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Service TrainingMALAGA
D5M / D6M / D6R
FrancisOCT 97
D5M / D6M / D6R
INTRODUCTION
TRACK TYPE TRACTORS
2Page:
TABLE OF CONTENTS
INTRODUCTION
POWER TRAIN CONTROL
Introduction
Major Component Locations and Functions
Valve Component Identification and Description
System Operation
STEERING AND BRAKE SYSTEM
Introduction
Major Component Locations and Functions
Valve Component Identification and Description
System Operation
ELECTRONIC CONTROL SYSTEM
Introduction
Major Component Locations and Functions
Valve Component Identification and Description
System Operation
LABORATORY EXERCISES
POSTTEST
CHAPTER : INTRODUCTION
D5M / D6M / D6RTRACK TYPE TRACTORS
3Page:
MODULE DESCRIPTION
CONTENT
This module is designed to prepare a service technician to identify the components and explain theoperation of the electronically controlled steering and brake system, steering and brake valve, andpriority valve. Testing, adjusting, and system troubleshooting procedures are also performed.
AUDIENCE
Level II--Field service personnel, resident mechanics, technical communicators and shop technicians.All students should have some overall experience with Caterpillar Track-type Tractors and a basicworking knowledge of servicing steering and brake systems.
REFERENCES
SERVICE TRAINING MEETING GUIDESD5M/D6M Track Type Tractors - Introduction SESV1684D5M/D6M/D6R/D7R Technical Instructio Module SEGV2628
Specalogs
D5M Track-type Tractor AEHQ5147D6M Track-type Tractor AEHQ5168D6R Track-type Tractor AEHQ5148D7R Track-type Tractor AEHQ51
Service Manual Modules Form No.
D5M Power Train Specifications SENR8484D5M Power Train Systems Operation, Testing andAdjusting SENR8485D5M Electrical System Schematic SENR8492D5M Operation and Maintenance Manual SEBU6886D6M Power Train Specifications SENR8384D6M Power Train Systems Operation, Testing andAdjusting SENR8385D6M Electrical System Schematic SENR8392D6M Operation and Maintenance Manual SEBU6888D6R Power Train Specifications SENR8354D6R Power Train Systems Operation SENR8355D6R Power Train Testing and Adjusting SENR8356D6R Electrical System Schematic SENR8362D6R Operation and Maintenance Manual SEBU6887D7R Power Train Specifications SENR8339
CHAPTER : INTRODUCTION
D5M / D6M / D6RTRACK TYPE TRACTORS
4Page:
Service Manual Modules contin...) Form No.
D7R Power Train Systems Operation SENR8340D7R Power Train Testing and Adjusting SENR8341D7R Electrical System Schematic SENR8362D7R Operation and Maintenance Manual SEBU6890Power Train Electronic Control System ServiceManual SENR8367Caterpillar Monitoring System SENR6717
Specalogs
D5M Track-type Tractor AEHQ5147D6M Track-type Tractor AEHQ5168D6R Track-type Tractor AEHQ5148D7R Track-type Tractor AEHQ5149
Miscellaneous
Interactive Video Course "Fundamentals of Mobile Hydraulics" TEVR9001Interactive Video Course "Fundamentals of ElectricalSystems" TEVR9002Programmed Instruction Course "Basic Electricity" SEBV0534Fluid Power Graphic Symbols SEEV0529Fluid Power Graphic Symbols User's Guide SENR3981
CHAPTER : INTRODUCTION
D5M / D6M / D6RTRACK TYPE TRACTORS
5Page:
DIFFERENCES FROM FORMER MACHINES
CHAPTER : INTRODUCTION
D5M / D6M / D6RTRACK TYPE TRACTORS
ENGINEENGINE
POWER TRAIN CONTROL SYSTEM*POWER TRAIN CONTROL SYSTEM*
STEERING SYSTEM*STEERING SYSTEM*
CACATERPILLAR MONITTERPILLAR MONITORING SYSTEM*ORING SYSTEM*
The machines can be equipped with mechanical lever steering asstandard equipment or Finger Tip Control (FTC) for steering andtransmission operation. The FTC is an electronically controlledsystem that provides simultaneous one-hand operation of thesteering and the speed and directional selections of the transmission.The Caterpillar Monitoring System is included on machinesequipped with the Finger Tip Control option.
