650L, 750L and 850L

1150K Series 3 and 1650L

Crawler Dozers

Drive Train
Rev. 6-22-2010
Crawler Dozer Drivetrain

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Table of Contents
Drive Train Specifications................................................................................................ 4 
General Hydrostatic System Overview ............................................................................ 5 
Crawler Hydrostatic System Overview ............................................................................ 7 
Functionality .................................................................................................................... 9 
650-850 Hydrostatic Component Overview ................................................................... 13 
1150K Hydrostatic Component Overview...................................................................... 18 
1650L Hydrostatic Component Overview ...................................................................... 23 
Servo Piston Orifices ..................................................................................................... 29 
Park Brakes ................................................................................................................... 30 
Parking Brake Hydraulic – Preliminary Test (650-850 machines) .............................. 32 
Service Brakes .............................................................................................................. 36 
Final Drives ................................................................................................................... 39 
650-850 Dozers ......................................................................................................... 39 
1150K and 1650L Final Drive .................................................................................... 46 
Changing Vehicle Configurations .................................................................................. 48 
Calibration ..................................................................................................................... 51 
Calibrating the 650L, 750L, 850L, 1150K, 1650L Drivetrain ...................................... 51 
Pressure Testing ........................................................................................................... 54 
Charge Pressure Drop Test ....................................................................................... 55 
Drive Pressure Test ................................................................................................... 59 
650L, 750L, 850L Test Procedure .......................................................................... 59 
650-850 Drive Pressure Setting Adjustment (left and right .................................... 65 
1150K Drive Pressure Setting Adjustment (left and right side) .............................. 66 
650-850 Pressure override valve – Pressure setting ................................................. 70 
1150K Pressure Override valve – Pressure setting ................................................... 72 
Mechanical Pump Centering ......................................................................................... 74 
Hydraulically Centering the Servo Control Piston .......................................................... 77 
Moving a Disabled Crawler ........................................................................................... 79 
Opening the Pressure Release Valves ...................................................................... 80 
Releasing the Brakes................................................................................................. 81 
TROUBLESHOOTING THE HYDRAULIC / HYDROSTATIC OIL COOLING SYSTEM 83 
Hydrostatic Crawler/Dozer Left Hand Joystick Troubleshooting .................................... 87 

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Drive Train Specifications

650L, 750L-850L Specifications
Charge pump pressure……………………………………...…24 Bar (350 psi) at idle
Left Forward Circuit Relief…………………………………… …….414 bar (6000 psi)
Left Reverse Circuit Relief………………………………………….414 bar (6000 psi)
Right Forward Circuit Relief………………………………………...…4 bar (6000 psi)
Right Reverse Circuit Relief……………………………………...…414 bar (6000 psi)
Right Pressure Override Valve…. Blocked (Screwed in tight) not used on machine
Left Pressure Override Valve……Blocked (Screwed in tight) not used on machine

1150K Specifications
Charge Pump Pressure……………………………………….. 30 bar (435 psi) at idle
Left Forward Circuit Relief……………………………………...…..420 bar (6100 psi)
Left Reverse Circuit Relief………………………………….……... 420 bar (6100 psi)
Right Forward Circuit Relief……………………………………...…420 bar (6100 psi)
Right Reverse Circuit Relief……………………………………...…420 bar (6100 psi)
Right Pressure Override Valve…. Blocked (Screwed in tight) not used on machine
Left Pressure Override Valve……Blocked (Screwed in tight) not used on machine

1650L Specifications
Charge Pump Pressure…………………………………….…. 30 bar (435 psi) at idle
Left Forward Circuit Relief…………………………………………. 420 bar (6100 psi)
Left Reverse Circuit Relief………………………………………….420 bar (6100 psi)
Right Forward Circuit Relief……………………………………….. 420 bar (6100 psi)
Right Reverse Circuit Relief……………………………………….. 420 bar (6100 psi)
Right Pressure Override Valve…. Blocked (Screwed in tight) not used on machine
Left Pressure Override Valve……Blocked (Screwed in tight) not used on machine

Note: all pressures above are when bench tested.

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General Hydrostatic System Overview

In a hydrostatic closed loop system, the pump and the drive motor are directly
connected to each other. The hydrostatic pump sends oil directly to the motor and this
same oil returns back to the pump. The pump is usually a piston type unit that has the
ability to vary the rate and the direction of the oil flow. This is accomplished by
changing the position of the pump's swash plate in relation to the rotating group (made
up of pistons and cylinder block). The angle of the swash plate causes the pistons to
stroke into and out of the cylinder block bores as it is rotated. Changing this angle
varies the piston stroke and, therefore, the amount of oil being pumped to the motor.
Tilting the swash plate in the opposite direction will reverse the flow to the motor and
hence the direction of motor rotation.

This is a simple closed loop circuit showing one half of the entire machine’s closed loop
system. The Rexroth tandem piston pump shares one common charge pump between
the left and right systems. This system utilizes an electro proportional servo controlled
swash plate, variable piston pump, and variable bent axis piston motors.

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High pressure oil is also used to minimize wear in the rotating group, as well as drive
the motors. To prevent the slippers on the pistons from wearing out too rapidly as they
rotate, there is a small hole drilled through the piston and slipper to allow oil to
constantly form a cushion between the slipper and swash plate. The same pressure the
piston sees while pumping will be passed through the drilled hole to provide a column of
oil for the piston to ride upon. A smaller area of the slipper is pressurized than the area
of the piston. This difference in area will keep the slipper held against the swash plate.
The head of the slipper seals this pressurized oil to the swash plate.

With the high pressures required to drive the machines, some of the closed loop oil will
leak into the case drain of the components. This lost oil must be re-supplied to keep the
system working. A fixed displacement charge pump is used to make up for this loss.
The charge pump supplies cooled and filtered oil from the reservoir, under a relatively
low pressure (350 – 500 psi) to the closed loop, keeping the system charged and supply
fluid to operate the control system.

In order for the low pressure charge oil to get into the closed loop, a check valve is
placed between the charge oil supply and each side of the closed loop. As the unit
drives, one side of the closed loop will increase in pressure. This increase in pressure
would increase the leakage from the loop and, the oil returning from the motor to the
pump would not be adequate to compensate for the excess leakage.

The pressure on the return side of the loop would be maintained at charge pressure
because the check valve allows flow from the charge pump circuit. The check valve on
the drive side of the circuit would be held closed by the high pressure on that side of the
loop. When the direction of travel is reversed, charge flow would then enter the loop on
the opposite side.

If the machine were to become disabled, the drive sprockets would lock because they
are directly coupled to the hydrostatic drive system through the final drives. A pair of
bypass (tow) valves in each pump will allow the machine to be moved for service, once
the brakes are released. The bypass valve separates the forward and reverse side of
the closed loop. When the valves are opened approximately three turns, the loop oil
can bypass the pump and the machine can be moved. Use caution when the bypass
valves are opened to prevent the machine from moving out of control. With the bypass
valves are open; do not move the machine more than 1 mph or more than 100 feet.

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Crawler Hydrostatic System Overview

The Crawler/Dozers utilize a dual path closed loop hydrostatic drive system to operate
both tracks independently. The engine provides power for two hydrostatic pumps, one
for each track, to supply oil to the drive motor for each track. The drive motors are
directly coupled to the left or right final drive assembly. The tracks are then controlled
via a joystick from the left side of the operator’s platform. The two tracks being powered
individually allow for power turns and counter rotation.

Each hydrostatic pump is a piston pump design that allows for the variable
displacement of oil. The amount of oil flow from the pump to the drive motor controls the
speed of the vehicle in the forward and reverse directions.
As the amount of oil being pumped increases so does the vehicle speed. As one might
expect as the amount of oil being pumped decreases the vehicle speed decreases and
the amount of torque or pulling power the vehicle has increases. The swash plate is
controlled by the operator electronically and changes the angle of the rotating piston
group. As the angle of the swash plate gets larger the amount of oil pumped increases.
As the swash plate goes to a neutral position, the flow of oil stops and the vehicle
comes to rest. The direction of the swash plate is what controls the directional flow of
oil. Therefore, the pump always turns the same direction but the swash plate angles
determine which way the flow available to do work travels.

The piston motors then receives oil from the pump, which causes a piston group to
rotate. The motors are used to power the final drives. The variable motor also has a
swash plate which can change angle to increase or decrease speed. With variable
pumps and motors the operator can select an appropriate speed for operation. Oil
leaving the motors goes directly back to the pump and the cycle starts again.

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Not all of the original oil returns to the hydrostatic pump. Some of the oil is lost to the
reservoir through internal leakage of the pumps and motors. This oil is then picked up
by the equipment hydraulic pump, cooled, filtered, and put back into the closed loop via
the charge pump. The oil that leaks from the pump and motors is not enough to keep
the closed loop oil cool; therefore, a cooling shuttle valve is incorporated into the motor
to direct some additional oil back to the reservoir. If the system continued to operate
without a charge pump it would only operate for a few cycles before pump cavitation
and failure would occur. For that reason a charge pump supplies cool and filtered oil to
replenish oil lost from the internal leakage of the pump and motors as well as the oil that
is drained off from the cooling shuttle valve. The charge pump also provides oil to
release the parking brake.

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Functionality
The variable displacement hydrostatic pump and the charge pump are driven by the
diesel engine.

The charge pump pumps oil through the charge filter. If the charge filter cartridge is
excessively dirty, the charge filter restriction indicator will alert you of this problem. The
Normally Open (NO) pressure switch closes at 36-44 psi to ground the light in the
instrument cluster and tell the operator that the filter is plugged. If back pressure is too
high in front of a dirty charge filter cartridge (50 psi differential pressure from the inlet to
the outlet), the charge circuit bypass valve opens and directs part of the charge oil back
to the inlet side of the charge pump after going through the charge circuit strainer.

The charge pressure is limited by two charge pressure relief valves, 1 in each pump
assembly, and can be checked at the test port located on the test panel. Charge
pressure oil is directed to the appropriate low pressure side of the variable displacement
pump (dependent upon travel direction) by way of the check/replenishing valves. The
check/replenishing valves are integrated into the high pressure circuit relief valves.
Charge oil compensates for leakage in our closed loop system.

