Caterpillar Motor Graders 120K, 120K Series 2 Motor Graders Repair & Service Manual
Complete repair service manual with Electrical Wiring Diagrams for Caterpillar Motor Graders 120K, 120K Series 2, with all the technical information to maintain, diagnose, and repair like professional mechanics.
Caterpillar Motor Graders 120K, 120K Series 2 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
KENR8244 - Schematic (12K; 120K; 140K and 160K Motor Grader Electrical System).pdf
KENR8245 - Schematic (12K; 120K; 140K; and 160K Motor Grader Hydraulic System).pdf
KENR8412 - Specifications (120K and 120K Series 2 Motor Grader Hydraulic and Steering System).pdf
KENR8413 - Systems Operation (120K and 120K Series 2 Motor Graders Hydraulic and Steering System).pdf
KENR8413 - Testing and Adjusting (120K and 120K Series 2 Motor Graders Hydraulic and Steering System).pdf
KENR8413 - Troubleshooting (120K and 120K Series 2 Motor Graders Hydraulic and Steering System).pdf
KENR8414 - Specifications (120K and 120K Series 2 Motor Graders Air System and Brakes).pdf
KENR8415 - Systems Operation (120K and 120K Series 2 Motor Graders Air System and Brakes).pdf
KENR8415 - Testing and Adjusting (120K and 120K Series 2 Motor Graders Air System and Brakes).pdf
KENR8415 - Troubleshooting (120K and 120K Series 2 Motor Graders Air System and Brakes).pdf
KENR8416 - Specifications (120K and 120K Series 2 Motor Graders Power Train).pdf
KENR8437 - Disassembly and Assembly (120K and 120K Series 2 Motor Graders Engine Supplement).pdf
KENR8438 - Disassembly and Assembly (120K and 120K Series 2 Motor Graders Power Train).pdf
KENR8439 - Disassembly and Assembly (120K and 120K Series 2 Motor Graders Machine Systems).pdf
PRODUCT DETAILS:
Total Pages: 1,602 pages
File Format: PDF (Windows & Mac & Linux)
Language: English
TABLE OF CONTENTS
KENR8244 - Schematic (12K; 120K; 140K and 160K Motor Grader Electrical System)................1
Main................2
KENR8245 - Schematic (12K; 120K; 140K; and 160K Motor Grader Hydraulic System)................4
Main................5
Features................5
Cover Page................6
Information................0
Component Location................0
Volume 1 of 2 - Standard Implement Control Valve configuration................7
Volume 2 of 2 - Alternate Implement Control Valve Configurations................8
Tap Location................9
Fluid Power Symbols................10
Electrical Symbols................11
Schematics................0
Volume 1 of 2 - Standard Implement Control Valve Configuration................12
Volume 2 of 2 -Alternate Implement Control Valve Configurations................13
Machine Views................0
Central Machine Components................14
Forward Machine Components................15
LH Implement Control Valve Config1................16
LH Implement Control Valve Config2................17
LH Implement Control Valve Config3................18
LH Implement Control Valve Config4................19
LH Implement Control Valve Config5................20
Plow And Dozer Attachment................21
RH Implement Control Valve Config1................22
RH Implement Control Valve Config2................23
RH Implement Control Valve Config3................24
Scarifier And Ripper Attachments................25
Swivel, Blade Tip, And Side Shift Cylinders................26
Collage................27
KENR8412 - Specifications (120K and 120K Series 2 Motor Grader Hydraulic and Steering System)................60
Hydraulic Tank Mounting................63
Hydraulic Tank and Filter................64
Pump Drive Shaft (Implement and Steering)................66
Piston Pump (Implement; Steering)................67
Pump Control Valve (Pressure and Flow Compensator)................73
Relief Valve (Implement)................75
Relief Valve (Signal)................76
Steering Control................77
Accumulator (Blade Cushion)................78
Solenoid Valve (Blade Cushion)................80
Springs (Control Valves)................81
Control Valve (Articulation)................83
Control Valve (Centershift)................85
Control Valve (Circle Drive)................87
Control Valve (Wheel Lean)................89
Control Valve (Blade Lift)................91
Relief Valve (Blade Lift)................93
Control Valve (Blade Tip)................95
Relief Valve (Blade Tip)................97
Control Valve (Ripper)................99
Relief Valve (Ripper)................101
Control Valve (Scarifier)................103
Relief Valve (Scarifier)................105
Control Valve (Sideshift)................106
Relief Valve (Sideshift)................108
Control Valve (Snow Plow_Dozer Lift)................110
Relief Valve (Snow Plow_Dozer Lift)................112
Control Valve (Wing Lift)................114
Relief Valve (Wing Lift)................116
Control Valve (Wing Tilt)................118
Relief Valve (Wing Tilt)................120
Relief Valve (Steering)................122
Articulation Cylinder Mounting................124
Articulation Cylinder................126
Position Sender (Articulation)................130
Circle................133
Blade Lift Cylinder Mounting................135
Blade Lift Cylinder................136
Blade Tip Cylinder................138
Centershift Cylinder Mounting................140
Centershift Cylinder................141
Ball Switch (Centershift Indicator)................143
Centershift Lock................144
