Caterpillar cat 16 h motor grader (prefix ats) service repair manual (ats00001 and up)

Service Repair Manual
Models
16H Motor Grader

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Product: MOTOR GRADER
Model: 16H MOTOR GRADER ATS
Configuration: 16H Motor Grader ATS00001-UP (MACHINE) POWERED BY 3196 Engine
Disassembly and Assembly
16H Motor Grader Power Train
Media Number -RENR4196-02 Publication Date -01/10/2007 Date Updated -31/10/2007
i05244417
Transmission and Transfer Gears - Disassemble
SMCS - 3002-015; 3030-015; 3159-015
Disassembly Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 138-7575 Link Bracket 2
B 1U-6690 Socket Wrench As 1
C 1P-1863 Retaining Ring Pliers 1
D
FT-1233 Puller Bar 1
126-7183 Crossblock 2
E FT-0833 Clamp 2
F 1/2 IN - 13NC × 4 Bolt 3
G 3/8 IN - 16NC ×four Forcing Screw 2
H 156-7100 Slide Hammer Puller Gp 1
J
126-7175 Slide Hammer Puller Gp 1
8B-7554 Bearing Cup Puller Gp 1
K 1P-0510 Driver Gp 1
L 8B-7551 Bearing Puller Gp 1
M 8H-0663 Bearing Puller Gp 1
N 1P-7409 Eyebolt 1
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P
8B-7551 Bearing Puller Gp 1
6V-3010 Puller 1
8B-7550 Push-Puller Leg 2
126-7183 Crossblock 4
Q 6V-4072 Spanner Wrench 1
R 1P-1855 Retaining Ring Pliers 1
ZZ
9U-7069 Cap 1
9U-7077 Cap 1
9U-7079 Cap 1
9U-7081 Cap 2
9U-7082 Cap 2
9U-7088 Cap 2
9U-7089 Cap 2
Start By:
A. Remove the transmission. Refer to Disassembly and Assembly, "Transmission and Transfer
Gears - Remove".
Note: SERVICE DATA: TOOLING (ZZ) WILL NOT BE IDENTIFIED IN PHOTOGRAPHS IN
THE REMOVAL PROCEDURE. THIS TOOLING IS SHOWN TO ASSIST THE
EXPERIENCED SERVICEMAN.
Illustration 1 g00911242
1. Remove bolts (1) and filter base (2) .
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2. Remove bolts (3) and tube assembly (4) . Remove the O-ring seals from tube assembly (4) .
3. Remove bolts (3A) in order to remove tube assembly (5) . Remove the O-ring seals from
tube assembly (5) .
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4. Remove bolts (3B) in order to remove tube assembly (6) . Remove the O-ring seals from
tube assembly (6) .
5. Remove bolts (3C) in order to remove tube assembly (7) . Remove the O-ring seals from
tube assembly (7) .
6. Remove bolts (8) .
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7. Attach a suitable lifting device to gear pump (9) . Remove remaining bolts (8) . Remove
gear pump (9) .
8. Remove coupling assembly (10) from the pump drive shaft.
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9. Remove pins (11) from coupling assembly (10) .
10. Remove nuts (12) in order to remove cover (13) .
11. Remove bolts (14) in order to remove cover (15) and the gasket.
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12. Remove bolts (16) and plates (17) .
13. Slide sleeves (18) out of transmission control module (19) toward case (20) .
14. Install Tooling (A) and a suitable lifting device on transmission control module (19) .
15. Remove bolts (21) and the washers.
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16. Use a pry bar for balance in order to remove transmission control module (19) . The weight
of transmission control module (19) is approximately 54 kg (120 lb).
17. Mark sleeves (18) for installation purposes. Remove sleeves (18) from case (20) .
18. Remove O-ring seals from sleeves (18) .
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19. Remove nuts (22) and bolts (23) .
20. Remove manifold (23A) .
21. Remove O-ring seals (24) from manifold (23A) .
22. Use a suitable device in order to turn the transmission to a horizontal position. The weight
of the transmission is approximately 907 kg (2000 lb).
23. Remove O-ring seals (25) from housing (26) .
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24. Remove bolts (27) from housing (26) .
25. Attach Tooling (A) and a suitable lifting device to housing (26) .
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26. Remove planetary group (28) from the case. The weight of the planetary group is
approximately 386 kg (850 lb).
27. Attach Tooling (A) and a suitable lifting device to support assembly (29) in order to invert
planetary group (28) .
28. Lift support assembly (29) in order to access bolts (30) .
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29. Bend locks (31) in order to remove bolts (30) .
30. Remove locks (31) and retainers (32) .
31. Remove support assembly (29) .
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32. Peen nut (33) out of the notch in support assembly (29) .
33. Use Tooling (B) in order to remove the nut.
Note: Support assembly (29) must be held in place in order to keep support assembly (29)
from rotating. Refer to illustration 28.
34. Remove washer (34) and bearing cone (35) .
35. Use two people in order to remove gear (36) from support assembly (29) . The weight of
gear (36) is approximately 27 kg (60 lb).
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36. Remove spacer (37) and bearing cone (38) from support assembly (29) .
37. Remove O-ring seals (39) and studs (40) from support assembly (29) .
38. Remove bearing (41) and carrier assembly (42) from support assembly (29) .
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39. Remove O-ring seal (43) from carrier assembly (42) .
40. Remove bearing cup (44) from gear (36) .
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41. Turn the gear to opposite side in order to remove spacer (45) from gear (36) .
42. Remove spiral ring (46) and bearing cup (47) from gear (36) .
43. Remove bolts (48) and (49) from planetary group (28) .
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44. Install Tooling (A) and a suitable lifting device to housing (27) . Lift housing (27) . The
weight of housing (27) is approximately 36 kg (80 lb).
45. Remove springs (50) and plungers (50A) .
46. Remove housing (27) .
47. Remove O-ring seals (51) , dowel (52) , and pins (53) from housing (27) .
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48. Use Tooling (C) in order to remove retaining ring (54) from bearing cage (55) .
49. Remove bearing cage (55) from planetary group (28) .
50. Remove bearing (56) from bearing cage (55) .
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51. Remove ring (57) from bearing (56) .
52. Remove bolts (58) and dowels (59) from flange (60) .
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53. Remove flange (60) from planetary group (28) .
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.
54. Use Tooling (D) and a press in order to compress springs (61) .
55. Remove retaining ring (62) .
56. Remove Tooling (D) and the press.
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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.
57. Remove retainer (63) and springs (61) from cage (64) .
58. Remove piston (65) from cage (64) .
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59. Remove bolts (66) and the washers.
60. Remove cage (64) .
61. Remove bearing (67) and seal rings (68) from cage (64) .
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62. Remove discs (69) and plates (70) .
63. Remove coupling (71) .
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64. Remove piston assembly (72) .
65. Remove inserts (73) from piston assembly (72) .
66. Remove balls (74) , discs (75) , and plates (76) .
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67. Use Tooling (C) in order to remove retaining ring (77) .
68. Remove hub assembly (78) .
69. Install Tooling (A) and a suitable lifting device to carrier assembly (79) .
70. Remove carrier assembly (79) . The weight of carrier assembly (79) is approximately 20 kg
(45 lb).
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71. Remove spiral ring (80) and bearing (81) from carrier assembly (79) .
72. Use a hammer and a punch in order to drive pin (82) into shaft (83) .
73. Remove shaft (83) from carrier assembly (79) . Remove pins (82) from shaft (83) .
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