Caterpillar 12H 140H 160H Motor Grader Service Repair Manual PDF Download - MCAT12H160HOPES.zip
A full-service repair guide featuring complete electrical wiring schematics for the Caterpillar 12H, 140H, and 160H Motor Graders. This is the identical manual dealerships rely on, guaranteed to be complete, fully working, and free of any omitted pages.
The Caterpillar Motor Graders 12H, 140H & 160H workshop service and repair manual covers:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
MOTOR GRADER
Model Prefix
12H MOTOR GRADER 125
12H MOTOR GRADER 4ER
12H MOTOR GRADER 5ZM
12H MOTOR GRADER AMZ
12H MOTOR GRADER CBK
12H MOTOR GRADER XZJ
12H ES MOTOR GRADER 2GS
12H ES MOTOR GRADER 2LR
12H NA MOTOR GRADER 2WR
12H NA MOTOR GRADER 4XM
12H NA MOTOR GRADER 8MN
MOTOR GRADER
Model Prefix
140H MOTOR GRADER 126
140H MOTOR GRADER 5HM
140H MOTOR GRADER 8JM
140H MOTOR GRADER APM
140H MOTOR GRADER CCA
140H MOTOR GRADER XZH
140H ES MOTOR GRADER 3AS
140H ES MOTOR GRADER 8KM
140H NA MOTOR GRADER 2ZK
140H NA MOTOR GRADER 3FR
140H NA MOTOR GRADER 9TN
140H NA MOTOR GRADER 9ZN
MOTOR GRADER
Model Prefix
160H MOTOR GRADER 2FM
160H MOTOR GRADER 9JM
160H MOTOR GRADER ASD
160H MOTOR GRADER CCP
160H MOTOR GRADER XZK
160H ES MOTOR GRADER 2HS
160H ES MOTOR GRADER 6WM
160H NA MOTOR GRADER 3GM
160H NA MOTOR GRADER 3HR
160H NA MOTOR GRADER 9EJ
MANUAL LIST
RENR1417 - Systems Operation (120H, 12H, 135H, 140H, 143H, 160H & 163H Motor Graders Air System & Brakes)
RENR1417 - Testing & Adjusting (120H, 12H, 135H, 140H, 143H, 160H & 163H Motor Graders Air System & Brakes)
RENR1418 - Specifications (12H, 140H & 160H Motor Graders Air System & Brakes)
RENR1430 - Schematic (12H, 140H & 160H Motor Grader Hydraulic System)
RENR1436 - Schematic (12H, 140H & 160H Motor Graders (Standard Version) Electrical System)
RENR9540 - Schematic (12H, 140H &160H Motor Grader Electrical System (for SN 4ER1136-UP, 5HM3000-UP, 2FM909-UP) All Other SN 1_UP)
SENR6998 - Specifications (12H, 140H, 143H, 160H & 163H Motor Graders Power Train)
SENR8503 - Systems Operation (120H, 12H, 135H, 140H, 143H, 160H & 163H Motor Graders Power Train)
SENR8503 - Testing & Adjusting (120H, 12H, 135H, 140H, 143H, 160H & 163H Motor Graders Power Train)
SENR8503 - Troubleshooting (120H, 12H, 135H, 140H, 143H, 160H & 163H Motor Graders Power Train)
SENR8539 - Disassembly & Assembly (12H, 140H & 160H Motor Graders Engine Supplement)
SENR8548 - Disassembly & Assembly (12H, 140H & 160H Motor Graders Power Train)
SENR8549 - Disassembly & Assembly (12H, 140H & 160H Motor Graders Machine Systems)
SENR8571 - Schematic (12H, 140H &160H Motor Grader Standard Version Hydraulic System (for SNs 2FM1-399, 5HM1-1149, 8JM1-279, 9JM1-349, 4ER1-499) All Other SN 1-UP)
SENR8623 - Specifications (12H, 140H & 160H Motor Graders Hydraulic & Steering System)
SENR8669 - Specifications (12H, 140H & 160H Standard Version Motor Graders Air System...)
