Component Locations

Description Part Number Steering Circuit

223-1335 8J-8782 132-8876 160-9727 141-6389 224-4431 224-4432 119-4885 6J-3795 3E-6450 186-9959 1U-1643 157-7911 165-7948 180-4850 176-5691 122-6485 263-5833 240-6746 220-2290 210-0053 248-5605 222-6472 188-8726 265-5214

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

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

Description

Part Number
188-4455 150-8457 119-4885 162-5242 133-8810 157-7911 189-5772 224-1167 204-2124 126-6099

Machine Location
39 40 41 42 43 44 45 46 47 48 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 80

Schematic Location
C-7 A-7 A-7 A-7 B-5 A-8 B-6, C-6 C-6 C-6 C-6 F-5 F-7 F-5 D-4, F-4 D-8, F-8 D-7 D-5 D-8 B-8 F-7 F-7 D-5, D-7 F-6 F-5 F-6 F-6 F-5 F-7 F-5 F-6 F-6 F-5 D-5

KENR5538-01 January 2009

FLUID POWER SYMBOLS

BASIC COMPONENT SYMBOLS
MAIN AUX

Hoist Circuit - Continuned

Pump - Hoist Screen As. Screen As. - Pump Case Drain Tank - Hyd. Oil (Hoist/ Cooling) Valve Gp - Balance (Attach) Valve Gp - Breaker/ Relief Valve Gp - Hoist Valve Gp - Main Relief Valve Gp - Manual Lower Valve Gp - Relief Accumulator Gp - Diaphr. Accumulator Gp - Diaphr. Brake Gp - Hyd. Caliper Park Brake Gp - Hyd. (Front ) Brake Gp - Hyd. ( Rear) Core Gp - Cooler Manifold - Cooling Lines Manifold - Cooling Lines Pump Gp - Brakes Switch As.- ABL Control Switch As.- Brake Light Switch As.- Brake Temp. Switch As.- Low Brake Press. Switch As.- Park Brake EMS Valve Gp - Check Valve Gp - Check Valve Gp - Output Press. Control Valve Gp - Parking Brake Valve Gp - Press. Reducing Valve Gp - Relief Valve Gp - Solenoid Cylinder Gp - Front Cylinder

Cylinder Gp - Steering Drain Element -Filter (Steering Return) Pump Gp - Metering Pump Gp - Secondary Steering Pump Gp - Steering (735) - Steering (740) Screen As. - Pump Case Drain Screen As. - Steering Return Switch As.- Low Press. Warning Tank - Hydraulic Oil Valve Valve Gp - Breaker / Relief Valve Gp - Check Valve Gp - Check Valve Gp - Steering Comb. Mnfld Cooler Fan Control Valve Fan Drive Motor - 735 / 740 Fan Drive Motor - (ATAAC) Fan Drive Pump Fan Drive Pump - (ATAAC) Releif Valve Valve Gp - By-Pass (Thermal) Valve Gp - Solenoid

PUMP OR MOTOR

FLUID CONDITIONER

SPRING

CONTROL VALVES

RESTRICTION

LINE RESTRICTION (FIXED)

PUMP (2 - SECTION)

PUMP (VARIABLE & PRESSURE COMPENSATED)

VARIABILITY

SPRING (ADJUSTABLE)

LINE RESTRICTION (VARIABLE)

PRESSURE COMPENSATION

HYDRAULIC PNEUMATIC ENERGY TRIANGLES

LINE RESTRICTION (VARIABLE & PRESSURE COMPENSATED)

ATTACHMENT

VALVE ENVELOPES

VALVES

VALVE PORTS

Brake Circuit
163-5632 251-8265 160-8009 219-6710 219-6710 4P-7731 159-2880 194-4016 187-9090 172-7071 172-7071 3E-6451 213-6947 213-6947 134-9911 158-9956 217-9037 190-6290 140-0973 224-4630 152-8340
ONE POSITION TWO POSITION THREE POSITION TWO - WAY THREE - WAY FOUR - WAY

