Component Locations - Volume 1 KENR8227

FLUID POWER SYMBOLS

February 2007
Part Machine Schematic BASIC COMPONENT SYMBOLS
Description
Number Location Location
MAIN AUX.
PUMP: VARIABLE and
Brake Cooling and Hoist PUMP or MOTOR FLUID CONDITIONER SPRING CONTROL VALVES RESTRICTION LINE RESTRICTION
(FIXED)
2-SECTION PUMP PRESSURE COMPENSATED

Cylinder Gp - Hoist 219-9784 1 C-9

Cooler Gp - Front Brake Oil 241-9827 2 E-3 VARIABILITY SPRING LINE RESTRICTION PRESSURE HYDRAULIC PNEUMATIC LINE RESTRICTION ATTACHMENT
(ADJUSTABLE) (VARIABLE) COMPENSATION ENERGY TRIANGLES VARIABLE and PRESSURE

Cooler Gp - Rear Brake Oil 240-4606 3 F-12 COMPENSATED

VALVES
Filter Gp - Front Brake Cooling 194-0591 4 E-3, F-3 VALVE ENVELOPES VALVE PORTS

Motor Gp - Brake Cooling 171-1881 5 B-5

Pump Gp - Brake Cooling 196-4624 6 B-5 14 3 4 ONE POSITION TWO POSITION THREE POSITION TWO-WAY THREE-WAY FOUR-WAY

Pump Gp - Brake Cooling Drive 187-9683 7 B-7 CONTROL VALVES CHECK VALVES
AB AB
Pump Gp - Hoist 223-3749 8 B-7 to B-8
Screen As - Cooling Return 165-0056 9 B-5 P T P T
SHUTTLE PILOT
BASIC SPRING
NORMAL POSITION SHIFTED POSITION INFINITE POSITION
SYMBOL LOADED CONTROLLED
Screen As - Steering / Hoist Ret. 9T-9227 10 C-5
MEASUREMENT ROTATING SHAFTS
Screen Gp - Hoist 172-2395 11 C-7, C-8
Valve Gp - Brk Cooling Relief 6E-5855 12 B-5
Valve Gp - Hoist 245-1763 13 B-10 to D-13 PRESSURE TEMPERATURE FLOW UNIDIRECTIONAL BIDIRECTIONAL

Valve Gp - Rear Brk Cool. Dvrtr 172-6440 14 G-12 FLUID STORAGE RESERVOIRS
Service and Parking Brakes
797B Off-Highway Truck
Tap Locations - Volume 1
Hydraulic System
Accumulator Gp - Brake 253-4119 20 F-7, G-6 VENTED PRESSURIZED RETURN ABOVE FLUID LEVEL RETURN BELOW FLUID LEVEL

Adjuster - Brake Slack 245-3682 21 G-3,G-13

22
Pressure, Sampling, and Sensor COMBINATION CONTROLS
Brake Gp - Front 219-1633 D-2, I-2
Brake Gp - Rear 144-0244 23 D15, I15 Tap Schematic JSM220-UP
Description
Filter Gp - Brake 155-6061 24 D-7, D-8 Number Location SOLENOID SOLENOID
or MANUAL
SOLENOID
and PILOT
SOLENOID and
PILOT or MANUAL
SERVO THERMAL DETENT

Fitting - Orifice 222-5319 25 F-5 A Left Parking Brake Pressure H-12 MANUAL CONTROL SYMBOLS
Pump Gp - Brake and RAX: 223-3750 B Right Parking Brake Pressure H-11
26 B-7
Brake, RAX Lube, and RAX Fan: 223-3751
27
C Brake Pump Pressure F-11 PUSH-PULL LEVER MANUAL SHUTOFF GENERAL MANUAL PUSH BUTTON PEDAL SPRING
Pump Gp - Dead Eng. Tow 8W-9925 D-5
Sensor Gp - Brk Accum Press. 221-3407 28 F-6 D Hoist Pump Pressure B-8 RELEASED PRESSURE
PILOT CONTROL SYMBOLS
REMOTE SUPPLY PRESSURE

