3PW
4
RENR2117-02 January 2009 Volume 1 of 2: Brakes, Pilot Implements, and HMU Steering 966G and 972G Wheel Loader Hydraulic System 966G: AAH1-UP 3ZS1-UP 9RS1-UP 3PW1-UP 3SW1-UP 8XW1-UP 972G: 7LS1-UP AAW1-UP 1EW1-UP 4WW1-UP 6AW1-UP 9GW1-UP Printed in U.S.A. © 2009 Caterpillar, All Rights Reserved ONE POSITION TWO POSITION THREE POSITION VENTED PRESSURIZED RETURN ABOVE FLUID LEVEL RETURN BELOW FLUID LEVEL LINES CROSSING LINES JOINING TWO - WAY THREE - WAY FOUR - WAY SPRING CONTROL VALVES RESTRICTION LINE RESTRICTION (FIXED) PUMP (2 - SECTION) SPRING (ADJUSTABLE) VARIABILITY LINE RESTRICTION (VARIABLE) PRESSURE COMPENSATION PUMP (VARIABLE & PRESSURE COMPENSATED) MEASUREMENT PRESSURE TEMPERATURE FLOW ROTATING SHAFTS UNIDIRECTIONAL BIDIRECTIONAL PUSH - PULL LEVER PEDAL GENERAL MANUAL PUSH BUTTON SPRING FIXED DISPLACEMENT VARIABLE DISPLACEMENT NON-COMPENSATED UNIDIRECTIONAL BIDIRECTIONAL VALVE ENVELOPES VALVE PORTS FLUID CONDITIONER PUMP OR MOTOR FLUID POWER SYMBOLS UNIDIRECTIONAL BIDIRECTIONAL RELEASED PRESSURE EXTERNAL RETURN INTERNAL RETURN REMOTE SUPPLY PRESSURE SIMPLIFIED HYDRAULIC PUMPS ACCUMULATORS SPRING LOADED GAS CHARGED SOLENOID OR MANUAL SOLENOID & PILOT SOLENOID & PILOT OR MANUAL SOLENOID SERVO THERMAL DETENT HYDRAULIC & PNEUMATIC CYLINDERS DOUBLE ACTING SINGLE ACTING BASIC SYMBOL SPRING LOADED CHECK VALVES 2 POSITION INFINITE POSITIONING FLOW IN ONE DIRECTION FLOW IN EITHER DIRECTION 3 POSITION CROSS FLOW PARALLEL FLOW INTERNAL PASSAGEWAYS NORMAL POSITION AB P T AB PT SHIFTED POSITION INFINITE POSITION CONTROL VALVES ATTACHMENT MANUAL SHUTOFF SHUTTLE PILOT CONTROLLED MAIN AUX LINE RESTRICTION (VARIABLE & PRESSURE COMPENSATED) MANUAL CONTROL SYMBOLS HYDRAULIC MOTORS FLUID STORAGE RESERVOIRS CROSSING & JOINING LINES VALVES PILOT CONTROL SYMBOLS COMBINATION CONTROLS BASIC COMPONENT SYMBOLS ENERGY TRIANGLES HYDRAULIC PNEUMATIC INTERNAL SUPPLY PRESSURE COMPLETE FIXED DISPLACEMENT VARIABLE DISPLACEMENT NON-COMPENSATED HYDRAULIC SYMBOLS (ELECTRICAL) ELECTRICAL SYMBOLS TABLE 325-AG135 PK-14 HARNESS IDENTIFICATION CODE THIS EXAMPLE INDICATES WIRE 135 IN HARNESS “AG” 325-PK-14 WIRE GAUGE WIRE COLOR CIRCUIT NUMBER IDENTIFICATION WIRE NUMBER IDENTIFICATION CODES CURRENT STANDARD PREVIOUS STANDARD ELECTRICAL SCHEMATIC EXAMPLE HYDRAULIC SCHEMATIC EXAMPLE 325-PK WIRE COLOR CIRCUIT NUMBER IDENTIFICATION B WIRE WIRE (EXAMPLE VALVE) CURRENT STANDARD TRANSDUCER (FLUID) M ELECTRIC MOTOR TRANSDUCER (GAS / AIR) G GENERATOR PRESSURE SWITCH ELECTRICAL WIRE PRESSURE SWITCH (ADJUSTABLE) TEMPERATURE SWITCH PRESSURE SWITCH TEMPERATURE SWITCH LEVEL SWITCH FLOW SWITCH ELECTRICAL SYMBOLS (ELECTRICAL) A CIRCUIT NUMBER IDENTIFICATION WIRE COLOR WIRE GAUGE T RENR2117-02 VOL 1 of 2 24 Page, (Dimensions: 34 inches x 28 inches) 27 14 25 2 34 31 32 33 GG 9 5 7 6 51 52 59 53 54 37 8 CC DD MM 16 37 8 HH 50 11 FF 57 58 55 56 29 30 21 20 JJ 35 18 15 16 LL 36 17 24 3 13 19 4 6 11 59 16 50 BB DD MM AA 54 51 52 53 27 14 25 2 34 31 32 33 28 28 9 5 7 GG 51 37 8 HH 21 20 JJ 36 KK 24 3 13 17 LL 15 35 18 57 58 55 56 29 28 COMPONENT LOCATIONS DD 50 FF 55 CC KK MM 17 Tap Locations Pressure and Sampling Tap Number Description Schematic Location AA Tilt Cylinder Rod End Pressure F-5 BB Tilt Cylinder Head End Pressure F-5 CC Rear Service Brake Pressure F-3 DD Front Service Brake Presseure F-3 FF Service Brake Accumulator Pressure