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.

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

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

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

FRONT VIEW

32 33

REAR VIEW

Previous Standard
Wire Wire Color

23

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

ATTACHMENTS

CAB AIR SYSTEM

20 Page

10

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

AIR GUN (CLEAN OUT) 156-0927 VALVE GP AIR HORN SOL 7T-9074 ATTACHMENT

JUNCTION BLOCK

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

MAIN RESERVOIR

VALVE GP DRAIN (MAIN RESV) 7X-7655

2 10

AIR SEAT (BUDDY)

VALVE GP ENGINE WASTE GATE SOL 7T-9074

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

RESERVOIR AIR (MAIN) 5T-1049

VALVE GP AIR STARTER RELAY 115-9190

AIR SEAT

COMPRESSOR GP AIR 160-9820

K O

ATTACHMENTS
ENGINE WASTEGATE

VALVE GP RELAY 159-5149

VALVE GP REGULATOR (WASTE GATE) 8D-4755

E L F EXTERNAL AIR SUPPLY P

VALVE GP DRAIN (SEC RESV) 7X-7655

B

7
Z

4
BK ON

1
A C

SWITCH AS SERVICE BRAKE 3E-2034

VALVE GP PRESS PROTECT 2G-8815

12

VALVE GP DRAIN (SEC RESV) 7X-7655

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

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

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

3 10

VALVE GP RELAY 159-5149 CYLINDER GP REAR MASTER 8W-3405

X

X AIR

VALVE ASY PARK & SEC 213-1081

Y
1

AIR GUN (CLEAN OUT) 156-0927

J F

VALVE GP SEC & PARK BRAKE LOCK SOLENOID 188-3580

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

VALVE AS SERVICE BRAKE RETRACT 236-6570

OIL

OIL

SEE HYDRAULIC SYSTEM SCHEMATIC

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

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

A
INV VALVE CTRL

RENR9866

20 Page, Color 2

3 2 1

VALVE GP PARK BRAKE SW (DETENTED) 128-4971

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

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

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.

A

PARKING BRAKE APPLIED.

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, Troubleshooting and Specifications.

10