Caterpillar Grader 140m2 Service Training Manual

Full download: http://manualplace.com/download/caterpillar-grader-140m2-service-training-manual/

SERV1839
July 2007

GLOBAL SERVICE LEARNING

TECHNICAL PRESENTATION

140M/160M MOTOR GRADERS

Service Training Meeting Guide

(STMG)
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140M/160M MOTOR GRADERS
AUDIENCE

Level II - Service personnel who understands the principles of machine system operation,
diagnostic equipment, and procedures for testing and adjusting.

CONTENT

This presentation provides information on the system operation of the electrical system,
operator’s station, engine, power train, all-wheel drive, implement, steering, fan, and brake
systems.

OBJECTIVES
After learning the information in this meeting guide, the technician will be able to:
1. Locate and identify the major components in the electrical system, operator’s station,
engine, power train, all-wheel drive, implement, steering, fan, and brake systems;

2. Explain the operation of the major components in the systems; and

3. Trace the flow of oil through the systems

REFERENCES

140M Service Manual RENR9010

160M Service Manual RENR9020
C7 Engines for Caterpillar built machines RENR9319
C9 Engines for Caterpillar built machines RENR9830
140M Specalog AEHQ5731
160M Specalog AEHQ5732

Estimated Time: 36 Hour

Illustrations: 182
Form: SERV1839
Date: 07/07

© 2007 Caterpillar Inc.

SERV1839 -3- Text Reference
07/07

TABLE OF CONTENTS

INTRODUCTION ........................................................................................................................5

OPERATOR'S STATION..............................................................................................................7
Joystick Functions.................................................................................................................11

MESSENGER MAIN MENU ....................................................................................................23

Performance Menu Options ..................................................................................................24
Totals Menu Options.............................................................................................................26
Settings Menu Options .........................................................................................................28
Service Menu Options ..........................................................................................................30

ECM ARCHITECTURE.............................................................................................................37

C7/C9 ACERT™ ENGINE ........................................................................................................39

Engine Electrical Block Diagram .........................................................................................41
Engine ECM .........................................................................................................................44
Fuel System...........................................................................................................................50
Power Derate.........................................................................................................................53
Intake Manifold Air Temperature Sensor Derate .................................................................62
Intake Manifold Air Heater...................................................................................................72

POWER TRAIN .........................................................................................................................77

Transmission/Chassis Electrical System ..............................................................................80
Power Train Hydraulic System Components .......................................................................95
Hydraulic System Operation
Clutch Modulating Valve - No Commanded Signal ...........................................................108
Clutch Modulating Valve - Commanded Signal Below Maximum ...................................109
Clutch Modulating Valve - Commanded Signal At Maximum ..........................................111

ALL WHEEL DRIVE SYSTEM (AWD) .................................................................................115

AWD Electrical System ......................................................................................................118
AWD Derates .....................................................................................................................120
AWD Hydraulic System Components ................................................................................133
Hydraulic System Operation...............................................................................................145
SERV1839 -4- Text Reference
07/07

TABLE OF CONTENTS

IMPLEMENT AND STEERING SYSTEM ............................................................................149

Implement ECMs ................................................................................................................150
Implement Electrical Block Diagram .................................................................................151
Left Joystick Electronic Operation .....................................................................................154
Right Joystick Electronic Operation ...................................................................................156
Hydraulic Tank and Filter ...................................................................................................158
Implement and Steering Pump ...........................................................................................159
Control Manifold ................................................................................................................160
Pilot Oil Filter .....................................................................................................................161
Steering Control Valve ........................................................................................................162
Secondary Steering System ................................................................................................166
Steering Hydraulic System Operation ................................................................................171
Centershift Lock .................................................................................................................179
Implement Control Valves .................................................................................................180
Implement Hydraulic System Operation ............................................................................185

BRAKE AND FAN SYSTEM ..................................................................................................190

Service Brake System .........................................................................................................190
Accumulators ......................................................................................................................192
Service Brake Valve - Not Activated ..................................................................................194
Service Brake Valve - Activated .........................................................................................195
Service Brakes ....................................................................................................................197
Brake and Fan System Hydraulic Operation ......................................................................199
Parking Brake System.........................................................................................................205
Fan System ..........................................................................................................................207
Hydraulic Oil Cooler and Temperature Sensor - Non AWD Systems ...............................208
Hydraulic Oil Cooler and Temperature Sensor - AWD Systems .......................................209

CONCLUSION .........................................................................................................................210

HYDRAULIC SCHEMATIC COLOR CODE.........................................................................211

VISUAL LIST...........................................................................................................................212
SERV1839 -5- Text Reference
07/07

140M/160M MOTOR
NOTES GRADERS

© 2007 Caterpillar Inc.

INTRODUCTION

The 140M/160M Motor Graders have been designed as a direct replacement of the 140H/160H
Motor Graders. The 140M/160M meets U.S. Environmental Protection Agency (EPA) Tier III
and European Union Stage IIIa emissions control standards.