D-2 GG Implement Pilot Pump Pressure D-4 HH Implement Pump Pressure C-7 JJ Fluid Sampling Valve B-6 KK Steering Pump Pressure B-3 LL Fan Drive Pump Pressure B-6 MM Steering Signal Pressure A-4 STEERING PUMP Component Locations Description Part Number Machine Location Schematic Location Description Connector - Orifice 128-7063 1 D-4 to D-5 Valve Gp - Pilot Accumulator As - Ride Control 108-5933 2 F-4 Valve Gp - Pilot, Shut Off Cooler 130-8842 3 B-5 Valve Gp - Pilot (Oil Manifold, 2 Funct.) Pilot (Oil Manifold, 3 Funct.) Cooler As - Brake Oil Cooling Attachment 134-2454 4 A-6 Cylinder Gp - Auxiliary 5 F-6 Valve Gp - Relief (Line, Aux, HE) Cylinder Gp - Lift (LH) 133-2964 6 F-4 Valve Gp - Relief (Line, Aux, RE) Cylinder Gp - Lift (RH) 133-2963 7 F-4 Valve Gp - Relief (Line,Tilt, RE, HE) Standard 2 And 3 Valve Relief (Line, Tilt, RE), Logging Relief (Line,Tilt, HE), Logging Cylinder Gp - Steering 133-1747 8 C-2 Cylinder Gp - Tilt, 966 972 144-9005 133-2962 9 F-5 Elbow - Orifice 108-2144 10 B-4 Valve Gp - Relief, Main Standard Logging Filter Gp - Oil, Hydr. (Fan / Cooler Flow) 134-3016 11 B-6 Manifold Gp - (Lift, Standard) 130-2073 12 E-4 Valve Gp - Secondary Steering (Diverter) Motor Gp - Hydraulic Fan 161-8919 13 B-5 Valve Gp - Steering Plate - Orifice 8V-2080 14 F -5 Valve Gp - Steering Neutralizer Pump and Motor Gp - Sec. Steering 154-2563 15 A-5 BRAKES Pump Gp - HMU 147-7343 16 B-4 Accumulator Gp - Brake (Charged) Pump Gp - Hydraulic Fan 162-0772 17 B-6 Actuator As - Parking Brake Pump Gp - Steering Implement Pilot / Brake 167-1154 18 B-7 Control Gp - Foot Brake Sensor Gp - Position (Rotary, Lft Brk Pdl) Switch As - Limit (Stop Light) Screen Gp 6E-5065 19 A-7 Switch As - Pressure (Parking Brakes) Tank Gp - Hydraulic 133-1843 20 A-6 to A-7 Switch As - Pressure (Low Pressure Warning) Valve - Breaker Relief 9T-0818 21 A-7 Valve Gp - Accumulator Valve Gp - Check (Air Purge)(Air Bleed) 3G-8607 22 Valve Gp - Brake Control (Parking) Valve Gp - Check (Ride Control) 9T-3096 23 E-4 Valve Gp - Brake Control (Service) Valve Gp - Cooler Bypass 9T-6005 24 B-5 Valve Gp - Diverter (Ride Control) 137-3520 25 E-4 Valve Gp - Flow Divider (Axle Oil Cooler) 133-1729 26 B-6 Valve Gp - Main Control, 2 Func., Standard 3 Func. Logging 3 Func., (Attch) Control, 1 Func., Field Conversion 120-7477 120-7475 120-7473 120-7611 27 E-4 to E-7 Part Number Machine Location Schematic Location 144-0115 28 112-1817 29 D-5 152-6480 152-6481 30 D-4 to D-5 4T-2742 31 E-7 4T-4162 32 F-6 6E-2377 9T-8488 4T-2764 33 F-5 6E-6003 6E-6185 34 E-7 141-2597 35 142-3996 36 B-2 to B-3 146-7571 37 C-4 198-9841 50 F-2 154-8042 51 F-1 193-1448 52 F-2 214-4863 53 F-3 105-6117 54 F-3 3E-6452 55 E-1 3E-7693 56 D-3 229-9984 57 E-3 106-1774 58 D-1 210-5587 59 F-2 FRONT, RIGHT VIEW OF HITCH SERVICE BRAKES ACCUM CHARGING VALVE SERVICE BRAKES CONTROL VALVE
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Transcript of 3PW
RENR2117-02January 2009
Volume 1 of 2: Brakes, Pilot Implements, and HMU Steering
966G and 972G Wheel LoaderHydraulic System966G:AAH1-UP3ZS1-UP9RS1-UP3PW1-UP3SW1-UP8XW1-UP
972G:7LS1-UPAAW1-UP1EW1-UP4WW1-UP6AW1-UP9GW1-UP
Printed in U.S.A.© 2009 Caterpillar, All Rights Reserved
ONE POSITION TWO POSITION THREE POSITION
VENTED PRESSURIZED RETURN ABOVE FLUID LEVEL RETURN BELOW FLUID LEVEL
LINES CROSSING LINES JOINING
TWO - WAY THREE - WAY FOUR - WAY