Sensor Gp - Brk Pump Press. 221-3407 29 E-7 E Hoist Pump Pressure B-7 72 4
Switch As - Serv. Brk Actuation 128-5091 30 H-8, H-9
EXTERNAL RETURN INTERNAL RETURN SIMPLIFIED COMPLETE INTERNAL
Switch Gp - Low Acumm. Press 213-6947 31 F-7, G-6 SUPPLY PRESSURE

32 ACCUMULATORS CROSSING AND JOINING LINES HYDRAULIC AND PNEUMATIC CYLINDERS

Valve - Brake Control 215-6442 G14, G2
Valve Gp - Brake Manifold 270-4433 33 F-7 to G10 COOLING COMPONENTS SPRING LOADED GAS CHARGED LINES CROSSING LINES JOINING SINGLE ACTING DOUBLE ACTING
Valve Gp - Brake Relay 154-6832 34 F-5
Valve Gp - Cab Manifold 279-6515 35 H-6 to H-8 HYDRAULIC PUMPS HYDRAULIC MOTORS INTERNAL PASSAGEWAYS

Valve Gp - Sec. Brk Foot Pedal 223-2216 36 I-5 FIXED VARIABLE DISPLACEMENT FIXED VARIABLE DISPLACEMENT INFINITE THREE TWO
DISPLACEMENT NON-COMPENSATED DISPLACEMENT NON-COMPENSATED POSITIONING POSITION POSITION
Valve Gp - Serv. Brk Foot Pedal 159-4530 37 H-10
UNIDIRECTIONAL UNIDIRECTIONAL
Valve Gp - Traction Control 222-4744 38 H-12
FLOW IN ONE PARALLEL CROSS FLOW ALLOWED IN
Miscellaneous BIDIRECTIONAL BIDIRECTIONAL DIRECTION FLOW FLOW EITHER DIRECTION

Breather 4T-6788 70 D-5 Volume 1 of 2 Brakes, Brake Cooling, and Hoist Curcuits
Drive Gp - Pump Drive Box 149-3060 71 B-8 © 2007 Caterpillar Printed in U.S.A.
Pump Gp - Steering and Fan 194-0436 47 B-9 All Rights Reserved
Tank Gp - Hydraulic 205-0844 72 B-5 to C-6

32 31 29 A B 32 62 67 Electrical Symbols Table

46 53 48 54 45 42 47 70 21 27 25 24 38 21 61 66 Hydraulic Symbols (Electrical)

G M
Transducer Transducer Generator Electric Motor
(Fluid) (Gas / Air)

(Dimensions: 39 inches x 28 inches)

KENR8227 VOL 1
1 Pressure Switch Temperature Switch Electrical Wire
Pressure Switch
(Adjustable)
11 21 20 33 C
38 A B 21 24

Electrical Symbols (Electrical)

T
Pressure Temperature Level Flow
Symbol Symbol Symbol Symbol

Wire Number Identification Codes

Electrical Schematic Example Hydraulic Schematic Example

30 36 40 51 55 F H J 22 4 2 71 D 8 47 72 7 6 5 43 14 1 13 20 33 C 23 Current Standard Current Standard

Harness identification code
35 37 50 52 56 G I 3 E 11 10 9 44 28 34 This example indicates

30 Page,
wire 135 in harness "AG". Wire
Circuit Number
26 12 Identification
Wire Color

51 9 12
325-AG135 PK-14
53 52 40 55 45 22 42 4 70 47 2 5 44 43 7 6 10 72 70 26 67 1 27 325-PK
Circuit Identification Wire Color Wire Gauge
Number

Previous Standard
Wire Color
Wire
23

61 27 13 325-PK-14
D 13 E 6 7 8 72 B A
Circuit Number Wire Gauge
66 Identification (EXAMPLE VALVE)

