Caterpillar Cat 140M 2 MOTOR GRADER (Prefix R9G) Service Repair Manual (R9G00001 and up).pdf

Service Repair Manual
Models
140M 2 MOTOR GRADER

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Product: MOTOR GRADER
Model: 140M 2 MOTOR GRADER R9G
Configuration: 140M Series 2 Motor Grader - All Wheel Drive R9G00001-UP (MACHINE) POWERED BY C9 Engine
Disassembly and Assembly
12M Series 2, 140M Series 2 and 160M Series 2 Motor Graders Power Train
Media Number -KENR8899-03 Publication Date -01/05/2017 Date Updated -18/05/2017
i07506146
Piston Motor (Wheel Propel) - Assemble
SMCS - 4351-016-YW; 5058-016-YW
Assembly Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
B 317-3804 Spanner Wrench 1
D 1P-0510 Driver Gp 1
E 1P-1862 Pliers 1
F - Loctite 276 Thread Locker 1
G 5P-3037 Pusher Plate 1
H 4C-4032 Loctite 609 Retaining Compound 1
J 317-5303 Measuring Plate 1
K 1U-8846 Loctite High Flex GM 1
L 4C-9507 Loctite 620Retaining Compound 1
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
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
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replacement. Dirt and other contaminants can damage the precision component. Perform assembly
procedures on a clean work surface. Keep components covered and protected always.
Note: Check the O-ring seals for wear or for damage. Replace the components, if necessary.
Illustration 1 g01408523
1. Raise the temperature of bearing cone (45). Install bearing cone (45) onto shaft (43).
2. Raise the temperature of race (44). Apply Tooling (H) to shaft (43). Use Tooling (G) and a suitable
press to install race (44) onto shaft (43). The tapered end of race (44) should face away from the
bearing.
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3. Lower the temperature of bearing cup (66). Use Tooling (D) to install bearing cup (66) into housing
(35).
4. If necessary, install pins (67) into housing (35).
5. Install cradle bearings (68) into housing (35).
Note: Steps 6 through 14 are for determining the proper number of shims (34) (not shown) that will
be installed.
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6. Install shaft (43) into housing (35). Measure the distance from the shoulder on shaft (43) to the top of
housing (35) and record Dimension (A) to the nearest 0.010 mm (0.0004 inch).
7. Measure Dimension (B) and record Dimension (B) to the nearest 0.010 mm (0.0004 inch) on special
washer (47).
8. Measure Dimension (C) and record Dimension (C) to the nearest 0.010 mm (0.0004 inch) on bearing
cone (46) and bearing cup (33).
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9. Measure Dimension (D) and record Dimension (D) to the nearest 0.010 mm (0.0004 inch) on
housing (26).
Note: Ensure that all existing shims have been removed.
10. 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).
11. Calculate Dimension (Y) and record Dimension (Y) to the nearest 0.010 mm (0.0004 inch).
Note: Dimension (Y) equals Dimension (B) plus Dimension (C).
12. Calculate Dimension (Z) and record Dimension (Z) to the nearest 0.010 mm (0.0004 inch).
Note: Dimension (Z) equals Dimension (X) minus Dimension (Y).
13. 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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14. Use the measurement that was taken in Step 13 to install the proper number of shims (37) (not
shown) into housing (26).
15. Lower the temperature of bearing cup (33). Use Tooling (D) to install bearing cup (33) into housing
(26).
16. Use Steps 17 through 23 to determine the proper number of shims (53) (not shown) that will be
installed.
17. Install washer (52) into barrel (49). Use Tooling (E) to install retaining ring (48).
Note: Note the orientation of retaining ring (48) from the Disassembly Procedure.
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18. Install barrel (49) into housing (35). Measure Dimension (L) and record Dimension (L) to the nearest
0.010 mm (0.0004 inch).
19. Install port plate (36) onto housing (26). Measure Dimension (M) and record Dimension (M) to the
nearest 0.010 mm (0.0004 inch).
20. Calculate Dimension (N) and record Dimension (N).
Note: Dimension (N) equals Dimension (L) minus Dimension (M).
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21. Select a combination of shims (53) (not shown) that equals Dimension (N) minus 0.090 ± 0.040 mm
(0.0035 ± 0.0016 inch).
22. Use Tooling (E) to remove retaining ring (48) from barrel (49). Remove washer (52) from barrel
(49).
23. Install washer (50), spring (51), washer (52), and the correct number of shims (53) that were
determined in Step 21.
Note: Be sure that the tapered edge of washer (50) is facing away from spring (51).
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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.
24. Use Tooling (D) and a suitable press to apply slight compression to barrel assembly (37). Use
Tooling (E) to install retaining ring (48).
Note: Note the orientation of the white mark on retaining ring (48).
25. Steps 25 through 32 are for determining the proper number of shims (57) (not shown) that will be
installed.
26. Measure Dimension (P) and record Dimension (P) on plate (58) to the nearest 0.010 mm
(0.0004 inch).
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27. Measure Dimension (R) and record Dimension (R) on washer (56) to the nearest 0.010 mm
(0.0004 inch).
28. Measure Dimension (S) and record Dimension (S) on piston (59) to the nearest 0.010 mm
