Caterpillar 120K Series 2 Motor Grader Parts Manual SEBP6015 – PDF Download

Description

Caterpillar 120K Series 2 Motor Grader Parts Manual – SEBP6015

This is the full Caterpillar 120K Series 2 Motor Grader parts manual published under document number SEBP6015. It is the parts identification reference for machines built from serial number SZS1-Up, and it belongs to the general arrangement 368-3025 listed in the machine arrangement section. Every information element in the book is presented with an illustration, a reference number, a part number, a quantity and a part name, so a part can be traced from the drawing on the page straight to the number you order.

Because it is a parts manual rather than a service manual, the content is organised around assemblies and groups instead of repair procedures. Engine arrangement and seat group are typical examples of the information elements used throughout. Elements are sorted alphabetically by part name and then by part number within each major section, which is why a technician who knows the name of the group can usually land on the right page within seconds.

File Details

• Manual type: Parts Manual
• Brand: Caterpillar
• Model: 120K Series 2 Motor Grader
• Document number: SEBP6015
• Serial number range covered: SZS1-Up
• Language: English
• Page count: 689 pages
• File format: PDF
• Publication date shown: 2011

Chapters and Sections Covered

The table of contents splits the book into major systems, and each system breaks down into the individual groups that make up that system on the machine. The main divisions are:

• General Information
• Machine Arrangement – General AR, Option AR-Cab, Option AR-Cold Weather, Option AR-Guard, Option AR-Regional, Option AR-Configuration, Option AR-Ripper, Option AR-Work Tool, Roading AR
• Engine – Engine AR-Complete, Basic Engine, Air Compressor GP, Carrier GP-Seal, Cover GP-Cylinder Block, Cover GP-Valve Mechanism, Damper & Pulley GP, Drive GP-Accessory, Drive GP-Fan, Fastener GP-Cylinder Head, Fastener GP-Engine, Fastener GP-Front Housing, Flywheel GP, Housing GP-Flywheel, Lifting GP-Engine, Mounting GP-Engine, Mounting GP-Engine & XMSN, Pan GP-Oil, Plug GP-Cylinder Block, Plug GP-Engine, Seal GP-Crankshaft
• Lubrication System – Breather GP, Filler GP-Engine Oil, Fumes Disposal GP, Gauge GP-Oil Level (Dipstick), Lines GP-Engine Oil, Lines GP-Engine Oil Drain, Lines GP-Turbocharger Oil, Manifold GP-Engine Oil
• Cooling System – Fan GP-Blower, Lines GP-Water, Pump GP-Water, Radiator & Hyd Oil Cooler GP, Radiator GP, Tank GP-Coolant
• Air Inlet and Exhaust System – Aftercooler GP-Air, Air Cleaner GP, Cover GP-Air Inlet, Elbow GP-Air Inlet, Lines GP-Aftercooler Air, Manifold GP-Exhaust, Muffler GP, Valve GP-Air Control
• Fuel System – Control GP-Governor, Filter GP-Water Sep & Fuel, Lines GP-Fuel, Pump GP-Fuel PRM & Water Sep, Regulator GP-Fuel Pressure, Tank GP-Fuel
• Electrical and Starting System – Alarm GP, Alternator GP-Charging, Application GP-Power Train, Battery & Wiring GP, Control & MTG GP-Engine Elek, Control GP-Power Train, Control GP-Unprogrammed, Converter AR-Electrical, Converter GP-Electrical, Electronics GP-Implement, Electronics GP-Power Train, Grade Control AR, Lamp GPs (Dome, Flood, Head & Signal, Registration Plate, Signal), Lighting AR-Roading, Lighting GPs, Motor GP-Electric, Sensor GPs (Engine, Position, Pressure, Speed, Temperature), Starting Aid GP-Ether, Starting Motor GP-Electric, Switch GPs, Wiring GPs
• Power Train – Axle GP-Front, Base GP-Oil Filter, Case & Parts GP-Planetary, Chain GP-Drive, Clutch GP-Transmission, Control GP-Differential Lock, Control GP-Transmission Hyd, Cooler GP-Transmission Oil, Coupling GP-Torsional, Differential & Bevel Gear GP, Differential GP, Drive GP-Final, Filler GP-Power Train Oil, Filter GP-Oil, Lines GP-Lubrication, Lines GP-Transmission Oil, Mounting GP-Wheel, Pump GP-Gear, Screen GP-Magnetic, Shaft GP-Drive, Shaft GP-Input, Tandem & Cover GP, Transmission AR, Universal Joint GP, Valve GPs, Wheel & Tire AR, Wheel & Tire GP, Wheel AR, Wheel GP
• Frame and Body – Boss GP-Frame, Box GP-Battery, Bumper GP-Rear, Case & Frame GP, Cover GP-Access, Enclosure GP-Engine, Frame GP-Front, Guard GP-Bottom, Guard GP-Drive Shaft, Guard GP-Platform, Hitch GP-Articulating, Link GP-Steering, Plate GP-Push, Reflector GP, Step GP, Support GP-Battery, Support GP-Radiator
• Braking System – Air Dryer GP, Brake GP-Parking, Brake GP-Service, Control GP-Parking Brake, Control GP-Service Brake, Valve GP-Solenoid
• Hydraulic System – Control AR-Hydraulic, Cylinder & Lines GP-Ripper, Cylinder & MTG GPs (Articulation, Blade Lift, Blade Tip, Centershift, Scarifier, Sideshift, Steering, Wheel Lean), Cylinder GPs, Detent GP-Control Valve, Drive GP-Circle, Lines GP-Centershift Lock, Lines GP-Hydraulic, Lines GP-Pump, Lines GP-Ripper, Lines GP-Steering, Lock GP-Centershift, Manifold GP-Valve, Motor GP-Gerotor, Pump & MTG GP-Steering, Pump GP-Piston, Rotating GP-Pump, Shaft GP-Pump Drive, Swashplate GP, Swivel GP, Tank & Filter GP-Hydraulic, Tank & MTG GP-Hydraulic, Valve & Linkage GPs, Valve GPs (Air Control, Bank 3, Bank 4, Bank 5, Combination, Control, Pump Control, Purge, Relief, Selector & Press Cont, Shuttle, Solenoid, Transmission Control)
• Implements – Boss GP-Drawbar, Circle GP, Drawbar GP, Link GP-Lower, Link GP-Upper
• Operator Station – Accessory GP-Cab, Adjuster GP-Seat, Air Conditioner & Heater GP, Air Conditioner AR/GP, Armrest GPs, Cab AR, Cab GP, Compressor GP-Refrigerant, Condenser & MTG GP-Refrigerant, Console GP-Operator, Control GP-Clutch, Control GP-Steering, Door GP-Cab, Duct & Control GP, Duct GP-Cab Air, Fan GP-Circulating, Filter GP-Cab Air, Heater & MTG GP-Cab, Heater AR-Cab, Heater GP-Cab, Horn GP-Electric, Housing GP-Seat Suspension, Installation AR-Radio, Installation GP-Radio, Insulation GP-Weather, Liner GP-Cab, Lines GP-Air Conditioner, Lines GP-Heater, Louver GP-Cab, Mirror GP-Rear View, Module GP-Quad Gauge, Module GP-Speedometer & Tach, Mounting GP-Cab, Mounting GP-ROPS, Pan GP-Backrest, Panel GP-Cab, Panel GP-Instrument, Recliner GP-Seat, ROPS AR, ROPS GP, Screen GP-Sun, Seat Belt GP, Seat GP, Seat GP-Static, Seat GP-Suspension, Support GP-Seat, Suspension GP-Seat, Washer GP-Window, Wiper AR-Window, Wiper GP-Window
• Work Tools – Bit GP-End, Blade & Tip AR-Power, Blade GP, Blade GP-Bulldozer, Bracket GP-Scarifier, Cylinder GP-Hydraulic, Edge GP-Cutting, Lift GP-Blade, Mounting GP-Ripper, Ripper AR, Ripper GP, Scarifier AR, Scarifier GP, Tooth GP-Ripper
• Service Equipment and Supplies – Box GP-Tool, Film GP, Plate & Film GP, Tank GP-Air
• Index and Part Number Index

Read together, these sections give a complete map of how a 120K Series 2 is assembled – from the engine arrangement through the cooling stack, the fuel and air systems, the electrical architecture with its grade control options, the transmission and final drive, the frame and articulating hitch, the braking and hydraulic circuits, right through to the operator station and the ripper, scarifier and bulldozer work tools. Each group is drawn with an exploded or assembled illustration plus a consist list, so an assembly can be pulled apart on paper before a single bolt is turned.