62

21 32 HOIST COMPONENTS BRAKE COMPONENT

13
21 32

25 31

38 A B
34

23

46 54 48 30 37 36 56 22 42 4 71 3 11 D 8 14 1 24 33 28 20
35 E 29 C

COMPONENT LOCATIONS
 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

BRAKE GP
144-0244 LEFT FRONT
VALVE GP
I TRACTION I
CONTROL
222-4744
TO RAX LUBE VALVE GP
(VOLUME 2, C-2) SEC. BRK
VALVE GP FOOT PEDAL
SERV. BRK 223-2216
FOOT PEDAL ARC PROPORTIONAL BRAKE GP
159-4530 FRONT
CONT VALVE PARK 219-1633
BRAKE
ON/OFF P A
VALVE

P A T
LEFT REAR ADJUSTER
BRAKE SLACK T ADJUSTER
245-3682 BRAKE SLACK
ARC ON/OFF VALVE 245-3682

H VALVE GP H
CAB MANIFOLD
A B 279-6515

SWITCH GP
SERVICE BRAKE ACTUATION
128-5091
P A

P2 P1

DIVERTER VALVE GP
PILOT PARKING BRAKE
RELAY
134-6832

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

VALVE GP
SERVICE
BRAKE RELAY
ACCUM 154-6832
BLEED DOWN VALVE
VALVE GP
BRAKE MANIFOLD VALVE
VALVE COOLER GP 270-4433 BRAKE CONTROL
BRAKE CONTROL REAR 215-6442
215-6442 BRAKE OIL
F 240-4606 UNLOADER CONT F
SENSOR GP
BRK ACCUM
211-3407
P A

PUMP UNLOADER SWITCH GP T

LOW ACCUMULATOR
PRESSURE
C 213-6947
FITTING
ORIFICE
SYSTEM RELIEF 222-5319

FILTER GP
FRONT BRAKE
COOLING
194-0591
E E
(Dimensions: 39 inches x 28 inches)

SENSOR GP COOLER GP
BRAKE PUMP FRONT
PRESSURE PUMP GP BRAKE OIL
KENR8227 VOL 1

221-3407 DEAD ENG. TOW 241-9827

8W-9925
FILTER GP
BRAKE
155-6061
P2 HOIST

M
RIGHT REAR
PUMP BYPASS SECTION SECTION

D D

BREATHER
4T-6788 BRAKE GP
CYL TO TANK FRONT
SCREEN AS 219-1633
ROD END HOIST RETURN
9T-9227 RIGHT FRONT
BRAKE GP
144-0244 PUMP TO CYL
TANK GP
ROD END CYLINDER GP HYDRAULIC
30 Page, Color 2,

HOIST 205-0844
219-9784

C PUMP TO CYL C
HEAD END
SCREEN GP
HOIST
172-2395
CYL TO TANK
HEAD END SCREEN AS Tap Locations - Volume 1
PILOT VALVE GP COOLING Pressure, Sampling, and Sensor
ON/OFF D E BRK COOLING RETURN Tap
Description
Schematic
PUMP GP RELIEF 165-0056 Number Location
HOIST 6E-5855 A Left Service Brake Pressure H-12
223-3749
B Right Service Brake Pressure H-11
C Brake Pump Pressure F-11
D Hoist Pump Pressure B-8
VALVE GP E Hoist Pump Pressure B-7
HOIST
245-1763
DRIVE GP LINE PATTERNS
PUMP
B DRIVE BOX B
Pressure Line
149-3060 BREATHER
4T-6788 Pilot / Load Sensing Pressure

Drain / Return Lines

PUMP GP Component Group

BRAKE AND RAX: 223-3750 MOTOR GP
PUMP GP BRAKE COOLING
STEERING AND FAN BRAKE,RAX LUBE,RAX FAN: 223-3751 Attachment
171-1881
194-0436 PUMP GP
BRAKE COOLING Air Line
196-4624
CALLOUTS
PUMP GP YY Taps (Pressure, Sampling,Sensor) by letter
BRK COOLING
DRIVE 52 Components by number
187-9683

