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

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

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D5M / D6M / D6R

TRACK TYPE TRACTORS
CHAPTER : INTRODUCTION

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

SESV1684
SEGV2628

Specalogs
D5M Track-type Tractor
D6M Track-type Tractor
D6R Track-type Tractor
D7R Track-type Tractor

AEHQ5147
AEHQ5168
AEHQ5148
AEHQ51

Service Manual Modules

Form No.

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

SENR8484
SENR8485
SENR8492
SEBU6886
SENR8384
SENR8385
SENR8392
SEBU6888
SENR8354
SENR8355
SENR8356
SENR8362
SEBU6887
SENR8339

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D5M / D6M / D6R

TRACK TYPE TRACTORS
CHAPTER : INTRODUCTION

Service Manual Modules contin...)

Form No.

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

SENR8340
SENR8341
SENR8362
SEBU6890
SENR8367
SENR6717

Specalogs
D5M Track-type Tractor
D6M Track-type Tractor
D6R Track-type Tractor
D7R Track-type Tractor

AEHQ5147
AEHQ5168
AEHQ5148
AEHQ5149

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

TEVR9001
TEVR9002
SEBV0534
SEEV0529
SENR3981

Page:

D5M / D6M / D6R

TRACK TYPE TRACTORS
CHAPTER : INTRODUCTION

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.

Page:

D5M / D6M / D6R

TRACK TYPE TRACTORS
CHAPTER : INTRODUCTION

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...

Page:

Service Training
MALAGA

D5M / D6M / D6R

TRACK TYPE TRACTORS
ELECTRONIC CONTROL SYSTEM

Francis
OCT 97

ELECTRONIC CONTROL SYSTEM

CAT DATA LINK :
CATERPILLAR MONITORIN SYSTEM
ENGINE ELECTRONICONTROL MODULE
SERVICE TOOL

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

HARNESS CODE

ENGINE OUTPUT SPEED SENSOR

BRAKE PEDAL :
TRANSMISSION

BRAKE PEDAL POSITION SENSOR

SERVICE BRAKE PEDAL SWITCH

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 OUTPUT SPEED 1 SENSOR
TRANSMISSION OUTPUT SPEED 2 SENSOR

AUTOSHIFT SWITCH
BACKUP ALARM
AUTO KICKDOWN SWITCH

Page:

INCHING PEDAL POSITION SENSOR

ATTACH SWITCH

PRIORITY VALVE SOLENOID

AIH RELAY

D5M / D6M / D6R

TRACK TYPE TRACTORS

SHIFT INDICATORS

ELECTRONIC
CONTROL
MODULE
(ECM)

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

D5M / D6M / D6R

TRACK TYPE TRACTORS
CHAPTER : ELECTRONIC CONTROL SYSTEM

UPSHIFT/DOWNSHIFT SWITCHES

SERVICE BRAKE PEDAL SWITCH

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D5M / D6M / D6R

TRACK TYPE TRACTORS
CHAPTER : ELECTRONIC CONTROL SYSTEM

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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D5M / D6M / D6R

TRACK TYPE TRACTORS
CHAPTER : ELECTRONIC CONTROL SYSTEM

TRANSMISSION LEVER POSITION SENSOR

BRAKE PEDAL POSITION SENSOR

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D5M / D6M / D6R

TRACK TYPE TRACTORS
CHAPTER : ELECTRONIC CONTROL SYSTEM

TRANSMISSION SOLENOID VALVE

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D5M / D6M / D6R

TRACK TYPE TRACTORS
CHAPTER : ELECTRONIC CONTROL SYSTEM

STEER AND BRAKE SOLENOID VALVES

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D5M / D6M / D6R

TRACK TYPE TRACTORS
CHAPTER : ELECTRONIC CONTROL SYSTEM

CATERPILLAR MONITORING SYSTEM

Page:

D5M / D6M / D6R

TRACK TYPE TRACTORS
CHAPTER : ELECTRONIC CONTROL SYSTEM

DISPLAY BUTTON

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D5M / D6M / D6R

TRACK TYPE TRACTORS
CHAPTER : ELECTRONIC CONTROL SYSTEM

MESSAGE CENTER MODULE

SERV
CODE

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10

D5M / D6M / D6R

TRACK TYPE TRACTORS
CHAPTER : ELECTRONIC CONTROL SYSTEM

CATERPILLAR MONITORING SYSTEM

FAULT CODE MDISPLAY

CENTER MODULE

GAUGE CLUSTER MODULE

SERV
CODE

SERV
CODE

SERV
CODE

MID

Page:

11

CID/FMI

D5M / D6M / D6R

TRACK TYPE TRACTORS
CHAPTER : ELECTRONIC CONTROL SYSTEM

MACHINE CODE LIST

Machine Code

Sales Model
938F, IT38F

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

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

HARNESS CODE TROUBLESHOOTING

Main Display Module
Connector Contact
Wire Identification
Harness Code Plug Contact

31

270-BK

271-BK

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

Machine Code
03
09
27
28
34
35
39
40
43
45
46
47
48
49
51
53
58
60

Page:

12

12
272-BK

22

16

273-BK

274-BK

275-BK

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

D5M / D6M / D6R

TRACK TYPE TRACTORS
CHAPTER : ELECTRONIC CONTROL SYSTEM

SERVICE
CONNECTORS
LOCATION

4C-8195
SERVICE TOOL

LAPTOP
ELECTRONIC TEHNICIAN

Page:

13

D5M / D6M / D6R

TRACK TYPE TRACTORS
CHAPTER : ELECTRONIC CONTROL SYSTEM

MODE OF OPERATION

Mode
Number

Mode

Available As
Operator Mode

Normal

Yes

Harness Code

No

Service Meter

Yes

Charge Pressure

Yes

Tachometer

Yes

Numeric Readout

No

Diagnostic Scrolling

Yes

Service

No

Tattletale

No

Units

No

Setup

*
*

Calibration

No

No

D5M, D6M, D6R,D7R

MONITORING SYSTEM MODE
Mode
Normal

Harness Code

Numeric Readout

Service
Tattletale

3
4

Steering/Braking Calib.

Transmission Calib.

Component Data Display

7
8

Charging System Display

Page:

14

Mode
Number

Service Training
MALAGA

D5M / D6M / D6R

TRACK TYPE TRACTORS
POWER TRAIN CONTROL SYSTEM

ECM

Francis
OCT 97

Page:

POWER TRAIN HYDRAULIC SYSTEM

2

WITH STEERING AND BRAKE CONTROL VALVE

TORQUE
CONVERTER

IMPLEMENT AND WINCH

PUMP DRIVE
TORQUE CONVERTER
OUTLET RELIEF VALVE

TRANSMISSION
CONTROL VALVE

COOLER
TORQUE
CONVERTER
SUMP
LUBE

P3

P2
P1

PUMP

TRANSMISSION
SCAVENGE
SECTION

FILTER

STEERING AND
BRAKE LUBE
SECTION
TRANSMISSION
SUMP

STEERING AND
BRAKE VALVE

CASE

TRANSMISSION
CHARGING SECTION

D5M / D6M / D6R

TRACK TYPE TRACTORS

STEERING CLUTCH
AND BRAKE LUBE

CHAPTER : POWER TRAIN CONTROL SYSTEM

PRIORITY
VALVE

Page:

