Caterpillarunderground articulated truck(no series)
Caterpillar AE40 II
Maintenance schedule, common problems & OEM parts breakdown
The Caterpillar AE40 II is a specialized underground articulated dump truck designed for high-production hard-rock mining. This machine features a 3408E HEUI diesel engine delivering 490 hp (net) and utilizes a Tele-Tram ejector box with a hydraulic controlled tailgate. It operates within a payload capacity of approximately 88,000 lb (39,916 kg) with a heaped capacity of 24.1 yd³ (18.4 yd³). The series is characterized by its heavy-duty configuration, including Caterpillar powershift transmissions, torque converters, and enclosed multi-disc liquid-cooled brakes.
The AE40 II represents an evolution in underground hauling, focusing on durability in rugged, low-clearance environments. While the base AE40 series established the platform's capability, the Series II incorporates specific refinements to the engine arrangement and chassis for improved mining efficiency. In today's secondary market, this machine is a critical asset for fleet managers seeking reliable, high-capacity underground transport. Its value is driven by the availability of heavy-duty components like the 340 and 3500 series compatible parts and its proven ability to handle abrasive materials in extreme mining conditions.
Below: full specifications, fluids & capacities, the factory service schedule, common service parts, verified fault codes, what owners discuss, attachment guidance, the complete assembly directory, and a serial-number reference. Complete parts lists with full OEM part numbers, exploded diagrams, quantities, and fitment data are available free in Heavy Parts AI.
Caterpillar AE40 II specifications
Engine
| Engine Model | 3408E HEUI |
| Gross Power | 490 hp |
Weights
| Total Empty Weight | 92,170 lb |
| Total Loaded Weight | 180,370 lb |
| Rated Payload | 88,000 lb |
Dimensions
| Overall Length | 36.96 ft |
| Overall Width | 10.5 ft |
| Overall Height | 9.49 ft |
| Ground Clearance | 1.49 ft |
| Dump Height | 8.73 ft |
| Heaped Capacity | 24.1 yd³ |
Performance
| Maximum Speed | 29.9 mph |
| Transmission Gears | 8 forward, 2 reverse |
Service capacities (summary)
| Fuel Capacity | 158.6 gal |
Values vary by configuration, region, and serial range — confirm against your machine before planning transport or lifts.
AE40 II fluids & capacities
| System | Capacity | Recommended fluid |
|---|---|---|
| Engine Crankcase | Not specified | Cat DEO (Diesel Engine Oil). Use SAE 10W-30 for ambient temperatures between -18°C (0°F) and 40°C (104°F). For extreme cold, use SAE 0W-40. For hot climates, use SAE 50. |
| Cooling System | Not specified | Cat ELC (Extended Life Coolant) |
| Transmission/Powertrain | Not specified | Cat TDTO (Transmission/Drive Train Oil). Use Cat TDTO Cold Weather for operations below -25°C (-13°F). |
| Final Drives | Not specified | Cat TDTO (Transmission/Drive Train Oil) |
| Hydraulic System and Tank | Not specified | Cat HYDO Advanced. Use Cat HYDO Advanced 10 (SAE 10W) for cold to moderate temperatures; use Cat HYDO Advanced 30 (SAE 30W) for moderate to hot temperatures. |
| Grease | Not specified | Cat Multipurpose Grease for low-load/low-speed; Cat Advanced 3Moly Grease for medium-load/medium-speed; Cat Ultra 5Moly Grease for high-load/high-speed. |
Capacities are refill values from factory literature — always fill to the dipstick/sight gauge, not the number.
Caterpillar AE40 II maintenance schedule
| Service interval | Tasks |
|---|---|
| Every 10 h |
|
| Every 250 h |
|
| Every 500 h |
|
| Every 1,000 h |
|
| Every 2,000 h |
|
Servicing the AE40 II beyond the schedule
Predictive Maintenance & Fluid Analysis
Utilize Caterpillar S.O.S Services to monitor engine oil, hydraulic fluid, and transmission oil. Analyze wear metals such as iron or copper to detect early pump or gear degradation. Monitor coolant for sodium or silicon to identify potential leaks. Regular hydraulic oil sampling is critical to prevent particle contamination that destroys high-pressure valves and cylinders.
Corrective & Common Repairs
Address electrical instability by inspecting wiring harnesses and ground connections. Monitor the 3408E HEUI engine for injector flow issues or rough operation, which may require electronic diagnostic tools like CAT ET. If hydraulic performance drops, inspect for air ingestion or cavitation. Ensure all brake system components, specifically multi-disc liquid-cooled units, are free from debris.
Overhaul & Rebuild Points
Plan major component evaluations during 2,000-hour intervals. Focus on the turbocharger assembly and engine valve trains. Inspect the articulation joint and steering pins for excessive play that necessitates replacement. When rebuilding final drives or differentials, verify all seals and bearings to prevent catastrophic failure of the drivetrain under high-load underground hauling cycles.
Seasonal & Environment Servicing
In dusty or quarry environments, check air filter restriction indicators daily and clean radiator fins frequently. For high-altitude operations, inspect turbocharger and exhaust manifold components for heat stress. In extreme cold, utilize appropriate Caterpillar Arctic grease and ensure fuel quality is maintained to prevent waxing in the fuel system.
AE40 II common service parts
| Part number | Part | Notes | |
|---|---|---|---|
| 253-5431 | Exhaust Ar-Particulate Filter | Scheduled service item | Check fitment → |
Always confirm against your machine's serial number — cross-check any part in Heavy Parts AI before ordering.
