INTERACTIVE SCHEMATIC

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 KENR5538-03
March 2014

735 and 740 Articulated Truck

Hydraulic System
735: 740:
B1N1-799 B1P1-4827

© 2014 Caterpillar, All Rights Reserved Printed in U.S.A.

 COMPONENT LOCATION
Part Machine Schematic Part Machine Schematic
Description Number Location Location Description Number Location Location
Steering Circuit Hoist Circuit - Continuned
Cylinder Gp - Steering 223-1335 1 F-2 Pump - Hoist 188-4455 39 C-7
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
Pump Gp - Metering 160-9727 4 F-3 Tank - Hyd. Oil (Hoist/ Cooling) 162-5242 42 A-7
Pump Gp - Secondary Steering 141-6389 5 B-3 Valve Gp - Balance (Attach) 133-8810 43 B-5
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
Screen As. - Steering Return 6J-3795 8 A-2 Valve Gp - Main Relief 224-1167 46 C-6
Switch As.- Low Press. Warning 3E-6450 9 E-3 Valve Gp - Manual Lower 204-2124 47 C-6
Tank - Hydraulic Oil 186-9959 10 A-3 Valve Gp - Relief 126-6099 48 C-6
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
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
Valve Gp - Steering Comb. Mnfld 176-5691 16 E-4 Brake Gp - Hyd. ( Rear) 219-6710 54 D-8, F-8
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
Fan Control Valve 263-5833 21 C-2 Manifold - Cooling Lines 194-4016 57 D-8
Fan Drive Motor - 735 / 740 240-6746 22 C-2 Pump Gp - Brakes 187-9090 58 B-8
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. 213-6947 62 F-6
Valve Gp - By-Pass (Thermal) 188-8726 27 C-2 Switch As.- Park Brake EMS 213-6947 63 F-5
Valve Gp - Solenoid 265-5214 28 C-2 Valve Gp - Brake Check Manifold 224-1209 64 F-6
Hoist Circuit Valve Gp - Check 134-9911 65 F-6
Actuator As. - Lower 192-6443 30 C-6 Valve Gp - Check 158-9956 66 F-5
Actuator As. - Raise 196-2403 31 B-6 Valve Gp - Output Press. Control 217-9037 67 F-7
Cylinder Gp - Hoist 735 241-4065
32 B-5, C-5 Valve Gp - Parking Brake 190-6290 68 F-5
- Hoist 740 241-4068
Cylinder Gp - Tailgate (Attach.) 151-2611 34 B-5 Valve Gp - Press. Reducing 140-0973 69 F-6
Drain 8J-8782 35 A-8 Valve Gp - Relief 224-4630 70 F-6
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
Manifold - Hoist / Tailgate 153-3528 38 B-5 Cylinder Gp - Front Cylinder 228-2758 80 D-5
Always check component part numbers with Parts Manual for your specific machine.
TAP LOCATION

Tap Schematic
Number Description Location
A Hoist Raise / Lower Pressure C-6
B Secondary Steering Pressure E-4
C Front Brake Pressure F-7
D Brake Pump Pressure F-6
E OTG Lube & Diff. Lock Press. (Not Shown)
F Load Sense Press. -Main & Sec. Steer C-3
G Steer Pressure - Main Steering Pump E-4
H Fan Drive Pressure D-2
J Hoist Pilot Pressure B-6
K Rear Brake Pressure E-7
L Scheduled Oil Sampling - Steer B-2
M Park Brake Pressure F-5
N Scheduled Oil Sampling - Hoist A-7
P Pump Case Pressure B-8, C-3
R Body Over Center - Service Point C-5
T ATAAC Fan Pressure D-2
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
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)
 8 7 6 5 4 3 2 1

