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KENR8379-01

February 2010
COMPONENT LOCATIONS

Description Part Number


Machine
Location
Schematic
Location 64 58 7
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
Steering and 1

KENR8379-01 VOL 1
FILTER GP - CASE DRAIN (VOL. 1) 290-2569 2 E-3
Fan Pump
B-8 6

(Dimensions: 48 inches x 35 inches)


FILTER GP - OIL (VOL. 1) 290-2569 3
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
PUMP GP - METERING (VOL. 1) 192-3897 4 H-7
PUMP GP - STEERING and FAN (VOL. 1) 301-4678 54 C-9
PUMP GP - STEERING and FAN (VOL. 1) 284-9631 60 C-9
UU
SENSOR GP - PRESSURE (VOL. 1) 221-3405 71 J-12
SENSOR GP - SPEED (VOL. 1) 186-0131 70 H-9
SENSOR GP - SPEED (VOL. 1) 163-0265 97 A-3
C-3 ACCUMULATOR PRESSURE

797F Off-Highway Truck


SENSOR GP - TEMP (VOL. 1) 134-2252 85
SENSOR
SWITCH AS - STEERING OIL LEVEL (VOL. 1) 172-8660 94 C-3
D-4 6
Hydraulic and Power Train System
TANK GP - HYDRAULIC (SEE NOTE) (VOL. 1)* 280-1634 58
TANK GP - HYDRAULIC (SEE NOTE) (VOL. 1)* 280-2090 64 D-4
X
G-12
VALVE GP - MAKE UP (FAN ANTI-CAV) (VOL. 1)
VALVE GP - PRESSURE REDUCING (VOL. 1)
183-7170
226-0835
45
44 H-14 RR 71
LAJ1-UP
VALVE GP - SOL (VOL. 1) 288-4351 6 H-11
Steering Pump Fan Pump
VALVE GP - STEERING (VOL. 1) 151-5933 1 I-3

UU

36 Page,
TAP LOCATIONS (VOL. 1)
Machine Schematic
Description
Location Location
BRAKE COOLING DRIVE PUMP PRESSURE Y E-14
RADIATOR FAN PRESSURE W G-12
STEERING ACCUMULATOR PRESSURE RR I-12
STEERING FLOW AMP X I-5
SS I-12
STEERING PUMP PRESSURE
STEERING RETURN YY H-11
YY
STEERING SUPPLY UU I-11 PRESSURE AND FLOW
COMPENSATOR VALVES

Volume 1 of 3: Steering

STEERING and FAN PUMP STEERING CONTROL VALVE and RELIEF VALVE MANIFOLD 2010 Caterpillar, All Rights Reserved Printed in U.S.A.

7 FLUID POWER SYMBOLS


15 BASIC COMPONENT SYMBOLS

MAIN AUX.
PUMP: VARIABLE and
PUMP or MOTOR FLUID CONDITIONER SPRING CONTROL VALVES RESTRICTION LINE RESTRICTION 2-SECTION PUMP PRESSURE COMPENSATED
(FIXED)

STEERING POSITION SENSOR


Sensor Head VARIABILITY SPRING LINE RESTRICTION PRESSURE HYDRAULIC PNEUMATIC LINE RESTRICTION ATTACHMENT
Magnet (ADJUSTABLE) (VARIABLE) COMPENSATION ENERGY TRIANGLES VARIABLE and PRESSURE
COMPENSATED

Cylinder - Head End VALVES


VALVE ENVELOPES VALVE PORTS

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

4 Rod AB
CONTROL VALVES
AB
CHECK VALVES

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

FLUID STORAGE RESERVOIRS

VENTED PRESSURIZED RETURN ABOVE FLUID LEVEL RETURN BELOW FLUID LEVEL

44 MEASUREMENT ROTATING SHAFTS

6 PRESSURE FLOW UNIDIRECTIONAL BIDIRECTIONAL

PRESSURE REDUCING VALVE


TEMPERATURE

64 COMBINATION CONTROLS

58 SOLENOID SOLENOID
or MANUAL
SOLENOID
and PILOT
SOLENOID and
PILOT or MANUAL
SERVO THERMAL DETENT

1 MANUAL CONTROL SYMBOLS

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

PILOT CONTROL SYMBOLS


RELEASED PRESSURE REMOTE SUPPLY PRESSURE

14 EXTERNAL RETURN

ACCUMULATORS
INTERNAL RETURN SIMPLIFIED COMPLETE INTERNAL
SUPPLY PRESSURE

CROSSING AND JOINING LINES HYDRAULIC AND 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 THREE TWO


DISPLACEMENT

60
NON-COMPENSATED DISPLACEMENT NON-COMPENSATED POSITIONING POSITION POSITION

UNIDIRECTIONAL UNIDIRECTIONAL

FLOW IN ONE PARALLEL CROSS FLOW ALLOWED IN


DIRECTION FLOW FLOW EITHER DIRECTION
BIDIRECTIONAL BIDIRECTIONAL

CHASSIS VIEW

Electrical Symbols Table


64 58 Hydraulic Symbols (Electrical)

