MAGNETO GP 4P8905 - Caterpillar

Image1.8.1
7. On the back side (steel) of the valve plate apply assembly, grease to the lapped surfaces. Refer to Image1.9.1. Install the valve plate onto the motor cover. Position the valve plate with the timing dowel pin. Refer to Image1.9.2. Apply grease to outer diameter of the bearing in order to help it maintain its installed position.
Image1.9.1
Image1.9.2
8. Install two M10 alignment rods on opposing sides of the motor housing.
ALIGNMENT RODS ARE ESSENTIAL TO PREVENT DAMAGE TO THE REAR SHAFT SEAL DURING REASSEMBLY.
9. Ensure the following parts are in place and seated properly: steel insert, small O-ring, large O-ring, and alignment dowel pins. Refer to Image1.10.1.
10. Check that the inner bearing race on the motor shaft is in position with flange side down.
11. Perform a final inspection of the flange surface in order to ensure that there is no debris.
Image1.10.1
12. Remove the M8 threaded rod extraction tool from the cover.
13. Line up the motor cover onto the two M10 alignment rods ensuring that the notch in the motor cover lines up over the two speed O-ring and insert. Refer to Image1.11.1.
Image1.11.1
14. Place a feeler gauge on top of the steel insert and hold down while motor cover is being installed. For GROUPS 1 and 3 refer to Image1.12.1. For GROUP 2 refer to Image1.12.2.
Image1.12.1
Image1.12.2
CAUTION!
As the motor cover is lowered, residual oil in the motor housing will travel up the two speed passage and can unknowingly dislodge the steel insert from the counterbore. If the insert leaves its position it will likely get crushed between the top cover and lower motor interface as the bolts are tightened. This will most likely damage the motor resulting in complete motor replacement. Refer to Image1.13.1.
Image1.13.1
15. Lower the cover as level as possible to ensure it is centered up when the motor shaft passes thru the shaft seal. Refer to Image1.14.1.
16. Lower the cover until the top of the shaft contacts the internal splines of the brake coupler.
17. If the motor shaft aligns correctly with the brake coupler splines, the motor cover may lower down all the way until the valve plate contacts the top of the rotating kit. It is likely that the cover will not align immediately. Remove the M10 alignment rods. Holding the weight of the motor cover, gently rotate a few degrees clockwise/counterclockwise until the splines line up. Keeping the cover level will assist the alignment. Refer to Image1.14.2.
DO NOT FORCE THE MOTOR COVER DOWN. IF ALIGNMENT IS CORRECT THE COVER WILL LOWER WITH ITS OWN WEIGHT.
Image1.14.1
Image1.14.2
18. With the motor cover lowered, install two of the M10 assembly bolts on opposite side, adjacent to the main work ports.
19. Alternate tightening the two bolts, slowly 1/2 turn at a time. Refer to Image1.15.1. When top cover begins to contact the feeler gauge, remove the gauge and continue tightening the bolts until the cover is mated to the motor housing.
DO NOT FORCE THE END COVER DOWN. IF EXCESSIVE TORQUE IS FELT ON THE BOLTS DURING THE DRAW DOWN, THEN SOMETHING IS NOT