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.

Transfer Drive

Check Oil Level

1. Park the machine on level ground.

2. Clean the area around the filler plug (1) and remove the plug.

3. If necessary, add oil to the level of the filler hole.

4. Clean and install the plug.

Fuel System

Change Secondary Filter, Clean Primary Filter and Strainer

1. Loosen the bolt (1) on top of the primary filter base and lower the housing (2).

2. Remove the filter element (3) and wash both the element and housing in clean, nonflammable solvent.

3. Dry the element using pressure air.

4. Install the filter element and housing using a new gasket (4) if necessary.

5. Use a strap wrench to remove the secondary filter (5). Discard the used filter.

6. Clean the filter housing base. Make sure that all of the old seal is cleaned off the base.

7. Lightly smear the seal of the new filter with clean fuel.

8. Install the new filter by hand. When the seal contacts the base, tighten the filter by 3/4 turn more.

There are rotation index marks 1/4 turn apart on the filter. Use them as a guide for proper tightening.

9. Prime the fuel system. See the topic "Priming the Fuel System".

10. Remove the fuel tank filler cap (6) and check the seal for damage. Install a new seal if necessary.

11. Remove the retainer clip (7) and pull out the strainer (8).

12. Wash the strainer in clean nonflammable solvent and inspect for damage. Install a new part if necessary.

Priming the Fuel System

The fuel lines must be primed if the engine will not start, or runs rough, after priming the filters and pump housing.

Priming the Filters and Pump Housing

1. Unlock the priming pump plunger (1) and operate the pump until strong resistance is felt.

2. Lock the pump plunger.

3. Start the engine and check for leaks.

4. If the engine will not start, or runs rough, prime the fuel lines.

Priming the Fuel Lines

1. Wrap a dry cloth around one of the fuel line nuts (2) to soak up fuel.

2. Loosen the fuel line nut (2).

3. If the engine will not start, crank the engine until fuel flows free of air bubbles from the fuel line nut.

4. Tighten the fuel line nut to a torque of 41 +/- 7 Nm (30 +/- 5 lb.ft.)

5. Repeat steps 1 to 4 for each fuel line nut.

6. If the engine runs rough, run the engine at low idle and loosen each fuel line nut in turn until fuel flows free of air bubbles. Avoid bleeding excessive amounts of fuel.

7. Remove cloths and wipe away any other spillage. Dispose of fual soaked materials safely.

Transmission Filter

Change

1. Remove the filter housing drain plug (1) and allow oil to drain into a suitable container.

2. Unscrew the housing (2).

3. Remove and discard the old filter element (3).

4. Wash the housing in clean, nonflammable solvent and wipe dry.

5. Install the drain plug (1) and a new filter element.

6. Inspect the seal in the filter base. If it is damaged, install a new one.

7. Install the filter housing complete with element. Hand tighten the housing.

8. Start the engine and check for leaks from the filter housing. Tighten the housing a little more if necessary.

9. Check the transmission oil level and add oil if necessary.

10. Clean up any oil spills.

Hydraulic Tank

Change Filters, Clean Strainer and Breather

1. Slowly loosen and remove the hydraulic tank filler cap (1).

2. Inpect the filler cap seal (2). If damaged install a new one.

3. Remove the retainer clip (3) and pull out the strainer (4).

4. Wash the strainer in clean nonflammable solvent and check for damage. If necessary install a new one.

5. Unscrew the center retaining bolt (5) and withdraw the filter assembly (6).

6. Remove the cotter pin (7), washer (8) and discard the old filter elements.

7. Install three new filter elements.

8. Install the filter assembly using a new cover seal (9) if necessary.

9. Unscrew the hydraulic tank breather (10) and wash in clean nonflammable solvent.

10. Install the clean breather (or a new one if necessary).

11. Install the filler cap (1).

12. Clean up any oil spills.

Brake Oil Tank (D40D only)

Change Filters, Clean Strainer and Breather

1. Slowly loosen and remove the brake oil tank filler cap (1).

2. Inspect the filler cap seal (2). If damaged install a new one.

3. Remove the retainer clip (3) and pull out the strainer (4).

4. Wash the strainer in clean nonflammable solvent and check for damage. If necessary install a new one.

5. Raise the hood and remove cover plate (5).

6. Unscrew the center retaining bolt (6) and withdraw the filter assembly (7).

7. Remove the cotter pin (8), washer (9) and discard the old filter elements.

8. Install two new filter elements.

9. Install the filter assembly using a new cover seal (10) if necessary.

10. Unscrew the brake oil tank breather (11) and wash in clean nonflammable solvent.

11. Install the clean breather (or a new one if necessary).

12. Install the filler cap (1).

13. Clean up any oil spills.

Axles

Check Oil Levels

1. Position the machine on level ground with the level plug (1) on either of the front final drives on the horizontal center line.

2. Clean the surrounding area and remove the level plug (1).

3. If necessary, add oil to the level of the plug hole. Allow time for the oil to flow along the axle housing and settle at a common level.

4. Clean and install the plug.

5. Repeat steps 1 to 4 for the center axle (D400D) or rear axle (D40D).

6. Repeat steps 2 to 4 for the D400D rear axle. Note that the level plug is higher on the D400D rear axle.