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KENR8379-03

September 2012

64 58 7

KENR8379-03 VOL 1 of 3
COMPONENT LOCATIONS
Machine Schematic
Steering and
Fan Pump
1
Description Part Number
Location Location
6

(Dimensions: 48 inches x 35 inches)


ACCUMULATOR GP - PRECHARGE PRESSURE (VOL. 1) 253-4120 7 J-13
CORE AS - STEERING COOLER (VOL. 1) N/A 133 B-5
CYL GROUP - LEFT STEER (VOL. 1) 194-6171 14 I-1
CYL GROUP - RIGHT STEER (VOL. 1) 288-5537 15 G-1
FILTER - HYDRAULIC (VOL. 1) 4T-6788 46 D-5
E-3
FILTER GP - CASE DRAIN (VOL. 1)
FILTER GP - OIL (VOL. 1)
290-2569
290-2569
2
3 B-8
UU
FILTER GP - OIL (VOL. 1) 289-9904 5 F-5
MOTOR GP - FAN SPEED CONTROL (VOL. 1) 240-7790 57 G-10
PUMP GP - BRAKE COOLING DRIVE (VOL. 1) (OPTION) 281-8284 62 C-13 ACCUMULATOR PRESSURE
PUMP GP - METERING (VOL. 1)
PUMP GP - STEERING and FAN (VOL. 1)
192-3897
301-4678
4
54
H-7
C-9 6
SENSOR
797F Off-Highway Truck
PUMP GP - STEERING and FAN (VOL. 1)
SENSOR GP - PRESSURE (VOL. 1)
284-9631
221-3405
60
71
C-9
J-12
X Hydraulic and Power Train System
SENSOR GP - SPEED (VOL. 1) 186-0131 70 H-9 RR 71 LAJ1-UP
SENSOR GP - SPEED (VOL. 1) 163-0265 97 A-3
SENSOR GP - TEMP (VOL. 1) 134-2252 85 C-3 Steering Pump Fan Pump WSP1-UP
SWITCH AS - STEERING OIL LEVEL (VOL. 1) 172-8660 94 C-3
TANK GP - HYDRAULIC (SEE NOTE) (VOL. 1)* 280-1634 58 D-4
TANK GP - HYDRAULIC (SEE NOTE) (VOL. 1)* 280-2090 64 D-4 UU
VALVE GP - MAKE UP (FAN ANTI-CAV) (VOL. 1) 183-7170 45 G-12
VALVE GP - PRESSURE REDUCING (VOL. 1) 226-0835 44 H-14

36 Page,
VALVE GP - SOL (VOL. 1) 288-4351 6 H-11
VALVE GP - STEERING (VOL. 1) 151-5933 1 I-3

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 FLUID POWER SYMBOLS


15 BASIC COMPONENT SYMBOLS

MAIN AUX

PUMP OR MOTOR FLUID CONDITIONER SPRING CONTROL VALVES RESTRICTION LINE RESTRICTION PUMP PUMP
(FIXED) (2 - SECTION) (VARIABLE & PRESSURE
COMPENSATED)
STEERING POSITION SENSOR
Sensor Head VARIABILITY SPRING
(ADJUSTABLE)
LINE RESTRICTION
(VARIABLE)
PRESSURE
COMPENSATION
HYDRAULIC PNEUMATIC
ENERGY TRIANGLES
LINE RESTRICTION
(VARIABLE & PRESSURE
ATTACHMENT
Magnet COMPENSATED)

Cylinder - Head End VALVE ENVELOPES VALVES VALVE PORTS

ONE POSITION TWO POSITION THREE POSITION TWO - WAY THREE - WAY FOUR - WAY

4 Rod
AB
CONTROL VALVES
A B
CHECK VALVES

TAP LOCATIONS (VOL. 1)


P T P T
Machine Schematic Connector NORMAL POSITION SHIFTED POSITION INFINITE POSITION
BASIC SPRING SHUTTLE PILOT
SYMBOL LOADED CONTROLLED
Description
Location Location
FLUID STORAGE RESERVOIRS
BRAKE COOLING DRIVE PUMP PRESSURE Y E-14
RADIATOR FAN PRESSURE W G-12
STEERING ACCUMULATOR PRESSURE RR I-12
X I-5
VENTED PRESSURIZED RETURN ABOVE FLUID LEVEL RETURN BELOW FLUID LEVEL
STEERING FLOW AMP
STEERING PUMP PRESSURE SS I-12 44 MEASUREMENT ROTATING SHAFTS

STEERING RETURN YY H-11


STEERING SUPPLY UU I-11
6
64 PRESSURE REDUCING VALVE PRESSURE TEMPERATURE FLOW

COMBINATION CONTROLS
UNIDIRECTIONAL BIDIRECTIONAL

58 SOLENOID SOLENOID
OR MANUAL
SOLENOID
& PILOT
SOLENOID &
PILOT OR MANUAL
SERVO THERMAL DETENT

1 MANUAL CONTROL SYMBOLS

PUSH - PULL LEVER MANUAL SHUTOFF GENERAL MANUAL PUSH BUTTON PEDAL SPRING

RELEASED PRESSURE PILOT CONTROL SYMBOLS REMOTE SUPPLY PRESSURE

14 EXTERNAL RETURN INTERNAL RETURN SIMPLIFIED COMPLETE INTERNAL


SUPPLY PRESSURE

ACCUMULATORS CROSSING & JOINING LINES HYDRAULIC & PNEUMATIC CYLINDERS

75
SPRING LOADED GAS CHARGED LINES CROSSING LINES JOINING SINGLE ACTING DOUBLE ACTING

54 HYDRAULIC PUMPS HYDRAULIC MOTORS INTERNAL PASSAGEWAYS

FIXED VARIABLE DISPLACEMENT FIXED VARIABLE DISPLACEMENT INFINITE


DISPLACEMENT NON-COMPENSATED DISPLACEMENT NON-COMPENSATED POSITIONING 3 POSITION 2 POSITION

60
UNIDIRECTIONAL UNIDIRECTIONAL

FLOW IN ONE PARALLEL CROSS FLOW IN


BIDIRECTIONAL BIDIRECTIONAL DIRECTION FLOW FLOW EITHER
DIRECTION

CHASSIS VIEW

ELECTRICAL SYMBOLS TABLE


64 58 HYDRAULIC SYMBOLS (ELECTRICAL)

