Francis
OCT 97
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
Introduction
Major Component Locations and Functions Valve Component Identification and Description System Operation
ELECTRONIC CONTROL SYSTEM
Introduction
3 Page:
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 SESV1684 D5M/D6M/D6R/D7R Technical Instructio Module SEGV2628 Specalogs
D5M Track-type Tractor AEHQ5147
D6M Track-type Tractor AEHQ5168
D6R Track-type Tractor AEHQ5148
D7R Track-type Tractor AEHQ51
Service Manual Modules Form No.
D5M Power Train Specifications SENR8484
D5M Power Train Systems Operation, Testing and
Adjusting SENR8485
D5M Electrical System Schematic SENR8492
D5M Operation and Maintenance Manual SEBU6886
D6M Power Train Specifications SENR8384
D6M Power Train Systems Operation, Testing and
Adjusting SENR8385
D6M Electrical System Schematic SENR8392
D6M Operation and Maintenance Manual SEBU6888
D6R Power Train Specifications SENR8354
D6R Power Train Systems Operation SENR8355
D6R Power Train Testing and Adjusting SENR8356
D6R Electrical System Schematic SENR8362
D6R Operation and Maintenance Manual SEBU6887
D7R Power Train Systems Operation SENR8340 D7R Power Train Testing and Adjusting SENR8341 D7R Electrical System Schematic SENR8362 D7R Operation and Maintenance Manual SEBU6890 Power Train Electronic Control System Service
Manual SENR8367
Caterpillar Monitoring System SENR6717
Specalogs
D5M Track-type Tractor AEHQ5147
D6M Track-type Tractor AEHQ5168
D6R Track-type Tractor AEHQ5148
D7R Track-type Tractor AEHQ5149
Miscellaneous
Interactive Video Course "Fundamentals of Mobile
Hydraulics" TEVR9001
Interactive Video Course "Fundamentals of Electrical
Systems" TEVR9002
Programmed Instruction Course "Basic Electricity" SEBV0534
Fluid Power Graphic Symbols SEEV0529
5 Page:
DIFFERENCES FROM FORMER MACHINES
ENGINE
ENGINE
POWER TRAIN CONTROL SYSTEM*
POWER TRAIN CONTROL SYSTEM*
STEERING SYSTEM*
STEERING SYSTEM*
CA
CA
TERPILLAR MONIT
TERPILLAR MONIT
ORING SYSTEM*
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.
ENGINE
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.
Francis
OCT 97
D5M / D6M / D6R
TRACK TYPE TRACT
BRAKE PEDAL :
BRAKE PEDAL POSITION SENSOR SERVICE BRAKE PEDAL SWITCH
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
ENGINE OUTPUT SPEED SENSOR
TORQUE CONVERTER OUTPUT SPEED SENSOR TRANSMISSION TEMPERATURE SENSOR
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
ELECTRONIC CONTROL MODULE (ECM)
3 Page:
UPSHIFT/DOWNSHIFT SWITCHES
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
5 Page:
BRAKE PEDAL POSITION SENSOR
7 Page:
9 Page:
SERV CODE
SERV CODE
CENTER MODULE GAUGE CLUSTER MODULE
MID CID/FMI SERV CODE SERV CODE 11 Page:
CATERPILLAR MONITORING SYSTEM
953C D9R D/S HEUI D9R D/S MECH 36 37 769D, 771D, 773D, 775D, 777D 5110 950F 960F 966F 970F 980G 825G 826G 525 1DN1-374 24H 814F, 815F, 816F 515, 525 1DN375-UP 09 35 40 43 45 46 51 53 58 60 34 39 47 48 49 824G D4 D6 D5 DR C/B HEUI D7 D/S D10R D11R-B D11R-A D7 C/B 27 28 35 40 43 45 46 34 39 D9R C/B MECH 27
HARNESS CODE TROUBLESHOOTING Main Display Module
Connector 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 Status 1 2 3 4 5 6 03 09 27 28 35 34 39 O O O G O G O O G O G O O O G G G O G G O G O O O G G G G G O O G G G G G G G O O O
13 Page:
SERVICE
CONNECTORS
LOCATION
4C-8195
SERVICE TOOL
LAPTOP
ELECTRONIC TEHNICIAN
