KENR5814

March 2008

Specifications
993K Wheel Loader
Power Train
LWA1-Up (Machine) JXJ1-Up (Transmission) T8C1-Up (Torque Converter)
Z9K1-Up (Machine) MRX1-Up (Transmission) T9C1-Up (Torque Converter)

SAFETY.CAT.COM
 i01658146

Important Safety Information

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

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or pictorially
presented.
Operations that may cause product damage are identified by NOTICE labels on the product and in
this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
The warnings in this publication and on the product are, therefore, not all inclusive. If a tool,
procedure, work method or operating technique that is not specifically recommended by Caterpillar
is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that
the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
The information, specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before you
start any job. Caterpillar dealers have the most current information available.

When replacement parts are required for this

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

Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or
death.
KENR5814 3
Power Train
Table of Contents

Table of Contents
Specifications Section
Torque Converter and Transmission Pressures .... 4
Torque Converter and Pump Drive Housing ........ 6
Torque Converter ................................................. 8
Torque Converter (Lockup) ................................... 10
Torque Converter Priority Valve ............................ 12
Modulating Valve (Torque Converter Impeller
Clutch) ................................................................. 12
Modulating Valve (Torque Converter Lockup
Clutch) ................................................................. 13
Relief Valve (Torque Converter Outlet) ................. 13
Pressure Sensor (Torque Converter Impeller Clutch
Oil) ...................................................................... 14
Temperature Sensor (Torque Converter Oil) ......... 14
Temperature Sensor (Axle Oil) (Transmission Sump
Oil) ...................................................................... 15
Transmission Oil Pump ........................................ 15
Oil Filter (Torque Converter Charging) .................. 17
Oil Filter (Transmission Charging) ........................ 18
Bypass Switch (Torque Converter Charge Filter)
(Transmission Charge Filter) ............................... 19
STIC Control ......................................................... 19
Limit Switch (STIC Lockout Control) ..................... 20
Transmission Control Valve .................................. 21
Selector and Pressure Control Valve
(Transmission) .................................................... 24
Solenoid Valve (Transmission Clutch) .................. 26
Transmission Planetary ....................................... 27
Input Transfer Gears ............................................. 30
Speed Sensor (Transmission Input) ..................... 30
Output Transfer Gears .......................................... 31
Speed Sensor (Transmission Output) ................... 38
Liquid Level Sensor (Transmission Oil) ................ 39
Input Drive Shaft ................................................... 39
Drive Shaft ........................................................... 40
Differential and Bevel Gear .................................. 42
Fixed Axle (Front) ................................................. 43
Oscillating Axle (Rear) .......................................... 45
Axle Mounting ....................................................... 48
Final Drive and Wheel .......................................... 49
Rim Mounting ........................................................ 51
Piston Pump (Implement Pilot) (Axle Oil Cooler) (Axle
Oil Cooler Supply Oil) ......................................... 52
Piston Pump (Implement Pilot) (Axle Oil Cooler) .. 54
Axle Oil Cooler Pump and Motor .......................... 56
Oil Filter (Implement Pilot) (Axle Oil Cooler) ......... 57
Oil Filter (Screen) (Axle Oil Cooler) ...................... 58
Bypass Valve (Axle Oil Cooler) (Thermal Relief) .. 58
Pressure Switch (Brake Lubrication Oil) ............... 58
Pressure Sensor (Axle Brake Oil) ......................... 59

Index Section
Index ..................................................................... 60
4 KENR5814
Power Train
Specifications Section

Specifications Section
i02897735

Torque Converter and

Transmission Pressures
SMCS Code: 3030-R0; 3030-PX; 3073-R0; 3101-PX;
3101-R0; 7513-PK; 7554-PK
Part No.: 307-6598

g01443248
Illustration 2
Output side of torque converter
(2) Torque converter outlet pressure tap
(3) Hose connection for the lockup clutch pressure tap
(4) Hose connection for the impeller clutch pressure tap
g01443227
Illustration 1
Pressure taps for the transmission are located behind the cab.
(1) Pressure tap group
KENR5814 5
Power Train
Specifications Section

The following pressures should be checked with the

engine at high idle. The transmission oil should be
at the normal operating temperature of 95 20C
(203 36F).

(2) Torque converter outlet pressure ... 380 69 kPa

(55 10 psi)

(3) Lockup clutch pressure with the engine at high idle

and the lockup clutch engaged .... 2520 69 kPa
(365 10 psi)

(3) The lockup clutch pressure with the

engine at high idle and the lockup clutch
disengaged ............. 415 205 kPa (60 30 psi)

(4) Impeller clutch pressure with the engine

at high idle and the left brake pedal fully
released. ............. 2420 138 kPa (350 20 psi)

(4) Impeller clutch pressure with the engine at

high idle and the left brake pedal is fully
depressed. .............. 415 205 kPa (60 30 psi)

(5) Minimum pressure for the transmission lubrication

oil ................................................ 69 kPa (10 psi)

(6) Transmission clutch pressure

(P1) ..................... 2550 138 kPa (370 20 psi)

(7) Output pressure of the oil pump .. 2550 138 kPa

(370 20 psi)

(8) Directional clutch pressure (P2) .. 2170 138 kPa

(315 20 psi)

(9) Torque converter inlet pressure

(P3) ........................... 550 70 kPa (80 10 psi)

g01442976
Illustration 3
(1) Pressure tap group
(3) Lockup clutch pressure tap
(4) Impeller clutch pressure tap
(5) Transmission lubrication pressure tap
(6) Speed clutch pressure tap (P1)
(7) Oil pump output pressure tap
(8) Directional clutch pressure tap (P2)
(9) Torque converter inlet pressure (P3)
(10) Transmission control valve
6 KENR5814
Power Train
Specifications Section

i02772550

Torque Converter and Pump

Drive Housing
SMCS Code: 3101; 3105; 3108
Part No.: 246-5244, 246-5256

246-5244 Torque Converter and

Housing and 246-5256 Torque
Converter and Housing with
Lockup

g01390241
Illustration 4
KENR5814 7
Power Train
Specifications Section

g01390229
Illustration 5
View B-B

(1) Torque for nipple assembly ................ 27 3 Nm

(20 2 lb ft)

(2) Lubricate the seal prior to assembly.

(3) Lubricate the lip seal with a minimal amount of

the lubricant that is being sealed.

(4) Use a 246-5249 Shim Pack that is required,

in order to obtain a shaft end play that is
0.1 0.05 mm (0.004 0.002 inch).

(5) Install the seal so that the seal is flush with this
surface or within 0.25 mm ( 0.010 inch) of this
surface.

The manifold and the passages that lead in and

out of the manifold on the torque converter housing
must be free of debris. Clean the manifold and the
passages prior to assembly.
8 KENR5814
Power Train
Specifications Section

i02866771

Torque Converter
SMCS Code: 3101
Part No.: 246-5255

g01428089
Illustration 6

(1) Torque for the three bolts ............... 120 15 Nm
(90 10 lb ft)
(2) Torque for the 20 bolts ................... 120 15 Nm
(90 11 lb ft)
(A) Clearance between the converter turbine
and the converter housing across the
diameter ........ 1.29 0.25 mm (.051 .010 inch)
Total thickness of two new clutch plates and of
three new friction discs ........... 29.47 0.40 mm
(1.160 .016 inch)
Thickness of one new 6Y-7198 Clutch Plate
...................... 6.35 0.08 mm (.250 .003 inch)
Thickness of one new 6I-8597 Friction Disc
...................... 5.59 0.08 mm (.220 .003 inch)
(C) Turbine Hub Assembly and Stator Carrier

(B) Impeller Clutch

KENR5814 9
Power Train
Specifications Section

Sleeve bearing inside diameter after installation

in the turbine hub assembly .... 114.45 0.05 mm
(4.506 .002 inch)
Diameter of the bearing surface of the stator
carrier ..... 114.30 0.03 mm (4.500 .001 inch)

(D) Clearance between the converter turbine and the

stator across the diameter ........ 0.82 0.12 mm
(.032 .005 inch)

(E) Clearance between the impeller and the converter

housing across the diameter .... 1.20 0.17 mm
(.047 .007 inch)

(F) Clutch Adapter

Sleeve bearing inside diameter after installation
in the adapter assembly .... 209.633 0.066 mm
(8.2533 .0026 inch)
Diameter of the bearing surface of the impeller
housing ............................. 209.363 0.025 mm
(8.2426 .0010 inch)

(3) Torque for the 12 bolts ................... 240 25 Nm

(175 20 lb ft)

(4) Lubricate the lip seal with a minimal amount

of the lubricant that is being sealed. Install the
seal even with the outside surface. Tolerance is
0.25 mm (0.010 inch).

