Caterpillar Cat 120H NA Motor Grader (Prefix 4MK) Service Repair Manual Instant Download

Service Repair Manual Models 120H NA M otor Grader

120H Motor Grader 4MK00001-UP (MACHINE) POWERED BY 3116 Engine(SEBP... 1/14 Shutdown SIS Previous Screen Product: MOTOR GRADER Model: 120H NA MOTOR GRADER 4MK Configuration: 120H Motor Grader 4MK00001-UP (MACHINE) POWERED BY 3116 Engine Disassembly and Assembly 120H & 135H MOTOR GRADERS MACHINE SYSTEM Media Number -SENR8544-01 Publication Date -01/10/2004 Date Updated -04/02/2016 SENR85440037 Implement Control Valves SMCS - 5051-016; 5051-011; 5051-012; 5051-015 Remove Implement Control Valves 1. Release the pressure in the hydraulic system as follows: At operating temperature, the hydraulic oil is hot and under pressure. Hot oil can cause burns. Sudden movement of the machine or release of oil pressure can cause injury to persons on or near the machine. To prevent possible injury, perform the following procedure before working on the hydraulic and steering systems. a. Move the machine to a smooth horizontal location. Move away from working machines and personnel. Lower all implements to the ground. Install the wheel lean pin in front axle. b. Permit only one operator on the machine. Keep all other personnel either away from the machine or in view of the operator. c. Activate the parking brake. Place all implements on the ground and put the blade in the "FLOAT" position. d. Stop the engine. e. Turn the steering wheel back and forth several times to relieve pressure in the steering accumulator. f. Carefully loosen the filler cap on the hydraulic tank to release pressure in the tank. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/3/11

120H Motor Grader 4MK00001-UP (MACHINE) POWERED BY 3116 Engine(SEBP... 2/14 g. Be sure all hydraulic pressure is released before any fitting, hose, or component is loosened, tightened, removed or adjusted. h. Tighten the cap on the hydraulic tank. i. The pressure in the hydraulic system must be released before lines or components can be removed. Hydraulic pressure can exist in the hydraulic lines between the control valves and the cylinders with the engine stopped. Manually relieve pressure before working on any hydraulic circuit. 2. Put identification marks on hose assemblies (1) for installation purposes. The number of control valves and hoses will vary with the amount of implements on the machine. 3. Remove hose assemblies (1) from the implement control valves. Plug the fittings on the hoses in order to prevent the loss of hydraulic oil, and to keep dirt out of the hydraulic oil system. 4. Remove bolts (2) from cover (3). Raise cover (3) up and out of the way. Pull floor mat (4) back and out of the way. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/3/11

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120H Motor Grader 4MK00001-UP (MACHINE) POWERED BY 3116 Engine(SEBP... 3/14 5. Remove four bolts (7) from control valve linkages (8). Move four control valve linkages (8) up and out of the way. 6. Remove bolts (5) and the washers from cover (6). Remove cover (6) from the floor of the cab. 7. Remove bolts (9), bolt (10), the washers, the nuts and the rubber mountings that hold the implement control valves. Remove the implement control valves from the mounting plates. 8. Repeat Steps 2 through 7 for the implement control valves located on the other side of the machine. Install Implement Control Valves 1. Make sure all of the components of the implement control valves are clean prior to installation. During the installation, check condition of all the O-ring seals used on the hydraulic hoses that were disconnected. If any of these seals are damaged, use new parts for replacement. 2. Position the implement control valves to their original locations and install bolts (9), bolt (10), the washers, the nutsand the rubber mountings in order to secure the valves to the mounting plates. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/3/11

