793 (FDB)

OFF-HIGHWAY TRUCK

© 2006 Caterpillar Inc.

 793D MAINTENANCE

ice
793D Serv
Procedure

WALK AROUND INSPECTION

 Grease Drain Hoist and
MAINTENANCE Reservoir Air Reservoir Brake Oil Level
10 HOURS/DAILY Level Moisture

Batteries

Air Filters
Suspension
Steering Oil Level
Cylinder Height
Coolant Level
Ether Cylinders Rear Axle
Oil Level
Belts and Breather
Engine Oil Level
Inspect Frame
Windshield for Cracks and
Washer Level Body Support Pads
And A/C Filters
Check for Leaks
Drain Air Reservoir Moisture
and Trash Build-up

Wash Windows, Transmission and Brake Cylinder

Cab Fresh Air Filters, Torque Converter Breathers
Seat Belt, Oil Level
Indicators and Gauges,
Brake Tests,
793D
Secondary Steering
Backup Alarm, and
Traction Control System

Suspension Cylinder Height

and Grease Breathers

Front Wheel Breathers Tire Inflation

Pressure

Wheel Nuts
Final Drive
Check Fuel Level Primary Magnetic Plug
and Drain Moisture Fuel Filter
 VITAL INFORMATION
MANAGEMENT SYSTEM (VIMS)
MESSAGE CENTER AND OPERATOR KEYPAD

Data Logger
Indicator Dots
Alert
Indicator Universal
ENG COOL TEMP [135]
Gauge
60 Deg F
Red
Indicator Display

Gauge OK
F1 ABC DEF

Key
F2 F3 GH1 JKL MNO

PRS TUV WXY

ID
 793D ELECTRONIC SYSTEMS
VIMS-PC VIMS
- Gauges
- Monitoring
- Prognostics
mph
12 Km/h 3F - Warnings
- Telemetry
VIMS Main Module - Payload Measurement
ET Service Tool ABL2M - Clock Synchronization
RS232 Link - Machine ID
- Auto-lube

Engine ECM
- Emission Control - Fuel Injection
- Engine Shutdowns - Ether Injection
- Throttle Position - Wastegate Control
- Throttle Bypass - Engine Speed
- Engine Speed - Diagnostics
- Manual Start Aid - Fan Control
CAT Data Link
- Engine Pre-lube

Brake ECM Transmission /

(ARC) (TCS) Chassis ECM
- Top Gear Limit
- Reverse Neutralize
- Load Counter
- Neutral Coast Inhibit
- Body Up Gear Limit
- Starter Protection
- Body Hoist Control
- Traction Control System (TCS) - Speed Limiter
- Auto Retarder Control (ARC)
- Rear Axle Cooling
- Brake Cooling Control
- Shift Control
- Neutral-start
- Back-up Alarm
- Overspeed Protection
- CTS
- Engine Pre-lube
- Directional Shift Management
- Autolube
 VIMS Main Module
ABL2M

INPUT COMPONENTS OUTPUT COMPONENTS

Torque Converter TPMS

Front Aftercooler
Outlet Screen Switch Lamp (Green)
Temperature Sensor
LF Brake Oil
Torque Converter TPMS
Temperature Sensor
Inlet Filter Switch Lamp (Red)
RF Brake Oil
Key Start Switch VIMS Service
Temperature Sensor
Lamp (Blue)
LR Brake Oil VIMS
Aftercooler
Temperature Sensor Action Lamp
Coolant Level Switch
RR Brake Oil VIMS
Temperature Sensor Jacket Water Action Alarm
Coolant Level Switch
Fuel Level Sensor
Alternator Four Gauge
R-terminal Cluster
Ambient Air
Temperature Sensor With 2 Lights
Steering Oil
Temperature Sensor
Dash Speed / Tach
Dimmer Switch St eering Oil Filt er Cluster
Bypass Swit ch With 2 Lights
12 MPH
km/h 3F
Steering Pressure
(High) Switch VIMS Keypad VIMS Message
Center
Left Front Strut with 2 Lights
Pressure Sensor Diagnostic Connector
Right Front Strut (ECAP, ET, Flash)
Pressure Sensor
Telemetry
Left Rear Strut Download Port
Pressure Sensor
Cab Serial
Right Rear Strut
Download Port
Pressure Sensor
 3516B ELECTRONIC CONTROL SYSTEM COMPONENT DIAGRAM
Engine ECM
CAT Data Link
INPUTS
Timing Calibration
Connector

