Service manual Caterpillar D6R SERIES II TRACK-TYPE TRACTOR with C-9 Engine | BLE00001-UP

561N, 572R Series II and 572R Pipelayers and D10R, D11R, D5M, D5N, D6M, D6N, D6R, D6R Series II, D7R, D7R Series II and D8R Series II Track-Type Tractors Power Train Electronic Control System
– Air Inlet Heater Does Not Perform Additional Heating Cycles
– Air Inlet Heater Does Not Turn Off
– Air Inlet Heater Does Not Turn On
– Air Inlet Heater Performs Additional Heating Cycles That Are
– Backup Alarm
– Backup Alarm Always Off
– Backup Alarm Always On
– Blade Control Lever Does Not Stay in Float Position
– Calibration
– Calibration
– Calibration Operation
– Cat Data Link
– Diagnostic Capabilities
– Diagnostic Code List
– Electrical Component and Connector Locations
– Electrical Connector – Inspect
– Electronic Control Module (ECM) – Flash Program
– Electronic Control Module (ECM) – Replace
– Electronic Control Module (Power Train)
– General Information
– General Information
– Glossary of Electrical Terms
– Indicators
– MID 113 – CID 0070 – FMI 02
– MID 113 – CID 0075 – FMI 03
– MID 113 – CID 0075 – FMI 04
– MID 113 – CID 0168 – FMI 03
– MID 113 – CID 0168 – FMI 04
– MID 113 – CID 0177 – FMI 03
– MID 113 – CID 0177 – FMI 04
– MID 113 – CID 0190 – FMI 02
– MID 113 – CID 0248 – FMI 09
– MID 113 – CID 0254 – FMI 12
– MID 113 – CID 0254 – FMI 13
– MID 113 – CID 0269 – FMI 03
– MID 113 – CID 0269 – FMI 04
– MID 113 – CID 0298 – FMI 02
– MID 113 – CID 0299 – FMI 08
– MID 113 – CID 0299 – FMI 13
– MID 113 – CID 0368 – FMI 02
– MID 113 – CID 0468 – FMI 08
– MID 113 – CID 0490 – FMI 02
– MID 113 – CID 0573 – FMI 08
– MID 113 – CID 0573 – FMI 13
– MID 113 – CID 0618 – FMI 02
– MID 113 – CID 0621 – FMI 02
– MID 113 – CID 0622 – FMI 02
– MID 113 – CID 0623 – FMI 02
– MID 113 – CID 0623 – FMI 07
– MID 113 – CID 0650 – FMI 02
– MID 113 – CID 0668 – FMI 12
– MID 113 – CID 0671 – FMI 02
– MID 113 – CID 0672 – FMI 02
– MID 113 – CID 0673 – FMI 02
– MID 113 – CID 0674 – FMI 02
– MID 113 – CID 0675 – FMI 02
– MID 113 – CID 0676 – FMI 08
– MID 113 – CID 0677 – FMI 08
– MID 113 – CID 0681 – FMI 03
– MID 113 – CID 0681 – FMI 05
– MID 113 – CID 0681 – FMI 06
– MID 113 – CID 0689 – FMI 03
– MID 113 – CID 0689 – FMI 05
– MID 113 – CID 0689 – FMI 06
– MID 113 – CID 0690 – FMI 03
– MID 113 – CID 0690 – FMI 05
– MID 113 – CID 0690 – FMI 06
– MID 113 – CID 0691 – FMI 03
– MID 113 – CID 0691 – FMI 05
– MID 113 – CID 0691 – FMI 06
– MID 113 – CID 0691 – FMI 07
– MID 113 – CID 0692 – FMI 03
– MID 113 – CID 0692 – FMI 05
– MID 113 – CID 0692 – FMI 06
– MID 113 – CID 0692 – FMI 07
– MID 113 – CID 0693 – FMI 03
– MID 113 – CID 0693 – FMI 05
– MID 113 – CID 0693 – FMI 06
– MID 113 – CID 0693 – FMI 07
– MID 113 – CID 0694 – FMI 03
– MID 113 – CID 0694 – FMI 05
– MID 113 – CID 0694 – FMI 06
– MID 113 – CID 0694 – FMI 07
– MID 113 – CID 0695 – FMI 03
– MID 113 – CID 0695 – FMI 05
– MID 113 – CID 0695 – FMI 06
– MID 113 – CID 0695 – FMI 07
– MID 113 – CID 0697 – FMI 03
– MID 113 – CID 0697 – FMI 05
– MID 113 – CID 0697 – FMI 06
– MID 113 – CID 0698 – FMI 03
– MID 113 – CID 0698 – FMI 05
– MID 113 – CID 0698 – FMI 06
– MID 113 – CID 0699 – FMI 03
– MID 113 – CID 0699 – FMI 05
– MID 113 – CID 0699 – FMI 06
– MID 113 – CID 0718 – FMI 07
– MID 113 – CID 0722 – FMI 03
– MID 113 – CID 0722 – FMI 05
– MID 113 – CID 0722 – FMI 06
– MID 113 – CID 1327 – FMI 08
– MID 113 – CID 1328 – FMI 08
– MID 113 – CID 1329 – FMI 02
– MID 113 – CID 1330 – FMI 02
– MID 113 – CID 1488 – FMI 03
– MID 113 – CID 1488 – FMI 05
– MID 113 – CID 1488 – FMI 06
– MID 113 – CID 1870 – FMI 03
– MID 113 – CID 1870 – FMI 04
– MID 113 – CID 1933 – FMI 03
– MID 113 – CID 1933 – FMI 05
– MID 113 – CID 1933 – FMI 06
– MID 113 – CID 1934 – FMI 03
– MID 113 – CID 1934 – FMI 05
– MID 113 – CID 1934 – FMI 06
– Power Supply Circuit of Electronic Control Module
– Quick Left Turn Does Not Function
– Quick Right Turn Does Not Function
– Related Operations of the Caterpillar Monitoring System
– Related Operations of the Vital Information Display System
– Relays
– Sensors
– Service Tools
– Solenoid Valves
– Speed Sensor – Adjust
– Switches
– System Operation
– System Schematic
– Transmission Does Not Downshift
– Transmission Does Not Upshift
– Using Caterpillar Electronic Technician to Determine
– Using Caterpillar Monitoring System to Determine Diagnostic
– Warning Operation
– Wiring Harness (Open Circuit) – Test
– Wiring Harness (Short Circuit) – Test
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
Alternator – Delco 21SI
– Alternator
– Alternator – Assemble
– Alternator – Disassemble
– Brush Length – Check
– Capacitor – Test
– Charging System
– Component Description
– Diode Assembly – Test
– Field Winding – Test
– General Information
