D8R - 7XM - TRANS..pdf

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Welcome: k260abc
Product: TRACK-TYPE TRACTOR
Model: D8R TRACK-TYPE TRACTOR 7XM00378
Configuration: D8R Track-Type Tractor 7XM00001-UP (MACHINE) POWERED BY 3406 Engine
Testing and Adjusting
D8R Track-Type Tractor Power Train
Media Number -SENR8326-04 Publication Date -01/09/2013 Date Updated -09/09/2013
i05426766
Testing and Adjusting
SMCS - 3000-036; 4000-036
Personal injury or death can result from sudden machine movement.
Sudden movement of the machine can cause injury to persons on or
near the machine.
Prevent possible injury by performing the procedure that follows before
working on the machine.
Move the machine to a smooth horizontal location. Move away from
working machines and personnel and lower the buckets or implements
(loader and backhoe) and stabilizers to the ground.
Permit only one operator on the machine. Keep all other personnel
away from machine or in view of the operator.
Engage the parking brake. Stop the engine.
Move the hydraulic control levers to all positions to release the pressure
in the hydraulic system.
Note: All tests and adjustments must be made with the oil in the power train hydraulic system at operating
temperature. Be sure that the linkage adjustments are correct before the tests are made.
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1. Move the machine to a smooth horizontal location. Move away from working machines and
personnel. Lower all implements to the ground.
2. Permit only one operator on the machine. Keep all personnel away from the machine or in the viewing
area of the operator.
3. Put blocks in the front of the tracks and behind the tracks.
4. The testing must be done in a closed area. If the test requires the parking brake to be disengaged,
engage the service brakes.
5. Stop the engine.
Procedure
When you are defining a power train hydraulic system problem, the following procedure should be used.
First, do visual checks. If the problem has not been identified, do the operation checks. If the problem is not
fully understood, do the instrument tests.
The procedures help to identify the power train hydraulic system problems. When the problem is defined, go
to the troubleshooting.
The troubleshooting section lists the probable causes of a known problem. Since there may be more than one
cause for a problem, the troubleshooting section may suggest specific instructions or instrument tests be
done.
The tests will help to identify the most probable cause.
This list cannot give all possible problems and corrections. The service personnel must find the problem and
the service personnel must locate the source of the problem. Then make the necessary repairs.
During a diagnosis of the power train hydraulic system, remember that correct oil flow and pressure are
necessary for correct operation.
The output of the pump increases with an increase in engine speed and decreases when the engine speed is
decreased. Oil pressure is caused by resistance to the flow of oil.
When more checks are necessary use the following tools: 8t-5320 Hydraulic Test Group , 4c-4890 Hydraulic
Test Group , 4c-4892 ORFS Fittings Group , stop watch, magnet, thermometer and ruler.
Visual Checks
Personal injury or death can result from improperly checking for a
leak.
Always use a board or cardboard when checking for a leak. Escaping
air or fluid under pressure, even a pin-hole size leak, can penetrate
body tissue causing serious injury, and possible death.
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If fluid is injected into your skin, it must be treated immediately by a
doctor familiar with this type of injury.
A visual inspection of the power train hydraulic system and the components of the system is the first step
when a diagnosis of a problem is made.
Stop the engine. Lower the blade and the ripper to the ground.
Make the following inspections:
1. Check all oil line connections for damage and leaks.
2. Follow all power train hydraulic system oil lines from the power train connections to the valve
connections.
Check the lines and connections for damage and leaks.
3. Check the power train control valves for leaks.
4. Follow the power train pump lines to the transmission sump and the main sump.
Check the lines, the transmission sump and the main sump for damage or leaks.
5. Check the transmission sump and the main sump oil level.
6. Remove the filter element. Check for particles that were removed from the oil by the filter element. A
magnet separates ferrous particles from nonferrous particles.
