Component Locations

Description
Accumulator Gp - Brake (Charged) Brake Gp - Serv/Parking (Front), STD Brake Gp - Serv/Parking (Front), XLWS Breather As - Hoist Lines Core As - Oil Clr, (Brk, Hydr.Fan, Strng) Core As - Oil Cooler Core As - Oil Cooler (Front Brakes) Cylinder Gp - Air/Hydr. (Frnt Serv. Brk) Cylinder Gp - Air/Hydr. (Rear Brake) Cylinder Gp - Hoist,Telescoping Filter Gp - Oil (Hydr. Oil Cooler) Filter Gp - Oil, Service Brakes Rear Plug - Pipe, Orifice Pump and Motor Gp - Brake Release Pump Gp - Brake Cooling Drive Pump Gp - Hoist & Brake Retract Screen As - Hoist lines Screen As - Parking Brake Screen As - Hydr. Oil Cooler Screen Gp - Hoist Pump Screen Gp - Hydr. Oil Clr Lines Slack Adjuster Gp -Front Brakes Slack Adjuster Gp -Rear Brakes Switch Gp - Filter Bypass Switch Gp - Filter Bypass Tank Gp - Brake Tank Gp - Hydraulic Valve - Check Valve and Mtg Gp - Brake (Auto Rtrdr) Valve As - Check, Valve As - Shuttle Valve Gp - Brake Valve Gp - Control (Hoist) Valve Gp - Diverter, (Hydr. Oil Clr Lines) Valve Gp - Relief Valve Gp - Traction Control Wheel Gp - Final Drv / Brk (Rear), STD Wheel Gp - Fnl Drv / Brk (Rear), XLWS

Part Number
241-3147 252-8709 188-5020 8X-4575 251-4511 253-1807 250-6186 STD: 8W-3406 XLWS: 230-9517 8W-3405 121-2071 274-7575 246-1001 122-7765 8W-9925 197-8885 284-3536 9T-3850 210-1753 251-7708 6E-5472 7J-2656 205-0559 205-0560 164-7577 253-2673 6E-1851 267-5592 138-4733 177-8840 9T-3752 8J-6173 149-4133 247-1437 251-7763 6E-5855 222-4742 246-5264 188-5019

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

Schematic Location
D-5

RENR8331-01 November 2008

FLUID POWER SYMBOLS

BASIC COMPONENT SYMBOLS
MAIN AUX

E-1, B-1 E-3 D-1 C-5 D-1 D-1 D-5 B-2 C-5, D-2 E-4 F-4 E-4 D-3 D-3 D-3 D-3 D-2 E-3 C-5 C-1 D-5 E-4, E-3 C-5, D-2 E-4 D-3 E-4 C-5 D-5 C-1, D-5 E-4 B-3 to C-3 D-2 D-3, D-4 C-4 E-5, B-5
PUMP OR MOTOR FLUID CONDITIONER SPRING CONTROL VALVES RESTRICTION LINE RESTRICTION (FIXED) PUMP (2 - SECTION) PUMP (VARIABLE & PRESSURE COMPENSATED)

36 9 29 28 10 24 32 22 19 58 52 35 31 12 27 36 13 23 50 15 25 1 30 8 21 7 59 66 45 33 18 6

44

70 41
VARIABILITY SPRING (ADJUSTABLE) LINE RESTRICTION (VARIABLE) PRESSURE COMPENSATION HYDRAULIC PNEUMATIC ENERGY TRIANGLES LINE RESTRICTION (VARIABLE & PRESSURE COMPENSATED) ATTACHMENT

