Service manual Caterpillar D6K XL, LGP Track-Type Tractor with C7.1 Engine | 6S600001-UP

Air Conditioning and Heating R134a for All Cat Machines
– General Information
– Refrigerant Orifice Tube System
– Refrigerant Compressor
– Refrigerant Compressor
– Refrigerant Compressor
– Refrigerant Condenser
– Refrigerant Condenser
– Refrigerant Receiver-Dryer
– Refrigerant Receiver-Dryer
– Refrigerant Expansion Valve
– In-line Refrigerant Dryer
– Identifying the Refrigerant
– In-line Refrigerant Dryer
– Refrigerant Orifice Tube Assembly
– Refrigerant Orifice Tube Assembly
– Evaporator Coil
– Refrigerant Accumulator
– Refrigerant Accumulator
– Refrigerant Accumulator
– Refrigerant Compressor Protection System
– Temperature Control
– Temperature Control
– Identifying the Refrigerant
– Pressure Switch (Refrigerant)
– Pressure Switch (Refrigerant)
– Cab Pressurization and Filtration System
– Cab Pressurization and Filtration System
– Cab Pressurization and Filtration System
– Condensate Drainage System
– Condensate Drainage System
– Service Intervals
– Service Intervals
– Glossary of Terms
– Identifying the Air Conditioning System
– General Troubleshooting Information
– General Troubleshooting Information
– Machine Preparation for Testing and Adjusting
– Machine Preparation for Testing and Adjusting
– Air Conditioning Performance – Test
– Refrigerant Leakage – Test
– Manifold Gauge Set (Refrigerant) – Install
– Manifold Gauge Set (Refrigerant) – Install
– Refrigerant Recovery
– Refrigerant Recovery
– Identifying the Air Conditioning System
– Refrigerant System – Flush
– Refrigerant Oil – Test
– Refrigerant Compressor – Test
– Refrigerant Compressor – Test
– Refrigerant Compressor – Test
– Refrigerant System – Evacuate
– Refrigerant System – Evacuate
– Refrigerant System – Charge
– Refrigerant System – Charge
– Manifold Gauge Set (Refrigerant) – Remove
– Identifying the Heating System
– Manifold Gauge Set (Refrigerant) – Remove
– Compressor Protection System – Test
– Compressor Protection System – Test
– Electronic Heat Control – Test
– Electronic Heat Control – Test
– Heater Performance – Test
– Heating and Air Conditioning Service Publications
– General Information
– General Information
– Machine Preparation for Disassembly and Assembly
– Refrigerant Expansion Valve System
– Air Conditioner Lines – Remove and Install
– Refrigerant Compressor – Remove and Install
– Refrigerant Accumulator – Remove and Install
– Refrigerant Expansion Valve – Remove and Install
– Refrigerant Receiver-Dryer – Remove and Install
– In-Line Refrigerant Dryer – Remove and Install
– Refrigerant Orifice Tube Assembly – Remove and Install
– Refrigerant Expansion Valve System
– Refrigerant Orifice Tube System
– General Information
Cat® GRADE System for D3K2, D4K2, D5K2, D6K, and D6K2 Next Generation Track-Type Tractors
– Calibration
– Calibration Error Codes
– CAN Data Link – Test
– Connector Contact Description
– Determining Diagnostic Trouble Codes
– Diagnostic Capabilities
– Diagnostic Trouble Codes
– ECM – Configure
– ECM – Replace
– ECM Software – Install
– Electrical Connector – Inspect
– Electrical Power Supply – Test
– Emerging Symptom Information
– Event Codes
– Features
– Firmware Upgrade
– General Information
– General Information
– Machine Preparation for Troubleshooting
– Operator Control Switch (Switch to Ground) – Test
– Sensor (Data Link Type) – Test
– Service Tools
– Solenoid Valve – Test
– Symptom Troubleshooting
– System Accuracy – Test
– System Components
– Visual Inspection
– Wiring Harness (Open Circuit) – Test
– Wiring Harness (Short Circuit) – Test
D4, D6K, and D6K2 Electrical & Hydraulic Troubleshooting
– Backup Alarm Does Not Function
– Brake Does Not Engage
– Brake Does Not Release
– CAN Data Link – Test
– Connector Contact Description
– Connector Locations
– Determining Diagnostic Trouble Codes
– Diagnostic Capabilities
– Diagnostic Trouble Codes
– ECM – Configure
– ECM – Replace
– ECM Location Code – Test
– ECM Software – Install
– Electrical Connector – Inspect
– Electrical Power Supply – Test
– Emerging Symptom Information
– Event Codes
– Fast Fill Fuel System
– General Information
– HVAC, Air Conditioning System