A A
HYDRAULIC CIRCUIT COLOR DESCRIPTIONS THIS SCHEMATIC IS FOR THE 797B 0FF-HIGHWAY TRUCK
ELECTRICAL CURCUIT
HOIST PUMPS AND CURCUIT HYDRAULIC SYSTEM
SUPPLY LINE PART #: 224-0763 CHNG 03
DRAIN / RETURN LINE
BRAKE COOLING PUMPS AND CURCUIT VOLUME 1 OF 2
RAX PUMP AND CURCUIT Components are shown installed on a fully operable machine with the key and engine
PARKING BRAKES / TRACTION CONTROL PUMP AND CURCUIT off and transmission shifter in neutral.
SERVICE BRAKES PUMP AND CURCUIT
Refer to the appropriate Service Manual for Troubleshooting, Specifications and Systems Operations

15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
 KENR8227 FLUID POWER SYMBOLS
February 2006
BASIC COMPONENT SYMBOLS

Component Locations - Volume 2 PUMP or MOTOR FLUID CONDITIONER SPRING CONTROL VALVES RESTRICTION LINE RESTRICTION
MAIN AUX.

2-SECTION PUMP
PUMP: VARIABLE and
PRESSURE COMPENSATED
(FIXED)
Part Machine Schematic
Description
Number Location Location
VARIABILITY SPRING LINE RESTRICTION PRESSURE HYDRAULIC PNEUMATIC LINE RESTRICTION ATTACHMENT
Steering and Fan (ADJUSTABLE) (VARIABLE) COMPENSATION ENERGY TRIANGLES VARIABLE and PRESSURE
COMPENSATED

Accumulator Gp - Steering 253-4120 40 H-12, H-13 VALVE ENVELOPES

VALVES
VALVE PORTS

Cooler Gp - Front Brake Oil 241-9827 2 B-12

Cylinder Gp - Steering 194-6171 42 G-3, H-3 ONE POSITION TWO POSITION THREE POSITION TWO-WAY THREE-WAY FOUR-WAY

Filter Gp - Case Drain 160-7752 43 B-8 CONTROL VALVES CHECK VALVES

Filter Gp - Case Drain 160-7752 44 C-7 AB AB

Filter Gp - Steering Return 219-6629 45 B-14

P T P T
46 BASIC SPRING SHUTTLE PILOT
Motor Gp - Fan Drive 183-7170 C-14 NORMAL POSITION SHIFTED POSITION INFINITE POSITION
SYMBOL LOADED CONTROLLED

Pump Gp - Steering and Fan 194-0436 47 D-10 to E-13 MEASUREMENT ROTATING SHAFTS

Pump Gp - Strg Hand Metering 192-3897 48 G-9

Screen As - Steering / Hoist Ret. 9T-9227 10 B-5 Tap Locations - Volume 2 PRESSURE TEMPERATURE FLOW UNIDIRECTIONAL BIDIRECTIONAL

