Caterpillar Cat 120H Motor Grader (Prefix CAF) Service Repair Manual (CAF00001 and up).pdf

Service Repair Manual
Models
120H Motor Grader

Shutdown SIS
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Product: MOTOR GRADER
Model: 120H MOTOR GRADER CAF
Configuration: 120H Motor Grader CAF00001-UP (MACHINE) POWERED BY 3126B Engine
Disassembly and Assembly
120H and 135H Motor Graders Machine Systems
Media Number -RENR4164-01 Publication Date -01/04/2005 Date Updated -30/04/2005
i07430989
Piston Pump (Hydraulic and Steering) - Assemble
SMCS - 4306-016; 5070-016
Assembly Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
B 1P-1861 Retaining Ring Pliers 1
D 1P-0510 Driver Group 1
E 8T-5096 Dial Indicator Group 1
F
- Loctite LB 8632 Silicone Lubricant (1)
-
-
-
- Loctite LB Superlube (4)
-
G - Loctite 243 -
(1)
North America
(2)
EAME
(3)
Asia Pacific Division
(4)
South America
Note: The axial end play must be adjusted if the swashplate, the swashplate bearings, the shaft,
the shaft bearings, the head, or the housing has been replaced.
1. During the assembly of the piston pump, check the condition of all the O-ring seals and the
lip seals that are used in the pump. If any of these seals are damaged, use new parts for
replacement.
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Illustration 1 g00991054
2. Lower the temperature of bearing cup (40). Use Tooling (D) to install bearing cup (40) in
head (31). Install bearing cup (40) until the bearing cup is seated.
3. Lower the temperature of bearing cup (66). Use Tooling (D) to install bearing cup (66) in
housing (26). Install bearing cup (66) until the bearing cup is seated.
4. Install bearing (58) in housing (26).
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5. Install bearing (63) and bearing (64) into housing (26). Install set screws (65).
6. Use Tooling (D) to install lip seal (62) in housing (26) until the lip seal is seated. The
sealing lip must face inward. Lubricate the sealing lip lightly with hydraulic oil before
installation. Use Tooling (B) to install retaining ring (61) into housing (26).
7. Install shield (60) into housing (26).
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8. Place a light coat of hydraulic oil on bearing (64) and bearing (65). The hydraulic oil will
hold swashplate (54) in position during the following steps. Install swashplate (44) into
housing (26). Swashplate (44) should fit into bearing (64) and bearing (65).
9. Place housing (26) onto support blocks to allow space for installation of shaft (59). Shaft
(59) extends beyond the end of housing (26). Install shaft (59) through swashplate (44),
through bearing (58) (not shown), and through housing (26).
10. Install plug (48) into housing (26). Install the O-ring seal into housing (26).
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11. Install spacer (55), spring (56), and spacer (57) into barrel (52).
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. Use Tooling (D) and use a suitable press to compress spring (56).
13. Use Tooling (B) to install retaining ring (54) into barrel (52).
Note: Set bearing preload before you install the rotating group. The bearing preload should
be 0.010 mm (0.0004 inch) to 0.100 mm (0.0039 inch).
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14. Do not install shim (41). Install bearing cone (42) onto shaft (59). Assemble the pump
without shim (41) to check the preload of bearing cone (42).
15. Install the head (31) on housing (26). Install bolts (33).
Typical example
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Typical example
16. Install Tooling (E) onto the pump housing. Use the dial indicator to determine the end play
of shaft (59). Be sure that you move shaft (59) completely in both directions. Use
appropriate tools to move shaft (59).
17. Subtract desired shaft bearing end play of 0.010 mm (0.0004 inch) to 0.100 mm
(0.0039 inch) from the dial indicator reading. This is the thickness of shims (50).
18. Remove bolts (33), head (31), and the bearing.
19. Install pistons (51) into the original locations in spacer (53) and barrel (52). For best results,
place the barrel in an upright position. Insert the pistons into spacer (53). Lift the pistons
with spacer (53) and insert pistons (51) into barrel (52).
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20. Position housing (26) horizontally. Install rotating group (49) and install shim kit (50) onto
shaft (59).
21. Install shims (41) and install bearing cone (42) onto shaft (59).
22. Position two spacers (45) and two locking plates (46) to the original positions on swashplate
(44).
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23. Apply Tooling (G) on bolts (47). Install bolts (47) to hold locking plates (46) and spacers
(45) to swashplate (44).
24. Install pin (39) in head (31).
25. Apply Tooling (G) to piston rods (34) and (37).
26. Install piston rod (34) and piston rod (37) in head (31).
27. Install spring (37), piston (35), and piston (38) onto head (31):
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28. Use a light coat of Tooling (F) to hold plate (43) to head (31) during assembly.
29. Position head (31) onto housing (26) and bearing (42).
30. Install bolts (33) to hold head (31) to housing (26).
31. Install plug (30) in head (31). Install the O-ring seal in head (31).
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32. Install O-ring seal (29) to housing (26).
33. Install cover (28) and install bolts (27) to housing (26).
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34. Install spool (25), guide (24), spring (23), and guide (22) to valve (2).
35. Install spool (21), guide (20), pin (19), spring (18), and guide (17) to valve (2).
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Sudden release of spring force can cause injury.
To prevent the possibility of injury, follow the procedure to relieve the
spring pressure.
36. Install O-ring seal (16) to plug (15).
37. Install plug (15) to valve (2).
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46. Install needle valve (6), ring (5), and O-ring seal (4) to valve (2).
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48. Install valve group (2) and install bolts (1) to the pump.
End By:
a. Install the piston pump (hydraulic and steering). Refer to Disassembly and Assembly,
"Piston Pump (Hydraulic and Steering) - Install" for the correct procedure.
Copyright 1993 - 2020 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Mon Mar 2 00:47:00 UTC+0800 2020
16/16
2020/3/2

Shutdown SIS
Previous Screen
Product: MOTOR GRADER
Model: 120H MOTOR GRADER CAF
Configuration: 120H Motor Grader CAF00001-UP (MACHINE) POWERED BY 3126B Engine
Disassembly and Assembly
120H and 135H Motor Graders Machine Systems
Media Number -RENR4164-01 Publication Date -01/04/2005 Date Updated -30/04/2005
i04685309
Piston Pump (Hydraulic and Steering) - Install
SMCS - 4306-012; 5070-012
Installation Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A
183-4797 Track Roller Lifting Fork 1
FT-2930 Extension 1
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2020/3/2

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1. Attach Tooling (A) to a suitable lifting device. Position Tooling (A) under implement pump
(3) . The weight of implement pump (3) is approximately 73 kg (160 lb).
2. Install implement pump (3) .
3. Install bracket (7) .
4. Install bolts (6) . Tighten bolts (6) to a torque of 160 ± 30 N·m (118 ± 22 lb ft).
5. Install yoke (5) , nut (4) , and the washer. Tighten nut (4) to a torque of 190 ± 25 N·m (140
± 18 lb ft).
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6. Connect hose assembly (2) .
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7. Connect fitting assembly (1) .
End By: Install the fan drive pump. Refer to Disassembly and Assembly, "Fan Drive Pump -
Install".
Copyright 1993 - 2020 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Mon Mar 2 00:47:56 UTC+0800 2020
4/4
2020/3/2

Caterpillar Cat 120H Motor Grader (Prefix CAF) Service Repair Manual (CAF00001 and up).pdf

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