Caterpillar Cat M318 Excavator (Prefix 8AL) Service Repair Manual (8AL01020 and up).pdf

Service Repair Manual
Models
M318 Excavator

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Product: EXCAVATOR
Model: M318 EXCAVATOR 8AL
Configuration: M318 Excavator 8AL01020-UP (MACHINE) POWERED BY 3116 Engine
Disassembly and Assembly
M318 and M320 Excavators Power Train
Media Number -SENR6258-06 Publication Date -01/08/2008 Date Updated -14/08/2008
i07432296
Transmission - Assemble
SMCS - 3150-016
Assembly Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A
1U-5750 Engine Stand 1
1U-7510 Adapter 1
1U-7508 Adapter 1
B 136-1452 Internal Pliers 1
C 1U-5834 Sleeve 1
D 1P-1859 Retaining Ring Pliers 1
E 8T-5096 Dial Indicator 1
F 1P-0510 Driver 1
G 1P-1855 Retaining Ring Pliers 1
H 1P-1861 Retaining Ring Pliers 1
J 1P-0520 Driver 1
K 1P-1860 Retaining Ring Pliers 1
L 9U-6048 Seal Guide 1
M 9U-6071 Jig Assembly 1
N 9U-6049 Hydraulic Adapter 1
P 439-5246 Pump 1
5S-2403 Nipple Fitting 1
1S-8937 Needle Valve 1
2D-7325 Pipe Tee 1
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8T-0855 Pressure Gauge 1
6V-3966 Fitting 1
6V-4143 Coupler 2
177-7860 Hose Assembly 1
6V-3965 Fitting 1
3J-1907 O-Ring Seal 1
8T-5114 Adapter 1
8T-5115 Hose Assembly 1
Q 9U-6050 Cover 1
R 6V-7030 Micrometer Depth Gauge 1
S 1U-5826 Adjusting Screw 2
T
8B-7548 Push-Puller Tool Gp 1
8B-7554 Bearing Cup Puller 1
8B-7549 Puller Leg 2
8S-6586 Forcing Screw 1
7B-1756 Locknut 1
U 1P-1863 Retaining Ring Pliers 1
V 9U-6053 Seal Installer 1
W
- Loctite LB 8632 Silicone Lubricant (1)
-
-
-
- Loctite LB Superlube (4)
-
(1)
North America
(2)
EAME
(3)
Asia Pacific Division
(4)
South America
Note: Cleanliness is an important factor. Before assembly, all parts should be thoroughly cleaned in
cleaning fluid. Allow the parts to air dry. Wiping cloths or rags should not be used to dry parts. Lint may be
deposited on the parts which may cause later trouble. Inspect all parts. If any parts are worn or damaged,
use new parts for replacement. Replace all seals with new seals.
1. Fasten the transmission housing to Tooling (A).
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Illustration 1 g00679267
2. Install roller bearing (98) in flange (95). The roller bearing is a slip fit. Use Tooling (B) to install retaining
ring (97) in the flange.
3. Use a press and a suitable sized sleeve to install bearing (99) on gear (96). Make sure that the bearing
contacts with the shoulder on the gear.
4. Use Tooling (C) and a press to install flange (95) on gear (96). Install the flange on the splined end of the
gear. Install the flange with retaining ring (97) upward, as shown.
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5. Install shifting collar (93) on gear (96), as shown.
Note: Washer (92) is available in several thicknesses. Washer (92) controls the end play of shifting collar
(93).
6. Install the original washer (92) on gear (96). Use Tooling (D) to install retaining ring (91). ()
7. Use Tooling (E) to check the end play of shifting collar (93). The end play of shifting collar (93) must not
be more than 0.10 mm (.004 inch). If the end play is not correct, change the thickness of washer (92) to
obtain the correct end play.
8. Use Tooling (F) and a press to install roller bearing (94) in the end of gear (96). Install the roller bearing
until the roller bearing contacts with the shoulder in the gear. Install the roller bearing with the
identification toward the outside of the gear.
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9. Install new O-ring seals (23) on valve (16).
10. Install valve (16) in the transmission housing.
11. Use Tooling (A) to rotate the transmission housing to a vertical position, as shown. Install gear assembly
(90) in the transmission housing.
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12. Use Tooling (B) to install retaining ring (89) in the transmission housing.
The photograph displays the shift lever and the shift fork.
(71) Sliding Collar
(72) Plug
(73) Spring Pin
(74) Shift Lever
(75) Pin
(76) Socket Head Bolt
(77) Shift Fork
(78) O-ring Seal
(79) Thrust Pads
(80) Retaining Ring
13. Install a new O-ring seal (78) on pin (75). Use Tooling (G) to install retaining ring (80) on pin (75).
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14. Install two thrust pads (79) in shift fork (77). Install sliding collar (71) on the shift fork, as shown. Place the
sliding collar and the shift fork in position in the transmission housing. Make sure that sliding collar (71)
engages with shifting collar (93).
