D5M

Service Training MALAGA
D5M / D6M / D6R

TRACK TYPE TRACTORS
INTRODUCTION
Francis OCT 97
D5M / D6M / D6R TRACK TYPE TRACTORS

CHAPTER : INTRODUCTION
TABLE OF CONTENTS
INTRODUCTION POWER TRAIN CONTROL
Introduction Major Component Locations and Functions Valve Component Identification and Description System Operation
STEERING AND BRAKE SYSTEM

ELECTRONIC CONTROL SYSTEM

LABORATORY EXERCISES POSTTEST
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MODULE DESCRIPTION CONTENT

This module is designed to prepare a service technician to identify the components and explain the operation of the electronically controlled steering and brake system, steering and brake valve, and priority 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 basic working knowledge of servicing steering and brake systems. REFERENCES SERVICE TRAINING MEETING GUIDES D5M/D6M Track Type Tractors - Introduction D5M/D6M/D6R/D7R Technical Instructio Module Specalogs D5M Track-type Tractor D6M Track-type Tractor D6R Track-type Tractor D7R Track-type Tractor Service Manual Modules D5M Power Train Specifications D5M Power Train Systems Operation, Testing and Adjusting D5M Electrical System Schematic D5M Operation and Maintenance Manual D6M Power Train Specifications D6M Power Train Systems Operation, Testing and Adjusting D6M Electrical System Schematic D6M Operation and Maintenance Manual D6R Power Train Specifications D6R Power Train Systems Operation D6R Power Train Testing and Adjusting D6R Electrical System Schematic D6R Operation and Maintenance Manual D7R Power Train Specifications AEHQ5147 AEHQ5168 AEHQ5148 AEHQ51 Form No. SENR8484 SENR8485 SENR8492 SEBU6886 SENR8384 SENR8385 SENR8392 SEBU6888 SENR8354 SENR8355 SENR8356 SENR8362 SEBU6887 SENR8339
SESV1684 SEGV2628
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Service Manual Modules contin...) D7R Power Train Systems Operation D7R Power Train Testing and Adjusting D7R Electrical System Schematic D7R Operation and Maintenance Manual Power Train Electronic Control System Service Manual Caterpillar Monitoring System
Form No. SENR8340 SENR8341 SENR8362 SEBU6890 SENR8367 SENR6717
Specalogs D5M Track-type Tractor D6M Track-type Tractor D6R Track-type Tractor D7R Track-type Tractor Miscellaneous Interactive Video Course "Fundamentals of Mobile Hydraulics" Interactive Video Course "Fundamentals of Electrical Systems" Programmed Instruction Course "Basic Electricity" Fluid Power Graphic Symbols Fluid Power Graphic Symbols User's Guide AEHQ5147 AEHQ5168 AEHQ5148 AEHQ5149
TEVR9001 TEVR9002 SEBV0534 SEEV0529 SENR3981
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DIFFERENCES FROM FORMER MACHINES
ENGINE POWER TRAIN CONTROL SYSTEM* STEERING SYSTEM* CATERPILLAR MONIT ORING SYSTEM*
The machines can be equipped with mechanical lever steering as standard equipment or Finger Tip Control (FTC) for steering and transmission operation. The FTC is an electronically controlled system that provides simultaneous one-hand operation of the steering and the speed and directional selections of the transmission. The Caterpillar Monitoring System is included on machines equipped with the Finger Tip Control option.
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ENGINE
D5M and D6M are equipped with the Caterpillar 3116 turbocharged engine. In the D5M, the engine is rated at 82 kW (110 flywheel hp). The D6M engine is rated at 104 kW (140 flywheel hp). The 3116 engine has a direct injection fuel system and reduced emissions.
D6R and D7R engines are the same as the former machines...
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D5M / D6M / D6R

