Title: Caterpillar Cat 5080 FRONT SHOVEL (Prefix 8SL) Service Repair Manual (8SL00001 and up)
1Service Repair Manual
Models 5080 FRONT SHOVEL
2Shutdown SIS
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Product FRONT SHOVEL Model 5080 FRONT SHOVEL
8SL Configuration 5080 Excavator 8SL00001-UP
(MACHINE) POWERED BY 3406B Engine
Disassembly and Assembly 3406C DIESEL ENGINES FOR
CATERPILLAR BUILT MACHINES Media Number
-SENR6409-02 Publication Date -01/07/2006
Date Updated -19/05/2015
SENR64090025
Fuel Injection Nozzles Adapters SMCS -
1106-010 1254 Remove Install Fuel Injection
Nozzles Adapters
Start By a. remove valve covers
31. Use Tool (A) and disconnect fuel line (1) at
each end. Remove the fuel line from the engine.
- Use Tool (B) and remove retainer (2) from the
adapter. - Remove the fuel injection nozzles with Tool (C)
as follows - Install the 6V6983 Adapter and the 8T3199 Screw
into nozzle assembly (3). - Install the 8T3198 Tube over the 8T3199 Screw.
- Use the 1B4206 Nut on the 8T3199 Screw to pull
the fuel injection nozzle (3). - Remove compression seal (4) and carbon dam seal
(8) from fuel injection nozzle (3). - Use Tool (D) and remove adapter (6) from the
cylinder head. - Remove gasket (7) and seal (5) from adapter (6).
- NOTE The following steps are for the
installation of the fuel injection nozzles and
adapters.
4- Use Tool (E) to clean the bore in adapter (6).
Use an open end wrench or tap driver to turn Tool
(E). - Inspect seal (5) for damage or wear. Replace the
seal if necessary. - Put washer (7) and seal (5) in position on
adapter (6). - Put liquid soap in the bores of the cylinder head
and on seals (5) in the adapters. - Put 5P3931 Anti-Seize Compound on the threads of
adapter (6) and install the adapter in the
cylinder head assembly. - Use Tool (D) and tighten the adapter to a torque
of 205 14 Nm (150 10 lb ft). - NOTICE
- Make sure the correct compression seal washer (4)
is used when the nozzle assembly is installed in
the adapter. Only copper washers are to be used
with this adapter.
- Install compression seal washer (4) and use Tool
(F) to install carbon dam seal (8) on the fuel
injection nozzle. - Put fuel injection nozzle (3) in position in the
adapter and install retainer (2). - Use Tool (B) to tighten retainer (2) to a torque
of 48 7 Nm (35 5 lb ft). - Install fuel line (1). Tighten the nuts on the
fuel line with Tool (A) to a torque of 40 7 Nm
(30 5 lb ft). - End By
- a. install valve covers
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Product FRONT SHOVEL Model 5080 FRONT SHOVEL
8SL Configuration 5080 Excavator 8SL00001-UP
(MACHINE) POWERED BY 3406B Engine
Disassembly and Assembly 3406C DIESEL ENGINES FOR
CATERPILLAR BUILT MACHINES Media Number
-SENR6409-02 Publication Date -01/07/2006
Date Updated -19/05/2015
SENR64090026
- Cylinder Head Assembly
- SMCS - 1100-011 1100-012
- Remove Cylinder Head Assembly
- Start By
- remove rocker shaft assemblies and push rods
- remove water temperature regulator
- remove aftercooler housing
- remove fuel injection lines
- remove exhaust manifold
- Typical Example
- Remove bolts (1) from the alternator bracket.
- Remove the bolts that hold plate (3) and remove
the plate. - Disconnect water line (2) from the air
compressor. - NOTE Turn the water line tee toward the lifting
bracket in order to provide clearance to remove
the head bolt.
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7- Remove bolts (4) and (5) that hold the cylinder
head assembly to the cylinder block. - Fasten a hoist and remove the cylinder head
assembly. The weight is approximately 135 kg (300
lb). - NOTICE
- Do not put the cylinder head assembly down on a
flat surface. This can cause damage to the fuel
injection valves.
6. Remove the gasket and seals from the spacer
plate. Install Cylinder Head Assembly NOTE Be
sure a new gasket has been installed between the
spacer plate and the cylinder block. See topic,
"Remove Install Spacer Plate".