*
6Page:
ENGINEENGINE
CHAPTER : INTRODUCTION
D5M / D6M / D6RTRACK TYPE TRACTORS
D5M and D6M are equipped with the Caterpillar 3116 turbochargedengine. In the D5M, the engine is rated at 82 kW (110 flywheel hp). TheD6M engine is rated at 104 kW (140 flywheel hp). The 3116 engine hasa direct injection fuel system and reduced emissions.
D6R and D7R engines are the same as the former machines...
Service TrainingMALAGA
FrancisOCT 97
D5M / D6M / D6RTRACK TYPE TRACTORS
ELECTRONIC CONTROL SYSTEM
2P
age:
D5M
/ D6M
/ D6R
TR
AC
K T
YP
E T
RA
CTO
RS
ELECTRONIC CONTROL SYSTEM
TRANS. DIRECT. LEVER SENSORDIRECTION SWITCHUPSHIFT SWITCHDOWNSHIFT SWITCHLEFT STEER LEVER SENSORRIGHT STEER LEVER SENSORPARKING BRAKE SWITCH
BRAKE PEDAL :
BRAKE PEDAL POSITION SENSORSERVICE BRAKE PEDAL SWITCH
STEERING AND BRAKECONTROL VALVE :
PARKING BRAKE SOLENOIDSECONDARY BRAKE SOLENOIDLEFT BRAKE SOLENOIDRIGHT BRAKE SOLENOIDLEFT STEER CLUCHE SOLENOIDRIGHT STEER CUCHE SOLENOID
SHIFT INDICATORS
AUTOSHIFT SWITCH
AUTO KICKDOWN SWITCH
INCHING PEDAL POSITION SENSOR
ATTACH SWITCH
CAT DATA LINK :CATERPILLAR MONITORIN SYSTEMENGINE ELECTRONICONTROL MODULESERVICE TOOL
HARNESS CODE
ENGINE OUTPUT SPEED SENSOR
TORQUE CONVERTER OUTPUT SPEED SENSORTRANSMISSION TEMPERATURE SENSOR
FORWARD CLUCH 2 SOLENOIDREVERSE CLUCH 1 SOLENOIDFIRST GEAR CLUCH 5 SOLENOIDSECOND GEAR CLUH 4 SOLENOIDTHIRD GEAR CLUCH 3 SOLENOID
TRANSMISSION INTERMEDIATE SPEED 1 SENSORTRANSMISSION INTERMEDIATE SPEED 2 SENSORTRANSMISSION OUTPUT SPEED 1 SENSORTRANSMISSION OUTPUT SPEED 2 SENSOR
BACKUP ALARM
PRIORITY VALVE SOLENOID
AIH RELAY
TRANSMISSION
ELECTRONIC CONTROL MODULE (ECM)
FTC CONTROLLER ORTILLER HANDLE :
CH
AP
TE
R : E
LE
CT
RO
NIC
CO
NT
RO
L S
YS
TE
M
3Page:
D5M / D6M / D6RTRACK TYPE TRACTORS
CHAPTER : ELECTRONIC CONTROL SYSTEM
UPSHIFT/DOWNSHIFT SWITCHES
SERVICE BRAKE PEDAL SWITCH
4Page:
D5M / D6M / D6RTRACK TYPE TRACTORS
CHAPTER : ELECTRONIC CONTROL SYSTEM
FREQUENCY SENSOR
PULSE WIDTH MODULATED
- TORQUE CONVERTER OUTPUT SPEED- ENGINE SPEED- TRANSMISSION SPEED
- BRAKE PEDAL POSITION SENSOR- RIGHT STEER LEVER POSITION SENSOR- LEFT STEER LEVER POSITION SENSOR- TRANSMISSION DIREC, LEVER POSITION SENSOR
5Page:
D5M / D6M / D6RTRACK TYPE TRACTORS
CHAPTER : ELECTRONIC CONTROL SYSTEM