(5) Torque for the bolt .. 240 25 Nm (175 20 lb ft)

(6) Torque for the 12 bolts ................... 120 15 Nm

(90 10 lb ft)

(7) Torque for the 30 bolts ................... 120 15 Nm

(90 10 lb ft)

(8) Torque for the 12 bolts ................... 120 15 Nm

(90 10 lb ft)

(9) Torque for the 11 bolts ... 50 7 Nm (35 5 lb ft)

10 KENR5814
Power Train
Specifications Section

i02868330

Torque Converter (Lockup)

SMCS Code: 3101-L7
Part No.: 246-5257

g01428884
Illustration 7

(1) Torque for the three bolts ............... 120 15 Nm
(90 11 lb ft)
(2) Torque for the 12 bolts ... 50 7 Nm (37 5 lb ft)
(A) Lockup clutch
Total thickness of one new clutch plate and of two
new friction discs ..................... 13.09 0.21 mm
(0.515 0.008 inch)
KENR5814 11
Power Train
Specifications Section

Thickness of one new 8E-8328 Friction (9) Torque for the 12 bolts ................... 120 15 Nm
Disc ........... 4.83 0.08 mm (0.190 0.003 inch) (90 11 lb ft)
Thickness of one new 1T-1897
Plate ......... 3.43 0.05 mm (0.135 0.002 inch) (10) Torque for the 11 bolts .. 50 7 Nm (37 5 lb ft)

(B) Clearance between the converter turbine (11) Lubricate the lip type seal with a minimal amount
and the converter housing across the of the lubricant that is being sealed. Install the
diameter .... 1.29 0.25 mm (0.051 0.010 inch) seal even with the outside surface. Tolerance is
0.25 mm (0.010 inch).
(C) Impeller clutch
Total thickness of two new clutch plates and of
three new friction discs ............ 29.47 0.40 mm
(1.160 0.016 inch)
Thickness of one new 6Y-7198 Plate
.................. 6.35 0.08 mm (0.250 0.003 inch)
Thickness of one new 6I-8597 Friction Disc
.................. 5.59 0.08 mm (0.220 0.003 inch)

(D) Hub assembly

Sleeve bearing inside diameter after installation
in the turbine hub assembly .... 114.45 0.05 mm
(4.506 0.002 inch)
Diameter of the bearing surface of the
race ........ 114.30 0.03 mm (4.500 0.001 inch)

(E) Clearance between the converter turbine

and the torque converter stator across the
diameter .... 0.82 0.12 mm (0.032 0.005 inch)

(F) Clearance between the torque converter

impeller and the converter housing across the
diameter .... 1.20 0.17 mm (0.047 0.007 inch)

(G) Clearance between the torque converter impeller

and the torque converter stator across the
diameter .... 0.82 0.12 mm (0.032 0.005 inch)

(H) Clutch adapter

Sleeve bearing inside diameter after installation
in the adapter assembly .... 209.633 0.066 mm
(8.2533 0.0026 inch)
Diameter of the bearing surface of the impeller
housing .............................. 209.363 0.025 mm
(8.2426 0.0010 inch)

(3) Torque for the 12 bolts ................... 240 25 Nm

(175 18 lb ft)

(4) Torque for the bolt .. 240 25 Nm (175 18 lb ft)

(5) Torque for the 12 bolts ................... 120 15 Nm

(90 11 lb ft)

(6) Torque for the 20 bolts ................... 120 15 Nm

(90 11 lb ft)

(7) Torque for the six bolts .. 30 5 Nm (22 4 lb ft)

(8) Torque for the 30 bolts ................... 120 15 Nm

(90 11 lb ft)
12 KENR5814
Power Train
Specifications Section

i02871004

Torque Converter Priority

Valve
SMCS Code: 3180-VC
Part No.: 6I-8563

g01429902
Illustration 8

Pressure setting ............ 2206 34 kPa (320 5 psi) i02713467

Flow rate ........ 49.2 0.8 L/min (13.0 0.2 US gpm) Modulating Valve (Torque
Converter Impeller Clutch)
(1) 3P-4053 Spring
SMCS Code: 3139-VC
Length under test force ....... 32.3 mm (1.27 inch)
Test force ............ 531.5 34.5 N (119.5 7.8 lb) Part No.: 217-2708
Free length after test .......... 41.1 mm (1.62 inch)
Outside diameter ............ 19.05 mm (0.750 inch)

(2) As required, use the following shim in order to

adjust the priority valve pressure:
5M-9624 Shim
Quantity ............................................................ 6
Thickness of one shim ...... 0.25 mm (0.010 inch)
Pressure change by adding or removing one
shim ............................................ 76 kPa (11 psi)

(3) 4M-2381 Spring

Length under test force ....... 12.2 mm (0.48 inch)
Test force .............. 2.5 0.5 N (0.517 0.041 lb) Illustration 9
g01055037
Free length after test .......... 22.6 mm (0.89 inch)
Outside diameter .............. 7.62 mm (0.300 inch) (1) Torque for the self-locking nut ........ 13 1.5 Nm
(115 13 lb in)
(B) Installation depth of the dowel ... 5 mm (0.2 inch)
(2) Torque for installing the fitting
assembly .................. 14 4 Nm (125 35 lb in)
KENR5814
(3) 118-3731 Spring
Length under test force ... 14.00 mm (0.551 inch)
Test force .................... 36.0 1.8 N (8.1 0.4 lb)
Free length after test ...... 15.99 mm (0.630 inch)
Outside diameter ................ 12.1 mm (0.48 inch)
(4) Torque for installing the cartridge
assembly ....................... 50 5 Nm (37 4 lb ft)
Flow of SAE 30 oil at 1000 kPa (145 psi) pressure
drop ...................................... 140 L/min (37 US gpm)
Nominal coil voltage ...................................... 12 VDC
Maximum coil voltage ................................ 14.5 VDC
Nominal coil resistance at 25 5 C
(77 9 F) ..................................... 7.75 1.00 Ohms
Maximum coil resistance at 121 C
(220 F) .................................................. 12.68 Ohms
Minimum coil resistance at 40 C
(40 F) .................................................... 5.81 Ohms
Nominal current draw at 25 C (77 F) .. 1.55 Amperes
Maximum current draw at 40 C
(40 F) ................................................. 2.5 Amperes
i02775429
Modulating Valve (Torque
Converter Lockup Clutch)
SMCS Code: 3139-VC
Part No.: 216-5342
g01387063
Illustration 10
(1) Torque for the self-locking nut ........ 13 1.5 Nm
(115 13 lb in)
(2) Torque for installing the fitting
assembly .................. 14 4 Nm (125 35 lb in)
Nominal coil voltage ...................................... 24 VDC
13
Power Train
Specifications Section
Nominal coil resistance at 25 C (77 F)
........................................................... 8.7 0.4 Ohms
i02713477
Relief Valve (Torque Converter
Outlet)
SMCS Code: 3133-OL
Part No.: 8E-9727
Illustration 11
g01362964
Pressure setting ................ 552 34 kPa (80 5 psi)
(1) 5M-9548 Spring for the poppet valve
Length under test force ....... 21.3 mm (0.84 inch)
Test force .................... 4.5 0.5 N (1.0 0.08 lb)
Free length after test .......... 34.0 mm (1.34 inch)
Outside diameter ................ 12.2 mm (0.48 inch)
(2) As required, install the shims.
5M-9623 Shim
Shim thickness ................. 0.90 mm (0.035 inch)
Shim outside diameter ............. 20.62 0.25 mm
(0.812 0.010 inch)
Adding one shim or removing one shim will
change the outlet pressure by the following
amount. ................................. 18.2 kPa (2.64 psi)
5M-9624 Shim
Shim thickness ................. 0.25 mm (0.010 inch)
Shim outside diameter ............. 20.62 0.25 mm
(0.812 0.010 inch)
Adding one shim or removing one shim will
change the outlet pressure by the following
amount. ................................... 5.0 kPa (0.73 psi)
14 KENR5814
Power Train
Specifications Section

(3) 2P-5711 Spring i02856527

Length under test force ....... 61.5 mm (2.42 inch) Temperature Sensor (Torque
Test force .................................. 390 N (87.80 lb)
Free length after test .......... 86.4 mm (3.40 inch)
Converter Oil)
Outside diameter ............ 22.23 mm (0.875 inch)
SMCS Code: 301T

i02762933
Part No.: 195-2150

Pressure Sensor (Torque

Converter Impeller Clutch Oil)
SMCS Code: 1408-PXS; 3101-PXS; 3104-PXS
Part No.: 221-3415

g01435149
Illustration 13

(1) Final installation torque .. 48 5 Nm (35 4 lb ft)

(A) Signal pin

(B) Ground pin

Measurement range .... 40 to 150 C (40 to 302F)

Input supply voltage ............................. 5 0.25 VDC

Maximum output current ................................. 10 mA

g01441074
Illustration 12 Output voltage (signal) ...................... 0.3 to 4.9 Volts

(1) Final installation torque for the pressure sensor

group ............................. 45 5 Nm (33 4 lb ft)

Input supply voltage ............................... 8 to 32 VDC

Maximum supply current ................................. 35 mA

Maximum operating pressure ..... 3163 kPa (460 psi)

Output frequency ................................. 500 100 Hz

Operating temperature ........................ 40 to 110 C

(40 to 230 F)
KENR5814 15
Power Train
Specifications Section

i02883192 Rotation is counterclockwise when the pump is

viewed from the drive end. Use SAE 10W at a
Temperature Sensor (Axle Oil) temperature of 49 C (120 F) in order to bench test
(Transmission Sump Oil) the pump.

