1 / 26

Caterpillar Cat 120G MOTOR GRADER (Prefix 82V) Service Repair Manual (82V00668 and up)

service repair manual

km76dnmopcmk
Télécharger la présentation

Caterpillar Cat 120G MOTOR GRADER (Prefix 82V) Service Repair Manual (82V00668 and up)

An Image/Link below is provided (as is) to download presentation Download Policy: Content on the Website is provided to you AS IS for your information and personal use and may not be sold / licensed / shared on other websites without getting consent from its author. Content is provided to you AS IS for your information and personal use only. Download presentation by click this link. While downloading, if for some reason you are not able to download a presentation, the publisher may have deleted the file from their server. During download, if you can't get a presentation, the file might be deleted by the publisher.

E N D

Presentation Transcript

  1. Service Repair Manual Models 120G M otor Grader

  2. 120G MOTOR GRADER 82V00668-UP (MACHINE) POWERED BY 3304 ENGIN... 1/9 Shutdown SIS Previous Screen Product: MOTOR GRADER Model: 120G MOTOR GRADER 82V Configuration: 120G MOTOR GRADER 82V00668-UP (MACHINE) POWERED BY 3304 ENGINE Disassembly and Assembly 12G, 120G, 130G & 140G MOTOR GRADERS POWER TRAIN Media Number -SENR3649-00 Publication Date -01/10/1987 Date Updated -27/09/2012 SENR36490004 Brake And Wheel Spindle Housings SMCS - 4205-011; 4205-012; 4205-015; 4205-016; 4251 Remove Brake And Wheel Spindle Housings Start By: a. remove drive chains https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/11/2

  3. 120G MOTOR GRADER 82V00668-UP (MACHINE) POWERED BY 3304 ENGIN... 2/9 1. Release the air pressure in the air tank by loosening the bleed valves. Do not disconnect the air line to the brake and wheel spindle housing until the air pressure is zero. 2. Remove two nuts (2), the washers and guard (1) from the housing. 3. Disconnect the air line from the housing and the block on the tandem housing. Remove the air line. 4. Fasten a hoist and tooling (A) to the plate on the brake and wheel spindle housing and to the stud on the wheel spindle. 5. Remove nuts (3) and the washers that hold the brake and wheel spindle housing to the tandem housing. Remove brake and wheel spindle housing (4). Weight is 159 kg (350 lb.). Install Brake And Wheel Spindle Housings https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/11/2

  4. 120G MOTOR GRADER 82V00668-UP (MACHINE) POWERED BY 3304 ENGIN... 3/9 1. Fasten a hoist and tooling (A) to brake and wheel spindle housing. Put brake and wheel spindle housing (1) in position on the studs in tandem housing (2). 2. Install the nuts (3) and the washers that hold the brake and wheel spindle housing to the tandem housing. 3. Remove the hoist and tooling (A). Install the air line on the brake and wheel spindle housing and the block on the tandem housing. Install the guard on the housing. Install the two nuts and the washers that hold it. End By: a. install drive chains Disassemble Brake And Wheel Spindle Housings Start By: a. remove brake and wheel spindle housings https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/11/2

  5. 120G MOTOR GRADER 82V00668-UP (MACHINE) POWERED BY 3304 ENGIN... 4/9 1. Remove wire (3) from the bolts. Remove bolts (1). Remove retainer (2) and the shims that are under the retainer. 2. Remove sprocket (4). Weight is 16 kg (36 lb.). 3. Remove bearing cone (5) from the spindle and cover (6). Remove O-ring seal (7) from cover (6). 4. Remove the bolts and plate (8) that hold cover (6) to the housing. Install two 5/8" - 11 NC forged eyebolts in the cover. Fasten a hoist to the eyebolts and remove the cover. Weight is 23 kg (50 lb.). Remove bearing cup (10) from the cover. 5. Remove O-ring seal (9) from the cover. 6. Remove hub (11) from the wheel spindle. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/11/2

  6. 120G MOTOR GRADER 82V00668-UP (MACHINE) POWERED BY 3304 ENGIN... 5/9 7. Remove ten discs (12) and nine disc assemblies from the housing. 8. Put springs (15) in compression with tool (A). 9. Remove rings (14) from the studs with pliers. 10. Remove tool (A). Remove washers (13) and springs (15) from the studs. 11. Install two 5/8" - 11 NC forged eyebolts (16) in housing (17). Fasten a hoist to the eyebolts. 12. Remove housing (17) from the wheel spindle. Weight is 45 Kg (100 lb.). 13. Remove Duo-Cone seals (18) from the wheel spindle and the housing. 14. Install tooling (B) and blocks on the housing as shown. 15. Remove piston (19) with tooling (B). 16. Remove the O-ring seals from the piston. Remove the bearing cup from the housing. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/11/2