The charge pump generates a variable flow dependent upon the speed of the engine.
The faster the engine speed, the higher the charge pump flow. The charge flow is
directed to the Electro-Proportional Valve (EP Valve). The EP Valve is controlled by the
Pulse Width Modulated (PWM) Solenoid valves. The PWM solenoids receive a varying
voltage signal from the Drive Train Controller (DTC) to shift the EP valve spool. The EP
valve spool diverts the charge pressure to the desired side of the servo cylinder. The
servo cylinder then creates the angular movement of the swash plate.

The EP Valve is spring centered to its neutral position. While in neutral oil from both
sides of the servo cylinder has a path to tank through the case drain line of the pump.
When forward movement is requested by the operator the joystick sends a signal to the
DTC stating which direction the operator would like to travel and at what speed. Based
upon this input from the operator the DTC controller sends a signal to the appropriate
PWM solenoid. The solenoid shifts the EP valve spool and charge pressure is diverted
to the appropriate side of the servo piston.

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Hi speed Servo travel

stop bolt adjustment
Factory Set (Factory set)

Low speed
stop bolt
(Factory set)

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The DTC controller receives a motor shaft speed signal from the Hall Effect sensors in
each motor. With the motor speed information, the DTC can then compensate for
mistracking by de-rating the appropriate solenoid. The EP valve then shifts as
necessary to maintain the desired speed. When the machine is traveling, high pressure
oil is pumped to the hydraulic motors by the travel pumps. In the event the oil pressure
exceeds approximately 6500 PSI in the travel circuit, the related circuit relief valve
opens to dump the excess drive pressure into the charge circuit. The service manual
states the circuit reliefs are set at 6000 to 6100 psi (depending on the size of the
machine), which is correct for a bench setting. But when they are installed in the hydro
system, charge pressure (350-500psi) is added to the spring setting to bring the drive
pressure to 6350 to 6600 psi (depending on the size of the machine) in the forward and
reverse directions.

The pump and motor swatch plate angles have ten preset positions. These positions
are controlled by the DTC controller and EP valves and toggled between by the
operator with bump up and bump down buttons located on the joystick. By toggling
between these preset positions the speed of the vehicle is changed in the pump up to
the 60 % preset position (startup default speed) on the instrument cluster. Once the
operator commands more than 60%, the DTC then starts to destroke the motors
accordingly.

From 70 % to 100 % preset positions, the motor EP valves control the motor swash
plate by allowing a certain amount of drive side high pressure oil to energize the
appropriate side of the adjusting cylinder. The adjusting cylinder will either retract or
extend based upon how the EP valve is set. The swash plate angle is increased or
decreased by retracting and extending the adjusting cylinder. As the angle increases,
speed decreases, and torque increases. As the angle decreases, speed increases, and
torque decreases. The motor swash plate is defaulted to the full swash position and
requires a voltage signal to the motor EP valve to decrease the swash and increase
machine speed.

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A cooling shuttle spool is also integrated into the motor housing. The spool reacts to
drive side high pressure oil and allows return side low pressure (charge pressure) hot oil
to exit the motor and return to the hydraulic reservoir.
Direction and speed are both controlled by a joystick located in the left hand console. As
the joystick is moved forward the machine begins forward movement. Once out of the
neutral position, track speed is controlled by the amount of movement of the joystick
and the bump up and bump down buttons located on the joystick. These buttons
change the speed by a predetermined amount and display the selected speed on the
dash. There are 10 preset operating positions that the operator can bump up and down
between. The speed defaults to the 60 % position of 3 MPH every time the engine is
started. Holding the bump up and bump down buttons for a continuous time will
continue to shift up or down through the preset operating speeds. This same process
also holds true for the reverse direction.

For greater working efficiency the speed of reverse is variable based upon maximum
speed in the forward direction. The maximum reverse speed can be 80%, 100%, 115%,
or 130% of the maximum forward speed. The forward to reverse ratio is controlled by
the forward speed set by the bump up and bump down buttons as well as the setting
selected on the reverse ratio speed knob.

Steering is also commanded by the joystick located in the left hand console. When the
operator commands turning (must be in forward or reverse to turn) the inside track
decreases in speed and the outside track remains at the same speed (Pivot Turn).
Counter rotation is possible when a pivot turn is not adequate (NOTE: Joystick lever
must be in the forward or reverse direction). When the operator moves the joystick past
the pivot turn position, counter rotation will take place. The inside track shall begin to
move in the reverse direction of the outside track. As the joystick is stroked against its
stop the tracks will be driven at commanded speed for the forward or reverse direction
with both tracks being driven in opposite directions.

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650-850 Hydrostatic Component Overview

(1) INPUT SHAFT (8) REAR CHARGE PUMP (15) PUMP FEED
INLET CROSSOVER LINE
(2) FRONT MOUNT BOLTS (9) HYDRAULIC PUMP (16) (REAR PUMP) RIGHT
INLET LINE REVERSE PRESSURE
RELIEF VALVE
(3) CASE DRAIN LINE T2 (10) BRAKE SOLENOID (17) SOLENOID AND
PRESSURE LINE PRESSURE SWITCH
WIRING HARNESS
(4) LIFT CYLINDER (11) EQUIPMENT VALVE (18) OIL COOLER BYPASS
CROSSOVER LINES RETURN LINE VALVE SUPPLY
(5) RIGHT MOTOR HIGH (12) LEFT MOTOR HIGH (19) FRONT PUMP
PRESSURE LINES PRESSURE LINES PRESSURE OVERRIDE
VALVE
(6) CASE DRAIN TO (13) DIAGNOSTIC CENTER (20) (FRONT PUMP) LEFT
RESERVOIR LINE T2 LINES REVERSE PRESSURE
RELIEF VALVE
(7) HYDRAULIC PUMP (14) CHARGE PRESSURE
OUTLET LINE FILTER OUTPUT LINE
NOTE: The forward pressure relief valves are located directly below the reverse pressure
relief valves.
The rear pump pressure override valve is located near the rear pump forward pressure relief
valve

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650-850 Component Overview Cont.

(1) RIGHT HYDROSTATIC (7) LEFT MOTOR SOLENOID (13) RIGHT MOTOR HIGH
MOTOR PRESSURE HOSE
(2) LEFT HYDROSTATIC (8) LEFT MOTOR SPEED (14) RIGHT SPEED
MOTOR SENSOR SENSOR DISCONNECT
(3) LEFT MOTOR HIGH (9) LEFT MOTOR CASE (15) RIGHT SOLENOID
PRESSURE HOSE DRAIN HOSE DISCONNECT
(4) RIGHT MOTOR HIGH (10)LEFT SOLENOID (16) RIGHT MOTOR CASE
PRESSURE HOSE DISCONNECT DRAIN HOSE
(5) RIGHT MOTOR SPEED (11) LEFT SPEED SENSOR (17) MAIN HYDRAULIC
SENSOR DISCONNECT PUMP
(6) RIGHT MOTOR (12) LEFT MOTOR HIGH
SOLENOID PRESSURE HOSE

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650-850 Component Overview Cont.

(1) LEFT MOTOR HIGH PRESSURE LINES (5) LEFT MOTOR

(2) RIGHT DRIVE PUMP (6) RIGHT MOTOR
(7) MOTOR FRONT CASE
(3) LEFT DRIVE PUMP
DRAIN LINES
(4) RIGHT MOTOR HIGH PRESSURE (8) MOTOR REAR CASE DRAIN
LINES LINES

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650-850 Component Overview Cont.

(1) CHARGE PUMP FEED (6) FILTER BYPASS (11) CHARGE PUMP
LINE RETURN LINE SUPPLY TO THE RIGHT
PUMP ASSEMBLY
(12) G PORT (CHARGE
(2) RESERVOIR SUPPLY (7) HYDROSTATIC
PUMP SUPPLY TO LEFT
LINE FILTER
PUMP ASSEMBLY
(3) CASE DRAIN TO (8) FILTER PRESSURE (13) T2 PORT FOR CASE
RESERVOIR LINE FEED LINE DRAIN
(4) CASE DRAIN CROSS (9) CHARGE PUMP
OVER LINE SUPPLY TO FILTER
HEAD
(5) CHARGE PUMP (10) INLET TO THE
CROSS OVER FEED CHARGE PUMP FROM
LINE RESERVOIR

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1150K Hydrostatic Component Overview

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1150K Hydrostatic Component Overview (cont.)

1. FROM EQUIPMENT 10. FROM FRONT CHARGE 19. RIGHT PUMP
VALVE PUMP (REAR)
2. RESERVOIR TO 20. CASE DRAIN TO
11. MOUNT BRACKET
HYDRAULIC PUMP RESERVOIR
21. RIGHT MOTOR
3. HYDRAULIC PUMP 12. LEFT PUMP (FRONT) HIGH PRESSURE
LINES
13. RIGHT REVERSE
4. TO HYDRAULIC
DRIVE CIRCUIT RELIEF 22. “T” FITTING
FILTER
VALVE
5. FROM HYDROSTAT 14. CLAMP MOUNTING 23. TO HYDROSTATIC
FILTER BOLTS FILTER
15. CASE DRAIN CROSS 24. LEFT REVERSE
6. “T” FITTING OVER DRIVE CIRCUIT RELIEF
VALVE
16. CHARGE PRESSURE 25. PRESSURE
7. RIGHT PUMP (REAR) SETTING OVERRIDE VALVE
8. FRONT CHARGE
17. DIAGNOSTIC LINES
PUMP INLET HOSE
9. LEFT MOTOR HIGH 18. CHARGE PUMP
PRESSURE LINES CROSS OVER
Note: The forward pressure relief valves are located directly below the reverse
pressure relief valves. The Front pump pressure override valve is located near the
front pump forward pressure relief valve

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1150K Hydrostatic Component Overview Cont.

1. MAIN RELIEF 3. MAIN RELIEF

2. CHARGE PRESSURE RELIEF 4. PRESSURE OVERRIDE VALVE (NOT SHOWN)

NOTE: The rear charge pump will be rotated 180° and the location of the pressure relief
valves will be on the opposite side.

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1150K Hydrostatic Component Overview Cont.

