Caterpillar Cat 12M 2 MOTOR GRADER (Prefix R9S) Service Repair Manual (R9S00001 and up).pdf

Service Repair Manual
Models
12M 2 MOTOR GRADER

Shutdown SIS
Previous Screen
Product: MOTOR GRADER
Model: 12M 2 MOTOR GRADER R9S
Configuration: 12M Series 2 Motor Grader R9S00001-UP (MACHINE) POWERED BY C9.3 Engine
Disassembly and Assembly
12M Series 2, 140M Series 2 and 160M Series 2 Motor Graders Power Train
Media Number -KENR8899-03 Publication Date -01/05/2017 Date Updated -18/05/2017
i05493253
Gear Group (All Wheel Drive) - Disassemble
SMCS - 4351-015-YW
Disassembly Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 140-7742 Sleeve 2
B
1U-9200 Lever Puller Hoist 1
140-7742 Sleeve 1
138-7575 Link Bracket 3
C 1P-2420 Transmission Repair Stand 1
D 1P-1859 Retaining Ring Pliers 1
E 154-6182 Forcing Bolt 2
F
1P-0820 Hydraulic Puller 1
5P-9605 Stud 2
3H-0468 Puller Plate 2
350-7768 Electric Hydraulic Pump Gp (115V) 1
350-7769 Electric Hydraulic Pump Gp (230V)
198-4904 Bearing Driver 1
150-1782 Crossblock 1
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12M Series 2 Motor Grader R9S00001-UP (MACHINE) POWERED BY C9.3 Engine...
2021/1/4
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Start By:
a. Remove the gear assembly.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
Note: Put orientation and location marks on all fittings for installation purposes.
Note: Cleanliness is an important factor. Before you begin the disassembly procedure, the exterior
of the components should be thoroughly cleaned. This will help to prevent dirt from entering the
internal mechanism. Precision components can be damaged by contaminants or by dirt. Perform
disassembly procedures on a clean work surface. Keep components covered and protected at all
times.
Illustration 1 g01405850
1. Attach Tooling (A) and a suitable lifting device to gear assembly (1). The weight of gear
assembly (1) is approximately 181 kg (400 lb).
2. Remove bolts (2).
3. Use Tooling (A) and the suitable lifting device in order to separate gear assembly (1) from
cover assembly (3). Remove Tooling (A).
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4. Attach Tooling (B) to gear assembly (1). The weight of gear assembly (1) is approximately
181 kg (400 lb). Use Tooling (B) and the suitable lifting device in order to position gear
assembly (1) onto Tooling (C).
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.
5. Use Tooling (D) in order to remove retaining ring (4). Remove gear (5). Repeat this step for
the remaining gears.
6. Remove bolts (7) in order to remove ring (6).
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7. Remove pad (8).
8. Remove bolts (9) and plate (10).
9. Remove first reduction (11).
10. Remove clutch plates and friction discs (12). Remove springs (13).
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11. Remove brake piston (14).
12. Remove bolts (15) in order to remove clutch spindle (16) from spindle (17). If necessary,
use Tooling (E) in order to help separate clutch spindle (16) from spindle (17).
13. Attach Tooling (B) to spindle (17). The weight of spindle (17) is approximately 79 kg
(175 lb).
14. Remove seal rings (18) from brake piston (14).
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15. Remove O-ring seal (19).
16. Attach Tooling (F) to housing (20). Use Tooling (F) in order to separate spindle (17) from
housing (20).
Note: Use Tooling (B) and the suitable lifting device in order to lower spindle (17) while
you are separating spindle (17) from housing (20).
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17. Remove race (21) from housing (20).
18. Remove roller assembly (22) from housing (20).
19. Remove O-ring seal (23) from housing (20).
20. Use two people in order to remove housing (20). The weight of housing (20) is
approximately 41 kg (90 lb).
21. Remove Duo-Cone seal (24) from housing (20).
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22. Remove race (25) from spindle (17).
23. Remove roller assembly (26) from spindle (17).
24. Remove Duo-Cone seal (27) from spindle (17).
25. Remove planetary assembly (28) from cover assembly (3).
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All Rights Reserved.
