Caterpillar cat 160 h motor grader (prefix 9jm) service repair manual (9jm00001 and up)

Service Repair Manual
Models
160H Motor Grader

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Product: MOTOR GRADER
Model: 160H MOTOR GRADER 9JM
Configuration: 160H Motor Grader 9JM00001-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
i07432427
Piston Pump (Hydraulic and Steering) - Assemble
SMCS - 4306-016; 5070-016
S/N - 2FM1-UP
S/N - 2GS1-UP
S/N - 2HS1-UP
S/N - 2LR1-294
S/N - 2WR1-UP
S/N - 2ZK1-UP
S/N - 3AS1-UP
S/N - 3GM1-UP
S/N - 4ER1-UP
S/N - 4XM1-UP
S/N - 5HM1-UP
S/N - 5ZM1-UP
S/N - 6WM1-340
S/N - 8JM1-UP
S/N - 8KM1-393
S/N - 8MN1-UP
1/10160H Motor Grader 9JM00001-UP (MACHINE) POWERED BY 3306 Engine(SEBP...
2019/11/27https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis...

S/N - 9EJ1-UP
S/N - 9JM1-UP
S/N - 9TN1-UP
S/N - 9ZN1-UP
S/N - XZJ1-UP
S/N - XZK1-UP
Assembly Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 1P-1861 Retaining Ring Pliers 1
B 1P-0510 Driver Group 1
C 8T-5096 Dial Indicator Group 1
D
- Loctite LB 8632 Silicone Lubricant (1)
-
-
-
- Loctite LB Superlube (4)
-
(1)
North America
(2)
EAME
(3)
Asia Pacific Division
(4)
South America
Note: The axial end play must be adjusted if the swashplate, the swashplate bearings, the shaft,
the shaft bearings, the head, or the housing has been replaced.
Refer to Testing and Adjusting, "Bearing Endplay (Piston Pump) - Adjust" for the proper
procedure.
Note: Cleanliness is an important factor. Before the assembly procedure, the exterior of the
component should be thoroughly cleaned. This will help to prevent dirt from entering the internal
mechanism. Verify that all the components of the piston pump are clean and free of foreign
material prior to installation.
1. During the assembly of the piston pump, check the condition of all the O-ring seals and the
lip seals that are used in the pump. If any of these seals are damaged, use new parts for
replacement.

Illustration 1 g00636162
2. Lower the temperature of bearing cup (17). Use Tooling (B) to install bearing cup (17) in
head (8). Install bearing cup (17) until the bearing cup is seated.
3. Lower the temperature of bearing cup (43). Use Tooling (B) to install bearing cup (43) in
housing (3). Install bearing cup (43) until the bearing cup is seated.
4. Install bearing (35) in housing (3).

5. Install bearing (40) and bearing (41) into housing (3). Install set screws (42).
6. Use Tooling (B) to install lip seal (39) in housing (3) until the lip seal is seated. The sealing
lip must face inward. Lubricate the sealing lip lightly with hydraulic oil before installation.
Use Tool (A) to install retaining ring (38) into housing (3).
7. Install shield (37) into housing (3).

8. Place a light coat of hydraulic oil on bearing (41) and bearing (42). The hydraulic oil will
hold swashplate (21) in position during the following steps. Install swashplate (21) into
housing (3). Swashplate (21) should fit into bearing (41) and bearing (42).
9. Place housing (3) onto support blocks to allow space for installation of shaft (36). Shaft (36)
extends beyond the end of housing (3). Install shaft (36) through swashplate (21), through
bearing (35) (not shown), and through housing (3).
10. Install plug (25) into housing (3). Install the O-ring seal into housing (3). Tighten plug (25)
to a torque of 102 ± 4 N·m (75 ± 3 lb ft).

11. Install spacer (32), spring (33), and spacer (34) into barrel (29).
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.
12. Use Tooling (B) and use a suitable press to compress spring (33).
13. Use Tool (A) to install retaining ring (31) into barrel (29).
14. Install nine pistons (28) into the original locations in spacer (30) and barrel (29). For best
results, place the barrel in an upright position. Insert the pistons into spacer (30). Lift the
pistons by using spacer (30) and insert pistons (28) into barrel (29).

15. Position housing (3) horizontally. Install rotating group (26) and install shim kit (27) onto
shaft (36).
16. Install bearing (19) and install shims (18) onto shaft (36).
17. Position two spacers (22) and two locking plates (23) to the original positions on swashplate
(21).

