KENR8379-03 September 2012

64

58

COMPONENT LOCATIONS
Description ACCUMULATOR GP - PRECHARGE PRESSURE (VOL. 1) CORE AS - STEERING COOLER (VOL. 1) CYL GROUP - LEFT STEER (VOL. 1) CYL GROUP - RIGHT STEER (VOL. 1) FILTER - HYDRAULIC (VOL. 1) FILTER GP - CASE DRAIN (VOL. 1) FILTER GP - OIL (VOL. 1) FILTER GP - OIL (VOL. 1) MOTOR GP - FAN SPEED CONTROL (VOL. 1) PUMP GP - BRAKE COOLING DRIVE (VOL. 1) (OPTION) PUMP GP - METERING (VOL. 1) PUMP GP - STEERING and FAN (VOL. 1) PUMP GP - STEERING and FAN (VOL. 1) SENSOR GP - PRESSURE (VOL. 1) SENSOR GP - SPEED (VOL. 1) SENSOR GP - SPEED (VOL. 1) SENSOR GP - TEMP (VOL. 1) SWITCH AS - STEERING OIL LEVEL (VOL. 1) TANK GP - HYDRAULIC (SEE NOTE) (VOL. 1)* TANK GP - HYDRAULIC (SEE NOTE) (VOL. 1)* VALVE GP - MAKE UP (FAN ANTI-CAV) (VOL. 1) VALVE GP - PRESSURE REDUCING (VOL. 1) VALVE GP - SOL (VOL. 1) VALVE GP - STEERING (VOL. 1) Part Number 253-4120 N/A 194-6171 288-5537 4T-6788 290-2569 290-2569 289-9904 240-7790 281-8284 192-3897 301-4678 284-9631 221-3405 186-0131 163-0265 134-2252 172-8660 280-1634 280-2090 183-7170 226-0835 288-4351 151-5933 Machine Location 7 133 14 15 46 2 3 5 57 62 4 54 60 71 70 97 85 94 58 64 45 44 6 1 Schematic Location J-13 B-5 I-1 G-1 D-5 E-3 B-8 F-5 G-10 C-13 H-7 C-9 C-9 J-12 H-9 A-3 C-3 C-3 D-4 D-4 G-12 H-14 H-11 I-3

UU
ACCUMULATOR PRESSURE SENSOR

6
X RR
Steering Pump Fan Pump

797F Off-Highway Truck Hydraulic and Power Train System

LAJ1-UP WSP1-UP

71

UU

YY
PRESSURE AND FLOW COMPENSATOR VALVES

Volume 1 of 3: Steering

STEERING and FAN PUMP

STEERING CONTROL VALVE and RELIEF VALVE MANIFOLD

2012 Caterpillar, All Rights Reserved

Printed in U.S.A.

7 15
PUMP OR MOTOR FLUID CONDITIONER

FLUID POWER SYMBOLS

BASIC COMPONENT SYMBOLS
MAIN AUX

SPRING

CONTROL VALVES

RESTRICTION

LINE RESTRICTION (FIXED)

PUMP (2 - SECTION)

STEERING POSITION SENSOR

Sensor Head Cylinder - Head End
VARIABILITY

PUMP (VARIABLE & PRESSURE COMPENSATED)

Magnet

SPRING (ADJUSTABLE)

LINE RESTRICTION (VARIABLE)

PRESSURE COMPENSATION

HYDRAULIC PNEUMATIC ENERGY TRIANGLES

LINE RESTRICTION (VARIABLE & PRESSURE COMPENSATED)

ATTACHMENT

VALVE ENVELOPES

VALVES

VALVE PORTS

ONE POSITION

TWO POSITION

THREE POSITION

TWO - WAY

THREE - WAY

FOUR - WAY

4
TAP LOCATIONS (VOL. 1) Description
BRAKE COOLING DRIVE PUMP PRESSURE RADIATOR FAN PRESSURE STEERING ACCUMULATOR PRESSURE STEERING FLOW AMP STEERING PUMP PRESSURE STEERING RETURN STEERING SUPPLY

CONTROL VALVES

CHECK VALVES

Rod Connector

AB

A B

P T NORMAL POSITION

P T SHIFTED POSITION INFINITE POSITION BASIC SYMBOL SPRING LOADED SHUTTLE PILOT CONTROLLED

Machine Location Y W RR X SS YY UU

Schematic Location E-14 G-12 I-12 I-5 I-12 H-11 I-11

FLUID STORAGE RESERVOIRS

44 6 64 58 1

VENTED

PRESSURIZED

RETURN ABOVE FLUID LEVEL

RETURN BELOW FLUID LEVEL

MEASUREMENT

ROTATING SHAFTS

PRESSURE REDUCING VALVE

PRESSURE

TEMPERATURE

FLOW

UNIDIRECTIONAL

BIDIRECTIONAL

COMBINATION CONTROLS

SOLENOID

SOLENOID OR MANUAL

SOLENOID & PILOT

SOLENOID & 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

14 75 54 60

EXTERNAL RETURN

INTERNAL RETURN

SIMPLIFIED

COMPLETE

INTERNAL SUPPLY PRESSURE

ACCUMULATORS

CROSSING & JOINING LINES

HYDRAULIC & PNEUMATIC CYLINDERS

SPRING LOADED

GAS CHARGED

LINES CROSSING

LINES JOINING

SINGLE ACTING

DOUBLE ACTING

HYDRAULIC PUMPS
FIXED DISPLACEMENT VARIABLE DISPLACEMENT NON-COMPENSATED

HYDRAULIC MOTORS
FIXED DISPLACEMENT VARIABLE DISPLACEMENT NON-COMPENSATED

INTERNAL PASSAGEWAYS
INFINITE POSITIONING

3 POSITION

2 POSITION

UNIDIRECTIONAL

UNIDIRECTIONAL

BIDIRECTIONAL

BIDIRECTIONAL

FLOW IN ONE DIRECTION

PARALLEL FLOW

CROSS FLOW

FLOW IN EITHER DIRECTION

CHASSIS VIEW

ELECTRICAL SYMBOLS TABLE

64

58

HYDRAULIC SYMBOLS (ELECTRICAL)

