Caterpillar cat d8 r track type tractor dozer bulldozer (prefix t5x) service repair manual (t5x00001 and up)

Service Repair Manual
Models
D8R TRACK-TYPE TRACTOR
Dozer Bulldozer

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Product: TRACK-TYPE TRACTOR
Model: D8R TRACK-TYPE TRACTOR T5X
Configuration: D8R TRACK-TYPE TRACTOR T5X00001-UP (MACHINE) POWERED BY 3406C Engine
Disassembly and Assembly
D8R Track-Type Tractor Power Train
Media Number -UENR1377-00 Publication Date -01/06/2013 Date Updated -27/06/2013
i01022178
Track Roller - Assemble
SMCS - 4180-016
Assembly Procedure
Table 1
Required Tools
Tool Part Number Description Qty
A
1U-8840 Seal Installer 1
8T-0534 Gauge 1
B FT-1028 Sleeve 1
C 5P-7419 Plug Installer 1
D FT-0575 Test Tool 1
E 8T-5096 Dial Indicator 1
Reference: See the procedure in Disassembly and Assembly, "Duo-Cone Conventional Seals -
Install" in this module before you assemble the track rollers.
Reference: Refer to Specifications, SENR8324, "Track Rollers" in the Service Manual for your
machine.
1. Clean the components. Inspect the components for wear and for damage. Replace any worn
components or any damaged components.
1/7D8R TRACK-TYPE TRACTOR T5X00001-UP (MACHINE) POWERED BY 3406C...
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Illustration 1 g00523386
NOTICE
Follow this step carefully to avoid damage to the components during
assembly.
Note: The shaft weighs 22 kg (49 lb).
2. Fasten a hoist to shaft (8). Carefully install the shaft in track roller (9).
Note: Early track rollers have no toric stabilizers (7).
3. Install toric stabilizers (7) on both ends of shaft (8).
Reference: See the procedure in Disassembly and Assembly, "Duo-Cone Conventional
Seals - Install" in this module.

4. Install toric ring (10) in seal ring (6). Make sure that the toric ring is straight in seal ring (6).
5. Use tool (A) to install the toric ring and seal ring (6) on shaft (8). Install the ring until tool
(A) makes contact with the end of the shaft.
6. Use a depth micrometer (11) to measure the distance between seal ring (6) and the shaft.
Measure the distance at four locations that are separated by 90 degrees. The difference in
these measurements must not be more than 0.8 mm (0.0315 inch).

7. If adjustments to seal ring (6) are necessary, use tool (A) to adjust the seal ring on the shaft.
8. Repeat Steps 5 through 7 for installation of the toric ring. Also, install the seal ring on the
other side of the track roller.
9. Install O-ring seal (12) on seal ring (4). Make sure that the O-ring seal is straight on the seal
ring.
10. Lubricate the O-ring seal on the seal ring with isopropyl alcohol.
11. Position the O-ring seal and seal ring (4) in retainer (1). Use tool (A) to install the seal ring
in the retainer. Install the O-ring seal and seal ring (4) until the O-ring seal makes contact
with the bottom of the retainer.
12. Use depth micrometer (11) to measure the distance from the surface of the retainer to the
surface of seal ring (4). Measure the distance at four locations that are separated by 90
degrees. The difference in these measurements must not be more than 0.08 mm
(0.0315 inch).
13. If adjustments to the seal ring are necessary, use tool (A) to adjust the seal ring in the
retainer.

14. Position O-ring seal (5) in the groove in retainer (1).
15. Apply petroleum jelly or grease to the O-ring seal. The petroleum jelly or grease will hold
the seal in place on the retainers.
16. Make sure that the faces of the seal rings are clean and free of any foreign material.
17. Apply clean oil to the contacting surfaces of the seal rings.
18. Position tool (B) in the bore of retainer (1) and of the seal ring. Use tool (B) to install the
retainer and the seal ring in the original positions on the track roller.

19. Use tool (B) to hold the seal ring and retainer (1) in the correct position, and install bolts (3).
Tighten the bolts evenly in order to keep the retainer in alignment with the track roller.
20. Tighten the 3/8 inch twelve point bolts to a torque of 55 ± 10 N·m (41 ± 7 lb ft). If
equipped, tighten the 1/2 inch bolts with hex heads to a torque of 135 ± 15 N·m
(100 ± 11 lb ft).
21. Repeat Steps 11 through 20 in order to install the retainer on the other side of the track
roller.
22. Apply clean oil to stopper (2). Install the stopper in one end of shaft (8). Install the stopper
7 ± 7 mm (0.275 ± 0.275 inch) below the surface of the end of the shaft.
23. Use tool (C) to install the plug in stopper (2). Install the plug even with the end of the
stopper.
24. Use tool (D) to pressure test the track roller by the following steps:
a. Use dry air to pressurize the track roller to 280 kPa (40 psi).
b. Observe the pressure reading of the track roller. The pressure should remain constant
for ten seconds. A reduction in pressure in ten seconds or less indicates a leak in the
track roller. If the reading indicates that a leak exists, disassemble the track roller.
Inspect the seals on the track roller.

