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

Removal Procedure

Start By:

1. Remove the air cleaner. Refer to Disassembly and Assembly, SENR9124, "Air Cleaner - Remove and Install" for the correct procedure.

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Personal injury or death can result from a fire. Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. Clean up all leaked or spilled fuel. Do not smoke while working on the fuel system. Turn the disconnect switch OFF or disconnect the battery when changing fuel filters.

1. 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 fuel system.

2. Open the hood to the engine compartment.

3. Drain the fuel tank. The capacity of the fuel tank is 375 L (99 US gal).
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   Illustration 1	g00525941

4. Remove electric connector (2) from the wire clip. Disconnect electric connector (2) that is on wire assembly (4). Move wire assembly (4) aside. Remove bolt (3), the washers and the nut that secures fuel tank (1) to the machine frame.

5. Remove collar (5) and nylon washer (6) from the top of the mounting bracket. There is a nylon washer (7), shims (8), a hard washer (9) and a bushing (10) between the mounting bracket and the machine frame.
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   Illustration 2	g00526008

6. Disconnect cover (12) from receptacle (14). Remove four bolts (11) and the washers that secure receptacle (14) to the mounting plate that is on the fuel tank. Move receptacle (14) aside. Disconnect connector wire (13) and remove cover (12).
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   Illustration 3	g00526040

7. Disconnect fuel lines (15) and (16).
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   Illustration 4	g00526042
   This is a view of the area that is just below the air cleaner.

8. Remove bolt (17), the washers, washer (18) and the nut that secures fuel tank (1) to the machine frame. There are shims (19), a hard washer (20) and a bushing (21) between the mounting bracket and the machine frame.
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   Illustration 5	g00526043
   This is a view of the fuel tank from inside of the engine compartment.

9. Remove bolt (22), the washers, washer (23) and the nut that secures the fuel tank to the machine frame. There are shims, a hard washer and a bushing between the mounting bracket and the machine frame.
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   Illustration 6	g00525997
   This is a view of the fuel tank from inside of the engine compartment.

10. Disconnect harness connector (26) from wire harness (27). Remove three bolts (25) and the washers that secure wire clips (28) and mounting bracket (24) to fuel tank (1).

11. Move mounting bracket (24) and wire harness connector (26) aside. Wire harness (27) and wire clips (28) will stay with the fuel tank.
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    Illustration 7	g00528582

12. Attach Tooling (A) and appropriate nylon lifting straps to the fuel tank, as shown. Use the hoist in order to remove the fuel tank from the machine. The weight of an empty fuel tank is 200 kg (441 lb).

13. Note the location of the shims, the hard washers and the bushings that were located between the mounting brackets on the fuel tank and the machine frame. The information is needed for installation purposes. Remove the shims, the hard washers and the bushings from the machine frame.