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KENR9942-02 February 2014
777G Off-Highway Truck Hydraulic System GT71-UP T5A1-UP T4Y1-UP TNM1-UP RDR1-UP
Volume 1 of 3: Steering System and Rear Axle Lube System Volume 2 of 3: Hoist and Brake Cooling System Volume 3 of 3: Service Brakes, Parking Brakes and Traction Control System
COMPONENT LOCATION Volume 1 of 3 - STEERING AND REAR AXLE LUBE SYSTEMS
COMPONENT LOCATIONS (VOLUME 1) Part Number
Machine Location
Schematic Location
SWITCH AS-PRESSURE (SECONDARY STEERING LOAD SENSING)
9X-4455
1
D-4
PUMP GP-ELECTRIC 2 SECTION (STEERING)
319-5405
*2
D-4
TANK GP-HYDRAULIC
331-7128
3
B-3
VALVE AS - VACUUM RELIEF BREATHER (STEERING)
358-9476
4
C-4
FILTER GP-OIL (STEERING PUMP RETURN)
158-3491
5
C-3
VALVE GP-STEERING DISABLE CHECK
346-6351
6
D-3
PUMP GP-HAND METERING UNIT (STEERING)
195-6617
7
F-3
CYLINDER GP - STEERING (POSITION SENSING)
334-8703
8
F-3
CYLINDER GP - STEERING
105-2440
9
F-2
SENSOR GP-PRESSURE (MAIN STEERING PUMP)
344-7391
*10
D-2
PUMP GP-LOAD SENSING CONTROL WITH HIGH PRESSURE CUTOFF
261-5630
11
C-1
FILTER GP-OIL (STEERING CASE DRAIN)
249-2334
12
B-2
SENSOR AS-FLUID LEVEL MONITORING
330-9321
*13
B-2
Description
* = (2) See also Volume 3 * = (10) See also Volume 3 * = (13) See also Volume 2 and Volume 3
COMPONENT LOCATIONS - REAR AXLE LUB ATTACHMENT (VOLUME 1) Part Number
Machine Location
Schematic Location
MANIFOLD GP - REAR AXLE CONTROL
333-0362
42
E-7
PUMP and MOTOR GP - REAR AXLE LUBE
249-7012
43
E-6
MANIFOLD AS - REAR AXLE
327-0361
44
E-6
FILTER GP - REAR AXLE
192-3841
45
D-5
Description
COMPONENT LOCATION Volume 2 of 3 - HOIST AND BRAKE COOLING
COMPONENT LOCATIONS (VOLUME 2) Description SENSOR GP - LEVEL
Part Number
Machine Location
Schematic Location
*13
330-9321
A-6 D-1
SENSOR GP - TEMPERATURE
14
134-2252
F-1 D-7 F-7
BRAKE GP - SERVICE and PARK
*15
308-3208
C-6, F-6
CORE AS - OIL COOLER
16
200-5975
E-5
TANK GP (HYD)
*17
331-7060
A-3
PUMP GP - 4 SECTION PUMP (CCW)
18
350-9965
B-5
PUMP GP - 3 SECTION PUMP (CCW)
19
375-0678
B-4, B-3
FILTER - BREATHER
20
8X-4575
B-4, B-3
CYLINDER GP - TELESCOPING (HOIST)
21
296-0608
B-3, C-3
PLATE - ORIFICE (HOIST)
22
8X-7224
B-3, C-3
VALVE GP - CONTROL (HOIST)
23
245-1668
F-4
PLATE AS - BRAKE COOLING ORIFICE
24
382-9203
D-2
BRAKE GP - SERVICE
25
330-9471
B-3
* = (13) See also Volume 1 and Volume 3 * = (15) See also Volume 3 * = (17) See also Volume 3
COMPONENT LOCATION Volume 3 of 3 - SERVICE AND PARKING BRAKES AND TRACTION CONTROL
COMPONENT LOCATIONS (VOLUME 3) Part Number
Machine Location
Schematic Location