G
M
TRANSDUCER TRANSDUCER GENERATOR ELECTRIC MOTOR
Hydraulic Tank, Right Side (FLUID) (GAS / AIR)

PRESSURE SWITCH PRESSURE SWITCH TEMPERATURE ELECTRICAL WIRE


(ADJUSTABLE) SWITCH
85 Steering and
Fan Section
2 ELECTRICAL SYMBOLS (ELECTRICAL)

PRESSURE TEMPERATURE LEVEL FLOW


Steering and 5 SWITCH SWITCH SWITCH SWITCH

Fan Section 94
WIRE NUMBER IDENTIFICATION CODES

ELECTRICAL SCHEMATIC EXAMPLE HYDRAULIC SCHEMATIC EXAMPLE


CURRENT STANDARD CURRENT STANDARD

HARNESS IDENTIFICATION CODE THIS EXAMPLE


INDICATES WIRE 135 IN HARNESS AG
WIRE

133 325-AG135 PK-14


CIRCUIT NUMBER
IDENTIFICATION WIRE COLOR
Lower Sight Gauge Upper Sight Gauge
Screen Steering Pump Suction Port CIRCUIT NUMBER WIRE WIRE GAUGE
IDENTIFICATION COLOR 325-PK

PREVIOUS STANDARD

WIRE WIRE COLOR

325-PK-14 B A

CIRCUIT NUMBER WIRE GAUGE (EXAMPLE VALVE)


IDENTIFICATION

HYDRAULIC TANK
14 13 12 11 10 9 8 7 6 5 4 3 2 1

(7) ACCUMULATOR GP-A


253-4120
KENR8379-03 VOL 1 of 3

J J
(71) SENSOR GP-PRESS
221-3405
(Dimensions: 48 inches x 35 inches)

(14) CYL GROUP - LEFT STEER


194-6171
SENSOR GP-
ACCUMULATOR PRESSURE
(Part #: N/A) (1) VALVE GP-STEERING
151-5933
P

L
I PP P L I

T R

LS
36 Page,

CL
(6) VALVE GP-SOL
HP
288-4351

H H

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

(44) VALVE GP-PRESS (57) MOTOR GP-FAN SPEED CONTROL


226-0835 240-7790
(45) VALVE GP-MAKE UP
183-7170
CR
G HT G
T EF R

(15) CYL GROUP - RIGHT STEER


288-5537

F F

PRESSURE AND FLOW PRESSURE AND FLOW


COMPENSATOR VALVE COMPENSATOR VALVE (5) FILTER GP-OIL
289-9904

(2) FILTER GP-OIL


290-2569

E E

A M G T1 L1 L1 T1 G1 MA A B MB G2 T1A

(46) FILTER-HYDRAULIC
4T-6788

(64) TANK GP-HYD (STEEP GRADE)


280-2090
(58) TANK GP-HYD (SHALLOW GRADE)
PUMP 280-1634

D Vg MIN Vg MAX
DRIVE Vg MAX Vg MIN
Vg MIN Vg MAX D
BOX

(94) SWITCH AS
172-8660

C S M1 T2 R L2 U R1 T2 M1A SL S M1B T2A R2 (85) SENSOR GP-TEMP


C
134-2252

(54) PUMP GP - STEERING and FAN (60) PUMP GP - STEERING and FAN
(SHALLOW GRADE) (STEEP GRADE)
(62) PUMP GP - BRAKE COOLING 301-4678 284-9631
STEEP GRADE ONLY 281-8284

(3) FILTER GP-OIL


290-2569

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

Pilot / Load Sensing Pressure


See Volume 3
A-5 / B-5 Drain / Return Lines

Component Group

CALLOUTS
BB YY Taps (Pressure, Sampling, Sensor - by letter)

Callout Number Component


(Machine Location from (52) VALVE GP - CONTROL Name
Component LocationsTable)
A 138-1234 Part Number
A
( 97 ) SENSOR GP-SPEED
THIS SCHEMATIC IS FOR THE797F OFF HIGHWAY TRUCKHY DRAULIC SYSTEM
163-0265
STEEP GRADE (ADD'L) RETARDING AR ONLY
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 9 8 7 6 5 4 3 2 1
KNER8379-03
COMPONENT LOCATIONS September 2012
Machine Schematic Hoist Screens - Internal
Description Part Number
Location Location
ACCUMULATOR GP - BRAKE PRECHARGE (VOL. 2) 286-0796 27 G-8
ACCUMULATOR GP - BRAKE PRECHARGE (VOL. 2) 286-0796 29 F-6
17 33
ADJUSTER GP (VOL. 2) 205-0560 42 I-11

KENR8379-03 VOL 2 of 3
ADJUSTER GP (VOL. 2) 205-0560 43 I-1
CONNECTOR AS - ORIFICE (VOL. 2) 311-6676 10 D-7
CONNECTOR AS - ORIFICE (VOL. 2) 311-6676 11 D-7
CONT GP - SERVICE BRAKE (VOL. 2) 321-5086 35 E-5 TANK
I-8
TANK 22

(Dimensions: 48 inches x 35 inches)


CONTROL GP - HYD (TRACTION CONTROL SYSTEM) (VOL. 2) 222-4744 31
COOLER SCREEN (VOL. 2) 165-0056 56 C-4
CORE AS - REAR BRAKE COOLER (VOL. 2) 285-0255 84 D-3
CORE AS (VOL. 2) 299-3290 113 J-13
CYL GP - TEL (VOL. 2) 289-8616 17 I-3
37 TANK
FILTER GP - OIL (BRAKE COOLING) (VOL. 2) 339-9703 25 C-3
FILTER GP - BRAKE SYSTEM OIL (VOL. 2) 290-2567 134 B-9
FILTER GP - TRANS (VOL. 2) 334-0572 118 I-12
G-13
FILTER GP - TRANS (VOL. 2)
MANIFOLD GP - POWER ACCESS LINE RELIEF (VOL. 2)
334-0572
336-0981
119
124 C-13
17
MOTOR GP - REAR AXLE FAN (VOL. 2) 257-6844 67 B-7 25 84 55 56 Service Brake Check Valve

