140 Motor Grader Power Train Caterpillar

Assembly Procedure

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Illustration 1	g06386198

1. Install fitting (75) and the O-ring seal.
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   Illustration 2	g06386197

2. Install plug (74) and the O-ring seal.
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   Illustration 3	g06386195

3. Install plug (73) and the O-ring seal.
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   Illustration 4	g06386192

4. Lower the temperature of bearing cup (72). Use Tooling (G) to install bearing cup (72) into the housing.

5. Install pins (71).
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   Illustration 5	g06387096

6. Apply Tooling (H) to cradle bearings (69). Install cradle bearings (69).
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   Illustration 6	g06387836

7. Apply Tooling (K) to lip seal (70). Use Tooling (G) to install lip seal (70) into housing (67).

8. Install retaining ring (68) into housing (67).
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   Illustration 7	g06387104

9. Raise the temperature of bearing cone (53). Install bearing cone (53) onto shaft assembly (51).

   Note: The following steps are for determining the proper number of shims (34) (not shown) that will be installed.

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   Illustration 8	g06387119

10. Install shaft assembly (51) into housing (67). Measure the distance from the shoulder on shaft (51) to the top of housing (67) and record Dimension (A) to the nearest 0.010 mm (0.0004 inch).
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    Illustration 9	g06387144

11. Measure dimension (B) and record dimension (B) to the nearest 0.010 mm (0.0004 inch) on special washer (45).
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    Illustration 10	g06387152

12. Measure dimension (C) and record dimension (C) to the nearest 0.010 mm (0.0004 inch) on bearing cone (44) and bearing cup (33).
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    Illustration 11	g06387154

13. Calculate Dimension (D) and record Dimension (D) to the nearest 0.01 mm (0.00039 inch) on housing (27).

    Note: Ensure that all existing shims have been removed.

14. Calculate Dimension (X) and record Dimension (X) to the nearest 0.010 mm (0.0004 inch).

    Note: Dimension (X) is equal to Dimension (A) plus Dimension (D).

15. Calculate Dimension (Y) and record Dimension (Y) to the nearest 0.010 mm (0.0004 inch).

    Note: Dimension (Y) is equal to Dimension (B) plus Dimension (C).

16. Calculate Dimension (Z) and record Dimension (Z) to the nearest 0.010 mm (0.0004 inch).

    Note: Dimension (Z) is equal to Dimension (X) minus Dimension (Y).

17. The number of shims is equal to the value of Dimension (Z) with a tolerance of +0.020 mm (+0.0008 inch) or -0.070 mm (-0.0028 inch).
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    Illustration 12	g06389727

18. Use the measurement that was taken in steps 14 through 17 to install the proper number of shims (34) (not shown) into housing (27).

19. Lower the temperature of bearing cup (33). Use Tooling (G) to install bearing cup (33).

20. Use the following steps to determine the proper number of shims (59) (not shown) that will be installed.
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    Illustration 13	g06387561

21. Install washer (58) and retaining ring (55) into barrel (54).
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    Illustration 14	g06387553

22. Install barrel (54) into housing (67). Measure Dimension (L) and record Dimension (L) to the nearest 0.010 mm (0.0004 inch).
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    Illustration 15	g06387558

23. Install control plate (30) onto housing (27). Measure Dimension (M) and record Dimension (M) to the nearest 0.010 mm (0.0004 inch).

24. Calculate Dimension (N) and record Dimension (N).

    Note: Dimension (N) equals Dimension (L) minus Dimension (M).

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    Illustration 16	g06387561

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    Illustration 17	g06386161

25. Remove retaining ring (55) and washer (58) from barrel (54).

26. Install washer (56), spring (57), washer (58), and the correct number of shims (59) that were determined in steps 22 through 24.
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    Illustration 18	g06386117

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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.

27. Use Tooling (G) and a suitable press to install retaining ring (55) into barrel (54).
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    Illustration 19	g06389731

28. Use the following steps to determine the proper number of shims (62) (not shown) that will be installed under retainer (65).

