Parts 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.

Parts

Man

ual

D6H S/n 2KD1 & Up D6H LGP S/n 1KD1 & Up

Volume 1 of 2

CT-P-D6H1KD

INDEX

A N o me Po,.

Aid -Ether Starling ....... ----- ............ 127

Air Cleoner ····-----··········· ·· ·········· · .. ·56

Air Conditioner ' ... -........................ 379

A ir Conditioner Arrangement ............ 378

Air lines ············· · ···· __ ····· ·· .. ··· · .. 58 & 59

Alarm-Bock·up ··· ··· ··········· -." .-"'-'-' 118

Alternotor -_········ · .. ········ __ · __ ············ ·99

Arm-Push · __ ······ .. · .. ··········--··· 310 & 311

Axle - Powertrain .. ------ ......... ---- ...... 170

B Bock-up Warning ... _- ........... .. 141A

Bar - Equa lizer ... --- ..... ----- .. . -- m & 230

Bollery & W iring ... . ----- .... ..... ......... 112

Blade-Angling-Bulldozer ·· -··· ···· ····· 308 Blade Position Control

Arrangement .. __ ···· ···· ······· ········ 141 B

Blade - Straight - Bulldozer ...... 306 & 307

Blade - Universal- Bulldozer . ......... 309

Block -Cylinder ··················· · ············· 10 Blower Fan ...................................... ·48

Blower - fan - Co b Pressurizer ......... 360

Bottle - Windshield Washer 357 Box - Battery ........ -........................ 126

Broce - BuuUdozer ........... .. ........... 312

Breather - Crankcase ········ -··············· 40

Bulldozer Arrangemenl ···········- 302 thru 305

C Cab ······························· - _ ........... 368

Cob Arrangement .............. -.- . 354 & 355 Cab Heater ................................. 363

Cab liner .................................... 364

Cab-Pressurizer . . ........................ 358

Canopy ........... -.................. 340 & 342

Camshaft ··························· -·- ··· 15 & 84

Cop - Fuel Filler Protection ··-·· -············69

Cap - fuel Tonk .- .... ·······················68

Cop - Radiator Filler ············· .. ··-········· 43 Cap - Track Idler .. -....................... 233

Nome

Cap - Track Roller ................... .... . 233

Carrier Roller _. _. __ ......... -. -. 232A

Cartridge - Turbocharger ·····················61

Case & Covers - Winch ............. .... . 330

Case & Frame ...................... ..... ... 183

C - Frame .. -................................ 313

Case & Ports-Transmission ............ 156

Cleaner - Air ····································56 Clutch & Broke - Steering ....... -. __ .... 176

Compressor - Refrigerant ............. ..... 382

Connecting Rod & Piston ·················· 15

Control -Clutch & Broke Steering ······ 178

Control - Hydraulic Hand······ 288 thru 292

Control - Hydraul ic Transmission ...... 152 Control - Transmission ..................... 161

Contral- Winch ··············· 293, 294 & 295 Converter - Torque ........................ 143

Cooler - filter Bose & Engine Oil-·-52 & 53

Cooler - Transmission Oil ······· ······· ····54

Coupling & Guard - Transmission ...... 171

Cover - Cylinder Blo<;k··· ··········· ······ ···· 12

Cover-Front Housing ··············-··-······21

Cover - Protection - Radiator Cap · -·· ····47

Cover - Protection - Hydraulic Tank Cop ....... . ................ _- ... 250

Cover - Sound Suppression ·········· · ·······21

Cover - Valve Mechanism _······· 19

Crankshaft ······································· 14

Crankshaft Pulley ······················ · ·······25

Crankshaft Seol ································· 14 Cylinder Block. .............................. ·· 10

