INTERACTIVE SCHEMATIC

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 RENR9866-02
September 2017

793D Off-Highway Truck

Air System
FDB1-UP

© 2017 Caterpillar, All Rights Reserved Printed in U.S.A.

COMPONENT LOCATION
Part Schematic Machine
Description
Number Location Location
Compressor Gp - Air 160-9845 C-4 , D-9 1
Cylinder Gp - Air/Hydraulic (Master Cyls. Front) 8W-3406 B-1 , B-8 2
Cylinder Gp - Air/Hydraulic (Master Cyls. Rear) 8W-3405 B-1 , B-8 3
Dryer Gp - Air 194-1986 C-3 , D-8 4
Filter Gp - Air Lines (Oil Seperator) 267-5286 D-3 , D-8 5
Governor GP - Air Compressor 4N-9680 D-4 , D-9 6
Gun - Air/Vaccum 129-5659 C-3 , D-5 7
Horn Gp - Air 5D-6998 B-4 , D-6 8
Motor Gp - Starting Air, Turbine 105-4324
D-2 , C-7 9
Motor Gp - Starting Air, Vane 4W-6633
Pump As - Auto Lube 8X-2317 D-4 , D-6 11
Regulator (Auto Lube) 8D-4755 D-4 , D-6 12
Regulator (Engine Wastegate) 8D-4755 C-2 , C-5 13*
Reservior - Air (Main) 5T-1049 D-3 , C-7 14
Reservior - Air (Sec) 162-7880 B-2 , B-5 15
Sensor Gp - Pressure (Brake Air) 141-5746 C-2 , C-8 16
Switch As - Pressure (Brake On) 242-8903 C-2 , B-7 17
Switch As - Pressure (Lockout Brake) 242-8903 B-3 , B-7 18
Switch As - Pressure (Manual Retarder) 3E-2035 B-4 , B-9 19
Switch As - Pressure (Service Brake) 3E-2034 C-2 , C-9 20
Valve - Drain (Air Tank) 7X-7655 C-2 , C-5 21
Valve As - Check 4D-0487 B-2 , B-5 22
Valve As - Control (Air Dryer) 217-4184 C-3 , D-7 23
Valve As - Park and Sec 213-1081 B-3 , B-6 24
Valve As - Preesure Protection 2G-8815 C-2 , C-6 46
Valve Gp - Air Control (Manual Retarder) 351-0524 B-4 , B-9 25
Valve Gp - Air Control (Parking Brake) 2G-3594 B-3 , B-6 26
Valve Gp - Air Control (Sec Brake Pedal) 247-1293 B-3 , C-6 27
Valve Gp - Air Control (Service Brake Pedal) 247-1292 B-4 , B-9 28
Valve Gp - Air Relief (Primary Air Tank) 6B-9664 D-3 , C-7 29
Valve Gp - Brake 149-4133 B-6 , C-2 30
Valve Gp - Check (Drain) 6K-5741 D-3 , D-7 31
Valve Gp - Check (Main Air Reservoir) 4I-8443 C-8 , D-3 32
Valve Gp - Diverter (1-38) 105-0170 C-2 , B-5 33
Valve Gp - Inverter 172-6232 B-3 , B-6 34
Valve Gp - Relay (Air Starting Motor) 115-9190 D-2 , C-7 35
Valve Gp - Relay (Service Brake) 159-5149 C-1 , B-8 36
Valve Gp - Relief (Air Dryer) 222-0570 D-3 , D-7 37
Valve Gp - Shuttle (Service Brake) 6D-3781 B-4 , B-9 38
Valve Gp - Solenoid 185-0008 C-2 , D-5 39*
Valve Gp - Solenoid (Air Horn) 185-0008 C-3 , D-6 40
Valve Gp - Solenoid (Air Start) 221-9576 C-2 , C-6 41
Valve Gp - Solenoid (Auto Lube) 221-9576 C-3 , C-6 42
Valve Gp - Solenoid (Cooling Diverter) 188-2481 C-2 , B-5 43
Valve Gp - Solenoid (Lockout) 188-2461 C-2 , B-7 44
Valve Gp - Vent (Lubrication Pump) 8X-2320 D-4 , D-6 45
*Note : NOT SHOWN ON GRAPHICS
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)
 9 8 7 6 5 4 3 2 1

