) Duo-Cone Seal
Track roller frames (4) are connected at the rear by
pivot shaft (1). Pivot shaft (1) is also connected to the Each track roller frame has a front idler and a rear
main frame of the machine. idler.
Track roller frames (4) oscillate about pivot shaft (1) The idler has retainer assembly (2) that contain Duo-
on bearings (2) and (3). Cone seal (6) at both ends of shaft (3). Thrust washer
(1) is behind Duo-Cone seal (6) and absorb the side
load on the idler.
The center of shaft (3) is an oil reservoir. This oil is
used for lubrication of the bearing surfaces. The oil is
installed in shaft (3) through a hole in the center of
rubber stopper (4). When the chambers in shaft (3)
are filled with oil, neoprene plug (5) is installed in
rubber stopper (4).
KENR5631-05 371
Undercarriage

i05677851 Note: All 16 rollers are single flange for machines

equipped with the optional Abrasion Package.
Track Roller The track rollers have Duo-Cone seals (2) at both
SMCS Code: 4180 ends of shaft (1). Thrust washers (3) absorb the side
load on the roller. The center of shaft (1) is an oil
reservoir. This oil is used for lubrication of the bearing
surfaces.

Illustration 376 g03603797

Double Flange Track Roller
(1) Shaft
(2) Duo-Cone Seal
(3) Thrust Washer

The track rollers are fastened to the minor bogies.

The track rollers are in contact with the inside
surfaces of the track links. Flanges on the track
rollers prevent movement of the track from side to
side. The inside surfaces of the track links equally
distribute the weight of the machine over the track.
Each track roller frame has eight track rollers. Four of
the rollers are single flange rollers. Four of the rollers
are double flange rollers.
Rollers are arranged in the following sequence. Start
at the front of the machine.
No. 1 Roller – Single flange
No. 2 Roller – Single flange
No. 3 Roller – Double flange
No. 4 Roller – Double flange
No. 5 Roller – Double flange
No. 6 Roller – Double flange
No. 7 Roller – Single flange
No. 8 Roller – Single flange
372 KENR5631-05
Undercarriage

i05677899

Tracks
SMCS Code: 4169; 4170

Illustration 377 g03604137

Track assembly
(1) Link (5) Link (9) Hole
(2) Bushing (6) Link (10) Polyurethane plug
(3) Hole (7) Thrust ring (11) Rubber stopper
(4) Link (8) Pin (12) Seal Assembly
KENR5631-05 373
Undercarriage

Radial hole (3) allows oil flow to the surface, between

pin (8) and bushing (2), and to the lip of the seal
rings.
The oil gives lubrication to pin (8) and bushing (2).
Also, the oil makes the lip of the seal ring wet. The lip
of the seal ring must be kept wet in order to prevent
wear. Oil is kept in the pin by stopper (11) and plug
(10).
The oil is installed in pin (8) through a hole in the
center of stopper (11). When the chambers in pin (8)
are filled, plug (10) is installed in stopper (11).
Two-piece master link (15) and master shoe (13) are
held together with bolts (14).
Each pin (8) and bushing assembly (2) is sealed.
Each pin (8) and bushing assembly (2) has internal
lubrication. The result is no internal wear on the track
joint.

Illustration 378 g03607124

Master link and master shoe
(13) Master shoe
(14) Bolts
(15) Master link

The machine has a sealed lubricated track. Each

track assembly has the following components:links,
pins, bushing assemblies, thrust rings, polyurethane
seal assemblies, rubber stoppers and polyurethane
plugs.
Each of track links (1) and (4) fits over the track links
in front. Link (1) makes a fit over link (8). Link (4)
makes a fit over link (5). The connection of the track
links, make the track assembly.
Each link has a counterbore in the end. The
counterbore makes a fit with the next link.
Seal assemblies (12) are installed in the
counterbores of the links. Each seal assembly has a
load ring and a seal ring.
The load ring pushes the seal ring against the end of
bushing assembly (2) and the link counterbore. The
seal ring gives a positive seal between the bushing
and the link counterbore.
The edge of the seal ring is against the end of
bushing assembly (2). Thrust rings (7) are installed
on pin (8). Thrust rings (7) give a specific amount of
compression to seal assemblies (12) and control the
end play of the track joint.
The arrangement of seal assembly (12) and thrust
ring (7) keeps foreign materials out of the track joint
and oil in the track joint.
Pin (8) has a hole (9) that is almost the full length of
the pin. Hole (3) is drilled radially in the pin near the
center of the pin.
374 KENR5631-05
HVAC System

HVAC System

i05269932

General Information (HVAC

System)
SMCS Code: 7304; 7316; 7320; 7337; 7342
KENR5631-05 375
HVAC System

Illustration 379 g03353420

(1) HVAC operator panel (6) Blower (11) Low-pressure switch

(2) Air conditioning switch (7) Return air temperature sensor (12) High-pressure switch
(3) Louver temperature sensor (8) A/C clutch (13) Accumulator
(4) Heater coil (9) A/C compressor (14) Dryer
(5) Evaporator coil (10) Condenser (15) Water valve actuator
376 KENR5631-05
HVAC System

The standard automatic temperature control HVAC Louver Temperature Sensor

system allows for the temperature of the cab to be
controlled by continuously varying the position of a
water valve and appropriately turning on and off the
operation of the A/C compressor. The temperature
can be controlled by the HVAC automatically or
manually by the operator. The HVAC system is
electronically controlled through the Implement ECM.

i05333962

Location of Components
(HVAC System)
SMCS Code: 1802; 1805; 1807; 1808; 7304; 7309;
7316; 7320; 7322; 7337; 7342; 734D
Illustration 382 g03353479
HVAC Control Panel
The louver temperature sensor is located outside of
the blower system after the heater coil. For more
information refer to System Operation, “Electronic
Control (HVAC System)”.

Heater Coil

Illustration 380 g03353474

The HVAC control panel is located on the ceiling of

the cab. For more information refer to System
Operation, “Electronic Control (HVAC System)”.

Air Conditioning Switch Illustration 383 g03353679

The heater coil is located in the rear of the HVAC

blower unit. For more information refer to System
Operation, “HVAC System”.

Illustration 381 g03353475

The air conditioning switch is located on the HVAC

panel. For more information refer to System
Operation, “Electronic Control (HVAC System)”.
KENR5631-05 377
HVAC System

Evaporator Coil Return Air Temperature Sensor

Illustration 384 g03353680 Illustration 386 g03353688

The evaporator coil is in the rear of the HVAC blower The return air temperature sensor is located behind
unit, in front of the heater coil. For more information the return air filter on the left side of the cab. For
refer to System Operation, “HVAC System”. more information refer to System Operation,
“Electronic Control (HVAC System)”.
Blower Motor
Air Conditioning Compressor
Clutch

Illustration 387 g03353694

The air condition compressor clutch is located on the

air conditioning compressor with the belt system
driving the compressor. For more information refer to
Illustration 385 g03353685
System Operation, “Electronic Control (HVAC
The blower motor is located in the rear of the HVAC System)”.
blower unit. For more information refer to System
Operation, “HVAC System”.
378 KENR5631-05
HVAC System

Air Conditioning Compressor Low-Pressure Switch

Illustration 388 g03353698 Illustration 390 g03353724

The air conditioning compressor is located on the The low-pressure switch is located just above the
front left side of the engine. For more information accumulator, below the cab on the left side of the
refer to System Operation, “HVAC System”. machine. For more information refer to System
Operation, “Electronic Control (HVAC System)”.
Condenser
High-Pressure Switch

Illustration 389 g03353712

Illustration 391 g03353735
The condenser is located on the front of the machine
just behind the front grill. For more information refer The high-pressure switch is located just below the
to System Operation, “HVAC System”. dryer on the left side of the machine. For more
information refer to System Operation, “Electronic
Note: Certain condenser arrangement options locate Control (HVAC System)”.
the condenser to the top or side of the cab ROPS.
KENR5631-05 379
HVAC System

Accumulator Water Valve Actuator

Illustration 392 g03353726 Illustration 394 g03353755

The accumulator is located below the cab, on the left The water valve actuator is located on the left side of
side of the machine. For more information refer to the machine right in front of the heater coil. For more
System Operation, “HVAC System”. information refer to System Operation, “Electronic
Control (HVAC System)”.
Dryer
i05293473

Electronic Control (HVAC

System)
SMCS Code: 1400; 7309; 7610

Electronic Control Modules

Implement ECM

Illustration 393 g03353747

The dryer is located below the cab on the left side of

the machine. For more information refer to System
Operation, “HVAC System”.

Illustration 395 g03307257

(1) Implement ECM
(2) J1 machine harness connector
(3) J2 machine harness connector
380 KENR5631-05
HVAC System

ECM Pull Up Voltage

In order to aid in diagnostics of certain types of
electrical circuits that are controlled by the ECM, an
internal “pull up voltage” is connected to ECM switch
and sensor signal input contacts. An above normal
voltage is internally connected to the ECM signal
input circuit through a resister.
During normal operation, the switch or sensor signal
will hold the circuit low or at a certain signal
amplitude, however, circuit conditions such as a loss
of power to the component, a disconnection, or an
open circuit will allow the circuit to be pulled high by
the ECM pull up voltage. This condition will result in
an above normal voltage condition at the ECM
contact. As a result, the ECM will activate an FMI 03
(voltage above normal) diagnostic code for the
affected circuit.
The types of ECM input circuits that have pull up
voltage present are:
• Pulse Width Modulated (PWM) sensor input
circuits
• Switch to Ground Input switch input circuits

• Active analog (voltage) input signal circuits

• Passive analog (resistance) input signal circuits

ECM Pull Down Voltage

In order to aid in diagnostics of electrical circuits that
are controlled by the ECM, an internal “pull down
voltage” is connected to ECM switch to battery type
input circuits.
During normal operation, the switch contacts that are
allowing the connection to a voltage source will hold
the circuit high. When circuit conditions such as a
loss of power to the switch supply voltage, a
disconnection in the switch circuit or an open circuit
Illustration 396 g01309473 will allow the circuit to be pulled low by the ECM pull
ECM Connectors and Contacts down voltage. This condition will result in a below
normal voltage condition at the ECM contact. As a
The Implement ECM determines actions that are result, the ECM will activate an FMI 04 (voltage
based on input information and memory information. below normal) diagnostic code for the affected circuit.
After the Implement ECM receives the input
information, the ECM sends a corresponding Pin Locations
response to the outputs. The inputs and outputs of Table 165
the Implement ECM are connected to the machine
harness by two 70 contact connectors (J1 and J2). Implement ECM Contact Description J1 Contact De-
The ECM sends the information to the Caterpillar scriptions(1)
Electronic Technician (Cat ET) on the Cat Data Link. No.(2) Type Function
Note: The ECM is not serviceable. The ECM must be 10 CAN C Data Link - CAN C Data Link -
replaced if the ECM is damaged. Replace the ECM if
a failure is diagnosed. 11 Sensor Power +5V Sensor Supply

13 Battery Return Battery -

(continued)
KENR5631-05 381
HVAC System

(Table 165, contd) (Table 166, contd)

Implement ECM Contact Description J1 Contact De- Implement ECM Contact Description J2(1)
scriptions(1)
No.(2) Type Function
No.(2) Type Function
67 CAN Data Link + CAN A Data Link +
Switch to Battery
14 A/C Auto Switch 68 CAN Data Link - CAN A Data Link -
Input
(1) The ECM responds to an active input only when all of the nec-
20 CAN C Data Link + CAN C Data Link + essary conditions are satisfied.
(2) The connector contacts that are not listed are not used.
21 Sensor Power Return 5V Sensor Return

23 Battery Return Battery -

Inputs
Switch to Battery
25
Input
A/C Switch The machine has several different types of input
devices. The ECM receives machine status
Recirculation Filter Temperature information from the input devices and determines
29 Analog Input the correct output action that is needed in order to
Sensor
control machine operations based on memory and
30 Analog Input Louver Temperature Sensor software parameters. The machine utilizes the
Battery Power Input Battery +
following types of inputs: switch type and sensor
31
type.
38 Battery Power Input Battery +
Switches provide signals to the switch inputs of the
39 Battery Power Input Battery + ECM. The possible outputs of a switch are listed: an
open signal, a grounded signal and + battery signal.
Switch to Ground
43 A/C High/Low Switch
Input Sensors provide an electrical signal to the ECM that
Battery Power Input Battery +
constantly changes. The sensor input to the ECM
47
can be one of several different types of electrical
Evaporator Freeze Probe Tem- signals such as: pulse width modulated (PWM)
53 Analog Input
perature Sensor signals, voltage signals and frequency input signals.
Each possible input to the ECM is listed in the tables
56 Sensor Power Return 10V Return for the 70-pin connectors.
57 Battery Return Battery -
Inputs provide information to the ECM in the form of
Sensory Power sensors or switches.
69 10V Sensor Supply
Output

70 Battery Return Battery - Sensors

(1) Contacts that are not listed are not used. Sensors provide information to the ECM about the
(2) The connector contacts that are not listed are not used. intent of the operator or changing conditions. The
sensor signal changes proportionally to the changing
Table 166 of operator input or changing conditions. The
Implement ECM Contact Description J2(1) following types of sensor signals are used by the
ECM.
No.(2) Type Function
Frequency – The sensor produces a signal and the
Sourcing Driver frequency (Hz) varies as the condition changes.
3 A/C Clutch Solenoid
Output
Pulse width modulated – The sensor produces a
4
Sourcing Driver
Load Return 1 signal. The duty cycle of the signal varies as the
Return condition changes. The frequency of this signal is
9 Sinking Driver Output Condenser Motor Relay
constant.

20 Sinking Driver Output Water Valve Actuator

Analog – The ECM measures the voltage that is
22 Return Sensor / Driver Return associated to a specific condition of the control.
Switch to Ground
60 A/C Temperature Dial
Input

64 CAN Data Link + CAN B Data Link +

65 CAN Data Link - CAN B Data Link -

(continued)
382 KENR5631-05
HVAC System

Recirculation Temperature Sensor Louver Temperature Sensor

Illustration 397 g03325780 Illustration 398 g03325780

The recirculation temperature sensor is a passive The cab temperature sensor is a passive sensor
sensor located in the return air passage. The sensor located in the sending air passage. The sensor
creates a different resistance depending on the creates a different resistance depending on the
surrounding temperature. The variations in surrounding temperature. The variations in
resistance cause a proportional variation in voltage. resistance cause a proportional variation in voltage.
This voltage is measured at the ECM contact, and This voltage is measured at the ECM contact, and
allows the ECM to determine the air temperature. allows the ECM to determine the air temperature.
KENR5631-05 383
HVAC System

Evaporator Freeze Probe Operator Temperature Control

Illustration 399 g03350808 Illustration 400 g03326001

The evaporator freeze probe sensor is a passive The operator temperature control sensor monitors
analog sensor located on the evaporator. The sensor the signal from the temperature control knob on the
creates a different resistance depending on the HVAC panel. This knob sets the operators desired
surrounding temperature. The variations in temperature in automatic mode and adjusts the water
resistance cause a proportional variation in voltage. valve in manual mode. In either mode, the ECM
This voltage is measured at the ECM contact, and receives a pulse width modulated signal from the
allows the ECM to determine the evaporator knob and HVAC panel that corresponds to a desired
temperature. temperature or water valve position. The duty cycle is
proportional to the position of the knob.

Switches
Switches provide an open signal, a ground signal, or
a +battery signal to the inputs of the ECM. Switches
are open or closed.

• When a switch is open, no signal is provided to the

corresponding input of the ECM. This “no signal”
condition is also called “floating”.
• When a switch is closed, a ground signal or a
+battery signal is provided to the corresponding
input of the ECM.
384 KENR5631-05
HVAC System

Air Conditioning Mode Switch Air Conditioning Low Pressure Switches

Illustration 401 g03325737

The air conditioning mode switch is a two pole switch.

The switch has two positions that control the
operation of the air conditioning. In the automatic
position the ECM controls the operation of the air
conditioning to maintain a specified cab temperature.
In the manual position, the air conditioning is Illustration 402 g03350773
manually engaged. The ECM has two contacts that (1) High-pressure side low-pressure switch
pertain to this switch, one signals the ECM the switch (2) Low-pressure side low-pressure switch
is automatic mode, the other signals the ECM the (A) To ECM contact
switch is in manual mode. These contacts will float to
a high voltage state unless the switch is closed to The air conditioning low-pressure contact at the ECM
that contact. When the switch closes to a contact, the monitors the voltage state of the high and low
contact is pulled to a low or ground voltage state. pressure cutoff switches for the air conditioning. The
switches are set up in series from a power source.
The switches close and allow power to pass when
the pressure in the high pressure and low pressures
air conditioning loops is high exceeds the actuation
pressure for the switch. If both switches have been
actuated, both switches are closed and the ECM
contact is pulled to a low or ground voltage state. If
either switch has not been actuated, the ECM contact
is pulled to a high voltage state.

Outputs
The ECM responds to decisions by sending electrical
signals to the outputs. The outputs can create an
action or the outputs can provide information to the
operator or the service technician.
KENR5631-05 385
HVAC System

Relays Actuators

Condenser Fan Relays Water Valve Actuator

Illustration 403 g03352416 Illustration 404 g03091818

The condenser fan relays control the operation of the The water valve actuator controls the amount of heat
condenser fans. The relay is activated by the ECM that enters the HVAC system. When the water valve
when the air conditioning system is active. When the actuator is activated, the water valve opens and
relay is activated, the relay allows power to flow to allows heat from the engine into the heater coils. The
the condenser fans. When the ECM has not activated water valve is controlled by a pulse width modulated
the relay, power is not allowed to flow to the signal from the Machine ECM.
condenser fans.
386 KENR5631-05
HVAC System

Solenoids
Illustration 405 g03352237

AC Compressor Solenoid The AC compressor solenoid is an on/off solenoid.

The ECM sends a signal to active the compressor
when the ECM has determined that the AC
compressor should be active. The solenoid controls
the movement of a clutch engaging and disengaging
the AC compressor.