MOTOR GP - REAR AXLE LUBE (VOL. 2)


ORIFICE (VOL. 2)
296-5306
N/A
37
130
D-11
C-13
Pressure Reducing Valve 797F Off-Highway Truck
PLUG AS (VOL. 2) 242-7114 115 I-13 134 Hydraulic and Power Train System
PUMP GP - COOLING and BRAKE CHARGE (VOL. 2) 317-2659 55 A-9 134 33 43 19 39 Front Brake Relay Valve
E-4 Bypass Switch
PUMP GP - ELEC DR (RELIEF VALVE) (VOL. 2) 5T-1060 13 Rear Brake Relay Valve LAJ1-UP
PUMP GP - HOIST (VOL. 2) 281-8288 22 B-10
Unloader Solenoid WSP1-UP
PUMP GP - REAR AXLE LUBE (VOL. 2) 324-2716 39 E-11 PP DD
SCREEN AS (VOL. 2) 9P-9555 99 F-13 Unloader Diverter Valve
Parking Brake Check Valve
SCREEN AS (VOL. 2) 172-6104 109 F-13 EE Parking Brake Relay Valve LEFT SIDE Screen
SCREEN GP - BYPASS SWITCH (VOL. 2) 172-2395 21 B-10
SENSOR GP - PARKE BRAKE PRESSURE (VOL. 2) 221-3410 80 J-8 TANK Front Brake
I-8

36 Page,
SENSOR GP - PARKE BRAKE PRESSURE (VOL. 2) 221-3410 81
ARC Solenoid Rear Brake
SENSOR GP - PRESSURE (VOL. 2) 221-3405 75 F-8/F-7 ARC Solenoid
SENSOR GP - PRESSURE (VOL. 2) 221-3405 76 F-5 BACK FRONT
SENSOR GP - PRESSURE (VOL. 2) 221-3405 77 D-6
SENSOR GP - PRESSURE (VOL. 2) 221-3415 105 G-13
SENSOR GP - TEMP (VOL. 2) 134-2252 87 J-11 Accumulator
SENSOR GP - TEMP (VOL. 2) 134-2252 86 F-11 Purge Solenoid
SENSOR GP - TEMP (VOL. 2) 134-2252 92 J-1 LL Parking Brake
SENSOR GP - TEMP (VOL. 2) 134-2252 93 F-13 FF KK JJ HH GG Solenoid
SENSOR GP - TEMP (VOL. 2) 288-8390 100 H-13
SWITCH AS - LEVEL (VOL. 2) 172-8660 96 B-9
SWITCH AS - PRESSURE (VOL. 2) 130-7459 102 I-13
Rear Service Brake RIGHT SIDE
SWITCH GP - FILTER BYPASS (VOL. 2) 164-7577 122 G-13 27 29 42 Shuttle Valve Front Service Brake
Relief Valve Shuttle Valve
SWITCH GP - FILTER BYPASS (VOL. 2) 164-7577 123 I-12
TANK GP - HYDRAULIC (VOL. 2) 280-1634 59 B-5 Volume 2 of 3: Shallow Grade - Braking and Cooling
VALVE - CHECK (VOL. 2) 123-4750 51 E-4
VALVE - CHECK (VOL. 2) 123-4750 52 F-7 CHASSIS VIEW BRAKE CHASSIS VALVE BRAKE SYSTEM FILTER
VALVE - CHECK (VOL. 2) 123-4750 53 F-8 2012 Caterpillar, All Rights Reserved Printed in U.S.A.
VALVE GP - RELIEF (VOL. 2) 346-4815 69 C-7
VALVE GP - CONT (VOL. 2) 293-4974 19 H-4
VALVE GP - DIVERTER (VOL. 2) 168-7859 111 H-12
VALVE GP - MANUAL BYPASS CONTROL (VOL. 2) 336-0978 126 D-13
VALVE GP - MTG (VOL. 2) 285-5630 33 D-8
VALVE GP - MTG (VOL. 3) 285-5630 32 E-8
VALVE GP - RELIEF (VOL. 2) 172-5381 107 H-13
FLUID POWER SYMBOLS
BASIC COMPONENT SYMBOLS

MAIN AUX

PUMP OR MOTOR FLUID CONDITIONER SPRING CONTROL VALVES RESTRICTION LINE RESTRICTION PUMP PUMP
(FIXED) (2 - SECTION) (VARIABLE & PRESSURE
COMPENSATED)

VARIABILITY SPRING LINE RESTRICTION PRESSURE HYDRAULIC PNEUMATIC LINE RESTRICTION ATTACHMENT
(ADJUSTABLE) (VARIABLE) COMPENSATION ENERGY TRIANGLES (VARIABLE & PRESSURE
COMPENSATED)

80 BB Accumulator(s) - VALVE ENVELOPES VALVES VALVE PORTS


TAP LOCATIONS (VOL. 2) Brake Precharge
Machine Schematic
Description
Location Location ONE POSITION TWO POSITION THREE POSITION TWO - WAY THREE - WAY FOUR - WAY

BRAKE ACCUMULATOR C F-8 CONTROL VALVES CHECK VALVES


BRAKE ACCUMULATOR D F-6 AB A B

BRAKE CHARGE PRESSURE K B-9


P T P T
BRAKE COOLING P C-4 NORMAL POSITION SHIFTED POSITION INFINITE POSITION
BASIC SPRING SHUTTLE PILOT
SYMBOL LOADED CONTROLLED
BRAKE PEDAL E D-5
BRAKE TO TANK I C-5 FLUID STORAGE RESERVOIRS