  7. 120G MOTOR GRADER 82V00668-UP (MACHINE) POWERED BY 3304 ENGIN... 6/9 17. Remove bearing cone (21) from wheel spindle (20) with tooling (C). 18. Do Steps 1 through 17 for the other brake and wheel spindle housings. Assemble Brake And Wheel Spindle Housings 1. Lower the temperature of bearing cup (22) and install it in housing (3). 2. Make sure the Duo-Cone seals for the wheel spindle housing (17) and the wheel spindle are clean and dry. Make sure all metal surfaces that the seals make contact with are clean and dry. Install Duo-Cone seal (18) in wheel spindle housing (17) with tool (A). 3. Install Duo-Cone seal (18) on wheel spindle (20) with tool (A). Put a small amount of oil on the metal surfaces of the seals that make contact with each other. 4. Heat bearing cone (21) in oil to a maximum temperature of 135°C (275°F). Install bearing cone (21) on the shaft of wheel spindle (20). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/11/2

  8. 120G MOTOR GRADER 82V00668-UP (MACHINE) POWERED BY 3304 ENGIN... 7/9 5. Install two 5/8" - 11 NC forged eyebolts in housing (23). Fasten a hoist to the eyebolts. 6. Put housing (23) in position on wheel spindle (20). Be careful not to damage the Duo-Cone seals. Remove the hoist and the eyebolts. 7. Install small O-ring seal (24) on the piston. Install the large O-ring seal (25) on piston (19). Install piston (19) in housing (23). 8. Put springs (15) in position on the studs. 9. Put washers (13) in position on the springs. 10. Put springs (15) in compression with tooling (B). 11. Install rings (14) on the studs with pliers. 12. Slowly release the pressure on the springs. 13. Remove tooling (B). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/11/2

  9. 120G MOTOR GRADER 82V00668-UP (MACHINE) POWERED BY 3304 ENGIN... 8/9 14. Install hub (11) on the wheel spindle. 15. Put clean SAE 30 oil on the discs and on the discs assemblies. 16. Put discs (12) and disc assemblies (26) in position in the wheel spindle housing starting with a disc. There are ten discs and nine disc assemblies. Make sure there is a disc assembly between each disc. 17. Install the O-ring seal in cover (6). 18. Install O-ring seal (7) on cover (6). Put clean grease on the two O-ring seals. 19. Lower the temperature of bearing cup (27) and install it in cover (6). 20. Install two 5/8" - 11 NC forged eyebolts in cover (6). Fasten a hoist to the eyebolts. 21. Put cover (6) in position on wheel spindle housing (17). Remove the hoist and the eyebolts. 22. Install the bolts and the plate that hold cover (6) to the housing. 23. Install bearing cone (5) on the wheel spindle and in cover (6). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/11/2

  10. 120G MOTOR GRADER 82V00668-UP (MACHINE) POWERED BY 3304 ENGIN... 9/9 24. Put sprocket (4) in position on the splines of the wheel spindle. NOTE: The sprocket for the front brake and wheel spindle housing must be installed with the teeth next to the cover. The sprocket for the rear brake and wheel spindle housing must be installed with the teeth away from the cover. 25. Put retainer (2) in position on the wheel spindle without shims. Install bolts. Tighten the bolts to a torque of 47 N·m (35 lb.ft.) while turning the housing. Remove the bolts and the retainer. Measure the distance between the end of the sprocket and the wheel spindle. Install the retainer and shims (21) that are the same thickness as the distance measured minus .025 to 0.38 mm (.010 to .015 in.). Install bolts (23). Install the wire on the bolts. End By: a. install brake and wheel spindle housings Copyright 1993 - 2020 Caterpillar Inc. Mon Nov 2 14:21:14 UTC+0800 2020 All Rights Reserved. Private Network For SIS Licensees. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/11/2

