Caterpillar Cat 12H NA Motor Grader (Prefix 4XM) Service Repair Manual Instant Download.pdf

Service Repair Manual
Models
12H NA MOTOR GRADER

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Product: MOTOR GRADER
Model: 12H NA MOTOR GRADER 4XM
Configuration: 12H Motor Grader 4XM00001-UP (MACHINE) POWERED BY 3306B 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
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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
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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80. Install gear (56) to the original location on First/Third shaft assembly (14) . Install the thrust
disc that was on top of gear (56) .
First/Third shaft assembly (14) until inner bearing (55) contacts gear (56) . The thrust disc
that is under inner bearing (55) should not spin.
82. Install seal extension ring (53) and seal ring (54) on piston (52) . Install seal extension ring
(53) and seal ring (54) with the sealing lips toward the small diameter of the piston (52) .
Apply a light coat of hydraulic oil on the lip seals.
83. Rotate First/Third shaft assembly (14) in order to assemble the other end. The weight of
First/Third shaft assembly (14) is approximately 55 kg (121 lb). Place the First/Third shaft
assembly (14) on the modified work bench, or on blocks. Install piston (52) to the original
location on First/Third shaft assembly (14) . Rotate the piston slightly while the seal is being
installed. Ensure that the lip seals are installed properly.
84. Install wave spring (51) to the original location on First/Third shaft assembly (14) .
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85. As you install clutch assembly (48) to First/Third shaft assembly (14) , position the five
clutch plates, six friction disc and the hub assembly to the original locations on First/Third
86. Install Tooling (H) and Tooling (K) on First/Third shaft assembly (14) . Tighten Tooling (J)
on Tooling (H) in order to compress clutch assembly (48) . Install two half rings (49) and
two lock rings (50) on First/Third shaft assembly (14) .
assembly (48) . Remove Tooling (K) and Tooling (H) .
88. Install washer (47) and thrust disc (46) to the original locations on First/Third shaft
assembly (14) .
89. Install the sleeve bearing on First/Third shaft assembly (14) .
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90. Install gear assembly (45) in the original location on First/Third shaft assembly (14) . Install
gear assembly (45) on First/Third shaft assembly (14) . Align the spline teeth on the outer
diameter of the clutch plates with the splines on the inside of gear assembly (45) . Ensure
that the gear assembly (45) is completely down over the clutch assembly.
91. Install thrust disc (44) on First/Third shaft assembly (14) .
92. Install gear assembly (43) on First/Third shaft assembly (14) .
93. Install the thrust disc that was under bearing (42) on First/Third shaft assembly (14) . Heat
bearing (42) to a maximum of 132 °C (270 °F). Install bearing (42) on First/Third shaft
assembly (14) until bearing (42) contacts gear assembly (43) . Thrust disc should not spin.
94. Install Tooling (S) (not shown) in First/Third shaft assembly (14) and place First/Third shaft
assembly (14) aside. The weight of First/Third shaft assembly (14) is approximately 89 kg
(196 lb).
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95. Install seal ring (40) and seal extension ring (41) on piston (39) . Install seal ring (40) and
seal extension ring (41) with the sealing lip toward the small diameter of piston (39) .
96. Place High/Low shaft assembly (15) in the modified work bench or on blocks. Apply a light
coat of hydraulic oil on the lip seals. Install piston (39) to the original location on High/Low
shaft assembly (15) . Ensure that seal ring (40) , and seal extension ring (41) are installed
properly.
97. Install 15 springs (38) in the recess pockets in piston (39) .
98. Install one lip seal (37) on balance piston (39) .
99. Install balance piston (35) on High/Low shaft assembly (15) and in piston (39) . Ensure that
the guides that are located on balance piston (35) are placed in the center of each spring
(38) .
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100. Install Tooling (K) and Tooling (N) on High/Low shaft assembly (15) and balance piston
(35) . Tighten Tooling (P) on Tooling (N) in order to compress balance piston (35) . Rotate
balance piston (35) slightly while the seal is being installed.
101. Use Tooling (Q) in order to install retaining ring (36) to High/Low shaft assembly (15) .
102. Carefully loosen Tooling (P) on Tooling (N) in order to relieve pressure from balance piston
(35) . Remove Tooling (B) from balance piston (35) and High/Low shaft assembly (15) .
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103. Install the clutch assembly (32) to the original locations on High/Low shaft assembly (15) .
The clutch assembly (32) includes seven friction discs, eight clutch plates, and the hub
assembly.
104. Install Tooling (K) and Tooling (N) on High/Low shaft assembly (15) and clutch assembly
(32) . Tighten Tooling (P) on Tooling (N) in order to compress clutch assembly (32) .
105. Install two lock rings (34) and two half rings (33) to High/Low shaft assembly (15) .
106. Carefully loosen Tooling (P) on Tooling (N) in order to relieve pressure from clutch
assembly (32) . Remove Tool (K) and Tooling (N) from High/Low shaft assembly (15) and
clutch assembly (32) .
107. Install thrust disc and washer (31) to the original locations on High/Low shaft assembly
(15) .
