Caterpillar Cat 120G MOTOR GRADER (Prefix 82V) Service Repair Manual Instant Download (82V00668)

1
Service Repair Manual
Models 120G Motor Grader
2
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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
3
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.

1. Remove two nuts (2), the washers and guard (1)
   from the housing.
2. Disconnect the air line from the housing and the
   block on the tandem housing. Remove the air
   line.
3. Fasten a hoist and tooling (A) to the plate on
   the brake and wheel spindle housing and to the
   stud on the wheel spindle.
4. 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
4
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• 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).
• Install the nuts (3) and the washers that hold
  the brake and wheel spindle housing to the tandem
  housing.
• 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
6

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.).

1. Remove bearing cone (5) from the spindle and
   cover (6). Remove O-ring seal (7) from cover
   (6).
2. 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.
3. Remove O-ring seal (9) from the cover.

6. Remove hub (11) from the wheel spindle.
7
7. Remove ten discs (12) and nine disc assemblies
from the housing.

1. Put springs (15) in compression with tool (A).
2. Remove rings (14) from the studs with pliers.
3. Remove tool (A). Remove washers (13) and springs
   (15) from the studs.

1. Install two 5/8" - 11 NC forged eyebolts (16) in
   housing (17). Fasten a hoist to the eyebolts.
2. Remove housing (17) from the wheel spindle.
   Weight is 45 Kg (100 lb.).
3. Remove Duo-Cone seals (18) from the wheel spindle
   and the housing.

1. Install tooling (B) and blocks on the housing as
   shown.
2. Remove piston (19) with tooling (B).
3. Remove the O-ring seals from the piston. Remove
   the bearing cup from the housing.

8

1. Remove bearing cone (21) from wheel spindle (20)
   with tooling (C).
2. 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).

• 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.
• Heat bearing cone (21) in oil to a maximum
  temperature of 135C (275F). Install bearing
  cone
• (21) on the shaft of wheel spindle (20).

9

1. Install two 5/8" - 11 NC forged eyebolts in
   housing (23). Fasten a hoist to the eyebolts.
2. Put housing (23) in position on wheel spindle
   (20). Be careful not to damage the Duo-Cone
   seals. Remove the hoist and the eyebolts.
3. 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).

1. Put springs (15) in position on the studs.
2. Put washers (13) in position on the springs.
3. Put springs (15) in compression with tooling (B).
4. Install rings (14) on the studs with pliers.
5. Slowly release the pressure on the springs.
6. Remove tooling (B).

10

1. Install hub (11) on the wheel spindle.
2. Put clean SAE 30 oil on the discs and on the
   discs assemblies.
3. 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.

1. Install the O-ring seal in cover (6).
2. Install O-ring seal (7) on cover (6). Put clean
   grease on the two O-ring seals.
3. Lower the temperature of bearing cup (27) and
   install it in cover (6).
4. Install two 5/8" - 11 NC forged eyebolts in cover
   (6). Fasten a hoist to the eyebolts.
5. Put cover (6) in position on wheel spindle
   housing (17). Remove the hoist and the eyebolts.
6. Install the bolts and the plate that hold cover
   (6) to the housing.
7. Install bearing cone (5) on the wheel spindle and
   in cover (6).

11

• 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.
• Put retainer (2) in position on the wheel spindle
  without shims. Install bolts. Tighten the bolts
  to a torque of 47 Nm (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. All
Rights Reserved. Private Network For SIS
Licensees.
Mon Nov 2 142114 UTC0800 2020
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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.
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3. Disconnect air line (1) from the junction
block on the frame.

1. Remove nuts (4) and the washers that hold tandem
   housing (2) to final drive housing (3).
2. Remove tandem housing (2). Weight is 594 kg (1310
   lb.).
3. 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 Nm
   (185 10 lb.ft.).

14

• Remove the hoist and tooling (A) from the tandem
  housing.
• Connect the air line to its correct location.
• Do Steps 1 through 5 for the other tandem
  housing. End By
• a. install drive chains

Copyright 1993 - 2020 Caterpillar Inc. All
Rights Reserved. Private Network For SIS
Licensees.
Mon Nov 2 142210 UTC0800 2020
15
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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).
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1. Remove sprockets (2) and (3). Weight of one
   sprocket is 15 kg (32 lb.).
2. 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.

• Put sprocket (2) in position on the shaft.
  Install sprocket (2) with the hub toward the hub
  on sprocket (1).
• 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

1. Tighten the nut to a torque of 135 Nm (100
   lb.ft.) with tool (A).
2. Turn the sprockets to put the bearings in their
   seats.
3. Hit the hub of the sprocket with a large punch
   and a hammer.

17

• Do Steps a, b and c until the nut does not turn
  when it is tightened.
• Loosen the nut.
• Tighten the nut to a torque of 70 Nm (50
  lb.ft.).
• If the nut is in a locking position, install the
  cover and the bolts that hold it.
• If the nut is not in a locking position, tighten
  the nut to the next nearest locking position.
  Install the cover and the bolts.
• Do Steps 1 through 3 for the other drive
  sprockets. End By
• a. install tandem housings

Copyright 1993 - 2020 Caterpillar Inc. All
Rights Reserved. Private Network For SIS
Licensees.
Mon Nov 2 142306 UTC0800 2020
18
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
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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.
20

• 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).
• 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.
• Remove nuts (2) and the washers that hold the
  tandem housing to the final drive housing.
• 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.

1. Remove tooling (B) from the shaft. Do not remove
   tooling (B) from the sprockets.
2. Move the tandem housing away from the machine.
   Weight is 1043 kg (2300 lb.).

1. Remove O-ring seal (3) from the housing. Remove
   bearing (4) from the shaft.
2. Remove bolts (5) that hold retainer (6) to the
   housing. Remove retainer (6).
3. Remove the washer that is between the final drive
   housing and retainer (6). The washer is in three
   sections.

21

1. 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.
2. Pull the outer housing (8) from the inner housing
   with tooling (F).
3. Remove two oscillation bearing rings (9) from the
   housings. Remove washer (7) from the inner
   housing. Washer (7) is in three sections.

1. 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.
2. Remove nuts (10) and the washers that hold inner
   housing (13) to the bevel gear case.
3. 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.
4. 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).
5. 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.).
22

1. 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.
2. 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.).
23
26. Remove bearing (28) from shaft (27) with
tooling (J).

1. 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.
2. Do Steps 1 through 27 for the other final drive.

Assemble Final Drives
24

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.

1. Put inner housing (13) in position on blocks as
   shown. Lower the temperature of the bearing cup
   and install it in the housing.
2. 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).
3. 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.

25

1. Install the washer in the carrier. Install the
   large retaining ring that holds the washer with
   tool (B).
2. 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.

1. 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.
2. 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.
3. 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.
4. 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).
5. Tighten nuts (10) to a torque of 440 20 Nm
   (320 15 lb.ft.). Install O-ring seal (33) on
   the housing. Put STP OIL TREATMENT or CASITE
   MOTOR HONEY on the seal.

26
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1. 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.
2. 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 Nm (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 Nm (185 11 lb.ft.).
28
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