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Component Locations KENR5538-01

Part Machine Schematic Part Machine Schematic January 2009


Description Number Location Location Description Number Location Location FLUID POWER SYMBOLS
Steering Circuit Hoist Circuit - Continuned
BASIC COMPONENT SYMBOLS
A B C D E Cylinder Gp - Steering 223-1335 1 F-2 Pump - Hoist 188-4455 39 C-7
Drain 8J-8782 2 A-4 Screen As. 150-8457 40 A-7 MAIN AUX

Element -Filter (Steering Return) 132-8876 3 A-2 Screen As. - Pump Case Drain 119-4885 41 A-7
PUMP OR MOTOR FLUID CONDITIONER SPRING CONTROL VALVES RESTRICTION LINE RESTRICTION PUMP PUMP
Pump Gp - Metering 160-9727 4 F-3 Tank - Hyd. Oil (Hoist/ Cooling) 162-5242 42 A-7 (FIXED) (2 - SECTION) (VARIABLE & PRESSURE
COMPENSATED)
Pump Gp - Secondary Steering 141-6389 5 B-3 Valve Gp - Balance (Attach) 133-8810 43 B-5
Pump Gp - Steering (735) 224-4431
6 C-3 Valve Gp - Breaker/ Relief 157-7911 44 A-8
- Steering (740) 224-4432
VARIABILITY SPRING LINE RESTRICTION PRESSURE HYDRAULIC PNEUMATIC LINE RESTRICTION ATTACHMENT
Screen As. - Pump Case Drain 119-4885 7 A-3 Valve Gp - Hoist 189-5772 45 B-6, C-6 (ADJUSTABLE) (VARIABLE) COMPENSATION ENERGY TRIANGLES (VARIABLE & PRESSURE
COMPENSATED)
Screen As. - Steering Return 6J-3795 8 A-2 Valve Gp - Main Relief 224-1167 46 C-6
Switch As.- Low Press. Warning 3E-6450 9 E-3 Valve Gp - Manual Lower 204-2124 47 C-6 VALVE ENVELOPES VALVES VALVE PORTS
Tank - Hydraulic Oil 186-9959 10 A-3 Valve Gp - Relief 126-6099 48 C-6
Valve 1U-1643 11 A-2 Brake Circuit
Valve Gp - Breaker / Relief 157-7911 12 A-4 Accumulator Gp - Diaphr. 163-5632 50 F-5
Valve Gp - Check 165-7948 13 C-3 Accumulator Gp - Diaphr. 251-8265 51 F-7 ONE POSITION TWO POSITION THREE POSITION TWO - WAY THREE - WAY FOUR - WAY

Valve Gp - Check 180-4850 14 B-2 Brake Gp - Hyd. Caliper Park 160-8009 52 F-5
CONTROL VALVES CHECK VALVES
Valve Gp - Fluid Sampling (SOS) 164-5590 15 B-2 Brake Gp - Hyd. (Front ) 219-6710 53 D-4, F-4 AB A B
Valve Gp - Steering Comb. Mnfld 176-5691 16 E-4 Brake Gp - Hyd. ( Rear) 219-6710 54 D-8, F-8
Fan Drive Circuit Core Gp - Cooler 4P-7731 55 D-7 P T P T
BASIC SPRING SHUTTLE PILOT
Cooler 122-6485 20 C-2 Manifold - Cooling Lines 159-2880 56 D-5 NORMAL POSITION SHIFTED POSITION INFINITE POSITION
SYMBOL LOADED CONTROLLED
Fan Control Valve 263-5833 21 C-2 Manifold - Cooling Lines 194-4016 57 D-8
Fan Drive Motor - 735 / 740 240-6746 22 C-2 Pump Gp - Brakes 187-9090 58 B-8 FLUID STORAGE RESERVOIRS
Fan Drive Motor - (ATAAC) 220-2290 23 D-2 Switch As.- ABL Control 172-7071 59 F-7
Fan Drive Pump 210-0053 24 C-3 Switch As.- Brake Light 172-7071 60 F-7
Fan Drive Pump - (ATAAC) 248-5605 25 B-3 Switch As.- Brake Temp. 3E-6451 61 D-5, D-7
VENTED PRESSURIZED RETURN ABOVE FLUID LEVEL RETURN BELOW FLUID LEVEL
Releif Valve 222-6472 26 D-2 Switch As.- Low Brake Press. 213-6947 62 F-6
Valve Gp - By-Pass (Thermal)
Valve Gp - Solenoid
188-8726
265-5214
27
28
C-2
C-2
Switch As.- Park Brake EMS 213-6947
Valve Gp - Brake Check Manifold 224-1209
63
64
F-5
F-6 735 and 740 Articulated Trucks MEASUREMENT ROTATING SHAFTS

