Caterpillar Cat 12K Motor Grader (Prefix JJA) Service Repair Manual (JJA00001 and up)

1
Service Repair Manual
Models 12K Motor Grader
2
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Product MOTOR GRADER Model 12K MOTOR GRADER
JJA Configuration 12K Motor Grader JJA00001-UP
(MACHINE) POWERED BY C7 Engine
Disassembly and Assembly 12K, 140K and 160K Motor
Graders Power Train Media Number
-KENR8443-04 Publication Date -01/03/2017
Date Updated -28/03/2017
i01973878
Transmission - Disassemble SMCS - 3002-015
3030-015 3159-015 Disassembly Procedure Table 1
Required Tools Required Tools Required Tools Required Tools
Tool Part Number Part Description Qty
A 138-7575 Link Bracket 1
B 154-6181 Forcing Screw 2
C 6V-5221 Bolt 1
D 4C-8156 Fixture 1
E 6V-3918 Bolt 1
F 4C-8157 Fixture 2
G 1U-6405 Three Jaw Puller 1
H 1U-6341 Threaded Rod 1
J 5P-7970 Nut 1
K 9U-7479 Compressing Tube 1
L 5B-0637 High Idle Nut 1
L 5F-7353 Washer 1
L 1B-4207 Full Nut 2
L 5F-7369 Puller Leg 2
L 3H-0465 Push-Puller Plate 2
3
5F-7366 Screw 1
5P-4808 1U-9895 Cap Crossblock 2 1
M N P Q R 9S-9151 1B-4206 8B-7552 1U-6343 6V-8149 2P-8312 1P-2326 1P-2325 3H-0462 8H-0709 5F-7373 Block Nut Bolt Threaded Rod Nut Pliers Screw Head Bolt and Nut Strap Jaw 2 4 2 1 1 1 1 1 4 4 3
S 3E-3882 Eyebolt 1

• Start By
• Remove the transmission control valve. Refer to
  Disassembly and Assembly, "Transmission Control
  Valve - Remove".
• Remove the parking brake. Refer to Disassembly
  and Assembly, "Parking Brake - Remove".
• Remove the transmission speed sensor.
• Remove the transmission oil pump. Refer to
  Disassembly and Assembly, "Gear Pump
  (Transmission Charging and Scavenge) - Remove".
• Remove the transmission magnetic screen base.
  Refer to Disassembly and Assembly, "Magnetic
  Screen - Remove and Install".

4
Illustration 1
g00623100

1. Place transmission (1) level on the floor.
2. Remove 12 bolts (2), four covers, and the O-ring
   seals from transmission case assembly (3).
3. Remove 41 bolts (4) from the transmission case
   assembly (3).

• Illustration 2 g00623105
• Note Identify the location of seal carrier (5)
  in the transmission case assembly (3) for
  assembly purposes.
• Remove two bolts (6) from seal carrier (5).
• Install Tooling (A) (not shown) in seal carrier
  (5). Remove seal carrier (5) and the three ring
  seals from the transmission case assembly bore
  (7).
• Repeat Step 4 through Step 5 on the three
  remaining seal carriers (5).

5

• Illustration 3 g00623108
• Remove seal rings (9) from seal carrier (5).
• Remove three or four seals (8) from seal carrier
  (5).
• Remove spring pin (10) from seal carrier (5).
• Repeat Step 7 and Step 9 for the remaining three
  seal carriers (5).

• Illustration 4 g00623110
• Install Tooling (B) in the transmission case
  assembly (3). Tighten Tooling (B) evenly to
  separate transmission case assembly (3) from
  transmission cover assembly (11).
• Attach Tooling (A) to transmission case assembly
  (3). Position a lifting device to Tooling
• (A). Secure the lifting device to a hoist. Slowly
  raise the transmission case assembly (3) from the
  transmission cover assembly (11). Be careful not
  to bind the transmission case assembly (3) during
  separation.

6
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• Illustration 5 g00623113
• Remove three bolts (12) from tube assembly (13).
  Remove tube assembly (13) from the transmission
  cover assembly (11).
• Remove the O-ring seal from tube assembly (13).

