Caterpillar cat 120 m motor grader (prefix d9w) service repair manual (d9w00001 and up)

Service Repair Manual
Models
120M Motor Grader

Shutdown SIS
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Product: MOTOR GRADER
Model: 120M MOTOR GRADER D9W
Configuration: 120M Motor Grader - All Wheel Drive D9W00001-UP (MACHINE) POWERED BY C6.6 Engine
Disassembly and Assembly
12M and 120M Motor Graders Power Train
Media Number -KENR6419-08 Publication Date -01/05/2017 Date Updated -15/05/2017
i02391399
Transmission - Disassemble
SMCS - 3030-015; 3159-015; 3176-015
S/N - D9W1-UP
Disassembly Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A
1P-0074 Slide Hammer Puller Gp 1
4C-5651 Threaded Adapter 1
B 5P-4758 Retaining Ring Pliers As 1
C 5P-5197 Retaining Ring Pliers As 1
D 1P-1863 Retaining Ring Pliers 1
E 5F-7465 Puller Gp 1
F
6V-3010 Puller Gp 1
8B-7557 Threaded Adapter 2
126-7177 Puller Leg 2
126-7181 Sliding Plate 4
G 8H-0663 Bearing Puller Gp 1
H 9U-7289 Ruler 1
Start By:
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https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw...

a. Remove the transmission. Refer to Disassembly and Assembly, "Transmission - Remove".
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, "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.
Illustration 1 g01136987
Personal injury can result from being struck by parts propelled by a
released spring force.
Make sure to wear all necessary protective equipment.
Follow the recommended procedure and use all recommended tooling to
release the spring force.
1. Remove plug (1) in order to drain the oil from the transmission into a suitable container.
Evenly remove bolts (2) and remove housing (3).
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2. Remove seal (4) from housing (3).
3. Remove springs (5) and (6).
4. Remove spring (7), O-ring seal (8), and spool (9).
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5. Remove seal (10) from spool (9).
6. Remove piston (11).
7. Remove race (13) and thrust bearing (12).
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8. Remove race (14).
9. Use Tooling (A) in order to remove piston (15).
10. Remove seals (16) and (17) from piston (15). Remove pins (18) from piston (15).
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NOTICE
containing fluids.
Cat products.
11. Remove ring (19).
12. Remove spring (20) and ring (21).
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13. Remove seals (22), (23), and (24) from ring (21).
14. Remove ring (25).
15. Remove seal (26) from ring (25).
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16. Remove discs (27).
Note: The thickness of discs (27) may vary.
17. Remove discs (28).
18. Remove washer (29).
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19. Use Tooling (B) in order to remove retaining ring (30).
20. Remove shaft (31) and gear (32) as an assembly.
21. Remove retaining ring (33) and shim (34) from gear (32).
22. Remove discs (35) from gear (32).
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23. Remove clutch discs (36) from gear (32).
Note: The thickness of clutch discs (36) may vary.
24. Use Tooling (B) in order to remove retaining ring (37). Remove shaft assembly (31).
25. Use Tooling (C) in order to remove retaining ring (38) from shaft assembly (31).
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26. Use Tooling (D) in order to remove retaining ring (39) from shaft assembly (31). Remove
race (40) from shaft assembly (31).
27. Use a suitable press in order to remove washer (42) and ball bearing (41) from shaft
assembly (31).
28. Use a suitable press in order to remove ball bearing (41) from washer (42).
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29. Remove bearing (44) and race (43).
30. Remove bolt (45A), speed sensor (45), bolts (46), and lubrication pump (47).
31. Remove bolts (48) and washer (49).
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32. Use Tooling (E) in order to press gear assembly (50) from bearing cone (51).
33. Remove bearing cone (51).
34. Remove gear assembly (50).
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35. Remove bearing cone (52) from gear assembly (50).
Note: Bearing cone (52) will be damaged when bearing cone (52) is removed.
36. Remove spring pins (53) from gear assembly (50).
37. Use Tooling (C) to remove retaining ring (54) and planetary pinion (55) from gear assembly
(50).
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Note: Shim (56) and rollers (57) will fall when planetary pinion (55) is removed.
38. Use Tooling (F) in order to remove inner race (58) from gear assembly (50).
39. Repeat Step 37 and Step 38 for the remaining planetary pinions.
40. Remove bearing cup (59).
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41. Remove bearing cup (60).
42. Remove seals (61) and (62).
43. Remove bolts (63) and (64). Remove plate (65).
44. Remove O-ring seal (66). Remove gear (67).
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45. Use Tooling (G) and a suitable press in order to remove plate (68) from gear (67).
46. If it is necessary, remove studs (69) from gear (67).
47. Remove seal (70).
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48. Use Tooling (G) in order to remove pinion (71).
49. Remove O-ring seal (72) and bushing (73) from pinion (71).
50. Use Tooling (G) in order to remove bearing cone (74) from pinion (71).
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51. Remove bearing cone (75), washer (76), and bearing cup (77).
52. Remove bearing cup (78) and shim (79). Remove cover (80).
53. Use Tooling (H) in order to measure the depth of seal (81) and record the measurement for
installation purposes. Remove seal (81) from cover (80).
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54. Remove O-ring seals (82) from cover (80).
55. Remove deflector plate (83).
56. Remove gear (84).
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57. Remove shroud (85).
58. Remove spring pin (86) if it is necessary.
Copyright 1993 - 2020 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Fri May 1 15:25:55 UTC+0800 2020
21/21
2020/5/1

