Caterpillar Cat 120M Series 2 OEM Motor Grader (Prefix M92) Service Repair Manual Instant Download

Service Repair Manual Models 120M Series 2 M otor Grader

120M Series 2 OEM Motor Grader M9200001-UP (MACHINE) POWERED BY C7.1... 1/20 Shutdown SIS Previous Screen Product: MOTOR GRADER Model: 120M 2 MOTOR GRADER M92 Configuration: 120M Series 2 OEM Motor Grader M9200001-UP (MACHINE) POWERED BY C7.1 Engine Disassembly and Assembly 120M Series 2 Motor Grader Power Train Media Number -KENR9467-02 Publication Date -01/05/2017 Date Updated -16/05/2017 i06013976 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 439-3940 Link Bracket 4 B 140-7742 Sleeve 2 C 386-6031 Lever Puller Hoist 1 D 154-6182 Forcing Bolt 3 E 439-3939 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. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/5/6

120M Series 2 OEM Motor Grader M9200001-UP (MACHINE) POWERED BY C7.1... 2/20 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 (1) onto suitable blocking. The weight of rear axle (1) is approximately 1089 kg (2400 lb). Illustration 2 g01418559 https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/5/6

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120M Series 2 OEM Motor Grader M9200001-UP (MACHINE) POWERED BY C7.1... 3/20 2. Remove bolts (3) , retainer (4) , shims (5) , sprocket (2) , and sprocket (6) . Note: Note the quantity and the order of shims (5) . Illustration 3 g01414357 3. Remove bearing cone (7) . Illustration 4 g01412778 https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/5/6

120M Series 2 OEM Motor Grader M9200001-UP (MACHINE) POWERED BY C7.1... 4/20 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 191 kg (420 lb). Remove nuts (9) and bolts (9A) . 5. Use Tooling (D) in order to remove final drive housing (8) . 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 54 kg (120 lb). Note: Note the quantity and the order of shims (12) . https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/5/6

120M Series 2 OEM Motor Grader M9200001-UP (MACHINE) POWERED BY C7.1... 5/20 Illustration 7 g01352292 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) . https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/5/6

120M Series 2 OEM Motor Grader M9200001-UP (MACHINE) POWERED BY C7.1... 6/20 Illustration 10 g01352320 11. Remove lip seal (19) . Remove bearing cup (20) . 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 136 kg (300 lb). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/5/6

120M Series 2 OEM Motor Grader M9200001-UP (MACHINE) POWERED BY C7.1... 7/20 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) . 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. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/5/6

120M Series 2 OEM Motor Grader M9200001-UP (MACHINE) POWERED BY C7.1... 8/20 Illustration 15 g01352384 16. Remove axle shaft assembly (31) . 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. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/5/6

120M Series 2 OEM Motor Grader M9200001-UP (MACHINE) POWERED BY C7.1... 9/20 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 25 kg (55 lb). 20. Repeat Step 2 through Step 19 for the opposite side. Illustration 19 g01353587 21. Position differential housing (36) with intermediate housing (37) upward. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/5/6

120M Series 2 OEM Motor Grader M9200001-UP (MACHINE) POWERED BY C... 10/20 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 56 kg (123 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... 2020/5/6

120M Series 2 OEM Motor Grader M9200001-UP (MACHINE) POWERED BY C... 11/20 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) . Illustration 24 g01353570 26. Remove pinion (48) . Remove bearing cone (49) . Remove bearing cup (50) . Remove bearing cone (51) . Remove bearing cup (52) . 27. Use Tooling (G) in order to remove nut assembly (54) . https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/5/6

120M Series 2 OEM Motor Grader M9200001-UP (MACHINE) POWERED BY C... 12/20 Illustration 25 g03772865 28. Remove bolts (53) . Remove bolts (54) . Illustration 26 g01419996 Typical Example 29. Use Tooling (J) in order to separate intermediate housing (37) from differential housing (36) . https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/5/6

120M Series 2 OEM Motor Grader M9200001-UP (MACHINE) POWERED BY C... 13/20 Illustration 27 g01420124 Typical Example 30. Use Tooling (E) in order to remove intermediate housing (37) . The weight of intermediate housing (37) is approximately 32 kg (71 lb). Illustration 28 g03772901 Typical Example 31. Before installing Tooling (A) remove the shims. Use Tooling (A) in order to remove bearing assembly (55) and differential (56) . The weight of bearing assembly (55) and differential (56) is approximately 102 kg (225 lb). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/5/6

