Course Caterpillar d9r Bulldozer Track Type Tractor Engines Diagrams Components Systems Controls

D 9 R T R A C K - T Y P E T R A C TO R S

©2000 Caterpillar Inc.

D9R ENGINES • 3408 Engine with Mechanical Controls • 3408E Engine with HEUI

PRELUBRICATION STARTING SYSTEM OIL PRESSURE SWITCH

CHECK VALVE

SUCTION LINE

GEAR PUMP

STARTER MOTOR

PRELUBRICATION SYSTEM

337 WH

R 308 YL

200 BK

KEY START SWITCH

C OFF S ON B ST

NEUTRAL SWITCH (DIFFERENTIAL STEER ONLY)

STARTER RELAY 306 GN

RD 06

RD 06

MOTOR

FRAME 101 RD

RD 00

ENGINE BK 00

POS NEG

POS NEG

POS NEG

POS NEG

G

BAT MTR

BUS BAR

MOTOR

SECOND STARTER MOTOR AND RELAY

STARTER MOTOR/ PRELUBE PUMP

200 BK

RD 00

314 PU

306 GN

BAT MTR

ALTERNATE BREAKER

MAIN RELAY

S 200 BK

RD 00

MAIN BREAKER

177 RD

G

S

307 OR

200 BK

301 BU

101 RD

OIL PRESSURE CUTOFF SWITCH

307 OR

200 BK

PRELUBE TIMER/ SOLENOID

447 PK

RD 00

RD 00

BUS BAR BATTERIES

BK 00

3408E/12HUIFLSYTM TO LUBE SY TEM HEUI HYDRAULIC TEMP RA U SEN OR COLD STAR FLUIDMANO

OIL OIL PRES U

RES VOI

HYDRAULICPSGE

SEN OR CO L D WN HYDRAULIC

PRES U

TEMP RA U

SUP LY

OIL

SEN OR

SEN OR

PUM

FILTER

HYDRAULIC

FUEL

CIR U T GROUP

FLUIDMANO HYDRAULICPSGE

PUM CONTR L OIL

HEUI

ECM

VAL E

CO LER FUEL TRANSFE

SECONDARY

PUM

LUBE OI PUM

FUEL FILTER

PRIMA Y FUEL I T R/ WATER SEPAR TO OIL SUMP

FUEL TANK

PRES U REGULATIN VAL E

8 INJECTORS

ADEM II ELECTRONIC CONTROL MODULE (ECM)

ENGINE HARNESS

MACHINE HARNESS

3408E HEUI SYSTEM COMPONENT DIAGRAM GROUND BOLT

DISCONNECT SWITCH

15 AMP BREAKER

MAIN KEY POWER RELAY SWITCH

24 V

PUMP CONTROL VALVE HYDRAULIC PRESSURE SENSOR PRIMARY SPEED/TIMING SENSOR

TDC SERVICE PROBE ACCESS

MACHINE INTERFACE CONNECTOR THROTTLE SENSOR

ACCELERATOR PEDAL

SECONDARY SPEED/TIMING SENSOR

THROTTLE BACK-UP, ELEVATED LOW IDLE ENABLE, AND GROUND LEVEL SHUTDOWN (2) SWITCHES TURBO INLET PRESSURE SENSOR

COOLANT TEMP. SENSOR

FAN CONTROL VALVE TURBO OUTLET PRESS. SENSOR FAN SPEED SENSOR FAN

ATMOSPHERIC PRESS. SENSOR CAT DATA LINK OIL PRESSURE SENSOR

ELECTRONIC SERVICE TOOL EPTC II TRANSMISSION CONTROL

HYDRAULIC TEMP. SENSOR FUEL TEMPERATURE SENSOR COOLANT FLOW SWITCH

AUTO RETARDER CONTROL CATERPILLAR MONITORING SYSTEM

D9R COMPONENT LOCATIONS AMOCS RADIATOR QUICK-DROP VALVE TORQUE DIVIDER

STEERING PUMP

IMPLEMENT PUMP

IMPLEMENT PUMP

PTO PUMP (3-SECTION)

