Caterpillar Cat 120H Motor Grader (Prefix CAF) Service Repair Manual (CAF00001 and up)

Service Repair Manual

Models

120H Motor Grader

120H Motor Grader CAF00001-UP (MACHINE) POWERED BY 3126B Engine(SEB...

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Shutdown SIS Previous Screen Product: MOTOR GRADER Model: 120H MOTOR GRADER CAF Configuration: 120H Motor Grader CAF00001-UP (MACHINE) POWERED BY 3126B Engine

Disassembly and Assembly 120H and 135H Motor Graders Machine Systems Media Number -RENR4164-01

Publication Date -01/04/2005

Date Updated -30/04/2005

i07430989

Piston Pump (Hydraulic and Steering) - Assemble SMCS - 4306-016; 5070-016

Assembly Procedure Table 1 Required Tools Tool

Part Number

B

1P-1861

Retaining Ring Pliers

1

D

1P-0510

Driver Group

1

E

8T-5096

Dial Indicator Group

1

-

Loctite LB 8632 Silicone Lubricant (1)

-

-

Loctite LB 8104 Silicone Lubricant (2)

-

-

Loctite LB 8801 Silicone Lubricant (3)

-

-

Loctite LB Superlube (4)

-

-

Loctite 243

-

F

G (1)

North America

(2)

EAME

(3)

Asia Pacific Division

(4)

South America

Part Description

Qty

Note: The axial end play must be adjusted if the swashplate, the swashplate bearings, the shaft, the shaft bearings, the head, or the housing has been replaced.

1. During the assembly of the piston 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.

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120H Motor Grader CAF00001-UP (MACHINE) POWERED BY 3126B Engine(SEB...

Illustration 1

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2. Lower the temperature of bearing cup (40). Use Tooling (D) to install bearing cup (40) in head (31). Install bearing cup (40) until the bearing cup is seated.

Illustration 2

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Illustration 3

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3. Lower the temperature of bearing cup (66). Use Tooling (D) to install bearing cup (66) in housing (26). Install bearing cup (66) until the bearing cup is seated.

4. Install bearing (58) in housing (26).

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120H Motor Grader CAF00001-UP (MACHINE) POWERED BY 3126B Engine(SEB...

5. Install bearing (63) and bearing (64) into housing (26). Install set screws (65).

Illustration 4

g00990391

6. Use Tooling (D) to install lip seal (62) in housing (26) until the lip seal is seated. The sealing lip must face inward. Lubricate the sealing lip lightly with hydraulic oil before installation. Use Tooling (B) to install retaining ring (61) into housing (26).

Illustration 5

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7. Install shield (60) into housing (26).

Illustration 6

g00990696

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120H Motor Grader CAF00001-UP (MACHINE) POWERED BY 3126B Engine(SEB...

Illustration 7

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8. Place a light coat of hydraulic oil on bearing (64) and bearing (65). The hydraulic oil will hold swashplate (54) in position during the following steps. Install swashplate (44) into housing (26). Swashplate (44) should fit into bearing (64) and bearing (65).

Illustration 8

g00990697

9. Place housing (26) onto support blocks to allow space for installation of shaft (59). Shaft (59) extends beyond the end of housing (26). Install shaft (59) through swashplate (44), through bearing (58) (not shown), and through housing (26).

10. Install plug (48) into housing (26). Install the O-ring seal into housing (26).

Illustration 9

g00990382

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11. Install spacer (55), spring (56), and spacer (57) into barrel (52).

Illustration 10

g00990700

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.

12. Use Tooling (D) and use a suitable press to compress spring (56).

13. Use Tooling (B) to install retaining ring (54) into barrel (52).

Note: Set bearing preload before you install the rotating group. The bearing preload should be 0.010 mm (0.0004 inch) to 0.100 mm (0.0039 inch).

Illustration 11

g00990702

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120H Motor Grader CAF00001-UP (MACHINE) POWERED BY 3126B Engine(SEB...

14. Do not install shim (41). Install bearing cone (42) onto shaft (59). Assemble the pump without shim (41) to check the preload of bearing cone (42).

Illustration 12

g00990368

15. Install the head (31) on housing (26). Install bolts (33).

Illustration 13

g00990706

Typical example

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120H Motor Grader CAF00001-UP (MACHINE) POWERED BY 3126B Engine(SEB...

Illustration 14

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g00990708

Typical example

16. Install Tooling (E) onto the pump housing. Use the dial indicator to determine the end play of shaft (59). Be sure that you move shaft (59) completely in both directions. Use appropriate tools to move shaft (59).

17. Subtract desired shaft bearing end play of 0.010 mm (0.0004 inch) to 0.100 mm (0.0039 inch) from the dial indicator reading. This is the thickness of shims (50).

Illustration 15

g00990368

18. Remove bolts (33), head (31), and the bearing.

Illustration 16

g00990379

19. Install pistons (51) into the original locations in spacer (53) and barrel (52). For best results, place the barrel in an upright position. Insert the pistons into spacer (53). Lift the pistons with spacer (53) and insert pistons (51) into barrel (52).

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120H Motor Grader CAF00001-UP (MACHINE) POWERED BY 3126B Engine(SEB...

Illustration 17

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20. Position housing (26) horizontally. Install rotating group (49) and install shim kit (50) onto shaft (59).

