140H and 160H Motor Graders Engine Supplement Caterpillar

Assembly Procedure

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Illustration 1	g02961438

1. Install bearing (71) into compressor housing (69).
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   Illustration 2	g02961417

2. Install thrust washer (70) onto crankshaft (61).
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   Illustration 3	g02961398

3. Install crankshaft (61) into compressor housing (69).
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   Illustration 4	g02961381

4. Install bearing (68) into connecting rod (63). Repeat this step for the remaining connecting rod assembly
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   Illustration 5	g02961378

5. Install caps (67) onto wrist pin (64).
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   Illustration 6	g02961357

6. Install piston rings (65). Install piston (66) onto connecting rod (63). Install wrist pin (64). Repeat this step for the remaining piston and connecting rod assembly.
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   Illustration 7	g02961340

7. Install bearing (62) onto connecting rod (63). Repeat this step for the remaining connecting rod.
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   Illustration 8	g02961326

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   Illustration 9	g02961337

8. Install piston and connecting rod assemblies (60). Push piston and connecting rod assemblies (60) into the block and onto crankshaft (61).
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   Illustration 10	g02961321

9. Install bearings (59) onto bearing caps (58).
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   Illustration 11	g02961316

10. Install bearing cap (58). Install bolts (57). Repeat this step for the remaining bearing cap.
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    Illustration 12	g02961278

11. Install thrust washer (56).
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    Illustration 13	g02961237

12. Install bearing (55) and O-ring seal (54) onto cover (53).
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    Illustration 14	g02961216

13. Install cover (53). Install bolts (52).
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    Illustration 15	g02961198

14. Install cover (51). Install bolts (50). Install fitting (49).
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    Illustration 16	g02960987

15. Install fittings (48).
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    Illustration 17	g02960980

16. Apply Tooling (B) onto plugs (47). Install plugs (47).
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    Illustration 18	g02960958

17. Install valve seats (46). Install inlet valves (45).
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    Illustration 19	g02960920

18. Install inlet valve springs (44).
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    Illustration 20	g02960896

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    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.

19. Use Tooling (A) to install inlet valves (43). Install valves (42).
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    Illustration 21	g02960818

20. Install springs (41).
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    Illustration 22	g02960816

21. Install valves (40).
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    Illustration 23	g02960800

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    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.

22. Install valve seats (39).
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    Illustration 24	g02960776

23. Install spring (38), backup ring (37), and O-ring seal (36) onto unloader valve (35). Repeat this step for the remaining unloader valve (35).
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    Illustration 25	g02960759

24. Install unloader valves (35).
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    Illustration 26	g02960756

25. Install gasket (34) onto unloader cover (33).
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    Illustration 27	g02960736

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    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.

26. Install unloader cover (33) and bolts (32). T
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    Illustration 28	g02960722

27. Install gasket (31).
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    Illustration 29	g02960696

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    Illustration 30	g02962830

28. Install head (30) and bolts (29). Tighten bolts (29) to a torque of 23 N·m (200 lb in) in a crisscross pattern in the order indicated. Tighten bolts (29) again to a torque of 45 to 57 N·m (400 to 500 lb in) in a crisscross pattern in the order indicated.
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    Illustration 31	g02960676

29. Install O-ring seals (28) onto valve assembly (26).
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    Illustration 32	g02960636

30. Install check valve (27), valve assembly (26), and spacer (25).
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    Illustration 33	g02959776

31. Install spring (24).
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    Illustration 34	g02959759

32. Install O-ring seals (23) onto locking nut (22).
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    Illustration 35	g02959698

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    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.

33. Install locking nut (22). Apply Tooling (B) onto fitting (21). Install fitting (21).
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    Illustration 36	g02959676

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    Illustration 37	g02959683

34. Install gasket (20). Install manifold (19). Install bolts (18).
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    Illustration 38	g02959656

35. Install O-ring seal (17).
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    Illustration 39	g02959642

36. Install valve (16). Install spring (15).
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    Illustration 40	g02959636

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    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 retainer (14).
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    Illustration 41	g02959622

38. Install valve assembly (10). Install O-ring seals (13).
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    Illustration 42	g02959577

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    Illustration 43	g02959596

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    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.

39. Install valve assembly (10), tappet (11), and spring (12). Install spring assembly (9) and retaining ring (8).
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    Illustration 44	g02959528

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    Illustration 45	g02959557

40. Install O-ring seal (7) onto cap (6). Install cap (6).
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    Illustration 46	g02959525

41. Apply Tooling (B) onto fittings (5) and fitting (4). Install fittings (5) and fitting (4).
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    Illustration 47	g02959522

42. Install gasket (3).
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    Illustration 48	g02959516

43. Install governor (2). Install bolts (1).

End By:

1. Install the air compressor.