Caterpillar Cat 120H Motor Grader (Prefix ALZ) Service Repair Manual (ALZ00001 and up).pdf

Service Repair Manual
Models
120H Motor Grader

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Product: MOTOR GRADER
Model: 120H MOTOR GRADER ALZ
Configuration: 120H Motor Grader ALZ00001-UP (MACHINE) POWERED BY 3126B Engine
Disassembly and Assembly
120H and 135H Motor Graders Power Train
Media Number -RENR4160-05 Publication Date -01/04/2005 Date Updated -22/05/2017
i01967370
Transmission - Disassemble
SMCS - 3002-015; 3030-015; 3159-015
Disassembly Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 138-7575 Link Bracket 3
B 154-6181 Forcing Screw 2
C 6V-5221 Bolt 1
D 4C-8156 Fixture 1
E 6V-3918 Bolt 1
F 4C-8157 Lifting Fixture 2
G 1U-6405 Three Jaw Puller 1
H 1U-6341 Threaded Rod 1
J 5P-7970 Nut 1
K 9U-7479 Compressing Tube 1
L 5B-0637 High Idle Nut 1
5F-7353 Washer 1
1B-4207 Full Nut 2
5F-7369 Puller Leg 2
3H-0465 Push-Puller Plate 2
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120H Motor Grader ALZ00001-UP (MACHINE) POWERED BY 3126B Engine(SEB...
2020/3/3
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5F-7366 Screw 1
5P-4808 Cap 2
1U-9895 Crossblock 1
M
9S-9152 Block 2
1B-4206 Nut 4
8B-7552 Forcing Bolt 2
N 1U-6343 Threaded Rod 1
P 6V-8149 Nut 1
Q 2P-8312 Pliers 1
R
1P-2326 Screw 1
1P-2325 Head 1
3H-0462 Bolt and Nut 4
8H-0709 Strap 4
5F-7373 Jaw 3
T 3E-3882 Eyebolt 1
Start By:
a. Remove the transmission. Refer to Disassembly and Assembly, "Transmission - Remove"
for the correct procedure.
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Illustration 1 g00997069
1. Install Tooling (A) on transmission control valve (1). Attach a suitable lifting device to
Tooling (A).
2. Remove bolts (2) and remove transmission control valve (1). The weight of transmission
control valve (1) is approximately 30 kg (65 lb).
3. Remove temperature sensor (3). Remove tube assembly (4). Remove hose assemblies (5).
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4. Remove hose assembly (8) and remove intermediate sensors (9) and (6).
5. Attach a suitable lifting device to pump (11). Remove bolts (10). Remove pump (11). The
weight of pump (11) is approximately 25 kg (55 lb).
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6. Remove bolt (12) and yoke (13). Remove bolts (14) and brake (15). Use two people to
remove brake (15). The weight of brake (15) is approximately 34 kg (75 lb).
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7. Remove O-ring seal (14A).
8. Remove plates (15A), disc (15B), hub (15C), and dowels (15D).
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9. Remove cover (16). Remove output speed sensors (17).
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10. Remove input sensor (18). Remove bolts (20A). Remove plate assembly (20) and harness
assembly (19).
11. Place transmission (21) level on the floor.
12. Remove bolts (22) , the four covers, and the O-ring seals from transmission case assembly
(23).
13. Remove bolts (24) from the transmission case assembly (23).
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Note: Identify the location of seal carrier (25) in the transmission case assembly (23) for
assembly purposes.
14. Remove bolts (26) from seal carrier (25).
15. Install Tooling (A) (not shown) in seal carrier (25). Remove seal carrier (25) and the three
ring seals from the transmission case assembly bore (27).
16. Repeat Step 14 through Step 15 on the three remaining seal carriers (25).
17. Remove seal rings (29) from seal carrier (25).
18. Remove seals (28) from seal carrier (25).
19. Remove spring pin (30) from seal carrier (25).
20. Repeat Step 17 and Step 19 for the remaining three seal carriers (25).
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21. Install Tooling (B) in the transmission case assembly (23). Tighten Tooling (B) evenly to
separate transmission case assembly (23) from transmission cover assembly (31).
