D40D AND D400D ARTICULATED DUMP TRUCKS Caterpillar

When Required

Usage:

You must read and understand the warnings and instructions contained in the Safety section of this manual before performing any operation or maintenance procedures.

Engine Air Intake

Service Filters

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NOTICE

Never service air cleaners when the engine is running. Engine damage can result.

Service the filter elements when the window on the indicator shows red.

Primary Element

1. Loosen the cover retaining screws (1) and remove the cover and primary element (2).

2. Clean and inspect the element. See "Cleaning Air Cleaner Elements."

3. Loosen the clamp (3) and remove the precleaner screen (4).

4. Clean the screen and check that the gauze has not been punctured.

5. Loosen the clamp (5) and remove the body (6).

6. Thoroughly clean out the body.

7. Assemble the body and precleaner screen to the filter housing.

8. Mark the secondary element (7) to indicate the number of times the primary element has been cleaned or replaced.

9. Clean the inside of the filter housing and cover.

10. Install a clean element and replace the cover. Tighten the retaining screws finger tight. Do not use a tool.

If the indicator shows red after the installation of a clean primary element, or if the exhaust smoke is still black, change the secondary element.

The primary element should be discarded after it has been cleaned a maximum of six times. Replace the element once a year, even if it has not been cleaned six times.

Secondary Element

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NOTICE

Always replace the secondary element. Never attempt to re-use it by cleaning. Replace the secondary element when the primary element is serviced for the third time. The secondary filter element should also be replaced if the indicator shows red after installation of a clean primary element, or if the exhaust smoke is still black.

1. Remove the cover and primary element.

2. Unscrew eight bolts (8) and remove the secondary filter element (7). Leave the top and bottom bolt in place. Discard the element.

3. Cover the air inlet opening and clean the inside of the housing.

4. Uncover the air inlet opening and install a new secondary element. Tighten the bolts to a torque setting of 20-34 Nm (15-25 lb ft).

5. Install a clean primary element and replace the cover.

Cleaning Air Cleaner Elements

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NOTICE

Do not clean the elements by bumping or tapping them. Inspect the elements after cleaning. Do not use an element with damaged pleats, gaskets or seals. Elements can be cleaned with pressure air, pressure water, or detergent. When cleaning with pressure air, use 205kPa (30psi) maximum pressure to prevent element damage. When cleaning with pressure water, use 280kPa (40psi) maximum pressure to prevent element damage.

1. Direct the air or water inside the element along the length of the pleats.

2. Direct the air or water outside the element along the length of the pleats.

3. If the element has been washed in detergent, rinse with clean water.

4. If necessary, dry the element thoroughly.

5. Inspect the element after cleaning and drying. Do not use an element with damaged pleats, gaskets or seals.

6. Wrap and store all good elements in a clean, dry place.

Radiator

Clean

The radiator must be kept clean in order to maintain an adequate cooling air flow.

Remove all trash and debris from the grille and inspect the radiator fins. If necessary, remove the grille and wash down the fins with a low pressure water jet.

Differential Lock Cylinder

Clean or Replace Breather

The differential lock cylinder breather should be cleaned or replaced on a schedule established by service experience.

A blocked breather can interfere with the proper function of the inter-axle differential.

1. Install the steering frame lock links.

2. Unscrew the breather from the cylinder.

3. Wash the breather in clean, nonflammable solvent and wipe dry.

4. If undamaged, screw the breather back into the cylinder. If the breather is damaged, install a new one.

Windshield Wiper and Washer

Replace Wiper Blade and Fill Reservoir

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NOTICE

When operating in freezing temperatures, use Caterpillar nonfreezing window washer solvent. Any commercially available nonfreezing window washer solvent may also be used.