120H Motor Grader 4MK00001-UP (MACHINE) POWERED BY 3116 Engine(SEBP... 4/14 3. Install cover (6), bolts (5) and washers that hold cover (6) to the floor of the cab. 4. Install control valve linkages (8) and bolts (7) that hold the linkages to the implement control valves. 5. Position floor mat (4) to its original location on the floor of the cab. Install cover (3) and bolts (2). 6. Install hose assemblies (1) to their original locations on the implement control valves. 7. Repeat Steps 2 through 6 for the other side. 8. Fill the hydraulic tank with oil to its correct level. Refer to the "Operation & Maintenance Manual" for the proper procedure. Disassemble Implement Control Valve Start By: a. remove implement control valve https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/3/11

120H Motor Grader 4MK00001-UP (MACHINE) POWERED BY 3116 Engine(SEBP... 5/14 1. Put identification marks on cover (2), valves (5) and manifold (4), showing the location of the components, for assembly purposes. Remove bolts (1) and cover (2) from the control valve. 2. Remove bolts (3) and manifold (4) from the control valve. NOTE: The number of valves may vary in order to match the number of implements. 3. Separate individual valves (5) and seal plates (6) from the unit. 4. Remove bolts (7) and washers from valve (5). 5. Remove cover (9), O-ring seal (10) and spring (11) from valve (5). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/3/11

120H Motor Grader 4MK00001-UP (MACHINE) POWERED BY 3116 Engine(SEBP... 6/14 6. Remove bolts (8), the washers and control assembly (12) from valve (5). 7. Remove bolts (13), the washers and cover (14) from control assembly (12). 8. Remove O-ring seal (15) and lever (16) from control assembly (12). 9. Remove lever assembly (17) and spool assembly (20) from control assembly (12). 10. Remove two O-ring seals (18) and two back-up rings (19) from lever assembly (17). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/3/11

120H Motor Grader 4MK00001-UP (MACHINE) POWERED BY 3116 Engine(SEBP... 7/14 11. Compress spring (21) and remove retainers (22) from spool (20). 12. Remove two plugs (23) and plug (24) from valve (5). 13. Remove spring (25), valve (26), seat (27), O-ring seal (28) and piston (29) from valve (5). 14. Remove spring (33), valve (32), seat (30) and O-ring seal (31) from valve (5). 15. Remove plug (34), spring (35), and valve (36) from valve body (5). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/3/11

120H Motor Grader 4MK00001-UP (MACHINE) POWERED BY 3116 Engine(SEBP... 8/14 16. Remove plug (37), O-ring seal (38), spring (39), and ball (40) from valve body (5). 17. Repeat Steps 4 through 16 for the other valve sections. 18. Some of the valve groups are equipped with detent valve (41) and relief valve (42). If so, complete Steps 19 through 25. 19. Remove bolts and washers (43) and detent housing (41) from valve body (5). 20. Remove detent (47), spring (46), and spool (45) from valve body (5). 21. Compress detent spring (51) by pressing on retainer (48). Remove six balls (49) and spring (51) from retainer (50). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/3/11

120H Motor Grader 4MK00001-UP (MACHINE) POWERED BY 3116 Engine(SEBP... 9/14 22. Remove relief valve (42) from valve (5). 23. Remove O-ring seal (53), O-ring seal (54), and retainer (57) from relief valve body (52). 24. Remove valve (55) and spring (56) from relief valve body (52). 25. Remove O-ring seal (60), washer (59) and nut (58) from retainer (57). Assemble Implement Control Valves NOTE: Make sure all of the components of the implement control valves are clean prior to assembly. During assembly, check the condition of all the O-ring seals used in the valve. If any of these seals are damaged, use new parts for replacement. 1. Install O-ring seal (60), washer (59) and nut (58) to retainer (57). 2. Install valve (55), spring (56) and retainer (57) to relief valve body (52). 3. Install O-ring seal (53) and O-ring seal (54) to relief valve body (52). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/3/11

