Caterpillar cat 135 h motor grader (prefix 8wn) service repair manual (8wn00001 and up)

Service Repair Manual
Models
135H Motor Grader

Shutdown SIS
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Product: MOTOR GRADER
Model: 135H MOTOR GRADER 8WN
Configuration: 135H Motor Grader 8WN00001-UP (MACHINE) POWERED BY 3116 Engine
Disassembly and Assembly
120H & 135H MOTOR GRADERS MACHINE SYSTEM
Media Number -SENR8544-01 Publication Date -01/10/2004 Date Updated -04/02/2016
SENR85440036
Implement Hydraulic Pump
SMCS - 5070-011; 5070-012; 5070-017
Remove Implement Hydraulic Pump
1. Articulate the machine to the right in order to achieve working space.
2. Release pressure in the hydraulic system as follows:
At operating temperature, the hydraulic oil is hot and under pressure.
Hot oil can cause burns. Sudden movement of the machine or release of
oil pressure can cause injury to persons on or near the machine. To
prevent possible injury, perform the following procedure before
working on the hydraulic and steering systems.
a. Move the machine to a smooth horizontal location. Move away from working machines and
personnel. Lower all implements to the ground. Install the wheel lean pin in front axle.
b. Permit only one operator on the machine. Keep all other personnel either away from the
machine or in view of the operator.
c. Activate the parking brake. Place all implements on the ground and put the blade in the
"FLOAT" position.
d. Stop the engine.
e. Turn the steering wheel back and forth several times to relieve pressure in the steering
accumulator.
f. Carefully loosen the filler cap on the hydraulic tank to release pressure in the tank.
1/16135H Motor Grader 8WN00001-UP (MACHINE) POWERED BY 3116 Engine(SEBP...
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g. Be sure all hydraulic pressure is released before any fitting, hose, or component is loosened,
tightened, removed or adjusted.
h. Tighten the cap on the hydraulic tank.
i. The pressure in the hydraulic system must be released before lines or components can be
removed.
Hydraulic pressure can exist in the hydraulic lines between the control
valves and the cylinders with the engine stopped. Manually relieve
pressure before working on any hydraulic circuit.
3. Drain hydraulic system. Remove plug from ecology drain at the bottom of the oil tank. Drain
the hydraulic oil in a suitable container for storage or disposal. The capacity of the hydraulic oil
tank is 63 liters (16.8 U.S. gal).
4. Remove bolts (1), (3) and the washers that hold two split shields (2) together and to the machine
frame.
5. Remove bolts (4) and the washers from pump drive shaft (5). Remove pump drive shaft (5)
from the implement hydraulic pump.

6. Remove tube assembly (6) from valves (8) & (10).
7. Remove cap screws (9) that holdcompensator valve (10) to the implement hydraulic pump.
Remove compensator valve (10) from the implement hydraulic pump.
8. Remove bolts (7) and the washers that hold combination valve (8) to the implement hydraulic
pump. Remove combination valve (8) from the implement hydraulic pump.
9. Remove bolts (11) from elbow (12). Move elbow (12) and its seal from the implement
hydraulic pump.
10. Remove hose assembly (14) from implement hydraulic pump (13).
11. Remove nut (18) and the washer from the implement hydraulic pump shaft.
12. Remove yoke (16) from implement hydraulic pump (13).
13. Remove bolts (15) and the washers that hold bracket (15) to implement hydraulic pump (13).
14. Remove mounting bolts (19), the washers and rubber mountings (20) that hold mounting
bracket (17) to the machine frame. Remove mounting bracket (17) from the machine frame.
15. Use a lifting sling and a hoist, or a power truck in order to remove implement hydraulic pump
(13) from the left side of the vehicle. the weight of implement hydraulic pump (13) is 50 Kg (110
lb).

