Caterpillar Cat 12H ES MOTOR GRADER (Prefix 2GS) Service Repair Manual Instant Download.pdf

Service Repair Manual
Models
12H ES MOTOR GRADER

Shutdown SIS
Previous Screen
Product: MOTOR GRADER
Model: 12H ES MOTOR GRADER 2GS
Configuration: 12H Motor Grader 2GS00001-UP (MACHINE) POWERED BY 3306 Engine
Disassembly and Assembly
12H, 140H and 160H Motor Graders Power Train
Media Number -SENR8548-14 Publication Date -01/10/2011 Date Updated -12/10/2011
i01973878
Transmission - Disassemble
SMCS - 3030-015
Disassembly Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 138-7575 Link Bracket 1
B 154-6181 Forcing Screw 2
C 6V-5221 Bolt 1
D 4C-8156 Fixture 1
E 6V-3918 Bolt 1
F 4C-8157 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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12H Motor Grader 2GS00001-UP (MACHINE) POWERED BY 3306 Engine(SEBP2...
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https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis...

5F-7366 Screw 1
5P-4808 Cap 2
1U-9895 Crossblock 1
M
9S-9151 Block 2
1B-4206 Nut 4
8B-7552 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
S 3E-3882 Eyebolt 1
Start By:
a. Remove the transmission control valve. Refer to Disassembly and Assembly, "Transmission
Control Valve - Remove".
b. Remove the parking brake. Refer to Disassembly and Assembly, "Parking Brake -
Remove".
c. Remove the transmission speed sensor.
d. Remove the transmission oil pump. Refer to Disassembly and Assembly, "Gear Pump
(Transmission Charging and Scavenge) - Remove".
e. Remove the transmission magnetic screen base. Refer to Disassembly and Assembly,
"Magnetic Screen - Remove and Install".
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Illustration 1 g00623100
1. Place transmission (1) level on the floor.
2. Remove 12 bolts (2), four covers, and the O-ring seals from transmission case assembly (3).
3. Remove 41 bolts (4) from the transmission case assembly (3).
Note: Identify the location of seal carrier (5) in the transmission case assembly (3) for
assembly purposes.
4. Remove two bolts (6) from seal carrier (5).
5. Install Tooling (A) (not shown) in seal carrier (5). Remove seal carrier (5) and the three ring
seals from the transmission case assembly bore (7).
6. Repeat Step 4 through Step 5 on the three remaining seal carriers (5).
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7. Remove seal rings (9) from seal carrier (5).
8. Remove three or four seals (8) from seal carrier (5).
9. Remove spring pin (10) from seal carrier (5).
10. Repeat Step 7 and Step 9 for the remaining three seal carriers (5).
11. Install Tooling (B) in the transmission case assembly (3). Tighten Tooling (B) evenly to
separate transmission case assembly (3) from transmission cover assembly (11).
12. Attach Tooling (A) to transmission case assembly (3). Position a lifting device to Tooling
(A). Secure the lifting device to a hoist. Slowly raise the transmission case assembly (3)
from the transmission cover assembly (11). Be careful not to bind the transmission case
assembly (3) during separation.
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13. Remove three bolts (12) from tube assembly (13). Remove tube assembly (13) from the
transmission cover assembly (11).
14. Remove the O-ring seal from tube assembly (13).
Note: First/Third shaft assembly (14) and High/Low shaft assembly (15) must be removed
together.
15. Install Tooling (D) on First/Third shaft assembly (14) and High/Low shaft assembly (15).
Use Tooling (C) and Tooling (E) in order to hold Tooling (D) on First/Third shaft assembly
(14) and High/Low shaft assembly (15), as shown. First/Third shaft assembly (14) and
High/Low shaft assembly (15) must be removed together.
16. Attach a suitable lifting device to Tooling (D). Carefully remove First/Third shaft assembly
(14) and High/Low shaft assembly (15) from the transmission cover assembly (11). The
weight of the two shaft assemblies is 177 kg (390 lb).
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17. Place First/Third shaft assembly (14) and High/Low shaft assembly (15) on Tooling (F) or
on blocks and remove Tooling (D). Carefully separate First/Third shaft assembly (14) and
High/Low shaft assembly (15). The weight of each shaft assembly is 89 kg (195 lb).
Note: Place High/Low shaft (15) 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.
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Note: Do not attach Tooling (G) to rotor (17). If pressure is applied to rotor (17) with
Tooling (G), rotor (17) will brake. Attach the Tooling (G) to gear assembly (18).
