16M Motor Grader Power Train Transmission

Transmission - Assemble

16M Motor Grader Power Train [KENR6019]

16M Motor Grader Power Train Transmission - Disassemble

POWER TRAIN

TRANSMISSION GP

16M Motor Grader Power Train Transmission - Remove

16M Motor Grader Power Train Transmission - Install

16M Motor Grader Power Train Transmission - Disassemble

16M Motor Grader Power Train Transmission - Assemble

1.1. Assembly Procedure

Assembly Procedure

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Table 1
Required Tools
Tool	Part Number	Part Description	Qty
A	439-3940	Link Brackets	4
B	386-6033	Lever Puller Hoist	1
C	1P-2420	Transmission Repair Stand	1
D	4C-8156	Lifting Fixture	1
E	FT-2769	Table	1
G	9U-7480	Compressing Tube	1
	5P-7970	Nut	1
	8T-4224	Hard Washer	1
	-	Bolt M13 - 1.25 by 460 mm	1
J	9U-7480	Compressing Tube	1
	8T-4133	Nut	1
	8T-4121	Washer	1
	-	Bolt M10 - 1.5 by 460mm	1
K	189-0408	Shackle As	1
L	3E-3882	Eyebolt	1
N	271-2911	Alignment Tool	1
N	271-2922	Alignment Tool	1
M	9U-7480	Compressing Tube	1
	6V-8149	Nut	1
	5P-8245	Hard Washer	1
	-	Bolt M12- 1.75 by 460 mm	1
P	426-2786	Seal Installer	1
R	8C-8422	Sealant	-

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NOTICE

Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Note: Lubricate all seal rings and O-ring seals prior to assembly.

Note: Inspect the O-ring seals. Replace O-ring seals that are worn or damaged.

Note: Remove old anaerobic sealant from the bottom of the blind tapped holes in housing (251) before assembling.

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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, PERJ1017, "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.

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Illustration 1	g02517381

Lower the temperature of race (246) and race (245). Install race (246) and race (245) into housing (247). Lower the temperature of bearings (244). Install bearings (244) into housing (247).
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Illustration 2 g02517378
Lower the temperature of races (241) and races (240) . Install races (241) and races (240) into housing (54).
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Illustration 3 g02517376
Install O-ring seal (239).
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Illustration 4 g02517362
Raise the temperature of bearing (238). Install bearing (238). Install retaining ring (237).
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Illustration 5 g02517360
Install gear (236).
Install retaining ring (235).
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Illustration 6 g02517359
Install retainer (234). Install bearing (233). Install retaining ring (232).
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Illustration 7 g02517358
Install gear (231). Install bolts (230). Tighten bolts (230) to a torque of 28 ± 7 N·m (21 ± 5 lb ft).
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Illustration 8 g02517437
Use a suitable lifting device to position shaft assembly (227) onto Tooling (E). The weight of shaft assembly (227) is approximately 20 kg (44 lb). Use suitable blocking to support shaft assembly (227). Install gear (229). Raise the temperature of race (228). Install race (228).
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Illustration 9 g02517216
Use a suitable lifting device to remove shaft assembly (227). The weight of shaft assembly (227) is approximately 20 kg (44 lb).
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Illustration 10 g01391080
Use a suitable lifting device to position clutch assembly (185) onto Tooling (E). The weight of clutch assembly (185) is approximately 35 kg (77 lb).
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Illustration 11 g01390889
Install O-ring seal (226) and seal ring (225).
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Illustration 12 g06082035

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Illustration 13 g06085755
Install piston seal ring (224). Lubricate piston and seal groove with the oil being sealed. Use Tooling (P) to install the O-ring (242) and seal ring (243) as shown.
Note: Do not overstretch the seals.
Note: Assure that the seal rings are properly seated in the groove of the piston.
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Illustration 14 g01390885
Install piston (223).
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Illustration 15 g01390883

