Caterpillar Cat 120H Motor Grader (Prefix 6TM) Service Repair Manual (6TM00001-00442)

Service Repair Manual

Models

120H Motor Grader

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Shutdown SIS Previous Screen Product: MOTOR GRADER Model: 120H MOTOR GRADER 6TM Configuration: 120H Motor Grader 6TM00001-00442 (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

SENR85440036

Implement Hydraulic Pump SMCS - 5070-011; 5070-012; 5070-017

Remove Implement Hydraulic Pump 1. Articulate the machine to the right in order to achieve working space.

2. Release 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.

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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.

3. Drain hydraulic system. Remove plug from ecology drain at the bottom of the 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).

4. Remove bolts (1), (3) and the washers that hold two split shields (2) together and to the machine frame.

5. Remove bolts (4) and the washers from pump drive shaft (5). Remove pump drive shaft (5) from the implement hydraulic pump.

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6. Remove tube assembly (6) from valves (8) & (10).

7. Remove cap screws (9) that holdcompensator valve (10) to the implement hydraulic pump.

Remove compensator valve (10) from the implement hydraulic pump.

8. Remove bolts (7) and the washers that hold combination valve (8) to the implement hydraulic pump. Remove combination valve (8) from the implement hydraulic pump.

9. Remove bolts (11) from elbow (12). Move elbow (12) and its seal from the implement hydraulic pump.

10. Remove hose assembly (14) from implement hydraulic pump (13).

11. Remove nut (18) and the washer from the implement hydraulic pump shaft.

12. Remove yoke (16) from implement hydraulic pump (13).

13. Remove bolts (15) and the washers that hold bracket (15) to implement hydraulic pump (13).

14. Remove mounting bolts (19), the washers and rubber mountings (20) that hold mounting bracket (17) to the machine frame. Remove mounting bracket (17) from the machine frame.

15. Use a lifting sling and a hoist, or a power truck in order to remove implement hydraulic pump (13) from the left side of the vehicle. the weight of implement hydraulic pump (13) is 50 Kg (110 lb).

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Install Implement Hydraulic Pump 1. Make sure that all components of the implement Hydraulic Pump and the matching components are clean prior to installation of the pump. During the installation of the Implement Hydraulic Pump, check the condition of all O-ring seals used in the assembly. If any of the seals are damaged, use new parts for replacement.

2. Position implement hydraulic pump (13) to the machine frame.

3. Position mounting bracket (17) to the machine frame and to implement hydraulic pump (13).

4. Install rubber mounts (20), bolts (16) and the washers that that hold mounting bracket (17) to the machine frame.

5. Install bolts (15) and the washers that hold bracket (15) to implement hydraulic pump (13).

Tighten bolts (15) to a torque of 160 ± 30 N·m (118 ± 22 lb ft).

6. Install yoke (16), nut (18) and the washer to implement hydraulic pump (13). Tighten nut (18) to a torque of 190 ± 25 N·m (140 ± 18 lb ft).

7. Install hose assembly (14) to implement hydraulic pump (13).

8. Position elbow (12) and its seal to implement hydraulic pump (13). Install bolts (11) that hold elbow (12) to implement hydraulic pump (13).

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9. Position combination valve (8) to implement hydraulic pump (13). Install bolts (5) and the washers that hold combination valve (8) to implement hydraulic pump (13).

10. Position compensator valve (10) to implement hydraulic pump (13). Install cap screws (9) that hold compensator valve (10) to implement hydraulic pump (13).

11. Install assembly (6) to valves (8) and (10).

12. Position pump drive shaft (5) to implement hydraulic pump (13). Install bolts (3) and the washers that hold pump drive shaft (5) to implement hydraulic pump (13).

13. Position two split shields (2) over drive shaft (5). Install bolts (1), (3) and the washers that hold the guards together and to the machine frame. Tighten bolts (3) to a torque of 135 ¹ 20 N¡m (99 ¹ 15 lb ft).

14. Fill the hydraulic oil system with the proper amount of hydraulic oil. Refer to the "Operation & Maintenance Manual" for the proper oil, procedure and amount of oil.

Disassemble & Assemble Implement Hydraulic Pump

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Start By: a. remove implement hydraulic pump

1. Remove bolts (1) from valve group (2). Remove valve group (2) from the implement pump.

2. Remove bolts (4) and cover (5) from housing (3).

3. Remove O-ring seal (6) from housing (3).

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4. Remove plug (7) and the O-ring seal from head (8). Slowly and evenly remove five bolts (10) and bolt (9), in order to release the spring force on the valve assembly.

5. Remove head (8) and the gasket from housing (3).

6. Remove piston (12) and spring (13) from piston rod (11).

7. Remove piston (15) from piston rod (14).

8. Remove pin (16) from head (8).

9. Remove piston rod (11) from head (8).

10. Remove piston rod (14) from head (8).

11. Use Tooling (A) in order to remove bearing cup (17) from head (8).

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12. Remove bearing (19), shims (18) that are underneath the bearing, and plate (20) from the pump group. Remove two pins (Z) from the pump housing.

13. Remove four bolts (24), two locking plates (23) and two spacer plates (22) from swashplate (21).

14. Remove swashplate plug (25) and its O-ring seal from housing (3).

15. Remove rotating group (26) and shim kit (27) from housing (3).

Rotating Group (26)

16. Put identification marks on nine pistons (28), in relationship to barrel (29) and plate (30), for assembly purposes. Remove nine piston assemblies (28) and plate (30) from barrel (29).

