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7 9 3 C O F F - H I G H WAY T R U C K

1997 Caterpillar Inc.

793C MAINTENANCE
ice 793C Serv Procedure

WALK AROUND INSPECTION

SERVICE LAMP VIMS RS-232 PORT

GAUGE CLUSTER MODULE

SPEEDOMETER/ TACHOMETER MODULE

MESSAGE CENTER MODULE

KEYPAD MODULE

SERVICE KEYSWITCH

12 VIMS SERVICE TOOL AND SOFTWARE DISPLAY DATA LINK

MPH km/h

3F ELECTRONIC TECHNICIAN/ECAP KEYPAD DATA LINK CAT DATA LINK

VIMS

MAIN MODULE

VIMS INTERFACE MODULE

VIMS INTERFACE MODULE

ADEM II CONTROL ACTION ALARM

ACTION LAMP CAT DATA LINK SENSORS SENSORS SENSORS

VITAL INFORMATION MANAGEMENT SYSTEM (VIMS)

AUTO RETARDER CONTROL

TRANSMISSION CONTROL

ADEM II CONTROL MODULE ELECTRONIC UNIT INJECTORS

3516B ELECTRONIC CONTROL SYSTEM COMPONENT DIAGRAM


GROUND BOLT 15 AMP BREAKER DISCONNECT SWITCH
24 V

MAIN KEY START POWER RELAY SWITCH

THROTTLE TIMING PROBE CONNECTOR OIL LEVEL SWITCH (ADD)

ENGINE COOLANT TEMPERATURE REAR AFTERCOOLER TEMPERATURE

SPEED/TIMING SENSOR OIL LEVEL SWITCH (LOW) ENGINE OIL PRESSURE (UNFILTERED) ETHER SOLENOID

ENGINE OIL PRESSURE (FILTERED)

ATMOSPHERIC PRESSURE MANUAL ETHER SWITCH THROTTLE OVERRIDE SWITCH GROUND LEVEL SHUTDOWN SWITCH FUEL FILTER SWITCH LEFT TURBO INLET PRESSURE CRANKCASE PRESSURE A/C PRESSURE SWITCH EXHAUST WASTEGATE SOLENOID CAT DATA LINK SERVICE TOOL EPTC II ARC VIMS

TURBO OUTLET PRESSURE (BOOST)

RIGHT TURBO INLET PRESSURE

RIGHT TURBO EXHAUST LEFT TURBO EXHAUST FAN CLUTCH SOLENOID FAN FAN SPEED SENSOR

ENGINE OIL RENEWAL SOLENOID

SHUTTER SOLENOID PRE-LUBRICATION RELAY COOLANT FLOW SWITCH

3516B IMPROVEMENTS
INPUT SWITCHES AND SENSORS COOLANT FLOW REAR AFTERCOOLER TEMPERATURE ENGINE OIL LEVEL TURBOCHARGER TEMPERATURE ENGINE OIL FILTER PRESSURE/RESTRICTION ENGINE FAN SPEED FUEL FILTER RESTRICTION AIR CONDITIONER COMPRESSOR PRESSURE CRANKCASE PRESSURE

3516B IMPROVEMENTS
PREVIOUS LOGGED EVENTS AIR FILTER RESTRICTION LOW OIL PRESSURE HIGH COOLANT TEMPERATURE ENGINE OVERSPEED

3516B IMPROVEMENTS
ADDITIONAL LOGGED EVENTS

OIL FILTER RESTRICTION FUEL FILTER RESTRICTION HIGH EXHAUST TEMPERATURE HIGH AFTERCOOLER TEMPERATURE ENGINE OIL LEVEL LOW

HIGH CRANKCASE PRESSURE LOW COOLANT FLOW USER DEFINED SHUTDOWN LOW BOOST PRESSURE HIGH BOOST PRESSURE

3516B IMPROVEMENTS
SYSTEMS CONTROLLED BY ECM

ETHER INJECTION RADIATOR SHUTTER CONTROL COLD CYLINDER CUTOUT ENGINE START FUNCTION ENGINE OIL PRE-LUBRICATION VARIABLE SPEED FAN CONTROL ENGINE OIL RENEWAL SYSTEM EXHAUST BYPASS AT HIGH BOOST

