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Special Instruction
Procedure to Install the New Pinion Shaft in the Circle Drive{5207}
Media Number -REHS4207-00 Publication Date -25/04/2008 Date Updated -25/04/2008

i02849542

Procedure to Install the New Pinion Shaft in the Circle Drive

{5207}
SMCS - 5207

Motor Grader:
14H (S/N: ASE1-UP; 7WJ1-UP)
120G (S/N: 4HD1-UP; 1LK1-UP; 87V1-UP; 11W1-UP)
120H (S/N: CAF1-UP; 4MK1-UP; 5FM1-UP; 6NM1-UP; 6TM1-UP; 2AN1-UP; 6YN1-
UP; 9FN1-UP; 9YR1-UP; ALZ1-UP; 1241-UP)
120M (S/N: B9N1-UP)
12G (S/N: 3WC1-UP; 3PL1-UP; 61M1-UP)
12H (S/N: CBK1-UP; 4XM1-UP; 5ZM1-UP; 8MN1-UP; 2LR1-UP; 2WR1-UP; 4ER1-
UP; 2GS1-UP; AMZ1-UP)
130G (S/N: 74V1-UP)
135H (S/N: CBC1-UP; BDJ1-UP; 3YK1-UP; 7MM1-UP; 8WN1-UP; AMX1-UP)
140G (S/N: 5MD1-UP; 72V1-UP; 13W1-UP)
140H (S/N: CCA1-UP; APM1-UP; 5HM1-UP; 8JM1-UP; 8KM1-UP; 9TN1-UP; 9ZN1-
UP; 3AS1-UP)
140M (S/N: B9M1-UP)
143H (S/N: 1AL1-UP; APN1-UP)
14G (S/N: 03L1-UP; 96U1-UP)
14M (S/N: B9J1-UP)
160G (S/N: 4JD1-UP)
160H (S/N: ASD1-UP; 9EJ1-UP; 2FM1-UP; 3GM1-UP; 6WM1-UP; 9JM1-UP; CCP1-
UP; 2HS1-UP)
160M (S/N: B9L1-UP)
163H (S/N: 5AK1-UP; ARL1-UP)
16M (S/N: B9H1-UP)
16G (S/N: 93U1-UP)
16H (S/N: 6ZJ1-UP; 3JR1-UP; ATS1-UP)
24H (S/N: 7KK1-UP)
24M (S/N: B9K1-UP)

Introduction
The pinion gear has been replaced for improved wear. Replace the pinion shaft, the shims, the cover
and the bolts. This procedure will provide information regarding the inspection, and the repair of the
specific machines.

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

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containing fluids.

Refer to Special Publication, NENG2500, "Caterpillar Dealer Service

Tool Catalog" for tools and supplies suitable to collect and contain
fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates.

Do not perform any procedure in this Special Instruction until you read this information and you
understand this information. Do not perform any procedure until you read the information and you
understand the information. Use only proper tools and observe all precautions that pertain to the use
of those tools. Failure to follow these procedures can result in personal injury. The following
procedures should also be observed.

Specifications for Cables, Chains, and Lifting Devices

Use approved cables, chains, and lifting devices in order to lift components. Refer to the
manufacturer's weight's in order to determine the application when you select the following items:
cable, chain and lifting devices. When you lift a component, the lift angle is critical. Refer to the
Illustration that follows in order to see the effect of the lift angle on the working load limit.

Note: The lifting devices that are shown in this publication are not Caterpillar parts.

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Illustration 1 g00629745
Lift angles for lifting slings.

(A) The load capacity is 100% of the working load limit for the sling.

(B) The load capacity is 86% of the working load limit for the sling.

(C) The load capacity is 70% of the working load limit for the sling.

(D) The load capacity is 50% of the working load limit for the sling.

Procedure to Update the Circle Drive on Motor Graders

.

Procedure to Remove the Circle Drive

Refer to Disassembly and Assembly, "Circle Drive - Remove" for your machine in order to get
specific procedures to remove the circle drive from your machine.