1150K Left Motor Component Locations

1. Left Motor Speed Sensor 3. Left Motor Speed Sensor Connector P5
2. Left Motor Solenoid 4. Left Motor Solenoid Connector P7

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1150K Hydrostatic Component Overview Cont.

1150K Right Motor Component Locations

1. Right Motor Speed Sensor Connector 3. Right Motor Solenoid Connector P8
P6
2. Right Motor Solenoid 4. Right Motor Speed Sensor

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1650L Hydrostatic Component Overview

Top View

1. HYDRAULIC PUMP 8. CHARGE PRESSURE SWITCH

CONNECTOR
9. PILOT PRESSURE TO CONTROL
2. SUCTION HOSE REAR CHARGE PUMP
VALVE
3. BRAKE PRESSURE HOSE 10. TO HYDROSTAT FILTER
4. RIGHT MOTOR LOWER HIGH 11. LEFT MOTOR UPPER HIGH
PRESSURE PRESSURE
5. LEFT MOTOR LOWER HIGH PRESSURE 12. SOLENOID CONNECTORS
6. FROM EQUIPMENT VALVE 13. FILTER RETURN HOSE
7. SUCTION HOSE FRONT CHARGE
PUMP 14. DIAGNOSTIC HOSES

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1650L Hydrostatic Component Overview (cont.)

Right Side View

1650L RIGHT SIDE VIEW

1. MAIN PRESSURE RELIEF LEFT 2. FRONT CHARGE PUMP PRESSURE
REVERSE RELIEF
NOTE: Main pressure relief for the left side forward is located on the opposite side of
the pump directly across from the forward pressure relief valve.

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1650L Hydrostatic Component Overview (cont.)

Left Side View

1650L LEFT SIDE VIEW

1. REAR CHARGE PUMP PRESSURE 2. MAIN PRESSURE RELIEF RIGHT

RELIEF FORWARD
NOTE: Main pressure relief for the right side reverse is located on the opposite side of
the pump directly across from the reverse pressure relief valve.

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1650L Hydrostatic Component Overview (cont.)

Bottom View

1650L BOTTOM VIEW

1. RIGHT OVERRIDE PRESSURE RELIEF 2. LEFT OVERRIDE PRESSURE RELIEF

VALVE VALVE

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1650L Hydrostatic Component Overview (cont.)

Left Drive Motor Components

1650L LEFT MOTOR COMPONENTS

1. LEFT MOTOR SPEED SENSOR 3. LEFT MOTOR SOLENOID
CONNECTOR
2. LEFT MOTOR SPEED SENSOR 4. LEFT MOTOR SOLENOID
CONNECTOR P5

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1650L Hydrostatic Component Overview (cont.)

Right Drive Motor Components

1650L RIGHT MOTOR COMPONENTS

1. RIGHT MOTOR SPEED SENSOR 3. RIGHT MOTOR SOLENOID
CONNECTOR P6 CONNECTOR
2. RIGHT MOTOR SOLENOID 4. RIGHT MOTOR SPEED SENSOR

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Servo Piston Orifices

Orifices are installed on the inlet/outlet port of each side of the servo piston. These
orifices are installed in order to control the machines rate of stroke on the pump. These
orifices are drilled to 1/16 of an inch from the factory. A plugged orifice or an incorrect
sized orifice will cause mistracking momentarily when the machine is shifted from
neutral forward, neutral to reverse, and forward to reverse. A momentary mistrack is
then followed by straight tracking. Incorrectly sized orifices can also cause symptoms of
one track is lazy or slow reacting compared to another.

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Park Brakes
The park brake assemblies are located at the top of each final drive assembly. The park
brakes are spring applied and hydraulically released. With no hydraulic pressure, the
spring force clamps 3 friction and 4 separator plates together. When this clutch pack is
locked up, the internal spline acts against a gear on the input shaft, which acts as the
brake. The park brake pack is subject to wear and should be inspected periodically.
When the friction plates have worn to 0.1 mm (0.004 inches), the frictions should be
replaced.

Hydrostatic Charge Pressure is diverted to each park brake assembly via the ON/OFF
brake solenoid valve located on the front side of the fuel tank. When the park brakes are
commanded to be released, 12 or 24 volts (depending on the size of the machine) and
a ground are supplied to the park brake solenoid. The solenoid opens to divert charge
pressure to both park brake assemblies.

The command to release the park brakes comes from the Drive Train Controller (DTC)
when the following 3 conditions are met:
1) Both safety levers need to be in the down position,
2) The engine rpm needs to increase off of low idle,
3) The joystick lever needs to be moved from the neutral position.

The park brakes are commanded to reapply when ever:

1) The brake pedal is fully depressed,
2) The joystick lever is in neutral for longer than 30 seconds,
3) At least 1 safety lever is in the raised position, or
4) The machine is turned off.

The park brakes (2) are controlled by the brake solenoid valve assembly (1) shown
below.

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Drivetrain Crawler Dozer

(1) Brake lever (4) Adjustment bolt

(2) Spring (5) Stop plate
(3) Pivot mounting bolt (6) Proximity switch bracket (2)

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Parking Brake Hydraulic – Preliminary Test (650-850

machines)
WARNING
Always know the location of all workers in your area. Warn them before you start
working the machine. Always keep all other persons away from your area.
Serious injury or death can result if you do not follow these instructions.

1. Remove the drain plug from the final drive, start the engine and set the
instrument cluster to read engine r/min (rpm).
2. Release the parking brake levers and place the directional control in the F or R
position. Increase engine r/min (rpm) to 950 for 1 minute.
3. Place the directional control in neutral, apply the parking brakes and turn off the
engine.
4. Check for fluid coming out of the final drive drain, if no fluid is present install the
drain plug and torque to 43 46 Nm (32 34 lb ft).
NOTE: If fluid is leaking out of the final drive drain plug the brake piston should be
inspected for damage and the brake O-rings must be replaced.
5. Fill the final drive with the authorized lubricant. Reinstall the fill/check plug and
torque to 43 46 Nm (32 34 lb ft).
6. Open the left side ROPS access
panel and disconnect the brake
solenoid.

7. Start the engine and set the

instrument cluster to read engine
r/min (rpm), use the bump up
button on the directional control
and place the range selector at
100%.
8. Release the parking brake levers
and place the directional control in the F or R position. Increase engine r/min
(rpm) to 1250, there should be no movement of the machine.
ATTENTION: DO NOT press the foot brake unless the machine moves, if machine
moves quickly press the foot brake and place the directional control in neutral.
IMPORTANT: DO NOT exceed 1250 r/min (rpm).
NOTE: If the machine moves the brakes are misassembled.
9. Place the directional control in neutral, apply the parking brakes and turn off the
engine.
10. Connect the brake solenoid and close the left side ROPS access panel.

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Hydraulic Brake Leak Check

Prior operation:
Apply vacuum to the hydraulic system.
NOTE: Check oil levels in both final drives to determine if hydraulic system oil is
present. If oil pours out of the final drive plug it could indicate that the brake solenoid
valve, brake piston o-ring seals, or a motor shaft seal is leaking.
1. Tilt the ROPS cab/canopy.
2. The brake system can be isolated
by plugging the feed line (1) to the
brake solenoid.
3. Disconnect the feed line (1) from
the brake solenoid, plug the line
and cap the fitting.
4. Turn off the vacuum pump.
5. Lower the ROPS cab/canopy.
6. Perform a Charge Pump Pressure
Test.
NOTE: If the pressure increases perform
the following steps to further isolate the
problem.
7. Tilt the ROPS cab/canopy.
8. Turn on the vacuum pump.
9. Connect the feed line to the brake solenoid.
10. Disconnect the reservoir return line from the brake solenoid, plug the line and
cap the fitting.
11. Turn off the vacuum pump.
12. Lower the ROPS cab/canopy.
13. Perform the Charge pump Pressure test.
14. If the pressure increases replace the brake solenoid.
15. If the pressure still remains low during the charge pump pressure test, replace
the brake piston O-rings.
16. Tilt the ROPS cab/canopy.
17. Connect the reservoir return line from the brake solenoid.
18. Lower the ROPS cab/canopy.
19. Remove the vacuum pump from the machine.
20. Perform the Charge Pump Pressure Test again.
Note: If the charge pressure does not come up after replacing the Brake Piston O-ring
Seal there is an internal problem in the hydrostatic pump/motor system. Perform the
following procedures to isolate the problem.

34
Drivetrain Crawler Dozer

NOTE: Leave gauges connected to the test port.

21. While moving the machine forward at low speed, note the pressure reading,
make a slow right turn, note the pressure reading, make a slow left turn, and note
the pressure reading.
22. While moving the machine in reverse at low speed, note the pressure reading,
make a slow right turn, note the pressure reading, make a slow left turn, and note
the pressure reading.
23. If the pressure did not recover during straight forward motion check both right
and left forward pumps. If pressure did not recover during right turn check the left
forward pump, during left turn check the right forward pump.
24. If the pressure did not recover during straight reverse motion, check both right
and left reverse pumps. If pressure did not recover during right turn check the left
reverse pump, during left turn check the right reverse pump.

35
Crawler Dozer Drivetrain

Service Brakes
There are no service brakes on the Crawlers. The braking is controlled by the brake
pedal or inching pedal and works in conjunction with the DTC controller to slow down
the hydrostatic drive system. During normal operation, as the brake pedal is depressed
the controller sends a signal to the forward or reverse electro-proportional valve and
decreases the amount of charge pressure acting upon the servo piston. This then starts
to destroke the hydrostatic pump. As the brake pedal reaches the bottom of travel, the
hydrostatic pump is completely destroked. At the same time, the park brake solenoid
valve is de-energized to supply a path to tank for the brake release oil. The park brakes
are then spring applied.

The brake pedal stops need to be adjusted periodically. See the Pedals and Linkages
section. The brake pedal potentiometer needs to be calibrated periodically to ensure the
park brakes are engaged at the proper time. See the Hydrostatic section.

The park brakes (2) are controlled by the brake solenoid valve assembly (1) shown
below.