7. Inspect the control linkages for damaged components.
Troubleshooting
Problem Checklist
Transmission Problem List
1. The transmission does not operate in any speed. The transmission does not engage in all speeds.
2. The transmission does not make a shift.
3. Slow shifts
4. The transmission engages very suddenly. There is rough shifting.
5. The transmission operates in FORWARD speeds only.
6. The transmission operates in REVERSE speeds only.
7. The transmission does not operate in First speed FORWARD or REVERSE.
8. The transmission does not operate in Second speed FORWARD or REVERSE.
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9. The transmission does not operate in Third speed FORWARD or REVERSE.
10. The transmission does not disengage when the selection lever is in NEUTRAL.
11. The transmission engages but the machine does not move.
12. The transmission gets hot.
13. The pump noise is not normal.
Transmission
Problem 1: The transmission does not operate in any speed. The transmission does not engage in all
speeds.
Probable Cause:
1. There is low oil pressure that is caused by the following causes:
a. The oil level is low.
b. The control linkage is loose or the adjustment is not correct.
c. Failure of the oil pump or pump drive.
d. Air leaks on the inlet side of the pump.
e. Priority valve adjustment is not correct.
f. There is leakage inside the transmission.
g. Adjustment of the modulation relief valve is not correct, or the valve does not close.
h. The load piston or the differential valve operation is not correct.
2. There is a mechanical failure in the transmission.
3. There is a failure of the torque converter.
4. There is a failure of the transfer gears or the bevel gears.
5. There is a failure in the final drives.
Problem 2: The transmission does not make a shift.
Probable Cause:
1. The control linkage is loose or the adjustment is not correct.
2. The oil level is low.
3. The clutch pressures are low.
Problem 3: Slow shifts.
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Probable Cause:
1. Low oil pressure.
2. The adjustment of the control linkage is not correct.
3. Air leaks on the inlet side of the pump.
4. The load piston or the differential valve does not move.
Problem 4: The transmission engages very suddenly. There is rough shifting.
Probable Cause:
1. The Initial setting of the modulation relief valve is not correct.
2. The load piston or the differential valve does not move.
3. The valve springs are weak or the springs are damaged.
Problem 5: The transmission operates in FORWARD speeds only.
Probable Cause:
2. The No. 1 clutch is not engaged. The clutch slips due to the following causes:
a. Low oil pressure, or oil leakage.
b. Discs and plates have too much wear.
c. The clutch has parts that are broken.
Problem 6: The transmission operates in REVERSE speeds only.
Probable Cause:
a. Low oil pressure, or oil leakage.
Problem 7: The transmission does not operate in First speed FORWARD or REVERSE.
Probable Cause:
a. Low oil pressure or oil leakage.
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Problem 8: The transmission does not operate in Second speed FORWARD or REVERSE.
Probable Cause:
Problem 9: The transmission does not operate in Third speed FORWARD or REVERSE.
Probable Cause:
Problem 10: The transmission does not disengage when the selection lever is in NEUTRAL.
Probable Cause:
2. The direction clutch is engaged, and the clutch does not release.
Problem 11: The transmission engages but the machine does not move.
Probable Cause:
1. There is a failure in the final drives.
2. There is a failure in the steering clutches.
3. There is a failure in the transfer gears or the bevel gears.
4. Gears in the transmission will not move due to the following causes:
a. Too many clutches are engaged.
b. There is a mechanical failure in the transmission.
c. There is a mechanical failure in the torque divider or the torque converter.
Problem 12: The transmission gets hot.
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Probable Cause:
1. The oil level is low.
2. The oil level is high.
3. Cores of oil cooler not completely open.
4. Low oil flow as a result of pump wear.
5. Long periods of operation with converter at stall speed or near stall speed.
6. There is too much resistance between the plates and discs of the clutches.
Problem 13: There is a pump noise that is not normal.
Probable Cause:
1. There is loud sounds at short intervals. The sounds indicate that particles are going through the pump.
The sounds can be caused by pump cavitation.
2. A constant loud noise is an indication of pump failure.
3. There is air at the inlet side of the pump.
Schematic for the Power Train Hydraulic System
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Illustration 1 g00507741
Schematic for the Power Train Hydraulic System
(1) Selector and pressure control valve
(2) Torque converter
(3) Pump drive
(4) Torque converter outlet relief valve
(5) Cooler
(6) Breather
(7) Sump in torque converter housing
(8) Parking brake valve spool
(9) Service brakes with shuttle valves.