FRONT BRAKE SLACK ADJUSTER B H-1


HOIST CYLINDER HEAD END PRESSURE LL H-4
HOIST CYLINDER ROD END PRESSURE FF J-4 VENTED PRESSURIZED RETURN ABOVE FLUID LEVEL RETURN BELOW FLUID LEVEL

HOIST PUMP DISCHARGE/BRAKE COOLING SUPPLY PP I-5 MEASUREMENT ROTATING SHAFTS


LEFT BRAKE PRESSURE BB J-7
LEFT FRONT BRAKE COOLING OUT S J-2
LEFT FRONT BRAKE COOLING OUT T J-1 PRESSURE TEMPERATURE FLOW UNIDIRECTIONAL BIDIRECTIONAL
LEFT FRONT SERVICE BRAKE N I-2
COMBINATION CONTROLS
LEFT REAR BRAKE COOLING IN Q G-2
LEFT REAR PARK BRAKE G J-10
LEFT REAR SERVICE BRAKE M I-10
PILOT OIL BYPASS (to Front Brake Cooling) DD J-6 SOLENOID SOLENOID
OR MANUAL
SOLENOID
& PILOT
SOLENOID &
PILOT OR MANUAL
SERVO THERMAL DETENT

PILOT OIL BYPASS (to Rear Brake Cooling) EE I-6


MANUAL CONTROL SYMBOLS
PILOT PRESSURE - HEAD END to TANK (Lower) KK H-4
PILOT PRESSURE - PUMP to HEAD END (Raise) JJ I-4
PILOT PRESSURE - PUMP to ROD END (Lower) HH I-4
PILOT PRESSURE - ROD END to TANK (Raise) GG J-4 PUSH - PULL LEVER MANUAL SHUTOFF GENERAL MANUAL PUSH BUTTON PEDAL SPRING

RAXL DRIVE PUMP PRESSURE J D-11 81 H CC 31 RELEASED PRESSURE PILOT CONTROL SYMBOLS REMOTE SUPPLY PRESSURE
REAR BRAKE SLACK ADJUSTER
RIGHT BRAKE PRESSURE
A
CC
H-11
I-7
35 55
RIGHT FRONT BRAKE COOLING IN U F-2 EXTERNAL RETURN INTERNAL RETURN SIMPLIFIED COMPLETE INTERNAL
RIGHT FRONT BRAKE COOLING OUT V F-1 SUPPLY PRESSURE

RIGHT FRONT SERVICE BRAKE O G-2 ACCUMULATORS CROSSING & JOINING LINES HYDRAULIC & PNEUMATIC CYLINDERS
RIGHT REAR PARK BRAKE F F-10
RIGHT REAR SERVICE BRAKE
TCS PILOT
L
H
G-10
T-7
21 SPRING LOADED GAS CHARGED LINES CROSSING LINES JOINING SINGLE ACTING DOUBLE ACTING

HYDRAULIC PUMPS HYDRAULIC MOTORS INTERNAL PASSAGEWAYS

FIXED VARIABLE DISPLACEMENT FIXED VARIABLE DISPLACEMENT INFINITE


DISPLACEMENT NON-COMPENSATED DISPLACEMENT NON-COMPENSATED POSITIONING 3 POSITION 2 POSITION

UNIDIRECTIONAL UNIDIRECTIONAL

FLOW IN ONE PARALLEL CROSS FLOW IN


BIDIRECTIONAL BIDIRECTIONAL DIRECTION FLOW FLOW EITHER

SERVICE BRAKE CONTROL VALVE TRACTION CONTROL SYSTEM VALVE BRAKE COOLING and CHARGE BRAKE COOLING SCREENS
DIRECTION

ELECTRICAL SYMBOLS TABLE


HYDRAULIC SYMBOLS (ELECTRICAL)

93 G
87 M
86
TRANSDUCER TRANSDUCER GENERATOR ELECTRIC MOTOR
Hoist Screens (FLUID) (GAS / AIR)
Return Screens

PRESSURE SWITCH PRESSURE SWITCH TEMPERATURE ELECTRICAL WIRE


(ADJUSTABLE) SWITCH

ELECTRICAL SYMBOLS (ELECTRICAL)

Hoist Oil Port


LEFT FRONT REAR Brake Actuation T
Hoist Valve Port Section Filler Tube
PRESSURE TEMPERATURE LEVEL FLOW
SWITCH SWITCH SWITCH SWITCH

WIRE NUMBER IDENTIFICATION CODES

Brake Actuation
ELECTRICAL SCHEMATIC EXAMPLE HYDRAULIC SCHEMATIC EXAMPLE
Section
CURRENT STANDARD CURRENT STANDARD

HARNESS IDENTIFICATION CODE THIS EXAMPLE


INDICATES WIRE 135 IN HARNESS AG
WIRE
Hoist and Brake
Cooling Section
92 Accumulator
Purge Solenoid 325-AG135 PK-14
CIRCUIT NUMBER
IDENTIFICATION WIRE COLOR

CIRCUIT NUMBER WIRE WIRE GAUGE


IDENTIFICATION COLOR 325-PK

PREVIOUS STANDARD
Hoist Screens
WIRE WIRE COLOR

325-PK-14 B A

Return Screens CIRCUIT NUMBER WIRE GAUGE (EXAMPLE VALVE)


RIGHT FRONT IDENTIFICATION

BRAKE TEMPERATURE SENSORS TANK


14 13 12 11 10 9 8 7 6 5 4 3 2 1
(92) SENSOR GP
TEMP: 1342252
LEFT REAR (80) SENSOR GPPRESS LEFT FRONT
(87) SENSOR GPTEMP 2213410
1342252
P2
PUMP BYPASS SECTION HOIST SECTION
KENR8379-03 VOL 2 of 3

J LEFT WHEELGP & FD FF


J
PILOT
ON/OFF
P L
(Dimensions: 48 inches x 35 inches)

CYLINDER ROD END


LEFT BRAKE PRESSURE
TO TANK (RAISE)

