14H Motor Grader Power Train Transmission and Transfer Gears - Assemble Caterpillar

Assembly Procedure

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Illustration 1	g00919299

1. Install bearings (1) in gear (2).
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   Illustration 2	g00919300

2. Install gear (2) and washers (3) into carrier assembly (4).

3. Install shaft (5) into carrier assembly (4) to hold gear (2).

4. Install new pin (6) that holds shaft (5).

5. Repeat Steps 1 through 4 for remaining gears in carrier assembly (4).
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   Illustration 3	g00919301

6. Install ring (7) on bearing (8).
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   Illustration 4	g00919302

7. Install bearing (8) in carrier assembly (4). Ensure that notch (9) is facing toward the top of carrier assembly (4).
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   Illustration 5	g00919303

8. Install ring (10) on cage assembly (11).
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   Illustration 6	g00919305

9. Install cage assembly (11) in bearing (8). Align ball (12) on cage (11) in the notch.
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   Illustration 7	g00919306

10. Install cage (13) on carrier assembly (4).

11. Install new bolts (14).
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    Illustration 8	g00919307

12. Install shaft assembly (15) in carrier assembly (4).

13. Install gear (16) on shaft assembly (15).

    Note: You may need to rotate gears (2) to seat shaft (15) and gear (16) to the REAR of carrier assembly (4).

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    Illustration 9	g00919308

14. Raise the temperature of bearing (17) to install bearing (17) on cage (18).
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    Illustration 10	g00919309

15. Install bearing (17), cage (18), and ring (20) in gear assembly (19).
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    Illustration 11	g00919311

16. Install gear assembly (19) on shaft assembly (15).

    Note: You may need to rotate gears (2) in order for gear assembly (19) to be seated correctly.

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    Illustration 12	g00919312

17. Install spacer (20) on shaft assembly (15).
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    Illustration 13	g00919313

18. Install gear (21) on shaft assembly (15).

19. Use Tooling (D) to install retaining ring (22) and hold gear (21) in place.
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    Illustration 14	g00919314

    Note: Block the assembly in a vertical position.

20. Install ring (23). Put ring (23) into compression and install gear (24). Release ring (23) to hold gear (24).

21. Install new pins (25) into carrier assembly (4). Use a hammer and a punch to drive pins (25) into carrier assembly (4). Ensure that pins (25) are flush with the bottom of carrier assembly (4).
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    Illustration 15	g00919739

22. Install dowels (26) in housing (27) to a height of 15.7 ± 5.0 mm (0.62 ± 0.20 inch).
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    Illustration 16	g00919747

23. Install seal rings (28) and (29) on piston (30). Lubricate seal rings (28) and (29) lightly with the lubricant that is being sealed.
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    Illustration 17	g00919316

24. Install housing (27), piston (30), and gear (31).
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    Illustration 18	g00919317

25. Install bearings (32) in gear (33).
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    Illustration 19	g00919318

26. Install gear (33) and washers (34) in carrier assembly (35).

27. Install shaft (36) in carrier assembly (35) to hold gear (33) in place.

28. Install new pin (37) in carrier assembly (35) to hold shaft (36).

    Note: Repeat Steps 25 through 28 for remaining gears in carrier assembly (35).

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    Illustration 20	g00919319

29. Use two people to install carrier assembly (35). The weight of carrier assembly (35) is approximately 25 kg (55 lb).
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    Illustration 21	g00919878

30. Install retainer (38) on shaft assembly (15). Use Tooling (D) to install retaining ring (39).
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    Illustration 22	g00919321

31. Lubricate discs (40) and plates (41) with Tooling (J). Install discs (40) and plates (41).
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    Illustration 23	g00919906

32. Install springs (42) and end plate (43).
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    Illustration 24	g00919322

33. Attach Tooling (A) and a suitable lifting device to rotate carrier assembly (35). The weight of carrier assembly is approximately 100 kg (220 lb).

    Note: Use Tooling (F) (not shown) to secure carrier assembly (35) during rotation.

