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.

Drive Shafts

Lubricate Splines and Bearings.

Wipe fittings clean before lubricating.

1. Lower the front suspension to the service position. See the topic "Suspension Lowering".

2. Lubricate the transmission drive shaft spider bearings through two fittings (1).

3. Lubricate the front drive shaft spider bearings through two fittings (2).

4. Lubricate the center drive shaft splines and spider bearings through three fittings (3).

NOTE: The drive shaft splines on later machines do not have grease fittings as they require no maintenance.

5. Lubricate D400D trailer drive shaft splines and spider bearings through eight fittings.

NOTE: Some of the drive shaft splines on later machines do not have grease fittings as they require no maintenance.

6. Lubricate D40D trailer drive shaft splines and spider bearings through three fittings.

NOTE: The drive shaft splines on later machines do not have grease fittings as they require no maintenance.

Fan Pulley

Lubricate Bearings

1. Lift the hood.

2. Lubricate the fan pulley through two fittings.

3. Close the hood.

If regular lubrication is carried out at the recommended interval, only two or three shots will be required.

Cooling System

Change Conditioner Element

1. Close the inlet valve (1) and outlet valve (2) by turning them clockwise.

2. Use a strap wrench to remove the old conditioner element (3). Discard the old element.

3. Clean the base (4).

4. Lightly smear the seal of a new MAINTENANCE element with clean engine oil or antifreeze then install the new element. Tighten the element by 3/4 of a turn after it contacts the base.

5. Open the inlet valve (1) and outlet valve (2).

6. Start the engine and check for leaks.

Engine

Change Oil and Filter

On new or reconditioned engines, check and adjust valve lash at first oil change.

Refer to 'Every 2000 hour or yearly service'

After the first oil change, revert to the normal 2000 hour or yearly service interval for this item.

The machine must be level and the engine oil warm.

1. Lower the front suspension to the service position. See the topic "Suspension Lowering"

2. Remove the crankcase drain plug and allow the oil to drain into a suitable container.

3. Wipe the plug clean and install.

4. Remove and discard the old oil filter.

NOTE: The filter will contain oil.

5. Clean the filter housing base. Make sure all of the old seal is removed.

6. Apply a thin film of clean engine oil to the new filter seal.

7. Install the new filter and hand tighten by 3/4 turn after it contacts the base.

8. Release the hose clamp (1) and disconnect the fumes disposal tube (2).

9. Release the clamp (3) and remove the breather (4).

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

11. Inspect the breather seal (5) and install a new one if necessary.

12. Install the breather and re-connect the fumes disposal tube.

13. Remove the filler cap (6) and fill the crankcase with new oil. Add oil to the "F" (full) mark on the dipstick (7).

See the sections "Lubricant Specifications", Recommended Lubricant Viscosities" and "Refill Capacities".

14. Start the engine and allow the suspension to self level.

15. Check for leaks while the engine is running at low idle for two minutes.

16. Stop the engine, wait ten minutes for the oil to drain back to the crankcase and check the level. Add oil if necessary.

Air Dryer

Check Operation

1. Open the air reservoir drain tap (1) and allow air to exhaust for a short time. The reservoir pressure must fall to 600 kPa (90 psi) or less.

2. Close the drain tap.

3. Check that the parking brake is engaged and the direction selector is in neutal, then start the engine. Allow the engine to run at low idle.

4. Observe the air dryer discharge tube (2) from a distance. Do not get too close. When the reservoir pressure reaches compressor cut out value, the purge valve should open and expel air under pressure through the tube. This purge operation should only last for a short time and regenerates the air dryer dessicant cartridge.

5. Stop the engine when the air system is fully charged.

If the purge operation does not occur, the air dryer needs service.

A small amount of water discharge is normal when the drain tap (1) is opened due to condensation within the tank, particularly in areas where there is a large variation in ambient temperature. Excessive water discharge indicates that the air dryer dessicant cartridge needs changing.

Consult the Service Manual or your Caterpillar dealer for instructions on changing the dessicant cartridge.

Alternator and Fan Belts

Inspect - Replace and/or Adjust

1. Inspect the fan belts for wear, fraying or cracking. If the belts are damaged, replace them.

2. Apply a 110N (25 lb) load perpendicular to the belt midway between the drive and driven pulleys. A correctly adjusted belt set will deflect 15 - 20mm (0.6 - 0.8 in). Adjust belt tension if required.

