INTERACTIVE SCHEMATIC

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 KENR9561
September 2009

793F Off-Highway Truck

Air System
SSP1-UP

2009 Caterpillar, All Rights Reserved Printed in U.S.A.

 COMPONENT TABLE
Part Machine Schematic
Description Number Location Location
Air Compressor Gp 261-4881 1 F-7
Block - Manifold (Air System Pressure) 160-0980 2 D-4
Dryer Gp - Air 194-1986 3 F-3
Governor As 4N-9680 4 E-5
Horn Gp - Air 5D-6998 5 B-3
Pump Gp - Lubrication 178-6919 6 B-2
Regulator 8D-4755 7 B-2
Reservoir - Air (NA) 296-9870 8 D-3
Sensor Gp - Pressure, Air System 141-5746 9 C-4
Starting Motor Gp - Air, TDI Turbine 294-5599
10 C-6
IR Turbine 294-5613
Valve - Air Relief (Air Tank) 6B-9664 11 D-3
Valve - Drain 7X-7655 12 D-2
Valve As - Check 204-2658 13 D-2
Valve Gp - Relay, Air Starting Motor 4N-3411 14 D-3
Valve Gp - Solenoid, Air Horn 185-0008 15 B-3
Valve Gp - Solenoid, Air Starting 221-9576 16 C-5
Valve Gp - Solenoid, Autolube Actuation 221-9576 17 C-3

2009 Caterpillar, All Rights Reserved

 FLUID POWER SYMBOLS
BASIC COMPONENT SYMBOLS

MAIN AUX.
PUMP: VARIABLE and
PUMP or MOTOR FLUID CONDITIONER SPRING CONTROL VALVES RESTRICTION LINE RESTRICTION 2-SECTION PUMP PRESSURE COMPENSATED
(FIXED)

VARIABILITY SPRING LINE RESTRICTION PRESSURE HYDRAULIC PNEUMATIC LINE RESTRICTION ATTACHMENT
(ADJUSTABLE) (VARIABLE) COMPENSATION ENERGY TRIANGLES VARIABLE and PRESSURE
COMPENSATED

VALVE ENVELOPES
VALVES
VALVE PORTS

ONE POSITION TWO POSITION THREE POSITION TWO-WAY THREE-WAY FOUR-WAY

CONTROL VALVES CHECK VALVES

AB AB

P T P T
BASIC SPRING SHUTTLE PILOT
NORMAL POSITION SHIFTED POSITION INFINITE POSITION
SYMBOL LOADED CONTROLLED

FLUID STORAGE RESERVOIRS

VENTED PRESSURIZED RETURN ABOVE FLUID LEVEL RETURN BELOW FLUID LEVEL

MEASUREMENT ROTATING SHAFTS

PRESSURE TEMPERATURE FLOW UNIDIRECTIONAL BIDIRECTIONAL

COMBINATION CONTROLS

SOLENOID SOLENOID SOLENOID SOLENOID and SERVO THERMAL DETENT

or MANUAL and PILOT PILOT or MANUAL

MANUAL CONTROL SYMBOLS

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

RELEASED PRESSURE PILOT CONTROL SYMBOLS

REMOTE SUPPLY PRESSURE

EXTERNAL RETURN INTERNAL RETURN SIMPLIFIED COMPLETE INTERNAL

SUPPLY PRESSURE

ACCUMULATORS CROSSING AND JOINING LINES HYDRAULIC AND PNEUMATIC CYLINDERS

SPRING LOADED GAS CHARGED LINES CROSSING LINES JOINING SINGLE ACTING DOUBLE ACTING

HYDRAULIC PUMPS HYDRAULIC MOTORS INTERNAL PASSAGEWAYS

FIXED VARIABLE DISPLACEMENT FIXED VARIABLE DISPLACEMENT INFINITE THREE TWO

DISPLACEMENT NON-COMPENSATED DISPLACEMENT NON-COMPENSATED POSITIONING POSITION POSITION

UNIDIRECTIONAL UNIDIRECTIONAL

FLOW IN ONE PARALLEL CROSS FLOW ALLOWED IN

BIDIRECTIONAL BIDIRECTIONAL DIRECTION FLOW FLOW EITHER DIRECTION

2009 Caterpillar, All Rights Reserved

 ELECTRICAL SYMBOLS
Hydraulic Symbols (Electrical)

