Caterpillar cat 163 h motor grader (prefix arl) service repair manual (arl00001 and up)

Service Repair Manual
Models
163H Motor Grader

Shutdown SIS
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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
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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.
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injury.
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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) .
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) .
7. Raise the temperature of bearing cone (64). Install bearing cone (64) on shaft (52) .
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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) .
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.
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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) .
12. Install retainer (58) on three pins (59) on barrel (57) .
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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.
15. Install swashplate (53) onto shaft (52) .
16. Install rotating assembly (54) onto shaft (52) .
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.
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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.
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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) .
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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) .
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.
30. Install head (38) onto housing (39) .
31. Secure head (38) with socket head bolts (37) .
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32. Move the assembled pump to the vertical position with shaft (52) upward.
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33. Use Tooling (D) to determine the vertical movement of shaft (52). This measurement is
Dimension (X) .
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) .
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38. Remove socket head bolts (37). Remove head (38) from pump housing (39) .
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) .
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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.
43. Install head (38) onto housing (39) .
44. Secure head (38) with socket head bolts (37) .
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45. Install Tooling (D) for a second time.
46. Check the pump shaft for the proper measurement.
injury.
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) .
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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) .
injury.
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).
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54. Install O-ring seals on pressure and flow compensator valve (7) .
55. Install pressure and flow compensator valve (7) on the pump. Secure the pressure and flow
compensator valve (7) with bolts (6) .
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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.
All Rights Reserved.
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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
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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.
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.
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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).
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Caterpillar cat 163 h motor grader (prefix arl) service repair manual (arl00001 and up)

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