K

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3
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)
Hydraulic Symbols (Electrical)
Electrical Symbols Table
325-AG135 PK-14
Circuit Identification
Number Wire Color Wire Gauge
Harness identification code
This example indicates
wire 135 in harness "AG".
325-PK-14
Wire Gauge
Wire Color
Circuit Number
Identification
Wire Number Identification Codes
Current Standard
Previous Standard
Electrical Schematic Example Hydraulic Schematic Example
325-PK
Wire Color Circuit Number
Identification
B A
Wire
Wire
(EXAMPLE VALVE)
Current Standard
Transducer
(Fluid)
Transducer
(Gas / Air)
G
Generator
Electrical Wire Pressure Switch
M
Electric Motor
Pressure Switch
(Adjustable)
Temperature Switch
Pressure
Symbol
Temperature
Symbol
Level
Symbol
Flow
Symbol
Electrical Symbols (Electrical)
ONE POSITION TWO POSITION THREE POSITION
VENTED PRESSURIZED RETURNABOVE FLUIDLEVEL RETURN BELOWFLUIDLEVEL
LINES CROSSING LINES J OINING
TWO-WAY THREE-WAY FOUR-WAY
SPRING CONTROL VALVES RESTRICTION LINE RESTRICTION
(FIXED)
2-SECTION PUMP
MAIN AUX.
SPRING
(ADJ USTABLE)
VARIABILITY LINE RESTRICTION
(VARIABLE)
LINE RESTRICTION VARIABLE and PRESSURE COMPENSATED
PRESSURE
COMPENSATION
PUMP: VARIABLE and PRESSURE COMPENSATED
ENERGY TRIANGLES
HYDRAULIC PNEUMATIC
MEASUREMENT
PRESSURE TEMPERATURE FLOW
ROTATING SHAFTS
UNIDIRECTIONAL BIDIRECTIONAL
PUSH-PULL LEVER PEDAL GENERAL MANUAL PUSH BUTTON SPRING
MANUAL CONTROL SYMBOLS
HYDRAULIC MOTORS
FIXED
DISPLACEMENT
VARIABLE DISPLACEMENT
NON-COMPENSATED
UNIDIRECTIONAL
BIDIRECTIONAL
HYDRAULIC PUMPS
FLUID STORAGE RESERVOIRS
CROSSING AND JOINING LINES
VALVE ENVELOPES VALVE PORTS
BASIC COMPONENT SYMBOLS
FLUIDCONDITIONER PUMP or MOTOR
FLUID POWER SYMBOLS
FIXED
DISPLACEMENT
VARIABLE DISPLACEMENT
NON-COMPENSATED
UNIDIRECTIONAL
BIDIRECTIONAL
VALVES
PILOT CONTROL SYMBOLS RELEASEDPRESSURE
EXTERNAL RETURN INTERNAL RETURN
REMOTE SUPPLY PRESSURE
SIMPLIFIED COMPLETE INTERNAL
SUPPLY PRESSURE
ACCUMULATORS
SPRING LOADED GAS CHARGED
SOLENOID
or MANUAL
SOLENOID
and PILOT
SOLENOIDand
PILOT or MANUAL
COMBINATION CONTROLS
SOLENOID SERVO THERMAL DETENT
HYDRAULIC AND PNEUMATIC CYLINDERS
DOUBLE ACTING SINGLE ACTING
BASIC
SYMBOL
SPRING
LOADED
CHECK VALVES
TWO
POSITION
INFINITE
POSITIONING
FLOWIN ONE DIRECTION FLOWALLOWEDIN EITHER DIRECTION
THREE
POSITION
CROSS FLOW PARALLEL FLOW
INTERNAL PASSAGEWAYS
NORMAL POSITION
A B
P T
A B
P T
SHIFTEDPOSITION INFINITE POSITION
CONTROL VALVES
ATTACHMENT
MANUAL SHUTOFF
SHUTTLE PILOT
CONTROLLED
T
Volume 1 of 3: Steering
KENR8379
November 2009
797F Of f -Hi ghway Tr uck
Hydr aul i c Syst em
LAJ1-UP
2009 Caterpillar, All Rights Reserved Printed in U.S.A.
Hydraulic Tank, Right Side
Upper Sight Gauge Lower Sight Gauge
Steering and
Fan Section
Steering and
Fan Section
Steering and
Fan Pump
Fan Pump Steering Pump
STEERING and FAN PUMP
CHASSIS VIEW
HYDRAULIC TANK
Description
Machine
Location
Schematic
Location
BRAKE COOLING DRIVE PUMP PRESSURE Y E-14
RADIATOR FAN PRESSURE W G-12
STEERING ACCUMULATOR PRESSURE RR I-12
STEERING FLOWAMP X I-5
STEERING PUMP PRESSURE SS I-12
STEERING RETURN YY H-11
STEERING SUPPLY UU I-11
TAP LOCATIONS (VOL. 1)
Cylinder - Head End
Sensor Head
Magnet
Rod
STEERING POSITION SENSOR
Connector
Description Part Number Machine
Location
Schematic
Location
ACCUMULATOR GP - PRECHARGE PRESSURE (VOL. 1) 253-4120 7 J-13
CORE AS - STEERING COOLER (VOL. 1) N/A 133 B-5
CYL GROUP - LEFT STEER (VOL. 1) 194-6171 14 I-1
CYL GROUP - RIGHT STEER (VOL. 1) 288-5537 15 G-1
FILTER - HYDRAULIC (VOL. 1) 4T-6788 46 D-5
FILTER GP - CASE DRAIN (VOL. 1) 290-2569 2 E-3
FILTER GP - OIL (VOL. 1) 290-2569 3 B-8
FILTER GP - OIL (VOL. 1) 289-9904 5 F-5
MOTOR GP - FAN SPEEDCONTROL (VOL. 1) 240-7790 57 G-10
PUMP GP - BRAKE COOLING DRIVE (VOL. 1) (OPTION) 281-8284 62 C-13
PUMP GP - METERING (VOL. 1) 192-3897 4 H-7
PUMP GP - STEERING and FAN (VOL. 1) 301-4678 54 C-9
PUMP GP - STEERING and FAN (VOL. 1) 284-9631 60 C-9
SENSOR GP - PRESSURE (VOL. 1) 221-3405 71 J-12
SENSOR GP - SPEED(VOL. 1) 186-0131 70 H-9
SENSOR GP - SPEED(VOL. 1) 163-0265 97 A-3
SENSOR GP - TEMP (VOL. 1) 134-2252 85 C-3
SWITCH AS - STEERING OIL LEVEL (VOL. 1) 172-8660 94 C-3
TANK GP - HYDRAULIC (SEE NOTE) (VOL. 1)* 280-1634 58 D-4
TANK GP - HYDRAULIC (SEE NOTE) (VOL. 1)* 280-2090 64 D-4
VALVE GP - MAKE UP (FAN ANTI-CAV) (VOL. 1) 183-7170 45 G-12
VALVE GP - PRESSURE REDUCING (VOL. 1) 226-0835 44 H-14
VALVE GP - SOL (VOL. 1) 288-4351 6 H-11
VALVE GP - STEERING (VOL. 1) 151-5933 1 I-3
COMPONENT LOCATIONS
Screen Steering Pump Suction Port
ACCUMULATOR PRESSURE
SENSOR
PRESSURE ANDFLOW
COMPENSATOR VALVES
PRESSURE REDUCING VALVE
STEERING CONTROL VALVE and RELIEF VALVE MANIFOLD
K
E
N
R
8
3
7
9