STEERING AND BRAKE VALVE

BRAKES ENGAGED

LEVER
PARKING BRAKE
SHAFT

RIGHT STEERING
CLUTCH SPOOL

POPPET VALVE
CHECK VALVE
TO RIGHT
CLUTCH

RIGHT STEERING
SHAFT
SERVICE BRAKE
PEDAL SHAFT

PUMP
SUPPLY
RIGHT STEERING
CLUTCH PLUNGER

RIGHT BRAKE
PLUNGER

TO LEFT
BRAKE

LEFT BRAKE
PLUNGER

LEFT BRAKE
SPOOL

LEFT STEERING
CLUTCH PLUNGER

LEFT STEERING
CLUTCH SPOOL

LEFT STEERING
SHAFT
TO LEFT CLUTCH

D5M / D6M / D6R

TRACK TYPE TRACTORS

TO RIGHT
BRAKE

CHAPTER : POWER TRAIN CONTROL SYSTEM

RIGHT BRAKE
SPOOL

Page:
4

MONITORING
SYSTEM

FTC

PARKING
BRAKE

ELECTRONICALLY CONTROLLED
STEERING AND BRAKE SYSTEM

CAT DATA LINK

ELECTRONIC POWER TRAIN

ECM
SERVICE
BRAKE

CONTROL I/O

SERVICE TOOL

PARKING BRAKE AND

SECONDARY BRAKE
VALVE
FILTER

STEERING
CLUTCH AND
BRAKE LUBE

STEERING
CLUTCH AND
BRAKE LUBE

PUMP
DRIVE
LUBE

MAIN RELIEF AND

MODULATING
VALVES

STEERING
AND BRAKE
VALVE

TRANSMISSION AND
BEVEL GEAR LUBE

OUTLET RELIEF
VALVE
TORQUE
CONVERTER
COOLER

STEERING
CLUTCH /
BRAKE

D5M / D6M / D6R

TRACK TYPE TRACTORS

TRANSMISSION
CASE

STEERING
CLUTCH /
BRAKE

CHAPTER : POWER TRAIN CONTROL SYSTEM

PRIORITY
VALVE

D5M / D6M / D6R

TRACK TYPE TRACTORS
CHAPTER : POWER TRAIN CONTROL SYSTEM

FINGER TIP CONTROL

1 - Directional control knob

2 - Upshift and Downshift buttons

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D5M / D6M / D6R

TRACK TYPE TRACTORS
CHAPTER : POWER TRAIN CONTROL SYSTEM

PULSE WIDTH MODULATION SENSOR

Page:

Page:
7

POWER TRAIN HYDRAULIC SYSTEM

FILTER

STEERING
CLUTCH /
BRAKE

PRIORITY
VALVE

STEERING
AND BRAKE
VALVE

STEERING
CLUTCH AND
BRAKE LUBE

MODULATING
VALVES

PUMP DRIVE
LUBE

TRANSMISSION AND
BEVEL GEAR LUBE
OUTLET RELIEF
VALVE

TORQUE
CONVERTER
TRANSMISSION
CASE

3 MAIN RELIEF AND

COOLER

STEERING
CLUTCH /
BRAKE

D5M / D6M / D6R

TRACK TYPE TRACTORS

STEERING
CLUTCH AND
BRAKE LUBE

CHAPTER : POWER TRAIN CONTROL SYSTEM

Page:
8

PRIORITY VALVE
NORMAL MODE

FROM CONTROL SECTION

TO STEERING, BRAKE AND

TRANSMISSION CONTROLS

TO TORQUE
CONVERTER

D5M / D6M / D6R

TRACK TYPE TRACTORS

PRIORITY
VALVE
SOLENOID

CHAPTER : POWER TRAIN CONTROL SYSTEM

FROM TORQUE CONVERTER AND

LUBRICATION SECTION

Page:
9

PRIORITY VALVE
PRIORITY MODE

FROM CONTROL SECTION OF PUMP

TO STEERING, BRAKE AND

TRANSMISSION CONTROLS

TO TORQUE
CONVERTER

D5M / D6M / D6R

TRACK TYPE TRACTORS

PRIORITY
VALVE
SOLENOID

CHAPTER : POWER TRAIN CONTROL SYSTEM

FROM TORQUE CONVERTER

AND LUBRICATION SECTION

D5M / D6M / D6R

TRACK TYPE TRACTORS
CHAPTER : POWER TRAIN CONTROL SYSTEM

CONTROL VALVE GROUP

Page:

10

D5M / D6M / D6R

TRACK TYPE TRACTORS

Page:

11

TO DRAIN

TRANSMISSION
MODULATING VALVE

TO CLUTCH

SUPPLY
OIL

CHAPTER : POWER TRAIN CONTROL SYSTEM

D5M / D6M / D6R

TRACK TYPE TRACTORS
CHAPTER : POWER TRAIN CONTROL SYSTEM

AUTOSHIFT AND AUTO KICKDOWN MODES

2
3

1. 1F/2R LED
2. 2F/2R LED
3. Autoshift switch
4. Auto Kickdown LED
5. Auto Kickdown switch

Page:

