Manual 789C

SERV1857
June 2008
SERVICE TRAINING
TECHNICAL PRESENTATION
785C (1HW), 785D (MSY), 789C (2BW)

LARGE OFF-HIGHWAY TRUCKS
Service Training Meeting Guide

(STMG
785C (1HW), 785D (MSY), 789C (2BW)
TEXT REFERENCE
AUDIENCE
Level II--Service personnel who understand the principles of machine systems operation,
diagnostic equipment, and procedures for testing and adjusting.
CONTENT
This presentation provides basic maintenance information and describes the systems operation
of the engine, power train, steering, hoist, and the air system and brakes for the 785C/789C
Off-highway Trucks. The Automatic Retarder Control (ARC) and the Traction Control System
(TCS) are also discussed.
OBJECTIVES
After learning the information in this meeting guide, the serviceman will be able to:
1. locate and identify the major components in the engine, power train, steering, hoist and
the air system and brakes;
2. explain the operation of the major components in the systems; and
3. trace the flow of oil or air through the systems
4. identify what is new and different on the 785D 3512C HD engine along with RAXL
filtration
REFERENCES
784C Tractor/785C Truck Service Manual SENR1485
784C Tractor/785C Truck Operation and Maintenance Manual SEBU7173
785C Truck with High Altitude Arrangement (HAA) Operation and Maintenance
Manual SEBU7176
789C Truck Service Manual SENR1515
789C Truck Operation and Maintenance Manual SEBU7174
Cold Weather Recommendations for Caterpillar Machines SEBU5898
Caterpillar Machine Fluids Recommendations SEBU6250
PREREQUISITES
Interactive Video Course "Fundamentals of Mobile Hydraulics" TEMV9001
Interactive Video Course "Fundamentals of Electrical Systems" TEMV9002
STMG 546 "Graphic Fluid Power Symbols" SESV1546
Estimated Time: 24 Hours

Visuals: 268 Visuals
Serviceman Handouts: 16 Data Sheets
Form: SERV1857
© 2008 Caterpillar Inc. Date: 06/08
SERV1857 -3- Text Reference
06/08
SUPPLEMENTAL MATERIAL
Reference Manuals
Fluid Power Graphic Symbols User's Guide SENR3981

Flexxaire™ Fan Installation and Maintenance Manual SEBC1152
Automatic Lubrication System SENR4724
Off-Highway Truck/Tractors Vital Information Management System (VIMS)
--System Operation" RENR2630
Off-Highway Truck/Tractors Vital Information Management System (VIMS)
--Testing and Adjusting Troubleshooting" RENR2631
Variable Speed Fan Clutch" SENR8603
Oil Renewal System" RENR2223
Off-Highway Truck/Tractors Brake Electronic Control System" SENR1503
Specification Sheets
785C Off-highway Truck AEHQ5320

789C Off-highway Truck AEHQ5321
793C Update Off-highway Truck AEHQ5186
Salesgrams and Product Bulletins
Salesgram "Vital Information Management System (VIMS)" TELQ4478

Training Bulletin "Caterpillar Transmission/Drive Train Oil" TEJB1002
Product Bulletin "Reporting Particle Count By ISO Code" PEJT5025
Salesgram "Caterpillar Extended Life Coolant" TEKQ0072
Salesgram "785C/789C/793C Mining Truck Introduction" TELQ4459
Salesgram "Cat 769, 771, 773, 775, 777, 785 and 789 Flexxaire™ Fan
Custom Attachment" TELQ4010
Product Bulletin "793C Off-highway Truck" TEJB3060
Video Tapes
793C Off-highway Truck--Service Introduction SEVN4016

793C Off-highway Truck--Marketing Introduction AEVN3742
Suspension Cylinder Charging TEVN2155
Introduction to the Automatic Electronic Traction Aid (AETA) SEVN9187
3500 Engines--EUI Service Introduction SEVN2241
Mining Trucks--Cleanliness and Component Life SEVN4142
06/08
Booklets
Know Your Cooling System SEBD0518

Diesel Fuels and Your Engine SEBD0717
Oil and Your Engine SEBD0640
C-Series Mining Trucks--3500B Diesel Engines LEDH8400
Special Instructions
Repair of 4T8719 Bladder Accumulator Group" SEHS8757

Using 1U5000 Auxiliary Power Unit (APU)" SEHS8715
Using the 1U5525 Attachment Group" SEHS8880
Suspension Cylinder Servicing SEHS9411
06/08
TABLE OF CONTENTS
INTRODUCTION ........................................................................................................................7
WALK AROUND INSPECTION ...............................................................................................11
OPERATOR'S STATION............................................................................................................45
ENGINE......................................................................................................................................65
Engine Electronic Control System .......................................................................................66
Cooling System .....................................................................................................................88
Lubrication System ...............................................................................................................97
Fuel System.........................................................................................................................101
Air Induction and Exhaust System .....................................................................................106
POWER TRAIN .......................................................................................................................111

Torque Converter ................................................................................................................112
Torque Converter Hydraulic System ..................................................................................115
Transmission and Transfer Gears ........................................................................................125
Transmission Hydraulic System .........................................................................................128
Differential ..........................................................................................................................138
Final Drives.........................................................................................................................143
Transmission/Chassis Electronic Control System ..............................................................144
STEERING SYSTEM ..............................................................................................................154
HOIST SYSTEM ......................................................................................................................187
AIR SYSTEM AND BRAKES.................................................................................................207

Air Charging System...........................................................................................................209
Brake Systems.....................................................................................................................216
BRAKE ELECTRONIC CONTROL SYSTEM.......................................................................236

Automatic Retarder Control (ARC) ....................................................................................239
Hydraulic Automatic Retarder Control (HARC) ................................................................245
Traction Control System (TCS) ..........................................................................................255
OPTIONAL EQUIPMENT.......................................................................................................263
FlexxaireTM Fan ................................................................................................................263
785D LARGE OFF-HIGHWAY TRUCKS ..............................................................................266

3512C High Displacement Engine......................................................................................267
Right Side Engine Components ..........................................................................................268
Left Side Engine Components ............................................................................................269
Front Engine Components ..................................................................................................270
Rear Engine Components ...................................................................................................271
Turbocharger Location ........................................................................................................272
Engine Electronic Control Module Diagram ......................................................................273
06/08
Engine ECM and Atmospheric Pressure Sensor .................................................................275

Primary Speed/Timing Sensor ............................................................................................280
Engine Speed Sensor...........................................................................................................281
Coolant Temperature Sensor ...............................................................................................282
Coolant Flow Switch...........................................................................................................283
Crankcase Pressure Sensor .................................................................................................284
Turbo Inlet Pressure Sensors (Taken on the Truck) ............................................................285
Intake Manifold Air Temperature Sensor............................................................................287
Intake Manifold Pressure Sensor (Boost) ...........................................................................288
Left and Right Side Exhaust Temperature Sensors .............................................................290
Fuel Filter Differential Switch ............................................................................................292
Filtered and Unfiltered Engine Oil Pressure Sensors .........................................................293
Fuel System Diagram..........................................................................................................299
Fuel System Diagram (Fuel Priming) .................................................................................302
Top Center Position.............................................................................................................303
Valve Lash...........................................................................................................................304
Steering and Front Brake Oil Cooling System ...................................................................305
Air Induction and Exhaust System "D" Series Truck .........................................................307
3512D HD Engine with ATAAC.........................................................................................309
785D Truck Rear Axle Lubrication (RAXL) ......................................................................310
"D" Series RAXL filtration (Warm Oil) .............................................................................311
RAX Lubrication Strategy ..................................................................................................314
RAXL Control Valve...........................................................................................................316
RAXL Pump Drive Oil Diverter Solenoid Relay Control ..................................................318
Differential Lube .................................................................................................................320
RAXL Final Drive Bypass Valve ........................................................................................321
RAXL Motor and Pump ......................................................................................................323
Temperature and Pressure Sensors for the RAXL ..............................................................324
CONCLUSION .........................................................................................................................326
HYDRAULIC SCHEMATIC COLOR CODE .........................................................................327
VISUAL LIST...........................................................................................................................329
SERVICEMAN'S HANDOUTS ...............................................................................................333
NOTES
06/08
785C, 785D, AND 789C

© 2008 Caterpillar Inc.
INTRODUCTION
Shown is the 789C Off-highway Truck. The "C" Series trucks are the same as the "B" Series
except for the following changes: 3500B engines, improved cab, two different Electronic
Control Modules (Transmission/Chassis and Brake) and an electronically controlled hoist. The
789C also has a 40% larger cooling system with a shunt tank located above the radiator.
The second generation Electronic Programmable Transmission Control (EPTC II) has been
replaced with the Transmission/Chassis Electronic Control System. The Transmission/Chassis
Electronic Control Module (ECM) controls the same functions as the EPTC II plus the hoist and
some other functions.
The Automatic Retarder Control (ARC) and the Traction Control System (TCS) control modules
have been replaced with one Brake System ECM. The Brake System ECM controls both
the ARC and the TCS functions. The TCS is now connected to the CAT Data Link and the
Electronic Technician (ET) service tool can be used to diagnose the TCS.
The load carrying capacities and the Gross Machine Weights (GMW) of the "C" Series trucks
are:
785C: 118 to 136 Metric tons (130 to 150 tons)
249480 kg (550000 lb.) GMW
789C: 154 to 177 Metric tons (170 to 195 tons)
317520 kg (700000 lb.) GMW
06/08
Shown is the right side of a 789C truck. The large air tank on the right platform supplies air for
starting the truck and for the service and retarder brake system.
The hoist, brake, and torque converter hydraulic tank (rear) and the transmission hydraulic
tank (front) are also visible. The transmission hydraulic system is separate from all the other
hydraulic systems.
06/08
Shown is the front of a 789C truck. The 789C is similar in appearance to the 793C and may
be difficult to identify from a distance. The 793C can be identified by the four air filters and
the diagonal access ladder. The 789C has only two air filters and is equipped with two vertical
ladders.
The "C" Series trucks use a folded core radiator. The folded core radiator provides the
convenience of repairing or replacing smaller individual cores.
SERV1857 - 10 - Text Reference
06/08
The truck bodies on "C" Series trucks are mandatory options. Two body styles are available for
the "C" Series trucks:
- A 12 degree flat floor design that provides uniform load dumping, excellent load retention,
and a low center of gravity.
- A dual-slope design with a "V" bottom main floor to reduce shock loading, center the load,
and reduce spills.
All internal wear surfaces of the truck bodies are made with 400 Brinell hardness steel. All
attachment body liners are also made with 400 Brinell hardness steel. The external components
of the bodies are made of steel with a yield strength of 6205 bar (90000 psi).
The forward two-thirds of the body floor is made with 20 mm (.79 in.) thick 400 Brinell steel
plate. The rear one-third of the body floor is made with a 10 mm (.39 in.) thick 400 Brinell sub
plate and a 20 mm (.79 in.) thick 400 Brinell body grid liner plate. As an option, the grid liner
plate can be made with 500 Brinell steel.
The rear suspension cylinders absorb bending and twisting stresses rather than transmitting them
to the main frame.
06/08
785C/789C MAINTENANCE
ice
789C Serv
P ro c e d u re
WALK AROUND INSPECTION
WALK AROUND INSPECTION
Before working on or operating the truck, read the Operation and Maintenance Manual
thoroughly for information on safety, maintenance, and operating techniques.
Safety Precautions and Warnings are provided in the manual and on the truck. Be sure to
identify and understand all symbols before starting the truck.
The first step to perform when approaching the truck is to make a thorough walk around
inspection. Look around and under the truck for loose or missing bolts, trash build-up and for
coolant, fuel, or oil leaks. Look for indications of cracks. Pay close attention to high stress
areas as shown in the Operation and Maintenance Manual.
INSTRUCTOR NOTE: The form numbers for the Operation and Maintenance Manuals
are provided under "References" on Page 2.
06/08
10 HOURS/DAILY MAINTENANCE CHECKS

Batteries Transmission
Oil Level Hoist, Converter
and Brake Oil Level
Steering Oil Level
Auto Lube Reservoir

Air Filter, Suspension Cylinder Height
Restriction Indicators
and Precleaners Rear Axle Oil Level
Coolant Level
Rear Axle and
Belts and Ether Cylinders Brake Cylinder
Breathers
Engine Oil Level
Windshield Washer Level Frame For Cracks and

and A/C Filter Body Support Pads
Leaks and Trash Build-up

Air Reservoir Moisture
Wash Windows,
Cab Fresh Air Filters,
Seat Belt, Indicators, Gauges,
Brake Tests
Secondary Steering and
Back-up Alarm
Tire Inflation
Pressure
Suspension Cylinder Height,
Grease Breathers
and Wheel Breathers
Wheel Nuts Fuel Level and

Drain Moisture
The following list identifies the items that must be serviced every 10 Hours or Daily.
- Walk around inspection: Check for loose or missing bolts, leaks, and cracks in frame
structures
- Suspension cylinders: Measure/recharge
- Transmission oil: Check level
- Hoist, converter and brake system oil: Check level
- Rear axle oil: Check level
- Fuel tank: Drain moisture
- Engine crankcase oil: Check level
- Radiator: Check level and radiator core plugging
- Air filters and precleaners: Check restriction indicators and precleaner dirt level
- Steering system oil: Check level
- Air tanks: Drain moisture
- Brakes: Check operation
- Indicators and gauges: Test operation
- Seat belt: Inspect
- Back-up alarm: Test operation
- Secondary steering: Test operation
06/08
The front wheel bearing oil level is checked and filled by removing the plug (1) in the center
of the wheel bearing cover. The oil should be level with the bottom of the plug hole. The fill
plug is a magnetic plug. Inspect the fill plug weekly for metal particles. If any metal particles
are found, remove the wheel cover and inspect the bearings for wear. The oil is drained by
removing the drain plug (2).
The service interval for changing the front wheel bearing oil is 500 hours.
Use only Final Drive and Axle Oil (FDAO) or Transmission Drive Train Oil (TDTO) with
a specification of (TO-4) or newer. FDAO and TDTO TO-4 provides increased lubrication
capability for bearings.
Check the tire inflation pressure. Operating the truck with the wrong tire inflation pressure can
cause heat build-up in the tire and accelerate tire wear.
NOTE: Care must be taken to ensure that fluids are contained while performing any
inspection, maintenance, testing, adjusting and repair of the machine. Be prepared to
collect the fluid in suitable containers before opening any compartment or disassembling
any component containing fluids. Refer to the "Tools and Shop Products Guide" (Form
NENG2500) for tools and supplies suitable to collect and contain fluids in Caterpillar
machines. Dispose of fluids according to local regulations and mandates.
06/08
Check the front suspension cylinders for leaks or structural damage. Check the charge condition
of the front suspension cylinders when the truck is empty and on level ground. Measure the
charge height of the suspension cylinders and compare the dimension with the dimension that
was recorded the last time the cylinders were charged. Recharge the cylinders with oil and
nitrogen if necessary.
Inspect the condition of the front wheel bearing axle housing breather (1). The breather prevents
pressure from building up in the axle housing. Pressure in the axle housing may cause brake
cooling oil to leak through the Duo-Cone seals in the wheel brake assemblies.
Two grease outlet fittings (2) are located on the front of each suspension cylinder. The grease
supply line for the Auto Lubrication System is located at the rear of the suspension cylinder. No
grease outlet fittings should be located on the same side of the suspension cylinder as the grease
fill location. An outlet fitting positioned on the same side of the suspension cylinder as the
grease fill location will prevent proper lubrication of the cylinder.
Make sure that grease is flowing from the outlet fittings to verify that the suspension cylinders
are being lubricated and that the pressure in the cylinders is not excessive.
INSTRUCTOR NOTE: For more detailed information on servicing the suspension system,
refer to the Special Instruction "Suspension Cylinder Servicing" (Form SEHS9411).
06/08
On the 785C truck, an air filter housing and a precleaner are located behind the front wheels
on both sides of the truck. Check the dust valves (1) for plugging. If necessary, disconnect the
clamp and open the cover for additional cleaning.
The dust valve is OPEN when the engine is OFF and closes when the engine is running. The
dust valve must be flexible and close when the engine is running or the precleaner will not
function properly and the service life of the air filters will be reduced. Replace the rubber dust
valve if it becomes hard and brittle.
The "C" Series trucks may have the optional primary fuel filters with a water separator (2). Two
primary filter/water separators are installed, one on each side of the truck. Open the drain valve
at the bottom of each housing to drain the water when required. The drain interval is determined
by the humidity of the local climate.
Replace the filter element in each housing every 500 hours or when restricted. The filter
elements are removed from the top of the housings.
06/08
10
Shown is the right side of the 3512B engine used in the 784C tractor and 785C truck.
Engine oil samples can be taken at the Scheduled Oil Sampling (S•O•S) tap (arrow) located in
the tube between the engine oil cooler and the engine oil filters.
06/08
4
5
2 1
11
Located behind the right front tire is the transmission charging filter (1), the transmission lube
filter (2), and the torque converter charging filter (3). Transmission oil samples can be taken at
the Scheduled Oil Sampling (S•O•S) tap (4).
An oil filter bypass switch is located on each filter. The transmission oil filter bypass switches
provide input signals to the Transmission/Chassis ECM. The Transmission/Chassis ECM sends
the signals to the VIMS, which informs the operator if the filters are restricted. The torque
converter charging filter bypass switch provides an input signal directly to the VIMS.
One of the three injector banks (5) for the automatic lubrication system is also in this location.
These injectors are adjustable and regulate the quantity of grease that is injected during each
cycle.
A solenoid air valve provides a controlled air supply for the automatic lubrication system.
The solenoid air valve is controlled by the Vital Information Management System (VIMS),
which energizes the solenoid ten minutes after the machine is started. The VIMS energizes
the solenoid for 75 seconds before it is de-energized. Every 60 minutes thereafter, the VIMS
energizes the solenoid for 75 seconds until the machine is stopped (shut down). These settings
are adjustable through the VIMS keypad in the cab (LUBSET and LUBMAN).
INSTRUCTOR NOTE: For more detailed information on servicing the automatic

lubrication system, refer to the Service Manual module "Automatic Lubrication System"
(Form SENR4724).
06/08
3
1
12
Shown are the transmission hydraulic tank (1) and the hoist, converter and brake hydraulic
tank (2). Both tanks are equipped with oil level sight gauges.
The oil level of both hydraulic tanks should first be checked with cold oil and the engine
stopped. The level should again be checked with warm oil and the engine running.
The lower sight gauge (3) on the hoist, converter and brake hydraulic tank can be used to fill
the tank when the hoist cylinders are in the RAISED position. When the hoist cylinders are
lowered, the hydraulic oil level will increase. After the hoist cylinders are lowered, check the
hydraulic tank oil level with the upper sight gauge.
Inspect the hoist, converter and brake hydraulic tank breather (4), and the transmission hydraulic
tank breather (behind the mud flap) for plugging.
When filling the hydraulic tanks after an oil change, fill the tanks with oil to the FULL COLD
mark on the sight gauge. Turn on the engine manual shutdown switch (see Visual No. 25) so
the engine will not start. Crank the engine for approximately 15 seconds. The oil level will
decrease as oil fills the hydraulic systems. Add more oil to the tanks to raise the oil level to the
FULL COLD mark. Crank the engine for an additional 15 seconds. Repeat this step as required
until the oil level stabilizes at the FULL COLD mark.
Turn off the engine manual shutdown switch and start the engine. Warm the hydraulic oil. Add
more oil to the tank as required to raise the oil level to the FULL WARM mark.
06/08
In both tanks, use only Transmission Drive Train Oil (TDTO) with a specification of TO-4 or
newer.
TDTO TO-4 oil:

- Provides maximum frictional capability required for clutch discs used in the transmission,
torque converter and brakes.
- Increases rimpull because of reduced slippage.
- Increases brake holding capability by reducing brake slippage.
- Controls brake chatter.
- Provides maximum frictional capability required for gears.
NOTICE
Failure to correctly fill the hydraulic tanks after an oil change may cause component
damage.
06/08
13
The rear axles are equipped with double reduction planetary-type final drives (see Visual No.
122). Rotate the final drive until the cover and plug are positioned as shown. The final drive oil
level is checked and filled by removing the magnetic plug (arrow). The oil should be level with
the bottom of the plug hole. Fill the rear axle housing with oil before filling the final drives with
oil. Allow enough time for the oil to settle in all of the compartments. This can be as much as
20 minutes during cold temperatures.
The magnetic inspection plugs should be removed weekly from the final drives and checked for
metal particles. For some conditions, checking the magnetic plugs is the only way to identify a
problem which may exist.
Use only Final Drive and Axle Oil (FDAO) or Transmission Drive Train Oil (TDTO) with a
specification of (TO-4) or newer. FDAO and TDTO TO-4 oil provides:
- Maximum lubrication capability required for gears.
- Increased lubrication capability for bearings.
NOTICE
The rear axle is a common sump for the differential and both final drives. If a final
drive or the differential fails, the other final drive components must also be checked for
contamination and then flushed. Failure to completely flush the rear axle after a failure
can cause a repeat failure within a short time.
06/08
2 1 2
14
The differential oil level is checked by viewing the oil level sight glass (1). The oil should be
level with the bottom of the inspection hole.
Two oil level sensors (2) provide input signals to the Brake ECM. The Brake ECM sends the
signals to the VIMS, which informs the operator of the rear axle oil level. A rear axle oil
filter (3) removes contaminants from the rear axle housing.
Check the rear suspension cylinders for leaks or structural damage. Check the charge condition
of the rear suspension cylinders when the truck is empty and on level ground. Measure the
charge height of the suspension cylinders and compare the dimension with the dimension that
was recorded the last time the cylinders were charged. Recharge the cylinders with oil and
nitrogen if necessary.
The second of three injector banks (4) for the automatic lubrication system is mounted on the top
rear of the differential housing.
Above the lubrication injectors is a breather (5) for the rear axle. Inspect the condition of
the breather at regular intervals. The breather prevents pressure from building up in the axle
housing. Excessive pressure in the axle housing can cause brake cooling oil to leak through the
Duo-Cone seals in the wheel brake assemblies.
INSTRUCTOR NOTE: For more detailed information on servicing the suspension system,
refer to the Special Instruction "Suspension Cylinder Servicing" (Form SEHS9411).
06/08
15
The cable that holds the body up is stored below the rear of the body. Whenever work is to be
performed while the body is raised, the safety cable must be connected between the body and the
rear hitch to hold the body in the raised position.
The space between the body and the frame becomes a zero clearance area when the body is
lowered. Failure to install the cable can result in injury or death to personnel working in
this area.
06/08
16
The fuel tank is located on the left side of the truck. The fuel level sight gauge (arrow) is used to
check the fuel level during the walk around inspection.
The percentage of sulfur in the fuel will affect the engine oil recommendations. The following is
a summary of fuel sulfur and oil recommendations:
1. Use API CH-4 performance oils.

2. With fuel sulfur below 0.5%, any API CH-4 oils will have a sufficient Total Base
Number (TBN) for acid neutralization.
3. For fuel sulfur values above 0.5%, the new oil TBN should be a minimum of 10 times
the fuel sulfur.
4. When 10 times the fuel sulfur exceeds the oil TBN, reduce the oil change interval to
approximately one-half the normal change interval.
06/08
17
The primary fuel filter (1) is mounted on the inner side of the fuel tank.
Open the drain valve (2) to remove condensation from the fuel tank.
A fuel level sensor (3) is also located on the fuel tank. The fuel level sensor emits an ultrasonic
signal that bounces off a metal disk on the bottom of a float. The time it takes for the ultrasonic
signal to return is converted to a Pulse Width Modulated (PWM) signal. The PWM signal
changes as the fuel level changes. The fuel level sensor provides the input signals to the VIMS,
which informs the operator of the fuel level. A category level 1 warning (FUEL LVL LO) is
shown on the VIMS display if the fuel level is less than 15%. A category level 2 warning (FUEL
LVL LO ADD FUEL NOW) is shown on the VIMS display if the fuel level is less than 10%.
The fuel level sensor receives 24 Volts from the VIMS. To check the supply voltage of the
sensor, connect a multimeter between Pins 1 and 2 of the sensor connector. Set the meter to read
"DC Volts."
The fuel level sensor output signal is a Pulse Width Modulated (PWM) signal that varies with
the fuel level. To check the output signal of the fuel level sensor, connect a multimeter between
Pins 2 and 4 of the fuel level sensor connector. Set the meter to read "Duty Cycle." The duty
cycle output of the fuel level sensor should be approximately 6% at 0 mm (0 in.) of fuel depth
and 84% at 2000 mm (78.8 in.) of fuel depth.
06/08
18
Located in front of the fuel tank is the parking brake release filter (1) and the torque converter
outlet screen (2).
An oil filter bypass switch is located on each housing. The parking brake filter bypass switch
provides an input signal to the Brake ECM and the torque converter outlet screen bypass switch
provides an input signal to the VIMS. The Brake ECM sends the signal to the VIMS, which
informs the operator if the filter or screen are restricted.
The 789C trucks have two air dryers (3) to accommodate the larger four-cylinder air compressor.
Shown is the rear of the two air dryers.
The third injector bank for the automatic lubrication system is also located in this area.
06/08
2 2
1 1
19
Inspect the condition of the three breathers (1) (two visible) for the brake cylinders. The third
breather is located on the front brake master cylinder behind the cross tube. Oil should not leak
from the breathers. Oil leaking from the breathers is an indication that the oil piston seals in
the brake cylinder need replacement. Air flow from the breathers during a brake application
indicates that the brake cylinder air piston seals need replacement.
If air is in the system or a loss of oil downstream from the cylinders occurs, the piston in the
cylinder will overstroke and cause an indicator rod to extend and open the brake overstroke
switch (2). The switch provides an input signal to the VIMS, which informs the operator of the
condition of the service and retarder brake oil circuit. If an overstroke condition occurs, the
problem must be repaired and the indicator rod pushed in to end the warning.
06/08
1
3
20
On the 789C truck, the second air dryer (1) is located in front of the left front suspension
cylinder. On the 785C truck, the only air dryer is located here.
The air system can be charged from a remote air supply through a ground level connector (2)
inside the left frame.
Engine oil can be added at the quick fill connector (3).
Use only Diesel Engine Oil (DEO) with a specification of CF-4 or newer. DEO oil with a CH-4
specification is available and should be used if possible.
CH-4 engine oil:
- Requires more performance tests than previous oils, such as CE or CF, and has a narrower
performance band.
- Can withstand higher temperatures before coking and has better dispersing capability for
controlling soot.
- Has better fuel sulfur neutralization capability.
06/08
21
The engine oil filters (789C shown) are located on the left side of the engine. Engine oil should
be added at the fill tube (1) and checked with the dipstick (2). The 785C has three engine oil
filters and is checked and filled through the engine cover (see Visual No. 22).
On the 789C truck, engine oil samples can be taken at the Scheduled Oil Sampling (S•O•S)
tap (3). (For the 785C truck, see Visual No. 10.).
The engine lubrication system is equipped with two oil pressure sensors (4). A sensor is located
on each end of the oil filter base. One sensor measures engine oil pressure before the filters.
The other sensor measures oil pressure after the filters. The sensors provide input signals to the
Engine Electronic Control Module (ECM). The ECM provides input signals to the VIMS, which
informs the operator of the engine oil pressure. Together, these sensors inform the operator if
the engine oil filters are restricted.
Use only Diesel Engine Oil (DEO) with a specification of (CF-4) or newer. DEO oil with a
(CH-4) specification is available and should be used if possible.
- CH-4 engine oil requires more performance tests than previous oils, such as CE or CF, and
has a narrower performance band.
- CH-4 engine oil can withstand higher temperatures before coking and has better dispersing
capability for controlling soot.
- CH-4 engine oil has better fuel sulfur neutralization capability.
06/08
22
Shown is the 3512B engine used in the 785C truck. Three oil filters are located on the left side
of the engine. The 3512B engine also has a fitting (1) that can be used to drain the engine oil
that is trapped above the filters. Do not add oil through the fitting because unfiltered oil will
enter the engine. Any contamination could cause damage to the engine.
Aftercooler coolant samples can be taken at the Scheduled Oil Sampling (S•O•S) coolant
analysis tap that is installed at the location of the pipe plug (2).
NOTICE
When changing the engine oil filters, drain the engine oil that is trapped above the oil
filters through the fitting (1) to prevent spilling the oil. Oil added to the engine through the
fitting will go directly to the main oil galleries without going through the engine oil filters.
Adding oil to the engine through the fitting may introduce contaminants into the system
and cause damage to the engine.
06/08
23
Engine oil can be added through a high speed oil change connector and will enter the oil pan
through the fitting (1).
An engine oil level switch (2) provides input signals to the Engine ECM. The Engine ECM
provides an input signal to the VIMS, which informs the operator of the engine oil level.
The oil level switch tells the operator when the engine oil level is low and it is unsafe to operate
the truck without causing damage to the engine. The ENG OIL LEVEL LOW message is a
Category 2 or 3 Warning.
06/08
1
2
24
The secondary fuel filters and the fuel priming pump (1) are located above the engine oil filters
on the left side of the engine. The fuel priming pump is used to fill the filters after they are
changed.
A fuel filter bypass switch (2) is located on the filter base. The bypass switch provides an input
signal to the Engine ECM. The Engine ECM sends the signal to the VIMS, which informs the
operator if the filters are restricted.
NOTE: If the fuel system requires priming, it may be necessary to block the fuel return
line during priming to force the fuel into the injectors.
06/08
6 1
4
25
Before climbing the truck ladder, make sure that the manual engine shutdown switch (1) is OFF.
The engine will not start if the manual shutdown switch is ON. If necessary, the switch can
be used to stop the engine from the ground level. Operate the switch periodically to check the
secondary steering system.
The toggle switches (2) control the lights in the engine compartment and above the access
ladder.
The RS-232 service connector (3) is used to connect a laptop computer with VIMS PC
software to upload new source and configuration files, view real time data or download logged
information from the VIMS.
The battery disconnect switch (4) and VIMS service connector key switch (5) must be in the ON
position before the laptop computer with VIMS software will communicate with the VIMS.
The blue service lamp (6) is part of the VIMS. When the key start switch is turned to the ON
position, the VIMS runs through a self test. During the self test, the service lamp will flash three
times if any logged events are stored in the VIMS main module and once if no logged events are
stored.
During normal operation, the service lamp will turn ON to notify service personnel that the
VIMS has an active data (machine) or maintenance (system) event. The service lamp flashes to
indicate when an event is considered abusive to the machine.
06/08
26
Shown is the 789C truck. While climbing the ladder, make a thorough inspection of the radiator.
Be sure that no debris or dirt is trapped in the cores. Check the air filter restriction indicators (1)
located on both sides of the truck. If the yellow pistons are in the red zone (indicating that the
filters are plugged), the air filters must be serviced. Check the dust valves (2) for plugging. If
necessary, disconnect the clamp and open the cover for additional cleaning. Replace the dust
valve if the rubber is not flexible.
The VIMS will also provide the operator with an air filter restriction warning when the filter
restriction is approximately 6.2 kPa (25 in. of water). Black exhaust smoke is also an indication
of air filter restriction.
Two filter elements are installed in the filter housings. The large element is the primary element
and the small element is the secondary element.
Air intake system tips:

- The primary element can be cleaned a maximum of six times.
- Never clean the secondary element for reuse. Always replace the secondary element.
- Air filter restriction causes black exhaust smoke and low power.
- A 0.6°C (1°F) increase in intake temperature increases exhaust temperature 1.8°C (3°F).
- Exhaust temperature should not exceed 750°C (1382°F).
06/08
1 2
27
Shown is a 789C truck. The capacity of the 789C cooling system has been increased by 40%
from 474 Liters (125 gal.) to 663 Liters (175 gal.). The radiator is larger and a shunt tank (1) has
been added above the radiator.
The cooling system on the "C" Series trucks is divided into two systems. The two systems
are the jacket water cooling system and the aftercooler cooling system. These two systems
are not connected. When servicing the cooling systems, be sure to drain and fill both systems
separately.
The coolant levels are checked at the shunt tank. Use the gauges (2) on top of the shunt tank to
check the two coolant levels.
The water used in the cooling system is critical for good cooling system performance. Use
distilled or deionized water whenever possible to prevent acids or scale deposits in the cooling
system. Acids and scale deposits result from contaminants that are found in most common water
sources.
Never use water alone. All water is corrosive at engine operating temperatures without coolant
additives. Also, water alone has none of the lubrication properties which are required for water
pump seals.
06/08
The "C" Series trucks are filled at the factory with Extended Life Coolant (ELC). If ELC is
maintained in the radiator, it is not necessary to use a supplemental coolant additive. If more
than 10% of conventional coolant is mixed with the ELC, a supplemental coolant additive is
required.
With conventional coolant, maintain a 3 to 6% concentration of supplemental coolant additive.

- Too much additive will form insoluble salts that cause water pump seal wear, plugging and
will coat parts with excessive deposits that prevent heat transfer.
- Not enough additive will result in severe cavitation erosion which will pit and corrode
cylinder liner and block surfaces.
Maintain a 30 to 60% concentration of Caterpillar Antifreeze.

- More than 60% antifreeze concentration will reduce freeze protection and cause radiator
plugging.
- Less than 30% antifreeze concentration will result in cavitation erosion, which will pit and
corrode cylinder liner and block surfaces and decrease water pump life.
- Most commercial antifreezes are formulated with high silicate content for gasoline engines
and are not recommended for diesel engines.
The engine should operate between 88 and 99°C (190 and 210°F).
- Operating below this temperature range will cause overcooling problems.
- Operating above this temperature range will cause overheating problems.
Cooling system pressure should be between 55 and 110 kPa (8 and 16 psi).
- Raising the pressure raises the boiling point. If the pressure is inadequate, the coolant will
boil over and the engine will overheat.
Do not fill the cooling system faster than 20 L/min. (5 gpm).

- Filling the cooling system faster than 20 L/min. (5 gpm) will cause air pockets that could
produce damaging steam.
Keep the fan belts adjusted.
Keep the radiator cooling fins straight and clean.

06/08
1 1
28
Shown is a 785C truck. The air cleaner indicators (1) are located on the filter housings. If the
yellow pistons are in the red zone (indicating that the filters are plugged), the air cleaners must
be serviced.
Check the dust valves (2) for plugging. If necessary, disconnect the clamp and open the cover
for additional cleaning. Replace the dust valve if the rubber is not flexible.
06/08
29
The ether cylinders (arrow) are located in the engine compartment behind the radiator. Make
sure the ether cylinders are not empty.
The Engine ECM will automatically inject ether from the ether cylinders during cranking. The
duration of automatic ether injection depends on the jacket water coolant temperature. The
duration will vary from 10 to 130 seconds.
The operator can also inject ether manually with the ether switch in the cab on the center console
(see Visual No. 48). The manual ether injection duration is 5 seconds.
Ether will be injected only if the engine coolant temperature is below 10°C (50°F) and engine
speed is below 1900 rpm.
Ether starting tip:

- Cold weather causes rough combustion and white exhaust smoke from unburned fuel.
Ether injection will reduce the duration and severity of unburned fuel symptoms.
06/08
30
The batteries are located below the access panel on the right platform. Inspect the battery
connections for corrosion or damage. Keep the battery terminals clean and coated with
petroleum jelly.
Inspect the electrolyte level in each battery cell, except for maintenance free batteries. Maintain
the level to the bottom of the fill openings with distilled water.
Batteries give off flammable fumes that can explode resulting in personal injury.
Prevent sparks near batteries. They could cause vapors to explode.
Do not allow jumper cable ends to contact each other or the machine.
Do not smoke when checking battery electrolyte levels. Electrolyte is an acid and can cause
personal injury if it contacts skin or eyes.
Always wear eye protection when starting a machine with jumper cables.
Always connect the battery positive (+) to battery positive (+) and the battery negative (-)
to the stalled machine frame (-).
06/08
3
2
31
Located on the right platform are the automatic lubrication system grease tank (1), the main air
system tank (2), and the steering system tank (3).
Check the level of the grease in the automatic lubrication system tank with the grease level
indicator located on top of the tank.
A drain valve is located at the bottom right of the main air system tank. Drain the condensation
from the air tank each morning.
06/08
3 4
5 1
32
The oil level for the steering system tank is checked at the upper sight gauge (1) when the oil is
cold and the engine is stopped. After the engine is started, the oil level will decrease as the oil
fills the steering accumulators.
After the accumulators are filled, the oil level should be checked again at the lower sight
gauge (2). When the engine is running and the accumulators are fully charged, the oil level
should not be below the ENGINE RUNNING marking of the lower gauge. If the ENGINE
RUNNING level is not correct, check the nitrogen charge in each accumulator. A low nitrogen
charge will allow excess oil to be stored in the accumulators and will reduce the secondary
steering capacity.
Before removing the cap to add oil to the steering system, be sure that the engine was shut off
with the key start switch, and the steering oil has returned to the tank from the accumulators.
Then, depress the pressure release button (3) on the breather to release any remaining pressure
from the tank.
Also located on the tank are the main steering oil filter (4) and the steering pump case drain
filter (5).
If the steering pump fails or if the engine cannot be started, the connector (6) is used to attach
an Auxiliary Power Unit (APU). The APU will provide supply oil from the steering tank at the
connector (6) to charge the steering accumulators. Steering capability is then available to tow
the truck.
06/08
INSTRUCTOR NOTE: For more detailed information on servicing the steering

accumulators, refer to the Special Instruction "Repair of 4T8719 Bladder Accumulator
Group" (Form SEHS8757). For more information on using the APU, refer to the Special
Instructions "Using 1U5000 Auxiliary Power Unit (APU)"(Form SEHS8715) and "Using
the 1U5525 Attachment Group" (Form SEHS8880).
06/08
33
Another small air tank (not visible) is located behind the cab (see Visual No. 178). The air tank
behind the cab supplies air to the parking and secondary brakes. Drain the moisture from the
tank daily with the drain valve (arrow).
06/08
34
The windshield washer reservoir (1) is located in the compartment in front of the cab. Keep the
reservoir full of windshield washer fluid.
The air conditioner filter (2) is also located in the compartment in front of the cab. Clean or
replace the filter element when a reduction of circulation in the cab is noticed.
06/08
35
The remaining 10 Hours or Daily checks are performed in the operator's compartment:
- Brakes: Check operation

