D6R Series III Track Type Tractor Power Train System

D

COMPONENT LIST No.

Schematic Location

Part Number

Description

1 2 3 4 5 6 7 8 9 10 11 12 13 14

C-4 A-5 E-5 E-4 N/A D-3 B-1 C-4 E-5 F-6 A-6 B-2 N/A N/A

226-3902 235-5812 213-1308 263-9949 9G-5127 220-1418 238-1116 231-4166 220-1429 231-5969 231-5990 232-6207 241-5635 223-9039

POWER TRAIN OIL PUMP (3 SECTION) POWER TRAIN OIL FILTERS ELECTRONIC BRAKE CONTROL VALVE LUBE DIST. / TC INLET RELIEF MANIFOLD BREATHER TORQUE CONVERTER OUTLET RELIEF VALVE OIL COOLER PUMP INLET SCREEN / HOUSING GP. TRANSMISSION AR. LEFT DRIVE / BRAKE GP. RIGHT DRIVE / BRAKE GP. TORQUE CONVERTER / HOUSING GP. DIPSTICK OIL FILL TUBE

The three-section gear-type power train oil pump (B) is mounted to the front of the main case, at the upper right.

E-6 D-8

M N L2 L1 LB1 LB2 CL1 CL2 CL3 CL4 CL5 AA BB

E-4 D-3 E-2 C-8 E-6 A-6 C-6 C-7 D-7 D-7 D-6 A-4 A-5

T/C SUPPLY PRESSURE T/C OUTLET PRESSURE FLYWHEEL LUBE PRESSURE TRANS. LUBE PRESSURE L BRAKE LUBE PRESSURE R BRAKE LUBE PRESSURE TRANS. CLUTCH 1 PRESSURE TRANS. CLUTCH 2 PRESSURE TRANS. CLUTCH 3 PRESSURE TRANS. CLUTCH 4 PRESSURE TRANS. CLUTCH 5 PRESSURE PTO SAMPLING PORT (SOS) PTO PRESSURE

PRESSURE COMPENSATION

LINE RESTRICTION (VARIABLE)

SPRING (ADJUSTABLE)

VARIABILITY

TWO POSITION

VALVE PORTS

I

The transmission and torque converter scavenge section (H) of the power train oil pump draws approximately 125 L/min. (33 US gal./min.) from the torque divider case, and the transmission case.

The scavenge oil is used for lubrication of the steering differential. The power train oil temperature sensor (I) provides main sump oil temperature information to the Machine ECM. This is the temperature sensor that is considered when performing power train calibrations, such as brake touch-ups and transmission clutch fill calibrations.

K

J

L

The torque converter inlet relief valve (J) and the lube distribution manifold (L) are both contained in one housing. Oil from the torque converter charging section of the power train oil pump is supplied to the torque converter inlet relief valve through the upper hose (K).

M

N

INFINITE POSITION

PRESSURE

PILOT CONTROLLED

ROTATING SHAFTS

FLOW

TEMPERATURE

UNIDIRECTIONAL

BIDIRECTIONAL

FLUID STORAGE RESERVOIRS

D6R Series III Track-Type Tractor Power Train System GJB1-UP WCB1-UP HDC1-UP RFC1-UP TBC1-UP JEK1-UP HCD1-UP HKE1-UP WRG1-UP MTJ1-UP

SHUTTLE

SPRING LOADED

BASIC SYMBOL

MEASUREMENT

VENTED

RETURN ABOVE FLUID LEVEL

PRESSURIZED

RETURN BELOW FLUID LEVEL

COMBINATION CONTROLS

DMK1-UP LGP1-UP JDL1-UP DLM1-UP LFM1-UP EXL1-UP DPS1-UP EXW1-UP GMT1-UP MRT1-UP

SOLENOID

SOLENOID or MANUAL

SERVO

SOLENOID and PILOT or MANUAL

SOLENOID and PILOT

DETENT

THERMAL

MANUAL CONTROL SYMBOLS

PUSH-PULL LEVER

GENERAL MANUAL

MANUAL SHUTOFF

PUSH BUTTON

PEDAL

SPRING

PILOT CONTROL SYMBOLS RELEASED PRESSURE

EXTERNAL RETURN

REMOTE SUPPLY PRESSURE

INTERNAL RETURN

SIMPLIFIED

CROSSING AND JOINING LINES

ACCUMULATORS

The torque converter inlet relief valve is installed in the housing. Excess oil flows past the inlet relief valve into the main sump through a port in the front of the case, and behind the housing. Oil flow to the torque converter inlet is through the hose on the right (N).

P

CHECK VALVES

P T SHIFTED POSITION

The power train oil pump draws oil for the torque converter charging circuit and for the transmission charging circuit from a screened suction manifold that connects to the pump at the pump inlet (E).

The transmission charging section (G) of the power train oil pump supplies approximately 54 L/min. (14.3 US gal./min.) of oil to the transmission and brakes circuit.

