Service manual Caterpillar D6K2 TRACK-TYPE TRACTOR LGP, XL with C6.6 Engine | WMR00001-UP

Air Conditioning and Heating R134a for All Caterpillar Machines
– Refrigerant Compressor
– System Capacities for Refrigerant (Off-Highway Trucks)
– General Information
– Identifying the Refrigerant
– Identifying the Air Conditioning System
– Identifying the Heating System
– Refrigerant Expansion Valve System
– Refrigerant Orifice Tube System
– Refrigerant Compressor
– Refrigerant Condenser
– Refrigerant Receiver-Dryer
– Refrigerant Compressor
– Refrigerant Expansion Valve
– In-line Refrigerant Dryer
– Refrigerant Orifice Tube Assembly
– Evaporator Coil
– Refrigerant Accumulator
– Refrigerant Compressor Protection System
– Temperature Control
– Pressure Switch (Refrigerant)
– Cab Pressurization and Filtration System
– Condensate Drainage System
– Refrigerant Compressor
– Service Intervals
– Glossary of Terms
– Required Tools
– Machine Preparation for Troubleshooting
– General Troubleshooting Information
– General Troubleshooting Information
– Visual Inspection (Troubleshooting)
– Air Conditioning System Troubleshooting
– Heating System Troubleshooting
– Automatic Temperature Control System (ECM Controlled)
– Refrigerant Compressor
– Troubleshooting Heating and Air Conditioning Control System
– Troubleshooting Heating and Air Conditioning Control System
– Automatic Temperature Control Panel Troubleshooting – 584
– Troubleshooting Condensate Drainage System
– Machine Preparation for Testing and Adjusting
– Air Conditioning Performance – Test
– Refrigerant Leakage – Test
– Manifold Gauge Set (Refrigerant) – Install
– Refrigerant Recovery
– Refrigerant System – Flush
– Refrigerant Compressor
– Refrigerant Oil – Test
– Refrigerant Compressor – Test
– Refrigerant System – Evacuate
– Refrigerant System – Charge
– Manifold Gauge Set (Refrigerant) – Remove
– Compressor Protection System – Test
– Electronic Heat Control – Test
– Heater Performance – Test
– Heating and Air Conditioning Service Publications
– General Information
– Refrigerant Compressor
– Machine Preparation for Disassembly and Assembly
– 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 Compressor
– System Capacities for Refrigerant (Motor Graders)
– System Capacities for Refrigerant (Off-Highway Trucks) –
– Refrigerant Compressor
D6K2 Track-Type Tractor Monitoring System
– Connector Contact Description
– Data Link
– Display Module
– Electrical Connector – Inspect
– General Information
– Menu Navigation
– Menus (Compact Instrument Cluster)
– Module – Replace
– Monitoring System
– Output Components
– Self Test
– System Schematic
– Warning Operation
– Wiring Harness (Open Circuit) – Test
– Wiring Harness (Short Circuit) – Test
D6K2 Track-Type Tractor Systems
– Accumulator (Hydraulic)
– Accumulator (Pilot) – Test and Charge
– Additional Electrical Components
– Air Cleaner
– Air Cleaner
– Air Cleaner
– Air Conditioner
– Air Conditioner Lines
– Air Conditioner Lines
– Angle and Tilt Lines
– Angle Cylinder (Bulldozer)
– Angling Blade
– Angling Blade
– Angling Blade
– Angling Blade
– Bank Valve (Four)
– Bank Valve (Three)
– Brake System
– Bulldozer Angle Hydraulic System
– Bulldozer Lift Hydraulic System
– Bulldozer Tilt Hydraulic System
– Calibration
– Charge Relief Valve (Winch) – Test and Adjust
– Charge Relief Valve – Test and Adjust
– Configuration Parameters
– Control Manifold (Automatic Reversing Fan)
– Control Manifold (Hydraulic Fan)
– Counterweight
– Cover (Cab)
– 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
– Drawbar
– Electronic Control (HVAC System)
– Electronic Control (Hydraulic System)
– Electronic Control (Power Train System)
– Electronic Control (Winch System)