18. Apply 9S-3263 Thread Lock Compound on bolts (24). Install four bolts (24) to hold plates
(23) and spacers (22) to swashplate (21). Tighten bolts (24) to a torque of 34 ± 3 N·m
(25 ± 2 lb ft).
19. Install pin (16) in head (8).
20. Apply 9S-3263 Thread Lock Compound to piston rods (11) and (14).
21. Install piston rod (11) and piston rod (14) in head (8). Tighten piston rod (11) and tighten
piston rod (14) to a torque of 79 ± 4 N·m (58 ± 3 lb ft).
22. Install spring (13), piston (12), and piston (15) onto head (8):

23. Use a light coat of Tooling (D) to hold plate (20) to head (8) during assembly.
24. Position head (8) and the gasket onto housing (3) and bearing (19).
25. Install bolt (9) and bolt (10) to hold head (8) to housing (3). Slowly tighten the bolts to a
torque of 91 ± 4 N·m (67 ± 3 lb ft).
26. Install plug (7) in head (8). Install the O-ring seal in head (8). Tighten plug (7) to a torque of
13.0 ± 0.1 N·m (114 ± 1 lb in).

27. Install O-ring seal (6) to housing (3).
28. Install cover (5) and install bolts (4) to housing (3). Tighten bolts (4) to a torque of
8.5 ± 1.0 N·m (75 ± 9 lb in).
29. Install valve group (2) and install bolts (1) to the pump.
End By:
a. Install the piston pump.
Copyright 1993 - 2019 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Wed Nov 27 09:15:03 UTC+0800 2019
10/10160H Motor Grader 9JM00001-UP (MACHINE) POWERED BY 3306 Engine(SEB...

Shutdown SIS
Previous Screen
i01187578
Piston Pump (Hydraulic and Steering) - Install
SMCS - 4306-012; 5070-012
S/N - 2FM1-UP
S/N - 2GS1-UP
S/N - 2HS1-UP
S/N - 2LR1-294
S/N - 2WR1-UP
S/N - 2ZK1-UP
S/N - 3AS1-UP
S/N - 3GM1-UP
S/N - 4ER1-UP
S/N - 4XM1-UP
S/N - 5HM1-UP
S/N - 5ZM1-UP
S/N - 6WM1-340
S/N - 8JM1-UP
S/N - 8KM1-393
S/N - 8MN1-UP

S/N - 9EJ1-UP
S/N - 9JM1-UP
S/N - 9TN1-UP
S/N - 9ZN1-UP
S/N - XZJ1-UP
S/N - XZK1-UP
Installation Procedure
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.
1. Make sure that all components of the piston pump are clean prior to installation of the
pump. During the installation of the piston pump, check the condition of all O-ring seals
that are used in the assembly. Replace damaged parts with new parts.
2. Position a suitable lifting device to piston pump (13). Secure the lifting device to a hoist.
From the left side of the machine, position piston pump (13) to the machine frame. The
weight of the piston pump is 50 kg (110 lb).
3. Position mounting bracket (17) to the machine frame and to piston pump (13).
4. Install rubber mounts (20). Install bolts (16) and install the washers that hold mounting
bracket (17) to the machine frame.
5. Install bolts (15) and the washers that hold bracket (15) to piston pump (13). Tighten bolts
(15) to a torque of 160 ± 30 N·m (118 ± 22 lb ft).
6. Install yoke (16). Install nut (17) and install the washer to piston pump (13).

7. Connect hose assembly (14) to piston pump (13).
8. Position elbow (12) and the seal to piston pump (13). Install bolts (11) that hold elbow (12)
to piston (13).
9. Position combination valve (8) to piston pump (13). Install bolts (5) and the washers that
hold combination valve (8) to piston pump (13) .
10. Position compensator valve (10) to piston pump (13). Install hex head bolts (9) that hold
compensator valve (10) to piston pump (13).
11. Install assembly (6) to combination valve (8) and compensator valve (10) .

