INTERACTIVE SCHEMATIC

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 RENR8123-01
October 2006

785C Off-Highway Truck

Hydraulic System
785C: 785C (HAA):
APX451-UP 5AZ400-UP

© 2006 Caterpillar, All Rights Reserved Printed in U.S.A.

COMPONENT LOCATION
Page 1 of 2

Part Machine Schematic

Description
Number Location Location
Accumulator Gp
APX451-Up, 5AZ400-Up 241-3147 64 B-11
Accumulator Gp - Steering 219-2539 8 I-4
Adjuster Gp - Front Service Brake Slack 205-0557 43 C-7
Adjuster Gp - Rear Service Brake Slack 205-0559 46 C-12
Brake Gp - Service and Park (LF) 5T-3280 44 D-7 , I-7
Brake Gp - Service and Park (LR) 6G-9385 47 D-12 , I-12
Brake Gp - Service and Park (RF) 5T-3280 44 B-7 , G-7
Brake Gp - Service and Park (RR) 6G-9385 47 A-12 , F-12
Breather Gp 6G-0078 50 D-3
Control Gp - Park Brake / AETA 9G-9208 49 C-11
Converter - Torque 117-3357 52 D-8 , H-8
Cooler Gp - Brake
APX451-Up, 5AZ400-Up 200-5975 35 F-11 , I-8
Cooler Gp - Transmission 7W-1713 25 D-4
Cylinder Gp - Hoist 4T-5931 19 E-11
Cylinder Gp - Service Brake 8W-3406 45 C-7 , C-12
Cylinder Gp - Steering 1U-3182 11 I-2
Drive Gp - Gear 2A-6516 40 B-4 , F-4 , H-8
Filter Gp - Brake Retract 6P-4603 24 D-9 , I-10
Filter Gp - Converter Charge 4T-4760 31 I-9
Filter Gp - Hoist Tank Breather 8X-4575 23 I-8
Filter Gp - Steer Return 4J-6064 9 F-4
Filter Gp - Transmission Charge & Lube 6P-4603 30 C-5
Fitting Gp - Orifice (Steer Pressure) 8X-7851 54 H-4
Manifold Gp - Hoist 186-6317 38 F-8
Plate Gp - Orifice 8W-5002 57 G-7
Plug Gp - Orifice 122-7765 42 E-11
Pump Gp - Converter (Charge) 6T-6148 28 D-9 , H-9
Pump Gp - Converter (Park Brake Retract) 6T-6148 29 D-9 , H-9
Pump Gp - Converter (Scavenge) 6T-6148 27 D-8 , H-9
Pump Gp - Dead Engine Lower (Electric) 5T-1060 48 B-10
Pump Gp - Hoist 211-6626 13 B-5 , F-4 , H-8
Pump Gp - Metering 9T-4247 3 G-2
Pump Gp - Steering 190-2279 7 B-4 , F-4 , G-8
COMPONENT LOCATION
Page 2 of 2

Part Machine Schematic

Description
Number Location Location
Pump Gp - Transmission (Charge) 3T-0259 20 B-5 , F-4 , G-9
Pump Gp - Transmission (Lube) 3T-0259 21 B-4 , F-4 , G-9
Pump Gp - Transmission (Scavenge) 3T-0259 22 B-4 , F-4 , G-8
Screen Gp 6E-5065 15 E-11
Screen Gp - Brake Cooling 6E-6640 37 F-11
Screen Gp - Converter 9T-3838 61 B-9 , G-9
Screen Gp - Converter 186-6434 36 I-8
Screen As - Hydraulic and Xmsn Pump 9T-3850 62 A-5
Screen Gp - Hoist 6E-5471 16 F-8
Screen As - Hydraulic and Xmsn Pump 9T-3850 62 G-9
Switch As - Bypass Pressure 116-9933 53 I-9
Switch Gp - Low Steer Pressure 3E-7812 55 H-4
Switch Gp - Bypass Charge, Lube, Brake 164-7577 59 C-5,D-9,I-10
Tank Gp - Hydraulic Brake Make Up 6E-1851 41 E-10
Tank Gp - Hydrualic and Transmission 161-0536 12 A-4 , B-9 , G-10
Tank Gp - Steering 155-4127 10 F-3
Valve Gp - Brake Retract 113-1543 39 D-10 , I-11
Valve Gp - Check 138-4733 14 D-10 , I-11
Valve Gp - Check, Brake Accum.
APX451-Up, 5AZ400-Up 9T-3752 5 B-11
Valve Gp - Check, Steering 176-6448 4 I-4
Valve Gp - Check, Tow Pump 9T-3096 63 B-11
Valve Gp - Converter Lock-Up Clutch 8E-6146 51 I-9
Valve Gp - Counterbalance 132-7102 18 E-9
Valve Gp - Cross Over Relief 3G-4667 1 H-2
Valve Gp - Front Brake Cooler Diverter 105-0170 34 I-8
Valve Gp - Hoist 132-2048 17 F-9
Valve Gp - Hydraulic ARC
APX451-Up, 5AZ400-Up 177-8840 2 A-11
Valve Gp - Relief, Breaker 6E-3528 58 F-5
Valve Gp - Relief, Solenoid 6E-6298 6 I-4
Valve Gp - Shuttle 8J-6173 60 C-7 , C-12
APX451-Up, 5AZ400-Up
Valve Gp - T/C Inlet Relief 3P-0348 32 I-9
Valve Gp - T/C Outlet Relief 3P-0349 33 I-8
Valve Gp - Transmission Cooler Inlet Relief 2P-2859 26 D-4
TAP LOCATION