– Equalizer Bar
– Ether Starting Aid
– Exhaust Pipe
– 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 Hydrostatic Speed – Test
– Flexible Exhaust Pipe
– Flushing Valve
– Fuel Tank
– Gear Motor (Hydraulic Fan)
– Gear Pump (Hydraulic Fan)
– General Information (HVAC System)
– General Information (Hydraulic System)
– General Information (Power Train System)
– General Information (Undercarriage)
– General Information (Winch System)
– Grade Control
– Graphic Color Codes
– Handle Control (Ripper)
– Heater Lines
– HVAC System
– Hydraulic Block
– Hydraulic Fan Drive Lines
– Hydraulic Fan Drive Lines
– Hydraulic Pump – Test and Adjust
– Hydraulic Tank
– Hydraulic Tank and Mounting
– Joystick Control (Bulldozer)
– Lift Cylinder (Bulldozer)
– Lift Cylinder (Ripper)
– Lift Cylinder (Ripper)
– Line Relief and Makeup Valve
– Lines (Charge Pressure)
– Location of Components (HVAC System)
– Location of Components (Hydraulic System)
– Location of Components (Power Train System)
– Location of Components (Undercarriage)
– Location of Components (Winch System)
– Machine Preparation
– Motor Control Valve (Hydrostatic) (Displacement)
– Muffler
– Oil Cooler Core (Power Train)
– Oil Filter (Hydraulic)
– Operational Checks
– Operator Console
– Pilot Lines
– Piston Motor (Hydrostatic)
– Piston Motor (Hydrostatic)
– Piston Motor (Winch)
– Piston Pump (Hydrostatic)
– Piston Pump (Hydrostatic)
– Piston Pump (Implement)
– Piston Pump (Implement)
– Piston Pump (Winch)
– 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 – Cylinder Pin
– Power Train System
– Pressure Override Valve (Winch) – Test and Adjust
– Proportional Priority Pressure Compensation System
– Proportional Priority Pressure Compensation System – Test
– Pump and Lines (Implement, Hydraulic Fan)
– Pump Coupling
– Recoil Spring
– Refrigerant Compressor
– Refrigerant Condenser
– Relief Valve (Charge Pressure)
– Relief Valve (Charge Pressure) (Winch)
– Relief Valve (Crossover)
– Relief Valve (Crossover) (Winch)
– Relief Valve (Line) – Test and Adjust
– Relief Valve (Pressure Override) – Winch
– Ripper
– Ripper Mounting
– Ripper/Fourth Function Hydraulic System
– Solenoid Valve (Pilot On/Off)
– Sprocket Segment
– Sprocket Segment
– Steering – Test
– Suspension Seat
– Sweep Group
– Sweep Group
– Tilt Cylinder (Bulldozer)
– Track Carrier Roller
– Track Carrier Roller (SystemOne)
– Track Carrier Roller – Heavy-Duty
– Track Guide Guard
– Track Idler – Heavy-Duty
– Track Idler – System One
– Track Links – Heavy-Duty
– Track Links – System One
– Track Roller (Double Flange)
– Track Roller (Single Flange)
– Track Roller (Single Flange, SystemOne)
– Track Roller – Double Flange Heavy-Duty
– Track Roller – Single Flange Heavy-Duty
– Track Roller – Single Flange, System One
– Track Roller Frame – Heavy Duty
– Track Roller Frame – Heavy Duty
– Track Roller Frame – Heavy Duty
– Track Roller Frame – Heavy Duty
– Track Roller Frame – System One
– Track Roller Frame – System One
– Track Roller Frame Guard
– Track Roller Guard – Heavy Duty
– Track Roller Guard – Heavy Duty
– Track Roller Guard – Heavy Duty
– Track Roller Guard – Heavy-Duty
– Track Roller Guard – System One
– Water Lines
– Water Lines
– Winch Fairlead
– Winch Operation
– Window Wiper and Wiper Motor
– Window Wiper Motor
– Window Wiper Motor
Disassembly and Assembly C7.1 Engines for Caterpillar Built Machines
– Accessory Drive – Remove and Install – Accessory Drive SAE
– Accessory Drive – Remove and Install – Accessory Drive SAE
– Air Compressor – Remove and Install – Single Cylinder
– Air Compressor – Remove and Install – Twin Cylinder
– Air Control Valve – Remove and Install – Clean Emissions
– Alternator – Install
– Alternator – Remove