Key new features include:

- Improved operator's station
- C7/C9 ACERT™ Engine
- ECPC controlled power shift countershaft transmission
- Joystick steering
- Electro-hydraulic steering
- Electro-hydraulic implements
- Hydraulic braking system
SERV1839 -6- Text Reference
07/07

TECHNICAL SPECIFICATIONS

140M serial number prefix: B9M

- Base machine weight: 15,130 kg (33,356 lb)
- Maximum machine weight: 23,077 kg (50,875 lb)
- Maximum ground speed forward: 46.6 km/h (29 mph)
- Maximum ground speed reverse: 36.8 km/h (22.9 mph)
- Engine: C7 ACERT™ with VHP (Variable Horse Power)
- Net power with VHP: 136 - 148 kW (183 - 198 hp)
- Net power with VHP Plus: 136 - 163 kW (183 - 218 hp)
- Derating Altitude: 3048 m (10,000 ft.)
- Length: 8.7 m (28 ft., 7 in)
- Width: 2.5 m (8 ft., 2 in)
- Height: 3.3 m (10 ft., 10 in)

160M serial number prefix: B9L

- Base machine weight: 15,903 kg (35,060 lb)
- Maximum machine weight: 23,947 kg (52,795 lb)
- Maximum ground speed forward: 47.4 km/h (29.5 mph)
- Maximum ground speed reverse: 37.4 km/h (23.3 mph)
- Engine: C9 ACERT™ with VHP (Variable Horse Power)
- Net power with VHP: 159 - 170 kW (213 - 228 hp)
- Net power with VHP Plus: 159 - 185 kW (213 - 248 hp)
- Derating Altitude: 3048 m (10,000 ft.)
- Length: 8.7 m (28 ft., 7 in)
- Width: 2.5 m (8 ft., 2 in)
- Height: 3.3 m (10 ft., 10 in)
SERV1839 -7- Text Reference
07/07

OPERATOR'S STATION

The redesigned operator's station provides better visibility to the work area. The "M" series
operator's station also has new features and improvements over the "H" series.
SERV1839 -8- Text Reference
07/07

"M" SERIES MONITORING SYSTEM

Parking Transmission
Brake Secondary
Primary Steering Action System Steering System
System Indicator Lamp Indicator Indicator
(10) Indicator
Implement (6) (7) (11) (12)
System Indicator (5) Operator Present
Starting Aid Indicator
Indicator (4) (14)

Charging System Action Park

Brake Right
Impl Primary Lamp Trans Sec
Indicator (3) Sys Steer Sys Steer Blade Float
Left Blade Float Inlet Air Engine Throt Diff High Brake Indicator
Heater Sys Lock Lock Beam Sys
Indicator (2) Charge
Sys
Operator
Present
(15)

Left Turn Left

Float
Right
Float
Indicator (1)
Coolant
Left
G2
Tach
G3
Right
Right Turn
Temp
Turn Turn Indicator
% mph
n/min km/h
(16)
Hyd Oil Fuel
G1 kPa psi G5
Temp Level
CF kmmiles

(8) (9) (17) (18) (13)

Engine Throttle Differential High Beam Primary
System Lock Lock Indicator Brake System
Indicator Indicator Indicator Indicator

The "M" Series dash cluster contains the following:

- Left turn indicator (1): Illuminates when the left turn signal is operating.
- Left blade float indicator (2): Illuminates when the left blade control valve is in the float
position.
- Charging system indicator (3): Illuminates when there is a problem with the charging
system.
- Starting aid indicator (4): Illuminates when the starting aid is active.
- Implement system indicator (5): Illuminates when the Implement ECM or the optional
AccuGrade™ system has an active diagnostic or event.
- Primary steering system indicator (6): Illuminates when the primary steering system has
an active diagnostic.
- Action lamp (7): Illuminates when the machine has a serious issue that requires the
operator's attention. The action lamp will flash whenever there is a level 2 or level 3 event
in any of the machine systems.
SERV1839 -9- Text Reference
07/07

- Engine system indicator (8): Illuminates when the Engine ECM has an active diagnostic
or event.
- Throttle lock indicator (9): Informs the operator when the throttle lock is engaged.
- Parking brake indicator (10): Illuminates when the parking brake is engaged.
- Transmission system indicator (11): Illuminates when the Transmission/Chassis ECM has
an active diagnostic or event.
- Secondary steering system indicator (12): Illuminates when the secondary steering system
has an active diagnostic or event. This indicator will also illuminate when the secondary
steering system is active.
- Primary brake system indicator (13): Illuminates when the brake system has an active
diagnostic.
- Operator present indicator (14): Illuminates when the operator is not present. The
operator is considered present if any of the following is true:
- The operator is seated and the Operator in Seat switch recognizes operator as
present.
- The Transmission Output Speed (TOS) is not zero.
- The Actual Gear is not Neutral.
- The Inching Pedal is pressed more than 90%.

The operator is considered not present if all of the following are true:
- The Operator in Seat switch does not detect operator presence or the switch is
faulted.
- The TOS is zero.
- The Actual Gear is Neutral.
- The Inching Pedal is not pressed.