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    Illustration 25	g00919323

34. Install discs (44) and plates (45). Lubricate discs (44) and plates (45) with Tooling (J).

35. Install springs (46) and dowels (47).
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    Illustration 26	g00919324

36. Install seal rings (48) and (49) on piston (50). Lubricate seal rings (48) and (49) with lubricant that is being sealed.
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    Illustration 27	g00919325

37. Install piston (50) on housing (51).
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    Illustration 28	g00919326

38. Install Tooling (C) to hold piston (50) and housing (51). Install piston (50) and housing (51) as one unit. Ensure that piston (50) is facing DOWNWARD.
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    Illustration 29	g00919327

39. Install seal rings (52) and (53) on piston (54). Lubricate seal rings (52) and (53) with lubricant that is being sealed.
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    Illustration 30	g00919329

40. Install piston (54) and gear (55) in housing (51).
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    Illustration 31	g00919330

41. Install discs (56) and plate (57).

42. Install dowels (58) and spring (59).
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    Illustration 32	g00919331

43. Install dowels (60) in housing (61) to a height of 15.7 ± 0.5 mm (0.62 ± 0.02 inch).
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    Illustration 33	g00919332

44. Install housing (61).
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    Illustration 34	g00919333

45. Install seal rings (62) and (63) on piston (64). Lubricate seal rings (62) and (63) with lubricant that is being sealed.
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    Illustration 35	g00919334

46. Install piston (64) in housing (61).
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    Illustration 36	g00919335

47. Install gear (65).
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    Illustration 37	g00919336

48. Install discs (66) and plate (67). Lubricate discs (66) and plate (67) with Tooling (J).
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    Illustration 38	g00919337

49. Install dowels (68) and springs (69).
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    Illustration 39	g00919338

50. If necessary install the twelve bolt dampers into housing (70). Install housing (70).
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    Illustration 40	g00919339

51. Install seal rings (71) and (72) on piston (73). Lubricate seal rings (71) and (72) with lubricant that is being sealed.
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    Illustration 41	g00919340

52. Install piston (73) in housing (70).
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    Illustration 42	g00919341

53. Install gear (74).
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    Illustration 43	g00919344

54. Install discs (75) and plates (76). Alternate the order of discs (75) and plates (76). Lubricate discs (75) and plates (76) with Tooling (J).

55. Install springs (77).
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    Illustration 44	g00919345

56. Install pins (78) in housing assembly (79) to a height of 15.7 ± 0.5 mm (0.62 ± 0.02 inch).

57. Install pins (80) in housing assembly (79) to a height of 7.9 ± 0.5 mm (0.31 ± 0.02 inch). From the bottom of the counterbore, install pins (81) on housing assembly (79).
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    Illustration 45	g00919347

58. Install housing assembly (79).
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    Illustration 46	g00919348

59. Install bearings (82) in gear (83).
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    Illustration 47	g00919349

60. Install gear (83) and washers (84) in carrier assembly (85).

61. Install shaft (86) in carrier assembly (85) to hold gear (83).

62. Install new pin (87) to hold shaft (86) in place.

63. Repeat Steps 60 through 62 for the remaining gears in carrier assembly (85).
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    Illustration 48	g00919350

64. Install bearing (88). Ensure that the notch is facing UPWARD in carrier assembly (85).

65. Install ring (89) in carrier assembly (85) to hold bearing (88) in place.
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    Illustration 49	g00919351

66. Attach Tooling (A) and a suitable lifting device to carrier assembly (85). Install carrier assembly (85). The weight of carrier assembly (85) is approximately 14 kg (30 lb).
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    Illustration 50	g00919352

67. Install hub assembly (90) and align ball (91) with the notch in bearing (88).
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    Illustration 51	g00919353

68. Use Tooling (D) to install retaining ring (92).
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    Illustration 52	g00919355

69. Install balls (93) on inserts (81).
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    Illustration 53	g00919356

70. Install new pins (94) on piston assembly (95) to a height of 7.9 ± 0.5 mm (0.31 ± 0.02 inch) from the bottom of the counterbore.

