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 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 Specifications SENR8339

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 D5M / D6M / D6R
TRACK TYPE TRACTORS
CHAPTER : INTRODUCTION

Service Manual Modules contin...) Form No.

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
Fluid Power Graphic Symbols User's Guide SENR3981

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 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.

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 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: 6
Service Training
MALAGA

D5M / D6M / D6R

TRACK TYPE TRACTORS

ELECTRONIC CONTROL SYSTEM

Francis
OCT 97
 ELECTRONIC CONTROL SYSTEM
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
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
SHIFT INDICATORS
AUTOSHIFT SWITCH
AUTO KICKDOWN SWITCH
INCHING PEDAL POSITION SENSOR
Page:
ATTACH SWITCH
2
CAT DATA LINK :
CATERPILLAR MONITORIN SYSTEM
ENGINE ELECTRONICONTROL MODULE
SERVICE TOOL
HARNESS CODE
ENGINE OUTPUT SPEED SENSOR
TRANSMISSION
TORQUE CONVERTER OUTPUT SPEED SENSOR
TRANSMISSION TEMPERATURE SENSOR
CHAPTER : ELECTRONIC CONTROL SYSTEM
ELECTRONIC FORWARD CLUCH 2 SOLENOID
CONTROL REVERSE CLUCH 1 SOLENOID
TRACK TYPE TRACTORS
MODULE FIRST GEAR CLUCH 5 SOLENOID
SECOND GEAR CLUH 4 SOLENOID
(ECM) THIRD GEAR CLUCH 3 SOLENOID
D5M / D6M / D6R
TRANSMISSION INTERMEDIATE SPEED 1 SENSOR
TRANSMISSION INTERMEDIATE SPEED 2 SENSOR
TRANSMISSION OUTPUT SPEED 1 SENSOR
TRANSMISSION OUTPUT SPEED 2 SENSOR
BACKUP ALARM
PRIORITY VALVE SOLENOID
AIH RELAY
 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

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 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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 D5M / D6M / D6R
TRACK TYPE TRACTORS
CHAPTER : ELECTRONIC CONTROL SYSTEM

CATERPILLAR MONITORING SYSTEM

FAULT CODE MDISPLAY

CENTER MODULE
GAUGE CLUSTER MODULE

SERV
CODE

SERV SERV
CODE CODE

MID CID/FMI

Page: 11
 D5M / D6M / D6R
TRACK TYPE TRACTORS
CHAPTER : ELECTRONIC CONTROL SYSTEM

Sales Model Machine Code MACHINE CODE LIST

938F, IT38F 03
938F (Fuel Tank) 04
953C 09
D4 27
D6 28
D5 34
DR C/B HEUI 35
D7 D/S 39
D10R 40
D11R-B 43
D11R-A 45
D7 C/B 46
D9R C/B MECH 27
769D, 771D, 773D, 775D, 777D 34
5110 35
D9R D/S HEUI 36
D9R D/S MECH 37
950F 39
960F 40
966F 43
970F 45
980G 46
824G 47
825G 48
826G 49
525 1DN1-374 51
24H 53
814F, 815F, 816F 58
515, 525 1DN375-UP 60

HARNESS CODE TROUBLESHOOTING

Main Display Module
Connector Contact 31 3 12 22 16 6

Wire Identification 270-BK 271-BK 272-BK 273-BK 274-BK 275-BK

Harness Code Plug Contact 1 2 3 4 5 6
Machine Code Specified Status
03 O O G G G G
09 O G G O G G
27 O O G O O G
28 G G O O O G
34 G O G G G O
35 O O G G G O
39 O O O G G O
40 G G G O G O
43 O O G O G O
45 O O O O O O
46 G O O O G O
47 O O O O G O
48 G G G G O O
49 O G G G O O
51 O O G G O O
53 O G O G O O
58 G O G O O O
60 G G O O O O

Page: 12
 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 Available As
Mode Operator Mode
Number
Normal 0 Yes
Harness Code 1 No
Service Meter * Yes
Charge Pressure * Yes
Tachometer * Yes
Numeric Readout * No
Diagnostic Scrolling * Yes
Service * No
Tattletale * No
Units * No
Setup * No
Calibration * No

D5M, D6M, D6R,D7R

MONITORING SYSTEM MODE
Mode
Mode Number
Normal 0
Harness Code 1
Numeric Readout 2
Service 3
Tattletale 4
Steering/Braking Calib. 5
Transmission Calib. 6
Component Data Display 7
Charging System Display 8

Page: 14
Service Training
MALAGA

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 IMPLEMENT AND WINCH
TORQUE PUMP DRIVE
2

