Caterpillar Cat D8K TRACK-TYPE TRACTOR Dozer Bulldozer (Prefix 77V) Service Repair Manual Instant Download 9

Service Repair Manual Models D8K TRACK-TYPE TRACTOR

D8K TRACTOR / POWERSHIFT / 77V05006-UP (MACHINE) POWERED BY D34... 1/19 Shutdown SIS Previous Screen Product: TRACK-TYPE TRACTOR Model: D8K TRACK-TYPE TRACTOR 77V Configuration: D8K TRACTOR / POWERSHIFT / 77V05006-UP (MACHINE) POWERED BY D342 ENGINE Disassembly and Assembly D8K TRACTOR POWER TRAIN Media Number -SENR7011-01 Publication Date -01/06/1976 Date Updated -12/12/2017 SENR70110037 Torque Divider (Power Shift) SMCS - 3100-11; 3100-12; 3100-15; 3100-16 Remove Torque Divider (Power Shift) start by: a) remove seat and seat frame b) remove crankcase guard (rear) c) remove universal joint (power shift) d) remove torque divider scavenge and circulating oil pump e) remove torque converter outlet relief valve f) remove brake pedals and dash 1. Drain the oil from the transmission and torque divider. 2. Remove rods (1), (2), (3) and (9) for the steering clutches and brakes. Put identification on the rods to prevent mixing at assembly. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/1/1

D8K TRACTOR / POWERSHIFT / 77V05006-UP (MACHINE) POWERED BY D34... 2/19 3. Remove seat frame support (10) and cross-member (12). 4. Remove oil supply line (11) for the transmission hydraulic controls. 5. Remove oil supply line (6) for the torque converter. 6. Remove vent line (7) for the torque divider. 7. Remove vent line (8). 8. Remove transmission priority valve (4). 9. Remove oil outlet and inlet lines (5). 10. Install two 5/8" - 11 NC forged eyebolts in the torque divider as shown. Fasten a hoist to the torque divider. Remove the nuts and washers that hold the torque divider to the flywheel housing. Make a separation of the torque divider from the flywheel housing until a wire (14) can be installed around the planet carrier. NOTICE The wire is to prevent the planet carrier from falling from the output shaft when the torque divider is being removed. 11. Remove torque divider (13). Weight of the torque divider is 850 lb. (386 kg). 12. Remove bolts (15), locks (16) and retainers (17). Remove gear (18). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/1/1

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D8K TRACTOR / POWERSHIFT / 77V05006-UP (MACHINE) POWERED BY D34... 3/19 13. Remove snap ring (19). Remove washer (20). 14. Remove snap ring (21) and pilot bearing (22). Install Torque Divider (Power Shift) 1. Install the pilot bearing in the flywheel. Install the snap ring that holds it. 2. Install the washer over the pilot bearing. Install the snap ring that holds it. 3. Put gear (1) into position in the flywheel. Install the retainers, locks and bolts that hold it. NOTICE Make sure wire (3) is around the planet carrier. The wire will prevent the planet carrier from falling off of the output shaft when the torque divider is installed. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/1/1

D8K TRACTOR / POWERSHIFT / 77V05006-UP (MACHINE) POWERED BY D34... 4/19 4. Fasten a hoist to the torque divider (2) and put it into position on the flywheel housing. Remove wire (3). Make sure the teeth of the gears for the planet carrier are in alignment with the teeth on the gear that is fastened to the flywheel. Turn the output shaft slowly while the torque divider is pushed in position against the flywheel housing. NOTICE Do not use force to engage the torque divider in the flywheel housing. 5. Install outlet and inlet lines (7). 6. Install the priority valve on the transmission. 7. Install vent line (10). 8. Install vent line (8) for the torque divider. 9. Install oil supply line (9) for the torque converter. 10. Install oil supply line (13) for the transmission hydraulic controls. 11. Install crossmember (14) and seat frame support (12). 12. Install rods (4), (5), (6) and (11) for the steering clutches and brakes. 13. Fill the transmission and torque divider with oil to the correct level. See, LUBRICATION AND MAINTENANCE GUIDE. end by: a) install brake pedals and dash b) install torque converter outlet relief valve c) install torque divider scavenge and circulating oil pump d) install universal joint (power shift) https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/1/1

