Caterpillar Cat D8R II TRACK-TYPE TRACTOR Dozer Bulldozer (Prefix AKA) Service Repair Manual (AKA00001 and up).pdf

Service Repair Manual
Models
D8R II TRACK-TYPE TRACTOR

Shutdown SIS
Previous Screen
Product: TRACK-TYPE TRACTOR
Model: D8R II TRACK-TYPE TRACTOR AKA
Configuration: D8R TRACK-TYPE TRACTOR Differential Steering AKA00001-UP (MACHINE) POWERED BY 3406E Engine
Disassembly and Assembly
D8R Series II Track-Type Tractor Power Train
Media Number -RENR3677-06 Publication Date -01/01/2013 Date Updated -24/07/2018
i01500569
Torque Converter Outlet Relief Valve - Install
SMCS - 3133-012
Installation Procedure
Note: O-ring seals, gaskets, and seals should always be replaced. A used O-ring may not have the
same sealing properties as a new O-ring seal. A reconditioning procedure should not be degraded
because of a low cost component such as an O-ring seal or a gasket. Use 1U-6396 O-Ring
Assembly Compound during the assembly procedure.
Illustration 1 g00778498
1. Install the O-ring seals to the torque converter outlet relief valve. Place the torque converter
outlet relief valve in the original position and install the three washers, clip (6) with the
wiring, and three bolts (5).
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D8R TRACK-TYPE TRACTOR Differential Steering AKA00001-UP (MACHINE) P...
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2. Connect wire (7) with the washer and nut (8).
3. Connect hose assembly (4) to torque converter outlet relief valve (3).
4. Connect tube assembly (2) to torque converter outlet relief valve (3) with the four washers
and four bolts (1).
Note: The bolts and washers may be required to be placed in the block of the tube assembly
before installation purposes.
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All Rights Reserved.
Private Network For SIS Licensees.
Tue Jan 21 01:01:06 UTC+0800 2020
2/2
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Shutdown SIS
Previous Screen
i07223877
Transmission and Bevel Gears - Remove
SMCS - 3010-011; 3150-011
Removal Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A
FT-1952 Axle Removal Tool 1
1U-7432 Adapter 1
B
FT-1897 Adapter 1
138-7575 Link Bracket 1
8S-9089 Bolt (1/2 inch by 13 by 4 1/2 inch) 1
1D-4719 Nut (1/2 inch by 13) 1
C 138-7575 Link Bracket 2
D
4C-4089 Transmission Jack 1
4C-4090 Holding Tool 1
Start By:
a. Remove the main drive shaft. Refer to Disassembly and Assembly, "Main Drive Shaft -
Remove and Install"
in this module.
b. Drain the oil from the transmission system. Refer to Operation and Maintenance Manual,
SEBU7247, "Transmission System Oil and Screens - Change/Clean"
for the correct procedure.
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c. Remove the drive axles. Refer to Disassembly and Assembly, "Axle - Remove and Install"
in this module.
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, "Dealer Service Tool
Catalog" for tools and supplies suitable to collect and contain fluids on
Cat®
products.
Dispose of all fluids according to local regulations and mandates.
Note: Put identification marks on all lines, on all hoses, on all wires, and on all tubes for