Data Link
Electronic communication between the Implement
ECM, Power Train ECM, Engine ECM, and the other
control modules on the machine is conducted over
data link circuits. The data link circuits allow the
sharing of information with other electronic control
modules. The data link circuits are bidirectional. The
data link circuit allows the ECM to send information
and to receive information.
The electronic communication system consists of
multiple CAN datalink systems.
KENR5631-05 387
HVAC System

The SAE J1939 CAN Data Link circuit is separated Caterpillar Electronic Technician (CAT ET). The other
into different groups. “CAN A” is connected to all of data link systems are high speed data links used for
the ECMs on the machine, and is used primarily for machine control purposes.
information and service purposes, such as the
i05268253

HVAC System
SMCS Code: 1802; 1805; 1807; 1808; 7304; 7309;
7316; 7320; 7322; 7342; 734D

HVAC System

Illustration 406 g03352659

(1) Compressor (8) Engine

(2) Condenser (9) Machine ECM
(3) Expansion orifice (10) HVAC operator controls
(4) Evaporator (11) A/C Switch
(5) Accumulator (12) Condenser fan relays
(6) Water Valve (13) Condenser fan motors
(7) Heater Coil (14) Blower resistor pack
388 KENR5631-05
HVAC System

(15) High-pressure switch (21) Water valve actuator (E) Coolant from engine
(16) Blower fan motor (A) High temperature, high-pressure vapor (F) High temperature coolant
(17) Recirculation temperature sensor (B) High temperature, high-pressure liquid (G) Medium temperature coolant
(18) Louver temperature sensor (C) Low temperature, low pressure liquid (H) Coolant to radiator
(19) Low-pressure switch vapor mixture (J) Air from cab recirculation
(20) Thermostat switch (D) Low temperature, low-pressure vapor (K) Air to cab louvers

The HVAC system has three modes of operation: The refrigerant is sent through the condenser coil (2).
MANUAL, AUTO, and AIR CONDITIONING. The In the condenser coil, heat is transferred from the
operator selects the mode of operation through the A/ refrigerant to the outside air. This changes the
C Switch (11). In MANUAL mode the operator has refrigerant to a high temperature and high-pressure
direct control of the blower fan and heating system, liquid. The heat is transferred by two condenser fan
but the air conditioning system is not engaged. In motors (13). The condenser fan motors (13) are
AUTO mode the operator sets a preferred activated by machine ECM (9) when the machine
temperature and the Machine ECM operates the ECM (9) sends a signal to two condenser fan relays
heating and air conditioning system automatically. (12). The condenser fan motors (13) are activated
The operator still has direct control over the blower whenever the air conditioning system is active.
fan. In AIR CONDITIONING mode the air
conditioning system is engaged but the operator still From the condenser coil (2), the refrigerant moves to
has direct control over the blower fan and heating the expansion valve (3). The expansion valve
system. restricts the flow of refrigerant and causes a pressure
drop in refrigerant. The pressure drop causes the
Note: The HVAC system will not operate if the blower refrigerant to change from a high pressure and a high
fan control is in the OFF. temperature liquid to a low pressure and a low
temperature mixture of liquid and vapor.
A/C System The low pressure and low temperature refrigerant
moves to the evaporator coil (4). While the refrigerant
The air conditioning system is activated either is in the evaporator coil, the refrigerant absorbs heat
through operator request from the A/C switch (11) in from the air flow. This changes the refrigerant to a
air conditioning mode or from the machine ECM (9) low pressure and low temperature vapor.
when in auto mode and the ECM determines that the
air conditioning should be activated. From the evaporator coil (4), the refrigerant moves to
When the air conditioning system is activated, the the accumulator (5). The accumulator acts as a
machine ECM (9) sends a signal to the A/C clutch on recieve/dryer. In the accumulator, moisture is
compressor (1). High-pressure switch (15) and low- removed from the refrigerant by an internal
pressure switch (19) verify that the high and low- desiccant. The accumulator (5) also stores a small
pressure sides of the A/C system are functioning amount of refrigerant to adapt to changing system
correctly. If either of the two switches detect needs.
pressures out of specifications, the machine ECM (9) The refrigerant returns to the compressor (1) as a low
receives a signal and shuts off the signal to the A/C pressure and low temperature vapor. This marks the
clutch on compressor (1). Thermostat switch (20) end of the cycle. The cycle is repeated continuously.
monitors the temperature of the evaporator (4). When
the temperature of evaporator coil drops below a
specific point, machine ECM (9) receives a signal Heating System
and shuts off the signal to the A/C clutch on
compressor (1). Once the temperature of the The heater system operates using coolant from the
evaporator coil raises back above the specific point, engine (E). The hot coolant from the engine
machine ECM (9) receives a signal and re-engages circulates through the heating system. This coolant
the signal to the A/C clutch on compressor (1). The flows from the outlet valve for engine cooling system
process of the air conditioning system turning on and (1), through water valve (2), through heater coil (3),
off is called cycling. and back to the return valve for the engine cooling
system (4). The heating system is controlled either by
When machine ECM (9) has engaged the air the machine ECM (9) when in auto mode, or by the
conditioning system, the air conditioner refrigerant temperature control knob, which is located on the
begins to flow in the air conditioning system at the HVAC operator controls (10).
refrigerant compressor (1). The compressor is driven
by a belt from the engine (8). The compressor is In auto mode the machine ECM (9) monitors
designed to change the air conditioner refrigerant recirculation temperature sensor (17) and louver
from a vapor that has low pressure into a vapor that temperature sensor (18) to determine how much
has high pressure. Also, the compressor changes the engine coolant flow is required. The machine ECM
refrigerant from a vapor with low temperature to a (9) uses that information to send a signal to water
vapor with high temperature. The increase in valve actuator (21) which varies the opening of water
pressure causes the increase in temperature. valve (6).
KENR5631-05 389
HVAC System

In manual or A/C mode, the heater system is

controlled through HVAC operator controls (10). With
the temperature control knob in the maximum cold
position, water valve (6) is closed. The CLOSED
position prevents the flow of coolant into heater coil
(7). When the control knob is moved away from the
maximum cold position toward the maximum heating
position, the heater control valve begins to open. As
the control valve opens, coolant begins to flow from
the outlet valve for engine cooling system (1) through
the heater control valve and into the heater coil. As
the hot coolant flows through the heater coil, the
temperature of the air that is flowing through the coil
increases.
The temperature of the air that is flowing out of
heater coil (7) and into the cab is controlled by the
amount of coolant that circulates through the heater
coil. The coolant transfers the heat into the air
stream. By increasing the amount of coolant that is
circulating through the heater coil, the temperature of
the air that is flowing out of the coil also increases.
The coolant leaves the heater coil at a reduced
temperature and flows back into the return valve for
the engine cooling system (4).

Blower System
The blower system controls how much air flow is
passed through the evaporator (4) and heater coil
(7). The blower system is controlled manually
through HVAC operator controls (10). When the
HVAC operator controls (10), put the blower in the off
position the HVAC system is not engaged. Neither
the air conditioning system or the heating system will
operate. When the HVAC operator controls (10) put
the blower in the LOW, MEDIUM, MEDIUM-HIGH, or
HIGH position, the HVAC system is activated.
Depending on the position of the blower control,
power is sent from HVAC operator controls (10) to
blower resistor pack (14). The resistor pack (14)
contains different resistors designed to adjust the
power sent to blower fan motor (16). The different
power levels correspond to different fan speeds in
the blower system. The blower fan motor (16) pulls in
air from the cab recirculation (J). This air comes from
a return vent to the lower left of the operator seat.
The fan pushes the air through the evaporator (4)
and the heater coil (7). The air is then sent to the
louvers (K).
390 KENR5631-05
Additional Information

Additional Information

i05260610

Access Ladder System

SMCS Code: 7254

Illustration 407 g03348957

(1) Actuator (5) Flow control/check valve (9) Ladder lower test port
(2) Check valve (6) Solenoid valve (10) Counterbalance valve
(3) Ladder raise test port (7) Relief valve (12) Suction hose from hydraulic tank
(4) Motor/pump group (8) Pump/motor unit
KENR5631-05 391
Additional Information

Illustration 408 g03349117

(1) Actuator (11) Toggle switch (13) Hydraulic tank

(4) Motor/pump group (12) Suction hose from hydraulic tank (14) Ladder
392 KENR5631-05
Additional Information

The ladder circuit uses toggle switch (11) to activate

electric motor powered pump (4). Motor/pump (4)
draws hydraulic oil from hydraulic tank (13) through
suction hose (12). Solenoid valve (6) enables
actuator (1 ) to move ladder (14) from a RAISE
position to a LOWER position or the opposite.
Actuator (1) contains counterbalance valve (10) that
prevents ladder (14) from drifting and to stabilize the
movement and speed of ladder (14). Relief valve (7)
provides protection from sudden pressure spikes.
The combination of motor/pump (4) and actuator (1)
will convert machine electrical power into hydraulic
power to cycle ladder (14). Ladder (14) may be
raised and lowered when the engine is not running.

i05249063

Fast Fill Fuel Adapter

SMCS Code: 1273-FAF; 1710
The Shaw Aero fast fuel system is a non-pressurized
fuel system that utilizes a float and a feedback
system. A signal line is used to shut off fuel flow at
the end of a tank fill. The system consists of four
major functional components.

• The vented cap (1)

• The vent for the tank (2) Illustration 409 g01273227

• The float (3) As the tank fills, the fuel level begins to lift float (3).
• The signal line (4) When float (3) rises, the float blocks signal line (4)
and the flow of fuel that is purged. As signal line (4)
• The shutoff valve (5) builds pressure inlet valve (5) is closed, and the flow
of fuel to the tank is blocked. The fuel nozzle
When float (3) is in the DOWN position, fuel enters disengages due to back pressure. When float (3) is in
the tank from the receiver for the nozzle and flows the UP position, shutoff valve (5) is hydraulically
through the open shutoff valve (5). A small amount of locked and fuel cannot be pumped into the tank.
fuel is purged through a flexible stainless steel
braided signal line (4) to float (3). During filling, the
fuel that is purged spills freely into the tank from float
(3), and air is displaced out of the tank through relief
valve (2). Air vent (2) will not open immediately after
the fuel flow begins but only after a certain amount of
air pressure has built up in the fuel tank. Larger tanks
may require significant filling before the vent opens.
KENR5631-05 393
Additional Information

Illustration 410 g01271188

252-5806 Valve As and 252-5805 Vent Assembly
operation
(A) Float (3) in the OPEN position
(B) Surge suppressor “(Yellow)”
(C) Diaphragm
(D) Small orifice
(E) Valve housing
(F) Bottom of fuel tank
(G) Signal Line “Red” indicates the circuit for the signal.
(H) The flow for the signal line is unrestricted until the valve for the
float closes.
(J) Fuel inlet
394 KENR5631-05
Additional Information

Illustration 411 g01271417

252-5805 Vent Assembly (FF) with the vent closed.
252-5805 Vent Assembly (GG) with the vent open.
(AA) orifice for the vent valve (EE) Vent Valve (GG) 252-5805 Vent Assembly with the
(BB) Spring for the vent (FF) 252-5805 Vent Assembly with the vent vent open.
(CC) Vent hole closed. (HH) Path for air that is displaced by
(DD) Diaphragm incoming fuel
KENR5631-05 395
Additional Information

i05717982 Timer Relay

Additional Electrical
Components
SMCS Code: 1400

Key Switch

Illustration 413 g03349994

The timer relay is controlled by the Powertrain ECM.

The relay keeps the lights energized for a variable
length of time after the machine is shut off.

Operator Presence Switch

The operator presence sensor is located in the seat
Illustration 412 g03329390 cushion for the operator seat. The sensor is an
analog voltage sensor that varies with pressure.
The key switch is a three position switch with two
inputs into the chassis ECM. When the key switch is
moved to the ON position, a system voltage input is
provided to the chassis ECM. The presence of this
voltage input will cause the ECM to transition from
the “sleep mode” to the operational mode. When this
mode change occurs, the ECM will initialize and then
become operational.
When the key switch is moved to the OFF, the
system voltage is no longer present at the ECM
contact. The absence of the system voltage signals
the ECM to transition from the operational mode to
the sleep mode. The ECM will perform some inter
power down procedures and then enter the sleep
mode.
The transition period from the sleep mode to the
operational mode happens in a short time. When the
ke switch is moved to the start position, a system
voltage input will be provided to the chassis ECM
start contact. When the ECM detects this voltage and
the machine system start status is correct, the ECM
will initiate the engine cranking sequence.
396 KENR5631-05
Additional Information

Main Power Relay Driver Cylinder High Intensity Flood Light

Relay
The cylinder high intensity flood light relay allows
power to travel to the high intensity flood lights
mounted on the cylinders. The ECM controls the
operation of the relay.

Cylinder Low Intensity Flood Light

Relay
The cylinder low intensity flood light relay allows
power to travel to the low intensity flood lights
mounted on the cylinders. The ECM controls the
operation of the relay.

Forward ROPS Light Relay

The forward ROPS light relay allows power to travel
to the lights mounted on the ROPS. The ECM
controls the operation of the relay.

Rear ROPS Light Relay

The rear ROPS light relay allows power to travel to
the lights mounted on the rear ROPS. The ECM
controls the operation of the relay.

Fender Light Relay

The fender light relay allows power to travel to the
lights mounted on the fender. The ECM controls the
Illustration 414 g03350009
operation of the relay.
The main power relay is controlled by the power train
ECM. When the keyswitch is moved into the ON or Ripper Light Relay
START, the ECM energizes the main power relay. The ripper light relay allows power to travel to the
The relay provides power from the battery to all lights mounted by the ripper. The ECM controls the
switched systems. operation of the relay.
Backup Alarm

Illustration 415 g03350044

The backup alarm is controlled by the power train

ECM. When in the REVERSE position, the backup
alarm sounds.
KENR5631-05 397
Additional Information

Master Light Switch Seatbelt Switch

Illustration 416 g03350076

The master light switch is a single pole switch. The

switch has a normally connected and a normally
open contact. When the switch is not engaged the
normally connected contact is connected to the
return, and the normally open contact floats to a high
voltage state. When the switch is engaged, the Illustration 417 g03350093
normally open contact is connected to the return and
the normally connected contact floats to a high The seatbelt switch is a double pole switch. The
voltage state. The switch is a momentary switch and switch has a normally connected and a normally
based on the voltage state of the two ECM contacts, open contact. When the switch is not engaged the
the ECM toggles the master light switch. The switch normally connected contact is connected to the
controls overall light operation. return, and the normally open contact floats to a high
voltage state. When the switch is engaged, the
normally open contact is connected to the return and
the normally connected contact floats to a high
voltage state. Based on the voltage state of the two
ECM contacts, the ECM determines if the switch is
engaged. The switch alerts the power train ECM of
the state of the seatbelt.

Access Ladder Sensor

Illustration 418 g03350120

The access ladder sensor is a pulse width proximity

sensor. The sensor determines the position of the
access ladder. The sensor sends a signal to the
power train ECM alerting the ECM of the position of
the access ladder.
398 KENR5631-05
Additional Information

Fuel Level Sensor

Illustration 419 g03350145

The fuel level sensor is an active analog sensor. The

sensor determines the amount of fuel in the fuel tank
and reports that information to the ECM with an
analog voltage signal.
KENR5631-05 399
Reference

Reference (KK) Red . . . . . . . . . . . . . . . . . . . . . High pressure oil

(LL) Red Stripes and White Stripes . . . . Signal (First

pressure reduction)

i03960395 (MM) Red Crosshatch . . . . . Signal (Second pressure

reduction)
Graphic Color Codes
(NN) Pink . . . . . . . . Signal (Third pressure reduction)
SMCS Code: 1350; 1359; 1359-HFN; 3000; 3030;
3100; 4000; 4250; 4300; 4300-SE; 4350; 5050 (PP) Red and Pink Stripes . . Secondary source of oil
pressure

(RR) Orange . . . Pilot, charge, or torque converter oil

(SS) Orange Stripes and White Stripes . . . . Reduced

pilot, charge, or torque converter oil

(TT) Orange Crosshatch . . Second reduction in pilot,

charge, or torque converter oil

(UU) Blue . . . . . . . . . . . . . . . . . . . . . . . . . . Trapped oil

Illustration 420 g01861138

(AA) Black . . . . . . . . . Mechanical connection or seal

(BB) Dark Gray . . . . . . . . . . . . . . . . .Cutaway section

(CC) Light Gray . . . . . . . . . . . . . . . Surface of the part

(DD) White . . . . . . . . Atmosphere or air (no pressure)

(EE) Purple . . . . . . . . . . . . . . . . . Pneumatic pressure

(FF) Yellow . . . Moving parts or activated components

(GG) Green . . . . . Tank oil, suction oil, return oil, and

case drain oil

(HH) Brown . . . . . . . . . . . . . . . . . . . . . . Lubricating oil

(JJ) Green Stripes and White Stripes . . Scavenge or

suction oil
400 KENR5631-05
General Information

Testing And Adjusting Locations of the pressure taps and of the

components are given in the Systems Operation
Section portion of this manual. The pressure taps are also
identified in each Testing and Adjusting procedure.

Note: The monitoring system (if equipped) for your

General Information machine accesses many values that are useful in
troubleshooting the power train system. When the
situation is appropriate, use the monitoring system in
order to find a pressure or determine a system
problem.
i06256240

Warnings
Machine Preparation
Refer to the following warnings and notices for all
SMCS Code: 3030; 4250; 4350; 4350-035; 5050; inspections and tests of the power train.
5050-035; 7000

Note: During a diagnosis of the hydraulic system,

remember that correct oil flow, correct temperature, Sudden movement of the machine or release of
and correct pressure are necessary for correct oil under pressure can cause injury to persons
operation. on or near the machine.
To prevent possible injury, perform the procedure
General Information that follows before testing and adjusting the
When you are defining a problem in the power train power train.
system, the following procedure should be followed:
1. Prepare the machine for service.
2. Perform the visual inspection.
Hot hydraulic oil under high pressure can remain
3. If the problem has not been identified, perform the in the components of the hydraulic system or the
operational checks that apply to your machine. power train system after the engine has been
stopped. The uncontrolled release of the hydraul-
4. Perform any applicable calibration procedures that ic oil can cause sudden machine movement and
apply to your machine. can also result in the following conditions:
5. If the problem is not fully understood, perform the • Burns
instrument tests.
• The penetration of body tissue
6. When the problem is defined, go to
Troubleshooting. Troubleshooting information can • Other personal injury
be found in this manual or in a separate
Troubleshooting manual for this machine. The • Death
Troubleshooting lists the probable causes of a If hydraulic oil penetrates body tissue, the injury
known problem. As there may be more than one must be treated immediately by a doctor who is
cause for a problem, the Troubleshooting familiar with this type of injury. Use a board or a
information may suggest specific inspections or piece of cardboard to check for a hydraulic oil
leak. Make sure that all of the attachments have
instrument tests be done. The inspections and the been lowered to the ground and that all trapped
tests help identify the most probable cause of a pressure has been released from the hydraulic
problem. The list cannot give all possible problems system and the power train system. Also, make
and corrections. sure that the hydraulic oil is cool before the re-
moval of any components or lines. Remove the
During a diagnosis of the power train system, hydraulic oil filler cap only when the engine is
remember that correct oil flow and pressure are stopped and the filler cap is cool enough to touch
necessary for correct operation. The potential output with your bare hand.
of the power train oil pump increases with an
increase in engine speed and decreases when
engine speed is decreased. Oil pressure is caused
by resistance to the flow of oil.
KENR5631-05 401
General Information

5. Lower the attachments to the ground on Track-

Type Tractors and Track-Type Loaders. Make sure
Escaping fluid under pressure, even a pinhole that there is no load on the hook of the Pipelayers
size leak, can penetrate body tissue, causing seri- and fully retract the counterweights.
ous injury, and possible death. If fluid is injected
into your skin, it must be treated immediately by 6. Stop the engine.
a doctor familiar with this type of injury.
7. Turn the key to the ON position, but do not start the
Always use a board or cardboard when checking engine.
for a leak.
8. Verify that the implement controls are
UNLOCKED.
9. Move the control levers through the full range of
travel several times. Moving the control levers
Personal injury or death can result from not en- should relieve any pressure that may be present in
gaging the parking brake. the implement hydraulic system.
Transmission engagement alone will not prevent 10. Loosen the filler cap on the hydraulic tank so that
machine from rolling when the engine is stopped.
the pressure in the tank is released. The machine
may be equipped with a breaker valve. The
breaker valve will be located on top of the tank. To
release the pressure of the tank, press the button
Personal injury can result if the machine moves on top of the breaker valve (if equipped).
while testing. 11. Tighten the filler cap on the hydraulic tank.
If the machine begins to move during test, reduce 12. Make sure that the pressure in the entire
the engine speed immediately and engage the hydraulic system has been released.
parking brake.
Reference: Refer to Troubleshooting for additional
guidance for preparing the machine for testing.
NOTICE
Care must be taken to ensure that fluids are con- Hydraulic Visual Inspection
tained during performance of inspection, mainte-
nance, testing, adjusting, and repair of the product. 1. Check all hydraulic oil line connections for damage
Be prepared to collect the fluid with suitable contain- and for leaks.
ers before opening any compartment or disassem-
bling any component containing fluids. 2. Follow all hydraulic oil lines from the attachment to
the valve. Check the lines and connections for
Refer to Special Publication, NENG2500, “Dealer
Service Tool Catalog” for tools and supplies suitable damage and for leaks.
to collect and contain fluids on Cat products. 3. Check the control valves for leaks.
Dispose of all fluids according to local regulations 4. Check the connections on the pumps and motors
and mandates. (if equipped) for damage and for leaks.
5. Follow the pump lines and the motor lines (if
Procedure equipped) to the tank and to the valves. Check for
Before you troubleshoot, complete the following damage and for leaks on the hydraulic lines and
procedure. on the hydraulic tank .
1. Move the machine to a smooth, horizontal location 6. Check the oil level in the tank.
that is away from operating machines and away
7. Remove the filter element. Check for particles in
from personnel.
the filter elements. A magnet separates ferrous
2. Permit only one operator on the machine. Keep all particles from nonferrous particles.
other personnel away from the machine or in the If you find metal or rubber particles, all components
operator sight. of the hydraulic oil system must be cleaned out.
Always replace damaged parts with new parts.
3. Place the steering control lever in the NEUTRAL
position. Power Train Visual Inspection
4. Engage the parking brake. 1. Check the power train oil level.
2. Check the oil level in the final drives.
402 KENR5631-05
General Information

3. Check all oil lines, all hoses, and all hose Required Tools
connections for leaks and for damage. Look for oil
on the ground under the machine.
4. Check the electrical wiring for all power train
components.
5. Check the adjustment of the track.
6. Check the screens (if equipped) that are in the
following locations for foreign material: bevel gear
case, transmission and torque converter housing.
Check the filter element for foreign material. A
magnet separates ferrous particles from
nonferrous particles.
If you find excessive metal or rubber particles, all
components of the power train oil system must be
cleaned out. Always replace damaged parts with new Illustration 421 g03623456
parts. The presence of some metal or rubber
particles are considered normal during the break-in Table 167
period.
Required Tools
Electrical Visual Inspection
1. Check the lights for broken bulbs or broken lenses. Qty Part Description
Tool Item
Replace the bulb or lenses, if needed. Number
Communication
2. Check for loose wiring. C 1 317-7484(1)
Adapter Gp
3. Check for frayed wiring. Cable As (USB PC
C1 1 370-4617
4. Check for any loose electrical components. Communication)

5. Check for any damaged electrical components. Communication

C2 1 317-7485
Adapter III

i05701219 C3 1 327-8981 Cable As (Data Link)