– HVAC, Automatic Temperature Control System
– HVAC, Condensate Drainage System
– HVAC, Control System
– HVAC, General Troubleshooting
– HVAC, Heating System
– HVAC, Required Tools
– HVAC, Visual Inspection
– Hydraulic Cylinder Movement Is Harsh
– Hydraulic Fan System
– Hydraulic System
– Hydraulic System Oil Level Is Low
– Hydraulic System Oil Temperature Is High
– Implement Cycle Time Is Fast
– Implement System
– Machine Preparation for Troubleshooting
– Power Train Oil
– Relay – Test
– Ripper Does Not Function
– Sensor Signal (Analog, Active) – Test
– Sensor Signal (Analog, Passive) – Test
– Sensor Signal (PWM) – Test
– Sensor Supply – Test
– Service Tools
– Solenoid Return – Test
– Solenoid Valve (Switch Controlled) – Test
– Solenoid Valve – Test
– Speed Sensor (Dual Signal) – Test
– Switch Circuits – Test
– Symptom Troubleshooting
– System Schematic
– Visual Inspection
– Wiring Harness (Open Circuit) – Test
– Wiring Harness (Short Circuit) – Test
D4, D6K2 and D6K Track-Type Tractor Systems
– Access Door
– Access Door
– Access Door
– Accumulator (Hydraulic)
– Accumulator (Pilot) – Test and Charge
– Additional Electrical Components
– Adjustable Seat
– Air Cleaner
– Air Cleaner
– Air Cleaner
– Air Conditioner
– Air Conditioner Lines
– Air Precleaner
– Air Precleaner
– Angle Cylinder (Bulldozer)
– Angle Cylinder (Bulldozer)
– Angle Cylinder (Bulldozer)
– Angle Cylinder (Bulldozer)
– Angling Blade
– Angling Blade
– Angling Blade
– Angling Blade
– Angling Blade
– Bank Valve (Four)
– Bank Valve (Four)
– Bank Valve (Implement)
– Bank Valve (Implement)
– Bank Valve (Three)
– Brake System
– Calibration
– Calibration Error Codes
– Case and Frame
– Charge Relief Valve (Winch) – Test and Adjust
– Charge Relief Valve – Test and Adjust
– Communication Electronic Control Module (Product Link) –
– Communication Electronic Control Module (Product Link) –
– Control Group (Implement)
– Coolant Lines
– Cover (Console)
– Crossover Relief Valve (Winch) – Test and Adjust
– Crossover Relief Valve – Test and Adjust – Hydrostatic Stall
– Cutting Edges and End Bits
– Cutting Edges and End Bits
– Cutting Edges and End Bits
– Deceleration/Brake Pedal – Test
– Decelerator Pedal and Brake Pedal
– Display Mounting
– Drawbar
– Electronic Control (HVAC System)
– Electronic Control (Hydraulic System)
– Electronic Control (Power Train System)
– Electronic Control (Winch System)
– Electronic Control – Without WIFI
– Equalizer Bar
– Equalizer Bar
– Ether Starting Aid
– Fan and Motor
– Fan Hydraulic System
– Fan Speed – Calibrate
– Filling and Flushing the Hydrostatic System
– Final Drive
– Final Drive and Parking Brake
– Final Drive and Parking Brake
– Final Drive Mounting
– Final Hydrostatic Speed – Test
– Flexible Exhaust Pipe
– Flexible Exhaust Pipe
– Flood Lamp
– Flood Lamp
– Flushing Valve
– Fuel Tank
– Fuel Tank
– General Information (HVAC System)
– General Information (Hydraulic System)
– General Information (Power Train System)
– General Information (Undercarriage)
– General Information (Winch System)
– Graphic Color Codes
– Guard (Fuel Tank)
– Guard (Fuel Tank)
– Handle Control (Blade)
– Handle Control (Blade)
– Handle Control (Steering and Transmission)
– Heater Lines
– High Speed Oil Change Group
– High Speed Oil Change Group
– HVAC System
– Hydraulic Fan Drive Lines
– Hydraulic Fan Drive Lines
– Hydraulic Pump – Test and Adjust
– Hydraulic Tank
– Hydraulic Tank
– Hydraulic Tank and Mounting
– Inertial Sensor – GS420
– Inertial Sensor – GS520
– Inertial Sensor – Inertial Measurement Unit
– Inertial Sensor – Inertial Measurement Unit (GS510)
– Joystick Control (Blade)
– Joystick Control (Blade)
– Joystick Control (Blade)
– Joystick Control (Steering and Transmission)
– Joystick Control (Steering and Transmission)
– Lift Cylinder (Bulldozer)
– Lift Cylinder (Bulldozer)
– Lift Cylinder (Bulldozer)
– Lift Cylinder (Ripper)
– Lines (Charge Pressure)
– Lines (Charge Pressure)
– Lines (Charge Pressure)
– Lines (Winch)
– Location of Components (HVAC System)
– Location of Components (Hydraulic System)
– Location of Components (Power Train System)
– Location of Components (Undercarriage)
– Machine Preparation