71. Install inserts (96) on piston assembly (95).
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    Illustration 54	g03344335

72. Install seal (93A) on the shaft. Install piston assembly (95) on balls (93).
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    Illustration 55	g00919358

73. Install gear (97).
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    Illustration 56	g00919359

74. Install discs (98) and plates (99). Start with a plate and alternate with a disc. Lubricate discs (98) and plates (99) with Tooling (J).
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    Illustration 57	g03124536

75. Install dowels (99A) to install discs (100) , and friction discs (99B). Lubricate discs with Tooling (J). Install seal (99C) to shaft assembly (15).
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    Illustration 58	g00919361

76. Install seal rings (101) and (102) on cage (103). Lubricate seal rings (101) and (102) with lubricant that is being sealed.
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    Illustration 59	g00920781

77. Use Tooling (K) and a hammer to install bearing (104) in cage (103).
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    Illustration 60	g00919362

78. Install cage (103) on flange (105) and attach with bolts (106).
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    Illustration 61	g00919364

79. Install piston (107) on flange (105).
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    Illustration 62	g00919365

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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.

80. Install springs (108) and retainer (109).
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    Illustration 63	g00919366

81. Put springs (108) into compression and install retaining ring (110) on cage (103).
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    Illustration 64	g00919367

82. Install flange (105).

83. Install bolts (111). Tighten bolts (111) to a torque of 55 ± 10 N·m (40.6 ± 7.3 lb ft).
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    Illustration 65	g06474872

84. Lower the temperature of bearing (111A). Install bearing (111A) and retaining ring (112) in bearing cage (113). Ensure that the notch in bearing (111A) is on the bottom.
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    Illustration 66	g00919369

85. Install bearing cage (113).
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    Illustration 67	g00919370

86. Use Tooling (D) to install ring (114) on flange (105).
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    Illustration 68	g00919372

87. Install O-ring seals (115) on housing (116).
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    Illustration 69	g00920882

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    Illustration 70	g06311372

88. Install dowel (117) to a height of 13.5 ± 0.5 mm (0.53 ± 0.02 inch) in housing (116).

89. Install pins (118) to Dimension (X). Dimension (X) should be 50.8 ± 0.5 mm (2.0 ± 0.02 inch).
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    Illustration 71	g00919373

90. Attach Tooling (A) and a suitable lifting device to the bottom of housing (116).
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    Illustration 72	g00919375

91. Lift housing (116). The weight of housing (116) is approximately 36 kg (80 lb).

92. Install springs (119) and plunger (120).
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    Illustration 73	g00919376

93. Install bolts (121) and (122). Tighten bolts (121) to a torque of 115 ± 7 N·m (85 ± 5 lb ft). Tighten bolts (122) to a torque of 47 ± 9 N·m (35 ± 7 lb ft).
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    Illustration 74	g00919378

94. Rotate the planetary assembly to a horizontal position. Apply 689 kPa (100 psi) to 827 kPa (120 psi) of air pressure to test the clutch pistons.
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    Illustration 75	g00919379

95. Install spiral ring (123) in gear (124).
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    Illustration 76	g00919380

96. Lower the temperature of bearing cup (125). Install bearing cup (125) in gear (124) against spiral ring (123).
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    Illustration 77	g00919381

97. Invert gear (124). Install spacer (126) with the notch toward spiral ring (123).
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    Illustration 78	g00919383

98. Lower the temperature of bearing cup (127) and install bearing cup (127) in gear (124).
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    Illustration 79	g00919384

99. Install studs (128) in support assembly (129). Tighten studs (128) to a torque of 54 ± 7 N·m (40 ± 5 lb ft).

100. Install O-ring seals (130) and (131) on support assembly (129).
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     Illustration 80	g00919385

101. Use Tooling (K) and a hammer to install bearing (132) in support assembly (129).
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     Illustration 81	g00919388

102. Install O-ring seal (133) on carrier assembly (134).
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     Illustration 82	g00919389

103. Use Tooling (K) and a hammer to install carrier assembly (134) in support assembly (129).

     Note: Be sure to install carrier assembly (134) into support assembly (129) with the beveled edge of carrier assembly (134) facing up.

