INTERACTIVE SCHEMATIC

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Component Table Tap Table Fluid Power Symbols Electrical Symbols

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RENR8828-03 March 2011

966H and 972H Wheel Loader Hydraulic System

966H: A6D1-UP RYF1-UP A6G1-UP A6J1-UP TAL1-UP 972H: GTA1-UP A7D1-UP A7G1-UP A7J1-UP

2011 Caterpillar, All Rights Reserved

Printed in U.S.A.

COMPONENT LOCATION Page 1 of 2

Item Number
1 2 3 4 5 6 7 8 9 10 11 12 13 14

Description
HMU STEERING CIRCUIT Hand Metering Unit Connector - Orifice Cylinder Gp - Steer Valve Gp - Neutralizer Valve Gp - Steer Valve Gp - Neutralizer Valve Gp - Steer Cylinder Gp - Steer Valve Gp - Check Valve Gp - Pilot Valve Gp - Shuttle Screen Gp MAIN SCHEMATIC Pump Gp - Steering Pump Gp - Implement Cylinder Gp - Tilt 966 Tilt 972

Part Number
230-4176 108-2144 133-1747 146-7571 142-3996 8J-1553 133-1728 133-1747 111-7775 164-4116 8J-6875 154-2883 241-9157 254-4109 242-4273 244-8777 245-7484 244-8777 245-7486 180-8585 112-1817 237-0946 112-1817 242-4275 242-4274 152-2646 112-1817 245-2975 254-5147 161-8919 142-8977

Schematic Location
A-4 B-4 B-1 B-4 B-2 D-2 D-1 E-1 D-3 D-4 C-3 E-2 A-6 A-7

COMMAND CONTROL STEERING

15

Tilt (High Lift) 966 Tilt (Logger) 966 Tilt (High Lift) 972

F-8

16 17 18 19 20 21 22 23 24 25 26 27

Valve Gp - Quick Coupler Control Valve Gp - Ball (Quick Coulper) Cylinder Gp - Quick Coupler Valve Gp - Ball (QC Return Oil) Cylinder - Lift (LH) Cylinder - Lift (RH) Valve - Choke Check Valve Gp - Manual Lowering Accumulator - Pilot Oil Pump Gp - Fan Motor Gp - Fan Valve Gp - Cooler Bypass

C-5 C-5 C-5 D-6 F-7 F-7 D-9 E-9 F-5 B-8 D-6 B-9

COMPONENT LOCATION Page 2 of 2

Item Number
28 29 30 31 32 33 34 35

Description
Filter Gp - Return Oil Valve Gp - Flow Divider Manifold Gp - Fan & Brake Charge Filter Gp - Case Drain Valve Gp - Breaker Relief Tank Gp - Hydraulic Oil Valve Gp - Secondary Steer Diverter Pump Gp - Secondary Steer Valve Gp - Control (2 Function Standard) (2 Function W/RC)

Part Number
244-1031 237-8180 242-1307 249-2334 220-0814 237-2742 141-2597 275-8543

Schematic Location
B-9 A-9 C-8 A-8 A-8 A-8 B-6 A-6

261-3945 261-2337 261-3972 261-2338 256-3644 245-2974 263-5832 183-4077 254-5147 242-1307 193-1448 105-6117 214-4863 210-5587 198-9841 220-2726 154-8042 106-1774 174-4312 175-3244 F-6 C-6 C-6 F-2 F-2 F-3 F-3 F-3 F-3 F-2 F-2 F-1 F-2 F-1 F-3 D-9

36

(3 Function) (2 Function W/RC)

41 42 43 25 30 45 46 47 48 49a 49b 50 51 52 53

(3 Function W/RC) Accumulator - Ride Control (RC) Valve Gp - Control & Relief Motor Gp - Reversing Fan BRAKE SYSTEM Pump Gp - Fan Manifold Gp - Fan & Brake Charge Control Gp - Foot Brake Switch As - Foot Brake Limit Sensor Gp - Foot Brake Valve Gp - Foot Brake Accumulator - Service Brake Accumulator - Service Brake (CE) Actuator As - Parking Brake Valve Gp - Parking Brake Switch As - Parking Brake Pressure Switch As - Brake Pressure