G M
Transducer Transducer Generator Electric Motor
(Fluid) (Gas / Air)
Hydraulic Tank, Right Side

Pressure Switch Pressure Switch Temperature Switch Electrical Wire


(Adjustable)
85 Steering and
Fan Section
Electrical Symbols (Electrical)
2
T

Pressure Temperature Level Flow


Steering and 5 Symbol Symbol Symbol Symbol
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 Circuit Number


Identification
Wire Color

Lower Sight Gauge Upper Sight Gauge 325-AG135 PK-14


Screen Steering Pump Suction Port 325-PK
Circuit Identification Wire Color Wire Gauge
Number

Previous Standard
Wire Color
Wire

325-PK-14
B A
Circuit Number Wire Gauge
Identification (EXAMPLE VALVE)

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

(7) ACCUMULATOR GP-A


253-4120

(71) SENSOR GP-PRESS


J J
(Dimensions: 48 inches x 35 inches)

221-3405
KENR8379-01 VOL 1

(14) CYL GROUP - LEFT STEER


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

L
P L
RR SS PP

I
UU I

T R

LS
36 Page, Color,

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

H H
LS
STEERING POSITION
SENSOR
YY (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
HT T EF R
G G

W (15) CYL GROUP - RIGHT STEER


288-5537

F PRESSURE AND FLOW PRESSURE AND FLOW F


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

(2) FILTER GP-OIL


290-2569

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

(94) SWITCH AS
172-8660

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


134-2252

C C
(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
LINE PATTERNS
Pressure Line

Pilot / Load Sensing Pressure

Drain / Return Lines


B B
(137) MOTOR GP - Component Group
BRAKE COOLING
Part #: N/A Attachment

AA Air Line

CALLOUTS
See Volume 3 YY Taps (Pressure, Sampling,Sensor) by letter
A-5 / B-5
52 Components by number

CIRCUIT COLOR DESCRIPTIONS


BB
SUPPLY LINE
DRAIN / RETURN LINE
STEERING CIRCUIT
LOAD SENSING

( 97 ) SENSOR GP-SPEED
A 163-0265 A
797F OFF HIGHWAY TRUCK HYDRAULIC and POWER TRAIN SCHEMATIC.
STEEP GRADE (ADD'L) RETARDING AR ONLY
(STEERING SYSTEM.)

MEDIA NUMBER: KENR8379-01 (VOL. 1)


PART NUMBER: 272-3213 CHANGE: 02
Components are shown installed on a fully operable machine.

Refer to the appropriate Service Manual for Troubleshooting, Specifications.

14 13 12 11 10 9 8 7 6 5 4 3 2 1
KENR8379-01
February 2010
COMPONENT LOCATIONS
Hoist Screens - Internal
Machine Schematic
Description Part Number
Location Location

33
ACCUMULATOR GP - BRAKE PRECHARGE (VOL. 2) 286-0796 27 G-8
ACCUMULATOR GP - BRAKE PRECHARGE (VOL. 2) 286-0796 29 F-6 17
ADJUSTER GP (VOL. 2) 205-0560 42 I-11
ADJUSTER GP (VOL. 2) 205-0560 43 I-1
CONNECTOR AS - ORIFICE (VOL. 2) 311-6676 10 D-7

KENR8379-01 VOL 2
CONNECTOR AS - ORIFICE (VOL. 2) 311-6676 11 D-7
CONT GP - SERVICE BRAKE (VOL. 2) 321-5086 35 E-5
TANK
22

(Dimensions: 48 inches x 35 inches)


CONTROL GP - HYD (TRACTION CONTROL SYSTEM) (VOL. 2) 222-4744 31 I-8 TANK
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)
FILTER GP - OIL (BRAKE COOLING) (VOL. 2)
289-8616
339-9703
17
25
I-3
C-3
37 TANK
FILTER GP - BRAKE SYSTEM OIL (VOL. 2) 290-2567 134 B-9
FILTER GP - TRANS (VOL. 2) 334-0572 118 I-12
FILTER GP - TRANS (VOL. 2) 334-0572 119 G-13
17
25 84 55 56
MANIFOLD GP - POWER ACCESS LINE RELIEF (VOL. 2) 336-0981 124 C-13

797F Off-Highway Truck


Service Brake Check Valve
MOTOR GP - REAR AXLE FAN (VOL. 2) 257-6844 67 B-7
MOTOR GP - REAR AXLE LUBE (VOL. 2) 296-5306 37 D-11 Pressure Reducing Valve
ORIFICE (VOL. 2) N/A 130 C-13
134 Hydraulic and Power Train System
PLUG AS (VOL. 2)
PUMP GP - COOLING and BRAKE CHARGE (VOL. 2)
242-7114
317-2659
115
55
I-13
A-9
134 33 43 19 39 Front Brake Relay Valve
E-4
Bypass Switch LAJ1-UP
PUMP GP - ELEC DR (RELIEF VALVE) (VOL. 2) 5T-1060 13 Rear Brake Relay Valve

