Caterpillar Service Manual D6 & D6C Crawlers S/n 74A, 76A, 4A, 7A, 73A, 82A & 96A & 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 (76A)
IOA-5 Group 0.8 Page I SERVICE MANUAL 'or CATERPILLAR D6 TRACTOR SERIAL NUMBERS 74A -UP AND 76A -UP Section Engine 0 - Starting Engine ---- 20 Power Transmission Units ----------------------------------------- 30 Track Roller Frame -- -------- ------------ ----- ------- ------------- 40 Seat, Fuel Tank and Miscellaneous 200 r- FORM NO. RE00034 PRINTED IN U.E,A.
SERVICE MANUAL GENERAL INSTRUCTIONS IA-S Group 30 Page 9. For ease of seal installation, remove the wear ring. 2. Install the inner expansion rings on the piston. 3. Measure the diameter of the piston to determine the diameter to which the seal must be expanded. The outer seals of the seal assemblies must be expanded to a diameter slightly larger than the diameter of piston to allow the seal to be placed over the piston. Be careful not to overexpand the seals or they can be ruined. NOTE The bars of the expander are graduated, representing piston diameters. If the seal can be slipped off the expander when the inside face of the movable block is at point (A) (indicated piston diameter) the seal is expanded sufficiently. 4. Place a seal on the expander. Turn the crank on the expander until the inside face of the movable block is slightly past point (A). Then return to point (A). Rotate the seal on the expander and expand again. Check to see if the seal will slip off the expander If not, repeat the procedure, expanding the seal farther each time, until seal will slip off the expander when block is returned to point (A). 5. Lubricate the outer seals and place them on the piston. Install and lubricate the wear ring. 6. Select the applicable compressor from the COM PRESSOR SELECTION CHART. Install the clamp on the compressor. Place the compressor loosely over the outer seals. Place the compressor on the piston so the rolled side of the compressor will be facing the cylinder when the piston is installed in the cylinder. This shows the seal on the expander. Illustrated are: -4898 Expander Assembly. A-Indicated piston diameter. 7. Slowly turn the handle on the clamp and force the seals into their grooves. Be certain the seals are being seated in their grooves as they are being compressed. The tools illustrated compressing seals are: 2-8eal compressor. 3-489446 Clamp Assembly. This shows the installation of the piston into the cylinder. 8. Place the piston assembly into the cylinder bore as illustrated; be certain the piston is square in the bore. 9. Drive on the piston rod until the entire piston assembly is in the cylinder bore. Remove the clamp and the compressor. 0. Install the bolts securing the cylinder head to the cylinder with the piston rod fully extended. Tighten the bolts to the torque value in the SPECIFICATIONS. Pumps The direction of pump rotation, clockwise (CW) or counterclockwise (CCW), is the direction the pump turns when viewed from the drive shaft end. Refer to the SPECIFICATIONS for the rotation of a particular pump. After assembling any pump, lubricate it thoroughly. After assembly, the pump must rota'te freely by hand. Assembly of Insert Vane-type Pumps The insert vane-type pump capacity and direction of rotation will vary with different applications. The assembly procedure however will be the same. Before disassembling a pump, mark the pump body and cover to insure correct assembly with respect to port relationship.