57 4 69 68 62 49 63

VALVE ENVELOPES

VALVES

VALVE PORTS

ONE POSITION

TWO POSITION

THREE POSITION

TWO - WAY

THREE - WAY

FOUR - WAY

CONTROL VALVES
AB A B

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

51 67

793D Off-Highway Truck Hydraulic System

FDB1-UP

MEASUREMENT

ROTATING SHAFTS

PRESSURE

TEMPERATURE

FLOW

UNIDIRECTIONAL

BIDIRECTIONAL

COMBINATION CONTROLS

SOLENOID

SOLENOID OR MANUAL

SOLENOID & PILOT

SOLENOID & PILOT OR MANUAL

SERVO

THERMAL

DETENT

MANUAL CONTROL SYMBOLS

Steering and RAX System

Accumulator Gp - Steering Adapter Core As Core As - Oil Clr (Hydr. Fan, Steering) Cylinder Gp - Steering Drive Gp Filter Element - Hydr. (Steering Oil) Filter Gp - Oil, (Hydr. Fan, Steering) Filter Gp - Oil, (Rear Axle Oil) Manifold Gp - Control (RAX Lubrication) Motor Gp - Brake Cooling Motor Gp - Fan, Standard Motor Gp - Fan, Additional Motor Gp - RAX Lube System Motor Gp - Rear Axle Oil Cooler Fan Plug As Pump Gp - Brake Cooling Pump Gp - Hydr. Fan Pump Gp - Metering Pump Gp - Rear Axle Lubrication Pump Gp - Steering Sensor Gp - Pressure, Differential Switch As - Pressure, High Steering Oil Switch As - Pressure, Low Steering Oil Switch Gp - Bypass Tank and Fliter Gp - Steering Valve - Breaker Relief Valve Gp - Check (Steering) Valve Gp - Makeup Valve Gp - Sol. and Mnfld Combination Valve Gp - Steer Solenoid & Relief Valve Gp - Steering NA: 205-0224 EU: 219-2538 132-6194 209-7824 199-6683 9T-8912 271-0163 249-2337 177-6979 192-3841 283-5462 198-6041 242-4042 240-7790 202-9940 207-8609 242-7114 197-8885 240-7789 9T-1318 214-1555 198-6040 221-3414 3E-7812 3E-7809 164-7577 248-6246 117-9152 166-3438 183-7170 198-6577 272-9849 9T-8931 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 E-8 E-7 E-8 A-8 C-7 B-7, D-3 A-8 A-8 D-8 D-8 D-6, D-2 C-7 C-8 E-8 D-8 D-6, D-3 B-7 D-7 C-8 B-6 D-8 D-8 C-7 D-8 A-8 A-8 A-6 E-7 C-7 E-8 E-7

PUSH - PULL LEVER

MANUAL SHUTOFF

GENERAL MANUAL

PUSH BUTTON

PEDAL

SPRING

44 9 11 23 43

47

RELEASED PRESSURE

PILOT CONTROL SYMBOLS

REMOTE SUPPLY PRESSURE

EXTERNAL RETURN

INTERNAL RETURN

SIMPLIFIED

COMPLETE

INTERNAL SUPPLY PRESSURE

ACCUMULATORS

CROSSING & JOINING LINES

HYDRAULIC & PNEUMATIC CYLINDERS

SPRING LOADED

GAS CHARGED

LINES CROSSING

LINES JOINING

SINGLE ACTING

DOUBLE ACTING

34 26 14 16 17

20 5

56

65 64 46

HYDRAULIC PUMPS

HYDRAULIC MOTORS
FIXED DISPLACEMENT VARIABLE DISPLACEMENT NON-COMPENSATED

INTERNAL PASSAGEWAYS
INFINITE POSITIONING

61

40

FIXED DISPLACEMENT

VARIABLE DISPLACEMENT NON-COMPENSATED

3 POSITION

2 POSITION

UNIDIRECTIONAL

UNIDIRECTIONAL

MACHINE COMPONENT LOCATIONS

2008 Caterpillar, All Rights Reserved

BIDIRECTIONAL

BIDIRECTIONAL

FLOW IN ONE DIRECTION

PARALLEL FLOW

CROSS FLOW

FLOW IN EITHER DIRECTION

Printed in U.S.A.

21 7 35
TP11

ELECTRICAL SYMBOLS TABLE

HYDRAULIC SYMBOLS (ELECTRICAL)

M
ELECTRIC MOTOR

40 57

TRANSDUCER (FLUID)

TRANSDUCER (GAS / AIR)

GENERATOR

Tap Locations Pressure, Sampling, and Sensor

Tap Number
TP1 TP2 TP3 TP6 TP7 PT8 TP9 TP10 TP11 TP12 TP13

Description
Traction Control Valve Right Brake Press Traction Control Valve Left Brake Press Steering Pump Discharge Pressure Steering Pump Case/ Brake Cooling Motor Case Drains Filter Output Pressure Steering Pump Case/ Brake Cooling Motor Case Drains Filter Input Pressure Brake Cooling Motor/ Fan Motor Case Drains Filter Output Pressure Brake Cooling Motor/ Fan Motor Case Drains Filter Input Pressure Parking Brake Pressure (Rear) Parking Brake Pressure (Front) Service Brake Pressure, Right , Rear Service Brake Pressure, Left , Rear

Schematic Location
B-4 C-4 E-7 A-8 A-8 A-8 A-8 D-5 D-1 B-5 E-5

TP1 TP2

69

70

PRESSURE SWITCH

PRESSURE SWITCH (ADJUSTABLE)

