KENR8398-03

May 2011
Component Locations
Part Machine Schematic
Description
Number Location Location
Accumulator Gp -Brake (ACC1) 291-1546 1 I-5
Accumulator Gp -Brake (ACC2) 291-1546 2 I-14
Accumulator Gp -Steering 308-2856 3 F-11
Breather 157-7911 4 D-7 31
Connector -Orifice 311-6676 6 G-4, G-5
H-13

(Dimensions: 48 inches x 35 inches)

Cylinder Gp -Telescoping, Hoist 295-5708 7
Filter -Oil, Adv Eff., Breather 4T-6788 8 D-5 14 35
Filter Gp -Case Drain 290-2569 9 D-7
Filter Gp -Fan / Steering Return 339-9706 10 A-5

KENR8398-03
Filter Gp -Oil, Brake 290-2567 11 F-5
I-9
Filter Gp -Oil, Hoist / Brk Cooling
Fitting -Orifice
339-9702
8X-7851
12
13 G-4
34 J1 J2
Fitting -Orifice 8X-7851 14 F-8 35
Fitting -Orifice 8X-7851 15 E-11
Motor Gp -Fan 240-7790 16 E-9
Pump / Motor Gp -Brake Release
Pump Gp -Fan / Steering
5T-1060
291-7263
17
18
I-8
B-9
793F Off-Highway Truck
Pump Gp -Hoist / Brake
Pump Gp -Metering (HMU)
310-4846
9T-1318
19
20
F-6
C-2
Hydraulic System
Screen -Pmp Brng Flushing Return 247-8298 21 C-7 SND1-UP
Screen Gp -Hoist Lines 6E-5472 22 H-10
SSP1-UP
Slack Adjustor Gp -Front 205-0560 23 G-2 20
Slack Adjustor Gp -Rear 205-0560 24 G-14
Valve Gp -Check 332-7350 25 C-7
Valve Gp -Check 6E-4701 26 I-5
Valve Gp -Check, Brk Rel Pump 123-4750 27 I-8
K2

36 Page,
Valve Gp -Check, Brk Rel, El Pump 123-4750 28 I-14 K3
Valve Gp -Cntrl, Hoist / Brk Cooling 247-1437 29 I-12
E-9
Valve Gp -Makeup
Valve Gp -Sol / Mnfld
183-7170
198-6577
30
31 F-8
VIEW A-A 3 48
Valve Gp -Sol / Rlf, Str Acc. 272-9849 32 E-11 VIEW A-A
Valve Gp -Steering 9T-8931 33 F-3
Mechanical Drive (Hydraulic Arrangement 278-8418)
Control Gp -Foot Brake 315-5037 34 I-13 33 32
Cylinder Gp -Steering 9T-8912 35 F-3
Filter Gp -Oil, RAX 333-6434 36 G-13
F-12
Manifold Gp-Control, RAX 299-3258 37
E
Motor Gp -Brake Cooling 198-6041 38 C-4
Motor Gp -RAX 202-9940 39 D-12 23 I1
Pump Gp -Brake Cooling 197-8885 40 C-5
Pump Gp -RAX 214-1555 41 D-12
A 62 15
Screen As -Hydr. Oil Cooler 42 I-9
Tank Gp -Hydraulic
149-2754
288-5701 43 B-5
21 © 2011 Caterpillar, All Rights Reserved Printed in U.S.A.

44 H-4
Valve / Mtg Gp -Cntrl, Brks, Std Whl 285-5630
K4
Valve / Mtg Gp -Cntrl, Brks, XL Whl 283-9559 45 H-3 K1 STEERING CONTROL
Valve Gp -Relief, Brake Oil Cooler 6E-5855 46 D-5
I-7
Valve Gp -Traction Control 222-4744
Attachments
47
46
Accumulator Gp -Steering (PED) 308-3556 48 F-11 17 53
Cooler Gp -RAX Oil Cooler 320-8196 49 G-11 FLUID POWER SYMBOLS
Motor Gp -RAX Oil Cooler Fan 307-1504 50 G-11 BASIC COMPONENT SYMBOLS

Plug As -Rear Axle Cooler 242-7114 51 D-8 54

Valve Gp -Press. Rdc, Rad Fan Cntrl 226-0835 52 D-9 PUMP or MOTOR FLUID CONDITIONER SPRING CONTROL VALVES RESTRICTION LINE RESTRICTION
MAIN AUX.

