Caterpillar D8k 8a 58 Service Manual

Full download: http://manualplace.com/download/caterpillar-d8k-8a-58-service-manual/

TM 5-2410-234-14&P-1

TECHNICAL MANUAL

OPERATOR’S, ORGANIZATIONAL, DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE

MANUAL
(INCLUDING REPAIR PARTS INFORMATION AND SUPPLEMENTAL MAINTENANCE
AND REPAIR PARTS INSTRUCTIONS)

TRACTOR, FULL TRACKED, LOW SPEED,

HEAVY DRAWBAR PULL, (SIZE T-11)

W/ANGLE DOZER, WINCH AND ROPS

CATERPILLAR MODEL D8K-8A-58 (CCE)

NSN 2410-00-574-7597

AND W/BULLDOZER (SEMI-U-TILT), RIPPER

AND ROPS CATERPILLAR MODEL D8K-8S-8 (CCE)

NSN 2410-00-574-7598

This copy is a reprint w hich includes

current pages from Change 1.

H E A D Q U A R T E R S , D E P A R T M E N T O F T H E A R M Y

30 JUNE 1981

This is the cut pages sample. Download all 913 page(s) at: ManualPlace.com
 TM 5-2410-234-14&P-1
C1

CHANGE HEADQUARTERS
DEPARTMENT OF THE ARMY
NO. 1 WASHINGTON, DC, 3 November 1986

TECHNICAL MANUAL

OPERATOR’S, ORGANIZATIONAL, DIRECT SUPPORT AND GENERAL SUPPORT

MAINTENANCE MANUAL (INCLUDING REPAIR PARTS INFORMATION AND

SUPPLEMENTAL MAINTENANCE AND REPAIR PARTS INSTRUCTIONS)

TRACTOR, FULL TRACKED, LOW SPEED, HEAVY DRAWBAR PULL, (SIZE T-11)

W/ANGLE DOZER, WINCH AND ROPS, CATERPILLAR MODEL D8K-8A-58 (CCE)

NSN 2410-00-5747597

AND W/BULLDOZER (SEMI-U-TILT), RIPPER AND ROPS, CATERPILLAR

MODEL D8K-8S-8 (CCE)

NSN 2410-00-574-7598

TM 5-2410-234-14&P-1, 30 June 1981 is changed as follows:

1. Chapter 7, Repair Parts, in this manual has been superseded by TM 5-2410-234-20P, Organizational Maintenance
Repair Parts and Special Tools Lists, and TM 5-2410-234-34P Direct Support and General Support Maintenance
Repair Parts and Special Tools Lists

2. File this change sheet in front of the publication for reference purposes.

By Order of the Secretary of the Army.

JOHN A WICKHAM, JR.

General, United States Army
Official: Chief of Staff

R.L. DILWORTH
Brigadier General, United States Army
The Adjutant General

Distribution.:
To be distributed m accordance with DA Form 12-25 A , Operator’s Organizational, Direct Support and General
Support Maintenance Requirements for Tractor, Full Tracked, Low Speed with Angle Dozer Models D8K-8A-58, D8K-8S-8
 TM 5-2410-234-14&P-1