Tap Schematic
Description
Number Location
AA Right Rear Park Brake Pressure Tap A-12
BB Right Brake Pressure Tap B-11
CC Rear Service Brake Pressure Tap B-12
DD Left Rear Park Brake Pressure Tap D-12
EE Left Brake Pressure Tap C-11
GG Front Service Brake Pressure Tap C-7
HH Transmission Charge Pressure Tap D-5
II Transmission Lube Pressure Tap D-4
JJ Oil Sample Tap C-4
KK Steering Pressure Tap H-5
LL Auxiliary Power Unit Tap I-4
MM Oil Sample Tap H-4
NN Right Cylinder Pressure Tap H-2
OO Left Cylinder pressure Tap H-1
PP Auxiliary Power Unit Tap E-3
QQ Rear Brake Cooling Pressure Tap I-12
SS Torque Converter Charge Pressure Tap I-9
TT Auxiliary Power Unit Tap F-11
UU Torque Con. Lock-Up Clutch Press. Tap I-9
VV Torque Con. Outlet Pressure Tap I-8
WW Hoist Pump Pressure Test Tap H-8
FLUID POWER SYMBOLS
BASIC COMPONENT SYMBOLS

MAIN AUX.
PUMP: VARIABLE and
PUMP or MOTOR FLUID CONDITIONER SPRING CONTROL VALVES RESTRICTION LINE RESTRICTION 2-SECTION PUMP PRESSURE COMPENSATED
(FIXED)

VARIABILITY SPRING LINE RESTRICTION PRESSURE HYDRAULIC PNEUMATIC LINE RESTRICTION ATTACHMENT
(ADJUSTABLE) (VARIABLE) COMPENSATION ENERGY TRIANGLES VARIABLE and PRESSURE
COMPENSATED

