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Component Locations - Volume 1

Description Part Number


219-9784 241-9827 240-4606 194-0591 171-1881 196-4624 187-9683 223-3749 165-0056 9T-9227 172-2395 6E-5855 245-1763 172-6440 253-4119 245-3682 219-1633 144-0244 155-6061 222-5319 223-3750 223-3751 8W-9925 221-3407 221-3407 128-5091 213-6947 215-6442 270-4433 154-6832 279-6515 223-2216 159-4530 222-4744 Miscellaneous Breather Drive Gp - Pump Drive Box Pump Gp - Steering and Fan Tank Gp - Hydraulic 4T-6788 149-3060 194-0436 205-0844
70 71 47 72

KENR8227 February 2007

FLUID POWER SYMBOLS


BASIC COMPONENT SYMBOLS
MAIN AUX.

Machine Location
1 2 3 4 5 6 7 8 9 10 11 12 13 14 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38

Schematic Location
PUMP or MOTOR FLUID CONDITIONER SPRING

Brake Cooling and Hoist Cylinder Gp - Hoist Cooler Gp - Front Brake Oil Cooler Gp - Rear Brake Oil Filter Gp - Front Brake Cooling Motor Gp - Brake Cooling Pump Gp - Brake Cooling Pump Gp - Brake Cooling Drive Pump Gp - Hoist Screen As - Cooling Return Screen As - Steering / Hoist Ret. Screen Gp - Hoist Valve Gp - Brk Cooling Relief Valve Gp - Hoist Valve Gp - Rear Brk Cool. Dvrtr Accumulator Gp - Brake Adjuster - Brake Slack Brake Gp - Front Brake Gp - Rear Filter Gp - Brake Fitting - Orifice Pump Gp Brake and RAX: Brake, RAX Lube, and RAX Fan: Pump Gp - Dead Eng. Tow Sensor Gp - Brk Accum Press. Sensor Gp - Brk Pump Press. Switch As - Serv. Brk Actuation Switch Gp - Low Acumm. Press Valve - Brake Control Valve Gp - Brake Manifold Valve Gp - Brake Relay Valve Gp - Cab Manifold Valve Gp - Sec. Brk Foot Pedal Valve Gp - Serv. Brk Foot Pedal Valve Gp - Traction Control C-9 E-3 F-12 E-3, F-3 B-5 B-5 B-7 B-7 to B-8 B-5 C-5 C-7, C-8 B-5 B-10 to D-13 G-12 F-7, G-6 G-3,G-13 D-2, I-2 D15, I15 D-7, D-8 F-5 B-7 D-5 F-6 E-7 H-8, H-9 F-7, G-6 G14, G2 F-7 to G10 F-5 H-6 to H-8 I-5 H-10 H-12

CONTROL VALVES

RESTRICTION

LINE RESTRICTION (FIXED)

2-SECTION PUMP

PUMP: VARIABLE and PRESSURE COMPENSATED

VARIABILITY

SPRING (ADJUSTABLE)

LINE RESTRICTION (VARIABLE)

PRESSURE COMPENSATION

HYDRAULIC PNEUMATIC ENERGY TRIANGLES

LINE RESTRICTION
VARIABLE and PRESSURE COMPENSATED

ATTACHMENT

VALVES
VALVE ENVELOPES VALVE PORTS

14

ONE POSITION

TWO POSITION

THREE POSITION

TWO-WAY

THREE-WAY

FOUR-WAY

CONTROL VALVES
AB AB

CHECK VALVES

P T NORMAL POSITION

P T SHIFTED POSITION

INFINITE POSITION

BASIC SYMBOL

SPRING LOADED

SHUTTLE

PILOT CONTROLLED

MEASUREMENT

ROTATING SHAFTS

PRESSURE

TEMPERATURE

FLOW

UNIDIRECTIONAL

BIDIRECTIONAL

Service and Parking Brakes

Tap Locations - Volume 1 Pressure, Sampling, and Sensor


Tap Number
A B C D E

797B Off-Highway Truck Hydraulic System


Schematic Location
H-12 H-11 F-11 B-8 B-7

FLUID STORAGE RESERVOIRS

VENTED

PRESSURIZED

RETURN ABOVE FLUID LEVEL

RETURN BELOW FLUID LEVEL

COMBINATION CONTROLS

Description
Left Parking Brake Pressure Right Parking Brake Pressure Brake Pump Pressure Hoist Pump Pressure Hoist Pump Pressure

