Service Training

MALAGA
Large Track Type Tractors
Adolfo
May 1997
2. POWERTRAIN D11R
1. Components Layout
2. Operation
3. Testing & Adjusting
CHAPTER : POWERTRAIN D11R
Large Track Type Tractors
2-2 Page:
TORQUE DIVIDER
75% TORQUE (FLUID COUPLING)
25% TORQUE (MECHANICAL COUPLING)
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SUN GEAR
ROTATING
HOUSING
IMPELLER
TURBINE
OUTLET
PASSAGE
OUTPUT SHAFT
STATOR
PLANET CARRIER
PLANET GEARS
ENGINE FLYWHEEL
INLET
PASSAGE
RING GEAR
TORQUE DIVIDER
CHAPTER : POWERTRAIN D11R
Large Track Type Tractors
2-4 Page:
POWER SHIFT TRANSMISSION
3F-3R PLANETARY POWER SHIFT TRANSMISSION
ELCTRONICALLY CONTROLLED
HYDRAULICALLY ACTUATED (ECS)
3 SPEED CLUTCHES
2 DIRECTIONAL CLUTCHES
ADDITIONAL PLATE & DISC IN PLANETARY GROUP
CHAPTER : POWERTRAIN D11R
Large Track Type Tractors
2-5 Page:
LUBE PRESSURE TAP
XMS TEMPERATURE TAP
T/C INLET PRESSURE TAP SOS
P1 & P2 PRESSURE TAPS REMOTELY MOUNTED
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PLANETARY
CARRIER
INPUT SUN GEARS
RING GEARS
INPUT SHAFT
OUTPUT SHAFT
OUTPUT SUN GEARS
RING GEAR
1 2 3 4
5
POWER SHIFT TRANSMISSION
1 REVERSE
2 FORWARD
3 THIRD
4 SECOND
5 FIRST
CHAPTER : POWERTRAIN D11R
Large Track Type Tractors
2-7 Page:
POWER TRAIN OIL PUMP
5 SECTION GEAR PUMP:
CONVERTER SCAVENGE
TRANSMISSION SCAVENGE
BRAKE COOLING
CONVERTER CHARGE
TRANSMISSION CHARGE
CHAPTER : POWERTRAIN D11R
Large Track Type Tractors
2-8 Page:
FILTERS
TRANSMISSION FILTER
TORQUE CONVERTER FILTER
CHAPTER : POWERTRAIN D11R
Large Track Type Tractors
2-9 Page:
TRANSMISSION CASE DRAIN
PLUG DRAIN VALVE
CHAPTER : POWERTRAIN D11R
Large Track Type Tractors
2-10 Page:
TRANSMISSION CONTROL VALVE
P1 SPEED
P2 DIRECTION
CHAPTER : POWERTRAIN D11R
Large Track Type Tractors
2-11 Page:
CONVERTER OUTLET RELIEF VALVE
PRESSURE TAP
POWERTRAIN OIL TEMPERATURE SENSOR
CONVERTER OUTPUT SPEED SENSOR
CHAPTER : POWERTRAIN D11R
Large Track Type Tractors
2-12 Page:
LUBE MANIFOLD LUBE PRESSURE TAP
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TRANSMISSION
OIL FILTER
TORQUE CONVERTER
OIL FILTER
OIL
COOLER
3508
ENGINE
FAN PUMP
IMPLEMENT
GROUP
OUTLET
RELIEF
VALVE
TORQUE
CONVERTER
A B C D E
PRIORITY
VALVE
TRANSMISSION
CONTROL
VALVE
CASE AND
FRAME
LUBE
MANIFOLD
STEERING
CLUTCH AND
BRAKE
VALVE
MANIFOLD
CLUTCH BRAKE LUBE
VENT
POWER TRAIN HYDRAULIC OIL SYSTEM
D11R AND D11R CD CARRYDOZER
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5 1 4
TORQUE
CONVERTER
OUTLET
RELIEF VALVE
OIL
COOLERS
TRANSMISSION
OIL FILTER