BRAKE PEDAL POSITION SENSOR
TRANSMISSION LEVER POSITION SENSOR
6Page:
D5M / D6M / D6RTRACK TYPE TRACTORS
CHAPTER : ELECTRONIC CONTROL SYSTEM
TRANSMISSION SOLENOID VALVE
7Page:
D5M / D6M / D6RTRACK TYPE TRACTORS
CHAPTER : ELECTRONIC CONTROL SYSTEM
STEER AND BRAKE SOLENOID VALVES
8Page:
D5M / D6M / D6RTRACK TYPE TRACTORS
CHAPTER : ELECTRONIC CONTROL SYSTEM
CATERPILLAR MONITORING SYSTEM
9Page:
D5M / D6M / D6RTRACK TYPE TRACTORS
CHAPTER : ELECTRONIC CONTROL SYSTEM
DISPLAY BUTTON
SERVCODE
10Page:
D5M / D6M / D6RTRACK TYPE TRACTORS
CHAPTER : ELECTRONIC CONTROL SYSTEM
MESSAGE CENTER MODULE
SERVCODE
CENTER MODULEGAUGE CLUSTER MODULE
MID CID/FMI
SERVCODE
SERVCODE
11Page:
D5M / D6M / D6RTRACK TYPE TRACTORS
CHAPTER : ELECTRONIC CONTROL SYSTEM
CATERPILLAR MONITORING SYSTEM
FAULT CODE MDISPLAY
MACHINE CODE LISTSales Model Machine Code
938F, IT38F
953C
D9R D/S HEUID9R D/S MECH
3637
769D, 771D, 773D, 775D, 777D5110
950F960F966F970F980G
825G826G525 1DN1-37424H814F, 815F, 816F515, 525 1DN375-UP
03
09
35
40434546
51535860
34
39
474849
824G
938F (Fuel Tank) 04
D4D6D5DR C/B HEUID7 D/SD10RD11R-BD11R-AD7 C/B
2728
35
40434546
34
39
D9R C/B MECH 27
HARNESS CODE TROUBLESHOOTING
Main Display ModuleConnector Contact
Wire Identification
Harness Code Plug Contact
Machine Code
31 3 12 22 16 6
270-BK 271-BK 272-BK 273-BK 274-BK 275-BK
Specified Status1 2 3 4 5 6
03
09
27
28
35
40
43
45
46
51
53
58
60
34
39
4748
49
OOOG
O
GOOG
OOGG
G
O
OGO
OGOG
O
GOOO
OGOG
O
O
OGG
GGGO
G
GGOO
GOGO
G
O
OGG
GOOO
G
OOOO
GGOO
G
G
OGG
GGOO
G
GGOG
OOOO
G
G
GOO
GGGG
O
OOOO
OOOO
O
O
OOO
12Page:
D5M / D6M / D6RTRACK TYPE TRACTORS
CHAPTER : ELECTRONIC CONTROL SYSTEM
13Page:
D5M / D6M / D6RTRACK TYPE TRACTORS
CHAPTER : ELECTRONIC CONTROL SYSTEM
SERVICECONNECTORS
LOCATION
4C-8195SERVICE TOOL
LAPTOPELECTRONIC TEHNICIAN
MODE OF OPERATION
Mode ModeNumber
Available AsOperator Mode
Normal
Harness Code
Service Meter
Charge Pressure
Tachometer
Numeric Readout
Diagnostic Scrolling
Service
Tattletale
Units
Setup
Calibration
0
1
*
*
*
*
*
*
*
*
*
*
Yes
No
Yes
Yes
Yes
No
Yes
No
No
No
No
No
D5M, D6M, D6R,D7RMONITORING SYSTEM MODE
Mode ModeNumber
Normal
Harness Code
Service
Tattletale
0
1
34
5
2Numeric Readout
6
Steering/Braking Calib.
Transmission Calib.