Cylinder Block. Cover _ .. _ ................. ·· 12

Cylinder Head ....... ... ...... ············· ·· 16

Cylinder Head Fastener .......... -. ·- ······ 18

Cylinder - Dozer lift ··············· 285 & 286

Cylinder Mounting - Bulldozer ......... 315

Cylinder - Ripper lift ..................... 287

Cylinder - Tilt ........................ 283 & 284

D Damper .......... -29

Nome Poge

Disposol - Fumes ~~~ ~~~·············· 40

Drain lines ....... ····.···· ... ·· ···.···· ... ·· .. ·.·71 Drowbor .... ... ....................... 198 & 199

Drive - Final 174

E Ejector - Dust ····································65

Enclosure ······································· 187

Enclosure-Engine - Open ROPS ..... . 188

Enclosure - Engine -Enclosed ROPS ... 188 End Bit ....................................... 315

Engine Arrangement ........................... 8

Engine lift ing ··························· ·········22

Engine Mounting ··········· ················ ·· ·22

Engine Oil Filler · · ······-·· ··· ················39

Engine Oil Filter Base ·····-··············-·· -54

Engine Oil level Gauge · ········ ············35 Engine Oil lines ...................... ····38

Engine Oil Pan ··················-········-·····34

Engine Oil Pump ... ··························36

Engine Support ·································24 Exhaust Manifold ...................... ······55

E)(haust Shield ·································64

F Fan - Blower ... ·····48

Fan Drive ······-································30

Fan - Reversible ........... ····················· 49

fastener - Cylinder Head ····················· 18

Fastener-bhaust Manifold ··················55 Fastener - Final Drive ..................... 173

Fastener - Front Housing ··-··················20

Fastener - Oil Pan ......... .. ·- ············-· -34 Fender .......... ... ............................. 200

Filler - Engine Oil ······························39

Filler - Powertrain Oil ····················· 160 Filter Bypass - Winch ..................... 299

Filter - Primary Fuel ···························73

Fil ter -Secondary Fuel ························74 Filter-Transmission ' -.................. 166

Flywheel ............... -........ ·················32

Flywheel Housing ........................ ···31

Nom. Pog.

Frome & Case .............................. 183

Frome - Track Roller

ITelescoping Recoil) ......... 222 & 224

Front Housing Cover ········· -···· ········ · ·21 Front Pull Hook .............................. 212

Fuel Injection lines ············_·············85 Fuel Injection Pump ..... . ............ 82 & 84

Fuel lines ········ -··· ···························70

Fuel Pump HOUSing -·············-············83 Fuel Tonk ........................... ···· ·······68

Fuel Tonk Droin lines ························71 Fuel Tonk Guard ........................... 209

Fuel Transfer & Mounting Pump··· ·········75

Fuel Transfer Pump ····· ········ ·-············75

G Gouge - Engine Oil level ·····--·-·········35 Gouges - Instrument -.............. 333

Gear & Clutch - Winch ......... -." "'. 326

Gear - Bevel & Transfer ........ -......... 150

Gear - Front Timing ···························25

Gears - Engine Rear ···························33

Governor & Fuel Injection Pump ·········76 Governor · ......... ...... ....................... ···78

Governor 8. Decelerator Control ·········66 Grill· ·········· ........................ 2128. 213

Guard-Bottom .................. ............ 194

Guard-Bottom-Heavy Duty· ··········· 196

Guard - Bottom - Sound Suppression ... 195 Guard - Radiator .............. -.......... .. 210

Guard - Track Guide ""'.". -". - 237

Guard - Track Roller ··············· 235 8. 236

Guard - Transmission ························ 197

Guard - Vandalism -Instrument Panel ··· 338

H Head - Cylinder ·- -···············-·-··-········· 16 Healer - Cab ..... ....... .......... .......... 363

Hood & Guard ................... -- 185 8. 191 Hood -................................. -..... 186

