120M Series 2 and 120M2 Motor Graders Machine Systems Caterpillar

Connection Procedure

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When you are using hydraulic cylinders and puller studs, always ensure that the rated capacity of the puller stud meets or exceeds the rated capacity of the hydraulic cylinder. If the puller stud does not meet or exceed the rated capacity of the hydraulic cylinder, a sudden failure of the puller stud could occur. The sudden failure of the puller stud could result in personal injury or death.

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Illustration 1	g02731166

1. Lower the temperature of bearing assembly (49) . Install bearing assembly (49) .

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Illustration 2	g02731164

2. Install lip seal (48) into upper cap (45) .

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Illustration 3	g02731159

3. Install lip seal (47) into lower cap (44) .

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Illustration 4	g02731152

4. Install upper cap (45) . Position lower cap (44) . Install four of bolts (43) that are spaced equally. A hole must exist between the bolts. Tighten three of bolts (43) in a diagonal pattern by an equal number of turns to a torque of 47 ± 7 N·m (34 ± 5 lb ft). Ensure that lower cap (44) is flush with the frame. Measure the gap between upper cap (45) and the frame at each of the three bolts and record the measurement. Remove upper cap (45) . Install a number of shims (46) that is equal in thickness to the gap between upper cap (45) and the frame. Install upper cap (45) . Install bolts (43) . Install spacer (42) .

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Illustration 5	g02731175

5. Lower the temperature of bearing (41) . Use Tooling (E) to install bearing (41) to a depth of 12.5 ± 0.5 mm (0.50 ± 0.02 inch).

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Illustration 6	g02731145

6. Lubricate lip seals (40) . Use Tooling (G) to install lip seals (40) .

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Illustration 7	g02731139

7. Lower the temperature of bearing sleeve (39) to -57° to minus 91°C (-91° to minus 132°F). Use Tooling (E) in order to install bearing sleeve (39) .

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Illustration 8	g02731176

8. Use Tooling (E) to install collar (38) .

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Illustration 9	g02731180
Typical Example

9. Position a suitable lift truck at the rear of the machine. Attach two suitable lifting devices onto the rear bumper and the forks. Use the suitable lift truck to connect the rear frame to the front frame. Use Tooling (A) to chock the rear tires.

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Illustration 10	g02731115

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Illustration 11	g02731112

10. Install pin (37) . Install spacer (36) .

11. Install lock plate (34) . Apply Tooling (F) onto bolts (33) . Install two of bolts (33) that are 180 degrees opposite. Tighten two of bolts (33) to a torque of 81 ± 14 N·m (60 ± 10). Measure the gap between lock plate (34) and the frame in four places and record the measurements. Remove lock plate (34) . Install a number of shims (35) that are equal in thickness to the minimum gap measurement minus 0.25 mm (0.010 inch). Install lock plate (34) . Install bolts (33) . Tighten bolts (33) to a torque of 100 ± 20 N·m (77 ± 15 b ft). Install bolts (32) . Tighten bolts (32) to a torque of 105 ± 20 N·m (77 ± 15 lb ft).

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Illustration 12	g02731191

12. Install pin (31) .

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Illustration 13	g02731089

13. Remove Tooling (B) and the suitable blocking from front frame (30) .

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Illustration 14	g02731073

14. Connect links (29) .

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Illustration 15	g02731040

15. Install clamp (28) . Connect ground strap (27) .

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Illustration 16	g02731029

16. connect hose assemblies (26) and hose assemblies (25) .

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Illustration 17	g02731026

17. Connect hose assemblies (24) and hose assemblies (23) .

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Illustration 18	g02730963

18. Install covers (23A) .

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Illustration 19	g02730944

19. Install pin (21) . Install cotter pin (20) . Repeat this step for the opposite side.

20. Install clip (22) . Connect hose assembly (23) and hose assemblies (19) .

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Illustration 20	g02730920

21. Install cover (18) . Install bolts (17) . Connect hose assembly (16) . Connect brackets (15) .

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Illustration 21	g02730910

22. Install bracket (14) . Connect hose assemblies (13) .

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Illustration 22	g02730915

23. Position the hose assemblies and connect bracket (12) .

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Illustration 23	g02730907

24. Install clamp (11) . Connect hose assemblies (10) .

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Illustration 24	g02730897

25. Connect hoses (9) , hose assemblies (8) , and hose assemblies (7) . Connect harness assemblies (6) and install the connecting hardware.

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Illustration 25	g01363690

26. Install cover (5) .

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Illustration 26	g02730872

27. Remove lock pin (4) . Remove the suitable blocking from wheel lean bar (2) .

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Illustration 27	g02732179

28. Remove Tooling (A) from front and rear wheels (1) .

29. Refer to Operation and Maintenance Manual, "Hydraulic System Oil - Change" for the correct draining and filling procedures.

30. Refer to Service Manual, SENR5664, "Air Conditioning and Heating Systems with R-134a Refrigerant" for the correct procedure. Refer to Dealer Service Tool Catalog, NENG2500, "Air Conditioning Tools" for the correct tools.

End By:

1. Install the drive shaft.
2. Install the ripper.