CATERPILLAR

RENR1414-01
August 1999

12H, 140H and 160H Motor Graders Air

System and Brakes
9EJ510-Up (Machine)
2ZK2392-Up (Machine)
3GM80-Up (Machine)
4XM1396-Up (Machine)
6WM1-Up (Machine)
8KM1-Up (Machine)
8MN500-Up (Machine)
9TN400-Up (Machine)
9ZN205-Up (Machine)
2LR1-Up (Machine)
2WR642-Up (Machine)
2GS360-Up (Machine)
2HS380-Up (Machine)
3AS450-Up (Machine)

01097883

Important Safety Information

Most accidents that involve product operation, maintenance and repair are caused by failure to
observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially
hazardous situations before an accident occurs. A person must be alert to potential hazards. This
person should also have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not oprate or perform any lubrication, maintenance or repair on this product. until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard
warnings are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the "Safety Alert Symbol" and followed by a "Signa! Word3 such as
"DANGER", "WARNING" or "CAUTION". The Safety Alert "WARNING" label is shown below.

A WARNING
The meaning of this safety alert symbol is as follows:
Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be eiher written or
pictorially presented.
Operations that may cause product damage are identified by "NOTICE" labels on the product and in
this publication.
Caterpillar cannot anticpate every possible circumstance that might involve a potent s - azard, The
warnings in this publication and on the product are, therefore, not all inclusive, If a tool. procedure,
work method or operating technique that is not specifically recommended by Caterpillar is used.
you must satisfy yourself that it is safe for you and for others. You should also ensure that :he
product will not be damaged or be made unsafe by the operation. lubrication. maintenance or
repair procedures that you choose.
The information, specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other tems can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before
you start any job. Caterpillar dealers have the most current information available. For a list of the most
current publication form numbers available, see the Service Manual Contents Microfiche, REG1139F.

3
Air System and Brakes
Table of Contents

Table of Contents
Specifications Section
Air Compressor
Air Compressor Governor
AirTank
AirTank
Relief Valve (Air Tank)
Solenoid Valve (Air Horn)
Air Horn
Air Dryer
Pressure Switch (Low Brake Air)
Pressure Switch (Brake Air) (Stop Lamp)
Front Wiring
Front Wiring
Service Brake Control
Service Brake Control
Air Control Valve (Parking Brake)
Check Valve (Parking Brake Relase)
Solenoid Valve (Parking Brake)
Pressure Switch (Brake Air) (Parking Brake)
Service Brakes
Service Brakes
Parking Brake

4
4
5
5
6
6
6
7
7
8
9
10
11
13
14
14
14
15
15
17
18

Index Section
Index

19

t*

Air System and Brakes

Specifications Section

Specifications Section
Air Compressor Governor
Air Compressor

SMCSCode: 1803: 1804

PartNo.: 61-1240

SMCSCode: 1803
PartNo.: 110-5765

lllustration 2

g00628769

Governor settings
Mnimum cut-in pressure
793 kPa (115 psi)
Cut-out pressure
965 34 kPa (140 5 psi)

lllustration 1

(1) Torque for two bolts

160
30 Nm (118 22 Ib ft)

Note: Before you apply 9S-3263 Thread Lock to the

threads of the bolts, olean the bolts and allow the
bolts to dry. Apply the thread lock compound evenly
and apply the thread lock compound sparingly to
the threads of the bolts. Wipe off excess thread lock
compound after the bolts are tightened.
NOTICE
Avoid prolonged contact of the thread lock compound
to the hands. Wash your hands with water and soap
after you have come into contact with the thread lock
compound.
(2) Front face of the engine block

Air System and Brakes

Specifications Section

Air Tank

Air Tank

SMCS Code: 4272

SMCS Code: 4272

PartNo.: 113-5061
PIN: 6WM1-Up

PartNo.: 8W-5547
PIN:9EJ510-Up

PartNo.: 113-5061
PIN: 8KM1-Up

PartNo.:8W-5547
PIN: 2ZK2392-Up

PartNo.: 113-5061
PIN: 2LR1-Up

PartNo.: 8W-5547
PIN: 3GM80-Up

PartNo.: 113-5061
PIN: 2GS360-Up

PartNo.:8W-5547
PIN:4XM1396-Up

PartNo.: 113-5061
PIN: 2HS380-Up

PartNo.: 8W-5547
PIN: 8MN500-Up

PartNo.: 113-5061
PIN: 3AS450-Up

PartNo.: 8W-5547
PIN: 9TN400-Up
PartNo.: 8W-5547
PIN: 9ZN205-Up
PartNo.: 8W-5547
PIN: 2WR642-Up

lllustration 3

(1) Torque for four bolts and four nuts that hold the
tank in position
15 5 N-m (11 4 Ib ft)
lllustration 4