SENR9149 - Schematic (12H, 140H &160H Motor Grader Standard Version Electrical System (for SN 4ER500-1135, 8JM280-UP, 5HM1150-2999, 9JM350-UP, 2FM400-908)
SENR9156 - Specifications (12H, 140H, 143H, 160H & 163H Motor Graders Power Train)
SENR9159 - Systems Operation (120H, 12H, 135H, 140H, 143H, 160H & 163H Motor Graders)
SENR9159 - Testing & Adjusting (120H, 12H, 135H, 140H, 143H, 160H & 163H Motor Graders)
SENR9178 - Specifications (12H, 140H, 143H, 160H & 163H Motor Graders Hydraulic and Steering System)
SENR9186 - Systems Operation (120H, 12H, 135H, 140H, 143H, 160H & 163H Motor Graders Hydraulic & Steering System)
SENR9186 - Testing & Adjusting (120H, 12H, 135H, 140H, 143H, 160H & 163H Motor Graders Hydraulic & Steering System)
SENR9186 - Troubleshooting (120H, 12H, 135H, 140H, 143H, 160H & 163H Motor Graders Hydraulic & Steering System)
RENR9540 - Schematic (12H, 140H & 160H Motor Grader Electrical System)
RENR9571 - Schematic (12H, 140H & 160H Motor Graders Standard Versions Hydraulic System)
SENR8518 - Systems Operation (120H,135H,12H,140H,160H,143H,163H MG HYD System & Steering)
SENR8518 - Testing & Adjusting (120H,135H,12H,140H,160H,143H,163H MG HYD System & Steering)
SENR8670 - Systems Operation (120H, 135H, 12H, 140H & 160H Standard Version Motor Graders)
SENR8670 - Testing & Adjusting (120H, 135H, 12H, 140H & 160H Standard Version Motor Graders)
PRODUCT DETAILS:
Total Pages: 2,263 pages
File Format: PDF (bookmarked, Searchable, Printable, high quality)
Language: English
RENR1417 - Systems Operation (120H, 12H, 135H, 140H, 143H, 160H & 163H Motor Graders Air System & Brakes)......4
Air Compressor......5
Air Control Valve (Parking Brake)......7
Air Control Valve (Service Brake)......9
Air Dryer......12
General Information......14
Monitoring System......17
Parking Brake......21
Relief Valve (Air Tank)......25
Service Brakes......27
RENR1417 - Testing & Adjusting (120H, 12H, 135H, 140H, 143H, 160H & 163H Motor Graders Air System & Brakes)......32
Air Compressor Governor - Test and Adjust......33
Air Pressure Gauge - Test......36
Bearing Preload for Service Brake - Adjust......39
Brake Disc Wear - Check......42
General Troubleshooting Information......46
Machine Preparation for Troubleshooting......47
Operation Checks......51
Parking Brake - Test......54
Parking Brake Control - Adjust......55
Pressure Switch (Brake Air) (Stop Lamp) - Test......56
Pressure Switch (Low Brake Air) - Test......59
Service Brake - Test......62
Service Brake Control (Pedal) - Adjust......64
Service Brake Control Valve - Check......68
Visual Inspection......71
RENR1418 - Specifications (12H, 140H & 160H Motor Graders Air System & Brakes)......72
Air Compressor Governor......73
Air Compressor......74
Air Control Valve (Parking Brake)......76
Air Horn - If Equipped......77
Air Tank......79
Centershift Lock Pin......80
Check Valve (Air Tank)......81
Check Valve (Parking Brake Release)......82
Front Wiring......83
Parking Brake......89
Pressure Switch (Brake Air) (Parking Brake)......91
Pressure Switch (Brake Air) (Stop Lamp)......92
Pressure Switch (Low Brake Air)......93
Relief Valve (Air Tank)......94
Service Brake Control......95
Service Brakes......98
Solenoid Valve (Air Horn)......101
Solenoid Valve (Centershift Lock)......105
Solenoid Valve (Parking Brake)......107
RENR1430 - Schematic (12H, 140H & 160H Motor Grader Hydraulic System)......110
Collage......111
Main......126
RENR1436 - Schematic (12H, 140H & 160H Motor Graders (Standard Version) Electrical System)......135
Collage......136
Main......164
RENR9540 - Schematic (12H, 140H & 160H Motor Grader Electrical System)......173
RENR9540 - Schematic (12H, 140H &160H Motor Grader Electrical System (for SN 4ER1136-UP, 5HM3000-UP, 2FM909-UP) All Other SN 1_UP)......175
