Service Manual

C at e r p i l l a r
Service Manual
12 Grader
S/n 9K1 to 9K9999
& 7T1 to 7T3099

THIS IS A MANUAL PRODUCED BY JENSALES INC. WITHOUT THE AUTHORIZATION OF

CATERPILLAR OR IT’S SUCCESSORS. CATERPILLAR AND IT’S SUCCESSORS
ARE NOT RESPONSIBLE FOR THE QUALITY OR ACCURACY OF THIS MANUAL.

TRADE MARKS AND TRADE NAMES CONTAINED AND USED HEREIN ARE THOSE OF OTHERS,
AND ARE USED HERE IN A DESCRIPTIVE SENSE TO REFER TO THE PRODUCTS OF OTHERS.

CT-S-GRDR#129K
 REF ERE NeE BOO K
FOR

CATERPILLAR
DIESEL NO.12
tI.
i
I
1
,
MOTOR GRADER

*
~. ".:

.1 .

CATERPILLAR TRACTOR CO.

PEORIA, ILLINOIS • u. s. A.
 TABLE OF CONTENTS

INDEX. 2

SPECIFICATIONS 8

GENERAL INSTRUCTIONS 10

ENGINE 17
Cooling System - Fuel System - Governor - Lubri-
cating System - Manifold Group - Cylinder Head and
Valve Mechanism - Timing Gear Assembly - Cam-
shaft - Hour Meter - Connecting Rod - Pistons,
Rings, and Cylinder Liners - Removing Diesel Engine
- Main Bearings - Flywheel - Crankshaft

STARTING ENGINE 85
Crankshaft and Bearings - Timing Gears - Connect-
ing Rod - Piston and Rings - Valves and Valve Mech-
anism - Water Pump - Carburetor - Governor -
Magneto - Starter Mechanism

POWER TRANSMISSION UNITS 113

Flywheel Clutch - Transmission Bevel Gear and
Pinion - Final Drive - Tandem Drive Housing As-
sembly - Brake Reconditioning

POWER CONTROLS 149

Clutch Control - Power Control Column - Blade Lift
Control- Leaning Wheel Control - Circle Centershift
Control - Circle Reverse Control - Universal Joints
and Control Shafts - Ball and Socket Joints

STEERING 165
Steering Gear Control - Front Axle and Wheels

ATTACHMENTS 173
Cab - Lighting System - Scarifier Controls - Scarifier
Teeth - Power Tire Pump - Odometer

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 INDEX
ENGINE
Accessory Gear and Shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 64
Bearings, Main ......................................................... 78
Bushings, Piston Pin.................................................... 69
Bushings, Valve Stem....... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 55
Camshaft ............................................................... 65
Connecting Rod ........................................................ 68
Cooling System ......................................................... 18
Crankshaft ............................................................. 83
Cylinder Head and Valve Mechanism. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 52
Cylinder Liners ........................................................ 73
Diesel Engine, Removing ............................................... 77
Fan and Water Pump ................................................... 22
Flywheel ............................................................... 81
Fuel Injection Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 29
Fuel Injection Pumps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 30
Fuel Injection Pump Lifter Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 32
Fuel Injection Valve Cleaning ........................................... 30
Fuel System ..................•......................................... 26
Governor .................•..... "........................................ 37
Governor Adjustment ...... ~ , ..."; . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 38
Governor Removal ..................................................... 41
Hour Meter" ............................................................ 66
Lifter Springs, Fuel Injection Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 34
Liners, Cylinder ........................................................ 73
Lubricating System ..................................................... 46
Manifold Group ........................................................ 51
Oil Cooler ................................•............................ 49
Oil Filters ............................................................. 49
Oil Pressure Gauge ..................................................... 47
Oil Pressure Relief Valve .....•............•............................. 49
Piston Pin Bushing... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 69
Pistons, Rings and Cylinder Liners. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 70
Precombustion Chambers ............................................... 59
Pump, Fuel Injection .................................................... '30
Pump, Fuel Transfer .................................................... 27
Pump, Oil .•............•............................................... 47
Pump, Water ........................................................... 22
Radiator .....•......................................................... 21
Regulator, Water Temperature ........................................... 20
Rings, Piston ...............................................•........... 72
Running.In Schedule .................................................... 73
Timing Gear Assembly •................................................. 62
Valve Clearance Adjustment .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 59
Valve Inspection and Reconditioning ...................................... 55
Valve Lifter Assemblies •.......•........................................ 61
Valve Timing .......................................................... 60
Valves and Valve Mechanism. . . • . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . .. 54
Water Directors ........................................................ 58
Water Temperature Regulator ........................................... 20
Water Pump ............• . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 22

