Component Locations

FLUID POWER SYMBOLS

23

Machine
Location

Schematic
Location

Part
Number

B - 11,J - 11

Service and Parking Brake (Rear)

5T-4489

F-9

Traction Control Valve

9G-9208

B-8

Hoist Cylinders

9T-2807

F-9

Check Valve (Electric Drive Pump)

9T-3086

E - 10

Electric Drive Pump (Parking and Secondary Brake Release)

5T-1060

Description

RENR8121
October 2004

BASIC COMPONENT SYMBOLS

MAIN AUX.

I-9

Brake Valve (Parking and Secondary)

149-4133

J-9

Orifice

122-7765

J-9

Screen

6E-5065

H-9

Check Valve

138-4733

10

I-5

Lockup Clutch and Synchronizing Valve (Torque Converter)

8E-6146

11

D - 2,I - 2

Service and Parking Brake (Front)

5T-5070

18

J-9

Makeup Tank for Service Brake Oil

6E-1851

19

H-7

Hydraulic Filter (Parking Brake Release)

6P-4603

20

B - 3,C - 3

Bypass Switch (5)

9X-7781

21

J-4

Diverter Valve (Torque Converter and Front Brake Cooling)

105-0170

24

I-5

Relief Valve (Torque Converter Outlet)

9W-7403

26

G - 11

Air Over Hydraulic Cylinder (Brake)

8W-3405

27

J-5

Screen (Torque Converter and Front Brake Cooling)

6E-1349

28

J-3

Oil Cooler (Front Brake Cooling)

141-4108

29

E-3

Orifice

8W-4042

32

F - 11

Slack Adjuster (Rear)

5T-7670

33

B - 10

Oil Cooler (Rear Brake Cooling)

141-4108

34

B - 10

Screen

6E-6640

35

F-2

Slack Adjuster (Front)

2G-5900

38

D-8

Control Valve

132-2048

39

B-7

Counterbalance Valve (Hoist)

132-7102

40

F-4

Pump Drive

2A-6516

41

G - 14

Piston Pump (Steering)

6E-5650

45

C - 3,D - 3

48

G-7

Hoist Screens

6E-5471

Rear Brake Cooling Pump Section

3E-3882

49

H-6

Parking Brake Release Pump Selection

6T-6147

50

H-6

Torque Converter Charging Pump Section

6T-6147

51

H-6

Torque Converter Scavenge Pump Section

6T-6147

52

E-7

Hydraulic Tank (Torque Converter, Hoist, Brake and Transmission)

161-0536

53

E-6

Suction Screens

9T-3850

58

H-4

Air Breather (Hoist, Torque Converter and Brake)

8X-4575

61

B - 11,I - 11

Service and Parking Brake (Rear)

5T-4489

62

J-6

Relief Valve (Torque Converter Inlet)

3P--0348

63

G-5

Hoist and Rear Brake Cooling Gear Pump

139-2454

64

I-6

Hydraulic Filter (Torque Converter)

4T4760

66

D - 2,I - 2

Service and Parking Brake (Front)

5T-5070

73

H-5

Torque Converter

116-5811

80

D-9

HARC Valve

177-8840

80

E-9

Check Valve

9T-6173

PUMP or MOTOR

D - 10

Accumulator Grp.

Pressure Switch (Steering Pump Oil Low)

3E-7809

13

I - 15

Orifice

8X-7851

14

G - 13

Metering Pump (Steering)

9T-1318

22

J - 13

Steering Cylinders

4T-6797

23

I - 13

Steering Control Valve

9T-1318

30

I - 17

Accumulator Charging Valve

148-9237

36

J - 16

Solenoid and Relief Valve (Steering)

6E-3965

41

H - 15

Piston Pump (Steering) and Pressure Compensator Valve

6E-5656

42

I - 15

Orifice

1T-0936

46

J - 17

Pressure Switch (Steering Pump Oil High)

3E-6461

47

J - 16

Steering Accumulators

6E-6611

60

G - 16

Filter (Steering Pump Case Drain)

4T-4284

67

G - 16

Steering Tank

155-6660

68

G - 17

Steering Tank Filter

9J-5461

69

H - 17

Brake Relief Valve

9T-0818

70

J - 16

Check Valve (Steering)