– Motor Control Valve (Hydrostatic) (Displacement)
– Oil Filter (Hydraulic)
– Oil Filter (Hydraulic)
– Oil Filter (Hydraulic)
– Operational Checks
– Operator Console
– Operator Monitor
– Operator Monitor
– Operator Monitor
– Pilot Lines
– Pilot Lines
– Piston Motor (Hydrostatic)
– Piston Motor (Hydrostatic)
– Piston Motor (Winch)
– Piston Pump (Hydrostatic)
– Piston Pump (Implement)
– Piston Pump (Implement)
– Piston Pump (Implement)
– Piston Pump (Winch)
– Piston Pump and Motor Maximum Displacement – Test
– Piston Pump Neutral (Winch) – Test and Adjust
– Piston Pump Neutral – Test and Adjust
– Pivot Bar
– Pivot Bar
– Power Angling Frame
– Power Angling Frame
– Power Angling Frame – Cylinder Pin
– Power Train System
– Pressure Override Valve (Winch) – Test and Adjust
– Pressure Sensor
– Pump and Lines (Implement, Hydraulic Fan)
– Pump and Lines (Implement, Hydraulic Fan)
– Pump and Lines (Implement, Hydraulic Fan)
– Pump Coupling
– Radiator Guard
– Rear Enclosure
– Recoil Spring
– Refrigerant Condenser
– Relief Valve (Charge Pressure)
– Relief Valve (Charge Pressure) (Winch)
– Relief Valve (Crossover)
– Relief Valve (Crossover) (Winch)
– Relief Valve (Main) – Test and Adjust – Line Reliefs
– Relief Valve (Pressure Override) – Winch
– Ripper
– Ripper Mounting
– Sprocket Segment
– Sprocket Segment
– Steering – Test
– Step
– Suspension Seat
– Sweep Group
– Sweep Group
– Tilt Cylinder (Bulldozer)
– Tilt Cylinder (Bulldozer)
– Track Adjuster and Recoil
– Track Adjuster and Recoil
– Track Carrier Roller
– Track Carrier Roller (SystemOne)
– Track Carrier Roller – Heavy-Duty
– Track Idler
– Track Idler – Heavy-Duty
– Track Idler – System One
– Track Links
– Track Links – Heavy-Duty
– Track Roller (Double Flange)
– Track Roller (Single Flange)
– Track Roller (Single Flange, SystemOne)
– Track Roller – Double Flange
– Track Roller – Double Flange Heavy-Duty
– Track Roller – Single Flange
– Track Roller – Single Flange Heavy-Duty
– Track Roller – Single Flange, System One
– Track Roller Frame
– Track Roller Frame
– Track Roller Guard – Heavy Duty
– Track Roller Guard – Heavy-Duty
– Track Roller Guard – System One
– Water Lines
– Winch Fairlead
– Winch Operation
– Window Wiper and Wiper Motor
– Window Wiper Motor
D6K, D6K2 and D4 Track-Type Tractor Monitoring System
– Connector Contact Description
– Data Link
– Diagnostic Operation
– Display Is Blank
– Display Menu
– Display Module
– Electrical Connector – Inspect
– Emerging Symptom Information
– General Information
– Machine Menu
– Menu Navigation
– Menus
– Module – Flash Program
– Module – Replace
– Monitoring System
– Operator Profile Menu
– Output Components
– Pop-Up Messages
– Service Menu
– Service Tools
– Symptom Troubleshooting
– System Schematic
– Totals Menu
– Warning Operation
– Wiring Harness (Open Circuit) – Test
– Wiring Harness (Short Circuit) – Test
Disassembly and Assembly C7.1 Engines
– Accessory Drive – Remove and Install – Accessory Drive SAE
– Accessory Drive – Remove and Install – Accessory Drive SAE
– Accessory Drive – Remove and Install – Accessory Drive SAE “A” –
– Air Compressor – Remove and Install – Single Cylinder Air
– Air Compressor – Remove and Install – Twin Cylinder Air
– Alternator – Install
– Alternator – Remove
– Alternator Belt – Remove and Install
– Bearing Clearance – Check
– Belt Tensioner – Remove and Install
– Boost Pressure Sensor – Remove and Install
– Camshaft – Remove and Install
– Camshaft Bearings – Remove and Install
– Camshaft Gear – Remove and Install
– Camshaft Position Sensor – Remove and Install
– Connecting Rod Bearings – Install – Connecting rods in position
– Connecting Rod Bearings – Remove – Connecting rods in
– Coolant Temperature Sensor – Remove and Install
– Crankcase Breather – Install – Filtered Breather
– Crankcase Breather – Install – Unfiltered Breather
– Crankcase Breather – Remove – Filtered Breather
– Crankcase Breather – Remove – Unfiltered Breather
– Crankshaft – Install
– Crankshaft – Remove
– Crankshaft Front Seal – Remove and Install
– Crankshaft Front Seal – Remove and Install – Crankshaft Front
– Crankshaft Gear – Remove and Install
– Crankshaft Main Bearings – Remove and Install – Crankshaft