SPRING CONTROL VALVES RESTRICTION LINE RESTRICTION(FIXED)
PUMP(2 - SECTION)
SPRING(ADJUSTABLE)
VARIABILITY LINE RESTRICTION(VARIABLE)
PRESSURECOMPENSATION
PUMP(VARIABLE & PRESSURE
COMPENSATED)
MEASUREMENT
PRESSURE TEMPERATURE FLOW
ROTATING SHAFTS
UNIDIRECTIONAL BIDIRECTIONAL
PUSH - PULL LEVER PEDALGENERAL MANUAL PUSH BUTTON SPRING
FIXEDDISPLACEMENT
VARIABLE DISPLACEMENTNON-COMPENSATED
UNIDIRECTIONAL
BIDIRECTIONAL
VALVE ENVELOPES VALVE PORTS
FLUID CONDITIONERPUMP OR MOTOR
FLUID POWER SYMBOLS
UNIDIRECTIONAL
BIDIRECTIONAL
RELEASED PRESSURE
EXTERNAL RETURN INTERNAL RETURN
REMOTE SUPPLY PRESSURE
SIMPLIFIED
HYDRAULIC PUMPS
ACCUMULATORS
SPRING LOADED GAS CHARGED
SOLENOID OR MANUAL
SOLENOID & PILOT
SOLENOID &PILOT OR MANUAL
SOLENOID SERVO THERMAL DETENT
HYDRAULIC & PNEUMATIC CYLINDERS
DOUBLE ACTINGSINGLE ACTING
BASICSYMBOL
SPRINGLOADED
CHECK VALVES
2 POSITIONINFINITE
POSITIONING
FLOW IN ONEDIRECTION
FLOW INEITHER
DIRECTION
3 POSITION
CROSSFLOW
PARALLELFLOW
INTERNAL PASSAGEWAYS
NORMAL POSITION
A B
P T
A B
P TSHIFTED POSITION INFINITE POSITION
CONTROL VALVES
ATTACHMENT
MANUAL SHUTOFF
SHUTTLE PILOTCONTROLLED
MAIN AUX
LINE RESTRICTION(VARIABLE & PRESSURE
COMPENSATED)
MANUAL CONTROL SYMBOLS
HYDRAULIC MOTORS
FLUID STORAGE RESERVOIRS
CROSSING & JOINING LINES
VALVES
PILOT CONTROL SYMBOLS
COMBINATION CONTROLS
BASIC COMPONENT SYMBOLS
ENERGY TRIANGLESHYDRAULIC PNEUMATIC
INTERNALSUPPLY PRESSURE
COMPLETE
FIXEDDISPLACEMENT
VARIABLE DISPLACEMENTNON-COMPENSATED
HYDRAULIC SYMBOLS (ELECTRICAL)
ELECTRICAL SYMBOLS TABLE
325-AG135 PK-14
HARNESS IDENTIFICATION CODE THIS EXAMPLEINDICATES WIRE 135 IN HARNESS “AG”
325-PK-14
WIRE GAUGE
WIRE COLOR
CIRCUIT NUMBERIDENTIFICATION
WIRE NUMBER IDENTIFICATION CODES
CURRENT STANDARD
PREVIOUS STANDARD
ELECTRICAL SCHEMATIC EXAMPLE HYDRAULIC SCHEMATIC EXAMPLE
325-PK
WIRE COLORCIRCUIT NUMBER
IDENTIFICATION
B
WIRE
WIRE
(EXAMPLE VALVE)
CURRENT STANDARD
TRANSDUCER(FLUID)
MELECTRIC MOTORTRANSDUCER
(GAS / AIR)
G
GENERATOR
PRESSURE SWITCH ELECTRICAL WIREPRESSURE SWITCH(ADJUSTABLE)
TEMPERATURESWITCH
PRESSURESWITCH
TEMPERATURESWITCH
LEVELSWITCH
FLOWSWITCH
ELECTRICAL SYMBOLS (ELECTRICAL)
A
CIRCUIT NUMBERIDENTIFICATION
WIRECOLOR
WIRE GAUGE
T
RE
NR
211
7-0
2 V
OL
1 o
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24
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271425
2
3431
3233 GG
9 57
6
51
52
59
53
54378 CC
DD
MM 16
378
HH5011
FF
57
585556
293021
20
JJ
35
18
1516LL
3617243
13
194611 59
1650
BB
DD
MMAA
54515253
271425
2
3431
323328
28
9
57GG51378HH
2120
JJ
36
KK243
13 17
LL 1535 18 57
585556
2928
COMPONENT LOCATIONS
DD
50
FF55
CC
KK
MM
17
Tap LocationsPressure and Sampling
TapNumber Description Schematic
LocationAA Tilt Cylinder Rod End Pressure F-5BB Tilt Cylinder Head End Pressure F-5CC Rear Service Brake Pressure F-3DD Front Service Brake Presseure F-3FF Service Brake Accumulator Pressure D-2GG Implement Pilot Pump Pressure D-4HH Implement Pump Pressure C-7JJ Fluid Sampling Valve B-6KK Steering Pump Pressure B-3LL Fan Drive Pump Pressure B-6MM Steering Signal Pressure A-4
STEERING PUMP
Component Locations Description Part
NumberMachineLocation
SchematicLocation Description
Connector - Orifice 128-7063 1 D-4 to D-5 Valve Gp - PilotAccumulator As - Ride Control 108-5933 2 F-4 Valve Gp - Pilot, Shut OffCooler 130-8842 3 B-5 Valve Gp - Pilot (Oil Manifold, 2 Funct.)
