Professional Documents
Culture Documents
October 2009
Systems Operation
797F Off-Highway Truck Power Train
LAJ1-Up (Machine)
SAFETY.CAT.COM
i03684547
KENR8370
3
Table of Contents
Table of Contents
Systems Operation Section
Graphic Color Codes ............................................
Power Train System ..............................................
Power Train Electrical System .............................
Transmission Electronic Control Module (ECM) ...
Transmission Control ...........................................
Electronic Control (Transmission Gear Indicator) ..
Speed Sensor (Torque Converter Output) ............
Speed Sensor (Transmission Output) ...................
Torque Converter and Transmission Hydraulic
System ................................................................
Gear Pump (Torque Converter Charging and
Transmission Lubrication) ...................................
Gear Pump (Transmission Charging and
Scavenge) ...........................................................
Oil Filter (Torque Converter) .................................
Oil Cooler (Power Train) .......................................
Torque Converter Inlet and Outlet Relief Valves ..
Modulating Valve (Torque Converter Lockup
Clutch) .................................................................
Torque Converter Case Reservoir ........................
Torque Converter .................................................
Transmission ........................................................
Oil Filter (Transmission) ........................................
Magnetic Screen (Transmission) ..........................
Relief Valve (Transmission Lubrication) ................
Relief Valve (Transmission Main) .........................
Modulating Valve (Transmission Clutch
Engaging) ............................................................
Transmission Planetary (Front Module) ................
Transmission Planetary (Rear Module) ................
Transmission Hydraulic Control ...........................
Rear Axle and Final Drive Hydraulic System ........
Pump Drive ..........................................................
Gear Pump (Brake, Rear Axle Lubrication) ..........
Gear Motor (Rear Axle Lubrication) ......................
Gear Pump (Rear Axle Oil) ...................................
Gear Motor (Rear Axle Oil Cooler Fan) ................
Oil Filter (Differential) ............................................
Oil Filter (Final Drive) ............................................
Control Valve (Final Drive Diverter) ......................
Differential and Bevel Gear ..................................
Final Drive ............................................................
4
4
8
10
16
18
19
19
21
26
26
27
29
29
31
34
34
40
43
45
46
48
49
52
53
54
55
57
58
59
60
62
63
64
65
66
69
Index Section
Index ..................................................................... 71
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Operation
The power train is made up of four basic systems.
The following systems are the four systems:
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Illustration 2
(1) Chassis ECM
(2) Transmission ECM
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Torque Converter
Illustration 3
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(4)
(7)(8)
Rear Axle
Transmission
Illustration 5
Illustration 4
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Illustration 6
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Illustration 7
(2)
(4)
(5)
(6)
Final Drives
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Illustration 8
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Illustration 9
Lubrication schematic for the rear axle
(8) Brake/Cooling ECM
(9) Diverter valve (final drive oil)
(10) Gear motor (rear axle pump drive)
(11) Relief valve and unloader valve
(12) Final drive oil filter
(13) Gear pump (rear axle motor drive)
(20)
(21)
(22)
(23)
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Illustration 10
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Electrical system
(1) Transmission ECM
(2) Requested gear command
(3) Engine speed sensor
(4) Transmission input speed sensor
(5) Transmission intermediate speed sensor
(6) Transmission output speed sensor 1
(7) Transmission output speed sensor 2
(8) Torque converter charge filter bypass
switch
(9) Torque converter screen bypass switch
(10) Bypass switch for the transmission
charge filter
(11) Transmission oil level sensor and torque
converter sump sensor
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Transmission Electronic
Control Module (ECM)
SMCS Code: 3168; 4020; 4800
Illustration 11
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Input Components
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Illustration 12
Miscellaneous Input
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Transmission Shifting
(switch open).
Torque Limiting
Output Components
The following components are output components of
the Transmission ECM:
Speed Limiting
Fail In Gear Protection
Transmission Shifting
Table 1
Torque
Converter Drive
Reverse
Neutral
First
Direct Drive
with an
Engaged
Lockup Clutch
Second
Third
Fourth
Fifth
Sixth
Seventh
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Systems Operation Section
Shifting Procedures
The following sections will explain the operations
of automatic upshifts and downshifts. Except for
different electrical wires that must be grounded or
activated, the shifting sequence is basically identical
for all speeds.
