Procedure to Install the New Pinion Shaft and Circle Worm Drive in the Circle Drive{5207} Caterpillar

Motor Grader:

120G (S/N: 4HD1-UP; 1LK1-UP; 87V1-UP; 11W1-UP)

120H (S/N: CAF1-UP; 4MK1-UP; 5FM1-UP; 6NM1-UP; 6TM1-UP; 2AN1-UP; 6YN1-UP; 9FN1-UP; 9YR1-UP; ALZ1-UP; 1241-UP)

120M (S/N: B9N1-UP)

12G (S/N: 3WC1-UP; 3PL1-UP; 61M1-UP)

12H (S/N: CBK1-UP; 4XM1-UP; 5ZM1-UP; 8MN1-UP; 2LR1-UP; 2WR1-UP; 4ER1-UP; 2GS1-UP; AMZ1-UP)

130G (S/N: 74V1-UP)

135H (S/N: CBC1-UP; BDJ1-UP; 3YK1-UP; 7MM1-UP; 8WN1-UP; AMX1-UP)

140G (S/N: 5MD1-UP; 72V1-UP; 13W1-UP)

140H (S/N: CCA1-UP; APM1-UP; 5HM1-UP; 8JM1-UP; 8KM1-UP; 9TN1-UP; 9ZN1-UP; 3AS1-UP)

140M (S/N: B9M1-UP)

143H (S/N: 1AL1-UP; APN1-UP)

14G (S/N: 03L1-UP; 96U1-UP)

14H (S/N: ASE1-UP; 7WJ1-UP)

14M (S/N: B9J1-UP)

160G (S/N: 4JD1-UP)

160H (S/N: ASD1-UP; 9EJ1-UP; 2FM1-UP; 3GM1-UP; 6WM1-UP; 9JM1-UP; CCP1-UP; 2HS1-UP)

160M (S/N: B9L1-UP)

163H (S/N: 5AK1-UP; ARL1-UP)

Introduction

ReferenceDisassembly and Assembly, SENR3650, "12G, 120G, 130G and 140G Motor Grader Vehicle Systems", "Circle Drive"

ReferenceDisassembly and Assembly, SENR3650 can also be used to provide information for the 160G center drive only.

ReferenceRefer to Disassembly and Assembly, REG01699, "14G Motor Grader Vehicle Systems", "Circle Drive" for information about the circle drive.

ReferenceRefer to Disassembly and Assembly, RENR4124, "12H,140H, and 160H Motor Grader Machine Systems", "Circle Drive" for information about the circle drive.

ReferenceRefer to Disassembly and Assembly, RENR4164, "120H and 135H Motor Grader Machine Systems", "Circle Drive" for information about the circle drive.

ReferenceRefer to Disassembly and Assembly, RENR4193, "14H Motor Grader Machine Systems", "Circle Drive" for information about the circle drive.

ReferenceRefer to Disassembly and Assembly, RENR4153, "143H and 163H Motor Grader Machine Systems", "Circle Drive" for information about the circle drive.

ReferenceRefer to Disassembly and Assembly, KENR6418, "120M and 12M Motor Grader Machine Systems", "Circle Drive" for information about the circle drive.

ReferenceRefer to Disassembly and Assembly, KENR6424, "140M Motor Grader Machine Systems", "Circle Drive" for information about the circle drive.

ReferenceRefer to Disassembly and Assembly, RENR9704, "14M Motor Grader Machine Systems", "Circle Drive" for information about the circle drive.

ReferenceRefer to Disassembly and Assembly, RENR9727, "160M Motor Grader Machine Systems", "Circle Drive" for information about the circle drive.

The pinion gear has been replaced for improved wear. Replace the pinion shaft, the shims, the cover, and the bolts. This procedure will provide information regarding the inspection, and the repair of the specific machines.

This procedure covers the rework of certain G Series, H Series, M Series, and M2 Series Machines.

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NOTICE
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat products. Dispose of all fluids according to local regulations and mandates.

