D400E Series II Articulated Truck Caterpillar

Hoist, Steering, and Brake System Tank - Install

Usage:

Installation Procedure

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Table 1
Required Tools
Tool	Part Number	Part Description	Qty
A	138-7575	Link Bracket	4

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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, PERJ1017, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat^® products. Dispose of all fluids according to local regulations and mandates.

Inspect all parts and clean all parts. If any parts are worn or damaged, use new Caterpillar parts for replacement.
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Illustration 1 g00557906
Attach Tooling (A), appropriate nylon lifting slings, and a hoist to the tank, as shown. The tank must be held level when the tank is installed. Position the tank to the mounting positions.
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Illustration 2 g00558088

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Illustration 3 g00557904
There are two mounting assemblies on the bottom of the tank. The graphics above show one of the two mountings from a point below the machine frame. Use the hoist in order to raise the tank slightly. Shims (47), mounting (41), and steel sleeve (45) (not shown) must be installed before the tank is lowered. At this point in time, Step 4 must be completed. After Step 4 is complete install bolts (44), hard washers (43), hard washers (42), nuts (49), and washers (46) in order to secure the tank to the machine frame. Remove the hoist and Tooling (A) from the tank. Proceed to Step 5.
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Illustration 4 g00557883
Shims (34), mounting (35), and steel sleeve (40) (not shown) must be installed to mounting bracket (33) before the tank is lowered. Lower the tank to the machine. Install bolt (39), nut (38), hard washer (37), and hard washer (36) in order to secure the tank to mounting bracket (33). Bolt (39) is installed through the top plate of the tank. There is a hard washer under the hex head of bolt (39). Use the amount of shims at the three mounting assemblies in order to install the tank in a parallel plane to the machine frame. Return to Step 3 at this point in time.
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Illustration 5 g00557882
Install the O-ring seal to hose (30). Install four bolts (28), the washers, and two half clamps (29) in order to connect hose (30) to the tank. Install the O-ring seals to hoses (31) and (32). Connect hoses (31) and (32) to the tank.
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Illustration 6 g00558063
Install the O-ring seal to hose (26). Install bolts (24), the washers, and two half clamps (25) in order to connect hose (26) to brake oil cooler (27).
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Illustration 7 g00557881
Install the O-ring seal to hose (23). Connect hose (23) to the tank.
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Illustration 8 g00557880
Install the O-ring seal to hose (18). Install four bolts (20), the washers, and two half clamps (21) in order to connect hose (18) to the tank. Install two band clamps (22) and hose (15) to the tank. Install the O-ring seal to hose (16). Install four bolts (17), the washers, and two half clamps (19) in order to connect hose (16) to the tank.
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Illustration 9 g00557879
Install bolt (13), the washer, and hose clamp (14) in order to connect hose (7) to the fender.
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Illustration 10 g00557877
Install bolt (10), the washer, and hose clamp (12) in order to connect pipe (8) to the fender. Install bolt (9), the washer, and hose clamp (11) in order to connect hose (7) to the fender.
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Illustration 11 g00557876
Install the O-ring seals to hoses (7). Install the O-ring seal to pipe (8). Install 12 bolts (6), the washers, and six half clamps (5) in order to connect two hoses (7) and pipe (8) to the tank.
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Illustration 12 g00557874
Position guard (3) to the tank. Install three bolts (4) and the washers that secure guard (3) to the tank.
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Illustration 13 g00557873

This is a photograph of one of the ecology drains that are on the bottom of the tank.
Note that the tank assembly has two separate fluid reservoirs. There is an ecology drain valve for each reservoir. Install the rectangular seals to drain plugs (2). Install drain plugs (2) to ecology drains (1).
Fill the tank with fluid to the proper level. See Operation and Maintenance Manual, SEBU7064, "Hoist, Steering, and Brake System Oil Level - Check" for the correct procedure.
Adjust the suspension to the proper height. See Operation and Maintenance Manual, SEBU7064, "Suspension System - Check/Adjust" for the correct procedure.