Caterpillar Cat 135H Series NA Motor Grader (Prefix BDJ) Service Repair Manual (BDJ00001 and up).pdf

Service Repair Manual
Models
135H NA Motor Grader

Start By:
a. remove transmission hydraulic control valve.
b. remove parking brake
c. remove transmission speed sensor
d. remove transmission oil pump
e. remove transmission magnetic filter screen base.
1. Place transmission level on floor as shown.
2. Remove twelve bolts (1). Remove four covers (2) and their O-ring seals from the transmission
case.
3. Remove 43 bolts (3) from the transmission case flange.
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4. Identify the location of seal carrier (4) in the transmission case for assembly purposes. Remove
two bolts (5) from seal carrier (4). Install an 8mm Eyebolt in seal carrier (4). Remove seal carrier
(4) and its O-ring seals from the transmission case bore.
5. Repeat Step (4) on the three remaining seal carriers.
6. Remove three seal rings (6) from seal carrier (4).
7. Remove three, or four O-ring seals (7) from seal carrier (4). Remove locating pin (8) from seal
carrier (4).
8. Repeat Steps (6) and (7) for the remaining three seal carriers.
9. Install two 10 x 1.5 mm Forcing Bolts (9) in the transmission case flange. Tighten them evenly
to separate the transmission cases.
10. Install Tool (G), attach lifting chains and a hoist to the transmission case, as shown. Slowly
raise the upper portion of the transmission case from the lower portion of the transmission case.
Be careful not to bind the transmission case during separation.
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11. Remove three bolts (10) from tube (11). Remove tube (11) from the transmission case.
12. Remove the O-ring seal from the elbow end of tube assembly (11).
NOTE: First/Third shaft assembly (12) and High/Low shaft assembly (13) must be removed
together.
13. Install Tool (A) on First/Third shaft assembly (12) and High/Low shaft assembly (13). Use
one 8 x 1.25 x 75 mm Bolt and one 8 x 1.25 x 50 mm Bolt, in order to hold Tool (A) on
First/Third shaft assembly (12) and High/Low shaft assembly (13) as shown. First/Third shaft
assembly (12) and High/Low shaft assembly (13) must be removed together.
14. Attach a suitable lifting device to Tool (A). Carefully remove First/Third shaft assembly (12)
and High/Low shaft assembly (13) from the transmission case. The weight of the two shaft
assemblies is 177 kg (390 lb).
15. Place First/Third shaft assembly (12) and High/Low shaft assembly (13) on Tooling (I) or on
blocks and remove Tool (A). Carefully separate First/Third shaft assembly (12) and High/Low
shaft assembly (13). The weight of each shaft assembly is 88.530 kg (195 lb)
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NOTE: Place High/Low shaft assembly (13) in a modified work bench or on blocks. Modify a
substantial workbench by cutting a 116 ± 2 mm (4.6 ± .08 in) clearance hole in the top of the
bench.
NOTICE
Do not attach Tooling (E) to rotor (15). The rotor is cast iron, and will
be broken if pressure is applied to it with the puller. Attach the tooling
to gear assembly (16).
16. With High/Low shaft assembly (13) on the modified work bench or on blocks, use Tooling (E)
in order to remove bearing (14), rotor (15) and gear assembly (16) from shaft assembly (13).
Bearing (14) and rotor (15) are press fit on High/Low shaft assembly (13).
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17. Remove bearing (14), rotor (15), thrust disc (15A) and gear assembly (16), as a unit, from
High/Low shaft assembly (13). Attach the tooling to gear assembly (16), not rotor (15).
18. Remove thrust disc and washer (17) from High/Low shaft assembly (13).
19. Install Tool (B) on High/Low shaft assembly (13) and clutch assembly (18). Use an 8 mm
Threaded Rod that is approximately 508 mm (20 in) long. Tighten an 8 mm Nut on the threaded
rod in order to compress clutch assembly (18). Remove two half rings (19) and two lock rings (20)
from the shaft groove.
20. Carefully loosen the nut on Tool (B) in order to relieve pressure from clutch assembly (18).
Remove Tool (B) from High/Low shaft assembly (13) and clutch assembly (18). As you remove
clutch assembly (18) from the High/Low shaft assembly (13), identify the positions of the five
clutch plates, six friction disc and the hub assembly for assembly purposes.
21. Remove wave spring (21) from High/Low shaft assembly (13).
22. Remove piston (22) from High/Low shaft assembly (13).
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23. Remove two lip seals (23) from piston (22).
