Caterpillar cat 120 m motor grader (prefix r9a) service repair manual (r9a00001 and up)

Service Repair Manual
Models
120M Motor Grader

Shutdown SIS
Previous Screen
Product: MOTOR GRADER
Model: 120M MOTOR GRADER R9A
Configuration: 120M Motor Grader R9A00001-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
i03096382
Rear Axle, Differential and Final Drive - Disassemble
SMCS - 3258-015; 3278-015; 3282-015-RE; 4050-015; 4068-015
Disassembly Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 138-7575 Link Bracket 4
B 140-7742 Sleeve 2
C 1U-9200 Lever Puller Hoist 1
D 154-6182 Forcing Bolt 3
E 138-7574 Link Bracket 2
F
8B-7551 Bearing Puller Gp 1
1P-5546 Crossarm 1
3H-0465 Push-Puller Plate 2
5F-7366 Forcing Screw 1
G 292-4949 Socket Wrench As 1
H 154-6183 Forcing Bolt 3
J 1U-6405 Three Jaw Puller 1
Start By:
a. Remove the rear axle, differential, and final drive. Refer to Disassembly and Assembly,
"Rear Axle, Differential, and Final Drive - Remove".
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https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw...

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
Note: Inspect the O-ring seals. Replace the O-ring seals that are worn or damaged.
Illustration 1 g01413868
1. Use Tooling (A), Tooling (B), and two suitable lifting devices in order to position rear axle,
differential, and final drive (1) onto suitable blocking. The weight of rear axle, differential,
and final drive (1) is approximately 1089 kg (2400 lb).
2. Remove bolts (3), retainer (4), shims (5), sprocket (2), and sprocket (6).
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Note: Note the quantity and the order of shims (5).
3. Remove bearing cone (7).
4. Attach Tooling (A), Tooling (C), and two suitable lifting devices onto final drive housing
(8). The weight of final drive housing (8) is approximately 181 kg (400 lb). Remove nuts
(9).
5. Use Tooling (D) in order to remove final drive housing (8).
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6. Remove bolts (10). Remove retainer (11).
7. Remove shims (12). Use Tooling (A) and a suitable lifting device in order to remove
housing (13). The weight of housing (13) is approximately 57 kg (126 lb).
Note: Note the quantity and the order of shims (12).
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8. Remove thrust washer (14). Remove wear sleeves (15).
9. Turn over housing (13). Remove lip seal (16).
10. Remove bearing cup (17). Remove thrust washer (18).
11. Remove lip seal (19). Remove bearing cup (20).
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12. Use Tooling (E) in order to remove carrier assembly (21) and drive shaft (22). The weight
of carrier assembly (21) and drive shaft (22) is approximately 58 kg (128 lb).
13. Use Tooling (F) in order to remove bearing cone (23).
14. Remove retaining ring (24) in order to remove axle shaft (22) from carrier assembly (21).
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15. Remove bolts (25) and retainer (26). Remove pin (27). Remove gear (28). Remove thrust
washers (29) and bearings (30). Repeat this step for the remaining planetary gears.
16. Remove axle shaft assembly (31).
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17. Remove retaining ring (32) in order to remove gear (33) from axle shaft (34).
18. Use Tooling (D) in order to separate ring gear (35) from the intermediate housing.
19. Use Tooling (B) and a suitable lifting device in order to remove ring gear (35). The weight
of ring gear (35) is approximately 23 kg (51 lb).
20. Repeat Step 2 through Step 19 for the opposite side.
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21. Position differential housing (36) with intermediate housing (37) upward.
22. Attach a suitable lifting device onto pinion (38). Use Tooling (H) in order to separate pinion
(38) from the center housing. Remove bolts (39) in order to remove pinion (38). The weight
of pinion (38) is approximately 47 kg (104 lb).
23. Remove shims (40). Remove O-ring seal (41).
Note: Note the order and the quantity of shims (40).
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24. Remove bolt (42). Remove retainer (43). Remove yoke (44). Remove guard (45).
25. Remove shims (46). Remove lip seal (47).
Note: Note the order and the quantity of shims (46).
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120M Motor Grader R9A00001-UP (MACHINE) POWERED BY C6.6 Engine(SE...
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26. Remove pinion (48). Remove bearing cone (49). Remove bearing cup (50). Remove bearing
cone (51). Remove bearing cup (52).
27. Remove bolts (53).
Typical Example
28. Use Tooling (G) in order to remove nut assembly (54).
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29. Remove bolts (55). Remove bolts (56).
30. Use Tooling (H) in order to separate intermediate housing (37) from differential housing
(36).
31. Use Tooling (E) in order to remove intermediate housing (37). The weight of intermediate
housing (37) is approximately 31 kg (68 lb).
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32. Remove shims (57).
33. Use Tooling (A) in order to remove bearing assembly (58) and differential (59). The weight
of bearing assembly (58) and differential (59) is approximately 91 kg (200 lb).
34. Remove bolts (60). Remove shroud (61).
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35. Use Tooling (F) in order to remove bearing assembly (62).
36. Remove bearing cone (63). Remove bearing cups (64).
37. Use Tooling (J) in order to remove spacer (65) and bearing cone (66).
Note: This step is a destructive procedure. Replace bearing cone (66).