Collage......176
Main......184
RENR9571 - Schematic (12H, 140H & 160H Motor Graders Standard Versions Hydraulic System)......193
SENR6998 - Specifications (12H, 140H, 143H, 160H & 163H Motor Graders Power Train)......195
Bevel Gear and Pinion......196
Case and Frame......199
Clutch Control (Modulation)......201
Differential and Bevel Gear......204
Drive Shaft SMCS - 3253......207
Final Drive......209
Gear Pump (Transmission Charging and Scavenge)......212
Magnetic Screen (Transmission)......215
Oil Filter (Power Train)......217
Pressure Switch (Transmission Modulation)......220
Selector and Pressure Control Valve......222
Solenoid Valve (Differential Lock)......237
Solenoid Valve (Transmission Clutch)......241
Tandem and Cover......243
Transmission Control Valve......245
Transmission......251
Wheel Group......274
SENR8503 - Systems Operation (120H, 12H, 135H, 140H, 143H, 160H & 163H Motor Graders Power Train)......277
Centershift Lock......278
Differential and Bevel Gear......282
Features......287
Final Drive and Tandem Drive......290
Introduction......293
Power Train Hydraulic System......295
Transmission Control Valve......300
Transmission......311
SENR8503 - Testing & Adjusting (120H, 12H, 135H, 140H, 143H, 160H & 163H Motor Graders Power Train)......320
Clutch Control - Test......321
Clutch Pedal - Adjust......326
Differential Lock Pressure - Check......330
Differential and Bevel Gear - Test......332
Drive Chain - Check......340
Electrical Connector - Inspect......343
Electronic Control Module (ECM) - Flash Program......349
Electronic Control Module (ECM) - Replace......350
Final Drive Bearings - Adjust......352
Glossary of Electrical Terms......355
Initial Pressures - Test and Adjust......361
Pump Efficiency (Gear Pumps) - Test......368
System Schematic......370
Transmission Charging Pump Pressure - Test and Adjust......372
Transmission Clutch Running Clearance - Check......374
Transmission Control (Shift Lever) - Test......379
Transmission Lubrication Oil Pressure - Test......384
Transmission Pressures - Test......388
Wiring Harness (Open Circuit) - Test......394
Wiring Harness (Short Circuit) - Test......395
SENR8503 - Troubleshooting (120H, 12H, 135H, 140H, 143H, 160H & 163H Motor Graders Power Train)......396
Connector Locations......397
Diagnostic Capabilities......400
General Information......405
Machine Preparation for Troubleshooting......406
Operational Checks......407
Power Train......408
Service Tools......416
Visual Inspection......418
SENR8518 - Systems Operation (120H,135H,12H,140H,160H,143H,163H MG HYD System & Steering)......419
SENR8518 - Testing & Adjusting (120H,135H,12H,140H,160H,143H,163H MG HYD System & Steering)......443
SENR8539 - Disassembly & Assembly (12H, 140H & 160H Motor Graders Engine Supplement)......473
Air Cleaner - Remove and Install......474
Air Compressor - Remove and Install......484
Alternator - Remove and Install......493
Battery - Remove and Install......503
Electric Starting Motor - Remove and Install......514
Engine - Install......518
Engine - Remove......526
Engine Enclosure (Hood) - Install......535
Engine Enclosure (Hood) - Remove......538
Engine Oil Cooler - Remove and Install......542
Engine Oil Filler - Remove and Install......545
Engine Oil Filter and Base - Remove and Install......547
Exhaust Extension - Remove and Install......556
Fan - Remove and Install......558
Fan Drive - Remove and Install......567
Fuel Filter (Primary) and Fuel Filter Base - Install......569
Fuel Filter (Primary) and Fuel Filter Base - Remove......575
Fuel Filter (Secondary) and Fuel Filter Base - Remove and Install......580
Fuel Priming Pump - Remove and Install......584
Muffler - Remove and Install......586
