Service Training SERV7102

New Product Introduction January 2002

Volume 1, Number 4

TECHNICAL PRESENTATION

D6R SERIES II
TRACK-TYPE TRACTOR

New Product Introduction

(NPI)
D6R SERIES II
TRACK-TYPE TRACTORS

CONTENT

This self paced, self directed presentation provides new and different New Product Introduction
(NPI) information for the D6R Series II Track-type Tractor.

OBJECTIVES

After learning the information in this meeting guide, the serviceman will be able to:
1. locate and identify the new components on the D6R Series II Track-type Tractor;
2. locate and identify the new components in the tractor systems; and
3. trace the flow of oil through the new hydraulic systems.

REFERENCES

STMG 687 "D6R/D7R Track-type Tractors" SESV1687

D6R Service Manual (Finger Tip Control) RENR4250
D6R Service Manual (Differential Steering) RENR4265

Estimated Time: 1 Hour

Visuals: 32
Form: SERV7102-01
Date: 1/02

© 2002 Caterpillar Inc.

SERV7102-01 -3- NPI
Vol. 1, No. 4, 2002

TABLE OF CONTENTS

INTRODUCTION ........................................................................................................................5

OPERATOR COMPARTMENT...................................................................................................9

ENGINE......................................................................................................................................18

COOLING SYSTEM .................................................................................................................22

POWER TRAIN
No Changes

IMPLEMENT HYDRAULIC SYSTEM....................................................................................24

System Components .............................................................................................................28

HYDRAULIC OIL COOLER ....................................................................................................31

SIGNIFICANT MAINTENANCE CHANGES .........................................................................32

System Filters and Pressure Taps..........................................................................................33
Fuse Panel .............................................................................................................................35

NEW TOOLING/SKILLS REQUIRED FOR SERVICE

No Changes

CONCLUSION...........................................................................................................................36
SERV7102-01 -4- NPI
Vol. 1, No. 4, 2002

NOTES
SERV7102-01 -5- NPI
Vol. 1, No. 4, 2002

D6R SERIES II
TRACK-TYPE TRACTOR

© 2002 Caterpillar Inc.

INTRODUCTION

Shown above is the left side of the D6R Series II XL Track-type Tractor. The D6R Series II is a
direct replacement for the D6R. The machine can be equipped with either the Finger Tip
Control (FTC) steering or the optional Differential Steering (DS).
SERV7102-01 -6- NPI
Vol. 1, No. 4, 2002

D6R SERIES II TRACK-TYPE TRACTOR

KEY NEW FEATURES
• C-9 Electronic Engine with HEUI-B Fuel System
• Air to Air AfterCooler (ATAAC)
• Power train upgrade
• Hydraulic system upgrades
• Operator Station upgrades
• Undercarriage changes
(Discontinuation of IG and XR, addition of XW)
• Product Link ready

The graphic above shows some of the key new features for the D6R Series II Track-type Tractor.
SERV7102-01 -7- NPI
Vol. 1, No. 4, 2002

SIMILARITIES AND DIFFERENCES

FEATURES DIFFERENT SIMILAR SAME
Transmission X
Steering System X
Machine Appearance X
Power Train X
Engine X
Braking System X
Monitoring System X
Implement Hydraulic System X
Operators Station X
Nomenclature X

The chart above compares the D6R Series II Track-type Tractor to the current D6R. Although
not comprehensive, it gives an "at a glance" look at what is different, similar, and the same.
SERV7102-01 -8- NPI
Vol. 1, No. 4, 2002