Solenoid Valve (Centershift Lock)................146
Ripper Lift Cylinder................148
Scarifier Cylinder................150
Sideshift Cylinder................152
Steering Cylinder................154
Wheel Lean Cylinder and Mounting................156
Wheel Lean Cylinder................157
Gerotor Motor (Circle Drive)................159
Circle Drive - Slip Clutch................160
Swivel................165
Metering Pump (Steering)................167
Combination Valve................168
Valve and Linkage Group................172
Operator Console................176
Articulated Hitch................181
Blade Lift................183
Drawbar................185
Front Axle................189
Scarifier................195
KENR8413 - Systems Operation (120K and 120K Series 2 Motor Graders Hydraulic and Steering System)................197
Introduction................198
Features................200
Location Of Components................202
Implement and Steering System................208
Implement System................211
Hydraulic Tank and Filter................214
Piston Pump (Implement and Steering)................216
Pump Control Valve (Implement; Steering)................230
Combination Valve................232
Control Valve (Implement)................240
Control Valve (Blade Lift)................243
Centershift Lock................248
Steering System................251
Metering Pump (Steering)................259
KENR8413 - Testing and Adjusting (120K and 120K Series 2 Motor Graders Hydraulic and Steering System)................269
System Pressure - Release................270
Pump Efficiency (Piston Pumps) - Test................272
Bearing End Play (Piston Pump) - Adjust................275
Pump Control Valve (Implement; Steering) - Test and Adjust................276
Relief Valves (Implement) - Test and Adjust................290
Disc Pack Preload for Circle Drive - Adjust................294
Steering Wheel Slip - Check................298
Hydraulic Cylinder Drift - Check................299
Cylinder Cycle Time - Check................302
Relief Valve (Steering) - Test and Adjust................305
Steering System - Purge................308
Steering Linkage - Adjust................312
Axle Toe-In (Front) - Adjust................314
Position Sender (Articulation) - Adjust................317
KENR8413 - Troubleshooting (120K and 120K Series 2 Motor Graders Hydraulic and Steering System)................320
General Information................321
Machine Preparation for Troubleshooting................322
Visual Inspection................324
Operational Checks................326
Hydraulic and Steering System................327
KENR8414 - Specifications (120K and 120K Series 2 Motor Graders Air System and Brakes)................335
Air Compressor Governor................336
Air Tank................338
Relief Valve (Air Tank)................339
Check Valve (Air Tank)................340
Electric Horn................341
Air Dryer................343
Air Control Valve (Service Brake)................344
Pressure Switch (Low Brake Air)................346
Pressure Switch (Brake Air) (Stop Lamp)................347
Service Brake Control................348
Parking Brake Control................352
Air Control Valve (Parking Brake)................353
Check Valve (Parking Brake Release)................354
Solenoid Valve (Parking Brake)................355
Pressure Switch (Brake Air) (Parking Brake)................357
Service Brakes................358
Parking Brake................361
KENR8415 - Systems Operation (120K and 120K Series 2 Motor Graders Air System and Brakes)................363
Introduction................364
Location of Components................367
Air System and Brakes................373
Monitoring System................374
Air Dryer - If Equipped................378
Relief Valve (Air Tank)................380
Air Control Valve (Service Brakes)................382
Air Control Valve (Parking Brake)................385
Service Brakes................387
Parking Brake................392
Air System Schematic................396
KENR8415 - Testing and Adjusting (120K and 120K Series 2 Motor Graders Air System and Brakes)................399
System Pressure - Release................400
Air System - Test................402
Air Pressure Gauge - Test................405
Air Compressor Governor - Test and Adjust................408
Pressure Switch (Low Brake Air) - Test................412
Pressure Switch (Brake Air) (Stop Lamp) - Test................415
Limit Switch (Service Brake) - Test and Adjust................417
Service Brakes - Test................421
Service Brake Control (Pedal) - Adjust................423
Service Brake Control Valve - Check................428
Bearing Preload for Service Brake - Adjust................433
Brake Disc Wear - Check................435
Parking Brake - Test................438
Parking Brake Control - Adjust................439
KENR8415 - Troubleshooting (120K and 120K Series 2 Motor Graders Air System and Brakes)................441
General Information................442
Machine Preparation for Troubleshooting................443
Visual Inspection................446
Operational Checks................447
Air System and Brakes................449
KENR8416 - Specifications (120K and 120K Series 2 Motor Graders Power Train)................452
Torsional Coupling................454
Magnetic Screen (Transmission)................455