WARNING
The proper and safe lubrication and maintenance procedures for this machine, recommended by Caterpillar, are
outlined m the LUBRICATION & MAINTENANCE GUIDE for this machine. Improper performance of lubrication or
maintenance procedures is dangerous and could result in injury or death Read and understand the LUBRICATION
& MAINTENANCE GUIDE before performing any lubrication or maintenance.
WARNING
To avoid possible weakening of this ROPS, consult a Caterpillar dealer before altering this ROPS in any way.
WARNING
The protection offered by this ROPS will be impaired if it has been structurally damaged or has been involved in
an overturn accident.
WARNING
Seat adjustment should be checked at the beginning of each shift and when operators change.
WARNING
Always use seat belts when operating machine.
WARNING
Always check condition of seat belt and connecting brackets.
WARNING
Attach ground cable last, and remove first, to prevent sparks from occurring near the battery which could cause
battery vapors to explode. Attach ground cable from booster battery to frame of machine to be started at a point
away from, and below, the battery on the machine to be started.
WARNING
Use starting fluid sparingly. Follow manufacturer’s instructions carefully.
WARNING
Do not store starting fluid in operator’s compartment.
WARNING
Keep tractor under control at all times. Do not neutralize transmission or forward-reverse lever, or disengage
flywheel clutch to allow machine to coast.
WARNING
Select gear range necessary before starting downgrade. Do not change gears while going downhill.
WARNING
Do not allow tractor to coast downhill.
WARNING
When load is pushing tractor, put gear selector in first speed before starting downhill.
WARNING
Do not release clutch or shift transmission while moving.
WARNING
Use extra caution when crossing side hills, ridges, logs and ditches.
WARNING
Make certain personnel are clear of cable when there is a load on the cable. Cable can break and cause personal
injury.
WARNING
Exercise care with suspended loads. If engine speed is too low, the weight of the load may cause it to drop, even
though the winch is in the Reel In position.
WARNING
Check travel route for overpass clearances. Make sure there will be adequate clearance if vehicle being
transported is equipped with ROPS, cab or canopy.
1
 TM 5-2410-234-14&P-1
WARNING
If the rack setting or the high idle speed is higher than the setting in the book RACK SETTING INFORMATION for
the "altitude" (height above sea level) at which the engine is operated, there can be damage to the engine or to
parts of the turbocharger.

WARNING
Be sure to make an adjustment to the regulator so the air supply in the tank is a maximum of 15 psi (1.05 kg/cm2).

WARNING
When making the (cooling system) checks, fasten the transmission in neutral, put the parking brakes on and
lower all equipment. Make all checks at engine LOW IDLE and on the side of the radiator opposite the fan Wear
eye protection.

WARNING
Never disconnect any charging unit circuit or battery circuit cable from battery when the charging unit is
producing a charge.

WARNING
Disconnect batteries before performance of any service work.
WARNING
The (valve) locks can be thrown from the valve when the valve spring compressor is released. Make sure the
locks are in the correct position on the valve.
WARNING
When (transmission) tests must be done in a closed area, activate the brakes and use blocks to prevent the
machine from moving during the tests. Let only approved personnel on the machine Keep other personnel off
the machine and in view of the operator.
WARNING
Do not make any adjustments to the (transmission) linkage with the engine running.
WARNING
The adjuster cylinder for the track is under high hydraulic pressure. Do not visually inspect the relief valve to see
if grease is being released. Check the adjuster cylinder that it moves to the rear into the front pilot for the recoil
springs. Use this warning any time that the track is loosened or tightened.

WARNING
Make sure the hydraulic jack is tight against the track roller frame when the track is lifted.

WARNING
Make sure the hydraulic pressure in the track adjusting mechanism is completely released and the cylinder can
be moved to the rear into the front pilot for the recoil spring before making a separation of the track or installing
the track adjusting mechanism. On machines with badly worn tracks, it is possible for the hydraulic track
adjuster to have a maximum forward adjustment and the stop will be against the front support for the track roller
frame. The hydraulic track adjuster is under high pressure. Do not visually inspect the relief valve to see if
grease is being released. Check the adjuster cylinder to see that it moves to the rear into the front pilot for the
recoil spring. Use this warning any time that the track is loosened or tightened.
WARNING
Do not remove the front cover for the recoil springs until Step 4 (spring compression) is completed. If the front
pilot for the recoil spring is broken, the procedure on page II-40 must not be used. See RECOIL SPRINGS (with
broken pilots) for correct procedures.
WARNING
The recoil springs are assembled under a force of several tons This force is released against legs during
disassembly. Caution must be used to make sure the correct tooling is used and the correct procedure is
followed.

