Caterpillar Cat 120M Motor Grader (Prefix B9W) Service Repair Manual (B9W00001 and up)

Service Repair Manual

Models

120M Motor Grader

120M Motor Grader - All Wheel Drive B9W00001-UP (MACHINE) POWERED BY ...

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Shutdown SIS Previous Screen Product: MOTOR GRADER Model: 120M MOTOR GRADER B9W Configuration: 120M Motor Grader - All Wheel Drive B9W00001-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 Tool

Part Number

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

367-9109

Caliper(1)

1

8T-5096

Dial Indicator Gp

1

301-3405

Gauge

1

P

8T-4140

Bolt

4

R

7M-7456

Bearing Mount Compound

1

M

Part Description

Qty

N

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120M Motor Grader - All Wheel Drive B9W00001-UP (MACHINE) POWERED BY ...

(1)

S

-

T

8T-5096

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Cat Advance 3Moly Grease or Dow Corning Molykote BR2 Plus

1

Dial Indicator Gp

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

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1. Install seals (94) onto piston (90).

Illustration 2

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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

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3. Install piston (90). Lower the temperature of bearing assembly (89). Install bearing assembly (89).

Illustration 4

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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).

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120M Motor Grader - All Wheel Drive B9W00001-UP (MACHINE) POWERED BY ...

Illustration 5

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6. Install thrust washer (85). Install differential gear (84).

Note: Install thrust washer (85) with the groove side against gear (84).

Illustration 6

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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

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8. Install spider assembly (79).

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120M Motor Grader - All Wheel Drive B9W00001-UP (MACHINE) POWERED BY ...

Illustration 8

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9. Install differential gear (78).

Illustration 9

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10. Install housing (77).

Note: Ensure that the notches on the housings are aligned.

Illustration 10

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120M Motor Grader - All Wheel Drive B9W00001-UP (MACHINE) POWERED BY ...

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

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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)

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120M Motor Grader - All Wheel Drive B9W00001-UP (MACHINE) POWERED BY ...

Illustration 12

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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

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14. Raise the temperature of bearing cone (66). Install bearing cone (66) and spacer (65).

Illustration 14

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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).

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120M Motor Grader - All Wheel Drive B9W00001-UP (MACHINE) POWERED BY ...

Illustration 15

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16. Use Tooling (G) to Install nut assembly (60). Tighten nut assembly (60) to a torque of 300 ± 40 N·m (221 ± 30 lb ft).

17. Install bolts (59). Tighten bolts (59) to a torque of 28 ± 7 N·m (21 ± 5 lb ft).

Illustration 16

g03772901

Typical Example

18. Use Tooling (A) and a suitable lifting device to install bearing assembly (55) and differential (56). The weight of bearing assembly (55) and differential (56) is approximately 102 kg (225 lb).

19. Remove Tooling (A) and install shims that are equal to 2.29 mm (0.09 inch).

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Illustration 17

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Typical Example

20. Use Tooling (E) and a suitable lifting device to install intermediate housing (37). The weight of intermediate housing (37) is approximately 32 kg (71 lb).

Illustration 18

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21. Install bolts (54). Tighten bolts (54) to a torque of 300 ± 40 N·m (221 ± 30 lb ft). Install bolts (53). Tighten bolts (53) to a torque of 105 ± 20 N·m (77 ± 15 lb ft).

Illustration 19

g01353570

22. Lower the temperature of bearing cup (52). Install bearing cup (52). Lower the temperature of bearing cup (50). Install bearing cup (50). Raise the temperature of bearing cone (49).

Install bearing cone (49) onto pinion gear (48). Install pinion (48). Install bearing cone (51).

Note: Lubricate the splines of the pinion shaft prior to assembly.

Note: Lubricate bearing cups and cones with the lubricant being sealed prior to assembly.

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Note: Use a 0.04 mm (0.0015 inch) feeler gauge to check bearing cups (50) and (52), and bearing cone (49). If the bearing cups and cones are completely seated, the feeler gauge will not fit.

Illustration 20

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Illustration 21

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23. Install guard (45), yoke (44), and the original shim pack (46). Install retainer (43) and bolt (42). Tighten bolt (42) to a torque of 300 ± 40 N·m (221 ± 30 lb ft).

24. Measure the rolling torque. Add or remove shims to obtain a rolling torque measurement of 1.2 ± 0.5 N·m (10.5 ± 4.5 lb in).

Note: Loosen the bearing after the rolling torque is measured and shims are added or removed.