Component Data Display
Charging System Display
78
14Page:
D5M / D6M / D6RTRACK TYPE TRACTORS
CHAPTER : ELECTRONIC CONTROL SYSTEM
ECM
Service TrainingMALAGA
FrancisOCT 97
D5M / D6M / D6RTRACK TYPE TRACTORS
POWER TRAIN CONTROL SYSTEM
TRANSMISSIONCONTROL VALVE
COOLER
PUMP
FILTER
PRIORITYVALVE
TORQUECONVERTER
SUMPLUBE
IMPLEMENT AND WINCHPUMP DRIVE
STEERING CLUTCHAND BRAKE LUBE
STEERING ANDBRAKE VALVE
TORQUECONVERTER
CASE
TRANSMISSIONSUMP
TRANSMISSIONCHARGING SECTION
STEERING ANDBRAKE LUBE
SECTION
TRANSMISSIONSCAVENGE
SECTION
P3
P1P2
TORQUE CONVERTER OUTLET RELIEF VALVE
POWER TRAIN HYDRAULIC SYSTEMWITH STEERING AND BRAKE CONTROL VALVE2
Pag
e:
CH
AP
TE
R : P
OW
ER
TR
AIN
CO
NT
RO
L S
YS
TE
M
D5M
/ D6M
/ D6R
TR
AC
K T
YP
E T
RA
CTO
RS
PUMPSUPPLY
TO RIGHTBRAKE
TO LEFTBRAKE
TO RIGHTCLUTCH
TO LEFT CLUTCH
LEFT STEERINGSHAFT
LEFT STEERINGCLUTCH PLUNGER
LEFT BRAKEPLUNGER
RIGHT BRAKEPLUNGER
RIGHT STEERINGCLUTCH PLUNGER
SERVICE BRAKEPEDAL SHAFT
RIGHT STEERINGSHAFT
LEFT STEERINGCLUTCH SPOOL
LEFT BRAKESPOOL
RIGHT BRAKESPOOL
RIGHT STEERINGCLUTCH SPOOL
PARKING BRAKESHAFT
LEVERPOPPET VALVE
CHECK VALVE
STEERING AND BRAKE VALVEBRAKES ENGAGED
3P
age:
CH
AP
TE
R : P
OW
ER
TR
AIN
CO
NT
RO
L S
YS
TE
M
D5M
/ D6M
/ D6R
TR
AC
K T
YP
E T
RA
CTO
RS
FILTER
STEERINGCLUTCH /BRAKE
STEERINGAND BRAKE
VALVE
ELECTRONIC POWER TRAIN
CONTROL I/O
PRIORITYVALVE
TORQUECONVERTER
SERVICEBRAKE
PARKINGBRAKE
CAT DATA LINK
ECM
SERVICE TOOL
MONITORINGSYSTEM
TRANSMISSION ANDBEVEL GEAR LUBE
PUMPDRIVELUBE
MAIN RELIEF ANDMODULATING
VALVES
5
1
2
3
STEERINGCLUTCH ANDBRAKE LUBE
COOLER
OUTLET RELIEFVALVE
ELECTRONICALLY CONTROLLEDSTEERING AND BRAKE SYSTEM
4
PARKING BRAKE ANDSECONDARY BRAKE
VALVE
TRANSMISSIONCASE
STEERINGCLUTCH /BRAKE
STEERINGCLUTCH ANDBRAKE LUBE
FTC
4P
age:
CH
AP
TE
R : P
OW
ER
TR
AIN
CO
NT
RO
L S
YS
TE
M
D5M
/ D6M
/ D6R
TR
AC
K T
YP
E T
RA
CTO
RS
1
2
5Page:
D5M / D6M / D6RTRACK TYPE TRACTORS
CHAPTER : POWER TRAIN CONTROL SYSTEM
FINGER TIP CONTROL
1 - Directional control knob
2 - Upshift and Downshift buttons
6Page:
D5M / D6M / D6RTRACK TYPE TRACTORS
CHAPTER : POWER TRAIN CONTROL SYSTEM
PULSE WIDTH MODULATION SENSOR
FILTER
PRIORITYVALVE
