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Component Locations

Description
Air Gun - Clean Out Compressor Gp - Air Cylinder Gp - Front Master Cylinder Gp - Rear Master Dryer As - Air Governor As Motor Gp - Air Start

Part Number
156-0927 160-9820 8W-3406 8W-3405 101-8352 4N-9680

Machine Location
C-3 , E-6 D-4 , D-10 C-1 , C-8 C-1 , C-8 D-3 , D-10 D-4 , D-10 D-2 , D-7 E-3 , D-8 B-2 , C-6 D-2 , D-8 D-2 , C-7 B-3 , B-7 D-2 , D-10 C-3 , C-6 B-4 , C-10 C-3 , E-6 D-2 , D-7 E-2 , D-7 C-3 , E-7 D-1 , B-5 D-2 , B-6 E-3 , D-8 D-2 , D-6 D-2 , D-5 B-3 , C-6 B-3 , B-7 C-3 , D-7 D-2 , D-5 D-1 , C-9 C-2 , C-7 D-2 , B-7 B-4 , C-6 C-4 , C-10 C-4 , C-10

Schematic Location
1 2 3 4 5 6 7

8 22 3
CAB WALL R.H. PLATFORM GP

OPERATORS COMPARTMENT

RENR9866 October 2005
PUMP or MOTOR FLUID CONDITIONER SPRING

FLUID POWER SYMBOLS
BASIC COMPONENT SYMBOLS
MAIN AUX.

7

CONTROL VALVES

RESTRICTION

LINE RESTRICTION (FIXED)

2-SECTION PUMP

PUMP: VARIABLE and PRESSURE COMPENSATED

VARIABILITY

SPRING (ADJUSTABLE)

LINE RESTRICTION (VARIABLE)

PRESSURE COMPENSATION

HYDRAULIC PNEUMATIC ENERGY TRIANGLES

LINE RESTRICTION
VARIABLE and PRESSURE COMPENSATED

ATTACHMENT

TDI Turbine 205-4824 Ingersol Turbine 170-1133 Ingersol Vane 4W-6633 5T-1049 162-7880 141-5746 242-8903 242-8903 3E-2034 213-1081 236-6570 7T-9074 7D-6081 115-9190 7D-6081 251-7763 188-3580 7X-7655 7X-7655 7T-9074 172-6232 128-4971 2G-8815 8D-4755 159-5149 149-4133 188-3580 247-1293 247-1292 6D-3781

30
ONE POSITION

VALVE ENVELOPES

VALVES

VALVE PORTS

TWO POSITION

THREE POSITION

TWO-WAY

THREE-WAY

FOUR-WAY

Reservoir - Air (Main) Reservoir - Air (Secondary) Sensor Gp - Air Pressure Switch As - Sec & Park Brake Press Switch As - Sec & Park Lockout Press Switch As - Service Brake Valve As - Park & Secondary Valve As - Service Brake Retract Valve Gp - Air Horn Solenoid Valve Gp - Air Start Solenoid Valve Gp - Air Starter Relay Valve Gp - Auto Lube Solenoid Valve Gp - Diverter Solenoid Valve Gp - Diverter Lockout Sol Valve Gp - Drain (Main Reservoir) Valve Gp - Drain (Sec Reservoir) Valve Gp - Engine Waste Gate Sol Valve Gp - Inversion (Sec & Park Brk) Valve Gp - Park Brake SW (Detented) Valve Gp - Pressure Protect Valve Gp - Regulator (Waste Gate) Valve Gp - Relay (Master Cyl) Valve Gp - Sec & Park Brake Control Valve Gp - Sec & Park Brake Lock Sol Valve Gp - Sec Foot Air Brake Valve Gp - Service Brake Valve Gp - Shuttle

