Caterpillar Cat 140M 2 MOTOR GRADER (Prefix R9G) Service Repair Manual Instant Download

Service Repair Manual Models 140M2 M OTOR GRADER

140M Series 2 Motor Grader - All Wheel Drive R9G00001-UP (MACHINE) POWER... 1/21 Shutdown SIS Previous Screen 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 https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/1/6

140M Series 2 Motor Grader - All Wheel Drive R9G00001-UP (MACHINE) POWER... 2/21 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). Illustration 2 g01408574 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. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/1/6

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140M Series 2 Motor Grader - All Wheel Drive R9G00001-UP (MACHINE) POWER... 3/21 Illustration 3 g01408585 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. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/1/6

140M Series 2 Motor Grader - All Wheel Drive R9G00001-UP (MACHINE) POWER... 4/21 Illustration 4 g01408606 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). Illustration 5 g01408628 7. Measure Dimension (B) and record Dimension (B) to the nearest 0.010 mm (0.0004 inch) on special washer (47). Illustration 6 g01408635 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). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/1/6

140M Series 2 Motor Grader - All Wheel Drive R9G00001-UP (MACHINE) POWER... 5/21 Illustration 7 g01408647 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). Illustration 8 g01408691 https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/1/6

140M Series 2 Motor Grader - All Wheel Drive R9G00001-UP (MACHINE) POWER... 6/21 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. Illustration 9 g01408860 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. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/1/6

140M Series 2 Motor Grader - All Wheel Drive R9G00001-UP (MACHINE) POWER... 7/21 Illustration 10 g01408867 18. Install barrel (49) into housing (35). Measure Dimension (L) and record Dimension (L) to the nearest 0.010 mm (0.0004 inch). Illustration 11 g01408880 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). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/1/6

140M Series 2 Motor Grader - All Wheel Drive R9G00001-UP (MACHINE) POWER... 8/21 21. Select a combination of shims (53) (not shown) that equals Dimension (N) minus 0.090 0.040 mm (0.0035 0.0016 inch). Illustration 12 g01408860 Illustration 13 g01408179 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). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/1/6

140M Series 2 Motor Grader - All Wheel Drive R9G00001-UP (MACHINE) POWER... 9/21 Illustration 14 g01408159 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. Illustration 15 g01409043 26. Measure Dimension (P) and record Dimension (P) on plate (58) to the nearest 0.010 mm (0.0004 inch). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/1/6

140M Series 2 Motor Grader - All Wheel Drive R9G00001-UP (MACHINE) POW... 10/21 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). Illustration 16 g01408122 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). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/1/6

140M Series 2 Motor Grader - All Wheel Drive R9G00001-UP (MACHINE) POW... 11/21 Illustration 17 g01409370 37. Position swashplate assembly (42) into barrel assembly (37). Illustration 18 g01409529 38. Install shaft (43) into barrel assembly (37) and swashplate assembly (42). Illustration 19 g01409547 39. Install special washer (47) onto barrel assembly (37). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/1/6

140M Series 2 Motor Grader - All Wheel Drive R9G00001-UP (MACHINE) POW... 12/21 Illustration 20 g01409564 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. Illustration 21 g01409596 Illustration 22 g01409572 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). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/1/6

140M Series 2 Motor Grader - All Wheel Drive R9G00001-UP (MACHINE) POW... 13/21 44. Install pipe (27A) and pipe (27B) into barrel assembly (37). Illustration 23 g01409607 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). Illustration 24 g01409686 49. Measure Dimension (FF) and record Dimension (FF) in housing (26) to the nearest 0.010 mm (0.0004 inch). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/1/6

140M Series 2 Motor Grader - All Wheel Drive R9G00001-UP (MACHINE) POW... 14/21 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). Illustration 25 g01409716 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). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/1/6

140M Series 2 Motor Grader - All Wheel Drive R9G00001-UP (MACHINE) POW... 15/21 Illustration 26 g01409572 55. Remove pipe (27A) and pipe (27B) from housing (35). Remove barrel assembly (37) from housing (35). Illustration 27 g01407631 56. Install O-ring seal (40) onto piston (38). Repeat this step for the other piston. Illustration 28 g01410022 57. Install rod (41). Install pistons (39) and (38). Note: The longer piston (39) is installed on the same side as rod (41). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/1/6

140M Series 2 Motor Grader - All Wheel Drive R9G00001-UP (MACHINE) POW... 16/21 Illustration 29 g01410102 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). Illustration 30 g01407569 61. Apply Tooling (L) to shuttle valve (32). Use Tooling (B) to install shuttle valve (32) into housing (26). 62. Install relief valve (31). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/1/6

140M Series 2 Motor Grader - All Wheel Drive R9G00001-UP (MACHINE) POW... 17/21 Illustration 31 g01407324 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). Illustration 32 g01410264 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. 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). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/1/6

140M Series 2 Motor Grader - All Wheel Drive R9G00001-UP (MACHINE) POW... 18/21 Illustration 33 g01410274 66. Install port plate (36) onto housing (26). Illustration 34 g01410304 67. Install barrel assembly (37) and swashplate assembly (42) onto housing (26). Illustration 35 g01410343 68. Apply Tooling (K) to the mating surface of housing (26). Position housing (35) onto housing (26). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/1/6

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140M Series 2 Motor Grader - All Wheel Drive R9G00001-UP (MACHINE) POW... 19/21 Illustration 36 g01410356 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). Illustration 37 g01407281 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). Illustration 38 g01407274 Improper assembly of parts that are spring loaded can cause bodily injury. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/1/6

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