CONVERTER
TORQUE CONVERTER
OUTLET RELIEF VALVE
TRANSMISSION
CONTROL VALVE
COOLER

TORQUE
CONVERTER
SUMP
P3 LUBE

PRIORITY

CHAPTER : POWER TRAIN CONTROL SYSTEM

VALVE P2
P1

TRACK TYPE TRACTORS

STEERING CLUTCH
AND BRAKE LUBE

D5M / D6M / D6R

PUMP

TRANSMISSION STEERING AND

SCAVENGE BRAKE VALVE
SECTION

STEERING AND
FILTER BRAKE LUBE
SECTION CASE TRANSMISSION
CHARGING SECTION
TRANSMISSION
SUMP
Page:

STEERING AND BRAKE VALVE

BRAKES ENGAGED
3

LEVER
POPPET VALVE

PARKING BRAKE
SHAFT CHECK VALVE

RIGHT STEERING
TO RIGHT
SHAFT
CLUTCH
RIGHT STEERING
CLUTCH SPOOL SERVICE BRAKE
PEDAL SHAFT

PUMP
SUPPLY
RIGHT STEERING
CLUTCH PLUNGER
RIGHT BRAKE

CHAPTER : POWER TRAIN CONTROL SYSTEM

SPOOL
RIGHT BRAKE
PLUNGER
TO RIGHT

TRACK TYPE TRACTORS

BRAKE

D5M / D6M / D6R

TO LEFT LEFT BRAKE
BRAKE PLUNGER

LEFT BRAKE
SPOOL LEFT STEERING
CLUTCH PLUNGER

LEFT STEERING LEFT STEERING

CLUTCH SPOOL SHAFT
TO LEFT CLUTCH
Page:

MONITORING
4

PARKING SYSTEM ELECTRONICALLY CONTROLLED

FTC
BRAKE STEERING AND BRAKE SYSTEM
CAT DATA LINK

ELECTRONIC POWER TRAIN

ECM
SERVICE CONTROL I/O
SERVICE TOOL
BRAKE
PARKING BRAKE AND
SECONDARY BRAKE
VALVE
FILTER 5
PRIORITY
VALVE STEERING

CHAPTER : POWER TRAIN CONTROL SYSTEM

1 CLUTCH /
BRAKE

TRACK TYPE TRACTORS

2 STEERING
AND BRAKE STEERING
STEERING STEERING CLUTCH /

D5M / D6M / D6R

MAIN RELIEF AND VALVE
CLUTCH AND CLUTCH AND 4 BRAKE
BRAKE LUBE BRAKE LUBE 3 MODULATING
VALVES
PUMP
DRIVE TRANSMISSION AND
LUBE BEVEL GEAR LUBE

OUTLET RELIEF
VALVE
TORQUE
CONVERTER

TRANSMISSION COOLER
CASE
 D5M / D6M / D6R
TRACK TYPE TRACTORS
CHAPTER : POWER TRAIN CONTROL SYSTEM

FINGER TIP CONTROL

1 - Directional control knob

2 - Upshift and Downshift buttons

Page: 5
 D5M / D6M / D6R
TRACK TYPE TRACTORS
CHAPTER : POWER TRAIN CONTROL SYSTEM

PULSE WIDTH MODULATION SENSOR

Page: 6
Page:

POWER TRAIN HYDRAULIC SYSTEM

7

STEERING
CLUTCH /
FILTER 5 BRAKE
PRIORITY STEERING
VALVE AND BRAKE
1 VALVE

CHAPTER : POWER TRAIN CONTROL SYSTEM

2
STEERING STEERING
CLUTCH AND CLUTCH AND 4 3 MAIN RELIEF AND

TRACK TYPE TRACTORS

BRAKE LUBE BRAKE LUBE MODULATING
VALVES STEERING
PUMP DRIVE CLUTCH /

D5M / D6M / D6R

LUBE TRANSMISSION AND BRAKE
BEVEL GEAR LUBE

OUTLET RELIEF
VALVE
TORQUE
CONVERTER

TRANSMISSION COOLER
CASE
Page:
8

PRIORITY VALVE FROM CONTROL SECTION

NORMAL MODE

TO STEERING, BRAKE AND

TRANSMISSION CONTROLS

CHAPTER : POWER TRAIN CONTROL SYSTEM

TRACK TYPE TRACTORS
FROM TORQUE CONVERTER AND
LUBRICATION SECTION

D5M / D6M / D6R

PRIORITY
TO TORQUE
VALVE
CONVERTER
SOLENOID
Page:
9

PRIORITY VALVE FROM CONTROL SECTION OF PUMP

PRIORITY MODE

TO STEERING, BRAKE AND

TRANSMISSION CONTROLS

CHAPTER : POWER TRAIN CONTROL SYSTEM

TRACK TYPE TRACTORS
FROM TORQUE CONVERTER
AND LUBRICATION SECTION

D5M / D6M / D6R

PRIORITY
TO TORQUE
VALVE
CONVERTER
SOLENOID
 D5M / D6M / D6R
TRACK TYPE TRACTORS
CHAPTER : POWER TRAIN CONTROL SYSTEM

CONTROL VALVE GROUP

Page: 10
 D5M / D6M / D6R
TRACK TYPE TRACTORS
CHAPTER : POWER TRAIN CONTROL SYSTEM

SUPPLY
OIL
TO CLUTCH
TO DRAIN
MODULATING VALVE
TRANSMISSION

Page: 11
 D5M / D6M / D6R
TRACK TYPE TRACTORS
CHAPTER : POWER TRAIN CONTROL SYSTEM

AUTOSHIFT AND AUTO KICKDOWN MODES

1 4
2

3 5

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
ELECTRONICALLY CONTROLLED
2