VALVE ENVELOPES
VALVES
VALVE PORTS

ONE POSITION TWO POSITION THREE POSITION TWO-WAY THREE-WAY FOUR-WAY

CONTROL VALVES CHECK VALVES

AB AB

P T P T
BASIC SPRING SHUTTLE PILOT
NORMAL POSITION SHIFTED POSITION INFINITE POSITION
SYMBOL LOADED CONTROLLED

FLUID STORAGE RESERVOIRS

VENTED PRESSURIZED RETURN ABOVE FLUID LEVEL RETURN BELOW FLUID LEVEL

MEASUREMENT ROTATING SHAFTS

PRESSURE TEMPERATURE FLOW UNIDIRECTIONAL BIDIRECTIONAL

COMBINATION CONTROLS

SOLENOID SOLENOID SOLENOID SOLENOID and SERVO THERMAL DETENT

or MANUAL and PILOT PILOT or MANUAL

MANUAL CONTROL SYMBOLS

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

RELEASED PRESSURE PILOT CONTROL SYMBOLS

REMOTE SUPPLY PRESSURE

EXTERNAL RETURN INTERNAL RETURN SIMPLIFIED COMPLETE INTERNAL

SUPPLY PRESSURE

ACCUMULATORS CROSSING AND JOINING LINES HYDRAULIC AND PNEUMATIC CYLINDERS

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

HYDRAULIC PUMPS HYDRAULIC MOTORS INTERNAL PASSAGEWAYS

FIXED VARIABLE DISPLACEMENT FIXED VARIABLE DISPLACEMENT INFINITE THREE TWO

DISPLACEMENT NON-COMPENSATED DISPLACEMENT NON-COMPENSATED POSITIONING POSITION POSITION

UNIDIRECTIONAL UNIDIRECTIONAL

FLOW IN ONE PARALLEL CROSS FLOW ALLOWED IN

BIDIRECTIONAL BIDIRECTIONAL DIRECTION FLOW FLOW EITHER DIRECTION
ELECTRICAL SYMBOLS
Hydraulic Symbols (Electrical)

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

Pressure Switch Pressure Switch Temperature Switch Electrical Wire

(Adjustable)

Electrical Symbols (Electrical)

Pressure Temperature Level Flow

Symbol Symbol Symbol Symbol

Wire Number Identification Codes

Electrical Schematic Example Hydraulic Schematic Example

Current Standard Current Standard

Harness identification code
This example indicates
wire 135 in harness "AG". Wire
Circuit Number Wire Color
Identification

325-AG135 PK-14
325-PK
Circuit Identification Wire Color Wire Gauge
Number

Previous Standard
Wire Color
Wire

325-PK-14
B A
Circuit Number Wire Gauge
Identification (EXAMPLE VALVE)
 12 11 10 9 8 7 6 5 4 3 2 1

(35) COOLER GP (8) ACCUMULATOR GP

(36) SCREEN GP
BRAKE STEERING
(32) VALVE GP CONVERTER
200-5975 219-2539 (11) CYLINDER GP
TO FRONT PARK
T/C INLET RELIEF 186-6434 (44) BRAKE GP
BRAKE CIRCUIT
SS (33) VALVE GP (4) VALVE GP STEERING
QQ AND REAR TRACTION 3P-0348 SERVICE AND PARK
I CONTROL T/C OUTLET CHECK 1U-3182 I
(53) SWITCH AS LEFT FRONT
RELIEF STEERING
BYPASS PRESS 5T-3280
3P-0349 176-6448
116-9933
UU LL
(39) VALVE GP
BRAKE RETRACT VV
113-1543
KK
(47) BRAKE GP (14) VALVE GP CHECK
SERVICE AND PARK 138-4733 (31) FILTER GP
LEFT REAR (59) SWITCH GP (23) FILTER GP
CONVERTER BRAKE T/C SCAV
(6) VALVE GP
6G-9385 BYPASS PRESS HOIST TANK
CHARGE SOLENOID AND RELIEF
PRESS TO 164-7577 BREATHER MM
PILOT 4T-4760 (STEERING)
TRACTION CNTRL 8X-4575 (1) VALVE GP
SYS VALVE (24)
FILTER GP (29) PUMP GP 6E-6298
(52) TORQUE CONVERTER CROSS OVER OO
BRAKE RETRACT CONVERTER (34) VALVE GP
H 117-3357 RELIEF H
TO BRAKE 6P-4603 (PARK BRAKE) FRONK BRAKE
MAKE-UP 3G-4667 NN
TANK 6T-6148 COOLER DIVERTER
FROM TOW (28) PUMP GP (27) PUMP GP WW 105-0170
PUMP
CONVERTER (55) SWITCH GP
CONVERTER
(CHARGE) (51) VALVE GP LOW STEERING
(SCAVANGE)
6T-6148 LOCKUP PRESSURE
6T-6148 PUMP
CLUTCH 3E-7812
(20) PUMP GP DRIVE
BOX
8E-6146
TRANSMISSION
(CHARGE)
CHARGE LUBE SCAV
(54) FITTING GP
3T-0259 STEER PRESSURE
(21) PUMP GP
(40) DRIVE GP (7) PUMP GP ORIFICE (3) PUMP GP
TRANSMISSION
GEAR STEERING 8X-7851 METERING
(LUBE)
2A-6516 190-2279 9T-4247
3T-0259
(13) PUMP GP (40) DRIVE GP GEAR
G (57) PLATE GP (44) BRAKE GP G
(62) SCREEN GP HOIST
ORIFICE SERVICE AND PARK (58) VALVE GP 2A-6516
HYDR AND XMSN PUMP 211-6626
8W-5002 RIGHT FRONT RELIEF
9T-3850 (22) PUMP GP
5T-3280 BREAKER (13) PUMP GP HOIST
TRANSMISSION
(12) TANK GP 6E-3528 211-6626
(SCAVENGE)
HYDRAULIC AND 3T-0259
TRANSMISSION
161-0536 HIGH PRESSURE
RELIEF
(37) SCREEN GP MAIN RELIEF
DUMP SPOOL (17) VALVE GP
BRAKE (61) SCREEN GP (7) PUMP GP
HOIST CHARGE LUBE SCAV