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Drivetrain Crawler Dozer

650-850 Service Brake Hydraulic – Exploded View

(1) Snap ring (8) Brake piston inner O-ring

(2) Park brake shaft (9) Brake piston outer O-ring
(3) Separator plates (10) Brake piston
(4) Friction plates (11) Spring washers
(5) Dowel pins (3) (12) Housing cover
(6) Piston plate O-ring (13) Bolts 24MM hex head (3)
(7) Piston plate (14) Bolts 18MM hex head

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Crawler Dozer Drivetrain

(1) Potentiometer (5) Return Spring

(2) Height adjusting bolt (6) Travel stop adjusting bolt
(3) Jam nut (7) Jam nut
(4) Brake pedal (8) Foot Rest

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Drivetrain Crawler Dozer

Final Drives

650-850 Dozers
The final drives are directly coupled to the hydrostatic piston motors and have a final
gear reduction of (62.4:1). Below is a cut away drawing of the final drive. The final
drive has a maximum input speed of 5700 RPM, because of this it is necessary to have
the final drive filled with oil prior to operation.

NOTE: Take care when removing the brake cover. It is under tension created by the
spring washers. When installing and reinstalling remove the brake cover evenly to
prevent the brake cover from cracking due to an uneven load.

39
Crawler Dozer Drivetrain

650-850 Final Drive Sectional View

40
Drivetrain Crawler Dozer

650-850 Final Drive Sectional View Component Listing

1. Drop housing 20. Bearing cup 39. Plug
2. Dowel pin (3) 21. Bearing cone 40. Dowel pin (2)
3. Fiction plate (3) 22. Flange 41. Bearing cup (2)
4. Separator plate (4) 23. O-ring 42. Bearing cone (2)
5. O-ring 24. Retaining ring 43. Sun shaft
6. Apply Loctite 515 25. Spacer washer 44. Dowel pin (3)
7. O-ring 26. Wheel end plate 45. Check plug
8. Expansion plug 27. Hex plug 46. Locking bolt (3)
9. O-ring 28. Retaining ring 47. Pin washer (3)
10. Apply Loctite 515 29. Seal 48. Bearing cone (2)
11. Brake piston 30. Wheel hub housing 49. Countershaft gear
12. Spring washer (2) 31. Bearing cone 50. Bearing cup (2)
13. Brake cover 32. Bearing cup 51. Bearing cup (2)
14. Piston plate 33. Locking bolt 52. Bearing cone (2)
15. Apply Loctite 596 34. Planetary assembly 53. Apply Loctite 767 anti-seize
16. Ring gear 35. O-ring 54. Brake hub
17. Roller bearing (198) 36. Sandwich housing 55. Input gear
18. Planet gears (3) 37. Axle wear insert 56. Retaining ring
19. Bearing retainer plate 38. Lower gear 57. O-ring
58. Brake line connector

41
Crawler Dozer Drivetrain

650-850 Final Drive – Exploded View

1. O-ring brake feed 11. Counter shaft gear 21. Park brake shaft
2. Fill/check plug with o-ring 12. Dowel pins (6) 22. Separator plates (4)
13. Lower gear
3. Plugs with o-rings (3) 23. Brake o-rings (3)
bearings
4. Drive motor o-ring 14. Lower gear 24. Sandwich housing
5. Input gear bearings 15. Sun Gear 25. Brake piston
6. Input gear 16. Wear plate 26. Spring washers (2)
7. Input bearing housing 17. Piston plate 27. Brake cover bolts (5)
8. Input bearing housing bolts
18. Dowel pins (3) 28. Park brake cover
(4)
29. Sandwich housing bolts
9. Dowel pins (2) 19. Friction plates (3)
(8)
20. Brake shaft snap
10. Counter shaft bearings 30. Drop box
ring

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Drivetrain Crawler Dozer

650-850 Final Drive – External View

53. ROPS/tank frame mount bolts (8) 56. Left ROPS/tank frame support
bracket
57. Right ROPS/tank frame support
54. Bracket to final mount bolts (4)
bracket
55. Mounting bolts (7) per side

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Crawler Dozer Drivetrain

650-850 Wheel Hub – Exploded View

31. Planetary gears (3) 42. Wheel hub housing

32. O-ring wheel hub 43. Two piece face seal
33. Wheel hub bearings 44. Wheel hub
34. Bearing retainer plate 45. Spacer washer
35. Bearing retainer plate bolts (8) 46. External retaining ring
36. Planetary hub 47. O-ring
37. Planet gear pins 48. Wheel hub end plate
38. Bearing 66 per gear 49. Internal retaining ring
39. Pin washer (3) 50. Wheel end plate puller plug
40. Dowel pins (3) 51. Locking bolts (6)
41. Locking bolts (3) 52. Locking bolts (6)

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Drivetrain Crawler Dozer

This page is left blank intentionally

45
Crawler Dozer Drivetrain

1150K and 1650L Final Drive

46
Drivetrain Crawler Dozer

1150K Final Drive Component List

Reference Description Reference Description
1 Final drive housing 37 Shim
2 Bearing cup 38 Shim
3 Bearing cone 39 Bearing cone
4 Spindle 40 Bearing cup
5 Block, shim 41 Bearing cup
6 Block shim 42 Bearing cone
7 Block shim 43 Shim
8 Bearing cover 44 Retaining plate
9 Idler gear bearing cover 45 Drive plate
10 Sun Gear bearing cover 46 Brake Separator
11 Idler driver gear 47 Piston brake
12 Driven gear 48 Parking brake housing
13 Gear, shaft, sun gear 49 Spring
14 Pinion gear 50 Sleeve
15 Hub 51 Dowel
15A Hub 52 screw
16 Planetary carrier assembly 53 Park brake housing
17 Carrier ring gear 54 Bearing cup
18 Bolt 55 Bearing cone
19 Ring gear 56 Parke brake hub
20 Retainer 57 Seal ring
21 Bolt 58 O-ring
22 Retainer 59 O-ring
23 Bolt 60 Snap ring
24 Face Seal 61 O-ring
25 Adjusting plate 62 Screw
26 Shim 63 12 point flange head screw
27 Shim 64 Plug
28 Shim 65 O-ring
29 Shim 66 Expansion plug
30 Bearing cone 67 Connector
31 Bearing cup 68 O-ring
32 Bearing cone 69 O-ring
33 Bearing cup
34 Snap ring
35 O-ring
36 O-ring

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Crawler Dozer Drivetrain

Changing Vehicle Configurations

NOTE: The settings menu may be hidden entirely with the EST.
ADJUSTING THE MAXIMUM HYDROSTATIC DRIVE SPEED PARAMETER
1. Press and hold the Enter Key switch for 2 or 3 seconds until the screen displays
SERVICE at the top.
2. Press the Down Key until SETTINGS is displayed on the Digital Display.

1 3

2 4

1. UP KEY 3. ESCAPE KEY

2. DOWN KEY 4. ENTER KEY

3. Select the SETTINGS menu by pressing on Enter key. The screen will show
settings at the top followed by:
• Max Spd
• Shuttle
• Steer
4. Select the Max Spd option by pressing the Enter Key. Note: pressing the Up Key
or Down Key will allow you to choose different parameters (Max Spd, Shuttle, or
Steer).
5. Choose the desired maximum speed setting (70%, 80%, 90%, or 100%) by
pressing the Enter Key. Note: to change the maximum speed from 70%, 80%,
90%, or 100% press the Up Key or Down Key until the desired parameter is
blinking.
6. Once the desired parameter is blinking, push the Enter Key again to confirm the
chosen selection and store the choice.

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Drivetrain Crawler Dozer

ADJUSTING THE SHUTTLE PARAMETER

1. Press and hold the Enter Key switch for 2 or 3 seconds until the screen displays
SERVICE at the top.
2. Press the Down Key until SETTINGS is displayed on the Digital Display.

1 3

2 4

1. UP KEY 3. ESCAPE KEY

2. DOWN KEY 4. ENTER KEY

3. Select the SETTINGS menu by pressing on Enter key. The screen will show
settings at the top followed by:
• Max Spd
• Shuttle
• Steer
4. Select the Shuttle option by pressing the Enter Key. Note: pressing the Up Key
or Down Key will allow you to choose different parameters (Max Spd, Shuttle, or
Steer).
5. Choose the desired Shuttle setting (Smooth, Normal, or Fast), by pressing the
Enter Key. Note: to change the Shuttle setting from (Smooth, Normal, or Fast)
press the Up Key or Down Key until the desired parameter is blinking. The
Normal parameter is the setting from factory.
6. Once the desired parameter is blinking, push the Enter Key again to confirm the
chosen selection and store the choice.

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Crawler Dozer Drivetrain

ADJUSTING THE STEERING PARAMETER

1. Press and hold the Enter Key switch for 2 or 3 seconds until the screen displays
SERVICE at the top.
2. Press the Down Key until SETTINGS is displayed on the Digital Display.

1 3

2 4

1. UP KEY 3. ESCAPE KEY

2. DOWN KEY 4. ENTER KEY

3. Select the SETTINGS menu by pressing on Enter key. The screen will show
settings at the top followed by:
• Max Spd
• Shuttle
• Steer
4. Select the Steering option by pressing the Enter Key. Note: pressing the Up Key
or Down Key will allow you to choose different parameters (Max Spd, Shuttle, or
Steer).
5. Choose the desired Steering setting (Smooth, Normal, or Fast), by pressing the
Enter Key. Note: to change the Steering setting from (Smooth, Normal, or Fast)
press the Up Key or Down Key until the desired parameter is blinking. The
Normal parameter is the setting from factory.
6. Once the desired parameter is blinking, push the Enter Key again to confirm the
chosen selection and store the choice.

50
Drivetrain Crawler Dozer

Calibration

Calibrating the 650L, 750L, 850L, 1150K, 1650L Drivetrain

Calibration of the 750L, 850L, 1150K, and 1650L is required for any drive issue, when
any potentiometer’s are found loose, adjusted, or recommended whenever service is
performed on the machine. In order to calibrate the machine the machine must be
parked on flat level ground and the park brake levers must be in the raised position.
Note: it is not necessary to have the engine running when the crawler dozer is
equipped with an electronic engine.

STEP 1: Press and hold

both the Rabbit and the
Turtle speed selection
buttons on the joystick.

While continuing to hold the buttons turn the key switch to the on position. Let off the
buttons when the display shows HP XXX-XXX.