MODE OF OPERATION
Mode Mode Number Available As Operator 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 NoD5M, D6M, D6R,D7R
MONITORING SYSTEM MODE
Mode ModeNumber
Normal Harness Code 0 1 2 Numeric Readout
ECM
Francis
OCT 97
PUMP PRIORITY VALVE TORQUE CONVERTER SUMP LUBE STEERING CLUTCH AND BRAKE LUBE
P3
P1
P2
CHAPTER : POWER TRAIN CONTROL SYSTEM
D5M / D6M / D6R
PUMP SUPPLY TO RIGHT BRAKE TO LEFT BRAKE TO RIGHT CLUTCH TO LEFT CLUTCH LEFT STEERING SHAFT LEFT STEERING CLUTCH PLUNGER LEFT BRAKE PLUNGER RIGHT BRAKE PLUNGER RIGHT STEERING CLUTCH PLUNGER SERVICE BRAKE PEDAL SHAFT SHAFT LEFT STEERING CLUTCH SPOOL LEFT BRAKE SPOOL RIGHT BRAKE SPOOL RIGHT STEERING CLUTCH SPOOL
CHAPTER : POWER TRAIN CONTROL SYSTEM
D5M / D6M / D6R
TRACK TYPE TRACT
FILTER STEERING CLUTCH / BRAKE STEERING AND BRAKE VALVE CONTROL I/O PRIORITY VALVE SERVICE
BRAKE SERVICE TOOL
TRANSMISSION AND PUMP
DRIVE
MAIN RELIEF AND MODULATING VALVES 5 1 2 3 STEERING CLUTCH AND BRAKE LUBE 4
PARKING BRAKE AND SECONDARY BRAKE VALVE STEERING CLUTCH / BRAKE STEERING CLUTCH AND BRAKE LUBE
CHAPTER : POWER TRAIN CONTROL SYSTEM
D5M / D6M / D6R
1
2
5 Page:
FINGER TIP CONTROL
1 - Directional control knob 2 - Upshift and Downshift buttons
FILTER PRIORITY
VALVE
TRANSMISSION AND BEVEL GEAR LUBE
MAIN RELIEF AND MODULATING VALVES 5 1 2 3 4 STEERING CLUTCH / BRAKE STEERING CLUTCH AND BRAKE LUBE TORQUE CONVERTER PUMP DRIVE LUBE COOLER OUTLET RELIEF VALVE TRANSMISSION CASE STEERING AND BRAKE VALVE STEERING CLUTCH AND BRAKE LUBE BRAKE
CHAPTER : POWER TRAIN CONTROL SYSTEM
D5M / D6M / D6R
TRACK TYPE TRACT
FROM TORQUE CONVERTER AND LUBRICATION SECTION
TO TORQUE CONVERTER TO STEERING, BRAKE AND
TRANSMISSION CONTROLS
PRIORITY VALVE SOLENOID
CHAPTER : POWER TRAIN CONTROL SYSTEM
D5M / D6M / D6R
FROM TORQUE CONVERTER AND LUBRICATION SECTION
TO TORQUE CONVERTER TO STEERING, BRAKE AND
TRANSMISSION CONTROLS
PRIORITY VALVE SOLENOID
CHAPTER : POWER TRAIN CONTROL SYSTEM
D5M / D6M / D6R
TRACK TYPE TRACT
TO DRAIN TO CLUTCH SUPPLY OIL
TRANSMISSION
MODULATING VALVE
11 Page:1
2
3
5
4
Francis
OCT 97
FILTER STEERING CLUTCH / BRAKE STEERING AND BRAKE VALVE CONTROL I/O PRIORITY VALVE SERVICE
BRAKE SERVICE TOOL
TRANSMISSION AND BEVEL GEAR LUBE PUMP
DRIVE
MAIN RELIEF AND MODULATING VALVES 5 1 2 3 STEERING CLUTCH AND BRAKE LUBE 4
PARKING BRAKE AND SECONDARY BRAKE VALVE STEERING CLUTCH / BRAKE STEERING CLUTCH AND BRAKE LUBE
D5M / D6M / D6R
TRACK TYPE TRACT
1
2
3 Page:
STEERING AND BRAKE CONTROL SYSTEM
1 - Left steering and brake lever 2 - Right steering and brake lever
1
2
PARKING BRAKE SWITCH LEFT STEERING SENSOR RIGHT STEERING SENSOR LEFT CLUTCH VALVE LEFT BRAKE VALVE RIGHT BRAKE VALVE RIGHT CLUTCH VALVE SERVICE CONNECTOR SERVICE BRAKE SENSOR SERVICE BRAKE SWITCH 1F MACHINE (F-N-R) DIRECTION SENSOR PARKING BRAKE VALVE SECONDARY BRAKE VALVE
D5M / D6M / D6R
TRACK TYPE TRACT
ORS
1
2
PROPORTIONAL SOLENOID ACCUMULATOR PISTON REDUCING SPOOL SHUTOFF VALVE SOLENOID VALVES PILOT VALVE
D5M / D6M / D6R
TRACK TYPE TRACT
ORS
TO RIGHT CLUTCH TO RIGHT BRAKE SOLENOID CLUTCH SOLENOID SOLENOIDS
D5M / D6M / D6R
TRACK TYPE TRACT
SUPPLY OIL TO LEFT BRAKE TO LEFT CLUTCH TO RIGHT CLUTCH TO RIGHT BRAKE SOLENOID CLUTCH SOLENOID SOLENOIDS PISTON PARKING BRAKE SOLENOID SECONDARY BRAKE SOLENOID REDUCING SPOOL
D5M / D6M / D6R
TRACK TYPE TRACT
ORS
TO RIGHT CLUTCH TO RIGHT BRAKE SOLENOID CLUTCH SOLENOID SOLENOIDS