– General Information
– Insulated Screw – Check
– Normal Operation
– Rectifier – Test
– Regulator – Test
– Residual Magnetism – Restore
– Service Tools
– Stator – Test
Alternator – Delco 27SI
– Alternator
– Alternator
– Alternator – Assemble
– Alternator – Disassemble
– Brush Length – Check
– Capacitor – Test
– Charging System
– Component Description
– Diode Assembly – Test
– Field Winding – Test
– General Information
– General Information
– Insulated Screw – Check
– Normal Operation
– Rectifier – Test
– Regulator – Test
– Residual Magnetism – Restore
– Service Tools
– Stator – Test
C-9 Engines for Caterpillar Built Machines
– Aftercooler – Test
– Air in Fuel – Test
– Air Inlet and Exhaust System
– Air Inlet and Exhaust System – Inspect
– Alternator – Test
– Basic Engine
– Battery – Test
– Charging System – Test
– Compression – Test
– Connecting Rod Bearings – Inspect
– Cooling System
– Cooling System – Check – Overheating
– Cooling System – Inspect
– Cooling System – Test
– Cylinder Block – Inspect
– Cylinder Liner Projection – Inspect
– Electric Starting System – Test
– Electrical System
– Electronic Control System Components
– Electronic Unit Injector – Test
– Engine Crankcase Pressure (Blowby) – Test
– Engine Oil Pressure – Test
– Engine Oil Pump – Inspect
– Engine Valve Lash – Inspect/Adjust
– Excessive Bearing Wear – Inspect
– Excessive Engine Oil Consumption – Inspect
– Exhaust Temperature – Test
– Finding Top Center Position for No. 1 Piston
– Flywheel – Inspect
– Flywheel Housing – Inspect
– Fuel Quality – Test
– Fuel System
– Fuel System – Inspect
– Fuel System – Prime
– Fuel System Pressure – Test
– Gear Group (Front) – Time
– General Information
– Increased Engine Oil Temperature – Inspect
– Inlet Manifold Pressure – Test
– Lubrication System
– Main Bearings – Inspect
– Pinion Clearance – Adjust
– Piston Ring Groove – Inspect
– Slave Piston Lash – Adjust
– Turbocharger – Inspect
– Vibration Damper – Check
– Water Pump – Test
– Water Temperature Regulator – Test
Caterpillar Advanced Ride Management (CARM) Seat Suspension System
– Component Descriptions
– General Information
– Troubleshooting
Comfort Series Seat For Caterpillar Machines
– Air Suspension with Air Valve Knob Height Adjustment –
– Air Suspension With Air Valve Knob Height Adjustment –
– Air Suspension With System Air – Assemble
– Air Suspension With System Air – Disassemble
– Air Suspension With Toggle Switch Height Adjustment –
– Air Suspension With Toggle Switch Height Adjustment –
– Comfort Seat Air Suspension with Air Compressor
– Comfort Seat Air Suspension with Air Compressor –
– Comfort Seat Air Suspension with Air Compressor – Assemble
– Comfort Seat Air Suspension with System Air
– Comfort Seat Controls
– Comfort Seat with Front Controls – Assemble
– Comfort Seat with Front Controls – Disassemble
– Comfort Seat with Lumbar Option and Side Controls –
– Comfort Seat with Lumbar Option and Side Controls –
– Comfort Seat with Lumbar, Side Controls, and Slide Swivel
– Component Descriptions
– General Information
– Mechanical Suspension With Fixed Damper – Assemble
– Mechanical Suspension With Fixed Damper – Disassemble
– Mechanical Suspension With Variable Damper – Assemble
– Mechanical Suspension With Variable Damper – Disassemble
– Optimized Seat Air Suspension with Air Compressor
– Optimized Seat Controls
– Optimized Seat with Front Controls – Disassemble and
– Optimized Seat with Lumbar, Side Controls, and Slide Swivel
– Seat Maintenance Interval Schedule
– Serial Number Effectivity
– Swivel Seat – Assemble
– Swivel Seat – Disassemble
– Troubleshooting
– Troubleshooting Chart
Contour Series Seat
– Air Suspension with Air Valve Knob Height Adjustment –
– Air Suspension With Air Valve Knob Height Adjustment –
– Air Suspension With System Air – Assemble
– Air Suspension With System Air – Disassemble
– Air Suspension With Toggle Switch Height Adjustment –
– Air Suspension With Toggle Switch Height Adjustment –
– Contour Seat Air Suspension with Air Compressor
– Contour Seat Air Suspension with Air System
– Contour Seat Controls
– Contour Seat With Front Controls – Assemble
– Contour Seat With Front Controls – Disassemble
– Contour Seat With Lumbar Option and Side Controls –
– Contour Seat With Lumbar Option and Side Controls –
– Mechanical Suspension
– Mechanical Suspension With Fixed Damper – Assemble
– Mechanical Suspension With Fixed Damper – Disassemble
– Mechanical Suspension With Variable Damper – Assemble
– Mechanical Suspension With Variable Damper – Disassemble
– Swivel Seat – Assemble
– Swivel Seat – Disassemble
– Troubleshooting Chart
D6R Series II Track-Type Tractor
– Electronic Control System
– Fan Clutch
– Fan Clutch – Install
– Fan Clutch – Remove
– Fan Clutch Oil Lines