PP
PUMP GP - HOIST (VOL. 2) 281-8288 22 B-10
Unloader Solenoid
PUMP GP - REAR AXLE LUBE (VOL. 2) 324-2716 39 E-11 DD Unloader Diverter Valve
F-13
EE
SCREEN AS (VOL. 2) 9P-9555 99 Parking Brake Check Valve
SCREEN AS (VOL. 2) 172-6104 109 F-13 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

36 Page,
Front Brake
SENSOR GP - PARKE BRAKE PRESSURE (VOL. 2) 221-3410 81 I-8
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
Rear Service Brake
SWITCH AS - PRESSURE (VOL. 2)
SWITCH GP - FILTER BYPASS (VOL. 2)
130-7459
164-7577
102
122
I-13
G-13
27 29 42 Shuttle Valve
RIGHT SIDE
Front Service Brake
Relief Valve Shuttle Valve
SWITCH GP - FILTER BYPASS (VOL. 2) 164-7577 123 I-12 Volume 2 of 3: Shallow Grade - Braking and Cooling
TANK GP - HYDRAULIC (VOL. 2) 280-1634 59 B-5
VALVE - CHECK (VOL. 2) 123-4750 51 E-4
VALVE - CHECK (VOL. 2)
VALVE - CHECK (VOL. 2)
123-4750
123-4750
52
53
F-7
F-8
CHASSIS VIEW BRAKE CHASSIS VALVE BRAKE SYSTEM FILTER 2010 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: VARIABLE and
PUMP or MOTOR FLUID CONDITIONER SPRING CONTROL VALVES RESTRICTION LINE RESTRICTION 2-SECTION PUMP PRESSURE COMPENSATED
(FIXED)

TAP LOCATIONS (VOL. 2)


Machine Schematic
Description VARIABILITY SPRING LINE RESTRICTION PRESSURE HYDRAULIC PNEUMATIC LINE RESTRICTION ATTACHMENT
Location Location (ADJUSTABLE) (VARIABLE) COMPENSATION ENERGY TRIANGLES VARIABLE and PRESSURE
COMPENSATED

BRAKE ACCUMULATOR
BRAKE ACCUMULATOR
C
D
F-8
F-6 80 BB Accumulator(s) - VALVE ENVELOPES
VALVES
VALVE PORTS

BRAKE CHARGE PRESSURE K B-9 Brake Precharge


BRAKE COOLING P C-4
ONE POSITION TWO POSITION THREE POSITION TWO-WAY THREE-WAY FOUR-WAY
BRAKE PEDAL E D-5
BRAKE TO TANK I C-5 CONTROL VALVES CHECK VALVES
FRONT BRAKE SLACK ADJUSTER B H-1 AB AB

HOIST CYLINDER HEAD END PRESSURE LL H-4


P T
HOIST CYLINDER ROD END PRESSURE FF J-4 P T
NORMAL POSITION SHIFTED POSITION INFINITE POSITION
BASIC SPRING SHUTTLE PILOT
SYMBOL LOADED CONTROLLED
HOIST PUMP DISCHARGE/BRAKE COOLING SUPPLY PP I-5
FLUID STORAGE RESERVOIRS
LEFT BRAKE PRESSURE BB J-7
LEFT FRONT BRAKE COOLING OUT S J-2
LEFT FRONT BRAKE COOLING OUT T J-1
VENTED PRESSURIZED RETURN ABOVE FLUID LEVEL RETURN BELOW FLUID LEVEL
LEFT FRONT SERVICE BRAKE N I-2
LEFT REAR BRAKE COOLING IN Q G-2 MEASUREMENT ROTATING SHAFTS
LEFT REAR PARK BRAKE G J-10
LEFT REAR SERVICE BRAKE M I-10
PILOT OIL BYPASS (to Front Brake Cooling) DD J-6 PRESSURE TEMPERATURE FLOW UNIDIRECTIONAL BIDIRECTIONAL

PILOT OIL BYPASS (to Rear Brake Cooling) EE I-6 COMBINATION CONTROLS
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
SOLENOID SOLENOID SOLENOID SOLENOID and SERVO THERMAL DETENT
PILOT PRESSURE - ROD END to TANK (Raise) GG J-4 or MANUAL and PILOT PILOT or MANUAL