CONTROL VALVE STACK

T/C SCAVANGE PUMP

HYDRAULIC MOTOR

PTO PUMP (4-SECTION)

DIFFERENTIAL STEER PLANETARIES

CONTROL VALVE STACK TRANSMISSION

SERVICE BRAKES

DIFFERENTIAL STEER SYSTEM

FINAL DRIVES CLUTCH AND BRAKE PACKS

CLUTCH AND BRAKE SYSTEM

TORQUE DIVIDER ROLLERS ENGINE FLYWHEEL

HOUSING INLET PASSAGE

PLANET GEARS

SPRINGS CAM

SUN GEAR

FREEWHEEL STATOR

OUTPUT SHAFT

STATOR PLANET CARRIER

CARRIER

RING GEAR

OUTLET PASSAGE TURBINE

IMPELLER

POWER SHIFT TRANSMISSION RING GEARS

RING GEARS

INPUT SUN GEARS

INPUT SHAFT

OUTPUT SHAFT PLANETARY CARRIER

OUTPUT SUN GEARS

1

2

3

4

5

POWER TRAIN HYDRAULIC SYSTEM STEERING CLUTCH AND BRAKE

TORQUE CONVERTER

TORQUE CONVERTER OUTLET RELIEF VALVE

BREATHER TRANSMISSION CONTROL VALVE

5

CHECK VALVE

4

TC CASE SUMP

COOLER BYPASS

P3

MANIFOLD PRIORITY VALVE

2

P1

1

OIL COOLER

P2

3

LUBE STEERING CLUTCH AND BRAKE VALVE

1

2

3

4

TRANSMISSION PUMP

TRANSMISSION FILTER

TRANSMISSION CASE SUMP

MAIN FRAME CASE SUMP

TORQUE CONVERTER FILTER

STEERING CLUTCH AND BRAKE TRANSMISSION CONTROL VALVE NEUTRAL MODULATING RELIEF VALVE SPEED SELECTOR SPOOL

5

4

N 1 2 3

LOAD PISTON

LOAD PISTON ORIFICE

P3

DIRECTIONAL SELECTOR SPOOL

DIFFERENTIAL VALVE R

F

P1

2

3 RATIO VALVE

1

P2

STEERING CLUTCH AND BRAKE TRANSMISSION CONTROL VALVE FIRST FORWARD 5

4

N 1 2 3

P3

R

F

P1

3

2

1

P2

STEERING AND BRAKE VALVE RIGHT STEERING SHAFT

CHECK VALVE

SERVICE BRAKE PEDAL SHAFT TO RIGHT CLUTCH

RIGHT STEERING CLUTCH SPOOL

RIGHT STEERING CLUTCH PLUNGER

RIGHT BRAKE SPOOL RIGHT BRAKE PLUNGER

TO RIGHT BRAKE

TO LEFT BRAKE

LEFT BRAKE PLUNGER

LEFT BRAKE SPOOL FROM PUMP LEFT STEERING CLUTCH SPOOL REACTION CHAMBER

TO LEFT CLUTCH PUMP INLET CHAMBER

OUTLET CHAMBER

LEFT STEERING CLUTCH PLUNGER LEFT STEERING SHAFT

STEERING AND BRAKE VALVE NO LEVER MOVEMENT

TO RIGHT CLUTCH

TO RIGHT BRAKE

FROM PUMP

TO LEFT BRAKE TO LEFT CLUTCH

STEERING AND BRAKE VALVE GRADUAL RIGHT TURN