POWER TRAIN
OIL
PUMP
LUBE
MANIFOLD
TORQUE
CONVERTER
OIL FILTER
PRIORITY
VALVE
STEERING
CLUTCH
AND BRAKE
VALVE
SPEED
SELECTOR
SPOOL
3
2
POWER TRAIN HYDRAULIC SYSTEM
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TRANSMISSION
HYDRAULIC CONTROL VALVE
MODULATION
RELIEF VALVE
FIRST AND THIRD SPEED
SELECTOR SPOOL
LOAD PISTON
SECOND SPEED
SELECTOR SPOOL
PRESSURE
DIFFERENTIAL
VALVE
DIRECTIONAL
SELECTOR
SPOOL
CONVERTER INLET
RATIO VALVE
P3
P1
P2
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5 1 4
TORQUE
CONVERTER
OUTLET
RELIEF VALVE
OIL
COOLERS
TRANSMISSION
OIL FILTER
POWER TRAIN
OIL
PUMP
LUBE
MANIFOLD
TORQUE
CONVERTER
OIL FILTER
PRIORITY
VALVE
STEERING
CLUTCH
AND BRAKE
VALVE
SPEED
SELECTOR
SPOOL
3
2
POWER TRAIN HYDRAULIC SYSTEM
1ST SPEED FORWARD
CHAPTER : POWERTRAIN D11R
Large Track Type Tractors
2-17 Page:
FINGER TIP CONTROL
LEFT & RIGHT
STEERING LEVERS
DIRECTIONAL
LEVER
SPEED SHIFT
CONTROL BUTTONS
CHAPTER : POWERTRAIN D11R
Large Track Type Tractors
2-18 Page:
STEERING AND BRAKE CONTROL VALVE
LEFT BRAKE
PRESSURE TAP
LEFT CLUTCH
PRESSURE TAP
RIGHT BRAKE
PRESSURE TAP
RIGHT CLUTCH
PRESSURE TAP
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PROPORTIONAL
SOLENOID
ACCUMULATOR PISTON
REDUCING
SPOOL
SHUTOFF
VALVE
PARKING/SECONDARY BRAKE
SOLENOID VALVES
PILOT
VALVE
STEERING AND BRAKE CONTROL VALVE
PILOT
PRESSURE
CHAMBER
DRAIN
SERVICE BRAKES ENGAGED
SUPPLY
OIL
BRAKE
CHAMBER
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PROPORTIONAL
SOLENOID
ACCUMULATOR PISTON
REDUCING
SPOOL
SHUTOFF
VALVE
PARKING/SECONDARY BRAKE
SOLENOID VALVES
PILOT
VALVE
STEERING AND BRAKE CONTROL VALVE
PILOT
PRESSURE
CHAMBER
DRAIN
SERVICE BRAKES RELEASED
SUPPLY
OIL
BRAKE
CHAMBER
CHECK
VALVE
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STEERING AND BRAKE
CONTROL VALVE
SERVICE BRAKES ENGAGED
SUPPLY OIL
TO LEFT BRAKE
TO LEFT CLUTCH
TO RIGHT CLUTCH
TO RIGHT BRAKE
PARKING AND
SECONDARY BRAKE
SOLENOIDS
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STEERING AND BRAKE
CONTROL VALVE
SUPPLY OIL
TO LEFT BRAKE
TO LEFT CLUTCH
TO RIGHT CLUTCH
TO RIGHT BRAKE
STRAIGHT LINE OPERATION
PARKING AND
SECONDARY BRAKE
SOLENOIDS
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STEERING AND BRAKE
CONTROL VALVE
SUPPLY OIL
TO LEFT BRAKE
TO LEFT CLUTCH
TO RIGHT CLUTCH
TO RIGHT BRAKE
GRADUAL RIGHT TURN
PARKING AND
SECONDARY BRAKE
SOLENOIDS
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STEERING AND BRAKE
CONTROL VALVE
SUPPLY OIL
TO LEFT BRAKE
TO LEFT CLUTCH
TO RIGHT CLUTCH