2
 TM 5-2410-234-14&P-1
WARNING
The recoil springs are assembled under a force of several tons. This force is released against legs during
assembly. Caution must be used to make sure the correct tooling is used and the correct procedure is followed.
WARNING
Do not remove the hoist from the track roller frame at this time (following Step 6 of track roller frame
disassembly).
WARNING
Make sure the track roller frame does not hit the equalizer bar when it is removed. Weight of the track roller
frame is 8000 lb. (3629 kg).

WARNING
Do not hit the equalizer bar when the track roller frame is put in position.
WARNING
The recoil springs are under several tons of force. Do not remove cover until force is controlled by (proper)
tooling.
WARNING
Do not put more than 50 ton (45t) of force on (pilot) bolt.
WARNING
(Valve assembly) Cover is under spring tension. Hold the cover in position when the bolts that hold it to the
housing are removed.
WARNING
The access cover is under spring pressure. Hold the cover when the bolts that hold it are removed.
WARNING
Exercise care with suspended loads; if engine speed is too low, the weight of the load may cause it to drop, even
though the winch is in the REEL IN position.
WARNING
Do not underwind cable onto winch drum unless the winch has been modified to operate in this manner.
WARNING
When testing or making an adjustment to the hydraulic system, move the machine to a location away from other
moving machines. The operator must be sure that other personnel are not near the machine when the engine is
running and he is making tests.
WARNING
To avoid possible weakening of the ROPS (Rollover Protective Structure), consult a Caterpillar Dealer before
altering the ROPS in any way. The protection offered by the ROPS will be impaired if it has been subjected to
structural damage or has been involved in an overturn accident.
WARNING
When using pressure air, wear safety glasses and protective clothing. Maximum air pressure must be below 30
psi (2 kg/cm2).
WARNING
(Corrosion) Inhibitor contains alkali, avoid contact with skin and eyes.
WARNING
Never service air cleaners with engine running.
WARNING
If track is sealed and lubricated type, secure track with chain before separating links. Sealed and lubricated track
is very flexible. When disconnected, it can move and cause injury.
WARNING
Never visually inspect relief valve or fill valve to see if grease is escaping. Always observe the track to see if it
has loosened.
WARNING
Never service air cleaners with engine running.
3
 TM 5-2410-234-14&P-1

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4
 This manual contains copyright material

TM 5-2410-234-14&P-1

TECHNICAL MANUAL HEADQUARTERS

DEPARTMENT OF THE ARMY
No. 5-2410-234-14&P-1 WASHINGTON, DC, 30 June 1981

OPERATOR’S, ORGANIZATIONAL, DIRECT SUPPORT

AND GENERAL SUPPORT MAINTENANCE MANUAL
(INCLUDING REPAIR PARTS INFORMATION AND SUPPLEMENTAL
MAINTENANCE AND REPAIR PARTS INSTRUCTIONS)
FOR
TRACTOR, FULL TRACKED, LOW SPEED,
HEAVY DRAWBAR PULL, (SIZE T-1 1)
W/ANGLE DOZER, WINCH AND ROPS
CATERPILLAR MODEL D8K-8A-58 (CCE)
NSN 2410-00-574-7597
AND
W/BULLDOZER (SEMI-U-TILT), RIPPER
AND ROPS
CATERPILLAR MODEL D8K-8S-8 (CCE)
NSN 2410-00-574-7598

REPORTING OF ERRORS
You can Improve this manual by recommending Improvements using DA Form 2028 (Recommended
Changes to Publications and Blank Forms) or DA Form 2028-2 located in the back of this manual. Mail
the form direct to Commander, US Army Tank-Automotive Command, ATTN: DRSTA-MBS, Warren, MI
48090. A reply will be furnished direct to you.