RAXL DRIVE PUMP PRESSURE J D-11 MANUAL CONTROL SYMBOLS


REAR BRAKE SLACK ADJUSTER A H-11
RIGHT BRAKE PRESSURE CC I-7
RIGHT FRONT BRAKE COOLING IN U F-2
PUSH-PULL LEVER MANUAL SHUTOFF GENERAL MANUAL PUSH BUTTON PEDAL SPRING
RIGHT FRONT BRAKE COOLING OUT V F-1
RIGHT FRONT SERVICE BRAKE O G-2 81 H CC 31 RELEASED PRESSURE
PILOT CONTROL SYMBOLS
REMOTE SUPPLY PRESSURE
RIGHT REAR PARK BRAKE
RIGHT REAR SERVICE BRAKE
F
L
F-10
G-10
35 55
TCS PILOT H T-7 EXTERNAL RETURN INTERNAL RETURN SIMPLIFIED COMPLETE INTERNAL
SUPPLY PRESSURE

ACCUMULATORS CROSSING AND JOINING LINES HYDRAULIC AND PNEUMATIC CYLINDERS

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 THREE TWO


DISPLACEMENT NON-COMPENSATED DISPLACEMENT NON-COMPENSATED POSITIONING POSITION POSITION

UNIDIRECTIONAL UNIDIRECTIONAL

FLOW IN ONE PARALLEL CROSS FLOW ALLOWED IN


DIRECTION FLOW FLOW EITHER DIRECTION
BIDIRECTIONAL BIDIRECTIONAL

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

Electrical Symbols Table


Hydraulic Symbols (Electrical)

93 G M
87
86 Transducer Transducer Generator Electric Motor
Hoist Screens (Fluid) (Gas / Air)
Return Screens

Pressure Switch Pressure Switch Temperature Switch Electrical Wire


(Adjustable)

Electrical Symbols (Electrical)


Hoist Oil Port

LEFT FRONT REAR Brake Actuation T


Hoist Valve Port Section Filler Tube
Pressure Temperature Level Flow
Symbol Symbol Symbol Symbol

Wire Number Identification Codes


Brake Actuation
Section Electrical Schematic Example Hydraulic Schematic Example

Current Standard Current Standard


Harness identification code
This example indicates
Hoist and Brake wire 135 in harness "AG". Wire
Accumulator Cooling Section
92
Circuit Number Wire Color
Identification
Purge Solenoid
325-AG135 PK-14
325-PK
Circuit Identification Wire Color Wire Gauge
Number

Hoist Screens Previous Standard


Wire Color
Wire

325-PK-14
Return Screens B A
RIGHT FRONT Circuit Number
Identification
Wire Gauge
(EXAMPLE VALVE)

BRAKE TEMPERATURE SENSORS TANK


14 13 12 11 10 9 8 7 6 5 4 3 2 1
(92) SENSOR GP-
TEMP: 134-2252
LEFT REAR (80) SENSOR GP-PRESS LEFT FRONT
(87) SENSOR GP-TEMP 221-3410
134-2252

T
P2
BB PUMP BYPASS SECTION HOIST SECTION
S
LEFT WHEEL-GP & FD
J
DD FF J
(Dimensions: 48 inches x 35 inches)

PILOT
KENR8379-01 VOL 2

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

(102) SWITCH AS -

G
(113) CORE AS -
PRESSURE: 130-7459 299-3290 BYPASS TO FRONT
BRAKE COOLING GG

D
PUMP TO CYLINDER
(123) SWITCH GP -
ROD END (LOWER)
FILTER BYPASS
164-7577
(31) CONTROL GP-HYD
222-4744 HH

EE PP (17) CYL GP-TEL N


I
(118) FILTER GP -
TRANS: 334-0572 M 289-8616
I
RIGHT BRAKE PRESSURE
R TCS BYPASS TO REAR
BRAKE COOLING PUMP TO CYLINDER
(115) PLUG AS - HEAD END (RAISE)
242-7114 (42) ADJUSTER GP
205-0560 (43) ADJUSTER GP

CC JJ
(110) VALVE GP - DIVERTER 205-0560
168-7859
36 Page, Color,

(100) SENSOR GP - (81) SENSOR GP-PRESS


TEMP: 288-8390 221-3410
A
CYLINDER HEAD END

H
TO TANK (LOWER)

KK B

H H

LL
(107) VALVE GP -
RELIEF: 172-5381

BANJO-HOUSING
OIL SUMP
(105) SENSOR GP -
PRESS: 221-3415

(122) SWITCH GP -
FILTER BYPASS (19) VALVE GP-CONT
164-7577 293-4974

L
G
O G

(119) FILTER GP -
TRANS: 334-0572
BRAKE
CONTROL
MODULE (93) SENSOR GP-

F (27) ACCUM GP
286-0796
(29) ACCUMULATOR GP
TEMP: 134-2252

286-0796 O
C (53) VALVE-CHECK
(109) SCREEN AS -
172-6104
123-4750
D
(99) SCREEN AS -
9P-9555
(52) VALVE-CHECK
V
F (75) SENSOR GP- 123-4750
(76) SENSOR GP-PRESS F
U
PRESS: 221-3405 221-3405
(86) SENSOR GP-TEMP
134-2252
RIGHT REAR (35) CONT GP-
RIGHT FRONT
ACC1 PS1 SUPPLY PS2 TCS HOIST BCD ACC2 SERVICE BRAKE
RV1
321-5086
SQ1 SV3
LE1 PS3

