Caterpillar Cat 12M 3 MOTOR GRADER (Prefix N9F) Service Repair Manual (N9F00001 and up).pdf

Service Repair Manual
Models
12M 3 MOTOR GRADER

Shutdown SIS
Previous Screen
Product: MOTOR GRADER
Model: 12M 3 MOTOR GRADER N9F
Configuration: 12M Series 3 Motor Grader N9F00001-UP (MACHINE) POWERED BY C9.3 Engine
Disassembly and Assembly
12M Series 3, 140M Series 3 and 160M Series 3 Motor Graders Power Train
Media Number -UENR3483-02 Publication Date -01/01/2014 Date Updated -10/04/2018
i05471731
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 Bolt 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.
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Illustration 1 g01413868
1. Use Tooling (A), Tooling (B), and two suitable lifting devices in order to position rear axle
(1) onto suitable blocking. The weight of rear axle (1) is approximately 1089 kg (2400 lb).
2. Remove bolts (3), retainer (4), shims (5), sprocket (2), and sprocket (6).
Note: Note the quantity and the order of shims (5).
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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 191 kg (420 lb). Remove nuts (9)
and bolts (9A).
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 54 kg (120 lb).
Note: Note the quantity and the order of shims (12).
8. Remove thrust washer (14). Remove wear sleeves (15).
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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. Attach Tooling (E) and a suitable lifting device in order to remove carrier assembly (21) and
drive shaft (22). The weight of carrier assembly (21) and drive shaft (22) is approximately
136 kg (300 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 25 kg (55 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 56 kg (123 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).
10/19
12M Series 3 Motor Grader N9F00001-UP (MACHINE) POWERED BY C9.3 Engi...
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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 setscrews (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 (J) in order to separate intermediate housing (37) from differential housing
(36).
31. Attach Tooling (E) and a suitable lifting device in order to remove intermediate housing
(37). The weight of intermediate housing (37) is approximately 32 kg (71 lb).
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32. Remove shims (57).
33. Attach Tooling (A) and a suitable lifting device in order to remove bearing assembly (58)
and differential (59). The weight of bearing assembly (58) and differential (59) is
approximately 102 kg (225 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).
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).
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Note: Note the quantity and the order of plates (74) and discs (75).
41. Remove housing (77).
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 suitable lifting device in order to turn over housing (86) and bevel gear (87). The
combined weight of housing (86) and bevel gear (87) is approximately 59 kg (130 lb).
Remove bolts (88). Use two people in order to remove housing (86) from bevel gear (87).
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The weight of housing (86) is approximately 41 kg (90 lb). The weight of bevel gear (87) is
approximately 19 kg (41 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).
18/19
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Shutdown SIS
Previous Screen
Product: MOTOR GRADER
Model: 12M 3 MOTOR GRADER N9F
Configuration: 12M Series 3 Motor Grader N9F00001-UP (MACHINE) POWERED BY C9.3 Engine
Disassembly and Assembly
12M Series 3, 140M Series 3 and 160M Series 3 Motor Graders Power Train
Media Number -UENR3483-02 Publication Date -01/01/2014 Date Updated -10/04/2018
i07247061
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 138-7575 Link Bracket 4
B 140-7742 Sleeve 2
C 1U-9200 Lever Puller Hoist 1
E 138-7574 Link Bracket 2
G 292-4949 Socket Wrench As 1
H 154-6183 Forcing Bolt 2
K 4C-4030 Loctite 242 -
L 1U-8846 LoctiteHigh Flex GM -
M 6V-2012 Depth Micrometer 1
N
8T-5096 Dial Indicator Gp 1
301-3405 Gauge 1
P 8T-4140 Bolt 4
R 7M-7456 Loctite 609 -
S - Dow Corning Molykote BR2 - Plus 1
T 8T-5096 Dial Indicator Gp 1
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Note: Lubricate O-ring seals and lip seals with the lubricant that is being sealed.
1. Install seals (94) onto piston (90).
2. Install thrust race (93), thrust bearing (92), and thrust race (91) onto piston (90).
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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 a suitable lifting device 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).
6. Install thrust washer (85). Install differential gear (84).
Note: Install thrust washer (85) with the groove side against gear (84).
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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).
9. Install differential gear (78).
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10. Install housing (77).
