Caterpillar Cat E120B EXCAVATOR (Prefix 6JF) Service Repair Manual (6JF00001 and up).pdf

Service Repair Manual
Models
E120B EXCAVATOR

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Product: EXCAVATOR
Model: E120B EXCAVATOR 6JF
Configuration: E120B TRACK-TYPE EXCAVATOR 6JF00001-UP (MACHINE) POWERED BY 3114 ENGINE
Disassembly and Assembly
E120B EXCAVATOR VEHICLE SYSTEM
Media Number -SENR4577-01 Publication Date -01/06/2005 Date Updated -07/06/2005
SENR45770024
Travel Drives
SMCS - 4050-017
Disassemble And Assemble Travel Drives
Start By:
a. remove travel drives and travel motors
1. Thoroughly clean the outside of the travel drive and travel motor prior to disassembly.
2. Fasten the travel drive and travel motor to tool (A) as shown. The combined weight of the travel
drive and travel motor is 215 kg (475 lb).
3. Put an alignment mark across the outside of the travel drive and travel motor so the components
of the unit can be reinstalled in their original positions.
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4. Remove sixteen bolts (1) and cover (2) from the ring gear.
5. Remove plate (3) from cover (2).
6. Remove plate (4) from the carrier.
7. Remove sun gear (5) from carrier assembly (6). Remove carrier assembly (6) from the ring
gear. Weight of the carrier assembly is 15 kg (33 lb).
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8. Disassemble carrier assembly (6) as follows:
a. Drive spring pin (8) into planetary shaft (7) with a hammer and a punch.
b. Remove planetary shaft (7), two thrust washers (9) and planetary gear (11) from the carrier.
c. Remove bearing (10) from the planetary gear.
d. Drive spring pin (8) out of planetary shaft (7) with a hammer and a punch.
e. Remove the other two planetary gears from the carrier as in Steps 8a through 8d.
f. Remove snap ring (12) that holds sun gear (13) in the carrier. Use a screwdriver to remove the
snap ring. Remove the sun gear from the carrier.
9. Remove plate (14) from the carrier assembly.
10. Install two forcing screws (15) of the appropriate size in ring gear (16). Tighten the forcing
screws evenly to separate ring gear (16) from the unit.
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11. Install two forcing screws (17) of the appropriate size in ring gear (19). Tighten the forcing
screws evenly to separate ring gear (19) from the unit.
12. Remove locating pins (20) from the main case.
13. Remove carrier assembly (18). Weight of the carrier assembly is 20 kg (45 lb).
14. Disassemble carrier assembly (18) as follows:
a. Drive spring pin (22) into planetary shaft (21) with a hammer and a punch.
b. Remove planetary shaft (21), two thrust washers (23) and planetary gear (25) from the carrier.
c. Remove two bearings (24) from the planetary gear.
d. Drive spring pin (22) out of planetary shaft (21) with a hammer and a punch.
e. Remove the other two planetary gears from the carrier as in Steps 14a through 14d.
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15. Remove twelve socket head bolts (28) that hold gear coupling (27) in position. Install a forcing
screw of the appropriate size in each of the four holes (26) in the gear coupling. Tighten the
forcing screws evenly to loosen the gear coupling from the four locating pins.
16. Remove shims (29) from the main casing.
17. Fasten tool (B) and a hoist to main casing (30) as shown. Remove the main casing from the
travel motor.
18. Remove Duo-Cone seal (31) from the main casing.
19. Remove bearings (32) and (33) from the main casing.
20. Remove Duo-Cone seal (34) from the main casing of the travel motor.
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NOTE: The following steps are for the assembly of the travel drive.
21. Be sure all parts of the travel drive are thoroughly clean and free of dirt and debris prior to
assembly. Reassemble the travel drive on tool (A).
22. Install bearings (32) and (33) in their original locations in the main casing with a press. Install
the bearings until each one makes contact with the counterbores in the main casing.