D6R SERIES II SPECIFICATIONS

OPERATING NET
ARRANGEMENT LENGTH WIDTH * HEIGHT
WEIGHT POWER
D6R Series II 18 000 kg 3.86 m 2.44 m 3.195 m 123 kW
Standard, FTC (40,000 lbs.) (12’ 8") (8’ 0") (10’ 6") (165 hp)
D6R Series II 18 000 kg 3.86 m 2.44 m 3.195 m 123 kW
Standard, DS (40,000 lbs.) (12’ 8") (8’ 0") (10’ 6") (165 hp)
D6R Series II 19 200 kg 3.86 m 2.44 m 3.195 m 138 kW
XL, FTC (42,300 lbs.) (12’ 8") (8’ 0") (10’ 6") (185 hp)
D6R Series II 19 200 kg 3.86 m 2.44 m 3.195 m 138 kW
XL, DS (42,300 lbs.) (12’ 8") (8’ 0") (10’ 6") (185 hp)
D6R Series II 19 868 kg 3.86 m 2.74 m 3.195 m 138 kW
XW, DS (43,800 lbs.) (12’ 8") (9’ 0") (10’ 6") (185 hp)
D6R Series II 20 700 kg 4.25 m 3.14 m 3.245 m 138 kW
LGP, FTC (45,600 lbs.) (13’ 11") (10’ 4") (10’ 8") (185 hp)
D6R Series II 20 700 kg 4.25 m 3.14 m 3.245 m 138 kW
LGP, DS (45,600 lbs.) (13’ 11") (10’ 4") (10’ 8") (185 hp)

Specifications for the D6R Series II Track-type Tractors are shown in the above matrix. Net
Power ratings apply at 2000 rpms.

* Width specifications for the D6R Series II models are overall widths from outside of track
shoe to outside of track shoe. For the width over trunions, add .2 m (8 in.) for all models, except
the LGP model. For the overall width over trunions of the D6R Series II LGP model, add
.288 m (10 in.).
SERV7102-01 -9- NPI
Vol. 1, No. 4, 2002

OPERATOR COMPARTMENT

The D6R Series II Track-type Tractor is equipped with the C550 seat as standard equipment
with air suspension as an option.
SERV7102-01 - 10 - NPI
Vol. 1, No. 4, 2002

1
2

The D6R Series II dash contains the following components: the Quad Gauge Module (1), the
Gear/Direction Module (2), and the Main Display Module (3).

Other components of the D6R Series II dash include the AutoShift switch, the Auto Kickdown
switch, the Action Lamp, the auxiliary light switch, and the light switch.

Also located on the dash are the fan switch (if equipped), the air conditioning/heater
temperature control (if equipped), the air conditioning condenser switch (if equipped), and the
operator scroll switch.
SERV7102-01 - 11 - NPI
Vol. 1, No. 4, 2002

The Quad Gauge Module contains four analog gauges which alert the operator to the status of:

- Engine coolant temperature

- Power train oil temperature

- Hydraulic oil temperature

- Fuel level
SERV7102-01 - 12 - NPI
Vol. 1, No. 4, 2002

The Gear/Direction Module displays the digital engine speed and the gear selection and
direction in the display window (arrow). This module also contains LED indicators, which alert
the operator of the following:

- Low engine oil pressure

- Abnormal alternator output at the "R" terminal

- Excessive inlet air temperature

- Low fuel level

- Parking brake status

- AutoShift mode activated, 1F-2R range

- AutoShift mode activated, 2F-2R range

- AutoShift mode activated, 2F-1R range

- Auto Kickdown mode activated

- Implement lockout activated

SERV7102-01 - 13 - NPI
Vol. 1, No. 4, 2002

The Main Display Module displays different modes and messages to the operator and the service
technician in the display area (arrow). This module also contains LED indicators that alert the
operator of the following:

- Intake air filter restriction

- Fuel filter restriction

- Power train oil filter bypass

- Inlet air heater activated

- Steering system fault (on FTC machines only)

- Brake system fault

- Transmission system fault

- Check engine condition

- Implement system fault

NOTE: The Main Display Module shown above is from a FTC machine.
SERV7102-01 - 14 - NPI
Vol. 1, No. 4, 2002

10

Located behind the seat at the left rear of the operator compartment are the diagnostic
connectors.

There are two 12 volt connectors (1) that may be used to power a laptop computer, Data View,
etc., a connector for the 4C8195 Service Tool (2), and a connector for the Communication
Adapter, and Electronic Technician (ET) (3).
SERV7102-01 - 15 - NPI
Vol. 1, No. 4, 2002

2 3
1

11

The D6R Series II is equipped with Finger Tip Control (FTC) as standard equipment. The left
steering clutch and brake lever (1) controls gradual or sharp left turns.