9T-2553

PUMP: VARIABLE and

PRESSURE COMPENSATED

2-SECTION PUMP

HYDRAULIC
PNEUMATIC
ENERGY TRIANGLES

LINE RESTRICTION

ATTACHMENT

VARIABLE and PRESSURE

COMPENSATED

VALVES

16

VALVE PORTS

VALVE ENVELOPES

TWO POSITION

ONE POSITION

THREE POSITION

(1) Torque converter, hoist, brake, and transmission hydraulic tank

(2) Torque converter, hoist, and brake section
(3) Transmission section

(Y) Parking Brake Filter Oil (Sampling)

(6) Parking brake release hydraulic filter
(23) Bypass switch
(16) Torque converter and front brake cooling screen

FOUR-WAY

THREE-WAY

TWO-WAY

CONTROL VALVES

CHECK VALVES

AB

AB

P T
SHIFTED POSITION

P T
NORMAL POSITION

INFINITE POSITION

SPRING LOADED

BASIC SYMBOL

ROTATING SHAFTS

MEASUREMENT

(1) Steering accumulators

(2) Pressure switch for high pressur
oil from the steering piston pump
(3) Accumulator charging valve
(4) Steering cylinders
(5) Steering solenoid and relief valve

17

12

16

PRESSURE

(7) Steering control valve

(8) Steering pump case drain filter
(10) Steering hydraulic tank
(12) Steering piston pump
(14) Pressure switch for low pressure
oil from the steering piston pump

Top view of steering oil lines

FLOW

TEMPERATURE

UNIDIRECTIONAL

BIDIRECTIONAL

FLUID STORAGE RESERVOIRS

789C Off-Highway Truck

Hydraulic System

RETURN ABOVE FLUID LEVEL

PRESSURIZED

VENTED

RETURN BELOW FLUID LEVEL

COMBINATION CONTROLS

2BW659-UP

SOLENOID
or MANUAL

SOLENOID

SERVO

SOLENOID and
PILOT or MANUAL

SOLENOID
and PILOT

DETENT

THERMAL

MANUAL CONTROL SYMBOLS

(12) Steering piston pump
(16) Pressure compensator valve
(17) Pump drive
(A) Low steering pump pressure test port.
(1) Low pressure switch from steering piston pump

GENERAL MANUAL

MANUAL SHUTOFF

PUSH-PULL LEVER

PUSH BUTTON

PEDAL

SPRING

H
PILOT CONTROL SYMBOLS

RELEASED PRESSURE

REMOTE SUPPLY PRESSURE

F
13

10

EXTERNAL RETURN

INTERNAL RETURN

SIMPLIFIED

CROSSING AND JOINING LINES

ACCUMULATORS

GAS CHARGED

(1) Steering accumulators

(2) Pressure switch for high pressur
oil from the steering piston pump
(4) Steering cylinders
(7) Steering control valve
(8) Steering pump case drain filter
(10) Steering hydraulic tank

(H) Pressure tap for Rear Service Brake

(F) Pressure tap for Left parking brake release pressure
(G) Pressure tap for Right parking brake release pressure

SINGLE ACTING

INTERNAL PASSAGEWAYS

HYDRAULIC MOTORS

VARIABLE DISPLACEMENT
NON-COMPENSATED

FIXED
DISPLACEMENT

VARIABLE DISPLACEMENT
NON-COMPENSATED

UNIDIRECTIONAL

UNIDIRECTIONAL

BIDIRECTIONAL

BIDIRECTIONAL

DOUBLE ACTING

PARALLEL
FLOW

FLOW IN ONE
DIRECTION

TWO
POSITION

THREE
POSITION

INFINITE
POSITIONING

CROSS
FLOW

FLOW ALLOWED IN
EITHER DIRECTION

Side view of steering oil lines

Top view of Rear Brake Lines

(8) Steering pump case drain filter
(9) Steering filter
(10) Steering hydraulic tank
(13) Breaker relief valve

FIXED
DISPLACEMENT

(12) Steering piston pump

(14) Pressure switch for low pressure
oil from the steering piston pump
(15) Orifice
(16) Pressure compensator valve
(AA) Pressure tap for low pressure oil
from the steering piston pump

INTERNAL
SUPPLY PRESSURE

COMPLETE

HYDRAULIC AND PNEUMATIC CYLINDERS

LINES JOINING

LINES CROSSING

HYDRAULIC PUMPS

241-3147

I - 15

PRESSURE
COMPENSATION

LINE RESTRICTION
(VARIABLE)

SPRING
(ADJUSTABLE)

VARIABILITY

Steering Hydraulic System

12

LINE RESTRICTION
(FIXED)

RESTRICTION

SPRING LOADED

81

CONTROL VALVES

SPRING

FLUID CONDITIONER

Printed in U.S.A.

