Service Training

New Product Introduction Volume 10, Number 1

SERV7102-10 October 2002

TECHNICAL PRESENTATION

D5N/D6N TRACK-TYPE TRACTORS

New Product Introduction (NPI)

D5N/D6N TRACK-TYPE TRACTORS

CONTENT This self paced, self directed presentation provides new and different New Product Introduction (NPI) information for the D5N and D6N Track-type Tractors equipped with Finger Tip Control (FTC). OBJECTIVES After learning the information in this presentation, the serviceman will be able to: 1. locate and identify the new components on the D5N/D6N Track-type Tractor; 2. explain the function of the new components in the systems; 3. explain the basic operation of the new systems; and 3. trace the flow of oil or air through the new systems. REFERENCES D5N Track-type Tractor Service Manual (Finger Tip Control) RENR5280 D6N Track-type Tractor Service Manual (Finger Tip Control) RENR5260 STMG 684 "D5M/D6M Track-type Tractors" SESV1684 Technical Instruction Module "Electronically Controlled Steering and Brake System for D5M/D6M/D6R/D7R" SEBV2628

Estimated Time: 1.5 Hours Visuals: 41 Form: SERV7102-10 Date: 10/02

2002 Caterpillar Inc.

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TABLE OF CONTENTS
INTRODUCTION ........................................................................................................................5 OPERATOR'S COMPARTMENT................................................................................................8 CATERPILLAR MONITORING SYSTEM ..............................................................................15 ENGINE......................................................................................................................................19 Air Intake and Exhaust System.............................................................................................31 POWER TRAIN .........................................................................................................................32 IMPLEMENT HYDRAULIC SYSTEM....................................................................................38 SIGNIFICANT MAINTENANCE CHANGES .........................................................................43 NEW TOOLING/SKILLS REQUIRED FOR SERVICE No Changes CONCLUSION...........................................................................................................................47

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NOTES

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D5N/D6N TRACK-TYPE TRACTORS

2002 Caterpillar Inc.

INTRODUCTION Shown above is the D5N LGP Track-type Tractor, equipped with Finger Tip Control (FTC). The D5N and D6N Track-type Tractors are equipped with FTC as standard equipment and have been redesigned to meet U.S. Environmental Protection Agency (EPA) Tier II Emissions Regulations for North America and Stage II European Emissions Regulations. The D5N and the D6N are both powered by the 3126B electronic engine, with Hydraulic Electronic Unit Injection (HEUI) fuel system. This engine also utilizes the Advanced Diesel Engine Management (ADEM III) system engine control and is equipped with an Air To Air AfterCooler (ATAAC). The D5N and D6N Track-type Tractors are direct replacements for the D5M and D6M Track-type Tractors.

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D5N AND D6N TRACK-TYPE TRACTORS KEY NEW FEATURES

3126B Electronic Engine with HEUI Fuel System ADEM III controller Air To Air AfterCooler (ATAAC) Power train upgrade Serviceability upgrades Hydraulic system upgrades Operator's compartment upgrades Product Link ready

The graphic above shows some of the key new features for the D5N and D6N Track-type Tractors.

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D5N/D6N TRACK-TYPE TRACTORS SIMILARITIES AND DIFFERENCES

FEATURES Machine Appearance Operator's Station Monitoring System Engine Transmission Steering System Power Train Braking System Implement Hydraulic System Nomenclature X X X X X X X X X DIFFERENT SIMILAR X SAME

The chart above compares the D5N and D6N Track-type Tractors to the current D5M and D6M. Although not comprehensive, it gives an "at a glance" look at what is different, similar, and the same.

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OPERATOR'S COMPARTMENT Upgrades and improvements to the operator's compartment include: - Cat contour series seat with air suspension as an option - More glass area in cab for better overall visibility - Integrated air conditioning in cab - Better sound suppression for a quieter operator environment - Upgraded operator controls and dash

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The left arm rest is manually adjustable fore and aft using the sliding lever (1). Optional power height adjustment is controlled using the rocker switch (2). The parking brake key lockout (3) and parking brake switch (4) are located just under the armrest. Engaging the parking brake automatically shifts the transmission to FIRST speed NEUTRAL. The D5N and D6N are now equipped with Finger Tip Control (5) as standard equipment. FTC combines steering, shifting, and directional control into one component.

