Component Locations 23 FLUID POWER SYMBOLS

Machine Schematic
Description
Part RENR8121 BASIC COMPONENT SYMBOLS
Location Location Number
Y October 2004
1 B - 11,J - 11 Service and Parking Brake (Rear) 5T-4489
MAIN AUX.
PUMP: VARIABLE and
2 F-9 Traction Control Valve 9G-9208 PUMP or MOTOR CONTROL VALVES RESTRICTION LINE RESTRICTION 2-SECTION PUMP PRESSURE COMPENSATED
FLUID CONDITIONER SPRING
(FIXED)
3 B-8 Hoist Cylinders 9T-2807
6
4 F-9 Check Valve (Electric Drive Pump) 9T-3086

5 E - 10 Electric Drive Pump (Parking and Secondary Brake Release) 5T-1060 VARIABILITY SPRING LINE RESTRICTION PRESSURE HYDRAULIC PNEUMATIC LINE RESTRICTION
ATTACHMENT
COMPENSATION ENERGY TRIANGLES VARIABLE and PRESSURE
1 2 3 (ADJUSTABLE) (VARIABLE)
COMPENSATED
6 I-9 Brake Valve (Parking and Secondary) 149-4133

7 J-9 Orifice 122-7765 VALVES

16 VALVE ENVELOPES VALVE PORTS
8 J-9 Screen 6E-5065

9 H-9 Check Valve 138-4733

ONE POSITION TWO POSITION THREE POSITION TWO-WAY THREE-WAY FOUR-WAY
10 I-5 Lockup Clutch and Synchronizing Valve (Torque Converter) 8E-6146

11 D - 2,I - 2 Service and Parking Brake (Front) 5T-5070 CONTROL VALVES CHECK VALVES
AB AB
18 J-9 Makeup Tank for Service Brake Oil 6E-1851
(Y) Parking Brake Filter Oil (Sampling) (1) Torque converter, hoist, brake, and transmission hydraulic tank
19 H-7 Hydraulic Filter (Parking Brake Release) 6P-4603 (6) Parking brake release hydraulic filter (2) Torque converter, hoist, and brake section
(23) Bypass switch (3) Transmission section P T P T
20 B - 3,C - 3 Bypass Switch (5) 9X-7781 NORMAL POSITION SHIFTED POSITION INFINITE POSITION BASIC SYMBOL SPRING LOADED
(16) Torque converter and front brake cooling screen
21 J-4 Diverter Valve (Torque Converter and Front Brake Cooling) 105-0170
MEASUREMENT ROTATING SHAFTS
24 I-5 Relief Valve (Torque Converter Outlet) 9W-7403

26 G - 11 Air Over Hydraulic Cylinder (Brake) 8W-3405 1 A

27 J-5 Screen (Torque Converter and Front Brake Cooling) 6E-1349
(1) Steering accumulators (7) Steering control valve PRESSURE TEMPERATURE FLOW UNIDIRECTIONAL BIDIRECTIONAL
28 J-3 Oil Cooler (Front Brake Cooling) 141-4108 (2) Pressure switch for high pressur (8) Steering pump case drain filter
oil from the steering piston pump (10) Steering hydraulic tank FLUID STORAGE RESERVOIRS
29 E-3 Orifice 8W-4042
(3) Accumulator charging valve (12) Steering piston pump
17 (4) Steering cylinders
32 F - 11 Slack Adjuster (Rear) 5T-7670 (14) Pressure switch for low pressure
(5) Steering solenoid and relief valve oil from the steering piston pump
33 B - 10 Oil Cooler (Rear Brake Cooling) 141-4108

34 B - 10 Screen 6E-6640 Top view of steering oil lines 789C Off-Highway Truck VENTED
PRESSURIZED RETURN ABOVE FLUID LEVEL RETURN BELOW FLUID LEVEL

35 F-2 Slack Adjuster (Front) 2G-5900 12 COMBINATION CONTROLS

38

39
D-8

B-7
Control Valve

Counterbalance Valve (Hoist)

132-2048

132-7102
Hydraulic System
40 F-4 Pump Drive 2A-6516 SOLENOID SOLENOID SOLENOID and SERVO THERMAL DETENT