AE40 II fault codes & troubleshooting
| Code | Meaning | Likely cause | What to do |
|---|---|---|---|
| E360 | Engine Coolant Temperature — High | Low coolant level, failed thermostat, or water pump issue | Diagnose cooling system; do not operate until resolved |
| E361 | Engine Coolant Temperature — Very High (Shutdown) | Severe cooling system failure | Perform full cooling system diagnosis; engine shutdown required |
| 110-0 | Engine Coolant Temp — Above Normal | Low coolant level or thermostat failure | Inspect cooling system, refill coolant, and test thermostat |
| 110-3 | Engine Coolant Temp Sensor — Voltage High | Open circuit or sensor failure | Check wiring and replace sensor if confirmed faulty |
| 174-3 | Engine Fuel Temperature — Voltage Above Normal | Open circuit in sensor wiring | Inspect harness and replace sensor if necessary |
| 190-8 | Engine Speed — Abnormal Frequency | Speed sensor air gap, sensor failure, or tone ring damage | Check sensor gap and test speed sensor/tone ring |
| 2458-2 | DPF #1 Differential Pressure — Erratic | Plugged pressure ports or failing sensor | Clean pressure ports and test sensor; verify DPF soot load |
| 41-3 | 8-Volt DC Supply — Voltage Above Normal | Short to power on 8V reference circuit | Inspect sensors sharing the 8V supply and isolate fault |
| 41-4 | 8-Volt DC Supply — Voltage Below Normal | Short to ground on 8V reference circuit | Disconnect sensors one at a time to locate short |
| 2348-9 | SAE J1939 Data Link #2 — Abnormal Update Rate | CAN bus wiring damage or termination fault | Check CAN wiring and measure termination resistance |
Codes and remedies are general guidance for this model family — always confirm with diagnostic tooling and your dealer before major repairs.
AE40 II attachments & work tools
Body and Dump Configurations
Standard configurations include steel or aluminum bodies for handling abrasive versus non-abrasive materials. The machine features a rated payload of 88,000 lb (39,916 kg) and a heaped capacity of 24.1 yd³ (18.41 m³).
Exhaust and Emission Systems
Available configurations include an exhaust group with a particulate filter for specific serial ranges. High-altitude operations may utilize specialized turbocharger and air inlet manifolds.
Hydraulic and Engine Components
The machine is powered by a Caterpillar 3408E HEUI engine producing 490 hp (365 kW). Hydraulic systems are integrated with solenoid valve groups for operational control.
All AE40 II assemblies by section
Every catalogued assembly group for the Caterpillar AE40 II. Open an assembly to preview the parts inside — full OEM part numbers are available in Heavy Parts AI.
Air Inlet And Exhaust System
1267290 - Aftercooler Gp-Water
| 12***90 | Aftercooler Group-Water | 1 |
1882189 - Air Cleaner Gp
| 18***89 | Air Cleaner Group | 1 |
1w1653 - Cartridge Gp-Turbocharger
| 1W***53 | Cartridge Group-Turbocharger | 1 |
2535431 - Exhaust Ar-Particulate Filter
| 22***17 | Exhaust Group-Particulate Filter | 1 |
| 25***29 | Lines Group-Exhaust Back Pressure | 1 |
| 25***30 | Alarm Group | 1 |
2272717 - Exhaust Gp-Particulate Filter
| 22***17 | Exhaust Group-Particulate Filter | 1 |
2026737 - Exhaust Gp-Purifier
| 20***37 | Exhaust Group-Purifier | 1 |
2246083 - Guard Gp-Lines
| 22***83 | Guard Group-Lines | 1 |
2408755 - Lines Gp-Air (High Altitude)
| 24***55 | Lines Group-Air | 1 |
1267288 - Lines Gp-Air
| 12***88 | Lines Group-Air | 1 |
2535429 - Lines Gp-Exhaust Back Pressure
| 25***29 | Lines Group-Exhaust Back Pressure | 1 |
1883161 - Lines Gp-Water Injection
| 18***61 | Lines Group-Water Injection | 1 |
1660164 - Manifold Gp-Exhaust
| 16***64 | Manifold Group-Exhaust | 1 |
1944972 - Shield Gp-Heat (Manifold & Turbocharger)
| 19***72 | Shield Group-Heat | 1 |
2408758 - Turbocharger Ar (High Altitude)
| 24***55 | Lines Group-Air | 1 |
| 24***58 | Turbocharger Ar | 1 |
| 24***31 | Turbocharger Group | 1 |
1w5580 - Turbocharger Gp
| 1W***80 | Turbocharger Group | 1 |
1831199 - Turbocharger Gp (High Altitude)
| 18***99 | Turbocharger Group | 1 |
