INTERACTIVE SCHEMATIC

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Component Table Tap Table Fluid Power Symbols Electrical Symbols

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RENR9009-05 June 2010

140M and 160M Motor Grader Hydraulic System

140M: B9D1-UP B9M1-UP B9G1-UP D9G1-UP 160M: B9E1-UP B9L1-UP B9T1-UP D9T1-UP

Volume 1 of 2: Machine Systems Volume 2 of 2: All Wheel Drive

2010 Caterpillar, All Rights Reserved

Printed in U.S.A.

COMPONENT LOCATION Volume 1 of 2 - Machine Systems

Description
Accumulator Gp - Blade Cushion Accumulator Gp - Brake Breather Assembly Control Gp - Brake Pedal Cylinder Gp - Articulation Cylinder Gp - Blade Lift (LH) Cylinder Gp - Blade Lift (RH) Cylinder Gp - Blade Tip Cylinder Gp - Center Shift Cylinder Gp - LH Steering Cylinder Gp - RH Steering Cylinder Gp - Ripper Lift Cylinder Gp - Side Shift Cylinder Gp - Wheel Lean Filter Gp - Pilot Filter Gp - Return Lock Gp - Center Shift Manifold Gp - Control Blade Cushion Manifold Gp - Pilot Shutoff Solenoid Motor Gp - Circle Drive Motor Gp - Fan Pump Gp - Fan / Brake Pump Gp - Implement / Steering Pump Gp - Secondary Steer Screen - Fan / Brake Control Screen - Implement Control Valve (Front) Screen - Implement Control Valve (Rear) Screen - Steer Pilot Manifold Valve Sensor Gp - Pressure (Brake Accumulators) Sensor Gp - Pressure (Secondary Steering) Sensor As - Temperature (Hydraulic Fan Oil) Switch As - Pressure (Pilot Filter Bypass) Swivel - Blade Tank Gp - Hydraulic Oil Valve - Shuttle (Load Signal Resolver) Valve Gp - Check (E) Valve Gp - Check (Implement / Steer) Valve Gp - Check (Secondary Steer) Valve Gp - Cooler Bypass Valve Gp - Fan / Brake Control Valve Gp - Implement Control (Front)

Part Number
219-7265 249-3860 9R-9925 301-4129 247-0096 262-1900 262-1900 131-7191 262-1907 276-5682 (AWD) 262-5766 276-5681 (AWD) 262-5766 113-7754 249-4116 249-5299 191-9784 249-2307 298-2600 253-1320 263-1790 105-3196 250-9831 250-8337 236-7296 273-8714 6E-5066 250-1420 250-1420 6E-5066 237-0957 237-0957 264-4297 7X-8549 260-6502 241-3867 6R-7605 193-9230 255-3631 9T-1013 266-1595 251-8256 (5-BANK) 248-6168 (6-BANK) 249-7295 (7-BANK) 249-5328

Schematic Location
D-5 B-2 B-8 E-1 D-6 D-5 D-4 F-3 F-4 D-3 E-2 D-7 F-4 F-6 B-4 A-8 D-4 D-5 B-5 F-5 A-3 B-7 B-6 A-6 B-3 E-3 C-4 C-2 B-3 B-5 A-4 B-5 F-4 B-7 B-3 B-5 B-6 A-5 A-4 A-3 F-2

Machine Location
1 2 3 4 5 6 7 8 9 10 12 11 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 45 31 32 33 34 35 36 37 38 39 40

Valve Gp - Implement Control (Rear) Valve Gp - Relief (Secondary Steer) Valve Gp - Steering Control Valve Gp - Steering Pilot Manifold

(4-BANK) 249-7298 (6-BANK) 291-9517 9T-8071 308-0934 254-3415

C-4 A-5 D-2 C-1

41 42 43 44

COMPONENT LOCATION Volume 2 of 2 - All Wheel Drive

Description
Filter Gp - Charge (Front Pump) Filter Gp - Charge (Rear Pump) Manifold Gp - Control (AWD) Motor Gp - LH Front AWD Motor Gp - RH Front AWD Pump Gp - All Wheel Drive Sensor Gp - Pressure (LT AWD Sensor Control) Sensor Gp - Pressure (RT AWD Sensor Control) Sensor Gp - Temperature Switch As - Pressure (Oil Filter Bypass) Switch As - Pressure (Oil Filter Bypass) Valve Gp - Thermal Bypass

