Disassembly and Assembly Power Train 12m Motor Grader Caterpillar 1

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Disassembly and Assembly

12M Motor Grader Power Train
Media Number -UENR3472-00
Publication Date -01/08/2012
Date Updated -10/08/2012
i05000362
Transmission - Assemble
SMCS - 3002-016; 3030-016; 3159-016
Assembly Procedure
Table 1
Required Tools
Tool
Part Number
138-7575
Link Bracket
308-3470
Jack Stand Gp
1U-9202
Lever Puller Hoist Gp
1P-1863
Retaining Ring Pliers
308-3470
Jack Stand Gp
140-7742
Sleeve
FT-2769
Table
4C-8156
Lifting Fixture
9U-7480
Compressing Tube
5C-7201
Nut
8T-4224
Hard Washer
Part Description
Qty
Bolt
-
1
M10 - 1.5 by 460mm
2P-8312
Retaining Ring Pliers
189-0408
Shackle As
https://sisweb.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 12/08/2012
3E-3882
T
Eyebolt
Loctite 242
Pagina 2 di 48
Note: Lubricate all seal rings and O-ring seals prior to assembly.
Note: Remove old anaerobic sealant from the bottom of the blind tapped holes in housing (237)
before assembling.
Illustration 1
g01389210
This Illustration is viewed from the bottom.
1. Install filter (246) and O-ring seal (245). Position cover (244) and install bolts (243).
Tighten bolts (243) to a torque of 28 7 Nm (21 5 lb ft).
Illustration 2
g01389019
2. Position plate (241) and install bolts (242). Tighten bolts (242) to a torque of 12 3 Nm
(106 27 lb in).
3. Lower the temperature of bearing outer races (240), (239), and (238). Install bearing outer
races (240), (239), and (238) into housing (237) .
Illustration 3
Pagina 3 di 48
g01389010
4. Install the O-ring seals and covers (236) onto housing (49). Tighten the bolts for covers
(236) to a torque of 28 7 Nm (21 5 lb ft). Install the O-ring seals and covers (235) onto
housing (49). Tighten the bolts for covers (235) to a torque of 28 7 Nm (21 5 lb ft).
Illustration 4
g01394193
5. Lower the temperature of races (234) and races (233) . Install races (234) and races (233)
into housing (49) .
Illustration 5
Pagina 4 di 48
g01394189
6. Install O-ring seal (232) .
Illustration 6
g01394188
7. Raise the temperature of bearing (231). Install bearing (231). Install retaining ring (230) .
Illustration 7
g01394185
8. Install gear (229) .
Pagina 5 di 48
9. Install retaining ring (228) .
Illustration 8
g01394184
10. Install retainer (227). Install bearing (226). Install retaining ring (225) .
Illustration 9
g01394180
11. Install gear (224). Install bolts (223). Tighten bolts (223) to a torque of 28 7 Nm (21 5
lb ft).
Illustration 10
Pagina 6 di 48
g01394236
12. Use two people in order to position shaft assembly (130) onto Tooling (H). The weight of
input shaft assembly (130) is approximately 25 kg (55 lb). Use suitable blocking in order to
support input shaft assembly (130). Install retaining ring (222) (not shown) onto input shaft
assembly (130). Install gear (221). Raise the temperature of inner bearing (220). Install
inner bearing (220) onto input shaft assembly (130) .
Illustration 11
g01394368
13. Use a suitable lifting device in order to position input shaft assembly (130) to housing (237).
The weight of input shaft assembly (130) is approximately 23 kg (50 lb). Use Tooling (N) in
order to install retaining ring (219) onto input shaft assembly (130). Install ring seal (218) .
Illustration 12
g01388797
Illustration 13
g01394379
Pagina 7 di 48
14. Install seal rings (217) and (216) onto piston (215) .
Illustration 14
g01388786
15. Install piston (215) and valve assembly (214) onto clutch assembly (174) .
Illustration 15
Pagina 8 di 48
g01388754
16. Install friction discs (213) and clutch plates (212) onto clutch assembly (174). Install friction
disc (211), spring (210), and hub assembly (207) onto clutch assembly (174) .
Illustration 16
g01388732
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.
17. Use Tooling (L) in order to compress hub assembly (207). Install two half rings (209) (not
shown) and lock rings (208) onto clutch assembly (174) .
Illustration 17
Pagina 9 di 48
g01388726
18. Position washer (205) to clutch assembly (174). Apply Tooling (T) to screws (206). Install
screws (206). Tighten screws (206) to a torque of 12 3 Nm (106 27 lb in).
