UENR1078-05

September 2014

5 6 17 18 BB 3
YY 83 ZZ SS 80
16 A1 Component Locations
Part Schematic Machine Part Schematic Machine
Description Description
Number Location Location Number Location Location
STEERING SYSTEM Pump Gp - Gear (Brake Cooling) 8E-3882 G-6 40

11 A2
308-2856
308-2857
Screen As
Screen As - (Rear Brake Coolers)
6E-5065
224-3895
I-8
C-9
41
42
Accumulator Gp - Steering (Charged) I-16 1
348-9270 Switch Gp - Oil Filter Bypass 164-7577 H-6 43

(Dimensions: 56 inches x 35 inches)

348-9277 Tank Gp - Brake (Service) 6E-1851 I-9 44
Core As - Oil Cooler (Steering) 370-9329 E-14 2 Valve - Check 9T-3752 D-9 45
Cylinder Gp-steering 4T-6797 J-13 3 Valve - Check 138-4732 H-8 46

47 Filter - Oil (Steering) 139-1536 E-16 4 Valve And Mtg Gp - Brake (Automatic Retarder) 177-8840 D-9 47

33 Filter Gp - Oil (Steering Pump Case Drain)

Orifice (Sensor Protection)
4T-4284
268-1508
E-15
G-14
5
6
Valve As - Shuttle
Valve As - Shuttle
305-5410
305-5410
F-10
F-2
48
49

UENR1078-05
Orifice (Steering Load Sense) 1T-0936 F-15 7 Valve Gp - Brake (Parking) 149-4133 H-8 50

45 Pump Gp - Metering (HMU)

Pump Gp - Piston (Steering)
9T-1318
349-9480
H-13
F-14, F-3
8
9
Valve Gp - Check 9T-3096
REAR AXLE LUBRICATION SYSTEM
E-9 51

Sensor Gp - Temperature (Differential Oil) 118-7226 E-15 10 Filter Gp - Oil (Rear Axle Lubrication) 334-0572 G-13 52
31 Switch As - Pressure (High Pressure, Steering) 307-6719 I-16 11 Manifold Gp - Control (RRAX Lubrication, Pump) 313-9544 F-12 53
Switch As - Pressure (Low Pressure, Steering) 307-6718 G-15 12 Pump And Motor Gp - Rear Axle Lube 380-7683 G-13 54
CC A3 Tank And Filter Gp - Steering 155-6660 E-15 13 Pump Gp - Gear (Rear Axle Lubrication) 380-7682 F-14, F-3 55
Valve - Breaker Relief 220-0814 F-16 14* Sensor Gp - Liquid Level 330-9321 F-13 56

1 Valve - Check (Hydraulic Oil Cooler Bypass)

Valve Gp - Accumulator Charging
200-6311
148-9236
E-14
G-16
15
16
Sensor Gp - Pressure (Final Drive Oil)
Sensor Gp - Temperature (Differential Oil) 118-7226
221-3414 G-12
F-12
57
58
789D Off-Highway Truck
30 Valve Gp - Check (Steering Oil Cooler Bypass)
Valve Gp - Solenoid And Relief
6E-1454
349-9263
H-15
H-16
17
18
Switch Gp - Filter Bypass Mechanical
Valve Gp - Solenoid (Rear Axle Motor Drive)
164-7577
380-0784
G-13
G-14
59
60
Valve Gp - Steering 9T-1317 J-13 19 TORQUE CONVERTER SYSTEM Hydraulic System
AA HOIST SYSTEM Filter Gp - Oil (TC Charging) 4T-4760 H-5 61

12 20 Cylinder Gp - Hoist
Manifold Gp - Hydraulic (Hoist Lines)
9T-2807
186-6317
B-8
C-4
20
21
Pump Gp - Gear
Screen Gp - Hydraulic (TC, Front Brake Cooling)
6T-6147
186-6434
G-5
I-4
62
63 SPD1-UP
41 Pump Gp - Gear (Hoist And Rear Brake Cooling)
Screen Gp - Hoist Lines
175-6253
6E-5472
F-4
C-3
22
23
Switch As - Pressure (Fuel Filter, Differential)
Torque Converter And Housing Gp
255-2282
299-0726
H-6
H-4
64
65 SHH1-UP
50 Valve Gp - Control 354-8558 D-7 24 Valve Gp - Lock-up Clutch And Sync (TC) 8E-6146 H-5 66