24. Turn High/Low shaft assembly (13) over in order to work on the other end. Place High/Low
shaft (13) in the modified work bench, or on blocks. The weight of the High/Low shaft assembly
(13) is 49.9 kg (110 lb). Place High/Low shaft assembly (13) on the modified work bench or on
blocks.
25. Install Tooling (F) and Tooling (H) on High/Low shaft assembly (13) and bearing (24).
Remove bearing (24) from High/Low shaft assembly (13). Remove two thrust disc (25) and gear
assembly (26) from High/Low shaft assembly (13).
26. Remove thrust disc and washer (27) from High/Low shaft assembly (13).
NOTE: If the 9U-7479 Tube, Tool (B), is the old style tool it will have to be modified. If it is the
new style tool, it will work without modification. Tool (B) may have to be modified so the hole in
the top of the tube will have clearance for a 12 mm Threaded Rod.
27. Install Tool (B) on High/Low shaft assembly (13) and clutch assembly (28). Use a 12 mm
Threaded Rod that is approximately 508 mm (20 in) long. Tighten a 12 mm Nut on the threaded
rod in order to compress clutch assembly (28). Remove two half rings (29) and two lock rings (30)
Remove Tool (B) from High/Low shaft assembly (13) and clutch assembly (28). As you remove
clutch assembly (28) from the High/Low shaft assembly (13), identify the positions of the seven
clutch plates, eight friction disc and the hub assembly for assembly purposes.
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NOTE: If the 9U-7479 Tube, Tool (B), is the old style tool it will have to be modified. If it is the
new style tool, it will work without modification. Tool (B) may have to be modified so the hole in
the top of the tube will have clearance for a 12 mm Threaded Rod.
29. Install Tool (B) on High/Low shaft assembly (13) and balance piston (31). Use a 12 mm
Threaded Rod that is approximately 508 mm (20 in) long. Tighten a 12 mm Nut on the threaded
rod in order to compress balance piston (31).
30. Use Tool (C) in order to remove retaining ring (32) from High/Low shaft assembly (13).
31. Carefully loosen the nut on Tool (B) in order to relieve pressure from the balance piston (31).
Remove Tool (B) from High/Low shaft assembly (13) and balance piston (31).
32. Remove balance piston (31) and lip seal (33) from High/Low shaft assembly (13).
33. Remove fifteen springs (34) from piston (35).
34. Remove piston (35) and two lip seals (not shown), from High/Low shaft assembly (13).
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First/Third Shaft assembly (12)
36. Place First/Third shaft assembly (12) on the modified work bench or on blocks. Use Tooling
(E) in order to remove bearing (37), thrust disc (not shown) and gear (38) from First/Third shaft
assembly (12).
37. Remove thrust disc (39) and gear assembly (40) from First/Third shaft assembly (12).
38. Remove thrust disc (41) and washer (42) from First/Third shaft assembly (12).
39. Install Tool (B) on First/Third shaft assembly (12) and clutch assembly (43). Use an 8 mm
Threaded Rod that is approximately 508 mm (20 in) long. Tighten a 8 mm Nut on the threaded rod
in order to compress clutch assembly (43). Remove two half rings (44) and two lock rings (45)
Remove Tool (B) from First/Third shaft assembly (12) and clutch assembly (43). As you remove
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clutch assembly (43) from First/Third shaft assembly (12), identify the positions of the five clutch
plates, six friction disc and the hub assembly for assembly purposes.
41. Remove wave spring (46) from First/Third shaft assembly (12).
42. Remove piston (47) from First/Third shaft assembly (12).
44. Turn First/Third shaft assembly (12) over in order to work on the other end. Place First/Third
shaft assembly (12) in the modified work bench, or on blocks. The weight of First/Third shaft
assembly (12) is 54.5 kg (120 lb). Place First/Third shaft assembly (12) on the modified work
bench or on blocks.
45. Use Tool (E) in order to remove bearing (49), thrust disc (not show), gear (50) and thrust disc
(not shown).
46. Remove gear assembly (51), the thrust disc and washer (not shown) from First/Third shaft
assembly (12).
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47. Install Tool (B) on First/Third shaft assembly (12) and clutch assembly (52). Use an 8 mm
Threaded Rod that is approximately 508 mm (20 in) long. Tighten a 8 mm Nut on the threaded rod
in order to compress clutch assembly (52). Remove two half rings (53) and two lock rings (54)
48. Carefully loosen the nut on Tool (B) to relieve pressure from clutch assembly (52). Remove
Tool (B) from First/Third shaft assembly (12) and clutch assembly (52). As you remove clutch
assembly (52) from First/Third shaft assembly (12), identify the positions of the three clutch
plates, four friction disc and the hub assembly for assembly purposes.
