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

O F F - H I G H WAY T R U C K S

2005 Caterpillar Inc.

785C/789C MAINTENANCE
ice
789C Serv
Procedure

WALK AROUND INSPECTION

10 HOURS/DAILY MAINTENANCE CHECKS

Batteries

Transmission
Oil Level

Steering Oil Level

Hoist, Converter
and Brake Oil Level

Auto Lube Reservoir

Suspension Cylinder Height

Air Filter,
Restriction Indicators
and Precleaners

Rear Axle Oil Level

Coolant Level
Rear Axle and
Brake Cylinder
Breathers

Belts and Ether Cylinders

Engine Oil Level

Frame For Cracks and

Body Support Pads

Windshield Washer Level

and A/C Filter
Air Reservoir Moisture

Leaks and Trash Build-up

Wash Windows,
Cab Fresh Air Filters,
Seat Belt, Indicators, Gauges,
Brake Tests
Secondary Steering and
Back-up Alarm

Suspension Cylinder Height,

Grease Breathers
and Wheel Breathers

Wheel Nuts

Tire Inflation
Pressure

Fuel Level and

Drain Moisture

Gauge
Cluster
Module

Service
Lamp
Service
Key Start
Switch

Vims

VIMS
RS-232
Port

Main Module

Speedometer/
Tachometer
Module

Message
Center
Module

Keypad
Module

MPH
3F
1 2 km/h

VIMS
Service Tool
and
Software

Vims Interface
Module

Electronic
Technician /ECAP
Display
Data Link

Vims Interface
Module

Keypad
Data Link
CAT Data Link

Engine
ECM
Action
Alarm
Action
Lamp
CAT Data Link
Sensors

VITAL INFORMATION
MANAGEMENT SYSTEM
(VIMS)

Sensors

Brake ECM
(ARC /TCS)

Transmission /
Chassis ECM

Engine
ECM
Electronic Unit
Injectors

3500B ELECTRONIC CONTROL SYSTEM

COMPONENT DIAGRAM
Ground
Bolt
15 Amp
Breaker

Throttle

Disconnect Switch
Main
Power Relay

Key Start
Switch

24 V

Timing Probe
Connector

Engine Coolant Temperature

Rear Aftercooler Temperature

Oil Level
Switch (Low)

Speed /Timing Sensor

Engine Oil Pressure
(Unfiltered)

Engine Oil Pressure (Filtered)

Ether Solenoid

Atmospheric Pressure

Manual Ether
Switch

Throttle Override Switch

Turbo Outlet Pressure (Boost)

Ground Level
Shutdown Switch

Right Turbo Inlet Pressure

Fuel Filter
Switch

Left Turbo Inlet Pressure

Service Tool
Transmission /Chassis ECM

Crankcase
Pressure

Right Turbo Exhaust

Left Turbo Exhaust

Brake ECM
Vims

Engine Oil
Renewal Solenoid

Shutter Solenoid

Fan Clutch
Solenoid
Fan

CAT Data Link

A/C Pressure
Switch
Fan Speed Sensor

Pre-lubrication Relay
Coolant Flow Switch

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

3500B IMPROVEMENTS
PREVIOUS LOGGED EVENTS
- Air Filter Restriction
- Low Oil Pressure
- High Coolant Temperature
- Engine Overspeed

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

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

OIL RENEWAL SOLENOID VALVE

Piston

Piston

ON

OFF
To Fuel
Return

To Fuel
Return

From Engine
Oil Gallery

From Engine
Oil Gallery

JACKET WATER COOLANT FLOW

Thermostat
Housing

Shunt
Tank

Engine
Block

Engine Oil Cooler

Hoist, Converter and
Brake Oil Cooler
Hoist, Converter and
Brake Oil Cooler
Transmission Oil Cooler

