D400E Series II Articulated Truck Power Train Caterpillar

Installation Procedure

1. Clean all parts and inspect all parts. If any parts are worn or damaged, use new Caterpillar parts for replacement.

2. Lubricate O-ring seals with an appropriate lubricant.
   Show/hide table

   Illustration 1	g00586558

3. Install the O-rings to sleeves (38). Lift manifold (37) and install the two sleeves.

4. Install the two O-rings to each sleeve. Install sleeve (35) and sleeve (36).
   Show/hide table

   Illustration 2	g00586555

5. Install plate (34) and bolt (33). Tighten the bolt to a torque of 30 ± 4 N·m (22 ± 3 lb ft).
   Show/hide table

   Illustration 3	g00586554

6. Use two people in order to place selector and pressure control valve (32) into position. The weight of the valve is 25 kg (55 lb). Install thirteen bolts (31) that secure the valve. Tighten the bolts to a torque of 30 ± 4 N·m (22 ± 3 lb ft).
   Show/hide table

   Illustration 4	g00586350

   Show/hide table

   Illustration 5	g00587866

   Note: Bolt (29) consists of three different sizes of bolts. Be sure to install the proper bolt in the correct hole. Bolt (A) is 3/8 inch - 16. Bolts (B) are 3/8 inch - 16. Bolts (C) are 5/16 inch - 16.

7. Place pressure control valves (30) and the cover into position. Install ten bolts (29) and the washers that secure the cover and the valves. Tighten bolts (A) and bolts (B) to a torque of 48 ± 4 N·m (35 ± 3 lb ft). Tighten bolts (C) to a torque of 30 ± 4 N·m (22 ± 3 lb ft).
   Show/hide table

   Illustration 6	g00586058
   This photograph was taken near the front transmission mount.

8. Install the two O-rings to hose assembly (28) and the adapter. Install the adapter and the hose assembly.
   Show/hide table

   Illustration 7	g00586055

9. Install a new gasket and place cover (27) into position.

10. Install 22 bolts (24), the washers, bracket (26), and wire clips (25).

11. Install bolt (23), the washers, the nut, and the wire clip.
    Show/hide table

    Illustration 8	g00586057

12. Connect wire connector (22) to the rear of the circuit breaker panel.
    Show/hide table

    Illustration 9	g00586052

13. Install the O-ring to flange adapter (21). Place the adapter into position.

14. Install the O-ring to hose assembly (20). Install the four bolts, the washers, and the two half clamps that secure the hose assembly.

15. Install the two O-rings to hose assemblies (19). Connect the two hose assemblies.
    Show/hide table

    Illustration 10	g00587771

    Show/hide table

    Illustration 11	g00587767

16. Install the six O-rings to manifold (16). Install the seals to sleeves (17). Install the retaining ring to coupling (18). Install the three sleeves and the coupling to the transmission. Align the groove on the coupling with the dowel on the spool.
    Show/hide table

    Illustration 12	g00586810

17. Place sensor (14) into position. Install the two bolts, the spacers, the mounts, and the retainers that secure the sensor.

18. Connect wire connector (13) to sensor (14).

19. Place manifold (16) into position. Install four bolts (15) that secure the manifold to the transmission.
    Show/hide table

    Illustration 13	g00586051

20. Install the gasket. Position cover (12) to the manifold and install the ten bolts.

21. Connect three electrical connectors (11).
    Show/hide table

    Illustration 14	g00586049

22. Install the O-ring to hose assembly (10). Connect the hose assembly to the transmission.
    Show/hide table

    Illustration 15	g00586046

23. Install the two bolts, the washers, and the nuts that secure four clamps (9).
    Show/hide table

    Illustration 16	g00586050

24. Install the O-ring to hose assembly (8). Connect the hose assembly.
    Show/hide table

    Illustration 17	g00586045
    This photograph was taken near the base of the transmission filter.

25. Install bolt (7), the washer, and the clamp that secures the hose assembly to the manifold.
    Show/hide table

    Illustration 18	g00586043

26. Install the O-ring to hose assembly (6). Install the four bolts, the washers, and the two half clamps that secure the hose assembly to the hydraulic tank.
    Show/hide table

    Illustration 19	g00585896

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

28. Place the transmission cover assembly into position on the machine. The assembly weighs 40 kg (88 lb).

29. Place strut (5) into position. Install the two nuts that secure the strut to the machine.
    Show/hide table

    Illustration 20	g00585888

30. Install four bolts (3), the washers, and the nuts.

31. Position tube (2) to the machine. Install four clamps (1). Tighten the clamps to a torque of 48 ± 10 N·m (35 ± 7 lb ft).