F G H J K Hoist Circuit Valve Gp - Check 134-9911 65 F-6


Actuator As. - Lower
Actuator As. - Raise
192-6443
196-2403
30
31
C-6
B-6
Valve Gp - Check
Valve Gp - Output Press. Control
158-9956
217-9037
66
67
F-5
F-7
Hydraulic System PRESSURE TEMPERATURE FLOW UNIDIRECTIONAL BIDIRECTIONAL

Cylinder Gp - Hoist 735 241-4065 COMBINATION CONTROLS


32 B-5, C-5 Valve Gp - Parking Brake 190-6290 68 F-5
- Hoist 740 241-4068
NOTE: Test panel located at left rear of the front chassis Cylinder Gp - Tailgate (Attach.) 151-2611 34 B-5 Valve Gp - Press. Reducing 140-0973 69 F-6
735: 740:
Port E is not illustrated on this print Drain 8J-8782 35 A-8 Valve Gp - Relief 224-4630 70 F-6 B1N1-UP WWD1-UP
Element - Filter 132-8876 36 A-7 Valve Gp - Solenoid 152-8340 71 F-5
Manifold - Cold Oil By-Pass 190-1514 37 B-6 Suspension Circuit WWC1-UP B1P1-UP SOLENOID SOLENOID
OR MANUAL
SOLENOID
& PILOT
SOLENOID &
PILOT OR MANUAL
SERVO THERMAL DETENT

Diagnositic and Service Ports Manifold - Hoist / Tailgate 153-3528 38 B-5 Cylinder Gp - Front Cylinder 228-2758 80 D-5
MANUAL CONTROL SYMBOLS

PUSH - PULL LEVER MANUAL SHUTOFF GENERAL MANUAL PUSH BUTTON PEDAL SPRING

RELEASED PRESSURE PILOT CONTROL SYMBOLS REMOTE SUPPLY PRESSURE


Tap Locations
Pressure, Sampling, and Sensor
Tap Schematic
Number Description Location EXTERNAL RETURN INTERNAL RETURN SIMPLIFIED COMPLETE INTERNAL
SUPPLY PRESSURE
A Hoist Raise / Lower Pressure C-6
ACCUMULATORS CROSSING & JOINING LINES HYDRAULIC & PNEUMATIC CYLINDERS
B Secondary Steering Pressure E-4
C Front Brake Pressure F-7
D Brake Pump Pressure E-6
E OTG Lube & Diff. Lock Press. (Not Shown) SPRING LOADED GAS CHARGED LINES CROSSING LINES JOINING SINGLE ACTING DOUBLE ACTING

F Load Sense Press. -Main & Sec. Steer C-3


HYDRAULIC PUMPS HYDRAULIC MOTORS INTERNAL PASSAGEWAYS
G Steer Pressure - Main Steering Pump E-4
H Fan Drive Pressure D-2
FIXED VARIABLE DISPLACEMENT FIXED VARIABLE DISPLACEMENT INFINITE
J Hoist Pilot Pressure B-6 DISPLACEMENT NON-COMPENSATED DISPLACEMENT NON-COMPENSATED POSITIONING 3 POSITION 2 POSITION

K Rear Brake Pressure E-7


L Scheduled Oil Sampling - Steer B-2 UNIDIRECTIONAL UNIDIRECTIONAL
M Park Brake Pressure F-5
N Scheduled Oil Sampling - Hoist A-7
P Pump Case Pressure B-8, C-3
Brake, Fan Drive, Hoist, Steering, and Suspension Circuits BIDIRECTIONAL BIDIRECTIONAL
FLOW IN ONE
DIRECTION
PARALLEL
FLOW
CROSS
FLOW
FLOW IN
EITHER
DIRECTION
R Body Over Center - Service Point C-5
T ATAAC Fan Pressure D-2

© 2009 Caterpillar, All Rights Reserved Printed in U.S.A.

63 62 35 41 59 ELECTRICAL SYMBOLS TABLE


HYDRAULIC SYMBOLS (ELECTRICAL)
66 64 69 1 36 42 60 23
34 43 54 52 32 68 71 38 65 70 6 39 57 53 40 44 4 67 25 26
G
M
TRANSDUCER TRANSDUCER GENERATOR ELECTRIC MOTOR
(FLUID) (GAS / AIR)

(Dimensions: 39 inches x 28 inches)


KENR5538-01
PRESSURE SWITCH PRESSURE SWITCH TEMPERATURE ELECTRICAL WIRE
(ADJUSTABLE) SWITCH

P 68 ELECTRICAL SYMBOLS (ELECTRICAL)


L 3 8 11 10 12

The hydraulic tank is on the right side of the machine.


