Caterpillar cat d8 r track type tractor dozer bulldozer (prefix rjm) service repair manual (rjm00001 and up)

Service Repair Manual
Models
D8R TRACK-TYPE TRACTOR

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Product: TRACK-TYPE TRACTOR
Model: D8R TRACK-TYPE TRACTOR RJM
Configuration: D8R TRACK-TYPE TRACTOR RJM00001-UP (MACHINE) POWERED BY 3406C Engine
Disassembly and Assembly
D8R Track-Type Tractor Power Train
Media Number -UENR1350-01 Publication Date -01/11/2013 Date Updated -10/03/2016
i07404909
Track Roller - Remove and Install
SMCS - 4180-010
Removal Procedure
Table 1
Required Tools
Tool Part Number Description Qty
A FT-2213 Strap 1
B 183-4799 Track Roller Lifting Fork 1
C - Loctite C5-A Copper Anti-seize Lubricant -
1. Loosen track. Refer to Operation and Maintenance Manual, "Track - Adjust" for correct
loosening and tightening procedures.
Illustration 1 g00617904
2. Install Tooling (A).
1/3D8R TRACK-TYPE TRACTOR RJM00001-UP (MACHINE) POWERED BY 3406C...
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3. Raise the side of the machine.
4. Remove track guide (1) from the outside of the major bogie.

Note: Mark the location of double flange track rollers (4) and single flange track rollers (5)
for installation.
5. Use Tooling (B) and a suitable lifting device to remove double flange track roller (4). The
weight of double flange track roller (4) is approximately 222 kg (489 lb). The weight of
single flange track roller (5) is approximately 149 kg (328 lb)
6. Remove bolts (3) and caps (2).
7. Use Tooling (B) and the suitable lifting device to remove double flange track roller (4) from
the minor bogie.
Note: Refer to Undercarriage Reconditioning Bulletin for further information regarding track
rollers.
Installation Procedure
1. Install double flange track roller (4) and single flange track roller (5) in the reverse order of
removal.
a. Apply Tooling (C) to threads of bolts (3). Tighten bolt (3) on abutment side first.
Tighten bolts (3) to a torque of 750 ± 70 N·m (553 ± 51 lb ft).
b. Tighten bolts (1) to a torque of 485 ± 15 N·m (358 ± 11 lb ft)
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Fri Jan 24 17:36:54 UTC+0800 2020

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i05296568
Track - Separate
SMCS - 4170-076
Separation Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A
284-5122 Stands GP-Tube 3
283-1498 Saddles 3
283-1500 Lock-Pins 3
283-1482 Tubes 3
B 260-9412 Chain Assembly 1
Personal injury can result from the track coming off of the roller frame.
The track can move off the track roller frame very quickly when a
separation of the track is made.
Keep away from the front of the machine when the track is removed
from the track roller frame.
Note: The following procedure can be used to separate the master link for the standard track and
for the SystemOne track. Refer to Special Instruction, REHS4336, "Correct replacement of the

master links in D8SI", Special Instruction, REHS3373, "Conversion to D8SI", and Special
Instruction, SEBF9100, "Field repair for SystemOne track with multi-pitch track press tool".
1. Release the track tension. Refer to Operation and Maintenance Manual , "Track Tension -
Check/Adjust".
2. Lower the blade onto Tooling (A).
3. Move the track until master link (3) is just above the centerline of rear idler (1). Position
suitable blocking under the grouser bar just below master link (3). Move the track to the rear
until the track is in contact with the suitable blocking.
4. Attach Tooling (B) to track shoe (4). Remove bolts (2) and track shoe (4). The weight of
track shoe (4) is approximately 45 kg (100 lb). Discard bolts (2). Separate master link (3).