NOTICE
See, "Assembly And Installation Of Conventional Duo-Cone Seals" in
this module.
NOTE: The rubber seals and all surfaces that make contact with the seals must be clean and dry.
After installation of the seals, put clean SAE 30 oil on the contact surfaces of the metal seals.
23. Install Duo-Cone seal (31) in the main casing of the travel drive with tool (C).
24. Fasten tool (B) and a hoist to the main casing for the travel drive. Temporarily install the main
casing on the main casing of the travel motor. It may be necessary to tap around the circumference
of the casing with a soft faced hammer to seat it properly.
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25. Using a depth micrometer, measure the step height [dimension (X)] of gear coupling (27) at
several locations around the gear coupling. Find the average of the dimensions measured, and
record it.
26. Using a depth micrometer, measure the distance between the top face of the travel motor main
casing and the inner race of bearing (33) [dimension (Y)] at several locations around the main
casing of the travel motor. Find the average of the dimensions measured, and record it.
27. Determine the correct thickness of the shim pack to be used between the main casing for the
travel motor and gear coupling (27). The shim pack thickness is equal to dimension (X) - (Y) + 0
to 0.05 mm (0 to 0.002 in).
28. Temporarily install the shim pack determined in Step 27 and gear coupling (27) on the main
casing of the travel motor. Only use eight socket head bolts (28) to hold the gear coupling. Tighten
the bolts evenly.
29. Turn the casing by hand. It must turn smoothly. If the casing does not turn smoothly, install a
shim which is 0.05 mm (0.002 in) thinner. Be sure the shim pack is positioned correctly under the
gear coupling.
30. Remove the gear coupling, shim pack and main casing for the travel drive.
NOTICE
See, "Assembly And Installation Of Conventional Duo-Cone Seals" in
this module.
NOTE: The rubber seals and all surfaces that make contact with the the seals must be clean and
dry. After installation of the seals, put clean SAE 30 oil on the contact surfaces of the metal seals.
31. Install Duo-Cone seal (34) in the main casing of the travel motor with tool (C).
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NOTICE
Do not scratch or damage the Duo-Cone seals in the main casing or the
travel motor casing during assembly of the components. After
installation of the main casing for the travel drive on the travel motor
casing, there will be a gap between the components. The gap is caused
by the Duo-Cone seals and will be eliminated during installation of
gear coupling (27).
32. Fasten tool (B) and a hoist to the main casing. Put the main casing in position on the main
casing of the travel motor. Do not scratch or damage the Duo-Cone seals in either component
during installation.
33. Put the shim pack determined in Step 27 and gear coupling (27) in the correct position on the
main casing of the travel motor. If two shims are required, put the thinner shim in contact with the
gear coupling. Be sure all of the holes in the components are in alignment with each other. Install
two of the locating pins to hold the gear coupling and shim pack.
34. Put a thin coat of 9S3263 Thread Lock on the threads of twelve socket head bolts (28). Install
the socket head bolts to hold gear coupling (26) in place. Tighten the bolts evenly to a torque of
226 N·m (165 lb ft).
35. Use a hammer and punch to install the remaining locating pins in gear coupling (27).
36. If the two locating pins used to position ring gear (19) on the main casing were removed,
reinstall them in the main casing in their original locations. Be sure the larger bevel on each pin is
facing up after installation.
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NOTICE
Identification grooves (N) in planetary gears (25) must be facing
toward gear coupling (27), after installation in carrier (18) and in the
main casing. See Illustration C33671P1
37. Assemble carrier assembly (18) as follows:
a. Put clean SAE 30 oil on bearings (24). Install two bearings (24) in planetary gear (25).
b. Install a thrust washer (23) on each side of the planetary gear. Install the planetary gear and
thrust washers in carrier (18). Be sure identification grooves (N) are facing in the correct direction.
c. Install planetary shaft (21) in carrier (18) and through planetary gear (25). Be sure the spring pin
hole in the planetary shaft is in alignment with the spring pin hole in the carrier.
d. Install spring pin (22) in the carrier and into the planetary shaft. Install the spring pin until it is 2
to 3 mm (.078 to .118 in) below the outside surface of the carrier, and with the split in the spring
pin facing to either side of the carrier as shown in illustration C28668P1. To prevent the spring pin
from falling out, make a stake mark on each side of the spring pin hole in the carrier. Each stake
mark should be approximately 1.5 to 2.5 mm (0.06 to 0.10 in) from the spring pin hole.
e. Install the other two planetary gears in carrier (18) as is Steps 37a through 37d.
