Service Repair Manual
Models
160H Motor Grader
160H Motor Grader 2FM00001-UP (MACHINE) POWERED BY 3306 Engine(SEBP...
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Shutdown SIS Previous Screen Product: MOTOR GRADER Model: 160H MOTOR GRADER 2FM Configuration: 160H Motor Grader 2FM00001-UP (MACHINE) POWERED BY 3306 Engine
Disassembly and Assembly 12H, 140H and 160H Motor Graders Machine Systems Media Number -SENR8549-06
Publication Date -01/10/2011
Date Updated -12/10/2011
i01584480
Blade Lift - Remove SMCS - 5219-011; 5222-011
Removal Procedure Table 1 Required Tools Tool
A
B
Part Number
Part Description
Qty
6V-3175
Double Acting Cylinder
1
4C-5809
Electric Hydraulic Pump
1
5P-4184
Tool Stud
1
9U-6832
Nut
1
4K-0684
Hard Washer
1
1P-1837
Bearing Puller Adapter
1
9S-8546
Installer
1
6V-3175
Double Acting Cylinder
1
4C-5809
Electric Hydraulic Pump
1
9S-8546
Installer
1
6V-2078
Stud
1
1P-1834
Adapter
1
1A-1935
Full Nut
1
5P-8250
Washer
1
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160H Motor Grader 2FM00001-UP (MACHINE) POWERED BY 3306 Engine(SEBP...
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Start By: A. Remove the centershift cylinder. Refer to Disassembly and Assembly, "Centershift Cylinder - Remove" for the correct procedure. B. Remove the blade lift cylinder. Refer to Disassembly and Assembly, "Blade Lift Cylinder Remove" for the correct procedure. Note: Cleanliness is an important factor. Before the removal procedure, the exterior of the components should be thoroughly cleaned. This will help to prevent dirt from entering the internal components. 1. Release the centershift lock pin from the centershift lock bar.
Illustration 1
g00634867
Typical Example
2. Position suitable lifting slings to the locator holes at the ends of the bar assembly. Secure the lifting slings to a hoist. The weight of the bar assembly is 73 kg (160 lb).
Illustration 2
g00634869
3. Remove two bolts (2) from the blade lift arm that is on the right side of the machine.
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4. Remove lock (3) and remove pin (4) that holds the blade lift arm to the bar assembly.
Illustration 3
g00634871
5. Remove two bolts (5) from the blade lift arm that is on the left side of the machine. 6. Remove pin (6) and remove lock (7) that holds the blade lift arm to the bar assembly. 7. Remove the bar assembly. 8. Position suitable lifting slings around the blade lift arm. Secure the lifting slings to a hoist. The weight of the blade lift arm is 97 kg (214 lb).
Illustration 4
g00634836
9. Remove the blade lift cylinder. Refer to Disassembly and Assembly, "Blade Lift Cylinder Remove" for the proper procedure. 10. Remove bolt (8) from plate (9) . 11. Remove plate (9) from the frame and the pin. 12. Remove three bolts (10) from the arm assembly.
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160H Motor Grader 2FM00001-UP (MACHINE) POWERED BY 3306 Engine(SEBP...
13. Remove lock (11) from the frame and the pin.
Illustration 5
g00634849
14. Remove pin (12) that holds the top of the lift arm to machine frame (13) . 15. Remove the blade lift arm from the machine.
Illustration 6
g00634854
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160H Motor Grader 2FM00001-UP (MACHINE) POWERED BY 3306 Engine(SEBP...
Illustration 7
g00634856
16. Remove two bolts (14), retainer (15), and shim (17) from yoke assembly (16) . 17. Remove seal (18) from retainer (15) .
Illustration 8
g00634858
Illustration 9
g00634860
18. Move yoke assembly (16) partially out of the arm. Remove three washers (19) from the arm. 19. Position a suitable lifting sling around yoke assembly (16). Secure the lifting sling to a hoist. Remove yoke assembly (16) from the blade lift arm. The weight of yoke assembly (16) is 20 kg (44 lb). 20. Remove three washers (20) and two seals (21) from yoke assembly (16) .
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160H Motor Grader 2FM00001-UP (MACHINE) POWERED BY 3306 Engine(SEBP...
Illustration 10
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g00634861
21. Remove bearing sleeves (22) and (23) from the blade lift arm by placing a saw cut down the length of each bearing. Be careful not to cause damage to the inside of the lift arm.
Illustration 11
g00634862
Illustration 12
g00634864
22. Remove four lip seals (24) .
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23. Support Tooling (A) with a lifting sling and a hoist. Use Tooling (A) in order to remove two bearing sleeves (25) from the frame.
Illustration 13
g00634865
Illustration 14
g00634866
Typical Example
24. Remove two lip seals (26) from bar assembly (29) . 25. Use Tooling (B) in order to remove bearing sleeve (27) . Note: Tooling (B) is on face (28) for installation purposes. 26. Repeat Step 8 through Step 23 for the remaining blade lift arm. Copyright 1993 - 2019 Caterpillar Inc.
