Caterpillar Cat 120M Motor Grader (Prefix R9A) Service Repair Manual Instant Download

Service Repair Manual Models 120M M otor Grader

120M Motor Grader R9A00001-UP (MACHINE) POWERED BY C6.6 Engine(SEBP... 1/19 Shutdown SIS Previous Screen Product: MOTOR GRADER Model: 120M MOTOR GRADER R9A Configuration: 120M Motor Grader R9A00001-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 i03096382 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 8B-7551 Bearing Puller Gp 1 1P-5546 Crossarm 1 F 3H-0465 Push-Puller Plate 2 5F-7366 Forcing Screw 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, differential, and final drive. Refer to Disassembly and Assembly, "Rear Axle, Differential, and Final Drive - Remove". https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/5/3

120M Motor Grader R9A00001-UP (MACHINE) POWERED BY C6.6 Engine(SEBP... 2/19 NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. Note: Inspect the O-ring seals. Replace the O-ring seals that are worn or damaged. Illustration 1 g01413868 1. Use Tooling (A), Tooling (B), and two suitable lifting devices in order to position rear axle, differential, and final drive (1) onto suitable blocking. The weight of rear axle, differential, and final drive (1) is approximately 1089 kg (2400 lb). Illustration 2 g01418559 2. Remove bolts (3), retainer (4), shims (5), sprocket (2), and sprocket (6). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/5/3

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120M Motor Grader R9A00001-UP (MACHINE) POWERED BY C6.6 Engine(SEBP... 3/19 Note: Note the quantity and the order of shims (5). Illustration 3 g01414357 3. Remove bearing cone (7). Illustration 4 g01412778 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 181 kg (400 lb). Remove nuts (9). 5. Use Tooling (D) in order to remove final drive housing (8). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/5/3

120M Motor Grader R9A00001-UP (MACHINE) POWERED BY C6.6 Engine(SEBP... 4/19 Illustration 5 g01419912 6. Remove bolts (10). Remove retainer (11). Illustration 6 g01352280 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 57 kg (126 lb). Note: Note the quantity and the order of shims (12). Illustration 7 g01352292 https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/5/3

120M Motor Grader R9A00001-UP (MACHINE) POWERED BY C6.6 Engine(SEBP... 5/19 8. Remove thrust washer (14). Remove wear sleeves (15). Illustration 8 g01352299 9. Turn over housing (13). Remove lip seal (16). Illustration 9 g01414353 10. Remove bearing cup (17). Remove thrust washer (18). Illustration 10 g01352320 11. Remove lip seal (19). Remove bearing cup (20). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/5/3

120M Motor Grader R9A00001-UP (MACHINE) POWERED BY C6.6 Engine(SEBP... 6/19 Illustration 11 g01419983 12. Use Tooling (E) in order to remove carrier assembly (21) and drive shaft (22). The weight of carrier assembly (21) and drive shaft (22) is approximately 58 kg (128 lb). Illustration 12 g01419985 13. Use Tooling (F) in order to remove bearing cone (23). Illustration 13 g01352339 14. Remove retaining ring (24) in order to remove axle shaft (22) from carrier assembly (21). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/5/3

120M Motor Grader R9A00001-UP (MACHINE) POWERED BY C6.6 Engine(SEBP... 7/19 Illustration 14 g01352406 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. Illustration 15 g01352384 16. Remove axle shaft assembly (31). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/5/3

120M Motor Grader R9A00001-UP (MACHINE) POWERED BY C6.6 Engine(SEBP... 8/19 Illustration 16 g01352402 17. Remove retaining ring (32) in order to remove gear (33) from axle shaft (34). Illustration 17 g01352438 18. Use Tooling (D) in order to separate ring gear (35) from the intermediate housing. Illustration 18 g01352445 19. Use Tooling (B) and a suitable lifting device in order to remove ring gear (35). The weight of ring gear (35) is approximately 23 kg (51 lb). 20. Repeat Step 2 through Step 19 for the opposite side. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/5/3

120M Motor Grader R9A00001-UP (MACHINE) POWERED BY C6.6 Engine(SEBP... 9/19 Illustration 19 g01353587 21. Position differential housing (36) with intermediate housing (37) upward. Illustration 20 g01419994 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 47 kg (104 lb). Illustration 21 g01353021 23. Remove shims (40). Remove O-ring seal (41). Note: Note the order and the quantity of shims (40). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/5/3