JSM220-UP
SOLENOID SOLENOID or MANUAL SOLENOID and PILOT SOLENOID and PILOT or MANUAL SERVO THERMAL DETENT

MANUAL CONTROL SYMBOLS

PUSH-PULL LEVER

MANUAL SHUTOFF

GENERAL MANUAL

PUSH BUTTON

PEDAL

SPRING

PILOT CONTROL SYMBOLS


RELEASED PRESSURE REMOTE SUPPLY PRESSURE

72

4
EXTERNAL RETURN INTERNAL RETURN SIMPLIFIED COMPLETE INTERNAL SUPPLY PRESSURE

COOLING COMPONENTS

ACCUMULATORS

CROSSING AND JOINING LINES

HYDRAULIC AND PNEUMATIC CYLINDERS

SPRING LOADED

GAS CHARGED

LINES CROSSING

LINES JOINING

SINGLE ACTING

DOUBLE ACTING

HYDRAULIC PUMPS
FIXED DISPLACEMENT VARIABLE DISPLACEMENT NON-COMPENSATED

HYDRAULIC MOTORS
FIXED DISPLACEMENT VARIABLE DISPLACEMENT NON-COMPENSATED

INTERNAL PASSAGEWAYS
INFINITE POSITIONING THREE POSITION TWO POSITION

UNIDIRECTIONAL

UNIDIRECTIONAL
CROSS FLOW

BIDIRECTIONAL

BIDIRECTIONAL

FLOW IN ONE DIRECTION

PARALLEL FLOW

FLOW ALLOWED IN EITHER DIRECTION

D-5 B-8 B-9 B-5 to C-6

Volume 1 of 2

Brakes, Brake Cooling, and Hoist Curcuits


2007 Caterpillar All Rights Reserved

Printed in U.S.A.

32 46 53 48 54 45 42 47 70 21

31 27 25

29 24

A B
38

32 21

62 67 61 66

Electrical Symbols Table


Hydraulic Symbols (Electrical)

G
Transducer (Fluid) Transducer (Gas / Air) Generator

M
Electric Motor

1 11
21 38 A

Pressure Switch

Pressure Switch (Adjustable)

Temperature Switch

Electrical Wire

20

33 C

21

24
Electrical Symbols (Electrical)

Pressure Symbol

Temperature Symbol

Level Symbol

Flow Symbol

Wire Number Identification Codes Electrical Schematic Example Hydraulic Schematic Example
Current Standard
Wire Circuit Number Identification Wire Color

30 35

36 40 51 55 F 37 50 52 56 G 51

H I

22

2 3

71

D 8 E 11
26

47

72

6 10 12

5 9

43 14 44 9 12

13 20 33 C 28 34

23

Current Standard
Harness identification code This example indicates wire 135 in harness "AG".

KENR8227 VOL 1

325-AG135 PK-14

53 52 40

55 45 22 42

70 47 2

44 43

10 72 70

26

67

27
Circuit Identification Number Wire Color Wire Gauge

325-PK

Previous Standard

23 61 66 62 21 32 13 21 32 25 31 38 A 34 23
27 13

Wire

Wire Color

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

13

72

HOIST COMPONENTS

BRAKE COMPONENT

46 54 48 30 37 36 56 22 42 35

71

11

D 8 E

14

24 29

33

28

20

COMPONENT LOCATIONS

30 Page,

(Dimensions: 39 inches x 28 inches)

