Caterpillar cat d400 articulated truck (prefix 1 md) service repair manual (1md00001 00246)

Service Repair Manual
Models
D400 ARTICULATED TRUCK

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Product: ARTICULATED TRUCK
Model: D400 ARTICULATED TRUCK 1MD
Configuration: D400 ARTICULATED TRUCK(SEE MACHINE AR FOR SERIAL NO. CHART) 1MD00001-00246 (MACHINE) POWERED BY 3406B ENGINE
Disassembly and Assembly
ARTICULATED DUMP TRUCK OUTPUT TRANSFER DRIVE
Media Number -SENR8109-01 Publication Date -01/01/1986 Date Updated -12/10/2001
Output Transfer Drive
SMCS - 1453-016
Remove Output Transfer Drive
Tools Required:
NOTE: The following photographs show the removal/installation procedure for a typical output transfer drive
assembly. The procedure is similar for 'C' trucks and the D400 - where there are differences, these are noted and
specific instructions are given.
1. Stop the truck in the straight ahead position and apply the parking brake. Move the gear lever to the Neutral
position and stop the engine. Remove the key and place suitable warning notices to prevent personnel starting the
engine and operating the controls. Use the hand lever on the suspension control valve to fully lower the front
suspension.
2. With the oil warm, remove the drain plug (1) and allow the oil to drain into a suitable container (C Truck - 35
litres) (D400 - 105 litres).
3. Remove the transmission compartment grille (2).
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4. Release the retaining clips (3) from the access door struts (4).
5. Remove the rear access door assembly (5).
6. Disconnect and remove the hoist control linkage and rod assembly.
7. C-trucks: Remove the cam housing cover (6). Disconnect and remove the selector cable (7) from the housing.
Refit the cover (6) to prevent dirt entering the housing.
8. D400: Disconnect the torque converter lock up oil line (8) from the transfer gearbox.
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9. D400: Disconnect the transmission control cables (9) from the rear of the transmission control group housing.
10. Trucks fitted with supplementary steering: Remove the supplementary steer hoses (10 and 11) from the diverter
valve (12) to the pipes (13) and (14). Plug the ports on the diverter valve and cap the hoses to prevent
contamination.
11. Trucks fitted with supplementary steering: Remove both pipe assemblies (13) and (14) from the supplementary
steer pump.
12. Trucks fitted supplementary steering: Remove the supplementary steer pump (15).
13. Remove the bolts that secure the transmission drive shaft (16). Remove the drive shaft. D400 (early trucks) -
Disconnect the wires (17) from the magnetic pick-up. Mark the wires to ensure correct reconnection.
14. Remove the bolts that secure the spider (18). Remove the spider.
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15. Remove the cotter pin (19) and the clevis pin (20) from the differential lock actuator.
16. Remove the bolts securing the output transfer drive rear output yoke to the centre drive shaft (21). Slide the
centre drive shaft backward.
17. D400 - Remove the bolts securing the torque converter valve group (22) to the transmission mounting bracket.
Disconnect the valve group oil supply line (24). Move the valve group to allow clearance when the transmission and
output transfer drive assembly is hoisted out of the compartment. Remove the oil filler tube assembly (25).
Disconnect the remaining oil lines (26) and (27) from the front of the transmission. Disconnect the oil cooler return
line (23).
18. C Trucks - Disconnect the oil lines (28-34) from the front of the transmission. Mark the oil lines to ensure
correct reconnection. Plug the ports and cap the hoses to reduce oil spillage and prevent contamination.
19. All trucks - Disconnect the sump line connection (35) from the output transfer drive housing.
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20. D400 - Disconnect the torque converter drain line (36) from the output transfer drive housing.
21. Remove the upper bolts (37) securing the left and right hand mounting brackets (38).
NOTE: On current trucks it is not necessary to remove the left and right hand mounting brackets.
22. Remove the bolts securing the upper transmission mounting assembly (39). Remove the mounting assembly.
Remove the torque converter selector valve (40) to provide more clearance.
