Caterpillar cat d400 e ii articulated truck (prefix 8ps) service repair manual (8ps00001 and up)

Service Repair Manual
Models
D400E II ARTICULATED
TRUCK

Shutdown SIS
Previous Screen
Product: ARTICULATED TRUCK
Model: D400E II ARTICULATED TRUCK 8PS
Configuration: D400E Series II Articulated Truck 8PS00001-UP (MACHINE) POWERED BY 3406E Engine
Disassembly and Assembly
D400E Series II Articulated Truck Power Train
Media Number -RENR1511-02 Publication Date -01/12/2005 Date Updated -19/12/2005
i02251927
Torque Converter - Disassemble
SMCS - 3101-015
Disassembly Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A
138-7573 Link Bracket 2
8S-9906 Ratchet Puller 1
B 1P-0520 Driver Group 1
C
5F-7366 Forcing Screw 1
1H-3112 Puller Assembly 1
D 2P-8312 Snap Ring Pliers 1
E
8B-7551 Bearing Puller 1
8B-7550 Leg 2
8B-7548 Puller 1
8H-0684 Ratchet Wrench 1
F 1P-2321 Combination Puller 1
Start By:
A. Separate the torque converter from the engine. Refer to Disassembly and Assembly,
RENR1511, "Engine and Torque Converter - Separate".
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https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw...

NOTICE
Care must be taken to ensure that fluids are contained during
performance of inspection, maintenance, testing, adjusting and repair
of the product. Be prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any component
containing fluids.
Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop
Products Guide" for tools and supplies suitable to collect and contain
fluids on Caterpillar products.
Dispose of all fluids according to local regulations and mandates.
Note: Cleanliness is an important factor. Before the disassembly procedure, the exterior of the
component should be thoroughly cleaned. This will help to prevent dirt from entering the internal
mechanism.
Illustration 1 g00583290
1. Remove O-ring seal (1) from torque converter cover (2) .
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2. Remove bolt (3) , hard washer (4) , shims (7) , O-ring seal (6) , and flange (5) from the
torque converter cover.
3. Remove bolts (8) and the hard washers that secure cover (2) to the torque converter.
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4. Use three 1/2" - 13 NC forcing screws (9) in order to separate the cover from the torque
converter.
5. Attach Tooling (A) , appropriate lifting straps, and a hoist to cover (2) . Remove cover (2)
from torque converter (10) . The weight of the cover is approximately 153 kg (338 lb).
6. Rotate the torque converter assembly by 180 degrees. The weight of the converter assembly
is approximately 180 kg (397 lb).
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7. Remove bolts (11) and torque converter pilot hub (12) from housing (13) .
8. Remove two bolts (14) , plate (15) , and the washer from the shaft.
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9. Rotate the torque converter assembly by 180 degrees. The weight of the converter assembly
is approximately 180 kg (397 lb). Remove two O-ring seals (18) . Remove bolts (16) , the
lockwashers, retainer (17) and the gasket.
10. Remove lip type seal (19) from retainer (17) . Note the orientation of the lip type seal to
retainer (17) for assembly purposes.
11. Remove shaft assembly (20) from the torque converter.
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12. Put a support under carrier (22) . Use a press in order to push shaft (20) out of bearing (21)
and the carrier. Remove the O-ring seals from the carrier.
13. Use Tooling (D) in order to remove retainer ring (24) that holds carrier (23) on the carrier
assembly. Remove the carrier from the converter assembly.
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14. Rotate carrier (23) by 180 degrees. Remove retainer ring (25) that holds sleeve (26) and
bearing (27) in carrier (23) .
15. Use Tooling (B) and (C) in order to remove sleeve (26) and bearing (27) from carrier (23) .
16. Use Tooling (D) in order to remove retainer ring (28) from carrier assembly (29) . Remove
bolts (30) and the hard washers that secure plate (31) and the impeller to housing (13) .
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17. Install two 3/8 " - 16 NC Forged Eyebolts. Attach a hoist, as shown. Use two 3/8 " - 16 NC
forcing screws (32) in order to separate the impeller and carrier assembly (29) from housing
(13) . Remove plate (31) and remove the impeller from housing (13) . The weight of the
impeller assembly is 29 kg (64 lb).
18. Use Tooling (B) and (E) in order to remove bearing race (33) from the hub.
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19. Use Tooling (B) and (F) in order to remove carrier (34) from the hub. Remove the ring seal
from the hub.
20. Remove bolts (37) that hold hub (36) , gear (35) , plate (31) , and the impeller together.
Remove the gear and the plate from the hub and the impeller.
21. Remove O-ring seal (39) and impeller (38) from hub (36) .
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22. Remove the race and retainer assembly (40) from the stator assembly. Remove the bearing
from the stator assembly.
23. Use two persons in order to remove the stator and carrier assembly (41) from the turbine
and the housing. The weight of the stator and carrier assembly is approximately 28 kg (62
lb).
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24. Remove retaining ring (42) from stator assembly (41) .
25. Remove carrier assembly (29) from stator assembly (41) . Remove plate (43) , the springs,
and the rollers from the stator assembly.
26. Remove springs (45) and rollers (44) from cam (46) .
27. Remove ring (47) from carrier (29) . Remove bearing (48) from the carrier only if a
replacement is required. Removal can cause damage to the bearing.
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28. Rotate the stator by 180 degrees. Remove retainer ring (49) and plate (50) from the stator.
29. Remove retainer ring (51) from the stator. Heat the stator to a maximum temperature of 135
°C (275 °F) for approximately fifteen minutes. Push cam (46) out of the stator.
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30. Remove bearing (52) , the race and the retainer from turbine (53) .
31. Rotate the housing and the turbine by 180 degrees. Place the housing on wood blocks. Use a
hammer and a soft punch in order to push hub (54) , Roller bearing (55) and the turbine
assembly out of bearing race (55) .
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32. Remove bolts (56) and hub (54) from turbine (53) . Install two bolts (56) in turbine (53) and
ring (57) . Use a soft mallet to remove the ring from turbine (53) . Remove two bolts (56) .
33. Remove internal retaining ring (59) from hub (54) . Remove seal ring (60) from the hub.
Remove bearing race (58) from the hub only if a replacement is required. Removal can
cause damage to the bearing race.
34. Remove retainer ring (61) from housing (13) . Remove plate (62) . Remove the three clutch
plates and discs from the housing.
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35. Remove three clutch disc (64) and three clutch plates (63) from housing (13) .
36. Use two 3/8 " - 16 NC forged eyebolts in order to remove piston (65) from housing (13) .
37. Remove seals (66) from piston (65) . Note the location of the seals for assembly purposes.
16/17
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38. Remove bearing race (67) from housing (13) only if a replacement is needed. Removal can
cause damage to the bearing race.
Copyright 1993 - 2020 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Fri Feb 7 19:25:14 UTC+0800 2020
17/17
2020/2/7