Throttle Key Start Switch

OUTPUTS

Engine Coolant Temperature Speed / Timing Sensor

Engine Oil Pressure Electronic Unit

Intake Air Temperature (Unfiltered) Injectors (16)

Throttle Backup Switch

Engine Oil Pressure (Filtered)

Oil Level
Atmospheric Pressure Switch (Low) Ether Aid Relay

Manual Ether Switch

Turbo Outlet Pressure (Boost) St art Aid Hold Relay

User Defined Shut down

Right Turbo Inlet Pressure Engine Oil
Renewal Solenoid
Crankcase Pressure
Left Turbo Inlet Pressure Pre-lubrication Relay

Fuel Filter
Right Turbo Exhaust Bypass Switch Wast egat e Solenoid

Coolant Flow
Left Turbo Exhaust Switch

Ground Level
Rear Aft ercooler Temperat ure Shutdown Switch
 3516B LOGGED EVENTS
- Air Filter Restriction - Engine Oil Level Low

- Low Oil Pressure - High Crankcase Pressure

- High Coolant Temperature - Low Coolant Flow

- Engine Overspeed - User Defined Shutdown

- Oil Filter Restriction - Prelube Override

- Fuel Filter Restriction - Low Boost Pressure

- High Exhaust Temperature - High Boost Pressure

- High Aftercooler Temperature - Low Coolant Temperature

SYSTEMS CONTROLLED BY ENGINE ECM

- Ether Injection
- Cool Engine Elevated Idle
- Cold Cylinder Cutout
- Engine Start Function
- Engine Oil Pre-lubrication
- Exhaust Bypass at High Boost
- Engine Oil Renewal System
 Thermostat
JACKET WATER COOLANT FLOW Housing Shunt
Tank

Radiator
Engine Oil Cooler

Torque Converter/
Hydraulic Mot or Transmission Oil Cooler
Rear Brake Jacket
Ret urn Oil Cooler
Oil Coolers Water Pump
 AFTERCOOLER COOLANT FLOW
Shunt
Tank

Aftercooler Aftercooler Front Brake

Oil Cooler

Radiator
Air
Aftercooler Compressor
Water Pump
 ENGINE OIL SYSTEM

Engine
Oil Renewal
Scavenge
System Solenoid
Pump

To Fuel
Tank

Bypass
Valve
Engine
Engine
Oil Filters
Oil Cooler
Engine
Oil Pump
 OIL RENEWAL SOLENOID VALVE

Pist on Pist on

ON OFF
To Fuel To Fuel
Ret urn Ret urn

From Engine From Engine

Oil Gallery Oil Gallery
 FUEL SYSTEM

Fuel
Engine
Pressure
Block
Regulator
Primary Engine Oil
Fuel Fuel Renewal
Tank Filters Solenoid

Fuel Cylinder
Transfer Head
Pump
Fuel
Heater Fuel
Priming Pump
Switch

Cylinder
Head
Fuel Priming
Pump And Filt er

Secondary
Fuel Filters
AIR INDUCTION AND EXHAUST SYSTEM

From Air
Filters Muffler

Aftercooler

From Air
Filters
 793D FAN DRIVE HYDRAULIC SYSTEM

Fan Makeup
Valve

Fan Mot or

Filt er

Steering Pump

Fan Pump

Hoist Tank
Steering / Fan Steering
Cooler Tank
 Speed
Sensor

Pist on
Out put
Shaft Barrel

Ret urn Port

Case Drain Port

Port Plat e Supply Port
 Pressure and Flow
Compensator FAN DRIVE PUMP

Maximum Angle
Actuator Piston

Drive
Shaft

Charge Pump Minimum Angle

Impeller Actuator Piston
 To Minimum Angle FAN DRIVE
Act uat or Pist on
Pump Drain PUMP CONTROL
Supply High Pressure
Cut -off