JACKET WATER COOLANT FLOW

THERMOSTAT HOUSING

SHUNT TANK

ENGINE BLOCK

RADIATOR

ENGINE OIL COOLER

TORQUE CONVERTER/ TRANSMISSION OIL COOLER REAR BRAKE OIL COOLERS

JACKET WATER PUMP

AFTERCOOLER COOLANT FLOW


SHUNT TANK AFTERCOOLER FRONT BRAKE OIL COOLER

RADIATOR

AFTERCOOLER WATER PUMP

ENGINE OIL SYSTEM


ENGINE BLOCK ENGINE OIL RENEWAL SYSTEM SOLENOID

TO FUEL SYSTEM

SCAVENGE PUMP

BYPASS VALVE ENGINE OIL FILTERS ENGINE OIL COOLER ENGINE OIL PUMP

FUEL SYSTEM
FUEL PRESSURE REGULATOR ENGINE OIL RENEWAL SYSTEM SOLENOID ENGINE BLOCK CYLINDER HEAD

SECONDARY FUEL FILTERS

FUEL TANK

PRIMARY FUEL FILTER

FUEL TRANSFER PUMP

ADEM II CONTROL

FUEL HEATER

EXHAUST SYSTEM
WASTEGATE SOLENOID VALVE FROM BRAKE AIR SYSTEM EXHAUST BYPASS VALVE MUFFLER

PRESSURE REDUCING VALVE

HIGH PRESSURE TURBOCHARGER

AFTERCOOLER

FROM AIR FILTER LOW PRESSURE TURBOCHARGER

POWER TRAIN
793C

LOCKUP PISTON

TURBINE

IMPELLER

TORQUE CONVERTER
STATOR

CONVERTER DRIVE

TORQUE CONVERTER INLET OIL

FREEWHEEL ASSEMBLY

TORQUE CONVERTER LOCKUP OIL PASSAGE

LOCKUP PISTON

TURBINE

IMPELLER

TORQUE CONVERTER
DIRECT DRIVE
STATOR
TORQUE CONVERTER INLET OIL

STATOR

FREEWHEEL ASSEMBLY

TORQUE CONVERTER LOCKUP OIL PASSAGE

POWER SHIFT PLANETARY TRANSMISSION

3 4 5 6

REAR AXLE OIL COOLING AND FILTER SYSTEM


OIL COOLER FLOW CONTROL VALVE TEMPERATURE/ PRESSURE CONTROL VALVE OIL FILTER

DIFFERENTIAL OIL PUMP

REAR AXLE

SUCTION SCREEN

FIRST REDUCTION RING GEAR

SECOND REDUCTION RING GEAR

SECOND REDUCTION CARRIER SECOND REDUCTION PLANETARY GEAR

FINAL DRIVE
SECOND REDUCTION SUN GEAR

FIRST REDUCTION SUN GEAR

FIRST REDUCTION CARRIER

FIRST REDUCTION PLANETARY GEAR

TORQUE CONVERTER LOCKUP CLUTCH CONTROL


DIRECT DRIVE
LOCKUP CLUTCH PILOT OIL PRESSURE SELECTOR PISTON LOCKUP MODULATION VALVE

LOCKUP SOLENOID

TO TRANSMISSION LUBE PUMP

TO LOCKUP CLUTCH LOCKUP REDUCING VALVE

ON

FROM TRANSMISSION CHARGE PUMP

TO STATION "D"