Calibrations (Cat ET) C4 1 317-7492

Cable As Wireless
Radio
SMCS Code: 1439-524; 5479-524
Caterpillar Electronic
C5 1 JERD2129
Technician (Cat ET)
Introduction
Some of the components that are connected to the (1) Cat Electronic Technician (ET) and Software CD, NETG5057
electronic control modules can be calibrated by using are required when using the communication adapter.
the Caterpillar Electronic Technician (Cat ET).
Calibrations are performed when directed by
troubleshooting procedures or replacing a
component within the calibrated system.
The calibration of a component allows the ECM to
determine the correct output level. The calibration
also allows the ECM to determine the correct input
signal of displacement.
For more information on error codes that may occur
during calibration refer to Testing and Adjusting ,
KENR5631, “Calibration Error Codes”.
KENR5631-05 403
General Information

Cat ET Calibration Screen

Illustration 422 g03623356

Calibration screen

Implement ECM Calibrations Once the specific calibration is selected, the Cat ET
will guide you through the calibration procedure.
The following calibrations can be performed to the
Implement ECM: The Cat ET will list initial machine conditions that
must be satisfied before the ECM will allow the
• Control Lever Calibration calibration procedure to continue. Follow the specific
instructions on the display in order to complete the
• Ripper Solenoid Calibration calibration procedure.
• Blade Solenoid Calibration Transmission ECM Calibrations
• Machine Inclination Sensing Device Calibration The following calibration can be performed to the
Transmission/Chassis ECM:
• Tool Automation Implement Valve Calibration
• FNR Shifter Sensor Calibration
To access the calibration procedures for the
Implement ECM, establish the connections of the Cat • Brake Touch-Up Pressure Calibrations (Manual)
ET to the machine. Navigate to the calibration screen
by clicking “Service” on the tool bar and then clicking • Service Brake Pedal Calibration
“Calibrations” . Select the desired calibration
procedure that is required. Click on the “Start” button • Transmission Fill Calibration
at the bottom of the screen.
• Steering Clutch/Brake Pressure Calibrations
404 KENR5631-05
General Information

To access the calibration procedures for the Trans/

Chassis ECM, establish the connections of the Cat
ET to the machine. Navigate to the calibration screen
by clicking “Service” on the tool bar and then clicking
“Calibrations” . Select the desired calibration
procedure that is required. Click on the “Start” button
at the bottom of the screen.
Once the specific calibration is selected, the Cat ET
will guide you through the calibration procedure.
The Cat ET will list initial machine conditions that
must be satisfied before the ECM will allow the
calibration procedure to continue. Follow the specific
instructions on the display in order to complete the
calibration procedure.

i05833051

Calibration Error Codes

SMCS Code: 1439-524; 5479-524

General Error Codes

KENR5631-05 405
General Information

General Calibration Error Codes

Table 168
Error Codes That Can Be Activated When Any General Calibration Procedures Are Performed

Probable Cause of
Error Code Recommended Actions
Activation
· An active diagnostic code for any of the following will inhibit
an Implement calibration:

- Parking Brake Diagnostic Code

- Implement Lockout Switch Diagnostic Code
An active diagnostic is preventing - Lift Lever or Tilt Lever Diagnostic Code other than an FMI 13
0002 - Active Diagnostic the calibration from being per- - Lift Linkage or Tilt Linkage Diagnostic Code other than an FMI
formed successfully . 13.
- An active diagnostic code for the solenoid that is being calibrated
other than an FMI 13.

· Resolve the problem that is causing the active diagnostic code.

Then retry the calibration.

· A calibration procedure is trying · Only run one calibration procedure at a time.

to run on the Monitoring System
Display and Cat ET at the same · If a calibration is canceled, wait at least 15 seconds before start-
0003 - Another Calibration is Active time. ing another calibration procedure.
OR
A calibration was started and did · If the error message continues to pop up, key OFF and back ON
not successfully close out. before attempting the calibration again.

A calibration procedure is trying to · Only run one calibration procedure at a time.

run on the Monitoring System Dis-
play and Cat ET at the same time. · If one calibration is canceled, wait at least 15 seconds before
starting another calibration procedure.
0004 - Calibration Active By another
OR
ECM
A calibration was started, then can-
celed and another calibration is
started too fast.
· Check for any active Cat Data Link diagnostic codes. Resolve
any active codes.

· Check the Cat Data Link Connections.

Cat ET has lost communication
0005 - Loss of Calibration Interlock · Check the ET communication connections.
with the ECM.
· Cycle the key start switch from ON to OFF, wait 10 seconds, then
turn the key start switch to ON.

Perform the calibration procedure again.

· Cancellation may cause activation of the 0006 or the 0009 error

The calibration has been canceled
0006 - Calibration aborted by Tool / code.
by the user in Cat ET or in the
Monitor
Monitor
· Wait at least 15 seconds before performing another calibration.

· Cancellation may cause activation of the 0006 or the 0009 error

The calibration has been canceled code.
by the ECM. Normally another er-
0009 - Calibration aborted by ECM ror code will also be active indicat- · Wait at least 15 seconds before performing another calibration.
ing the cause of the ECM
cancellation. · Check for another active error code that indicates the cause of
the problem and resolve the problem.

(continued)
406 KENR5631-05
General Information

(Table 168, contd)

Error Codes That Can Be Activated When Any General Calibration Procedures Are Performed

Probable Cause of
Error Code Recommended Actions
Activation
· Ensure no active diagnostics are present.

000A - Calibration Failure Calibration failed to complete. · Ensure all setup conditions are met.

· Ensure all calibration steps are followed exactly.

· Ensure that the latest version of Cat ET is installed on your PC.

Incorrect / early version of Cat ET
· Verify that the correct flash file is downloaded into the Implement
is used that does not support the
ECM.
000B - Calibration Not Supported calibration.
Incorrect flash file is downloaded
Note: After the ECM has been flashed, cycle the key start switch
into the Implement ECM
from ON to OFF. Wait 10 seconds, then turn the key start switch to
ON. Rerun the calibration procedure.
KENR5631-05 407
General Information

General Service Test Error Codes

Table 169
Error Codes That Can Be Activated When Any General Service Test Procedures Are Performed

Probable Cause of
Error Code Recommended Actions
Activation
· An active diagnostic code for any of the following will inhibit
an Implement service test:

- Parking Brake Diagnostic Code

- Implement Lockout Switch Diagnostic Code
An active diagnostic is preventing - Lift Lever or Tilt Lever Diagnostic Code other than an FMI 13
0002 - Active Diagnostic the service test from being per- - Lift Linkage or Tilt Linkage Diagnostic Code other than an FMI
formed successfully . 13.
- An active diagnostic code for the solenoid that is being tested
other than an FMI 13.

· Resolve the problem that is causing the active diagnostic code.

Repeat the service test.

· Only run one service test procedure at a time.

A service test procedure is trying to
run on the Monitoring System Dis-
· If one service test is canceled, wait at least 15 seconds before
play and Cat ET at the same time.
0003 - Another Service Test is Active starting another service test procedure.
OR
A service test was started and did
· If the error message continues to pop up, Cycle the keyswitch
not successfully close out.
OFF and back ON before attempting the service test again.

A service test procedure is trying to · Only run one service test procedure at a time.
run on the Monitoring System Dis-
play and Cat ET at the same time. · If one service test is canceled, wait at least 15 seconds before
starting another service test procedure.
0004 - Service Test Active By another
OR
ECM
A service test was started, then
canceled and another service test
is started too fast.
· Check for any active Cat Data Link diagnostic codes. resolve any
active codes.

· Check the Cat Data Link Connections.

Cat ET has lost communication
0005 - Loss of Service Test Interlock · Check the ET communication connections.
with the ECM.
· Cycle the key start switch from ON to OFF, wait 10 seconds, then
turn the key start switch to ON.

Repeat the service test procedure.

· Cancellation may cause activation of the 0006 or the 0009 error

The service test has been can-
0006 - Service Test Aborted by Tool / code.
celed by the user in Cat ET or in
Monitor
the Monitor
· Wait at least 15 seconds before performing another service test.

· Cancellation may cause activation of the 0006 or the 0009 error

The service test has been can- code.
celed by the ECM. Normally anoth-
0009 - Service Test Aborted by ECM er error code will also be active · Wait at least 15 seconds before performing another service test.
indicating the cause of the ECM
cancellation. · Check for another active error code that indicates the cause of
the problem and resolve the problem.

(continued)
408 KENR5631-05
General Information

(Table 169, contd)

Error Codes That Can Be Activated When Any General Service Test Procedures Are Performed

Probable Cause of
Error Code Recommended Actions
Activation
· Ensure no active diagnostics are present.

000A - Service Test Failure Service test failed to complete. · Ensure all setup conditions are met.

· Ensure all service test steps are followed exactly.

· Ensure that the latest version of Cat ET is installed on your PC.

Incorrect / early version of Cat ET · Verify that the correct flash file is downloaded into the Implement
is used that does not support the ECM.
calibration.
000B - Service Test Not Supported
Note: After the ECM has been flashed, cycle the key start switch
Incorrect flash file is downloaded from ON to OFF. Wait 10 seconds, then turn the key start switch to
into the Implement ECM ON.

Rerun the service test procedure.

KENR5631-05 409
General Information

Implement ECM Calibrations

410 KENR5631-05
General Information

Control Lever Calibrations

Table 170
Error Codes That Can Be Activated When Lever Position Sensor Calibrations Are Performed
Error Code Probable Cause of Activation Recommended Actions
· Check that the lever is in the correct position
before trying to advance to the next step.

During calibration, the Implement ECM sensed · For full travel positions, ensure that the lever is
10F0 - Calibration Value Out of Range
that the duty cycle of the sensor was lower than at the full travel position and not at the detent
Low
the allowable duty cycle limit. position.

· For the center position, ensure that the lever is

released and no external forces are causing the
lever to remain out of center.

· Check that the lever is mounted in the correct

orientation.
During calibration, the Implement ECM sensed
10F1 - Calibration Value Out of Range
that the duty cycle of the sensor was higher than If the calibration is performed properly (pushing
High
the allowable duty cycle limit. the lever firmly all the way to the correct posi-
tion) and the out of range error code is still ac-
tive, the handle is probably out of specifications
and needs replaced.
KENR5631-05 411
General Information

Blade and Ripper Solenoid Calibrations

Table 171
Error Codes That Can Be Activated When Blade and Ripper Solenoid Calibrations Are Performed

Error Code Probable Cause of Activation Recommended Actions

Hydraulic oil temperature is below the recom- Increase the hydraulic oil temperature to within
1048 - Hydraulic Oil Temperature Too Low
mended range the recommended range.

1054 - Hydraulic Oil Temperature Too Hydraulic oil temperature is above the recom- Decrease the hydraulic oil temperature to within
High mended range. the recommended range.

· Verify that the correct flash file is downloaded

into the Implement ECM.

The Implement ECM recorded an average pres- · Verify that the pressure sensor used in the cali-
104C - Hold Pressure Too High
sure that was too high for this calibration to begin. bration is reading correctly by comparing the
pressure shown in ET to the standard operating
pressure listed in the manuals.

· This error code is often caused when the hy-

draulic plumbing / lines are incorrectly routed.
Check for swapped hydraulic connections. Also
check for hydraulic oil leakage.

· Check that the electrical wiring from the com-

ponent back to the ECM is correct and that
wires/harnesses have not been swapped.

· Verify that the correct flash file is downloaded

into the Implement ECM.
The Implement ECM recorded an average pres-
104D - Hold Pressure Too Low
sure that was too low for this calibration to begin
· Verify that the pressure sensor used in the cali-
bration is reading correctly by comparing the
pressure shown in ET to the standard operating
pressure listed in the manuals

· Check for excessive leakage through the

pump, valve, and cylinder.

· If the root cause is not found, replace the sole-

noid or solenoids indicated in the calibration and
run the calibration test again.

· Measure current to the solenoid or solenoids

indicated in the calibration. The solenoid current
During calibration, the Implement ECM could not should be matching what is shown in ET during
obtain a valid, constant baseline pressure needed the calibration.
104E - Hold Pressure Inconsistent
to complete the calibration because pump dis-
charge pressure varied too much. · If the root cause is not found, replace the sole-
noid or solenoids indicated in the calibration and
run the calibration test again.

(continued)
412 KENR5631-05
General Information

(Table 171, contd)

Error Codes That Can Be Activated When Blade and Ripper Solenoid Calibrations Are Performed

Error Code Probable Cause of Activation Recommended Actions

· This error code is often caused when the hy-
draulic plumbing / lines are incorrectly routed.
Check for swapped hydraulic connections. Also
check for hydraulic oil leakage.

· Check that the electrical wiring from the com-

The Implement ECM failed to detect a pressure ponent back to the ECM is correct and that
105F - Calibration Timed Out
spike within a reasonable time period.. wires/harnesses have not been swapped.

· Verify that the correct flash file is downloaded

into the Implement ECM.

· Check for excessive leakage through the

pump, valve, and cylinder.

· Verify the correct flash file is downloaded into

the Implement ECM.
During calibration, the Implement ECM sensed
10F0 - Calibration Value Out of Range
that the calibrated current of the solenoid was low- · Verify the pressure sensor used in the calibra-
Low
er than the minimum allowable calibrated current. tion is reading correctly by comparing the pres-
sure shown in ET during the calibration to the
pressure on a manual gauge.

· Check for excessive leakage through the

During calibration, the Implement ECM sensed pump, valve, and cylinder.
10F1 - Calibration Value Out of Range that the calibrated current of the solenoid was
High higher than the maximum allowable calibrated · If the root cause is not found, replace the sole-
current. noid or solenoids indicated in the calibration and
run the calibration test again.
KENR5631-05 413
General Information

Inclination Sensor Calibrations

Table 172
Error Codes That Can Be Activated When Inclination Sensor Calibrations Are Performed
Error Code Probable Cause of Activation Recommended Actions
Set the engine speed to the required value in
1012 - Engine RPM Incorrect Engine speed is incorrect.
the calibration setup conditions.

1018 - Parking Brake Not Engaged The parking brake is not engaged. Set the parking brake.

Set the Implement Lockout Switch to the

1043 - Implement Lockout Switch OFF The implements are not LOCKED.
LOCKED position.
414 KENR5631-05
General Information

Tool Automation Valve Calibrations

Table 173

Error Codes That Can Be Activated When Valve Solenoid Calibrations Are Performed
Error Code Probable Cause of Activation Recommended Actions
· Verify that the correct flash file is downloaded into the
Implement ECM.
The Implement ECM recorded an average
104C - Hold Pressure Too High pressure that was too high for this calibration · Verify that the pressure sensor used in the calibration is
to begin. reading correctly by comparing the pressure shown in ET
to the standard operating pressure listed in the manuals

· This error code is often caused when the hydraulic

plumbing / lines are incorrectly routed. Check for
swapped hydraulic connections. Also check for hydraulic
oil leakage.

· Check that the electrical wiring from the component

back to the ECM is correct and that wires/harnesses have
not been swapped.

The Implement ECM recorded an average · Verify that the correct flash file is downloaded into the
104D - Hold Pressure Too Low pressure that was too low for this calibration Implement ECM.
to begin
· Use a calibrated pressure sensor to perform the calibra-
tion test.

· Check for excessive leakage through the pump, valve,

and cylinder.

· If the root cause is not found, replace the solenoid or

solenoids indicated in the calibration and run the calibra-
tion again.

· Measure current to the solenoid or solenoids indicated

in the calibration. The solenoid current should match what
During calibration, the Implement ECM could
is shown in ET during the calibration.
not obtain a valid, constant baseline pressure
104E - Hold Pressure Inconsistent
needed to complete the calibration because
· If the root cause is not found, replace the solenoid or
pump discharge pressure varied too much.
solenoids indicated in the calibration and run the test
again.

106A - Implement Not in Hold The lever is moved out of center while · Ensure the lever is released and no external forces are
Position calibrating. causing the lever to remain out of center.

During the calibration setup, the Implement · Ensure the blade is positioned as requested by the
10F0 - Calibration Value Out of ECM sensed the extension of the lift cylinders calibration.
Range Low was lower than the minimum allowable lift cyl-
inder extension. · Verify the lift cylinder extension listed in ET is approxi-
mately equal to actual cylinder extension. If these exten-
During the calibration setup, the Implement
sions are different, replace the cylinder position sensor or
10F1 - Calibration Value Out of ECM sensed the extension of the lift cylinders
sensors.
Range High was higher than the maximum allowable lift
cylinder extension.
KENR5631-05 415
General Information

Transmission ECM Calibrations

416 KENR5631-05
General Information

Transmission Fill Calibration

Table 174
Error Codes That Can Be Activated When Any Transmission Fill Calibrations Are Performed

Error Code Probable Cause of Activation Recommended Actions

1010 - Engine Stopped (No Engine The engine is not running. Start the engine.
RPM)

1012 - Engine RPM Incorrect Engine speed is incorrect. Set engine speed to the required value in the cali-
bration setup conditions.

1017 - Service Brake Pedal Pressed The service brake pedal is pressed. Release the service brake.

1018 - Parking Brake Not Engaged The parking brake is not engaged. Set the parking brake.

1019 - Parking Brake Engaged The parking brake is engaged. Disengage the parking brake.

101B - Machine Speed Not 0 Transmission output speed is detected. Neutralize the transmission and apply the brakes.

101F - Direction Lever Not In The direction lever is out of the NEUTRAL Set the FNR switch to NEUTRAL.
NEUTRAL position.

1021 - Transmission Oil Temp Too Transmission oil temperature is below the recom- Increase the transmission oil temperature to within
Low mended range. the recommended range.

1022 - Transmission Oil Temp Too Transmission oil temperature is above the recom- Decrease the transmission oil temperature to with-
High mended range. in the recommended range.

1023 - Transmission Clutch 1 At A Calibrated value is at the maximum or minimum al- Repeat the calibration procedure. If this warning
Limit lowed value. persists, replace the clutch valve.

1024 - Transmission Clutch 2 At A Calibrated value is at the maximum or minimum al- Repeat the calibration procedure. If this warning
Limit lowed value. persists, replace the clutch valve.

1025 - Transmission Clutch 3 At A Calibrated value is at the maximum or minimum al- Repeat the calibration procedure. If this warning
Limit lowed value. persists, replace the clutch valve.

1026 - Transmission Clutch 4 At A Calibrated value is at the maximum or minimum al- Repeat the calibration procedure. If this warning
Limit lowed value. persists, replace the clutch valve.

1027 - Transmission Clutch 5 At A Calibrated value is at the maximum or minimum al- Repeat the calibration procedure. If this warning
Limit lowed value. persists, replace the clutch valve.

1049 - Torque Converter Output The torque converter output speed sensor or en- Monitor torque converter output speed and engine
Speed Too High gine speed sensor is reporting an incorrect speed. speed in ET. Verify speeds are similar when ma-
chine is not under load.
104A - Torque Converter Output The torque converter speed sensor or engine Monitor torque converter output speed and engine
Speed Too Low speed sensor is reporting an incorrect speed. speed in ET. Verify speeds are similar when ma-
chine is not under load.
1074 - Engine RPM Too Low The engine speed sensor is reporting an incorrect Monitor engine speed in ET.
speed.

10A2 - Transmission Oil Filter Bypass Transmission oil filter is contaminated or Trans- Warm transmission oil to the recommended tem-
Active mission oil is below normal operating temperature. perature. If problem persists, replace the filter.

10BD - Transmission Clutch 1 Failed The transmission clutch was not able to be cali- Reference the Test and Adjust procedure to verify
Calibration brated within the allowed number of attempts. the clutch pressures. If necessary, replace the
valve.
10BE - Transmission Clutch 2 Failed The transmission clutch was not able to be cali- Reference the Test and Adjust procedure to verify
Calibration brated within the allowed number of attempts. the clutch pressures. If necessary, replace the
valve.