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 STARTING ENGINE
Bearings, Connecting Rod ............................................... 90
Bearings, Main ......................................................... 88
Bushing, Piston Pin .. "................................................... 90
Carburetor ............................................................. 95
Clutch Mechanism ..................................................... 108
Crankshaft ............................................................. 86
Governor .............................................................. 98
Magneto ............................................................... 100
Magneto, Timing to Engine ............................................... 106
Piston Pin Bushing ..................................................... 90
Piston and Rings.... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 91
Pump, Water ........................................................... 94
Removing and Replacing Starting Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 85
Starter Mechanism ...................................................... 106
Starting Engine, Removal and Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 85
Timing Gears ................ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 89
Valve Clearance Adjustment............................................. 94
Valves and Valve Mechanism ........................................... " 93
Water Pump ............................................................ 94
POWER TRANSMISSION
Axle Shaft ............................................................. 136
Bearing, Flywheel Clutch Release ........................................ 117
Bevel Gear and Pinion .................................................. 126
Bevel Gear .......... , ............ " ..................... , .............. 127
Bevel Pinion ........................................................... 127
Bevel Gear and Pinion Adjustment ....................................... 128
Brake Adjustment ...................................................... 143
Brake Cylinder, Wheel .................................................. 145
Brake Cylinder Removal, WheeL ........................................ 144
Brake, Flywheel Clutch ........... " ., ................................... 118
Brake, Hydraulic Master Cylinder ........................................ 146
Brake Reconditioning .................................................. 141
Brake, Transmission .............. _..................................... 121
Braking System, Bleeding ................................................ 144
Chain Installation ....................................................... 138
Chain Removal ......................................................... 134
.~. - .' Clutch, Flywheel ....................................................... 113
Final Drive ............................................................. 131
Final Drive Pinion Removal. ............................................ 133
Flywheel Clutch ........•............................................... 113
Flywheel Clutch Brake .................................................. 118
Flywheel Clutch Release Bearing ........................................ 117
Hydraulic Brake Master Cylinder ........................................ 146
Pinion, Bevel .......................................................... 127
Pinion Adjustment ..................................................... 129
Spindles, Wheel ........................................................ 139
Sprocket, Removal ...................................................... 135
Tandem Drive Housing Assembly ......................................... 134
Transmission ........................................................... 119
Transmission Brake .................................................... 121
Wheel Brake Cylinder .................................................. 145
Wheel Brake Cylinder Removal .......................................... 144
Wheel Spindles ......................................................... 139

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POWER CONTROLS
Ball and Socket Joints ................................................... 168
Blade Lift Control. ...................................................... 156
Circle Centershift Control. ............................................... 161
Circle Drawbar ......................................................... 163
Circle Removal ......................................................... 166
Circle Reverse Control ..................... , ........ , .... " ...... , ....... 163
Clutch Control .......................................................... 153
Drawbar, Circle ......................................................... 163
Leaning Wheel Control .................................................. 158
Power Control Column................................................... 155
Universal Joints and Control Shafts ....................................... 168

STEERING
Axle, Front ............................................................. 171
Drag Link .............................................................. 1 73
Front Axle and Wheels ........................•.... '.' .................... 171
Front Axle Removal ....... , ..... , .......................... , ..... , ...... 176
Lean Control Tie Bar .................................................... 173
Leaning Wheel Arm ..................................................... 175
Radius Rod ............................................................ 176
Steering Gear Control. ................................................... 169
Tie Bar, Lean Control ................................................... 173
Tie Rod ...................................................... , ......... 174
Tires ................................................................... 172
Toe·In Adjustment ...................................................... 174
Wheels, Front ........................................................... 171