38. Install carrier assembly (18).
39. Put a bead of 6V6640 Gasket Maker on the mating surface of the main casing. Put ring gear
(19) its original location on the main casing. It may be necessary to use a soft faced hammer to
seat the ring gear on the main casing.
40. Thoroughly clean the mating surface of ring gear (19) that makes contact with ring gear (16).
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41. Put a bead of 6V6640 Gasket Maker on the mating surface of ring gear (19). Put ring gear (16)
in its original position on ring gear (19). It may be necessary to use a soft faced hammer to seat the
ring gear.
42. Install plastic plate (14) in the groove of carrier assembly (18).
NOTICE
Identification grooves (L) in planetary gears (11) must be facing up
toward the top of carrier assembly (6) after installation.
43. Assemble carrier assembly (6) as follows:
a. Install sun gear (13) in carrier (6). Using a screwdriver, install snap ring (12) that holds the sun
gear in the carrier.
b. Put clean SAE 30 oil on bearing (10). Install the bearing in planetary gear (11). Install a thrust
washer (9) on each side of the planetary gear.
c. Install the thrust washers and planetary gear in carrier (6). Be sure identification grooves (L) in
the planetary gear are facing up toward the top of the carrier assembly after installation. Install
planetary shaft (7) in carrier (6) and through planetary gear (11). Be sure the spring pin hole in the
planetary shaft is in alignment with the spring pin hole in the carrier.
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d. Install spring pin (8) until it is 2 to 3 mm (.078 to .118 in) below the outside surface of the
carrier, and with the split in the spring pin facing to either side of the carrier as shown in
illustration C28668P1. To Prevent the spring pin from falling out, make a stake mark on each side
of the spring pin hole in the carrier. Each stake mark should be approximately 1.5 to 2.5 mm (0.06
to 0.10 in) from the spring pin hole.
e. Install the other two planetary gears in carrier (6) as in Steps 43a through 43d.
44. Install carrier assembly (6) and sun gear (5) into carrier assembly (18). Be sure the sun gear,
planetary gears and the travel motor shaft all mesh properly.
NOTE: In Steps 45a through 45e, the thickness of plate (4) must be determined. Plate (4) is
available in several thicknesses.
45. Determine the required thickness of plate (4) as follows:
a. Using a straight edge and a depth micrometer, measure the distance between the outer machined
surface of cover (2) and the inner machined surface of cover (2) as shown. Record this as
dimension (D). The standard value of dimension (D) is 17.5 ± 0.2 mm (0.69 ± .008 in).
b. Using a straight edge and a depth micrometer, measure the distance between the top surface of
carrier assembly (6) and the machined surface of ring gear (16). Record this as dimension (E).
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c. Using a straight edge and a depth micrometer, measure the distance from the top surface of
carrier assembly (6) to the bottom of the counterbore which holds plate (4) in position. Record this
as dimension (F).
d. The required thickness of plate (4) equals [(D - E) + F] - 1 to 2 mm (0.04 to 0.08 in).
e. After the correct thickness of plate (4) has been determined, install the plate in the counterbore
of carrier assembly (6). The plate is the same on both sides and can be installed either way.
NOTE: In Steps 46a through 46e, the thickness of plate (3) must be determined. Plate (3) is
available in several sizes.
