AccuGrade® Dealer ARO Installation For M-Series, M-Series 2, and M-Series 3 Motor Graders {7220} Caterpillar

Motor Grader

120M (S/N: R9A1-UP; PJB1-UP; B9C1-UP; R9C1-UP; NJD1-UP; B9N1-UP; CBS1-UP; B9W1-UP; D9W1-UP; RMY1-UP)

120M Series 2 (S/N: M9C1-UP; M9H1-UP; R9N1-UP; R9W1-UP)

12M (S/N: R9B1-UP; B9F1-UP; B9R1-UP)

12M Series 2 (S/N: F9B1-UP; F9M1-UP; R9P1-UP; R9S1-UP)

12M Series 3 (S/N: N9B1-UP; N9F1-UP; N9P1-UP; N9R1-UP)

140M (S/N: B9D1-UP; B9G1-UP; D9G1-UP; B9M1-UP)

140M Series 2 (S/N: M9D1-UP; R9G1-UP; M9J1-UP; R9M1-UP)

140M Series 3 (S/N: N9D1-UP; N9G1-UP; N9J1-UP; N9M1-UP)

14L (S/N: B941-UP)

14M (S/N: B9J1-UP; R9J1-UP)

160M (S/N: B9E1-UP; B9L1-UP; B9T1-UP; D9T1-UP)

160M Series 2 (S/N: M9E1-UP; M9K1-UP; R9L1-UP; R9T1-UP)

160M Series 3 (S/N: N9E1-UP; N9K1-UP; N9L1-UP; N9T1-UP)

16M (S/N: B9H1-UP; R9H1-UP)

24M (S/N: B9K1-UP)

Introduction

This Special Instruction provides information for the installation of the AccuGrade Attachment Ready Option (ARO) on M Series, M Series 2, and M Series 3 Motor Graders.

Important Safety Information

Work safely. 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.

Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.

Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. If a tool, a procedure, a work method, or operating technique that is not recommended by Caterpillar is used, verify that the procedure is safe for you and for other people to use.

Ensure that the product will not be damaged or the product will be made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.

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Do not operate or work on this machine unless you have read and understand the instructions and warnings in the Operation and Maintenance Manual. Failure to follow the instructions or heed the warnings could result in injury or death. Contact your Caterpillar dealer for replacement manuals. Proper care is your responsibility.

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Personal injury or death can result from improper assembly procedures. Do not attempt any assembly until you have read and understand the assembly instructions.

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Sudden movement or accidental starting of the machine can cause personal injury or death to persons on or near the machine. To prevent personal injury or death, perform the following: Park the machine on a smooth level surface. Lower the blade and or attachments to the ground. Stop the engine and engage the parking brake. Block the wheels and install the steering frame lock. Turn the battery disconnect switch to the OFF position and remove the key. Place a Special Instruction, SEHS7332, "Do Not Operate" tag at the battery disconnect switch location to inform personnel that the machine is being worked on.

Reference Section

• Schematic, RENR9014, "12M & 120M Motor Grader Electrical System"

• Schematic, RENR9018, "140M & 160M Motor Grader Electrical System"

• Schematic, RENR9023, "14M Motor Grader Electrical System"

• Schematic, RENR9024, "16M Motor Grader Electrical System"

• Schematic, KENR6663, "12M, 120M, 14M, 140M, 16M, & 160M Electrical System AccuGrade Ready Option (ARO)"

• Schematic, UENR1241, "12M Series 2, 120M Series 2, 140M Series 2 and 160M Series 2 Motor Grader Electrical System"

• Schematic, KENR9044, "120M Series 2 Motor Grader Electrical System 354-4211-02 (Cab), 354-4214"

• Schematic, KENR9046, "140M and 160M Series 2 Motor Grader Electrical System"

• Schematic, UENR2158, "12M, 140M, and 160M Series 2 Motor Grader Electrical System 354-4211-02 (For Serial Numbers M9D500-UP, M9J400-UP, M9E400-UP, M9K400-UP). All other Serial Number 1-UP)"