TO RIGHT BRAKE
SHARP RIGHT TURN
PARKING AND
SECONDARY BRAKE
SOLENOIDS
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STEERING AND BRAKE
CONTROL VALVE
PARKING BRAKE ENGAGED
SUPPLY OIL
TO LEFT BRAKE
TO LEFT CLUTCH
TO RIGHT CLUTCH
TO RIGHT BRAKE
PARKING AND
SECONDARY BRAKE
SOLENOIDS
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POWER TRAIN ELECTRONIC CONTROL
SYSTEM D10R D11R TRACTORS
MAIN FUNCTIONS
TRANSMISSION SHIFTING (Electronic Clutch Selection)
BRAKING
STEERING CLUTCH & BRAKE (Finger Tip Control)
ADDITIONAL FUNCTIONS
PARKING BRAKE FUNCTION
NEUTRAL START FUNCTION
WARNING FUNCTION
BACKUP ALARM FUNCTION
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. . .
MESSAGE CENTER
MODULE GAUGE CLUSTER
MODULE
CAT DATA LINK
ACTION
LAMP
ACTION
ALARM
DISPLAY
DATA LINK
TACHOMETER
MODULE
INPUT
COMPONENTS
INPUT
COMPONENTS
ENGINE
CONTROL
MID 036
TRANSMISSION
CONTROL
C kPa Miles KM RPM Liter
SERV
CODE
X10
CATERPILLAR
MONITORING
SYSTEM MID 030
POWER
TRAIN
CONTROL
MID 113
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CLUTCH 3
3RD GEAR SOLENOID
CLUTCH 4
2ND GEAR SOLENOID
CLUTCH 5
1ST GEAR SOLENOID
CLUTCH 2
FORWARD SOLENOID
CLUTCH 1
REVERSE SOLENOID
CONTROL AND
MONITOR SYSTEMS
POWER TRAIN ECM
(MAC-14)
BACKUP
ALARM
CONVERTER SPEED SENSOR
TRANSMISSION
TEMPERATURE SENSOR
CAT DATA
LINK
INPUT COMPONENTS OUTPUT COMPONENTS
POWER TRAIN ELECTRICAL SYSTEM
LEFT & RIGHT STEER
LEVER SENSORS
UPSHIFT SWITCH
DOWNSHIFT SWITCH
DIRECTION SENSOR
F
T
C
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PARKING BRAKE SWITCH
SERVICE BRAKE
PEDAL SWITCH
BRAKE PEDAL
POSITION SENSOR
HARNESS CODE
PARKING BRAKE SOL
SECONDARY BRAKE SOL
LEFT BRAKE SOLENOID
RIGHT BRAKE SOLENOID
LEFT STEER CLUTCH SOL
RIGHT STEER CLUTCH SOL
D10R D11R
FINGER TIP CONTROL
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ECM CONNECTOR CONTACT
WIRE IDENTIFICATION
HARNESS CODE PLUG CONTACT
J1-14 J1-36 J1-32 J1-26 J1-25
280-BK 279-BK 278-BK 277-BK 276-BK
5 4 3 2 1
FINGER TIP CONTROL
ELECTRONIC CLUTCH SELECTION
(ECS)
D10R , D11R
FINGER TIP CONTROL
ELECTRONIC CLUTCH PRESSURE
CONTROL (ECPC)
POWER SHIFT TORQUE CONVERTER
PSTC D5M, D6M, D5R, D6R
FINGER TIP CONTROL
ELECTRONIC CLUTCH PRESSURE
CONTROL (ECPC)
POWER SHIFT DIRECT DRIVE
PSDD D5M, D6R
DIFFERENTIAL STEER
ELECTRONIC CLUTCH PRESSURE
CONTROL (ECPC)
POWER SHIFT TORQUE CONVERTER
DS D6R, D7R
0
0
0
G
0 0 0 G
G G 0 0
G G 0
0
G 0 G
0
HARNESS CODE PLUG CONTACT
CHAPTER : POWERTRAIN D11R
Large Track Type Tractors
2-30 Page:
ALERT
INDICATORS