TO RIGHT CLUTCH

TO RIGHT BRAKE

FROM PUMP


STEERING AND BRAKE VALVE SHARP RIGHT TURN

TO RIGHT CLUTCH

TO RIGHT BRAKE

FROM PUMP


STEERING AND BRAKE VALVE BRAKES ENGAGED

TO RIGHT CLUTCH

TO RIGHT BRAKE

FROM PUMP


POWER TRAIN HYDRAULIC SYSTEM DIFFERENTIAL STEER TORQUE CONVERTER TRANSMISSION CONTROL VALVE

5

TORQUE CONVERTER OUTLET RELIEF VALVE

4

TORQUE CONVERTER CASE SUMP COOLER BYPASS

P3

PRIORITY VALVE

2

P1

1

P2

3

OIL COOLER

PARKING BRAKE SPOOL SERVICE BRAKE SPOOL

LUBE

MANIFOLD TRANSMISSION PUMP

TORQUE CONVERTER SCAVENGE PUMP TRANSMISSION FILTER TRANSMISSION CASE SUMP

MAIN FRAME CASE SUMP

TORQUE CONVERTER FILTER

DIFFERENTIAL STEER TRANSMISSION CONTROL VALVE NEUTRAL 5

4

1 2 3

P3

R N F

P1

3

2

1

P2

SERVICE AND PARKING BRAKE CONTROL VALVE FROM TRANSMISSION CHARGING PUMP

PARKING BRAKE SPOOL

TO BRAKES SERVICE BRAKE SPOOL PASSAGE A SERVICE BRAKE PLUNGER

D9R STEERING AND IMPLEMENT HYDRAULIC SYSTEM

STEERING MOTOR

STEERING SYSTEM

STEERING PUMP CHARGE PUMP

STEERING PILOT VALVE

BYPASS AND PRESSURE CONTROL GROUP CHARGE COOLER AND FILTER LOOP

TANK

RIPPER CYLINDERS

IMPLEMENT SYSTEM IMPLEMENT PUMP INLET MANIFOLD QUICK-DROP VALVE

BLADE LIFT BLADE TILT RIPPER LIFT RIPPER TILT END COVER

DUAL TILT VALVE

TILT CYLINDERS

LIFT CYLINDERS

D9R STEERING SYSTEM STEERING MOTOR

STEERING PUMP

PILOT VALVE

CHARGE PRESSURE RELIEF VALVE

CHARGE PUMP

CROSSOVER RELIEF VALVES RESOLVER VALVE

STEERING SERVO VALVE BYPASS AND PRESSURE CONTROL GROUP

THERMAL BYPASS VALVE

FROM IMPLEMENT PUMP SUPPLY

COOLER

STEERING CHARGE CIRCUIT FILTER

D9R STEERING PILOT VALVE NO TURN

RIGHT STEER LOOP PRESSURE

TO PUMP CONTROL SPOOL

LEFT STEER LOOP PRESSURE

FROM BYPASS AND PRESSURE CONTROL GROUP


D9R STEERING PUMP STEERING PUMP

NO TURN

TO RIGHT STEER MOTOR


CHARGE PUMP

CROSSOVER RELIEF VALVES

TO LEFT STEER MOTOR

RESOLVER VALVE TO BYPASS AND PRESSURE CONTROL VALVE (CASE DRAIN)