– Alternator Belt – Remove and Install
– ARD Spark Plug – Remove and Install
– Atmospheric Pressure Sensor – 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
– Catalyst – Remove and Install – Diesel Oxidation Catalyst
– Combustion Head – Remove and Install – Pilot Only System
– Connecting Rod Bearings – Install – Connecting rods in position
– Connecting Rod Bearings – Remove – Connecting rods in
– Coolant Temperature Sensor – Remove and Install
– Crankcase Breather – Install
– Crankcase Breather – Remove
– Crankshaft – Install
– Crankshaft – Remove
– Crankshaft Front Seal – Remove and Install
– 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
– Diesel Particulate Filter – Assemble
– Diesel Particulate Filter – Disassemble
– Diesel Particulate Filter – Install
– Diesel Particulate Filter – Remove
– ECM Mounting Bracket – Remove and Install
– Electric Starting Motor – Remove and Install
– Electronic Control Module – Remove and Install – Electronic
– Electronic Control Module – Remove and Install – Electronic
– 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 Filter Base – Remove and Install – Engine Oil Filter
– Engine Oil Pan – Install – Aluminum Oil Pan
– Engine Oil Pan – Remove – Aluminum Oil Pan
– Engine Oil Pan Plate – Remove and Install – Aluminum Oil Pan
– Engine Oil Pressure Sensor – Remove and Install
– Engine Oil Pump – Install
– Engine Oil Pump – Remove
– Exhaust Cooler (NRS) – Remove and Install
– Exhaust Gas Valve (NRS) – Remove and Install
– Exhaust Manifold – Remove and Install
– Fan – Remove and Install
– Fan Drive – Remove and Install
– Flame Detection Temperature Sensor – Remove and Install –
– Flexible Exhaust Pipe – 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 – Remove and Install
– Flywheel Housing – Remove and Install
– Flywheel Housing – Remove and Install
– Flywheel Housing – Remove and Install
– Flywheel Housing – Remove and Install – Flywheel Housing that is
– Flywheel Housing – Remove and Install – Standard Housing
– Front Cover – Remove and Install
– Front Cover – Remove and Install – Heavy Duty Front Cover
– Fuel Filter Base – Remove and Install – Single Secondary Fuel
– Fuel Filter Base – Remove and Install – Twin Secondary Fuel
– 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 (ARD) – Remove and Install – Pilot Solenoid
– Fuel Manifold (Rail) – Remove and Install
– Fuel Pressure Sensor – Remove and Install
– Fuel Priming Pump – Remove and Install – Electric Fuel Lift
– Fuel Pump (ARD) – Remove and Install
– Fuel Temperature Sensor – Remove and Install
– 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
– Ignition Coil (ARD) – Remove and Install – Clean Emissions
– Inlet Air Control – Install – NRS Inlet Air Mixer
– Inlet Air Control – Remove – NRS Inlet Air Mixer
– Inlet and Exhaust Valve Springs – Remove and Install
– Inlet and Exhaust Valves – Remove and Install
– Inlet Manifold Temperature Sensor – Remove and Install
– Lifter Group – Remove and Install – Hydraulic Lifter Group
– Nozzle Heater Harness – Remove and Install – Heated Nozzle
– 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
– Pressure Sensor (Cooled Exhaust Gas) – Remove and Install –
– Pressure Sensor (DPF) – Remove and Install – Clean Emissions
– Rear Power Take-Off (RPTO) – Install
– Rear Power Take-Off (RPTO) – Remove
– Refrigerant Compressor – Remove and Install
– Relay (ARD Nozzle Heater) – Remove and Install – Clean
– Relief Valve (Fuel) – Remove and Install
– Rocker Shaft – Assemble
– Rocker Shaft – Disassemble
– Rocker Shaft and Pushrod – Install
– Rocker Shaft and Pushrod – Remove
– Soot Antenna – Remove and Install
– Temperature Sensor (Cooled Exhaust Gas) – Remove and
– Temperature Sensor (DPF) – Remove and Install – Temperature