2004 Caterpillar
All Rights Reserved

Electrical Symbols Table

Hydraulic Symbols (Electrical)

Transmission Hydraulic System

Bypass Switch

9X-7781

E - 14

Magnetic Screen (Transmission)

7T-4554

40

C - 15

Pump Drive

2A-6516

43

E - 16

Oil Cooler (Transmission)

4W-5056

44

D - 15

Relief Valve (Transmission Cooler Inlet)

2P-2859

52

B - 14

Hydraulic Tank (Torque Converter, Hoist, Brake and Transmission)

161-0536

53

B - 16

Suction Screen

9T-3850

54

C - 15

Transmission Charging Pump Section

156-8525

55

C - 15

Transmission Planetary

156-8525

56

C - 15

Transmission Scavenge Pump Section

156-8525

57

D - 16

Hydraulic Filter (Transmission Charging)

6P-4603

59

E - 13

Air Breather (Transmission)

6G-0078

65

D - 15

Hydraulic Filter (Transmission Lubrication)

6P-4603

66

53

52
61

46

57 65

67

N 43 44

22

30

23

G
37
H 32
F
HH

Machine
Location

Low Steering Pump Pressure

I - 15

41

High Steering Pressure (Accumulator)

H - 13

23

Hoist Pump Pressure (Front)

G-5

63

Hoist Pump Pressure (Rear)

G-5

63

Left Rear Brake Cooling Pressure

J - 10

Left Rear Parking Brake Pressure

I - 10

32

Right Rear Parking Brake Pressure

C - 10

32

Rear Service Brake Pressure

F - 11

32

Front Service Brake Pressure

F-3

35

Torque Converter Charge Pump Pressure

I-6

64

Torque Converter Lock-up Clutch Pressure

I-5

10

Torque Converter Outlet Pressure

I-4

24
43

Transmission Lube Pump Pressure

E - 15

Left Brake Pressure Test Port

F - 10

Transmission Charge Pump Pressure

E - 16

37

Right Brake Pressure Test Port

E - 10

Hoist System Power Unit (Auxiliary)

C-9

38

Steering System Power Unit (Auxiliary)

G - 15

36

Transmission System Oil (Sampling)

D - 15

57

Hoist and Torque Converter System Oil (Sampling)

H-7

19

Streeting System Oil (Sampling)

I - 16

36

Pressure Switch
(Adjustable)

Pressure Switch

(N) Pressure Tap for Transmission Lube Pump.

(1) Pump drive
(2) Hoist and rear brake cooling gear pump (front section)
(3) Hoist and rear brake cooling gear pump (rear section)
(4) Inlet from the hydraulic tank
(5) Inlet from the hydraulic tank
(6) Outlet to the hoist control valve
(7) Outlet to the hoist control valve

Electrical Wire

Temperature Switch

Electrical Symbols (Electrical)

1
T

27 19 Y
20

14

Schematic
Location

Electric Motor

22

Tap Locations
Pressure, Sampling, and Sensor

54
81
56
80 72 55
41 40
63 D
20 38 39
13
42 C
51
R
62
35
29
73
48 49
J
L
24 50
28
10
26
21
7 M
Q 2 O
45
9 8
18
5
6
4

12

Generator

59

70

33 36

Transducer
(Gas / Air)

58

34 60
(1)Torque converter outlet relief valve.
(M)Pressure tap for torque converter outlet pressure.
(2) Torque converter inlet relief valve.
(L) Pressure tap for lockup clutch pilot oil.

20
64

X 20

68 69
47

Description

Transducer
(Fluid)

Tap
Number

D
1

Pressure
Symbol

Temperature
Symbol

Flow
Symbol

Level
Symbol

Wire Number Identification Codes

19

Electrical Schematic Example

11
5
(5) Steering solenoid and relief valve
(6) Steering check valve
(18) Steering relief valve
(19) Steering solenoid valve
(Z) Steering system oil sampling port
(S) Steering system Power Unit (Auxiliary)

(E) Left Rear Brake Cooling Pressure

(1) Torque converter and front brake cooling oil cooler
(5) Torque converter and front brake cooling diverter valve

18

Hydraulic Schematic Example

Current Standard

Current Standard
K

Harness identification code

This example indicates
wire 135 in harness "AG".