Horn - Electric ··················-·············· 333

Housing & Regulator ... ····· ·-·-····· ······51

Name Palle

Housing - Flywheel .... ·.···············.· ··· 31

Housing - Front ·············-···· · ·- ············20

Hydraul ic Arrangement ············ 247 & 248

Hydra ulic O il Cooler Arra ngement · . 248E

Idler - Track ························ 220 & 221

Instrument ··························· 335 & 336

K Kits - Related Repa ir ....... -... . . . ......... 390

L lamps - Flood ............................... 136

lamps - Head .................... . ............ 136

lever - HydrauliC Control ··· ···· ··········· 265

lifting - Engine ·····················-···········22 lighting . . . -. ...................... . .. -....... 130

lighting - Rood ................ .. .. .......... 132

liner - Cob .. .................................. 364

lines - Fuel ·················· ....... . .......... ···70

lines - Air ······························ 58 & 59 lines - Air Conditioner ...... . .. . ........... 380

lines - Cab Heater ....... .. . ..... ......... 364

lines - Engine Oil ··· .. ········ · ···· · · · ·········38

lines - Fuel Injection ··········· · ···············85

lines - Fuel T anlt Drain ····· -···········71

li nes-tift Cylinder ········· 268, 270 & 271 Unes - Powertrain Oil . . ..... -. -.- ......... 164

lines - Powertrain Cooler """"""""" 159 lines - Ripper ... -..... ·········· ··· · 277 & 278

lines-Tilt Cylinder ··· ··· 269,274, 275&276 lines - Turbocharger O il ...... . ........... ··62

lines - Water ····································51 lines - Winch Oil ................ 279 & 280

link - Track .................................... 245

linkage - Implement - Winch ............ 296

low Temperature

Starting Arrangement ----------- --- 128

M Manifold - Exhaust ··············· ............. ··55

Mirror - Side - ROPS ························ 345

Name Palle

Motor - Electric Starting · ············· -··· 86 Mounting - Cob .. . ........................... 202

Mounting-Carrier Roller -' . 232B

Mounting - Eng ine ......... .. ···········-···22

Mounting- Ripper ............ 318

Mou nt ing - ROPS ......... ········· -······ 201

Mounting - Transmission ................ 158 Mount ing - W inch ... -...................... 332

Muff ler ........... -....... ·················-···63

N Nome Plates and Transfers """ . ... .... 389

o O il Pan ------ ---------34

p Piston & Connecting Rod ···············-·· 15

Pivot - Wiper Arm ··························· 375

Pivot Bar ······································· 234

Planetary ······· .. ·························· · ··· 146 Platform ....................................... 204

Protection - Vanda lism -Engine Oil

level Gauge ······················ · ·······35

Prescreener ····· .... ·················· -·- ·· .. · -.. ·57

Protection - Vanda lism - Engine O il Filler ······ ................................. ···39

Pulley- Crankshaft ············ .. ·············25

Pump - Engine Oi l········ ·····················36

Pump - Fuel Priming ············ .. ·············72

Pump - Fuel Transfer & Mounting ·········75 Pump - Gear - Hydrau lic .................. 250

Pump - Gear - Transm ission ............... 168

Pump - Gear- W inch ..................... 251

Pump - Governor & Fuel Injection ·· .... · .. 76

Pump - Water ··································· 50

R Rad iator ........................... -··········42

Roading Arrangement ..................... 128

Recoil & Adjustment Track ............... 228

Regulator & Housing ········ .... ··· ·· --·····51 Ripper ................................. -........ 317

Nom. P ...

Ripper Arrangement .... . . . . . ............... 316 Roller - Track .................. . .............. 231 ROPS ....................................... 345

ROPS - Open ................................. 344

5 Screen-Pawertroin Oil l ines ............ 167

Screen -Winch Magnetic ··············· 282

Seal - Crankshaft ······························ 14 Seal ......................... . ... . . . ·· · 346 & 348 Seal - Adjusler ............... .. .. -.. . ....... 352

Seat - Suspension ........................... 347

Shaft - Main Drive··························· 172

Shield - Exhaust ·············· ···················64 Sound Suppression

Arrangement ········ -·· · ······ 384 & 385

Sound Suppression Cover ·-- ···············21 Sound Suppression Ponel-·· · · ·········· . ··· 13 Specifications ··', ..... ... . . .... . . ......... .... 392

