Service Training

MALAGA

Large Track Type Tractors

2. POWERTRAIN D11R
1. Components Layout
2. Operation
3. Testing & Adjusting

Adolfo
May 1997
 Large Track Type Tractors
CHAPTER : POWERTRAIN D11R

TORQUE DIVIDER

75% TORQUE (FLUID COUPLING)

25% TORQUE (MECHANICAL COUPLING)

Page: 2-2
Page:
2-3

TORQUE DIVIDER
ENGINE FLYWHEEL ROTATING
HOUSING

OUTLET
PLANET GEARS PASSAGE

SUN GEAR

CHAPTER : POWERTRAIN D11R

OUTPUT SHAFT

Large Track Type Tractors

STATOR

PLANET CARRIER

RING GEAR INLET

PASSAGE
TURBINE

IMPELLER
 Large Track Type Tractors
CHAPTER : POWERTRAIN D11R

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

Page: 2-4
 Large Track Type Tractors
CHAPTER : POWERTRAIN D11R

SOS T/C INLET PRESSURE TAP

LUBE PRESSURE TAP

XMS TEMPERATURE TAP

P1 & P2 PRESSURE TAPS REMOTELY MOUNTED

Page: 2-5
Page:

POWER SHIFT TRANSMISSION

2-6

RING GEAR
RING GEARS

INPUT SUN GEARS

INPUT SHAFT

CHAPTER : POWERTRAIN D11R

Large Track Type Tractors
OUTPUT SHAFT

1 REVERSE 5
2 FORWARD OUTPUT SUN GEARS
3 THIRD 1 2 3 4
4 SECOND
5 FIRST

PLANETARY
CARRIER
 Large Track Type Tractors
CHAPTER : POWERTRAIN D11R

POWER TRAIN OIL PUMP

5 SECTION GEAR PUMP:

CONVERTER SCAVENGE
TRANSMISSION SCAVENGE
BRAKE COOLING
CONVERTER CHARGE
TRANSMISSION CHARGE
Page: 2-7
 Large Track Type Tractors
CHAPTER : POWERTRAIN D11R

FILTERS

TRANSMISSION FILTER

TORQUE CONVERTER FILTER

Page: 2-8
 Large Track Type Tractors
CHAPTER : POWERTRAIN D11R

TRANSMISSION CASE DRAIN

PLUG DRAIN VALVE

Page: 2-9
 Large Track Type Tractors
CHAPTER : POWERTRAIN D11R

TRANSMISSION CONTROL VALVE

P2 DIRECTION P1 SPEED

Page: 2-10
 Large Track Type Tractors
CHAPTER : POWERTRAIN D11R

CONVERTER OUTLET RELIEF VALVE

PRESSURE TAP
POWERTRAIN OIL TEMPERATURE SENSOR

CONVERTER OUTPUT SPEED SENSOR

Page: 2-11
 Large Track Type Tractors
CHAPTER : POWERTRAIN D11R

LUBE MANIFOLD LUBE PRESSURE TAP

Page: 2-12
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POWER TRAIN HYDRAULIC OIL SYSTEM

2-13

D11R AND D11R CD CARRYDOZER

TRANSMISSION
OIL FILTER TORQUE CONVERTER
OIL FILTER

TORQUE
CONVERTER
OUTLET
RELIEF

CHAPTER : POWERTRAIN D11R

STEERING VALVE
CLUTCH AND
BRAKE

Large Track Type Tractors

VALVE A B C D E

3508 OIL
ENGINE COOLER
TRANSMISSION
CONTROL
VALVE
LUBE
MANIFOLD

PRIORITY
MANIFOLD VALVE VENT
FAN PUMP

IMPLEMENT
GROUP
CASE AND CLUTCH BRAKE LUBE
FRAME
Page:
2-14

POWER TRAIN HYDRAULIC SYSTEM

TORQUE
2 3 CONVERTER
LUBE OIL FILTER TORQUE
MANIFOLD CONVERTER

1 5 4

OIL
COOLERS

CHAPTER : POWERTRAIN D11R

Large Track Type Tractors
OUTLET
RELIEF VALVE

STEERING
CLUTCH POWER TRAIN
AND BRAKE OIL
VALVE TRANSMISSION
PUMP OIL FILTER

SPEED PRIORITY
SELECTOR VALVE
SPOOL
Page:

TRANSMISSION
2-15

HYDRAULIC CONTROL VALVE

P1

P3

MODULATION
RELIEF VALVE

FIRST AND THIRD SPEED

SELECTOR SPOOL
CONVERTER INLET
RATIO VALVE

CHAPTER : POWERTRAIN D11R

P2
LOAD PISTON

Large Track Type Tractors

DIRECTIONAL
SELECTOR
SPOOL

PRESSURE
DIFFERENTIAL
VALVE

SECOND SPEED
SELECTOR SPOOL
Page:

POWER TRAIN HYDRAULIC SYSTEM

2-16

1ST SPEED FORWARD

TORQUE
2 3 CONVERTER
LUBE OIL FILTER TORQUE
MANIFOLD CONVERTER

1 5 4

OIL
COOLERS

CHAPTER : POWERTRAIN D11R

OUTLET

Large Track Type Tractors

RELIEF VALVE

STEERING
CLUTCH POWER TRAIN
AND BRAKE OIL
VALVE TRANSMISSION
PUMP OIL FILTER

SPEED PRIORITY
SELECTOR VALVE
SPOOL
 Large Track Type Tractors
CHAPTER : POWERTRAIN D11R

FINGER TIP CONTROL

LEFT & RIGHT

STEERING LEVERS

DIRECTIONAL SPEED SHIFT

LEVER CONTROL BUTTONS

Page: 2-17
 Large Track Type Tractors
CHAPTER : POWERTRAIN D11R

STEERING AND BRAKE CONTROL VALVE

LEFT BRAKE LEFT CLUTCH

PRESSURE TAP PRESSURE TAP

RIGHT BRAKE RIGHT CLUTCH

PRESSURE TAP PRESSURE TAP

Page: 2-18
Page:
STEERING AND BRAKE CONTROL VALVE
SERVICE BRAKES ENGAGED
2-19

PARKING/SECONDARY BRAKE
SOLENOID VALVES BRAKE
CHAMBER
REDUCING
SPOOL

ACCUMULATOR PISTON

CHAPTER : POWERTRAIN D11R

Large Track Type Tractors
DRAIN

PROPORTIONAL PILOT PILOT

SOLENOID VALVE PRESSURE
SHUTOFF SUPPLY
CHAMBER
VALVE OIL
Page:

STEERING AND BRAKE CONTROL VALVE

SERVICE BRAKES RELEASED
2-20

CHECK
VALVE
PARKING/SECONDARY BRAKE
SOLENOID VALVES BRAKE
CHAMBER
REDUCING
SPOOL

ACCUMULATOR PISTON

CHAPTER : POWERTRAIN D11R

Large Track Type Tractors
DRAIN

PROPORTIONAL PILOT PILOT

SOLENOID VALVE PRESSURE
SHUTOFF SUPPLY
CHAMBER
VALVE OIL
Page:
2-21

PARKING AND
SECONDARY BRAKE
SOLENOIDS

STEERING AND BRAKE

CONTROL VALVE
SERVICE BRAKES ENGAGED

CHAPTER : POWERTRAIN D11R

Large Track Type Tractors
TO RIGHT CLUTCH

TO RIGHT BRAKE

SUPPLY OIL

TO LEFT BRAKE

TO LEFT CLUTCH
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2-22

PARKING AND
SECONDARY BRAKE
SOLENOIDS

STEERING AND BRAKE

CONTROL VALVE

CHAPTER : POWERTRAIN D11R

STRAIGHT LINE OPERATION

Large Track Type Tractors

TO RIGHT CLUTCH

TO RIGHT BRAKE

SUPPLY OIL

TO LEFT BRAKE
TO LEFT CLUTCH
Page:
2-23

PARKING AND
SECONDARY BRAKE
SOLENOIDS

STEERING AND BRAKE

CONTROL VALVE

CHAPTER : POWERTRAIN D11R

GRADUAL RIGHT TURN

Large Track Type Tractors

TO RIGHT CLUTCH

TO RIGHT BRAKE

SUPPLY OIL

TO LEFT BRAKE
TO LEFT CLUTCH
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2-24