– Fan Control Solenoid Valve
– Fan Drive – Assemble
– Fan Drive – Disassemble
– Fan Drive System Troubleshooting
– Fan Speed Sensor
– General Information
– General Information
– Lubrication System
Disassembly and Assembly C9 Engine For Caterpillar Built Machines
– Air Compressor – Remove and Install
– Air Compressor Drive Gear – Install
– Air Compressor Drive Gear – Remove
– Alternator – Remove and Install
– Atmospheric Pressure Sensor – Remove and Install
– Bearing Clearance – Check
– Belt Tensioner – Remove and Install
– Camshaft – Install
– Camshaft – Remove
– Camshaft Bearings – Install
– Camshaft Bearings – Remove
– Camshaft Gear – Remove and Install
– Connecting Rod Bearings – Install
– Connecting Rod Bearings – Remove
– Coolant Temperature Sensor – Remove and Install
– Crankcase Breather – Remove and Install
– Crankshaft – Install
– Crankshaft – Remove
– Crankshaft Front Seal – Install
– Crankshaft Front Seal – Remove
– Crankshaft Main Bearings – Install
– Crankshaft Main Bearings – Remove
– Crankshaft Rear Seal – Install
– Crankshaft Rear Seal – Remove
– Cylinder Block Cover – Remove and Install
– Cylinder Head – Install
– Cylinder Head – Remove
– Cylinder Liner – Install
– Cylinder Liner – Remove
– Electric Starting Motor – Remove and Install
– Electronic Unit Injector Sleeve – Install
– Electronic Unit Injector Sleeve – Remove
– Engine Oil Cooler – Install
– Engine Oil Cooler – Remove
– Engine Oil Filter Base – Assemble
– Engine Oil Filter Base – Disassemble
– Engine Oil Filter Base – Install
– Engine Oil Filter Base – Remove
– Engine Oil Pan – Remove and Install
– Engine Oil Pressure Sensor – Remove and Install
– Engine Oil Pump – Assemble
– Engine Oil Pump – Disassemble
– Engine Oil Pump – Install
– Engine Oil Pump – Remove
– Engine Oil Temperature Sensor – Remove and Install
– Exhaust Manifold – Remove and Install
– Flywheel – Install
– Flywheel – Remove
– Flywheel Housing – Remove and Install
– Front Cover – Install
– Front Cover – Remove
– Fuel Filter Base – Remove and Install
– Fuel Pressure Sensor – Remove and Install
– Fuel Priming Pump – Remove and Install
– Fuel Transfer Pump – Install
– Fuel Transfer Pump – Remove
– Housing (Front) – Install
– Housing (Front) – Remove
– Injection Actuation Pressure Sensor – Remove and Install
– Inlet Air Temperature Sensor – Remove and Install
– Inlet and Exhaust Valve Guides – Remove and Install
– Inlet and Exhaust Valve Seat Inserts – Remove and Install
– Inlet and Exhaust Valves – Remove and Install
– Inlet Manifold – Install
– Inlet Manifold – Remove
– 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
– Rocker Arm – Assemble
– Rocker Arm – Disassemble
– Rocker Arm and Shaft – Install
– Rocker Arm and Shaft – Remove
– Speed/Timing Sensor – Remove and Install
– Turbocharger – Assemble
– Turbocharger – Disassemble
– Turbocharger – Install
– Turbocharger – Remove
– Turbocharger Outlet Pressure Sensor – Remove and Install
– Unit Injector – Install
– Unit Injector – Remove
– Unit Injector Hydraulic Pump – Install
– Unit Injector Hydraulic Pump – Remove
– Valve Mechanism Cover – Remove and Install
– Valve Mechanism Cover Base – Remove and Install
– Vibration Damper and Pulley – Remove and Install
– Water Pump – Assemble
– Water Pump – Disassemble
– Water Pump – Install
– Water Pump – Remove
– Water Temperature Regulator – Remove and Install
Disassembly and Assembly D6R Series II Track-Type Tractor C9 Engine Supplement
– Aftercooler – Remove and Install
– Air Cleaner – Remove and Install
– Alternator – Remove and Install
– Belt Tightener – Assemble
– Belt Tightener – Disassemble
– Belt Tightener – Install
– Belt Tightener – Remove
– Crankshaft Front Seal – Remove and Install
– Crankshaft Vibration Damper and Pulley – Remove and Install
– Cylinder Head – Install
– Cylinder Head – Remove
– Electric Starting Motor – Remove and Install
– Engine and Torque Converter – Install
– Engine and Torque Converter – Remove
– Engine Front Support – Remove and Install
– Engine Oil Cooler – Install
– Engine Oil Cooler – Remove
– Engine Oil Filter and Base – Install
– Engine Oil Filter and Base – Remove
– Engine Oil Filter Base – Assemble
– Engine Oil Filter Base – Disassemble
– Engine Oil Level Gauge (Dipstick) – Remove and Install
– Engine Oil Pan – Remove and Install
– Engine Oil Pump – Assemble
– Engine Oil Pump – Disassemble
– Engine Oil Pump – Install
– Engine Oil Pump – Remove
– Engine Side Guards – Remove and Install
– Engine Trunnion – Remove and Install
– Exhaust Manifold – Remove and Install
– Fan – Remove and Install
– Fan Drive – Assemble
– Fan Drive – Disassemble
– Fan Drive – Install
– Fan Drive – Remove
– Hood and Dust Ejector – Remove and Install
– Muffler – Remove and Install