• Schematic, RENR9043, "24M Motor Grader Electrical System (Interactive)"

• Schematic, UENR3921, "12M3, 140M3, and 160M3 Motor Grader Electrical System, Cab 417-8801, Chassis 417-8806"

Parts List

120M

12M/140M/160M

14M

14L

16M

24M

120M Series 2

12M Series 2 / 140M Series 2/ 160M Series 2

12M Series 3/ 140M Series 3/ 160M Series 3

Procedures

Removing the Covers

1. Park machine on flat service and lower all implements.

2. Make sure that the blade is square to the machine.

3. Stop engine and turn "off" electrical disconnect.

4. Remove the front nose covers
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   Illustration 1	g01424040
   (1) Bolts

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   Illustration 2	g01424058
   (1) Bolts

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   Illustration 3	g01424105
   (1) Bolts

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   Illustration 4	g02879517
   (1) Bolts

5. Remove the bolts (1) from the covers on the neck of the motor grader.

6. Remove the covers.

   Note: Use a proper lifting device to remove the covers.

Routing the Harness

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Illustration 5	g01424143
Not applicable for 24M (2) Front Harness

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Illustration 6	g02902997
Not applicable for 24M (2) Front Harness (3) 7K-1181 Cable Straps

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Illustration 7	g06005182
Not Applicable for 24M

Note: Front wiring harness that will be used varies based on model.

1. 120M and 120M2 - 356-3637 Chassis Harness As

   12M/140M/14M/14L/12M2/140M2/160M2 - 356-3649 Chassis Harness As

   14M - 295-4322 Front Harness As

   16M - 263-6893 Wiring Harness

   12M3/140M3/160M3 - 380-3061 Chassis Harness As

   24M - 276-8827 Sensor Harness As

   Extend the Upper Front Harness Assembly along the neck of the Motor Grader.

   Use (3) 7K-1181 Cable Straps to attach the (2) Front Harness As to the other machine harnesses.

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   Illustration 8	g02965337
   298-3644 Bracket As (4) 8T-4121 Hard Washer (5) 8T-4137 Bolt (6) 8T-4186 Bolt (7) 9C-5344 Spacer

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   Illustration 9	g02965517
   (8) 298-3644 Bracket As

2. For Non-All Wheel Drive Machines Attach the (8) 298-3644 Bracket As.
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   Illustration 10	g02878918
   (9) Harness Connector on cab

3. Connect the connector on the front harness to the main connector that is on the front of the cab of the Motor Grader

4. For 14M and 16M Motor Graders, proceed to Step 7.

5. For other non-All Wheel Drive Models secure the harness with clamps that are provided.
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   Illustration 11	g02965537
   Harness Bracket

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   Illustration 12	g02965619
   288-5515 Plate As (10) 096-4883 Locknut (11) 8T-4121 Hard Washer (12) 287-6688 Plate (13) 288-0693 Block (14) 8T-4137 Bolt

6. Secure the harness with the clamps that are provided.
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   Illustration 13	g02965677

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   Illustration 14	g02965701
   288-5516 Plate As (10) 096-4883 Locknut (11) 8T-4121 Hard Washer (12) 287-6688 Plate (13) 288-0693 Block (14) 8T-4137 Bolt

7. Extend the Lower Front Harness  Assembly along the drawbar to front frame. Refer the below Tables for lower front harness for different models.
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   Table 24

   120M and 120M2
   369-0950 Chassis Harness As
   Part Number	Description
   130-5300	Clip
   9X-8250	Clip
   8T-4121	Hard Washer
   8T-4137	Bolt
   125-8534	Plate As
   8T-4136	Bolt

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   Table 25

   12M/140M/14M/14L/12M2/140M2/160M2
   308-9367 Switch Harness As
   Part Number	Description
   130-5300	Clip
   223-3490	Clip
   4S-1962	Clip
   6V-1228	Clip
   8T-4121	Hard Washer
   8T-4137	Bolt