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Illustration 16 g01390880
Install plates (222) and discs (221).
Install slider (220).
Use Tooling (K) to align plates (222) and discs (221). Install end plate (219). Install retaining ring (218). Remove Tooling (K).
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Illustration 17 g06210706

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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.
Install spring (215). Install retainer (217). Use Tooling (J) to compress spring (215). Install retaining ring (216). Remove Tooling (J).
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Illustration 18 g01390877
Install thrust washer (214).
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Illustration 19 g01390872
Lower the temperature of bearing (213). Install bearing (213) into gear (212).
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Illustration 20 g01390871
Install gear (212).
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Illustration 21 g01391086
Install thrust washer (211). Install thrust washer (210). Install thrust race (209). Lower the temperature of race (208). Install race (208).
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Illustration 22 g01390946
Use a suitable lifting device to turn over clutch assembly (185). The weight of clutch assembly (185) is approximately 68 kg (150 lb).
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Illustration 23 g01390689
Install O-ring seal (207) and seal ring (206).
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Illustration 24 g06082035

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Illustration 25 g06085763
Lubricate the piston and seal groove with the oil being sealed. Use Tooling (P) to install O-ring seal (244) and seal ring (205) as shown.
Note: Do not overstretch the seals.
Note: Assure that the seal ring is properly seated in the groove of the piston.
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Illustration 26 g01390686
Install piston (204).
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Illustration 27 g01390685

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Illustration 28 g01390949
Install plates (203) and discs (202).
Install slider (201).
Use Tooling (K) to align plates (203) and discs (202). Install end plate (200). Install retaining ring (219). Remove Tooling (K).
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Illustration 29 g01390682

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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.
Install spring (196). Install retainer (198). Use Tooling (G) to compress spring (196). Install retaining ring (197). Remove Tooling (G).
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Illustration 30 g01390680
Install thrust washer (195).
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Illustration 31 g01390676
Lower the temperature of bearing sleeves (194). Install bearing sleeves (194) into gear (193).
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Illustration 32 g01390672
Install gear (193). Install thrust washer (192).
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Illustration 33 g03780804
Install spacer (191).
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Illustration 34 g01390668
Install gear (188). Install spacer (187).
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Illustration 35 g01391096
Raise the temperature of bearing (186). Install bearing (186) with the radius towards the shaft.
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Illustration 36 g01390658
Use Tooling (K), Tooling (L), and a suitable lifting device to install clutch assembly (185). The weight of clutch assembly (185) is approximately 68 kg (150 lb).
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Illustration 37 g01391099
Use a suitable lifting device to position clutch assembly (145) onto Tooling (E). The weight of clutch assembly (145) is approximately 34 kg (75 lb).
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Illustration 38 g01391047
Install O-ring seal (180) and seal ring (179).
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Illustration 39 g06082035

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Illustration 40 g06085771
Install piston seal ring (178). Lubricate the piston and seal groove with the oil being sealed. Use Tooling (P) to install O-ring (245) and seal ring (246) as shown.
Note: Do not overstretch the seals.
Note: Assure that the seal rings are properly seated in the groove of the piston.
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Illustration 41 g01390651
Install piston (177).
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Illustration 42 g01390647

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Illustration 43 g01390646
Install plates (176) and discs (175).
Install slider (174).
Use Tooling (N) to align plates (176) and discs (175). Install end plate (173). Install retaining ring (172).
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Illustration 44 g06210699

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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.
Install spring (169). Install retainer (171). Use Tooling (G) to compress spring (169). Install retaining ring (170). Remove Tooling (G).
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Illustration 45 g01390641
Install thrust washer (168).
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Illustration 46 g01390639
Lower the temperature of bearing (167). Install bearing (167) into gear (166).
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Illustration 47 g01390634
Install gear (166).
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Illustration 48 g01391104
Install thrust washer (165). Install thrust washer (164). Install thrust race (163). Raise the temperature of race (162). Install race (162).
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Illustration 49 g01391110
Use a suitable lifting device to turn over clutch assembly (145). The weight of clutch assembly (145) is approximately 86 kg (190 lb).
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Illustration 50 g02407538
Install O-ring seal (161B) and seal ring (161A).
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Illustration 51 g06082035

