Caterpillar cat 140 g motor grader (prefix 72v) service repair manual (72v10334 and up)

Service Repair Manual
Models
140G Motor Grader

Start By:
a. remove differential
1. Bend the lock away from nut (1) and loosen nut (1) with tool (A).
2/12140G Motor Grader 72V10334-UP (MACHINE) POWERED BY 3306 Engine(SEBP1...
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2. Remove nut (1), lock (3) and washer (2).
3. Put the differential and the carrier in position as shown.
4. Remove wire (5) from the nuts on each side of the differential. Remove nuts (8).
5. Bend the locks away from bolts (6). Remove the bolts, the locks and locks (7) from the cap.
6. Remove cap (4) from the carrier.
7. Remove the dowel that holds the small cage in alignment with the cap.
8. Fasten a hoist and a strap to the differential (9) as shown. Lift the differential and remove it
from the carrier. Weight is 240 lb. (109 kg).

9. Remove the ring and seal (10) from the carrier.
10. Remove small cage (11) from the differential. Remove the nut and the bearing cup from the
cage.
11. Remove bearing (12) from housing (14) with tooling (B).
12. Remove bolts (13) and the washers that hold housing (14) to the clutch housing. Remove
housing (14). Remove the brass washer from the inner face of housing (14).
13. Remove gear (15) from the spinder gears.
14. Remove spider (18) and the gears and washers from the clutch housing.
15. Remove brass washers (16) and gears (17) from the spider.

16. Remove the brass bearings from the gears with tooling (C).
17. Remove gear (19) from the housing.
18. Turn the bevel gear, clutch housing and the piston housing over.
19. Remove cage (20). Remove the nut, the bearing cup, the ring and the two seals from cage (20).
20. Remove bolts (21) and the washers that hold piston housing (22) to the bevel gear and the
clutch housing. Remove piston housing (22).
21. Remove bearing (23) from the piston housing with tooling (B).
22. Turn the piston housing over.
23. Remove brass washer (24) and piston (25) from the piston housing. Remove the two seals
from the piston.

24. Remove discs (26) and disc assemblies (27) from the clutch housing.
25. Remove the pressure disc from the housing.
26. Remove pinion (28) from the carrier with tooling (D).
27. Remove bearing cups (29) and (31) from the carrier with a punch and a hammer.
28. Remove seal (30) from the carrier.

29. Remove bearing (32) from the pinion with tooling (E).
Assemble Differential (Unlocking)
1. Heat bearing (32) in oil to a temperature of 135° C (275° F). Install bearing (32) on pinion (1).
2. Lower the temperature of the two bearing cups for the pinion. Install the bearing cups in
differential carrier (33).

3. Install the seal in the differential carrier. Install the seal with the lip toward the bevel gear. Put a
small amount of oil on the lip of the seal.
4. Put pinion (28) in position on a block as shown. Install tooling (A) on carrier (33) and fasten a
hoist to tooling (A). Lift the carrier and put it in position over pinion (28) so bearing (32) is in its
seat in the bearing cup.
5. Heat bearing (34) in oil to a temperature of 135° C (275° F).
6. Install bearing (34) on pinion (28). Make sure the bearing is in its seat in the bearing cup. Lift
the carrier and remove the block from under the pinion. Put the carrier on the floor. Remove
tooling (A) from the carrier.
7. Install the washer, the lock and nut (35) on the pinion. Do not tighten the nut.
8. Put two 6.35 mm (.250 in.) dowels in the splines of the pinion. Put the dowels in position 180°
apart. Install tooling (B) over the pinion and the dowels.
9. Check the amount of torque needed to move the pinion without any preload on the pinion
bearings. Remove the torque wrench from tooling (B).
10. Install a ratchet on tooling (B).

11. Install tool (C) on nut (35). Tighten nut (35) with tool (C) while holding the pinion with the
ratchet. Tighten the nut enough to get a torque of 0.7 ± 0.5 N·m (6 ± 4 lb.in.) more than the torque
needed to turn the pinion when the bearings were not preloaded. Remove tooling (B) and (C).
12. Put clutch housing (36) in position on the floor as shown. Put a block of wood 63.5 mm (2 1/2
in.) high in the center of the housing. Put gear (37) in position on the block.
13. Put the pressure disc in position in clutch housing (36). Install the eight discs and the seven
disc assemblies in the housing starting with a disc.
NOTE: Put clean SAE 30 oil on the discs and disc assemblies (27) at installation.
14. Put the large brass washer on the face of gear (37). Make sure the hole in the washer is in
alignment with the dowel in the housing.
15. Install the seals on the outside and the inside of the piston. Install the seals so the lips are
toward the bottom of the bore for the piston in the piston housing. Put some clean SAE 30 oil on
the lips of the seals. Install the piston in housing (22).
16. Heat bearing (38) in oil to a temperature of 135° C (275° F). Install bearing (38) on the hub of
piston housing (22).
17. Put piston housing (22) and the bevel gear in position on clutch housing (36). Make sure the
holes in both housings and the bevel gear are in alignment.