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   Table 26

   14M
   257-7111 Sensor Harness As
   6D-4244	Clip

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   Table 27

   16M
   263-6894 Wiring Harness
   6D-4244	Clip

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   Table 28

   12M3/140M3/160M3
   308-9367 Switch Harness As
   Part Number	Description
   223-3490	Clip
   4S-1962	Clip
   6V-1228	Clip
   8T-4121	Hard Washer
   8T-4137	Bolt

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   Table 29

   24M
   272-3261 Work Tool Harness As

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   Illustration 15	g02965716

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   Illustration 16	g02965718
   (15) 6V-7555 Cable Strap (16) 7W-5672 Pipe (17) 8T-4121 Hard Washer (18) 8T-5005 Bolt (19) 6D-4244 Clip (20) 7L-6463 Spacer (21) 8T-4198 Bolt

8. Route the Blade Slope Sensor Harness along the neck toward the circle. Refer the below Tables for Blade Slope Sensor for different models.
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   Table 30

   120M and 120M2
   448-1938 Sensor Harness As
   Part Number	Description
   4P-7428	Clip
   8T-4121	Hard Washer
   8T-4137	Bolt
   8T-4192	Bolt
   8T-4223	Hard Washer
   9M-8406	Clip

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   Table 31

   12M/140M/14M/14L/12M2/140M2/160M2
   448-1938 Sensor Harness As
   Part Number	Description
   7K-1181	Cable Strap
   092-5524	Bolt
   4P-7428	Clip
   5P-4135	Bolt
   8T-4121	Hard Washer
   8T-4123	Washer
   9M-8406	Clip
   8T-4192	Bolt
   8T-4223	Hard Washer
   8T-4244	Nut
   8T-4994	Hard Washer

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   Table 32

   14M
   236-2356 Sensor Harness As
   Part Number	Description
   4P-7428	Clip
   4P-7429	Clip
   7K-1181	Cable Strap
   8T-4121	Hard Washer
   8T-4137	Bolt
   9M-8406	Clip

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   Table 33

   16M
   236-2356 Sensor Harness As
   Part Number	Description
   033-8248	Clip
   4P-7429	Clip
   7Y-0589	Bolt
   8T-4121	Hard Washer
   8T-4137	Bolt
   8T-4223	Hard Washer
   8T-4224	Hard Washer

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   Table 34

   12M3/140M3/160M3
   448-1938 Sensor Harness As
   Part Number	Description
   4P-7428	Clip
   8T-4121	Hard Washer
   8T-4137	Bolt
   8T-4192	Bolt
   8T-4223	Hard Washer
   9M-8406	Clip
   7K-1181	Cable Strap

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   Table 35

   24M
   350-1336 Sensor Harness As
   Part Number	Description
   4K-8302	Clip
   8T-4121	Hard Washer
   8T-4137	Bolt
   8T-4223	Hard Washer
   8T-4244	Nut
   264-3643	Bolt

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   Illustration 17	g02879561
   (2) Front Harness

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   Illustration 18	g02879576
   (2) Front Harness

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   Illustration 19	g02879596
   (2) Front Harness

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   Illustration 20	g02968143
   (22) Clip (23) Bolt (24) Washer

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   Illustration 21	g02968160

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   Illustration 22	g02968398
   (22) Clip (23) Bolt (24) Washer (25) Circle Harness

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   Illustration 23	g02883803
   (2) Front Harness

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   Illustration 24	g02968458
   (26) 8T-4136 Bolt (27) 8T-4121 Hard Washer (28) 8M-2773 Clip

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   Illustration 25	g02884838
   (2) Front Harness

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   Illustration 26	g01427054

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   Illustration 27	g02968497
   (26) 8T-4136 Bolt (27) 8T-4121 Hard Washer (28) 8M-2773 Clip

9. Route the Blade Slope Sensor Harness through the circle to the bracket for the angle sensor.

Rework of 356-3649 Chassis Harness As

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Illustration 28	g06175591
356-3649 Chassis Harness As

1. Remove the connector from 356-3649 Chassis Harness As. Save 8T-8737 Seal Plugs for reuse.
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   Illustration 29	g06175603
   (C1) 9X-7146 Connector Plug As

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   Illustration 30	g06175623
   Pin diagram for 9X-7146 Connector Plug As

2. Install connector plug assembly (C1) on the end of 356-3649 Chassis Harness As. Refer to Illustration 30 to correctly wire connector plug assembly (C1). Install 8T-8737 Seal Plugs that were saved in previous step, in the open spots on the connector. Install additional 8T-8737 Seal Plugs in the remaining spots on the connector.

