Caterpillar Cat 120M Motor Grader (Prefix D9W) Service Repair Manual Instant Download

Service Repair Manual Models 120M M otor Grader

120M Motor Grader - All Wheel Drive D9W00001-UP (MACHINE) POWERED BY ... 1/21 Shutdown SIS Previous Screen Product: MOTOR GRADER Model: 120M MOTOR GRADER D9W Configuration: 120M Motor Grader - All Wheel Drive D9W00001-UP (MACHINE) POWERED BY C6.6 Engine Disassembly and Assembly 12M and 120M Motor Graders Power Train Media Number -KENR6419-08 Publication Date -01/05/2017 Date Updated -15/05/2017 i02391399 Transmission - Disassemble SMCS - 3030-015; 3159-015; 3176-015 S/N - D9W1-UP Disassembly Procedure Table 1 Required Tools Tool Part Number Part Description Qty 1P-0074 Slide Hammer Puller Gp 1 A 4C-5651 Threaded Adapter 1 B 5P-4758 Retaining Ring Pliers As 1 C 5P-5197 Retaining Ring Pliers As 1 D 1P-1863 Retaining Ring Pliers 1 E 5F-7465 Puller Gp 1 6V-3010 Puller Gp 1 8B-7557 Threaded Adapter 2 F 126-7177 Puller Leg 2 126-7181 Sliding Plate 4 G 8H-0663 Bearing Puller Gp 1 H 9U-7289 Ruler 1 Start By: https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/5/1

120M Motor Grader - All Wheel Drive D9W00001-UP (MACHINE) POWERED BY ... 2/21 a. Remove the transmission. Refer to Disassembly and Assembly, "Transmission - Remove". NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat products. Dispose of all fluids according to local regulations and mandates. Illustration 1 g01136987 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. 1. Remove plug (1) in order to drain the oil from the transmission into a suitable container. Evenly remove bolts (2) and remove housing (3). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/5/1

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120M Motor Grader - All Wheel Drive D9W00001-UP (MACHINE) POWERED BY ... 3/21 Illustration 2 g01136993 2. Remove seal (4) from housing (3). Illustration 3 g01136995 3. Remove springs (5) and (6). Illustration 4 g01137000 4. Remove spring (7), O-ring seal (8), and spool (9). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/5/1

120M Motor Grader - All Wheel Drive D9W00001-UP (MACHINE) POWERED BY ... 4/21 Illustration 5 g01137027 5. Remove seal (10) from spool (9). Illustration 6 g01137040 6. Remove piston (11). Illustration 7 g01150446 7. Remove race (13) and thrust bearing (12). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/5/1

120M Motor Grader - All Wheel Drive D9W00001-UP (MACHINE) POWERED BY ... 5/21 Illustration 8 g01150456 8. Remove race (14). Illustration 9 g01150462 9. Use Tooling (A) in order to remove piston (15). Illustration 10 g01137074 10. Remove seals (16) and (17) from piston (15). Remove pins (18) from piston (15). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/5/1

120M Motor Grader - All Wheel Drive D9W00001-UP (MACHINE) POWERED BY ... 6/21 Illustration 11 g01137081 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat products. Dispose of all fluids according to local regulations and mandates. 11. Remove ring (19). Illustration 12 g01137084 12. Remove spring (20) and ring (21). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/5/1

120M Motor Grader - All Wheel Drive D9W00001-UP (MACHINE) POWERED BY ... 7/21 Illustration 13 g01137088 13. Remove seals (22), (23), and (24) from ring (21). Illustration 14 g01137089 14. Remove ring (25). Illustration 15 g01137095 15. Remove seal (26) from ring (25). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/5/1

120M Motor Grader - All Wheel Drive D9W00001-UP (MACHINE) POWERED BY ... 8/21 Illustration 16 g01137103 16. Remove discs (27). Note: The thickness of discs (27) may vary. Illustration 17 g01137106 17. Remove discs (28). Illustration 18 g01137111 18. Remove washer (29). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/5/1

120M Motor Grader - All Wheel Drive D9W00001-UP (MACHINE) POWERED BY ... 9/21 Illustration 19 g01150464 19. Use Tooling (B) in order to remove retaining ring (30). 20. Remove shaft (31) and gear (32) as an assembly. Illustration 20 g01137130 21. Remove retaining ring (33) and shim (34) from gear (32). Illustration 21 g01137133 22. Remove discs (35) from gear (32). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/5/1