Pilot (Oil Manifold, 3 Funct.)Cooler As - Brake Oil Cooling Attachment 134-2454 4 A-6Cylinder Gp - Auxiliary 5 F-6 Valve Gp - Relief (Line, Aux, HE)Cylinder Gp - Lift (LH) 133-2964 6 F-4 Valve Gp - Relief (Line, Aux, RE)Cylinder Gp - Lift (RH) 133-2963 7 F-4 Valve Gp - Relief (Line,Tilt, RE, HE)
Standard 2 And 3 Valve Relief (Line, Tilt, RE), Logging Relief (Line,Tilt, HE), Logging
Cylinder Gp - Steering 133-1747 8 C-2Cylinder Gp - Tilt, 966 972
144-9005133-2962 9 F-5
Elbow - Orifice 108-2144 10 B-4 Valve Gp - Relief, Main Standard LoggingFilter Gp - Oil, Hydr. (Fan / Cooler Flow) 134-3016 11 B-6
Manifold Gp - (Lift, Standard) 130-2073 12 E-4 Valve Gp - Secondary Steering (Diverter)Motor Gp - Hydraulic Fan 161-8919 13 B-5 Valve Gp - SteeringPlate - Orifice 8V-2080 14 F -5 Valve Gp - Steering NeutralizerPump and Motor Gp - Sec. Steering 154-2563 15 A-5 BRAKESPump Gp - HMU 147-7343 16 B-4 Accumulator Gp - Brake (Charged)Pump Gp - Hydraulic Fan 162-0772 17 B-6 Actuator As - Parking Brake
Pump Gp - Steering Implement
Pilot / Brake167-1154 18 B-7
Control Gp - Foot BrakeSensor Gp - Position (Rotary, Lft Brk Pdl)Switch As - Limit (Stop Light)
Screen Gp 6E-5065 19 A-7 Switch As - Pressure (Parking Brakes)Tank Gp - Hydraulic 133-1843 20 A-6 to A-7 Switch As - Pressure (Low Pressure Warning)Valve - Breaker Relief 9T-0818 21 A-7 Valve Gp - AccumulatorValve Gp - Check (Air Purge)(Air Bleed) 3G-8607 22 Valve Gp - Brake Control (Parking)Valve Gp - Check (Ride Control) 9T-3096 23 E-4 Valve Gp - Brake Control (Service)Valve Gp - Cooler Bypass 9T-6005 24 B-5Valve Gp - Diverter (Ride Control) 137-3520 25 E-4Valve Gp - Flow Divider (Axle Oil Cooler) 133-1729 26 B-6
Valve Gp - Main Control, 2 Func., Standard 3 Func. Logging 3 Func., (Attch) Control, 1 Func., Field Conversion
120-7477120-7475120-7473
120-7611
27 E-4 to E-7
PartNumber
MachineLocation
SchematicLocation
144-0115 28112-1817 29 D-5152-6480152-6481 30 D-4 to D-5
4T-2742 31 E-74T-4162 32 F-6
6E-23779T-84884T-2764
33 F-5
6E-60036E-6185 34 E-7
141-2597 35142-3996 36 B-2 to B-3146-7571 37 C-4
198-9841 50 F-2154-8042 51 F-1193-1448 52 F-2214-4863 53 F-3105-6117 54 F-33E-6452 55 E-13E-7693 56 D-3229-9984 57 E-3106-1774 58 D-1210-5587 59 F-2
FRONT, RIGHT VIEW OF HITCH
SERVICE BRAKES ACCUM CHARGING VALVE SERVICE BRAKES CONTROL VALVE
LINE PATTERNS
Drain / Return Lines
Component Group
Pilot / Load Sensing Pressure
Pressure Line
Attachment
Air Line
CALLOUTS
Taps (Pressure, Sampling, Sensor - by letter)
Components (By number)
YY
52
HYDRAULIC CIRCUIT COLOR DESCRIPTIONSPILOT / BRAKE PUMP OUTPUTIMPLEMENT PUMP OUTPUTTILT CONTROL CIRCUITSTEERING CIRCUITFAN PUMP AND CIRCUITSUPPLY LINEBRAKE CONTROL CIRCUITAUXILIARY CONTROL CIRCUITDRAIN / RETURN LINELIFT CONTROL CIRCUITELECTRICAL WIRESSECONDARY STEERING PUMP CIRCUIT
RE
NR
211
7-0
2 V
OL
1 o
f 2
24
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THIS SCHEMATIC IS FOR THE 966G AND 972G WHEEL LOADER HYDRAULIC SYSTEMMEDIA NUMBER: RENR2117-02, VOLUME 1 OF 2PART NUMBER: 133-1727, CHANGE: 03, VERSION: - (STEERING AND IMPLEMENTS)PART NUMBER: 142-0727, CHANGE 04, VERSION: - (BRAKES)Components are shown installed on a fully operable machine.
Refer to the appropriate Service Manual for Troubleshooting, Specifications.