- Indicators and gauges: Test operation
- Seat belt: Inspect
- Back-up alarm: Test operation
- Secondary steering: Test operation
The brakes are checked by engaging one of the brake systems and placing the shift lever in
FIRST FORWARD. Accelerate the engine until the truck moves. The truck must not move
below 1200 rpm. This procedure should be repeated for each brake lever or pedal.
The cab fresh air filter is located behind the cover (arrow). Clean or replace the cab fresh air
filter when necessary.
INSTRUCTOR NOTE: Refer to the Operation and Maintenance Manual for more
information on the remaining tests performed in the cab.
06/08
36
OPERATOR'S STATION
The operator's station for the "C" Series Off-highway Trucks has been changed to improve
operator comfort and ergonomics. The "C" Series cab now resembles the cab used on the
smaller "D" Series Off-highway Trucks.
The VIMS controls the Truck Payload Measurement System (TPMS) on the 785C and 789C
trucks. There are two sets of TPMS external loading lamps on the truck. One set of lamps is on
the left side of the cab (arrow) and the other set is on the right platform. The lamps are green
and red. The lamps inform the loader operator of the loading progress toward a target payload
weight (set through the VIMS Keypad). The lamps are active only during the loading cycle and
are off at all other times.
During loading, the green (continue loading) lamps will be ON until the payload is 95% of the
target weight setting. Then, the red (stop loading) lamp will light. A "last pass" indication can
be programmed into the system using the VIMS Keypad. With last pass indication, the VIMS
calculates an average loader pass size and predicts payload weight. If the predicted weight after
the NEXT loader pass will be above 95% of the target weight setting, the red lamps FLASH.
The red lamps will be ON continuously after the last pass (when fully loaded).
A minimum of three loader passes are required for the "last pass" indication option to function
correctly.
06/08
37
Shown is a view of the operator's seat and the trainer's seat. The seats are more comfortable
with improved seat adjustments.
The trainer's seat has more leg room and can be replaced with an attachment air suspension seat.
06/08
38
The "C" Series truck hoist system is electronically controlled. The hoist control lever (arrow)
activates the four positions of the hoist control valve. The four positions are: RAISE, HOLD,
FLOAT, and LOWER.
A fifth position of the hoist valve is called the SNUB position. The operator does not have
control over the SNUB position. The body position sensor (see Visual No. 129) controls the
SNUB position of the hoist valve. When the body is lowered, just before the body contacts the
frame, the Transmission/Chassis ECM signals the hoist solenoids to move the hoist valve spool
to the SNUB position. In the SNUB position, the body float speed is reduced to prevent hard
contact of the body with the frame.
The truck should normally be operated with the hoist lever in the FLOAT position. Traveling
with the hoist in the FLOAT position will make sure the weight of the body is on the frame and
body pads and not on the hoist cylinders. The hoist valve will actually be in the SNUB position.
If the transmission is in REVERSE when the body is being raised, the hoist lever sensor is used
to shift the transmission to NEUTRAL. The transmission will remain in NEUTRAL until:
1. The hoist lever is moved into the HOLD or FLOAT position; and
2. the shift lever has been cycled into and out of NEUTRAL.
NOTE: If the truck is started with the body raised and the hoist lever in FLOAT, the
lever must be moved into HOLD and then FLOAT before the body will lower.
06/08
39
Shown is an overall view of the dash from the left side of the cab. Some of the improvements
are:
- Telescopic/tilt steering column for individual adjustment
- Intermittent wiper/washer, turn signal control and dimmer switch
- Enhanced instrument layout
- Backlit rocker switches
- Steering wheel mounted electric horn control
06/08
40
The operator controls to the left of the steering column are:
- Telescopic/tilt steering column adjustment lever (1): Push for telescoping and pull for tilt
- Intermittent wiper/washer, turn signal control and dimmer switch (2)
- Steering wheel mounted electric horn control (3)
- Cigarette lighter (4): The cigarette lighter socket receives a 12-Volt power supply. This
socket can be used as a power supply for 12-Volt appliances. Another 12-Volt power port
is provided behind the operator's seat.
06/08
41
Shown is a closer view of the intermittent wiper/washer, turn signal control and dimmer switch.
Windshield washer: Push the button at the end of the lever to activate the electrically powered
windshield washer.
Intermittent wiper switch (six positions):
- OFF (0)
- Intermittent position 1 (one bar)
- Intermittent position 2 (two bars)
- Intermittent position 3 (three bars)
- Low speed continuous wiper (I)
- High speed continuous wiper (II)
Dimmer switch: Pull the lever toward the operator for BRIGHT lights, and push the lever away
from the operator for DIM lights.
Turn signals: Lift the lever for a RIGHT turn, and lower the lever for a LEFT turn.
06/08
42
Located on the right side of the steering column is the manual retarder lever. The manual
retarder lever is used to modulate engagement of the service brakes on all four wheels. The
retarder system allows the machine to maintain a constant speed on long downgrades. The
retarder will not apply all of the normal braking capacity.
Located on the dash to the right of the retarder lever are (from left to right):
- Key start switch

- Temperature variable knob
- Fan speed switch
NOTICE
Do not use the retarder control as a parking brake or to stop the machine.
06/08
3
2
43
Located on the floor of the cab are:
- Secondary brake pedal (1): Used to modulate application of the parking brakes on all four
wheels.
- Service brake pedal (2): Used to modulate engagement of the service brakes on all four
wheels. For more precise modulation of the service brakes, use the manual retarder lever
on the right side of the steering column.
- Throttle pedal (3): A throttle position sensor is attached to the throttle pedal. The throttle
position sensor provides the throttle position input signals to the Engine ECM.
NOTE: The throttle position must be programmed to the 10 to 90% setting. The earlier
trucks must be programmed to a 10 to 50% throttle position. The setting is changed in
the Engine ECM configuration screen with ET.
The Engine ECM provides an elevated engine idle speed of 1300 rpm when the engine coolant
temperature is below 60°C (140°F). The rpm is gradually reduced to 1000 rpm between 60°C
(140°F) and 71°C (160°F). When the temperature is above 71°C (160°F), the engine will idle at
LOW IDLE (700 rpm).
Increasing the low idle speed helps prevent incomplete combustion and overcooling. To
temporarily reduce the elevated idle speed, the operator can release the parking brake or depress
the throttle momentarily, and the idle speed will decrease to LOW IDLE for 10 minutes.
06/08
44
To the right of the operator's seat is the shift console. Located on the shift console are the
transmission shift lever (1) and the parking brake air valve (2).
The "C" Series truck transmissions have SIX speeds FORWARD and ONE speed REVERSE.
The top gear limit and body up gear limit are programmable through the Transmission/Chassis
ECM. The top gear limit can be changed from THIRD to SIXTH. The body up gear limit can
be changed from FIRST to THIRD.
06/08
1 2 3 4 5
45
Located in the overhead panel are several switches:
- Hazard lights (1)

- Headlights and parking/taillights (2)
- Fog lights (3)
- Back-up lights (4)
- Front flood/ladder lights (5)
06/08
46
Shown is the circuit breaker panel located behind the operator's seat. The previous "B" Series
trucks used fuses to protect many of the electrical circuits. The "C" Series trucks use only circuit
breakers to protect the electrical circuits.
A 12-Volt/5 amp power port (1) provides a power supply for 12-Volt appliances, such as a laptop
computer.
A laptop computer with the VIMS software installed can be connected to the diagnostic
connector (2) to obtain diagnostic and production information from the VIMS Electronic
Control.
A laptop computer with the Electronic Technician (ET) software installed can be connected to
the CAT Data Link connector (3) to obtain diagnostic information and perform programming
functions on all the electronic controls.
06/08
47
Shown is the center of the front dash panel. Eight dash indicators, the four-gauge cluster
module, and the speedometer/tachometer module are visible.
The four dash indicators to the left of the four-gauge cluster module are (from top to bottom):
- Left turn
- Body up: Lights when the body is up. Input is from the body position sensor.
- Reverse: Lights when the shift lever switch is in REVERSE.
- High beam
The four dash indicators to the right of the speedometer/tachometer module are (from top to
bottom):
- Right turn
- Action lamp: Lights when a Category 2, 2-S, or Category 3 Warning is active.
- Retarder: Lights when the retarder is ENGAGED (Auto or Manual). Flashes rapidly when
a fault in the ARC system is detected.
- TCS: Lights when the Traction Control System (TCS) is ENGAGED.
06/08
The four systems monitored by the four-gauge cluster module are (top and bottom, left to right):
- Engine coolant temperature: Maximum operating temperature is 107° C (225° F).

- Brake oil temperature: Maximum operating temperature is 121° C (250° F).
- System air pressure: Minimum operating pressure is 450 kPa (65 psi).
- Fuel level: Minimum operating levels are 15% (Category 1) and 10% (Category 2).
The three systems monitored by the speedometer/tachometer module are:
- Tachometer: Displays the engine speed in rpm.

- Ground speed: Displayed in the left side of the three-digit display area and can be
displayed in miles per hour (mph) or kilometers per hour (km/h).
- Actual gear: Displayed in the right side of the three-digit display area and consists of
two digits that show the actual transmission gear that is engaged. The left digit shows the
actual gear (such as "1," "2," etc.). The right digit shows the direction selected ("F," "N" or
"R").
06/08
48
To the right of the Speedometer/Tachometer Module are several rocker switches. The rocker
switches control the following systems:
Top row (from left to right)

- Throttle back-up: Raises the engine speed to 1300 rpm if the throttle sensor signal is
invalid.
- Ether starting aid: Allows the operator to manually inject ether if the engine oil
temperature is below 10°C (50°F) and engine speed is below 1900 rpm. The manual ether
injection duration is five seconds (see Visuals No. 66 and 90).
- ARC: Activates the Automatic Retarder Control (ARC) system.
- Brake release/hoist pilot: Used to release the parking brakes for towing and provide hoist
pilot oil to lower the body with a dead engine. The small latch must be pushed UP before
the switch can be pushed DOWN.
- TCS test: Tests the Traction Control System (TCS). Use this switch when turning in a
tight circle with the engine at LOW IDLE and the transmission in FIRST GEAR. The
brakes should ENGAGE and RELEASE repeatedly. The test must be performed while
turning in both directions to complete the test.
Bottom row (from left to right)
- Panel Lights: Use this switch to DIM the panel lights
- Air Conditioning: Use this switch to turn ON the air conditioner.
06/08
49
Shown is the Vital Information Management System (VIMS) message center module (1) and the
keypad module (2).
The message center module consists of an alert indicator, a universal gauge, and a message
display window. The alert indicator flashes when a Category 1, 2, 2-S, or 3 Warning is present.
The universal gauge displays active or logged data (machine) and maintenance (system)
events. The universal gauge will also display the status of a sensor parameter selected for
viewing by depressing the GAUGE key on the keypad.
The message display window shows various types of text information to the operator, depending
on the menu selected with the keypad. An active event will override most displays until
acknowledged by depressing the OK Key.
06/08
The VIMS provides three Warning Categories. The first category requires only operator
awareness. The second category states that the operation of the machine and the maintenance
procedure of the machine must be changed. The third Warning Category states that the machine
must be safely shut down immediately.
Warning Category 1
For a Category 1 Warning, the alert indicator will flash. The universal gauge may display the
parameter and a message will appear in the message display window. A Category 1 Warning
alerts the operator that a machine system requires attention. The "OK" key on the keypad can be
used to acknowledge the warning. Some warnings will be silenced for a predetermined period.
After this time period, if the abnormal condition is still present, the warning will reappear.
Warning Category 2
For a Category 2 Warning, the alert indicator and the action lamp will flash. The universal
gauge may display the parameter and a message will appear in the message display window.
A Category 2 warning alerts the operator that a change in machine operation is required to
avoid possible damage to the indicated system. The "OK" key on the keypad can be used to
acknowledge the warning. Some warnings will be silenced for a predetermined period. After
this time period, if the abnormal condition is still present, the warning will reappear.
Warning Category 2-S
For a Category 2-S Warning, the alert indicator and the action lamp will flash and a continuous
action alarm will sound, which indicate a SEVERE Category 2 Warning. The universal gauge
may display the parameter and a message will appear in the message display window. A
Category 2-S Warning alerts the operator to immediately change the operation of the machine
to avoid possible damage to the indicated system. When the change in operation is made to an
acceptable condition, the action alarm will turn off.
Warning Category 3
For a Category 3 Warning, the alert indicator and the action lamp will flash and the action
alarm will sound intermittently. The universal gauge may display the parameter and a message
will appear in the message display window. A Category 3 Warning alerts the operator that the
machine must be safely shut down immediately to avoid damage to the machine or prevent
personal injury. Some Category 3 Warnings cannot be stopped by pressing the "OK" key.
06/08
Gauge Speedometer/ Message

Cluster Tachometer Center Keypad
Service Module Module Module Module
Lamp
Service VIMS
Key Start RS-232 1 2 km/ h 3F
Switch
MPH
Port
VIMS Electronic
Service Tool Technician /ECAP
and
Software Display Keypad
Data Link Data Link
Vims Interface CAT Data Link

Vims Main Module Vims Interface
Module Module
Engine
ECM
Action
Alarm
Action
Lamp
CAT Data Link
Sensors Sensors
Transmission /
VITAL INFORMATION Chassis ECM
Brake ECM
MANAGEMENT SYSTEM (ARC /TCS)
(VIMS)
50
The VIMS uses two interface modules to receive input signals from many switches and sensors
located around the machine. The VIMS also communicates with other electronic controls on the
machine. The VIMS provides the operator and the service technician with a complete look at
the current and past conditions of all the systems on the truck.
The Truck Production Management System (TPMS) is an integral part of the VIMS. Access to
the TPMS information is provided through the VIMS message center and keypad modules and a
laptop computer with the VIMS PC software installed.
The VIMS monitors all the systems on the truck, but ET is used for programming, running
diagnostic tests and retrieving logged information from the Engine ECM, the Transmission/
Chassis ECM, and the Brake ECM (ARC and TCS).
06/08
51
Shown is the location are the Brake ECM (1) and the Transmission/Chassis ECM (2).
The Brake ECM controls the Automatic Retarder Control (ARC) system, the Traction Control
System (TCS), and rear axle cooling.
The Transmission/Chassis ECM controls the shifting of the transmission, torque converter
lockup, the hoist system, the neutral-start feature, power train filter and temperature monitoring,
and the automatic lubrication feature.
All these electronic controls, along with the Engine ECM, communicate with each other on the
CAT Data Link. All the information from these controls can be accessed through the VIMS
message center or a laptop computer with Electronic Technician (ET) or VIMS PC software.
06/08
52
Shown is a laptop computer with the VIMS PC diagnostic software installed. The laptop
computer is connected to the VIMS diagnostic connector.
Some of the operations that can be performed with a laptop computer with VIMS PC installed
are:
- View real time data (similar to the status menu of ET)
- View payload data
- Start and stop a data logger
- Calibrate the payload system
- Upload source and configuration files (similar to flash programming other ECM’s with ET)
- Assign serial and equipment numbers
- Reset onboard date, time, and hourmeter
- Download event list, data logger, event recorder, payload data, trend data, cumulative data,
and histogram data
INSTRUCTOR NOTE: For more detailed information on the VIMS, refer to the Service
Manual Modules "Off-Highway Truck/Tractors Vital Information Management System
(VIMS)--System Operation" (Form RENR2630) and "Off-Highway Truck/Tractors Vital
Information Management System (VIMS)--Testing and Adjusting Troubleshooting" (Form
RENR2631).
06/08
53
Shown is the 7X1700 Communication Adapter and a laptop computer with the Electronic
Technician (ET) diagnostic software installed. The communication adapter is connected to the
CAT Data Link diagnostic connector located on the circuit breaker panel.
The electronic controls (Transmission/Chassis ECM and Brake ECM) used on the "C" Series
trucks no longer have diagnostic windows to access diagnostic information. To perform
diagnostic and programming functions with these electronic controls, the service technician must
use a laptop computer with ET.
06/08
54
ENGINE
Shown is the 3516B engine used in the 789C Off-highway Truck. The 789C is equipped with
the Caterpillar 3516B quad turbocharged and aftercooled engine. The 785C is equipped with the
Caterpillar 3512B twin turbocharged and aftercooled engine.
The 785C and 789C engines have increased horsepower.
The engine power ratings for the 785C and 789C trucks are:
785C: gross power--1082 kW (1450 hp)

net power--1007 kW (1350 flywheel hp)
789C: gross power--1417 kW (1900 hp)
net power--1335 kW (1790 flywheel hp)
These engines utilize the Electronic Unit Injection (EUI) system for power, reliability and
economy with reduced sound levels and low emissions.
06/08
3500B ELECTRONIC CONTROL SYSTEM

Engine COMPONENT DIAGRAM
ECM
Ground
Electronic Unit Bolt Disconnect Switch
Injectors
24 V
Main Key Start
15 Amp Power Relay Switch
Breaker
Throttle
Timing Probe
Engine Coolant Temperature Connector
Rear Aftercooler Temperature Oil Level Speed /Timing Sensor

Switch (Low)
Engine Oil Pressure
Engine Oil Pressure (Filtered) (Unfiltered)
Ether Solenoid
Atmospheric Pressure Manual Ether
Switch
Throttle Override Switch
Turbo Outlet Pressure (Boost)
Ground Level
Shutdown Switch
Right Turbo Inlet Pressure
Fuel Filter CAT Data Link
Switch
Service Tool
Left Turbo Inlet Pressure Transmission / Chassis ECM
Brake ECM
Right Turbo Exhaust Crankcase VIMS
Pressure Engine Oil Renewal Solenoid
Left Turbo Exhaust Shutter Solenoid
Fan Clutch A/C Pressure

Solenoid Pre-lubrication Relay
Switch
Fan Fan Speed Sensor Coolant Flow Switch
55
Engine Electronic Control System
Shown is the electronic control system component diagram for the 3500B engines used in the
"C" Series trucks. Fuel injection is controlled by the Engine Electronic Control Module (ECM).
Many electronic signals are sent to the Engine ECM by sensors, switches, and senders. The
Engine ECM analyzes these signals and determines when and for how long to energize the
injector solenoids.
When the injector solenoids are energized determines the timing of the engine. How long the
solenoids are energized determines the engine speed.
06/08
"Pull-up voltage" is a voltage supplied from within an ECM through an internal resister which
"pulls up" the signal circuit contact on the connector of the control input. Pull-up circuits are
used on most sensor and switch inputs of electronic controls. Frequency sensors do not receive
a pull-up voltage (except for suspension cylinder pressure sensors). The pull-up voltage is
determined by the ECM design and will vary between ECMs. Pull-up voltage sometimes is the
same value as the voltage source that powers the sensor, but does not have to be. Remember,
pull-up voltage is on the SIGNAL input to the ECM for a given sensor (or switch) and most
often HAS NO relationship to the voltage that POWERS the sensor. PWM sensors most often
have a pull-up voltage value DIFFERENT than the voltage that powers them. Analog sensors,
as used with the engine ECM, most often have a pull-up voltage that is the SAME as the voltage
that powers them. The Engine ECM will provide a "pull-up voltage" to the signal circuit of the
sensors when the ECM senses an OPEN circuit. The signal circuit is pin C of the 3-pin sensor
connectors. The pull-up voltage for the Engine ECM sensors is approximately 6.50 volts.
To test for pull-up voltage, use a digital multimeter set to DC voltage, and use the following
procedure (key start switch must be ON):
1. Measure between pins B (analog or digital return) and C (signal) on the ECM side of a
sensor connector before it is disconnected. The voltage that is associated with the current
temperature or pressure should be shown.
2. Disconnect the sensor connector while still measuring the voltage between pins B and C. If
the circuit between the ECM and the sensor connector is good, the multimeter will display
the pull-up voltage.
06/08
56
Fuel injection and some other systems are controlled by the Engine ECM (arrow) located on top
of the engine. Other systems controlled by the Engine ECM include:
- Ether injection - Engine start function

- Engine oil pre-lubrication - Variable speed fan control
The Engine ECM has two 40-pin connectors. The connectors are identified as "J1" and "J2." Be
sure to identify which connector is the J1 or J2 connector before performing diagnostic tests.
The Engine ECM is cooled by fuel. Fuel flows from the fuel transfer pump through the ECM to
the secondary fuel filters.
Occasionally, Caterpillar will make changes to the internal software (personality module)
that controls the performance of the engine. These changes can be performed by physically
installing a new personality module, located below the ECM, or by using the WinFlash program
that is part of the laptop software program, Electronic Technician (ET). ET is used to diagnose
and program the electronic controls used in Off-highway Trucks. If using the WinFlash
program, a "flash" file must be obtained from Caterpillar and uploaded into the existing ECM
personality module.
The ECM in earlier 3500 engines had one 70-pin connector and cannot be reprogrammed with
the WinFlash application in ET. Reprogramming of the earlier ECM requires a replacement of
the personality module located behind an access cover on the ECM.
06/08
A timing calibration connector is located next to the ECM. If the engine requires timing
calibration, a timing calibration sensor (magnetic pickup) is installed in the flywheel housing
and connected to the timing calibration connector.
Using the Caterpillar ET service tool, timing calibration is performed automatically for the
speed/timing sensors. The desired engine speed is set to 800 rpm. This step is performed
to avoid instability and ensures that no backlash is present in the timing gears during the
calibration process.
Timing calibration improves fuel injection accuracy by correcting for any slight tolerances
between the crankshaft, timing gears, and timing wheel.
Timing calibration is normally performed after the following procedures:
1. ECM replacement
2. Speed/timing sensor replacement
3. Timing wheel replacement
INSTRUCTOR NOTE: Some of the engine electronic control system input components
are shown during the discussion of other systems. See the following visual numbers:
23. Engine oil level switch
25. Engine shutdown switch
46. CAT Data Link connector
48. Throttle back-up switch
48. Manual ether switch
62. Air conditioner compressor pressure switch
63. Engine crankcase pressure sensor
68. Coolant temperature sensor
68. Turbocharger outlet pressure sensor
68. Engine fan speed sensor
74. Coolant flow switch
78. Rear aftercooler temperature sensor
81. Engine oil pressure and filter restriction sensors
86. Fuel filter restriction switch
90. Turbocharger inlet pressure sensor
92. Turbocharger temperature sensor
06/08
57
The atmospheric pressure sensor (arrow) is located adjacent to the Engine ECM. The Engine
ECM uses the atmospheric pressure sensor as a reference for calculating boost and air filter
restriction.
The sensor is also used for derating the engine at high altitudes. The ECM will derate the engine
at a rate of 1% per kPa to a maximum of 20%. Derating begins at a specific elevation. The
elevation specification can be found in the Technical Marketing Information (TMI) located
on the Caterpillar Network. If the Engine ECM detects an atmospheric pressure sensor fault,
the ECM will derate the fuel delivery to 20%. If the Engine ECM detects an atmospheric and
turbocharger inlet pressure sensor fault at the same time, the ECM will derate the engine to the
maximum rate of 40%.
The Engine ECM also uses the atmospheric pressure sensor as a reference when calibrating all
the pressure sensors.
The atmospheric pressure sensor is one of the many analog sensors that receive a regulated
5.0 ± 0.5 Volts from the Engine ECM. The atmospheric pressure sensor output signal is a DC
Voltage output signal that varies between 0.2 and 4.8 Volts DC with an operating pressure range
between 0 and 111 kPa (0 and 15.7 psi).
To check the output signal of analog sensors, connect a multimeter between Pins B and C of the
sensor connector. Set the meter to read "DC Volts." The DC Voltage output of the atmospheric
pressure sensor should be between 0.2 and 4.8 Volts DC.
06/08
58
The engine speed/timing sensor (1) is positioned near the rear of the left camshaft. The sensor
signals the speed, direction, and position of the camshaft by counting the teeth and measuring
the gaps between the teeth on the timing wheel which is mounted on the camshaft.
The engine speed/timing sensor is one of the most important inputs to the Engine ECM. If the
Engine ECM does not receive an input signal from the engine speed/timing sensor, the engine
will not run.
The engine speed/timing sensor receives a regulated 12.5 ± 1.0 Volts from the Engine ECM. To
check the output signal of the speed/timing sensor, connect a multimeter between Pins B and C
of the speed/timing sensor connector. Set the meter to read "Frequency." The frequency output
of the speed/timing sensor should be approximately:
- Cranking: 23 to 40 Hz
- Low Idle: 140 Hz
- High Idle: 385 Hz
A passive (two wire) engine speed sensor (2) is positioned on top of the flywheel housing. The
passive speed sensor uses the passing teeth of the flywheel to provide a frequency output. The
passive speed sensor sends the engine speed signal to the Transmission/Chassis ECM and the
Brake ECM.
06/08
The signal from the passive speed sensor is used for several purposes:
- Automatic Retarder Control (ARC) engine control speed
- Shift time calculations
- Transmission Output Speed (TOS) ratification
The output signal of the passive speed sensor can also be checked by connecting a multimeter
between the two pins of the speed sensor connector and setting the meter to read frequency.
NOTE: Turn ON the engine shutdown switch (see Visual No. 25) during the cranking
test to prevent the engine from starting. The cranking speed and frequency output will
vary depending on weather and machine conditions. When viewing engine speed in the
ET status screen, cranking speed should be between 100 and 250 rpm.
06/08
59
The throttle position sensor (arrow) provides the desired throttle position to the Engine ECM. If
the Engine ECM detects a fault in the throttle position sensor, the throttle back-up switch (see
Visual No. 48) can be used to increase the engine speed to 1300 rpm.
The throttle position sensor receives a regulated 8.0 ± 0.5 Volts from the Engine ECM. The
throttle position sensor output signal is a Pulse Width Modulated (PWM) signal that varies with
throttle position and is expressed as a percentage between 0 and 100%.
To check the output signal of the throttle position sensor, connect a multimeter between Pins B
and C of the throttle position sensor connector. Set the meter to read "Duty Cycle." The duty
cycle output of the throttle position sensor should be:
- Low Idle: 16 ± 6%
- High Idle: 85 ± 4%
NOTE: The throttle position must be programmed to the 10 to 90% setting. The earlier
trucks must be programmed to a 10 to 50% throttle position. The setting is changed in
the Engine ECM configuration screen with ET.
06/08
60
Shown is the top of a cylinder head with the valve cover removed. The most important output
from the Engine ECM is the Electronic Unit Injection (EUI) injector solenoid (arrow). One
injector is located in each cylinder head. The engine control analyzes all the inputs and sends a
signal to the injector solenoid to control engine timing and speed.
Engine timing is determined by controlling the start and end time that the injector solenoid is
energized. Engine speed is determined by controlling the duration that the injector solenoid is
energized.
3500B injectors are calibrated during manufacturing for precise injection timing and fuel
discharge. After the calibration, a four-digit "E-trim" code number is etched on the injector
tappet surface. The E-trim code identifies the injector’s performance range.
When the injectors are installed into an engine, the trim code number of each injector is entered
into the personality module (software) of the Engine ECM using the ECAP or ET service tool.
The software uses the trim code to compensate for the manufacturing variations in the injectors
and allows each injector to perform as a nominal injector.
When an injector is serviced, the new injector’s trim code should be programmed into the
Engine ECM. If the new trim code is not entered, the previous injector’s characteristics are
used. The engine will not be harmed if the new code is not entered, but the engine will not
provide peak performance.
06/08
3500B IMPROVEMENTS
INPUT SWITCHES AND SENSORS
- Coolant Flow
- Rear Aftercooler Temperature
- Engine Oil Level
- Turbocharger Temperature
- Engine Oil Filter Pressure / Restriction
- Engine Fan Speed
- Fuel Filter Restriction
- Air Conditioner Compressor Pressure
- Crankcase Pressure
61
The 3500B engines have many improvements over the original 3500 engines. Some of the
improvements are accomplished by adding additional switch and sensor inputs to the Engine
ECM. Adding additional inputs allows the ECM to control the engine more precisely.
Additional inputs to the 3500B ECM are:
- Coolant flow is monitored (see Visual No. 74).

- Rear aftercooler temperature is measured (see Visual No. 78).
- Engine oil level is monitored (see Visual No. 23).
- Two turbocharger temperature sensors measure exhaust temperatures (see Visual No. 92).
- Two engine oil pressure sensors are located on the oil filter base to measure oil pressure
and oil filter restriction (see Visual No. 81.
- Engine fan speed is measured (with variable fan speed attachment).
- Fuel filter restriction is monitored (see Visual No. 86).
- Air conditioner compressor pressure is monitored (for variable fan speed control) (see
Visual No. 62).
- Engine crankcase pressure is measured (see Visual No. 63).
06/08
62
An air conditioner compressor switch (arrow) is located at the rear of the air conditioner
compressor. If the truck is equipped with the variable fan speed attachment, the air conditioner
compressor switch signals the Engine ECM when the air conditioner system is ON. When the
air conditioner system is ON, the ECM sets the variable speed fan at MAXIMUM rpm.
Disconnecting the air conditioner compressor switch will also signal the ECM to set the fan
speed at MAXIMUM rpm.
06/08
63
The crankcase pressure sensor (arrow) is located on the right side of the engine above the engine
oil cooler. The crankcase pressure sensor provides an input signal to the Engine ECM. The
ECM provides the signal to the VIMS, which informs the operator of the crankcase pressure.
High crankcase pressure may be caused by worn piston rings or cylinder liners.
If crankcase pressure exceeds 3.6 kPa (.5 psi) or 14.4 inches of water, a high crankcase pressure
event will be logged. No factory password is required to clear this event.
06/08
3500B IMPROVEMENTS
PREVIOUS LOGGED EVENTS
- Air Filter Restriction
- Low Oil Pressure
- High Coolant Temperature
- Engine Overspeed
64
The 3500B ECM logs the four events of the previous 3500 engine plus some additional events.
The four events logged by the 3500 ECM and the 3500B ECM are:
Air filter restriction: Greater than 6.25 kPa (25 in. of water). Maximum derate of 20%.
If the atmospheric and turbo inlet pressure sensors both fail at the same time, a derate of 40%
will occur.
Low oil pressure: From less than 44 kPa (6.4 psi) at LOW IDLE to less than 250 kPa (36 psi)
at HIGH IDLE.
High coolant temperature: Greater than 107° C (226° F).
Engine overspeed: Greater than 2200 rpm.
NOTE: Factory passwords are required to clear all the events listed above.
06/08
3500B IMPROVEMENTS
ADDITIONAL LOGGED EVENTS
- Oil Filter Restriction - Low Coolant Flow
- Fuel Filter Restriction - User Defined Shutdown
- High Exhaust Temperature - Low Boost Pressure
- High Aftercooler Temperature - High Boost Pressure
- Engine Oil Level Low - Pre-lube Override
- High Crankcase Pressure
65
Additional events logged by the 3500B ECM are:
Oil filter restriction: Greater than 70 kPa (10 psi), no factory password required. Greater than
200 kPa (29 psi), factory password required.
Fuel filter restriction: Greater than 138 kPa (20 psi). No factory password required.
Exhaust temperature high: Greater than 750° C (1382° F). Maximum derate of 20%. Factory
password required.
Aftercooler coolant temperature high: Greater than 107° C (226° F). Factory password
required.
Engine oil level low: No factory password required.
Crankcase pressure high: Greater than 3.6 kPa (.5 psi) or 14.4 inches of water. No factory
password required.
06/08
Coolant flow low: Factory password required.
User defined shutdown: The customer has the option of installing systems (fire suppression)
that will shut down the engine if desired. If the installed system sends a ground signal to the
Engine ECM at Connector J1 Pin 19, a user defined shutdown will occur. Factory password
required.
The VIMS will shut down the engine for any of the following conditions:
- Engine oil level low
- Engine oil pressure low
- Engine coolant temperature high
- Engine coolant level low
- Aftercooler coolant level low
The engine will only shutdown when ground speed is 0 and the parking brake is ENGAGED.
The Engine ECM does not log events for VIMS initiated engine shutdowns.
Pre-lube override: Override the engine oil pre-lubrication system with the key start switch.
Factory password required. (see Visual No. 67)
06/08
3500B IMPROVEMENTS
SYSTEMS CONTROLLED BY ECM
- Ether Injection
- Radiator Shutter Control
- Cold Mode
- Cold Cylinder Cutout
- Engine Start Function
- Engine Oil Pre-lubrication
- Variable Speed Fan Control
- Engine Oil Renewal System
66
The Engine ECM also regulates other systems by energizing solenoids or relays. Some of the
other systems controlled by the ECM are:
Ether Injection: The Engine ECM will automatically inject ether from the ether cylinders
during cranking. The duration of automatic ether injection depends on the jacket water coolant
temperature. The duration will vary from 10 to 130 seconds. The operator can also inject
ether manually with the ether switch in the cab on the center console (see Visual No. 48). The
manual ether injection duration is 5 seconds. Ether will be injected only if the engine coolant
temperature is below 10° C (50° F) and engine speed is below 1900 rpm.
Radiator Shutter Control (attachment): On trucks that operate in cold weather, shutters can
be added in front of the radiator. Installing shutters in front of the radiator allows the engine to
warm up to operating temperature quicker. If a truck is equipped with the attachment radiator
shutter control, the shutters are controlled by the Engine ECM.
06/08
Cool Engine Elevated Idle: The Engine ECM provides an elevated engine idle speed of
1300 rpm when the engine coolant temperature is below 60° C (140° F). The rpm is gradually
reduced to 1000 rpm between 60° C (140° F) and 71° C (160° F). When the temperature is
greater than 71° C (160° F), the engine will operate at low idle (700 rpm).
temporarily reduce the elevated idle speed, the operator can release the parking brake or depress
Cold Cylinder Cutout: The 3500B engine uses a cold cylinder cutout function to:
- Reduce white exhaust smoke (unburned fuel) after start-up and during extended idling in
cold weather
- Minimize the time in Cold Mode
- Reduce the use of ether injection.
After the engine is started and the automatic ether injection system has stopped injecting ether,
the Engine ECM will cut out one cylinder at a time to determine which cylinders are firing. The
ECM will disable some of the cylinders that are not firing.
The ECM can identify a cylinder which is not firing by monitoring the fuel rate and engine
speed during a cylinder cutout. The ECM averages the fuel delivery and analyzes the fuel rate
change during a cylinder cutout to determine if the cylinder is firing.
Disabling some of the cylinders during Cold Mode operation will cause the engine to run rough
until the coolant temperature increases above the Cold Mode temperature. This condition is
normal, but the operator should be aware it exists to prevent unnecessary complaints.
Engine Start Function: The Engine Start function is controlled by the Engine ECM and the
Transmission/Chassis ECM. The Engine ECM provides signals to the Transmission/Chassis
ECM regarding the engine speed and the condition of the engine pre-lubrication system. The
Transmission/Chassis ECM will energize the starter relay only when:
- The shift lever is in NEUTRAL.
- The parking brake is ENGAGED.
- The engine speed is zero rpm.
- The engine pre-lubrication cycle is complete or turned OFF.
NOTE: To protect the starter, the starter is disengaged when the engine rpm is above
300 rpm.
06/08
1 2
67
Engine Oil Pre-lubrication (attachment): Engine oil pre-lubrication is controlled by the Engine
ECM and Transmission/Chassis ECM. The Engine ECM energizes the pre-lubrication pump
relay located behind the cab (see Visual No. 53) The relay behind the cab then energizes the
pre-lube relay (1) on the front engine mount. The Engine ECM signals the Transmission/
Chassis ECM to crank the engine when:
- Engine oil pressure is 3 kPa (.4 psi) or higher.
- The pre-lubrication pump (2) has run for 17 seconds. (If the system times out after 17
seconds, a pre-lubrication time out fault is logged in the Engine ECM.)
- The engine has been running in the last two minutes.
- Coolant temperature is above 50° C (122° F).
The engine oil pre-lubrication system can be bypassed to allow quick starts. To override the
pre-lubrication system, turn the key start switch to the CRANK position for a minimum of two
seconds. The Transmission/Chassis ECM will begin the pre-lube cycle. While the pre-lube
cycle is active, turn the key start switch to the OFF position. Within 10 seconds, turn the key
start switch back to the CRANK position. The Transmission/Chassis ECM will energize the
starter relay.
If the engine oil pre-lubrication system is bypassed using the above procedure, the Engine ECM
will log a pre-lube override event that requires a factory password to clear.
NOTE: The ECAP and ET can enable or disable the pre-lubrication feature in the
Engine ECM.
06/08
68
Variable Speed Fan Control (attachment): If the engine is equipped with a variable speed fan,
the Engine ECM regulates the fan speed. Fan speed varies according to the temperature of the
engine. The ECM sends a signal to the variable speed fan control solenoid valve (1) and engine
oil pressure engages a clutch as needed to change the speed of the fan.
The jacket water coolant temperature sensor (2) is located in the jacket water temperature
regulator (thermostat) housing. The ECM uses the coolant temperature sensor information as
the main parameter to control the fan speed. The aftercooler temperature sensor, air conditioner
pressure sensor and brake cooling oil temperature sensors are also used as inputs to determine
the required fan speed. A speed sensor (not shown) is located behind the fan pulley and informs
the ECM of the current fan speed.
The variable speed fan feature can be turned off using the ECAP or ET service tool. Turning
off the variable speed fan feature will set the fan speed at MAXIMUM rpm. Disconnecting the
air conditioning compressor switch will also signal the ECM to set the fan speed at MAXIMUM
rpm (see Visual No. 62).
The turbocharger outlet pressure sensor (3) sends an input signal to the Engine ECM. The ECM
compares the value of the turbo outlet pressure sensor with the value of the atmospheric pressure
sensor and calculates boost pressure.
INSTRUCTOR NOTE: For more information on the variable speed fan, refer to the
Service Manual "Variable Speed Fan Clutch" (Form SENR8603).
06/08
69
Engine Oil Renewal System (attachment): Located on the right side of the engine are the
components of the engine oil renewal system. Engine oil flows from the engine block to the
engine oil renewal solenoid valve (arrow). When the solenoid is energized and de-energized,
a small amount of oil flows from the engine oil renewal solenoid valve into the fuel line that
returns to the fuel tank. The engine oil mixes with the fuel in the tank and flows with the fuel to
the EUI injectors to be burned.
If the machine is equipped with the engine oil renewal system, the engine oil filters, the engine
oil renewal system filter, the primary fuel filter, and the secondary fuel filters must all be
changed at 500 hour intervals. The engine oil should be changed at least once per year or 4000
service meter hours.
Engine oil samples must be taken regularly to ensure that the soot level of the engine oil is in a
safe operating range.
06/08
The Engine ECM regulates the amount of oil that is injected by the engine oil renewal solenoid
valve. Several parameters must be met before the ECM will allow the injection of oil through
the engine oil renewal system. The parameters that must be met are:
- Fuel position is greater than 10.
- Engine rpm is between 1100 and 1850 rpm.
- Jacket water temperature is between 63° C (145° F) and 107° C (225° F).
- Fuel filter differential pressure is less than 140 kPa (20 psi).
- Fuel level is greater than 10%.
- Engine oil level switches are sending a valid signal to the Engine ECM.
- Engine has been running more than five minutes.
The engine oil renewal system can be turned ON or OFF with the ET service tool. The amount
of oil injected can also be adjusted by programming the Engine ECM with the ET service tool.
The factory setting shown in the service tool is "0" and is equivalent to a 0.5% oil to fuel ratio.
The ratio can be changed with the service tool from minus 50 (-50) to plus 50 (+50), which is
equivalent to 0.25% to 0.75% oil to fuel ratios.
INSTRUCTOR NOTE: For more detailed information on servicing the oil renewal
system, refer to the Service Manual Module "Oil Renewal System" (Form RENR2223).
06/08
OIL RENEWAL SOLENOID VALVE
Piston Piston
ON OFF
To Fuel To Fuel
Return Return
From Engine From Engine