18. With High/Low shaft assembly (15) on the modified work bench or on blocks, use Tooling
(G) in order to remove race and bearing (16), rotor (17), gear assembly (18), and two sleeve
bearings (not shown) from High/Low shaft assembly (15). Press fit Bearing (16) and rotor
(17) on High/Low shaft assembly (15).
19. Remove bearing (16), rotor (17), thrust disc (19), and gear assembly (18) from High/Low
shaft assembly (15). Attach Tooling (G) to gear assembly (18). Do not attach Tooling (G) to
rotor (17).
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20. Remove thrust disc (20) and the washer from High/Low shaft assembly (15).
21. Install Tooling (H) and Tooling (K) on High/Low shaft assembly (15) and clutch assembly
(21). Tighten Tool (J) on Tooling (H) (not shown) in order to compress clutch assembly
(21). Remove two half rings (22) and two lock rings (23) from the High/Low shaft assembly
(15).
22. Carefully loosen Tool (J) on Tooling (H) in order to relieve pressure from clutch assembly
(21). Remove Tooling (K) and Tooling (H) from High/Low shaft assembly (15) and clutch
assembly (21). The clutch assembly (21) is made up of five clutch plates, six friction discs,
and the hub assembly. Identify the position of the clutch assembly (21) for assembly
purposes.
23. Remove wave spring (25) from High/Low shaft assembly (15).
24. Remove piston (24) from High/Low shaft assembly (15).
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25. Remove seal extension ring (27) and seal ring (26) from piston (22).
26. Position High/Low shaft assembly (15), as shown. Place High/Low shaft (15) in the
modified work bench, or on blocks. The weight of High/Low shaft assembly (15) is 50 kg
(110 lb).
27. Install Tooling (L) and Tooling (M) on High/Low shaft assembly (15) and inner bearing
(28). Remove inner bearing (28) from High/Low shaft assembly (15). Remove two thrust
discs (29), two bearing sleeves, and gear assembly (30) from High/Low shaft assembly (15).
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28. Remove thrust disc (31) and the washer from High/Low shaft assembly (15).
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).
29. Install Tooling (N) and Tooling (K) on High/Low shaft assembly (15) and clutch assembly
(32). Tighten Tooling (P) on Tooling (N) in order to compress clutch assembly (32).
Remove two half rings (33) and two lock rings (34) from the High/Low shaft assembly (15).
30. Carefully loosen Tooling (P) on Tooling (N) in order to relieve pressure from clutch
assembly (32). Remove Tooling (K) and Tooling (N) from High/Low shaft assembly (15)
and clutch assembly (32). The clutch assembly (32) is made up of eight clutch plates, seven
friction discs, and the hub assembly. Identify the position of the clutch assembly (32) for
assembly purposes.
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).
31. Install Tooling (N) and Tooling (K) on High/Low shaft assembly (15) and balance piston
(35). Tighten Tooling (P) on Tooling (N) in order to compress balance piston (35).
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12H Motor Grader 2GS00001-UP (MACHINE) POWERED BY 3306 Engine(SEB...
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32. Use Tooling (Q) in order to remove retaining ring (36) from High/Low shaft assembly (15).
33. Carefully loosen Tooling (P) on Tooling (N) in order to relieve pressure from balance piston
(35). Remove Tooling (K) and Tooling (N) in order to relieve pressure from High/Low shaft
assembly (15) and balance piston (35).
34. Remove balance piston (35) and seal extension ring (37) from High/Low shaft assembly
(15).
35. Remove 15 springs (38) from piston (39).
36. Remove piston (39), the seal extension ring (not shown), and a ring seal (not shown) from
High/Low shaft assembly (15).
37. Remove seal ring (40) and seal extension ring (41) from piston (39).
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38. Place First/Third shaft assembly (14) on the modified work bench or on blocks. Use Tooling
(F) in order to remove race and bearing (42), thrust disc (not shown), and gear assembly
(43) from First/Third shaft assembly (14).
39. Remove thrust disc (44) and gear assembly (45) from First/Third shaft assembly (14).
40. Remove sleeve bearing (not shown), thrust disc (46) and washer (47) from First/Third shaft
assembly (14).
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41. Install Tooling (H) and Tooling (K) on First/Third shaft assembly (14) and clutch assembly
(48). Tighten Tooling (K) on Tooling (H) in order to compress clutch assembly (48).
Remove two half rings (49) and two lock rings (50) from First/Third shaft assembly (14).
42. Carefully loosen Tooling (J) on Tooling (H) in order to relieve pressure from clutch
assembly (48). Remove Tooling (K) and Tooling (H) from First/Third shaft assembly (14)
and clutch assembly (48). As you remove clutch assembly (48) from First/Third shaft
assembly (14), identify the positions of the five clutch plates, the six friction disc, and the
hub assembly for assembly purposes.