T2 SV2
(51) VALVE-CHECK
PR2
123-4750

PR1 FL1
(13) PUMP GP-ELEC DR
5T-1060

CV1 CV2 TSB

E RIGHT WHEEL-GP & FD P A


E
M
T PD1 HF1 SV1 PD2 HF2 PD3 PLUG HF3 T1 T

POWER TRAIN
(REAR AXEL) 1

SH1 SH2
(39) PUMP GP - REAR AXLE LUBE
324-2716
PS5 FSB
PB R PS4 F
J

(33) VALVE GP-MTG


285-5630
(10) CONNECTOR AS
311-6676
(11) CONNECTOR AS E
J
311-6676
(128) CYLINDER GP - BASIC 339-3275
(77) SENSOR GP-
PRESS: 221-3405

D D
RAISE
(37) MOTOR GP -
LOWER REAR AXLE LUBE (84) CORE AS - FRONT REAR
296-5306 BRAKE COOLER: 285-0255

(56) COOL SCREEN


HOIST PILOT DRAIN 165-0056
(67) VALVE GP - MANUAL FROM FILTER

BYPASS CONTROL: 336-0978


2 1

(130) ORIFICE
I (25) FILTER GP- OIL
339-9703

C
(124) MANIFOLD GP -
(69) VALVE GP-MTG
346-4815 P C
POWER ACCESS
LINE RELIEF: 336-0981
P MAKE UP FLOW
(21) SCREEN GP
S FROM FILTER
172-2395
TO CYLINDER TO CYLINDER
HEAD END ROD END

C2 C1
LINE PATTERNS
K T F
Pressure Line

Pilot / Load Sensing Pressure


(22) PUMP GP - HOIST
Drain / Return Lines
281-8288
Component Group

Attachment
B (134) FILTER GP - B
BRAKE SYSTEM Air Line
172-8660
CALLOUTS
YY Taps (Pressure, Sampling,Sensor) by letter

52 Components by number
PUMP
DRIVE HYDRAULIC CIRCUIT COLOR DESCRIPTIONS
M PILOT PUMP - CIRCUIT
BOX (67) MOTOR GP- (59) TANK GP-HYD 1435 PUMP GP - REAR AXEL LUBE CIRCUIT
(55) PUMP GP- COOLING and REAR AXLE FAN PUMP GP - HOIST CIRCUIT
280-1634 SUPPLY LINE
BRAKE CHARGE: 317-2659 257-6844 DRAIN / RETURN LINE

FILL BRAKE COOLING


MOTOR GP - REAR AXEL LUBE CIRCUIT
TUBE PUMP GP - BRAKE CHARGE CIRCUIT
BRAKE ADJUSTER CIRCUIT

797F OFF HIGHWAY TRUCK HYDRAULIC and POWER TRAIN SCHEMATIC.


A SHALLOW GRADE RETARDING ARRANGEMENT. A
(SERVICE, PARKING, BRAKE COOLING, HOIST SYSTEM and REAR AXEL.)

MEDIA NUMBER: KENR8379-01 (VOL. 2)


PART NUMBER: 272-3213 CHANGE: 02 and 272-3216 CHANGE: 03
POWER ACCESS Components are shown installed on a fully operable machine.

Refer to the appropriate Service Manual for Troubleshooting, Specifications.

14 13 12 11 10 9 8 7 6 5 4 3 2 1
KENR8379-01
COMPONENT LOCATIONS
February 2010
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
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
TANK 41
CONNECTOR AS - ORIFICE (VOL. 3) 311-6676 9 E-7
32

KENR8379-01 VOL 3
CONT GP - BRAKE (VOL. 3) 321-5086 34 F-6

(Dimensions: 48 inches x 35 inches)


78
CONTROL GP - HYD (TRACTION CONTROL SYSTEM) (VOL. 3) 222-4744 30 I-8
CORE AS - FRONT BRAKE COOLER (VOL. 3) 285-0255 82 H-3 BB Accumulator(s) -
CORE AS - REAR BRAKE COOLERS (VOL. 3) 285-0255 83 B-4 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