120H Motor Grader 4MK00001-UP (MACHINE) POWERED BY 3116 Engine(SE... 10/14 4. Install relief valve (42) to valve (5). 5. Install spring (51) and retainer (48) to retainer (50). 6. Compress spring (51) and install six balls (49) between retainers (48) and (50). 7. Install spool (45), spring (46), detent (47), detent housing (41), and bolts (43) and washers to control valve (5). 8. Install ball (40), spring (39), plug (37), and O-ring seal (38) in valve (5). Tighten plug (37) to a torque of 9 + 1 - 0 N m (80 + 9 - 0 lb in). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/3/11

120H Motor Grader 4MK00001-UP (MACHINE) POWERED BY 3116 Engine(SE... 11/14 9. Install valve (36), spring (35) and plug (34) to valve (5). 10. Install piston (29), seat (27), O-ring seal (28), valve (26), and spring (25) in valve (5). 11. Install seat (30), O-ring seal (31), valve (32), and spring (33) to valve (5). 12. Install two plugs (23) and plug (24) to valve (5). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/3/11

120H Motor Grader 4MK00001-UP (MACHINE) POWERED BY 3116 Engine(SE... 12/14 13. Install spring (21) and retainers (22) to spool (20). 14. Install two O-ring seals (18) and two back-up rings (19) to lever assembly (17). 15. Install spool (20), lever assembly (17) and lever (16) to control assembly (12). 16. Install O-ring seal (15) to control assembly (12). 17. Install cover (14), bolts (13) and washers to control assembly (12). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/3/11

120H Motor Grader 4MK00001-UP (MACHINE) POWERED BY 3116 Engine(SE... 13/14 18. Install control assembly (12), bolts (8) and washers in valve (5). 19. Install spring (11), O-ring seal (10), cover (9), bolts (7) and washers in valve (5). 20. Position valves (5), plates (6), manifold (4) and cover (2) to their original locations in order to assemble the valve group. 21. Install bolts (3) through manifold (4), valves (5) and seal plates (6). Install bolts (3) in the last valve. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/3/11

120H Motor Grader 4MK00001-UP (MACHINE) POWERED BY 3116 Engine(SE... 14/14 22. Install cover (2) and bolts (1) to the control valve. Copyright 1993 - 2020 Caterpillar Inc. Wed Mar 11 12:23:17 UTC+0800 2020 All Rights Reserved. Private Network For SIS Licensees. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/3/11

120H Motor Grader 4MK00001-UP (MACHINE) POWERED BY 3116 Engine(SEBP... 1/9 Shutdown SIS Previous Screen Product: MOTOR GRADER Model: 120H NA MOTOR GRADER 4MK Configuration: 120H Motor Grader 4MK00001-UP (MACHINE) POWERED BY 3116 Engine Disassembly and Assembly 120H & 135H MOTOR GRADERS MACHINE SYSTEM Media Number -SENR8544-01 Publication Date -01/10/2004 Date Updated -04/02/2016 SENR85440038 Combination Valve SMCS - 5064-016; 5064-011; 5064-012; 5064-015 Remove Combination Valve At operating temperature, the hydraulic oil is hot and under pressure. Hot oil can cause burns. Sudden movement of the machine or release of oil pressure can cause injury to persons on or near the machine. To prevent possible injury, perform the following procedure before working on the hydraulic and steering systems. a. Move the machine to a smooth horizontal location. Move away from working machines and personnel. Lower all implements to the ground. Install the wheel lean pin in front axle. b. Permit only one operator on the machine. Keep all other personnel either away from the machine or in view of the operator. c. Activate the parking brake. Place all implements on the ground and put the blade in the "FLOAT" position. d. Stop the engine. e. Turn the steering wheel back and forth several times to relieve pressure in the steering accumulator. f. Carefully loosen the filler cap on the hydraulic tank to release pressure in the tank. g. Be sure all hydraulic pressure is released before any fitting, hose, or component is loosened, tightened, removed or adjusted. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/3/11