1. Thoroughly clean the spacer plate and the
bottom surface of the cylinder head assembly.
Install a new head gasket, new seals (1) and two
O-ring seals (2).
- Fasten a hoist and put the cylinder head assembly
(3) in position on the cylinder block. - Tighten the bolts in sequence shown in
Illustration D11970.
8- Large bolts (3/4 inch). Put 6V4876 Molycoat Paste
Lubricant on bolt threads and between washers and
underside of bolt heads. - Small bolts (3/8 inch). See Step 4h.
- Install the cylinder head bolts and washers.
Tighten the bolts in sequence shown. - Tighten bolts 1 through 14 in number sequence to
270 25 Nm (200 20 lb ft). - Tighten bolts 1 through 14 in number sequence to
470 20 Nm (345 15 lb ft). - Tighten bolts 1 through 14 in number sequence
again to 470 20 Nm (345 15 lb ft). - Install the rocker arm shafts for the engine
valves and the remaining (3/4 in) bolts and/or
compression brake studs. - Tighten bolts 15 through 26 in number sequence to
270 25 Nm (200 20 lb ft). - Tighten bolts 15 through 26 in number sequence to
450 20 Nm (330 15 lb ft). - Tighten bolts 15 through 26 in number sequence
again to 450 20 Nm (330 15 lb ft). - Tighten the thirteen small bolts (2) to 45 7
Nm (33 5 lb ft). - Make an adjustment to the valves to have a
clearance of 0.38 mm (.015 in) for intake and
0.76 mm (.030 in) for exhaust. Tighten the
locknuts for the valve adjustment screws to a
torque of 28 4 Nm (21 3 lb ft). - Install the valve cover bases and the inner fuel
lines. See topic, "Install Rocker Shaft
Assemblies Push Rods". - Install the valve covers. See topic, "Install
Valve Covers".
Typical Example 8. Install plate (4).
9- Connect the water line to the air compressor.
- Install bolts (5) for the alternator bracket.
End By - install exhaust manifold
- install fuel injection lines
- install aftercooler housing
- install water temperature regulator
- install rocker shaft assemblies and push rods
Copyright 1993 - 2021 Caterpillar Inc. All
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Product FRONT SHOVEL Model 5080 FRONT SHOVEL
8SL Configuration 5080 Excavator 8SL00001-UP
(MACHINE) POWERED BY 3406B Engine
Disassembly and Assembly 3406C DIESEL ENGINES FOR
CATERPILLAR BUILT MACHINES Media Number
-SENR6409-02 Publication Date -01/07/2006
Date Updated -19/05/2015
SENR64090027
Spacer Plate SMCS - 1221-011 1221-012 Remove
Spacer Plate Start By a. remove cylinder head
assembly
1. Remove spacer plate (1) from the cylinder
block. NOTICE Do not cause damage to the
dowels.
2. Remove the spacer plate gasket and two O-ring
seals.
Install Spacer Plate
111. Thoroughly clean the spacer plate and cylinder
block surface. Install two O-ring seals (1) in
the cylinder block.
NOTICE Both surfaces of the spacer plate, top of
cylinder block and both sides of the spacer
plate gasket must be clean and dry. Gasket
adhesives or other substances must not be used
on these surfaces.
- Install a new gasket between the spacer plate and
cylinder block. Put spacer plate (2) in position
on the cylinder block. - Check cylinder liner projection. See topic,
"Install Cylinder Liners". End By - a. install cylinder head assembly
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Product FRONT SHOVEL Model 5080 FRONT SHOVEL
8SL Configuration 5080 Excavator 8SL00001-UP
(MACHINE) POWERED BY 3406B Engine
Disassembly and Assembly 3406C DIESEL ENGINES FOR
CATERPILLAR BUILT MACHINES Media Number
-SENR6409-02 Publication Date -01/07/2006
Date Updated -19/05/2015
SENR64090028
Valves SMCS - 1105-011 1105-012 Remove Valves
Start By a. remove cylinder head assembly
- Use Tool (A) to compress springs (1).
- Remove the locks.
- Remove Tool (A), the valve, the rotocoil, and the
spring. - NOTE If a valve can be used again, put
identification on the valve for location at
installation.