Part Schematic Number Location

196-1803 196-1803 294-1109 287-1893 287-1893 246-4490 214-6863 214-6863 264-4297 134-0404 134-3404 188-8726 C-5 D-3 E-5 E-7 E-2 C-6 D-5 E-5 C-1 D-3 C-5 C-2

Machine Location
1 2 3 4 5 6 7 8 9 10 11 12

TAP LOCATION Volume 1 of 2 - Machine Systems

Tap Number
AA BB CC DD EE FF SOS 1 SOS 2

Description
Implement / Steering Pump Load Sense Implement / Steering Pump Pressure Pilot Supply Pressure Fan Motor Supply Pressure Service Brake LH Pressure Service Brake RH Pressure Hydraulic Oil Sampling Hydraulic Oil Sampling

Schematic Location
B-6 B-5 B-5 A-3 D-1 D-1 B-5 B-5

TAP LOCATION Volume 2 of 2 - All Wheel Drive

Tap Number
A1 A2 B1 B2 LL NN

Description
LH Motor Forward Pressure RH Motor Reverse Pressure RH Motor Forward Pressure LH Motor Reverse Pressure Front Charge Pump Pressure Rear Charge Pump Pressure

Schematic Location
E-4 E-4 E-6 E-6 C-5 C-4

FLUID POWER SYMBOLS

BASIC COMPONENT SYMBOLS
MAIN AUX.

PUMP or MOTOR

FLUID CONDITIONER

SPRING

CONTROL VALVES

RESTRICTION

LINE RESTRICTION (FIXED)

2-SECTION PUMP

PUMP: VARIABLE and PRESSURE COMPENSATED

VARIABILITY

SPRING (ADJUSTABLE)

LINE RESTRICTION (VARIABLE)