Typical Automatic Upshift (SECOND to THIRD)
When the transmission control is put in THIRD speed
position, the rotor for the shift lever switch is turned
to the THIRD speed position. Current goes from
the Chassis ECM through the shift lever switch to
machine ground. The Chassis ECM analyzes this
signal in order to understand that the shift lever
switch is in the THIRD speed position. The Chassis
ECM sends a command for the position of the shift
lever to the Transmission ECM. The command for the
shift lever switch and a signal from the speed sensors
for the torque converter and for the transmission
will inform the Transmission ECM that an upshift is
needed. The upshift to THIRD speed position from
SECOND speed position is automatic when the
correct ground speed signal from the speed sensors
for the torque converter and for the transmission is
sent to the Transmission ECM. Also, the transmission
control must be in THIRD speed position or above
THIRD speed position.
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Special Upshifts
Special Downshifts
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Shift Inhibiting
Torque Limiting
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Speed Limiting
Cold Mode for the Transmission
Refer to Service Manual , Temperature Sensor
(Transmission Oil).
Cold Mode for the Differential
Until the differential oil temperature is warm enough to
allow proper lubrication of the rear axle components,
the Transmission ECM will limit the top speed of the
transmission. When the temperature of the differential
oil is below 4 C (25 F), the Transmission ECM will
limit the speed to FIFTH gear. When the temperature
of the differential oil is between 4 C (25 F) and
24 C (75 F) the Transmission ECM will limit the
speed to SIXTH gear.
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Transmission Control
SMCS Code: 3065
Shift Lever
Coasting In Neutral
Transmission Abuse
Illustration 13
g02000334
Coasting In Neutral
Transmission Abuse
If the operator shifts from NEUTRAL gear to FIRST
gear or to REVERSE gear with the engine speed
above 1500 RPM, the Desired Engine Speed will be
momentarily reduced to low idle and an event will be
logged by the Transmission ECM as a Transmission
Abuse Event. Refer to this Systems Operation
module Directional Shift Management.
Manual Shifting
In the manual shifting mode, the Transmission
Electronic Control Module keeps the transmission
in the same gear that has been selected. Manual
operation includes REVERSE, NEUTRAL, and
FIRST gears. The maximum forward gear is also the
minimum automatic gear.
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Systems Operation Section
Automatic Shifting
The Transmission ECM provides fully automatic
shifting from the minimum automatic gear to the top
gear limit.
In the automatic shifting mode, the operator sets
shift lever (1) to the maximum gear range that
is desired. All of the automatic upshifts and the
automatic downshifts are dependent on the speed of
the machine. The automatic upshifts and automatic
downshifts are preprogrammed in the Transmission
ECM for each gear. The shift points are raised slightly
by the use of the retarder or by the service brakes.
During normal shifting, the Transmission ECM does
not allow a turnaround shift until approximately
4.5 seconds after a shift occurs. This delay allows
mechanical conditions to stabilize before an opposite
shift occurs. This delay also allows hydraulic
conditions to stabilize before an opposite shift occurs.
Inputs from the service/retarder brake and from the
parking and secondary brake eliminate this feature.
Illustration 15
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Hoist Control
Illustration 14
(1)
(2)
(3)
(4)
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LOWER position
FLOAT position
HOLD position
RAISE position
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Illustration 16
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(1) Rod
(2) Dump body position sensor
Electronic Control
(Transmission Gear Indicator)
SMCS Code: 7459
Illustration 17
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Illustration 18
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Illustration 19
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Illustration 20
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Schematic
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Illustration 21
Power train hydraulic schematic
(1) Pump drive
(2) Modulating valve (torque converter
lockup clutch)
(3) Torque converter inlet relief valve
(4) Torque converter outlet relief valve
(5) Breather
(6) Transmission charging filter
(7) Transmission hydraulic control
(8) Torque converter lockup clutch
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Location Of Components
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Illustration 22
Left side view of the torque converter lines
(1) Pump drive
(14) Screen
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Illustration 23
g01998836
View A-A
(2) Modulating valve (torque converter
lockup clutch)
(3) Torque converter inlet relief valve
(4) Torque converter outlet relief valve
(12) Filter for the charge oil for the torque
converter
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Systems Operation Section
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Illustration 24
Left side of power train oil lines
(6) Transmission charging filter
(9) Torque converter
(10) Transmission rear module
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Illustration 25
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Illustration 27
Illustration 26
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Illustration 28
Location of the torque converter oil filter
(1)
(2)
(3)
(4)
(5)
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Illustration 29
Components of the torque converter oil filter
(2) Auxiliary port
(3) Pressure port for sensor
(4) Oil sampling port
(5) Inlet
(6) Outlet
(7) Housing
(8) Elements
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Systems Operation Section
Oil flows through inlet (5). The oil fills the space
between the inside of housing (7), and elements
(8). During normal operation, the oil goes through
elements (8) and through outlet (6). The oil then goes
to the torque converter.
