Caterpillar cat d400 e articulated truck (prefix 2yr) service repair manual (2yr00001 and up)

Service Repair Manual
Models
D400E Articulated Truck

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Product: ARTICULATED TRUCK
Model: D400E ARTICULATED TRUCK 2YR
Configuration: D400E Articulated Truck 2YR00001-UP (MACHINE) POWERED BY 3406 Engine
Disassembly and Assembly
D350E & D400E ARTICULATED TRUCKS POWER TRAIN
Media Number -SENR8692-02 Publication Date -01/03/2004 Date Updated -15/12/2010
SENR86920019
Transmission Planetary
SMCS - 3150-015; 3150-016
Disassemble Transmission
Start By:
a. remove transfer gears (input and output)
b. remove transmission control valve
1/45D400E Articulated Truck 2YR00001-UP (MACHINE) POWERED BY 3406 Engine(...
2020/2/8https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw...

NOTICE
When the transmission is disassembled, keep the plates and disc
assemblies in the original sequence in which they are removed. This is
important because some clutch plates or disc assemblies can be used
again only in their original position. The failure to follow this caution
will cause too much wear in the transmission and cause a possible
failure of the transmission. A 2P5501 Transmission Internal Parts
Rack is used to keep the plates and disc assemblies in correct order.
1. Remove O-ring seal (1).
3. Install Tool (A) on the input shaft. Use bolt (3) and washer that were removed at time of input
transfer gear removal. Tool (A) will hold the parts on the shaft assembly when it is removed.

4. Put transmission in position on blocks with the output shaft up and remove two bolts (4).
5. Fasten Tooling (B) and a hoist to the transmission planetary group. The weight of the planetary
group is 545 kg (1200 lb).
6. Use bolts (4) installed in the transmission case (6) to move planetary group (5) out of the
transmission case (6).
7. Remove planetary group (5) from transmission case (6) and put on blocks.
8. Put a cover over transmission case (6) to keep it clean. If it is necessary to move transmission
case (6), fasten Tooling (B) and a hoist to the case. The weight of the case is 104.5 kg (230 lb).
NOTICE
Make a mark across all the clutch housings for correct assembly.
9. Remove twenty bolts (7).

10. Use Tooling (C) to hold the piston in No. 6 clutch housing (8).
11. Fasten Tooling (B) and a hoist No. 6 clutch housing and remove it. The weight of the No. 6
clutch housing is 29.5 kg (65 lb).
12. Remove piston (9) from clutch housing (8).
13. Remove two seals (10) from piston (9).
14. Remove twelve springs (11), six dowels (12), three disc assemblies (13) and two plates (14).

15. Remove gear (15).
16. Remove snap ring (16) with Tool (D). Remove spacer (17).
17. Fasten Tooling (E) and a hoist to carrier assembly (18). Remove the carrier assembly.
18. Remove slinger (19) and gasket.

19. Drive pin (21) through carrier (18) in shaft (20).
20. Remove shaft (20), discs (22) and (24) and gear (23).
21. Remove the other three planet gears.
22. Remove bearing (25) from planet gear (23).
23. Remove retaining ring (26) and sun gear (27).
24. Fasten Tooling (B) to manifold (28). The weight of the manifold is 73 kg (160 lb).
25. Remove two bolts (29) in the holes in manifold (28).
26. Remove manifold (28).

27. Use Tool (F) to remove lockring (30). Remove bearing (31) from manifold (28).
29. Turn manifold (28) over. Remove O-ring seals (33) and (34).
30. Remove two bolts (35) that hold the No. 4 clutch housing (36).
31. Use Tooling (C) to hold the clutch piston in the No. 4 clutch housing.
32. Fasten Tooling (B) and a hoist to the No. 4 clutch housing. The weight of the No. 4 clutch
housing (36) is 27 kg (60 lb).

35. Remove twelve springs (39), six dowels (40), two disc assemblies (41) and one plate (42).
36. Remove retaining ring (43) from the shaft assembly.
37. Remove twenty bolts that hold housing assembly (44).

38. Fasten Tooling (E) and a hoist to housing assembly (44). Remove housing assembly (44).
39. Put housing (44) in an arbor press as shown. Put force on plate (46) until ring (45) can be
removed. Release the tension and remove the plate and three springs (47) from the housing.
40. Remove dowel (48) from the carrier.
41. Install two 3/8 in - 16 NC bolts three inches long in the rear of the housing assembly as
shown. Turn the bolts evenly to remove carrier (49). Remove two rings (50) from the carrier.

