R3000H Load Haul Dump Machine Systems Caterpillar

Specifications (Pilot Valve)

Illustration 1	g02692517

Specifications (STIC Control)

Illustration 2	g03199416

Assembly Procedure

Note: Cleanliness is an important factor. Before assembly, thoroughly clean all parts in cleaning fluid. Allow the parts to air dry. Do not use wiping cloths or rags to dry parts. Lint may be deposited on the parts which may cause trouble. Inspect all parts. If any parts are worn or damaged, use new parts for replacement. Dirt and other contaminants can damage the precision component. Perform assembly procedures on a clean work surface. Keep components covered and protected always

Note: Lubricate the internal components with the lubricant that is being sealed.

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Illustration 3	g01073603

1. Install shims (45), two O-ring seals (43) and (44), and backup ring (42) to capsule assembly (41).
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   Illustration 4	g01073602

2. Install two capsule assemblies (41) to the valve body. Tighten capsule assemblies (41) to a torque of 35 ± 3 N·m (26 ± 2 lb ft).
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   Illustration 5	g01073601

3. Install O-ring seal (40) to each fitting (39).
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   Illustration 6	g01073599

4. Install two fittings (39) to the pilot valve.
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   Illustration 7	g01073598

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   Improper assembly of parts that are spring loaded can cause bodily injury. To prevent possible injury, follow the established assembly procedure and wear protective equipment.

5. Install spring (36), retainer (37) and the screw to retainer (35).

6. Install retainer (35) and pin (38) to spool (31).
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   Illustration 8	g00690553

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   Illustration 9	g00690536

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   Improper assembly of parts that are spring loaded can cause bodily injury. To prevent possible injury, follow the established assembly procedure and wear protective equipment.

7. Install plunger (34), cap (33), retainer (32), spool assembly (31), and spring (30) to each capsule assembly.

8. Install two capsule assemblies (29) to the valve body.
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   Illustration 10	g00690482

9. Install spacer (28) and two bolts (27) to the steering pilot valve. Tighten two bolts (27) to a torque of 13 ± 1.5 N·m (115 ± 13 lb in).
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   Illustration 11	g00690430

10. Install clamp (24) for the boot.

11. Install bracket (26).

12. Apply Tooling (A) and then apply Tooling (B) to the threads of bolt (25).

13. Install bolt (25). Tighten bolt (25) to a torque of 25 ± 2.5 N·m (18 ± 2 lb ft).
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    Illustration 12	g00690428

14. Install handle (23) and dowel (22) to the steering pilot valve.
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    Illustration 13	g00690427

15. Install two connecting links (21).
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    Illustration 14	g00690391

16. Install boot (20) to the steering pilot valve (7).
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    Illustration 15	g00690390

17. Install base (19) to the steering pilot valve.

18. Install set screw (18). Repeat for the other side.
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    Illustration 16	g00690387

19. Install locknut (17). Tighten locknut (17) to a torque of 25 ± 5 N·m (18.5 ± 3.5 lb ft).
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    Illustration 17	g00690383

20. Install eight wires to connector (15). For instructions on servicing refer to Deutsch connectors Special Instruction, SEHS9615.

21. Install wedge (16) to the connector (15).
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    Illustration 18	g00690381

22. Install two wire harnesses.

23. Install two nuts (14) and the washers.

24. Attach two cable straps (13).
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    Illustration 19	g00690339

25. Install rocker switch (12).

26. Install two bolts (11).

27. Install ground wire and bolt (10).
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    Illustration 20	g00690337

28. Install cover (9) to the rocker switch.
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    Illustration 21	g00690333

29. Install two screws (8) to the rocker switch assembly.
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    Illustration 22	g01150237

30. Install STIC steering control lever (6) to the steering pilot valve (7).

31. Install two screws (5). Repeat for the other side.

32. Tighten four screws (5) to 6 ± 1 N·m (53 ± 9 lb in).
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    Illustration 23	g00690331

33. Install housing (4) and two screws (3). Tighten two screws (3) to a torque of 5 ± 1 N·m (44 ± 9 lb in).
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    Illustration 24	g00690330

34. Install cover (2) and two screws (1). Tighten two screws (1) to a torque of 5 ± 1 N·m (44 ± 9 lb in).

End By:

1. Install the STIC steering pilot valve. Refer to Disassembly and Assembly, "Pilot Valve (STIC Steering) - Install".