Caterpillar cat d400 d articulated truck (prefix 8tf) service repair manual (8tf00001 and up)

Service Repair Manual
Models
D40D, D400D
ARTICULATED TRUCK

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Product: ARTICULATED TRUCK
Model: D400D ARTICULATED TRUCK 8TF
Configuration: D40D, D400D ARTICULATED TRUCK 8TF00001-UP (MACHINE) POWERED BY 3406 ENGINE
Disassembly and Assembly
D40D & D400D ARTICULATED DUMP TRUCKS POWER TRAIN
Media Number -SENR8202-01 Publication Date -01/06/2005 Date Updated -12/07/2005
SENR82020014
Transmission Hydraulic Control Valve
SMCS - 3152-011; 3152-012; 3152-015; 3152-016; 3159-016; 3159-015; 3409-015; 3409-016
Remove Selector & Pressure Control Valve
NOTICE
The steps to follow show selector and pressure control valve removal
with the transmission moved from the machine. This is for better photo
illustration. Removal of the control valve with the transmission in the
machine is the same after the components have been removed for
access to the top of the transmission.
1. Remove cover assembly (1) and gasket.
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2. Remove manifold (2).
3. Remove O-ring seals (3) from manifold.
4. Remove bolt and plate (4) and sleeves (5).
5. Remove O-ring seals (6) from sleeve (5).
6. Remove four 3/8"-16 NC bolts that hold the control valve to the transmission.

7. Remove two bolts (7) that hold the control valve together and install tool (A), a nylon strap and
hoist. The weight of the control valve is 41 kg (90 lb).
8. Remove control valve (8) from the transmission.
NOTICE
The junction of control valve (8) and the transmission is sealed by a
precision finished surface. Give protection to these surfaces after
control valve (8) is removed so that leakage will not occur.
Install Selector & Pressure Control Valve
1. Fasten tool (A), a nylon strap and hoist to control valve (1). The weight of the control valve is
41 kg (90 lb).
2. Remove the covers for protection and be sure the junction surfaces of control valve (1) and the
transmission are thoroughly clean.
3. Carefully put control valve (1) in position on the transmission and remove tool (A).
4. Install the four 3/8"-16 NC bolts that hold the control valve to the transmission. Tighten the
bolts to a torque of 48 ± 4 N·m (35 ± 3 lb ft).
5. Install two bolts that hold the control valve together that were used to hold tool (A).

6. Install new O-ring seals (3) on two sleeves (2). Put clean oil on O-ring seals (3).
7. Put sleeves (2) in position in the control valve and transmission case and install washers (4) and
bolt.
8. Put new O-ring seals (6) on manifold (5).
9. Install manifold (5) on the transmission case.

10. Install cover assembly (7) and gasket.
Disassemble Transmission Hydraulic Control Valve
Start By:
a. remove transmission hydraulic control valve from transmission
1. Remove twenty-six bolts (1) and washers.
2. Remove manifold (2) from the valve group.
3. Remove valve group (3) from the plate.
4. Remove two detent assemblies (4) from each side of the valve group.
5. Remove two pins (5) and stops (6) from the valve body.

6. Remove direction control valve spool (7) from the valve body.
7. Remove speed control valve spool (8).
8. Remove cover (9) from the valve body.
9. Remove spring (10) and valve spool.
Retainer ring is under spring pressure. Remove slowly to prevent
personal injury.

10. Remove spring from the retainer. Remove retainer ring from valve spool (11). Remove
retainer (12) and two springs from the valve spool.
11. Remove piston (13) and two springs from the valve body.
12. Remove springs (14) and shims from piston.
13. Remove valve spool assembly (15) from the valve body. If necessary, remove dowel and stop
from the valve body.
Retainer ring is under spring pressure. Remove slowly to prevent
personal injury.

14. Remove slug (16), retainer ring, retainer, spring and ball from the valve spool.
15. Remove dowel (17) and remove stop from valve.
16. Remove valve spool (21), slug (20) and spring (19). If necessary, remove the dowel (18) and
stop from behind the spool.
17. Remove plate (22) from behind the manifold group.
Assemble Transmission Hydraulic Control Valve
NOTE: Make sure all the parts of the transmission hydraulic control valves are clean and free of
dirt and foreign material. Put clean oil on all the parts before the valves are assembled.
1. Put plate (1) in position on the manifold group.

