D6 Crawler S/n 37A1 & 44A1 & up

Caterpillar Service Manual D6 Crawler S/n 37A1 & 44A1 & up Service Manual THIS IS A MANUAL PRODUCED BY JENSALES INC. WITHOUT THE AUTHORIZATION OF CATERPILLAR OR IT S SUCCESSORS. CATERPILLAR AND IT S SUCCESSORS ARE 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. CT-S-D6 37A1+

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.

IOA-IO Group 20.5 Page 1 ENGINE TABLE OF CONTENTS Index.. Specifications Section IOA-lO loa-lo Group 30.5 40.4 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 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 0.2 130.4. 140.4 160.2 1.4 180.4 190.4 200.4 210.4 230.3 240.4 250 260.4 265.3 2.6 280.4 290 310 320.4 340 350 360 3 390.3 400.1 410.2

10A-1O Group 30.5 Page 1 ENGINE INDEX Accessory Drive Accessory Drive Gear Accessory Drive Shaft Adjustments: 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 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 A B C D 265.3 320.4 2 265.3-2 250 7 260.4 5 260.4 4 2.6 1 2.6 320.4 4 340 2 360 210.4 2 240.4-2 210.4 1 190.4-320.4-3 280.4 2 2.6 290 2 340 40.4-290 - 3 340-2.2-1 160.2-1 320.4-2 3 320.4-280.4-350 - 1 280.4 2 265.3 260.4-4 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 G Gauge: Fuel Oil Gear: Accessory Drive Camshaft Crankshaft Idler Ring, Flywheel Timing Timing Marks Generator Generator Regulator Governor: Adjustments Operation and Lubrication Governor and Fuel Injection Pump Housing Removal Head, Cylinder Heater Pipe, Air Inlet Housing:- Flywheel Fuel Injection Pump Governor H 240.4 4 210.4 -.2 230.3 1.4 390.3-240.4 2 240.4 2 250 250 2 250 3 250 6 250-1 230.3-240.4-1 240.4 3 230.3 1.4 2 320.4 2 320.4 3 3 320.4 5 390.3 320.4-320.4 410.2 1 410.2 2 260.4 4 260.4 1 265.3 280.4-2.6-390.3-2 250-3 260.4 - Electric Starting Motor Electrical System Engine Data Exhaust Manifold E 410.2-2 410.2 40.4-2.6 - Idler Gear Injection, Fuel Inlet: Air Heater Pipe Manifold Valves 320.4-5 250-1 2.6-2.6-290 - 2 Fan Assembly Fan Belt Fan Belt Tightener F 130.4 2 130.4-130.4 Lifters: Fuel Injection Pump Valve L 250-6 290-3

Group 30.5 Page 2 IOA-lO ENGINE INDEX Liners, Cylinder Lubricating System Lubrication: Piston and Ring 350-1 1.4 340 Rings, Piston Rocker Arms, Valve Rod, Connecting 340 290 340 2 2 Main Bearings Manifolds: Exhaust Fuel Inlet Oil Meter, Service M Oil: By-pass Valve Filter Manifold Pan Pan Plate Pump Operating Difficulties: Engine Coolant Overheating Engine Fuel System Engine Lubricating System Overflow, Sealed Pressure Overheating, Coolant o 360 2.6 1 230.3-1 2.6 1.4-265.3 2 210.4-210.4-1.4 180.4 180.4 190.4.2 230.3 1.4 160.2.2 2 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 s 140.4-2 350 1 265.3-2 265.3 320.4 2 40.4 260.4-290 2-3 320.4-290 3 250-7 320.4-2 320.4-320.4 40.4 Pan, Oil Pistons Piston Rings Plate, Oil Pan Precombustion Chambers Pump: Fuel: Injection Priming Transfer Oil Water Pressure, Oil Gauge p 180.4 340 340 180.4 280.4 2 250 2 240.4 3 240.4 190.4-140.4-1 1.4 2 1.4 2 Valve: By-pass, Fuel By-pass, Oil Inlet and Exhaust Fuel Injection Inspection and Reconditioning Lifters Operation Pressure Regulator, Oil Pump Rocker Arm Assembly Seat Specifications Stem Bushings Timing Valves and Valve Mechanism v 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 Radiator Removing Ring Ridge in Cylinder Liners Regulator, Water Temperature Release, Compression Ring Gear, Flywheel R 160.2 350-2 290 3 390.3 w Water: Directors, Seals and Ferrules Pump Seal Replacement Temperature Regulator 280.4 140.4 140.4 2 1 2