Radiator
Jacket
Water Pump

AFTERCOOLER COOLANT FLOW

Shunt
Tank

Front Brake
Oil Cooler

Aftercooler

Diverter
Valve

Air
Compressor

Radiator
Aftercooler
Water Pump

ENGINE OIL SYSTEM

Engine
Oil Renewal
System Solenoid

Scavenge
Pump

To Fuel
Tank
Bypass
Valve
Engine
Oil Filters

Engine
Oil Cooler
Engine
Oil Pump

FUEL SYSTEM

Engine
Block
Engine Oil
Renewal
Solenoid

Fuel
Tank
Primary
Fuel
Filter
Fuel
Heater

Engine
Ecm

Fuel
Pressure
Regulator

Cylinder
Head
Fuel
Transfer
Pump

Fuel
Priming
Pump
Secondary
Fuel Filters

Cylinder
Head

From Air
Filters

3512B
AIR INDUCTION
AND
EXHAUST SYSTEM

Muffler

Aftercooler

From Air
Filters

POWER TRAIN
785C

Lockup Piston

Turbine

TORQUE CONVERTER

Impeller
Stator

CONVERTER DRIVE

Torque Converter
Inlet Oil

Freewheel
Assembly

Torque Converter
Lockup Oil Passage

Lockup Piston

Turbine

Impeller

TORQUE CONVERTER
Stator

DIRECT DRIVE

Torque Converter
Inlet Oil

Freewheel
Assembly

Torque Converter
Lockup Oil Passage

TORQUE CONVERTER LOCKUP CLUTCH CONTROL

DIRECT DRIVE

Lockup Clutch
Pilot Pressure
(RV)

Signal Oil
Lockup
Modulation
Valve

Selector
Piston

Lockup
Solenoid

To Lockup
Clutch (LU)

To
Transmission
Lube

From
Transmission
Charge Pump

Lockup
Reducing
Valve

To
Station
"D"

Shuttle
Valve
Relay Valve

From Parking Brake

Release Pump (PMP)

TORQUE CONVERTER
HYDRAULIC SYSTEM

Front
Brakes

Rear
Brakes

To Hoist
Solenoid
Manifold

Torque Converter
Charging Filter
Outlet
Relief Valve

Front Brake
Oil Cooler

Converter
Lockup
Valve

Inlet
Relief Valve
Diverter
Valve

Parking
Brake
Release
Valve

Rear Brake
Oil Coolers
Converter
Outlet
Screen

Parking
Brake
Filter

Converter
Scavenge
Screen

POWER SHIFT PLANETARY TRANSMISSION

3
4
5

TRANSMISSION ICM HYDRAULIC SYSTEM

Upshift
Pressure
Lockup
Solenoid

Downshift Upshift
Solenoid Solenoid

On

Downshift
Pressure

Rotary Actuator

E
N1

To Torque Converter
Relay Valve

Priority Neutralizer
Reduction
Valve
Valve

Pilot Oil Pressure

Rotary
Selector
Spool

Pump Pressure
Filters
Charging
Pump

Lube
Pump

Scavenge
Pump

Lube
Pressure

Oil
Cooler

G
D

Cooler
Bypass
Valve

Relief Valve
Transmission
Tank
Transmission Case

Lubrication
Relief Valve

Selector Valve Group

Lockup Dual
Stage Relief Valve

Pressure Control
Group

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

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

First Reduction
Ring Gear

Second Reduction
Ring Gear

Second Reduction
Carrier
Second Reduction
Planetary Gear

FINAL DRIVE

First Reduction
Sun Gear

First Reduction
Carrier

First Reduction
Planetary Gear

Second Reduction
Sun Gear

"C" SERIES TRUCK

TRANSMISSION / CHASSIS ELECTRONIC CONTROL SYSTEM
INPUT COMPONENTS
Transmission Gear
Switch
Converter Output
Speed Sensor
Service / Retarder
Brake
Pressure Switch
Body
Position Sensor

Shift Lever
Position Switch
Transmission Output
Speed Sensor
Engine Output
Speed Sensor

OUTPUT COMPONENTS
CAT Data Link
Electronic Service Tool
Engine ECM
Brake ECM
VIMS
Upshift Solenoid

Parking/secondary Brake
Pressure Switch
Key Start Switch

Downshift Solenoid
Lockup Solenoid

Low Steering
Pressure Switch
Hoist Lever
Position Sensor
Hoist Screen Switch

Starter
Solenoid

Auto Lube Solenoid

Transmission Oil
Temp Sensor
Transmission Charge
Filter Switch
Transmission Lube
Filter Switch