  11. 120G MOTOR GRADER 82V00668-UP (MACHINE) POWERED BY 3304 ENGIN... 1/3 Shutdown SIS Previous Screen Product: MOTOR GRADER Model: 120G MOTOR GRADER 82V Configuration: 120G MOTOR GRADER 82V00668-UP (MACHINE) POWERED BY 3304 ENGINE Disassembly and Assembly 12G, 120G, 130G & 140G MOTOR GRADERS POWER TRAIN Media Number -SENR3649-00 Publication Date -01/10/1987 Date Updated -27/09/2012 SENR36490005 Tandem Housings SMCS - 4064-011; 4064-012 Remove Tandem Housings Start By: a. remove drive chains 1. Fasten a hoist to tandem housing (2) as shown. Install tooling (A) on the brake and wheel spindle housings and the hoist. 2. Release the air pressure from the air tank by loosening the bleed valves. Do not disconnect the air line from the tandem housing until the air pressure is zero. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/11/2

  12. 120G MOTOR GRADER 82V00668-UP (MACHINE) POWERED BY 3304 ENGIN... 2/3 3. Disconnect air line (1) from the junction block on the frame. 4. Remove nuts (4) and the washers that hold tandem housing (2) to final drive housing (3). 5. Remove tandem housing (2). Weight is 594 kg (1310 lb.). 6. Do Steps 1 through 5 for the other tandem housing. Install Tandem Housings 1. Fasten a hoist and tooling (A) to the tandem housing. 2. Put tandem housing (1) in position on final drive housing (3). 3. Install nuts (2) and the washers that hold the tandem housing to the final drive housing. Tighten the nuts to a torque of 250 ± 13 N·m (185 ± 10 lb.ft.). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/11/2

  13. 120G MOTOR GRADER 82V00668-UP (MACHINE) POWERED BY 3304 ENGIN... 3/3 4. Remove the hoist and tooling (A) from the tandem housing. 5. Connect the air line to its correct location. 6. Do Steps 1 through 5 for the other tandem housing. End By: a. install drive chains Copyright 1993 - 2020 Caterpillar Inc. Mon Nov 2 14:22:10 UTC+0800 2020 All Rights Reserved. Private Network For SIS Licensees. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/11/2

  14. 120G MOTOR GRADER 82V00668-UP (MACHINE) POWERED BY 3304 ENGIN... 1/3 Shutdown SIS Previous Screen Product: MOTOR GRADER Model: 120G MOTOR GRADER 82V Configuration: 120G MOTOR GRADER 82V00668-UP (MACHINE) POWERED BY 3304 ENGINE Disassembly and Assembly 12G, 120G, 130G & 140G MOTOR GRADERS POWER TRAIN Media Number -SENR3649-00 Publication Date -01/10/1987 Date Updated -27/09/2012 SENR36490006 Drive Sprockets SMCS - 4072-011; 4072-012 Remove Drive Sprockets Start By: a. remove tandem housings 1. Remove nut (1) with tool (A). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/11/2

  15. 120G MOTOR GRADER 82V00668-UP (MACHINE) POWERED BY 3304 ENGIN... 2/3 2. Remove sprockets (2) and (3). Weight of one sprocket is 15 kg (32 lb.). 3. Do Steps 1 through 2 for the other drive sprockets. Install Drive Sprockets 1. Put sprocket (1) in position on the shaft. Install sprocket (1) with the hub of the sprocket away from the final drives. 2. Put sprocket (2) in position on the shaft. Install sprocket (2) with the hub toward the hub on sprocket (1). 3. Put the nut that holds the sprockets on the shaft in position on the shaft. Install the axle in the differential and final drive. NOTICE The following procedure must be used to put the correct amount of preload on the bearings for the final drives: a. Tighten the nut to a torque of 135 N·m (100 lb.ft.) with tool (A). b. Turn the sprockets to put the bearings in their seats. c. Hit the hub of the sprocket with a large punch and a hammer. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/11/2

  16. 120G MOTOR GRADER 82V00668-UP (MACHINE) POWERED BY 3304 ENGIN... 3/3 d. Do Steps a, b and c until the nut does not turn when it is tightened. e. Loosen the nut. f. Tighten the nut to a torque of 70 N·m (50 lb.ft.). g. If the nut is in a locking position, install the cover and the bolts that hold it. h. If the nut is not in a locking position, tighten the nut to the next nearest locking position. Install the cover and the bolts. 4. Do Steps 1 through 3 for the other drive sprockets. End By: a. install tandem housings Copyright 1993 - 2020 Caterpillar Inc. Mon Nov 2 14:23:06 UTC+0800 2020 All Rights Reserved. Private Network For SIS Licensees. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/11/2

