Caterpillar Cat D8K TRACK-TYPE TRACTOR Dozer Bulldozer (Prefix 77V) Service Repair Manual (77V00001-05005).pdf

Service Repair Manual
Models
D8K TRACK-TYPE TRACTOR

Shutdown SIS
Previous Screen
Product: TRACK-TYPE TRACTOR
Model: D8K TRACK-TYPE TRACTOR 77V
Configuration: D8K TRACTOR / POWERSHIFT / 77V00001-05005 (MACHINE)
Disassembly and Assembly
173, 183, 193 HYDRAULIC CONTROLS
Media Number -SENR7008-02 Publication Date -01/10/1980 Date Updated -12/10/2001
Dozer Control Valve
SMCS - 5076-15; 5076-16
Disassemble Dozer Control Valve
1. Remove detent plugs (1), springs (2), seats (3) and balls (4).
NOTE: There are two of these detents, 180° opposite of each other on housing (5).
2. Remove four bolts from housing (5) and remove housing from valve body.
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D8K TRACTOR / POWERSHIFT / 77V00001-05005 (MACHINE)(UEG0891S - 01) ...
2019/12/31
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3. Remove four bolts from control lever housing (6) and remove housing from valve body.
4. Carefully remove spool valve (7) from valve body.
NOTE: Spool must be removed from body through the detent end.
5. Remove two plugs, (8) and (12) from the valve body. Remove shims (in the plugs), pistons (9),
springs (10) and valves (11) from the valve body.
NOTE: The plugs are marked with the pressure setting for the respective valve.
6. Remove four bolts from cover (13) and remove from valve body.
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7. Remove spring (14) and valve (15).
NOTE: This is the relief valve for the tilt circuit.
8. Remove springs (17) and (18) and valve (16).
NOTE: This is the dump valve for the main relief valve.
9. Remove four bolts from valve body (19) and remove body from valve group.
10. Remove, inspect and clean shuttle valve (37) and resolver valve (38).
11. Remove four bolts from end cover (20) and remove cover from valve body.
NOTE: There is a small amount of tension on the spring behind the cover.
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12. Remove springs (22) and (23), sleeve (21) and spool (24) from valve body.
NOTE: There are two more springs and a sleeve on the opposite end of spool (24). Remove these
too.
13. Remove sleeve (27), spring (26) and valve (25).
NOTE: There is another sleeve, spring and valve on the other side of the valve. Remove these too.
These are make-up valves for the tilt circuit.
14. Remove plug (31), spring (30) and valve (29) from body of valve.
NOTE: This is a make-up valve for the dozer lift. The other make-up valve is located under plug
(28). Remove it too.
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15. Use a 1/4 inch hex wrench to remove bolt (36) from the end of spool (7). Take the bolt out
carefully because of force by spring (34) behind retainer (35). Remove retainer (35) spring (34)
retainer (33) and washer (32) from the valve spool.
Assemble Dozer Control Valve
1. Install washer (32), retainer (33), spring (34) and retainer (35) on spool (7). Put 9S3263 Thread
Lock Compound on threads of bolt (36) and install into spool.
2. Install valve (29), spring (30) and plug (31) into valve body. Do this for two valves. Second
valve is behind plug (28).
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3. Install valve (25), spring (26) and sleeve (27). Be sure and use a new O-ring seal on the sleeve.
Do this for two valves, one on each side of the body.
NOTE: Do not push the sleeve in even with the valve body.
4. Install valve spool (24) for tilt circuit. Install retainer (21) and springs (22) and (23). Install O-
ring in cover (20).
5. Use four bolts and assemble cover (20) to the valve body. This will cause the valve in Step 3 to
become flush with the valve body.
6. Install shuttle valve (39) and resolver valve (40) in body.
7. Install O-rings in body and assemble to valve body with four bolts.
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8. Put SAE oil on the valves. Install tilt relief valve (15) in the valve body. Install spring (14) in
valve (15). Install dump valve (16) for the main relief valve in the valve body. Install springs (17)
and (18) in the bore in dump valve (16).