0A-IO Group 20.8 Page ENGINE TABLE OF CONTENTS Index.... Specifications.... Cooling System.... Water Temperature Regulator.... Fan Group.... Water Pump.... Radiator... '.... Lubrication System....... Oil Pan and Oil Pan Plate.... Oil Pump.... Oil Cooler.... Oil Filter.... Fuel System.... Fuel Supply Equipment... Fuel Injection Equipment Governor.... Accessory Drive.... Air Induction and Exhaust System... Turbocharger (Schwitzer 4D).... Cylinder Head.... Valve and Valve Mechanism.... Vibration Damper.... Front Support.... Timing Gears.... Pistons, Rings and Connecting Rods. '.. Cylinder Liners.... Main Bearings.... Crankshaft.... Flywheel and Flywheel Housing.... Engine Removal and Installation (74AI) Engine Removal and Installation (76AI) Electrical System.... Section loa-i 0 loa-lo loa-lo 0A-IO 0A-IO 0A-IO 0A-IO 0A-IO 0A-IO loa-lo 2A-O 0A-IO 0A-l0 9A-O 9A-O 9A-O 9A-O loa-l 0 Group 30.S 40.7 70.4.4 30.7 40.S 60.5 70.S ls0.7.6 200.7 20.0 230.5 240.7 250 260.9 265.6 270.0 27. 2S0.S 2 300. 30 320.S 340.2 350 360 370.4 3.6 400.4 400.5 40.5
IOA-IO Group30.S Page ENGINE INDEX A Accessory Drive.... 265.6 - Fan Belt Tightener 30.it\;-. Accessory Drive Gear.... 320.8-2 Filter: -.t": Accessory Drive Shaft.... 265.6 Fuel. Primary.... 240.7 - Adjustments: Oil........ 20.0- Fuel Injection Pump Timing Dimension Setting 250 7 Flow of Coolant.... 70.4 -'J Fuel Rack Selling.... 260.9-4 230.5 Governor.... 260.9-4 70.8 - Air Cleaner 270.0-2 3.6 - Air Inlet Manifold.. 270.0-30 - B Backlash, Timing Gear... Bearings: Connecting Rod.... Main.... Breather, Crankcase Bypass: Fuel.. Oil Filter Oil Pump 320.8-4 340.2-2 360-20.0-2 240.7-2 20.0-2.6 - Flow of Fuel.... Flow of Lubricating Oil........ Flywheel.... Front Support Fuel: Bypass......,.... Filter Housing.... Injection: Equipment.... Pumps....... Pump Housing.... Pump Lifters...................... Valves.... System, Diesel Transfer Pump Priming Pump 240.7-2 240.7 250 250-2 250-3 250 6 250 230.5 240.7 240.7-2 C Camshaft Gear Chambers, Precombustion Cleaner, Air.... Cleaning: Engine Valves.... Pistons.... Clearances and Tolerances.... Compression Release Mechanism Connecting Rods and Bearings....... Coolers, Oil. Cooling System.... Core, Radiator.... Cover, Timing Gear Crankshaft................. Crankshaft Pulley............. Cylinder Head.... Cylinder Liners Decelerator Control Directors, Water.. ' Drive: Accessory Tachometer E Electrical System Engine Data.... Engine Removal and Installation Exhaust Manifold Fan Removal Fan Belt... o F 320.8-3 2.8-2 270.0-2 2-2 340.2-40.7-2 - 3 340.2-2 200.7 70.4-60.5-320.8-2 370.4 320.8 2.8 350 260.9-2.8-265.6-260.9-4 40.5-40.7-400.4-400.5-270.0-2 30.7-30.7 - 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.. Idler Gear Injection, Fuel.. Inlet: Air Heater Pipe Manifold Valves H 230.5 70.8 320.8-2 320.8-3 370.4-2 320.8-5 3.6-320.8 320.8-40.5-40.5-260.9-4 260.9-2 265.6-2.8-270.0-3.6 2 250 3 260.9 3 320.8 250 5 270.0-270.0-2 - 2
Group 30.8 Page 2 0A-IO ENGINE INDEX Lifters: Fuel Injection Pump Valve Liners, Cylinder Lubricating System Lubrication: Piston and Ring Main Bearings Manifolds: Exhaust Fuel.... Inlet Oil Meter, Service L M...,......,............,... 