!
!
44
!
SERV
CODE
MESSAGE CENTER MODULE
STEERING SYSTEM:
LEVEL1: STEERING CLUTCHES OUT OF CALIBRATION
NEW SOFTWARE, NEW ECM)
LEVEL3: FAULT IN STEERING CIRCUIT
BRAKE SYSTEM:
LEVEL1: BRAKES OUT OF ADJUSTMENT
LEVEL3: FAULT IN BRAKE SYSTEM
TRANSMISSION SYSTEM:
LEVEL1: DOWNSHIFT, UPSHIFT, DIRECTION SWITCHES, XMS OIL TEMP
1, 2, 3 GEAR SOLENOID,
LEVEL3: XMS LEVER POSITION SENSOR, HARNESS CODE, BAD ECM,
REVERSE, FORWARD SOLENOID
PARKING BRAKE
LEVEL1: PARKING BRAKE ENGAGED
LEVEL3: PARKING BRAKE ON, TRANSMISSION IN GEAR
ENGINE OIL
PRESSURE
PARKING
BRAKE
POWER TRAIN
OIL FILTER
BATTERY VOLTAGE
"R" TERMINAL Hz
AIR FILTER
RESTRICTION
STEERING
SYSTEM
TRANMISSION
SYSTEM
LOSS OF
COOLANT
FLOW
CHECK ENGINE
LIGHT
ACTIVE CODE
INDICATOR
P
BRAKE
SYSTEM
CHAPTER : POWERTRAIN D11R
Large Track Type Tractors
2-31 Page:
OPERATOR MODES
D10R D11R
SERV
CODE
41.4
MILES or KM
170
700
RPM
SERV
CODE
030
420
SERVICE
METER
MODE
ODOMETER
MODE
DIGITAL
TACHOMETER
MODE
ENGINE
OIL
PRESSURE
DIAGNOSTIC
SCROLLING
MODE
- ENGINE SPEED RPM
SERV
CODE
271 F05
MID CID, FMI
MACHINE TRAVEL
DISTANCE
kPa
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725
6.1
6.2
6.3
6.4
6.5
1
6.6
6.7
MODES
8 0
1 5 5
2 0 0
SET APPLICATION
MODE
LEFT BRAKE ADJUSTMENT
LEFT STEER CLUTCH HIGH PRESSURE ADJUSTMENT
MODE 6 SUB-MODES
USE "S" SERVICE SWITCH TO SCROLL SUB-MODES
6.8
6.9
D10R D11RB
9TR1-UP
D11RA
8ZR1-UP
726 793
D11R CD
790
RIGHT BRAKE ADJUSTMENT
RIGHT STEER CLUTCH HIGH PRESSURE ADJUSTMENT
LEFT BRAKE LOW PRESSURE ADJUSTMENT
RIGHT BRAKE LOW PRESSURE ADJUSTMENT
LEFT STEER CLUTCH LOW PRESSURE ADJUSTMENT
RIGHT STEER CLUTCH LOW PRESSURE ADJUSTMENT
1 2 3
1 4 8
2 0 0
STEERING/BRAKING CALIBRATION MODE
1 3 1
0 8 3
CHAPTER : POWERTRAIN D11R
Large Track Type Tractors
2-34 Page:
CALIBRATION MODE
PARKING
BRAKE
STATUS
SUBMODE
NUMBER
SUBMODE
DESCRIPTION
Steering / Calibration Mode
Mode No. 6 ... D10R and D11R
Mode No. 5 ... D5M, D6M, D6R and D7R
ON
OFF
OFF
ON
ON
OFF
OFF
ON
ON
01
02
03
04
05
06
07
08
09
Set Application
Left Brake Adjustment
Right Brake Adjustment
Left Steer Cluch High Pressure Adj.
Right Steer Cluch High Pressure Adj.
Left Brake Low Pressure Adj.
Right Brake Low Pressure Adj.
Left Steer Cluch Low Pressure Adj.
Righ Steer Cluch High Pressure Adj.
Transmission Calibration Mode
Mode No. 7 ... D10R and D11R
Mode No. 6 ... D5M, D6M, D6R and D7R
ON
ON
ON
ON
ON
ON
ON
ON
ON
20
21
22
31
32
33
34
35
40
Set Forward High Speed Lockup
Set Reverse High Speed Lockup
Transmission Direction Lever Adj.