To Fan
Drive Mot or

High
Pressure
Cut -off

Displacement
Solenoid and Valve

Maximum Angle
Current Act uat or Pist on
Adjust ment
Minimum Angle
Act uat or Pist on

Pump Case Charge

Drain
Supply Drain Pump
Displacement
To Minimum Angle Solenoid and
Act uat or Pist on Valve
POWER TRAIN
793D
Lockup Piston Turbine Impeller
TORQUE CONVERTER
Stator CONVERTER DRIVE
Torque Converter
Inlet Oil

Freewheel Torque Converter

Assembly Lockup Oil Passage
Lockup Piston Turbine Impeller
TORQUE CONVERTER
DIRECT DRIVE
Stator
Torque Converter
Inlet Oil

Freewheel Torque Converter

Assembly Lockup Oil Passage
 TORQUE CONVERTER AND
TRANSMISSION HYDRAULIC SYSTEM

TC Lockup Torque Converter /

Valve Transmission Cooler
TC Charging
Filter

Transmission
Charging Filter Breather TC Lockup
TC Outlet Valve
Relief
Valve
Priming
Bleed
TC Inlet
Orifice
Relief
Valve
TC Outlet
Orifice
and
TC / Trans Screen
Return Return
Pumps Screen
Transmission Screen Suction
Magnetic Screen
Screens
Suction
Manifold
 TORQUE CONVERTER LOCKUP CLUTCH CONTROL
DIRECT DRIVE

Pilot Oil
Lockup Pressure
Select or Modulat ion Valve
Pist on ( RV)

Load Load Pist on

Lockup
Solenoid Pist on Plug

Signal Oil To Lockup

To Load Clut ch ( LU)
Transmission Pist on
Lube Pump Orifice Pilot
Reducing
Valve

From To
Transmission St at ion Ret urn
Charge "D" Shut t le Spring
Pump Valve

Relay Valve From

Transmission Charging
Pump ( PMP)
 TRANSMISSION ICM
HYDRAULIC SYSTEM
Upshift Downshift
NEUTRAL Pressure Pressure

Lockup Downshift Upshift

Solenoid Solenoid Solenoid Rotary Actuator A

On
E

To Torque Converter Neutralizer

B
Relay Valve Valve
Priority Rotary
Pilot Oil Reduction Selector
Pressure Valve Spool
Pump F
Transmission Pressure
Charging
Filter C

Lube
Charging Pump
Pump Scavenge
Pump
G
To TC
Inlet D
Relief
Valve
H
Lube
Pressure

Lockup Dual
Stage Relief Valve Pressure Control
Selector Valve Group
Relief Valve Group

Torque Converter
Housing Lubrication
Transmission Case Relief Valve
 TRANSMISSION ICM
HYDRAULIC SYSTEM
DIRECT DRIVE
Upshift Downshift
Pressure Pressure

Lockup Downshift Upshift

Solenoid Solenoid Solenoid Rotary Actuator A

On
3
E
To Lockup Clutch N1
Relay Valve B
Neutralizer
Priority Valve Rotary
Pilot Oil Reduction
To Lockup Selector
Clutch Valve Pressure Valve Spool
Supply Pump F
Pressure

Charging Lube
Pump Pump Scavenge
Pump G
To TC
Inlet D
Relief
Valve H
Lube
Pressure

Lockup Dual
Stage Relief Valve Pressure Control
Selector Valve Group Group
Relief Valve

Torque Converter Lubrication

Housing Transmission Case Relief Valve
 VALVE STATION
CLUTCH RELEASED
Slug Ball Check Valve
Load Piston Selector Piston

Pilot Oil
Passage

Plug

Return
Decay Orifice
Spring
(Optional)

Drain Load Load

Drain
Piston Piston
Orifice Plug
Modulation Clutch To Clutch
Reduction Supply Clutch Pressure
Valve Rail Tap
 VALVE STATION
CLUTCH FILLING
Slug Ball Check Valve
Load Piston Selector Piston