  17. 120G MOTOR GRADER 82V00668-UP (MACHINE) POWERED BY 3304 ENGIN... 1/10 Shutdown SIS Previous Screen Product: MOTOR GRADER Model: 120G MOTOR GRADER 82V Configuration: 120G MOTOR GRADER 82V00668-UP (MACHINE) POWERED BY 3304 ENGINE Disassembly and Assembly 12G, 120G, 130G & 140G MOTOR GRADERS POWER TRAIN Media Number -SENR3649-00 Publication Date -01/10/1987 Date Updated -27/09/2012 SENR36490007 Final Drives SMCS - 4050-015 Disassemble Final Drives https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/11/2

  18. 120G MOTOR GRADER 82V00668-UP (MACHINE) POWERED BY 3304 ENGIN... 2/10 Start By: a. remove axles 1. Remove the nut that holds the sprockets on the shaft with tooling (A). Install tooling (B) on the shaft. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/11/2

  19. 120G MOTOR GRADER 82V00668-UP (MACHINE) POWERED BY 3304 ENGIN... 3/10 2. Lift the machine off the ground. Install tooling (D) under the rear frame as shown. Remove the bolts that hold covers (1) from the tandem housing. Remove covers (1). 3. Install tooling (C) on the rear wheels. Fasten a hoist to the tandem housing and tooling (C). Install tooling (E) between tooling (C) and the hoist to help keep the tandem housing in balance. Disconnect the air line from the tandem housing. 4. Remove nuts (2) and the washers that hold the tandem housing to the final drive housing. 5. Move the tandem housing away from the final drive housing and on to tooling (B). NOTE: Tooling (B) keeps the sprockets in their correct positions in the tandem housing. 6. Remove tooling (B) from the shaft. Do not remove tooling (B) from the sprockets. 7. Move the tandem housing away from the machine. Weight is 1043 kg (2300 lb.). 8. Remove O-ring seal (3) from the housing. Remove bearing (4) from the shaft. 9. Remove bolts (5) that hold retainer (6) to the housing. Remove retainer (6). 10. Remove the washer that is between the final drive housing and retainer (6). The washer is in three sections. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/11/2

  20. 120G MOTOR GRADER 82V00668-UP (MACHINE) POWERED BY 3304 ENGIN... 4/10 11. Install two 5/8" - 11 NC forged eyebolts (11) and nuts in the housing as shown. Put a fork lift truck in position under the housing. Install tooling (F) on the lift truck and the eyebolts. 12. Pull the outer housing (8) from the inner housing with tooling (F). 13. Remove two oscillation bearing rings (9) from the housings. Remove washer (7) from the inner housing. Washer (7) is in three sections. 14. Put tooling (G) and a floor jack in position under inner housing (13). A rag can be put between tooling (G) and the housing to prevent damage to the housing. 15. Remove nuts (10) and the washers that hold inner housing (13) to the bevel gear case. 16. Install two 3/4" - 10 NC forcing screws (14) in the housing. Remove the inner housing far enough to install tooling (H) on the housing. Fasten a hoist to tooling (H). Put an axle in position in the final drive housing to help keep the housing in balance. 17. Install a wire around the forcing screws and the planet carrier to keep the planet carrier from falling. Remove inner housing (13) and the planet carrier. Weight is 163 kg (360 lb.). Remove O- ring seal (12). Remove the O-ring seal from the inside surface of inner housing (13). 18. Put the final drive housing in position on blocks with the planet carrier up. Remove the wire and the forcing screws from the housing. 19. Remove pinion (16) from planet carrier (15). Fasten a hoist to planet carrier (15) and remove it. Weight is 41 kg (90 lb.). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/11/2

  21. 120G MOTOR GRADER 82V00668-UP (MACHINE) POWERED BY 3304 ENGIN... 5/10 20. Bend the locks away from the bolts that hold shafts (17) to the planet carrier. Remove the locks and the bolts. Remove retainers (18) from the shafts. 21. Remove shafts (17) from the planet carrier. Remove gears (21) and washers (20) from the planet carrier. Remove rollers (19) from gears (21). 22. Remove ring (23) from the planet carrier with tooling (I). Remove washer (22) from the planet carrier. 23. Bend the locks away from bolts (25). Remove bolts (25). Remove plates (26) that hold ring (24) to the housing. 24. Remove ring gear (24). Weight is 17 kg (38 lb.). 25. Remove shaft (27) from the housing. Weight is 18 kg (40 lb.). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/11/2