5. Insert suitable cribbing to protect undercarriage from possible damage from track (5).
6. Install Tooling (B) and a suitable lifting device to track (5).
7. Turn the final drive in a forward direction and permit track (5) to move forward while track
(5) is supported by Tooling (B).
Fri Jan 24 17:37:53 UTC+0800 2020

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i05331411
Track - Connect
SMCS - 4170-077
Connection Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A
284-5122 Stands GP-Tube 3
283-1498 Saddles 3
283-1500 Lock-Pins 3
283-1482 Tubes 3
B 260-9412 Chain As 1
C 138-7576 Link Bracket 1
D 4C-5593 Thread Lubricant 1
Note: The following procedure can be used to connect the master link for the standard track and
for the SystemOne track. Refer to Special Instruction, REHS4336, "Correct replacement of the
master links in D8SI", Special Instruction, REHS3373, "Conversion to D8SI", and Special
Instruction, SEBF9100, "Field repair for SystemOne track with multi-pitch track press tool".
Note: Machines equipped with differential steering MUST HAVE the opposite track on the
ground to use this procedure.
Note: Two people are required for this procedure to ensure safety.

1. Install Tooling (C) to the final drive. Attach a suitable chain to Tooling (C) and to the track.
The suitable chain must be long enough to go around the final drive one revolution.
2. Start the machine and turn the final drive in a reverse direction to pull the track together.
Remove Tooling (C) and the suitable chain.
Note: Ensure that mating surfaces of (3), (4), and (2) are free from paint and debris.
3. Use Tooling (B) to position track shoe (4) on master link (3). The weight of track shoe (4) is
approximately 45 kg (100 lb). Apply Tooling (D) to the threads, the body, and the washer
face of new bolts (2). Install bolts (2). Tighten bolts (2) to a torque of 650 ± 70 N·m
(480 ± 50 lb ft). Turn bolts (2) for an additional 120 ± 5 degrees. Remove Tooling (B).
Remove the suitable blocking.

4. Remove suitable cribbing from under track (5).
5. Raise the blade and remove Tooling (A).
6. Adjust the track tension. Refer to Operation and Maintenance Manual, "Track Tension -
Check/Adjust".
Fri Jan 24 17:38:53 UTC+0800 2020

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i06054245
Sprocket Segment - Remove and Install
SMCS - 4164-010
Removal Procedure
1. Move the machine forward or backward to position sprocket segment (2) for accessibility.
2. Remove the bolts, the washers, and nuts (1) .
3. Remove sprocket segment (2) .

Note: Ensure that all mating surfaces are free from paint and debris.
1. Apply SAE 30W oil on the washer face, nut face, and threads of the bolts of the sprocket
segment.
2. Position sprocket segment (2) on the machine.
3. Install bolts, washers, and nuts (1) .
Note: The heads of the bolts and the washers must be against the final drive.
4. Tighten nuts (1) to a torque of 300 ± 50 N·m (220 ± 37 lb ft). Turn nuts (1) for an additional
120 ± 5 degrees.
Fri Jan 24 17:39:52 UTC+0800 2020

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i05348187
Track Roller Frame (Front) - Remove
SMCS - 4151-011
Removal Procedure
Table 1
Required Tools
A
9U-7536 Lift Stands 2
277-7200 Hydraulic Pump 1
B FT-2213 Strap 1
C
8B-7548 Push-Puller Tooling Gp 1
5P-4808 Caps 2
0S-1601
Bolts
(5/8 - 18 by 2 3/4 inch)
2
8S-9089
Bolts
(1/2 - 13 by 4 1/2 inch)
2
5P-8245
Bolts
(3 mm by 25.5 mm)
2
5P-8247
Hard Washers
(3.5 mm by 32 mm)
4
D 8S-9906 Ratchet Puller Gp 2
E 8T-5071 Seal Guard 1
F 422-2352
Stands
(Vehicle Support)
3

Start By:
a. Separate the track.
Personal injury can result from performing service on the track roller
frame.
Refer to Special Instruction, SMHS8273 for inspection and removal
procedures before performing any service.
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.
1. Position Tooling (A) under the front of the machine. Raise the machine until the front track
roller frame is up 25 mm (1.0 inch).

