Caterpillar Cat D8R II TRACK-TYPE TRACTOR Dozer Bulldozer (Prefix AKA) Service Repair Manual Instant Download

Service Repair Manual Models D8R IITRACK-TYPE TRACTOR

D8R TRACK-TYPE TRACTOR Differential Steering AKA00001-UP (MACHINE) P... 1/2 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). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/1/21

D8R TRACK-TYPE TRACTOR Differential Steering AKA00001-UP (MACHINE) P... 2/2 2. Connect wire (7) with the washer and nut (8). Illustration 2 g00778462 3. Connect hose assembly (4) to torque converter outlet relief valve (3). Illustration 3 g00778437 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. Copyright 1993 - 2020 Caterpillar Inc. Tue Jan 21 01:01:06 UTC+0800 2020 All Rights Reserved. Private Network For SIS Licensees. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/1/21

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D8R TRACK-TYPE TRACTOR Differential Steering AKA00001-UP (MACHINE) P... 1/6 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 i07223877 Transmission and Bevel Gears - Remove SMCS - 3010-011; 3150-011 Removal Procedure Table 1 Required Tools Tool Part Number Part Description Qty FT-1952 Axle Removal Tool 1 A 1U-7432 Adapter 1 FT-1897 Adapter 1 138-7575 Link Bracket 1 B 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 4C-4089 Transmission Jack 1 D 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. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/1/21

D8R TRACK-TYPE TRACTOR Differential Steering AKA00001-UP (MACHINE) P... 2/6 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. Illustration 1 g00751625 1. Remove seventeen bolts (1) and remove plate (2) and the gasket. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/1/21

D8R TRACK-TYPE TRACTOR Differential Steering AKA00001-UP (MACHINE) P... 3/6 Illustration 2 g00751870 2. Disconnect hose (3). Illustration 3 g00751865 3. Disconnect wire harness (4). Illustration 4 g00751883 4. Remove yoke (5). Remove four bolts and washers (6) and remove retainer (7) and the O- ring seal. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/1/21

D8R TRACK-TYPE TRACTOR Differential Steering AKA00001-UP (MACHINE) P... 4/6 Illustration 5 g00619138 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. Illustration 6 g00751888 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). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/1/21

D8R TRACK-TYPE TRACTOR Differential Steering AKA00001-UP (MACHINE) P... 5/6 Illustration 7 g00594420 Illustration 8 g00751900 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. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/1/21

D8R TRACK-TYPE TRACTOR Differential Steering AKA00001-UP (MACHINE) P... 6/6 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. Copyright 1993 - 2020 Caterpillar Inc. Tue Jan 21 01:02:06 UTC+0800 2020 All Rights Reserved. Private Network For SIS Licensees. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/1/21

D8R TRACK-TYPE TRACTOR Differential Steering AKA00001-UP (MACHINE) P... 1/2 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 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. Illustration 1 g00620565 https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/1/21

D8R TRACK-TYPE TRACTOR Differential Steering AKA00001-UP (MACHINE) P... 2/2 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). Copyright 1993 - 2020 Caterpillar Inc. Tue Jan 21 01:03:05 UTC+0800 2020 All Rights Reserved. Private Network For SIS Licensees. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/1/21

D8R TRACK-TYPE TRACTOR Differential Steering AKA00001-UP (MACHINE) P... 1/22 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 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. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/1/21

D8R TRACK-TYPE TRACTOR Differential Steering AKA00001-UP (MACHINE) P... 2/22 The electronic control module is replaced. Reference: Refer to Testing and Adjusting, SENR8367, "Calibration" for the calibration procedures. Illustration 1 g00595589 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. Illustration 2 g00752309 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. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/1/21

D8R TRACK-TYPE TRACTOR Differential Steering AKA00001-UP (MACHINE) P... 3/22 Illustration 3 g00595597 6. Remove locknut (6). Push connector (7) out of the case. Illustration 4 g00595602 7. Disconnect electrical connector (8). Illustration 5 g00595604 8. Remove four bolts and washers (9) and remove control valve (10). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/1/21

D8R TRACK-TYPE TRACTOR Differential Steering AKA00001-UP (MACHINE) P... 4/22 Illustration 6 g00595608 9. Remove bolt (11) and remove tube (12). 10. Remove the O-ring seal from tube (12). Illustration 7 g00595609 11. The weight of the planetary transmission is 340 kg (750 lb). Install tool (B). Attach a hoist to tool (B). Illustration 8 g00595610 https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/1/21

D8R TRACK-TYPE TRACTOR Differential Steering AKA00001-UP (MACHINE) P... 5/22 12. Remove 21 bolts and washers (13) that hold the planetary transmission to the transmission cover. Remove the planetary transmission. Illustration 9 g00752321 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). Illustration 10 g00595611 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). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/1/21

D8R TRACK-TYPE TRACTOR Differential Steering AKA00001-UP (MACHINE) P... 6/22 Illustration 11 g00595612 18. Remove guard (21) and remove the bracket with four sensors (22) from the planetary transmission. Illustration 12 g00595614 19. Use tool (C) to remove retaining ring (23). Remove rotor (24). Illustration 13 g00595678 20. Remove ring (25) and remove rotor (26). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/1/21

D8R TRACK-TYPE TRACTOR Differential Steering AKA00001-UP (MACHINE) P... 7/22 Illustration 14 g00595680 21. Use tool (C) to remove retaining ring (27). Remove ten bolts and washers (28) from manifold (29). Illustration 15 g00595682 22. Install tool (B) and attach a hoist. Remove manifold (29). Manifold (29) weighs 23 kg (51 lb). Illustration 16 g00752387 23. Use tool (D) to remove retaining ring (30) from manifold (29). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/1/21

D8R TRACK-TYPE TRACTOR Differential Steering AKA00001-UP (MACHINE) P... 8/22 24. Remove bearing (31) from manifold (29). Illustration 17 g00752442 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). Illustration 18 g00752449 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). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/1/21

D8R TRACK-TYPE TRACTOR Differential Steering AKA00001-UP (MACHINE) P... 9/22 Illustration 19 g00752458 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). Illustration 20 g00752488 31. Remove piston (39) from housing (35). Remove ring (40) and seal (38) from the piston. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/1/21

D8R TRACK-TYPE TRACTOR Differential Steering AKA00001-UP (MACHINE)... 10/22 Illustration 21 g00752505 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. Illustration 22 g00752598 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). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/1/21

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D8R TRACK-TYPE TRACTOR Differential Steering AKA00001-UP (MACHINE)... 11/22 Illustration 23 g00752614 Illustration 24 g00752619 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. Illustration 25 g00752622 38. Remove ten springs (50). 39. Remove three friction discs (51) and the two clutch plates. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/1/21

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