(10) Left brake lube section
(11) Right brake lube section
(12) Transmission lube
(13) Transmission
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(14) Sump
(15) Sump (transmission)
(16) Brake control valve
(17) Service brake spool
(18) Regulating relief valve
(19) Priority and makeup valve group
(20) Priority valve.
(21) Check valve
(22) Power train oil pump
(23) Transmission oil filter
(24) Load piston
(A) Torque converter inlet pressure tap (P3)
(B) Speed clutch pressure tap (P1)
(C) Direction clutch pressure tap (P2)
(E) Brake pressure tap
(F) Low pump pressure tap (torque converter charging pump)
(G) Priority valve pressure tap
(H) High pump pressure tap (transmission charging pump)
(J) Outlet from torque converter pressure tap
(A) Torque converter inlet (P3)
(B) Speed clutch (P1)
(C) Direction clutch (P2)
(D) Transmission lubrication
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(E) Brake
(F) Torque converter charging pump
(G) Priority valve
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D8R Track-Type Tractor 7XM00001-UP (MACHINE) POWERED BY 3406 Engine(S...
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(H) Transmission charging pump
Pressure Tap Locations
Many of the pressure taps have quick disconnect couplings that are installed. In order to prevent damage to
the seal in the coupling, do not connect or disconnect the couplings when there is pressure in the system.
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(J) Outlet from torque converter
(K) Brake lubrication
(L) Pump drive lubrication
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(LP) Load piston plug
Transmission Pressure Chart
Table 1
Transmission Pressure Chart
Pressure
Pressure
Tap
Low Idle High Idle Adjustment
Converter Inlet
Pressure (P3)
(A)
860 ± 140 kPa (125 ± 20
psi)
None
With cold oil the
value should be
1000 kPa (145 psi)
maximum.
Speed Clutch
(P1) (Initial
Pressure)
(B)
530 ± 35 kPa (77 ± 5 psi)
with the transmission
selector lever in
NEUTRAL Load piston
plug (LP) removed.
Add or remove
spacers (25) in load
piston (24) in
selector and
pressure control
valve (1) . See the
Spacer Chart.
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Speed Clutch
(P1)
(B) Maximum of
345 kPa (50 psi) less than
the pressure at HIGH
IDLE. Selection lever in
any FORWARD or
REVERSE speed. Load
piston plug (LP) installed
2620 ± 140 kPa (380 ± 20
psi) with the selector
lever in any FORWARD
or REVERSE speed.
Load piston plug (LP)
installed
None
Final pressure is
controlled by the
initial pressure
setting.
Direction
Clutch (P2)
(C)
380 ± 55 kPa (55 ± 8 psi)
less than the speed clutch
pressure at tap (B) . The
selector lever in any
FORWARD or
REVERSE speed. Load
piston plug (LP)
installed.
380 ± 55 kPa (55 ± 8 psi)
less than the speed clutch
pressure at tap (B) . The
selector lever in any
FORWARD or
REVERSE speed. Load
piston plug (LP) installed.
None
Direction clutch
pressure is
controlled by the
spring rate for the
pressure differential
valve spring.
Transmission
Lubrication Oil (D)
With brakes on
12 ± 11 kPa (1.7 ± 1.6
psi)
With brakes on.
160 ± 35 kPa (23 ± 5 psi) None
Brake Pressure
(E)
3170 ± 140 kPa (460 ± 20
psi) with brakes off. Less
than
70 kPa (10 psi) with
brakes on.
None
Low pressure
(torque
converter
charging) pump
(F) 965 ± 140 kPa (140 ± 20
psi)
Add or remove
spacers (26) in
regulating relief
valve (18) . See the
spacer chart.
Priority Valve
Setting
(G) 2760 kPa (400 psi)
minimum.
