D40D AND D400D ARTICULATED DUMP TRUCKS Caterpillar

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

Walk Around Inspection

Inspect Machine

1. Inspect the lights for broken bulbs and lenses. Replace if broken.

2. Inspect the condition of all steps and hand holds. Repair any damaged steps and hand holds and ensure they are clean.

3. Inspect the operator's compartment for cleanliness, remove trash or debris. Check for broken gauges or indicator lights. Ensure that all windows, mirrors and light lenses are clean.

4. Inspect the cooling system for leaks and trash build up around the radiator and grille. Check the condition of radiator hoses and the fan belt.

5. Inspect the engine compartment for leaks and trash build up.

6. Inspect the cab for damage. If repair is necessary, consult your Caterpillar dealer.

7. Inspect the hydraulic system for leaks and damaged hoses or fittings.

8. Inspect the transmission, axles, transfer drive and/or oscillating hitch for leaks.

9. Inspect the tires for damage and ensure they are inflated to the correct pressure. Consult your tire supplier for correct inflation pressures for your particular application. Replace any missing valve caps. Have damaged tires inspected and repaired by your tire dealer.

10. Look around and under the machine for items such as loose or missing bolts, trash buildup etc.

Seat Belt

Inspect for Damage

Always check the condition of the seat belt and mounting hardware before operating the machine. Replace any damaged or worn parts.

Replace the seat belt after three years of use, regardless of appearance.

1. Check the belt webbing for wear or fraying. Replace if damaged.

2. Check the buckles for correct operation. The buckles should snap firmly shut and release promptly.

3. Check that the belt mountings and hardware are secure.

Cooling System

Check Coolant Level

1. Remove the radiator cap slowly to relieve pressure. Maintain the coolant level to within 12mm of the filler neck base.

2. Clean and inspect the filler cap. If the seal is damaged, install a new one.

If it is necessary to add make-up water daily, inspect for leaks.

Engine Oil

Measure Level

1. Open the hood.

2. Before starting the engine the oil level must be in the shaded area on the dipstick (1).

3. Remove the filler cap (2) and add oil if necessary.

4. Install the filler cap and close the hood.

Transmission Oil

Measure Level

Measure the transmission oil level with the machine level, the engine running at low idle and the oil at normal operating temperature.

1. Measure the oil level on the dipstick (1). The level must be between the LOW and FULL marks (the shaded area) on the dipstick.

2. Remove the filler cap (2) and add oil if necessary.

3. Replace the filler cap.

Hydraulic Oil

Check Level

The hydraulic oil level must be checked with the body fully lowered and the suspension at the normal ride height.

The hydraulic tank is located on the right side of the machine.

1. Allow the suspension to self level before stopping the engine.

2. Check the oil level on the sight glass (1). The level must be in the middle of the sight glass.

3. Remove the filler cap (2) slowly and add oil if necessary.

Brake Oil Tank (D40D only)

Check Level

The brake oil tank (1) is located on the right side of the machine.

1. Check the brake oil level on the sight glass (2). The level must be in the middle of the sight glass.

2. Remove the filler cap (3) slowly and add oil if necessary.

Headlights, Turn Signals, Horn, Back-up Alarm, Indicators and Gauges

Test for Proper Function

1. Start the engine and move the EMS test switch to the TEST position. All indicator lights should come on and the warning horn should sound.

2. Check all gauges and indicators are intact. Replace any which are broken or do not work.

3. Sound the horn to ensure it works.

4. Operate the turn signals, hazard light switch and machine lights to ensure they work.

5. Stop the engine but leave the start switch ON.

6. Shift the transmission to REVERSE and listen for the back-up alarm. Shift the transmission back to neutral.

7. Have any faulty item repaired or replaced.

Suspension, Oscillating Hitch and Tailgate

Lubricate Bearings and Pins

Wipe all fittings clean before lubricating.

1. Install the steering frame lock links and lubricate the front suspension cylinder pins and suspension frame pins through six remote mounted fittings (three on each side of the machine).

2. Lubricate D400D center axle suspension cylinder pins and A-frame pin through five remote mounted fittings.

3. Lubricate D400D rear axle suspension cylinder pins and A-frame pin through five remote mounted fittings.

4. Lubricate D40D rear suspension frame pins through two fittings (one on each side of the machine).

5. Lubricate D40D rear suspension cylinder pins through four fittings.

6. Start the engine and fully raise the dump body. This takes the load off the hitch bearings and allows the grease to penetrate better.

7. Install the steering frame lock links and lubricate the hitch pins through two fittings (1).

8. Lubricate the hitch bearings through two fittings (2). The middle fitting (3) is provided to initially fill the cavity between the two hitch bearings. This fitting does not require regular lubrication.

9. Lubricate D400D tailgate pins through four fittings.

If regular lubrication is carried out at the recommended interval the suspension pin, oscillating hitch pin and tailgate pin fittings should only take one or two shots. The oscillating hitch bearings will take up to twenty shots.

Fuel Tank

Drain Water and Sediment

Drain water and sediment from the fuel tank at the beginning of the shift or after the tank has been filled and allowed to stand for ten minutes.

The fuel tank is located on the right side of the machine.

1. Loosen the bleed screw and allow water and sediment to flow into a suitable container.

2. Close the bleed screw.

Wheel Nuts

Check Torque on New or Repaired Wheels

Check the wheel nut torque on new or repaired wheels until the correct torque is maintained.

The correct tightening torque is:-

D40D/D400D Front Wheels 415 N.m to 535 N.m (306 lb ft to 395 lb ft).

D400D Center/Rear Wheels 415 N.m to 535 N.m (306 lb ft to 395 lb ft).

D40D Rear Wheels 660 N.m to 840 N.m (486 lb ft to 619 lb ft)