22. Install Tooling (A) to transmission case assembly (23). Attach a suitable lifting device to
Tooling (A). Slowly raise the transmission case assembly (23) from the transmission cover
assembly (31). Be careful not to bind the transmission case assembly (23) during separation.
23. Remove bolts (32) from tube assembly (33). Remove tube assembly (33) from the
transmission cover assembly (31).
24. Remove the O-ring seal from tube assembly (33).
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120H Motor Grader ALZ00001-UP (MACHINE) POWERED BY 3126B Engine(S...
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Note: First/Third shaft assembly (34) and High/Low shaft assembly (35) must be removed
together.
25. Install Tooling (D) on First/Third shaft assembly (34) and High/Low shaft assembly (35).
Use Tooling (C) and Tooling (E) in order to hold Tooling (D) on First/Third shaft assembly
(34) and High/Low shaft assembly (35), as shown. First/Third shaft assembly (34) and
High/Low shaft assembly (35) must be removed together.
26. Attach a suitable lifting device to Tooling (D). Carefully remove First/Third shaft assembly
(34) and High/Low shaft assembly (35) from the transmission cover assembly (31). The
weight of the two shaft assemblies is approximately 177 kg (390 lb).
27. Place First/Third shaft assembly (34) and High/Low shaft assembly (35) on Tooling (F) or
on blocks and remove Tooling (D). Carefully separate First/Third shaft assembly (34) and
High/Low shaft assembly (35). The weight of each shaft assembly is approximately 89 kg
(195 lb).
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Note: Place High/Low shaft (35) in a modified work bench or on blocks. Modify a
substantial workbench by cutting a 116.0 ± 2.0 mm (4.60 ± 0.08 inch) clearance hole in the
top of the bench.
Note: Do not attach Tooling (G) to rotor (37). If pressure is applied to rotor (37) with
Tooling (G), rotor (37) will brake. Attach Tooling (G) to gear assembly (38).
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28. With High/Low shaft assembly (35) on the modified work bench or on blocks, use Tooling
(G) in order to remove race and bearing (36), rotor (37), gear assembly (38), and two sleeve
bearings (not shown) from High/Low shaft assembly (35). Press fit bearing (36) and rotor
(37) on High/Low shaft assembly (35).
29. Remove bearing (36), rotor (37), thrust disc (39), and gear assembly (38) from High/Low
shaft assembly (35). Attach Tooling (G) to gear assembly (38). Do not attach Tooling (G) to
rotor (37).
30. Remove thrust disc (40) and the washer from High/Low shaft assembly (35).
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.
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31. Install Tooling (H) and Tooling (K) on High/Low shaft assembly (35) and clutch assembly
(41). Tighten Tooling (J) on Tooling (H) (not shown) in order to compress clutch assembly
(41). Remove two half rings (42) and two lock rings (43) from the High/Low shaft assembly
(35).
32. Carefully loosen Tooling (J) on Tooling (H) in order to relieve pressure from clutch
assembly (41). Remove Tooling (K) and Tooling (H) from High/Low shaft assembly (35)
and clutch assembly (41). The clutch assembly (41) is made up of five clutch plates, six
friction discs, and the hub assembly. Identify the position of the clutch assembly (41) for
assembly purposes.
33. Remove wave spring (45) from High/Low shaft assembly (35).
34. Remove piston (44) from High/Low shaft assembly (35).
35. Remove seal extension ring (47) and seal ring (46) from piston (42).
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36. Position High/Low shaft assembly (35), as shown. Place High/Low shaft (35) in the
modified work bench, or on blocks. The weight of High/Low shaft assembly (35) is
approximately 50 kg (110 lb).
37. Install Tooling (L) and Tooling (M) on High/Low shaft assembly (35) and inner bearing
(48). Remove inner bearing (48) from High/Low shaft assembly (35). Remove two thrust
discs (49), two bearing sleeves, and gear assembly (50) from High/Low shaft assembly (35).