12. Position pump drive shaft (5) to piston pump (13). Install bolts (3) and install the washers
that hold pump drive shaft (5) to piston pump (13) .
13. Position two split shields (2) over drive shaft (5). Install the bolt and the washer (1). Install
the bolt and the washer (3). The bolts and the washers hold the guards to the machine frame.
Tighten bolts (3) to a torque of 135 ± 20 N·m (100 ± 15 lb ft).
14. Fill the hydraulic oil system with the proper amount of hydraulic oil. Refer to the Operation
and Maintenance Manual, "Check the Oil Level" for the correct procedure.
Private Network For SIS Licensees.
Wed Nov 27 09:15:58 UTC+0800 2019

Shutdown SIS
Previous Screen
i01188728
Combination Valve - Remove
SMCS - 5064-011
S/N - 2FM1-UP
S/N - 2GS1-UP
S/N - 2HS1-UP
S/N - 2LR1-294
S/N - 2WR1-UP
S/N - 2ZK1-UP
S/N - 3AS1-UP
S/N - 3GM1-UP
S/N - 4ER1-UP
S/N - 4XM1-UP
S/N - 5HM1-UP
S/N - 5ZM1-UP
S/N - 6WM1-340
S/N - 8JM1-UP
S/N - 8KM1-393
S/N - 8MN1-UP

S/N - 9EJ1-UP
S/N - 9JM1-UP
S/N - 9TN1-UP
S/N - 9ZN1-UP
S/N - XZJ1-UP
S/N - XZK1-UP
Removal Procedure
Personal injury can result from hydraulic oil pressure and hot oil.
Hydraulic oil pressure can remain in the hydraulic system after the
engine has been stopped. Serious injury can be caused if this pressure is
not released before any service is done on the hydraulic system.
Make sure all of the attachments have been lowered, oil is cool before
removing any components or lines. Remove the oil filler cap only when
the engine is stopped, and the filler cap is cool enough to touch with
your bare hand.
Personal injury can result from the sudden release of high pressure oil.
Be sure the engine has been shut off for a minimum of five minutes to
ensure that the accumulator pressure is zero.
The accumulator is filled with dry nitrogen. Do not loosen or remove
the valve or the cap from the top of the accumulator.
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
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.
1. Release the hydraulic system pressure. Refer to Disassembly and Assembly, "Machine
Preparation for Disassembly and Assembly".
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. Remove the plug from the ecology drain at the bottom of the hydraulic oil tank. Drain the
hydraulic oil into a suitable container for storage or disposal. The capacity of the hydraulic
oil tank is 38 L (10 US gal).
3. Remove steering accumulator (2) from combination valve (3) .
4. Disconnect eight oil lines (1) from combination valve (3) .
5. Disconnect oil line (5) from combination valve (3) and pressure and flow compensator (6) .
6. Remove four mounting bolts (4). Remove combination valve (3) from the piston pump.
Wed Nov 27 09:16:54 UTC+0800 2019

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Previous Screen
i01797872
Combination Valve - Disassemble
SMCS - 5064-015
Disassembly Procedure
Start By:
a. Remove the combination valve. Refer to Disassembly and Assembly, "Combination Valve -
Remove" for the proper procedure.
Personal injury can result from being struck by parts propelled by a
released spring force.
Make sure to wear all necessary protective equipment.
Follow the recommended procedure and use all recommended tooling to
release the spring force.
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 disassembly procedure, the exterior of the
component should be thoroughly cleaned. This will help to prevent dirt from entering the internal
components.

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1. Remove relief valve (1) from the combination valve.
2. In order to release spring pressure, hold retainer assembly (2) when you loosen retainer
assembly (2). Slowly remove retainer assembly (2). Remove nut (3), O-ring seal (4), plate
(5), spring (6), plate (7), valve (8), body (9), O-ring seal (10), and O-ring seal (11) from
relief valve (1).

3. In order to release spring pressure, hold steering relief valve (12) as bolts (13) are loosened.
Slowly remove steering relief valve (12) from the combination valve.

4. In order to release spring pressure, hold retainer assembly (19) as the retainer assembly is
loosened. Slowly remove retainer assembly (19). Remove nut (24), O-ring seal (18), spring
(23), valve (17), body (16), O-ring seal (22), ring (21), O-ring seal (15), O-ring seal (14),
and seat (20) from steering relief valve (12).
5. Remove spring (27), spring (28), and valve spool (26) from the combination valve. Remove
plug (30) from each end of valve spool (26). If necessary, remove fitting (25) and remove
the plug and O-ring seal (29) from the inside of the combination valve.

Caterpillar cat 160 h motor grader (prefix 9jm) service repair manual (9jm00001 and up)

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