– Primary Fuel Filter and Base – Remove and Install
– Radiator Core – Remove and Install
– Radiator Guard – Install
– Radiator Guard – Remove
– Radiator Guard – Tilt
– Secondary Fuel Filter and Base – Remove and Install
– Turbocharger – Install
– Turbocharger – Remove
– Unit Injector Hydraulic Pump – Install
– Unit Injector Hydraulic Pump – Remove
– Valve Cover – Remove and Install
– Water Pump – Install
– Water Pump – Remove
– Water Temperature Regulator – Remove and Install
Disassembly and Assembly D6R Series II Track-Type Tractor Power Train
– Axle – Remove and Install
– Bevel and Transfer Gears – Assemble
– Bevel and Transfer Gears – Disassemble
– Drawbar – Remove and Install
– Drive Shaft (Pump Coupling) – Remove and Install
– Duo-Cone Conventional Seals – Install
– Duo-Cone Floating Seals – Install
– Duo-Cone Inverted Seals – Install
– Equalizer Bar – Assemble
– Equalizer Bar – Disassemble
– Equalizer Bar – Install
– Equalizer Bar – Remove
– Final Drive – Assemble
– Final Drive – Disassemble
– Final Drive – Install
– Final Drive – Remove
– Final Drive Planetary Carrier (In Chassis) – Install
– Final Drive Planetary Carrier (In Chassis) – Remove
– Final Drive, Steering Clutch and Brake – Install
– Final Drive, Steering Clutch and Brake – Remove
– Final Drive, Steering Clutch, and Brakes – Connect
– Final Drive, Steering Clutch, and Brakes – Separate
– Front Track Roller Frame – Install
– Front Track Roller Frame – Remove
– Idler – Install
– Idler – Remove
– Main Drive Shaft – Remove and Install
– Pivot Bar-Remove and Install
– Power Train Oil Filter – Assemble
– Power Train Oil Filter – Disassemble
– Power Train Oil Filter – Install
– Power Train Oil Filter – Remove
– Power Train Oil Pump – Assemble
– Power Train Oil Pump – Disassemble
– Power Train Oil Pump – Install
– Power Train Oil Pump – Remove
– Priority Valve – Assemble
– Priority Valve – Disassemble
– Priority Valve – Install
– Priority Valve – Remove
– Recoil Spring – Install
– Recoil Spring – Remove
– Sprocket Segment – Remove and Install
– Steering Clutch and Brake – Assemble
– Steering Clutch and Brake – Disassemble
– Steering Clutch and Brake Control Valve – Assemble
– Steering Clutch and Brake Control Valve – Disassemble
– Steering Clutch and Brake Control Valve – Install
– Steering Clutch and Brake Control Valve – Remove
– Torque Converter – Assemble
– Torque Converter – Disassemble
– Torque Converter – Install
– Torque Converter – Remove
– Torque Converter Outlet Relief Valve – Assemble
– Torque Converter Outlet Relief Valve – Disassemble
– Torque Converter Outlet Relief Valve – Install
– Torque Converter Outlet Relief Valve – Remove
– Track – Connect
– Track – Separate
– Track Adjuster – Assemble
– Track Adjuster – Disassemble
– Track Adjuster – Install
– Track Adjuster – Remove
– Track Roller – Install
– Track Roller – Remove
– Track Roller Frame – Install
– Track Roller Frame – Remove
– Transmission – Assemble
– Transmission – Disassemble
– Transmission – Install
– Transmission – Remove
– Transmission and Bevel Gears – Connect
– Transmission and Bevel Gears – Install
– Transmission and Bevel Gears – Remove
– Transmission and Bevel Gears – Separate
– Transmission Hydraulic Control Valve – Assemble
– Transmission Hydraulic Control Valve – Disassemble
– Transmission Hydraulic Control Valve – Install
– Transmission Hydraulic Control Valve – Remove
Disassembly and Assembly D6R Series II Track-Type TractorMachine Systems
– Air Conditioner and Heater Fan Motor – Remove and Install
– Battery – Remove and Install
– Bottom Guard – Install
– Bottom Guard – Remove
– Bulldozer Lift Cylinder – Assemble
– Bulldozer Lift Cylinder – Disassemble
– Bulldozer Lift Cylinder – Install
– Bulldozer Lift Cylinder – Remove
– Bulldozer Lift Cylinder Mounts – Remove and Install
– Bulldozer Tilt Cylinder – Assemble
– Bulldozer Tilt Cylinder – Disassemble
– Bulldozer Tilt Cylinder – Install
– Bulldozer Tilt Cylinder – Remove
– Cab – Install
– Cab – Remove
– Cartridge Valve – Install – Cartridge Valves In Chassis
– Cartridge Valve – Remove
– Decelerator and Brake Control – Assemble
– Decelerator and Brake Control – Disassemble
– Decelerator and Brake Control – Install
– Decelerator and Brake Control – Remove
– Fuel Tank – Install
– Fuel Tank – Remove
– Hydraulic Control Valve – Assemble
– Hydraulic Control Valve – Disassemble
– Hydraulic Control Valve – Install
– Hydraulic Control Valve – Remove
– Hydraulic Oil Filter – Remove and Install
– Hydraulic Tank – Assemble
– Hydraulic Tank – Disassemble
– Hydraulic Tank – Install
– Hydraulic Tank – Remove
– Implement Pump – Assemble
– Implement Pump – Disassemble
– Implement Pump – Install
– Implement Pump – Remove
– Quick-Drop Valve – Assemble
– Quick-Drop Valve – Disassemble