• Illustration 6 g00849491
• Note First/Third shaft assembly (14) and
  High/Low shaft assembly (15) must be removed
  together.
• Install Tooling (D) on First/Third shaft assembly
  (14) and High/Low shaft assembly (15). Use
  Tooling (C) and Tooling (E) in order to hold
  Tooling (D) on First/Third shaft assembly
• (14) and High/Low shaft assembly (15), as shown.
  First/Third shaft assembly (14) and
• High/Low shaft assembly (15) must be removed
  together.
• Attach a suitable lifting device to Tooling (D).
  Carefully remove First/Third shaft assembly
• (14) and High/Low shaft assembly (15) from the
  transmission cover assembly (11). The weight of
  the two shaft assemblies is 177 kg (390 lb).

8
Illustration 7 g00623117 17. Place First/Third
shaft assembly (14) and High/Low shaft assembly
(15) on Tooling (F) or on blocks and remove
Tooling (D). Carefully separate First/Third shaft
assembly (14) and High/Low shaft assembly (15).
The weight of each shaft assembly is 89 kg (195
lb).
Illustration 8
g00623120
Illustration 9 g00849492 Note Place High/Low
shaft (15) in a modified work bench or on blocks.
Modify a substantial workbench by cutting a 116.0
2.0 mm (4.60 0.08 inch) clearance hole in the
top of the bench.
9
Illustration 10
g00623124
Illustration 11 g00623126 Note Do not attach
Tooling (G) to rotor (17). If pressure is applied
to rotor (17) with Tooling (G), rotor (17) will
brake. Attach the Tooling (G) to gear assembly
(18). 18. With High/Low shaft assembly (15) on
the modified work bench or on blocks, use
Tooling (G) in order to remove race and bearing
(16), rotor (17), gear assembly (18), and two
sleeve bearings (not shown) from High/Low shaft
assembly (15). Press fit Bearing (16) and
rotor (17) on High/Low shaft assembly (15). 19.
Remove bearing (16), rotor (17), thrust disc
(19), and gear assembly (18) from High/Low shaft
assembly (15). Attach Tooling (G) to gear
assembly (18). Do not attach Tooling (G) to rotor
(17).
10
Illustration 12 g00623129 20. Remove thrust disc
(20) and the washer from High/Low shaft assembly
(15).
Illustration 13 g00623131 21. Install Tooling
(H) and Tooling (K) on High/Low shaft assembly
(15) and clutch assembly (21). Tighten Tool (J)
on Tooling (H) (not shown) in order to compress
clutch assembly (21). Remove two half rings (22)
and two lock rings (23) from the High/Low shaft
assembly (15). 22. Carefully loosen Tool (J) on
Tooling (H) in order to relieve pressure from
clutch assembly (21). Remove Tooling (K) and
Tooling (H) from High/Low shaft assembly (15) and
clutch assembly (21). The clutch assembly (21) is
made up of five clutch plates, six friction
discs, and the hub assembly. Identify the
position of the clutch assembly (21) for assembly
purposes.

• Illustration 14 g00623132
• Remove wave spring (25) from High/Low shaft
  assembly (15).
• Remove piston (24) from High/Low shaft assembly
  (15).

11
Illustration 15 g00623134 25. Remove seal
extension ring (27) and seal ring (26) from
piston (22).

• Illustration 16 g00623138
• Position High/Low shaft assembly (15), as shown.
  Place High/Low shaft (15) in the modified work
  bench, or on blocks. The weight of High/Low shaft
  assembly (15) is 50 kg (110 lb).
• Install Tooling (L) and Tooling (M) on High/Low
  shaft assembly (15) and inner bearing
• (28). Remove inner bearing (28) from High/Low
  shaft assembly (15). Remove two thrust discs
  (29), two bearing sleeves, and gear assembly (30)
  from High/Low shaft assembly (15).

Illustration 17
g00623141
12
28. Remove thrust disc (31) and the washer from
High/Low shaft assembly (15).