CONTROL VALVES
AB A B

CHECK VALVES

Valve Gp - Fluid Sampling (SOS) 164-5590

Fan Drive Circuit

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

Valve Gp - Brake Check Manifold 224-1209

K
Actuator As. - Lower Actuator As. - Raise Cylinder Gp - Hoist 735 - Hoist 740

Hoist Circuit
192-6443 196-2403 241-4065 241-4068 151-2611 8J-8782 132-8876 190-1514 153-3528

735 and 740 Articulated Trucks Hydraulic System

735: B1N1-UP WWC1-UP 740: WWD1-UP B1P1-UP

MEASUREMENT

ROTATING SHAFTS

PRESSURE

TEMPERATURE

FLOW

UNIDIRECTIONAL

BIDIRECTIONAL

COMBINATION CONTROLS

NOTE: Test panel located at left rear of the front chassis Port E is not illustrated on this print Diagnositic and Service Ports

Cylinder Gp - Tailgate (Attach.) Drain Element - Filter Manifold - Cold Oil By-Pass Manifold - Hoist / Tailgate

SOLENOID

Suspension Circuit
228-2758

SOLENOID OR MANUAL

SOLENOID & PILOT

SOLENOID & 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

Tap Locations Pressure, Sampling, and Sensor

Tap Number
A B C D E F G H J K L M N P R T

Description
Hoist Raise / Lower Pressure Secondary Steering Pressure Front Brake Pressure Brake Pump Pressure OTG Lube & Diff. Lock Press. (Not Shown) Load Sense Press. -Main & Sec. Steer Steer Pressure - Main Steering Pump Fan Drive Pressure Hoist Pilot Pressure Rear Brake Pressure Scheduled Oil Sampling - Steer Park Brake Pressure Scheduled Oil Sampling - Hoist Pump Case Pressure Body Over Center - Service Point ATAAC Fan Pressure

Schematic Location
C-6 E-4 F-7 E-6

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

C-3 E-4 D-2 B-6 E-7 B-2 F-5 A-7 B-8, C-3 C-5 D-2

HYDRAULIC PUMPS
FIXED DISPLACEMENT VARIABLE DISPLACEMENT NON-COMPENSATED

HYDRAULIC MOTORS
FIXED DISPLACEMENT VARIABLE DISPLACEMENT NON-COMPENSATED

INTERNAL PASSAGEWAYS
INFINITE POSITIONING

3 POSITION

2 POSITION

UNIDIRECTIONAL

UNIDIRECTIONAL

Brake, Fan Drive, Hoist, Steering, and Suspension Circuits

BIDIRECTIONAL

BIDIRECTIONAL

FLOW IN ONE DIRECTION

PARALLEL FLOW

CROSS FLOW

FLOW IN EITHER DIRECTION

2009 Caterpillar, All Rights Reserved

Printed in U.S.A.

63 66 34 43 54 52 32 68 71 38

62 64 69 65 70 1 6 39 57 53

35 41 36 42 40 44 4

59 60 23 67 25 26

ELECTRICAL SYMBOLS TABLE

HYDRAULIC SYMBOLS (ELECTRICAL)

G
TRANSDUCER (FLUID) TRANSDUCER (GAS / AIR) GENERATOR

M
ELECTRIC MOTOR

PRESSURE SWITCH

PRESSURE SWITCH (ADJUSTABLE)

TEMPERATURE SWITCH

ELECTRICAL WIRE

3 8 11

10

12

68

ELECTRICAL SYMBOLS (ELECTRICAL)

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

Brake Pump
PRESSURE SWITCH

Steering and Fan Drive Systems

56 61 54 52 32 50 20 27 21 28 22 1 39 13 51 53 30 45 48 24 31 46 37 47 2 3 7 9 16 5 55 58

TEMPERATURE SWITCH

LEVEL SWITCH

FLOW SWITCH

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

8 10 11 12 14 15

KENR5538-01

325-AG135 PK-14

CIRCUIT NUMBER IDENTIFICATION

WIRE COLOR

63 66 34 43 68 71

20 27 21 28 22 39

30 45 31 46 37 47 13 4 55 58

CIRCUIT NUMBER IDENTIFICATION

WIRE COLOR

WIRE GAUGE

325-PK

PREVIOUS STANDARD
WIRE WIRE COLOR

325-PK-14

B
WIRE GAUGE

36 40

42

44

60

81

73

78

CIRCUIT NUMBER IDENTIFICATION

(EXAMPLE VALVE)