Back-up Alarm
Relay

Torque Converter
Oil Temp Sensor

Body Up Lamp
Hoist Lower Solenoid
Hoist Raise Solenoid

STEERING
789C

789C STEERING SYSTEM

High Steering
Pressure Switch

NO STEER / MAXIMUM FLOW

Solenoid and
Relief Valve
Return
Manifold

Steering
Directional
Valve

Case
Drain
Filter

T
LS

Piston Pump

Low Steering
Pressure Switch

Accumulator
Charging Valve
Hand
Metering Unit

785C STEERING SYSTEM

HOLD

Case Drain
Filter
Piston
Pump

Crossover
Relief
Valves

Pump
Switch
Hand
Metering
Unit

Solenoid and
Relief Valve
Return Manifold

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PUMP COMPENSATOR VALVE

MAXIMUM PUMP FLOW

Drain Passages

From
Pump
To
Control Piston

MINIMUM PUMP FLOW

Drain Passages

From
Pump
To
Control Piston

785C STEERING PUMP

MINIMUM FLOW

Swashplate

Piston
Supply Passage
for Pump

Output Passage
From Pump

Control Piston

Pressure
Compensator Valve

789C STEERING PUMP

MAXIMUM FLOW
From Accumulators

To Accumulators
Accumulator
Charging Valve

Pump Output
Actuator
Piston

Load Sensing
Pressure
Flow
Compensator
Load Sensing
Controller
Swashplate
Piston

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

LOAD SENSING CONTROLLER

From
Accumulator
Accumulator
Charging Valve

Disconnect and Plug Line

for
High Pressure Cutoff Test

To
Accumulator
High Pressure Cutoff
Adjustment Screw

Low Pressure
Standby Adjustment Screw

To Tank
To Actuator Piston
From Pump Output Port

SOLENOID AND
RELIEF VALVE MANIFOLD

Supply
From Pump

To / From
Accumulators

To Steering
Control Valve

To Tank

Bleed Down
Solenoid
Back-up Relief
Valve

Left Turn
Cylinder

To Tank

Right Turn
Cylinder

Relief / Makeup
Valve

Back Pressure
Valve
Relief / Makeup
Valve

STEERING
DIRECTIONAL VALVE
NO TURN

Right Turn
Pilot Oil

Left Turn
Pilot Oil

Combiner / Check
Spool

Amplifier Spool

Priority Spool
Load
Sensing Port
From
Accumulator

Hand Metering Unit Supply

and Thermal Bleed

Left Turn
Cylinder

To Tank

Right Turn
Cylinder

Back
Pressure Valve

Relief / Makeup
Valve
Relief/makeup
Valve

STEERING
DIRECTIONAL VALVE
RIGHT TURN

Right Turn
Pilot Oil

Left Turn
Pilot Oil

Combiner / Check
Spool

Amplifier Spool

Priority Spool
Load Sensing Port
From
Accumulator

Hand Metering
Unit Supply and
Thermal Bleed

785C CROSSOVER RELIEF SYSTEM

EXTERNAL IMPACT

Crossover
Relief Valves

Hand
Metering Unit

HOIST SYSTEM
789C

Lower
Solenoid

Parking Brake
Release Pressure

"C" SERIES
HOIST CONTROL VALVE
HOLD

Rear Brake
Oil Cooler
Relief Valve

To Tank

To Hoist Cylinder
Head End

Load Check
Valve

To Hoist Cylinder
Rod End

Low Pressure
Relief Valve
High Pressure
Relief Valve

Rod End
Vent Slot

Counterbalance
Valve
To Rear Brake Oil Coolers

Dual Stage
Relief Valve
Signal Stem

Main Relief
Dump Spool

Pump
Supply Port

Parking Brake
Release Pressure

Raise
Solenoid

Lower
Solenoid

"C" SERIES
HOIST CONTROL VALVE

Parking Brake
Release Pressure

RAISE

Rear Brake
Oil Cooler
Relief Valve

To Tank

To Hoist Cylinder
Head End

Load Check
Valve

From Hoist Cylinder

Rod End

Low Pressure
Relief Valve
High Pressure
Relief Valve

Rod End
Vent Slot

Dual Stage
Relief Valve
Signal Stem

Main Relief
Dump Spool

Counterbalance
Valve

Pump
Supply Port

Parking Brake
Release Pressure

Raise
Solenoid

On

To Rear Brake
Oil Coolers

HOIST
COUNTERBALANCE
VALVE

Head End
Signal Pressure
From
Pump

To Tank

From
Hoist Cylinder
Rod End

Rod End
Pressure
Piston

RAISE

To
Hoist Cylinder
Rod End

Check Valve

LOWER AND FLOAT

Lower
Solenoid

On

Parking Brake
Release Pressure

"C" SERIES
HOIST CONTROL VALVE
LOWER (POWER DOWN)

