Make sure your Adobe Acrobat Reader is up

SCHEMATIC FEATURES AND TIPS

to date in order to access the latest features
of this schematic.

GET
Adobe Acrobat Reader

SAVE
a copy of this schematic

THE BOOKMARKS PANEL WILL ALLOW YOU TO THE FUNCTION ISOLATION TOOLS ISOLATE
QUICKLY NAVIGATE TO POINTS OF INTEREST. CIRCUITS FOR TRACING HYDRAULIC LINES

Function Isolation Tools

Grids On/Off

All Circuits Off

STANDARD VIEW
All Circuits On

021 (Orange) (Pilot Pump Output)

032 (Red) (Main Pump Output)

577 (Lt Green) (Drain/Return Line)

Machine Views

Machine View - Front

Machine View - Rear

Implement Stack 021 (Orange) (Pilot Output)

CIRCUIT ISOLATED
CLICK HERE TO VIEW THE SCHEMATIC
UTILIZE HYPERTEXT TO NAVIGATE TO COMPONENTS AND THEIR MACHINE LOCA- SYMBOLS AND DEFINITIONS PAGE
TION QUICKLY. HYPERTEXT IS INDICATED BY TEXT THAT IS BLUE AND UNDERLINED. ELECTRICAL SYMBOLS

Pressure Temperature Level

Switch Switch Switch Circuit Breaker

BASIC HYDRAULIC SYMBOLS

Fluid Pump Spring

Variability
Conditioner or Motor (Adjustable)

HOTKEYS (Keyboard Shortcuts)

FUNCTION KEYS
Zoom In “CTRL” / “+”
Zoom Out “CTRL” / “-”
Fit to Page “CTRL” / “0” (zero)
Hand Tool “SPACEBAR” (hold down)
Find “CTRL” / “F”
WHEN ONLY ONE CALLOUT IS SHOWING ON A Search “CTRL” / “SHIFT” / “F”

MACHINE VIEW, CLICKING ON THIS BUTTON WILL

VIEW ALL CALLOUTS MAKE ALL OF THE CALLOUTS VISIBLE. THIS
BUTTON IS TYPICALLY LOCATED IN THE TOP RIGHT
CORNER OF EVERY MACHINE VIEW PAGE.
Due to different monitor sizes and PDF reader
preferences there may be some variance in linked
schematic locations. This document is best viewed at
a screen resolution of 1024 X 768.

© 2022 Caterpillar. All Rights Reserved. CAT, CATERPILLAR, LET’S DO THE

WORK, their respective logos, “Caterpillar Corporate Yellow”, the “Power Edge”
and Cat “Modern Hex” trade dress as well as corporate and product identity used
herein, are trademarks of Caterpillar and may not be used without permission.
SCHEMATIC SYMBOLS AND DEFINITIONS
VALVES INTERNAL PASSAGEWAYS PUMPS BASIC HYDRAULIC
ENVELOPES FLOW IN ONE
DIRECTION
FLOW ALLOWED IN
EITHER DIRECTION
PARALLEL
FLOW
CROSS
FLOW
FIXED DISPLACEMENT
COMPONENT SYMBOLS

One Position Two Position Three Position Unidirectional Bidirectional Pump

Infinite Two Three Variability
Positioning Position Position or Motor
PORTS VARIABLE DISPLACEMENT
NON- COMPENSATED

CYLINDERS Fluid Spring

(Adjustable)
Two-way Three-Way Four-Way Conditioner
Unidirectional Bidirectional
CONTROL
AB AB
Single Acting Double Acting
MOTORS Pressure
FIXED DISPLACEMENT Spring
P T P T Compensation
Normal Position Shifted Position Infinite Position

CHECK
Control
ACCUMULATORS Unidirectional Bidirectional
Valves
Line Restriction
(Variable)
VARIABLE DISPLACEMENT
Basic Spring Shuttle NON- COMPENSATED
Pilot
Symbol Loaded Line Restriction
Controlled Spring Loaded Gas Charged Restriction
(Fixed)

Unidirectional Bidirectional

PILOT CONTROL Line Restriction

MAIN AUX.

