-
CT-S-D6 37A1+
CCaatteerr ppii ll llaarrService Manual
D6 CrawlerS/n 37A1 & 44A1 & up
THIS IS A MANUAL PRODUCED BY JENSALES INC. WITHOUT THE
AUTHORIZATION OF CATERPILLAR OR IT’S SUCCESSORS. CATERPILLAR AND
IT’S SUCCESSORSARE NOT RESPONSIBLE FOR THE QUALITY OR ACCURACY OF
THIS MANUAL.
TRADE MARKS AND TRADE NAMES CONTAINED AND USED HEREIN ARE THOSE
OF OTHERS, AND ARE USED HERE IN A DESCRIPTIVE SENSE TO REFER TO THE
PRODUCTS OF OTHERS.
Serv
ice
Man
ual
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IOA~5 Group 10.5
Pagel
5ERV·ICE ··MANUAL '.:,..
for
CATERPILLAR
D6 TRACTOR SERIAL NUMBERS 37 A I-UP AND 44A I-UP
Section
Engine 10-
Starting Engine
_________________________________________________________ _ 20
Power Transmission Units
_________________________________________ _ 30
Track Roller Frame
___________________________________________________ _ 40
Seat, Fuel Tank and Miscellaneous ___________________________ :
200 r
. ',' - ,
PRINTED_IN U,S,A.
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ENGINE
TABLE OF CONTENTS
Index ..
Specifications
Cooling System ...
Water Temperature Regulator
Fan Group
Water Pump
Radiator
Lubricating System
Oil Pan
Oil Pump
Oil Cooler ..
Oil Filter
Fuel System
Fuel Supply Equipment
Fuel Injection Equipment
Governor
Accessory Drive
Air Induction and Exhaust System.
Cylinder Head
Valve and Valve Mechanism
Front Support
Timing Gears
Pistons, Rings and Connecting Rods
Cylinder Liners
Main Bearings
Crankshaft
Flywheel and Flywheel Housing
Engine Removal and Installation
Electrical System
Section
IOA-lO
lOA-lO
10A-IO
lOA-lO
lOA-lO
10A-IO
lOA-lO
IOA-lO
lOA-IO
10A-IO
lOA-I 0
lOA-IO
lOA-lO
lOA-IO
IOA-IO
lOA-IO
lOA-IO
IOA-IO
lOA-IO
9A-IO
9A-IO
10A-IO
IOA-IO
9A-IO
9A-IO
IOA-IO
IOA-IO
lOA-IO
1 OA-I 0
IOA-IO
Group
30.5
40.4
70.2
100.1
130.4 .
140.4
160.2
170.4
180.4
190.4
200.4
210.4
230.3
240.4
250
260.4
265.3
270.6
280.4
290
310
320.4
340
350
360
370
390.3
400.1
410.2
Group 20.5 Page 1
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Accessory Drive Accessory Drive Gear Accessory Drive Shaft
Adjustments:
A
Fuel Injection Pump Timing Dimension Setting Fuel Rack Setting
Governor
Air Cleaner Air Inlet Manifold
Backlash, Timing Gear Bearings:
Connecting Rod Main
Breather, Crankcase By-pass:
Fuel Oil Filter Oil Pump
Camshaft Gear Chambers, Precombustion Cleaner, Air Cleaning:
Engine Valves
Pistons
B
C
Clearances and Tolerances Compression Release Mechanism
Connecting Rods and Bearings Cooling System Core, Radiator Cover,
Timing Gear Crankshaft Crankshaft Pulley Cylinder Head Cylinder
Liners
Directors, Water Drive:
Accessory Tachometer
Electric Starting Motor Electrical System Engine Data Exhaust
Manifold
Fan Assembly Fan Belt Fan Belt Tightener
D
E
F
ENGINE
INDEX
265.3 320.4 2 265.3 - 2
250 7 260.4 5 260.4 4
270.6 1 270.6
320.4 4
340 2
360 210.4 2
240.4 - 2
210.4 1 190.4 -
320.4 - 3 280.4 2 270.6
290 2
340 40.4 -
290 - 3
340 - 2
70.2 - 1 160.2 - 1 320.4 - 2 370
320.4 -280.4 -350 - 1
280.4 2
265.3
260.4 - 4
410.2 - 2 410.2