8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34

4
ENGINE

CONTROL VALVES

CHECK VALVES

18

AB

AB

P T NORMAL POSITION

P T SHIFTED POSITION

INFINITE POSITION

BASIC SYMBOL

SPRING LOADED

SHUTTLE

PILOT CONTROLLED

2 6 5 4 29 3 5 20

29
PRESSURE

MEASUREMENT

ROTATING SHAFTS

TEMPERATURE

FLOW

UNIDIRECTIONAL

BIDIRECTIONAL

17
FRONT VIEW
FRAME AS. OPERATORS COMPARTMENT PORT NO.2

FLUID STORAGE RESERVOIRS

793D Off-Highway Truck Air System
FDB1-UP

VENTED

PRESSURIZED

RETURN ABOVE FLUID LEVEL

RETURN BELOW FLUID LEVEL

COMBINATION CONTROLS

SOLENOID

SOLENOID or MANUAL

SOLENOID and PILOT

SOLENOID and PILOT or MANUAL

SERVO

THERMAL

DETENT

MANUAL CONTROL SYMBOLS

30
L.H. FRAME AS.

PUSH-PULL LEVER

MANUAL SHUTOFF

GENERAL MANUAL

PUSH BUTTON

PEDAL

SPRING

PILOT CONTROL SYMBOLS
RELEASED PRESSURE REMOTE SUPPLY PRESSURE

EXTERNAL RETURN

INTERNAL RETURN

SIMPLIFIED

COMPLETE

INTERNAL SUPPLY PRESSURE

ACCUMULATORS CONTROL GP - BRAKE K

CROSSING AND JOINING LINES

HYDRAULIC AND PNEUMATIC CYLINDERS

Related Manuals
Description Parts Manual:
Parts Book:

Media Number
SEBP3976 RENR8330 RENR8336 RENR8341 SENR2986 RENR8333 RENR8331

6 8 2 18
LEFT SIDE VIEW

17

SPRING LOADED

GAS CHARGED

LINES CROSSING

LINES JOINING

SINGLE ACTING

DOUBLE ACTING

HYDRAULIC PUMPS
FIXED DISPLACEMENT VARIABLE DISPLACEMENT NON-COMPENSATED

HYDRAULIC MOTORS
FIXED DISPLACEMENT VARIABLE DISPLACEMENT NON-COMPENSATED

INTERNAL PASSAGEWAYS
INFINITE POSITIONING THREE POSITION TWO POSITION

Machine System:
Air System & Brake SOTA Steering System Fan Drive Hydraulic System Traction Control System

7

UNIDIRECTIONAL

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

BIDIRECTIONAL

BIDIRECTIONAL

Electrical System:
Schematic

Hydraulic System:
Schematic

CHASSIS AIR SYSTEM

AIR START
19

© 2005 Caterpillar All Rights Reserved

Printed in U.S.A.

Electrical Symbols Table

27 10

CAB PORT FUNCTION
PORT
1 2 3 4 5 CAB SUPPLY PROTECTED AIR SECONDARY/PARK SIGNAL SERVICE/RETARDER SIGNAL SERVICE/RETARDER/ARC SIGNAL TO DIVERTER ARC SIGNAL LUBE SYSTEM

Hydraulic & Pneumatic Symbols (Electrical)

G
Transducer (Fluid) Transducer (Gas / Air) Generator

M
Electric Motor

23 28 24
PORT 2
7 6 3

1 2 4 5

13 21

6 7

Pressure Switch

Pressure Switch (Adjustable)

Temperature Switch

Electrical Wire

CAB LINES GP-AIR

14 26 15 23 9 12 11
REAR VIEW
E

Electrical Symbols (Electrical)

RENR9866

INSIDE VIEW OF CAB JUNCTION PLATE

25 9

25

16

15

T

Pressure Symbol

Temperature Symbol

Level Symbol

Flow Symbol

Wire Number Identification Codes Electrical Schematic Example
Current Standard

Hydraulic Schematic Example
Current Standard

34

Harness identification code This example indicates wire 135 in harness "AG".