(102) SWITCH AS (113) CORE AS


PRESSURE: 1307459 2993290 BYPASS TO FRONT
BRAKE COOLING GG

D
PUMP TO CYLINDER
(123) SWITCH GP
ROD END (LOWER)
FILTER BYPASS
1647577
(31) CONTROL GPHYD
2224744 HH
(17) CYL GPTEL
(118) FILTER GP
TRANS: 3340572
2898616
I I
RIGHT BRAKE PRESSURE
R TCS BYPASS TO REAR
BRAKE COOLING PUMP TO CYLINDER
(115) PLUG AS HEAD END (RAISE)
2427114 (42) ADJUSTER GP
2050560 (43) ADJUSTER GP
(110) VALVE GPDIVERTER
1687859
JJ 2050560

(100) SENSOR GP (81) SENSOR GPPRESS


TEMP: 2888390
36 Page,

2213410 CYLINDER HEAD END


TO TANK (LOWER)

KK

H H

LL
(107) VALVE GP
RELIEF: 1725381

BANJOHOUSING
OIL SUMP
(105) SENSOR GP
PRESS: 2213415

(122) SWITCH GP
FILTER BYPASS (19) VALVE GPCONT
1647577 2934974

G G

(119) FILTER GP
TRANS: 3340572
BRAKE
CONTROL
MODULE (93) SENSOR GP
(27) ACCUM GP TEMP: 1342252
2860796
(29) ACCUMULATOR GP
2860796 O
(53) VALVECHECK
(109) SCREEN AS 1234750
1726104

(99) SCREEN AS
9P9555
(52) VALVECHECK
F (75) SENSOR GP 1234750
(76) SENSOR GPPRESS F
PRESS: 2213405 2213405
(86) SENSOR GPTEMP
1342252
RIGHT REAR (35) CONT GP
RIGHT FRONT
ACC1 PS1 SUPPLY PS2 TCS HOIST BCD ACC2 SERVICE BRAKE
RV1
3215086
SQ1 SV3
LE1 PS3

T2 SV2
(51) VALVECHECK
PR2
1234750

PR1 FL1
(13) PUMP GPELEC DR
5T1060

CV1 CV2 TSB


E RIGHT WHEELGP & FD P A
E
M
T PD1 HF1 SV1 PD2 HF2 PD3 PLUG HF3 T1 T

POWER TRAIN
(REAR AXLE) 1

SH1 SH2
(39) PUMP GPREAR AXLE LUBE
3242716
PS5 FSB
PB R PS4 F
J

(33) VALVE GPMTG (10) CONNECTOR AS (11) CONNECTOR AS


2855630 3116676 3116676
(128) CYLINDER GPBASIC 3393275
(77) SENSOR GP
PRESS: 2213405

D D
RAISE
(37) MOTOR GP
LOWER REAR AXLE LUBE (84) CORE ASFRONT REAR
2965306 BRAKE COOLER: 2850255

(56) COOL SCREEN


HOIST PILOT DRAIN 1650056
(67) VALVE GPMANUAL FROM FILTER

BYPASS CONTROL: 3360978


2 1

(130) ORIFICE (25) FILTER GP OIL


3399703
(69) VALVE GPMTG
C 3464815 C
(124) MANIFOLD GP
POWER ACCESS
LINE RELIEF: 3360981
P MAKE UP FLOW
(21) SCREEN GP FROM FILTER
S
1722395
TO CYLINDER TO CYLINDER
HEAD END ROD END

C2 C1 HYDRAULIC CIRCUIT COLOR DESCRIPTIONS


PILOT PUMP OUTPUT
POWER ACCESS
T F PUMP GP - HOIST CIRCUIT
SUPPLY LINE
BRAKE ADJUSTER CUIRCUIT
(22) PUMP GPHOIST MOTOR GP - REAR AXLE LUBE CIRCUIT
2818288 DRAIN / RETURN LINE
PUMP GP - REAR AXLE LUBE CIRCUIT
PUMP GP - BRAKE CHARGE CIRCUIT
BRAKE COOLING
B (134) FILTER GP ELECTRICAL CIRCUITS B
BRAKE SYSTEM
1728660
LINE PATTERNS
Pressure Line

Pilot / Load Sensing Pressure

PUMP Drain / Return Lines

DRIVE Component Group


M
BOX (67) MOTOR GP (59) TANK GPHYD 1435
CALLOUTS
(55) PUMP GP COOLING and REAR AXLE FAN 2801634 YY Taps (Pressure, Sampling, Sensor - by letter)
BRAKE CHARGE: 3172659 2576844
Callout Number Component
FILL (Machine Location from
Component LocationsTable)
(52) VALVE GP - CONTROL Name

138-1234 Part Number


TUBE

A THIS SCHEMATIC IS FOR THE 797F OFF-HIGHWAY TRUCK HYDRAULIC AND A


POWER TRAIN SYSTEM
VOLUME 2 of 3: SHALLOW GRADE - BRAKING AND COOLING
MEDIA NUMBER: KENR8379-03
SCHEMATIC PART NUMBER: 272-3213, CHANGE: 02, VERSION: -
POWER ACCESS 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.

14 13 12 11 10 9 8 7 6 5 4 3 2 1
KENR8379-03
COMPONENT LOCATIONS September 2012
Machine Schematic
Description Part Number
Location Location
ACCUMULATOR GP - BRAKE PRECHARGE (VOL. 3) 286-0796 26 G-9
ACCUMULATOR GP - BRAKE PRECHARGE (VOL. 3) 286-0796 28 F-6

KENR8379-03 VOL 3 of 3
ADJUSTER GP (VOL. 3) 205-0560 40 I-11
ADJUSTER GP (VOL. 3) 205-0560 41 I-1
CONNECTOR AS - ORIFICE (VOL. 3) 311-6676 8 E-7
CONNECTOR AS - ORIFICE (VOL. 3) 311-6676 9 E-7 TANK 41
CONT GP - BRAKE (VOL. 3) 321-5086 34 F-6 32

(Dimensions: 48 inches x 35 inches)