PUMP GP - ELECTRIC 2 SECTION PUMP
319-5405
*2
B-4
SENSOR AS. - PRESSURE (LOW BRAKE SUPPLY)
344-7391
*10
D-3
SENSOR GP - FLUID LEVEL MONITORING
330-9321
*13
A-5
BRAKE GP - SERVICE and PARK (REAR)
308-3208
*15
A-7, E-7
TANK GP - HYDRUALIC
331-7060
*17
A-3
PUMP GP - 3 SECTION PUMP (CCW)
375-0678
*19
B-3
FILTER - BREATHER (HOIST TANK)
8X-4575
20
A-4
BRAKE GP - SERVICE (FRONT)
330-9471
*25
C-1, E-1
319-6291
26
B-7, D-7
VALVE GP - ARC/TCS
340-6409
27
C-7
SWITCH AS.- PRESSURE (SECONDARY BRAKE DEACTIVATION INDICATOR)
160-2609
28
F-6
VALVE GP - SECONDARY BRAKE (ACCUMULATOR BLEED DOWN)
361-2239
29
F-5
357-4342
30
B-6, D-6
309-1615
31
C-4
360-3828
32
D-3
ACCUMULATOR GP - PARK BRAKE (PED CERTIFIED) (ATTACHMENT)
330-7828
32
D-3
ACCUMULATOR GP - SERVICE BRAKE
356-3346
33
D-2
ACCUMULATOR GP - SERVICE BRAKE (PED CERTIFIED) (ATTACHMENT)
318-2532
33
D-2
VALVE GP - CAB MANIFOLD (FRONT BRAKE)
334-8054
34
B-4
VALVE GP - ACCUMULATOR CHARGING
341-2634
35
B-3
VALVE GP - ACCUMULATOR CHARGING (PED CERTIFIED) (ATTACHMENT)
320-5075
35
B-3
SWITCH AS - BRAKE FILTER BYPASS SWITCH
156-1382
36
B-4
FILTER GP - BRAKE CHARGE
335-0980
37
C-4
PEDAL GP - SERVICE BRAKE PEDAL VALVE
342-9078
38
F-3
8X-7921
39
D-2
Description
ADJUSTER GP - SLACK ADJUSTER (REAR BRAKES)
APAPTER AS. - ORIFICE MANIFOLD GP - TOW VALVE (BRAKE) ACCUMULATOR GP - PARK BRAKE
ADJUSTER GP - SLACK ADJUSTER (FRONT BRAKES) * = (2) See also Volume 1 * = (10) See also Volume 1 * = (13) See also Volume 1 and Volume 2 * = (15) See also Volume 2 * = (17) See also Volume 2 * = (19) See also Volume 2 * = (20) See also Volume 2
TAP LOCATION
TAP LOCATIONS Pressure, Sampling, Sensor Tap Number A
Description
Schematic Location
REAR PARKING BRAKES (VOL. 3)
F-7
B
LEFT REAR SERVICE BRAKE (VOL. 3)
D-7
C
RIGHT REAR SERVICE BRAKE (VOL. 3)
B-7
D
BRAKE ACCUMULATOR CHARGE (VOL. 3)
D-3
E
BRAKE CHARGE PUMP OUTPUT (VOL. 3)
B-4
F
FRONT SERVICE BRAKES (VOL. 3)
D-1
G
LEFT REAR BRAKE COOLING OUT (VOL. 2)
F-7
H
LEFT REAR BRAKE COOLING IN (VOL. 2)
F-6
I
RIGHT REAR BRAKE COOLING OUT (VOL. 2)
D-7
J
RIGHT REAR BRAKE COOLING IN (VOL. 2)
D-6
K
BRAKE COOLER OUT (SOS) (VOL. 2)
E-5
M
HOIST PUMP OUTPUT (VOL. 2)
B-4
N
HOIST CYLINDER HEAD END (VOL. 2)
C-3
O
HOIST CYLINDER ROD END (VOL. 2)
C-3
P
HOIST LOWER PILOT (VOL. 2)
E-3
Q
HOIST RAISE PILOT (VOL. 2)
D-3
R
FRONT BRAKE COOLING IN (VOL. 2)
E-2
S
FRONT BRAKE COOLING OUT (VOL. 2)
C-1
T
STEERING RETURN (SOS) (VOL. 1)
C-3
U
HMU INPUT (VOL. 1)
D-2
V
STEERING LOAD SENSE (VOL. 1)
D-1
W
REAR AXLE LUBRICATION (VOL. 1)
E-6
FLUID POWER SYMBOLS BASIC COMPONENT SYMBOLS
MAIN AUX.