Do not perform any procedure in this Special Instruction until you read this information and you understand this information. Do not perform any procedure until you read the information and you understand the information. Use only proper tools and observe all precautions that pertain to the use of those tools. Failure to follow these procedures can result in personal injury. The following procedures should also be observed.

Specifications for Cables, Chains, and Lifting Devices

Use approved cables, chains, and lifting devices in order to lift components. Refer to the weight from the manufacturer to determine the application when you select the following items: cable, chain and lifting devices. When you lift a component, the lift angle is critical. Refer to the Illustration that follows in order to see the effect of the lift angle on the working load limit.

Note: The lifting devices that are shown in this publication are not Caterpillar parts.

Illustration 1	g00629745
Lift angles for lifting slings. (A) The load capacity is 100% of the working load limit for the sling. (B) The load capacity is 86% of the working load limit for the sling. (C) The load capacity is 70% of the working load limit for the sling. (D) The load capacity is 50% of the working load limit for the sling.

Procedure to Update the Circle Drive on Motor Graders on H Machines

Refer to the Disassembly and Assembly Manual for any additional information regarding the rework of your machines circle drive.

Procedure to Remove the Circle Drive

Refer to Disassembly and Assembly, "Circle Drive - Remove" for your machine in order to get specific procedures to remove the circle drive from your machine.

The Disassembly Procedure for the Circle Drive

Table 1

Required Tools
Item	Qty	Part Number	Part Description
A	2		3/8 inch by 16 by 4 inch
B	1	138-7575	Link Bracket
C	1	8B-7554	Bearing Cup Puller Gp
	1	8B-7548	Push-Puller Tool Gp

Note: Cleanliness is an important factor. Before you begin the disassembly procedure, clean the exterior of the components. This cleaning will help to prevent dirt from entering the internal mechanism. Precision components can be damaged by contaminants or by dirt. Perform disassembly procedures on a clean work surface. Keep components covered and protected at all times.

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Illustration 2	g01428220
A typical example View of the circle drive and the connector

1. Remove coupling (1) from housing (3). Remove pin (2) from coupling (1) .

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Illustration 3	g01428222
A typical example View of the removal of the bracket for the worm gear

2. Remove nuts (4). Remove bracket (5). Removing the bracket will allow the worm gear (8) to float.

3. Remove O-ring seal (6) and shims (7) .

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Illustration 4	g01428223
A typical example View of the access plate for the circle drive

4. Remove bolts (9) and cover (10) .

5. Remove bolts (11) .

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Illustration 5	g01428225
A typical example The view of the bolts that are used to remove the cover for the circle drive .

6. Install Tooling (A) and remove cover (12) .

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Illustration 6	g01428227
A typical example View of the circle drive

7. Remove plug (13) and O-ring seal (14) from cover (12) .

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Illustration 7	g03351762
A typical example View of the lifting device that is used to remove the pinion

8. Install Tooling (B) on shaft assembly (15). Attach a suitable lifting device to Tooling (B). The weight of shaft assembly (15) is approximately 32 kg (70 lb).

9. Position the worm gear (8) away from shaft assembly (15) and remove shaft assembly (15). Remove Tooling (B) .

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Illustration 8	g01427983
A typical example View of the disassembly of the pinion

10. Remove three bolts (16), and remove three washers (17) in order to disassemble the shaft assembly (15). Refer to Illustration 7. Discard bolts (16), washers (17), retainer (18), shims (20), and shims (21). Retain the spacer (19) for reassembly.

11. Remove spring (22) and spacer (23) .

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Illustration 9	g01427984
A typical example View of the disassembly of the pinion

12. Remove gear (24) from shaft (28). Remove friction discs (25) and discs (26) from gear (24). Remove spacer (27). Discard shaft (28) .