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160H Motor Grader 2FM00001-UP (MACHINE) POWERED BY 3306 Engine(SEBP...
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Shutdown SIS Previous Screen Product: MOTOR GRADER Model: 160H MOTOR GRADER 2FM Configuration: 160H Motor Grader 2FM00001-UP (MACHINE) POWERED BY 3306 Engine
Disassembly and Assembly 12H, 140H and 160H Motor Graders Machine Systems Media Number -SENR8549-06
Publication Date -01/10/2011
Date Updated -12/10/2011
i01584528
Blade Lift - Install SMCS - 5219-012; 5222-012
Installation Procedure Table 1 Required Tools Tool
A
B
C
Part Number
Part Description
Qty
6V-3175
Double Acting Cylinder
1
4C-5809
Electric Hydraulic Pump
1
5P-4184
Tool Stud
1
9U-6832
Nut
1
4K-0684
Hard Washer
1
1P-1837
Bearing Puller Adapter
1
9S-8546
Installer
1
6V-3175
Double Acting Cylinder
1
4C-5809
Electric Hydraulic Pump
1
9S-8546
Installer
1
6V-2078
Stud
1
1P-1834
Adapter
1
1A-1935
Full Nut
1
5P-8250
Washer
1
6V-3175
Double Acting Cylinder
1
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160H Motor Grader 2FM00001-UP (MACHINE) POWERED BY 3306 Engine(SEBP...
D
4C-5809
Electric Hydraulic Pump
1
5P-4184
Tool Stud
1
9U-6832
Nut
1
4K-0684
Hard Washer
1
1P-1835
Bearing Puller Adapter
1
1P-1837
Bearing Puller Adapter
1
1P-0510
Driver Group
1
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Note: Verify that all of the components of the blade lift arms are clean and free of foreign material prior to installation. Note: Check all of the components for wear or for damage. Replace worn components or damaged components with new parts.
Illustration 1
g00634864
Illustration 2
g00634862
1. Use Tooling (A) in order to install bearing sleeves (25) in the frame.
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2. Install bearing sleeves (25) until the bearing sleeves are even with the face of the seal counterbores. 3. Use Tooling (D) (not shown) in order to install four lip seals (24) into the frame until the lip seals contact the face of the counterbore. Ensure that the sealing lip is facing outward.
Illustration 3
g00634865
Illustration 4
g00634866
Typical Example
4. Use Tooling (B) in order to install bearing sleeve (27) in bar (29). Install bearing sleeve (23) until the bearing sleeve is 10 Âą 1 mm (.4 Âą .04 inch) below face (24) . 5. Use Tooling (D) (not shown) in order to install two lip seals (26) until the lip seals contact bearing sleeve (27). Ensure that the sealing lip is facing outward.
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160H Motor Grader 2FM00001-UP (MACHINE) POWERED BY 3306 Engine(SEBP...
Illustration 5
g00634861
Illustration 6
g00634988
6. Use Tooling (C) in order to install bearing sleeve (22) in the blade lift arm. Install bearing sleeve (22) until the bearing sleeve is even with the counterbore surface of the shim bore. 7. Use Tooling (C) in order to install bearing sleeve (23) in the blade lift arm. Install bearing sleeve (23) until the bearing sleeve is even with the counterbore surface of the shim bore.
Illustration 7
g00634860
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160H Motor Grader 2FM00001-UP (MACHINE) POWERED BY 3306 Engine(SEBP...
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8. Install two seals (21) and three washers (20) in the original position on yoke assembly (16) . 9. Use a lifting sling and a hoist in order to install yoke assembly (16) in the blade lift arm. The weight of the yoke assembly is 20 kg (44 lb).
Illustration 8
g00634858
10. Install three washers (19) in the blade lift arm in the original position.
Illustration 9
g00634856
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160H Motor Grader 2FM00001-UP (MACHINE) POWERED BY 3306 Engine(SEBP...
Illustration 10
g00634854
11. Install seal (18) to retainer (15) . 12. Install two bolts (14), retainer (15), and shims (17) to yoke assembly (16). Shims (15) should be added or removed in order to obtain 0.25 mm (.010 inch) maximum end play. Yoke assembly (16) must rotate without binding.
Illustration 11
g00634836
Typical Example
Illustration 12
g00634849
Typical Example
13. Attach lifting slings and a hoist to the blade lift arm. Position the blade lift arm to machine frame (13). The weight of the blade lift arm is 97 kg (214 lb). 14. Install pin (12) in frame (13) and in the top end of the blade lift assembly. Ensure that the retention slot in pin (12) is aligned with lock (11) .
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160H Motor Grader 2FM00001-UP (MACHINE) POWERED BY 3306 Engine(SEBP...
Illustration 13
7/9
g00634836
Typical Example
15. Install lock (11) and three bolts (10) in the blade lift arm. 16. Position plate (9) to frame (13) and pin (12). Install bolt (8) in plate (9) . Note: Refer to Specifications, "Blade Lift" for the correct torque specifications.