3275 ± 140 kPa (475 ± 20
psi)
Add or remove
spacers (27) in
priority valve (20) .
See the spacer
chart.
Transmission
Oil Pump
(H) 2840 kPa (410 psi)
minimum.
3170 ± 175 kPa (460 ± 25
psi)
Priority valve
Converter
Outlet Pressure (J)
415 ± 70 kPa (60 ± 10
psi) with the brakes on,
selector in THIRD
SPEED FORWARD, and
the converter in a stall
condition.
Add or remove
spacers (28) in
converter outlet
relief valve (4) . See
the spacer chart.
(K)
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Brake
Lubrication 200 ± 75 kPa (29 ± 11
psi) with brakes off.
140 ± 70 kPa (20 ± 10
psi) with brakes on.
Brakes off (priority
valve)
Brakes on (Check
linkage)
Pump drive
lubrication
(L)
With brakes on
310 ± 70 kPa (45 ± 10
psi)
With brakes on
620 ± 140 kPa (90 ± 20
psi)
None
Specifications for the Transmission Oil Pump Bench Test
For the bench test, use SAE 10W oil at 49°C (120°F).
Type ... Gear
Number of sections ... Three
Rotation (from drive end) ... Counterclockwise
Output of transmission charging section:
Minimum ... 72 L/min (19 US gpm)
Pump speed ... 1800 rpm
Pressure ... 2900 kPa (420 psi)
Output of torque converter charging section:
Output of transmission and torque converter scavenge section:
Spacer Chart
Table 2
Spacer Chart
Pressure Change To The Valves By Removal Or Addition Of One Spacer
Pt. No. For Spacer
Thickness
Change in Pressure
Component Used
(27)
5m9622
1.6 mm (0.063 inch)
208 kPa (30.2 psi)
Priority Valve (20)
(27) 5m9623
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.9 mm (0.035 inch) 116 kPa (16.8 psi)
(27) 5m9624
.25 mm (0.01 inch) 33 kPa (4.8 psi)
(26) 5m9622 1.6 mm (0.063 inch)
127 kPa (18 psi)
Regulating Relief Valve (18)
(26) 5m9623
.9 mm (0.035 inch) 71 kPa (10.3 psi)
(26) 5m9624
.25 mm (0.01 inch) 20 kPa (2.9 psi)
(25) 5m9622 1.6 mm (0.063 inch)
98 kPa (14.2 psi)
Load Piston (24)
(25) 5m9623
.9 mm (0.035 inch) 57 kPa (8.3 psi)
(25) 5m9624
.25 mm (0.01 inch) 16 kPa (2.3 psi)
(28) 5m9623
.9 mm (0.035 inch) 16.5 kPa (2.4 psi)
Converter Outlet Relief Valve (4)
Table 3
Transmission Selection Clutches Engaged In Transmission
Neutral 3
First Speed Forward 2 and 5
Second Speed Forward 2 and 4
Third Speed Forward 2 and 3
First Speed Reverse 1 and 5
Second Speed Reverse 1 and 4
Third Speed Reverse 1 and 3
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Converter Outlet Relief Valve
(4) Converter outlet relief valve
(28) Spacers
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Transmission Hydraulic Control Valve
(1) Body of selector and pressure control valve
(24) Load piston
(25) Spacers
Priority and Makeup Valve Group
(18) Regulating relief valve
(19) Priority and makeup valve group
(20) Priority valve
(26) Shims
(27) Shims
Linkage For Service Brake Pedal
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Personal injury or death can result from sudden machine movement.
Accidental disengagement of the parking brake or transmission
engagement while the engine is running can cause sudden machine
movement.
Do not make any adjustments to the control linkage with the engine
running.
Brake Pedal Linkage
(1) Brake valve spool
(3) Pin
(4) Rod end
(5) Spring
(6) Locknuts
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(7) Rod
(B) Rod assembly
(C) Rod assembly
Torque for all of the locknuts that hold the rod ends in place on the rod. ... 60 ± 12 N·m (44 ± 9 lb ft)
Note: All rod assembly measurements must be made in a straight line between the centerlines of the rod end
mounting holes.