49. Remove wave spring (55) from First/Third shaft assembly (12).
50. Remove piston (56) from First/Third shaft assembly (12).
Input Shaft Assembly (58)
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52. Use Tooling (E) in order to remove bearing (59) and gear (60) from Input shaft assembly (58).
This is necessary at this time in order to remove the remaining two shaft assemblies.
53. Install an 8 mm Eyebolt and remove Reverse/Second shaft assembly (61) from the
transmission case. The weight of Reverse/Second shaft assembly (61) is 63.6 kg (140 lb).
54. Place Reverse/Second shaft assembly (61) on the modified work bench, or on blocks.
55. Use Tooling (E) in order to remove bearing (62), spacer (63) and gear (64) from
Reverse/Second shaft assembly (61).
56. Remove spacer (65) and thrust disc (not shown) from Reverse/Second shaft assembly (61).
57. Remove gear assembly (66), thrust disc and washer (not shown) from Reverse/Second shaft
assembly (61).
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58. Install Tool (B) on Reverse/Second shaft assembly (61) and clutch assembly (67). Use an 8
mm Threaded Rod that is approximately 508 mm (20 in) long. Tighten an 8 mm Nut on the
threaded rod in order to compress clutch assembly (67). Remove two half rings (68) and two lock
rings (69) from the shaft groove.
59. Carefully loosen the nut on Tool (B) to relieve pressure from clutch assembly (67). Remove
Tool (B) from Reverse/Second shaft assembly (61) and clutch assembly (67). As you remove
clutch assembly (67) from Reverse/Second shaft assembly (61), identify the positions of the three
clutch plates, four friction disc and the hub assembly for assembly purposes.
60. Remove wave spring (70) from Reverse/Second shaft assembly (61).
61. Remove piston (71) from Reverse/Second shaft assembly (61).
62. Remove two lip seals (72) from piston (71)
63. Turn Reverse/Second shaft assembly (61) over in order to work on the other end. Weight of
Reverse/Second shaft assembly (61) is 41 kg (90 lb).
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64. Place Reverse/Second shaft assembly (61) on the modified work bench, or on blocks.
65. Install Tooling (D) and (F) on gear assembly (74) and Reverse/Second shaft assembly (61).
66. Remove bearing (73), the thrust race (not shown), two thrust disc (not shown) and gear
assembly (74) from Reverse/Second shaft assembly (61).
67. Remove needle bearing (75) from Reverse/Second shaft assembly (61).
68. Remove thrust disc and washer (76) from Reverse/Second shaft assembly (61).
69. Use a second person in order to compress clutch assembly (77).
70. Remove two half rings (78) from the shaft groove. Release the pressure from clutch assembly
(77), slowly, until the spring underneath clutch assembly (77) is extended and relaxed.
71. Remove hub assembly (79) from Reverse/Second shaft assembly (61).
72. Remove spring (81) from Reverse/Second shaft assembly (61).
73. When removing the clutch plates and friction disc, identify their locations for installation
purposes. Remove six clutch plates and seven friction disc (80) from Reverse/Second shaft
assembly (61).
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74. Remove valve assembly (82) from Reverse/Second shaft assembly (61).
75. Remove piston (83) from Reverse/Second shaft assembly (61).
77. Install an 8 mm Eyebolt in Forward shaft assembly (85). Remove Forward shaft assembly
(85) from the transmission case. The weight of Forward shaft assembly (85) is 63.6 kg (140 lb).
78. Place Forward shaft assembly (85) on the modified work bench, or on blocks. Install Tooling
(D) and Tooling (F) to Forward shaft assembly (85) and gear assembly (87).
79. Remove bearing (86), two thrust disc, (not shown), and gear assembly (87) from Forward shaft
assembly (85).
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80. Remove needle bearing (88) from Forward shaft assembly (85).
81. Remove thrust disc and washer (89) from Forward shaft assembly (85).
83. Remove two half rings (91) from the shaft groove. Release the pressure from clutch assembly
(90), slowly, until the spring underneath clutch assembly (90) is extended and relaxed.
84. Remove hub assembly (92) from the Forward shaft assembly (85).
85. Remove spring (94) from Forward shaft assembly (85).
86. Remove six clutch plates and seven friction discs (93) from Forward shaft assembly (85).
Identify the positions of the clutch plates and friction disc for assembly purposes.
87. Remove valve assembly (95) from Forward shaft assembly (85).
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88. Remove piston (96) from Forward shaft assembly (85).