Wire

Circuit Number Identification

Wire Color

31
Circuit Identification Number

325-AG135 PK-14 325-PK
Wire Color Wire Gauge

1

FRONT VIEW

32 33

REAR VIEW

Previous Standard
Wire Wire Color

23

325-PK-14
B
Circuit Number Identification Wire Gauge
(EXAMPLE VALVE)

A

ATTACHMENTS

CAB AIR SYSTEM

20 Page

Color 2 3 2 1 VALVE GP PARK BRAKE SW (DETENTED) 128-4971 2 X AIR 1 2 10 1 12 3 VALVE AS SERVICE BRAKE RETRACT 236-6570 VALVE GP INVERSION (SEC & PARK BRAKE) 172-6232 B INV VALVE SUP 6 B 7 Y 3 2 B AIR CIRCUIT COLOR DESCRIPTIONS AIR COMPRESSOR OUTPUT PILOT PUMP OUTPUT AIR HORN CICUIT AIR START MOTOR CIRCUIT AUTO LUBE CIRCUIT CLEAN OUT CIRCUIT ENGINE WASTE GATE CIRCUIT SECONDARY & PARKING BRAKE CONTROL CIRCUIT DIVERTER CONTROL CIRCUIT SERVICE BRAKE CONTROL CIRCUIT OIL AIR HORN REAR CAB WALL LINE PATTERNS Pressure Line Pilot / Load Sensing Pressure Component Group Attachment VALVE GP INVERSION (SEC & PARK BRAKE) 172-6232 SWITCH AS SEC & PARK LOCKOUT PRESSURE 242-8903 SEE HYDRAULIC SYSTEM SCHEMATIC RESERVOIR AIR (SEC) 162-7880 B VALVE GP DIVERTER LOCKOUT SOL 188-3580 AIR CIRCUIT COLOR DESCRIPTIONS LINE PATTERNS Pressure Line Pilot / Load Sensing Pressure Component Group Attachment AIR COMPRESSOR OUTPUT PILOT PUMP OUTPUT AIR HORN CICUIT AIR START MOTOR CIRCUIT AUTO LUBE CIRCUIT CLEAN OUT CIRCUIT ENGINE WASTE GATE CIRCUIT SECONDARY & PARKING BRAKE CONTROL CIRCUIT DIVERTER CONTROL CIRCUIT SERVICE BRAKE CONTROL CIRCUIT NOTE A: TRUCK RUNNING.10 9 8 7 6 5 4 3 2 1 F F VALVE GP DRAIN (MAIN RESV) 7X-7655 ATTACHMENT AUTO LUBE E 2 AIR HORN 2 CLEAN OUT 2 RESERVOIR AIR (MAIN) 5T-1049 ATTACHMENT ENGINE WASTE GATE AUTO LUBE TANK PRIMARY AIR RESERVOIR SAFETY VALVE E 1 CHECK VALVE EXTERNAL AIR SUPPLY 10 1 3 12 MOTOR GP AIR START 205-4824 DRYER ASY AIR 101-8325 VALVE GP AUTO LUBE SOL 7D-6081 1 AIR GUN (CLEAN OUT) 156-0927 VALVE GP AIR HORN SOL 7T-9074 ATTACHMENT 2 JUNCTION BLOCK 1 H VALVE GP AIR START SOL 7D-6081 2 G S VALVE GP AIR STARTER RELAY 115-9190 VALVE GP REGULATOR (WASTE GATE) 8D-4755 VALVE GP ENGINE WASTE GATE SOL 7T-9074 MOTOR GP AIR START 205-4824 (TDI TURBINE) 170-1133 (INGERSOL TURBINE) 4W-6633 (INGERSOL VANE) COMPRESSOR GP AIR 160-9820 1 3 MAIN RESERVOIR VALVE GP DRAIN (MAIN RESV) 7X-7655 2 10 AIR SEAT (BUDDY) VALVE GP ENGINE WASTE GATE SOL 7T-9074 J GOVERNOR AS 4N-9680 2 FROM DRYER ASY AIR 101-8325 UNLOAD PORT AIR DRYER SAFETY VALVE VALVE GP AIR START SOL 7D-6081 SWITCH AS SERVICE BRAKE 3E-2034 12 1 3 D 4 RESERVOIR AIR (MAIN) 5T-1049 VALVE GP AIR STARTER