G M
Transducer Transducer Generator Electric Motor
(Fluid) (Gas / Air)

Pressure Switch Pressure Switch Temperature Switch Electrical Wire

(Adjustable)

Electrical Symbols (Electrical)

Pressure Temperature Level Flow

Symbol Symbol Symbol Symbol

Wire Number Identification Codes

Electrical Schematic Example Hydraulic Schematic Example

Current Standard Current Standard

Harness identification code
This example indicates
wire 135 in harness "AG". Wire
Circuit Number Wire Color
Identification

325-AG135 PK-14
325-PK
Circuit Identification Wire Color Wire Gauge
Number

Previous Standard
Wire Color
Wire

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

2009 Caterpillar, All Rights Reserved

 7 6 5 4 3 2 1

EXTERNAL
(1) AIR COMPRESSOR GP (3) DRYER GP AIR SUPPLY
261-4881 AIR
194-1986

F F

(4) GOVERNOR AS
E 4N-9680 E

(14) VALVE GP
RELAY,
STARTING MOTOR (11) VALVE
4N-3411 AIR RELIEF
(AIR TANK)
6B-9664

R (13) VALVE AS
CHECK
D E 204-2658 D
S
E
R
(2) BLOCK
MANIFOLD, V
(10) STARTING MOTOR GP AIR SYSTEM PRESSURE O
AIR 160-0980
TDI TURBINE : 294-5599 I
IR TURBINE : 294-5613 (12) VALVE
R DRAIN
(8) RESERVOIR
7X-7655
AIR (NA)
296-9870

(17) VALVE GP
(16) VALVE GP SOLENOID,
C SOLENOID, AUTOLUBE ACTUATION C
AIR STARTTING 221-9576
221-9576 (9) SENSOR GP
PRESSURE
AIR SYSTEM
141-5746 (7) REGULATOR
8D-4755

AUTO (6) PUMP GP

LUBRICATION
LUBE 178-6919

B (15) VALVE GP B
SOLENOID,
AIR HORN
185-0008
COMPRESSED AIR CIRCUIT COLOR DESCRIPTIONS
AIR COMPRESSOR OUTPUT AND CIRCUITS
(5) HORN GP AIR SUPPLY
AIR AIR EXHAUST

5D-6998
LINE PATTERNS
Pressure Line

Pilot / Load Sensing Pressure

Drain / Return Lines

Component Group

CALLOUTS
YY Taps (Pressure, Sampling, Sensor - by letter)

Callout Number
A (Machine Location from (52) VALVE GP - CONTROL
Component
Name A
Component LocationsTable)
138-1234 Part Number

THIS SCHEMATIC IS FOR THE 793F OFF-HIGHWAY TRUCK

AIR SYSTEM
MEDIA NUMBER: KENR9561
PART NUMBER: 278-8453, CHANGE: 00, VERSION: -
Components are shown installed on a fully operable machine.

Refer to the appropriate Service Manual for Troubleshooting, Specifications.

7 6 5 4 3 2 1
 LEFT SIDE - FRONT FORWARD OF THE TIRES
VIEW ALL CALLOUTS

15

7
6

17

AUTO LUBE (FRONT OF TRUCK)

2009 Caterpillar, All Rights Reserved

 RIGHT SIDE - BEHIND FRONT TIRE
(RIGHT SIDE OF ENGINE COMPARTMENT)
VIEW ALL CALLOUTS

10 3
12

2009 Caterpillar, All Rights Reserved

 BACK OF AIR RESERVOIR
VIEW ALL CALLOUTS

11

13 16

14
9

2009 Caterpillar, All Rights Reserved