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

Hoist and Brake Cooling System

Parking Brake

23

38

56 61

54

52

32

50

32

6 39

62 64 80 57 53 51 69 70 65

24

8 12

9 16

59 60 67

3 10 14 7 11 15

Component Locations

ATAAC Fan

Steering Pump

Hoist Manifold

30 Page,

(Dimensions: 39 inches x 28 inches)

RIGHT FRONT

BRAKE GP- HYDRAULIC (FRONT AND REAR) 219-6710

VALVE GPBRAKE CONTROL 217-9037

ACCUMULATOR DIAPHRAGM 251-8265

VALVE GPBRAKE CHECK MANIFOLD 224-1209 VALVE GPCHECK 134-9911

ACCUMULATOR GPDIAPHRAGM 163-5632 SWITCH AS- PRESSURE (PARK BRAKE EMS SWITCH) 213-6947

BRAKE GP- HYDRAULIC (FRONT AND REAR) 219-6710

RIGHT REAR

PUMP GPMETERING 160-9727 CYLINDER GPSTEER 223-1335

HYDRAULIC CIRCUIT COLOR DESCRIPTIONS

BRAKE PUMP OUTPUT FAN DRIVE PUMP OUTPUT HOIST CONTROL CIRCUIT STEERING CIRCUIT SUPPLY LINE BRAKES CONTROL CIRCUIT SECONDARY STEERING PUMP FAN DRIVE PUMP OUTPUT (ATTACHMENT) DRAIN / RETURN LINE HOIST PUMP OUTPUT PRIMARY STEERING PUMP OUTPUT BRAKE COOLING

SWITCH AS(BRAKE LIGHT) 172-7071

D REMOTE PANEL TEST POINT TP SW VALVE GPPARKING BRAKE 190-6290 SWITCH LOW BRAKE PRESSURE 213-6947

PARKING BRAKE

C B1 REMOTE PANEL TEST POINT SWITCH AS(ABL CONTROL) 172-7071 K REMOTE PANEL TEST POINT P1 T1

RB ASBS

ACC

PS B M

FB

P VALVE GPP PRESSURE REDUCING 140-0973 VALVE-CHECK 158-9956

SWITCH AS-PRESSURE (LOW PRESSURE WARNING) 3E-6450 VALVE GP STEERING COMBINER MANIFOLD T 176-5691 LS PP P G REMOTE PANEL TEST POINT T1

Tap Locations Pressure, Sampling, and Sensor

Tap Number Description
Hoist Raise / Lower Pressure Secondary Steering Pressure Front Brake Pressure Brake Pump Pressure OTG Lube & Diff. Lock Press. (Not Shown) Load Sense Press. -Main & Sec. Steer Steer Pressure - Main Steering Pump Fan Drive Pressure Hoist Pilot Pressure Rear Brake Pressure Scheduled Oil Sampling - Steer Park Brake Pressure Scheduled Oil Sampling - Hoist Pump Case Pressure Body Over Center - Service Point ATAACz Fan Pressure C-3 E-4 D-2 B-6 E-7 B-2 F-5 A-7 B-8, C-3 C-5 D-2

Schematic Location
C-6 E-4 F-7 E-6

B2

P2 T2 VALVE GPRELIEF 224-4530 T RBP RBP P

T VALVE GPSOLENOID 152-8340

REMOTE PANEL TEST POINT

R PS1 CYLINDER GPSTEER 223-1335

RIGHT TURN TRACTOR TRAILER

A B C D E F G H J K

BRAKE GP-HYDRAULIC CALIPER PARK (DYNAMIC PARKING BRAKE) 160-8009

P1

HITCH C.L.