120M Motor Grader - All Wheel Drive D9W00001-UP (MACHINE) POWERED B... 10/21 Illustration 22 g01137136 23. Remove clutch discs (36) from gear (32). Note: The thickness of clutch discs (36) may vary. Illustration 23 g01137145 24. Use Tooling (B) in order to remove retaining ring (37). Remove shaft assembly (31). Illustration 24 g01137149 25. Use Tooling (C) in order to remove retaining ring (38) from shaft assembly (31). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/5/1

120M Motor Grader - All Wheel Drive D9W00001-UP (MACHINE) POWERED B... 11/21 Illustration 25 g01137155 26. Use Tooling (D) in order to remove retaining ring (39) from shaft assembly (31). Remove race (40) from shaft assembly (31). Illustration 26 g01137164 27. Use a suitable press in order to remove washer (42) and ball bearing (41) from shaft assembly (31). Illustration 27 g01137169 28. Use a suitable press in order to remove ball bearing (41) from washer (42). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/5/1

120M Motor Grader - All Wheel Drive D9W00001-UP (MACHINE) POWERED B... 12/21 Illustration 28 g01137172 29. Remove bearing (44) and race (43). Illustration 29 g01194426 30. Remove bolt (45A), speed sensor (45), bolts (46), and lubrication pump (47). Illustration 30 g01137179 31. Remove bolts (48) and washer (49). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/5/1

120M Motor Grader - All Wheel Drive D9W00001-UP (MACHINE) POWERED B... 13/21 Illustration 31 g01150471 32. Use Tooling (E) in order to press gear assembly (50) from bearing cone (51). Illustration 32 g01150474 33. Remove bearing cone (51). Illustration 33 g01137187 34. Remove gear assembly (50). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/5/1

120M Motor Grader - All Wheel Drive D9W00001-UP (MACHINE) POWERED B... 14/21 Illustration 34 g01137217 35. Remove bearing cone (52) from gear assembly (50). Note: Bearing cone (52) will be damaged when bearing cone (52) is removed. Illustration 35 g01137229 36. Remove spring pins (53) from gear assembly (50). Illustration 36 g01137242 37. Use Tooling (C) to remove retaining ring (54) and planetary pinion (55) from gear assembly (50). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/5/1

120M Motor Grader - All Wheel Drive D9W00001-UP (MACHINE) POWERED B... 15/21 Note: Shim (56) and rollers (57) will fall when planetary pinion (55) is removed. Illustration 37 g01137244 38. Use Tooling (F) in order to remove inner race (58) from gear assembly (50). 39. Repeat Step 37 and Step 38 for the remaining planetary pinions. Illustration 38 g01137246 40. Remove bearing cup (59). Illustration 39 g01150588 https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/5/1

120M Motor Grader - All Wheel Drive D9W00001-UP (MACHINE) POWERED B... 16/21 41. Remove bearing cup (60). Illustration 40 g01150597 42. Remove seals (61) and (62). Illustration 41 g01150600 43. Remove bolts (63) and (64). Remove plate (65). Illustration 42 g01137273 44. Remove O-ring seal (66). Remove gear (67). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/5/1

120M Motor Grader - All Wheel Drive D9W00001-UP (MACHINE) POWERED B... 17/21 Illustration 43 g01137280 45. Use Tooling (G) and a suitable press in order to remove plate (68) from gear (67). Illustration 44 g01137286 46. If it is necessary, remove studs (69) from gear (67). Illustration 45 g01150605 47. Remove seal (70). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/5/1

120M Motor Grader - All Wheel Drive D9W00001-UP (MACHINE) POWERED B... 18/21 Illustration 46 g01150612 48. Use Tooling (G) in order to remove pinion (71). Illustration 47 g01150614 49. Remove O-ring seal (72) and bushing (73) from pinion (71). Illustration 48 g01150616 50. Use Tooling (G) in order to remove bearing cone (74) from pinion (71). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/5/1

120M Motor Grader - All Wheel Drive D9W00001-UP (MACHINE) POWERED B... 19/21 Illustration 49 g01150617 51. Remove bearing cone (75), washer (76), and bearing cup (77). Illustration 50 g01150620 52. Remove bearing cup (78) and shim (79). Remove cover (80). Illustration 51 g01150623 53. Use Tooling (H) in order to measure the depth of seal (81) and record the measurement for installation purposes. Remove seal (81) from cover (80). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/5/1