Pilot Oil
Passage

Plug

Return Decay Orifice

Spring (Optional)

Drain Load Load

Drain
Piston Piston
Orifice Plug

Modulation Clutch To Clutch

Reduction Supply Clutch Pressure
Valve Rail Tap
 VALVE STATION
CLUTCH ENGAGED
Slug Ball Check Valve
Load Selector
Piston Piston

Pilot Oil
Passage

Plug

Return
Decay Orifice
Spring
(Optional)

Drain Drain Load Load

Piston Piston
Orifice Plug

Modulation Clutch To Clutch

Reduction Supply Clutch Pressure
Valve Rail Tap
 VALVE STATION
CLUTCH DECAY
Slug Ball Check Valve
Load Selector
Piston Piston

Pilot Oil
Passage

Plug

Return
Decay Orifice
Spring
(Optional)

Drain Drain Load Load

Piston Piston
Orifice Plug
Modulation Clutch To Clutch Clutch
Reduction Supply Pressure Tap
Valve Rail
 "D" STATION
CONVERTER DRIVE
Slug Ball Check Valve
Load Piston Selector Piston

Passage
From Lockup
Solenoid

Plug

Return
Spring

Drain Blocking
Drain Plate

Modulation Clutch To Pressure

Reduction Supply Two-stage Tap
Valve Rail Relief
Valve
 "D" STATION
DIRECT DRIVE
Slug Ball Check Valve
Load Piston Selector Piston

Passage
From Lockup
Solenoid

Plug

Return
Spring

Drain Blocking
Drain Plate

Modulation Clutch To Pressure

Reduction Supply Two-stage Tap
Valve Rail Relief
Valve
 Clutch SHIFT CYCLE
Pressure
(psi)
Transmission Converter
Clutch Slip Clutch Slip

400
Lockup Clutch Final Pressure
300
Transmission Clutch Final Pressure
200
Clutch 2 Lockup Clutch
Primary Pressure Primary Pressure
100
Lockup Clutch
Fill Pressure And Time
0
0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 Time
Clutch 2
Fill Pressure
and Time

Clutch 1 Clutch 2 Clutch 5 Lockup Clutch

 CLUTCH FILL AND MODULATION PROBLEMS
Clutch
Pressure

Maximum Pressure
High Primary Pressure (Clutch Rail Pressure)
Harsh Shift

Initial Clutch Final Clutch

Engagement Slow Engagement
(Primary Pressure) Modulation
Excessive Slip
Short
Fill Low Primary
Pressure
Excessive Slip

Time
Long
Fill

High Primary Low Primary Slow

Normal
Pressure Pressure Modulation
 TRANSMISSION/CHASSIS ELECTRONIC CONTROL SYSTEM

INPUT COMPONENTS OUTPUT COMPONENTS

ECM Location Cat Data Link
Code
Shift Lever Electronic Service Tool
Position Switch
Engine ECM
Transmission Gear
Switch Brake ECM
Machine Lockout
Swit ch VIMS
Transmission Out put
Speed Sensor 2
Transmission Output Upshift Solenoid
Speed Sensor 1
Converter Output
Speed Sensor Downshift Solenoid
Engine Output
Speed Sensor
Service/retarder
Brake Lockup Solenoid
Pressure Switch
Parking / Secondary Brake
Pressure Switch Back-up Alarm
Body Relay
Position Sensor
Starter Solenoid
Key Start Switch
Low Steering Auto Lube Solenoid
Pressure Switch
Body Up Lamp
Hoist Lever
Position Sensor Hoist Lower Solenoid
Transmission Lube
Filt er Swit ch
Hoist Screen Switch Hoist Raise Solenoid