PUMP or MOTOR
SPRING (ADJUSTABLE)
VARIABILITY
CONTRO L VALVES
SPRING
FLUID CONDITIONER
LINE RESTRICTION (FIXED)
RESTRICTION
PRESSURE COMPENSATION
LINE RESTRICTION (VARIABLE)
2-SECTION PUMP
HYDRAULIC PNEUMATIC ENERGY TRIANGLES
TWO POSITION
PUMP: VARIABLE and PRESSURE COMPENSATED
ATTACHMENT
LINE RESTRICTION VARIABLE and PRESSURE COMPENSATED
VALVES
VALVE ENVELOPES
ONE POSITION
VALVE PORTS
TWO-WAY
THREE POSITION
THREE-WAY
CONTROL VALVES
FOUR-WAY
CHECK VALVES
A B
A B
P T SHIFTED POSITION
P T NORMAL POSITION
INFINITE POSITION
SHUTTLE
SPRING LOADED
BASIC SYMBOL
PILOT CONTROLLED
FLUID STORAGE RESERVOIRS
VENTED
RETURN ABOVE FLUID LEVEL
PRESSURIZED
RETURN BELOW FLUID LEVEL
MEASUREMENT
PRESSURE
TEMPERATURE
ROTATING SHA FTS
FLOW
UNIDIRECTIONAL
BIDIRECTIONAL
COMBINATION CONTROLS
SOLENOID
SOLENOID or MANUAL
SOLENOID and PILOT or MANUAL
SOLENOID and PILOT
SERVO
THERMAL
DETENT
MANUAL CONTROL SYMBOLS
PUSH-PULL LEVER
MANUAL SHUTOFF
RELEASED PRESSURE
EXTERNAL RETURN
SPRING LOADED
HYDRAULIC PUMPS VARIABLE DISPLACEMENT NON-COMPENSATED
LINES CROSSING
LINES JOINING
PEDAL
VARIABLE DISPLACEMENT NON-COMPENSATED
UNIDIRECTIONAL
UNIDIRECTIONAL
BIDIRECTIONAL
BIDIRECTIONAL
COMPLETE
INTERNAL SUPPLY PRESSURE
HYDRAULIC AND PNEUMATIC CYLINDERS
SINGLE ACTING
HYDRAULIC MOTORS FIXED DISPLACEMENT
SPRING
REMOTE SUPPLY PRESSURE
SIMPLIFIED
CROSSING AND JOINING LINES
GAS CHARGED
PUSH BUTTON
PILOT CONTROL SYMBOLS
INTERNAL RETURN
ACCUMULATORS
FIXED DISPLACEMENT
GENERAL MANUAL
DOUBLE ACTING
INTERNAL PASSAGEWAYS INFINITE POSITIONING
FLOW IN ONE DIRECTION
THREE POSITION
PARALLEL FLOW
TWO POSITION
CROSS FLOW
FLOW ALLOWED IN EITHER DIRECTION
ELECTRICAL SYMBOLS Hydraulic Symbols (Electrical)
M
G Transducer (Fluid)
Transducer (Gas / Air)
Pressure Switch (Adjustable)
Pressure Switch
Generator
Electric Motor
Electrical Wire
Temperature Switch
Electrical Symbols (Electrical)
T
Pressure Symbol
Temperature Symbol
Level Symbol
Flow Symbol
Wire Number Identifi cation 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 Identification
Wire Color
325-AG135 PK-14 325-PK Circuit Identification Number