9. Install seal (38) for the pilot valve of the tilt relief valve and seal (37) for the pilot valve of the
dozer relief valve. Install O-rings.
10. Install cover (13) with four bolts.
11. Install valve (11), piston (9), spring (10), shims and plug (12) in the bore for the tilt relief
valve. The plug that is marked 2500 psi is the plug for the tilt relief valve. The plug marked 2400
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psi is for the main relief valve. Install the valve, piston, spring, shims and plug (8) for the main
relief valve.
12. Put SAE 10 oil on spool (7). Install spool (7) in the valve body.
NOTE: Spool (7) for the control valve must be installed from the detent end.
13. Install control lever housing (6) with four bolts. Be sure that the pawls on the lever engage the
spool correctly.
14. Install housing (5) over the end of spool (7). Fasten the housing to the valve body with four
bolts.
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15. Install ball detents (4), seat (3), spring (2) and plug (1) in housing (5). Be sure the O-ring seal
is on plug (1) before installation.
NOTE: There are two detents in housing (5). Do the procedure above for the other detent. The
chamfer side of seat (3) goes down against ball (4).
Copyright 1993 - 2019 Caterpillar Inc.
All Rights Reserved.
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Tue Dec 31 19:22:06 UTC+0800 2019
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Shutdown SIS
Previous Screen
Pilot Valve Group
SMCS - 5076-15; 5076-16
Disassemble Pilot Valve Group
NOTICE
Before pilot valve group (1) is removed from the tractor, be sure that
all the pressure in the system has been released. Disconnect the linkage
and oil lines and remove the valve from the machine.
1. Remove three bolts (2) from valve body (1).
2. With the removal of bolts (2), the group can now be divided into pilot valve (6) for dozer tilt
control, pilot valve (5) for ripper lift control, pilot valve (4) for ripper tip control and two end
manifolds (3) and (7).
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3. Remove the bolts that hold cover (8) on the end opposite the shaft end of the valve. Remove
cover (8). Carefully remove spool (9) from body (5).
NOTE: The pilot valve in the illustration is used on the ripper lift or ripper tip control.
4. Carefully put spring (11) under compression. Remove retainers (10) from the valve spool.
Slowly release the compression on spring (11).
5. Remove two bolts holding cover (12) to body (5). Remove the cover.
NOTE: There is a seal in cover (12). Check this seal for damage. If the seal is damaged, replace
with a new one. Do not remove the seal if it is not damaged.
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6. Remove plug (13) from the end of the spool. This will open a passage to the small hole (14).
Check the seal on plug (13).
7. Do Steps 2 through 5 for the other two valves.
NOTE: There is no plug (Step 6) in the end of the spool for the control valve for dozer tilt.
Assemble Pilot Valve Group
1. If necessary, install a new shaft seal in cover (12) on the shaft end of the valve.
2. Install a new O-ring on plug (13) and install in the end of spool (14). Be sure that the passage in
spool (14) is open.
3. Put a new O-ring seal in the housing and install cover (12) on the end of the body.
4. Assemble the valve spool with retainers and spring.
5. Install spool (9) in the valve body. Put the spool in oil for easier installation.
6. Do Steps 1 through 5 for the other valves.
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7. Assemble the valves in correct order. Install three bolts (2) through the end manifold, the valves
and the remaining manifold. Tighten bolts. Be sure not to cut an O-ring seal between each part.
Tue Dec 31 19:23:05 UTC+0800 2019
4/4
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Shutdown SIS
Previous Screen
Ripper Control Valve
SMCS - 5076-16; 5076-15
Disassemble Ripper Control Valve
NOTICE
Before the ripper control valve is removed from the machine, be sure
that all of the pressure in the system has been released. Disconnect the
pilot lines and pressure lines from the main system and remove the
valve assembly.
