Product: MOTOR GRADER
Model: 120K MOTOR GRADER SZN
Configuration: 120K Motor Grader SZN00001-UP (MACHINE) POWERED BY C7 Engine
Disassembly and Assembly
120K and 120K Series 2 Motor Graders Engine Supplement
Media Number -KENR8437-01 Publication Date -01/12/2010 Date Updated -14/12/2010
Aftercooler - Remove and Install
SMCS - 1063-010
Removal Procedure
i03425861
Note: Cleanliness is an important factor. Before the disassembly procedure, the exterior of the component should be thoroughly cleaned. This will help to prevent dirt from entering the internal mechanism.
Note: Put identification marks on all lines, on all hoses, on all wires, and on all tubes for installation purposes. Plug all lines, hoses, and tubes. This helps to prevent fluid loss and this helps to keep contaminants from entering the system.
Illustration 1
1. Remove bolts (1). Remove door (2) .
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2
2. Remove bolts (3). Remove cover (4) .
Illustration 3
3. Remove clamp (5). Repeat for top clamp.
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Illustration 4
g01778858
4. Remove bolts (6). Use two people in order to remove cover (7). The approximate weight of cover (7) is 27 kg (60 lb).
Illustration 5
5. Remove bolts (8). Remove plates (9).
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Illustration 6
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6. Remove bolts (12). Remove bracket (10). Use two people in order to remove aftercooler (11). The approximate weight of aftercooler (11) is 29 kg (65 lb).
Installation Procedure
7
1. Use two people in order to position aftercooler (11). The approximate weight of aftercooler (11) is 29 kg (65 lb). Position bracket (10). Install bolts (12) .
8
Position plates (9). Install bolts (8) .
9
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3. Use two people in order to position cover (7). The approximate weight of cover (7) is 27 kg (60 lb). Install bolts (6) .
10
4. Install clamp (5). Repeat for top clamp.
11
Position cover (4). Install bolts (3) .
6. Install door (2). Install bolts (1). Repeat steps for opposite side.
Copyright 1993 - 2023 Caterpillar Inc. All Rights Reserved.
Private Network For SIS Licensees.
Thu Nov 16 13:12:22 UTC+0530 2023
Product: MOTOR GRADER
Model: 120K MOTOR GRADER SZN
Configuration: 120K Motor Grader SZN00001-UP (MACHINE) POWERED BY C7 Engine
Disassembly and Assembly
120K and 120K Series 2 Motor Graders Engine Supplement
Air Cleaner - Remove and Install
SMCS - 1051-010-HG; 1054-010
Removal Procedure
Note: Cleanliness is an important factor. Before the disassembly procedure, the exterior of the component should be thoroughly cleaned. This will help to prevent dirt from entering the internal mechanism.
1. Remove clamps (1) and (3). Remove hoses (2) and (4).
2
2. Remove hose (7). Remove restriction indicator (5). Remove bolts (8). Remove air cleaner assembly (6) .
Installation Procedure
Illustration 3
g01782314
1. Position air cleaner assembly (6). Install bolts (8). Install restriction indicator (5). Install hose (7) .
Illustration 4
2. Install hoses (2) and (4). Install clamps (1) and (3).
Copyright 1993 - 2023 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Thu Nov 16 13:05:49 UTC+0530 2023
Product: MOTOR GRADER
Model: 120K MOTOR GRADER SZN
Configuration: 120K Motor Grader SZN00001-UP (MACHINE) POWERED BY C7 Engine
Disassembly and Assembly
120K and 120K Series 2 Motor Graders Engine Supplement Media Number -KENR8437-01
Air Compressor - Remove and Install
SMCS - 1803-010
Removal Procedure
Note: Cleanliness is an important factor. Before the disassembly procedure, the exterior of the component should be thoroughly cleaned. This will help to prevent dirt from entering the internal mechanism.