Remanufactured Components and Repair Alternatives

The general information section explains how the book flags components that are available through the Caterpillar Remanufactured Program. Three separate markers are used inside the parts lists – the letter R in the note field, or an R marker at the start or end of the first caption line. Typical components in the programme include alternators, connecting rods, undersize crankshafts, crankshafts upgraded to new, cylinder heads, electronic control modules, electronic sensors, fuel injectors, fuel nozzles, fuel pumps, governors, oil pumps, pistons, short blocks, starters, complete turbochargers, turbocharger cartridges and water pumps. Remanufactured engines are also available for many engine arrangements. Knowing which parts can come back as remanufactured is often the difference between a quick repair and a long wait on a new part.

Supplemental Coolant Additives and Maintenance Parts

A dedicated section covers supplemental coolant additives by cooling system capacity, listing liquid SCA quantities for initial fill and maintenance intervals alongside the spin-on element part numbers for each capacity band from 22-30 litres up to 163-242 litres. There is also a maintenance parts index that gathers the most frequently ordered consumables in one place – fuel filler caps, water separator and fuel filters, hydraulic filter elements and strainers, crankcase breathers, engine oil filler caps and oil filters, serpentine belts, wiper blades, cab air filter elements, fuses, lamps and seat belts – each with quantity, where used and page reference. For anyone maintaining a machine rather than rebuilding it, that single section removes a lot of guesswork.

Index, Part Number Index and Identification Notes

The book carries an alphabetical index of every information element with page numbers, and at the back a numerical part number index listing every part number with its corresponding page. There is also a machine identification section explaining the Product Identification Number format, including the change from 8-character to 17-character PINs that took effect in the first quarter of 2001, and noting that components such as engines, transmissions, axles and work tools continue to use an 8-character serial number. The parts lists carry a note field with legend letters – A for not part of this group, B for use as required, C for change from previous type, D to order by the meter, E to order by the centimetre, F not shown, G to order by the inch, I to refer to the hydraulic information system, M for metric part, R for remanufactured part may be available, Y for separate illustration and Z for not serviced separately. Reading those letters correctly is what stops you ordering the wrong variant.

Serial Numbers and Arrangement Numbers

Coverage is tied to serial numbers rather than model years, which is the normal Caterpillar convention. The general arrangement 368-3025 applies from serial number SZS1-Up. The engine arrangement 364-7493 applies from engine serial number KHX29829-Up, and it is listed as front exhaust turbocharger with rear sump. The transmission arrangement 275-6535 applies from transmission serial number DMJ1-Up. The planetary case and parts group, the transmission clutches, the gear pump, the magnetic screen, the input shaft and the hydraulic transmission control all fall under that DMJ1-Up transmission serial. Front axle group 134-1080 is listed under SZS1-Up. Because the parts lists in each caption repeat the PIN and serial information, the right page can be confirmed against the actual machine before an order is placed.

Options and Attachments Covered

The machine arrangement section documents the option arrangements that were available on this model, including the cab option without air conditioning, the cab option with air conditioning, the cold weather starting option, the guard option, the regional option, the configuration option, the ripper option and the work tool option, plus roading arrangements with cab, with canopy, and without cab or canopy. Several of these notes carry explicit combination restrictions – for example the roading arrangement with canopy cannot be used with certain cab and ROPS part numbers, and the roading arrangement without cab or canopy cannot be used with a defined list of other arrangements. Grade control arrangements are also documented, covering AccuGrade boss groups on the frame and drawbar, mounting groups on the circle, the indicator lamp wiring in the cab and the chassis harnesses that run the length of the machine.

What This Parts Manual Lets You Do

With the Caterpillar 120K Series 2 Motor Grader Parts Manual SEBP6015 in front of you, the parts side of any job becomes a lookup rather than an investigation. You can identify a group by name and find its illustration, trace a reference number from the drawing to the part number and quantity in the consist list, confirm that a part is correct for an SZS1-Up machine, check whether a remanufactured option exists, and follow indented part names to see what is included inside a larger assembly. Because the manual also lists field replacement options and marks parts that are not serviced separately, it shows where an assembly has to be replaced as a unit rather than repaired piece by piece – which is exactly the kind of thing that otherwise gets discovered after the parts arrive.

For a working motor grader, that matters. Ordering the wrong variant of a hydraulic valve, a transmission clutch plate or a sensor costs days of downtime, and on a machine with this many optional arrangements the risk is real. Having the exploded views and consist lists on hand means the part number is verified against the drawing before the order goes out, and the maintenance parts index keeps the everyday consumables in one short list rather than scattered across a dozen sections.

IMAGES PREVIEW

The manual is delivered as an instant PDF download – no shipping, no waiting on a courier, no physical binder to lose. It opens on a laptop, tablet or phone in the workshop or the field, and any page or section can be printed for the job at hand.