25. Use tool (E) to check the end play of shaft (8). The end play must be 0.31 to 1.21 mm
(0.012 to 0.048 inch).
26. Fill track roller shaft (8) with 0.50 ± 0.015 L (17 ± 0.5 oz) of SAE 30 oil.
27. Apply clean oil to the stopper. Install the stopper in the end of shaft (8). Install the stopper
7 ± 7 mm (0.275 ± 0.275 inch) below the surface of the end of the shaft.
28. Use tool (C) to install the plug in the stopper. Install the plug even with the end of the
stopper.
End By:
a. Install the track roller. See the procedure in Disassembly and Assembly, "Track Roller -
Install" in this module.
Copyright 1993 - 2020 Caterpillar Inc.
All Rights Reserved.
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Wed Jan 22 23:42:04 UTC+0800 2020

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i05281516
Track Roller - Install
SMCS - 4180-012
Installation Procedure
Table 1
Required Tools
A FT-2213 Strap (Group) 1
B 183-4799 Track Roller Lifting Fork 1
ReferenceRefer to Specifications, SENR8324, "Track Rollers" in the Service Manual for your
machine.
Note: The track roller weighs approximately 95 kg (209 lb).

1. Use Tooling (B) and a hoist to position track roller (4) in the minor bogie.
2. Align the dowel in caps (2) with the holes in the track roller shaft.
3. Install caps (2) and bolts (3) .
4. Tighten bolts (3) to a torque of 750 ± 70 N·m (550 ± 50 lb ft).
5. Position track guide (1) on the major bogie.
6. Install the bolts in track guide (1) .
7. Tighten the bolts to a torque of 475 ± 50 N·m (350 ± 37 lb ft).
8. Lower the machine to the ground.

9. Remove Tooling (A) .
End By: Adjust the track. See the procedure in Disassembly and Assembly, "Track - Connect" in
this module.
Wed Jan 22 23:43:03 UTC+0800 2020

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i01294502
Track - Separate
SMCS - 4170-076
Separation 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 Washer (6 mm by 49 mm) 18
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.

The machine must be on a level, hard surface before a separation of the
track is made. Any time a separation of both tracks is made, the
machine must have blocks correctly positioned so the machine will not
move.
1. Remove track adjuster cover (1).
2. Remove the O-ring seal from track adjuster cover (1).
Grease is under high pressure.
Grease coming out of the relief valve under pressure can penetrate the
body causing injury or death.
Do not watch the relief valve to see if grease is escaping. Watch the track
or track adjustment cylinder to see if the track is being loosened.
Loosen the relief valve only one turn.
3. Use the following procedure to loosen the track:

a. Turn relief valve (2) counterclockwise by one turn in order to release the grease from
the track adjuster. If the track does not loosen, proceed to Step 3.b.
b. Rotate fill valve (3) counterclockwise by one turn in order to release the grease from
the track adjuster. If the track does not loosen, start the machine and move the
machine forward and backward. If the track does not loosen, proceed to Step 3.c.
c. Install a piece of round bar stock between the bushing and sprocket inside the track
links. Start the machine and move the machine backward in order to push the track
upward with the round bar stock. The track adjuster should move inward.
4. Move the track until the master link is just above the centerline of rear idler (4).
5. Position wood blocks under the grouser just below the master link.
6. Move the track backward until the grouser contacts the wood blocks solidly.
Note: The master track shoe weighs 28 kg (62 lb).
7. Remove four bolts (5) and master track shoe (6).

8. Separate master link (7).
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.
9. Attach a chain to the end of the track and to a wheel loader or to a similar machine. Rotate
the final drive forward and allow track (8) to fall forward as the wheel loader or the similar
machine is moved forward.

Note: Raising the machine releases the pressure from the bogie pads. Raise the machine
before installing tool (A).
10. Raise the side of the machine 25 mm (1 inch) in order to install tool (A).
11. Install tool (A).
Note: The track weighs 2600 kg (5730 lb).
12. Raise the side of the machine and remove the track.
Wed Jan 22 23:44:02 UTC+0800 2020

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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.

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).

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.
Wed Jan 22 23:45:02 UTC+0800 2020

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i01022202
Track - Assemble
SMCS - 4170-016
Assembly Procedure
Table 1
Required Tools
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

K 5P-7419 Plug Installer 1
Reference: Refer to Specifications, SENR8324, "Tracks" in the Service Manual for your machine.
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.

Caterpillar cat d8 r track type tractor dozer bulldozer (prefix t5x) service repair manual (t5x00001 and up)

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