– Quick-Drop Valve – Install
– Quick-Drop Valve – Remove
– Refrigerant Accumulator – Remove and Install
– Refrigerant Compressor – Remove and Install
– Refrigerant Condenser – Remove and Install
– Refrigerant Evaporator Core and Heater Core – Remove and
– Ripper Carriage (Beam) – Remove and Install
– Ripper Frame – Remove and Install
– Ripper Lift Cylinder – Remove and Install
– Rollover Protective Structure (ROPS) – Remove and Install
– Seat – Remove and Install
– Trunnion – Remove and Install
Disassembly and Assembly
– Brake Control – Remove and Install
– Control Module – Remove and Install
– Guide Bushings – Remove and Install
– Height Adjustment Motor – Remove and Install
– Steering Gear – Install
– Steering Gear – Remove
– Transmission Position Sensor – Remove and Install
– Transmission Support Assembly – Remove and Install
Flexxaire Fan
– Calibration
– Control System
– Control System
– Control System – Remove and Install
– Hydraulic Actuated Fan – Assemble
– Hydraulic Actuated Fan – Disassemble
– Hydraulic Actuated Fan System
– Mechanical Actuated Fan
– Mechanical Actuated Fan – Assemble
– Mechanical Actuated Fan – Disassemble
– Mechanical Actuated Fan System
– Setup
– Torque Specifications (Flexxaire Fan)
MSS3s Machine Security System
– Cat Data Link – Test
– Connector Contact Description
– Connector Locations
– Data Links
– Determining Diagnostic Trouble Codes
– Diagnostic Capabilities
– Diagnostic Operation
– Diagnostic Trouble Codes
– ECM – Configure
– ECM – Replace
– ECM Output Driver – Test
– ECM Software – Install
– Electrical Connector – Inspect
– Electrical Power Supply – Test
– Electronic Control Module (ECM)
– Emerging Symptom Information
– Engine Does Not Crank and Status Indicator Is Green
– Engine Does Not Start and Status Indicator Is Continuously
– Events
– Factory Password – Obtain
– General Information
– General Information
– General Information
– Glossary of Terms
– Key – Program
– Key Information
– Lost Key (MSS)
– Machine Preparation for Troubleshooting
– Normal Operation
– Operation of Status Indicator
– Product Identification Number – Program
– Protected Functions
– Scheduled Access – “Security System Bypass Times”
– Service Operation Using Machine Security System
– Service Operation Using Service Tool
– Service Tools
– Software – Uninstall – “Immobilizer” Feature
– Symptom Troubleshooting
– System Components
– System Disarm – Program – Security System Bypass
– System Overview
– System Schematic
– Time – Set
– Visual Inspection
– Wiring Harness (Open Circuit) – Test
– Wiring Harness (Short Circuit) – Test
Machine Security System
– Cat Data Link
– Diagnostic Code List
– Diagnostic Operation
– Electrical Component and Connector Locations
– Electrical Connector – Inspect
– Electronic Control Module (ECM)
– Electronic Control Module (ECM) – Flash Program
– Electronic Control Module (ECM) – Replace
– Emerging Symptom Information
– Engine Does Not Crank and Status Indicator Is Green
– Engine Does Not Start and Status Indicator Is Continuously
– Events
– Factory Password – Obtain
– General Information
– General Information
– General Information
– Glossary of Terms
– Key – Program
– Key Information
– Lost Key
– MID 124 – CID 0168 – FMI 00
– MID 124 – CID 0168 – FMI 01
– MID 124 – CID 0248 – FMI 12
– MID 124 – CID 0817 – FMI 04
– MID 124 – CID 1391 – FMI 03
– MID 124 – CID 1391 – FMI 04
– MID 124 – CID 1392 – FMI 03
– MID 124 – CID 1392 – FMI 04
– Normal Operation
– Operation of Status Indicator
– Product Identification Number – Program
– Protected Functions
– Scheduled Access – “Security System Bypass Times”
– Service Operation Using Machine Security System
– Service Operation Using Service Tool
– Service Tools
– Software – Uninstall – “Immobilizer” Feature
– Symptom Troubleshooting
– System Components
– System Disarm – Program – Security System Bypass
– System Overview
– System Schematic
– Time – Set
– Using Caterpillar Electronic Technician to Determine
Schematic Caterpillar D6R Series II Track-Type Tractor Hydraulic System
Schematic Caterpillar D6RSeriesIITrack-TypeTractor ElectricalSystem
Specifications C-9 Engines for Caterpillar Built Machines
– Air Compressor
– Air Inlet Elbow
– Alternator and Regulator
– Alternator and Regulator
– Atmospheric Pressure Sensor
– Belt Tension Chart
– Camshaft
– Compression Brake
– Connecting Rod
– Connecting Rod Bearing Journal
– Coolant Temperature Sensor
– Crankshaft
– Crankshaft Seals
– Cylinder Block
– Cylinder Block Cover Group
– Cylinder Head
– Cylinder Head Valves
– Cylinder Liner
– Cylinder Liner Projection
– Electric Starting Motor
– Electric Starting Motor
– Electronic Control Module
– Engine Design
– Engine Oil Pan
– Engine Oil Pressure Sensor
– Engine Oil Pump
– Engine Oil Temperature Sensor