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Illustration 31
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Illustration 30
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Systems Operation Section
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Illustration 32
Inlet relief valve and outlet relief valve
(3) Pressure tap for the drain
(4) Pressure tap (oil inlet)
(6) Pressure tap for the oil cooler
Inlet relief valve (2) and outlet relief valve (1) are
identical. The valves are adjusted to a different
pressure setting. The pressure setting depends on
the function of the valve.
(10) Slug
(11) Orifice
(12) Spool
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Illustration 33
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Deactivated
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Illustration 34
Modulating valve torque converter lockup clutch
(2) Solenoid
(3) Pin
(4) Ball
(5) Passage
(6) Spool
(7) Spring
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Activated
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Illustration 35
Modulating valve torque converter lockup clutch
(2) Solenoid
(3) Pin
(4) Ball
(5) Passage
(6) Spool
(7) Spring
34
Systems Operation Section
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Torque Converter
SMCS Code: 3101; 3102; 3129; 3130; 3131; 3134;
3135; 3136
g01998797
transmission lubrication)
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Systems Operation Section
Table 2
Torque
Converter Drive
Reverse
Neutral
First
Direct Drive
with an
Engaged
Lockup Clutch
Illustration 37
g00932464
Second
Third
Fourth
Fifth
Sixth
Seventh
(1)
(2)
(3)
(4)
(5)
Illustration 38
View of torque converter in the front housing
(6) Oil passage for torque converter inlet
(7) Oil passage for torque converter lockup clutch
(8) Drive gear for transmission oil pumps
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Illustration 39
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Illustration 40
(11) Rotating housing
(12) Turbine
(13) Impeller
(14) Drive gear for the torque converter
charging and transmission lubrication
gear pump and for the transmission
charging and scavenge gear pump
(15)
(16)
(17)
(18)
(19)
(20)
(21)
Outlet passage
Carrier
Output yoke
Output shaft
Hub
Lockup clutch
Stator
(22) Hub
(23) Inlet passage
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One-Way Clutch
Illustration 41
(21)
(24)
(25)
(26)
(27)
(28)
(29)
g01998819
Stator
Race
Cam for the one-way clutch
Rollers
Cage
Spring
Slot
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Systems Operation Section
Direct Drive
g01998822
Illustration 42
(11) Rotating housing
(12) Turbine
(13) Impeller
(14) Drive gear for the torque converter
charging and transmission lubrication
gear pump and for the transmission
charging and scavenge gear pump
(15)
(16)
(17)
(18)
(19)
(20)
(21)
Outlet passage
Carrier
Output yoke
Output shaft
Hub
Lockup clutch
Stator
(22) Hub
(23) Inlet passage
(31) Inlet passage for lockup clutch oil
(32) Piston
(33) Disc
(34) Plate
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Lockup Clutch
Lockup clutch (20) is part of the torque converter.
Lockup clutch (20) is located between the engine
flywheel and turbine (12). Lockup clutch (20) is
engaged when the transmission is in SECOND
through SEVENTH speeds. Lockup clutch (20) will
engage in FIRST speed as the output speed of the
transmission increases. When lockup clutch (20)
is engaged, impeller (13) and turbine (12) turn at
the same speed as the engine and there is no loss
of power in the torque converter. The connection
between the engine and the transmission is now
direct.
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Transmission
SMCS Code: 3030
Operation
Rotating housing (11) is connected to the engine
flywheel by splines. Rotating housing (11) is fastened
to impeller (13) by bolts. Piston (32) and plates
(34) are also connected to rotating housing (11)
by splines. Discs (33) and output shaft (18) are
connected to hub (19) by splines. Turbine (12) is
fastened to hub (19).