V
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1
3
6

P
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,

C
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,

(
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s
io
n
s
:
4
8
in
c
h
e
s
x
3
5
in
c
h
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s
)
LINE PATTERNS
Drain / Return Lines
Component Group
Pilot / Load Sensing Pressure
Pressure Line
Attachment
Air Line
CALLOUTS
Taps (Pressure, Sampling,Sensor) by letter
Components by number
YY
52
CIRCUIT COLOR DESCRIPTIONS
SUPPLY LINE
DRAIN / RETURN LINE
STEERING CIRCUIT
LOADSENSING
797F OFF HIGHWAY TRUCK HYDRAULIC SCHEMATIC.
(STEERING SYSTEM.)
MEDIA NUMBER: KENR8379 (VOL. 1)
PART NUMBER: 272-3213 CHANGE: 02
Components are shown installed on a fully operable machine.
Refer to the appropriate Service Manual for Troubleshooting, Specifications.
A
B
C
D
E
F
1 2 3 4 5 6 7 8 9 10 11 12 13 14
G
H
I
J
1 2 3 4 5 6 7 8 9 10 11 12 13 14
A
B
C
D
E
F
G
H
I
J
AA
BB
PP P L
CL
CR
R EF T HT
LS
HP
L
R
LS
T
P
STEEP GRADE (ADD'L) RETARDING AR ONLY
Vg MIN Vg MAX
T1 G1 MA A
U R1 T2 M1A SL S
Vg MIN Vg MAX
T1A B G2 MB
R2 T2A M1B
L1 T1 L1 G M A
L2 R T2 M1 S
Vg MIN Vg MAX
PUMP
DRIVE
BOX
STEEP GRADE ONLY
163-0265
134-2252
172-8660
183-7170
240-7790
186-0131
288-4351
253-4120
221-3405
192-3897
151-5933
194-6171
288-5537
280-2090
280-1634
4T-6788
290-2569
289-9904
290-2569
284-9631 301-4678
281-8284
226-0835
(Part #: N/A)
STEERING POSITION
SENSOR
PRESSURE AND FLOW
COMPENSATOR VALVE
PRESSURE AND FLOW
COMPENSATOR VALVE
Part #: N/A
K
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N
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8
3
7
9