2-Section
RELEASED PRESSURE Variable and Pressure
ROTATING SHAFTS Compensated
Pump

External Return Internal Return Unidirectional Bidirectional

REMOTE SUPPLY PRESSURE Attachment Pump: Variable and
Pressure Compensated

Internal
Simplified Complete Supply Pressure Hydraulic Pneumatic
Energy Triangles

COMBINATION CONTROLS
LINES MEASUREMENT

Solenoid Solenoid Solenoid Solenoid and Servo Thermal Detent Crossing Joining
or Manual and Pilot Pilot or Manual Pressure Temperature Flow

MANUAL CONTROL FLUID STORAGE RESERVOIRS

Push-pull Lever Manual Shutoff General Manual Push Button Pedal Spring Vented Pressurized Return Above Fluid Level Return Below Fluid Level

HYDRAULIC SYMBOLS - ELECTRICAL ELECTRICAL SYMBOLS

G
M T

Pressure Temperature Level Flow

Transducer Transducer Generator Electric Pressure Pressure Switch Temperature Electrical
Switch Switch Switch Switch Circuit Breaker
(Fluid) (Gas / Air) Motor Switch (Adjustable) Switch Wire

BASIC ELECTRICAL COMPONENT SYMBOLS HARNESS AND WIRE SYMBOLS

Wire, Cable, or Harness Assembly Identification:
Fuse: A component in an electrical circuit that will open the circuit if too much current flows through it. Includes Harness Identification Letters and Harness
Connector Serialization Codes (see sample).
Switch (Normally Open): A switch that will close at a specified point (temp, press, etc.). The circle indicates
that the component has screw terminals and a wire can be disconnected from it.
AG-C4 L-C12
Switch (Normally Closed): A switch that will open at a specified point (temp, press, etc.). 111-7898 3E-5179
No circle indicates that the wire cannot be disconnected from the component. Part Number: for 1
Connector Plug
Ground (Wired): This indicates that the component is connected to a grounded wire. 2
The grounded wire is fastened to the machine.
Plug Receptacle
Pin or Socket Number
Ground (Case): This indicates that the component does not have a wire connected to ground.
It is grounded by being fastened to the machine. Harness Identification Letter(s): (A, B, C, AA, AB, AC, ...)
Harness Connector Serialization Code: The "C" stands for
"Connector" and the number indicates which connector in the
Reed Switch: A switch whose contacts are controlled by a magnet. A magnet closes the contacts of
harness (C1, C2, C3, ...)
a normally open reed switch; it opens the contacts of a normally closed reed switch.
L-C12
3E-5179
Sender: A component that is used with a temperature or pressure gauge.
The sender measures the temperature or pressure. 5A
T Its resistance changes to give an indication to the gauge of the temperature or pressure. Component
Fuse (5 Amps) 9X-1123 Part Number
Relay (Magnetic Switch): A relay is an electrical component that is activated by electricity. 325-AG135 PK-14
It has a coil that makes an electromagnet when current flows through it. Harness identification code:
This example indicates wire group 325, Wire Gauge*
The electromagnet can open or close the switch part of the relay. wire 135 in harness "AG". Wire Color
*Wire gauge is shown in AWG (American Wire Gauge)
Solenoid: A solenoid is an electrical component that is activated by electricity. but could also be shown in metric denoted with mm
It has a coil that makes an electromagnet when current flows through it.
The electromagnet can open or close a valve or move a piece of metal that can do work. 1 Deutsch connector: Typical representation
of a Deutsch connector. The plug contains all
2 sockets and the receptacle contains all pins.
Magnetic Latch Solenoid: An electrical component that is activated by electricity and held latched by a
permanent magnet. It has two coils (latch and unlatch) that make electromagnet 1 Sure-Seal connector: Typical representation
when current flows through them. It also has an internal switch that places of a Sure-Seal connector. The plug and receptacle
2 contain both pins and sockets.
the latch coil circuit open at the time the coil latches.

© 2022 Caterpillar. All Rights Reserved. CAT, CATERPILLAR, LET’S DO THE

WORK, their respective logos, “Caterpillar Corporate Yellow”, the “Power Edge”
and Cat “Modern Hex” trade dress as well as corporate and product identity used
herein, are trademarks of Caterpillar and may not be used without permission.
 M0137475
March 2022

7495 and 7495HF Electric Rope Shovel

Hydraulic System
R3R1-UP
R3F1-UP

Open Gear Lube A and B System (With Rope Crowd)

