160M and 160 Motor Grader Machine Systems Steering Cylinder - Remove and Install Caterpillar


Steering Cylinder - Remove and Install
`
1.1. Removal Procedure (AWD)
2.1. Removal Procedure (Non AWD)
3.1. Sensor Removal Procedure
4.1. Sensor Installation Procedure
5.1. Disassembly and Assembly Information
6.1. Installation Procedure (Non AWD)
7.1. Installation Procedure (AWD)

Removal Procedure (AWD)

Table 1
Required Tools 
Tool  Part Number  Part Description  Qty 
311-1362  Vacuum Cap 

Start By:

  1. Connect the steering frame lock.

------ WARNING! ------

Cylinders equipped with lock valves can remain pressurized for very long periods of time, even with the hoses removed.

Failure to relieve pressure before removing a lock valve or disassembling a cylinder can result in personal injury or death.

Ensure all pressure is relieved before removing a lock valve or disassembling a cylinder.



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, PERJ1017, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat® products.

Dispose of all fluids according to local regulations and mandates.


------ WARNING! ------

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

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.


  1. Release the system pressure. Refer to Operation and Maintenance Manual, "System Pressure - Release".


    Illustration 1g01397769

  2. Install Tooling (A) onto the hydraulic tank. Attach an air supply hose onto Tooling (A). Apply 138 kPa (20 psi). This procedure will pull a vacuum on the hydraulic system.


    Illustration 2g01410665

  3. Remove bolts (1) and the washers. Remove cover (2).


    Illustration 3g01410670

  4. Remove nut (3).


    Illustration 4g01410679

  5. Disconnect harness assembly (5). Disconnect hose assemblies (4) and (6).


    Illustration 5g01410719

  6. Attach a suitable lifting device onto steering cylinder (8). The weight of steering cylinder (8) is approximately 23 kg (50 lb). Remove pin assembly (7). Remove steering cylinder (8).


    Illustration 6g01491493

  7. Remove retaining ring (9). Remove cap assembly (10). Remove O-ring seal (11). Remove boot (12).

  8. Repeat Step 2 through Step 7 for the remaining steering cylinder.

Removal Procedure (Non AWD)

Table 2
Required Tools 
Tool  Part Number  Part Description  Qty 
311-1362  Vacuum Cap 

Start By:

  1. Connect the steering frame lock.

------ WARNING! ------

Cylinders equipped with lock valves can remain pressurized for very long periods of time, even with the hoses removed.

Failure to relieve pressure before removing a lock valve or disassembling a cylinder can result in personal injury or death.

Ensure all pressure is relieved before removing a lock valve or disassembling a cylinder.



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, PERJ1017, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat® products.

Dispose of all fluids according to local regulations and mandates.


------ WARNING! ------

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.


  1. Release the system pressure. Refer to Operation and Maintenance Manual, "System Pressure - Release".


    Illustration 7g01368952

  2. Install Tooling (A) onto the hydraulic tank. Attach an air supply hose onto Tooling (A). Apply 138 kPa (20 psi). This procedure will pull a vacuum on the hydraulic system.


    Illustration 8g01344371

  3. Disconnect fitting (1). Disconnect hose assembly (2).


    Illustration 9g01344386

  4. Remove cover (3). Disconnect harness assembly (4). Disconnect clips (5).


    Illustration 10g01344395


    Illustration 11g01344413

  5. Attach a suitable lifting device onto steering cylinder (6). The weight of steering cylinder (6) is approximately 20 kg (44 lb). Remove pin assembly (7).

  6. Remove cotter pin (8). Remove nut (9). Remove steering cylinder (6).


    Illustration 12g01491113

  7. Remove retaining ring (10). Remove cap assembly (11). Remove O-ring seal (12). Remove boot (13).

  8. Repeat Step 2 through Step 7 for the remaining steering cylinder.

Sensor Removal Procedure

Table 3
Required Tools 
Tool  Part Number  Part Description  Qty 
4C-5649  Threaded Adapter 
1P-0074 Slide Hammer Puller Gp 

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.

Note: Put identification marks on all lines, on all hoses, on all wires, and on all tubes for installation purposes. Plug all lines, hoses, and tubes. This helps to prevent fluid loss and this helps to keep contaminants from entering the system.

Note: The Illustrations that are shown in the following Steps demonstrate the correct removal procedure for the sensor assembly, and these Illustrations may not represent the exact cylinder that is on your machine.