40.4 -270.6 -
130.4 2 130.4 -130.4
Filter: Fuel, Primary
Oil Flow of Coolant Flow of Fuel Flow of Lubricating Oil
Flywheel Fuel:
By-pass Filter Housing Injection:
Equipment Pumps Pump Housing Pump Lifters Valves
System, Diesel Transfer Pump Priming Pump
Gauge: Fuel Oil
Gear: Accessory Drive Camshaft Crankshaft Idler Ring, Flywheel
Timing Timing Marks
Generator Generator Regulator Governor:
Adjustments
G
Operation and Lubrication Governor and Fuel Injection
Pump Housing Removal
Head, Cylinder Heater Pipe, Air Inlet Housing:-
Flywheel Fuel Injection Pump Governor
Idler Gear Injection, Fuel Inlet:
Air Heater Pipe Manifold Valves
Lifters: Fuel Injection Pump Valve
H
L
10A-1O Group 30.5 Page 1
240.4 4 210.4 -
70.2 230.3 170.4 390.3 -
240.4 2 240.4 2
250 250 2 250 3 250 6 250 - 1 230.3 -240.4 - 1 240.4 3
230.3 170.4 2
320.4 2 320.4 3 370 320.4 5 390.3 320.4 -
320.4 410.2 1 410.2 2
260.4 4 260.4 1
265.3
280.4 -270.6 -
390.3 - 2 250 - 3 260.4 -
320.4 - 5 250 - 1
270.6 -270.6 -290 - 2
250 - 6 290 - 3
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Group 30.5 Page 2
Liners, Cylinder Lubricating System Lubrication:
Piston and Ring
Main Bearings Manifolds:
Exhaust Fuel Inlet Oil
Meter, Service
Oil: By-pass Valve Filter Manifold Pan Pan Plate Pump
IOA-lO
Operating Difficulties:
M
o
Engine Coolant Overheating Engine Fuel System Engine Lubricating
System
Overflow, Sealed Pressure Overheating, Coolant
Pan, Oil Pistons Piston Rings Plate, Oil Pan Precombustion
Chambers Pump:
Fuel: Injection Priming Transfer
Oil Water
Pressure, Oil Gauge
Radiator
p
R
Removing Ring Ridge in Cylinder Liners Regulator, Water
Temperature Release, Compression Ring Gear, Flywheel
ENGINE INDEX
350 - 1 170.4
340
360
270.6 1 230.3 - 1 270.6 170.4 -265.3 2
210.4 -210.4 -170.4 180.4 180.4 190.4
70.2 230.3 170.4 160.2
70.2
180.4 340 340 180.4 280.4
250
2
2
2 3 240.4
240.4 190.4 -140.4 - 1 170.4 2 170.4 2
160.2 350 - 2 100.1 290 3 390.3
Rings, Piston Rocker Arms, Valve Rod, Connecting
s Seal Replacement, Water Pump Seals, Liner Service Meter Shaft,
Accessory Drive
Specifications Springs:
Governor Valve
T
Testing Temperature Regulator Thrust Bearing, Crankshaft
Timing:
Engine Gears Engine Valves Fuel Injection
Timing Gear Cover Timing Gears Timing Marks Tolerances
Valve: By-pass, Fuel By-pass, Oil Inlet and Exhaust Fuel
Injection
v
Inspection and Reconditioning Lifters Operation Pressure
Regulator, Oil Pump Rocker Arm Assembly Seat Specifications Stem
Bushings Timing
Valves and Valve Mechanism
w Water:
Directors, Seals and Ferrules Pump
Seal Replacement Temperature Regulator
340 290 340
2
2
140.4 - 2 350 1 265.3 - 2 265.3 320.4 2
40.4
260.4 -290 2
100.1 -370
320.4 -290 3 250 - 7 320.4 - 2 320.4 -320.4
40.4
240.4 2 210.4 - I 290 - 2 250 - 1 290 - 2 290 3 290 190.4
290
40.4 6 290 3 290 3 290 - I
280.4 140.4 140.4 100.1
2 1 2
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10A-IO Group 260.4 Page 2 ENGINE
GOVERNOR
156559
PREPARING TO REMOVE GOVERNOR HOUSING
U3115
o Remove I-Cover.