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Illustration 10	g03310177
A typical example View of the removal of the thrust washer

13. Remove thrust washer (29) .

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Illustration 11	g03317153

14. Remove the circle worm drive (8) and bearings then discard. Retain the components for reassembly.

15. Inspect the existing bearing cups (30) and replace if necessary. Refer to Step 16 for information to remove existing bearing cups (32)

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Illustration 12	g03317176

16. Use tooling (C) to remove bearing cup (30) from the housing

Installation of Bearing Cones and Bearing Cups

Table 2

Required Part for the Update of the Circle Drive
Item	Qty	Part Number	Description
1	1	Part number required for your machine	Circle Worm Drive
2	2	1B-4046	Bearing Cone
3	2	1B-4038 (1)	Bearing Cup

( 1 )

Inspect the existing bearing cup to determine if replacement is necessary. New bearing cups require a lowered temperature to allow for installation.

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Illustration 13	g03317131

1. Raise the temperature of new bearing cones (2) to install new bearing cones onto new worm shaft (1) .

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Illustration 14	g03319293

2. Lower the temperature of new bearing cups (3) to install the bearing cups into the circle drive housing. Use tooling (C) .

Assembly Procedure for the Circle Drive on the 14H and 14M Motor Graders

All of the parts in the table below are required to perform this rework unless specified otherwise.

Note: Replace (11) pinion drive shaft and (35) circle drive pinion as a set. Replace (33) circle worm drive and (10) worm gear as a set.

Table 3

Required Parts for the Update of the Circle Drive
Item	Qty	Part Number	Description
3	2	1B-4038	Bearing Cup
10	1	8X-5303	Worm Gear
11	1	281-9460	Pinion Drive Shaft
12	3	6V-5686	Bolt
13	3	8D-5054	Hard Washer
14	1	307-1961	Plate
16	2	307-1959	Shim
17	1	307-1960	Shim
18	12	307-1962	Shim
33	1	312-0781	Circle Worm Drive
34	2	1B-4046	Bearing Cone
35	1	261-8554	Circle Drive Pinion

Table 4

Required Tools
Item	Qty	Part Number	Part Description
A	1	8T-5096	Dial Indicator Gp
B	1	138-7575	Link Bracket

Note: Cleanliness is an important factor. Before assembly, thoroughly clean all parts in cleaning fluid. Allow the parts to air dry. Do not use wiping cloths or rags to dry parts. Lint may be deposited on the parts which may cause trouble. Inspect all parts. If any parts are worn or damaged, use new parts for replacement. Dirt and other contaminants can damage the precision component. Perform assembly procedures on a clean work surface. Keep components covered and protected at all times.

Note: Check the O-ring seals, the gaskets, and the seals for wear or for damage. Replace the components, if necessary.

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Illustration 15	g03351740
A typical example

1. Install circle worm drive (33) and the two bearing cones (34) that were assembled previously, into the housing. Reinstall nuts (1), bracket (2), O-ring (3), and shim (4) onto housing (5). This reinstallation will allow you to verify the proper amount of preload for the circle worm drive (33) .

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Illustration 16	g01428350
A typical example View of the dial gauge on the end of the worm gear

2. Install Tooling (A) and check the preload. Remove shims (4) in order to obtain zero preload or a maximum of 0.13 mm (0.005 inch) preload.

3. After the preload has been verified remove tooling (A) .

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Illustration 17	g03351752
A typical example

4. Remove nuts (1), bracket (2), O-ring (3), and shims (4) from housing (5) .

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Illustration 18	g01428370
A typical example View of the assembly of the new pinion

5. Install gear (10) on 281-9460 Pinion Drive Shaft (11). Install spacer (9). Install friction discs (7) and discs (8) on pinion drive shaft (11) .

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Illustration 19	g01428371
A typical example View of the assembly of the pinion

6. Install spacer (20), spring (19) and spacer (15). Use a depth micrometer to obtain the distance from the end of 281-9460 Pinion Drive Shaft (11) to the flat surface on spacer (15). Remove spacer (15) .

7. Subtract 2.30 ± 0.25 mm (0.091 ± 0.010 inch) from the dimension that was measured in Step 6. The calculated dimension is the thickness of shims (16), shims (17), and shims (18) .

   Note: Install the maximum number of 307-1962 Shims (18) that will allow you to remain within the tolerance for the preload. Then use the 307-1959 Shims (16) and the 307-1960 Shims (17) in order to get the proper preload.

