INTERACTIVE SCHEMATIC

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 KENR9942-01
November 2011

777G Off-Highway Truck

Hydraulic System
T5A1-UP
T4Y1-UP
TNM1-UP
RDR1-UP

Volume 1 of 3: Steering System and Rear Axle Lube System

Volume 2 of 3: Hoist and Brake Cooling System
Volume 3 of 3: Service Brakes, Parking Brakes and Traction Control System
COMPONENT LOCATION
Volume 1 of 3 - STEERING AND REAR
AXLE LUBE SYSTEMS

COMPONENT LOCATIONS (VOLUME 1)

Part Machine Schematic

Description
Number Location Location
SWITCH AS-PRESSURE (SECONDARY STEERING LOAD SENSING) 9X-4455 1 D-4
PUMP GP-ELECTRIC 2 SECTION (STEERING) 319-5405 *2 D-4
TANK GP-HYDRAULIC 331-7128 3 B-3
VALVE AS - VACUUM RELIEF BREATHER (STEERING) 358-9476 4 C-4
FILTER GP-OIL (STEERING PUMP RETURN) 158-3491 5 C-3
VALVE GP-STEERING DISABLE CHECK 346-6351 6 D-3
PUMP GP-HAND METERING UNIT (STEERING) 195-6617 7 F-3
CYLINDER GP - STEERING (POSITION SENSING) 334-8703 8 F-3
CYLINDER GP - STEERING 105-2440 9 F-2
SENSOR GP-PRESSURE (MAIN STEERING PUMP) 344-7391 *10 D-2
PUMP GP-LOAD SENSING CONTROL WITH HIGH PRESSURE CUTOFF 261-5630 11 C-1
FILTER GP-OIL (STEERING CASE DRAIN) 249-2334 12 B-2
SENSOR AS-FLUID LEVEL MONITORING 330-9321 *13 B-2
* = (2) See also Volume 3
* = (10) See also Volume 3
* = (13) See also Volume 2 and Volume 3

COMPONENT LOCATIONS - REAR AXLE LUB ATTACHMENT (VOLUME 1)

Part Machine Schematic
Description
Number Location Location
MANIFOLD GP - REAR AXLE CONTROL 333-0362 42 E-7
PUMP and MOTOR GP - REAR AXLE LUBE 249-7012 43 E-6
MANIFOLD AS - REAR AXLE 327-0361 44 E-6
FILTER GP - REAR AXLE 192-3841 45 D-5
COMPONENT LOCATION
Volume 2 of 3 - HOIST AND BRAKE COOLING

COMPONENT LOCATIONS (VOLUME 2)

Part Machine Schem atic
Description
Num ber Location Location
SENSOR GP - LEVEL *13 330-9321 A-6
D-1
F-1
SENSOR GP - TEMPERATURE 14 134-2252
D-7
F-7
BRAKE GP - SERVICE and PARK *15 308-3208 C-6, F-6
CORE AS - OIL COOLER 16 200-5975 E-5
TANK GP (HYD) *17 331-7060 A-3
PUMP GP - 4 SECTION PUMP (CCW) 18 350-9965 B-5
PUMP GP - 3 SECTION PUMP (CCW) 19 375-0678 B-4, B-3
FILTER - BREATHER 20 8X-4575 B-4, B-3
CYLINDER GP - TELESCOPING (HOIST) 21 296-0608 B-3, C-3
PLATE - ORIFICE (HOIST) 22 8X-7224 B-3, C-3
VALVE GP - CONTROL (HOIST) 23 245-1668 F-4
PLATE AS - BRAKE COOLING ORIFICE 24 382-9203 D-2
BRAKE GP - SERVICE 25 330-9471 B-3
* = (13) See also Volume 1 and Volume 3
* = (15) See also Volume 3
* = (17) See also Volume 3
COMPONENT LOCATION
Volume 3 of 3 - SERVICE AND PARKING
BRAKES AND TRACTION CONTROL

COMPONENT LOCATIONS (VOLUME 3)