– Exhaust Manifold
– Fan Drive
– Flywheel
– Flywheel Housing
– Front Housing and Covers
– Fuel Filter Base
– Fuel Pressure Sensor
– Fuel Priming Pump and Water Separator
– Gear Group (Front)
– Injection Actuation Oil Temperature Sensor
– Injection Actuation Pressure Sensor
– Inlet Air Temperature Sensor
– Lifter Group
– Main Bearing Journal
– Piston and Rings
– Rear Power Take-Off (RPTO)
– Rocker Shaft
– Speed/Timing Sensor
– Speed/Timing Sensor
– Turbocharger
– Turbocharger Outlet Pressure Sensor
– Unit Injector
– Unit Injector Hydraulic Pump
– Valve Mechanism
– Valve Mechanism Cover
– Water Pump – Pulley for Serpentine Belt
– Water Pump – V-Belt Pulley
– Water Temperature Regulator
– Water Temperature Regulator Housing
Specifications D6R Series II Track-Type Tractor Hydraulic System
– Accumulator
– Bulldozer Blade
– Bulldozer Brace
– Bulldozer Lift Control Valve
– Bulldozer Lift Cylinder
– Bulldozer Tilt Control Valve
– Bulldozer Tilt Cylinder
– Bulldozer Trunnion
– Charging Valve
– Check Valve – Bulldozer – Ripper
– Cylinder Mounting
– Hydraulic Pump (Piston)
– Hydraulic Tank and Filter
– Implement Control Valves
– Main Relief Valve
– Pilot Control Valve – Bulldozer Lift and Tilt
– Pilot Control Valve – Ripper Lift
– Pressure Reducing Valve (Pilot)
– Pump Control Valve
– Push Arm
– Quick-Drop Valve
– Ripper Control Valve
– Ripper Lift Cylinder
– Ripper Mounting
Specifications D6R Series II Track-Type Tractor Power Train
– Bevel and Transfer Gears
– Cab Mounting
– Drawbar
– Drive Shaft
– Equalizer Bar
– Fender
– Final Drive
– Idlers (Track)
– Magnetic Screen
– Main Relief Valve
– Modulating Valve (Transmission)
– Pivot Shaft
– Platform
– Priority Valve
– Recoil Group
– Relief Valve (Torque Converter Outlet)
– Rollover Protective Structure (ROPS)
– Steering and Brake Control Valve
– Steering Clutches and Brakes
– Torque Converter
– Track Carrier Roller
– Track Guide Guard – If Equipped
– Track Roller
– Track Roller Frames
– Track Roller Guard – If Equipped
– Tracks
– Transmission
– Transmission and Torque Converter Pump
– Transmission Control Linkage
– Transmission Hydraulic Control
– Transmission Mounting
– Transmission Oil Filter
Systems Operation D6R Series II Track-Type Tractor Hydraulic System
– Accumulator
– Bulldozer Lift Control Valve
– Bulldozer Tilt Control Valve
– General Information
– Hydraulic Pump – Piston
– Hydraulic Tank and Filter
– Implement Control Valve
– Main Relief Valve
– Oil Cooler and Bypass Valve
– Pilot Hydraulic System
– Pressure Reducing Valve
– Quick-Drop Valve
– Ripper Lift Control Valve
– Signal Resolver Network
Systems Operation D6R Series II Track-Type Tractor Power Train
– Check Valve
– Electronic Control System Components
– Equalizer Bar
– Final Drive
– General Information
– Magnetic Screen
– Main Relief Valve
– Pivot Shaft
– Power Train Hydraulic System
– Power Train Oil Cooler
– Power Train Oil Pump
– Priority Valve
– Relief Valve (Torque Converter Inlet)
– Relief Valve (Torque Converter Outlet)
– Steering and Brake Control Valve
– Steering Clutch and Brake
– Torque Converter
– Track Carrier Roller
– Track Idler
– Track Roller
– Track Roller Frame
– Tracks
– Transfer and Bevel Gears
– Transmission
– Transmission Hydraulic Control
– Transmission Lubrication
– Transmission Oil Filter
– Undercarriage
Systems Operation EquipmentManager Dealer Administrator Manual
– Active Fleet
– Administration
– Asset Watch
– Enable Program
– Equipment Usage
– Fault Codes
– Fuel Results
– General Information
– Getting Started
– Health Watch
– Maintenance Watch
– Major Repair
– Manage Equipment Groups
– Manage Event Tracking
– Manage Hardware
– Manage Major Repair Tracking
– Manage Planned Maintenance
– Manage Time Fence and Geographic Fence
– Manage Users
– Operation and Maintenance Manual
– Planned Maintenance
– Preference Detail
– Preferences
– Product Link Installation
– Product Monitoring
– Product Usage
– Reports
– Setup Subscriptions
– Time Fence and Geographic Fence
– Upload Data
– Verify Machine Records and Ownership
Systems Operation EquipmentManager User Guide
– Getting Started
– Manage Major Repair Tracking
– Manage Time Fence and Geographic Fence
– Manage Planned Maintenance
– Preferences
– Preference Detail
– Asset Watch
– Time Fence and Geographic Fence
– Maintenance Watch
– Planned Maintenance
– Major Repair
– Verify Machine Records and Ownership
– Health Watch
– Fuel Results
– Fault Codes
– Reports
– Product Usage
– Product Monitoring
– Operation and Maintenance Manual
– Equipment Usage
– Manage Users
– Product Link Installation
– Administration
– Manage Equipment Groups
– Manage Hardware
– Manage Event Tracking
– Upload Data
– General Information
Systems Operation Troubleshooting Testing and Adjusting Product Link – PL522 523