SHUTTLE VALVE RELAY VALVE FROM TRANSMISSION CHARGE PUMP

TRANSMISSION ICM HYDRAULIC SYSTEM


LOCKUP SOLENOID DOWNSHIFT UPSHIFT SOLENOID SOLENOID

UPSHIFT PRESSURE

DOWNSHIFT PRESSURE

ROTARY ACTUATOR

ON 3

E
N1

TO TORQUE CONVERTER RELAY VALVE PILOT OIL PRESSURE TRANSMISSION CHARGING FILTER PUMP PRESSURE

NEUTRALIZER VALVE PRIORITY REDUCTION VALVE

ROTARY SELECTOR SPOOL

F C
OIL COOLER

CHARGING PUMP

LUBE PUMP

SCAVENGE PUMP

G
COOLER BYPASS VALVE LUBE PRESSURE LOCKUP DUAL STAGE RELIEF VALVE

D H

RELIEF VALVE

SELECTOR VALVE GROUP

PRESSURE CONTROL GROUP

TORQUE CONVERTER HOUSING

TRANSMISSION CASE

LUBRICATION RELIEF VALVE

TC LOCKUP VALVE

TORQUE CONVERTER AND TRANSMISSION HYDRAULIC SYSTEM


TORQUE CONVERTER/ TRANSMISSION COOLER

TC CHARGING FILTER TRANSMISSION CHARGING FILTER

TC OUTLET RELIEF VALVE

TC LOCKUP VALVE

TC/TRANS PUMPS TC OUTLET SCREEN

TC INLET RELIEF VALVE

TRANSMISSION MAGNETIC SCREENS

RETURN SCREEN SUCTION SCREEN

RETURN SCREEN

711 - BR

A11 A12 A13 A14 A15 A16 A6


D1 10 D2 D3

SHIFT LEVER SWITCH

712 - WH 713 - OR 714 - YL 715 - GN 716 - BU

A17 A18 A19 A36 A37

217 - BK 218- BK 219 - BK 280 - BK 227 - BK

MACHINE ID CODE

EPTC II
A31 A32
2 13

SERVICE/ RETARDER BRAKE SECONDARY BRAKE HOIST LEVER BODY UP KEY START SWITCH ENGINE SPEED CONVERTER SPEED SERVICE "SET" AND "CLEAR" SWITCHES

706 - BR

G714 - PU G711 - BR

RAISE SOLENOID FLOAT SOLENOID LOWER SOLENOID

720 - PU 707 - PU E750 - PU 307 - OR 450 - YL

A20 A28 A27 B5

11

12

A33

G712- GN

B1

306 - GN

STARTER SOLENOID

B2 A29 B9 B10

321- BR

BACK-UP ALARM RELAY DATA LINK

452- PU D996 - PU D997 - YL

A30 B6 B7 A9 A10 709 - OR 710 - GN A21 A22 A23 A24 A25 A26
721 - BR

893 - GN 892 - BR

A3 A4 A5 703 - BU 704 - GY 705 - PK

722 - WH

723 - OR

725 - GN

724 - YL

726 - BU

A - 37 PIN CONNECTOR B - 10 PIN SURE-SEAL CONNECTOR

TOS

TRANSMISSION GEAR SWITCH TRANSMISSION

UP, DOWN, LOCKUP SOLENOIDS

EPTC II DIAGNOSTIC WINDOW


D1 10 11 12 2 13 D2 D3

STEERING
793C

STEERING PUMP
DURING CHARGING (CUT-IN)
CUT-OUT VALVE CUT-IN VALVE ACCUMULATOR CHARGING VALVE PUMP OUTPUT HIGH PRESSURE CUTOFF VALVE ACTUATOR PISTON LOAD SENSING PRESSURE FROM ACCUMULATORS

TO ACCUMULATORS

FLOW COMPENSATOR LOAD SENSING CONTROLLER SWASHPLATE PISTON

STEERING PUMP
LOW PRESSURE STANDBY (CUT-OUT)
CUT-OUT VALVE CUT-IN VALVE ACCUMULATOR CHARGING VALVE PUMP OUTPUT ACTUATOR PISTON FROM ACCUMULATORS

