120H and 135H Motor Graders Power Train Bevel Gear and Pinion Caterpillar


Bevel Gear and Pinion
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120H and 135H Motor Graders Power Train [SENR6994]
POWER TRAIN
DIFFERENTIAL & BEVEL GEAR GP
120H and 135H Motor Graders Power Train Bevel Gear and Pinion
120H and 135H Motor Graders Power Train Differential and Bevel Gear
1.1. Preload Adjustment for Pinion
2.1. Differential Backlash and Bearing Adjustment
3.1. Checking the Pinion and Ring Gear Tooth Contact



Illustration 1g02152948

(1) Lubricate the sealing lip of the lip type seal lightly with the lubricant that is being sealed. Before you install the lip type seal coat the bore surface of the retainer with Loctite Low Breakloose PST.

(2) Lubricate the bore of the O-ring seal lightly with the lubricant .

(3) Before you press the sleeve into the carrier assembly, coat the outer diameter of the sleeve with green Loctite 609

(4) Assembled backlash ... 0.250 + 0.100 - 0.075 mm (0.0098 + 0.0039 - 0.0030 inch)

(5) Torque for eight bolts ... 135 ± 15 N·m (100 ± 11 lb ft)

(6) 8V-3273 Shim Pack

Thickness of four shims ... 0.05 mm (0.002 inch)
Thickness of five shims ... 0.20 mm (0.008 inch)
Thickness of one shim ... 0.81 mm (0.032 inch)



Illustration 2g02152958

Differential and Bevel Gear

(3) Sleeve

(5) Bolts

(6) Shim pack

(7) Carrier

(8) Adjustment nut

(9) Differential housing

(10) Lock for adjustment nut

(11) Nut

(12) Bearing cone

(13) Pinion housing

(14) Bearing cone

(15) Cap

(16) Bevel gear

(17) Bevel pinion

(18) Lock for nut

(19) Washer

(20) Bearing cup

(21) Bearing cup

(22) Cap

(23) Dowel pin

(24) Adjustment nut

Preload Adjustment for Pinion

  1. Install bearing cups (20) and (21) in pinion housing (13) . Bearing cups (20) and (21) must be against the shoulders in pinion housing (13) .

  1. Install bearing cone (14) next to the pinion teeth on bevel pinion (17) . Bearing cone (14) must be against the shoulder on bevel pinion (17) .

  1. Lubricate the bearing and install bevel pinion (17) in pinion housing (13) . Lubricate bearing cone (12) and install bearing cone (12) .

  1. Position the assembly in a soft jawed vise. Tighten the vise against the teeth on bevel pinion (17) . Install washer (19) and nut (11) . While you are turning pinion housing (13) , tighten nut (11) . Tighten nut (11) until the specified torque that is needed to turn bevel pinion (17) is reached.

    New bearings ... 0.9 ± 0.2 N·m (8.0 ± 2.0 lb in)

    Used bearings ... 0.45 ± 0.10 N·m (4.00 ± 1.00 lb in)

    Check bevel pinion (17) in order to ensure that there is zero end play.

  1. If the bearing preload exceeds the specified torque, loosen nut (11) by 1/8 of a turn. Reseat bearing cone (12) . Repeat Step 4.

  1. When the torque that is needed to turn bevel pinion (17) is correct, lock the nut (11) . Lock the nut (11) by bending one of the tabs on lock (18) into the closest slot in nut (11) . If necessary, tighten nut (11) slightly in order to align a slot in the nut with a tab on lock (18) .

Note: The nut may be reused if the nut is not damaged during disassembly.

Differential Backlash and Bearing Adjustment

Note: The following procedure controls backlash and bearing preload. This procedure gives the same results for used bearings and for new bearings.

  1. Fasten pinion housing (13) to carrier (7) . If the original gears, the carrier assembly and the housing are used again, use the original thickness of shim pack (6) . If any of these parts are replaced, install a shim pack thickness of 1.73 mm (0.068 inch).

    Note: When you adjust the tooth contact pattern, make sure that there is a change in the thickness of shim pack (6) .