Oil Gallery Oil Gallery
70
Shown is a sectional view of the engine oil renewal solenoid valve. When the Engine Slave
ECM determines that oil can be injected into the fuel return line, a Pulse Width Modulated
(PWM) duty cycle signal is sent to the oil renewal solenoid. The solenoid is turned ON for
1.25 seconds and turned OFF for 1.25 seconds for a total cycle time of 2.5 seconds. How many
times the solenoid is turned ON and OFF will determine the volume of oil that is injected. Oil
is injected when the solenoid is turned ON and oil is also injected when the solenoid is turned
OFF. When the solenoid is turned ON, engine oil flows to the left side of the piston and pushes
the piston to the right. The volume of oil that is trapped between the right side of the piston and
the check ball compresses the spring and opens the passage to the fuel return line. When the
solenoid is turned OFF, engine oil flows to the right side of the piston and pushes the piston to
the left. The volume of oil that is trapped between the left side of the piston and the check ball
compresses the spring and opens the passage to the fuel return line. The volume of delivery is
equal to 3.04 ml/cycle (0.1 oz/cycle).
06/08
2
1
71
Cooling System
Shown is a 789C truck. The capacity of the 789C cooling system has been increased by 40%
from 474 Liters (125 gal.) to 663 Liters (175 gal.). The radiator is larger and a shunt tank (1) has
been added above the radiator. The shunt tank provides a positive pressure at the coolant pump
inlets to prevent cavitation during high flow conditions.
The cooling system is divided into two systems. The two systems are the jacket water cooling
system and the aftercooler cooling system. The only connection between these two systems is
a small hole in the separator plate in the shunt tank. The small hole in the shunt tank prevents
a reduction of coolant from either of the two systems if leakage occurs in one of the separator
plates in the radiator top or bottom tank. When servicing the cooling systems, be sure to drain
and fill both systems separately.
The coolant levels are checked at the shunt tank. Use the gauges (2) on top of the shunt tank to
check the coolant level.
A coolant level switch (3) is located on each side of the shunt tank to monitor the coolant
level of both cooling systems (guard removed for viewing switch). The coolant level switches
provide input signals to the VIMS, which informs the operator of the engine coolant levels.
The jacket water and the aftercooler cooling systems each have their own relief valve (4). If a
cooling system overheats or if coolant is leaking from a relief valve, clean or replace the relief
valve.
06/08
3 1
72
Shown is the radiator on an earlier 785C. The earlier 785C did not have a shunt tank. The
coolant levels are checked at the radiator top tank. Use the gauges (1) on the top tank to check
the coolant level.
Two coolant level switches (2) are located on the top tank to monitor the coolant level of both
cooling systems. The coolant level switches provide input signals to the VIMS, which informs
the operator of the engine coolant levels.
Pressure relief valves (3) prevent the cooling systems from becoming over pressurized.
The jacket water cooling system uses the cores on the right side of the radiator (approximately
60% of the total capacity). The jacket water cooling system temperature is controlled by
temperature regulators (thermostats).
The aftercooler cooling system uses the cores on the left side of the radiator (approximately 40%
of the total capacity). The aftercooler cooling system does not have thermostats in the circuit.
The coolant flows through the radiator at all times to keep the turbocharged inlet air cool for
increased horsepower.
06/08
73
The jacket water pump (1) is located on the right side of the engine. The pump draws coolant
from the bypass tube (2) until the temperature regulators (thermostats) open. The thermostats
are located in the housing (3) at the top of the bypass tube. When the thermostats are open,
coolant flows through the radiator to the water pump inlet.
If the jacket water cooling system temperature increases above 107° C (226° F), the Engine
ECM will log an event that requires a factory password to clear.
06/08
74
Coolant flows from the jacket water pump, past the coolant flow warning switch (1), and
through the various system oil coolers (engine, torque converter/transmission and rear brake).
The coolant flow switch sends an input signal to the Engine ECM. The Engine ECM provides
the input signal to the VIMS, which informs the operator of the coolant flow status.
If the ECM detects a low coolant flow condition, a low coolant flow event will be logged. A
factory password is required to clear this event.
Jacket water coolant samples can be taken at the Scheduled Oil Sampling (S•O•S) coolant
analysis tap (2).
06/08
2 3
75
Shown is the right side of the engine. The engine oil cooler (1) and the rear brake oil coolers (2)
are visible in this view. Jacket water coolant flows through these coolers and through the
tube (3) to the transmission oil cooler.
Jacket water coolant flows through the transmission oil cooler, the engine oil cooler and the
rear brake oil coolers to both sides of the engine cylinder block. Coolant flows through the
engine block and through the cylinder heads. From the cylinder heads, the coolant flows to the
temperature regulators and either goes directly to the water pump through the bypass tube or to
the radiator (depending on the temperature of the coolant).
06/08
Thermostat
JACKET WATER COOLANT FLOW Housing Shunt
Tank
Engine
Block
Engine Oil Cooler
Hoist, Converter and

Brake Oil Cooler
Hoist, Converter and

Brake Oil Cooler Radiator
Jacket
Transmission Oil Cooler Water Pump
76
Shown is the jacket water cooling circuit. Coolant flows from the jacket water pump through
the coolers to the engine block. Coolant flows through the engine block and the cylinder heads.
From the cylinder heads, the coolant flows to the temperature regulators (thermostats) and either
goes directly to the water pump through the bypass tube or to the radiator (depending on the
temperature of the coolant).
The shunt tank (789C only) increases the cooling capacity and provides a positive pressure at the
coolant pump inlet to prevent cavitation during high flow conditions.
In this illustration and those that follow, the colors used to identify the various pressures in the
systems are:
Red - Supply oil/water pressure
Green - Drain or tank oil/water
Red and White Stripes - Reduced supply oil pressure
Brown - Lubrication or cooling pressure
Orange - Pilot or load sensing signal pressure
Blue - Blocked oil
Yellow - Moving components
Purple - Air pressure
06/08
77
The auxiliary (aftercooler) water pump (1) for the aftercooler cooling system is located on the
left side of the engine. Coolant enters the aftercooler water pump from the radiator or the shunt
tank supply tube (2) on the 789C truck. Coolant flows from the pump to the aftercooler cores
through the large tube (3)
Aftercooler coolant samples can be taken at the Scheduled Oil Sampling (S•O•S) coolant
analysis tap (not shown) located on the pump.
06/08
3 1
78
Located in a tube at the rear of the aftercooler is the rear aftercooler temperature sensor (1). The
rear aftercooler temperature sensor provides an input signal to the Engine ECM. The Engine
ECM uses the rear aftercooler temperature sensor signal with the jacket water temperature
sensor signal, the brake temperature sensor signals (four) and the air conditioner compressor
pressure signal to control the variable speed fan attachment.
The Engine ECM also provides the input signal to the VIMS, which informs the operator of
the aftercooler coolant temperature. If the rear aftercooler temperature increases above 107° C
(226° F), the Engine ECM will log an event that requires a factory password to clear.
Coolant flows through the aftercooler cores to the front brake oil cooler (2) located at the rear of
the engine.
Coolant flows through the front brake oil cooler to the aftercooler section of the radiator. The
aftercooler cooling system does not have temperature regulators (thermostats) in the circuit.
When the service or retarder brakes are ENGAGED, the front brake oil cooler diverter valve (3)
allows brake cooling oil to flow through the front brake oil cooler.
Normally, front brake cooling oil is diverted around the cooler and goes directly to the front
brakes. Diverting oil around the cooler provides lower temperature aftercooler air during high
power demands (when climbing a grade with the brakes RELEASED, for example).
06/08
AFTERCOOLER COOLANT FLOW

Shunt
Tank
Front Brake
Aftercooler
Oil Cooler
Diverter
Valve
Air
Radiator Compressor
Aftercooler
Water Pump
79
Shown is the aftercooler cooling circuit. Coolant flows from the aftercooler water pump through
the aftercooler.
Coolant flows through the aftercooler core to the front brake oil cooler located at the rear of the
engine.
Coolant then flows through the front brake oil cooler to the aftercooler section of the radiator.
The aftercooler cooling circuit does not have temperature regulators (thermostats) in the circuit.
The shunt tank increases the cooling capacity and provides a positive pressure at the aftercooler
water pump inlet to prevent cavitation during high flow conditions.
The earlier 785C truck does not have a shunt tank.

06/08
3
1
4
80
Lubrication System
Shown is the 3512B engine used in the 785C truck. The engine oil pump is located behind the
jacket water pump on the right side of the engine. The pump draws oil from the oil pan through
a screen. The relief valve (1) for the lubrication system is located on the pump.
The engine also has a scavenge pump at the rear of the engine to transfer oil from the rear of the
oil pan to the main sump.
Oil flows from the pump through an engine oil cooler bypass valve (2) to the engine oil
cooler (3). The bypass valve for the engine oil cooler permits oil flow to the system during cold
starts when the oil is thick or if the cooler is plugged.
On the 3512B engine used in the 785C truck, engine oil samples can be taken at the Scheduled
Oil Sampling (S•O•S) tap (4).
06/08
81
Oil flows from the engine oil cooler to the oil filters on the left side of the engine. The oil flows
through the filters and enters the engine cylinder block to clean, cool and lubricate the internal
components and the turbochargers.
Engine oil is added at the fill tube (1) and checked with the dipstick (2). A bypass valve for
each filter is located in each oil filter base. Engine oil samples can be taken at the Scheduled Oil
Sampling (S•O•S) tap (3) (789C only). (See Visual No. 80 for the 785C S•O•S tap location.)
The engine has two oil pressure sensors. One sensor is located on each end of the oil filter base.
The front sensor measures engine oil pressure before the filters. The rear sensor (4) measures
oil pressure after the filters. The sensors send input signals to the Engine ECM. The ECM
provides the input signal to the VIMS, which informs the operator of the engine oil pressure.
Used together, the two engine oil pressure sensors inform the operator if the engine oil filters are
restricted.
If the engine oil pressure is less than 44 kPa (6.4 psi) at LOW IDLE to less than 250 kPa (36 psi)
at HIGH IDLE, the Engine ECM will log an event that requires a factory password to clear.
If the oil filter restriction exceeds 70 kPa (10 psi), a low oil filter restriction event will be logged.
No factory password is required to clear this event. If the oil filter restriction exceeds 200 kPa
(29 psi), a high oil filter restriction event will be logged. A factory password is required to clear
this event.
06/08
82
Shown is the 3512B engine used in the 785C truck. The 3512B engine uses three oil filters
located on the left side of the engine. The 3512B engine also has a fitting (arrow) that can be
used to drain the engine oil trapped above the filters. Do not add oil through the fitting (arrow)
because unfiltered oil will enter the engine. Any contamination could cause damage to the
engine.
NOTICE
When changing the engine oil filters, drain the engine oil trapped above the oil filters
through the fitting (arrow) to prevent spilling the oil. Oil added to the engine through the
fitting will go directly to the main oil galleries without going through the engine oil filters.
Adding oil to the engine through the fitting may introduce contaminants into the system
and cause damage to the engine.
06/08
ENGINE OIL SYSTEM
Engine
Oil Renewal
Syst em Solenoid Scavenge
Pump
To Fuel
Tank
Bypass
Valve
Engine Engine
Oil Filt ers Oil Cooler
Engine
Oil Pump
83
The engine oil pump draws oil from the oil pan through a screen.
The engine also has a scavenge pump at the rear of the engine to transfer oil from the rear of the
oil pan to the main sump.
Oil flows from the pump through an engine oil cooler bypass valve to the engine oil cooler. The
bypass valve for the engine oil cooler permits oil flow to the system during cold starts when the
oil is thick or if the cooler is plugged.
Oil flows from the engine oil cooler to the oil filters. The oil flows through the filters and
enters the engine cylinder block to clean, cool and lubricate the internal components and the
turbochargers.
Some trucks are equipped with the optional engine oil renewal system. Engine oil flows from
the engine block to an engine oil renewal system manifold. A small amount of oil flows from
the engine oil renewal system manifold into the return side of the fuel pressure regulator. The
engine oil returns to the fuel tank with the return fuel (see Visuals No. 69
and 70).
06/08
84
Fuel System
The fuel tank is located on the left side of the truck. Fuel is pulled from the tank through the
fuel heater (not shown), if equipped, and through the primary fuel filter (1) by the fuel transfer
pump located on the right side of the engine behind the engine oil pump.
A fuel level sensor (2) is also located on the fuel tank. The fuel level sensor emits an ultrasonic
signal that bounces off a metal disk on the bottom of a float. The time it takes for the ultrasonic
signal to return is converted to a Pulse Width Modulated (PWM) signal. The PWM signal
changes as the fuel level changes. The fuel level sensor provides the input signals to the VIMS,
which informs the operator of the fuel level. A category level 1 warning (FUEL LVL LO)
is shown on the VIMS display if the fuel level is less than 15%. A category level 2 warning
(FUEL LVL LO ADD FUEL NOW) is shown on the VIMS display if the fuel level is less than
10%.
The fuel level sensor receives 24 Volts from the VIMS. To check the supply voltage of the
sensor, connect a multimeter between Pins 1 and 2 of the sensor connector. Set the meter to read
"DC Volts."
The fuel level sensor output signal is a Pulse Width Modulated (PWM) signal that varies with
the fuel level. To check the output signal of the fuel level sensor, connect a multimeter between
Pins 2 and 4 of the fuel level sensor connector. Set the meter to read "Duty Cycle." The duty
cycle output of the fuel level sensor should be approximately 6% at 0 mm (0 in.) of fuel depth
and 84% at 2000 mm (78.8 in.) of fuel depth.
06/08
85
Fuel flows from the transfer pump (1) through the Engine ECM to the secondary fuel filters
located on the left side of the engine.
The fuel transfer pump contains a bypass valve (2) to protect the fuel system components from
excessive pressure. The bypass valve setting is 860 kPa (125 psi), which is higher than the
setting of the fuel pressure regulator.
06/08
2 1
86
The secondary fuel filters and the fuel priming pump (1) are located above the engine oil filters
on the left side of the engine. The fuel priming pump is used to fill the filters after they are
changed.
Fuel filter restriction is monitored with a fuel filter bypass switch (2) located on the fuel filter
base. The fuel filter bypass switch provides an input signal to the Engine ECM. The ECM
provides a signal to the VIMS, which informs the operator if the secondary fuel filters are
restricted.
If fuel filter restriction exceeds 138 kPa (20 psi), a fuel filter restriction event is logged. No
Fuel flows from the fuel filter base through the Electronic Unit Injection (EUI) fuel injectors
(see Visual No. 60), the fuel pressure regulator, and then returns to the fuel tank. The injectors
receive 4 1/2 times the amount of fuel needed for injection. The extra fuel is used for cooling.
06/08
1 2
87
Fuel flows from the fuel filter base through the steel tubes (1) to the EUI fuel injectors. Return
fuel from the injectors flows through the fuel pressure regulator (2) before returning to the fuel
tank. Fuel pressure is controlled by the fuel pressure regulator.
Fuel pressure should be 482 + 138 - 103 kPa (70 + 20 - 15 psi) at Full Load rpm.
06/08
FUEL SYSTEM
Engine Fuel
Block Pressure
Regulator
Engine Oil
Fuel Renewal
Tank Solenoid
Primary
Fuel Cylinder
Filter Head
Fuel
Transfer
Fuel
Pump
Heater Fuel
Priming
Pump
Secondary Cylinder
Engine Fuel Filters Head
Ecm
88
Fuel is pulled from the tank through a fuel heater, if equipped, and sent through the primary fuel
filter by the fuel transfer pump. Fuel flows from the transfer pump through the Engine ECM to
the secondary fuel filters.
Fuel flows from the fuel filter base through the fuel injectors in the cylinder heads. Return fuel
from the injectors flows through the fuel pressure regulator before returning through the fuel
heater to the tank.
If equipped with the engine oil renewal system, engine oil flows from the engine block to the
engine oil renewal system manifold. A small amount of oil flows from the engine oil renewal
system manifold into the return side of the fuel pressure regulator. The engine oil returns to the
fuel tank with the return fuel.
The engine oil mixes with the fuel in the tank and flows with the fuel to the injectors to be
burned.
06/08
89
Air Induction and Exhaust System
The engine receives clean air through the air filters located on the front of the truck (789C) or on
either side of the engine (785C). Any restriction caused by plugged filters can be checked at the
filter restriction indicators (1). If the yellow piston is in the red zone, the filters must be cleaned
or replaced.
Check the dust valves (2) for plugging. If necessary, disconnect the clamp and open the cover
for additional cleaning. The dust valve is OPEN when the engine is OFF and closes when the
engine is running. The dust valve must be flexible and close when the engine is running or the
precleaner will not function properly and the air filters will have a shortened life. Replace the
rubber dust valve if it becomes hard and not flexible.
The VIMS will also provide the operator with an air filter restriction warning when the filter
restriction is approximately 6.2 kPa (25 in. of water). Black exhaust smoke is also an indication
of air filter restriction.
Two filter elements are installed in the filter housings. The large element is the primary element
and the small element is the secondary element.
06/08
2 1
90
The turbocharger inlet pressure sensor (1) is located in a tube between the air filters and the
turbochargers. The Engine ECM uses the turbocharger inlet pressure sensor in combination with
the atmospheric pressure sensor to determine air filter restriction. The ECM provides the input
signal to the VIMS, which informs the operator of the air filter restriction.
If air filter restriction exceeds 6.25 kPa (25 in. of water), an air filter restriction event will
be logged, and the ECM will derate the fuel delivery (maximum derating of 20%) to prevent
excessive exhaust temperatures. A factory password is required to clear this event. If the
Engine ECM detects a turbocharger inlet pressure sensor fault, the ECM will derate the engine
to the maximum rate of 20%. If the Engine ECM detects a turbocharger inlet and atmospheric
pressure sensor fault at the same time, the ECM will derate the engine to the maximum rate of
40%.
The Engine ECM will automatically inject ether from the ether cylinders (2) during cranking.
The duration of automatic ether injection depends on the jacket water coolant temperature. The
duration will vary from 10 to 130 seconds. The operator can also inject ether manually with the
ether switch in the cab on the center console (see Visual No. 48). The manual ether injection
duration is 5 seconds. Ether will be injected only if the engine coolant temperature is below 10°
C (50° F) and engine speed is below 1900 rpm.
06/08
91
Shown is the 3516B engine used in the 789C truck. The 3516B engine is equipped with four
turbochargers (arrows). The 785C truck has a 3512B engine with two turbochargers.
The turbochargers are driven by the exhaust gas from the cylinders which enters the turbine side
of the turbochargers. The exhaust gas flows through the turbochargers, the exhaust piping, and
the mufflers.
The clean air from the filters enters the compressor side of the turbochargers. The compressed
air from the turbochargers flows to the aftercoolers. After the air is cooled by the aftercoolers,
the air flows to the cylinders and combines with the fuel for combustion.
06/08
92
An exhaust temperature sensor (arrow) is located in each exhaust manifold before the
turbochargers. The two exhaust temperature sensors provide input signals to the Engine ECM.
The ECM provides the input signal to the VIMS, which informs the operator of the exhaust
temperature.
Some causes of high exhaust temperature may be faulty injectors, plugged air filters, or a
restriction in the turbochargers or the muffler.
If the exhaust temperature is above 750° C (1382° F), the Engine ECM will derate the fuel
delivery to prevent excessive exhaust temperatures. The ECM will derate the engine by 2% for
each 30 second interval that the exhaust temperature is above 750° C (1382° F) (maximum
derate of 20%). The ECM will also log an event that requires a factory password to clear.
06/08
From Air
Filters Muffler
3512B
AIR INDUCTION
AND Aftercooler
EXHAUST SYSTEM
From Air
Filters
93
This schematic shows the flow through the air induction and exhaust system.
The turbochargers are driven by the exhaust gas from the cylinders which enters the turbine side
of the turbochargers. The exhaust gas flows through the turbochargers, the exhaust piping, and
the mufflers.
The clean air from the filters enters the compressor side of the turbochargers. The compressed
air from the turbochargers flows to the aftercoolers. After the air is cooled by the aftercoolers,
the air flows to the cylinders and combines with the fuel for combustion.
06/08
POWER TRAIN
785C
94
POWER TRAIN
Power flows from the engine to the rear wheels through the power train. The components of the
power train are:
- Torque converter
- Transfer gears
- Transmission
- Differential
- Final drives
INSTRUCTOR NOTE: In this section of the presentation, component locations and a

brief description of the component functions are provided.
06/08
4 3
2 5 1
95
Torque Converter
The first component in the power train is the torque converter. The torque converter provides a
fluid coupling that permits the engine to continue running with the truck stopped. In converter
drive, the torque converter multiplies engine torque to the transmission. At higher ground
speeds, a lockup clutch engages to provide direct drive. The NEUTRAL and REVERSE ranges
are converter drive only. FIRST SPEED is converter drive at low ground speed and direct drive
at high ground speed. SECOND through SIXTH SPEEDS are direct drive only. The torque
converter goes to converter drive between each shift (during clutch engagement) to provide
smooth shifts.
Mounted on the torque converter are the inlet relief valve (1), the outlet relief valve (2), and the
torque converter lockup clutch control valve (3).
A torque converter outlet temperature sensor (4) provides an input signal to the Transmission/
Chassis ECM. The Transmission/Chassis ECM sends the signal to VIMS, which informs the
operator of the torque converter outlet temperature.
A Converter Output Speed (COS) sensor (5) sends an input signal to the Transmission/Chassis
ECM. The Transmission/Chassis ECM uses the information to calculate shift times for the
torque converter lockup clutch and the transmission clutches. The shift time information is sent
to VIMS for shift time analysis.
06/08
Lockup Piston Turbine Impeller TORQUE CONVERTER

Stator CONVERTER DRIVE
Torque Converter
Inlet Oil
Freewheel Torque Converter

Assembly Lockup Oil Passage
96
This sectional view shows a torque converter in CONVERTER DRIVE. The lockup clutch
(yellow piston and blue discs) is not engaged. During operation, the rotating housing and
impeller (red) can rotate faster than the turbine (blue). The stator (green) remains stationary
and multiplies the torque transfer between the impeller and the turbine. The output shaft rotates
slower than the engine crankshaft, but with increased torque.
06/08
Lockup Pist on Turbine Impeller TORQUE CONVERTER

DIRECT DRIVE
St at or
Torque Convert er
Inlet Oil
Freewheel Torque Convert er

Assembly Lockup Oil Passage
97
In DIRECT DRIVE, the lockup clutch is engaged by hydraulic pressure and locks the turbine to
the impeller. The housing, impeller, turbine, and output shaft then rotate as a unit at engine rpm.
The stator, which is mounted on a freewheel assembly, is driven by the force of the oil in the
housing and will freewheel at approximately the same rpm.
06/08
4 5 2 1
98
Torque Converter Hydraulic System
The three (785C) or four (789C) section torque converter pump is located at the bottom rear of
the torque converter. The four sections (from the front to the rear) are:
- Torque converter scavenge (1)

- Torque converter charging (2)
- Parking brake release (3)
- Rear brake oil cooling (4) (789C only)
Excess oil that accumulates in the bottom of the torque converter is scavenged by the first
section of the pump through a screen behind the access cover (5) and returned to the hydraulic
tank.
06/08
99
Oil flows from the torque converter charging section of the pump to the torque converter
charging filter (1).
An oil filter bypass switch (2) is located on the torque converter charging filter. The oil filter
bypass switch provides an input signal to the VIMS, which informs the operator if the filter is
restricted.
06/08
2 3 1
100
Oil flows from the torque converter charging filter to the torque converter inlet relief valve (1).
The inlet relief valve limits the maximum pressure of the supply oil to the torque converter.
The torque converter inlet relief pressure can be measured at this valve by removing a plug and
installing a pressure tap. Inlet relief pressure should not exceed 930 ± 35 kPa (135 ± 5 psi) at
high idle when the oil is cold. Normally, the inlet relief pressure will be slightly higher than the
outlet relief valve pressure.
Oil flows through the inlet relief valve and enters the torque converter.
Some of the oil will leak through the torque converter to the bottom of the housing to be
scavenged. Most of the oil in the torque converter is used to provide a fluid coupling and
flows through the torque converter outlet relief valve (2). The outlet relief valve maintains the
minimum pressure inside the torque converter. The main function of the outlet relief valve is
to keep the torque converter full of oil to prevent cavitation. The outlet relief pressure can be
measured at the tap (3) on the outlet relief valve. The outlet relief pressure should be:
785C: 345 to 585 kPa (50 to 85 psi) at 1640 ± 65 rpm (TC Stall)
789C: 345 to 585 kPa (50 to 85 psi) at 1715 ± 65 rpm (TC Stall)
A torque converter outlet temperature sensor (4) provides an input signal to the Transmission/
Chassis ECM. The Transmission/Chassis ECM sends a signal to VIMS, which informs the
operator of the torque converter outlet temperature.
06/08
4 3
2 1
101
Most of the oil from the torque converter outlet relief valve flows through the torque converter
outlet screen (1) located outside the left frame.
A torque converter outlet screen bypass switch (2) provides an input signal to the VIMS, which
informs the operator if the torque converter outlet screen is restricted.
Oil flows from the torque converter outlet screen to the front brake oil cooler located behind the
engine.
Oil flows from the parking brake release section of the torque converter pump to the parking
brake release filter (3).
A parking brake release filter bypass switch (4) is located on the parking brake release filter.
The bypass switch provides an input signal to the Brake ECM. The Brake ECM sends a signal
to VIMS, which informs the operator if the parking brake release filter is restricted.
06/08
102
The oil from the torque converter outlet screen flows through a diverter valve (1) before flowing
through the front brake oil cooler (2). When the retarder or service brakes are ENGAGED,
the oil is diverted through the cooler to the brakes. When the brakes are RELEASED, the oil
bypasses the cooler and flows directly to the brakes.
Diverting oil around the cooler provides lower temperature aftercooler air during high power
demands (when climbing a grade with the brakes RELEASED, for example).
06/08
103
Oil from the parking brake release filter flows to the parking brake release valve (1). The
parking brake release section of the torque converter pump provides supply oil for several
purposes:
- Release the parking brakes

- Engage the torque converter lockup clutch
- Hoist valve pilot oil
- Front (789C) or rear (785C) brake oil cooling
The parking brake relief valve (2) controls the pressure for parking brake release, torque
converter lockup and hoist valve pilot oil. The parking brake release pressure is 4700 ± 200 kPa
(680 ± 30 psi).
Most of the oil from the parking brake release valve flows to the front brake oil cooler on the
789C truck and to the rear brake oil coolers on the 785C truck.
06/08
3
4
104
The parking brake release pump supplies oil to the torque converter lockup clutch valve through
the inlet port (1). When the lockup clutch solenoid (located on the transmission housing) is
energized by the Transmission/Chassis ECM, transmission pump supply oil (signal oil) enters
the lockup valve through the center hose (2). The signal oil pressure is approximately 1725
kPa (250 psi). The signal oil causes the lockup valve to start the modulation process for torque
converter lockup. The lockup clutch valve then supplies oil to ENGAGE the lockup clutch in
the torque converter.
Torque converter lockup clutch pressure can be measured at the tap (3). Torque converter
lockup clutch pressure should be 2135 ± 70 kPa (310 ± 10 psi) at 1300 rpm or higher. Do not
check the torque converter lockup clutch pressure below 1300 rpm.
The Converter Output Speed (COS) sensor (4) sends an input signal to the Transmission/
Chassis ECM. The Transmission/Chassis ECM memory also contains the engine rpm and the
Transmission Output Speed (TOS) for each gear of the transmission. The Transmission/Chassis
ECM provides all of these input signals to the VIMS.
Using the information from the Transmission/Chassis ECM, the VIMS calculates if any
slippage exists in the torque converter lockup clutch or any transmission clutches and stores this
information in the VIMS main module. This information can be downloaded from the VIMS
with a laptop computer.
06/08
TORQUE CONVERTER LOCKUP CLUTCH CONTROL

DIRECT DRIVE
Lockup Clutch
Pilot Pressure
(RV)
Signal Oil
Selector Lockup
Piston Modulation
Lockup
Valve
Solenoid
To Lockup
Clutch (LU)
To
Transmission Lockup
Lube Reducing
Valve
To
From Station
Transmission "D"
Charge Pump Shuttle
Valve
Relay Valve From Parking Brake

Release Pump (PMP)
105
Shown is a sectional view of the torque converter lockup clutch valve in DIRECT DRIVE.
Supply oil from the parking brake release pump is used to provide lockup clutch oil.
First, supply pressure is reduced to provide pilot pressure to the relay valve. Supply oil to the
pressure reduction valve flows through cross-drilled orifices in the spool, past a check valve, and
enters the slug chamber. The check valve dampens spool movement and reduces the possibility
of valve chatter and pressure fluctuation. Oil pressure moves the slug in the right end of the
spool to the right and the spool moves to the left against the spring force. The slug reduces
the effective area on which the oil pressure can push. Because of the reduced effective area, a
smaller, more sensitive spring can be used. Pilot pressure will be equal to the force of the spring
on the left end of the spool. The spring force can be adjusted with shims. Pilot pressure is
1725 ± 70 kPa (250 ± 10 psi).
When the lockup solenoid is energized, transmission pump supply (signal) pressure is directed
to the relay valve. Before moving the selector piston, the pilot oil moves a shuttle valve to the
right, which closes the lower left drain passage and opens the check valve. Oil then flows to the
selector piston. Moving the selector piston blocks the upper drain passage, and the load piston
springs are compressed.
06/08
When the solenoid is energized, supply oil from the parking brake release pump is reduced to
provide the lockup clutch pressure. Lockup clutch pressure depends mainly on the force of the
load piston valve springs. When the solenoid is energized, pilot oil moves the selector piston
down against a stop. When the load piston that compresses the springs is at the top against the
selector piston, lockup clutch pressure is at its lowest controlled value. This value is called
"primary pressure." As the load piston moves down, lockup clutch pressure increases gradually
until the load piston stops. Maximum lockup clutch pressure is then reached. The gradual
increase in pressure, which depends on how fast the load piston moves, is called "modulation."
The speed of the load piston movement depends on how fast the oil can flow to the area above
the load piston. The load piston orifice meters the flow of oil to the load piston chamber and
determines the modulation time.
Primary pressure is adjusted with shims in the load piston. Final lockup clutch pressure is not
adjustable. If the primary pressure is correct and final lockup clutch pressure is incorrect, the
load piston should be checked to make sure that it moves freely in the selector piston. If the
load piston moves freely, the load piston springs should be replaced.
06/08
Front TORQUE CONVERTER Rear

Brakes Brakes
HYDRAULIC SYSTEM
To Hoist
Torque Converter
Solenoid
Charging Filter
Manifold
Outlet
Relief Valve
Front Brake Converter
Oil Cooler Lockup
Inlet Valve
Relief Valve
Diverter
Valve
Rear Brake
Oil Coolers
Parking
Brake Converter Parking Converter
Release Outlet Brake Scavenge
Valve Screen Filter Screen
106
This schematic shows the flow of oil from the torque converter pump through the torque
converter hydraulic system on the 789C truck.
The scavenge pump section pulls oil through a screen from the torque converter housing and
sends the oil to the hydraulic tank.
The charging pump section sends oil through the torque converter charging filter to the torque
converter inlet relief valve. Oil flows from the inlet relief valve through the torque converter to
the outlet relief valve. Oil flows from the outlet relief valve through the converter outlet filter
and the front brake oil cooler to the front brakes.
The parking brake release pump section sends oil through the parking brake release filter to the
parking brake release valve and the torque converter lockup clutch valve. Most of the oil flows
through the parking brake release valve and the front brake oil cooler to the front brakes.
The brake cooling pump section of the torque converter pump (789C only) sends oil through the
two oil coolers located on the right side of the engine to the rear brakes.
06/08
3
1
107
Transmission and Transfer Gears
Power flows from the torque converter through a drive shaft to the transfer gears (1). The
transfer gears are splined to the transmission input shaft.
The transmission (2) is located between the transfer gears and the differential (3). The
transmission is electronically controlled and hydraulically operated as in all other ICM
(Individual Clutch Modulation) transmissions in Caterpillar rigid frame trucks.
The differential is located in the rear axle housing behind the transmission. Power from the
transmission flows through the differential and is divided equally to the final drives in the rear
wheels. The final drives are double reduction planetaries.
06/08
1
2
3
108
Oil flows from the transmission oil cooler to the transfer gears through a hose (1). Transmission
lube oil flows through the transfer gears and the transmission to cool and lubricate the internal
components.
The transmission lube pressure relief valve is in the transmission case near the transmission
hydraulic control valve. The relief valve limits the maximum pressure in the transmission lube
circuit. Transmission lube oil pressure can be measured at the tap (2).
At HIGH IDLE, the transmission lube pressure should be 140 to 205 kPa (20 to 30 psi). At
LOW IDLE, the transmission lube pressure should be a minimum of 4 kPa (.6 psi).
The Transmission Output Speed (TOS) sensor (3) is located on the front of the transfer gears.
A small shaft runs from the speed sensor location through the entire length of the transmission
and engages the transmission output shaft. The transmission speed sensor signal serves many
purposes. Some of the purposes are:
- Transmission automatic shifting

- Speedometer operation
- Traction Control System (TCS) top speed limit
- Truck Production Management System (TPMS) distance calculations
- Machine speed input to VIMS to determine some warning categories
06/08
POWER SHIFT PLANETARY TRANSMISSION
1 2 3
4
5 6
109
The transmission is a power shift planetary design which contains six hydraulically engaged
clutches. The transmission provides six FORWARD speeds and one REVERSE speed.
06/08
1 2 3
110
Transmission Hydraulic System
The transmission pump pulls oil through a suction screen from the transmission tank (see
Visuals No. 12 and 159) located on the right side of the truck.
The three-section transmission pump is mounted on the rear of the pump drive, which is located
inside the right frame near the torque converter. The three sections are:
- Transmission scavenge (1)

- Transmission lube (2)
- Transmission charging (3)
The transmission scavenge section pulls oil through the magnetic screens located at the bottom
of the transmission. The scavenged oil from the transmission is sent to the transmission tank.
06/08
111
Shown is the location of the transmission magnetic scavenge screens (arrow). These screens
should always be checked for debris if a problem with the transmission is suspected.
Oil is scavenged from the transmission by the first section of the transmission pump (see Visual
No. 110).
06/08
4
2
3 1
112
Oil flows from the charging section of the transmission pump to the transmission charging
filter (1) located on the frame behind the right front tire.
Oil flows from the transmission charging filter to the transmission control valve located on top
of the transmission. A transmission oil temperature sensor (2) is located in the tube between the
transmission charging filter and the transmission control valve. The temperature sensor provides
an input signal to the Transmission/Chassis ECM. The Transmission/Chassis ECM sends a
signal to VIMS, which informs the operator of the transmission oil temperature.
Oil flows from the lube section of the transmission pump to the transmission lube filter (3).
Oil flows from the transmission lube filter through the transmission oil cooler to the transfer
gears. Transmission lube oil flows through the transfer gears and the transmission to cool and
lubricate the internal components.
An oil filter bypass switch is located on each filter. The oil filter bypass switches provide input
signals to the Transmission/Chassis ECM. The Transmission/Chassis ECM sends signals to the
VIMS, which informs the operator if the filters are restricted.
Transmission oil samples can be taken at the Scheduled Oil Sampling (S•O•S) tap (4).
06/08
113
Oil flows from the transmission lube filter and the transmission control valve through the
transmission oil cooler bypass valve (1) to the transmission oil cooler (2). The bypass valve for
the transmission oil cooler permits oil flow to the system during cold starts when the oil is thick
or if the cooler is restricted.
Oil flows from the transmission oil cooler to the transfer gears and the transmission to cool and
lubricate the internal components.
06/08
3 5
2 1
114
The transmission charging pump supplies oil to the transmission hydraulic control valve and the
shift solenoids through the inlet port (1). Excess transmission charging oil either drops to the
bottom of the housing to be scavenged or flows to the transmission oil cooler through the outlet
hose (2).
The torque converter lockup clutch solenoid (3) is energized by the Transmission/Chassis ECM
when DIRECT DRIVE (lockup clutch ENGAGED) is required. Transmission charge pump
supply (signal) oil flows through the small hose (4) to the lockup clutch control valve. The
lockup clutch control valve then engages the lockup clutch.
The transmission charging pressure relief valve is part of the transmission hydraulic control
valve. The relief valve limits the maximum pressure in the transmission charging circuit.
Transmission charging pressure can be measured at the tap (5).
06/08
2 3
115
Shown is the Individual Clutch Modulation (ICM) transmission hydraulic control valve.
Transmission clutch pressures are measured at the pressure taps (1).
The transmission hydraulic control valve contains a priority valve. The priority valve
controls the pressure that is directed to the selector pistons in each of the clutch stations. The
transmission priority valve pressure is 1720 kPa (250 psi).
The transmission lube pressure relief valve (2) limits the maximum pressure in the transmission
lube circuit.
The "D" Station (3) is used to control the dual stage relief valve setting for the clutch
supply pressure. In DIRECT DRIVE, the pressure measured at the tap for station "D" will
be approximately 1380 kPa (200 psi). This valve station is adjusted to obtain the correct
transmission charge pressure in DIRECT DRIVE.
At LOW IDLE in TORQUE CONVERTER DRIVE, transmission charging pressure should

be 2515 kPa (365 psi) minimum. At HIGH IDLE in TORQUE CONVERTER DRIVE,
transmission charging pressure should be 3175 kPa (460 psi) maximum.
During torque converter lockup (DIRECT DRIVE), clutch supply pressure is reduced to extend
the life of the transmission clutch seals. At 1300 rpm in DIRECT DRIVE, the clutch supply
pressure should be 2020 + 240 - 100 kPa (293 + 35 - 15 psi). The corresponding transmission
charge pressure is reduced to 2100 ± 100 kPa (305 ± 15 psi).
06/08
To test the transmission clutch pressures in torque converter lockup (DIRECT DRIVE),
disconnect the signal line (4) and install a plug in the hose and a cap on the fitting. An 8T5200
Signal Generator/Counter can be used to shift the transmission during the diagnostic tests. If a
Signal Generator is not available, disconnect the upshift and downshift solenoids and rotate the
rotary selector spool manually by inserting a 1/4 in. ratchet extension through the transmission
case.
06/08
TRANSMISSION ICM HYDRAULIC SYSTEM
Upshift Downshift
Pressure Pressure
Lockup Downshift Upshift

Solenoid Solenoid Solenoid A
Rotary Actuator
On
3
E
To Torque Converter N1 B
Relay Valve Priority Neutralizer
Reduction Valve Rotary
Pilot Oil Pressure Valve Selector
Spool
Pump Pressure F
Filters C
Charging Lube
Pump Pump Scavenge Oil
Pump Cooler
G
Cooler D
Bypass
Valve H
Lube
Pressure
Lockup Dual
Selector Valve Group Stage Relief Valve Pressure Control
Relief Valve Group
Transmission
Tank Lubrication
Transmission Case Relief Valve
116
Shown is a sectional view of the ICM transmission hydraulic control valve group. The rotary
selector spool is in a position that engages two clutches. Pump supply oil from the lockup
solenoid flows to the selector piston in station "D." Station "D" reduces the pump supply
pressure, and the reduced pressure flows to the lower end of the relief valve. Providing oil
pressure to the lower end of the relief valve reduces the clutch supply pressure.
06/08
785C / 789C TRANSMISSION HYDRAULIC SYSTEM
Transmission
Charging Filter Transmission
Lube Filter
Transmission
Oil Cooler
Signal
To Lockup
Valve Relay Transmission
Pump
Lube
Port
Magnetic Scavenge
Screens
117
Shown is the transmission hydraulic system. The transmission pump pulls oil through a suction
screen from the transmission tank.
The three-section transmission pump is mounted on the rear of the pump drive, which is located
inside the right frame near the torque converter. The three sections are:
- Transmission scavenge
- Transmission lube
- Transmission charging
The transmission scavenge section pulls oil through the magnetic screens located at the bottom
of the transmission. The scavenged oil from the transmission is sent to the transmission tank.
06/08
Oil flows from the charging section of the transmission pump to the transmission charging filter.
Oil flows from the transmission charging filter to the transmission control valve located on top
of the transmission. Transmission charging oil flows from the transmission control valve and
joins with the oil from the transmission lube section of the transmission pump.
Oil flows from the lube section of the transmission pump to the transmission lube filter.
Oil from the transmission lube filter and the transmission control valve flows through the
transmission oil cooler. Oil flows from the transmission oil cooler to the transfer gears and the
transmission to cool and lubricate the internal components.
06/08
3
1
2 4
118
Differential
Shown is the differential removed from the rear axle housing. The rear axle cooling and filter
system starts with a rear axle pump (1) that is driven by the differential. Since the pump rotates
only when the machine is moving, no oil flow is produced when the machine is stationary.
Cooling oil flow increases with ground speed to provide cooling when it is most needed.
The rear axle pump pulls oil from the bottom of the rear axle housing through a suction
screen (2). Oil flows from the pump through a temperature and flow control valve located on
top of the differential housing to a filter mounted on the rear of the axle housing. Oil then flows
from the filter back to the valve located on top of the differential housing. Oil then flows from
the valve to the rear wheel bearings and the differential bearings.
Oil flows through tubes (3) to the differential bearings.
The fiberglass shroud (4) reduces the temperature of the rear axle oil on long hauls by reducing
the oil being splashed by the bevel gear.
06/08
2
4
119
Oil flows from the pump through the large hose (1) to the rear axle temperature and flow control
valve (2). A differential oil temperature sensor (3) and pressure sensor (4) are located on the
temperature and flow control valve. The sensors provide input signals to the Brake ECM. The
Brake ECM sends signals to the VIMS.
The differential temperature sensor input signal is used to warn the operator of a high rear axle
oil temperature condition or to turn on the attachment rear axle cooling fan (if equipped).
The differential oil pressure sensor input signal is used to warn the operator of a HIGH or LOW
rear axle oil pressure condition.
A HIGH oil temperature warning is provided if the temperature is above 118° C (244° F).
A LOW oil pressure warning is provided if the pressure is below35 kPa (5 psi) when the
differential oil temperature is above 52° C (125° F) and the ground speed is higher than 24 km/h
(15 mph).
A HIGH oil pressure warning is provided if the pressure is above 690 kPa (100 psi) when the
differential oil temperature is above 52° C (125° F).
06/08
The temperature and pressure control valve (2) prevents high oil pressure when the rear axle
oil is cold. When the oil temperature is below 43° C (110° F), the valve is OPEN and allows
oil to flow to the rear axle housing. When the oil temperature is above 43° C (110° F), the
valve is CLOSED and all the oil flows through the filter to a flow control valve located in
the temperature and flow control valve. The temperature and pressure control valve is also
the system main relief valve. If the pressure exceeds 690 kPa (100 psi), the temperature and
pressure control valve will open to prevent high oil pressure to the rear axle oil filter.
The flow control valve distributes the oil flow to the rear wheel bearings and the differential
bearings.
Oil flows from the temperature and flow control valve to the differential oil filter mounted on
the rear of the axle housing. Oil then flows from the filter back to the temperature and flow
control valve. Some of the oil that flows from the temperature and flow control valve flows
through the small supply hose (5) to the differential bearings.
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120
The differential oil filter bypass switch (1) and the two rear axle oil level switches (2) (one
behind differential filter) provide input signals to the Brake ECM. The Brake ECM sends
signals to the VIMS.
The differential oil filter bypass switch signal is used to warn the operator when the differential
oil filter is restricted.
The rear axle oil level switch input signals are used to warn the operator when the rear axle oil
level is LOW.
When the truck is initially put into operation, a 1R0719 (40 micron) filter is installed. This filter
removes the rust inhibitor used during manufacturing. The 40 micron filter should be changed
after the first 50 hours of operation and replaced with a 4T3131 (13 micron) filter. The 13
micron filter should be changed every 500 hours.
A differential carrier thrust pin is located behind the small cover (3). The thrust pin prevents
movement of the differential carrier during high thrust load conditions.
06/08
REAR AXLE
OIL COOLING AND FILTER SYSTEM
Oil Cooler Oil
Filter
Temperature and
Flow Control Valve
Temperature /
Pressure
Control Valve
Differential
Oil Pump
Rear Axle Suction