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Illustration 52 g06085780
Install piston seal rings (161). Lubricate piston and seal groove with the oil being sealed. Use Tooling (P) to install O-ring (247) and ring seal (248) as shown.
Note: Do not overstretch the seals.
Note: Assure that the ring seals are properly seated in the groove of the piston.
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Illustration 53 g01390627
Install piston (160).
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Illustration 54 g01390625

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Illustration 55 g01390622
Install plates (159) and discs (158).
Install slider (157).
Use Tooling (N) to align plates (159) and discs (158). Install end plate (156). Install retaining ring (155).
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Illustration 56 g01390617

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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.
Install spring (152). Install retainer (154). Use Tooling (G) to compress spring (152). Install retaining ring (153). Remove Tooling (G).
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Illustration 57 g01390620
Install thrust washer (151).
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Illustration 58 g01390614
Lower the temperature of bearing (150). Install bearing (150) into gear (149).
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Illustration 59 g01390612
Install gear (149).
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Illustration 60 g01391116
Install thrust washer (148). Install spacer (147). Raise the temperature of bearing (146). Install bearing (146) with the radius towards the shaft.
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Illustration 61 g01390604
Use Tooling (K), Tooling (L), and a suitable lifting device to install clutch assembly (145). The weight of clutch assembly (145) is approximately 86 kg (190 lb).
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Illustration 62 g02521778
Install gear (140D) and spacer (140C). Raise the temperature of bearing (140B). Install bearing (140B). Install seal ring (140A).
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Illustration 63 g01391124
Use a suitable lifting device to position clutch assembly (64) onto Tooling (E). The weight of clutch assembly (64) is approximately 34 kg (75 lb).
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Illustration 64 g01390597
Install O-ring seal (140) and seal ring (139).
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Illustration 65 g06082035

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Illustration 66 g06085796
Lubricate the piston and seal groove with the oil being sealed. Use Tooling (P) to install O-ring seal (138) and seal ring (249) as shown.
Note: Do not overstretch seals.
Note: Assure that the seal ring is properly seated in the groove of the piston.
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Illustration 67 g01390595
Install piston (137). Install slider (136).
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Illustration 68 g01390593
Install plates (135) and discs (134).
Install hub (133).
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Illustration 69 g01390592
Install end plate (132). Install retaining ring (131).
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Illustration 70 g06210695

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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.
Install spring (128). Install retainer (130). Use Tooling (J) to compress spring (128). Install retaining ring (129). Remove Tooling (J).
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Illustration 71 g01390588
Install thrust washer (127).
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Illustration 72 g01390586
Lower the temperature of bearing sleeves (126). Install bearing sleeves (126) into gear (125).
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Illustration 73 g01390584
Install gear (125).
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Illustration 74 g01390583
Install thrust washer (124). Install spacer (123).
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Illustration 75 g01390582
Install gear (122). Install spacer (121).
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Illustration 76 g01391134
Raise the temperature of bearing (120). Install bearing (120) with the radius towards the shaft.
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Illustration 77 g01391136
Use a suitable lifting device to turn over clutch assembly (64). The weight of clutch assembly (64) is approximately 113 kg (250 lb).
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Illustration 78 g01390578
Install O-ring seal (119) and seal ring (118).
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Illustration 79 g06082035

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Illustration 80 g06497026
Lubricate the piston (115) and seal groove with the oil being sealed. Use Tooling (P) to install O-ring seal (250) and seal ring (251) as shown.
Note: Do not overstretch seals.
Note: Assure that the seal ring is properly seated in the groove of the piston.
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Illustration 81 g01390572
Install piston (115). Install slider (114).
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Illustration 82 g01390565
Install plates (113) and discs (112).
Install hub (111).
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Illustration 83 g01390562
Install end plate (110). Install retaining ring (109).
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Illustration 84 g01390555

