Component Locations

Part Machine Schematic Part Machine Schematic

Description
Number Location Location
Description
Number Location Location KENR5538
Steering Circuit Hoist Circuit - Continuned October 2006 FLUID POWER SYMBOLS
Cylinder Gp - Steering 223-1335 1 F-2 Pump - Hoist 188-4455 39 C-7 BASIC COMPONENT SYMBOLS
A B C D E
Drain 8J-8782 2 A-4 Screen As. 150-8457 40 A-7
Element -Filter (Steering Return) 132-8876 3 A-2 Screen As. - Pump Case Drain 119-4885 41 A-7
MAIN AUX.
Pump Gp - Metering 160-9727 4 F-3 Tank - Hyd. Oil (Hoist/ Cooling) 162-5242 42 A-7 PUMP: VARIABLE and
PUMP or MOTOR FLUID CONDITIONER SPRING CONTROL VALVES RESTRICTION LINE RESTRICTION 2-SECTION PUMP PRESSURE COMPENSATED
Pump Gp - Secondary Steering 141-6389 5 B-3 Valve Gp - Balance (Attach) 133-8810 43 B-5 (FIXED)

Pump Gp - Steering (735) 224-4431

6 C-3 Valve Gp - Breaker/ Relief 157-7911 44 A-8
- Steering (740) 224-4432
Screen As. - Pump Case Drain 119-4885 7 A-3 Valve Gp - Hoist 189-5772 45 B-6, C-6 VARIABILITY SPRING LINE RESTRICTION PRESSURE HYDRAULIC PNEUMATIC LINE RESTRICTION ATTACHMENT
(ADJUSTABLE) (VARIABLE) COMPENSATION ENERGY TRIANGLES VARIABLE and PRESSURE
Screen As. - Steering Return 6J-3795 8 A-2 Valve Gp - Main Relief 224-1167 46 C-6 COMPENSATED

Switch As.- Low Press. Warning 3E-6450 9 E-3 Valve Gp - Manual Lower 204-2124 47 C-6 VALVES
Tank - Hydraulic Oil 186-9959 10 A-3 Valve Gp - Relief 126-6099 48 C-6 VALVE ENVELOPES VALVE PORTS

Valve 1U-1643 11 A-2 Brake Circuit

Valve Gp - Breaker / Relief 157-7911 12 A-4 Accumulator Gp - Diaphr. 163-5632 50 F-5
Valve Gp - Check 165-7948 13 C-3 Accumulator Gp - Diaphr. 251-8265 51 F-7 ONE POSITION TWO POSITION THREE POSITION TWO-WAY THREE-WAY FOUR-WAY
Valve Gp - Check 180-4850 14 B-2 Brake Gp - Hyd. Caliper Park 160-8009 52 F-5
Valve Gp - Fluid Sampling (SOS) 164-5590 15 B-2 Brake Gp - Hyd. (Front ) 219-6710 53 D-4, F-4
CONTROL VALVES CHECK VALVES
Valve Gp - Steering Comb. Mnfld 176-5691 16 E-4 Brake Gp - Hyd. ( Rear) 219-6710 54 D-8, F-8 AB AB

Fan Drive Circuit Core Gp - Cooler 4P-7731 55 D-7

Cooler 122-6485 20 C-2 Manifold - Cooling Lines 159-2880 56 D-5 P T P T
BASIC SPRING SHUTTLE PILOT
Fan Control Valve 263-5833 21 C-2 Manifold - Cooling Lines 194-4016 57 D-8 NORMAL POSITION SHIFTED POSITION INFINITE POSITION
SYMBOL LOADED CONTROLLED
Fan Drive Motor - 735 / 740 240-6746 22 C-2 Pump Gp - Brakes 187-9090 58 B-8
MEASUREMENT ROTATING SHAFTS
Fan Drive Motor - (ATAAC) 220-2290 23 D-2 Switch As.- ABL Control 172-7071 59 F-7
Fan Drive Pump 210-0053 24 C-3 Switch As.- Brake Light 172-7071 60 F-7
Fan Drive Pump - (ATAAC) 248-5605 25 B-3 Switch As.- Brake Temp. 3E-6451 61 D-5, D-7
Releif Valve 222-6472 26 D-2 Switch As.- Low Brake Press. 172-7073 62 F-6 PRESSURE TEMPERATURE FLOW UNIDIRECTIONAL BIDIRECTIONAL
Valve Gp - By-Pass (Thermal) 188-8726 27 C-2 Switch As.- Park Brake EMS 213-6947 63 F-5