Cluch 1 Engagement Calibration
Cluch 2 Engagement Calibration
Cluch 3 Engagement Calibration
Cluch 4 Engagement Calibration
Cluch 5 Engagement Calibration
Cluch Fill Calibration
Componenet Data Display Mode
Mode No. 8 ... D10R and D11R
Mode No. 7 ... D5M, D6M, D6R and D7R
ON NONE Component Data
1
Only the submode required for a particular machine will appear.
1
PROCEDURE : D5M, D6M, D6R, D7R - 910 rpm
D10R, D11R - Low Idle
3rd Forward, press "CLEAR' to Decrease (-).
Observe the left track to see if stops on the 20 sc.
If stops, increse the value by 5 higher.
If does not Stop, decrease the value on the
disply to 1 lower
PROCEDURE : Eng. at HI rpm, Transm.
in Neutral.
PROCEDURE : Eng. at HI rpm, Transm.
in Neutral.
Use the Increase (+) or Decrease (-) of
the CLEAR switch to adj. the Cluch
Pressure. (See the chart for specs)
PROCEDURE : Eng. at HI rpm, Transm.
in Neutral.
Use the Increase (+) or Decrease (-) of
the CLEAR switch to adj. the Cluch
Pressure. (See the chart for specs
Use the Increase (+) or Decrease (-) of
the CLEAR switch to adj. the Cluch
Pressure. (See the chart for specs)
ERROR CODE LIST
E01 - Active cluch solenoid or Speed sensor fault
E02 - Engine speed not zero
E03 - Sensor calibration faelure
E04 - Transmission direction lever not in neutral
E05 - Transmission oil temp below 68C
E06 - Engine speed below 1500 rpm
E07 - Parking brake is not on
E08 - Active CID 299
E09 - Machine speed not zero
E10 - Service brake pedal pressed
E21 - Clutch 1 at A limit
E22 - Clutch 2 at A limit
E23 - Clutch 3 at A limit
E24 - Clutch 4 at A limit
E25 - Clutch 5 at A limit
Use the Increase (+) or Decrease (-) of
the CLEAR switch to select the desire
max. speed, R2 or R3
PROCEDURE : Eng. at HI rpm,
PROCEDURE : Eng. at HI rpm,Transm. in
Neutral.at list fou times.
Error codes EXX can occur. the letter "F"
should be flashing. Move the lever to the
max. forward position several times to
stop the flashing "F". N (neutral) et R
(reverse), will be flashing; repette the
same prodedure as before.
PROCEDURE : Eng. at HI rpm, Transm.
in Neutral.
Error codes EXX can occur. Enter sub-
mode, move lever to FWR. posit.. Use the
Increase (+) or Decrease (-) of the CLEAR
switch to adj. the electrical current of the
solenoid to control the pressure.
PROCEDURE : Eng. at HI rpm, Transm.
in Neutral.
Error codes EXX can occur. Enter sub-
mode, move lever to FWR. posit.. This
bigins the actual cluch fill calib.. When the
calib. is completed "- - -" will be shown.
C
H
A
P
T
E
R