G
TRANSDUCER (FLUID) TRANSDUCER (GAS / AIR) GENERATOR

M
ELECTRIC MOTOR

Hydraulic Tank, Right Side

PRESSURE SWITCH

85

PRESSURE SWITCH (ADJUSTABLE)

TEMPERATURE SWITCH

ELECTRICAL WIRE

Steering and Fan Section

2
PRESSURE SWITCH

ELECTRICAL SYMBOLS (ELECTRICAL)

Steering and Fan Section

94

TEMPERATURE SWITCH

LEVEL SWITCH

FLOW SWITCH

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

133
Lower Sight Gauge Screen Steering Pump Suction Port Upper Sight Gauge
CIRCUIT NUMBER IDENTIFICATION

325-AG135 PK-14

CIRCUIT NUMBER IDENTIFICATION

WIRE COLOR

WIRE COLOR

WIRE GAUGE

325-PK

PREVIOUS STANDARD
WIRE WIRE COLOR

325-PK-14

B
WIRE GAUGE

CIRCUIT NUMBER IDENTIFICATION

(EXAMPLE VALVE)

HYDRAULIC TANK

36 Page,

(Dimensions: 48 inches x 35 inches)

Steering and Fan Pump

1 6

KENR8379-03 VOL 1 of 3

14

13

12

11

10

KENR8379-03 VOL 1 of 3

(7) ACCUMULATOR GP-A 253-4120

J (Dimensions: 48 inches x 35 inches)

(71) SENSOR GP-PRESS 221-3405

SENSOR GPACCUMULATOR PRESSURE (Part #: N/A)

(14) CYL GROUP - LEFT STEER 194-6171 (1) VALVE GP-STEERING 151-5933

P L
I

PP

36 Page,

LS
(6) VALVE GP-SOL 288-4351

CL HP

LS
STEERING POSITION SENSOR (70) SENSOR GP-SPEED 186-0131 (4) PUMP GP-METERING 192-3897

(44) VALVE GP-PRESS 226-0835 (45) VALVE GP-MAKE UP 183-7170

(57) MOTOR GP-FAN SPEED CONTROL 240-7790

CR
G

HT

EF

(15) CYL GROUP - RIGHT STEER 288-5537

F
PRESSURE AND FLOW COMPENSATOR VALVE PRESSURE AND FLOW COMPENSATOR VALVE

(5) FILTER GP-OIL 289-9904

(2) FILTER GP-OIL 290-2569

A M

T1

L1

L1

T1

G1 MA

B MB

G2

T1A

(46) FILTER-HYDRAULIC 4T-6788

(64) TANK GP-HYD (STEEP GRADE) 280-2090

Vg MIN

Vg MAX

PUMP DRIVE BOX

(58) TANK GP-HYD (SHALLOW GRADE) 280-1634

Vg MAX Vg MIN Vg MIN Vg MAX

(94) SWITCH AS 172-8660

M1

T2

L2

R1

T2

M1A
(54) PUMP GP - STEERING and FAN (SHALLOW GRADE) 301-4678 (60) PUMP GP - STEERING and FAN (STEEP GRADE) 284-9631

SL

M1B

T2A

R2

(85) SENSOR GP-TEMP 134-2252

(62) PUMP GP - BRAKE COOLING STEEP GRADE ONLY 281-8284

(3) FILTER GP-OIL 290-2569

B
HYDRAULIC CIRCUIT COLOR DESCRIPTIONS (137) MOTOR GP BRAKE COOLING Part #: N/A
SUPPLY LINE DRAIN / RETURN LINE TBD 2 PUMP OUTPUT CON 021

AA
See Volume 3 A-5 / B-5

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

CALLOUTS

BB
A
( 97 ) SENSOR GP-SPEED 163-0265 STEEP GRADE (ADD'L) RETARDING AR ONLY

YY

Taps (Pressure, Sampling, Sensor - by letter)

(52) VALVE GP - CONTROL 138-1234 Part Number
Component Name

Callout Number
(Machine Location from Component LocationsTable)

THIS SCHEMATIC IS FOR THE797F OFF HIGHWAY TRUCKHY DRAULIC SYSTEM VOLUME 1 of 3: STEERING MEDIA NUMBER: KENR8379-03 SCHEMATIC PART NUMBER: 272-3213, CHANGE: 02, VERSION: 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.

