Caterpillar Cat 120H Motor Grader (Prefix ALZ) Service Repair Manual (ALZ00001 and up)

Service Repair Manual

Models

120H Motor Grader

120H Motor Grader ALZ00001-UP (MACHINE) POWERED BY 3126B Engine(SEB...

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Shutdown SIS Previous Screen Product: MOTOR GRADER Model: 120H MOTOR GRADER ALZ Configuration: 120H Motor Grader ALZ00001-UP (MACHINE) POWERED BY 3126B Engine

Disassembly and Assembly 120H and 135H Motor Graders Power Train Media Number -RENR4160-05

Publication Date -01/04/2005

Date Updated -22/05/2017

i01967370

Transmission - Disassemble SMCS - 3002-015; 3030-015; 3159-015

Disassembly Procedure Table 1 Required Tools Tool

Part Number

Part Description

Qty

A

138-7575

Link Bracket

3

B

154-6181

Forcing Screw

2

C

6V-5221

Bolt

1

D

4C-8156

Fixture

1

E

6V-3918

Bolt

1

F

4C-8157

Lifting Fixture

2

G

1U-6405

Three Jaw Puller

1

H

1U-6341

Threaded Rod

1

J

5P-7970

Nut

1

K

9U-7479

Compressing Tube

1

L

5B-0637

High Idle Nut

1

5F-7353

Washer

1

1B-4207

Full Nut

2

5F-7369

Puller Leg

2

3H-0465

Push-Puller Plate

2

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120H Motor Grader ALZ00001-UP (MACHINE) POWERED BY 3126B Engine(SEB...

5F-7366

Screw

1

5P-4808

Cap

2

1U-9895

Crossblock

1

9S-9152

Block

2

1B-4206

Nut

4

8B-7552

Forcing Bolt

2

N

1U-6343

Threaded Rod

1

P

6V-8149

Nut

1

Q

2P-8312

Pliers

1

1P-2326

Screw

1

1P-2325

Head

1

3H-0462

Bolt and Nut

4

8H-0709

Strap

4

5F-7373

Jaw

3

3E-3882

Eyebolt

1

M

R

T

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Start By: a. Remove the transmission. Refer to Disassembly and Assembly, "Transmission - Remove" for the correct procedure.

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120H Motor Grader ALZ00001-UP (MACHINE) POWERED BY 3126B Engine(SEB...

Illustration 1

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1. Install Tooling (A) on transmission control valve (1). Attach a suitable lifting device to Tooling (A).

2. Remove bolts (2) and remove transmission control valve (1). The weight of transmission control valve (1) is approximately 30 kg (65 lb).

3. Remove temperature sensor (3). Remove tube assembly (4). Remove hose assemblies (5).

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120H Motor Grader ALZ00001-UP (MACHINE) POWERED BY 3126B Engine(SEB...

Illustration 2

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4. Remove hose assembly (8) and remove intermediate sensors (9) and (6).

5. Attach a suitable lifting device to pump (11). Remove bolts (10). Remove pump (11). The weight of pump (11) is approximately 25 kg (55 lb).

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120H Motor Grader ALZ00001-UP (MACHINE) POWERED BY 3126B Engine(SEB...

Illustration 3

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6. Remove bolt (12) and yoke (13). Remove bolts (14) and brake (15). Use two people to remove brake (15). The weight of brake (15) is approximately 34 kg (75 lb).

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120H Motor Grader ALZ00001-UP (MACHINE) POWERED BY 3126B Engine(SEB...

Illustration 4

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7. Remove O-ring seal (14A).

Illustration 5

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8. Remove plates (15A), disc (15B), hub (15C), and dowels (15D).

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120H Motor Grader ALZ00001-UP (MACHINE) POWERED BY 3126B Engine(SEB...

Illustration 6

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9. Remove cover (16). Remove output speed sensors (17).

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120H Motor Grader ALZ00001-UP (MACHINE) POWERED BY 3126B Engine(SEB...

Illustration 7

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10. Remove input sensor (18). Remove bolts (20A). Remove plate assembly (20) and harness assembly (19).

Illustration 8

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11. Place transmission (21) level on the floor.

12. Remove bolts (22) , the four covers, and the O-ring seals from transmission case assembly (23).

13. Remove bolts (24) from the transmission case assembly (23).

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120H Motor Grader ALZ00001-UP (MACHINE) POWERED BY 3126B Engine(SEB...

Illustration 9

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Note: Identify the location of seal carrier (25) in the transmission case assembly (23) for assembly purposes.

14. Remove bolts (26) from seal carrier (25).

15. Install Tooling (A) (not shown) in seal carrier (25). Remove seal carrier (25) and the three ring seals from the transmission case assembly bore (27).