108. Install gear assembly (30) in the original location on High/Low shaft assembly (15) . Install
gear assembly (30) on High/Low shaft assembly (15) . Align the spline teeth on the outer
diameter of the clutch plates with the splines on the inside of gear assembly (30) . Ensure
that gear assembly (30) is completely down over clutch assembly.
109. Install two thrust discs (29) and the two bearing sleeves on High/Low shaft assembly (15) .
110. Heat inner bearing (28) to a maximum of 132 °C (270 °F). Install inner bearing (28) on the
High/Low shaft assembly (15) until the inner bearing (28) contacts the thrust disc.
111. The thrust disc (29) should not spin.
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112. Install seal extension ring (27) and seal ring (26) on piston (24) . Install seal extension ring
(27) and seal ring (26) with the sealing lips toward the small diameter of the piston (24) .
Apply a light coat of hydraulic oil on seal extension ring (27) and seal ring (26) .
113. Position High/Low shaft assembly (15) , as shown. The weight of the High/Low shaft
assembly (15) is 50 kg (110 lb). Place High/Low shaft assembly (15) on the modified work
bench, or on blocks. Install piston (24) to the original location on High/Low shaft assembly
(15) . Rotate the piston (24) slightly while the seal is being installed. Ensure that the seal
extension ring (27) and seal ring (26) are installed properly.
114. Install wave spring (25) to the original location on High/Low shaft assembly (15) .
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115. As you install clutch assembly (21) to High/Low shaft assembly (15) , position the five
clutch plates, six friction discs, and the hub assembly to the original locations on High/Low
116. Install Tooling (K) and Tooling (H) on High/Low shaft assembly (15) and clutch assembly
(21) . Tighten Tooling (J) on Tooling (H) in order to compress clutch assembly (21) .
117. Install two half rings (22) and two lock rings (23) to High/Low shaft assembly (15) .
assembly (21) . Remove Tooling (H) and Tooling (K) from High/Low shaft assembly (15)
and clutch assembly (21) .
119. Install the thrust disc, the two sleeve bearings and washer (20) to the original locations on
High/Low shaft assembly (15) .
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120. Install gear assembly (18) , align the internal spline of the cylinder welded to the external
teeth of the clutch. Ensure that gear assembly (18) is completely down over clutch assembly
(23) .
121. Install thrust disc (19) that was under rotor (17) to High/Low shaft assembly (15) . Heat
rotor (17) to a maximum of 135 °C (275 °F). Install rotor (17) to High/Low shaft assembly
(15) until rotor (17) makes contact with the shoulder of shaft assembly (15) . Ensure that
rotor (17) is completely down against the shoulder of shaft assembly (15) . Thrust disc (19)
should spin freely.
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122. Heat bearing (16) to a maximum of 135 °C (275 °F). Install bearing (16) to High/Low shaft
assembly (15) until bearing (16) makes contact with rotor (17) .
123. Install Tooling (F) in High/Low shaft assembly (15) and place High/Low shaft assembly
(15) next to First/Third shaft assembly (14) and in Tooling (F) . The weight of High/Low
shaft assembly (15) is approximately 89 kg (195 lb). The use of Tooling (F) will hold
First/Third shaft assembly (14) and High/Low shaft assembly (15) to the proper height of
the gear mesh. This will allow Tooling (D) to be installed properly. Slide the two shafts
together until the gear mesh is obtained.
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124. Use Tooling (C) and Tooling (E) to install Tooling (D) on First/Third shaft assembly (14)
and High/Low shaft assembly (15) . First/Third shaft assembly (14) and High/Low shaft
assembly (15) must be installed in the transmission cover assembly (11) together.
125. Attach a suitable lifting device to Tooling (D) . Carefully install First/Third shaft assembly
(14) and High/Low shaft assembly (15) to the original locations in the transmission case
assembly. The weight of the two shaft assemblies is 177 kg (390 lb).
126. Position tube assembly (13) and the O-ring (not shown) to the original locations in the
transmission case assembly. Install three bolts (12) to secure tube assembly (13) to the
transmission case assembly. Tighten bolts (12) to a torque of 55 ± 10 N·m (40 ± 7 lb ft).
127. Clean the flanges of both halves of the transmission cover assembly (11) and the
transmission case assembly (3) . Apply a 3.0 mm (0.12 inch) bead of Tooling (T) to the joint
between transmission case assembly (3) and transmission cover assembly (11) .
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Note: Remove Tooling (B) from transmission cover assembly (11) .
128. Attach Tooling (A) and a suitable lifting device to the transmission cover assembly (11) .
Carefully install the transmission cover assembly (11) to the transmission case assembly
(3) . Be careful not to bind on the locating pins during the installation.
129. Install spring pin (10) in seal carrier (5) .
130. Install three seal rings (9) on seal carrier (5) .
131. Install O-ring seals (8) in seal carriers (5) .
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132. Install Tooling (A) (not shown) in seal carrier (5) . Carefully install seal carrier (5) in the
original transmission case assembly bore (7) . Ensure that spring pin (10) is installed in the
proper location in the shaft assembly.
133. Install two bolts (6) to secure seal carrier (5) to the shaft assembly. Tighten bolts (6) to a
torque of 55 ± 10 N·m (41 ± 7 lb ft).
134. Repeat Steps 132 and 133 in order to install the remaining three seal carriers to the original
locations in the transmission case assembly (11) .
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