The Disassembly Procedure for the Circle Drive

Table 1

Required Tools
Item Qty Part Number Part Description
A 2 3/8 inch by 16 by 4 inch
B 1 138-7575 Link Bracket

Note: Cleanliness is an important factor. Before you begin the disassembly procedure, the exterior of
the components should be thoroughly cleaned. This will help to prevent dirt from entering the
internal mechanism. Precision components can be damaged by contaminants or by dirt. Perform
disassembly procedures on a clean work surface. Keep components covered and protected at all
times.

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Illustration 2 g01428220
A typical example

View of the circle drive and the connector

1. Remove coupling (1) from housing (3). Remove pin (2) from coupling (1) .

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Illustration 3 g01428222
A typical example

View of the removal of the bracket for the worm gear

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2. Remove nuts (4). Remove bracket (5). This will allow the worm gear (8) to float.

3. Remove O-ring seal (6) and shims (7) .

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Illustration 4 g01428223
A typical example

View of the access plate for the circle drive

4. Remove bolts (9) and cover (10) .

5. Remove bolts (11) .

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Illustration 5 g01428225
A typical example

The view of the bolts that are used to remove the cover for the circle drive .

6. Install Tooling (A) and remove cover (12) .

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Illustration 6 g01428227
A typical example

View of the circle drive

7. Remove plug (13) and O-ring seal (14) from cover (12) .

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Illustration 7 g01427980
A typical example

View of the lifting device that is used to remove the pinion

8. Install Tooling (B) on shaft assembly (15). Attach a suitable lifting device to Tooling (B). The
weight of shaft assembly (15) is approximately 32 kg (70 lb).

9. Position the worm gear (6) away from shaft assembly (15) and remove shaft assembly (15).
Remove Tooling (B) .

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Illustration 8 g01427983
A typical example

View of the disassembly of the pinion

10. Remove three bolts (16),and remove three washers (17) in order to disassemble the shaft
assembly (15). Refer to Illustration 7. Discard bolts (16), washers (17), retainer (18), shims
(20), and shims (21). Retain the spacer (19) for reassembly.

11. Remove spring (22) and spacer (23) .

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Illustration 9 g01427984
A typical example

View of the disassembly of the pinion

12. Remove gear (24) from shaft (28). Remove friction discs (25) and discs (26) from gear (24).
Remove spacer (27). Discard shaft (28) .

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Illustration 10 g01428146
A typical example

View of the removal of the thrust washer

13. Remove thrust washer (29) .

Assembly Procedure for the Circle Drive for Specific 14G and
14H Series Motor Graders
Table 2

Required Part for the Update of the Circle Drive

Item Qty Part Number Description
12 3 6V-5686 Bolt
13 3 8D-5054 Hard Washer
14 1 307-1961 Plate
11 1 308-6295 Pinion Drive Shaft
16 2 307-1959 Shim
17 1 307-1960 Shim
18 12 307-1962 Shim

Table 3

Required Tools

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Item Qty Part Number Part Description

A 1 8T-5096 Dial Indicator Gp
B 1 138-7575 Link Bracket

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 replacement. Dirt and other contaminants can damage the precision component. Perform
assembly procedures on a clean work surface. Keep components covered and protected at all times.

Note: Check the O-ring seals, the gaskets, and the seals for wear or for damage. Replace the
components, if necessary.

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Illustration 11 g01428352
A typical example

1. Reinstall nuts (1), bracket (2), O-ring (3), and shim (4) onto housing (5) in order to verify the
proper amount of end play for the worm gear (6) .

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Illustration 12 g01428350
A typical example

View of the dial gauge on the end of the worm gear

2. Install Tooling (A) and check the end play. Remove shims (4) in order to obtain zero preload
or a maximum of 0.13 mm (0.005 inch) end play.

3. After the end play has been verified remove tooling (A) .

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Illustration 13 g01428352

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A typical example

4. Remove nuts (1), bracket (2), O-ring (3), and shims (4) from housing (5) in order to allow the
installation of the pinion shaft assembly.

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Illustration 14 g01428370
A typical example

View of the assembly of the new pinion

5. Install gear (7) on 308-6295 Pinion Drive Shaft (11). Install spacer (9). Install friction discs (7)
and discs (8) on pinion drive shaft (11) .