PUBLICATIONS.CAT.COM
© 2022 Caterpillar. All Rights Reserved. CAT, CATERPILLAR, LET’S DO THE WORK, their respective logos, “Caterpillar Corporate Yellow”, the “Power Edge”
and Cat “Modern Hex” trade dress as well as corporate and product identity used herein, are trademarks of Caterpillar and may not be used without permission.
 COMPONENT LOCATION
Schematic Machine Schematic Machine
Description Description
Location Location Location Location
Gauge - Pressure (A1) F-6 1 Valve Gp - Lube Distribution (2-Injector) C-4 29
Gauge - Pressure (A2) F-5 2 Valve Gp - Lube Distribution (2-Injector) (Lower Roller, LH) B-6 30
Gauge - Pressure (B1) F-1 3 Valve Gp - Lube Distribution (2-Injector) (Lower Roller, RH) B-4 31
Gauge - Pressure (B2) F-4 4 Valve Gp - Lube Distribution (3-Injector) (LH) A-6 32
Injector (Four) (Ship Shaft) D-7 5 Valve Gp - Lube Distribution (3-Injector) (RH) A-4 33
Injector (Single) (Axle, LH) B-6 6 Valve Gp - Lube Distribution (4-Injector 1) D-3 34
Injector (Single) (Axle, RH) B-4 7 Valve Gp - Lube Distribution (4-Injector 2) D-3 35
Sensor - Pressure (Transducer) (A1 1) B-6 8* Valve Gp - Lube Distribution (4-Injector 3) C-4 36
Sensor - Pressure (Transducer) (A1) E-6 9 Valve Gp - Lube Distribution (4-Injector 4) B-4 37
Sensor - Pressure (Transducer) (A2) E-5 10 Valve Gp - Lube Distribution (4-Injector 5) C-6 38
Sensor - Pressure (Transducer) (B1 1) D-1 11 Valve Gp - Lube Distribution (4-Injector 6) C-6 39
Sensor - Pressure (Transducer) (B1) E-1 12 Valve Gp - Lube Distribution (4-Injector) D-4 40*
Sensor - Pressure (Transducer) (B2) E-4 13 Valve Gp - Lube Distribution (4-Injector) (Lower Roller, LH1) B-6 41
Switch - Pressure (Axle, LH) B-5 14 Valve Gp - Lube Distribution (4-Injector) (Lower Roller, LH2) B-6 42
Switch - Pressure (Axle, RH) B-4 15 Valve Gp - Lube Distribution (4-Injector) (Lower Roller, LH3) A-6 43
Pump Gp - Lubrication (A1) F-6 16 Valve Gp - Lube Distribution (4-Injector) (Lower Roller, RH1) B-4 44
Pump Gp - Lubrication (A2) F-5 17 Valve Gp - Lube Distribution (4-Injector) (Lower Roller, RH2) B-4 45
Pump Gp - Lubrication (B1) F-2 18 Valve Gp - Lube Distribution (4-Injector) (Lower Roller, RH3) A-4 46
Pump Gp - Lubrication (B2) F-4 19 Valve Gp - Lube Distribution (4-Injector) (Rear Roller, LH) A-6 47
Tank Gp - Lubrication F-6, F-2 20 Valve Gp - Lube Distribution (4-Injector) (Rear Roller, RH) A-4 48
Valve - Unloader (Safety (A1)) E-6 21 Valve Gp - Lube Distribution (4-Injector) (Saddle Block, LH) C-7 49
Valve - Unloader (Safety (A2)) E-5 22 Valve Gp - Lube Distribution (4-Injector) (Saddle Block, RH) C-7 50
Valve - Unloader (Safety (B1)) E-2 23 Valve Gp - Lube Distribution (5-Injector 1) C-6 51
Valve - Unloader (Safety (B2)) E-3 24 Valve Gp - Lube Distribution (5-Injector 2) C-6 52
Valve As - Vent (A1) E-6 25 Valve Gp - Lube Distribution (6-Injector 1) D-2 53
Valve As - Vent (A2) E-5 26 Valve Gp - Lube Distribution (6-Injector 2) D-1 54
Valve As - Vent (B1) E-1 27 Valve Gp - Lube Distribution (Boom, LH) E-7 55
Valve As - Vent (B2) E-4 28 Valve Gp - Lube Distribution (Boom, RH) D-6 56
* - Not shown on the graphics.
 7 6 5 4 3 2 1

F7 F6 F5 F4 F3 F2 F1
(20) TANK GP - LUBRICATION (20) TANK GP - LUBRICATION
470-4567 470-4567

F F
(17) PUMP GP - LUBRICATION (A2)
536-0532
OGL SYSTEM "A" OGL - SYSTEM "B"
(16) PUMP GP - LUBRICATION (A1) PUMP
PUMP PUMP
PUMP 536-0532 STATION STATION (18) PUMP GP - LUBRICATION (B1) STATION
STATION (2) GAUGE - PRESSURE (A2) "B2" (19) PUMP GP - LUBRICATION (B2) 536-0532 "B1"
(1) GAUGE - PRESSURE (A1) "A2"
"A1" 8T-0860 536-0532
8T-0860
AIR SYSTEM