A
B
C
D
E
F
1234567
A
B
C
D
E
F
1234567
M PILOT IMPLEMENTS / HMU STEERING
E9
E8
AA
BB
HH
JJ
LL
MM
KK
FF
CC
DD
GG
IMPLEMENT
STEER
PILOT/BRAKE
TO HYD BRAKE DRAIN
TO HYD BRAKES
VE
NT
TO BRAKELIGHTS
TO TRANSMISSIONCONTROL
TO HYDRAULICOIL FILTER
TO SEMS
TRANSMISSION CONTROL
RELEASE APPLY
FROM DEMANDFAN
NC
NO
CC
NC
NO
C
RAISE
LOWER
RA
CK
BA
CK
DU
MP
LOW
ER
CLO
SE
OP
EN
RA
ISE
ACCUMULATOR AS.RIDE CONTROL108-5933
CONNECTORORIFICE128-7063
CONNECTORORIFICE128-7063
COOLER ASBRAKE OILCOOLINGATTCH134-2454
COOLER ASBRAKE OILCOOLINGATTCH134-2454
CYLINDER GPLIFT (LH)133-2964
CYLINDER GPLIFT (RH)133-2963
CYLINDER GPTILT966: 144-9005972: 133-2962
CYLINDER GPAUXILIARY
FILTER GPOIL, HYDR.FAN / COOLER FLOW134-3016
MANIFOLD GPLIFT, STANDARD130-2073
MOTOR GPHYDRAULIC FAN161-8919
PUMP GPSTEERINGIMPLEMENTPILOT / BRAKE167-1154
PUMP AND MOTOR GPSECONDARY STEERING154-2563
SC
RE
EN
GP
6E-5
065
VALVE GPCHECKAIR PURGE, AIR BLEED3G-8607
VALVE GPMAIN CONTROL2 FUNCTION, STANDARD: 120-74773 FUNCTION, LOGGING: 120-74753 FUNCTION, ATTACHMENT: 120-74731 FUNCTION, FIELD CONVERSION: 120-7611
VALVE GPCOOLER BYPASS9T-6005
VALVE GPSEC. STEERINGDIVERTER141-2597
VALVE GPDIVERTERRIDE CONTROL137-3520
VALVE GPFLOW DIVIDERAXLE OIL CLR133-1729
VALVE GPPILOTOIL MANIFOLD2 FUNCTION: 152-64803 FUNCTION: 152-6481
VALVE GPRELIEFLINE, AUX,HEAD END4T-2742
VALVE GPRELIEFLINE, AUX,ROD END4T-4162
VALVE GPRELIEFMAIN, STANDARD: 6E-6003LOGGING: 6E-6185
VALVE GPRELIEFLINE, TILT,HEAD ENDSTANDARD 2 OR 3VALVE: 6E-2377LOGGING: 4T-2764
VALVE GPRELIEFLINE, TILT,ROD ENDSTANDARD 2 OR 3VALVE: 6E-2377LOGGING: 9T-8488
ACCUMULATOR AS.BRAKE (CHARGED)198-9841
ACTUATOR AS.PARKING BRAKE154-8042
CONTROL GPFOOT BRAKE193-1448
SENSOR GPPOSITION(ROTARY, LFT BRK PDL)214-4863
SWITCH ASLIMITSTOP LIGHT105-6117
SWITCH ASPRESSUREPARKING BRAKES3E-6452
VALVE GPACCUMULATOR229-9984
VALVE GPBRAKE CONTROLPARKING106-1774
VALVE GPBRAKE CONTROLSERVICE210-5587
BRAKES, PARKING AND SERVICE
PLATEORIFICE8V-2080
VALVE GPCHECKRIDE CONTROL9T-3096
CONNECTORORIFICE128-7063
CONNECTORORIFICE128-7063
CONNECTORORIFICE128-7063
CONNECTORORIFICE128-7063
VALVE GPPILOTSHUT OFF112-1817
VALVE GPPILOT144-0115
COOLER130-8842
PUMP GPHYDRAULIC FAN162-0770
TANK GPHYDRAULIC133-1843
VALVEBREAKER RELIEF9T-0818
FRONT BRAKES
REAR BRAKES
SWITCH ASPRESSURELOW PRESSURE WARNING3E-7693
VALVE GPSTEERINGNEUTRALIZER146-7571
VALVE GPSTEERINGNEUTRALIZER146-7571
ELBOWORIFICE108-2144
ELBOWORIFICE108-2144
PUMP GPHMU147-7343
VALVE GPSTEERING142-3996
CYLINDER GPSTEERING133-1747
BACK-UPRELIEF MAKE-UP
CHECK
CROSSOVER RELIEF
PILOT CONTROL SPOOLDIRECTIONAL SPOOL
RENR2117-02January 2009
Volume 2 of 2: Brakes, E/H Implements, and Command Control Steering
966G and 972G Wheel LoaderHydraulic System966G:AAH1-UP3ZS1-UP9RS1-UP3PW1-UP3SW1-UP8XW1-UP
972G:7LS1-UPAAW1-UP1EW1-UP4WW1-UP6AW1-UP9GW1-UP
Printed in U.S.A.© 2009 Caterpillar, All Rights Reserved
ONE POSITION TWO POSITION THREE POSITION
VENTED PRESSURIZED RETURN ABOVE FLUID LEVEL RETURN BELOW FLUID LEVEL
LINES CROSSING LINES JOINING
TWO - WAY THREE - WAY FOUR - WAY
SPRING CONTROL VALVES RESTRICTION LINE RESTRICTION(FIXED)