2411131 - Turbocharger Gp (High Altitude)
| 24***31 | Turbocharger Group | 1 |
1279177 - Turbocharger Gp
| 12***77 | Turbocharger Group | 1 |
Basic Engine
1884243 - Belt Tightener Gp
| 18***43 | Belt Tightener Group | 1 |
1081547 - Camshaft Gp
| 10***47 | Camshaft Group | 1 |
1295242 - Cover Gp-Cylinder Block
| 12***42 | Cover Group-Cylinder Block | 1 |
4n6876 - Cover Gp-Flywheel Housing
| 4N***76 | Cover Group-Flywheel Housing; Flywheel Housing Cover Group | 1 |
1260768 - Cover Gp-Front Housing
| 12***68 | Cover Group-Front Housing | 1 |
1884267 - Cover Gp-Oil Pan
| 18***67 | Cover Group-Oil Pan | 1 |
1295243 - Cover Gp-Valve Mechanism
| 12***43 | Cover Group-Valve Mechanism | 1 |
1w5009 - Crankshaft As
| 1W***09 | Crankshaft As | 1 |
1w5010 - Crankshaft Gp
| 1W***10 | Crankshaft Group; Crankshaft Group | 1 |
1179509 - Cylinder Block As
| 11***09 | Cylinder Block As | 1 |
1099009 - Cylinder Block Gp
| 10***09 | Cylinder Block Group | 1 |
1433613 - Cylinder Head As
| 14***13 | Cylinder Head As | 1 |
1433614 - Cylinder Head As
| 14***14 | Cylinder Head As | 1 |
1928886 - Cylinder Head Gp
| 19***86 | Cylinder Head Group | 1 |
1928887 - Cylinder Head Gp
| 19***87 | Cylinder Head Group | 1 |
1w0998 - Damper Gp
| 1W***98 | Damper Group | 1 |
1884270 - Drive Gp-Fan
| 18***70 | Drive Group-Fan | 1 |
9y1569 - Flywheel Gp
| 9Y***69 | Flywheel Group | 1 |
1267281 - Gear Gp-Front
| 12***81 | Gear Group-Front | 1 |
1884244 - Gear Gp-Rear
| 18***44 | Gear Group-Rear | 1 |
1884269 - Housing Gp-Flywheel
| 18***69 | Housing Group-Flywheel | 1 |
1267280 - Housing Gp-Front
| 12***80 | Housing Group-Front | 1 |
1267279 - Lifting Gp-Engine
| 12***79 | Lifting Group-Engine | 1 |
1884891 - Mounting Gp-Alternator
| 18***91 | Mounting Group-Alternator | 1 |
1882191 - Mounting Gp-Engine (Rear)
| 18***91 | Mounting Group-Engine | 1 |
1884893 - Mounting Gp-Engine (Front)
| 18***93 | Mounting Group-Engine | 1 |
6i3744 - Pan Gp-Oil
| 6I***44 | Pan Group-Oil; -Engine | 1 |
1928808 - Piston & Rod Gp
| 19***08 | Piston & Rod Group | 1 |
1884890 - Platform Gp-Engine
| 18***90 | Platform Group-Engine | 1 |
1267278 - Plug Gp-Cylinder Block
| 12***78 | Plug Group-Cylinder Block | 1 |
1244456 - Plug Gp-Cylinder Head
| 12***56 | Plug Group-Cylinder Head | 1 |
1884873 - Pulley Gp
| 18***73 | Pulley Group | 1 |
1071954 - Rocker Arm Gp
| 10***54 | Rocker Arm Group | 1 |
7e6385 - Support Gp-Engine
| 7E***85 | Support Group-Engine; -Front | 1 |
4n4303 - Trunnion Gp-Engine
| 4N***03 | Trunnion Group-Engine; Engine Trunnion Group | 1 |
1081551 - Valve Mechanism Gp
| 10***51 | Valve Mechanism Group | 1 |
Cooling System
1889593 - Coolant Conditioner Gp
| 18***93 | Coolant Conditioner Group | 1 |
1877315 - Core Gp-Oil Cooler
| 18***15 | Core Group-Oil Cooler | 1 |
1414109 - Core Gp-Oil Cooler
| 14***09 | Core Group-Oil Cooler; -Brake, Frame Mount-Transmission, Engine Mount-Tc, Bk, Hoist, Engine Mount | 1 |
1889580 - Drain Gp-High Speed Fluid (Radiator Evacuation)
| 18***80 | Drain Group-High Speed Fluid | 1 |
1882190 - Fan Gp-Blower
| 18***90 | Fan Group-Blower | 1 |
2007472 - Lines Gp-Brake Oil Cooler (Rear)
| 20***72 | Lines Group-Brake Oil Cooler | 1 |
2033948 - Lines Gp-Brake Oil Cooler (Front)
| 20***48 | Lines Group-Brake Oil Cooler | 1 |
1877319 - Lines Gp-Brake Oil Cooler
| 18***19 | Lines Group-Brake Oil Cooler | 1 |
1877318 - Lines Gp-Steering Oil Cooler
| 18***18 | Lines Group-Steering Oil Cooler | 1 |
1870766 - Lines Gp-Tmsn Oil Cooler
| 18***66 | Lines Group-Tmsn Oil Cooler | 1 |
1873377 - Lines Gp-Torque Conv Cooler
| 18***77 | Lines Group-Torque Conv Cooler | 1 |
1884896 - Lines Gp-Water
| 18***96 | Lines Group-Water | 1 |
1889976 - Lines Gp-Water
| 18***76 | Lines Group-Water | 1 |
1338404 - Lines Gp-Water
| 13***04 | Lines Group-Water; -Oil Cooler | 1 |
1371338 - Pump Gp-Water
| 13***38 | Pump Group-Water | 1 |
4n1951 - Pump Gp-Water
| 4N***51 | Pump Group-Water; Water Pump Group | 1 |
1882194 - Radiator Gp-Basic
| 18***94 | Radiator Group | 1 |
1964286 - Radiator Gp
| 19***86 | Radiator Group | 1 |
Electrical And Starting System