(continued)
KENR5631-05 417
General Information

(Table 174, contd)

10BF - Transmission Clutch 3 Failed The transmission clutch was not able to be cali- Reference the Test and Adjust procedure to verify
Calibration brated within the allowed number of attempts. the clutch pressures. If necessary, replace the
valve.
10C0 - Transmission Clutch 4 Failed The transmission clutch was not able to be cali- Reference the Test and Adjust procedure to verify
Calibration brated within the allowed number of attempts. the clutch pressures. If necessary, replace the
valve.
10C1 - Transmission Clutch 5 Failed The transmission clutch was not able to be cali- Reference the Test and Adjust procedure to verify
Calibration brated within the allowed number of attempts. the clutch pressures. If necessary, replace the
valve.
10FE - Torque Converter Ratio Engine speed or torque converter output speed is Monitor torque converter output speed and engine
Unstable unstable. speed in ET. Verify speeds are stable when ma-
chine is idle.
418 KENR5631-05
General Information

FNR Shifter Sensor Calibration

Table 175
Error Codes That Can Be Activated When Any FNR Shifter Sensor Calibration Procedures Are Performed

Error Code Probable Cause of Activation Recommended Actions

1011 - Engine Running (Engine RPM The engine is running. Stop the engine. Turn the key to the OFF position
Present) and wait for the engine to stop running completely.
Then turn the key to the ON position and restart
the calibration.
1018 - Parking Brake Not Engaged The parking brake is not engaged.. Set the parking brake..
KENR5631-05 419
General Information

Service Brake Pedal Calibration

Table 176
Error Codes That Can Be Activated When Any Service Brake Pedal Calibration Procedures Are Performed

Error Code Probable Cause of Activation Recommended Actions

1011 - Engine Running (Engine RPM Present) The engine is running. Stop the engine. Turn the
key to the OFF position
and wait for the engine to
stop running completely.
Then turn the key to the
ON position and restart
the calibration.
1018 - Parking Brake Not Engaged To meet the setup conditions during calibration the park brake Apply the park brake and
must be applied. If the park brake is not applied (if pressure feed- proceed to next step.
back is available) or commanded to apply at this time, the cali-
bration will indicate that the park brake is not applied.

1079 - Transmission Not in Neutral During calibration, to meet the setup conditions, the shift lever Check shift lever position
must be in NEUTRAL. If the shift lever position is unknown or not and move it to NEUTRAL.
in NEUTRAL, the calibration will indicate to the technician that
the shift lever is not in NEUTRAL.
· Check that the pedal
sensor is in the correct
position before trying to
advance to the next step.

· Check that the pedal is

completely released or
completely depressed at
the required calibration
During calibration, the Power Train ECM sensed the duty cycle
step.
of the sensor was lower than the allowable duty cycle limit. An
10F0 error can occur at any of the two calibration steps:
10F0 - Calibration Out of Range Low ·· Check that the sensor
is mounted in the correct
- Pedal required to be completely released
orientation.
- Pedal required to be completely depressed
· Use Cat ET to verify the
duty cycle of pedal
position.

· If the duty cycle values

are not correct, replace
the sensor and perform
the calibration again.

(continued)
420 KENR5631-05
General Information

(Table 176, contd)

· Check that the pedal
sensor is in the correct
position before trying to
advance to the next step.

· Check that the pedal is

completely released or
completely depressed at
the required calibration
During calibration, the Power Train ECM sensed the duty cycle
step.
of the sensor was Higher than the allowable duty cycle limit. An
10F1 error can occur at any of the two calibration steps:
10F1 - Calibration Out of Range High ·· Check that the sensor
is mounted in the correct
- Pedal required to be completely released
orientation.
- Pedal required to be completely depressed
· Use Cat ET to verify the
duty cycle of pedal
position.

· If the duty cycle values

are not correct, replace
the sensor and perform
the calibration again.

10FF - Service Brake Switch Position Incorrect During calibration, the operator proceeded to the next step be- - During calibration the
fore the Power Train ECM captured the required duty cycle with operator must depress
the pedal slowly to cap-
respect to the pedal switch. A 10FF error can occur at any of the
two calibration steps: - ture the Switch CLOSED
duty cycle and release
- The switch CLOSED duty cycle is not captured or pedal was the pedal slowly to cap-
not fully pressed ture the Switch OPEN du-
The switch OPEN duty cycle is not captured or the pedal was not ty cycle.
fully released (a short to battery detected on Brake Dump
solenoid). - Check that brake pedal
Switch is not stuck in the
CLOSED position (short
to battery on Brake dump
solenoid).
KENR5631-05 421
General Information

Transmission ECM Service Tests

422 KENR5631-05
General Information

Transmission Main Relief Service Tests

Table 177
Error Codes That Can Be Activated When Any Transmission Main Relief Service Test Procedures Are Performed

Error Code Probable Cause of Activation Recommended Actions

1017 - Service Brake Pedal Pressed The service brake pedal is pressed. Fully depress the service brake..

1018 - Parking Brake Not Engaged The parking brake is not engaged. Set the parking brake.

1019 - Transmission Output Speed The transmission output speed sensor is reporting Monitor transmission output speed in ET.
Too High an incorrect speed.

101B - Shift Lever Not in NEUTRAL The shift lever is out of the NEUTRAL position. Set the FNR switch to Neutral.

101C - Transmission Gear Incorrect The transmission is not in the correct gear. Shift the transmission to the requested gear.

1075 - Transmission Oil Temperature Transmission oil temperature is above the recom- Decrease the transmission oil temperature to with-
Too High mended range. in the recommended range.

1164 - Engine Speed/Load Incorrect The decelerator pedal is pressed or the throttle Release the decelerator pedal and set the throttle
switch position is incorrect. switch to the requested position.
KENR5631-05 423
General Information

Torque Converter Stall Service Tests

Table 178
Error Codes That Can Be Activated When Any Torque Converter Service Test Procedures Are Performed

Error Code Probable Cause of Activation Recommended Actions

1018 - Parking Brake Not Engaged The parking brake is not engaged. Set the parking brake.

101B - Shift Lever Not in NEUTRAL The shift lever is out of the NEUTRAL position. Set the FNR switch to NEUTRAL.

119D - Parking Brake Engaged The parking brake is engaged. Disengage the parking brake.

101C - Transmission Gear Incorrect The transmission is not in the requested gear. Shift the transmission to the requested gear.

1021 - Transmission Oil Temperature Transmission oil temperature is below the recom- Increase the transmission oil temperature to
Too Low mended range. within the recommended range.

1075 - Transmission Oil Temperature Transmission oil temperature is above the recom- Decrease the transmission oil temperature to
Too High mended range. within the recommended range.

1048 - Hydraulic Oil Temperature Too Hydraulic oil temperature is below the recommended Increase the hydraulic oil temperature to with-
Low range. in the recommended range.

1054 - Hydraulic Oil Temperature Too Hydraulic oil temperature is above the recommended Decrease the hydraulic oil temperature to
High range. within the recommended range.

1074 - Engine RPM Too Low Engine speed is below the required value. Set engine speed to the required value using
the throttle switch.
10A7 - Coolant Temperature Too Low Coolant temperature is below the recommended Increase the coolant temperature to within the
range. recommended range.

10FA - Coolant Temperature Too High Coolant oil temperature is above the recommended Decrease the coolant oil temperature to within
range. the recommended range.

10FC - Engine RPM Too High Engine speed is above the required value. Set engine speed to the required value using
the throttle switch.
110C - Brake Pedal Depressed The service brake pedal is depressed. Release the service brake pedal.

111B - Brake Pedal Not Depressed The service brake pedal is not depressed. Fully depress the service brake pedal.
424 KENR5631-05
Testing and Adjusting

Testing and Adjusting Drift

Table 182
Lift Cylinder Drift

i05755231
38° to 48°C
49° to 66°C Above 67°C
Oil Temperature (100° to 120°
(120° to 150°F) (150°F)
F)
Operational Checks
Maximum Al- 38.1 mm 38.1 mm 38.1 mm
SMCS Code: 1000; 3030; 3030-535; 3030-035; lowable Drift (1.5 inch) (1.5 inch) (1.5 inch)
5050-535; 5050; 7000-035; 7000
Time Interval
5.0 2.7 1.7
(Minutes)
Specifications
Table 183
Cycle Times Tilt Cylinder Drift
Table 179 38° to 48°C
49° to 66°C Above 67°C
Bulldozer Lift Cylinders Speed Test Oil Temperature (100° to 120°
(120° to 150°F) (150°F)
F)
Specification Actual
Maximum Al- 11.2 mm 11.2 mm 11.2 mm
RAISE (Ground lowable Drift (0.44 inch) (0.44 inch) (0.44 inch)
Level to Maximum 3.7 ± 0.4 Time Interval
Height) 5.0 2.7 1.7
(Minutes)
LOWER (Maximum
Height to Ground 1.8 ± 0.4 Table 184
Level)
Ripper Cylinder Drift
Table 180 38° to 48°C
49° to 66°C Above 67°C
Oil Temperature (100° to 120°
Bulldozer Tilt Cylinder Speed Test (120° to 150°F) (150°F)
F)
Specification Actual Maximum Al-
lowable Drift 25 mm 25 mm 25 mm
Single TILT (Right
3.8 ± 0.6 (Machine Off (1.0 inch) (1.0 inch) (1.0 inch)
to Left)
the Ground
Single TILT (Left to
3.8 ± 0.6 Maximum Al-
Right) 9.6 mm 9.6 mm 9.6 mm
lowable Drift
(Ripper Off the (0.38 inch) (0.38 inch) (0.38 inch)
Dual TILT (Right to
3.8 ± 0.6 Ground
Left)
Time Interval
Dual TILT (Left to 5.0 2.7 1.7
3.8 ± 0.6 (Minutes)
Right)

Table 181 Introduction

Ripper Cylinder Speed Test The Operational Checks can be used in order to find
Specification
any of the following problems: leakage in the system,
Actual
a bad valve and a bad pump. The speed of the rod
RAISE (Ground to movement can be measured in order to check the
Maximum Height)
2.7 ± 0.4 condition of the cylinders and the condition of the
pump.
LOWER (Maximum
2.2 ± 0.4 The oil in the hydraulic system must be the oil which
Height to Ground)
is recommended in the Operation and Maintenance
Manual, and at a temperature of 28° to 88°C
(80° to 190°F).

Test Preparation
1. Move the machine to a smooth, horizontal location
that is away from operating machines and away
from personnel.
KENR5631-05 425
Testing and Adjusting

2. Permit only one operator on the machine. Keep all 1. Check hydraulic oil temperature.
other personnel away from the machine or in the
2. Lift the bulldozer until the cutting edge is
operator sight.
approximately 254 mm (10.0 inch) off the ground.
3. Place the steering control lever in the NEUTRAL With the lift control lever in the HOLD position,
position. stop the engine.
4. Engage the parking brake. 3. Obtain a measurement of the length of the cylinder
rod.
5. Lower the attachments to the ground.
4. Obtain a measurement of the distance of cylinder
6. Stop the engine.
drift over time. Compare the values to the values
Initial Test in the chart.
Extend the cylinder and retract the cylinder. Repeat Note: The drift distances in the chart are for new
several times for each cylinder. machines.
1. Watch the operation of the cylinder. Movement Note: Take a measurement of the length of the
must be uniform and regular. cylinder rod for this chart.
2. Listen for noise from the pump.
Drift Test for Tilt Cylinder
3. Listen for the sound of the relief valves. The relief
valves must not open while the attachment Measure tilt cylinder rod drift by using the following
cylinders are in motion. procedure:

Test Procedures - Cycle Times 1. Check hydraulic oil temperature.

The oil in the system must be the oil which is 2. Fully retract the tilt cylinder.
recommended in Operation and Maintenance 3. Lower the bulldozer in order to lift the front idlers
Manual, and at a temperature of 75° ± 5°C
(167° ± 9°F). All speed tests should be done with the off the ground. Move the control levers to the
engine at the HIGHEST throttle position. HOLD position and stop the engine.

Identify the speed of each cylinder. Compare these 4. Obtain a measurement of the length of the cylinder
values to the values in the chart. Equal values rod.
indicate normal circuit operation.
5. Obtain a measurement of the distance of cylinder
If the speed of a cylinder is too slow, check that circuit drift over time. Compare the values to the values
for cylinder drift. in the chart.

Test Procedures - Drift Note: The drift distances in the chart are for new
machines.
The drift rates change with different conditions of the
hydraulic components. The drift rates change with Note: Take a measurement of the length of the
machine operation, hydraulic oil temperature, etc. cylinder rod for this chart.
Before you measure drift of the cylinder rods, the
cylinders must be extended at least five times.
Drift Test for Ripper Cylinder
Cylinder rod drift is caused by the following
conditions: Measure ripper cylinder rod drift by using the
following procedure:
• Loose oil line connections or damaged oil lines
with oil leaks 1. Check hydraulic oil temperature.

• Leakage around the piston seals in the cylinder 2. Lift the ripper so that the ripper teeth are
approximately 254 mm (10.0 inch) off the ground.
• Leakage in the control valve (worn valve section Move the ripper control lever to the HOLD
and worn spool valve) position. Stop the engine.
• Leakage through check valves or makeup valves 3. Obtain a measurement of the length of the cylinder
rod.
Drift Test for Lift Cylinders 4. Obtain a measurement of the distance of cylinder
drift over time. Compare the values to the values
Measure lift cylinder rod drift by using the following
procedure: in the chart.
426 KENR5631-05
Testing and Adjusting

Note: The drift distances in the chart are for new

NOTICE
machines. Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
Note: Take a measurement of the length of the nance, testing, adjusting, and repair of the product.
cylinder rod for this chart. Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
i05460592 bling any component containing fluids.

Piston Pump (Implement) - Refer to Special Publication, NENG2500, “Dealer

Service Tool Catalog” for tools and supplies suitable
Test and Adjust to collect and contain fluids on Cat products.

SMCS Code: 5070-036-II; 5070-025; 5070-081 Dispose of all fluids according to local regulations
and mandates.

Specifications
Hot hydraulic oil under high pressure can remain
in the components of the hydraulic system or the Table 185
power train system after the engine has been D10T Implement Pump Pressure
stopped. The uncontrolled release of the hydraul-
ic oil can cause sudden machine movement and Date Equipment ID Code
can also result in the following conditions:
Pump Pressure Specification Actual
• Burns
Standby Pressure at
Greater than
• The penetration of body tissue High Idle (Left
1800 kPa (260 psi)
Pump) (HA)
• Other personal injury Margin Pressure at
2200 ± 170 kPa
High Idle (Left
• Death Pump) (HA) - (HB)
(320 ± 25 psi)

If hydraulic oil penetrates body tissue, the injury High Pressure Cutoff
must be treated immediately by a doctor who is (High Idle) at pres- 28000 ± 500 kPa
familiar with this type of injury. Use a board or a sure port (HA) (Left (4061 ± 72 psi)
piece of cardboard to check for a hydraulic oil Pump)
leak. Make sure that all of the attachments have
been lowered to the ground and that all trapped Standby Pressure at
Greater than
pressure has been released from the hydraulic High Idle (Right
1800 kPa (260 psi)
system and the power train system. Also, make Pump) (HA)
sure that the hydraulic oil is cool before the re-
moval of any components or lines. Remove the Margin Pressure at
2100 ± 170 kPa
hydraulic oil filler cap only when the engine is High Idle (Right
(305 ± 25 psi)
Pump) (HA) - (HB)
stopped and the filler cap is cool enough to touch
with your bare hand. High Pressure Cutoff
(High Idle) at pres- 28000 ± 500 kPa
sure port (HA) (Right (4061 ± 72 psi)
Pump)

Personal injury or death can result from not en-

gaging the parking brake.
Transmission engagement alone will not prevent
machine from rolling when the engine is stopped.
KENR5631-05 427
Testing and Adjusting

Illustration 423 g03452856 Illustration 424 g02571852

Tooling (A) 198-4240 Digital Pressure Indicator Gp
Table 186
D10T Torque Specifications

Callout Torque

Locknut (4)
21 N·m (15 lb ft)
High Pressure Cutoff

Locknut (6)
21 N·m (15 lb ft)
Margin Pressure

Introduction
This story includes the following tests for each
pump:

• Test Procedure - Standby / Margin Pressure

• Test Procedure - High Pressure Cutoff
This story includes the following adjustment
procedures for each pump:
• Adjustment Procedure - Margin Pressure
• Adjustment Procedure - High Pressure Cutoff Illustration 425 g03453835

Table 187
Required Tools
Required Tools
Note: You can view the discharge pressure of the
Tool Item Qty Part No Description
implement pump through Advisor.
Digital Pressure Indi-
A 198-4240
cator Gp

A1 1 198-4234 Digital Indicator

Pressure Sensor Gp
A2 2 198-4239 (0 to 41,368 kPa (0 to
6,000 psi))

A3 1 198-4236 Adapter Cable As

B1 1 6V-9508 Plug
B
B2 1 6V-8397 O-Ring Seal
428 KENR5631-05
Testing and Adjusting

Reference: Refer to Tool Operating Manual, Test Procedures - Left Pump

NEHS0818, “Using the 198-4240 Digital Pressure
Indicator Group” for more information on using Test Procedure - Standby / Margin
Tooling (A).
Pressure
Test Preparation - Left Pump
1. Start the engine. Warm the hydraulic oil to a
1. Move the machine to a smooth horizontal location. minimum temperature of 65° C (150° F).
2. Place the steering control lever in the NEUTRAL 2. Operate the engine at HIGH IDLE.
position.
3. With the implement control handles in the
3. Engage the parking brake. NEUTRAL position, record the pressure at
4. Lower the attachments to the ground. pressure tap (HA). The implement pump discharge
pressure should be greater than 1800 kPa
5. Stop the engine. (260 psi). This pressure is also known as low-
6. Turn the key to the ON position, but do not start the pressure standby.
engine. 4. Move the bulldozer control lever or the ripper
7. Verify that the implement lockout switch is in the control lever to a position between 25% and 33%
UNLOCKED position. of the RAISE command. Take the difference
between the pressure reading from the pump
8. Move the control levers through the full range of discharge pressure tap (HA) and the load sense
travel several times. This will relieve any pressure pressure at pressure tap (HB). This difference is
that may be present in the implement hydraulic the margin pressure.
system.
5. The margin pressure should be 2200 ± 170 kPa
9. Make sure that the pressure in the entire hydraulic (320 ± 25 psi). If the margin pressure is not within
system has been released. the specified limit, perform the adjustment
10. Turn the key to the OFF position. procedure in “Adjustment Procedure - Margin
Pressure”.
11. Remove the floorplate from the machine.
Test Procedure - High Pressure Cutoff
1. Start the engine. Warm the hydraulic oil to a
minimum temperature of 65° C (150° F).
2. Operate the engine at HIGH IDLE.
Note: Do not hold the pump in a HIGH PRESSURE
CUTOFF CONDITION for more than 5 seconds at
a time.

3. Move the ripper control lever in order to initiate a

stall condition in the ripper lift cylinders. Hold the
command and allow pressure to stabilize for 5
seconds.
Illustration 426 g03452842 4. Record pump discharge pressure at pressure tap
(HA). High-pressure cutoff should be
12. Disconnect hose (1) from the right-hand pump. 28000 ± 500 kPa (4061 ± 72 psi).
Cap hose (1) with Tooling (B).
5. If the pressure is within the specified limit, the test
Note: Leave the pump controller for the right- is complete. If the pressure is not within the
hand pump vented to the atmosphere. specified limit, perform the adjustment procedure
in “Adjustment Procedure - High Pressure Cutoff”.
13. Attach Tooling (A) to pressure taps (HA) and
(HB). 6. Once the pressure is correct reconnect hose (1).
14. Replace the floorplate making sure not to
damage the test equipment.
KENR5631-05 429
Testing and Adjusting

Adjustment Procedures - Left

Pump
Adjustment Procedure - Margin Pressure
1. Remove the floorplate in front of the operators seat
in the cab.

Illustration 428 g03452856

(3) Adjustment screw for high-pressure cutoff
(4) Locknut
(5) Adjustment screw for margin pressure
(6) Locknut

2. Loosen locknut (4) while you hold adjustment

screw (3) in place.
Illustration 427 g03452856 3. Turn adjustment screw (3) clockwise in order to
(3) Adjustment screw for high-pressure cutoff increase the cutoff pressure. Turn adjustment
(4) Locknut screw (3) counterclockwise in order to decrease
(5) Adjustment screw for margin pressure the cutoff pressure.
(6) Locknut
4. High-pressure cutoff should be 28000 ± 500 kPa
2. Loosen locknut (6) while you hold adjustment (4061 ± 72 psi).
screw (5) in place.
5. After the pressure is adjusted within the specified
3. Turn adjustment screw (5) clockwise in order to limit, tighten locknut (4). Make sure that you hold
increase the margin pressure. Turn adjustment adjustment screw (3) in place.
screw (5) counterclockwise in order to decrease
the margin pressure. 6. Check the cutoff pressure again. If the pressure is
within the specified limit, the adjustment procedure
4. Perform the steps in “Test Procedure - Standby / is complete.
Margin Pressure” in order to check the margin
pressure. Note: The High Pressure Cutoff adjustment and the
Margin Pressure adjustment influence each other.
5. If the margin pressure is 2200 ± 170 kPa Whenever you adjust one pressure, always check the
(320 ± 25 psi), tighten locknut (6). Make sure that other pressure and then make any necessary
you hold adjustment screw (5) in place. adjustment.
6. Check the margin pressure again. If the margin
pressure is within the specified limit, the
Test Preparation - Right Pump
adjustment procedure is complete. 1. Move the machine to a smooth horizontal location.
Note: The High Pressure Cutoff adjustment and the 2. Place the steering control lever in the NEUTRAL
Margin Pressure adjustment influence each other. position.
Whenever you adjust one pressure, always check the
other pressure and then make any necessary 3. Engage the parking brake.
adjustment. 4. Lower the attachments to the ground.

