This document provides assembly instructions for a piston pump used in a 163H motor grader. It describes 57 assembly steps to install various components like pistons, springs, seals, manifolds and fittings. Special tools are required and cleanliness is important to prevent contamination. The assembly must be checked using indicators to ensure proper clearance and operation of the pump.
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𝘼𝙣𝙩𝙞𝙦𝙪𝙚 𝙋𝙡𝙖𝙨𝙩𝙞𝙘 𝙏𝙧𝙖𝙙𝙚𝙧𝙨 𝙞𝙨 𝙫𝙚𝙧𝙮 𝙛𝙖𝙢𝙤𝙪𝙨 𝙛𝙤𝙧 𝙢𝙖𝙣𝙪𝙛𝙖𝙘𝙩𝙪𝙧𝙞𝙣𝙜 𝙩𝙝𝙚𝙞𝙧 𝙥𝙧𝙤𝙙𝙪𝙘𝙩𝙨. 𝙒𝙚 𝙝𝙖𝙫𝙚 𝙖𝙡𝙡 𝙩𝙝𝙚 𝙥𝙡𝙖𝙨𝙩𝙞𝙘 𝙜𝙧𝙖𝙣𝙪𝙡𝙚𝙨 𝙪𝙨𝙚𝙙 𝙞𝙣 𝙖𝙪𝙩𝙤𝙢𝙤𝙩𝙞𝙫𝙚 𝙖𝙣𝙙 𝙖𝙪𝙩𝙤 𝙥𝙖𝙧𝙩𝙨 𝙖𝙣𝙙 𝙖𝙡𝙡 𝙩𝙝𝙚 𝙛𝙖𝙢𝙤𝙪𝙨 𝙘𝙤𝙢𝙥𝙖𝙣𝙞𝙚𝙨 𝙗𝙪𝙮 𝙩𝙝𝙚 𝙜𝙧𝙖𝙣𝙪𝙡𝙚𝙨 𝙛𝙧𝙤𝙢 𝙪𝙨.
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2. 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
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3. 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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4. 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.
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5. 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) .
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6. 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.
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7. 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) .
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8. 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.
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9. 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.
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10. 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
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11. 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) .
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12. Illustration 18 g00824206
32. Move the assembled pump to the vertical position with shaft (52) upward.
Illustration 19 g00823712
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13. 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) .
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14. 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) .
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15. 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) .
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16. 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) .
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17. 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).
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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
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19. 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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20. Thank you very much for
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21. 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
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22. 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.
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23. 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).
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