Step 2: Check and adjust the horsepower

range if needed. The 750L must be set to 80-
90 HP, 850L must be set to 90-100 HP, the
1150k must be set to 125-135HP and the
1650L must be set to 150-160 HP. The bump
up and bump down buttons will change the
horsepower between horsepower selections.

Note: the display may actually tell you the

machine model i.e. (650L), (750L), (850L)
etc.

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Crawler Dozer Drivetrain

Step 3: Press and hold both buttons for 1

second or until “Gauge” Is displayed. Check
and adjust the gauge of the crawler. Two
choices are available LT or WT. The LT
selection is chosen for LT and XLT machines
and WT is chosen for WT and LGP
machines.

Step 4: Press and hold both buttons for 1

second or until “Brake Pedal” Is displayed.
Press and release the brake pedal from fully
up to fully down for 3 cycles.
**Note: If “ERR RANGE” is displayed the
min/max values are out of range or the
potentiometer has not moved since this mode
has been started.

Step 5: Press and hold both buttons for 1

second or until “Hand Throttle” is displayed.
Move the hand throttle from the full idle
position to the full high idle position 3 times.
**Note: If “ERR RANGE” is displayed the
min/max values are out of range or the
potentiometer has not moved since this mode
has been started.

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Drivetrain Crawler Dozer

Step 6: Press and hold both buttons for 1

second or until “Foot Throttle” is displayed.
Press and release the foot throttle from fully
up to fully down for 3 cycles.

**Note: If “ERR RANGE” is displayed the

min/max values are out of range or the
potentiometer has not moved since this mode
has been started.

**Note: If “ERR SWITCH” is displayed the

idle switch has not passed self check.

Step 7: Press and hold both buttons for 1

second or until “Calibration OK” is displayed.
Turn the key switch off, this will store the
calibration.
**Note: If “CAL FAIL” is displayed the new
data acquired from the calibration has not
been stored and the DTC will default back to
the old values prior to calibration.

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Crawler Dozer Drivetrain

Pressure Testing

54
Drivetrain Crawler Dozer

Charge Pressure Drop Test

WARNING: Sudden machine movement can cause injury or death. Make sure all
persons are away from the machine and that the controls are in neutral prior to starting
the engine.
IMPORTANT: Verify the machine is properly calibrated prior to performing the test
procedure.

Test Procedure:
1. Install a 600 to 1000 psi gauge in the charge pressure test port behind the right
hand access door.
2. Operate the unit to raise the hydraulic oil temperature to at least 120° F and key
off the machine.
650L, 750L, 850L, 1150K, 1650L
a. Remove the retaining nut on the brake solenoid valve coil and leave
connector V24 connected to the coil. Remove the coil from the shaft and
lay it away from the brake valve. Failure to perform this will log a fault and
disable the drivetrain.
b. Disconnect the V25 Connector at the brake pressure switch located on the
brake valve and jumper the two terminals on the harness side.

2
3

1. Connector V25 Brake Pressure

Switch
2. Brake Solenoid Valve
3. Connector V24

Note: on a 650L, 750L, or 850L dozer might drive through the brakes during
the test. If the machine drives through the brakes pin the tracks in order to
stop track movement.

55
Crawler Dozer Drivetrain

3. Using the chart on the next page; record the pressure readings. In neutral, run
the engine at low idle (800-1050 rpm); record the charge pressure at (1.)
4. Increase the throttle to high idle and record the charge pressure at (2.)
NOTE: For the remaining steps, it is necessary to operate only 1 track (left or right) and
only 1 direction (forward or reverse). To obtain a 1 track and 1 direction operation,
locate the left and right points on the FNR joystick, where the resistance to move the
control lever increases significantly. This point is the end of operating only 1 track and
the beginning of counter-rotation. This point is the correct position for each of the below
steps.
CAUTION: Do NOT lug the engine during this test. Lugging the engine down may result
in brake failure and inaccurate charge pressure readings.
5. Set the engine rpm to High Idle and record the pressure at (3.)
6. Press and hold the brake pedal to the floor. With the FNR joystick in neutral, pull
the joystick to the right to locate the point just before right counter-rotation, and
push the joystick forward. Slowly release the brake pedal to engage the forward
left track drive (the park brake light turns off at this time) and monitor the charge
pressure gauge for a drop in pressure. As soon as the pressure drops, record the
lowest pressure reading at (4) followed by pressing and holding the brake pedal
to the floor.
7. Repeat step 7 for the right reverse position and record the pressure at (5.).
8. Repeat step 7 for the left forward position and record the pressure at (6.).
9. Repeat step 7 for the left reverse position and record the pressure at (7.).

56
Drivetrain Crawler Dozer

Charge Pressure Test Sheet

Low Idle (800-1050rpm)

1. Neutral

High Idle (2170-2270 rpm)

2. Neutral

High Idle

3. Neutral
Reading 3
4. Right Forward minus reading
4:
Reading 3
5. Right Reverse minus reading
5:
Reading 3
6. Left Forward minus reading
6:
Reading 3
7. Left Reverse minus reading
7:

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Crawler Dozer Drivetrain

Charge Pressure Drop Test

Test Analysis
For the system to operate correctly under all conditions, the charge pressure reading
with the pump in neutral must be adjusted to specification. The charge pressure must
be within the specifications (refer to Drivetrain Specifications) with the engine at low idle
and the oil temperature at least 120°F.
Once the charge pressure meets specification with the levers in the neutral position,
compare the pressure readings under load with the neutral readings. The readings
should be highest with the levers in the neutral position, for this is when the direct acting
charge relief has to handle the greatest amount of flow. With the engine at high idle, the
maximum difference in charge pressure readings between the system in neutral and
with the system loaded in both directions must be the following:
• 50 PSI or less for the 650L, 750L, 850L
• 25 PSI for the 1150K and the 1650L
Note: Any difference greater than specification indicates that there is excessive
leakage from the closed loop system and will require repair.

The lower charge pressure indicates internal leakage from the system with the system
under load. This is caused by less oil flowing over the charge relief and thereby the
lower pressure. Excessive leakage will result in slower drive speed, or jerky drive on
that side of the machine, but depending on what is damaged in the system, the leakage
may only show up under heavy load conditions.

How do you determine if a pump or a motor is at fault? By capping off one drive motor
at a time you can isolate whether the leakage is in the pump or the motor by retesting
each direction. If one component fails, the debris will be sent directly to the mating
component and cause damage. As this damage progresses, contamination will return
to the reservoir through the case drain system. At the very least once a failure has
occurred, the mating component in the hydrostatic system must be inspected for
damage. If any contamination has been returned to the reservoir, tear down and
inspection of both complete closed loop systems is necessary since the same charge
pump feeds them. Also, because the hydraulic system shares the reservoir with the
hydrostatic system, all lines, and components must be thoroughly cleaned to prevent
contamination from reentering the repaired system.

58
Drivetrain Crawler Dozer

Drive Pressure Test

650L, 750L, 850L Test Procedure
NOTE: The same procedure for left hand and right hand pump pressures can be used.

NOTE: Make sure the hydraulic and hydrostatic oil is at operating temperature.

1. To test the hydrostatic pump relief valves, the drive sprockets must be locked in
position. To properly lock the drive sprockets, while rotating in the forward
direction, a pin must be inserted in the sprocket teeth, at the top of the track
frame, and a stop bracket must be provided to prevent the locking pin from
moving away from the sprocket. Locally fabricate a pair of steel track locking pin
brackets, as shown.
2. Fabricate brackets to lock the sprockets sing 12.7 mm (0.5 in) thick steel.

(1) The spread on the brackets to the outside edges should be 127 mm (5 in).
(2) Use 12.7 mm (0.5 in) thick steel.

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Crawler Dozer Drivetrain

3. Fabricate the two end pieces as shown.

4
5

6
3

(1) 241.3 mm (9.50 in)

(2) 215.9 mm (8.50 in)
(3) 228.6 mm (9.00 in)
(4) The tab is 9.52 mm (0.4 in) high and the cut in from the end is 12.7 mm
(0.5 in).
(5) The plates are 50.8 mm (2.0 in) wide.
(6) 12.7 mm (0.5 inch)

60
Drivetrain Crawler Dozer

4. Run a diagonal weld on both sides of the bracing plate.

5. The pin used is a bucket pin from a backhoe, a pin of equal size and hardness
can be used in its place.

(1) The length of the pin used is 371.5 mm (14.63 in).

(2) Diameter of the pin used is 44.4 mm (1.75 in).

61
Crawler Dozer Drivetrain

6. Install the pin and bracket at each sprocket. To test the reverse relief valves, only
the pins are required. In reverse, the pin will lock between the sprocket and the
rear end of the track frame.

62
Drivetrain Crawler Dozer

WARNING
Always know the location of all workers in your area. Warn them before you start
working the machine. Always keep all other persons away from your area.
Serious injury or death can result if you do not follow these instructions. SA015

7. Connect two 690 bar (10,000 psi)

gauges on the quick disconnect
fitting marked Right Reverse Pump
Port and Right Forward Pump Port.
The hose for the pressure gauge
must have at least a 690 bar (10,000
psi) rating.
8. Direct the gauges into the ROPS or
cab to view them from the operator’s
seat.
9. Start the engine.
10. Make sure the Hand Throttle is in the idle position.
11. Use the UP range button to place the machine in its highest range. The
instrument cluster will reflect the hydrostatic range.
12. Make sure both parking brakes are in the OFF position.
13. Place the directional control in the F position.
14. Raise and maintain engine r/min (rpm) at 2000. When the pressure stops
increasing; record the pressure reading.
15. Move the Hand throttle to the IDLE position.
16. Move the sprocket stop pins to the bottom of the track rail, have an assistant
ensure that the pins are secure before proceeding.
17. Place the directional control in the R position.
18. Raise and maintain engine r/min (rpm) at 2000. When the pressure stops
increasing; record the pressure readings.
19. Move the Hand throttle to the IDLE position, place the directional control in
neutral and apply the parking brakes, stop the engine.
20. Compare the pressure readings recorded to the specifications, 414 bar (6000
psi). NOTE: The drive pressure relief valve is set to 414 bar (6000 psi) plus
charge pressure at 2000 rpm.
21. If pressures are not within specification tilt the ROPS cab/canopy to allow access
to the drive pressure relief valves.
22. Check the torque of the pressure relief valves in the pump body, 150 Nm (110 lb
ft).
23. Remove the plastic cap from the pressure relief valve, loosen the jam nut and
turn the adjusting screw in to raise the pressure and out to lower the pressure,
tighten the jam nut. NOTE: The pressure relief valve must be adjusted to 414
bar (6000 psi) plus charge pressure at 2000 rpm. The Forward pressure
reliefs are located directly below the reverse pressure reliefs.