2-SECTION PUMP
PUMP: VARIABLE and
PRESSURE COMPENSATED

Misc. Ref. Left Side, Center of Chassis (FIXED)

J-8 B
Core As -Oil Cooler, Brake
Core As -Oil Cooler, Brake
290-2729
336-9641
53
54 J-9
40 VARIABILITY SPRING LINE RESTRICTION PRESSURE HYDRAULIC PNEUMATIC LINE RESTRICTION ATTACHMENT

27 COMPENSATION
(ADJUSTABLE) (VARIABLE) ENERGY TRIANGLES VARIABLE and PRESSURE
COMPENSATED

Core Gp -Oil Cooler, Steering 199-6683 55 A-8 VALVES

Sensor Gp -Press., Brake Pump 221-3405 56 I-5 24 38 57 45 44 56 26 G 2 VALVE ENVELOPES VALVE PORTS

Sensor Gp -Press., Brk Acc. (ACC1) 221-3405 57 I-5 12

Sensor Gp -Press., Brk Acc. (ACC2) 221-3405 58 I-13 I2 H ONE POSITION TWO POSITION THREE POSITION TWO-WAY THREE-WAY FOUR-WAY

Sensor Gp -Press., Differential Oil 221-3415 59 F-12 64 CONTROL VALVES CHECK VALVES

Sensor Gp -Press., Rr Brk Oil, LH 221-3410 60 I-7

K6 42 AB AB

Sensor Gp -Press., Rr Brk Oil, RH 221-3410 61 E-9 P T P T

BASIC SPRING SHUTTLE PILOT
NORMAL POSITION SHIFTED POSITION INFINITE POSITION
Sensor Gp -Press., Steering Acc. 221-3405 62 E-11 SYMBOL LOADED CONTROLLED

Sensor Gp -Press., Steering Pump 221-3405 63 F-8 K8 28 FLUID STORAGE RESERVOIRS

C-5
Sensor Gp -Speed, Clng Pmp Drive
Sensor Gp -Speed, Fan
186-0131
186-0131
64
65 H-7
1 VENTED PRESSURIZED RETURN ABOVE FLUID LEVEL RETURN BELOW FLUID LEVEL

Switch As -Press., Serv. Brake (Frnt) 128-5091 67 G-4 MEASUREMENT ROTATING SHAFTS

Switch As -Press., Serv. Brake (Rear) 128-5091 68 G-6

6 PRESSURE TEMPERATURE FLOW UNIDIRECTIONAL BIDIRECTIONAL

Tap Locations COMBINATION CONTROLS

Pressure, Sampling and Sensor

Tap Schematic
Description SOLENOID SOLENOID SOLENOID SOLENOID and SERVO THERMAL DETENT
Number Location or MANUAL and PILOT PILOT or MANUAL

Brake Pump Filter Outlet Pressure R F-5 MANUAL CONTROL SYMBOLS

Brake Pump Pressure N F-6

Case Drain Return Filter Pressure P2 C-7 PUSH-PULL LEVER MANUAL SHUTOFF GENERAL MANUAL PUSH BUTTON PEDAL SPRING

Front Slack Adjuster Pressure I1 G-1 PILOT CONTROL SYMBOLS

RELEASED PRESSURE REMOTE SUPPLY PRESSURE
Front, Left Parking Brake Release Press. J1 J-1 J3 J4 K5 K7
Front, Right Parking Brake Release Press. J2 D-1
Hoist Control Pilot Pressure L1 H-11 EXTERNAL RETURN INTERNAL RETURN SIMPLIFIED COMPLETE INTERNAL
SUPPLY PRESSURE