CHAPTER 1. OPERATOR’S GUIDE

2. ENGINE
Section I. Specifications
II. Systems Operation, Testing and Adjusting
CHAPTER 3. POWER TRAIN
Section I. Specifications
II. Systems Operation, Testing and Adjusting
III. Disassembly and Assembly
CHAPTER 4. VEHICLE SYSTEMS
5. LUBRICATION AND MAINTENANCE
Section I. Direct Drive Tractor
II. Power Shift Tractor
CHAPTER 6. SUPPLEMENTAL OPERATING, MAINTENANCE AND REPAIR PARTS INSTRUCTIONS
APPENDIX A. REFERENCES
B. WARRANTY GUIDE LINES
C. MAINTENANCE ALLOCATION CHART
D. MODIFICATION PROCEDURE
E. BASIC ISSUE ITEMS LIST
F. MAINTENANCE AND OPERATING SUPPLIED
G. SAMPLE FORMAT, DA FORM 2765-1, NSN OR PART NUMBER REQUEST
H. SAMPLE FORMAT, MILSTRIP REQUISITION FOR CCE (NSN)
I. SAMPLE FORMAT, MILSTRlP REQUISITION FOR CCE (NON-NSN)
J. SAMPLE FORMAT, MILSTRIP REQUISITION FOR CCE (NON-NSN) (MANUAL)
K. DDS PROIECT CODES
L. PRESCRIBED LOAD LIST (PLL)
AUTHORIZED STOCKAGE LIST (ALS)
M. PREVENTIVE MAINTENANCE CHECKS AND SERVICES

i
 TM 5-2410-234-14&P-1
N. WALK-AROUND INSPECTION
O. SUPPLEMENTAL INFORMATION
P. CATERPILLAR DEALER LOCATIONS (CONUS & O/CONUS)
VOLUME 11

CHAPTER 7. REPAIR PARTS

Section I. D342 Vehicular Engine
II. D8K Tractor (D342 Engine)
III. D8K Tractor
IV. 183B Hydraulic Control
V. Bulldozers (8A, 8S & 8U)
VI. 58 & 59 Winch
VI. Ripper

This technical manual is an authentication of the manufacturers’ commercial literature and does
not conform with the format and content specified in AR 310-3, Military Publications. This
technical manual does, however, contain available Information that is essential to the operation
and maintenance of the equipment.

ii
 TM 5-2410-234-14&P-1

CHAPTER 1
OPERATOR’S GUIDE
SEBU5473 -01
 IMPORTANT SAFETY NOTICE

Most accidents involving machine operation are

caused by failure to observe basic safety rules or
precautions. An accident can often be avoided by
recognizing potentially hazardous situations before
an accident occurs.

Improper operation is dangerous and could result in

injury or death.

READ AND UNDERSTAND ALL SAFETY

PRECAUTIONS AND WARNINGS BEFORE
OPERATING THIS MACHINE.

Basic safety precautions are outlined in the SAFETY

section of this Guide and in the description of
operations where hazards exist. Warning labels
have also been put on the machine to provide
instructions and to identify specific hazards which, if
not heeded, could cause bodily injury or death to
you or other persons. These warnings in the Guide
and on the machine labels are identified by the
symbol

Operations that may result only in machine damage

are identified by CAUTION labels on the machine and
in the Guide.

Caterpillar cannot anticipate every possible

circumstance that might involve a potential hazard.
The warnings in this Guide and on the machine are
therefore not all inclusive. If an operation is not
performed as specifically recommended by
Caterpillar, you must satisfy yourself that it is safe
for you and others. You should also ensure that the
machine will not be damaged or made unsafe by the
method of operation you choose.

WARNING

The proper and safe lubrication and maintenance

procedures for this machine, recommended by
Caterpillar, are outlined in the LUBRICATION &
MAINTENANCE GUIDE for this machine.

lmproper performance of lubrication or maintenance

procedures is dangerous and could result in injury
or death. Read and understand the LUBRICATION &
MAINTENANCE GUIDE before performing any
lubrication or maintenance.
 FOREWORD

This guide is a reference for the new operator and a refresher

for the experienced one Read Study and keep it handy.

Illustrations help guide the operator through the correct

procedures of checking, starting, operating and stopping the
vehicle and attachments.

Operating techniques outlined in the guide are basic Skill and

techniques develop as the operator gains knowledge of the
vehicle and its capabilities.