TRANSMISSION ANDBEVEL GEAR LUBE
MAIN RELIEF ANDMODULATING
VALVES
5
1
2
34
STEERINGCLUTCH /BRAKE
STEERINGCLUTCH ANDBRAKE LUBE
TORQUECONVERTER
PUMP DRIVELUBE
COOLER
OUTLET RELIEFVALVE
TRANSMISSIONCASE
STEERINGAND BRAKE
VALVE
STEERINGCLUTCH ANDBRAKE LUBE
POWER TRAIN HYDRAULIC SYSTEM
STEERINGCLUTCH /BRAKE
7P
age:
CH
AP
TE
R : P
OW
ER
TR
AIN
CO
NT
RO
L S
YS
TE
M
D5M
/ D6M
/ D6R
TR
AC
K T
YP
E T
RA
CTO
RS
FROM TORQUE CONVERTER ANDLUBRICATION SECTION
FROM CONTROL SECTION
TO TORQUECONVERTER
TO STEERING, BRAKE ANDTRANSMISSION CONTROLS
PRIORITYVALVE
SOLENOID
PRIORITY VALVENORMAL MODE
8P
age:
CH
AP
TE
R : P
OW
ER
TR
AIN
CO
NT
RO
L S
YS
TE
M
D5M
/ D6M
/ D6R
TR
AC
K T
YP
E T
RA
CTO
RS
FROM TORQUE CONVERTERAND LUBRICATION SECTION
FROM CONTROL SECTION OF PUMP
TO TORQUECONVERTER
TO STEERING, BRAKE ANDTRANSMISSION CONTROLS
PRIORITYVALVE
SOLENOID
PRIORITY VALVEPRIORITY MODE
9P
age:
CH
AP
TE
R : P
OW
ER
TR
AIN
CO
NT
RO
L S
YS
TE
M
D5M
/ D6M
/ D6R
TR
AC
K T
YP
E T
RA
CTO
RS
10Page:
D5M / D6M / D6RTRACK TYPE TRACTORS
CHAPTER : POWER TRAIN CONTROL SYSTEM
CONTROL VALVE GROUP
TO
DR
AIN
TO
CL
UT
CH
SU
PP
LY
OIL
TR
AN
SM
ISS
ION
MO
DU
LA
TIN
G V
AL
VE
11Page:
CHAPTER : POWER TRAIN CONTROL SYSTEM
D5M / D6M / D6RTRACK TYPE TRACTORS
1
2
3 5
4
12Page:
D5M / D6M / D6RTRACK TYPE TRACTORS
CHAPTER : POWER TRAIN CONTROL SYSTEM
AUTOSHIFT AND AUTO KICKDOWN MODES
1. 1F/2R LED
2. 2F/2R LED
3. Autoshift switch
4. Auto Kickdown LED
5. Auto Kickdown switch
Service TrainingMALAGA
FrancisOCT 97
D5M / D6M / D6RTRACK TYPE TRACTORS
STEERING AND BRAKE SYSTEM
FILTER
STEERINGCLUTCH /BRAKE
STEERINGAND BRAKE
VALVE
ELECTRONIC POWER TRAIN
CONTROL I/O
PRIORITYVALVE
TORQUECONVERTER
SERVICEBRAKE
PARKINGBRAKE
CAT DATA LINK
ECM
SERVICE TOOL
MONITORINGSYSTEM
TRANSMISSION ANDBEVEL GEAR LUBE
PUMPDRIVELUBE
MAIN RELIEF ANDMODULATING
VALVES
5
1
2
3
STEERINGCLUTCH ANDBRAKE LUBE
COOLER
OUTLET RELIEFVALVE
ELECTRONICALLY CONTROLLEDSTEERING AND BRAKE SYSTEM
4
PARKING BRAKE ANDSECONDARY BRAKE
VALVE
TRANSMISSIONCASE
STEERINGCLUTCH /BRAKE
STEERINGCLUTCH ANDBRAKE LUBE
FTC
2P
age:
D5M
/ D6M
/ D6R
TR
AC
K T
YP
E T
RA
CTO
RS
CH
AP
TE
R : S
TE
ER
ING
AN
D B
RA
KE
SY
ST
EM
