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Schematic
797 Truck Electrical Schematic Tables and Symbol Definitions
5YW1-UP
The meaning of this safety alert symbol is as follows: Attention! Become Alert! Your Safety is Involved. The message that appears under the warning, explains the hazard and can be either written or pictorially presented. Operations that may cause product damage are identified by NOTICE labels on the product and in this publication. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure, work method or operating technique that is not specifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that the product will not be damaged or made unsafe by the operation, lubrication, maintenance or repair procedures you choose. The information, specifications, and illustrations in this publication are on the basis of information available at the time it was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service given to the product. Obtain the complete and most current information before you start any job. Caterpillar dealers have the most current information available. For a list of the most current publication form numbers available, see the Service Manual Contents Microfiche, REG1139F.
3 Table of Contents
Table of Contents
Machine View......................................................................... 4 Cab View............................................................................. 5 Engine Views......................................................................... 6-8 Component Location Charts............................................................ 9-11 Connector Location Charts............................................................ 12 Wire Description Chart............................................................... 13-16 Switch Specification Chart........................................................... 17 Resistor and Solenoid Specifications Chart........................................... 18 Component Identifier Charts.......................................................... 19-20 VIMS Component Identifier Chart...................................................... 21-22 Failure Mode Identifier Chart........................................................ 23 Related Electrical Manuals........................................................... 24 Harness and Wire Symbols............................................................. 25 Symbols and Definitions.............................................................. 26 Note: Use the Hand Tool to select the desired page.
4 Machine View
52
28 4 41 40 7 11 55 51 38 27 36 33 43 9 78 20 39 79 12 14 35 48 34 46 21 24 44 23 10 32 47 18 37 15 8 26 5 25 22 17 42 45 2 29 50 31 16 30
13
77
49 54
6 3 19
53
52 11 12 54 53 55 77 13 4 46 35 28 24 1 21 50 16 48 36 43 30 34 39 44 33 31 78 23 20 79 9 47 22 10 17 18 8 15 37 27 26 32 42 45 2 25 29 3 6 5
41
14 51 7 40 49
38 19
5 Cab View
71
71
B
68 69 69
B
68
D E
57 58 72 59 76 75
E A
67
A
66 60 76 74 65 58 72
67 59 56
D F C
57 60 75
F
56 74
66
73
70
64
62
63 61
62 61 70
64 63
73 65 3
Side View
Rear View
75
68 3
71 60 57
73
C B D
67 56
F
66 64
65
58
63
E
72 70 59
A
62 74 76 69 61
Top View
85
152
130 94 90 91 92 87 97 95 98 99 101 100 103 86 96 106 89 129 107 108 150 148 151 83 102 82 104 84 105 88 131 132 133 135 134
149
93
113
111
112
147
146
145
144
143
142
141
140
139
138
137
136
110
109
117
116 118
115
119 81
123
127
128
125 121
Top View
8 Engine Views
Note: Use the Hand Tool to select the desired schematic or machine location.
Note: Use the Hand Tool to select the desired schematic or machine location.
Note: Use the Hand Tool to select the desired schematic or machine location.
Machine Location
3 3 3 3 3 3 3 3 45 46 47 47 78 39 39 48 78 48 48 48 37 49 49 55 52 51 13 49 40 40 53 54 1 1 39
Machine Location
3 3 3 3 3 3 3 3 64 64 64 63 63 64 64 65 56 56 56 56 56 75 56 71 71 71 56 3 F 76 75 C C C E E E 72 74 74 74 74 D D D 56 56
Machine Location
3 3 3 3 3 3 3 3 116 118 84 84 82 84 83 110
Note: The connectors shown in these charts are for harness to harness connectors. Connectors that join a harness to a component are generally located at or near the component. See the Component Location Charts.