(B) Assembled length of rod assembly (midrange reference) ... 935 mm (36.8 inch)
(C) Assembled length of rod assembly ... 410 ± 1.5 mm (16.14 ± 0.06 inch)
(D) Dimension (maximum) ... 37 mm (1.5 inch)
(E) Dimension (midrange reference) ... 41 mm (1.6 inch)
(F) Dimension ... 308 ± 17 mm (12.13 ± 0.67 inch)
Procedure To Adjust The Brake Pedal Linkage
Brake Pedal Linkage
(8) Adjusting bolt (upper stop)
(9) Locknut
1. Adjust rod assembly (C) to the specified length.
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2. Remove pin (3) in order to disconnect rod assembly (B) from brake spool (1) .
3. Adjust the position of the upper brake stop.
a. Adjust bolt (8) until spring (5) is extended 3 ± 1 mm (0.12 ± 0.04 inch). Turning bolt (8)
clockwise into the support stretched spring (5) .
b. Tighten locknut (9) .
4. Adjust the brake pedal position.
a. Release brake pedal (10) against the upper stop.
b. Index the pedal on the shaft spline and position the pedal to dimension (F) .
c. Tighten bolt (11) .
5. Adjust rod assembly (B) .
a. Release brake pedal (10) against the upper stop.
b. Loosen two locknuts (6) .
c. Push brake valve spool (1) all the way into brake control valve (2) . Hold the valve spool in
place.
Brake Pedal Linkage
(10) Brake pedal
(11) Bolt
(12) Adjusting bolt (lower stop)
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(13) Locknut
d. To adjust the length of rod assembly (B) , turn rod (7) while both rod ends are held from
turning. Adjust the rod assembly length in order to obtain a free fit of pin (3) with rod end (4)
and brake valve spool (1) . Then assemble pin (3) . If the rod assembly (B) is adjusted properly,
then the brake valve spool (1) will remain in the brake control valve (2) while the brake pedal is
against the upper stop.
e. Check maximum dimension (D) in two places in order to make sure that the dimension has not
been exceeded.
f. Tighten two locknuts (6) and assemble the cotter into pin (3) .
6. Adjust the lower stop for the brake pedal.
a. Depress brake pedal (10) until brake valve spool (1) reaches the maximum extension from brake
control valve (2) . Bolt (12) must be turned far enough into the support so that the brake pedal
will not contact bolt (12) at this time.
b. Turn the bolt counterclockwise until the bolt head contacts brake pedal (10) . Make sure that
brake valve spool (1) is at the maximum extension.
c. Release brake pedal (10) . Turn bolt (12) counterclockwise by an additional one-half turn.
d. Tighten locknut (13) .
Linkage For Parking Brake
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(1) Parking brake lever
(3) Parking brake valve spool
(4) Spring pin assembly
(5) Rod end
(6) Locknut
(7) Locknut
(8) Rod
(9) Rod end
(10) Spring pin assembly
(11) Rod end
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(12) Locknut
(13) Rod
(A) Rod assembly
(C) Dimension
(D) Dimension
(E) Dimension
Torque for all the locknuts that hold the rod ends in place on the rods. ... 25 ± 6 N·m (19 ± 4 lb ft)
Note: All rod assembly measurements must be made in a straight line between the centerlines of the rod end
mounting holes.
(1) Testing and Adjusting, "Hand Control Group"
(C) Dimension ... 15 ± 1.5 mm (0.59 ± 0.06 inch)
(D) Assembled length of rod assembly (midrange reference) ... 450 mm (17.7 inch)
(E) Dimension (maximum) ... 34 mm (1.34 inch)
Procedure To Adjust The Parking Brake Linkage
1. Engage the parking brake.
2. Adjust rod end (9) in order to obtain dimension (C) . The dimension is measured on rod (8) from the
end of the threads to the nut face on rod end (9) . Tighten locknut (7) and install spring pin assembly
(10) .