Hoist Control Pilot Pressure L2 G-11 ACCUMULATORS CROSSING AND JOINING LINES HYDRAULIC AND PNEUMATIC CYLINDERS

Hoist Pump 1 Pressure M1 F-6

Hoist Pump 2 Pressure M2 F-6 SPRING LOADED GAS CHARGED LINES CROSSING LINES JOINING SINGLE ACTING DOUBLE ACTING

Left, Front Wheel, Brake Cooling Input Press. K1 J-2 P1 13 58 R 11 HYDRAULIC PUMPS HYDRAULIC MOTORS INTERNAL PASSAGEWAYS
Left, Front Wheel, Brake Cooling Output Press. K2 I-1
J-13
FIXED VARIABLE DISPLACEMENT FIXED VARIABLE DISPLACEMENT INFINITE THREE TWO
Left, Rear Wheel, Brake Cooling Input Press. K5 DISPLACEMENT NON-COMPENSATED DISPLACEMENT NON-COMPENSATED POSITIONING POSITION POSITION

Left, Rear Wheel, Brake Cooling Output Press. K6 I-14

Left, Rear Wheel, Traction Pilot Pressure S1 I-7 UNIDIRECTIONAL UNIDIRECTIONAL

Purge Point for Comissioning P1 H-3 BIDIRECTIONAL BIDIRECTIONAL

FLOW IN ONE
DIRECTION
PARALLEL
FLOW
CROSS
FLOW
FLOW ALLOWED IN
EITHER DIRECTION

Radiator Fan Pressure F D-9 SERVICE and PARKING BRAKES BRAKE COOLING BRAKE CONTROL
RAX System Pressure Q E-12
Rear Slack Adjuster Pressure I2 G-14
Rear, Left Parking Brake Release Press. J3 J-14
Rear, Right Parking Brake Release Press. J4 B-14
Right, Front Wheel, Brake Cooling Input Press. K3 E-2
Right, Front Wheel, Brake Cooling Output Press. K4 D-2
Right, Rear Wheel, Brake Cooling Input Press. K7 C-14
Right, Rear Wheel, Brake Cooling Output Press. K8 B-14
S2 H-7
Electrical Symbols Table
Right, Rear Wheel, Traction Pilot Pressure Viewed from Rear and Above Hydraulic Symbols (Electrical)
I-5
Secondary Retract Accumulator Pressure
Service Brake Acummulator Pressure
H
G I-4
8
SOS, Brake Actuation C I-6
G M
SOS, Hoist and Brake Cooling B I-9
SOS, Strg, Fan, Drive A E-10 Transducer Transducer Generator Electric Motor
Steering Accumulator Pressure E E-3 (Fluid) (Gas / Air)
Steering Pump Pressure D F-8
Supply Pump Pressure P3 C-9
50 49 22

Fan Steering
18 M2 M1 N Pressure Switch Pressure Switch Temperature Switch Electrical Wire

Viewed From Front L2 Pump Pump (Adjustable)

59
Electrical Symbols (Electrical)
55 29
63 L1 Pressure Temperature
T

Level Flow
51
4 Symbol Symbol Symbol Symbol

D Wire Number Identification Codes

10 Electrical Schematic Example Hydraulic Schematic Example

31 Q
Current Standard Current Standard
43 Pump Hoist Brake
7 P3 Drive Pump
19 Pump
Harness identification code
This example indicates
wire 135 in harness "AG". Wire
Circuit Number Wire Color
Identification

39 41 36 37 325-AG135 PK-14

7 Circuit Identification
Number
Wire Color Wire Gauge
325-PK

Previous Standard
25 9 P2 Wire Color
Wire

F 30 16 65 325-PK-14
B A
Circuit Number Wire Gauge
Identification (EXAMPLE VALVE)

FAN CIRCUIT RAX OIL COOLER HOIST CONTROL HYDRAULIC OIL TANK PUMPS and DRIVE
 14 13 12 11 10 9 8 7 6 5 4 3 2 1

K5 K1
J3

J J1 J
(54) CORE AS - OIL COOLER (53) CORE AS - OIL COOLER
BRAKE: 336-9641 BRAKE: 290-2729
(Dimensions: 48 inches x 35 inches)