Sensor Gp - Strg Accum Press. 221-3407 50 H-13

51
Pressure, Sampling, and Sensor FLUID STORAGE RESERVOIRS

797B Off-Highway Truck

Sensor Gp - Strg Pump Press. 221-3407 H-11 10
Switch Gp - High Press. Low 256-3638 52 H-13 Tap Schematic
Description
53 Number Location
Hydraulic System
VENTED PRESSURIZED RETURN ABOVE FLUID LEVEL RETURN BELOW FLUID LEVEL
Valve Gp - Makeup 183-7170 C-14
Valve Gp - Press. Reducing 226-0835 54 G-14 12 COMBINATION CONTROLS
F Steering Oil Sample Port G-12
Valve Gp - Solenoid and Relief 275-6390 55 G-12
G Auxillary Power Unit Port H-12 JSM220-UP
Valve Gp - Strg Flow Ampl. 151-5933 56 G-4 to G-7 SOLENOID SOLENOID SOLENOID SOLENOID and SERVO THERMAL DETENT
H Steering Pump Pressure F-11 or MANUAL and PILOT PILOT or MANUAL
Brake Cooling Pump Drive
Rear Axle Lube Pump Drive I Steering Pump Pressure H-11 MANUAL CONTROL SYMBOLS
9
Motor Gp - Brake Cooling 171-1881 5 B-4 J Steering Accumulator Pressure H-11
Motor Gp - RAX Drive 210-2642 61 E-2 PUSH-PULL LEVER MANUAL SHUTOFF GENERAL MANUAL PUSH BUTTON PEDAL SPRING
5
Motor Gp - RAX Fan 207-8609 62 D-1 PILOT CONTROL SYMBOLS
RELEASED PRESSURE REMOTE SUPPLY PRESSURE
Pump Gp - Brake and RAX: 223-3750 6
26 D-6
Brake, RAX Lube, and RAX Fan: 223-3751
Pump Gp - Brake Cooling 196-4624 6 B-4 to B-5 EXTERNAL RETURN INTERNAL

HYDRAULIC TANK COMPONENTS

INTERNAL RETURN SIMPLIFIED COMPLETE
SUPPLY PRESSURE

Pump Gp - Brake Cooling Drive 187-9683 7 D-7 to D-8 ACCUMULATORS CROSSING AND JOINING LINES HYDRAULIC AND PNEUMATIC CYLINDERS
Pump Gp - RAX Lube 151-4472 66 E-2 to E-3
Valve Gp - Relief 173-5399 67 E-2 SPRING LOADED GAS CHARGED LINES CROSSING LINES JOINING SINGLE ACTING DOUBLE ACTING

Miscellaneous HYDRAULIC PUMPS INTERNAL PASSAGEWAYS

HYDRAULIC MOTORS
Breather 4T-6788 70 D-5
FIXED VARIABLE DISPLACEMENT FIXED VARIABLE DISPLACEMENT THREE TWO
INFINITE
Drive Gp - Pump Drive Box 149-3060 71 D-9 DISPLACEMENT NON-COMPENSATED DISPLACEMENT NON-COMPENSATED POSITIONING POSITION POSITION

Pump Gp - Hoist 223-3749 8 E-8 UNIDIRECTIONAL UNIDIRECTIONAL

Tank Gp - Hydraulic 205-0844 72 C-5 BIDIRECTIONAL BIDIRECTIONAL

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

Volume 2 of 2 Steering, Fan, and RAX Lube Curcuits

© 2007 Caterpillar Printed in U.S.A.
All Rights Reserved

32 31 29 A B 32 62 67 Electrical Symbols Table

46 53 48 54 45 42 47 70 21 27 25 24 38 21 61 66
Hydraulic Symbols (Electrical)

G M
Transducer Transducer Generator Electric Motor
(Fluid) (Gas / Air)

(Dimensions: 39 inches x 28 inches)

KENR8227 VOL 2
Pressure Switch Pressure Switch Temperature Switch Electrical Wire
(Adjustable)

45 40 55 G F H 56 42 2 47 72
Electrical Symbols (Electrical)

T
Pressure Temperature Level Flow
Symbol Symbol Symbol Symbol

Wire Number Identification Codes

Electrical Schematic Example Hydraulic Schematic Example

30 36 40 51 55 F H J 22 4 2 71 D 8 47 72 7 6 5 43 14 1 13 20 33 C 23 Current Standard Current Standard
35 37 50 52 56 G I 3 E 11 10 9 44 28 34 Harness identification code
This example indicates
Wire

30 Page,
wire 135 in harness "AG".
26 12 Circuit Number Wire Color
51 9 12 Identification

325-AG135 PK-14
53 52 40 55 45 22 42 4 70 47 2 5 44 43 7 6 10 72 70 26 67 1 27
325-PK
Circuit Identification Wire Color Wire Gauge
Number

Previous Standard
Wire Color
23 Wire

61 325-PK-14
B A
66 Circuit Number Wire Gauge
Identification (EXAMPLE VALVE)