2. Install slug (3) and spring (2) on valve spool (4).
3. If stop was removed, put stop in position in the valve body and install dowel (7) that holds it.
4. Install spring, slug and valve spool in the valve body. Install dowel (6) that holds them in
position.
5. If stop (8) was removed, put stop (8) in position and install dowel (9).
6. Install ball (11), spring (12), retainer (13) and ring (14) in valve spool (10). Install slug (15) in
spool.

7. Install valve spool assembly (10) in the valve body.
8. Install shims (17), springs (18) and (19) in piston (16).
9. Install piston (16), shims and spring in the valve body.
10. Install springs (21) and (22), retainer (23) and retainer ring (24) in valve spool (20).
11. Install valve spool assembly (25) and spring (26) in the valve body.
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12. Put new O-ring seals on cover (27). Install cover (27) on the valve body.
13. Install direction control valve spool (28) and speed control valve spool (30) in the valve body.
NOTICE
Do not use force or hit the halve valve spools to install them.
14. Be sure the orifice screen (29) is assembled with screen out.
15. Put stops (32) in position on each side of the valve body. Install pins (31) that hold them.
16. Put O-ring seals on the detent assemblies and install two detent assemblies (33) in each side of
the valve body.

17. Install setscrew (34) so it is below the surface of valve group (35).
18. Put valve group (35) in position on the plate.
19. Put manifold (36) in position on the valve group. Install the bolts in the hydraulic control
valve. Tighten the bolts to a torque of 30 ± 4 N·m (22 ± 3 lb ft).
End By:
a. install transmission hydraulic control valve
Disassemble Transfer Gears (Input)
Start By:
a. remove transfer gears (input and output)
1. Put the input transfer gears on wood blocks as shown.

2. Remove yoke assembly (1).
3. Remove six bolts (2) from the bearing cage.
4. Use two of the bolts (2) to loosen the bearing cage. Install the two bolts as shown. Tighten the
bolts evenly until cage (3) is loose. Remove the cage and shims (4).
5. Remove O-ring seal (6) from the cage. Check the condition of the seal. If the seal has damage
use a new part for replacement.
6. Remove seal (5) from the cage.
7. Remove the bearing cup from the cage with tooling (A).

8. Remove driver gear (7) from the case.
9. Remove bearing cones (8) and (9) from the driver gear with tooling (B).
10. Remove the bearing cup from the case with tooling (A).
11. Turn the transfer case over.
12. Remove the six bolts that hold cage (10) in position. Use two of the six bolts as forcing screws
to loosen the cage. Tighten the bolts evenly until the cage is loose. Remove the cage and shims.

13. Remove the bearing cup from cage (10) with tooling (A).
14. Remove driven gear (11) from the case.
15. Remove two bearing cones (12) from the driven gear with tooling (C).
16. Remove the bearing cup for the driven gear from the case with tooling (A).
Assemble Transfer Gears (Input)

1. Lower the temperature of the bearing cup (1). Install it in the case until it makes contact with
the counterbore in the case.
2. Heat the two bearing cones to a maximum temperature of 135°C (275°F). Install two bearing
cones (2) on the driven gear.
3. Install drive gear (3) in the case.
4. Lower the temperature of the bearing cup. Install the bearing cup in cage (4).
5. Install tooling (A) as shown. Make sure the indicator from tooling (A) is in contact with the
driven gear. Tighten the six bolts (5) evenly until the end play of the driven gear is .08 to .15 mm
(.003 to .006 in). Move the driven gear up and down to check the end play.
6. Measure the gap between the cage and case with a feeler gauge.
7. Remove tooling (A) and the cage from the case.