• Illustration 18 g00623145
• Note Tooling (K) is the old style tool that is
  now modified. Tooling (K) (new style tool) works
  without being modified. Tooling (K) may need to
  be modified so the hole in the top of the tube
  will have clearance for Tooling (N).
• Install Tooling (N) and Tooling (K) on High/Low
  shaft assembly (15) and clutch assembly
• (32). Tighten Tooling (P) on Tooling (N) in order
  to compress clutch assembly (32). Remove two half
  rings (33) and two lock rings (34) from the
  High/Low shaft assembly (15).
• Carefully loosen Tooling (P) on Tooling (N) in
  order to relieve pressure from clutch assembly
  (32). Remove Tooling (K) and Tooling (N) from
  High/Low shaft assembly (15) and clutch assembly
  (32). The clutch assembly (32) is made up of
  eight clutch plates, seven friction discs, and
  the hub assembly. Identify the position of the
  clutch assembly (32) for assembly purposes.

Illustration 19 g00623148 Note Tooling (K) is
the old style tool that must be modified. Tooling
(K) (new style tool) works without being
modified. Tooling (K) may need to be modified so
the hole in the top of the tube will have
clearance for Tooling (N). 31. Install Tooling
(N) and Tooling (K) on High/Low shaft assembly
(15) and balance piston (35). Tighten Tooling (P)
on Tooling (N) in order to compress balance
piston (35).
13

• Use Tooling (Q) in order to remove retaining ring
  (36) from High/Low shaft assembly (15).
• Carefully loosen Tooling (P) on Tooling (N) in
  order to relieve pressure from balance piston
• (35). Remove Tooling (K) and Tooling (N) in order
  to relieve pressure from High/Low shaft assembly
  (15) and balance piston (35).

• Illustration 20 g00623149
• Remove balance piston (35) and seal extension
  ring (37) from High/Low shaft assembly (15).
• Remove 15 springs (38) from piston (39).
• Remove piston (39), the seal extension ring (not
  shown), and a ring seal (not shown) from High/Low
  shaft assembly (15).

Illustration 21 g00623150 37. Remove seal ring
(40) and seal extension ring (41) from piston
(39).
14
Illustration 22 g00623152 38. Place First/Third
shaft assembly (14) on the modified work bench or
on blocks. Use Tooling (F) in order to remove
race and bearing (42), thrust disc (not shown),
and gear assembly (43) from First/Third shaft
assembly (14).
Illustration 23 g00623154 39. Remove thrust disc
(44) and gear assembly (45) from First/Third
shaft assembly (14).
Illustration 24 g00623240 40. Remove sleeve
bearing (not shown), thrust disc (46) and washer
(47) from First/Third shaft assembly (14).
15

• Illustration 25 g00623241
• Install Tooling (H) and Tooling (K) on
  First/Third shaft assembly (14) and clutch
  assembly
• (48). Tighten Tooling (K) on Tooling (H) in order
  to compress clutch assembly (48). Remove two half
  rings (49) and two lock rings (50) from
  First/Third shaft assembly (14).
• Carefully loosen Tooling (J) on Tooling (H) in
  order to relieve pressure from clutch assembly
  (48). Remove Tooling (K) and Tooling (H) from
  First/Third shaft assembly (14) and clutch
  assembly (48). As you remove clutch assembly (48)
  from First/Third shaft assembly (14), identify
  the positions of the five clutch plates, the six
  friction disc, and the hub assembly for assembly
  purposes.

• Illustration 26 g00623242
• Remove wave spring (51) from First/Third shaft
  assembly (14).
• Remove piston (52) from First/Third shaft
  assembly (14).

16
Illustration 27 g00623245 45. Remove seal
extension ring (53) and seal ring (54) from
piston (52).

• Illustration 28 g00623247
• Position First/Third shaft assembly (14), as
  shown. Place First/Third shaft assembly (14) in
  the modified work bench, or on blocks. The weight
  of First/Third shaft assembly (14) is
• 55 kg (120 lb).
• Remove the seal ring (not shown) from First/Third
  shaft assembly (14).
• Use Tooling (R) in order to remove inner bearing
  (55), thrust disc (not shown), gear (56), and
  thrust disc (not shown).
• Remove gear assembly (57), the bearing sleeve
  (not shown), the thrust disc, and the washer (not
  shown) from First/Third shaft assembly (14).