12

Service Training
MALAGA

D5M / D6M / D6R

TRACK TYPE TRACTORS
STEERING AND BRAKE SYSTEM

Francis
OCT 97

Page:
MONITORING
SYSTEM

2
FTC

PARKING
BRAKE

ELECTRONICALLY CONTROLLED
STEERING AND BRAKE SYSTEM

CAT DATA LINK

ELECTRONIC POWER TRAIN

ECM
SERVICE
BRAKE

CONTROL I/O

SERVICE TOOL

PARKING BRAKE AND

SECONDARY BRAKE
VALVE
FILTER

PRIORITY
VALVE

PUMP
DRIVE
LUBE

MAIN RELIEF AND

MODULATING
VALVES

STEERING
AND BRAKE
VALVE

TRANSMISSION AND
BEVEL GEAR LUBE

OUTLET RELIEF
VALVE
TORQUE
CONVERTER
COOLER

STEERING
CLUTCH /
BRAKE

D5M / D6M / D6R

TRACK TYPE TRACTORS

STEERING
CLUTCH AND
BRAKE LUBE

STEERING
CLUTCH AND
BRAKE LUBE

CHAPTER : STEERING AND BRAKE SYSTEM

TRANSMISSION
CASE

STEERING
CLUTCH /
BRAKE

D5M / D6M / D6R

TRACK TYPE TRACTORS
CHAPTER : STEERING AND BRAKE SYSTEM

STEERING AND BRAKE CONTROL SYSTEM

1 - Left steering and brake lever

2 - Right steering and brake lever

Page:

D5M / D6M / D6R

TRACK TYPE TRACTORS
CHAPTER : STEERING AND BRAKE SYSTEM

PARKING BRAKE CONTROL

1 - Parking brake switch

2 - ECM

Page:

Page:
5

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

RIGHT
RIGHT
BRAKE CLUTCH
VALVE VALVE

D5M / D6M / D6R

TRACK TYPE TRACTORS

LEFT
LEFT
CLUTCH BRAKE
VALVE VALVE

SECONDARY
BRAKE
VALVE

CHAPTER : STEERING AND BRAKE SYSTEM

PARKING
BRAKE
VALVE

D5M / D6M / D6R

TRACK TYPE TRACTORS
CHAPTER : STEERING AND BRAKE SYSTEM

STEERING AND BRAKE 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

SHUTOFF
VALVE

D5M / D6M / D6R

TRACK TYPE TRACTORS

PILOT
VALVE

CHAPTER : STEERING AND BRAKE SYSTEM

PROPORTIONAL
SOLENOID

Page:
8

STEERING AND BRAKE CONTROL VALVE

GRADUAL RIGHT TURN

BRAKE
SOLENOIDS

ACCUMULATOR
PISTON

CLUTCH
SOLENOID

CLUTCH
SOLENOID

TO
TO
LEFT
LEFT
CLUTCH BRAKE
SUPPLY OIL

REDUCING
SPOOL

PARKING
BRAKE
SOLENOID

SECONDARY
BRAKE
SOLENOID

D5M / D6M / D6R

TRACK TYPE TRACTORS

TO
RIGHT
BRAKE

CHAPTER : STEERING AND BRAKE SYSTEM

TO
RIGHT
CLUTCH

Page:

STEERING AND BRAKE CONTROL VALVE

SHARP RIGHT TURN

BRAKE
SOLENOIDS
CLUTCH
SOLENOID

ACCUMULATOR
PISTON

CLUTCH
SOLENOID

TO
TO
LEFT
LEFT
CLUTCH BRAKE
SUPPLY OIL

REDUCING
SPOOL

PARKING
BRAKE
SOLENOID

SECONDARY
BRAKE
SOLENOID

D5M / D6M / D6R

TRACK TYPE TRACTORS

TO
RIGHT
BRAKE

CHAPTER : STEERING AND BRAKE SYSTEM

TO
RIGHT
CLUTCH

Page:
10

STEERING AND BRAKE CONTROL VALVE

BRAKES ENGAGED

BRAKE
SOLENOIDS

ACCUMULATOR
PISTON

CLUTCH
SOLENOID

CLUTCH
SOLENOID

TO
TO
LEFT
LEFT
CLUTCH BRAKE
SUPPLY OIL

REDUCING
SPOOL

PARKING
BRAKE
SOLENOID

SECONDARY
BRAKE
SOLENOID

D5M / D6M / D6R

TRACK TYPE TRACTORS

TO
RIGHT
BRAKE

CHAPTER : STEERING AND BRAKE SYSTEM

TO
RIGHT
CLUTCH