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

Assembly Procedure

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Illustration 1	g00516363

1. Install three packings (13) in the grooves of the bores. The bores are located in the outer side of the brake caliper.
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   Illustration 2	g00516367

2. Install Tooling (B) in boot (12).
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   Illustration 3	g00516368

3. Insert piston (11) through Tooling (B) and in the bore in the outer side of the brake caliper.

4. Use Tooling (A) in order to push the piston to the bottom of the bore in the outer side of the brake caliper.

5. Make sure that boot (12) is engaged in the groove of the bore in the outer side of the brake caliper.

6. Remove Tooling (A) and (B) from piston (11) and boot (12).

7. Repeat Steps 2, 3, 4 and 5 in order to install the pistons and the boots for the remaining two bores that are in the outer side of the caliper.
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   Illustration 4	g00516370

8. Install three plugs (7) and three seals (6) to the inner side of the brake caliper.
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   Illustration 5	g00516373

9. Install bolts (4) and plate (5) to the inner side of the brake caliper.
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   Illustration 6	g00516374

10. Install three packings (10) to the bores in the inner side of the brake caliper.
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    Illustration 7	g00516375

11. Install Tooling (B) in boot (9). Install boot (9) in the groove of the bore. The bore is located in the inner side of the brake caliper.
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    Illustration 8	g00516398

12. Insert piston (8) through Tooling (B) and in the bore in the inner side of the brake caliper.
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    Illustration 9	g00516399

13. Install Tooling (C) in position in the brake caliper and against piston (8).

14. Expand Tooling (C) in order to push piston (8) into the bore in the inner side of the brake caliper. Install the other two boots and pistons in the same manner. Remove Tooling (C) from the assembly.
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    Illustration 10	g00516401

15. Install Tooling (C) in position in the brake caliper and use an appropriate plate from Tooling (D) in order to push the pistons further in the bores. Add more plates in order to push the pistons to the bottom of the bores.

16. Remove the tooling from the assembly. Make sure that boots (9) are engaged in the grooves of the bores. The bores are located in the inner side of the brake caliper.
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    Illustration 11	g00516403

17. Install four bolts (3) and four pins (2) to brake caliper (1).

End By:

1. Install the service brakes. Refer to Disassembly and Assembly, "Service Brakes - Install". The information is in this manual.