TAP LOCATION
Tap Number
AA CC DD EE FF GG HH KK LL MM NN PP QQ RR YY ZZ SOS

Description
Fan Pump Discharge Pressure Implement Pump Charge Pressure Implement Pump Load Sense Pressure Steer Pump Pressure Steer Pump Load Sense Pressure Pilot Supply Pressure Fan Pump Load Sense Pressure Command Control Right Steer Pilot Pressure Command Control Left Steer Pilot Pressure Command Control Steering Neutral Pilot Press Command Control Steering Supply Pressure Service Brake Pressure Front Service Brake Pressure Rear Service Brake Pressure Tilt Cylinder Head End Pressure Quck Coupler Cylinder Pressure Hydraulic Oil Sampling Port

Schematic Location
B-8 E-9 B-7 B-7 A-4, C-4 E-5 B-8 D-2 D-2 D-3 D-3 F-3 F-4 F-4 F-8 C-5 B-9

FLUID POWER SYMBOLS

BASIC COMPONENT SYMBOLS
MAIN AUX.

PUMP or MOTOR

FLUID CONDITIONER

SPRING

CONTROL VALVES

RESTRICTION

LINE RESTRICTION (FIXED)

2-SECTION PUMP

PUMP: VARIABLE and PRESSURE COMPENSATED

VARIABILITY

SPRING (ADJUSTABLE)

LINE RESTRICTION (VARIABLE)

PRESSURE COMPENSATION

HYDRAULIC PNEUMATIC ENERGY TRIANGLES

LINE RESTRICTION
VARIABLE and PRESSURE COMPENSATED

ATTACHMENT

VALVE ENVELOPES

VALVES

VALVE PORTS

ONE POSITION

TWO POSITION

THREE POSITION

TWO-WAY

THREE-WAY

FOUR-WAY

CONTROL VALVES
AB AB

CHECK VALVES

P T NORMAL POSITION

P T SHIFTED POSITION

INFINITE POSITION

BASIC SYMBOL

SPRING LOADED

SHUTTLE

PILOT 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 or MANUAL

SOLENOID and PILOT

SOLENOID and PILOT or MANUAL

SERVO

THERMAL

DETENT

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
FIXED DISPLACEMENT VARIABLE DISPLACEMENT NON-COMPENSATED UNIDIRECTIONAL

HYDRAULIC MOTORS
FIXED DISPLACEMENT VARIABLE DISPLACEMENT NON-COMPENSATED

INTERNAL PASSAGEWAYS
INFINITE POSITIONING THREE POSITION TWO POSITION

UNIDIRECTIONAL

BIDIRECTIONAL

BIDIRECTIONAL

FLOW IN ONE DIRECTION

PARALLEL FLOW

CROSS FLOW

FLOW ALLOWED IN EITHER DIRECTION

ELECTRICAL SYMBOLS
Hydraulic Symbols (Electrical)

G
Transducer (Fluid) Transducer (Gas / Air) Generator

M
Electric Motor

Pressure Switch

Pressure Switch (Adjustable)

Temperature Switch

Electrical Wire

Electrical Symbols (Electrical)

Pressure Symbol

Temperature Symbol

Level Symbol

Flow Symbol

Wire Number Identification Codes

Electrical Schematic Example

Current Standard
Harness identification code This example indicates wire 135 in harness "AG". Wire

Hydraulic Schematic Example

Current Standard

Circuit Number Identification

Wire Color

325-AG135 PK-14 325-PK

Circuit Identification Number Wire Color Wire Gauge

Previous Standard
Wire Wire Color

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

TILT INLET MANIFOLD

TILT ANTIDRIFT VALVE

(15) CYLINDER GP TILT 966 242-4273 TILT 972 244-8777 TILT (HIGH LIFT) 966 245-7484 TILT (LOGGER) 966 244-8777 TILT (HIGH LIFT) 972 245-7486