83 61
FILTER GP - BRAKE SYSTEM OIL (VOL. 3) 290-2567 135 B-9
FILTER GP - TRANS (VOL. 3) 334-0572 116 I-12 24 TANK
FILTER GP - TRANS (VOL. 3)
MANIFOLD GP - POWER ACCESS LINE RELIEF (VOL. 3)
334-0572
336-0981
117
125
G-13
C-13
135
797F Off-Highway Truck
MOTOR GP - REAR AXLE FAN (VOL. 3) 257-6844 66 B-7 135 Hydraulic and Power Train System
82 83 63
MOTOR GP - REAR AXLE LUBE (VOL. 3) 296-5306 36 D-11
Bypass Switch
MOTOR GP - BRAKE COOLING (VOL. 3) N/A 136 B-5
ORIFICE (VOL. 3) N/A 131 C-13
LAJ1-UP
PLUG AS (VOL. 3) 242-7114 114 I-13
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
79 H CC 30
SCREENS - BRAKE COOLING (VOL. 3) N/A 132 B-5
TANK
SENSOR GP - PARKE BRAKE PRESSURE (VOL. 3) 221-3410 78 J-8
SENSOR GP - PARKE BRAKE PRESSURE (VOL. 3) 221-3410 79 H-8
SENSOR GP - PRESSURE (VOL. 3)
SENSOR GP - PRESSURE (VOL. 3)
221-3405
221-3405
72
73
F-8/F-7
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 - Braking and Cooling
SENSOR GP - TEMP (VOL. 3) 288-8390 103 H-13
SWITCH AS - LEVEL (VOL. 3) 172-8660 95 B-9
TRACTION CONTROL SYSTEM VALVE BRAKE SYSTEM FILTER
SWITCH AS - PRESSURE (VOL. 3) 130-7459 101 I-13 2010 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
32
16
VALVE GP - MANUAL BYPASS CONTROL (VOL. 3) 336-0978 127 C-13
VALVE GP - RELIEF (VOL. 3) 172-5381 106 G-13 MAIN AUX.
PUMP: VARIABLE and
PUMP or MOTOR FLUID CONDITIONER SPRING CONTROL VALVES RESTRICTION LINE RESTRICTION 2-SECTION PUMP PRESSURE COMPENSATED
(FIXED)

TAP LOCATIONS (VOL. 3) VARIABILITY SPRING LINE RESTRICTION PRESSURE HYDRAULIC PNEUMATIC LINE RESTRICTION ATTACHMENT
(ADJUSTABLE) (VARIABLE) COMPENSATION ENERGY TRIANGLES VARIABLE and PRESSURE

Machine Schematic COMPENSATED

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


BRAKE TO TANK
FRONT BRAKE COOLING SUPPLY
I
Z
D-5
B-5
36 TANK AB
CONTROL VALVES
AB
CHECK VALVES

FRONT BRAKE SLACK ADJUSTER B H-1


34
P T P T
BASIC SPRING SHUTTLE PILOT
HOIST CYLINDER HEAD END PRESSURE LL H-4 NORMAL POSITION SHIFTED POSITION INFINITE POSITION
SYMBOL LOADED CONTROLLED

HOIST CYLINDER ROD END PRESSURE


HOIST PUMP DISCHARGE/BRAKE COOLING SUPPLY
FF
PP
J-4
I-5
16 FLUID STORAGE RESERVOIRS

LEFT BRAKE PRESSURE BB J-8


Service Brake Check Valve
LEFT FRONT BRAKE COOLING OUT S J-2
SERVICE BRAKE CONTROL VALVE
VENTED PRESSURIZED RETURN ABOVE FLUID LEVEL RETURN BELOW FLUID LEVEL

LEFT FRONT BRAKE COOLING OUT T J-1 MEASUREMENT ROTATING SHAFTS


Pressure Reducing Valve
LEFT FRONT SERVICE BRAKE N I-4
LEFT REAR BRAKE COOLING IN
LEFT REAR PARK BRAKE
Q
G
J-10
J-10 18 38 PRESSURE TEMPERATURE FLOW UNIDIRECTIONAL BIDIRECTIONAL
LEFT REAR SERVICE BRAKE M I-11 Front Brake Relay Valve
COMBINATION CONTROLS
PILOT OIL BYPASS (to Front Brake Cooling) DD J-7 Rear Brake Relay Valve
PILOT OIL BYPASS (to Rear Brake Cooling)
PILOT PRESSURE - HEAD END to TANK (Lower)
EE
KK
I-6
H-5
PP Unloader Solenoid
PILOT PRESSURE - PUMP to HEAD END (Raise) JJ I-5
EE DD Unloader Diverter Valve
Parking Brake Check Valve
SOLENOID SOLENOID
or MANUAL
SOLENOID
and PILOT
SOLENOID and
PILOT or MANUAL
SERVO THERMAL DETENT

PILOT PRESSURE - PUMP to ROD END (Lower) HH I-5


PILOT PRESSURE - ROD END to TANK (Raise) GG J-4 Parking Brake Relay Valve LEFT SIDE Screen MANUAL CONTROL SYMBOLS