TO ACCUMULATORS

HIGH PRESSURE CUTOFF VALVE

LOAD SENSING PRESSURE

FLOW COMPENSATOR LOAD SENSING CONTROLLER SWASHPLATE PISTON

ACCUMULATOR CHARGE VALVE


DURING CHARGING (CUT-IN)
FROM PUMP TO TANK FEEDBACK ORIFICE TO PUMP CONTROL SIGNAL PORT

CUT-OUT VALVE

FROM ACCUMULATOR

CUT-IN VALVE

ACCUMULATOR CHARGE VALVE


LOW PRESSURE STANDBY (CUT-OUT)
FROM PUMP TO TANK TO PUMP CONTROL SIGNAL PORT FEEDBACK ORIFICE

CUT-OUT VALVE

FROM ACCUMULATOR

CUT-IN VALVE

ACCUMULATOR CHARGE VALVE


LOW PRESSURE STANDBY (CUT-OUT)
FROM PUMP TO TANK TO PUMP CONTROL SIGNAL PORT FEEDBACK ORIFICE

CUT-OUT VALVE

FROM ACCUMULATOR

CUT-IN VALVE

ACCUMULATOR CHARGE VALVE


BEGINNING STAGE OF CUT-IN
FROM PUMP TO TANK FEEDBACK ORIFICE TO PUMP CONTROL SIGNAL PORT

CUT-OUT VALVE

FROM ACCUMULATOR

CUT-IN VALVE

SOLENOID AND RELIEF VALVE MANIFOLD


SUPPLY FROM PUMP AND ACCUMULATORS

TO TANK

BLEED DOWN SOLENOID BACK-UP RELIEF VALVE

STEERING DIRECTIONAL VALVE


NO TURN
RELIEF/MAKEUP VALVE LEFT TURN CYLINDER TO TANK RIGHT TURN CYLINDER BACK PRESSURE VALVE RELIEF/MAKEUP VALVE

RIGHT TURN PILOT OIL COMBINER/CHECK SPOOL

LEFT TURN PILOT OIL

AMPLIFIER SPOOL

PRIORITY SPOOL LOAD SENSING PORT FROM ACCUMULATOR

HAND METERING UNIT SUPPLY AND THERMAL BLEED

STEERING DIRECTIONAL VALVE


RIGHT TURN
LEFT TURN CYLINDER RELIEF/MAKEUP VALVE RELIEF/MAKEUP VALVE TO TANK RIGHT TURN CYLINDER BACK PRESSURE VALVE

RIGHT TURN PILOT OIL COMBINER/CHECK SPOOL

LEFT TURN PILOT OIL

AMPLIFIER SPOOL

PRIORITY SPOOL LOAD SENSING PORT FROM ACCUMULATOR HAND METERING UNIT SUPPLY AND THERMAL BLEED

HAND METERING UNIT


NEUTRAL POSITION

P
STATOR METERING SECTION

CONTROL SECTION CENTERING SPRINGS

ROTOR SPOOL

PIN

DRIVE

SLEEVE

THERMAL BLEED PASSAGES

HAND METERING UNIT


RIGHT TURN

P
STATOR METERING SECTION

CONTROL SECTION CENTERING SPRINGS

ROTOR SPOOL

PIN

DRIVE

SLEEVE

HOIST SYSTEM
793C

PARKING BRAKE RELEASE PRESSURE RAISE SOLENOID

793C HOIST CONTROL VALVE


HOLD
TO TANK FRONT BRAKE OIL COOLER RELIEF VALVE TO HOIST CYLINDER HEAD END

LOAD CHECK VALVE

TO HOIST CYLINDER ROD END LOW PRESSURE RELIEF VALVE HIGH PRESSURE RELIEF VALVE DUAL STAGE RELIEF VALVE SIGNAL STEM COUNTERBALANCE VALVE ROD END VENT SLOT TO FRONT BRAKE OIL COOLERS PUMP SUPPLY PORT LOWER SOLENOID PARKING BRAKE RELEASE PRESSURE FLOAT SOLENOID

PARKING BRAKE RELEASE PRESSURE RAISE SOLENOID


ON

793C HOIST CONTROL VALVE


RAISE
TO TANK FRONT BRAKE OIL COOLER RELIEF VALVE TO HOIST CYLINDER HEAD END

LOAD CHECK VALVE

FROM HOIST CYLINDER ROD END LOW PRESSURE RELIEF VALVE HIGH PRESSURE RELIEF VALVE DUAL STAGE RELIEF VALVE SIGNAL STEM COUNTERBALANCE VALVE ROD END VENT SLOT TO FRONT BRAKE OIL COOLERS PUMP SUPPLY PORT LOWER SOLENOID PARKING BRAKE RELEASE PRESSURE FLOAT SOLENOID