Adjustment Procedure - High Pressure 5. Stop the engine.

Cutoff 6. Turn the key to the ON position, but do not start the
engine.
1. Remove the floorplate in front of the operators seat 7. Verify that the implement lockout switch is in the
in the cab. UNLOCKED position.
430 KENR5631-05
Testing and Adjusting

8. Move the control levers through the full range of 4. Move the bulldozer control lever or the ripper
travel several times. This will relieve any pressure control lever to a position between 25% and 33%
that may be present in the implement hydraulic of the RAISE command. Take the difference
system. between the pressure reading from the pump
discharge pressure tap (HA) and the load sense
9. Make sure that the pressure in the entire hydraulic
pressure at pressure tap (HB). This difference is
system has been released.
the margin pressure.
10. Turn the key to the OFF position.
5. The margin pressure should be 2100 ± 170 kPa
11. Remove the floorplate from the machine. (305 ± 25 psi). If the margin pressure is not within
the specified limit, perform the adjustment
procedure in “Adjustment Procedure - Margin
Pressure”.

Test Procedure - High Pressure Cutoff

1. Start the engine. Warm the hydraulic oil to a
minimum temperature of 65° C (150° F).
2. Operate the engine at HIGH IDLE.
Note: Do not hold the pump in a HIGH PRESSURE
CUTOFF CONDITION for more than 5 seconds at
a time.

3. Move the ripper control lever in order to initiate a

Illustration 429 g03452842
stall condition in the ripper lift cylinders. Hold the
command and allow pressure to stabilize for 5
12. Disconnect hose (2) from the left-hand pump.
seconds.
Cap hose (2) with Tooling (B).
4. Record pump discharge pressure at pressure tap
Note: Leave the pump controller for the left-hand (HA). High-pressure cutoff should be
pump vented to the atmosphere. 28000 ± 500 kPa (4061 ± 72 psi).
13. Attach Tooling (A) to pressure taps (HA) and 5. If the pressure is within the specified limit, the test
(HB). is complete. If the pressure is not within the
14. Replace the floorplate making sure not to specified limit, perform the adjustment procedure
damage the test equipment. in “Adjustment Procedure - High Pressure Cutoff”.
6. Once the pressure is correct reconnect hose (2).
Test Procedures - Right Pump
Adjustment Procedures - Right
Test Procedure - Standby / Margin Pump
Pressure
Adjustment Procedure - Margin Pressure
1. Start the engine. Warm the hydraulic oil to a
minimum temperature of 65° C (150° F). 1. Remove the floorplate in front of the operators seat
2. Operate the engine at HIGH IDLE. in the cab.

3. With the implement control handles in the

NEUTRAL position, record the pressure at
pressure tap (HA). The implement pump discharge
pressure should be greater than 1800 kPa
(260 psi). This pressure is also known as low-
pressure standby.
KENR5631-05 431
Testing and Adjusting

Illustration 430 g03452897 Illustration 431 g03452897

(3) Adjustment screw for high-pressure cutoff (3) Adjustment screw for high-pressure cutoff
(4) Locknut (4) Locknut
(5) Adjustment screw for margin pressure (5) Adjustment screw for margin pressure
(6) Locknut (6) Locknut

2. Loosen locknut (6) while you hold adjustment 2. Loosen locknut (4) while you hold adjustment
screw (5) in place. screw (3) in place.
3. Turn adjustment screw (5) clockwise in order to 3. Turn adjustment screw (3) clockwise in order to
increase the margin pressure. Turn adjustment increase the cutoff pressure. Turn adjustment
screw (5) counterclockwise in order to decrease screw (3) counterclockwise in order to decrease
the margin pressure. the cutoff pressure.
4. Perform the steps in “Test Procedure - Standby / 4. High-pressure cutoff should be 28000 ± 500 kPa
Margin Pressure” in order to check the margin (4061 ± 72 psi).
pressure.
5. After the pressure is adjusted within the specified
5. If the margin pressure is 2100 ± 170 kPa limit, tighten locknut (4). Make sure that you hold
(305 ± 25 psi), tighten locknut (6). Make sure that adjustment screw (3) in place.
you hold adjustment screw (5) in place.
6. Check the cutoff pressure again. If the pressure is
6. Check the margin pressure again. If the margin within the specified limit, the adjustment procedure
pressure is within the specified limit, the is complete.
adjustment procedure is complete.
Note: The High Pressure Cutoff adjustment and the
Margin Pressure adjustment influence each other.
Whenever you adjust one pressure, always check the
other pressure and then make any necessary
adjustment.

Adjustment Procedure - High Pressure

Cutoff
1. Remove the floorplate in front of the operators seat
in the cab.
432 KENR5631-05
Testing and Adjusting

Note: The High Pressure Cutoff adjustment and the Specifications

Margin Pressure adjustment influence each other.
Table 188
Whenever you adjust one pressure, always check the
other pressure and then make any necessary Pilot System Pressure Test
adjustment. Date Equipment ID Code

i05443350 Item Specification Actual

3100 ± 200 kPa

Pilot System Pressure - Test Charge Pressure (K)
(450 ± 29 psi)
and Adjust Pilot Pressure (HPS)
3050 ± 200 kPa
(442 ± 29 psi)
SMCS Code: 5050-025-PS; 5050-081-PS

Introduction
The oil for the pilot system comes from the charge
Personal injury or death can result from escaping pump for the fan system. So this test procedure will
fluid under pressure. be testing the pressure of the charge pressure and
the pilot pressure.
Escaping fluid under pressure, even a very small
pin-hole size leak, can penetrate body tissue and Required Tools
cause serious injury and possible death. If fluid is
injected into your skin, it must be treated immedi-
ately by a doctor familiar with this type of injury.
Always use a board or cardboard when checking
for a leak.

Always replace the floorplate when performing

tests.
Perform tests with oil temperature below 66 deg c
(150 deg f) to prevent serious burns.
Do not hold pressure gauges in your hand or lap
when checking pressure readings. Illustration 432 g02571852
Tooling (A) 198-4240 Digital Pressure Indicator Gp

NOTICE Table 189

Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte- Required Tools
nance, testing, adjusting, and repair of the product.
Be prepared to collect the fluid with suitable contain- Tool Item Qty Part No Description
ers before opening any compartment or disassem- Digital Pressure Indi-
bling any component containing fluids. A 198-4240
cator Gp

Refer to Special Publication, NENG2500, “Dealer A1 1 198-4234 Digital Indicator

Service Tool Catalog” for tools and supplies suitable
to collect and contain fluids on Cat products. Pressure Sensor Gp
A2 1 198-4239 (0 to 41,368 kPa (0 to
Dispose of all fluids according to local regulations 6,000 psi))
and mandates.
A3 1 198-4236 Adapter Cable As

Test Preparation
1. Move the machine to a smooth, horizontal location
that is away from operating machines and away
from personnel.
KENR5631-05 433
Testing and Adjusting

2. Permit only one operator on the machine. Keep all

other personnel away from the machine or in the
sight of the operator.
3. Place the steering and transmission control lever
in the NEUTRAL position.
4. Engage the parking brake.
5. Lower the attachments to the ground.
6. Stop the engine.
7. Turn the key to the ON position, but do not start the
engine.
8. Verify that the implement shutoff control is in the
UNLOCKED position. Illustration 434 g03451102

9. Move the control levers through the full range of 2. Loosen locknut (1) while holding adjustment screw
travel several times. This will relieve any pressure (2) in place.
that may be present in the implement hydraulic
system. 3. Turn adjustment screw (2) clockwise in order to
increase the cutoff pressure. Turn adjustment
10. Make sure that the pressure in the entire screw (2) counterclockwise in order to decrease
hydraulic system has been released. the cutoff pressure.
11. Open the access door on the right side of the 4. Repeat the steps in “Test Procedure” in order to
machine. check the charge pressure.
5. After the pressure is adjusted within the specified
limit, tighten locknut (1). Make sure that you hold
adjustment screw (2) in place.
6. Check the pressure at port (K) again. When the
pressure is at the specified limit, the adjustment
procedure is complete.

Pilot System Pressure Test

Preparation
1. Move the machine to a smooth, horizontal location
that is away from operating machines and away
from personnel.
Illustration 433 g03450316 2. Permit only one operator on the machine. Keep all
other personnel away from the machine or in the
12. Attach Tooling (A) to pressure tap (K) located on sight of the operator.
the oil filter base.
3. Place the steering and transmission control lever
Test Procedure in the NEUTRAL position.
1. Start the engine and run the engine at high idle. 4. Engage the parking brake.

2. Check the pressure of the charge pump (K). The 5. Lower the attachments to the ground.
pressure should be 3100 ± 200 kPa (450 ± 29 psi) 6. Stop the engine.
.
7. Turn the key to the ON position, but do not start the
Adjustment Procedure engine.
1. Remove the floorplate from the machine. 8. Verify that the implement shutoff control is in the
UNLOCKED position.
434 KENR5631-05
Testing and Adjusting

9. Move the control levers through the full range of 5077-PS

travel several times. This will relieve any pressure
that may be present in the implement hydraulic
system.
Hot hydraulic oil under high pressure can remain
10. Make sure that the pressure in the entire in the components of the hydraulic system or the
hydraulic system has been released. power train system after the engine has been
stopped. The uncontrolled release of the hydraul-
11. Remove the floorplate from the machine. ic oil can cause sudden machine movement and
can also result in the following conditions:

• Burns
• The penetration of body tissue

• Other personal injury

• Death
If hydraulic oil penetrates body tissue, the injury
must be treated immediately by a doctor who is
familiar with this type of injury. Use a board or a
piece of cardboard to check for a hydraulic oil
leak. Make sure that all of the attachments have
been lowered to the ground and that all trapped
pressure has been released from the hydraulic
Illustration 435 g03450680 system and the power train system. Also, make
sure that the hydraulic oil is cool before the re-
12. Attach Tooling (A) to pressure tap (HPS). moval of any components or lines. Remove the
hydraulic oil filler cap only when the engine is
13. Install the floorplate. stopped and the filler cap is cool enough to touch
with your bare hand.
Pilot System Pressure Test
1. Start the engine and run the engine at high idle. NOTICE
Care must be taken to ensure that fluids are con-
2. Check the pressure of the hydraulic pilot supply tained during performance of inspection, mainte-
(HPS). The pressure should be 3050 ± 200 kPa nance, testing, adjusting, and repair of the product.
(442 ± 29 psi). Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
Adjusting the Pilot System bling any component containing fluids.
Pressure Refer to Special Publication, NENG2500, “Dealer
Pilot pressure is controlled by the charge pump so Service Tool Catalog” for tools and supplies suitable
perform the steps in “Adjustment Procedure”. to collect and contain fluids on Cat products.
Dispose of all fluids according to local regulations
i05755229 and mandates.

Accumulator (Pilot) - Test and

Charge
SMCS Code: 5077-081; 5077-045; 5077-036-PS;
5077-081-PS; 5077-045-PS; 5077-081-PX; 5077;
KENR5631-05 435
Testing and Adjusting

Specifications Table 191

D10T Test for the accumulator pressure
Date Equipment ID Code
Dry nitrogen is the only gas approved for use in Item Specification Actual
the accumulator. Charging the accumulator with
oxygen gas will cause an explosion. This danger Engine speed High Idle
will not happen if nitrogen cylinders with stand-
Accumulator Charge 3100 ± 200 kPa
ard CGA (Compressed Gas Association, Inc.)
Pressure (450 ± 29 psi)
Number 580 connections are used. When you or-
der nitrogen gas, be sure that the cylinders are
equipped with CGA No. 580 Connections. Do not
use color codes or other methods of identifica- Introduction
tion to tell the difference between nitrogen and The accumulator stores hydraulic oil pressure that
oxygen cylinders. can be used to lower the implements when the
engine is off. The accumulator is located on the pilot
Nitrogen gas pressure varies with the temperature. manifold.
To obtain the most accurate nitrogen charge, the
temperature of the accumulator must be identical to The following procedure will determine if the
the air temperature around the accumulator. accumulator for the pilot system is charged to the
appropriate pressure.
Note: Adjust the pressure for ambient conditions, as
required. Refer to the following table for the Required Tools
accumulator precharge pressure/temperature
relationship.
Table 190
Charging Pressure for the Accumulator at Different
Temperatures

Temperature Pressure

−40° C (−40° F) 811 kPa (118 psi)

−34.4° C (−30° F) 833 kPa (121 psi)

−28.9° C (−20° F) 854 kPa (124 psi)

−23.3° C (−10° F) 876 kPa (127 psi)

−17.8° C (0° F) 898 kPa (130 psi)

−12.2° C (10° F) 920 kPa (133 psi) Illustration 436 g02726620

Tooling (B)
−6.7° C (20° F) 941 kPa (137 psi)
Table 192
−1.1° C (30° F) 963 kPa (140 psi)
Part
4.4° C (40° F) 985 kPa (143 psi) Tool Item Qty Description
Number
10° C (50° F) 1007 kPa (146 psi) Pressure Gauge
B1 1 8T-0855
(0 to 4,000 kPa (0 to 580 psi))
15.6° C (60° F) 1028 kPa (149 psi)
B2 1 6V-3989 Fitting
21.1° C (70° F) 1050 kPa (152 psi) B
B3 2 6V-4143 Quick Connect Coupler
26.7° C (80° F) 1072 kPa (155 psi)
B4 1 177-7860 Hose As (10 ft)
32.2° C (90° F) 1093 kPa (159 psi)

37.8° C (100° F) 1115 kPa (162 psi)

Test Preparation
43.3° C (110° F) 1137 kPa (165 psi)
1. Move the machine to a smooth horizontal location.
48.9° C (120° F) 1159 kPa (168 psi)
2. Place the steering control lever in the NEUTRAL
54.4° C (130° F) 1180 kPa (171 psi)
position.
60° C (140° F) 1202 kPa (174 psi)
3. Engage the parking brake.
436 KENR5631-05
Testing and Adjusting

4. Lower the attachments to the ground. 4. Stop the engine. Turn the key to the ON position
but do not start the machine.
5. Stop the engine.
5. With the implement lockout switch in the
6. Turn the key to the ON position, but do not start the
UNLOCKED position, record the pressure reading
engine.
at pressure tap (AP).
7. Verify that the implement lockout switch is in the
6. The pressure reading should not drop more than
UNLOCKED position.
700 kPa (101 psi) in 2 minutes. If a pressure drop
8. Move the control levers through the full range of greater than 700 kPa (101 psi) occurs, the pilot oil
travel several times. This will relieve any pressure system should be checked for excessive leakage.
that may be present in the implement hydraulic
system. Adjustment Procedure - Pressure
9. Make sure that the pressure in the entire hydraulic Leak Down
system has been released. There are no adjustments that can be made to
reduce pressure leaks in the system. Investigate the
10. Turn the key to the OFF position. components of the charging system to determine the
cause of the system leakage.
11. Remove the floorplate from the machine.
12. Locate the pressure test port on the accumulator Test Procedure (Accumulator
manifold. Charge Pressure)
1. Complete steps in “Test Preparation” then continue
with step 2.
2. Start the engine. Warm the hydraulic oil to a
minimum temperature of 65° C (150° F).
3. Operate the engine at HIGH IDLE.
4. Exercise the implement hydraulics. At the
accumulator, the pilot pressure at tooling (AP)
should be 3100 ± 200 kPa (450 ± 29 psi).
5. Shut off the engine. Turn the key to the ON
position. The accumulator charge pressure should
remain steady until an implement control is
exercised.
Illustration 437 g03450157
(1) Accumulator for the fan system 6. With the implement lockout switch in the
(2) Accumulator for the implement system UNLOCKED position, move the implement control
(HPS) Pressure port for pilot supply pressure after the pilot shutoff out of the HOLD position in any direction in order
valve
(AP) Pressure port for pilot supply pressure to actuate a function. Return the handle to the hold
position between activations of the handle. Quick
Note: This test will only test the accumulator for the movement of the handle should increase the
implement system (2). In order to test the accuracy of this test.
accumulator for the fan system (1), the accumulators
must be switched. 7. With the handle in the HOLD position between
activations, record the reading on tooling (B).
13. Attach tooling (B) to pressure port (AP) on the 8. Repeat Step 6 and Step ,7 recording the reading
accumulator manifold. each time the handle is returned to the HOLD
position until the pressure reading at tooling (B) is
Test Procedure - Accumulator Pilot zero.
Oil Pressure Leak Down
9. The last pressure reading recorded on tooling (B)
1. Complete steps in “Test Preparation” then continue is a close approximation of the nitrogen precharge
with step 2. in the accumulator.
2. Start the engine. Warm the hydraulic oil to a 10. Refer to Table 190 for the appropriate
minimum temperature of 65° C (150° F). accumulator charge.
3. Record the pressure reading on pressure tap (AP).
KENR5631-05 437
Testing and Adjusting

11. If the precharge of the original accumulator is out (Table 193, contd)
of the specifications, the accumulator will need to Machine Flow Rate Pressure Setting
be replaced. The replacement accumulator has a Configuration
charging valve and may be charged if needed.
Standard 38 ± 2 L/min 28200 ± 500 kPa
(10.0 ± 0.5 US gpm) (4090 ± 73 psi)
Charging Procedure - Accumulator
Actual
Charge Flow and Pressure
1. Refer to Special Instruction, REHS5464,
“Accumulator Discharging and Charging
Procedures”.

Illustration 439 g03478496

Table 194
Illustration 438 g01947173
D6T Torque Specifications
(5) Cap
(6) Charging valve Item Torque
(7) Accumulator
Relief Valve (2) 203 ± 20 N·m (150 ± 15 lb ft)
2. The accumulator is located on the pilot manifold. Locknut (4) 12 ± 1 N·m (106 ± 9 lb in)
Charging valve (6) is located on the top of the
accumulator under the cap (5).
Introduction
Note: Do not attempt to charge the accumulator until
all pressure has been removed from the pilot The main relief valve for the hydraulic system is
accumulator. located in the inlet manifold on the main control
valve. The main relief valve is not adjustable on
the machine.
3. When all of the adjustments are complete, remove
all tooling and reinstall all guards. The following procedure will determine if the main
relief valve is out of adjustment.
i05499174
Required Tools
Relief Valve (Main) - Test Table 195
Required Tools
SMCS Code: 5069-081; 5069-081-PX; 5117-081-
PX; 5117-081 Tooling Part Number Description Qty

Test Block
Specifications A 1U-9358
Manifold
1

Table 193
Main Relief Valve

Date Equipment ID Code

(continued)
438 KENR5631-05
Testing and Adjusting

Test Procedure Adjustment Procedure

Illustration 440 g03478496 Illustration 441 g03478496

Location of the implement main relief valve Implement main relief valve
(1) Inlet manifold (2) Main relief valve
(2) Main relief valve (3) Retainer
(4) Locknut
Note: The implement valve stack is mounted under
the right side of the operator platform. The main relief 1. Loosen locknut (4).
valve is located on the left side of the inlet manifold
2. Turn retainer (3) clockwise in order to increase the
near the bottom.
pressure setting and turn the retainer
1. Remove the main relief valve (2) from the inlet counterclockwise in order to decrease the
manifold (1). pressure setting.
2. Install the main relief valve (2) in the 1U-9358 3. After setting the pressure, tighten locknut (4) to a
Test Manifold Block tooling (A) in order to test the torque of 12 ± 1 N·m (106 ± 9 lb in).
relief valve on the test bench. Tighten the main
relief valve to a torque of 203 ± 20 N·m
(150 ± 15 lb ft).

Note: The implement main relief valve has a setting

that is higher than the pump cutoff pressure. The
pressure setting for the main relief valve should be
28200 ± 500 kPa (4090 ± 73 psi).
KENR5631-05 439
Testing and Adjusting

4. Install the main relief valve (2) back into the

machine. Tighten the main relief valve to a torque
of 203 ± 20 N·m (150 ± 15 lb ft).

i05505749

Hydraulic Fan Speed (On

Demand) - Test and Adjust
SMCS Code: 1386-081-VF; 1386-025-VF; 1386-036;
1387-025-PX; 1387-081-PX; 1387-036

Hydraulic oil pressure can remain in the hydraulic

system on this machine after the engine and
pump have been stopped. Serious injury can re-
sult if this pressure is not released before any
service is done on the hydraulic systems. In order
to prevent possible injury, release the hydraulic
system pressure before working on any fitting,
hose, or hydraulic component.
Lower all attachments to the ground before serv-
ice is started. If the hydraulic system must be
serviced, tested, or adjusted with the attachment
in the raised position, the attachments and lift
cylinders must be supported properly.
Always move the machine to a location away
from the travel of other machines. Be sure that
other personnel are not near the machine when
the engine is running and tests or adjustments
are being made.

NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting, and repair of the machine.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
bling any component containing fluids.
Dispose of all fluids according to local regulations
and mandates.

Specifications
Table 196
D10T Test for Fan Pump

Date Product

Item Specification Actual

Engine speed High idle

Pressure Override Valve 29000 ± 1000 kPa (4206 ± 145 psi) Bench Test Value

Crossover Relief and Makeup Valve 32000 ± 1000 kPa (4641 ± 145 psi) Bench Test Value
440 KENR5631-05
Testing and Adjusting

Introduction 5. Stop the engine.

This test will help the technician determine if the 6. Turn the key to the ON position, but do not start the
pump is providing the correct pressure to the fan engine.
system.
7. Verify that the implement lockout switch is in the
This procedure includes the following tests and
UNLOCKED position.
the following adjustment procedures:
8. Move the control levers through the full range of
• “Test Procedure (POR Valve)” travel several times. This will relieve any pressure
• “Bench Test Procedure (Crossover Relief and that may be present in the implement hydraulic
Makeup Valve)” system.

• “Adjustment Procedure (POR Valve)” 9. Make sure that the pressure in the entire hydraulic
system has been released.
• “Adjustment Procedure (Crossover Relief and
10. Turn the key to the OFF position.
Makeup Valve)”

Required Tools

Illustration 443 g03354361

(1) Pressure override valve (POR)
(2) Crossover relief valves (COR)
Illustration 442 g02571852
Tooling (A) 198-4240 Digital Pressure Indicator Gp 11. Locate pressure relief valve (1) and crossover
Table 197 relief valves (2).
Required Tools 12. Connect Tooling (A) to pressure taps (FMA) and
(FMB).
Tool Item Qty Part No Description
13. Connect Cat ® Electronic Technician (Cat ET)
Digital Pressure Indi-
A 198-4240 Service Tool to the communication port in the
cator Gp
operator station.
A1 1 198-4234 Digital Indicator

Pressure Sensor Gp
Test Procedure (POR Valve)
A2 2 198-4239 (0 to 41,368 kPa (0 to 1. Start the engine. Warm the hydraulic oil to a
6,000 psi))
minimum of 65° C (150° F).
A3 2 198-4236 Adapter Cable As 2. Engage the parking brake.
B 1 9U-5829 Manifold 3. Operate the engine at LOW idle.
4. Make sure that all controls are in the HOLD
Test Preparation position.
1. Move the machine to a smooth horizontal location.
2. Place the control levers in the NEUTRAL position.
3. Engage the parking brake.
4. Lower the attachments to the ground.
KENR5631-05 441
Testing and Adjusting

Illustration 444 g02354856 Illustration 446 g02762525

5. Initialize Cat ET. Select the "Service" tab at the top 7. Make sure that there is a check mark on the line
of the screen. Select "Calibrations" from the drop- with "Engine Cooling Fan Maximum Speed". Click
down menu. the "Begin" button.

Illustration 447 g02354898

Illustration 445 g03490245

6. Highlight the "Engine Cooling Fan Calibration" and

select the "Start" button near the bottom of the
page.

Illustration 448 g02354896

8. Follow the on-screen prompts until you can use the

"increment and decrement" buttons near the
bottom of the screen.
442 KENR5631-05
Testing and Adjusting

9. Make a note of the Amperage value before you 4. Turn adjustment screw (3) in a clockwise direction
begin the test. When the test is complete, set the in order to increase the pressure setting. Turn
Amperage back to the original value before adjustment screw (3) counterclockwise in order to
conducting any further tests. decrease the pressure setting.
10. Slowly "Decrement" the Amperage until the slider 5. Tighten locknut (4) while you hold adjustment
bar is all the way to the left. screw (3) in place.
11. Check the pressure at Tooling (A). The pressure 6. Perform the Steps in “Test Procedure (POR Valve)”
for the POR valve should be 29000 ± 1000 kPa in order to check the pressure setting.
(4206 ± 145 psi)
7. When the pressure is within the specified limit, the
12. If the pressure is not within the specified limit, adjustment procedure is complete.
perform the procedure in “Adjustment Procedure
(POR Valve)”. Bench Test Procedure (Crossover
Relief and Makeup Valve)
Adjustment Procedure (POR Valve)
The crossover relief and makeup valve has a setting
that is higher than the main relief valve for the
steering. The valve cannot be adjusted on the
machine.
1. Install the crossover relief and makeup valve into
tooling (B).
2. The setting for the valve is 32000 ± 1000 kPa
(4641 ± 145 psi) under the following conditions:

• SAE 10W hydraulic oil

• 65°C (150°F)

• Flow rate between 20 to 100 L/min

(5 to 26 gpm)
Illustration 449 g03354361
(1) Pressure override valve (POR)
(2) Crossover relief valves (COR)
Adjustment Procedure (Crossover
Relief and Makeup Valve)
1. Locate pressure relief valve (1).
Note: The crossover relief and makeup valve cannot
2. Make sure that the engine is off. be adjusted on the machine. Use the following
procedure to adjust this valve.
If the crossover relief and makeup valve is not within
the specifications, use the adjustment screw to
change the pressure setting until the specifications
are met.

Illustration 450 g03489498

3. Loosen locknut (4) while you hold adjustment

screw (3) in place.
KENR5631-05 443
Testing and Adjusting

i05509731

Resolver Network - Test

SMCS Code: 5050-081

Illustration 452 g03486257

(2) Ripper Lift Control Valve
(3) Blade Tilt Control Valve (Right)
(4) Blade Lift Control Valve (Right)
(5) Blade Lift Control Valve (Left)
(6) Blade Tilt Control Valve (Left)
(7) Ripper Shank Control Valve
Illustration 451 g02501778

Resolver (1) is located on all implement control

valves except the first valve section of the signal
resolver network. See Illustration 451 . In this case,
the ripper lift control valve does not have a resolver.
The resolver compares two pressures. The lower
pressure of the two pressures is blocked. The higher
pressure or the higher signal goes to the next
component in the resolver network.
Each implement control valve has a resolver except
the first valve section of the signal resolver network.
The resolver compares the highest primary signal in
the control valve to the highest primary signal in the
next control valve. The signal resolver network is
arranged in a series. The series stops at the pump
compensator valves of the dual load sensing pumps.
The signal network can be easily checked. Start the
engine and warm up the oil. Run the engine at HIGH
IDLE for the check. Operate each control lever in the
following order:
1. Ripper Lift
2. Blade Tilt (Right)
3. Blade Lift
4. Blade Tilt (Left)
5. Ripper Shank
If one or more valve sections fail to work correctly,
the resolver that is in the valve section that is closest
to the pump that malfunctions may be bad.
444 KENR5631-05
Testing and Adjusting

When any resolver is suspected of being bad, do the (Table 198, contd)
following check. Stall any control valve that is closer Item Specification Actual
to the pump supply. The resolver should supply pump
stall pressure to the entire system. Try to use the D10T2 3088 ± 215 kPa
malfunctioning valve. If the malfunctioning valve Relief Valve (Trans- (448 ± 31 psi)
works properly, the resolver may be bad. If the valve mission) - LOW
does not work properly, the problem is not a resolver IDLE at Pressure
problem. If a resolver is bad, remove the resolver. Tap (P)
Check the seals and the resolver. Clean the resolver
or replace the resolver. The seals may be failed if the
stall pressure is not met on the machine. Introduction
The main relief valve for the transmission maintains
i05569670
the maximum pressure of the oil that is delivered to
the transmission clutches by the transmission
Relief Valve (Transmission) - modulating valves. Also, the main relief valve
protects the transmission hydraulic system from any
Test high-pressure spikes.
SMCS Code: 4095-081 The following test procedure will verify whether the
pressure setting is within the specified limit. The
adjustment procedure provides the information that is
needed to adjust the main relief valve to the specified
Hydraulic oil pressure can remain in the hydraulic limit.
system on this machine after the engine and
pump have been stopped. Serious injury can re- Required Tools
sult if this pressure is not released before any
service is done on the hydraulic systems. In order
to prevent possible injury, release the hydraulic
system pressure before working on any fitting,
hose, or hydraulic component.
Lower all attachments to the ground before serv-
ice is started. If the hydraulic system must be
serviced, tested, or adjusted with the attachment
in the raised position, the attachments and lift
cylinders must be supported properly.
Always move the machine to a location away
from the travel of other machines. Be sure that
other personnel are not near the machine when
the engine is running and tests or adjustments
are being made.
Illustration 453 g02571852
Tooling (A) 198-4240 Digital Pressure Indicator Gp
NOTICE
Care must be taken to ensure that fluids are con- Table 199
tained during performance of inspection, mainte-
nance, testing, adjusting, and repair of the machine. Required Tools
Be prepared to collect the fluid with suitable contain- Qty Description
Tool Item Part No
ers before opening any compartment or disassem-
bling any component containing fluids. Digital Pressure Indi-
A 198-4240
cator Gp
Dispose of all fluids according to local regulations
and mandates. A1 1 198-4234 Digital Indicator

Pressure Sensor Gp
A2 1 198-4237 (0 to3,445 kPa (0 to
Specifications 500 psi))
Table 198
A3 1 198-4236 Adapter Cable As
D10T2 Relief Valve (Transmission) - Test

Date Product or Component SN Reference: Refer to Tool Operating Manual,

NEHS0818, “Using the 198-4240 Digital Pressure
Indicator Group” for more information on using
(continued) Tooling (A).
KENR5631-05 445
Testing and Adjusting

Machine Preparation 4. If the pressure at tooling (A) is not within the

specified limit, replace the relief valve.
1. Move the machine to a smooth horizontal location.
2. Lower all of the implements. i05573514

3. Shut off the engine.

Relief Valve (Torque Converter
4. Turn the key to the ON position. Make sure that the
implement lockout switch is turned to the
Inlet) Pressure - Test
UNLOCKED position. Move the implement control SMCS Code: 3133-081-PX; 3133-081; 3133-081-IL
levers to all positions several times in order to
release any pressure in the hydraulic system.

Hydraulic oil pressure can remain in the hydraulic

system on this machine after the engine and
pump have been stopped. Serious injury can re-
sult if this pressure is not released before any
service is done on the hydraulic systems. In order
to prevent possible injury, release the hydraulic
system pressure before working on any fitting,
hose, or hydraulic component.
Lower all attachments to the ground before serv-
ice is started. If the hydraulic system must be
serviced, tested, or adjusted with the attachment
in the raised position, the attachments and lift
cylinders must be supported properly.
Always move the machine to a location away
Illustration 454 g03532499 from the travel of other machines. Be sure that
(P) Pressure Tap for the Transmission Main Relief Valve other personnel are not near the machine when
the engine is running and tests or adjustments
5. Locate pressure tap (P) on the machine. Pressure are being made.
tap (P) is located on the rear left-hand side of the
transmission..
NOTICE
6. Attach tooling (A) to pressure tap (P). Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting, and repair of the machine.
Test Procedure Be prepared to collect the fluid with suitable contain-
1. Start the engine. Warm the power train oil to a ers before opening any compartment or disassem-
minimum temperature of 84° ± 8°C (183° ± 14°F). bling any component containing fluids.

2. Operate the engine at LOW IDLE. Make sure that Dispose of all fluids according to local regulations
the steering control lever is in the NEUTRAL and mandates.
position and that all brakes are in the OFF
position. Specifications
3. Check the pressure at tooling (A). The pressure at Table 200
tooling (A) should be 3088 ± 215 kPa
D10T2 Pressure Test for the Torque Converter Inlet
(448 ± 31 psi). Relief Valve
Date Product or Component SN

Item Specification Actual

INLET RELIEF - Less than

HIGH IDLE with the 965 ± 70 kPa
parking brake en- (140 ± 10 psi)
gaged at Pressure
Tap (M)
446 KENR5631-05
Testing and Adjusting

Introduction 5. Turn the key to the ON position. Make sure that the
The torque converter inlet relief valve limits the implement lockout switch is turned to the
maximum pressure to the torque converter section of UNLOCKED position. Move the implement control
the torque divider. The torque converter inlet relief levers to all positions several times in order to
valve also prevents damage to the torque converter release any pressure in the hydraulic system.
when the engine is started and the power train oil is
cold.
The following test will check the maximum pressure
of the power train oil that is delivered to the torque
converter section of the torque divider. The pressure
setting of the torque converter inlet relief valve is not
adjustable.

Required Tools

Illustration 456 g03534697

(M) Torque Converter Inlet Pressure

6. Attach tooling (A) to pressure tap (M).

Test Procedure
1. Do not warm the power train oil.

Illustration 455 g02571852 2. Start the engine.

Tooling (A) 198-4240 Digital Pressure Indicator Gp Note: You will only achieve these results if the power
Table 201
train oil is less than 40 °C (104 °F).

Required Tools 3. Make sure that the steering control lever is in the
NEUTRAL position and the parking brake is
Tool Item Qty Part No Description
engaged. Operate the engine starting at LOW
Digital Pressure Indi- IDLE and slowly increase the engine rpm to HIGH
A 198-4240
cator Gp IDLE.
A1 1 198-4234 Digital Indicator 4. Watch the pressure at Tooling (A). The pressure
Pressure Sensor Gp should rise with the engine rpm. The pressure
A2 1 198-4237 (0 to3,445 kPa (0 to should not exceed 965 ± 70 kPa (140 ± 10 psi).
500 psi))
5. Continue raising the engine rpm until reaching
A3 1 198-4236 Adapter Cable As HIGH IDLE.
6. The torque converter inlet relief valve is not
Reference: Refer to Tool Operating Manual, adjustable. If the pressure continues to rise above
NEHS0818, “Using the 198-4240 Digital Pressure 965 ± 70 kPa (140 ± 10 psi), replace the relief
Indicator Group” for more information on using valve.
Tooling (A).

Machine Preparation
1. Move the machine to a smooth horizontal location.
2. Lower all of the implements.
3. Shut off the engine.
4. Engage the parking brake.
KENR5631-05 447
Testing and Adjusting

Note: The torque converter inlet relief valve is (Table 202, contd)
located under the lubrication distribution manifold on Torque Converter 400 ± 60 kPa
the front of the main case. Outlet Relief Valve (58 ± 9 psi)
- HIGH IDLE at
i05574989 Pressure Tap(N)
with the machine in
Relief Valve (Torque Converter THIRD GEAR FOR-
WARD position
Outlet) Pressure - Test and while holding the
service brakes
Adjust engaged

SMCS Code: 3133-036-OL Torque Converter 300 ± 70 kPa

Outlet Relief Valve (44 ± 10 psi)
- LOW IDLE at
Pressure Tap (N)
with the parking
Hydraulic oil pressure can remain in the hydraulic brake engaged
system on this machine after the engine and
pump have been stopped. Serious injury can re-
sult if this pressure is not released before any
service is done on the hydraulic systems. In order
Introduction
to prevent possible injury, release the hydraulic The torque converter outlet relief valve maintains a
system pressure before working on any fitting, minimum pressure in the torque converter.
hose, or hydraulic component.
The following test procedure will verify whether the
Lower all attachments to the ground before serv- pressure setting is within the specified range. The
ice is started. If the hydraulic system must be pressure setting may be adjusted by adding or
serviced, tested, or adjusted with the attachment removing shims.
in the raised position, the attachments and lift
cylinders must be supported properly. Required Tools
Always move the machine to a location away
from the travel of other machines. Be sure that
other personnel are not near the machine when
the engine is running and tests or adjustments
are being made.

NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting, and repair of the machine.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
bling any component containing fluids.
Dispose of all fluids according to local regulations
and mandates. Illustration 457 g02571852
Tooling (A) 198-4240 Digital Pressure Indicator Gp
Specifications Table 203
Table 202 Required Tools
D10T2 Torque Converter Outlet Relief Valve (Pressure Test) Qty Description
Tool Item Part No
Date Product or Component SN Digital Pressure Indi-
A 198-4240
Item Specification Actual cator Gp

A1 1 198-4234 Digital Indicator

(continued) Pressure Sensor Gp

A2 1 198-4237 (0 to3,445 kPa (0 to
500 psi))

A3 1 198-4236 Adapter Cable As

448 KENR5631-05
Testing and Adjusting

Reference: Refer to Tool Operating Manual, 3. Check the pressure at tooling (A). The pressure at
NEHS0818, “Using the 198-4240 Digital Pressure tooling (A) should be 400 ± 60 kPa (58 ± 9 psi).
Indicator Group” for more information on using
Tooling (A). 4. Operate the engine at LOW IDLE. Make sure that
the transmission is in the NEUTRAL position with
Test Preparation the parking brake engaged.
1. Move the machine to a smooth horizontal location. 5. Check the pressure at tooling (A). The pressure at
tooling (A) should be 300 ± 70 kPa (44 ± 10 psi).
2. Lower all of the implements.
6. If the pressure at tooling (A) is not within the
3. Shut off the engine.
specified range, perform the following adjustment
4. Turn the key to the ON position. Make sure that the procedure.
implement lockout switch is turned to the
UNLOCKED position. Move the implement control Adjustment Procedure
levers to all positions several times in order to
release any pressure in the hydraulic system.

Illustration 459 g03535444

(1) Torque converter outlet relief valve
(2) Torque converter
Illustration 458 g03535199
(N) Outlet relief valve pressure tap
(1) Torque converter outlet relief valve
(2) Torque converter
(N) Outlet relief valve pressure tap 1. Torque converter outlet relief valve (1) is located
on torque converter (2).
5. Attach tooling (A) to pressure tap (N) on torque
converter outlet relief valve (1). The torque
converter outlet relief valve (1) is located on torque
converter (2).

Test Procedure
1. Start the engine. Warm the power train oil to
84° ± 8°C (183° ± 14°F).
2. Operate the engine at HIGH IDLE. Place the
machine in the THIRD GEAR FORWARD position
while holding the service brakes engaged.
Note: Do not stall the transmission for more than 30
seconds at a time.
KENR5631-05 449
Testing and Adjusting

Illustration 460 g03539276

Torque converter outlet relief valve
(3) 5M-9622 Shim increases the pressure (5) 5M-9624 Shim increases the pressure
42 kPa (6.10 psi) 6.9 kPa (1.00 psi)
(4) 5M-9623 Shim increases the pressure (6) Bolts and washers
23 kPa (3.4 psi) (7) Cover

2. Remove bolts and washers (6). Remove cover (7)

in order to gain access to shims (3), (4), and (5).
3. Add one shim (3), (4), or (5) to increase the
pressure setting or remove one shim (3), (4), or (5)
to decrease the pressure setting.
Reference: Refer to the procedures in Disassembly
and Assembly, “Torque Converter Outlet Relief Valve”
for more information.
4. Reassemble the torque converter outlet relief
valve.
5. Perform Step 1 through Step 6 in “Test Procedure”
in order to check the pressure at tooling (A).
450 KENR5631-05
Testing and Adjusting

6. If the pressure is at the specified limit, the test is

complete.
Dry nitrogen is the only gas approved for use in
i05556195 the accumulator. Charging the accumulator with
oxygen gas will cause an explosion. This danger
Accumulator (Power Train) - will not happen if nitrogen cylinders with stand-
ard CGA (Compressed Gas Association, Inc.)
Test and Charge Number 580 connections are used. When you or-
der nitrogen gas, be sure that the cylinders are
SMCS Code: 5077-036-PWT; 5077-081-PWT; 5077- equipped with CGA No. 580 Connections. Do not
045-PWT use color codes or other methods of identifica-
tion to tell the difference between nitrogen and
oxygen cylinders.