Illustration 43
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View of transmission
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Systems Operation Section
Illustration 44
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Input shaft
Front transmission planetary group
Rear transmission planetary group
Output shaft
Transmission Operation
Illustration 45
View of transmission
(1) Transmission lubrication valve
(2) Transmission filter
(7) Port
(8) Port
(9) Port
(10) Housing
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Illustration 46
(11) Clutch modulating valves
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Illustration 47
Location of the transmission oil filter
(1)
(2)
(3)
(4)
(5)
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Illustration 48
Components of the transmission oil filter
(2) Auxiliary port
(3) Pressure port for sensor
(4) Oil sampling port
(5) Inlet
(6) Outlet
(7) Housing
(8) Elements
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Systems Operation Section
Oil flows through inlet (5). The oil fills the space
between the inside of housing (7), and elements
(8). During normal operation, the oil goes through
elements (8) and through outlet (6). The oil then goes
to the transmission controls.
Elements (8) stop any debris that is in the oil.
Correct maintenance must be used to be certain that
elements (8) do not become full of debris. Debris
in elements (8) will stop the flow of clean oil to the
hydraulic system.
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Magnetic Screen
(Transmission)
SMCS Code: 3067; 5068
Illustration 50
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Illustration 49
Location of the magnetic screens
(1) Magnetic screen (transmission)
(2) Outlet
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Illustration 51
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Illustration 52
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Illustration 53
Transmission lubrication relief valve
(12) Spring
(13) Inlet port
(14) Outlet ports
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Illustration 54
(1) Check ball
(2) Pressure tap (transmission relief)
(3) Transmission main relief valve
(7) Orifice
(8) Slug
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Modulating Valve
(Transmission Clutch
Engaging)
SMCS Code: 3139
Illustration 55
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Deactivated
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Illustration 56
(3) Solenoid
(4) Pin
(5) Ball
(6) Passage
(7) Spool
(8) Spring
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Activated
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Illustration 57
(3) Solenoid
(4) Pin
(5) Ball
(6) Passage
(7) Spool
(8) Spring
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Illustration 58
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Output shaft
Rear transmission planetary group
Front transmission planetary group
Input shaft
Illustration 59
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Illustration 61
Illustration 60
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Output shaft
Rear transmission planetary group
Front transmission planetary group
Input shaft
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Transmission Hydraulic
Control
Illustration 62
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Outlet tube
Transmission main relief valve
Clutch modulating valves
Tubes
Solenoids
Inlet tube
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Schematic
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Illustration 63
Schematic of rear axle and final drive
(1) Brake/Cooling ECM
(2) Diverter valve for the final drive oil
(3) Relief diverter solenoid valve
(4) Gear motor for the rear axle oil gear
pump
(5) Piston pump for the motor drive for brake
cooling
(6) Screens
(7) Gear pumps
(8) Level of rear axle oil when temperature
is below 60 C (140 F).
(9) Level of rear axle oil when temperature
is above 60 C (140 F).
(10) Final drive oil level
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Systems Operation Section
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The oil that flows from gear pump (7) must pass
through final drive oil filter (12) for the final drive
before the oil flows to final drives. When the filter
becomes plugged, unfiltered oil bypasses the filter.
This unfiltered oil is dumped into the sump for the
rear axle. This prevents contaminated oil from flowing
through the rear wheel bearings and through the final
drive components. When the oil bypasses the filter,
the bypass switch will be activated. An alarm will be
registered in the cab.
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Pump Drive
SMCS Code: 3108
Illustration 64
g00890729
(1) Yoke
(2) Pump drive
(3) Gear pumps for hoist and brake cooling
(4) Fan drive pump
(5) Steering pump
(6) Brake cooling drive pump
(7) Brake actuation pump
(8) Gear pump for the motor drive for the rear axle oil pump
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Systems Operation Section
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(1) Yoke
(9) Case
(10) Bearings
(11) Shims
(12) Drive gear
(13) Bearing cage
(14) Idler gear
(15) Shims
(16) Shaft
(17) Bearings
(18) Driven gear
(19) Bearing cage
(20) Shims
(21) Bearings
Illustration 66
(1) Gear pump for the shallow retarding arrangement
(2) Pump drive
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Systems Operation Section
Illustration 69
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g01974095
Gear pump (1) for the brake and rear axle lubrication
is located between the transmission and the frame on
the right side of the truck. Gear pump (1) is powered
by pump drive (2).