(1) Torque for four bolts and four nuts that hold the
tank in position
15 5 N-m (11 4 Ib ft)

6
Air System and Brakes
Specifications Section
Coil resistance at 25 5C (77 9F)

Relief Valve (Air Tank)

74.0
7.4 ohms

SMCS Code: 4272-PV

Air Horn

PartNo.:2G-1034

SMCS Code: 7402

Part No.: 8X-9440

lllustration 5

Pressure to open valve

1207
55 kPa (175 8 psi)

Solenoid Valve (Air Horn)

SMCS Code: 5509; 7402

lllustration 7

900100514

Part No.: 7T-9074

(1) 3G-1701 Spring:
Test length
Test
force
Free length after test
Outside diameter

26.2 mm (1.03 inch)

0.0 N (.0 Ib)
26.2
0.8 mm (1.03 .03 inch)
15.85 mm (.624 inch)

(2) 009-4184 Spring:

Quantity
Free length after test
Outside diameter

00058200

lllustration 6

(1) The valve has a normally closed position.

Part No.: 8W-5750

PIN: 9EJ510-Up

(B) Electrical Schematic

Duty

Air Dryer
SMCS Code: 4285

(A) Hydraulic Schematic

Operating Voltage

4
38.0 mm (1.50 inch)
4.83 mm (.190 inch)

24 voltage direct current

Part No.: 8W-5750

PIN: 2ZK2392-Up

continuous

Part No.: 8W-5750

PIN: 3GM80-Up

Air System and Brakes

Specifications Section
Part No.: 8W-5750
PIN: 4XM1396-Up

Pressure Switch (Low Brake

Air)

Part No.: 8W-5750PIN: 6WM1-Up

SMCSCode: 1435; 4265

Part No.: 8W-5750

PIN: 8KM1-Up

Part No.: 3E-2033

Part No.: 8W-5750

PIN: 8MN500-Up
Part No.: 8W-5750
PIN: 9TN400-Up
Part No.: 8W-5750
PIN: 2LR1-Up
900629637

Illustration 9

Part No.: 8W-5750

PIN: 2GS360-Up

Quantity

Part No.: 8W-5750

PIN: 2HS380-Up

Switch Type

Part No.: 8W-5750

PIN: 3AS450-Up

pressure

Medium

oil, fuel, or air

The pressure switch is used in air.

Operating Temperature Range
-40
to +121 C (-40 to +250 F)
Maximum actuation pressure in the operating
temperature range
640 kPa (93 psi)
Deactuation pressure in the operating temperature
range
530 40 kPa (77 6 psi)
Contact Position

normally open
below deactuation pressure

Final Installation Torque for the pressure switch .. 30

3 N-m (22 2 lb ft)

Illustration 8

(1) Torque for four nuts

16
3 N-m (11.8 2.2 lb ft)

(2) Hand tighten the nipple. Do not use sealant.

**

Air System and Brakes

Specifications Section

Pressure Switch (Brake Air)

(Stop Lamp)
SMCS Code: 1432; 1435; 4265

(2) Final Installation Torque for the pressure

switch
22 3 N-m (16 2 lb ft)
Note: Mount the pressure switch with the terminals
in the down position.

