W345B Series II Material Handler Machine Systems Main Control Valve - Disassemble Caterpillar

Disassembly Procedure

Start By:

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

Note: Put identification marks on all of the components of the main control valve as the components are being removed. All of the parts must be reinstalled in the part's original location. Do not damage any of the internal parts during the removal. Keep all of the internal parts of the valve clean and lubricated.

1. Thoroughly clean the outside of the main control valve prior to disassembling the main control valve.

2. The weight of the main control valve is 454 kg (1000 lb).

Swing Priority Valve

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Illustration 1	g00638555

1. Remove swing priority valve (2).

   Note: There is spring force against swing priority valve (2). When four bolts (1) that hold the swing priority valve in place are removed, the spring force will be released. To prevent possible personal injury, hold swing priority valve (2) in place by hand as bolts (1) are being removed.

2. While you hold swing priority valve (2) in place, slowly remove four bolts (1).

3. Remove swing priority valve (2) from the main valve body.
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   Illustration 2	g00638556

4. Remove spring (3) from the main valve body.
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   Illustration 3	g00638557

5. Remove check valve (4) from the main valve body.

6. Disassemble swing priority valve (2), as follows:
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   Illustration 4	g00638763

   1. Remove O-ring seals (5) and (6) from the valve body.
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      Illustration 5	g00638765

   2. Remove plug (7).

   3. Remove plug (13), valve (11), spool (10) and spring (9) from the valve body.

   4. Remove O-ring seal (8) from plug (7).

   5. Remove O-ring seal (12) from plug (13).

Check valve for the Stick I Control Valve

1. Remove the check valve from the stick I control valve, as follows.
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   Illustration 6	g00638768

2. Remove plate (14) from the stick I control valve. Remove O-ring seal (15) from the plate.
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   Illustration 7	g00638780

3. Remove pilot valve (16) from the stick I control valve.
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   Illustration 8	g00638782

4. Remove spring (17) from the stick I control valve.
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   Illustration 9	g00638783

5. Remove check valve (18) from the stick I control valve.
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   Illustration 10	g00638786

6. Remove sleeve (19) and two shims (20) from the stick I control valve.

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Illustration 11	g00638787

1. Remove adapter (21) from the front of the main valve body.
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   Illustration 12	g00638836

2. Remove O-ring seal (22) from adapter (21).

Load Check Valves

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Illustration 13	g00638841

1. Remove six load check valves (23) from the main control valve, as follows:
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   Illustration 14	g00638838

   1. Remove six plugs (27), six springs (25), and six check valves (24) from the main valve body.

   2. Remove O-ring seal (26) from each plug (27).

Check Valves for the Straight Travel Control Valve

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Illustration 15	g00638844

1. Remove two check valves (28) from the straight travel control valve, as follows:
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   Illustration 16	g00638848

   1. Remove two plugs (31) from the main valve body.

   2. Remove O-ring seal (29) and backup ring (30) from each plug.
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      Illustration 17	g00638851

   3. Remove two springs (33) and two check valves (32) from the left travel control valve and the right travel control valve.

Check Valves for the Left Travel Control Valve and the Right Travel Control Valve

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Illustration 18	g00638858

1. Remove two check valves (34) from the travel control valves, as follows:
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   Illustration 19	g00638861

   1. Remove two plugs (36). Remove O-ring seal (35) from each plug (36).
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      Illustration 20	g00638862

   2. Remove two sleeves (37) from the travel control valves.

Check Valve for the Boom II Control Valve

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Illustration 21	g00638863

1. Remove check valve (38) from the boom II control valve, as follows:
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   Illustration 22	g00638878

   1. Remove plug (42), spring (40) and check valve (39) from the Boom II Control Valve.

   2. Remove O-ring seal (41) from plug (42).

Line Relief Valves

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Illustration 23	g00638926

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Illustration 24	g00638940

1. Remove line relief valve (43), (44) and (45) from the top of the main valve. Remove line relief valve (46), (47), and (48) from the bottom of the main valve.

   Note: Only the O-ring seals and backup rings in line relief valves (43), (44), (45), (46), (47), and (48) are serviceable.

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   Illustration 25	g00638941

2. Disassemble line relief valves (43), (44), (45), (46), (47), and (48), as follows:

   1. Separate adapter (50) from adapter (66).

   2. Remove cap (61) from adjusting screw (60).

   3. Mark the location of nut (68) with a suitable pencil. Unscrew nut (68) from adjusting screw (60). Make sure that you note the number of turns that are needed to remove nut (68). The valve must be reset if the number of turns are not documented.

   4. Remove spring (67) and needle valve (57).

   5. Remove sleeve (51), valve (53), valve (63), spring (54), and spring (64) from the bottom half of the relief valve.

   6. Remove O-ring seal (49) from adapter (50).

   7. Remove O-ring seal (52) and backup ring (62) from valve (53).

   8. Remove seal (55), backup ring (65), and O-ring seal (56) from adapter (66).

   9. Remove O-ring seals (58) and (59) from nut (68).

Plug for the Attachment Control Valve

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Illustration 26	g00638943

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Illustration 27	g00638944

1. Remove plug (69) from the attachment control valve.

2. Remove O-ring seal (70), backup ring (71), and O-ring seal (72) from plug (69).

Main Relief Valve

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Illustration 28	g00638945

1. Remove main relief valve (73) from the main valve body.

2. Disassemble main relief valve (73), as follows:
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   Illustration 29	g00638946

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   Illustration 30	g00638949