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     Illustration 83	g00919390

104. Install bearing cone (135) and spacer (136) on support assembly (129).
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     Illustration 84	g00919391

105. Use two people to install gear (124) on support assembly (129). The weight of gear (124) is approximately 27 kg (60 lb).
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     Illustration 85	g00919393

106. Install bearing cone (137) on support assembly (129).
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     Illustration 86	g00919395

107. Install washer (138) on support assembly (129).
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     Illustration 87	g00919396

108. Apply Tooling (M) to the face and thread of nut (139). Install nut (139).
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     Illustration 88	g00919398

109. Use Tooling (B) to torque nut (139). Tighten nut (139) to a torque of 450 ± 41 N·m (332 ± 30 lb ft).
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     Illustration 89	g00919399

110. Use a hammer and a punch to peen nut (139) to support assembly (129).
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     Illustration 90	g00919401

111. Install Tooling (A) and a suitable lifting device to install support assembly (129). The weight of support assembly is approximately 41 kg (90 lb).
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     Illustration 91	g00919403

112. Install retainers (140), locks (141), and bolts (142). Bend locks (141) against bolts (142).
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     Illustration 92	g00919404

113. Install O-ring seal (143) on carrier assembly (144).
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     Illustration 93	g00919405

114. Use Tooling (D) (not shown) to install snap ring (145) on carrier assembly (144).

115. Use Tooling (K) (not shown) to install carrier assembly (144) into case (146) until snap ring (145) seats against case (146).

     Note: Be sure to install carrier assembly (144) into case (146) with the beveled edge of carrier assembly (144) facing up.

116. Lower the temperature of the bearing cup (147). Install bearing cup (147) in case (146).

117. Repeat Steps 113 through 116 for the second carrier and the second bearing cup.
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     Illustration 94	g00919407

118. Lower the temperature of the bearing cup (147B). Install bearing cup (147B) in carrier assembly (146).
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     Illustration 95	g00919408

119. Apply Tooling (P) to the sides of plug (148) and allow plug (148) to dry. Use Tooling (K) to install plug (148) in case (146).
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     Illustration 96	g00919409

120. Install seal (149) on hub (150). Ensure that the lip of the seal is facing DOWNWARD. Lubricate seal (149) with lubricant that is being sealed.
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     Illustration 97	g00919410

121. Install hub (150) in gear (151).
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     Illustration 98	g00919412

122. Install dowel (152) in shaft (153) to a height of 4.1 ± 0.5 mm (0.16 ± 0.02 inch).

123. Install dowels (154) in shaft (153) to a height of 20.6 ± 0.5 mm (0.81 ± 0.02 inch).

124. Install seal rings (155) and O-ring seal (156). Lubricate seal rings (155) with lubricant that is being sealed.

125. Raise the temperature of bearing cone (157). Install bearing cone (157) on shaft (153).
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     Illustration 99	g00919414

126. Install shaft (153) on gear (151).
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     Illustration 100	g00919415

127. Hold shaft (153) in position to install bolts (158).
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     Illustration 101	g00919416

128. Install plates (159) and discs (160). Lubricate plates (159) and discs (160) with Tooling (J).
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     Illustration 102	g00919417

129. Install springs (161) and plate (162).
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     Illustration 103	g00919419

130. Align dowels (154) with two shallow holes (164) in piston (163). Install piston (163). Align springs (161) with the remaining holes on piston (163).
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     Illustration 104	g00919420

131. Install O-ring seal (165) and seal ring (165A) on plate (166). Lubricate O-ring seal (165) and seal ring (165A) with lubricant that is being sealed.
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     Illustration 105	g00919422

132. Install plate (166). Align the notch in plate (166) with dowel (152).
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     Illustration 106	g00919423

133. Install bearing cone (167) and spacer (168).
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     Illustration 107	g00919426

134. Install ring (169) in drum (170).
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     Illustration 108	g00919428