46. Determine the required thickness of plate (3) as follows:
a. Using a straight edge and a depth micrometer, measure the distance from the outer machined
surface of cover (2) to the bottom of the counterbore which holds plate (3) in position. Record this
as dimension (G). The standard value of dimension (G) is 24.0 ± 0.1 mm (0.94 ± .004 in).
b. Using a straight edge and a depth micrometer, measure the distance from the end surface of sun
gear (5) to the outer machined surface of ring gear (16). Record this as dimension (H).
c. Using a straight edge and a depth micrometer, measure the distance from the top surface of sun
gear (5) to the top surface of carrier assembly (6). Record this as dimension (J).
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d. The required thickness of plate (3) equals [(G - H) + J] - 1 to 2 mm (0.04 to 0.08 in).
e. After the correct thickness of plate (3) has been determined, install the plate in the counterbore
in cover (2).
NOTE: After cover (2) is installed on the travel drive, the distance between the top surface of sun
gear (5) and plate (3) must be 1 to 2 mm (0.02 to 0.08 in).
47. Be sure the machined surface of ring gear (16) is thoroughly clean, free of dirt and debris and
is dry. Put a bead of 6V6652 Gasket Eliminator around the machined surface of the ring gear.
Install cover (2) in its original position on ring gear (16).
48. Put a thin coat of 9S3263 Thread Lock on the threads of sixteen bolts (1) that hold the cover in
position. Install the bolts, and tighten them to a torque of 110 N·m (80 lb ft).
End By:
a. install travel drives and travel motors
Copyright 1993 - 2019 Caterpillar Inc.
All Rights Reserved.
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2019/9/15

Shutdown SIS
Previous Screen
Product: EXCAVATOR
Model: E120B EXCAVATOR 6JF
Configuration: E120B TRACK-TYPE EXCAVATOR 6JF00001-UP (MACHINE) POWERED BY 3114 ENGINE
Disassembly and Assembly
E120B EXCAVATOR VEHICLE SYSTEM
Media Number -SENR4577-01 Publication Date -01/06/2005 Date Updated -07/06/2005
SENR45770025
Travel Motors
SMCS - 4351-017
Disassemble And Assemble Travel Motors
Start By:
a. remove travel drives and travel motors
1. Thoroughly clean the outside of the travel motor prior to disassembly. Fasten the travel motor to
tool (A) as shown. Weight of the travel motor is approximately 125 kg (275 lb).
2. Put an alignment mark across the cover and body of the travel motor for assembly purposes.
The cover must be reinstalled in its original position on the body.
NOTICE
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During removal of cover (2) from the travel motor, do not scratch or
damage the mating surfaces of the components.
3. Remove thirteen socket head bolts (1) and cover (2) from the body of the travel motor.
4. Turn cover (2) over, and remove shim (5), valve plate (3), bearing (4) and o-ring seal (6).
NOTE: There is a retainer located under spring (9). This retainer has been press-fitted in cover
(2).
5. Install a small diameter rod in hole (X). Tap the rod with a plastic hammer to remove retainer
(10), spring (9), poppet (8) and seat (7) from the cover.
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6. Put identification marks on fittings (14) and (16) and the adapter joints for the fittings, as to
their location in the cover. Remove the fittings and adapter joints. Remove the o-ring seals from
the adapters.
7. Remove plug (15) from the cover. Remove the o-ring seal from the plug.
8. Remove stopper (11), spring (12) and spool (13) from the cover. Remove the o-ring seal from
stopper (11).
9. Remove two retainers (17) from the cover. Remove two balls (18) which are located under
retainers (17). Remove o-ring seal (19) and ring (20) from each retainer.
10. Remove two disc springs (21) from the brake piston.
11. Remove three o-ring seals (22) from the body of the travel motor.
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Brake piston (23) must be removed from the body of the travel motor
with shop air pressure. The brake piston can come out of the body with
force during the removal procedure. To prevent possible personal
injury, install tool (B) as shown. Tool (B) will retain the brake piston in
the body when applying shop air pressure.