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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.
Install spring (106). Install retainer (108). Use Tooling (G) to compress spring (106). Install retaining ring (107). Remove Tooling (G).
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Illustration 85 g01390554
Lower the temperature of bearing sleeve (105). Install bearing sleeve (105) into gear (104).
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Illustration 86 g01390549
Install gear (104). Install thrust washer (103).
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Illustration 87 g01390547
Install gear (102). Install thrust washer (101).
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Illustration 88 g01391152
Raise the temperature of bearing (100). Install bearing (100) with the radius towards the shaft.
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Illustration 89 g01391164
Use a suitable lifting device to position clutch assembly (64) onto Tooling (E). The weight of clutch assembly (64) is approximately 38 kg (84 lb).
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Illustration 90 g01390540
Install O-ring seal (99) and seal ring (98).
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Illustration 91 g01390430
Lubricate the piston and seal groove with the oil being sealed. Install seal ring (97).
Note: Do not over stretch seal ring.
Note: Assure that the seal ring is properly seated in the groove of the piston.
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Illustration 92 g01390428
Install piston (96).
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Illustration 93 g01390426

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Illustration 94 g01390425
Install plates (95) and discs (94).
Use Tooling (N) to align plates (95) and discs (94). Install end plate (93). Install retaining ring (92).
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Illustration 95 g06210691

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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.
Install spring (89). Install retainer (91). Use Tooling (M) to compress spring (89). Install retaining ring (90). Remove Tooling (M).
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Illustration 96 g01390420
Install thrust washer (88).
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Illustration 97 g01390419
Install gear (86). Lower the temperature of bearing sleeves (87). Install bearing sleeves (87).
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Illustration 98 g01390414
Install gear (86).
Install thrust washer (85). Install spacer (84).
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Illustration 99 g01391166
Raise the temperature of bearing (83). Install bearing (83).
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Illustration 100 g01391168
Use a suitable lifting device to turn over clutch assembly (64). The weight of clutch assembly (64) is approximately 104 kg (230 lb).
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Illustration 101 g01390409
Install O-ring seal (82) and seal ring (81).
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Illustration 102 g06082035

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Illustration 103 g06085833
Lubricate the piston and seal groove with the oil being sealed. Use Tooling (P) to install O-ring seal (80) and seal ring (252) as shown.
Note: Do not overstretch seals.
Note: Assure that the seal ring is properly seated in the groove of the piston.
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Illustration 104 g01390403
Install piston (79).
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Illustration 105 g01390400

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Illustration 106 g01390395
Install plates (78) and discs (77).
Use Tooling (N) to align plates (78) and discs (77). Install end plate (76). Install retaining ring (75).
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Illustration 107 g01390392
Install slider (74).
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Illustration 108 g01390389