  1. Tighten eight bolts (5) to a torque of 135 ± 15 N·m (100 ± 11 lb ft).

  1. When pinion housing (13) is fastened to carrier (7) , position bevel pinion (17) in a downward vertical position.

  1. Lubricate bearings and install bearing cups on the differential bearings in order to protect the bearings.

  1. With a lifting device, lower the differential into carrier (7) . Bevel gear (16) should be oriented next to dowel pin (23) . Check sleeve (3) for proper seating.

  1. Install caps (15) and (22) and adjustment nuts (8) and (24) . Adjustment nuts (8) and (24) must turn freely.

  1. Tighten the four cap bolts to a torque of 100 N·m (75 lb ft).

  1. Tighten adjustment nuts (8) and (24) until there is a small amount of backlash and zero preload on differential bearings.

  1. Reposition the assembly so that bevel pinion (17) is in the horizontal position. The centerline of the axle must be vertical and the bevel gear must be facing upward. Measure the torque that is required to rotate bevel pinion (17) . Record this measurement.

  1. While you turn the bevel gear, tighten adjustment nut (24) until the pinion backlash is zero.

  1. Loosen adjustment nut (24) to the nearest lock position.

  1. While you turn the bevel gear, tighten adjustment nut (8) until the torque that is required to rotate bevel pinion (17) increases 20% over the torque reading in Step 9.

  1. Without moving the bevel gear, loosen adjustment nut (8) . Hand tighten adjustment nut (8) .

  1. Attach a magnetic base for a dial indicator at location (7A) . Place the dial indicator on the differential housing at location (9) .

  1. While you turn the bevel gear, tighten adjustment nut (24) by three notches. The reading on the dial indicator should be 0.30 ± 0.05 mm (0.012 ± 0.002 inch).

    Note: If the reading on the dial indicator is too low, tighten adjustment nut (24) by one additional notch. In order to preload the bearings repeat the procedure until the reading on the dial indicator is correct.

  1. Measure the rolling torque at bevel pinion (17) . The correct rolling torque is shown below.

    New bearings ... 1.7 ± 0.3 N·m (15.0 ± 2.5 lb in)

    Used bearings ... 0.85 ± 0.30 N·m (7.50 ± 2.50 lb in)

    Note: If the rolling torque is not correct, repeat Step 7 through Step 16.

  1. Torque the four cap bolts to 370 ± 50 N·m (273 ± 37 lb ft).

  1. Measure the backlash between the bevel gear (16) and bevel pinion (17) . The backlash must be 0.25 + 0.10 - 0.07 mm (0.010 + 0.004 - 0.003 inch).

  1. If there is too much backlash, loosen adjustment nut (8) and tighten adjustment nut (24) to the same amount.

  1. If there is not enough backlash, loosen adjustment nut (24) and tighten adjustment nut (8) to the same amount.

    Note: The differential preload will be kept only if one adjustment nut is loosened and the other adjustment nut is tightened to the same amount.

  1. Install the locks (10) for the adjustment nuts.

Checking the Pinion and Ring Gear Tooth Contact




Illustration 3g00578231

After the backlash and preload adjustments have been made, the tooth contact between bevel pinion (17) and bevel gear (16) must be checked. Do the following procedure.

  1. Put a small amount of paint pigment and oil on the teeth of bevel gear (16) .

  1. Turn bevel pinion (17) in both directions.

  1. The correct area of tooth contact is located equally on both sides. The area starts near the inside end of the teeth of bevel gear (16) . Refer to Illustration 3 for an example of the correct area of tooth contact.



Illustration 4g00578253

If the marks that are made on the teeth of bevel gear (16) look like the marks in Illustration 4, do the following procedures.

  1. Add some of shim pack (6) .

  1. Loosen the four cap bolts to the torque that is indicated in Step 7.

  1. Repeat Step 17 through Step 21.



Illustration 5g00578254

Illustration D

If the marks that are made on the teeth of bevel gear (16) look like the marks in Illustration 5, do the following procedures.

  1. Remove some of shim pack (6) .

  1. Loosen the four cap bolts to the torque that is indicated in Step 7.

  1. Repeat Step 17 through Step 21.

    Note: Always make sure that the backlash adjustment is correct before an adjustment is made to the area of tooth contact. Several adjustments to the backlash and tooth contact may be necessary to get the correct adjustments.

After adjustments are made, remove the paint from the gears. Install the locks and bolts on caps (15) and (22) .

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