89. Remove two lips seals (97) from piston (96).
90. Turn Forward shaft assembly (85) over in order to work on the other end. The weight of
Forward shaft assembly (85) is 43.1 kg (95 lb). Place Forward shaft assembly (85) in the modified
work bench, or on blocks.
91. Install Tooling (D) and (F) to Forward shaft assembly (85) and gear assembly (99).
92. Remove bearing (98), the thrust race (not shown), the two thrust disc (not shown) and gear
assembly (99) from Forward shaft assembly (85).
93. Remove needle bearing (100) from Forward shaft assembly (85).
94. Remove thrust disc and washer (101) from Forward shaft assembly (85).
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96. Remove two half rings (103) from the shaft groove.
97. Release the pressure from clutch assembly (102), slowly, until the spring underneath clutch
assembly (102) is extended and relaxed.
98. Remove hub assembly (104) from Forward shaft assembly (85).
99. Remove spring (105) from Forward shaft assembly (85).
100. Remove six clutch plates and seven friction disc (106) from Forward shaft assembly (85).
Identify the positions of the clutch plates and friction disc (106) for assembly purposes.
101. Remove valve assembly (107) from Forward shaft assembly (85).
102. Remove piston (108) from Forward shaft assembly (85).
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104. Install an 8 mm Eyebolt in Input shaft assembly (58). Remove Input shaft assembly (58)
from the transmission case. The weight of Input shaft assembly (58) is 22.7 kg (50 lb).
105. Remove two seal rings (110) from Input shaft assembly (58).
106. Remove bearing (111) and gear (112) from Input shaft assembly (58).
107. Remove four bolts (113) from pump drive gear (114). Rotate pump drive gear (114) to locate
the two bolts not seen.
108. Remove drive pump gear (114) from the transmission case.
109. Turn pump drive gear (114) over. Use Tool (C) to remove retaining ring (117) from pump
drive gear (114).
110. Turn pump drive gear (114) over. Use a small driver through three small holes (not shown) in
order to drive bearing (115) off of gear (114).
111. Remove bearing (115) from retainer (116). This is a slip fit.
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112. Remove five bearing races (118) from the transmission case.
113. Repeat Step 112 on the other half of the transmission case.
Assemble Transmission
1. Lower the temperature of bearing races (118). Install bearing races (118) in their original
locations in both transmission case halves until they are seated.
2. Install retainer (116) on pump drive gear (114).
3. Heat bearing (115) to a maximum temperature of 135° C (275° F). Install bearing (115) to its
original location on pump drive gear (114).
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4. Use Tool (C) in order to install retaining ring (117) to its original location on pump drive gear
(114).
5. Install pump drive gear (114) to its original location in the transmission case.
6. Install four bolts (113) in the pump drive gear (114). Tighten bolts (113) to a torque of 28 ± 7
N·m (21 ± 5 lb ft).
7. Install gear (112) on Input shaft assembly (58).
8. Heat bearing (111) to a maximum of 135° C (275° F). Install bearing (111) on Input shaft
assembly (58) until it is seated. Gear (112) should be tight on Input shaft assembly (58).
9. Install two seal rings (110) to their original locations on Input shaft assembly (58).
10. Install an 8 mm Eyebolt to Input shaft assembly (58). Use a hoist to position Input shaft
assembly (58) to its original location in the transmission case. Install Input shaft assembly (58) in
the transmission case. Remove the eyebolt.
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11. Install two lip seals (109) on piston (108). Install both seals (108) and (109) with the sealing
lips facing towards the small diameter of the piston.
12. Place Forward shaft assembly (85) in the modified work bench or on blocks. Apply a light
coat of clean hydraulic oil on the lip seals. Install piston (108) to its original location on Forward
shaft assembly (85). Rotate the piston slightly during the seal entry. Make sure the lip seals are
installed properly.
13. Install valve assembly (107) to its original location on Forward shaft assembly (85).
14. Install six clutch plates and seven friction disc (106) in their original order on hub assembly
(104). The splines on hub (104) must align with the splines on the friction plates.
15. Install spring (105) to its original location on Forward shaft assembly (85).
16. As one unit, install hub assembly (104), six plates and seven friction disc (106) to their
original location on Forward shaft assembly (85).
17. Use a second person in order to manually compress clutch assembly (102) on spring (105).
Install two half rings (103) in the shaft groove.
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Caterpillar Cat 135H Series NA Motor Grader (Prefix BDJ) Service Repair Manual (BDJ00001 and up).pdf

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Caterpillar Cat 135H Series NA Motor Grader (Prefix BDJ) Service Repair Manual (BDJ00001 and up).pdf