PUMP(2 - SECTION)
SPRING(ADJUSTABLE)
VARIABILITY LINE RESTRICTION(VARIABLE)
PRESSURECOMPENSATION
PUMP(VARIABLE & PRESSURE
COMPENSATED)
MEASUREMENT
PRESSURE TEMPERATURE FLOW
ROTATING SHAFTS
UNIDIRECTIONAL BIDIRECTIONAL
PUSH - PULL LEVER PEDALGENERAL MANUAL PUSH BUTTON SPRING
FIXEDDISPLACEMENT
VARIABLE DISPLACEMENTNON-COMPENSATED
UNIDIRECTIONAL
BIDIRECTIONAL
VALVE ENVELOPES VALVE PORTS
FLUID CONDITIONERPUMP OR MOTOR
FLUID POWER SYMBOLS
UNIDIRECTIONAL
BIDIRECTIONAL
RELEASED PRESSURE
EXTERNAL RETURN INTERNAL RETURN
REMOTE SUPPLY PRESSURE
SIMPLIFIED
HYDRAULIC PUMPS
ACCUMULATORS
SPRING LOADED GAS CHARGED
SOLENOID OR MANUAL
SOLENOID & PILOT
SOLENOID &PILOT OR MANUAL
SOLENOID SERVO THERMAL DETENT
HYDRAULIC & PNEUMATIC CYLINDERS
DOUBLE ACTINGSINGLE ACTING
BASICSYMBOL
SPRINGLOADED
CHECK VALVES
2 POSITIONINFINITE
POSITIONING
FLOW IN ONEDIRECTION
FLOW INEITHER
DIRECTION
3 POSITION
CROSSFLOW
PARALLELFLOW
INTERNAL PASSAGEWAYS
NORMAL POSITION
A B
P T
A B
P TSHIFTED POSITION INFINITE POSITION
CONTROL VALVES
ATTACHMENT
MANUAL SHUTOFF
SHUTTLE PILOTCONTROLLED
MAIN AUX
LINE RESTRICTION(VARIABLE & PRESSURE
COMPENSATED)
MANUAL CONTROL SYMBOLS
HYDRAULIC MOTORS
FLUID STORAGE RESERVOIRS
CROSSING & JOINING LINES
VALVES
PILOT CONTROL SYMBOLS
COMBINATION CONTROLS
BASIC COMPONENT SYMBOLS
ENERGY TRIANGLESHYDRAULIC PNEUMATIC
INTERNALSUPPLY PRESSURE
COMPLETE
FIXEDDISPLACEMENT
VARIABLE DISPLACEMENTNON-COMPENSATED
HYDRAULIC SYMBOLS (ELECTRICAL)
ELECTRICAL SYMBOLS TABLE
325-AG135 PK-14
HARNESS IDENTIFICATION CODE THIS EXAMPLEINDICATES WIRE 135 IN HARNESS “AG”
325-PK-14
WIRE GAUGE
WIRE COLOR
CIRCUIT NUMBERIDENTIFICATION
WIRE NUMBER IDENTIFICATION CODES
CURRENT STANDARD
PREVIOUS STANDARD
ELECTRICAL SCHEMATIC EXAMPLE HYDRAULIC SCHEMATIC EXAMPLE
325-PK
WIRE COLORCIRCUIT NUMBER
IDENTIFICATION
B
WIRE
WIRE
(EXAMPLE VALVE)
CURRENT STANDARD
TRANSDUCER(FLUID)
MELECTRIC MOTORTRANSDUCER
(GAS / AIR)
G
GENERATOR
PRESSURE SWITCH ELECTRICAL WIREPRESSURE SWITCH(ADJUSTABLE)
TEMPERATURESWITCH
PRESSURESWITCH
TEMPERATURESWITCH
LEVELSWITCH
FLOWSWITCH
ELECTRICAL SYMBOLS (ELECTRICAL)
A
CIRCUIT NUMBERIDENTIFICATION
WIRECOLOR
WIRE GAUGE
T
RE
NR
211
7-0
2 V
OL
2 o
f 2
24
Pa
ge
, (D
ime
ns
ion
s:
34
in
ch
es
x 2
8 i
nc
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s)
115
2926 34
38
36
35
EE
8 1110
6
235259
53
54317 CC
DD
207
NN5012
MM
57
585556
28
17
19
42
TT 301627
4
12 593120
BB
CC
DDAA5451
52
53
115
2926 34
38
36
3537
37
9 11
6GG517NN
2120 RR17
274
14 16
TT
2818
19 57
58
5556
COMPONENT LOCATIONS
Component Locations Description Part
NumberMachineLocation
SchematicLocation Description
Accumulator As - Ride Control 108-5933 1 F-4 Valve Gp - Cooler BypassConnector 8C-0564 2 E-5 Valve Gp - Secondary Steering (Diverter)Connector - Orifice 128-7063 3 D-6 Valve Gp - Diverter (Ride Control)Cooler 130-8842 4 B-5 Valve Gp - Flow Divider (Axle Oil Cooler)Cooler As - Brake Oil Cooling Attachment 134-2454 5 A-6 Valve Gp - Steering NeutralizerCylinder Gp - Lift (LH) 133-2964 6 F-5 Valve Gp - Pilot (Command Control Steering)Cylinder Gp - Steering 133-1747 7 C-2 Valve Gp - Pilot (Oil Manifold, 2 Funct.)