NOTE: Place a wooden plank or similar form of protection at the rear of the transmission compartment. This will
prevent damage to any components when the upper transmission mounting assembly is removed and the
transmission/output transfer drive assembly pivots backwards.
23. Place a suitable hoisting sling around the assembly as shown and connect the sling to a hoist.
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24. Early trucks: If necessary, disconnect the steering line pipe connections (41), also ...
It is important that the complete assembly is securely supported by the
hoist and sling during the following procedure. This will prevent the
assembly from moving downward when finally released from the truck
frame, thus avoiding the possibility of injury or damage.
25. Early trucks: ... slacken the mounting brackets for both pipes (42) to allow sufficient movement of the pipes to
provide clearance for the output transfer drive assembly during the hoisting procedure.
26. Drill out the indented lip of the locating ring (43) and remove the locating ring using tool 6V3133 Spanner
Wrench. Remove the bolts (44) from the left and right hand pivot pins. Remove the pivot pins (45).
27. Remove the remaining lower bolts (46) from the left and right hand mounting brackets. Remove both mounting
brackets (38).
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28. Hoist the complete transmission/output transfer drive assembly out of the truck.
29. Lower the assembly on to suitable stands, disconnect the hoist and remove the sling.
30. Attach a sling and hoist to the transmission. Install two 3/8 - 16NC forcing bolts (47) to separate the
transmission from the output transfer drive. Remove the transmission from the output transfer drive. The weight of
the transmission is 622 kg (1370 lb.).
31. End by:
(a) Disassemble output transfer drive.
(b) Disassemble transmission - see CAT Form Number SENR 2393 '615 Tractor-Scraper Power Train-Disassembly
and Assembly' which can be found in CAT Service Manual SENR 2386 '615 Tractor-Scraper'.
Install Output Transfer Drive
New Parts Required:
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Tools Required:
1. Start by:
(a) Assemble output transfer drive
(b) Assemble transmission - see CAT Form Number SENR 2393 '615 Tractor-Scraper Power Train-Disassembly
and Assembly' which can be found in CAT Service Manual SENR 2386 '615 Tractor-Scraper.'
(c) Assemble transmission to output transfer drive using 3S9896 or 5P2587 seal as appropriate.
2. Attach a sling and connect to a hoist. Lower the assembly into position in the transmission compartment. Take
care when lowering past the steering system pipes. The two pipes, slackened previously in "Remove Output
Transfer Drive" procedure - steps 24 and 25, can be moved to provide the clearance necessary to position the
assembly in the compartment.
It is important that the complete assembly is securely supported by the
hoist and sling during this procedure.
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3. Position the left and right hand mounting brackets (1) against the output transfer drive. Install the lower bolts and
washers (2) initially and fully tighten to a torque setting of 360±47 Nm (265±35 lb.ft.).
NOTE: On current trucks the transmission and output transfer drive assembly can be installed with the left and right
hand mounting brackets in position.
4. Position the assembly so that the pivot pins (3) can be installed through the right and left hand mounting brackets
(1). Install the pivot pins. Be sure the slot in each pin is facing towards the front of the truck.
5. Install the bolts (4) and washers and tighten to a torque setting of 360±47 Nm (265±35 lb.ft.).
6. Install the locating ring (5). Use tool 6V3133 Spanner Wrench to tighten the locating ring until it just touches the
face of the mounting bracket (1). Measure the gap (6) on each side of the truck and adjust the locating rings until
both dimensions are equal to within 2mm.
7. Lock the locating ring (5) in position by using a punch to indent the ring lip into the slot in each pivot pin (3).
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8. Check the alignment of the transmission to the front axle. The centre lines of the transfer drive output shaft and
the front differential input shaft must be within 1.5mm (0.06 inch) measured sideways. Measure by placing a
straight edge across the machined surfaces of the respective yokes.