15

14

13

12

11

10

BRAKE GP 144-0244

LEFT FRONT VALVE GP TRACTION CONTROL 222-4744

I
TO RAX LUBE (VOLUME 2, C-2)
VALVE GP SEC. BRK FOOT PEDAL 223-2216 ARC PROPORTIONAL CONT VALVE PARK BRAKE ON/OFF VALVE BRAKE GP FRONT 219-1633

VALVE GP SERV. BRK FOOT PEDAL 159-4530

P T

LEFT REAR

P
ADJUSTER BRAKE SLACK 245-3682

T
ARC ON/OFF VALVE VALVE GP CAB MANIFOLD 279-6515 SWITCH GP SERVICE BRAKE ACTUATION 128-5091

ADJUSTER BRAKE SLACK 245-3682

P T

P2

P1
DIVERTER PILOT

VALVE GP PARKING BRAKE RELAY 134-6832

G
VALVE GP REAR BRAKE COOLING DIVERTER 172-6440 PRESS. REDUCING VALVE ACCUMULATOR GP BRAKE 253-4119 VALVE GP SERVICE BRAKE RELAY 154-6832

ACCUM BLEED DOWN VALVE VALVE GP BRAKE MANIFOLD 270-4433 UNLOADER CONT SENSOR GP BRK ACCUM 211-3407

VALVE BRAKE CONTROL 215-6442

COOLER GP REAR BRAKE OIL 240-4606

VALVE BRAKE CONTROL 215-6442

P PUMP UNLOADER
SWITCH GP LOW ACCUMULATOR PRESSURE 213-6947

T
FITTING ORIFICE 222-5319

C
SYSTEM RELIEF

FILTER GP FRONT BRAKE COOLING 194-0591

(Dimensions: 39 inches x 28 inches)

E
COOLER GP FRONT BRAKE OIL 241-9827

KENR8227 VOL 1

RIGHT REAR
PUMP BYPASS SECTION

P2

HOIST SECTION

FILTER GP BRAKE 155-6061

SENSOR GP BRAKE PUMP PRESSURE 221-3407

PUMP GP DEAD ENG. TOW 8W-9925

M
D

CYL TO TANK ROD END


BRAKE GP 144-0244

BREATHER 4T-6788 SCREEN AS HOIST RETURN 9T-9227

BRAKE GP FRONT 219-1633 RIGHT FRONT

30 Page, Color 2,

PUMP TO CYL ROD END

CYLINDER GP HOIST 219-9784

TANK GP HYDRAULIC 205-0844

PUMP TO CYL HEAD END


SCREEN GP HOIST 172-2395 SCREEN AS COOLING RETURN 165-0056

CYL TO TANK HEAD END PILOT ON/OFF


PUMP GP HOIST 223-3749

VALVE GP BRK COOLING RELIEF 6E-5855

Tap Number
A B C D E

Tap Locations - Volume 1 Pressure, Sampling, and Sensor


Description
Left Service Brake Pressure Right Service Brake Pressure Brake Pump Pressure Hoist Pump Pressure Hoist Pump Pressure

Schematic Location
H-12 H-11 F-11 B-8 B-7

VALVE GP HOIST 245-1763

DRIVE GP PUMP DRIVE BOX 149-3060

LINE PATTERNS
BREATHER 4T-6788

Pressure Line Pilot / Load Sensing Pressure Drain / Return Lines

PUMP GP STEERING AND FAN 194-0436

PUMP GP BRAKE AND RAX: 223-3750 BRAKE,RAX LUBE,RAX FAN: 223-3751

PUMP GP BRAKE COOLING 196-4624

MOTOR GP BRAKE COOLING 171-1881

Component Group Attachment Air Line

CALLOUTS
PUMP GP BRK COOLING DRIVE 187-9683
YY

Taps (Pressure, Sampling,Sensor) by letter Components by number

52

HYDRAULIC CIRCUIT COLOR DESCRIPTIONS


ELECTRICAL CURCUIT HOIST PUMPS AND CURCUIT SUPPLY LINE DRAIN / RETURN LINE BRAKE COOLING PUMPS AND CURCUIT RAX PUMP AND CURCUIT PARKING BRAKES / TRACTION CONTROL PUMP AND CURCUIT SERVICE BRAKES PUMP AND CURCUIT