17

• Illustration 29 g00623248
• Install Tooling (K) and Tooling (H) on
  First/Third shaft assembly (14) and clutch
  assembly
• (58). Tighten Tooling (J) on Tooling (H) in order
  to compress clutch assembly (58). Remove two half
  rings (59) and two lock rings (60) from the
  First/Third shaft assembly (14).
• Carefully loosen Tooling (J) on Tooling (H) in
  order to relieve pressure from clutch assembly
  (58). Remove Tooling (H) and Tooling (K) from
  First/Third shaft assembly (14) and clutch
  assembly (58). As you remove clutch assembly (58)
  from First/Third shaft assembly (14), identify
  the position of the three clutch plates, four
  friction disc, and the hub assembly for assembly
  purposes.

• Illustration 30 g00623249
• Remove wave spring (61) from First/Third shaft
  assembly (14).
• Remove piston (62) from First/Third shaft
  assembly (14).

18
Illustration 31 g00623250 54. Remove seal
extension ring (63) and seal ring (64) from
piston (62).
Illustration 32
g00623252
Illustration 33 g00623253 55. Use Tooling (R) in
order to remove inner bearing (66) and gear (67)
from input shaft assembly (65). This is necessary
at this time in order to remove the remaining two
shaft assemblies.
19
Illustration 34 g01024451 56. Install Tooling
(S) and remove Reverse/Second shaft assembly (68)
from the transmission cover assembly (11). The
weight of Reverse/Second shaft assembly (68) is
64 kg (140 lb).

• Illustration 35 g00623257
• Place Reverse/Second shaft assembly (68) on the
  modified work bench, or on blocks.
• Use Tooling (R) in order to remove race and
  bearing (69), spacer (70), and gear (71) from
  Reverse/Second shaft assembly (68).

Illustration 36
g00623258
20

1. Remove spacer (72) and thrust disc (not shown)
   from Reverse/Second shaft assembly (68).
2. Remove gear assembly (73), the sleeve bearing
   (not shown), the thrust disc (not shown), and the
   washer (not shown) from Reverse/Second shaft
   assembly (68).

• Illustration 37 g00623259
• Install Tooling (K) and Tooling (H) on
  Reverse/Second shaft assembly (68) and clutch
  assembly (74). Tighten Tooling (J) on Tooling (H)
  in order to compress clutch assembly
• (74). Remove two half rings (75) and two lock
  rings (76) from Reverse/Second shaft
• assembly (68).
• Carefully loosen Tooling (J) on Tooling (H) in
  order to relieve pressure from clutch assembly
  (74). Remove Tooling (H) and Tooling (K) from
  Reverse/Second shaft assembly
• (68) and clutch assembly (74). As you remove
  clutch assembly (74) from Reverse/Second
• shaft assembly (68), identify the positions of
  the three clutch plates, four friction disc and
  the hub assembly for assembly purposes.

• Illustration 38 g00623260
• Remove wave spring (77) from Reverse/Second shaft
  assembly (68).
• Remove piston (78) from Reverse/Second shaft
  assembly (68).

21
Illustration 39 g00623261 65. Remove seal ring
(80) and seal extension ring (79) from piston
(78).

• Illustration 40 g00623263
• Position Reverse/Second shaft assembly (68), as
  shown. The weight of Reverse/Second shaft
  assembly (68) is 41 kg (90 lb).
• Place Reverse/Second shaft assembly (68) on the
  modified work bench, or on blocks.
• Install Tooling (L) and Tooling (M) on gear
  assembly (82) and Reverse/Second shaft assembly
  (68).
• Remove inner bearing (81), the thrust race (not
  shown), the two thrust discs (not shown), and
  gear assembly (82) from Reverse/Second shaft
  assembly (68).

22

• Illustration 41 g00623264
• Remove roller bearing (83) from Reverse/Second
  shaft assembly (68).
• Remove thrust disc and washer (84) from
  Reverse/Second shaft assembly (68).