Transmission Oil
Temp Sensor Machine Lockout Solenoid
Transmission Charge
Filter Switch
Torque Converter Machine Lockout Lamp
Transmission Oil Oil Temp Sensor
Level Swit ch Throt t le Lock Lamp
Park Brake
Swit ch Main Power Relay
TRANSMISSION/CHASSIS ECM
SYSTEMS CONTROLLED BY ECM
- Transmission Shifting - Torque Converter Lockup
- Top Gear Limit - Body Up Gear Limit
- Reverse Inhibitor - Body Hoist Control
- Starter Protection - Engine Oil Pre-lubrication
- Neutral Start - Fail In Gear Protection
- Shift Counter - Control Throttle Shifting (CTS)
- Load Counter - Directional Shift Management
- Back-up Alarm - Neutral Coast Inhibiting
- Anti-hunt - Engine Overspeed Protection
- Auto Lube (Grease)
TRANSMISSION / CHASSIS ECM
LOGGED EVENTS
- Coasting In Neutral
- Transmission Abuse
 793D REAR AXLE LUBRICATION
WARM OIL

RAX Oil
Filter System
Pressure
Sensor Auxiliary RAX
Cooler Package

Priority Valve

Brake
Cooling Bypass Valve
Supply Mot or
Valve Differential
Lube

Final Drive
St eer Bypass
ACC Manifold

RAX
From Mot or
RAX Left Right
St eering Final Drive Final Drive
Pump
Pump St eering Lube Lube
Tank Banjo Housing
Sump
 REAR AXLE LUBRICATION STRATEGY

Rear Axle Supply Solenoid Final Drive Bypass Solenoid

COLD COOL HOT COLD COOL HOT
Rear Axle < -3° C < -3 ° C -3 ° C t o 3 8 ° C > 38 ° C
-3° C t o 3 8 ° C > 38° C
Oil Temperature
(< 25° F) (25° F to 102° F) (> 102° F) (< 25 °F) (25 °F to 102 °F) (> 102 °F)

NOT Moving OFF OFF

OFF ON ON OFF
0 MPH ON after 5 mins ON after 5 mins

Moving
ON OFF OFF ON ON OFF
0-22 MPH

Moving Fast 5 mins ON

ON OFF OFF ON ON
> 2 2 MPH 1 min OFF

Gear Limit 3 rd 4th NO

 First Reduction Second Reduction Second Reduction
Ring Gear Carrier
Ring Gear

Second Reduction
Planetary Gear

Second Reduction
FINAL DRIVE Sun Gear

First Reduction
Sun Gear

First Reduction
Carrier

First Reduction
Planetary Gear
STEERING
793D
 793D STEERING SYSTEM
Accumulators NO TURN

Solenoid and Priority

Relief Valve Manifold Valve

Steering
Control Valve
To
Brake Cooling
Mot or

Steering
Pump

Fan Pump

Hand Steering
Steering Steering Tank
Cylinders Metering Cooler
Unit
 SOLENOID AND RELIEF VALVE MANIFOLD
To and From Supply
Accumulators From Priority Valve

To Steering
Control Valve

To Tank

Bleed Down
Solenoid

Back-up Relief
Valve
 Left Turn To Tank Right Turn
Cylinder Back Pressure
Cylinder
Valve
Relief / Makeup
Valve
Relief / Makeup
Valve

STEERING
DIRECTIONAL VALVE
NO TURN Right Turn Left Turn
Pilot Oil Pilot Oil
Combiner / Check Amplifier Spool
Spool

Priority Spool

Load
Sensing Port Hand Metering
From Unit Supply and
Accumulator Thermal Bleed
 To Tank
Left Turn Right Turn Back
Cylinder Cylinder Pressure Valve
Relief / Makeup
Valve

Stabilizing Relief / Makeup

Orifice Valve

STEERING
DIRECTIONAL VALVE Directional
Spool
RIGHT TURN
Right Turn Left Turn
Pilot Oil Pilot Oil
Combiner / Check
Spool Amplifier Spool

Stabilizing
Orifice

Connecting
Pin Hole

Priority Spool

Load Sensing Port

Hand Metering
Mid-connecting From Unit Supply and
Pin Accumulator Thermal Bleed
 CL CR
Steering
Control Valve