135. Lower the temperature of bearing cup (171). Install bearing cup (171) in drum (170). Ensure that bearing cup (171) is seated on ring (169).
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     Illustration 109	g00919429

136. Invert drum (170). Install spacer (172) in drum (170). Ensure that the lip of spacer (172) is facing downward.
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     Illustration 110	g00919430

137. Lower the temperature of bearing cup (173). Install bearing cup (173) in drum (170).
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     Illustration 111	g00919431

138. Install drum (170).
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     Illustration 112	g00919433

139. Install bearing cone (174).
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     Illustration 113	g00919434

140. Install washer (175).
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     Illustration 114	g00919435

141. Apply Tooling (M) to the face and threads of nut (176). Install nut (176).
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     Illustration 115	g00919436

142. Use Tooling (Q) to torque nut (176). Tighten nut (176) to a torque of 340 ± 27 N·m (251 ± 20 lb ft). Use a hammer and punch to peen nut (176) to the shaft.
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     Illustration 116	g00919437

143. Raise the temperature of bearing cone (177). Install bearing cone (177).
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     Illustration 117	g00919438

144. Install Tooling (N) and a suitable lifting device on the direction clutch. Install the direction clutch in case (146). The weight of the direction clutch is approximately 68 kg (150 lb).

145. Repeat Steps 120 through 144 for the second direction clutch.
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     Illustration 118	g00919439

146. Raise the temperature of bearing cone (178). Install bearing cone (178) on pump drive shaft (179).
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     Illustration 119	g00919440

147. Raise the temperature of bearing cone (180). Install bearing cone (180) on pump drive shaft (179).
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     Illustration 120	g00919442

148. Install O-ring seal (181) on pump drive shaft (179).
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     Illustration 121	g00919444

149. Install pump drive shaft (179) in case (146).
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     Illustration 122	g00919445

     Note: Lower the temperature of the bearing cups (182) and (185) before installation.

150. Install spiral ring (182), bearing cup (183), spacer (184), and bearing cup (185) in gear (186).

     Note: Place a mark on the side of gear (186) that has spacer (184).

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     Illustration 123	g00919446

151. Raise the temperature of bearing cone (187). Install bearing cone (187) and spacer (188) on idler shaft (189).
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     Illustration 124	g00919447

152. Install gear (186). Ensure that the side with the mark is facing downward, on idler shaft (189). Place a mark on idler shaft (189) directly above dowel (190).
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     Illustration 125	g00919448

153. Install bearing cone (191).
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     Illustration 126	g00919449

154. Install idler shaft (189) in case (146).
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     Illustration 127	g00919452

155. Install seven O-ring seals (192) on cover (193).
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     Illustration 128	g00919453

156. Flip cover (193) and mark cover (193) directly above the notch (193B). Idler shaft (193) will be installed at this location.
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     Illustration 129	g00919456

157. Install Tooling (A) and a suitable lifting device to cover (193). Install cover (193). The weight of cover (193) is approximately 59 kg (130 lb).
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     Illustration 130	g00919457

158. Ensure that the marks on idler shaft (189) and cover (193) are aligned (as shown).
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     Illustration 131	g00919458

159. Install bolts (194) that hold cover (193) in place.
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     Illustration 132	g00919459

160. Install O-ring seal (195) on carrier assembly (196).
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     Illustration 133	g00919460

161. Lower the temperature of bearing cup (197). Install bearing cup (197) in cage (198).
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     Illustration 134	g00919461

162. Use Tooling (K) to install carrier assembly (196) in cage (198).

     Note: Be sure to install carrier assembly (196) into cage (198) with the beveled edge of carrier assembly (196) facing up.

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     Illustration 135	g00919462

163. Install O-ring seals (199) on cage (198).

164. Repeat Steps 160 through 163 for the second cage.
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     Illustration 136	g00919464

165. Install O-ring (200), retainer (201), and bolt (202). Tighten bolt (202) to a torque of 115 ± 7 N·m (85 ± 5 lb ft).
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     Illustration 137	g00919465

166. Install Tooling (G) in shaft (153).
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     Illustration 138	g00919466

167. Install original shim pack (203) and cage (198).
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     Illustration 139	g00919467

168. Install bolts (204) and tighten evenly.

169. Install Tooling (H) on Tooling (G). Use two pry bars to measure the end play of the direction clutch. Add shims or remove shims to get an end play of 0.050 mm (0.0020 inch) to 0.150 mm (0.0059 inch).