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2
3
6

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,

(
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4
8
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c
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s
x
3
5
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c
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s
)
Hydraulic Symbols (Electrical)
Electrical Symbols Table
325-AG135 PK-14
Circuit Identification
Number Wire Color Wire Gauge
Harness identification code
This example indicates
wire 135 in harness "AG".
325-PK-14
Wire Gauge
Wire Color
Circuit Number
Identification
Wire Number Identification Codes
Current Standard
Previous Standard
Electrical Schematic Example Hydraulic Schematic Example
325-PK
Wire Color Circuit Number
Identification
B A
Wire
Wire
(EXAMPLE VALVE)
Current Standard
Transducer
(Fluid)
Transducer
(Gas / Air)
G
Generator
Electrical Wire Pressure Switch
M
Electric Motor
Pressure Switch
(Adjustable)
Temperature Switch
Pressure
Symbol
Temperature
Symbol
Level
Symbol
Flow
Symbol
Electrical Symbols (Electrical)
ONE POSITION TWO POSITION THREE POSITION
VENTED PRESSURIZED RETURNABOVE FLUIDLEVEL RETURN BELOWFLUIDLEVEL
LINES CROSSING LINES J OINING
TWO-WAY THREE-WAY FOUR-WAY
SPRING CONTROL VALVES RESTRICTION LINE RESTRICTION
(FIXED)
2-SECTION PUMP
MAIN AUX.
SPRING
(ADJ USTABLE)
VARIABILITY LINE RESTRICTION
(VARIABLE)
LINE RESTRICTION VARIABLE and PRESSURE COMPENSATED
PRESSURE
COMPENSATION
PUMP: VARIABLE and PRESSURE COMPENSATED
ENERGY TRIANGLES
HYDRAULIC PNEUMATIC
MEASUREMENT
PRESSURE TEMPERATURE FLOW
ROTATING SHAFTS
UNIDIRECTIONAL BIDIRECTIONAL
PUSH-PULL LEVER PEDAL GENERAL MANUAL PUSH BUTTON SPRING
MANUAL CONTROL SYMBOLS
HYDRAULIC MOTORS
FIXED
DISPLACEMENT
VARIABLE DISPLACEMENT
NON-COMPENSATED
UNIDIRECTIONAL
BIDIRECTIONAL
HYDRAULIC PUMPS
FLUID STORAGE RESERVOIRS
CROSSING AND JOINING LINES
VALVE ENVELOPES VALVE PORTS
BASIC COMPONENT SYMBOLS
FLUIDCONDITIONER PUMP or MOTOR
FLUID POWER SYMBOLS
FIXED
DISPLACEMENT
VARIABLE DISPLACEMENT
NON-COMPENSATED
UNIDIRECTIONAL
BIDIRECTIONAL
VALVES
PILOT CONTROL SYMBOLS RELEASEDPRESSURE
EXTERNAL RETURN INTERNAL RETURN
REMOTE SUPPLY PRESSURE
SIMPLIFIED COMPLETE INTERNAL
SUPPLY PRESSURE
ACCUMULATORS
SPRING LOADED GAS CHARGED
SOLENOID
or MANUAL
SOLENOID
and PILOT
SOLENOIDand
PILOT or MANUAL
COMBINATION CONTROLS
SOLENOID SERVO THERMAL DETENT
HYDRAULIC AND PNEUMATIC CYLINDERS
DOUBLE ACTING SINGLE ACTING
BASIC
SYMBOL
SPRING
LOADED
CHECK VALVES
TWO
POSITION
INFINITE
POSITIONING
FLOWIN ONE DIRECTION FLOWALLOWEDIN EITHER DIRECTION
THREE
POSITION
CROSS FLOW PARALLEL FLOW
INTERNAL PASSAGEWAYS
NORMAL POSITION
A B
P T
A B
P T
SHIFTEDPOSITION INFINITE POSITION
CONTROL VALVES
ATTACHMENT
MANUAL SHUTOFF
SHUTTLE PILOT
CONTROLLED
T
Volume 2 of 3: Shallow Grade - Braking and Cooling
KENR8379
November 2009
797F Of f -Hi ghway Tr uck
Hydr aul i c Syst em
LAJ1-UP
2009 Caterpillar, All Rights Reserved Printed in U.S.A.
FRONT BACK
TANK
TANK
TANK
TANK
TRACTION CONTROL SYSTEM VALVE BRAKE COOLING SCREENS BRAKE COOLING and CHARGE
Hoist Screens - Internal
Rear Brake
ARC Solenoid
Front Brake
ARC Solenoid
Front Service Brake
Shuttle Valve
Rear Service Brake
Shuttle Valve
Relief Valve
Accumulator
Purge Solenoid
Parking Brake
Solenoid
RIGHT SIDE
LEFT SIDE
Service Brake Check Valve
Pressure Reducing Valve
Parking Brake Check Valve
Screen Parking Brake Relay Valve
Unloader Diverter Valve
Unloader Solenoid
Rear Brake Relay Valve
Front Brake Relay Valve
Bypass Switch
Accumulator(s) -
Brake Precharge
BrakeActuation
Section Filler Tube
Hoist and Brake
Cooling Section Accumulator
Purge Solenoid
BrakeActuation
Section
Hoist Screens
Return Screens
Return Screens
Hoist Screens
Hoist Valve Port
RIGHT FRONT
LEFT FRONT REAR
Hoist Oil Port
BRAKE CHASSIS VALVE CHASSIS VIEW