Rear Brake
Oil Cooler
Relief Valve

To Tank

From Hoist Cylinder

Head End

Load Check
Valve

To Hoist Cylinder
Rod End

Low Pressure
Relief Valve
High Pressure
Relief Valve

Rod End
Vent Slot

Counterbalance
Valve
To Rear Brake Oil Coolers

Dual Stage
Relief Valve
Signal Stem

Main Relief
Dump Spool

Pump
Supply Port

Parking Brake
Release Pressure

Raise
Solenoid

Lower
Solenoid

On

Parking Brake
Release Pressure

"C" SERIES
HOIST CONTROL VALVE
FLOAT

Rear Brake
Oil Cooler
Relief Valve

To Tank

From Hoist Cylinder

Head End

Load Check
Valve

To Hoist Cylinder
Rod End

Low Pressure
Relief Valve
High Pressure
Relief Valve

Rod End
Vent Slot

Counterbalance
Valve
To Rear Brake Oil Coolers

Dual Stage
Relief Valve
Signal Stem

Main Relief
Dump Spool

Pump
Supply Port

Parking Brake
Release Pressure

Raise
Solenoid

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AIR SYSTEM AND BRAKES

789C

789C AIR CHARGING SYSTEM

Air Compressor
and Governor
Air
Dryers

To Air Start
Solenoid
Remote
Supply
Service / Retarder
Brake Tank
Low Air
Sensor

To Auto Lube Solenoid

To Horn / Seat / Clean-out
Pressure
Protection
Valve
Parking / Secondary
Brake Tank

TOWING SYSTEM

From Cab Secondary

or Parking Brake Valve

Relief
Valve

Parking
Brake
Release
Pump

To
TC Lockup
Valve
Parking
Brake
Release
Filter

To Hoist
Pilot
System

Parking Brake
Release Valve

Check
Valve

Towing Pump
Relief Valve

Towing Pump
and Motor

PARKING / SECONDARY BRAKES

SECONDARY BRAKES RELEASED
PARKING BRAKES ENGAGED

Parking
Brake
Valve

Secondary
Brake
Valve

Parking /
Secondary
Brake
Switch

Parking
Brake
Release
Pump

Parking
Brake
Release
Valve

Inverter
Valve
To TC Lockup Valve
and Hoist
Pilot System

Parking / Secondary
Brake Tank

BRAKE CYLINDER
BRAKES ENGAGED
Air
Piston

Indicator Rod

From
Makeup
Tank

Oil
Piston

To
Slack
Adjuster

Air
Inlet

Breather
Port
Spring

Rod

Valve

BRAKE SLACK ADJUSTER

Oil Flow
To Brake
Cylinder

Small Piston

From
Wheel
Brakes

Large Piston

Oil Flow
From Brake
Cylinder

From
Wheel
Brakes

To
Wheel
Brakes
To
Wheel
Brakes

BRAKES RELEASED

BRAKES ENGAGED

SERVICE / RETARDER BRAKE AIR SYSTEM

SERVICE BRAKES ENGAGED

Front Brake Cooler

Diverter Valve

Service
Brake Valve

Service
Relay
Valve

Pressure
Protection
Valve

Brake
Light
and
Service /
Retarder
Switch

Retarder
Valve

ARC
Valve

Retarder
Switch

Brake Cylinders

ARC
Relay
Valve

789C BRAKE
COOLING SYSTEM

Hoist Pump
Hoist
Screens

Front
Brakes

Rear Brakes

Hoist
Valve
Front Brake
Oil Cooler

Outlet
Relief Valve
Inlet
Relief Valve

Diverter
Valve

Torque
Converter
Charging
Filter
Rear Brake
Oil Coolers

Parking Brake
Release Valve

Converter
Outlet
Filter

Parking
Brake
Filter

BRAKE ELECTRONIC CONTROL SYSTEM

INPUT COMPONENTS
Parking Brake Filter
Brake Overstroke
Switch

Engine ECM
Brake Air Pressure

Left Brake
Release
Pressure
Right Brake
Release Pressure
Differential
Filter
Differential Oil
Temp Sensor

Differential
Oil Level

ARC
On Input
Off Input

TCS

Transmission/chassis ECM
VIMS
Shift Lever
Switch

Throttle
Sensor

Transmission Output
Speed Sensor

Actual Gear
Switch

Engine
Speed/timing
Sensor

Service/retarder
Brake Switch

Parking / Secondary
Brake Switch

OUTPUT COMPONENTS

Differential
Pressure

Arc On / Off
Switch

CAT DATA LINK

Service Tool

Differential Fan Relay

ARC Supply
Solenoid

Engine Output
Speed Sensor

Retarder
Pressure Switch
Auto Retarder
Pressure Switch

ARC Control
Solenoid
Retarder
Engaged Lamp

TCS
Engaged Lamp

TCS Test
Switch

TCS
TCS Selector Solenoid
Left and Right

Left Wheel Speed Sensor

Right Wheel Speed Sensor

ARC

Proportional
(Servo) Solenoid

AUTOMATIC RETARDER CONTROL

Engine Speed
Sensor

Brake ECM
(ARC / TCS)
On Input

Arc On / Off
Switch
Off Input
Service Tool
Engine ECM
Transmission /
Chassis ECM
VIMS