Part Machine Schematic
Description
Number Location Location
PUMP GP - ELECTRIC 2 SECTION PUMP 319-5405 *2 B-4
SENSOR AS. - PRESSURE (LOW BRAKE SUPPLY) 344-7391 *10 D-3
SENSOR GP - FLUID LEVEL MONITORING 330-9321 *13 A-5
BRAKE GP - SERVICE and PARK (REAR) 308-3208 *15 A-7, E-7
TANK GP - HYDRUALIC 331-7060 *17 A-3
PUMP GP - 3 SECTION PUMP (CCW) 375-0678 *19 B-3
FILTER - BREATHER (HOIST TANK) 8X-4575 20 A-4
BRAKE GP - SERVICE (FRONT) 330-9471 *25 C-1, E-1
ADJUSTER GP - SLACK ADJUSTER (REAR BRAKES) 319-6291 26 B-7, D-7
VALVE GP - ARC/TCS 340-6409 27 C-7
SWITCH AS.- PRESSURE (SECONDARY BRAKE DEACTIVATION INDICATOR) 160-2609 28 F-6
VALVE GP - SECONDARY BRAKE (ACCUMULATOR BLEED DOWN) 361-2239 29 F-5
APAPTER AS. - ORIFICE 357-4342 30 B-6, D-6
MANIFOLD GP - TOW VALVE (BRAKE) 309-1615 31 C-4
ACCUMULATOR GP - PARK BRAKE 360-3828 32 D-3
ACCUMULATOR GP - PARK BRAKE (PED CERTIFIED) (ATTACHMENT) 330-7828 32 D-3
ACCUMULATOR GP - SERVICE BRAKE 356-3346 33 D-2
ACCUMULATOR GP - SERVICE BRAKE (PED CERTIFIED) (ATTACHMENT) 318-2532 33 D-2
VALVE GP - CAB MANIFOLD (FRONT BRAKE) 334-8054 34 B-4
VALVE GP - ACCUMULATOR CHARGING 341-2634 35 B-3
VALVE GP - ACCUMULATOR CHARGING (PED CERTIFIED) (ATTACHMENT) 320-5075 35 B-3
SWITCH AS - BRAKE FILTER BYPASS SWITCH 156-1382 36 B-4
FILTER GP - BRAKE CHARGE 335-0980 37 C-4
PEDAL GP - SERVICE BRAKE PEDAL VALVE 342-9078 38 F-3
ADJUSTER GP - SLACK ADJUSTER (FRONT BRAKES) 8X-7921 39 D-2
* = (2) See also Volume 1
* = (10) See also Volume 1
* = (13) See also Volume 1 and Volume 2
* = (15) See also Volume 2
* = (17) See also Volume 2
* = (19) See also Volume 2
* = (20) See also Volume 2
TAP LOCATION

TAP LOCATIONS
Pressure, Sampling, Sensor
Schematic
Tap Number Description
Location
A REAR PARKING BRAKES (VOL. 3) F-7
B LEFT REAR SERVICE BRAKE (VOL. 3) D-7
C RIGHT REAR SERVICE BRAKE (VOL. 3) B-7
D BRAKE ACCUMULATOR CHARGE (VOL. 3) D-3
E BRAKE CHARGE PUMP OUTPUT (VOL. 3) B-4
F FRONT SERVICE BRAKES (VOL. 3) D-1
G LEFT REAR BRAKE COOLING OUT (VOL. 2) F-7
H LEFT REAR BRAKE COOLING IN (VOL. 2) F-6
I RIGHT REAR BRAKE COOLING OUT (VOL. 2) D-7
J RIGHT REAR BRAKE COOLING IN (VOL. 2) D-6
K BRAKE COOLER OUT (SOS) (VOL. 2) E-5
M HOIST PUMP OUTPUT (VOL. 2) B-4
N HOIST CYLINDER HEAD END (VOL. 2) C-3
O HOIST CYLINDER ROD END (VOL. 2) C-3
P HOIST LOWER PILOT (VOL. 2) E-3
Q HOIST RAISE PILOT (VOL. 2) D-3
R FRONT BRAKE COOLING IN (VOL. 2) E-2
S FRONT BRAKE COOLING OUT (VOL. 2) C-1
T STEERING RETURN (SOS) (VOL. 1) C-3
U HMU INPUT (VOL. 1) D-2
V STEERING LOAD SENSE (VOL. 1) D-1
W REAR AXLE LUBRICATION (VOL. 1) E-6
FLUID POWER SYMBOLS
BASIC COMPONENT SYMBOLS

MAIN AUX.
PUMP: VARIABLE and
PUMP or MOTOR FLUID CONDITIONER SPRING CONTROL VALVES RESTRICTION LINE RESTRICTION 2-SECTION PUMP PRESSURE COMPENSATED
(FIXED)