installation purposes. Plug all lines, hoses, and tubes. This helps to prevent fluid loss and to keep
contaminants from entering the system.
1. Remove seventeen bolts (1) and remove plate (2) and the gasket.
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2. Disconnect hose (3).
3. Disconnect wire harness (4).
4. Remove yoke (5). Remove four bolts and washers (6) and remove retainer (7) and the O-
ring seal.
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5. Insert tool (A) into the left final drive by approximately 940 mm (37 inch). Rotate tool (A)
by 180 degrees, or rotate tool (A) until the sliding carrier is off the bevel gear shaft. Rotate
tool (A) backward by 180 degrees and remove the tool from the final drive.
Note: The transmission and bevel gears weigh 830 kg (1830 lb).
6. Remove six bolts, the cover, and the gasket. Install tool (B). Attach a hoist to tool (B).
Note: Four bolts (9) fasten the transmission cover to the bevel gear case. Do not remove
four bolts (9).
7. Remove 22 bolts and washers (8).
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8. Use forcing bolts to separate the transmission from the transmission and bevel gear case.
Use a hoist to slowly pull the transmission and bevel gears from the case. The transmission
and bevel gears will roll onto the tube assemblies.
Note: The transmission and bevel gears must be supported when the hoist is moved from
tool (B) to tool (C) on top of the transmission.
During the removal of the hoist, the support for the transmission and
bevel gears must be on a hard, level surface. If the support is on a slope
or soft footing, the transmission and bevel gears could fall off the
support. This could cause personal injury or death.
9. Install tool (C) on the top of the transmission case. Use tool (D) to support the transmission.
10. Remove the hoist from tool (B). Attach the hoist to tool (C). Remove the transmission and
bevel gears from the tube assemblies.
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11. Remove large O-ring seal (11) from the outer diameter of the transmission case. Remove
three O-ring seals (10) and remove O-ring seal (12) from the transmission and bevel gear
case.
Tue Jan 21 01:02:06 UTC+0800 2020
6/6
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Shutdown SIS
Previous Screen
i01434705
Transmission and Bevel Gears - Separate
SMCS - 3010-076
Procedure to Separate the Unit
Table 1
Required Tools
Tool Part Number Description Qty
A 1P-2420 Repair Stand (Transmission) 1
B 138-7575 Link Bracket 3
Start By:
a. Remove the transmission and bevel gears. Refer to Disassembly and Assembly,
"Transmission and Bevel Gears - Remove" in this module.
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Note: The transmission and bevel gears weigh 830 kg (1820 lb).
1. Install tool (A) on the bevel gear case. Attach a hoist to tool (A).
2. Position the transmission and bevel gears on tool (B).
3. Remove the four bolts that hold the transfer and bevel gears (1) to transmission (2).
Note: The transfer and bevel gears weigh 380 kg (840 lb).
4. Separate the transfer and bevel gears (1) from transmission (2).
Tue Jan 21 01:03:05 UTC+0800 2020
2/2
2020/1/21

