Service Repair Manual
Models
120M Motor Grader
120M Motor Grader - All Wheel Drive D9W00001-UP (MACHINE) POWERED BY ... 1/21
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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:
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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).
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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).
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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).
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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).
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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).
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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).
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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).
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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).
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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).
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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).
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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).
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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).
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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).
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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
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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).
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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).
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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).
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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).
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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).
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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.
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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
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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.
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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).
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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.
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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).
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Hello dear friend!
Thank you very much for reading.
Enter the link into your browser.
The full manual is available for immediate
download.
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