RENR2618-01

October 2009
FLUID POWER SYMBOLS
8 7 6 5 4 3 2 1
BASIC COMPONENT SYMBOLS

59 53 V 61 S T 60 MAIN AUX

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

VALVE ENVELOPES VALVES VALVE PORTS

Steering Hydraulic System

ONE POSITION TWO POSITION THREE POSITION TWO - WAY THREE - WAY FOUR - WAY
Machine Location Schematic
Item Number Component Description Location CONTROL VALVES CHECK VALVES
AB A B
12 Steering Cylinders D-1
15 Steering Metering Pump D-5 P T P T
BASIC SPRING SHUTTLE PILOT
E 29 Steering Control Valve D-2 NORMAL POSITION SHIFTED POSITION INFINITE POSITION
SYMBOL LOADED CONTROLLED
E
42 Oil Cooler (Steering and Fan Drive) A-6
52 FLUID STORAGE RESERVOIRS
48 Pump Drive C-5
50 Piston Pumps (Steering) B-5, B-7
51 Oil Filter (Steering and Fan Drive) A-8
VENTED PRESSURIZED RETURN ABOVE FLUID LEVEL RETURN BELOW FLUID LEVEL
52 Accumulator Charging Valve D-7
53
59
Steering Accumulators
Solenoid and Relief Valve (Steering)
F-8
E-7
797 Off-Highway Truck MEASUREMENT ROTATING SHAFTS

12 60
61
Pressure Switch (Steering Pump Oil High)
Pressure Switch (Steering Pump Oil Low)
F-5
F-6
Hydraulic System PRESSURE TEMPERATURE FLOW UNIDIRECTIONAL BIDIRECTIONAL

62 Breather (Steering Tank Section) B-3 COMBINATION CONTROLS

D D
63 Steering Tank Section A-2 5YW1-UP
69 Hydraulic Filter (Pump Case Drain) A-3
S Pressure Tap (Steering Pump) F-6
SOLENOID SOLENOID SOLENOID SOLENOID & SERVO THERMAL DETENT
T Pressure Tap (Steering Accumulator) F-6 OR MANUAL & PILOT PILOT OR MANUAL

U Sampling Valve (Steering and Fan Drive System) - MANUAL CONTROL SYMBOLS
V Auxiliary Power Unit Port (Steering System) F-7

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

RELEASED PRESSURE PILOT CONTROL SYMBOLS REMOTE SUPPLY PRESSURE

15 48 29
C C

EXTERNAL RETURN INTERNAL RETURN SIMPLIFIED COMPLETE INTERNAL

SUPPLY PRESSURE

ACCUMULATORS CROSSING & JOINING LINES HYDRAULIC & PNEUMATIC CYLINDERS

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

62 HYDRAULIC PUMPS HYDRAULIC MOTORS INTERNAL PASSAGEWAYS

FIXED VARIABLE DISPLACEMENT FIXED VARIABLE DISPLACEMENT INFINITE

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

B B
UNIDIRECTIONAL UNIDIRECTIONAL

50 69
FLOW IN ONE PARALLEL CROSS FLOW IN
BIDIRECTIONAL BIDIRECTIONAL DIRECTION FLOW FLOW EITHER
DIRECTION

2009 Caterpillar, All Rights Reserved Printed in U.S.A.

A
A

O 51 42 63

ELECTRICAL SYMBOLS TABLE

8 7 6 5 4 3 2 1
HYDRAULIC SYMBOLS (ELECTRICAL)
Steering Hydraulic System

G
8 7 6 5 4 3 2 1
I 2 68 45
M
68 34 55 45 45
TRANSDUCER TRANSDUCER GENERATOR ELECTRIC MOTOR
F F (FLUID) (GAS / AIR)

(Dimensions: 39 inches x 28 inches)

48
23

48 A M

RENR2618-01
PRESSURE SWITCH PRESSURE SWITCH TEMPERATURE ELECTRICAL WIRE
Fan, Brake Cooling Motor Drive, and Rear Axle Motor Drive Hydraulic Systems
(ADJUSTABLE) SWITCH
E E Machine Location Schematic
Item Number Component Description Location 39
33 Fan Drive 55
34 Gear Pump (Rear Axle Oil) F-3 32 ELECTRICAL SYMBOLS (ELECTRICAL)
37 Piston Motor (Fan Drive) B-8 34
38 Makeup Valve (Fan Motor) B-8
43 Piston Motor (Brake Cooling) B-1
54 T
D D 45 Pilot Operated Relief Valve (Rear Axle Motor) E-2
46 Gear Pump (Brake Actuation and Rear Axle Motor Drive) C-3
PRESSURE TEMPERATURE LEVEL FLOW
47 Piston Pump (Brake Cooling Motor Drive) D-3 SWITCH SWITCH SWITCH SWITCH
64
48 Pump Drive D-4
49 Piston Pump (Fan Drive) D-5
WIRE NUMBER IDENTIFICATION CODES
55 Gear Motor (Rear Axle Pump Drive) B-1
63 Steering Tank Section B-2
64 Hydraulic Tank C-1 ELECTRICAL SCHEMATIC EXAMPLE HYDRAULIC SCHEMATIC EXAMPLE
C C
65 Gear Pump (Brake Cooling) B-1 CURRENT STANDARD CURRENT STANDARD
38 L 33 49 47 69 46
68 Electronic Control Module (Brake/Cooling) F-7 HARNESS IDENTIFICATION CODE THIS EXAMPLE
69 Hydraulic Filter (Pump Case Drain) A-4, B-3 INDICATES WIRE 135 IN HARNESS AG
65 Rear Axle Hydraulic System
L Pressure Tap (Fan Drive Oil) B-8 WIRE
Machine Location
Component Description
Item Number