Hydraulic oil flows directly into gear pump (1) from the
hydraulic tank. Gear pump (1) has two outlets. Outlet
(A) sends oil to the brake oil filter. Outlet (B) sends oil
to the gear motor for the rear axle lubrication.
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Illustration 68
(1) Gear pump for the shallow retarding arrangement
(2) Pump drive
(A) Outlet to the brake oil filter
(B) Outlet to the gear motor for the rear axle lubrication
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Illustration 70
(1) Pump drive
(2) Gear pump for the rear axle motor drive
(3) Relief valve and unloader valve
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Illustration 71
(4)
(5)
(6)
(7)
g01902844
Gear motor (7) for the rear axle pump drive drives
the following three pump sections:
Illustration 72
(1)
(2)
(3)
(4)
(5)
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Systems Operation Section
Pump section (3) takes oil from the sump for the rear
axle. This oil flows through inlet line (11) to suction
screen (1). Oil from suction screen (95) flows to inlet
(6) into pump section (3) for lubrication oil for the
differential. During normal operation, the oil flows
through the differential oil filter. This oil then flows in
order to lubricate the components in the differential.
Pump section (2) is located on the drive end. Pump
section (2) also takes oil from the sump for the rear
axle. This oil flows through inlet line (11) to suction
screen (1). Oil from suction screen (1) flows to inlet
(6) into pump section (2) for lubrication oil for the final
drive. The oil flows to the diverter valve for the final
drive oil. During normal operation, the diverter valve
sends this oil through the final drive oil filter. This oil
then flows in order to lubricate the components in
the final drives.
Illustration 73
g01902538
Illustration 74
g01902543
(7) Inlet for pump section (4) for differential sump scavenge
(8) Outlet for pump section (4) for differential sump scavenge
(9) Outlet of pump section (3) for lubrication of the differential
(10) Outlet of pump section (2) for lubrication of the final drive
(11) Inlet line from the sump
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Schematic
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Illustration 75
(1) Oil from the brake valve
(2) Directional valve
(3) Bypass valve for the fan for the rear axle
(4) Oil from service brake accumulators
System Operation
Oil from the brake valve (1) flows to the directional
valve (2) in the manifold for the fan for the rear axle.
When the bypass valve for the fan for the rear axle
(3) is de-energized by the brake electronic control
module, the valve blocks oil from the service brake
accumulators (4) from flowing to the right side of
the directional valve (2). Spring force moves the
directional valve (2) to the right and the oil from the
brake valve (1) flows to the fan motor for the rear axle
(5) in order to drive the motor.
When the bypass valve for the fan for the rear axle
(3) is energized by the brake electronic control
module, the valve directs oil from the service brake
accumulators (4) to the right end of the direction
valve (2). Oil pressure moves the directional valve to
the left and the oil from the brake valve (1) flows to
the tank. The fan motor (5) stops rotating.
The relief valve (6) limits the oil pressure in the fan
system for the rear axle lubrication.
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Illustration 76
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Illustration 77
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Illustration 78
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Bypass spool
Spring
Outlet
Inlet
Element
Housing
Oil from the inlet line flows into inlet (6). This oil fills
the space that is between element (5) and the inside
of housing (4). During normal operation, the oil flows
through element (5). The oil then flows through outlet
passage (9). Element (5) stops any debris that is in
the oil.
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Systems Operation Section
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Illustration 79
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Illustration 80
Final drive oil filter (1)
(2)
(3)
(4)
(5)
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Systems Operation Section
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Illustration 82
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Illustration 81
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Oil from the inlet line flows into inlet passage (8). This
oil fills the space that is between element (7) and the
inside of housing (6). During normal operation, the oil
flows through element (7). The oil then flows through
outlet passage (12). Element (7) stops any debris
that is in the oil.
If the filter element becomes full of debris, the
restriction to the flow of oil causes a pressure
increase inside the filter. If the pressure of the oil
achieves the bypass pressure, the pressure oil
causes bypass spool (9) to move against the force
of spring (11). The oil then goes through the open
bypass spool (9). This oil flows through bypass
passage (10) to the rear axle housing and the bypass
line to the rear axle housing (sump). Filter bypass
switch (2) notifies the VIMS of this occurrence. When
the oil does not go through the filter element, the
debris that is in the oil may cause damage to the
other components in the system.