   1. Remove nut (74) and adjuster (76) from adapter (77).

   2. Remove adapter (77), spring (79) and valve (80) from valve body (84).

   3. Remove O-ring seal (78) from adapter (77).

   4. Remove O-ring seal (75) from adjuster (76).

   5. Disassemble valve body (84). Remove seat (81), spring (82) and valve (83) from valve body (84).

   6. Remove O-ring seals (85), (86) and (87) from valve body (84).
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      Illustration 31	g00638955

   7. Remove ring (89), collar (88) and the filter from valve (83).

Relief Valve for Negative Flow Control

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Illustration 32	g00638957

1. Remove two relief valves (90) for the negative flow control from the main valve bodies.

2. Disassemble the two relief valves for negative flow control, as follows:
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   Illustration 33	g00638969

   1. Remove plug (97), spring (92) and valve (91) from valve body (95).

   2. Remove O-ring seal (96) from plug (97).

   3. Remove O-ring seal (93) and O-ring seal (94) from valve body (95).

Straight Travel Stem Assembly

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Illustration 34	g00638971

1. Remove plug (98) from the main valve body.
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   Illustration 35	g00638972

2. Remove O-ring seal (99) from plug (98).
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   Illustration 36	g00638973

3. Remove stem (100) for straight travel from the main valve body.

4. Disassemble the stem (100) for straight travel, as follows:
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   Illustration 37	g00638974

   1. Remove piston (107) from spool (106).

   2. Remove plug (101), dowel (103), spring (104) and valve (105) from spool (106).

   3. Remove O-ring seal (102) from plug (101).

Stem Assemblies for the Main Control Valve

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Illustration 38	g00638980

1. Remove bolts (127) that hold nine housings (128) to the main valve bodies.

2. Remove the nine housings.
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   Illustration 39	g00638982

3. Remove O-ring seal (129) from each housing (128).
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   Illustration 40	g00638983

4. Remove the stems for boom II (130), swing (132), right travel (134), bucket (136), and stick II (138) from the main valve bodies.

5. Remove the stems for stick I (131), left travel (133), attachment (135), and boom I (137) from the main valve bodies.

6. Disassemble the stems for boom II (130), swing (132), right travel (134), bucket (136), and stick II (138), as follows:
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   Illustration 41	g00638984

   1. Remove bolt (139) from the end of spool (143).

   2. Remove retainer (140), spring (141) and retainer (142) from spool (143).

      Note: The disassembly for the stem for right travel (134) and the stem for left travel (133) is identical as the previous stems except the stems for travel have an adapter.

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   Illustration 42	g00638985

7. Remove O-ring seals (144), (146) and (147) from adapter (145).

8. Disassemble the stem for boom I (137), as follows:
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   Illustration 43	g00638986

   1. Remove plug (156), spring (154), valve (153), valve (152), spring (151), valve (150), and spring (149) from spool (148).

   2. Remove O-ring seal (155) from plug (156).
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      Illustration 44	g00638987

   3. Remove bolt (157) and washer (158) from the other end of spool (148).

   4. Remove retainer (160), spring (161), and retainer (162) from the end of rod (159).

   5. Remove rod (159).

   6. Remove spring (163) and valve (164) from the end of spool (148).

   7. Remove O-ring seal (165) from rod (159).

Stroke Limiter for Tamping Mode

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Illustration 45	g00638988

Note: There is spring force against stroke limiter (167). When two bolts (166) that hold stroke limiter (167) in position are removed the spring force will be released. To prevent possible personal injury, hold stroke limiter (167) in place by hand as two bolts (166) are being removed.

1. While you hold stroke limiter (167) in place, slowly remove two bolts (166). Remove stroke limiter (167) from the main valve body.

2. Disassemble stroke limiter (167), as follows:
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   Illustration 46	g00639012

   1. Remove plug (168) from valve body (170).

   2. Remove spacer (172), spring (173) and piston (174) from valve body (170).

   3. Remove O-ring seal (169) from plug (168).

   4. Remove O-ring seal (171) from valve body (170).

Regeneration Valve for the Stick

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Illustration 47	g00639036

1. Remove four bolts (175) from the regeneration valve (176) for the stick.

2. Disassemble the regeneration valve (176) for the stick, as follows:
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   Illustration 48	g00639038

   1. Remove spring (179), spool valve (180), rod (181), spring (182), valve (183), and pin (185) from valve body (177).

   2. Remove O-ring seals (178), and (184) from valve body (177).
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   Illustration 49	g00639039

3. Remove bolts (186) and nine housings (187) from the main valve bodies.
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   Illustration 50	g00639041

4. Remove O-ring seal (188) from each housing (187).
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   Illustration 51	g00639044

5. Remove spring (189) from the stem for straight travel.
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   Illustration 52	g00639046

6. Remove seat (190) from the stem for straight travel.
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   Illustration 53	g00639051

7. Remove two sensors (191) and plug (192).
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   Illustration 54	g00639054

8. Remove O-ring seal (193) from sensors (191).
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   Illustration 55	g00639055

9. Remove O-ring seal (194) from plug (192).
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   Illustration 56	g00639060

10. Remove four bolts (196) and washers that hold left main valve body (197) and right main valve body (195) together. Separate the main valve bodies. The weight of each main valve body is 227 kg (500 lb).
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    Illustration 57	g00639061

11. Remove two large O-ring seals (200), two medium O-ring seals (199), and six small O-ring seals (198) from the right main valve body.
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    Illustration 58	g00639066

12. Remove O-ring seal (201) from the left main valve body.