78 19 Valve Gp - Counterbalance 132-7102

HOIST AND BRAKE COOLING SYSTEMS
C-6 25 Valve Gp - Relief (Torque Converter Inlet)
Valve Gp - Relief (Torque Converter Outlet)
3P-0348
9W-7403
I-6
H-4
67
68
38 Filter - Oil 4T-6788 H-3 26 TRANSMISSION SYSTEM
46 Screen As - (Hydraulic, Transmission)
Screen As - (Hydraulic, Transmission)
9T-3838
9T-3850
E-5
E-6, E-5, A-15
27
28
Breather
Filter Gp - Oil (Hydraulic, Transmission)
4T-6788
332-8833
D-13
C-15
69
70

81 Tank Gp - Hydraulic And Transmission 356-5203 E-6, A-14 29 Pump Gp - Gear (Transmission) 156-8525 B-15 71

42 Page,
39 20 BRAKE AND BRAKE COOLING SYSTEMS
241-3147
Screen Gp - Magnetic
Sensor Gp - Liquid Level (Transmission Oil)
7T-4554
330-9321
D-14
A-15
72
73
348-9268 Switch As - Pressure (Power Train Oil) 341-6644 B-15 74
Accumlator Gp - Brake E-9 30
243-5339 MISCELLANEOUS SYSTEMS

FWD
348-9274 Slack Adjuster Gp (Front) 205-0558 F-1 75

DD 51 44
Brake Gp - Service And Parking (Left Front)
Brake Gp - Service And Parking (Left Rear)
257-6301
257-6298
H-2
I-10
31
32
Core As - Oil Cooler (Brake Oil, Front)
Core As - Oil Cooler (Brake Oil, Rear)
200-5972
200-5972
I-4
C-10
76
77
Brake Gp - Service And Parking (Right Front) 257-6301 D-2 33 Core Gp - Oil Cooler (Transmission) 7W-1713 C-15 78
Drive Gp - Pump 2A-6546 F-4, F-15, B-14 79

D
Brake Gp - Service And Parking (Right Rear) 257-6298 B-10 34
Slack Adjuster Gp (Rear) 205-0560 F-11 80

FW
Cylinder Gp - Air / Hydraulic 8W-3405 G-10 35

15 A4 Cylinder Gp - Air / Hydraulic

Filter Gp - Oil (Hydraulic, Transmission)
8W-3405
332-8833
G-2
H-6
36
37
Valve Gp - Cooler Bypass
Valve Gp - Diverter
7T-0297
105-0170
C-14
I-3
81
82
Plug - Orifice 8J-9990 I-8 38 Valve Gp - Traction Control 222-4744 F-9 83
Pump And Motor Gp - Brake Release (Parking, Secondary) 5T-1060 E-9 39
Note * - Not shown on the graphic.

2 35 48
A5

STEERING SYSTEM BRAKE AND BRAKE COOLING SYSTEM

© 2014 Caterpillar, All Rights Reserved Printed in U.S.A.

LL
II FLUID POWER SYMBOLS
Tap Locations
Pressure, Sampling, and Sensor BASIC COMPONENT SYMBOLS
Tap Schematic
4 Number
AA
Description

Steering System - Auxiliary Power Unit Port

Location
H-15 PUMP OR MOTOR FLUID CONDITIONER SPRING CONTROL VALVES RESTRICTION LINE RESTRICTION
MAIN

PUMP
AUX

PUMP
(FIXED) (2 - SECTION) (VARIABLE & PRESSURE
COMPENSATED)
BB Steering System - Oil Sample Port H-15
CC High Steering Accumulator Pressure I-13
DD Low Steering Pump Pressure G-15
VARIABILITY SPRING LINE RESTRICTION PRESSURE HYDRAULIC PNEUMATIC LINE RESTRICTION ATTACHMENT
EE Manifold Control Pressure F-12 (ADJUSTABLE) (VARIABLE) COMPENSATION ENERGY TRIANGLES (VARIABLE & PRESSURE

GG FF* Transmission Charge Pump Pressure D-15

COMPENSATED)