The right steering clutch and brake lever (2) controls gradual or sharp right turns. FORWARD,
NEUTRAL, and REVERSE is controlled by the rotating paddle (3).

The top button (4) upshifts the tractor one gear range at a time, and the bottom button (5)
downshifts the tractor one gear range at a time.
SERV7102-01 - 16 - NPI
Vol. 1, No. 4, 2002

3
4

2 5
6

12

The D6R Series II can be equipped with optional Differential Steering. The parking brake
switch (1) with a key lockout (2) energizes the parking brake solenoid on the brake valve, which
engages the brakes and shifts the transmission to FIRST gear NEUTRAL. FORWARD,
NEUTRAL, and REVERSE are controlled by the rotating tiller hand grip (3).

The top button (4) upshifts the tractor one gear range at a time, and the bottom button (5)
downshifts the tractor one gear range at a time.

Left turns are accomplished by rotating the tiller (6) toward the front, and right turns are
accomplished by rotating the tiller toward the rear.
SERV7102-01 - 17 - NPI
Vol. 1, No. 4, 2002

3
4
2

13

The implement controls are to the right of the operator's seat. The standard dozer control
lever (1) allows the operator to control all the blade functions with one lever. The functions are:
RAISE, LOWER, FLOAT, TILT LEFT, or TILT RIGHT.

The high/low idle switch (2) is located behind the dozer control lever. Pressing the top of the
switch sets the engine speed to high idle. Pressing the bottom of the switch sets the engine
speed to low idle.

Machines equipped with an optional ripper have a ripper control lever (3) located behind the
implement control lever and the high/low idle switch. The ripper control lever is used to control
RIPPER RAISE, or RIPPER LOWER. On machines equipped with a winch, the winch control
lever would replace the ripper control lever.

The implement lockout switch (4) is located behind the ripper control lever. Turning this switch
to the locked position prevents inadvertent implement movement.

Located at the right rear of the console is an additional action lamp (5) which alerts the operator
of an abnormal condition.

The horn button (6) is located between the dozer control lever and the ripper control lever.
SERV7102-01 - 18 - NPI
Vol. 1, No. 4, 2002

14

ENGINE

The D6R Series II is powered by the C-9 Electronic Engine with Hydraulic Electronic Unit
Injection - B (HEUI-B) Fuel System.

The engine also utilizes the Advanced Diesel Engine Management (ADEM III) Electronic
Engine Control. The C-9 engine in the Standard D6R Series II model is rated at
123 kW (165 hp), and the XL, XW, and LGP D6R Series II models are rated at 138 kW (185
hp).

This engine has an in-line six cylinder arrangement with a displacement of 8.8 liters.
SERV7102-01 - 19 - NPI
Vol. 1, No. 4, 2002

1 2

15

The left side of the engine provides access to:

- Engine oil fill tube (1)

- Engine oil dipstick (2)
- Power train oil fill tube (3)
- Power train oil dipstick

Other components accessible from the left side of the engine are:

- ADEM III Engine ECM

- Fuel transfer pump
- Atmospheric pressure sensor
- Turbo outlet pressure sensor
- Upper (high speed) speed/timing sensor
- Lower (cranking) speed/timing sensor
- Engine oil pressure sensor
- Starter
SERV7102-01 - 20 - NPI
Vol. 1, No. 4, 2002

3
4

16

Mounted to the under side of the hood, and also accessible from the left side of the engine are
the following:

- Electric fuel primer switch (1)

- Primary fuel filter and water separator (2)
- Secondary fuel filter (3)
- Primary and secondary air filters (4)
SERV7102-01 - 21 - NPI
Vol. 1, No. 4, 2002

17

The right side of the engine compartment provides access to:

- Alternator (1)
- Engine oil filter (2)
- Engine oil cooler (3)
- Turbo inlet air pressure sensor (4)
- Power train oil cooler (not visible)
- Turbo (behind shield)
SERV7102-01 - 22 - NPI
Vol. 1, No. 4, 2002

