Kenr8379kenr8379-03 Sis

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
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
WIRE COLOR
WIRE COLOR
WIRE GAUGE
325-PK
PREVIOUS STANDARD
WIRE WIRE COLOR
325-PK-14
B
WIRE GAUGE
(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
(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
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
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

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

Printed in U.S.A.
FLUID POWER SYMBOLS

MAIN AUX
PUMP OR MOTOR
FLUID CONDITIONER
SPRING
CONTROL VALVES
RESTRICTION
PUMP (2 - SECTION)
VARIABILITY
SPRING (ADJUSTABLE)
LINE RESTRICTION (VARIABLE)
80
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
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
VENTED
PRESSURIZED
MEASUREMENT
ROTATING SHAFTS
PRESSURE
TEMPERATURE
FLOW
UNIDIRECTIONAL
BIDIRECTIONAL
SOLENOID
SOLENOID OR MANUAL
SOLENOID & PILOT
SERVO
THERMAL
DETENT
PUSH - PULL LEVER
MANUAL SHUTOFF
GENERAL MANUAL
PUSH BUTTON
PEDAL
SPRING
35
81
CC
31
55
RELEASED PRESSURE
EXTERNAL RETURN
INTERNAL RETURN
SIMPLIFIED
COMPLETE
ACCUMULATORS
21
SPRING LOADED
GAS CHARGED
LINES CROSSING
LINES JOINING
SINGLE ACTING
DOUBLE ACTING
HYDRAULIC PUMPS
HYDRAULIC MOTORS
3 POSITION
2 POSITION
UNIDIRECTIONAL
UNIDIRECTIONAL
SERVICE BRAKE CONTROL VALVE
BIDIRECTIONAL
BIDIRECTIONAL
PARALLEL FLOW
CROSS FLOW
TRACTION CONTROL SYSTEM VALVE
BRAKE COOLING and CHARGE
BRAKE COOLING SCREENS

93
87
86
Hoist Screens Return Screens
M
ELECTRIC MOTOR
PRESSURE SWITCH
TEMPERATURE SWITCH
ELECTRICAL WIRE
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
Hoist and Brake Cooling Section

325-AG135 PK-14
WIRE
WIRE COLOR
WIRE COLOR
WIRE GAUGE
325-PK
PREVIOUS STANDARD
Hoist Screens
WIRE WIRE COLOR
325-PK-14
B
WIRE GAUGE
RIGHT FRONT
Return Screens
(EXAMPLE VALVE)
BRAKE TEMPERATURE SENSORS
TANK
36 Page,
Front Brake ARC Solenoid
22
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
PUMP BYPASS SECTION
P2
HOIST SECTION
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
CYLINDER HEAD END TO TANK (LOWER)
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
BRAKE CONTROL MODULE

(27) ACCUM GP 2860796 (29) ACCUMULATOR GP 2860796 (53) VALVECHECK 1234750
(109) SCREEN AS 1726104
(99) SCREEN AS 9P9555
F
(86) SENSOR GPTEMP 1342252
(75) SENSOR GP PRESS: 2213405
(52) VALVECHECK 1234750
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
(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

Component Name
Callout Number
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

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

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)

MAIN AUX
CONTROL VALVES
RESTRICTION
PUMP (2 - SECTION)

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
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
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
34 16
Service Brake Check Valve Pressure Reducing Valve
NORMAL POSITION
SERVICE BRAKE CONTROL VALVE
VENTED
PRESSURIZED
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
SOLENOID
Parking Brake Check Valve
SOLENOID OR MANUAL
SOLENOID & PILOT
SERVO
THERMAL
DETENT
Front Brake ARC Solenoid
BACK
FRONT
Rear Brake ARC Solenoid
PUSH - PULL LEVER
MANUAL SHUTOFF
GENERAL MANUAL
PUSH BUTTON
PEDAL
SPRING
RELEASED PRESSURE
EXTERNAL RETURN
INTERNAL RETURN
SIMPLIFIED
COMPLETE
ACCUMULATORS
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
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
PARALLEL FLOW
CROSS FLOW