PARKING AND
SECONDARY BRAKE
SOLENOIDS

STEERING AND BRAKE

CONTROL VALVE

CHAPTER : POWERTRAIN D11R

SHARP RIGHT TURN

Large Track Type Tractors

TO RIGHT CLUTCH

TO RIGHT BRAKE

SUPPLY OIL

TO LEFT BRAKE
TO LEFT CLUTCH
Page:
2-25

PARKING AND
SECONDARY BRAKE
SOLENOIDS

STEERING AND BRAKE

CONTROL VALVE

CHAPTER : POWERTRAIN D11R

PARKING BRAKE ENGAGED

Large Track Type Tractors

TO RIGHT CLUTCH

TO RIGHT BRAKE

SUPPLY OIL

TO LEFT BRAKE

TO LEFT CLUTCH
Page:

POWER TRAIN ELECTRONIC CONTROL

2-26

SYSTEM D10R D11R TRACTORS

MAIN FUNCTIONS

TRANSMISSION SHIFTING (Electronic Clutch Selection)

BRAKING

CHAPTER : POWERTRAIN D11R

STEERING CLUTCH & BRAKE (Finger Tip Control)

Large Track Type Tractors

ADDITIONAL FUNCTIONS

PARKING BRAKE FUNCTION

NEUTRAL START FUNCTION
WARNING FUNCTION
BACKUP ALARM FUNCTION
Page:
2-27

MESSAGE CENTER ACTION

GAUGE CLUSTER TACHOMETER MODULE LAMP
MODULE MODULE
ACTION
ALARM
°C kPa Miles KM RPM Liter
SERV
... CODE
X10

CATERPILLAR
MONITORING
SYSTEM MID 030
DISPLAY
DATA LINK

CHAPTER : POWERTRAIN D11R

Large Track Type Tractors
TRANSMISSION CAT DATA LINK
CONTROL
INPUT
COMPONENTS

ENGINE INPUT
POWER CONTROL COMPONENTS
TRAIN MID 036
CONTROL
MID 113
Page:

POWER TRAIN ELECTRICAL SYSTEM

CAT DATA
2-28

D10R D11R POWER TRAIN ECM LINK

CONTROL AND
(MAC-14)
FINGER TIP CONTROL MONITOR SYSTEMS

INPUT COMPONENTS OUTPUT COMPONENTS

CLUTCH 1
REVERSE SOLENOID
LEFT & RIGHT STEER
CONTROLLER

LEVER SENSORS CLUTCH 2

FORWARD SOLENOID
FTC

UPSHIFT SWITCH CLUTCH 3

3RD GEAR SOLENOID
DOWNSHIFT SWITCH
CLUTCH 4
DIRECTION SENSOR 2ND GEAR SOLENOID

CHAPTER : POWERTRAIN D11R

PARKING BRAKE SWITCH CLUTCH 5

Large Track Type Tractors

1ST GEAR SOLENOID

PARKING BRAKE SOL

STEERING & BRAKE

CONTROL VALVE
BRAKE

SERVICE BRAKE
PEDAL

PEDAL SWITCH SECONDARY BRAKE SOL

BRAKE PEDAL
POSITION SENSOR LEFT BRAKE SOLENOID

RIGHT BRAKE SOLENOID

HARNESS CODE
LEFT STEER CLUTCH SOL
CONVERTER SPEED SENSOR
RIGHT STEER CLUTCH SOL
TRANSMISSION
TEMPERATURE SENSOR
BACKUP
ALARM
Page:

HARNESS CODE PLUG CONTACT

2-29

ECM CONNECTOR CONTACT J1-14 J1-36 J1-32 J1-26 J1-25

WIRE IDENTIFICATION 280-BK 279-BK 278-BK 277-BK 276-BK
HARNESS CODE PLUG CONTACT 5 4 3 2 1

FINGER TIP CONTROL

ELECTRONIC CLUTCH SELECTION
(ECS) 0 0 0 0 G
D10R , D11R
FINGER TIP CONTROL
ELECTRONIC CLUTCH PRESSURE

CHAPTER : POWERTRAIN D11R

CONTROL (ECPC) 0 G G 0 0

Large Track Type Tractors

POWER SHIFT TORQUE CONVERTER
PSTC D5M, D6M, D5R, D6R
FINGER TIP CONTROL
ELECTRONIC CLUTCH PRESSURE
CONTROL (ECPC)
0 G 0 G 0
POWER SHIFT DIRECT DRIVE
PSDD D5M, D6R
DIFFERENTIAL STEER
ELECTRONIC CLUTCH PRESSURE
CONTROL (ECPC)
POWER SHIFT TORQUE CONVERTER
G G 0 G 0
DS D6R, D7R
 Large Track Type Tractors
CHAPTER : POWERTRAIN D11R

MESSAGE CENTER MODULE

BATTERY VOLTAGE AIR FILTER

"R" TERMINAL Hz RESTRICTION
LOSS OF
ENGINE OIL COOLANT CHECK ENGINE
PRESSURE FLOW LIGHT

ALERT
INDICATORS
!
! ! P
STEERING
SYSTEM
SERV PARKING

44
CODE BRAKE
BRAKE
SYSTEM

TRANMISSION POWER TRAIN

SYSTEM OIL FILTER

ACTIVE CODE
INDICATOR
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

Page: 2-30
 Large Track Type Tractors
CHAPTER : POWERTRAIN D11R

OPERATOR MODES
D10R D11R

SERVICE SERV
METER CODE
MODE 41.4

MILES or KM
ODOMETER MACHINE TRAVEL
MODE 170 DISTANCE

DIGITAL RPM
TACHOMETER - ENGINE SPEED RPM
MODE 700

ENGINE kPa
OIL
PRESSURE 420

DIAGNOSTIC SERV SERV

SCROLLING CODE CODE
MODE 030 271 F05
MID CID, FMI

Page: 2-31
 Large Track Type Tractors
CHAPTER : POWERTRAIN D11R
Page: 2-32
Page:
STEERING/BRAKING CALIBRATION MODE
MODE 6 SUB-MODES
2-33