    Illustration 13g01151971

  1. Remove bolts (2) and cover (1).


    Illustration 14g01151970

  2. Remove connector assembly (3) and sleeve (4) from the harness assembly.

  3. Remove plate (5) and grommet (6).


    Illustration 15g01370084

  4. Install Tooling (B) to sensor assembly (7).


    Illustration 16g01151955

  5. Remove screw (8) and discard screw (8).


    Illustration 17g01152067

  6. Remove sensor assembly (7).

  7. Remove O-ring seal (9) and backup ring (10) from sensor assembly (7).

    Note: For pistons that are retained with a nut, refer to the following instructions for the removal of the magnet.



    Illustration 18g01154825

  8. Remove retainer (11) and magnet (12) from carrier (13).

  9. Remove carrier (13) from rod (14).

    Note: For pistons that are retained with a bolt, refer to the following instructions for the removal of the magnet.



    Illustration 19g01154827

  10. Remove retainer (15) and magnet (16) from carrier (17).

  11. Remove carrier (17) from bolt (18).

Sensor Installation Procedure

Table 4
Required Tools 
Tool  Part Number  Part Description  Qty 
265-4177  Installation Kit(1) 
264-4181  Sleeve(1) 
265-4208  Wire Assembly(1) 
154-9731  Thread Lock Compound 
6V-6640  Sealant 
155-0695  Thread Lock Compound 
(1) Part of 265-4177 Installation Kit

Note: Cleanliness is an important factor. Before assembly, all parts should be thoroughly cleaned in cleaning fluid. Allow the parts to air dry. Wiping cloths or rags should not be used to dry parts. Lint may be deposited on the parts which may cause later trouble. Inspect all parts. If any parts are worn or damaged, use new parts for replacement.

Note: The Illustrations that are shown in the following Steps demonstrate the correct installation procedure for the sensor assembly, and these Illustrations may not represent the exact cylinder that is on your machine.



    Illustration 20g01152067

  1. Lubricate backup ring (10) and O-ring seal (9) with the lubricant that is being sealed. Install backup ring (10) and O-ring seal (9) on sensor assembly (7).

    Note: Install backup ring (10) so that the split in backup ring (10) is in alignment with the slotted notch on the side of sensor assembly (7).



    Illustration 21g01370088

  2. Assemble Tooling (C), as shown. Refer to Tool Operating Manual, NEHS0935.


    Illustration 22g01370090


    Illustration 23g01370093

  3. Install sensor assembly (7) into Tooling (C).

  4. Slide Tooling (D) over sensor assembly (7) until Tooling (D) has cleared the dimple in the side of sensor assembly (7), as shown.

    Note: If Tooling (D) is installed to the point which exposes the O-ring seal on sensor assembly (7), continue pulling sensor assembly (7) through Tooling (D) and repeat Steps 3 and 4. This will help prevent cutting the O-ring seal with Tooling (D).



    Illustration 24g01151972

  5. Install sleeve (4) over the harness assembly.


    Illustration 25g01370094

  6. Start by threading Tooling (E) through the wire passage of the cylinder. Continue threading Tooling (E) through the cylinder and secure Tooling (E) to the wires of sensor assembly (7), as shown.


    Illustration 26g01370099


    Illustration 27g01370102

  7. With the help of another person, use Tooling (C) and Tooling (E) in order to guide the sensor assembly into position.

    Note: Use the alignment marks on Tooling (C) to ensure proper alignment of the sensor assembly into the counterbore. The sensor assembly should be installed with the alignment marks that are found on Tooling (C) toward the TOP, or in line with the wire passage in the cap if the wire passage is not in a vertical position.

  8. Use Tooling (C) in order to push the sensor assembly into the counterbore until the pin engages the slot on the side of the sensor assembly. Make sure that the sensor assembly has engaged the counterbore correctly. Gently try to rotate Tooling (C) in both directions in order to ensure proper engagement of the sensor assembly.

  9. Use a suitable mallet and Tooling (C) in order to tap the sensor assembly into the counterbore until the sensor assembly rests against the face of the counterbore.


    Illustration 28g01151955

  10. Apply Tooling (F) to set screw (8). Install set screw (8). Tighten set screw (8) to a torque of 25 ± 6 N·m (18 ± 4 lb ft).