Support - Engine· · · .......... . .. . . . ............. ·24

Support - Platform ........... .. - -. .......... 208 Sweeps ........ . .... . ........ . . . - -. .......... 218

Switch - Disconnect ........................ 118

Switch - Filter Bypass ............ . .. . ... . . 119

Switch-Start ································· 338

T Tonk & Filter - HydrauliC ... . .. -.......... 249

Tank - Fuel ··· ·················· ······-···········68 Tool······ .. ······················ .... ··········· 387 Tooth - Ripper ........................ ···· 319

Torque Control ···························· ···17 Torque Converter .. '..................... 142

Track ................ - . -. .... 238 thru 244

Transmission Arrangement 145

Transm ission Guard · ... -.. . 197

Transmission Oil Cooler ·····················54

Trunnion - Bulldozer ······················· 314

Trunnion - Engine ············ .. ················29 Turbocharger ................................ 60

Turbocharger 0 ;1 lines ············-········62

v Nome POll·

Valve Mechanism Cover ...... -. . ........... 19

Valve - Check - Hydraulic Control ······ 263

Valve-Control - Clutch & Broke Steering ....................... . . .. .... 182

Valve - Hydraul iC Control ··· ·252 thru 255 Valve - HydrauliC Control Shuttle .. -... 261

Valve-Inlet Flow Control & Relief ... 257

Valve-Mechanism········ .. ··· ···· ············ 19

Valve - Pressure Control - W inch ...... 301

Valve - Priority - Transmission Hydraulic

Control ·························.. 153 Valve - Quick. Drop - Hydraulic

Control ······························· .. 256

Valve - Re lief - HydrauliC Control ······ 262

Valve - Relief - Powertrain Oil lines ... 167

Valve - Selector & Pressure Control - Transmission . . . . -.. ...... . 155

Valve - Selector & Pressure

Control - Winch ············· ·· 298 & 300

Valve - Unit Test - Transmission

Hydraulic Control ······· · ·· ······ . ... 154

Vandalism Guard - Fuel Drain Lock. · .. · .. 71

W Washer - W indshield····· .. ·· .. ·· .. · .... · .. · 366

Water Pump · .. ··········· .. ······ .. ··· .. · .. ·· .. 50

Water-lines ···················· · ···············51

Winch Conversion··············· .. · 323 & 324

Winch - Installation Arrongement ...... 322

Winch - Towing

Arrangement ············ 320, 321 & 324 W incher Undercarriage Arrangement ··· 219 Window - Sliding - Cob ...... ... 370 & 371 W iper ................ . ................ 372 & 374 Wiper - Motor .............................. 376

Wiring & Battery ····················· ·· · .. · 112

y Yoke - Pump Drive ...................... . .. 172

8 BASIC ENGINE

Consists of :

CENTRAL STRUCTURE

8N5286 CYLINDER BLOCK GROUP ......... .

Page

10

lNI342

6N8079

CYLINDER BLOCK COVER GROUP CRANKSHAFT GROUP······ ..... .. ........ .

.... ... ............ 12

................ 14

2P6224 CRANKSHAFT SEAL GROUP - --, ... '" .. ··············· 14

- OR -

2P6226 CRANKSHAFT SEAL GROUP ..... -,_ ............... 14A

6 lW6588 CONNECTING ROD & PISTON GROUP .....•.......... · 15

lN4406 CAMSHAFT GROUP········ ............. -......................... 15

UPPE R STR UCTURE

7N8876 CYLINDER HEAD GROUP ..................... ....... 16

7N9536 CYLINDER HEAD FASTENER GROUp·· .......... ···· 18

7N8026 VALVE MECHANISM GROUP ... .. ................. ," 19

BN4745

6N8326

VALVE MECHANISM COVER GROUP

ENGINE LIFTING GROUP

19 ......... ·22

fRONT STRUCTURE

8N303

8N872

lW5634

1w7831

BN4422

2W6683 2P6528

8Nl07

fRONT HOUSING GROUP ... ....... .. . . . .......... ..... 20

fRONT HOUSING fASTENER GROUP· ........ . ····20

FRONT TIMING GEAR GROUP ········· .... ... . .. ...... . 25 DAMPER GROUP ... ...... ...... ........ .... ..... .... .......... . ..... 29