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38. Remove retaining ring (67). Remove bearing race (68). Remove O-ring seals (69). Remove
thrust ring (70).
Typical Example
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.
39. Remove bolts (71). Remove case (72).
40. Remove thrust washer (73). Remove plates (74) and discs (75). Remove springs (76).
Note: Note the quantity and the order of plates (74) and discs (75).
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41. Use two people in order to remove housing (77). The weight of housing (77) is
approximately 23 kg (50 lb).
42. Remove differential gear (78).
43. Remove spider assembly (79).
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44. Remove thrust washer (80), pinion gear (81), and bearing sleeve (82) from spider (83).
Repeat this step for the remaining pinion gears (81).
45. Remove differential gear (84). Remove thrust washer (85).
46. Use two people in order to turn over housing (86) and bevel gear (87). Remove bolts (88).
The weight of housing (86) and bevel gear (87) is approximately 40 kg (88 lb). Remove
bolts (88). Use two people in order to remove housing (86) from bevel gear (87). The
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weight of housing (86) is approximately 23 kg (50 lb). The weight of bevel gear (85) is
approximately 17 kg (38 lb).
47. Remove bearing assembly (89). Remove piston (90).
48. Remove thrust race (91), thrust bearing (92), and thrust race (93) from piston (90).
49. Remove seals (94) from piston (90).
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Shutdown SIS
Previous Screen
Product: MOTOR GRADER
Model: 120M MOTOR GRADER R9A
Configuration: 120M Motor Grader R9A00001-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
i07285127
Rear Axle, Differential and Final Drive - Assemble
SMCS - 3258-016; 3278-016; 3282-016-RE; 4050-016; 4068-016
Assembly Procedure
Table 1
Required Tools
Tool
Part
Number
Part Description Qty
A 439-3940 Link Bracket 4
B 140-7742 Sleeve 2
C 386-6031 Lever Puller Hoist 1
E 143-3939 Link Bracket 2
G 292-4949 Socket Wrench As 1
H 154-6183 Forcing Bolt 2
K 4C-4030 Thread Lock Compound 1
L 1U-8846 Gasket Sealant 1
M
6V-2012 Depth Micrometer 1
367-9109 Caliper(1)
1
N
8T-5096 Dial Indicator Gp 1
301-3405 Gauge 1
P 8T-4140 Bolt 4
R 7M-7456 Bearing Mount Compound 1
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S - Cat Advance 3Moly Grease or Dow Corning Molykote BR2 -
Plus
1
T 8T-5096 Dial Indicator Gp 1
(1)
For use with three bolt retainers
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
Note: Inspect the O-ring seals, gaskets, and lip seals. Replace O-ring seals, gaskets, and lip seals
that are worn or damaged.
Note: Lubricate O-ring seals and lip seals with the lubricant that is being sealed.
1. Install seals (94) onto piston (90).
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Note: Grease is used to hold thrust race (93) and thrust bearing (92) in place during
assembly.
2. Apply a liberal amount of grease to thrust race (93) and to thrust bearing (92). Install thrust
race (93) and thrust bearing (92) onto piston (90).
3. Install piston (90). Lower the temperature of bearing assembly (89). Install bearing
assembly (89).
4. Use two people to install housing (86) onto bevel gear (87). The weight of housing (86) is
approximately 41 kg (90 lb). Install bolts (88). Tighten bolts (88) to a torque of
300 ± 40 N·m (221 ± 30 lb ft).
5. Use two people to turn over bevel gear (87) and housing (86). The combined weight of
bevel gear (87) and housing (86) is approximately 59 kg (130 lb).
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6. Install thrust washer (85). Install differential gear (84).
Note: Install thrust washer (85) with the groove side against gear (84).
7. Install bearing sleeve (82), pinion gear (81), and thrust washer (80) onto spider (83). Repeat
this step for the remaining pinion gears (81).
8. Install spider assembly (79).
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9. Install differential gear (78).
10. Install housing (77).
Note: Ensure that the notches on the housings are aligned.
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11. Install plates (74) and discs (75). Install thrust washer (73). Install springs (76).
Note: Lubricate the discs with the lubricant that is being sealed.
Note: Install thrust washer (73) with the groove side against the gear.
Typical Example
Improper assembly of parts that are spring loaded can cause bodily
injury.
To prevent possible injury, follow the established assembly procedure
and wear protective equipment.
Note: Determine bolt size before torquing bolts (71).
12. Install case (72). Install bolts (71). Tighten M16 bolts (71) to a torque of 300 ± 40 N·m
(220 ± 30 lb ft). Tighten M12 bolts (71) to a torque of 120 ± 20 N·m (90 ± 15 ft)
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Note: Grease is used to hold thrust race (91) in place during assembly.
13. Install thrust ring (70). Apply a liberal amount of grease to thrust race (91). Install thrust
race (91) onto thrust ring (70). Install O-ring seals (69). Raise the temperature of bearing
race (68). Install bearing race (68). Install retaining ring (67).
14. Raise the temperature of bearing cone (66). Install bearing cone (66) and spacer (65).
15. Use a suitable press to install bearing assembly (55). Install shroud (58). Apply Tooling (K)
to the threads of bolts (57) and install bolts (57). Tighten bolts (57) to a torque of
28 ± 7 N·m (21 ± 5 lb ft).
7/27
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Caterpillar cat 120 m motor grader (prefix r9a) service repair manual (r9a00001 and up)

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