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.

Cooling System

Change Coolant

Coolant should be drained and replaced every 2000 service hours or one year unless the conditioner maintenance element has been replaced every 250 service hours as recommended. If the element has been replaced every 250 hours the drain period can be extended to 4000 service hours or two years.

1. Remove the radiator cap slowly to relieve pressure.

2. Remove the access panel (1).

3. Open the radiator drain tap (2) and drain coolant into a suitable container.

4. Close the drain tap (2).

5. Fill the system with a solution made of 1 kg (2.2 lb) of sodium bisulfate to every 38 liters (10 gal) of water.

6. Start the engine and run for a 1/2 hour.

7. Stop the engine and drain the cleaning solution.

8. Flush the system with clean water until water runs out clean. Do not run the engine while flushing.

9. Fill the system with neutralizer. Use a commercially available neutralizer or use a solution made of 250g (0.5 lb) of sodium carbonate crystals to every 38 liters (10 gal) of water.

10. Run the engine for 10 minutes then stop the engine and drain the neutralizing solution.

11. Flush the system with clean water until the water runs out clean. Do not run the engine while flushing.

12. Replace the access panel (1).

13. Mix coolant solution to provide freeze protection to the lowest expected outside temperature.

14. Fill the system with the prepared coolant.

15. If Caterpillar antifreeze was used when mixing the coolant, do not install a new conditioner element. Leave the old element in place on initial fill and continue with the regular 250 service hour MAINTENANCE element replacement schedule. Caterpillar antifreeze already contains enough conditioner. See the topic "Cooling System - Change Conditioner Element" in the "Every 250 Service Hours or Monthly" section. If Caterpillar antifreeze was not used when mixing the coolant, install a conditioner PRECHARGE element.

16. Start the engine with the radiator cap off. Add coolant, if necessary, until the level stabilizes.

16. Install the filler cap.

Hydraulic Tank

Change Oil and Suction Strainer

1. Remove the hydraulic tank filler cap (1) slowly to relieve pressure.

2. Remove the drain plug (2) from the bottom of the tank and drain the oil into a suitable container.

3. Replace the drain plug.

4. Disconnect the suction and return pipes (4) and remove the cover assembly (5) - 18 bolts (6).

5. Cover the hole to prevent anything from falling into the tank while the cover is off.

6. Service the oil filters. See the subject "Hydraulic Tank - Change Filters, Clean Strainer and Breather" in the "Every 500 Service Hours or 3 Months" topic.

7. Flush out the filler tube (7).

8. Unscrew the suction strainer (8) and wash in clean nonflammable solvent.

9. Unscrew the supplemental steering strainer (9) and wash in clean nonflammable solvent.

10. Inspect both strainers for damage. Install cleaned or new parts as necessary.

11. Install the cover assembly (5) using a new gasket and connect the suction and return pipes (4).

12. Fill the tank with new oil.

13. Remove priming plug (10), fill the suction pipe with oil and install the plug.

14. Start the engine.

15. Check there is adequate overhead clearance then power the body up and down.

16. Check there is adequate sideways clearance then steer the machine from lock to lock.

17. Stop the engine and allow the machine to stand long enough for air bubbles to be released.

18. Check the oil level and add oil if necessary.

19. Clean up any oil spills.

Brake Oil Tank (D40D only)

Change Oil and Suction Strainer

1. Remove the brake oil tank filler cap (1) slowly to relieve pressure.

2. Remove the drain plug (2) from the bottom of the tank and drain the oil into a suitable container.

3. Clean and replace the drain plug.

4. Disconnect the suction and return pipes (3) and remove the cover assembly (4).

5. Cover the hole to prevent anything from falling into the tank while the cover is off.

6. Service the oil filters. See the subject "Brake Oil Tank - Change Filters, Clean Strainer and Breather" in the "Every 500 Service Hours or 3 Months" topic.

7. Flush out the filler tube (5).

8. Unscrew the suction strainer (6) and wash in clean nonflammable solvent.

9. Inspect the strainer for damage. Install a cleaned or new part as necessary.

10. Install the cover assembly (4) using a new gasket and connect the suction and return pipes (3).

11. Fill the tank with new oil.

12. Start the engine and check the oil level.

13. Clean up any oil spills.

Air Dryer

Change Dessicant

The air dryer dessicant cartridge needs replacing with a new or reconditioned unit whenever excessive water drains from the reservoir drain tap.

The cartridge should normally last for 2000 service hours or more.

Refer to your Caterpillar dealer for repair kits and instructions.

Wheel Bearings

Check, Adjust if necessary

Refer to the Service Manual or your Caterpillar dealer for the correct procedure for checking and adjusting the wheel bearings.

Engine Valve Lash

Adjust

Show/hide table

To prevent possible injury, do not use the starter motor to turn the engine flywheel. Hot engine components and hot oil can cause burns. Allow time for the engine to cool before measuring valve lash (clearance). When inspecting valve rotators, protective glasses (or face shield) and protective clothing must be worn, to prevent being burned by hot oil spray.

Exhaust valve lash must be 0.69 - 0.84 mm (0.027 - 0.033 in).

Intake valve lash must be 0.30 - 0.46 mm (0.012 - 0.018 in).

Refer to the Service Manual or your Caterpillar dealer for the correct procedure for checking and adjusting valve lash.

After checking the valve lash, start the engine and run at low idle.

Watch the top surface of each valve rotator. Each rotator should turn slightly when the valve closes. If a valve fails to rotate, contact your Caterpillar dealer.