3. Remove spring assembly (4) .
4. Pull out parking brake valve spool (3) from brake control valve (2) to the stop for the spool.
5. Adjust the length of rod assembly (A) in order to obtain a free fit of spring pin assembly (4) with rod
end (5) and parking brake valve spool (3) . If rod assembly (A) is properly adjusted, the parking brake
valve spool must remain out from the brake valve against the stops for the spool while lever (1) is up
in the ENGAGED position.
6. Check dimension (E) from the end of the threads on rod (13) to the nut face on rod ends (5) and (11) .
Make sure that the dimension has not been exceeded. Tighten locknuts (6) and (12) .
Transmission Control Adjustments
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(1) Testing and Adjusting, "Hand Control Group"
Torque for all locknuts on cable assembly that hold the rod ends in place. ... 6 ± 1 N·m (53 ± 9 lb in)
Torque for all locknuts that fasten the cable assemblies to cover (17) and cover (20) . ... 38 ± 7 N·m (28 ± 5
lb ft)
(7) Dimension ... 12 ± 2 mm (0.47 ± 0.08 inch)
Forward/Reverse Assembly Procedure
1. Engage the parking brake.
2. At the transmission, move the transmission rotary selector spool to the NEUTRAL position.
3. Assemble cable (4) to the dimensions that are shown in View B-B.
4. Adjust cable (4) in order to allow the free fit of pin assembly (9) into the transmission bellcrank. To
adjust the cable, remove the bolts that hold cover (5) to the housing. Loosen the locknut that is on
cable (4) . Turn cover (5) , as required.
Speed Control Assembly Procedure
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1. Assemble cable (3) to the dimensions that are shown in View B-B.
2. At the transmission, move the transmission speed selector spool to the SECOND GEAR position.
3. Turn handle (2) to the SECOND GEAR position.
4. Adjust cable (3) in order to allow the free fit of pin assembly (10) into the transmission bellcrank. To
adjust the cable, remove the bolts that hold cover (6) to the housing. Loosen the locknut on cable (3)
and turn cover (6) , as required.
Hand Control Group
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Torque for all locknuts on cable assembly that hold the rod ends in place. ... 6 ± 1 N·m (53 ± 9 lb in)
Torque for the locknut that holds the swivel end ... 25 ± 6 N·m (18 ± 4 lb ft)
Torque for all locknuts on the cable assemblies ... 38 ± 7 N·m (28 ± 5 lb ft)
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(1) Apply 4c-4030 Thread Lock Compound to the threads on the parking brake lever.
(2) Apply lubricant to the inside of the handle.
(4) Dimension (two places) ... 15 ± 2 mm (0.6 ± 0.08 inch)
Ball joint assemblies:
Torque for both ball joint assemblies ... 8 ± 2 N·m (6 ± 1.5 lb ft)
(5) Dimension (two places) ... 16 ± 2 mm (0.63 ± 0.08 inch)
(6) Torque for rod end ... 8 ± 2 N·m (6 ± 1.5 lb ft)
(7) Torque for nut ... 8 ± 2 N·m (6 ± 1.5 lb ft)
(10) Torque for the screws that fasten the neutral start switch to the plate ... 0.5 ± .05 N·m (4.425 ± 0.442 lb
in)
Attach the green wire number 306 to the common post of the switch assembly. Attach the orange wire
number 307 to the normally open post of the switch assembly.
(11) Torque for the pin with 4c-4030 Thread Lock Compound ... 8 ± 2 N·m (6 ± 1.5 lb ft)
Apply lubricant to the rod assembly.
(12) Install the seal with the lip downward.
(13) 6y-2846 Spring
Length under test force ... 74.64 mm (2.939 inch)
Test force ... 626 N (140.7 lb)
Free length after test ... 79.92 mm (3.146 inch)
Outside diameter ... 20 mm (0.79 inch)
(14) 5n-6096 Spring
Length under test force ... 25.50 mm (1.004 inch)
Test force ... 19.57 N (4.400 lb)
Free length after test ... 48.77 mm (1.920 inch)
Outside diameter ... 13.82 mm (0.544 inch)
(15) Torque for the screws that fasten the backup switch to the plate ... 0.5 ± .05 N·m (4.425 ± 0.442 lb in)
Attach brown wire number 321 to the common post of the switch assembly and black wire number 200 to
the normally open post.