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Mon Jan 4 09:56:37 UTC+0800 2021
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Shutdown SIS
Previous Screen
i07528757
Gear Group (All Wheel Drive) - Assemble
SMCS - 4351-016-YW
Assembly Procedure
Table 1
Required Tools
A 140-7742 Sleeve 2
B
140-7742 Sleeve 1
C 1P-2420 Transmission Repair Stand 1
D 1P-1859 Retaining Ring Pliers 1
G 317-3806 Seal Installer 1
H
150-1782 Crossblock 1
- Threaded Rod 5/8 - 18 by 12 in 2
J - Loctite 242 Thread Locker -
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1. Install planetary assembly (28) into cover assembly (3).
2. Use two people to position housing (20) onto Tooling (C). The weight of housing (20) is
approximately 41 kg (90 lb). Use Tooling (G) to install Duo-Cone Seal (24). Refer to
Disassembly and Assembly, "Duo-Cone Conventional Seals - Install".
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3. Install roller assembly (26) into housing (20).
Note: Install the bearing assemblies with the open side of the bearing cages toward the
bearing races. The cages must be oriented correctly to avoid being crushed by the clutch
housing and the spindle.
4. Use Tooling (G) to install Duo-Cone Seal (27) into spindle (17). Refer to Disassembly and
Assembly, "Duo-Cone Conventional Seals - Install".
5. Raise the temperature of race (25). Install race (25).
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Note: During installation, ensure that the bearing and the race are properly aligned to
prevent damaging the bearing.
6. Attach Tooling (B) and a suitable lifting device to spindle (17). The weight of spindle (17)
is approximately 79 kg (175 lb). Use Tooling (B) and the suitable lifting device to position
spindle (17) onto housing (20).
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7. Attach Tooling (H) to spindle (17) to secure spindle (17) to housing (20). Use Tooling (B)
and the suitable lifting device to reposition spindle (17) and housing (20) onto Tooling (C).
The combined weight of spindle (17) and housing (20) is approximately 120 kg (265 lb).
Note: This photo is a typical example.
8. Install roller assembly (22) onto housing (20).
9. Raise the temperature of race (21). Install race (21) onto spindle (17).
10. Install O-ring seal (19).
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11. Position clutch spindle (16). Apply Tooling (J) to bolts (15). Install bolts (15). Tighten bolts
(15) to a torque of 360 ± 40 N·m (266 ± 30 lb ft).
12. Remove Tooling (H).
13. Install seal rings (18) to brake piston (14).
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14. Install brake piston (14).
15. Install O-ring seal (23), springs (13), and first reduction (11).
16. Position plate (10).
17. Apply Tooling (J) to bolts (9). Install bolts (9). Tighten bolts (9) to a torque of 25 ± 4 N·m
(18 ± 3 lb ft).
18. Install pad (8).
19. Install clutch plates and friction discs (12).
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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.
20. Install ring (6).
21. Apply Tooling (J) to bolts (7). Install bolts (7). Tighten bolts (7) to a torque of 86 ± 10 N·m
(63 ± 7 lb ft).
22. Install gear (5). Use Tooling (D) to install retaining ring (4). Repeat this step for the
remaining gears.
23. Attach Tooling (B) and a suitable lifting device to gear assembly (1). The weight of gear
assembly (1) is approximately 181 kg (400 lb). Use Tooling (B) and the suitable lifting
device to reposition gear assembly (1) onto Tooling (C).
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assembly (1) is approximately 181 kg (400 lb). Use Tooling (A) and the suitable lifting
device to position gear assembly (1) onto cover assembly (3).
25. Install bolts (2). Tighten bolts (2) to a torque of 215 ± 25 N·m (159 ± 18 lb ft).
End By:
a. Install the gear assembly.