120M Series 2 OEM Motor Grader M9200001-UP (MACHINE) POWERED BY C... 14/20 Illustration 29 g03772885 32. Remove bolts (57) . Remove shroud (58) . Illustration 30 g03772948 33. Remove bolts (59) . Use Tooling (G) and remove lock-nut (60) . Illustration 31 g03772966 34. Use Tooling (F) in order to remove bearing assembly (55) . https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/5/6

120M Series 2 OEM Motor Grader M9200001-UP (MACHINE) POWERED BY C... 15/20 Illustration 32 g01354900 35. Remove bearing cone (63) . Remove bearing cups (64) . Illustration 33 g01420000 36. Use Tooling (J) in order to remove spacer (65) and bearing cone (66) . Note: This step is a destructive procedure. Replace bearing cone (66) . https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/5/6

120M Series 2 OEM Motor Grader M9200001-UP (MACHINE) POWERED BY C... 16/20 Illustration 34 g01353751 37. Remove retaining ring (67) . Remove bearing race (68) . Remove O-ring seals (69) . Remove thrust ring (70) . Illustration 35 g01353760 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. 38. Remove bolts (71) . Remove case (72) . https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/5/6

120M Series 2 OEM Motor Grader M9200001-UP (MACHINE) POWERED BY C... 17/20 Illustration 36 g01353766 39. 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) . Illustration 37 g01353940 40. Remove housing (77) . Illustration 38 g01353944 41. Remove differential gear (78) . https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/5/6

120M Series 2 OEM Motor Grader M9200001-UP (MACHINE) POWERED BY C... 18/20 Illustration 39 g01353945 42. Remove spider assembly (79) . Illustration 40 g01353954 43. Remove thrust washer (80) , pinion gear (81) , and bearing sleeve (82) from spider (83) . Repeat this step for the remaining pinion gears (81) . Illustration 41 g01353965 https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/5/6

120M Series 2 OEM Motor Grader M9200001-UP (MACHINE) POWERED BY C... 19/20 44. Remove differential gear (84) . Remove thrust washer (85) . Illustration 42 g01353970 45. Use two people in order to turn over housing (86) and bevel gear (87) . The combined weight of housing (86) and bevel gear (87) is approximately 59 kg (130 lb). Remove bolts (88) . Use two people in order to remove housing (86) from bevel gear (87) . The weight of housing (86) is approximately 41 kg (90 lb). The weight of bevel gear (87) is approximately 19 kg (41 lb). Illustration 43 g01355203 46. Remove bearing assembly (89) . Remove piston (90) . https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/5/6

120M Series 2 OEM Motor Grader M9200001-UP (MACHINE) POWERED BY C... 20/20 Illustration 44 g01355208 47. Remove thrust race (91) , thrust bearing (92) , and thrust race (93) from piston (90) . Illustration 45 g01355211 48. Remove seals (94) from piston (90) . Copyright 1993 - 2020 Caterpillar Inc. Wed May 6 12:13:29 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... 2020/5/6

120M Series 2 OEM Motor Grader M9200001-UP (MACHINE) POWERED BY C7.1... 1/27 Shutdown SIS Previous Screen Product: MOTOR GRADER Model: 120M 2 MOTOR GRADER M92 Configuration: 120M Series 2 OEM Motor Grader M9200001-UP (MACHINE) POWERED BY C7.1 Engine Disassembly and Assembly 120M Series 2 Motor Grader Power Train Media Number -KENR9467-02 Publication Date -01/05/2017 Date Updated -16/05/2017 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... 2020/5/6

120M Series 2 OEM Motor Grader M9200001-UP (MACHINE) POWERED BY C7.1... 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... 2020/5/6

120M Series 2 OEM Motor Grader M9200001-UP (MACHINE) POWERED BY C7.1... 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... 2020/5/6

120M Series 2 OEM Motor Grader M9200001-UP (MACHINE) POWERED BY C7.1... 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... 2020/5/6

120M Series 2 OEM Motor Grader M9200001-UP (MACHINE) POWERED BY C7.1... 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... 2020/5/6

120M Series 2 OEM Motor Grader M9200001-UP (MACHINE) POWERED BY C7.1... 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... 2020/5/6

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120M Series 2 OEM Motor Grader M9200001-UP (MACHINE) POWERED BY C7.1... 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... 2020/5/6

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