16. Repeat Step 14 through Step 15 on the three remaining seal carriers (25).

Illustration 10

g00997253

17. Remove seal rings (29) from seal carrier (25).

18. Remove seals (28) from seal carrier (25).

19. Remove spring pin (30) from seal carrier (25).

20. Repeat Step 17 and Step 19 for the remaining three seal carriers (25).

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120H Motor Grader ALZ00001-UP (MACHINE) POWERED BY 3126B Engine(S...

Illustration 11

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21. Install Tooling (B) in the transmission case assembly (23). Tighten Tooling (B) evenly to separate transmission case assembly (23) from transmission cover assembly (31).

22. Install Tooling (A) to transmission case assembly (23). Attach a suitable lifting device to Tooling (A). Slowly raise the transmission case assembly (23) from the transmission cover assembly (31). Be careful not to bind the transmission case assembly (23) during separation.

Illustration 12

g01022248

23. Remove bolts (32) from tube assembly (33). Remove tube assembly (33) from the transmission cover assembly (31).

24. Remove the O-ring seal from tube assembly (33).

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120H Motor Grader ALZ00001-UP (MACHINE) POWERED BY 3126B Engine(S...

Illustration 13

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Note: First/Third shaft assembly (34) and High/Low shaft assembly (35) must be removed together.

25. Install Tooling (D) on First/Third shaft assembly (34) and High/Low shaft assembly (35).

Use Tooling (C) and Tooling (E) in order to hold Tooling (D) on First/Third shaft assembly (34) and High/Low shaft assembly (35), as shown. First/Third shaft assembly (34) and High/Low shaft assembly (35) must be removed together.

26. Attach a suitable lifting device to Tooling (D). Carefully remove First/Third shaft assembly (34) and High/Low shaft assembly (35) from the transmission cover assembly (31). The weight of the two shaft assemblies is approximately 177 kg (390 lb).

Illustration 14

g00997258

27. Place First/Third shaft assembly (34) and High/Low shaft assembly (35) on Tooling (F) or on blocks and remove Tooling (D). Carefully separate First/Third shaft assembly (34) and High/Low shaft assembly (35). The weight of each shaft assembly is approximately 89 kg (195 lb).

Illustration 15

g00997259

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120H Motor Grader ALZ00001-UP (MACHINE) POWERED BY 3126B Engine(S...

Illustration 16

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Note: Place High/Low shaft (35) in a modified work bench or on blocks. Modify a substantial workbench by cutting a 116.0 Âą 2.0 mm (4.60 Âą 0.08 inch) clearance hole in the top of the bench.

Illustration 17

g00997262

Illustration 18

g00997263

Note: Do not attach Tooling (G) to rotor (37). If pressure is applied to rotor (37) with Tooling (G), rotor (37) will brake. Attach Tooling (G) to gear assembly (38).

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120H Motor Grader ALZ00001-UP (MACHINE) POWERED BY 3126B Engine(S...

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28. With High/Low shaft assembly (35) on the modified work bench or on blocks, use Tooling (G) in order to remove race and bearing (36), rotor (37), gear assembly (38), and two sleeve bearings (not shown) from High/Low shaft assembly (35). Press fit bearing (36) and rotor (37) on High/Low shaft assembly (35).

29. Remove bearing (36), rotor (37), thrust disc (39), and gear assembly (38) from High/Low shaft assembly (35). Attach Tooling (G) to gear assembly (38). Do not attach Tooling (G) to rotor (37).

Illustration 19

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30. Remove thrust disc (40) and the washer from High/Low shaft assembly (35).

Illustration 20

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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.

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120H Motor Grader ALZ00001-UP (MACHINE) POWERED BY 3126B Engine(S...

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31. Install Tooling (H) and Tooling (K) on High/Low shaft assembly (35) and clutch assembly (41). Tighten Tooling (J) on Tooling (H) (not shown) in order to compress clutch assembly (41). Remove two half rings (42) and two lock rings (43) from the High/Low shaft assembly (35).

32. Carefully loosen Tooling (J) on Tooling (H) in order to relieve pressure from clutch assembly (41). Remove Tooling (K) and Tooling (H) from High/Low shaft assembly (35) and clutch assembly (41). The clutch assembly (41) is made up of five clutch plates, six friction discs, and the hub assembly. Identify the position of the clutch assembly (41) for assembly purposes.

Illustration 21

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33. Remove wave spring (45) from High/Low shaft assembly (35).

34. Remove piston (44) from High/Low shaft assembly (35).

Illustration 22

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35. Remove seal extension ring (47) and seal ring (46) from piston (42).

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120H Motor Grader ALZ00001-UP (MACHINE) POWERED BY 3126B Engine(S...

Illustration 23

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36. Position High/Low shaft assembly (35), as shown. Place High/Low shaft (35) in the modified work bench, or on blocks. The weight of High/Low shaft assembly (35) is approximately 50 kg (110 lb).