Attaching The Brackets To The Blade

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Illustration 31	g02884848
Not applicable for 24M Bolts to be Removed from Blade Edge (LH) (29) 5F-8933 Bolt

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Illustration 32	g02884868
Not applicable for 24M (29) Bolts to be Removed from Blade Edge (RH)

1. Bolts to be removed from Left-Hand Blade Edge.
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   Illustration 33	g01426981
   Not applicable for 24M Left Side Blade

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   Illustration 34	g01426983
   Not applicable for 24M Right Side Blade

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   Illustration 35	g02968737
   Not applicable for 24M (30) Spacer

2. Bolts to be removed from Right-Hand Blade Edge.

3. Remove the bolts and nuts from the blade edge on each side.

4. Install the brackets on left blade edge using the necessary spacers.

   Note: Tighten the brackets to 370 ± 50 N·m (273 ± 37 lb ft).

5. Install the brackets on right blade edge using the necessary spacers.

   Note: Tighten the brackets to 370 ± 50 N·m (273 ± 37 lb ft).

Installing The Pointer

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Illustration 36	g02968777
(31) 255-3482 Bracket

1. Attach the pointer 255-3482 Bracket (31) to the circle using 8T-4137 Bolt and 8T-4121 Hard Washer.

Installing The Brackets For The Sensors (120 - 160 M, M2, M3)

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Illustration 37	g02968816
(32) 8T-4194 Bolts (33) 5P-1076 Hard Washers or 7D-1649 Hard Washer

1. Attach the 308-9398 Bracket As to the left-hand knuckle of the Motor Grader with two 8T-4194 Bolts (32) and four 5P-1076 Hard Washers or 7D-1649 Hard Washer (33).

   Note: Place the washers on both sides of the bracket.

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   Illustration 38	g02968842
   (34) 236-8826 Bosses (35) 308-9398 Bracket As

2. Attach two 236-8826 Bosses (34) to the 308-9398 Bracket As (35) using 131-3539 Flat Head Screw.

   Reference: Illustration 38

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   Illustration 39	g01428274

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   Illustration 40	g02968880
   (36) 6D-3033 Screws (37) Chain

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   Illustration 41	g02968882
   (38) 132-8487 Ring Nuts

3. Attach the Front Harness Assembly to the 308-9398 Bracket As. Use eight 6D-3033 Screws (36) and two 132-8487 Ring Nuts (38).

   Note: Front Harness Assembly:

   120M & 120M2 - 356-3637 Chassis Harness As

   12M/140M/14M/14L/12M2/140M2/160M2 - 356-3649 Chassis Harness As

   12M3/140M3/160M3 - 380-3061 Chassis Harness As

4. Attach the chain (37) for the 7R-3029 Dust Cap to the 6D-3033 Screw that is on the lower right.
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   Illustration 42	g02884956

5. Attach the 308-9399 Bracket As to the right-hand knuckle.

6. Repeat Step 1 through Step 3 to install the 308-9399 Bracket As on the right side of the Motor Grader.

Installing the Brackets for the Sensors (14M and 16M)

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Illustration 43	g02968816
(32) 8T-4140 Bolt (14M) or 7X-2563 Bolt (16M) (33) 9X-8257 Washer (14M) or 8T-4123 Washer (16M)

1. Attach the 288-5508 Bracket As to the left-hand knuckle of the Motor Grader with two Bolts and four Hard Washers.

   Note: Place the washers on both sides of the bracket.

