160M Motor Grader Machine Systems Caterpillar

Steering Cylinder - Remove and Install

Usage:

160M B9E

Removal Procedure (AWD)

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

Start By:

Connect the steering frame lock.

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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.

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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.

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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.

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NOTICE

Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Release the system pressure. Refer to Operation and Maintenance Manual, "System Pressure - Release".
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Illustration 1 g01397769
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.
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Illustration 2 g01410665
Remove bolts (1) and the washers. Remove cover (2).
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Illustration 3 g01410670
Remove nut (3).
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Illustration 4 g01410679
Disconnect harness assembly (5). Disconnect hose assemblies (4) and (6).
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Illustration 5 g01410719
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).
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Illustration 6 g01491493
Remove retaining ring (9). Remove cap assembly (10). Remove O-ring seal (11). Remove boot (12).
Repeat Step 2 through Step 7 for the remaining steering cylinder.

Removal Procedure (Non AWD)

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Table 2
Required Tools
Tool	Part Number	Part Description	Qty
A	311-1362	Vacuum Cap	1

Start By:

Connect the steering frame lock.

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

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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.

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Release the system pressure. Refer to Operation and Maintenance Manual, "System Pressure - Release".
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Illustration 7 g01368952
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.
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Illustration 8 g01344371
Disconnect fitting (1). Disconnect hose assembly (2).
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Illustration 9 g01344386
Remove cover (3). Disconnect harness assembly (4). Disconnect clips (5).
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Illustration 10 g01344395

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Illustration 11 g01344413
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).
Remove cotter pin (8). Remove nut (9). Remove steering cylinder (6).
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Illustration 12 g01491113
Remove retaining ring (10). Remove cap assembly (11). Remove O-ring seal (12). Remove boot (13).
Repeat Step 2 through Step 7 for the remaining steering cylinder.

Sensor Removal Procedure

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

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.

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Illustration 13	g01151971

Remove bolts (2) and cover (1).
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Illustration 14 g01151970
Remove connector assembly (3) and sleeve (4) from the harness assembly.
Remove plate (5) and grommet (6).
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Illustration 15 g01370084
Install Tooling (B) to sensor assembly (7).
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Illustration 16 g01151955
Remove screw (8) and discard screw (8).
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Illustration 17 g01152067
Remove sensor assembly (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.
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Illustration 18 g01154825
Remove retainer (11) and magnet (12) from carrier (13).
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.
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Illustration 19 g01154827
Remove retainer (15) and magnet (16) from carrier (17).
Remove carrier (17) from bolt (18).

Sensor Installation Procedure

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

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⁽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.

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Illustration 20	g01152067

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).
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Illustration 21 g01370088
Assemble Tooling (C), as shown. Refer to Tool Operating Manual, NEHS0935.
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Illustration 22 g01370090

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Illustration 23 g01370093
Install sensor assembly (7) into Tooling (C).
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).
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Illustration 24 g01151972
Install sleeve (4) over the harness assembly.
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Illustration 25 g01370094
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.
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Illustration 26 g01370099

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Illustration 27 g01370102
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.
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.
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.
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Illustration 28 g01151955
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).
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Illustration 29 g01151970
Install grommet (6).
Apply Tooling (G) to the mating surface of plate (5) and install plate (5).
Install sleeve (4) and connector assembly (3).
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Illustration 30 g01151971
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.
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Illustration 31 g01154825
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).
Install magnet (12) into carrier (13).
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.
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Illustration 32 g01154827
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).
Install magnet (16) into carrier (17).
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

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

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

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Illustration 33	g01367442

(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)

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Table 6
Required Tools
Tool	Part Number	Part Description	Qty
A	311-1362	Vacuum Cap	1

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Illustration 34	g01491113

Install boot (13). Install O-ring seal (12). Install cap assembly (11). Install retaining ring (10).
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Illustration 35 g01344395

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Illustration 36 g01344413
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).
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).
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Illustration 37 g01344386
Connect clips (5). Connect harness assembly (4). Install cover (3).
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Illustration 38 g01344371
Connect hose assembly (2). Connect fitting (1).
Repeat Step 1 through Step 5 for the remaining steering cylinder.
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Illustration 39 g01368952
Remove Tooling (A).
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".
Check the hydraulic oil level. Refer to Operation and Maintenance Manual, "Hydraulic System Oil Level - Check".

End By:

Disconnect the steering frame lock.

Installation Procedure (AWD)

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

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Illustration 40	g01491493

Install boot (12). Install O-ring seal (11). Install cap assembly (10). Install retaining ring (9).
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Illustration 41 g01410719
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).
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Illustration 42 g01410679
Connect hose assemblies (6) and (4). Connect harness assembly (5).
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Illustration 43 g01410784
Install nut (3). Tighten nut (3) to a torque of 220 ± 14 N·m (162 ± 10 lb ft).
Apply Tooling (T) to Surface (U).
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Illustration 44 g01410665
Position cover (2). Install the washers and bolts (1).
Repeat Steps 1 through 6 for the remaining steering cylinder.
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Illustration 45 g01397769
Remove Tooling (A).
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".
Check the hydraulic oil level. Refer to Operation and Maintenance Manual, "Hydraulic System Oil Level - Check".