(53) BRAKE GP- HYDRAULIC

(54) BRAKE GP- HYDRAULIC (51) ACCUMULATOR
(FRONT AND REAR) (4) PUMP GP
(FRONT AND REAR) DIAPHRAGM
219-6710 METERING (1) CYLINDER GP
RIGHT 219-6710 (67) VALVE GP 251-8265 (64) VALVE GP RIGHT 160-9727 STEER
FRONT BRAKE CONTROL BRAKE CHECK MANIFOLD (52) BRAKE GP-HYDRAULIC REAR
217-9037 224-1209 CALIPER PARK 223-1335
(60) SWITCH AS (DYNAMIC PARKING BRAKE)
(50) ACCUMULATOR GP
(BRAKE LIGHT) 160-8009
(65) VALVE GP DIAPHRAGM
172-7071 D (63) SWITCH AS- PRESSURE
CHECK 163-5632
F REMOTE PANEL (PARK BRAKE EMS SWITCH) F
134-9911 TEST POINT
(68) VALVE GP 213-6947
PARKING BRAKE
TP PARKING
RB 190-6290 BRAKE (16) VALVE GP
C
STEERING COMBINER L
ASBS (62) SWITCH
P1 SW MANIFOLD T
B1 LOW BRAKE PRESSURE ACC PS (9) SWITCH AS-PRESSURE 176-5691
REMOTE PANEL 213-6947 (LOW PRESSURE WARNING)
TEST POINT T1 LS
FB P B 3E-6450

(59) SWITCH AS M PP
(69) VALVE GP P
(ABL CONTROL) REMOTE PANEL
PRESSURE REDUCING P T G
172-7071 P2 TEST POINT
B2 140-0973 RIGHT
R TURN
(66) VALVE-CHECK (71) VALVE GP REMOTE PANEL
K T2 (70) VALVE GP 158-9956 TEST POINT (1) CYLINDER GP
T P
RELIEF
SOLENOID
T1 PS1 STEER TRACTOR TRAILER
REMOTE PANEL RBP RBP 152-8340 223-1335
TEST POINT 224-4530
P1
HITCH C.L.

P2 OUT

T2 PS2 AUX

E REMOTE PANEL E
TEST POINT
B L/S SIGNAL

(53) BRAKE GP- HYDRAULIC

(FRONT AND REAR)
219-6710
(61) SWITCH AS
BRAKE TEMPERATURE
3E-6451 (23) FAN DRIVE MOTOR
(57) MANIFOLD-BRAKES (ATAAC)
(80) CYLINDER GP T
COOLING LINES 220-2290
194-4016 (FRONT SUSP CYL)
(55) CORE GP
228-2758
OIL COOLER
4P-7731

LEFT
LEFT REAR
FRONT

(30) ACTUATOR AS. (26) RELIEF VALVE

LOWER 222-6472
(54) BRAKE GP- HYDRAULIC
D (FRONT AND REAR) 192-6443 D
VALVE GP
219-6710 165-7948
(6) STEERING-MAIN
X (22) FAN DRIVE MOTOR
PUMP GP-(735)
240-6746
224-4431
(56) MANIFOLD (6) PUMP GP-(740) (24) FAN DRIVE
224-4432 (21) FAN CONTROL VALVE
BRAKES COOLING LINES PUMP H 263-5833
159-2880 (61) SWITCH AS 210-0053 REMOTE PANEL
BRAKE TEMPERATURE TEST POINT
H1 T1 3E-6451 FAN DRIVE PUMP P A T
210-0053

(28) VALVE GP
(47) VALVE GP
SOLENOID

TRANSMISSION
MANUAL lOWER
265-5214
(DEAD ENGINE)
STEERING-MAIN 204-2124
PUMP GP-(735) (32) CYLINDER GP- HOIST 740
224-4431 285-4034 P
PUMP GP-(740) (32) CYLINDER GP- HOIST 735 PUMP GP
224-4432 REMOTE PANEL 285-4033 HOIST
TEST POINT 188-4455 (20) COOLER
C A
RAISE 122-6485 C
(27) VALVE GP
BY-PASS (THERMAL)
HOLD HE RAISE 188-8726
ENGINE
TRANSMISSION

REMOTE PANEL
TEST POINT
ENGINE
(48) VALVE GP RE F (13) VALVE GP
R FAN DRIVE PUMP
RELIEF (34) CYLINDER GP 165-7948
(ATAAC)
126-6099 FLOAT TAILGATE (ATTACH)
248-5605
B 151-2611
(39) PUMP GP
(14) VALVE GP
HOIST PUMP GP CHECK
188-4455 BRAKES 180-4850
LOWER 187-9090
OPEN
M