Illustration 18
g01388685
19. Install thrust disc (204) and roller bearing assembly (203) onto clutch assembly (174) .
Illustration 19
g01388678
Pagina 10 di 48
20. Install gear assembly (202), thrust disc (201), thrust disc (200), and thrust race (199) onto
clutch assembly (174). Raise the temperature of inner bearing (198). Install inner bearing
(198) onto clutch assembly (174) .
21. Use a suitable lifting device in order to turn over clutch assembly (174) onto Tooling (H).
The weight of clutch assembly (174) is approximately 43 kg (95 lb).
Illustration 20
g01388663
Illustration 21
g01394424
Illustration 22
Pagina 11 di 48
g01388653
Illustration 23
g01388635
24. Install friction discs (191), clutch plates (192), friction discs (193), spring (190), and hub
assembly (187) onto clutch assembly (174) .
Illustration 24
Pagina 12 di 48
g01388624
injury.
shown) and lock rings (188) .
Illustration 25
g01388618
26. Position washer (185) to clutch assembly (174). Apply Tooling (T) to screws (186). Install
screws (186). Tighten screws (186) to a torque of 12 3 Nm (106 27 lb in).
Illustration 26
Pagina 13 di 48
g01388614
27. Install thrust disc (184) and roller bearing assembly (183) onto clutch assembly (174) .
Illustration 27
g01388597
28. Install gear assembly (182), thrust disc (181), and thrust disc (180) onto clutch assembly
(174). Raise the temperature of inner bearing (179). Install inner bearing (179) onto clutch
assembly (174) .
Illustration 28
g01394545
Pagina 14 di 48
29. Attach Tooling (R) and a suitable lifting device to clutch assembly (174). The weight of
clutch assembly (174) is approximately 64 kg (140 lb). Use Tooling (R) and the suitable
lifting device in order to install clutch assembly (174) to housing (237) .
Illustration 29
g01388581
30. Install O-ring seals (177) and seal rings (178) onto seal carrier (176).
Illustration 30
g01388568
31. Position seal carrier (176) onto clutch assembly (174). Install bolts (175). Tighten bolts
(175) to a torque of 55 10 Nm (41 7 lb ft).
Illustration 31
g01388470
Illustration 32
g01394550
Pagina 15 di 48
Illustration 33
g01388335
Illustration 34
Pagina 16 di 48
g01388330
34. Install friction discs (169), clutch plates (168), friction disc (167), spring (166), and hub
assembly (163) onto clutch assembly (135) .
Illustration 35
g01388324
injury.
Illustration 36
Pagina 17 di 48
g01388320
36. Position washer (162) to clutch assembly (135). Apply Tooling (T) to screws (161). Tighten
screws (161) to a torque of 12 3 Nm (106 27 lb in).
Illustration 37
g01388296
37. Install thrust disc (160) and roller bearing (159) onto clutch assembly (135) .
Illustration 38
g01388277
Pagina 18 di 48
38. Install gear assembly (158). thrust disc (157), thrust disc (156), and thrust race (155) onto
clutch assembly (135). Raise the temperature of inner bearing (154). Install inner bearing
Illustration 39
g01388246
Illustration 40
g01394572
Illustration 41
Pagina 19 di 48
g01394574
41. Install piston (151) and wave spring (150) onto clutch assembly (135) .
Illustration 42
g01388240
42. Install clutch plates (149), friction discs (148), and hub assembly (145) .
Illustration 43
g01388208
Pagina 20 di 48
injury.
Illustration 44
g01388185
44. Lower the temperature of bearing (144). Install bearing (144) into gear assembly (141) .
Illustration 45
Pagina 21 di 48
g01388168
45. Install washer (143), thrust disc (142), gear assembly (141), thrust disc (140), and spacer
Illustration 46
g01394607
46. Install gear (138) and spacer (137) onto clutch assembly (135). Raise the temperature of
inner bearing (136). Install inner bearing (136) .
Illustration 47
g01394616
47. Attach Tooling (R) and a suitable lifting device to clutch assembly (135). The weight of
clutch assembly (135) is approximately 61 kg (135 lb). Use Tooling (R) and the suitable
lifting device in order to install clutch assembly (135) into housing (237) .