L R

STEERING SYSTEM
NO STEER / MAXIMUM FLOW
P

Return To Tank LS

Pump Supply

Hand
Metering Unit
 Hoist
Hoist Screens From Parking
Pump Brake Release
Valve

Suction
Screens

To / From To / From
Hoist Cylinder Hoist Cylinder
HOIST Rod End Head End
SYSTEM
HOLD From Parking
Brake Release
Valve
To Brake
Oil Cooling
Filters
 Lower
Solenoid

Parking Brake
HOIST CONTROL VALVE Release Pressure

HOLD

Brake Oil
To Tank Cooler
Relief Valve
To Hoist Cylinder
Load Check Head End
Valve

To Hoist Cylinder
Rod End

Low Pressure
Relief Valve
Counterbalance
High Pressure Valve
Relief Valve Rod End
Vent Slot
To Brake
Cooling Filters

Dual Stage Main Relief Pump

Relief Valve Dump Spool Supply Port
Signal Stem

Parking Brake
Release Pressure

Raise
Solenoid
 Lower
Solenoid

Parking Brake
Release Pressure
HOIST CONTROL VALVE
RAISE

Brake Oil
Cooler
To Tank
Relief Valve

To Hoist Cylinder
Load Check Head End
Valve

From Hoist Cylinder

Rod End

Low Pressure
Relief Valve
Counterbalance
High Pressure Valve
Relief Valve Rod End
Vent Slot
To Brake
Cooling Filters

Dual Stage Main Relief Pump

Relief Valve Dump Spool Supply Port
Signal Stem

Parking Brake
Release Pressure

Raise
On
Solenoid
 HOIST
COUNTERBALANCE
VALVE

Head End
Signal Pressure

To Tank From
Pump

From
Hoist Cylinder Rod End
Pressure To
Rod End
Piston Hoist Cylinder
Rod End Check Valve

RAISE LOWER AND FLOAT

 Lower
On
Solenoid

Parking Brake
Release Pressure

HOIST CONTROL VALVE

LOWER (POWER DOWN)

Brake Oil
Cooler
To Tank
Relief Valve
From Hoist Cylinder
Load Check Head End
Valve

To Hoist Cylinder
Rod End

Low Pressure
Relief Valve
Counterbalance
High Pressure Valve
Relief Valve Rod End
Vent Slot
To Brake
Cooling Filters

Dual Stage Main Relief Pump

Relief Valve Dump Spool Supply Port
Signal Stem

Parking Brake
Release Pressure

Raise
Solenoid
 Lower
On
Solenoid

Parking Brake
Release Pressure

HOIST CONTROL VALVE

FLOAT

Brake Oil
Cooler
To Tank
Relief Valve

Load Check From Hoist

Valve Cylinder
Head End

To Hoist
Cylinder
Rod End
Low Pressure
Relief Valve
Counterbalance
High Pressure Valve
Relief Valve Rod End
Vent Slot
To Brake
Cooling Filters

Dual Stage Main Relief Pump

Relief Valve Dump Spool Supply Port
Signal Stem

Parking Brake
Release Pressure

Raise
Solenoid
AIR SYSTEM AND BRAKES
793D
 793D AIR CHARGING SYSTEM
Air Compressor
and Governor

Air To Air Start

Dryers Solenoid
and
Wastegate

Remote
Supply
Service / Retarder
Brake Tank
Low Air
To Auto Lube Solenoid Sensor
To Horn / Seat / Clean-out
Pressure
Protection
Valve

Parking / Secondary
Brake Tank
 Primary Air Tank
SERVICE / RETARDER BRAKE AIR SYSTEM
SERVICE BRAKES ENGAGED
From Air
Compressor

Brake Light
and
Service / Front Brake Cooler
Air Pressure Retarder Diverter Valve
Sensor Switch
Service
Brake Valve Service
Brake
Relay
Valve
Retarder
Valve Cooling
Diverter
Solenoid

From Secondary
Air Reservoir

Cab
Brake Cylinders
 PARKING / SECONDARY BRAKES
SECONDARY BRAKES RELEASED
PARKING BRAKES ENGAGED

Parking /
Secondary Parking Parking
Brake Brake Brake
Parking Switch Release Release
Brake Lockout Pump Valve
Valve Solenoid

