Caterpillar Cat 163H Motor Grader (Prefix ARL) Service Repair Manual Instant Download
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Service Repair Manual Models 163H M otor Grader
163H Motor Grader ARL00001-UP (MACHINE) POWERED BY 3176C Engine(SEB... 1/18 Shutdown SIS Previous Screen Product: MOTOR GRADER Model: 163H MOTOR GRADER ARL Configuration: 163H Motor Grader ARL00001-UP (MACHINE) POWERED BY 3176C Engine Disassembly and Assembly 143H and 163H Motor Graders Machine Systems Media Number -RENR4153-01 Publication Date -01/02/2009 Date Updated -13/02/2009 i01906940 Piston Pump (Hydraulic Fan) - Assemble SMCS - 1387-016-QP; 5070-016-HFN Assembly Procedure Table 1 Required Tools Tool Part Number Part Description Quantity A 1P-1857 Retaining Ring Pliers 1 C 1P-0510 Driver Group 1 D 8T-5096 Dial Indicator Gp 1 E 6V-2055 Grease 1 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. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/1/30
163H Motor Grader ARL00001-UP (MACHINE) POWERED BY 3176C Engine(SEB... 2/18 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: Many times, the installation of new parts is not necessary. The installation of used parts during reconditioning is acceptable. Used parts can result in a substantial cost reduction. Reusable information is available on piston pumps and motors. Refer to Special Publication, SEBF8032, "Guideline For Reusable Parts - Piston Pumps and Motors". During reconditioning, correct any conditions that might have caused the original failure. Note: Cleanliness is an important factor. Before the disassembly procedure, the exterior of the component should be thoroughly cleaned. This will help to prevent dirt from entering the internal mechanism. Dirt and contaminants can damage precision components that are in pumps and motors. All disassembly and assembly procedures must be performed on a clean work surface. Clean all the interior components in clean solvent. Dry all the interior components with compressed air. Plug ports and plug hoses on the machine during repair. 1. Check all of the O-ring seals and the components for wear or damage. Replace the components, if necessary. 2. Lubricate all of the O-ring seals lightly with the lubricant that is being sealed. Illustration 1 g00993404 3. Install plug (68) and the O-ring seal. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/1/30
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163H Motor Grader ARL00001-UP (MACHINE) POWERED BY 3176C Engine(SEB... 3/18 Illustration 2 g00993403 Illustration 3 g00822750 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. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/1/30
163H Motor Grader ARL00001-UP (MACHINE) POWERED BY 3176C Engine(SEB... 4/18 4. Install disc (67) and spring (66) into barrel (57) . 5. Install pins (59) into the top of barrel (57). Note: There are three notches in the top of barrel (57) for pins (59). Place retaining ring (65) on top of spring (66) . Illustration 4 g00993401 6. Position barrel (57) in a suitable press, as shown. Use Tooling (C) and the press to compress spring (66). Use Tooling (A) to install retaining ring (65) . Illustration 5 g00822984 7. Raise the temperature of bearing cone (64). Install bearing cone (64) on shaft (52) . https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/1/30
163H Motor Grader ARL00001-UP (MACHINE) POWERED BY 3176C Engine(SEB... 5/18 Illustration 6 g00993397 8. Install seal (63) in housing (39) . Note: The lip of seal (63) will face INWARD. 9. Use Tooling (A) to install retaining ring (62) . Illustration 7 g00993515 10. Use Tooling (C) to install bearing cup (61) in housing (39) . Note: Bearing cup (61) must be fully seated in order to allow proper assembly of the pump. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/1/30
163H Motor Grader ARL00001-UP (MACHINE) POWERED BY 3176C Engine(SEB... 6/18 Illustration 8 g00993396 11. Install two bearing sleeves (60) in housing (39) . Note: Each bearing sleeve (60) contains a notch in the bearing. This notch must be installed in the corresponding notch in housing (39) . Illustration 9 g00993395 12. Install retainer (58) on three pins (59) on barrel (57) . https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/1/30