PREPARING TO REMOVE GOVERNOR HOUSING
o Remove 2-Nut. 3-Collar.
NOTE
Insert a pin through the hole in the full load stop bolt to
prevent the bolt from turning while removing and installing the nut
(2) and collar (3).
Remove the bolts securing the governor to the fuel injection
pump housing and slide the governor housing away from the fuel
injection pump housing.
Governor Weight Removal
Separate the governor housing from the fuel in-jection pump
housing as outlined in the covering topic.
T 41 9 21
PREPARING TO REMOVE GOVERNOR WEIGHT o Remove I-Bolt. 2-Pin.
3-Thrust bearing. 4-Bumper spring. 5-Seat.
NOTE The bumper spring (4) is installed with the con-cave face
toward the seat (5). This arrangement permits the outside edge of
the spring to contact the seat (5).
WEIGHT REMOVAL
o Remove 6-Weight assembly. 7-Snap ring.
GOVERNOR DISASSEMBLY
1. Remove the seat behind the spring (5).
2. Remove the bolts securing the cover assembly (6) to the
governor housing and remove the cover assembly (6), control shaft
assembly (9) and the governor shaft assembly (IO).
3. The gasket between the cover assembly (6) and the governor
housing should be inspected, and replaced if damaged.
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STARTING ENGINE
TABLE OF CONTENTS
Section
Index ........ 10A-20
Specifications 9A-20
Removal and Installation 10A-20
Lubrication System (Common) 9A-20
Lubrication System (Separate) 9A-20
Lubrication System (With Bypass Oil Filter) 9A-20
Fuel System 9A-20
Cylinder Head and Valves 9A-20
Pistons, Rings and Connecting Rods 9A-20
Timing Chain Housing (Earlier) 9A-2o
Timing Chain Housing (Later) 9A-20
Crankshaft and Main Bearings 9A-20
Starting Mechanism (Earlier) 9A-20
Starting Mechanism (Later) ....... ' . 9A-20
10A-20
Group
30.2
40
80.2
90
90.1
90.2
100
110
120
130
130.1
140
160
160.1
Group 20.2 Page 1
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A
Adjustments: Carburetor Clutch
Control Mechanism
Governor
Valve Clearance
B
Bearings: Connecting Rod Main Piston Pin
Brake, Starter Pinion
C
Cable, Starter
Camshaft
Camshaft End Clearance
Carburetor Chain, Timing
Clearances and Tolerances Cleaning Valves Clutch
Clutch Pinion and Brake Control
Connecting Rods Connecting Rod Bearings Crankshaft Crankshaft
End Clearance Cylinder Head Cylinders
D
Data, Engine
F
Fuel System
G
Gear: Oil Pump
Governor
lOA-20
STARTING ENGINE
INDEX
Group Page H
100 3 Head, Cylinder
160 5 Housing:
160.1 6 Starter Pinion
160 5 160.1 7
Timing Chain
130 3 130.1 5 110 3
L
Lifters, Valve
120 1 Lubricating System
140 2 120 160 3 160.1 3 M
Magneto Drive Trunnion
130 Main Bearings
130.1 2 Mechanism, Valve
130 4 130.1 5 0 130 - 4 130.1 6 Oil:
100 Pump
130 4 130.1 6
40 1 Pump Pressure Regulating Valve
110 2 160 4 160.1 5 160 5 P 160.1 6 120
Pan. Oil
120 Pan Plate, Oil
140 140 2
Pinion. Starter
110 I 120 2
Pinion, Mechanism
Pistons Piston Pin Bearings Pressure Regulating Valve
40 - 1
Pump, Oil
100 - 1
R
Recoil Starter 90 2 90.1 2 Removing Engine 90.2 3 Rings,
Piston
130 3 Rocker Arms 130.1 3 Rods, Connecting
Group 30.2
Page I
Group Page
110
160 160.1 130 1 130 3 130.1 130.1 - 6
110 3 90 - 1 90.1 90.2
130 3 130.1 4 140 - 2 110
90 - 2 90.1 2 90.2 3 90 3 90.1 3 90.2 - 4
90.1 - 1 90.1 - I 90.2 3
160 I 160.1 I 160 2 160.1 2 120 2 120 I
90 - 3 90.1 - 3 90.2 - 4 90 2 90.1 2 90.2 3
130 130.1
80.2 120 2 110 120
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Group 30.2
Page 2
Specifications Starter Cable
Starter Pinion
Starter Pinion Brake
Starter, Recoil ..
