Caterpillar Cat 120K Motor Grader (Prefix JAP) Service Repair Manual (JAP00001 and up).pdf

Service Repair Manual
Models
120K Motor Grader

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Product: MOTOR GRADER
Model: 120K MOTOR GRADER JAP
Configuration: 120K Motor Grader JAP00001-UP (MACHINE) POWERED BY C7 Engine
Disassembly and Assembly
120K and 120K Series 2 Motor Graders Power Train
Media Number -KENR8438-04 Publication Date -01/08/2018 Date Updated -09/08/2018
i05303122
Transmission - Assemble
SMCS - 3002-016; 3030-016; 3159-016
Assembly Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 5P-9736 Link Bracket 1
B 154-6181 Forcing Screw 2
C 6V-5221 Bolt 1
D 4C-8156 Lifting 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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5F-7366 Forcing Screw 1
5P-4808 Cap 2
1U-9895 Crossblock 1
M
9S-9151 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 Retaining Ring Pliers 1
R
1P-2326 Forcing Screw 1
1P-2325 Head 1
3H-0462 Bolt 4
8H-0709 Strap 4
5F-7373 Jaw 3
S 3E-3882 Eyebolt 1
T 6V-5765 Sealant 1
Note: Remove old anaerobic sealant from the bottom of the blind tapped holes in housing (11)
before assembling.
Illustration 1 g00623302
1. Lower the temperature of bearing outer races (130) . Install bearing outer races (130) to the
original locations in both transmission case assembly (3) (not shown) and the transmission
cover assembly (11) until bearing outer races (130) are seated.
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2. Install bearing retainer (128) on gear assembly (126) .
3. Heat ball bearing (127) to a maximum of 135 °C (275 °F). Install ball bearing (127) to the
original location on gear assembly (126) .
4. Use Tooling (Q) in order to install snap ring (129) to the original location on gear assembly
(126) .
5. Install gear assembly (126) to the original location in the transmission cover assembly (11) .
6. Install two bolts (not shown) on the gear assembly (126) .
7. Install four bolts (125) in the gear assembly (126) . Tighten bolts (125) to a torque of 28 ± 7
N·m (21 ± 5 lb ft).
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8. Install the cup plug (not shown) in input shaft assembly (65) .
9. Install gear (124) on Input shaft assembly (65) .
10. Heat inner bearing (123) to a maximum of 135 °C (275 °F). Install inner bearing (123) on
Input shaft assembly (65) until inner bearing (123) is seated. Gear (124) should be tight on
input shaft assembly (65) .
11. Install two seal rings (122) to the original locations on Input shaft assembly (65) .
12. Install Tooling (S) to Input shaft assembly (65) . Use a hoist in order to position Input shaft
assembly (65) to the original location in the transmission case assembly (11) . Install Input
shaft assembly (65) in the transmission case assembly (11) . Remove Tooling (S) from Input
shaft assembly (65) .
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13. Install seal rings (121) on piston (120) . Install both seal rings (121) with the sealing lips
facing toward the small diameter of piston (120) .
14. Place Forward shaft assembly (95) in the modified work bench or on blocks. Apply a light
coat of clean hydraulic oil on seal rings (121) . Install piston (120) at the original location on
Forward shaft assembly (95) . Slightly rotate piston (120) while the seal is being installed.
Ensure that the seal rings (121) are installed properly.
15. Install valve assembly (119) to the original location on Forward shaft assembly (95) .
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16. Install six clutch plates (117) and seven friction discs (118) in the original order on hub
assembly (115) . The splines on hub assembly (115) must align with the splines on the
friction discs (118) .
17. Install spring (116) in the original location on Forward shaft assembly (95) .
18. As one unit, install hub assembly (115) , six clutch plates (117) and seven friction discs
(118) to the original location on Forward shaft assembly (95) .
19. Use a second person in order to manually compress clutch assembly (113) on spring (116) .
20. Install two half rings (114) in the Forward shaft assembly (95) .
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21. Install the washer and thrust disc (112) to the original locations on Forward shaft assembly
(95) .
22. Install gear assembly (110) on Forward shaft assembly (95) and over clutch assembly
(113) . Align the spline teeth on the outer diameter of the clutch plates (117) with the splines
on the inside of gear assembly (110) . Ensure that gear assembly (110) is completely down
over the clutch assembly (113) .
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23. Install roller bearing (111) to the original location on Forward shaft assembly (95) .