250 6 2-3 350 70.8 340.2-360 270.0-2 230.5-270.0-70.8-265.6-2 Rings, Piston Rocker Arms, Valve Rod, Connecting... Seal Replacement, Water Pump Seals, Liner Service Meter Shaft, Accessory Drive Specifications Speed Limiter Springs: Governor Valve s 340.2-2 2 r 340.2-2 40.8 2 350 265.6 2 265.6-320.8-2 40.7-260.9-3 260.9 2 2 2 Oil: Bypass Valve Filter Manifold Pan Pan Plate Pump Operating Difficulties: Engine Coolant Overheating...... Engine Fuel System Engine Lubricating System Overflow, Sealed Pressure.................. Overheating, Coolant 0 20.0-2 20.0-70.8.7 -.7 -.6-70.4-230.5 70.8 60.5-70.4 Testing Temperature Regulator Thrust Bearing, Crankshaft Timing: Engine Gears Engine Valves Fuel Injection Timing Gear Cover Timing Gears Timing Marks Tolerances Turbocharger Turbocharger Removal T.4-370,4 320.8 2 3 250 7 320.8 2 320.8-320.8-40.7-27. - 270.0-. m, Oil Pistons Piston Rings Plate, Oil Pan Precombustion Chambers Pump: Fuel: Injection Priming Transfer Oil Water Pressure, Oil Gauge p.7-340.2-340.2 -.7 2.8-2 250-2 240.7 2 240.7.6-40.8-70.8-2 70.8 - V Valve: Bypass, Fuel Bypass, Oil Inlet and Exhaust Fuel Injection Inspection and Reconditioning Lifters.... Operation Pressure Regulator, Oil Pump Rocker Arm Assembly Rotators Seat Specifications Stem Bushings Timing Valves and Valve Mechanism Vibration Damper 240.7-2 20.0-2 2-2 250-2 - 2 2 3 2.6 2 2 40.7 3 2 2 2 3 2 300. Radiator Removing Ring Ridge in Cylinder Liners Regulator, Water Temperature Release, Compression.... Ring Gear, Flywheel R 60.5 350 2.4 2 3 3.6 - w Water: Directors, Seals and Ferrules Pump.... Seal Replacement Temperature Regulator 2.8-40.8-40.8 2,4 -
Group 320.8 Page 4 0A-IO ENGINE TIMING GEARS PREPARING TO REMOVE CAMSHAFT GEAR o Remove l-nut. ed in the topic, ACCESSORY DRIVE GEAR RE MOVAL AND INSTALLATION. 3. Install the lock and nut. 4. Check the gear backlash. See the covering topic. PREPARING TO REMOVE CAMSHAFT o Remove I-Bolts. 2-Thrust plate. 3-Camshaft and gear. Checking Camshaft Gear Backlash The backlash between the camshaft gear and the crankshaft gear can be checked by installing a dial indicator as illustrated. The backlash between the camshaft gear and the crankshaft gear is listed in the topic, SPECIFICATIONS. Camshaft Removal and Installation. Remove the pushrods and lift the valve lifters clear of the camshaft. 2. Remove the timing gear cover as described in the covering topic. NOTE Care should be taken when removing the camshaft and gear not to damage the bearings as the cam lobes pass through them. 3. Check the bearing clearance. For the permissible bearing clearance, see the topic, SPECIFI CATIONS. 4. Install the camshaft and gear. NOTE If the camshaft bearings are to be removed, see the topic, CAMSHAFT BEARING REMOV AL AND INSTALLATION. 5. Check the camshaft end clearance as described in the topic, CAMSHAFT END CLEARANCE. CHECKING CAMSHAFT GEAR BACKLASH When a dial indicator reading of a value greater than the permissible backlash is shown, a further check must be made to determine the cause. Excessive backlash indicates that either the timing gears, the main bearings or the camshaft bearings are badly worn.
IOA-20 Group 20.5 Page I STARTING ENGINE TABLE OF CONTENTS Section Index "............ loa - 20 Specifications... 9A- 20 Removal and Installation. loa - 20 Lubrication System. 9A -20 Fuel System 9A -20 Cylinder Head and Valves. 9A - 20 Pistons, Rings and Connecting Rods. 9A - 20 Timing Chain Housing. 9A - 20 Magneto (Wico)........ 2A - 20 Crankshaft and Main Bearings. 9A - 20 Starting Mechanism 9A - 20 Group 30.5 40..5 A. 0 20. 30.2 35 40. 60.2