(3) GAUGE - PRESSURE (B1)

(22) VALVE - UNLOADER 8T-0860
SAFETY (A2)
8X-2323 (24) VALVE - UNLOADER
(21) VALVE - UNLOADER SAFETY (B2)
(26) VALVE AS - VENT (A2)
SAFETY (A1) (4) GAUGE - PRESSURE (B2) 8X-2323
8X-2323 8X-2320 (23) VALVE - UNLOADER
8T-0860
SAFETY (B1)
8X-2323
(27) VALVE AS - VENT (B1)
8X-2320

E7 E6 E5 E4 E3 E2 E1
CIRCUIT CIRCUIT CIRCUIT CIRCUIT
"A1" (25) VALVE AS - VENT (A1) "A2" "B2" (28) VALVE AS - VENT (B2) "B1"
8 POINTS 8X-2320 24 POINTS 33 POINTS 8X-2320 12 POINTS
E E

(9) PRESSURE SENSOR (12) PRESSURE SENSOR

(TRANSDUCER) (A1) (13) PRESSURE SENSOR (TRANSDUCER) (B1)
441-8726 (TRANSDUCER) (B2) 441-8726
441-8726
(55) VALVE GP - LUBE DISTRIBUTION (10) PRESSURE SENSOR
(BOOM, LH) (TRANSDUCER) (A2)
468-3120 441-8726
(34) VALVE GP - LUBE DISTRIBUTION (11) PRESSURE SENSOR
(4-INJECTOR 1) (TRANSDUCER) (B1 1)
BOOM FOOT PIN LH 269-5352 441-8726

BOOM FOOT PIN RH

(56) VALVE GP - LUBE DISTRIBUTION

(BOOM, RH) (35) VALVE GP - LUBE DISTRIBUTION
468-3120 (4-INJECTOR 2)

D7 D6 D5 D4 D3 D2 D1
269-5352

(5) INJECTOR (FOUR)

(SHIP SHAFT)
D 529-0742 (54) VALVE GP - LUBE DISTRIBUTION
D
(40) VALVE GP - LUBE DISTRIBUTION (6-INJECTOR 2)
SUPPLY LINE THRU (4-INJECTOR)
SHIP SHFT BUSH, OUTER- LH CENTER PINTLE TO 292-4086
269-5352 (53) VALVE GP - LUBE DISTRIBUTION
LOWER WORKS (6-INJECTOR 1)
292-4086
SHIP SHFT BUSH, OUTER- RH