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Illustration 15 g01428371
A typical example

View of the assembly of the pinion

6. Install spacer (20), spacer (15) and spring (19). Use a depth micrometer in order to obtain the
distance from the end of 308-6295 Pinion Drive Shaft (11) to the flat surface on spring (19).
Remove spacer (15) .

7. Subtract 2.30 ± 0.25 mm (0.091 ± 0.010 inch) from the dimension that was measured in Step
6. The calculated dimension is the thickness of shims (16), shims (17), and shims (18) .

Note: Install the maximum number of 307-1962 Shims (18) that will allow you to remain
within the tolerance for the end play. Then use the 307-1959 Shims (16) and the 307-1960
Shims (17) in order to get the proper end play.

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8. Install 307-1959 Shim (16), 307-1960 Shim (17), 307-1962 Shim (18) and spacer (15). Install
307-1961 Plate (14) by using three 6V-5686 Bolts (12) and three 8D-5054 Hard Washers
(13) .

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Illustration 16 g01432074
A typical example

Reinstall the lifting bracket onto the pinion.

9. Install Tooling (B), bolts (12) and washers (13). Attach a suitable lifting device to Tooling (B).
The weight of shaft assembly (21) is approximately 32 kg (70 lb).

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Illustration 17 g01428372
A typical example

Reinstall the thrust washer.

10. Install thrust washer (22) .

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Illustration 18 g01428383
A typical example

Reinstall the pinion into the housing.

11. Position worm gear (6) away from pinion shaft assembly (21) and install the pinion shaft
assembly. Remove Tooling (B). Torque three 6V-5686 Bolts (12) to 120 ± 20 N·m (90 ± 15 lb
ft). Then final torque three 6V-5686 Bolts (12) to 240 ± 40 N·m (175 ± 30 lb ft).

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Illustration 19 g01428384
A typical example

Reinstall the cover.

12. Install O-ring seal (25) on cover (24). Lubricate the O-ring seal (25) with the lubricant that is
being sealed. Install plug (23) .

13. Install cover (12) .

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Illustration 20 g01428385
A typical example

Reinstall the access plate.

14. Install seven bolts (30). Replace bolt (30A) with a new bolt. Install gasket (29), cover (28),
bolts (26), and washer (27).

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Illustration 21 g01428386
A typical example

15. Install O-ring seal (3). Lubricate the O-ring seal with the lubricant that is being sealed.

16. Install shim (4), bracket (2) and nuts (1) .

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Illustration 22 g01428387
A typical example

Install the connector.

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17. Install pin (32) in coupling (31). Install coupling (31) in housing (5) .

Assembly Procedure for the Circle Drive for the 14M Series
Motor Grader
Table 4

Required Part for the Update of the Circle Drive

Item Qty Part Number Description
12 3 6V-5686 Bolt
13 3 8D-5054 Hard Washer
14 1 307-1961 Plate
11 1 281-9460 Pinion Drive Shaft
16 2 307-1959 Shim
17 1 307-1960 Shim
18 12 307-1962 Shim

Table 5

Required Tools
Item Qty Part Number Part Description
A 1 8T-5096 Dial Indicator Gp
B 1 138-7575 Link Bracket

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 replacement. Dirt and other contaminants can damage the precision component. Perform
assembly procedures on a clean work surface. Keep components covered and protected at all times.

Note: Check the O-ring seals, the gaskets, and the seals for wear or for damage. Replace the
components, if necessary.

View Image

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Illustration 23 g01428352
A typical example

1. Reinstall nuts (1), bracket (2), O-ring (3), and shim (4) onto housing (5) in order to verify the
proper amount of end play for the worm gear (6) .

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Illustration 24 g01428350
A typical example

View of the dial gauge on the end of the worm gear

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2. Install Tooling (A) and check the end play. Remove shims (4) in order to obtain zero preload
or a maximum of 0.13 mm (0.005 inch) end play.

3. After the end play has been verified remove tooling (A) .

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Illustration 25 g01428352
A typical example

4. Remove nuts (1), bracket (2), O-ring (3), and shims (4) from housing (5) in order to allow the
installation of the pinion shaft assembly.

