BAIC Industrial Hydraulic System Service Manual & Repair Guide (EN)

KENR6358-01 December 2007 FLUID POWER SYMBOLS 12 Page, (Dimensions: 25 inches x 24 inches) KENR6358-01 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) Component Locations VARIABILITY SPRING LINE RESTRICTION PRESSURE HYDRAULIC PNEUMATIC LINE RESTRICTION ATTACHMENT Part Machine Schematic (ADJUSTABLE) (VARIABLE) COMPENSATION ENERGY TRIANGLES VARIA CB OL ME P a En Nd SP AR TE ES DSURE Description Number Location Location VALVES VALVE ENVELOPES VALVE PORTS Cylinder Gp - LH Lift 272-2767 1 E-4 Cylinder Gp - RH Lift 272-2766 2 E-5 ONE POSITION TWO POSITION THREE POSITION TWO-WAY THREE-WAY FOUR-WAY Cylinder Gp - Ripper Lift 4T-9290 3 E-2 CONTROL VALVES CHECK VALVES Cylinder Gp - Tilt 272-2768 4 E-3 A B A B Filter Gp - Hydraulic Oil 271-0872 5 C-8 P T P T BASIC SPRING SHUTTLE PILOT Pump Gp - Main Hydraulic 270-6258 6 B-5 NORMAL POSITION SHIFTED POSITION INFINITE POSITION SYMBOL LOADED CONTROLLED FLUID STORAGE RESERVOIRS Tank Gp - Hydraulic & Fuel 269-8956 7 B-5 Valve Gp - Breaker Relief 191-5439 8 B-6 Valve Gp - Control ( Bulldozer Lift) 271-0874 9 C-4 VENTED PRESSURIZED RETURN ABOVE FLUID LEVEL RETURN BELOW FLUID LEVEL MEASUREMENT ROTATING SHAFTS Valve Gp - Control ( Bulldozer Tilt) 271-0875 10 C-3 D7G Series 2 Track-Type Tractor Valve Gp - Control ( Ripper) 271-0875 11 C-2 Valve Gp - LH Quick Drop 276-7928 12 E-4 Hydraulic System PRESSURE TEMPERATURE FLOW UNIDIRECTIONAL BIDIRECTIONAL COMBINATION CONTROLS Valve Gp - RH Quick Drop 276-7928 13 E-5 Valve Gp - Implement 14 C-2 thru C-4 7MB5000-UP Bank-1 (Lift) 273-5505 C7G1000-UP SOLENOID SOLENOID SOLENOID SOLENOID and SERVO THERMAL DETENT or MANUAL and PILOT PILOT or MANUAL Bank-2 (Lift,Tilt or Ripper) 273-5504 MANUAL CONTROL SYMBOLS Bank-1 (Lift, Tilt, Ripper) 271-0871 Valve - Inlet & Relief 271-0876 15 C-4 Valve - Outlet 271-0877 16 C-2 PUSH-PULL LEVER MANUAL SHUTOFF GENERAL MANUAL PUSH BUTTON PEDAL SPRING PILOT CONTROL SYMBOLS RELEASED PRESSURE REMOTE SUPPLY PRESSURE EXTERNAL RETURN INTERNAL RETURN SIMPLIFIED COMPLETE INTERNAL SUPPLY PRESSURE ACCUMULATORS CROSSING AND JOINING LINES HYDRAULIC AND PNEUMATIC CYLINDERS Tap Locations Pressure, Sampling, and Sensor SPRING LOADED GAS CHARGED LINES CROSSING LINES JOINING SINGLE ACTING DOUBLE ACTING Tap Schematic Description HYDRAULIC PUMPS HYDRAULIC MOTORS INTERNAL PASSAGEWAYS Number Location AA Main Hydraulic Pump Pressure C-6 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 ©2007 Caterpillar Printed in U.S.A.

All Rights Reserved 15 Electrical Symbols Table Hydraulic Symbols (Electrical) 9 G M 10 Transducer Transducer Generator Electric Motor (Fluid) (Gas / Air) 1 2 14 11 4 12 16 Pressure Switch Temperature Switch Electrical Wire Pressure Switch (Adjustable) 13 Electrical Symbols (Electrical) IMPLEMENT VALVE T 6 Pressure Temperature Level Flow Symbol Symbol Symbol Symbol Wire Number Identification Codes 14 Electrical Schematic Example Hydraulic Schematic Example Current Standard Current Standard 5 Harness identification code AA This example indicates wire 135 in harness "AG".