Pilot (Oil Manifold, 3 Funct.)Cylinder - Tilt (966) 144-9005 8 F-6Cylinder - Tilt (972) 133-2962 9 F-6 Valve Gp - Relief (Line, Aux, HE)Cylinder - Lift (RH) 133-2963 10 F-4 Valve Gp - Relief (Line, Aux, RE)Cylinder Gp - Auxiliary 11 F-6 Valve Gp - Relief, Main Standard
LoggingFilter Gp - Oil, Hydr. (Fan / Cooler Flow) 134-3016 12 B-6Manifold Gp - (Lift, Standard) 130-2073 13 E-4 Valve Gp - Relief (Line,Tilt, HE), LoggingMotor Gp - Hydraulic Fan 161-8919 14 B-6 Valve Gp - Relief (Line,Tilt, RE, HE)
Standard 2 And 3 ValvePlate - Orifice 8V-2080 15 F -5Pump Gp - Hydraulic Fan 162-0772 16 B-6 Valve Gp - Relief (Line, Tilt, RE), Logging
Pump Gp - Steering Implement Pilot / Brake
167-1154 17 B-7Valve Gp - Shuttle (Steering)Valve Gp - Steering (Command Control Str)Valve Gp = Ball, Manual (Lowering Control)
Pump and Motor Gp - Sec. Steering 154-2563 18 A-5 BrakesScreen Gp - Case Drain (Steering Pilot) 154-2883 19 C-3 Accumulator Gp - Brake (Charged)Screen Gp 6E-5065 20 A-7, D-7 Actuator As - Parking BrakeTank Gp - Hydraulic 133-1843 21 A-6 to A-7 Control Gp - Foot BrakeValve - Breaker Relief 9T-0818 22 A-7 Sensor Gp - Position (Rotary, Lft Brk Pdl)Valve Gp - Check (Steering Quad) 111-7775 23 B-4 Switch As - Limit (Stop Light)Valve Gp - Check (Ride Control) 9T-3096 24 E-4 Switch As - Pressure (Parking Brakes)Valve Gp - Check (Air Purge)(Air Bleed) 3G-8607 25 D-7 Switch As - PressureValve Gp - Main Control, 2 Func., Standard 3 Func. Logging 3 Func., (Attch) Control, 1 Func., Field Conversion
120-7477120-7475120-7473
120-7611
26 E-5 to E-7
Valve Gp - AccumulatorValve Gp - Brake Control (Parking)Valve Gp - Brake Control (Service)
PartNumber
MachineLocation
SchematicLocation
9T-6005 27 B-5141-2597 28 B-5137-3520 29 E-4133-1729 30 B-68J-1553 31 B-3
164-4116 32 B-4142-3997142-3998 33 D-4 to D-6
4T-2742 34 E-74T-4162 35 F-66E-60036E-6185 36 E-7
4T-2764 37 F-5
6E-2377 38 F-6
9T-8488 39 F-68J-6875 41 B-4
133-1728 42 B-2112-1817 43 D-7
198-9841 50 F-2154-8042 51 F-1193-1448 52 F-2214-4863 53 F-3105-6117 54 F-23E-6452 55 E-13E-7693 56 D-3229-9984 57 E-3106-1774 58 D-1210-5587 59 F-2
9
8
10
39
39
24
24
25
25 33
3313
13
50
3223
31
4230
14
41
4122
2120 RR
22
43
43
51
32
32
32
SS
WW FF
GG
HH
JJ
KK
LL
UU
VV
PP
ZZ
WW
MM
PP
ZZ
EE
FF
GG
HH
JJ
KK
LL
UU
VV
SSWW
Tap LocationsPressure and Sampling
TapNumber Description Schematic
LocationAA Tilt Cylinder Rod End Pressure F-5BB Tilt Cylinder Head End Pressure F-5CC Rear Service Brake Pressure F-3DD Front Service Brake Presseure F-3EE Auxiliary Pilot Pump Pressure E-7FF Auxiliary Pilot Pump Pressure E-7GG Tilt Pilot Pump Pressure E-6HH Tilt Pilot Pump Pressure E-6JJ Lift Pilot Pump Pressure E-5KK Lift Pilot Pump Pressure E-5LL Pilot Pump Pressure E-4MM Service Brake Accumulator Pressure D-2NN Implement Pump Pressure C-7PP Steering Pump Pressure B-7RR Fluid Sampling Valve B-6SS Steering Pilot Pump Pressure B-3TT Fan Drive Pump Pressure B-6
UU Steering Control ValveNeutral Pilot Pressure B-4
VV Steering Pilot Pressure B-4WW Steering Pilot Pressure B-3ZZ Steering Signal Pressure A-3 DD
50
FF55
CC
PP
ZZ
RIGHT REAR VIEW OFMAIN STEERING CONTROL VALVE
FRONT, RIGHT VIEW OF HITCH
SERVICE BRAKES ACCUM CHARGING VALVE SERVICE BRAKES CONTROL VALVE
LINE PATTERNS
Drain / Return Lines
Component Group
Pilot / Load Sensing Pressure
Pressure Line
Attachment
Air Line
CALLOUTS
Taps (Pressure, Sampling, Sensor - by letter)
Components (By number)
YY
52
HYDRAULIC CIRCUIT COLOR DESCRIPTIONSPILOT / BRAKE PUMP OUTPUTIMPLEMENT PUMP OUTPUTTILT CONTROL CIRCUITSTEERING CIRCUITFAN PUMP AND CIRCUITSUPPLY LINEBRAKE CONTROL CIRCUITAUXILIARY CONTROL CIRCUITDRAIN / RETURN LINELIFT CONTROL CIRCUITELECTRICAL WIRESSECONDARY STEERING CIRCUIT
RE
NR
211
7-0
2 V
OL
2 o
f 2
24
Pa
ge
, (D
ime
ns
ion
s:
34
in
ch
es
x 2
8 i
nc
he
s)
THIS SCHEMATIC IS FOR THE 966G AND 972G WHEEL LOADER HYDRAULIC SYSTEMMEDIA NUMBER: RENR2117-02, VOLUME 2 OF 2PART NUMBER: 133-1727, CHANGE: 03, VERSION: - (STEERING AND IMPLEMENTS)PART NUMBER: 142-0727, CHANGE 04, VERSION: - (BRAKES)Components are shown installed on a fully operable machine.