9g9813 - Alarm Gp
| 9G***13 | Alarm Group; -Action-Action, Engine Overspeed | 1 |
2535430 - Alarm Gp-Exhaust Back Press
| 25***30 | Alarm Group | 1 |
3e7577 - Alternator Gp-Charging
| 3E***77 | Alternator Group-Charging | 1 |
2235602 - Battery & Wiring Gp
| 22***02 | Battery & Wiring Group | 1 |
1838825 - Battery & Wiring Gp
| 18***25 | Battery & Wiring Group | 1 |
2232340 - Control & Mtg Gp-Engine Elek
| 22***40 | Control & Mtg Group-Engine Elek | 1 |
2070013 - Control Gp-Ejector Electronic
| 20***13 | Control Group-Ejector Electronic | 1 |
1567171 - Control Gp-Engine Electronic
| 15***71 | Control Group-Engine Electronic | 1 |
| 15***72 | Control Group-Engine Electronic | 1 |
1567172 - Control Gp-Engine Electronic
| 15***72 | Control Group-Engine Electronic | 1 |
2070754 - Electrical Ar
| 18***25 | Battery & Wiring Group | 1 |
| 18***07 | Lighting Group-Front | 1 |
| 18***08 | Horn Group-Electric | 1 |
1858308 - Horn Gp-Electric
| 18***08 | Horn Group-Electric | 1 |
8c9678 - Lamp Gp-Dome
| 8C***78 | Lamp Group-Dome; -With Switch | 1 |
1568363 - Lamp Gp-Dome
| 15***63 | Lamp Group-Dome | 1 |
9x1439 - Lamp Gp-Flood
| 9X***39 | Lamp Group-Flood; -Rear-Ladder Access-Engine Work Light | 1 |
5i8250 - Lamp Gp-Flood
| 5I***50 | Lamp Group-Flood; -Boom | 1 |
9x7170 - Lamp Gp-Head
| 9X***70 | Lamp Group-Head; -High Beam | 1 |
9x7169 - Lamp Gp-Head
| 9X***69 | Lamp Group-Head; -Low Beam | 1 |
1860418 - Lighting Gp-Cab
| 18***18 | Lighting Group-Cab | 1 |
1858307 - Lighting Gp-Front
| 18***07 | Lighting Group-Front | 1 |
1891038 - Lighting Gp-Rear
| 18***38 | Lighting Group-Rear | 1 |
1173915 - Motor Gp-Elec Hyd Pump
| 11***15 | Motor Group-Electric; -Engine Prelubrication-Sec Steering, Brake Release | 1 |
1877293 - Mounting Gp-Camera (Color)
| 18***93 | Mounting Group-Camera | 1 |
1877290 - Mounting Gp-Camera (Color)
| 18***90 | Mounting Group-Camera | 1 |
1884266 - Mounting Gp-Wiring (Engine)
| 18***66 | Mounting Group-Wiring | 1 |
1863437 - Panel Gp-Circuit Breaker
| 18***37 | Panel Group-Circuit Breaker | 1 |
1859239 - Sender Gp (Fuel)
| 18***39 | Sender Group | 1 |
1970767 - Sensor & Switch Gp
| 19***67 | Sensor & Switch Group | 1 |
2160280 - Sensor Gp-Tmsn Position
| 21***80 | Sensor Group-Position; (Transmission Speed) | 1 |
2661466 - Sensor Gp-Position
| 26***66 | Sensor Group-Position; -Throttle | 1 |
1267896 - Sensor Gp-Tmsn Position
| 12***96 | Sensor Group-Position; -Transmission Shift Lever | 1 |
1638530 - Sensor Gp-Pressure
| 16***30 | Sensor Group-Pressure; -Atmospheric Air | 1 |
1946725 - Sensor Gp-Pressure (Oil)
| 19***25 | Sensor Group-Pressure; -Engine Oil | 1 |
3q6838 - Sensor Gp-Speed
| 3Q***38 | Sensor Group-Speed | 1 |
1060735 - Sensor Gp-Temperature
| 10***35 | Sensor Group-Temperature; -Engine Oil | 1 |
2371962 - Starting Motor Gp-Electric
| 23***62 | Starting Motor Group-Electric | 1 |
4n1061 - Starting Motor Gp-Electric
| 4N***61 | Starting Motor Group-Electric | 1 |
7n0718 - Switch As-Disconnect (2 Post)
| 7N***18 | Switch As-Disconnect; -Battery-Ground Level | 1 |
2285697 - Switch Gp-Brake (Push To Engage Parking)
| 22***97 | Switch Group-Brake | 1 |
2285696 - Switch Gp-Brake (Pull To Engage Parking)
| 22***96 | Switch Group-Brake | 1 |
1718708 - Switch Gp-Flow
| 17***08 | Switch Group-Flow; -Engine Coolant | 1 |
1004417 - Switch Gp-Flow
| 10***17 | Switch Group-Flow; -Engine Coolant | 1 |
1891435 - Switch Gp-Tailgate Control
| 18***35 | Switch Group-Tailgate Control | 1 |
2033967 - Switch Gp-Wiper
| 20***67 | Switch Group-Wiper | 1 |
1891349 - Warning Gp-Backup
| 18***49 | Warning Group-Backup | 1 |
1863436 - Wiring Gp-Auto Retarder
| 18***36 | Wiring Group-Auto Retarder | 1 |
2199045 - Wiring Gp-Cab (Lower)
| 21***45 | Wiring Group-Cab | 1 |
1860419 - Wiring Gp-Cab (Upper)
| 18***19 | Wiring Group-Cab | 1 |
2070012 - Wiring Gp-Cab (Lower)
| 20***12 | Wiring Group-Cab | 1 |
1214082 - Wiring Gp-Engine Electronic
| 12***82 | Wiring Group-Engine Electronic | 1 |
1883163 - Wiring Gp-Fire Suppression (Engine Shutdown)
| 18***63 | Wiring Group-Fire Suppression | 1 |
