Caterpillar Cat D8L TRACK-TYPE TRACTOR Dozer Bulldozer (Prefix 7YB) Service Repair Manual (7YB00001-01572).pdf

Service Repair Manual
Models
D8L TRACK-TYPE TRACTOR

Shutdown SIS
Previous Screen
Product: TRACK-TYPE TRACTOR
Model: D8L TRACK-TYPE TRACTOR 7YB
Configuration: D8L TRACTOR / POWER SHIFT / 7YB00001-01572 (MACHINE) POWERED BY 3408 ENGINE
Disassembly and Assembly
3408E and 3412E Engines for Caterpillar Built Machines
Media Number -RENR2336-06 Publication Date -01/08/2018 Date Updated -10/08/2018
i02396384
Unit Injector Hydraulic Pump - Disassemble
SMCS - 1714-015
Disassembly Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A FT-2610 Driver Tube 1
B 4D-3120 Bolt 1
C FT-2612 Bearing Removal Tool 1
D 1P-1861 Retaining Ring Pliers 1
Start By:
a. Remove the unit injector hydraulic pump. Refer to Disassembly and Assembly, "Unit
Injector Hydraulic Pump - Remove".
b. Remove the injection actuation pressure control valve. Refer to Disassembly and Assembly,
"Injection Actuation Pressure Control Valve - Remove".
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
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D8L TRACTOR / POWER SHIFT / 7YB00001-01572 (MACHINE) POWERED BY ...
2020/1/4
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NOTICE
Do not allow dirt to enter the fuel system. Thoroughly clean the area
around a fuel system component that will be disconnected. Fit a
suitable cover over disconnected fuel system component.
Illustration 1 g01094410
1. Remove pressure compensator valve (1).
2. Remove manifold (2).
3. Remove bolts (4) from valve block (3).
4. Remove valve block (3), control piston (6), and gasket (5).
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5. Remove rotating group (7). Minor twisting of the rotating group may be necessary in order
to remove the rotating group.
6. Install Tooling (A) in the pump group. Use a suitable press in order to remove shaft (8) from
the front bearing.
7. Remove bolts (9). Remove covers (10).
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8. Remove O-ring seal (12) from pintle bearing (14) that is opposite of spring seat (11). Install
Tooling (B) into the pintle bearing finger tight.
9. Remove plug (13), if necessary.
10. Tighten Tooling (B) into the pintle bearing until the pintle bearing is removed.
11. In order to remove the pintle bearing from the other side of the pump group, you need to
hold yoke (15) firmly. Use Tooling (B) to remove the pintle bearing.
12. Remove yoke (15).
4/6
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Personal injury can result from parts and/or covers under spring
pressure.
Spring force will be released when covers are removed.
Be prepared to hold spring loaded covers as the bolts are loosened.
13. Remove spring seat (11) and the spring.
14. Use Tooling (D) to remove retaining ring (17). Remove bearing (16).
15. Use Tooling (D) to remove retaining ring (19). Remove shaft seal (18).
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16. Use Tooling (C) and a suitable press in order to remove bearing (20).
17. Remove plugs (21) and plug (22) from valve block (3).
Copyright 1993 - 2020 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Sat Jan 4 22:22:59 UTC+0800 2020
6/6
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Shutdown SIS
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i02396403
Unit Injector Hydraulic Pump - Assemble
SMCS - 1714-016
Assembly Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
D 1P-1861 Retaining Ring Pliers 1
E FT-2608 Bearing Installation Tool 1
F FT-2609 Valve Block Positioner 1
G FT-2607 Bearing Installation Tool 2
H FT-2606 Yoke Fixture 1
J FT-2611 Bearing Support 1
NOTICE
NOTICE
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1. Install plugs (21) and plug (22) in valve block (3). Tighten plugs (21) to a torque of
10.0 ± 0.2 N·m (88.51 ± 1.77 lb in). Tighten plug (22) to a torque of 12.25 ± 0.15 N·m
(108 ± 1 lb in).
2. Use Tooling (E), Tooling (F), and a suitable press in order to install the bearing in valve
block (3).
3. Install bearing (16). Use Tooling (D) to install retaining ring (17).
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Improper assembly of parts that are spring loaded can cause bodily
injury.
To prevent possible injury, follow the established assembly procedure
and wear protective equipment.
4. Install spring seat (11) and the spring.
5. Install yoke (15) inside the housing of the pump group.
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6. Install plug (13). Tighten the plug to a torque of 7.45 ± 0.65 N·m (65.938 ± 5.753 lb in).
7. Use Tooling (G), Tooling (H), and a suitable press in order to install pintle bearing (14).
The bearing that is located on the same side of the housing as spring seat (11) should be
installed first.
8. Ensure that the outer race of pintle bearing (14) is started in the housing on the side opposite
of the spring.
9. Lightly lubricate the yoke with clean engine oil. Ensure that the yoke is in the correct
position. The bearings will hold the yoke in place when the bearings are installed.
10. Use Tooling (G) and a suitable press in order to install the second bearing in the housing.
11. Ensure that the yoke moves freely before you proceed with the assembly procedure.
12. Install O-ring seal (12).
13. Install covers (10).
14. Install bolts (9). Tighten bolts (9) to a torque of 20 ± 1 N·m (15 ± 1 lb ft).
4/8
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15. Use the coupling from the fuel transfer pump and Tooling (J) in order to install shaft (8)