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The front of the right arm rest contains the High/Low Idle switch (1). Pressing the right, or HIGH IDLE (rabbit) side of the switch sets the engine speed to high idle. Pressing the left, or LOW IDLE (turtle) side of the switch sets the engine speed to low idle. To the right of the operator and in front of the arm rest is the dozer control lever (2), which allows the operator to control all the blade functions with one lever. The functions are: RAISE, LOWER, FLOAT, TILT LEFT, TILT RIGHT, ANGLE LEFT, and ANGLE RIGHT. On machines equipped with an optional ripper, the ripper control lever (3) is located to the right of the arm rest. The ripper control lever is used to control RIPPER RAISE or RIPPER LOWER. Located just behind the ripper control lever is a 12-Volt, switched power adapter (4), and the horn button (5).

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Located behind the seat at the left rear of the operator compartment are the diagnostic connectors. There is a 12-Volt connector that may be used to power a laptop computer, Data View, etc. (1), a connector for the Communication Adapter and Caterpillar Electronic Technician (ET) (2), and a connector for the 4C8195 Service Tool (3).

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The service brake pedal (1) applies the service brakes (both left and right) proportionately with the amount of pressure applied by the operator. When completely depressed, the brakes are fully engaged. The smaller pedal on the right (2) is the decelerator pedal. During normal operation, the machine operates at high idle. Depressing the decelerator pedal decreases the engine rpm, by a signal from the rotary position sensor connected to the pedal. Intermediate engine speeds are attained by first setting the High/Low Idle switch to the HIGH IDLE position, and then depressing the decelerator pedal to the desired engine speed. Press and hold the HIGH IDLE (rabbit) side of the High/Low Idle switch for approximately three seconds. Release the switch. This will be the maximum engine speed until the High/Low Idle switch is pressed again. The engine speed may then be reduced from this maximum engine speed by depressing the decelerator pedal. When the decelerator pedal is released, the engine speed will return to the intermediate setting.

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Located overhead are the controls for the front windshield wiper/washer (1), left door wiper/washer (2), right door wiper/washer (3), and the rear widow wiper/washer (4). The covered opening (5) to the right of the wiper/washer controls can accommodate a radio/cassette player, available as an option. Located to the left side of the rear view mirror is the air filter restriction indicator (6). NOTE: The air filter restriction indicator is located at the left rear of the engine compartment, mounted to the under side of the hood, on machines equipped with the Open Roll Over Protection System (OROPS).

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10

The lower portion of the D5N and D6N dash includes the operator scroll switch (1), the AutoShift switch (2), the Auto Kickdown switch (3), the key start switch (4), the fan speed control for heating, air conditioning, and defogging (5), the temperature control for heating, air conditioning, and defogging (6), the machine lighting controls (7), and the main display module and alert indicators (8), which will be discussed later in this presentation. NOTE: The fan speed control and the temperature control for heating and air conditioning are not present on OROPS machines.

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11

CATERPILLAR MONITORING SYSTEM The D5N and D6N dash has been upgraded to the programmable Caterpillar Monitoring System, which consists of the quad gauge module (1), the Action Lamp (2), the addition of the gear/direction and alert indicator module (3), and the main display module (4).

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2 5

12

At the upper left of the dash is the quad gauge module, which contains four analog gauges that monitor engine coolant temperature (1), transmission oil temperature (2), fuel level (3), and hydraulic oil temperature (4). The action lamp (5), flashes to alert the operator to abnormal machine conditions.

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8 1

2 5 3 4

13

Just below the quad gauge module is the gear/direction and alert indicator module, which contains LED indicators that alert the operator to different machine conditions when lit. It also contains a backlit LCD display. The indicators and display are: 1. 2. 3. 4. 5. 6. 7. 8. AutoShift indicator for 1F/2R AutoShift indicator for 2F/2R AutoShift indicator for 2F/1R LCD digital display, showing engine rpm on the left and the gear and direction at the right Auto Kickdown mode indicator (activated by pressing the Auto Kickdown switch) Air inlet heater (activated) Engine coolant level (low) Low fuel level (ten percent or less of tank capacity remaining)

The Cat Monitoring System provides three warning categories, utilizing the alert indicators, the Action Lamp, and an Action Alarm. They are: - Warning Category 1: Only the alert indicator will flash, to alert the operator that the machine system needs attention. - Warning Category 2: The alert indicator and the Action Lamp will flash, to alert the operator to change the machine operation. - Warning Category 3: The alert indicator and the Action Lamp will flash and the Action Alarm will sound. This category requires immediate and safe shutdown of the operation in order to prevent severe damage to the system and/or to the machine.

