MOTOR GRADERS

120H (2AN1-UP,3GR1-UP,4MK1-UP,5FM1-UP,6NM1-UP,6YN1-UP,9FN1-
UP,9YR1-UP),
135H (3YK1-UP,7MN1-UP,8WN1-UP,BDJ1-UP),
12H (2GS1-UP,2LR1-UP,2WR1-UP,4ER1-UP,4XM1-UP,5ZM1-UP,8MN1-UP),
140H (2ZK1-UP,3AS1-UP,3FR1-UP,5HM1-UP,8JM1-UP,8KM1-UP,9TN1-UP,9ZN1-
UP),
143H (1AL1-UP),
160H (2HS1-UP,2FM1-UP,3GM1-UP,3HR1-UP,6WM1-UP,9EJ1-UP,9JM1-UP),
163H (5AK1-UPMOTOR GRADERS

Problem:
There have been reports of unexplained No.7 clutch failures. The No.7 clutch is the
low range clutch and is engaged in all lower gears (1F-4F and 1R-3R). The
No.7 clutch is unique because it is the only clutch that uses a balance piston. The
balance piston is used to keep the clutch from self-engaging due to centrifugal
force when the transmission is being used in the higher gears (7th and 8th). Fifteen
springs and lube oil pressure in the balance piston cavity are used to exert a force
on the clutch piston to keep it from moving when the centrifugal force is high. The
lube oil is feed into the balance piston cavity through a supply passage orifice (A)
in the output shaft. Refer to the illustration.

Solution:
There are several things that could cause the No.7 clutch to fail. Listed below are
some on the obvious items that would not only apply to No.7 clutch, but to
all clutches.
1.Low clutch pressure, caused by control valve problem or clutch piston seal
failure.
2.Slow clutch pressure decay when the clutch is disengaged, caused by a
blocked decay orifice in the control valve.
3. Clutch piston cocking in its bore.
The things unique to the No.7 clutch deal with the balance piston and are
sometimes overlooked when investigating the failure. They are the balance piston
seal and the lube oil feed orifice. The balance piston seal can cause leakage of the
lube oil from the cavity. The feed orifice can become plugged or partially blocked by
debris in the oil system. In both cases, the loss of lube oil pressure can allow the
No.7 clutch to partially engage causing clutch slippage.
When investigating a No.7 clutch failure, special attention should be made to the
above two items. The balance piston seal should be inspected for cuts or any
damage that would allow oil leakage. The output shaft lube oil passage must be
inspected for debris. Use an inspection light in order to inspect for debris in the
passage.
NOTE: DO NOT use air pressure down the passage. This can jam the debris
tighter into the orifice and could go undetected.

COPYRIGHT 2001 CATERPILLAR ALL RIGHTS RESERVED

Usage:
143H 1AL 143H 1AL 120H 2AN 160H 2FM 160H 2FM 12H ES 2GS 12H
ES 2GS 160H ES 2HS 160H ES 2HS 12H ES 2LR 12H NA 2WR 12H
NA 2WR 140H NA 2ZK 140H NA 2ZK 140H ES 3AS 140H ES 3AS 160H
NA 3GM 160H NA 3GM 135H NA 3YK 135H
NA 3YK 12H 4ER 12H 4ER 120H NA 4MK 120H NA 4MK 12H NA 4XM 12H
NA 4XM 163H NA 5AK 163H
NA 5AK 120H 5FM 120H 5FM 140H 5HM 140H 5HM 12H 5ZM 120H
ES 6NM 120H ES 6NM 120H 6TM 120H 6TM 160H ES 6WM 120H
NA 6YN 120H NA 6YN 135H 7MM 135H 7MM 140H 8JM 140H 8JM 140H
ES 8KM 12H NA 8MN 12H NA 8MN 135H 8WN 135H 8WN 160H
NA 9EJ 160H NA 9EJ

Illustration 1 g009
Illustration 2 g009

View A-A

(1) Spring

Test length ... 160 mm (6.3 inch)

Test force ... 245 15 N (55 3 lb)
Free length after test ... 140 mm (5.5 inch)
Outside diameter ... 31.5 mm (1.24 inch)

(2) Cable assembly

(3) Shim

Outside diameter ... 45.0 mm (1.78 inch)

Thickness ... 0.51 mm (0.020 inch)
(A) Distance from cab floorplate to the bottom edge of the pedal ... 95 6 mm (3.7
0.2 inch)

(B) Distance from centerline to centerline of the rod ends ... 447 3 mm (17.6 0.1
inch)

Illustration 3 g009

Cable Assembly

(4) Final installation torque ... 38 7 Nm (28 5 lb ft)

(5) Final installation torque ... 8 3 Nm (71 27 lb in)

Usage:
143H 1AL 143H 1AL 120H 2AN 160H 2FM 160H 2FM 12H ES 2GS 12H
ES 2GS 160H ES 2HS 160H ES 2HS 12H ES 2LR 12H ES 2LR 12H
NA 2WR 12H NA 2WR 140H NA 2ZK 140H NA 2ZK 140H ES 3AS 140H
ES 3AS 160H NA 3GM 160H NA 3GM 135H NA 3YK 135H
NA 3YK 12H 4ER 12H 4ER 120H NA 4MK 120H NA 4MK 12H NA 4XM 12H
NA 4XM 163H NA 5AK 163H
NA 5AK 120H 5FM 120H 5FM 140H 5HM 140H 5HM 12H 5ZM 12H 5ZM
120H ES 6NM 120H ES 6NM 120H 6TM 120H 6TM 160H ES 6WM 160H
ES 6WM 120H NA 6YN 135H 7MM 135H 7MM 140H8JM 140H 8JM 140H
ES 8KM 140H ES 8KM 12H NA 8MN 12H NA 8MN 135H 8WN
Adjustment of the clutch pedal may be necessary after replacement of any of the
following items: mechanism for the clutch pedal, clutch control cable and
transmission control valve for the clutch pedal.

Use the following information for the adjustment of the clutch pedal.