TO PILOT CONTROL TO/FROM VALVE BYPASS AND PRESSURE CONTROL VALVE

PUMP CONTROL SERVO VALVE

STEERING SERVO VALVE

FROM LEFT STEERING VALVE

FROM RIGHT STEERING VALVE

D9R STEER MOTOR NO TURN FROM STEER PUMP


TO BYPASS AND PRESSURE CONTROL GROUP


FLUSHING VALVE

FROM STEER PUMP LEFT STEER LOOP PRESSURE

D9R STEERING PILOT VALVE RIGHT TURN





FROM PUMP CONTROL SPOOL

D9R STEERING PUMP STEERING PUMP

RIGHT TURN

TO RIGHT STEER MOTOR


CHARGE PUMP

CROSSOVER RELIEF VALVES

TO LEFT STEER MOTOR

RESOLVER VALVE

TO PILOT CONTROL TO/FROM VALVE BYPASS AND PRESSURE CONTROL VALVE

RIGHT STEER ACTUATOR STEERING PUMP

LEFT STEER ACTUATOR TO BYPASS AND PRESSURE CONTROL VALVE (CASE DRAIN) PUMP CONTROL SERVO VALVE

PRESSURE CUTOFF VALVE FROM LEFT STEERING VALVE

FROM RIGHT STEERING VALVE

FEEDBACK LEVER

SWASHPLATE

PUMP CONTROL ACTUATORS

STEER PUMP AND CONTROL VALVE NEUTRAL FROM PILOT VALVE

FROM STEER PUMP RESOLVER VALVE

FROM PILOT VALVE

ORIFICE

ORIFICE

CENTERING SPRING

PUMP CONTROL SERVO VALVE: OUTER SLEEVE

PUMP CONTROL SERVO VALVE: FEEDBACK SPOOL RESOLVER SPOOL

PRESSURE CUTOFF VALVE

STEER PUMP AND CONTROL VALVE RIGHT TURN TO PILOT VALVE

FROM STEER PUMP RESOLVER VALVE

FROM PILOT VALVE

ORIFICE

ORIFICE

OUTER SLEEVE RESOLVER SPOOL

FEEDBACK SPOOL

PRESSURE CUTOFF VALVE

PRESSURE CUTOFF STEM

FROM STEER PUMP RESOLVER VALVE FROM PILOT VALVE

FROM PUMP ACTUATOR

TO PUMP ACTUATOR

TO PILOT VALVE

ORIFICE

STEERING CONTROL VALVE PRESSURE CUTOFF

PRESSURE CUTOFF STEM

PRESSURE CUTOFF SPRING

RIGHT LOOP CROSSOVER RELIEF VALVE

HIGH PRESSURE

CROSSOVER RELIEF VALVE CHARGE PRESSURE CHECK VALVE

LEFT LOOP CROSSOVER RELIEF VALVE

TO LOW PRESSURE SIDE OF STEER LOOP

D9R STEER MOTOR RIGHT TURN FROM STEER PUMP


TO BYPASS AND PRESSURE CONTROL GROUP


FLUSHING VALVE


TO LOW PRESSURE SIDE OF STEER LOOP

BYPASS AND PRESSURE CONTROL GROUP TO STEER MOTOR CASE DRAIN

CASE DRAIN FOR STEER PUMP

CASE DRAIN PRESSURE

FROM CHARGE PUMP CHARGE PRESSURE

COOLING ORIFICE

FROM STEER MOTOR CASE DRAIN

COLD OIL BYPASS

CHARGE CIRCUIT MAKEUP VALVE

IMPLEMENT PUMP CASE DRAIN

FROM IMPLEMENT PUMP

TO COOLER

HYDRAULIC MOTOR INPUT

TRANSMISSION INPUT TRANSFER GEAR

DIFFERENTIAL STEER COMPONENTS TO LEFT FINAL DRIVE

TO RIGHT FINAL DRIVE

STEER PLANETARY

DRIVE PLANETARY

EQUALIZING PLANETARY

D9R STEERING AND IMPLEMENT HYDRAULIC SYSTEM

STEERING MOTOR

STEERING SYSTEM

STEERING PUMP CHARGE PUMP

STEERING PILOT VALVE

BYPASS AND PRESSURE CONTROL GROUP CHARGE COOLER AND FILTER LOOP

TANK

RIPPER CYLINDERS

IMPLEMENT SYSTEM IMPLEMENT PUMP INLET MANIFOLD QUICK-DROP VALVE