163H Motor Grader ARL00001-UP (MACHINE) POWERED BY 3176C Engine(SEB... 7/18 Illustration 10 g00823281 13. Install pistons (55) in reaction plate (56) . 14. Install pistons (55) and reaction plate (56) as a unit into barrel (57) . Note: Pistons (55) must be installed into the original cylinder. Illustration 11 g00821893 15. Install swashplate (53) onto shaft (52) . 16. Install rotating assembly (54) onto shaft (52) . Illustration 12 g00821821 17. Install shaft (52), swashplate (53), and rotating assembly (54) into housing (39) as a unit. Note: Orient swashplate (53) to the proper position for correct installation. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/1/30
163H Motor Grader ARL00001-UP (MACHINE) POWERED BY 3176C Engine(SEB... 8/18 Illustration 13 g00993393 18. Move the pump to the vertical position. 19. Install control piston (49) onto swashplate (53) . 20. Install spring (48) onto swashplate (53) . 21. Install O-ring (50) on housing (39) . Note: Do not install any shims at this time. 22. Install bearing (47) on the end of the shaft. Note: Bearing (47) is a slip fit. The bearing will not require tooling for installation. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/1/30
163H Motor Grader ARL00001-UP (MACHINE) POWERED BY 3176C Engine(SEB... 9/18 Illustration 14 g00821540 23. Install pin (45) in head (38) . 24. Install spacer (44) in head (38) . 25. Use Tooling (C) to install bearing cup (43) . Note: Bearing cup (43) must be fully seated against spacer (44) . Illustration 15 g00993392 https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/1/30
163H Motor Grader ARL00001-UP (MACHINE) POWERED BY 3176C Engine(S... 10/18 26. Install piston guide (42) into head (38). For the correct torque, refer to Specifications, "Piston Pump (Hydraulic Fan)". 27. Install plunger guide (41) into head (38). For the correct torque, refer to Specifications, "Piston Pump (Hydraulic Fan)". 28. Install O-ring seals (40) into head (38) . Illustration 16 g00824086 29. Install port plate (51) on head (38) . Note: Port plate (51) contains a notch. Pin (45) must fit in the notch. Note: Use Tooling (E) in order to secure the port plate to the head assembly during assembly. Illustration 17 g00993391 30. Install head (38) onto housing (39) . 31. Secure head (38) with socket head bolts (37) . https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/1/30
163H Motor Grader ARL00001-UP (MACHINE) POWERED BY 3176C Engine(S... 11/18 Illustration 18 g00824206 32. Move the assembled pump to the vertical position with shaft (52) upward. Illustration 19 g00823712 https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/1/30
163H Motor Grader ARL00001-UP (MACHINE) POWERED BY 3176C Engine(S... 12/18 Illustration 20 g00993510 33. Use Tooling (D) to determine the vertical movement of shaft (52). This measurement is Dimension (X) . Illustration 21 g00824208 34. Use a micrometer to measure the thickness of a new shim (46). This measurement is Dimension (Y) . 35. Subtract Dimension (Y) from Dimension (X). This measurement is Dimension (Z). 36. Dimension (Z) must be 0.05 mm (0.0020 inch). 37. Adjust the thickness of shim (46) to Dimension (Z) . https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/1/30
163H Motor Grader ARL00001-UP (MACHINE) POWERED BY 3176C Engine(S... 13/18 Illustration 22 g00993391 38. Remove socket head bolts (37). Remove head (38) from pump housing (39) . Illustration 23 g00824045 39. Remove bearing cone (47) from the shaft. Note: Bearing cone (47) is a slip fit. 40. Install the proper shim (46) on the shaft. 41. Install bearing cone (47) on the shaft on top of shim (46) . https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/1/30
163H Motor Grader ARL00001-UP (MACHINE) POWERED BY 3176C Engine(S... 14/18 Illustration 24 g00993500 42. Install port plate (51) on head (38) . Note: Port plate (51) contains a notch. Pin (45) must fit in the notch. Note: Use Tooling (E) in order to secure the port plate to the head assembly during assembly. Illustration 25 g00993391 43. Install head (38) onto housing (39) . 44. Secure head (38) with socket head bolts (37) . https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/1/30
163H Motor Grader ARL00001-UP (MACHINE) POWERED BY 3176C Engine(S... 15/18 Illustration 26 g00993510 45. Install Tooling (D) for a second time. 46. Check the pump shaft for the proper measurement. Illustration 27 g00993388 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. 47. Install seal (31) on plug (30). Install plug (31) into pressure and flow compensator valve (7) . 48. Install valve stem (32) into the pressure and flow compensator valve (7). Install spring retainer (33), spring (34), spring (35), and seat (36) into pressure and flow compensator valve (7) . https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/1/30