RELAY 115-9190 1 3 AIR SEAT COMPRESSOR GP AIR 160-9820 K O ATTACHMENTS ENGINE WASTEGATE M VALVE GP RELAY 159-5149 D VALVE GP REGULATOR (WASTE GATE) 8D-4755 E L F EXTERNAL AIR SUPPLY P VALVE GP DRAIN (SEC RESV) 7X-7655 B 1 2 7 Z 6 5 4 BK ON 3 2 1 A C SWITCH AS SERVICE BRAKE 3E-2034 3 VALVE GP PRESS PROTECT 2G-8815 12 VALVE GP DRAIN (SEC RESV) 7X-7655 F VALVE GP AUTO LUBE SOL 7D-6081 X ATTACHMENTS BUDDY AIR SEAT VALVE GP PRESS PROT 2G-8815 W U SENSOR GP AIR PRESSURE 141-5746 VALVE GP DIVERTER SOLENOID 251-7763 E H AIR SEAT T GOVERNOR AS 4N-9680 VALVE GP SHUTTLE 6D-3781 C VALVE GP SERVICE BRAKE 247-1292 12 3 2 1 SENSOR GP AIR PRESSURE 141-5746 VALVE GP SEC & PARK BRAKE CONTROL 149-4133 VALVE GP SEC FOOT AIR BRAKE 247-1293 2 1 S 3 10 3 1 RESERVOIR AIR (SEC) 162-7880 VALVE GP SERVICE BRAKE 247-1292 CLEAN OUT HOSE ATTACHMENTS VALVE GP AIR HORN SOL 7T-9074 VALVE GP DIVERTER LOCKOUT SOL 188-3580 SWITCH AS SEC & PARK PRESSURE XXX-XXXX VALVE GP SEC & PARK BRAKE CONTROL 149-4133 D D 2 1 3 10 VALVE GP RELAY 159-5149 CYLINDER GP REAR MASTER 8W-3405 X X AIR VALVE ASY PARK & SEC 213-1081 Y 1 2 AIR GUN (CLEAN OUT) 156-0927 J F VALVE GP SEC & PARK BRAKE LOCK SOLENOID 188-3580 C CAB SECONDARY RESERVOIR CAB VALVE GP SHUTTLE 6D-3781 M AIR X X AIR X CYLINDER GP FRONT MASTER 8W-3406 VALVE GP SEC & PARK BRAKE LOCKOUT SOLENOID 188-3580 OIL SEE HYDRAULIC SYSTEM SCHEMATIC 4 VALVE AS SERVICE BRAKE RETRACT 236-6570 Y OIL Y Y OIL Y SEE HYDRAULIC SYSTEM SCHEMATIC 2 SWITCH AS SEC & PARK PRESSURE 242-8903 DBL CK VALVE M RETR VALVE GP PARK BRAKE SW (DETENTED) 128-4971 VALVE GP SEC FOOT AIR BRAKE 247-1293 SECONDARY VALVE ASY PARK & SEC 213-1081 PARK BRAKE APPLIED E B PARK/SEC VALVE SWITCH AS SEC & PARK LOCKOUT PRESSURE XXX-XXXX A F CC AA INV VALVE DELIVERY Y CYLINDER GP FRONT MASTER 8W-3406 CYLINDER GP REAR MASTER 8W-3405 VALVE GP BRAKE DIVERTER SOLENOID 251-7763 D C CAB PORT FUNCTION PORT CHECK VALVE 1 2 3 SECONDARY RESERVOIR BB 4 5 CAB SUPPLY PROTECTED AIR SECONDARY/PARK SIGNAL SERVICE/RETARDER SIGNAL SERVICE/RETARDER/ARC SIGNAL TO DIVERTER ARC SIGNAL LUBE SYSTEM D S N A INV VALVE CTRL RENR9866 1 3 20 Page. A PARKING BRAKE APPLIED. A 10 9 8 7 6 5 4 3 2 1 . Troubleshooting and Specifications. AIR SYSTEM SCHEMATIC AIR SYSTEM BLOCK DIAGRAM THIS SCHEMATIC IS FOR THE 793D OFF-HIGHWAY TRUCK Part #: 193-6208 CHG 00 Components are shown installed on a fully operable machine with the key and engine off and transmission shifter in neutral. Refer to the appropriate service manual for System Operation.