SERVICE BRAKE CONTROL VALVE
TANK
BRAKE SYSTEM FILTER
BRAKE TEMPERATURE SENSORS
Description
Machine
Location
Schematic
Location
BRAKE ACCUMULATOR C F-8
BRAKE ACCUMULATOR D F-6
BRAKE CHARGE PRESSURE K B-9
BRAKE COOLING P C-4
BRAKE PEDAL E D-5
BRAKE TO TANK I C-5
FRONT BRAKE SLACK ADJ USTER B H-1
HOIST CYLINDER HEADENDPRESSURE LL H-4
HOIST CYLINDER RODENDPRESSURE FF J-4
HOIST PUMP DISCHARGE/BRAKE COOLING SUPPLY PP I-5
LEFT BRAKE PRESSURE BB J-7
LEFT FRONT BRAKE COOLING OUT S J-2
LEFT FRONT BRAKE COOLING OUT T J-1
LEFT FRONT SERVICE BRAKE N I-2
LEFT REAR BRAKE COOLING IN Q G-2
LEFT REAR PARK BRAKE G J-10
LEFT REAR SERVICE BRAKE M I-10
PILOT OIL BYPASS (to Front Brake Cooling) DD J-6
PILOT OIL BYPASS (to Rear Brake Cooling) EE I-6
PILOT PRESSURE - HEADENDto TANK (Lower) KK H-4
PILOT PRESSURE - PUMP to HEADEND(Raise) JJ I-4
PILOT PRESSURE - PUMP to RODEND(Lower) HH I-4
PILOT PRESSURE - RODENDto TANK (Raise) GG J-4
RAXL DRIVE PUMP PRESSURE J D-11
REAR BRAKE SLACK ADJ USTER A H-11
RIGHT BRAKE PRESSURE CC I-7
RIGHT FRONT BRAKE COOLING IN U F-2
RIGHT FRONT BRAKE COOLING OUT V F-1
RIGHT FRONT SERVICE BRAKE O G-2
RIGHT REAR PARK BRAKE F F-10
RIGHT REAR SERVICE BRAKE L G-10
TCS PILOT H T-7
TAP LOCATIONS (VOL. 2)
Description Part Number Machine
Location
Schematic
Location
ACCUMULATOR GP - BRAKE PRECHARGE (VOL. 2) 286-0796 27 G-8
ACCUMULATOR GP - BRAKE PRECHARGE (VOL. 2) 286-0796 29 F-6
ADJ USTER GP (VOL. 2) 205-0560 42 I-11
ADJ USTER GP (VOL. 2) 205-0560 43 I-1
CONNECTOR AS - ORIFICE (VOL. 2) 311-6676 10 D-7
CONNECTOR AS - ORIFICE (VOL. 2) 311-6676 11 D-7
CONT GP - SERVICE BRAKE (VOL. 2) 321-5086 35 E-5
CONTROL GP - HYD(TRACTION CONTROL SYSTEM) (VOL. 2) 222-4744 31 I-8
COOLER SCREEN (VOL. 2) 165-0056 56 C-4
CORE AS - REAR BRAKE COOLER (VOL. 2) 285-0255 84 D-3
CORE AS (VOL. 2) 299-3290 113 J-13
CYL GP - TEL (VOL. 2) 289-8616 17 I-3
FILTER GP - OIL (BRAKE COOLING) (VOL. 2) 339-9703 25 C-3
FILTER GP - BRAKE SYSTEMOIL (VOL. 2) 290-2567 134 B-9
FILTER GP - TRANS (VOL. 2) 334-0572 118 I-12
FILTER GP - TRANS (VOL. 2) 334-0572 119 G-13
MANIFOLDGP - POWER ACCESS LINE RELIEF (VOL. 2) 336-0981 124 C-13
MOTOR GP - REAR AXLE FAN (VOL. 2) 257-6844 67 B-7
MOTOR GP - REAR AXLE LUBE (VOL. 2) 296-5306 37 D-11
ORIFICE (VOL. 2) N/A 130 C-13
PLUG AS (VOL. 2) 242-7114 115 I-13
PUMP GP - COOLING and BRAKE CHARGE (VOL. 2) 317-2659 55 A-9
PUMP GP - ELEC DR (RELIEF VALVE) (VOL. 2) 5T-1060 13 E-4
PUMP GP - HOIST (VOL. 2) 281-8288 22 B-10
PUMP GP - REAR AXLE LUBE (VOL. 2) 324-2716 39 E-11
SCREEN AS (VOL. 2) 9P-9555 99 F-13
SCREEN AS (VOL. 2) 172-6104 109 F-13
SCREEN GP - BYPASS SWITCH (VOL. 2) 172-2395 21 B-10
SENSOR GP - PARKE BRAKE PRESSURE (VOL. 2) 221-3410 80 J-8
SENSOR GP - PARKE BRAKE PRESSURE (VOL. 2) 221-3410 81 I-8
SENSOR GP - PRESSURE (VOL. 2) 221-3405 75 F-8/F-7
SENSOR GP - PRESSURE (VOL. 2) 221-3405 76 F-5
SENSOR GP - PRESSURE (VOL. 2) 221-3405 77 D-6
SENSOR GP - PRESSURE (VOL. 2) 221-3415 105 G-13
SENSOR GP - TEMP (VOL. 2) 134-2252 87 J-11
SENSOR GP - TEMP (VOL. 2) 134-2252 86 F-11
SENSOR GP - TEMP (VOL. 2) 134-2252 92 J-1
SENSOR GP - TEMP (VOL. 2) 134-2252 93 F-13
SENSOR GP - TEMP (VOL. 2) 288-8390 100 H-13
SWITCH AS - LEVEL (VOL. 2) 172-8660 96 B-9
SWITCH AS - PRESSURE (VOL. 2) 130-7459 102 I-13
SWITCH GP - FILTER BYPASS (VOL. 2) 164-7577 122 G-13
SWITCH GP - FILTER BYPASS (VOL. 2) 164-7577 123 I-12
TANK GP - HYDRAULIC (VOL. 2) 280-1634 59 B-5
VALVE - CHECK (VOL. 2) 123-4750 51 E-4
VALVE - CHECK (VOL. 2) 123-4750 52 F-7
VALVE - CHECK (VOL. 2) 123-4750 53 F-8
VALVE GP - RELIEF (VOL. 2) 346-4815 69 C-7
VALVE GP - CONT (VOL. 2) 293-4974 19 H-4
VALVE GP - DIVERTER (VOL. 2) 168-7859 111 H-12
VALVE GP - MANUAL BYPASS CONTROL (VOL. 2) 336-0978 126 D-13
VALVE GP - MTG (VOL. 2) 285-5630 33 D-8
VALVE GP - MTG (VOL. 3) 285-5630 32 E-8
VALVE GP - RELIEF (VOL. 2) 172-5381 107 H-13
COMPONENT LOCATIONS
K
E
N
R
8
3
7
9