93
87
86
REAR
FRONT
Brake Actuation Section Filler Tube
M
ELECTRIC MOTOR
132 Z
LEFT FRONT REAR
97
F R 136
Return Screens
Brake Actuation Section
PRESSURE SWITCH
TEMPERATURE SWITCH
ELECTRICAL WIRE
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
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
(EXAMPLE VALVE)
BRAKE TEMPERATURE SENSORS
TANK
36 Page,
32
41
14
13
12
11
LEFT REAR
10
PUMP BYPASS SECTION
P2
HOIST SECTION
LEFT FRONT
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

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
RIGHT BRAKE PRESSURE
TCS
JJ
36 Page,
PILOT ON/OFF
KK
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
BRAKE CONTROL MODULE

(26) ACCUM GP 2860796
(72) SENSOR GP PRESS 2213405
(48) VALVECHECK 1234750 (28) ACCUMULATOR GP 2860796 (74) SENSOR GPPRESS 2213405
(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
(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
Component Name
(63) PUMP GP BRAKE COOLING 2818284
(136) MOTOR GP BRAKE COOLING Part #: N/A
Callout Number
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.

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KENR8379-03 September 2012

797F Off-Highway Truck Hydraulic and Power Train System

STEERING and FAN PUMP

STEERING CONTROL VALVE and RELIEF VALVE MANIFOLD

2012 Caterpillar, All Rights Reserved

FLUID POWER SYMBOLS

LINE RESTRICTION (FIXED)

STEERING POSITION SENSOR

PUMP (VARIABLE & PRESSURE COMPENSATED)

LINE RESTRICTION (VARIABLE)

HYDRAULIC PNEUMATIC ENERGY TRIANGLES

LINE RESTRICTION (VARIABLE & PRESSURE COMPENSATED)

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

FLUID STORAGE RESERVOIRS

RETURN ABOVE FLUID LEVEL

RETURN BELOW FLUID LEVEL

PRESSURE REDUCING VALVE

SOLENOID & PILOT

SOLENOID & PILOT OR MANUAL

MANUAL CONTROL SYMBOLS

PUSH - PULL LEVER

PILOT CONTROL SYMBOLS

REMOTE SUPPLY PRESSURE

INTERNAL SUPPLY PRESSURE

CROSSING & JOINING LINES

HYDRAULIC & PNEUMATIC CYLINDERS

FLOW IN ONE DIRECTION

FLOW IN EITHER DIRECTION

ELECTRICAL SYMBOLS TABLE

HYDRAULIC SYMBOLS (ELECTRICAL)

Hydraulic Tank, Right Side

PRESSURE SWITCH (ADJUSTABLE)

Steering and Fan Section

ELECTRICAL SYMBOLS (ELECTRICAL)

Steering and Fan Section

WIRE NUMBER IDENTIFICATION CODES

ELECTRICAL SCHEMATIC EXAMPLE CURRENT STANDARD

HYDRAULIC SCHEMATIC EXAMPLE CURRENT STANDARD

CIRCUIT NUMBER IDENTIFICATION

CIRCUIT NUMBER IDENTIFICATION

(Dimensions: 48 inches x 35 inches)

Steering and Fan Pump

(7) ACCUMULATOR GP-A 253-4120

J (Dimensions: 48 inches x 35 inches)

SENSOR GPACCUMULATOR PRESSURE (Part #: N/A)

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

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

(15) CYL GROUP - RIGHT STEER 288-5537

(5) FILTER GP-OIL 289-9904

(2) FILTER GP-OIL 290-2569

(46) FILTER-HYDRAULIC 4T-6788

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

PUMP DRIVE BOX

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

(94) SWITCH AS 172-8660

(85) SENSOR GP-TEMP 134-2252

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

(3) FILTER GP-OIL 290-2569

Taps (Pressure, Sampling, Sensor - by letter)

KNER8379-03 September 2012

Service Brake Check Valve Pressure Reducing Valve

797F Off-Highway Truck Hydraulic and Power Train System

Rear Brake ARC Solenoid