18

COOLING SYSTEM

Shown above is the D6R Series II Advanced MOdular Cooling System (AMOCS) radiator
cooling system with the Air To Air AfterCooler (ATAAC) core on the right side (arrow).
SERV7102-01 - 23 - NPI
Vol. 1, No. 4, 2002

19

On machines equipped with air conditioning, the air conditioning condenser coil (arrow) is
mounted just behind the fan guard, on the left side of the engine compartment.
SERV7102-01 - 24 - NPI
Vol. 1, No. 4, 2002

D6R SERIES II IMPLEMENT HYDRAULIC SYSTEM

HOLD / DIFFERENTIAL STEER

STEERING MOTOR

INLET
MANIFOLD

STEERING
DUAL
TILT
PISTON
BYPASS
VALVE

TO ROD END
BLADE
LIFT

TO HEAD END

PRESSURE
REDUCING
AND CHECK
VALVES

BLADE
TILT

SINGLE
TILT
SHUTOFF
VALVE
DOZER PILOT VALVE
RIPPER
RIPPER PILOT VALVE

20

IMPLEMENT HYDRAULIC SYSTEM

The lift, tilt, and ripper control valves on the D6R Series II are now pilot operated. The
illustration above shows the hydraulic schematic of a differential steer machine with the
implements in the HOLD position.

Pump supply pressure is sent to the implement control valves and is at low pressure standby
when in the HOLD position. At the same time, oil is sent to the pressure reducing and check
valve group (where some of it now becomes pilot oil) which is directed to the pilot control
valves for the dozer control lever or ripper control lever.

The pilot oil is available to be directed to the appropriate control valve when the operator
requests an implement function.

NOTE: The steering control valve on the differential steer machine is still mechanically
shifted. This is the same as on earlier D6R Track-type Tractors equipped with differential
steering.
SERV7102-01 - 25 - NPI
Vol. 1, No. 4, 2002

D6R SERIES II LIFT CONTROL VALVE

DIFFERENTIAL STEER / HOLD

ROD END HEAD END MAKEUP

VALVE

MAIN
CONTROL
SPOOL

FROM
TILT
VALVE

RESOLVER

LOAD CHECK VALVE

FROM STEERING VALVE FLOW PRESSURE TO

CONTROL LIMITER STEERING
TO TILT VALVE VALVE VALVE VALVE

21

The graphic above shows an implement control valve with the implement in the HOLD position
(as described in illustration No. 20) and the pump at low pressure standby.
SERV7102-01 - 26 - NPI
Vol. 1, No. 4, 2002

D6R SERIES II IMPLEMENT HYDRAULIC SYSTEM

BLADE RAISE / DIFFERENTIAL STEER

STEERING MOTOR

INLET
MANIFOLD

STEERING
DUAL
TILT
PISTON
BYPASS
VALVE

TO ROD END
BLADE
LIFT

TO HEAD END

PRESSURE
REDUCING
AND CHECK
VALVES

BLADE
TILT

SINGLE
TILT
SHUTOFF
VALVE
DOZER PILOT VALVE
RIPPER
RIPPER PILOT VALVE

22

The illustration above shows the hydraulic schematic and oil flow when the operator requests a
blade RAISE function.

Pilot oil is directed to the lift control valve. The spool shifts, allowing pump oil to be directed to
the rod end of the lift cylinders. At the same time, the work port pressure is sensed through the
main spool.

This is signal oil, and is directed back to the compensator valve on the pump. The pump
upstrokes to supply the necessary oil required to raise the blade.
SERV7102-01 - 27 - NPI
Vol. 1, No. 4, 2002

D6R SERIES II LIFT CONTROL VALVE

DIFFERENTIAL STEER / RAISE

ROD END HEAD END MAKEUP

VALVE

MAIN
CONTROL
SPOOL

FROM
TILT
VALVE

RESOLVER

LOAD CHECK VALVE

FROM STEERING VALVE FLOW PRESSURE TO

CONTROL LIMITER STEERING
TO TILT VALVE VALVE VALVE VALVE

23

The graphic above shows the same control valve (as described in illustration No. 22) when the
operator requests a RAISE function.