43. Remove wave spring (51) from First/Third shaft assembly (14).
44. Remove piston (52) from First/Third shaft assembly (14).
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46. Position First/Third shaft assembly (14), as shown. Place First/Third shaft assembly (14) in
the modified work bench, or on blocks. The weight of First/Third shaft assembly (14) is
55 kg (120 lb).
47. Remove the seal ring (not shown) from First/Third shaft assembly (14).
48. Use Tooling (R) in order to remove inner bearing (55), thrust disc (not shown), gear (56),
and thrust disc (not shown).
49. Remove gear assembly (57), the bearing sleeve (not shown), the thrust disc, and the washer
(not shown) from First/Third shaft assembly (14).
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50. Install Tooling (K) and Tooling (H) on First/Third shaft assembly (14) and clutch assembly
(58). Tighten Tooling (J) on Tooling (H) in order to compress clutch assembly (58).
Remove two half rings (59) and two lock rings (60) from the First/Third shaft assembly
(14).
assembly (58). Remove Tooling (H) and Tooling (K) from First/Third shaft assembly (14)
and clutch assembly (58). As you remove clutch assembly (58) from First/Third shaft
assembly (14), identify the position of the three clutch plates, four friction disc, and the hub
assembly for assembly purposes.
52. Remove wave spring (61) from First/Third shaft assembly (14).
53. Remove piston (62) from First/Third shaft assembly (14).
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55. Use Tooling (R) in order to remove inner bearing (66) and gear (67) from input shaft
assembly (65). This is necessary at this time in order to remove the remaining two shaft
assemblies.
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56. Install Tooling (S) and remove Reverse/Second shaft assembly (68) from the transmission
cover assembly (11). The weight of Reverse/Second shaft assembly (68) is 64 kg (140 lb).
57. Place Reverse/Second shaft assembly (68) on the modified work bench, or on blocks.
58. Use Tooling (R) in order to remove race and bearing (69), spacer (70), and gear (71) from
Reverse/Second shaft assembly (68).
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59. Remove spacer (72) and thrust disc (not shown) from Reverse/Second shaft assembly (68).
60. Remove gear assembly (73), the sleeve bearing (not shown), the thrust disc (not shown),
and the washer (not shown) from Reverse/Second shaft assembly (68).
61. Install Tooling (K) and Tooling (H) on Reverse/Second shaft assembly (68) and clutch
assembly (74). Tighten Tooling (J) on Tooling (H) in order to compress clutch assembly
(74). Remove two half rings (75) and two lock rings (76) from Reverse/Second shaft
assembly (68).
assembly (74). Remove Tooling (H) and Tooling (K) from Reverse/Second shaft assembly
(68) and clutch assembly (74). As you remove clutch assembly (74) from Reverse/Second
shaft assembly (68), identify the positions of the three clutch plates, four friction disc and
the hub assembly for assembly purposes.
63. Remove wave spring (77) from Reverse/Second shaft assembly (68).
64. Remove piston (78) from Reverse/Second shaft assembly (68).
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65. Remove seal ring (80) and seal extension ring (79) from piston (78).
66. Position Reverse/Second shaft assembly (68), as shown. The weight of Reverse/Second
shaft assembly (68) is 41 kg (90 lb).
67. Place Reverse/Second shaft assembly (68) on the modified work bench, or on blocks.
68. Install Tooling (L) and Tooling (M) on gear assembly (82) and Reverse/Second shaft
assembly (68).
69. Remove inner bearing (81), the thrust race (not shown), the two thrust discs (not shown),
and gear assembly (82) from Reverse/Second shaft assembly (68).
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70. Remove roller bearing (83) from Reverse/Second shaft assembly (68).
71. Remove thrust disc and washer (84) from Reverse/Second shaft assembly (68).
72. Use a second person in order to compress clutch assembly (85).
73. Remove two half rings (86) from Reverse/Second shaft assembly (68). Release the pressure
from clutch assembly (85) slowly, until the spring (89) underneath clutch assembly (85) is
extended and relaxed.
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74. Remove hub assembly (87) from Reverse/Second shaft assembly (68).
75. Remove spring (89) from Reverse/Second shaft assembly (68).
76. As you remove clutch plates (88) and friction discs (90), identify the locations of clutch
plates (88) and friction discs (90) for installation purposes. Remove six clutch plates (88)
and seven friction disc (90) from Reverse/Second shaft assembly (68).