Part No.: 166-7781

PIN: 9EJ679-Up

Switch Type

Part No.: 166-7781

PIN: 2ZK3775-Up

Medium

Part No.: 166-7781

PIN: 3GM80-Up

pressure
air

Operating Temperature Range

-40
to +85C (-40 to +185F)

Part No.: 166-7781

PIN: 4XM1997-Up

Maximum actuation pressure in the operating

temperature range
45 kPa (7 psi)

Part No.: 166-7781

PIN: 6WM1-Up

Deactuation pressure in the operating temperature

range
5.0 kPa (.73 psi)

Part No.: 166-7781

PIN: 8KM1-Up

Contact Position

Part No.: 166-7781

PIN: 8MN500-Up
Part No.: 166-7781
PIN: 9TN400-Up
Part No.: 166-7781
PIN: 9ZN205-Up
Part No.: 166-7781
PIN: 2LR1-Up
Part No.: 166-7781
PIN: 2WR642-Up
Part No.: 166-7781
PIN: 2GS360-Up
Part No.: 166-7781
PIN: 2HS380-Up
Part No.: 166-7781
PIN: 3AS450-Up

Illustration 10

(1) Final Installation Torque

1.0
0.2 N-m (8.85 1.77 lb in)

900629716

normally open
below deactuation pressure

9
Air System and Brakes
Specifications Section

Front Wiring
SMCSCode: 1408
Part No.: 112-5979
PIN: 6WM1-Up
Part No.: 112-5979
PIN: 8KM1-Up
Part No.: 112-5979
PIN: 2LR1-Up
Part No.: 112-5979
PIN: 2GS360-Up
Part No.: 112-5979
PIN: 2HS380-Up
Part No.: 112-5979
PIN: 3AS450-Up

Illustration 11

(1) Final installation torque for two low brake air

pressure switches
30 3 N-m (22 2 lb ft)
(2) 166-7781 Pressure Switch

g00629912

Maximum final installation torque for stop lights

air pressure switch
22 3 N-m (16 2 lb ft)
Torque for 10-32 nuts
1.0
0.2 N-m (9 2 lb in)

10
Air System and Brakes
Specifications Section
(3) Final installation torque for parking brake air
pressure switch
30 3 N-m (22 2 lb ft)
(4) Platform
i01178072

Front Wiring
SMCSCode: 1408
Part No.: 8X-7709
PIN:9EJ510-Up
Part No.: 8X-7709
PIN: 2ZK2392-Up
Part No.: 8X-7709
PIN: 3GM80-Up
Part No.: 8X-7709
PIN:4XM1396-Up
Part No.: 8X-7709
PIN: 8MN500-Up
Part No.: 8X-7709
PIN: 9TN400-Up
Part No.: 8X-7709
PIN: 9ZN205-Up
Part No.: 8X-7709
PIN: 2WR642-Up

11
Air System and Brakes
Specifications Section

Illustration 12

(1) Final installation torque for two low brake air

pressure switches
30 3 N-m (22 2 lb ft)

Part No.: 8W-7490

PIN: 8KM1-Up

(2) 166-7781 Pressure Switch

Part No.: 8W-7490

PIN: 8MN500-Up

Maximum final installation torque for stop lights

air pressure switch
22 3 N-m (16 2 lb ft)
Torque for 10-32 nuts
1.0
0.2 N-m (9 2 lb in)
(3) Final installation torque for parking brake air
pressure switch
30 3 N-m (22 2 lb ft)
(4) Platform

Part No.: 8W-7490

PIN: 9TN400-Up
Part No.: 8W-7490
PIN: 9ZN205-Up
Part No.: 8W-7490
PIN: 2LR1-Up
Part No.: 8W-7490
PIN: 2WR642-Up

Service Brake Control

Part No.: 8W-7490

PIN: 2GS360-Up

SMCS Code: 4265; 4269

Part No.: 8W-7490

PIN: 3AS450-Up

Part No.: 8W-7490

PIN: 2ZK2392-Up
Part No.: 8W-7490
PIN:4XM1396-Up

12
Air System and Brakes
Specifications Section

TOP VIEW

VIEW A

Illustration 13

(1) Tighten the nuts until the rubber clamps contact

each other.
(2) Assembled length of rod from the centerline of
the pin hole to the centerline of the pin hole on
the remaining end is 530 2 mm (20.9 .1
inch).

Illustration 14

13
Air System and Brakes
Specifications Section
(01178599

Service Brake Control

SMCS Code: 4265; 4269
Part No.: 8W-4741
PIN: 9EJ510-Up
Part No.: 8W-4741
PIN: 3GM80-Up
Part No.: 8W-4741
PIN: 6WM1-Up
Part No.: 8W-4741
PIN: 2HS380-Up

Illustration 15

14
Air System and Brakes
Specifications Section

Check Valve (Parking Brake

Release)
SMCS Code: 4281; 5067
Part No.: 6D-1432

Illustration 16

(1) Tighten the nuts until the rubber clamps contact

each other.
(2) Assembled length of rod from the centerline of
the pin hole to the centerline of the pin hole on
the remaining end is 530 2 mm (20.9 .1
inch).