back into the proper position.
16. Install rotating group (7) by using the following procedure.
a. Position the housing so that the internal end of the shaft is angled downward.
b. Slide rotating group (7) over the shaft and into the housing. Ensure that the shoes of
rotating group (7) are against the yoke.
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c. Once the rotating group is installed, turn the rotating group in order to ensure that pins
(23) are still in the special notches. If the rotating group jams, pins (23) need to be
reinserted into the proper position. The pins in the rotating group are held in position
with a “C” clip. See Illustration 9.
17. Lightly lubricate the face of valve block (3) with clean engine oil. Position control piston (6)
on the control shaft.
18. Install gasket (5).
19. Install valve block (3) by using the following procedure.
a. Place a finger over large middle hole (24) on the mounting surface of valve block (3)
in order to create a vacuum. This will hold the control piston in place while you
install valve block (3).
b. Ensure that the housing gasket is not damaged. Align valve block (3) with the pins
that are in the housing of the pump group.
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20. Start bolts (4) in valve block (3) by hand.
21. Tighten bolts (4) by alternating from all four sides. Tighten the bolts in the corners first.
Tighten the bolts to a torque of 28 ± 3 N·m (20 ± 2 lb ft).
22. Install manifold (2).
23. Install pressure compensator valve (1).
24. Install shaft seal (18) by using the following procedure.
a. Lightly lubricate the shaft seal with clean engine oil.
b. Use Tooling (E) to lower shaft seal (18) below the edge of the bore.
c. Position retaining ring (19) against the shaft seal below the edge of the bore.
d. Use Tooling (E) in order to lower shaft seal (18) and retaining ring (19). Lower the
retaining ring until the retaining ring expands into position.
End By:
a. Install the injection actuation pressure control valve. Refer to Disassembly and Assembly,
"Injection Actuation Pressure Control Valve - Install".
7/8
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b. Install the unit injector hydraulic pump. Refer to Disassembly and Assembly, "Unit Injector
Hydraulic Pump - Install".
Sat Jan 4 22:23:58 UTC+0800 2020
8/8
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Shutdown SIS
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i01363607
Unit Injector Hydraulic Pump - Install
SMCS - 1714-012
Installation Procedure
NOTICE
NOTICE
Note: The aftercooler has been removed for photographic purposes only.
Note: Check the condition of the O-rings. If the O-rings are worn or damaged, use new parts for
replacement.
1. Install the O-ring on the unit injector hydraulic pump that seals against the unit injector
hydraulic pump drive. Lightly lubricate the seal with clean engine oil.
1/4
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Typical example
2. Attach a strap and a suitable lifting device to unit injector hydraulic pump (14), as shown.
The weight of the unit injector hydraulic pump is approximately 30 kg (66 lb).
Typical example
3. Install two bolts (15) and the washers.
2/4
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Typical example
4. Install three bolts (13) and the washers.
5. Connect injection actuation pressure sensor (10), engine oil temperature sensor connector
(11), and the connector for engine oil pressure sensor (12).
Typical example
6. Install two wire ties (8) and (9).
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Typical example
Note: The unit injector hydraulic pump must be primed before inlet tube assembly (3) is
installed. Pour 0.95 L (1.00 qt) of clean engine oil directly in the inlet of the unit injector
hydraulic pump before tube (3) is installed.
7. Install the O-ring seals in tube assembly (3). Lightly lubricate the O-ring seals with clean
engine oil. Install tube assembly (3).
8. Position clamp (4) and install bolt (5), the nut, and the washer.
9. Place clamp (7) in position and install bolt (6), the nut and the spacer.
Typical example
10. Install the O-ring seals in hose assemblies (1) and (2). Lightly lubricate the seals with clean
engine oil. Connect hose assemblies (1) and (2).
11. Tighten hose assemblies (1).
12. Tighten hose assemblies (2) to 125 ± 15 N·m (92 ± 11 lb ft).
Sat Jan 4 22:24:57 UTC+0800 2020
4/4
2020/1/4

Shutdown SIS
Previous Screen
i01363680
Unit Injector Hydraulic Pump Drive - Remove
SMCS - 1714-011-PD
Removal Procedure
Start By:
a. Remove the unit injector hydraulic pump. Refer to Disassembly and Assembly, "Unit
Injector Hydraulic Pump - Remove".
b. Remove the front cover. Refer to Disassembly and Assembly, "Front Cover - Remove".
NOTICE
NOTICE
Care must be taken to ensure that fluids are contained during
performance of inspection, maintenance, testing, adjusting and repair
of the product. Be prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any component
containing fluids.
Refer to Special Publication, NENG2500, "Caterpillar Dealer Service
Tool Catalog" for tools and supplies suitable to collect and contain
fluids on Caterpillar products.
1/4
2020/1/4

Caterpillar Cat D8L TRACK-TYPE TRACTOR Dozer Bulldozer (Prefix 7YB) Service Repair Manual (7YB00001-01572).pdf

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Caterpillar Cat D8L TRACK-TYPE TRACTOR Dozer Bulldozer (Prefix 7YB) Service Repair Manual (7YB00001-01572).pdf