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Spring (33) is under pressure. Release the spring pressure slowly in order to avoid personal injury.

17. Use Tooling (D) and a press in order to compress spring (33). Use Tooling (B) in order to remove snap ring (31) from barrel (29).

18. Remove snap ring (31), spacer (34), spring (33), and spacer (32) from barrel (29).

19. Note the orientation of swashplate (21) in relationship to housing (3) for assembly purposes.

Remove swashplate (21), shaft (36), and bearing (35) from housing (3).

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20. Remove bearing (35) from shaft (36).

21. Remove shield (37) from housing (3).

22. Use Tooling (B) in order to remove snap ring (38) from housing (3). Remove lip-type seal (39) from housing (3).

23. Remove two screws (42), bearing (40) and bearing (41) from housing (3).

24. Use Tooling (C) in order to remove roller bearing cup (43) from housing (3).

NOTE: The following steps are for the assembly of the implement hydraulic pump.

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NOTE: If a new swashplate, swashplate bearings, shaft, shaft bearings, head or housing are installed, axial end play must be set. Refer to the topic "Shaft Bearing Endplay Adjustment" in the Specifications Manual, SENR8509 and SENR8557.

25. During the assembly of the implement hydraulic pump, check the condition of all the O-ring seals and the lip seals that are used in the pump. If any of these seals are damaged, use new parts for replacement.

26. Lower the temperature of bearing cup (17). Use Tooling (D) in order to install bearing cup (17) in head (8). Install bearing cup (17) until it is seated.

27. Lower the temperature of bearing cup (43). Use Tooling (D) in order to install bearing cup (43) in housing (3). Install bearing cup (43) until it is seated.

28. Install bearing (35) in housing (3).

29. Install bearing (40), bearing (41), and setscrews (42) to housing (3).

30. Use Tooling (D) in order to install lip seal (39) in housing (3) until it is seated. The sealing lip must face inward. Lubricate the sealing lip lightly with hydraulic oil. Use Tooling (B) in order to install Retention ring (38) in housing (3).

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31. Install shield (37) to housing (3).

32. Put a light coat of hydraulic oil on bearings (41) and (42) in order to hold swashplate (21) in position during the next steps of assembly. Install swashplate (21) in housing (3) and in bearings (41) and (42).

33. Block up housing (3) in order to have clearance when shaft (36) is installed. Shaft (36) extends beyond the end of housing (3). Install shaft (36) through swashplate (21), in bearing (35) and housing (3).

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34. Install plug (25) and O-ring seal in housing (3). Tighten Plug (25) to a torque of 102 ¹ 4 N¡m (75 ¹ 3 lb ft).

35. Install spacer (32), spring (33) and spacer (34) in barrel (29).

36. Use Tooling (D) and a shop press in order to compress spring (33).

37. Use Tooling (B) to install snap ring (31) in barrel (29).

38. Install nine pistons (28) in their original locations in spacer (30) and barrel (29). This is easier accomplished if the barrel is set in an upright position and then the pistons, already in the spacer, are inserted from above.

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39. Lay housing (3) on its side. Install rotating group (26) and shim kit (27) on shaft (36) and in housing (3).

40. Install bearing (19) and shims (18) to shaft (36).

41. Position two spacers (22) and two locking plates (23) to their original positions on swashplate (21).

42. Apply 9S-3263 Compound on bolts (24). Install four bolts (24) in order to hold plates (23) and spacers (22) to swashplate (21). Tighten bolts (24) to a torque of 34 ± 3 N·m (25 ± 2 lb ft).

43. Install pin (16) in head (8).

44. Apply 9S-3263 Compound to piston rods (11) and (14).

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45. Install piston rods (11) and (14) in head (8). Tighten piston rods (11) and (14) to a torque of 79 ± 4.0 N·m (58 ± 3 lb ft).

46. Install spring (13), piston (12) and piston (15) to head (8).

47. Use a light coat of 5N-5561 Silicone Lubricant in order to hold plate (20) to head (8) during assembly.

48. Position head (8) and the gasket on housing (3) and bearing (19).

49. Install bolts (9) and (10) in order to hold head (8) to housing (3). Slowly and evenly tighten the bolts to a torque of 91 ± 4 N·m (67 ± 3 lb ft).

50. Install plug (7) and O-ring seal in head (8). Tighten plug (7) to a torque of 12.9 ± 0.1 N·m (10 ± .1 lb ft).

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51. Install O-ring seal (6) to housing (3).

52. Install plate (5) and bolts (4) to housing (3). Tighten bolts (4) to a torque of 8.5 ± 1.0 N·m (6 ± .8 lb ft).

53. Install valve group (2) and bolts (1) to the pump.

End By: a. install implement hydraulic pump Copyright 1993 - 2020 Caterpillar Inc.

Tue Mar 24 13:05:25 UTC+0800 2020

All Rights Reserved.

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Shutdown SIS Previous Screen Product: MOTOR GRADER Model: 120H MOTOR GRADER 6TM Configuration: 120H Motor Grader 6TM00001-00442 (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.

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Thank you very much for your reading. Please Click Here. Then Get COMPLETE MANUAL. NO WAITING

NOTE: If there is no response to click on the link above, please download the PDF document first and then click on it.

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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.

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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.

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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

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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).

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