1956175 - Wiring Gp-Front
| 19***75 | Wiring Group-Front | 1 |
2569416 - Wiring Gp-Front
| 25***16 | Wiring Group-Front | 1 |
1891348 - Wiring Gp-Rear
| 18***48 | Wiring Group-Rear | 1 |
1090401 - Wiring Gp-Unit Injector
| 10***01 | Wiring Group-Unit Injector | 1 |
Engine Arrangement
1905219 - Conversion Ar-Engine
| 10***90 | Switch Group-Temperature; -Engine Coolant | 1 |
| 16***94 | Engine Ar-Complete | 1 |
| 18***43 | Belt Tightener Group | 1 |
1658094 - Engine Ar-Complete
| 10***17 | Switch Group-Flow; -Engine Coolant | 1 |
| 10***47 | Camshaft Group | 1 |
| 10***51 | Valve Mechanism Group | 1 |
2026738 - Installation Ar-Engine
| 18***89 | Air Cleaner Group | 1 |
| 18***90 | Fan Group-Blower | 1 |
| 18***91 | Mounting Group-Engine | 1 |
Frame And Body
2089511 - Body Gp-Ejector (20.8m3 Sae)
| 20***11 | Body Group-Ejector | 1 |
1895667 - Body Gp-Ejector (22.9m3 Sae)
| 18***67 | Body Group-Ejector | 1 |
1989040 - Body Gp-Ejector (22.9m3 Sae)
| 19***40 | Body Group-Ejector | 1 |
1895668 - Body Gp-Ejector (17.7m3 Sae)
| 18***68 | Body Group-Ejector | 1 |
1896000 - Body Gp-Ejector (20.8m3 Sae)
| 18***00 | Body Group-Ejector | 1 |
1895669 - Body Gp-Ejector (18.4m3 Sae)
| 18***69 | Body Group-Ejector | 1 |
2070005 - Chassis Ar
| 18***61 | Fender Group-Front | 1 |
| 18***38 | Control Group-Brake | 1 |
| 18***77 | Cylinder & Mtg Group-Steering | 1 |
2026741 - Cover Gp-Deck
| 20***41 | Cover Group-Deck | 1 |
1853261 - Fender Gp-Front
| 18***61 | Fender Group-Front | 1 |
2113341 - Filter Gp-Grease
| 21***41 | Filter Group-Grease | 1 |
1854683 - Fire Extinguisher Gp (9.0kg)
| 18***83 | Fire Extinguisher Group | 1 |
2018742 - Fire Extinguisher Gp (9.0 Litre Foam)
| 20***42 | Fire Extinguisher Group | 1 |
1871517 - Fire Extinguisher Gp (4.5kg)
| 18***17 | Fire Extinguisher Group | 1 |
2345257 - Firewall Gp
| 23***57 | Firewall Group | 1 |
2030007 - Frame Gp-Engine End
| 20***07 | Frame Group-Engine End | 1 |
2130517 - Frame Gp-Engine End
| 21***17 | Frame Group-Engine End | 1 |
1854686 - Frame Gp-Suspension
| 18***86 | Frame Group-Suspension | 1 |
1854687 - Guard Gp-Bottom
| 18***87 | Guard Group-Bottom | 1 |
1891996 - Guard Gp-Ejector Cylinder
| 18***96 | Guard Group-Ejector Cylinder | 1 |
1961407 - Guard Gp-Radiator
| 19***07 | Guard Group-Radiator | 1 |
1855958 - Hitch Gp-Oscillating
| 18***58 | Hitch Group-Oscillating | 1 |
1898512 - Hood Gp
| 18***12 | Hood Group | 1 |
1896014 - Liner Gp-Body
| 18***14 | Liner Group-Body | 1 |
1871902 - Lines Gp-Central Lubrication (Hitch)
| 18***02 | Lines Group-Central Lubrication | 1 |
1898510 - Lines Gp-Central Lubrication (Tailgate)
| 18***10 | Lines Group-Central Lubrication | 1 |
1871895 - Lines Gp-Central Lubrication (Suspension)
| 18***95 | Lines Group-Central Lubrication | 1 |
1871901 - Lines Gp-Central Lubrication (Front)
| 18***01 | Lines Group-Central Lubrication | 1 |
1898511 - Lines Gp-Central Lubrication (Rear)
| 18***11 | Lines Group-Central Lubrication | 1 |
2068933 - Lines Gp-Fire Suppression (Retardant)
| 20***33 | Lines Group-Fire Suppression | 1 |
2275231 - Lines Gp-Fire Suppression (Dry Powder System)
| 22***31 | Lines Group-Fire Suppression | 1 |
2364717 - Lines Gp-Fire Suppression (Retardant)
| 23***17 | Lines Group-Fire Suppression | 1 |
2068932 - Lines Gp-Fire Suppression (Detonation)
| 20***32 | Lines Group-Fire Suppression | 1 |
2068934 - Lines Gp-Fire Suppression (Auto Detonation)
| 20***34 | Lines Group-Fire Suppression | 1 |
2575211 - Lines Gp-Lubrication
| 25***11 | Lines Group-Lubrication | 1 |
1896033 - Lines Gp-Lubrication (Bank 3)
| 18***33 | Lines Group-Lubrication | 1 |
1871571 - Lines Gp-Lubrication (Bank 1)
| 18***71 | Lines Group-Lubrication | 1 |
1898947 - Lines Gp-Lubrication
| 18***47 | Lines Group-Lubrication | 1 |
1896044 - Lines Gp-Lubrication
| 18***44 | Lines Group-Lubrication | 1 |
1871897 - Lines Gp-Lubrication (Bank 2)
| 18***97 | Lines Group-Lubrication | 1 |
1896031 - Lines Gp-Lubrication (Bank 4 & 5)
| 18***31 | Lines Group-Lubrication | 1 |
1858312 - Link Gp-Steering Frame Lock