D8K TRACTOR / POWERSHIFT / 77V05006-UP (MACHINE) POWERED BY D34... 5/19 e) install crankcase guard (rear) f) install seat and seat frame Disassemble Torque Divider (Power Shift) start by: a) remove torque divider NOTICE When a torque converter or divider has a failure, the complete oil system for the torque converter must be thoroughly cleaned. Any foreign material which is not removed from the oil system for the torque converter will be pushed through the hydraulic system for the transmission. 1. Remove wire (1). Remove planet carrier (2). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/1/1

D8K TRACTOR / POWERSHIFT / 77V05006-UP (MACHINE) POWERED BY D34... 6/19 2. Remove nuts (4), locks (6), and bolts (10). Remove shafts (8). Remove washers (7) and gears (5). Remove the bearings (9) from the gears. Check thrust washers (3) on each side of the planet carrier for damage or wear. Remove the thrust washers if necessary. 3. Install the torque divider on tool (A). Put blocks (13) under the torque converter housing (12) to keep it in position in the torque divider. 4. Remove output shaft (11). 5. Remove bolt (14), retainer (17), and output flange (15) from the output shaft. Remove the bearing races (16) from each end of the output shaft with tooling (B). 6. Remove the bolts that hold plate (21) to the cover for the torque divider. Install two 3/8" - 16NC forcing screws (19) in the plate. Tighten the forcing screws evenly and remove the plate. Remove the lip type seal (18) from the plate. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/1/1

D8K TRACTOR / POWERSHIFT / 77V05006-UP (MACHINE) POWERED BY D34... 7/19 7. Install one 1/2" - 13NC forged eyebolt and two 3/8" - 16NC forged eyebolts in the cover for the torque divider. Fasten a hoist to the eyebolts. Remove the cover (20). Weight is 180 lb. (82 kg). 8. Remove the oil from the torque converter. 9. Remove thirty-six bolts (22). 10. Install four 3/8"-16NC forcing screws in impeller (23). Tighten the forcing screws evenly until the impeller is free of the converter housing (12). Remove the forcing screws. Install two 3/8" - 16NC forged eyebolts in the impeller. Fasten a hoist to the eyebolts and remove the impeller. Weight is 100 lb. (45 kg). 11. Remove bolts (24) that hold the stator wheel to the carrier. 12. Put two blocks (26) on the impeller. Put a force, evenly, against the bottom of the stator wheel (25) until it is free of the impeller. Remove the stator wheel. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/1/1

D8K TRACTOR / POWERSHIFT / 77V05006-UP (MACHINE) POWERED BY D34... 8/19 13. Install three 3/8" - 16NC forcing screws in carrier (27). Tighten the forcing screws evenly and remove the carrier. 14. Remove snap ring (28). 15. Remove outer race and roller assembly (31) from the carrier with tooling (C). 16. Remove bolts (29). Install two 3/8" - 16NC forcing screws in the torque converter gear (30). Tighten the forcing screws evenly and remove the gear. 17. Remove carrier (33). Remove bearing cup (32) from the carrier with a hammer and soft punch through notches (34). 18. Remove screw (35). Remove nut (36) and washer (37). 19. Remove wheel (turbine) (38) if it is loose on the splines of the flange. If it is not loose, do not use force as it will be removed later. See Step 21. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/1/1

D8K TRACTOR / POWERSHIFT / 77V05006-UP (MACHINE) POWERED BY D34... 9/19 20. Remove spring pins (40). Pull the two ends of ring (39) together. Remove ring gear (41). 21. Put a block of wood under the turbine (if it has not been removed). Install three 3/8" - 16NC forcing screws in flange (42). Tighten the forcing screws evenly and remove the flange. The turbine (if it has not been removed) will fall on the block. Remove the two bearings from the flange. 22. Remove bearing race (43) and carrier (44). 23. Remove bolts (47). Install two 3/8" - 16NC forcing screws in retainer (48). Tighten the forcing screws evenly and remove the retainer. 24. Remove snap ring (45). Remove bearing (46). Assemble Torque Divider (Power Shift) https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/1/1

D8K TRACTOR / POWERSHIFT / 77V05006-UP (MACHINE) POWERED BY D... 10/19 1. There must be a minimum running clearance (G) between the stator wheel and turbine if the torque converter is to operate with efficiency. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/1/1

