D400E Series II Articulated Truck Power Train Caterpillar

Assembly Procedure

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Illustration 1	g00586660

1. Install body (90). Install the O-ring to the body. Tighten the body to a torque of 41 ± 7 N·m (30 ± 5 lb ft).
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   Illustration 2	g00586658

2. Put clean transmission oil onto the outside diameter of valve (88). Install spacer (89) to the valve. Install the valve, spring (87), and cap (86). Tighten the cap to a torque of 41 ± 7 N·m (30 ± 5 lb ft).
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   Illustration 3	g00586657

3. Put clean SAE 30W oil on slug (83). Install ball (85), spring (84) and slug (83). Use Tooling (B) in order to install retaining ring (82) to spool (79).
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   Illustration 4	g00586653

4. Put clean SAE 30W on spool (79). Install shims (81) to the spool. Install spring (80) and spool (79). Refer to Systems Operation/Testing and Adjusting, RENR1507 in order to determine the correct thickness of shims.
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   Illustration 5	g00586651

5. If necessary, install two dowels (78) to support (77). Install the dowels 6.5 ± .25 mm (0.26 ± 0.01 inch) above the surface.

6. Place support (77) into position. Install two bolts (76).
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   Illustration 6	g00586650

7. Install pin (75) to spool (68). If necessary, install dowel (74).
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   Illustration 7	g00586648

8. Install screen (71) to spool (68). Tighten the screen to a torque of 6.1 ± .7 N·m (54 ± 6 lb in). Install cam (70) to spool (68). Install two pins (72) in pin (69) so that the orientation of the inner pins is 90 degrees ± 20 degrees from the slot in the outer pin. Install the pins to the spool. Install the pins 1.0 ± .5 mm (0.04 ± 0.02 inch) below the surface of the spool.
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   Illustration 8	g00586647

9. Put clean SAE 30W oil on spool (68). Install the spool to the valve body.

10. Install bolt (67) and the washer. Tighten the bolt to a torque of 30 ± 7 N·m (22 ± 5 lb ft).

11. Install two springs (66), two retainers (65), and bolts (64). Tighten the bolts to a torque of 30 ± 7 N·m (22 ± 5 lb ft).

12. Loosen bolts (64). Center the roller of springs (66). Align the springs and the notches on the cam.

13. Tighten bolts (64). Tighten the bolts to a torque of 30 ± 7 N·m (22 ± 5 lb ft).
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    Illustration 9	g00586646

14. Use Tooling (A) and a hydraulic press in order to install bearing (63). Install the bearing 3 ± .5 mm (0.12 ± 0.02 inch) above the surface of the housing.
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    Illustration 10	g00587881

15. Lubricate the O-rings. Install the O-rings to plugs (62). Install valves (91) and the plugs.
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    Illustration 11	g00587124

16. Install vane (61) with the notch in a downward position. Install two bolts (60). Do not tighten the bolts at this time.

17. Install SAE 30W oil on all surfaces of rotor (59). Install the rotor.
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    Illustration 12	g00587133

18. Use Tooling (A) in order to install bearing (58) to cover (57). Install the bearing 1.3 ± .25 mm (0.05 ± 0.01 inch) below the surface of the cover.
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    Illustration 13	g00586639

19. Place cover (57) into position on the actuator. Install two bolts (56). Tighten the bolts to a torque of 30 ± 4 N·m (22 ± 3 lb ft).

20. Tighten bolts (60). Refer to Step 16. Tighten the bolts to a torque of 15 ± 3 N·m (11 ± 2 lb ft).

    Note: Check the rotor for binding. The rotor should rotate freely for 300 degrees.

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    Illustration 14	g00587149

21. Install actuator (55) to the valve body. Align slot (91) with dowel (75).
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    Illustration 15	g00586631

22. Install two bolts (54) that secure actuator (55). Tighten the bolts to a torque of 30 ± 4 N·m (22 ± 3 lb ft).
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    Illustration 16	g00586629

23. Lubricate the O-ring. Install the O-ring to seat (51).

24. Install spring (53), ball (52), and seat (51) in spool (46). Use a 8 - 32 threaded rod (50) in order to install the seat.