• Illustration 42 g00623265
• Use a second person in order to compress clutch
  assembly (85).
• Remove two half rings (86) from Reverse/Second
  shaft assembly (68). Release the pressure from
  clutch assembly (85) slowly, until the spring
  (89) underneath clutch assembly (85) is extended
  and relaxed.

Illustration 43
g00623269
23

1. Remove hub assembly (87) from Reverse/Second
   shaft assembly (68).
2. Remove spring (89) from Reverse/Second shaft
   assembly (68).
3. As you remove clutch plates (88) and friction
   discs (90), identify the locations of clutch
   plates (88) and friction discs (90) for
   installation purposes. Remove six clutch plates
   (88) and seven friction disc (90) from
   Reverse/Second shaft assembly (68).

• Illustration 44 g00623270
• Remove valve assembly (91) from Reverse/Second
  shaft assembly (68).
• Remove piston (92) from Reverse/Second shaft
  assembly (68).

• Illustration 45 g00623276
• Remove seal ring (93) and (94) from piston (92).
• Remove the cup plug (not shown) from
  Reverse/Second shaft assembly (68).

24
Illustration 46 g01024454 81. Install Tooling
(S) in Forward shaft assembly (95). Remove
Forward shaft assembly (95) from the transmission
cover assembly (11). The weight of Forward shaft
assembly (95) is 64 kg (140 lb).

• Illustration 47 g00623279
• Place Forward shaft assembly (95) on the modified
  work bench, or on blocks. Install Tooling (L) and
  Tooling (M) to Forward shaft assembly (95) and
  gear assembly (97).
• Remove race and bearing (96), two thrust disc
  (not shown), and gear assembly (97) from Forward
  shaft assembly (95).

Illustration 48
g00623280
25

1. Remove roller bearing (98) from Forward shaft
   assembly (95).
2. Remove the thrust disc and washer (99) from
   Forward shaft assembly (95).

• Illustration 49 g00623281
• Use a second person in order to compress clutch
  assembly (100).
• Remove two half rings (101) from Forward shaft
  assembly (95). Release the pressure from clutch
  assembly (100) slowly, until the spring (104)
  underneath clutch assembly (100) is extended and
  relaxed.

• Illustration 50 g00623284
• Remove hub assembly (102) from Forward shaft
  assembly (95).
• Remove spring (104) from Forward shaft assembly
  (95).
• Remove six clutch plates (105) and seven friction
  disc (103) from Forward shaft assembly
• (95). Identify the positions of the clutch plates
  (105) and friction discs (103) for assembly
  purposes.

26

• Illustration 51 g00623285
• Remove valve assembly (106) from Forward shaft
  assembly (55).
• Remove piston (107) from Forward shaft assembly
  (95).

Illustration 52 g00623287 93. Remove two seal
rings (108) from piston (107).
Illustration 53
g00623288
27

1. Position Forward shaft assembly (95), as shown.
   The weight of Forward shaft assembly (95) is 43
   kg (95 lb). Place Forward shaft assembly (95) in
   the modified work bench or on blocks.
2. Install Tooling (L) and Tooling (M) to Forward
   shaft assembly (95) and gear assembly (110).
3. Remove inner bearing (109), the thrust race (not
   shown), the two thrust disc (not shown), and gear
   assembly (110) from Forward shaft assembly (95).

• Illustration 54 g00623289
• Remove roller bearing (111) from Forward shaft
  assembly (95).
• Remove the thrust disc and washer (112) from
  Forward shaft assembly (95).

• Illustration 55 g00623291
• Use a second person in order to compress clutch
  assembly (113).
• Remove two half rings (114) from Forward shaft
  assembly (95).
• Release the pressure from clutch assembly (113)
  slowly, until the spring (116) underneath clutch
  assembly (113) is extended and relaxed.

28

• Illustration 56 g00623292
• Remove hub assembly (115) from Forward shaft
  assembly (95).
• Remove spring (116) from Forward shaft assembly
  (95).
• Remove six clutch plates (117) and seven friction
  discs (118) from Forward shaft assembly
• (95). Identify the positions of the clutch plates
  (117) and friction disc (118) for assembly
  purposes.