Precleaner - Remove and Install......592
Radiator - Install......594
Radiator - Remove......598
Radiator Core - Remove and Install......603
Refrigerant Compressor - Remove and Install......608
Refrigerant Condenser - Remove and Install......613
Turbocharger - Remove and Install......616
SENR8548 - Disassembly & Assembly (12H, 140H & 160H Motor Graders Power Train)......624
12H Motor Grader 4ER00001-UP (MACHINE) POWERED BY 3306 Engine(SEBP2540 - 97) - Documentation......626
Differential Lock Valve - Remove and Install......654
Differential and Bevel Gear (One Piece Cap) - Assemble......658
Differential and Bevel Gear (One Piece Cap) - Disassemble......682
Differential and Bevel Gear (One Piece Cap) - Install......698
Differential and Bevel Gear (One Piece Cap) - Remove......702
Differential and Bevel Gear (Two Piece Cap) - Assemble......707
Differential and Bevel Gear (Two Piece Cap) - Disassemble......731
Differential and Bevel Gear (Two Piece Cap) - Install......746
Differential and Bevel Gear (Two Piece Cap) - Remove......751
Drive Chain - Install......756
Drive Chain - Remove......760
Drive Shaft - Remove and Install......764
Drive Sprocket - Remove and Install......768
Final Drive - Assemble......773
Final Drive - Disassemble......783
Final Drive - Install......790
Final Drive - Remove......792
Gear Pump (Transmission Charging and Scavenge) - Assemble......795
Gear Pump (Transmission Charging and Scavenge) - Disassemble......800
Gear Pump (Transmission Charging and Scavenge) - Install......804
Gear Pump (Transmission Charging and Scavenge) - Remove......806
Machine Preparation for Disassembly and Assembly......809
Magnetic Screen - Remove and Install......812
Tandem and Cover - Remove and Install......815
Transmission - Assemble......820
Transmission - Disassemble......854
Transmission - Install......882
Transmission - Remove......889
Transmission Control Valve - Assemble......897
Transmission Control Valve - Disassemble......917
Transmission Control Valve - Install......937
Transmission Control Valve - Remove......941
Transmission Oil Cooler - Install......945
Transmission Oil Cooler - Remove......951
Transmission Oil Filter Base - Remove and Install......957
Wheel (Rear) - Remove and Install......965
SENR8549 - Disassembly & Assembly (12H, 140H & 160H Motor Graders Machine Systems)......968
Accumulator (Blade Cushion) - Remove and Install......972
Air Control Valve (Parking Brake) - Assemble......976
Air Control Valve (Parking Brake) - Disassemble......979
Air Control Valve (Parking Brake) - Install......982
Air Control Valve (Parking Brake) - Remove......986
Air Control Valve (Service Brake) - Assemble......990
Air Control Valve (Service Brake) - Disassemble......995
Air Control Valve (Service Brake) - Install......1000
Air Control Valve (Service Brake) - Remove......1003
Air Dryer - Remove and Install......1006
Air Tank - Remove and Install......1010
Articulation Cylinder - Install......1015
Articulation Cylinder - Remove......1018
Bank Valve - Assemble......1022
Bank Valve - Disassemble......1033
Bank Valve - Install......1044
Bank Valve - Remove......1048
Blade - Install......1052
Blade - Remove......1057
Blade Lift - Install......1061
Blade Lift - Remove......1070
Blade Lift Cylinder - Install......1077
Blade Lift Cylinder - Remove......1079
Blade Tip Cylinder - Remove and Install......1082
Brake and Wheel Spindle Housing - Assemble......1088
Brake and Wheel Spindle Housing - Disassemble......1093
Brake and Wheel Spindle Housing - Install......1098
Brake and Wheel Spindle Housing - Remove......1101
Cab - Install......1104
Cab - Remove......1112
Centershift Cylinder - Install......1119
Centershift Cylinder - Remove......1121
Centershift Lock - Assemble......1123