CAT Data Link

Retarder
Engaged
Lamp

Air From
Service Brake
Reservoir

Supply
Solenoid
Vent

Vent
Control
Solenoid

Service
Brake
Valve

To Service /
Retarder Brake
Relay Valve

Manual
Retarder
Valve

Automatic
Retarder
Valve
Auto Retarder
Pressure Switch

Retarder
Pressure
Switch

To ARC
Relay Valve

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ENGINE ON / ARC OFF

Control
Solenoid
Valve
Spool
To Tank

Supply Solenoid
Valve

Accumulator

Check Valve
Pump
Purge
Solenoid
Valve

To
Service
Brakes

ENGINE ON / ARC ON
Control
Solenoid
Valve

ON
Spool

To Tank

Supply Solenoid
Valve

Accumulator

ON

Check Valve
Pump
Purge
Solenoid
Valve

To
Service
Brakes

ENGINE OFF / ARC OFF

Control
Solenoid
Valve
Spool
To Tank

Supply Solenoid
Valve

Accumulator

Check Valve
Pump
Purge
Solenoid
Valve

ON

To
Service
Brakes

AUTOMATIC RETARDER CONTROL

ARC ENGAGED

Engine Speed
Sensor
On Input
ARC On / Off
Switch

Brake ECM
(ARC / TCS)
Off Input

Service Tool
Connector

Retarder
Engaged Lamp

CAT Data Link

Front Brake
Cooling Diverter
Solenoid
Parking Brake
Release Pump
Service
Brakes
Steering Bleed
Control

ARC Spool
Purge
Solenoid

Supply
Solenoid

To Tank

Control Solenoid

ARC
Valve

TRACTION CONTROL SYSTEM

Brake ECM
(ARC / TCS)

Electronic
Service Tool

TCS
Engaged
Lamp

Service / Retarder
Brake Switch
Transmission
Output Speed Sensor

TCS Selector
Solenoid
Left and Right

CAT Data Link

TCS Test
Switch

Proportional
Solenoid

Left Wheel
Speed Sensor
Right Wheel
Speed Sensor

+ 10V to
Wheel Sensors

TRACTION CONTROL SYSTEM (TCS)

ENGINE RUNNING/BRAKES RELEASED
Test
Switch
Service / Retarder
Brake Switch

Left
Drive Axle
Input
Signals

Ball Check
Transmission
Speed Sensor
Orifice
Tcs Engaged
Lamp

Screen
Selector
Solenoid

Right
Drive Axle

Proportional
Solenoid

Output
Signals

Parking
Brake
Valve

TRACTION CONTROL SYSTEM (TCS)

ENGINE RUNNING/LEFT BRAKE ENGAGED
Test
Switch
Service / Retarder
Brake Switch

Left
Drive Axle
Input
Signals

Ball Check
Transmission
Speed Sensor
Orifice
Tcs Engaged
Lamp

Screen
Selector
Solenoid

Right
Drive Axle

Proportional
Solenoid

Output
Signals

Parking
Brake
Valve

HYDRAULICSCHEMATICCOLORCODE
Black-Mechanicalconnection.Seal

Red-Highpressureoil

DarkGray-Cutawaysection

Red/WhiteStripes-1stpressurereduction

LightGray-Surfacecolor

RedCrosshatch-2ndreductioninpressure

White-Atmosphereor
Air(nopressure)

Pink-3rdreductioninpressure

Purple-Pneumaticpressure

Red/PinkStripes-Secondarysourceoilpressure

Yellow-Movingoractivatedcomponents

Orange-Pilot,signal,orTorqueConverteroil

CatYellow-(restrictedusage)
Identificationofcomponents
withinamovinggroup

Orange/WhiteStripesReducedpilot,signal,orTCoilpressure

Brown-Lubricatingoil

OrangeCrosshatch-2ndreductionin
pilot,signal,orTCoilpressure.

Green-Tank,sump,orreturnoil

Blue-Trappedoil

Green/WhiteStripesScavengeOilorHydraulicVoid