Caterpillar Cat 12M Motor Grader (Prefix B92) Service Repair Manual Instant Download

Service Repair Manual

Models

12M Motor Grader

12M Motor Grader B9200001-UP (MACHINE) POWERED BY C7.2 Engine(SEBP4...

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Shutdown SIS Previous Screen Product: MOTOR GRADER Model: 12M MOTOR GRADER B92 Configuration: 12M Motor Grader B9200001-UP (MACHINE) POWERED BY C7.2 Engine

Disassembly and Assembly 12M Motor Grader Power Train Media Number -UENR3472-02

Publication Date -01/08/2012

Date Updated -29/10/2018

i05000357

Transmission - Disassemble SMCS - 3030-015; 3159-015; 3176-015

Disassembly Procedure Table 1 Required Tools Tool

Part Number

Part Description

Qty

A

138-7575

Link Bracket

3

B

308-3470

Jack Stand Gp

3

C

1U-9202

Lever Puller Hoist Gp

1

D

1P-1863

Retaining Ring Pliers

1

E

308-3470

Jack Stand Gp

2

F

140-7742

Sleeve

1

G

154-6181

Forcing Screw

2

H

FT-2769

Table

1

J

4C-8156

Lifting Fixture

1

1U-6410

Three Jaw Puller

1

1P-0510

Driver Gp

1

9U-7480

Compressing Tube

1

5C-7201

Nut

1

8T-4224

Hard Washer

1

K L

-

1

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12M Motor Grader B9200001-UP (MACHINE) POWERED BY C7.2 Engine(SEBP4...

Bolt M10 - 1.5 by 460mm M

8B-7548

Push-Puller Tool Gp

1

N

2P-8312

Retaining Ring Pliers

1

1P-2321

Combination Puller

1

1P-0510

Driver Gp

1

189-0408

Shackle As

1

3E-3882

Eyebolt

1

126-7175

Push-Puller Tool Gp

1

4C-5653

Threaded Adapter

1

1P-0510

Driver Gp

1

P

R

S

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.

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12M Motor Grader B9200001-UP (MACHINE) POWERED BY C7.2 Engine(SEBP4...

Illustration 1

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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 in order to position transmission (1) onto Tooling (B). Remove hose assembly (2).

Illustration 2

g01386568

2. Remove bolts (3) in order to remove control module (4) and spacers (5).

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Illustration 3

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3. Remove yoke assembly (6).

Illustration 4

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4. Remove retaining ring (7).

5. Remove cup (8). Remove O-ring seal (9).

Illustration 5

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6. Attach Tooling (A), Tooling (C), and a suitable lifting device to transmission (1). Use Tooling (A), Tooling C, and () the suitable lifting device in order 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) in order to remove plate assembly (11).

Illustration 7

g01386589

8. Remove lip seal (12).

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12M Motor Grader B9200001-UP (MACHINE) POWERED BY C7.2 Engine(SEBP4...

Illustration 8

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9. Use Tooling (D) in order to remove retaining ring (13). Remove coned disc springs (14).

Note: Note the orientation of coned disc springs (14) for assembly purposes.

Illustration 9

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10. Remove O-ring seal (15) and piston (16).

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Illustration 10

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11. Remove piston seal (17). Remove piston seal (18).

Illustration 11

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12. Disconnect harness assembly (19) and harness assembly (21). Remove guard (20).

Illustration 12

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13. Remove bolts (22). Use two people in order to remove housing (23). The weight of housing (23) is approximately 20 kg (45 lb).

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Illustration 13

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14. Remove pressure sensor (24) and the O-ring seal. Remove solenoid (25).

Illustration 14

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15. Remove O-ring seal (26), O-ring seal (27), O-ring seal (28), O-ring seal (29), and O-ring seal (30).

Illustration 15

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16. Remove seal (31).

Illustration 16

g01386663

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17. Remove friction discs (32) and clutch plates (33).

Note: Note the quantity and the order of friction discs (32) and clutch plates (33) for assembly purposes.

18. Remove O-ring seals (34) and dowels (35).

Illustration 17

g01386675

19. Remove retaining ring (36). Remove hub (37).

Illustration 18

g01386684

20. Attach Tooling (A), Tooling (C), Tooling (F), and a suitable lifting device to transmission (1). Use Tooling (A), Tooling (C), Tooling (F), and the suitable lifting device to position transmission (1) onto Tooling (B) and Tooling (E) with the output shaft in the downward position. The weight of transmission (1) is approximately 862 kg (1900 lb).

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Illustration 19

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21. Remove bolt (38) in order to remove speed sensor (39) and guard (40).

Illustration 20

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22. Remove bolts (41) in order to remove speed sensor (42) and speed sensor (43).