8. Install 307-1959 Shim (16), 307-1960 Shim (17), 307-1962 Shim (18) and spacer (15). Install 307-1961 Plate (14) by using three 6V-5686 Bolts (12) and three 8D-5054 Hard Washers (13) .

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Illustration 20	g01432074
A typical example Reinstall the lifting bracket onto the pinion.

9. Install Tooling (B), bolts (12) and washers (13). Attach a suitable lifting device to Tooling (B). The weight of shaft assembly (21) is approximately 32 kg (70 lb).

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Illustration 21	g03319502
A typical example Reinstall the thrust washer.

10. Install circle worm drive (33) and the two cone bearings (34) that were assembled previously, into the housing. Then Install thrust washer (22) into the housing.

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Illustration 22	g03371576
A typical example Reinstall the pinion into the housing.

11. Position circle worm drive (33) away from pinion shaft assembly (21) and install the pinion shaft assembly. Remove Tooling (B). Torque three 6V-5686 Bolts (12) to 120 ± 20 N·m (90 ± 15 lb ft). Then final torque three 6V-5686 Bolts (12) to 240 ± 40 N·m (175 ± 30 lb ft).

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Illustration 23	g01428384
A typical example Reinstall the cover.

12. Install O-ring seal (25) on cover (24). Lubricate the O-ring seal (25) with the lubricant that is being sealed. Install plug (23) .

13. Install cover (12) .

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Illustration 24	g01428385
A typical example Reinstall the access plate.

14. Install seven bolts (30). Replace bolt (30A) with a new bolt. Install gasket (29), cover (28), bolts (26), and washer (27) .

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Illustration 25	g03351752
A typical example

15. Install O-ring seal (3). Lubricate the O-ring seal with the lubricant that is being sealed.

16. Install shim (4), bracket (2) and nuts (1) .

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Illustration 26	g01428387
A typical example Install the connector.

17. Install pin (32) in coupling (31). Install coupling (31) in housing (5) .

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Illustration 27	g03484796

18. Install one new circle drive pinion (35) onto pinion drive (11) shaft when reinstalling the circle drive.

Assembly Procedure for the Circle Drive on the 12, 120, 140, and 160 Motor Graders - Included are the H, M, and M Series 2 Machines

All of the parts in the table below are required to perform this rework unless specified otherwise.

Note: Replace (11) shaft and (35) pinion as a set. Replace (33) circle worm drive and (10) worm gear as a set.

Table 5

Required Parts for the Update of the Circle Drive
Item	Qty	Part Number	Description
3	2	1B-4038	Bearing Cup
10	1	323-8674	Worm Gear
11	1	422-9841	Shaft
12	3	6V-5686	Bolt
13	3	8D-5054	Hard Washer
14	1	307-1961	Plate
16	2	307-1959	Shim
17	1	307-1960	Shim
18	12	307-1962	Shim
33	1	323-8675	Circle Worm Drive
34	2	1B-4046	Bearing Cone
35	1	422-9842	Pinion

Table 6

Required Tools
Item	Qty	Part Number	Part Description
A	1	8T-5096	Dial Indicator Gp
B	1	138-7575	Link Bracket

Note: Cleanliness is an important factor. Before assembly, thoroughly clean all parts in cleaning fluid. Allow the parts to air dry. Do not use wiping cloths or rags to dry parts. Lint may be deposited on the parts which may cause trouble. Inspect all parts. If any parts are worn or damaged, use new parts for replacement. Dirt and other contaminants can damage the precision component. Perform assembly procedures on a clean work surface. Keep components covered and protected at all times.

Note: Check the O-ring seals, the gaskets, and the seals for wear or for damage. Replace the components, if necessary.

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Illustration 28	g03351740
A typical example

1. Install circle worm drive (33) and the two bearing cones (34) that were assembled previously, into the housing. Reinstall nuts (1), bracket (2), O-ring (3), and shim (4) onto housing (5). This reinstallation will allow you to verify the proper amount of preload for the worm gear (6) .

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Illustration 29	g01428350
A typical example View of the dial gauge on the end of the worm gear

2. Install Tooling (A) and check the preload. Remove shims (4) in order to obtain zero preload or a maximum of 0.13 mm (0.005 inch) preload.