Your safety and the safety of others depends upon care and
judgment in the operation of this vehicle. A careful operator is
good insurance against an accident.

Some photographs in this publication may show details or

attachments that may be different from your unit. Also, the
Rollover Protective Structure (ROPS), for some photographs
may have been removed for illustrative purposes.

Continuing improvement and advancement of product design

may cause changes to your machine which may not be included
in this publication Each publication is reviewed and revised, as
required, to update and include these changes in later editions.

When a question arises regarding your Caterpillar product, or

this publication, please consult your Caterpillar dealer for the
latest available information.
 TABLE OF CONTENTS

Tractor Model View ................................................................ 3

Safety .................................................................................... 4

Symbol Identification .............................................................. 7

Operator’s Compartment........................................................ 10

Controls .................................................................................. 15

Before Starting ...................................................................... 24

Starting the Engine................................................................. 27

After Starting ......................................................................... 32

Moving the Tractor ................................................................. 33

Parking the Tractor ................................................................ 39

Operating Adjustments .......................................................... 41

Operating Techniques ........................................................... 44

Transportation Hints............................................................... 60

2
TRACTOR
General Locations

3
SAFETY THIS SYMBOL WARNS OF POSSIBLE
PERSONAL INJURY

To avoid possible weakening The protection offered by this

of this ROPS, consult a ROPS will be impaired if it has
Caterpillar dealer before been structurally damaged or
altering this ROPS in any way. has been involved in an
overturn incident.

Lower or block equipment and Lower all equipment and set

stop engine before servicing. parking brake before leaving
machine.

Stay safe distance from edge of

cliff or overhang.

4
 General

Clean steps, grab irons and Make sure clearance flags, lights
operator’s compartment. and other required warnings are on
machine when roading.
Wear a hard hat, safety glasses
and respirator as required by job Know hand signals and who gives
conditions. them.

Do not wear loose clothing or Do not smoke while fueling

jewelry that could catch on controls. machine or when near batteries.

Report needed repairs.

Preparing to Operate

Clear all personnel from Move all controls to HOLD before

machine and surrounding area. starting engine

Clear obstacles from path of Move transmission to NEUTRAL

machine, note hazards such as and have brake lock engaged before
wires and ditches. starting engine

Make certain all safety guards Start engine in a well ventilated

and covers are secured in place area.
Adjust seat and fasten seat belt
before operating.

Testing Controls

Test all controls for proper Test brakes.

operation.
Test function of safety de-vices
Test right and left steering such as lights and backup alarm.
while moving slowly.

Mounting and Dismounting

Stop engine before leaving the

To park machine, lower machine.
blade to ground and apply down
pressure, engage parking brake. Do not jump off machine Use
steps and grab irons.

5
 Operating
Do not allow riders on the Stop machine frequently at
machine night, walk around and inspect
machine -- stay alert.
The operator must satisfy
himself that no one will be Road machine in forward
endangered before, and while, direction, not reverse.
backing the machine.
Stay clear of overhangs, electric
Observe all gauges wires, slide or other dangerous
frequently--investigate improper areas.
readings. Use caution in crossing side
hills, ridges, ditches, and other
Know traffic pattern of the job obstructions.
and obey flagmen, road signs Use caution when working on
and signals. hills, banks or slopes, to avoid
tipping.
Match speed with job Stay a safe distance from edge
conditions do not coast. of cliff or overhang.
Carry blade close to ground Listen for unusual noises Report
needed repairs noted during
Know stopping distance of operation.
your machine at any given
speed Regulate travel speed
accordingly.

Shipping

For shipping instructions consult your Caterpillar dealer.

6
SYMBOL IDENTIFICATION

THESE PAGES EXPLAIN THE MEANING OF SYMBOLS THAT MAY APPEAR

ON YOUR MACHINE.

7
8
Caterpillar D8k 8a 58 Service Manual
Full download: http://manualplace.com/download/caterpillar-d8k-8a-58-service-manual/

This is the cut pages sample. Download all 913 page(s) at: ManualPlace.com