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Crawler Dozer Drivetrain

24. Lower the ROPS cab/canopy and retest the pressure of the drive pressure relief
valve
25. Repeat this procedure for the other drive pressure relief valves.
Note: the remaining steps are only necessary if the drive pressure relief valves
can not be adjusted.
26. If the pressure is still not within specification adjust the pressure over ride valve.
27. After adjusting the pressure over ride valve retest the drive pressure relief valves
28. If the pressure readings still can not be set to specifications it will require more
inspection of the pump assembly and possibly require replacing pump
components.

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Drivetrain Crawler Dozer

650-850 Drive Pressure Setting Adjustment (left and right

side)

(1) INPUT SHAFT (8) REAR CHARGE PUMP (15) PUMP FEED CROSSOVER
INLET LINE
(2) FRONT MOUNT (9) HYDRAULIC PUMP (16) (REAR PUMP) RIGHT
BOLTS INLET LINE REVERSE PRESSURE RELIEF
VALVE
(3) CASE DRAIN LINE T2 (10) BRAKE SOLENOID (17) SOLENOID AND PRESSURE
PRESSURE LINE SWITCH WIRING HARNESS
(4) LIFT CYLINDER (11) EQUIPMENT VALVE (18) OIL COOLER BYPASS
CROSSOVER LINES RETURN LINE VALVE SUPPLY
(5) RIGHT MOTOR HIGH (12) LEFT MOTOR HIGH (19) FRONT PUMP PRESSURE
PRESSURE LINES PRESSURE LINES OVERRIDE VALVE
(6) CASE DRAIN TO (13) DIAGNOSTIC (20) (FRONT PUMP) LEFT
RESERVOIR LINE T2 CENTER LINES REVERSE PRESSURE RELIEF
VALVE
(7) HYDRAULIC PUMP (14) CHARGE PRESSURE
OUTLET LINE FILTER OUTPUT LINE
NOTE: The forward pressure relief valves are located directly below the reverse pressure
relief valves. The rear pump pressure override valve is located near the rear pump forward
pressure relief valve. The picture above does not include a 650L

65
Crawler Dozer Drivetrain

1150K Drive Pressure Setting Adjustment (left and right side)

Note: Make sure the hydraulic and hydrostatic oil is at operating temperature.

1. It will be necessary to operate the machine against an immovable object or into a

spoil pile. The surface must be one that will allow the track to dig in, in both
FORWARD and REVERSE.

2. Connect two 690 bar (10,000 psi)

gauges on the quick disconnect fitting
marked Right Reverse Pump Port and
Right Forward Pump Port. The hose
for the pressure gauge must have at
least a 690 bar (10,000 psi) rating.

3. Direct the gauges into the ROPS or cab to view them from the operator’s seat.
4. Start the engine.
5. Make sure the Hand Throttle is in the idle position.
6. Use the UP range button to place the
machine in its highest range. The
instrument cluster will reflect the
hydrostat range.

7. Make sure both parking brakes are in the OFF position.

8. Place the directional control in the F position.
9. Raise and maintain engine r/min (rpm) at 2000. When the pressure stops
increasing; record the pressure reading.
10. Move the Hand throttle to the IDLE position.
11. Place the directional control in the R position.

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Drivetrain Crawler Dozer

12. Raise and maintain engine r/min (rpm) at 2000. When the pressure stops
increasing; record the pressure readings.
13. Move the Hand throttle to the IDLE position, place the directional control in
neutral and apply the parking brakes, stop the engine.
14. Compare the pressure readings recorded to the specifications.
15. If pressures are not within specification, tilt the ROPS cab/canopy.
16. Adjust the pressure reliefs of the right pump by doing the following procedure:
A. Check the torque of the pressure relief valves in the pump body, 150 Nm (110
lb-ft).
B. Remove the plastic cap from the pressure relief valve, loosen the jam nut and
turn the adjusting screw in to increase the pressure and out to decrease the
pressure.
NOTE: The pressure relief valve must be adjusted to 415 bar (6100 psi)
plus charge pressure at 2000 rpm.

NOTE: The forward directional pressure relief valve is located on the bottom and the
reverse relief valve is located on the top.
17. Lower the ROPS cab/canopy, see section 9008.
18. Repeat Steps 3 through 14 to check the pressure setting.
19. If pressure is still not within specification on page 3, tilt the ROPS cab/canopy,
see section 9008.
20. Adjust the pressure over ride valve by doing the following procedure:
A. Remove the plastic cap from the Pressure Override valve, loosen the jam
nut and turn the adjusting screw in until it just seats, tighten the jam nut.
IMPORTANT: DO NOT over tighten the adjusting screw in the Pressure Override valve.
This WILL damage internal components of the PRESSURE OVERRIDE valve.
21. Lower the ROPS cab/canopy, see section 9008.
22. Repeat procedures 3 through 14 to check the pressure setting.
NOTE: If the pressure reading is not within specifications see section 6001 removal and
installation of power train components, replace the pumps.
WARNING: Always know the location of all workers in your area. Warn them before you
start working the machine. Always keep all other persons away from your area. Serious
injury or death can result if you do not follow these instructions.

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Crawler Dozer Drivetrain

1150K Drive Pressure Setting Adjustment (Left and right

pumps)

68
Drivetrain Crawler Dozer

1. FROM EQUIPMENT 10. FROM FRONT CHARGE 19. RIGHT PUMP

VALVE PUMP (REAR)
2. RESERVOIR TO 20. CASE DRAIN TO
11. MOUNT BRACKET
HYDRAULIC PUMP RESERVOIR
21. RIGHT MOTOR
3. HYDRAULIC PUMP 12. LEFT PUMP (FRONT) HIGH PRESSURE
LINES
13. RIGHT REVERSE
4. TO HYDRAULIC
DRIVE CIRCUIT RELIEF 22. “T” FITTING
FILTER
VALVE
5. FROM HYDROSTAT 14. CLAMP MOUNTING 23. TO HYDROSTATIC
FILTER BOLTS FILTER
15. CASE DRAIN CROSS 24. LEFT REVERSE
6. “T” FITTING OVER DRIVE CIRCUIT RELIEF
VALVE
16. CHARGE PRESSURE 25. PRESSURE
7. RIGHT PUMP (REAR) SETTING OVERRIDE VALVE
8. FRONT CHARGE
17. DIAGNOSTIC LINES
PUMP INLET HOSE
9. LEFT MOTOR HIGH 18. CHARGE PUMP
PRESSURE LINES CROSS OVER
Note: The forward pressure relief valves are located directly below the reverse
pressure relief valves. The Front pump pressure override valve is located near the
front pump forward pressure relief valve

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Crawler Dozer Drivetrain

650-850 Pressure override valve – Pressure setting

1. Tilt the ROPS cab/canopy.
2. Remove the plastic cap from the PRESSURE OVERRIDE valve, loosen the jam
nut and turn the adjusting screw in until it just seats, tighten the jam nut.
NOTE: DO NOT over tighten the adjusting screw in the PRESSURE OVERRIDE
valve because it WILL damage the internal components of the PRESSURE
OVERRIDE valve.
3. Lower the ROPS cab/canopy
Note: see next page for component locations.

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Drivetrain Crawler Dozer

Pressure Override Valve Setting

(1) INPUT SHAFT (8) REAR CHARGE PUMP (15) PUMP FEED CROSSOVER
INLET LINE
(2) FRONT MOUNT (9) HYDRAULIC PUMP (16) (REAR PUMP) RIGHT
BOLTS INLET LINE REVERSE PRESSURE RELIEF
VALVE
(3) CASE DRAIN LINE T2 (10) BRAKE SOLENOID (17) SOLENOID AND PRESSURE
PRESSURE LINE SWITCH WIRING HARNESS
(4) LIFT CYLINDER (11) EQUIPMENT VALVE (18) OIL COOLER BYPASS
CROSSOVER LINES RETURN LINE VALVE SUPPLY
(5) RIGHT MOTOR HIGH (12) LEFT MOTOR HIGH (19) FRONT PUMP PRESSURE
PRESSURE LINES PRESSURE LINES OVERRIDE VALVE
(6) CASE DRAIN TO (13) DIAGNOSTIC (20) (FRONT PUMP) LEFT
RESERVOIR LINE T2 CENTER LINES REVERSE PRESSURE RELIEF
VALVE
(7) HYDRAULIC PUMP (14) CHARGE PRESSURE
OUTLET LINE FILTER OUTPUT LINE
NOTE: The forward pressure relief valves are located directly below the reverse pressure
relief valves. The rear pump pressure override valve is located near the rear pump forward
pressure relief valve. The picture above does not include a 650L

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Crawler Dozer Drivetrain

1150K Pressure Override valve – Pressure setting

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Drivetrain Crawler Dozer

1. FROM EQUIPMENT 10. FROM FRONT CHARGE 19. RIGHT PUMP

VALVE PUMP (REAR)
2. RESERVOIR TO 20. CASE DRAIN TO
11. MOUNT BRACKET
HYDRAULIC PUMP RESERVOIR
21. RIGHT MOTOR
3. HYDRAULIC PUMP 12. LEFT PUMP (FRONT) HIGH PRESSURE
LINES
13. RIGHT REVERSE
4. TO HYDRAULIC
DRIVE CIRCUIT RELIEF 22. “T” FITTING
FILTER
VALVE
5. FROM HYDROSTAT 14. CLAMP MOUNTING 23. TO HYDROSTATIC
FILTER BOLTS FILTER
15. CASE DRAIN CROSS 24. LEFT REVERSE
6. “T” FITTING OVER DRIVE CIRCUIT RELIEF
VALVE
16. CHARGE PRESSURE 25. PRESSURE
7. RIGHT PUMP (REAR) SETTING OVERRIDE VALVE
8. FRONT CHARGE
17. DIAGNOSTIC LINES
PUMP INLET HOSE
9. LEFT MOTOR HIGH 18. CHARGE PUMP
PRESSURE LINES CROSS OVER
Note: The forward pressure relief valves are located directly below the reverse
pressure relief valves. The Front pump pressure override valve is located near the
front pump forward pressure relief valve