120H Motor Grader 4MK00001-UP (MACHINE) POWERED BY 3116 Engine(SEBP... 2/9 h. Tighten the cap on the hydraulic tank. i. The pressure in the hydraulic system must be released before lines or components can be removed. Hydraulic pressure can exist in the hydraulic lines between the control valves and the cylinders with the engine stopped. Manually relieve pressure before working on any hydraulic circuit. 1. Remove plug from ecology drain at the bottom of the hydraulic oil tank. Drain the hydraulic oil in a suitable container for storage or disposal. The capacity of the hydraulic oil tank is 63 liters (16.8 U.S. gal). To prevent possible injury, the pressure from the hydraulic system must be released. The accumulator will bleed down through the steering metering pump when it is in the Neutral (non-steer) position. With the engine off, accumulator bleed down takes eight minutes. To bleed down the accumulator sooner, turn the steering wheel to the right and to the left. The accumulator is charged to 6900 kPa (1000 psi) with dry Nitrogen. 2. Remove steering accumulator (2) from combination valve (3). 3. Disconnect eight oil lines (1) from combination valve (3). 4. Remove oil line (5) from combination valve (3) and pressure and flow compensator (6). 5. Remove four mounting bolts (4) and combination valve (3) from the hydraulic pump. Install Combination Valve https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/3/11

120H Motor Grader 4MK00001-UP (MACHINE) POWERED BY 3116 Engine(SEBP... 3/9 NOTE: Make sure all of the components of the combination valve are clean prior to assembly. During assembly, check the condition of all the O-ring seals used in the assembly. If any of these seals are damaged, use new parts for replacement. 1. Position combination valve (3) and install four mounting bolts (4). 2. Install oil line (5) to combination valve (3) and pressure and flow compensator (6). 3. Connect eight oil lines (1) to combination valve (3). 4. Install steering accumulator (2) to combination valve (3). Disassemble Combination Valve Start By: a. remove combination valve 1. Remove valve group (1) from the combination valve. 2. Remove retainer assembly (2), nut (3), O-ring seal (4), plate (5), spring (6), plate (7), valve (8), body (9), O-ring seal (10) and O-ring seal (11) from valve group (1). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/3/11

120H Motor Grader 4MK00001-UP (MACHINE) POWERED BY 3116 Engine(SEBP... 4/9 3. Remove valve group (12) from the combination valve. 4. Remove retainer assembly (13), nut (14), O-ring seal (15), spring (16), valve (17), body (18), O -ring seal (19), ring (20), O-ring seal (21), O-ring seal (22) and seat (23) from valve group (12). 5. Remove spring (24), spring (25) and valve spool (26) from the combination valve. 6. Remove valve group (27) from the combination valve. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/3/11

120H Motor Grader 4MK00001-UP (MACHINE) POWERED BY 3116 Engine(SEBP... 5/9 7. Remove O-ring seal (28), O-ring seal (29) and nut (30) from valve group (27). 8. Remove valve group (31) from the combination valve. 9. Remove nut (32), O-ring seal (33), valve spool (34) and spring (35) from valve group (31). 10. Remove valve group (36) from the combination valve. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/3/11

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120H Motor Grader 4MK00001-UP (MACHINE) POWERED BY 3116 Engine(SEBP... 6/9 11. Remove plug (37), O-ring seal (38), plate (39), O-ring seal (40), plate (41), ball (42) from inside barrel, plate (43), O-ring (44), plate (45) and seat (46) from valve group (36). 12. Remove valve group (47) from the combination valve. 13. Remove plug (48), O-ring seal (49), spring (50) and valve (51) from valve group (47). Assemble Combination Valve 1. Make sure that all the components of the combination valve are clean before assembly. During the assembly of the combination valve, check the condition of all the O-ring seals that are used in the assembly. If any of the seals are damaged, use new parts for replacement. 2. Install plug (48), O-ring seal (49), spring (50) and valve (51) on valve group (47). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/3/11

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