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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.
Install spring (71). Install retainer (73). Use Tooling (G) to compress spring (71). Install retaining ring (72). Remove Tooling (G).
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Illustration 109 g01390383
Install thrust washer (70).
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Illustration 110 g01390381
Lower the temperature of bearing sleeves (69). Install bearing sleeves (69) into gear (68).
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Illustration 111 g01390377
Install gear (68). Install thrust washer (67).
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Illustration 112 g01391176
Install rotor (66). Raise the temperature of bearing (65). Install bearing (65) with the radius towards the shaft.
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Illustration 113 g01390368
Use Tooling (D) and a suitable lifting device to install clutch assembly (64) and clutch assembly (63). The weight of clutch assembly (64) and clutch assembly (63) is approximately 204 kg (450 lb).
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Illustration 114 g01390365
Install tube assembly (56). Install bolts (55). Tighten bolts (55) to a torque of 55 ± 10 N·m (41 ± 7 lb ft). Install O-ring seal (54).
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Illustration 115 g02517501
Apply Tooling (R) onto the mating surface of housing (247). Use Tooling (A), Tooling (B), and a suitable lifting device to install housing (53). The weight of housing (53) is approximately 261 kg (575 lb).
Install bolts (52). Tighten bolts (52) to a torque of 55 ± 10 N·m (41 ± 7 lb ft).
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Illustration 116 g01391196
Install seal rings (183) and install O-ring seals (184) onto seal carrier (182).
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Illustration 117 g01391201
Install seal carrier (182). Install bolts (181).
Note: Ensure that the spring pin that is in the seal carrier is aligned with the hole that is in the end of the shaft assembly.
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Illustration 118 g01391205
Install O-ring seals (144) and install seal rings (143) onto seal carrier (142).
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Illustration 119 g01391212
Install seal carrier (142). Install bolts (141).
Note: Ensure that the spring pin that is in the seal carrier is aligned with the hole that is in the end of the shaft assembly.
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Illustration 120 g01391216
Install seal rings (61) and install O-ring seals (62) onto seal carrier (60). Repeat this step for seal carrier (58).
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Illustration 121 g01391217
Install seal carrier (58) and install bolts (57). Install seal carrier (60) and install bolts (59).
Note: Ensure that the spring pin that is in the seal carrier is aligned with the hole that is in the end of the shaft assembly.
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Illustration 122 g01390360
Install speed sensor (50) and speed sensor (51). Install bolts (49).
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Illustration 123 g01390359
Install cover (48).
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Illustration 124 g01390356
Install speed sensor (47) and speed sensor (46). Install bolts (45).
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Illustration 125 g01390355
Install speed sensor (44). Install bolt (43).
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Illustration 126 g02517380
Install covers (243) and covers (242) onto housing (54).
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Illustration 127 g01390322
Use Tooling (A), Tooling (B), and a suitable lifting device to position transmission (1) with the output shaft upward. The weight of transmission (1) is approximately 1043 kg (2300 lb).
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Illustration 128 g01390352
Install hub (42). Install retaining ring (41).
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Illustration 129 g01390351
Install O-ring seals (40) and O-ring seal (39).
Install discs (37) and plates (38).
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Illustration 130 g01390349
Install seal (36).
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Illustration 131 g01390345
Install O-ring seal (35), O-ring seal (34), O-ring seal (33), O-ring seal (32), and O-ring seal (31).
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Illustration 132 g01390343
Install solenoid (30). Install pressure sensor (29) and the O-ring seal.
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Illustration 133 g01390342
Use two people to install housing (28). The weight of housing (28) is approximately 27 kg (60 lb). Install bolts (27). Tighten bolts (27) to a torque of 55 ± 10 N·m (41 ± 7 lb ft).
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Illustration 134 g01390339
Connect harness assembly (26) and harness assembly (25).
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Illustration 135 g01390334
Install piston (22).
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Illustration 136 g01390331
Install spring discs (21).
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Illustration 137 g01390329
Install O-ring seal (20).
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Illustration 138 g01390327
Install lip seal (19).
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Illustration 139 g01390323

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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.
Install spring plate (18). Install bolts (17). Tighten bolts (17) to a torque of 100 ± 20 N·m (74 ± 15 lb ft).
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Illustration 140 g01391235

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Illustration 141 g01390304
Use Tooling (A), Tooling (B), and a suitable lifting device to remove transmission (1) from Tooling (C). The weight of transmission (1) is approximately 1043 kg (2300 lb). Position transmission (1) onto suitable cribbing.
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Illustration 142 g01390318
Install spacers (16) and control module (15). Install bolts (14).
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Illustration 143 g01390315
Install O-ring seal (13). Install cup (12). Install retaining ring (11).
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Illustration 144 g01390309
Install yoke assembly (10).
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Illustration 145 g01390308
Position filter base (9) and install bolts (8). Connect harness assembly (7).
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Illustration 146 g01390307
Install tube assembly (6). Install tube assembly (5). Install tube assembly (4). Install hose assembly (3). Install clip (2).