Group 260.4 Page 2 10A-IO ENGINE GOVERNOR 156559 T 41 9 21 PREPARING TO REMOVE GOVERNOR HOUSING o Remove I-Cover. 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 concave face toward the seat (5). This arrangement permits the outside edge of the spring to contact the seat (5). U3115 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 injection pump housing as outlined in the covering topic. 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.

10A-20 Group 20.2 Page 1 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 Group 30.2 40 80.2 90 90.1 90.2 100 Timing Chain Housing (Earlier) 9A-2o 130 Timing Chain Housing (Later) 9A-20 Crankshaft and Main Bearings 9A-20 Starting Mechanism (Earlier) 9A-20 Starting Mechanism (Later)... '. 9A-20 130.1 140 160 160.1

loa-20 Group 30.2 Page I STARTING ENGINE INDEX Adjustments: Carburetor Clutch Control Mechanism Governor Valve Clearance A Group Page 100 3 160 5 160.1 6 160 5 160.1 7 130 3 130.1 5 3 Head, Cylinder Housing: Starter Pinion Timing Chain H Group Page 160 160.1 130 1 130 3 130.1 130.1-6 Bearings: Connecting Rod Main Piston Pin Brake, Starter Pinion 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 Data, Engine Fuel System B C D F Lifters, Valve 1 Lubricating System 140 2 160 3 160.1 3 M Magneto Drive Trunnion Main Bearings 130 Mechanism, Valve 130.1 2 130 4 130.1 5 0 130-4 Oil: 130.1 6 Pump 100 130 4 130.1 6 40 1 Pump Pressure Regulating Valve 2 160 4 160.1 5 160 5 P 160.1 6 Pan. Oil Pan Plate, Oil 140 140 2 Pinion. Starter I 2 Pinion, Mechanism 40-1 100-1 Pistons Piston Pin Bearings Pressure Regulating Valve Pump, Oil L 3 90-1 90.1 90.2 130 3 130.1 4 140-2 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 2 I 90-3 90.1-3 90.2-4 90 2 90.1 2 90.2 3 Gear: Oil Pump Governor G Recoil Starter 90 2 90.1 2 Removing Engine 90.2 3 Rings, Piston 130 3 Rocker Arms 130.1 3 Rods, Connecting R 130 130.1 80.2 2

Group 30.2 Page 2 IOA-20 STARTING ENGINE INDEX s Group Page Group Page Specifications Starter Cable Starter Pinion Starter Pinion Brake Starter, Recoil.. Starting Engine Ring Gear Starting Mechanism... Timing Chain T 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 130-4 130.1-6 Rocker Arms.... v 130-1 130.1-1 130-4 130.1-6 40-1 130-3 130.1-4 - 3 1-3 - 1 90-3 90.1-3 90.2-4 - 1

Group 20 Page 1 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 l3b-30 l3b-30 l3b-30 l3b-30 l3b-30 Group 30 40 65 80 119 140 150 160 1 180