Shutdown SIS
Previous Screen
Product: MOTOR GRADER
Model: 120M MOTOR GRADER D9W
Configuration: 120M Motor Grader - All Wheel Drive D9W00001-UP (MACHINE) POWERED BY C6.6 Engine
Disassembly and Assembly
12M and 120M Motor Graders Power Train
Media Number -KENR6419-08 Publication Date -01/05/2017 Date Updated -15/05/2017
i07077362
Transmission - Disassemble
SMCS - 3030-015; 3159-015; 3176-015
Disassembly Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 439-3940 Link Bracket 3
B 422-8733 Jack Stand Gp 3
C 1U-9202 Lever Puller Hoist 1
D 1P-1863 Retaining Ring Pliers 1
E 308-3470 Jack Stand Gp 2
F 140-7742 Sleeve 1
G 154-6181 Forcing Bolt 2
H FT-2769 Table 1
J 4C-8156 Lifting Fixture 1
K
1U-6410 Three Jaw Puller 1
1P-0510 Driver Gp 1
L 9U-7480 Compressing Tube 1
5P-7970 Nut 1
8T-4224 Hard Washer 1
- 1
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Bolt
M8 - 1.25 by 460mm
M 8B-7548 Push-Puller Tool Gp 1
N 2P-8312 Retaining Ring Pliers 1
P
1P-2321 Combination Puller 1
1P-0510 Driver Gp 1
R
189-0408 Shackle As 1
3E-3882 Eyebolt 1
S
126-7175 Push-Puller Tool Gp 1
4C-5653 Threaded Adapter 1
1P-0510 Driver Gp 1
Start By:
a. Remove the transmission.
NOTICE
containing fluids.
Cat®
products.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
Note: Put identification marks on all harness assemblies for installation purposes.
2/45
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1. Attach Tooling (A) and a suitable lifting device to transmission (1). The weight of
transmission (1) is approximately 862 kg (1900 lb). Use Tooling (A) and the suitable lifting
device to position transmission (1) onto Tooling (B). Remove hose assembly (2).
2. Remove bolts (3) to remove control module (4) and spacers (5).
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3. Remove yoke assembly (6).
4. Remove retaining ring (7).
5. Remove cup (8). Remove O-ring seal (9).
6. Attach Tooling (A), Tooling (C), and a suitable lifting device to transmission (1). Use
Tooling (A), Tooling (C), and the suitable lifting device to position transmission (1) onto
Tooling (B) and suitable cribbing. Position transmission (1) with the output shaft upward.
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Personal injury can result from being struck by parts propelled by a
released spring force.
Make sure to wear all necessary protective equipment.
Follow the recommended procedure and use all recommended tooling to
release the spring force.
7. Remove bolts (10) to remove plate assembly (11).
8. Remove lip seal (12).
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Caterpillar cat 120 m motor grader (prefix d9w) service repair manual (d9w00001 and up)

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