13- Use Tool (B) to check spring force. The
specifications for the spring are given in
Specifications Manual, SENR6470. - Do Steps 1 through 4 again for the remainder of
the valves.
Install Valves
1. Put clean engine oil on the valve stem.
Install washer (3), spring (2), rotocoil (1) and
the valve.
- Use Tool (A) to compress the spring.
- Install locks (4) with the thick end up.
Locks can be thrown from valve when compressor is
released, if they are not in their correct
position on the valve stem.
14- Remove the compressor and hit the valve with a
soft faced hammer to be sure locks are in their
correct position on the valve. - Do Steps 1 through 4 again for the remainder of
the valves. End By - a. install cylinder assembly
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Product FRONT SHOVEL Model 5080 FRONT SHOVEL
8SL Configuration 5080 Excavator 8SL00001-UP
(MACHINE) POWERED BY 3406B Engine
Disassembly and Assembly 3406C DIESEL ENGINES FOR
CATERPILLAR BUILT MACHINES Media Number
-SENR6409-02 Publication Date -01/07/2006
Date Updated -19/05/2015
SENR64090029
Valve Seat Inserts SMCS - 1103-010 Remove
Install Valve Seat Inserts
Start By a. remove valves
- Use Tool (A) to remove the valve seat inserts
from the cylinder head. - Clean and remove any burrs from the valve seat
bores. - NOTE For reconditioning information of the
cylinder head, see Service Training Meeting
Guide, SESV1202. - NOTE The following steps are for the
installation of the valve seat inserts.
16- Lower the temperature of the new valve seat
inserts. Use Tool (B) to install the new valve
seat inserts in the cylinder head. - End By
- a. install valves
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17Shutdown SIS
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Product FRONT SHOVEL Model 5080 FRONT SHOVEL
8SL Configuration 5080 Excavator 8SL00001-UP
(MACHINE) POWERED BY 3406B Engine
Disassembly and Assembly 3406C DIESEL ENGINES FOR
CATERPILLAR BUILT MACHINES Media Number
-SENR6409-02 Publication Date -01/07/2006
Date Updated -19/05/2015
SENR64090030
Bridge Dowels SMCS - 1121-011 1121-012 Remove
Bridge Dowels
Start By a. remove valves
1. Use Tool (A) to remove bridge dowel (1).
Install Bridge Dowels
18- Use Tool (A) to install the bridge dowel.
- End By
- a. install valves
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19Shutdown SIS
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Product FRONT SHOVEL Model 5080 FRONT SHOVEL
8SL Configuration 5080 Excavator 8SL00001-UP
(MACHINE) POWERED BY 3406B Engine
Disassembly and Assembly 3406C DIESEL ENGINES FOR
CATERPILLAR BUILT MACHINES Media Number
-SENR6409-02 Publication Date -01/07/2006
Date Updated -19/05/2015
SENR64090031
Valve Guides SMCS - 1104-011 1104-012 Remove
Valve Guides
Start By a. remove valves
1. Use Tool (A) to remove the valve guides.
Install Valve Guides
20- Put clean engine oil on the outside of the valve
guide. - Use Tool (A) to install the valve guides.
- After installation, the inside diameter of the
valve guide must be 9.487 0.025 mm (.3735 - .0010 in). The maximum diameter of used guides
is 8.538 mm (.3361 in). - End By
- a. install valves
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Product FRONT SHOVEL Model 5080 FRONT SHOVEL
8SL Configuration 5080 Excavator 8SL00001-UP
(MACHINE) POWERED BY 3406B Engine
Disassembly and Assembly 3406C DIESEL ENGINES FOR
CATERPILLAR BUILT MACHINES Media Number
-SENR6409-02 Publication Date -01/07/2006
Date Updated -19/05/2015
SENR64090032
Oil Pan Plate SMCS - 1302-011 1302-012 Remove
Oil Pan Plate
- Typical Example
- Drain the oil from the engine into a suitable
container for storage or disposal. - Remove the lower clamp and bracket that hold the
breather tube to the cylinder block and oil pan. - Remove all but four of the bolts (1) that hold
the oil pan to the cylinder block.
Use two persons to hold the oil pan in position
while the last four bolts are removed.
