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

Assembly Procedure

Note: Cleanliness is an important factor. Before assembly, all parts should be thoroughly cleaned in cleaning fluid. Allow the parts to air dry. Wiping cloths or rags should not be used to dry parts. Lint may be deposited on the parts which may cause later trouble. Inspect all parts. If any parts are worn or damaged, use new parts for replacement.

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Illustration 1	g00566256

1. Heat and install two bearings (33) and ring (31) on shaft (32) .

2. Apply 9S-3263 Thread lock to threads (X). Tighten the nut in order to obtain 0.75 N·m to 1.100 N·m (7 lb in to 10 lb in) running torque for the new bearing preload.

3. Measure the drive shaft and bearing assembly in order to determine the thickness of the shim that will be used under the shaft seal cover. Refer to Specifications, "Steering Motor" for the proper measuring procedure.

4. Measure the center pin, the spring collar, the cylinder block, and the control plate. Use the measurements in order to determine the proper size of the spring collar. Refer to Specifications for the proper measuring procedure.

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Illustration 2	g00566257

5. Put the drive shaft and bearing assembly (16) in position on a section of pipe or wood blocks. Put center pin (23), retaining washer (24) and retainer plate (20) in position on the drive shaft and bearing assembly (16) .

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Illustration 3	g00566258

6. Put 6V-1541 Quick Cure Primer on seven screws (22) and allow the primer dry. Put 9S-3263 Thread Lock on the seven screws (22) and install the screws loosely in order to hold the retainer plate to the drive shaft assembly. Put three pistons (19) in position in order to align the retainer plate. Tighten seven screws (22) to a torque of 16 ± 2 N·m (140 ± 18 lb in). Remove three pistons (19) from the assembly.

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Illustration 4	g00566259

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Illustration 5	g00566260

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NOTICE
All piston rings must be installed with the marks toward the flat end of the piston or the motor will not operate.

7. The piston rings are spherical. The piston rings must be installed with marks (25) toward the flat end of piston (19). Use Tooling (A) in order to install upper piston ring (21). Use Tooling (A) in order to install the lower piston ring with marks (25) toward the flat end of piston (19). Repeat for all seven pistons.

8. Rotate the piston rings so the end gaps of the upper piston ring and lower piston ring are 180 degrees from each other.

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Illustration 6	g00566261

Note: Put a small wire through the six washers in order to prevent the washers from rotating.

9. The spring collar that was selected in Step 4 should be used at this time. Put spring collar (18) and six spring washers (17) into the center pin bore of cylinder block assembly (15) .

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Illustration 7	g00566262

10. Put system oil on seven pistons (19) and in the piston bores in cylinder barrel (15). Install seven pistons (19) into cylinder barrel (15), as shown.

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Illustration 8	g00566263

11. Put system oil on center pin (23). Put system oil on the center pin bore of the cylinder block. Lay the drive shaft and the bearing assembly with the drive shaft in the horizontal position. Lay the cylinder block with the pistons in the horizontal position. The spring washers must stay in the proper position when the cylinder is put in the horizontal position. Use the wire from step 9.

12. Align center pin (23) with the bore in the cylinder block and assemble the unit.

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Illustration 9	g00566265

13. Hold cylinder block (15) and drive shaft assembly (16) together. Put the cylinder block and the drive shaft in the vertical position. Support the cylinder block and the drive shaft on a section of pipe or with wood blocks. Push each piston into a drive shaft socket through the retainer plate. An audible click is made when each piston is seated properly.

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NOTICE
When all seven pistons are seated properly in the retainer plate sockets, the cylinder bolck will easily angle to one side. Do not force the cylinder block to angle or damage to the piston may result.

14. Angle cylinder block (15) to one side.

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Illustration 10	g00566266

15. Put the entire rotating group in a vise. Allow clearance between drive shaft bearing (26) and the top of the vise for the motor housing when the motor housing is installed over the rotating group.

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Illustration 11	g00566267

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NOTICE
Do not force the motor housing onto the rotating group or damage to the motor may result. The assembly should be done in one smooth, easy movement. If the housing does not fit over the rotating group easily, the problem should be found and corrected before continuing assembly.

16. Heat motor housing (27) evenly to a temperature of 80° C (176° F). Put the motor housing in position over the rotating group. Move motor housing (27) downward over the rotating group and tilt the motor housing in order to clear the rotating group. Continue until the rotating group bottoms out in the motor housing. A small amount of tapping on the outside of the motor housing may be needed. Do not force the motor assembly together. Allow the motor housing to cool before continuing assembly.

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Illustration 12	g00566269

Note: Check the position of the seals before installation. The seals were noted in the disassembly procedure.

Note: If the drive shaft is grooved at the seal contact area, use shim stock up to 1.0 mm (0.040 inch) between lip seal (4) and cover (3) .

17. Use Tooling (B) in order to install lip seal (4) into cover (3) .

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Illustration 13	g00566270

18. Install shims (28). Use 5P-0960 Multipurpose Grease on O-ring seal (29) and put the O-ring seal in position on the shim.

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Illustration 14	g00566271

19. Put Tooling (C) over the drive shaft. Put system oil on the lip seal and install cover (3). It may be necessary to lightly tap the cover into the motor housing.

20. Use Tooling (D) in order to install retaining ring (2) .

21. Install Tooling (E) and pull the rotating group upward against the retaining ring (2). This puts the rotating group in the correct location within the housing. Remove Tooling (E) .

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Illustration 15	g00565432

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Illustration 16	g00565430

22. Install bushing (13), the spring and retainer (10). Install center pin (12) to the left.

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Illustration 17	g00565429

23. Use needle nose pliers in order to hold center pin (12), as shown. Apply pressure to the right side away from the bushing, the spring and the retainer. Compress the retainer and the spring with the seal pick. This will allow the bushing (13), the spring and retainer (10) to be installed.

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Illustration 18	g00565427

24. Install dowel pins (11) with pliers, as shown. Repeat this procedure on the other side.

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Illustration 19	g00565424

25. Use a seal pick in order to compress the retainer and spring (10) and start dowel pin (11) in the bore. Repeat this procedure for the other side.

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Illustration 20	g00565421

26. Install the flushing valve plate (8) .

27. Install washer (6) on flushing plate (8) .

28. Note the position of locating pin (7) on flushing valve plate (8) .

29. Install O-ring seal (9) .

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Illustration 21	g00565419

30. Install six allen head screws with lockwashers (5) on the head. Tighten six bolts (5) to a torque of 86 N·m ± 12 N·m (66.0 lb ft ± 9.0 lb ft).

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Illustration 22	g00566272

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NOTICE
The motor must be filled with oil before installation or damage to motor may result.

Note: Use a suitable wrench. Apply the wrench to the splined end and rotate the shaft.

31. Put plugs in all openings except for one of two case drain holes (30) in the motor housing. Put the motor in position as the motor would be installed on the vehicle. Use the highest drain hole in the casing and fill the motor with system oil. Install a plug in the case drain hole.

End By: Install the steering motor. Refer to Disassembly and Assembly, "Steering Motor - Install" for the machine that is being serviced.