25. Remove bolt (42), retainer (43), and shims (46). Remove yoke (44) and guard (45).

26. Install lip seal (47) and guard (45). Install yoke (44), shims (46), and retainer (43). Install a new bolt (42). Tighten the new bolt (42) to a torque of 300 ± 40 N·m (221 ± 30 lb ft).

Note: Lubricate the seal and the shaft prior to installation.

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Illustration 22

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27. Install a number of shims (40) that is equal to 1.78 mm (0.07 inch). Do not install O-ring seal (41) at this time.

Illustration 23

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28. Use a suitable lifting device to install pinion (38). The weight of pinion (38) is approximately 56 kg (123 lb). Install bolts (39). Tighten bolts (39) to a torque of 270 ± 40 N·m (199 ± 30 lb ft).

Note: Lubricate the O-ring seal, the shaft, and the bore with the lubricant that is being sealed prior to assembly.

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Illustration 24

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29. Use Tooling (N) to measure the backlash between the pinion gear and the bevel gear.

Prevent the bevel gear from moving while you are checking the backlash. Measure the backlash at three locations that are separated by 120 degrees.

(12M) ( 120M) ( 120M2) The backlash must be 0.35 + 0.00 - 0.11 mm (0.014 + 0.000 - 0.004 inch).

(12M2) ( 140M) ( 160M) ( 140M2) ( 160M2) The backlash must be 0.39 + 0.00 - 0.13 mm (0.015 + 0.00 - 0.005 inch).

30. If the backlash measurement does not meet the specification, repeat Steps 20 through 23.

Add shims (57) or remove shims (57) to adjust the backlash.

31. After the backlash adjustment has been made, the tooth contact between the pinion shaft and bevel gear must be checked. Use the following procedure: a. Put a small amount of Prussian blue, red lead, or paint on three or four adjacent teeth of the bevel gear. b. Rotate the pinion shaft for five to eight revolutions in one direction. Then rotate the pinion shaft for five to eight revolutions in the opposite direction.

Illustration 25

g01419994

c. Attach a suitable lifting device onto pinion (38). Use Tooling (H) to separate pinion (38) from the center housing. Remove bolts (39) to remove pinion (38). Observe the contact pattern on the bevel gear. The weight of pinion (38) is approximately 56 kg (123 lb).

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Illustration 26

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Illustration 27

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Illustration 28

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32. The middle of the contact pattern must be within the acceptable range.

33. If the contact pattern does not fall into the acceptable range, either add shims or remove shims. Recheck the contact pattern of the bevel gear. Repeat this step until the desired contact pattern is achieved.

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Illustration 29

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Illustration 30

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34. Once the backlash and the contact pattern of the bevel gear are correct, Remove bolts (56) and bolts (55). Use Tooling (E) to remove intermediate housing (37). The weight of intermediate housing (37) is approximately 32 kg (71 lb).

35. Apply Tooling (L) onto the mating surface of the center housing. Install intermediate housing (37). Install new bolts (56). Tighten new bolts (56) to a torque of 300 ± 40 N·m (221 ± 30 lb ft). Install new bolts (55). Tighten new bolts (55) to a torque of 105 ± 20 N·m (77 ± 15 lb ft).

Illustration 31

g01353021

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36. Install O-ring seal (41). Retain shims (40).

37. Once the backlash and the contact pattern of the bevel gear are correct, install new bolts (39), (55), and (56) for final assembly.

Illustration 32

g01355005

38. Use a suitable lifting device to install pinion (38). The weight of pinion (38) is approximately 56 kg (123 lb). Install new bolts (39). Tighten bolts (39) to a torque of 270 ± 40 N·m (199 ± 30 lb ft).

Note: Lubricate the O-ring seal, the shaft, and the bore with the lubricant that is being sealed prior to assembly.

Illustration 33

g01352445

39. Position the differential housing horizontally onto suitable blocking. Apply Tooling (L) onto the mating surface of the differential housing. Use Tooling (B) and a suitable lifting device to install ring gear (35). The weight of ring gear (35) is approximately 25 kg (55 lb).

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Illustration 34

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40. Install gear (33) onto axle shaft (34). Install retaining ring (32).

Illustration 35

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41. Install axle shaft assembly (31).

Illustration 36

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42. Install bearings (30) into gear (28). Install gear (28). Install thrust washers (29). Install pin (27). Install retainer (26) and bolts (25). Repeat this step for the remaining planetary gears.

Illustration 37

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43. Install axle shaft (22) onto carrier assembly (21). Install retaining ring (24).

Illustration 38

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44. Raise the temperature of bearing cone (23). Install bearing cone (23).