D8K TRACTOR / POWERSHIFT / 77V05006-UP (MACHINE) POWERED BY D... 11/19 2. Check the clearance between the outside diameter (K) of the stator wheel (stator) and the inside diameter (L) of the turbine as follows: a) Put four steel balls (3) in the turbine (2) as shown. The balls must be .062 in. (1.57 mm) in diameter. Put the balls approximately 90 apart. b) Put the stator (1) in position on the balls as shown. Make sure the balls do not move. Turn the stator until the smooth surface of the turbine is against the balls. c) Install tool group (A) on the turbine. Move the stator toward the stem of the dial indicator until its outside diameter is against the inside diameter of the turbine. Move the stem against the stator as shown. Set the dial indicator on ZERO. d) Move the stator 180 away from the stem until its outside diameter is against the inside diameter of the turbine. Make this measurement at four points 90 apart around the turbine. The dimension read on the dial indicator is the total clearance across the diameters. This dimension must be .012 to .018 in. (0.30 to 0.46 mm). e) The running clearance or clearance (G) is one half of the clearance across the diameters. Clearance (G) must be .006 to .009 in. (0.15 to 0.23 mm). 3. Make a replacement of the stator or turbine if the dimensions measured are not acceptable. 4. There must be a minimum running clearance (H) between the stator and impeller if the torque converter is to operate with efficiency. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/1/1

D8K TRACTOR / POWERSHIFT / 77V05006-UP (MACHINE) POWERED BY D... 12/19 5. Check the clearance between the outside diameter (M) of the inner flange for the stator and the inside diameter (N) of the impeller flange as follows: a) Put two rods (5) on impeller (4) as shown. Make sure the rods are .62 in. (15.7 mm) in diameter and approximately 20 in. (508 mm) long. b) Put the stator (1) in position on the rods. c) Install tool group (A) on the edge of the impeller. Move the stator toward the stem of the dial indicator until the outside diameter of its flange is against the inside diameter of the impeller. Move the stem of the dial indicator against the stator. Set the dial indicator on ZERO. d) Move the stator 180 away from the stem until the outside diameter of its flange is against the inside diameter of the impeller. The dimension read on the dial indicator is the total clearance across the diameters. Make a measurement at four points 90 apart around the impeller. The total clearance across the diameters must be .009 to .015 in. (.023 to .038 mm). e) The running clearance or clearance (H) is one half of the clearance across the diameters. Clearance (H) must be .0045 to .0075 in. (0.114 to 0.191 mm). 6. Make a replacement of the stator or impeller if the dimensions measured are not acceptable. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/1/1

D8K TRACTOR / POWERSHIFT / 77V05006-UP (MACHINE) POWERED BY D... 13/19 7. Install bearing (9) in converter housing (6) with tooling (C). 8. Install snap ring (8) over the bearing. Install retainer (7) and the bolts that hold it. Tighten the bolts to a torque of 36 2 lb.ft. (5.0 0.3 mkg). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/1/1

D8K TRACTOR / POWERSHIFT / 77V05006-UP (MACHINE) POWERED BY D... 14/19 9. Install bearings (11) in flange (10). Make sure dimension (X) is .680 in. (17.27 mm). Make sure dimension (Y) is 1.14 in. (29.0 mm). 10. Install ring (13) in the groove in the flange. Pull the two ends of the ring together. Put the splines of ring gear (12) in alignment with the splines on the flange. Install the ring gear on the flange. Make sure the ring engages in the groove in the ring gear. Install the two spring pins that keep the ring in the grooves. 11. Turn the flange and ring gear over. Install carrier (15) and bearing race (14). Make sure the ends of the rings in the carrier are engaged. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/1/1

D8K TRACTOR / POWERSHIFT / 77V05006-UP (MACHINE) POWERED BY D... 15/19 12. Install three 3/8" - 16NC forged eyebolts in converter housing (6). Fasten a hoist to the eyebolts. Put the housing in position over the flange. NOTICE Make sure the rings in the carrier are in alignment with the bearing in the housing. 13. Install bearing race (16) over the flange. 14. Put the splines of the turbine (2) in alignment with the splines of the flange. Install the turbine. NOTE: Clearance between the outside diameter of the inner flange of the turbine (2) and the inside diameter of the converter housing (6) must be .055 to .075 in. (1.0 to 1.91 mm). The running clearance is one half of the clearance across the diameter. The running clearance must be .0275 to .0375 in. (0.699 to 0.953 mm). See the specifications. 15. Install washer (19) and nut (18) on the flange. Tighten the nut to a torque of 725 25 lb. ft. (100.3 3.5 mkg) with tool (B). Tighten the nut if necessary to put the hole in the nut in alignment with the hole in the washer. Install screw (17). Put two marks (stake) 180 apart in the nut to hold the screw in position. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/1/1