Wire
Circuit Number
Identification

Wire Color

325-AG135 PK-14

325-PK
Circuit Identification
Number

Wire Color

Wire Gauge

Previous Standard

Wire Color

Wire

325-PK-14

60 67 68

(2) Rear brake oil coolers

(3) Screens for the rear brake oil coolers

14

B
(1) Torque converter hydraulic filter
(2) Inlet line
(3) Outlet line
(4) Bypass switch
(K) Torque Converter Charge pump pressure

Circuit Number
Identification

Wire Gauge
(EXAMPLE VALVE)

29
28

21

(J) Pressure Tap for Front Service Brake

56
Related Manuals
Description
Power Train
Specifications
Systems Operation
Testing and Adjusting
Disassembly and Assembly
Machine Systems

47

Media Number

SENR1531

Testing and Adjusting: (Hydraulic System)

SENR1532

Specifications: (Steering System)

SENR1525

Testing & Adjusting: (Steering System)

SENR1526

Specifications: (Air System & Brakes)

SENR1527

Testing & Adjusting: (Air System & Brakes)

SENR1528

Specifications, System Operation, Testing &

Adjusting: (Oil Evacuation System)

RENR2223

Specifications: (Suspension Cylinder)

44

SENR1529

23

22
11

35

37
80 72

(B) High steering pressure test port.

Q
(H) Pressure Tap for Rear Service Brake.

SENR2986

71 55

E 61

30

H 32

SENR1535

Additional Manuals
Automatic Electronic Traction Aid (AETA)

43 33
66

Electrical System:
Schematic (Electrical System)

46

36

Specifications: (Hydraulic System)

18 26
20
63
26
2
45
6
57 65 5
19
4
70
41
40
53 52
38 39
20
49 54
48
51 56
50

12
70

G
64

10
24 62
27

SENR1521
SENR1522
SENR1523
SENR1524

59

(P) Pressure tap for the transmission charging section

(O) Left Brake Pressure Test Port

(Q) Right Brake Pressure Test Port.

30 Page, EAR

D - 16

37

RENR8121-00

20

17

16

15

14

13

12

11

10

Pressure Switch
(Steering Pump Oil High)
3E-6461

Steering
Accumulators
6E-6611

Auxiliary Power
Unit Port

Steering Cylinders
4T-6797

Makeup Tank for

Service Brake Oil
6E-1851

LEFT REAR

J
Relief Valve
3P-0348

Steering
Control Valve
9T-1317

OIL
SAMPLE
PORT

Torque Converter
Hydraulic Filter
9T-3838

Service and Parking

Brake (Rear) 5T-4489

Orifice
8X-7851

Low Steering Pump

Pressure Test Port

Bypass Switch
116-9933

Torque Converter and

Front Brake Cooling
Diverter Valve 105-0170

Service and
Parking Brake
(Front) 5T-5070

Torque Converter
Outlet Relief Valve
9W-7403

LEFT FRONT

M
Parking and
Secondary
Brake Valve
149-4133

EF

Torque Converter
116-5811
Parking Brake
Release Pump
Selection 6T-6147

Orifice
1T-0936

Accumulater
Charging Valve
148-9237

Torque Converter
Lockup Valve
8E-6146

Pressure Switch
(Steering Pump Oil Low)
3E-7809

Bypass Switch
9X-7781

R
Bypass Switch
9X-7781

Low Steering
Pressure Switch

CR

CL

Solenoid and Relief Valve

(Steering) 6E-6298

High Pressure
Screen 6E-1349

Orifice
122-7765

Check Valve (Steering)

9T-2553

Oil Cooler
(Front Brake Cooling)
141-4108

Screen
6E-5065

LOCK-UP
VALVE
Hoist, Torque Converter
and Brake Air Breather
8X-4575

Torque Converter
Charging Pump
Section 6T-6147

Check Valve
138-4733

T
Air Over Hydraulic Cylinder
(Brake) 8W-3405

HP

LS

HT

TORQUE CONVERTER

Parking Brake
Release Hydraulic
Filter 6P-4603

H
Torque Converter
Scavenge Pump
Section 6T-6147

Breake
Releif Valve
9T-0818
Filter (Steering Pump Case Drain)
4T-4284

High Steering
Pressure Test Port

Piston Pump (Steering) and

Pressure Compensator Valve
6E-5656

Left Brake
Pressure
Test Port

Rear Brake
Cooling Pump
Section 3E-3882

Traction Control
Vlave 9G-9208

Air Over Hydraulic

Cylinder 8W-3405

Steering Tank
155-6660

Shuttle Valve
8J-6173

Metering Pump
(Steering) 9T-1318

C
)(

PUMP
DRIVE
BOX

)(

Auxiliary Power
Unit Port

Steering Tank
Filter 9J-5461

Torque Converter, Hoist,

Brake and Transmission
Hydraulic Tank 161-0536

STEERING SYSTEM

Piston Pump (Steering)