Pilot oil is directed to the valve, shifting the main control spool. Load pressure enters the spool
and is now signal oil. This oil is directed behind the flow control spool, shifting it to the left,
allowing pump oil to open the load check valve and flow to the rod end of the lift cylinders,
raising the blade.

At the same time, the signal oil flows through the resolver network to the compensator valve on
the pump, causing the pump to upstroke to meet the requirements to lift the blade.
SERV7102-01 - 28 - NPI
Vol. 1, No. 4, 2002

24

System Components

Shown above is the redesigned implement pump (arrow) for the D6R Series II DS Track-type
Tractor.

Improved features on this load sensing variable displacement piston pump include:

- Compact design
- Quieter operation
- Increase in pump displacement
- Two bolt mount
- Pump defaults to upstroked position

The implement pump for the D6R Series II FTC Track-type Tractor remains unchanged.
SERV7102-01 - 29 - NPI
Vol. 1, No. 4, 2002

25

This illustration shows the valve stack for a D6R Series II Track-type Tractor equipped with
FTC steering.

The valve stack is located to the right of the operator, below the implement pilot valves (control
levers). The inlet manifold (1) is located on the bottom of the valve stack.

The dozer lift control valve (2), the tilt control valve (3), and the ripper control valve (4) are
pilot operated.
SERV7102-01 - 30 - NPI
Vol. 1, No. 4, 2002

3
2

26

The illustration above shows the pressure reducing and check valve group (1). This valve
reduces the implement pump oil to pilot oil.

The pilot oil flows to the accumulator (2) where some oil is stored and used to lower the
implements in a dead engine situation or during rapid deceleration.

The pilot oil then flows past the implement shut-off valve to the ripper pilot valve (3) and the
dozer pilot valve (4).
SERV7102-01 - 31 - NPI
Vol. 1, No. 4, 2002

27

HYDRAULIC OIL COOLER

The hydraulic oil cooler (arrow) is located on the right side of the engine compartment, behind
the fan guard. Only machines equipped with differential steering have a hydraulic oil cooler.
SERV7102-01 - 32 - NPI
Vol. 1, No. 4, 2002

MAINTENANCE INTERVALS

ITEM D6R D6R SERIES II

Engine Oil 250 hours 500 hours*
Engine Oil Filter 250 hours 500 hours*
Transmission Oil 1000 hours 1000 hours
Transmission Filter 500 hours 500 hours
Hydraulic Oil 2000 hours 2000 hours
Hydraulic Filter 500 hours 500 hours
Final Drive Oil 2000 hours 2000 hours
Fuel Filters 500 hours 500 hours

* Assumes use of recommended oils. Half interval oil changes are

acceptable with lower grade oils.

28

SIGNIFICANT MAINTENANCE CHANGES

All fluid check and fill points are outside the cab, with common groupings and easy access in
mind. Quick change systems for engine oil and power train oil are available as attachments.
Ecology drains are standard for all fluids.

Periodic maintenance item frequency intervals are shown in the chart, above.
SERV7102-01 - 33 - NPI
Vol. 1, No. 4, 2002

2
1
3

29

System Filters and Pressure Taps

Opening the hinged cover on the right fender allows access to the following:

- Case drain filter (1)

- Hydraulic oil S•O•S tap (2)
- Pilot oil pressure tap (3)
- Power train filter bypass switch (4)
- Power train oil pressure tap (5)
- Power train S•O•S tap (6)
SERV7102-01 - 34 - NPI
Vol. 1, No. 4, 2002

30

The power train oil fill tube (1) and power train oil dipstick (2) are located at the rear of the left
side engine compartment.
SERV7102-01 - 35 - NPI
Vol. 1, No. 4, 2002

31

Fuse Panel

Located inside the battery compartment, on the left fender, is the fuse and breaker panel (1).
The D6R Series II uses automotive type fuses.

Also located in the compartment, and below the fuse panel, is the 6V2150 Starting and Charging
Analyzer connector (2).
SERV7102-01 - 36 - NPI
Vol. 1, No. 4, 2002

32

CONCLUSION

This concludes the New Product Introduction (NPI) presentation on the D6R Series II Track-
type Tractor.