HOIST COUNTERBALANCE VALVE

HEAD END SIGNAL PRESSURE

TO FRONT BRAKE OIL COOLER

FROM PUMP

FROM HOIST CYLINDER ROD END

TO HOIST CYLINDER ROD END

RAISE POSITION

LOWER AND FLOAT POSITIONS

PARKING BRAKE RELEASE PRESSURE RAISE SOLENOID

793C HOIST CONTROL VALVE


LOWER (POWER DOWN)
TO TANK

FRONT BRAKE OIL COOLER RELIEF VALVE FROM HOIST CYLINDER HEAD END

LOAD CHECK VALVE

TO HOIST CYLINDER ROD END LOW PRESSURE RELIEF VALVE HIGH PRESSURE RELIEF VALVE DUAL STAGE RELIEF VALVE SIGNAL STEM COUNTERBALANCE VALVE ROD END VENT SLOT TO FRONT BRAKE OIL COOLERS PUMP SUPPLY PORT LOWER SOLENOID PARKING BRAKE RELEASE PRESSURE FLOAT SOLENOID
ON ON

PARKING BRAKE RELEASE PRESSURE RAISE SOLENOID

793C HOIST CONTROL VALVE


FLOAT
TO TANK FRONT BRAKE OIL COOLER RELIEF VALVE

LOAD CHECK VALVE

FROM HOIST CYLINDER HEAD END

TO HOIST CYLINDER ROD END LOW PRESSURE RELIEF VALVE HIGH PRESSURE RELIEF VALVE DUAL STAGE RELIEF VALVE SIGNAL STEM COUNTERBALANCE VALVE ROD END VENT SLOT TO FRONT BRAKE OIL COOLERS PUMP SUPPLY PORT LOWER SOLENOID PARKING BRAKE RELEASE PRESSURE FLOAT SOLENOID
ON

