Caterpillar Cat D8R II TRACK-TYPE TRACTOR Dozer Bulldozer (Prefix 6YZ) Service Repair Manual (6YZ00001 and up).pdf

Service Repair Manual
Models
D8R II TRACK-TYPE TRACTOR

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Product: TRACK-TYPE TRACTOR
Model: D8R II TRACK-TYPE TRACTOR 6YZ
Configuration: D8R Series II Track-Type Tractor 6YZ00001-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
i02872867
Track - Disassemble
SMCS - 4170-015
Disassembly Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 8S-9906 Ratchet Puller 1
B
9U-6600 Manual Pump 1
150-6624 Track Tool Arrangement 1
6V-4103 Forcing Pin 1
8T-5133 Receiver 1
C 2S-8215 Guide Pin 2
D
6V-3170 Hydraulic Cylinder 1
E
6V-4105 Bushing Driver 1
6V-4107 Bushing Adapter 1
1. Mark the track pin for removal. Position the track with this track pin between the front idler
and the sprocket.
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D8R Series II Track-Type Tractor 6YZ00001-UP (MACHINE) POWERED BY 3406...
2020/1/22
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Illustration 1 g00619723
2. Position blocks (3) under the front of the track.
3. Position blocks (2) under the track.
4. Release the pressure in the track adjuster. See the procedure in Disassembly and Assembly,
"Track - Separate" in this module.
5. Position tool (A) on the track. See Illustration 1. Use tool (A) to hold the track in position
when the track pins are removed.
6. Remove the bolts.
Note: The track shoe weighs 28 kg (62 lb).
7. Use two persons in order to remove four track shoes (1).
8. Attach a hoist to tool (B). Position tool (B) against the track pin.
9. Use tool (B) to push track pin out of the track.
10. Install tool (C) in order to hold the track together until the other track pin is removed.
11. Position tool (B) against track pin (4).
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12. Push track pin (4) out of the track and install tool (C).
13. Remove tool (B) from the track.
14. Position tool (D) between links (5) and (6).
15. Use tool (D) to force apart the links enough to move link (7) away from links (5) and (6).
16. Remove tool (C) from links (5), (6), and (7).
NOTICE
Do not damage the face of the seals when the track links are moved
apart.
17. Attach a hoist to link (7).
18. Move the link away from links (5) and (6).
19. Position a block under link (7) in order to hold link (7) away from links (5) and (6).
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20. Position tool (D) between links (8) and (9).
21. Use tool (D) to force apart the links enough to remove link assembly (10).
Note: The link assembly weighs 23 kg (51 lb).
22. Attach a hoist to link assembly (10).
23. Remove tool (C) from links (8) and (9) and link assembly (10).
24. Remove link assembly (10).
25. Remove seals (11) from links (5) and (6).
26. Position link assembly (6) in Tooling (E).
27. Use Tooling (E) to remove link (6) from the bushing.
28. Use Tooling (E) to remove the remaining link from the bushing.
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Wed Jan 22 15:36:07 UTC+0800 2020
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2020/1/22