25. Use Tooling (B) in order to install retaining ring (49).
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    Illustration 17	g00587166

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    Illustration 18	g00587168

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    Illustration 19	g00586628

26. Place spring (47) and spool (46) into position.

27. Lubricate O-ring (48). Install the O-ring to cover (45). Place the cover in position on the valve body. Install the two bolts that secure the cover. Tighten the bolts to a torque of 30 ± 7 N·m (22 ± 5 lb ft).
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    Illustration 20	g00586626

28. Install check valve (42), spring (41), retainer (40) and ring (39) to spool (37).

29. Place shims (44) into position at the end of the spool. Refer to Systems Operation/Testing and Adjusting, RENR1507 in order to determine the correct thickness of shims. Install retaining ring (43).

30. Put clean SAE 30W oil on the outside diameter of spool (37). Install spring (38), spool (37), and cover (36).
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    Illustration 21	g00586624

    Note: Repeat Steps 31 and 32 in order to assemble the spool from each valve group.

31. Install ball (29), spring (30), and retainer (31) in the spool.

32. Install retaining ring (32).
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    Table 2

    Valve Group	Orifice Thickness	Color of Plug	Color of Inner Spring	Color of Outer Spring
    A	4.58 mm (0.180 inch)	Green	Green	Light Blue
    B	2.54 mm (0.10 inch)	Red	Light Blue	Green
    C	4.58 mm (0.180 inch)	Green	Light Blue	Yellow
    E	4.58 mm (0.180 inch)	Red	Yellow	Light Blue
    F	2.54 mm (0.10 inch)	Red	Light Blue	Orange
    G	4.58 mm (0.180 inch)	Green	Light Blue	Light Blue
    H	4.58 mm (0.180 inch)	No Plug	Light Blue	Light Blue

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    Illustration 22	g00586622

    Note: The control valves for each clutch are identified by a letter on the valve body. The letters are located on the outer edge of valve body (15) in front of each valve. It is important to not mix parts between valve groups.

33. Lubricate slug (28) and spool (26) with clean SAE 30W oil. Install the slug to the spool.

34. Install spring (27), spool (26), and stop (25) in valve body (15).

35. Install the O-rings to plugs (24). Install the three plugs to body (17).

36. Lubricate O-ring (23). Install the O-ring. Install orifice (22) and spring (21) to the body.

37. Lubricate pistons (20) with clean SAE 30W oil. Install the inner piston to the outer piston.

38. Install shims (19) and two springs (18) to the end of outer piston (20). Refer to Systems Operation/Testing and Adjusting, RENR1507 in order to determine the correct thickness of shims.

39. Install the outer piston to valve body (17). Position the body to valve body (15). Install two bolts (16) that secure the body.

    Note: Repeat Steps 33 through 39 in order to assemble each valve group.

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    Illustration 23	g00586625

40. Lubricate piston (35) with clean SAE 30W oil . Install the piston to the valve body. Install bolt (33) and washer (34).
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    Illustration 24	g00586621

41. Lubricate the O-rings. Install the O-rings to plugs (13). Install the plugs to selector and pressure control valve (14).
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    Illustration 25	g00586618

42. Use Tooling (A) and a hydraulic press in order to install bearing (12) to the manifold. Install the bearing 0.5 mm (0.02 inch) below the surface. Do not exceed this amount.
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    Illustration 26	g00586617

43. Put 7M-7260 Liquid Gasket on the bore of the manifold. Do not put the gasket material on the lip seal case. Allow the gasket material to become dry. Use Tooling (A) and a mallet in order to install the lip seal. Slightly lubricate the sealing lip of the lip seal.
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    Illustration 27	g00586615

44. Position wire connector (10) and the cover in the manifold. Install two bolts that secure the cover to the manifold.
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    Illustration 28	g00586614

45. Lubricate O-rings (7) and backup rings (8). Install the O-rings and the backup rings to the cartridge.
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    Illustration 29	g00586610

46. Install cartridges (6) to the manifold.
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    Illustration 30	g00586609

47. Install the seals to plug (5). Install the plug to the manifold.

48. Install coils (3) and two nuts (4).

49. Lubricate six O-rings (1). Install the O-rings to manifold (2).

End By:

1. Install the transmission hydraulic control valve. Refer to Disassembly and Assembly, "Transmission Hydraulic Control Valve - Install".