41 G - 14 Piston Pump (Steering) 6E-5650

16
G
2BW659-UP SOLENOID
or MANUAL and PILOT PILOT or MANUAL

45 C - 3,D - 3 Hoist Screens 6E-5471 MANUAL CONTROL SYMBOLS

48 G-7 Rear Brake Cooling Pump Section 3E-3882

49 H-6 Parking Brake Release Pump Selection 6T-6147 (12) Steering piston pump
(16) Pressure compensator valve GENERAL MANUAL PUSH BUTTON PEDAL SPRING
50 H-6 Torque Converter Charging Pump Section 6T-6147 PUSH-PULL LEVER MANUAL SHUTOFF
(17) Pump drive
51 H-6 Torque Converter Scavenge Pump Section 6T-6147 (A) Low steering pump pressure test port. H
(1) Low pressure switch from steering piston pump PILOT CONTROL SYMBOLS
52 E-7 Hydraulic Tank (Torque Converter, Hoist, Brake and Transmission) 161-0536 RELEASED PRESSURE REMOTE SUPPLY PRESSURE

53 E-6 Suction Screens 9T-3850 F

58 H-4 Air Breather (Hoist, Torque Converter and Brake) 8X-4575 13 9 10
EXTERNAL RETURN INTERNAL RETURN SIMPLIFIED COMPLETE INTERNAL
61 B - 11,I - 11 Service and Parking Brake (Rear) 5T-4489
SUPPLY PRESSURE
62 J-6 Relief Valve (Torque Converter Inlet) 3P--0348
ACCUMULATORS CROSSING AND JOINING LINES HYDRAULIC AND PNEUMATIC CYLINDERS
63 G-5 Hoist and Rear Brake Cooling Gear Pump 139-2454

64 I-6 Hydraulic Filter (Torque Converter) 4T4760

SPRING LOADED GAS CHARGED LINES CROSSING LINES JOINING SINGLE ACTING DOUBLE ACTING
66 D - 2,I - 2 Service and Parking Brake (Front) 5T-5070

73 H-5 Torque Converter 116-5811

HYDRAULIC PUMPS HYDRAULIC MOTORS INTERNAL PASSAGEWAYS
80 D-9 HARC Valve 177-8840
FIXED VARIABLE DISPLACEMENT VARIABLE DISPLACEMENT THREE TWO
80 E-9 Check Valve 9T-6173 FIXED INFINITE
DISPLACEMENT NON-COMPENSATED DISPLACEMENT NON-COMPENSATED POSITIONING POSITION
(1) Steering accumulators (12) Steering piston pump POSITION
81 D - 10 Accumulator Grp. 241-3147
(2) Pressure switch for high pressur (14) Pressure switch for low pressure UNIDIRECTIONAL UNIDIRECTIONAL
Steering Hydraulic System oil from the steering piston pump oil from the steering piston pump
(4) Steering cylinders (15) Orifice
12 I - 15 Pressure Switch (Steering Pump Oil Low) 3E-7809 (H) Pressure tap for Rear Service Brake (7) Steering control valve (16) Pressure compensator valve FLOW IN ONE PARALLEL CROSS FLOW ALLOWED IN
BIDIRECTIONAL BIDIRECTIONAL DIRECTION FLOW FLOW EITHER DIRECTION
(F) Pressure tap for Left parking brake release pressure (8) Steering pump case drain filter (AA) Pressure tap for low pressure oil
13 I - 15 Orifice 8X-7851
(G) Pressure tap for Right parking brake release pressure (10) Steering hydraulic tank from the steering piston pump
14 G - 13 Metering Pump (Steering) 9T-1318

22 J - 13 Steering Cylinders 4T-6797

Top view of Rear Brake Lines Side view of steering oil lines
(8) Steering pump case drain filter
23 I - 13 Steering Control Valve 9T-1318
(9) Steering filter
8
30 I - 17 Accumulator Charging Valve 148-9237 (10) Steering hydraulic tank 2004 Caterpillar Printed in U.S.A.
(13) Breaker relief valve
36 J - 16 Solenoid and Relief Valve (Steering) 6E-3965 All Rights Reserved
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