TRACK TYPE TRACTORS
Francis OCT 97

FTC CONTROLLER OR TILLER HANDLE : TRANS. DIRECT. LEVER SENSOR DIRECTION SWITCH UPSHIFT SWITCH DOWNSHIFT SWITCH LEFT STEER LEVER SENSOR RIGHT STEER LEVER SENSOR PARKING BRAKE SWITCH CAT DATA LINK : CATERPILLAR MONITORIN SYSTEM ENGINE ELECTRONICONTROL MODULE SERVICE TOOL
HARNESS CODE
ENGINE OUTPUT SPEED SENSOR BRAKE PEDAL : BRAKE PEDAL POSITION SENSOR SERVICE BRAKE PEDAL SWITCH TRANSMISSION TORQUE CONVERTER OUTPUT SPEED SENSOR TRANSMISSION TEMPERATURE SENSOR
CHAPTER : ELECTRONIC CONTROL SYSTEM
STEERING AND BRAKE CONTROL VALVE : PARKING BRAKE SOLENOID SECONDARY BRAKE SOLENOID LEFT BRAKE SOLENOID RIGHT BRAKE SOLENOID LEFT STEER CLUCHE SOLENOID RIGHT STEER CUCHE SOLENOID SHIFT INDICATORS AUTOSHIFT SWITCH
ELECTRONIC CONTROL MODULE (ECM)
FORWARD CLUCH 2 SOLENOID REVERSE CLUCH 1 SOLENOID FIRST GEAR CLUCH 5 SOLENOID SECOND GEAR CLUH 4 SOLENOID THIRD GEAR CLUCH 3 SOLENOID TRANSMISSION INTERMEDIATE SPEED 1 SENSOR TRANSMISSION INTERMEDIATE SPEED 2 SENSOR TRANSMISSION OUTPUT SPEED 1 SENSOR TRANSMISSION OUTPUT SPEED 2 SENSOR
BACKUP ALARM AUTO KICKDOWN SWITCH INCHING PEDAL POSITION SENSOR ATTACH SWITCH PRIORITY VALVE SOLENOID
Page: 2
AIH RELAY

UPSHIFT/DOWNSHIFT SWITCHES
SERVICE BRAKE PEDAL SWITCH
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FREQUENCY SENSOR
- TORQUE CONVERTER OUTPUT SPEED - ENGINE SPEED - TRANSMISSION SPEED
PULSE WIDTH MODULATED
- BRAKE PEDAL POSITION SENSOR - RIGHT STEER LEVER POSITION SENSOR - LEFT STEER LEVER POSITION SENSOR - TRANSMISSION DIREC, LEVER POSITION SENSOR
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TRANSMISSION LEVER POSITION SENSOR
BRAKE PEDAL POSITION SENSOR
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TRANSMISSION SOLENOID VALVE
Page:

STEER AND BRAKE SOLENOID VALVES
Page:

CATERPILLAR MONITORING SYSTEM
Page:

DISPLAY BUTTON
Page:

MESSAGE CENTER MODULE
SERV CODE
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10

CATERPILLAR MONITORING SYSTEM

FAULT CODE MDISPLAY
GAUGE CLUSTER MODULE
CENTER MODULE
SERV CODE
SERV CODE
SERV CODE
MID
CID/FMI
Page:
11

Sales Model 938F, IT38F 938F (Fuel Tank) 953C D4 D6 D5 DR C/B HEUI D7 D/S D10R D11R-B D11R-A D7 C/B D9R C/B MECH 769D, 771D, 773D, 775D, 777D 5110 D9R D/S HEUI D9R D/S MECH 950F 960F 966F 970F 980G 824G 825G 826G 525 1DN1-374 24H 814F, 815F, 816F 515, 525 1DN375-UP
Machine Code 03 04 09 27 28 34 35 39 40 43 45 46 27 34 35 36 37 39 40 43 45 46 47 48 49 51 53 58 60
MACHINE CODE LIST
HARNESS CODE TROUBLESHOOTING Main Display Module Connector Contact Wire Identification Harness Code Plug Contact Machine Code 03 09 27 28 34 35 39 40 43 45 46 47 48 49 51 53 58 60 31 270-BK 1 3 271-BK 2 12 272-BK 22 273-BK 16 274-BK 5 6 275-BK 6
3 4 Specified Status
O O O G G O O G O O G O G O O O G G
O G O G O O O G O O O O G G O G O G
G G G O G G O G G O O O G G G O G O
G O O O G G G O O O O O G G G G O O
G G O O G G G G G O G G O O O O O O
G G G G O O O O O O O O O O O O O O
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12