GG Transmission Lube Pump Pressure D-15 VALVE ENVELOPES VALVES VALVE PORTS
HH Transmission System - Oil Sample Port C-15
34 32 II Left Rear Brake Cooling Outlet Pressure I-11
JJ Left Rear Parking Brake Pressure I-10
MM KK KK Left Rear Brake Cooling Inlet Pressure H-10
ONE POSITION TWO POSITION THREE POSITION TWO - WAY THREE - WAY FOUR - WAY

13 LL Right Rear Brake Cooling Outlet Pressure B-11 CONTROL VALVES CHECK VALVES
JJ EE 53 57 54 72 60 NN MM
NN
Right Rear Brake Cooling Inlet Pressure
Right Rear Parking Brake Pressure
B-10
C-10
AB A B

OO Left Front Brake Cooling Inlet Pressure H-2 P T P T

BASIC SPRING SHUTTLE PILOT
NORMAL POSITION SHIFTED POSITION INFINITE POSITION
PP Left Front Brake Cooling Outlet Pressure H-1 SYMBOL LOADED CONTROLLED
QQ Right Front Brake Cooling Inlet Pressure D-2
FLUID STORAGE RESERVOIRS
RR Right Front Brake Cooling Outlet Pressure D-1
SS Rear Service Brake Pressure F-10
TT Front Service Brake Pressure F-2
UU Torque Converter Charge Pressure I-5
VENTED PRESSURIZED RETURN ABOVE FLUID LEVEL RETURN BELOW FLUID LEVEL
VV Torque Converter Lock-Up Clutch Pressure H-5
WW Torque Converter Outlet Pressure H-4 MEASUREMENT ROTATING SHAFTS

59 XX*
YY
Hoist System And Torque Converter System - Oil Sample Port
Left Brake Pressure
H-7
F-9
ZZ Right Brake Pressure F-9
A1 Automatic Retarder Control Pressure D-10 PRESSURE TEMPERATURE FLOW UNIDIRECTIONAL BIDIRECTIONAL
A2 Automatic Retarder Control Pressure D-10
A3 Automatic Retarder Control Pressure D-8 COMBINATION CONTROLS

63 A4
A5
Hoist System - Auxiliary Power Unit Port
Hoist System - Auxiliary Power Unit Port
C-8
C-8
A6 Hoist Pump Pressure (First Section) F-4
A7 Hoist Pump Pressure (Second Section) F-4 SOLENOID SOLENOID SOLENOID SOLENOID & SERVO THERMAL DETENT
OR MANUAL & PILOT PILOT OR MANUAL
A8* Steering Tank Pressure A-8
QQ Note * - Not shown on the graphic. MANUAL CONTROL SYMBOLS

PP
STEERING TANK PUSH - PULL LEVER

RELEASED PRESSURE
MANUAL SHUTOFF GENERAL MANUAL

PILOT CONTROL SYMBOLS

PUSH BUTTON PEDAL

REMOTE SUPPLY PRESSURE

SPRING

RR 31 EXTERNAL RETURN INTERNAL RETURN SIMPLIFIED COMPLETE INTERNAL

SUPPLY PRESSURE

ACCUMULATORS CROSSING & JOINING LINES HYDRAULIC & PNEUMATIC CYLINDERS

52 56 58 33 OO SPRING LOADED GAS CHARGED LINES CROSSING LINES JOINING SINGLE ACTING DOUBLE ACTING

HYDRAULIC PUMPS HYDRAULIC MOTORS INTERNAL PASSAGEWAYS

FWD

FIXED VARIABLE DISPLACEMENT FIXED VARIABLE DISPLACEMENT INFINITE

DISPLACEMENT NON-COMPENSATED DISPLACEMENT NON-COMPENSATED POSITIONING 3 POSITION 2 POSITION
FWD
REAR AXLE LUBRICATION SYSTEM UNIDIRECTIONAL UNIDIRECTIONAL

FLOW IN ONE PARALLEL CROSS FLOW IN

BIDIRECTIONAL BIDIRECTIONAL
69 26 79 61 71 A6 29 22 A7
DIRECTION FLOW FLOW EITHER
DIRECTION

SERVICE AND PARKING BRAKE

9
ELECTRICAL SYMBOLS TABLE
77 HYDRAULIC SYMBOLS (ELECTRICAL)

G
82 M
23
10 TRANSDUCER TRANSDUCER GENERATOR ELECTRIC MOTOR
(FLUID) (GAS / AIR)
76
21
42
PRESSURE SWITCH PRESSURE SWITCH TEMPERATURE ELECTRICAL WIRE
75 (ADJUSTABLE) SWITCH