FOUR-WAY

THREE-WAY

AB

P T NORMAL POSITION

H

ATTACHMENT

LINE RESTRICTION VARIABLE and PRESSURE COMPENSATED

TWO-WAY

THREE POSITION

PUMP: VARIABLE and PRESSURE COMPENSATED

2-SECTION PUMP

HYDRAULIC PNEUMATIC ENERGY TRIANGLES

VALVES

VALVE ENVELOPES

ONE POSITION

E

B P

LINE RESTRICTION (FIXED)

RESTRICTION

CONTROL VALVES

Description

C-1

CONTROL VALVES

SPRING

FLUID CONDITIONER

AB

Tap Locations

ER1

MAIN AUX.

A

F

ENGINE SPEED TRANS. GEAR P/T OIL TYPE PTO SUMP OIL TEMP BRAKE PRESSURE TRANS. MAIN RELIEF

BASIC COMPONENT SYMBOLS

PUMP or MOTOR

The torque converter inlet relief valve and the lube distribution manifold are both incorporated into one housing (D). These two components are mounted to the left front of the main case, near the bottom.

G

Schematic Location

FLUID POWER SYMBOLS

The electronic brake valve (C) is located on top of the main case, to the left of center.

The torque converter charging section (F) of the power train oil pump supplies approximately 145 L/min. (38.3 US gal./min.) of oil to the torque converter circuit for operation of the torque converter and for lubrication purposes.

Tap Number

RENR7954-01 June 2006

The screened main suction manifold (A) for the power train oil pump is located at the right front of the main case, near the bottom.

C

B

SPRING LOADED

GAS CHARGED

LINES CROSSING

HYDRAULIC PUMPS FIXED DISPLACEMENT

Cooled oil from the power train oil cooler is directed to the lube distribution manifold (L) through the hose on the left (M). The smaller hose (P) is the line leading to the remote pressure test port for torque converter inlet pressure ( M ). This remote pressure test port is located inside the front compartment on the right fender

HYDRAULIC AND PNEUMATIC CYLINDERS

SINGLE ACTING

LINES JOINING

FIXED DISPLACEMENT

VARIABLE DISPLACEMENT NON-COMPENSATED

UNIDIRECTIONAL

UNIDIRECTIONAL

BIDIRECTIONAL

BIDIRECTIONAL

DOUBLE ACTING

INTERNAL PASSAGEWAYS

HYDRAULIC MOTORS

VARIABLE DISPLACEMENT NON-COMPENSATED

INTERNAL SUPPLY PRESSURE

COMPLETE

FLOW IN ONE DIRECTION

PARALLEL FLOW

CROSS FLOW

FLOW ALLOWED IN EITHER DIRECTION

Printed in U.S.A.

© 2006 Caterpillar All Rights Reserved

Power Train Oil Pump 1

TWO POSITION

THREE POSITION

INFINITE POSITIONING

Electrical Symbols Table Q

AA

BB

R

P

S

Hydraulic Symbols (Electrical)

Transmission Charge Circuit Accumulator

CL1 CL2 CL3 CL4 CL5 P L1

10

LB1

3

B

6

4

Transducer (Fluid)

L1

12

CL4

CL5

CL3

CL2

M

G

Transmission Lube Temperature Sensor

Transducer (Gas / Air)

Pressure Switch (Adjustable)

Pressure Switch

CL1

Generator

Electric Motor

Electrical Wire

Temperature Switch

Electrical Symbols (Electrical)

P

T L1

T

Pressure Symbol

Temperature Symbol

Flow Symbol

Level Symbol

CL4

ECPC XMSN Clutch Valves

CL5

Wire Number Identification Codes M

CL3

9

11

LB2

2

5

AA

M

N

1

8

7

13 14

3

B

Opening the front door of the forward compartment on the right fender gains access to the power train oil filter (S). This spin-on type canister contains a replaceable 6-micron filter element. The filter base contains a filter bypass switch (R). This is a normally open switch that is held closed by the filter bypass valve spool. The bypass valve opens, allowing the switch to open, when the difference in pressure between the filter inlet and the filter outlet becomes great enough (approximately 50 psi). The switch is monitored by the Caterpillar Monitoring System and alerts the operator to the filter bypass condition.

Transmission Lube Temperature Sensor

CL1

5 13 14

2

M

N

Electrical Schematic Example

Opening the top door of the forward compartment on the right fender gains access to the combination power train oil fill tube and dipstick (Q).

CL2

Transmission Housing

CL1 CL2 CL3 CL4 CL5 P L1

N

The filter base also contains the power train oil sampling (AA) and a pressure test port (BB) for the transmission charging circuit. The pressure test port is situated downstream from the filter. The power train oil sampling port is situated upstream, or before the filter.