900596043

Illustration 18

Maximum operating pressure ... 1030 kPa (150 psi)

Air Control Valve (Parking

Brake)
SMCS Code: 4282; 5506-PJ

Solenoid Valve (Parking Brake)

SMCS Code: 4282; 4284; 5479

Part No.: 5D-4382

Part No.: 7T-9074

900100610

Illustration 17

Maximum operating pressure .. 1030 kPa (150 psi)

The valve has a normally closed position.
(1) 4J-3957 Spring
Free length
Inside diameter

101179878

Illustration 19

90631712

(1) The valve has a normally closed position.

(A) Hydraulic Schematic
(B) Electrical Schematic

17.0 mm (.67 inch)

10.7 mm (.42 inch)

Operating Voltage
Duty

24 voltage direct current

continuous

15
Air System and Brakes
Specifications Section
Coil resistance at 2= r 5rC (77 9F)

74.0
7.4 ohms

Part No.: 7D-8440

PIN: 9ZN205-Up
Part No.: 7D-8440
PIN: 2LR1-Up

Pressure Switch (Brake Air)

(Parking Brake)

Part No.: 7D-8440

PIN: 2WR642-Up

SMCS Code: 1435; 7486

Part No.: 7D-8440

PIN: 2GS360-Up

Part No.: 3E-2033

Part No.: 7D-8440

PIN: 3AS450-Up

900629637

Illustration 20

Switch Type

pressure

Medium

oil, fuel, or air

The pressure switch is used in air.

Operating Temperature Range
-40
to +121 C (-40 to +250 F)
-

Maximum actuation pressure in the operating

temperature range
640 kPa (93 psi)
Deactuation pressure in the operating temperature
range
530 40 kPa (77 6 psi)
Contact Position

normally open
below deactuation pressure

Final Installation Torque for the pressure switch .. 30

3 N-m (22 2 lb ft)
i01149303

Service Brakes
SMCS Code: 4002; 4205; 4234; 4251; 4255
Part No.: 7D-8440
PIN: 2ZK2392-Up
Part No.: 7D-8440
PIN:4XM1396-Up
Part No.: 7D-8440
PIN: 8KM1-Up
-

Part No.: 7D-8440

PIN: 8MN500-Up
Part No.: 7D-8440
PIN: 9TN400-Up

Illustration 21

Note: All surfaces that contact the rubber toric

rings and the actual rings must be cleaned and
dry at assembly. Also apply a thin film of oil to the
contacting surfaces of the seals.
(1) Shims

16
Air System and Brakes
Specifications Section
Outer diameter of all shims
Thickness of 7D-8439 Shim
Thickness of 7D-8441 Shim
Thickness of 9D-7047 Shim
(2) Torque for 3 bolts

66.55
mm (2.620 inch)
0.18
mm (.007 inch)
0.13
mm (.005 inch)
0.51
mm (.020 inch)

260
14 N-m (192 10 lb ft)

(A) Complete Brake Pack

New Thickness

50.14
1.65 mm (1.974 .065 inch)
Maximum Wear Of The Thickness Of The Brake
Pack That Is Permissible ... 4.83 mm (.190 inch)
Thickness For Inspection
45.31
mm (1.784 inch)
(3) Lubricate the friction discs at assembly with the
lubricant that is being used.
(4) Lubricate the seals with a thin covering of the
lubricant that is being sealed.
(5) Lubricate the bores with a thin covering of the
lubricant that is being sealed.
(6) 7D-8434 Disc
Quantity
New Thickness

10
1.91
0.05 mm (.075 .002 inch)

(7) 6Y-7916 Friction Disc

Quantity
New Thickness

9
3.45
0.13 mm (.136 .005 inch)
Reusable Minimum Thickness
2.92
mm (.115 inch)
New Minimum Groove Depth
0.40
mm (.016 inch)
Reusable Minimum Groove Depth
0.127
mm (.0050 inch)

(8) Torque for six bolts

40 7 N-m (30 5 lb ft)