1 M L Electrical Symbols Table
68 G - 17 Steering Tank Filter 9J-5461

69 H - 17 Brake Relief Valve 9T-0818

Hydraulic Symbols (Electrical)
70 J - 16 Check Valve (Steering) 9T-2553 2 C 6 7 N
Transmission Hydraulic System

20 D - 16 Bypass Switch 9X-7781

37

40
E - 14

C - 15
Magnetic Screen (Transmission)

Pump Drive
7T-4554

2A-6516
66
1
D G M
43 E - 16 Oil Cooler (Transmission) 4W-5056
3
Transducer Transducer Generator Electric Motor
44 D - 15 Relief Valve (Transmission Cooler Inlet) 2P-2859
53 52 (Fluid) (Gas / Air)
52 B - 14 Hydraulic Tank (Torque Converter, Hoist, Brake and Transmission) 161-0536 61 E
2
53 B - 16 Suction Screen 9T-3850 20
54 C - 15 Transmission Charging Pump Section 156-8525
68 69 X 20 64 K 3
47 46 67 57 65 5
55 C - 15 Transmission Planetary 156-8525 58 4
34 60
56 C - 15 Transmission Scavenge Pump Section 156-8525 (1)Torque converter outlet relief valve. 5954 56 81
(M)Pressure tap for torque converter outlet pressure. N 43 44 70 12 80 72 55 Pressure Switch Temperature Switch Electrical Wire

RENR8121-00
41 40 G
57 D - 16 Hydraulic Filter (Transmission Charging) 6P-4603
(2) Torque converter inlet relief valve. A 63 D (N) Pressure Tap for Transmission Lube Pump. Pressure Switch
20 38 39 (1) Pump drive (Adjustable)
59 E - 13 Air Breather (Transmission) 6G-0078 (L) Pressure tap for lockup clutch pilot oil. 33 36 13 42 C P
S 22 51 R (2) Hoist and rear brake cooling gear pump (front section)
65 D - 15 Hydraulic Filter (Transmission Lubrication) 6P-4603
Z 62 37 (3) Hoist and rear brake cooling gear pump (rear section)
29 35 73
30 48 49 J H 32 (4) Inlet from the hydraulic tank
L (5) Inlet from the hydraulic tank
28 10 24 50 (6) Outlet to the hoist control valve E
S 21 7 M 26
F
(7) Outlet to the hoist control valve
Electrical Symbols (Electrical)
6 HH
B 23 9 8 45 Q 2 O

30 Page, EAR
6 5 18 1
4

T
Z 22 27 19 Y
20 3 Pressure Temperature Level Flow
Tap Locations 5 Symbol Symbol Symbol Symbol
14 1 E
Pressure, Sampling, and Sensor
Tap Schematic Machine
Description Wire Number Identification Codes
Number Location Location 19
A Low Steering Pump Pressure I - 15 41
B High Steering Pressure (Accumulator) H - 13 23
11
Electrical Schematic Example Hydraulic Schematic Example
C Hoist Pump Pressure (Front) G-5 63
D Hoist Pump Pressure (Rear) G-5 63 5 (E) Left Rear Brake Cooling Pressure
Current Standard Current Standard
E Left Rear Brake Cooling Pressure J - 10 1
(1) Torque converter and front brake cooling oil cooler Harness identification code
F Left Rear Parking Brake Pressure I - 10 32
(5) Steering solenoid and relief valve (5) Torque converter and front brake cooling diverter valve This example indicates
G Right Rear Parking Brake Pressure C - 10 32 (6) Steering check valve 18 K wire 135 in harness "AG". Wire
H Rear Service Brake Pressure F - 11 32 (18) Steering relief valve Circuit Number Wire Color
(19) Steering solenoid valve Identification
J Front Service Brake Pressure F-3 35
(Z) Steering system oil sampling port 325-AG135 PK-14
K Torque Converter Charge Pump Pressure I-6 64 2 3
(S) Steering system Power Unit (Auxiliary)
L Torque Converter Lock-up Clutch Pressure I-5 10 1 325-PK
M Torque Converter Outlet Pressure I-4 24 Circuit Identification Wire Color Wire Gauge
N Transmission Lube Pump Pressure E - 15 43 Number
O Left Brake Pressure Test Port F - 10 2 J
P Transmission Charge Pump Pressure E - 16 37
4 Previous Standard
Q Right Brake Pressure Test Port E - 10 2 L K C D X J P
R Hoist System Power Unit (Auxiliary) C-9 38 Wire Color
Wire
S Steering System Power Unit (Auxiliary) G - 15 36
X Transmission System Oil (Sampling) D - 15 57
Y Hoist and Torque Converter System Oil (Sampling) H-7 19 325-PK-14
Z Streeting System Oil (Sampling) I - 16 36 2 A
B
(1) Torque converter hydraulic filter Circuit Number Wire Gauge
(2) Inlet line 3 Identification (EXAMPLE VALVE)
(3) Outlet line
60 67 68 (2) Rear brake oil coolers (4) Bypass switch
14 (3) Screens for the rear brake oil coolers (K) Torque Converter Charge pump pressure