CONTROL GP - HYD (TRACTION CONTROL SYSTEM) (VOL. 3) 222-4744 30 I-8
CORE AS - FRONT BRAKE COOLER (VOL. 3)
CORE AS - REAR BRAKE COOLERS (VOL. 3)
285-0255
285-0255
82
83
H-3
B-4
78 BB Accumulator(s) -
Brake Precharge
CORE AS (VOL. 3) 299-3290 112 J-13
CYL GP - TEL (VOL. 3) 289-8616 16 I-3
CYLINDER GP - BASIC (VOL. 3) 339-3275 129 D-13
FILTER - HYDRAULIC (VOL. 3) 4T-6788 47 C-6
FILTER GP - OIL (BRAKE COOLING) (VOL. 3) 339-9703 24 H-2
FILTER GP - BRAKE SYSTEM OIL (VOL. 3) 290-2567 135 B-9
FILTER GP - TRANS (VOL. 3) 334-0572 116 I-12
24 83 61 TANK
FILTER GP - TRANS (VOL. 3)
MANIFOLD GP - POWER ACCESS LINE RELIEF (VOL. 3)
334-0572
336-0981
117
125
G-13
C-13
797F Off-Highway Truck
135
MOTOR GP - REAR AXLE FAN (VOL. 3)
MOTOR GP - REAR AXLE LUBE (VOL. 3)
257-6844
296-5306
66
36
B-7
D-11
135 Hydraulic and Power Train System
MOTOR GP - BRAKE COOLING PUMP DRIVE (VOL. 3) 171-1881 136 B-5 82 83 63 Bypass Switch
LAJ1-UP
ORIFICE (VOL. 3) N/A 131 C-13
PLUG AS (VOL. 3) 242-7114 114 I-13 WSP1-UP
PUMP GP - BRAKE CHARGE (VOL. 3) 314-9248 61 A-10
PUMP GP - BRAKE COOLING DRIVE (VOL. 3) 281-8284 63 A-10
PUMP GP - ELEC DR (RELIEF VALVE) (VOL. 3) 5T-1060 12 C-4
PUMP GP - HOIST (VOL. 3) 281-8288 23 B-10
PUMP GP - REAR AXLE LUBE (VOL. 3) 324-2716 38 E-11

36 Page,
SCREEN AS (VOL. 3) 9P-9555 98 F-13
SCREEN AS (VOL. 3) 172-6104 108 F-13
SCREEN GP - BYPASS SWITCH (VOL. 3) 172-2395 20 C-10
SCREENS - BRAKE COOLING (VOL. 3) N/A 132 B-5 79 H CC 30
SENSOR GP - PARKE BRAKE PRESSURE (VOL. 3) 221-3410 78 J-8
TANK
SENSOR GP - PARKE BRAKE PRESSURE (VOL. 3) 221-3410 79 H-8
SENSOR GP - PRESSURE (VOL. 3) 221-3405 72 F-8/F-7
SENSOR GP - PRESSURE (VOL. 3) 221-3405 73 E-7 26 28 40
SENSOR GP - PRESSURE (VOL. 3) 221-3405 74 F-6
SENSOR GP - PRESSURE (VOL. 3) 221-3415 104 G-13
SENSOR GP - TEMP (VOL. 3) 134-2252 88 F-1
SENSOR GP - TEMP (VOL. 3) 134-2252 89 J-1
SENSOR GP - TEMP (VOL. 3) 134-2252 90 J-11
SENSOR GP - TEMP (VOL. 3) 134-2252 91 F-11 Volume 3 of 3: Steep Grade - Brake and Cooling
SENSOR GP - TEMP (VOL. 3) 288-8390 103 H-13
SWITCH AS - LEVEL (VOL. 3)
SWITCH AS - PRESSURE (VOL. 3)
172-8660
130-7459
95
101
B-9
I-13
TRACTION CONTROL SYSTEM VALVE BRAKE SYSTEM FILTER
2012 Caterpillar, All Rights Reserved Printed in U.S.A.
SWITCH GP - FILTER BYPASS (VOL. 3) 164-7577 120 G-13
SWITCH GP - FILTER BYPASS (VOL. 3) 164-7577 121 I-12
TANK GP - HYDRAULIC (VOL. 3) 280-2090 65 B-6
VALVE - CHECK (VOL. 3) 123-4750 48 F-7
VALVE - CHECK (VOL. 3) 123-4750 49 G-8
VALVE - CHECK (VOL. 3) 123-4750 50 C-4
VALVE GP - RELIEF (VOL. 3) 346-4815 68 C-7 Hoist Screens - Internal
VALVE GP - CONT (VOL. 3) 293-4974 18 H-4 FLUID POWER SYMBOLS
VALVE GP - DIVERTER (VOL. 3) 168-7859 110 H-12 BASIC COMPONENT SYMBOLS
VALVE GP - MANUAL BYPASS CONTROL (VOL. 3) 336-0978 127 C-13 32 MAIN AUX

VALVE GP - RELIEF (VOL. 3) 172-5381 106 G-13


16 PUMP OR MOTOR FLUID CONDITIONER SPRING CONTROL VALVES RESTRICTION LINE RESTRICTION
(FIXED)
PUMP
(2 - SECTION)
PUMP
(VARIABLE & PRESSURE
COMPENSATED)

TAP LOCATIONS (VOL. 3) VARIABILITY SPRING


(ADJUSTABLE)
LINE RESTRICTION
(VARIABLE)
PRESSURE
COMPENSATION
HYDRAULIC PNEUMATIC
ENERGY TRIANGLES
LINE RESTRICTION
(VARIABLE & PRESSURE
ATTACHMENT

COMPENSATED)
Machine Schematic
Description
Location Location TANK 23
VALVE ENVELOPES VALVES VALVE PORTS

BRAKE ACCUMULATOR C F-9


BRAKE ACCUMULATOR D F-6
BRAKE CHARGE PRESSURE K B-9 ONE POSITION TWO POSITION THREE POSITION TWO - WAY THREE - WAY FOUR - WAY