THIS SCHEMATIC IS FOR THE 797B 0FF-HIGHWAY TRUCK HYDRAULIC SYSTEM


PART #: 224-0763 CHNG 03 VOLUME 1 OF 2
Components are shown installed on a fully operable machine with the key and engine off and transmission shifter in neutral. Refer to the appropriate Service Manual for Troubleshooting, Specifications and Systems Operations

15

14

13

12

11

10

KENR8227 February 2006

FLUID POWER SYMBOLS


BASIC COMPONENT SYMBOLS
MAIN AUX.

Component Locations - Volume 2


Description
Accumulator Gp - Steering Cooler Gp - Front Brake Oil Cylinder Gp - Steering Filter Gp - Case Drain Filter Gp - Case Drain Filter Gp - Steering Return Motor Gp - Fan Drive Pump Gp - Steering and Fan Pump Gp - Strg Hand Metering Screen As - Steering / Hoist Ret. Sensor Gp - Strg Accum Press. Sensor Gp - Strg Pump Press. Switch Gp - High Press. Low Valve Gp - Makeup Valve Gp - Press. Reducing Valve Gp - Solenoid and Relief Valve Gp - Strg Flow Ampl.

PUMP or MOTOR

Part Number
253-4120 241-9827 194-6171 160-7752 160-7752 219-6629 183-7170 194-0436 192-3897 9T-9227 221-3407 221-3407 256-3638 183-7170 226-0835 275-6390 151-5933

Machine Location 40 2 42 43 44 45 46 47 48 10 50 51 52 53 54 55 56

Schematic Location
H-12, H-13 B-12 G-3, H-3 B-8 C-7 B-14 C-14 D-10 to E-13 G-9 B-5 H-13 H-11 H-13 C-14 G-14 G-12 G-4 to G-7

FLUID CONDITIONER

SPRING

CONTROL VALVES

RESTRICTION

LINE RESTRICTION (FIXED)

2-SECTION PUMP

PUMP: VARIABLE and PRESSURE COMPENSATED

Steering and Fan

VARIABILITY

SPRING (ADJUSTABLE)

LINE RESTRICTION (VARIABLE)

PRESSURE COMPENSATION

HYDRAULIC PNEUMATIC ENERGY TRIANGLES

VARIABLE and PRESSURE COMPENSATED

LINE RESTRICTION

ATTACHMENT

VALVE ENVELOPES

VALVES

VALVE PORTS

ONE POSITION

TWO POSITION

THREE POSITION

TWO-WAY

THREE-WAY

FOUR-WAY

CONTROL VALVES
AB AB

CHECK VALVES

P T NORMAL POSITION

P T SHIFTED POSITION

INFINITE POSITION

BASIC SYMBOL

SPRING LOADED

SHUTTLE

PILOT CONTROLLED

MEASUREMENT

ROTATING SHAFTS

Tap Number
F G H I J

Tap Locations - Volume 2 Pressure, Sampling, and Sensor


Description
Steering Oil Sample Port Auxillary Power Unit Port Steering Pump Pressure Steering Pump Pressure Steering Accumulator Pressure

