D400E Series II Articulated Truck Power Train Caterpillar

Removal Procedure

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At operating temperature, the hydraulic tank is hot and under pressure. Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin. Remove the filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand. Remove the filler cap slowly in order to relieve pressure.

1. Park the machine on a hard, level surface. Engage the parking brake and chock the wheels. Turn the disconnect switch to the OFF position.

2. Put identification marks on all lines, hoses, wires and tubes for installation purposes. Plug all lines, hoses and tubes. This helps prevent fluid loss and contamination of the fluid system.
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   Illustration 1	g00585888

3. Remove four clamps (1). Remove tube (2) from the machine.

4. Remove four bolts (3), the washers and the nuts.
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   Illustration 2	g00585896

5. Attach appropriate nylon lifting slings and a hoist to the transmission cover assembly (4).

6. Remove the two nuts that secure strut (5) to the machine. Remove the strut.

7. Remove the transmission cover assembly from the machine. The assembly weighs 40 kg (88 lb).
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   Illustration 3	g00586043

8. Remove four bolts, the washers, and two half clamps that secure hose assembly (6) to the hydraulic tank. Remove the O-ring from the hose assembly.
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   Illustration 4	g00586045
   This photograph was taken near the base of the transmission filter.

9. Remove bolt (7), the washer, and the clamp that secures the hose assembly to the manifold.
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   Illustration 5	g00586050

10. Disconnect hose assembly (8). Remove the O-ring from the hose assembly.
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    Illustration 6	g00586046

11. Remove two bolts, the washers, and the nuts that secure four clamps (9). Position the hose assemblies away from the transmission.
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    Illustration 7	g00586049

12. Disconnect hose assembly (10) from the transmission. Remove the O-ring from the hose assembly.
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    Illustration 8	g00586051

13. Disconnect three electrical connectors (11).

14. Remove ten bolts that secure cover (12) to the manifold. Remove the gasket.
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    Illustration 9	g00586810

15. Disconnect wire connector (13) from sensor (14).

16. Remove the two bolts, the spacers, the mounts, and the retainers that secure sensor (14).

17. Remove four bolts (15) that secure manifold (16) to the transmission. Remove the manifold from the machine.
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    Illustration 10	g00586787

18. Remove three sleeves (17) and coupling (18) from manifold (16). Remove the retaining ring from the coupling. Remove the seals from the sleeves.

19. Remove the six O-rings from manifold (16).
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    Illustration 11	g00586052

20. Disconnect two hose assemblies (19). Remove the two O-rings from the hose assemblies.

21. Remove four bolts, the washers, and two half clamps that secure hose assembly (20). Remove the O-ring from the hose assembly.

22. Remove flange adapter (21). Remove the O-ring from the flange adapter.
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    Illustration 12	g00586057

23. Disconnect wire connector (22) at the rear of the circuit breaker panel.
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    Illustration 13	g00586055

24. Remove bolt (23), the washers, the nut, and the wire clip.

25. Remove 22 bolts (24), the washers, and wire clips (25).

    Note: There are several wire clips that secure the wire harness. Mark the location of wire clips (25) and bracket (26) for installation purposes.

26. Remove cover (27) from the machine. Remove the gasket.
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    Illustration 14	g00586058
    This photograph was taken near the front transmission mount.

27. Remove hose assembly (28) and the adapter. Remove the two O-rings from the hose assembly and the adapter.
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    Illustration 15	g00586350

    Note: Bolt (29) consists of three different bolts. Make a note of the location of each bolt for installation purposes.

28. Remove ten bolts (29) and the washers that secure the cover and pressure control valves (30). Remove the cover and the valves from the machine.
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    Illustration 16	g00586554

29. Remove thirteen bolts (31) that secure selector and pressure control valve (32). Use two people in order to remove the valve. The weight of the valve is 25 kg (55 lb).
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    Illustration 17	g00586555

30. Remove bolt (33) and plate (34).
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    Illustration 18	g00586558

31. Remove sleeve (35) and sleeve (36). Remove two O-rings from each sleeve.

32. Lift manifold (37) and remove two sleeves (38). Remove the O-rings from the sleeves.