E E

(11) PUMP AS
(23) VALVE AS (31) VALVE GP
EXTERNAL AUTO LUBE
(1) COMPRESSOR GP AIR SUPPLY CONTROL (AIR DRYER) CHECK (DRAIN)
8X-2317 (11) PUMP AS 6K-5741
AIR 217-4184 (12) REGULATOR
DELIVERY (AUTO LUBE) AUTO LUBE (14) RESERVOIR FROM AIR RESERVOIR
160-9845 8D-4755 8X-2317 AIR (MAIN)
DRAIN
VALVE
RELAY
AUTO 5T-1049
VALVE

LUBE PUMP (8) HORN GP REGULATOR (32) VALVE GP SAFETY

INGERSOLL
AIR CHECK VALVE AIR STARTER

SUPPLY
(45) VALVE AS 5D-6998 4I-8443 PRIMARY TURBINE AND
TDI AIR STARTER
AIR
VENT (LUBRICATION PUMP) RESERVOIR (29) VALVE GP
TURBINE

CLEAN-OUT (9) MOTOR GP TO SOLENOID

D 8X-2320 ATTACHMENT AIR RELIEF D
CONTROL ATTACHMENT STARTING AIR
AIR (PRIMARY AIR TANK)
(37) VALVE GP VENT CHECK 105-4324 (TURBINE)
(4) DRYER GP ENGINE VALVE PUMP
VALVE 6B-9664
RELIEF (AIR DRYER) HORN
AIR WASTEGATE
222-0570
194-1986 (12) REGULATOR AUTO
JUNCTION
BLOCK
LUBE
8D-4755 TANK
(37) VALVE GP (5) FILTER GP
RELIEF (AIR DRYER) AIR LINES (OIL SEPARATOR) RELAY
VALVE
(7) GUN 222-0570 267-5286 H INGERSOLL
AIR STARTER
DELIVERY AIR / VACCUM VANE
(45) VALVE AS (35) VALVE GP
(31) VALVE GP 129-5659 G
RELAY
VENT (LUBRICATION PUMP) (4) DRYER GP
CHECK (DRAIN) (40) VALVE GP 8X-2320 S
AIR (AIR STARTING MOTOR) (9) MOTOR GP
6K-5741 SOLENOID (AIR HORN) J 194-1986 (39) VALVE GP 115-9190 STARTING AIR
4W-6633 (VANE)
(9) MOTOR GP 185-0008 COMPRESSOR AIR SOLENOID
(39) VALVE GP (6) GOVERNOR GP GOVERNOR
COMPRESSOR 185-0008
STARTING AIR AIR COMPRESSOR
SUPPLY (42) VALVE GP ATTACHMENT SOLENOID
CONTROL 4W-6633 (VANE) 4N-9680 O CONTROL
(13) REGULATOR
SOLENOID 185-0008 MODULE
(41) VALVE GP
(36) VALVE GP
105-4324 (TURBINE) AIR SEAT AIR AIR SAFETY (ENGINE SOLENOID VALVE
RELAY (SERVICE BRAKE)
(6) GOVERNOR GP (AUTO LUBE) DRYER DRYER VALVE
WASTEGATE)
SOLENOID
159-5149
(5) FILTER GP 221-9576 (BUDDY) (20) SWITCH AS (21) VALVE 221-9576
AIR COMPRESSOR PRESSURE
8D-4755 DRAIN (AIR TANK)
4N-9680 AIR LINES (OIL SEPARATOR) (1) COMPRESSOR GP EXTERNAL
7X-7655
(SERVICE BRAKE) M RELAY VALVE
267-5286 MAIN
AIR
AIR SUPPLY
3E-2034 (SERV)
RESERVOIR
160-9845 K ENGINE
E
(32) VALVE GP WASTEGATE
L
CHECK
(23) VALVE AS (43) VALVE GP
4I-8443 (41) VALVE GP AIR F
(13) REGULATOR CONTROL (AIR DRYER) SOLENOID P
DRAIN VALVE
(29) VALVE GP (35) VALVE GP SOLENOID SEAT 217-4184 188-2461
B