30 Page,
CIRCUIT NUMBER
43 325-AG135 PK-14 IDENTIFICATION WIRE COLOR
2 Control Valve (Final Drive Diverter)

B B 23 Oil Filter (Final Drive)

32 Relief Valve (Differential Oil) CIRCUIT NUMBER WIRE WIRE GAUGE
IDENTIFICATION COLOR 325-PK
34 Gear Pump (Rear Axle Oil)
69
39 Oil Filter (Differential)
PREVIOUS STANDARD
45 Pilot Operated Relief Valve (Rear Axle Motor)
46 Gear Pump (Brake Actuation and Rear Axle Motor Drive)
WIRE WIRE COLOR
48 Pump Drive
37
63 54 Screen
A A 325-PK-14 B A
55 Gear Motor (Rear Axle Pump Drive
A Pressure Tap (Final Drive Pump Section)
CIRCUIT NUMBER WIRE GAUGE (EXAMPLE VALVE)
I Pressure Tap (Final Drive Oil) IDENTIFICATION
M Pressure Tap (Differential Oil)
8 7 6 5 4 3 2 1

Fan, Brake Cooling Motor Drive, and Rear Axle Motor Drive Hydraulic Systems
 Brake Actuation Hydraulic
y System
Machine Location Schematic
8 7 6 5 4 3 2 1 Component Description
Item Number Location
1,56 Service and Parking Brake (Rear) F-8, A-8 1 2 A 3 4 5 B C 6 7 D E 8 9 10 F 11 12 13 14 15
1 3 11
3 Traction Control Valve E-6
4 Brake Accumulator (Service) C-4, D-5 16 17 18 19 G 20 21 22 H
F
F 5 Brake Valve (Chassis) B-6
11,67 Service and Parking Brake (Front) F-1, B-1
13 Secondary Brake Control F-2
14 Service Brake Control F-5 23 I 24 25 26
17 Relay Valve (Service Brake/Retarder) D-3
18 Brake Accumulator (Parking) D-3
27 28 29
19 Relay Valve (Parking Brake) C-2
20 Hydraulic Filter (Brake Actuation) B-5
30 14 26 13 27 26 Valve and Mtg Gp - Brake E-5 30 31 12
E 27 Slack Adjuster (Front) D-1
80 E Slack Adjuster (Rear) D-7
30 32 33
36 Electric Drive Pump (Parking and Secondary Brake Release) C-3
44 Breather (Hydraulic Tank) C-3
46 Gear Pump (Brake Actuation and Rear Axle Motor Drive) A-5
4 17 48 Pump Drive A-6
34
64 Hydraulic Tank A-3
B Pressure Tap (Parking Brake Accumulator) C-7 35 J K 36 37 38 L
C Pressure Tap (Brake Actuation Pump) C-7
80 Elbow As E-3 39 M 40 N O 41 42
D D

43 44
18 Fan, Brake Cooling Motor Drive. and Rear Axle Motor Drive Hydraulic Systems
Machine Location Schematic 45 46 47 48 49 50 51 52 53
4 Item Number Component Description Location
33 Fan Drive B-7 54 55 56 57 P Q 58 R 59 60 61 S T U V
34 Gear Pump (Rear Axle Oil) F-3
37 Piston Motor (Fan Drive) B-8 62 63 64 65 66 W X 67
38 Makeup Valve (Fan Motor) B-8
43 Piston Motor (Brake Cooling) B-1
C C
45 Pilot Operated Relief Valve (Rear Axle Motor) E-2
46 Gear Pump (Brake Actuation and Rear Axle Motor Drive) C-3
19 47 Piston Pump (Brake Cooling Motor Drive) D-3 Steering Hydraulic System
48 Pump Drive D-4 Machine Location Schematic
49 Piston Pump (Fan Drive) D-5 Item Number Component Description Location
44 Steering Cylinders
55 Gear Motor (Rear Axle Pump Drive) B-1 12 D-1
63 Steering Tank Section B-2 15 Steering Metering Pump D-5
36 Steering Control Valve
64 Hydraulic Tank C-1 29 D-2
65 Gear Pump (Brake Cooling) B-1 42 Oil Cooler (Steering and Fan Drive) A-6
B B L Pressure Tap (Fan Drive Oil) B-8 48 Pump Drive C-5
C B 5 48 20 64 67 50 Piston Pumps (Steering) B-5, B-7
51 Oil Filter (Steering and Fan Drive) A-8
Rear Axle Hydraulic System 52 Accumulator Charging Valve D-7
Machine Location 53 Steering Accumulators F-8
Component Description
Item Number Solenoid and Relief Valve (Steering)
59 E-7
2 Control Valve (Final Drive Diverter) Pressure Switch (Steering Pump Oil High)
60 F-5
23 Oil Filter (Final Drive) Pressure Switch (Steering Pump Oil Low)
61 F-6
32 Relief Valve (Differential Oil) Breather (Steering Tank Section)
62 B-3
34 Gear Pump (Rear Axle Oil) Steering Tank Section
A A 63 A-2
39 Oil Filter (Differential) Pressure Tap (Steering Pump)
S F-6
45 Pilot Operated Relief Valve (Rear Axle Motor) Pressure Tap (Steering Accumulator)
46 T F-6
46 Gear Pump (Brake Actuation and Rear Axle Motor Drive) Sampling Valve (Steering and Fan Drive System)
56 U -
48 Pump Drive Auxiliary Power Unit Port (Steering System)
V F-7
8 7 6 5 4 3 2 1 54 Screen
55 Gear Motor (Rear Axle Pump Drive)
Brake Actuation Hydraulic System A Pressure Tap (Final Drive Pump Section)
I Pressure Tap (Final Drive Oil)
M Pressure Tap (Differential Oil)