BRAKE PEDAL E E-6 CONTROL VALVES CHECK VALVES


BRAKE TO TANK I D-5 36 TANK AB A B

FRONT BRAKE COOLING SUPPLY Z B-5 P T P T


FRONT BRAKE SLACK ADJUSTER B H-1 BASIC SPRING SHUTTLE PILOT

HOIST CYLINDER HEAD END PRESSURE LL H-4 34 NORMAL POSITION SHIFTED POSITION INFINITE POSITION
SYMBOL LOADED CONTROLLED

FLUID STORAGE RESERVOIRS


FF J-4
HOIST CYLINDER ROD END PRESSURE
HOIST PUMP DISCHARGE/BRAKE COOLING SUPPLY PP I-5
16
LEFT BRAKE PRESSURE BB J-8 Service Brake Check Valve
LEFT FRONT BRAKE COOLING OUT S J-2 VENTED PRESSURIZED RETURN ABOVE FLUID LEVEL RETURN BELOW FLUID LEVEL

LEFT FRONT BRAKE COOLING OUT T J-1 Pressure Reducing Valve SERVICE BRAKE CONTROL VALVE MEASUREMENT ROTATING SHAFTS
LEFT FRONT SERVICE BRAKE N I-4
Q J-10
LEFT REAR BRAKE COOLING IN
LEFT REAR PARK BRAKE G J-10 18 38 Front Brake Relay Valve
PRESSURE TEMPERATURE FLOW UNIDIRECTIONAL BIDIRECTIONAL

LEFT REAR SERVICE BRAKE M I-11 COMBINATION CONTROLS


PILOT OIL BYPASS (to Front Brake Cooling) DD J-7 Rear Brake Relay Valve
PILOT OIL BYPASS (to Rear Brake Cooling) EE I-6 PP Unloader Solenoid
PILOT PRESSURE - HEAD END to TANK (Lower) KK H-5
PILOT PRESSURE - PUMP to HEAD END (Raise) JJ I-5
EE DD Unloader Diverter Valve
Parking Brake Check Valve
SOLENOID SOLENOID
OR MANUAL
SOLENOID
& PILOT
SOLENOID &
PILOT OR MANUAL
SERVO THERMAL DETENT

PILOT PRESSURE - PUMP to ROD END (Lower) HH I-5 Parking Brake Relay Valve LEFT SIDE MANUAL CONTROL SYMBOLS
Screen
PILOT PRESSURE - ROD END to TANK (Raise) GG J-4
RAXL DRIVE PUMP PRESSURE J D-12
REAR BRAKE COOLING SUPPLY AA B-5 Front Brake PUSH - PULL LEVER MANUAL SHUTOFF GENERAL MANUAL PUSH BUTTON PEDAL SPRING
REAR BRAKE SLACK ADJUSTER A H-11 ARC Solenoid Rear Brake
RIGHT BRAKE PRESSURE CC I-8 ARC Solenoid RELEASED PRESSURE PILOT CONTROL SYMBOLS REMOTE SUPPLY PRESSURE

RIGHT FRONT BRAKE COOLING IN U F-2 BACK FRONT


RIGHT FRONT BRAKE COOLING OUT V F-1
RIGHT FRONT SERVICE BRAKE O G-1 EXTERNAL RETURN INTERNAL RETURN SIMPLIFIED COMPLETE INTERNAL
SUPPLY PRESSURE
RIGHT REAR BRAKE COOLING IN R F-10 Accumulator ACCUMULATORS CROSSING & JOINING LINES HYDRAULIC & PNEUMATIC CYLINDERS
RIGHT REAR PARK BRAKE F F-10 Purge Solenoid
RIGHT REAR SERVICE BRAKE L G-11 LL Parking Brake 20
TCS PILOT H H-7 FF KK JJ HH GG Solenoid SPRING LOADED GAS CHARGED LINES CROSSING LINES JOINING SINGLE ACTING DOUBLE ACTING

HYDRAULIC PUMPS HYDRAULIC MOTORS INTERNAL PASSAGEWAYS

FIXED VARIABLE DISPLACEMENT FIXED VARIABLE DISPLACEMENT INFINITE


Rear Service Brake RIGHT SIDE DISPLACEMENT NON-COMPENSATED DISPLACEMENT NON-COMPENSATED POSITIONING 3 POSITION 2 POSITION

Shuttle Valve Front Service Brake


Shuttle Valve
63 UNIDIRECTIONAL UNIDIRECTIONAL
Relief Valve
FLOW IN ONE PARALLEL CROSS FLOW IN
BIDIRECTIONAL BIDIRECTIONAL DIRECTION FLOW FLOW EITHER

CHASSIS VIEW BRAKE COOLING DRIVE BRAKE COOLING SCREENS DIRECTION

BRAKE CHASSIS VALVE

ELECTRICAL SYMBOLS TABLE


HYDRAULIC SYMBOLS (ELECTRICAL)

93 G
M
87 REAR
86 FRONT
Brake Actuation TRANSDUCER TRANSDUCER GENERATOR ELECTRIC MOTOR
Section Filler Tube (FLUID) (GAS / AIR)

Brake Actuation
Section PRESSURE SWITCH PRESSURE SWITCH TEMPERATURE ELECTRICAL WIRE

132
97 (ADJUSTABLE) SWITCH

Z Return Screens
ELECTRICAL SYMBOLS (ELECTRICAL)

F Hoist and Brake


Cooling Section

LEFT FRONT REAR AA R Brake Cooling T


136 Relief Valve
PRESSURE TEMPERATURE LEVEL FLOW
SWITCH SWITCH SWITCH SWITCH

132 VIEW A
WIRE NUMBER IDENTIFICATION CODES

ELECTRICAL SCHEMATIC EXAMPLE HYDRAULIC SCHEMATIC EXAMPLE


CURRENT STANDARD CURRENT STANDARD

HARNESS IDENTIFICATION CODE THIS EXAMPLE


VIEW A INDICATES WIRE 135 IN HARNESS AG
WIRE

CIRCUIT NUMBER
92 Hoist Valve Port
325-AG135 PK-14 IDENTIFICATION WIRE COLOR

Hoist Oil Port CIRCUIT NUMBER WIRE WIRE GAUGE


Rear Brake Cooling Pump IDENTIFICATION COLOR 325-PK

PREVIOUS STANDARD
Front Pumps
WIRE WIRE COLOR

325-PK-14 B A

CIRCUIT NUMBER WIRE GAUGE (EXAMPLE VALVE)