BLADE LIFT BLADE TILT RIPPER LIFT RIPPER TILT END COVER

DUAL TILT VALVE

TILT CYLINDERS

LIFT CYLINDERS

D9R HYDRAULIC SYSTEM TO BYPASS AND PRESSURE CONTROL GROUP

INLET MANIFOLD QUICK-DROP VALVE

BLADE LIFT

BLADE TILT RIPPER LIFT

RIPPER TILT END COVER

SINGLE TILT OPTION

DUAL TILT VALVE

DUAL TILT OPTION

TO BYPASS AND PRESSURE CONTROL VALVE IMPLEMENT PUMP INLET MANIFOLD

D9R IMPLEMENT SYSTEM BLADE LIFT

TO BYPASS AND PRESSURE CONTROL VALVE

TO STEERING CHARGE PUMP DOZER LIFT CYLINDER

QUICK-DROP VALVE TO ROD END

BLADE TILT

TO HEAD END

DOZER LIFT CYLINDER

RIPPER LIFT

SINGLE TILT

RIPPER SHANK IN/OUT

TANK

PRESSURE AND FLOW COMPENSATOR VALVE MARGIN PRESSURE ADJUSTMENT

PRESSURE CUTOFF ADJUSTMENT

SIGNAL FROM CONTROL VALVES

TO TANK

TO ACTUATOR FROM PUMP FLOW COMPENSATOR (MARGIN) SPOOL

PRESSURE COMPENSATOR (CUTOFF) SPOOL

PUMP AND COMPENSATOR OPERATION ENGINE OFF NO SIGNAL

PUMP OUTPUT

LARGE ACTUATOR

YOKE PAD

SWASHPLATE

DRIVE SHAFT FLOW COMPENSATOR (MARGIN) SPOOL


SMALL ACTUATOR AND BIAS SPRING PISTON AND BARREL ASSEMBLY

PUMP AND COMPENSATOR OPERATION LOW PRESSURE STANDBY NO SIGNAL

FLOW COMPENSATOR (MARGIN) SPOOL

PUMP OUTPUT


CROSS-DRILLED PASSAGE

LARGE ACTUATOR

SWASHPLATE

SMALL ACTUATOR AND BIAS SPRING

PUMP AND COMPENSATOR OPERATION UPSTROKING SIGNAL


PUMP OUTPUT


LARGE ACTUATOR

REDUCED PRESSURE

SWASHPLATE


PUMP AND COMPENSATOR OPERATION CONSTANT FLOW SIGNAL


PUMP OUTPUT


LARGE ACTUATOR

REDUCED PRESSURE

SWASHPLATE


PUMP AND COMPENSATOR OPERATION DESTROKING SIGNAL


PUMP OUTPUT


LARGE ACTUATOR

INCREASED PRESSURE

SWASHPLATE


PUMP AND COMPENSATOR OPERATION HIGH PRESSURE STALL SIGNAL AT MAXIMUM PRESSURE


PUMP OUTPUT AT MAXIMUM PRESSURE


LARGE ACTUATOR

REDUCED PRESSURE

SWASHPLATE


TO BYPASS AND PRESSURE CONTROL VALVE

INLET MANIFOLD

SYSTEM RELIEF VALVE

CHARGE RELIEF VALVE

FLOW CONTROL VALVE

RESOLVER

D9R IMPLEMENT CONTROL VALVE STACK

SIGNAL LINE TO IMPLEMENT PUMP

TO IMPLEMENT PUMP SUPPLY

BLADE LIFT TO LIFT CYLINDERS

PRESSURE LIMITER VALVE

FLOW CONTROL VALVE

RESOLVER

BLADE TILT TO TILT CYLINDERS FLOW CONTROL VALVE

RESOLVER

RIPPER LIFT

TO RIPPER LIFT CYLINDERS FLOW CONTROL VALVE RESOLVER

TO RIPPER TILT CYLINDERS

RIPPER SHANK IN/OUT

DOZER LIFT CONTROL VALVE HOLD ROD END

HEAD END

FROM PREVIOUS VALVE

MAKEUP VALVE RESOLVER TO NEXT VALVE

MAIN CONTROL SPOOL

LOAD CHECK VALVE FROM PUMP

FLOW CONTROL VALVE

DOZER LIFT CONTROL VALVE BLADE RAISE

ROD END

HEAD END

MAKEUP VALVE

FROM PREVIOUS VALVE

RESOLVER TO NEXT VALVE

MAIN CONTROL SPOOL


FLOW CONTROL VALVE

DOZER LIFT CONTROL VALVE BLADE LOWER ROD END