Function
Steering Low Press Brake Oil Accum Pressure Diff Lube Filter Bypass Fan Drive Filter Final Drive Filter Bypass Refrigerant Pressure (AC) ARC Pressure Brake System Pressure Foot Brake Pressure Diff Lube Pressure Coolant Flow Fuel Filter Diff Brake Oil Filter Steering High Press
Actuate
1900 kPa MAX (275 psi MAX) 13800 kPa MAX (2001.5 psi) 210 70 kpa (30 10 psi) 275 to 1750 kpa (40 to 255 psi) 551 kPa (36.3 psi) 93 20 kpa (13.5 2.9 psi) 362 29 mN (1.3 0.1 oz) at point X 137.9 13.8 kpa (20.0 2.0 psi) 276 28 kpa (40 4 psi) 14350 kPa MAX (2081.28 psi MAX)
Deactuate
1400 140 kpa (205 20 psi) 12300 345 kpa (1784 50 psi) ----344 20 kpa (49.9 2.9 psi) 70 20 kpa (10.2 2.9 psi) 303 mN MIN (1.1 oz MIN) at point X 82.7 kPa MIN (12.0 psi) 79 kPa MIN (26 psi) 12350 350 kpa (1791.20 50.76 psi)
Contact Position
B-A Normally Open B-C Normally Closed 1-2 Normally Open 1-3 Normally Closed Normally Open Normally Open B-A Normally Open A-C Normally Closed Normally Open Normally Open Normally Closed Normally Closed B-A Normally Open B-C Normally Closed
A hysteresis band exists: with increasing pressure the closed condition can be maintained up to 2800 kpa (405 psi), with decreasing pressure the closed condition can be maintained down to 170 kpa (25 psi). Contact position at the contacts of the harness connector.
Component Description
Solenoid: Solenoid: Solenoid: Solenoid: Solenoid: AETA Proportional Air Start Auto Lube Horn Wastegate Air Shutoff AETA Four way Wastegate Proportional Arc Supply Valve Brake Accum Bleed Diff Oil Bypass RAX Drive Pump Oil Div Blower Motor XMSN Latch Valve Torque Converter Lockup Transmission Clutch Pack (7) Hoist Head End: CT Hoist Head End: PC Hoist Pump Bypass (2) Hoist Rod End: CT Hoist Rod End: PC Brake Oil Diverter Park Brake Final Drive Oil Bypass Steering Bleed
Resistance (Ohms)
16 42.0 4.0 55.17 5.77 24.9 7.75
148-2350
Solenoid:
5.5 0.2
19 Component Identifier Charts Component Identifiers (CID) for the Engine Controls (MID 033,034, and 036)
CID
0001 0002 0003 0004 0005 0006 0007 0008 0009 0010 0011 0012 0091 0100 0101 0110 0168 0190 0248 0253 0254 0261 0262 0263 0267 0268 0273 0274 0275 0276 0291 0296 0338 0526 0542 0543 0544 0545 0546 0562 0569 0800 0827 0828 0829
Component Cylinder 1 Cylinder 2 Cylinder 3 Cylinder 4 Cylinder 5 Cylinder 6 Cylinder 7 Cylinder 8 Cylinder 9 Cylinder 10 Cylinder 11 Cylinder 12 Throttle Sensor Output Filtered Oil Pressure Crankcase Pressure Signal Coolant Temperature Battery Voltage Engine RPM Signal CAT Data Link Personality Module ECM Timing Calibration Analog Sensor Supply Digital Sensor Supply Shutdown Inputs System Parameters Turbocharger Outlet Pressure Atmospheric Pressure Right Turbocharger Inlet Pressure Left Turbocharger Inlet Pressure Engine Cooling Fan Solenoid Communicate w/Trans Prelube Pump Relay Wastegate Solenoid Unfiltered Oil Pressure Signal Filtered Oil Pressure Engine Fan Speed Sensor Signal Start Aid Relay Start Aid Hold Relay Caterpillar Monitoring System Communications Oil Renewal Solenoid CAT Data Link Communication Left Exhaust Temp Signal Right Exhaust Temp Signal Rear Aftercooler Coolant Temperature Signal