29. Measure Dimension (P) and record Dimension (P) on plate (61) to the nearest 0.010 mm (0.0004 inch).

30. Calculate Dimension (R) and record Dimension (R) to the nearest 0.010 mm (0.0004 inch) on retainer (65).

31. Calculate Dimension (S) and record Dimension (S) to the nearest 0.010 mm (0.0004 inch) on pistons (64).

32. Calculate Dimension (T) and record Dimension (T) to the nearest 0.010 mm (0.0004 inch).

    Note: Dimension (T) equals Dimension (R) plus Dimension (S).

33. Calculate Dimension (U) and record Dimension (U) to the nearest 0.010 mm (0.0004 inch).

    Note: Dimension (U) equals Dimension (T) minus Dimension (P).

34. Select a combination of shims (62) (not shown) that equals Dimension (U) minus .020 ± 0.010 mm (0.0008 ± 0.0004 inch).

35. Repeat steps 27 through 32 for the plate on the opposite side.

    Note: The slipper clearance is .020 ± 0.010 mm (0.0008 ± 0.0004 inch).

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    Illustration 20	g06387597

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    Illustration 21	g06387603

36. Install sleeves (66) into swashplate (63).

37. Position pistons (64) and retainer (65) onto swashplate (63).

38. Install the correct number of shims (62) that were determined in step 35. Position plate (61). Apply Tooling (J) to new bolts (60) and install. Tighten bolts (60) to a torque of 69 ± 7 N·m (51 ± 5 lb ft).
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    Illustration 22	g06387817

39. Install barrel (54) onto the rotating group.
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    Illustration 23	g06386094

40. Install shaft assembly (51) into the rotating assembly.
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    Illustration 24	g06386085

41. Install O-ring seal (50) into piston (49). Repeat for the other piston.
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    Illustration 25	g06386082

42. Install pistons (48) and (49) onto the rotating assembly.

43. Install rod (47) onto the rotating assembly.
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    Illustration 26	g06387846

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    Illustration 27	g06387870

    Note: Ensure that the swashplate engages the cradle bearings correctly.

    Note: Center the swashplate to the zero displacement angle.Each dimension that is measured and recorded is specific to each pipe (28).

44. Install back up rings (32) and O-ring seals (31) onto pipes (28).

45. Install rotating assembly (46) into the housing.

46. Install pipes (28).
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    Illustration 28	g06387874

47. Install Tooling (D).
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    Illustration 29	g06387885

48. Calculate Dimension (AA) and record Dimension (AA) to the nearest 0.010 mm (0.0004 inch).

49. Calculate Dimension (BB) and record Dimension (BB) to the nearest 0.010 mm (0.0004 inch).

50. Calculate Dimension (CC) and record Dimension (CC) to the nearest 0.010 mm (0.0004 inch).

51. Calculate Dimension (DD) and record Dimension (DD) to the nearest 0.010 mm (0.0004 inch).

    Note: Dimension (DD) equals Dimension (CC) minus Dimension (AA).

52. Calculate Dimension (EE) and record Dimension (EE) to the nearest 0.010 mm (0.0004 inch).

    Note: Dimension (EE) equals Dimension (CC) minus Dimension (BB).

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    Illustration 30	g06387893

53. Measure Dimension (FF) and record Dimension (FF) in housing (27) to the nearest 0.010 mm (0.0004 inch).

54. Measure Dimension (GG) and record Dimension (GG) in housing (27) to the nearest 0.010 mm (0.0004 inch).

55. Calculate Dimension (HH) and record Dimension (HH) to the nearest 0.010 mm (0.0004 inch).

    Note: Dimension (HH) equals Dimension (FF) minus Dimension (DD).

56. Calculate Dimension (JJ) and record Dimension (JJ) to the nearest 0.010 mm (0.0004 inch).

    Note: Dimension (JJ) equals Dimension (GG) minus Dimension (EE).

    Note: You must calculate a range for washer (29) that corresponds with each individual pipe (28).