– System Components
– Reports and Messages Not Available
– Position Reports Not Available
– Reporting Interval Erratic
– Diagnostics and Events Not Available
– Operating Hours Discrepancy
– Event Code List
– Diagnostic Code List
– MID 161 – CID 0168 – FMI 00
– MID 161 – CID 0168 – FMI 01
– MID 161 – CID 0254 – FMI 04
– Installation Parameters Configure
– MID 161 – CID 0254 – FMI 12
– MID 161 – CID 1250 – FMI 09
– MID 161 – CID 1251 – FMI 03
– MID 161 – CID 1888 – FMI 14
– MID 161 – CID 3766- FMI 14
– Electronic Control Module (ECM) – Flash Program
– Electronic Control Module (ECM) – Replace
– Electrical Connector – Inspect
– Wiring Harness (Open Circuit) – Test
– Wiring Harness (Short Circuit) – Test
– Configuration
– Specifications
– System Schematic
– Spare Input Configure
– Commands
– General Information
– Service Tools
– Diagnostic Capabilities
– Electronic Service Tool Does Not Communicate with ECM
– System Overview
Systems Operation Troubleshooting Testing and Adjusting Product Link 121S 300
– System Components
– Service Tools
– Diagnostic Capabilities
– Electronic Service Tool Does Not Communicate with ECM
– ECM Does Not Communicate with User Interface
– Position Reports Not Available
– Reporting Interval Erratic
– Diagnostics and Events Not Available
– Operating Hours Discrepancy
– Event Code List
– Diagnostic Code List
– Spare Inputs
– MID 122 – CID 0168 – FMI 00
– MID 122 – CID 0168 – FMI 01
– MID 122 – CID 0254 – FMI 04
– MID 122 – CID 0254 – FMI 12
– MID 122 – CID 0269 – FMI 03
– MID 122 – CID 0269 – FMI 04
– MID 122 – CID 1250 – FMI 09
– MID 122 – CID 1251 – FMI 03
– Electronic Control Module (ECM) – Flash Program
– Electronic Control Module (ECM) – Replace
– Configuration
– Electrical Connector – Inspect
– Wiring Harness (Open Circuit) – Test
– Wiring Harness (Short Circuit) – Test
– Specifications
– System Schematic
– Installation Parameters Configure
– Report Parameters Configure
– Wireless Service Configure
– Spare Input Configure
– Commands
– General Information
– System Overview
Testing and Adjusting D6R Series II Track-Type Tractor Hydraulic System
– Accumulator (Pilot) – Test and Charge
– Hydraulic System Troubleshooting
– Machine Preparation – Implement Hydraulic System
– Main Relief Valve – Test
– Operation Checks
– Pilot Control Valve – Test and Adjust
– Pressure Reducing Valve – Test and Adjust
– Pressure Taps
– Pump Control Valve – Adjust
– Pump Discharge Pressure – Test
– Troubleshooting Procedures
– Visual Inspection
Testing and Adjusting D6R Series II Track-Type Tractor Power Train
– Brake Troubleshooting
– Hour Meter Troubleshooting
– Machine Preparation
– Machine Troubleshooting
– Main Relief Valve – Adjust
– Oil (Air in Oil) Troubleshooting
– Oil Pressure Troubleshooting
– Oil Temperature Troubleshooting
– Pressure Charts
– Pressure Taps
– Priority Valve – Adjust
– References
– Relief Valve (Torque Converter Inlet) Pressure – Test and
– Relief Valve (Torque Converter Outlet) Pressure – Test and
– Schematic
– Software Troubleshooting
– Speed Sensor – Adjust
– Steering Clutch Troubleshooting
– Steering System Troubleshooting
– Symptom List
– Torque Converter Troubleshooting
– Track – Adjust
– Transmission Clutch Troubleshooting
– Transmission Controls
– Transmission Troubleshooting
– Troubleshooting Procedures
– Visual Inspection
Troubleshooting C-9 Engine for D6R Series II Track-Type Tractor
– 5 Volt Engine Pressure Sensor Supply Circuit – Test
– Air Inlet Heater Circuit – Test
– Alternator – Noisy Operation
– Analog Sensor Open or Short Circuit – Test
– Battery
– Can Not Reach Top Engine RPM
– Cat Data Link Circuit – Test
– CID 0001 FMI 11 Cylinder #1 Injector fault
– CID 0002 FMI 11 Cylinder #2 Injector fault
– CID 0003 FMI 11 Cylinder #3 Injector fault
– CID 0004 FMI 11 Cylinder #4 Injector fault
– CID 0005 FMI 11 Cylinder #5 Injector fault
– CID 0006 FMI 11 Cylinder #6 Injector fault
– CID 0041 FMI 03 8 Volt DC Supply short to +batt
– CID 0041 FMI 04 8 Volt DC Supply short to ground
– CID 0042 FMI 11 Inject Actuation Control Valve open/short
– CID 0091 FMI 02 Incorrect Throttle Switch inputs
– CID 0091 FMI 08 Throttle Position signal abnormal
– CID 0100 FMI 03 Engine Oil Pressure open/short to +batt
– CID 0100 FMI 04 Engine Oil Pressure short to ground
– CID 0110 FMI 03 Engine Coolant Temperature open/short to
– CID 0110 FMI 04 Engine Coolant Temperature short to ground
– CID 0164 FMI 00 High Injector Actuation Pressure
– CID 0164 FMI 02 Injector Actuation Pressure signal erratic
– CID 0164 FMI 03 Injector Actuation Pressure voltage high
– CID 0164 FMI 04 Injector Actuation Pressure voltage low
– CID 0164 FMI 11 Injector Actuation Pressure system fault
– CID 0168 FMI 00 System Voltage High