120M Motor Grader R9A00001-UP (MACHINE) POWERED BY C6.6 Engine(SE... 10/19 Illustration 22 g01353002 24. Remove bolt (42). Remove retainer (43). Remove yoke (44). Remove guard (45). Illustration 23 g01353512 25. Remove shims (46). Remove lip seal (47). Note: Note the order and the quantity of shims (46). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/5/3

120M Motor Grader R9A00001-UP (MACHINE) POWERED BY C6.6 Engine(SE... 11/19 Illustration 24 g01353570 26. Remove pinion (48). Remove bearing cone (49). Remove bearing cup (50). Remove bearing cone (51). Remove bearing cup (52). Illustration 25 g01420086 27. Remove bolts (53). Illustration 26 g01419995 Typical Example 28. Use Tooling (G) in order to remove nut assembly (54). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/5/3

120M Motor Grader R9A00001-UP (MACHINE) POWERED BY C6.6 Engine(SE... 12/19 Illustration 27 g01420082 29. Remove bolts (55). Remove bolts (56). Illustration 28 g01419996 30. Use Tooling (H) in order to separate intermediate housing (37) from differential housing (36). Illustration 29 g01420124 31. Use Tooling (E) in order to remove intermediate housing (37). The weight of intermediate housing (37) is approximately 31 kg (68 lb). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/5/3

120M Motor Grader R9A00001-UP (MACHINE) POWERED BY C6.6 Engine(SE... 13/19 Illustration 30 g01352893 32. Remove shims (57). Illustration 31 g01352898 33. Use Tooling (A) in order to remove bearing assembly (58) and differential (59). The weight of bearing assembly (58) and differential (59) is approximately 91 kg (200 lb). Illustration 32 g01352982 34. Remove bolts (60). Remove shroud (61). Illustration 33 g01419997 https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/5/3

120M Motor Grader R9A00001-UP (MACHINE) POWERED BY C6.6 Engine(SE... 14/19 35. Use Tooling (F) in order to remove bearing assembly (62). Illustration 34 g01354900 36. Remove bearing cone (63). Remove bearing cups (64). Illustration 35 g01420000 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). Illustration 36 g01353751 https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/5/3

120M Motor Grader R9A00001-UP (MACHINE) POWERED BY C6.6 Engine(SE... 15/19 38. Remove retaining ring (67). Remove bearing race (68). Remove O-ring seals (69). Remove thrust ring (70). Illustration 37 g01353760 Typical Example 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). Illustration 38 g01353766 40. Remove thrust washer (73). Remove plates (74) and discs (75). Remove springs (76). Note: Note the quantity and the order of plates (74) and discs (75). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/5/3

120M Motor Grader R9A00001-UP (MACHINE) POWERED BY C6.6 Engine(SE... 16/19 Illustration 39 g01353940 41. Use two people in order to remove housing (77). The weight of housing (77) is approximately 23 kg (50 lb). Illustration 40 g01353944 42. Remove differential gear (78). Illustration 41 g01353945 43. Remove spider assembly (79). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/5/3

120M Motor Grader R9A00001-UP (MACHINE) POWERED BY C6.6 Engine(SE... 17/19 Illustration 42 g01353954 44. Remove thrust washer (80), pinion gear (81), and bearing sleeve (82) from spider (83). Repeat this step for the remaining pinion gears (81). Illustration 43 g01353965 45. Remove differential gear (84). Remove thrust washer (85). Illustration 44 g01353970 46. Use two people in order to turn over housing (86) and bevel gear (87). Remove bolts (88). The weight of housing (86) and bevel gear (87) is approximately 40 kg (88 lb). Remove bolts (88). Use two people in order to remove housing (86) from bevel gear (87). The https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/5/3

120M Motor Grader R9A00001-UP (MACHINE) POWERED BY C6.6 Engine(SE... 18/19 weight of housing (86) is approximately 23 kg (50 lb). The weight of bevel gear (85) is approximately 17 kg (38 lb). Illustration 45 g01355203 47. Remove bearing assembly (89). Remove piston (90). Illustration 46 g01355208 48. Remove thrust race (91), thrust bearing (92), and thrust race (93) from piston (90). Illustration 47 g01355211 49. Remove seals (94) from piston (90). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/5/3

