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

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

2. Install the shims, the hard washers and the bushings to the machine frame. Use the proper amount of shims in order to install the fuel tank in a level position.
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   Illustration 1	g00528582

3. Attach Tooling (A) and appropriate nylon lifting straps to the fuel tank, as shown. Use the hoist in order to position the fuel tank to the machine. The weight of an empty fuel tank is 200 kg (441 lb).
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   Illustration 2	g00525997

4. Position mounting bracket (24) on the fuel tank. Position wire harness (27) and wire clips (28) to mounting bracket (24). Install three bolts (25) and the washers that secure wire clips (28) and mounting bracket (24) to fuel tank (1).

5. Connect harness connector (26) to wire harness (27).
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   Illustration 3	g00526043

6. Install 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 4	g00526042

7. Install 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	g00526040

8. Connect fuel lines (15) and (16).
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   Illustration 6	g00526008

9. Position receptacle (14) to the mounting plate that is on the fuel tank. Install connector wire (13), four bolts (11) and the washers that secure receptacle (14) to the mounting plate that is on the fuel tank. Connect cover (12) to receptacle (14).
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   Illustration 7	g00525941

10. Install collar (5) and nylon washer (6) to 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. Install bolt (3), the washers and the nut that secures fuel tank (1) to the machine frame.

11. Connect electric connector (2) to wire assembly (4). Install electric connector (2) to the wire clip.

12. Close the engine hood.

13. Fill the fuel tank.

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