12. Install tool (B) on the body of the travel motor as shown. Use two suitable sized bolts to hold
tool (B) in place. Apply shop air pressure (free of water) of approximately 525 kPa (75 psi) to
brake release port (Y). Brake piston (23) will move up and out of the bore in the body. Remove
tool (B) and the brake piston from the body.
13. Remove back-up rings (24) and (27) and o-ring seals (25) and (26) from the brake piston.
14. Remove three steel plates (28) and three friction plate (29) from the body of the travel motor.
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NOTICE
Do not let the components of the piston shoe assembly and barrel plate
assembly come apart during removal from the body of the travel
motor. The components of the two assemblies must be installed in their
original locations.
15. Remove piston shoe assemblies and barrel plate assembly (30) as a unit.
NOTICE
Retainer (32) and piston shoe assemblies (31) are not serviced
separately. Prior to removal of the retainer and piston shoe assemblies
from barrel plate assembly (33), put identification marks on piston
shoe assemblies (31) as to their location in retainer (32) and barrel
plate assembly (33). The piston shoe assemblies must be installed in
their original bores in the retainer and barrel plate assembly.
16. Remove retainer (32) and piston shoe assemblies (31) from barrel plate assembly (33).
Separate the piston shoe assemblies from the retainer.
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17. Remove retainer (34) and spacer (35) from the barrel. Remove nine springs (36) from the
barrel.
18. Put identification marks on cam plate (37) and the body of the travel motor so the cam plate
can be installed in its original position in the body. Remove cam plate (37) from the body of the
travel motor.
19. Put identification marks on woodruff keys (38) as to their location in the travel motor body.
Remove woodruff keys (38) from the body of the travel motor.
20. Using a soft faced hammer, remove shaft (39) from the body in the direction shown.
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21. Remove bearing inner race (41) from the end of the shaft.
22. Remove snap ring (40) from the groove in the shaft.
23. Push shaft (39) out of bearing (42) with a press as shown.
24. Remove oil seal (44) from the travel motor body. Remove two seats (43), two pistons (46) and
two balls (45) from the travel motor body.
25. Remove back-up ring (48) and o-ring seal (47) from each seat (44).
NOTE: The following steps are for the assembly of the travel motor.
26. Be sure all parts of the travel motor are thoroughly clean and free of dirt and debris prior to
assembly. Check the condition of all parts in the travel motor. Guideline For Reusable Parts
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"Piston Pumps And Motors", Form No. SEBF8032-01 can be used as a guide for reconditioning
and determining the reusability of parts.
27. Install back-up ring (48) and o-ring seal (47) on each seat (43) as shown.
28. Put clean hydraulic oil on seats (43), pistons (46) and balls (45). Reinstall the components in
the body of the travel motor.
29. Put a thin coat of 9S3265 Retaining Compound on surfaces (Y) of the travel motor body.
Install oil seal (44) in the body with the lip of the seal facing in as shown. Be sure the seal makes
contact with the counterbore in the body after installation.
30. Install snap ring (40) in the groove on shaft (39). Install bearing (42) on shaft (39) with a press.
Install the bearing until it makes contact with the snap ring.
31. Install bearing inner race (41) on the end of shaft (39) until it is seated against the shoulder on
the shaft.
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NOTICE
During installation of shaft (39) in the travel motor body, rotate the
shaft slowly to be sure it does not bind.
32. Put clean hydraulic oil on the lip of oil seal (44). Install shaft (39) in the travel motor body
with a press. Rotate the shaft slowly during installation making sure it does not bind. Be sure the
bearing on the shaft makes contact with the counterbore in the body.
NOTICE
The locating pin on each woodruff key (38) is not centered. To prevent
damage to the barrel plate assembly during assembly of the travel
motor, the woodruff keys must be installed as shown in the illustration.
Also, the woodruff keys must be reinstalled in their original locations
in the travel motor body.
33. Install two woodruff keys (38) in the travel motor body as shown.
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34. Install cam plate (37) in the travel motor body in its original position. Be sure the machined
cutouts in the cam plate engage with the woodruff keys.
