Caterpillar cat 160 h motor grader (prefix 2fm) service repair manual (2fm00001 and up)

Service Repair Manual
Models
160H Motor Grader

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Product: MOTOR GRADER
Model: 160H MOTOR GRADER 2FM
Configuration: 160H Motor Grader 2FM00001-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
i01584480
Blade Lift - Remove
SMCS - 5219-011; 5222-011
Removal Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A
6V-3175 Double Acting Cylinder 1
4C-5809 Electric Hydraulic Pump 1
5P-4184 Tool Stud 1
9U-6832 Nut 1
4K-0684 Hard Washer 1
1P-1837 Bearing Puller Adapter 1
9S-8546 Installer 1
B
9S-8546 Installer 1
6V-2078 Stud 1
1P-1834 Adapter 1
1A-1935 Full Nut 1
5P-8250 Washer 1
1/7160H Motor Grader 2FM00001-UP (MACHINE) POWERED BY 3306 Engine(SEBP...
2019/11/25https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis...

Start By:
A. Remove the centershift cylinder. Refer to Disassembly and Assembly, "Centershift Cylinder
- Remove" for the correct procedure.
B. Remove the blade lift cylinder. Refer to Disassembly and Assembly, "Blade Lift Cylinder -
Remove" for the correct procedure.
Note: Cleanliness is an important factor. Before the removal procedure, the exterior of the
components should be thoroughly cleaned. This will help to prevent dirt from entering the internal
components.
1. Release the centershift lock pin from the centershift lock bar.
Illustration 1 g00634867
Typical Example
2. Position suitable lifting slings to the locator holes at the ends of the bar assembly. Secure
the lifting slings to a hoist. The weight of the bar assembly is 73 kg (160 lb).
3. Remove two bolts (2) from the blade lift arm that is on the right side of the machine.

4. Remove lock (3) and remove pin (4) that holds the blade lift arm to the bar assembly.
5. Remove two bolts (5) from the blade lift arm that is on the left side of the machine.
6. Remove pin (6) and remove lock (7) that holds the blade lift arm to the bar assembly.
7. Remove the bar assembly.
8. Position suitable lifting slings around the blade lift arm. Secure the lifting slings to a hoist.
The weight of the blade lift arm is 97 kg (214 lb).
9. Remove the blade lift cylinder. Refer to Disassembly and Assembly, "Blade Lift Cylinder -
Remove" for the proper procedure.
10. Remove bolt (8) from plate (9) .
11. Remove plate (9) from the frame and the pin.
12. Remove three bolts (10) from the arm assembly.

13. Remove lock (11) from the frame and the pin.
14. Remove pin (12) that holds the top of the lift arm to machine frame (13) .
15. Remove the blade lift arm from the machine.

16. Remove two bolts (14), retainer (15), and shim (17) from yoke assembly (16) .
17. Remove seal (18) from retainer (15) .
18. Move yoke assembly (16) partially out of the arm. Remove three washers (19) from the
arm.
19. Position a suitable lifting sling around yoke assembly (16). Secure the lifting sling to a
hoist. Remove yoke assembly (16) from the blade lift arm. The weight of yoke assembly
(16) is 20 kg (44 lb).
20. Remove three washers (20) and two seals (21) from yoke assembly (16) .

21. Remove bearing sleeves (22) and (23) from the blade lift arm by placing a saw cut down the
length of each bearing. Be careful not to cause damage to the inside of the lift arm.
22. Remove four lip seals (24) .

23. Support Tooling (A) with a lifting sling and a hoist. Use Tooling (A) in order to remove two
bearing sleeves (25) from the frame.
Typical Example
24. Remove two lip seals (26) from bar assembly (29) .
25. Use Tooling (B) in order to remove bearing sleeve (27) .
Note: Tooling (B) is on face (28) for installation purposes.
26. Repeat Step 8 through Step 23 for the remaining blade lift arm.
Copyright 1993 - 2019 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Mon Nov 25 19:46:56 UTC+0800 2019

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i01584528
Blade Lift - Install
SMCS - 5219-012; 5222-012
Installation Procedure
Table 1
Required Tools
A
5P-4184 Tool Stud 1
9U-6832 Nut 1
9S-8546 Installer 1
B
9S-8546 Installer 1
6V-2078 Stud 1
1P-1834 Adapter 1
1A-1935 Full Nut 1
5P-8250 Washer 1
C 6V-3175 Double Acting Cylinder 1

5P-4184 Tool Stud 1
9U-6832 Nut 1
D 1P-0510 Driver Group 1
Note: Verify that all of the components of the blade lift arms are clean and free of foreign material
prior to installation.
Note: Check all of the components for wear or for damage. Replace worn components or damaged
components with new parts.
1. Use Tooling (A) in order to install bearing sleeves (25) in the frame.

2. Install bearing sleeves (25) until the bearing sleeves are even with the face of the seal
counterbores.
3. Use Tooling (D) (not shown) in order to install four lip seals (24) into the frame until the lip
seals contact the face of the counterbore. Ensure that the sealing lip is facing outward.
Typical Example
4. Use Tooling (B) in order to install bearing sleeve (27) in bar (29). Install bearing sleeve (23)
until the bearing sleeve is 10 ± 1 mm (.4 ± .04 inch) below face (24) .
5. Use Tooling (D) (not shown) in order to install two lip seals (26) until the lip seals contact
bearing sleeve (27). Ensure that the sealing lip is facing outward.