55
ELECTRICAL SYMBOLS (ELECTRICAL)
TT
7
UU PRESSURE TEMPERATURE LEVEL FLOW

74 66 SWITCH SWITCH SWITCH SWITCH

WIRE NUMBER IDENTIFICATION CODES

VV 24
ELECTRICAL SCHEMATIC EXAMPLE HYDRAULIC SCHEMATIC EXAMPLE
CURRENT STANDARD CURRENT STANDARD

70 64 65 25 HARNESS IDENTIFICATION CODE THIS EXAMPLE

INDICATES WIRE 135 IN HARNESS “AG”
WIRE
HH 70 74 CIRCUIT NUMBER
325-AG135 PK-14 IDENTIFICATION WIRE COLOR
68
CIRCUIT NUMBER WIRE WIRE GAUGE
IDENTIFICATION COLOR
73 325-PK

PREVIOUS STANDARD
8 WIRE WIRE COLOR

43 37 27 28 325-PK-14 B A

CIRCUIT NUMBER WIRE GAUGE (EXAMPLE VALVE)

IDENTIFICATION

WW 67 62 40 36 49
HYDRAULIC TANK AND FILTER CIRCUIT
METERING PUMP
HOIST AND TORQUE CONVERTER SYSTEM
 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

(3) CYLINDER GP
STEERING
4T-6797

CL CR
J (19) VALVE GP J
STEERING
9T-1317
(Dimensions: 56 inches x 35 inches)

L R
UENR1078-05

(38) PLUG
(44) TANK GP ORIFICE
(1) ACCUMULATOR GP (41) SCREEN AS (82) VALVE GP
P
BRAKE (SERVICE) 8J-9990
STEERING 6E-5065 DIVERTER
II 6E-1851 (67) VALVE GP
(CHARGED) LEFT JJ
RELIEF (TORQUE CONVERTER INLET)
105-0170
308-2856
308-2857 REAR 3P-0348
348-9270
I 348-9277 EF
I
(76) CORE AS
T (64) SWITCH AS OIL COOLER
PRESSURE (63) SCREEN GP (BRAKE OIL, FRONT)
(FUEL FILTER, DIFFERENTIAL) HYDRAULIC 200-5972
255-2282 (TC, FRONT BRAKE COOLING)
HP LS HT
C 186-6434
(17) VALVE GP UU
CC (61) FILTER GP (68) VALVE GP
AA CHECK
(STEERING OIL A OIL (TC CHARGING) RELIEF
4T-4760 (66) VALVE GP
42 Page,