Note: Put identification marks on all lines, on all hoses, on all wires, and on all tubes for installation purposes. Plug all lines, hoses, and tubes. This helps to prevent fluid loss and this helps to keep contaminants from entering the system.
NOTICE
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Refer to Special Publication, NENG2500, "Caterpillar Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products.
Dispose of all fluids according to local regulations and mandates.
1. Drain the cooling system. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change" for the correct procedure.
Illustration 1
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2. Remove mounting bolts (1) and remove side cover (2) .
Illustration 2
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3. Remove hose assemblies (3). Disconnect tube assemblies (4) .
Illustration 3
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4. Use suitable lifting device (5). The approximate weight of the air compressor (6) is 27 kg (60 lb). Remove bolts (7).
Installation Procedure
Note: Cleanliness is an important factor. Before assembly, all parts should be thoroughly cleaned in cleaning fluid. Allow the parts to air dry. Wiping cloths or rags should not be used to dry parts. Lint may be deposited on the parts which may cause later trouble. Inspect all parts. If any parts are worn or damaged, use new parts for replacement.
4
1. Attach a suitable lifting device (5). The approximate weight of air compressor (6) is 27 kg (60 lb). Install bolts (7) .
Illustration 5
2. Connect tube assemblies (4). Connect hose assemblies (3) .
3. Position side cover (2). Install bolts (1) .
Copyright 1993 - 2023 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Thu Nov 16 13:07:45 UTC+0530 2023
Product: MOTOR GRADER
Model: 120K MOTOR GRADER SZN
Configuration: 120K Motor Grader SZN00001-UP (MACHINE) POWERED BY C7 Engine
Disassembly and Assembly
120K and 120K Series 2 Motor Graders Engine Supplement Media Number -KENR8437-01
Alternator - Remove and Install
SMCS - 1405-010
Removal Procedure
Personal injury can result from failure to disconnect the battery.
First, disconnect the negative battery cable. Then, disconnect the positive battery cable.
A positive power lead can cause sparks if the battery is not disconnected. Sparks can possibly result in battery explosion or fire.
1. Turn the key for the battery disconnect switch to the OFF position. Remove the key.
1
2. Remove wire harness (3). Remove bolts (2). Remove belts (1). Remove alternator (4) .
Installation Procedure
Illustration 2
g01753558
1. Position alternator (4). Install belts (1). Install bolts (2). Install wire harness (3). Refer to Testing and Adjusting, "Belt Tightning Chart" for the correct belt (1) adjustment .
2. Install the key. Turn the key for the battery disconnect switch to the ON position. Copyright 1993 - 2023 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees. Thu Nov 16 13:06:51 UTC+0530 2023
Product: MOTOR GRADER
Model: 120K MOTOR GRADER SZN
Configuration: 120K Motor Grader SZN00001-UP (MACHINE) POWERED BY C7 Engine
Disassembly and Assembly
120K and 120K Series 2 Motor Graders Engine Supplement
Media Number -KENR8437-01
Battery - Remove and Install
SMCS - 1401-010
Removal Procedure
-01/12/2010
Updated -14/12/2010
Disconnect batteries before performance of any service work.
Illustration 1 g01773255
1. Use two people in order to remove battery cover (1). The weight of the battery cover (1) is approximately 23 kg (50 lb).