1. Tilt the ROPS cab/canopy.

2. Remove the plastic cap from the PRESSURE OVERRIDE valve, loosen the jam
nut and turn the adjusting screw in until it just seats, tighten the jam nut.
NOTE: DO NOT over tighten the adjusting screw in the PRESSURE OVERRIDE valve
because it WILL damage the internal components of the PRESSURE OVERRIDE valve.
3. Lower the ROPS cab/canopy

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Crawler Dozer Drivetrain

Mechanical Pump Centering

Note: It is necessary to mechanically center the pump before hydraulically
centering the pump.
1. Park the machine on a level surface and stop the engine.
2. Place the machine on jack stands so that the tracks do not contact the ground.
Secure the machine so that it is safe to work around and under.
3. Remove the front and rear belly pan covers.
4. Clean the area around the servo piston X1 and X2test port locations and the
Electro-proportional (EP) control valves on the bottom side of each pump.
5. To ensure that there is equal pressure
on both sides of the servo piston
during the centering operation, it is
necessary to connect the X1 and X2
ports together by means of a hose or
tubing (not less than 6.4mm, or 1/4
inch inside diameter). The port sizes
are 7/16 20 UNF. (#4 O-ring boss) Use
a 3/16 inch Allen wrench to remove
the X1 and X2 plugs.

6. Install (2) 1500 PSI pressure gauges

on the test ports under the right side
access door for the forward and
reverse pump ports for the pump being
adjusted. The front pump supplies the
right drive motor, and the rear pump
supplies the left drive motor

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Drivetrain Crawler Dozer

7. Disconnect the V24 connector at the

brake solenoid to lock the parking
brakes in the ON position. 1
8. Assure that any rotation of the tracks
will not move the machine, or cause
injury. Start the engine and set the
2
throttle at low idle. 3

1. Connector V25 Brake Pressure

Switch
2. Brake Solenoid Valve
3. Connector V24

9. Use a 24mm wrench (1) to loosen the

locknut on the servo piston adjusting
screw, and use a 6mm Allen wrench
(2) to turn the adjusting screw
clockwise until one of the gauges
reads 69 bar (1000 psi).
10. Then, turn the adjusting screw
counterclockwise until the other gauge
reads 69 bar (1000 psi), counting the
number of turns of the screw between
the two extreme positions.
11. Turn the adjusting screw clockwise
one half the number of turns to center
the servo piston. The pressure gauges
should read the same.
12. Tighten the locknut.
13. Stop the engine.
14. Remove the hose/tube between X1 and X2 ports, and reinstall the plugs.
15. Verify that the hydraulic reservoir is full. Top off with the correct oil if required.
16. Run the engine and verify that there are no leaks.
17. Reconnect the V24 connector at the brake solenoid.
18. Remove the machine from the jack stands.
19. Test drive the machine, if machine still does not track straight refer to the
hydraulically centering the servo control piston.

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Crawler Dozer Drivetrain

20. If machine tracks straight, reinstall the belly pan covers.

21. Return the machine to service.

The hydrostatic pumps all use an Electronic Proportional Valve (EP Valve) to control the
pump servo piston.

The size of the pumps and motors is part of the Rexroth part number stamped on the
identification tag of each pump and motor. The below chart illustrates the sizes for each
of the models of hydrostatic crawlers.

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Drivetrain Crawler Dozer

Hydraulically Centering the Servo Control Piston

Note: It is necessary to mechanically center the pump before hydraulically
centering the pump.

1. Park the machine on a level surface

and stop the engine.
2. Place the machine on jack stands so
that the tracks do not contact the
ground. Secure the machine so that it
is safe to work around and under.
3. Remove the front and rear belly pan
covers.
4. Verify that the machine is properly
mechanically centered

5. Clean the area around the servo

piston X1 and X2 test port locations
and the Electro-proportional (EP)
control valves on the bottom side of
each pump. Number (1) is the
centering screw for mechanical
adjustment.
6. Tag and disconnect the P3 and P4
connectors at the front and rear pump
solenoids.

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Crawler Dozer Drivetrain

7. Disconnect the V24 connector at the

brake solenoid to lock the parking
brakes in the ON position. 1
8. Remove the X1 and X2 port plugs
using a 3/16 inch Allen wrench.
9. Install a 0 40 bar (0 600 psi) pressure 2
gauge in each port. The ports are 3
7/16 20 UNF threads (#4 O-ring
boss).
10. Assure that any rotation of the tracks
will not move the machine, or cause
injury. Start the engine and set the
throttle at low idle.
11. Compare the readings of the two 1. Connector V25 Brake Pressure
pressure gauges. Switch
2. Brake Solenoid Valve
12. The pump is considered centered 3. Connector V24
when the readings are within 2 bar
(29 psi) of each other.
12. If the pressure differential is greater than 2 bar (29 psi) loosen the clamp screw
and adjust the centering screw very slightly until the pressure gauge readings are
within 2 bar (29 psi) or less of each other.
NOTE: This adjustment is extremely sensitive. A small turn of the centering screw
results in a large change in centering pressures. The centering screw must NEVER be
turned more than 90° in either direction.
13. Tighten the clamp screw to 6.1 Nm (54 lb in).
14. Stop the engine.
15. Remove the pressure gauges from the X1 and X2 ports, and reinstall the plugs.
16. Reconnect the P3 and P4 connectors at the front and rear pump solenoids,
remove tags.
17. Verify that the hydraulic reservoir is full. Top off with the correct oil if required.
18. Run the engine and verify that there are no leaks.
19. Reinstall the belly pan covers.
20. Reconnect the V24 connector at the brake solenoid.
21. Remove the machine from the jack stands.
22. Return the machine to service.

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Drivetrain Crawler Dozer

Moving a Disabled Crawler

If the machine is disabled, you must make a judgment if the machine can be moved
without more damage. If possible, repair the machine at the job site.

Precautionary Procedures before Moving the Machine

Before moving the machine the following topics must be followed for safety purposes:
• Make sure the machine used for moving the disabled one has the braking
capacity, weight, and power to control both machines.
• The towing machine must be equipped with a rear shield to protect the operator if
the cable or tow bar disengages. Do not use chain to tow this machine.
• If required, attach a second machine behind the disabled machine to assist with
additional control or braking.
• Attach a rigid drawbar or cables to the disabled machine.

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Crawler Dozer Drivetrain

Opening the Pressure Release Valves

This instruction is for moving the machine a few feet and no faster than 1.6 km/hr (1
mph). Park the haul trailer as close as possible to the machine.
1. Tilt the cab to access the service area. IMPORTANT: The cab may only be tilted
on a hard and level surface.
2. Remove the relief valve plastic end caps (if present). Loosen the jam nuts and
use an allen wrench and turn the engagement screw out three turns on each
relief valve.

1. NOTE: THE TOP OR UPPER 2. NOTE: THE BOTTOM OR

RELIEF VALVES ARE FOR MOVING LOWER RELIEF VALVES ARE FOR
THE CRAWLER REARWARD IN MOVING THE CRAWLER
NORMAL OPERATING FORWARD IN NORMAL
OPERATING CONDITIONS

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Drivetrain Crawler Dozer

Releasing the Brakes

Note: The brakes will also need to be released before the machine can be towed.

The machine is equipped with SAHR (spring applied hydraulically released) parking
brakes. Hydraulic pressure must release the brakes. If the engine will not run, you must
use a hand pump to release the brakes to prevent further damage to the machine.

1. Connect a vacuum pump (if available to the hydraulic Reservoir and hold a
vacuum to keep from loosing fluid.

2. Disconnect the fitting (2) at the brake solenoid

3. Install a cap on the brake solenoid valve as shown.

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Crawler Dozer Drivetrain

4. Connect a hand pump (with the capacity to reach and maintain 2275kPa, 22.7
bar, 330 ± 20 psi) to the hose that goes to the brakes.
To Brakes

5. Operate the pump until the correct pressure is reached and the brakes are now
released.
IMPORTANT: Check and maintain 2275 kPa, 22.7 bar, 330 ± 20 psi maximum in the
brake line when moving the machine. Damage to the brake system can result if the
pressure is reduced.
6. Remove tools and equipment from the service area and slowly lower the cab to
the operating position.
7. The machine is now ready to be moved.
8. After moving the machine, raise the cab back up all the way to over center by
making sure the retaining cable is fully extended.
9. Disconnect the hand pump.
10. Remove the plug and reconnect the line to the brake solenoid.
11. Remove the vacuum pump, if used.
12. Tighten the drive circuit relief valve engagement screws back in three turns.
Note: it will be necessary to perform a drive pressure test to ensure the drive circuit
relief valves are set to specification.

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Drivetrain Crawler Dozer

TROUBLESHOOTING THE HYDRAULIC / HYDROSTATIC OIL

COOLING SYSTEM

Verify the actual hydraulic system oil temperature by measuring the oil temperature
directly with a thermocouple, or measuring the hydraulic tank temperature at the
temperature sender using an infrared thermometer. If the temperature is reading more
than 38 degrees C (100 degrees F) above the ambient temperature, check for the
following problems:

Dirty Transmission Cooler: The radiator must be clean to maximize heat transfer from
the radiator to the cooling air. This is extremely important. Clean the transmission cooler
with a high pressure washer as needed. In some cases, because the cooling fins are
very close together, it may be necessary to soak and boil the debris from the finned
area. To verify the cleanliness, place a trouble light behind the cooler and look for the
light from the front side of the cooler. The light should be easily visible through the entire
cooler.