V
O
L

2
3
6

P
a
g
e
,

C
o
l
o
r
,

(
D
im
e
n
s
io
n
s
:
4
8
in
c
h
e
s
x
3
5
in
c
h
e
s
)
LINE PATTERNS
Drain / Return Lines
Component Group
Pilot / Load Sensing Pressure
Pressure Line
Attachment
Air Line
CALLOUTS
Taps (Pressure, Sampling,Sensor) by letter
Components by number
YY
52
HYDRAULIC CIRCUIT COLOR DESCRIPTIONS
PILOT PUMP - CIRCUIT
PUMP GP - REAR AXEL LUBE CIRCUIT
PUMP GP - HOIST CIRCUIT
SUPPLY LINE
DRAIN / RETURN LINE
BRAKE COOLING
MOTOR GP - REAR AXEL LUBE CIRCUIT
PUMP GP - BRAKE CHARGE CIRCUIT
BRAKE ADJ USTER CIRCUIT
797F OFF HIGHWAY TRUCK HYDRAULIC SCHEMATIC.
SHALLOWGRADE RETARDING ARRANGEMENT.
(SERVICE, PARKING, BRAKE COOLING and HOIST SYSTEM.)
MEDIA NUMBER: KENR8379 (VOL. 2)
PART NUMBER: 272-3213 CHANGE: 02 and 272-3216 CHANGE: 03
Components are shown installed on a fully operable machine.
Refer to the appropriate Service Manual for Troubleshooting, Specifications.
A
B
C
D
E
F
1 2 3 4 5 6 7 8 9 10 11 12 13 14
G
H
I
J
1 2 3 4 5 6 7 8 9 10 11 12 13 14
A
B
C
D
E
F
G
H
I
J
.065
C2 C1
TO CYLINDER
HEADEND
TO CYLINDER
RODEND
FILL
TUBE
RAISE
LOWER
1 2

MAKE UP FLOW
FROMFILTER
LEFT REAR
RIGHT REAR
RIGHT BRAKE PRESSURE
P
R
L
TCS
D
RIGHT FRONT
LEFT FRONT
P
T
A
PUMP
DRIVE
BOX
1
HF3 PLUG
SH2
PD3 HF2 HF1 PD1
SV3
PR1
CV2
SQ1
CV1
PD2
SH1
SV1
FL1
RV1
LE1
SV2 PR2
PS1 ACC1 PS2 ACC2 SUPPLY
PS3
TSB
T1
FSB
R PS4 F
HOIST TCS
PS5
T
T2
BCD
PB
P
S
T F
O
BYPASS TO FRONT
BRAKE COOLING
HOIST SECTION PUMP BYPASS SECTION
P2
CYLINDER ROD END
TO TANK (RAISE)
PUMP TO CYLINDER
ROD END (LOWER)
PUMP TO CYLINDER
HEAD END (RAISE)
CYLINDER HEAD END
TO TANK (LOWER)
PILOT
ON/OFF
LEFT BRAKE PRESSURE
HOIST PILOT DRAIN
FROMFILTER
M
J
REAR AXLE
205-0560
134-2252
134-2252
134-2252
205-0560
165-0056
317-2659
BYPASS TO REAR
BRAKE COOLING
RIGHT WHEEL-GP &FD
LEFT WHEEL-GP &FD
BRAKE
CONTROL
MODULE
BANJ O-HOUSING
OIL SUMP
134-2252
285-0255
289-8616
123-4750
5T-1060
339-9703
280-1634
257-6844
346-4815
172-2395
281-8288
324-2716
296-5306
311-6676 311-6676
321-5086
285-5630
221-3405 221-3405
123-4750
286-0796
123-4750
221-3405
286-0796
293-4974
221-3410
221-3410
222-4744
172-5381
221-3415
334-0572
164-7577
172-6104
9P-9555
168-7859
288-8390
242-7114
334-0572
164-7577
130-7459 299-3290
336-0981
336-0978
339-3275
(130) ORIFICE
POWER ACCESS
172-8660
K
E
N
R
8
3
7
9