(Extra Retarding Only)

(2) ACCUMULATOR GP
LEFT REAR (28) VALVE GP - CHECK BRAKE (ACC2)

B (1) ACCUMULATOR GP BRK REL: 123-4750 291-1546

KENR8398-03

BRAKE (ACC1) (26) VALVE GP

SOS 291-1546 CHECK: 6E-4701 LEFT FRONT
(29) VALVE GP - CONTROL
HOIST / BRK COOLING: (57) SENSOR GP - G
K6 247-1437
(27) VALVE GP
CHECK BRK REL
(60) SENSOR GP PRESS. BRK (Acc1)
221-3405
H (56) SENSOR GP
PRESS. RR BRK OIL, LH PRESS. BRAKE PUMP
EL PUMP: 123-4750
(12) FILTER GP - OIL 221-3410 221-3405 (58) SENSOR GP K2
HOIST / BRK COOLING
339-9702 (42) SCREEN AS
C PRESS. BRK (ACC2)
221-3405
HYDR. OIL COOLER
149-2754
S1
I DUAL STAGE (Extra Retarding Only) I

HOIST

ACC2
ACC1

PS2

TCS
RV1

PS1
RAX

BCD
SIGNAL SPOOL PS3
HIGH PRESS.
RLF
SV3

LE1
SQ1
(34)CONTROL GP
MAIN RELIEF
FOOT BRAKE
M
T2
LOW PRESS. DUMP SPOOL
RLF 315-5037
(22) SCREEN GP SV2 PR1
HOIST LINES FL1

6E-5472
36 Page,

OR1

S2 CV1 CV2
TSB
(17) PUMP / MOTOR GP P A
BRAKE RELEASE
L1 5T-1060
TANK
T1
T

PLUG1
HF1 SV1 HF2
(65) SENSOR GP PD2 PD3
H H
HF3

PRESS. RR BRK OIL, RH PD1

SIGNAL
ORIFICE #2 ROD END VENT 221-3410
SLOT ACROSS 0R3 0R4
0R7 0R8

P1
STEM
SIGNAL (47) VALVE GP 0R5 0R6
ORIFICE #1 COUNTERBALANCE
VALVE CARTRIDGE
TRACTION CONTROL 0R2 0R9
SH2
SH1
222-4744
PB (23) SLACK ADJ GP
(7) CYLINDER GP FSB
FRONT: 205-0560
TELESCOPING
HOIST: 295-5708 L2 PS5 R SUPPLY PS4 F

(6) CONNECTOR
(44) VALVE / MTG GP - CONTROL BRAKES
(24) SLACK ADJ GP (13) FITTING ORIFICE ORIFICE: 311-6676
(6) CONNECTOR (STD WHL): 285-5630
REAR: 205-0560 A.C. ONLY: 8X-7851
ORIFICE ORIFICE: 311-6676 (45) VALVE / MTG GP - CONTROL BRAKES
(68) SWITCH AS - PRESS. (13) FITTING ORIFICE (XL WHL) NOT SHOWN: 283-9559
SERV. BRK (REAR) A.C. ONLY: 8X-7851
I2 Spool sections by color = RAISE HOLD SNUB FLOAT LOWER
A.C. ONLY: 128-5091

(67) SWITCH AS - PRESS.