14

13

12

11

10

COMPONENT LOCATIONS
Description ACCUMULATOR GP - BRAKE PRECHARGE (VOL. 2) ACCUMULATOR GP - BRAKE PRECHARGE (VOL. 2) ADJUSTER GP (VOL. 2) ADJUSTER GP (VOL. 2) CONNECTOR AS - ORIFICE (VOL. 2) CONNECTOR AS - ORIFICE (VOL. 2) CONT GP - SERVICE BRAKE (VOL. 2) CONTROL GP - HYD (TRACTION CONTROL SYSTEM) (VOL. 2) COOLER SCREEN (VOL. 2) CORE AS - REAR BRAKE COOLER (VOL. 2) CORE AS (VOL. 2) CYL GP - TEL (VOL. 2) FILTER GP - OIL (BRAKE COOLING) (VOL. 2) FILTER GP - BRAKE SYSTEM OIL (VOL. 2) FILTER GP - TRANS (VOL. 2) FILTER GP - TRANS (VOL. 2) MANIFOLD GP - POWER ACCESS LINE RELIEF (VOL. 2) MOTOR GP - REAR AXLE FAN (VOL. 2) MOTOR GP - REAR AXLE LUBE (VOL. 2) ORIFICE (VOL. 2) PLUG AS (VOL. 2) PUMP GP - COOLING and BRAKE CHARGE (VOL. 2) PUMP GP - ELEC DR (RELIEF VALVE) (VOL. 2) PUMP GP - HOIST (VOL. 2) PUMP GP - REAR AXLE LUBE (VOL. 2) SCREEN AS (VOL. 2) SCREEN AS (VOL. 2) SCREEN GP - BYPASS SWITCH (VOL. 2) SENSOR GP - PARKE BRAKE PRESSURE (VOL. 2) SENSOR GP - PARKE BRAKE PRESSURE (VOL. 2) SENSOR GP - PRESSURE (VOL. 2) SENSOR GP - PRESSURE (VOL. 2) SENSOR GP - PRESSURE (VOL. 2) SENSOR GP - PRESSURE (VOL. 2) SENSOR GP - TEMP (VOL. 2) SENSOR GP - TEMP (VOL. 2) SENSOR GP - TEMP (VOL. 2) SENSOR GP - TEMP (VOL. 2) SENSOR GP - TEMP (VOL. 2) SWITCH AS - LEVEL (VOL. 2) SWITCH AS - PRESSURE (VOL. 2) SWITCH GP - FILTER BYPASS (VOL. 2) SWITCH GP - FILTER BYPASS (VOL. 2) TANK GP - HYDRAULIC (VOL. 2) VALVE - CHECK (VOL. 2) VALVE - CHECK (VOL. 2) VALVE - CHECK (VOL. 2) VALVE GP - RELIEF (VOL. 2) VALVE GP - CONT (VOL. 2) VALVE GP - DIVERTER (VOL. 2) VALVE GP - MANUAL BYPASS CONTROL (VOL. 2) VALVE GP - MTG (VOL. 2) VALVE GP - MTG (VOL. 3) VALVE GP - RELIEF (VOL. 2) Part Number 286-0796 286-0796 205-0560 205-0560 311-6676 311-6676 321-5086 222-4744 165-0056 285-0255 299-3290 289-8616 339-9703 290-2567 334-0572 334-0572 336-0981 257-6844 296-5306 N/A 242-7114 317-2659 5T-1060 281-8288 324-2716 9P-9555 172-6104 172-2395 221-3410 221-3410 221-3405 221-3405 221-3405 221-3415 134-2252 134-2252 134-2252 134-2252 288-8390 172-8660 130-7459 164-7577 164-7577 280-1634 123-4750 123-4750 123-4750 346-4815 293-4974 168-7859 336-0978 285-5630 285-5630 172-5381 Machine Location 27 29 42 43 10 11 35 31 56 84 113 17 25 134 118 119 124 67 37 130 115 55 13 22 39 99 109 21 80 81 75 76 77 105 87 86 92 93 100 96 102 122 123 59 51 52 53 69 19 111 126 33 32 107 Schematic Location G-8 F-6 I-11 I-1 D-7 D-7 E-5 I-8 C-4 D-3 J-13 I-3 C-3 B-9 I-12 G-13 C-13 B-7 D-11 C-13 I-13 A-9 E-4 B-10 E-11 F-13 F-13 B-10 J-8 I-8 F-8/F-7 F-5 D-6 G-13 J-11 F-11 J-1 F-13 H-13 B-9 I-13 G-13 I-12 B-5 E-4 F-7 F-8 C-7 H-4 H-12 D-13 D-8 E-8 H-13

KNER8379-03 September 2012

Hoist Screens - Internal

17
TANK TANK

33

37 17 25
134

TANK

84 33 43

55

56 19
PP EE

Service Brake Check Valve Pressure Reducing Valve

39
DD

134
Front Brake Relay Valve Rear Brake Relay Valve Unloader Solenoid Unloader Diverter Valve Parking Brake Relay Valve LEFT SIDE Screen Parking Brake Check Valve Bypass Switch

797F Off-Highway Truck Hydraulic and Power Train System

LAJ1-UP WSP1-UP

TANK
BACK FRONT
Accumulator Purge Solenoid

Rear Brake ARC Solenoid

FF

LL

KK

JJ

HH

GG

Parking Brake Solenoid

27 29

42

Rear Service Brake Shuttle Valve Relief Valve

RIGHT SIDE Front Service Brake Shuttle Valve

Volume 2 of 3: Shallow Grade - Braking and Cooling

CHASSIS VIEW

BRAKE CHASSIS VALVE

BRAKE SYSTEM FILTER

2012 Caterpillar, All Rights Reserved

Printed in U.S.A.

FLUID POWER SYMBOLS

BASIC COMPONENT SYMBOLS
MAIN AUX

PUMP OR MOTOR

FLUID CONDITIONER

SPRING

CONTROL VALVES

RESTRICTION

LINE RESTRICTION (FIXED)

PUMP (2 - SECTION)

PUMP (VARIABLE & PRESSURE COMPENSATED)

VARIABILITY

SPRING (ADJUSTABLE)

LINE RESTRICTION (VARIABLE)

PRESSURE COMPENSATION

HYDRAULIC PNEUMATIC ENERGY TRIANGLES

80
TAP LOCATIONS (VOL. 2) Description
BRAKE ACCUMULATOR BRAKE ACCUMULATOR BRAKE CHARGE PRESSURE BRAKE COOLING BRAKE PEDAL BRAKE TO TANK FRONT BRAKE SLACK ADJUSTER HOIST CYLINDER HEAD END PRESSURE HOIST CYLINDER ROD END PRESSURE HOIST PUMP DISCHARGE/BRAKE COOLING SUPPLY LEFT BRAKE PRESSURE LEFT FRONT BRAKE COOLING OUT LEFT FRONT BRAKE COOLING OUT LEFT FRONT SERVICE BRAKE LEFT REAR BRAKE COOLING IN LEFT REAR PARK BRAKE LEFT REAR SERVICE BRAKE PILOT OIL BYPASS (to Front Brake Cooling) PILOT OIL BYPASS (to Rear Brake Cooling) PILOT PRESSURE - HEAD END to TANK (Lower) PILOT PRESSURE - PUMP to HEAD END (Raise) PILOT PRESSURE - PUMP to ROD END (Lower) PILOT PRESSURE - ROD END to TANK (Raise) RAXL DRIVE PUMP PRESSURE REAR BRAKE SLACK ADJUSTER RIGHT BRAKE PRESSURE RIGHT FRONT BRAKE COOLING IN RIGHT FRONT BRAKE COOLING OUT RIGHT FRONT SERVICE BRAKE RIGHT REAR PARK BRAKE RIGHT REAR SERVICE BRAKE TCS PILOT