V
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3
3
6

P
a
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e
,

(
D
im
e
n
s
io
n
s
:
4
8
in
c
h
e
s
x
3
5
in
c
h
e
s
)
Hydraulic Symbols (Electrical)
Electrical Symbols Table
325-AG135 PK-14
Circuit Identification
Number Wire Color Wire Gauge
Harness identification code
This example indicates
wire 135 in harness "AG".
325-PK-14
Wire Gauge
Wire Color
Circuit Number
Identification
Wire Number Identification Codes
Current Standard
Previous Standard
Electrical Schematic Example Hydraulic Schematic Example
325-PK
Wire Color Circuit Number
Identification
B A
Wire
Wire
(EXAMPLE VALVE)
Current Standard
Transducer
(Fluid)
Transducer
(Gas / Air)
G
Generator
Electrical Wire Pressure Switch
M
Electric Motor
Pressure Switch
(Adjustable)
Temperature Switch
Pressure
Symbol
Temperature
Symbol
Level
Symbol
Flow
Symbol
Electrical Symbols (Electrical)
ONE POSITION TWO POSITION THREE POSITION
VENTED PRESSURIZED RETURNABOVE FLUIDLEVEL RETURN BELOWFLUIDLEVEL
LINES CROSSING LINES J OINING
TWO-WAY THREE-WAY FOUR-WAY
SPRING CONTROL VALVES RESTRICTION LINE RESTRICTION
(FIXED)
2-SECTION PUMP
MAIN AUX.
SPRING
(ADJ USTABLE)
VARIABILITY LINE RESTRICTION
(VARIABLE)
LINE RESTRICTION VARIABLE and PRESSURE COMPENSATED
PRESSURE
COMPENSATION
PUMP: VARIABLE and PRESSURE COMPENSATED
ENERGY TRIANGLES
HYDRAULIC PNEUMATIC
MEASUREMENT
PRESSURE TEMPERATURE FLOW
ROTATING SHAFTS
UNIDIRECTIONAL BIDIRECTIONAL
PUSH-PULL LEVER PEDAL GENERAL MANUAL PUSH BUTTON SPRING
MANUAL CONTROL SYMBOLS
HYDRAULIC MOTORS
FIXED
DISPLACEMENT
VARIABLE DISPLACEMENT
NON-COMPENSATED
UNIDIRECTIONAL
BIDIRECTIONAL
HYDRAULIC PUMPS
FLUID STORAGE RESERVOIRS
CROSSING AND JOINING LINES
VALVE ENVELOPES VALVE PORTS
BASIC COMPONENT SYMBOLS
FLUIDCONDITIONER PUMP or MOTOR
FLUID POWER SYMBOLS
FIXED
DISPLACEMENT
VARIABLE DISPLACEMENT
NON-COMPENSATED
UNIDIRECTIONAL
BIDIRECTIONAL
VALVES
PILOT CONTROL SYMBOLS RELEASEDPRESSURE
EXTERNAL RETURN INTERNAL RETURN
REMOTE SUPPLY PRESSURE
SIMPLIFIED COMPLETE INTERNAL
SUPPLY PRESSURE
ACCUMULATORS
SPRING LOADED GAS CHARGED
SOLENOID
or MANUAL
SOLENOID
and PILOT
SOLENOIDand
PILOT or MANUAL
COMBINATION CONTROLS
SOLENOID SERVO THERMAL DETENT
HYDRAULIC AND PNEUMATIC CYLINDERS
DOUBLE ACTING SINGLE ACTING
BASIC
SYMBOL
SPRING
LOADED
CHECK VALVES
TWO
POSITION
INFINITE
POSITIONING
FLOWIN ONE DIRECTION FLOWALLOWEDIN EITHER DIRECTION
THREE
POSITION
CROSS FLOW PARALLEL FLOW
INTERNAL PASSAGEWAYS
NORMAL POSITION
A B
P T
A B
P T
SHIFTEDPOSITION INFINITE POSITION
CONTROL VALVES
ATTACHMENT
MANUAL SHUTOFF
SHUTTLE PILOT
CONTROLLED
T
Volume 3 of 3: Steep Grade - Braking and Cooling
KENR8379
November 2009
797F Of f -Hi ghway Tr uck
Hydr aul i c Syst em
LAJ1-UP
2009 Caterpillar, All Rights Reserved Printed in U.S.A.
Description
Machine
Location
Schematic
Location
BRAKE ACCUMULATOR C F-9
BRAKE ACCUMULATOR D F-6
BRAKE CHARGE PRESSURE K B-9
BRAKE PEDAL E E-6
BRAKE TO TANK I D-5
FRONT BRAKE COOLING SUPPLY Z B-5
FRONT BRAKE SLACK ADJ USTER B H-1
HOIST CYLINDER HEADENDPRESSURE LL H-4
HOIST CYLINDER RODENDPRESSURE FF J-4
HOIST PUMP DISCHARGE/BRAKE COOLING SUPPLY PP I-5
LEFT BRAKE PRESSURE BB J-8
LEFT FRONT BRAKE COOLING OUT S J-2
LEFT FRONT BRAKE COOLING OUT T J-1
LEFT FRONT SERVICE BRAKE N I-4
LEFT REAR BRAKE COOLING IN Q J-10
LEFT REAR PARK BRAKE G J-10
LEFT REAR SERVICE BRAKE M I-11
PILOT OIL BYPASS (to Front Brake Cooling) DD J-7
PILOT OIL BYPASS (to Rear Brake Cooling) EE I-6
PILOT PRESSURE - HEADENDto TANK (Lower) KK H-5
PILOT PRESSURE - PUMP to HEADEND(Raise) JJ I-5
PILOT PRESSURE - PUMP to RODEND(Lower) HH I-5
PILOT PRESSURE - RODENDto TANK (Raise) GG J-4
RAXL DRIVE PUMP PRESSURE J D-12
REAR BRAKE COOLING SUPPLY AA B-5
REAR BRAKE SLACK ADJ USTER A H-11
RIGHT BRAKE PRESSURE CC I-8
RIGHT FRONT BRAKE COOLING IN U F-2
RIGHT FRONT BRAKE COOLING OUT V F-1
RIGHT FRONT SERVICE BRAKE O G-1