USE "S" SERVICE SWITCH TO SCROLL SUB-MODES

MODES

6.1 790 SET APPLICATION

725 726 793 MODE
D10R D11RB D11RA D11R CD
9TR1-UP 8ZR1-UP

6.2 LEFT BRAKE ADJUSTMENT

1 8 0

6.3 RIGHT BRAKE ADJUSTMENT

1 5 5

6.4 LEFT STEER CLUTCH HIGH PRESSURE ADJUSTMENT

2 0 0

CHAPTER : POWERTRAIN D11R

6.5 1 2 3

Large Track Type Tractors

RIGHT STEER CLUTCH HIGH PRESSURE ADJUSTMENT

6.6 1 4 8 LEFT BRAKE LOW PRESSURE ADJUSTMENT

6.7 2 0 0 RIGHT BRAKE LOW PRESSURE ADJUSTMENT

6.8 1 3 1 LEFT STEER CLUTCH LOW PRESSURE ADJUSTMENT

6.9 0 8 3 RIGHT STEER CLUTCH LOW PRESSURE ADJUSTMENT

 Large Track Type Tractors
CHAPTER : POWERTRAIN D11R

PROCEDURE : D5M, D6M, D6R, D7R - 910 rpm

CALIBRATION MODE
D10R, D11R - Low Idle
PARKING 1 3rd Forward, press "CLEAR' to Decrease (-).
SUBMODE SUBMODE Observe the left track to see if stops on the 20 sc.
BRAKE
NUMBER DESCRIPTION If stops, increse the value by 5 higher.
STATUS
If does not Stop, decrease the value on the
Steering / Calibration Mode disply to 1 lower
Mode No. 6 ... D10R and D11R
Mode No. 5 ... D5M, D6M, D6R and D7R
PROCEDURE : Eng. at HI rpm, Transm.
ON 01 Set Application in Neutral.
OFF 02 Left Brake Adjustment
OFF 03 Right Brake Adjustment Use the Increase (+) or Decrease (-) of
ON 04 Left Steer Cluch High Pressure Adj. the CLEAR switch to adj. the Cluch
ON 05 Right Steer Cluch High Pressure Adj. Pressure. (See the chart for specs)
OFF 06 Left Brake Low Pressure Adj.
OFF 07 Right Brake Low Pressure Adj. PROCEDURE : Eng. at HI rpm, Transm.
ON 08 Left Steer Cluch Low Pressure Adj. in Neutral.
ON 09 Righ Steer Cluch High Pressure Adj. Use the Increase (+) or Decrease (-) of
Transmission Calibration Mode
the CLEAR switch to adj. the Cluch
Mode No. 7 ... D10R and D11R
Pressure. (See the chart for specs
Mode No. 6 ... D5M, D6M, D6R and D7R
ON 20 Set Forward High Speed Lockup PROCEDURE : Eng. at HI rpm, Transm.
ON 21 Set Reverse High Speed Lockup in Neutral.
ON 22 Transmission Direction Lever Adj. Use the Increase (+) or Decrease (-) of
ON 31 Cluch 1 Engagement Calibration the CLEAR switch to adj. the Cluch
ON 32 Cluch 2 Engagement Calibration Pressure. (See the chart for specs)
ON 33 Cluch 3 Engagement Calibration
ON 34 Cluch 4 Engagement Calibration
ON 35 Cluch 5 Engagement Calibration PROCEDURE : Eng. at HI rpm,
ON 40 Cluch Fill Calibration
Componenet Data Display Mode Use the Increase (+) or Decrease (-) of
Mode No. 8 ... D10R and D11R the CLEAR switch to select the desire
Mode No. 7 ... D5M, D6M, D6R and D7R max. speed, R2 or R3
ON NONE Component Data
PROCEDURE : Eng. at HI rpm,Transm. in
1 Only the submode required for a particular machine will appear.
Neutral.at list fou times.
Error codes EXX can occur. the letter "F"
should be flashing. Move the lever to the
ERROR CODE LIST
max. forward position several times to
E01 - Active cluch solenoid or Speed sensor fault stop the flashing "F". N (neutral) et R
E02 - Engine speed not zero (reverse), will be flashing; repette the
E03 - Sensor calibration faelure same prodedure as before.
E04 - Transmission direction lever not in neutral
E05 - Transmission oil temp below 68C PROCEDURE : Eng. at HI rpm, Transm.
E06 - Engine speed below 1500 rpm in Neutral.
E07 - Parking brake is not on Error codes EXX can occur. Enter sub-
E08 - Active CID 299 mode, move lever to FWR. posit.. Use the
E09 - Machine speed not zero Increase (+) or Decrease (-) of the CLEAR
E10 - Service brake pedal pressed switch to adj. the electrical current of the
E21 - Clutch 1 at A limit solenoid to control the pressure.
E22 - Clutch 2 at A limit
E23 - Clutch 3 at A limit PROCEDURE : Eng. at HI rpm, Transm.
E24 - Clutch 4 at A limit in Neutral.
E25 - Clutch 5 at A limit 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.