29
28
21
(J) Pressure Tap for Front Service Brake
56 59 G
64
10 18 26 20 H 32
63 35 37
Related Manuals 46 24 62 26
47 6 45 2 80 72 F
Description Media Number
19 57 65 5 H P
Power Train 27 4 70
41 71 55
Specifications SENR1521
12 40 53 52 38 39
Systems Operation SENR1522 44 20
Testing and Adjusting SENR1523
49 54
70 43 33 22 48
Disassembly and Assembly SENR1524 51 56
Machine Systems 36 50
Specifications: (Hydraulic System) SENR1531 66 11 1 E
30 E 61
Testing and Adjusting: (Hydraulic System) SENR1532
23
Specifications: (Steering System) SENR1525
Testing & Adjusting: (Steering System) SENR1526
Specifications: (Air System & Brakes) SENR1527
Testing & Adjusting: (Air System & Brakes) SENR1528
O Q
Specifications, System Operation, Testing &
RENR2223 S Z B N M Y A R O Q
Adjusting: (Oil Evacuation System)
Specifications: (Suspension Cylinder) SENR1529
Electrical System: (H) Pressure Tap for Rear Service Brake. (P) Pressure tap for the transmission charging section (O) Left Brake Pressure Test Port
Schematic (Electrical System) SENR1535 (Q) Right Brake Pressure Test Port.
Additional Manuals (B) High steering pressure test port.
Automatic Electronic Traction Aid (AETA) SENR2986
B
 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

K K

Steering Auxiliary Power

Pressure Switch Accumulators Unit Port
(Steering Pump Oil High) Steering Cylinders
6E-6611 4T-6797
3E-6461
S Makeup Tank for
Screen
Oil Cooler
(Front Brake Cooling)
Service Brake Oil 141-4108
6E-5065
6E-1851 High Pressure
LEFT REAR E Screen 6E-1349
Orifice
Check Valve (Steering) 122-7765
9T-2553
J J
CL CR
Solenoid and Relief Valve Relief Valve
(Steering) 6E-6298 3P-0348 Bypass Switch
Steering
Control Valve Torque Converter 9X-7781
9T-1317 Hydraulic Filter
9T-3838 K Torque Converter and
Front Brake Cooling
Diverter Valve 105-0170
Service and
OIL Parking Brake
SAMPLE
L R Torque Converter (Front) 5T-5070
Z PORT Bypass Switch Bypass Switch Torque Converter
L Outlet Relief Valve
9W-7403
9X-7781 116-9933 Lockup Valve
Orifice Service and Parking 8E-6146
8X-7851 Brake (Rear) 5T-4489 F LEFT FRONT
Low Steering
Pressure Switch
M
I P Parking and
Torque Converter
I
Secondary
Pressure Switch
Brake Valve 116-5811
(Steering Pump Oil Low)
3E-7809 149-4133 Parking Brake
A Release Pump LOCK-UP
Orifice Selection 6T-6147
Low Steering Pump 1T-0936 VALVE
Pressure Test Port
Accumulater
Charging Valve Torque Converter Hoist, Torque Converter
148-9237 EF Check Valve Charging Pump
Section 6T-6147
and Brake Air Breather
8X-4575
138-4733

T
Air Over Hydraulic Cylinder
Parking Brake
TORQUE CONVERTER
(Brake) 8W-3405
Y Release Hydraulic
HP LS HT Filter 6P-4603
H H
Torque Converter
Scavenge Pump
Section 6T-6147