    Illustration 29g01151970

  11. Install grommet (6).

  12. Apply Tooling (G) to the mating surface of plate (5) and install plate (5).

  13. Install sleeve (4) and connector assembly (3).


    Illustration 30g01151971

  14. Install cover (1) and bolts (2).

    Note: For pistons that are retained with a nut, refer to the following instructions for the installation of the magnet.



    Illustration 31g01154825

  15. Apply Tooling (H) to the threads of carrier (13) and install carrier (13) into rod (14). Tighten carrier (13) to a torque of 35 ± 5 N·m (26 ± 4 lb ft).

  16. Install magnet (12) into carrier (13).

  17. Apply Tooling (H) to retainer (11) and install retainer (11) into carrier (13). Tighten retainer (11) to a torque of 35 ± 5 N·m (26 ± 4 lb ft).

    Note: For pistons that are retained with a bolt, refer to the following instructions for the installation of the magnet.



    Illustration 32g01154827

  18. Apply Tooling (H) to the threads of carrier (17) and install carrier (17) into bolt (18). Tighten carrier (17) to a torque of 35 ± 5 N·m (26 ± 4 lb ft).

  19. Install magnet (16) into carrier (17).

  20. Apply Tooling (H) to the threads of retainer (15) and install retainer (15) into carrier (17). Tighten retainer (15) to a torque of 35 ± 5 N·m (26 ± 4 lb ft).

Disassembly and Assembly Information

Table 5
Required Tools 
Tool  Part Number  Part Description  Qty 
127-4904  Repair Stand 
195-4609  Seal Pick 
7M-7456  Bearing Mount Compound 
1P-0808  Multipurpose Grease 
9U-7868  Spanner Wrench 
127-8064 Adjustable Plate 
155-0695  Thread Lock Compound 
8T-3198  Sleeve 

------ WARNING! ------

Cylinders equipped with lock valves can remain pressurized for very long periods of time, even with the hoses removed.

Failure to relieve pressure before removing a lock valve or disassembling a cylinder can result in personal injury or death.

Ensure all pressure is relieved before removing a lock valve or disassembling a cylinder.




Illustration 33g01367442

(1) Tighten the set screw to a torque of 25 ± 3 N·m (221 ± 27 lb in).

(2) Apply Tooling (P) to the carrier and the retainer prior to installation. Tighten the carrier to a torque of 35 ± 5 N·m (310 ± 44 lb in). Tighten the retainer to a torque of 35 ± 5 N·m (310 ± 44 lb in).

(3) Lubricate the seals with the lubricant that is being sealed.

(4) Apply Tooling (L) to the wiper seal prior to installation.

(5) Tighten the nut to a torque of 600 ± 20 N·m (443 ± 15 lb ft).

(6) Use a suitable press to remove the bearing and the ball stud. Use a suitable press and Tooling (R) to install the bearingand the ball stud.

(7) Apply Tooling (P) to the bottom of the plate prior to installation.

(8) Apply Tooling (M) to the threads of the head prior to installation. Use Tooling (N) in order to tighten the head to a torque of 600 ± 130 N·m (443 ± 96 lb ft).

(5) Use Tooling (R) in order to remove the bearing. Use Tooling (S) in order to install the bearing.

Installation Procedure (Non AWD)

Table 6
Required Tools 
Tool  Part Number  Part Description  Qty 
311-1362  Vacuum Cap 


    Illustration 34g01491113

  1. Install boot (13). Install O-ring seal (12). Install cap assembly (11). Install retaining ring (10).


    Illustration 35g01344395


    Illustration 36g01344413

  2. Use a suitable lifting device in order to install steering cylinder (6). The weight of steering cylinder (6) is approximately 20 kg (44 lb). Install pin assembly (7).

  3. Install nut (9). Tighten nut (9) to 220 ± 14 N·m (162 ± 10 lb ft). Align nut (9) with the hole that is in the rod end. Install cotter pin (8).


    Illustration 37g01344386

  4. Connect clips (5). Connect harness assembly (4). Install cover (3).


    Illustration 38g01344371

  5. Connect hose assembly (2). Connect fitting (1).

  6. Repeat Step 1 through Step 5 for the remaining steering cylinder.


    Illustration 39g01368952

  7. Remove Tooling (A).

  8. THE PARAMETERS FOR THE LENGTH OF THE CYLINDER AND THE TRIM FILES FOR THE POSITION SENSOR FOR BOTH OF THE STEERING CYLINDERS MUST BE CONFIGURED IN THE ECM BEFORE OPERATING THE MACHINE. Refer to Testing and Adjusting, "Electronic Control Module (ECM) - Configure" and Testing and Adjusting, "Electronic Control Module (ECM) - Replace".