42. Remove piston (51) from the housing.
43. Remove two seals (52) from the piston.
44. Fasten Tooling (E) and a hoist to housing assembly (53). Use the bolts that hold housing
assembly (44) to fasten Tooling (E) so ring gear (55) will be removed with housing assembly (53).
45. Remove housing assembly (53) and ring gear (55). The weight is 27 kg (60 lb).
46. Remove five disc assemblies (54) and four plates (56) from housing assembly (53).
47. Remove housing assembly (53) from ring gear (55).
48. Use Tooling (C) to hold the piston in No. 3 clutch housing (57).
10/45D400E Articulated Truck 2YR00001-UP (MACHINE) POWERED BY 3406 Engin...

49. Fasten Tooling (B) and a hoist to clutch housing (57). The weight of No. 3 clutch housing is
41 kg (90 lb).
50. Remove piston (58) from No. 3 clutch housing (57).
52. Remove twelve springs (60), three disc assemblies (61), two plates (62) for No. 3 clutch.
53. Use Tool (D) to remove ring (63).

54. Fasten Tooling (E) and a hoist to carrier (64). The weight of carrier (64) and ring gear is 29.5
kg (65 lb). Remove carrier (64) and ring gear.
55. Use three screwdrivers put between ring gear (65) and carrier (64) to move the snap ring in
carrier (64) so ring gear (65) can be removed.
56. Use Tooling (D) to remove retaining ring (66).
57. Remove hub assembly (67) from carrier.
58. Use Tool (F) to remove ring (68).
59. Remove bearing (69) from carrier.

61. Remove shaft (70), washers (72) and (74) and gear (73).
62. Remove bearing (75) from gear (73).
63. Remove gear (76).
64. Remove bolts (77) in the holes in the No. 2 clutch housing. The clutch release springs will
cause a separation of the No. 1 and No. 2 clutch housings as bolts (77) are removed.

65. Use Tooling (C) to hold the clutch piston in the No. 2 clutch housing.
66. Fasten Tooling (B) and a hoist to No. 2 clutch housing (78). The weight of clutchhousing (78)
is 36 kg (80 lb).
67. Remove clutch housing (78) and turn it over.
69. Remove seals (80) from piston (79).
70. Remove twelve springs (81), twelve rods (83), six dowels (85), five disc assemblies (82) and
four plates (84).

71. Remove clutch gear (86).
72. Remove plate assembly (87).
73. Remove five discs assemblies (88) and four plates (89).
74. Fasten Tool (G) and a hoist to shaft (90). The weight of shaft (90) and carrier assembly (91) is
73 kg (160 lb).

75. Remove Tool (A), spacer (92) and gear (93).
76. Fasten a nylon strap and hoist to shaft assembly (90). The weight of shaft assembly (90) is 73
kg (160 lb).
77. Remove shaft assembly (90) from carrier assembly (91).
78. Remove gear (94) from shaft assembly (90).
79. Remove ring (96). Remove input shaft (95) from shaft assembly (90).

80. Remove ring (99), spacer (98) and bearing (97) from input shaft.
81. Remove two seals (100) from the carrier on the output shaft.
82. Remove the carrier from the output shaft with Tooling (H) and an arbor press.
83. Use Tool (I) to remove bearing (101) from the end of the output shaft.

84. Use three screwdrivers put between ring gear (102) and carrier (91) to move the snap ring in
carrier (91) so ring gear (102) can be removed.
85. Remove seal (103) from carrier (91).
86. Remove spiral ring (104). Remove bearing (105).
87. Drive pin (107) through carrier (91) in pin (106).
88. As pin (106) is removed from carrier (91), remove gear (109) and washers (108) and (110) and
gear (112) and washers (111) and (113).
89. Drive pin (107) in shaft (106). Remove pin (107).

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91. Remove clutch gear (115).
92. Remove No. 1 clutch piston (116).
93. Remove seals (117) from clutch piston (116).

94. Turn housing (118) and carrier (91) over and put housing on blocks. The weight of the housing
and carrier is 63.5 kg (140 lb).
95. Use Tool (D) to remove snap ring (119).
96. Fasten Tooling (D) and a hoist to housing assembly (118). The weight of housing assembly
(118) is ( 41 kg (90 lb).
97. Remove housing assembly (118).
98. Use Tool (D) to remove snap ring (120). Remove bearing (121).
99. Remove seals (123) and (124) from carrier assembly (122).
100. Remove seal ring (125) from carrier (122).

102. Remove pin (126), gear (129) and washers (128) and (130) from carrier (122).
104. Inspect all parts and make replacements as necessary.

Caterpillar cat d400 e articulated truck (prefix 2yr) service repair manual (2yr00001 and up)

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Caterpillar cat d400 e articulated truck (prefix 2yr) service repair manual (2yr00001 and up)