RAXL DRIVE PUMP PRESSURE J D-12


REAR BRAKE COOLING SUPPLY AA B-5
Front Brake
REAR BRAKE SLACK ADJUSTER A H-11 PUSH-PULL LEVER MANUAL SHUTOFF GENERAL MANUAL PUSH BUTTON PEDAL SPRING
ARC Solenoid Rear Brake
CC I-8
BACK FRONT
RIGHT BRAKE PRESSURE PILOT CONTROL SYMBOLS
ARC Solenoid RELEASED PRESSURE REMOTE SUPPLY PRESSURE
RIGHT FRONT BRAKE COOLING IN U F-2
RIGHT FRONT BRAKE COOLING OUT V F-1
RIGHT FRONT SERVICE BRAKE O G-1
EXTERNAL RETURN INTERNAL RETURN SIMPLIFIED COMPLETE INTERNAL
RIGHT REAR BRAKE COOLING IN R F-10 SUPPLY PRESSURE
Accumulator ACCUMULATORS CROSSING AND JOINING LINES HYDRAULIC AND PNEUMATIC CYLINDERS
RIGHT REAR PARK BRAKE F F-10 Purge Solenoid
L G-11 LL
20
RIGHT REAR SERVICE BRAKE
TCS PILOT H H-7 FF KK JJ HH GG Parking Brake
Solenoid
SPRING LOADED GAS CHARGED LINES CROSSING LINES JOINING SINGLE ACTING DOUBLE ACTING

HYDRAULIC PUMPS HYDRAULIC MOTORS INTERNAL PASSAGEWAYS

FIXED
Rear Service Brake RIGHT SIDE DISPLACEMENT
VARIABLE DISPLACEMENT
NON-COMPENSATED
FIXED
DISPLACEMENT
VARIABLE DISPLACEMENT
NON-COMPENSATED
INFINITE
POSITIONING
THREE
POSITION
TWO
POSITION
Shuttle Valve Front Service Brake
Relief Valve Shuttle Valve 63 UNIDIRECTIONAL UNIDIRECTIONAL

FLOW IN ONE PARALLEL CROSS FLOW ALLOWED IN


DIRECTION FLOW FLOW EITHER DIRECTION
BIDIRECTIONAL BIDIRECTIONAL

CHASSIS VIEW BRAKE CHASSIS VALVE BRAKE COOLING DRIVE BRAKE COOLING SCREENS

Electrical Symbols Table


Hydraulic Symbols (Electrical)

93 G M
87
86 REAR FRONT Transducer Transducer
Brake Actuation Generator Electric Motor
(Fluid) (Gas / Air)
Section Filler Tube

Brake Actuation

132
97 Section Pressure Switch Pressure Switch
(Adjustable)
Temperature Switch Electrical Wire

Z Return Screens
Electrical Symbols (Electrical)
F Hoist and Brake
Cooling Section
LEFT FRONT REAR AA R Brake Cooling
136
T
Relief Valve
Pressure Temperature Level Flow
Symbol Symbol Symbol Symbol
132 VIEW A
Wire Number Identification Codes

Electrical Schematic Example Hydraulic Schematic Example

Current Standard Current Standard


VIEW A Harness identification code
This example indicates
wire 135 in harness "AG". Wire

92
Circuit Number Wire Color
Identification

Hoist Valve Port 325-AG135 PK-14


Hoist Oil Port 325-PK
Rear Brake Cooling Pump Circuit Identification Wire Color Wire Gauge
Number

Front Pumps
Previous Standard
Wire Color
Wire

325-PK-14

RIGHT FRONT
B A
Circuit Number Wire Gauge
Identification (EXAMPLE VALVE)

BRAKE TEMPERATURE SENSORS TANK


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

LEFT REAR (78) SENSOR GP-PRESS

G
(90) SENSOR GP- 221-3410
TEMP: 134-2252 PUMP BYPASS SECTION P2 HOIST SECTION
LEFT FRONT

J LEFT WHEEL-GP & FD


BB DD FF
T J
(Dimensions: 48 inches x 35 inches)
KENR8379-01 VOL 3

CYLINDER ROD END


TO TANK (RAISE)

BYPASS TO FRONT
(101) SWITCH AS - (112) CORE AS - BRAKE COOLING GG
P L
Q
PRESSURE: 130-7459 299-3290 LEFT BRAKE PRESSURE

PUMP TO CYLINDER

PP S
ROD END (LOWER)

(121) SWITCH GP -
FILTER BYPASS
164-7577 D HH (89) SENSOR GP-

M (30) CONTROL GP-HYD


(16) CYL GP-TEL
289-8616
TEMP: 134-2252

(116) FILTER GP -
222-4744
EE
I TRANS: 334-0572 I
BYPASS TO REAR

N
BRAKE COOLING PUMP TO CYLINDER
HEAD END (RAISE)