35. Install nine springs (36) in the barrel. Install spacer (35) and retainer (34) on the barrel.
36. Install piston shoe assemblies (31) in their original bores in retainer (32).
37. Put clean hydraulic oil in the bores of the barrel and on piston shoe assemblies (31). Install the
piston shoe assemblies with the retainer in their original bores in the barrel.
NOTICE
Prior to installing the piston shoe assembly and barrel plate assembly
as a unit, be sure cam plate (37) is correctly engaged on woodruff keys
(38). When the travel motor body is tilted to allow installation of the
piston shoe assembly and barrel plate assembly, the cam plate can slide
off of the woodruff keys. The remainder of the travel motor can be
assembled with the cam plate out of position, however extensive parts
damage will occur during the remaining assembly procedure. Use the
procedure which follows to prevent parts damage.
38. Put clean hydraulic oil on the sliding surfaces of the cam plate, the piston shoe assemblies and
on the splined shaft of the motor.
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39. Temporarily remove two seats (43), two pistons (46) and two balls (45) from the travel motor
body.
Route a strong piece of string through one of the low speed piston chambers in the bottom of the
body, over the sliding surface of the cam plate, and out the other low speed piston chamber. See
Illustration C33702P1. Hold the string tight to keep the cam plate properly engaged with the
woodruff keys. While keeping the string tight, put the travel motor body on its side. Do not release
the tension on the string at this time. Install the piston shoe assemblies and barrel plate assembly
(31) on the shaft as a unit. Pull the string out of the travel motor body. It may be necessary to pull
the barrel plate assembly and piston shoe assemblies away from the cam plate a small amount to
release the string.
40. Put the travel motor body in a vertical position.
41. Reinstall two balls (45), two pistons (46) and two seats (43) in the travel motor body.
42. Put clean hydraulic oil on three friction plates (29) and three steel plate (28). Install the plates
in alternating order in the travel motor body. Start with a friction plate and end with a steel plate.
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43. Be sure brake piston (23) is thoroughly clean and free of dirt and debris. Check the condition
of back-up rings (24) and (27) and o-ring seals (25) and (26). If the rings or seals are worn or
damaged, use new parts for replacement. Install back-up rings (24) and (27) and o-ring seals (25)
and (26) on brake piston (23) as shown. Put a coat of 1U6396 Assembly Compound on the back-
up rings and the o-ring seals.
44. Put a thin coat of clean hydraulic oil on the surface of the travel motor body which makes
contact with the brake piston. Install brake piston (23) in the travel motor body by hand. It may be
necessary to use a soft faced hammer to seat the piston properly.
45. Install two disc springs (21) in the brake piston as shown.
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46. Check the condition of three o-ring seals (22). If the seals are worn or damaged, use new parts
for replacement. Install three o-ring seals (23) in the body of the travel motor.
47. Check the condition of o-ring seals (19) and rings (20) used on retainers (17). If the seals and
rings are worn or damaged, use new parts for replacement.
48. Install rings (20) and o-ring seals (19) on retainers (17) as shown.
49. Install balls (18) and retainers (17) in cover (2) as shown.
50. Check the condition of the o-ring seal on plug (15). If the seal is worn or damaged, use new
parts for replacement. Install plug (15) in cover (2). Tighten the plug to a torque of 120 N·m (85 lb
ft).
51. Check the condition of the o-ring seal on stopper (11). If the seal is worn or damaged, use new
parts for replacement. Put clean hydraulic oil on spool (13), spring (12) and on the end of stopper
(11). Install the spool, spring and stopper in cover (2) as shown. Tighten the stopper to a torque of
49 N·m (36 lb ft).
52. Install the adapter joints and fittings (14) and (16) in their original locations in cover (2).
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Caterpillar Cat E120B EXCAVATOR (Prefix 6JF) Service Repair Manual (6JF00001 and up).pdf

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