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

VALVE ENVELOPES
VALVES
VALVE PORTS

ONE POSITION TWO POSITION THREE POSITION TWO-WAY THREE-WAY FOUR-WAY

CONTROL VALVES CHECK VALVES

AB AB

P T P T
BASIC SPRING SHUTTLE PILOT
NORMAL POSITION SHIFTED POSITION INFINITE POSITION
SYMBOL LOADED 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 SOLENOID SOLENOID and SERVO THERMAL DETENT

or MANUAL and PILOT PILOT or MANUAL

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 HYDRAULIC MOTORS INTERNAL PASSAGEWAYS

FIXED VARIABLE DISPLACEMENT FIXED VARIABLE DISPLACEMENT INFINITE THREE TWO

DISPLACEMENT NON-COMPENSATED DISPLACEMENT NON-COMPENSATED POSITIONING POSITION POSITION

UNIDIRECTIONAL UNIDIRECTIONAL

FLOW IN ONE PARALLEL CROSS FLOW ALLOWED IN

BIDIRECTIONAL BIDIRECTIONAL DIRECTION FLOW FLOW EITHER DIRECTION
ELECTRICAL SYMBOLS
Hydraulic Symbols (Electrical)

G M
Transducer Transducer Generator Electric Motor
(Fluid) (Gas / Air)

Pressure Switch Pressure Switch Temperature Switch Electrical Wire

(Adjustable)

Electrical Symbols (Electrical)

Pressure Temperature Level Flow

Symbol Symbol Symbol Symbol

Wire Number Identification Codes

Electrical Schematic Example Hydraulic Schematic Example

Current Standard Current Standard

Harness identification code
This example indicates
wire 135 in harness "AG". Wire
Circuit Number Wire Color
Identification

325-AG135 PK-14
325-PK
Circuit Identification Wire Color Wire Gauge
Number

Previous Standard
Wire Color
Wire

325-PK-14
B A
Circuit Number Wire Gauge
Identification (EXAMPLE VALVE)
 7 6 5 4 3 2 1

(8) CYLINDER GP - STEERING

(9) CYLINDER GP - STEERING
(POSITIONING SENSING)
105-2440
334-8703

F F
L R

(7) PUMP GP - HAND METERING UNIT CROSS OVER RELIEF

195-6617

FROM BRAKE SYSTEM

(Vol. 3 / B-3 ) W
(42) MANIFOLD GP - REAR AXLE
CONTROL: 333-0362
E E

T P LS
(44) MANIFOLD AS - REAR AXLE: 327-0361

1 1
(10) SENSOR GP -

U
PRESSURE

M
344-7391

(2) PUMP GP - ELECTRIC 2 SECTION

(SECONDARY STEERING)
319-5405
2 2
(43) PUMP and MOTOR GP -
REAR AXLE LUBE: 249-7012 D B PS SS HMU LS
PR1 C

LST
SECONDARY
TO BRAKE COOLING TO TOW VALVE DRAIN LS RELIEF PRIMARY
(Vol. 2 / E-5 ) (Vol. 3 / B-4 ) RELIEF
(45) FILTER GP - REAR AXLE:
D
V D
192-3841

STEERING

M
BRAKE SYSTEM
STEERING RETRACT DISABLE
SECTION SECTION SOLENOID
LS

S2
E A
(1) SWITCH AS - PRESSURE
(STEERING) 9X-4455

(6) VALVE GP - STEERING DISABLE CHECK

346-6351 P
(11) PUMP GP - LOAD SENSING CONTROL
261-5630

T
LEFT RIGHT
C (5) FILTER GP - OIL C
SPINDLE SPINDLE 158-3491

S C
REAR AXLE HOUSING

(4) VALVE AS - VACUUM RELIEF BREATHER

358-9476

(12) FILTER GP - OIL (STEERING CASE DRAIN)

249-2334

(13) SENSOR AS - FLUID LEVEL MONITORING

330-9321

FULL
B B
FILL

HYDRAULIC CIRCUIT COLOR DESCRIPTIONS

LOW STEERING CIRCUIT
SUPPLY LINE
BRAKE CIRCUIT
DRAIN / RETURN LINE
(3) TANK GP - HYDRAULIC
331-7128 LINE PATTERNS
Pressure Line