ATTACHMENTS
Baltery ................................................................. 189
Cab .................................................................... 177
Generator, Lighting System with Battery .................................. 190
Generator, Lighting System without Battery ............................... 180
Glass Installation ....................................................... 177
Lighting System with Battery ............................................. 188
Lighting System without Battery .......................................... 179
Odometer .............................................................. 206
Regulator, Lighting System with Battery .................................. 195
Regulator, Lighting System without Battery ............................... 185
Lights .................................................................. 189
Scarifier Controls ....................................................... 199
Scarifier Teeth .......................................................... 200
Tire Pump ............................................................. 200

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hearing (1). From the upper hearing, the oil passes through the drilled
governor shaft (12) to the thrust hearing (2) and governor weights (3).
Oil flowing down the outside of the governor shaft luhricates the lower
hearing (5).

ADJUSTMENTS
Engine R.P.M. can be checked at the tachometer drive connection on
the hour meter after removing the cover. This shaft turns at one half
engine speed.
The low idle and full load engine speeds can he adjusted hy removing
the cover (4) from the top of the governor and turning the adjusting
sockets (1 and 3). The socket (1), nearest the engine adjusts the low
idle speed and the socket (3) adjusts the full load speed. The adjust-
ment can be made by using a screwdriver or the socket may be removed

GOVERNOR ADJUSTMENT

as shewn and a %" socket wrench used in place of the socket. The dowels
(2) in the cover fit into the slots in the so~kets to prevent them from
turning after the adjustment is made.

LOW IDLE SPEED ADJUSTMENT

Remove the cover and turn the socket (1) clockwise to decrease the low
idle speed or counter clockwise to increase the speed. Push the throttle
control lever forward and check the speed at the tachometer drive con-
nection on the hour meter. Adjust the low idle engine speed to 550
R.P.M., or 225 R.P.M. at the tachometer drive connection.

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 RE~IOVING DIESEL ENGINE
Remove the following: >

1. Hood
2. Engine side plates and dash
3. Fuel line connection to transfer pump
4. Throttle control rod
5. Oil line connection to oil pressure gauge
6. Temperature indicator line from temperature regulator housing.
Remove line clips from cylinder block
7. Generator connections

8. Capscrews from the flywheel bell housing

9. Capscrews which hold the oil pan of the Diesel engine to the
top of the rear axle housing
If the Engine Carriage Arrangement IF7027 is used, roll the engine back
until the flywheel is clear of the power control shaft (See the topic
FLYWHEEL CLUTCH) and then remove the engine from the motor
grader frame with a 2-ton hoist.
Care should be taken to see that the lifting chains or cables are located
so that any point of bearing will be against a solid portion of the engine.
If the hoist alone is used, first raise the engine slightly and lower it again
to loosen the engine from the bevel gear and pinion housing. Remove

·-77 -
 WORM REMOVAL
Block under the housing and press the worm (19) out. The race (17)
and hearing (18) will come out with the worm. The other hearing (20)
can then he removed. The seal (21) should he replaced if it leaks.

STEERING WORM ASSEMBLY

FRONT AXLE AND WHEELS

THE front axle and wheels support the front end of the motor grader
and are used to guide the machine. Some motor graders have leaning
front wheels to improve the performance when operating under varying
conditions.

FRONT WHEELS
Each of the front wheels are supported on two tapered roller hearings.
To remove the front wheels, first jack up the front axle. Remove the
capscrews and take off the cover (4). Remove the cotter pin (3) in the
straight end of the hent lock pin (2) and then the lock pin. After re-
moving·,the nut (I), the wheel will come off.
The outer hearing will come off with the wheel. The inner hearing (6)

REMOVING WHEEL REMOVING BEARING

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