– Throttle Valve (Intake Air) – Install
– Throttle Valve (Intake Air) – Remove
– Turbocharger – Install – First Stage Turbocharger
– Turbocharger – Install – First Stage Turbocharger
– Turbocharger – Install – Second Stage Turbocharger
– Turbocharger – Install – Second Stage Turbocharger
– Turbocharger – Remove – First Stage Turbocharger
– Turbocharger – Remove – Second Stage Turbocharger
– Valve Mechanism Cover – 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 Caterpillar C6.6 Engines for Built Machines
– Flow Control Valve – Remove and Install
– Inlet Air Control – Remove – NRS Inlet Air Mixer
– Coolant Temperature Sensor – Remove and Install
– Engine Oil Pressure Sensor – Remove and Install
– Fuel Pressure Sensor – Remove and Install
– Fuel Temperature Sensor – Remove and Install
– Soot Antenna – Remove and Install
– Temperature Sensor (DPF) – Remove and Install
– Pressure Sensor (DPF) – Remove and Install – Clean Emissions
– Temperature Sensor (Cooled Exhaust Gas) – Remove and
– Pressure Sensor (Cooled Exhaust Gas) – Remove and Install –
– Boost Pressure Sensor – Remove and Install
– Inlet Air Control – Install – NRS Inlet Air Mixer
– Inlet Manifold Temperature Sensor – Remove and Install
– Glow Plugs – Remove and Install
– Alternator Belt – Remove and Install
– Idler Pulley – Remove and Install – Grooved Idler Pulley
– Idler Pulley – Remove and Install – Flat Idler Pulley
– Belt Tensioner – Remove and Install
– Fan – Remove and Install
– Fan Drive – Remove and Install
– Electronic Control Module – Remove and Install – Electronic
– Electronic Control Module – Remove and Install – Electronic
– Fuel Injection Pump – Remove
– Electronic Control Module – Remove and Install – Electronic
– ECM Mounting Bracket – Remove and Install
– Alternator – Remove
– Alternator – Install
– Alternator – Install
– Alternator – Install
– Electric Starting Motor – Remove and Install
– Air Compressor – Remove and Install – Twin Cylinder
– Air Compressor – Remove and Install – Single Cylinder
– Fuel Injection Pump – Install
– Fuel Injection Pump Gear – Remove
– Fuel Injection Pump Gear – Install
– Electronic Unit Injector – Remove
– Electronic Unit Injector – Install
– Wastegate Solenoid – Remove and Install
– Exhaust Back Pressure Valve – Remove and Install
– Fuel Filter Base – Remove and Install – Single Secondary Fuel
– Exhaust Gas Valve (NRS) – Remove and Install
– Flexible Exhaust Pipe – Remove and Install
– Exhaust Manifold and Turbocharger – Remove
– Exhaust Manifold and Turbocharger – Install
– Exhaust Elbow – Remove and Install
– Diesel Particulate Filter – Remove
– Diesel Particulate Filter – Install
– Inlet and Exhaust Valve Springs – Remove and Install
– Inlet and Exhaust Valves – Remove and Install
– Engine Oil Filter Base – Remove and Install
– Fuel Filter Base – Remove and Install – Twin Secondary Fuel
– Engine Oil Filter Base – Remove and Install – Engine Oil Filter
– Engine Oil Cooler – Remove – Engine Oil Cooler with a Low
– Engine Oil Cooler – Remove – Engine Oil Cooler with a High
– Engine Oil Cooler – Install – Engine Oil Cooler with a Low
– Engine Oil Cooler – Install – Engine Oil Cooler with a High
– Engine Oil Pump – Remove
– Engine Oil Pump – Install
– Water Pump – Remove
– Water Pump – Install
– Water Temperature Regulator – Remove and Install
– Water Separator and Fuel Filter (Primary) – Remove and
– Flywheel – Remove
– Flywheel – Remove – Equipped with Rear Power Take-Off
– Flywheel – Install
– Flywheel – Install – Equipped with Rear Power Take-Off
– Crankshaft Rear Seal – Remove
– Crankshaft Rear Seal – Install
– Flywheel Housing – Remove and Install – Standard Housing