57. Select a washer (29) (not shown) that equals Dimension (HH) minus 0.080 ± 0.070 mm (0.0031 ± 0.0028 inch) for pipe (28). Install washer (29) into housing (27).

58. Select a washer (29) (not shown) that equals Dimension (JJ) minus 0.080 ± 0.070 mm (0.0031 ± 0.0028 inch) for the other pipe (28). Install washer (29) into housing (27).
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    Illustration 31	g06387918

59. Install ring (45) onto the shaft assembly.
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    Illustration 32	g06387894

60. Raise the temperature of bearing cone (44) and install onto the shaft assembly.

61. Remove Tooling (D) and pipes (28) (not shown) from the housing.
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    Illustration 33	g06387910

62. Remove rotating assembly (46).
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    Illustration 34	g06386033

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    Illustration 35	g06386006

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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.

63. Install plunger (40), guide (41), spring (42), and guide (43) into the housing.

64. Install plug (39) and the O-ring seal into the housing.
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    Illustration 36	g06385997

65. Install valve (38) and the O-ring seal into the housing.
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    Illustration 37	g06385995

66. Install adjustment screws (37) to the depth determined in the disassembly. Tighten the lock nuts to a torque of 69 ± 7 N·m (51 ± 5 lb ft).

67. Install adjustment screw (36) to the depth determined in the disassembly.

68. Install fittings (35) and the O-ring seals.
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    Illustration 38	g06381439

69. Install O-ring seal (13), O-ring seal (14), spring (15), and piston (16) into cover (8).

70. Install retainer (12), washers (11). O-ring seal (10), and plug (9) into cover (8). Tighten plug (9) to a torque of 10 ± 1 N·m (86 ± 9 lb in).
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    Illustration 39	g06387976

71. Rotate housing (27) 90 degrees. Install cover (8) and screws (7). Tighten screws (7) to a torque of 5 ± 0.5 N·m (44 ± 4 lb in).
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    Illustration 40	g06381466

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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.

72. Install washers (23) and pilot valve (24) into bushing (17). Install retainer (22), spring (21), ring (20), and retaining ring (19) into bushing (17). Install spring (18) into bushing (17).
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    Illustration 41	g06388056

    Note: Ensure that pipes (28) are installed in the appropriate locations based on the measurements taken in steps 44 through 54.

73. Lay housing (27) flat. Install bushing (17) into housing (27).

74. Install washers (29) and pipes (28) into housing (27).

75. Install control plate (30) onto housing (27).
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    Illustration 42	g06388428

    Note: Ensure that the pipes, pistons, and rod engage the appropriate locations before final assembly.

76. Install rotating assembly (46) onto housing (27).
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    Illustration 43	g06388455

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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.

77. Apply Tooling (K) to the mating surfaces of housing (27) and housing (67).

78. Use Tooling (L) and a suitable lifting device to install housing (67) onto housing (27).

79. Install bolt (25) and bolts (26) (not shown) into head (27).
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    Illustration 44	g06388464

80. Reattach the motor to Tooling (A) or suitable fixture. The weight of the motor is approximately 40 kg (88 lb).

81. Tighten bolts (26) to a torque of 87 ± 8 N·m (64 ± 6 lb ft).

82. Tighten bolt (25) to a torque of 25 ± 2 N·m (221 ± 22 lb in).
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    Illustration 45	g06388468

83. Install gear (6) and bolt (5). Tighten bolt (5) to a torque of 51 ± 5 N·m (38 ± 4 lb ft).
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    Illustration 46	g06381414

84. Install cover (4) and bolts (3). Tighten bolts (3) to a torque of 10.4 ± 1 N·m (92 ± 9 lb in).
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    Illustration 47	g06381410

85. Install sensor (2), the O-ring seal, and bolt (1). Tighten bolt (1) to a torque of 25 ± 2 N·m (221 ± 18 lb in).

86. Remove the motor from Tooling (A) or suitable fixture. The weight of the motor is approximately 40 kg (88 lb).

End By:

1. Install the piston motor.