Service Repair Manual 160H MOTOR GRADER
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Shutdown SIS Previous Screen Product: MOTOR GRADER Model: 160H MOTOR GRADER ASD Configuration: 160H Motor Grader ASD00001-UP (MACHINE) POWERED BY 3176C Engine
Disassembly and Assembly 12H, 140H and 160H Motor Graders Power Train Media Number -RENR4108-15
Publication Date -01/05/2017
Date Updated -22/05/2017
i06148265
Differential and Bevel Gear - Assemble SMCS - 3256-016; 3258-016
Assembly Procedure Table 1 Required Tools Tool
Part Number
Part Description
Qty
A
1P-2420
Transmission Repair Stand
1
C
138-7575
Link Bracket
2
D
140-7742
Sleeve
2
E
5P-3413
Pipe Sealant
1
F
6V-4876
Lubricant
1
8T-5096
Dial Indicator Gp
1
6V-6042
Indicator Point Gp
1
6V-7920
Spanner Wrench
1
6V-4980
Torque Screwdriver Tool Gp
1
G
H
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.
Illustration 1
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1. Lower the temperature of bearing cups (52) . Install bearing cups (52) in housing assembly (43) and Oring seal (53) .
Illustration 2
g01001133
2. Raise the temperature of bearing cone (51) . Install bearing cone (51) on pinion (49) . Lubricate bearing cone (51) with SAE 30. Install housing (43) . Raise the temperature of bearing cone (50) . Install bearing cone (50) on pinion (49) . Lubricate bearing cone (50) with SAE 30. Install washer (48) , lock (47) , and locknut (46) . Use Tooling (H) to tighten locknut (46) , in order to achieve a rolling torque of 0.9 to 1.1 N·m (8 to 10 lb in).
Illustration 3
g01001433
3. Install the original shims (45) . Install housing assembly (43) . Install bolts (44) . Tighten bolts (44) to a torque of 250 ± 25 N·m (184 ± 18 lb ft).
Illustration 4
g01000823
4. Apply Tooling (E) to the bore of retainer (41) . Install seal (42) in retainer (41) . Install retainer (41) and bolts (40) .
Illustration 5
5. Install the sleeve and O-ring seal (39) .
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Illustration 6
g01000820
6. Install bearings (36) in pinions (35) . Note: Bearings (36) must be flush with the face of pinions (35) . 7. Lubricate the shafts on spider (38) with Tooling (F) . 8. Install the pinion assemblies, spacers (34) , gear (37) , and washer (33) .
Illustration 7
g01000817
9. Raise the temperature of bearing cone (32) . Install bearing cone (32) in housing (28) .
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Illustration 8
g01001435
10. Attach Tooling (C) to housing (28) . Install housing (28) in gear (31) and install bolts (30) . Tighten bolts (30) to a torque of 270 ± 25 N·m (199 ± 18 lb ft).
Illustration 9
g01001436
11. Install housing assembly (28) on housing (29) . Install bolts (27) . Tighten bolts (27) to a torque of 135 ± 15 N·m (100 ± 11 lb ft). The weight of housing assembly (28) is approximately 24 kg (52 lb). Note: The dowels in housing (28) must align with the slots in washer (33) . 12. Remove Tooling (C) . Install remaining bolts (30) . Tighten bolts (30) to a torque of 270 ± 25 N·m (199 ± 18 lb ft).
Illustration 10
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13. Install plate (26) . Lubricate discs (25) with SAE 30. Install discs (25) on gear (24) .
Illustration 11
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14. Install gear (24) with discs (25) .
Illustration 12
g01000811
15. Lubricate seals (22) and (23) . Install seals (22) and (23) on piston (21) .
Illustration 13
g01001437
16. Install piston (21) , washer (20) , and the upper half of housing (18) . Note: Dowel pins (20A) must align with the slots in washer (20) .
Illustration 14
g01001438
17. Raise the temperature of bearing cone (19) and install bearing cone (19) . Install bolts (17) . Tighten bolts (17) to a torque of 135 ± 15 N·m (100 ± 11 lb ft).
Illustration 15
18. Install bearing cup (16) and nut (15) in cage (10) .
g01001131
Illustration 16
g01000804
19. Install rings (14) , bearing cup (13) , ring (12) , and nut (11) on cage assembly (9) .
Illustration 17
20. Install cage assemblies (9) and (10) .
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Illustration 18
g01290833
21. Attach a suitable lifting device and Tooling (D) to differential (8) . 22. Install differential (8) . The weight of differential (8) is approximately 182 kg (400 lb). 23. Install dowel (7) .
Illustration 19
g01001439
24. Attach differential and bevel gear (1) to Tooling (A) so the ring gear is facing upward. 25. Install cap (6) and bolts (5) . Tighten bolts (5) to a torque of 370 ± 50 N·m (273 ± 37 lb ft). 26. Install O-ring seal (2) .
Illustration 20
g01291343
27. Rotate gear (31) . Adjust nut (15) to read zero and back off the nut to the closest lock position on nut (15) . 28. Rotate nut (11) until a heavy drag is felt. Loosen nut (11) and hand tighten nut (11) .