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10

6 7 9 11 8

14

The main display module also contains a backlit LCD display and LED indicators that alert the operator to different machine conditions when lit. The indicators are: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Fuel pressure (low) Engine oil pressure (low) Power train oil filter (bypass activated) Power train oil temperature (excessive) Electrical system (abnormal output at the "R" terminal) Parking brake (activated) Engine system (fault) Transmission system (fault) Brake system (fault) Steering system (fault)

The LCD digital display window (11) defaults to display total operational (service) hours. Each time the Operator Scroll switch is pressed, additional information is provided in this display window in the following sequence: Total operational distance (in miles/kilometers), then forward distance, then reverse Operational distance (in miles/kilometers) in 3F gear, then 3R gear, etc. Logged service codes (scrolls through all logged codes) Back to total operational hours

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ENGINE Shown is the 3126B engine, equipped with the HEUI fuel system and Air To Air AfterCooler (ATAAC). This engine also utilizes the Advanced Diesel Engine Management (ADEM III) Electronic Engine Control. The 3126B engine is rated at 85.8 kW (115 hp) in the D5N XL and D5N LGP models (at 2100 rpm). This engine is rated at 108.2 kW (145 hp) in the D6N XL and D6N LGP models (at 2200 rpm). The 3126B engine is an in-line six cylinder arrangement, with a displacement of 7.2 liters. A demand fan is standard equipment for machines in the European Union and available as an option for machines in NACD and SCM.

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16

The left side of the engine provides access to the following service points: - Two stage air cleaner (1) - Engine oil fill tube (2) - Engine oil dipstick (3) - Secondary fuel filter (4)

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4 5 3

2 1

17

Sensors and other engine components accessible from the left side are: - Lower (cranking) speed/timing sensor (1) - Upper (high speed) speed/timing sensor (2) - Injection actuation pressure (pump) control valve (3) - Injection actuation pressure sensor (4) - Timing calibration connector (5) Also accessible from the left side of the engine, but not visible here, is the coolant level sensor. It is located at the top, left of the coolant surge tank.

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Also accessible on the left side of the engine, and behind the air intake tube are these sensors: - Coolant temperature sensor (1) - Engine oil pressure sensor (2)

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1 2

19

Also accessible from the left side of the engine are: - Optional electric fuel priming pump switch (1) - Turbo outlet (intake air) pressure sensor (2) - Inlet air temperature sensor (3) - Engine oil temperature sensor (4) NOTE: The turbo outlet (intake air) pressure sensor (2) also serves as the atmospheric pressure sensor. When the key switch is turned to the ON position, and before the engine cranks, the sensor takes a "snapshot" of the atmospheric pressure. This snapshot reading is then stored in the engine ECM memory and is used to calculate boost.

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Additional components accessible from the left side of the engine are: - Crankcase breather (1) - ADEM III engine ECM (2) - Fuel pressure sensor (3) - HEUI pump (4)

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2 6 3

21

Opening the door to the right side of the engine compartment provides access to: - Water temperature regulator housing (1) - Engine coolant SOS tap (2) - Alternator (3) - Engine oil filter (4) - Starter (5) - Engine oil cooler (internal) (6) The engine oil SOS tap (7) is mounted to a fitting in the turbocharger lube line, making it easily accessible by simply opening the engine compartment door.

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3 2

22

Other components accessible from the right side of the engine are: - Turbocharger (1) - Air filter restriction indicator vacuum connector (2) - Under hood air pre-cleaner and auto dust ejector (3) - Dust ejector pipe (4)

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1 2

23

Located on the right side of the engine, behind the alternator, is the Deutsch connector (1) used for the "Crank without Injection" feature. By removing connector (2) and inserting connector (3), fuel injection is disabled during engine cranking.

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24

Shown above is the timing calibration probe (arrow). The threaded hole for the probe is located at the right, front of the flywheel housing, just above and behind the starter. Removing the plug installed in this hole allows the technician to insert the probe. The lead from the probe is then connected to the timing calibration connector, located on the left side of the engine (illustration #17).