(20) SWITCH AS 8D-4755

(14) RESERVOIR AIR RELIEF RELAY (AIR START)
C PRESSURE
AIR (MAIN) (PRIMARY AIR TANK) (AIR STARTING 221-9576 Z
7 6 5 4 3 2 1 AIR
PRESS.
SENSOR
DIVERTER
VALVE (33) VALVE GP C
(SERVICE BRAKE) 6B-9664 MOTOR) (42) VALVE GP
COOLING
DIVERTER
BK
DIVERTER (1-38)
A C

3E-2034 5T-1049 F SOLENOID AUTO LUBE PRESS SOLENOID

ON
105-0170
115-9190 221-9576
SOLENOID PROT
VALVE
X
E W
AIR (30) VALVE GP
FROM MAIN
(46) VALVE AS H BUDDY
SEAT
T
U BRAKE
RESERVOIR
PRESSURE (28) VALVE GP
AIR
SEAT
HORN SOL 149-4133
PROTECTION AIR CONTROL S SECONDARY & PARK

(38) VALVE GP (SERVICE CONTROL VALVE

2G-8815 (24) VALVE AS CAB
BRAKE PEDAL)
(40) VALVE GP
D D
SHUTTLE (16) SENSOR GP PARK & SECONDARY 247-1292
CLEAN
OUT
SOLENOID
(SERVICE BRAKE) (21) VALVE (AIR HORN)
PRESSURE (BRAKE AIR) (27) VALVE GP 213-1081
HOSE
SERVICE (7) GUN (46) VALVE AS
185-0008
6D-3781 141-5746 AIR CONTROL DRAIN (AIR TANK) BRAKE
VALVE AIR / VACCUM PRESSURE
(SEC BRAKE PEDAL) 7X-7655 129-5659 PROTECTION (16) SENSOR GP
3
J 2G-8815 PRESSURE (BRAKE AIR)
2 (30) VALVE GP 247-1293
F 141-5746
1
BRAKE (38) VALVE GP
SHUTTLE (44) VALVE GP
149-4133 M
SOLENOID (17) SWITCH AS MASTER CYLINDER MASTER CYLINDER
6D-3781 (24) VALVE AS (18) SWITCH AS
(LOCKOUT) PRESSURE FRONT REAR
PARK & SECONDARY PRESSURE
(36) VALVE GP (26) VALVE GP
(LOCKOUT BRAKE)
Y
188-2461 (BRAKE ON) (2) CYLINDER GP (3) CYLINDER GP
AIR CONTROL 213-1081 242-8903 AIR / HYDRAULIC
RELAY (SERVICE BRAKE)
DBL CK
VALVE M PARK BRAKE 242-8903 AIR / HYDRAULIC
(19) SWITCH AS (15) RESERVIOR (PARKING BRAKE) (MASTER CYL. FRONT) (MASTER CYL. REAR)
159-5149 SECONDARY
2G-3594
APPLIED B A

PRESSURE
RESERVOIR
AIR (SEC) RETR
E PARK/SEC
8W-3406 8W-3405
(28) VALVE GP SEE HYDRAULIC SCHEMATIC F CAB
(MANUAL RETARDER) 162-7880 VALVE

AIR CONTROL D CC
3E-2035 X X X X
(SERVICE BRAKE PEDAL) D S SECONDARY
(44) VALVE GP (17) SWITCH AS (22) VALVE AS C AA CHECK
247-1292 VALVE
MASTER
CYLINDERS
MASTER
CYLINDERS
SOLENOID PRESSURE (BRAKE ON) CHECK N
A
INV VALVE CTRL
INV VALVE