18. Install three 5/8" - 11 NC forged eyebolts (39) in piston housing (22). Install the bolts and the
washers that hold the piston housing to the bevel gear and the clutch housing. Put a bar in position
as shown in the eyebolts. Tighten bolts (21) to a torque of 250 ± 13 N·m (185 ± 10 lb.ft.).
19. Remove the bar and the eyebolts.
20. Turn the housings and the bevel gear over. Be careful that gear (37) does not fall out.
21. Install the brass bearings in spider gears (17) with tool (E) and an arbor press.
22. Install gears (17) and brass washers (16) on spider (18). Put the spider and the gears in position
on the clutch housing as shown.
NOTE: Make sure the notches in the brass washers are up.
23. Install gear (15) as shown on the spider gears. Install the large brass washer on the face of gear
(15). Make sure the hole in the washer is in alignment with the dowel in the housing.
24. Put housing (14) in position on the clutch housing. Tool (F) can be used to make sure the
notches in washers (16) are in alignment with the dowels in housing (14). Install bolts (13) the
washers. Tighten the bolts to a torque of 80 ± 7 N·m (60 ± 5 lb.ft.).
25. Heat bearing (12) in oil to a temperature of 135° C (275° F). Install bearing (12) on the hub of
housing (14).
10/12140G Motor Grader 72V10334-UP (MACHINE) POWERED BY 3306 Engine(SEB...

26. Install the bearing cup and nut (39) in cage (11). Install ring (40) and the two seals on the cage.
27. Put the cage in position over the bearing.
28. Install the nut and the bearing cup in cage (41). Put cage (41) in position over the bearing.
29. Fasten a hoist and a strap to the differential. Put the differential in position on the carrier.
Install the ring and seal between the carrier and cage (11). Make sure the opening in the cage is in
alignment with the ring and seal.
30. Put cap (4) in position over the studs in the carrier. Install the dowel in cage (41). Make sure
the dowel is in alignment with the hole in cap (4).
31. Install nuts (8) that hold the cap to the carrier. Tighten the four nuts to a torque of 380 ± 25
(280 ± 20 lb.ft.).
32. Put the differential in position as shown. Put tooling (D) in position on the differential and
against a tooth on the bevel gear. Turn the bevel gear to measure the gear clearance (backlash)
between the pinion and the bevel gear.
33. Make an adjustment to nut (39) under the bevel gear with tool (C), while keeping nut (42)
finger tight against the top bearing, to get a gear clearance (backlash) of 0.20 - 0.05 mm (.008
± .002 in.).

34. Loosen nut (42). Tighten the nut by hand to remove the end play. Tighten nut (42) 1 to 1
1/2notches and measure the amount of change in dimension (X) with tooling (D). Dimension (X)
must change by 0.13 ± 0.05 mm (.005 ± .002 in.).
35. Tighten nuts (8). Turn the differential and measure the gear clearance (backlash) again.
36. Put locks (7) in position on the cap. Install the locks and bolts that hold locks (7). Bend the
locks against the bolts. Install wires (5) through the studs and nuts on each side of the differential.
37. Install all the O-ring seals on the differential.
End By:
a. install differential
Copyright 1993 - 2020 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Thu Feb 27 02:26:10 UTC+0800 2020

Shutdown SIS
Previous Screen
Product: MOTOR GRADER
Model: 140G MOTOR GRADER 72V
Configuration: 140G Motor Grader 72V10334-UP (MACHINE) POWERED BY 3306 Engine
Disassembly and Assembly
12G, 120G, 130G & 140G MOTOR GRADERS POWER TRAIN
Media Number -SENR3649-00 Publication Date -01/10/1987 Date Updated -27/09/2012
SENR36490013
Differential (Direct Drive)
SMCS - 3258-016; 3258-015
Disassemble Differential (Direct Drive)
Start By:
a. remove differential

1. Remove all the O-ring seals from the differential. Bend the lock away from nut (1) and remove
nut (1) with tool (A).
2. Remove lock (2) and washer (3) from the shaft.
3. Put the differential in position with the bevel gear up as shown.
4. Remove wire (7) from each side of the differential. Remove nuts (6) that hold the cap to the
carrier.
5. Remove bolt (4) from each side of the differential.
6. Remove lock (5) from each side of the differential.
7. Remove cap (8) from the carrier.

8. Remove dowel (9) from each of the cages on the differential.
9. Fasten a hoist and a strap to the differential.
10. Remove differential (10). Weight is 73 kg (160 lb.).
11. Remove cages (11) and (12). Remove the nuts and the bearing cups from the cages.
13. Remove bearing cone (13) with tooling (B).
14. Turn the differential on its other end. Put it on blocks as shown. Remove bolts (14) and the
washers that hold the hub and the bevel gear to the other hub.