163H Motor Grader ARL00001-UP (MACHINE) POWERED BY 3176C Engine(S... 16/18 49. Install O-ring seal (23) onto plug (24). Install plug (24) onto pressure and flow compensator valve (7) . 50. Install seal (25) on adjustment nut (26). Install adjustment screw (27) into plug (24). Install seal (28) onto cap nut (29) and onto adjustment screw (27) . Illustration 28 g00993386 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. 51. Install seal (18) on plug (17). Install plug (17) into pressure and flow compensator valve (7) . 52. Install valve stem (9) into the pressure and flow compensator valve (7). Install spring retainer (10), spring (11), spring (12), and seat (19) into pressure and flow compensator valve (7) . 53. Install seal (20) onto adjustment plug (21). Install adjustment screw (22) into plug (21). Install seal (13) and adjustment nut (14) onto adjustment screw (22). Install seal (15) onto cap nut (16). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/1/30
163H Motor Grader ARL00001-UP (MACHINE) POWERED BY 3176C Engine(S... 17/18 Illustration 29 g00993385 54. Install O-ring seals on pressure and flow compensator valve (7) . Illustration 30 g00993383 55. Install pressure and flow compensator valve (7) on the pump. Secure the pressure and flow compensator valve (7) with bolts (6) . Illustration 31 g00993381 https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/1/30
163H Motor Grader ARL00001-UP (MACHINE) POWERED BY 3176C Engine(S... 18/18 56. Install manifold (5). Secure manifold (5) with bolts (4) . 57. Install manifold (3). Secure manifold (3) with bolts (2) . 58. Install tube assembly (1) . Note: The correct priming and break-in procedures should always be used, when the parts of the rotating group have been rebuilt or replaced. The break-in procedure is important because improper break-in will result in failures after minimal hours of the pumps and of the motors. Improper break-in procedures leave little evidence about the failure. Prime a rebuilt pump or a rebuilt motor. Note: Abrasive particles must be removed from the hydraulic system. Contamination is a frequent cause of pump failures. Pump failures are often due to improper flushing techniques from a previous failure. Note: Once all contaminants have been thoroughly flushed from the system, a baseline SOS analysis must be completed. Refer to Special Instruction, SEBF3116 for information on oil sampling. The SOS oil sample is used to determine the size and the quantity of the contaminants. Particle count is the recommended method for particle detection. End By: Install the piston pump (Hydraulic fan). Refer to Disassembly and Assembly, "Piston Pump (Hydraulic Fan) - Install ". Copyright 1993 - 2020 Caterpillar Inc. Thu Jan 30 14:17:35 UTC+0800 2020 All Rights Reserved. Private Network For SIS Licensees. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/1/30
163H Motor Grader ARL00001-UP (MACHINE) POWERED BY 3176C Engine(SEB... 1/5 Shutdown SIS Previous Screen Product: MOTOR GRADER Model: 163H MOTOR GRADER ARL Configuration: 163H Motor Grader ARL00001-UP (MACHINE) POWERED BY 3176C Engine Disassembly and Assembly 143H and 163H Motor Graders Machine Systems Media Number -RENR4153-01 Publication Date -01/02/2009 Date Updated -13/02/2009 i01945000 Piston Pump (Hydraulic Fan) - Install SMCS - 1387-012-QP; 5070-012-HFN Installation Procedure Illustration 1 g01012338 https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/1/30
163H Motor Grader ARL00001-UP (MACHINE) POWERED BY 3176C Engine(SEB... 2/5 1. Use two people and install pump assembly (19). The weight of pump assembly (19) is approximately 30 kg (65 lb). 2. Install bolts (20). Tighten bolts (20) to a torque of 100 20 N m (74 15 lb ft). Slide pump assembly (19) to the front of the machine. Illustration 2 g01012334 3. Install bolts (18). Tighten bolts (18) to a torque of 105 20 N m (77 15 lb ft). Repeat this step for the opposite side of the machine. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/1/30
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163H Motor Grader ARL00001-UP (MACHINE) POWERED BY 3176C Engine(SEB... 3/5 Illustration 3 g01012300 Illustration 4 g01012304 4. Position elbow (17) to the original location. Install bolts (16). Tighten bolts (16) to a torque of 100 20 N m (74 15 lb ft). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/1/30
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