(114) PLUG AS -
242-7114
(40) ADJUSTER GP R RIGHT BRAKE PRESSURE
TCS JJ (41) ADJUSTER GP
(110) VALVE GP - DIVERTER 205-0560 205-0560
36 Page, Color,

168-7859

(103) SENSOR GP -
TEMP: 288-8390
CC PILOT
ON/OFF (82) CORE AS -
FRONT REAR
BRAKE COOLER

(79) SENSOR GP-PRESS H KK 285-0255

221-3410
CYLINDER HEAD END
TO TANK (LOWER)
(24) FILTER GP-OIL
H 339-9703 H
B
LL

(106) VALVE GP -
A B
RELIEF: 172-5381 HOIST PILOT DRAIN
FROM FILTER

BANJO-HOUSING
OIL SUMP
(104) SENSOR GP - (18) VALVE GP-CONT
PRESS: 221-3415 293-4974
(120) SWITCH GP -
FILTER BYPASS
164-7577

G L (49) VALVE-CHECK
G
O
123-4750

(117) FILTER GP -
TRANS: 334-0572
BRAKE
CONTROL (26) ACCUM GP
(48) VALVE-CHECK
MODULE (88) SENSOR GP-

C
286-0796 (72) SENSOR GP- 123-4750 TEMP: 134-2252
(91) SENSOR GP-
TEMP: 134-2252
R
PRESS 221-3405

(28) ACCUMULATOR GP
D (74) SENSOR GP-PRESS
221-3405
U
O
286-0796

(108) SCREEN AS -
172-6104 ACC1 PS1 SUPPLY PS2 TCS HOIST BCD ACC2
RV1

F
(98) SCREEN AS -
9P-9555
LE1
SQ1 SV3
PS3
(34) CONT GP-BRAKE
V F
T2 321-5086
SV2
PR2

PR1

F
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 WHEEL-GP & FD FSB E


PB R PS4 F

POWER TRAIN (32) VALVE GP-MTG (8) CONNECTOR AS (9) CONNECTOR AS


311-6676 E
(REAR AXEL)
285-5630 311-6676

(38) PUMP GP - REAR AXLE LUBE


324-2716
(73) SENSOR GP-
J PRESS 221-3405

(128) CYLINDER GP - BASIC 339-3275


J
D
I D
RAISE
LOWER

(47) FILTER-
(50) VALVE-CHECK
HYDRAULIC
123-4750
4T-6788
(67) VALVE GP - MANUAL (36) MOTOR GP - P
BYPASS CONTROL: 336-0978 REAR AXLE LUBE
2 1 296-5306 S (12) PUMP GP-ELEC DR
5T-1060
(68) VALVE GP-MTG
346-4815
M
(130) ORIFICE (20) SCREEN GP
172-2395
C T F C
(124) MANIFOLD GP -
POWER ACCESS
LINE RELIEF: 336-0981

Z
TO CYLINDER TO CYLINDER
(23) PUMP GP
K
HEAD END ROD END
281-8288 LINE PATTERNS
(66) MOTOR GP-
C2 C1 REAR AXLE FAN (83) CORE AS - FRONT REAR Pressure Line
257-6844 BRAKE COOLER 285-0255
Pilot / Load Sensing Pressure
(95) SWITCH AS Drain / Return Lines
172-8660
Component Group

Attachment
(132) SCREEN GP - BRAKE COOLER
B Air Line B
CALLOUTS

PUMP Taps (Pressure, Sampling,Sensor) by letter


YY

AA Components by number
DRIVE
52

BOX See Volume 1

(65) TANK GP-HYD 1435


280-2090
A-2 / B-2
AA HYDRAULIC CIRCUIT COLOR DESCRIPTIONS
PILOT PUMP - CIRCUIT

M (61) PUMP GP-


BRAKE CHARGE BB
PUMP GP - REAR AXEL LUBE CIRCUIT
PUMP GP - HOIST CIRCUIT
314-9248 SUPPLY LINE
DRAIN / RETURN LINE
BRAKE COOLING
(136) MOTOR GP - MOTOR GP - REAR AXEL LUBE CIRCUIT
FILL BRAKE COOLING PUMP GP - BRAKE CHARGE CIRCUIT
BRAKE ADJUSTER CIRCUIT
Part #: N/A
TUBE (63) PUMP GP - BRAKE COOLING
281-8284
797F OFF HIGHWAY TRUCK HYDRAULIC and POWER TRAIN SCHEMATIC.
A STEEP GRADE RETARDING ARRANGEMENT. A
(SERVICE, PARKING, BRAKE COOLING, HOIST SYSTEM and REAR AXEL.)

MEDIA NUMBER: KENR8379-01 (VOL. 3)


PART NUMBER: 272-3213 CHANGE: 02 and 272-3216 CHANGE: 03

POWER ACCESS
Components are shown installed on a fully operable machine.

Refer to the appropriate Service Manual for Troubleshooting, Specifications.

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