D250E Series II and D300E Series II Articulated Trucks Power Train Caterpillar

Installation 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	g00496880

2. Install the O-ring seal to torque converter (41) . Attach Tooling (A) , nylon lifting straps and a hoist to torque converter (41) . Install the torque converter to the machine. The weight of the torque converter is 531 kg (1170 lb) .

3. Use the hoist and move torque converter (41) toward the front of the machine. Mesh the drive gears between the torque converter and the engine.

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Illustration 2	g00425078

4. Install the O-ring seal to pipe (69) . Position hydraulic pipe (69) to the retarder control valve. Remember that pipe (69) connects to the torque converter relief valve. The torque converter relief valve is located on the top and right side of the torque converter.

5. Install four bolts (75) and two half clamps (74) in order to connect pipe (69) to the retarder control valve.

6. Install the O-ring seal to hydraulic hose (76) . Connect hydraulic hose (76) to the solenoid operated control valve.

7. Install reusable strap (77) that secures hose (78) to pipe (69) .

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Illustration 3	g00424635

8. Install the O-ring seal to hydraulic hose (72) . Connect hydraulic hose (72) to solenoid operated control valve (73) .

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Illustration 4	g00424634

9. Install the O-ring seal to hydraulic hoist pump (39) . Attach a nylon lifting strap and a hoist to hydraulic hoist pump (39) . Use the hoist and lower hoist pump (39) in the machine. Use the hoist and move hydraulic hoist pump (39) in torque converter (41) .

10. Install two bolts (71) that secure hydraulic hoist pump (39) to torque converter (41) .

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Illustration 5	g00424633

11. Install the O-ring seal to hydraulic steering pump (28) . Attach a nylon lifting strap and a hoist to hydraulic steering pump (28) . Use the hoist and position hydraulic steering pump (28) in the machine. Use the hoist and move hydraulic steering pump (28) in torque converter (41) .

12. Install two bolts (70) that secure hydraulic steering pump (28) to torque converter (41) .

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Illustration 6	g00424632

13. Install the two O-ring seals to relief valve (65) . Position torque converter relief valve (65) to torque converter (41) . Install three bolts (67) that secure torque converter relief valve (65) to torque converter (41) .

14. Install the O-ring seal to pipe (69) . Install four bolts (68) and two half clamps (66) in order to connect pipe (69) to torque converter relief valve (65) .

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Illustration 7	g00424628

15. Position drive shaft (63) to torque converter (41) . Install four bolts (64) in order to connect drive shaft (63) to torque converter (41) . Tighten bolts (64) to a torque of 55 ± 10 N·m (41 ± 7 lb ft) .

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Illustration 8	g00420225

16. Install the O-ring seal to hydraulic hose (62) . Connect hydraulic hose (62) to steering pump pressure and flow compensator valve (61) .

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Illustration 9	g00420224

17. Install the O-ring seal to hydraulic hose (59) . Install four bolts (58) and two half clamps (60) in order to connect hose (59) to hydraulic hoist pump (39) .

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Illustration 10	g00420222

18. Install the O-ring seals to hose (55) . Move hoses (55) and (48) in position to steering pump (28) . Install four bolts (57) and two half clamps (56) in order to connect hose (55) to steering pump (28) .

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Illustration 11	g00420197

19. Install reusable strap (54) to hydraulic hoses (53) and (55) .

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Illustration 12	g00420196

20. Install the O-ring seals to hoses (51) and (52) . Connect hoses (51) and (52) to torque converter (41) .

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Illustration 13	g00420190

21. Install the O-ring seals to hoses (49) and (50) . Connect hydraulic hoses (49) and (50) to torque converter (41) .

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Illustration 14	g00420188

22. Install the O-ring seal to hose (48) . Connect hydraulic hose (48) to hydraulic steering pump (28) .

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Illustration 15	g00420187
This is a view from the right side of the machine and above the torque converter.

23. Install reusable strap (47) to pipe (45) and hose (46) .

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Illustration 16	g00420183
This is a view from a point below the torque converter.

24. Install the O-ring seal to hose (42) . Position hose (42) to torque converter (41) . Install four bolts (40) and two half clamps (43) in order to connect hose (42) to torque converter (41) .