RIGHT FRONT IDENTIFICATION

BRAKE TEMPERATURE SENSORS TANK


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

LEFT REAR (78) SENSOR GPPRESS


(90) SENSOR GP 2213410
TEMP: 1342252 PUMP BYPASS SECTION P2 HOIST SECTION
LEFT FRONT
KENR8379-03 VOL 3 of 3

J LEFT WHEELGP & FD FF J


CYLINDER ROD END
TO TANK (RAISE)
(Dimensions: 48 inches x 35 inches)

BYPASS TO FRONT
(101) SWITCH AS (112) CORE AS BRAKE COOLING GG
PRESSURE: 1307459 2993290
P L
LEFT BRAKE PRESSURE

PUMP TO CYLINDER
ROD END (LOWER)

(121) SWITCH GP
FILTER BYPASS
(89) SENSOR GP
1647577 D HH TEMP: 1342252
(16) CYL GPTEL
(30) CONTROL GPHYD 2898616
2224744
(116) FILTER GP
TRANS: 3340572
I BYPASS TO REAR
I
BRAKE COOLING PUMP TO CYLINDER
HEAD END (RAISE)

(114) PLUG AS
2427114
(40) ADJUSTER GP R RIGHT BRAKE PRESSURE
TCS JJ (41) ADJUSTER GP
(110) VALVE GP DIVERTER 2050560 2050560
1687859

(103) SENSOR GP
TEMP: 2888390 PILOT
36 Page,

ON/OFF (82) CORE AS


FRONT REAR
BRAKE COOLER
KK 2850255
(79) SENSOR GPPRESS
2213410
CYLINDER HEAD END
TO TANK (LOWER)
(24) FILTER GPOIL
H 3399703 H
B
LL

(106) VALVE GP
RELIEF: 1725381 HOIST PILOT DRAIN
FROM FILTER

BANJOHOUSING
OIL SUMP
(104) SENSOR GP (18) VALVE GPCONT
PRESS: 2213415 2934974
(120) SWITCH GP
FILTER BYPASS
1647577

(49) VALVECHECK
G 1234750 G

(117) FILTER GP
TRANS: 3340572
BRAKE
CONTROL (26) ACCUM GP
(48) VALVECHECK (88) SENSOR GP
MODULE 2860796 (72) SENSOR GP 1234750 TEMP: 1342252
(91) SENSOR GP PRESS 2213405
TEMP: 1342252 (74) SENSOR GPPRESS
(28) ACCUMULATOR GP 2213405 O
2860796

(108) SCREEN AS
1726104 ACC1 PS1 SUPPLY PS2 TCS HOIST BCD ACC2
RV1

SQ1 SV3
(98) SCREEN AS
9P9555
LE1 PS3
(34) CONT GPBRAKE
F 3215086
F
T2
SV2
PR2

PR1 FL1
RIGHT FRONT
RIGHT REAR
CV1 CV2
TSB
P A

T T1 T
HF1 PD2 HF2 PD3 PLUG HF3
PD1 SV1

1
PS5 SH1 SH2

E RIGHT WHEELGP & FD FSB


E
PB R PS4 F

POWER TRAIN (32) VALVE GPMTG


2855630
(8) CONNECTOR AS
3116676
(9) CONNECTOR AS
3116676
(REAR AXLE)
(38) PUMP GP REAR AXLE LUBE
3242716
(73) SENSOR GP
J PRESS 2213405

(128) CYLINDER GP BASIC 3393275

D D
RAISE
LOWER

(47) FILTER
(50) VALVECHECK
HYDRAULIC
1234750
4T6788
(67) VALVE GP MANUAL (36) MOTOR GP P
BYPASS CONTROL: 3360978 REAR AXLE LUBE
2 1 2965306 S (12) PUMP GPELEC DR
5T1060
(68) VALVE GPMTG
3464815
M
(130) ORIFICE (20) SCREEN GP
1722395
C T F C
(124) MANIFOLD GP
POWER ACCESS
LINE RELIEF: 3360981

TO CYLINDER TO CYLINDER
HEAD END ROD END (23) PUMP GP
2818288
(66) MOTOR GP
C2 C1 REAR AXLE FAN (83) CORE AS FRONT REAR HYDRAULIC CIRCUIT COLOR DESCRIPTIONS
2576844 BRAKE COOLER 2850255 PILOT PUMP OUTPUT
POWER ACCESS
(95) SWITCH AS PUMP GP - HOIST CIRCUIT
1728660 SUPPLY LINE
BRAKE ADJUSTER CUIRCUIT
MOTOR GP - REAR AXLE LUBE CIRCUIT
DRAIN / RETURN LINE
PUMP GP - REAR AXLE LUBE CIRCUIT
(132) SCREEN GP PUMP GP - BRAKE CHARGE CIRCUIT
B BRAKE COOLER BRAKE COOLING B
ELECTRICAL CIRCUITS

LINE PATTERNS
PUMP
Pressure Line
DRIVE
Pilot / Load Sensing Pressure
BOX Drain / Return Lines
(65) TANK GP HYD 1435
2802090
(61) PUMP GP (136) MOTOR GP Component Group
M BRAKE CHARGE BRAKE COOLING
CALLOUTS
3149248 PUMP DRIVE
BB
1711881 YY Taps (Pressure, Sampling, Sensor - by letter)
See Volume 1
A-2 Callout Number Component
FILL (Machine Location from
Component LocationsTable)
(52) VALVE GP - CONTROL Name

138-1234 Part Number


TUBE (63) PUMP GP BRAKE COOLING
2818284

A THIS SCHEMATIC IS FOR THE 797F OFF-HIGHWAY TRUCK HYDRAULIC AND A


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: -
POWER ACCESS 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 9 8 7 6 5 4 3 2 1

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