B B
DELIVERY
REAR
Y Y Y Y
FRONT
(LOCKOUT) 242-8903 4D-0487 SECONDARY
CAB PORT FUNCTION
SEE (27) VALVE GP RESERVOIR
HYDRAULIC 188-2461 AIR CONTROL (34) VALVE GP
INVERSION
VALVE PORT
SCHEMATIC (19) SWITCH AS (25) VALVE GP BB
(SEC BRK PDL) INVERTER INV VALVE SUP 1 CAB SUPPLY
PRESSURE AIR CONTROL 247-1293 172-6232 (22) VALVE AS 2 PROTECTED AIR
(3) CYLINDER GP (2) CYLINDER GP (MANUAL (MANUAL RETARDER) B B 3 SECONDARY/PARK SIGNAL
RETARDER) CHECK
AIR / HYDRAULIC (34) VALVE GP 351-0524
(25) VALVE GP AIR / HYDRAULIC AIR
HORN 3E-2035 REAR CAB WALL (15) RESERVIOR 4D-0487
4 SERVICE/RETARDER SIGNAL
5 SERVICE/RETARDER/ARC
AIR CONTROL (MASTER CYL. REAR) (MASTER CYL. FRONT) INVERTER AIR (SEC) SIGNAL TO DIVERTER
8W-3405 172-6232 162-7880
(MANUAL RETARDER) 8W-3406 6 ARC SIGNAL

351-0524 (8) HORN GP 7 LUBE SYSTEM

AIR
5D-6998
(26) VALVE GP LINE PATTERNS
LINE PATTERNS
AIR CONTROL Pressure Line
Pressure Line
(18) SWITCH AS (PARKING BRAKE) (33) VALVE GP
(43) VALVE GP AIR CIRCUIT COLOR DESCRIPTIONS
AIR CIRCUIT COLOR DESCRIPTIONS PRESSURE 2G-3594 DIVERTER (1-38) Pilot / Load Sensing Pressure
Pilot / Load Sensing Pressure SOLENOID
(LOCKOUT BRAKE) 105-0170 PILOT PUMP OUTPUT
PILOT PUMP OUTPUT (COOLING DIVERTER) Component Group AIR COMPRESSOR OUTPUT
Component Group AIR COMPRESSOR OUTPUT 242-8903 188-2461 ENGINE WASTE GATE CIRCUIT
ENGINE WASTE GATE CIRCUIT Attachment AIR START MOTOR CIRCUIT
Attachment AIR START MOTOR CIRCUIT
AUTO LUBE CIRCUIT
AUTO LUBE CIRCUIT CALLOUTS SECONDARY & PARKING BRAKE CONTROL CIRCUIT
CALLOUTS SECONDARY & PARKING BRAKE CONTROL CIRCUIT
CLEAN OUT CIRCUIT
CLEAN OUT CIRCUIT Callout Number Component
DIVERTER CONTROL CIRCUIT
Callout Number Component
DIVERTER CONTROL CIRCUIT (Machine Location from (52) VALVE GP - CONTROL Name
(Machine Location from (52) VALVE GP - CONTROL Name Component LocationsTable)
138-1234 SERVICE BRAKE CONTROL CIRCUIT
Component LocationsTable) SERVICE BRAKE CONTROL CIRCUIT Part Number
138-1234 AIR HORN CICUIT

AIR SYSTEM SCHEMATIC AIR SYSTEM BLOCK DIAGRAM

Part Number
AIR HORN CICUIT

A A

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

MEDIA NUMBER: RENR9866-02
SCHEMATIC PART NUMBER: 193-6208, CHANGE: 01, VERSION: (-)
Components are shown installed on a fully operable machine with the key and engine off, transmission shifter
in neutral and with parking brake set.
Refer to the appropriate Service Manual for Troubleshooting, Specifications and Systems Operations.
Refer to the Parts Manual using a specific serial number prefix in SIS before ordering parts from this schematic.

9 8 7 6 5 4 3 2 1
CAB
VIEW ALL CALLOUTS

25 46

24 16
42
26
18
21
7 20

43
(ROTATED FOR CLARITY)
44

38 19 28 27 15 22 34 40 17
FRONT SIDE REAR SIDE
ENGINE
VIEW ALL CALLOUTS

6 1
MACHINE TOP VIEW

8 VIEW ALL CALLOUTS

23 41 9 35

37

5 2 A
4 3 36 33
VIEW OF AREA “A”
(ROTATED FOR CLARITY)

32 11
30

45
29
14 B
12
31

VIEW OF AREA “B”

(ROTATED FOR CLARITY)