Shutdown SIS
Previous Screen
i01436098
Transmission - Disassemble
SMCS - 3030-015
Disassembly Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 1P-2420 Transmission Repair Stand 1
B 138-7575 Link Bracket 3
C 5P-5197 External Pliers 1
D 136-1452 Internal Tip Pliers 1
E FT-0947 Spring Compressor 2
F FT-0833 Spring Compressor 2
G 138-7575 Link Bracket 2
H 3K-4897 Spring Pin 8
Start By:
a. Separate the transmission and bevel gears. Refer to , "Transmission and Bevel Gears -
Separate" in this module.
Note: The transmission modulating valves must be recalibrated if any of the following procedures
are performed:
• The transmission modulating valve and/or the solenoid is replaced.
• The transmission is serviced or the transmission is replaced.
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• The electronic control module is replaced.
Reference: Refer to Testing and Adjusting, SENR8367, "Calibration" for the calibration
procedures.
1. Position the transmission on tool (A). Mark all the housings for alignment during the
assembly procedure.
2. Remove four small O-ring seals (1) and remove large O-ring seal (2) from the transmission
cover.
3. Remove three fittings (5) with the O-ring seals.
4. Remove three bolts and strips (4).
5. Remove three tubes (3). Remove the seals from the tubes.
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6. Remove locknut (6). Push connector (7) out of the case.
7. Disconnect electrical connector (8).
8. Remove four bolts and washers (9) and remove control valve (10).
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9. Remove bolt (11) and remove tube (12).
10. Remove the O-ring seal from tube (12).
11. The weight of the planetary transmission is 340 kg (750 lb). Install tool (B). Attach a hoist
to tool (B).
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12. Remove 21 bolts and washers (13) that hold the planetary transmission to the transmission
cover. Remove the planetary transmission.
13. The transmission cover (15) weighs 100 kg (220 lb). Attach tool (B) to the transmission
cover. Fasten a hoist to tool (B). Remove the transmission cover from tool (A).
14. Remove four bolts and cover (14). Remove the O-ring seal from cover (14).
15. Remove the suction screen from transmission cover (15).
16. Position the planetary transmission on tool (A). Use four bolts with nuts to fasten the
planetary transmission to tool (A).
17. Remove four electrical connectors (20) from the clips on the back side of plate (19).
Remove these components from planetary transmission (16): three bolts (18), the washers
and plate (19).
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18. Remove guard (21) and remove the bracket with four sensors (22) from the planetary
transmission.
19. Use tool (C) to remove retaining ring (23). Remove rotor (24).
20. Remove ring (25) and remove rotor (26).
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21. Use tool (C) to remove retaining ring (27). Remove ten bolts and washers (28) from
manifold (29).
22. Install tool (B) and attach a hoist. Remove manifold (29). Manifold (29) weighs 23 kg
(51 lb).
23. Use tool (D) to remove retaining ring (30) from manifold (29).
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24. Remove bearing (31) from manifold (29).
25. Clutch (31) with the clutch housing weighs 31 kg (68 lb). Remove clutch (31) and the clutch
housing.
26. Remove ten springs (32) and remove five dowels (34).
Note: The friction discs and the clutch plates from the individual clutches must be kept in
the correct order. The friction discs and the clutch plates must be kept with the original
clutch housings. The different clutches use different friction material. The friction discs and
the clutch plates must not be mixed together.
27. Remove the two friction discs and one clutch plate (33).
28. Remove retaining ring (34). Remove housing (35) from clutch (31).
29. Remove the four friction discs and the three clutch plates from clutch (31).
8/22
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Do not remove the retaining ring until the spring force has been
released. Failure to do so could result in personal injury or death. In
order to prevent this, use a suitable press to hold the spring force while
the retaining ring is removed. Slowly release the spring tension with the
press after the retaining ring has been removed.
30. Position housing (35) in a press, as shown. Compress the springs under plate (36). Remove
retaining ring (37). Slowly release the spring pressure. Remove plate (36). Remove the three
spring plates under plate (36).
31. Remove piston (39) from housing (35). Remove ring (40) and seal (38) from the piston.
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32. Turn over the housing. Remove O-ring seal (41). Remove two seal rings (43) from carrier
(42).
Note: Carrier (42) will be destroyed if the carrier is removed from the housing.
33. If carrier (42) must be removed, use a hammer and a chisel to break carrier (42). Remove
carrier (42). After the carrier is removed, remove dowel (44) that holds carrier (42) in
position.
34. Use tool (E) to clamp the two pistons in housing assembly (45).
Note: Housing assembly (45) weighs 46 kg (100 lb).
35. Use tool (G) and a hoist to remove housing assembly (45).
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D8R TRACK-TYPE TRACTOR Differential Steering AKA00001-UP (MACHINE)...
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36. Remove piston (46) from housing (45).
37. Remove seal rings (47) and (48) from piston (46). Turn over housing (45). Remove piston
(49) and the seal rings.
38. Remove ten springs (50).
39. Remove three friction discs (51) and the two clutch plates.
11/22
D8R TRACK-TYPE TRACTOR Differential Steering AKA00001-UP (MACHINE)...
2020/1/21

Caterpillar Cat D8R II TRACK-TYPE TRACTOR Dozer Bulldozer (Prefix AKA) Service Repair Manual (AKA00001 and up).pdf

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Caterpillar Cat D8R II TRACK-TYPE TRACTOR Dozer Bulldozer (Prefix AKA) Service Repair Manual (AKA00001 and up).pdf