Group 30 Page I POWER TRANSMISSION UNITS INDEX A Group Page H Group Page 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 180 -II 140 4 140 4 140 3 140 5 80 2 150 2 80-10 180-10 lid 4 lid 4 1 6 Hydraulic Control, Steering Clutch Hydraulic Pump, Steering Clutch Interlock Mechanism, Gear Shift Introduction: Transmission.. Joint, Universal 1-1 1-4 65 - I B L Bevel Gear Bevel Gear and Pinion Setting Brake, Flywheel Clutch Brakes, Steering Clutch 140 140 80 150 1 3 Lubrication, Flywheel Clutch Metal Floating Ring Seals M 80 - I 180-6 Clearances and Tolerances Clutch, Flywheel Clutches, Steering Controls, Steering Clutch Hydraulic Data Drive, Final... C D F 40 80 160 1 40 180 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 o 80-2 1 4 150 80 160 1 1 4 160-2 - I 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 Gear Shift and Interlock Mechanism G 180-1 180-10 180 3 180-5 180-6 180 -II 180-14 180-12 180-8 180-13 180 80 5 1 5 7 140-1 180-11 - 1 Pinion, Final Drive Pump: Flywheel Clutch, Oil Release Bearing, Steering Clutch Seals, Final Drive Seals, Metal Floating Ring Shifter Fork Mechanism. Specifications, Tolerances and Clearances Speed Selector Lever Sprocket, Final Drive Sprocket Shalt, Final Drive Steering Clutches P R s 180-14 80-2 160-7 180 180 5 6 5 40 1-5 180 8 180-13 160-1

Group 30 Page 2 POWER TRANSMISSION UNITS INDEX Group Page Group Page Steering Clutch Release Bearing 160-7 Idler Gear Group - 8 Steering Clutch Brake 150-1 Pinion Shaft - 6 Steering Clutch Hydraulic Control 1-1 Removal 119-1 Steering Clutch Hydraulic Pump 1-4 Upper Shaft - 4 T Track Roller Frame Outer Bearing 180-2 Universal Joint - I Transmission - 1 Bearing Race -10 Y Counters haft - 1 Gear Shift and Interlock Mechanism - 1 Yoke, Steering Clutch Release 160-2 U

Group 160 Page 6 POWER TRANSMISSION UNITS STEERING CLUTCHES 11. Turn the assembly over and install the yoke with the insert (23) toward the pressure plate (4). Steering Clutch Release Bearing Disassembly 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. 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. 10. Securely tighten the retaining bolt (17). REMOVING LOCK RING D Remove 3-Lock ring. T56278 STEERING CLUTCH ASSEMBLY 4-Pressure plate. 23-Insert. 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.

13B-40 Group 20 Page 1 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 Group 30 40 80 80.1 80.2 90 100

13B-40 Group 30 Page 1 TRACK ROLLER FRAME INDEX Adjustments: Front Idler Track Track Adjusting Mechanism Track Carrier Roller A Group Page M 100 80.2 100 90 4 3 5 7 7 3 Master Pin Mechanism, Track Adjusting Metal Floating Ring Seal Installation p Group Page 80-2 80.1 2 80.2 3 100 7 7 90 6 Bushings, Track Pins and Carrier Rollers, Track Clearances and Tolerances B C 80 80.1 80.2 90 40 4 4 5 Pins and Bushings, Track Recoil Spring Rollers: Carrier, Track Track Roller Frame Removal, Track R 80-4 80.1-4 80.2-5 100-4 - 3 90-1 90 3 Equalizer Spring 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 E F L - 1 90 6 100-3 100 80 80.1 80.2 3 3 3 1 80 3 80.1-4 80.2 4 100 90 90-3 Separating Tracks Specifications Spring: Equalizer Recoil Tracks Track: Adjusting Mechanism Carrier Rollers Installing Links Pins and Bushings Rollers Separating Track Roller Frame Introduction Track Roller Frame Removal s T 80-1 80.1 80.2 40 100 4-3 80-1 80.1-80.2 100-7 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 1-1

TRACK ROLLER FRAME FRONT IDLER AND RECOIL SPRING 13B-40 Group PageS 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 adjusting pressure. 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. T85177, REMOVING GUARDS I-Guards. 1. Install drawbar pin (4) or hardwood block between 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. 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 adjuster 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 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 hydraulic 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.

Group 20 Page 1 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 l3b-200 Group