Illustration 21

g01386749

23. Remove cover (44).

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Illustration 22

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24. Remove bolts (45) in order to remove speed sensor (46) and speed sensor (47).

Illustration 23

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25. Attach Tooling (A), Tooling (C), and a suitable lifting device to housing (49). The weight of housing (49) is approximately 136 kg (300 lb). Remove bolts (48).

26. Use Tooling (A), Tooling (C), and the suitable lifting device in order to remove housing (49).

Note: If necessary, use Tooling (G) in order to assist in the removal of housing (49).

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Illustration 24

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27. Remove O-ring seal (50). Remove bolts (51) and the locks. Remove tube assembly (52) and the O-ring seal.

Illustration 25

g01386795

28. Remove bolts (53) in order to remove seal carrier (54). Remove bolts (55) in order to remove seal carrier (56).

Illustration 26

g01386797

29. Remove seal rings (57). Remove O-ring seals (58). Repeat this step for the remaining seal carrier.

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Illustration 27

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Illustration 28

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30. Use Tooling (J) and a suitable lifting device in order to remove clutch assembly (59) and clutch assembly (60). The combined weight of clutch assembly (59) and clutch assembly (60) is approximately 163 kg (360 lb).

31. Position clutch assembly (59) and clutch assembly (60) onto Tooling (H). If necessary, support clutch assembly (60) with suitable cribbing.

32. Remove Tooling (J) in order to separate clutch assembly (59) from clutch assembly (60).

Illustration 29

g01386827

33. Use Tooling (K) in order to remove bearing (61) and rotor (62) from clutch assembly (59).

Note: Be sure to attach Tooling (K) to gear assembly (63) in order to prevent damage to rotor (62).

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Illustration 30

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34. Remove thrust washer (64) and gear assembly (63).

Note: Note the orientation of thrust washer (64) for assembly purposes.

Illustration 31

g01386992

35. Remove bearing sleeves (65) from gear assembly (63).

Illustration 32

g01386993

36. Remove thrust washer (66).

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Note: Note the orientation of thrust washer (66) for assembly purposes.

Illustration 33

g01386997

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.

37. Use Tooling (L) in order to compress hub assembly (67). Remove lock rings (68) and two half rings (69) (not shown).

Note: Note the orientation of lock rings (68) and two ring halves (69) for assembly purposes.

Illustration 34

g01387088

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12M Motor Grader B9200001-UP (MACHINE) POWERED BY C7.2 Engine(SEB...

38. Remove hub assembly (67), friction discs (70), and clutch plates (71).

Note: Note the order of friction discs (70) and clutch plates (71) for assembly purposes.

Illustration 35

g01387093

39. Remove wave spring (72) and piston (73).

Illustration 36

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40. Remove seal rings (74) and (75) from piston (73).

Illustration 37

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41. Use a suitable lifting device in order to turn over clutch assembly (59). The weight of clutch assembly (59) is approximately 59 kg (130 lb).

Illustration 38

g01387150

Illustration 39

g01387221

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.

42. Use Tooling (M) in order to remove bearing (76). Remove thrust washer (77), thrust disc (78), and gear assembly (79).

Note: Note the orientation of thrust disc (78) for assembly purposes.

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12M Motor Grader B9200001-UP (MACHINE) POWERED BY C7.2 Engine(SEB...

Illustration 40

g01387228

43. Remove thrust disc (80), washer (81), half rings (82), and lock rings (83).

Note: Note the orientation of thrust disc (80) for assembly purposes.

Illustration 41

g01387232

44. Remove hub assembly (84). Remove friction discs (85) and clutch plates (86).

Note: Note the orientation of friction discs (85) and clutch plates (86) for assembly purposes.

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Illustration 42

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45. Use Tooling (N) in order to remove retaining ring (87).

46. Remove balance piston (88). Remove seal ring (89) from balance piston (88).

47. Remove springs (90).

48. Remove piston (91). Remove seal rings (92) and (93) from piston (91).

Illustration 43

g01387511

49. Use Tooling (K) in order to remove inner bearing (94) from clutch assembly (60). Remove thrust disc (95) and gear (96).

Note: Note the orientation of thrust disc (95) for assembly purposes.

Illustration 44

g01387520

50. Remove thrust disc (97) and gear assembly (98) from clutch assembly (60).

Note: Note the orientation of thrust disc (97) for assembly purposes.

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12M Motor Grader B9200001-UP (MACHINE) POWERED BY C7.2 Engine(SEB...

Illustration 45

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51. Remove sleeve bearing (99) from gear assembly (98).

Illustration 46

g01387528

52. Remove thrust disc (100) and washer (101) from clutch assembly (60).

Note: Note the orientation of thrust disc (100) for assembly purposes.

Illustration 47

g01387541

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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.