8 7 6 5 4 3 2 1 48
Hoist and Brake Cooling Hydraulic System
1 40 11 Machine Location Schematic
Component Description
(Dimensions: 39 inches x 28 inches)

Item Number Location

F 10 57 P
1,56 Service and Parking Brake (Rear) F-7, A-7
F
6 Hoist Cylinders E-2
7 Hydraulic Filter (Rear Brake Cooling) D-7
RENR2618-01

11,67 Service and Parking Brake (Front) E-1, C-1

21 Diverter Valve (Rear Brake Cooling) C-7
24 Gear Pump (Hoist and Brake Cooling) C-5
25 Oil Coolers (Rear Brake) B-7
28 Hoist Screens C-5
70 71
35 Hydraulic Filter (Front Brake Cooling) D-3 F
G 40 Control Valve (Hoist and Brake Cooling) D-4
E
6 E 41 Oil Coolers (Front Brake) C-2
43 Piston Motor (Brake Cooling Pump Drive) A-3 72
44 Breather (Hydraulic Tank) C-4 R
47 Piston Pump (Brake Cooling Motor Drive) C-4 58
48 Pump Drive C-6
64 Hydraulic Tank B-3
65 Gear Pumps (Brake Cooling) A-3
D Pressure Tap (Rear Brake Cooling Oil) D-6
7 35 41
E Sampling Valve (Rear Brake Cooling Oil) -
D D
G Auxiliary Power Unit Port (Hoist System) E-3
J Pressure Tap (Front Brake Cooling Oil) D-3 73
K Sampling Valve (Front Brake Cooling Oil) -
28
O
30 Page,

N N Pressure Tap (Hoist) D-6 22

O Pressure Tap (Hoist) D-5 74 16 31
75
D 48 24 44 J 64 67

Torque Converter and Transmission Hydraulic System H

Machine Location
21 C Component Description
C Item Number
8 Gear Pump (Transmission Charging and Scavenge) 66
9 Gear Pump (Torque Converter Charging and Transmission Lubrication)
10 Modulating Valve (Torque Converter Lockup Clutch)
W
16 Magnetic Screen (Transmission)
22 Relief Valve (Torque Converter Outlet)
31 Differential Valve (Transmission Lubrication) 9 8
48 Pump Drive
57 Oil Filter (Transmission)
B B 58 Relief Valve (Torque Converter Inlet)
56 25 47 66 Oil Filter (Torque Converter)
70 Relief Valve (Transmission Main)
71 Transmission Planetary
72 Torque Converter
73 Magnetic Screen (Torque Converter Outlet)
74 Transmission Hydraulic Control
75 Oil Cooler (Torque Converter and Transmission)
F Pressure Tap (Torque Converter Lockup Clutch)
65 43 H Pressure Tap (Torque Converter Outlet Relief Valve) Torque Converter and Transmission Hydraulic System
A A
P Pressure Tap (Transmission Charging Pump Section)
Q Sampling Valve (Transmission Charging Oil)
R Pressure Tap (Torque Converter Inlet Relief Valve)
W Pressure Tap (Torque Converter Charging Pump Section)
8 7 6 5 4 3 2 1 X Sampling Valve (Torque Converter Charging Oil)

Hoist and Brake Cooling Hydraulic System

THIS SCHEMATIC IS FOR THE 797 OFF-HIGHWAY TRUCK

MEDIA NUMBER: RENR2618-01
PART NUMBER: 192-5797, CHANGE: 03, VERSION: -
Components are shown installed on a fully operable machine.

Refer to the appropriate Service Manual for Troubleshooting, Specifications.