TEMPERATURE SWITCH

ELECTRICAL WIRE

ELECTRICAL SYMBOLS (ELECTRICAL)

44
TP5

44
T

8 28 22
TP7 TP6 TP9 TP8

TP3

PRESSURE SWITCH

TEMPERATURE SWITCH

LEVEL SWITCH

FLOW SWITCH

64
CURRENT STANDARD

WIRE NUMBER IDENTIFICATION CODES

ELECTRICAL SCHEMATIC EXAMPLE

HYDRAULIC SCHEMATIC EXAMPLE CURRENT STANDARD

HARNESS IDENTIFICATION CODE THIS EXAMPLE INDICATES WIRE 135 IN HARNESS AG WIRE

RENR8331-01

Related Manuals
Description Parts Manual:
Parts Book: SEBP3976 RENR8330 RENR8336 RENR8341 SENR2986 RENR8333 RENR9866

13
TP10

TP4

1
CIRCUIT NUMBER IDENTIFICATION

325-AG135 PK-14

CIRCUIT NUMBER IDENTIFICATION

WIRE COLOR

Media Number

WIRE COLOR

WIRE GAUGE

325-PK

Machine System:
Air System & Brake SOTA Steering System Fan Drive Hydraulic System Traction Control System

47

STEER

11
FAN

50 59

68
WIRE

PREVIOUS STANDARD
WIRE COLOR

Electrical System:
Schematic

47

35

31

325-PK-14

B
WIRE GAUGE

Air System:
Schematic

56
TP13 TP12

CIRCUIT NUMBER IDENTIFICATION

(EXAMPLE VALVE)

FILTERS

BRAKES

STEERING

30 Page,

(Dimensions: 39 inches x 28 inches)

STEERING SYSTEM
CYLINDERS GP STEERING 9T-8912

HOIST, BRAKE COOLING, PARKING BRAKE RETRACT & TRACTION CONTROL SYSTEMS
MOTOR GP FAN REAR AXLE OIL COOLER 207-8609
CL

PLUG - PIPE ORIFICE 122-7765

CR

TANK GP BRAKE 6E-1851

CORE AS 209-7824

VALVE GP STEERING 9T-8931

LEFT REAR

VALVE GP BRAKE 149-4133

BREATHER AS HOIST LINES 8X-4575 BRAKE GP SERV./ PARKING FRONT STD: 252-8709 XLWS: 188-5020

ACCUMULATOR GP STEERING NA: 205-0224 VALVE GP EU:219-2538 STEER SOL. / RELIEF 272-9849
AUXILARY POWER UNIT PORT

EF T HP
TP3

WHEEL GP FINAL DRIVE BREAK , REAR STD : 246-5264 XLWS : 188-5019 TP13

SWITCH GP FILTER BYPASS 164-7577

SCREEN GP HOIST PUMP 6E-5472

SWITCH GP FILTER BYPASS 164-7577

LEFT FRONT

LS HT

PUMP/ MOTOR GP BRK RELEASE 8W-9925 VALVE AS CHECK 138-4733

ADAPTER 132-6194

CYLINDER GP AIR/ HYDR. REAR BRK 8W-3405

FILTER GP OIL, SERV BRK, REAR 246-1001 DRIVE GP 271-0163

PUMP GP HOIST/ BRK RTRCT 284-3536

SCREEN AS HYDR. OIL COOLERS 251-7708

CYLINDER GP AIR/ HYDR. FRONT SERV. BRK STD: 8W-3405 XLWS: 230-9517

SWITCH GP BYPASS 164-7577

SENSOR GP PRESSURE DIFFERENTIAL 221-3414

OIL SAMPLE PORT

SWITCH AS PRESSURE HIGH STEERING OIL 3E-7812

SLACK ADJ GP - REAR BRAKES 205-0560

PUMP DRIVE BOX

VALVE AS SHUTTLE 8J-6173 ACCMLTR GP BRAKE CHARGED 241-3147 VALVE GP RELIEF 6E-5855 TANK GP HYDRAULIC 267-5592 SCREEN GP HOIST LINES 9T-3850 SCREEN GP PARK BRK 210-1753 PUMP GP BRK COOLING DRIVE 197-8885 MOTOR GP BRAKE COOLING 198-6041 CORE AS OIL CLR BRK,HYDR. FAN, STEERING 251-4511 VALVE GP DIVERTER HYDR. OIL CLR LINES 251-7763
TP11