| 18***12 | Link Group-Steering Frame Lock | 1 |
2632231 - Lubrication Ar-Automatic (Hydraulic)
| 26***31 | Lubrication Ar-Automatic | 1 |
1898948 - Lubrication Ar-Automatic (Electric)
| 18***48 | Lubrication Ar-Automatic | 1 |
2632955 - Lubrication Ar-Automatic (Hydraulic)
| 18***54 | Pump Group-Lubrication | 1 |
| 18***71 | Lines Group-Lubrication | 1 |
| 18***95 | Lines Group-Central Lubrication | 1 |
1898939 - Lubrication Ar-Central
| 18***39 | Lubrication Ar-Central | 1 |
1858311 - Mounting Gp-Cab
| 18***11 | Mounting Group-Cab | 1 |
2130939 - Mounting Gp-Cab
| 21***39 | Mounting Group-Cab | 1 |
1716045 - Pump Gp-Lubrication
| 17***45 | Pump Group-Lubrication | 1 |
2113336 - Pump Gp-Lubrication
| 21***36 | Pump Group-Lubrication | 1 |
2574382 - Pump Gp-Lubrication (Hydraulic)
| 25***82 | Pump Group-Lubrication | 1 |
1856454 - Pump Gp-Lubrication
| 18***54 | Pump Group-Lubrication | 1 |
2068931 - Suppression Ar-Fire
| 20***31 | Suppression Ar-Fire | 1 |
| 20***32 | Lines Group-Fire Suppression | 1 |
| 20***33 | Lines Group-Fire Suppression | 1 |
1857247 - Suspension Gp-Front
| 18***47 | Suspension Group-Front | 1 |
2238456 - Suspension Gp-Front
| 22***56 | Suspension Group-Front; (Cylinder) | 1 |
1857246 - Suspension Gp-Front
| 18***46 | Suspension Group-Front | 1 |
2076171 - Tread Gp-Nonskid
| 20***71 | Tread Group-Nonskid | 1 |
5t5009 - Valve Gp-Lube Distribution
| 5T***09 | Valve Group-Lube Distribution; -3-Injector-Steering Cyl, Linkage, Rh, Lh-Hoist, Rear Susp Cyl, Rh, Lh-Front Susp, Steer Cyl, Rh, Lh | 1 |
5t5010 - Valve Gp-Lube Distribution
| 5T***10 | Valve Group-Lube Distribution; -5-Injector | 1 |
Fuel System
1883162 - Adapter Gp-Fast Fill Fuel
| 18***62 | Adapter Group-Fast Fill Fuel | 1 |
2038825 - Adapter Gp-Fast Fill Fuel
| 20***25 | Adapter Group-Fast Fill Fuel, . Shoe; Grouser (500g) | 1 |
1883164 - Adapter Gp-Fuel Fill
| 18***64 | Adapter Group-Fuel Fill | 1 |
1529139 - Drive Gp-Unit Inj Hyd Pump
| 15***39 | Drive Group-Unit Inj Hydraulic Pump | 1 |
1747527 - Injector Gp-Fuel
| 17***27 | Injector Group-Fuel | 1 |
1946269 - Lines Gp-Fuel
| 19***69 | Lines Group-Fuel | 1 |
1886367 - Lines Gp-Fuel Filter
| 18***67 | Lines Group-Fuel Filter | 1 |
1214034 - Lines Gp-Injector Hyd Pump
| 12***34 | Lines Group-Injector Hydraulic Pump | 1 |
1267292 - Pump & Mtg Gp-Unit Inj Hyd
| 12***92 | Pump & Mtg Group-Unit Inj Hydraulic | 1 |
1087090 - Pump Gp-Fuel Injection
| 10***90 | Pump Group-Fuel Injection | 1 |
1884894 - Pump Gp-Fuel Prm & Prim Filter
| 18***94 | Pump Group-Fuel Prm & Prim Filter | 1 |
2352024 - Pump Gp-Unit Injector Hyd
| 23***24 | Pump Group-Unit Injector Hydraulic | 1 |
1691034 - Pump Gp-Unit Injector Hyd
| 16***34 | Pump Group-Unit Injector Hydraulic | 1 |
2014201 - Pump Gp-Unit Injector Hyd
| 20***01 | Pump Group-Unit Injector Hydraulic | 1 |
1440835 - Pump Gp-Unit Injector Hyd
| 14***35 | Pump Group-Unit Injector Hydraulic | 1 |
2250568 - Pump Gp-Unit Injector Hyd
| 22***68 | Pump Group-Unit Injector Hydraulic | 1 |
2821915 - Valve Gp-Check
| 28***15 | Valve Group-Check; -Fuel | 1 |
1070677 - Valve Gp-Solenoid
| 10***77 | Valve Group-Solenoid; -Pressure Control | 1 |
Lubrication System
1889213 - Drain Gp-High Speed Fluid (Engine Sump Evacuation)
| 18***13 | Drain Group-High Speed Fluid | 1 |
1198583 - Fastener Gp-Oil Pump Mounting
| 11***83 | Fastener Group-Oil Pump Mounting; -Engine | 1 |
1884298 - Filler Gp-Oil
| 18***98 | Filler Group-Engine Oil | 1 |
1295246 - Filter Gp-Engine Oil
| 12***46 | Filter Group-Engine Oil | 1 |
1884271 - Fumes Disposal Gp
| 18***71 | Fumes Disposal Group | 1 |
1884273 - Gauge Gp-Oil Level (Dipstick)
| 18***73 | Gauge Group-Oil Level | 1 |
1295245 - Lines Gp-Engine Oil
| 12***45 | Lines Group-Engine Oil | 1 |
1267286 - Lines Gp-Turbocharger Oil
| 12***86 | Lines Group-Turbocharger Oil | 1 |
1161980 - Pump Gp-Engine Oil
| 11***80 | Pump Group-Engine Oil | 1 |
Machine Arrangement
2070686 - Common Ar
| 19***19 | Conversion Ar-Engine | 1 |
| 20***38 | Installation Ar-Engine | 1 |
| 20***05 | Chassis Ar | 1 |
Power Train