D8K TRACTOR / POWERSHIFT / 77V05006-UP (MACHINE) POWERED BY D... 16/19 16. Lower the temperature of the outer race and roller assembly (21) and install it in carrier (22). Install snap ring (20) that holds it. 17. Lower the temperature of the bearing race (23). Install the race in carrier (24). 18. Put carrier (24) and torque converter gear (26) in position on the impeller (4). Install bolts (25). Tighten the bolts to a torque of 36 2 lb.ft. (5.0 0.3 mkg). 19. Put a small amount of grease on the metal rings in the carrier. Make sure the ends of the metal rings are engaged. Install the impeller over the carrier with the torque converter gear toward the carrier. 20. Install bearing cone (27) over the carrier into its bearing race. 21. Put pins (28) for stator wheel (1) in alignment with their holes in the carrier. Install the stator wheel. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/1/1

D8K TRACTOR / POWERSHIFT / 77V05006-UP (MACHINE) POWERED BY D... 17/19 22. Install bolts (29) that hold the stator wheel to the carrier. Tighten the bolts to a torque of 81 4 lb.ft. (11.2 0.6 mkg). 23. Install two 3/8"-16NC forged eyebolts in the impeller (4). Fasten a hoist to the eyebolts. Install the impeller on the converter housing (6). 24. Install bolts (30) that hold the impeller to the converter housing. Tighten the bolts to a torque of 36 2 lb.ft. (5.0 0.3 mkg). 25. Install a 1/2"-13NC forged eyebolt and two 3/8"-16NC forged eyebolts in torque divider cover (31). Fasten a hoist to the eyebolts. Put the cover in position on the converter housing. 26. Install seal (33) in plate (32) with tooling (E). Put the plate in position on the cover. Install the 17 bolts that hold it. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/1/1

D8K TRACTOR / POWERSHIFT / 77V05006-UP (MACHINE) POWERED BY D... 18/19 27. Heat bearing races (35) and (36) in oil to a maximum temperature of 275 F (135 C). Install the races on their respective ends of output shaft (39). 28. Put the splines of output flange (38) in alignment with the splines of the output shaft. Install retainer (34) and bolt (37). Tighten the bolt to a torque of 85 5 lb.ft. (11.8 0.7 mkg). 29. Install output shaft (39) in the torque divider. 30. Install bearings (46) in gears (42). Install the gears and washers (45) in planet carrier (40). Install shafts (44) through the planet carrier, washers, and gears. Put the holes in the shafts in alignment with the holes in the planet carrier. Install the bolts (41), locks, and nuts. NOTE: Install bolts (41) so their heads are all toward the same direction. This will give balance to the planet carrier. 31. If new thrust washers (43) are installed, fasten the thrust washers with new rivets. 32. Install planet carrier (40) over the output shaft. Make sure the teeth of gears for the planet carrier engage in the teeth of ring gear (12). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/1/1

D8K TRACTOR / POWERSHIFT / 77V05006-UP (MACHINE) POWERED BY D... 19/19 33. Install a wire (47) around the planet carrier to prevent it from falling when assembling. end by: a) install torque divider Copyright 1993 - 2019 Caterpillar Inc. Wed Jan 1 01:08:11 UTC+0800 2020 All Rights Reserved. Private Network For SIS Licensees. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/1/1

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D8K TRACTOR / POWERSHIFT / 77V05006-UP (MACHINE) POWERED BY D34... 1/31 Shutdown SIS Previous Screen Product: TRACK-TYPE TRACTOR Model: D8K TRACK-TYPE TRACTOR 77V Configuration: D8K TRACTOR / POWERSHIFT / 77V05006-UP (MACHINE) POWERED BY D342 ENGINE Disassembly and Assembly D8K TRACTOR POWER TRAIN Media Number -SENR7011-01 Publication Date -01/06/1976 Date Updated -12/12/2017 SENR70110038 Transmission (Power Shift) SMCS - 3150-11; 3150-12; 3150-15; 3150-16 Remove Transmission (Power Shift) start by: a) remove crankcase guard (rear) b) remove seat and seat frame c) remove torque divider scavenge and circulating oil pump d) remove torque converter outlet relief valve e) remove universal joint (power shift) 1. Drain the oil from the transmission and the bevel gear case. 2. Remove rods (2), (3), (4) and (12) for the steering clutches and brakes. Put identification on the rods to prevent mixing at assembly. 3. Disconnect rod (7) from the lever on the crossmember. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/1/1

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