PRESSURE COMPENSATION

HYDRAULIC PNEUMATIC ENERGY TRIANGLES

LINE RESTRICTION
VARIABLE and PRESSURE COMPENSATED

ATTACHMENT

VALVE ENVELOPES

VALVES

VALVE PORTS

ONE POSITION

TWO POSITION

THREE POSITION

TWO-WAY

THREE-WAY

FOUR-WAY

CONTROL VALVES
AB AB

CHECK VALVES

P T NORMAL POSITION

P T SHIFTED POSITION

INFINITE POSITION

BASIC SYMBOL

SPRING LOADED

SHUTTLE

PILOT CONTROLLED

FLUID STORAGE RESERVOIRS

VENTED

PRESSURIZED

RETURN ABOVE FLUID LEVEL

RETURN BELOW FLUID LEVEL

MEASUREMENT

ROTATING SHAFTS

PRESSURE

TEMPERATURE

FLOW

UNIDIRECTIONAL

BIDIRECTIONAL

COMBINATION CONTROLS

SOLENOID

SOLENOID or MANUAL

SOLENOID and PILOT

SOLENOID and PILOT or MANUAL

SERVO

THERMAL

DETENT

MANUAL CONTROL SYMBOLS

PUSH-PULL LEVER

MANUAL SHUTOFF

GENERAL MANUAL

PUSH BUTTON

PEDAL

SPRING

RELEASED PRESSURE

PILOT CONTROL SYMBOLS

REMOTE SUPPLY PRESSURE

EXTERNAL RETURN

INTERNAL RETURN

SIMPLIFIED

COMPLETE

INTERNAL SUPPLY PRESSURE

ACCUMULATORS

CROSSING AND JOINING LINES

HYDRAULIC AND PNEUMATIC CYLINDERS

SPRING LOADED

GAS CHARGED

LINES CROSSING

LINES JOINING

SINGLE ACTING

DOUBLE ACTING

HYDRAULIC PUMPS
FIXED DISPLACEMENT VARIABLE DISPLACEMENT NON-COMPENSATED UNIDIRECTIONAL

HYDRAULIC MOTORS
FIXED DISPLACEMENT VARIABLE DISPLACEMENT NON-COMPENSATED

INTERNAL PASSAGEWAYS
INFINITE POSITIONING THREE POSITION TWO POSITION

UNIDIRECTIONAL

BIDIRECTIONAL

BIDIRECTIONAL

FLOW IN ONE DIRECTION

PARALLEL FLOW

CROSS FLOW

FLOW ALLOWED IN EITHER DIRECTION

ELECTRICAL SYMBOLS
Hydraulic Symbols (Electrical)

G
Transducer (Fluid) Transducer (Gas / Air) Generator

M
Electric Motor

Pressure Switch

Pressure Switch (Adjustable)

Temperature Switch

Electrical Wire

Electrical Symbols (Electrical)

Pressure Symbol

Temperature Symbol

Level Symbol

Flow Symbol

Wire Number Identification Codes

Electrical Schematic Example

Current Standard
Harness identification code This example indicates wire 135 in harness "AG". Wire

Hydraulic Schematic Example

Current Standard

Circuit Number Identification

Wire Color

325-AG135 PK-14 325-PK

Circuit Identification Number Wire Color Wire Gauge

Previous Standard
Wire Wire Color

325-PK-14
B
Circuit Number Identification Wire Gauge
(EXAMPLE VALVE)

PLOW ANGLE CYLINDER SCARIFIER CYLINDERS NOT SHOWN

F

PLOW LIFT CYLINDER

(14) CYLINDER GP WHEEL LEAN 249-5299 (20) MOTOR GP CIRCLE DRIVE 105-3196

(9) CYLINDER GP CENTER SHIFT 262-1907 (13) CYLINDER GP SIDE SHIFT 249-4116 (32) SWIVEL BLADE 260-6502

3 (8) CYLINDER GP BLADE TIP 131-7191

(40) VALVE GP IMPLEMENT CONTROL (FRONT) 248-6168 (5-BANK) 249-7295 (6-BANK)SCARIFIER 249-5328 (7-BANK)PLOW

LINES GROUP COLOR DESCRIPTIONS

IMPLEMENT & STEERING PUMP OUTPUT SECONDARY STEERING PUMP OUTPUT CENTERSHIFT LOCK CONTROL CIRCUIT FAN & BRAKE PUMP OUTPUT CENTERSHIFT CYLINDER CONTROL CIRCUIT SIDE SHIFT CYLINDER CONTROL CIRCUIT SUPPLY LINE DRAIN / RETURN LINE STEERING CYLINDER CONTROL CIRCUIT BLADE TIP CYLINDER CONTROL CIRCUIT PILOT SHUTOFF CIRCUIT CIRCLE DRIVE MOTOR CONTROL CIRCUIT IMPLEMENT & STEERING LOAD SENSE CIRCUITS BLADE LIFT CYLINDER CONTROL CIRCUITS WHEEL LEAN CYLINDER CONTROL CIRCUIT ARTICULATION CYLINDER CONTROL CIRCUIT SERVICE BRAKE CONTROL CIRCUIT RIPPER LIFT CYLINDER CONTROL CIRCUIT SNOW WING & PLOW CYLINDER CONTROL CIRCUITS

)(

(4) CONTROL GP BRAKE PEDAL 301-4129

PLOW ANGLE (7-BANK) OR SCARIFIER (6-BANK)

PLOW LIFT (7-BANK) OR REMOVED (6-BANK)

WHEEL LEAN

CIRCLE DRIVE
(1) ACCUMULATOR BLADE CUSHION 219-7265

CENTER SHIFT

SIDE SHIFT

BLADE TIP

(26) SCREEN IMPLEMENT CONTROL VALVE (FRONT) 250-1420

(17) LOCK GP CENTER SHIFT 298-2600 (10) CYLINDER GP LH STEERING 276-5682 262-5766 (AWD)
CENTER SHIFT LOCK

(12) CYLINDER GP RH STEERING 276-5681 262-5766 (AWD)