Correct maintenance must be used to ensure that
element (7) does not become full of debris and that
the flow of clean oil is not stopped.
Illustration 83
Bottom view of diverter valve (1)
(3)
(4)
(5)
(6)
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Illustration 84
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Oil from the gear pump for the rear axle oil flows
to inlet port (6) on diverter valve (1). When the
temperature of the differential oil is above 60 C
(140 F), solenoid valve (2) is deactivated. Pump
pressure will flow to both ends of poppet valve (7).
Since the surface area on the back side of poppet
valve (7) is greater than the surface area on the front
side of poppet valve (7), poppet valve (7) will be
closed. The outlet port to the differential (5) will be
blocked. Pump oil will flow past poppet valve (7) to
the outlet port to the final drive oil filter (4).
When the temperature of the differential oil is below
60 C (140 F), the Brake/Cooling ECM will activate
solenoid valve (2). The pump pressure that was
flowing behind poppet valve (7) will now dump to the
sump for the differential through outlet port (5) to the
differential. The pressure that is required for the oil to
flow through the filter for the final drive is greater than
the pressure that is required to move poppet valve
(7). Poppet valve (7) now opens outlet port (5) to the
differential. The outlet port to the final drive oil filter
(4) is never blocked. However, the oil will flow more
easily to the sump for the differential.
There are two advantages to diverting the oil away
from the final drives:
KENR8370
67
Systems Operation Section
Illustration 85
g02000354
(1) Bearing
(2) Differential housing (plain half)
(3) Spider
(4) Thrust washer
(5) Differential bevel pinions (four)
(6) Shims
(13)
(14)
(15)
(16)
Shims
Shims
Bearing
Bevel pinion
68
Systems Operation Section
KENR8370
KENR8370
69
Systems Operation Section
i03671397
Final Drive
SMCS Code: 4003; 4050; 4059; 4084
g02000174
Illustration 86
(1)
(2)
(3)
(4)
(5)
Reaction hub
Second reduction ring gear
Final drive adapter housing
Second reduction carrier
Wheel
70
Systems Operation Section
KENR8370
KENR8370
71
Index Section
Index
C
D
Differential and Bevel Gear ................................... 66
E
Electronic Control (Transmission Gear Indicator).. 18
F
Final Drive ............................................................. 69
G
Gear Motor (Rear Axle Lubrication).......................
Gear Motor (Rear Axle Oil Cooler Fan) .................
Schematic ..........................................................
Gear Pump (Brake, Rear Axle Lubrication) ...........
Gear Pump (Rear Axle Oil)....................................
Gear Pump (Torque Converter Charging and
Transmission Lubrication)....................................
Gear Pump (Transmission Charging and
Scavenge)............................................................
Graphic Color Codes .............................................
59
62
62
58
60
26
26
4
45
31
33
32
Table of Contents...................................................
Torque Converter...................................................
Direct Drive ........................................................
Inside of the Torque Converter...........................
Torque Converter Drive......................................
Torque Converter and Transmission Hydraulic
System.................................................................
Location Of Components ...................................
Schematic ..........................................................
Torque Converter Case Reservoir .........................
Torque Converter Inlet and Outlet Relief Valves....
Transmission .........................................................
Transmission Clutch Engagement .....................
Transmission Operation .....................................
Transmission Planetary Groups.........................
49
51
50
O
Oil Cooler (Power Train) ........................................
Oil Filter (Differential).............................................
Oil Filter (Final Drive).............................................
Oil Filter (Torque Converter) ..................................
Oil Filter (Transmission) ........................................
8
4
4
6
5
6
4
57
29
63
64
27
43
19
19
20
4
3
34
39
35
37
21
22
21
34
29
40
42
41
41
Transmission Control............................................. 16
Inputs for the Chassis ECM that are Used by the
Transmission ECM........................................... 16
Transmission Electronic Control Module (ECM).... 10
Input Components.............................................. 11
Miscellaneous Input ........................................... 11
Output Components........................................... 12
Systems Controlled by the Transmission ECM.. 12
Transmission ECM Logged Events.................... 16
Transmission Hydraulic Control............................. 54
Transmission Planetary (Front Module) ................ 52
Transmission Planetary Groups......................... 52
Transmission Planetary (Rear Module) ................. 53
Transmission Planetary Groups......................... 53
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