Note: Tooling (B) is installed after the front roller frame is up 25 mm (1.0 inch). Raise the
front track roller frame to release the pressure in the bogie pads.
2. Install Tooling (B) on the front bogie.
3. Raise the machine until the front track rollers are off the track.
4. Remove plug (3) and drain the oil from the rear track roller frame.
5. Remove bolts (1) and cover (2) from each side of the rear track roller frame.
6. Remove the O-ring seals from each cover (2).

7. Use Tooling (C) to remove guides (4) from both sides of the rear track roller frame.
Personal injury or death can result from lifting a heavy assembly.
The heavy assembly can fall if using an incorrect hoist to lift the load.
Be sure the hoist has the correct capacity to lift a heavy assembly.
Approximate weight of the assembly is given below.
8. Attach a suitable lifting device to front track roller frame (5) as shown in illustration 5. The
weight of front track roller frame (5) is approximately 1550 kg (3450 lb).
9. Install one end of Tooling (D) to front track roller frame (5) and the other end to the radiator
guard.
10. Use a suitable lifting device and Tooling (D) to pull front track roller frame (5) partially out
of the rear track roller frame.

11. Install Tooling (E) to protect the seal.
12. Attach two suitable lifting devices to the front idler shaft as shown in illustration 7.
13. Remove front track roller frame (5).
14. Position front track roller frame (5) onto Tooling (F).

15. If necessary, remove sleeve (6) from front track roller frame (5).
NOTICE
Seal (10) will be damaged when removed from the rear track roller
frame.
16. Remove these components from the rear track roller frame: retaining ring (9), seal (10),
retaining ring (8) and bearing (7).
Fri Jan 24 17:40:52 UTC+0800 2020

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i05350080
Track Roller Frame (Front) - Install
SMCS - 4151-012
Table 1
Required Tools
A
9U-7536 Lift Stands 2
277-7200 Hydraulic Pump 1
B FT-2213 Strap 1
D 8S-9906 Ratchet Puller Gp 2
E 8T-5071 Seal Guard 1
F 422-2352
Stands
(Vehicle Support)
3
G - Loctite Hi-Temp Flange Sealant 1
H FT-1965 Driver 1
J 1U-5753 Seal Starter 1
K - Eye Bolts (/2 -13) 2

1. Install bearing (7) and retaining ring (8) in the rear track roller frame.
Note: The seal bore should be clean and free of dirt, oil, and old adhesive.
2. Apply Tooling (G) to the seal bore.
3. Use Tooling (H) and Tooling (J) to install seal (10) in the rear track roller frame.
4. Install retaining ring (9).

5. Install Tooling (E) inside seal (10).
Note: The back leg of Tooling (E) should be in the gap between seal (10) and the track
roller frame.
6. Apply clean SAE 30W oil to the inside diameter of seal (10).
7. If sleeve (6) was removed, raise the temperature to a maximum of 175 °C (347 °F). Install
sleeve (6) on front track roller frame (5). Install sleeve (6) with the taper on the outside
diameter toward the rear of front track roller frame (5).

Personal injury or death can result from lifting a heavy assembly.
The heavy assembly can fall if using an incorrect hoist to lift the load.
Be sure the hoist has the correct capacity to lift a heavy assembly.
Approximate weight of the assembly is given below.
8. Attach a suitable lifting device to front track roller frame (5) as shown in Illustration 5. The
weight of front track roller frame (5) is approximately 1565 kg (3450 lb).
Note: Align the keyway in the cylinder assembly with the key in the rear track roller frame.
9. Install the front track roller frame in the rear track roller frame. Install the front track roller
frame until sleeve (6) is 25 to 50 mm (1.0 to 2.0 inch) from the seal in the rear track roller
frame.
10. Carefully remove Tooling (E) from the seal in the rear track roller frame.

Caterpillar cat d8 r track type tractor dozer bulldozer (prefix rjm) service repair manual (rjm00001 and up)

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