Illustration 48
Pagina 22 di 48
g01394625
48. Install O-ring seals (134) and seal rings (133) onto seal carrier (132) .
Illustration 49
g01394631
49. Position seal carrier (132) onto clutch assembly (135). Install bolts (131). Tighten bolts
Illustration 50
g01394649
Pagina 23 di 48
50. Install gear (129) onto input shaft assembly (130). Raise the temperature of inner bearing
(128). Install inner bearing (128) onto input shaft assembly (130) .
Illustration 51
g01387858
Illustration 52
g01394705
Illustration 53
Pagina 24 di 48
g01394707
Illustration 54
g01387846
Illustration 55
g01387824
injury.
Illustration 56
Pagina 25 di 48
g01387820
55. Install washer (118) and thrust disc (117) .
Illustration 57
g01387765
56. Lower the temperature of bearing (116). Install bearing (116) into gear assembly (115) .
Illustration 58
g01394711
Pagina 26 di 48
57. Install gear assembly (115) and thrust disc (114) onto clutch assembly (60) .
Illustration 59
g01394713
58. Install gear (113) and thrust disc (112) onto clutch assembly (60). Raise the temperature of
inner bearing (111). Install inner bearing (111) onto clutch assembly (60) .
Illustration 60
g01387580
Illustration 61
Pagina 27 di 48
g01394729
Illustration 62
g01387573
Illustration 63
g01387556
Pagina 28 di 48
62. Install clutch plates (106), friction discs (105), and hub assembly (102) onto clutch
assembly (60) .
Illustration 64
g01387541
injury.
Illustration 65
g01387528
64. Install washer (101) and thrust disc (100) onto clutch assembly (60) .
Illustration 66
Pagina 29 di 48
g01387526
65. Lower the temperature of sleeve bearing (99). Install sleeve bearing (99) into gear assembly
(98) .
Illustration 67
g01387520
66. Install gear assembly (98) and thrust disc (97) onto clutch assembly (60) .
Illustration 68
Pagina 30 di 48
g01394799
67. Install gear (96) and thrust disc (95) onto clutch assembly (60). Raise the temperature of
inner bearing (94). Install inner bearing (94) onto clutch assembly (60) .
Illustration 69
g01394809
Illustration 70
g01394820
69. Install seal ring (89) onto balance piston (88) .
Illustration 71
Pagina 31 di 48
g01394812
injury.
70. Install piston (91), springs (90), and balance piston (88) onto clutch assembly (59). Use
Tooling (N ) in order to install retaining ring (87) onto clutch assembly (59) .
Illustration 72
g01387232
Illustration 73
Pagina 32 di 48
g01387228
72. Install lock rings (83), half rings (82), washer (81), and thrust disc (80) .
Illustration 74
g01394862
73. Install gear assembly (79), thrust disc (78), and thrust washer (77). Raise the temperature of
bearing (76). Install bearing (76) .
74. Use a suitable lifting device in order to turn over clutch assembly (59). The weight of clutch
assembly (59) is approximately 59 kg (130 lb).
Illustration 75
g01394871
Illustration 76
g01387093
Pagina 33 di 48
75. Install seal rings (74) and (75) onto piston (73). Install piston (73) and wave spring (72) .
Illustration 77
g01387088
Illustration 78
Pagina 34 di 48
g01386997
injury.
Illustration 79
g01386993
78. Install thrust washer (66) .
Illustration 80
Pagina 35 di 48
g01386992
79. Lower the temperature of bearing sleeves (65). Install bearing sleeves (65) into gear
assembly (63) .
Illustration 81
g01386841
80. Install gear assembly (63) and thrust washer (64) .
Illustration 82
g01394888
Pagina 36 di 48
81. Raise the temperature of rotor (62). Install rotor (62) onto clutch assembly (59) .
82. Raise the temperature of bearing (61). Install bearing (61) onto clutch assembly (59) .
Illustration 83
g01386815
Illustration 84
g01386811
83. Attach Tooling (J) and a suitable lifting device to clutch assembly (59) and clutch assembly
(60). The combined weight of clutch assembly (59) and clutch assembly (60) is
approximately 163 kg (360 lb). Use Tooling (J) and the suitable lifting device in order to
move clutch assembly (59) and clutch assembly (60) from Tooling (H) to the housing.
Illustration 85
Pagina 37 di 48
g01395925
84. Install seal rings (57) and O-ring seals (58) to seal carrier (56). Repeat for the remaining
seal carrier.
Illustration 86
g01386795
85. Position seal carrier (56) and install bolts (55). Tighten bolts (55) to a torque of 55 10
Nm (41 7 lb ft).