P2 T2 PS2 AUX

OUT

L M N P R T

E
B

REMOTE PANEL TEST POINT L/S SIGNAL

MANIFOLD-BRAKES COOLING LINES 194-4016

SWITCH AS BRAKE TEMPERATURE 3E-6451

BRAKE GP- HYDRAULIC (FRONT AND REAR) 219-6710 CYLINDER GP(FRONT SUSP CYL) 228-2758

FAN DRIVE MOTOR (ATAAC) 220-2290

CORE GPOIL COOLER 4P-7731

LEFT FRONT ACTUATOR AS. LOWER 192-6443

LEFT REAR RELIEF VALVE 222-6472

BRAKE GP- HYDRAULIC (FRONT AND REAR) 219-6710

D
VALVE GP 165-7948 STEERING-MAIN PUMP GP-(735) 224-4431 PUMP GP-(740) 224-4432 SWITCH AS BRAKE TEMPERATURE 3E-6451 X FAN DRIVE MOTOR 240-6746 FAN CONTROL VALVE 263-5833 REMOTE PANEL TEST POINT

MANIFOLD BRAKES COOLING LINES 159-2880 H1 T1

H FAN DRIVE PUMP 210-0053

FAN DRIVE PUMP 210-0053

A T

(Dimensions: 39 inches x 28 inches)

KENR5538-01

STEERING-MAIN PUMP GP-(735) 224-4431 PUMP GP-(740) 224-4432

REMOTE PANEL TEST POINT A

CYLINDER GP- HOIST 740 285-4034 CYLINDER GP- HOIST 735 285-4033

TRANSMISSION

VALVE GPMANUAL lOWER (DEAD ENGINE) 204-2124

VALVE GPSOLENOID 265-5214

P PUMP GPHOIST 188-4455

RAISE HOLD
HE RAISE ENGINE

COOLER 122-6485

C
VALVE GPBY-PASS (THERMAL) 188-8726

TRANSMISSION

ENGINE

REMOTE PANEL TEST POINT F VALVE GP165-7948

RE VALVE GPRELIEF 126-6099 PUMP GPHOIST 188-4455

FLOAT

CYLINDER GPTAILGATE (ATTACH) 151-2611

FAN DRIVE PUMP (ATAAC) 248-5605 PUMP GPBRAKES 187-9090

VALVE GPCHECK 180-4850

LOWER
OPEN

30 Page,

S L

L1 P

VALVE GP MAIN RELIEF 224-1167 MANIFOLD 153-3528 MANIFOLD COLD OIL BY-PASS 190-1514 H2 REMOTE PANEL TEST POINT J VALVE GP-HOIST 189-5772 T2 CYLINDER GP- HOIST 740 285-4034 CYLINDER GP- HOIST 735 285-4033

B
PUMP GPBRAKES 187-9090

VALVE GPBALANCE (ATTACH) 133-8810

PUMP GP(SECONDARY STEER) 141-6389

L SOS VALVE GPBREAKER / RELIEF 157-7911

VALVE AS FLUID SAMPLING 164-5590

VALVE GPBREAKER/RELIEF 157-7911 VALVE GP FLUID SAMPLING 164-5590 ACTUATOR AS. RAISE 196-2403

N SOS

LINE PATTERNS
Pressure Line

SCREEN AS. 119-4885 SCREEN AS. 119-4885

Pilot / Load Sensing Pressure

TANK GP- HYDRAULIC 186-9959 SCREEN AS. 119-4885 ELEMENTFILTER 132-8876 VALVE 1U-1643 SCREEN AS. 6J-3795

Drain / Return Lines Component Group Attachment Air Line

TANK GP-HYDRAULIC 162-5242 DRAIN 8J-8782

A
DRAIN 8J-8782 ELEMENTFILTER 132-8876 SCREEN AS. 150-8457

CALLOUTS
YY

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

52

THIS SCHEMATIC IS FOR THE 735 AND 740 ARTICULATED TRUCKS

MEDIA NUMBER: KENR5538-01 PART NUMBER: 266-6459, CHANGE: 02, VERSION: -

BRAKE, HOIST AND SUSPENSION CIRCUITS

8 7 6 5 4

FAN AND STEERING CURCUITS

3 2

Components are shown installed on a fully operable machine. Refer to the appropriate Service Manual for Troubleshooting, Specifications.