24. Install two thrust discs (131) and thrust race (132) on Forward shaft assembly (95) . The
thrust discs (131) should not spin the thrust race (132) .
Forward shaft assembly (95) until inner bearing (109) contacts the bearing race.
26. Position Forward shaft assembly (95) , as shown. The weight of Forward shaft assembly
(95) is approximately 43 kg (95 lb). Place Forward shaft assembly (95) in the modified
work bench or blocks.
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27. Install lip seals (108) in piston (107) . Install lip seals (108) with the sealing lip toward the
small diameter of piston (107) .
28. Apply a light coat of clean hydraulic oil on lip seals (108) .
29. Install piston (107) to the original location on Forward shaft assembly (95) . Rotate the
piston slightly while the seal is being installed. Ensure that the lip seals are installed
properly.
30. Install valve assembly (106) to the original location on Forward shaft assembly (95) .
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Note: Friction discs 1 and 7 are different from the remaining discs. Assemble friction discs
(1) and (7) with the grooved pattern toward the center of the clutch pack.
31. Install six clutch plates (105) and seven friction discs (103) in the original order on hub
assembly (102) . The splines on hub assembly (102) must align with the splines on the
friction plates.
32. Install spring (104) to the original location on Forward shaft assembly (95) .
33. As one unit, install hub assembly (102) , six clutch plates (105) , and seven friction discs
(103) to the original location on Forward shaft assembly (95) .
34. Use two people to manually compress hub assembly (100) on spring (94) . Install two half
rings (101) in Forward shaft assembly (95) .
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35. Install thrust disc and washer (99) on Forward shaft assembly (95) . The thrust disc should
not spin the washer.
36. Install gear assembly (97) on Forward shaft assembly (95) and over clutch assembly (100) .
Align the spline teeth on the outer diameter of the clutch plates with the splines on the
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inside of gear assembly (97) . Ensure that the gear assembly (97) is completely down over
hub assembly (102) .
37. Install roller bearing (98) to the original location on Forward shaft assembly (95) .
38. Install the two thrust discs on Forward shaft assembly (95) .
39. Heat bearing (96) to a maximum of 132 °C (270 °F). Install bearing (96) on Forward shaft
assembly (95) until bearing (96) contacts the bearing race.
40. Install Tooling (S) in Forward shaft assembly (95) . Install Forward shaft assembly (95) to
the original location in the transmission cover assembly (11) . The weight of Forward shaft
assembly (95) is approximately 63.6 kg (140 lb). Remove Tooling (S) .
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41. Install the cup plug (not shown) from Reverse/Second shaft assembly (68) .
42. Install seals (93) and (94) with the sealing lip toward the small diameter of piston (92) .
43. Place Reverse/Second shaft assembly (68) in the modified work bench, or on blocks. Apply
a light coat of clean hydraulic oil on the lip seals. Install piston (92) to the original location
on Reverse/Second shaft assembly (68) . Rotate the piston slightly while the seal is being
installed. Ensure that the lip seals are installed properly.
44. Install valve assembly (91) to the original location on Reverse/Second shaft assembly (68) .
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45. Install six clutch plates (88) and seven friction disc (90) in the original order on hub
assembly (87) . The splines on the hub assembly (87) must align with the splines on the
friction discs (90) .
46. Install spring (89) in the original location on Reverse/Second shaft assembly (68) .
47. As one unit, install hub assembly (87) , six clutch plates (88) , and seven friction discs (90)
to the original location on Reverse/Second shaft assembly (68) .
48. Use two people to manually compress clutch plate (85) on spring (89) . Install two half rings
(86) in Reverse/Second shaft assembly.
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49. Install the washer and thrust disc (84) to the original locations on Reverse/Second shaft
assembly (68) . The thrust disc should not spin the washer.
50. Install gear assembly (82) on Reverse/Second shaft assembly (68) . Align the spline teeth on
the outer diameter of the clutch plates with the splines on the inside of gear assembly (82) .
Ensure that the gear assembly (82) is completely down over the clutch assembly (85) .
51. Install roller bearing (83) to the original location on Reverse/Second shaft assembly (68) .
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52. Install two thrust discs and one thrust race (133) .
Reverse/Second shaft assembly (68) until inner bearing (81) contacts the bearing race. The
thrust disc should not spin.
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54. Position Reverse/Second shaft assembly (68) , as shown. The weight of Reverse/Second
shaft assembly (68) is approximately 41 kg (90 lb). Place Reverse/Second shaft assembly
(68) in the modified work bench or on blocks.