Illustration 21
g01291391
29. Install Tooling (G) . Note: Be sure to preload the indicator. 30. Rotate nut (11) and rotate gear (31) . Note: Preload the bearings by watching the indicator movement. The indicator should move 0.25 ± 0.05 mm (0.009 ± 0.002 inch). 31. Remove Tooling (G) .
Illustration 22
g01001453
32. Install Tooling (G) . Check the backlash between gear (31) and pinion (49) . The backlash should be 0.25 + 0.10 mm - 0.07 mm (0.010 + 0.004 inch - 0.003 inch). Note: Make the check at the heel of gear (31) in three places. 33. Advance and retract nuts (11) and (15) equal amounts. Maintain the bearing preload.
Illustration 23
g01001446
34. Check the rolling torque at pinion (49) . The rolling torque should be 2.2 ± .4 N·m (20 ± 4 lb in). Note: The rolling torque for a used bearing should be 1.1 ± .2 N·m (10 ± 2 lb in). 35. Tighten bolts (5) to a torque of 370 ± 50 N·m (273 ± 37 lb ft). 36. The contact pattern between the pinion shaft and bevel gear must be checked. Apply marking compound to three teeth that are adjacent to the bevel gear. 37. Rotate the pinion shaft for several revolutions in one direction. Rotate the pinion shaft for several revolutions in the opposite direction. Turn the pinion shaft in one direction until the teeth that are marked can be viewed.
Illustration 24
g00101201
38. The correct area of tooth contact starts near the inside end of the teeth of the bevel gear. The maximum correct area of tooth contact is half the length of the teeth.
Illustration 25
g00101202
39. If the tooth contact looks like the contact pattern in Illustration 25, proceed to Step 41.
Illustration 26
g00101203
40. If the tooth contact looks like the contact pattern in Illustration 26, proceed to Step 43. 41. Remove some of the shims from the pinion housing. Recheck the backlash between the bevel gear and the pinion. Note: Make sure that the backlash adjustment is correct before an adjustment is made to the area of tooth contact. Several adjustments to the backlash and tooth contact may be necessary to get the correct adjustments. Always remember that a change to gear clearance (backlash) will also change the gear contact. A change in gear contact will also change gear clearance (backlash). 42. Repeat Step 36 through Step 41 until the correct pattern is achieved. 43. Add some shims to the pinion housing. Recheck the backlash between the bevel gear and the pinion. Note: Make sure that the backlash adjustment is correct before an adjustment is made to the area of tooth contact. Several adjustments to the backlash and tooth contact may be necessary to get the correct adjustments. Always remember that a change to gear clearance (backlash) will also change the gear contact. A change in gear contact will also change gear clearance (backlash). 44. Repeat Step 36 through Step 44 until the correct pattern is achieved. 45. After adjustments are made, remove the marking compound from the gears.
Illustration 27
g01291412
46. Install locks (4) and bolts (3) . End By: Install the differential and the bevel gear. Refer to Disassembly and Assembly, "Differential and Bevel Gear - Install". Copyright 1993 - 2020 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees.
Mon May 4 13:07:24 UTC+0530 2020
Shutdown SIS Previous Screen Product: MOTOR GRADER Model: 160H MOTOR GRADER ASD Configuration: 160H Motor Grader ASD00001-UP (MACHINE) POWERED BY 3176C Engine
Disassembly and Assembly 12H, 140H and 160H Motor Graders Power Train Media Number -RENR4108-15
Publication Date -01/05/2017
Date Updated -22/05/2017
i02575466
Differential and Bevel Gear - Disassemble SMCS - 3256-015; 3258-015
Disassembly Procedure Table 1 Required Tools Tool
Part Number
Part Description
Qty
A
1P-2420
Transmission Repair Stand
1
B
5J-0490
Bolt
2
C
138-7575
Link Bracket
2
D
140-7742
Sleeve
2
Start By: a. Remove the differential and the bevel gear. Refer to Disassembly and Assembly, "Differential and Bevel Gear - Remove". 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.
Illustration 1
1. Attach differential and bevel gear (1) to Tooling (A). 2. Remove O-ring seal (2), bolts (3), locks (4), bolts (5), and cap (6).
g01000800
Illustration 2
g01290833
3. Remove dowel (7). 4. Attach a suitable lifting device and Tooling (D) to differential (8). 5. Remove differential (8). The weight of differential (8) is approximately 182 kg (400 lb).
Illustration 3
g01000803
6. Remove cage assemblies (9) and (10).
Illustration 4
g01000804
7. Remove nut (11), ring (12), bearing cup (13), and rings (14) from cage (9).
Illustration 5
g01001131
8. Remove nut (15) and bearing cup (16) from cage (10).
Illustration 6
9. Remove bolts (17).
g01000807
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Illustration 7
g01000808
10. Use Tooling (B) to remove the upper half of housing (18). Remove bearing cone (19).
Illustration 8
g01000810