(9) 9J-5498 Spring

Quantity
Test length
Test force
Free length after test
Outside diameter

6
46.02 mm (1.812 inch)
200 10 N (45 2 lb)
68.8 mm (2.71 inch)
20.96 mm (.825 inch)

(10) Torque for ten bolts

240
40 N-m (175 29 lb ft)

(11) Torque for two bolts

240
40 N-m (175 29 lb ft)

17
Air System and Brakes
Specifications Section
(1) Shims

Service Brakes

Outer diameter of all shims

SMCS Code: 4002; 4205; 4234; 4251; 4255

Thickness of 7D-8439 Shim

Part No.: 8W-4265

PIN: 9EJ510-Up

Thickness of 7D-8441 Shim

Part No.: 8W- 4265

PIN: 3GM80-Up

Thickness of 9D-7047 Shim

Part No.: 8W-4265

PIN: 6WM1-Up

(2) Torque for 3 bolts

Part No.: 8W-4265

PIN: 2HS380-Up

(A) Complete Brake Pack

66.55
mm (2.620 inch)
0.18
mm (.007 inch)
0.13
mm (.005 inch)
0.51
mm (.020 inch)

260
14 N-m (192 10 lb ft)

New Thickness

50.14
1.65 mm (1.974 0.065 inch)
Maximum Wear Of The Thickness Of The Brake
Pack That Is Permissible .. 4.83 mm (0.190 inch)
Thickness For Inspection
45.31
mm (1.784 inch)
(3) Lubricate the friction discs at assembly with the
lubricant that is being used.
(4) Lubricate the seals with a thin covering of the
lubricant that is being sealed.
(5) Lubricate the bores with a thin covering of the
lubricant that is being sealed.
(6) 7D-8434 Disc
Quantity
New Thickness

10
1.91
0.05 mm (.075 .002 inch)

(7) 6Y-7916 Friction Disc

Quantity
New Thickness

9
3.45
0.13 mm (.136 .005 inch)
Reusable Minimum Thickness
2.92
mm (.115 inch)
New Minimum Groove Depth
0.40
mm (.016 inch)
Reusable Minimum Groove Depth
0.127
mm (.0050 inch)
(8) Torque for six bolts

40 7 N-m (30 5 lb ft)

(9) 9J-5498 Spring

Illustration 22

Note: All surfaces that contact the rubber toric

rings and the actual rings must be cleaned and
dry at assembly. Also apply a thin film of oil to the
contacting surfaces of the seals.

Quantity
Test length
Test force
Free length after test
Outside diameter

6
46.02 mm (1.812 inch)
200 10 N (45 2 lb)
68.8 mm (2.71 inch)
20.96 mm (.825 inch)

(10) Torque for ten bolts

240
40 N-m (175 29 lb ft)

18
Air System and Brakes
Specifications Section
(11) Torque for two bolts

240
4 0 N-m (175 2 9 lb ft)

Parking Brake
SMCS Code: 3077; 4267

Six new plates and five new friction

discs
43.83 1.43 mm (1.725 .056 inch)
Minimum allowable thickness of worn plates and
of worn friction discs
40.38 mm (1.590 inch)
(3) Lightly lubricate the sealing lip with the lubricant
that is being sealed.
(4) Torque for bolt

120 20 N-m (90 15 lb ft)

Part No.: 9W-5132

(5) 9W-4430 Outer Spring
Test length
49 mm (1.9 inch)
Test force
253.7 20.3 N (57.01 4.56 lb)
Free length after test
64.3 mm (2.53 inch)
Outside diameter
24 mm (.9 inch)
(6) 9W-4431 Inner Spring
Test length
49 mm (1.9 inch)
Test force
139.5 11.2 N (31.35 2.52 lb)
Free length after test
64.3 mm (2.53 inch)
Outside diameter
16.46 mm (.648 inch)
(7) Lightly lubricate the bore with the lubricant that
is being sealed.

Illustration 23

(1) 7G-0437 Plate

Thickness of one new plate
3.18
0.13 mm (.125 .005 inch)
Minimum allowable thickness of a worn
plate
2.97 mm (.117 inch)
(2) 6Y-5352 Friction Disc
Thickness of one new disc
4.95 + 0.08 0.13 mm (.195 + .003 - .005 inch)
Minimum allowable thickness of a worn
disc
4.51 mm (.178 inch)
(A) Assembled thickness