3. After the preload has been verified remove tooling (A) .

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Illustration 30	g03351752
A typical example

4. Remove nuts (1), bracket (2), O-ring (3), and shims (4) from housing (5) in order to allow the installation of the pinion shaft assembly.

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Illustration 31	g01428370
A typical example View of the assembly of the new pinion

5. Install gear (10) on 307-1958 Pinion Drive Shaft (11). Install spacer (9). Install friction discs (7) and discs (8) on pinion drive shaft (11) .

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Illustration 32	g01428371
A typical example View of the assembly of the pinion

6. Install spacer (20), spring (19) and spacer (15). Use a depth micrometer to obtain the distance from the end of 307-1958 Pinion Drive Shaft (11) to the flat surface on spacer (15). Remove spacer (15) .

7. Subtract 2.30 ± 0.25 mm (0.091 ± 0.010 inch) from the dimension that was measured in Step 6. The calculated dimension is the thickness of shims (16), shims (17), and shims (18) .

   Note: Install the maximum number of 307-1962 Shims (18) that will allow you to remain within the tolerance for the preload. Then use the 307-1959 Shims (16) and the 307-1960 Shims (17) in order to get the proper preload.

8. Install 307-1959 Shim (16), 307-1960 Shim (17), 307-1962 Shim (18) and spacer (15). Install 307-1961 Plate (14) by using three 6V-5686 Bolts (12) and three 8D-5054 Hard Washers (13) .

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Illustration 33	g01432074
A typical example Reinstall the lifting bracket onto the pinion.

9. Install Tooling (B), bolts (12) and washers (13). Attach a suitable lifting device to Tooling (B). The weight of shaft assembly (21) is approximately 32 kg (70 lb).

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Illustration 34	g03319504
A typical example Reinstall the thrust washer and circle worm drive

10. Install circle worm drive (33) and the two cone bearings (34) that were assembled previously, into the housing. Then Install thrust washer (22) into the housing.

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Illustration 35	g03371576
A typical example Reinstall the pinion into the housing.

11. Position circle worm drive (33) away from pinion shaft assembly (21) and install the pinion shaft assembly. Remove Tooling (B). Torque three 6V-5686 Bolts (12) to 120 ± 20 N·m (90 ± 15 lb ft). Then final torque three 6V-5686 Bolts (12) to 240 ± 40 N·m (175 ± 30 lb ft).

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Illustration 36	g01428384
A typical example Reinstall the cover.

12. Install O-ring seal (25) on cover (24). Lubricate the O-ring seal (25) with the lubricant that is being sealed. Install plug (23) .

13. Install cover (12) .

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Illustration 37	g01428385
A typical example Reinstall the access plate.

14. Install seven bolts (30). Replace bolt (30A) with a new bolt. Install gasket (29), cover (28), bolts (26), and washer (27) .

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Illustration 38	g03351752
A typical example

15. Install O-ring seal (3). Lubricate the O-ring seal with the lubricant that is being sealed.

16. Install shim (4), bracket (2) and nuts (1) .

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Illustration 39	g01428387
A typical example Install the connector.

17. Install pin (32) in coupling (31). Install coupling (31) in housing (5) .

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Illustration 40	g03484796

18. Install one new circle drive pinion (35) onto pinion drive (11) shaft when reinstalling the circle drive.

The Rework Procedure for the Circle Drives on the 12G, 120G, 130G, 140G, and 160G Motor Graders

ReferenceRefer to Disassembly and Assembly, SENR3650, "12G, 120G, 130G, and 140G Motor Grader Vehicle Systems", "Circle Drive" for more information about the circle drive.

ReferenceDisassembly and Assembly, SENR3650 can also be used to provide information for the 160G center drive only.

All of the parts in the table below are required to perform this rework unless specified otherwise.

Note: Replace (11) circle worm drive and (9) worm gear as a set.