• Illustration 57 g00623294
• Remove valve assembly (119) from Forward shaft
  assembly (95).
• Remove piston (120) from Forward shaft assembly
  (95).

29

• Illustration 58 g00623297
• Remove two seal rings (121) from piston (120).
• Remove the cup plug (not shown) from Forward
  shaft assembly (95).

Illustration 59 g01024466 109. Install Tooling
(S) in Input shaft assembly (65). Remove Input
shaft assembly (65) from the transmission cover
assembly (11). The weight of Input shaft assembly
(65) is 23 kg (50 lb).

• Illustration 60 g00623299
• Remove two seal rings (122) from Input shaft
  assembly (65).
• Remove inner bearing (123) and gear (124) from
  Input shaft assembly (65).
• Remove the cup plug (not shown) from input shaft
  assembly (65).

30

• Illustration 61 g00623300
• Remove four bolts (125) from gear assembly (126).
  Rotate gear assembly (126) in order to locate the
  two bolts (not shown).
• Remove gear assembly (126) from the transmission
  cover assembly (11).

• Illustration 62 g00623301
• Position gear assembly (126), as shown. Use
  Tooling (Q) to remove snap ring (129) from gear
  assembly (126).
• Position gear assembly (126) to the opposite
  side. In order to drive ball bearing (127) off
  gear assembly (126), push a small driver through
  three small holes (not shown).
• Remove ball bearing (127) from bearing retainer
  (128).
• Note This is a slip fit.

31
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• Illustration 63 g00623302
• Remove five bearing outer races (130) from the
  transmission cover assembly (11).
• Repeat Step 118 for transmission case assembly
  (3).

Copyright 1993 - 2021 Caterpillar Inc. All Rights
Reserved. Private Network For SIS Licensees.
Fri Jan 15 090519 UTC0800 2021
33
Shutdown SIS
Previous Screen
Product MOTOR GRADER Model 12K MOTOR GRADER
JJA Configuration 12K Motor Grader JJA00001-UP
(MACHINE) POWERED BY C7 Engine
Disassembly and Assembly 12K, 140K and 160K Motor
Graders Power Train Media Number
-KENR8443-04 Publication Date -01/03/2017
Date Updated -28/03/2017
i05303122
Transmission - Assemble SMCS - 3002-016
3030-016 3159-016 Assembly Procedure Table 1
Required Tools Required Tools Required Tools Required Tools
Tool Part Number Part Description Qty
A 5P-9736 Link Bracket 1
B 154-6181 Forcing Screw 2
C 6V-5221 Bolt 1
D 4C-8156 Lifting Fixture 1
E 6V-3918 Bolt 1
F 4C-8157 Lifting Fixture 2
G 1U-6405 Three Jaw Puller 1
H 1U-6341 Threaded Rod 1
J 5P-7970 Nut 1
K 9U-7479 Compressing Tube 1
L 5B-0637 High Idle Nut 1
L 5F-7353 Washer 1
L 1B-4207 Full Nut 2
L 5F-7369 Puller Leg 2
L 3H-0465 Push-Puller Plate 2
34
5F-7366 Forcing Screw 1
5P-4808 1U-9895 Cap Crossblock 2 1
M N P Q R 9S-9151 1B-4206 8B-7552 1U-6343 6V-8149 2P-8312 1P-2326 1P-2325 3H-0462 8H-0709 5F-7373 Block Nut Forcing Bolt Threaded Rod Nut Retaining Ring Pliers Forcing Screw Head Bolt Strap Jaw 2 4 2 1 1 1 1 1 4 4 3
S 3E-3882 Eyebolt 1
T 6V-5765 Sealant 1
Note Remove old anaerobic sealant from the
bottom of the blind tapped holes in housing (11)
before assembling.
Illustration 1 g00623302 1. Lower the
temperature of bearing outer races (130) .
Install bearing outer races (130) to the original
locations in both transmission case assembly (3)
(not shown) and the transmission cover assembly
(11) until bearing outer races (130) are seated.
35
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