1. Inspect the windshield wiper blade. Replace if damaged, hardened or worn.

2. Inspect the rear wiper blade (if equipped). Replace if damaged, hardened or worn.

3. Fill the windshield washer reservoir.

Body and Frames

Inspect for Cracks or Damage and Repair

All earthmoving equipment is subjected to a high degree of wear and tear. This makes it necessary for them to be inspected periodically for structural damage and for correct operation of all systems.

These inspections are particularly important for off highway trucks, which can be subjected to very arduous work cycles.

It is important that regular inspections are carried out in order to minimize the risk of accidents and down time.

The interval between these inspections depends on factors like the age of the truck, the severity of the application, loading, haul road condition and the amount of routine servicing which has been carried out.

Older trucks or trucks in particularly severe applications will require more frequent inspections but, in general, it is recommended that these inspections should be carried out at intervals not exceeding 1000 service meter hours or six months.

If the truck has been involved in a collision or any kind of accident it must be taken out of service immediately and inspected thoroughly, regardless of when the last full inspection was made.

In order to carry out a proper inspection it is essential that the truck is thoroughly cleaned. It is impossible to inspect the truck properly if it is dirty.

Early detection and repair of faults will ensure continued operation of the truck and will improve availability while reducing the risk of accidents.

However, proper repair of frames and structures requires specific knowledge of materials used, frame member construction and manufacturers recommended repair techniques.

If the need arises to carry out repairs it is recommended that you contact your local Caterpillar dealer who is qualified to carry out repairs on your behalf.

Caterpillar do not advise that repairs are carried out by anyone other than a Caterpillar dealer but, if you decide to carry out your own repairs, contact your dealer for advice regarding recommended repair techniques.

The front and rear frames, oscillating hitch and dump body should be thoroughly inspected for cracks and defects, particularly in welded structures.

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NOTICE

The areas highlighted are of particular importance but other areas must not be neglected. The entire structure should be carefully examined.

Front Frame

Inspect the following areas:

* Front engine mounting (1)

* Two rear engine mountings (2)

* Steering cylinder lugs (3)

* Cab mounts (4).

* The suspension towers (5)

* Suspension frame mounting bosses (6)

* Rear sub-assembly and hitch lugs (7).

* The entire suspension frame (8).

Oscillating Hitch

The entire oscillating hitch should be thoroughly inspected. The upper and lower hitch pin lugs(1) and the steering cylinder lugs(2) are particularly important but all areas of the hitch should be checked.

Rear Frames

D400D

Inspect the following areas:

* Oscillating hitch tube (1)

* Front plate (2)

* Suspension cylinder upper mounting brackets (3)

* A-frame heads (4)

* Suspension cylinder lower mounting brackets(5).

* Dump body mounting brackets (6)

D40D

Inspect the following areas:

* Oscillating hitch tube (1)

* Front plate (2)

* Hoist cylinder mounting brackets (3)

* Body pivot assemblies(4).

* Suspension frame (5)

Dump Body

Inspect the following areas:

* Hoist cylinder mountings (1)

* Dump body mountings (2).

Ether Cylinder

Change Cylinder

1. Open the hood. The ether cylinder is mounted in the engine compartment.

2. Loosen the cylinder clamp (1).

3. Unscrew and remove the empty ether cylinder (2).

4. Remove the used gasket and install the new gasket provided with the new cylinder.

5. Install the new cylinder hand tight, tighten the clamp and close the hood.

Fuses and Circuit Breakers

Replace or Reset

The fuse and circuit breaker panel is located in the operator's compartment.

Fuses and circuit breakers protect the electrical system from damage caused by electrical overload.

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NOTICE

Replace fuses with the same type and size only. Otherwise, electrical damage can result. If it is necessary to replace fuses or re-set circuit breakers frequently, an electrical problem may exist. Have the circuit checked and repaired by your Caterpillar dealer.

Change a fuse if the element separates. If the element of a new fuse separates, have the circuit checked and repaired.

Re-set a circuit breaker if it trips. If a circuit breaker trips soon after being re-set, have the circuit checked and repaired.

Circuit Breakers