HOIST SYSTEM
HOLD POSITION

HOIST PUMP

HOIST SCREENS

FROM PARKING BRAKE RELEASE VALVE

SUCTION SCREENS

FRONT BRAKES

FRONT BRAKE OIL COOLER

TO HOIST CYLINDER ROD END DIVERTER VALVE FRONT BRAKE OIL COOLER FILTERS

TO HOIST CYLINDER HEAD END

FROM PARKING BRAKE RELEASE VALVE

AIR SYSTEM AND BRAKES


793C

AIR CHARGING SYSTEM


AIR COMPRESSOR AND GOVERNOR AIR DRYER SERVICE/RETARDER BRAKE RESERVOIR REMOTE AIR SUPPLY CONNECTOR

PRESSURE PROTECTION VALVE

LOW AIR SWITCH

PARKING/SECONDARY BRAKE RESERVOIR

RELIEF VALVE

TOWING SYSTEM
PARKING BRAKE RELEASE VALVE

PARKING BRAKE RELEASE PUMP

TO HOIST PILOT SYSTEM

CHECK VALVE TOWING PUMP RELIEF VALVE

TOWING PUMP

PARKING/SECONDARY BRAKES
SECONDARY BRAKES RELEASED PARKING BRAKES ENGAGED

PARKING BRAKE SWITCH SECONDARY BRAKE VALVE

EPTC II SWITCH

PARKING BRAKE RELEASE PUMP

PARKING BRAKE RELEASE VALVE

PARKING/SECONDARY BRAKE RESERVOIR

TO HOIST PILOT SYSTEM

BRAKE CYLINDER
BRAKES ENGAGED
AIR PISTON INDICATOR ROD FROM MAKEUP TANK OIL PISTON

AIR INLET

TO SLACK ADJUSTER VALVE SPRING ROD

BRAKE SLACK ADJUSTER

OIL FLOW TO BRAKE CYLINDER

SMALL PISTON LARGE PISTON

OIL FLOW FROM BRAKE CYLINDER

FROM WHEEL BRAKES

FROM WHEEL BRAKES TO WHEEL BRAKES

TO WHEEL BRAKES

BRAKES RELEASED

BRAKES ENGAGED

SERVICE/RETARDER BRAKE AIR SYSTEM


SERVICE BRAKE ENGAGED

FRONT BRAKE OIL COOLER DIVERTER VALVE

SERVICE RELAY VALVE

ARC RELAY VALVE

SERVICE BRAKE VALVE

RETARDER VALVE

BRAKE ENGAGED SWITCH

ARC VALVE

BRAKE CYLINDERS

TO FRONT BRAKES

REAR BRAKE COOLING CIRCUIT

PARKING BRAKE RELEASE VALVE

TRACTION CONTROL SYSTEM (TCS) VALVE

PARKING BRAKE RELEASE FILTER

TO REAR BRAKES

HOIST VALVE

REAR BRAKE OIL COOLERS

PARKING BRAKE RELEASE PUMP

BRAKE COOLING PUMPS

REAR BRAKES

PUMP DRIVE SUCTION SCREENS

OIL COOLER RELIEF VALVES

ENGINE SPEED SENSOR ENGINE SPEED


A10

HARNESS CODE INPUTS


A17-19 36,37

HARNESS CODE PLUG BRAKE ENGAGED LAMP

SERVICE INPUTS SET CLEAR ARC ON/OFF SWITCH ON INPUT


A11 B6 B7

AUTOMATIC RETARDER CONTROL (ARC)

DATA LINK
B9 B10 A5 A21

BRAKE ENGAGED LAMP OUTPUT BRAKE ENGAGED PRESSURE INPUT AUTO RETARDER PRESSURE INPUT

A16 A3

CONTROL OUTPUT SUPPLY OUTPUT SUPPLY SOLENOID VENT VENT CONTROL SOLENOID

OFF INPUT
A26

Diagnostic Display

A4

AIR FROM SERVICE BRAKE RESERVOIR

BRAKE PEDAL AND VALVE

RETARDER LEVER AND VALVE

AUTOMATIC RETARDER VALVE AUTO RETARDER PRESSURE SWITCH BRAKE ENGAGED SWITCH

TO SERVICE BRAKE RELAY VALVE


A - 37 PIN CONNECTOR B - 10 PIN SURE-SEAL CONNECTOR

TO FRONT BRAKE OIL COOLER DIVERTER VALVE

TO ARC RELAY VALVE

ARC DIAGNOSTIC WINDOW

1 10 8

7 11 12 13

D1

D2

D3

BATTERY + BATTERY TRANSMISSION SPEED LEFT WHEEL SPEED RIGHT WHEEL SPEED

132- PK 255 - BK

A1 A2

A3

774 - YL

SELECTOR SOLENOID - LEFT SELECTOR SOLENOID - RIGHT PROPORTIONAL SOLENOID

768 - OR

A10

A4

775 - BR

769 - BU

A29

TCS
A5 773 - GY

770 - GN

A30
D1 2 D2 D3

214 - BK

A17 A18 A19 A36

3 4

13 12

A9

767 - WH

+V TO BRAKE SWITCH AND WHEEL SENSORS

MACHINE HARNESS CODES

213- BK 212 - BK 216 - BK 215 - BK

10

11

A37

SERVICE/RETARDER BRAKE SWITCH TEST SWITCH

772 - BR

B1

B9 B10

893 - GN 892 - BR

DATA LINK (NOT USED)

700 - PK

B2

A - 37 PIN CE CONNECTOR B - 10 PIN SURE-SEAL CONNECTOR

TCS DIAGNOSTIC WINDOW


D1 2 3 4 13 12 D2 D3

10

11

TRACTION CONTROL SYSTEM (TCS)


ENGINE RUNNING/BRAKES RELEASED
TEST SWITCH

BRAKE SWITCH

LEFT DRIVE AXLE

SPEED DISTRIBUTOR

BALL CHECK

INPUT SIGNALS OUTPUT SIGNALS

ORIFICE

TRANSMISSION SPEED SENSOR

SCREEN SELECTOR SOLENOID PARKING BRAKE VALVE RIGHT DRIVE AXLE PROPORTIONAL SOLENOID

TRACTION CONTROL SYSTEM (TCS)


ENGINE RUNNING/LEFT BRAKE ENGAGED
TEST SWITCH

BRAKE SWITCH

LEFT DRIVE AXLE

SPEED DISTRIBUTOR

BALL CHECK

INPUT SIGNALS OUTPUT SIGNALS

ORIFICE

TRANSMISSION SPEED SENSOR

SCREEN SELECTOR SOLENOID PARKING BRAKE VALVE RIGHT DRIVE AXLE PROPORTIONAL SOLENOID