Shims (7) are installed between the bearing cap (8) and the front suspension frame (9). If adjustment is necessary
remove shims from under one bearing cap and install the same shims under the bearing cap on the other side. Before
carrying out adjustment slacken clamp bolts (10). Tighten fully after adjustment.
9. Install upper bolts (2) and washers to the left and right hand mounting brackets (1). Fully tighten to a torque
setting of 360±47 Nm (265±35 lb.ft.).
10. Early trucks: Connect steering pipes (11).
11. Early trucks: Connect brackets (12) to the truck frame.
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D400 ARTICULATED TRUCK(SEE MACHINE AR FOR SERIAL NO. CHART) ...
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12. Install a wooden plank behind the transmission then remove the hoist and sling.
13. Install the upper transmission mounting bracket assembly (13).
14. 'C' Trucks & D400: Connect the sump line (14) to the front of the output transfer drive housing using a new seal.
15. D400: Connect the torque converter drain line (15) to the front of the output transfer drive housing.
16. C Truck - Connect the oil lines (16-22) to the transmission housing using new seals.
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17. D400 - Install the torque converter valve group (23) to the transmission mounting bracket (24). Connect the
valve group oil supply line (26). Install the oil filler tube assembly (28) using a new gasket. Install the remaining oil
lines (25 and 27) to the front of the transmission and the oil cooler return line (29) using new seals.
18. Slide the centre drive shaft (30) forward and connect it to the output yoke. Tighten the bolts to a torque setting of
135±14 Nm (100±10 lb.ft.).
19. Position the differential lock actuator shaft on the differential selector shaft and install clevis pin (31). Insert a
new cotter pin (32) making sure that sufficient washers are installed under the cotter pin to take up all free play on
the clevis pin.
20. Install the spider (33) connecting the front drive axle to the output transfer drive.
21. Install the transmission drive shaft (34). C Trucks:
The transmission drive shaft should have between 4 and 10mm sliding allowance between the male and female
parts. Measure the distance between the machined faces of the two spider and bearing assemblies with the shaft
fully compressed. Install the drive shaft then adjust the top transmission mounting until the distance between the
same two faces is 4-10mm greater than the fully compressed dimension.
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D400:
A clearance of 5-6mm should exist between the rear face of the input yoke and the face of the cage of the
transmission input transfer gear. The clearance is obtained by adjusting the top transmission mounting. The above
clearance is for a truck on wheels. If supported on stands the clearance should be 3-4mm.
Note for all trucks:
The method of adjusting the top transmission mounting depends on the arrangement fitted. On early trucks
adjustment is achieved by fitting washers under the head of the bolt which passes through the mounting. On later
trucks adjust the number of shims between the mounting block and the truck frame.
22. C trucks - Install the selector cable (35) to the cam housing (36). Install the cover (37) with a new gasket if
necessary. Refer to "Transmission Control Linkage Adjustment - C Trucks" if adjustment is required.
23. D400 - Install the transmission control cables (38) to the rear of the transmission control group housing. Refer to
"Transmission Control Linkage Adjustments - D400" if adjustment required.
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24. Connect the hoist control linkage and rod assembly.
25. Trucks equipped with supplemental steering: Install the supplemental steer pump (39) using a new gasket.
Tighten the nuts to a torque setting of 100±14 Nm (75±10 lb.ft.).
26. Trucks equipped with supplemental steering: Install the two pipe assemblies (40 and 41) to the supplemental
steer pump. Install the two hose assemblies (42) to the pipe assemblies (40 and 41) and to the connections at the
diverter valve (43). Tighten all bolts to a torque setting of 100±14 Nm (75±10 lb.ft.) except the bolts into the
diverter valve which are tightened to 80±4 Nm (60±3 lb.ft.). Use new seals
27. D400: Install the torque converter lock up oil line (44) to the output transfer drive.
28. Install the rear access doors assembly.
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29. Install the retaining clips (45) to the access door struts.
30. Early trucks: Install the transmission compartment rear grille (46).
31. End by:
a) Fill transmission with oil.
b) Top up hydraulic tank.