Wire Color
Wire Gauge
Previous Standard Wire Color
Wire
325-PK-14 B Circuit Number Identification
A
Wire Gauge (EXAMPLE VALVE)
7
6
5
4
3
2
1
(8)CYLINDERGP -STEERING (POSITIONING SENSING) 334-8703
(9)CYLINDERGP -STEERING 105-2440
F
F R
L
CROSS OVER RELIEF
(7)PUMP GP - HANDMETERING UNIT 195-6617
W
FROMBRAKE SYSTEM (Vol. 3/ B-3) (42)MANIFOLDGP -REARAXLE CONTROL: 333-0362
E
E T
LS
P
(44)MANIFOLDAS - REARAXLE:327-0361
1
1
(10)SENSORGP PRESSURE 344-7391
U
M
(2)PUMP GP - ELECTRIC2 SECTION (SECONDARY STEERING) 319-5405
2
2
(43)PUMP andMOTORGP REARAXLE LUBE: 249-7012
C
PR1
D
B
PS
SS
HMU
LS LST
TO BRAKE COOLING (Vol. 2/ E-5)
SECONDARY RELIEF
LS
TO TOW VALVE DRAIN (Vol. 3/ B-4)
PRIMARY RELIEF
(45)FILTERGP -REARAXLE: 192-3841
D
STEERING SECTION
BRAKE RETRACT SECTION
M
D
V
STEERING SYSTEM DISABLE SOLENOID
LS
S2
3 f o 1 L O V 2 0 2 4 9 e , 9 g a P R 4 2 N E K
) s e h c n i 8 2 x s e h c n i 4 3 : s n o i s n e m i D (
E
A
(1)SWITCHAS- PRESSURE (STEERING) 9X-4455 (6)VALVE GP -S TEERING DISABLE CHECK 346-6351
P
(11)PUMP GP -LOADSENSING CONTROL 261-5630
T C
LEFT SPINDLE
RETURN
RIGHT SPINDLE
(5)FILTERGP -OIL 158-3491
C S
C
(4)VALVE AS -VACUUMRELIEF BREATHER 358-9476
REAR AXLE HOUSING
(12)FILTER GP -OIL (STEERING CASE DRAIN) 249-2334
(13)SENSORAS -FLUIDLEVELMONITORIN G 330-9321
FULL B
B
FILL
LOW
HYDRAULIC CIRCUIT COLOR DESCRIPTIONS STEERINGCIRCUIT SUPPLYLINE BRAKECIRCUIT DRAIN/ RETURNLINE
(3)TANK GP -HYDRAULIC 331-7128
LINE PATTERNS PressureLine Pilot / LoadSensingPressure Drain/ ReturnLines
OPTIONAL REAR AXLE LUBRICATION SYSTEM
LOAD SENSE AND STEERING SYSTEM
Component Group Attachment AirLine
CALLOUTS
A
YY
Taps (Pressure, Sampling,Sensor)by letter
52
Componentsby number
777G OFF HIGHWAY TRUCK HYDRAULIC SYSTEM SCHEMATIC MEDIANUMBER: KENR9942-02, VOLUME 1 of 3 PARTNUMBER: 309-2869, CHANGE: 04, VERSION: --
HYDRAULIC CIRCUIT COLOR DESCRIPTIONS REARAXLE LUBRICATIONCIRCUIT SUPPLYLINE BRAKECOOLINGCIRCUIT DRAIN/ RETURNLINE
7
6
5
Components areshowninstalledon afully operablemachine. Refertotheappropriate ServiceManualforTroubleshooting,Specifications.
