D250E Series II and D300E Series II Articulated Trucks Machine Systems Caterpillar

Assembly Procedure

1. Inspect all parts and clean all parts. If any parts are worn or damaged, use new Caterpillar parts for replacement.
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   Illustration 1	g00480983

2. Install O-ring seals (98) to test ports (92). Install caps (97) to test ports (92).
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   Illustration 2	g00497586

3. Install valve (94), spring (95) and O-ring seal (96) to plug (91).
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   Illustration 3	g00480840

4. Install plug (91), the spring and the valve to the valve body. Install the O-ring seal to plug (93). Install two test ports (92) and plug (93) to the valve body.
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   Illustration 4	g00497448

5. Install valve (90) to valve body (81). Install O-ring seal (88) and O-ring seal (89) to valve body (81).
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   Illustration 5	g00497449
   This assembly is a component of valve assembly (69).

6. Install nut (82), washer (86), two O-ring seals (85) to valve assembly (83) and valve housing (84). Install valve assembly (83) to valve housing (84). Install retaining ring (87) to valve assembly (83).
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   Illustration 6	g00497444
   This assembly is a component of valve assembly (69).

7. Install valve housing (81) to valve assembly (80).
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   Illustration 7	g00497445

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   Illustration 8	g00578741

8. Install valve assembly (69) to valve body (3). Valve assembly (69) will need to be adjusted after the hoist control valve is installed. For instructions on adjustment of the valve, refer to Testing and adjusting, RENR3400.
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   Illustration 9	g00480609
   This assembly is a component of valve assembly (68).

9. Install spring (75), plate (74) , valve (73), O-ring seal (71) and O-ring seal (70) to valve assembly (72).

10. Install nut (77), O-ring seal (76) and washer (78) to retainer assembly (79). Install retainer assembly (79) to valve assembly (72).
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    Illustration 10	g00573437

11. Install valve assembly (68) to valve body (3). Valve assembly (68) will need to be adjusted after the hoist control valve is installed. For instructions on adjustment of the valve, refer to Testing and adjusting, RENR3400.
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    Illustration 11	g00498330

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    Illustration 12	g00497580
    This assembly is a component of valve assembly (53).

12. Use Tooling (A) and a hydraulic press in order to install seat (67), spring (66) and valve (65) to valve body (60).
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    Illustration 13	g00480588
    This assembly is a component of valve assembly (53).

13. Install nut (58) and retainer assembly (64) to cap assembly (57). Install O-ring seal (63) to cap assembly (57). Install O-ring seals (54) and (59) to valve body (60).

14. Install plate (56), pin (62), spring (61) and valve (55) to cap assembly (57) and to valve body (60). Install cap assembly (57) to valve body (60).
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    Illustration 14	g00480556

15. Install valve assembly (53) to valve body (3). Valve assembly (53) will need to be adjusted after the hoist control valve is installed. For instructions on adjustment of the valve, refer to Testing and adjusting, RENR3400.
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    Illustration 15	g00480553

16. Install O-ring seals (52) to valve body (3).
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    Illustration 16	g00573212

17. Install two bolts (50), the washers and manifold (51) to valve body (3).
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    Illustration 17	g00573211

18. Install valve stem (49) to valve body (3).
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    Illustration 18	g00480550

19. Install two straps (45) to wires (44). Install receptacle assembly (47) to wires (44).

20. Install two pins (48) to receptacle assembly (47). Install wedge (46) to receptacle assembly (47).
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    Illustration 19	g00480549

21. Install O-ring seal (43) to solenoid (41).
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    Illustration 20	g00480403

22. Position solenoid (41) to valve body (30). Install four bolts (42) that secure solenoid (41) to valve body (30). Install the six access plugs and the O-ring seals to valve body (30).
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    Illustration 21	g00480400

23. Install retainer (33), spring (34), spring (35), spring (36), stop (37), stop (39), control spool (38) and spring (37) to actuator housing (30).
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    Illustration 22	g00480395

24. Use Tooling (A) and a hydraulic press and exert downward pressure on retainer (33). Slowly increase the pressure from the hydraulic press and load the spring tension to springs (34), (35) and (36) that are in actuator (30).

25. Install retainer ring (32) to actuator (30).
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    Illustration 23	g00480391

26. Install two O-ring seals (31) to actuator (30). Install the large O-ring seal to the center of actuator (30).
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    Illustration 24	g00573313

27. Position actuator (30) to valve body (3). Install two bolts (29) that secure actuator (30) to valve body (3).
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    Illustration 25	g00480384

28. Install receptacle assembly (26) to wires (25).

29. Install two pins (28) to receptacle assembly (26). Install wedge (27) to receptacle assembly (26).
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    Illustration 26	g00472427

30. Install two straps (23) to the wires. Install O-ring seal (24) to solenoid (22).
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    Illustration 27	g00472374

31. Position solenoid (22) to actuator housing (9). Install four bolts (21) in order to secure solenoid (22) to actuator housing (9).
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    Illustration 28	g00472371

32. Install O-ring seals (20) to plugs (19). Install six plugs (19) to valve body (9).
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    Illustration 29	g00472261

33. Install retainer (12), spring (13), spring (14), spring (15), spacer (18), control spool (17) and spring (16) to actuator housing (9).
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    Illustration 30	g00472121

34. Use Tooling (A) and a hydraulic press and exert downward pressure on retainer (12). Slowly increase the pressure from the hydraulic press and load the spring tension to springs (13), (14) and (15) that are in actuator (9).

35. Install retainer ring (11) to actuator (9).
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    Illustration 31	g00472266

36. Install two O-ring seals (10) to actuator (9). Install the large O-ring seal to the center of actuator (9).
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    Illustration 32	g00577707

37. Position actuator (9) to valve body (3). Install two bolts (8) that secure actuator (9) to valve body (3).
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    Illustration 33	g00472030

38. Install the O-rings in hydraulic pipes (6) and (7). Position the hydraulic pipes to valve body (3). Tighten retaining nuts (1), (2), (3), and (4) in order to connect hydraulic pipes (6) and (7) to valve body (3).

39. Install the retainer clips to the hydraulic pipes.

End By:

1. Install the hoist control valve. Refer to Disassembly and Assembly, "Hoist Control Valve - Install".