(11) CYLINDER GP RIPPER LIFT 113-7754

(5) CYLINDER GP ARTICULATION 247-0096

(6) CYLINDER GP BLADE LIFT (LH) 262-1900

BLADE CUSHION ATTCH

(7) CYLINDER GP BLADE LIFT (RH) 262-1900

BLADE CUSHION ATTCH

CL

CR

(43) VALVE GP STEERING CONTROL 308-0934

EE FF

WING TILT CYLINDER

D

WING LIFT CYLINDER

LE

(18) MANIFOLD GP CONTROL BLADE CUSHION 253-1320

(41) VALVE GP IMPLEMENT CONTROL (REAR) 249-7298 (4-BANK) 291-9517 (6-BANK)

L RE R

A
(44) VALVE GP STEERING PILOT MANIFOLD 254-3415 (27) SCREEN IMPLEMENT CONTROL VALVE (REAR) 250-1420
)(

C Ps

EF Ts

WING TILT (6-BANK)

(3) BREATHER AS 9R-9925

WING LIFT (6-BANK)

(33) TANK GP HYDRAULIC OIL 241-3867 (22) PUMP GP FAN/BRAKE 250-8337

RIPPER

(36) VALVE GP CHECK (IMP/STEER) 255-3631

ARTICULATION

BLADE LIFT (LEFT)

BLADE LIFT (RIGHT)

P

LS

(23) PUMP GP IMPLEMENT/ STEERING 236-7296

(34) VALVE SHUTTLE (LOAD SIGNAL RESOLVER) 6R-7605

BB
SOS 2

(28) SCREEN (STEER PILOT MANIFOLD VALVE) 6E-5066

AA

CC

(30) SENSOR GP PRESSURE SEC STEERING 237-0957

PS LS

(29) SENSOR GP-PRESSURE BRAKE ACC 237-0957

A1
(2) ACCUMULATOR GP BRAKE 249-3860

(16) FILTER GP RETURN 249-2307

TO AWD PUMP
LOC VOL 2 SEC B-1

FAN/BRAKE PUMP IMPLEMENT/ STEERING

(37) VALVE GP CHECK (SEC STEER) 9T-1013

(19) MANIFOLD GP PILOT SHUTOFF (31) SWITCH AS SOLENOID PRESSURE 263-1790 PILOT FILTER BYPASS (35) VALVE GP 7X-8549 CHECK(E) 193-9230 (42) VALVE GP RELIEF (SEC STEER) 9T-8071 (38) VALVE GP COOLER BYPASS 266-1595

SOS 1

(15) FILTER GP PILOT 191-9784 (25) SCREEN (FAN/BRAKE CONTROL) 6E-5066

P A2

LINE PATTERNS
Pressure Line Pilot / Load Sensing Pressure Drain / Return Lines

TO AWD PUMP
A
LOC VOL 2 SEC B-1

DD

(21) MOTOR GP FAN 250-9831 (39) VALVE GP FAN/BRAKE CONTROL 251-8256

Component Group Attachment Air Line

CALLOUTS
YY

Taps (Pressure, Sampling,Sensor) by letter

(24) PUMP GP SECONDARY STEER 273-8714

8 7 6

FROM AWD PUMPS

LOC VOL 2 SEC B-1

(45) SENSOR AS TEMPERATURE (HYDRAULIC FAN OIL) 264-4297

5

THIS SCHEMATIC IS FOR THE 140M & 160M Motor Grader (Volume1)
PART #: 266-1591 CH03 (140M) & 236-8830 CH06 (160M)
Components are shown installed on a fully operable machine with the key and engine off and transmission shifter in neutral. Refer to the appropriate Service Manual for Troubleshooting, Specifications and Systems Operations