Hot hydraulic oil under high pressure can remain

in the components of the hydraulic system or the Specifications
power train system after the engine has been Table 204
stopped. The uncontrolled release of the hydraul-
Charging Pressure for the Accumulator at Different Oil
ic oil can cause sudden machine movement and
can also result in the following conditions: Temperatures

Temperature Pressure
• Burns
−7° C (20° F) 1550 kPa (225 psi)
• The penetration of body tissue
−1° C (30° F) 1587 kPa (230 psi)
• Other personal injury
4° C (40° F) 1618 kPa (235 psi)
• Death 10° C (50° F) 1656 kPa (240 psi)
If hydraulic oil penetrates body tissue, the injury 16 °C (60 °F) 1690 kPa (245 psi)
must be treated immediately by a doctor who is
familiar with this type of injury. Use a board or a 21 °C (70 °F) 1725 kPa (250 psi)
piece of cardboard to check for a hydraulic oil
leak. Make sure that all of the attachments have 27 °C (80 °F) 1760 kPa (255 psi)
been lowered to the ground and that all trapped
32° C (90° F) 1790 kPa (260 psi)
pressure has been released from the hydraulic
system and the power train system. Also, make 38° C (100° F) 1830 kPa (265 psi)
sure that the hydraulic oil is cool before the re-
moval of any components or lines. Remove the
hydraulic oil filler cap only when the engine is Introduction
stopped and the filler cap is cool enough to touch
with your bare hand. The accumulator supplements power train oil flow in
low flow conditions. The accumulator is located
underneath the fuel tank at the back of the machine.
NOTICE The following procedure will determine if the
Care must be taken to ensure that fluids are con- accumulator for the power train is charged to the
tained during performance of inspection, mainte- appropriate pressure.
nance, testing, adjusting, and repair of the product.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem- Test Preparation
bling any component containing fluids. 1. Move the machine to a smooth horizontal location.
Refer to Special Publication, NENG2500, “Dealer 2. Lower all of the implements.
Service Tool Catalog” for tools and supplies suitable
to collect and contain fluids on Cat products. 3. Shut off the engine.
Dispose of all fluids according to local regulations 4. Turn the key to the ON position. Make sure that the
and mandates. implement lockout switch is turned to the
UNLOCKED position. Move the implement control
levers to all positions several times in order to
release any pressure in the hydraulic system.
KENR5631-05 451
Testing and Adjusting

Test Procedure 3. When all of the adjustments are complete, remove

all tooling and reinstall all guards.
1. There is no onboard test for the nitrogen
precharge pressure in the accumulator.
i05584316

Charging Procedure - Accumulator

Transmission Lubrication Oil
Charge
Pressure - Test
1. Refer to Special Instruction, REHS5464,
“Accumulator Discharging and Charging SMCS Code: 3030-081-PX; 3080-081-PX; 3080-
Procedures”. 032-PX

Hydraulic oil pressure can remain in the hydraulic

system on this machine after the engine and
pump have been stopped. Serious injury can re-
sult if this pressure is not released before any
service is done on the hydraulic systems. In order
to prevent possible injury, release the hydraulic
system pressure before working on any fitting,
hose, or hydraulic component.
Lower all attachments to the ground before serv-
ice is started. If the hydraulic system must be
serviced, tested, or adjusted with the attachment
in the raised position, the attachments and lift
cylinders must be supported properly.
Always move the machine to a location away
from the travel of other machines. Be sure that
other personnel are not near the machine when
the engine is running and tests or adjustments
are being made.

Illustration 461 g02517596

(1) Accumulator NOTICE
(2) Charging valve Care must be taken to ensure that fluids are con-
(3) Protector tained during performance of inspection, mainte-
nance, testing, adjusting, and repair of the machine.
2. Accumulator (1) is located underneath the fuel Be prepared to collect the fluid with suitable contain-
tank at the back of the machine. Charging valve ers before opening any compartment or disassem-
(2) is located on the top of the accumulator. bling any component containing fluids.
Dispose of all fluids according to local regulations
Note: Do not attempt to charge the accumulator until and mandates.
all pressure has been removed from the power train
accumulator.
Specifications
Table 205
D10T2 Pressure Test for Transmission Lubrication Oil
Date Product or Component SN

Item Specification Actual

Transmission Lu- 145 ± 35 kPa

brication - HIGH (21 ± 5 psi)
IDLE at Pressure
Tap (L1) With All
Brakes In the OFF
Position

(continued)
452 KENR5631-05
Testing and Adjusting

(Table 205, contd) Reference: Refer to Tool Operating Manual,

D10T2 Pressure Test for Transmission Lubrication Oil NEHS0818, “Using the 198-4240 Digital Pressure
Indicator Group” for more information on using
Transmission Lu- 20 ± 10 kPa Tooling (A).
brication - LOW (3 ± 1.5 psi)
IDLE at Pressure
Tap (L1) With All
Test Preparation - Transmission
Brakes In the OFF Lubrication
Position
1. Move the machine to a smooth horizontal location.
Lubrication Distri- 185 ± 35 kPa
bution Manifold - (27 ± 5 psi) 2. Lower all of the implements. Engage the parking
HIGH IDLE at Pres- brake. Turn the engine OFF.
sure Tap (L2) With
All Brakes In the
OFF Position
Lubrication Distri- 45 ± 20 kPa
bution Manifold - (6.5 ± 3 psi)
LOW IDLE at Pres-
sure Tap (L2) With
All Brakes In the
OFF Position

Introduction
The following test will determine whether the
pressure of the transmission lubrication oil is at the
specified limit. This oil is delivered from the power
train oil cooler to the lubrication distribution manifold.

Required Tools

Illustration 463 g03545732

(L1) Pressure Tap ( “L1” )

3. Locate pressure tap (L1) on the machine. Pressure

tap (L1) is located on the back of the transmission.
4. Attach tooling (A) to pressure port (L1).

Test Procedure - Transmission

Lubrication
Illustration 462 g02571852
1. Start the engine. Warm the power train oil to a
Tooling (A) 198-4240 Digital Pressure Indicator Gp minimum temperature of 84° ± 8°C (183° ± 14°F).
Table 206 2. Operate the engine at HIGH IDLE. Make sure that
Required Tools all brakes are in the OFF position.

Tool Item Qty Part No Description 3. Check the pressure at tooling (A). The pressure at
tooling (A) should be 145 ± 35 kPa
Digital Pressure Indi- (21.03080 ± 5.07640 psi).
A 198-4240
cator Gp
4. Operate the engine at LOW IDLE. Make sure that
A1 1 198-4234 Digital Indicator
all brakes are in the OFF position.
Pressure Sensor Gp
A2 1 198-4237 (0 to 3,445 kPa (0 to
5. Check the pressure at tooling (A). The pressure at
500 psi)) tooling (A) should be 20 ± 10 kPa (3 ± 1.5 psi).

A3 1 198-4236 Adapter Cable As

KENR5631-05 453
Testing and Adjusting

Test Preparation - Lubrication 5. Check the pressure at tooling (A). The pressure at
Distribution Manifold tooling (A) should be 45 ± 20 kPa (they6.5 ± 3 psi)
.
1. Move the machine to a smooth horizontal location.
i05800685
2. Lower all of the implements. Engage the parking
brake. Turn the engine OFF.
Steering Clutch and Brake
Pressure - Test
SMCS Code: 4102-081-PX; 4120-081-PX

Hydraulic oil pressure can remain in the hydraulic

system on this machine after the engine and
pump have been stopped. Serious injury can re-
sult if this pressure is not released before any
service is done on the hydraulic systems. In order
to prevent possible injury, release the hydraulic
system pressure before working on any fitting,
hose, or hydraulic component.
Lower all attachments to the ground before serv-
ice is started. If the hydraulic system must be
serviced, tested, or adjusted with the attachment
in the raised position, the attachments and lift
cylinders must be supported properly.
Always move the machine to a location away
Illustration 464 g03547796 from the travel of other machines. Be sure that
other personnel are not near the machine when
(1) Lubrication Distribution Manifold the engine is running and tests or adjustments
(L2) Pressure Tap
are being made.
3. Locate pressure tap (L2) on lubrication distribution
manifold (1). Lubrication distribution manifold (1) is NOTICE
located on the front of the main case inside the Care must be taken to ensure that fluids are con-
right-hand frame. tained during performance of inspection, mainte-
nance, testing, adjusting, and repair of the machine.
4. Attach tooling (A) to pressure port (L2). Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
Test Procedure - Lubrication bling any component containing fluids.
Distribution Manifold Dispose of all fluids according to local regulations
and mandates.
1. Start the engine. Warm the power train oil to a
minimum temperature of 84° ± 8°C (183° ± 14°F).
2. Operate the engine at HIGH IDLE. Make sure that Specifications
all brakes are in the OFF position. Table 207
3. Check the pressure at tooling (A). The pressure at D10T2 Steering Clutch and Brake (Pressure Test)
tooling (A) should be 185 ± 35 kPa (27 ± 5 psi). Date Product or Component SN
4. Operate the engine at LOW IDLE. Make sure that Item Specification Actual
all brakes are in the OFF position.

(continued)
454 KENR5631-05
Testing and Adjusting

(Table 207, contd) Introduction

Right-hand steer- 2345 ± 138 kPa The following test will determine the pressure of the
ing clutch pressure (340 ± 20 psi) oil that is metered out to the steering clutches and the
- HIGH IDLE at brakes.
pressure tap (C2)
with the parking
brake disengaged
Required Tools
Right-hand steer- Less than 30 kPa
ing clutch pressure (4 psi)
- HIGH IDLE at
pressure tap (C2)
with the parking
brake disengaged
and the hand con-
trol engaged for a
right-hand turn

Left-hand steering 2345 ± 138 kPa

clutch pressure - (340 ± 20 psi)
HIGH IDLE at pres-
sure tap (C1) with
the parking brake
disengaged
Illustration 465 g02571852
Left-hand steering Less than 30 kPa
clutch pressure - (4 psi)
Tooling (A) 198-4240 Digital Pressure Indicator Gp
HIGH IDLE at pres-
Table 208
sure tap (C2) with
the parking brake Required Tools
disengaged and
the hand control Tool Item Qty Part No Description
engaged for a left-
hand turn Digital Pressure Indi-
A 198-4240
cator Gp
Right-hand brake 2893 ± 215 kPa
pressure - HIGH (420 ± 31 psi) A1 1 198-4234 Digital Indicator
IDLE at pressure
tap (B2) with the Pressure Sensor Gp
parking brake A2 1 198-4237 (0 to3,445 kPa (0 to
disengaged 500 psi))

Right-hand brake 224 ± 121 kPa A3 1 198-4236 Adapter Cable As

pressure - HIGH (33 ± 18 psi)
IDLE at pressure
tap (B2) with the Reference: Refer to Tool Operating Manual,
parking brake dis- NEHS0818, “Using the 198-4240 Digital Pressure
engaged and the Indicator Group” for more information on using
right-hand brake Tooling (A).
on the hand control
engaged Test Preparation - Steering Clutch
Left-hand brake 2893 ± 215 kPa Pressures
pressure - HIGH (420 ± 31 psi)
IDLE at pressure 1. Move the machine to a smooth horizontal location.
tap (B1) with the
parking brake
2. Lower all of the implements.
disengaged 3. Shut off the engine.
Left-hand brake 224 ± 121 kPa
4. Turn the key to the ON position. Make sure that the
pressure - HIGH (33 ± 18 psi)
IDLE at pressure implement lockout switch is turned to the
tap (B1) with the UNLOCKED position. Move the implement control
parking brake dis- levers to all positions several times in order to
engaged and the release any pressure in the hydraulic system.
left-hand brake on
the hand control
engaged
KENR5631-05 455
Testing and Adjusting

Note: Due to the Neutral default strategy, during

start-up of the tractor, the service brakes will
automatically be applied for 10 seconds in order for
the power train to stabilize. If the parking brake is
released within the first 10 seconds, and the tractor is
not shifted into gear, the service brakes will remain
applied until the parking brake switch is cycled after
the 10 second period. The Neutral default strategy
will also cause the service brakes to remain applied if
the power train oil is below 40° C (104° F).

8. Engage the hand control for a right turn by pulling

the right steering clutch and brake control back to
the first detent. Check the pressure at Tooling (A)
for the right steering clutch. The pressure at
Tooling (A) should be less than 30 kPa (4 psi).
9. Repeat the tests for pressure tap (C1) for the left-
hand steering clutch.

Test Preparation - Brake Pressures

Illustration 466 g03543003 1. Move the machine to a smooth horizontal location.
(1) Steering clutch and brake control valve
(C1) Left-hand steering clutch
2. Lower all of the implements.
(C2) Right-hand steering clutch
3. Shut off the engine.
5. Attach Tooling (A) to pressure tap (C2) on steering 4. Turn the key to the ON position. Make sure that the
clutch and brake control valve (1). Steering clutch implement lockout switch is turned to the
and brake control valve (1) is located on the rear UNLOCKED position. Move the implement control
of the machine on top of the transmission. levers to all positions several times in order to
release any pressure in the hydraulic system.
Test Procedure - Steering Clutch
Pressures
1. Start the engine. Warm the power train oil to
84° ± 8°C (183° ± 14°F).
2. Operate the engine at HIGH IDLE.
3. Place the transmission direction selector in
NEUTRAL.
4. Fully depress the service brake pedal.
5. Release the parking brake.
6. Slowly release the service brake pedal. The tractor
should not move.
7. Check the pressure at Tooling (A) for the right
steering clutch. The pressure at Tooling (A) should
be 2345 ± 138 kPa (340 ± 20 psi). There will be
no steering clutch pressure if the parking break is
engaged.

Illustration 467 g03543176

(1) Steering clutch and brake control valve
(B1) Left-hand brake clutch
(B2) Right-hand brake clutch
456 KENR5631-05
Testing and Adjusting

5. Attach Tooling (A) to pressure tap (B2) on steering 10. Repeat the test for pressure tap (B1) for the left-
clutch and brake control valve (1). Steering clutch hand brake.
and brake control valve (1) is located on the rear
of the machine on top of the transmission. i05590033

Test Procedure - Brake Pressures Engagement Pressure for

1. .Start the engine. Warm the power train oil to Transmission Clutch - Test
84° ± 8°C (183° ± 14°F).
SMCS Code: 3167-081
2. Operate the engine at HIGH IDLE.
3. Place the transmission direction selector in
NEUTRAL.
Hydraulic oil pressure can remain in the hydraulic
4. Fully depress the service brake pedal. system on this machine after the engine and
pump have been stopped. Serious injury can re-
5. Release the parking brake. sult if this pressure is not released before any
service is done on the hydraulic systems. In order
6. Slowly release the service brake pedal. The tractor to prevent possible injury, release the hydraulic
should not move. system pressure before working on any fitting,
hose, or hydraulic component.
7. Check the pressure at Tooling (A). The pressure at
Tooling (A) should be 2893 ± 215 kPa Lower all attachments to the ground before serv-
(420 ± 31 psi). ice is started. If the hydraulic system must be
serviced, tested, or adjusted with the attachment
Note: Due to the Neutral default strategy, during in the raised position, the attachments and lift
start-up of the tractor, the service brakes will cylinders must be supported properly.
automatically be applied for 10 seconds in order for
the power train to stabilize. If the parking brake is Always move the machine to a location away
released within the first 10 seconds, and the tractor is from the travel of other machines. Be sure that
not shifted into gear, the service brakes will remain other personnel are not near the machine when
the engine is running and tests or adjustments
applied until the parking brake switch is cycled after are being made.
the 10 second period. The Neutral default strategy
will also cause the service brakes to remain applied if
the power train oil is below 40° C (104° F).
NOTICE
Care must be taken to ensure that fluids are con-
8. Apply the right-hand brake on the hand control by tained during performance of inspection, mainte-
pulling the right steering clutch and brake control nance, testing, adjusting, and repair of the machine.
completely to the rear. Check the pressure at Be prepared to collect the fluid with suitable contain-
Tooling (A). The pressure at Tooling (A) should be ers before opening any compartment or disassem-
224 ± 121 kPa (33 ± 18 psi). bling any component containing fluids.

9. Fully depress the service brake pedal in order to Dispose of all fluids according to local regulations
apply both brakes. Check the pressure at Tooling and mandates.
(A). The pressure at Tooling (A) should be less
than 30 kPa (4 psi).
Specifications
Table 209
Specifications

Item Transmission Clutch Specification Actual

Clutch Engagement at Relief Pressure Setting of 2988 ± 215 kPa
No. 1 Clutch (433 ± 31 psi)
the Transmission at LOW IDLE

Clutch Engagement at Relief Pressure Setting of 2988 ± 215 kPa

No. 2 Clutch (433 ± 31 psi)
the Transmission at LOW IDLE

(continued)
KENR5631-05 457
Testing and Adjusting

(Table 209, contd)

Specifications

Item Transmission Clutch Specification Actual

Clutch Engagement at Relief Pressure Setting of 2988 ± 215 kPa
No. 3 Clutch (433 ± 31 psi)
the Transmission at LOW IDLE

Clutch Engagement at Relief Pressure Setting of 2988 ± 215 kPa

No. 4 Clutch (433 ± 31 psi)
the Transmission at LOW IDLE

Clutch Engagement at Relief Pressure Setting of 2422 ± 260 kPa

No. 5 Clutch (351 ± 38 psi)
the Transmission at LOW IDLE

Table 210
Checklist for Transmission Clutch Pressures

Transmission Speed Transmission Pressure Transmission Pressure

Clutch Measurement Clutch Measurement
FIRST SPEED FORWARD No. 2 Clutch No. 5 Clutch
SECOND SPEED FORWARD No. 2 Clutch No. 4 Clutch
THIRD SPEED FORWARD No. 2 Clutch No. 3 Clutch
NEUTRAL No. 3 Clutch N/A
FIRST SPEED REVERSE No. 1 Clutch No. 5 Clutch
SECOND SPEED REVERSE No. 1 Clutch No. 4 Clutch
THIRD SPEED REVERSE No. 1 Clutch No. 3 Clutch

Introduction Table 211

The following test will determine the pressures that Required Tools
are being delivered to each individual transmission
clutch. Tool Item Qty Part No Description
Digital Pressure Indi-
Required Tools A 198-4240
cator Gp

A1 1 198-4234 Digital Indicator

Pressure Sensor Gp
A2 1 198-4237 (0 to3,445 kPa (0 to
500 psi))

A3 1 198-4236 Adapter Cable As

Reference: Refer to Tool Operating Manual,

NEHS0818, “Using the 198-4240 Digital Pressure
Indicator Group” for more information on using
Tooling (A).

Test Preparation
Illustration 468 g02571852 1. Move the machine to a smooth horizontal location.
Tooling (A) 198-4240 Digital Pressure Indicator Gp 2. Place the steering control lever in the NEUTRAL
position.
3. Engage the parking brake.
4. Lower the attachments to the ground.
5. Stop the engine.
458 KENR5631-05
Testing and Adjusting

8. Run the hydraulic hoses from tooling (A) into the

cab.

Test Procedure
1. Start the engine. Warm the power train oil to a
minimum temperature of 84° ± 8°C (183° ± 14°F).
2. Operate the engine at LOW IDLE. Move the
machine with the steering control lever in the
FIRST SPEED FORWARD position.
3. Check the pressure at Tooling (A) for the No. 2
clutch. The pressure at Tooling (A) for the No. 2
clutch should be 2988 ± 215 kPa (433 ± 31 psi).
4. Check the pressure at Tooling (A) for the No. 5
clutch. The pressure at Tooling (A) for the No. 5
clutch should be 2422 ± 260 kPa (351 ± 38 psi).
5. Use Table 210 in order to check all of the other
combination of clutches. Record the pressure
measurements in Table 210 .
Illustration 469 g03548403
(1) Bolts i05460591
(2) Cover

6. Remove bolts (1) and remove cover (2) from the

Ladder System Pressure - Test
machine. and Adjust
SMCS Code: 7254-081; 7254-025

Specifications
Table 212
Ladder System Pressure Test

Date Equipment ID Code

Item Specification Actual

20684 kPa
Ladder Raise (LC2)
(3000 psi)

20684 kPa
Ladder Lower (LC1)
(3000 psi)

Introduction
The ladder system is controlled by an electronic
pump. This pump output is controlled by a relief valve
that can only be tested by stalling the pump.

Illustration 470 g03549516

(CL1) Pressure Tap (No. 1 Clutch)
(CL2) Pressure Tap (No. 2 Clutch)
(CL3) Pressure Tap (No. 3 Clutch)
(CL4) Pressure Tap (No. 4 Clutch)
(CL5) Pressure Tap (No. 5 Clutch)

7. Attach Tooling (A) to pressure tap (CL2) and

Tooling (A) to pressure tap (CL5). Pressure tap
(CL2) is for No. 2 Clutch (FORWARD). Pressure
tap (CL5) is for No. 5 Clutch (FIRST SPEED).
KENR5631-05 459
Testing and Adjusting

Required Tools 10. Make sure that the pressure in the entire
hydraulic system has been released.

Illustration 471 g02571852

Tooling (A) 198-4240 Digital Pressure Indicator Gp Illustration 472 g03449883
Located on the left hand fender
Table 213
(LC1) Ladder Lower Pressure
Required Tools (LC2) Ladder Raise Pressure

Tool Item Qty Part No Description

11. Attach Tooling (A) to pressure taps (LC1) and
Digital Pressure Indi- (LC2).
A 198-4240
cator Gp

A1 1 198-4234 Digital Indicator

Test Procedure
Pressure Sensor Gp
1. Start the engine. Warm the hydraulic oil to a
A2 1 198-4239 (0 to 41,368 kPa (0 to minimum temperature of 65° C (150° F).
6,000 psi))
2. Operate the engine at HIGH IDLE.
A3 1 198-4236 Adapter Cable As
3. With the ladder in the full RAISE position, give a
raise command to stall the pump.
Test Preparation 4. Record the pressure at pressure tap (LC2). The
stall pressure should be 20684 kPa (3000 psi).
1. Move the machine to a smooth, horizontal location
that is away from operating machines and away 5. With the ladder in the full LOWER position, give a
from personnel. lower command to stall the pump.
2. Permit only one operator on the machine. Keep all 6. Record the pressure at pressure tap (LC1). The
other personnel away from the machine or in the stall pressure should be 20684 kPa (3000 psi).
sight of the operator.
3. Place the steering and transmission control lever
in the NEUTRAL position.
4. Engage the parking brake.
5. Lower the attachments to the ground.
6. Stop the engine.
7. Turn the key to the ON position, but do not start the
engine.
8. Verify that the implement shutoff control is in the
UNLOCKED position.
9. Move the control levers through the full range of
travel several times. This will relieve any pressure
that may be present in the implement hydraulic
system.
460 KENR5631-05
Testing and Adjusting

Adjustment Procedure

Illustration 473 g03355419

Located under the floor plate on the left-hand side of
the frame.