G SERV. BRK (FRNT) G
(49) COOLER GP - 128-5091 I1
RAX OIL CLR
320-8196

(36) FILTER GP (35) CYLINDER GP - STEERING

OIL, RAX: 333-6434 9T-8912, 205-0560

(31) VALVE GP
SOL/ MNFLD
198-6577 R
B

(50) MOTOR GP
RAX OIL CLR FAN
307-1504 CL CR (33) VALVE GP
(14) FITTING
ORIFICE 8X-7851 STEERING
(11) FILTER GP 9T-8931
F (59) SENSOR GP
(63) SENSOR GP OIL BRAKE
F
PRESS. DIFF. OIL ACCUMULATOR GP
STEERING (PED) PRESS. STEER ACC. 290-2567
221-3415
221-3405 (19) PUMP GP
(51) PLUG AS
REAR AXLE CLR
(48) 308-3556, (3) 308-2856
SW N M1 M2 HOIST / BRAKE L R
A 310-4846
242-7114 P

TO
MECHANICAL FAN / STEERING
D PUMP DRIVE PUMP P
(15) FITTING K3
ORIFICE: 8X-7851

(37) MANIFOLD GP
CONTROL RAX:
299-3258 EF
T
(62) SENSOR GP
E PRESS. STEER ACC.
(61) SENSOR GP E
221-3405
Q SPEED, FAN: 186-0131 HP LS HT
(32) VALVE GP - SOL / RLF A (30) VALVE GP
MAKEUP: 183-7170
STR ACC.: 272-9849
RIGHT FRONT
E
F

(16) MOTOR GP
FAN: 240-7790
K4 J2
(8) FILTER OIL
(4) BREATHER
D BREATHER: 4T-6788 D
157-7911

(52) VALVE GP -
(9) FILTER
PRESS RDC. RAD.
CASE DRAIN
FAN CNTRL: 226-0835
290-2569

(46) VALVE GP
RELIEF BRAKE
OIL COOLER U B M1
(39) MOTOR GP - 6E-5855
FINAL RAX: 202-9940 (20) PUMP GP
DIFFERENTIAL
DRIVE METERING (HMU)
(41) PUMP GP - 9T-1318
(25) VALVE GP
P2
RAX: 214-1555
P3 CHECK: 332-7350
(40) PUMP GP
BRAKE COOLING (38) MOTOR GP -
197-8885 BRAKE COOLING
C 198-6041 C
REAR AXLE BANJO HOUSING SUMP
SEE POWERTRAIN SCHEMATIC (64) SENSOR GP - SPEED
COOLING PUMP DRIVE
186-0131
T1 T2 R G2 A Ma SL Mb B G1 R T2 T1 U2 (21) SCREEN -
PUMP BEARING
FLUSHING RET.:
K7 247-8298

Qmin Qmax Qmax Qmin

TO
MECHANICAL (43) TANK GP
DRIVE HYDRAULIC
288-5701
HYDRAULIC CIRCUIT DESCRIPTIONS
B B
M1 S M1 U1 L1 BRAKE RELEASE PUMP AND CIRCUIT
RIGHT REAR (18) PUMP GP HOIST PUMP AND CIRCUIT
FAN / STEERING
291-7263 STEERING CIRCUIT
SUPPLY LINE
FAN PUMP AND CIRCUIT
(55) CORE GP - OIL COOLER
BRAKE PUMP AND CIRCUIT
K8 J4 STEERING: 199-6683
LINE PATTERNS SUPPLY PUMP AND CIRCUIT
(10) FILTER GP Pressure Line PARKING BRAKE CIRCUIT
FAN/ STEER RETURN REAR AXLE LUBE PUMP AND CIRCUIT
339-9706 Pilot / Load Sensing Pressure
DRAIN / RETURN LINE
Drain / Return Lines
DRAIN / BRAKE COOLING
Component Group
A A
793F OFF-HIGHWAY TRUCK HYDRAULIC SCHEMATIC
CALLOUTS
MEDIA NUMBER: KENR8398-03
YY Taps (Pressure, Sampling, Sensor - by letter) PART NUMBER: 278-8439, CHANGE: 00,
Callout Number Component Components are shown installed on a fully operable machine.
(Machine Location from (52) VALVE GP - CONTROL Name
Component LocationsTable)

BRAKE SYSTEM, STEER AND FAN, HOIST AND BRAKE COOLING, MECHANICAL DRIVE: RM757 and RM952 138-1234 Part Number Refer to the appropriate Service Manual for Troubleshooting, Specifications.

14 13 12 11 10 9 8 7 6 5 4 3 2 1