– Crankshaft Position Sensor – Remove and Install
– Crankshaft Rear Seal – Install
– Crankshaft Rear Seal – Remove
– Crankshaft Timing Ring – Remove and Install
– Cylinder Head – Install
– Cylinder Head – Remove
– ECM Mounting Bracket – Remove and Install
– Electric Starting Motor – Remove and Install
– Electronic Control Module – Remove and Install
– Electronic Unit Injector – Install
– Electronic Unit Injector – Remove
– Engine Oil Cooler – Install – Engine Oil Cooler with a High
– Engine Oil Cooler – Install – Engine Oil Cooler with a Low
– Engine Oil Cooler – Remove – Engine Oil Cooler with a High
– Engine Oil Cooler – Remove – Engine Oil Cooler with a Low
– Engine Oil Filter Base – Remove and Install
– Engine Oil Pan – Install – Aluminum Oil Pan
– Engine Oil Pan – Remove – Aluminum Oil Pan
– Engine Oil Pressure Sensor – Remove and Install
– Engine Oil Pump – Install
– Engine Oil Pump – Remove
– Exhaust Elbow – Remove and Install
– Exhaust Manifold – Remove and Install – Side Mounted Exhaust
– Exhaust Manifold – Remove and Install – Top Mounted Exhaust
– Fan – Remove and Install
– Fan Drive – Remove and Install
– Flow Control Valve – Remove and Install
– Flywheel – Install
– Flywheel – Install – Equipped with Rear Power Take-Off
– Flywheel – Remove
– Flywheel – Remove – Equipped with Rear Power Take-Off
– Flywheel Housing – Remove and Install – Flywheel Housing that is
– Flywheel Housing – Remove and Install – Standard Housing
– Flywheel Housing – Remove and Install – Type A and Type B
– Front Cover – Remove and Install
– Front Cover – Remove and Install – Heavy Duty Front Cover
– Fuel Filter Base – Remove and Install
– Fuel Injection Lines – Install
– Fuel Injection Lines – Remove
– Fuel Injection Pump – Install
– Fuel Injection Pump – Remove
– Fuel Injection Pump Gear – Install
– Fuel Injection Pump Gear – Remove
– Fuel Manifold (Rail) – Remove and Install
– Fuel Pressure Sensor – Remove and Install
– Fuel Priming Pump – Remove and Install – Electric Fuel Lift
– Fuel Priming Pump – Remove and Install – Mechanical Priming
– Gear Group (Front) – Remove and Install
– Gear Group (Front) – Remove and Install – Heavy Duty Gear
– Glow Plugs – Remove and Install
– Housing (Front) – Install
– Housing (Front) – Install – Heavy Duty Housing (Front)
– Housing (Front) – Remove
– Housing (Front) – Remove – Heavy Duty Housing (Front)
– Idler Gear – Install
– Idler Gear – Remove
– Idler Pulley – Remove and Install – Flat Idler Pulley
– Idler Pulley – Remove and Install – Grooved Idler Pulley
– Inlet Air Temperature Sensor – Remove and Install
– Inlet and Exhaust Valve Springs – Remove and Install
– Inlet and Exhaust Valves – Remove and Install
– Inlet Manifold – Remove and Install
– Lifter Group – Remove and Install
– Piston Cooling Jets – Remove and Install
– Pistons and Connecting Rods – Assemble
– Pistons and Connecting Rods – Disassemble
– Pistons and Connecting Rods – Install
– Pistons and Connecting Rods – Remove
– Rear Power Take-Off (RPTO) – Install
– Rear Power Take-Off (RPTO) – Remove
– Refrigerant Compressor – Remove and Install
– Relief Valve (Fuel) – Remove and Install
– Rocker Shaft – Assemble
– Rocker Shaft – Disassemble
– Rocker Shaft and Pushrod – Install
– Rocker Shaft and Pushrod – Remove
– Turbocharger – Install – Turbocharger for Side Mounted
– Turbocharger – Install – Turbocharger for Top Mounted
– Turbocharger – Remove – Turbocharger for Side Mounted
– Turbocharger – Remove – Turbocharger for Top Mounted
– Valve Mechanism Cover – Remove and Install
– Valve Mechanism Cover Base – Remove and Install
– Vibration Damper and Pulley – Install
– Vibration Damper and Pulley – Remove
– Wastegate Solenoid – Remove and Install
– Water Pump – Install
– Water Pump – Remove
– Water Separator and Fuel Filter (Primary) – Remove and
– Water Temperature Regulator – Remove and Install
Disassembly and Assembly D6K2 and D4 Track-Type Tractors Engine Supplement
– Air Cleaner – Remove and Install
– Alternator – Remove and Install
– Battery – Remove and Install
– Belt Tensioner – Remove and Install
– Cooling System Package (Radiator, Aftercooler, Oil Cooler) –