– Flywheel Housing – Remove and Install – Wet Back End
– Vibration Damper and Pulley – Remove
– Vibration Damper and Pulley – Install
– Fuel Manifold (Rail) – Remove and Install
– Crankshaft Front Seal – Remove and Install
– Crankshaft Front Seal – Remove and Install – Crankshaft Front
– Front Cover – Remove and Install
– Front Cover – Remove and Install – Heavy Duty Front Cover
– Gear Group (Front) – Remove and Install
– Gear Group (Front) – Remove and Install
– Gear Group (Front) – Remove and Install – Heavy Duty Gear
– Gear Group (Front) – Remove and Install – Heavy Duty Gear
– Idler Gear – Remove
– Idler Gear – Install
– Fuel Injection Lines – Remove
– Housing (Front) – Remove
– Housing (Front) – Remove – Heavy Duty Housing (Front)
– Housing (Front) – Install – Heavy Duty Housing (Front)
– Housing (Front) – Install
– Accessory Drive – Remove and Install – Accessory Drive SAE
– Accessory Drive – Remove and Install – Accessory Drive SAE
– Crankcase Breather – Remove
– Crankcase Breather – Install
– Valve Mechanism Cover – Remove and Install
– Rocker Shaft and Pushrod – Remove
– Fuel Injection Lines – Install
– Rocker Shaft – Disassemble
– Rocker Shaft – Assemble
– Rocker Shaft and Pushrod – Install
– Cylinder Head – Remove
– Cylinder Head – Install
– Lifter Group – Remove and Install – Hydraulic Lifter Group
– Camshaft – Remove and Install
– Camshaft Gear – Remove and Install
– Camshaft Gear – Remove and Install
– Camshaft Bearings – Remove and Install
– Exhaust Cooler (NRS) – Remove
– Engine Oil Pan – Remove – Aluminum Oil Pan
– Engine Oil Pan – Install – Aluminum Oil Pan
– Engine Oil Pan Plate – Remove and Install – Aluminum Oil Pan
– Piston Cooling Jets – Remove and Install
– Pistons and Connecting Rods – Remove
– Pistons and Connecting Rods – Disassemble
– Pistons and Connecting Rods – Assemble
– Pistons and Connecting Rods – Install
– Connecting Rod Bearings – Remove – Connecting Rods in
– Connecting Rod Bearings – Install – Connecting Rods in
– Exhaust Cooler (NRS) – Install
– Crankshaft Main Bearings – Remove and Install – Crankshaft
– Crankshaft – Remove
– Crankshaft – Install
– Crankshaft Timing Ring – Remove and Install
– Crankshaft Gear – Remove and Install
– Bearing Clearance – Check
– Refrigerant Compressor – Remove and Install
– Atmospheric Pressure Sensor – Remove and Install
– Camshaft Position Sensor – Remove and Install
– Crankshaft Position Sensor – Remove and Install
– Fuel Priming Pump – Remove and Install – Electric Fuel Lift
Disassembly and Assembly D6K2 Track-Type Tractor Engine Supplement
– Air Cleaner – Remove and Install
– Alternator – Remove and Install
– Belt Tensioner – Remove and Install
– Belt Tensioner – Remove and Install
– Cooling System Package (Radiator, Aftercooler, Hydraulic Oil
– Crankshaft Front Seal – Remove and Install
– Crankshaft Front Seal – Remove and Install
– Crankshaft Front Seal – Remove and Install – Crankshaft Front
– Crankshaft Vibration Damper and Pulley – Remove and Install
– Diesel Particulate Filter – Remove and Install
– Disconnecting Snap To Connect Fittings
– Electric Starting Motor – Remove and Install
– Electric Starting Motor – 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
– Fan – Remove and Install
– Fumes Disposal Filter – Remove and Install
– Hood – 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
– Refrigerant Compressor – Remove and Install
– Secondary Fuel Filter and Base – Remove and Install
– Soot Sensor – Remove and Install
– System Pressure – Release
– Temperature Sensor (DPF) – Remove and Install
– Temperature Sensor (DPF) – Remove and Install
– Water Pump – Remove and Install
– Water Temperature Regulator – Remove and Install
– Water Temperature Regulator – Remove and Install