15. Install pin (75) in the transmission housing and shifting fork (77).
Note: Spring pin (73) holds pin (75) in shift fork (77). Make sure that spring pin (73) is centered in shift
fork (77) after the spring pin is installed. The spring pin must not interfere with the transmission housing.
16. Use a hammer and a punch to install spring pin (73) in shift fork (77) and in pin (75). Make sure that the
spring pin is centered in the assembly.
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17. Install plug (72) in the transmission housing. Tighten the plug to a torque of 60 N·m (44 lb ft).
18. Use the following procedure to assemble planetary carrier (63):
a. Apply Tooling (W) to the 46 rollers. Install the 46 rollers on bearing race (67). Install planetary gear
(66) over the bearing race and the rollers.
b. Use a press to install three planetary gears (66) on the planetary carrier (63).
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c. Install three thrust washers (64). Use Tooling (D) to install three retaining rings (65).
d. Reposition the planetary carrier, as shown. Install roller bearing (69) in the planetary carrier. Use
Tooling (H) to install retaining ring (68).
19. Heat planetary carrier (63) to a temperature of 120 °C (250 °F). Install the planetary carrier on gear
assembly (90) (not shown). Allow the planetary carrier to cool. Use Tooling (D) to install retaining ring
(62).
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20. Install shift lever (74) on pin (75). Position the shift lever in the OFF position. Install bolt (70).
21. Install an M8 bolt and a jam nut in pin (75). Tighten the jam nut and the bolt. Use a suitable sized wrench
to rotate pin (75) in a clockwise direction to the stop. Install socket head bolt (76). Tighten the socket head
bolt to a torque of 46 N·m (34 lb ft).
22. Remove bolt (70). Move the shift lever counterclockwise to the ON position. Install bolt (70). Tighten bolt
(70) to a torque of 46 N·m (34 lb ft).
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23. Use a press to install shaft (32) into roller bearing (57). Make sure that the roller bearing is seated against
the shoulder on the shaft. Install two retaining rings (61) on shaft (32).
24. Invert the shaft. Use Tooling (D) to install retaining ring (56) on the bottom side of roller bearing (57).
25. Use 4C-4079 Brake and Electrical Cleaner to clean the outside diameter of shaft seal (55). Use a press and
Tooling (J) to install shaft seal (55) in bushing (52). Apply 5P-0960 Molybdenum Grease to the lip of the
shaft seal. Install the shaft seal far enough to allow the installation of retaining ring (54).
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26. Install retaining ring (54) in bushing (52). Retaining ring (54) holds shaft seal (55) in position.
27. Apply 5P-0960 Molybdenum Grease to two retaining rings (61). Align the two retaining rings so that the
retaining rings are centered on the shaft.
Note: Make sure that two retaining rings (61) are centered on shaft (32). If the two retaining rings are not
centered correctly, the retaining rings will be damaged when shaft (32) is pressed into bushing (52).
28. Use a press to install shaft (32) in bushing (52). Install the shaft until the shoulder of the shaft contacts with
the bushing.
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29. Use Tooling (K) to install retaining ring (51).
30. Reposition the shaft, as shown. Use Tooling (D) to install retaining ring (50).
31. Install plate (48) on shaft (32).
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32. Use the following procedure to calculate value (B):
Note: Value (B) is determined by the overall thickness of clutch plates (41) and friction discs (40) that are
used in the transmission. Value (B) in transmissions with ten plates must be 10.70 ± 0.10 mm
(.421 ± .004 inch). Value (B) in transmissions with 11 plates must be 7.90 ± 0.10 mm (.311 ± .004 inch).
a. Install flange (45) on shaft (32).
b. Install gear (43) on shaft (32).
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c. Use a hammer and a brass punch to position gear (43) in flange (45). Tap around the gear to seat the
gear correctly in the flange.
d. Install plate (42) on gear (43).
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Note: Make sure that friction discs (40) and clutch plates (41) are dried prior to assembly.
e. Install friction discs (40) and clutch plates (41) on gear (43). Install the friction discs and the clutch
plates in alternating order. Start with a friction disc and end with a clutch plate.
f. Position a straight edge on the end of shaft (32), as shown. Use a caliper to measure the distance
from the end of the shaft to the top of gear (43). Record this dimension as dimension (V).
g. Position a straight edge on the end of shaft (32), as shown. Use a caliper to measure the distance
from the end of the shaft to the face of the last clutch plate (41). Record this dimension as dimension
(W).
h. Subtract dimension (V) from dimension (W). The difference is value (B). Value (B) in transmissions
with ten plates must be 10.70 ± 0.10 mm (.421 ± .004 inch). Value (B) in transmissions with 11
plates must be 7.90 ± 0.10 mm (.311 ± .004 inch). If value (B) is not correct, change the thickness of
the last clutch plate and the last friction disc. Refer to the Parts Manual for further information.