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Illustration 26 g01428370
A typical example

View of the assembly of the new pinion

5. Install gear (7) on 281-9460 Pinion Drive Shaft (11). Install spacer (9). Install friction discs (7)
and discs (8) on pinion drive shaft (11) .

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Illustration 27 g01428371
A typical example

View of the assembly of the pinion

6. Install spacer (20), spacer (15) and spring (19). Use a depth micrometer in order to obtain the
distance from the end of 281-9460 Pinion Drive Shaft (11) to the flat surface on spring (19).
Remove spacer (15) .

7. Subtract 2.30 ± 0.25 mm (0.091 ± 0.010 inch) from the dimension that was measured in Step
6. The calculated dimension is the thickness of shims (16), shims (17), and shims (18) .

Note: Install the maximum number of 307-1962 Shims (18) that will allow you to remain
within the tolerance for the end play. Then use the 307-1959 Shims (16) and the 307-1960
Shims (17) in order to get the proper end play.

8. Install 307-1959 Shim (16), 307-1960 Shim (17), 307-1962 Shim (18) and spacer (15). Install
307-1961 Plate (14) by using three 6V-5686 Bolts (12) and three 8D-5054 Hard Washers

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(13) .

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Illustration 28 g01432074
A typical example

Reinstall the lifting bracket onto the pinion.

9. Install Tooling (B), bolts (12) and washers (13). Attach a suitable lifting device to Tooling (B).
The weight of shaft assembly (21) is approximately 32 kg (70 lb).

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Illustration 29 g01428372
A typical example

Reinstall the thrust washer.

10. Install thrust washer (22) .

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Illustration 30 g01428383
A typical example

Reinstall the pinion into the housing.

11. Position worm gear (6) away from pinion shaft assembly (21) and install the pinion shaft
assembly. Remove Tooling (B). Torque three 6V-5686 Bolts (12) to 120 ± 20 N·m (90 ± 15 lb
ft). Then final torque three 6V-5686 Bolts (12) to 240 ± 40 N·m (175 ± 30 lb ft).

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Illustration 31 g01428384
A typical example

Reinstall the cover.

12. Install O-ring seal (25) on cover (24). Lubricate the O-ring seal (25) with the lubricant that is
being sealed. Install plug (23) .

13. Install cover (12) .

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Illustration 32 g01428385
A typical example

Reinstall the access plate.

14. Install seven bolts (30). Replace bolt (30A) with a new bolt. Install gasket (29), cover (28),
bolts (26), and washer (27).

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Illustration 33 g01428386
A typical example

15. Install O-ring seal (3). Lubricate the O-ring seal with the lubricant that is being sealed.

16. Install shim (4), bracket (2) and nuts (1) .

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Illustration 34 g01428387
A typical example

Install the connector.

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17. Install pin (32) in coupling (31). Install coupling (31) in housing (5) .

Assembly Procedure for the Circle Drive on the 120 Series

Through the 160 Series Motor Grader and the 12 Series
Table 6

Required Part for the Update of the Circle Drive

Item Qty Part Number Description
12 3 6V-5686 Bolt
13 3 8D-5054 Hard Washer
14 1 307-1961 Plate
11 1 307-1958 Pinion Drive Shaft
16 2 307-1959 Shim
17 1 307-1960 Shim
18 12 307-1962 Shim

Table 7

Required Tools
Item Qty Part Number Part Description
A 1 8T-5096 Dial Indicator Gp
B 1 138-7575 Link Bracket

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 replacement. Dirt and other contaminants can damage the precision component. Perform
assembly procedures on a clean work surface. Keep components covered and protected at all times.

Note: Check the O-ring seals, the gaskets, and the seals for wear or for damage. Replace the
components, if necessary.

View Image

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Illustration 35 g01428352
A typical example

1. Reinstall nuts (1), bracket (2), O-ring (3), and shim (4) onto housing (5) in order to verify the
proper amount of end play for the worm gear (6) .

View Image

Illustration 36 g01428350
A typical example

View of the dial gauge on the end of the worm gear

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2. Install Tooling (A) and check the end play. Remove shims (4) in order to obtain zero preload
or a maximum of 0.13 mm (0.005 inch) end play.

