143H and 163H Motor Graders Power Train Caterpillar

Assembly Procedure

Note: Cleanliness is an important factor. Before you begin the assembly procedure, the interior of the components should be thoroughly cleaned. This will help to prevent dirt to 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: Apply Tooling (M) to all O-ring seals for assembly.

Show/hide table



Illustration 1	g01004165

1. Install the pins and the clips only if the clips and the pins were replaced. Install pins (66) and clips (49) to swashplate (65) .

Show/hide table



Illustration 2	g01004107

2. Install O-ring seal (59) and seal (58) to control pistons (57) .

Show/hide table



Illustration 3	g01004219

3. Install plate (60) , spacer (61) , and control pistons (57) to swashplate (65) .

Note: Bolts (56) must go in the proper locations. Bolts are cap bolts and beveled bolts. Beveled bolts go on the inside so that the bolts do not hit the bushing.

4. Install bolts (56) to plates (60) . Tighten bolts (56) to a torque of 25 ± 5 N·m (18 ± 4 lb ft).

5. Measure the distance between swashplate (65) and the bottom of plate (60) . This measurement is Dimension (X) .

Show/hide table



Illustration 4	g01004221

6. Measure the thickness of the slipper on piston (64) . This measurement is Dimension (Y) .

7. Measure the thickness of retainer (63) . This measurement is Dimension (Z) .

8. The clearance with no shims is Dimension (A) . Dimension (A) = Dimension (X) - Dimension (Y) + Dimension (Z) .

9. Dimension (B) is the deviation. The deviation is between 0.010 to 0.030 mm (0.0004 to 0.0012 inch).

10. Dimension (A) + Dimension (B) = the proper measurement for the shims

Show/hide table



Illustration 5	g01004219

11. Remove bolts (56) from plates (60) .

Show/hide table



Illustration 6	g01004109

12. Remove plate (60) , spacer (61) , and control pistons (57) to swashplate (65) .

Show/hide table



Illustration 7	g01003804

13. Install Tooling (J) to sleeve (47A) . Install sleeve (47A) to shaft assembly (46) . Raise the temperature of bearing cone (47) . Install bearing cone (47) to shaft assembly (46) .

Show/hide table



Illustration 8	g01003803

14. Install shaft assembly (46) to housing (11) .

Show/hide table



Illustration 9	g01003802

15. Install bearing cup (45) to housing (11) .

Show/hide table



Illustration 10	g01003800

Note: Only install larger shim (44) .

16. Install shim (44) to housing (11) .

Show/hide table



Illustration 11	g01004243

17. Install cover (42) to housing (11) . Do not install seal (43) .

18. Install three bolts (41) to cover (42) . Tighten bolts (41) to a torque of 25 ± 5 N·m (18 ± 4 lb ft).

Show/hide table



Illustration 12	g01004298

19. Raise the temperature of bearing (34) . Install bearing (34) to shaft assembly (46) .

Show/hide table



Illustration 13	g01003147

20. Install bearing cup (13) to head (5) . Use Tooling (B) to seat bearing cup (13) .

Show/hide table



Illustration 14	g01003136

21. Install head (5) to housing (11) .

22. Install bolts (10) to head (5) . Tighten bolts (10) to a torque of 275 N·m (203 lb ft).

Show/hide table



Illustration 15	g01004299

23. Install Tooling (G) to housing (11) .

Show/hide table



Illustration 16	g01004300

24. Use Tooling (G) to determine the end play of the shaft. The final end play must be 0.03 mm to 0.05 mm (0.0012 inch to 0.002 inch). Add the number of shims (44) that are required to obtain the proper end play. Recheck the end play after installing the proper shims.

25. Remove Tooling (G) from housing (11) .

Show/hide table



Illustration 17	g01003136

26. Remove bolts (10) from head (5) . Remove head (5) from housing (11) .

Show/hide table



Illustration 18	g01003665

27. Remove bearing (34) . Use Tooling (A) to remove bearing (34) .

Show/hide table



Illustration 19	g01004306

Note: The measurement of the washer is 51.3 mm (2.02 inch). The thickness of the washer is 5 mm (0.2 inch).

28. Install washer (38) to barrel (35) . Install retaining ring (36) to barrel (35) . Use Tooling (C) to install retaining ring (36) .

Show/hide table



Illustration 20	g01003666

29. Install barrel (35) in housing (11) .

Show/hide table



Illustration 21	g01004378

Note: Use a depth gauge for this measurement.