IOA-20 Group 30.5 Page STARTING ENGINE INDEX A Adjustments: Carburetor..... - 2 Clutch.... Control Mechanism.... Governor.... 60.2-60.2-30.2-5 6 4 Valve Clearance.... 0-2 Bearings: Connecting Rod.................. Main.... Piston Pin... ".... Brake, Starter Pinion... Cable, Starter........ Camshaft.... Camshdft 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.... Gear: Oil Pump Governor Head, Cylinder.... Housing: Starter Pinion Timing Chain.. Lifters, Valve.... Lubricating System.... B C D F G H L 20. 40. 2 20. 60.2-3 30.2-30.2-5 30.2-6 0Q.l - 30.2-2 40. - 0 2 60.2-4 60.2-5 20. 20. 40. 40. 2 0-20. - 2 40. -. -.4-3 30.2-3 0 60.2-30.2-2 0.4 2 Magneto... Magneto Timing Main Bearings.. ' Mechanism, Valve Oil: Filter Pump.... Pump Pressure Regulating Valve.... Pan, Oil..,.... Pinion, Starter....... Pinion Mechanism.... Pistons.... Piston Pin Bearings.... Pressure Regulating Valve Pump, Oil.... Recoil Starter Removing Engine...................... Rings, Piston....... Rocker Arms....... Rods, Connecting...... Specifications Starter Cable Starter Pinion Starter Pinion Brake.... Starter, Recoil.... Starting Engine Ring Gear.... Starting Mechanism.... Timing Chain.... Timing Chain Housing.... Timing the Engine.... Tolerances...... Valve: Clearance Adjustment.... Lifters.... Mechanism.... Pressure Regulating............... Rocker Arms...... M o P R s T v 35-30.2-6 35-6 40. - 2 0 -.4-2.4-3.4-4.4-3 60.2-60.2-20. - 2 20. -.4-4.4-3 30.2 -.5-20. - 2 0 20. - 40. - 30.2-2 60.2-60.2-3 30.2-40. - 30.2-30.2-4 30.2-2 30.2-6 40. - 0-2 0-2 0 -.4-4 0 -
GB-3D Group 20 Page POWER TRANSMISSION UNITS TABLE OF CONTENTS Index.... Specifications.... Hydraulic Control System Testing and Adjustment (74Al).. Hydraulic Control System Testing and Adjustment (7SAl).. Introduction (74Al).... Introduction (7SAl).... Universal Joint (74Al).... Universal Joint (7SAl).... Flywheel Clutch.... Torque Divider Removal.... Torque Divider.... Transmission Hydraulic CQntrol.... Gear Shift and Interlock Mechanism.... Transmission Removal (74Al).... Transmission Removal (7SAl).... Transmission (74Al).... Transmission (7SAl).... Transmission Lubricating System (74Al).... Transmission Lubricating System (7SAl).... Bevel Gear (74Al).... Bevel Gear (7SAl).... Hydraulic System (74Al) Hydraulic System (7SAl).... Brakes.... Steering Clutches.... Steering Clutch Hydraulic Control.... Final Drive.... Section 6B-30 Group 30 40 43 43.. S5 S5. 70 70. 05 0 9 9. 20 20. 30 30. 40 40. 45 45. 50 ISO 70
Group 40 Page 2 6B-30 POWER TRANSMISSION UNITS SPECIFICATIONS Transmission lubrication valve: Location.... Front face of. transmission case Operating pressure at high idle engine speed..... 8 PSI Transmission (74Al)!ouble tapered - forward bearing on bevel pinion shaft: End clearance after assembly.....00 -.007 in. Permissible end clearance.....02 in. Double tapered - reverse idler gear bearing on bevel pinion shaft: End clearance after assembly...00 -.02 in. Permissible end clearance....08 in. Double tapered - forward bearing on upper shaft: End clearance after assembly.002 -.007 in. Permissible end clearance...........02 in. Lubrication regulator valve: Mounting location Set to bypass At pressure of...... Front face of transmission case 8GPM 0 PSI Transmission Interlock Mechanism Interlock linkage adjustment: Dimension between centerline of pins (see text).... Directional selector lever shaft: Shaft diameters Bearing (ID) Bearing (OD) Directional lever: Shaft diameter. Bearing (ld) Bearing (OD) Hydraulic Pump (74AI) Permissible clearance between pump shafts and bearings Pump cover bolt torque Capacity at 0 RPM When developing pressure of 5.22 in..9970 -.99 in..2470 -.24 in..002 -.004 in..25 -.252 in..252 -.253 in..495 -.496 in..99 -.99 in..004 -.006 in..25 -.252 in..006 in. 24-30 lb. ft. 7GPM 300 PSI Transmission (76AI) Type Power shift three speed forward and reverse planetary. Clutch designation: CLUTCH NO. FUNCTION No. Forward Directional Clutch No.2 Reverse Directional Clutch No.3 Second Speed Clutch No.4 Third Speed Clutch No 5 First Speed Clutch I-Transmission case to transler gear case retaining nut. 2-No. 3 clutch, No. 4 clutch and No.5 clutch release springs. 