LINE RESTRICTION (VARIABLE & PRESSURE COMPENSATED)

ATTACHMENT

BB

Accumulator(s) Brake Precharge

VALVE ENVELOPES

VALVES

VALVE PORTS

Machine Location C D K P E I B LL FF PP BB S T N Q G M DD EE KK JJ HH GG J A CC U V O F L H

Schematic Location F-8 F-6 B-9 C-4 D-5 C-5 H-1 H-4 J-4 I-5 J-7 J-2 J-1 I-2 G-2 J-10 I-10 J-6 I-6 H-4 I-4 I-4 J-4 D-11 H-11 I-7 F-2 F-1 G-2 F-10 G-10 T-7

ONE POSITION

TWO POSITION

THREE POSITION

TWO - WAY

THREE - WAY

FOUR - WAY

CONTROL VALVES
AB A B

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 & PILOT

SOLENOID & PILOT OR MANUAL

SERVO

THERMAL

DETENT

MANUAL CONTROL SYMBOLS

PUSH - PULL LEVER

MANUAL SHUTOFF

GENERAL MANUAL

PUSH BUTTON

PEDAL

SPRING

35

81

CC

31

55

RELEASED PRESSURE

PILOT CONTROL SYMBOLS

REMOTE SUPPLY PRESSURE

EXTERNAL RETURN

INTERNAL RETURN

SIMPLIFIED

COMPLETE

INTERNAL SUPPLY PRESSURE

ACCUMULATORS

CROSSING & JOINING LINES

HYDRAULIC & PNEUMATIC CYLINDERS

21

SPRING LOADED

GAS CHARGED

LINES CROSSING

LINES JOINING

SINGLE ACTING

DOUBLE ACTING

HYDRAULIC PUMPS
FIXED DISPLACEMENT VARIABLE DISPLACEMENT NON-COMPENSATED

HYDRAULIC MOTORS
FIXED DISPLACEMENT VARIABLE DISPLACEMENT NON-COMPENSATED

INTERNAL PASSAGEWAYS
INFINITE POSITIONING

3 POSITION

2 POSITION

UNIDIRECTIONAL

UNIDIRECTIONAL

SERVICE BRAKE CONTROL VALVE

BIDIRECTIONAL

BIDIRECTIONAL

FLOW IN ONE DIRECTION

PARALLEL FLOW

CROSS FLOW

TRACTION CONTROL SYSTEM VALVE

BRAKE COOLING and CHARGE

BRAKE COOLING SCREENS

FLOW IN EITHER DIRECTION

ELECTRICAL SYMBOLS TABLE

HYDRAULIC SYMBOLS (ELECTRICAL)

93

87

86
Hoist Screens Return Screens
TRANSDUCER (FLUID) TRANSDUCER (GAS / AIR) GENERATOR

M
ELECTRIC MOTOR

PRESSURE SWITCH

PRESSURE SWITCH (ADJUSTABLE)

TEMPERATURE SWITCH

ELECTRICAL WIRE

ELECTRICAL SYMBOLS (ELECTRICAL)

Hoist Oil Port

LEFT FRONT

REAR
Hoist Valve Port

Brake Actuation Section Filler Tube

PRESSURE SWITCH

TEMPERATURE SWITCH

LEVEL SWITCH

FLOW SWITCH

WIRE NUMBER IDENTIFICATION CODES

Brake Actuation Section

ELECTRICAL SCHEMATIC EXAMPLE CURRENT STANDARD

HARNESS IDENTIFICATION CODE THIS EXAMPLE INDICATES WIRE 135 IN HARNESS AG

HYDRAULIC SCHEMATIC EXAMPLE CURRENT STANDARD

92

Accumulator Purge Solenoid

Hoist and Brake Cooling Section

325-AG135 PK-14

WIRE
CIRCUIT NUMBER IDENTIFICATION

WIRE COLOR

CIRCUIT NUMBER IDENTIFICATION

WIRE COLOR

WIRE GAUGE

325-PK

PREVIOUS STANDARD

Hoist Screens
WIRE WIRE COLOR

325-PK-14

B
WIRE GAUGE

RIGHT FRONT

Return Screens

CIRCUIT NUMBER IDENTIFICATION

(EXAMPLE VALVE)

BRAKE TEMPERATURE SENSORS

TANK

36 Page,

Front Brake ARC Solenoid

(Dimensions: 48 inches x 35 inches)

22

KENR8379-03 VOL 2 of 3

14

13

12

11 LEFT REAR
(87) SENSOR GPTEMP 1342252

10

8
(80) SENSOR GPPRESS 2213410

2 LEFT FRONT

1
(92) SENSOR GP TEMP: 1342252

KENR8379-03 VOL 2 of 3

PUMP BYPASS SECTION

P2

HOIST SECTION

J (Dimensions: 48 inches x 35 inches)

LEFT WHEELGP & FD

P
(102) SWITCH AS PRESSURE: 1307459 (113) CORE AS 2993290

FF
L
PILOT ON/OFF LEFT BRAKE PRESSURE CYLINDER ROD END TO TANK (RAISE)

BYPASS TO FRONT BRAKE COOLING

GG

D
(123) SWITCH GP FILTER BYPASS 1647577
PUMP TO CYLINDER ROD END (LOWER)