SMCS Code: 301T Rotate the pump by hand. The pump must rotate
freely.
Part No.: 288-8390

g01422855
Illustration 14

Table 1
Wiring Table
Pin Circuit Color
A Source Voltage Orange
B Ground Black
C Signal White
D Inactive Inactive
g01367760
Illustration 15
(1) Torque for installing the sensor .......... 20 5 Nm Transmission oil pump
(15 4 lb ft)
(X) Transmission pump
Operating voltage .......................................... 8 Volts
Minimum pump output ... 160 L/min (42 US gpm)
Output type .......................... Pulse Width Modulated Pump speed ........................................ 1800 rpm
Pump pressure ..................... 2760 kPa (400 psi)
Output frequency ................................. 500 200 Hz
(Z) Torque converter pump
Maximum operating temperature of probe ..... 120 C
(248.0 F) Minimum pump output ... 110 L/min (29 US gpm)
Pump speed ........................................ 1800 rpm
Minimum operating temperature of probe ...... 40 C Pump pressure ....................... 900 kPa (130 psi)
(40.0 F)
(1) Torque for the locknut .................... 110 13 Nm
(80 10 lb ft)
i02713493
(D) Bore of the new bearing ...... 31.786 0.008 mm
Transmission Oil Pump (1.2514 0.0003 inch)
SMCS Code: 3066 Diameter of the new shaft .......... 31.742 0.005 mm
Part No.: 279-6751 (1.2497 0.0002 inch)

The pump is a two-section gear type pump.

16 KENR5814
Power Train
Specifications Section

g01367770 g01367778
Illustration 16 Illustration 17
View A-A View B-B

Use the following procedure to install the sleeve Use the following procedure to install the sleeve
bearings for the oil pump cover. bearings for the oil pump body.

1. Install sleeve bearings (2) in the oil pump cover 1. Install sleeve bearings (3) in the oil pump body
1.5 0.25 mm (0.06 0.01 inch) below the surface 1.50 0.25 mm (0.060 0.010 inch) below the
of the oil pump cover. surface of the oil pump body.

2. The distance between bearing joint position (E) 2. The distance between bearing joint position (F)
and the centerline of the shaft equals 30 15 and the centerline of the shaft equals 30 15
degrees, as shown. degrees, as shown.
KENR5814 17
Power Train
Specifications Section

i02763345

Oil Filter (Torque Converter

Charging)
SMCS Code: 3004
Part No.: 133-1295

g01367782
Illustration 18
View C-C

Use the following procedure to install the sleeve

bearings for the oil pump manifold.

1. Install sleeve bearings (4) in the oil pump manifold

1.6 0.5 mm (0.06 0.02 inch) below the surface
of the oil pump manifold.

2. The distance between bearing joint position (G)

and the centerline of the shaft equals 30 15
degrees, as shown.

g01443754
Illustration 19

Pressure differential that is needed in order to open

the bypass valve .............. 345 21 kPa (50 3 psi)

(1) 133-2199 Spring

Length under test force ... 46.11 mm (1.815 inch)
Test force ............... 107.4 5.3 N (24.1 1.2 lb)
Free length after test ......... 62.5 mm (2.46 inch)
Outside diameter ........... 15.24 mm (0.600 inch)

(2) Torque for the locknut .................. 30.0 5.4 Nm

(22 4 lb ft)

(3) Do not use an air wrench to tighten the filter

housing. Tighten until the shoulder of the filter
housing contacts the bottom of the oil filter base.

(4) Lubricate the seal with the fluid that is being

filtered.
18 KENR5814
Power Train
Specifications Section

i02763453

Oil Filter (Transmission

Charging)
SMCS Code: 3004; 3067
Part No.: 180-3377

g01443735
Illustration 20

Pressure differential that is needed in order to open (4) Lubricate the seal with the fluid that is being
the bypass valve .............. 345 21 kPa (50 3 psi) filtered.

(1) 133-2199 Spring

Length under test force ... 46.11 mm (1.815 inch)
Test force ............... 107.4 5.3 N (24.1 1.2 lb)
Free length after test ......... 62.5 mm (2.46 inch)
Outside diameter ........... 15.24 mm (0.600 inch)

(2) Torque for the locknut .................. 15.0 5.4 Nm

(11 4 lb ft)

(3) Do not use an air wrench to tighten the filter

housing. Tighten until the shoulder of the filter
housing contacts the bottom of the oil filter base.
KENR5814 19
Power Train
Specifications Section

i02763525 i02708390

Bypass Switch (Torque STIC Control

Converter Charge Filter) SMCS Code: 3033
(Transmission Charge Filter) Part No.: 268-9348
SMCS Code: 1408-ZS; 1435-FI; 3004-BY; 3067-BY
Part No.: 164-7577

g01435150
Illustration 21

(1) Prior to assembly, lubricate the O-ring seal with a

small amount of the lubricant that is being sealed. g01127328
Illustration 22

(2) Final installation torque .................... 80 10 Nm

(1) Torque for the four bolts .. 6 1 Nm (55 9 lb in)
(59 7 lb ft)

(A) Switch pin STIC Lockout Control

(B) Ground pin

Pressure differential that opens the bypass

valve ................................. 345 21 kPa (50 3 psi)

Minimum voltage for actuation ........................ 5 VDC

Maximum voltage for actuation ..................... 28 VDC

Operating temperature ........................ 32 to 121 C

(26 to 250 F)

................................................ 121 C (249.8000 F)

The contact position is normally open.

g01504463
Illustration 23
Front View

(2) Torque for one bolt ......... 28 7 Nm (20 5 lb ft)

20 KENR5814
Power Train
Specifications Section

(4) Apply 155-0695 Thread Lock Compound to the

threads.

(5) Torque for the one nut ... 30 7 Nm (22 5 lb ft)

Note: Apply 155-0695 Thread Lock Compound to

the threads (5).

(6) Torque for the two nuts .. 15 3 Nm (11 2 lb ft)

(7) Torque for the two set screws .............. 6 1 Nm

(55 9 lb in)

(8) Torque for the four bolts .. 6 1 Nm (55 9 lb in)

(9) 8C-3442 Coil Spring

Length under test force ....... 57.9 mm (2.28 inch)
Test force ............. 71.2 5.8 N (16.00 1.30 lb)
Free length after test .......... 50.3 mm (1.98 inch)
Outside diameter ..................... 17.48 0.25 mm
g01504462 (0.688 0.010 inch)
Illustration 24
Left Side View
i02976201
(3) Torque for one nut .......... 6 1 Nm (55 9 lb in)
Limit Switch (STIC Lockout
Note: Apply 155-0695 Thread Lock Compound to Control)
the threads (3).
SMCS Code: 1408-ZS; 3034-ZS
Part No.: 171-3759

g01444603
Illustration 26

Maximum actuating force ..................... 1.7 N (0.4 lb)

Minimum distance for overtravel ................. 2.39 Nm

(21.2 lb in)

(A) Operating position ................... 30.18 0.38 mm

(1.188 0.015 inch)

Illustration 25
g01504459 Contact (1) and contact (2) are closed when the
switch is in the operating position.
Left Side View

(B) Free position ........................... 32.16 0.38 mm

(1.266 0.015 inch)
KENR5814 21
Power Train
Specifications Section

Contact (2) and contact (4) are closed when the

switch is in the free position.