38. Remove thrust disc (51) and the washer from High/Low shaft assembly (35).
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Note: Tooling (K) is the old style tool that is now modified. Tooling (K) (new style tool)
works without being modified. Tooling (K) may need to be modified so the hole in the top
of the tube will have clearance for Tooling (N).
39. Install Tooling (N) and Tooling (K) on High/Low shaft assembly (35) and clutch assembly
(52). Tighten Tooling (P) on Tooling (N) in order to compress clutch assembly (52).
Remove two half rings (53) and two lock rings (54) from the High/Low shaft assembly (35).
40. Carefully loosen Tooling (P) on Tooling (N) in order to relieve pressure from clutch
assembly (52). Remove Tooling (K) and Tooling (N) from High/Low shaft assembly (35)
and clutch assembly (52). The clutch assembly (52) is made up of eight clutch plates, seven
friction discs, and the hub assembly. Identify the position of the clutch assembly (52) for
assembly purposes.
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Note: Tooling (K) is the old style tool that must be modified. Tooling (K) (new style tool)
works without being modified. Tooling (K) may need to be modified so the hole in the top
of the tube will have clearance for Tooling (N).
41. Install Tooling (N) and Tooling (K) on High/Low shaft assembly (35) and balance piston
(55). Tighten Tooling (P) on Tooling (N) in order to compress balance piston (55).
42. Use Tooling (Q) in order to remove retaining ring (56) from High/Low shaft assembly (35).
43. Carefully loosen Tooling (P) on Tooling (N) in order to relieve pressure from balance piston
(55). Remove Tooling (K) and Tooling (N) in order to relieve pressure from High/Low shaft
assembly (35) and balance piston (55).
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44. Remove balance piston (55) and seal extension ring (57) from High/Low shaft assembly
(35).
45. Remove fifteen springs (58) from piston (59).
46. Remove piston (59), the seal extension ring (not shown), and a ring seal (not shown) from
High/Low shaft assembly (35).
47. Remove seal ring (60) and seal extension ring (61) from piston (59).
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48. Place First/Third shaft assembly (34) on the modified work bench or on blocks. Use Tooling
(F) in order to remove race and bearing (62), thrust disc (not shown), and gear assembly
(63) from First/Third shaft assembly (34).
49. Remove thrust disc (64) and gear assembly (65) from First/Third shaft assembly (34).
50. Remove the sleeve bearing (not shown), thrust disc (66), and washer (67) from First/Third
shaft assembly (34).
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51. Install Tooling (H) and Tooling (K) on First/Third shaft assembly (34) and clutch assembly
(68). Tighten Tooling (K) on Tooling (H) in order to compress clutch assembly (68).
Remove two half rings (69) and two lock rings (70) from First/Third shaft assembly (34).
52. Carefully loosen Tooling (J) on Tooling (H) in order to relieve pressure from clutch
assembly (68). Remove Tooling (K) and Tooling (H) from First/Third shaft assembly (34)
and clutch assembly (68). As you remove clutch assembly (68) from First/Third shaft
assembly (34), identify the positions of the five clutch plates, the six friction disc, and the
hub assembly for assembly purposes.
53. Remove wave spring (71) from First/Third shaft assembly (34).
54. Remove piston (72) from First/Third shaft assembly (34).
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55. Remove seal extension ring (73) and seal ring (74) from piston (72).
56. Position First/Third shaft assembly (34), as shown. Place First/Third shaft assembly (34) in
the modified work bench, or on blocks. The weight of First/Third shaft assembly (34) is
approximately 55 kg (120 lb).
57. Remove the seal ring (not shown) from First/Third shaft assembly (34).
58. Use Tooling (R) in order to remove inner bearing (75), thrust disc (not shown), gear (76),
and thrust disc (not shown).
59. Remove gear assembly (77), the bearing sleeve (not shown), the thrust disc, and the washer
(not shown) from First/Third shaft assembly (34).
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Caterpillar Cat 120H Motor Grader (Prefix ALZ) Service Repair Manual (ALZ00001 and up).pdf

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