16H Motor Grader Machine Systems Caterpillar

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 at all times.

Note: Check the O-ring seals, the gaskets, and the seals for wear or for damage. Replace the components, if necessary.

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Illustration 1	g01072517

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Illustration 2	g01072789

Note: Pre soak the friction discs in clean oil prior to installation.

1. Install gear (40) on shaft (30). Install spacer (39). Install friction disks 37 and discs 38 . Install spacer (36) and spring (35). Install spacer (33) and retainer (32). Torque bolts (31) to 150 ± 20 N·m (110 ± 15 lb ft). Remove bolts after 45 minutes to add shims.

   Note: If the bolts are removed before 45 minutes, the clutch disks will not be properly compressed. Also the clutch setting will not be at the appropriate torque resistance.

2. Measure the distance between the top of the shaft (30) and the top of the spacer (33). Install shims (34) as necessary to obtain a distance of 2.54 ± 0.25 mm (0.100 ± 0.01 inch). Install retainer (32).
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   Illustration 3	g01072657

3. Raise the temperature of bearing cones (44). Install bearing cones (44) onto worm assembly (43).
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   Illustration 4	g01072656

4. Lower the temperature of bearing cup (45). Install bearing cup (45) into housing (7).

5. Lower the temperature of bearing (42). Install bearing (42) to a depth of 2.0 ± 0.5 mm (.079 ± .020 inch) below the face. Install thrust washer (41). Install worm assembly (43) into housing (7).
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   Illustration 5	g01072465

6. Lower the temperature of bearing cup (8) and install bearing cup (8) into adapter (3).
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   Illustration 6	g03885656

7. Torque nut (1A) to 20 N·m (15 lb ft) and nut (1B) 40 N·m (30 lb ft). Then Torque nut (1A) to 80 N·m (60 lb ft) and nut (1B) 80 N·m (60 lb ft). Then Torque nut (1A) to 130 N·m (96 lb ft) and nut (1B) 130 N·m (96 lb ft) rotate the worm 3 revolutions then back off the nuts.

8. Torque nut (1A) to 20 N·m (15 lb ft) and nut (1B) 40 N·m (30 lb ft) then torque nut (1A) to 40 N·m (30 lb ft) rotate the worm 3 revolutions.

9. Torque nut (1A) to 40 N·m (30 lb ft) and nut (1B) 40 N·m (30 lb ft). Measure the average gap between the housing and adapter at the locations being torqued. Subtract 0.065 ± 0.065 mm (0.0026 ± 0.0026 inch) to obtain the desire shim pack thickness.
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   Illustration 7	g01072796

10. Remove adapter assembly (3) and set aside with shim pack (6).

    Install Tooling (A) and bolts (31). Attach a suitable lifting device to Tooling (A). The weight of the shaft assembly is approximately 32 kg (70 lb). Install shaft assembly (30), as shown. Remove Tooling (A). Install washers and bolts (31) . Tighten bolts (31) to a torque of 150 ± 20 N·m (110 ± 14 lb ft). Torque bolts (31) to a torque of 240 ± 40 N·m (177 ± 30 lb ft). Re torque bolts (31) to a torque 240 ± 40 N·m (177 ± 30 lb ft).

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    Illustration 8	g01077943

11. Install Duo-cone (27) onto pinion (26). Install Duo-cone (29) onto housing (7). Install washer (28) and install pinion (26). Refer to Disassembly and Assembly, "Duo Cone Conventional Seals - Install".

    Note: Guarantee that there is a thin film of oil on both Duo-cone rings before installing the pinion assembly. Failure to oil will result in damaged Duo-cone seals.

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    Illustration 9	g01077940

12. Install collar (25), spacer (24), lock (23), and nut (22). Tighten nut (22) to a torque of 325 ± 27 N·m (240 ± 20 lb ft). Bend lock tab (23) onto nut (22).

13. Install Duo-cone (27) onto the other side of the pinion (26).
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    Illustration 10	g01078043

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    Illustration 11	g01077897

14. Use a suitable press to install bearing (21) into cage (19). Install bearing (21) until bearing (21) is flush with the surface of cage (19).

15. Install Duo-cone (20) onto cage assembly (19).
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    Illustration 12	g01078046

16. Install cage assembly (19). Install bolts (18). Install new gasket (17), cover (16) , washers, and bolts (15).

    Note: Guarantee that there is a thin film of oil on both Duo-cone rings before installing the pinion assembly. Failure to oil will result in damaged Duo-cone seals.

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    Illustration 13	g01072470

17. Install seal (14) and cover (13). Apply Tooling (B) to bolts (12). Install bolts (12). Install gasket (11) and cover (10). Install washers and bolts (9).
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    Illustration 14	g01079003

18. Lubricate seal (4) with the lubricant that is being sealed. Install seal (4). Install adapter (3) and nuts (2). Install coupling (5) and pin (1).

End By:

1. Install the circle drive.