Install Implement Hydraulic Pump
1. Make sure that all components of the implement Hydraulic Pump and the matching components
are clean prior to installation of the pump. During the installation of the Implement Hydraulic
Pump, check the condition of all O-ring seals used in the assembly. If any of the seals are
damaged, use new parts for replacement.
2. Position implement hydraulic pump (13) to the machine frame.
3. Position mounting bracket (17) to the machine frame and to implement hydraulic pump (13).
4. Install rubber mounts (20), bolts (16) and the washers that that hold mounting bracket (17) to
the machine frame.
5. Install bolts (15) and the washers that hold bracket (15) to implement hydraulic pump (13).
Tighten bolts (15) to a torque of 160 ± 30 N·m (118 ± 22 lb ft).
6. Install yoke (16), nut (18) and the washer to implement hydraulic pump (13). Tighten nut (18)
to a torque of 190 ± 25 N·m (140 ± 18 lb ft).
7. Install hose assembly (14) to implement hydraulic pump (13).
8. Position elbow (12) and its seal to implement hydraulic pump (13). Install bolts (11) that hold
elbow (12) to implement hydraulic pump (13).

9. Position combination valve (8) to implement hydraulic pump (13). Install bolts (5) and the
washers that hold combination valve (8) to implement hydraulic pump (13).
10. Position compensator valve (10) to implement hydraulic pump (13). Install cap screws (9) that
hold compensator valve (10) to implement hydraulic pump (13).
11. Install assembly (6) to valves (8) and (10).
12. Position pump drive shaft (5) to implement hydraulic pump (13). Install bolts (3) and the
washers that hold pump drive shaft (5) to implement hydraulic pump (13).
13. Position two split shields (2) over drive shaft (5). Install bolts (1), (3) and the washers that
hold the guards together and to the machine frame. Tighten bolts (3) to a torque of 135 ± 20 N·m
(99 ± 15 lb ft).
14. Fill the hydraulic oil system with the proper amount of hydraulic oil. Refer to the "Operation
& Maintenance Manual" for the proper oil, procedure and amount of oil.
Disassemble & Assemble Implement Hydraulic Pump

Start By:
a. remove implement hydraulic pump
1. Remove bolts (1) from valve group (2). Remove valve group (2) from the implement pump.
2. Remove bolts (4) and cover (5) from housing (3).
3. Remove O-ring seal (6) from housing (3).

4. Remove plug (7) and the O-ring seal from head (8). Slowly and evenly remove five bolts (10)
and bolt (9), in order to release the spring force on the valve assembly.
5. Remove head (8) and the gasket from housing (3).
6. Remove piston (12) and spring (13) from piston rod (11).
7. Remove piston (15) from piston rod (14).
8. Remove pin (16) from head (8).
9. Remove piston rod (11) from head (8).
10. Remove piston rod (14) from head (8).
11. Use Tooling (A) in order to remove bearing cup (17) from head (8).

12. Remove bearing (19), shims (18) that are underneath the bearing, and plate (20) from the
pump group. Remove two pins (Z) from the pump housing.
13. Remove four bolts (24), two locking plates (23) and two spacer plates (22) from swashplate
(21).
14. Remove swashplate plug (25) and its O-ring seal from housing (3).
15. Remove rotating group (26) and shim kit (27) from housing (3).
Rotating Group (26)
16. Put identification marks on nine pistons (28), in relationship to barrel (29) and plate (30), for
assembly purposes. Remove nine piston assemblies (28) and plate (30) from barrel (29).

Spring (33) is under pressure. Release the spring pressure slowly in
order to avoid personal injury.
17. Use Tooling (D) and a press in order to compress spring (33). Use Tooling (B) in order to
remove snap ring (31) from barrel (29).
18. Remove snap ring (31), spacer (34), spring (33), and spacer (32) from barrel (29).
19. Note the orientation of swashplate (21) in relationship to housing (3) for assembly purposes.
Remove swashplate (21), shaft (36), and bearing (35) from housing (3).