– Cooling System Package (Radiator, Aftercooler, Oil Cooler) –
– Cooling System Package (Radiator, Aftercooler, Oil Cooler) –
– Crankshaft Front Seal – Remove and Install
– Crankshaft Vibration Damper and Pulley – Remove and Install
– Disconnecting Snap To Connect Fittings
– Electric Starting Motor – Remove and Install
– Electronic Control Module (ECM) – Remove and Install
– Engine – Remove and Install
– Engine Enclosure – Remove and Install
– Engine Front Support – Remove and Install
– Engine Oil Filter and Base – Remove and Install
– Fan – Remove and Install
– Hood – Remove and Install
– Muffler – Remove and Install
– Oil Cooler (Engine) – Remove and Install
– Primary Fuel Filter, Water Separator and Base – Remove and
– Radiator Tank – Remove and Install
– Refrigerant Compressor – Remove and Install
– Secondary Fuel Filter and Base – Remove and Install
– System Pressure – Release
– Turbocharger – Remove and Install
– Water Pump – Remove and Install
– Water Temperature Regulator – Remove and Install
Disassembly and Assembly D6K2 and D4 Track-Type Tractors Machine Systems
– Accumulator (Hydraulic) – Remove and Install
– Air Conditioner and Heater Components – Assemble
– Air Conditioner and Heater Components – Disassemble
– Air Conditioner and Heater Components – Remove and Install
– Bank Valve (Main Hydraulic) – Assemble
– Bank Valve (Main Hydraulic) – Assemble
– Bank Valve (Main Hydraulic) – Disassemble
– Bank Valve (Main Hydraulic) – Disassemble
– Bank Valve (Main Hydraulic) – Remove and Install
– Bottom Guard – Remove and Install
– Bulldozer Angle Cylinder (VPAT) – Remove and Install
– Bulldozer Blade (VPAT) – Remove and Install
– Bulldozer C-Frame (VPAT) – Remove and Install
– Bulldozer Lift Cylinder (VPAT) – Remove and Install
– Bulldozer Tilt Cylinder (VPAT) – Remove and Install
– Cab – Remove and Install
– Decelerator and Brake Control – Assemble
– Decelerator and Brake Control – Disassemble
– Decelerator and Brake Control – Remove and Install
– Duo-Cone Conventional Seals – Install
– Fuel Level Sender – Remove and Install
– Fuel Tank – Remove and Install
– Gear Motor (Hydraulic Fan) – Remove and Install
– Gear Pump (Fan Drive) – Remove and Install
– Hydraulic Filter – Remove and Install
– Hydraulic Tank – Assemble
– Hydraulic Tank – Disassemble
– Hydraulic Tank – Remove and Install
– Joystick Control (Bulldozer) – Remove and Install
– Joystick Control (Steering, Transmission) – Remove and Install
– Oil Filter and Base (Winch) – Remove and Install
– Piston Pump (Implement) – Assemble
– Piston Pump (Implement) – Disassemble
– Piston Pump (Implement) – Remove and Install
– Piston Pump (Winch) – Assemble
– Piston Pump (Winch) – Disassemble
– Piston Pump (Winch) – Remove and Install
– Pitch Link – Remove and Install
– Refrigerant Condenser – Remove and Install
– Refrigerant Condenser Fan and Fan Motor – Remove and
– Refrigerant Receiver-Dryer – Remove and Install
– Ripper Carriage (Beam) – Remove and Install
– Ripper Control Linkage – Remove and Install
– Ripper Frame – Remove and Install
– Ripper Lift Cylinder – Remove and Install
– Seat – Remove and Install
– Suspension Seat – Remove and Install
– System Pressure – Release
– Winch – Remove and Install
– Window Wiper and Wiper Motor (Door) – Remove and Install
– Window Wiper and Wiper Motor (Front) – Remove and Install
– Window Wiper and Wiper Motor (Rear) – Remove and Install
Disassembly and Assembly D6K2 and D4 Track-Type Tractors Power Train
– Axle – Remove and Install
– Duo-Cone Conventional Seals – Install
– Duo-Cone Conventional Seals – Install
– Equalizer Bar – Remove and Install
– Final Drive and Brake – Remove and Install
– Final Drive and Sprocket – Assemble
– Final Drive and Sprocket – Disassemble
– Idler – Remove and Install
– Piston Motor (Hydrostatic) – Assemble
– Piston Motor (Hydrostatic) – Disassemble
– Piston Motor (Hydrostatic) – Remove and Install
– Piston Pump (Hydrostatic) – Assemble
– Piston Pump (Hydrostatic) – Disassemble
– Piston Pump (Hydrostatic) – Remove and Install
– Pivot Shaft – Remove and Install
– Pump Drive Coupling – Remove and Install
– Recoil Spring – Remove and Install
– Sprocket Segment – Remove and Install