– CID 0168 FMI 01 System Voltage Low
– CID 0168 FMI 02 System Voltage intermittent/erratic
– CID 0172 FMI 03 Intake Manifold Air Temp open/short to
– CID 0172 FMI 04 Intake Manifold Air Temp short to ground
– CID 0175 FMI 03 Engine Oil Temperature open/short to +batt
– CID 0175 FMI 04 Engine Oil Temperature short to ground
– CID 0190 FMI 02 Loss of Engine Speed Signal
– CID 0190 FMI 11 Engine Speed Sensor mechanical failure
– CID 0253 FMI 02 Personality Module mismatch
– CID 0254 FMI 12 Electronic Control Module Error
– CID 0261 FMI 13 Engine Timing Calibration required
– CID 0262 FMI 03 5 Volt Sensor DC Power Supply short to
– CID 0262 FMI 04 5 Volt Sensor DC Power Supply short to
– CID 0263 FMI 03 Digital Sensor Supply short to +batt
– CID 0263 FMI 04 Digital Sensor Supply short to ground
– CID 0264 FMI 08 Decel Throttle Position signal abnormal
– CID 0266 FMI 02 Incorrect Crank-without-inject inputs
– CID 0268 FMI 02 Check Programmable Parameters
– CID 0273 FMI 03 Turbo Outlet Pressure open/short to +batt
– CID 0273 FMI 04 Turbo Outlet Pressure short to ground
– CID 0274 FMI 03 Atmospheric Pressure open/short to +batt
– CID 0274 FMI 04 Atmospheric Pressure short to ground
– CID 0275 FMI 03 Right Turbo Inlet Pressure open/short to
– CID 0275 FMI 04 Right Turbo Inlet Pressure short to ground
– CID 0276 FMI 03 Left Turbo Inlet Pressure open/short to +batt
– CID 0276 FMI 04 Left Turbo Inlet Pressure short to ground
– CID 0320 FMI 02 Speed/Timing Sensor Loss of Signal
– CID 0320 FMI 11 Speed/Timing Sensor mechanical failure
– CID 0342 FMI 02 Loss of Secondary Engine Speed signal
– CID 0342 FMI 11 Secondary Engine Speed Sensor mechanical
– CID 0544 FMI 08 Engine Cooling Fan Speed signal abnormal
– CID 0545 FMI 05 Ether Start Relay open/short to +batt
– CID 0545 FMI 06 Ether Start Relay short to ground
– CID 0562 FMI 09 Unable to Communicate with Cat Monitoring
– CID 0617 FMI 05 Air Inlet Heater Relay open/current below
– CID 0617 FMI 06 Air Inlet Heater Relay grounded/current
– CID 0799 FMI 12 Need Service Tool update
– CID 1599 FMI 05 Engine Fan Pull Solenoid open circuit
– CID 1599 FMI 06 Engine Fan Pull Solenoid short to ground
– CID 1600 FMI 05 Engine Fan Push Solenoid open circuit
– CID 1600 FMI 06 Engine Fan Push Solenoid short to ground
– CID 1715 FMI 03 Engine Oil Temperature Sensor #2 short to
– CID 1715 FMI 04 Engine Oil Temperature Sensor #2 short to
– Coolant in Engine Oil
– Crank Without Inject Circuit – Test
– Customer Passwords
– Decelerator Position Sensor Circuit – Test
– Diagnostic Codes
– Digital Sensor Supply Circuit – Test
– E017 High Engine Coolant Temperature Warning
– E023 High Hydraulic Oil Temperature Derate
– E025 High Inlet Air Temperature Derate
– E027 High Inlet Air Temperature Warning
– E039 Low Engine Oil Pressure Derate
– E100 Low Engine Oil Pressure Warning
– E190 Engine Overspeed Warning
– E265 User Defined Shutdown
– ECM Will Not Accept Factory Passwords
– ECM Will Not Communicate with Other Systems or Display
– ECM/Personality Module – Test
– Electrical Connectors – Inspect
– Electrical Power Supply Circuit – Test
– Electronic Display Module – If Equipped
– Electronic Service Tool Will Not Communicate with ECM
– Electronic Service Tools
– Engine Cranks but Will Not Start
– Engine Has Early Wear
– Engine Misfires, Runs Rough or Is Unstable
– Engine Oil in Exhaust System
– Engine Oil Temperature Is Too High
– Engine Pressure Sensor Open or Short Circuit – Test
– Engine Speed/Timing Sensor – Calibrate
– Engine Speed/Timing Sensor Circuit – Test
– Engine Stalls at Low RPM
– Engine Temperature Sensor Open or Short Circuit – Test
– Engine Vibration
– Engine Wiring Information
– Ether Injection System – Test
– Event Codes
– Excessive Black Smoke
– Excessive Engine Oil Consumption
– Excessive Fuel Consumption
– Excessive Valve Lash
– Excessive White Smoke
– Factory Passwords
– Flash Programming
– Fuel Dilution of Engine Oil
– Fuel in Cooling System
– Injection Actuation Pressure – Test
– Injection Actuation Pressure Control Valve Circuit – Test
– Injection Actuation Pressure Sensor – Test
– Injector Code – Calibrate
– Injector Solenoid Circuit – Test
– Intermittent Engine Shutdown
– Intermittent Low Power or Power Cutout
– Low Engine Oil Pressure
– Low Power/Poor or No Response to Throttle
– Mechanical Noise (Knock) in Engine
– Noise Coming from Cylinder
– Poor Acceleration or Response
– Programming Parameters
– Replacing the ECM
– Self-Diagnostics
– Sensors and Electrical Connectors
– System Configuration Parameters
– System Overview
– Throttle Position Sensor Circuit – Test
– Throttle Switch Circuit – Test
– User Defined Shutdown Input Circuit – Test
– Valve Rotator or Spring Lock Is Free
– Variable Pitch Engine Fan Circuit – Test