735 and 740 Articulated Trucks

Valve Gp - Solenoid 265-5214 28 C-2 Valve Gp - Brake Check Manifold 224-1209 64 F-6 FLUID STORAGE RESERVOIRS
Hoist Circuit Valve Gp - Check 134-9911 65 F-6
F G H J K
Actuator As. - Lower 192-6443 30 C-6 Valve Gp - Check 158-9956 66 F-5

Hydraulic System
Actuator As. - Raise 196-2403 31 B-6 Valve Gp - Output Press. Control 217-9037 67 F-7
VENTED PRESSURIZED RETURN ABOVE FLUID LEVEL RETURN BELOW FLUID LEVEL
Cylinder Gp - Hoist 735 241-4065
32 B-5, C-5 Valve Gp - Parking Brake 190-6290 68 F-5
- Hoist 740 241-4068
NOTE: Test panel located at left rear of the front chassis Cylinder Gp - Tailgate (Attach.) 151-2611 34 B-5 Valve Gp - Press. Reducing 140-0973 69 F-6
COMBINATION CONTROLS
Port E is not illustrated on this print Drain 8J-8782 35 A-8 Valve Gp - Relief 224-4630 70 F-6
735: 740:
Element - Filter 132-8876 36 A-7 Valve Gp - Solenoid 152-8340 71 F-5
Manifold - Cold Oil By-Pass 190-1514 37 B-6 Suspension Circuit B1N1-UP B1P1-UP SOLENOID SOLENOID SOLENOID SOLENOID and SERVO THERMAL DETENT
Diagnositic and Service Ports Manifold - Hoist / Tailgate 153-3528 38 B-5 Cylinder Gp - Front Cylinder 228-2758 80 D-5 or MANUAL and PILOT PILOT or MANUAL

MANUAL CONTROL SYMBOLS

PUSH-PULL LEVER MANUAL SHUTOFF GENERAL MANUAL PUSH BUTTON PEDAL SPRING

Tap Locations
PILOT CONTROL SYMBOLS
Pressure, Sampling, and Sensor RELEASED PRESSURE REMOTE SUPPLY PRESSURE
Tap Schematic
Number Description Location
A Hoist Raise Lower Pressure C-6
EXTERNAL RETURN INTERNAL RETURN SIMPLIFIED COMPLETE INTERNAL
B Secondary Steering Pressure E-4 SUPPLY PRESSURE
C Front Brake Pressure F-7
ACCUMULATORS CROSSING AND JOINING LINES HYDRAULIC AND PNEUMATIC CYLINDERS
D Brake Pump Pressure E-6
E OTG Lube & Diff. Lock Press. (Not Shown)
F Load Sense Press. -Main & Sec. Steer C-3 SPRING LOADED GAS CHARGED LINES CROSSING LINES JOINING SINGLE ACTING DOUBLE ACTING
G Steer Pressure - Main Steering Pump E-4
H Fan Drive Pressure D-2 HYDRAULIC PUMPS HYDRAULIC MOTORS INTERNAL PASSAGEWAYS
J Hoist Pilot Pressure B-6
K Rear Brake Pressure E-7 FIXED VARIABLE DISPLACEMENT FIXED VARIABLE DISPLACEMENT THREE TWO
INFINITE
DISPLACEMENT NON-COMPENSATED DISPLACEMENT NON-COMPENSATED POSITIONING POSITION
L Scheduled Oil Sampling - Steer B-2 POSITION

M Park Brake Pressure F-5 UNIDIRECTIONAL UNIDIRECTIONAL

N Scheduled Oil Sampling - Hoist A-7
P Pump Case Pressure B-8, C-3 BIDIRECTIONAL BIDIRECTIONAL
FLOW IN ONE PARALLEL CROSS
FLOW
FLOW ALLOWED IN
DIRECTION FLOW EITHER DIRECTION
R Body Over Center - Service Point C-5
T Attachment Fan Pressure D-2

© 2006 Caterpillar Printed in U.S.A.

All Rights Reserved

Electrical Symbols Table

63 62 35 41 59
66 64 69 1 36 42 60 23 Hydraulic Symbols (Electrical)
34 43 54 52 32 68 71 38 65 70 6 39 57 53 40 44 4 67 25 26
G M
Transducer Transducer Generator Electric Motor
(Fluid) (Gas / Air)

(Dimensions: 39 inches x 28 inches)

Pressure Switch Pressure Switch Temperature Switch Electrical Wire
(Adjustable)

KENR5538
L
P 68
3 8 11 10 12 Electrical Symbols (Electrical)

The hydraulic tank is on the right side of the machine.