Disassembly and Assembly D6K2 Track-Type Tractor Machine Systems
– Accumulator (Hydraulic)
– Air Conditioner
– Air Conditioner Lines
– Angle and Tilt Lines
– Angle Cylinder (Bulldozer)
– Angling Blade
– Bank Valve (Four)
– Bank Valve (Three)
– Bottom Guard
– Cab
– Communication Electronic Control Module (Product Link)
– Control Manifold (Automatic Reversing Fan)
– Control Manifold (Hydraulic Fan)
– Cutting Edges and End Bits
– Decelerator and Brake Control
– Disconnecting Snap To Connect Fittings
– Drawbar
– Electronic Control Module (Machine)
– Electronic Control Module (Ripper System)
– Fan – Refrigerant Condenser
– Fuel Tank
– Gear Motor (Hydraulic Fan)
– Gear Pump (Hydraulic Fan)
– Handle Control (Ripper)
– Heater Lines
– Hydraulic Fan Drive Lines
– Hydraulic Tank
– Joystick Control (Bulldozer)
– Joystick Control (Steering and Transmission)
– Lift Cylinder (Bulldozer)
– Lift Cylinder (Ripper)
– Oil Filter (Hydraulic)
– Piston Motor (Winch)
– Piston Pump (Implement)
– Piston Pump (Winch)
– Pitch Link
– Power Angling Frame
– Refrigerant Accumulator
– Refrigerant Condenser
– Ripper
– Ripper Carriage (Beam)
– Ripper Control Linkage
– Ripper Frame
– Ripper Mounting
– Seat
– Suspension Seat
– Sweep Group
– System Pressure – Release
– Tilt Cylinder (Bulldozer)
– Winch
– Window Wiper and Wiper Motor (Door)
– Window Wiper and Wiper Motor (Front, Rear)
Disassembly and Assembly D6K2 Track-Type Tractor Power Train
– Control Manifold (Steering and Brake)
– Duo-Cone Conventional Seals
– Equalizer Bar
– Final Drive
– Piston Motor (Hydrostatic)
– Piston Pump (Hydrostatic)
– Pivot Shaft
– Pump Coupling
– Recoil Spring
– Sprocket Segment
– System Pressure – Release
– Track
– Track Adjuster
– Track Brake
– Track Carrier Roller
– Track Carrier Roller (SystemOne)
– Track Guide Guard
– Track Idler
– Track Links
– Track Roller
– Track Roller Frame
– Track Roller Guard
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 D6K2 Track-Type Tractor Electrical System
– Feature
– Cover Page
– Information
– Component Location
– Engine and Chassis
– Cab and Accugrade Wiring
– Connector Location
– Engine and Chassis
– Cab and Accugrade Wiring
– Schematics
– Engine and Chassis
– Cab and Accugrade Wiring
– Machine Views
– Engine and Chassis
– CEM Assembly Wiring
– Chassis and Implement Wiring
– Engine Wiring (Left View)
– Engine Wiring (Right View)
– Engine Wiring (Top View)
– Forward Horn Wiring
– Power Train Wiring
– Stable Blade Control Wiring
– Winch Motor Wiring (Rear View)
– Winch Pump and Filter Wiring
– Cab and Accugrade Wiring
– Accugrade and Product Link Wiring
– Cab Dash Wiring
– Cab Headliner Wiring
– Front Cab Wiper Wiring
– Left Console (Left Side View)
– Operator Control POD Wiring
– RH Console Wiring
Schematic Caterpillar D6K2 Track-Type Tractor Hydraulic System
– Features
– Cover Page
– Information
– Component Location
– Page 1 of 2
– Page 2 of 2
– Tap Location
– Fluid Power Symbols
– Electrical Symbols
– Schematic
– Machine Views
– Additional Chassis View
– Chassis View
– Implement Valve
– Rear Compartment on Left Fender
– Right Fender Compartment
– Winch and Ripper
– Winch Pump
Specifications C6.6 Engines For Caterpillar Built Machines
– Fuel Injection Lines
– Rocker Shaft
– Valve Mechanism Cover
– Cylinder Head Valves
– Cylinder Head
– Turbocharger
– Exhaust Gas Valve (NRS)
– Exhaust Sensor and Lines (NRS)
– Exhaust Cooler (NRS)
– Exhaust Manifold
– Flexible Exhaust Pipe
– Fuel Injection Pump
– Diesel Particulate Filter
– Camshaft
– Camshaft Bearings
– Engine Oil Filter Base
– Engine Oil Cooler
– Engine Oil Pump
– Engine Oil Pressure
– Engine Oil Pan
– Crankcase Breather
– Water Temperature Regulator and Housing
– Fuel Injection Nozzles
