Challenger 35, Challenger 45 and Challenger 55 Agricultural Tractors Machine Systems Caterpillar

Steering Motor - Assemble

Usage:

45 1DR

Assembly Procedure

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Table 1
Required Tools
Tool	Part Number	Description	Qty
A	1P-5546	Crossblock	1
	5F-7366	Forcing Screw	1
		Threaded Rod	2
	8T-1757	Nut	2
	5P-8247	Hard Washer	2
	8S-1596	Socket	1
B	1P-1854	Retaining Ring Pliers	1
C	5F-7465	Puller	1
		Threaded Rod	2
	6V-8225	Nut	2
	5P-0537	Hard Washer	2
D	136-1452	Internal Tip Pliers	1
E	6T-3011	Spanner Wrench	1
F	7H-1941	Block	1
G	6V-2012	Depth Micrometer	1
H		Outside Micrometer	1
J	8T-7681	Seal Driver	1
K	8T-7666	Seal Guide	1
L	6V-8225	Nut	2
		Threaded Rod	2
	5P-0537	Hard Washer	2
M	6V-2315	Bolt	2

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Illustration 1	g00700596

Install bearing (34) on input shaft (28) . Put Tooling (F) in a vise. Position three pistons (18) in input shaft (28) . Put input shaft (28) with three pistons (18) on Tooling (F) .

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Illustration 2	g00700597

Note: Rotate bearing (34) several times. The bearing must be seated. Then repeat the measurement for distance (B) . The measurement must be accurate.

Use Tooling (G) in order to measure distance (B) and record this dimension.

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Illustration 3	g00700596

Use Tooling (H) in order to measure the diameter of ball (C) and record this dimension. Use dimension (B) and dimension (C) in order to determine dimension (A) .

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Illustration 4	g00700602

Use Tooling (H) in order to measure the thickness of spacer (32) . Refer to dimension (D) .

Use the following calculation (F) plus (E) in order to set the point of articulation . Use all of the measurements in order to calculate dimension (F) . Refer to the chart in order to determine the proper thickness of shims (33) . Refer to dimension (E) .

Use the following chart in order to determine the correct shim.

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Table 2
Dimension (F ) and (E)	Part number for shim	Dimension (E) (Shim Thickness)
65.50 mm to 65.54 mm (2.578 inch to 2.579 inch)	9T-4564 shim	0.80 mm (0.031 inch)
65.55 mm to 65.59 mm (2.580 inch to 2.582 inch)	9T-4565 Shim	0.74 mm (0.029 inch)
65.60 mm to 65.64 mm (2.583 inch to 2.584 inch)	9T-4566 Shim	0.68 mm (0.027 inch)
65.65 mm to 65.69 mm (2.585 inch to 2.586 inch)	9T-5467 Shim	0.62 mm (0.024 inch)
65.70 mm to 65.74 mm (2.587 inch to 2.588 inch)	9T-4568 Shim	0.56 mm (0.022 inch)
65.75 mm to 65.80 mm (2.589 inch to 2.590 inch)	9T-4569 Shim	0.50 mm (0.020 inch)

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Illustration 5	g00700575

Determine shim washer (33) to use. Install shim (33) , spacer (32) and bearing (31) on input shaft (28) .

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Illustration 6	g00700569

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Illustration 7	g00700612

Install new spanner nut (30) on input shaft (28) . Use Tooling (E) in order to tighten spanner nut (30) until the bearing preload is 1.0 N·m to 1.5 N·m (9.00 lb ft to 13.00 lb ft). Check the bearing preload by positioning input shaft (28) in a soft jawed vise and clamp on spacer (32) . Install a bolt and a nut in the end of input shaft (28) , as shown.

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Illustration 8	g00700614

Position the splined end of input shaft (28) in a soft jawed vise. Install seven pistons (18) , seven retainers (19) and plate (17) .

Apply 9S-2363 Thread Lock on four bolts (16) and install the bolts in input shaft (28) . Tighten bolts (16) to a torque of 10 N·m ± 2 N·m (7.0 lb ft ± 1.0 lb ft).

Use Tooling (B) and install snap ring (15) in the cylinder barrel.

Lubricate the piston bores of cylinder barrel (14) with clean oil and carefully install cylinder barrel (14) on seven pistons (18) .

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Illustration 9	g00700620

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Illustration 10	g00700560

With input shaft (28) in the vise, slide housing (3) over cylinder barrel (14) and on the bearings. Maintain proper alignment and use a soft faced hammer in order to drive housing (3) in place. Drive housing (3) downward until snap ring (29) can be installed in housing (3) . Use Tooling (D) and install snap ring (29) .
Note: Cylinder barrel (14) must not come off pistons (18) .

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Illustration 11	g00700558

Use the proper tooling in order to reach through the center of cylinder barrel (14) (not shown). Tap input shaft (28) until spacer (32) is against snap ring (29) .

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Illustration 12	g00700555

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Illustration 13	g00700558

Apply 9S-3263 Thread Lock on set screws (27) and install set screws (27) in housing (3) . Tighten set screws (27) to a torque of 11 N·m ± 1 N·m (8.0 lb ft ± 1.0 lb ft).

Apply 9S-3263 Thread Lock on set screws (26) . Install set screws (26) in housing (3) until the set screws (26) seat against set screws (27) . Tighten the set screws (26) to a torque of 30 N·m ± 2.5 N·m (22.0 lb ft ± 2.00 lb ft).

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Illustration 14	g00700627

Use Tooling (J) and install seal (25) in cover (22) .

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Illustration 15	g00700628

Position ring (24) and seal (23) in housing (3) .

Install Tooling (K) over input shaft (28) . Put a light coat of clean oil on seal (25) and slide cover (22) in position on input shaft (28) .

Install Tooling (L) and pull cover (22) downward against spacer (32) .

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Illustration 16	g00700531

Remove Tooling (K) and Tooling (L) . Install six bolts (20) and the washers. Tighten bolts (20) to a torque of 10 N·m ± 2 N·m (7.0 lb ft ± 1.0 lb ft).

Install O-ring (21) .

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Illustration 17	g00700631

Install shaft (13) , spring (12) , and spacer (11) in cylinder barrel (14) . The chamfer on spacer (11) must be toward spring (12) .

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Illustration 18	g00700632

Install Tooling (A) , and strap material in order to hold up cylinder barrel (14) . Use Tooling (A) and compress spring (12) until spacer (11) is below the snap ring groove in cylinder barrel (14) . Use Tooling (B) and install snap ring (10) . Remove Tooling (A) and strap material.

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Illustration 19	g00700519

Install flush valve (7) in head (2) and torque to 15 N·m ± 5 N·m (10.0 lb ft ± 5.0 lb ft).

Install shuttle valve (8) . Install the plug and O-ring (9) in the head. Tighten to a torque of 60 N·m ± 10 N·m (45.0 lb ft ± 5.0 lb ft).

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Illustration 20	g00700514

Install sleeve (6) and dowel (5) in head (2) .

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Illustration 21	g00700635

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Illustration 22	g00700636

Align the hole in plate (4) with dowel (5) . Position plate (4) on head (2) .

Apply 6V-6640 Sealant on housing (3) .

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Illustration 23	g00700479

Position head (2) on housing (3) and align on shaft (13) . Install four bolts (1) in the marked locations. Tighten the two dowel bolts to a torque of 260 N·m ± 30 N·m (190.0 lb ft ± 22.0 lb ft). Tighten the remaining two bolts to a torque of 290 N·m ± 30 N·m (210.0 lb ft ± 22 lb ft).