Illustration 14
g00634995
17. Use 123-8187 Thrust Washers and 8D-4336 Thrust Washers at joint (X) in order to obtain a minimum gap of 1 mm (.040 inch). 18. Install the blade lift cylinder. Refer to Disassembly and Assembly, "Blade Lift Cylinder Install" for the proper procedure. 19. Repeat Step 1 through Step 18 in order to install the remaining blade lift arm.
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160H Motor Grader 2FM00001-UP (MACHINE) POWERED BY 3306 Engine(SEBP...
Illustration 15
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g00634867
Typical Example
20. Position suitable lifting slings around the bar assembly. Secure the lifting slings to a hoist. The weight of the bar assembly is 73 kg (161 lb). Position the bar assembly to the blade lift arm that is on the left side of the machine. Align the pin holes of the blade lift arm with the pin holes of the bar assembly.
Illustration 16
g00634871
21. Install pin (6), lock (7), two bolts (5), and the washers that hold the blade lift arm to the bar assembly.
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160H Motor Grader 2FM00001-UP (MACHINE) POWERED BY 3306 Engine(SEBP...
Illustration 17
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g00634869
22. Install pin (4), two bolts (2), and lock (3) to blade lift arm and the bar assembly. End By: a. Install the centershift cylinder. Refer to Disassembly and Assembly, "Centershift Lock Install" for the correct procedure. b. Install blade lift cylinder. Refer to Disassembly and Assembly, "Blade Lift Cylinder Install" for the correct procedure. Copyright 1993 - 2019 Caterpillar Inc.
Mon Nov 25 19:47:52 UTC+0800 2019
All Rights Reserved. Private Network For SIS Licensees.
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160H Motor Grader 2FM00001-UP (MACHINE) POWERED BY 3306 Engine(SEBP...
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Shutdown SIS Previous Screen Product: MOTOR GRADER Model: 160H MOTOR GRADER 2FM Configuration: 160H Motor Grader 2FM00001-UP (MACHINE) POWERED BY 3306 Engine
Disassembly and Assembly 12H, 140H and 160H Motor Graders Machine Systems Media Number -SENR8549-06
Publication Date -01/10/2011
Date Updated -12/10/2011
i01190855
Articulation Cylinder - Remove SMCS - 5265-011
Removal Procedure Table 1 Required Tools Tool
A
B
Part Number
Part Description
Qty
9U-6600
Hand Hydraulic Pump
1
6V-3160
Double Acting Cylinder
1
1P-5581
Spacer
1
8F-4225
Bolt
1
5F-7353
Washer
1
9U-6600
Hand Hydraulic Pump
1
6V-3160
Double Acting Cylinder
1
1P-1832
Adapter
1
5P-4197
Spacer
1
5F-7379
Bolt
1
Start By: A. Remove the batteries. Refer to Disassembly and Assembly, "Battery - Remove" for the correct procedure. B. Remove the battery boxes. Refer to Disassembly and Assembly, "Battery Box - Remove" for the correct procedure.
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160H Motor Grader 2FM00001-UP (MACHINE) POWERED BY 3306 Engine(SEBP...
Personal injury or death can result from sudden machine movement. Sudden movement of the machine can cause injury to persons on or near the machine. To prevent injury or death, make sure that the area around the machine is clear of personnel and obstructions before operating the machine.
NOTICE Never remove the fill/vent plug from the hydraulic tank if the oil is hot. Air can enter the system and cause pump damage.
1. Release the pressure in the hydraulic system. Refer to Disassembly and Assembly, "Machine Preparation for Disassembly and Assembly" for the proper procedure.
Hydraulic oil pressure can remain in the hydraulic system on this machine after the engine and pump have been stopped. Serious injury can result if this pressure is not released before any service is done on the hydraulic systems. In order to prevent possible injury, release the hydraulic system pressure before working on any fitting, hose, or hydraulic component. Lower all attachments to the ground before service is started. If the hydraulic system must be serviced, tested, or adjusted with the attachment in the raised position, the attachments and lift cylinders must be supported properly. Always move the machine to a location away from the travel of other machines. Be sure that other personnel are not near the machine when the engine is running and tests or adjustments are being made.
NOTICE
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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 containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates.
Note: Install caps and plugs on all openings in order to prevent dirt or debris from entering the system. Cleanliness is an important factor. Before the removal procedure, the exterior of the component should be thoroughly cleaned. This will help to prevent dirt from entering the internal components. Note: For easier assembly, mark all hose assemblies, tube assemblies, wire harnesses and cables for identification purposes. 2. Drain the oil from the hydraulic tank into a suitable container for storage or disposal. The capacity of the hydraulic system is 38 L (10 US gal).
Illustration 1
g00637120
3. Remove bolt (1) and remove the clamp that holds the wiring harness to hydraulic tank support (4) . 4. Position block (6) in order to support the hydraulic tank. 5. Remove bolt (2), the nut, and two washers from hydraulic tank support (4) and the bracket on the hydraulic oil tank. 6. Remove two bolts (5) and remove the two washers from hydraulic tank support (4) from the cab.
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