COOLING CONVERTER LOW PRESSURE

STEERING
RELIEF
132-2048
(35) COOLER GP 6E-6640 9T-3838 190-2279
BRAKE (22) PUMP GP
200-5975 TRANSMISSION F
(16) SCREEN GP
F
NOTE A:141-4108 (SCAVENGE)
TT HOIST
3T-0259
RAISE
BRAKE
COOLING RELIEF 6E-5471
SIGNAL (10) TANK GP
ORIFICE #1
SNUB
(9) FILTER GP STEERING
SIGNAL (20) PUMP GP 155-4127
ORIFICE #2 STEERING RETURN
FLOAT
TRANSMISSION
4J-6064
(19) CYLINDER GP LOWER (CHARGE) (21) PUMP GP
HOIST 3T-0259 TRANSMISSION PP
4T-5931 (LUBE)
(38) MANIFOLD GP 3T-0259
(47) BRAKE GP ROD END VENT
HOIST
(18) VALVE GP VENT ORIFICE FOR SLOT ACROSS STEM
SERVICE AND PARK RIGHT REAR COUNTERBALANCE VALVE
186-6317
COUNTERBALANCE
6G-9385
132-7102
STEERING SYSTEM
NOTE A: 785C HIGH ALTITUDE HYDRAULIC SCHEMATIC E
E ARRANGEMENT ONLY HOIST, BRAKE COOLING AND TORQUE CONVERTER
SYSTEMS HYDRAULIC SCHEMATIC

(47) BRAKE GP
SERVICE AND PARK, (15) SCREEN GP
(41) TANK GP HYDRAULIC
LEFT REAR 6E-5065 HH
BRAKE MAKE UP
6G-9385 6E-1851
(44) BRAKE GP HYD (50) BREATHER GP
PILOT PRESSURE TO CONTROLS TRANSMISSION 6G-0078
(39) VALVE GP
LOCK-UP CLUTCH VALVE SERVICE AND PARK
(42) PLUG GP (59) SWITCH GP
BRAKE RETRACT LEFT FRONT
ORIFICE BYPASS PRESSURE
113-1543 5T-3280
122-7765 164-7577
(29) PUMP GP (52) TORQUE CONVERTER II D
(14) VALVE GP
D CONVERTER 117-3357
DD CHECK
(PARK BRAKE)
138-4733
6T-6148
EXCESS FLOW
TO REAR BRAKE
COOLING CIRCUIT
(25) COOLER GP
(45) CYLINDER GP BRAKE T/C SCAV TRANSMISSION
SERVICE PILOT PRESSURE 7W-1713 (26) VALVE GP HYDRAULIC CIRCUIT COLOR DESCRIPTIONS

BRAKE TO HOIST VALVE (24) FILTER GP TRANSMISSION

TRANSMISSION CHARGE PUMP OUTPUT
PARKING BRAKE RETRACT PUMP OUTPUT

8W-3406 BRAKE RETRACT COOLER INLET DEAD ENGINE TOWING (ELECTRIC) PUMP

6P-4603 RELIEF
TORQUE CONVERTER SCAVENGE PUMP
(49) CONTROL GP (59) SWITCH GP STEERING PUMP OUTPUT

PARK BRAKE /AETA BYPASS PRESSURE 2P-2859 HOIST CYLINDER CONTROL CIRUIT
TORQUE CONVERTER CHARGE PUMP OUTPUT

9G-9208 (28) PUMP GP (27) PUMP GP 164-7577 HOIST PUMP OUTPUT

(60) VALVE GP JJ SUPPLY LINE

CONVERTER CONVERTER DRAIN / RETURN LINE C

C SHUTTLE (SCAVANGE) (45) CYLINDER GP
DRAIN / BRAKE COOLING
(CHARGE) STEERING CYLINDER CONTROL CIRCUIT
8J-6173 (63) VALVE GP 6T-6148 SERVICE BRAKE
EE 6T-6148 TRANSMISSION LUBE PUMP OUTPUT