Operating temperature ......................... 40 to 85 C

(40 to 185 F)

i02777515

Transmission Control Valve

SMCS Code: 3073
Part No.: 254-2295

g01387766
Illustration 27

(1) Torque for 21 bolts ........ 30 4 Nm (22 3 lb ft)

(2) Torque for five bolts ....... 30 7 Nm (22 5 lb ft)

(3) Torque for five locknuts ..................... 9 0.5 Nm

(80 4 lb in)

(4) Torque for ten bolts ........ 30 4 Nm (22 3 lb ft)

(5) Torque for the five cartridge

assemblies ..................... 50 5 Nm (37 4 lb ft)
22
Power Train
Specifications Section
Illustration 28
View B-B
(6) 4M-2381 Spring
Length under test force ......... 12.2 mm (.48 inch)
Test force ............. 2.30 0.18 N (.517 .041 lb)
Free length after test ........... 22.6 mm (.89 inch)
Outside diameter ................ 7.62 mm (.300 inch)
(7) 7G-4842 Spring (outside)
Color ........................................... two red stripes
Length under test force ...... 36.3 mm (1.43 inch)
Test force ........................ 175 6 N (39 1.3 lb)
Free length after test ..... 68.45 mm (2.695 inch)
Outside diameter ........... 27.79 mm (1.094 inch)
(8) 6I-9519 Spring
Length under test force ...... 31.3 mm (1.23 inch)
KENR5814
g01388062
Test force ............... 64.5 3.2 N (14.50 .72 lb)
Free length after test ..... 47.18 mm (1.857 inch)
Outside diameter ............... 24.5 mm (.965 inch)
(9) 9P-3041 Spring
Color ........................................... two red stripes
Length under test force ...... 85.5 mm (3.37 inch)
Test force ...................... 313 11 N (70 2.5 lb)
Free length after test .... 117.40 mm (4.622 inch)
Outside diameter ............. 21.21 mm (.835 inch)
(10) 6P-4978 Spring
Length under test force .. 27.15 mm (1.069 inch)
Test force .................... 67 3.4 N (15.1 .76 lb)
Free length after test ..... 38.10 mm (1.500 inch)
KENR5814 23
Power Train
Specifications Section

Outside diameter ............. 24.61 mm (.969 inch) Length under test force ...... 31.3 mm (1.23 inch)
Test force ............... 64.5 3.2 N (14.50 .72 lb)
(11) 6P-9784 Spring Free length after test ..... 47.18 mm (1.857 inch)
Outside diameter ............... 24.5 mm (.965 inch)
Color ....................................... one yellow stripe
Length under test force .. 56.39 mm (2.220 inch) (16) Torque for two bolts .... 30 7 Nm (22 5 lb ft)
Test force ................ 130 6.5 N (29.2 1.50 lb)
Free length after test ..... 88.60 mm (3.488 inch)
Outside diameter ............. 16.26 mm (.640 inch)

(12) 6P-9783 Spring

Color ....................................... one yellow stripe
Length under test force .. 56.39 mm (2.220 inch)
Test force ......................... 62 3 N (13.9 .7 lb)
Free length after test ..... 88.60 mm (3.488 inch)
Outside diameter .............. 11.02 mm (.434 inch)

(13) 6I-9519 Spring

Length under test force ...... 31.3 mm (1.23 inch)
Test force ............... 64.5 3.2 N (14.50 .72 lb)
Free length after test ..... 47.18 mm (1.857 inch)
Outside diameter ............... 24.5 mm (.965 inch)

(14) 6P-9785 Spring

Color ....................................... one yellow stripe
Length under test force .... 19.48 mm (.767 inch)
Test force ................. 23.5 1.2 N (5.28 .27 lb)
Free length after test ..... 32.00 mm (1.260 inch)
Outside diameter ............. 13.51 mm (.532 inch)

g01388331
Illustration 29
View C-C

(15) 6I-9519 Spring

24 KENR5814
Power Train
Specifications Section

i02977854

Selector and Pressure Control

Valve (Transmission)
SMCS Code: 3073
Part No.: 117-5860

g01439641
Illustration 30

(1) 4M-2381 Spring (3) 9P-3041 Spring

Length under test force ....... 12.2 mm (0.48 inch)
Test force .......... 2.30 0.18 N (0.517 0.041 lb)
Free length after test .......... 22.6 mm (0.89 inch)
Outside diameter .............. 7.62 mm (0.300 inch)
(2) 7G-4842 Spring
Length under first test force .................. 62.5 mm
(2.46 inch)
First test force ............. 32.3 1.6 N (7.3 0.4 lb)
Length under second test force ............ 36.3 mm
(1.43 inch)
Second test force .... 174.6 5.9 N (39.3 1.3 lb)
Free length after test ...... 68.45 mm (2.695 inch)
Outside diameter ............ 27.79 mm (1.094 inch)
Length under first test force ................. 110.0 mm
(4.33 inch)
First test force ........... 72.6 3.6 N (16.3 0.8 lb)
Length under second test force ............ 85.5 mm
(3.37 inch)
Second test force .. 312.9 10.8 N (70.3 2.4 lb)
Free length after test ..... 117.40 mm (4.622 inch)
Outside diameter ............ 21.21 mm (0.835 inch)
(4) 6I-9519 Spring
Quantity ............................................................ 3
Length under test force ....... 31.3 mm (1.23 inch)
Test force .................. 64.5 3.2 N (14.5 0.7 lb)
Free length after test ...... 47.18 mm (1.857 inch)
KENR5814 25
Power Train
Specifications Section

Outside diameter ................ 24.5 mm (0.96 inch)

(5) As required, use the following shims in order to

adjust the transmission pressure:
5M-9624 Shim
Quantity ............................................................ 3
Thickness of one shim ...... 0.25 mm (0.010 inch)
Outside diameter of the shim ... 20.62 0.25 mm
(0.812 0.010 inch)
Approximate pressure change by adding or
removing one shim .................... 16 kPa (2.5 psi)
5M-9623 Shim
Quantity ............................................................ 1
Thickness of one shim .......... 0.9 mm (0.04 inch)
Outside diameter of the shim ... 20.62 0.25 mm
(0.812 0.010 inch)
Approximate pressure change by adding or
removing one shim .................... 57 kPa (8.5 psi)
5M-9622 Shim
Quantity ............................................................ 1
Thickness of one shim .......... 1.6 mm (0.06 inch)
Outside diameter of the shim ... 20.62 0.25 mm
(0.812 0.010 inch)
Approximate pressure change by adding or
removing one shim ..................... 98 kPa (14 psi)

(6) 6P-4978 Spring

Length under test force ... 27.15 mm (1.069 inch)
Test force .................. 67.3 3.4 N (15.1 0.8 lb)
Free length after test ...... 38.10 mm (1.500 inch)
Outside diameter ............ 24.61 mm (0.969 inch)

(7) 6P-9784 Spring

Length under test force ... 56.39 mm (2.220 inch)
Test force ................ 130.4 6.5 N (29.3 1.5 lb)
Free length after test ...... 88.60 mm (3.488 inch)
Outside diameter ............ 16.26 mm (0.640 inch)

(8) 6P-9783 Spring

Length under test force ... 56.39 mm (2.220 inch)
Test force .................. 62.0 3.1 N (13.9 0.7 lb)
Free length after test ...... 88.60 mm (3.488 inch)
Outside diameter ............. 11.02 mm (0.434 inch)

(9) 6P-9785 Spring

Length under test force ... 19.48 mm (0.767 inch)
Test force .................... 23.5 1.2 N (5.3 0.3 lb)
Free length after test ...... 32.00 mm (1.260 inch)
Outside diameter ............ 14.83 mm (0.584 inch)

(10) Torque for the two bolts ................... 30 7 Nm

(22 5 lb ft)
26 KENR5814
Power Train
Specifications Section

g01439643
Illustration 31

(11) Torque for the five bolts ................... 30 7 Nm i02978800

(22 5 lb ft)
Solenoid Valve (Transmission
(12) Refer to Illustration 31 for installing 8P-9296 Clutch)
Plugs (12) into position.
SMCS Code: 3174
(13) Refer to Illustration 31 for installing 238-5508
Plug (13). Part No.: 302-3811

g01506793
Illustration 32

(1) 302-3817 Cartridge

Final installation torque for the cartridge
assembly ....................... 50 5 Nm (37 4 lb ft)
Final installation torque for the locknut that retains
the coil ......................... 9 0.5 Nm (80 4 lb in)
KENR5814 27
Power Train
Specifications Section

Flow of SAE 10 oil at 103 kPa (15 psi) pressure

drop and 23 C (73 F) ........................ 3.8 L/min
(1.00 US gpm)
Maximum pressure rating ..... 4138 kPa (600 psi)