53. Use Tooling (L) in order to compress hub assembly (102). Remove lock rings (103) and two half rings (104) (not shown).

Note: Note the orientation of lock rings (103) and two ring halves (104) for assembly purposes.

Illustration 48

g01387556

54. Remove hub assembly (102), friction discs (105), and clutch plates (106) from clutch assembly (60).

Note: Note the orientation of friction discs (105) and clutch plates (106) for assembly purposes.

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Illustration 49

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55. Remove wave spring (107) and piston (108) from clutch assembly (60).

Illustration 50

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56. Remove seal rings (109) and (110) from piston (108).

Illustration 51

g01387592

57. Use a suitable lifting device in order to turn over clutch assembly (60) onto Tooling (H).

The weight of clutch assembly (60) is approximately 54 kg (120 lb).

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Illustration 52

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58. Use Tooling (P) in order to remove inner bearing (111), thrust disc (112), and gear (113) from clutch assembly (60).

Note: Note the orientation of thrust disc (112) for assembly purposes.

Illustration 53

g01387755

59. Remove thrust disc (114) and gear assembly (115).

Note: Note the orientation of thrust disc (114) for assembly purposes.

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12M Motor Grader B9200001-UP (MACHINE) POWERED BY C7.2 Engine(SEB...

Illustration 54

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60. Remove bearing (116) from gear assembly (115).

Illustration 55

g01387820

61. Remove thrust disc (117) and washer (118).

Note: Note the orientation of thrust disc (117) for assembly purposes.

Illustration 56

g01387824

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.

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62. Use Tooling (L) in order to compress hub assembly (119). Remove lock rings (120) and two half rings (121) (not shown).

Note: Note the orientation of lock rings (120) and two ring halves (121) for assembly purposes.

Illustration 57

g01387846

63. Remove hub assembly (119), friction discs (122), and clutch plates (123).

Note: Note the orientation of friction discs (122) and clutch plates (123) for assembly purposes.

Illustration 58

g01387852

64. Remove wave spring (124) and piston (125).

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Illustration 59

g01387858

65. Remove seal rings (126) and (127) from piston (125).

Illustration 60

g01387876

66. Use Tooling (P) in order to remove inner bearing (128) and gear (129) from input shaft assembly (130). This is necessary at this time to remove the remaining two clutch assemblies.

Illustration 61

g01387884

67. Remove bolts (131) in order to remove seal carrier (132).

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Illustration 62

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68. Remove seal rings (133). Remove O-ring seals (134).

Illustration 63

g01387895

69. Attach Tooling (R) and a suitable lifting device to clutch assembly (135). The weight of clutch assembly (135) is approximately 61 kg (135 lb). Use Tooling (R) and the suitable lifting device in order to remove clutch assembly (135). Position clutch assembly (135) onto Tooling (H).

Illustration 64

g01387898

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70. Use Tooling (P) in order to remove inner bearing (136), spacer (137), and gear (138) from clutch assembly (135).

Illustration 65

g01388168

71. Remove spacer (139) and thrust disc (140) from clutch assembly (135).

Note: Note the orientation of thrust disc (140) for assembly purposes.

72. Remove gear assembly (141), thrust disc (142), and washer (143).

Note: Note the orientation of thrust disc (142) for assembly purposes.

Illustration 66

g01388185

73. Remove bearing (144) from gear assembly (141).

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Illustration 67

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g01388208

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.

74. Use Tooling (L) in order to compress hub assembly (145). Remove lock rings (146) and two half rings (147) (not shown).

Note: Note the orientation of lock rings (146) and two ring halves (147) for assembly purposes.

Illustration 68

g01388240

75. Remove hub assembly (145), friction discs (148), and clutch plates (149).

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Note: Note the orientation of friction discs (148) and clutch plates (149) for assembly purposes.

Illustration 69

g01388243

76. Remove wave spring (150) and piston (151).

Illustration 70

g01388246

77. Remove seal rings (152) and (153) from piston (151).

Illustration 71

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12M Motor Grader B9200001-UP (MACHINE) POWERED BY C7.2 Engine(SEB...

Illustration 72

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78. Use a suitable lifting device in order to turn over clutch assembly (135) onto Tooling (H).

The weight of clutch assembly (135) is approximately 41 kg (90 lb).

79. Attach Tooling (S) to clutch assembly (135) in order to remove inner bearing (154).

Remove thrust race (155), thrust disc (156), thrust disc (157), and gear assembly (158).

Note: Note the orientation of thrust discs (156) and (157) for assembly purposes.

Illustration 73

g01388296

80. Remove roller bearing assembly (159) and thrust disc (160) from clutch assembly (135).

Note: Note the orientation of thrust disc (160) for assembly purposes.

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