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Page:

TRANSMISSION CALIBRATION MODE

2-35

MODE 7 SUB-MODES
USE "S" SERVICE SWITCH TO SCROLL SUB-MODES

MODES

7.20 F 3 SETS MAX DESIRED FORWARD SPEED

D10R

7.21 R 2 SETS MAX DESIRED REVERSE SPEED

7.22 TRANSMISSION DIRECTION LEVER

- - - POSITION SENSOR CALIBRATION

CHAPTER : POWERTRAIN D11R

Large Track Type Tractors
COMPONENT DATA DISPLAY MODE
MODE 8

C CID 177 TRANSMISSION OIL TEMPERATURE SENSOR

65 17 7 TEMPERATURE 65°C
 Large Track Type Tractors
CHAPTER : POWERTRAIN D11R

LAB EXERCISES

TRANSMISSION PRESSURE TESTS

PRES S U RE S PEC PRES S U RE S PEC PRES S U RE
LOW IDLE AT LOW HIGH IDLE AT HIGH
IDLE IDLE
OIL PU MP 3380±100kPa
490±15 ps i

S PEED CLU TCH 530±35 kPa

P1 (IN ITIAL 77±5 ps i
PRES S U RE) Load pis ton
plug removed
N eutral
S PEED CLU TCH 480 kPa 2590±170kPa
P1 70 ps i 380±25 ps i
Les s than at Forw ard or
high idle Load revers e. Load
pis ton plug pis ton plug
ins talled ins talled
DIRECTION 380 ±35 kPa 380 ±35 kPa
CLU TCH P2 55±5 ps i 55±5 ps i
Les s than s peed Les s than s peed
clutch pres s ure clutch pres s ure
Load pis ton Load pis ton
plug ins talled plug ins talled
TRAN S MIS S ION 76±17 kPa
LU BE OIL 11±2. 5 ps i
N eutral brakes
off

Page: 2-36
 TORQUE CONVERTER PRESSURE

PRES S U RE S PEC LOW IDLE S PEC HIGH IDLE

TORQU E 920±50 kPa

CON VERTER 20±5 ps i
IN LET N eutral brakes
off

CHAPTER : POWERTRAIN D11R

LAB EXERCISES
TORQU E 680±55 kPa
CON VERTER 99±8 ps i

Large Track Type Tractors

OU TLET N eutral brakes
off
PRIORITY 2895±35 kPa
VALVE 420±5 ps i
S ETTIN G Load pis ton
plug removed
S TEERIN G 135±35 kPa
CLU TCH AN D 20±5 ps i
BRAKE LU BE N eutral, s teering
control lever and
foot brake off
Page:
2-37
 STEERING AND BRAKE PRESSURE TESTS

S TEERIN G AN D BRAKE S TEERIN G CLU TCH BRAKE PRES S U RE

PEDAL POS ITION PRES S U RE HIGH IDLE, N EU TRAL
HIGH IDLE, N EU TRAL
LEFT CLU TCH RIGHT LEFT BRAKE RIGHT
CLU TCH BRAKE

N O LEVER OR PEDAL 2310±100 kPa 2310±100 kPa 3140±172 kPa 3140±172 kPa
MOVEMEN T 335±15 ps i 335±15 ps i 455±25 ps i 455±25 ps i

CHAPTER : POWERTRAIN D11R

LAB EXERCISES

Large Track Type Tractors

RIGHT LEVER PU LLED 2310±100 kPa <70 kPa 3140±172 kPa
COMPLETELY BACK 335±15 ps i <10 ps i 455±25 ps i
N O MOVEMEN T OF LEFT
LEVER OR PEDAL
LEFT LEVER PU LLED <70 kPa 2310±100 kPa 259±172 kPa 3140±172 kPa
COMPLETELY BACK <10 ps i 335±15 ps i 38±25 ps i 455±25 ps i
N O MOVEMEN T OF LEFT
LEVER OR PEDAL
N O LEVER OR PEDAL 2310±100 kPa 2310±100 kPa <70 kPa <70 kPa
PEDAL PU S HED COMPLETELY 335±25 ps i 335±25 ps i <10 ps i <10 ps i
Page:
2-38