Pilot / Load Sensing Pressure

Drain / Return Lines

OPTIONAL REAR AXLE LOAD SENSE AND Component Group

Attachment
LUBRICATION SYSTEM STEERING SYSTEM Air Line

CALLOUTS
A YY Taps (Pressure, Sampling,Sensor) by letter A
52 Components by number

777G OFF HIGHWAY TRUCK HYDRAULIC SYSTEM SCHEMATIC

MEDIA NUMBER: KENR9942-01, VOLUME 1 of 3
HYDRAULIC CIRCUIT COLOR DESCRIPTIONS PART NUMBER: 309-2869, CHANGE: 03, VERSION: --
REAR AXLE LUBRICATION CIRCUIT
Components are shown installed on a fully operable machine.
SUPPLY LINE
BRAKE COOLING CIRCUIT Refer to the appropriate Service Manual for Troubleshooting, Specifications.
DRAIN / RETURN LINE

7 6 5 4 3 2 1
 7 6 5 4 3 2 1

(15) BRAKE GP - SERVICE and PARK (14) SENSOR GP - TEMP

308-3208 FROM BRAKE
134-2252
SYSTEM
(Vol. 1 / B-5 )
(14) SENSOR GP - TEMP (23) VALVE GP - PROPORTIONAL CONTROL 245-1668
134-2252

DUAL STAGE
H SIGNAL SPOOL

G MAIN RELIEF
DUMP SPOOL
F RAISE
F
RELIEF

FROM BRAKE SYSTEM

(Vol. 1 / B-3 )
FROM REAR AXLE
LUBRICATION
LOWER
(Vol. 1 / B-3 )
RELIEF
LEFT REAR LOWER, LEFT FRONT
FLOAT,
SNUB
SOLENOID
(25) BRAKE GP - SERVICE
330-9471

E P E

RAISE

B
(16) CORE AS - REAR BRAKE OIL
A
200-5975 H1 HOLD
R1 T

SNUB
R (14) SENSOR GP - TEMP
134-2252

(25) BRAKE GP - SERVICE

330-9471
FLOAT
(14) SENSOR GP - TEMP
134-2252
K
RIGHT REAR RIGHT FRONT
LOWER
D BRAKE D
I
COOLING

Q
RELIEF

RAISE
J SOLENOID (24) PLATE AS. -
BRAKE COOLING ORIFICE
382-9203

(15) BRAKE GP - SERVICE and PARK

308-3208
S2

C
S C

(22) PLATE - ORIFICE

8X-7224

N
M O
(21) CYLINDER GP - HOIST
296-0608

(19) PUMP GP - 3 SECTION:

375-0678

(18) PUMP GP. - 4 SECTION BRAKE BRAKE

350-9965 HOIST
CHARGE COOLING
B B
HOIST AND BRAKE
TRANS T/C TRANS BRAKE
(20) CLEANER AS - BREATHER
8X-4575
COOLING SYSTEM
SCAV PUMP CHARGE COOLING
HYDRAULIC CIRCUIT COLOR DESCRIPTIONS
HOIST CYLINDER CIRCUIT
SUPPLY LINE
BRAKE CIRCUIT
DRAIN / RETURN LINE
HOIST PUMP CIRCUIT
BRAKE COOLING

(13) SENSOR AS - FLUID LEVEL MONITORING

330-9321 LINE PATTERNS
FULL Pressure Line

Pilot / Load Sensing Pressure

FILL Drain / Return Lines

Component Group

Attachment
LOW Air Line

CALLOUTS
A A
YY Taps (Pressure, Sampling,Sensor) by letter

52 Components by number

777G OFF HIGHWAY TRUCK HYDRAULIC SYSTEM SCHEMATIC

MEDIA NUMBER: KENR9942-01, VOLUME 2 of 3
(17) TANK GP - HYDRAULIC PART NUMBER: 309-2869, CHANGE: 03, VERSION: --
331-7060 Components are shown installed on a fully operable machine.

Refer to the appropriate Service Manual for Troubleshooting, Specifications.