Shutdown SIS
Previous Screen
Product: ARTICULATED TRUCK
Model: D400E II ARTICULATED TRUCK 8PS
Configuration: D400E Series II Articulated Truck 8PS00001-UP (MACHINE) POWERED BY 3406E Engine
Disassembly and Assembly
D400E Series II Articulated Truck Power Train
Media Number -RENR1511-02 Publication Date -01/12/2005 Date Updated -19/12/2005
i02251928
Torque Converter - Assemble
SMCS - 3101-016
Assembly Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 1P-0520 Driver Group 1
B 2P-8312 Pliers 1
C
138-7573 Link Bracket 2
8S-9906 Ratchet Puller 1
D 8T-5096 Dial Indicator 1
1. Cleanliness is an important factor. Before assembly, all parts should be thoroughly cleaned
in cleaning fluid. Allow the parts to air dry. Wiping cloths or rags should not be used to dry
parts. Lint may be deposited on the parts which may cause later trouble. Inspect all parts.
Inspect all parts and clean all parts. If any parts are worn or damaged, use new Caterpillar
parts for replacement.
1/22
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Measure the clearance with a dial indicator.
2. Temporarily install the stator in the turbine. Check the clearance between the turbine and
the stator. Install Tooling (D) on the turbine wheel, as shown. Move the stator toward the
dial indicator until the outside diameter of the stator is against the inside diameter of the
turbine wheel. Move the dial indicator against the stator. Put the dial indicator on zero. Push
the stator away from the dial indicator until the stator outside diameter is in contact with the
opposite inside diameter of the turbine wheel. Measure the clearance. Make this
measurement at four points around the turbine wheel. The average of this measurement is
the difference between dimension (N) and dimension (M) . When new parts are used, the
difference between dimension (N) and dimension (M) must be from 0.71 mm (0.028 inch)
to 0.91 mm (0.036 inch). The maximum permissible clearance with worn parts is 1.37 mm
(0.054 inch).
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3. Temporarily install the stator in the impeller. Use the same procedure that was outlined in
Step in order to check the clearance between the impeller and the stator. When new parts are
used, the difference between dimension (P) and dimension (Q) must be 0.71 mm (0.028
inch) to 0.91 mm (0.036 inch). The maximum permissible clearance with worn parts is 1.37
mm (0.054 inch).
4. Use a suitable measuring device to measure the outer diameter of the stator at location (S) .
Use a suitable measuring device to measure the inner diameter of the ring at location (R) .
When new parts are used the difference between dimension (R) and dimension (S) must be
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0.56 mm (0.022 inch) to 0.71 mm (0.028 inch). The maximum permissible clearance with
worn parts is 1.07 mm (0.042 inch).
5. If bearing race (67) has been removed, install the race now. Lower the temperature of the
bearing race. Install the race in housing (13) until the race contacts the shoulder that is in the
bearing bore.
6. Install seals (66) on piston (65) .
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Caterpillar cat d400 e ii articulated truck (prefix 8ps) service repair manual (8ps00001 and up)

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Caterpillar cat d400 e ii articulated truck (prefix 8ps) service repair manual (8ps00001 and up)