PARKING SYSTEM
FTC
BRAKE STEERING AND BRAKE SYSTEM
CAT DATA LINK

ELECTRONIC POWER TRAIN

ECM
SERVICE CONTROL I/O
SERVICE TOOL
BRAKE
PARKING BRAKE AND
SECONDARY BRAKE
VALVE
FILTER 5
PRIORITY
VALVE STEERING
1 CLUTCH /
BRAKE

CHAPTER : STEERING AND BRAKE SYSTEM

TRACK TYPE TRACTORS

2 STEERING
AND BRAKE STEERING
STEERING STEERING CLUTCH /
VALVE

D5M / D6M / D6R

CLUTCH AND CLUTCH AND MAIN RELIEF AND BRAKE
4 3
BRAKE LUBE BRAKE LUBE MODULATING
VALVES
PUMP
DRIVE TRANSMISSION AND
LUBE BEVEL GEAR LUBE

OUTLET RELIEF
VALVE
TORQUE
CONVERTER

TRANSMISSION COOLER
CASE
 D5M / D6M / D6R
TRACK TYPE TRACTORS
CHAPTER : STEERING AND BRAKE SYSTEM

STEERING AND BRAKE CONTROL SYSTEM

1 2

1 - Left steering and brake lever

2 - Right steering and brake lever

Page: 3
 D5M / D6M / D6R
TRACK TYPE TRACTORS
CHAPTER : STEERING AND BRAKE SYSTEM

PARKING BRAKE CONTROL

1 - Parking brake switch

2 - ECM

Page: 4
Page:

STEERING AND BRAKE ELECTRICAL SYSTEM

5

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

SERVICE
CONNECTOR

CHAPTER : STEERING AND BRAKE SYSTEM

TRACK TYPE TRACTORS

PARKING SECONDARY

D5M / D6M / D6R

BRAKE BRAKE
VALVE VALVE

LEFT LEFT RIGHT RIGHT

CLUTCH BRAKE BRAKE CLUTCH
VALVE VALVE VALVE 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: 6
Page:
7

STEERING AND BRAKE CONTROL VALVE

PARKING/SECONDARY BRAKE
SOLENOID VALVES

REDUCING
SPOOL

ACCUMULATOR PISTON

CHAPTER : STEERING AND BRAKE SYSTEM

TRACK TYPE TRACTORS

D5M / D6M / D6R
PROPORTIONAL PILOT SHUTOFF
SOLENOID VALVE VALVE
Page:

STEERING AND BRAKE CONTROL VALVE

8

GRADUAL RIGHT TURN

ACCUMULATOR
BRAKE CLUTCH PISTON
SOLENOIDS SOLENOID
CLUTCH
SOLENOID

CHAPTER : STEERING AND BRAKE SYSTEM

TRACK TYPE TRACTORS

TO
RIGHT

D5M / D6M / D6R

CLUTCH
TO
RIGHT
BRAKE

TO TO
LEFT LEFT PARKING SECONDARY
CLUTCH BRAKE BRAKE BRAKE
REDUCING
SUPPLY OIL SOLENOID SOLENOID
SPOOL
Page:

STEERING AND BRAKE CONTROL VALVE

SHARP RIGHT TURN
9

ACCUMULATOR
BRAKE CLUTCH PISTON
SOLENOIDS SOLENOID
CLUTCH
SOLENOID

CHAPTER : STEERING AND BRAKE SYSTEM

TRACK TYPE TRACTORS

TO
RIGHT
CLUTCH

D5M / D6M / D6R

TO
RIGHT
BRAKE

TO TO
LEFT LEFT PARKING SECONDARY
CLUTCH BRAKE BRAKE BRAKE
SUPPLY OIL REDUCING
SOLENOID SOLENOID
SPOOL
Page:

STEERING AND BRAKE CONTROL VALVE

10

BRAKES ENGAGED

ACCUMULATOR
BRAKE CLUTCH PISTON
SOLENOIDS SOLENOID

CLUTCH
SOLENOID

CHAPTER : STEERING AND BRAKE SYSTEM

TRACK TYPE TRACTORS

TO
RIGHT
CLUTCH

D5M / D6M / D6R

TO
RIGHT
BRAKE

TO TO
LEFT LEFT PARKING SECONDARY
CLUTCH BRAKE BRAKE BRAKE
SUPPLY OIL REDUCING
SOLENOID SOLENOID
SPOOL