30. Record the measurement from the top of housing (11) to the top of barrel (35) in four places. Record these measurements in order to achieve the average Dimension. This measurement is Dimension (R) .

Show/hide table



Illustration 22	g01004379

Note: Use a depth gauge for this measurement.

31. Measure the face of port plate (12) to the face of head (5) in four places. Record these measurements in order to get the average Dimension. This measurement is Dimension (S) .

32. Dimension (T) = Dimension (R) - Dimension (S)

33. The clearance should be 0.01 to 0.03 mm (0.0004 to 0.0012 inch). This is Dimension (U) . Dimension (T) - Dimension (U) = shim thickness

Show/hide table



Illustration 23	g01003666

34. Remove barrel (35) from housing (11) .

Show/hide table



Illustration 24	g01004306

35. Remove retaining ring (36) to barrel (35) . Use Tooling (C) to remove retaining ring (36) . Remove washer (38) from barrel (35) .

Show/hide table



Illustration 25	g01003668

Note: Refer to step 33 for the proper shim thickness for shims (37) .

Note: The washer on the bottom of the barrel must have the beveled side facing downward.

36. Install washer (40) , spring (39) , washer (38) , and shims (37) to barrel (35) .

Show/hide table



Illustration 26	g01003667

Show/hide table

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.

37. Install retaining ring (36) . Use Tooling (B) and a suitable press. Use Tooling (C) to Install retaining ring (36) .

Show/hide table



Illustration 27	g01004243

38. Remove bolts (41) from cover (42) . Remove cover (42) to housing (11) .

Show/hide table



Illustration 28	g01003800

39. Remove shims (44) from housing (11) .

Show/hide table



Illustration 29	g01003802

40. Remove bearing cup (45) from housing (11) .

Show/hide table



Illustration 30	g01003803

41. Remove shaft assembly (46) from housing (11) .

Show/hide table



Illustration 31	g01004112

42. Install two control pistons (57) , plates (60) , spacers (61) , and shims (62) to swashplate (65) .

Note: Bolts (56) must go in the proper locations. Bolts are cap bolts and beveled bolts. Beveled bolts go on the inside so that the bolts do not hit the bushing.

43. Apply Tooling (H) to bolts (56) . Install bolts (56) to the swashplate. Tighten bolts (56) to a torque of 35 N·m (25 lb ft).

44. Install swashplate (65) to housing (11) .

45. Install control pistons (57) to housing (11) .

Show/hide table



Illustration 32	g01004111

46. Install pistons (64) to retainer (63) .

Show/hide table



Illustration 33	g01004110

47. Install retainer (63) and pistons (64) to housing (11) .

Show/hide table



Illustration 34	g01004107

48. Install O-ring seal (59) and seal (58) to control pistons (57) .

Show/hide table



Illustration 35	g01004109

Note: Keep plate (60) , spacer (61) , and shims (62) as a set. Plates (60) must be put in the original position.

49. Install plate (60) , spacer (61) , and shims (62) to swashplate (11) .

Show/hide table



Illustration 36	g01004100
The swashplate and the pistons are removed for photographic purposes.

50. Install control pistons (57) to housing (11) .

Note: Bolts (56) must go in the proper locations. Bolts are cap bolts and beveled bolts. Beveled bolts go on the inside so that the bolts do not hit the bushing.

51. Apply Tooling (H) to bolts (56) . Install bolts (56) to the swashplate. Tighten bolts (56) to a torque of 25 ± 5 N·m (18 ± 4 lb ft).

Show/hide table



Illustration 37	g01004098

52. Install rod (52) and spring (53) .

Show/hide table



Illustration 38	g01003806

Show/hide table

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.

53. Slide swashplate (65) and use Tooling (E) in order to compress spring (50) .

Show/hide table



Illustration 39	g01004096

54. Install bearings and races (51) to both sides of housing (11) .

Show/hide table



Illustration 40	g01003805

Note: Clips must engage the tab from the bearing and the race.

Note: Remove any old thread lock from each hole.

Note: A clearance of 0.3 to 0.2 mm (0.01 to 0.008 inch) must be present between top of the clip and the pin.

55. Apply Tooling (H) to pins (48) . Install pins (48) to housing (11) . Rotate clips (49) .

Show/hide table



Illustration 41	g01011163

56. Install spring (48B) to spool (48A) . Install spool (48A) to the swashplate.

Show/hide table



Illustration 42	g01003806
Typical Example

57. Align rod (52) with the socket and remove Tooling (E) .

Show/hide table



Illustration 43	g01004426

Note: Make a template of the pistons. Install the template in order to make the installation of the barrel easier.