8. Install the amount of shims (6) that was measured in Step 6 and cage (4). Install the six bolts
that hold the cage. Check the amount of end play again with tooling (A). Add or remove shims
until the end play is .08 to .15 mm (.003 to .006 in).
9. Heat bearing cones (7) to a maximum temperature of 135°C (275°F). Install the bearing cones
on the drive gear.
10. Turn the case over. Install drive gear (8) in the case.
11. Lower the temperature of the bearing cup. Install the bearing cup in cage (9). Install cage (9)
and the bolts that hold it. Install tooling (A). Make sure the indicator from tooling (A) is in contact
with the drive gear.
12. Tighten bolts (10) evenly until the end play of the drive gear is .08 to .15 mm (.003 to .006
in). Move the drive gear up and down to check the end play.
13. Measure the gap between the cage and case with a feeler gauge.

14. Remove cage (9). Install the amount of shims (11) that was measured in Step 13. Install cage
(9) and the bolts that hold it. Check the amount of end play again with tooling (A). Add or remove
shims until the end play is .08 to .15 mm (.003 to .006 in).
15. Remove cage (9) from the case.
16. Install the lip type seal in the cage with tooling (B). Install the seal until it makes contact with
the counterbore in the cage and with the lip of the seal towards the inside of the cage.
17. Install the O-ring seal on the cage.
18. Put the clean oil on the lip of the seal. Install the cage on the case.
19. Install yoke assembly (12).
End By:
a. install transfer gears (input and output)
Disassemble Transmission Gear (Output)

Start By:
a. remove transfer input gears (input)
b. remove transmission
1. Remove bolt (3) from yoke assembly (1).
2. Install two 3/8"-16 NC forcing screws (G) to bearing carrier (4). Remove six bolts (2). Use
forcing screws to remove the bearing carrier.

3. Remove shim pack (5).
4. Remove O-ring (9) from the bearing carrier. Remove retainer (8) with tool (A). Remove thrust
washer (6). Remove retainer (7) with tool (B).
5. Remove yoke assembly (1) with tooling (C) from the bearing carrier (4).
6. Use tooling (C) to remove the bearing from bearing carrier (4).

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7. Remove lip-type seal using tool (C) from bearing carrier (4).
8. Install two 3/8"-16 NC forcing screws (G) to carrier (10). Attach tooling (E) to the carrier.
Remove eleven bolts (11). Tighten the forcing screws evenly to remove the carrier.
9. Attach chains and hoist to carrier (10). Remove the carrier. The weight of the carrier is 29 kg
(65 lb).
NOTE: The length of carrier does not allow for the removal of the carrier while in the tractor.
10. Use tooling (D) to remove the bearing cup from carrier (10).
11. Use yoke assembly bolt (12) to secure tooling (F). Remove the differential group (13) with a
sling and hoist. The weight of the differential group is 66 kg (146 lb).

12. Attach tooling (F) and hoist to output gear case (14). Remove four bolts (16) and tube
assembly (15).
13. Turn the output gear case over. Position on wooden blocks as shown in next photo C42334P1.
14. Remove fourteen bolts (17) from carrier (18).
15. Install two 3/8"-16 NC forcing screws (G). Tighten the forcing screws evenly to loosen carrier
(18).
16. Remove carrier (18) and shims (19) that are under the carrier.

17. Remove shims (19) and O-ring seal (21) from carrier (18).
18. Remove bearing cup (20) from the carrier.
19. Install two 3/8"-16 NC forcing screws (G). Remove fifteen bolts (22). Tighten the forcing
screws evenly to remove carrier (23) and shims.
20. Remove shims (26) and O-ring seal (25) from carrier (23).
21. Remove bearing cup (24) from the carrier.
22. Install two 3/8"-16 NC forcing screws (G) to plate (28). Remove eighteen bolts (27). Tighten
the forcing screws evenly to loosen the plate.

23. Install tooling (F) to plate (28) with a strap and hoist. Remove the plate. The weight of the
plate is 21 kg (46 lb).
24. Install tooling (E) to gear (29). Attach chain and hoist. Remove gear (29). The weight of the
gear is 39 kg (85 lb).
25. Remove bearing (30) with tooling (H) and tooling (D). After removing bearing (30), rotate
gear 180°.
26. Remove bearing (31) with tooling (I) and tooling (D).

Caterpillar cat d400 d articulated truck (prefix 8tf) service repair manual (8tf00001 and up)

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Caterpillar cat d400 d articulated truck (prefix 8tf) service repair manual (8tf00001 and up)