3. After the end play has been verified remove tooling (A) .

View Image

Illustration 37 g01428352
A typical example

4. Remove nuts (1), bracket (2), O-ring (3), and shims (4) from housing (5) in order to allow the
installation of the pinion shaft assembly.

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Illustration 38 g01428370
A typical example

View of the assembly of the new pinion

5. Install gear (7) on 307-1958 Pinion Drive Shaft (11). Install spacer (9). Install friction discs (7)
and discs (8) on pinion drive shaft (11) .

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Illustration 39 g01428371
A typical example

View of the assembly of the pinion

6. Install spacer (20), spacer (15) and spring (19). Use a depth micrometer in order to obtain the
distance from the end of 307-1958 Pinion Drive Shaft (11) to the flat surface on spring (19).
Remove spacer (15) .

7. Subtract 2.30 ± 0.25 mm (0.091 ± 0.010 inch) from the dimension that was measured in Step
6. The calculated dimension is the thickness of shims (16), shims (17), and shims (18) .

Note: Install the maximum number of 307-1962 Shims (18) that will allow you to remain
within the tolerance for the end play. Then use the 307-1959 Shims (16) and the 307-1960
Shims (17) in order to get the proper end play.

8. Install 307-1959 Shim (16), 307-1960 Shim (17), 307-1962 Shim (18) and spacer (15). Install
307-1961 Plate (14) by using three 6V-5686 Bolts (12) and three 8D-5054 Hard Washers

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(13) .

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Illustration 40 g01432074
A typical example

Reinstall the lifting bracket onto the pinion.

9. Install Tooling (B), bolts (12) and washers (13). Attach a suitable lifting device to Tooling (B).
The weight of shaft assembly (21) is approximately 32 kg (70 lb).

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Illustration 41 g01428372
A typical example

Reinstall the thrust washer.

10. Install thrust washer (22) .

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Illustration 42 g01428383
A typical example

Reinstall the pinion into the housing.

11. Position the worm gear (6) away from pinion shaft assembly (21) and install the pinion shaft
assembly. Remove Tooling (B). Torque three 6V-5686 Bolts (12) to 120 ± 20 N·m (90 ± 15 lb
ft). Then final torque three 6V-5686 Bolts (12) to 240 ± 40 N·m (175 ± 30 lb ft).

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Illustration 43 g01428384
A typical example

Reinstall the cover.

12. Install O-ring seal (25) on cover (24). Lubricate the O-ring seal (25) with the lubricant that is
being sealed. Install plug (23) .

13. Install cover (12) .

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Illustration 44 g01428385
A typical example

Reinstall the access plate.

14. Install seven bolts (30). Replace bolt (30A) with a new bolt. Install gasket (29), cover (28),
bolts (26), and washer (27).

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Illustration 45 g01428386
A typical example

15. Install O-ring seal (3). Lubricate the O-ring seal with the lubricant that is being sealed.

16. Install shim (4), bracket (2) and nuts (1) .

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Illustration 46 g01428387
A typical example

Install the connector.

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17. Install pin (32) in coupling (31). Install coupling (31) in housing (5) .

Assembly Procedure for the Circle Drive on the 16 Series

Motor Grader
Table 8

Required Part for the Update of the Circle Drive

Item Qty Part Number Description
12 3 6V-5686 Bolt
13 3 8D-5054 Hard Washer
14 1 307-1961 Plate
11 1 307-1965 Pinion Drive Shaft
16 6 307-1959 Shim
17 1 307-1960 Shim
18 4 307-1962 Shim

Table 9

Required Tools
Item Qty Part Number Part Description
A 1 8T-5096 Dial Indicator Gp
B 1 138-7575 Link Bracket

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 replacement. Dirt and other contaminants can damage the precision component. Perform
assembly procedures on a clean work surface. Keep components covered and protected at all times.

Note: Check the O-ring seals, the gaskets, and the seals for wear or for damage. Replace the
components, if necessary.