Disassemble Inter Axle Differential
Start by:
a) Remove inter-axle differential.
1. Remove bearing cone (1).
2. Remove the screws (12 off) securing the drive dog (2) to the housing.
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3. Remove the bearing cone (3).
4. Remove the locking wire from all bolts (8 off) securing gear (4) to the housing assembly. Remove all bolts (5).
5. Install two 1/2" UNC forcing bolts to separate gear (4) from the housing. Remove the gear. Mark the gear and
housing to ensure correct alignment upon reassembly.
6. Remove the bolts (6).
7. Separate the housing assembly ...
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8. ... to reveal the gearing arrangement.
9. Remove the thrust washers (7) - 8 off.
10. Remove the gears (8) - 8 off.
11. Remove the thrust washers (9) - 8 off.
12. Remove the thrust washer (10).
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13. Remove gear (11).
14. Remove gear (12).
15. Remove thrust washer (13).
16. Remove all pins (14) - 4 long and 4 short. Note the location of both types of pins to ensure correct reassembly.
Inspect/Replace Worn Parts
1. Clean and inspect the long (1) and short (2) pins for excess wear or scoring. Replace if excessively worn.
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2. Clean and inspect the input gear (3) for burrs, excessive or incorrect wear or other damage. Stone away any burrs
and replace if damaged.
3. Inspect the small gears (4) for wear and the plain bearings within each gear for wear or scoring.
4. Inspect all thrust washers (5) for excessive wear and replace as necessary.
Assemble Inter Axle Differential
New Parts Required
1. Install all pins - 4 long (1) and 4 short (2) into the housing as shown.
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2. Install thrust washer (3).
3. Install gear (4).
4. Install gear (5).
5. Install thrust washer (6).
6. Install eight thrust washers (7).
7. Install eight gears (8).
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8. Install eight thrust washers (9).
9. The lower housing assembly is shown complete and ready for further assembly.
10. Install housing (10) on to the completed lower housing assembly (11) using roll pin (12) to ensure correct
assembly.
11. Install four bolts (13) and tighten evenly to a torque setting of 102 ± 15 Nm (75 ± 10 lb.ft.).
12. Use a suitable solvent to thoroughly clean and degrease the mating surfaces of the gear (14) and the housing and
the tapped holes in the housing. Apply a coating of 2U2856 retaining compound to the mating surfaces. Install gear
(14). Position the gear so that the four long pins locate into the four recessed holes in the mating surface of the gear.
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13. Install bolts (15) - 8 off. Tighten evenly to a torque setting of 129±15 Nm (95±10 lb.ft.). Wire lock all bolts
using 5P6027 locking wire.
14. Install bearing cone (16).
5. Use a suitable solvent to thoroughly clean and degrease the mating surfaces of drive dog (17) and the housing.
Smear the mating surfaces with 2U2856 retaining compound and install the drive dog (17). Apply a coating of
2U2855 thread lock to the screw threads after suitably degreasing. Tighten the screws to a torque setting of 122±15
Nm (90 ± 10 lb.ft.).
16. Install bearing cone (18).
Disassemble Output Transfer Drive
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1. Start by:
a) Remove inter axle differential.
2. Remove the differential guard (1) from the output transfer drive housing. The guard is secured by three bolts.
3. Attach bracket (2) to the output transfer drive housing cover (3). Attach a hoist to the bracket and lower onto a
prepared surface before further disassembly is started.
NOTE:
a) The bracket is to be found in the tool box located in the operator's compartment.
b) The dipstick tube assembly has already been removed in the illustration.
4. Remove all bolts (18 off) securing the housing cover (3). Install two 3/8" UNF eyebolts and attach a hoist.
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Caterpillar cat d400 articulated truck (prefix 1 md) service repair manual (1md00001 00246)

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Caterpillar cat d400 articulated truck (prefix 1 md) service repair manual (1md00001 00246)