:


P
O
W
E
R
T
R
A
I
N


D
1
1
R
L
a
r
g
e

T
r
a
c
k

T
y
p
e

T
r
a
c
t
o
r
s
2
-
3
5
P
a
g
e
:

7.20
7.21
7.22
MODES
-
MODE 7 SUB-MODES
USE "S" SERVICE SWITCH TO SCROLL SUB-MODES
D10R
TRANSMISSION DIRECTION LEVER
POSITION SENSOR CALIBRATION
TRANSMISSION CALIBRATION MODE
F 3
SETS MAX DESIRED FORWARD SPEED
SETS MAX DESIRED REVERSE SPEED R 2
- -
COMPONENT DATA DISPLAY MODE
MODE 8
7 7 1
C
5 6
CID 177 TRANSMISSION OIL TEMPERATURE SENSOR
TEMPERATURE 65C
CHAPTER : POWERTRAIN D11R
Large Track Type Tractors
2-36 Page:
LAB EXERCISES
TRANSMISSION PRESSURE TESTS
PRESSURE SPEC
LOW IDLE
PRESSURE
AT LOW
IDLE
SPEC
HIGH IDLE
PRESSURE
AT HIGH
IDLE
OIL PUMP 3380100kPa
49015 psi
SPEED CLUTCH
P1 (INITIAL
PRESSURE)
53035 kPa
775 psi
Load piston
plug removed
Neutral
SPEED CLUTCH
P1
480 kPa
70 psi
Less than at
high idle Load
piston plug
installed
2590170kPa
38025 psi
Forward or
reverse. Load
piston plug
installed
DIRECTION
CLUTCH P2
380 35 kPa
555 psi
Less than speed
clutch pressure
Load piston
plug installed
380 35 kPa
555 psi
Less than speed
clutch pressure
Load piston
plug installed
TRANSMISSION
LUBE OIL
7617 kPa
112. 5 psi
Neutral brakes
off
C
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A
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E
R

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P
O
W
E
R
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A
I
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D
1
1
R
L
a
r
g
e

T
r
a
c
k

T
y
p
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T
r
a
c
t
o
r
s
2
-
3
7
P
a
g
e
:

L
A
B

E
X
E
R
C
I
S
E
S
TORQUE CONVERTER PRESSURE
PRESSURE SPEC LOW IDLE SPEC HIGH IDLE
TORQUE
CONVERTER
INLET
92050 kPa
205 psi
Neutral brakes
off
TORQUE
CONVERTER
OUTLET
68055 kPa
998 psi
Neutral brakes
off
PRIORITY
VALVE
SETTING
289535 kPa
4205 psi
Load piston
plug removed
STEERING
CLUTCH AND
BRAKE LUBE
13535 kPa
205 psi
Neutral, steering
control lever and
foot brake off
C
H
A
P
T
E
R

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P
O
W
E
R
T
R
A
I
N


D
1
1
R
L
a
r
g
e

T
r
a
c
k

T
y
p
e

T
r
a
c
t
o
r
s
2
-
3
8
P
a
g
e
:

L
A
B

E
X
E
R
C
I
S
E
S
STEERING AND BRAKE PRESSURE TESTS
STEERING AND BRAKE
PEDAL POSITION
STEERING CLUTCH
PRESSURE
HIGH IDLE, NEUTRAL
BRAKE PRESSURE
HIGH IDLE, NEUTRAL
LEFT CLUTCH RIGHT
CLUTCH
LEFT BRAKE RIGHT
BRAKE
NO LEVER OR PEDAL
MOVEMENT
2310100 kPa
33515 psi
2310100 kPa
33515 psi
3140172 kPa
45525 psi
3140172 kPa
45525 psi
RIGHT LEVER PULLED
COMPLETELY BACK
NO MOVEMENT OF LEFT
LEVER OR PEDAL
2310100 kPa
33515 psi
<70 kPa
<10 psi
3140172 kPa
45525 psi
LEFT LEVER PULLED
COMPLETELY BACK
NO MOVEMENT OF LEFT
LEVER OR PEDAL
<70 kPa
<10 psi
2310100 kPa
33515 psi
259172 kPa
3825 psi
3140172 kPa
45525 psi
NO LEVER OR PEDAL
PEDAL PUSHED COMPLETELY
2310100 kPa
33525 psi
2310100 kPa
33525 psi
<70 kPa
<10 psi
<70 kPa
<10 psi