     Note: After achieving desired end play, remove cage (198), Tooling (G), Tooling (H), and the pry bars.

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     Illustration 140	g00919468

170. Install cage (198) and tighten bolts (204) evenly.

171. Repeat Steps 160 through 170 for the second cage and the second direction clutch.
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     Illustration 141	g00919469

172. Lower the temperature of bearing cup (205). Install bearing cup (205) in cage (206).
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     Illustration 142	g00919470

173. Install cage (206) with the original shim pack under the cage. Install bolts (207) and tighten evenly.
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     Illustration 143	g00919471

174. Install Tooling (E) into the end of the pump drive shaft. Install Tooling (H). Use pry bars to measure the end play.

175. Add shims or remove shims to get an end play of 0.050 mm (0.0020 inch) to 0.150 mm (0.0059 inch).
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     Illustration 144	g00919472

176. Install plug (208) in cage (197). Repeat this Step for the other cage.
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     Illustration 145	g02402881

177. Install coupler (209), retainer (210), O-ring (210A), and bolt (211). Tighten bolt (211) to a torque of 115 ± 7 N·m (85 ± 5 lb ft).
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     Illustration 146	g00919476

178. Install O-ring seal (212).
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     Illustration 147	g00919477

179. Turn transfer gear case (212A) to a HORIZONTAL position. Install Tooling (A) and a suitable lifting device on planetary group (212B).

180. Install planetary group (212B) in transfer gear case (212A). The weight of planetary group (212B) is approximately 386 kg (850 lb).
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     Illustration 148	g00919478

181. Install O-ring seals (213) and bolts (214).
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     Illustration 149	g00919479

182. Install O-ring seals (215) on manifold (216).
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     Illustration 150	g00919480

183. Install manifold (216). Install bolts (216A) and nuts (216B).
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     Illustration 151	g00919481

184. Install new pins (217) on coupling (217A).
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     Illustration 152	g00919482

185. Install tube (217B) and coupling (218) on pump drive shaft (179).
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     Illustration 153	g00919484

186. Install two O-ring seals (219) on each sleeve (220). Install sleeves (220) in position in case (212A).
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     Illustration 154	g00919485

187. Install Tooling (A) and a suitable lifting device to transmission control module (221).
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     Illustration 155	g00919487

188. Install transmission control module (221). Install bolts (222). Tighten bolts (222) to a torque of 47.5 ± 4 N·m (35.04 ± 2.95 lb ft).
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     Illustration 156	g00919488

189. Slide sleeves (220) into position in transmission control module (221).
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     Illustration 157	g00919489

190. Install plates (223) and bolts (224) to secure sleeves (220). Tighten bolts (224) to a torque of 30 ± 4 N·m (22 ± 3 lb ft).
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     Illustration 158	g00919492

191. Install gasket (225), plate (225A), and bolts (226).
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     Illustration 159	g00919493

192. Install cover (227) and nuts (228).
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     Illustration 160	g00923081

193. Use a suitable lifting device to install pump (229). The weight of pump (229) is approximately 27 kg (60 lb). Install bolts (230).
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     Illustration 161	g00923082

194. Install the O-ring seals on tube assembly (231) and install tube assembly (231). Install bolts (232).
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     Illustration 162	g00923083

195. Install the O-ring seals on tube assembly (233) and install tube assembly (233). Install bolts (234).
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     Illustration 163	g00923085

196. Install the O-ring seals on tube assembly (235) and install tube assembly (235). Install bolts (236).
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     Illustration 164	g00923086

197. Install the O-ring seals on tube assembly (237) and install tube assembly (237). Install bolts (238).

End By:

1. Install the transmission. Refer to Disassembly and Assembly, "Transmission and Transfer Gears - Install".