1. Remove valve seat (1), check valve (2), spring (3) and check valve (4).
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2. Remove six bolts (5) and separate the valve groups.
3. Remove two bolts from end housing (6). Remove these bolts carefully because of spring force
behind the housing. Remove end housing (6), spring (8), and retainer (7).
4. Remove spool (9).
5. Do Steps 3 and 4 for the housing (10), spring (13), retainer (12) and spool (11) in the other
valve group.
Assemble Ripper Control Valve
1. Install spool (11) in valve body. Put SAE 10 oil on the spool before installation.
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2. Put spring (13) in housing (10). Put retainer (12) over spring (13). Put the assembly in place
over the end of spool (11). Install two bolts and tighten as much as possible by hand. Finish
tighten bolts with a wrench. Be careful not to cut the O-ring seal between the housing and the
valve body.
3. Assemble the other valve group in the same way.
4. Be sure that seals (14) are in the valve body. Put the two parts together and install the six bolts.
Tighten the bolts. Be careful not to cut the O-rings between the valve bodies.
5. Install valve (4), spring (3) and valve (2) in the valve body. Make sure the O-ring seal on seat
(1) is correctly installed. Carefully install seat (1) in the body.
Tue Dec 31 19:24:04 UTC+0800 2019
3/3
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Shutdown SIS
Previous Screen
Pressure Control Valve
SMCS - 5050-15; 5050-16
Disassemble Pressure Control Valve
NOTICE
Before the pressure control valve is removed from the machine, be sure
that all of the pressure in the system has been released. Disconnect the
pump line and pilot lines, and remove the valve assembly.
1. Remove cover (1) from valve body. Be careful when removing the cover, because there is
spring force behind the cover.
2. Remove three springs (2), (3) and (4) from the bores in the valve body.
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3. Remove valves (5) and (6).
NOTE: The larger valve will have shims in it.
4. Remove plug (7), spring (8) and ball check (9).
NOTE: There is another ball check valve in the cover. Remove it too. Keep the parts of the two
ball checks separate. They must be installed in the same bore from which they were removed.
Assemble Pressure Control Valve
1. Install the ball check valves, springs and plugs.
NOTE: Be sure to get the ball checks back in their respective bores. These groups are different
and can not be mixed.
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2. Put SAE 10 oil on valves (5) and (6). Install the valves in their repsective bores. Install shims in
the larger valve.
3. Install the spring (2) in the bore for the small valve and springs (3) and (4) in the bore for the
large valve.
4. Be sure that the seals are installed in cover (1) and install the cover with four bolts.
NOTE: It may be necessary to use longer bolts to get compression of the springs for assembly.
Tue Dec 31 19:25:04 UTC+0800 2019
3/3
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Shutdown SIS
Previous Screen
Hydraulic Filter
SMCS - 5068-15; 5068-16
Disassemble Hydraulic Filter
1. Remove the filter from the tank.
2. Remove nut (1) from the bolt.
3. Remove screen assembly (5), element (3), cover (2) and bolt (4).
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NOTE: This is the same procedure used to change element (2).
4. Put screen assembly (5) in a press.
5. Use tool group (A). Put ring compressor (6) in a position to set on spacer (13). Put puller plate
(7) on top of ring compressor (6). Use the press for compression of spring (12) until spacer (13) is
below snap ring (14). Use pliers (8) to remove snap ring (14). Slowly release the force on spacer
(13). Remove spacer (13), valve (11) and tube assembly (9) from screen (10).
Assemble Hydraulic Filter
1. Install sleeve assembly (9) into screen (10). Install valve (11), spring (12) and spacer (13) in the
opposite end of screen (10).
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Caterpillar Cat D8K TRACK-TYPE TRACTOR Dozer Bulldozer (Prefix 77V) Service Repair Manual (77V00001-05005).pdf

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Caterpillar Cat D8K TRACK-TYPE TRACTOR Dozer Bulldozer (Prefix 77V) Service Repair Manual (77V00001-05005).pdf