Illustration 18

g00990712

21. Install shims (41) and install bearing cone (42) onto shaft (59).

Illustration 19

g00990376

22. Position two spacers (45) and two locking plates (46) to the original positions on swashplate (44).

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120H Motor Grader CAF00001-UP (MACHINE) POWERED BY 3126B Engine(SEB...

23. Apply Tooling (G) on bolts (47). Install bolts (47) to hold locking plates (46) and spacers (45) to swashplate (44).

Illustration 20

g00990371

24. Install pin (39) in head (31).

25. Apply Tooling (G) to piston rods (34) and (37).

26. Install piston rod (34) and piston rod (37) in head (31).

Illustration 21

g00990369

27. Install spring (37), piston (35), and piston (38) onto head (31):

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120H Motor Grader CAF00001-UP (MACHINE) POWERED BY 3126B Engine(S...

Illustration 22

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28. Use a light coat of Tooling (F) to hold plate (43) to head (31) during assembly.

29. Position head (31) onto housing (26) and bearing (42).

Illustration 23

g00990368

30. Install bolts (33) to hold head (31) to housing (26).

31. Install plug (30) in head (31). Install the O-ring seal in head (31).

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120H Motor Grader CAF00001-UP (MACHINE) POWERED BY 3126B Engine(S...

Illustration 24

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32. Install O-ring seal (29) to housing (26).

Illustration 25

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33. Install cover (28) and install bolts (27) to housing (26).

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120H Motor Grader CAF00001-UP (MACHINE) POWERED BY 3126B Engine(S...

Illustration 26

g00990339

34. Install spool (25), guide (24), spring (23), and guide (22) to valve (2).

35. Install spool (21), guide (20), pin (19), spring (18), and guide (17) to valve (2).

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120H Motor Grader CAF00001-UP (MACHINE) POWERED BY 3126B Engine(S...

Illustration 27

g00990325

Sudden release of spring force can cause injury.

To prevent the possibility of injury, follow the procedure to relieve the spring pressure.

36. Install O-ring seal (16) to plug (15).

37. Install plug (15) to valve (2).

38. Install O-ring seal (14) to plug (13).

39. Install plug (13) to valve (2).

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120H Motor Grader CAF00001-UP (MACHINE) POWERED BY 3126B Engine(S...

Illustration 28

g00990306

40. Install O-ring seal (12) to plug (11).

41. Install plug (11) to valve (2).

42. Install O-ring seal (10) to plug (9).

43. Install plug (9) to valve (2).

44. Install O-ring seal (8) to plug (7).

45. Install plug (7) to valve (2).

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120H Motor Grader CAF00001-UP (MACHINE) POWERED BY 3126B Engine(S...

Illustration 29

g00990315

46. Install needle valve (6), ring (5), and O-ring seal (4) to valve (2).

47. Install plug (3) to valve (2).

Illustration 30

g00834347

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

End By: a. Install the piston pump (hydraulic and steering). Refer to Disassembly and Assembly, "Piston Pump (Hydraulic and Steering) - Install" for the correct procedure.

Copyright 1993 - 2020 Caterpillar Inc.

Mon Mar 2 00:47:00 UTC+0800 2020

All Rights Reserved.

Private Network For SIS Licensees.

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120H Motor Grader CAF00001-UP (MACHINE) POWERED BY 3126B Engine(SEB...

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Shutdown SIS Previous Screen Product: MOTOR GRADER Model: 120H MOTOR GRADER CAF Configuration: 120H Motor Grader CAF00001-UP (MACHINE) POWERED BY 3126B Engine

Disassembly and Assembly 120H and 135H Motor Graders Machine Systems Media Number -RENR4164-01

Publication Date -01/04/2005

Date Updated -30/04/2005

i04685309

Piston Pump (Hydraulic and Steering) - Install SMCS - 4306-012; 5070-012

Installation Procedure Table 1 Required Tools Tool

Part Number

Part Description

Qty

183-4797

Track Roller Lifting Fork

1

Extension

1

A FT-2930

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120H Motor Grader CAF00001-UP (MACHINE) POWERED BY 3126B Engine(SEB...

Illustration 1

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g01012620

1. Attach Tooling (A) to a suitable lifting device. Position Tooling (A) under implement pump (3) . The weight of implement pump (3) is approximately 73 kg (160 lb).

2. Install implement pump (3) .

Illustration 2

g02797831

3. Install bracket (7) .

4. Install bolts (6) . Tighten bolts (6) to a torque of 160 ± 30 N·m (118 ± 22 lb ft).

5. Install yoke (5) , nut (4) , and the washer. Tighten nut (4) to a torque of 190 ± 25 N·m (140 ± 18 lb ft).

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120H Motor Grader CAF00001-UP (MACHINE) POWERED BY 3126B Engine(SEB...

Illustration 3

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6. Connect hose assembly (2) .

Illustration 4

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7. Connect fitting assembly (1) .

End By: Install the fan drive pump. Refer to Disassembly and Assembly, "Fan Drive Pump Install".

Copyright 1993 - 2020 Caterpillar Inc.

Mon Mar 2 00:47:56 UTC+0800 2020

All Rights Reserved.

Private Network For SIS Licensees.

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/3/2