(31) CONTROL GPHYD 2224744

HH
(17) CYL GPTEL 2898616

(118) FILTER GP TRANS: 3340572

R
(115) PLUG AS 2427114 (110) VALVE GPDIVERTER 1687859 (100) SENSOR GP TEMP: 2888390

RIGHT BRAKE PRESSURE

TCS

BYPASS TO REAR BRAKE COOLING

(42) ADJUSTER GP 2050560

PUMP TO CYLINDER HEAD END (RAISE)

JJ
(81) SENSOR GPPRESS 2213410
CYLINDER HEAD END TO TANK (LOWER)

(43) ADJUSTER GP 2050560

36 Page,

KK
H H

(107) VALVE GP RELIEF: 1725381 BANJOHOUSING OIL SUMP

LL

(105) SENSOR GP PRESS: 2213415 (122) SWITCH GP FILTER BYPASS 1647577

(19) VALVE GPCONT 2934974

G
(119) FILTER GP TRANS: 3340572

BRAKE CONTROL MODULE

(27) ACCUM GP 2860796 (29) ACCUMULATOR GP 2860796 (53) VALVECHECK 1234750

(93) SENSOR GP TEMP: 1342252

(109) SCREEN AS 1726104

(99) SCREEN AS 9P9555

F
(86) SENSOR GPTEMP 1342252

(75) SENSOR GP PRESS: 2213405

(52) VALVECHECK 1234750

(76) SENSOR GPPRESS 2213405

F RIGHT FRONT

RIGHT REAR

ACC1

PS1

RV1

SUPPLY
LE1

PS2

TCS
SQ1

HOIST
SV3

BCD

ACC2 PS3

(35) CONT GP SERVICE BRAKE 3215086

T2

PR2

SV2 PR1 FL1

(51) VALVECHECK 1234750

(13) PUMP GPELEC DR 5T1060

CV1 CV2

TSB P A

RIGHT WHEELGP & FD

T
PD1 HF1 SV1 PD2 HF2 PD3 PLUG HF3

T1 T

POWER TRAIN (REAR AXLE)

SH1

1
SH2

(39) PUMP GPREAR AXLE LUBE 3242716

PS5 J PB
(33) VALVE GPMTG 2855630 (10) CONNECTOR AS 3116676 (77) SENSOR GP PRESS: 2213405

FSB R PS4 F

(128) CYLINDER GPBASIC 3393275

(11) CONNECTOR AS 3116676

RAISE LOWER

(37) MOTOR GP REAR AXLE LUBE 2965306

(84) CORE ASFRONT REAR BRAKE COOLER: 2850255

(67) VALVE GPMANUAL BYPASS CONTROL: 3360978

HOIST PILOT DRAIN FROM FILTER

(56) COOL SCREEN 1650056

(130) ORIFICE

(25) FILTER GP OIL 3399703 (69) VALVE GPMTG 3464815

C
(124) MANIFOLD GP POWER ACCESS LINE RELIEF: 3360981

P
(21) SCREEN GP 1722395 TO CYLINDER HEAD END TO CYLINDER ROD END

MAKE UP FLOW FROM FILTER

C2

C1
T
(22) PUMP GPHOIST 2818288

HYDRAULIC CIRCUIT COLOR DESCRIPTIONS

PILOT PUMP OUTPUT POWER ACCESS PUMP GP - HOIST CIRCUIT SUPPLY LINE BRAKE ADJUSTER CUIRCUIT MOTOR GP - REAR AXLE LUBE CIRCUIT DRAIN / RETURN LINE PUMP GP - REAR AXLE LUBE CIRCUIT PUMP GP - BRAKE CHARGE CIRCUIT BRAKE COOLING ELECTRICAL CIRCUITS

(134) FILTER GP BRAKE SYSTEM 1728660

LINE PATTERNS
Pressure Line Pilot / Load Sensing Pressure

M
FILL TUBE
A

PUMP DRIVE BOX

Drain / Return Lines Component Group

(55) PUMP GP COOLING and BRAKE CHARGE: 3172659

(67) MOTOR GP REAR AXLE FAN 2576844

(59) TANK GPHYD 1435 2801634

CALLOUTS
YY

Taps (Pressure, Sampling, Sensor - by letter)

(52) VALVE GP - CONTROL 138-1234 Part Number
Component Name

Callout Number
(Machine Location from Component LocationsTable)

POWER ACCESS
14 13 12 11 10 9 8 7 6 5 4 3

THIS SCHEMATIC IS FOR THE 797F OFF-HIGHWAY TRUCK HYDRAULIC AND POWER TRAIN SYSTEM VOLUME 2 of 3: SHALLOW GRADE - BRAKING AND COOLING MEDIA NUMBER: KENR8379-03 SCHEMATIC PART NUMBER: 272-3213, CHANGE: 02, VERSION: SCHEMATIC PART NUMBER: 272-3216, CHANGE: 03, VERSION: 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.