Alternator Belt Adjustment:

Early Machines

Later Machines

3. Loosen the jam nut (1) on the belt tensioner rod and turn the adjusting nut (2) until the correct belt tension is obtained.

4. Tighten the jam nut (1).

Fan Belt Adjustment:

5. Loosen the bolts (3) and (4) holding the tensioner bracket.

6. Adjust the position of the tensioner bracket (5) until the correct belt tension is obtained.

7. Tighten bolts (3) and (4) and check the belt tension.

Transmission, Transfer Gearbox and Axle Breathers

Clean or Replace if Damaged

1. Remove the transmission breather and wash in clean, nonflammable solvent. Wipe dry and install. Install a new part if the breather is damaged.

2. Remove the front axle breather and wash in clean, nonflammable solvent. Wipe dry and install. Install a new part if the breather is damaged.

3. Remove the D400D transfer gearbox breather and wash in clean, nonflammable solvent. Wipe dry and install. Install a new part if the breather is damaged.

4. Remove the two D400D trailer axle breathers and wash in clean, nonflammable solvent. Wipe dry and install. Install a new part if a breather is damaged.

5. Remove the D40D transfer gearbox breather and wash in clean, nonflammable solvent. Wipe dry and install. Install a new part if the breather is damaged.

6. Remove the D40D rear axle breather and wash in clean, nonflammable solvent. Wipe dry and install. Install a new part if the breather is damaged.

Brakes

Test Holding Ability, Check Linings

Be sure the area around the machine is clear of personnel and obstructions.

Test the brakes on a dry level surface.

Fasten the seat belt before testing the brakes.

The following brake holding ability tests are to determine if the brakes are functional. These tests are not intended to measure maximum brake holding effect. Brake holding effort required to hold a machine at a specific engine rpm will vary from machine to machine due to differences in engine setting, power train efficiency, etc., as well as differences in brake holding ability.

Engine rpm at the beginning of machine movement should be compared to engine rpm your specific machine was able to hold during a previous test. This gives an indication of system deterioration.

Brake Holding Ability Test

1. Check that the parking brake is engaged and that the transmission is in neutral then start the engine.

2. Select first speed forward.

3. Gradually increase the engine speed to 1000 rpm. The machine should not move. If the machine starts to move reduce engine rpm immediately. Machine movement indicates the parking brake needs service.

4. Reduce the engine speed to low idle and apply the service brakes. Release the parking brake.

5. Select first speed forward.

6. Gradually increase the engine speed to 1300 rpm. The machine should not move. If the machine starts to move reduce engine rpm immediately. Machine movement indicates the service brakes need service.

Brake Lining Check

The D40D rear axle has oil immersed disc brakes. These brakes are self adjusting and require no attention.

The D40D front axle brakes and all brakes on the D400D are also self adjusting. These brakes require no attention other than a periodic check to ensure that the linings are not excessively worn.

Have new brake linings installed unless you are sure there is enough friction material left to last through the next 250 service hour interval.

If the brakes appear sluggish in operation, the cause must be investigated and repairs carried out.

1. Park the machine on hard level ground.

2. Lower the suspension to the service position. See the topic "Suspension Lowering".

3. On D400D models only, block the wheels and disengage the parking brake. The parking brake must be disengaged on D400D models because the center and rear axle wheel brakes are applied when the parking brake is engaged.

4. Remove the brake dust covers (1) - 6 bolts.

5. Inspect the brake linings (2) and measure the thickness of the friction material - dimension A. The minimum allowable thickness of the brake lining friction material is 8mm (5/16 in).

6. Measure the clearance between the brake linings (2) and the brake drum (3) - dimension B. The clearance should not exceed 1mm [0.040in). If the clearance is more than 1mm (0.040 in), the automatic adjusters may not be working correctly. Have the brake serviced by your Caterpillar dealer.

7. Have an assistant press down on the brake pedal and observe that the brake shoes move freely into contact with the brake drum.

8. Release the brake pedal and observe that the brake shoes move freely away from the brake drum.

9. Replace the dust covers.

10. Repeat the procedure for each wheel brake in turn.

11. Engage the parking brake and remove the wheel blocks (D400D only).

Suspension

Check/Adjust Ride Height, Purge D400D Rear Suspension

Check the suspension ride height with the machine parked on level ground.