  22. 120G MOTOR GRADER 82V00668-UP (MACHINE) POWERED BY 3304 ENGIN... 6/10 26. Remove bearing (28) from shaft (27) with tooling (J). 27. Remove bearing cup (29) from the housing with tooling (K). Remove the lip-type seal from the housing. Remove the bearing cup from the other end of the housing with a hammer and a punch. 28. Do Steps 1 through 27 for the other final drive. Assemble Final Drives https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/11/2

  23. 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.

  24. 120G MOTOR GRADER 82V00668-UP (MACHINE) POWERED BY 3304 ENGIN... 7/10 1. Lower the temperature of bearing cup (29). Install bearing cup (29) in the housing. 2. Install the seal in the housing with tooling (J). Install the seal with the lip toward bearing cup (29). Put clean oil on the seal. 3. Put inner housing (13) in position on blocks as shown. Lower the temperature of the bearing cup and install it in the housing. 4. Heat bearing (28) in oil to a maximum temperature of 135° C (275° F). Install bearing (28) on shaft (27). Install the shaft and the bearing in the bearing cup and housing (13). 5. Put ring gear (24) in position on housing (13). Install plates (26) in the groove of the ring gear. Install the locks and bolts (25) on the plates. Bend the locks against the bolts. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/11/2

  25. 120G MOTOR GRADER 82V00668-UP (MACHINE) POWERED BY 3304 ENGIN... 8/10 6. Install the washer in the carrier. Install the large retaining ring that holds the washer with tool (B). 7. Install the rollers in the gears. Install the gears and the washers in planet carrier (30). Install shafts (17) that hold the gears in the planet carrier. Install the retainers, the bolts and the locks that hold the retainers. Bend the lock against the bolts. 8. Put the carrier on its other end. Fasten a hoist to the carrier. Put planet carrier (30) in position on shaft (27) and in ring gear (24). Install pinion (16) in the planet carrier. Install a wire to hold the planet carrier in position in the housing. 9. Install O-ring seal (31) on the housing. Install tooling (C) on housing (4). Fasten a hoist to tooling (C). Lift housing (4) and put it in position on tooling (D) and a floor jack. Put axle in position in the housing to help keep the housing in balance. 10. Move the final drive housing toward the bevel gear case. Remove the wire that holds the planet carrier in the housing. Remove tooling (C) and the hoist from the housing. 11. Put the final drive housing in position over the studs in the bevel gear case. Install the nuts and the washers that hold it. Remove tooling (D). 12. Tighten nuts (10) to a torque of 440 ± 20 N·m (320 ± 15 lb.ft.). Install O-ring seal (33) on the housing. Put STP OIL TREATMENT or CASITE MOTOR HONEY on the seal. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/11/2

  26. 120G MOTOR GRADER 82V00668-UP (MACHINE) POWERED BY 3304 ENGIN... 9/10 13. Install tooling (E) on the outer housing. Fasten a hoist to tooling (E). Put some oil on the inside surfaces of the oscillation bearing rings (9) and on the outside surface of the inner housing. Install rings (9) in outer housing (8). Install washer (7) on the inner housing. Washer (7) is in three sections. Put some clean grease on the washer. 14. Put housing (8) in position on the inner housing. Rings (9) and housing (8) can be moved with a soft hammer if necessary. Remove tooling (E). 15. Install bearing (4) on the shaft. Install washer (34) on the face of the outer housing. Washer (34) is in three sections. Put some clean grease on the washer. Install retainer (6) on the washer. Install the bolts and the washers that hold the retainer. Tighten the bolts to a torque of 250 ± 15 N·m (185 ± 11 lb.ft.). 16. Install tooling (H) on the rear wheels. Fasten a hoist and chains to the tandem housing. Fasten chains and tooling (F) to the hoist and the rear wheels. Put the tandem housing and tooling (G) in position on the final drive housing and the shaft. Install the nuts and the washers that hold the tandem housing to the final drive housing. Tighten the nuts to a torque of 250 ± 15 N·m (185 ± 11 lb.ft.). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/11/2

More Related