120M Motor Grader - All Wheel Drive D9W00001-UP (MACHINE) POWERED B... 20/21 Illustration 52 g01150626 54. Remove O-ring seals (82) from cover (80). Illustration 53 g01150627 55. Remove deflector plate (83). Illustration 54 g01150629 56. Remove gear (84). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/5/1

120M Motor Grader - All Wheel Drive D9W00001-UP (MACHINE) POWERED B... 21/21 Illustration 55 g01150630 57. Remove shroud (85). Illustration 56 g01150633 58. Remove spring pin (86) if it is necessary. Copyright 1993 - 2020 Caterpillar Inc. Fri May 1 15:25:55 UTC+0800 2020 All Rights Reserved. Private Network For SIS Licensees. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/5/1

120M Motor Grader - All Wheel Drive D9W00001-UP (MACHINE) POWERED BY ... 1/45 Shutdown SIS Previous Screen Product: MOTOR GRADER Model: 120M MOTOR GRADER D9W Configuration: 120M Motor Grader - All Wheel Drive D9W00001-UP (MACHINE) POWERED BY C6.6 Engine Disassembly and Assembly 12M and 120M Motor Graders Power Train Media Number -KENR6419-08 Publication Date -01/05/2017 Date Updated -15/05/2017 i07077362 Transmission - Disassemble SMCS - 3030-015; 3159-015; 3176-015 Disassembly Procedure Table 1 Required Tools Tool Part Number Part Description Qty A 439-3940 Link Bracket 3 B 422-8733 Jack Stand Gp 3 C 1U-9202 Lever Puller Hoist 1 D 1P-1863 Retaining Ring Pliers 1 E 308-3470 Jack Stand Gp 2 F 140-7742 Sleeve 1 G 154-6181 Forcing Bolt 2 H FT-2769 Table 1 J 4C-8156 Lifting Fixture 1 1U-6410 Three Jaw Puller 1 K 1P-0510 Driver Gp 1 L 9U-7480 Compressing Tube 1 5P-7970 Nut 1 8T-4224 Hard Washer 1 - 1 https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/5/1

120M Motor Grader - All Wheel Drive D9W00001-UP (MACHINE) POWERED BY ... 2/45 Bolt M8 - 1.25 by 460mm M 8B-7548 Push-Puller Tool Gp 1 N 2P-8312 Retaining Ring Pliers 1 1P-2321 Combination Puller 1 P 1P-0510 Driver Gp 1 189-0408 Shackle As 1 R 3E-3882 Eyebolt 1 126-7175 Push-Puller Tool Gp 1 S 4C-5653 Threaded Adapter 1 1P-0510 Driver Gp 1 Start By: a. Remove the transmission. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat products. Dispose of all fluids according to local regulations and mandates. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. Note: Put identification marks on all harness assemblies for installation purposes. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/5/1

120M Motor Grader - All Wheel Drive D9W00001-UP (MACHINE) POWERED BY ... 3/45 Illustration 1 g01386565 1. Attach Tooling (A) and a suitable lifting device to transmission (1). The weight of transmission (1) is approximately 862 kg (1900 lb). Use Tooling (A) and the suitable lifting device to position transmission (1) onto Tooling (B). Remove hose assembly (2). Illustration 2 g01386568 2. Remove bolts (3) to remove control module (4) and spacers (5). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/5/1

120M Motor Grader - All Wheel Drive D9W00001-UP (MACHINE) POWERED BY ... 4/45 Illustration 3 g01386574 3. Remove yoke assembly (6). Illustration 4 g01386575 4. Remove retaining ring (7). 5. Remove cup (8). Remove O-ring seal (9). Illustration 5 g01386579 6. Attach Tooling (A), Tooling (C), and a suitable lifting device to transmission (1). Use Tooling (A), Tooling (C), and the suitable lifting device to position transmission (1) onto Tooling (B) and suitable cribbing. Position transmission (1) with the output shaft upward. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/5/1

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120M Motor Grader - All Wheel Drive D9W00001-UP (MACHINE) POWERED BY ... 5/45 Illustration 6 g01386585 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. 7. Remove bolts (10) to remove plate assembly (11). Illustration 7 g01386589 8. Remove lip seal (12). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/5/1

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