R2900G Load Haul Dump Machine Systems Caterpillar

Disassembly Procedure

Start By:

1. Remove the main control valve. Refer to Disassembly and Assembly, "Main Control Valve - Remove".

Note: Cleanliness is an important factor. Before you begin the disassembly procedure, the exterior of the components should be thoroughly cleaned. This will help to prevent dirt from entering the internal mechanism. Precision components can be damaged by contaminants or by dirt. Perform disassembly procedures on a clean work surface. Keep components covered and protected at all times.

Note: Put identification marks on all of the components of the main control valve as the components are being removed. All of the components must be reinstalled to original locations and to the original orientation.

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Illustration 1	g01073611

1. Put identification marks on relief valves (1) and (2) for assembly purposes. Remove relief valves (1) and (2) from valve body (3).

   Note: Relief valve (1) is for the rod end of the tilt cylinder. Relief valve (2) is for the head end of the tilt cylinder.

   Note: Relief valve (1) is different from relief valve (2). DO NOT mix the parts of the two relief valves.

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   Illustration 2	g01101183

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   Sudden release of spring force can cause injury. To prevent the possibility of injury, follow the procedure to relieve the spring pressure.

2. Disassemble O-ring seal (4), O-ring seal (5), locknut (7), retainer (8), O-ring seal (6), spring (12), plate (11), valve (10), and valve body (9) from relief valve (1).
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   Illustration 3	g01101184

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   Sudden release of spring force can cause injury. To prevent the possibility of injury, follow the procedure to relieve the spring pressure.

3. Disassemble O-ring seal (4), O-ring seal (5), locknut (7), retainer (8), O-ring seal (6), washer (13), spring (12), plate (11), valve (10), and valve body (9) from relief valve (2).
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   Illustration 4	g01073614

4. Remove main relief valve (14) from the main control valve
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   Illustration 5	g01073615

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   Sudden release of spring force can cause injury. To prevent the possibility of injury, follow the procedure to relieve the spring pressure.

5. Disassemble main relief valve (14). Remove O-ring seals (15) and (16) from valve body (18).

6. Remove cap (21) from valve body (18). Remove O-ring seal (17).

7. Remove spring (20) and valve (19) from valve body (18).
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   Illustration 6	g01073616

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   Illustration 7	g01073954

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   Sudden release of spring force can cause injury. To prevent the possibility of injury, follow the procedure to relieve the spring pressure.

8. Remove three load check valves (23). Each load check valve contains a plug (23), O-ring (24), spring (25) and valve (26).
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   Illustration 8	g01073947

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   Illustration 9	g01073948

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   Sudden release of spring force can cause injury. To prevent the possibility of injury, follow the procedure to relieve the spring pressure.

9. Remove make-up valve (27). Remove plug (31), spring (29) and valve (28). Remove O-ring seal (30).

10. Remove fitting (32) from plug (31).
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    Illustration 10	g01074366

11. Remove four bolts (34). Remove housings (33). Remove the O-ring seals from housings (33).
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    Illustration 11	g01074373

12. Remove four bolts (35). Remove housings (36). Remove the O-ring seals from housings (36).
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    Illustration 12	g01074368

13. Remove tilt valve spool assembly (37).

14. Remove lift valve spool assembly (38).
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    Illustration 13	g01101185

    Note: The lift valve spool is different from the tilt valve spool. DO NOT mix the parts of the two valve spools.

    Note: DO NOT mix the shims. The shim packs must be clearly identified for assembly purposes.

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    Sudden release of spring force can cause injury. To prevent the possibility of injury, follow the procedure to relieve the spring pressure.

15. Disassemble bolt (47), the washer, shim pack (46), retainer (45), shim pack (44), spring (43), spring (42), retainer (41), shims (40), and spool (39) from the tilt valve spool assembly (37).

16. Disassemble bolt (47), the washer, shim pack (46), retainer (45), shim pack (44), spring (43), spring (42), retainer (41), shims (40), and spool (39) from the lift valve spool assembly (38).