15. Install three 5/8" - 11 NC forged eyebolts in hub (17) as shown. Fasten a hoist to eyebolts (15).
16. Remove hub (17) from the bevel gear. Remove the bevel gear from the other hub.
17. Remove bearing cone (16) from hub (17) with tooling (B).
18. Remove pinion (18) from the differential carrier with tooling (C).
19. Remove bearing cups (20) and (21) from the differential carrier.
20. Remove seal (19) from the differential carrier.
21. Remove bearing cone (22) from pinion (18) with tooling (D).

Assemble Differential (Direct Drive)
1. Heat bearing (22) in oil to a temperature of 135°C (275°F). Install bearing (22) on pinion (18).
2. Lower the temperature of the two bearing cups for the pinion. Install the bearing cups in
differential carrier (23).
3. Install the seal in the differential carrier. Install the seal with the lip toward the bevel gear. Put a
small amount of oil on the lip of the seal.
4. Put pinion (18) in position on a block as shown. Install tooling (A) on carrier (23) and fasten a
hoist to tooling (A). Lift the carrier and put it in position over pinion (18) so bearing (22) is in its
seat in the bearing cup.

6. Install bearing (24) on pinion (18). Make sure the bearing is in its seat in the bearing cup. Lift
the carrier and remove the block from under the pinion. Put the carrier on the floor. Remove
tooling (A) from the carrier.
7. Install the washer, the lock and nut (25) on the pinion. Do not tighten the nut.
8. Put two 6.35 mm (.250 in.) dowels in the splines of the pinion. Put the dowels in position 180°
apart. Install tooling (B) over the pinion and the dowels.
9. Check the amount of torque needed to move the pinion without any preload on the pinion
bearings. Remove the torque wrench from tooling (B).
10. Install a ratchet on tooling (B).
11. Install tool (C) on nut (25). Tighten nut (25) with tool (C) while holding the pinion with the
ratchet. Tighten the nut enough to get a torque of 0.7 ± 0.5 N·m (6 ± 4 lb.in.) more than the torque
needed to turn the pinion when the bearings were not preloaded. Remove tooling (B) and (C).
13. Install bearing (13) on hub (26).

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14. Heat bearing (16) in oil to a temperature of 135° C (275° F). Install the bearing on hub (17).
15. Put hub (26) in position on blocks with its bearing down. Put bevel gear (27) in position on
hub (26). Install three 5/8" - 11 NC forged eyebolts in hub (17). Fasten a hoist to eyebolts (15). Put
the hub in position on the bevel gear. Remove the hoist.
16. Install bolts (14) and the washers that hold the hub and the bevel gear to hub (26). Tighten the
bolts to a torque of 250 ± 13 N·m (185 ± 10 lb.ft.).
17. Remove the eyebolts from the differential.
18. Install the bearing cups and nuts (28) in cages (14). Put the cages in position on the hubs.
19. Fasten a hoist and a strap to the differential.
20. Lift the differential and put it in position on the carrier. Remove the hoist and the strap.
NOTE: Make sure the holes in the cages are up.
21. Install dowels (9) in the cages.
22. Put cap (8) in position on the cages and the studs. Make sure the dowels in the cages are in
alignment with the holes in the cap.

23. Install nuts (6) that hold the cap to the carrier. Tighten the nuts to a torque of 380 ± 25 N·m
(280 ± 20 lb.ft.).
24. Put the differential in position as shown. Put tooling (D) in position on the differential and
against a tooth on the bevel gear. Turn bevel gear (27) to measure the gear clearance (backlash)
between the pinion and the bevel gear.
25. Make an adjustment to the nut under the bevel gear with tool (C), while keeping nut (29)
finger tight against the top bearing, to get a gear clearance (backlash) of 0.20 + 0.10 - 0.08 mm
(.008 + .004 - .003 in.).
26. Loosen nut (29). Tighten the nut by hand to remove the end play. Tighten nut (29) 1 1/2 to 2
notches and measure the amount of change in dimension (X) with tooling (D). Dimension (X)
must change by 0.13 ± 0.05 mm (.005 ± .002 in.).
27. Tighten nuts (6). Turn the differential and measure the gear clearance (backlash) again.

28. Put locks (5) in position on the cap. Install the locks and bolts (4) that hold the locks. Bend the
locks against the bolts.
29. Install wires (7) on the studs on each side of the differential.
30. Install all the O-ring seals on the differential.
End By:
a. install differential
Copyright 1993 - 2020 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Thu Feb 27 02:27:06 UTC+0800 2020

Caterpillar cat 140 g motor grader (prefix 72v) service repair manual (72v10334 and up)

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