86. Position seal carrier (54) and install bolts (53). Tighten bolts (53) to a torque of 55 10
Nm (41 7 lb ft).
Illustration 87
Pagina 38 di 48
g01386792
87. Install the O-ring seal and tube assembly (52). Install bolts (51) and the locks. Tighten bolts
Illustration 88
g01386764
88. Attach Tooling (A) and Tooling (C) to housing (49). The weight of housing (49) is
approximately 136 kg (300 lb).
89. Use Tooling (A), Tooling (C), and the suitable lifting device in order to position housing
(49). Install bolts (48). Tighten bolts (48) to a torque of 55 10 Nm (41 7 lb ft).
Illustration 89
Pagina 39 di 48
g01386757
90. Position speed sensor (47) and speed sensor (46). Install bolts (45). Tighten bolts (45) to a
torque of 28 7 Nm (21 5 lb ft).
Illustration 90
g01386749
91. Install cover (44) .
Illustration 91
g01386747
Pagina 40 di 48
92. Position speed sensors (43) and (42). Install bolts (41). Tighten bolts (41) to a torque of 28
7 Nm (21 5 lb ft).
Illustration 92
g01386730
93. Position speed sensor (39) and guard (40). Install bolt (38). Tighten bolt (38) to a torque of
28 7 Nm (21 5 lb ft).
Illustration 93
g01386684
This Illustration shows the transmission with the output shaft downward.
94. Attach Tooling (A), Tooling (C), Tooling (F), and a suitable lifting device to transmission
(1). Use Tooling (A), Tooling (C), Tooling (F), and the suitable lifting device in order to
position transmission (1) onto Tooling (B) and Tooling (E) with the output shaft in the
upward position. The weight of transmission (1) is approximately 861 kg (1900 lb).
Illustration 94
Pagina 41 di 48
g01386675
95. Install hub (37) and retaining ring (36) .
Illustration 95
g01386663
96. Install dowels (35) and O-ring seals (34) .

97. Install clutch plates (33) and friction discs (32) .
Illustration 96
Pagina 42 di 48
g01386662
98. Install seal (31) .
Illustration 97
g01395990
99. Install O-ring seal (30), O-ring seal (29), O-ring seal (28), O-ring seal (27), and O-ring seal
(26) onto solenoid (25) .
Illustration 98
g01386646
100. Install solenoid (25). Install pressure sensor (24) and the O-ring seal. Tighten pressure
sensor (24) to a torque of 60 6 Nm (44 4 lb ft).
Illustration 99
Pagina 43 di 48
g01386632
101. Use two people in order to install housing (23). The weight of housing (23) is approximately
20 kg (45 lb).
Illustration 100
g01386624
102. Install guard (20). Connect harness assembly (21) and harness assembly (19) .
Illustration 101
g01396019
Pagina 44 di 48
103. Install piston seal (18) and piston seal (17) onto piston (16) .
Illustration 102
g01386610
104. Install piston (16) and O-ring seal (15) .
Illustration 103
g01386599
105. Install coned disc springs (14). Use Tooling (D) in order to install retaining ring (13) .
Illustration 104
Pagina 45 di 48
g01386589
106. Install lip seal (12) .
Illustration 105
g01386585
injury.
107. Position plate assembly (11). Install bolts (10). Tighten bolts (10) to a torque of 100 20
Nm (74 15 lb ft).
Illustration 106
Pagina 46 di 48
g01386579
This Illustration shows the transmission with the output shaft upward.
108. Attach Tooling (A), Tooling (C), and a suitable lifting device to transmission (1). The
weight of transmission (1) is approximately 853 kg (1880 lb).
Illustration 107
g01386575
109. Install O-ring seal (9) and cup (8). Install retaining ring (7) .
Illustration 108
Pagina 47 di 48
g01386574
110. Install yoke assembly (6) .
Illustration 109
g01386565
Illustration 110
Pagina 48 di 48
g01386568
111. Attach Tooling (A) and a suitable lifting device to transmission (1). The weight of
transmission (1) is approximately 857 kg (1890 lb). Use Tooling (A) and the suitable lifting
device in order to position transmission (A) onto Tooling (B) .
112. Position spacers (5) and control module (4). Install bolts (3). Tighten bolts (3) to a torque of
28 7 Nm (21 5 lb ft).
113. Install hose assembly (2) .
End By: Install the transmission.
Copyright 1993 - 2012 Caterpillar Inc.
Sun Aug 12 23:58:11 UTC+0200 2012
All Rights Reserved.

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