FROM AWD MOTORS

LOC VOL 2 SEC C-1

(4) MOTOR GP LH FRONT AWD 287-1893

(8) SENSOR GP PRESSURE (RT AWD SENSOR CONT) 214-6863

)( A E
PS2 C2 RIGHT CONT B2 B2 RIGHT FWD REV MR

(3) MANIFOLD GP CONTROL (AWD) 294-1109

(5) MOTOR GP RH FRONT AWD 287-1893

L
A2 A2 A2G T A1G A1

A
E

B2 B1

B2G T1 B1G B1 B1 REV LEFT FWD

A2 A1

max min B

LEFT CONT

A1

max min
PS1 C1 ML P

)(

(7) SENSOR GP PRESSURE LT AWD SENSOR CONT 214-6863

(10) SWITCH AS PRESSURE (OIL FILTER BYPASS) 134-0404 (2) FILTER GP CHARGE (REAR PUMP) 196-1803

(6) PUMP GP ALL WHEEL DRIVE 246-4490

(11) SWITCH AS PRESSURE (OIL FILTER BYPASS) 134-0404

(1) FILTER GP CHARGE FRONT PUMP 196-1803

F S(P) Mp

P(S)

LL

F P(S) L S(P) Mp X

NN

B
(12) VALVE GP THERMAL BYPASS 188-8726

TO COOLER INLET
LOC VOL 1 SEC A-4

(9) SENSOR GP TEMPERATURE 264-4297

FRONT PISTON PUMP

REAR PISTON PUMP

FRONT CHARGE PUMP

REAR CHARGE PUMP

Ms

Ms

Z
B

Z Y

FROM TANK
LOC VOL 1 SEC A-8

FROM TANK
LOC VOL 1 SEC A-8

TO RTN MANIFOLD
LOC VOL 1 SEC A-6

HYDRAULIC CIRCUIT COLOR DESCRIPTIONS

FRONT CHARGE PUMP OUTPUT REAR AWD PUMP AND RIGHT MOTOR CONTROL CIRCUIT FRONT AWD PUMP AND LEFT MOTOR CONTROL CIRCUIT REAR CHARGE PUMP OUTPUT FRONT WHEEL BRAKE CONTROL CIRCUIT SUPPLY LINE DRAIN / RETURN LINE

LINE PATTERNS
Pressure Line Pilot / Load Sensing Pressure Drain / Return Lines Component Group

Attachment Air Line

CALLOUTS
YY

Taps (Pressure, Sampling,Sensor) by letter

THIS SCHEMATIC IS FOR THE 140M & 160M Motor Grader (Volume2)
PART #: 266-1591 CH03 (140M) & 236-8830 CH06 (160M)
Components are shown installed on a fully operable machine with the key and engine off and transmission shifter in neutral. Refer to the appropriate Service Manual for Troubleshooting, Specifications and Systems Operations

MACHINE COMPONENT LOCATIONS

36 30 42 22 3 16 37 24 5 8 17 28 43 44 13 7 9 18 1 34 10
VIEW ALL CALLOUTS

11

21 31

25 29 39

41 27 34

32 20 12 14 40 26

37 30 36 22 21 11

16

43

28

44

17

27 41 34

18

34 26 40

31

42

29

25

39

24

13

32

20

10

12

14

MACHINE COMPONENT LOCATIONS

VIEW ALL CALLOUTS

10 11

12

10 11

12

ALL WHEEL DRIVE PUMP GROUP

6
NN

VIEW ALL CALLOUTS

LL

FWD

12

AWD CHARGE FILTERS

VIEW ALL CALLOUTS

11

10

AWD CONTROL MANIFOLD

CONTROL RT SOLENOID RIGHT REV SOLENOID RIGHT FWD SOLENOID CONTROL LT SOLENOID LEFT FWD SOLENOID LEFT REV SOLENOID
VIEW ALL CALLOUTS

8
PS2 B2G A2G A1G PS1 B1G

B2

A2

A1

B1

B2

B1

A2

A1

VIEW A-A

FAN AND BRAKE CONTROL

VIEW ALL CALLOUTS

45 38

DD

IMPLEMENT AND STEERING CIRCUIT

VIEW ALL CALLOUTS

33 35 19
BB CC
SOS 2

23

AA

FW

S0S 1

15 35 19 15

SERVICE BRAKES
VIEW ALL CALLOUTS

FF (RH)

EE (LH)

LH VIEW