62
STEERING COMPONENTS
21 32

13
21 32

25 31

38 A B
34

23

46 54 48 30 37 36 56 22 42 4 71 3 11 D 8 14 1 24 33 28 20
35 E 29 C

COMPONENT LOCATIONS
 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

ACCUMULATOR
STEERING SENSOR GP
SWITCH GP STEERING PUMP
HIGH PRESSURE LOW 253-4120
PRESSURE
256-3638 221-3407
I I
VALVE GP
STEERING FLOW
AMPLIFIER
I 151-5933
SENSOR GP
STEERING ACCUMULATOR PUMP GP
PRESSURE STEERING
221-3407 HAND METERING
P L
192-3897
G H
J

H H
CL
HP

CYLINDER GP
STEERING
LS 194-6171
VALVE GP
PRESSURE REDUCING VALVE GP
226-0835 SOLENOID/ RELIEF
F 275-6390
G G

CR

HT EF R
T

F PUMP GP SEE 156-1885 PT OIL F

PUMP RAX LUBE FOR REAR AXLE LUBE
MOTOR SPEED 151-4472
ECM DISPLACEMENT SCHEMATIC

BRAKE & COOLING

FAN SPEED

PUMP DISPLACEMENT
PUMP GP FROM FAN PUMP MOTOR GP
T1 T2 R G2 B Mb Ma A G1 R T2 T1 HOIST RAX DRIVE
223-3749 VALVE GP 210-2642
30 Page, Color 2, (Dimensions: 39 inches x 28 inches)

RELIEF
173-5399
E E
KENRN8227 VOL 2

PUMP GP
BRAKE AND RAX: 223-3750
BRAKE,RAX LUBE,RAX FAN: 223-3751
DRIVE GP
PUMP DRIVE
BOX
149-3060

D
L1 D
Qmin Qmax Qmax Qmin
BREATHER
VALVE GP 4T-6788
MOTOR GP
MAKEUP RAX FAN:207-8609
183-7170
L2

M1 S M1
PUMP GP
PUMP GP BRAKE COOLING
STEERING DRIVE TANK GP
AND FAN 187-9683 HYDRAULIC
C 194-0436 C
MOTOR GP FILTER GP 205-0844 FROM BRAKE SYSTEM
FAN DRIVE CASE DRAIN (VOLUME 1,I-11)
183-7170 160-7752

FILTER GP
CASE DRAIN PUMP GP
BRAKE COOLING MOTOR GP
160-7752 BRAKE COOLING
196-4624
171-1881

B B
COOLER GP LINE PATTERNS
FRONT BRAKE OIL Pressure Line
241-9827 Pilot / Load Sensing Pressure

Drain / Return Lines

SCREEN GP
Component Group
STEERING / HOIST
Attachment
RETURN
9T-9227 Air Line

FILTER GP CALLOUTS

STEERING RETURN YY Taps (Pressure, Sampling,Sensor) by letter

HYDRAULIC CIRCUIT COLOR DESCRIPTIONS
219-6629 ELECTRICAL CURCUIT 52 Components by number
A BRAKE COOLING PUMP, FAN, AND CURCUIT
HOIST PUMPS AND CURCUIT
A
SUPPLY LINE
THIS SCHEMATIC IS FOR THE 797B 0FF-HIGHWAY TRUCK
DRAIN / RETURN LINE HYDRAULIC SYSTEM
BRAKE COOLING PUMPS AND CURCUIT
BRAKE COOLING DRIVE PUMP AND CURCUIT
PART #: 224-0763 CHNG 03
STEERING PUMP AND CIRCUIT VOLUME 2 0F 2
RAX PUMP AND CURCUIT Components are shown installed on a fully operable machine with the key and engine
PARKING BRAKES / TRACTION CONTROL PUMP AND CURCUIT off and transmission shifter in neutral.
SERVICE BRAKES PUMP AND CURCUIT
Refer to the appropriate Service Manual for Troubleshooting, Specifications and Systems Operations

15 14 13 12 11 10 9 8 7 6 5 4 3 2 1