4
3
2
1
A
7
6
5
4
3
2
(15)BRAKE GP -SERVICE andPARK 308-3208 (14)SENSORGP -TEMP 134-2252
F
(Vol. 1/ B-5)
(23)VALVE GP -PROPORTIONAL CONTROL245-1668
DUAL STAGE SIGNAL SPOOL
H
G
1 (14)SENSORGP -TEMP 134-2252
FROM BRAKE SYSTEM
MAIN RELIEF DUMP SPOOL
F
RAISE RELIEF
S FROM BRAKE SYSTEM (Vol. 1 / B-3 ) FROM REAR AXLE LUBRICATION (Vol. 1 / B-3 )
LEFT REAR
LOWER RELIEF
LEFT FRONT
LOWER, FLOAT, SNUB SOLENOID
(25)BRAKE GP -SERVICE 330-9471
P
E
E
RAISE
B (16)CORE AS -REARBRAKE OIL 200-5975
A
H1
HOLD
R1
T
R
SNUB
FLOAT
(14)SENSORGP -TEMP 134-2252
K RIGHT REAR
D
3 f o 2 L O V 2 0 2 4 9 e , 9 g a P R 4 2 N E K
) s e h c n i 8 2 x s e h c n i 4 3 : s n o i s n e m i D (
(14)SENSORGP -TEMP 134-2252 (25)BRAKE GP -SERVICE 330-9471
RIGHT FRONT
LOWER BRAKE COOLING RELIEF
I
D
Q
RAISE
J
(24)PLATE AS. BRAKE COOLING ORIFICE 382-9203
SOLENOID
(15)BRAKE GP -SERVICE andPARK 308-3208
S2
C
S
C
(22)PLATE- ORIFIC E 8X-7224
N
M
O
(21)CYLINDERGP -HOIST 296-0608 (19)PUMP GP -3 SECTION: 375-0678
BRAKE BRAKE CHARGE COOLING
(18)PUMP GP. -4 SECTION 350-9965
B
TRANS SCAV
T/C PUMP
TRANS BRAKE CHARGE COOLING
HOIST
HOIST AND BRAKE COOLING SYSTEM
(20)CLEANERAS- BREATHER 8X-4575
B
HYDRAULIC CIRCUIT COLOR DESCRIPTIONS HOIST CYLINDERCIRCUIT SUPPLYLINE BRAKECIRCUIT DRAIN/ RETURNLINE HOIST PUMP CIRCUIT BRAKECOOLING
(13)SENSORAS -FLUIDLEVELMONITORIN G 330-9321
LINE PATTERNS
FULL
PressureLine Pilot / LoadSensingPressure Drain/ ReturnLines
FILL
Component Group Attachment
LOW
AirLine
CALLOUTS
A
YY
Taps (Pressure, Sampling,Sensor)by letter
52
Componentsby number
777G OFF HIGHWAY TRUCK HYDRAULIC SYSTEM SCHEMATIC MEDIANUMBER: KENR9942-02, VOLUME 2 of 3 PARTNUMBER: 309-2869, CHANGE: 04, VERSION: --
(17)TANK GP -HYDRAULIC 331-7060
Componentsare showninstalledona fullyoperablemachine. Refertotheappropriate ServiceManualforTroubleshooting,Specifications.