Screen
121
Shown is a schematic of the rear axle oil cooling and filter system. The differential oil pump
pulls oil from the bottom of the rear axle housing through a suction screen. Oil flows from the
pump through a temperature and flow control valve located on top of the differential housing.
The temperature and pressure control valve, which is part of the temperature and flow control
valve, prevents high oil pressure when the rear axle oil is cold. When the oil temperature is
below 43° C (110° F), the valve is OPEN and allows oil to flow to the rear axle housing. When
the oil temperature is above 43° C (110° F), the valve is CLOSED and all the oil flows through
the differential oil filter and the oil cooler (if equipped) to a flow control valve, which is also
part of the temperature and flow control valve.
The temperature and pressure control valve is also the system main relief valve. If the pressure
exceeds 690 kPa (100 psi), the temperature and pressure control valve will open to prevent high
oil pressure to the rear axle oil filter.
The flow control valve distributes the oil flow to the rear wheel bearings and the differential
bearings. At high ground speeds, excess oil flow is diverted to the axle housing to prevent
overfilling the wheel bearing and final drive compartments.
06/08
Second Reduction Second Reduction

First Reduction
Ring Gear Carrier
Ring Gear
Second Reduction
Planetary Gear
Second Reduction
FINAL DRIVE Sun Gear
First Reduction
Sun Gear
First Reduction
Carrier
First Reduction
Planetary Gear
122
Final Drives
Shown is a sectional view of the double reduction planetary gear final drive. Power flows from
the differential through axles to the sun gear of the first reduction planetary set. The ring gears
of the first reduction planetary set and the second reduction planetary set cannot rotate. Since
the ring gears cannot rotate, the first reduction sun gear causes rotation of the first reduction
planetary gears and the first reduction carrier.
The first reduction carrier is splined to the second reduction sun gear. The second reduction sun
gear causes rotation of the second reduction planetary gears and the second reduction carrier.
Since the second reduction carrier is connected to the wheel assembly, the wheel assembly also
rotates.
The wheel assembly rotates much slower than the axle shaft but with increased torque.
06/08
123
Transmission/Chassis Electronic Control System
The Transmission/Chassis Electronic Control Module (ECM) (arrow) is located in the

compartment at the rear of the cab. The transmission control used in the "B" Series trucks is
referred to as the second generation Electronic Programmable Transmission Control (EPTC II).
The transmission control used in the "C" Series trucks performs the transmission control
functions, plus some other machine functions (hoist control). Because of the added functionality
of the control, it is now referred to as the "Transmission/Chassis ECM."
The Transmission/Chassis ECM does not have a diagnostic window as in the EPTC II.
Diagnostic and programming functions must be performed with an Electronic Control Analyzer
Programmer (ECAP) or a laptop computer with the Electronic Technician (ET) software
installed. ET is the tool of choice because the Transmission/Chassis ECM can be reprogrammed
with a "flash" file using the WinFlash application of ET. The ECAP cannot upload "flash" files.
The Transmission/Chassis ECM appears identical to the Engine ECM with two 40-pin
connectors, but the Transmission/Chassis ECM does not have fittings for cooling fluid. Also,
the Transmission/Chassis ECM has no access plate for a personality module.
06/08
"C" SERIES TRUCK

TRANSMISSION / CHASSIS ELECTRONIC CONTROL SYSTEM
INPUT COMPONENTS OUTPUT COMPONENTS

Shift Lever CAT Data Link
Position Switch
Transmission Gear Electronic Service Tool
Switch
Transmission Output Engine ECM
Speed Sensor Brake ECM
Converter Output
Speed Sensor VIMS
Engine Output
Service / Retarder Speed Sensor
Brake Upshift Solenoid
Pressure Switch Parking / Secondary Brake
Pressure Switch
Body Downshift Solenoid
Position Sensor
Key Start Switch Lockup Solenoid
Low Steering
Pressure Switch
Hoist Lever Back-up Alarm

Position Sensor Starter
Relay
Solenoid
Hoist Screen Switch
Transmission Oil Auto Lube Solenoid
Temp Sensor
Transmission Charge
Body Up Lamp
Filter Switch Hoist Lower Solenoid
Transmission Lube
Filter Switch
Torque Converter Hoist Raise Solenoid
Oil Temp Sensor
124
The purpose of the Transmission/Chassis ECM is to determine the desired transmission gear and
energize solenoids to shift the transmission up or down as required based on information from
both the operator and machine.
The Transmission/Chassis ECM receives information (electrical signals) from various

input components such as the shift lever switch, Transmission Output Speed (TOS) sensor,
transmission gear switch, body position sensor, and the hoist lever sensor.
Based on the input information, the Transmission/Chassis ECM determines whether the
transmission should upshift, downshift, engage the lockup clutch, or limit the transmission gear.
These actions are accomplished by sending signals to various output components.
Output components include the upshift, downshift and lockup solenoids, the back-up alarm, and
others.
The Transmission/Chassis ECM also provides the service technician with enhanced diagnostic
capabilities through the use of onboard memory, which stores diagnostic codes for retrieval at
the time of service.
06/08
The Engine Electronic Control, the Brake Electronic Control System (ARC and TCS), the Vital
Information Management System (VIMS) and the Transmission/Chassis Electronic Control
System all communicate through the CAT Data Link. Communication between the electronic
controls allows the sensors of each system to be shared. Many additional benefits are provided,
such as Controlled Throttle Shifting (CTS). CTS occurs when the Transmission/Chassis ECM
signals the Engine ECM to reduce or increase engine fuel during a shift to lower stress to the
power train.
The Transmission/Chassis ECM is also used to control the hoist, the automatic lubrication
(grease), the neutral-start and the back-up alarm systems on the "C" Series trucks.
Many of the sensors and switches that provided input signals to the VIMS interface modules
on the "B" Series trucks have been moved to provide input signals to the Transmission/Chassis
ECM and the Brake ECM. Sensors and switches that were in the VIMS and now provide input
signals to the Transmission/Chassis ECM are:
- Low steering pressure - Hoist screen bypass

- Transmission oil temperature - Transmission charge filter bypass
- Transmission lube filter bypass - Torque converter oil temperature
The Electronic Control Analyzer Programmer (ECAP) and the Electronic Technician (ET)
Service Tools can be used to perform several diagnostic and programming functions.
Some of the diagnostic and programming functions that the service tools can perform are:
- Display real time status of input and output parameters

- Display the internal clock hour reading
- Display the number of occurrences and the hour reading of the first and last occurrence for
each logged diagnostic code and event
- Display the definition for each logged diagnostic code and event
- Display load counters
- Display the lockup clutch engagement counter
- Display the transmission gear shift counter
- Program the top gear limit and the body up gear limit
- Upload new Flash files
06/08
3
2
125
The shift lever (also referred to as the "Cane" or "Gear Selector") switch (1) is located inside the
cab in the shift console and provides input signals to the Transmission/Chassis ECM. The shift
lever switch controls the desired top gear selected by the operator. The shift lever switch inputs
consist of six wires. Five of the six wires provide codes to the Transmission/Chassis ECM.
Each code is unique for each position of the shift lever switch. Each shift lever switch position
results in two of the five wires sending a ground signal to the Transmission/Chassis ECM. The
other three wires remain open (ungrounded). The pair of grounded wires is unique for each shift
lever position. The sixth wire is the "Ground Verify" wire, which is normally grounded. The
Ground Verify wire is used to verify that the shift lever switch is connected to the Transmission/
Chassis ECM. The Ground Verify wire allows the Transmission/Chassis ECM to distinguish
between loss of the shift lever switch signals and a condition in which the shift lever switch is
between detent positions.
To view the shift lever switch positions or diagnose problems with the switch, use the VIMS
message center module or the status screen of the ET service tool and observe the "Gear Lever"
status. As the shift lever is moved through the detent positions, the Gear Lever status should
display the corresponding lever position shown on the shift console.
The position of the shift lever can be changed to obtain better alignment with the gear position
numbers on the shift console by loosening the three nuts (2) and rotating the lever. The position
of the shift lever switch is also adjustable with the two screws (3).
06/08
2 4
126
The transmission gear switch (1) provides input signals to the Transmission/Chassis ECM. The
transmission gear switch inputs (also referred to as the "actual gear inputs") consist of six wires.
Five of the six wires provide codes to the Transmission/Chassis ECM. Each code is unique for
each position of the transmission gear switch. Each transmission gear switch position results in
two of the five wires sending a ground signal to the Transmission/Chassis ECM. The other three
wires remain open (ungrounded). The pair of grounded wires is unique for each gear position.
The sixth wire is the "Ground Verify" wire, which is normally grounded. The Ground Verify
wire is used to verify that the transmission gear switch is connected to the Transmission/Chassis
ECM. The Ground Verify wire allows the Transmission/Chassis ECM to distinguish between
loss of the transmission gear switch signals and a condition in which the transmission gear
switch is between gear detent positions. Earlier transmission gear switches use a wiper contact
assembly that does not require a power supply to Pin 4 of the switch. Current transmission
gear switches are Hall-Effect type switches. A power supply is required to power the
switch. A small magnet passes over the Hall cells, which then provide a non-contact position
switching capability. The Hall-Effect type switch uses the same 24-Volt power supply used
to power the Transmission/Chassis ECM. The solenoid outputs provide +Battery voltage to
the upshift solenoid (2), the downshift solenoid (3) or the lockup solenoid (4) based on the
input information from the operator and the machine. The solenoids are energized until the
transmission actual gear switch signals the Transmission/Chassis ECM that a new gear position
has been reached.
06/08
127
The Transmission Output Speed (TOS) sensor (arrow) is located on the transfer gear housing
on the input side of the transmission. Although the sensor is physically located near the input
end of the transmission, the sensor is measuring the speed of the transmission output shaft. The
sensor is a Hall-Effect type sensor. Therefore, a power supply is required to power the sensor.
The sensor receives 10 Volts from the Transmission/Chassis ECM. The sensor output is a
square wave signal of approximately 10 Volts amplitude. The frequency in Hz of the square
wave is exactly equal to twice the output shaft rpm. The signal from this sensor is used for
automatic shifting of the transmission. The signal is also used to drive the speedometer and as
an input to other electronic controls.
An 8T5200 Signal Generator/Counter can be used to shift the transmission during diagnostic
tests. Disconnect the harness from the lockup solenoid and the speed sensor and attach the
Signal Generator to the speed sensor harness. Depress the ON and HI frequency buttons. Start
the engine and move the shift lever to the highest gear position. Rotate the frequency dial to
increase the ground speed and the transmission will shift.
NOTE: A 196-1900 adapter is required to increase the frequency potential from the
signal generator when connecting to the ECM’s used on these trucks. When using the
signal generator, the lockup clutch will not engage above SECOND GEAR because the
Engine Output Speed (EOS) and the Converter Output Speed (COS) verification speeds
will not be correct for the corresponding ground speed signal.
06/08
2 4
5
3
128
The service/retarder brake switch (1) is located in the compartment behind the cab. The switch
is normally closed and opens when service/retarder brake air pressure is applied. The switch has
three functions for the Transmission/Chassis ECM:
- Signals the Transmission/Chassis ECM to use elevated shift points, which provides
increased engine speed during downhill retarding for increased oil flow to the brake
cooling circuit.
- Cancels Control Throttle Shifting (CTS).
- Signals the Transmission/Chassis ECM to override the anti-hunt timer.
Rapid upshifting and downshifting is always allowed. The anti-hunt timer prevents a rapid
upshift-downshift sequence or a rapid downshift-upshift sequence (transmission hunting). The
timer is active during normal operation. It is overridden when either the service/retarder or
parking/secondary brakes are engaged.
A diagnostic code is stored if the Transmission/Chassis ECM does not receive a closed (ground)
signal from the switch within seven hours of operation time or an open signal from the switch
within two hours of operation time.
The Traction Control System (TCS) also uses the service/retarder brake switch as an input
through the CAT Data Link (see Visual No. 199).
06/08
The parking/secondary brake switch (2) is in the parking/secondary brake air pressure line. The
normally open switch is closed during the application of air pressure. The purpose of the switch
is to signal the Transmission/Chassis ECM when the parking/secondary brakes are ENGAGED.
Since the parking/secondary brakes are spring engaged and pressure released, the parking/
secondary brake switch is closed when the brakes are RELEASED and opens when the brakes
are ENGAGED. This signal is used to override the anti-hunt timer for rapid downshifting and is
used to sense when the machine is parked.
A diagnostic code is stored if the Transmission/Chassis ECM does not receive a closed (ground)
signal from the switch within seven hours of operation time or an open signal from the switch
within one hour of operation time.
Many relays (3) are located behind the cab. Some of these relays receive output signals from
the Transmission/Chassis ECM, and the relays turn on the desired function. The back-up alarm
relay is one of the Transmission/Chassis ECM output components located behind the cab.
When the operator moves the shift lever to REVERSE, the Transmission/Chassis ECM provides
a signal to the back-up alarm relay, which turns ON the back-up alarm.
The system air pressure sensor (4) and the brake light switch (5) are also located in the
compartment behind the cab. The low air pressure sensor provides an input signal to the Brake
ECM. The Brake ECM sends a signal to the VIMS, which informs the operator of the system
air pressure condition.
06/08
129
The body position sensor (1) is located on the frame near the left body pivot pin. A rod
assembly (2) is connected between the sensor and the body. When the body is raised, the rod
rotates the sensor, which changes the Pulse Width Modulated (PWM) signal that is sent to the
Transmission/Chassis ECM. The adjustment of the rod between the sensor and the body is very
important. The length of the rod must be within 10 mm (.39 in.) of the following dimensions
(center to center of the rod ends):
350 ± 3 mm (13.78 ± .12 in.)

After the rod has been adjusted, a calibration should be performed. The body position sensor is
calibrated by the Transmission/Chassis ECM when the following conditions occur:
- Engine is running
- Hoist output is in FLOAT or LOWER
- No ground speed is present for one minute
- Body position sensor duty cycle output is stable for 23 seconds (body is down)
- Body position is different than previous calibration
- Duty cycle output from the sensor is between 3% and 30%
Use the VIMS display to view the body position. When the body is down, the VIMS should
display zero degrees. If the position is greater than zero degrees, the sensor rod may have to be
adjusted.
06/08
The body position signal is used for several purposes.
- Body up gear limiting

- Hoist snubbing
- Signals a new load count (after 10 seconds in RAISE position)
- Lights the body up dash lamp
- Allows the VIMS to provide body up warnings
The body position sensor signal is used to limit the top gear into which the transmission will
shift when the body is UP. The body up gear limit value is programmable from FIRST to
THIRD gear using the ECAP or ET service tool. The Transmission/Chassis ECM comes
from the factory with this value set to FIRST gear. When driving away from a dump site, the
transmission will not shift past the programmed gear until the body is down. If the transmission
is already above the limit gear when the body goes up, no limiting action will take place.
The body position sensor signal is also used to control the SNUB position of the hoist control
valve. When the body is being lowered, the Transmission/Chassis ECM signals the hoist
LOWER solenoid to move the hoist valve spool to the SNUB position. In the SNUB position,
the body float speed is reduced to prevent the body from making hard contact with the frame.
The body position sensor signal is used to provide warnings to the operator when the truck is
moving with the body UP. The faster the ground speed, the more serious the warning.
The body position sensor receives + Battery Voltage (24 Volts) from the Chassis ECM. To
check the supply voltage to the sensor, connect a multimeter between Pins A and B of the
connector. Set the meter to read "DC Volts."
The body position sensor output signal is a Pulse Width Modulated (PWM) signal that varies
with the body position. To check the output signal of the body position sensor, disconnect the
rod and connect a multimeter between Pins B and C of the connector. Set the meter to read
"Duty Cycle." The duty cycle output of the body position sensor should change smoothly
between 3% and 98% when rotated. The duty cycle should be low when the body is DOWN
and high when the body is UP.
06/08
STEERING
789C
130
STEERING SYSTEM
This section of the presentation explains the operation of the steering system. As on other
Caterpillar Off-highway Trucks, the steering system uses hydraulic force to change the direction
of the front wheels. The system has no mechanical connection between the steering wheel and
the steering cylinders.
If the oil flow is interrupted while the truck is moving, the system incorporates a secondary
steering system. Secondary steering is accomplished by accumulators which supply oil flow to
maintain steering.
The steering system on the "C" Series trucks is the same as the steering system on the "B" Series
trucks. No changes were made to the steering system.
06/08
High Steering 789C STEERING SYSTEM

Pressure Switch NO STEER / MAXIMUM FLOW
Steering
Solenoid and Directional
Relief Valve Valve
Return
Manifold
L R
P
Case
Drain
Filter
T
LS
Piston Pump
Accumulator
Low Steering Charging Valve
Pressure Switch
Hand
Metering Unit
131
When the engine is started, oil for the steering system is drawn from the steering hydraulic tank
by the steering pump and sent through a one-way check valve to the solenoid and relief valve
manifold. Oil from the solenoid and relief valve manifold flows to the steering directional
valve, the accumulator charging valve and the accumulators. After the oil pressure increases to a
predetermined pressure in both accumulators, the steering pump will destroke.
When a steering demand occurs, the accumulators supply the necessary oil flow for steering, and
pressure in the accumulators decreases. When the oil pressure in the accumulators decreases to
a predetermined level, the steering pump will automatically upstroke to maintain the oil pressure
required for steering in the accumulators.
Oil from the accumulators flows through the steering directional valve to the Hand Metering
Unit (HMU).
If the steering wheel is not turned, the oil flows through the HMU and the main steering oil filter
to the tank.
06/08
Allowing oil to circulate through the HMU while the steering wheel is stationary provides a
"thermal bleed" condition, which maintains a temperature differential of less than 28°C (50°F)
between the HMU and the tank. This "thermal bleed" prevents thermal seizure of the HMU
(sticking steering wheel).
When the steering wheel is turned, the HMU directs oil back to the steering directional valve.
The steering directional valve directs oil to the steering cylinders. Depending on which
direction the steering wheel is turned, oil will flow to the head end of one steering cylinder and
to the rod end of the other cylinder. The action of the oil on the pistons and rods in the steering
cylinders causes the wheels to change direction. Displaced oil from the steering cylinders flows
through the back pressure valve in the steering directional valve and returns through the main
steering oil filter to the tank.
06/08
785C STEERING SYSTEM

HOLD
Case Drain
Filter
Crossover
Piston Relief
Pump Valves
Pump
Switch
Hand
Metering
Unit
Solenoid and
Relief Valve
Return Manifold
132
Oil from the steering pump flows through a one-way check valve to the solenoid and relief
valve return manifold and is then sent to the accumulators and the Hand Metering Unit (HMU).
The 785C truck does not use a steering directional valve. Oil from the HMU flows through a
crossover relief valve group directly to the steering cylinders.
In the HOLD position, oil flows through an orifice in the HMU to the tank. Allowing oil to flow
through the HMU in the HOLD position provides a "thermal bleed" condition, which prevents
thermal seizure of the HMU (sticking steering wheel).
The crossover relief valves protect the steering cylinders and oil lines from pressure surges when
the steering wheel is in the HOLD position by equalizing the oil pressure between the head ends
and rod ends of the steering cylinders.
During a turn, the HMU directs oil through the crossover relief valves to the steering cylinders.
Displaced oil from the steering cylinders flows back through the HMU to the main steering oil
filter.
06/08
3
5
4 1
7 2
133
The steering tank is located on the right platform. Two sight gauges are on the side of the
tank. When the engine is shut off and the oil is cold, the oil should be visible between the
FULL and ADD OIL markings of the upper sight gauge (l). When the engine is running and
the accumulators are fully charged, the oil level should not be below the ENGINE RUNNING
marking of the lower sight gauge (2). If the ENGINE RUNNING level is not correct, check the
nitrogen charge in each accumulator. A low nitrogen charge will allow excess oil to be stored in
the accumulators and will reduce the secondary steering capacity.
A combination vacuum breaker/pressure relief valve is used to limit the tank pressure. Before
removing the fill cap, be sure that the engine was shut off with the key start switch and the oil
has returned to the tank from the accumulators. Depress the pressure release button (3) on the
breather to vent any remaining pressure from the tank.
Supply oil for the steering system is provided by a piston-type pump. Case drain oil from the
pump returns to the tank through the filter (4). The remaining steering system oil returns to the
tank through the main steering filter (5). Both filters are equipped with bypass valves to protect
the system if the filters are restricted or during cold oil start-up.
If the steering pump fails or if the engine cannot be started, the connector (6) is used to attach
an Auxiliary Power Unit (APU). The APU will provide supply oil from the steering tank at the
connector to charge the steering accumulators. Steering capability is then available to tow the
truck.
06/08
The steering oil temperature sensor (7) provides an input signal to the VIMS, which informs the
operator of the steering system oil temperature. If the steering oil temperature exceeds 108 °C
(226 °F), the operator will receive a warning on the VIMS display (STRG OIL TEMP HI).
INSTRUCTOR NOTE: For more information on using the APU, refer to the Special
Instructions "Using 1U5000 Auxiliary Power Unit (APU)" (Form SEHS8715) and "Using
the 1U5525 Attachment Group" (Form SEHS8880).
06/08
2 1
134
The piston-type steering pump (1) for the 785C truck is mounted to the pump drive. The pump
drive is located on the inside of the right frame rail near the torque converter.
The steering pump operates only when the engine is running and provides the necessary oil flow
to the accumulators for steering system operation.
The steering pump for the 785C truck contains a pressure compensator valve (2) that monitors
and controls steering pump output.
06/08
785C STEERING PUMP

MAXIMUM FLOW
Swashplate Piston
Supply Oil
Output
Oil
Spring Control Piston Pressure Compensator

Valve
135
Shown is a sectional view of the piston-type steering pump for the 785C truck in the
MAXIMUM FLOW condition. No oil pressure is present in the control piston. In this
condition, the swashplate is kept at maximum angle by the force of the spring in the pump
housing. The pistons travel in and out of the barrel and maximum flow is provided through the
outlet port. Since the pump is driven by a shaft off the engine, it should be remembered that
engine rpm also affects pump output.
06/08
PUMP COMPENSATOR VALVE
MAXIMUM PUMP FLOW MINIMUM PUMP FLOW
From From
Drain Passages Pump Drain Passages Pump
To To
Control Piston Control Piston
136
Shown is a sectional view of the pump compensator valve for the 785C truck. The pump
compensator valve senses pump supply pressure through a passage in the valve body. When the
outlet pressure is less than the force of the spring on the end of the compensator spool, the oil is
blocked from flowing to the pump control piston.
As the accumulators fill, the pressure of the oil through the pump outlet increases. The pump
supply pressure will increase until the pressure of the oil in the pump passage in the pump
compensator valve is high enough to overcome the spring force on the compensator spool. The
spool then moves to the left and opens the passage to the control piston. This movement occurs
when the outlet oil pressure is approximately 17580 ± 345 kPa (2550 ± 50 psi).
The pressure setting can be adjusted by changing the shim thickness behind the compensator
spool spring. Remove the plug and add shims to increase the pressure setting. Remove shims to
lower the setting.
06/08
785C STEERING PUMP

MINIMUM FLOW
Swashplate Piston
Supply Passage
for Pump
Output Passage
From Pump
Control Piston Pressure

Compensator Valve
137
The pressure of the oil from the compensator valve passage moves the control piston, which
rotates the swashplate toward the minimum angle. The pistons now have very little movement
in and out of the barrel as the retraction plate and slippers follow the minimum angle of the
swashplate.
While the accumulators are filled, this small movement of the pistons maintains the pressure
at the setting of the pressure compensator valve. The compensator spool will remain open to
provide pressure oil behind the control piston. Excess oil from the pump outlet goes into the
pump case for cooling and lubrication. The oil then goes through a drain line to the case drain
oil filter and steering hydraulic tank.
As the steering wheel is turned and oil is taken from the accumulators, the pressure at the pump
outlet will decrease. When accumulator pressure decreases, the pressure compensator valve will
allow the swashplate to move toward maximum angle and increase pump output.
06/08
3
4
138
The 789C is equipped with a load sensing, pressure compensated, piston-type pump (1). The
steering pump is mounted to the pump drive. The pump drive is located on the inside of the
right frame rail near the torque converter.
The steering pump operates only when the engine is running and provides the necessary flow of
oil to the accumulators for steering system operation. The steering pump contains a load sensing
controller (2) that works with an accumulator charging valve to monitor and control steering
pump output.
The steering pump will produce flow at high pressure until the steering accumulators are charged
with oil and the pressure increases to 18300 ± 350 kPa (2655 ± 50 psi) at LOW IDLE. This
pressure is referred to as the CUT-OUT pressure. When the CUT-OUT pressure is reached, the
accumulator charging valve reduces the load sensing signal pressure to the pump load sensing
controller, and the pump destrokes to the LOW PRESSURE STANDBY condition. During
LOW PRESSURE STANDBY, the pressure should be between 2070 and 3600 kPa
(300 and 525 psi).
The pump operates at minimum swashplate angle to supply oil for lubrication and leakage.
Because of the normal leakage in the steering system and Hand Metering Unit (HMU) "thermal
bleed," the pressure in the accumulators will gradually decrease to 16470 ± 350 kPa
(2390 ± 50 psi). This pressure is referred to as the CUT-IN pressure.
06/08
When the pressure in the accumulators decreases to the CUT-IN pressure, the accumulator
charging valve blocks the load sensing signal line to the load sensing controller from returning
to the tank, and the pump upstrokes to maximum displacement (full flow).
A pressure tap (3) is located on the pump pressure switch manifold. If steering pump supply
pressure is measured at this tap during LOW PRESSURE STANDBY, a gauge acceptable for
testing maximum steering system pressure must be used to avoid damaging the gauge when the
steering pump upstrokes to provide maximum oil flow.
Two pressure switches monitor the condition of the steering system on the 789C. One
switch (4) monitors the output of the steering pump. This switch monitors pump supply
pressure during LOW PRESSURE STANDBY. The VIMS refers to this switch as the "low
steering pressure" switch.
The other steering pressure switch is mounted on the bottom of one of the steering accumulators
(see Visual No. 153). This switch monitors the steering system accumulator pressure. The
VIMS refers to this switch as the "high steering pressure" switch.
Both steering pressure switches provide input signals to the Transmission/Chassis ECM. The
Transmission/Chassis ECM sends signals to the VIMS, which informs the operator of the
condition of the steering system. A steering system warning is only displayed if the ground
speed is above 8 km/h (5 mph) or the actual gear switch is not in NEUTRAL.
06/08
2 4
6 3 5
139
On the 789C truck, steering pump supply oil flows through a check valve (1) to the solenoid and
relief valve manifold (2). The solenoid and relief valve manifold connects the steering pump to
the accumulator charging valve (3), the accumulators and the steering directional valve (4). The
solenoid and relief valve manifold also provides a path to drain for the steering oil.
When checking the steering system CUT-OUT and CUT-IN pressures, a gauge can be connected
at the pressure tap (5).
Steering system oil samples can be taken at the steering system Scheduled Oil Sampling (S•O•S)
tap (6).
06/08
789C STEERING PUMP

MAXIMUM FLOW
From Accumulators
To Accumulators
Accumulator
Pump Output
Charging Valve
Actuator
Piston
Load Sensing
Pressure
Flow
Compensator
Load Sensing
Controller
Swashplate
Piston
140
After the engine is started, pressure increases in the steering accumulators. The pump load
sensing controller is spring biased to vent the actuator piston pressure to drain. Venting pressure
from the load sensing controller and the actuator piston positions the spring biased swashplate to
maximum displacement (full flow).
As pressure increases in the accumulators, pump supply pressure is sensed in the accumulator
charging valve and on both ends of the flow compensator. With pressure on both ends of the
flow compensator, the swashplate is kept at maximum angle by the force of the spring in the
pump housing and pump discharge pressure on the swashplate piston. The pistons travel in
and out of the barrel and maximum flow is provided through the outlet port. Since the pump is
driven by the engine, engine rpm also affects pump output.
NOTE: Because the signal lines are sensing pump supply pressure and not a "load"
pressure, the steering system does not operate the same as other load sensing systems
with a margin pressure.
06/08
789C STEERING PUMP

LOW PRESSURE STANDBY
From Accumulators
To Accumulators
Accumulator
Charging Valve Pump Output Actuator
Piston
Load Sensing
Pressure
Flow
Compensator
Load Sensing
Controller
Swashplate
Piston
141
Pump supply pressure will increase until the accumulator pressure acting on the accumulator
charging valve shifts the spool, and the load sensing signal pressure is vented to the tank.
The accumulator charging valve spool shifts (cut-out) when the pump outlet oil pressure is
approximately 18300 ± 350 kPa (2655 ± 50 psi).
An orifice prevents supply pressure from filling the drained load sensing passage above the
flow compensator. Pump oil (at low pressure standby pressure) flows past the lower end of the
displaced flow compensator spool to the actuator piston. The actuator piston has a larger surface
area than the swashplate piston. The oil pressure at the actuator piston overcomes the spring
force of the swashplate piston and moves the swashplate to destroke the pump. The pump is
then at a low flow, LOW PRESSURE STANDBY condition. Pump output pressure is equal to
the setting of the flow compensator. The LOW PRESSURE STANDBY setting must be between
2070 and 3600 kPa (300 and 525 psi).
In the NEUTRAL or NO STEER position, demand for oil from the accumulators is low. The
pump operates at minimum swashplate angle to supply oil for lubrication and leakage. Because
of the normal leakage in the steering system and HMU "thermal bleed," the pressure in the
accumulators will gradually decrease to approximately 16470 ± 350 kPa (2390 ± 50 psi)
(90% of the accumulator charging valve cut-out pressure).
06/08
When the pressure in the accumulators decreases to 16470 ± 350 kPa (2390 ± 50 psi), the
accumulator charging valve shifts (cut-in) and blocks the load sensing signal line pressure from
the tank. Pump supply oil flows through the orifice and pressurizes the load sensing signal line.
The load sensing signal shifts the flow compensator spool and drains the actuator piston oil to
the tank. Venting pressure from the actuator piston positions the spring biased swashplate to
maximum displacement (full flow).
At LOW lDLE in the NEUTRAL or NO STEER position, the pump will cycle between the
cut-out and cut-in conditions in 25 seconds or more. Connecting a pressure gauge to the
pressure tap on the bottom of the steering directional valve will indicate these steering system
pressures. If pump pressure cycles in less than 25 seconds, leakage is in the system and must be
corrected. Typical sources of leakage can be the accumulator bleed down solenoid or the back-
up relief valve located on the return manifold.
06/08
1 2
142
Shown is the accumulator charging valve (1). The accumulator charging valve is located on the
frame rail near the front of the truck and below the engine oil pan.
The pressure setting of the accumulator charging valve can be changed by adjusting the spring
force that keeps the valve seated (closed). Change the setting by removing the protective cap
(2) and turning the adjustment screw clockwise to increase or counterclockwise to decrease the
pressure setting. Do not exceed 14 N•m (10 lb. ft.) torque on the adjustment screw when making
the adjustments. One turn of the adjustment screw changes the pressure approximately 4000
kPa (580 psi).
Operate the engine at LOW IDLE and check the pump (accumulator) pressure at the pressure
tap (3). The pump will cycle between cut-out and cut-in every 25 seconds or more. The
pressure gauge will indicate these steering system pressures. Turn the adjusting screw until the
cut-out pressure is correct.
If the accumulator charging pressure cannot be adjusted within specifications, an adjustment of

the high pressure cutoff valve is required. The high pressure cutoff setting must be a minimum
of 1720 kPa (250 psi) higher than the accumulator charging valve setting.
NOTE: When testing or adjusting any steering system pressure settings, always allow
the accumulator charge cycle to occur at least three times before testing the pressures.
Failure to allow the charging cycle to occur three times will result in inaccurate
readings.
06/08
LOAD SENSING CONTROLLER
From
Accumulator
Accumulator
Charging Valve
To
Accumulator
Disconnect and Plug Line
for High Pressure Cutoff
High Pressure Cutoff Test Adjustment Screw
Low Pressure
Standby Adjustment Screw
To Tank
To Actuator Piston
From Pump Output Port
143
Pump pressure limiting (high pressure cutoff) is adjustable. To adjust the pump high pressure
cutoff valve, turn the accumulator charging valve adjustment screw all the way in, or disconnect
the load sensing (LS) line (pump to accumulator charging valve) at the pump. Plug the line
to the accumulator charging valve and cap the fitting on the pump. Operate the engine at
LOW IDLE, and check the pump (accumulator) pressure at the pressure tap below the steering
directional valve.
Turn the compensator (high pressure cutoff) adjusting screw while watching the pressure gauge.
One turn is equal to approximately 2800 kPa (405 psi). Adjust the pressure to 20000 ± 350 kPa
(2900 ± 50 psi). When the adjustment is complete, reconnect the LS line to the pump.
The high pressure cutoff setting must be a minimum of 1720 kPa (250 psi) higher than the
accumulator charging valve setting. If the high pressure cutoff setting of the compensator valve
(in the load sensing controller) is lower than the accumulator charging valve setting, the pump
will stay at MINIMUM FLOW, and the steering system will take too long to recharge. The high
pressure cutoff adjustment provides a back-up if the accumulator charging valve malfunctions.
06/08
Pump LOW PRESSURE STANDBY is also adjustable. Connect a gauge to the low pressure
standby pressure tap (see Visual No. 138). With the signal line connected, operate the engine at
LOW IDLE and check the pump pressure. The pump will cycle to low pressure standby every
25 seconds or more. Low pressure standby must be between 2070 and 3600 kPa
(300 and 525 psi). If adjustment is required, stop the engine.
Turn the low pressure standby adjustment screw clockwise to increase the pressure and
counterclockwise to decrease the pressure until the pressure is between 2070 and 3600 kPa (300
and 525 psi). Each 1/4 turn changes the pressure setting approximately 345 kPa (50 psi).
NOTE: If the steering pump is adjusted on a hydraulic test stand, set the margin
pressure to 2070 ± 100 kPa (300 ± 15 psi) with a flow of 115 ± 12 L/min (30 ± 3 gpm),
1838 rpm and 15000 kPa (2180 psi) discharge pressure. The low pressure standby
reading measured on a truck is higher than the test stand margin pressure due to
parasitic loads in the truck steering system.
06/08
2 3 4
144
On the 789C truck, steering pump supply oil flows through a check valve (1) to the solenoid and
relief valve manifold. The solenoid and relief valve manifold connects the steering pump to the
accumulator charging valve, the accumulators and the steering directional valve. The solenoid
and relief valve manifold also provides a path to drain for the steering oil.
The check valve (1) prevents accumulator oil from flowing back to the steering pump when the
pump destrokes to LOW PRESSURE STANDBY.
The accumulator bleed down solenoid (2) drains pressure oil from the accumulators when the
truck is not in operation.
The back-up relief valve (3) protects the system from pressure spikes if the pump cannot
destroke fast enough or limits the maximum pressure if the steering pump high pressure cutoff
valve does not open.
tap (4).
To operate the steering system on a disabled truck, an Auxiliary Power Unit (APU) can be
connected to the secondary steering connector (5) on the solenoid and relief valve manifold and
to a suction port on the hydraulic tank (see Visual No. 133). The APU will provide supply oil to
charge the accumulators. Steering capability is then available to tow the truck.
06/08
1
6
3 2
145
On the 785C truck, steering pump supply oil flows through a check valve (1) to the solenoid
and relief valve manifold. The solenoid and relief valve manifold connects the steering pump to
the accumulators and the HMU. The solenoid and relief valve manifold also provides a path to
drain for the steering oil.
The check valve (1) prevents accumulator oil from flowing back to the steering pump
The accumulator bleed down solenoid (not shown) drains pressure oil from the accumulators
when the truck is not in operation.
The back-up relief valve (2) limits the maximum pressure if the steering pump compensator
valve fails.
tap (3)
To operate the steering system on a disabled truck, an Auxiliary Power Unit (APU) can be
connected to the secondary steering connector (4) on the solenoid and relief valve manifold and
to a suction port on the hydraulic tank (see Visual No. 133). The APU will provide supply oil to
charge the accumulators. Steering capability is then available to tow the truck.
The 785C has two accumulators (5). The steering system pressure tap (6) is located on the
bottom of the left steering accumulator.
06/08
SOLENOID AND Supply

From Pump
RELIEF VALVE MANIFOLD
To / From
Accumulators
To Steering
Control Valve
To Tank
Bleed Down
Solenoid
Back-up Relief
Valve
146
Shown is a sectional view of the solenoid and relief valve manifold. The accumulator bleed
down solenoid is energized by the bleed down solenoid shutdown control (see Visual No. 154)
when the key start switch is moved to the OFF position. The bleed down solenoid shutdown
control holds the solenoid open for 70 seconds.
Pressure oil from the accumulators is sensed by the bleed down solenoid. When the solenoid is
ENERGIZED, the plunger moves and connects the pressure oil to the drain passage. Pressure
oil flows through an orifice, past the plunger, to the tank. The orifice limits the return oil flow
from the accumulators to a rate which is lower than the flow limit (restriction) of the steering
oil filter in the hydraulic tank. When the solenoid is DE-ENERGIZED, spring force moves the
plunger and pressure oil cannot go to drain.
06/08
The back-up relief valve protects the steering system if the steering pump malfunctions (fails to
destroke). Pressure oil from the steering pump works against the end of the back-up relief valve
and the spring. The relief valve unseats (opens) if the pressure reaches approximately:
785C: 20700 ± 400 kPa (3000 ± 60 psi) at 8 ± 2 L/min (2 ± .5 gpm)