(2) 312-4288 Coil

Nominal coil voltage ............................... 12 VDC
Maximum coil voltage .......................... 14.5 VDC
Current
Nominal current draw at 25 C (77 F) winding
temperature .................................. 1.47 Amperes
Maximum current draw at 40 C (40 F)
winding temperature ....................... 2.4 Amperes
Resistance
Nominal coil resistance at 25 5 C
(77 41 F) ............................... 8.15 0.6 Ohms
Maximum coil resistance at 121 C
(250 F) .............................................. 13.3 Ohms
Minimum coil resistance at 40 C
(40 F) .................................................. 6 Ohms

i02773385

Transmission Planetary
SMCS Code: 3160
Part No.: 243-1736
28 KENR5814
Power Train
Specifications Section

g01426622
Illustration 33
KENR5814
(1) Torque for the 17 bolts ................... 410 50 Nm
(300 37 lb ft)
(2) Number 1 clutch
Thickness of six new disc assemblies and
of five new clutch plates for the number 1
clutch ........ 65.29 .88 mm (2.570 0.035 inch)
Thickness of one new 8E-0985 Clutch
Disc ........... 5.59 0.08 mm (0.220 0.003 inch)
Thickness of one new 194-3811
Plate ......... 6.35 0.08 mm (0.250 0.003 inch)
(3) Number 2 clutch
Thickness of six new disc assemblies and
of five new clutch plates for the number 2
clutch ........ 65.29 .88 mm (2.570 0.035 inch)
Thickness of one new 8E-0985 Clutch
Disc ........... 5.59 0.08 mm (0.220 0.003 inch)
Thickness of one new 194-3811
Plate ......... 6.35 0.08 mm (0.250 0.003 inch)
(4) Number 3 clutch
Thickness of four new disc assemblies and
of three new clutch plates for the number 3
clutch ...... 41.41 0.56 mm (1.630 0.022 inch)
Thickness of one new 8E-0985 Clutch
Disc ........... 5.59 0.08 mm (0.220 0.003 inch)
Thickness of one new 194-3811
Plate ......... 6.35 0.08 mm (0.250 0.003 inch)
(5) Number 4 clutch
Thickness of three new disc assemblies and
of two new clutch plates for the number 4
clutch ...... 29.47 0.40 mm (1.160 0.016 inch)
Thickness of one new 8E-0985 Clutch
Disc ........... 5.59 0.08 mm (0.220 0.003 inch)
Thickness of one new 194-3811
Plate ......... 6.35 0.08 mm (0.250 0.003 inch)
(6) Number 5 clutch
Thickness of five new disc assemblies and
of four new clutch plates for the number 5
clutch ........ 54.97 .72 mm (2.164 0.028 inch)
Thickness of one new 233-9748 Friction
Disc ............. 5.61 .08 mm (0.221 0.003 inch)
Thickness of one new 3P-7447
Plate ......... 6.73 0.08 mm (0.265 0.003 inch)
(7) Lubricate the bore lightly with the lubricant that is
being sealed.
(8) Torque for twelve bolts .. 115 7 Nm (85 5 lb ft)
(9) 3P-7566 Spring
Quantity .......................................................... 12
Assembled length .............. 74.4 mm (2.93 inch)
Load at assembled length ................. 305 16 N
(69 3.6 lb)
Minimum operating length .. 69.9 mm (2.75 inch)
29
Power Train
Specifications Section
Load at minimum operating length ............ 422 N
(95 lb)
Free length after test .......... 86.1 mm (3.39 inch)
Outside diameter ............ 16.36 mm (0.644 inch)
(10) 1S-8480 Spring
Quantity .......................................................... 24
Outside diameter ....................... 14.27 .25 mm
(0.562 0.01 inch)
Free length after test .......... 83.1 mm (3.27 inch)
Assembled length .............. 66.5 mm (2.62 inch)
Load at assembled length ........... 222.4 17.8 N
(50 4 lb)
(11) 9H-5537 Spring
Quantity .......................................................... 24
Length under test force ....... 46.7 mm (1.84 inch)
Test force ............. 130 10.0 N (28.75 2.30 lb)
Free length after test .......... 62.7 mm (2.47 inch)
Outside diameter ............ 14.30 mm (0.563 inch)
(A) Installation dimension of the dowel in the
shaft ......... 117.15 .13 mm (4.612 0.005 inch)
(B) Installation dimension of the dowel in the
shaft ........ 84.33 0.13 mm (3.320 0.005 inch)
(C) The inside diameter of a new planetary gear for
the number 1, 2 and 3 clutch .. 66.274 0.010 mm
(2.6092 0.0004 inch)
(D) Diameter of new planetary gear
shaft ..................................... 47.193 0.008 mm
(1.8580 0.0003 inch)
(E) Diameter of new planetary gear
shaft ..................................... 42.395 0.008 mm
(1.6691 0.0003 inch)
(F) Inside diameter of new planetary
gear ..................................... 58.298 0.010 mm
(2.2952 0.0004 inch)
(G) 3.5 .5 mm (0.14 0.02 inch)
30 KENR5814
Power Train
Specifications Section

i02776583

Input Transfer Gears

SMCS Code: 3159-IV
Part No.: 243-1732

g01387565
Illustration 35
View A

(4) Lubricate the sealing lip with a minimal amount of

the lubricant that is being sealed.

(5) Apply 6V-6640 Sealant (Gasket Maker) to the lip

seal prior to installation.

(6) Install the lip seal to a depth of 1.0 0.1 mm

(0.04 0.004 inch) below the face of the cage.

i02894995

Speed Sensor (Transmission

Input)
SMCS Code: 3175-IV
Part No.: 122-8863

g01387499
Illustration 34

(1) Lubricate the bore with a minimal amount of the g01441198

lubricant that is being sealed. Illustration 36

Table 2
(2) Use a 250-6666 Shim Pack in order to attain a
shaft end play that is 0.152 mm (0.0060 inch) to Wiring Table
0.203 mm (0.0080 inch).
Connector Pin Circuit Color
(3) Use a 112-8633 Shim Pack in order to attain a 1 Signal - Black
shaft end play that is 0.152 mm (0.0060 inch) to
2 Signal + White
0.203 mm (0.0080 inch).
KENR5814 31
Power Train
Specifications Section

(1) Final installation torque for the speed sensor

group ............................. 37 4 Nm (27 3 lb ft)

Operating temperature range ............. 40 to 120 C

(40 to 248 F)

Resistance ................................................ 142 ohms

Output type ................................................... Passive

i02871384

Output Transfer Gears

SMCS Code: 3159-OJ
Part No.: 243-1733, 249-0218

243-1733 Output Transfer Gear

Group (Standard Steering)
32 KENR5814
Power Train
Specifications Section

g01430050
Illustration 37
KENR5814 33
Power Train
Specifications Section

(1) Torque for speed sensor .................... 37 4 Nm

(27 3 lb ft)

(2) Torque for level sensor .. 22 3 Nm (16 2 lb ft)

34 KENR5814
Power Train
Specifications Section

g01430049
Illustration 38
KENR5814 35
Power Train
Specifications Section

View A-A

(3) Install the lip seal even with the face of the
bearing cage. Lightly lubricate the lip of the seal
with the lubricant that is being sealed.

(4) Lubricate the bore with a minimal amount of the

lubricant that is being sealed.

(5) Torque for the two bolts ................. 475 50 Nm

(350 37 lb ft)

(6) Apply 5P-3413 Pipe Sealant to threads of drain

assembly.

(7) Torque for the plug of the drain assembly

................................... 100 10 Nm (75 7 lb ft)

Note: Use 4C-8563 Drain Adapter in order to open

the drain valve.

Note: Refer to the Disassembly and Assembly

manual for the instructions in order to set the preload
for the input shaft bearings.
36 KENR5814
Power Train
Specifications Section

249-0218 Transfer Gears and Case

Group (Secondary Steering)

g01430367
Illustration 39

(1) Torque for speed sensor .................... 37 4 Nm

(27 3 lb ft)

(2) Torque for level sensor .. 22 3 Nm (16 2 lb ft)

(8) Torque for six bolts ...... 55 10 Nm (40 7 lb ft)

KENR5814 37
Power Train
Specifications Section

g01430442
Illustration 40
38 KENR5814
Power Train
Specifications Section

(3) Install the lip seal even with the face of the i02763812
bearing cage. Lightly lubricate the lip of the seal
with the lubricant that is being sealed. Speed Sensor (Transmission
Output)
(4) Lubricate the bore with a minimal amount of the
lubricant that is being sealed. SMCS Code: 3175-OJ
(5) Torque for the two bolts ................. 475 50 Nm Part No.: 183-8597
(350 37 lb ft)

(6) Apply 5P-3413 Pipe Sealant to threads of drain

assembly.