– System Pressure – Release
– Track – Connect
– Track – Connect
– Track – Separate
– Track – Separate
– Track Adjuster – Assemble
– Track Adjuster – Disassemble
– Track Adjuster – Remove and Install
– Track Brake – Assemble
– Track Brake – Disassemble
– Track Brake – Remove and Install
– Track Carrier Roller – Remove and Install
– Track Roller – Remove and Install
– Track Roller Frame – Remove and Install
Machine Security System (MSS3i) Integrated
– System Overview
– System Components
– Data Link
– General Information
– Troubleshooting
– Key – Program
– Scheduled Access – Program – Security System Bypass
– Time – Set
– Factory Password – Obtain
– Configuration
– Machine Security System – Uninstall
– Normal Operation
– Glossary of Terms
– System Schematic
– Operation of Status Indicator
– Key Information
– Scheduled Access – “Security System Bypass Times”
– Diagnostic Operation
– Protected Functions
– Service Operation Using Service Tool
– Electronic Control Module (ECM)
– General Information
Schematic Caterpillar D4 and D6K2 Track-Type Tractor Electrical System
– Features
– Cover Page
– Information
– Component Location
– Vol 1 – Cab and Chassis
– Page 1 of 2
– Page 2 of 2
– Vol 2 – Accugrade
– Connector Location
– Vol 1 – Cab and Chassis
– Page 1 of 2
– Page 2 of 2
– Vol 2 – Accugrade
– Schematics
– Function Isolation Tools
– Grids On/Off
– All Circuits Off
– All Circuits On
– Vol 1 – Cab and Chassis
– Unspecified Circuit
– Black (Ground)
– 032 (Red) (Battery Power)
– 640 (Blue) (Key Power)
– 305 (Lt Blue) (Converter 12v Out)
– 021 (Orange) (Starting)
– 190 (Dk Pink) (Start Aid)
– 258 (Dk Purple) (Transmission Control Circuit))
– 464 (Brown) (Brake/AccuGrade/CAES)
– 509 (Lt Pink) (Engine Master)
– 613 (Dk Yellow) (Heat/AC)
– 4665 (Tan) (Turn/Wiper/Washer)
– CON 509 (J1939/1587 D.L.)
– CON 032 (RS232/485 D.L.)
– CON 190 (CAN “A” D.L.)
– CON 522 (CAN “B” D.L.)
– CON 141 (CAN “C” D.L.)
– CON 464 (Winch Control Circuit)
– CON 5767 (Olive Green) (DEF)
– SUB 651 (Blue Gray) (Ethernet)
– Vol 2 – Accugrade
– Unspecified Circuit
– Black (Ground)
– 032 (Red) (Battery Power)
– 640 (Blue) (Key Power)
– 464 (Brown) (Brake/AccuGrade/CAES)
– CON 509 (J1939/1587 D.L.)
– CON 032 (RS232/485 D.L.)
– CON 190 (CAN “A” D.L.)
– CON 522 (CAN “B” D.L.)
– CON 141 (CAN “C” D.L.)
– CON 305 (CAN “D” D.L.)
– SUB 500 (Med Pink) (Rear Engine)
– SUB 651 (Blue Gray) (Ethernet)
– Machine Views
– Vol 1 – Cab and Chassis
– Cab Bottom and Headliner
– Cab Right Side View and Battery Compartment
– Chassis
– Dashboard Rear and Fuse Block
– Engine Left Side View
– Engine Right Side View
– Engine Top View and Blade View
– HVAC
– Right Side Console and Dashboard View
– Vol 2 – Accugrade
– Cab View
– Dashboard
– Radiator View
Schematic Caterpillar D4 and D6K2 Track-Type Tractor Hydraulic System
– Features
– Cover Page
– Information
– Component Location
– Tap Location
– Schematic
– Function Isolation Tools
– Grids On/Off
– All Circuits Off
– All Circuits On
– 640 (Blue) Winch Pump Control Circuit)
– CON 464 (Brown/Gray Stripe) (Winch Brake Control Circuit)
– 021 (Orange) (Pilot Pump Output)
– 032 (Red)
– 141 (Lt Orange)
– 190 (Dk Pink)
– 258 (Dk Purple)
– 305 (Lt Blue)
– 347 (Dk Green)
– 430 (Dk Gray)
– 464 (Brown)
– 500 (Med Pink)
– 522 (Lt Purple)
– 577 (Lt Green)
– 613 (Dk Yellow)
– Machine Views
– Machine View – Front
– Machine View – Right and Left
– Radiator Group
– Ripper
– Winch Ar
Schematic Caterpillar D6K Track-Type Tractor Electrical System
– Features
– Cover Page
– Information
– Component Location
– Vol 1 – Machine Wiring
– Page 1 of 2
– Page 2 of 2
– Vol 2 – Accugrade
– Connector Location
– Vol 1 – Machine Wiring
– Vol 2 – Accugrade
– Schematics
– Function Isolation Tools
– Grids On/Off
– All Circuits Off
– All Circuits On
– Vol 1 – Machine Wiring
– Unspecified Circuit
– Black (Ground)
– 032 (Red) (Battery Power)
– 640 (Blue) (Key Power)
– 305 (Lt Blue) (Converter 12v Out)
– 021 (Orange) (Starting)
– 190 (Dk Pink) (Start Aid)
– 258 (Dk Purple) (Machine Control Circuit)
– 509 (Lt Pink) (Engine Master)
– 613 (Dk Yellow) (Heat/AC)
– 4665 (Tan) (Turn/Wiper/Washer)
– SUB 141 (Lt Orange) (Winch Control Circuit)
– CON 190 (CAN “A” D.L.)