789C: 20670 ± 400 kPa (3000 ± 60 psi) at 8 ± 2 L/min (2 ± .5 gpm)
Oil then flows past the relief valve and drains to the tank.
The back-up relief valve must be adjusted only on a test bench. The pressure setting of the
back-up relief valve can be changed by adjusting the spring force that keeps the relief valve
seated (closed). To change the relief valve setting, remove the protective cap and turn the
adjustment screw clockwise to increase or counterclockwise to decrease the pressure setting.
One revolution of the setscrew will change the pressure setting 3800 kPa (550 psi).
A functional test of the back-up relief valve can be performed on the machine by installing
a manual hydraulic pump at the location of the Auxiliary Power Unit (APU) connector and
installing blocker plates to prevent oil from flowing to the accumulators. See the service manual
for more detailed information.
NOTE: Using the functional test procedure to adjust the back-up relief valve will
provide only an approximate setting. Accurate setting of the back-up relief valve can
only be performed on a hydraulic test bench.
06/08
147
The steering directional valve (1) used on the 789C truck is pilot operated from the HMU in the
operator’s station. Five pilot lines connect these two components. The pilot lines send pilot
oil from the HMU to shift the spools in the steering directional valve. The spools control the
amount and direction of pressure oil sent to the steering cylinders. Four pilot lines are used for
pump supply, tank return, left turn, and right turn. The fifth pilot line is for the load sensing
signal.
When checking the steering system cut-out and cut-in pressures, a gauge can be connected at the
pressure tap (2).
06/08
Left Turn To Tank Right Turn

Cylinder Back Pressure
Cylinder
Valve
Relief / Makeup
Valve
Relief / Makeup
Valve
STEERING
DIRECTIONAL VALVE
NO TURN Right Turn Left Turn
Pilot Oil Pilot Oil
Combiner / Check Amplifier Spool
Spool
Priority Spool
Load
Sensing Port
Hand Metering Unit Supply
From and Thermal Bleed
Accumulator
148
Shown is a sectional view of the steering directional valve. The main components of the
steering directional valve are: the priority spool, the amplifier spool with internal combiner/
check spool, the directional spool, the relief/makeup valves and the back pressure valve.
Pressure oil from the accumulators flows past the spring biased priority spool and is blocked
by the amplifier spool. The same pressure oil flows through an orifice to the right end of
the priority spool. The orifice stabilizes the flow to the priority spool and must be present to
open and close the priority spool as the flow demand changes. The same pressure oil flows to
the HMU. After all the passages fill with pressure oil, the priority spool shifts to the left, but
remains partially open. In this position, the priority spool allows a small amount of oil flow
(thermal bleed) to the HMU and decreases the pressure to the HMU supply port. The "thermal
bleed" prevents the HMU from sticking.
With the truck in the NEUTRAL or NO TURN position, all four working ports (supply, tank,
right turn, and left turn) are vented to the tank through the HMU. The directional spool is held
in the center position by the centering springs.
06/08
While the truck is traveling straight (no steer), any rolling resistance (opposition) acting on the
steering cylinders creates a pressure increase. The increased pressure acts on the relief/makeup
valve in that port. If the pressure increase exceeds 28000 ± 1000 kPa (4065 ± 150 psi), the relief
poppet will open. A pressure drop occurs across the orifice. The pressure drop causes the dump
valve to move and allows oil to flow to the tank passage.
The relief action causes the makeup portion of the other relief/makeup valve to open and
replenish oil to the low pressure ends of the cylinders.
The excess (dumped) oil flows across the back pressure valve and enters the outer end of the
other relief/makeup valve. A pressure difference of 48 kPa (7 psi) between the tank passage and
the low pressure cylinder port causes the makeup valve to open. The excess oil flows into the
low pressure cylinder port to prevent cavitation of the cylinder. The back pressure valve also
prevents cavitation of the cylinders by providing a positive pressure of 170 kPa (25 psi) in the
passage behind the makeup valve. A pressure higher than 170 kPa (25 psi) will open the back
pressure valve to the tank.
The steering directional valve must be removed and tested on a hydraulic test bench to
accurately check the setting of the relief/makeup valves.
A functional test of the relief/makeup valves can be performed on the machine by connecting a
manual hydraulic pump and installing blocker plates to prevent oil from flowing to the steering
cylinders. See the service manual for more detailed information.
NOTE: Using the functional test procedure to adjust the relief/makeup valves will
provide only an approximate setting. Accurate setting of the relief/makeup valves can
only be performed on a hydraulic test bench.
06/08
To Tank Back
Left Turn Right Turn
Cylinder Cylinder Pressure Valve
Relief / Makeup
Valve
Relief/makeup
Valve
STEERING
DIRECTIONAL VALVE
RIGHT TURN
Right Turn Left Turn
Pilot Oil Pilot Oil
Combiner / Check Amplifier Spool
Spool
Priority Spoo
Load Sensing Port

Hand Metering
Unit Supply and
From
Thermal Bleed
Accumulator
149
When the steering wheel is turned to the RIGHT, the "thermal bleed" and venting of the four
work ports to the tank is stopped. The increased supply pressure flows to the HMU and the
load sensing pilot line. The load sensing pilot line directs cylinder pressure to the priority spool
in the directional valve. Cylinder pressure is present in the HMU because pilot oil combines
with accumulator oil in the combiner/check valve spool in the directional valve. The increased
pressure in the load sensing line causes the priority spool to move to the right and allows more
oil flow to the HMU through the supply line. The load sensing port supply pressure varies with
the steering load. The priority spool moves proportionally, allowing sufficient oil flow to meet
the steering requirements.
Pilot oil flows through a stabilizing orifice to the right turn pilot port of the directional valve and
moves the directional spool. Movement of the directional spool allows pilot oil to flow to the
amplifier and combiner/check spools.
The pilot oil divides at the amplifier spool. Pilot oil flows through a narrow groove around the
combiner/check spool. The pilot oil is momentarily blocked until the amplifier spool moves far
enough to the right to allow partial oil flow through one of eight orifices.
06/08
Pilot oil also flows through a connecting pin hole and a stabilizing orifice to the left end of
the amplifier spool and causes the amplifier spool to move to the right. Accumulator oil at the
spring end (right end) of the amplifier spool flows through a mid-connecting pin to the left end
of the amplifier spool and also causes the amplifier spool to move to the right.
When the amplifier spool moves to the right, accumulator oil flows to the inner chamber, forcing
the combiner/check spool to the left. Accumulator oil then flows through seven of the eight
orifices. Pilot and accumulator oil combine. Oil flows across the directional spool (which has
already shifted) for a RIGHT TURN.
The faster the steering wheel is turned, the farther the directional spool and the amplifier spool
are shifted. A higher flow rate is available, which causes the truck to turn faster. The ratio of
pilot and pump supply oil that combine is always the same because one orifice is dedicated to
pilot flow and seven orifices are dedicated to accumulator supply flow.
Return oil from the cylinders flows across the directional spool, around the relief/makeup valve,
forces the back pressure valve open and returns to the tank.
During a turn, if a front wheel strikes a large obstruction that cannot move, oil pressure in that
steering cylinder and oil line increases. Oil flow to the cylinder is reversed. This pressure spike
is felt in the amplifier spool. The combiner/check spool moves to the right and blocks the seven
pump supply oil orifices to the steering cylinders. The amplifier spool moves to the left and
blocks the pilot oil orifice. Pilot oil flow to the steering cylinders stops. The pressure spike is
not felt at the HMU. If the pressure spike is large enough, the relief/makeup valve drains the
pressure oil to the tank as previously described.
06/08
4
2
150
Shown is the solenoid and relief valve manifold (1) and the crossover relief valves (2) on the
785C truck.
The crossover relief valves (2) are located in one housing mounted on the inside of the left frame
rail near the front of the truck. The crossover relief valves prevent damage from high pressure
oil in the steering cylinder circuit caused by an outside force applied to a front wheel when the
steering wheel is stationary.
The crossover relief valve housing contains two pressure taps (3) where steering system pressure
can be measured. One tap shows pressure during a left turn and the other tap shows pressure
during a right turn.
To check the steering system pressure, turn the steering wheel completely in either direction.
Operate the engine at LOW IDLE. Continue to turn the steering wheel after the wheels have
stopped and the pressure will increase to the pump compensator valve setting. Check the
steering pressure while turning in both directions. The pump compensator valve setting should
be observed on the gauge in both directions. If the pressure readings are different, one of the
crossover relief valve settings is probably incorrect. A misadjusted valve must be removed and
readjusted on a test bench.
On the 785C, one pressure switch (4) monitors the condition of the steering system. The switch
provides an input signal to the Transmission/Chassis ECM. The Transmission/Chassis ECM
sends a signal to the VIMS.
06/08
785C CROSSOVER RELIEF SYSTEM

EXTERNAL IMPACT
Crossover
Relief Valves
Hand
Metering Unit
151
On the 785C truck, when the steering wheel is stationary, the HMU blocks oil in the steering
cylinders and in the lines between the steering cylinders and the HMU. The oil blockage
prevents the front wheels from moving when the steering wheel is not turned. If pressure is
applied against the front wheels while the steering wheel is stationary, the pressure of the oil
increases in the head end of one cylinder and the rod end of the other cylinder. If the increase of
oil pressure exceeds 18270 kPa (2650 psi) at the affected crossover relief valve, the valve will
open. Oil from the high pressure ends of the steering cylinders then transfers to the low pressure
ends of the cylinders.
06/08
152
The 789C Hand Metering Unit (HMU) (arrow) is located at the base of the steering column
behind a cover at the front of the cab. The HMU is connected to the steering wheel and
controlled by the operator.
The 789C HMU meters the amount of oil sent to the steering directional valve by the speed at
which the steering wheel is turned. The faster the HMU is turned, the higher the flow sent to
the steering cylinders from the steering directional valve, and the faster the wheels will change
direction.
The 785C HMU is larger because oil flows directly from the HMU, through the crossover relief
valve, to the steering cylinders. The capacity of the 785C HMU must be large enough to handle
the flow required to fill the steering cylinders and allow satisfactory steering cycle times.
On the front of the HMU are four ports:
- Return to tank - Left turn

- Pump supply - Right turn
The 789C HMU has a fifth port on the side of the HMU. The fifth port is the load sensing signal
line to the steering directional valve.
06/08
153
Two steering accumulators (1) provide the supply oil during normal operation and temporary
secondary steering if a loss of pump flow occurs (789C shown).
Inside each accumulator is a rubber bladder that is charged with nitrogen. The nitrogen charge
provides energy for normal steering and secondary steering capability if steering pump flow
stops.
To check the secondary steering system, the engine must be shut off with the manual engine
shutdown switch (see Visual No. 25) while leaving the key start switch in the ON position.
When the manual shutdown switch is used, the bleed down solenoid is not energized and the
accumulators do not bleed down. The truck can then be steered with the engine stopped.
The steering accumulator pressure switch (2) monitors the steering accumulator pressure. The
switch provides an input to the VIMS. The VIMS refers to this switch as the "high steering
pressure" switch.
High pressure oil remains in the accumulators if the manual shutdown switch is used. To
release the oil pressure in the accumulators, turn the key start switch to the OFF position
and turn the steering wheel left and right until the oil is drained from the accumulators
(steering wheel can no longer be turned).
06/08
154
Shown is the shutdown control (arrow) for the steering accumulator bleed down solenoid. The
control is located in the compartment behind the cab.
The steering accumulator bleed down solenoid is activated by the control when the key start
switch is moved to the OFF position. The bleed down solenoid shutdown control holds the
solenoid open for 70 seconds.
The charge pressure for the steering accumulators is:
785C: 8270 ± 0 kPa (1200 ± 0 psi)

789C: 5512 ± 345 kPa (800 ± 50 psi)
06/08
HOIST SYSTEM
789C
155
HOIST SYSTEM
The hoist system on the 785C and 789C trucks is electronically controlled by the Transmission/
Chassis ECM. The hoist control system operates similarly to the earlier trucks. The four
operating positions are: RAISE, HOLD, FLOAT, and LOWER.
The hoist valve has a fifth position referred to as the SNUB position. The operator is unaware
of the SNUB position because a corresponding lever position is not provided. When the body is
being lowered, just before the body contacts the frame, the Transmission/Chassis ECM signals
the hoist solenoids to move the hoist valve spool to the SNUB position. In the SNUB position,
the body float speed is reduced to prevent the body from making hard contact with the frame.
The hoist system can be enabled or disabled using ET. All trucks shipped from the factory
without bodies installed are set at the Hoist Enable Status 2. The Hoist Enable Status 2 is a test
mode only and will prevent the hoist cylinders from accidentally being activated. After the body
is installed, change the Hoist Enable Status to 1 for the hoist system to function properly.
06/08
156
The operator controls the hoist lever (arrow). The four positions of the hoist lever are RAISE,
HOLD, FLOAT, and LOWER.
body pads and not on the hoist cylinders. The hoist control valve will actually be in the SNUB
position.
If the transmission is in REVERSE when the body is being raised, the hoist lever sensor is used
to shift the transmission to NEUTRAL. The transmission will remain in NEUTRAL until:
1. The hoist lever is moved into the HOLD or FLOAT position; and
2. the shift lever has been cycled into and out of NEUTRAL.
NOTE: If the truck is started with the body raised and the hoist lever in FLOAT, the
lever must be moved into HOLD and then FLOAT before the body will lower.
06/08
157
The hoist lever controls a Pulse Width Modulated (PWM) position sensor (arrow). The PWM
sensor sends duty cycle input signals to the Transmission/Chassis ECM. Depending on the
position of the sensor and the corresponding duty cycle, one of the two solenoids located on the
hoist valve is energized.
The four positions of the hoist lever are RAISE, HOLD, FLOAT, and LOWER, but since the
sensor provides a duty cycle signal that changes for all positions of the hoist lever, the operator
can modulate the speed of the hoist cylinders.
The hoist lever sensor also replaces the body raise switch (transmission neutralizer switch) that
was located behind the operator's seat. The hoist lever sensor performs three functions:
- Raises and lowers the body

- Neutralizes the transmission in REVERSE
- Starts a new TPMS cycle
The hoist lever position sensor receives 24 Volts from the Transmission/ Chassis ECM. To
check the supply voltage of the sensor, connect a multimeter between Pins A and B of the sensor
connector. Set the meter to read "DC Volts."
To check the output signal of the hoist lever position sensor, connect a multimeter between Pins
B and C of the hoist lever position sensor connector. Set the meter to read "Duty Cycle." The
duty cycle output of the sensor should be approximately 5 to 95% between full RAISE to full
LOWER.
06/08
158
Shown is the hoist, converter and brake oil hydraulic tank (1) and the oil level sight gauges
(2). The oil level is normally checked with the upper sight gauge. The oil level should first be
checked with cold oil and the engine stopped. The level should again be checked with warm oil
and the engine running.
The lower sight gauge is used when filling the hydraulic tank with the hoist cylinders in the
RAISED position. When the hoist cylinders are lowered, the hydraulic oil level will increase.
After the hoist cylinders are lowered, check the hydraulic tank oil level with the upper sight
gauge as explained above.
Use only Transmission Drive Train Oil (TDTO) with a specification of TO-4 or newer.
TDTO-4 oil:
- Provides maximum frictional capability required for clutch discs used in the brakes.
- Increases brake holding capability by reducing brake slippage.
- Controls brake chatter.
Check the hydraulic tank breather (3) for restriction. Clean the filter if it is restricted.
06/08
159
Shown is the rear of the transmission and hoist hydraulic tank and the converter and brake oil
hydraulic tank. The hoist system pumps pull oil from the hydraulic tank through the suction
screens (arrows) located in the rear of the tank.
06/08
2 2
160
The hoist system oil for the "C" Series Trucks is supplied by a two-section pump (1) located at
the top rear of the pump drive. Oil flows from the hoist pump through two screens to the hoist
valve. The hoist system pressure can be tested at the two pressure taps (2).
The hoist system relief pressures are different in the RAISE and LOWER positions.
The hoist system relief pressure during RAISE is:
785C/789C: 17225 + 700 - 0 kPa (2500 + 100 - 0 psi)

789C (with cast iron pump): 18960 ± 345 (2750 ± 50 psi)
The hoist system relief pressure during LOWER is:
785C/789C: 3450 + 350 - 0 kPa (500 + 50 - 0 psi)
When the body is in the DOWN position, the hoist valve will be in the SNUB position. The
body position sensor rod must be disconnected from the body and the sensor must be rotated to
the RAISE position before the LOWER relief pressure can be tested.
In the HOLD, FLOAT, and SNUB positions, the gauge will show the brake cooling system
pressure, which is a result of the restriction in the coolers, brakes, and hoses (normally much
lower than the actual oil cooler relief valve setting). The maximum pressure is limited by the oil
cooler relief valve, which has a setting of 790 ± 20 kPa (115 ± 3 psi).
06/08
1 2
161
Oil flows from the hoist pump through the hoist screens (1) to the hoist control valve. Two
hoist screen bypass switches (2) provide input signals to the Transmission/Chassis ECM. The
Transmission/Chassis ECM sends signals to the VIMS, which informs the operator if the hoist
screens are restricted.
06/08
2 4 3
1
5
162
Oil flows from the hoist pump through two ports (1) (only one visible in this view) to the hoist
control valve located inside the right frame next to the hoist cylinder. Two load check valves,
one for each pump port, are located below the two plugs (2). The load check valves remain
closed until the pump supply pressure is higher than the pressure in the hoist cylinders. The load
check valves prevent the body from dropping before the RAISE pressure increases.
The hoist system relief pressures are different in the RAISE and LOWER positions. The RAISE
relief valve (3) controls the pressure in the hoist system during RAISE. The LOWER relief
valve (4) controls the pressure in the hoist system during LOWER. The relief valve housing
must be removed to install shims (see Visual No. 164).
Oil flows through the drain port (5) to the hydraulic tank. When the hoist valve is in the HOLD,
FLOAT, or SNUB position, all the hoist pump oil flows through two ports (6), one on each side
of the hoist valve, to the two rear brake oil coolers located on the right side of the engine.
06/08
7 1 2 3
163
A counterbalance valve (1) is mounted on the left side of the hoist valve. The counterbalance
valve prevents cavitation of the cylinders when the body raises faster than the pumps can supply
oil to the cylinders (caused by a sudden shift of the load). The counterbalance valve signal
pressure can be checked at the test port (2) by removing the plug and installing a pressure tap.
The counterbalance signal pressure is equal to the RAISE pressure.
An oil cooler relief valve is located behind the large plug (3). The oil cooler relief valve limits
the rear brake oil cooling pressure when the hoist valve is in the HOLD, FLOAT, or SNUB
position. The setting of the oil cooler relief valve is 790 kPa (115 psi).
The hoist valve uses parking brake release pressure as the pilot oil to shift the directional spool
inside the hoist valve. The parking brake release pressure is 4700 ± 200 kPa (680 ± 30 psi).
Pilot pressure is always present at both ends of the directional spool. Two solenoid valves are
used to drain the pilot oil from the ends of the directional spool, which then allows the spool to
move. On the left is the RAISE solenoid valve (4), and on the right is the LOWER solenoid
valve (5).
The RAISE and LOWER solenoid valves are always receiving approximately 300 millivolts at a
frequency of 80 Hz when they are in any position except HOLD. The excitation, referred to as
"dither," is used to keep the solenoids in a ready state for quick response.
06/08
When the Transmission/Chassis ECM receives an input signal from the hoist lever sensor, the
Transmission/Chassis ECM sends an output signal current between 0 and 1.9 amps to one of the
solenoids. The amount of current sent to the solenoid determines the amount of pilot oil that
is drained from the end of the directional spool and, therefore, the distance that the directional
spool travels toward the solenoid.
Oil flows through two upper ports (6), one on each side of the hoist valve, to RAISE the
hoist cylinders. Oil flows through two lower ports (7), one on each side of the hoist valve, to
LOWER the hoist cylinders.
06/08
Lower
Solenoid
Parking Brake
"C" SERIES Release Pressure
HOIST CONTROL VALVE

HOLD
Rear Brake
Oil Cooler
To Tank
Relief Valve
To Hoist Cylinder
Load Check Head End
Valve
To Hoist Cylinder
Rod End
Low Pressure
Relief Valve
Counterbalance
High Pressure Valve
Relief Valve Rod End
Vent Slot
To Rear Brake Oil Coolers
Dual Stage Main Relief Pump

Relief Valve Dump Spool Supply Port
Signal Stem
Parking Brake
Release Pressure
Raise
Solenoid
164
Shown is a sectional view of the hoist valve in the HOLD position. Pilot oil pressure is directed
to both ends of the directional spool. The spool is held in the centered position by the centering
springs and the pilot oil. Passages in the directional spool vent the dual stage relief valve signal
stem to the tank. All the hoist pump oil flows through the rear brake oil coolers to the rear
brakes.
The position of the directional spool blocks the oil in the head end of the hoist cylinders. Oil in
the rod end of the hoist cylinders is connected to the rear brake cooling oil by a small vent slot
cut in the directional spool.
A gauge connected to the hoist system pressure taps while the hoist valve is in the HOLD
position will show the brake cooling system pressure, which is a result of the restriction in the
coolers, brakes, and hoses (normally much lower than the actual oil cooler relief valve setting).
The maximum pressure in the circuit should correspond to the setting of the rear brake oil
cooler relief valve. The setting of the oil cooler relief valve is 790 kPa (115 psi).
06/08
Lower
Solenoid
"C" SERIES Parking Brake

Release Pressure
HOIST CONTROL VALVE
RAISE
Rear Brake
Oil Cooler
To Tank
Relief Valve
To Hoist Cylinder
Load Check Head End
Valve
From Hoist Cylinder

Rod End
Low Pressure
Relief Valve
Counterbalance
High Pressure Valve
Vent Slot
To Rear Brake
Oil Coolers

Signal Stem
Parking Brake
Release Pressure
Raise
On
Solenoid
165
Shown is a sectional view of the hoist valve in the RAISE position. The RAISE solenoid
is energized and drains pilot oil pressure from the lower end of the directional spool. The
directional spool moves down. Pump oil flows past the directional spool to the head end of the
hoist cylinders.
When the directional spool is initially shifted, the two load check valves (one shown) remain
closed until the pump supply pressure is higher than the pressure in the hoist cylinders. The load
check valves prevent the body from dropping before the RAISE pressure increases.
The directional spool also sends hoist cylinder raise pressure to the dual stage relief valve signal
stem and the counterbalance valve. The dual stage relief valve signal stem moves down and
blocks the supply pressure from opening the low pressure relief valve.
06/08
The counterbalance valve is held open by the hoist cylinder raise pressure. Oil from the rod end
of the hoist cylinders flows freely to the rear brake oil coolers. If the body raises faster than the
pump can supply oil to the hoist cylinders (caused by a sudden shift of the load) and the raise
pressure drops below 2275 kPa (330 psi), the counterbalance valve starts to close and restricts
the flow of oil from the rod end of the hoist cylinders. Restricting the flow of oil from the rod
end of the hoist cylinders will slow down the cylinders and prevent cavitation. Cavitation in
the hoist cylinders can cause the body to drop suddenly when the hoist lever is moved from the
RAISE position to the LOWER position.
The pressure in the head end of the hoist cylinders cannot exceed:
785C/789C: 17225 + 700 - 0 kPa (2500 + 100 - 0 psi)

789C (with cast iron pump): 18960 ± 345 (2750 ± 50 psi)
The high pressure relief valve will open if the pressure increases above this specification. When
the high pressure relief valve opens, the dump spool moves to the left, and pump oil is directed
to the rear brake oil coolers.
The high pressure hoist relief valve setting is checked at the two pressure taps located on the
hoist pump. Check the relief pressures with the hoist lever in the RAISE position and the engine
at HIGH IDLE.
06/08
HOIST
COUNTERBALANCE
VALVE
Head End
Signal Pressure
To Tank From
Pump
From
Hoist Cylinder Rod End
Rod End Pressure To
Piston Hoist Cylinder
Rod End Check Valve
RAISE LOWER AND FLOAT
166
During RAISE, the counterbalance valve prevents the dump body from running ahead of the
hoist pumps if the load shifts rapidly to the rear of the body and attempts to pull the hoist
cylinders. Signal pressure from the head end of the hoist cylinders holds the counterbalance
valve open. Oil from the rod end of the hoist cylinders flows unrestricted through the
counterbalance valve to the tank. If the head end pressure decreases below 2270 kPa (330
psi), the counterbalance valve moves down and restricts the flow of oil from the rod end of the
cylinders to the tank.
If no head end signal pressure is present, rod end pressure can still open the counterbalance
valve. If the rod end pressure exceeds 6900 ± 690 kPa (1000 ± 100 psi) at the rod end pressure
piston, the valve will move up and allow rod end oil to flow from the cylinders to the tank.
During LOWER and FLOAT, the counterbalance valve allows unrestricted flow from the pump
through a check valve to the rod end of the hoist cylinders.
06/08
Lower
On
Solenoid
Parking Brake
HOIST CONTROL VALVE

LOWER (POWER DOWN)
Rear Brake
To Tank Oil Cooler
Relief Valve
From Hoist Cylinder
Load Check Head End
Valve
To Hoist Cylinder
Rod End
Low Pressure
Relief Valve
Counterbalance
High Pressure Valve
Vent Slot

Signal Stem
Parking Brake
Release Pressure
Raise
Solenoid
167
Shown is a sectional view of the hoist valve in the LOWER (power down) position. The
LOWER solenoid is energized and drains pilot oil pressure from the upper end of the directional
spool. The directional spool moves up.
Supply oil from the pump flows past the directional spool, through the counterbalance valve, to
the rod end of the hoist cylinders. Oil in the head end of the hoist cylinders flows to the tank.
The supply oil in the rod end of the cylinders and the weight of the body move the cylinders to
their retracted positions.
Just before the body contacts the frame, the body position sensor sends a signal to the
Transmission/Chassis ECM to move the valve spool to the SNUB position. In the SNUB
position, the valve spool moves slightly to restrict the flow of oil and lower the body gently.
The directional spool also vents the passage to the dual stage relief valve signal stem. The dual
stage relief valve signal stem allows supply pressure to be limited by the low pressure relief
valve.
06/08
If the pressure in the rod end of the hoist cylinders exceeds 3450 + 350 - 0 kPa
(500 + 50 - 0 psi), the low pressure relief valve will open. When the low pressure relief valve
opens, the dump spool moves to the left and pump oil flows to the rear brake oil coolers.
The low pressure hoist relief valve setting is checked at the two pressure taps located on the
hoist pump. Check the relief pressures with the hoist lever in the LOWER position and the
engine at HIGH IDLE.
When the body is in the DOWN position, the hoist valve will be in the SNUB position. The
body position sensor rod must be disconnected from the body, and the sensor must be rotated to
the RAISE position before the LOWER relief pressure can be tested.
06/08
Lower
On
Solenoid
Parking Brake
HOIST CONTROL VALVE

FLOAT
Rear Brake
To Tank Oil Cooler
Relief Valve
From Hoist Cylinder
Load Check Head End
Valve
To Hoist Cylinder
Rod End
Low Pressure
Relief Valve
Counterbalance
High Pressure Valve
Vent Slot

Signal Stem
Parking Brake
Release Pressure
Raise
Solenoid
168
Shown is a sectional view of the hoist valve in the FLOAT position. The LOWER solenoid is
partially energized and drains part of the pilot oil pressure above the directional spool to the
tank. The directional spool moves up. Because the pilot pressure is only partially drained, the
directional spool does not move as far up as during LOWER.
Pump supply oil flows past the directional spool, through the counterbalance valve, to the rod
end of the hoist cylinders. Oil in the head end of the hoist cylinders flows to the tank. The
directional valve is in a position that permits the pressure of the oil flowing to the rear brake oil
coolers to be felt at the rod end of the hoist cylinders.
body pads and not the hoist cylinders. The hoist valve will actually be in the SNUB position.
Just before the body contacts the frame, the body position sensor sends a signal to the
Transmission/Chassis ECM to move the valve spool to the SNUB position. In the SNUB
position, the valve spool moves slightly to restrict the flow of oil and lower the body gently.
06/08
169
Shown are the twin two-stage hoist cylinders used to raise and lower the body.
Check the condition of the body pads (arrow) for wear or damage.
To LOWER the body with a dead engine, hoist pilot pressure is required. The towing pump can
be used to provide the hoist pilot oil. To lower the body with a dead engine:
- Turn ON the key start switch so the towing motor and the hoist solenoids can be energized.
- Move the hoist lever to the RAISE position for 15 seconds, then to the FLOAT position.
- Depress the brake retraction switch on the dash (see Visual No. 48).
To RAISE the body with a dead engine, connect an Auxiliary Power Unit (APU) to the hoist
cylinders. Follow the same procedure used to lower the body with a dead engine, except keep
the hoist lever in RAISE after the 15 seconds interval.
NOTE: For more information on using the APU, refer to the Special Instructions "Using
1U5000 Auxiliary Power Unit (APU)" (Form SEHS8715) and "Using the 1U5525
Attachment Group" (Form SEHS8880).
06/08
Hoist Pump Hoist

Screens From Parking
Suction Brake Release Valve
Screens
HOIST SYSTEM
HOLD
To Hoist Cylinder To Hoist Cylinder

Rear Rod End Head End
Brakes
Rear Brake
Oil Coolers
170
The hoist system pumps pull oil from the hydraulic tank through suction screens.
Oil flows from the hoist pump through the hoist screens to the hoist control valve.
The hoist valve uses parking brake release pressure as pilot oil to shift the directional spool
inside the hoist valve. Two solenoid valves are used to drain the pilot oil from the ends of
the directional spool. The solenoid valve on the left is energized in the RAISE position. The
solenoid valve on the right is energized in the LOWER or FLOAT position.
When the hoist valve is in the HOLD or FLOAT position, all the hoist pump oil flows through
the rear brake oil coolers to the rear brakes.
An oil cooler relief valve is located in the hoist valve. The relief valve limits the rear brake oil
cooling pressure when the hoist valve is in the HOLD or FLOAT position.
Two hydraulic cylinders are used to raise the body away from the frame of the truck. When the
hoist lever is held in the RAISE position, supply oil flows to the head end of the hoist cylinders
and moves the two stage cylinders to their extended lengths. The oil from the rod end of the
cylinders flows through the hoist valve to the rear brake oil cooling circuit.
06/08
When the hoist lever is moved to the LOWER or FLOAT position and the cylinders are
extended, supply oil enters the rod end of the hoist cylinders and lowers the second stage of
the cylinders. The oil from the head end of the cylinders flows through the hoist valve to the
hydraulic tank.
06/08
AIR SYSTEM AND BRAKES
789C
171
AIR SYSTEM AND BRAKES
Two separate brake systems are used on the "C" Series trucks. The two brake systems are: the
parking/secondary brake system and the service/retarder brake system.
The parking/secondary brakes are spring engaged and hydraulically released. The service/
retarder brakes are engaged hydraulically by an air-over-oil brake system.
The "C" Series trucks are also equipped with an air system. An engine driven air compressor
supplies the air and fills two tanks. Air from the tanks provides energy to perform several
functions:
- Engine start-up
- Service and retarder brake control
- Secondary and parking brake control
- Automatic lubrication injection (grease)
- Horn, air seat, and cab clean-out
06/08
172
Shown is a cutaway illustration of an oil cooled brake assembly. The brakes are environmentally
sealed and adjustment free. Oil continually flows through the brake discs for cooling. Duo-
Cone seals prevent the cooling oil from leaking to the ground or transferring into the axle
housing. The wheel bearing adjustment must be maintained to keep the Duo-Cone seals from
leaking.
The smaller piston (yellow) is used to ENGAGE the secondary and parking brakes. The parking
brakes are spring ENGAGED and hydraulically RELEASED.
The larger piston (purple) is used to ENGAGE the retarder/service brakes. The retarder/service
brakes are engaged hydraulically by an air-over-oil brake system.
06/08
173
Air Charging System
The air system is charged by an air compressor mounted on the left front of the engine.
System pressure is controlled by the governor (arrow). The governor maintains the system
pressure between 660 and 830 kPa (95 and 120 psi).
The governor setting can be adjusted with a screw below the cover on top of the governor. Turn
the adjustment screw OUT to increase the pressure and IN to decrease the pressure.
The capacity of the air charging system has been increased. The air compressor has been
increased from a two-cylinder compressor to a four-cylinder compressor. To handle the
increased air flow, two larger air dryers are used, and the hoses and tubing have also been
increased in size.
To test the air compressor efficiency, lower the air system pressure to 480 kPa (70 psi). Start the
engine and raise the engine speed to HIGH IDLE. When the air system pressure reaches
585 kPa (85 psi), measure the time that it takes to build system pressure from 585 kPa (85 psi)
to 690 kPa (100 psi). The time to raise the pressure should be 50 seconds or less. If the time
recorded is greater than 50 seconds, check for leaks or a restriction in the system. If no leaks or
restrictions are found, the air compressor may have a problem.
06/08
174
On the 789C truck, air flows from the air compressor to two air dryers (1) located behind the left
front tire. The 785C has two air dryers located in front of the left front suspension cylinder.
The air system can be charged from a remote air supply through a ground level connector (2)
inside the left frame.
The air dryers remove contaminants and moisture from the air system. The condition of
the desiccant in the air dryers should be checked every 250 hours and changed periodically
(determined by the humidity of the local climate).
When the air compressor governor senses that system air pressure is at the cut-out pressure of
830 kPa (120 psi), the governor sends an air pressure signal to the purge valve in the bottom of
the dryers. The purge valve opens and air pressure that is trapped in the air dryers is exhausted
through the desiccant, an oil filter and the purge valve.
An air system relief valve is located on the air dryers to protect the system if the air compressor
governor malfunctions.
A heating element in the bottom of the dryers prevents moisture in the dryers from freezing in
cold weather.
06/08
175
Air flows through the air dryers and fills two tanks. The service/retarder brake tank (1) is
located on the right platform. This tank also supplies air for the air start system.
The second tank is located behind the cab and supplies air for the parking/secondary brake
system.
Condensation should be drained from the tank daily through the drain valve (2).
A relief valve located near the tank drain is installed in the service/retarder brake tank. This
relief valve protects the air system when the air dryers have exhausted and the ball check valves
in the air dryer outlet ports close. The check valves separate the air system from the air dryer
relief valves.
06/08
176
Located behind the operator’s station is a pressure protection valve (1). Supply air flows from
the large service/retarder brake tank, through the pressure protection valve, to the secondary air
system and accessories. The pressure protection valve opens at 550 kPa (80 psi) and closes at
482 kPa (70 psi). If the secondary air lines or an accessory circuit fails, the pressure protection
valve maintains a minimum of 482 kPa (70 psi) in the service/retarder brake circuit.
To test the pressure protection valve, drain the air pressure to approximately 345 kPa (50 psi).
Use the VIMS display to observe the brake air pressure. With the engine running at LOW IDLE,
press the horn button. Record the air pressure when the horn sounds. This pressure reading is
the open setting of the pressure protection valve. Slowly drain the air pressure and record the air
pressure when the horn turns off. This pressure reading is the setting of the pressure protection
valve when it closes.
The air system pressure sensor (2) provides an input signal to the Brake ECM. The Brake ECM
sends a signal to the VIMS, which informs the operator if a problem exists in the air system.
Also located behind the operator’s station are the service/retarder brake switch, the parking/
secondary brake switch and the brake light switch (see Visual No. 128).
06/08
177
The solenoid air valve (arrow) provides a controlled air supply for the automatic lubrication
(grease) system. The solenoid air valve is controlled by the VIMS. The VIMS ENERGIZES the
solenoid ten minutes after the machine is started. The VIMS keeps the solenoid ENERGIZED
for 75 seconds and then DE-ENERGIZES it. Every 60 minutes thereafter, the VIMS
ENERGIZES the solenoid for 75 seconds until the machine is stopped (turned off). These
settings are adjustable through the VIMS keypad in the cab.
06/08
178
Located behind the operator’s station is the parking/secondary brake air tank. A drain valve is
located on the right side of the cab. Moisture should be drained from the tank daily through the
drain valve (see Visual No. 33).
A check valve (arrow) prevents a loss of air if an air line breaks upstream of the air tank.
06/08
789C AIR CHARGING SYSTEM