SERVICE CONNECTORS LOCATION
4C-8195 SERVICE TOOL
LAPTOP ELECTRONIC TEHNICIAN
Page:
13

MODE OF OPERATION
Mode
Normal Harness Code Service Meter Charge Pressure Tachometer Numeric Readout Diagnostic Scrolling Service Tattletale Units Setup Calibration
Mode Number
0 1 * * * * * * * * * *
Available As Operator Mode

Yes No Yes Yes Yes No Yes No No No No No
D5M, D6M, D6R,D7R MONITORING SYSTEM MODE

Mode
Normal Harness Code Numeric Readout Service Tattletale Steering/Braking Calib. Transmission Calib. Component Data Display Charging System Display
Mode Number
0 1 2 3 4 5 6 7 8
Page:
14
D5M / D6M / D6R

TRACK TYPE TRACTORS
POWER TRAIN CONTROL SYSTEM
ECM
Francis OCT 97
Page:
POWER TRAIN HYDRAULIC SYSTEM

WITH STEERING AND BRAKE CONTROL VALVE
TORQUE CONVERTER
IMPLEMENT AND WINCH PUMP DRIVE TORQUE CONVERTER OUTLET RELIEF VALVE COOLER TORQUE CONVERTER SUMP
TRANSMISSION CONTROL VALVE
P3
LUBE
PRIORITY VALVE
P1
CHAPTER : POWER TRAIN CONTROL SYSTEM
P2
STEERING CLUTCH AND BRAKE LUBE
PUMP
TRANSMISSION SCAVENGE SECTION STEERING AND BRAKE LUBE SECTION TRANSMISSION SUMP
STEERING AND BRAKE VALVE
FILTER
CASE
TRANSMISSION CHARGING SECTION
Page: 3
RIGHT STEERING CLUTCH SPOOL PUMP SUPPLY RIGHT BRAKE SPOOL TO RIGHT BRAKE TO LEFT BRAKE LEFT BRAKE SPOOL LEFT STEERING CLUTCH SPOOL PARKING BRAKE SHAFT

BRAKES ENGAGED
LEVER POPPET VALVE CHECK VALVE TO RIGHT CLUTCH RIGHT STEERING SHAFT SERVICE BRAKE PEDAL SHAFT
RIGHT STEERING CLUTCH PLUNGER
RIGHT BRAKE PLUNGER
LEFT BRAKE PLUNGER
LEFT STEERING CLUTCH PLUNGER LEFT STEERING SHAFT TO LEFT CLUTCH
Page:
FTC PARKING BRAKE CAT DATA LINK ELECTRONIC POWER TRAIN SERVICE TOOL CONTROL I/O PARKING BRAKE AND SECONDARY BRAKE VALVE FILTER PRIORITY VALVE 5 1 STEERING CLUTCH / BRAKE MONITORING SYSTEM
4
ECM SERVICE BRAKE STEERING CLUTCH AND BRAKE LUBE STEERING CLUTCH AND BRAKE LUBE PUMP DRIVE LUBE TORQUE CONVERTER TRANSMISSION CASE
ELECTRONICALLY CONTROLLED STEERING AND BRAKE SYSTEM
2 4 MAIN RELIEF AND MODULATING VALVES
STEERING CLUTCH / BRAKE
TRANSMISSION AND BEVEL GEAR LUBE
OUTLET RELIEF VALVE
COOLER

FINGER TIP CONTROL
1 - Directional control knob 2 - Upshift and Downshift buttons
Page:

PULSE WIDTH MODULATION SENSOR
Page:
Page:
POWER TRAIN HYDRAULIC SYSTEM

STEERING CLUTCH / BRAKE STEERING AND BRAKE VALVE
7
TRANSMISSION CASE
FILTER PRIORITY VALVE
5 1
2
STEERING CLUTCH AND BRAKE LUBE PUMP DRIVE LUBE STEERING CLUTCH AND BRAKE LUBE
3 MAIN RELIEF AND

MODULATING VALVES STEERING CLUTCH / BRAKE
TRANSMISSION AND BEVEL GEAR LUBE OUTLET RELIEF VALVE
TORQUE CONVERTER COOLER
Page: 8
PRIORITY VALVE
NORMAL MODE
TO STEERING, BRAKE AND TRANSMISSION CONTROLS
FROM CONTROL SECTION
FROM TORQUE CONVERTER AND LUBRICATION SECTION PRIORITY VALVE SOLENOID TO TORQUE CONVERTER
Page: 9
PRIORITY VALVE
PRIORITY MODE
TO STEERING, BRAKE AND TRANSMISSION CONTROLS
FROM CONTROL SECTION OF PUMP
FROM TORQUE CONVERTER AND LUBRICATION SECTION PRIORITY VALVE SOLENOID TO TORQUE CONVERTER

CONTROL VALVE GROUP
Page:
10

Page:
11
TRANSMISSION MODULATING VALVE
TO DRAIN
TO CLUTCH
SUPPLY OIL

AUTOSHIFT AND AUTO KICKDOWN MODES
1 2 3
1. 1F/2R LED 2. 2F/2R LED 3. Autoshift switch 4. Auto Kickdown LED 5. Auto Kickdown switch
Page:
12
D5M / D6M / D6R

TRACK TYPE TRACTORS
STEERING AND BRAKE SYSTEM
Francis OCT 97
Page:
FTC PARKING BRAKE CAT DATA LINK ELECTRONIC POWER TRAIN SERVICE TOOL CONTROL I/O PARKING BRAKE AND SECONDARY BRAKE VALVE FILTER PRIORITY VALVE 5 1 STEERING CLUTCH / BRAKE MONITORING SYSTEM
ELECTRONICALLY CONTROLLED STEERING AND BRAKE SYSTEM
2
ECM SERVICE BRAKE STEERING CLUTCH AND BRAKE LUBE STEERING CLUTCH AND BRAKE LUBE PUMP DRIVE LUBE TORQUE CONVERTER TRANSMISSION CASE
CHAPTER : STEERING AND BRAKE SYSTEM
2 4 MAIN RELIEF AND MODULATING VALVES
STEERING CLUTCH / BRAKE
TRANSMISSION AND BEVEL GEAR LUBE
OUTLET RELIEF VALVE
COOLER

STEERING AND BRAKE CONTROL SYSTEM
1 - Left steering and brake lever 2 - Right steering and brake lever
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PARKING BRAKE CONTROL
1 - Parking brake switch 2 - ECM
Page:
Page:
STEERING AND BRAKE ELECTRICAL SYSTEM

MONITORING SYSTEM PARKING BRAKE SWITCH LEFT RIGHT STEERING STEERING SENSOR SENSOR MACHINE (F-N-R) DIRECTION SENSOR
1F
SERVICE SERVICE BRAKE BRAKE SENSOR SWITCH
SERVICE CONNECTOR
PARKING BRAKE VALVE
SECONDARY BRAKE VALVE
LEFT LEFT CLUTCH BRAKE VALVE VALVE
RIGHT RIGHT BRAKE CLUTCH VALVE VALVE

1 - Steering and brake valve 2 - Priority valve
Page:
Page: 7
STEERING AND BRAKE CONTROL VALVE

PARKING/SECONDARY BRAKE SOLENOID VALVES REDUCING SPOOL ACCUMULATOR PISTON
PROPORTIONAL SOLENOID
PILOT VALVE
SHUTOFF VALVE
Page:

GRADUAL RIGHT TURN
ACCUMULATOR PISTON
8
BRAKE SOLENOIDS CLUTCH SOLENOID
CLUTCH SOLENOID
TO RIGHT CLUTCH TO RIGHT BRAKE TO TO LEFT LEFT CLUTCH BRAKE SUPPLY OIL
REDUCING SPOOL
PARKING BRAKE SOLENOID
SECONDARY BRAKE SOLENOID
Page: 9

SHARP RIGHT TURN
ACCUMULATOR PISTON
CLUTCH SOLENOID
REDUCING SPOOL
Page:

BRAKES ENGAGED
ACCUMULATOR PISTON
10
CLUTCH SOLENOID
REDUCING SPOOL

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Service Training MALAGA

D5M / D6M / D6R

D5M / D6M / D6R TRACK TYPE TRACTORS

STEERING AND BRAKE SYSTEM

ELECTRONIC CONTROL SYSTEM

LABORATORY EXERCISES POSTTEST

D5M / D6M / D6R TRACK TYPE TRACTORS

MODULE DESCRIPTION CONTENT

D5M / D6M / D6R TRACK TYPE TRACTORS

Form No. SENR8340 SENR8341 SENR8362 SEBU6890 SENR8367 SENR6717

TEVR9001 TEVR9002 SEBV0534 SEEV0529 SENR3981

D5M / D6M / D6R TRACK TYPE TRACTORS

DIFFERENCES FROM FORMER MACHINES

D5M / D6M / D6R TRACK TYPE TRACTORS

Service Training MALAGA

D5M / D6M / D6R

ELECTRONIC CONTROL SYSTEM

CHAPTER : ELECTRONIC CONTROL SYSTEM

ELECTRONIC CONTROL MODULE (ECM)

D5M / D6M / D6R TRACK TYPE TRACTORS

D5M / D6M / D6R TRACK TYPE TRACTORS

SERVICE BRAKE PEDAL SWITCH

D5M / D6M / D6R TRACK TYPE TRACTORS

- TORQUE CONVERTER OUTPUT SPEED - ENGINE SPEED - TRANSMISSION SPEED

PULSE WIDTH MODULATED

D5M / D6M / D6R TRACK TYPE TRACTORS

TRANSMISSION LEVER POSITION SENSOR

BRAKE PEDAL POSITION SENSOR

D5M / D6M / D6R TRACK TYPE TRACTORS

TRANSMISSION SOLENOID VALVE

D5M / D6M / D6R TRACK TYPE TRACTORS

STEER AND BRAKE SOLENOID VALVES

D5M / D6M / D6R TRACK TYPE TRACTORS

CATERPILLAR MONITORING SYSTEM

D5M / D6M / D6R TRACK TYPE TRACTORS

D5M / D6M / D6R TRACK TYPE TRACTORS

MESSAGE CENTER MODULE

D5M / D6M / D6R TRACK TYPE TRACTORS

CATERPILLAR MONITORING SYSTEM

GAUGE CLUSTER MODULE

D5M / D6M / D6R TRACK TYPE TRACTORS

MACHINE CODE LIST

D5M / D6M / D6R TRACK TYPE TRACTORS

SERVICE CONNECTORS LOCATION

4C-8195 SERVICE TOOL

LAPTOP ELECTRONIC TEHNICIAN

D5M / D6M / D6R TRACK TYPE TRACTORS

Available As Operator Mode

D5M, D6M, D6R,D7R MONITORING SYSTEM MODE

Service Training MALAGA

D5M / D6M / D6R

POWER TRAIN HYDRAULIC SYSTEM

TRANSMISSION CONTROL VALVE

CHAPTER : POWER TRAIN CONTROL SYSTEM

D5M / D6M / D6R TRACK TYPE TRACTORS

STEERING CLUTCH AND BRAKE LUBE

STEERING AND BRAKE VALVE

TRANSMISSION CHARGING SECTION

STEERING AND BRAKE VALVE

RIGHT STEERING CLUTCH PLUNGER

CHAPTER : POWER TRAIN CONTROL SYSTEM

RIGHT BRAKE PLUNGER

D5M / D6M / D6R TRACK TYPE TRACTORS