D250E Series II and D300E Series II Articulated Trucks 3306B Engine Supplement Caterpillar

Installation Procedure

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

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Illustration 1	g00437291

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Illustration 2	g00437294

2. Attach tool (A) , Tool (B) and a hoist to lifting eye plate (34) and lifting eye plate (200) . Carefully install the engine and the torque converter as one unit in the machine. The weight of the engine and the torque converter is 1612 kg (3551 lb) .

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Illustration 3	g00437289

3. Position wire clip (199) and mounting bracket (197) to the machine frame. Install three bolts (198) that secure mounting bracket (197) to the machine.

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Illustration 4	g00437288

4. Install bolt (192) , hard washer (195) and mount assembly (196) to the left engine mount. Untie hose bundle (191) .

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Illustration 5	g00437285

5. Install two half clamps (188) on hydraulic hose bundle (191) . Position hydraulic hose bundle (191) and install nut (189) and the bolt that secures two half clamps (188) to mounting bracket (190) .

6. Install hose clamp assembly (194) to hydraulic hose bundle (191) . Install two bolts (193) and the nuts that secure hose clamp assembly (194) to the machine frame.

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Illustration 6	g00437283

7. Install bolt (186) , hard washer (185) and mount assembly (187) to the right hand engine mount.

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Illustration 7	g00437251
This is a view from a point below the engine.

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Illustration 8	g00437262

8. Install bolt (183) , hard washer (182) , mount assembly (181) and nut (184) to the front engine mount.

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Illustration 9	g00437250

9. Install the front half of drive shaft (179) to the machine. Position drive shaft (179) to torque converter (156) . Install four bolts (180) to drive shaft (179) . Bolts (180) must be tightened to a torque of 55 ± 10 N·m (41 ± 7 lb ft) .

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Illustration 10	g00437249

10. Install the O-ring seal to hydraulic hose (178) . Connect hydraulic hose (178) to pressure and flow compensator valve (177) .

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Illustration 11	g00437248

11. Install the O-ring seal to hydraulic hose (174) . Install four bolts (176) and two half clamps (175) in order to connect hydraulic hose (174) to hoist pump (153) .

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Illustration 12	g00437247

12. Install the O-ring seal to hydraulic hose (171) . Install four bolts (172) and two half clamps (173) in order to connect hydraulic hose (171) to steering pump (141) .

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Illustration 13	g00437246

13. Install reusable strap (170) to hoses (169) and (171) .

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Illustration 14	g00437245

14. Install the O-ring seals to hydraulic hoses (166) and (165) . Connect hydraulic hose (166) to torque converter (156) . Install four bolts (167) and two half clamps (168) in order to connect hydraulic hose (165) to torque converter (156) .

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Illustration 15	g00437244

15. Install the O-ring seals to hydraulic hoses (163) and (164) . Connect hydraulic hoses (163) and (164) to torque converter (156) .

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Illustration 16	g00437243

16. Install the O-ring seal to hydraulic hose (162) . Connect hydraulic hose (162) to steering pump (141) .

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Illustration 17	g00437182

17. Install the O-ring seal to hydraulic hose (160) . Connect hydraulic hose (160) to solenoid valve (159) . Install reusable strap (161) to hydraulic hose (160) and the hydraulic pipe.

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Illustration 18	g00437179

18. Install the O-ring seal to hydraulic hose (155) . Install four bolts (154) and two half clamps (157) in order to connect hydraulic hose (155) to torque converter (156) .

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Illustration 19	g00437178

19. Install the O-ring seal to hydraulic hose (150) . Install four bolts (151) and two half clamps (152) in order to connect hydraulic hose (150) to hoist pump (153) . Install reusable strap (149) to hoses (148) and (150) .

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Illustration 20	g00437177

20. Install the O-ring seal to hydraulic hose (145) . Connect hydraulic hose (145) to hose adapter (146) on torque converter screen (147) .

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Illustration 21	g00437175

21. Install the O-ring seal to hydraulic hose (144) . Install four bolts (143) and two half clamps (142) in order to connect hydraulic hose (144) to steering pump (141) .