6. Use Tooling (C) in order to install bearing sleeve (22) in the blade lift arm. Install bearing
sleeve (22) until the bearing sleeve is even with the counterbore surface of the shim bore.
7. Use Tooling (C) in order to install bearing sleeve (23) in the blade lift arm. Install bearing
sleeve (23) until the bearing sleeve is even with the counterbore surface of the shim bore.

8. Install two seals (21) and three washers (20) in the original position on yoke assembly (16) .
9. Use a lifting sling and a hoist in order to install yoke assembly (16) in the blade lift arm.
The weight of the yoke assembly is 20 kg (44 lb).
10. Install three washers (19) in the blade lift arm in the original position.

11. Install seal (18) to retainer (15) .
12. Install two bolts (14), retainer (15), and shims (17) to yoke assembly (16). Shims (15)
should be added or removed in order to obtain 0.25 mm (.010 inch) maximum end play.
Yoke assembly (16) must rotate without binding.
Typical Example
Typical Example
13. Attach lifting slings and a hoist to the blade lift arm. Position the blade lift arm to machine
frame (13). The weight of the blade lift arm is 97 kg (214 lb).
14. Install pin (12) in frame (13) and in the top end of the blade lift assembly. Ensure that the
retention slot in pin (12) is aligned with lock (11) .

Typical Example
15. Install lock (11) and three bolts (10) in the blade lift arm.
16. Position plate (9) to frame (13) and pin (12). Install bolt (8) in plate (9) .
Note: Refer to Specifications, "Blade Lift" for the correct torque specifications.
17. Use 123-8187 Thrust Washers and 8D-4336 Thrust Washers at joint (X) in order to obtain a
minimum gap of 1 mm (.040 inch).
18. Install the blade lift cylinder. Refer to Disassembly and Assembly, "Blade Lift Cylinder -
Install" for the proper procedure.
19. Repeat Step 1 through Step 18 in order to install the remaining blade lift arm.

Typical Example
20. Position suitable lifting slings around the bar assembly. Secure the lifting slings to a hoist.
The weight of the bar assembly is 73 kg (161 lb). Position the bar assembly to the blade lift
arm that is on the left side of the machine. Align the pin holes of the blade lift arm with the
pin holes of the bar assembly.
21. Install pin (6), lock (7), two bolts (5), and the washers that hold the blade lift arm to the bar
assembly.

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22. Install pin (4), two bolts (2), and lock (3) to blade lift arm and the bar assembly.
End By:
a. Install the centershift cylinder. Refer to Disassembly and Assembly, "Centershift Lock -
Install" for the correct procedure.
b. Install blade lift cylinder. Refer to Disassembly and Assembly, "Blade Lift Cylinder -
Install" for the correct procedure.
Copyright 1993 - 2019 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Mon Nov 25 19:47:52 UTC+0800 2019

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i01190855
Articulation Cylinder - Remove
SMCS - 5265-011
Removal Procedure
Table 1
Required Tools
A
9U-6600 Hand Hydraulic Pump 1
1P-5581 Spacer 1
8F-4225 Bolt 1
5F-7353 Washer 1
B
9U-6600 Hand Hydraulic Pump 1
1P-1832 Adapter 1
5P-4197 Spacer 1
5F-7379 Bolt 1
Start By:
A. Remove the batteries. Refer to Disassembly and Assembly, "Battery - Remove" for the
correct procedure.
B. Remove the battery boxes. Refer to Disassembly and Assembly, "Battery Box - Remove"
for the correct procedure.

Personal injury or death can result from sudden machine movement.
Sudden movement of the machine can cause injury to persons on or
near the machine.
To prevent injury or death, make sure that the area around the
machine is clear of personnel and obstructions before operating the
machine.
NOTICE
Never remove the fill/vent plug from the hydraulic tank if the oil is hot.
Air can enter the system and cause pump damage.
1. Release the pressure in the hydraulic system. Refer to Disassembly and Assembly,
"Machine Preparation for Disassembly and Assembly" for the proper procedure.
Hydraulic oil pressure can remain in the hydraulic system on this
machine after the engine and pump have been stopped. Serious injury
can result if this pressure is not released before any service is done on
the hydraulic systems. In order to prevent possible injury, release the
hydraulic system pressure before working on any fitting, hose, or
hydraulic component.
Lower all attachments to the ground before service is started. If the
hydraulic system must be serviced, tested, or adjusted with the
attachment in the raised position, the attachments and lift cylinders
must be supported properly.
Always move the machine to a location away from the travel of other
machines. Be sure that other personnel are not near the machine when
the engine is running and tests or adjustments are being made.
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.
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. Drain the oil from the hydraulic tank into a suitable container for storage or disposal. The
capacity of the hydraulic system is 38 L (10 US gal).
3. Remove bolt (1) and remove the clamp that holds the wiring harness to hydraulic tank
support (4) .
4. Position block (6) in order to support the hydraulic tank.
5. Remove bolt (2), the nut, and two washers from hydraulic tank support (4) and the bracket
on the hydraulic oil tank.
6. Remove two bolts (5) and remove the two washers from hydraulic tank support (4) from the
cab.

Caterpillar cat 160 h motor grader (prefix 2fm) service repair manual (2fm00001 and up)

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Caterpillar cat 160 h motor grader (prefix 2fm) service repair manual (2fm00001 and up)