140H and 160H Motor Graders Engine Supplement Caterpillar

Disassembly Procedure

Start By:

1. Remove the air compressor.

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Illustration 1	g02959516

1. Remove bolts (1) and governor (2).
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   Illustration 2	g02959522

2. Remove gasket (3).
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   Illustration 3	g02959525

3. Mark the orientation of fitting (4). Remove fitting (4) and fittings (5).
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   Illustration 4	g02959528

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   Illustration 5	g02959557

4. Remove cap (6). Remove O-ring seal (7) from cap (6).
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   Illustration 6	g02959577

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   Illustration 7	g02959596

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   Personal injury can result from being struck by parts propelled by a released spring force. Make sure to wear all necessary protective equipment. Follow the recommended procedure and use all recommended tooling to release the spring force.

5. Remove retaining ring (8) and spring assembly (9).

6. Remove spring (12), tappet (11), and valve assembly (10).
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   Illustration 8	g02959622

7. Remove O-ring seals (13) from valve assembly (10).
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   Illustration 9	g02959636

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   Personal injury can result from being struck by parts propelled by a released spring force. Make sure to wear all necessary protective equipment. Follow the recommended procedure and use all recommended tooling to release the spring force.

8. Remove retainer (14).
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   Illustration 10	g02959642

9. Remove spring (15) and valve (16).
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   Illustration 11	g02959656

10. Remove O-ring seal (17).
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    Illustration 12	g02959676

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    Illustration 13	g02959683

11. Remove bolts (18) and manifold (19).

12. Remove gasket (20).
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    Illustration 14	g02959698

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    Personal injury can result from being struck by parts propelled by a released spring force. Make sure to wear all necessary protective equipment. Follow the recommended procedure and use all recommended tooling to release the spring force.

13. Mark the orientation of fitting (21). Remove fitting (21). Remove locking nut (22).
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    Illustration 15	g02959759

14. Remove O-ring seals (23) from locking nut (22).
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    Illustration 16	g02959776

15. Remove spring (24).
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    Illustration 17	g02960636

16. Remove spacer (25), valve assembly (26), and check valve (27).
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    Illustration 18	g02960676

17. Remove O-ring seals (28) from valve assembly (26)
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    Illustration 19	g02960696

18. Drain any excess coolant from the compressor head. Remove bolts (29) and head (30).
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    Illustration 20	g02960722

19. Remove gasket (31).
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    Illustration 21	g02960736

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    Personal injury can result from being struck by parts propelled by a released spring force. Make sure to wear all necessary protective equipment. Follow the recommended procedure and use all recommended tooling to release the spring force.

20. Remove bolts (32) and unloader cover (33).
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    Illustration 22	g02960756

21. Remove gasket (34) from unloader cover (33).
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    Illustration 23	g02960759

22. Remove unloader valves (35).
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    Illustration 24	g02960776

23. Remove O-ring seal (36), backup ring (37), and spring (38) from unloader valve (35). Repeat this step for the remaining unloader valve (35).
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    Illustration 25	g02960800

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    Personal injury can result from being struck by parts propelled by a released spring force. Make sure to wear all necessary protective equipment. Follow the recommended procedure and use all recommended tooling to release the spring force.

24. Remove valve seats (39).
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    Illustration 26	g02960816

25. Remove valves (40).
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    Illustration 27	g02960818

26. Remove springs (41).
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    Illustration 28	g02960896

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    Personal injury can result from being struck by parts propelled by a released spring force. Make sure to wear all necessary protective equipment. Follow the recommended procedure and use all recommended tooling to release the spring force.

27. Remove valves (42). Use Tooling (A) to remove inlet valves (43).
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    Illustration 29	g02960920

28. Remove inlet valve springs (44).
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    Illustration 30	g02960958

29. Remove inlet valves (45) and valve seats (46).
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    Illustration 31	g02960980

30. Remove plugs (47).
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    Illustration 32	g02960987

31. Remove fittings (48).
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    Illustration 33	g02961198

32. Remove fitting (49). Remove bolts (50) and cover (51).
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    Illustration 34	g02961216

33. Remove bolts (52) and cover (53).
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    Illustration 35	g02961237

34. Remove O-ring seal (54) and bearing (55) from cover (53).
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    Illustration 36	g02961278

35. Remove thrust washer (56).
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    Illustration 37	g02961316

36. Remove bolts (57) and bearing cap (58). Repeat this step for the remaining bearing cap.
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    Illustration 38	g02961321

37. Remove bearings (59) from bearing caps (58).
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    Illustration 39	g02961326

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    Illustration 40	g02961337

38. Push piston and connecting rod assemblies (60) from crankshaft (61) and out of the block.
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    Illustration 41	g02961340

39. Remove bearing (62) from connecting rod (63). Repeat this step for the remaining connecting rod.
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    Illustration 42	g02961357

40. Remove wrist pin (64). Remove piston (66) from connecting rod (63). Remove piston rings (65). Repeat this step for the remaining piston and connecting rod assembly.
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    Illustration 43	g02961378

41. Remove caps (67) from wrist pin (64).
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    Illustration 44	g02961381

42. Remove bearings (68) from connecting rod (63). Repeat this step for the remaining connecting rod assembly
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    Illustration 45	g02961398

43. Remove crankshaft (61) from compressor housing (69).
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    Illustration 46	g02961417

44. Remove thrust washer (70) from crankshaft (61).
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    Illustration 47	g02961438

45. Remove bearing (71) from compressor housing (69).