1. Remove the cap to access the relief valve.

2. Turn the adjustment screw clockwise to increase
the pressure or counterclockwise in order to
decrease the pressure.

Note: ¼ of a turn will either increase or decrease the

pressure by about 689 kPa (100 psi).

3. Repeat the steps in “Test Procedure” in order to

check the pump pressure.
4. After the pressure is adjusted to the specified
pressure, replace the cap on the relief valve.
KENR5631-05 461
Index Section

Index
A Calibration Error Codes ..................................... 404
General Error Codes ...................................... 404
Access Ladder System ...................................... 390 Implement ECM Calibrations .......................... 409
Accumulator (Charged) .......................................49 Transmission ECM Calibrations ...................... 415
Accumulator (Pilot)............................................ 257 Transmission ECM Service Tests .................... 421
Accumulator (Pilot) - Test and Charge................. 434 Calibrations (Cat ET) ......................................... 402
Adjustment Procedure - Pressure Leak Down .. 436 Cat ET Calibration Screen .............................. 403
Charging Procedure - Accumulator Charge...... 437 Implement ECM Calibrations .......................... 403
Introduction ................................................... 435 Introduction ................................................... 402
Required Tools .............................................. 435 Required Tools .............................................. 402
Specifications ................................................ 435 Transmission ECM Calibrations ...................... 403
Test Preparation ............................................ 435 Case and Frame ........................................170, 172
Test Procedure - Accumulator Pilot Oil Pressure Charge Pump .....................................................26
Leak Down .................................................. 436 Check Valve .......................................................51
Test Procedure (Accumulator Charge Check Valve (Implement Back Pressure) ............ 262
Pressure) .................................................... 436 Control Manifold (Implement Lockout)................. 255
Accumulator (Power Train)................................. 339 Control Manifold (Pilot Oil) ...................................28
Accumulator (Power Train) - Test and Charge ..... 450 Control Valve ......................................................46
Charging Procedure - Accumulator Charge...... 451 Control Valve (Implement).................................. 234
Introduction ................................................... 450 Blade Control Valve FLOAT Position ............... 240
Specifications ................................................ 450 Blade Control Valve HOLD Position................. 235
Test Preparation ............................................ 450 Blade Control Valve PITCH Position ................ 246
Test Procedure .............................................. 451 Blade Control Valve RAISE Position ................ 237
Accumulator (Uncharged) ....................................48 Blade Control Valve TILT RIGHT Position (Dual
Additional Electrical Components ....................... 395 Tilt) ............................................................. 244
Access Ladder Sensor ................................... 397 Control Valve Solenoids ................................. 235
Backup Alarm ................................................ 396 Ripper Control Valve RAISE Position............... 249
Cylinder High Intensity Flood Light Relay......... 396 Ripper Control Valve SHANK IN Position ......... 252
Cylinder Low Intensity Flood Light Relay.......... 396 Cooling System................................................. 349
Fender Light Relay......................................... 396 Cooling System (Aftercooler, ATAAC) ................. 358
Forward ROPS Light Relay............................. 396 Air Flow......................................................... 359
Fuel Level Sensor .......................................... 398 Components.................................................. 358
Key Switch .................................................... 395 Counterweight Group ........................................ 192
Main Power Relay Driver ................................ 396 Cover (Cab)...................................................... 189
Master Light Switch........................................ 397 Cutting Edges and End Bits ........................... 89–93
Operator Presence Switch.............................. 395
Rear ROPS Light Relay.................................. 396
Ripper Light Relay ......................................... 396 D
Seatbelt Switch.............................................. 397
Timer Relay................................................... 395 Drive Shaft ....................................................... 132
Additional Information........................................ 390 Dust Ejector...................................................... 202
Air Cleaner ....................................................... 201
E
B Electric Drive Pump (Ladder) ............................. 195
Bank Valve (Five) ................................................30 Electronic Control (Fan Hydraulic System) .......... 269
Bank Valve (Six)..................................................32 Data Link....................................................... 272
Bevel and Transfer Gears .................................. 129 Electronic Control Modules ............................. 269
Bogie Suspension ......................................173, 175 Inputs ........................................................... 271
Breaker Relief Valve ............................................15 Pin Locations................................................. 270
Bulldozer Brace ..................................................87 Electronic Control (HVAC System)...................... 379
Bulldozer Dual Tilt Cylinder ..................................61 Data Link....................................................... 386
Bulldozer Installation ...........................................86 Electronic Control Modules ............................. 379
Bulldozer Lift Control Valve ..................................37 Inputs ........................................................... 381
Bulldozer Lift Cylinder.................................... 54–55 Outputs ......................................................... 384
Bulldozer Tilt Control Valve ..................................35 Pin Locations................................................. 380
Bulldozer Trunnion ..............................................88 Electronic Control (Hydraulic System)................. 209
Bypass Valve (Flushing) .................................... 282 Data Link....................................................... 219
Bypass Valve (Implement, Hydraulic Fan) .............33 Electronic Control Modules ............................. 209
Inputs ........................................................... 211
Outputs ......................................................... 217
C Pin Locations................................................. 210
Electronic Control (Power Train System) ............. 296
Cab.................................................................. 187 Data Link....................................................... 307
Cab Air Filter..................................................... 186
462 KENR5631-05
Index Section

Electronic Control Modules ............................. 296 Hydraulic System .............................................. 203

Inputs ........................................................... 298 Hydraulic Tank and Filter ............................. 13, 220
Outputs ......................................................... 305 Charge Filter ................................................. 222
Pin Locations................................................. 297 Hydraulic Tank............................................... 220
Electronic Control and Mounting (Ripper) ..............71
Engagement Pressure for Transmission Clutch
- Test .............................................................. 456 I
Introduction ................................................... 457 Idlers (Track) .............................. 157, 159, 161, 163
Required Tools .............................................. 457 Implement Hydraulic Pump ..................................19
Specifications ................................................ 456 Important Safety Information ..................................2
Test Preparation ............................................ 457 Inlet Manifold .................................................... 258
Test Procedure .............................................. 458 Operation of the Inlet Manifold ........................ 258
Engine Cooling System ..................................... 353
Components.................................................. 353
Coolant Flow ................................................. 355 J
Engine Oil Cooling System ................................ 357
Components and Engine Oil Flow ................... 357 Joystick Control (Bulldozer) ........................... 79–80
Coolant Flow ................................................. 358 Joystick Control and Mounting ..................74–75, 77
Equalizer Bar .............................................143, 368
Ether Starting Aid .............................................. 199
Expansion Tank ..................................................14 L
Ladder System Pressure - Test and Adjust .......... 458
Adjustment Procedure.................................... 460
F Introduction ................................................... 458
Fan Hydraulic System ....................................... 265 Required Tools .............................................. 459
Fan Motor...........................................................27 Specifications ................................................ 458
Fast Fill Fuel Adapter ........................................ 392 Test Preparation ............................................ 459
Filter (Power Train)..............................................52 Test Procedure .............................................. 459
Filters (Torque Converter and Transmission) ....... 114 Lines (Hydraulic Fan) ..........................................34
Final Drive ......................................... 136, 138, 344 Lines (Lift Cylinder) .............................................57
Final Drive Mounting ..................................141–142 Lines (Tilt Cylinder) .............................................62
Fuel Tank ..................................................193–194 Location of Components (Cooling System).......... 350
Cab Heater.................................................... 350
Engine Oil Cooler........................................... 352
G Hydraulic Demand Fan................................... 351
Hydraulic Oil Cooler ....................................... 351
Gear Pump (Power Train) ....................................20 NOx Reduction System (NRS) ........................ 352
General Information .......................................... 400 Power Train Oil Cooler ................................... 352
General Information (Cooling System) ................ 349 Radiator ........................................................ 351
General Information (Fan Hydraulic System) ....... 265 Shunt Tank .................................................... 351
General Information (HVAC System) .................. 374 Thermostat Housing....................................... 350
General Information (Hydraulic System).............. 203 Turbocharger................................................. 350
General Information (Power Train System).......... 283 Water Pump .................................................. 352
General Information (Undercarriage) .................. 361 Location of Components (Fan Hydraulic
Graphic Color Codes ......................................... 399 System) .......................................................... 267
Boost Pump .................................................. 267
H Charge Pump ................................................ 268
Fan Charging System Accumulator ................. 268
Heater and Air Conditioner................................. 182 Fan Motor ..................................................... 267
HVAC System ............................................374, 387 Fan Pump ..................................................... 267
HVAC System................................................ 387 Flushing Bypass Valve ................................... 268
Hydraulic Fan Speed (On Demand) - Test and High Efficiency Filter ...................................... 268
Adjust ............................................................. 439 Hydraulic Oil Temperature Sensor................... 269
Adjustment Procedure (Crossover Relief and Location of Components (HVAC System) ............ 376
Makeup Valve) ............................................. 442 Accumulator .................................................. 379
Adjustment Procedure (POR Valve) ................ 442 Air Conditioning Compressor .......................... 378
Bench Test Procedure (Crossover Relief and Air Conditioning Compressor Clutch ................ 377
Makeup Valve) ............................................. 442 Air Conditioning Switch .................................. 376
Introduction ................................................... 440 Blower Motor ................................................. 377
Required Tools .............................................. 440 Condenser .................................................... 378
Specifications ................................................ 439 Dryer ............................................................ 379
Test Preparation ............................................ 440 Evaporator Coil.............................................. 377
Test Procedure (POR Valve) ........................... 440 Heater Coil .................................................... 376
Hydraulic Oil Cooler .................................... 16, 264 High-Pressure Switch..................................... 378
Hydraulic Oil Cooling System ............................. 360 HVAC Control Panel....................................... 376
Components.................................................. 360 Louver Temperature Sensor ........................... 376
Oil Flow......................................................... 360 Low-Pressure Switch ..................................... 378
KENR5631-05 463
Index Section

Return Air Temperature Sensor....................... 377 Hydraulic Fan System (Maximum Fan Clip Speed
Water Valve Actuator...................................... 379 in the Forward Direction)............................... 275
Location of Components (Hydraulic System) ....... 205 Hydraulic Fan System (Maximum Fan Clip Speed
Accumulator .................................................. 207 in the Reverse Direction) .............................. 276
Charge Filter Bypass Switch ........................... 208 Hydraulic Fan System (Minimum Fan Speed) .. 273
Hydraulic Oil Cooler ....................................... 207
Hydraulic Oil Filter ......................................... 207
Hydraulic Oil Temperature Sensor................... 208 O
Hydraulic Tank............................................... 207 Oil Cooler (Power Train) .................................... 342
Hydraulic Tank Filter Bypass Switch ................ 208 Oil Filter (Power Train)....................................... 340
Implement Control Valves............................... 206 Operational Checks........................................... 424
Implement Controls........................................ 205 Initial Test...................................................... 425
Implement Pumps.......................................... 205 Introduction ................................................... 424
Pin Puller Cylinder and Valve .......................... 207 Specifications ................................................ 424
Location of Components (Power Train System) ... 285 Test Preparation ............................................ 424
Brake Pedal Switch........................................ 295 Test Procedures - Cycle Times........................ 425
Brakes .......................................................... 290 Test Procedures - Drift.................................... 425
Electronic Steering Clutch and Brake Control Operator Console.............................................. 185
Valve........................................................... 290 Operator Platform (Remote)............................... 191
Final Drive..................................................... 291
Operator Controls .......................................... 285
Parking Brake Switch ..................................... 294 P
Pin Puller Valve ............................................. 292
Power Train Accumulator ............................... 292 Pilot Oil Filter ......................................................53
Power Train ECM........................................... 292 Pilot System Pressure - Test and Adjust .............. 432
Power Train Filter Bypass Switch .................... 295 Adjusting the Pilot System Pressure ................ 434
Power Train Oil Coolers.................................. 288 Adjustment Procedure.................................... 433
Power Train Oil Fill Tube and Dipstick.............. 286 Introduction ................................................... 432
Power Train Oil Filters .................................... 291 Pilot System Pressure Test ............................. 434
Power Train Oil Level Sensor.......................... 294 Pilot System Pressure Test Preparation ........... 433
Power Train Oil Pump .................................... 286 Required Tools .............................................. 432
Service Brake Position Sensor........................ 294 Specifications ................................................ 432
Torque Converter Inlet Relief Valve ................. 287 Test Preparation ............................................ 432
Torque Converter Oil Temperature Sensor ....... 293 Test Procedure .............................................. 433
Torque Converter Outlet Relief Valve ............... 287 Pin Puller...................................................... 69–70
Torque Converter Speed Sensor ..................... 293 Pin Puller Control Valve .......................................50
Torque Divider ............................................... 287 Pin Puller Cylinder...............................................68
Transfer and Bevel Gears............................... 289 Pin Puller Hydraulic System ............................... 346
Transmission................................................. 288 Piston Motor (Fan Drive).................................... 280
Transmission Breather for the Power Train ...... 292 Piston Pump (Fan Drive).................................... 279
Transmission Hydraulic Control....................... 289 Fan Pump Components.................................. 279
Transmission Speed Sensors ......................... 293 Piston Pump.................................................. 279
Transmission Sump Temperature Sensor ........ 294 Piston Pump (Implement) .................................. 223
Location of Components (Undercarriage)............ 363 Constant Flow ............................................... 232
Equalizer Bar................................................. 364 Destroke ....................................................... 230
Major Bogies ................................................. 365 High Pressure Stall ........................................ 233
Minor Bogies ................................................. 365 Low Pressure Standby ................................... 226
Pivot Shaft..................................................... 365 Upstroke ....................................................... 228
Sprocket Segments........................................ 365 Piston Pump (Implement) - Test and Adjust ......... 426
Track Idler ..................................................... 364 Adjustment Procedures - Left Pump ................ 429
Track Roller................................................... 363 Adjustment Procedures - Right Pump .............. 430
Track Roller Frame ........................................ 363 Introduction ................................................... 427
Tracks........................................................... 364 Required Tools .............................................. 427
Specifications ................................................ 426
Test Preparation - Left Pump .......................... 428
M Test Preparation - Right Pump ........................ 429
Test Procedures - Left Pump........................... 428
Machine Preparation ......................................... 400 Test Procedures - Right Pump ........................ 430
Electrical Visual Inspection ............................. 402 Pivot Shaft ........................................................ 369
General Information ....................................... 400 Planetary Case and Parts .................................. 125
Hydraulic Visual Inspection............................. 401 Power Train Oil Cooling System ......................... 358
Power Train Visual Inspection ......................... 401 Components.................................................. 358
Procedure ..................................................... 401 Coolant Flow ................................................. 358
Warnings....................................................... 400 Power Train Oil Lines ........................................ 113
Modes of Operation (Fan Hydraulic System) ....... 272 Power Train Oil Pump.................................105, 326
Boost Pump and Cooler Bypass...................... 278 Power Train Oil Pump (Mounting) ....................... 108
Fan Motor Internal Flushing Valve ................... 277 Power Train System .......................................... 283
Pressure Control Valve ........................................45
464 KENR5631-05
Index Section

Pump Control Valve (Implement) ..........................47 Service Brakes Engaged ................................ 315
Pump Lines ........................................................17 Sharp Right Turn ........................................... 313
Push Arm ...........................................................83 Steering Clutch and Brake Pressure - Test .......... 453
Introduction ................................................... 454
Required Tools .............................................. 454
R Specifications ................................................ 453
Recoil Group..................................................... 148 Test Preparation - Brake Pressures ................. 455
Reference ........................................................ 399 Test Preparation - Steering Clutch Pressures ... 454
Refrigerant Compressor .............................177, 179 Test Procedure - Brake Pressures ................... 456
Refrigerant Condenser ...................................... 180 Test Procedure - Steering Clutch Pressures ..... 455
Relief Valve (Bulldozer) .......................................64 Steering Clutches and Brakes ............................ 134
Relief Valve (Main) - Test ................................... 437 Systems Operation Section................................ 203
Adjustment Procedure.................................... 438
Introduction ................................................... 437 T
Required Tools .............................................. 437
Specifications ................................................ 437 Table of Contents ..................................................3
Test Procedure .............................................. 438 Telescoping Recoil Frame.................................. 144
Relief Valve (Ripper)............................................67 Testing and Adjusting ........................................ 424
Relief Valve (Torque Converter Inlet)................... 110 Testing and Adjusting Section ............................ 400
Relief Valve (Torque Converter Inlet) Pressure - Tilt Cylinder (Ripper)............................................59
Test ................................................................ 445 Toggle Switch (Ground Level Shutdown)............. 198
Introduction ................................................... 446 Toggle Switch (Ladder) ...................................... 197
Machine Preparation ...................................... 446 Torque Converter .............................................. 101
Required Tools .............................................. 446 Torque Converter and Housing........................... 103
Specifications ................................................ 445 Torque Divider ...........................................104, 319
Test Procedure .............................................. 446 Components.................................................. 319
Relief Valve (Torque Converter Outlet) ................ 109 Torque Converter Inlet Relief Valve ................. 323
Relief Valve (Torque Converter Outlet) Pressure Torque Converter Operation ........................... 321
- Test and Adjust.............................................. 447 Torque Converter Outlet Relief Valve ............... 325
Adjustment Procedure.................................... 448 Torque Divider Lubrication .............................. 323
Introduction ................................................... 447 Torque Divider Operation................................ 322
Required Tools .............................................. 447 Track Carrier Roller ........................................... 151
Specifications ................................................ 447 Track Idler ........................................................ 370
Test Preparation ............................................ 448 Track Roller ...................................................... 371
Test Procedure .............................................. 448 Track Roller (Double Flange) ............................. 155
Relief Valve (Transmission) - Test....................... 444 Track Roller (Single Flange)............................... 153
Introduction ................................................... 444 Track Roller Frame............................................ 366
Machine Preparation ...................................... 445 Tracks ............................................... 165, 167, 372
Required Tools .............................................. 444 Transfer and Bevel Gears .................................. 338
Specifications ................................................ 444 Transmission .................................................... 327
Test Procedure .............................................. 445 Introduction ................................................... 327
Resolver Network - Test..................................... 443 Neutral Default Strategy ................................. 334
Ripper Control ....................................................72 Power Flow ................................................... 330
Ripper Frame................................................ 94, 96 Transmission Components ............................. 328
Ripper Lift Control Valve ......................................40 Transmission (Mounting) ................................... 115
Ripper Lift Cylinder..............................................65 Transmission (Planetary) ................................... 116
Ripper Mounting ......................................... 98–100 Transmission Hydraulic Control ................... 111, 335
Ripper Tip Control Valve ......................................42 Electronic Main Relief Valve............................ 337
Roller Frame Mounting ...................................... 146 Transmission Modulating Valves ..................... 336
ROPS Mounting ................................................ 190 Transmission Lubrication Oil Pressure - Test ....... 451
Introduction ................................................... 452
Required Tools .............................................. 452
S Specifications ................................................ 451
Signal Resolver Network.................................... 261 Test Preparation - Lubrication Distribution
Solenoid Valve (Bulldozer, Ripper)........................44 Manifold ...................................................... 453
Solenoid Valve (Steering Clutch, Brake).............. 126 Test Preparation - Transmission Lubrication..... 452
Solenoid Valve (Transmission Clutch) ................. 127 Test Procedure - Lubrication Distribution
Specifications Section ...........................................5 Manifold ...................................................... 453
Speed Sensor (Transmission Output) ................. 128 Test Procedure - Transmission Lubrication....... 452
Sprocket Segment............................................. 169 Transmission Oil Lines ...................................... 112
Stabilizer Link .....................................................85
Steering and Brake Control Valve ....................... 133 U
Steering and Transmission Control Group .............82
Steering Clutch and Brake Control Valve............. 308 Undercarriage................................................... 361
General Information ....................................... 308
Gradual Right Turn ........................................ 311
Parking Brake Engaged.................................. 317
KENR5631-05 465
Index Section

V
Valve Manifold (Inlet) ...........................................29

W
Window Wiper and Wiper Motor .............................5
Door ...............................................................10
Front.................................................................6
Rear .................................................................8
KENR5631 CAT, CATERPILLAR, their respective logos, “Caterpillar Yellow”, and the POWER EDGE trade
©2016 Caterpillar dress as well as corporate and product identity used herein, are trademarks of Caterpillar and
All Rights Reserved may not be used without permission.

466 February 2016