Air Compressor
and Governor
Air
Dryers To Air Start
Solenoid
Remote
Supply
Service / Retarder
Brake Tank
Low Air
To Auto Lube Solenoid
Sensor
To Horn / Seat / Clean-out
Pressure
Protection
Valve
Parking / Secondary
Brake Tank
179
This schematic shows the flow of air through the 789C air charging system. Air flows from the
air compressor, through the two air dryers, to the service/retarder brake tank.
The 785C air charging system is the same as the 789C, but has only one air dryer.
Air from the service/retarder brake tank enters the pressure protection valve. When the pressure
in the service/retarder tank reaches 550 kPa (80 psi), the pressure protection valve allows air to
flow to the parking/secondary brake tank, the air start system, the automatic lubrication system,
and the accessory circuits (horn, air seat, and cab clean-out).
All tanks have a check valve at the air supply port to prevent a loss of air if a leak upstream of
the tank occurs.
06/08
180
Brake Systems
The manual retarder valve (arrow) is controlled by the retarder lever in the cab. Normally, the
retarder valve blocks air flow to the service brake relay valve near the brake master cylinders
and to the front brake oil cooler diverter valve.
When the retarder lever is pulled down, air flows to the service brake relay valve and the front
brake oil cooler diverter valve [maximum pressure is approximately 550 kPa (80 psi)]. The
retarder lever is used to modulate the service brake engagement by metering the amount of air
flow to the service brake relay valve.
The retarder engages the same brakes as the service brake pedal (see Visual No. 43), but is easier
to control for brake modulation.
The retarder system allows the machine to maintain a constant speed on long downgrades. The
retarder will not apply all of the normal braking capacity.
NOTICE
Do not use the retarder control as a parking brake or to stop the machine.
06/08
2
5
3
1 8 7 6
181
The service brake valve (1) is controlled by the brake pedal in the cab. Supply air for the service
brake valve, the manual retarder valve, and the Automatic Retarder Control (ARC) valve (2) is
supplied from the manifold (3).
When the service brakes are engaged, air flows from the service brake valve to the service
brake relay valve near the brake master cylinders and to the front brake oil cooler diverter valve
[maximum pressure is 825 kPa (120 psi)].
The service brake valve engages the same brakes as the retarder, but does not control brake
modulation as precisely as the retarder.
Air from the service brake valve and the manual retarder valve flows through the double check
valve (4) to the service brake relay valve and through the double check valve (5) to the front
brake oil cooler diverter valve. If the manual retarder and the service brakes are engaged at the
same time, air from the system with the highest pressure will flow through the double check
valves to the service brake relay valve and to the front brake oil cooler diverter valve.
Air from the manual retarder valve also flows through the double check valve (6) to the retarder
switch (7). The retarder switch turns on the amber retarder lamp on the dash in the operator’s
station when the manual retarder is ENGAGED (see Visual No. 47).
06/08
The function of the Automatic Retarder Control (ARC) system is to modulate truck braking
(retarding) when descending a long grade to maintain a constant engine speed.
When the ARC is engaged, air flows from the ARC valve to a separate ARC relay valve located
near the brake master cylinders. Air also flows from the ARC valve through the double check
valve (6), to the retarder switch (7), and through double check valve (5) to the front brake oil
cooler diverter valve.
The brake light switch and the service/retarder brake switch (see Visual No. 128) are located
in the supply line to the front brake oil cooler diverter valve (see Visual No. 102). The service
brake valve, the manual retarder valve, and the Automatic Retarder Control (ARC) valve send
air to these switches when engaged.
The secondary brake valve (8) is controlled by the red pedal in the cab (see Visual No. 43).
When the secondary brakes are engaged, air flows from the secondary brake valve to the signal
port of an inverter valve (see next visual). The inverter valve then blocks the flow of air from
the secondary brake tank to the brake release valve (see Visual No. 183).
Blocking the air from the brake release valve positions the spool in the brake release valve to
drain the oil from the parking brakes, which allows the springs in the parking brake to ENGAGE
the brakes. The secondary brake valve can be used to modulate parking brake engagement by
metering the amount of air flow to the brake release valve.
The parking brake air valve (see Visual No. 44) on the shift console in the cab also controls
the flow of air to the brake release valve, but the parking brake air valve does not modulate the
parking brake application.
The parking/secondary brake switch (see Visual No. 128) is located in the supply line to the
brake release valve. The secondary brake valve and the parking brake air valve send air to this
switch when engaged.
INSTRUCTOR NOTE: The ARC system will be discussed in more detail later in this
presentation.
06/08
182
When the secondary brakes are engaged, air flows from the secondary brake valve to the
signal port (1) of the inverter valve (2). The inverter valve then blocks the flow of air from the
secondary brake tank to the brake release valve.
Blocking the air from the brake release valve positions the spool in the brake release valve to
drain the oil from the parking brakes, which allows the springs in the parking brake to ENGAGE
the brakes.
06/08
2 1
5
4
3
183
Oil from the parking brake release pump (see Visual No. 98) flows through the parking brake
release filter (see Visual No. 101) to the brake release valve (1) located inside the left frame near
the torque converter. Oil flows from the parking brake release valve to the parking brake piston
in the brakes when the parking brakes are released.
Supply air from the parking brake air valve in the cab or the secondary brake valve flows
through the small hose (2) to an air chamber in the brake release valve. The brake release valve
contains an air piston that moves a spool. The spool either directs oil to RELEASE the parking
brakes or drains oil to ENGAGE the parking brakes. A relief valve (3) in the brake release valve
limits the system pressure for releasing the brakes. The setting of the relief valve is
4700 ± 200 kPa (680 ± 30 psi).
Supply oil flows from the brake release valve through an orifice and a screen (4) to the brake oil
makeup tank.
To release the parking brakes for service work or towing, the electric motor that turns the towing
pump (5) can be energized by the brake release switch located in the cab (see Visual No. 48).
The pump sends oil to the brake release valve to RELEASE the parking brakes. Towing pump
pressure is controlled by a relief valve in the towing pump.
06/08
TOWING SYSTEM
From Cab Secondary
Relief or Parking Brake Valve
Valve
To To Hoist
TC Lockup Pilot Parking Brake
Valve System Release Valve
Parking Parking
Brake Brake
Release Release
Pump Filter
Check
Valve
Towing Pump
and Motor
Towing Pump
Relief Valve
184
Normally, supply oil flows from the parking brake release pump, through the parking brake
release filter, to the parking brake release valve. If air pressure is present from the parking brake
air valve or the secondary brake valve, supply oil flows past the relief valve, the check valve,
and the spool to RELEASE the parking brakes. The relief valve limits the system pressure for
releasing the brakes, torque converter lockup, and for the pilot oil to shift the hoist valve. The
setting of the relief valve in the parking brake valve is 4700 ± 200 kPa (680 ± 30 psi).
This schematic shows the flow of oil through the parking brake release system when the towing
system is activated.
Oil flow from the parking brake release pump has stopped. The towing motor is energized, and
air pressure is present above the parking brake release valve piston. The air pressure moves the
spool in the parking brake release valve down to block the drain port.
Oil flows from the towing pump to the parking brake release valve and the parking brakes. The
check valve to the right of the parking brake release filter blocks the oil from the towing pump
from flowing to the parking brake release pump.
06/08
During towing, the parking brake release pressure is limited by a relief valve in the towing
pump. When the relief valve opens, oil transfers from the pressure side to the suction side of the
towing pump. The setting of the relief valve is approximately 4480 kPa (650 psi).
A check valve in the outlet port of the towing pump prevents oil from flowing to the towing
pump during normal operation.
To check the brake release system used for towing, connect a gauge to the parking brake release
pressure tap on the rear axle (see Visual No. 189). Use a long gauge hose so the gauge can be
held in the cab. With the parking brake air valve in the RELEASE position and the key start
switch in the ON position, energize the parking brake release switch used for towing (on the
dash). The parking brake release pressure should increase to 4480 kPa (650 psi). Turn off the
switch when the pressure stops increasing.
The parking brake release pressure must increase to a minimum of 3790 kPa (550 psi). The
parking brakes start to release between 3100 and 3445 kPa (450 and 500 psi). During towing,
the brake release switch on the dash must be energized whenever the parking brake release
pressure decreases below this level or the brakes will drag. The parking brakes are fully
released between 3445 and 3860 kPa (500 and 560 psi).
NOTE: A minimum of 550 kPa (80 psi) air pressure must be available at the parking
brake release valve to ensure full release of the brakes for towing.
NOTICE
Activate the brake release switch only when additional pressure is required to release the
brakes. Leaving the brake release (towing) motor energized continuously will drain the
batteries.
The parking brake release pressure setting must not exceed 5445 kPa (790 psi). Exceeding
this pressure can cause internal damage to the brake assembly.
06/08
PARKING / SECONDARY BRAKES

SECONDARY BRAKES RELEASED
PARKING BRAKES ENGAGED
Parking /
Secondary Parking
Brake Brake Parking
Parking Switch Release Brake
Brake Pump Release
Valve Valve
Inverter
Secondary Valve
Brake
Valve To TC Lockup Valve
and Hoist
Pilot System
Parking / Secondary
Brake Tank
185
Shown is the parking/secondary brake hydraulic and air system with the secondary brakes
RELEASED and the parking brakes ENGAGED.
Supply air from the parking/secondary brake air tank flows to the secondary brake valve and is
blocked from flowing to the inverter valve signal port. Supply air is allowed to flow through the
inverter valve and is blocked by the parking brake air valve.
No air pressure is present to move the spool in the parking brake release valve. Supply oil from
the parking brake release pump is blocked by the spool. Oil from the parking brake is open to
drain through the parking brake release valve, which allows the springs in the parking brake to
ENGAGE the brakes.
A parking/secondary brake switch is located in the air line between the parking brake valve
and the parking brake release valve. The switch provides an input signal to the Transmission/
Chassis ECM. When the parking or secondary brakes are ENGAGED, the switch signals the
Transmission/Chassis ECM to allow rapid downshifts.
06/08
5 2 1
4
3 3
186
The front service brake relay valve (1) receives metered air from only the service brake valve
or the manual retarder valve. The rear Automatic Retarder Control (ARC) brake relay valve (2)
receives metered air from only the ARC valve.
When the service brakes or manual retarder brakes are ENGAGED, the front relay valve opens
and metered air flows from the service brake tank, through the double check valves (3), to the
three brake cylinders (4). The brake relay valves reduce the time required to engage and release
the brakes. The double check valves (3) are used to separate the service and manual retarder
brakes from the ARC brake system.
When the ARC brake system is ENGAGED, the rear relay valve opens and metered air flows
from the service brake tank, through a pressure protection valve (5) and the double check valves
(3), to the three brake cylinders (4). The pressure protection valve prevents a total loss of air
pressure in the service brake air system if the ARC relay valve fails. The protection valve opens
to send flow to the ARC relay valve at 380 kPa (55 psi) and closes when the pressure decreases
below 310 kPa (45 psi).
The brake cylinders operate by air-over-oil. When the metered air enters the brake cylinders, a
piston moves down and pressurizes the oil in the bottom of the cylinders. One brake cylinder
supplies oil to the front brakes through the slack adjuster (6). Two brake cylinders supply oil to
the rear brakes through a separate slack adjuster.
06/08
2
3
187
As the brake discs in the brake assemblies wear, more oil is needed from the brake cylinders
to compensate for the wear. The brake makeup oil tank (1) supplies makeup oil for the brake
cylinders. Oil from the parking brake release valve flows through an orifice and the screen (2)
to provide a continuous supply of oil to the makeup tank. Low flow to the makeup tank can
cause the makeup oil reserve to decrease and cause the brake cylinders to overstroke.
To check for makeup oil flow, remove the cover from the makeup oil tank. With the engine at
HIGH IDLE, a stream of oil filling the tank should be visible. If a stream of oil is not visible,
the filter or hose to the tank may be restricted or pump flow may be low.
Keep the service brake ENGAGED for at least one minute. If air is in the system or a loss of
oil downstream from the cylinders occurs, the piston in the cylinder will overstroke and cause
an indicator rod to extend and open the brake overstroke switch (3). The switch provides an
input signal to the Brake ECM. The Brake ECM sends the signal to the VIMS, which informs
the operator of the condition of the service/retarder brake oil circuit. If an overstroke condition
occurs, the problem must be repaired and the indicator rod pushed in to end the warning.
Front brake oil pressure can be measured at the pressure tap (4) located on the front brake slack
adjuster.
06/08
The oil-to-air ratio of the brake cylinder is approximately 6.6 to 1. To test the brake cylinder,
install a gauge in the fitting on top of the brake cylinder and a gauge on the pressure tap on the
slack adjuster. When the service brakes are ENGAGED, if the air pressure in the brake cylinder
is 690 kPa (100 psi), the oil pressure measured at the slack adjuster should be approximately
4560 kPa (660 psi). When the brakes are RELEASED, both pressures should return to zero.
Inspect the condition of the breather (5) for the brake cylinders. Oil should not leak from
the breathers. Oil leaking from the breathers is an indication that the oil piston seals in the
brake cylinder need replacement. Air flow from the breathers during a brake application is an
indication that the brake cylinder air piston seals need replacement.
06/08
BRAKE CYLINDER
BRAKES ENGAGED
Air Indicator Rod From
Piston Makeup
Tank
Oil
Piston
Air To
Inlet Slack
Adjuster
Breather Valve
Port
Spring Rod
188
This visual shows a sectional view of the brake cylinder when the brakes are ENGAGED.
Air pressure from the brake relay valve enters the air inlet. The air pressure moves the air piston
and the attached rod closes the valve in the oil piston. When the valve in the oil piston is closed,
the oil piston pressurizes the oil in the cylinder. The pressure oil flows to the slack adjuster.
If air is in the system or a loss of oil downstream from the cylinders occurs, the piston in the
cylinder will overstroke, which causes the indicator rod to extend and open the brake overstroke
switch. If an overstroke condition occurs, the problem must be repaired and the indicator rod
pushed in to end the warning.
When the air pressure is removed from behind the air piston, the spring moves the air piston and
the attached rod opens the valve in the oil piston. Any makeup oil that is needed flows into the
passage at the top of the oil chamber, through the valve, and into the oil chamber at the right of
the oil piston.
06/08
3 2 3
189
The truck is equipped with two slack adjusters--one for the front brakes and one for the rear
brakes. The slack adjuster (1) shown is for the rear brakes. The slack adjusters compensate for
brake disc wear by allowing a small volume of oil to flow through the slack adjuster and remain
between the slack adjuster and the brake piston under low pressure. The slack adjusters maintain
a slight pressure on the brake piston at all times.
Brake cooling oil pressure maintains a small clearance between the brake discs.
The service brake oil pressure can be measured at the two taps (2) located on top of the slack
adjusters.
Air can be removed from the service brakes through two remote bleed valves (not shown)
mounted on the rear axle housing.
The parking brake release pressure can be measured at the two taps (3) on the axle housing.
NOTE: Air can be removed from the front service brakes through bleed valves located
on each wheel.
06/08
BRAKE SLACK ADJUSTER
Oil Flow Oil Flow

To Brake From Brake
Cylinder Cylinder
Small Piston Large Piston
From From To
Wheel Wheel Wheel
Brakes Brakes Brakes
To
Wheel
Brakes
BRAKES RELEASED BRAKES ENGAGED
190
This visual shows sectional views of the slack adjuster when the brakes are RELEASED and
ENGAGED.
When the brakes are ENGAGED, oil from the brake cylinders enters the slack adjusters and the
two large pistons move outward. Each large piston supplies oil to one wheel brake. The large
pistons pressurize the oil to the service brake pistons and ENGAGE the brakes.
Normally, the service brakes are FULLY ENGAGED before the large pistons in the slack
adjusters reach the end of their stroke. As the brake discs wear, the service brake piston will
travel farther to FULLY ENGAGE the brakes. When the service brake piston travels farther, the
large piston in the slack adjuster moves farther out and contacts the end cover. The pressure in
the slack adjuster increases until the small piston moves and allows makeup oil from the brake
cylinders to flow to the service brake piston.
When the brakes are RELEASED, the springs in the service brakes push the service brake
pistons away from the brake discs. The oil from the service brake pistons pushes the large
pistons in the slack adjuster to the center of the slack adjuster. Makeup oil that was used to
ENGAGE the brakes is replenished at the brake cylinders from the makeup tank.
06/08
The spring behind the large piston causes some oil pressure to be felt on the service brake piston
when the brakes are RELEASED. Keeping some pressure on the brake piston provides rapid
brake engagement with a minimum amount of brake cylinder piston travel.
The slack adjusters can be checked for correct operation by opening the service brake bleed
screw with the brakes RELEASED. A small amount of oil should flow from the bleed screw
when the screw is opened. The small flow of oil verifies that the spring behind the large piston
in the slack adjuster is maintaining some pressure on the service brake piston.
Another check to verify correct slack adjuster operation is to connect a gauge to the pressure tap
on top of the slack adjuster and another gauge at the service brake bleed screw location. With
system air pressure at maximum and the service brake pedal depressed, the pressure reading on
both gauges should be approximately the same.
When the brakes are RELEASED, the pressure at the slack adjuster should return to zero. The
pressure at the service brake bleed screw location should return to the residual pressure held on
the brakes by the slack adjuster piston.
The residual pressures at the service brake bleed screw location should be:
785C front: 103 kPa (14.9 psi) 785C rear: 59 kPa (8.6 psi)
789C front: 106 kPa (15.3 psi) 789C rear: 65 kPa (9.5 psi)
Low residual pressure may indicate a failed slack adjuster. High residual pressure may also
indicate a failed slack adjuster or warped brake discs. To check for warped brake discs, rotate
the wheel to see if the pressure fluctuates. If the pressure fluctuates while rotating the wheel, the
brake discs are probably warped and should be replaced.
To check for brake cooling oil leakage, block the brake cooling ports and pressurize each brake
assembly to a maximum of 138 kPa (20 psi). Close off the air supply source and observe the
pressure trapped in the brake assembly for five minutes. The trapped pressure should not
decrease.
06/08
SERVICE / RETARDER BRAKE AIR SYSTEM

SERVICE BRAKES ENGAGED
Front Brake Cooler

Service Diverter Valve
Brake Valve Service Pressure ARC
Relay Protection Relay
Valve Valve Valve
Brake
Light
and
Retarder Service /
Valve Retarder
Switch
ARC
Valve
Retarder
Switch Brake Cylinders
191
This schematic shows the flow of air through the service/retarder brake air system when the
retarder (manual and automatic) is RELEASED, and the service brakes are ENGAGED. Supply
air pressure flows from the large service brake air tank to the relay valves and the service brake
valve, manual retarder valve, and the ARC valve.
The manual retarder valve and the ARC solenoids block the flow of air. The service brake valve
allows air to flow to two double check valves that block the passages to the manual retarder and
ARC valves. Air pressure from the service brake valve flows through the double check valves to
the service brake relay valve and the front brake oil cooler diverter valve.
The service brake relay valve opens and metered air flows from the large service brake air tank
to the brake cylinders. The relay valves reduce the time required to engage and release the
brakes. A pair of double check valves above the brake cylinders prevent the flow of service
brake air to the ARC relay valve.
Air from the service brake valve also flows to the brake light switch and the service/retarder
brake switch. Depressing the service brake pedal turns ON the brake lights and changes the
transmission shift points and anti-hunt timer.
06/08
When the manual retarder lever is moved, air flows through three double check valves that
block the passages to the service brake valve and the ARC valve. Air pressure from the manual
retarder brake valve flows through the double check valves to the service brake relay valve and
the front brake oil cooler diverter valve.
Air from the manual retarder brake valve also flows to the retarder switch, the brake light
switch, and the service/retarder brake switch. Engaging the manual retarder turns ON the
retarder dash lamp, the brake lights, and changes the transmission shift points and anti-hunt
timer.
When the ARC is activated, air flows through two double check valves that block the passages
to the service brake valve and the manual retarder brake valve. Air pressure from the ARC
valve flows through the double check valves to the front brake oil cooler diverter valve.
When the ARC brake system is ENGAGED, the ARC relay valve opens and metered air flows
from the service brake tank, through a pressure protection valve and the double check valves,
to the three brake cylinders. The pressure protection valve prevents a total loss of air pressure
in the service brake air system if the ARC relay valve fails. The protection valve opens to send
flow to the ARC relay valve at 380 kPa (55 psi) and closes when the pressure decreases below
310 kPa (45 psi).
Air from the ARC valve also flows to the retarder switch, the brake light switch, and the service/
retarder brake switch. Engaging the ARC turns ON the retarder dash lamp, the brake lights, and
changes the transmission shift points and anti-hunt timer.
06/08
789C BRAKE
Hoist Pump
COOLING SYSTEM
Hoist
Rear Brakes
Screens
Front
Brakes
Hoist
Valve
Front Brake Outlet

Oil Cooler Relief Valve
Inlet Torque
Relief Valve Converter
Diverter Charging
Valve Filter
Rear Brake
Oil Coolers
Converter Parking
Parking Brake Outlet Brake
Release Valve Filter Filter
192
This schematic shows the flow of oil through the 789C brake cooling system. Three pump
sections provide oil for rear brake cooling: the two-sections of the hoist pump and the fourth
section of the torque converter pump. Two pump sections provide oil for front brake cooling:
the torque converter charging and the brake release sections of the torque converter pump. All
the pumps pull oil from the hydraulic tank through suction screens.
Oil flows from the hoist pump sections through two screens to the hoist valve. In the HOLD
and FLOAT positions, oil from the pump flows through the hoist valve to the rear brake cooling
system.
Oil flows from the fourth section of the torque converter pump, joins with the oil from the hoist
valve, and flows to the rear brake oil coolers.
Oil from all three pump sections combines and flows through the screens and rear brake oil
coolers located on the right side of the engine. The rear brake oil coolers are cooled by the
engine jacket water cooling system. From the coolers, oil flows through the brakes and returns
to the hydraulic tank.
06/08
The pressure in the rear brake cooling system is controlled by the oil cooler relief valve located
in the hoist valve. The relief valve setting is 790 kPa (115 psi).
Oil flows from the torque converter charging pump through the torque converter charging filter,
the torque converter, and the torque converter outlet screen to the front brake oil cooler diverter
valve.
Oil flows from the brake release pump through the brake release filter to the brake release valve.
The brake release valve controls the oil pressure to release the parking brakes, lock up the torque
converter and shift the directional spool in the hoist valve. These functions require minimal oil
flow. Most of the oil from the brake release pump flows through the brake release valve and
joins with the torque converter charging pump oil at the front brake oil cooler diverter valve.
When the service or retarder brakes are ENGAGED, the front brake oil cooler diverter valve
allows brake cooling oil to flow through the front brake oil cooler to the front brakes. When the
brakes are RELEASED, the oil bypasses the cooler and flows directly to the brakes. The front
brake oil cooler is cooled by the engine aftercooler cooling system. The aftercooler cooling
system does not have temperature regulators (thermostats) in the circuit.
Normally, front brake cooling oil is diverted around the cooler and goes directly to the front
brakes. Diverting oil around the cooler provides lower temperature aftercooler air during high
power demands (when climbing a grade with the brakes RELEASED, for example).
The brake cooling system on the 785C truck is slightly different from the 789C truck. The 785C
truck does not have a fourth section on the torque converter pump for rear brake cooling. The
parking brake release pump sends oil to the rear brake cooling system, not to the front brake
cooling system.
06/08
193
Shown is the left rear brake housing on a 789C truck. Brake cooling oil pressure can be tested
at the two taps (arrow) located in the brake cooling oil tubes. One tap is located on the brake
cooling inlet tube and another tap is located on the brake cooling outlet tube. The pressure
measured at the brake inlet tube (from the oil coolers) will always be higher than the pressure
measured at the brake outlet tube.
With the brake cooling oil temperature between 79 to 93°C (175 to 200°F), the pressure
measured at the brake inlet tube should be above 14 kPa (2 psi) at LOW IDLE and below
172 kPa (25 psi) at HIGH IDLE.
Four brake oil temperature sensors, one for each brake, are located in the brake oil cooling tubes.
The brake oil temperature sensors provide input signals to the VIMS, which keeps the operator
informed of the brake cooling oil temperature.
The most common cause of high brake cooling oil temperature is operating a truck in a gear that
is too high for the grade and not maintaining sufficient engine speed. Engine speed should be
kept at approximately 1900 rpm during long downhill hauls.
Also, make sure the pistons in the slack adjuster are not stuck and retaining too much pressure
on the brakes (see Visuals No. 189 and 190).
06/08
BRAKE ELECTRONIC CONTROL SYSTEM
INPUT COMPONENTS
Parking Brake Filter CAT DATA LINK
Service Tool
Brake Overstroke
Switch Engine ECM
Transmission/chassis ECM
Brake Air Pressure
Left Brake VIMS
Release Shift Lever Throttle Transmission Output
Pressure Switch Sensor Speed Sensor
Right Brake
Release Pressure Actual Gear Engine Service/retarder
Switch Speed/timing Brake Switch
Differential Sensor
Filter Parking / Secondary
Brake Switch
Differential Oil
Temp Sensor
Differential OUTPUT COMPONENTS
Pressure
Differential
Differential Fan Relay
Oil Level
ARC Engine Output ARC Supply ARC

On Input Speed Sensor Solenoid
ARC Control
Off Input Solenoid
Retarder
ARC On / Off Pressure Switch
Switch Retarder
Auto Retarder Engaged Lamp
Pressure Switch
TCS TCS TCS

TCS Test
Switch Engaged Lamp TCS Selector Solenoid
Left and Right
Left Wheel Speed Sensor
Proportional
Right Wheel Speed Sensor (Servo) Solenoid
194
BRAKE ELECTRONIC CONTROL SYSTEM
The "C" Series trucks use an additional Electronic Control Module (ECM) for controlling both
the Automatic Retarder Control (ARC) and the Traction Control System (TCS).
The Automatic Retarder Control (ARC) and the Traction Control System (TCS) control modules
are replaced with one Brake ECM. The Brake ECM controls both the ARC and the TCS
functions. The TCS is now on the CAT Data Link, and the Electronic Technician (ET) service
tool can be used to diagnose the TCS.
The Brake ECM receives information from various input components such as the Engine Output
Speed (EOS) sensor, retarder pressure switch, left and right wheel speed sensors, and the TCS
test switch.
Based on the input information, the Brake ECM determines whether the service/retarder brakes
should ENGAGE for the ARC or the parking/secondary brakes should ENGAGE for the TCS.
These actions are accomplished by sending signals to various output components.
06/08
Output components include the ARC supply and control solenoids, the retarder ENGAGED
lamp, the TCS selector and proportional solenoids, and the TCS ENGAGED lamp.
The Brake ECM also provides the service technician with enhanced diagnostic capabilities
through the use of onboard memory, which stores possible diagnostic codes for retrieval at the
time of service.
The Engine ECM, the Transmission/Chassis ECM, the Vital Information Management System
(VIMS), and the Brake ECM all communicate through the CAT Data Link. Communication
between the electronic controls allows the sensors of each system to be shared.
The Electronic Control Analyzer Programmer (ECAP) and the Electronic Technician (ET)
Service Tools can be used to perform several diagnostic and programming functions.
Some of the diagnostic and programming functions that the service tools can perform are:
- Display real time status of input and output parameters

- Display the internal clock hour reading
- Display the number of occurrences and the hour reading of the first and last occurrence for
each logged diagnostic code and event
- Display the definition for each logged diagnostic code and event
- Display the supply and control solenoid engagement counter
- Program the ARC control speed
- Perform ARC diagnostic tests
- Upload new Flash files
06/08
195
The Brake ECM (arrow) is located in the compartment at the rear of the cab. The Brake ECM
does not have a diagnostic window like the ARC and the TCS used on the "B" Series trucks.
All diagnostic and programming functions must be performed with an Electronic Control
Analyzer Programmer (ECAP) or a laptop computer with the Electronic Technician (ET)
software installed. ET is the tool of choice because the Brake ECM can be reprogrammed with a
"flash" file using the WinFlash application of ET. ECAP cannot upload "flash" files.
The Brake ECM looks like the Engine ECM with two 40-pin connectors, but the Brake
ECM does not have fittings for cooling fluid. Also, the Brake ECM has no access plate for a
personality module.
06/08
AUTOMATIC RETARDER CONTROL

Engine Speed Brake ECM
Sensor (ARC / TCS)
On Input
ARC On / Off
Switch
Off Input
Service Tool
Engine ECM CAT Data Link
Transmission /
Chassis ECM Retarder Supply
VIMS Engaged Solenoid
Air From Lamp
Service Brake Vent
Reservoir Vent
Control
Solenoid
Manual Automatic
Retarder Retarder
Service Valve Valve
Brake
Valve Auto Retarder
Pressure Switch
Retarder
To Service /
Pressure To ARC
Retarder Brake
Switch Relay Valve
Relay Valve
196
Automatic Retarder Control (ARC)
The Automatic Retarder Control (ARC) system function is to modulate truck braking (retarding)
when descending a long grade to maintain a constant engine speed. The ARC system engages
the service/retarder brakes. If the ON/OFF switch is moved to the ON position, the ARC
will be activated if the throttle pedal is not depressed and the parking/ secondary brakes are
RELEASED. The ARC system is disabled when the throttle is depressed or when the parking/
secondary brakes are ENGAGED.
The ARC is not connected to the service brakes and the manual retarder. When the ARC is
ENGAGED, air flows from the ARC valve to a separate relay valve located near the brake
master cylinders (see Visual No. 182).
The ARC is set at the factory to maintain a constant engine speed of 1900 ± 50 rpm (engine
speed setting is programmable). When the ARC initially takes control of retarding, the engine
speed may oscillate out of the ± 50 rpm target, but the engine speed should stabilize within a few
seconds.
06/08
For proper operation of the ARC, the operator needs only to activate the control with the ARC
ON/OFF switch and select the correct gear for the grade, load, and ground conditions. The ARC
is designed to allow the transmission to upshift to the gear selected by the shift lever. After the
transmission shifts to the gear selected by the operator and the engine speed exceeds 1900 rpm,
the ARC will apply the retarder as needed to maintain a constant engine speed.
The ARC system also provides engine overspeed protection. If an unsafe engine speed is
reached, the ARC will engage the brakes, even if the ARC ON/OFF switch is in the OFF
position and the throttle is depressed.
Trucks approaching an overspeed condition will sound a horn and activate a light at 2100 rpm.
If the operator ignores the light and horn, the ARC will engage the retarder at 2180 rpm. If the
engine speed continues to increase, the Transmission/Chassis ECM will either upshift (one gear
only above shift lever position) or unlock the torque converter (if the shift lever is in the top gear
position) at 2300 rpm.
The ARC also provides service personnel with enhanced diagnostic capabilities through the
use of onboard memory, which stores possible faults, solenoid cycle counts and other service
information for retrieval at the time of service.
By using an ECAP or a laptop computer with the Electronic Technician (ET) software installed,
service personnel can access the stored diagnostic information or set the adjustable engine speed
control setting.
The Auto Retarder Control receives signals from several switches and sensors. The control
analyzes the various input signals and sends signals to the output components. The output
components are two solenoids and a lamp.
NOTE: The ARC ON/OFF switch must be in the OFF position to run the ARC
diagnostic test with ET.
INSTRUCTOR NOTE: For more detailed information about the Automatic Retarder
Control (ARC) system, refer to the Service Manual Module "Off-Highway Truck/Tractors
Brake Electronic Control System" (Form SENR1503).
06/08
197
Shown is the location of the Engine Output Speed (EOS) sensor (1) that provides the primary
input signal used by the ARC. The engine speed information is the main parameter that the
Brake ECM uses to control retarding. The engine speed sensor is a frequency sensor that
generates an AC signal from the passing flywheel gear teeth.
The EOS sensor also provides an input signal to the Transmission/Chassis ECM for
Transmission Output Speed (TOS) ratification and lockup clutch shift time. The Transmission/
Chassis ECM uses the EOS signal and the Converter Output Speed (COS) signal to calculate
torque converter lockup clutch shift time. This information is then sent to VIMS. The EOS
signal is also used for TOS ratification. EOS is compared to the EOS calculated from the TOS
and the ratio for the current transmission gear. If the speeds do not agree, the transmission will
not downshift. If EOS is less than 1000 rpm the lockup clutch will release. If EOS exceeds
2300 rpm the lockup clutch will release. If EOS exceeds 2500 rpm the transmission will upshift
as many gears as necessary to keep engine speed less than 2500 rpm.
The engine speed/timing sensor (2) is also used by the ARC for diagnostic purposes. If the
Brake ECM receives an input signal from the engine speed/timing sensor, but not the EOS
sensor, the Brake ECM will log an engine speed fault. The ARC will not function without an
engine speed signal from EOS sensor (1).
06/08
NOTE: The 8T5200 Signal Generator/Counter Group can be connected to the engine
speed sensor wiring harness and be used to simulate engine speed for diagnostic
purposes. A 196-1900 adapter is required to increase the frequency potential from the
signal generator when connecting to the ECM's used on these trucks. To connect the
8T5201 Signal Generator to the engine speed sensor wiring harness, fabricate jumper
wires and connect the 8T5198 Adapter Cable (part of the 8T5200 Signal Generator/
Counter Group) to the speed sensor harness Deutsch DT connector.
8T5198 Adapter Deutsch DT Connector

Pin B J765 BU Pin 2 (ground)
Pin C 450 YL Pin 1 (signal)
06/08
3
2
5
1
198
Shown is the location of the retarder pressure switch (1). The retarder pressure switch signals
the Brake ECM when manual or automatic retarder air pressure is present. The switch is
normally open and closes when the manual or automatic retarder is engaged.
A fault is recorded when the Brake ECM detects the absence of retarder pressure (switch open)
while the supply solenoid and the control solenoid are energized.
The auto retarder pressure switch (2) signals the Brake ECM when air pressure is present and the
automatic retarder valve (3) is functioning. The auto retarder pressure switch is located in front
of the cab in the output port of the automatic retarder valve. The switch is normally closed and
opens only when the auto retarder is engaged.
A fault is recorded when the Brake ECM detects the presence of auto retarder pressure (switch
open) while the supply solenoid and the control solenoid are not energized.
The supply solenoid valve (4) turns ON or OFF to control the flow of supply air to the automatic
retarder valve (3). The Brake ECM energizes the supply solenoid valve with +Battery voltage
(24 Volts) at 100 rpm less than the programmed control speed setting. Normally, the reduced
speed will be 1800 rpm, since the control speed is set to 1900 rpm at the factory.
A fault is recorded if the Brake ECM senses the signal to the supply solenoid as open, shorted to
ground, or shorted to battery.
06/08
The control solenoid valve (5) modulates the air flow to the brakes during automatic retarding.
The control solenoid receives a Pulse Width Modulated (PWM) signal from the Brake ECM.
The longer the duty cycle, the more time the control solenoid valve is open, and more air
pressure is allowed to the brakes. Voltage to the control solenoid increases proportionally from
zero to approximately 22 Volts with the demand for more brake pressure.
A fault is recorded if the Brake ECM senses the signal to the control solenoid as open, shorted to
ground, or shorted to battery.
Normal resistance through the supply and control solenoids is 31 Ohms. An excess resistance of
approximately 40 Ohms will prevent the valves from opening and will cause a supply or control
valve fault to be logged. Therefore, a measurement of approximately 71 Ohms or more will
show that the solenoid is defective.
The Brake ECM can also determine if the solenoid valves have malfunctioned (valves leaking).
If air pressure is present at the auto retarder pressure switch when the solenoids are DE-
ENERGIZED, the auto retarder pressure switch will signal the Brake ECM that the ARC valve
has malfunctioned.
06/08
SERVICE / RETARDER BRAKE AIR SYSTEM

ARC ENGAGED
From Air
Compressor
Brake Light and Front Brake Cooler

Air Pressure Service / Diverter Valve
Sensor Retarder Switch
Service
Relay
Service Valve
Brake Valve
Retarder
Valve
Cooling
Diverter
Solenoid
From Secondary
Air Reservoir
Cab
Brake Cylinders
199
Hydraulic Automatic Retarder Control (ARC)
Signal air from the primary air tank flows to the service brake valve and the retarder valve. A
shuttle valve, after these valves, then sends the highest signal pressure to the service brake
relay valve. The service brake relay valve opens and actuates the brake cylinders with a greater
volume of air from the primary air tank.
An addition to the air system is the front brake cooling oil diverter solenoid. Air is supplied
to this valve from a smaller secondary air tank behind the cab. The Brake ECM energizes this
valve when the service brakes are applied. When the Brake ECM energizes this solenoid, signal
air is sent to the diverter valve for the front brake cooling oil. Brake cooling oil is then sent
through the cooler for front brake cooling oil.
06/08
HYDRAULIC ARC SYSTEM

ARC ENABLED
Service Service
Relay Valve Relay Valve
Rear Rear Brake
Brakes Oil Coolers
Brake Brake
Cylinders Cylinders
Front Brake Front
Oil Coolers Brakes
Shuttle
Valve Accumulator
Check
ARC Valve
Valve
Shuttle
Valve
Pump
Parking Brake Drive
Release Pump
Hoist Hydraulic
Tank
200
This schematic shows the flow of oil for the ARC system when ENABLED.
The parking brake release pump provides oil flow for the ARC system. The flow continues from
the pump, through a check valve to the ARC valve. The ARC valve modulates the amount of
pressure to the service brakes in order to control the ground speed of the truck.
The air over hydraulic brake cylinders also use the same service brakes. A shuttle valve between
the ARC system and brake cylinders separates these two systems. Whichever system has the
greatest pressure, that system will control the service brakes.
06/08
201
The hydraulic ARC valve (arrow) is located on the left frame rail near the rear differential. This
valve contains a supply solenoid valve and a control solenoid valve. A purge solenoid valve is
located on the bottom of the ARC valve. The ARC accumulator is located to the right of the
ARC valve.
NOTE: The hydraulic ARC valve performs the same functions as the previous air
controlled ARC valve. The hydraulic ARC valve use oil pressure instead of air pressure.
06/08
HYDRAULIC ARC VALVE

ENGINE ON / ARC OFF
Control
Solenoid
Valve
Spool
To Tank
Supply Solenoid Accumulator

Valve
Check Valve
Pump
Purge To
Solenoid Service
Valve Brakes
202
Supply oil from the parking brake release pump flows across a check valve. Oil flow then enters
the ARC valve. Hydraulic flow is stopped because the ARC spool is in the blocked position.
Hydraulic flow is then directed to the accumulator to charge the accumulator to the same
pressure as the parking brake release system pressure. Hydraulic flow is also routed through the
supply solenoid valve to apply pilot pressure to the left end of the ARC spool. This pressure will
keep the ARC spool in the blocked position.
06/08
HYDRAULIC ARC VALVE

ENGINE ON / ARC ON
Control
Solenoid
Valve ON
Spool
To Tank
Supply Solenoid Accumulator

Valve ON
Check Valve
Pump
Purge To
Solenoid Service
Valve Brakes
203
The Brake ECM supplies current to the supply solenoid. The supply solenoid valve sends pilot
oil to the right end of the ARC spool. This pilot oil shifts the ARC spool to the left opening the
left side of the ARC spool to tank. At the same time, pump supply oil is directed to the right side
of the ARC spool. Now, pump oil is directed to the control solenoid valve.
The Brake ECM will send varying levels of current to the control solenoid. This variable current
will modulate the spool within the proportional valve. The level of current is dependent on the
brake requirements for the ARC valve to maintain a constant breaking force.
When the control solenoid is energized, the pin moves to the right and pushes against the
ball. The ball blocks the pump supply oil from flowing to the drain. Pressure increases in the
chamber to the left of the spool to move the spool to the right.
When the spool moves to the right, pump supply oil flows to the service brakes. In order to
maintain the correct brake pressure, the Brake ECM will vary the current to the control solenoid
to open and close the oil drain port.
06/08
HYDRAULIC ARC VALVE

ENGINE OFF / ARC OFF
Control
Solenoid
Valve
Spool
To Tank
Supply Solenoid
Valve Accumulator
Check Valve
Pump
Purge To
Solenoid ON Service
Valve Brakes
204
No current is supplied from the Brake ECM to the supply solenoid. The supply solenoid valve
directs any pressurized oil acting on the ARC spool to flow to the tank. Current is supplied
from the Steering Bleed Control to the purge solenoid valve for approximately 70 seconds. This
allows the pressure within the accumulator to drain from the accumulator back to the tank.
06/08
Engine Speed AUTOMATIC RETARDER CONTROL

Sensor
ARC ENGAGED
On Input
ARC On / Off
Switch Brake ECM
(ARC / TCS)
Off Input
Retarder
CAT Data Link Engaged Lamp
Service Tool
Connector Front Brake
Cooling Diverter
Solenoid
Parking Brake
Release Pump
Service Brakes
ARC Spool
Supply
Purge
Steering Bleed Solenoid
Solenoid
Control
To Tank
ARC
Control Solenoid Valve
205
The introduction of the hydraulic ARC control valve has required a number of additional
component changes. The basic function of the new system remains the same as the previous
system. The Engine ECM, the Transmission/Chassis ECM, the Vital Information Management
System (VIMS), and the Brake ECM all communicate through the CAT DATA Link.
Communication between the electronic controls allows the sensors of each system to be shared.
06/08
206
The steering bleed down control (1) is located in the compartment behind the cab. While the
steering bleed control is not a new component, the control serves an additional function. The
steering bleed control is used to purge the ARC accumulator when the machine is shut down.
When the control receives a signal from the key start switch, a timer built into the control
will energize the purge solenoid for a period of approximately 70 seconds to purge the ARC
accumulator.
06/08
207
One of the new components, located in the compartment behind the cab, is the front brake
cooling diverter solenoid (arrow). When the ARC is engaged, the Brake ECM energizes this
solenoid to send an air signal to shift the brake cooling oil diverter valve. This will route the
brake cooling oil through the front brake oil cooler for increased cooling. Normally the brake
cooling oil is routed around the front brake oil cooler. This is a 24 V normally closed solenoid
valve.
06/08
208
Shown is the location of the Engine Output Speed (EOS) sensor that provides the primary input
signal used by the ARC. The EOS sensor is a passive (two wire) sensor and is located on top of
the flywheel housing. The engine speed information is the main parameter that the Brake ECM
uses to control retarding. The engine speed sensor is a frequency sensor that generates an AC
signal from the passing flywheel gear teeth.
The EOS sensor also provides an input signal to the Transmission/Chassis ECM for
Transmission Output Speed (TOS) ratification and lockup clutch shift time. The Transmission/
Chassis ECM uses the EOS signal and the Converter Output Speed (COS) signal to calculate
torque converter lockup clutch shift time. This information is then sent to VIMS. The EOS
signal is also used for TOS ratification. EOS is compared to the EOS calculated from the TOS
and the ratio for the current transmission gear. If the speeds do not agree, the transmission will
not downshift. If EOS is less than 1000 rpm the lockup clutch will release.
If EOS exceeds 2300 rpm the lockup clutch will release. If EOS exceeds 2500 rpm the
transmission will upshift as many gears as necessary to keep engine speed less than 2500 rpm.
ARC also uses the engine speed/timing sensor for diagnostic purposes. The engine/timing speed
sensor is located near the rear of the left camshaft. If the Brake ECM receives an input signal
from the engine speed/timing sensor, but not the EOS sensor, the Brake ECM will log an engine
speed fault. The ARC will not function without an engine speed signal from EOS sensor.
06/08
TRACTION CONTROL SYSTEM
Brake ECM
(ARC / TCS)
Electronic
Service Tool
Service / Retarder TCS

Brake Switch Engaged
Lamp
Transmission
Output Speed Sensor TCS Selector
CAT Data Link
Solenoid
Left and Righ
TCS Test
Switch
Proportional
Left Wheel
Speed Sensor Solenoid
Right Wheel + 10V to