(0.0004 inch).
29. 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).
30. 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).
31. Select a combination of shims (57) (not shown) that equals Dimension (U) minus 0.020 ± 0.010 mm
(0.0008 ± 0.0004 inch).
32. Repeat Steps 26 through 31 for plate (62).
Note: The slipper clearance is 0.020 ± 0.010 mm (0.0008 ± 0.0004 inch).
33. Install sleeves (55) and sleeves (60) into swashplate (54).
34. Install pistons (59) and washer (56) to swashplate (54).
35. Install the correct number of shims (61) that were determined in Step 32. Position plate (62). Apply
Tooling (F) to screws (63). Install screws (63). Tighten screws (63) to a torque of 35 N·m (26 lb ft).
36. Install the correct number of shims (57) that were determined in Step 31. Position plate (58). Apply
Tooling (F) to screws (63). Install screws (63). Tighten screws (63) to a torque of 35 N·m (26 lb ft).
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37. Position swashplate assembly (42) into barrel assembly (37).
38. Install shaft (43) into barrel assembly (37) and swashplate assembly (42).
39. Install special washer (47) onto barrel assembly (37).
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40. Raise the temperature of bearing cone (46). Install bearing cone (46) onto shaft (43).
41. Steps 42 through 54 are for determining the proper washer (28) (not shown) that will be installed.
42. Install barrel assembly (37) into housing (35).
43. Install ring (29) and O-ring seal (30) onto pipe (27A). Repeat this step for pipe (27B).
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44. Install pipe (27A) and pipe (27B) into barrel assembly (37).
45. Center the swashplate to the zero displacement angle.
Note: Each dimension that is measured and recorded is specific to each pipe (27A) and pipe
(27B).
46. Attach Tooling (J) to housing (35). Measure Dimension (BB) and record Dimension (BB) to the
nearest 0.010 mm (0.0004 inch). Measure Dimension (CC) and record Dimension (CC) to the nearest
0.010 mm (0.0004 inch).
47. 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).
48. 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).
49. Measure Dimension (FF) and record Dimension (FF) in housing (26) to the nearest 0.010 mm
(0.0004 inch).
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50. Measure Dimension (GG) and record Dimension (GG) in housing (26) to the nearest 0.010 mm
(0.0004 inch).
51. 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).
52. 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).
Pipe (27A) and pipe (27B) are shown for illustration purposes only.
Note: You must calculate a range for washer (28) that corresponds with each individual pipe (27A)
and pipe (27B).
53. Select a washer (28) (not shown) that equals Dimension (HH) minus 0.080 ± 0.070 mm
(0.0031 ± 0.0028 inch) for pipe (27A). Install washer (28) into housing (26).
54. Select a washer (28) (not shown) that equals Dimension (JJ) minus 0.080 ± 0.070 mm
(0.0031 ± 0.0028 inch) for pipe (27B). Install washer (28) into housing (26).
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55. Remove pipe (27A) and pipe (27B) from housing (35). Remove barrel assembly (37) from housing
(35).
56. Install O-ring seal (40) onto piston (38). Repeat this step for the other piston.
57. Install rod (41). Install pistons (39) and (38).
Note: The longer piston (39) is installed on the same side as rod (41).
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58. Apply Tooling (H) to seal (65).
59. Use Tooling (D) to install seal (65) into housing (35).
60. Use Tooling (E) to install retaining ring (64) into housing (35).
61. Apply Tooling (L) to shuttle valve (32). Use Tooling (B) to install shuttle valve (32) into housing
(26).
62. Install relief valve (31).
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63. Install retaining spring (19), spring (20), ring (21), retaining ring (22), and spring (23) into bushing
(16). Install washer (18) and pilot valve (17) into bushing (16).
injury.
To prevent possible injury, follow the established assembly procedure
and wear protective equipment.
64. Install bushing (16) into housing (26).
65. Install pipe (27A) and pipe (27B) into housing (26).
Note: Be sure that the correct pipe (27A) and pipe (27B) are installed into the correct cavity in
housing (26).
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66. Install port plate (36) onto housing (26).
67. Install barrel assembly (37) and swashplate assembly (42) onto housing (26).
68. Apply Tooling (K) to the mating surface of housing (26). Position housing (35) onto housing (26).
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69. Reposition the wheel propel motor. Install bolts (24). Tighten bolts (24) to a torque of 87 N·m
(64 lb ft). Install bolt (25). Tighten bolt (25) to a torque of 25 N·m (18 lb ft).
70. Install O-ring seal (12), O-ring seal (13), spring (14), and piston (15) into cover (8). Install retaining
ring (11), washer (10), and plug (9) into cover (8). Tighten plug (9) to a torque of 10 N·m (89 lb in).
injury.
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Caterpillar Cat 140M 2 MOTOR GRADER (Prefix R9G) Service Repair Manual (R9G00001 and up).pdf

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Caterpillar Cat 140M 2 MOTOR GRADER (Prefix R9G) Service Repair Manual (R9G00001 and up).pdf