120M Motor Grader R9A00001-UP (MACHINE) POWERED BY C6.6 Engine(SEBP... 1/27 Shutdown SIS Previous Screen Product: MOTOR GRADER Model: 120M MOTOR GRADER R9A Configuration: 120M Motor Grader R9A00001-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 i07285127 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 Part Number Tool Part Description Qty A 439-3940 Link Bracket 4 B 140-7742 Sleeve 2 C 386-6031 Lever Puller Hoist 1 E 143-3939 Link Bracket 2 G 292-4949 Socket Wrench As 1 H 154-6183 Forcing Bolt 2 K 4C-4030 Thread Lock Compound 1 L 1U-8846 Gasket Sealant 1 6V-2012 Depth Micrometer 1 M Caliper(1) 367-9109 1 8T-5096 Dial Indicator Gp 1 N 301-3405 Gauge 1 P 8T-4140 Bolt 4 R 7M-7456 Bearing Mount Compound 1 https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/5/3

120M Motor Grader R9A00001-UP (MACHINE) POWERED BY C6.6 Engine(SEBP... 2/27 S - Cat Advance 3Moly Grease or Dow Corning Molykote BR2 - Plus 1 T 8T-5096 Dial Indicator Gp 1 (1)For use with three bolt retainers NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. Note: Inspect the O-ring seals, gaskets, and lip seals. Replace O-ring seals, gaskets, and lip seals that are worn or damaged. Note: Lubricate O-ring seals and lip seals with the lubricant that is being sealed. Illustration 1 g03831520 1. Install seals (94) onto piston (90). Illustration 2 g03831488 https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/5/3

120M Motor Grader R9A00001-UP (MACHINE) POWERED BY C6.6 Engine(SEBP... 3/27 Note: Grease is used to hold thrust race (93) and thrust bearing (92) in place during assembly. 2. Apply a liberal amount of grease to thrust race (93) and to thrust bearing (92). Install thrust race (93) and thrust bearing (92) onto piston (90). Illustration 3 g01355203 3. Install piston (90). Lower the temperature of bearing assembly (89). Install bearing assembly (89). Illustration 4 g01353970 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 two people 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). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/5/3

120M Motor Grader R9A00001-UP (MACHINE) POWERED BY C6.6 Engine(SEBP... 4/27 Illustration 5 g01353965 6. Install thrust washer (85). Install differential gear (84). Note: Install thrust washer (85) with the groove side against gear (84). Illustration 6 g01353954 7. Install bearing sleeve (82), pinion gear (81), and thrust washer (80) onto spider (83). Repeat this step for the remaining pinion gears (81). Illustration 7 g01353945 8. Install spider assembly (79). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/5/3

120M Motor Grader R9A00001-UP (MACHINE) POWERED BY C6.6 Engine(SEBP... 5/27 Illustration 8 g01353944 9. Install differential gear (78). Illustration 9 g01353940 10. Install housing (77). Note: Ensure that the notches on the housings are aligned. Illustration 10 g01353766 https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/5/3

120M Motor Grader R9A00001-UP (MACHINE) POWERED BY C6.6 Engine(SEBP... 6/27 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. Illustration 11 g01353760 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. Note: Determine bolt size before torquing bolts (71). 12. Install case (72). Install bolts (71). Tighten M16 bolts (71) to a torque of 300 40 N m (220 30 lb ft). Tighten M12 bolts (71) to a torque of 120 20 N m (90 15 ft) https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/5/3

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120M Motor Grader R9A00001-UP (MACHINE) POWERED BY C6.6 Engine(SEBP... 7/27 Illustration 12 g03831494 Note: Grease is used to hold thrust race (91) in place during assembly. 13. Install thrust ring (70). Apply a liberal amount of grease to thrust race (91). Install thrust race (91) onto thrust ring (70). Install O-ring seals (69). Raise the temperature of bearing race (68). Install bearing race (68). Install retaining ring (67). Illustration 13 g01354921 14. Raise the temperature of bearing cone (66). Install bearing cone (66) and spacer (65). Illustration 14 g06240309 15. Use a suitable press to install bearing assembly (55). Install shroud (58). Apply Tooling (K) to the threads of bolts (57) and install bolts (57). Tighten bolts (57) to a torque of 28 7 N m (21 5 lb ft). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/5/3

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