ENGINE SUPPORT GROUP····· · ... .... .. ... ........... ........ 24

CRANKSHAfT PUllEY GROUP ...... ... ...... ... . .............. 25

fRONT HOUSING COVER G ROUP ......... ................. 21

ENGINE TRUNNION GROUP .. .... ...... .. .................. 29

REAR STRUCTURE

1WI154 FlYWHEEL HOUSING GROUP ·· ··································31 7N2729 FlYWHEEL GROUP .. .......... .... ................................ 32

I W5034 REAR GEAR G ROUP ... ......... .. ............. .. .................... 33

l OWER STRUCTURE

2P6152

2P6200

4W4269

Oil PAN GROUP ..... . . ... ..... ....... . . .. . . ...... .... 34

Oil PAN FASTENER GROUP .... .............. .... ...... 34

OIL LEVEl GAGE GROUP ......... ... . . .... ... .. 35

lW2630 ENGINE ARRANGEMENT - BaSIC - Part 1 of 2 EflecllYe Wllh Senal No. 10Z876.5 - UP

J3.52.52E

BASIC ENGINE

Consists of :

LUBRICATION SYSTEM

2P1784

2P6105

I P4244

4W4270

Page ENGINE OIL PUMP GROUP .................... ... ......•.. ... .. 36

ENGINE Oil LINES GROUP ··· ·· ··············· ····· ········ .... . 38 BREATHER GROUP ... .. .. .. .. .... ... .... ................ .......... .. 40

OIL f iLLER GROUP .... ............ ..... ...... .. ......... ............ 39

COOLING SYSTEM

lN5909

2W6779

2W2272

7N2731

WATER PUMP GROUP······ .. ..... ....... ... ... ... ............. .... 50

WATER LINES GROUP ······· ··· ··· ·····. · ... · .. · ..... ... ............. 51

f ILTER BASE & ENGINE OIL COOlER GROUP ··· ···· ....... . 52

TRANSMISSION O IL COOLER GROUP ····· ······· ··· ··· ·· .... 54

INTAKE & EXHAUST SYSTEM

8N3726 AIR LINES GROUP ········ ··· ·· ···· ······ · ............. ...... ........ 58

6N l 64 EXHAUST MANIFOLD GROUP ---······ ·········.····· · .. .. ....... 55

8N2669 TUR80CHARGER GROUP··· ······ ·························· ..... 60

- OR-

7C8657 TURBOCHARGER GROUP ·· ····· ........................ .. .. .. .. . 60A

8NI501 TURBOCHARGER OIL LINES GROUP .·.·.· ....... ...... . .. .. ... 62

- OR -

9Y5727 TURBOCHARGER OIL LINES GROUP ... ...................... 62A

IW4486 EXHAUST MANifOLD fASTENER GROUP ....... ....... ... ... . 55

FUEL SYSTEM & G O V ERNO R

lW3489 GOVERNOR & FUEL INJECTION PUMP GROUP ......... .. . 76

7C9602

lW3609

7W5156

IWI690

2W 1605

2W41 60

- OR -

GOVERNOR & fUEL INJECTION PUMP GROUP ...... ... .76A

fUEL INJECTION LINES GROUP ··· ..... ...................... ... 85

SECONDARY filTER GROUP ................................ ... ... .74

PRIMARY FUEL FILTER GROUP ............................ ....... .13

DRAIN LINES GROUP ·············· .. ·· .............................. 71

FUEL TRANSFER PUMP & MOUNTING GROUP .- ..... ____ 75

J36322E

lW2630 ENGINE ARRANGEMENT Basic - ParI 2 01 2 Effective wHh Sfmal No. 10Z876!l - UF'

9