(16) Apply lubricant to the rod assembly.
(17) Apply 4c-4030 Thread Lock Compound to the threads on the rod assembly.
(19) Drive the bearing on the stamped end.
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(1A) The handle is in ENGAGED position.
(1B) The handle is in DISENGAGED position.
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(21) Torque for four screws. ... 6 ± 1 N·m (53 ± 9 lb in)
(22) Torque for three screws. ... 1.7 ± .25 N·m (15.05 ± 2.21 lb in)
(23) Depth for the bearing ... 4.5 ± 1 mm (0.18 ± 0.04 inch)
(24) Apply 4c-4030 Thread Lock Compound to the shaft.
(25) Drive the bearing on the stamped end only.
(26) Torque for nut ... 25 ± 6 N·m (18 ± 4 lb ft)
(27) Depth for the bearing ... 1.5 ± 1 mm (0.06 ± 0.04 inch)
(28) Dimension for the washers on the end of the shaft ... 0.10 to 2.0 mm (.004 to .08 inch)
(29) Torque for the bolt on the collar ... 1.7 ± .2 N·m (15.05 ± 1.77 lb in)
(33) Torque for two screws ... 0.8 ± 0.1 N·m (7.08 ± 0.89 lb in)
Speed Control Adjustment Procedure
1. Rotate collar (32) until the number 2 is 30 ± 1 degrees counterclockwise from vertical. Vertical is
viewed from the end of handle (2) .
Torque for the bolt that holds collar (29) ... 1.7 ± 0.2 N·m (15.05 ± 1.77 lb in)
2. Remove plate (20) . Rotate lever (9) until the plate is parallel with the top of housing (8) .
3. Install handle assembly (3) with the white mark in line with the number 2 on collar (29) .
Forward/Reverse Adjustment Procedure
1. Rotate ring (32) so screw (31) is in the center of the slot.
Torque for two screws (33) ... 0.8 ± 0.1 N·m (7.08 ± 0.89 lb in)
2. With parking brake lever (1) in the ENGAGED position (1A) , rotate handle (2) until the white mark
on the handle lines up with N (neutral) on ring (32) .
Torque for three screws (22) ... 1.7 ± 0.25 N·m (15.05 ± 2.21 lb in)
Parking Brake Lever and Neutral Start Switch Adjustment Procedure
1. With parking brake lever (1) in ENGAGED position (1A) , loosen the screw for parking brake lever
(1) and remove the lever.
2. Install parking brake lever (1) on splined shaft (19) so the hole in lever (1) is in line with the hole in
plate (20) .
3. Check continuity through neutral start switch (10) . If there is no continuity, adjust the position of
switch (10) .
Backup Alarm Adjustment Procedure
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1. Engage the parking brake ( (1A) position). Disengage the parking brake ( (1B) position). Rotate
handle (2) by 15 degrees toward reverse.
2. Check continuity through switch (15) . If there is no continuity within 1 degree of the 15 degree angle,
adjust the position of switch (15) .
3. To adjust the position of switch (15) , remove three screws (31) and remove cover assembly (30) .
4. Loosen the screws for the switch and slide switch (15) to the correct position. Tighten the screws.
Check the continuity through the switch. Readjust the switch, if necessary.
5. Install cover assembly (30) and three screws (31) .
Governor and Decelerator Control Group
Page 32 of 36
2/4/2016

Note: Apply 1p-0808 Multipurpose Grease to all bearings and bearing cavities.
(4) Drive the bearing on the stamped end only.
(6) Lubricate all of the parts in the decelerator with SAE (30W) oil.
(8) Lubricate the seal lip with SAE (30W) oil.
(11) Align the timing mark with the centerline of the saw cut.
Note: Apply 1u-8801 Rust Preventive Oil to all rod ends, pins, locknuts, adjusting threads, and pin holes.