77. Remove valve assembly (91) from Reverse/Second shaft assembly (68).
78. Remove piston (92) from Reverse/Second shaft assembly (68).
79. Remove seal ring (93) and (94) from piston (92).
80. Remove the cup plug (not shown) from Reverse/Second shaft assembly (68).
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81. Install Tooling (S) in Forward shaft assembly (95). Remove Forward shaft assembly (95)
from the transmission cover assembly (11). The weight of Forward shaft assembly (95) is
64 kg (140 lb).
82. Place Forward shaft assembly (95) on the modified work bench, or on blocks. Install
Tooling (L) and Tooling (M) to Forward shaft assembly (95) and gear assembly (97).
83. Remove race and bearing (96), two thrust disc (not shown), and gear assembly (97) from
Forward shaft assembly (95).
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84. Remove roller bearing (98) from Forward shaft assembly (95).
85. Remove the thrust disc and washer (99) from Forward shaft assembly (95).
87. Remove two half rings (101) from Forward shaft assembly (95). Release the pressure from
clutch assembly (100) slowly, until the spring (104) underneath clutch assembly (100) is
extended and relaxed.
88. Remove hub assembly (102) from Forward shaft assembly (95).
89. Remove spring (104) from Forward shaft assembly (95).
90. Remove six clutch plates (105) and seven friction disc (103) from Forward shaft assembly
(95). Identify the positions of the clutch plates (105) and friction discs (103) for assembly
purposes.
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91. Remove valve assembly (106) from Forward shaft assembly (55).
92. Remove piston (107) from Forward shaft assembly (95).
93. Remove two seal rings (108) from piston (107).
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94. Position Forward shaft assembly (95), as shown. The weight of Forward shaft assembly (95)
is 43 kg (95 lb). Place Forward shaft assembly (95) in the modified work bench or on
blocks.
95. Install Tooling (L) and Tooling (M) to Forward shaft assembly (95) and gear assembly
(110).
96. Remove inner bearing (109), the thrust race (not shown), the two thrust disc (not shown),
and gear assembly (110) from Forward shaft assembly (95).
97. Remove roller bearing (111) from Forward shaft assembly (95).
98. Remove the thrust disc and washer (112) from Forward shaft assembly (95).
100. Remove two half rings (114) from Forward shaft assembly (95).
101. Release the pressure from clutch assembly (113) slowly, until the spring (116) underneath
clutch assembly (113) is extended and relaxed.
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102. Remove hub assembly (115) from Forward shaft assembly (95).
103. Remove spring (116) from Forward shaft assembly (95).
104. Remove six clutch plates (117) and seven friction discs (118) from Forward shaft assembly
(95). Identify the positions of the clutch plates (117) and friction disc (118) for assembly
purposes.
105. Remove valve assembly (119) from Forward shaft assembly (95).
106. Remove piston (120) from Forward shaft assembly (95).
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107. Remove two seal rings (121) from piston (120).
108. Remove the cup plug (not shown) from Forward shaft assembly (95).
109. Install Tooling (S) in Input shaft assembly (65). Remove Input shaft assembly (65) from the
transmission cover assembly (11). The weight of Input shaft assembly (65) is 23 kg (50 lb).
110. Remove two seal rings (122) from Input shaft assembly (65).
111. Remove inner bearing (123) and gear (124) from Input shaft assembly (65).
112. Remove the cup plug (not shown) from input shaft assembly (65).
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113. Remove four bolts (125) from gear assembly (126). Rotate gear assembly (126) in order to
locate the two bolts (not shown).
114. Remove gear assembly (126) from the transmission cover assembly (11).
115. Position gear assembly (126), as shown. Use Tooling (Q) to remove snap ring (129) from
gear assembly (126).
116. Position gear assembly (126) to the opposite side. In order to drive ball bearing (127) off
gear assembly (126), push a small driver through three small holes (not shown).
117. Remove ball bearing (127) from bearing retainer (128).
Note: This is a slip fit.
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118. Remove five bearing outer races (130) from the transmission cover assembly (11).
119. Repeat Step 118 for transmission case assembly (3).
Copyright 1993 - 2021 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Mon Jan 25 21:00:42 UTC+0800 2021
29/29
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Shutdown SIS
Previous Screen
Product: MOTOR GRADER
Model: 12H ES MOTOR GRADER 2GS
Configuration: 12H Motor Grader 2GS00001-UP (MACHINE) POWERED BY 3306 Engine
Disassembly and Assembly
12H, 140H and 160H Motor Graders Power Train
Media Number -SENR8548-14 Publication Date -01/10/2011 Date Updated -12/10/2011
i05303122
Transmission - Assemble
SMCS - 3030-016
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
1/35
2021/1/25

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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.
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.
2/35
2021/1/25

Caterpillar Cat 12H ES MOTOR GRADER (Prefix 2GS) Service Repair Manual Instant Download.pdf

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