High Steering
Breake
Releif Valve
B Pressure Test Port Rear Brake
9T-0818 Cooling Pump
Filter (Steering Pump Case Drain) Traction Control Section 3E-3882 Air Over Hydraulic
Piston Pump (Steering) and
4T-4284 Vlave 9G-9208 Cylinder 8W-3405
Pressure Compensator Valve Left Brake
6E-5656 Pressure
Test Port
O
D
Steering Tank
G 155-6660
G
Shuttle Valve
S Metering Pump 8J-6173 C
(Steering) 9T-1318

)(
PUMP
Auxiliary Power DRIVE Shuttle Valve
Unit Port 8J-6173

)(
BOX

Steering Tank
Filter 9J-5461 Torque Converter, Hoist,
H Brake and Transmission Pump Drive

STEERING SYSTEM Hydraulic Tank 161-0536

Hoist and Rear Brake
Cooling Gear Pump
2A-6516
Piston Pump (Steering)
J
Right Brake 6E-5650 - See Steer System
139-2454
Q Pressure
Test Port Slack Adjuster
F 2G-5900
F
Electric Drive Pump
Transmission Planetary Check Valve
9T-3096
Suction Screen
Slack Adjuster (Rear) 9T-3850 Suction Screen
HYD Air Breather
(Transmission) 5T-7670 9T-3838
P TRANSMISSION
CONTROLS 6G-0078

Motor Suction Screens

9T-3850

Accumulator Group
241-3147
E E
Magnetic Screen Electric Drive Pump:
Transmission Hydraulic Control
Oil Cooler N (Transmission)
7T-4554
Parking and Secondary Check Valve
DUAL STAGE
(Transmission) Brake Release 9T-3752
5T-1060 SIGNAL SPOOL
4W-5056
Transmission Cooler Control Valve
Inlet Relief Valve 245-1662
2P-2859
HIGH PRESSURE RELIEF

MAIN RELIEF
X )( DUMP SPOOL Orifice
Hydraulic Filter Hoist Screens
6E-5471
8W-4042 RIGHT FRONT
Bypass Switch (Transmission Lubrication)
9X-7781 6P-4603
LOW PRESSURE RELIEF
D Hydraulic Filter D
RENR8121-00

(Transmission Charging) Service and

6P-4603 Parking Brake

)(
(Front) 5T-5070
Page, Color 2, DGM

Bypass Switch
Hydraulic ARC 9X-7781
Valve 177-8840
Bypass Switch
9X-7781 LINE PATTERNS
R BRAKE COOLING RELIEF
RAISE
Pressure Line
Screen
G 6E-6640 Pilot / Load Sensing Pressure
HOLD Hoist Screens
6E-5471 Drain / Return Lines
Pump Drive SIGNAL ORIFICE #1
2A-6516 Service and Parking Brake Component Group
C PUMP (Rear) 5T-4489 SIGNAL ORIFICE #2 SNUB C
DRIVE
BOX Attachment
Transmission Scavenge Pump FLOA T Air Line
Transmission Charging Pump Section Section 156-8525
156-8525 Oil Cooler
(Rear Brake Cooling) CALLOUTS
141-4108 LOWER
Transmission Planetary Bypass Switch YY Taps (Pressure, Sampling,Sensor) by letter
156-8525 Counterbalance Valve 9X-7781
(Hoist) 132-7102 52 Components by number

HYDRAULIC CIRCUIT COLOR DESCRIPTIONS

Suction Screen VENT ORIFICE FOR ROD END VENT
COUNTERBALANCE VALVE Hoist and Rear Brake Cooling Pump Circuit
9T-3850 SLOT ACROSS STEM
Primary and Secondary Parking Brake Pump Circuit
30

B RIGHT REAR Hoist Cylinders Steering Pump Circuit B

9T-2807 Transmission Pump Circuit
Torque Converter Charge Pump Circuit
Supply Line.
Hydraulic Tank Drain / Return Line.
(Torque Converter, Hoist, Brake and Transmission) Service and Parking Brake Circuit
161-0536
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 9 8 7 6 5 4 3 2 1