58. Install the barrel to pistons (64) in housing (11) .

Show/hide table



Illustration 44	g01003803

Note: Position the pump on a side.

59. Install shaft assembly (46) to housing (11) .

Show/hide table



Illustration 45	g01003802

60. Install bearing cup (45) to housing (11) .

Show/hide table



Illustration 46	g01003800

61. Install shims (44) to housing (11) .

Show/hide table



Illustration 47	g01003671

62. Apply Tooling (L) to seal (43) . Install seal (43) to cover (42) .

Show/hide table



Illustration 48	g01003670

63. Apply Tooling (K) to the cover. Install cover (42) to housing (11) .

Show/hide table



Illustration 49	g01003669

64. Install bolts (41) to cover (42) . Tighten bolts (41) to a torque of 9.5 N·m (84 lb in).

Show/hide table



Illustration 50	g01004419

65. Raise the temperature of bearing (34) to a temperature of 180 °C (356 °F). Install bearing (34) to the shaft assembly.

Show/hide table



Illustration 51	g01003664

66. Install valve (33) to actuator (18) .

Show/hide table



Illustration 52	g01003663

67. Install O-ring seal (31) to cam (30) .

Show/hide table



Illustration 53	g01003658

68. Install yoke (32) to actuator (18) .

69. Install cam (30) to actuator (18) .

Show/hide table



Illustration 54	g01003657

70. Install nut (29) to actuator (18) .

Show/hide table



Illustration 55	g01003656

71. Install O-ring seal (28) to actuator (18) .

Show/hide table



Illustration 56	g01003655

72. Apply Tooling (J) to actuator (18) . Install actuator (18) to housing (11) .

Note: Make sure that the dowels are engaged on the cover.

73. Install bolts (27) to actuator (18) . Tighten bolts (27) to a torque of 46 N·m (34 lb ft).

Show/hide table



Illustration 57	g01003654

74. Install retainers (26) to actuator (18) .

75. Install springs (24) and (25) to retainer (22) .

76. Install O-ring seals (23) to retainer (22) .

Show/hide table



Illustration 58	g01003653

Show/hide table

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.

Note: Use a depth gauge to set this measurement to the original setting.

77. Install retainer (22) to actuator (18) . Tighten nuts (21) .

Show/hide table



Illustration 59	g01003159

Note: The spools are a matched set. Do not interchange the spools.

78. Install O-ring seals (19) to actuator (18) . Install spools (20) and body (20A) to actuator (18) .

Show/hide table



Illustration 60	g01003157

79. Install solenoids (17) to actuator (18) . Tighten the bolts to a torque of 2.7 N·m (24 lb in).

Show/hide table



Illustration 61	g01003156

Note: Make sure that the dowels are engaged.

80. Apply Tooling (J) to cover (16) . Install cover (16) to housing (11) . Install bolts (15) to cover (16) . Tighten the bolts to a torque of 46 N·m (34 lb ft).

Show/hide table



Illustration 62	g01003150

81. Install O-ring seals (14) to housing (11) .

Show/hide table



Illustration 63	g01004099

82. Install O-ring seal (55) to spacer (54) .

83. Install spacer (54) to the top of housing (11) .

Show/hide table



Illustration 64	g01003136

84. Apply Tooling (K) to head (5) . Install head (5) to housing (11) .

85. Install bolts (10) to head (5) . Tighten bolts (10) to a torque of 275 N·m (203 lb ft).

Show/hide table



Illustration 65	g01003135

86. Install O-ring seal (9) to cover (8) .

Show/hide table



Illustration 66	g01003134

87. Install cover (8) to head (5) .

Show/hide table



Illustration 67	g01003133

88. Install bolts (7) to cover (8) . Tighten the bolts to a torque of 46 N·m (34 lb ft).

Show/hide table



Illustration 68	g01003129

89. Install back up rings and O-ring seals (6) to relief valves (4) .

Show/hide table



Illustration 69	g01003128

90. Install relief valves (4) to head (5) . Tighten the relief valves to a torque of 130 N·m (96 lb ft).

Show/hide table



Illustration 70	g01003127

91. Install O-ring seal (3) to housing (2) .

92. Install housing (2) to the pump.

Show/hide table



Illustration 71	g01003124

93. Install bolts (1) to housing (2) . Tighten the bolts to a torque of 34 N·m (25 lb ft).

Note: Fill the pump with oil prior to using the pump.

End By: Install the piston pump. Refer to Disassembly and Assembly, "Piston Pump (All Wheel Drive) - Install".