D400E Series II Articulated Truck Caterpillar

Assembly Procedure

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Illustration 1	g00573543

1. Place Tooling (A) on a suitable work bench.

   Note: The future production of Tooling (A) will differ from the above photo. The new tool will function in the same way.

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   Illustration 2	g00575781

2. Install an O-ring on the bottom side of plate (1). Lubricate the O-ring with specified lubricant before installation. Install plate (1) onto housing (2). Install 17 bolts and washers into plate (1). Turn housing assembly (2) upside-down.
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   Illustration 3	g00573654

3. Attach three suitable lifting eyes, chains, and a hoist to housing assembly (2). Place housing assembly (2) over Tool (A). Remove the lifting eyes, chains and the hoist.
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   Illustration 4	g00573698

4. Soak the plates and the disc in suitable oil before installation. Install plates and the disc (3) into housing (2). You should install the first disc with the fiber in a downward position. You should install the last disc with the fiber in an upward position.
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   Illustration 5	g00573900

5. A cut out area (4) may be used in order to inspect the order and the number of disc and plates in the assembly.
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   Illustration 6	g00573933

6. Place anchor (5) on a clean work bench.
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   Illustration 7	g00573994

7. Coat O-rings (6) with a suitable lubricant. Install the O-rings on piston (7). Install the O-rings with the white stripe outward.
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   Illustration 8	g00574056

8. Install flat Teflon seals (8) over the O-rings on piston (7). Coat the Teflon seals with the proper lubricant before installation.
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   Illustration 9	g00574145

9. Use a smooth metal dowel in order to seat the Teflon seal. You should go completely around the piston with the dowel.
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   Illustration 10	g00574215

10. You should use Vaseline in order to lubricate the cylinder. You should use a brush which is made of foam in order to apply the Vaseline. A bristle brush may leave bristles on the surface of the cylinder.
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    Illustration 11	g00574198

11. Carefully install piston (7) into anchor (5). A mallet with a soft head may be used in order to assist the installation of the piston.
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    Illustration 12	g00574656

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    Illustration 13	g00574659

12. Install suitable lifting eyes and chains to a hoist. Raise anchor assembly (9) in order to install four guide pins (10), springs (11), and the pins that hold the guide pins in place.
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    Illustration 14	g00574714

13. Install spring (11) to pin (10). Insert the one pin assembly at a time into the brake anchor.
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    Illustration 15	g00574755

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    Illustration 16	g00574762

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    Illustration 17	g00574835

14. Install Tooling (B) into the hole for the guide pin and the spring. Install Tooling (C) into Tooling (B) until pin (13) can be inserted into pin (10). Remove Tooling (C) from Tooling (B). Remove Tooling (B). Insert plug (12) into the threaded hole. Install the remaining pin assemblies.
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    Illustration 18	g00575081

15. Rotate the anchor assembly by 180 degrees. Install 2 suitable lifting eyes. Attach suitable chains and a hoist to the lifting eyes. Elevate the anchor assembly in order to install O-ring (14). Lubricate the O-ring with specified lubricant before you install the O-ring.
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    Illustration 19	g00575090

16. Lower anchor assembly (14) into housing assembly (15).
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    Illustration 20	g00575128

17. Install 42 bolts and washers into holes (16) at the outer edge of the anchor assembly.
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    Illustration 21	g00576141

18. The brake cylinder may be pressure tested. The piston should be tested with oil pressure. The oil pressure must be regulated. The pressurized oil is piped into the pressure side of the brake system. A valve and a pressure gauge is incorporated into the pressure line. You should install an overflow hose. You should pipe the overflow hose into a plastic container. The plastic container is placed in the center of the brake assembly. The oil pressure must be setto 4000 kPa (580 psi). Apply oil pressure. Shut off the valve. Watch the pressure gauge. The pressure gauge should not drop below 3847 kPa (558 psi) over a two minute time period.
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    Illustration 22	g00575206

19. Insert two 3/8 bolts (17) in order to hold the disc and plates in place during the removal of the anchor from Tooling (A). The length of the 3/8 bolts should be 110 mm (4 inches) for new brakes and 126 mm (5 inches) for a brake pack that is worn fifty percent. Tighten the bolts in order to hold the disc and the plates.
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    Illustration 23	g00575283

20. Attach suitable lifting eyes, chains, and a hoist to brake assembly (18). Raise the brake assembly from Tooling (A).
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    Illustration 24	g00575594

21. Use suitable lifting eyes, chains, and a hoist in order to rotate the brake assembly by 180 degrees. The brake assembly is now sitting on the anchor.
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    Illustration 25	g00575599

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    Illustration 26	g00575635

22. Install the Duo Cone Seal. Make sure that the rubber toric seals (19) are clean and dry. Make sure that all metal surfaces that make contact with the rubber toric seals are clean and dry. Use Tooling (D) in order to install Duo Cone Seal into the brake assembly. Put a small amount of clean SAE 30W oil on the metal surfaces that make contact. See Special Instruction, "Assembly and Installation of Conventional Duo-Cone Seals".

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1. Install the spindle. See Disassembly and Assembly, RENR1511, "Spindle - Install" for further information.