COOLER BYPASS) (TORQUE CONVERTER OUTLET) (31) BRAKE GP

(11) SWITCH AS ACC
LOCK-UP CLUTCH 9W-7403 SERVICE AND PARKING
6E-1454 (32) BRAKE GP (43) SWITCH GP
PRESSURE
ACC
P
L R
KK
H
B AND SYNC (TC) LEFT 257-6301
(HIGH PRESSURE, SERVICE AND PARKING (50) VALVE GP OIL FILTER BYPASS 8E-6146 (65) TORQUE CONVERTER AND HOUSING GP
STEERING)
STEERING SUPPLY
257-6298 164-7577 VV 299-0726 FRONT
BRAKE
307-6719 (8) PUMP GP (PARKING)
STER BLEED
STEERING RETURN METERING (HMU)
SOL
LS 149-4133
T 9T-1318 WW
H H
(18) VALVE GP F E
(40) PUMP GP LOCK-UP (26) FILTER
SOLENOID AND RELIEF BB VALVE OIL PP
GEAR (BRAKE COOLING)
349-9263 8E-3882 4T-6788 OO
SUPPLY RETURN (62) PUMP GP
TO GEAR
HOIST VALVE 6T-6147
(59) SWITCH GP PILOT
(52) FILTER GP PRESSURE (46) VALVE
OIL (REAR AXLE LUBRICATION) FILTER BYPASS MECH (35) CYLINDER GP
164-7577
CHECK XX (37) FILTER GP
(12) SWITCH AS 334-0572 AIR / HYDRAULIC 138-4732 TORQUE CONVERTER
PRESSURE 8W-3405 OIL (HYDRAULIC,
(16) VALVE GP TRANSMISSION)
(LOW PRESSURE, STEERING) (54) PUMP AND MOTOR GP
ACCUMULATOR 332-8833
307-6718 REAR AXLE LUBE
CHARGING
(60) VALVE GP 380-7683
148-9236 (57) SENSOR GP
SOLENOID
PRESSURE
(REAR AXLE MOTOR DRIVE)
(FINAL DRIVE OIL)
G 380-0784 G
221-3414
(36) CYLINDER GP
P
AIR / HYDRAULIC
DD
8W-3405
(6) ORIFICE
SENSOR PROTECTION (53) MANIFOLD GP (83) VALVE GP
268-1508 CONTROL TRACTION CONTROL
(7) ORIFICE FINAL DRIVE (RRAX LUBRICATION, PUMP) 222-4744
BYPASS SOL
(9) PUMP GP 313-9544 A7
STEERING LOAD SENSE YY
1T-0936
PISTON A6
(STEERING) L P-SIG
349-9480 EE S-2
LS P TCS PROPNL
(79) DRIVE GP (48) VALVE AS SOL

PUMP SHUTTLE (49) VALVE AS

P
2A-6546 305-5410 D PUMP SHUTTLE
F DRIVE 305-5410 F
(14) VALVE BOX
PUMP
BREAKER RELIEF FINAL S-1
DRIVE DRIVE DIFFERENTIAL
220-0814 BOX
T

(58) SENSOR GP
SS TCS 4-WAY SOL
TT
(29) TANK GP (22) PUMP GP
TEMPERATURE R
HYDRAULIC AND XMSN
(56) SENSOR GP BANJO HOUSING SUMP GEAR (HOIST AND (9) PUMP GP
(DIFFERENTIAL OIL) 356-5203 (79) DRIVE GP
REAR BRAKE COOLING) PISTON
LIQUID LEVEL 118-7226 ZZ PUMP
330-9321 175-6253 (STEERING)
L2 2A-6546
S
349-9480
(5) FILTER GP
OIL (STEERING PUMP (51) VALVE GP (55) PUMP GP
CASE DRAIN) (10) SENSOR GP CHECK GEAR
(80) SLACK ADJUSTER GP (39) PUMP AND MOTOR GP
(55) PUMP GP 9T-3096 (REAR AXLE LUBRICATION) (75) SLACK ADJUSTER GP
4T-4284 TEMPERATURE (REAR) BRAKE RELEASE
GEAR 380-7682 (FRONT)
(DIFFERENTIAL OIL) 205-0560 (PARKING, SECONDARY)
(REAR AXLE LUBRICATION) 205-0558
118-7226 5T-1060 HOIST/BRAKE COOLING TANK (28) SCREEN AS
380-7682 XMSN (27) SCREEN AS
TANK (HYDRAULIC, TRANSMISSION)
(HYDRAULIC,
(15) VALVE BRAKE RETRACT 9T-3850
E
MOTOR
(30) ACCUMULATOR GP TRANSMISSION) E
T
CHECK (28) SCREEN AS
BRAKE 9T-3838
(HYD. OIL COOLER BYPASS) M (HYD., TRANSMISSION)
A8 200-6311 241-3147 (CHARGED) 9T-3850
348-9268 (CHARGED)
(4) FILTER (13) TANK AND FILTER GP 243-5339 (UNCHARGED)
OIL (STEERING) STEERING (2) CORE AS 348-9274 (UNCHARGED)
139-1536 155-6660 OIL COOLER (STEERING)
370-9329 (45) VALVE
HIGH PRESSURE
CHECK RELIEF
(24) VALVE GP
STEERING SYSTEM AND REAR AXLE LUBRICATION ACC
9T-3752
P C
CONTROL DUAL STAGE
SIGNAL SPOOL

354-8558
(69) BREATHER A1 A3
MAIN RELIEF
HYDRAULIC 4T-6788 LOW PRESSURE
RR
FF HARC SUPPLY RELIEF
DUMP SPOOL
QQ
CONTROLS TRANSMISSION HARC BLEED SOL
SOL