Brake Pump T

PRESSURE TEMPERATURE LEVEL FLOW


Steering and Fan Drive Systems SWITCH SWITCH SWITCH SWITCH

WIRE NUMBER IDENTIFICATION CODES


56 54 52 32 50 20 27 1 39 13 51 53 9 5 58
30 45 48 24 2 3 7
ELECTRICAL SCHEMATIC EXAMPLE HYDRAULIC SCHEMATIC EXAMPLE
61 21 28 16 55
31 46 8 10 11 CURRENT STANDARD CURRENT STANDARD

22 12 14 15 HARNESS IDENTIFICATION CODE THIS EXAMPLE


37 47 INDICATES WIRE 135 IN HARNESS “AG”
WIRE

30 Page,
CIRCUIT NUMBER
325-AG135 PK-14 IDENTIFICATION WIRE COLOR

63 20 27 30 45
CIRCUIT NUMBER WIRE WIRE GAUGE
66 21 28 31 46 IDENTIFICATION COLOR 325-PK

34 43 68 71 22 39 37 47 13 4 55 58 PREVIOUS STANDARD

WIRE WIRE COLOR

325-PK-14 B A
36 40 N 42 44
60 81 M 73 78 CIRCUIT NUMBER WIRE GAUGE (EXAMPLE VALVE)
IDENTIFICATION
The hydraulic tank is on the left side of the machine.

Hoist and Brake Cooling System Parking Brake

23 T P 6 R 38

56 54 52 32 50 32 6 1 62 64 80 57 53 51 24 2 8 12 9 59 5
61 39 69 70 3 10 14 16 60
65 7 11 15 67

Component Locations ATAAC Fan Steering Pump Hoist Manifold


8 7 6 5 4 3 2 1

BRAKE GP- HYDRAULIC BRAKE GP- HYDRAULIC PUMP GP-


(FRONT AND REAR) ACCUMULATOR HYDRAULIC CIRCUIT COLOR DESCRIPTIONS
(FRONT AND REAR) METERING
RIGHT 219-6710 VALVE GP- DIAPHRAGM VALVE GP- ACCUMULATOR GP- RIGHT BRAKE PUMP OUTPUT
219-6710 160-9727
FRONT BRAKE CONTROL 251-8265 BRAKE CHECK MANIFOLD DIAPHRAGM REAR FAN DRIVE PUMP OUTPUT
HOIST CONTROL CIRCUIT
217-9037 224-1209 163-5632
SWITCH AS- PRESSURE CYLINDER GP- STEERING CIRCUIT
SWITCH AS- SUPPLY LINE
(PARK BRAKE EMS SWITCH) STEER
BRAKES CONTROL CIRCUIT
(BRAKE LIGHT) 223-1335
VALVE GP- D 213-6947 SECONDARY STEERING PUMP
172-7071 FAN DRIVE PUMP OUTPUT (ATTACHMENT)
F CHECK
REMOTE PANEL DRAIN / RETURN LINE
F
134-9911 TEST POINT PARKING HOIST PUMP OUTPUT
VALVE GP- BRAKE PRIMARY STEERING PUMP OUTPUT
SWITCH AS-PRESSURE BRAKE COOLING
TP PARKING BRAKE (LOW PRESSURE WARNING)
C RB 190-6290 3E-6450 L
SWITCH VALVE GP
ASBS SW
P1 LOW BRAKE PRESSURE ACC PS STEERING COMBINER MANIFOLD T
B1
213-6947 176-5691
REMOTE PANEL T1
TEST POINT LS Tap Locations
FB P B
Pressure, Sampling, and Sensor
SWITCH AS- M PP Tap Schematic
P Number Description Location
(ABL CONTROL) VALVE GP-
P T REMOTE PANEL G A Hoist Raise / Lower Pressure C-6
172-7071 P2 PRESSURE REDUCING TEST POINT
B2 RIGHT
140-0973 R TURN
B Secondary Steering Pressure E-4

VALVE GP- VALVE-CHECK VALVE GP- REMOTE PANEL C Front Brake Pressure F-7
K T2 TEST POINT CYLINDER GP-
RELIEF T P 158-9956 SOLENOID TRACTOR TRAILER D Brake Pump Pressure E-6
T1 PS1 STEER
224-4530 RBP RBP 152-8340 E OTG Lube & Diff. Lock Press. (Not Shown)
REMOTE PANEL BRAKE GP-HYDRAULIC 223-1335 F Load Sense Press. -Main & Sec. Steer C-3
TEST POINT
CALIPER PARK P1 G Steer Pressure - Main Steering Pump E-4
HITCH C.L.
(DYNAMIC PARKING BRAKE) H Fan Drive Pressure D-2
160-8009 J Hoist Pilot Pressure B-6
K Rear Brake Pressure E-7
P2 OUT L Scheduled Oil Sampling - Steer B-2
M Park Brake Pressure F-5
T2 PS2 AUX N Scheduled Oil Sampling - Hoist A-7