Fan Belt:

• The fan belt must be tensioned properly to maximize the airflow through the
radiator fan. Inspect the fan belt for wear, and the belt tensioner for proper
operation. Repair or replace the belt and / or the tensioner, as needed. Also, if
equipped with a reversible fan (ROPS canopy equipped machines only), verify
that all blades are positioned correctly for pusher or suction intent.
• On Case 650K and 750K Series 2 and 3 crawlers, and New Holland DC75,
DC85, D75, and D85 crawlers, replace the existing fan belt and fan drive pulley
with fan belt (part number 87564117) and pulley (part number 2853010) from the
Case 850K Series 2 and 3, and the New Holland DC95 and D95.
• On Case 650K and 750K Series 1 crawlers, replace the existing fan belt and fan
drive pulley with fan belt (part number J911559) and pulley (part number
J914462) from the Case 850K Series 1. This increases the fan speed and moves
more air through the oil cooler and the engine radiator.

Improper Machine Operation: Do not operate the machine at high speed settings and
partial throttle. The oil flow through the transmission cooler is controlled by the speed of
the equipment pump. To maximize the oil flow , the engine must be operated at wide-
open-throttle, with the speed controlled by the bump-up and bump-down switches on
the left hand joystick controller.

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Crawler Dozer Drivetrain

Thermo Bypass Failure: The thermo bypass valve must operate correctly to maximize
the oil flow through the oil cooler. First, verify that the valve is installed properly. The
inlet port (with the hose from the blade control valve) must face up, the tank port must
face to the rear of the machine, and the cooler port must face toward the front of the
machine. Second, inspect the thermo bypass valve per Section 8009 of the Series 1
Service Manual, or Section A in the Series 2 Service Manual, to determine if the valve is
operating correctly. The valve starts sending oil to the oil cooler at 49 degrees C (120
degrees F), and is completely open at 63 degrees C (145 degrees F). At oil
temperatures above 63 degrees C (145 degrees F), all of the oil should be flowing
through the oil cooler.

(A quick method to determine if the thermo bypass is operating correctly is to check the
temperature of the hydraulic tank at the temperature sender, the temperature of the oil
cooler inlet, and the temperature of the oil cooler outlet. The oil tank and cooler inlet
temperatures should be within 5 degrees C, or 9 degrees F, of each other. Also, the
temperature drop from the oil cooler inlet to the outlet should be no more than 8
degrees C, or 15 degrees F. If the differences are greater than specified, the thermo
bypass is not flowing all of the oil to the cooler.) If it is not, remove the thermo bypass
valve, and, replace it with the 200 psi check tee used on the 1150K and 1650L/D150B.
Use the following parts:

Quantity Part Number Description

1 87578785 Bypass Tee
2 201-147 ORFS Reducing Adapter
1 201-418 ORFS Tee
1 87585367 Mounting Bracket
2 627-10020 Bolt
2 895-11010 Washer
1 87590350 Bracket
2 627-8016 Bolt
2 895-1108 Washer

The two ORFS reducing adapters (part number 201-147) are used to connect the hose
from the control valve and the hose to the cooler to the bypass tee. The ORFS tee (part
number 201-418) connects the return hose from the cooler and the hose to the filter to
the bypass tee. The bypass valve is installed so that the flow direction arrow on the tee
points toward the tank. The mounting bracket (part number 87585367) bolts to the same
holes that currently mount the thermo bypass.

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Drivetrain Crawler Dozer

Incorrectly Calibrated Temperature Sender / Instrument Cluster Combination: The

transmission oil temperature gauge in the instrument cluster should read 87.8 degrees
C (190 degrees F) at the top of the green / bottom of the red, and 104.4 degrees C (220
degrees F) at the top of red. The over-temperature alarm should activate at 105.5
degrees C (222 degrees F). If the actual temperature is lower than the gauge indication,
install a jumper harness, part number 87625470, at the x69 connector on the main
wiring harness on machines prior to the following serial numbers (all machines starting
with these serial numbers and after had the jumper harness installed at assembly):

Brand Model Serial Number

Case 650K CAL012200
Case 750K CAL003400
Case 850K CAL005700
New Holland DC75/D75 N7DC75282
New Holland DC85/D85 N7DC85264
New Holland DC95/D95 N7DC95431

Incorrectly Set Hydrostatic Pump Reliefs: Test the hydrostatic pump relief valves per
Section 6002 in the Series 1 Service Manual, or Section C in the Series 2 Service
Manual. The tracks must be stalled, and the pressure must be 448 bar (6500 psi). If the
pressure is not correct, remove the plastic cap from the valve, loosen the jam nut, and
turn the adjusting screw in to increase the pressure, or out to decrease the pressure.
Then retighten the jam nut. If the valve cannot be adjusted, replace the entire valve
cartridge.

Blade Hydraulic System Issues: Ensure that none of the blade hydraulic system
components are contributing to excessive heat build-up.

1. Test the equipment pump flow rate. It must be 76.8 L/min (20.3 gpm) at 207 bar
(3000 psi) at 2000 rpm. If the flow rate is low, replace the pump to ensure
maximum oil flow through the cooler.
2. Test the neutral system pressure at the 'Pump Pressure' test port. It must be 12
to 15 bar (180 to 220 psi) at 2000 rpm. If the pressure is higher, check all of the
components downstream of the hydraulic valve inlet section for restriction,
including the pressure relief valve, hoses, thermo bypass valve, cooler, and the
filter and filter head.
3. Check all of the cylinders for hot spots. If one cylinder is noticeably hotter than
the others, disassemble the cylinder and check the seal for leakage.

Hydraulic Oil Type: If the hydraulic / hydrostatic system is filled with MAT 3505 Case
MS-1209 Hy-Tran Ultra or New Holland Mastertran, replace it with MAT 3509 Case
Hydraulic Excavator Fluid or New Holland Hydrosystem 46 HV, or MAT 3508 Case
AW68, or New Holland Hydrosystem 68 hydraulic oil. All of these oils provide improved
high-temperature viscosity characteristics and lower the overall operating temperatures
(see Case Service Bulletin NCR SB 001 09, or New Holland Service Bulletin 0109-
CE9).

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Crawler Dozer Drivetrain

Optional Add-on Oil Cooler: If all of the previously noted steps have been performed,
and the hydraulic / hydrostatic system continues to overheat, there is an optional add-on
oil cooler kit available to improve system cooling. Contact your Product Support
Manager (PSM) to discuss the availability of this kit. Fill out the attached 'Hydraulic /
Hydrostatic Overheat Checklist', and either attach it to an ASIST concern, or fax it to
Technical Support at 262-636-5043, for review by Technical Support. After review,
information on the cooler kit will be supplied via the ASIST concern.

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Drivetrain Crawler Dozer

Hydrostatic Crawler/Dozer Left Hand Joystick

Troubleshooting
General
The below procedure is a quick test of the functionality of the left hand joystick controller
using the instrument cluster and a dynamic driving test of the machine. This quick test
can be used to test the majority of the joystick issues in the field. But in some cases a
joystick may pass this test and still be failed. In these instances, connect the Electronic
Service Tool (EST) to the machine, key on the machine, and Monitor the Parameters of
‘Joystick – Speed Decrease Button’, ‘Joystick – Speed Increase Button’, ‘Joystick Signal
– Forward/Backward’, and ‘Joystick Signal – Left/Right’.

The speed buttons are momentary switches, so the EST should change between ‘OFF’
and ‘ON’ while the switches are held. The forward/reverse signals and the left/right
signals are variable from internal potentiometers, so the EST should vary from 0 to 125
in full forward, 0 to -125 in full reverse, 0 to -125 in full left, and 0 to 125 in full right.
During left and right, the point in the joystick where handle movement effort begins to
increase should be roughly at -100 for the left and roughly 100 for the right. If the
joystick does not pass the potentiometer checks, replace the joystick controller. If the
joystick does not pass the bump up or bump down checks, repair or replace the
switches in the handle.

1. Key ON the machine with the joystick in Neutral. The Instrument panel needle
should default to 60% on the display. The digital area should display ‘N’ for
Neutral in the lower left side. If this is not correct, troubleshoot the reoccurring
error codes and see step 11.

2. Press the bump up shift button. With every press of the button the display needle
should increase by 10% up to the maximum speed selected in the ‘Settings’
menu. If this is not correct, troubleshoot the reoccurring error codes and see step
12.

3. Press the bump down shift button. With every press of the button the display
needle should decrease by 10% down to the minimum speed of 10%.If this is not
correct, troubleshoot the reoccurring error codes and see step 12.

4. Shift the joystick to Forward. The digital area should display a flashing ‘F’ for
requested Forward. If this is not correct, troubleshoot the reoccurring error codes
and see step 13.

5. Shift the joystick to Reverse. The digital area should display a flashing ‘R’ for
requested Reverse. If this is not correct, troubleshoot the reoccurring error codes
and see step 13.

6. If steps 1-5 changed the display properly and there are no errors codes in the
machine, drive the machine to verify that it turns properly per steps 7-10. If the
joystick failed any of steps 1-5, see the designated step.

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Crawler Dozer Drivetrain

7. In forward as the joystick is slowly pushed to the left, the inboard (left) track
should slow down and the outboard (right) track should continue to turn forward.
As the joystick reaches a point of increasing handle movement effort, the inboard
(left) track should be stopped and the outboard (right) track should continue to
drive forward. As the joystick is pushed further to the left, the inboard (left) track
should start to turn in reverse and the outboard (right) track should continue to
turn forward for counter-rotation.

8. Perform step 7 for Forward and pulling the joystick to the right. The inboard track
is now right and the outboard track is now left.

9. Perform step 7 for Reverse and pushing the joystick to the left. The inboard track
is now left, the outboard track is now right, and forward and reverse are
swapped.

10. Perform step 7 for Reverse and pulling the joystick to the right. The inboard track
is now right, the outboard track is now left, and forward and reverse are
swapped.

11. Verify the joystick has keyed battery power to pins 1 and 5, ground to pin 2, 1.5-
2.5 volts to pin 3, and 2.5-3.5 volts to pin 4. If these readings are correct, replace
the joystick.

12. If the bump up and/or the bump down switch(s) do not change the display, repair
or replace the switch(s).

13. If the potentiometers do not change the display correctly or the machine does not
drive correctly in forward, reverse, left, right, or counter rotation and there are no
error codes, replace the joystick controller.

88