COMPONENT LOCATIONS
Description ACCUMULATOR GP - BRAKE PRECHARGE (VOL. 3) ACCUMULATOR GP - BRAKE PRECHARGE (VOL. 3) ADJUSTER GP (VOL. 3) ADJUSTER GP (VOL. 3) CONNECTOR AS - ORIFICE (VOL. 3) CONNECTOR AS - ORIFICE (VOL. 3) CONT GP - BRAKE (VOL. 3) CONTROL GP - HYD (TRACTION CONTROL SYSTEM) (VOL. 3) CORE AS - FRONT BRAKE COOLER (VOL. 3) CORE AS - REAR BRAKE COOLERS (VOL. 3) CORE AS (VOL. 3) CYL GP - TEL (VOL. 3) CYLINDER GP - BASIC (VOL. 3) FILTER - HYDRAULIC (VOL. 3) FILTER GP - OIL (BRAKE COOLING) (VOL. 3) FILTER GP - BRAKE SYSTEM OIL (VOL. 3) FILTER GP - TRANS (VOL. 3) FILTER GP - TRANS (VOL. 3) MANIFOLD GP - POWER ACCESS LINE RELIEF (VOL. 3) MOTOR GP - REAR AXLE FAN (VOL. 3) MOTOR GP - REAR AXLE LUBE (VOL. 3) MOTOR GP - BRAKE COOLING (VOL. 3) ORIFICE (VOL. 3) PLUG AS (VOL. 3) PUMP GP - BRAKE CHARGE (VOL. 3) PUMP GP - BRAKE COOLING DRIVE (VOL. 3) PUMP GP - ELEC DR (RELIEF VALVE) (VOL. 3) PUMP GP - HOIST (VOL. 3) PUMP GP - REAR AXLE LUBE (VOL. 3) SCREEN AS (VOL. 3) SCREEN AS (VOL. 3) SCREEN GP - BYPASS SWITCH (VOL. 3) SCREENS - BRAKE COOLING (VOL. 3) SENSOR GP - PARKE BRAKE PRESSURE (VOL. 3) SENSOR GP - PARKE BRAKE PRESSURE (VOL. 3) SENSOR GP - PRESSURE (VOL. 3) SENSOR GP - PRESSURE (VOL. 3) SENSOR GP - PRESSURE (VOL. 3) SENSOR GP - PRESSURE (VOL. 3) SENSOR GP - TEMP (VOL. 3) SENSOR GP - TEMP (VOL. 3) SENSOR GP - TEMP (VOL. 3) SENSOR GP - TEMP (VOL. 3) SENSOR GP - TEMP (VOL. 3) SWITCH AS - LEVEL (VOL. 3) SWITCH AS - PRESSURE (VOL. 3) SWITCH GP - FILTER BYPASS (VOL. 3) SWITCH GP - FILTER BYPASS (VOL. 3) TANK GP - HYDRAULIC (VOL. 3) VALVE - CHECK (VOL. 3) VALVE - CHECK (VOL. 3) VALVE - CHECK (VOL. 3) VALVE GP - RELIEF (VOL. 3) VALVE GP - CONT (VOL. 3) VALVE GP - DIVERTER (VOL. 3) VALVE GP - MANUAL BYPASS CONTROL (VOL. 3) VALVE GP - RELIEF (VOL. 3) Part Number 286-0796 286-0796 205-0560 205-0560 311-6676 311-6676 321-5086 222-4744 285-0255 285-0255 299-3290 289-8616 339-3275 4T-6788 339-9703 290-2567 334-0572 334-0572 336-0981 257-6844 296-5306 N/A N/A 242-7114 314-9248 281-8284 5T-1060 281-8288 324-2716 9P-9555 172-6104 172-2395 N/A 221-3410 221-3410 221-3405 221-3405 221-3405 221-3415 134-2252 134-2252 134-2252 134-2252 288-8390 172-8660 130-7459 164-7577 164-7577 280-2090 123-4750 123-4750 123-4750 346-4815 293-4974 168-7859 336-0978 172-5381 Machine Location 26 28 40 41 8 9 34 30 82 83 112 16 129 47 24 135 116 117 125 66 36 136 131 114 61 63 12 23 38 98 108 20 132 78 79 72 73 74 104 88 89 90 91 103 95 101 120 121 65 48 49 50 68 18 110 127 106 Schematic Location G-9 F-6 I-11 I-1 E-7 E-7 F-6 I-8 H-3 B-4 J-13 I-3 D-13 C-6 H-2 B-9 I-12 G-13 C-13 B-7 D-11 B-5 C-13 I-13 A-10 A-10 C-4 B-10 E-11 F-13 F-13 C-10 B-5 J-8 H-8 F-8/F-7 E-7 F-6 G-13 F-1 J-1 J-11 F-11 H-13 B-9 I-13 G-13 I-12 B-6 F-7 G-8 C-4 C-7 H-4 H-12 C-13 G-13

KENR8379-03 September 2012

TANK

78

BB

Accumulator(s) Brake Precharge

24

83

61
135

TANK
135
Bypass Switch

797F Off-Highway Truck Hydraulic and Power Train System

LAJ1-UP WSP1-UP

82

83

63

TANK

79 26 28 40

CC

30

Volume 3 of 3: Steep Grade - Brake and Cooling

TRACTION CONTROL SYSTEM VALVE

BRAKE SYSTEM FILTER

2012 Caterpillar, All Rights Reserved

Printed in U.S.A.

Hoist Screens - Internal

FLUID POWER SYMBOLS

16

32
PUMP OR MOTOR FLUID CONDITIONER SPRING VARIABILITY SPRING (ADJUSTABLE) LINE RESTRICTION (VARIABLE)

BASIC COMPONENT SYMBOLS

MAIN AUX

CONTROL VALVES

RESTRICTION

LINE RESTRICTION (FIXED)

PUMP (2 - SECTION)

PUMP (VARIABLE & PRESSURE COMPENSATED)

TAP LOCATIONS (VOL. 3) Description

BRAKE ACCUMULATOR BRAKE ACCUMULATOR BRAKE CHARGE PRESSURE BRAKE PEDAL BRAKE TO TANK FRONT BRAKE COOLING SUPPLY FRONT BRAKE SLACK ADJUSTER HOIST CYLINDER HEAD END PRESSURE HOIST CYLINDER ROD END PRESSURE HOIST PUMP DISCHARGE/BRAKE COOLING SUPPLY LEFT BRAKE PRESSURE LEFT FRONT BRAKE COOLING OUT LEFT FRONT BRAKE COOLING OUT LEFT FRONT SERVICE BRAKE LEFT REAR BRAKE COOLING IN LEFT REAR PARK BRAKE LEFT REAR SERVICE BRAKE PILOT OIL BYPASS (to Front Brake Cooling) PILOT OIL BYPASS (to Rear Brake Cooling) PILOT PRESSURE - HEAD END to TANK (Lower) PILOT PRESSURE - PUMP to HEAD END (Raise) PILOT PRESSURE - PUMP to ROD END (Lower) PILOT PRESSURE - ROD END to TANK (Raise) RAXL DRIVE PUMP PRESSURE REAR BRAKE COOLING SUPPLY REAR BRAKE SLACK ADJUSTER RIGHT BRAKE PRESSURE RIGHT FRONT BRAKE COOLING IN RIGHT FRONT BRAKE COOLING OUT RIGHT FRONT SERVICE BRAKE RIGHT REAR BRAKE COOLING IN RIGHT REAR PARK BRAKE RIGHT REAR SERVICE BRAKE TCS PILOT