(20) CYLINDER LIFT (LH) 242-4275

LIFT

(21) CYLINDER LIFT (RH) 242-4274

(41) ACCUMULATOR RIDE CONTROL (RC) 245-2974

FRONT AXLE

(49a) ACCUMULATOR 198-9841 SERVICE BRAKE (46) SWITCH AS FOOT BRAKE LIMIT 105-6117 (45) CONTROL GP FOOT BRAKE 193-1448 (53) SWITCH AS BRAKE PRESSURE 175-3244
PS

AUX
(24) ACCUMULATOR PILOT OIL COVER 245-2975 MANIFOLD
R H B4
AUX HEAD END SOL VALVE

(49b) ACCUMULATOR SERVICE BRAKE (CE) 106-1774 (50) ACTUATOR AS PARKING BRAKE 154-8042
RELEASE APPLY

YY
LINE RELIEF VALVES LIFT ANTIDRIFT VALVE

(47) SENSOR GP FOOT BRAKE 214-4863

TO TRANSMISSION CONTROL

A2

A1

TO BRAKE LIGHTS

A4

HYDRAULIC LOCKOUT VALVE

QQ
C C

NO

(30) MANIFOLD GP FAN AND BRAKE CHARGE 242-1307

NC

HEAD END SOL VALVE

RR

PP
(48) VALVE GP FOOT BRAKE 210-5587

(51) VALVE GP PARKING BRAKE 220-2726 (52) SWITCH AS PARKING BRAKE (25) PUMP GP PRESSURE 174-4312 FAN 254-5147

RACK BACK
TILT BACK PILOT SOL VALVE

RAISE
RAISE PILOT SOL VALVE

ROD END SOL VALVE

HEAD END

GG

TO FAN MOTOR

LS

(8) CYLINDER GP STEER 133-1747

TO CASE DRAIN MANIFOLD
HYDRAULIC TANK

CC

(23) VALVE GP MANUAL LOWERING 112-1817

REAR AXLE

RACK BACK
TILT SPOOL

RAISE

LIFT SPOOL

RIDE CTRL VALVE

HEAD END

AUX SPOOL

BRAKE SYSTEM
PILOT PRESSURE REDUCING VALVE

HOLD DUMP
SCREEN

HOLD
PRESSURE COMPENSATOR VALVE PRESSURE COMPENSATOR VALVE

HOLD

LOWER FLOAT
RESOLVER VALVE BALANCE VALVE CHECK VALVE

ROD END

A1

(12) SCREEN GP 154-2883

RESOLVER VALVE

RESOLVER VALVE

PRESSURE COMPENSATOR VALVE

CROSSOVER RELIEF

(7) VALVE GP STEER 133-1728

CYL PORT "B" CYL PORT "A" SHUTTLE VLV LOAD SENSING PUMP PORT

LL
SIGNAL RELIEF VALVE SIGNAL DUPLICATION VALVE

KK

DUMP PILOT SOL VALVE

LOWER / FLOAT PILOT SOL VALVE

RIDE CONTROL
LOWER/ FLOAT

AUX ROD END SOL VALVE

(10) VALVE GP PILOT 164-4116

MARGINE RELIEF VALVE

DUMP

ROD END

DIRECTIONAL SPOOL PILOT PORT"A"

LS
D

DR

1 )(

D
MAKE UP CHECK

(22) VALVE CHOKE CHECK 152-2646

(26) MOTOR GP FAN (19) VALVE GP 161-8919 BALL (QC RETURN OIL) FOR REVERSING 112-1817
FAN SEE ITEM 42 & 43

B1
QUICK COUPLER
C2

(6) VALVE GP NEUTRALIZER 8J-1553

PILOT PORT"B" TANK PORT PRESSURE REDUCING VALVE BACK UP RELIEF

(36) VALVE GP CONTROL (2 FUNCTION STANDARD) 261-3945 (2 FUNCTION W/RC) 261-2337 (3 FUNCTION) 261-3972 (2 FUNCTION W/RC) 261-2338 (3 FUNCTION W/RC) 256-3644