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Illustration 47 g01428352
A typical example

1. Reinstall nuts (1), bracket (2), O-ring (3), and shim (4) onto housing (5) in order to verify the
proper amount of end play for the worm gear (6) .

View Image

Illustration 48 g01428350
A typical example

View of the dial gauge on the end of the worm gear

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2. Install Tooling (A) and check the end play. Remove shims (4) in order to obtain zero preload
or a maximum of 0.13 mm (0.005 inch) end play.

3. After the end play has been verified remove tooling (A) .

View Image

Illustration 49 g01428352
A typical example

4. Remove nuts (1), bracket (2), O-ring (3), and shims (4) from housing (5) in order to allow the
installation of the pinion shaft assembly.

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Illustration 50 g01428370
A typical example

View of the assembly of the new pinion

5. Install gear (7) on 307-1965 Pinion Drive Shaft (11). Install spacer (9). Install friction discs (7)
and discs (8) on pinion drive shaft (11) .

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Illustration 51 g01428371
A typical example

View of the assembly of the pinion

6. Install spacer (20), spacer (15) and spring (19). Use a depth micrometer in order to obtain the
distance from the end of 307-1965 Pinion Drive Shaft (11) to the flat surface on spring (19).
Remove spacer (15) .

7. Subtract 2.30 ± 0.25 mm (0.091 ± 0.010 inch) from the dimension that was measured in Step
6. The calculated dimension is the thickness of shims (16), shims (17), and shims (18) .

Note: Install the maximum number of 307-1962 Shims (18) that will allow you to remain
within the tolerance for the end play. Then use the 307-1959 Shims (16) and the 307-1960
Shims (17) in order to get the proper end play.

8. Install 307-1959 Shim (16), 307-1960 Shim (17), 307-1962 Shim (18) and spacer (15). Install
307-1961 Plate (14) by using three 6V-5686 Bolts (12) and three 8D-5054 Hard Washers

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(13) .

View Image

Illustration 52 g01432074
A typical example

Reinstall the lifting bracket onto the pinion.

9. Install Tooling (B), bolts (12) and washers (13). Attach a suitable lifting device to Tooling (B).
The weight of shaft assembly (21) is approximately 32 kg (70 lb).

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Illustration 53 g01428372
A typical example

Reinstall the thrust washer.

10. Install thrust washer (22) .

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Illustration 54 g01428383
A typical example

Reinstall the pinion into the housing.

11. Position the worm gear (6) away from pinion shaft assembly (21) and install the pinion shaft
assembly. Remove Tooling (B). Torque three 6V-5686 Bolts (12) to 120 ± 20 N·m (90 ± 15 lb
ft). Then final torque three 6V-5686 Bolts (12) to 240 ± 40 N·m (175 ± 30 lb ft).

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Illustration 55 g01428384
A typical example

Reinstall the cover.

12. Install O-ring seal (25) on cover (24). Lubricate the O-ring seal (25) with the lubricant that is
being sealed. Install plug (23) .

13. Install cover (12) .

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Illustration 56 g01428385
A typical example

Reinstall the access plate.

14. Install seven bolts (30). Replace bolt (30A) with a new bolt. Install gasket (29), cover (28),
bolts (26), and washer (27).

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Illustration 57 g01428386
A typical example

15. Install O-ring seal (3). Lubricate the O-ring seal with the lubricant that is being sealed.

16. Install shim (4), bracket (2) and nuts (1) .

View Image

Illustration 58 g01428387
A typical example

Install the connector.

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17. Install pin (32) in coupling (31). Install coupling (31) in housing (5) .

Assembly Procedure for the Circle Drive on the 24 Series

Motor Grader
Table 10

Required Part for the Update of the Circle Drive

Item Qty Part Number Description
12 3 6V-5686 Bolt
13 3 8D-5054 Hard Washer
14 1 307-1961 Plate
11 1 307-1965 Pinion Drive Shaft
16 6 307-1959 Shim
17 1 307-1960 Shim
18 4 307-1962 Shim

Table 11

Required Tools
Item Qty Part Number Part Description
A 1 8T-5096 Dial Indicator Gp
B 1 138-7575 Link Bracket

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 replacement. Dirt and other contaminants can damage the precision component. Perform
assembly procedures on a clean work surface. Keep components covered and protected at all times.