PRESSURE COMPENSATION

HYDRAULIC PNEUMATIC ENERGY TRIANGLES

Machine Location C D K E I Z B LL FF PP BB S T N Q G M DD EE KK JJ HH GG J AA A CC U V O R F L H

Schematic Location F-9 F-6 B-9 E-6 D-5 B-5 H-1 H-4 J-4 I-5 J-8 J-2 J-1 I-4 J-10 J-10 I-11 J-7 I-6 H-5 I-5 I-5 J-4 D-12 B-5 H-11 I-8 F-2 F-1 G-1 F-10 F-10 G-11 H-7

LINE RESTRICTION (VARIABLE & PRESSURE COMPENSATED)

ATTACHMENT

TANK

23 36
TANK

VALVE ENVELOPES

VALVES

VALVE PORTS

ONE POSITION

TWO POSITION

THREE POSITION

TWO - WAY

THREE - WAY

FOUR - WAY

CONTROL VALVES
AB A B

CHECK VALVES

P T

P T SHIFTED POSITION INFINITE POSITION BASIC SYMBOL SPRING LOADED SHUTTLE PILOT CONTROLLED

34 16
Service Brake Check Valve Pressure Reducing Valve

NORMAL POSITION

FLUID STORAGE RESERVOIRS

SERVICE BRAKE CONTROL VALVE

VENTED

PRESSURIZED

RETURN ABOVE FLUID LEVEL

RETURN BELOW FLUID LEVEL

MEASUREMENT

ROTATING SHAFTS

18
PP EE

38
DD

Front Brake Relay Valve Rear Brake Relay Valve Unloader Solenoid Unloader Diverter Valve Parking Brake Relay Valve LEFT SIDE Screen

PRESSURE

TEMPERATURE

FLOW

UNIDIRECTIONAL

BIDIRECTIONAL

COMBINATION CONTROLS

SOLENOID

Parking Brake Check Valve

SOLENOID OR MANUAL

SOLENOID & PILOT

SOLENOID & PILOT OR MANUAL

SERVO

THERMAL

DETENT

MANUAL CONTROL SYMBOLS

Front Brake ARC Solenoid

BACK

FRONT
Accumulator Purge Solenoid

Rear Brake ARC Solenoid

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 & JOINING LINES

HYDRAULIC & PNEUMATIC CYLINDERS

FF

LL

KK

JJ

HH

GG

Parking Brake Solenoid

20
SPRING LOADED GAS CHARGED LINES CROSSING LINES JOINING SINGLE ACTING DOUBLE ACTING

HYDRAULIC PUMPS

HYDRAULIC MOTORS
FIXED DISPLACEMENT VARIABLE DISPLACEMENT NON-COMPENSATED

INTERNAL PASSAGEWAYS
INFINITE POSITIONING

Rear Service Brake Shuttle Valve Relief Valve

RIGHT SIDE Front Service Brake Shuttle Valve

FIXED DISPLACEMENT

VARIABLE DISPLACEMENT NON-COMPENSATED

3 POSITION

2 POSITION

63

UNIDIRECTIONAL

UNIDIRECTIONAL

CHASSIS VIEW

BRAKE CHASSIS VALVE

BRAKE COOLING DRIVE

BIDIRECTIONAL

BIDIRECTIONAL

BRAKE COOLING SCREENS

FLOW IN ONE DIRECTION

PARALLEL FLOW

CROSS FLOW

FLOW IN EITHER DIRECTION

ELECTRICAL SYMBOLS TABLE

HYDRAULIC SYMBOLS (ELECTRICAL)

93

87

86

REAR

FRONT
Brake Actuation Section Filler Tube
TRANSDUCER (FLUID) TRANSDUCER (GAS / AIR) GENERATOR

M
ELECTRIC MOTOR

132 Z
LEFT FRONT REAR

97
F R 136
Return Screens

Brake Actuation Section

PRESSURE SWITCH

PRESSURE SWITCH (ADJUSTABLE)

TEMPERATURE SWITCH

ELECTRICAL WIRE

ELECTRICAL SYMBOLS (ELECTRICAL)

Hoist and Brake Cooling Section Brake Cooling Relief Valve

PRESSURE SWITCH
T

AA 132

TEMPERATURE SWITCH

LEVEL SWITCH

FLOW SWITCH

VIEW A
WIRE NUMBER IDENTIFICATION CODES ELECTRICAL SCHEMATIC EXAMPLE CURRENT STANDARD HYDRAULIC SCHEMATIC EXAMPLE CURRENT STANDARD

VIEW A

HARNESS IDENTIFICATION CODE THIS EXAMPLE INDICATES WIRE 135 IN HARNESS AG WIRE
CIRCUIT NUMBER IDENTIFICATION

92
Hoist Oil Port

325-AG135 PK-14

WIRE COLOR

Hoist Valve Port Rear Brake Cooling Pump Front Pumps

WIRE CIRCUIT NUMBER IDENTIFICATION WIRE COLOR WIRE GAUGE

325-PK

PREVIOUS STANDARD
WIRE COLOR

325-PK-14

B
WIRE GAUGE

RIGHT FRONT

CIRCUIT NUMBER IDENTIFICATION

(EXAMPLE VALVE)