HEAD END

MAKEUP VALVE

FROM PREVIOUS VALVE

RESOLVER TO NEXT VALVE

MAIN CONTROL SPOOL PIN


FLOW CONTROL VALVE

BLADE TILT CONTROL VALVE TILT LEFT ROD END

FROM PREVIOUS VALVE

HEAD END RESOLVER

TO NEXT VALVE MAIN CONTROL SPOOL


SIGNAL PRESSURE LIMITER FLOW CONTROL VALVE

RIPPER LIFT CONTROL VALVE FROM PREVIOUS VALVE

RAISE MAKEUP VALVE

HEAD END

ROD END

MAKEUP VALVE RESOLVER

TO NEXT VALVE MAIN CONTROL SPOOL


FLOW CONTROL VALVE

RIPPER SHANK IN/OUT CONTROL VALVE SHANK OUT RELIEF VALVE

HEAD END

ROD END

MAKEUP VALVE

FROM PREVIOUS VALVE

RESOLVER

TO NEXT VALVE

MAIN CONTROL SPOOL


FLOW CONTROL VALVE

D9R QUICK-DROP VALVE

DOZER LIFT CYLINDER

QUICK-DROP VALVE

TO ROD END DUMP VALVE MAIN VALVE SPOOL

TO HEAD END

SOLENOID VALVE

FROM CONTROL VALVE ROD END

FROM CONTROL VALVE HEAD END

DOZER LIFT CYLINDER

CYLINDER HEAD END

QUICK-DROP VALVE HOLD CYLINDER ROD END

MAIN VALVE SPOOL

DUMP VALVE

A B C D

B C

SOLENOID VALVE

A D

FROM CONTROL VALVE ROD END


CYLINDER HEAD END

QUICK-DROP VALVE DOZER RAISE

MAIN VALVE SPOOL

CYLINDER ROD END

DUMP VALVE

A B C

B C

A

D SOLENOID VALVE

D FROM CONTROL VALVE ROD END

TO CONTROL VALVE HEAD END

CYLINDER HEAD END

QUICK-DROP VALVE DOZER LOWER CYLINDER ROD END

MAIN VALVE SPOOL

DUMP VALVE

A B C D

B C

SOLENOID VALVE

A D

TO CONTROL VALVE ROD END


CYLINDER HEAD END

QUICK-DROP VALVE QUICK-DROP SOLENOID ENERGIZED

MAIN VALVE SPOOL

CYLINDER ROD END

DUMP VALVE

A B C

B C

A

D SOLENOID VALVE (ENERGIZED)

D TO CONTROL VALVE ROD END


CYLINDER HEAD END

QUICK-DROP VALVE DOWN PRESSURE SOLENOID ENERGIZED

MAIN VALVE SPOOL

CYLINDER ROD END

DUMP VALVE

A B C

B C

D SOLENOID VALVE (ENERGIZED)

A D

TO CONTROL VALVE ROD END


DUAL TILT VALVE HOLD

TO ROD END

FROM IMPLEMENT PUMP S2

S1

TO HEAD END

TILT CYLINDERS

FROM BLADE TILT VALVE

DUAL TILT CIRCUIT DUAL TILT RIGHT

FROM TILT CONTROL VALVE

TO ROD END LEFT TILT CYLINDER RIGHT TILT CYLINDER

TO HEAD END

TO TILT CONTROL VALVE FROM IMPLEMENT PUMP

FROM TRIGGER SWITCH FROM TOGGLE SWITCH

DUAL TILT CIRCUIT SINGLE TILT RIGHT



TO HEAD END



DUAL TILT CIRCUIT BLADE PITCH FORWARD



TO HEAD END



THREE LEVELS OF WARNING • CATEGORY 1 • CATEGORY 2 • CATEGORY 3

THREE WARNING CATEGORIES • Category 1 - Alert Indicator Flashes • Category 2 - Alert Indicator Flashes - Action Lamp Flashes • Category 3 - Alert Indicator Flashes - Action Lamp Flashes - Action Alarm Sounds

Course Caterpillar d9r Bulldozer Track Type Tractor Engines Diagrams Components Systems Controls

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