(7) Torque for the plug of the drain assembly

................................... 100 10 Nm (75 7 lb ft)

Note: Use 4C-8563 Drain Adapter in order to open

the drain valve.

Note: Refer to the Disassembly and Assembly

manual for instructions to set the preload for the input
shaft bearings for the machine being serviced.
g01441417
Illustration 42

Table 3
Wiring Table
Connector Pin Circuit Color
1 Signal - Black
2 Signal + White

(1) Final installation torque .. 37 4 Nm (27 3 lb ft)

Resistance between the connector pins at 25 C

(77 F) ........................................ 1000 to 1200 ohms

Operating temperature range ............. 40 to 120 C

(40 to 248 F)

Output type .............................................. Frequency

g01430417 Maximum operating frequency ...................... 15 kHz

Illustration 41
View F-F Output voltage ........................................ 39 8 volts
(9) Torque for four studs .... 65 10 Nm (48 7 lb ft)

Note: Apply 9S-3263 Thread Lock Compound to the

threads before installing studs (9).

(10) Lubricate the bore with a minimal amount of the

lubricant that is being sealed.

(A) Height of four studs ............... 26 mm (1.02 inch)

KENR5814 39
Power Train
Specifications Section

i02763919

Liquid Level Sensor

(Transmission Oil)
SMCS Code: 7422-T3
Part No.: 306-6875

g01428696
Illustration 43

(1) Final installation torque for liquid level sensor

group ............................. 22 3 Nm (16 2 lb ft)

Operating temperature ........................ 40 to 125 C

(40 to 257 F)

Medium ........................................ Hydrocarbon base

i02784098

Input Drive Shaft

SMCS Code: 3253-IV
Part No.: 253-4613

g01390630
Illustration 44

(1) Torque for eight bolts .................... 300 40 Nm

(220 30 lb ft)

(2) Prior to assembly, wipe the face of the bearing

cap and the face of the yoke. Make sure that both
of the mounting faces are clean.
40 KENR5814
Power Train
Specifications Section

i02784248

Drive Shaft
SMCS Code: 3253
Part No.: 253-4612

g01390718
Illustration 45

(1) Torque for the forty bolts ................ 530 70 Nm

(390 50 lb ft)

Note: The mounting face of the bearing cap and the

mounting face of the yoke should be clean prior to
assembly.

(2) The joint assemblies and the yokes must be

in-phase.

(3) Lubricate the splined slip shaft at this location.

(4) Orient the shaft with the female end toward the
transmission.

(5) Lubricate the splined slip shaft with 5P-0960

Grease when the machine is fully articulated.

(6) The non-engine end frame of the machine

g01390951
Illustration 46
View A-A

(7) Torque for twelve bolts ..................... 55 10 Nm

(40 7 lb ft)

(8) Lubricate the sealing lip lightly with grease that is

being sealed.
KENR5814 41
Power Train
Specifications Section

(9) Torque for one bolt ......................... 530 70 Nm

(390 50 lb ft)

(10) When the bearings are assembled, the words

THRUST will be positioned back to the back on
the inside diameter of the bearing races.

g01390956
Illustration 47
View B-B

(11) Torque for six bolts .. 120 20 Nm (90 15 lb ft)

(12) Be sure to align the lube hole on the housing for

easy access.

Note: Lubricate support bearing with 1P-0808

Multipurpose Grease only.
42 KENR5814
Power Train
Specifications Section

i02785231

Differential and Bevel Gear

SMCS Code: 3256; 3258
Part No.: 242-8673

g01391474
Illustration 48

(1) Torque the 35 bolts in an alternating sequence
that fasten the carrier assembly to the axle
housing to 875 125 Nm (640 90 lb ft) and
then turn each bolt by an additional 120 10 in
an alternating sequence.
(2) Torque for the 25 bolts that fasten the pinion
housing to the carrier assembly .. 1000 125 Nm
(740 90 lb ft)
KENR5814 43
Power Train
Specifications Section

(3) Assembled backlash of bevel

gear .................... 0.4 0.12 mm (0.016 0.005)

(4) Torque for four bolts of the locknut ... 28 7 Nm

(20 5 lb ft)

(5) Torque for the 30 bolts that fasten the bevel gear
to the carrier assembly .................. 530 70 Nm
(390 50 lb ft)

(6) Torque for the bolts that fasten the bearing

caps to the carrier assembly to 1800 200 Nm
(1320 150 lb ft) after the gear and the shroud
have been properly adjusted.

(7) Lubricate the sealing lip lightly with the lubricant

that is being sealed.

i02786721

Fixed Axle (Front)

SMCS Code: 3278
Part No.: 245-5963

g01392111
Illustration 49
Rear view
(2) Shim pack (3) Pin
44 KENR5814
Power Train
Specifications Section

(1) Torque for four bolts ....................... 100 20 Nm

(75 15 lb ft)

Note: Refer to the manual for Disassembly and

Assembly of this machine for the correct procedure
to set the proper preload for the differential carrier
assembly.

(4) Torque for connector ...... 70 7 Nm (50 5 lb ft)

(5) Torque for adapter ....... 70 7 Nm (50 50 lb ft)

(6) Torque for purging screw ................... 11 4 Nm

(82 3 lb ft)

(7) Torque for 80 bolts ..................... 1800 200 Nm

(1320 150 lb ft)

(8) Torque for drain assembly ............. 230 15 Nm

(170 11 lb ft)

Note: A pipe with a one inch diameter is needed to

activate the valve for draining.

(9) Torque for plug ............... 80 7 Nm (60 5 lb ft)

(10) Torque for plug assembly ............ 210 20 Nm

(155 15 lb ft)
KENR5814 45
Power Train
Specifications Section

i02787490

Oscillating Axle (Rear)

SMCS Code: 3278
Part No.: 245-5964

g01394316
Illustration 50
Top view

(1) Torque for the 80 bolts ............... 1800 200 Nm Note: Refer to the manual for Disassembly and
(1320 150 lb ft) Assembly of this machine for the correct procedure
to set the proper preload for the differential carrier
assembly.

g01394750
Illustration 51
View A-A
(3) Shim pack
(4) Pin

(2) Torque for the four bolts ................. 100 20 Nm

(75 15 lb ft)
46 KENR5814
Power Train
Specifications Section

g01392394
Illustration 52
Rear view

(5) Torque for the connector .................... 70 7 Nm

(50 5 lb ft)

(6) Torque for adapter ......... 70 7 Nm (50 5 lb ft)

(7) Torque for purging screw ................... 11 4 Nm

(95 35 lb in)

(8) Torque for drain assembly ............. 230 15 Nm

(170 11 lb ft)

Note: A pipe with a one inch diameter is needed to

activate the valve for draining.

(9) Torque for plug ............... 80 7 Nm (60 5 lb ft)

(10) Torque for plug assembly ............ 210 20 Nm

(155 15 lb ft)
KENR5814 47
Power Train
Specifications Section

g01392861
Illustration 53
View B-B

(11) Torque for the 18 bolts ............. 1000 125 Nm (18) Outside diameter of the
(740 90 lb ft) trunnion ...... 370 0.05 mm (14.57 0.002 inch)

(12) The correct orientation of oil seal is shown. (19) Sleeve bearing

(13) Torque for 25 bolts ................... 1000 125 Nm Outside diameter of the sleeve
(740 90 lb ft) bearing ................................... 388.93 0.15 mm
(15.312 0.006 inch)
(14) Torque for 12 bolts .. 100 20 Nm (75 15 lb ft) Inside diameter of the sleeve
bearing ................................... 371.31 0.15 mm
(15) Apply 6V-5765 Sealant to the machined face (14.618 0.006 inch)
of the support before you install the retainer.
(20) Inside diameter of the trunnion
(16) Sleeve bearing support ...... 388.5 0.1 mm (15.30 0.004 inch)

Outside diameter of the sleeve

bearing ................................... 388.93 0.15 mm
(15.312 0.006 inch)
Inside diameter of the sleeve
bearing ................................... 371.31 0.15 mm
(14.618 0.006 inch)

(17) Inside diameter of the trunnion

support ...... 388.5 0.1 mm (15.30 0.004 inch)
48 KENR5814
Power Train
Specifications Section

i02865736

Axle Mounting
SMCS Code: 3278-MT
Part No.: 244-1116

g01427490
Illustration 54
Front Axle

(1) Torque for the 20 bolts .............. 3100 350 Nm

(2280 260 lb ft)

Note: The nuts will need to be held as the bolts are

tightened.

g01427500
Illustration 55
Rear Axle
KENR5814 49
Power Train
Specifications Section

(2) Torque for the twelve bolts ........ 3100 350 Nm

(2280 260 lb ft)

(3) Torque for the six bolts ............. 3100 350 Nm

(2280 260 lb ft)

i02786091

Final Drive and Wheel

SMCS Code: 4051
Part No.: 245-5950

g01429932
Illustration 56

(1) Torque for 38 bolts ..................... 1800 200 Nm

(1320 150 lb ft)

(2) Torque for drain plug ...... 65 5 Nm (48 4 lb ft)

(3) Torque for drain assembly ............. 130 10 Nm

(95 7 lb ft)

Note: A pipe with a diameter of 19.050 mm (0.75 inch)

is needed to activate the valve for draining oil.