Wire Circuit Number Wire Color Identification 7 8 325-AG135 PK-14 325-PK Circuit Identification Wire Color Wire Gauge 6 Number 3 Previous Standard Wire Color Wire 325-PK-14 B A Circuit Number Wire Gauge Note: The pressure tap (AA) is located under an acess plate Identification (EXAMPLE VALVE) on the floor of the operator station. COMPONENT LOCATIONS HYDRAULIC PUMP 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 VARIA CB OL ME P a En Nd SP AR TE ES DSURE VALVES VALVE ENVELOPES VALVE PORTS ONE POSITION TWO POSITION THREE POSITION TWO-WAY THREE-WAY FOUR-WAY CONTROL VALVES CHECK VALVES A B A B 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 PRESSURE TEMPERATURE FLOW ROTATING SHAFTS 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 PILOT CONTROL SYMBOLS RELEASED PRESSURE REMOTE SUPPLY PRESSURE EXTERNAL RETURN INTERNAL RETURN SIMPLIFIED COMPLETE INTERNAL SUPPLY PRESSURE ACCUMULATORS SPRING LOADED GAS CHARGED CROSSING AND JOINING LINES HYDRAULIC PUMPS FIXED VARIABLE DISPLACEMENT DISPLACEMENT NON-COMPENSATED D UNIDIRECTIONAL BIDIRECTIONAL HYDRAULIC MOTORS 1 2 4 12 13 6 14 5 7 8 3 COMPONENT LOCATIONS Component Locations Part Machine Schematic Description Number Location Location Cylinder Gp - LH Lift 272-2767 1 E-4 Cylinder Gp - RH Lift 272-2766 2 E-5 Cylinder Gp - Ripper Lift 4T-9290 3 E-2 Cylinder Gp - Tilt 272-2768 4 E-3 Filter Gp - Hydraulic Oil 271-0872 5 C-8 Pump Gp - Main Hydraulic 270-6258 6 B-5 Tank Gp - Hydraulic & Fuel 269-8956 7 B-5 Valve Gp - Breaker Relief Valve Gp - Control ( Bulldozer Lift) 191-5439 271-0874 8 9 B-6 C-4 Valve Gp - Control ( Bulldozer Tilt) 271-0875 10 C-3 Valve Gp - Control ( Ripper) 271-0875 11 C-2 Valve Gp - LH Quick Drop 276-7928 12 E-4 Valve Gp - RH Quick Drop 276-7928 13 E-5 Valve Gp - Implement Bank-1 (Lift) Bank-2 (Lift,Tilt or Ripper) Bank-1 (Lift, Tilt, Ripper) 273-5505 273-5504 271-0871 14 C-2 thru C-4 Valve - Inlet & Relief 271-0876 15 C-4 Valve - Outlet 271-0877 16 C-2 Tap Locations Pressure, Sampling, and Sensor Tap Number Description Schematic Location AA Main Hydraulic Pump Pressure C-6

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F E D C 12 Page, Color 2, (Dimensions:

25 inches x 24 inches) KENR6358-01 B A F 7 6 5 4 3 2 ENLARGED VALVE DETAIL CYLINDER GP 2 PLACES CYLINDER GP CYLINDER GP CYLINDER GP RIPPER LIFT RH LIFT LH LIFT TILT 4T-9290 272-2766 272-2767 272-2768 VALVE GP VALVE GP RH QUICK DROP LH QUICK DROP 276-7928 276-7928 VALVE GP IMPLEMENT BANK-1 (LIFT) 273-5505 BANK-2 (LIFT,TILT or RIPPER) 273-5504 BANK-3 (LIFT,TILT,RIPPER) 271-0871 FILTER GP HYDRALIC OIL 271-0872 VALVE GP BREAKER RELIEF 191-5439 AA AIR VACUUM AIR RELIEF TANK GP INLET DOZER LIFT DOZER TILT RIPPER LIFT HYDRAULIC & FUEL 269-8956 VALVE OUTLET 271-0877 VALVE VALVE GP VALVE GP VALVE GP INLET & RELIEF CONTROL CONTROL CONTROL 271-0876 (BULLDOZER LIFT) (BULLDOZER TILT) (RIPPER) 271-0874 271-0875 271-0875 LINE PATTERNS Pressure Line PUMP GP Pilot / Load Sensing Pressure MAIN HYDRAULIC Drain / Return Lines 270-6258 TANK Component Group Attachment Air Line CALLOUTS YY Taps (Pressure, Sampling,Sensor) by letter HYDRAULIC CIRCUIT COLOR DESCRIPTIONS MAIN PUMP OUTPUT 52 Components by number DOZER LIFT CYLINDER CONTROL CIRCUIT DOZER TILT CYLINDER CONTROL CIRUIT THIS SCHEMATIC IS FOR THE D7G2 Track-Type Tractor REAR IMPLEMENT CONTROL CIRCUITS PART #:

REF 281-6266 (MM) Chg 02 RIPPER LIFT CYLINDER CONTROL CIRCUIT SUPPLY LINE Components are shown installed on a fully operable machine with the key and engine DRAIN / RETURN LINE off and transmission shifter in neutral. Refer to the appropriate Service Manual for Troubleshooting, Specifications and Systems Operations E D C B LINE PATTERNS Pressure Line A Pilot / Load Sensing Pressure Drain / Return Lines Component Group Attachment Air Line CALLOUTS YY Taps (Pressure, Sampling,Sensor) by letter 52 Components by number THIS SCHEMATIC IS FOR THE D7G2 Track-Type Tractor PART #:

REF 281-6266 (MM) Chg 02 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 7 6 5 4 3 2 DOZER LIFT DOZER TILT RIPPER LIFT HYDRAULIC CIRCUIT COLOR DESCRIPTIONS MAIN PUMP OUTPUT DOZER LIFT CYLINDER CONTROL CIRCUIT DOZER TILT CYLINDER CONTROL CIRUIT REAR IMPLEMENT CONTROL CIRCUITS RIPPER LIFT CYLINDER CONTROL CIRCUIT SUPPLY LINE DRAIN / RETURN LINE

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