1437 The CID is a diagnostic code that indicates which component is faulty.
Component +8 Volt Sensor Supply Operator Park Brake On/Off Switch System Voltage Engine Output Speed(EOS) Signal CAT Data Link Sensor Supply Voltage Engine Cooling Fan Solenoid Transmission Control Engine Cooling Fan Speed Left Wheel Speed Sensor Right Wheel Speed Sensor Parking Brake Switch Parking Brake Solenoid TCS Left Brake Solenoid TCS Right Brake Solenoid Brake System Pressure Switch ARC Supply Solenoid ARC Control Solenoid ARC Lamp Operator ARC On/Off Switch ARC Pressure Switch TCS Proportional Solenoid Service Brake Lamp Relay Differential High Speed Fan Solenoid Rear Differential Temperature Sensor Right Front Brake Temperature Sensor Left Front Brake Temperature Sensor Right Rear Brake Temperature Sensor Left Rear Brake Temperature Sensor TCS Lamp Machine Application Left Rear Park Brake Pressure Sensor Right Rear Park Brake Pressure Sensor Retarder Lever Brake Cooling Pump Speed Brake Cooling Pump Drive Solenoid Brake Oil Diverter Solenoid Rear Differential Lube Bypass Solenoid Operator Service Brake Pressure Switch Final Drive Lube Pressure Switch Front Engine Electronic Control Module Rear Axle Pump Diverter Solenoid Valve
The MID is a diagnostic code that indicates which electronic control module diagnosed the fault.
20 Component Identifier Charts Component Identifiers (CID) for the Transmission Control (MID 081)
CID
0041 0127 0168 0177 0190 0248 0268 0533 0585 0672 0673 0674 0709 0826 0967 1233 1235 1244 1273 1401 1402 1403 1404 1405 1406 1407 1427 1428
Component +8 Volt Sensor Supply Transmission Oil Pressure Sensor System Voltage Transmission Oil Temperature Sensor Engine Output Speed(EOS) Signal CAT Data Link Programmable Parameters Brake Control Transmission Output Speed I Converter Output Speed(COS) Transmission Output Speed II Transmission Intermediate Speed 1 Lockup Solenoid Torque Converter Oil Temperature Sensor Machine Application Transmission Latching Pressure Sensor 1 Transmission Latching Solenoid Transmission Second Stage Relief Solenoid Chassis Electronic Control Module Transmission Solenoid 1 Transmission Solenoid 2 Transmission Solenoid 3 Transmission Solenoid 4 Transmission Solenoid 5 Transmission Solenoid 6 Transmission Solenoid 7 Machine Lockout Indicator Lamp Requested Gear Command Signal
Component Backup Alarm Relay System Voltage CAT Data Link Transmission Electronic Control Module Start Relay Brake Control Gear Selector Lever Hoist Lever Machine Application Body Position Sensor Body Up Lamp Hoist Pump Bypass 1 Solenoid Hoist Pump Bypass 2 Solenoid Hoist Control To Tank Head Solenoid Hoist Control To Tank Rod Solenoid Hoist Pump To Control Head Solenoid Hoist Pump To Control Rod Solenoid Hoist Pilot System Enable Solenoid Accumulator Bleed Relay Machine Operation State
The CID is a diagnostic code that indicates which component is faulty. The MID is a diagnostic code that indicates which electronic control module diagnosed the fault.
21 VIMS Component Identifier Chart Component Identifiers (CID) and Module Identifiers (MID) For VIMS (MID NO's. 49, 57, 58, 59, 60, 65, 66, 67, and 68)
CID
0041 0075 0091 0096 0098 0100 0101 0102 0110 0127 0168 0171 0177 0190 0248 0253 0245 0261 0262 0263 0267 0268 0269 0271 0272 0273 0274 0275 0276 0277 0278 0279 0280 0291 0292 0295 0296 0298 0324 0341 0350 0351 0352 0353 0354 0355 0356 0357 0358 0359 0360 0361 0363 0364 0365 0367 0370