(4) Torque for plug ............... 65 6 Nm (48 4 lb ft)

(5) All of the surface areas must be clean and dry.

Clean the surfaces with solvent. Apply lubricant to
the carrier on the surface that comes into contact
with the washer. Finger tighten the screws to
the thrust washer. Torque the four screws in a
cross-tightening sequence.
50 KENR5814
Power Train
Specifications Section

g01429879
Illustration 57
View A-A

(6) Lubricate the contacting surfaces of the seal. Use

the lubricant to be used in the power train.

(7) Rubber torics, and all contacting surfaces must

be clean and dry prior to assembly. Smear a thin
film of oil onto the contacting surfaces of the
metal seals just before installation. Lubricate all
other seals on assembly. The seal rings must be
assembled square with the bore. The O-ring seal
must not be twisted.

(8) Final torque for 16 bolts 900 100 Nm

(660 75 lb ft).

For the procedure to install the wheel bearings, refer

to the Disassembly and Assembly manual for the
machine that is being serviced.
KENR5814 51
Power Train
Specifications Section

i02870389

Rim Mounting
SMCS Code: 4209-MT
Part No.: 249-4346

g01429772
Illustration 58

(2) Torque for the 50 nuts ............... 1800 200 Nm

(1320 150 lb ft)

(4) Torque for the two nuts for the valve assembly
................................ 19 to 24 Nm (14 to 18 lb ft)
52 KENR5814
Power Train
Specifications Section

i02895220

Piston Pump (Implement Pilot)

(Axle Oil Cooler)
(Axle Oil Cooler Supply Oil)
SMCS Code: 5070-PS; 5070-AOC
Part No.: 249-7013

g01441372
Illustration 59

Displacement per revolution ............... 74 cc (4.5 in3)

Pressure cutoff ...... 21000 350 kPa (3050 50 psi)

Margin pressure ........ 2100 100 kPa (305 15 psi)

The pump rotates in a counterclockwise direction

when the pump is viewed from the shaft end.

(1) Torque for four bolts ................ 12 Nm (106 lb in)

(2) Torque for the plug .................. 15 Nm (133 lb in)

g01441370
Illustration 60
View A-A

(3) 6E-4000 Spacer

(C) 0.025 0.025 mm (0.001 0.001 inch)

Grind spacer (3) in order to achieve dimension (C).

The faces of the spacer should be parallel within
0.05 mm (0.002 inch).
KENR5814 53
Power Train
Specifications Section

Outside diameter .................. 7.7 mm (0.30 inch)

(10) Torque for two nuts ................. 21 Nm (15 lb ft)

(11) Torque for two nuts ................. 21 Nm (15 lb ft)

(12) 6E-3276 Spring

Length under test force ....... 32.6 mm (1.28 inch)
Test force ...................... 462 71 N (105 16 lb)
Free length after test .......... 35.6 mm (1.40 inch)
Outside diameter ................ 19.2 mm (0.76 inch)

(13) 193-1036 Spring

Free length ......................... 31.1 mm (1.22 inch)
Outside diameter .................. 8.3 mm (0.33 inch)

g01441371
Illustration 61
View B-B

(4) Torque for the cylinder ............ 130 Nm (95 lb ft)

(5) Torque for two plugs ................. 30 Nm (22 lb ft)

(6) Torque for the piston guide ..... 130 Nm (95 lb ft)

135-6616 Pump Control Valve

g01441373
Illustration 62

(7) Apply 4C-4030 Thread Lock Compound to the

threads of two plugs prior to installation.

(8) 6E-3275 Spring

Length under test force ....... 15.1 mm (0.59 inch)
Test force .................... 40.2 2.8 N (9.0 0.6 lb)
Free length after test .......... 20.5 mm (0.81 inch)
Outside diameter ................ 10.7 mm (0.42 inch)

(9) 6E-3274 Spring

Length under test force ....... 14.4 mm (0.57 inch)
Test force ...................... 81.7 14.5 N (18 3 lb)
Free length after test .......... 15.9 mm (0.63 inch)
54 KENR5814
Power Train
Specifications Section

i02757104

Piston Pump (Implement Pilot)

(Axle Oil Cooler)
SMCS Code: 5070-PS; 5070-AOC
Part No.: 249-7013

g01380662
Illustration 63

Displacement per revolution ............... 74 cc (4.5 in3) Case drain flow .............. 2.7 L/min (0.7 US gpm)

Pressure cutoff ...... 21000 350 kPa (3050 50 psi) (1) Torque for four bolts ................ 12 Nm (106 lb in)

Margin pressure ........ 2100 100 kPa (305 15 psi) (2) Torque for the plug .................. 15 Nm (133 lb in)

The pump rotates in a counterclockwise direction

when the pump is viewed from the shaft end.

Maximum case drain pressure ........ 200 kPa (29 psi)

Test at Full Speed:

Output ......................... 129.1 L/min (34 US gpm)
Pressure ............................... 5000 kPa (725 psi)
Pump speed ........................................ 1760 rpm
Engine speed ....................................... 1785 rpm
Case drain flow .............. 1.2 L/min (0.3 US gpm)
Output ......................... 126.1 L/min (33 US gpm)
Pressure ........................... 20000 kPa (2900 psi)
Pump speed ........................................ 1760 rpm
Engine speed ....................................... 1785 rpm
Case drain flow .............. 4.2 L/min (1.1 US gpm)

Test at Half Speed:

Output ........................ 64.2 L/min (17.0 US gpm) Illustration 64
g01380676
Pressure ............................... 5000 kPa (725 psi)
View A-A
Pump speed .......................................... 880 rpm
Engine speed ......................................... 890 rpm
(3) 6E-4000 Spacer
Case drain flow .............. 0.9 L/min (0.2 US gpm)
Output ........................ 62.5 L/min (16.5 US gpm) (C) 0.025 0.025 mm (0.001 0.001 inch)
Pressure ........................... 20000 kPa (2900 psi)
Pump speed .......................................... 880 rpm
Engine speed ......................................... 890 rpm
KENR5814 55
Power Train
Specifications Section

Grind spacer (3) in order to achieve dimension (C). Length under test force ....... 14.4 mm (0.57 inch)
The faces of the spacer should be parallel within Test force ...................... 81.7 14.5 N (18 3 lb)
0.05 mm (0.002 inch). Free length after test .......... 15.9 mm (0.63 inch)
Outside diameter .................. 7.7 mm (0.30 inch)

(10) Torque for two nuts ................. 21 Nm (15 lb ft)

(11) Torque for two nuts ................. 21 Nm (15 lb ft)

(12) 6E-3276 Spring

Length under test force ....... 32.6 mm (1.28 inch)
Test force ...................... 462 71 N (105 16 lb)
Free length after test .......... 35.6 mm (1.40 inch)
Outside diameter ................ 19.2 mm (0.76 inch)

(13) 193-1036 Spring

Free length ......................... 31.1 mm (1.22 inch)
Outside diameter .................. 8.3 mm (0.33 inch)

g01380686
Illustration 65
View B-B

(4) Torque for the cylinder ............ 130 Nm (95 lb ft)

(5) Torque for two plugs ................. 30 Nm (22 lb ft)

(6) Torque for the piston guide ..... 130 Nm (95 lb ft)

135-6616 Pump Control Valve

g01380702
Illustration 66

(7) Apply 4C-4030 Thread Lock Compound to the

threads of two plugs prior to installation.