4. Remove the oil pan (2). Weight of the oil pan
is 57 kg (126 lb).
225. Remove suction bell (3). Remove suction bell
and tube (4). Remove oil supply tube (5). Remove
plate (6).
Install Oil Pan Plate
- Put plate (1) in position on the cylinder block.
Put suction bell and tube (2) in position on the
oil pump and cylinder block. Install the bolts
that hold it. - Install oil supply tube (4).
- Install the suction bell (3).
- Install two 3/8 in 16 NC Guide Pins 6 in long in
the cylinder block. Put the oil pan (5) in
position on the cylinder block. Install all but
two of the bolts that hold it. Remove the two
guide pins. Install the last two bolts. - Fill the engine with oil to the correct level.
See the Operation Maintenance Manual.
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Product FRONT SHOVEL Model 5080 FRONT SHOVEL
8SL Configuration 5080 Excavator 8SL00001-UP
(MACHINE) POWERED BY 3406B Engine
Disassembly and Assembly 3406C DIESEL ENGINES FOR
CATERPILLAR BUILT MACHINES Media Number
-SENR6409-02 Publication Date -01/07/2006
Date Updated -19/05/2015
SENR64090033
Oil Pump SMCS - 1304-016 1304-010
1304-015 Remove Install Oil Pump Start By a.
remove oil pan
1. Remove oil supply tube (1) and suction bell
and tube (2).
- Remove bolts (3) that hold the oil pump to the
cylinder block and remove oil pump (4). - To install, put oil pump (4) in position on the
cylinder block. Install the bolts that hold the
oil pump to the cylinder block. - Put clean engine oil on the O-ring seals of the
tubes.
24- Install oil supply tube (1), suction bell and
tube (2). - End By
- a. install oil pan
Disassemble Oil Pump
Start By a. remove oil pump
- Remove the bolt and washer that hold the gear on
the shaft. - Use Tool (A) and remove drive gear (1) from the
shaft. Remove the key from the shaft.
- Remove retainer (3) for the bypass valve. Remove
the spring and the bypass valve. - Remove cover (2) from the pump body.
255. Use Tool (B) and remove the bearings from the
cover.
- Remove gears (5) from pump body (4).
- Use Tool (B) and remove the bearings from pump
body (4).
Assemble Oil Pump
1. Use Tool (B) to install the bearings in the
pump body. Install the bearings so the joint in
the bearings is 30 15 degrees from the center
line of the oil pump outlet passage (2).
262. Install idler gear and drive gear (5) in the
oil pump body (4). Put clean engine oil on the
bearings and the gears.
- Use Tool (A) and install the bearings in cover
(2). Install the bearings so the joint of the
bearing bores toward oil pump outlet passage
(6). - Install bypass valve (7), spring (8) and the
retainer. - Install the key on the shaft.
- Install gear (1) on the shaft. Install the washer
and bolt that hold the gear on the shaft. Be sure
the pump turns freely after assembly. - End By
- a. install oil pump
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Product FRONT SHOVEL Model 5080 FRONT SHOVEL
8SL Configuration 5080 Excavator 8SL00001-UP
(MACHINE) POWERED BY 3406B Engine
Disassembly and Assembly 3406C DIESEL ENGINES FOR
CATERPILLAR BUILT MACHINES Media Number
-SENR6409-02 Publication Date -01/07/2006
Date Updated -19/05/2015
SENR64090034
Piston Cooling Tubes SMCS - 1307-010 Remove
Install Piston Cooling Tubes
Start By a. remove oil pump NOTE The piston and
connecting rod were removed for better
illustration.
- Remove bolts (1). Remove piston cooling tubes (2)
from the engine. Use Tool (A) to turn the
crankshaft in a clockwise direction (as seen from
the front of the engine) to get access to all of
the piston cooling tubes. - NOTE The following steps are for the
installation of the piston cooling tubes. - Check the alignment of the piston cooling tubes
with Tool (B). See Use Of 5P8709 Tool Group for
Alignment Of Piston Cooling Jets, SMHS7267 for
the correct alignment procedure.
28- Install piston cooling tubes (2) on the engine.