Mon Jan 4 09:57:32 UTC+0800 2021
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Shutdown SIS
Previous Screen
i05490009
Gear Group (All Wheel Drive) - Install
SMCS - 4351-012-YW
Installation Procedure
Table 1
Required Tools
A
D
1P-1833 Bearing Puller Adapter 1
5P-4776 Tool Stud 1
9U-6833 Nut 1
4K-0684 Hard Washer 1
E 1U-8846 Gasket Sealant 1
1/8
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When you are using hydraulic cylinders and puller studs, always ensure
that the rated capacity of the puller stud meets or exceeds the rated
capacity of the hydraulic cylinder. If the puller stud does not meet or
exceed the rated capacity of the hydraulic cylinder, a sudden failure of
the puller stud could occur. The sudden failure of the puller stud could
result in personal injury or death.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
Note: Check the O-ring seals and the seals for wear or for damage. Replace the components, if
necessary.
1. Lower the temperature of bearings (32). Use Tooling (D) in order to install bearings (32).
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2. Install lip seal (31). Install thrust washers (29) and thrust washer (30).
3. Install metal seal ring (28) onto pin (20). Install metal seal ring (27) onto pin (19).
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4. Install coupling (26) and install O-ring seal (25) onto piston motor (23).
5. Use two people in order to position piston motor (23) onto gear assembly (18). The weight
of piston motor (23) is approximately 36 kg (80 lb). Install bolts (24).
6. Install O-ring seals (22) and seals (21) into gear assembly (18).
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assembly (18) is approximately 318 kg (700 lb). Use Tooling (A) and the suitable lifting
device in order to position gear assembly (18) to the machine.
8. Lower the temperature of pins (20) and (19). Install pin (19). Install pin (20) (not shown).
9. Install washer (16) and bolt (15). Install bolt (17) (not shown).
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10. Position tie rod end (12).
11. Install nut (14). Tighten nut (14) to a torque of 220 N·m (162 lb ft). Additional torque may
be required in order to align the cotter slot. Install cotter pin (13).
12. Position steering cylinder (11). Install nut (10). Tighten nut (10) to a torque of
220 ± 14 N·m (162 ± 10 lb ft).
13. Apply Tooling (E) to cover (9). Position cover (9). Install the washers and bolts (8).
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14. Position guard (7) and install bolts (6).
15. Position hose assemblies (5). Connect harness assembly (4).
16. Connect hose assemblies (3). Connect hose assembly (2).
17. Connect hose assemblies (1).
End By:
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a. Install wheel and tire.
Mon Jan 4 09:58:28 UTC+0800 2021
8/8
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Shutdown SIS
Previous Screen
i05493300
Wheel Spindle and Wheel Spindle Housing - Remove
SMCS - 4234-011
Removal Procedure
Table 1
Required Tools
A 1A-5666 Full Nut 1
B
8T-3282 Hard Washer 1
123-4370 Puller Stud 1
6V-7742 Full Nut 1
1U-5230 Hand Hydraulic Pump 1
5P-4197 Spacer 1
C 1P-0510 Driver Gp 1
Start By:
a. Remove the wheel and tire.
When you are using hydraulic cylinders and puller studs, always ensure
that the rated capacity of the puller stud meets or exceeds the rated
capacity of the hydraulic cylinder. If the puller stud does not meet or
1/6
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exceed the rated capacity of the hydraulic cylinder, a sudden failure of
the puller stud could occur. The sudden failure of the puller stud could
result in personal injury or death.
1. Remove cotter pin (6). Remove nut (3). Install Tooling (A) (not shown). Break the taper on
tie rod (2). Position link (1) to the side.
2. Remove cotter pin (7). Remove nut (10). Install Tooling (A) (not shown). Break the taper on
tie rod (9). Position steering cylinder (8) to the side.
3. Remove bolts (4) and washers (5).
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4. Attach a suitable lifting device to housing assembly (11). The weight of housing assembly
(11) is approximately 136 kg (300 lb). Use Tooling (B) in order to remove pins (12).
Remove housing assembly (11).
3/6
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5. Remove seals (14) and O-ring seals (13) from housing assembly (11).
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6. Remove thrust washers (16) and seal (17) from arm assembly (15).
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7. Use Tooling (C) (not shown) in order to remove bearings (18) from arm assembly (15).
Mon Jan 4 09:59:24 UTC+0800 2021
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Caterpillar Cat 12M 2 MOTOR GRADER (Prefix R9S) Service Repair Manual (R9S00001 and up).pdf

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