BRAKE TEMPERATURE SENSORS

TANK

36 Page,

(Dimensions: 48 inches x 35 inches)

32

41

KENR8379-03 VOL 3 of 3

14

13

12

11
LEFT REAR
(90) SENSOR GP TEMP: 1342252

10

(78) SENSOR GPPRESS 2213410

PUMP BYPASS SECTION

P2

HOIST SECTION
LEFT FRONT

KENR8379-03 VOL 3 of 3

J (Dimensions: 48 inches x 35 inches)

LEFT WHEELGP & FD

BYPASS TO FRONT BRAKE COOLING
LEFT BRAKE PRESSURE

FF
CYLINDER ROD END TO TANK (RAISE)

(101) SWITCH AS PRESSURE: 1307459

(112) CORE AS 2993290

GG

PUMP TO CYLINDER ROD END (LOWER)

(121) SWITCH GP FILTER BYPASS 1647577

D
(30) CONTROL GPHYD 2224744

HH
(16) CYL GPTEL 2898616

(89) SENSOR GP TEMP: 1342252

(116) FILTER GP TRANS: 3340572

BYPASS TO REAR BRAKE COOLING
PUMP TO CYLINDER HEAD END (RAISE)

(114) PLUG AS 2427114 (110) VALVE GP DIVERTER 1687859 (103) SENSOR GP TEMP: 2888390

(40) ADJUSTER GP 2050560

RIGHT BRAKE PRESSURE

TCS

JJ

(41) ADJUSTER GP 2050560

36 Page,

PILOT ON/OFF

KK
(79) SENSOR GPPRESS 2213410
CYLINDER HEAD END TO TANK (LOWER)

(82) CORE AS FRONT REAR BRAKE COOLER 2850255

(24) FILTER GPOIL 3399703

H
B

LL
(106) VALVE GP RELIEF: 1725381 BANJOHOUSING OIL SUMP
HOIST PILOT DRAIN FROM FILTER

(104) SENSOR GP PRESS: 2213415 (120) SWITCH GP FILTER BYPASS 1647577

(18) VALVE GPCONT 2934974

G
(117) FILTER GP TRANS: 3340572

(49) VALVECHECK 1234750

BRAKE CONTROL MODULE

(91) SENSOR GP TEMP: 1342252

(26) ACCUM GP 2860796

(72) SENSOR GP PRESS 2213405

(48) VALVECHECK 1234750 (28) ACCUMULATOR GP 2860796 (74) SENSOR GPPRESS 2213405

(88) SENSOR GP TEMP: 1342252

(108) SCREEN AS 1726104

ACC1

PS1

RV1

SUPPLY
LE1

PS2

TCS
SQ1

HOIST

BCD
SV3

ACC2 PS3
(34) CONT GPBRAKE 3215086

(98) SCREEN AS 9P9555

T2
PR2

SV2 PR1 FL1

RIGHT FRONT
TSB

RIGHT REAR
CV1 CV2

P
T
PD1 HF1 SV1 HF2 PLUG HF3

PD2

T1

PD3

1 PS5
SH1 SH2

RIGHT WHEELGP & FD

PB R
(32) VALVE GPMTG 2855630 (8) CONNECTOR AS 3116676

FSB PS4 F
(9) CONNECTOR AS 3116676

POWER TRAIN (REAR AXLE)

(38) PUMP GP REAR AXLE LUBE 3242716

(73) SENSOR GP PRESS 2213405

(128) CYLINDER GP BASIC 3393275

RAISE LOWER
(47) FILTER HYDRAULIC 4T6788

(50) VALVECHECK 1234750

(67) VALVE GP MANUAL BYPASS CONTROL: 3360978

(36) MOTOR GP REAR AXLE LUBE 2965306

P S
(68) VALVE GPMTG 3464815 (12) PUMP GPELEC DR 5T1060

M
T F

(130) ORIFICE

(20) SCREEN GP 1722395

C
(124) MANIFOLD GP POWER ACCESS LINE RELIEF: 3360981

TO CYLINDER HEAD END

TO CYLINDER ROD END

(23) PUMP GP 2818288

C2

C1
(95) SWITCH AS 1728660

(66) MOTOR GP REAR AXLE FAN 2576844

(83) CORE AS FRONT REAR BRAKE COOLER 2850255

HYDRAULIC CIRCUIT COLOR DESCRIPTIONS

PILOT PUMP OUTPUT POWER ACCESS PUMP GP - HOIST CIRCUIT SUPPLY LINE BRAKE ADJUSTER CUIRCUIT MOTOR GP - REAR AXLE LUBE CIRCUIT DRAIN / RETURN LINE PUMP GP - REAR AXLE LUBE CIRCUIT PUMP GP - BRAKE CHARGE CIRCUIT BRAKE COOLING ELECTRICAL CIRCUITS

(132) SCREEN GP BRAKE COOLER

PUMP DRIVE BOX

AA
(65) TANK GPHYD 1435 2802090
See Volume 1 A2 / B2

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

M
FILL TUBE
A

(61) PUMP GP BRAKE CHARGE 3149248

BB
YY

CALLOUTS
Taps (Pressure, Sampling, Sensor - by letter)
(52) VALVE GP - CONTROL 138-1234 Part Number
Component Name

(63) PUMP GP BRAKE COOLING 2818284

(136) MOTOR GP BRAKE COOLING Part #: N/A

Callout Number
(Machine Location from Component LocationsTable)

POWER ACCESS
14 13 12 11 10 9 8 7 6 5 4 3

THIS SCHEMATIC IS FOR THE 797F OFF-HIGHWAY TRUCK HYDRAULIC AND POWER TRAIN YSTEM VOLUME 3 of 3: STEEP GRADE - BREAKING AND COOLING MEDIA NUMBER: KENR8379-03 SCHEMATIC PART NUMBER: 272-3213, CHANGE: 02, VERSION: SCHEMATIC PART NUMBER: 272-3216, CHANGE: 03, VERSION: 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.