  9. Check the hydraulic oil level. Refer to Operation and Maintenance Manual, "Hydraulic System Oil Level - Check".

End By:

  1. Disconnect the steering frame lock.

Installation Procedure (AWD)

Table 7
Required Tools 
Tool  Part Number  Part Description  Qty 
311-1362  Vacuum Cap 
1U-8846  Gasket Sealant 


    Illustration 40g01491493

  1. Install boot (12). Install O-ring seal (11). Install cap assembly (10). Install retaining ring (9).


    Illustration 41g01410719

  2. Use a suitable lifting device in order to position steering cylinder (8). The weight of steering cylinder (8) is approximately 23 kg (50 lb). Install pin assembly (7).


    Illustration 42g01410679

  3. Connect hose assemblies (6) and (4). Connect harness assembly (5).


    Illustration 43g01410784

  4. Install nut (3). Tighten nut (3) to a torque of 220 ± 14 N·m (162 ± 10 lb ft).

  5. Apply Tooling (T) to Surface (U).


    Illustration 44g01410665

  6. Position cover (2). Install the washers and bolts (1).

  7. Repeat Steps 1 through 6 for the remaining steering cylinder.


    Illustration 45g01397769

  8. Remove Tooling (A).

  9. THE PARAMETERS FOR THE LENGTH OF THE CYLINDER AND THE TRIM FILES FOR THE POSITION SENSOR FOR BOTH OF THE STEERING CYLINDERS MUST BE CONFIGURED IN THE ECM BEFORE OPERATING THE MACHINE. Refer to Testing and Adjusting, "Electronic Control Module (ECM) - Configure" and Testing and Adjusting, "Electronic Control Module (ECM) - Replace".

  10. Check the hydraulic oil level. Refer to Operation and Maintenance Manual, "Hydraulic System Oil Level - Check".

Information System:

793D Off-Highway Truck Machine Systems Front Suspension (Cylinder) - Install
793D Off-Highway Truck Machine Systems Front Suspension (Cylinder) - Remove
793C Off-Highway Truck Machine Systems Front Suspension (Cylinder) - Install
793C Off-Highway Truck Machine Systems Front Suspension (Cylinder) - Remove
793D Off-Highway Truck Machine Systems Service and Parking Brake (Front) - Assemble
793D Off-Highway Truck Machine Systems Service and Parking Brake (Front) - Disassemble
793D Off-Highway Truck Machine Systems Service and Parking Brake (Front) - Install
793D Off-Highway Truck Machine Systems Service and Parking Brake (Front) - Remove
938H Wheel Loader and IT38H Integrated Toolcarrier Hydraulic System Ride Control Accumulator - Test and Charge
3176C Engine for the R1600G and the R1700G Load Haul Dumps Speed Control (Remote Throttle) - Test
3176C Engine for the R1600G and the R1700G Load Haul Dumps Power Is Intermittently Low or Power Cutout Is Intermittent
3176C Engine for the R1600G and the R1700G Load Haul Dumps Oil Pressure Is Low
140M and 150 Motor Graders Engine Supplement Water Temperature Regulator - Remove and Install
CP76 and CS76 Vibratory Compactors Propel System Case Drain Flow for Piston Motor (Drum Propel) - Test
2007/08/27 New AccuGrade Software is Now Available {7220, 7620}
CS54 and CP54 Vibratory Soil Compactors Fuel System Secondary Filter - Replace
CP76 and CS76 Vibratory Compactors Propel System Case Drain Flow for Piston Motor (Axle Propel) - Test
CS54 and CP54 Vibratory Soil Compactors Fuel System Primary Filter - Clean/Inspect/Replace
2007/08/27 The Traction Control System (If Equipped) is Updated {1408, 4801}
CS56, CS64, CS74, CS76, CP56, CP64, CP74 and CP76 Vibratory Soil Compactors Fuel System Primary Filter (Water Separator) - Replace
CP76 and CS76 Vibratory Compactors Propel System Travel Speed - Check
CP76 and CS76 Vibratory Compactors Propel System Parking Brake - Test
797B Off-Highway Truck Braking System Oil Cooler (Fan Drive, Front Brake, Steering)
CP76 and CS76 Vibratory Compactors Propel System Pump Synchronization - Test and Adjust