Inverter
Secondary Valve
Brake
Valve Parking Brake To Hoist
Reset Valve Pilot System

Parking / Secondary
Brake Tank
 From Cab Secondary
TOWING SYSTEM Relief or Parking Brake Valve
Valve

To Hoist Parking Brake

Pilot Release Valve
Parking Parking System
Brake Brake
Release Release
Pump Filter

Check
Valve

Towing Pump
and Motor
Towing Pump
Relief Valve
 BRAKE CYLINDER
BRAKES ENGAGED

Air Indicator Rod From

Piston Makeup
Tank
Oil
Piston

Air To
Inlet Slack
Adjuster

Breather Valve
Port
Spring Rod
 BRAKE SLACK ADJUSTER

Oil Flow
Oil Flow
to Brake
Small Piston from Brake
Cylinder
Cylinder
Large Piston

From From To
Wheel Wheel Wheel
Brakes Brakes Brakes

To
Wheel
Brakes

BRAKES RELEASED BRAKES ENGAGED

 793D BRAKE COOLING CIRCUIT
Screens
Divert er
To
Rear Brakes Valve
Hoist
Tank
Screen

To
Front Brakes Cooler Engine
RAX Cooling Fan
Cooling Fan Mot or Brake Cooling Pumps
Mot or
RAX
Mot or
RAX
Lube Filter Filt er
System

RAX
Hoist
Pump
Valve

Priority
To St eering Syst em Valve
Manifold
Screens Parking
Brake
Syst em

Fan St eering
Pump Pump
Filters Pump Filt er
St eering Drive
Tank Gear Parking Brake
Box Pump

Hoist Tank

Hoist Pumps
 BRAKE COOLING CONTROL SYSTEM

Brake
ECM

INPUT COMPONENTS OUTPUT COMPONENTS

Rear
Engine Cooling Aft ercooler Engine Cooling
Fan Speed Sensor Temperat ure Fan Solenoid
St at us
Brake Cooling Pump Drive
Mot or Speed Sensor Brake
Temperat ure Brake Cooling
Transmission
St at us Pump Solenoid
Lube
Temperat ure
St at us Torque
Convert er
Brake Cooling
Engine Out let
Divert er Solenoid
Coolant Temperat ure
Temperat ure St at us
St at us

High Speed
Braking
St at us
 BRAKE ELECTRONIC CONTROL SYSTEM

INPUT COMPONENTS
ECM Location Code CAT DATA LINK
Service Tool
Front Brake
Filter Switch Engine ECM
Hydraulic Fan Speed Sensor Transmission / Chassis ECM

VIMS
Brake Cooling Pump Speed Sensor
Shift Lever Throttle Transmission Output
Switch Sensor Speed Sensor
Parking Brake Filter Actual Gear Engine Service / Retarder
Switch Speed / Timing Brake Switch
Brake Overstroke Sensor
Switch Parking / Secondary
Brake Switch
Brake Air Pressure
Left Brake OUTPUT COMPONENTS
Release
Differential Fan Solenoid
Pressure
Right Brake
Release Pressure Final Drive Lube
Solenoid
Differential
Filter Brake Cooling Diverter
Differential Oil Solenoid
Temp Sensor
Differential Brake Cooling Pump
Pressure Solenoid
Differential Hydraulic Fan Pump
Oil Level Solenoid
On Input
HARC Supply
Solenoid
Off Input
HARC On / Off HARC Control
Switch Retarder
Pressure Switch Solenoid
Retarder
Engaged Lamp
TCS Test TCS
Switch Engaged Lamp TCS Selector Solenoid
Left and Right
Left Wheel Speed Sensor
Proportional
Right Wheel Speed Sensor
(Servo) Solenoid
 SERVICE/RETARDER BRAKE AIR SYSTEM
ARC ENGAGED

From Air
Compressor

Brake Light and Front Brake Cooler

Air Pressure Service / Diverter Valve
Sensor Retarder Switch Service
Relay
Service
Valve
Brake Valve