– Water Pump
– Cylinder Block
– Crankshaft
– Crankshaft Seals
– Vibration Damper and Pulley
– Connecting Rod Bearing Journal
– Main Bearing Journal
– Connecting Rod
– Piston and Rings
– Piston Cooling Jet
– Fuel Transfer Pump – Electric Transfer Pump
– Accessory Drive
– Accessory Drive – SAE “B”
– Front Housing and Covers
– Gear Group (Front)
– Flywheel
– Flywheel Housing – Flywheel Housing that is Equipped with
– Flywheel Housing
– Belt Tensioner
– Refrigerant Compressor
– Fan Drive
– Fuel Filter Base – Primary Fuel Filter Base
– Engine Lifting Bracket
– Alternator
– Alternator
– Starter Motor
– Coolant Temperature Sensor
– Engine Oil Pressure Sensor
– Boost Pressure Sensor
– Atmospheric Pressure Sensor
– Inlet Manifold Temperature Sensor
– Temperature Sensor (DPF Inlet)
– Fuel Filter Base – Single Secondary Fuel Filter Base
– Pressure Sensor (NOx Reduction System)
– Temperature Sensor (NOx Reduction System)
– Speed/Timing Sensor
– Electronic Control Module
– Glow Plugs
– Air Compressor – Twin Cylinder Compressor
– Air Compressor – Single Cylinder
– Fuel Filter Base – Twin Secondary Fuel Filter Base
– Fuel Manifold (Rail)
– Lifter Group
– Engine Design
Systems Operation Starting and Charging Systems
– Alternator Breaker Test Description
– Alternator Test Description
– Analyzer Test Description
– Basic Operation
– Batteries Test Description
– Coolant Switch Test Description
– General Information
– Key Breaker Test Description
– Key Start Switch Test Description
– Main Relay and/or Breaker Test Description
– Reference Information
– Specifications
– Start Aid Switch/Solenoid Test Description
– Start Relay (Starter One) Test Description
– Start Relay (Starter Two) Test Description
– Starter Ground Circuit Test Description
– Starter Solenoid (Starter One) Test Description
– Starter Solenoid (Starter Two) Test Description
– Starter Solenoid Power Circuit (Starter One) Test Description
– Starter Solenoid Power Circuit (Starter Two) Test Description
– Test Considerations
– Test Setup A, Hookup
– Test Step B, Crank
– Test Step C, Start Aid
– Test Step D, High Idle
– Troubleshooting
Systems Operation and Testing and Adjusting C6.6 Engines for Caterpillar Built Machines
– Basic Engine
– Power Sources
– Glossary of Electronic Control Terms
– Fuel System – Inspect
– Air in Fuel – Test
– Finding Top Center Position for No. 1 Piston
– Fuel Injection Timing – Check
– Fuel Quality – Test
– Fuel System – Prime
– Gear Group (Front) – Time
– Air Inlet and Exhaust System – Inspect
– Air Inlet and Exhaust System
– Turbocharger – Inspect – Single Turbocharger
– Exhaust Cooler (NRS) – Test
– Compression – Test
– Engine Valve Lash – Inspect
– Valve Depth – Inspect
– Valve Guide – Inspect
– Engine Oil Pressure – Test
– Engine Oil Pump – Inspect
– Excessive Bearing Wear – Inspect
– Excessive Engine Oil Consumption – Inspect
– Clean Emissions Module
– Increased Engine Oil Temperature – Inspect
– Cooling System – Check
– Cooling System – Inspect
– Cooling System – Test
– Engine Oil Cooler – Inspect
– Water Temperature Regulator – Test
– Water Pump – Inspect
– Position the Valve Mechanism Before Maintenance Procedures
– Piston Ring Groove – Inspect
– Connecting Rod – Inspect
– Cooling System
– Cylinder Block – Inspect
– Cylinder Head – Inspect
– Piston Height – Inspect
– Flywheel – Inspect
– Flywheel Housing – Inspect
– Gear Group – Inspect
– Vibration Damper – Check
– Alternator – Test
– Battery – Test
– Charging System – Test
– Lubrication System
– V-Belt – Test
– Electric Starting System – Test
– Electrical System
– Cleanliness of Fuel System Components
– Fuel Injection
– Electronic Control System
– Introduction
Troubleshooting C4.4 and C6.6 Engines