(18) CYLINDER GP QUICK COUPLER 237-0946

NN

MM

(9) VALVE GP CHECK 111-7775

TO FRONT BRAKES

A1

TO REAR BRAKES

A2

TO PARKING BRAKE

REVERSING FAN P P T C1

A1 E1 C1 D1

(11) VALVE GP SHUTTLE 8J-6875

REGULATED PRESS PORT TO PILOT VALVE

PS

T
C

(43) MOTOR GP REVERSING FAN 183-4077 (30) MANIFOLD GP FAN AND BRAKE CHARGE 242-1307 (42) VALVE GP CONTROL AND RELIEF 263-5832
HYDRAULIC CIRCUIT COLOR DESCRIPTIONS
IMPLEMENT PUMP OUTPUT IMPLEMENT PILOT SUPPLY OIL PRIMARY STEERING PUMP CIRCUIT STEERING CIRCUIT SECONDARY STEERING CIRCUIT IMPLEMENT PUMP LOAD SENSING CIRCUIT MAIN RELIEF VALVE LOAD SENSING CIRCUIT SUPPLY LINE DRAIN / RETURN LINE LIFT CYLINDER CIRCUIT TILT CYLINDER CIRCUIT AUXILIARY CIRCUIT BRAKE CHARGE VALVE AND FAN CONTROL CIRCUIT BRAKE CONTROL CIRCUIT

(16) VALVE GP QUICK COUPLER CONTROL 180-8585

ZZ

(17) VALVE GP BALL (QUICK COULPER) 112-1817

FF

LINE PATTERNS
Pressure Line Pilot / Load Sensing Pressure Drain / Return Lines Component Group Attachment Air Line

COMMAND CONTROL STEERING AND 3PC IMPLEMENT ATTACHMENT

PILOT CONTROL SPOOL PILOT PORT "B" CYL PORT "B"

(27) VALVE GP COOLER BYPASS 142-8977

CALLOUTS
YY

(4) VALVE GP NEUTRALIZER 146-7571

LS

Taps (Pressure, Sampling,Sensor) by letter

PILOT PORT "A"

(25) PUMP GP FAN HH 254-5147

FLOW CONTROL SPOOL PUMP CONTROL VALVE

CONNECTION B1 ONLY FOR COMMAND CONTROL STEERING

DD EE

(34) VALVE GP SECONDARY STEER DIVERTER 141-2597

B1 E1 E1 D1

(5) VALVE GP STEER 142-3996

CROSSOVER RELIEF

B
CYL PORT "A"

SOS

(28) FILTER GP RETURN OIL 244-1031

DIRECTIONAL SPOOL PUMP PORT

(3) CYLINDER GP STEER 133-1747

PRESSURE CUTOFF SPOOL

AA
(29) VALVE GP FLOW DIVIDER 237-8180
ACTUATOR

(2) CONNECTOR ORIFICE 108-2144

BRAKE AND HYDRAULIC FAN PUMP

HMU SUPPLY PORT

MAKE-UP CHECKS

BACK-UP RELIEF

(31) FILTER GP CASE DRAIN 249-2334

A

C1

C1

FF
(1) HAND METERING UNIT 230-4176

(32) VALVE GP BREAKER RELIEF 220-0814

(33) TANK GP HYDRAULIC OIL 237-2742
9 8

HMU STEER AND 3PC IMPLEMENT

THIS SCHEMATIC IS FOR THE 966H AND 972H WHEEL LOADER
PART #: 242-0337 CHG 07 and BRAKE SYSTEM PART # 236-9049 CHG 06
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