AA Located at the rear of the machine, on top of the the transmission case are the following service points:

Also located in the forward compartment on the right fender and inboard from the power train oil filter canister are the following service points:

1. Transmission main relief pressure test port (P) 2. Transmission lube pressure test port (L1) 3. Transmission lube temperature sensor

(T). remote power train breather (M). remote pressure test port for torque converter inlet pressure (N). remote pressure test port for torque converter outlet pressure

Current Standard

Current Standard Harness identification code This example indicates wire 135 in harness "AG".

Wire

Circuit Number Identification

Wire Color

325-AG135 PK-14 325-PK Circuit Identification Number

Wire Color

Wire Gauge

Previous Standard Wire Color

Wire

Pressure test ports for each of the five transmission clutches remain on the transmission cover. These pressure test ports are:

325-PK-14

Power Train Oil Filter Group 2

(CL1). Transmission clutch (reverse clutch) (CL2). Transmission clutch (forward clutch) (CL3). Transmission clutch (speed 3) (CL5). Transmission clutch (speed 1) (CL4). Transmission clutch (speed 2)

Hydraulic Schematic Example

B Circuit Number Identification

A

Wire Gauge (EXAMPLE VALVE)

Clutch engagement pressure calibrations are no longer required, with the common top pressure strategy. Proper adjustment of the transmission main relief valve will set the proper pressure for the operation of all five transmission clutches and the brakes. It is still necessary to perform transmission clutch fill calibrations and to perform brake touch-up calibrations.

Engine Oil Cooler The transmission charge circuit accumulator is mounted beneath the fuel tank and located above the transmission case.

9

11 10

LB1 LB2

1

8

4

6

12

This accumulator is pre-charged to approximately 1724 kPa (250 psi). It is used to help maintain transmission charge circuit pressure for short periods of time, such as when transmission clutches are filling (shifts) or at other times when the pressure in the transmission charging circuit may become too low (cold oil, low idle, etc.).

7

Power Train Oil Cooler

CL4

Right Side

CL5

CL3

CL2

ECPC XMSN Clutch Valves

Transmission Charge Circuit Accumulator

Left Side

Below and to the rear of the engine oil cooler is the oil-to-water type power train oil cooler.

CL1

Component and Tap Locations

Transmission Group 9

Power Train Oil Cooler 7

24 Page

BB

RENR7954-01

AA

8

7

P

6

4

5

2

3

1

L1

F

F

LB1 CLUTCH/BRAKES

LEFT BRAKE PRESSURE PORT

10

9 CL4

CL5

CL3

CL1

CL2

4 BRAKE

LUBE

E

L2

EB BRAKE VALVE

E

FLYWHEEL HOUSING

M

B PROPORTIONAL VALVE XMSN LUBE

3 MAIN RELIEF

2ND

3RD

1ST

CL4

CL3

CL5

ENGINE

IMPLEMENT PUMP

PROPORTIONAL VALVE

D

D

N

DIFF STEER BEVEL & TRANSFER GEAR LUBE

P PROPORTIONAL VALVE

PROPORTIONAL VALVE

C9

6

XL, XW, LGP 200 NET HP STD 185 NET HP AT 1850 RPM

TORQUE CONVERTER

ECPC XMSN CLUTCH VALVES

PROPORTIONAL VALVE

PROPORTIONAL VALVE

VENT LINE

CL2

CL1

FWD

REV

ER1

PTO TEMP. SENSOR

C

C

SUCTION SCREEN

1

L1

24 Page, Color 2

RENR7954-01

8

TRANS. LUBE TEMP. SENSOR

DRIVESHAFT

SCREEN

SCAV SCAVENGE OUTPUT AND DIFF STEER LUBE TRANSMISSION CONTROL VALVE

A

TRANS

T/C C

B

12

POWERTRAIN OIL COOLER

7 B

B

BRAKE

LUBE

11

AA

RIGHT BRAKE PRESSURE PORT

CLUTCH/BRAKES

LB2

LINE PATTERNS

BB

NOTES: (A) TRANSMISSION AND CONVERTER SCAVENGE PUMP (B) TRANSMISSION CHARGE PUMP (C) TORQUE CONVERTER CHARGE PUMP

Pressure Line Pilot / Load Sensing Pressure

2

Drain / Return Lines

HYDRAULIC CIRCUIT COLOR DESCRIPTIONS

Component Group

A

Brakes. Supply Line. Drain / Return Line.

Attachment

Transmission Charge Pump. Transmission and Torqueconverter Scavenge Pump Torque Converter Charge Pump and Powertrain Oil Cooler

Air Line

CALLOUTS YY

Taps (Pressure, Sampling,Sensor) by letter

52

Components by number

A

THIS SCHEMATIC IS FOR THE D6R TRACK-TYPE TRACTOR PART #: 270-8369 CHG 01 Components are shown installed on a fully operable machine with the key and engine off and transmission shifter in neutral. Refer to the appropriate Service Manual for Troubleshooting, Specifications and Systems Operations

8

7

6

5

4

3

2

1