3-No. I clutch and No.2 clutch release springs. 4-Bearing cage to No. carrier retaining bolts. 5-Planet gear shafts. 6-Bearing cage to No.2 carrier retaining bolts. TRANSMISSION 7-Clutch housing retaining bolts. S-No. 4 clutch, and No. S clutch reaction pins. 9-Transmission case to transler gear case retaining bolts. IO-No. S clutch. ll-no. 4 clutch. 2-No. 3 clutch. 3-No. 2 clutch. 4-No. I clutch. IS-No. I clutch, No.2 clutch and No.3 clutch reaction pins. Transmission clutches: No. clutch (4), No.2 clutch (3): Over-all width of 3 new disc assemblies and 2 new plates.42 -.72 in. No.3 clutch (2), No.4 clutch () and No.5 clutch (0): Over-all width of 2 new assemblies and new plate....679 -.697 in. Clutch piston release springs (3): Pounds force........ 27.6-32.4 3.25 in. 3.98 in..56 in. When compressed to Free length after test Spring diameter Clutch release springs (2): Pounds force When compressed to Free length after test 24.9-27.5.375 in..76 in. Spring diameter.....56 in. Clutch reaction pins (5), length Clutch reaction pins (8), length Shafts (5), outside diameter 7.625 in. 5.000 in..3877 -.3883 in. Clutch housing retaining bolt (7), torque Nuts () and bolts (9), torque Bolts (4), torque Bolts (6), torque - lb. ft. 70 - lb. ft. 24-30 lb. ft. 60-70 lb. ft. Hydraulic Pump (76Al) Permissible clearance between pump shafts and bearings Capacity at 0 RPM When developing a pressure of.006 in. 28GPM 300 PSI
6B-40 Group 20 Page TRACK ROLLER FRAME TABLE OF CONTENTS Section Index.. 6B-40 Specifications 6B-40 Introduction.. 6B-40 Group 30 40 70 B C ' Tracks. l6b-40 Track Carrier Rollers and Track Rollers.... 6B-40 Front Idler and Recoil Spring.... 6B-40 Equalizer Bar.... 6B-40 Track Roller Frame Removal... 6B-40 0 20
6B-40 Group 30 Page TRACK ROLLER FRAME INDEX Adjustments: Front Idler Track.... Track Adjusting Mechanism.... Bar, Equalizer Bushings, Track Pins and Carrier Roller Support Carrier Rollers, Track.... Clearances and Tolerances.... Equalizer Bar 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 A B C E F L 0 40-4 - 4-7 - - 4 8 0 - - 6 20 3 70 - - 3 - - 3 Master Pin.... Mechanism, Track Adjusting.... Metal Floating Ring Seal Installation..,.... Pins and Bushings, Track Recoil Spring Rollers: Carrier, Track....... Track.... Roller Frame Removal, Track.... Separating Tracks....... Specifications.... Spring, Recoil.... Support, Carrier Roller.. '.... Tracks Track: Adjusting Mechanism.... Carrier Rollers.... Installing Links.... Pins and Bushings.. Rollers Separating.............. Track Roller Frame Introduction Track Roller Frame Removal........ Yoke Assembly, Front Idler M P R s T y 20 40 70 20 7 6-4 4 3 - - 4-8 7 3 ~ 4 3-3
6B-2oo Group 20 Page SEAT, FUEL TANK AND MISCELLANEOUS TABLE OF CONTENTS Section Group Seat, Seat Frame and Battery Box Removal.... 6B-200 70 :,;- Fuel Tank Removal.... 6B-200 70 Fender Removal.... 6B-200 70 Rear Crossmember Removal.... 6B-200 70 Dash and Control Support Removal.... 6B-200 70 Floor Plate Removal.... 6B-200 70 Brake Pedal and Support Assembly Removal.... 6B-200 70 Hood and Radiator Cover Removal.... 6B-200 70 Drawbar Removal and Installation.... 6B-200 70 Crankcase Guard and Pull Hook Removal.... 6B-200 70 Track Roller Guards.... 6B-200 70