20. Remove bearing (35) from shaft (36).
21. Remove shield (37) from housing (3).
22. Use Tooling (B) in order to remove snap ring (38) from housing (3). Remove lip-type seal (39)
from housing (3).
23. Remove two screws (42), bearing (40) and bearing (41) from housing (3).
24. Use Tooling (C) in order to remove roller bearing cup (43) from housing (3).
NOTE: The following steps are for the assembly of the implement hydraulic pump.
10/16135H Motor Grader 8WN00001-UP (MACHINE) POWERED BY 3116 Engine(SE...

NOTE: If a new swashplate, swashplate bearings, shaft, shaft bearings, head or housing are
installed, axial end play must be set. Refer to the topic "Shaft Bearing Endplay Adjustment" in the
Specifications Manual, SENR8509 and SENR8557.
25. During the assembly of the implement hydraulic pump, check the condition of all the O-ring
seals and the lip seals that are used in the pump. If any of these seals are damaged, use new parts
for replacement.
26. Lower the temperature of bearing cup (17). Use Tooling (D) in order to install bearing cup
(17) in head (8). Install bearing cup (17) until it is seated.
27. Lower the temperature of bearing cup (43). Use Tooling (D) in order to install bearing cup
(43) in housing (3). Install bearing cup (43) until it is seated.
28. Install bearing (35) in housing (3).
29. Install bearing (40), bearing (41), and setscrews (42) to housing (3).
30. Use Tooling (D) in order to install lip seal (39) in housing (3) until it is seated. The sealing lip
must face inward. Lubricate the sealing lip lightly with hydraulic oil. Use Tooling (B) in order to
install Retention ring (38) in housing (3).

31. Install shield (37) to housing (3).
32. Put a light coat of hydraulic oil on bearings (41) and (42) in order to hold swashplate (21) in
position during the next steps of assembly. Install swashplate (21) in housing (3) and in bearings
(41) and (42).
33. Block up housing (3) in order to have clearance when shaft (36) is installed. Shaft (36) extends
beyond the end of housing (3). Install shaft (36) through swashplate (21), in bearing (35) and
housing (3).

34. Install plug (25) and O-ring seal in housing (3). Tighten Plug (25) to a torque of 102 ± 4 N·m
(75 ± 3 lb ft).
35. Install spacer (32), spring (33) and spacer (34) in barrel (29).
36. Use Tooling (D) and a shop press in order to compress spring (33).
37. Use Tooling (B) to install snap ring (31) in barrel (29).
38. Install nine pistons (28) in their original locations in spacer (30) and barrel (29). This is easier
accomplished if the barrel is set in an upright position and then the pistons, already in the spacer,
are inserted from above.

39. Lay housing (3) on its side. Install rotating group (26) and shim kit (27) on shaft (36) and in
housing (3).
40. Install bearing (19) and shims (18) to shaft (36).
41. Position two spacers (22) and two locking plates (23) to their original positions on swashplate
(21).
42. Apply 9S-3263 Compound on bolts (24). Install four bolts (24) in order to hold plates (23)
and spacers (22) to swashplate (21). Tighten bolts (24) to a torque of 34 ± 3 N·m (25 ± 2 lb ft).
43. Install pin (16) in head (8).
44. Apply 9S-3263 Compound to piston rods (11) and (14).

45. Install piston rods (11) and (14) in head (8). Tighten piston rods (11) and (14) to a torque of 79
± 4.0 N·m (58 ± 3 lb ft).
46. Install spring (13), piston (12) and piston (15) to head (8).
47. Use a light coat of 5N-5561 Silicone Lubricant in order to hold plate (20) to head (8) during
assembly.
48. Position head (8) and the gasket on housing (3) and bearing (19).
49. Install bolts (9) and (10) in order to hold head (8) to housing (3). Slowly and evenly tighten the
bolts to a torque of 91 ± 4 N·m (67 ± 3 lb ft).
50. Install plug (7) and O-ring seal in head (8). Tighten plug (7) to a torque of 12.9 ± 0.1 N·m (10
± .1 lb ft).