Note: Ensure that the notches on the housings are aligned.
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.
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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.
12. Install case (72). Install bolts (71). Tighten bolts (71) to a torque of 300 ± 40 N·m
(220 ± 30 lb ft).
13. Install 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).
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Note: Bearing cone (66) is replaced by a bearing assembly. The bearing assembly includes
a retaining clips, which hold the assembly in place. This retaining clip can either be installed
with the assembly or removed if the assembly will be disassembled and installed in
individual pieces.
15. Lower the temperature of bearing cups (64). Install bearing cups (64).
16. Install bearing assembly (62). Raise the temperature of bearing cone (63). Install bearing
cone (63). Install shroud (61). Apply Tooling (K) to the threads of bolts (60) and install
bolts (60). Tighten bolts (60) to a torque of 28 ± 7 N·m (21 ± 5 lb ft).
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17. Attach Tooling (A) and a suitable lifting device to install bearing assembly (58) and
differential (59). The weight of bearing assembly (58) and differential (59) is approximately
102 kg (225 lb).
18. Install a number of shims (57) that is equal to 2.29 mm (0.090 inch).
19. Attach Tooling (E) and a suitable lifting device to install intermediate housing (37). The
weight of intermediate housing (37) is approximately 32 kg (71 lb).
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20. Install bolts (56). Tighten bolts (56) to a torque of 300 ± 40 N·m (221 ± 30 lb ft). Install
bolts (55). Tighten bolts (55) to a torque of 105 ± 20 N·m (77 ± 15 lb ft).
21. Use Tooling (G) to Install nut assembly (54). Tighten nut assembly (54) to a torque of
300 ± 40 N·m (221 ± 30 lb ft).
22. Install setscrews (53). Tighten setscrews (53) to a torque of 28 ± 7 N·m (21 ± 5 lb ft).
9/26
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23. Lower the temperature of bearing cup (52). Install bearing cup (52). Lower the temperature
of bearing cup (50). Install bearing cup (50). Raise the temperature of bearing cone (49).
Install bearing cone (49) onto pinion gear (48). Install pinion (48). Raise the temperature of
bearing cone (51). Install bearing cone (51).
Note: Lubricate the splines of the pinion shaft prior to assembly.
Note: Lubricate bearing cone (49) prior to assembly.
10/26
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24. Install guard (45). Install yoke (44). Install shims (46). Install retainer (43). Install bolt (42).
Tighten bolt (42) to a torque of 300 N·m (221 lb ft).
Note: Lubricate the seal and the shaft prior to installation.
25. Ensure that the bearings are seated correctly.
26. Measure the rolling torque. Add or remove shims to obtain a rolling torque measurement
of .7 to 1.7 N·m (6 to 15 lb in).
Note: Loosen the bearing after the rolling torque is measured and shims are added or
removed.
27. Remove bolt (42). Remove retainer (43). Remove shims (46). Remove yoke (44). Remove
guard (45).
28. Install lip seal (47). Install guard (45). Install yoke (44). Install shims (46). Install retainer
(43). Install a new bolt (42). Tighten new bolt (42) to a torque of 300 ± 40 N·m
(221 ± 30 lb ft).
29. Install a number of shims (40) that is equal to 1.78 mm (0.070 inch). Do not install O-ring
seal (41) at this time.
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30. Use a suitable lifting device to install pinion (38). The weight of pinion (38) is
approximately 56 kg (123 lb). Install bolts (39). Tighten bolts (39) to a torque of
270 ± 40 N·m (199 ± 30 lb ft).
Note: Lubricate the O-ring seal, the shaft, and the bore with the lubricant that is being
sealed prior to assembly.
31. Use Tooling (N) to measure the backlash between the pinion gear and the bevel gear.
Prevent the bevel gear from moving while you are checking the backlash. Measure the
backlash at three locations that are separated by 120 degrees. The backlash must be
0.40 + 0.00 - 0.14 mm (0.016 + 0.00 - 0.006 inch)
32. If the backlash measurement does not meet the specification, repeat Steps 18 through 22.
Add shims (57) or remove shims (57) to adjust the backlash.
33. After the backlash adjustment has been made, the tooth contact between the pinion shaft and
bevel gear must be checked. Use the following procedure:
a. Put a small amount of Prussian blue, red lead, or paint on three or four adjacent teeth
of the bevel gear.
b. Rotate the pinion shaft for five to eight revolutions in one direction. Then rotate the
pinion shaft for five to eight revolutions in the opposite direction.
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Caterpillar Cat 12M 3 MOTOR GRADER (Prefix N9F) Service Repair Manual (N9F00001 and up).pdf

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Caterpillar Cat 12M 3 MOTOR GRADER (Prefix N9F) Service Repair Manual (N9F00001 and up).pdf