Retarder
Valve
Cooling
Diverter
Solenoid

From Secondary
Air Reservoir

Cab
Brake Cylinders
 HYDRAULIC ARC SYSTEM
ARC ENABLED

Rear
Brakes Brake Brake
Cylinders Cylinders
Front
Brakes
Accumulator
Shuttle
Valve

ARC Check
Valve Valve Shuttle
Valve

Parking Brake Pump

Release Pump Drive

Hoist Hydraulic
Tank
 HYDRAULIC ARC VALVE
Control ENGINE ON / ARC OFF
Solenoid
Valve

Spool

To Tank

Supply Solenoid
Valve Accumulator

Check Valve

Pump
Purge To
Solenoid Service
Valve Brakes
 HYDRAULIC ARC VALVE
Control ENGINE ON / ARC ON
Solenoid
Valve ON

Spool

To Tank

Supply Solenoid
Valve Accumulator
ON

Check Valve

Pump
Purge To
Solenoid Service
Valve Brakes
 HYDRAULIC ARC VALVE
Control ENGINE OFF / ARC OFF
Solenoid
Valve

Spool

To Tank

Supply Solenoid
Valve Accumulator

Check Valve

Pump
Purge To
Solenoid ON Service
Valve Brakes
Engine Speed
AUTOMATIC
Sensor RETARDER CONTROL
On Input
ARC ENGAGED
ARC On / Off
Switch Brake ECM
(ARC / TCS)
Off Input

CAT Data Link Retarder

Service Tool Engaged Lamp
Connector
Front Brake
Cooling Diverter Solenoid

From Parking Brake Release Pump

To Service Brakes

ARC Spool
Supply
Purge
Solenoid
Solenoid
Steering Bleed
Control

To Tank

ARC
Control Solenoid Valve
 TRACTION CONTROL SYSTEM

Brake ECM
(ARC / TCS)
Electronic
Service Tool

Service / Retarder TCS

Brake Switch Engaged
Lamp
Transmission
Output Speed
Cat Data Link TCS Selector
Sensor
Solenoid
Left and Right
TCS Test
Switch

Proportional
Left Wheel
Speed Sensor Solenoid

Right Wheel + 10V to

Speed Sensor Wheel Sensors
 TRACTION CONTROL SYSTEM (TCS)
ENGINE RUNNING / BRAKES RELEASED
Test
Switch
Service / Retarder
Brake Switch

Left
Drive Axle

Input
Ball Check
Signals
Transmission
Speed Sensor Output
Signals
Orifice

Screen Tcs Engaged

Lamp

Selector
Solenoid
Parking
Brake
Valve
Right
Drive Axle
Proportional
Solenoid
 TRACTION CONTROL SYSTEM (TCS)
ENGINE RUNNING / LEFT BRAKE ENGAGED
Test
Switch
Service / Retarder
Brake Switch

Left
Drive Axle

Input
Ball Check Signals
Transmission
Speed Sensor Output
Signals
Orifice

Screen Tcs Engaged

Lamp

Selector
Solenoid
Parking
Brake
Valve
Right
Drive Axle
Proportional
Solenoid
 HYDRAULIC SCHEMATIC COLOR CODE

Black - Mechanical connection. Seal Red - High pressure oil

Dark Gray - Cutaway section Red/White Stripes - 1st pressure reduction

Light Gray - Surface color Red Crosshatch - 2nd reduction in pressure

White - Atmosphere or Pink - 3rd reduction in pressure

Air (No pressure)

Purple - Pneumatic pressure Red/Pink Stripes - Secondary source oil pressure

Yellow - Moving or activated components Orange - Pilot, charge, or Torque Converter oil

Cat Yellow - (R estricted usage) Orange / White Stripes -

Identification of components Reduced pilot, charge, or TC oil pressure
within a moving group
Orange Crosshatch - 2nd reduction in
Brown - Lubricating oil pilot, charge, or TC oil pressure.

Green - Tank, sump, or return oil Blue - Trapped oil

Green / White Stripes -

Scavenge Oil or Hydraulic Void