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Illustration 22	g00437174

22. Connect engine oil drain hose (140) to oil pan (139) .

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Illustration 23	g00437173

23. Install reusable strap (138) to two overflow hoses (137) .

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Illustration 24	g00437172

24. Position wire harness (132) to the engine oil pan. Install bolt (136) .

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Illustration 25	g00437168

25. Connect electrical connection (134) . Install bolt (133) and wire clip (131) in order to secure wire harness (132) to the engine oil pan.

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Illustration 26	g00437167

26. Install the O-ring seal to hydraulic hose (130) . Install four bolts (128) and two half clamps (129) in order to connect hydraulic hose (130) to transmission oil and scavenge pump (127) .

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Illustration 27	g00437166

27. Install the O-ring seal to hydraulic hose (125) . Install four bolts (124) and two half clamps (126) in order to connect hydraulic hose (125) to transmission oil and scavenge pump (127) .

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Illustration 28	g00437165

28. Install the O-ring seal to hydraulic hose (123) . Install four bolts (122) and two half clamps (121) in order to connect hydraulic hose (123) to the retarder hydraulic control valve.

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Illustration 29	g00437163

29. Connect electrical connection (119) . Install bolt (120) and harness clip (118) to the machine frame.

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Illustration 30	g00437143

30. Remove two plugs (117) from the retarder hydraulic control valve.

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Illustration 31	g00437123

31. Install the O-ring seals to pipes (50) and (53) . Position sensor housing (113) and hydraulic pipes (50) and (53) to the retarder hydraulic control valve.

32. Install eight bolts (115) , two half clamps (114) and two half clamps (116) in order to connect hydraulic pipes (50) and (53) to the retarder hydraulic control valve.

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Illustration 32	g00437098

33. Position wire harness (108) to the alternator. Connect electrical connection (112) .

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Illustration 33	g00437097

34. Position wire harness (108) to the machine frame. Install bolt (111) to harness clip (110) in order to secure wire harness (108) to the machine frame. Connect electrical connection (109) .

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Illustration 34	g00437096

35. Position shims (105) to the machine frame.

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Illustration 35	g00437095

36. Install four bolts (107) , hose bracket (104) , hood support assembly (106) and shims (105) to the machine frame.

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Illustration 36	g00437092

37. Position wire harness (90) to the machine frame. Install bolt (100) and wire clamp (101) to the machine frame. Install bolt (102) and wire clip (103) to the machine frame.

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Illustration 37	g00437091

38. Position wire harness (90) to the engine. Install bolt (91) , bolt (93) , the wire clips, and spacer (92) to the engine.

39. Connect electrical wires (96) and (97) to the solenoid. Install the cover to the solenoid. Install two bolts (99) to cover (98) . Connect electrical connection (94) .

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Illustration 38	g00437090

40. Install bolt (88) and bracket (87) to the engine. Connect electric wires (89) to the starter.

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Illustration 39	g00437089

41. Position electric wire (84) and wire clip (85) to the engine. Install bolt (83) to wire clip (85) .

42. Connect electrical wires (81) and (82) to the fuel injection pump body. Connect electrical wires (86) to the starter.

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Illustration 40	g00437088

43. Connect fuel lines (79) and (80) .

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Illustration 41	g00437087

44. Position wire harness (73) to the alternator. Install bolt (77) and the nut that secures harness clip (76) to the alternator. Connect electrical wires (74) , (75) , and (78) to the alternator.

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Illustration 42	g00437085

45. Position hose clamps (66) and (68) on hoses (67) and (72) . Install pipe assembly (65) to hoses (67) and (72) . Tighten the hose clamps.

46. Install nuts (71) , U-bolt (70) , and pipe clamp (69) to pipe assembly (65) and the mounting bracket.

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Illustration 43	g00437084

47. Position tube assembly (63) and tube clamps (62) and (64) to the exhaust system. Tighten tube clamps (62) and (64) that secure tube assembly (63) to the exhaust system.

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Illustration 44	g00437083

48. Position heat shield (60) to the mounting bracket and three bolts (61) . Tighten three bolts (61) that secure heat shield (60) to the mounting bracket.

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Illustration 45	g00437082

49. Install two nuts (58) , the U-bolt, mounting bracket (57) , and mounting bracket (59) to heat shield (60) .

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Illustration 46	g00437081

50. Position refrigerant hose (54) and hose clip (55) to the machine frame. Install bolt (56) to hose clip (55) .

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Illustration 47	g00437078

51. Install the O-ring seal to hydraulic pipe (53) . Install four bolts (52) and two half clamps (51) in order to connect hydraulic pipe (53) to the transmission oil cooler.