7
6
5
4
3
2
1
A
7
6
5
4
3
(28)SWITCHAS- PRESSURE 160-2609
1
(38)CONTROLGP -BRAKE PEDAL 342-9078
(29)VALVE GP SECONDARY BRAKE / ACCUMULATOR 361-2239
PS
2
PARK BRAKE SOLENOID
F
F
ACC. BLEED SOLENOID
P
A
A T
B
T
F
(34)VALVE GP -FRONT BRAKE MANIFOLD 334-8054
P
(15)BRAKE GP -SERVICE andPARK (REAR) 308-3208
E
(25)BRAKE GP -SERVICE (FRONT) 330-9471
FRONT BRAKE SOLENOID
E
14 P1 ACC
B
T
LEFT REAR
(33)ACCUMULATORGP SERVICE BRAKE: 356-3346
D
(30)ADAPTERAS- ORIFICE 357-4342
ACC
) s e h c n i 8 2 x s e h c n i 4 3 : s n o i s n e m i D (
F
D
(32)ACCUMULATORGP PARK BRAKE: 360-3828
D
(10)SENSORGP PRESSURE 344-7391
SLK2
(26)ADJUSTERGP REARBRAKE SLACK 319-6291
3 f o 3 L O V 2 0 2 4 9 e , 9 g a P R 4 2 N E K
T1
LHBRAKE SOLENOID
A2
A1
SW
A3
ARC/TCS ENABLE SOLENOID
(39)ADJUSTERGP -SLACK 8X-7921
(31)MANIFOLDGP TOW VALVE (BRAKE) 309-1615
PDL
C
C
A2 RHBRAKE SOLENOID
(27)VALVE GP -ARC/TCS 304-6409
(37)FILTERGP BRAKE CHARGE OIL 335-0980
(25)BRAKE GP -SERVICE (FRONT) 330-9471 TOW PUMP RELIEF
SLK1
TANK
(30)ADAPTERAS -ORIFICE 357-4342 (26)ADJUSTERGP REARBRAKE SLACK 319-6291
S
HOIST PILOT PRV
TO HOIST PILOT (Vol. 2/ F-2)
B
(36)SWITCHAS PRESSURE 156-1382
T
P
E
(2)PUMP GP ELECTRIC 2 SECTION 319-5405
SERVICE BRAKES, PARKING BRAKES, AND TRACTION CONTROL SYSTEM
(35)MANIFOLDGP ACCUMULATORCHARGE: 341-2634 (35)MANIFOLDGP ACCUMULATORCHARGE (PED CERT):341-2634
TO BRAKE COOLING (Vol. 2/ F-5)
TO BRAKE COOLING (Vol. 2/ F-5)
B
LINE PATTERNS PressureLine
P
Pilot / LoadSensingPressure
RIGHT REAR
M
BRAKE SECONDARY RETRACT STEERING SECTION
Drain/ ReturnLines
BRAKE BRAKE CHARGE COOLING
HOIST
Component Group
S1
(19)PUMP GP - 3SECTION:375-0678
Attachment AirLine
CALLOUTS
C
(20)CLEANERAS BREATHER 8X-4575
YY
Taps (Pressure, Sampling,Sensor)by letter
52
Componentsby number
CIRCUIT COLOR DESCRIPTIONS (13)SENSORAS -FLUIDLEVELMONITORIN G 330-9321 (15)BRAKE GP -SERVICE andPARK (REAR) 308-3208
A
FULL
BRAKE CHARGE PUMP HOIST CIRCUIT SUPPLY LINE DRAIN/ RETURNLINE DRAIN/ BRAKE COOLING PUMP STEERING PUMP BRAKERETRACTCIRCUIT
(17)TANK GP -HYDRAULIC:331-7060
FILL
777G OFF HIGHWAY TRUCK HYDRAULIC SYSTEM SCHEMATIC MEDIA NUMBER: KENR9942-02, VOLUME 3 of 3 PARTNUMBER: 309-2869, CHANGE: 04, VERSION: --
LOW
Components areshowninstalledonafully operablemachine. Refertotheappropriate ServiceManualforTroubleshooting,Specifications.
7
6
5
4
3
2
1
A
LEFT VIEW VIEW ALL CALLOUTS
11
13
34
19
26
M
43 W
25 AA
42 17 29 1 16
28
FRONT
31 18
2 F
39
8
35
25
32
D
33
RIGHT VIEW
30
VIEW ALL CALLOUTS
27
21
B
4
3
R
7
38
C
14
22 20 6
23 24 9
S E
36
V T
37
12
5
FRONT
U
10
REAR VIEW VIEW ALL CALLOUTS
G
J
H
I
A
44 45
15
HOIST CONTROL VALVE VIEW ALL CALLOUTS
P
Q
N O