(14) PUMP GP IMPLEMENT 254-4109

(13) PUMP GP STEERING 241-9157

(35) PUMP GP SECONDARY STEER 275-8543

D1
6 5 4 3 2

MACHINE COMPONENT LOCATIONS

VIEW ALL CALLOUTS

35 33 32 12 5 26 42 43 25 30

34

46

47 48

45

10

11

20

17 15 18 22 24 36 21 41

53 13 14 19

23 27

28 29 31 49A 49B

50 51 52

16

32 26 42 43 25 30 53 13 14 35 3

33

34

51 52

12

45

46

47

48

15

9 10 11 41 21 20 18 17 36 24

19

23 27 28 29 31 49A 49B 50

16

22

COMMAND CONTROL STEERING

VIEW ALL CALLOUTS

NN

MM
RIGHT SIDE MACHINE VIEW

10

MM

10
LL KK

12
LEFT SIDE MACHINE VIEW

FAN AND BRAKE PUMP

VIEW ALL CALLOUTS

AA

25

HH

30

FAN AND BRAKE HYDRAULIC SYSTEM The fan and brake pump (25) is located on the front gear train of the engine, on the right side ofthe machine. The fan and brake pump provides oil flow for the electronic demand fan systemand the brake hydraulic system. The signal pressure tap (HH) and the outlet pressure tap (AA) are located on the fan and brake pump. Also located on the engine on the right side of the machine is the fan control and brakeaccumulator charging valve (30).

HMU AND SERVICE BRAKES

VIEW ALL CALLOUTS

48

RR

QQ

FF

The following components are located under the front of the cab. - Hand metering unit (1) - Foot service brake valve (48) - Steer pump load sense test port (FF) - Front sercive brake test port (QQ) - Rear service brake test port (RR)

IMPLEMENT CONTROL VALVE

A K J G H
VIEW ALL CALLOUTS

C D E F

GG

24

This photo shows a front view of the implement control valve (36) in the loader frame. The following components can be seen in this view: - Pilot accumulator (24) - Pilot supply pressure tap (GG) The Following components are not referenced on the Hydraulic System Schematic: - Pressure differential relief valve (A) - Head end solenoid valve (ride control) (B) - Signal relief valve (C) - Tilt anti-drift valve (D) - Rod end solenoid valve (ride control) (E) - Ride control balance solenoid valve (F) - Pilot pressure reducing valve (G) - Lift cylinder head end pressure tap (H) - Lift cylinder head end pressure sensor for Payload Control System and Autodig (J)

DD

CC
This drawing shows a right side view of the wheel loader. The following components can be seen in this view: - Implement pump charge pressure tap (CC) - Implement pump load Sense pressure tap (DD)

N M L K J H

CC
E G F

This photo shows a left rear view of the implement control valve (36). The following components can be seen in this view: - Implement control valve supply pressure tap (GG) The Following components are not referenced on the Hydraulic System Schematic: - Tilt anti-drift valve (A) - Signal relief valve (B) - Signal duplication valve (C) - Return to tank port (D) - Supply port from pump (E) - Signal line to pump (E) - Tank line (G) - Screen (H) - Tilt back pilot solenoid valve (J) - Tilt back pilot (K) - Tilt cylinder rod end line relief (L) - Ride control balance solenoid valve (M) - Rod end solenoid valve (ride control) (N)

QUICK COUPLER CIRCUIT

VIEW ALL CALLOUTS

19

16

ZZ

SERVICE CENTER
VIEW ALL CALLOUTS

SOS

28

31
B
49

The service center is located on the right side of the machine below the cab. The Following components are located in the service center: Case drain filter (31) Hydraulic oil fluid sampling valve (SOS) Hydraulic systems kidney loop filter (28) Brake system accumulators (49)

The Following components are not referenced on the Hydraulic System Schematic: - Power train oil fluid sampling valve (A) - Power train oil filter (B) - Ecology drain for the hydraulic tank (C)

A F

EE

PP
M L

The following remote pressure taps are located inside the panel on the frontside of the service center: - Steering pump outlet pressure (EE) - Brake system accumulator pressure (PP) The Following components are not referenced on the Hydraulic System Schematic: - Transmission reverse clutch (A) - Transmission forward clutch (B) - Transmission fourth speed clutch (C) - Transmission third speed clutch (D) - Transmission second speed clutch (E) - Transmission first speed clutch (F) - Torque converter inlet pressure (G) - Transmission lubrication pressure (H) - Transmission pump outlet pressure (J) - Torque converter outlet pressure (K) - Steering cylinder rod end grease fittings (L) - Rear axle oscillation bearing grease fittings (M)

TILT CYLINDER LINES GROUP

VIEW ALL CALLOUTS

YY

15

FWD TOP VIEW

YY

15

RIHT SIDE VIEW