– CON 522 (CAN “B” D.L.)
– SUB 651 (Blue Gray) (Ethernet)
– Vol 2 – Accugrade
– Unspecified Circuit
– Black (Ground)
– 032 (Red) (Battery Power)
– 640 (Blue) (Key Power)
– 258 (Dk Purple) (Machine Control Circuit)
– 464 (Brown) (Accugrade Circuit)
– CON 032 (RS232/485 D.L.)
– CON 190 (CAN “A” D.L.)
– CON 522 (CAN “B” D.L.)
– CON 141 (CAN “C” D.L.)
– CON 305 (CAN “D” D.L.)
– SUB 651 (Blue Gray) (Ethernet)
– Machine Views
– Vol 1 – Machine Wiring
– Blade View
– Cab -Bottom View
– Cab – Front View
– Cab – Monitor (Rear View)
– Chassis
– Engine
– Winch
– Vol 2 – Accugrade
– Accugrade
– Cab Side View
– Chassis Side View
– Headliner
Schematic Caterpillar D6K Track-Type Tractor Hydraulic System
– Features
– Cover Page
– Information
– Component Location
– Tap Location
– Schematic
– Function Isolation Tools
– Grids On/Off
– All Circuits Off
– All Circuits On
– 021 (Orange) (Pilot Pump Output)
– 032 (Red) (Implement Pump Output)
– 190 (Dk Pink) (Winch Circuit)
– 258 (Dk Purple) (Power Pitch Circuit)
– 305 (Lt Blue) (Steering Motor Circuit)
– 347 (Dk Green) (Supply Line)
– 464 (Brown) (Brake Circuit)
– 500 (Med Pink) (Tilt Cylinder Circuit)
– 522 (Lt Purple) (Lift Cylinder Circuit)
– 577 (Lt Green) (Drain / Return Line)
– 640 (Blue) (Winch Pump Circuit)
– 5655 (Lt Gray) (Angle Cylinder Circuit)
– 5767 (Olive Green) (Ripper Cylinder Circuit)
– CON 500 (Med Pink/Black Stripe) (Brake Control Circuit (Winch))
– Machine Views
– Hydraulic Tank and Pump Circuit
– Machine Component Locations
– Radiator
– Winch Arrangement
Specifications C7.1 Engines for Caterpillar Built Machines
– Alternator
– Belt Tensioner
– Boost Pressure Sensor
– Camshaft
– Camshaft Bearings
– Connecting Rod
– Connecting Rod Bearing Journal
– Coolant Temperature Sensor
– Crankcase Breather
– Crankshaft
– Crankshaft Seals
– Cylinder Block
– Cylinder Head
– Cylinder Head Valves
– Electronic Control Module
– Engine Design
– Engine Lifting Bracket
– Engine Oil Cooler
– Engine Oil Filter Base
– Engine Oil Pan
– Engine Oil Pressure
– Engine Oil Pressure Sensor
– Engine Oil Pump
– Exhaust Manifold
– Fan Drive
– Flywheel
– Flywheel Housing
– Front Housing and Covers
– Fuel Filter Base – Twin Secondary Fuel Filter Base
– Fuel Injection Lines
– Fuel Injection Nozzles
– Fuel Injection Pump
– Fuel Manifold (Rail)
– Fuel Priming Pump – Electric Fuel Priming Pump
– Gear Group (Front)
– Glow Plugs
– Inlet Manifold
– Inlet Manifold Temperature Sensor
– Lifter Group
– Main Bearing Journal
– Piston and Rings
– Piston Cooling Jet
– Refrigerant Compressor
– Rocker Shaft
– Speed/Timing Sensor
– Starter Motor
– Turbocharger
– Valve Mechanism Cover
– Vibration Damper and Pulley
– Water Pump
– Water Temperature Regulator and Housing
Systems Operation & Testing and Adjusting C7.1 Engines for Caterpillar Built Machines
– Air in Fuel – Test
– Air Inlet and Exhaust System
– Air Inlet and Exhaust System – Inspect
– Alternator – Test
– Basic Engine
– Battery – Test
– Charging System – Test
– Cleanliness of Fuel System Components
– Compression – Test
– Connecting Rod – Inspect
– Cooling System
– Cooling System – Check
– Cooling System – Inspect
– Cooling System – Test
– Cylinder Block – Inspect
– Cylinder Head – Inspect
– Electric Starting System – Test
– Electrical System
– Electronic Control System
– Engine Oil Cooler – Inspect
– Engine Oil Pressure – Test
– Engine Oil Pump – Inspect
– Engine Valve Lash – Inspect/Adjust
– Excessive Bearing Wear – Inspect
– Excessive Engine Oil Consumption – Inspect
– Finding Top Center Position for No. 1 Piston
– Flywheel – Inspect
– Flywheel Housing – Inspect
– Fuel Injection
– Fuel Injection – Engines with a Primary and Secondary Fuel
– Fuel Injection Timing – Check
– Fuel Quality – Test