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i02877157
Track - Assemble
SMCS - 4170-016
Assembly Procedure
Table 1
Required Tools
Tool Part Number Description Qty
A 8S-9906 Ratchet Puller 1
C 2S-8215 Guide Pin 2
D
6V-3170 Double Acting Cylinder 1
F 4C-8619 Seal Installer 1
G
6V-4108 Offset Adapter 1
H
8T-5133 Receiver 1
8T-7783 Cap 1
J 8T-3115 Track Lubricator 1
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K 5P-7419 Plug Installer 1
Note: Inspect all the components of the track for wear or damage. Replace the worn components
and the damaged components. The components must be clean and dry before assembly.
Note: Maintain some clearance between the link and tool (G) at location (Y) .
1. Apply SAE 90W gear oil to each end of bushing (12) for a minimum length of 6.5 mm (0.25
inch).
NOTICE
Use a maximum force of 660 kN (148500 lb) when the track is
assembled.
2. Use tool (G) to install bushing (12) in the link.
3. Install the bushing in the link until the bushing makes contact with the 6V-4108 Offset
Adapter in tool (G). The track bushing must extend 1.76 ± 0.13 mm (0.069 ± 0.005 inch)
above the surface of the link.
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4. Position link (5), bushing (12), and link (6) in tool (G) .
5. Install tool (C) in order to align links (6) and (5) .
6. Install bushing (12) in link (5) until the bushing makes contact with the 6V-4108 Offset
Adapter in tool (G). The track bushing must extend 1.76 ± 0.13 mm (0.069 ± 0.005 inch)
above the surface of the link.
NOTICE
The seal must be completely sealed in the link counterbore. The load
ring of the seal must make a minimum amount of contact with oil. Oil
expands the load ring. This expansion is not desired until after
assembly.
7. Use tool (F) to install seals in links (6) and (5) .
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(L) Track link
(M) Load ring
(N) Track link
(P) Track bushing
(R) Seal
(S) Thrust ring
(T) Track pin
(X) Contacting surface
NOTICE
Make sure there is contact at area (X) between the seal and load ring.
8. Install the thrust ring in the links.
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9. Apply clean oil to stoppers (13) and install the stoppers in the track pins. The stopper must
be installed to a depth of 8 ± 4 mm (0.32 ± 0.16 inch) below the surface of the track pin.
10. Position tool (D) between the track links. Use tool (D) to force apart the links enough to
install link assembly (10) .
11. Attach a hoist to link assembly (10). Position the link assembly and install tool (C) in order
to hold the link assembly in place.
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12. Position tool (D) between links (5) and (6). Use tool (D) to force apart the links enough to
install link assembly (7) .
13. Attach a hoist to the link assembly. Position the link assembly on link assembly (7) .
Note: If necessary, use tool (A) to pull the track links together until tool (C) can be
installed.
14. Install tool (C) in order to hold the link assemblies together.
15. Attach a hoist to tool (H). Position tool (H) and track pin (4) on the track links.
Note: The hole end of the pin must be installed on the same side of the track for the entire
length of the track. The oil cross hole in the pin must be within 20 degrees of the vertical
centerline of the pin bore. The oil cross hole in the pin must be closest to the rail of the link.
The track pins are marked on the end for the location of the oil cross hole. The pin must be
installed with a minimum amount of force in order to obtain a maximum of 0.20 mm (0.008
inch) of end play between the bushing and the thrust ring.
16. Use tool (H) to install track pin (4). Install track pin (4) until the track pin extends 2.9 ± 0.8
mm (0.11 ± 0.03 inch) beyond the link assembly.
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17. Repeat Steps 15 and 16 in order to install the remaining track pin.
Note: If the joint fails the vacuum test or the pressure test, the joint must be disassembled
and repaired.
18. Use tool (J) to evacuate the joint. Release the button that controls the evacuation of the joint
when the maximum vacuum is reached. Observe the gauge reading for ten to fifteen
seconds. No reduction in vacuum should be observed.
19. Press the button that controls the oil in order to fill the joint with SAE 90W gear oil. Fill the
joint until the needle on the gauge stabilizes. Release the button that controls the oil and
observe the gauge reading. No pressure drop should be observed. If a pressure drop occurs,
press the button that controls the oil for ten to fifteen seconds. Fill times will vary for seal
cavities. Oil must seep by the small grooves in the thrust rings. Repeat the procedure in
order to fill the joint with oil until no pressure drop is observed.
20. Press the button that controls the evacuation of the joint and hold the button for five seconds
before removing tool (J) .
21. Apply clean oil to the plug.
22. Use tool (K) to install the plug in the stopper in the end of the track pin. Install the plug in
the stopper until the plug is flush with the end of the stopper.
Note: The track shoe weighs 28 kg (62 lb).
23. Use two persons to position the four track shoes on the track.
24. Apply clean SAE 30W oil to the washer face and the threads of the track shoe bolts.
25. Install the track shoe bolts.
26. Tighten the track shoe bolts to a torque of 650 ± 70 N·m (480 ± 50 lb ft). Tighten the bolts
by another 1/3 turn.
End By: Adjust the track. Refer to Disassembly and Assembly, "Track - Connect" in this module.
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i01465379
Track - Connect
SMCS - 4170-077
Connection Procedure
Table 1
Required Tools
A
FT-2213 Strap (Group) 1
8S-4755 Bolt (1 inch by 14 by 1 1/2 inch) 4
6B-9194 Bolt (1 inch by 14 by 3 inch) 2
3K-5234 Hard Washer (6 mm by 49 mm) 18
1. Position the track under the machine.
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2. Lower the machine on the track.
3. Remove Tooling (A).
4. Attach a chain to a wheel loader or a similar machine and to the end of track (8). Pull track
(8) over the front idler.
5. Lift the end of the track in order to position the wood blocks under the grouser.
6. Pull the track until the bushings engage the sprocket segments on the final drive.
7. Start the machine and rotate the final drive backward in order to pull the track together.
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8. Align the lower end of master link (7) with the upper end of the master link.
9. Position master shoe (6) on the master link and rear idler (4).
10. Apply 4C-5593 Anti-Seize Compound to bolts (5).
11. Install bolts (5).
12. Tighten bolts (5) to a torque of 650 ± 70 N·m (480 ± 50 lb ft). Tighten the bolts by 1/3 turn
more.
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13. Tighten relief valve (2). Fill valve (3) with MPGM grease. Refer to Operation and
Maintenance Manual, SEBU7247, "Track - Check/Adjust" for the correct Tight Track
Adjustment procedure.
14. Adjust the track. Refer to Operation and Maintenance Manual, SEBU7247, "Track -
Check/Adjust" for the correct track adjustment procedure.
15. Install track adjuster cover (1) and a new O-ring seal on the track roller frame.
16. Install the four bolts and the four washers in order to fasten the track adjuster cover.
Wed Jan 22 15:38:05 UTC+0800 2020
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i01431446
Sprocket Segment - Remove and Install
SMCS - 4164-010
Removal Procedure
1. Move the machine forward or backward in order to position sprocket segment (2). See
Illustration 2.
2. Remove the five bolts, the washers, and five nuts (1).
3. Remove sprocket segment (2).
Installation Procedure
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1. Apply SAE 30W oil on the 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). Tighten nuts (1) by another
1/3 turn. The final torque must be a minimum of 570 N·m (420 lb ft).
Wed Jan 22 15:39:04 UTC+0800 2020
2/2
2020/1/22

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i02873698
Track Roller - Remove
SMCS - 4180-011
Removal Procedure
Table 1
Required Tools
A FT-2213 Strap Group 1
B 183-4799 Track Roller Lifting Fork 1
Start By:
A. Loosen the track. Refer to Disassembly and Assembly, "Track - Separate" in this module.
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1. Install tool (A). See Illustration 1.
2. Raise the side of the machine.
3. Remove track guide (1) from the outside of the major bogie.
Note: The track roller weighs 95 kg (209 lb).
4. Install tool (B) and a hoist on the track roller. See Illustration 3.
5. Remove four bolts (3) and two caps (2) .
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