55. Apply a light coat of clean hydraulic oil on the lip seals. Install lip seals (79) and (80) in
piston (78) . Install lip seals (79) and (80) with the sealing lip toward the small diameter of
the piston (78) . Rotate the piston slightly while the seal is being installed.
56. Install piston (78) to the original location on Reverse/Second shaft assembly (68) . Ensure
that the lip seals are installed properly.
57. Install wave spring (77) on Reverse/Second shaft assembly (68) .
58. Install clutch assembly (74) on Reverse/Second shaft assembly (68) . Position the three
clutch plates, the four friction disc, and the hub assembly in the original locations on
Reverse/Second shaft assembly (68) .
59. Install Tooling (K) and Tooling (H) on Reverse/Second shaft assembly (68) . Tighten
Tooling (J) on Tooling (H) in order to compress clutch assembly (74) . Install two half rings
(75) and two lock rings (76) in Reverse/Second shaft assembly (68) .
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60. Carefully loosen Tooling (J) on Tooling (H) in order to relieve pressure from clutch
assembly (74) . Remove Tooling (H) and Tooling (K) from clutch assembly (74) .
61. Install the thrust disc and the washer on Reverse/Second shaft assembly (68) .
62. Install the sleeve bearing (not shown) on Reverse/Second shaft assembly (68) .
63. Install gear assembly (73) on Reverse/Second shaft assembly (68) . Align the spline teeth on
the outer diameter of the clutch plates with the splines on the inside of gear assembly (73) .
Ensure that gear assembly (73) is down over the clutch assembly completely.
64. Install the thrust disc (not shown) and spacer (72) to the original locations on
Reverse/Second shaft assembly (68) .
65. Install gear (71) on Reverse/Second shaft assembly (68) .
66. Install spacer (70) on Reverse/Second shaft assembly (68) .
67. Heat bearing (69) to a maximum of 132 °C (270 °F). Install bearing (69) on Reverse/Second
shaft assembly (68) until bearing (69) contacts spacer (70) . Spacer (70) should not spin.
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68. Install Tooling (S) in Reverse/Second shaft assembly (68) . Place Reverse/Second shaft
assembly (68) to the original location in the transmission case assembly (11) . The weight of
Reverse/Second shaft assembly (68) is approximately 64 kg (141 lb). Remove Tooling (S) .
69. Install gear (67) to the original location on Input shaft assembly (65) .
Input shaft assembly (65) until inner bearing (66) contacts gear (67) . Gear (67) should be
tight on input shaft assembly (65) .
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71. Install seal extension ring (63) and seal ring (64) on piston (62) . Install seal (63) and seal
(64) with the sealing lips toward the small diameter of the piston (62) . Apply a light coat of
clean hydraulic oil on the lip seals of piston (62) .
72. Place First/Third shaft assembly (14) in the modified work bench, or on blocks. Install
piston (62) to the original location on First/Third shaft assembly (14) . Rotate the piston (62)
slightly while the seal is being installed. Ensure that the lip seals are installed properly.
73. Install wave spring (61) to the original location on First/Third shaft assembly (14) .
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74. As you install clutch assembly (58) to First/Third shaft assembly (14) , position the three
clutch plates, four friction disc and the hub assembly to the original locations on First/Third
shaft assembly (14) .
75. Install Tooling (K) and Tooling (H) on First/Third shaft assembly (14) . Tighten Tooling (J)
on Tooling (H) in order to compress clutch assembly (58) . Install two half rings (59) and
two lock rings (60) to First/Third shaft assembly (14) .
76. Carefully loosen the nut on Tooling (J) in order to relieve pressure from clutch assembly
(58) . Remove Tooling (K) and Tooling (H) .
77. Install the washer, the thrust disc, and the bearing sleeve to the original locations on
First/Third shaft assembly (14) .
78. Install gear assembly (57) in the original location on First/Third shaft assembly (14) and
over clutch assembly (58) . Align the spline teeth on the outer diameter of the clutch plates
with the splines on the inside of gear assembly (57) . Ensure that the gear assembly (57) is
completely down over clutch assembly (58) .
79. Install the thrust disc that was under gear (56) to the original location on First/Third shaft
assembly (14) .
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Caterpillar Cat 120K Motor Grader (Prefix JAP) Service Repair Manual (JAP00001 and up).pdf

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Caterpillar Cat 120K Motor Grader (Prefix JAP) Service Repair Manual (JAP00001 and up).pdf