Gear Pump (Transmission Charging and Scavenge)................458
Relief Valve (Cooler Bypass)................460
Oil Filter (Transmission)................461
Governor Control................464
Clutch Control (Modulation)................466
Transmission Case................468
Transmission................474
Transmission Control Valve................478
Selector and Pressure Control Valve................481
Solenoid Valve (Transmission Clutch)................490
Toggle Switch (Ground Level Shutdown)................493
Speed Sensor (Transmission Intermediate)................494
Speed Sensor (Transmission Output)................495
Temperature Sensor (Transmission Oil)................496
Drive Shaft................497
Differential and Bevel Gear................498
Solenoid Valve (Differential Lock)................506
Final Drive................507
Tandem and Cover................509
Drive Chain................510
Case and Frame................511
Rollover Protective Structure (ROPS) - If Equipped SMCS - 7325................513
Fuel Tank................515
Window Wipers................517
Window Washer................520
Air Conditioner................521
Battery................524
Muffler................525
Wheel and Mounting................527
Wheel Group................528
KENR8437 - Disassembly and Assembly (120K and 120K Series 2 Motor Graders Engine Supplement)................530
Battery - Remove and Install................531
Engine Enclosure (Hood) - Remove................534
Engine Enclosure (Hood) - Install................537
Air Cleaner - Remove and Install................540
Turbocharger - Remove and Install................542
Muffler - Remove and Install................544
Alternator - Remove and Install................547
Engine Support (Front) - Remove and Install................549
Air Compressor - Remove and Install................554
Refrigerant Compressor - Remove and Install................558
Engine Oil Filter Base - Remove................563
Engine Oil Filter Base - Disassemble................566
Engine Oil Filter Base - Assemble................568
Engine Oil Filter Base - Install................570
Engine Oil Cooler - Remove and Install................572
Fuel Priming Pump - Remove and Install................577
Water Pump - Remove................579
Water Pump - Install................583
Water Separator and Fuel Filter (Primary) - Remove and Install................586
Fuel Filter (Secondary) and Fuel Filter Base - Remove and Install................588
Electric Starting Motor - Remove and Install................590
Refrigerant Condenser - Remove and Install................592
Radiator Guard and Support; Aftercooler; and Radiator - Remove................597
Aftercooler - Remove and Install................601
Radiator - Remove and Install................607
Radiator Guard and Support; Aftercooler; and Radiator - Install................614
Engine - Remove................617
KENR8438 - Disassembly and Assembly (120K and 120K Series 2 Motor Graders Power Train)................625
Duo-Cone Conventional Seals - Install................627
Wheel and Tire (Rear) - Remove and Install................639
Drive Chain - Remove................646
Drive Chain - Install................651
Service Brake (Wheel Spindle) - Remove................656
Service Brake (Wheel Spindle) - Disassemble................659
Service Brake (Wheel Spindle) - Assemble................668
Service Brake (Wheel Spindle) - Install................679
Tandem and Cover - Remove and Install................682
Drive Sprocket - Remove and Install................689
Final Drive - Remove................692
Final Drive - Disassemble................694
Final Drive - Assemble................704
Final Drive - Install................714
Transmission Oil Filter Base - Remove................716
Transmission Oil Filter Base - Disassemble................718
Transmission Oil Filter Base - Assemble................720
Transmission Oil Filter Base - Install................722
Gear Pump (Transmission Charging and Scavenge) - Remove................724
Gear Pump (Transmission Charging and Scavenge) - Disassemble................728
Gear Pump (Transmission Charging and Scavenge) - Assemble................732
Gear Pump (Transmission Charging and Scavenge) - Install................737
Transmission Oil Cooler - Remove................741
Transmission Oil Cooler - Install................744
Transmission Control Valve - Remove and Install................747
Transmission Control Valve - Remove................752
Transmission Control Valve - Disassemble................757
Transmission Control Valve - Assemble................778
Transmission Control Valve - Install................799
Transmission - Remove................804
Transmission - Disassemble................812
Transmission - Assemble................840
Transmission - Install................874
Parking Brake - Remove................882
Parking Brake - Disassemble................886
Parking Brake - Assemble................891
Parking Brake - Install................896
Drive Shaft - Remove and Install................899
Differential Lock Valve - Remove and Install................903
Differential and Bevel Gear - Remove................906
Differential and Bevel Gear - Disassemble................915
Differential and Bevel Gear - Assemble................930
Differential and Bevel Gear - Install................952