Illustration 39

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45. Use Tooling (E) to install carrier assembly (21) and drive shaft (22). The weight of carrier assembly (21) and drive shaft (22) is approximately 136 kg (300 lb).

Illustration 40

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46. Lower the temperature of bearing cup (20). Install bearing cup (20). Install lip seal (19).

Illustration 41

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47. Apply Tooling (S) onto thrust washer (18). Apply liberal amounts of Tooling (S) onto surface (X) and surface (Y) to avoid binding of oscillation joint. Install thrust washer (18).

Lower the temperature of bearing cup (17). Install bearing cup (17).

Illustration 42

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48. Install lip seal (16) into housing (13).

Illustration 43

g01355702

49. Turn over housing (13). Install wear sleeves (15). The diagonal cuts that are in wear sleeves (15) are separated by 90°. Apply liberal amounts of Tooling (S) onto thrust washer (14).

Install thrust washer (14).

Illustration 44

g02033793

50. Use Tooling (A) and a suitable lifting device to install housing (13). The weight of housing (13) is approximately 54 kg (120 lb). Use a suitable soft hammer to drive the wear sleeves into housing (13) until the sleeves are flush with the top of the bore surface. Do not install the shims at this time.

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Illustration 45

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51. Drill three equally spaced 8 mm (5/16 inch) holes in retainer (11). The holes must be centered on the existing bolt hole pattern and perpendicular to each surface.

52. Measure the thickness of retainer (11) at the three hole locations. Average the three measurements and record the result as Dimension (A).

Illustration 46

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53. Remove plug (10A).

54. Install retainer (11). Install three of bolts (10). Tighten bolts (10) to a torque of 50 ± 7 N·m (37 ± 5 lb ft). Completely loosen bolts (10). Finger tighten bolts (10). Use Tooling (T) to measure the gap between the top surface of retainer (11) and the final drive housing at the three 8 mm (5/16 inch) hole locations. Record the measurement from each of the three locations as the nominal gap or Dimension (B).

55. Calculate the shim pack thickness for the three measurement locations by subtracting Dimension (A) from the Dimension (B) giving you Dimension (C). Remove bolts (10) and retainer (11).

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Illustration 47

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56. Install a number of shims (12) that is equal to Dimension (C) plus + 0.075 - 0.025 mm (+ 0.003 - 0.001 inch). Install retainer (11). Install bolts (10). Tighten bolts (10) to a torque of 270 ± 40 N·m (199 ± 30 lb ft).

Illustration 48

g03880633

57. Install plug (10A).

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Illustration 49

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58. Apply Tooling (L) to the mating surface of final drive housing (8). Use Tooling (A), Tooling (C), and two suitable lifting devices to install final drive housing (8). The weight of final drive housing (8) is approximately 191 kg (420 lb). Install bolts (9A). Tighten bolts (9A) to a torque of 105 ± 20 N·m (77 ± 15 lb ft). Install nuts (9). Tighten nuts (9) to a torque of 530 ± 70 N·m (391 ± 52 lb ft).

Illustration 50

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59. Install bearing cone (7).

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Illustration 51

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60. Drill three 6.40 mm (0.252 inch) equally spaced holes (Y) on a circle with a diameter of 55.00 mm (2.16 inch) on retainer (4).

Illustration 52

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Illustration 53

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typical example

61. Install sprocket (2) and sprocket (6) onto rear axle (1).

Note: Assemble sprocket (2) and sprocket (6) so that the teeth on the sprockets are aligned with each other.

62. Install retainer (4) and Tooling (P). Tighten Tooling (P) to a torque of 48 ± 3 N·m (35 ± 2 lb ft) while you are turning the sprocket. Ensure that the torque has equalized. Turn the sprocket three times. Use Tooling (M) to measure the distance from the face of the spindle shaft to surface (X) in three places and record the average distance. Remove Tooling (P) and retainer (4). Measure the thickness of retainer (4). Install a number of shims (5) that is equal to the average distance minus 0.18 mm (0.0071 inch) and the thickness of retainer (4). The determined shim pack thickness can have a tolerance of + 0.0000 - 0.050 mm (+ 0.0000 - 0.0020 inch).

Illustration 54

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63. Install retainer (4). Apply Tooling (R) to bolts (3) and install bolts (3). Tighten bolts (3) to a torque of 270 ± 40 N·m (199 ± 30 lb ft).

64. Repeat Step 39 through Step 63 for the opposite side.

End By: a. Install the rear axle. Refer to Disassembly and Assembly, "Rear Axle - Install".

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