Component 8 Volt Sensor Power Supply Steering Oil Temperature Sensor Throttle Position Sensor Fuel Level Sensor Engine Oil Level Sensor Engine Oil Pressure Sensor Crankcase Air Pressure Sensor Boost Pressure Sensor Engine Coolant Temperature Sensor Transmission Oil Pressure Sensor Electrical System Voltage Ambient Air Temperature Sensor Transmission Oil Temperature Sensor Engine Speed Sensor CAT Data Link Personality Module (Engine Control) Electronic Control Module (ECM) Engine Timing Calibration 5 Volt Sensor Power Supply 8V (or 12V) Sensor Pwr Supply Engine Shutdown Switch (Remote) Programmable Parameters (Eng Ctrl) Sensor Power Supply Action Alarm Turbo Outlet High Press Sensor Turbocharger Outlet Pressure Sensor Atmospheric Pressure Sensor Right Turbo Inlet Press Sensor Left Turbo Inlet Press Sensor Timing Calibration Sensor AESC Enable Lamp Aftercooler Coolant Temp Sensor Gear Box Temperature Sensor Engine Coolant Cooling Fan Solenoid Hydraulic Oil Cooling Fan Solenoid Electronic Control Module (ECM) Transmission ECM Service Brake Pedal Switch Action (Warning) Lamp Hyd Ctrl Valve Warm Up Sol #4 Lift Linkage Position Sensor Tilt Linkage Position Sensor Lift Lever (Cab) Sensor Tilt Lever (Cab) Sensor Lift Raise Solenoid #1 Lift Lower Solenoid #1 Tilt Dump Solenoid #1 Tilt Rackback Solenoid #1 Pilot Pressure Solenoid (Supply) Lift Raise Kickout Solenoid Lift Lower Kickout Solenoid Tilt Kickout Solenoid Machine Ride Control Actuator Lift Cylinder Head Pressure Sensor Kickout Set Switch Ride Control Switch Boom Float Solenoid
CID
0558 0559 0562 0569 0580 0581 0590 0592 0593 0594 0595 0596 0600 0621 0623 0626 0627 0628 0641 0642 0643 0644 0645 0646 0650 0654 0655 0656 0657 0658 0659 0670 0671 0672 0678 0679 0700 0701 0702 0703 0704 0705 0706 0707 0708 0709 0710 0711 0712 0713 0714 0715 0800 0801 0802 0803 0804
Component Autolube Relay Boom Float Relay Caterpillar Monitoring System Oil Injection Solenoid Power Shift Pressure Sensor Power Shift Solenoid Engine Electronic Control Module Lift Raise Solenoid #2 Lift Lower Solenoid #2 Tilt Rackback Solenoid #2 Tilt Dump Solenoid #2 Implement Electronic Control Module Hydraulic Oil Temperature Sensor Downshift Switch Directional Switch Steering/Transmission Lock Switch Parking Brake Pressure Switch Quickshift Switch Transmission Solenoid #1 Transmission Solenoid #2 Transmission Solenoid #3 Transmission Solenoid #4 Transmission Solenoid #5 Transmission Solenoid #6 Harness Code Trailer Right Brake Oil Temp Sensor Trailer Left Brake Oil Temp Sensor Trailer Brake Oil Cooler Inlet Temp Sen Trailer Brake Oil Cooler Temp Sensor Trailer Rt Suspension Cyl Press Sensor Trailer Lt Suspension Cyl Press Sensor Torque Converter Pedal Pos Sensor Transmission Output Speed Sensor Torque Converter Output Spd Sensor Torque Converter Impeller Clutch Sol Torque Converter Lockup Clutch Sol Transmission Gear Actuator Sensor Transmission Output Speed Sensor Transmission Gear Selector Switch Trailer Door Position Sensor Service Brake Pressure Switch Body Raise Switch Body Up Sensor Transmission Upshift Solenoid Transmission Downshift Solenoid Trans Lockup Clutch Sol ARC Supply Valve ARC Control Valve ARC Lamp ARC ON/OFF Switch ARC Pressure Switch Retarder Pressure Switch VIMS Main Module VIMS Interface Module #1 VIMS Interface Module #2 VIMS Interface Module #3 VIMS Interface Module #4
22 VIMS Component Identifier Chart Component Identifiers (CID) and Module Identifiers (MID) For VIMS (MID NO's. 49, 57, 58, 59, 60, 65, 66, 67, and 68)
CID
0371 0372 0373 0374 0376 0377 0378 0379 0423 0424 0425 0426 0427 0428 0429 0430 0431 0432 0433 0434 0436 0438 0439 0440 0444 0457 0458 0459 0489 0490 0499 0526 0533 0541 0542 0544 0545 0546 0548