6E-5650 - See Steer System

Slack Adjuster
2G-5900

Suction Screen
9T-3850

Slack Adjuster (Rear)

5T-7670

Air Breather
(Transmission)
6G-0078

TRANSMISSION

Hoist and Rear Brake

Cooling Gear Pump
139-2454

Electric Drive Pump

Check Valve
9T-3096

Transmission Planetary

HYD
CONTROLS

Pump Drive
2A-6516

Right Brake
Pressure
Test Port

Shuttle Valve
8J-6173

Suction Screen
9T-3838

Motor

Suction Screens
9T-3850

Accumulator Group
241-3147

E
Transmission Hydraulic Control

Magnetic Screen
(Transmission)
7T-4554

Oil Cooler
(Transmission)
4W-5056

Electric Drive Pump:

Parking and Secondary
Brake Release
5T-1060

Check Valve
9T-3752

DUAL STAGE
SIGNAL SPOOL

Control Valve
245-1662

Transmission Cooler
Inlet Relief Valve
2P-2859

HIGH PRESSURE RELIEF

MAIN RELIEF
DUMP SPOOL

)(

Hoist Screens
6E-5471

Hydraulic Filter
(Transmission Lubrication)
6P-4603

Bypass Switch
9X-7781

Orifice
8W-4042

RIGHT FRONT

30

Page, Color 2, DGM

Hydraulic Filter
(Transmission Charging)
6P-4603

Bypass Switch
9X-7781

Hydraulic ARC
Valve 177-8840
Bypass Switch
9X-7781

LINE PATTERNS

RAISE

Pressure Line

BRAKE COOLING RELIEF

Screen
6E-6640

Pilot / Load Sensing Pressure

Hoist Screens
6E-5471

HOLD

PUMP
DRIVE
BOX

Drain / Return Lines

SIGNAL ORIFICE #1

Pump Drive
2A-6516

Service and Parking Brake

(Rear) 5T-4489

Component Group

SNUB

SIGNAL ORIFICE #2

Attachment
Transmission Scavenge Pump
Section 156-8525

Transmission Charging Pump Section

156-8525

Service and
Parking Brake
(Front) 5T-5070

)(

RENR8121-00

LOW PRESSURE RELIEF

FLOA

Oil Cooler
(Rear Brake Cooling)
141-4108

Air Line

CALLOUTS
LOWER

Transmission Planetary
156-8525

Bypass Switch
9X-7781

Counterbalance Valve
(Hoist) 132-7102

YY

Taps (Pressure, Sampling,Sensor) by letter

52

Components by number

HYDRAULIC CIRCUIT COLOR DESCRIPTIONS

VENT ORIFICE FOR
COUNTERBALANCE VALVE

Suction Screen
9T-3850

ROD END VENT

SLOT ACROSS STEM

Hoist and Rear Brake Cooling Pump Circuit

Primary and Secondary Parking Brake Pump Circuit

Hoist Cylinders
9T-2807

RIGHT REAR

Steering Pump Circuit

Transmission Pump Circuit
Torque Converter Charge Pump Circuit
Supply Line.
Drain / Return Line.

Hydraulic Tank
(Torque Converter, Hoist, Brake and Transmission)
161-0536

Service and Parking Brake Circuit

Steering Cylinder Circuit
Hoist Cylinder Circuit

TRANSMISSION

Torque Converter Relief Circuit

Brake Cooling

HOIST, BRAKE COOLING, AND TORQUE CONVERTER SYSTEMS

A

THIS SCHEMATIC IS FOR THE 789C OFF HIGHWAY TRUCK A

PART #: 158-3405 CHG 01
Components are shown installed on a fully operable machine with the key and engine
off and transmission shifter in neutral.

17

16

15

14

13

12

11

10