IOA-20
Starting Engine Ring Gear Starting Mechanism ....
Timing Chain
s
T
STARTING ENGINE INDEX
Group Page
40 - 1 130 - 1 130.1 - 2 160 - 1 160.1 - 1 160 - 3 160.1 - 3 130
1 130.1 1 140 130 130.1
Timing Chain Housing
Timing the Engine ..
Tolerances Trunnion, Magneto Drive
Valve: Clearance Adjustment Components Lifters Mechanism ......
. Pressure Regulating
v
130 - 4 130.1 - 6 Rocker Arms ........................... .
Group Page
130 - 1 130.1 - 1 130 - 4 130.1 - 6
40 - 1 130 - 3 130.1 - 4
110 - 3 110 1 110 - 3 110 - 1 90 - 3 90.1 - 3 90.2 - 4
110 - 1
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13B-30
POWER TRANSMISSION UNITS
T ABLE OF CONTENTS
Index ....... .
Specifications ..
Introduction .................................... .
Universal Joint .....
Flywheel Clutch .....
Gear Shift and Interlock Mechanism ..
Transmission Removal
Transmission ..... .
Bevel Gear .....
Brakes
Steering Clutches ...... .
Steering Clutch Hydraulic Control
Final Drive ....
Section
13B-30
13B-30
13B-30
13B-30
l3B-30
l3B-30
13B-30
l3B-30
l3B-30
13B-30
13B-30
l3B-30
13B-30
Group
30
40
65
70
80
110
119
120
140
150
160
170
180
Group 20 Page 1
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13B-30
POWER TRANSMISSION UNITS
A
Adjustments: Aligning Track Roller Frame with Sprocket Bevel
Gear Backlash Bevel Gear Shaft Bearing Bevel Gear and Pinion
Setting Bevel Pinion Location Brake, Flywheel Clutch Brake,
Steering Clutch Clutch, Flywheel Final Drive Gear Shift and
Interlock Mechanism Interlock Linkage Steering Clutch Hydraulic
Controls
B
Bevel Gear Bevel Gear and Pinion Setting Brake, Flywheel Clutch
Brakes, Steering Clutch
Clearances and Tolerances Clutch, Flywheel Clutches,
Steering
C
Controls, Steering Clutch Hydraulic
D
Data Drive, Final ...
F
Final Drive Bearing Adjustment Bearing Cage Holder Assembly
Final Drive Seals Floating Ring Seals Gear Pinion Pinion Outer
Bearing Sprocket Sprocket Shaft
Final Drive Seals Flywheel Clutch Fork, Shifter Mechanism
Forward-Reverse Lever
Gear: Bevel Final Drive
G
Gear Shift and Interlock Mechanism
INDEX
Group Page
180 -II 140 4 140 4 140 3 140 5 80 2
150 2 80 -10
180 -10 lID 4 lID 4 170 6
140 140
80 150
40 80
160 170
40 180
1 3
180 - 1 180 -10 180 3 180 - 5 180 - 6 180 -II 180 -14 180 -12
180 - 8 180 -13 180
80 110 110
5 1 5 7
140 - 1 180 -11 110 - 1
H
Hydraulic Control, Steering Clutch Hydraulic Pump, Steering
Clutch
Interlock Mechanism, Gear Shift Introduction:
Transmission ..
Joint, Universal
L
Lubrication, Flywheel Clutch
M
Metal Floating Ring Seals
o Oil Pump:
Flywheel Clutch Steering Clutch Hydraulic Control
Operation: Brakes Flywheel Clutch Gear Shift and Interlock
Mechanism Steering Clutches Steering Clutch Hydraulic Controls
Steering Clutch Hydraulic Pump Steering Clutch Release Yoke
Transmission
Pinion, Final Drive Pump:
Flywheel Clutch, Oil
P
R
Release Bearing, Steering Clutch
Seals, Final Drive Seals, Metal Floating Ring Shifter Fork
Mechanism.