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4 5

25

Opening the access door on the rear of the tractor, below the fuel tank (illustration 33), provides access to the primary fuel filter (1), and water separator (2), and the optional electric fuel priming pump (3). If the machine is equipped with a manual fuel priming pump, it would be located here. Also located here is the fuel tank shutoff valve (4) and the fuel tank drain valve (5).

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26

27

On machines equipped with optional air conditioning, the compressor is located on the left side of the engine (illustration 26). The condenser coil is integrated into the cab structure, above and behind the rear window (illustration 27).

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3126B AIR INTAKE AND EXHAUST SYSTEM

EXHAUST MANIFOLD

INLET AIR HEATER

AIR TO AIR AFTERCOOLER

EXHAUST VALVE

INTAKE VALVE

AIR INLET COMPRESSOR SIDE TURBINE SIDE

EXHAUST OUTLET

TURBOCHARGER

28

Air Intake and Exhaust System The 3126B engine is equipped with an Air To Air AfterCooler (ATAAC) system. Air is drawn through the air inlet by the turbocharger and cooled as it passes through the ATAAC core. The cooler, more dense air enters the cylinders through the the intake valve. By cooling the precharged air, the ATAAC increases the mass flow of air through the engine, thus allowing more horsepower. The inlet air heater is used to aid in starting and reduces white smoke in cold conditions. No ether is used as a starting aid.

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FTC

PARKING BRAKE SWITCH CAT DATA LINK

CATERPILLAR MONITORING SYSTEM

D5N AND D6N FTC POWER TRAIN ELECTRONIC CONTROL SYSTEM

POWER TRAIN ELECTRONIC CONTROL I/O

ECM SERVICE BRAKE POWER TRAIN OIL FILTER AND BYPASS SERVICE TOOL

PRIORITY VALVE

5 1
TORQUE CONVERTER INLET RELIEF VALVE

PARKING BRAKE AND SECONDARY BRAKE VALVES

STEERING CLUTCH / BRAKE

4
STEERING CLUTCH AND BRAKE LUBE

MAIN RELIEF VALVE

STEERING CLUTCH AND BRAKE VALVES TRANSMISSION MODULATING VALVES TRANSMISSION AND BEVEL GEAR LUBE

STEERING CLUTCH / BRAKE

TORQUE CONVERTER OUTLET RELIEF VALVE TORQUE CONVERTER POWER TRAIN OIL COOLER

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POWER TRAIN Numerous upgrades in performance and serviceability have been implemented for the power trains on the D5N and D6N Track-type Tractors. These include: - Power train software improvements with load compensated shifting and controlled throttle shifting - New speed sensors - New priority valve (similar to that used on the D6R) - Remote pressure taps for power train pressures - Easy access to power train filter

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1 2

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The priority valve group, which contains the priority valve (1) and the torque converter inlet relief valve (2), has been relocated. The priority valve group and the electronic steering clutch and brake valves (3) are mounted on the front of the bevel gear case, just below the floor plate in the operator compartment.

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31

Opening the door on the compartment above the right fender allows easy access to these power train remote pressure taps: - Right steering clutch pressure (1) - Right brake pressure (2) - Left brake pressure (3) - Left steering clutch pressure (4) - Torque converter inlet pressure (5) - Torque converter outlet pressure (6) - Priority valve pressure (7)

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32

Opening the door on the front compartment above the left fender allows easy access to the power train oil fill tube (1) and the power train oil dipstick (2).

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2 1

33

Transmission lube pressure may be checked using the provided pressure tap (1). Opening the rear compartment door (2) gains access to more transmission and power train test and service points (see illustration 34).

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10

3 4 5 1 2

34

Opening the access door at the rear of the tractor, just below the fuel tank, gains access to: - Power train SOS tap (8) - Power train oil filter bypass switch (9) - Power train oil filter (10)

Also accessible in this compartment are the following transmission pressure taps: - Clutch pressure for clutch #3 (3) - Clutch pressure for clutch #4 (4) - Clutch pressure for clutch #5 (5) - Clutch pressure for clutch #1 (1) - Clutch pressure for clutch #2 (2) Transmission main relief pressure may be checked by removing plug (6) and replacing it with a pressure tap. Also, power train oil temperature may be checked by removing plug (7) and installing a temperature probe with a threaded fitting.