(46) VALVE GP
MAIN RELIEF
224-1167 (43) VALVE GP
S L L1 BALANCE (ATTACH)
(25) PUMP GP
(38) MANIFOLD 133-8810
B (SECONDARY STEER) B
P (58) PUMP GP 153-3528
(37) MANIFOLD 141-6389 HYDRAULIC CIRCUIT COLOR DESCRIPTIONS
BRAKES
187-9090 COLD OIL BRAKE PUMP OUTPUT
BY-PASS FAN DRIVE PUMP OUTPUT

190-1514 (15) VALVE AS HOIST CONTROL CIRCUIT

L STEERING CIRCUIT
SOS FLUID SAMPLING SUPPLY LINE
(32) CYLINDER GP- HOIST 740 164-5590 BRAKES CONTROL CIRCUIT
(44) VALVE GP H2 T2 285-4034 SECONDARY STEERING PUMP
(12 ) VALVE GP
BREAKER/RELIEF (32) CYLINDER GP- HOIST 735 FAN DRIVE PUMP OUTPUT (ATTACHMENT)
BREAKER / RELIEF DRAIN / RETURN LINE
157-7911 285-4033
(31) ACTUATOR AS (45) VALVE GP HOIST 157-7911 HOIST PUMP OUTPUT
REMOTE PANEL PRIMARY STEERING PUMP OUTPUT
RAISE TEST POINT 189-5772 BRAKE COOLING
VALVE GP 196-2403
J
N FLUID SAMPLING
164-5590 LINE PATTERNS
SOS Pressure Line

Pilot / Load Sensing Pressure

(41) SCREEN AS
SCREEN AS Drain / Return Lines
119-4885
119-4885
Component Group
(42) TANK GP HYDRAULIC
162-5242 (11) VALVE CALLOUTS
1U-1643 YY Taps (Pressure, Sampling, Sensor - by letter)

A (2) DRAIN Callout Number Component A

(52) VALVE GP - CONTROL
8J-8782 (Machine Location from
Component LocationsTable)
Name

138-1234 Part Number

(36) ELEMENT
FILTER
(35) DRAIN (40) SCREEN AS (7) SCREEN AS (3) ELEMENT- FILTER (8) SCREEN AS.
132-8876 THIS SCHEMATIC IS FOR THE 735 AND 740 ARTICULATED TRUCK HYDRAULIC SYSTEM
8J-8782 150-8457 (10) TANK GP HYDRAULIC 119-4885 132-8876 6J-3795
186-9959 MEDIA NUMBER: KENR5538-03
SCHEMATIC PART NUMBER: 266-6459, CHANGE: 02, VERSION: -
BRAKE, HOIST AND SUSPENSION CIRCUITS FAN AND STEERING CIRCUITS 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.
Note: Refer to the Parts Manual using a specific serial number prefix in SIS before ordering parts from this schematic.

8 7 6 5 4 3 2 1
MACHINE COMPONENT LOCATIONS
VIEW ALL CALLOUTS

52 32 38 62 64 65 69 6 1 70 39 57 53 40 36 35 41 42 44 4 59 60
71 67

68 25

54 23
26
66
55
63
58
56
5
34
16
43
9
61
15
54 14
32 12
52 11
50 28 27 22 21 20 1 39 13 51 53 30 31 37 45 46 47 48 24 2 3 7 8 10

66 63 71 50 32 32 1 39 6 22 21 20 27 28 39 37 31 30 45 46 47 4

68 13

52 67

61 60

34 58

43 59

55
56
5
54
16

15

14

62 64 65 69 70 80 57 53 51 24 2 3 7 8 10 11 12
STEERING PUMP

VIEW ALL CALLOUTS

P 6
STEERING AND FAN DRIVE SYSTEMS
VIEW ALL CALLOUTS

L 3 8 11 10 12
PARKING BRAKE
VIEW ALL CALLOUTS

60 M
HOIST MANIFOLD
VIEW ALL CALLOUTS

R
38
HOIST AND BRAKE COOLING SYSTEM
VIEW ALL CALLOUTS

36 40 N 42 44
DIAGNOSITIC AND SERVICE PORTS
VIEW ALL CALLOUTS
A B C D E

F G H J K

NOTE: Test panel located at left rear of the front chassis

Port E is not illustrated on this print
BRAKE PUMP
VIEW ALL CALLOUTS

P
68
ATAAC FAN
VIEW ALL CALLOUTS

23 T