RIGHT REAR BRAKE COOLING IN R F-10
RIGHT REAR PARK BRAKE F F-10
RIGHT REAR SERVICE BRAKE L G-11
TCS PILOT H H-7
TAP LOCATIONS (VOL. 3)
Hoist Screens - Internal
Rear Brake
ARC Solenoid
Front Brake
ARC Solenoid
Front Service Brake
Shuttle Valve
Rear Service Brake
Shuttle Valve
Relief Valve
Accumulator
Purge Solenoid
Parking Brake
Solenoid
RIGHT SIDE
LEFT SIDE
Service Brake Check Valve
Pressure Reducing Valve
Parking Brake Check Valve
Screen Parking Brake Relay Valve
Unloader Diverter Valve
Unloader Solenoid
Rear Brake Relay Valve
Front Brake Relay Valve
Bypass Switch
Accumulator(s) -
Brake Precharge
FRONT BACK
TANK
TANK
TANK
TANK
TRACTION CONTROL SYSTEM VALVE
BRAKE CHASSIS VALVE CHASSIS VIEW
SERVICE BRAKE CONTROL VALVE
BRAKE SYSTEM FILTER
TANK
REAR FRONT
BRAKE COOLING SCREENS BRAKE COOLING DRIVE
RIGHT FRONT
LEFT FRONT REAR
F
R
Rear Brake Cooling Pump
VIEW A
VIEW A
BrakeActuation
Section Filler Tube
Hoist and Brake
Cooling Section
BrakeActuation
Section
Hoist Oil Port
Return Screens
Hoist Valve Port
Brake Cooling
Relief Valve
Front Pumps
Description Part Number Machine
Location
Schematic
Location
ACCUMULATOR GP - BRAKE PRECHARGE (VOL. 3) 286-0796 26 G-9
ACCUMULATOR GP - BRAKE PRECHARGE (VOL. 3) 286-0796 28 F-6
ADJ USTER GP (VOL. 3) 205-0560 40 I-11
ADJ USTER GP (VOL. 3) 205-0560 41 I-1
CONNECTOR AS - ORIFICE (VOL. 3) 311-6676 8 E-7
CONNECTOR AS - ORIFICE (VOL. 3) 311-6676 9 E-7
CONT GP - BRAKE (VOL. 3) 321-5086 34 F-6
CONTROL GP - HYD(TRACTION CONTROL SYSTEM) (VOL. 3) 222-4744 30 I-8
CORE AS - FRONT BRAKE COOLER (VOL. 3) 285-0255 82 H-3
CORE AS - REAR BRAKE COOLERS (VOL. 3) 285-0255 83 B-4
CORE AS (VOL. 3) 299-3290 112 J-13
CYL GP - TEL (VOL. 3) 289-8616 16 I-3
CYLINDER GP - BASIC (VOL. 3) 339-3275 129 D-13
FILTER - HYDRAULIC (VOL. 3) 4T-6788 47 C-6
FILTER GP - OIL (BRAKE COOLING) (VOL. 3) 339-9703 24 H-2
FILTER GP - BRAKE SYSTEMOIL (VOL. 3) 290-2567 135 B-9
FILTER GP - TRANS (VOL. 3) 334-0572 116 I-12
FILTER GP - TRANS (VOL. 3) 334-0572 117 G-13
MANIFOLDGP - POWER ACCESS LINE RELIEF (VOL. 3) 336-0981 125 C-13
MOTOR GP - REAR AXLE FAN (VOL. 3) 257-6844 66 B-7
MOTOR GP - REAR AXLE LUBE (VOL. 3) 296-5306 36 D-11
MOTOR GP - BRAKE COOLING (VOL. 3) N/A 136 B-5
ORIFICE (VOL. 3) N/A 131 C-13
PLUG AS (VOL. 3) 242-7114 114 I-13
PUMP GP - BRAKE CHARGE (VOL. 3) 314-9248 61 A-10
PUMP GP - BRAKE COOLING DRIVE (VOL. 3) 281-8284 63 A-10
PUMP GP - ELEC DR (RELIEF VALVE) (VOL. 3) 5T-1060 12 C-4
PUMP GP - HOIST (VOL. 3) 281-8288 23 B-10
PUMP GP - REAR AXLE LUBE (VOL. 3) 324-2716 38 E-11
SCREEN AS (VOL. 3) 9P-9555 98 F-13
SCREEN AS (VOL. 3) 172-6104 108 F-13
SCREEN GP - BYPASS SWITCH (VOL. 3) 172-2395 20 C-10
SCREENS - BRAKE COOLING (VOL. 3) N/A 132 B-5
SENSOR GP - PARKE BRAKE PRESSURE (VOL. 3) 221-3410 78 J-8
SENSOR GP - PARKE BRAKE PRESSURE (VOL. 3) 221-3410 79 H-8
SENSOR GP - PRESSURE (VOL. 3) 221-3405 72 F-8/F-7
SENSOR GP - PRESSURE (VOL. 3) 221-3405 73 E-7
SENSOR GP - PRESSURE (VOL. 3) 221-3405 74 F-6
SENSOR GP - PRESSURE (VOL. 3) 221-3415 104 G-13
SENSOR GP - TEMP (VOL. 3) 134-2252 88 F-1
SENSOR GP - TEMP (VOL. 3) 134-2252 89 J-1
SENSOR GP - TEMP (VOL. 3) 134-2252 90 J-11
SENSOR GP - TEMP (VOL. 3) 134-2252 91 F-11
SENSOR GP - TEMP (VOL. 3) 288-8390 103 H-13
SWITCH AS - LEVEL (VOL. 3) 172-8660 95 B-9
SWITCH AS - PRESSURE (VOL. 3) 130-7459 101 I-13
SWITCH GP - FILTER BYPASS (VOL. 3) 164-7577 120 G-13
SWITCH GP - FILTER BYPASS (VOL. 3) 164-7577 121 I-12
TANK GP - HYDRAULIC (VOL. 3) 280-2090 65 B-6
VALVE - CHECK (VOL. 3) 123-4750 48 F-7
VALVE - CHECK (VOL. 3) 123-4750 49 G-8
VALVE - CHECK (VOL. 3) 123-4750 50 C-4
VALVE GP - RELIEF (VOL. 3) 346-4815 68 C-7
VALVE GP - CONT (VOL. 3) 293-4974 18 H-4
VALVE GP - DIVERTER (VOL. 3) 168-7859 110 H-12
VALVE GP - MANUAL BYPASS CONTROL (VOL. 3) 336-0978 127 C-13
VALVE GP - RELIEF (VOL. 3) 172-5381 106 G-13
COMPONENT LOCATIONS
BRAKE TEMPERATURE SENSORS
TANK
K
E
N
R
8
3
7
9