Note: Check the O-ring seals, the gaskets, and the seals for wear or for damage. Replace the
components, if necessary.

View Image

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Illustration 59 g01428352
A typical example

1. Reinstall nuts (1), bracket (2), O-ring (3), and shim (4) onto housing (5) in order to verify the
proper amount of end play for the worm gear (6) .

View Image

Illustration 60 g01428350
A typical example

View of the dial gauge on the end of the worm gear

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2. Install Tooling (A) and check the end play. Remove shims (4) in order to obtain zero preload
or a maximum of 0.13 mm (0.005 inch) end play.

3. After the end play has been verified remove tooling (A) .

View Image

Illustration 61 g01428352
A typical example

4. Remove nuts (1), bracket (2), O-ring (3), and shims (4) from housing (5) in order to allow the
installation of the pinion shaft assembly.

View Image

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Illustration 62 g01428370
A typical example

View of the assembly of the new pinion

5. Install gear (7) on 307-1965 Pinion Drive Shaft (11). Install spacer (9). Install friction discs (7)
and discs (8) on pinion drive shaft (11) .

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Illustration 63 g01428371
A typical example

View of the assembly of the pinion

6. Install spacer (20), spacer (15) and spring (19). Use a depth micrometer in order to obtain the
distance from the end of 307-1965 Pinion Drive Shaft (11) to the flat surface on spring (19).
Remove spacer (15) .

7. Subtract 1.50 ± 0.25 mm (0.060 ± 0.010 inch) from the dimension that was measured in Step
6. The calculated dimension is the thickness of shims (16), shims (17), and shims (18) .

Note: Install the maximum number of 307-1962 Shims (18) that will allow you to remain
within the tolerance for the end play. Then use the 307-1959 Shims (16) and the 307-1960
Shims (17) in order to get the proper end play.

8. Install 307-1959 Shim (16), 307-1960 Shim (17), 307-1962 Shim (18) and spacer (15). Install
307-1961 Plate (14) by using three 6V-5686 Bolts (12) and three 8D-5054 Hard Washers

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(13) .

View Image

Illustration 64 g01432074
A typical example

Reinstall the lifting bracket onto the pinion.

9. Install Tooling (B), bolts (12) and washers (13). Attach a suitable lifting device to Tooling (B).
The weight of shaft assembly (21) is approximately 32 kg (70 lb).

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Illustration 65 g01428372
A typical example

Reinstall the thrust washer.

10. Install thrust washer (22) .

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Illustration 66 g01428383
A typical example

Reinstall the pinion into the housing.

11. Position the worm gear (6) away from pinion shaft assembly (21) and install the pinion shaft
assembly. Remove Tooling (B). Torque three 6V-5686 Bolts (12) to 120 ± 20 N·m (90 ± 15 lb
ft). Then final torque three 6V-5686 Bolts (12) to 240 ± 40 N·m (175 ± 30 lb ft).

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Illustration 67 g01428384
A typical example

Reinstall the cover.

12. Install O-ring seal (25) on cover (24). Lubricate the O-ring seal (25) with the lubricant that is
being sealed. Install plug (23) .

13. Install cover (12) .

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Illustration 68 g01428385
A typical example

Reinstall the access plate.

14. Install seven bolts (30). Replace bolt (30A) with a new bolt. Install gasket (29), cover (28),
bolts (26), and washer (27).

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Illustration 69 g01428386
A typical example

15. Install O-ring seal (3). Lubricate the O-ring seal with the lubricant that is being sealed.

16. Install shim (4), bracket (2) and nuts (1) .

View Image

Illustration 70 g01428387
A typical example

Install the connector.

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17. Install pin (32) in coupling (31). Install coupling (31) in housing (5) .

Installation Procedure for the Circle Drive for the Motor

Grader
Refer to Disassembly and Assembly, "Circle Drive - Install" for your machine in order to get specific
procedures to install the circle drive on your machine.

Copyright 1993 - 2008 Caterpillar Inc. Fri May 2 09:44:46 EST 2008
All Rights Reserved.
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