37. Install Tooling (L) and Tooling (M) on High/Low shaft assembly (35) and inner bearing (48). Remove inner bearing (48) from High/Low shaft assembly (35). Remove two thrust discs (49), two bearing sleeves, and gear assembly (50) from High/Low shaft assembly (35).

Illustration 24

g00997273

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 thrust disc (51) and the washer from High/Low shaft assembly (35).

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120H Motor Grader ALZ00001-UP (MACHINE) POWERED BY 3126B Engine(S...

Illustration 25

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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.

Note: Tooling (K) is the old style tool that is now modified. Tooling (K) (new style tool) works without being modified. Tooling (K) may need to be modified so the hole in the top of the tube will have clearance for Tooling (N).

39. Install Tooling (N) and Tooling (K) on High/Low shaft assembly (35) and clutch assembly (52). Tighten Tooling (P) on Tooling (N) in order to compress clutch assembly (52).

Remove two half rings (53) and two lock rings (54) from the High/Low shaft assembly (35).

40. Carefully loosen Tooling (P) on Tooling (N) in order to relieve pressure from clutch assembly (52). Remove Tooling (K) and Tooling (N) from High/Low shaft assembly (35) and clutch assembly (52). The clutch assembly (52) is made up of eight clutch plates, seven friction discs, and the hub assembly. Identify the position of the clutch assembly (52) for assembly purposes.

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120H Motor Grader ALZ00001-UP (MACHINE) POWERED BY 3126B Engine(S...

Illustration 26

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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.

Note: Tooling (K) is the old style tool that must be modified. Tooling (K) (new style tool) works without being modified. Tooling (K) may need to be modified so the hole in the top of the tube will have clearance for Tooling (N).

41. Install Tooling (N) and Tooling (K) on High/Low shaft assembly (35) and balance piston (55). Tighten Tooling (P) on Tooling (N) in order to compress balance piston (55).

42. Use Tooling (Q) in order to remove retaining ring (56) from High/Low shaft assembly (35).

43. Carefully loosen Tooling (P) on Tooling (N) in order to relieve pressure from balance piston (55). Remove Tooling (K) and Tooling (N) in order to relieve pressure from High/Low shaft assembly (35) and balance piston (55).

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120H Motor Grader ALZ00001-UP (MACHINE) POWERED BY 3126B Engine(S...

Illustration 27

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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.

44. Remove balance piston (55) and seal extension ring (57) from High/Low shaft assembly (35).

45. Remove fifteen springs (58) from piston (59).

46. Remove piston (59), the seal extension ring (not shown), and a ring seal (not shown) from High/Low shaft assembly (35).

Illustration 28

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47. Remove seal ring (60) and seal extension ring (61) from piston (59).

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120H Motor Grader ALZ00001-UP (MACHINE) POWERED BY 3126B Engine(S...

Illustration 29

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48. Place First/Third shaft assembly (34) on the modified work bench or on blocks. Use Tooling (F) in order to remove race and bearing (62), thrust disc (not shown), and gear assembly (63) from First/Third shaft assembly (34).

Illustration 30

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49. Remove thrust disc (64) and gear assembly (65) from First/Third shaft assembly (34).

Illustration 31

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50. Remove the sleeve bearing (not shown), thrust disc (66), and washer (67) from First/Third shaft assembly (34).

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120H Motor Grader ALZ00001-UP (MACHINE) POWERED BY 3126B Engine(S...

Illustration 32

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g00997284

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.

51. Install Tooling (H) and Tooling (K) on First/Third shaft assembly (34) and clutch assembly (68). Tighten Tooling (K) on Tooling (H) in order to compress clutch assembly (68).

Remove two half rings (69) and two lock rings (70) from First/Third shaft assembly (34).

52. Carefully loosen Tooling (J) on Tooling (H) in order to relieve pressure from clutch assembly (68). Remove Tooling (K) and Tooling (H) from First/Third shaft assembly (34) and clutch assembly (68). As you remove clutch assembly (68) from First/Third shaft assembly (34), identify the positions of the five clutch plates, the six friction disc, and the hub assembly for assembly purposes.

Illustration 33

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53. Remove wave spring (71) from First/Third shaft assembly (34).

54. Remove piston (72) from First/Third shaft assembly (34).

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120H Motor Grader ALZ00001-UP (MACHINE) POWERED BY 3126B Engine(S...

Illustration 34

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55. Remove seal extension ring (73) and seal ring (74) from piston (72).

Illustration 35

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56. Position First/Third shaft assembly (34), as shown. Place First/Third shaft assembly (34) in the modified work bench, or on blocks. The weight of First/Third shaft assembly (34) is approximately 55 kg (120 lb).

57. Remove the seal ring (not shown) from First/Third shaft assembly (34).

58. Use Tooling (R) in order to remove inner bearing (75), thrust disc (not shown), gear (76), and thrust disc (not shown).

59. Remove gear assembly (77), the bearing sleeve (not shown), the thrust disc, and the washer (not shown) from First/Third shaft assembly (34).

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