– Welding Precaution
– Diagnostic Trouble Codes
– Electrical Connectors – Inspect
– Cooling Fan – Calibrate – If Applicable
– Injector Code – Calibrate
– Event Codes
– Acceleration Is Poor or Throttle Response Is Poor
– Alternator Problem
– Battery Problem
– Belt Tensioner Noise
– Coolant Contains Oil
– Coolant Level Is Low
– Coolant Temperature Is High
– Coolant Temperature Is Low
– Electronic Service Tools
– Cooling Fan Is Always ON
– Crankcase Breather Ejects Oil
– Crankcase Fumes Disposal Tube Has Oil Draining
– Cylinder Is Noisy
– Diesel Particulate Filter Collects Excessive Soot
– Diesel Particulate Filter Temperature Is Low
– Engine Cranks but Does Not Start
– Engine Does Not Crank
– Engine Has Early Wear
– Engine Has Mechanical Noise (Knock)
– Service Information Report
– Engine Misfires, Runs Rough or Is Unstable
– Engine Overcrank Occurrence
– Engine Overspeeds
– Engine Shutdown Occurrence
– Engine Shutdown Occurs Intermittently
– 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
– System Overview
– Exhaust System Contains Coolant
– Exhaust System Contains Oil
– Fuel Consumption Is Excessive
– Fuel Contains Water
– Fuel Rail Pressure Problem
– Fuel Temperature Is High
– Inlet Air Is Restricted
– Intake Manifold Air Pressure Is High
– Intake Manifold Air Pressure Is Low
– Intake Manifold Air Temperature Is High
– Component Location
– NRS Exhaust Gas Temperature Is High
– NRS Mass Flow Rate Problem
– Oil Consumption Is Excessive
– Oil Contains Coolant
– Oil Contains Fuel
– Oil Level Is Low
– Oil Pressure Is Low
– Power Is Intermittently Low or Power Cutout Is Intermittent
– Valve Lash Is Excessive
– Aftertreatment Identification Module – Test
– Engine Monitoring System
– CAN Data Link – Test
– Coolant Level – Test
– Cooling Fan Control – Test
– Cooling Fan Reversing – Test
– Cooling Fan Speed – Test
– Data Link – Test
– Data Link Configuration Status – Test
– Electrical Power Supply – Test
– Ether Starting Aid – Test
– Fuel Transfer Pump – Test
– Diagnostic Capabilities
– Glow Plug Starting Aid – Test
– Idle Validation – Test
– Indicator Lamp – Test
– Injector Data Incorrect – Test
– Injector Solenoid – Test
– Mode Selection – Test
– Motorized Valve – Test
– Power Take-Off – Test
– Relay – Test – Start Relay
– Sensor Calibration Required – Test
– Electrical Connectors
– Sensor Signal (Analog, Active) – Test
– Sensor Signal (Analog, Passive) – Test
– Sensor Supply – Test
– Shutdown (Ground Level) – Test
– Solenoid Valve – Test
– Soot Sensor – Test
– Speed Control (Analog) – Test
– Speed Control (PWM) – Test
– Speed/Timing – Test
– Switch Circuits – Test – Multiposition Throttle Switch
– Configuration Parameters
– Switch Circuits – Test – Air Filter Restriction Switch
– Valve Position – Test
– Water in Fuel – Test
– Customer Passwords
– Factory Passwords
– ECM Will Not Accept Factory Passwords
– Electronic Service Tool Does Not Communicate
– Test ECM Mode
– ECM Software – Install
– ECM – Replace
– General Information
Troubleshooting D6K2 Track-Type Tractor Electrohydraulic System
– CAN Data Link – Test
– Cat 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
– Hydraulic Fan System
– Implement System – D6K2
– Machine Preparation for Troubleshooting
– Operator Control Switch (Switch to Battery) – Test
– Operator Control Switch (Switch to Ground) – Test
– Power Train Oil – D6K2
– Relay – Test
– Sensor Signal (Analog, Active) – Test
– Sensor Signal (Analog, Passive) – Test
– Sensor Signal (PWM) – Test
– Sensor Supply – Test
– Service Tools
– Solenoid Return – Test
– Solenoid Valve – Test
– Speed Sensor – Test
– Symptom Troubleshooting
– System Schematic
– Wiring Harness (Open Circuit) – Test
– Wiring Harness (Short Circuit) – Test