– Fuel System – Inspect
– Fuel System – Prime
– Gear Group (Front) – Time
– Gear Group – Inspect
– Glossary of Electronic Control Terms
– Increased Engine Oil Temperature – Inspect
– Introduction
– Lubrication System
– Piston Height – Inspect
– Piston Ring Groove – Inspect
– Power Sources
– Turbocharger – Inspect
– V-Belt – Test
– Valve Depth – Inspect
– Valve Guide – Inspect
– Vibration Damper – Check
– Water Pump – Inspect
– Water Temperature Regulator – Test
Troubleshooting C4.4 and C7.1 Engines
– Welding Precaution
– Diagnostic Trouble Codes
– Customer Passwords
– Factory Passwords
– ECM Will Not Accept Factory Passwords
– Electronic Service Tool Does Not Communicate
– Test ECM Mode
– ECM Software – Install
– ECM – Replace
– Electrical Connectors – Inspect
– Cooling Fan – Calibrate – If Applicable
– Event Codes
– Acceleration Is Poor or Throttle Response Is Poor
– Alternator Problem – Charging Problem and/or Noisy
– Battery Problem
– Belt Tensioner Noise
– Coolant Contains Oil
– Coolant Level Is Low
– Coolant Temperature Is High
– Coolant Temperature Is Low
– Electronic Service Tools
– Cylinder Is Noisy
– Engine Cranks but Does Not Start
– Engine Does Not Crank
– Engine Has Early Wear
– Engine Has Mechanical Noise (Knock)
– Engine Misfires, Runs Rough or Is Unstable
– Engine Overcrank Occurrence
– Engine Overspeeds
– Engine Shutdown Occurrence
– Engine Shutdown Occurs Intermittently
– Service Information Report
– Engine Stalls at Low RPM
– Engine Top Speed Is Not Obtained
– Engine Vibration Is Excessive
– Exhaust Has Excessive Black Smoke
– Exhaust Has Excessive White Smoke
– Exhaust Has Excessive White Smoke
– Exhaust System Contains Coolant
– Exhaust System Contains Oil
– Fuel Consumption Is Excessive
– Fuel Contains Water
– System Overview
– Fuel Filter Is Restricted
– Fuel Pressure Is Low
– Fuel Pressure Problem
– Fuel Rail Pressure Problem
– Inlet Air Is Restricted
– Intake Manifold Air Pressure Is High
– Intake Manifold Air Pressure Is Low
– Intake Manifold Air Temperature Is High
– Oil Consumption Is Excessive
– Oil Contains Coolant
– Component Location
– Oil Contains Fuel
– Oil Pressure Is Low
– Oil Pressure Is Low
– Power Is Intermittently Low or Power Cutout Is Intermittent
– Valve Lash Is Excessive
– CAN Data Link – Test
– CAN Data Link – Test
– Cooling Fan Control – Test – Hydraulic Driven Fan
– Cooling Fan Control – Test
– Cooling Fan Reversing – Test
– Engine Monitoring System
– Data Link – Test
– Data Link – Test
– Data Link Configuration Status – Test
– Electrical Power Supply – Test
– Electrical Power Supply – Test
– Ether Starting Aid – Test
– Glow Plug Starting Aid – Test
– Glow Plug Starting Aid – Test
– Idle Validation – Test
– Idle Validation – Test
– Diagnostic Capabilities
– Injector Solenoid – Test
– Injector Solenoid – Test
– Mode Selection – Test
– Mode Selection – Test
– Power Take-Off – Test
– Relay – Test – Start Relay
– Relay – Test – Electric Fuel Lift Pump Relay
– Relay – Test – ECM Power Relay
– Relay – Test – ECM Power Relay
– Sensor Calibration Required – Test
– Electrical Connectors
– Sensor Signal (Analog, Active) – Test
– Sensor Signal (Analog, Active) – Test
– Sensor Signal (Analog, Passive) – Test
– Sensor Signal (Analog, Passive) – Test
– Sensor Supply – Test
– Sensor Supply – Test
– Shutdown – Test
– Solenoid Valve – Test
– Solenoid Valve – Test
– Speed Control – Test – Analog
– Configuration Parameters
– Speed Control – Test – Analog
– Speed Control – Test – PWM
– Speed/Timing – Test
– Speed/Timing – Test
– Switch Circuits – Test – Multiposition Throttle Switch
– Switch Circuits – Test
– Throttle Lock – Test
– Water in Fuel – Test
– Service Tool Features
– Service Tool Error Identifiers
– General Information