Front Suspension - All Models

1. Lower the front suspension to the service position. See the topic "Suspension Lowering".

2. Measure the distance between the wheel arch and wheel rim - dimension A.

3. Block the trailer wheels.

4. Start the engine.

5. Check that differential lock is disengaged, release the parking brake and allow the suspension to self level.

6. When the suspension has self leveled, engage the parking brake and stop the engine.

7. Measure the distance between the wheel arch and the wheel rim - dimension B.

8. Subtract dimension A from dimension B. The difference should be 97 - 112 mm (3.8 - 4.4 in).

If the ride height is not within specification, adjustment will be necessary. Refer to the Service Manual or your Caterpillar dealer for correct adjustment procedures.

Rear Suspension - D40D

1. With the machine parked on level ground, start the engine and run at low idle.

2. Disengage the park brake and differential lock and allow both front and rear suspension to self level.

3. Engage the park brake.

4. Stop the engine.

5. Measure the amount of chromed rod visible from one of the rear suspension cylinders - dimension C. Dimension C should be 90 - 100 mm (3.5 - 3.9 in).

If the ride height is not within specification, adjustment will be necessary. Refer to the Service Manual or your Caterpillar dealer for correct adjustment procedures.

Rear Suspension - D400D

Purge the rear suspension immediately after the machine has been stopped to ensure the oil in the system is well mixed.

1. Park the machine on hard level ground.

2. Open the two bleed valves (1) - one each side - and allow the rear suspension to fully lower. Catch as much split oil as possible in a suitable container and wipe up the rest. Wipe oil spills off the machine.

3. Close the bleed valves (1).

4. Start the engine and operate at low idle.

5. Open the flow control valve (2) on one side of the machine and allow the suspension to rise until...

...the total amount of chromed rod visible from the pair of cylinders (dimension d plus dimension E) is 175 - 190 mm (7 - 7.5 in).

6. Close the flow control valve.

7. Repeat steps 5 and 6 for the other side of the machine.

Oscillating Hitch

Adjust Pin Clearance and End Float

Adjust the oscillating hitch pin clearance and end float with the machine parked on level ground. - Inset shows pin adjustment on later machines.

1. Loosen the jam nuts (1).

2. Turn the adjusting screws (2) slowly and evenly to take up excessive clearance. DO NOT OVERTIGHTEN.

3. Tighten the jam nuts (1).

FIRST TYPE

4. Remove the locking lug (3).

5. Tighten the thrust flange (4).

6. Back off the thrust flange until the locking lug locates in the next hole.

7. Install the locking lug.

SECOND TYPE

1. Remove three nuts and washers (1) securing the locking lug (2).

2. Remove and reposition the locking lug on one of the holes in the hitch thrust flange (3) using the dowel (4).

3. Insert a 3/4" square drive (5) through the hole (6) in the locking lug.

4. Engage the the outer rim of the thrust flange with the drive (See inset).

5. Using a suitable wrench tighten the thrust flange.

6. Back off the thrust flange until the locking lug locates in the next hole.

7. Reposition and install the locking lug using the existing hardware.

Batteries

Check Electrolyte Level/Clean Terminals

The machine is normally factory equipped with low maintenance, high output batteries. Check the electrolyte level in the batteries according to the chart below.

Tighten the battery retainers every 1000 hours on all batteries.

Check the following at least every 1000 hours, and more often as conditions require:

* Clean the top of the batteries with a clean cloth.

* Keep the terminals clean and coated with petroleum jelly.

At the proper charging rate, in a moderate climate, a battery should not require more than 30cc (1 ounce) of water per cell per week.

Check the cells weekly in extreme temperatures, cell water usage could be higher.

When the batteries are inspected, also inspect the battery cables. Look for cuts or damaged insulation. Replace damaged cables.

The batteries are located under the cab in a sliding battery carrier.

1. Release the battery carrier catches (1).

2. Pull the battery carrier out and lock in position with the bolt (2).

3. Remove the battery cover, clean the top of the batteries, remove the vent caps and add distilled water as necessary to bring the level to the bottom of each vent well. If distilled water is not available, use clean drinking water.

4. Release the bolt (2), slide the battery carrier fully in and lock in place with the catches (1).