R1600H Load Haul Dump Power Train Caterpillar

Disassembly Procedure

Start By:

1. Remove the transmission hydraulic control valve. Refer to Disassembly and Assembly Manual, "Transmission Hydraulic Control Valve - Remove".

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Illustration 1	g00520024

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Illustration 2	g00520026

1. Perform the following steps in order to remove the solenoid valve from the transmission hydraulic control valve.

   1. Remove electrical connector (4) from the support clip.

   2. Remove the nut, the washer, and the coil assembly (2) from cartridge (1) .

   3. Remove cartridge (1) from manifold (3) .

   4. Repeat Step 1.a through Step 1.c for the remaining solenoid valves.

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Illustration 3	g00520033

2. Remove the bolts from the clamps that are holding wiring harness (7) .

3. Remove bolts (5) from manifold (3) .

4. Remove manifold (3) and wiring harness (7) from manifold (6) .

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Illustration 4	g00520034

5. Remove two connectors (8) from manifold (6) .

6. Remove plug (10) from manifold (6) .

7. Remove bolts (9) from manifold (6) .

8. Remove manifold (6) from valve (11) .

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Illustration 5	g00520036

9. Remove valve (11) from plate (12) .

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Illustration 6	g00520037

10. Remove the bolts and cover (13) from valve (11) .

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Illustration 7	g00520039

11. Remove stop (14) and spool (15) from valve (11) .

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Illustration 8	g00521500

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Illustration 9	g00521502

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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.

12. Support two retainers (17) and spring (18). Remove retainer ring (16). Remove two retainers (17) and spring (18) .

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Illustration 10	g00521504

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Illustration 11	g00521505

13. Remove spring (19) and spool (20) from valve (11) .

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Illustration 12	g00521507

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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.

14. Support retainer (22), spring (23), and spring (24). Remove retainer ring (21). Remove retainer (22), spring (23), and spring (24) from spool (20) .

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Illustration 13	g00521509

Note: Spool (20) and spool (25) are located in the same bore of valve (11). Spool (25) must be removed from the end of valve (11) that is opposite spool (20).

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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. Perform the following steps in order to remove spool (25) from valve (11) .

    1. Invert valve (11). Place valve (11) on wood blocks.

    2. Use a punch to drive pin (26) into valve (11). Pin (26) must be clear of spool (25). Do not remove the punch at this time.
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    Illustration 14	g00521510

    3. Use a screwdriver to depress spool (25) slightly.

    4. Remove the punch from the hole for pin (26) .

    5. Slowly remove the screwdriver that is depressing spool (25) to relieve the spring pressure that is against spool (25) .

    6. Remove spool (25) from valve (11) .

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Illustration 15	g00521511

16. Remove spring (27) from valve (11) .

17. Remove slug (28) from spool (25) .

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Illustration 16	g00521512

18. Invert valve (11) .

19. Remove piston (29) from valve (11) .

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Illustration 17	g00521513

20. Remove spacer (30) from the inside diameter of piston (29) .

21. Remove spring (31) and spring (32) from valve (11) .

Note: Use a punch or a screwdriver to keep the outside diameters of spool (33) aligned with the bore of the valve. Avoid damaging or scratching the highly finished surface of spool (33) and the bore of valve (11) .

22. Remove spool (33) from valve (11) .

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Illustration 18	g00520040

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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.

23. Remove slug (34) from spool (33) .

24. Support retainer (37). Remove retainer ring (38). Remove retainer (37), spring (36), and ball (35) from spool (33) .

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Illustration 19	g00520041

25. Remove stop (39) and spool (40) from valve (11) .

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Illustration 20	g00520047

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Illustration 21	g00520051

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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.

26. Support two retainers (42) and spring (43). Remove retaining ring (41), retainer (42), spring (43), and retainer (42) from spool (40) .

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Illustration 22	g00520052

27. Remove plate (12) from valve (44) .

28. Remove two plugs (45) from plate (12). Remove the O-ring seals from plugs (45) .

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Illustration 23	g00520053

29. Remove the bolts and cover (46) from valve (44).

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Illustration 24	g00520054

30. Remove O-ring seal (47) from underneath cover (46) .

31. Remove stop (48) from valve (44) .

32. Remove spool (52) from valve (44) .

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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.

33. Support two retainers (50) and spring (51). Remove retainer ring (49), retainer (50), spring (51), and retainer (50) from spool (52) .