VALVE GP RELIEF 6E-5855

FILTER GP HYDR. OIL COOLER 274-7575

CORE AS OIL CLR FRONT BRK 250-6186

FILTER GP OIL, REAR AXLE OIL 192-3841

PUMP GP METERING 9T-1318 MOTOR GP BRAKE COOLING 198-6041

TP10

VALVE AS CHECK 9T-3752

PLUG AS 242-7114

SCREEN GP HYDR. OIL CLR LINES 7J-2656 PUMP GP BRAKE COOLING 197-8885

SWITCH GP FILTER BYPASS 253-2673

(Dimensions: 39 inches x 28 inches)

MANIFOLD GP CONTROL (RAX LUBRICATION PUMP GP REAR AXLE LUBRICATION 214-1555

VALVE AS SHUTTLE 8J-6173

ROD END VENT SLOT ACROSS STEM

RENR8331-01

SWITCH GP PRESSURE LOW STEERING OIL 3E-7809 VALVE GP SOL. / MNFLD COMBINATION 198-6577 VALVE GP MAKEUP 183-7170

VENT ORIFICE FOR COUNTERBALANCE VALVE COUNTERBALANCE VALVE CARTRIDGE

C
FINAL DRIVE

CORE AS OIL CLR 253-1807

SLACK ADJ. GP FRONT BRAKES 205-0559

TP2

VALVE / MTG GP BRAKE AUTO RETRDR 177-8840

C
LOWER FLOAT SIGNAL ORIFICE #2 SIGNAL ORIFICE #1 CYLINDER ROD END

DIFFERENTIAL

LEFT BRAKE

MOTOR GP RAX LUBE SYSTEM 202-9940

BANJO HOUSING SUMP

MOTOR GP FAN STANDARD: 242-4042 ADDITIONAL: 240-7790

SWITCH GP FILTER BYPASS 253-2673

FILTER GP HYDR. OIL COOLER 274-7575

SNUB CYLINDER HEAD END BRAKE COOLING COOLING RELIEF PORT

HOLD

RAISE

RIGHT FRONT
BRAKE GP SERV./ PARKING FRONT STD: 252-8709 XLWS: 188-5020 CYLINDER GP HOIST TELESCOPING 121-2071

30 Page,

BRAKE
RIGHT BRAKE

B
A M G

PUMP GP HYDR. FAN 240-7789

T1 L

PUMP GP STEERING 198-6040

TP1

RIGHT REAR
L1 T1 G M A

TP12

VALVE GP TRACTION CONTROL 222-4742

VALVE GP CONTROL HOIST 247-1437

LOW PRESSURE RELIEF MAIN RELIEF DUMP SPOOL HIGH PRESSURE RELIEF

VALVE GP BREAKER RELIEF 117-9152

FILTER GP HYDR. FAN STEERING 177-6979

S

V g min

V g max

PUMP DRIVE BOX

Vg max

Vg min

WHEEL GP FINAL DRIVE BREAK , REAR STD : 246-5264 XLWS : 188-5019

DUAL STAGE SIGNAL SPOOL

M1

T2 R

L2

L2

R T2

M1

DRIVE GP 271-0163
TP7 TP9

CORE AS OIL COOLER HYDR. FAN / STEERING 199-6683

VALVE GP CHECK (STEERING) 166-3438

LINE PATTERNS
TP6 TP8

Pressure Line

A
FILTER ELEMENTS HYDR. STEERING OIL 249-2337

TANK AND FILTER GP STEERING 248-6246

AUXILIARY POWER UNIT PORT

Pilot / Load Sensing Pressure Drain / Return Lines Component Group Attachment Air Line

HYDRAULIC CIRCUIT COLOR DESCRIPTIONS

BRAKE SYSTEM CHARGE PUMP OUTPUT FAN PUMP AND CIRCUIT HOIST PUMP AND CONTROL CIRCUIT STEERING CIRCUIT SUPPLY LINE PARKING BRAKE CONTROL CIRCUIT REAR BRAKE COOLING SYSTEM FRONT BRAKE COOLING SYSTEM DRAIN / RETURN LINE SERVICE BRAKES CONTROL CIRCUIT STEERING, RAX FAN, AND BREAK COOLING MOTOR PUMP OUTPUT RAX SYSTEM

CALLOUTS
YY

THIS SCHEMATIC IS FOR THE 793D OFF-HIGHWAY TRUCK HYDRAULIC SYSTEM

MEDIA NUMBER: RENR8331-01 PART NUMBER: 193-6202, CHANGE: 01, VERSION: Components are shown installed on a fully operable machine. Refer to the appropriate Service Manual for Troubleshooting, Specific ations.

Taps (Pressure, Sampling, Sensor - by letter) Components (By number)

52