R1600H Load Haul Dump Machine Systems Caterpillar

Disassembly Procedure

Start By:

1. Remove the hydraulic tank. Refer to Disassembly and Assembly, "Hydraulic Tank - Remove".

Note: Cleanliness is an important factor. Before you begin the disassembly procedure, thoroughly clean the exterior of the components. Thoroughly cleaning the exterior of the component 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.

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Illustration 1	g01091821

1. Remove snap ring (1) and cover (2) from the breaker relief valve.
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   Illustration 2	g01099372

2. Remove element (3).
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   Illustration 3	g01099373

3. Remove breaker relief valve (4) from the hydraulic tank.
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   Illustration 4	g01099374

4. Remove O-ring seals (5), (6) and (7) from breaker relief valve (4).
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   Illustration 5	g03732576

5. Remove cap (11).

6. Remove gasket (8), plate (9) and ball (10) from cap (11).
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   Illustration 6	g03732577

7. Remove strainer (13) and O-ring seal (14) from filler (12).
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   Illustration 7	g03732578

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   Illustration 8	g03732579

8. Loosen bolt (15). Remove cover (16) and element (17) from the hydraulic tank.
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   Illustration 9	g03732581

9. Remove retaining ring (18), spacer (19) and six disc springs (20).
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   Illustration 10	g03732582

10. Remove retaining ring (22). Remove bolt (15). Remove O-ring seal (21) from bolt (15).

11. Remove O-ring seal (23).

12. Repeat Step 8 through Step 11 for the other filter assembly.
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    Illustration 11	g03732583

13. Remove bracket (26).

14. Loosen two bolts (24) and remove liquid level gauge (25).
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    Illustration 12	g03732584

15. Remove O-ring seal (27) from two bolts (24).

16. Remove two bolts (24) from liquid level gauge (25).
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    Illustration 13	g03732585

17. Install Tooling (B) and a suitable lifting device to cover (28). The weight of cover (28) is approximately 75 kg (165 lb).

18. Remove 70 bolts (29), the locknuts and cover (28).

19. Turn cover (28).
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    Illustration 14	g03732586

20. Remove gasket (30).

21. Remove gasket (31).

22. Remove six bolts (33). Remove baffle (32) from the inside of the tank assembly.
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    Illustration 15	g03732587

23. Remove two bolts (34). Remove filter base (35) from the outside of the cover.
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    Illustration 16	g03732589

24. Remove two studs (36) from filter base (35).

25. Remove ten O-ring seals (37).

26. Remove two O-ring seals (38).
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    Illustration 17	g03732590

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    Illustration 18	g03732591

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    Personal injury can result from parts and/or covers under spring pressure. Spring force will be released when covers are removed. Be prepared to hold spring loaded covers as the bolts are loosened.

27. Carefully remove two bolts (39).

28. Remove cover (40), spring (42) and valve (41).

29. Remove the O-ring seal from cover (40).
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    Illustration 19	g03732596

30. Remove two locknuts (44) and baffle tube (43).
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    Illustration 20	g03732599

31. Remove two locknuts (45), the washers and drain valve assembly (46).
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    Illustration 21	g03732600

32. Remove plug (47). Remove O-ring seal (48) from plug (47).

33. Remove O-ring seal (49), valve (50), spring (51) and valve guide (52) from drain valve body (46).
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    Illustration 22	g03733104

34. Remove four bolts (54) and cover (55).

35. Remove two bolts (53).
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    Illustration 23	g03733102

36. Remove block (56).
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    Illustration 24	g03733101

37. Remove 12 O-ring seals (57) from block (56).
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    Illustration 25	g03733100

38. Remove four bolts (59) and cover (60) from the hydraulic tank.

39. Remove two bolts (58).
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    Illustration 26	g03733099

40. Remove block (61).

41. Remove seven O-rings seals (62).
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    Illustration 27	g03733097

42. Remove four bolts (63) and cover (64).

43. Remove two bolts (65).
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    Illustration 28	g03733091

44. Remove block (66).

45. Remove seven O-ring seals (67).