Speed Sensor Wheel Sensors
209
Traction Control System (TCS)
The Traction Control System (TCS) uses the rear parking/secondary brakes (spring engaged and
hydraulically released) to decrease the revolutions of a spinning wheel. The TCS allows the
tire with better underfoot conditions to receive an increased amount of torque. The system is
controlled by the Brake ECM (see Visuals No. 194 and 195).
The Brake ECM monitors the drive wheels through three input signals: one at each drive axle,
and one at the transmission output shaft. When a spinning drive wheel is detected, the Brake
ECM sends a signal to the selector and proportional valves which ENGAGE the brake of the
affected wheel. When the condition has improved and the ratio between the right and left axles
returns to 1:1, the Brake ECM sends a signal to RELEASE the brake.
The TCS was formerly referred to as the Automatic Electronic Traction Aid (AETA). The
operation of the system has not changed. The main differences are the appearance of the
ECM, and the TCS is now on the CAT Data Link. Also, the ECAP and ET Service Tools can
communicate with the TCS.
06/08
A service/retarder brake switch (see Visual No. 128) provides an input signal to the TCS through
the CAT Data Link and performs two functions:
1. When the service brakes or retarder are ENGAGED, the TCS function is stopped.
2. The service/retarder brake switch provides the input signal needed to perform a diagnostic
test. When the TCS test switch and the retarder lever are ENGAGED simultaneously, the
TCS will engage each rear brake independently. Install two pressure gauges on the TCS
valve, and observe the pressure readings during the test cycle. The left brake pressure
will decrease and increase. After a short pause, the right brake pressure will decrease and
increase. The test will repeat as long as the TCS test switch and the retarder lever are
ENGAGED.
The TCS valve has a left and right brake release pressure sensor. A laptop computer with the
ET software installed can also be used to view the left and right parking brake pressures during
the test discussed above in function No. 2. When the proportional solenoid is ENERGIZED, ET
will show 44% when the brake is FULLY ENGAGED.
NOTE: During the diagnostic test, the parking/secondary brakes must be released.
INSTRUCTOR NOTE: For more detailed information about the Traction Control
System (TCS), refer to the Service Manual Module "Off-Highway Truck/Tractors Brake
Electronic Control System" (Form SENR1503).
06/08
210
Shown is the right rear wheel speed sensor (arrow). The TCS monitors the drive wheels through
three input speed signals: one at each drive axle, and one at the transmission output shaft.
The Transmission Output Speed (TOS) sensor (see Visual No. 127) monitors the ground speed
of the machine and provides input signals to the TCS through the CAT Data Link. The TCS uses
the TOS sensor to disable the TCS when ground speed is above 19.3 km/h (12 mph).
06/08
4
4
3
3
1 2
211
The Traction Control System (TCS) valve is mounted inside the rear of the left frame rail. Two
solenoids are mounted on the valve.
Electrical signals from the Brake ECM cause the selector solenoid valve (1) to shift and select
either the left or right parking brake. If the selector valve shifts to the left parking brake
hydraulic circuit, the control oil is drained. The left reducing spool of the control valve can then
shift and engage the parking brake.
The Brake ECM energizes the selector solenoid valve with + Battery voltage (24 Volts). Normal
resistance through the selector solenoid is between 18 and 45 Ohms.
The proportional solenoid valve (2) controls the volume of oil being drained from the selected
parking brake control circuit. The rate of flow is controlled by a signal from the Brake ECM.
The proportional solenoid receives a current between 100 and 680 mA (or 0 to 12 Volts) from
the Brake ECM. The more current that is sent, the more the proportional solenoid valve is open,
and more oil pressure is drained from the brakes. Normal resistance through the solenoid is
between 12 and 22 Ohms.
The pressure taps (3) or pressure sensors (4) can be used to check the left and right brake release
pressures when performing diagnostic tests on the TCS. The pressure at the taps in the TCS
valve will be slightly less than the brake release pressure measured at the wheels. The pressure
sensors are also used to provide parking brake dragging information to the operator.
06/08
TRACTION CONTROL SYSTEM (TCS)

ENGINE RUNNING/BRAKES RELEASED
Test
Switch
Service / Retarder
Brake Switch
Left
Drive Axle
Input
Ball Check
Signals
Transmission
Speed Sensor Output
Signals
Orifice
Screen Tcs Engaged

Lamp
Selector
Solenoid
Parking
Brake
Valve
Right
Drive Axle
Proportional
Solenoid
212
Shown is the TCS with the engine running and the brakes RELEASED.
When the machine is started:
- Oil flows from parking brake release pump through the brake release oil filter where the
flow is divided. One line from the filter directs oil to the parking brake release valve. The
other line sends oil to the signal port (right end of signal piston) of the TCS control valve.
- Oil flow to the TCS control valve signal port causes the ball check piston to move to the
left and unseat the drain ball check valve. Opening the drain ball check valve opens a drain
passage to the hydraulic tank.
06/08
When the operator releases the parking brakes:
- Air pressure is increased at the parking brake release valve forcing the valve spool down.
- Parking brake release oil can now flow through the parking brake release valve to the TCS
control valve.
- In the control valve, oil closes the parking/secondary ball check valve and flows through
the screen.
- Oil flows through the right and left brake control circuit orifices.
- Oil flows to the ends of the left and right brake reducing valve spools.
- When the control circuit pressure is high enough, the reducing spools shift toward the
center of the TCS control valve and parking brake release oil flows to release the brakes.
06/08
TRACTION CONTROL SYSTEM (TCS)

ENGINE RUNNING/LEFT BRAKE ENGAGED
Test
Switch
Service / Retarder
Brake Switch
Left
Drive Axle
Input
Ball Check Signals
Transmission
Speed Sensor Output
Signals
Orifice
Screen Tcs Engaged

Lamp
Selector
Solenoid
Parking
Brake
Valve
Right
Drive Axle
Proportional
Solenoid
213
Shown is the TCS with the engine running and the left brake ENGAGED. When signals from
the sensors indicate that the left wheel is spinning 60% faster than the right wheel, the following
sequence of events occurs:
- The Brake ECM sends a signal to the selector solenoid valve and the proportional solenoid
valve.
- The selector solenoid valve opens a passage between the outer end of the left brake
pressure reducing valve and the proportional solenoid valve.
- The proportional solenoid valve opens a passage from the selector solenoid valve to drain.
The proportional solenoid valve also controls the rate at which the oil is allowed to drain.
- Control circuit oil drains through the selector valve and enters the proportional valve.
The reducing valve spool for the left parking brake shifts and blocks the flow of oil to the
parking brake.
- Oil in the left parking brake control circuit begins to drain.
- The left parking brake begins to ENGAGE.
- The left brake orifice restricts the flow of oil from the parking brake release valve.
06/08
When the signals from the sensors indicate that the left wheel is no longer spinning, the
following sequence occurs:
- The Brake ECM stops sending signals to the selector solenoid and the proportional
solenoid.
- The selector solenoid valve and proportional solenoid valve block the passage to drain and
allow the control circuit pressure to increase.
- The left brake reducing valve spool shifts to the center position and blocks the passage to
drain.
- Parking brake release oil is directed to the left parking brake and the brake is RELEASED.
06/08
214
OPTIONAL EQUIPMENT
FlexxaireTM Fan
Shown is a 3516B Engine with a FlexxaireTM Fan installed. The FlexxaireTM fan provides full
control of air movement through the radiator with an automatically controlled, variable pitch
fan. The fan is designed to help control cooling requirements in specific applications such as
cold weather and high altitude. The thermostatic controller automatically adjusts the blade pitch
to maintain an optimum engine coolant temperature.
With zero-pitch start-up, the air dam effect prevents air flow through the radiator and the engine
reaches the recommended operating temperature more quickly. The pitch will vary throughout
the day based on the engine cooling temperature and air conditioning requirements. The
automatic blade pitch control reduces the horsepower loss when engine cooling is not required.
The 10 fan blades attach to the hub assembly (1). A coolant temperature sensor (2) and an air
conditioning pressure sensor (see Visual No. 62) provide input signals to an electronic control
box located behind the cab (see next page). The electronic control analyzes the input signals and
sends an electrical signal to the actuator (3). The actuator rotates and changes the fan pitch as
needed to increase or decrease the engine coolant temperature.
06/08
3 4
215
The FlexxaireTM Fan electronic control box (1) and the remote display (2) are located in the
compartment behind the operator's station. The control box is used to set up and calibrate the
Flexxaire™ fan. Remove the cover from the control box and follow the instructions on the label
inside the cover.
The FlexxaireTM control box provides many features. The customer must decide which features
he wants to use before setting up the system. Some of the features are:
Timed Auto-Purge, Purge Interval Override, Temperature Driven Auto-Purge: Off-

highway Trucks normally PULL air through the radiator. For a PURGE to occur, the fan
blades rotate and PUSH air through the radiator. Changing air flow direction can help
clear debris from the radiator.
Actuator Stall Detection: If the fan pitch actuator encounters excessive resistance
(bolt falls into the linkage), the control will sense the increased current and attempt an
automatic calibration. If the obstruction continues, as a safety measure, the control will
rotate the fan blades to full pitch.
Second Fluid Temperature Control: A second temperature sensor can be installed

to control the fan pitch in addition to the engine coolant temperature sensor (brake oil
temperature).
06/08
Blaze Blocker: A fire suppression system can provide an input signal to the control that
will rotate the fan blades to the NEUTRAL position. In the NEUTRAL position, the fan
provides no air flow. Limiting the air flow reduces the amount of oxygen to the fire, and
the fire suppressant is not blown from the engine compartment.
The following two FlexxaireTM Fan Controls must be set up properly:
Actuator Limits: This procedure sets the travel limits and the NEUTRAL position of
the actuator.
Temperature Set Point Calibration: This procedure sets the temperature range that the
controller will try to maintain by changing the fan pitch.
The remote display (2) can be used to change the air flow from PUSH to PULL by depressing
the air flow button (3). The nine LED bar display to the right of the air flow button indicates
the position of the fan. The bottom four LED's indicate the PULL direction. The center LED
indicates the NEUTRAL position. The top four LED's indicate the PUSH direction.
The purge button (4) will start the purge cycle if one has been programmed into the control
(optional).
INSTRUCTOR NOTE: More detailed information about the FlexxaireTM Fan System can
be found in the Service Manual module "FlexxaireTM Fan Installation And Maintenance
Manual" (Form SEBC1152).
06/08
216
785D LARGE OFF-HIGHWAY TRUCKS
The 785D Truck is an update to the 785C Large Off-Highway Truck. This presentation shows
what is new and different for the "D" series compared to the current production "C" Series truck.
Basically the engine is similar to the engine in the "C" Series. The "D" series truck has similar
power while equipped with a 3512C HD engine. Along with the engine replacement, the intake
manifold air is cooled with an Air To Air Aftercooler (ATAAC). The SCAC pump will now be
used as the auxiliary coolant pump which circulate coolant through the steering oil cooler and
the front brake oil cooler.
The "D" Series truck will use the folded core radiator which provides the convenience of
repairing or replacing smaller individual cores. The "D" model also is equipped with an ATAAC
on the both sides of the radiator. The machine components are very similar with the exception
of a diagonal ladder across the front of the radiator, an optional Power Assisted Ladder (PAL)
(not shown), and with a continuous RAXL filtration again similar to the 793D LOHT.
The load carrying capacity of the truck is between 118 to 136 Metric tons (130 to 150 tons). The
Gross Machine Weights (GMW) of the "D" Series trucks is approximately 249480 kg
(550000 lb.).
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217
3512C High Displacement Engine
Shown is the 3512C HD engine used in the 785D Large Off-highway Truck. This engine
replaces the production Caterpillar 3512B twin turbocharged and coolant aftercooled engine.
The new truck will use an ATAAC system to cool the intake manifold.
The controller for the 3512C HD engine will be the ADEM 3 with two seventy pin connectors.
This ECM replaces the ADEM 2 with two forty pin connectors that is used on the production
3512B.
These engines utilize the Electronic Unit Injection (EUI) system for power, reliability, and
economy with reduced sound levels and low emissions
The 3512C HD engines meet US Environmental Protection Agency (EPA) Tier II Emission
Regulations for North America and Stage IIa European Emission Regulations.
06/08
The 3512C HD engine has the following features.

- Electronic Speed Governing
- Cold Mode Strategy
- Altitude Compensation
- Variable Injection Timing
- Engine Monitoring and Protection
- Optional engine pre-lubrication
These features result in precise speed control, faster cold starting, reduced smoke (under all
operating conditions), and electronic engine protection.
The engine performance specifications for the 785D truck are:
- Serial No. Prefix: B7F
- Performance spec: 0K8508
- Max altitude: 4467 m (14000 ft.)
- Gross power: 1081 kW (1450 hp))
- Net power: 1005 kW (1348 hp)
- Full load rpm: 1750 rpm
- High idle rpm: 1937 rpm
- Stall speed rpm: 1672
06/08
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7 8 9 10 12 13
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Right Side Engine Components
The following is a list of the engine components located on the right side of the engine.
- Right side exhaust temperature sensor (1)
- Location for the turbo inlet pressure sensor (2)
- Regulator housing (3)
- Right side turbo oil lubrication supply (4)
- Fuel priming pump and fuel filter (5)
- Alternator (6)
- Crankcase pressure sensor (7)
- Engine oil cooler (8)
- Rear brake oil coolers (9)
- Fuel transfer pump (10)
- Engine coolant flow switch (11)
- Coolant S•O•S port (12)
- Primary coolant pump (13)
06/08
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7
6
9 10
8
13
11 12
14
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Engine Components Left Side
The following is a list of the components on the 3512C HD engine.

- Left side turbo inlet pressure sensor (1)
- Exhaust temperature sensor (2)
- Coolant temperature sensor (3)
- Left side turbo oil lubrication supply (4)
- Fuel filter differential switch (5)
- Air conditioning Compressor (6)
- Fuel filter base with fuel priming pump switch (7)
- Air compressor (8)
- Fuel filters (9)
- Speed/timing sensor (10)
- Auxiliary coolant pump (11)
- Engine oil filters (on the filter base there is a filtered and unfiltered pressure sensor) (12)
- Starter location (13)
- Engine oil level switch (14)
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4 5
7 8
220
Engine Components Front
The following is a list of the components on the 3512C HD engine front.

- Regulator housing (1)
- Engine ECM (2)
- Alternator (3)
- Intake manifold pressure sensor (boost) (4)
- Atmospheric pressure sensor (5)
- Air conditioning Compressor (6)
- Primary coolant pump (7)
- Air compressor (8)
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Engine Components Rear
The following is a list of the rear components on the 3512C HD engine.

- Intake manifold temperature sensor (1)
- Right side turbo lubrication connector (2)
- Engine speed sensor (3)
- Pump drive (4)
06/08
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222
Turbocharger Location
The following is a turbo list for the 3512C HD engine.

- Left front turbo (1)
- Right front turbo (2)
- Left rear turbo (3)
- Right rear turbo (4)
06/08
3512C HD ELECTRONIC CONTROL SYSTEM DIAGRAM

Engine ECM
CAT Data Link
INPUTS
Timing Calibration
Connector
Throttle Position Sensor Key Start Switch

OUTPUTS
Engine Coolant Temperature Speed / Timing Sensor

Electronic Unit
Intake Air Temperature Injectors (12)
Throttle Backup Switch
Engine Oil Pressure (Filtered)

Manual Ether Switch
Engine Oil Pressure (Unfiltered)
Ether Aid Relay
User Defined Shut down
Atmospheric Pressure
Turbo Outlet Pressure (Boost) St art Aid Hold Relay

Ground Level
Rear Aftercooler Temperature Shutdown Switch
Engine Oil
Right Turbo Inlet Pressure Renewal Solenoid
Oil Level
Switch (Low) Pre-lubrication Relay
Left Turbo Inlet Pressure
Coolant Flow
Crankcase Pressure Switch Wast egat e Solenoid
Fuel Filter
Right Turbo Exhaust Bypass Switch
Left Turbo Exhaust
223
Engine Electronic Control Module Diagram
The above illustration shows the inputs to and the output from the electronic control system for
the 3512C High Displacement (HD) engine. Fuel injection through the Electronic Unit Injectors
(EUI) is controlled by the Engine ECM. The Engine ECM in the 785D truck is the ADEM
III. The input signals to the Engine ECM are normally through switches, and sensors. The
sensor inputs are both analog and Pulse Width Modulation (PWM). The switch inputs are either
pressure, flow, level, and contact type.
When the injector solenoids are energized determines the timing of the engine. How long the
solenoids are energized determines the engine speed.
The 785D (MSY) truck engines are designed to meet the US Environmental Protection Agency
(EPA) Tier II emissions regulations for engines over 1082 gross kW (1450 gross hp). To
meet this regulation the 785D (MSY) truck engine will use a new Emission Software. When
installing the new Emission Software "flash" files in an Engine ECM, ET can use the American
Trucking Association (ATA) Data Link or the CAT Data Link. The ATA and CAT Data Links
consist of a pair of twisted wires that connect to the Engine ECM and the diagnostic connector
in the cab. The wires are twisted to reduce electrical interference from unwanted sources such as
radio transmissions.
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Engine ECM and Atmospheric Pressure Sensor
The illustration above shows the location of the Engine ECM (1) and the atmospheric pressure
sensor (2).
The Engine ECM is an ADEM III module and is equipped with two 70 pin connectors. On the
ADEM III ECM, J1 is callout (4) and J2 is callout (3).
The Engine ECM (1) is mounted on the front of the engine on the right side of the machine. The
engine ECM is accessed from below the machine.
The Engine ECM makes decisions based on control program information in memory, switch
inputs, analog input signals, and sensor input signals.
The Engine ECM responds to machine control decisions by sending a signal voltage to the
appropriate circuit which creates an action. For example, as the operator depresses the throttle
pedal, the Engine ECM interprets the input signal from the throttle pedal position sensor,
evaluates the engine status, and sends a signal to the injectors to increase fuel.
The Engine ECM receives three different types of input signals:

- Switch input: Provides the signal line to battery, ground, or open.
- PWM input: Provides the signal line with a square wave of a specific frequency and a
varying positive duty cycle.
- Speed signal: Provides the signal line with either a repeating, fixed voltage level pattern
signal or a sine wave of varying level and frequency.
06/08
The Engine ECM has three types of output drivers:

- ON/OFF driver: Provides the output device with a signal level of +Battery voltage (ON)
or less than one Volt (OFF).
- PWM solenoid driver: Provides the output device with a square wave of fixed frequency
and a varying positive duty cycle.
- Controlled current output driver: The ECM will energize the solenoid with 1.25 amps
for approximately one half second and then decrease the level to 0.8 amps for the duration
of the on time. The initial higher amperage gives the actuator rapid response and the
decreased level is sufficient to hold the solenoid in the correct position. An added benefit
is an increase in the life of the solenoid.
The Engine ECM receives signals from the speed timing sensors, oil level switch, coolant flow
switch, exhaust temperature sensors, coolant temperatures sensors, engine pressure sensors,
and the current engine operating status. The Engine ECM interprets signals and determines the
appropriate output signals to the engine. Different conditions of the inputs affect the output
conditions.
The Engine ECM communicates through the CAT Data Link. The CAT Data Link allows high
speed proprietary serial communications over a twisted pair of wires. The CAT Data Link
allows different systems on the machine to communicate with each other and also with service
tools such as Caterpillar Electronic Technician (ET).
The Engine ECM has built-in diagnostic capabilities. As the Engine ECM detects a fault
condition developed by the engine, the ECM logs the faults in memory and displays them on the
VIMS. The fault codes can also be accessed using the ET service tool.
NOTE: Engine ECM faults displayed on the VIMS relating to the Engine ECM
will have a Module Identifier (MID) of "36." For more information, refer to the Service
Manual module "Engine, Systems Operation Testing and Adjusting"
06/08
The following is a list of Diagnostic Codes for the Engine ECM
- MID 036 - CID 0168 - FMI 01 - System voltage - data below normal range
- MID 036 - CID 0168 - FMI 02 - System voltage - incorrect signal
- MID 036 - CID 0253 - FMI 11 - Personality Module - mechanical failure
- MID 036 - CID 0261 - FMI 13 - Engine timing - out of calibration
- MID 036 - CID 0262 - FMI 03 - 5 Volt DC supply - short/open to + Batt
- MID 036 - CID 0262 - FMI 04 - 5 Volt DC supply - short to ground
- MID 036 - CID 0263 - FMI 03 - Digital sensor voltage - short/open to + Batt
- MID 036 - CID 0263 - FMI 04 - Digital sensor voltage - short to ground
- MID 036 - CID 0267 - FMI 02 - Incorrect engine shutdown switch input - incorrect signal
- MID 036 - CID 0268 - FMI 02- Check programmable parameters - incorrect signal
- MID 036 - CID 0800 - FMI 09- Unable to communicate with VIMS - abnormal update
Atmospheric Pressure Sensor

The atmospheric pressure sensor is located behind the Engine ECM on the right front of the
engine. The Engine ECM uses the atmospheric sensor as a reference when calibrating the
pressure sensors. The sensor receives a regulated 5.0 ± 0.5 Volts from the ECM. The sensor
output is a DC signal that varies between 0.3 and 4.8 VDC with an operating pressure between
0 and 111 kPA (0 and 15.7 psi). When troubleshooting an analog sensor, connect a multimeter
between pin B and Pin C of the sensor connector. Set the meter to read "DC Volts." The DC
Voltage should read between 0.2 and 4.8 VDC.
Also, the Engine ECM uses the atmospheric pressure sensor to derate the fuel delivery at a high
elevations (altitudes). At 14,000 feet, the atmospheric pressure data that is sent to the Engine
ECM will initiate a derate 1%. The fuel delivery will be derated 1% per 1 kPa up to 20% derate.
If the Engine ECM detects a fault for the atmospheric pressure sensor, the fuel delivery will
be derated to 20%. If the Engine ECM detects an atmospheric sensor and a turbocharger inlet
pressure sensor fault at the same time, fuel delivery will be derated to 40%.
The following is a list of Diagnostic Codes for the atmospheric pressure sensor.
- MID 036 - CID 0274 - FMI 03 - Atmospheric Pressure Sensor - Short/open to + Batt
- MID 036 - CID 0274 - FMI 04 - Atmospheric Pressure Sensor - Short to Ground
- MID 036 - CID 0274 - FMI 13 - Atmospheric Pressure Sensor - out of calibration
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225
Shown is the top of a cylinder head with the valve cover removed. The most critical output
from the Engine ECM is the signal to the Electronic Unit Injection (EUI) solenoid (arrow). One
injector is located in each cylinder head. The Engine ECM analyzes all the inputs and sends a
signal to the injector solenoid to control engine timing and speed.
Engine timing is determined by controlling the start time that the injector solenoid is energized.
Engine speed is determined by controlling the duration that the injector solenoid is energized.
3500 injectors are calibrated during manufacturing for precise injection timing and fuel
discharge. After the manufacturer's calibration, a four-digit "E-trim" code number is etched on
the injector tappet surface. This E-trim code identifies the injector’s performance range. Load
the code etched on the injector to the personality module (software) of the Engine ECM using
the ET service tool. The software uses the trim code to compensate for the manufacturing
variations in the injectors and allows each injector to perform as a nominal injector.
When an injector is serviced, the new injector’s trim code should be programmed into the
Engine ECM. If the new trim code is not entered, the previous injector’s characteristics is used.
The engine will not be harmed if the new code is not entered, but the engine will not provide
peak performance. On the following page there is a list of the diagnostic codes for each injector
solenoid.
NOTE: No. 1 injector is located on the front right side of the engine and No. 2 injector
is located on the front left side of the engine. The odd number injectors is on the right
side and the even number injectors is on the left side.
06/08
The following is a list of the injector Diagnostic Codes in the 3512C HD Engine.
- MID 0036 - CID 0001 - FMI 05 Cylinder #1 Injector coil - open circuit
- MID 0036 - CID 0001 - FMI 06 Cylinder #1 Injector coil - short circuit
- CID 0036 - CID 0002 - FMI 06 Cylinder #2 Injector coil - short circuit
- MID 036 - CID 1495 - FMI 02- Injector codes not programmed - incorrect signal
06/08
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Primary Speed/Timing Sensor
The primary speed timing sensor (arrow) is located near the rear of the engine on the left
side. The sensor is mounted in the housing for the camshaft gear. The sensor sends the speed,
direction, and the position of the camshaft data to the Engine ECM by counting the passing teeth
and measuring the gaps between the teeth on the timing wheel that is mounted on the camshaft.
The primary speed timing sensor receives has a 12 VDC input from the Engine ECM.
If the Engine ECM does not receive an input signal from the sensor, the engine will not start.
The following is a list of the Diagnostic Codes for the speed/timing sensor:
- MID 036 - CID 0190 - FMI 02 - Loss of engine Speed Signal
- MID 036 - CID 0274 - FMI 03 - Engine Speed - Short to + Battery
- MID 036 - CID 0274 - FMI 08 - Engine Speed - Signal abnormal
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Engine Speed Sensor
A passive (two wire) engine speed sensor (arrow) is positioned on top of the flywheel housing.
The passive speed sensor uses the passing teeth of the flywheel to provide a frequency output.
The passive speed sensor sends the engine speed signal to the Transmission ECM and the Brake
ECM. The signal from the passive speed sensor is used for the Automatic Retarder Control
(ARC) engine control speed, shift time calculations, and transmission output speed (TOS)
calculations.
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Coolant Temperature Sensor
The coolant temperature sensor (1) is located in the thermostat (regulator) housing (2) on the
left side of the engine. The sensor sends the temperature data to the Engine ECM. Then, the
ECM sends the temperature data to the VIMS module which relays the information to the VIMS
message center.
The Engine ECM uses the coolant temperature sensor information for cold mode functions such
as timing changes, elevated idle, cold cylinder cut-out, ether injection, and others.
The following is a list of the Diagnostic Codes for the coolant temperature sensor:
- MID 036 - CID 0110 - FMI 03 - Engine coolant temperature sensor - open/short to +bat
- MID 036 - CID 0110 - FMI 04 - Engine coolant temperature sensor - short to ground
If the coolant temperature increases above 107° C (226° F), the Engine ECM will log an event
that requires a factory password to clear.
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Coolant Flow Switch
Coolant flows from the jacket water pump, past the coolant flow warning switch (1), and
through the various system oil coolers (engine oil, torque converter/transmission, and rear
brake).
The coolant flow switch sends an input signal to the Engine ECM. The Engine ECM sends the
signal to the VIMS, which in turn informs the operator of the coolant flow status.
If the ECM detects a low coolant flow condition, a low coolant flow event will be logged. A
Also shown is the coolant S•O•S port (2).

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230
Crankcase Pressure Sensor
The crankcase pressure sensor (arrow) is located on the right side of the engine above the engine
oil cooler. The crankcase pressure sensor provides an input signal to the Engine ECM. The
ECM provides the signal to the VIMS, which informs the operator of the crankcase pressure.
High crankcase pressure may be caused by worn piston rings or cylinder liners.
If crankcase pressure exceeds 3.6 kPa (.5 psi) or 14.4 inches of water, a high crankcase pressure
event will be logged. No factory password is required to clear this event.
The following is a list of the Diagnostic Codes for the crankcase pressure sensor:
- MID 036 - CID 0110 - FMI 03 - Engine coolant temperature sensor - open/short to +bat
- MID 036 - CID 0110 - FMI 04 - Engine coolant temperature sensor - short to ground
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232
Turbo Inlet Pressure Sensors (Taken on the truck)
The following is a list of the Diagnostic Codes for the left turbo inlet pressure sensor:
- MID 036 - CID 0276 - FMI 03 - Left turbo inlet pressure sensor - open/short to +bat
- MID 036 - CID 0276 - FMI 04 - Left turbo inlet pressure sensor - short to ground
The following is a list of the Diagnostic Codes for the right turbo inlet pressure sensor:
- MID 036 - CID 0275 - FMI 03 - Right turbo inlet pressure sensor - open/short to +bat
- MID 036 - CID 0275 - FMI 04 - Right turbo inlet pressure sensor - short to ground
06/08
The 3512C Engine ECM logs several data events that could cause damage to the engine. Some
of the events require factory passwords to clear from the ECM memory. The events logged by
the Engine ECM, their maximum derate, and their trip points are listed below:
Air filter restriction: Greater than 6.25 kPa (25 in. of water). Maximum derate of 20%. Factory
password required.
06/08
233
Intake Manifold Air Temperature Sensor
The intake manifold temperature sensor is located at the rear of the engine in the intake
manifold. This sensor is a intake manifold air temperature to the Engine ECM.
The following are the Diagnostic Codes for the intake manifold air temperature sensor.
- MID 36 - CID 0179 - FMI 03 Intake manifold temperature sensor - open/short to +batt
- MID 36 - CID 0179 - FMI 04 Intake manifold temperature sensor - short to ground
An E279 event will initiate and log a Level 2 derate if the intake manifold air temperature is
above 107° C (224° F).
Intake manifold air temperature can be high for the following reasons:
- High ambient air temperature
- High inlet air restriction and/or high altitude
- Restriction in the exhaust system
- Faulty inlet air temperature sensor and/or circuit
- Faulty ATAAC
- Faulty fan
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Intake Manifold Pressure Sensor (Boost)
The intake manifold pressure sensor (arrow) is located in the Y-pipe monitoring the air pressure
from the ATAAC. Shown is the turbocharger outlet pressure sensor. The turbocharger outlet
pressure sensor sends an input signal to the Engine ECM. The Engine ECM compares the
value of the turbo outlet pressure sensor with the value of the atmospheric pressure sensor and
calculates boost pressure.
The best way to check for a power problem is to compare the truck performance with the rimpull
charts in the performance handbook (SEBD0340). The truck should be able to climb a grade in
the same gear as specified in this publication.
If an engine power problem is suspected, check boost pressure at full load rpm. If boost pressure
is correct at full load rpm, the engine is not the problem and other systems such as the torque
converter should be checked.
To check boost pressure at full load rpm, the truck must be operated in FIRST GEAR with the
throttle at MAXIMUM and the retarder gradually engaged. Traveling up a grade is best as long
as the engine rpm does not fall below the full load rpm specification during the test. Gradually
engage the retarder until the full load rpm is displayed. When the full load rpm is displayed,
record the boost pressure. If boost pressure is within the specifications at full load rpm, the
engine is operating correctly.
06/08
Use ET or the VIMS display panel to view the engine rpm and boost pressure. The boost and
full load rpm specifications are:
Engines with no series turbochargers or wastegate:

- Boost Pressure: Approximately 178 kPa (25 psi)
- Full load rpm: Approximately 1672 rpm
Generally, Torque Converter (TC) stall speed (in gear, full throttle, zero ground speed) is used to
determine if the engine power is low or a torque converter problem exists. For example, if the
engine power is within specification and the stall speed is high, the torque converter may have a
problem (low internal oil pressure, poor internal tolerances, or damaged components).
Since the torque converter stall rpm is very close to the full load rpm, the boost pressure at
torque converter stall will be very close to the full load boost specifications.
- Torque Converter Stall rpm: approximately 1672 rpm
The following are the Diagnostic Codes for the intake manifold pressure sensor.
- MID 36 - CID 0273 - FMI 03 Intake manifold temperature sensor - open/short to +batt
- MID 36 - CID 0273 - FMI 04 Intake manifold temperature sensor - short to ground
Below is a list of possible causes for boost pressure below normal.

- Fuel supply (Possible restriction and/or air in fuel supply)
- Injector solenoid (Active codes)
- Engine speed/timing signal (Ensure no 190 - 08 Diagnostic Code)
- Active engine derate (Check for other active engine derate)
- Intermittent sensor problem (Check for logged codes)
- Air Inlet Restrictions (Check for restrictions)
- ATAAC system air leak(s) (Check for leaks)
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Left And Right Side Exhaust Temperature Sensors
The exhaust temperature sensors are located in the exhaust manifold that is attached to the
inlet of the turbine section of the turbo. The sensors monitor the exhaust temperature and send
the results to the Engine ECM. This sensor sends data to the Engine ECM with a Pulse Width
Modulated (PWM) signal.
The following is a list of the Diagnostic Codes for the Exhaust Temperature Sensors.
- MID 0036 - CID 0827 - FMI 08 Left Exhaust Temperature Sensor - signal abnormal
- MID 0036 - CID 0828 - FMI 08 Right Exhaust Temperature Sensor - signal abnormal
06/08
An E021 event will initiate and log a Level 2 Derate if the exhaust temperature is above
750° C (1382° F) for five seconds. The Engine ECM will derate the fuel delivery 2% for every
15 second interval with a maximum derate of 20%.
- Left side exhaust temperature sensor (1)
- Right side exhaust temperature sensor (2)
Probable Causes
-Air inlet and exhaust system (Air inlet restrictions, exhaust restrictions, and any leaks in the
ATAAC tubing)
- Fuel injectors (Excessive amount of fuel is dispersed by the injectors)
- Aftercooler (Blocked air flow through the ATAAC)
- Accessory equipment (parasitic loads on the engine through either the flywheel and/or the
damper)
06/08
237
Fuel Filter Differential Switch
The fuel filter differential switch (1) is located in the housing for the secondary fuel
filters (2). This switch monitors the restriction of fuel through the filters and fuel system. When
the pressure differential is approximately 148.9 kPa (21.5 psi) for 30 seconds the switch opens,
the Engine ECM will see the fuel restriction trip point and an E095 Event will be logged. Then,
a Level 1 Warning will be initiated.
No factory password is required after the fuel restriction is repaired and the differential fuel
pressure in the system is below the de-actuation pressure of 69 kPa (10 psi).
Probable Causes
- Plugged fuel filters
06/08
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2 3
Filtered And Unfiltered Engine Oil Pressure Sensors
Oil flows from the engine oil cooler to the oil filters on the left side of the engine. The oil flows
through the filters and enters the engine cylinder block to clean, cool, and lubricate the internal
components and the turbochargers.
The engine has two oil pressure sensors. One sensor is located on each end of the oil filter base.
The front sensor (2) measures engine oil pressure before the filters. This sensor is located above
the fast fill adapter (3). The rear sensor (1) measures oil pressure after the filters. The sensors
send input signals to the Engine ECM. The ECM provides the input signal to the VIMS, which
informs the operator of the engine oil pressure. Used together, the two engine oil pressure
sensors inform the operator if the engine oil filters are restricted.
06/08
The following is a list of the Diagnostic Codes for the engine oil pressure Sensor (unfiltered).
- MID 0036 - CID 0542 - FMI 03 Unfiltered oil pressure Sensor - open/short to + batt
- MID 0036 - CID 0542 - FMI 04 Unfiltered oil pressure Sensor - short to ground
The following is a list of the Diagnostic Codes for the engine oil pressure Sensors (filtered).
- MID 0036 - CID 0543 - FMI 03 Filtered oil pressure Sensor- open/short to + batt
- MID 0036 - CID 0543 - FMI 04 Filtered oil pressure Sensor - short to ground
An E073 event will initiate when the pressure differential between the filtered and unfiltered
pressure is equal or greater than 69 kPa (10 psi). No factory password is required to clear the
event.
An E074 event will initiate when the pressure differential between the filtered and unfiltered
pressure is equal or greater than 200 kPa (29 psi). A factory password is required to clear the
event.
Probable Causes of a 073 Event and/or a 074 Event are:

- Restricted engine oil filters
A bypass valve (not shown) for each filter is located in each oil filter base.
06/08
3512C LOGGED EVENTS

- Air Filter Restriction - Engine Oil Level Low
- Low Oil Pressure - High Crankcase Pressure
- High Coolant Temperature - Low Coolant Flow
- Engine Overspeed - User Defined Shutdown
- Oil Filter Restriction - Prelube Override
- Fuel Filter Restriction - Low Coolant Temperat ure
- High Exhaust Temperature - High Int ake Manifold Temperat ure
240
The 3512C Engine ECM logs several data events that could cause damage to the engine. Some
of the events require factory passwords to clear from the ECM memory. The events logged by
the Engine ECM, their maximum derate, and their trip points are listed below:
Air filter restriction: Greater than 6.25 kPa (25 in. of water). Maximum derate of 20%.
Factory password required.
If the atmospheric and turbo inlet pressure sensors both fail at the same time, a derate of 40%
will occur.
Low oil pressure: From less than 44 kPa (6.4 psi) at LOW IDLE to less than 250 kPa (36 psi)
at HIGH IDLE. Factory password required.
High coolant temperature: Greater than 107° C (226° F). Factory password required.
Engine overspeed: Engine speed is greater than 2200 rpm. Factory password required.
06/08
Oil filter restriction: Greater than 70 kPa (10 psi). No factory password required. Greater
than 200 kPa (29 psi). Factory password required.
Fuel filter restriction: Greater than 138 kPa (20 psi). No factory password required.
Exhaust temperature high: Greater than 750° C (1382° F). Maximum derate of 20%.
Intake manifold temperature high: Greater than 107° C (226° F). Maximum derate of 25%.
Engine oil level low: No factory password required.
Crankcase pressure high: Greater than 3.6 kPa (.5 psi) or 14.4 inches of water. No factory
password required.
Coolant flow low: Factory password required.
User defined shutdown: The customer has the option of installing systems that will shut
down the engine if desired. If the installed system sends a ground signal to the Engine ECM at
connector J1 pin 19, a user defined shutdown will occur. Factory password required.
The VIMS will shut down the engine for any of the following conditions:
- Engine oil level low
- Engine oil pressure low
- Engine coolant temperature high
- Engine coolant level low
- Aftercooler coolant level low
The engine will only shutdown when the shift lever is in NEUTRAL, ground speed is zero,
and the parking brake is ENGAGED. The Engine ECM does not log events for VIMS initiated
engine shutdowns.
Prelube override: Override the engine oil prelube system with the key start switch. Factory
password required.
06/08
SYSTEMS CONTROLLED BY ENGINE ECM
- Ether Injection
- Cool Engine Elevated Idle
- Cold Cylinder Cutout
- Engine Start Function
- Engine Oil Pre-lubrication
- Exhaust Bypass at High Boost
- Engine Oil Renewal System
241
The Engine ECM also regulates other systems by energizing solenoids or relays. Some of the
other systems controlled by the Engine ECM are:
Ether Injection: The Engine ECM will automatically inject ether from the ether cylinders
during cranking. The duration of automatic ether injection depends on the jacket water coolant
temperature. The duration will vary from 10 to 130 seconds. The operator can also inject ether
manually with the ether switch in the cab on the center console. The manual ether injection
duration is 5 seconds. Ether will be injected only if the engine coolant temperature is below
10° C (50° F) and engine speed is below 1900 rpm.
Cool Engine Elevated Idle: The Engine ECM provides an elevated engine idle speed of
1600 rpm when the engine coolant temperature is below 60° C (140° F). The rpm is gradually
reduced to 1000 rpm between 60° C (140° F) and 71° C (160° F). When the temperature is
greater than 71° C (160° F), the engine will operate at low idle (700 rpm).
temporarily reduce the elevated idle speed, the operator can release the parking brake or step on
06/08
Cold Cylinder Cutout: The 3512C engine uses a cold cylinder cutout function to:
- Reduce white exhaust smoke (unburned fuel) after start-up and during extended idling in
cold weather
- Minimize the time in Cold Mode
- Reduce the use of ether injection.
After the engine is started and the automatic ether injection system has stopped injecting ether,
the Engine ECM will cut out one cylinder at a time to determine which cylinders are firing. The
ECM will disable some of the cylinders that are not firing.
The ECM can identify a cylinder which is not firing by monitoring the fuel rate and engine
speed during a cylinder cutout. The ECM averages the fuel delivery and analyzes the fuel rate
change during a cylinder cutout to determine if the cylinder is firing.
Disabling some of the cylinders during Cold Mode operation will cause the engine to run rough
until the coolant temperature increases above the Cold Mode temperature. This condition is
normal, but the operator should be aware it exists to prevent unnecessary complaints.
Engine Start Function: The Engine Start function is controlled by the Engine ECM and the
Transmission/Chassis ECM. The Engine ECM provides signals to the Transmission/Chassis
ECM regarding the engine speed and the condition of the engine pre-lubrication system. The
Transmission/Chassis ECM will energize the starter relay only when:
- The shift lever is in NEUTRAL.
- The parking brake is ENGAGED.
- The engine speed is zero rpm.
- The engine pre-lubrication cycle is completed or turned OFF.
06/08
3512C HD ENGINE FUEL SYSTEM
Engine Oil Renewal