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D5N/D6N FTC HYDRAULIC SYSTEM

END COVER

BULLDOZER LIFT VALVE BLADE RAISE

RIPPER LIFT CYLINDER ANGLE CYLINDER

ANGLE

TILT CYLINDER RIPPER CYLINDERS PUMP TILT CYLINDER BYPASS R.E H.E

FLOAT DETENT

LIFT

PUMP SIGNAL RETURN OIL RESTRICTOR INLET MANIFOLD ANGLE CYLINDER LIFT CYLINDER

PUMP CASE DRAIN BAFFLE

PUMP SUCTION

35

IMPLEMENT HYDRAULIC SYSTEM The implement hydraulic system has been upgraded for the D5N and D6N Track-type Tractors. Upgrades include: - Improved load sensing, pressure compensated variable displacement piston pump - Re-styled hydraulic tank, common to both D5N and D6N (now mounted to ROPS support) - Improved hydraulic lines routings - Case drain filter - Remote pressure taps for implement hydraulics Shown above is a color schematic of the D5N and D6N hydraulic system in the BLADE RAISE state.

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FROM PREVIOUS VALVE

PRIMARY RESOLVER

BULLDOZER LIFT VALVE

RAISE
ROD END HEAD END MAKEUP VALVE

LINE RELIEF AND MAKEUP VALVE SECONDARY RESOLVER TO PUMP COMPENSATOR

SIGNAL PASSAGE

RETURN TO TANK SIGNAL PASSAGE SIGNAL CAVITY LOAD CHECK VALVE FROM PUMP

RETURN TO TANK

36

Shown above is a color cutaway drawing of the implement control valve for the bulldozer lift function. This graphic shows the valve in the blade raise position. Improvements to the throttling slots on the main valve spool, along with the elimination of the advance signal passage through the center of the spool has improved the performance of the valves for finer implement control and smoother operation.

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37

Opening the door to the compartment on the right fender allows access to the following: - Implement hydraulic oil SOS tap (1) - Implement pump pressure tap (2) - Case drain filter (3) - Case drain SOS tap (4) - Pump signal pressure tap (5)

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38

The hydraulic tank is located at the right rear of the machine. Shown above, is the fill tube (1), the integrated hydraulic filter (2), and fluid level sight glass (3).

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39

Mounted to the left, rear and at the bottom of the torque converter housing is the implement hydraulic pump (arrow). It is a load sensing, pressure compensated, variable displacement piston type pump. Pump output has been increased, as outlined below. - D5N flow rate is now 100 lpm (26 gpm). The D5M flow rate was 95 lpm (25 gpm). - D6N flow rate is now 133 lpm (35 gpm). The D6M flow rate was 119 lpm (31.5 gpm).

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40

SIGNIFICANT MAINTENANCE CHANGES Opening the door on the compartment at the front of the left fender provides access to the following maintenance/service points: - Main electrical disconnect switch (1) - Main electrical fuse panel (2), using automotive type fuses - 80 amp alternator breaker (3) - Connector for the 6V-2150 starting and charging analyzer (4) - Windshield/window washer fluid reservoir (5)

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41

For a dust free operator environment inside the cab, two fresh air filters are located immediately in front of the windshield.

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42

Opening the door on the compartment at the rear of the left fender gains access to the batteries (arrow).

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D5N/D6N MAINTENANCE INTERVALS

ITEM Engine Oil Engine Oil Filter Transmission Oil Transmission Filter Hydraulic Oil Hydraulic Filter Final Drive Oil Primary Fuel Filter Secondary Fuel Filter D5M/D6M 250 hours 250 hours 1000 hours 500 hours 2000 hours 500 hours 2000 hours 500 hours 250 hours D5N/D6N 500 hours* 500 hours* 1000 hours 500 hours 4000 hours 500 hours 2000 hours 500 hours 500 hours

* Assumes use of recommended oils. Half interval oil changes are acceptable with lower grade oils. First engine oil/filter change at 250 hours, then 500 hours thereafter.

43

All fluid check and fill points are outside the cab, with common groupings and easy access in mind. Ecology drains are standard for engine oil, engine coolant, and power train oil. Periodic maintenance item frequency intervals are shown in the chart, above.

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CONCLUSION This presentation has provided New Product Introduction (NPI) information for the Caterpillar D5N and D6N Track-type Tractors. All new components and their locations were identified and discussed. When used in conjunction with the Service Manuals for these machines, the information in this package will help the serviceman analyze problems in any of the major systems for these tractors.