6p5901 - Manifold Gp-Torque Converter
| 6P***01 | Manifold Group-Torque Converter | 1 |
9w4119 - Actuator Gp-Rotary
| 9W***19 | Actuator Group-Rotary; -Transmission Control Valve | 1 |
1800658 - Axle Ar-Front
| 17***85 | Final Drive & Brake Group | 2 |
| 17***86 | Differential & Bevel Gear Group | 1 |
| 18***58 | Axle Ar-Front | 1 |
2070713 - Axle Ar-Rear
| 17***85 | Final Drive & Brake Group | 2 |
| 17***86 | Differential & Bevel Gear Group | 1 |
| 18***29 | Breather Group-Axle | 1 |
1937736 - Axle Gp-Front
| 19***36 | Axle Group-Front | 1 |
1994469 - Axle Gp-Rear
| 19***69 | Axle Group-Rear | 1 |
1858929 - Breather Gp-Axle
| 18***29 | Breather Group-Axle | 1 |
9u8381 - Case & Parts Gp-Planetary
| 9U***81 | Case Group-Transmission | 1 |
1862647 - Control Gp-Transmission
| 18***47 | Control Group-Transmission | 1 |
8e4966 - Control Gp-Transmission Hyd
| 8E***66 | Control Group-Transmission Hydraulic | 1 |
1789086 - Differential & Bevel Gear Gp
| 17***86 | Differential & Bevel Gear Group | 1 |
1800021 - Differential Gp
| 18***21 | Differential Group | 1 |
2033601 - Drain Gp-High Speed Fluid (Transmission Evacuation)
| 20***01 | Drain Group-High Speed Fluid | 1 |
1749417 - Drive Gp-Input
| 17***17 | Drive Group-Input | 1 |
2034004 - Filler Gp-Power Train Oil
| 20***04 | Filler Group-Power Train Oil | 1 |
7g5000 - Filter Gp-Transmission
| 7G***00 | Filter Group; -Torque Converter-Parking Brake Release-Transmission | 1 |
6p4603 - Filter Gp-Transmission
| 6P***03 | Filter Group-Oil; -Park Brake Release, Xmsn-Parking Brake Release-Rear Brakes | 1 |
1789085 - Final Drive & Brake Gp
| 17***85 | Final Drive & Brake Group | 1 |
2034005 - Gauge Gp-Liquid Level
| 20***05 | Gauge Group-Liquid Level | 1 |
1946055 - Gear & Case Gp-Output Transfer
| 19***55 | Gear & Case Group-Output Transfer | 1 |
1863442 - Lines Gp-Scavenge
| 18***42 | Lines Group-Scavenge | 1 |
1871190 - Lines Gp-Torque Conv Suction
| 18***90 | Lines Group-Torque Conv Suction | 1 |
1871191 - Lines Gp-Torque Converter
| 18***91 | Lines Group-Torque Converter | 1 |
1995158 - Lines Gp-Transmission Oil
| 19***58 | Lines Group-Transmission Oil | 1 |
2388416 - Mounting Gp-Axle (Rear)
| 23***16 | Mounting Group-Axle | 1 |
1937747 - Mounting Gp-Differential
| 19***47 | Mounting Group-Differential | 1 |
1937748 - Mounting Gp-Final Drive
| 19***48 | Mounting Group-Final Drive | 1 |
1946872 - Mounting Gp-Rim
| 19***72 | Mounting Group-Rim | 1 |
9u8383 - Planetary Gp-Transmission
| 9U***83 | Planetary Group-Transmission | 1 |
2070714 - Power Train Ar
| 18***58 | Axle Ar-Front | 1 |
| 18***47 | Control Group-Transmission | 1 |
| 18***42 | Lines Group-Scavenge | 1 |
6t4258 - Pump Gp-Gear (Torque Conv & Brake)
| 6T***58 | Pump Group-Gear; -Converter Charging, Scavenge, & Brake Release | 1 |
6t4257 - Pump Gp-Gear (Torque Conv & Brake)
| 6T***57 | Pump Group-Gear; -Converter Charging, Scavenge, & Brake Release | 1 |
1946874 - Rim Ar
| 19***74 | Rim Ar | 1 |
1946873 - Rim Gp-Demountable
| 19***73 | Rim Group-Demountable | 1 |
1900865 - Shaft Gp-Drive
| 19***65 | Shaft Group-Drive | 1 |
1873741 - Shaft Gp-Drive
| 18***41 | Shaft Group-Drive | 1 |
1900866 - Shaft Gp-Drive
| 19***66 | Shaft Group-Drive | 1 |
1873383 - Shaft Gp-Drive (Upper)
| 18***83 | Shaft Group-Drive | 1 |
2070712 - Shaft Gp-Drive
| 20***12 | Shaft Group-Drive | 1 |
1873745 - Shaft Gp-Drive (Oscillation)
| 18***45 | Shaft Group-Drive | 1 |
3q6837 - Shaft Gp-Main
| 3Q***37 | Shaft Group-Main | 1 |
7u2259 - Slip Joint Gp
| 7U***59 | Slip Joint Group | 1 |
7u2239 - Slip Joint Gp
| 7U***39 | Slip Joint Group | 1 |
7u2258 - Slip Joint Gp
| 7U***39 | Slip Joint Group | 1 |
| 7U***58 | Slip Joint Group | 1 |
| 7U***59 | Slip Joint Group | 1 |
1859854 - Support Gp-Differential (Front)
| 18***54 | Support Group-Differential | 1 |
1860420 - Support Gp-Differential (Rear)
| 18***20 | Support Group-Differential | 1 |
1874165 - Support Gp-Transmission (Upper)
| 18***65 | Support Group-Transmission | 1 |
2085641 - Support Gp-Transmission (Lower)
| 20***41 | Support Group-Transmission | 1 |
1876404 - Tire Gp
