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

Illustration 1	g00914571

(1) Clutch 1

Thickness of the four new discs and the three new plates ... 37.36 ± 0.56 mm (1.471 ± 0.022 inch)

(2) Height of the pin in the plate ... 10.0 ± 0.5 mm (0.39 ± 0.02 inch)

(3) Clutch 2

Thickness of the five new discs and the four new plates ... 47.95 ± 0.72 mm (1.888 ± 0.028 inch)

(4) Clutch 3

Thickness of the three new discs and the two new plates ... 26.77 ± 0.40 mm (1.054 ± 0.016 inch)

(5) Height for the two dowels in the clutch housing ... 11.0 ± 0.5 mm (0.43 ± 0.02 inch)

(6) 6Y-4421 Planet Gears

Inner diameter of the four new planet gears ... 38.123 ± 0.008 mm (1.5009 ± 0.0003 inch)

Outer diameter of the four new planet gears ... 62.84 ± 0.07 N·m (46.348 ± 0.052 lb ft)

(7) 6Y-4425 Planet Shafts

Length of the four shafts ... 132.5 ± 0.5 mm (5.22 ± 0.02 inch)

Outer diameter of the four shafts ... 28.570 ± 0.008 mm (1.1248 ± 0.0003 inch)

(8) Clutch 6

Thickness of the four new discs and the three new plates ... 31.80 ± 0.56 mm (1.252 ± 0.022 inch)

(9) 7G-2343 Disc Spring

Number of disc springs ... Three

Assembled height ... 5.58 mm (0.220 inch)

Load at the assembled height ... 1846 N (415.0 lb)

Minimum operating height ... 3.49 mm (0.137 inch)

Load at the minimum operating height ... 6400 ± 650 N (1440.0 ± 145.0 lb)

(10) Before you install the O-ring seal, lubricate the groove and the O-ring seal. Before you install the bearing, lubricate the O-ring seal.

(11) Torque for the ten bolts ... 115 ± 7 N·m (85.0 ± 5.0 lb ft)

(12) 8P-7899 Planet Gears

Inner diameter of the four new planet gears ... 51.948 ± 0.010 mm (2.0452 ± 0.0004 inch)

Outer diameter of the four new planet gears ... 82.82 ± 0.08 mm (3.261 ± 0.003 inch)

(13) 8P-7898 Planet Shafts

Outer diameter of four new planet shafts ... 42.395 ± 0.008 mm (1.6691 ± 0.0003 inch)

Length of the four new planet shafts ... 77.0 mm (3.03 inch)

(14) Depth of the spring pin in the clutch housing ... 2.0 ± 1.0 mm (0.08 ± 0.04 inch)

(15) 9G-7197 Sleeve Bearing

Inner diameter of the sleeve bearing after installation ... 31.724 ± 0.039 mm (1.2490 ± 0.0015 inch)

Depth of the sleeve bearing ... 13.00 ± 0.25 mm (0.512 ± 0.010 inch)

(16) 9F-1847 Sleeve Bearing

Inner diameter of the bearing after installation ... 40.790 ± 0.141 mm (1.6059 ± 0.0056 inch)

Depth of the sleeve bearing ... 5.00 ± 0.25 mm (0.197 ± 0.010 inch)

(17) Height of the two dowels in the clutch housing after installation ... 11.0 ± 0.5 mm (0.43 ± 0.02 inch)

(18) 4M-1677 Reaction Dowels

Length of the five reaction dowels ... 92.96 ± 0.25 mm (3.660 ± 0.010 inch)

Outer diameter of the five reaction dowels ... 12.637 ± 0.013 mm (0.4975 ± 0.0005 inch)

(19) 7M-1199 Springs

Number of springs ... Ten

Assembled length ... 55.1 ± 0.5 mm (2.17 ± 0.02 inch)

Load at the assembled length ... 128 ± 10 N (28.8 ± 2.3 lb)

Free length after test ... 70.9 ± 0.5 mm (2.79 ± 0.02 inch)

Outer diameter ... 14.27 ± 0.25 mm (0.562 ± 0.010 inch)

(20) Clutch 6

Thickness of the five new discs and the four new plates ... 47.95 ± 0.82 mm (1.888 ± 0.032 inch)

(21) Height of the dowel after installation in the manifold ... 15.0 ± 0.5 mm (0.59 ± 0.02 inch)

(22) Before assembly, lubricate the O-ring seal with the fluid that is being sealed.

(23) 8J-6704 Spring

Number of springs ... Ten

Assembled length ... 42.06 mm (1.656 inch)

Load at the assembled length ... 125 ± 10 N (28.6 ± 2.3 lb)

Free length after test ... 62.51 mm (2.461 inch)

Outer diameter of the spring ... 14.2240 mm (0.560 inch)

(24) Clutch 4

Thickness of the three new discs and two new plates ... 26.77 ± 0.46 mm (1.054 ± 0.018 inch)

(25) 4M-9592 Springs

Number of springs ... Ten

Assembled length ... 34.87 ± 0.25 mm (1.373 ± 0.010 inch)

Load at the assembled length ... 115 ± 6 N (26.2 ± 1.3 lb)

Free length after test ... 44.70 ± 0.25 mm (1.760 ± 0.010 inch)

Outer diameter of the spring ... 14.28 ± 0.25 mm (0.562 ± 0.010 inch)

(26) 3K-2511 Reaction Dowels

Length of the ten reaction dowels ... 176.22 ± 0.25 mm (6.938 ± 0.010 inch)

Outer diameter of the ten reaction dowels ... 12.637 ± 0.013 mm (0.4975 ± 0.0005 inch)

(27) 6Y-4420 Planet Gears

Inner diameter of the four planet gears ... 58.298 ± 0.010 mm (2.2952 ± 0.0004 inch)

Outer diameter of the four planet gears ... 90.49 ± 0.08 mm (3.563 ± 0.003 inch)

(28) 6Y-4422 Planet Shafts

Length of the four planet shafts ... 71.5 ± 0.5 mm (2.82 ± 0.02 inch)

Outer diameter of the four planet shafts ... 42.395 ± 0.008 mm (1.6691 ± 0.0003 inch)

(29) 7H-7658 Springs

Number of springs ... Ten

Assembled length ... 105.56 mm (4.156 inch)

Load at the assembled length ... 186.8 ± 14.5 N (42.00 ± 3.25 lb)

Free length after test ... 140.49 mm (5.531 inch)

Outer diameter of the ten springs ... 14.30 mm (0.563 inch)

Color Marking ... Brown

(30) 8P-1919 Planet Gears

Inner diameter of the three planet gears ... 47.653 ± 0.008 mm (1.8761 ± 0.0003 inch)

Outer diameter of the three planet gears ... 76.43 ± 0.07 mm (3.009 ± 0.003 inch)

(31) Installation depth of the plug in the housing ... 1.25 ± 0.25 mm (0.049 ± 0.010 inch)

(32) 8P-2043 Planet Shafts

Length of the three planet shafts ... 79.00 ± 0.25 mm (3.110 ± 0.010 inch)

Outer diameter of the three planet shafts ... 38.095 ± 0.008 mm (1.4998 ± 0.0003 inch)

(33) Before you install the two O-ring seals, lubricate the grooves and the O-ring seals. Before you install the two bearings, lubricate the O-ring seals.

(34) Before you install the O-ring seal, lubricate the groove and the O-ring seal. Before you install the bearing, lubricate the O-ring seal.