7 6 5 4 3 2 1
 7 6 5 4 3 2 1

(28) SWITCH AS - PRESSURE

160-2609
(38) CONTROL GP - BRAKE PEDAL
PS (29) VALVE GP - 342-9078
SECONDARY BRAKE / ACCUMULATOR
361-2239
PARK BRAKE
SOLENOID
F F
ACC. BLEED
SOLENOID
P

A A

B T

(34) VALVE GP - FRONT BRAKE MANIFOLD F

334-8054
P

(25) BRAKE GP - SERVICE (FRONT)

(15) BRAKE GP - SERVICE and PARK (REAR)
330-9471
308-3208 FRONT BRAKE
E SOLENOID E

14
P1
ACC

B T T1

LEFT REAR
(33) ACCUMULATOR GP -
SERVICE BRAKE:
356-3346

F
D (30) ADAPTER AS - ORIFICE
(32) ACCUMULATOR GP -
D D
357-4342
PARK BRAKE:
360-3828 (10) SENSOR GP -
PRESSURE
ACC SLK2 344-7391
(26) ADJUSTER GP -
REAR BRAKE SLACK
319-6291
LH BRAKE
SOLENOID

A2 A1 SW A3
ARC/TCS (39) ADJUSTER GP - SLACK
ENABLE
8X-7921
SOLENOID

(31) MANIFOLD GP -
TOW VALVE (BRAKE)
PDL 309-1615

C A2 C
RH BRAKE
(27) VALVE GP - ARC/TCS SOLENOID
(37) FILTER GP -
340-6409 BRAKE CHARGE OIL
335-0980

(25) BRAKE GP - SERVICE (FRONT)

330-9471

TOW
PUMP
RELIEF
TANK SLK1

(30) ADAPTER AS - ORIFICE

357-4342 (36) SWITCH AS -
PRESSURE
SERVICE BRAKES,
HOIST
(26) ADJUSTER GP - PILOT 156-1382 (35) MANIFOLD GP -
S PRV P T
REAR BRAKE SLACK ACCUMULATOR CHARGE: 341-2634
319-6291 (35) MANIFOLD GP -
ACCUMULATOR CHARGE (PED CERT): 341-2634
PARKING BRAKES,
AND
TRACTION CONTROL
B
TO HOIST PILOT
(Vol. 2 / F-2 ) (2) PUMP GP -
ELECTRIC 2 SECTION
E TO BRAKE
COOLING
(Vol. 2 / F-5)
SYSTEM
B
319-5405
TO BRAKE
COOLING LINE PATTERNS
(Vol. 2 / F-5)
P Pressure Line

Pilot / Load Sensing Pressure

M
RIGHT REAR BRAKE
SECONDARY Drain / Return Lines
RETRACT
STEERING
SECTION BRAKE BRAKE
HOIST Component Group
CHARGE COOLING
S1 (19) PUMP GP - 3 SECTION: 375-0678 Attachment

Air Line

CALLOUTS

C (20) CLEANER AS -
YY Taps (Pressure, Sampling,Sensor) by letter

BREATHER 52 Components by number

8X-4575

CIRCUIT COLOR DESCRIPTIONS

(13) SENSOR AS - FLUID LEVEL MONITORING
BRAKE CHARGE PUMP
330-9321 HOIST CIRCUIT
(15) BRAKE GP - SERVICE and PARK (REAR) FULL SUPPLY LINE
308-3208 (17) TANK GP - HYDRAULIC: 331-7060
A DRAIN / RETURN LINE A
DRAIN / BRAKE COOLING PUMP
FILL STEERING PUMP
BRAKE RETRACT CIRCUIT

777G OFF HIGHWAY TRUCK HYDRAULIC SYSTEM SCHEMATIC

MEDIA NUMBER: KENR9942-01, VOLUME 3 of 3
PART NUMBER: 309-2869, CHANGE: 03, VERSION: --
LOW
Components are shown installed on a fully operable machine.

Refer to the appropriate Service Manual for Troubleshooting, Specifications.

7 6 5 4 3 2 1
LEFT VIEW
VIEW ALL CALLOUTS

13 11 34 19 M 26

43

25 W

AA

42

17
29
1
16 FRONT 28
31
2 18
D
33
F 39 8 35 25 32
RIGHT VIEW
VIEW ALL CALLOUTS

30 27 B 21 4 3 R
7 38

14

22
20
23 6
24
S 9 V
E T
36 37 U FRONT
12 5

10
REAR VIEW
VIEW ALL CALLOUTS

G J

H I

44

45

15
HOIST CONTROL VALVE
VIEW ALL CALLOUTS

P Q

N
O