PRESSURE

TEMPERATURE

FLOW

UNIDIRECTIONAL

BIDIRECTIONAL

Schematic Location
G-12 H-12 F-11 H-11 H-11

10 12

797B Off-Highway Truck Hydraulic System


JSM220-UP

FLUID STORAGE RESERVOIRS

VENTED

PRESSURIZED

RETURN ABOVE FLUID LEVEL

RETURN BELOW FLUID LEVEL

COMBINATION CONTROLS

SOLENOID

Brake Cooling Pump Drive Rear Axle Lube Pump Drive Motor Gp - Brake Cooling Motor Gp - RAX Drive Motor Gp - RAX Fan Pump Gp Brake and RAX: Brake, RAX Lube, and RAX Fan: Pump Gp - Brake Cooling Pump Gp - Brake Cooling Drive Pump Gp - RAX Lube Valve Gp - Relief Breather Drive Gp - Pump Drive Box Pump Gp - Hoist Tank Gp - Hydraulic 171-1881 210-2642 207-8609 223-3750 223-3751 196-4624 187-9683 151-4472 173-5399 Miscellaneous 4T-6788 149-3060 223-3749 205-0844

SOLENOID or MANUAL

SOLENOID and PILOT

SOLENOID and PILOT or MANUAL

SERVO

THERMAL

DETENT

5 61 62 26 6 7 66 67 70 71 8 72

B-4 E-2 D-1 D-6 B-4 to B-5 D-7 to D-8 E-2 to E-3 E-2 D-5 D-9 E-8 C-5

9 5 6
PUSH-PULL LEVER MANUAL SHUTOFF

MANUAL CONTROL SYMBOLS

GENERAL MANUAL

PUSH BUTTON

PEDAL

SPRING

RELEASED PRESSURE

PILOT CONTROL SYMBOLS

REMOTE SUPPLY PRESSURE

HYDRAULIC TANK COMPONENTS

EXTERNAL RETURN

INTERNAL RETURN

SIMPLIFIED

COMPLETE

INTERNAL SUPPLY PRESSURE

ACCUMULATORS
SPRING LOADED GAS CHARGED

CROSSING AND JOINING LINES

HYDRAULIC AND PNEUMATIC CYLINDERS


SINGLE ACTING DOUBLE ACTING

LINES CROSSING

LINES JOINING

HYDRAULIC PUMPS
FIXED DISPLACEMENT VARIABLE DISPLACEMENT NON-COMPENSATED

HYDRAULIC MOTORS
FIXED DISPLACEMENT VARIABLE DISPLACEMENT NON-COMPENSATED

INTERNAL PASSAGEWAYS
INFINITE POSITIONING THREE POSITION TWO POSITION

UNIDIRECTIONAL

UNIDIRECTIONAL
FLOW IN ONE DIRECTION PARALLEL FLOW CROSS FLOW FLOW ALLOWED IN EITHER DIRECTION

BIDIRECTIONAL

BIDIRECTIONAL

Volume 2 of 2

Steering, Fan, and RAX Lube Curcuits


2007 Caterpillar All Rights Reserved

Printed in U.S.A.

32 46 53 48 54 45 42 47 70 21

31 27 25

29 24

A B
38

32 21

62 67 61 66

Electrical Symbols Table


Hydraulic Symbols (Electrical)

G
Transducer (Fluid) Transducer (Gas / Air) Generator

M
Electric Motor

Pressure Switch

Pressure Switch (Adjustable)

Temperature Switch

Electrical Wire

45

40

55 G

56

42

47

72

Electrical Symbols (Electrical)

Pressure Symbol

Temperature Symbol

Level Symbol

Flow Symbol

Wire Number Identification Codes Electrical Schematic Example Hydraulic Schematic Example
Current Standard
Wire

30 35

36 40 51 55 F 37 50 52 56 G 51

H I

22

2 3

71

D 8 E 11
26 5

47

72

6 10 12

5 9

43 14 44 9 12

13 20 33 C 28 34

23

Current Standard
Harness identification code This example indicates wire 135 in harness "AG".