Brake Pump
T
Steering and the Fan Drive Systems Pressure Temperature Level Flow
Symbol Symbol Symbol Symbol

56 54 52 32 50 20 27 1 39 13 51 53 9 5 58
30 45 48 24 2 3 7 Wire Number Identification Codes
61 21 28 16 55
31 46 8 10 11 Electrical Schematic Example Hydraulic Schematic Example
22 12 14 15
37 47 Current Standard Current Standard
Harness identification code
This example indicates

30 Page,
wire 135 in harness "AG". Wire
Circuit Number Wire Color
63 20 27 30 45 Identification

325-AG135 PK-14
66 21 28 31 46 325-PK
Circuit Identification Wire Color Wire Gauge
34 43 68 71 22 39 37 47 13 4 55 58 Number

Previous Standard
Wire Color
Wire

36 40 N 42 44
60 81 M 73 78 325-PK-14
The hydraulic tank is on the left side of the machine. B A
Circuit Number Wire Gauge
Identification (EXAMPLE VALVE)

Hoist System and the Brake Cooling System Parking Brake

60
23 T P 6 R 38

56 54 52 32 50 32 6 1 62 64 80 57 53 51 24 2 8 12 9 59 5
61 39 69 70 3 10 14 16 60
65 7 11 15 67

Component Locations ATAAC Fan Steering Pump Hoist Manifold

 8 7 6 5 4 3 2 1

BRAKE GP- HYDRAULIC BRAKE GP- HYDRAULIC PUMP GP-

(FRONT AND REAR) ACCUMULATOR HYDRAULIC CIRCUIT COLOR DESCRIPTIONS
(FRONT AND REAR) METERING BRAKE PUMP OUTPUT
RIGHT 219-6710 VALVE GP- DIAPHRAGM VALVE GP- ACCUMULATOR GP- RIGHT
219-6710 160-9727 HOIST PUMP OUTPUT
FRONT BRAKE CONTROL 251-8265 BRAKE CHECK MANIFOLD DIAPHRAGM REAR PRIMARY STEERING PUMP OUTPUT
217-9037 224-1209 163-5632 SECONDARY STEERING PUMP OUTPUT
SWITCH AS- PRESSURE CYLINDER GP- FAN DRIVE PUMP OUTPUT
SWITCH AS- STEER FAN DRIVE PUMP OUTPUT (ATTACHMENT)
(PARK BRAKE EMS SWITCH)
(BRAKE LIGHT) 223-1335 HOIST CONTROL CIRCUIT
VALVE GP- D 213-6947
172-7071 FRONT / REAR / PARKING BRAKES CONTROL CIRCUIT
F
F CHECK SUPPLY LINE
REMOTE PANEL
134-9911 TEST POINT PARKING DRAIN / RETURN LINE
BRAKE COOLING (LARGE OFF-HIGHWAY TRUCKS)
VALVE GP- BRAKE
SWITCH AS-PRESSURE STEERING
TP PARKING BRAKE (LOW PRESSURE WARNING)
C RB 190-6290 3E-6450 L
SWITCH VALVE GP
ASBS SW
P1 LOW BRAKE PRESSURE ACC PS STEERING COMBINER MANIFOLD T
B1 176-5691 Tap Locations
REMOTE PANEL 172-7073
TEST POINT T1 LS Pressure, Sampling, and Sensor
FB P B Tap Schematic
Description
SWITCH AS- M PP Number Location

(ABL CONTROL) P A Hoist Raise Lower Pressure C-6

VALVE GP-
P T REMOTE PANEL G
B Secondary Steering Pressure E-4
172-7071 P2 PRESSURE REDUCING TEST POINT
B2 R RIGHT C Front Brake Pressure F-7
140-0973 TURN
VALVE GP- VALVE-CHECK VALVE GP- REMOTE PANEL D Brake Pump Pressure E-6
K T2 TEST POINT CYLINDER GP- E OTG Lube & Diff. Lock Press. (Not Shown)
RELIEF T P 158-9956 SOLENOID TRACTOR TRAILER
T1 PS1 STEER F Load Sense Press. -Main & Sec. Steer C-3
224-4530 RBP RBP 152-8340
REMOTE PANEL BRAKE GP-HYDRAULIC 223-1335 G Steer Pressure - Main Steering Pump E-4
TEST POINT
CALIPER PARK P1 H Fan Drive Pressure D-2
HITCH C.L. J Hoist Pilot Pressure B-6
(DYNAMIC PARKING BRAKE)
K Rear Brake Pressure E-7
160-8009 L Scheduled Oil Sampling - Steer B-2