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Illustration 17	g00420181

25. Install the O-ring seal to hose (37) . Position hose (37) to hydraulic hoist pump (39) . Install four bolts (38) and two half clamps (35) in order to connect hose (37) to hydraulic hoist pump (39) . Install reusable strap (34) to hydraulic hoses (36) and (37) .

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Illustration 18	g00420180
This is a view from a point below the torque converter.

26. Install the O-ring seal to hose (32) . Connect hydraulic hose (32) to torque converter screen (33) .

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Illustration 19	g00420179

27. Install the O-ring seal to hose (31) . Position hose (31) to hydraulic steering pump (28) . Install four bolts (29) and two half clamps (30) in order to connect hose (31) to hydraulic steering pump (28) .

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Illustration 20	g00420116
This is a view from a point below the torque converter.

28. Install the O-ring seal to hose (26) . Position hose (26) to transmission oil and scavenge pump (23) . Install four bolts (25) and two half clamps (27) in order to connect hose (26) to transmission oil and scavenge pump (23) .

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Illustration 21	g00420114
This is a view from a point below the torque converter.

29. Install the O-ring seal to hose (24) . Position hose (24) to transmission oil and scavenge pump (23) . Install four bolts (22) and two half clamps (21) in order to connect hose (24) to transmission oil and scavenge pump (23) .

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Illustration 22	g00420113
This is a view from a point below the torque converter.

30. Install the O-ring seal to hose (20) . Position hose (20) to retarder control valve (8) . Install four bolts (19) and two half clamps (18) in order to connect hose (20) to retarder control valve (8) .

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Illustration 23	g00420112
This is a view from a point below the torque converter.

31. Connect the electrical connection on wire harness (16) . Install bolt (17) and harness clip (15) to the machine frame.

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Illustration 24	g00420110
This is a view from a point below the torque converter.

32. Remove four bolts (11) and two half clamps (10) in order to remove plug (14) and sensor housing (9) from retarder control valve (8) . Remove half clamps (13) and bolts (12) and remove the other plug.

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Illustration 25	g00420107
This is a view from a point below the torque converter.

33. Install the O-ring seals to both ends of hydraulic pipe (6) .

34. Position hydraulic pipe (6) to retarder control valve (8) and the transmission oil cooler. Remember that pipe (6) was disconnected from the transmission oil cooler.

35. Install four bolts (12) and two half clamps (13) in order to connect hydraulic pipe (6) to retarder control valve (8) .

36. Install the O-ring seals to both ends of hydraulic pipe (4) .

37. Check the O-ring seal in sensor housing (9) . If the O-ring seal is worn or damaged, use new Caterpillar parts for replacement. Position sensor housing (9) to retarder control valve (8) .

38. Position hydraulic pipe (4) to sensor housing (9) , retarder control valve (8) and the transmission oil cooler. Remember that pipe (4) was disconnected from the transmission oil cooler.

39. Install four bolts (11) and two half clamps (10) in order to connect hydraulic pipe (4) to sensor housing (9) and retarder control valve (8) .

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Illustration 26	g00420101
This is a view of the engine from the driver's side of the machine. Some hoses have been moved aside for photographic purposes.

40. Install four bolts (7) and two half clamps (5) in order to connect hydraulic pipe (6) to transmission oil cooler (2) .

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Illustration 27	g00420099
This is a view of the engine from the driver's side of the machine. Some hoses have been moved aside for photographic purposes.

41. Install four bolts (3) and two half clamps (1) in order to connect hydraulic pipe (4) to transmission oil cooler (2) .

42. Run the engine for a brief period of time in order to circulate the hydraulic oil in the torque converter.

43. Check the fluid level in the hydraulic oil tank. Fill the hydraulic tank to the proper level. See Operation and Maintenance Manual, SEBU7028 for the correct procedure.

End By:

1. Install the crankcase guard. Refer to Disassembly and AssemblySENR9124, "Crankcase Guard- R&I" for the proper procedure.
2. Install the cab. Refer to Disassembly and AssemblySENR9124, "Cab - R&I" for the proper procedure.