(49) VALVE GP - LUBE DISTRIBUTION

(4-INJECTOR) (SADDLE BLOCK, LH)
269-5352
L5 PORT
SADDLE BLOCK BUSH- LH
CROWD SHEAVE BRG - LH

(51) VALVE GP - LUBE DISTRIBUTION

(Dimensions: 34 inches x 28 inches

(5-INJECTOR 1)
269-5353

C4 C3 C2 C1
SADDLE BLOCK BUSH- RH

C7 C6 C5
CROWD SHEAVE BRG - RH
(50) VALVE GP - LUBE DISTRIBUTION
(4-INJECTOR) (SADDLE BLOCK, RH)
269-5352
M0137475

(36) VALVE GP - LUBE DISTRIBUTION

C (4-INJECTOR 3)
C
(38) VALVE GP - LUBE DISTRIBUTION
(4-INJECTOR 5) 269-5352
269-5352

(39) VALVE GP - LUBE DISTRIBUTION

(4-INJECTOR 6) (29) VALVE GP - LUBE DISTRIBUTION
269-5352 (2-INJECTOR)
269-5346

(52) VALVE GP - LUBE DISTRIBUTION

(5-INJECTOR 2)
269-5353

(8) PRESSURE SENSOR

(TRANSDUCER) (A1 1) (37) VALVE GP - LUBE DISTRIBUTION
441-8726 (4-INJECTOR 4)
269-5352
24 Page,

B7 B6 B5 B4 B3 B2 B1
(7) INJECTOR (SINGLE)
(6) INJECTOR (SINGLE) (14) PRESSURE SWITCH (15) PRESSURE SWITCH (AXLE, RH) LINE PATTERNS
(AXLE, LH) (AXLE, LH) (AXLE, RH) 445-2992
B 445-2992 441-8725 441-8725 Pressure Line B
Pilot / Load Sensing Pressure
TAKE-UP AXLE - LH TAKE-UP AXLE - RH
(30) VALVE GP - LUBE DISTRIBUTION (31) VALVE GP - LUBE DISTRIBUTION Drain / Return Lines
(2-INJECTOR) (LOWER ROLLER, LH) TAKE-UP AXLE - RH (2-INJECTOR) (LOWER ROLLER, RH)
TAKE-UP AXLE - LH Air Line
269-5346 269-5346
Component Group
LOWER ROLLER LOWER ROLLER CALLOUTS
3RD FROM FRONT,LH LOWER ROLLER 2ND 3RD FROM FRONT,RH
FROM FRONT,RH YY Taps (Pressure, Sampling, Sensor - by letter)
LOWER ROLLER 2ND LOWER ROLLER Do not operate or work on this product unless you have
LOWER ROLLER FROM FRONT, LH 6TH FROM FRONT,RH DL DL D Connectors (By letter) read and understood the instruction and warnings in the
6TH FROM FRONT,LH LOWER ROLLER relevant Operation and Maintenance Manuals and
LOWER ROLLER FRONT, RH LOWER ROLLER Callout Number relevant service literature. Failure to follow the instruc-
LOWER ROLLER
Component
(52) VALVE GP - CONTROL
7TH FROM FRONT,RH (45) VALVE GP - LUBE DISTRIBUTION (Machine Location from Name tions or heed the warnings could result in injury or
7TH FROM FRONT,LH FRONT, LH Component LocationsTable)
138-1234 death. Proper care is your responsibility.
(4-INJECTOR) (LOWER ROLLER, RH2) Part Number

(41) VALVE GP - LUBE DISTRIBUTION (44) VALVE GP - LUBE DISTRIBUTION 269-5352

(4-INJECTOR) (LOWER ROLLER, LH1) (42) VALVE GP - LUBE DISTRIBUTION (4-INJECTOR) (LOWER ROLLER, RH1) LOWER ROLLER
LOWER ROLLER (4-INJECTOR) (LOWER ROLLER, LH2) 269-5352
269-5352 5TH FROM FRONT,LH 5TH FROM FRONT,RH
269-5352 (46) VALVE GP - LUBE DISTRIBUTION
LOWER ROLLER LOWER ROLLER HYDRAULIC CIRCUIT COLOR DESCRIPTIONS
(4-INJECTOR) (LOWER ROLLER, RH3)

A5 A4 A3 A2 A1
4TH FROM FRONT,RH

A7 A6
4TH FROM FRONT,LH (43) VALVE GP - LUBE DISTRIBUTION
PUMP A2 CIRCUIT
(4-INJECTOR) (LOWER ROLLER, LH3) 269-5352
PUMP A1 CIRCUIT
REAR ROLLER 269-5352
REAR ROLLER 2ND FROM REAR,RH SUPPLY LINE
2ND FROM REAR,LH (48) VALVE GP - LUBE DISTRIBUTION DRAIN / RETURN LINE
INJECTOR VALVES TO BE INITIALLY SET
(4-INJECTOR) (REAR ROLLER, RH) REAR ROLLER,RH
PUMP B2 CIRCUIT
(47) VALVE GP - LUBE DISTRIBUTION AT MAXIMUM OUTPUT UNLESS OTHERWISE
REAR ROLLER,LH 269-5352
PUMP B1 CIRCUIT
(4-INJECTOR) (REAR ROLLER, LH)
A NOTED. SETTINGS TO BE READJUSTED AS A
269-5352 REQUIRED IF EXCESS LUBRICANT IS OBSERVED.
(33) VALVE GP - LUBE DISTRIBUTION
(3-INJECTOR) (RH) CENTER PINTLE BUSH
CENTER PINTLE BUSH (32) VALVE GP - LUBE DISTRIBUTION 269-5348 IN TRUCK FRAME, RH
IN TRUCK FRAME,LH (3-INJECTOR) (LH) THIS SCHEMATIC IS FOR THE 7495 AND 7495HF ELECTRIC ROPE SHOVEL HYDRAULIC SYSTEM
269-5348
OPEN GEAR LUBE A AND B SYSTEM (WITH ROPE CROWD)
MEDIA NUMBER: M0137475
SCHEMATIC PART NUMBER: 617-9234, CHANGE: 00, 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.

7 6 5 4 3 2 1
CHASSIS

49 51

50 38

39
5
52

55
56

36 37 29
34

35

53 11

54
LUBRICATION STATION

10 12 19 18 22 17

13 16

4
2

28
1
24

20
27

23 3 26 21 25
UNDERCARRIAGE

14 30 6

RIGHT TRACK

42 43 32 41 47

7 44 31 15

LEFT TRACK

48 45 33 46