P2 OUT M Park Brake Pressure F-5

N Scheduled Oil Sampling - Hoist A-7
T2 PS2 AUX P Pump Case Pressure B-8, C-3

E R Body Over Center - Service Point C-5

T Attachment Fan Pressure D-2 E
REMOTE PANEL
TEST POINT
B L/S SIGNAL

BRAKE GP- HYDRAULIC

MANIFOLD-BRAKES (FRONT AND REAR)
COOLING LINES 219-6710
194-4016 FAN DRIVE MOTOR
(ATAAC)
CYLINDER GP- 220-2290 T
(FRONT SUSP CYL)
CORE GP- 228-2758
OIL COOLER
4P-7731

LEFT
LEFT REAR
FRONT RELIEF VALVE
222-6472
ACTUATOR AS.
LOWER
D BRAKE GP- HYDRAULIC D
192-6443 VALVE GP
(FRONT AND REAR) SWITCH AS 165-7948
219-6710 BRAKE TEMPERATURE FAN DRIVE MOTOR
3E-6451 STEERING-MAIN X 240-6746
PUMP GP-(735)
224-4431
PUMP GP-(740) FAN CONTROL VALVE
MANIFOLD 263-5833
224-4432 H
BRAKES COOLING LINES
FAN DRIVE PUMP REMOTE PANEL
159-2880 SWITCH AS 210-0053 TEST POINT
H1 T1 BRAKE TEMPERATURE FAN DRIVE PUMP P A T
3E-6451 210-0053
(Dimensions: 39 inches x 28 inches)

VALVE GP-
VALVE GP-
MANUAL lOWER
SOLENOID

TRANSMISSION
(DEAD ENGINE)
265-5214
204-2124
STEERING-MAIN
PUMP GP-(735) CYLINDER GP- HOIST 740
P
224-4431 241-4068
PUMP GP-(740) CYLINDER GP- HOIST 735 PUMP GP-
REMOTE PANEL HOIST
224-4432 TEST POINT 241-4065
KENR5538

188-4455 COOLER
C A
RAISE C
122-6485
VALVE GP-
BY-PASS (THERMAL)
HOLD HE RAISE 188-8726
ENGINE
TRANSMISSION

REMOTE PANEL
TEST POINT
ENGINE
RE F VALVE GP-
R CYLINDER GP- FAN DRIVE PUMP 165-7948
VALVE GP- (ATAAC)
RELIEF FLOAT TAILGATE (ATTACH)
248-5605
B 151-2611
126-6099
VALVE GP-
PUMP GP-
PUMP GP- CHECK
HOIST
BRAKES 180-4850
30 Page, Color 2,

188-4455
LOWER 187-9090
OPEN
M

VALVE GP
MAIN RELIEF
S L L1 224-1167 VALVE GP-
BALANCE (ATTACH) PUMP GP-
MANIFOLD 133-8810 (SECONDARY STEER) B
B P 141-6389
PUMP GP- 153-3528
BRAKES MANIFOLD
187-9090 COLD OIL
BY-PASS VALVE AS
190-1514 L
SOS FLUID SAMPLING
CYLINDER GP- HOIST 740 164-5590
VALVE GP-
H2 T2 241-4068
VALVE GP- BREAKER / RELIEF
CYLINDER GP- HOIST 735
BREAKER/RELIEF 157-7911
241-4065
157-7911 REMOTE PANEL
ACTUATOR AS. TEST POINT
RAISE
VALVE GP
196-2403 J
N FLUID SAMPLING VALVE GP-HOIST
164-5590 189-5772
SOS LINE PATTERNS
Pressure Line
SCREEN AS.
119-4885 Pilot / Load Sensing Pressure
TANK GP- HYDRAULIC
SCREEN AS. 186-9959 Drain / Return Lines
119-4885 TANK GP-HYDRAULIC ELEMENT- Component Group
SCREEN AS.
162-5242 FILTER VALVE
119-4885 Attachment
DRAIN 132-8876 1U-1643
A 8J-8782 Air Line
ELEMENT- A
DRAIN FILTER SCREEN AS. CALLOUTS
8J-8782 132-8876 6J-3795
YY Taps (Pressure, Sampling,Sensor) by letter

SCREEN AS. 52 Components by number

150-8457 THIS SCHEMATIC IS FOR THE 735 / 740 T3
PART #: 266-6459 Chng 00
BRAKE, HOIST AND SUSPENSION CIRCUITS FAN AND STEERING CURCUITS 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 Troubleshooting, Specifications and Systems Operations

8 7 6 5 4 3 2 1