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

Removal Procedure

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At operating temperature, the hydraulic tank is hot and under pressure. Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin. Remove the filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand. Remove the filler cap slowly in order to relieve pressure.

Note: Turn off the engine. Apply the foot brake several times in order to relieve the pressure in the brake system. Turn the steering wheel in order to relieve the pressure in the metering pump.

1. Pull the hood release lever in the cab. Open the engine hood and engage the hood latch.

2. Raise the cab. See Disassembly and Assembly, SENR9124, "Cab - Tilt" for the correct procedure.

3. Put identification marks on all lines, hoses, wires and tubes for installation purposes. Plug all lines, hoses and tubes. This helps prevent fluid loss and contamination of the oil system.
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   Illustration 1	g00513171

4. Loosen nuts (1) and (2) in order to disconnect hydraulic hoses (3) and (4) from the metering pump. Remove hose strap (5) from the hoses. Remove the O-ring seals from hydraulic hoses (3) and (4). Move hydraulic hoses (3) and (4) out of the way.
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   Illustration 2	g00513172

5. Loosen six retaining nuts (6) in order to disconnect six hydraulic hoses (7) from the control valve. Remove the O-ring seals from hydraulic hoses (7). Move the hydraulic hoses aside.
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   Illustration 3	g00513174

6. Note the orientation of six hydraulic fittings (8) for installation purposes. Remove six hydraulic fittings (8) from control valve (9). Remove the O-ring seals from hydraulic fittings (8).
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   Illustration 4	g00513177

7. Remove three bolts (10) that secure control valve (9) to the floor of the cab. Remove control valve (9) from the floor of the cab.
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   Illustration 5	g00513178

8. Remove four nuts (14) and two U-bolts (15) that secure pedal assembly (13) to control valve (9). Remove pedal assembly (13) from control valve (9).

9. Remove dowel pin (12) from plate (11).
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   Illustration 6	g00513211

10. Remove seal (16) from plate (11) and control valve (9).

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 7	g00513211

2. Install a new seal (16) to plate (11) and control valve (9).
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   Illustration 8	g00513178

3. Install dowel pin (12) to plate (11).

4. Position pedal assembly (13) to control valve (9) and the dowel pin. Install four nuts (14) and two U-bolts (15) that secure pedal assembly (13) to control valve (9) and the dowel pin.
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   Illustration 9	g00513177

5. Install control valve (9) in the floor of the cab. Install three bolts (10) that secure control valve (9) to the floor of the cab.
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   Illustration 10	g00513174

6. Install the O-ring seals to hydraulic fittings (8). Install six hydraulic fittings (8) to control valve (9) in the correct orientation.
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   Illustration 11	g00513172

7. Install the O-ring seals in hydraulic hoses (7). Tighten six retaining nuts (6) in order to connect six hydraulic hoses (7) to the control valve.
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   Illustration 12	g00513171

8. Install the O-ring seals to hydraulic hoses (3) and (4). Tighten nuts (1) and (2) in order to connect hydraulic hoses (3) and (4) to the metering pump. Install hose strap (5) to the hoses.

9. Lower the cab. See Disassembly and Assembly, SENR9124, "Cab - Tilt" for the correct procedure.

10. Close the engine hood.

11. Check the level of fluid in the hydraulic system and fill the hydraulic system to the proper level. See Operation and Maintenance Manual, SEBU7028 for the correct procedure.