33. Use the following procedure to determine the end play of gear (43) and gear (34):
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a. Install roller bearing (39) on shaft (32).
b. Install gear (34) on shaft (32).
Note: Washer (33) controls the amount of end play for gear (34), bearing (39) and gear (43). The
washer is available in several thicknesses.
c. Install the original washer (33). Use Tooling (D) to install retaining ring (31).
d. Use Tooling (E) to check the end play of gear (34), bearing (39), and gear (43). The end play of the
components must not be more than 0.10 mm (.004 inch). If the end play is not correct, change the
thickness of washer (33). Refer to the Parts Manual for further information.
34. Use Tooling (D) to remove retaining ring (31) from the end of shaft (32). Remove washer (33), gear (34),
and bearing (39) from shaft (32).
35. Remove clutch plates (41) and friction discs (40) from gear (43). Remove plate (42) from gear (43).
36. Remove gear (43) and flange (45) from shaft (32).
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37. Install Tooling (L) on shaft (32), as shown. Slide backup ring (49) over Tooling (L). Make sure that the
backup ring is installed with the sealing lip toward the end of shaft (32). Slide backup ring (49) off Tooling
(L) and into the groove in shaft (32). Remove Tooling (L) from shaft (32). Apply 5P-0960 Molybdenum
Grease to the sealing lip of the backup ring.
38. Install a new O-ring seal (47) on shaft (32). Apply 5P-0960 Molybdenum Grease to the O-ring seal.
39. Install belleville springs (46) on shaft (32). Make sure that the three belleville springs are positioned, as
shown.
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40. Install flange (45) on shaft (32). Position the flange on the belleville springs.
41. Install a new backup ring (44) on gear (43). Install the backup ring with the sealing lip toward flange (45).
Apply 5P-0960 Molybdenum Grease on backup ring (44).
42. Install gear (43) on shaft (32).
43. Use a hammer and a brass punch to position gear (43) in flange (45). Tap around the gear to seat the gear
correctly in the flange.
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44. Install plate (42) on gear (43).
45. Put clean hydraulic oil on each friction disc and on each clutch plate prior to installation. Install friction
discs (40) and clutch plates (41) in alternating order. Start with a friction disc and end with a clutch plate.
Install the friction discs and the clutch plates that are determined in Step 32.a through Step 32.h.
46. Use Tooling (F) to install roller bearing (39) in centering disk (36). Use Tooling (H) to install retaining ring
(38) in the centering disk.
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47. Install centering disk (36) in ring gear (35). Use Tooling (B) to install retaining ring (37).
48. Carefully install ring gear (35) over clutch plates (41) and friction discs (40).
49. Install gear (34) on the end of shaft (32). Install the gear with the shoulder toward the roller bearing.
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50. Install washer (33) on gear (34). The correct size for washer (33) is determined in Step 33.a through Step
33.d.
51. Position the clutch assembly in a press, as shown. Position Tooling (M) on the end of the shaft, as shown.
Make sure that the opening in Tooling (M) is positioned so that retaining ring (31) can be installed. Use the
press to compress the clutch assembly. Use Tooling (K) to install retaining ring (31). Slowly release the
pressure on the clutch assembly.
52. Use the following procedure to check the clutch assembly for leaks:
a. Install Tooling (N) in the end of the clutch assembly, as shown.
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(1) 9U-6049 Hydraulic Adapter
(2) 8T-5115 Hose Assembly
(3) 6V-3965 Fitting
(4) 3J-1907 O-Ring Seal
(5) 6V-4143 Coupler
(6) 8T-5114 Adapter
(7) 8T-0855 Pressure Gauge
(8) 6V-3966 Fitting
(9) 1U-5230 Hand Hydraulic Pump
(10) 5S-2403 Nipple Fitting
(11) 1S-8937 Needle Valve
(12) 2D-7325 Pipe Tee
(13) 6V-3014 Hose Assembly
b. Assemble Tooling (P), as shown.
c. Attach Tooling (P) to Tooling (N). Fill the piston area of the clutch assembly and drain the piston
area of the clutch assembly several times with clean hydraulic oil to make sure that there is no air in
the piston area of the clutch assembly.
d. Apply 3495 kPa (507 psi) of pressure to the clutch assembly for a minimum of three minutes.
Assume that there is no leakage if the gauge pressure does not change after three minutes.
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e. Reduce the pressure to 1998 kPa (290 psi). The clutch should not rotate at this pressure. If the clutch
rotates at this pressure, replace belleville springs (46).
f. Remove Tooling (P). Remove Tooling (N).
53. Install a new O-ring seal (59) and a new O-ring seal (60) on the throttle valve.
54. Install throttle valve (58) in the end of shaft (32).
55. Install the clutch assembly in the transmission housing.
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Caterpillar Cat M318 Excavator (Prefix 8AL) Service Repair Manual (8AL01020 and up).pdf

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