E P Pump Case Pressure B-8, C-3


E
REMOTE PANEL R Body Over Center - Service Point C-5
TEST POINT T ATAACz Fan Pressure D-2
B L/S SIGNAL

BRAKE GP- HYDRAULIC


MANIFOLD-BRAKES (FRONT AND REAR)
COOLING LINES SWITCH AS 219-6710
194-4016 BRAKE TEMPERATURE FAN DRIVE MOTOR
3E-6451 (ATAAC)
CYLINDER GP- 220-2290 T
(FRONT SUSP CYL)
CORE GP- 228-2758
OIL COOLER
4P-7731

LEFT
LEFT REAR
FRONT RELIEF VALVE
222-6472
ACTUATOR AS.
D LOWER D
BRAKE GP- HYDRAULIC 192-6443 VALVE GP
(FRONT AND REAR)
165-7948
219-6710 FAN DRIVE MOTOR
STEERING-MAIN X 240-6746
PUMP GP-(735)
224-4431
PUMP GP-(740) FAN CONTROL VALVE
MANIFOLD 263-5833
224-4432 H
BRAKES COOLING LINES
FAN DRIVE PUMP REMOTE PANEL
159-2880 SWITCH AS 210-0053 TEST POINT
H1 T1 BRAKE TEMPERATURE FAN DRIVE PUMP P A T
3E-6451 210-0053

VALVE GP-
VALVE GP-
MANUAL lOWER
(Dimensions: 39 inches x 28 inches)

TRANSMISSION
SOLENOID
(DEAD ENGINE)
265-5214
204-2124
STEERING-MAIN
PUMP GP-(735) CYLINDER GP- HOIST 740
KENR5538-01

P
224-4431 285-4034
PUMP GP-(740) CYLINDER GP- HOIST 735 PUMP GP-
REMOTE PANEL HOIST
224-4432 TEST POINT 285-4033
C 188-4455 COOLER C
A
RAISE
122-6485
VALVE GP-
BY-PASS (THERMAL)
HOLD HE RAISE 188-8726
ENGINE
TRANSMISSION

REMOTE PANEL
TEST POINT
ENGINE
RE F VALVE GP-
R CYLINDER GP- FAN DRIVE PUMP 165-7948
VALVE GP- TAILGATE (ATTACH) (ATAAC)
RELIEF FLOAT 248-5605
B 151-2611
126-6099
VALVE GP-
PUMP GP-
PUMP GP- CHECK
HOIST
BRAKES 180-4850
188-4455
LOWER 187-9090
OPEN
M
30 Page,

VALVE GP
MAIN RELIEF
S L L1 224-1167 VALVE GP-
PUMP GP-
B BALANCE (ATTACH)
(SECONDARY STEER) B
MANIFOLD 133-8810
P 141-6389
PUMP GP- 153-3528
BRAKES MANIFOLD
187-9090 COLD OIL
BY-PASS VALVE AS
L
190-1514 FLUID SAMPLING
SOS
CYLINDER GP- HOIST 740 164-5590
285-4034 VALVE GP-
H2 T2
VALVE GP- BREAKER / RELIEF
CYLINDER GP- HOIST 735
BREAKER/RELIEF 157-7911
285-4033
157-7911 REMOTE PANEL
ACTUATOR AS. TEST POINT
RAISE
VALVE GP
196-2403 J
N FLUID SAMPLING VALVE GP-HOIST
164-5590 189-5772
LINE PATTERNS
SOS
Pressure Line

SCREEN AS. Pilot / Load Sensing Pressure


119-4885 Drain / Return Lines
TANK GP- HYDRAULIC
SCREEN AS. 186-9959 Component Group
119-4885 TANK GP-HYDRAULIC ELEMENT-
SCREEN AS. Attachment
162-5242 FILTER VALVE
119-4885
A DRAIN 132-8876 1U-1643 Air Line
A
8J-8782 CALLOUTS
ELEMENT-
DRAIN FILTER SCREEN AS. YY Taps (Pressure, Sampling, Sensor - by letter)
8J-8782 132-8876 6J-3795
52 Components (By number)

SCREEN AS.
THIS SCHEMATIC IS FOR THE 735 AND 740 ARTICULATED TRUCKS
150-8457
MEDIA NUMBER: KENR5538-01
PART NUMBER: 266-6459, CHANGE: 02, VERSION: -

BRAKE, HOIST AND SUSPENSION CIRCUITS FAN AND STEERING CURCUITS Components are shown installed on a fully operable machine.

Refer to the appropriate Service Manual for Troubleshooting, Specifications.

8 7 6 5 4 3 2 1