Circuit Number Identification

Wire Color

53 52 40

55 45 22 42

70 47 2

44 43

10 72 70

26

67

27
Circuit Identification Number

325-AG135 PK-14 325-PK


Wire Color Wire Gauge

Previous Standard

23 61 66 62 21 32 13 21 32 25 31 38 A 34 23

Wire

Wire Color

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

STEERING COMPONENTS

46 54 48 30 37 36 56 22 42 35

71

11

D 8 E

14

24 29

33

28

20

COMPONENT LOCATIONS

30 Page,

KENR8227 VOL 2

(Dimensions: 39 inches x 28 inches)

15

14

13

12

11

10

SWITCH GP HIGH PRESSURE LOW 256-3638


I

ACCUMULATOR STEERING 253-4120

SENSOR GP STEERING PUMP PRESSURE 221-3407 VALVE GP STEERING FLOW AMPLIFIER 151-5933 PUMP GP STEERING HAND METERING 192-3897
I

SENSOR GP STEERING ACCUMULATOR PRESSURE 221-3407 G


H

J
H

HP

CL

LS VALVE GP PRESSURE REDUCING 226-0835


G

CYLINDER GP STEERING 194-6171

VALVE GP SOLENOID/ RELIEF 275-6390 CR

HT T

EF

MOTOR SPEED FAN SPEED

ECM
BRAKE & COOLING

PUMP DISPLACEMENT

PUMP GP RAX LUBE 151-4472

SEE 156-1885 PT OIL FOR REAR AXLE LUBE SCHEMATIC

T1 T2

G2

Mb

Ma

G1

T2 T1

30 Page, Color 2, (Dimensions: 39 inches x 28 inches)

PUMP GP HOIST 223-3749

PUMP DISPLACEMENT FROM FAN PUMP VALVE GP RELIEF 173-5399

MOTOR GP RAX DRIVE 210-2642


E

KENRN8227 VOL 2

DRIVE GP PUMP DRIVE BOX 149-3060


D

PUMP GP BRAKE AND RAX: 223-3750 BRAKE,RAX LUBE,RAX FAN: 223-3751

L1 VALVE GP MAKEUP 183-7170

Qmin

Qmax

Qmax

Qmin

BREATHER 4T-6788

MOTOR GP RAX FAN:207-8609

L2

M1 PUMP GP STEERING AND FAN 194-0436

M1

PUMP GP BRAKE COOLING DRIVE 187-9683 FILTER GP CASE DRAIN 160-7752

MOTOR GP FAN DRIVE 183-7170

TANK GP HYDRAULIC 205-0844

FROM BRAKE SYSTEM (VOLUME 1,I-11)

FILTER GP CASE DRAIN 160-7752

PUMP GP BRAKE COOLING 196-4624

MOTOR GP BRAKE COOLING 171-1881


B
LINE PATTERNS Pressure Line Pilot / Load Sensing Pressure

COOLER GP FRONT BRAKE OIL 241-9827 SCREEN GP STEERING / HOIST RETURN 9T-9227 FILTER GP STEERING RETURN 219-6629
YY 52

Drain / Return Lines Component Group Attachment Air Line CALLOUTS

HYDRAULIC CIRCUIT COLOR DESCRIPTIONS


ELECTRICAL CURCUIT BRAKE COOLING PUMP, FAN, AND CURCUIT HOIST PUMPS AND CURCUIT SUPPLY LINE DRAIN / RETURN LINE BRAKE COOLING PUMPS AND CURCUIT BRAKE COOLING DRIVE PUMP AND CURCUIT STEERING PUMP AND CIRCUIT RAX PUMP AND CURCUIT PARKING BRAKES / TRACTION CONTROL PUMP AND CURCUIT SERVICE BRAKES PUMP AND CURCUIT

Taps (Pressure, Sampling,Sensor) by letter

Components by number

THIS SCHEMATIC IS FOR THE 797B 0FF-HIGHWAY TRUCK HYDRAULIC SYSTEM PART #: 224-0763 CHNG 03 VOLUME 2 0F 2

Components are shown installed on a fully operable machine with the key and engine off and transmission shifter in neutral. Refer to the appropriate Service Manual for Troubleshooting, Specifications and Systems Operations

15

14

13

12

11

10

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