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Illustration 48	g00437077

52. Install the O-ring seal to hydraulic pipe (50) . Install four bolts (49) and two half clamps (48) in order to connect hydraulic pipe (50) to the transmission oil cooler.

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Illustration 49	g00484401

53. Position mounting bracket (43) to the transmission oil cooler.

54. Install two bolts (46) and spacer (47) to mounting bracket (43) on the transmission oil cooler.

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Illustration 50	g00437073

55. Position hydraulic hoses (38) , (39) , and (42) by the transmission oil cooler. Position hose clamp (45) to mounting bracket (43) . Install bolt (44) and the nut that secures hose clamp (45) to mounting bracket (43) .

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Illustration 51	g00437076

56. Install the O-ring seal to hydraulic hose (42) . Position hydraulic hose (42) to the hydraulic tank.

57. Install four bolts (41) and two half clamps (40) in order to connect hydraulic hose (42) to the hydraulic oil tank.

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Illustration 52	g00437071

58. Install the O-ring seals to hydraulic hoses (38) and (39) . Position hydraulic hoses (38) and (39) to the hydraulic oil tank.

59. Install eight bolts (37) and four half clamps (36) in order to connect hydraulic hoses (38) and (39) to the hydraulic tank.

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Illustration 53	g00442383

60. Remove two 5/8 " - 11 NC two inch long bolts (35) in order to remove lifting eye plate (34) from the engine.

61. Position the expansion tank on the engine.

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Illustration 54	g00437070

62. Position lifting eye plate (34) and mounting bracket (32) to the engine. Install two bolts (33) that secure mounting bracket (32) and lifting eye plate (34) to the engine.

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Illustration 55	g00440567

63. Install bolt (30) and the nut that secures mounting bracket (31) to the engine.

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Illustration 56	g00440566

64. Position two hose clips (29) and the hoses to the mounting bracket. Install bolt (28) and the nut that secures two hose clips (29) and the hoses to the mounting bracket.

65. Move coolant hose (27) on pipe (25) . Tighten hose clamps (26) on coolant hose (27) .

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Illustration 57	g00440564

66. Install overflow hose (22) in two hose clips (24) . Install reusable strap (23) to overflow hose (22) and pipe (25) .

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Illustration 58	g00437074

67. Connect overflow hose (22) to relief valve (21) . Connect three coolant hoses (19) to expansion tank (20) .

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Illustration 59	g00437068

68. Install the O-ring seal to hydraulic hose (18) . Connect hydraulic hose (18) to brake pump (5) .

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Illustration 60	g00437067

69. Position wire assembly (12) and wire clip (16) to the engine. Install nut (17) in order to secure wire clip (16) to the engine.

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Illustration 61	g00439434

70. Connect electrical connection (14) . Install new wire straps (13) to wire assembly (12) and electrical connection (14) . Position wire assembly (12) and the wire clip to the engine and install bolt (15) .

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Illustration 62	g00437066

71. Position wire assembly (12) and connect electrical connection (11) .

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Illustration 63	g00437064

72. Position hoses (4) and (10) to pipe (9) . Install bolt (8) , the nut, and clamps (7) that secure hose (10) to pipe (9) .

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Illustration 64	g00437063

73. Install the O-ring seal to hydraulic hose (6) . Connect hydraulic hose (6) to brake pump (5) .

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Illustration 65	g00437043

74. Position refrigerant hose (3) and hose clip (1) to the machine frame. Install bolt (2) to secure hose clip (1) to the machine frame.

    Note: After the engine is run briefly the level of fluid in the hydraulic oil tank will need to be checked. Fill the hydraulic oil tank, as needed. Refer to Operation and Maintenance Manual, SEBU7028 for the correct procedure.

End By:

1. Install the radiator. Refer to Disassembly and Assembly, "Radiator - Install". The information is in this manual.
2. Install the cab. Refer to Disassembly and Assembly, "Cab - Install". The information is in this manual.
3. Install the hood. Refer to Disassembly and Assembly, "Hood - Remove and Install". The information is in this manual.