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
g00990468
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
g00990390
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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120H Motor Grader CAF00001-UP (MACHINE) POWERED BY 3126B Engine(SEB...
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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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g00990378
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
g00990715
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
g00990366
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
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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
g01012616
6. Connect hose assembly (2) .
Illustration 4
g01012617
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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
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