Refer to the appropriate Service Manual for Troubleshooting, Specifications.
A
B
C
D
E
F
1234567
A
B
C
D
E
F
1234567
966G & 972G E/H IMPLEMENT AND COMMAND CONTROL STEERING
MM
CC
SS
VV
UU
DD
TO BRAKELIGHTS
TO TRANSMISSIONCONTROL
NC
NO
CC
NC
NO
C
M
NN
RR
TT
IMPLEMENT
STEER
PILOT/BRAKE
PP
ZZ
WW
TO SEMS
TRANSMISSION CONTROL
RELEASE APPLY
TO HYD BRAKE DRAIN
TO HYD BRAKES
E9
E8
AA
BB
RAISE
LOWER
RA
CK
BA
CK
DU
MP
LOW
ER
CLO
SE
OP
EN
RA
ISE
LLKKJJHHGGFFEE
E4
E1
E2
E3 E5
E6
E7
ACCUMULATOR AS.RIDE CONTROL108-5933
CONNECTOR8C-0564
CONNECTORORIFICE128-7063
CONNECTORORIFICE128-7063
COOLER130-8842
COOLER ASBRAKE OILCOOLINGATTCH134-2454
COOLER ASBRAKE OILCOOLINGATTCH134-2454
CYLINDER GPLIFT (LH)133-2964
CYLINDER GPLIFT (RH)133-2963
CYLINDER GPSTEERING133-1747
CYLINDER GPTILT966: 144-9005972: 133-2962
CYLINDER GPAUXILIARY
FILTER GPOIL, HYDR.FAN / COOLER FLOW134-3016
MANIFOLD GPLIFT, STANDARD130-2073
MOTOR GPHYDRAULIC FAN161-8919
PUMP GPHYDRAULIC FAN162-0770
PUMP GPSTEERINGIMPLEMENTPILOT / BRAKE167-1154
PUMP AND MOTOR GPSECONDARY STEERING154-2563
SCREEN GPCASE DRAINSTEERING PILOT154-2883
VALVEBREAKER RELIEF9T-0818
SC
RE
EN
GP
6E-5
065
TANK GPHYDRAULIC133-1843
VALVE GPCHECKSTEERING QUAD111-7775
VALVE GPCHECKRIDE CONTROL9T-3096
VALVE GPCHECKAIR PURGE, AIR BLEED3G-8607
VALVE GPMAIN CONTROL2 FUNCTION, STANDARD: 120-74773 FUNCTION, LOGGING: 120-74753 FUNCTION, ATTACHMENT: 120-74731 FUNCTION, FIELD CONVERSION: 120-7611
VALVE GPCOOLER BYPASS9T-6005
VALVE GPSEC. STEERINGDIVERTER141-2597
VALVE GPDIVERTERRIDE CONTROL137-3520
VALVE GPFLOW DIVIDERAXLE OIL CLR133-1729
VALVE GPSTEERINGNEUTRALIZER8J-1553
VALVE GPSTEERINGNEUTRALIZER8J-1553
VALVE GPPILOTCOMMAND CONTROL STEERING164-4116
VALVE GPPILOTOIL MANIFOLD2 FUNCTION: 142-39973 FUNCTION: 142-3998
VALVE GPRELIEFLINE, AUX,HEAD END4T-2742
VALVE GPRELIEFLINE, AUX,ROD END4T-4162
VALVE GPRELIEFMAIN, STANDARD: 6E-6003LOGGING: 6E-6185
VALVE GPRELIEFLINE, TILT,HEAD ENDSTANDARD 2 OR 3VALVE: 6E-2377LOGGING: 4T-2764
VALVE GPRELIEFLINE, TILT,ROD ENDSTANDARD 2 OR 3VALVE: 6E-2377LOGGING: 9T-8488
VALVE GPSHUTTLESTEERING8J-6875
VALVE GPSTEERINGCOMMAND CONTROL STEERING133-1728
VALVE GPBALL,MANUAL(LOWERINGCONTROL)112-1817
PLATEORIFICE8V-2080
SCREEN GP6E-5065
FRONT BRAKES
REAR BRAKES
ACCUMULATOR AS.BRAKE (CHARGED)198-9841
ACTUATOR AS.PARKING BRAKE154-8042
PARKING BRAKES
CONTROL GPFOOT BRAKE193-1448
SENSOR GPPOSITION(ROTARY, LFT BRK PDL)214-4863
SWITCH ASLIMITSTOP LIGHT105-6117
SWITCH ASPRESSUREPARKING BRAKES3E-6452
VALVE GPACCUMULATOR229-9984
VALVE GPBRAKE CONTROLPARKING106-1774
VALVE GPBRAKE CONTROLSERVICE210-5587
BRAKES, PARKING AND SERVICE
SWITCH ASPRESSURE3E-7693
CROSSOVER RELIEF
SHUTTLE VALVE
DIRECTIONAL SPOOL
MAKE-UPCHECK
BACK-UPRELIEF
PRESSUREREDUCINGVALVE
REGULATED PRESS. PORTTO PILOT VALVE
PILOT PORT “B”
PILOT PORT “A”
CYLINDERPORT“A”
CYLINDERPORT“A”
CYLINDER PORT “B”