Table 7

Required Parts for the Update of the Non-Slip Clutch Circle Drive
Item	Qty	Part Number	Description
3	2	1B-4038	Bearing Cup
8	2	1B-4046	Bearing Cone
9	1	243-0341	Worm Gear
11	1	282-6623	Circle Worm Drive
23	1	8D-7427	Drive Pinion Shaft

Illustration 41	g03366135
(23) Shaft (9) Worm Gear

Illustration 42	g03366136
(11) Circle worm drive (8) Bearing cone

Illustration 43	g03366156
(3) Bearing cup

All of the parts in the table below are required to perform this rework unless specified otherwise.

Note: Replace (23) shaft and (35) pinion as a set. Replace (22) circle worm drive and (11) worm gear as a set.

Table 8

Required Parts for the Update of the Circle Drive if Equipped With a Slip Clutch
Item	Qty	Part Number	Description
4	2	1B-4038	Bearing Cup
10	2	1B-4046	Bearing Cone
11	1	323-8674	Worm Gear
13	3	6V-5686	Bolt
14	3	8D-5054	Hard Washer
15	1	307-1961	Plate
17	2 As Needed	307-1959	Shim
17	1 As Needed	307-1960	Shim
17	12 As Needed	307-1962	Shim
22	1	323-8675	Circle Worm Drive
23	1	422-9841	Shaft
35	1	422-9842	Pinion

Illustration 44	g03366176
(11) Worm Gear (23) Pinion drive shaft

Illustration 45	g03366208
(17) Assorted shims

Illustration 46	g03366213
(13) Bolt (14) Hard washer (15) Plate

Illustration 47	g03366177
(10) Bearing Cone at each end of (11) (22) Circle Worm Drive

Illustration 48	g03366180
(4) Bearing cup

Illustration 49	g03485489
(23) Shaft (35) Pinion

The Rework Procedure for the Circle Drives on the 14G Motor Grader

ReferenceRefer to Disassembly and Assembly, REG01699, "14G Motor Grader Vehicle Systems", "Circle Drive" for more information about the circle drive.

All of the parts in the table below are required to perform this rework unless specified otherwise.

Note: Replace (6) circle worm drive and (7) worm gear as a set.

Table 9

Required Parts for the Update of the Non-Slip Clutch Circle Drive
Item	Qty	Part Number	Description
6	1	282-6623	Circle Worm Drive
7	1	243-0341	Worm Gear
8	2	1B-4046	Bearing Cone
9	2	1B-4038	Bearing Cup
23	1	9D-5921	Drive Pinion Shaft

Illustration 50	g03371701
(23) Shaft (7) Worm gear

Illustration 51	g03371718
(6) Circle worm drive (8) Bearing cone

Illustration 52	g03371724
(9) Bearing cup

All of the parts in the table below are required to perform this rework unless specified otherwise.

Note: Replace (23) shaft and (35) pinion as a set. Replace (22) circle worm drive and (11) worm gear as a set.

Table 10

Required Parts for the Update of the Circle Drive if Equipped With a Slip Clutch
Item	Qty	Part Number	Description
4	2	1B-4038	Bearing Cup
10	2	1B-4046	Bearing Cone
11	1	323-8674	Worm Gear
13	3	6V-5686	Bolt
14	3	8D-5054	Hard Washer
15	1	307-1961	Plate
17	2 As Needed	307-1959	Shim
17	1 As Needed	307-1960	Shim
17	12 As Needed	307-1962	Shim
22	1	323-8675	Circle Worm Drive
23	1	422-9841	Shaft
35	1	422-9842	Pinion

Illustration 53	g03366176
(11) Worm gear (23) Pinion

Illustration 54	g03366208
(17) Assorted shims

Illustration 55	g03366213
(13) Bolt (14) Hard washer (15) Plate

Illustration 56	g03366177
(10) Bearing Cone at each end of (11) (22) Circle worm drive

Illustration 57	g03366180
(4) Bearing cup

Illustration 58	g03485636

Installation Procedure for the Circle Drive for the Motor Grader

ReferenceRefer to Disassembly and Assembly, "Circle Drive - Install" for your machine in order to get specific procedures to install the circle drive on your machine.