(15) Torque for rod end nut ... 14 ± 4 N·m (10 ± 3 lb ft)
(16) Assembled length of the rod assembly (midrange reference) ... 769 mm (30.3 inch)
(24) Torque for rod end nut ... 14 ± 4 N·m (10 ± 3 lb ft)
(25) Assembled length of rod assembly ... 376 ± 3 mm (14.8 ± 0.1 inch)
Page 33 of 36
2/4/2016

Adjustment For The Governor Control Lever Effort
1. Disconnect rod end (14) from lever (13) . Disconnect spring (17) .
2. Housing nut (7) adjusts the force that is needed to move handle (1) . Measure the lever effort by the
force on handle (1) or by the torque of shaft assembly (3) .
Force on handle (1) ... 60 ± 4 N (13.5 ± 0.9 lb)
Torque on shaft assembly (3) ... 24.5 ± 1.6 N·m (217 ± 14 lb in)
Adjustment Of The Governor Control Linkage
1. Disconnect rod end (14) from lever (13) . Disconnect spring (17) .
2. Move governor control lever (2) to the vertical position.
Page 34 of 36
2/4/2016

3. Turn lever (13) counterclockwise until the governor control shaft enters the shut off detent position
(J) .
4. Loosen bolt (12) . Position lever (13) on splined governor shaft (27) at angle (H) . Angle (H) is 55 ± 5
degrees from vertical position (G) . Tighten bolt (12) .
5. Loosen bolt (10) and position lever (9) on splined shaft (5) . Align the timing mark on the shaft with
the centerline of the lever saw cut. Tighten bolt (10) .
6. Loosen nuts (24) and adjust rod assembly (25) to the correct assembled length. Tighten nuts (24) .
7. Loosen locknut (15) . Adjust rod end (14) in order to allow the free fit with pin (26) and lever (13) .
Tighten locknut (15) . If the adjustment is correct, the governor control shaft (27) will be in the shut
off detent when governor control lever (2) is vertical.
Reference dimension (F) is 15 degrees from vertical position (G) .
Adjustment For The High Idle Stop Bolt
1. Connect a tachometer in order to measure the engine speed.
2. Loosen locknut (21) and back high idle stop bolt (22) away from governor control lever (2) .
3. Start the engine. Move governor control lever (2) , until the engine speed does not increase. The
governor control shaft (27) should be rotated clockwise to HIGH IDLE position (E) .
4. Adjust high idle stop bolt (22) so that the bolt contacts governor control lever (2) . Back off the bolt
away from the lever by one turn. Tighten locknut (21) in order to lock high idle stop bolt (22) in
position.
5. Check the high idle rpm by pulling governor control lever (2) against stop bolt (22) . High idle stop
bolt (22) is not an adjustment for high idle.
When the bolt allows the governor shaft to rotate to the HIGH IDLE position (E) , stop bolt (22) is
correctly adjusted and the bolt is protecting the governor and the governor control linkage from
damage.
If HIGH IDLE RPM is not 2240 ± 50 rpm, System Operations, Testing & Adjusting Manual for
3406C Engine, senr1028, "Governor Adjustments"
6. Disconnect the tachometer.
Decelerator Adjustment
1. Connect a tachometer in order to measure the engine speed.
2. Loosen locknut (18) .
3. Start the engine. Move governor control lever (2) until the engine speed is at least 1200 RPM.
4. When decelerator pedal (20) is depressed against the stop bolt, adjust decelerator stop bolt (19) until
the engine speed is 1000 ± 50 RPM .
5. Tighten locknut (18) in order to lock the stop bolt in position.
Page 35 of 36
2/4/2016

6. Recheck decelerated engine speed by depressing pedal (20) against stop bolt (19) .
7. Disconnect the tachometer.
Copyright 1993 - 2016 Caterpillar Inc.
All Rights Reserved.
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Thu Feb 4 10:58:32 UTC+0300 2016
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2/4/2016

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D8R - 7XM - TRANS..pdf