Solenoid
Engine Fuel
Fuel Block Pressure
Tank
Regulator
Primary Fuel
Filter
Fuel
Transfer Cylinder
Pump Head
Fuel Fuel
Heater Priming Pump
(Optional) Switch w/10A
Breaker
Fuel Priming Cylinder

Highest Fuel Pressure Pump and Filter Head
Fuel Differential
Engine Oil Pressure Switch
Return Fuel
Moving Object Secondary

Fuel Filters
Electrical Harness Engine ECM
242
Fuel System Diagram
Fuel is drawn from the tank through an optional fuel heater, and through the primary fuel filter
by the fuel transfer pump (a fuel/water separator can be installed the primary fuel filter). Then,
fuel flows from the fuel transfer pump to the secondary fuel filters.
Fuel flows from the secondary fuel filter base to the fuel injectors in the cylinder heads. Unused
fuel returns from the injectors and flows through the fuel pressure regulator. As the pressure
builds above the regulator pressure, the regulator opens and flow is directed back to the fuel
tank. Return oil is sent through the fuel heater.
The secondary fuel filter has a fuel pressure differential switch installed at the outlet of the filter
base which monitors the restriction in the secondary fuel filters. This switch is an input to the
Engine ECM warning the ECM of an E095 Event "Fuel Filter Restriction."
06/08
1
2
243
6
7
244
The fuel priming pump is used to fill the filters after they are serviced. The fuel priming
pump (1) has changed location from the previous information in this manual. The pump is now
located on the right side of the engine in the fuel priming pump filter base (2). The filter base
along with the fuel transfer pump is located above the fuel transfer pump (3). Also shown is the
engine oil cooler (4).
The fuel priming pump is electrically controlled with a toggle switch (5) on the secondary fuel
filter base (shown in the lower illustration). The fuel priming switch circuit is protected with a
10 Amp breaker (6). Also shown is the location of the fuel differential pressure switch (7).
06/08
245
Fuel flows through the system to the EUI fuel injectors. Return fuel from the injectors flows
through the fuel pressure regulator (arrow) before returning to the fuel tank. The fuel pressure
in the system is controlled through the fuel pressure regulator. The fuel pressure should between
380 kPa (55 psi) and 621 kPa (90 psi).
06/08
3512C HD ENGINE FUEL PRIMING SYSTEM
Engine Oil Renewal

Solenoid
Engine Fuel
Fuel Block Pressure
Tank
Regulator
Primary Fuel
Filter
Fuel
Transfer Cylinder
Pump Head
Fuel Fuel
Heater Priming Pump
(Optional) Switch w/10A
Breaker
Fuel Priming Cylinder

Highest Fuel Pressure Pump and Filter Head
Fuel Differential
Engine Oil Pressure Switch
Return Fuel
Moving Object Secondary

Fuel Filters
Electrical Harness Engine ECM
246
Fuel System Diagram (Fuel Priming)

Normally, after a filter change or a repair is made to the fuel system, it will be necessary to
prime the fuel system (remove air). The fuel priming system will be manually initiated by
activating the fuel priming pump switch. At this time, current is sent to the fuel priming pump
and the pump rotates and draws fuel from the tank and primary fuel filter. The fuel is directed
to the fuel transfer pump. At the pump, fuel is blocked from passing through the fuel transfer
pump and is pulled through the fuel priming pump filter and directed over the check valve to the
secondary fuel filters (priming fuel is blocked at the fuel transfer pump). From the secondary
fuel filters, the fuel flow through the system is similar to normal operation in the fuel system.
line during priming in order to force the fuel into the injectors.
06/08
247
Top Center Position
The timing bolt is located on the flywheel housing on the right rear of the engine.
This illustration shows the location of the timing bolt (1) and the access cover (2) for the turning
tool. Use the Engine Turning Tool (9S-9082) to rotate the engine flywheel.
NOTE: Always turn the flywheel in the counterclockwise direction looking at the
flywheel.
06/08
248
Steering And Front Brake Oil Cooling System
The previous 3500 engine used the Separate Circuit AfterCooler pump to supply coolant to cool
the aftercooler on the production "C" Series 785 Truck. Now, this pump used on the "D" Series
truck with the 3512C HD engine supplies coolant to the steering oil cooler and the front brake
cooler. The pump is not shown in the transparent graphic because it is shrinkwrapped with the
engine. Coolant supplied by the auxiliary pump is used to cool the air compressor (not shown).
The following is a list of the components in the steering and front brake oil cooling system.
- Steering oil cooler (1)

- Front brake oil cooler (2)
- Outlet tube for the radiator (3)
- Radiator top tank (4)
- Auxiliary coolant tank (5)
06/08
Auxiliary STEERING OIL AND FRONT BRAKE

Coolant Tank OIL COOLING SYSTEM
Front Brake
Radiator Oil Cooler
Top
Tank
To
R Front Brake
A Cooling From
D Front Brake
I Steering Oil Cooler Cooling
A
T
O To
R Steering System
Auxiliary From
Coolant Pump Steering System
Highest Pressure Coolant
2nd Highest Pressure Coolant
Return Coolant
Oil
Air Compressor
Moving Objects
249
This illustration is a schematic for the steering and front brake oil cooling system. In this
system, the auxiliary coolant pump draws coolant from the radiator outlet tube and directs the
coolant through the tube to the steering oil cooler and then the front brake oil cooler. From the
front brake oil cooler the coolant is returned to the radiator top tank. Coolant from the auxiliary
coolant tank supplies coolant to the auxiliary coolant pump inlet to replenish the coolant due to a
drop in the coolant level.
The air compressor (not shown) is connected to the auxiliary coolant pump outlet and the return
coolant is sent back to the inlet of the pump.
06/08
3512C HD AIR INDUCTION AND EXHAUST SYSTEM

From Air Filters
Left Rear Left Front

Turbocharger Turbocharger A
T
A
A
C
Intake Manifold
Hot Air
Filtered Air
Compressor Air
Cooled Air
Intake Exhaust
Moveable Component
A
T
A
Muffler Right Rear Right Front A
Turbocharger Turbocharger C
From Air Filters
250
Air Induction And Exhaust System "D" Series Truck
The illustration is a schematic showing the air flow from the air filters to the mufflers. Air is
drawn into the air cleaner group, passing through the precleaner and the air filter (not shown),
and the clean air passes out of the air cleaner group through the tube. Then, air flows into the
divider tube (violet) and into the turbocharger compressor inlet. Air flows out of the compres-
sor, into the divider tube, and into the ATAAC inlet. This engine is equipped with an ATAAC on
each side to cool the intake air supply.
From the ATAAC, cooled air flows through the lower tube and up into the Y-tube which is bolted
to the air inlet cover for the intake manifold. Then, the air is directed through the manifold. The
manifold has twelve elbows, air flows to each cylinder on the intake stroke to aid along with the
fuel for combustion.
From the aftercooler at the exhaust stroke, hot air flows to the turbocharger turbine inlet and out
of the turbo through the outlets. The hot air is then directed to a Y pipe which is connected to
one muffler.
06/08
The turbo bearings are lubricated by the flow of engine oil. The turbo bearing lubricating oil for
the left side is supplied from the outlet at the left front of the engine at the engine oil filter outlet.
This supply provides oil to the two left side turbos. The supply for the right side lubricating oil
comes from turbo supply (located at the right rear of the engine) and is directed to the right side
turbos and then back to the engine oil reservoir.
Air leaks in the ATAAC system normally will cause the exhaust temperatures to increase above
the normal operating temperatures. The exhaust temperatures can be monitored through VIMS
with Advisor or Caterpillar ET.
06/08
1
2
3 4
251
6 5
252
3512C HD Engine With ATAAC
The upper illustration shows the air flow to the inlet of the ATAAC.
- Air cleaners (1)
- Air cleaner tube (2)
- Compressor in Y-tube (3)
- Compressor out Y-tube (4)
- ATAAC (5)
- ATAAC outlet tube (6)
The lower illustration shows the flow to the intake manifold from the ATAAC
- Air inlet cover (7)
06/08
785D REAR AXLE LUBRICATION Differential Lube Oil Filter

Pressure Switch
COLD OIL
Differential Oil
Filter
RAXL Pump Drive Differential

Oil Diverter Valve Lube Oil
Pressure
Sensor
Relief Valve
Solenoid
Valve
RAXL Final Drive
Bypass Valve
Flow Solenoid
Control Valve Orifice
Logic Element
Sequence RAXL RAXL

Valve Motor Pump
To Steering
Solenoid
and
Relief Valve
Left Right
Final Drive Final Drive Differential
From Lube
Lube Lube
Steering Pump
Steering Tank Differential Housing
T
Differential Oil
Temperature Sensor
253
785D Truck Rear Axle Lubrication (RAXL)
The 785D pilot truck will be equipped with a new Rear Axle Lubrication (RAXL) system. The
pump for the new RAXL has been removed from inside the banjo and installed on the outside
of the differential housing. This system does not require that the truck be moving in order to
provide flow, so the flow can be controlled according to the current conditions. This system will
filter while lubricating the rear axle and left/right final drives.
In the upper illustration, the RAXL is shown to be OFF because of cold oil temperature in the
differential. When the engine is running and the differential oil temperature is below
13° C (55° F) the Brake ECM sends current to energize the RAXL pump drive oil diverter valve
solenoid. The solenoid valve blocks steering oil. The oil that would have been directed to the
RAXL motor is returned to the steering tank. At this time, no lubrication oil is displaced and the
Brake ECM sends a message to the Chassis/Transmission ECM to limit transmission upshifting.
7/05
785D REAR AXLE LUBRICATION Differential Lube Oil Filter

Pressure Switch
WARM OIL
Differential Oil
Filter
RAXL Pump Drive Differential

Oil Diverter Valve Lube Oil
Pressure
Sensor
Relief Valve
Solenoid
Valve
RAXL Final Drive
Bypass Valve
Flow Solenoid
Control Valve Orifice
Logic Element
Sequence RAXL RAXL

Valve Motor Pump
To Steering
Solenoid
and
Relief Valve
Left Right
Final Drive Final Drive Differential
From Lube
Lube Lube
Steering Pump
Steering Tank Differential Housing
T
Differential Oil
Temperature Sensor
254
"D" Series RAXL Filtration (Warm Oil)
This illustration shows the schematic for the rear axle lubrication system with the differential oil
temperature above 13° C (55° F).
In the RAXL system, the steering pump supplies oil to the steering valve and then on to the
RAXL pump drive oil diverter valve. Once the steering system demands are met and the
pressure builds to 18600 kPa (2650 psi) in the RAXL pump drive diverter valve, the sequence
valve opens and sends approximately 6.9 L/min oil flow through the flow control valve to the
solenoid valve.
With the solenoid de-energized, oil flows through the solenoid valve to the RAXL motor. The
rotation of the RAXL motor drives the RAXL pump sending flow first to the differential lube
oil filter, and then to the RAXL final drive bypass valve. The oil flow through the RAXL motor
returns to the tank.
06/08
On the RAXL final drive bypass valve, the following components are installed:
- Solenoid valve
- Relief valve
- Orifice
- Logic element
The solenoid valve controls the movement of the logic element and allows lube oil flow to both
the final drives and the differential bevel gear, or bypass the final drives. The orifice regulates
an equal amount of lube oil flow through the differential and the final drives. The RAXL
strategy prevents the final drives from receiving excessive amount of oil flow under certain
temperature conditions. The tubes to the final drives and bevel gear contain orifices that balance
the oil flow throughout to each final drive.
Differential Lube Oil Pressure Sensor: The differential lube oil pressure sensor is used to
sense the pressure in the RAXL system after the filter. The sensor is located on the RAXL filter
base. This sensor is PWM pressure sensor that monitors the lube oil pressure in the RAXL
system and sends the pressure data back to the Brake ECM. This sensor data is also used by the
Transmission ECM for the transmission shifting control strategy.
Differential Oil Temperature Sensor: The differential oil temperature sensor is used to sense
the temperature of the oil in the rear axle. It is located on the rear left of the differential housing
next to the oil level switch. The temperature sensor produces a PWM signal This temperature
sensor monitors the oil temperature in the differential and sends the temperature data back to the
Brake ECM.
Differential Oil Filter Pressure Switch: The differential oil filter bypass switch is used to
monitor restriction in the filter. If the filter becomes plugged, the switch sends a signal to the
Brake ECM indicating the filter is plugged and that the filter requires changing. The switch
is located on a filter base which is attached to the RAXL final drive bypass valve. The switch
should have a normally closed status and should have the contacts open when the filter is
plugged.
RAXL Final Drive Bypass Solenoid Feedback: The RAXL final drive bypass solenoid
feedback is used to read the status of the voltage being applied to the final drive bypass solenoid.
It is needed because the final drive bypass solenoid is being operated from an Open Collector
output driven by a relay. The Brake ECM cannot directly read the status of the relay output
without feedback. It will be read by the Brake ECM. The final drive bypass solenoid is used
to direct oil flow away from the final drives. When the solenoid is de-energized, oil flows to
the final drives and the differential. When the solenoid is energized, oil flows to the differential
only. The solenoid will be driven by the Brake ECM.
06/08
RAXL Pump Drive Oil Diverter Solenoid Feedback: The RAXL pump drive oil diverter
solenoid feedback is used to read the status of the voltage being applied to the RAXL pump drive
oil diverter solenoid. It is needed because the lube control solenoid is being operated from an
Open Collector output driven by a relay. The brake ECM cannot directly read the status of the
relay output without feedback. It will be read by the Brake ECM.
RAXL Final Drive Bypass Solenoid: The final drive bypass solenoid is used to divert pilot oil
from the logic element which allows final drive oil back to the differential from the final drives.
When the solenoid is de-energized, oil is directed to the pilot of the logic element blocking any
lube oil flow to the differential and sending all oil to the final drives and the differential.
When the solenoid is energized, pilot oil to the logic element pilot is allowed to flow to the
differential. The logic element moves to the lower envelope and the final drive oil flows back to
the differential. The solenoid will be driven by the Brake ECM.
Rear Axle Lube Pump Drive Oil Diverter Solenoid: The RAXL lube pump drive oil diverter
solenoid is used to divert steering pump supply oil flow away from the RAXL motor and return it
to tank. When the solenoid is de-energized, steering pump supply oil flows to the RAXL motor.
When the solenoid is energized, steering pump supply oil returns to tank. The solenoid will be
driven by the Brake ECM.
06/08
REAR AXLE LUBRICATION STRATEGY

Rear Axle Supply Solenoid Final Drive Bypass Solenoid
COLD COOL HOT COLD COOL HOT
Rear Axle 13 C 15 C to 56 C 58 C 13 C 15 C to 56 C 58 C
Oil Temperature ( 55 F) (59 F to 133 F) ( 136 F) ( 55 F) (59 F to 133 F) ( 136 F)
NOT Moving OFF OFF OFF ON

ON OFF
0 mph ON after 5 min ON after 5 min
Moving
0 to 35 km/h ON OFF OFF ON ON OFF
(0-22 mph)
Moving Fast
35 Km/h 5 min ON
ON OFF OFF ON ON 1 min OFF
(>22 mph)
255
RAX Lubrication Strategy
This illustration shows the lubrication strategy for the rear axle. The main input that the Brake
ECM uses to control the rear axle lube system is the temperature of the rear axle oil. This
temperature, along with some basic information about the state of the machine, such as ground
speed and engine speed, allows the Brake ECM to control the energizing of both the RAXL
pump drive oil diverter solenoid and the RAXL final drive bypass solenoid.
During start-up, the system is turned ON to charge the lube system. There is no advantage to
lubing the rear axle due to the high viscosity of the cold oil. Therefore, the system is turned OFF
after 5 minutes when the lube oil is cold. If the machine is traveling greater than 22 mph, the
lube to the final drives is cycled ON and OFF. This cycling prevents the filling of the final drives
due to centrifugal force by keeping only a small amount of oil in the final drives.
The temperature gear limit is used to limit the actual transmission gear to keep the machine from
doing any high speed traveling until the differential oil has warmed up enough for the lube
system to be effective. When the temperature is below 13° C (55° F) the gear limit is 3rd gear.
When the temperature is between 15° C (59° F) and 56° C (133° F), the gear will be limited to
4th gear.
06/08
Rear Axle Lube Pump Drive Oil Diverter Logic
When the engine is off, then the RAXL pump drive oil diverter solenoid is not energized. This
strategy eliminates battery drain when the key switch is in the ON position without the engine
running.
If the engine is running, or the running status is unknown, then the next set of conditions are
checked.
1. If the machine is NOT MOVING and the diverter temperature status is either COOL or
COLD and the diverter solenoid has been OFF for a minimum of 300 seconds, then the
RAXL pump drive oil diverter solenoid can be turned energized. The five minute delay
is intended to charge the system during typical machine start-up, and keep the RAXL
pump drive oil diverter solenoid valve from cycling too often during typical machine
operation.
2. If machine status is MOVING or MOVING FAST and the differential (oil) temperature
status is COLD, then the RAXL manifold solenoid valve will be energized to divert oil
flow. There is no advantage in lubing the rear axle due to the high viscosity of the rear
axle lube oil under these cold conditions.
3. If the temperature status is HOT (Moving, Moving Fast or NOT Moving) or COOL with
a MOVING or MOVING FAST machine status, then the RAXL pump drive oil diverter
solenoid will be turned de-energized. This is the normal operating mode of the diverter.
Oil will flow from the engine driven steering pump, which will in turn drive the RAXL
motor, which will in turn drive the RAXL pump.
06/08
256
3 2 1
257
5
7
6
RAXL Control Valve
The new RAXL pump drive oil diverter valve (arrow) is located on the left inside of the truck
frame above the rear axle. This valve controls the steering oil flow to the RAXL motor when
the conditions are met
The lower illustration shows the components of the RAXL pump drive oil diverter valve and the
flow paths into and out of the valve. The hose (1) supplies steering pump supply oil through the
steering valve (not shown) at the front of the truck
06/08
The pump drive oil diverter valve is equipped with a solenoid valve (2). The solenoid valve is
normally de-energized when the key start switch is in the OFF position and/or the differential oil
temperature is above 13° C (55° F).
The diverter valve is also equipped with a sequence valve (3). This valve blocks oil flow
from hose (5) when the steering oil pressure is below 13800 kPa (2000 psi). In the flow path
between the solenoid valve and the sequence valve within the valve is the variable flow control
(3). While oil is flowing past the sequence valve, the flow control valve is limiting flow to
approximately 7.5 L/min (118 Gal/hr).
The hose (5) supplies a path of oil between the RAXL pump drive oil diverter valve and
the RAXL motor. The hose (5) supplies a path to tank from both the RAXL motor. The
combination of the RAXL motor drain and the drain from the diverter flows back to the
hydraulic tank (not shown) through hose (7).
The following Diagnostic Code covers the RAXL solenoid control valve. MID 116 - Brake
ECM
- CID 1437 - FMI 03 - Solenoid (Rear Axle Supply) Voltage above normal
- CID 1427 - FMI 06 - Solenoid (Rear Axle Supply) Current above normal
06/08
258
259
RAXL Pump Drive Oil Diverter Solenoid Relay Control
The upper illustration shows the location of the solenoid relay control (arrow). To access the
relay control, remove the rear cover from the cab.
The lower illustration shows the relay control (1) and the plug (2). This relay controls the
RAXL pump drive oil diverter solenoid (located on the frame) and the final drive bypass
solenoid (on the diverter valve on the axle).
06/08
REAR AXLE LUBRICATION ELECTRICAL SYSTEM

Final Drive Bypass Solenoid Feedback
RAXL Pump Drive Oil Diverter Solenoid Feedback
+ Batt
RAXL Pump Drive

Oil Diverter Solenoid
Relay Control
J1-35 J2-40
Final Drive
Bypass Solenoid
J1-29 J2-28
J1-32 J2-6
J2-10
RAXL Pump Drive
Oil Diverter Solenoid
Differential Lube Pressure Sensor

J1 J2
Differential Oil Temperature Sensor

Brake ECM
Differential Filter Bypass Switch
260
The illustration above shows the electrical diagram for the rear axle lubrication system.
06/08
3 261
5
262
Differential Lube
When the control temperature reaches the appropriate value for the 785D truck, the RAXL pump
drive oil diverter valve directs steering oil to the RAXL drive motor (not shown). The motor
drives the pump and oil from the differential sump is drawn through the tube and strainer (1),
through the hose (2) to the pump. From the pump, oil is directed to the RAXL diverter valve
(3) through the hose (4) (lower illustration). The oil is directed through the hose (5) to the hose
(6) which is internal located between the transmission and the differential. Also, oil is ported
through the differential case to the three tubes which are located on the reverse side compared to
the hose (5). These three tubes (upper illustration) lubricate the pinion gear and the bearings on
each side of the carrier.
06/08
263
5
2
3
4
264
RAXL Final Drive Bypass Valve
The RAXL final drive bypass valve is located on the rear of the banjo on the left side. This
valve has two purposes, one is that is diverters the oil from the banjo housing for filtration.
Also, the valve is used to divide the oil flow between the differential and the final drives.
The differential lube oil filter is equipped with an internal bypass valve (5) allowing the oil to
flow into the filtered oil of the filter. On the filter base, there is a S•O•S port (6). This port
is used to check the quality of the oil lubricating moveable components in the axle. Also, the
diverter valve has a relief valve (4) for limiting the pressure through the RAXL filtration system
preventing over-pressurization.
06/08
Between the path of oil to the differential lube and the final drive lube is an orifice (not shown).
The orifice restricts the flow of oil to the final drives. The diverter valve has two position
solenoid valve (2) which controls the pilot oil pressure to the pilot end of the diverter valve (1).
In the relaxed position, the solenoid valve sends flow to the pilot end of the diverter, holding the
diverter in the blocked position.
The following Diagnostic Code covers the RAXL final drive bypass solenoid valve. MID 116
- Brake ECM
- CID 1232 - FMI 03 - Solenoid (Rear Axle Diverter) Voltage above normal
- CID 1232 - FMI 06 - Solenoid (Rear Axle Diverter) Current above normal
Installed on the diverter valve is a pressure tap (3). This pressure tap measures the pressure of
the final drives lubrication.
The lower illustration shows the location of the ports on the lower side of the diverter valve.
The port (7) directs lubrication oil to the final drives.
The port (8) directs oil to the differential housing.

06/08
265
RAXL Motor and Pump
The RAXL pump (2) is a single section gear pump.
The RAXL motor (1) is also a single section gear motor which rotates in the counterclockwise
direction when looking at the gear motor from the drive shaft end.
06/08
1 2
266
3 4
267
Temperature and Pressure Sensors for the RAXL
The upper illustration shows the location of the differential housing oil temperature sensor (1).
The Brake ECM uses this sensor to determine whether the solenoid valve on the RAXL control
valve will be de-energized.
The following Diagnostic Code covers this temperature sensor. MID 116 - Brake ECM
- CID 0835 - FMI 03 - Temperature sensor (Differential Oil) Voltage above normal
- CID 0835 - FMI 04 - Temperature sensor (Differential Oil) Voltage below normal
The right side level sensor is not shown.

06/08
The housing is equipped with two level sensors one for each side of the axle. Level sensor (2) is
shown in the illustration, monitors the oil level in the left side of the differential housing.
The lower illustration shows the differential lube oil filter base with the differential lube oil
pressure sensor and the differential oil filter pressure switch installed. The pressure sensor
monitors the pressure of oil from the filter into the diverter valve. This sensor is also used for
gear shift limiting with a low RAXL pressure situation.
The differential oil filter pressure switch monitors the difference in pressure at the filter inlet and
outlet.
06/08
268
#
CONCLUSION
This presentation has provided a basic introduction to the Caterpillar 785C 785D, and 789C Off-
highway Trucks. All the major component locations were identified and the major systems were
discussed. When used in conjunction with the service manual, the information in this package
should permit the serviceman to analyze problems in any of the major systems on these trucks.
SERV1857 - 326 -
06/08
HYDRAULIC SCHEMATIC COLOR CODE
Black - Mechanical Connection. Seal Red - High Pressure Oil
Dark Gray - Cutaway Section Red / White Stripes - 1st Pressure Reduction
Light Gray - Surface Color Red Crosshatch - 2nd Reduction in Pressure
White - Atmosphere or Air (No Pressure) Pink - 3rd Reduction in Pressure
Purple - Pneumatic Pressure Red / Pink Stripes - Secondary Source Oil Pressure
Yellow - Moving or Activated Components Orange - Pilot, Charge or Torque Converter Oil
Cat Yellow - (Restricted Usage) Orange / White Stripes - Reduced Pilot, Charge, or
Identification of Components TC Oil Pressure
within a Moving Group
Orange / Crosshatch - 2nd Reduction in Pilot,
Brown - Lubricating Oil Charge, or TC Oil Pressure
Green - Tank, Sump, o r Return Oil Blue - Trapped Oil
Green / White Stripes -

Scavenge / Suction Oil or Hydraulic Void
This illustration identifies the meanings of the colors used in the hydraulic schematics and
cross-sectional views shown throughout this presentation.
06/08

SERV1857
Black - Mechanical Connection. Seal Red - High Pressure Oil
Dark Gray - Cutaway Section Red / White Stripes - 1st Pressure Reduction
Light Gray - Surface Color Red Crosshatch - 2nd Reduction in Pressure
White - Atmosphere or Air (No Pressure) Pink - 3rd Reduction in Pressure
Purple - Pneumatic Pressure Red / Pink Stripes - Secondary Source Oil Pressure
- 327 -
Yellow - Moving or Activated Components Orange - Pilot, Charge or Torque Converter Oil
Cat Yellow - (Restricted Usage) Orange / White Stripes - Reduced Pilot, Charge, or
Identification of Components TC Oil Pressure
within a Moving Group
Orange / Crosshatch - 2nd Reduction in Pilot,
Brown - Lubricating Oil Charge, or TC Oil Pressure
Green - Tank, Sump, o r Return Oil Blue - Trapped Oil
Green / White Stripes -

Scavenge / Suction Oil or Hydraulic Void
Serviceman's Handout
SERV1857 - 328 -
06/08
VISUAL LIST
1. 789C model view 43. Brake and throttle pedals
2. Right side 789C truck 44. Shift console
3. Front of 789C truck 45. Overhead switches
4. Truck body options 46. Circuit breaker panel
5. Walk around inspection 47. Center dash panel
6. Maintenance checks 48. Rocker switches
7. Front wheel bearing 49. VIMS message center module
8. Front suspension cylinder 50. VIMS interface modules
9. Air filter housing 51. VIMS main module
10. Right side engine 52. VIMS diagnostic connector
11. Transmission charging filter 53. Electronic Technician (ET)
12. Transmission hydraulic tank 54. 3516B engine model view
13. Final drive 55. Electronic control system component
14. Differential oil level diagram
15. Safety cable 56 Engine ECM
16. Fuel tank 57. Atmospheric pressure sensor
17. Primary fuel filter 58. Engine speed/timing sensor
18. Parking brake and torque converter 59. Throttle position sensor
19. Brake cylinder breathers 60. EUI fuel injector solenoid
20. Front air dryer 61. Input switches and sensors
21. 789C engine oil filters 62. Air conditioner compressor switch
22. 785C engine oil filters 63. Crankcase pressure sensor
23. Oil change connector 64. ECM logged events
24. Secondary fuel filters 65. Additional ECM logged events
25. Engine shutdown switch 66. Systems controlled by ECM
26. Air filter restriction indicators 67. Engine oil pre-lubrication
27. 789C cooling system 68. Speed fan control
28. Air cleaner indicators 69. Oil renewal system components
29. Ether cylinders 70. Oil level switches
30. Batteries 71. Cooling system
31. Lubrication tank 72. Radiator
32. Steering system tank 73. Water pump
33. Air tank drain valve 74. Coolant
34. Windshield washer reservoir 75. Engine (right side)
35. Daily checks 76. Jacket water coolant flow
36. Operator's station 77. Auxiliary (aftercooler) water pump
37. Operator and trainer seats 78 Rear aftercooler temperature sensor
38. Hoist control lever 79. 789C air charging system
39. Dash (left side) 80. Lubrication system
40. Operator controls 81. Oil filters
41. Switches and signals 82. 785C engine oil filters
42. Manual retarder lever 83. Engine oil system
SERV1857 - 329 -
06/08
VISUAL LIST
84.
1. Primary fuel filter 121. Rear axle oil cooling and filter system
85. Fuel transfer pump 122. Double reduction planetary gear final
86. Secondary fuel filters drives
87. Fuel injectors 123. Transmission/Chassis ECM
88. Fuel system circuit 124. Transmission/Chassis electronic control
89. Air induction and exhaust system system
90. Turbocharger inlet pressure sensor 125. Shift lever switch
91. 351B turbochargers 126. Transmission gear switch
92. Exhaust temperature sensor 127. Transmission Output Speed (TOS)
93. 3512B air induction and exhaust system sensor
94. Power train components 128. Service/retarder brake switch
95. Torque converter 129. Body position sensor
96. Torque converter (converter drive) 130. Steering system
97. Torque converter drive (direct drive) 131. 789C steering system (no steer/
98. Torque converter pump (four sections) maximum flow
99. Torque converter charging filter 132 785C steering system (hold)
100. Torque converter inlet relief valve 133. Steering tank and filter
101. Torque converter outlet screen 134. 785C steering pump
102. Brake oil cooler and diverter valve 135. 785C steering pump (maximum flow)
103. Parking brake release valve 136. Pump compensator valve
104. Torque converter lockup clutch valve 137. 785C steering pump (minimum flow)
(iron) 138. 789C steering pump
105. Torque converter lockup clutch control 139. 789C steering pump supply oil
(direct drive) 140. 789C steering pump operation
106. Torque converter hydraulic system (maximum flow)
107. Transfer gears 141. 789C steering pump (low pressure
108. Transmission lube supply hose standby)
109. Power shift planetary transmission 142. Accumulator charging valve
110. Transmission pump 143. Load sensing controller
111. Transmission scavenge screens 144. 789C solenoid and relief valve manifold
112. Transmission charging filter 145. 785C solenoid and relief valve manifold
113. Transmission oil cooler bypass valve and 146. Solenoid and relief valve manifold
oil cooler (sectional view)
114. Transmission charging pump 147. 789C steering directional valve
115. Transmission clutch pressures 148. Steering directional valve (no turn)
116. ICM transmission controls (sectional 149. Steering directional valve (right turn)
view) 150. 785C solenoid and relief valve manifold
117. Transmission hydraulic system and crossover relief valves
118. Rear axle pump 151. 785C crossover relief system (external
119. Pump supply hose impact)
120. Oil filter bypass switch 152. 789C Hand Metering Unit (HMU)
153. 789C steering accumulators
SERV1857 - 330 -
06/08
VISUAL LIST
154.
1. Shutdown control 191. Service/retarder brake air system
155. Hoist control system (engaged)
156. Hoist lever 192. 789C brake oil cooling schematic
157. Hoist control position sensor 193. Brake cooling oil pressure tap
158. Hoist, converter and brake tank 194. Brake electronic control system
159. Hydraulic tanks (rear) 195. Brake ECM (iron)
160. Two-section hoist pump 196. Automatic Retarder Control (ARC)
161. Hoist screens schematic
162. Pump supply ports 197. Engine Output Speed (EOS) sensor
163. Counterbalance valve 198. Retarder pressure switch
164. Hoist control valve (hold) 199. Service/retarder brake air system
165. Hoist control valve (raise) 200. Hydraulic ARC System
166. Hoist counterbalance valve (raise, lower 201. Hydraulic ARC Valve
and float) 202. Engine On/ARC Off
167. "C" Series hoist control valve (lower) 203. Engine On/ARC On
168. "C" Series hoist control valve (float) 204. Engine Off/ARC Off
169. Two-stage hoist cylinders 205. Automatic retarder control schematic
170. Hoist system (hold) (engaged)
171. Air and brake systems 206. Steering bleed down control
172. Oil cooled brake assembly (cutaway) 207. Brake cooling diverter solenoid
173. Air charging system 208. Engine Output Speed (EOS) sensor
174. 789C air dryers 209. Traction Control System (TCS)
175. Service/retarder brake tank schematic
176. Pressure protection valve 210. Wheel speed sensor
177. Automatic lubrication solenoid air valve 211. Traction Control System (TCS) valve
178. Parking/secondary brake tank 212. Traction Control System (TCS)
179. 789C air charging system operation (brakes released)
180. Manual retarder valve 213. Traction Control System (TCS)
181. Service brake valve operation (left brake engaged)
182. Inverter valve signal port 214. Flexxaire™ fan
183. Brake release valve 215. Flexxaire™ fan electronic control box
184. Normal parking and secondary brake 216. 785D large off-highway truck
operation 217. 3512C high displacement engine
185. Parking/secondary brakes released and 218. Engine components (right side)
parking brakes engaged 219. Engine components (left side)
186. Service brake and manual retarder relay 220. Engine components (front)
valve 221. Engine components (rear)
187. Brake oil makeup tank 222. Turbocharger location
188. Brake cylinder (engaged) 223. Engine Electronic Control Module
189. Slack adjuster (iron) diagram
190. Slack adjuster (released and engaged) 224. Engine ECM and atmospheric pressure
sensor
225. Injector with valve cover removed
226. Primary speed/timing sensor
227. Engine speed sensor
SERV1857 - 331 -
06/08
VISUAL LIST
228. Coolant temperature sensor 251. Air flow to inlet of ATAAC
229. Coolant flow switch 252. Air flow from the ATAAC
230. Crankcase pressure sensor 253. 785D rear axle lubrication (RAXL)
231. Turbo inlet pressure sensors (left) 254. "D" series RAXL filtration (warm oil)
232. Turbo inlet pressure sensors (right) 255. RAX lubrication strategy
233. Intake manifold air temperature sensor 256. RAXL pump drive oil diverter valve
234. Intake manifold pressure sensor (boost) 257. RAXL pump drive oil diverter valve
235. Exhaust temperature sensor (left side) (components)
236. Exhaust temperature sensor (right side) 258. Solenoid relay control connector
237. Fuel filter differential switch 259. Solenoid relay control and connector
238. Rear oil pressure sensor 260. Electrical diagram for the rear axle
239. Front oil pressure sensor lubrication system
240. 3512C logged events 261. Differential lube - tube and strainer
241. Systems controlled by ECM 262. Differentail lube - (hoses)
242. Fuel system diagram 263. RAXL final drive bypass valve
243. Fuel priming pump 264. Diverter valve ports
244. Fuel priming pump toggle switch 265. RAXL motor and pump
245. Fuel pressure regulator 266. Differential housing oil temperature
246. Fuel system diagram (fuel priming) sensor
247. Timing bolt and access cover 267. Differential lube oil filter base
248. Steering and front brake oil cooling 268. Truck rear view
system
249. Steering and front brake oil cooling
system
250. Air induction and exhaust system "D"
series truck
06/08
VIMS KEYPAD OPERATIONS

The keypad allows the operator or a service technician to interact with the VIMS. Some of the
functions that can be performed by the keypad are:
PAYCONF 7292663 Configure Payload Monitor (requires VIMS PC connection)
PAYCAL 729225 Calibrate Payload Monitor (requires VIMS PC connection)
TOT 868 Show Payload Cycle Resettable Totals
RESET 73738 Reset Displayed Payload Data
ESET 3738 Customize Events (requires VIMS PC connection)
SVCLIT 782548 Turn OFF Service Light
SVCSET 782738 Service Light Set (requires VIMS PC connection)
TEST 8378 Self Test Instrumentation
MSTAT 67828 Show Machine Statistics (source and configuration codes)
LUBSET 582738 Set Lube Cycle Times
LUBMAN 582626 Manual Lube
EACK 3225 Show Acknowledged Events (Active)
ESTAT 37828 Show Event Statistics
ELIST 35478 Show Event List (Intermittent)
EREC 3732 Start Event Recorder
ERSET 37738 Configure 1 Event Recorder (requires VIMS PC connection)
DLOG 3564 Start/Stop Data Logger
DLRES 35737 Reset Data Logger
LA 52 Change Language
UN 86 Change Units
ODO 636 Odometer Set/Reset (requires VIMS PC connection)
BLT 258 Change Backlight
CON 266 Change Display Contrast
ATTACH 288224 Used to recognize if RAC module is present (0 - NO, 4 - YES)
RAC 722 Set Haul Road Severity (0 - OFF, 1 - high, 2 - medium, 3 - low)
(requires VIMS PC connection)
OK Key: Used to complete keypad entries and to acknowledge events. Acknowledging
an event will remove the event from the display temporarily. Severe events cannot be
acknowledged.
GAUGE Key: Displays parameters monitored by the VIMS. Depressing the arrow keys will
scroll through the parameters. Entering the parameter number and the GAUGE key selects that
parameter.
F1 Key: Provides additional information on the current event being displayed. For
MAINTENANCE events, the MID, CID, and FMI are displayed. For DATA events, the current
parameter value is displayed (temperature, pressure, rpm).

Manual 789C

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Manual 789C

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SERV1857

785C (1HW), 785D (MSY), 789C (2BW)

Service Training Meeting Guide

Estimated Time: 24 Hours

Fluid Power Graphic Symbols User's Guide SENR3981

785C Off-highway Truck AEHQ5320

Salesgrams and Product Bulletins

Salesgram "Vital Information Management System (VIMS)" TELQ4478

793C Off-highway Truck--Service Introduction SEVN4016

Know Your Cooling System SEBD0518

Repair of 4T8719 Bladder Accumulator Group" SEHS8757

WALK AROUND INSPECTION ...............................................................................................11

POWER TRAIN .......................................................................................................................111

STEERING SYSTEM ..............................................................................................................154

HOIST SYSTEM ......................................................................................................................187

AIR SYSTEM AND BRAKES.................................................................................................207

BRAKE ELECTRONIC CONTROL SYSTEM.......................................................................236

785D LARGE OFF-HIGHWAY TRUCKS ..............................................................................266

Engine ECM and Atmospheric Pressure Sensor .................................................................275

HYDRAULIC SCHEMATIC COLOR CODE .........................................................................327

SERVICEMAN'S HANDOUTS ...............................................................................................333

785C, 785D, AND 789C

© 2008 Caterpillar Inc.

WALK AROUND INSPECTION

WALK AROUND INSPECTION

10 HOURS/DAILY MAINTENANCE CHECKS

Auto Lube Reservoir

Windshield Washer Level Frame For Cracks and

Leaks and Trash Build-up

Wheel Nuts Fuel Level and

INSTRUCTOR NOTE: For more detailed information on servicing the automatic

TDTO TO-4 oil:

1. Use API CH-4 performance oils.

Engine oil can be added at the quick fill connector (3).

CH-4 engine oil:

Air intake system tips:

With conventional coolant, maintain a 3 to 6% concentration of supplemental coolant additive.

Maintain a 30 to 60% concentration of Caterpillar Antifreeze.

Do not fill the cooling system faster than 20 L/min. (5 gpm).

Keep the fan belts adjusted.

Keep the radiator cooling fins straight and clean.

Ether starting tip:

INSTRUCTOR NOTE: For more detailed information on servicing the steering

- Brakes: Check operation

The operator controls to the left of the steering column are:

Intermittent wiper switch (six positions):

- Key start switch

Located on the floor of the cab are:

Located in the overhead panel are several switches:

- Hazard lights (1)

- Engine coolant temperature: Maximum operating temperature is 107° C (225° F).

The three systems monitored by the speedometer/tachometer module are:

- Tachometer: Displays the engine speed in rpm.

Top row (from left to right)

Warning Category 2-S

Gauge Speedometer/ Message

Vims Interface CAT Data Link

The 785C and 789C engines have increased horsepower.

785C: gross power--1082 kW (1450 hp)

3500B ELECTRONIC CONTROL SYSTEM

Rear Aftercooler Temperature Oil Level Speed /Timing Sensor

Fan Clutch A/C Pressure

Fan Fan Speed Sensor Coolant Flow Switch

Engine Electronic Control System