- Right blade float indicator (15): Illuminates when the right blade control valve is in the
float position.
- Right turn indicator (16): Illuminates when the right turn signal is operating.
- Differential lock indicator (17): Illuminates when the differential lock is engaged.
- High beam indicator (18): Illuminates when the high beams are on.
SERV1839 - 10 - Text Reference
07/07

5
2

1
7

The front console contains the following:

- Secondary steering test switch (1)
- Hydraulic oil temperature gauge (2)
- Coolant temperature gauge (3)
- Tachometer (4)
- Articulation angle (5)
- Fuel gauge (6)
- Parking brake switch (7)
- Key start switch (8)

When the key start switch (8) is turned to the ON position, the dash cluster will perform a three
second self-test. During this test all alert indicators will illuminate, and the gauges will do a
single sweep.
Sometimes the data needed for an indicator is unknown. This can be due to data link
communication problems or active sensor diagnostics. Effects of unknown data at the dash
cluster are as follows:
- When data needed for an indicator is unknown, the indicator will be illuminated.
- When data needed for a gauge is unknown, the gauge will be driven to its red zone.
- When data needed for the LCD is unknown, the LCD will either be blank or display"---".
- When there is a Messenger to dash cluster communication problem, all indicators will be
off, all gauges will point to the left, and the action lamp will blink amber.
SERV1839 - 11 - Text Reference
07/07

1 2 3 4 13 14 15 16

17 18
5
7
20
6 9 19

8
21

22

10 11 12 23 24

Joystick Functions

The electronic joysticks work in conjunction with the Machine ECMs to give the operator
precise control of the machine. The position sensors and switches in the joysticks provide
an input signal to the ECMs. The ECMs will send a corresponding output signal if certain
conditions are met.

The electronic functionality of the joysticks will be explained later in this presentation.

The left joystick controls are as follows:

- Wheel lean left (1)

- Transmission upshift (2)
- Wheel lean right (3)
- Left blade lower/float (4)
- Steer left (5)
- Transmission downshift (6)
- Steer right (7)
SERV1839 - 12 - Text Reference
07/07

- Left blade raise (8)

- Articulation auto recenter (9)
- Articulate right (10)
- Articulate left (11)
- Transmission direction control (12)

The right joystick controls are as follows:

- Right blade lower/float (13)

- Blade tip forward (14)
- Centershift right (15)
- Blade sideshift right (16)
- Centershift left (17)
- Blade tip back (18)
- Blade sideshift left (19)
- Right blade raise (20)
- Throttle resume/decelerate switch (21)
- Differential lock (22)
- Circle drive clockwise (23)
- Circle drive counterclockwise (24)
SERV1839 - 13 - Text Reference
07/07

1 2
3

5 #6

7#

The left joystick controls are as follows:

- Wheel lean left (1)

- Transmission upshift (2)
- Wheel lean right (3)
- Transmission downshift (4)
- Articulation auto recenter (5)
- Transmission direction control (6)
SERV1839 - 14 - Text Reference
07/07

2 3

4
8#

9#
6

The right joystick controls are as follows:

- Blade tip forward (1)
- Center shift left (2)
- Center shift right (3)
- Blade tip back (4)
- Throttle resume/decelerate switch (5)
- Differential lock (6)
SERV1839 - 15 - Text Reference
07/07

2
3
#
10

5 6

7 8
#
11

The "M" Series cab switches are now located on a panel to the right of the operator’s seat. The
cab switches are as follows:
- Centershift lock switch (1)
- Defroster fan switch (2)
- All Wheel Drive (AWD) controls (3)
- Warning beacon switch (4)
- Headlights and tail lights switch (5)
- Blade cushion switch (6)
- Front and rear work lights switch (7)
- Hydraulic lockout switch (8)
SERV1839 - 16 - Text Reference
07/07

2
1

5
4

1
12

Additional controls shown are:

- Hazard flasher switch (1)

- Autoshift switch (2)
- Cigar lighter (24V) (3)
- Throttle control mode switch (4)
- Throttle set/accelerate Switch (5)
- Power port (12V) (6)
SERV1839 - 17 - Text Reference
07/07

13

Additional controls shown are:

- Messenger display (arrow)

SERV1839 - 18 - Text Reference
07/07

3 4

14

The "M" Series window wiper switches are on the top right of the cab. The switches are as
follows:

- Front window wiper (1)

- Left front window wiper (2)
- Rear window wiper (3)
- Right front window wiper (4)
SERV1839 - 19 - Text Reference
07/07

1 2 3

15

The "M" Series heating and air conditioning controls are now located on the top, right side of
the cab. The controls are as follows:

- Fans speed switch (1)

- Variable temperature control (2)
- Air conditioning ON/OFF switch (3)
Caterpillar Grader 140m2 Service Training Manual
Full download: http://manualplace.com/download/caterpillar-grader-140m2-service-training-manual/
SERV1839 - 20 - Text Reference
07/07

3
2

16

The fuse panel (1) is located on the left side of the cab floor. The circuit breaker (2) is for the
defroster fan motor. The diagnostic port (3) is used Caterpillar Electronic Technician (Cat ET).

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