351-0982 351-0988 RIGHT

D D

HARC CONT T BODY LOWER

FRONT
SOL SOL

GG (72) SCREEN GP
A2 HOIST (INSIDE)
SCREEN SW
(33) BRAKE GP
MAGNETIC SERVICE AND PARKING
S1
(78) CORE GP 7T-4554 257-6301
OIL COOLER C1

(TRANSMISSION) (47) VALVE AND MTG GP

7W-1713 BRAKE (AUTOMATIC RETARDER) C2

177-8840
BRAKE A1
COOLING RELIEF RAISE

H1

(70) FILTER GP (81) VALVE GP

HOLD
OIL (HYDRAULIC, COOLER BYPASS
H2 A2
C TRANSMISSION) 7T-0297 LINE PATTERNS C
332-8833 (34) BRAKE GP A4 A5 SIGNAL ORIFICE #1
ROD END Pressure Line
SERVICE AND PARKING VENT SLOT SNUB (23) SCREEN GP
SIGNAL ORIFICE #2 ACROSS STEM
(HOIST LINES) Pilot / Load Sensing Pressure
257-6298
HH NN 6E-5472 Drain / Return Lines

FLOAT Component Group

(42) SCREEN AS R1
Attachment
(77) CORE AS (REAR BRAKE COOLERS) HOIST (OUTSIDE)
OIL COOLER 224-3895 (21) MANIFOLD GP SCREEN SW Air Line
R2 (25) VALVE GP LOWER
HYDRAULIC
(BRAKE OIL, REAR) COUNTERBALANCE CALLOUTS
(20) CYLINDER GP (HOIST LINES)
LL 200-5972 132-7102
HOIST 186-6317 YY Taps (Pressure, Sampling, Sensor - by letter)
9T-2807 Callout Number Component
(Machine Location from (52) VALVE GP - CONTROL Name
Component LocationsTable)
138-1234 Part Number

MM VENT ORIFICE FOR

COUNTERBALANCE VALVE
(74) SWITCH AS (71) PUMP GP
GEAR (TRANSMISSION)
B PRESSURE
156-8525
RIGHT B
(POWER TRAIN OIL)
341-6644 REAR S2 HYDRAULIC CIRCUIT COLOR DESCRIPTIONS
BODY RAISE SOL PRIMARY AND REAR BRAKE COOLING PUMP CIRCUIT
(79) DRIVE GP HOIST AND SECONDARY PARKING BRAKE PUMP CIRCUIT
XMSN XMSN
XMSN
SCAV
PUMP HOIST CYLINDER CIRCUIT
CHARGE LUBE PUMP TORQUE CONVERTER CHARGE PUMP CIRCUIT
2A-6546 STEERING CYLINDER CIRCUIT
DRIVE RAXL GEAR PUMP CIRCUIT
BOX SUPPLY LINE
TORQUE CONVERTER RELIEF CIRCUIT
TRANSMISSION PUMP CIRCUIT

(28) SCREEN AS
(HYDRAULIC, TRANSMISSION)
HOIST, BRAKE COOLING, PARKING BRAKES, SERVICE BRAKES AND TORQUE CONVERTER SYSTEM RAXL OIL PUMP CIRCUIT
DRAIN / RETURN LINE
SERVICE AND PARKING BRAKE CIRCUIT
BRAKE COOLING CIRCUIT
9T-3850
(73) SENSOR GP
LIQUID LEVEL
(TRANSMISSION OIL) (29) TANK GP
330-9321 HYDRAULIC AND XMSN
A 356-5203 A
XMSN HOIST/BRAKE COOLING TANK
TANK THIS SCHEMATIC IS FOR THE 789D OFF-HIGHWAY TRUCK HYDRAULIC SYSTEM
MEDIA NUMBER: UENR1078-05
SCHEMATIC PART NUMBER: 288-5601, CHANGE: 03, VERSION: -
Components are shown installed on a fully operable machine with the key and engine off, transmission shifter
TRANSMISSION in neutral and with parking brake set.
Refer to the appropriate Service Manual for Troubleshooting, Specifications and Systems Operations.
Refer to the Parts Manual using a specific serial number prefix in SIS before ordering parts from this schematic.

16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1