1 2
3Page:
D5M / D6M / D6RTRACK TYPE TRACTORS
CHAPTER : STEERING AND BRAKE SYSTEM
STEERING AND BRAKE CONTROL SYSTEM
1 - Left steering and brake lever
2 - Right steering and brake lever
1
2
4Page:
D5M / D6M / D6RTRACK TYPE TRACTORS
CHAPTER : STEERING AND BRAKE SYSTEM
PARKING BRAKE CONTROL
1 - Parking brake switch
2 - ECM
PARKINGBRAKESWITCH
LEFTSTEERINGSENSOR
RIGHTSTEERINGSENSOR
LEFTCLUTCHVALVE
LEFTBRAKEVALVE
RIGHTBRAKEVALVE
RIGHTCLUTCHVALVE
SERVICECONNECTOR
MONITORINGSYSTEM
SERVICEBRAKE
SENSOR
SERVICEBRAKESWITCH
1F
MACHINE(F-N-R)
DIRECTIONSENSOR
PARKINGBRAKEVALVE
SECONDARYBRAKEVALVE
STEERING AND BRAKE ELECTRICAL SYSTEM5P
age:
D5M
/ D6M
/ D6R
TR
AC
K T
YP
E T
RA
CTO
RS
CH
AP
TE
R : S
TE
ER
ING
AN
D B
RA
KE
SY
ST
EM
1
2
6Page:
D5M / D6M / D6RTRACK TYPE TRACTORS
CHAPTER : STEERING AND BRAKE SYSTEM
STEERING AND BRAKE VALVE
1 - Steering and brake valve
2 - Priority valve
PROPORTIONALSOLENOID
ACCUMULATOR PISTON
REDUCINGSPOOL
SHUTOFFVALVE
PARKING/SECONDARY BRAKESOLENOID VALVES
PILOT VALVE
STEERING AND BRAKE CONTROL VALVE
7P
age:
D5M
/ D6M
/ D6R
TR
AC
K T
YP
E T
RA
CTO
RS
CH
AP
TE
R : S
TE
ER
ING
AN
D B
RA
KE
SY
ST
EM
SUPPLY OIL
TOLEFT
BRAKE
TOLEFT
CLUTCH
TORIGHT
CLUTCH
TORIGHTBRAKE
STEERING AND BRAKE CONTROL VALVEGRADUAL RIGHT TURN
CLUTCHSOLENOID
CLUTCHSOLENOID
BRAKESOLENOIDS
ACCUMULATORPISTON
PARKINGBRAKE
SOLENOID
SECONDARYBRAKE
SOLENOIDREDUCING
SPOOL
8P
age:
D5M
/ D6M
/ D6R
TR
AC
K T
YP
E T
RA
CTO
RS
CH
AP
TE
R : S
TE
ER
ING
AN
D B
RA
KE
SY
ST
EM
SUPPLY OIL
TOLEFT
BRAKE
TOLEFT
CLUTCH
TORIGHT
CLUTCH
TORIGHTBRAKE
STEERING AND BRAKE CONTROL VALVESHARP RIGHT TURN
CLUTCHSOLENOID
CLUTCHSOLENOID
BRAKESOLENOIDS
ACCUMULATORPISTON
PARKINGBRAKE
SOLENOID
SECONDARYBRAKE
SOLENOIDREDUCING
SPOOL
9P
age:
D5M
/ D6M
/ D6R
TR
AC
K T
YP
E T
RA
CTO
RS
CH
AP
TE
R : S
TE
ER
ING
AN
D B
RA
KE
SY
ST
EM
SUPPLY OIL
TOLEFT
BRAKE
TOLEFT
CLUTCH
TORIGHT
CLUTCH
TORIGHTBRAKE
STEERING AND BRAKE CONTROL VALVEBRAKES ENGAGED
CLUTCHSOLENOID
CLUTCHSOLENOID
BRAKESOLENOIDS
ACCUMULATORPISTON
PARKINGBRAKE
SOLENOID
SECONDARYBRAKE
SOLENOIDREDUCING
SPOOL
10P
age:
D5M
/ D6M
/ D6R
TR
AC
K T
YP
E T
RA
CTO
RS
CH
AP
TE
R : S
TE
ER
ING
AN
D B
RA
KE
SY
ST
EM