120K and 120K Series 2 Motor Graders Power Train Caterpillar

Illustration 1	g01704273

(1) Assemble the threads of the plug without sealant.

Note: Apply blue Loctite 242 sparingly to the threads of screws.

(2) Torque for six screws ... 12 ± 3 N·m (106 ± 27 lb in)

(3) Thickness of two 108-5751 Friction Discs , five 6I-8911 Friction Discs and six 9U-9995 Plates for forward high clutch is 46.00 ± 1.04 mm (1.811 ± 0.041 inch).

Thickness of one new 108-5751 Friction Disc ... 4.00 ± 0.08 mm (0.157 ± 0.003 inch)

Thickness of one new 6I-8911 Friction Disc ... 4.00 ± 0.08 mm (0.157 ± 0.003 inch)

Thickness of one new 9U-9995 Plate ... 3.00 ± 0.08 mm (0.118 ± 0.003 inch)

(4) 9U-8815 Spring

Length under test force ... 41.030 mm (1.6153 inch)

Test force ... 459.57 ± 36.80 N (103.3 ± 8.3 lb)

Free length after test ... 150.63 mm (5.930 inch)

Outside diameter ... 106 mm (4.2 inch)

Note: Measure the clutch pack with applied pressure so that the wave in 6I-9502 Plate is flattened.

(5) Torque for eight bolts ... 55 ± 10 N·m (41 ± 7 lb ft)

(6) Thickness of one 159-0927 Friction Disc , six 6I-8912 Friction Discs , and six 6I-9502 Plates for forward low clutch is 45.00 ± 1.04 mm (1.772 ± 0.041 inch).

Thickness of one new 159-0927 Friction Disc ... 3.00 ± 0.08 mm (0.118 ± 0.003 inch)

Thickness of one new 6I-8912 Friction Disc ... 4.00 ± 0.08 mm (0.157 ± 0.003 inch)

Thickness of one new 6I-9502 Plate ... 3.00 ± 0.08 mm (0.118 ± 0.003 inch)

(7) Thickness of one 159-0927 Friction Disc , six 6I-8912 Friction Discs , and six 6I-9502 Plates for reverse clutch is 45.00 ± 1.04 mm (1.772 ± 0.041 inch).

Thickness of one new 159-0927 Friction Disc ... 3.00 ± 0.08 mm (0.118 ± 0.003 inch)

Thickness of one new 6I-8912 Friction Disc ... 4.00 ± 0.08 mm (0.157 ± 0.003 inch)

Thickness of one new 6I-9502 Plate ... 3.00 ± 0.08 mm (0.118 ± 0.003 inch)

(8) 102-5881 Wave Spring

Length under test force ... 38.2 mm (1.50 inch)

Test force ... 2090 ± 222 N (470 ± 50 lb)

Free length ... 50 mm (2.0 inch)

Outside diameter ... 106.01 ± 0.81 mm (4.174 ± 0.032 inch)

(9) Thickness of four 6I-8912 Friction Discs and three 6I-9502 Plates for second speed clutch is 25.00 ± 0.56 mm (0.984 ± 0.022 inch).

Thickness of one new 6I-8912 Friction Disc ... 4.00 ± 0.08 mm (0.157 ± 0.003 inch)

Thickness of one new 6I-9502 Plate ... 3.00 ± 0.08 mm (0.118 ± 0.003 inch)

(10) Thickness of four 6I-8912 Friction Discs and three 6I-9502 Plates for the third speed clutch is 25.00 ± 0.56 mm (0.984 ± 0.022 inch).

Thickness of one new 6I-8912 Friction Disc ... 4.00 ± 0.08 mm (0.157 ± 0.003 inch)

Thickness of one new 6I-9502 Plate ... 3.00 ± 0.08 mm (0.118 ± 0.003 inch)

(11) Thickness of six 6I-8912 Friction Discs and five 6I-9502 Plates for the first speed clutch is 39.00 ± 0.88 mm (1.535 ± 0.035 inch).

Thickness of one new 6I-8912 Friction Disc ... 4.00 ± 0.08 mm (0.157 ± 0.003 inch)

Thickness of one new 6I-9502 Plate ... 3.00 ± 0.08 mm (0.118 ± 0.003 inch)

(12) Thickness of seven 6Y-7981 Friction Discs and eight 3P-0337 Plates for low speed clutch is 52.56 ± 1.34 mm (2.069 ± 0.053 inch).

Thickness of one 6Y-7981 Friction Disc ... 4.32 ± 0.10 mm (0.170 ± 0.004 inch)

Thickness of one 3P-0337 Plate ... 2.79 ± 0.08 mm (0.110 ± 0.003 inch)

(13) 8M-4295 Spring

Length under test force ... 26.9 mm (1.06 inch)

Test force ... 74.3 ± 5.8 N (16.7 ± 1.3 lb)

Free length after test ... 44.4 mm (1.75 inch)

Outside diameter ... 15.2 mm (0.60 inch)

(14) Thickness of six 6I-8912 Friction Discs and five 6I-9502 Plates for high speed clutch is 39.00 ± 0.88 mm (1.535 ± 0.035 inch).

Thickness of one new 6I-8912 Friction Disc ... 4.00 ± 0.08 mm (0.157 ± 0.003 inch)

Thickness of one new 6I-9502 Plate ... 3.00 ± 0.08 mm (0.118 ± 0.003 inch)