D5M

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



System Operation

ELECTRONIC CONTROL SYSTEM

Introduction



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



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



5Page:

DIFFERENCES FROM FORMER MACHINES



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



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...


FrancisOCT 97



2P

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D5M

/ D6M

/ D6R

TR

AC

K T

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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:


CHAPTER : ELECTRONIC CONTROL SYSTEM

UPSHIFT/DOWNSHIFT SWITCHES

SERVICE BRAKE PEDAL SWITCH

4Page:



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:



BRAKE PEDAL POSITION SENSOR

TRANSMISSION LEVER POSITION SENSOR

6Page:



TRANSMISSION SOLENOID VALVE

7Page:



STEER AND BRAKE SOLENOID VALVES

8Page:



CATERPILLAR MONITORING SYSTEM

9Page:



DISPLAY BUTTON

SERVCODE

10Page:



MESSAGE CENTER MODULE

SERVCODE

CENTER MODULEGAUGE CLUSTER MODULE

MID CID/FMI

SERVCODE

SERVCODE

11Page:



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:



13Page:



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:



ECM


FrancisOCT 97


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

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D5M

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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

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OW

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YS

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D5M

/ D6M

/ D6R

TR

AC

K T

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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



FTC

4P

age:

CH

AP

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D5M

/ D6M

/ D6R

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1

2

5Page:


CHAPTER : POWER TRAIN CONTROL SYSTEM

FINGER TIP CONTROL

1 - Directional control knob

2 - Upshift and Downshift buttons

6Page:



PULSE WIDTH MODULATION SENSOR

FILTER

PRIORITYVALVE



VALVES

5

1

2

34



TORQUECONVERTER

PUMP DRIVELUBE

COOLER

OUTLET RELIEFVALVE

TRANSMISSIONCASE

STEERINGAND BRAKE

VALVE


POWER TRAIN HYDRAULIC SYSTEM


7P

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D5M

/ D6M

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FROM TORQUE CONVERTER ANDLUBRICATION SECTION

FROM CONTROL SECTION

TO TORQUECONVERTER

TO STEERING, BRAKE ANDTRANSMISSION CONTROLS

PRIORITYVALVE

SOLENOID

PRIORITY VALVENORMAL MODE

8P

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FROM TORQUE CONVERTERAND LUBRICATION SECTION

FROM CONTROL SECTION OF PUMP

TO TORQUECONVERTER

TO STEERING, BRAKE ANDTRANSMISSION CONTROLS

PRIORITYVALVE

SOLENOID

PRIORITY VALVEPRIORITY MODE

9P

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CH

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10Page:



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:



1

2

3 5

4

12Page:



AUTOSHIFT AND AUTO KICKDOWN MODES

1. 1F/2R LED

2. 2F/2R LED

3. Autoshift switch

4. Auto Kickdown LED

5. Auto Kickdown switch


FrancisOCT 97


STEERING AND BRAKE SYSTEM

FILTER


STEERINGAND BRAKE

VALVE

ELECTRONIC POWER TRAIN

CONTROL I/O

PRIORITYVALVE

TORQUECONVERTER

SERVICEBRAKE

PARKINGBRAKE

CAT DATA LINK

ECM

SERVICE TOOL

MONITORINGSYSTEM


PUMPDRIVELUBE


VALVES

5

1

2

3


COOLER

OUTLET RELIEFVALVE

ELECTRONICALLY CONTROLLEDSTEERING AND BRAKE SYSTEM

4

PARKING BRAKE ANDSECONDARY BRAKE

VALVE

TRANSMISSIONCASE



FTC

2P

age:

D5M

/ D6M

/ D6R

TR

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CH

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1 2

3Page:


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:



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:

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1

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6Page:



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

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CH

AP

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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

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CH

AP

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R : S

TE

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SY

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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

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CH

AP

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R : S

TE

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AN

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SY

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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

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D5M

Documents

finger tip

service training

electronic

outlet relief

caterpillar

bevel gear

secondary

description