Component Horn Solenoid (Forward) Bucket/Shovel Open Solenoid Bucket/Shovel Close Solenoid Swing Brake Solenoid Travel Alarm (Solenoid/Switch) Travel Brake Solenoid Machine Autolube Solenoid Machine Autolube Pressure Sensor Front Brake Accumulator Press Sw Rear Brake Accumulator Press Sw Front Brake Oil Pressure Sensor Rear Brake Oil Pressure Sensor Front Axle Oil Temperature Sensor Rear Axle Oil Temperature Sensor Steering Pump Oil Pressure Sensor Steering Pilot Pressure Sensor Steering Oil Level Switch Steering Filter By-Pass Switch Implement Filter Switch Hyd Pilot Oil Press Sensor Torque Converter Oil Pressure Sensor Hyd Ctrl Valve Warm Up Sol #1 Hyd Ctrl Valve Warm Up Sol #2 Hyd Ctrl Valve Warm Up Sol #3 Start Relay Brake Oil Temperature Sensor Tilt Cylinder Rod Pressure Sensor Impeller Clutch System Switch Implement Select Switch Implement Lockout Switch Implement Variable Hyd Oil Pump Sol Turbocharger Wastegate Valve Auto Retarder Control (ARC) Differential (Axle) Oil Pressure Sensor Engine Oil Pressure/uh/Unfiltered Sensor Engine Fan Speed Sensor Start Aid Relay Start Aid Hold Relay Throttle Lock Lamp
CID
0805 0806 0807 0808 0809 0810 0811 0812 0813 0814 0815 0816 0817 0819 0820 0821 0822 0823 0824 0825 0856 0827 0828 0829 0830 0833 0835 0838 0839 0840 0841 0849 0851 0852 0853 0854 0855 0890
Component VIMS Interface Module #5 VIMS Interface Module #6 VIMS Interface Module #7 VIMS Interface Module #8 Speedometer/Tachometer #1 Speedometer/Tachometer #2 Gauge (Quad) Cluster #1 Gauge (Quad) Cluster #2 Gauge (Quad) Cluster #3 Gauge (Quad) Cluster #4 Message Center #1 Message Center #2 ECM Internal Backup Battery Display Data Link Keypad Data Link Display Power Supply (9 Volt) Display Lighting Power Supply VIMS Service Lamp Truck Payload Lamp #1 (Green) Truck Payload Lamp #2 (Red) Torque Converter Oil Temp Sensor Left Exhaust Temp Sensor Right Exhaust Temp Rear Aftercooler Cool Temp Sensor Front Brake Oil Temperature Sensor Rear Brake Oil Temperature Sensor Differential (Axle) Oil Temp Sensor Lt Front Suspension Cyl Press Sensor Rt Front Suspension Cyl Press Sensor Lt Rear Suspension Cyl Press Sensor Rt Rear Suspension Cyl Press Sensor System Air Pressure Sensor Gear Box Pressure Sensor Brake Oil Temp Sensor (Rt Front) Brake Oil Temp Sensor (Lt Front) Brake Oil Temp Sensor (Rt Rear) Brake Oil Temp Sensor (Lt Rear) Broadcast Port (Data Link)
The CID is a diagnostic code that indicates which component is faulty. The MID is a diagnostic code that indicates which electronic control module diagnosed the fault.
The FMI is a diagnostic code that indicates what type of failure has occurred.
Form Number
RENR2275 RENR2677 RENR2676 RENR2678 RENR2630 RENR2631
9X-1123
* AG-C4 111-7898 1
* L-C12 3E-5179
325-L25 PK-14
Single Wire Connector * Harness identification letter(s) and a serializing code. The "C" stands for connector and the number indicates which connector in the harness. 2 Circuit Number Identification 200-L32 BK-14 Wire Color Wire Gauge
Pressure Symbol
Temperature Symbol
Level Symbol
Flow Symbol
Normally open switch that will close with an increase of a specific condition (temp-press-etc.).
Normally open switch that is closed due to an applied condition, and will open again with a specific decrease in that condition.
Normally closed switch that will open with an increase of a specific condition.
Normally closed switch that is open due to an applied condition, and will close again with a specific decrease in that condition.
The circle indicates that the component has screw terminals and a wire can be disconnected from it.
No circle indicates that the wire cannot be disconnected from the component.
This indicates that the component has a wire connected to it that is connected to ground.
This indicates that the component does not have a wire connected to ground. It is grounded by being fastened to the machine.
Printed in U.S.A.