TOW PUMP 8W-3406 TRANSMISSION SCAVENGE PUMP

PARKING BRAKE CONTROL CIRCUIT
CHECK GG SERVICE BRAKE CONTROL CIRCUIT
9T-3096 (61) SCREEN GP
CONVERTER
9T-3838 (21) PUMP GP
(30) FILTER GP TRANSMISSION
(60) VALVE GP TRANSMISSION (LUBE)
SHUTTLE 6P-4603 3T-0259 LINE PATTERNS
8J-6173 (43) ADJUSTER GP (20) PUMP GP Pressure Line
TRANSMISSION (22) PUMP GP
M FRONT SERVICE
(CHARGE) TRANSMISSION Pilot / Load Sensing Pressure
BB BRAKE SLACK
3T-0259 (SCAVENGE) Drain / Return Lines
CC 205-0557 (40) DRIVE GP
B 3T-0259 B
GEAR Component Group
2A-6516
(12) TANK GP Attachment
(46) ADJUSTER GP (64) ACCUMULATOR GP (48) PUMP GP PUMP
HYDRAULIC AND TRANSMISSION DRIVE
Air Line
REAR SERVICE 241-3147 DEAD ENGINE BOX
161-0536 CHARGE LUBE SCAV
(7) PUMP GP
BRAKE SLACK TOWING (13) PUMP GP CALLOUTS
(5) VALVE GP 5T-1060 STEERING
205-0559 HOIST 190-2279 YY Taps (Pressure, Sampling,Sensor) by letter
CHECK BRAKE 211-6626
ACCUMULATOR 52 Components by number

AA 9T-3752
(44) BRAKE GP
SERVICE AND PARK
(2) VALVE GP RIGHT FRONT
HYDRAULIC 5T-3280
A ARC A
(47) BRAKE GP 177-8840 (62) SCREEN AS (12) TANK GP
SERVICE AND PARK, RIGHT REAR
HYDRAULLIC AND XMSN PUMP HYDRAULIC AND TRANSMISSION THIS SCHEMATIC IS FOR THE 785C TRACTOR / OFF-HIGWAY TRUCK
6G-9385
9T-3850 161-0536 PART #: 158-6004 CHG 03

PARKING BRAKE AND SERVICE BRAKE TRANSMISSION SYSTEM Components are shown installed on a fully operable machine with the key and engine
off and transmission shifter in neutral.
HYDRAULIC SCHEMATIC HYDRAULIC SCHEMATIC Refer to the appropriate Service Manual for Troubleshooting, Specifications and Systems Operations

12 11 10 9 8 7 6 5 4 3 2 1
MACHINE COMPONENT LOCATIONS
VIEW ALL CALLOUTS

47 60 45 41 48 19 63 14 15 39 42 33 24 59 36 51 32 34 35 44 11 57 54 55 3 4

45
8

49
6
43
1
16
37
38
35
46

60 25

5 26
64
52
17
8
TT
9

47 58

18 10
16 38 27 28 19 12 61 62 29 53 31 13 30 59 20 21 22 40 50 23 44 7 11 PP
BRAKE SYSTEM TAP LOCATIONS
VIEW ALL CALLOUTS

DD CC

AA
46

Area of Rear Brake Slack Adjuster

49 BB

EE

TCS Valve Inside Rear of the Left Frame Rail

GG

43

Oil Makeup Tank Area

HOIST, BRAKE COOLING AND TORQUE CONVERTER
TAP LOCATIONS
VIEW ALL CALLOUTS

52 UU

32 33

VV

Torque Converter Area

WW
13

Hoist System Components

SS

24 31

QQ

Left Rear Brake Housing

STEERING SYSTEM TAP LOCATIONS
VIEW ALL CALLOUTS

1 8
KK

LL

6
MM Left Steering Accumulator Area

NN

1 OO
TRANSMISSION SYSTEM TAP LOCATIONS
VIEW ALL CALLOUTS

JJ

31
30
Area Aft of the Right Front Tire

HH

Transmission System Components

II