| 18***04 | Tire Group | 1 |
1876405 - Tire Gp
| 18***05 | Tire Group | 1 |
1876406 - Tire Gp
| 18***06 | Tire Group | 1 |
| 24***00 | Tire-29.5x29 ** Vsnt E4e2a | 4 |
2388417 - Tire Gp
| 17***43 | Tire Group | 1 |
| 23***16 | Mounting Group-Axle | 1 |
| 23***17 | Tire Group | 1 |
1793743 - Tire Gp
| 17***43 | Tire Group | 1 |
1898513 - Torque Converter & Updrive Gp
| 18***13 | Torque Converter & Updrive Group | 1 |
1807972 - Torque Converter Gp
| 18***72 | Torque Converter Group | 1 |
1944880 - Transmission Ar
| 19***80 | Transmission Ar | 1 |
1951027 - Valve Gp-Drain
| 19***27 | Valve Group-Drain | 1 |
6i9514 - Valve Gp-Lockup Clutch & Sol
| 6I***14 | Valve Group-Lockup Clutch & Sol | 1 |
8e4963 - Valve Gp-Selector & Press Cont
| 8E***63 | Valve Group-Pressure Control | 1 |
3p0348 - Valve Gp-Relief
| 3P***48 | Valve Group-Relief; -Torque Converter Inlet | 1 |
8p1471 - Valve Gp-Relief
| 8P***71 | Valve Group-Relief; -Torque Converter Outlet | 1 |
9u8847 - Valve Gp-Selector & Press Cont
| 9U***47 | Valve Group-Selector & Press Cont; -Transmission | 1 |
1446292 - Valve Gp-Solenoid
| 14***92 | Valve Group-Solenoid; -Torque Converter Lockup Clutch | 1 |
8e4965 - Valve Gp
| 8E***65 | Valve Group-Transmission Control | 1 |
AE40 II serial number reference
Locate the machine ID plate on the outer frame of the truck. The prefix consists of the first three alphanumeric characters of the serial number/PIN.
| Prefix | Identifies | Notes |
|---|---|---|
| BLW | AE40 II Underground Articulated Truck | Covers serial range BLW00181-UP. This series is equipped with a Caterpillar 3408E engine. |
| 1ZZ | AE40 Underground Articulated Truck | Covers serial range 1ZZ00001-UP. |
Frequently asked questions
What engine powers the AE40 II?
The machine is equipped with a Caterpillar 3408E HEUI diesel engine producing 490 hp.
What is the total operating weight range?
The shipping weight is approximately 85,554 lb (38,810 kg), with a total loaded weight reaching up to 180,370 lb (81,806 kg).
What model replaced the AE40 series?
Specific successor model names are not documented in the provided technical literature; however, it is part of the Caterpillar underground mining truck lineage.
What AE40 II owners discuss
What are the typical dimensions and ground clearance for a Caterpillar AE40 II?
The machine features an overall length of 36.96 ft, an overall width of 10.5 ft, and an overall height of 9.49 ft. Ground clearance is rated at 1.49 ft.
How does material abrasiveness affect the choice of body material for this truck?
For handling abrasive materials, an aluminum body is ideal for durability; if materials are non-abrasive, a steel body is suitable.
What common engine symptoms should be monitored during operation?
Operators should watch for power loss, excessive smoke (black, white, or blue), and overheating. Black smoke may indicate overfueling or turbo issues; white smoke can signal coolant entry or injector faults; blue smoke often indicates oil burning from worn rings or valve seals.
What are the primary causes of electrical instability in Caterpillar machines?
Electrical issues frequently stem from moisture intrusion into connectors, stressed wiring harnesses, and failing charging systems. Problems can also arise from loose or corroded grounds and battery deterioration.
What should be checked regarding the hydraulic system performance?
Loss of pressure, overheated oil, and jerky movement are indicators of internal leakage or contamination. As hydraulic oil breaks down, pump tolerances suffer, which accelerates component wear.
What is a critical check when purchasing a used AE40 II?
Inspect the engine for excessive smoke during startup and through the breather, as this can indicate internal wear. Additionally, verify the condition of electrical connectors for moisture or corrosion and check the cooling system for potential blockages.
Compiled from owner and technician discussions across the industry — experiences vary by serial range and machine history.
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