2
2. Remove clamps (5). Disconnect cables (4). Remove nuts (2). Remove bracket (3) .
Illustration 3
g01773396
3. Attach a suitable lifting device (6). Remove battery (7). The approximate weight of battery (7) is 61 kg (135 lb).
Installation Procedure
Illustration 4
1. Attach a suitable lifting device (6). Position battery (7). The approximate weight of battery (7) is 61 kg (135 lb).
Illustration 5
2. Install bracket (3). Install nuts (2). Attach cables (4). Install clamps (5) .
Illustration 6
g01780176
3. Use two people in order to install battery cover (1). The approximate weight of the battery cover is 23 kg (50 lb).
Copyright 1993 - 2023 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees. Thu Nov 16 13:04:57 UTC+0530 2023
Product: MOTOR GRADER
Model: 120K MOTOR GRADER SZN
Configuration: 120K Motor Grader SZN00001-UP (MACHINE) POWERED BY C7 Engine
Disassembly and Assembly
120K and 120K Series 2 Motor Graders Engine Supplement
Media Number -KENR8437-01
Electric Starting Motor - Remove and Install
SMCS - 1453-010
Removal Procedure
-14/12/2010
Note: Put identification marks on all lines, on all hoses, on all wires, and on all tubes for installation purposes. Plug all lines, hoses, and tubes. This helps to prevent fluid loss and this helps to keep contaminants from entering the system.
1. Turn the battery disconnect switch to the OFF position.
Illustration 1 g01753741
2. Disconnect wires (1). Attach a suitable lifting device to electric starting motor (3). Use two people in order to support starting motor (3). The weight of electric starting motor (3) is approximately 27 kg (60 lb). Remove bolts (2) under electric starting motor (3). Remove electric starting motor (3).
Installation Procedure
Note: Cleanliness is an important factor. Before assembly, all parts should be thoroughly cleaned in cleaning fluid. Allow the parts to air dry. Wiping cloths or rags should not be used to dry parts. Lint may be deposited on the parts which may cause later trouble. Inspect all parts. If any parts are worn or damaged, use new parts for replacement.
1. Position starting motor (3). Use two people in order to support starting motor (3). The weight of electric starting motor (3) is approximately 27 kg (60 lb). Install bolts (2). Connect wires (1). Tighten the nuts on the cable to a torque of 30.5 ± 3.5 N·m (23 ± 3 lb ft).
2. Turn the battery disconnect switch to the ON position.
1993 - 2023 Caterpillar Inc.
Thu Nov 16 13:11:15 UTC+0530 2023
Product: MOTOR GRADER
Model: 120K MOTOR GRADER SZN
Configuration: 120K Motor Grader SZN00001-UP (MACHINE) POWERED BY C7 Engine
Disassembly and Assembly
120K and 120K Series 2 Motor Graders Engine Supplement
Media Number -KENR8437-01
Engine - Install
SMCS - 1000-012
Installation Procedure
Table 1
Required Tools Tool Part Number Part
A 189-0408 Shackle As 2
B 138-7573 Link Bracket 2
C 6v-3145 Load Leveler Gp 1
Note: Cleanliness is an important factor. Before assembly, all parts should be thoroughly cleaned in cleaning fluid. Allow the parts to air dry. Wiping cloths or rags should not be used to dry parts Lint may be deposited on the parts which may cause later trouble. Inspect all parts. If any parts are worn or damaged, use new parts for replacement.
Illustration 1
2
1. Attach tooling (C) and a suitable lifting device to engine assembly (34). Position engine assembly (34). The approximate weight of the engine assembly (34) is 907 kg (2000 lb). Install bolts (33).
Illustration 3
2. Install bolt (32). Repeat for opposite side.
4
3. Connect hose assemblies (31) .
Illustration 5
4. Install harness assembly (29). Install harness assembly (25). Install clips (30). Position tube (26). Install hose (28). Install clamp (27). Install clamp (24) .
6
5. Position fitting and install nut (22). Install clip (23) .
6. Position tube (20). Install clamp (21). Position the refrigerant compressor (16). Install mounting bolts (19). Install belt (18). Refer to Operation and Maintenance Manual, "BeltInstall" for the correct procedure. Connect harness assembly (17). Install clips (15). Position tube (14) and tighten the nut.
8
7. Attach tooling (A). Attach tooling (B) and a suitable lifting device. Install panel (13). The approximate weight of panel (13) is 41 kg (90 lb).
9
This is the sample of the manual
Click on the download link for complete Manual
12
11. Install cover (5). Install panel (4). Repeat for opposite side.
13
12. Attach cable assemblies (3). Install clips (2) .