s
Specifications, Tolerances and Clearances Speed Selector Lever
Sprocket, Final Drive Sprocket Shalt, Final Drive Steering
Clutches
Group 30
Page I
Group Page
170 - 1 170 - 4
110
120 65
70 - I
80 - I
180 - 6
80 - 2 170 4
150 80
110 160 170 170 4 160 - 2 120 - I
180 -14
80 - 2
160 - 7
180 180
5 6
110 5 40 1
110 - 5 180 8 180 -13 160 - 1
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Group 30 13B-30
Page 2 POWER TRANSMISSION UNITS INDEX
Group Page Group Page
Steering Clutch Release Bearing 160 - 7 Idler Gear Group 120 - 8
Steering Clutch Brake 150 - 1 Pinion Shaft 120 - 6 Steering Clutch
Hydraulic Control 170 - 1 Removal 119 - 1 Steering Clutch Hydraulic
Pump 170 - 4 Upper Shaft 120 - 4
T U
Track Roller Frame Outer Bearing 180 - 2 Universal Joint 70 -
I
Transmission 120 - 1 Bearing Race 120 -10 Y Counters haft 120 -
1 Gear Shift and Interlock Mechanism 110 - 1 Yoke, Steering Clutch
Release 160 - 2
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13B-30 Group 160 Page 6 POWER TRANSMISSION UNITS
STEERING CLUTCHES
STEERING CLUTCH ASSEMBLY 2-Shaft. 5-Inner drum. A-Dimension to
be checked.
7. Install the inner drum (5) on the shaft (2) using the 7F9540
Hydraulic Puller, 7B8363 Bolt, 7M7238 Sleeve, 5F7353 Washer.
8. Press the steering clutch inner drum (5) onto the clutch
shaft (2) to the pressure given in the topic, SPECIFICATIONS.
9. Measure the clearance (A) from the shoulder on the clutch
shaft (2) to the face of the steering clutch inner drum (5) hub.
See the topic, SPECI-FICATIONS, for the correct dimension.
10. Securely tighten the retaining bolt (17).
T56278
STEERING CLUTCH ASSEMBLY 4-Pressure plate. 23-Insert.
11. Turn the assembly over and install the yoke with the insert
(23) toward the pressure plate (4).
Steering Clutch Release Bearing Disassembly
REMOVING LOCK SCREWS
D Remove I-Pressure plate. 2-Retaining nut.
Inspect the bearing in the pressure plate (I) for excessive wear
and replace if necessary.
REMOVING LOCK RING
D Remove 3-Lock ring.
Turn the bearing cage (6) over. Place it on a sleeve (10) with
an inside diameter large enough to accept the bearing as it is
driven from the cage.
Drive the bearing (8) from the cage using the holes (9)
provided.
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TRACK ROLLER FRAME
T ABLE OF CONTENTS
Section
Index 13B-40
Specifications 13B-40
In trod uction 13B-40
Tracks 13B-40
Tracks 13B-40
Tracks 13B-40
Track Carrier Rollers and Track Rollers . 13B-40
Front Idler and Recoil Spring 13B-40
Front Idler and Recoil Spring 13B-40
Equalizer Spring 13B-40
Track Roller Frame Removal 13B-40
13B-40
Group
30
40
70
80
80.1
80.2
90
100
100.1
110
120
Group 20
Page 1
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A
Adjustments: Front Idler
Track Track Adjusting Mechanism
Track Carrier Roller
Bushings, Track Pins and
Carrier Rollers, Track Clearances and Tolerances
Equalizer Spring
B
C
E
F
Floating Ring Seal Installation Frame Removal, Track Roller
Front Idler
Front Idler Yoke Assembly
Idler, Front
Installing Track
Introduction, Track Roller Frame
Links, Track
Lubrication: Front Idler
Track Carrier Rollers Track Rollers
L
13B-40
TRACK ROLLER FRAME
INDEX
Group Page M
Master Pin
Mechanism, Track Adjusting
100 100.1
80.2 100 100.1
90
4 3 5 7 7 3
Metal Floating Ring Seal Installation
80 80.1 80.2
90 40
4 4 5
110 - 1
90 120 100
6
100.1 100.1 - 3
100 100.1
80 80.1 80.2 70
80
3 3 3 1
3 80.1 - 4 80.2 4
100 100.1
90 90 - 3
Pins and Bushings, Track
Recoil Spring
Rollers: Carrier, Track Track
Roller Frame Removal, Track
Separating Tracks
Specifications Spring:
Equalizer Recoil
Tracks
Track: Adjusting Mechanism
Carrier Rollers Installing
Links
Pins and Bushings
Rollers Separating
p
R
s
T
Track Roller Frame Introduction Track Roller Frame Removal
Group 30
Page 1
Group Page
80 - 2 80.1 2 80.2 3
100 7 100.1 7
90 6
80 - 4 80.1 - 4 80.2 - 5
100 - 4 100.1 - 3
90 - 1 90 3
120
80 - 1 80.1 80.2 40
110 100 4 100.1 - 3
80 - 1 80.1 -80.2
100 - 7 100.1 7
90 - 1 80 3 80.1 3 80.2 3 80 - 3 80.1 - 4 80.2 - 4 80 - 4 80.1 -
4 80.2 - 5 90 3 80 - 1 80.1 - 1 80.2 1 70 1
120 - 1
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13B-40 TRACK ROLLER· FRAME
FRONT IDLER AND RECOIL SPRING
Group 100.1
PageS
REMOVING RECOIL SPRING
8. Install in the reverse order of removaL
9. After recoil spring stops (6) have been installed, loosen
recoil spring bolt nut (2) releasing the recoil spring tension
against the stops, continue turning nut (2) until the end of the
nut extends 1/16/1 beyond the end of the recoil spring bolt.
Install bolt and washer (5) to lock nut (2) in place.
T85188
POSITIONING NUT 2-Recoil spring bolt nut. 5-Locking bolt and
washer.
A-Dimension to be obtained.
Removal and Installation (Hydraulic Type)
NOTE
On machines equipped with the hydraulic track adjusting
mechanism, the recoil spring can be removed without separating the
track providing the recoil spring bolt is not broken.
WARNING
Be certain the hydraulic pressure in the track adjusting
mechanism is completely relieved and the cylinder can be moved to
the rear into the recoil spring front pilot before attempting to
separate the track or remove the track adjusting mechanism. On
machines that have badly worn track. it is possible for the
hydraulic track ad-juster to be adjusted forward to the limits of
its travel and the stop will be against the stop on the track
roller frame. The hydraulic cylinder
could have high oil pressu: a in it even though the track is
loose enough to remove the master pin without relieving the
hydraulic track adjust-ing pressure.
T85177 ,
REMOVING GUARDS I-Guards.
1. Install drawbar pin (4) or hardwood block be-tween the
sprocket and the track, and back the machine slightly to compress
the recoil spring. When all the tension is removed from recoil
spring stops (6), loosen locking bolt and washer (5), and screw
recoil spring bolt nut (2) tight against rear pilot (3). Remove the
drawbar pin or hardwood block.
REMOVING TENSION FROM RECOIL SPRING STOPS 2-Recoil spring bolt
nut. 3-Recoil spring rear pilot.
4-Drawbar pin. 5-Locking bolt and washer.
2. Separate the track and lay it out flat. See the topic
SEPARATING TRACK.
WARNING
See the topic SEPARATING TRACK for correct procedure on
releasing pressure in the hydrau-lic track adjuster cylinder.
3. Remove bolts (7) and separate the cylinder from idler recoil
rod (10). Move cylinder (9) to the rear as far as possible into
front pilot (8). Move the idler rod (10) to the front as far as
possible.
4. Attach a hoist to and remove the recoil spring assembly as
shown.
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13B-200
SEAT, FUEL TANK AND MISCELLANEOUS
TABLE OF CONTENTS
Seat, Fuel Tank and Battery Box Removal .
Seat Cushion Removal .....
Fender Removal
Floor Plate Removal ............ .
Hood Removal ............. .
Dash Removal ...
Stationary Drawbar
Swinging Drawbar ............ .
Crankcase Guard
Front Pull Hook
Track Roller Dirt Guard ..
Section
13B-200
13B-200
13B-200
13B-200
13B-200
l3B-200
13B-200
13B-200
13B-200
13B-200
13B-200
Group
70
70
70
70
70
70
70
70
70
70
70
Group 20 Page 1
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