V
O
L

3
3
6

P
a
g
e
,

C
o
l
o
r
,

(
D
im
e
n
s
io
n
s
:
4
8
in
c
h
e
s
x
3
5
in
c
h
e
s
)
LINE PATTERNS
Drain / Return Lines
Component Group
Pilot / Load Sensing Pressure
Pressure Line
Attachment
Air Line
CALLOUTS
Taps (Pressure, Sampling,Sensor) by letter
Components by number
YY
52
797F OFF HIGHWAY TRUCK HYDRAULIC SCHEMATIC.
STEEP GRADE RETARDING ARRANGEMENT.
(SERVICE, PARKING, BRAKE COOLING and HOIST SYSTEM.)
MEDIA NUMBER: KENR8379 (VOL. 3)
PART NUMBER: 272-3213 CHANGE: 02 and 272-3216 CHANGE: 03
Components are shown installed on a fully operable machine.
Refer to the appropriate Service Manual for Troubleshooting, Specifications.
HYDRAULIC CIRCUIT COLOR DESCRIPTIONS
PILOT PUMP - CIRCUIT
PUMP GP - REAR AXEL LUBE CIRCUIT
PUMP GP - HOIST CIRCUIT
SUPPLY LINE
DRAIN / RETURN LINE
BRAKE COOLING
MOTOR GP - REAR AXEL LUBE CIRCUIT
PUMP GP - BRAKE CHARGE CIRCUIT
BRAKE ADJ USTER CIRCUIT
A
B
C
D
E
F
1 2 3 4 5 6 7 8 9 10 11 12 13 14
G
H
I
J
1 2 3 4 5 6 7 8 9 10 11 12 13 14
A
B
C
D
E
F
G
H
I
J
.065
C2 C1
TO CYLINDER
HEADEND
TO CYLINDER
RODEND
FILL
TUBE
RAISE
LOWER
1 2

B
LEFT REAR
RIGHT REAR
RIGHT BRAKE PRESSURE
P
R
L
TCS
D
RIGHT FRONT
LEFT FRONT
P
T
A
PUMP
DRIVE
BOX
1
HF3 PLUG
SH2
PD3 HF2 HF1
PD1
SV3
PR1
CV2
SQ1
CV1
PD2
SH1
SV1
FL1
RV1
LE1
SV2
PR2
PS1 ACC1 PS2 ACC2 SUPPLY
PS3
TSB
T1
FSB
R PS4 F
HOIST TCS
PS5
T
T2
BCD
PB
P
S
T F
O
HOIST SECTION PUMP BYPASS SECTION P2
CYLINDER ROD END
TO TANK (RAISE)
PUMP TO CYLINDER
ROD END (LOWER)
PUMP TO CYLINDER
HEAD END (RAISE)
CYLINDER HEAD END
TO TANK (LOWER)
PILOT
ON/OFF
LEFT BRAKE PRESSURE
HOIST PILOT DRAIN
FROMFILTER
M
134-2252
134-2252
134-2252
134-2252
J
REAR AXLE
RIGHT WHEEL-GP &FD
LEFT WHEEL-GP &FD
BRAKE
CONTROL
MODULE
BANJ O-HOUSING
OIL SUMP
172-5381
221-3415
334-0572
164-7577
172-6104
9P-9555
168-7859
288-8390
242-7114
334-0572
164-7577
130-7459 299-3290
BYPASS TO FRONT
BRAKE COOLING
BYPASS TO REAR
BRAKE COOLING
324-2716
296-5306
AA
BB
172-8660
172-2395
281-8288
314-9248
281-8284
257-6844
346-4815
280-2090
285-0255
123-4750
5T-1060
311-6676 311-6676
321-5086
285-5630
221-3405
221-3405
123-4750
286-0796
286-0796
123-4750
221-3405
205-0560
221-3410
221-3410
222-4744
293-4974
289-8616
205-0560
339-9703

285-0255
4T-6788
336-0981
336-0978
339-3275
(130) ORIFICE
POWER ACCESS
Part #: N/A