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   Illustration 44	g02968842
   (343) 236-8826 Bosses (35) 288-5508 Bracket As (14M and 16M)

2. Attach two 236-8826 Boss to the 288-5508 Bracket As using 131-3539 Flat Head Screw.
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   Illustration 45	g01428274

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   Illustration 46	g02968880
   (36) 6D-3033 Screws (37) Chain

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   Illustration 47	g02968882
   (38) 132-8487 Ring Nut

3. Attach the Front Harness Assembly to the 288-5508 Bracket As. Use eight 6D-3033 Socket Head Screw and two 132-8487 Ring Nut.

4. Attach the chain for the 7R-3029 Dust Cap to the 6D-3033 Socket Head Screw that is on the lower right-hand corner. 
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   Illustration 48	g02884956

5. Attach the 288-5509 Bracket As to the right-hand knuckle.

6. Repeat Step 1 through Step 4 to install the 288-5509 Bracket As on the right side of the Motor Grader.

Installing The Power Supply Module on M Series Motor Graders without Common Cab

Note: If installing the power supply module on M Series with Common Cab or M Series 2 machines proceed to next section. Refer to Table 36 for a list of M Series Motor Graders without Common Cab.

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Illustration 49	g01428297

1. Remove the cover in the upper right-hand portion of the cab.
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   Illustration 50	g01428302

2. Move the wires to gain access to the mounting plate.
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   Illustration 51	g01428310

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   Illustration 52	g01428306

3. Mount the 283-7960 Power Supply Gp with four bolts.
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   Illustration 53	g01430823

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   Illustration 54	g01430824

4. Attach the connectors to both ends of the 283-7960 Power Supply Gp.

Installing The Power Supply Module on M Series Motor Graders with Common Cab and M Series 2, and M Series 3 Machines

Note: Refer to Table 37 for a list of M Series Motor Graders with Common Cab.

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Illustration 55	g02895937
(39) Rearview Mirror (40) Wiper Switch Plate (41) Radio (42) Radio Plate (43) Rear Headliner (44) C-Post Cover

1. Remove C-post covers (44), rear headliner panel (43), radio (41), radio plate (42), wiper switch plate (40), rearview mirror assembly (39) and front headliner panel.
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   Illustration 56	g02896359
   (45) Jack Screw (46) Wiper Switch Panel Opening (47) Switch Panel

2. Loosen jack screw (45) through wiper switch panel opening (46) in headliner to disconnect switch panel harness and remove switch panel (47).

   Note: Remove the All Wheel Drive (AWD) control panel, and the in-cab camera display on machines equipped with AWD or rear camera.

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   Illustration 57	g02895998
   (48) Headliner Screws (49) Dome Lamp (50) Speakers (51) Rear Headliner Panel (52) Front Headliner Panel

3. Remove headliner screws (48), disconnect speakers (50) and dome lamps (49), and remove headliner (51) and (52).

   Note: While not required, removal of the seat back and one of the joystick pods will make removal of the headliner from the cab easier.

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   Illustration 58	g02896279
   (53) 360-2969 Wiring Harness

4. Install the 283-7960 Power Supply Gp power module to the cab if not equipped on rear left-hand side and connect the jumper wiring harness 360-2969 Wiring Harness to cab harness.

5. Reinstall headliner and other components in reverse order.

Installing The Main Fall Sensor Bracket

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Illustration 59	g01430798

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Illustration 60	g06005274
(54) 251-1133 Tube

1. Install the 251-1133 Tube (54).

   Use 8T-4121 Hard Washer and 8T-4137 Bolt.

Updating The Hydra Swivel Pin

Illustration 61	g06005281
(55) Hydra Swivel Pin

The connection of the hose tray to the hydra swivel is made with a pin and results in a loose connection. The loose connection may cause inaccuracy on the rotation sensor in AccuGrade. Refer to Illustration 61.

Illustration 62	g06005286
(56) 1K-6870 Locknut (57) 7X-0619 Hard Washer (58) 5P-4135 Bolt

Replace the pin to make an improvement in the accuracy of the sensor. Use a 5P-4135 Bolt , a 1K-6870 Locknut and four 7X-0619 Hard Washer to eliminate the slack in the joint.