(8) 6E-3275 Spring

Length under test force ....... 15.1 mm (0.59 inch)
Test force .................... 40.2 2.8 N (9.0 0.6 lb)
Free length after test .......... 20.5 mm (0.81 inch)
Outside diameter ................ 10.7 mm (0.42 inch)

(9) 6E-3274 Spring

56 KENR5814
Power Train
Specifications Section

i02857083

Axle Oil Cooler Pump and

Motor
SMCS Code: 1365-NP; 1365-MQ; 5061-AOC;
5073-AOC
Part No.: 249-7012

g01423238
Illustration 67
249-7012 Axle Oil Cooler Pump and Motor
(1) 267-8900 Gear Motor (2) 267-8901 Gear Pump (3) 267-8972 Relief valve

(4) Torque for plug ............... 85 4 Nm (65 3 lb ft)

(5) Torque for four nuts ..... 115 7 Nm (85 5 lb ft)

(6) Torque for four bolts ..... 115 7 Nm (85 5 lb ft)

(7) Torque for four bolts ....................... 105 20 Nm

(75 15 lb ft)

(8) Torque for eight bolts ... 115 7 Nm (85 5 lb ft)

Displacement of the motor .. 39.7 cc/rev (2.43 in3/rev)

Displacement of the pump .. 59.4 cc/rev (3.63 in3/rev)

Maximum rpm for pump and motor ............ 2500 rpm

Maximum pressure for motor .. 17200 kPa (2500 psi)

Maximum pressure for pump .. 17200 kPa (2500 psi)

Note: With the flow rate of the pump supply at Illustration 68

g01423262
117.3 L/min (31 US gpm), block the pump outlet. Set 267-8901 Gear Pump
relief valve (3) at 1034 34 kPa (150 5 psi). Use
SAE 10W oil at 37.8 C (100 F). (9) Torque for four bolts .................... 8 Nm (70 lb in)
KENR5814 57
Power Train
Specifications Section

(10) The backs of the seals are against each other. (13) Torque for cap .............. 37 3 Nm (27 2 lb ft)

(14) Torque for fitting .......... 10 1 Nm (90 9 lb in)

i02763977

Oil Filter (Implement Pilot)

(Axle Oil Cooler)
SMCS Code: 3004-AOC; 5068-PS
Part No.: 155-6061, 156-1382

g00730431
Illustration 71
g01423438
Illustration 69
267-8900 Gear Motor

(11) Back up ring

Note: Insert the O-ring into the groove of the back up

ring. The flat surface of the back up ring goes against
the bushing.

(12) Sealing strip

Note: Rotation of the shaft is clockwise when the

axle oil cooler pump and motor is viewed from the
motor end of the assembly.
g00730435
Illustration 72

267-8972 Relief Valve View A-A

(1) Torque for housing ...................... 101.7 10 Nm

(75 7.0 lb ft)

(2) Torque for plug .......... 51 10 Nm (38 7.0 lb ft)

(3) 156-1382 Switch

Final installation torque ...................... 19 3 Nm
(14.0 2.0 lb ft)
Maximum actuation pressure at40 to +120C
(40 to +248F) .... 276 28 kPa (40.0 4.0 psi)
Deactuation pressure at 40 to +120C
(40 to +248F) ..................... 179 kPa (26.0 psi)

Illustration 70
g01423423 The switch is normally closed.
Relief valve (3)
Bypass valve pressure setting ........ 345 kPa (50 psi)
58 KENR5814
Power Train
Specifications Section

i02767705 Contact position .......................................... Normally

closed below deactuation pressure
Oil Filter (Screen) (Axle Oil
Cooler) i02767961

SMCS Code: 3004-Z3; 3004-AOC Bypass Valve (Axle Oil Cooler)

Part No.: 117-7773, 230-3633 (Thermal Relief)
SMCS Code: 5074-AOC
Part No.: 251-1635

g01351820
Illustration 75

(1) 251-1635 Bypass Valve (AXLE OIL COOLER)

g01047954
Illustration 73
Opening temperature ................ 82.2 C (180 F)
Pressure setting of the bypass valve ........... 345 kPa Relief pressure ......................... 345 kPa (50 psi)
(50 psi)
i02769246
117-7773 Pressure Switch (Filter Pressure Switch (Brake
Bypass)
Lubrication Oil)
SMCS Code: 1365-ZS; 1408-ZS
Part No.: 130-7459

g00578752
Illustration 76

Illustration 74
g00658892 The switch has a normally open position.

(1) Final installation torque for the pressure The switch closes when the pressure increases to
switch ............................. 48 5 Nm (35 4 lb ft) the actuation pressure.

Actuation pressure ......... 138 28 kPa (20 4.0 psi) Actuation pressure .............. 93 20 kPa (13 3 psi)

Deactuation pressure (minimum) ........... 89 20 kPa When the pressure decreases below the deactuation
(13 3.0 psi) pressure, the switch will open again.
KENR5814 59
Power Train
Specifications Section

Deactuation pressure .......... 70 20 kPa (10 3 psi)

(1) Installation torque .......... 35 3 Nm (26 2 lb ft)

i02883193

Pressure Sensor (Axle Brake

Oil)
SMCS Code: 1408-PXS; 3278-PXS
Part No.: 224-8496

g01062547
Illustration 77

(1) Torque for the pressure sensor .......... 10 2 Nm

(7.4 1.5 lb ft)

Table 4
Wiring table
Pin Circuit Color
A Volts Orange
B Ground Yellow
C Signal Green

Maximum pressure of the pressure

sensor ......................................... 5701 kPa (827 psi)

Supply voltage of the pressure

sensor ................................................. 8.0 0.5 VDC

Maximum input current of the pressure

sensor ............................................................. 20 mA

Maximum current draw of the pressure

sensor ............................................................. 15 mA

Output frequency of the pressure

sensor .................................................. 500 150 Hz
Index
A Output Transfer Gears........................................... 31
243-1733 Output Transfer Gear Group (Standard
Axle Mounting........................................................ 48 Steering)........................................................... 31
Axle Oil Cooler Pump and Motor ........................... 56 249-0218 Transfer Gears and Case Group
267-8972 Relief Valve...................................... 57 (Secondary Steering) ....................................... 36

B P

Bypass Switch (Torque Converter Charge Filter) Piston Pump (Implement Pilot) (Axle Oil Cooler)... 54
(Transmission Charge Filter) ............................... 19 135-6616 Pump Control Valve ......................... 55
Bypass Valve (Axle Oil Cooler) (Thermal Relief)... 58 Piston Pump (Implement Pilot) (Axle Oil Cooler) (Axle
Oil Cooler Supply Oil) .......................................... 52
135-6616 Pump Control Valve ......................... 53
D Pressure Sensor (Axle Brake Oil).......................... 59
Pressure Sensor (Torque Converter Impeller Clutch
Differential and Bevel Gear ................................... 42 Oil) ....................................................................... 14
Drive Shaft............................................................. 40 Pressure Switch (Brake Lubrication Oil)................ 58

F R

Final Drive and Wheel ........................................... 49 Relief Valve (Torque Converter Outlet).................. 13
Fixed Axle (Front) .................................................. 43 Rim Mounting ........................................................ 51

I S

Important Safety Information ................................. 2 Selector and Pressure Control Valve

Input Drive Shaft.................................................... 39 (Transmission) ..................................................... 24
Input Transfer Gears ............................................. 30 Solenoid Valve (Transmission Clutch) ................... 26
Specifications Section ........................................... 4
Speed Sensor (Transmission Input) ...................... 30
L Speed Sensor (Transmission Output) ................... 38
STIC Control.......................................................... 19
Limit Switch (STIC Lockout Control)...................... 20 STIC Lockout Control......................................... 19
Liquid Level Sensor (Transmission Oil) ................. 39

M
Modulating Valve (Torque Converter Impeller
Clutch) ................................................................. 12
Modulating Valve (Torque Converter Lockup
Clutch) ................................................................. 13
O 246-5244 Torque Converter and Housing and
Oil Filter (Implement Pilot) (Axle Oil Cooler).......... 57
Oil Filter (Screen) (Axle Oil Cooler) ....................... 58
117-7773 Pressure Switch (Filter Bypass) ...... 58
Oil Filter (Torque Converter Charging) .................. 17
Oil Filter (Transmission Charging) ......................... 18
Oscillating Axle (Rear)........................................... 45
T
Table of Contents................................................... 3
Temperature Sensor (Axle Oil) (Transmission Sump
Oil) ....................................................................... 15
Temperature Sensor (Torque Converter Oil) ......... 14
Torque Converter................................................... 8
Torque Converter (Lockup).................................... 10
Torque Converter and Pump Drive Housing.......... 6
246-5256 Torque Converter and Housing with
Lockup.............................................................. 6
Torque Converter and Transmission Pressures .... 4
Torque Converter Priority Valve............................. 12
Transmission Control Valve ................................... 21
Transmission Oil Pump ......................................... 15
Transmission Planetary ......................................... 27

2008 Caterpillar
All Rights Reserved Printed in U.S.A.
2008 Caterpillar
All Rights Reserved Printed in U.S.A.