51. Install O-ring seal (6) to housing (3).
52. Install plate (5) and bolts (4) to housing (3). Tighten bolts (4) to a torque of 8.5 ± 1.0 N·m (6
± .8 lb ft).
53. Install valve group (2) and bolts (1) to the pump.
End By:
a. install implement hydraulic pump
Copyright 1993 - 2020 Caterpillar Inc.
All Rights Reserved.
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Product: MOTOR GRADER
Model: 135H MOTOR GRADER 8WN
Configuration: 135H Motor Grader 8WN00001-UP (MACHINE) POWERED BY 3116 Engine
Disassembly and Assembly
120H & 135H MOTOR GRADERS MACHINE SYSTEM
Media Number -SENR8544-01 Publication Date -01/10/2004 Date Updated -04/02/2016
SENR85440037
Implement Control Valves
SMCS - 5051-012; 5051-015; 5051-016; 5051-011
Remove Implement Control Valves
1. Release the pressure in the hydraulic system as follows:
At operating temperature, the hydraulic oil is hot and under pressure.
Hot oil can cause burns. Sudden movement of the machine or release of
oil pressure can cause injury to persons on or near the machine. To
prevent possible injury, perform the following procedure before
working on the hydraulic and steering systems.
a. Move the machine to a smooth horizontal location. Move away from working machines and
personnel. Lower all implements to the ground. Install the wheel lean pin in front axle.
b. Permit only one operator on the machine. Keep all other personnel either away from the
machine or in view of the operator.
c. Activate the parking brake. Place all implements on the ground and put the blade in the
"FLOAT" position.
d. Stop the engine.
e. Turn the steering wheel back and forth several times to relieve pressure in the steering
accumulator.
f. Carefully loosen the filler cap on the hydraulic tank to release pressure in the tank.

g. Be sure all hydraulic pressure is released before any fitting, hose, or component is loosened,
tightened, removed or adjusted.
h. Tighten the cap on the hydraulic tank.
i. The pressure in the hydraulic system must be released before lines or components can be
removed.
Hydraulic pressure can exist in the hydraulic lines between the control
valves and the cylinders with the engine stopped. Manually relieve
pressure before working on any hydraulic circuit.
2. Put identification marks on hose assemblies (1) for installation purposes. The number of control
valves and hoses will vary with the amount of implements on the machine.
3. Remove hose assemblies (1) from the implement control valves. Plug the fittings on the hoses
in order to prevent the loss of hydraulic oil, and to keep dirt out of the hydraulic oil system.
4. Remove bolts (2) from cover (3). Raise cover (3) up and out of the way. Pull floor mat (4) back
and out of the way.

5. Remove four bolts (7) from control valve linkages (8). Move four control valve linkages (8) up
and out of the way.
6. Remove bolts (5) and the washers from cover (6). Remove cover (6) from the floor of the cab.
7. Remove bolts (9), bolt (10), the washers, the nuts and the rubber mountings that hold the
implement control valves. Remove the implement control valves from the mounting plates.
8. Repeat Steps 2 through 7 for the implement control valves located on the other side of the
machine.
Install Implement Control Valves
1. Make sure all of the components of the implement control valves are clean prior to installation.
During the installation, check condition of all the O-ring seals used on the hydraulic hoses that
were disconnected. If any of these seals are damaged, use new parts for replacement.
2. Position the implement control valves to their original locations and install bolts (9), bolt (10),
the washers, the nutsand the rubber mountings in order to secure the valves to the mounting plates.

3. Install cover (6), bolts (5) and washers that hold cover (6) to the floor of the cab.
4. Install control valve linkages (8) and bolts (7) that hold the linkages to the implement control
valves.
5. Position floor mat (4) to its original location on the floor of the cab. Install cover (3) and bolts
(2).
6. Install hose assemblies (1) to their original locations on the implement control valves.
7. Repeat Steps 2 through 6 for the other side.
8. Fill the hydraulic tank with oil to its correct level. Refer to the "Operation & Maintenance
Manual" for the proper procedure.
Disassemble Implement Control Valve
Start By:
a. remove implement control valve

Caterpillar cat 135 h motor grader (prefix 8wn) service repair manual (8wn00001 and up)

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