Wheel and Tire (Front) - Remove and Install................961
Front Axle - Install................973
Wheel Spindle - Remove................978
Wheel Spindle - Install................986
Wheel Spindle and Wheel Spindle Housing - Remove................993
Wheel Spindle and Wheel Spindle Housing - Install................1002
KENR8439 - Disassembly and Assembly (120K and 120K Series 2 Motor Graders Machine Systems)................1009
Machine Preparation for Disassembly and Assembly................1012
Duo-Cone Conventional Seals - Install................1014
Guards - Remove and Install................1026
Hydraulic Tank and Filter - Remove and Install................1030
Pump Drive Shaft - Remove and Install................1038
Piston Pump (Hydraulic and Steering) - Remove................1042
Piston Pump (Hydraulic and Steering) - Disassemble................1047
Piston Pump (Hydraulic and Steering) - Assemble................1055
Piston Pump (Hydraulic and Steering) - Install................1064
Combination Valve - Remove................1068
Combination Valve - Disassemble................1072
Combination Valve - Assemble................1080
Combination Valve - Install................1088
Bank Valve - Remove................1091
Bank Valve - Disassemble - Bank Valve with Hydraulic Detent................1102
Bank Valve - Disassemble - Bank Valve with Mechanical Detent................1110
Bank Valve - Disassemble - Bank Valve with out Detent................1117
Bank Valve - Assemble - Bank Valve with out Detent................1124
Bank Valve - Assemble - Bank Valve with Mechanical Detent................1131
Bank Valve - Install................1138
Accumulator (Blade Cushion) - Remove and Install................1149
Solenoid Valve (Blade Cushion) - Remove and Install................1153
Blade Lift Cylinder - Remove and Install................1158
Sideshift Cylinder - Remove and Install................1168
Centershift Cylinder - Remove and Install................1180
Blade Tip Cylinder - Remove and Install................1188
Blade - Remove................1195
Blade - Install................1202
Circle - Remove................1209
Circle - Install................1225
Drawbar - Remove................1242
Drawbar - Install................1250
Gerotor Motor (Circle Drive) - Remove................1260
Gerotor Motor (Circle Drive) - Disassemble................1262
Gerotor Motor (Circle Drive) - Assemble................1268
Gerotor Motor (Circle Drive) - Install................1273
Circle Drive - Remove................1275
Circle Drive - Disassemble................1280
Circle Drive - Assemble................1288
Circle Drive - Install................1299
Swivel - Remove................1304
Swivel - Disassemble................1308
Swivel - Assemble................1315
Swivel - Install................1320
Solenoid Valve (Centershift Lock) - Remove and Install................1323
Centershift Lock Bar and Bushings - Remove................1327
Centershift Lock Bar and Bushings - Install................1333
Centershift Lock - Remove................1341
Centershift Lock - Disassemble................1346
Centershift Lock - Assemble................1349
Centershift Lock - Install................1352
Blade Lift Arm - Remove................1357
Blade Lift Arm - Install................1365
Articulation Cylinder - Remove and Install................1374
Ripper Lift Cylinder - Remove and Install................1382
Ripper - Remove................1390
Ripper - Install................1401
Tie Rod (Steering) - Remove and Install................1412
Wheel Lean Bar - Remove and Install................1415
Wheel Lean Arm and Axle Bushings - Remove................1422
Wheel Lean Arm and Axle Bushings - Install................1430
Wheel Lean Cylinder - Remove and Install................1438
Steering Cylinder - Remove and Install................1447
Metering Pump (Steering) - Remove and Install................1457
Bottom Guard - Remove and Install................1471
Air Dryer - Remove and Install................1473
Air Tank - Remove and Install................1477
Air Control Valve (Service Brake) - Remove................1481
Air Control Valve (Service Brake) - Disassemble................1485
Air Control Valve (Service Brake) - Assemble................1492
Air Control Valve (Service Brake) - Install................1499
Air Control Valve (Parking Brake) - Remove................1502
Air Control Valve (Parking Brake) - Disassemble................1507
Air Control Valve (Parking Brake) - Assemble................1509
Air Control Valve (Parking Brake) - Install................1511
Window Wiper and Wiper Motor (Front) - Remove and Install................1517
Window Wiper and Wiper Motor (Rear) - Remove and Install................1527
Governor Control - Remove and Install................1533
Seat - Remove and Install................1535
Cab - Remove................1537
Cab - Install................1544
Evaporator Coil and Heater Coil - Remove and Install................1554
Blower Motor (Air Conditioner and Heater) - Remove and Install................1567
Fuel Tank - Remove................1572
Fuel Tank - Install................1576
Front Frame from Rear Frame (Articulating Hitch) - Separate................1580
Front Frame to Rear Frame (Articulating Hitch) - Connect................1595
Caterpillar Motor Graders 120K, 120K Series 2 Motor Graders Repair & Service Manual