Use Tool (A) to turn the crankshaft clockwise (as
seen from the front of the engine) to get access
for the installation of the piston cooling tubes. - End By
- a. install oil pump
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Product FRONT SHOVEL Model 5080 FRONT SHOVEL
8SL Configuration 5080 Excavator 8SL00001-UP
(MACHINE) POWERED BY 3406B Engine
Disassembly and Assembly 3406C DIESEL ENGINES FOR
CATERPILLAR BUILT MACHINES Media Number
-SENR6409-02 Publication Date -01/07/2006
Date Updated -19/05/2015
SENR64090035
- Pistons Connecting Rod Assemblies
- SMCS - 1225-017 1225-011 1225-012
- Remove Pistons Connecting Rod Assemblies
- Start By
- remove cylinder head assembly
- remove oil pump
- remove piston cooling tubes
- Remove the carbon ridge from the top inside
surface of the cylinder liners.
- Turn the crankshaft until two pistons are at
bottom center. - Remove bolts (1) and the bearing caps. Push the
rods and pistons up until the rings are out of
the cylinder liners.
30- Remove pistons (2) and connecting rods from the
cylinder liners. - Do Steps 1 through 4 for the remainder of the
pistons and connecting rods.
Install Pistons Connecting Rod Assemblies
1. Put clean engine oil on piston rings,
connecting rod bearings and cylinder liners.
- Use Tool (A), and install piston (2) and the
connecting rod in the cylinder liner. - Install the bearing cap on the connecting rod
with the number on the side of the bearing cap on
the same side and same number as on the
connecting rod. - Put 2P2506 Thread Lubricant on the threads of the
bolts. Install the nuts, and tighten them to a
torque of 90 8 Nm (67 6 lb ft). Put a mark
on the nuts and cap, and tighten the nuts an
extra 90 5 degrees. - Do Steps 1 through 4 for the remainder of the
pistons and connecting rods. End By - install piston cooling tubes
- install oil pump
- install cylinder head assembly
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32Disassemble Assemble Pistons Connecting Rod
Assemblies
Start By a. remove pistons and connecting rod
assemblies
- Remove bearings (3) from the connecting rod and
connecting rod cap. - Remove retainer ring (1) with Tool (A).
- Remove pin (2) and connecting rod (4) from the
piston.
4. Remove piston rings (5) from the piston with
Tool (B). Clean the piston ring grooves on the
pistons with an acceptable ring groove cleaning
tool.
33NOTE See, Use Of Piston Bearing Removal And
Installation Tools, Special Instructions,
SMHS7295. 5. Heat connecting rod (4) in an oven
to a temperature of 177 to 260C (350 to 500
F). Never use a direct flame to heat a
connecting rod.
- Put connecting rod (4) in position on the base
plate of Tool (C). Put a new rod pin bearing (6)
on the adapter part of Tool (C). - NOTE The old bearing is pushed out by Tool (C)
as the new bearing is installed. - Use Tool (C) to push the new bearing into the
connecting rod until the push adapter of Tool (C)
makes full contact with the connecting rod
surface. - Use a pin boring machine to make the rod pin
bearing the correct size. The bore in the new rod
pin bearing must be 50.830 0.008 mm (2.0012
.0003 in). - Check the clearance between the ends of the
piston rings. See the topic, "Pistons Rings" in
Specifications Manual, SENR6470. - Install the oil ring spring in the oil ring
groove of the piston. - NOTE The oil ring is to be installed over the
spring with the oil ring end gap 180 from the
oil ring spring joint. - Install the oil ring on the piston with tool (B).
- Install the second (intermediate) piston ring
with the side that has the identification "UP-2"
toward the top of the piston. Use Tool (B) to
install the ring. - Install the first (top) piston ring with the side
that has the identification "UP-1" toward the top
of the piston. Use Tool (B) to install the ring. - NOTE After the installation of all three piston
rings, put the piston rings in position so the
end gaps are 120 degrees apart. - Put the piston in position on connecting rod (4).
Put clean engine oil on pin (2), and install the
pin. Install retainer rings (1) with Tool (A).
Make sure the retainer rings are in the grooves
of the piston.
34NOTE Be sure the tabs in back of the bearings
are in tab slots of the connecting rod and
connecting rod cap. End By a. install pistons
and connecting rod assemblies
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Licensees.
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