23 6 1 44 12 11 3

22 47 15 39

SOS

KENR8311-01 April 2009

FLUID POWER SYMBOLS

BASIC COMPONENT SYMBOLS
MAIN AUX.

12 44 41 45 26 58 57 30 54 38 35 18 13

PUMP or MOTOR

FLUID CONDITIONER

SPRING

CONTROL VALVES

RESTRICTION

LINE RESTRICTION (FIXED)

2-SECTION PUMP

PUMP: VARIABLE and PRESSURE COMPENSATED

VARIABILITY

SPRING (ADJUSTABLE)

LINE RESTRICTION (VARIABLE)

PRESSURE COMPENSATION

HYDRAULIC PNEUMATIC ENERGY TRIANGLES

LINE RESTRICTION
VARIABLE and PRESSURE COMPENSATED

ATTACHMENT

46 50 20 53 16 38 4

28

VALVE ENVELOPES

VALVES

VALVE PORTS

17 15
Area Aft of the Right Front Tire

ONE POSITION

TWO POSITION

THREE POSITION

TWO-WAY

THREE-WAY

FOUR-WAY

CONTROL VALVES
AB AB

CHECK VALVES

2 56 48 59 49 7
Transmission System Components

P T NORMAL POSITION

P T SHIFTED POSITION

INFINITE POSITION

BASIC SYMBOL

SPRING LOADED

SHUTTLE

PILOT CONTROLLED

FLUID STORAGE RESERVOIRS

GG
VENTED PRESSURIZED RETURN ABOVE FLUID LEVEL RETURN BELOW FLUID LEVEL

MEASUREMENT

ROTATING SHAFTS

785D Off-Highway Truck Hydraulic System

DMC1-UP MSY1-UP

PRESSURE

TEMPERATURE

FLOW

UNIDIRECTIONAL

BIDIRECTIONAL

COMBINATION CONTROLS

SOLENOID

SOLENOID or MANUAL

SOLENOID and PILOT

SOLENOID and PILOT or MANUAL

SERVO

THERMAL

DETENT

MANUAL CONTROL SYMBOLS

PUSH-PULL LEVER

MANUAL SHUTOFF

GENERAL MANUAL

PUSH BUTTON

PEDAL

SPRING

10 25 21 12 19 36 11 52 31 24 29 17 32 42 37 51 27 5 14 15 38 9 43 13 55 2
HH

RELEASED PRESSURE

PILOT CONTROL SYMBOLS

REMOTE SUPPLY PRESSURE

EXTERNAL RETURN

INTERNAL RETURN

SIMPLIFIED

COMPLETE

INTERNAL SUPPLY PRESSURE

ACCUMULATORS

CROSSING AND JOINING LINES

HYDRAULIC AND PNEUMATIC CYLINDERS

SPRING LOADED

GAS CHARGED

LINES CROSSING

LINES JOINING

SINGLE ACTING

DOUBLE ACTING

HYDRAULIC PUMPS
FIXED DISPLACEMENT VARIABLE DISPLACEMENT NON-COMPENSATED

HYDRAULIC MOTORS
FIXED DISPLACEMENT VARIABLE DISPLACEMENT NON-COMPENSATED

INTERNAL PASSAGEWAYS
INFINITE POSITIONING THREE POSITION TWO POSITION

UNIDIRECTIONAL

UNIDIRECTIONAL

BIDIRECTIONAL

BIDIRECTIONAL

FLOW IN ONE DIRECTION

PARALLEL FLOW

CROSS FLOW

FLOW ALLOWED IN EITHER DIRECTION

2009 Caterpillar All Rights Reserved

Printed in U.S.A.

COMPONENT LOCATIONS
Component Locations
Description
Accumulator Gp - H.A.R.C. Accumulator Gp - PED Accumulator Gp - Steering Adjuster Gp - Frnt Serv. Brk Slack Adjuster Gp - Rear Serv. Brk Slack Breather Gp - Xmssn Case / Tank Control Gp - Park Brakes Cooler Gp - Brake Cooler Gp - Brake, High Alt. Opt. Cooler Gp - Strng and RAXL Cooler Gp - Transmission Cylinder Gp - Hoist Cylinder Gp - Master, Brake Cylinder Gp - Steering Filter Gp - Breather Filter Gp Filter Gp Filter Gp - Converter Fitting - Orifice Manifold Gp - Diff. Switch Manifold Gp - Flow Control Motor Gp - Rear Axle Lube Orifice Pump Gp - Dead Eng. Towing Pump Gp - Hoist Pump Gp - Rear Axle Lube Pump Gp - Scavenge, T/C Pump Gp - Steering Pump Gp - Steering HMU Pump Gp - Transmission Screen Screen Screen Screen As Screen Gp - Brake Coolers Screen Gp - Converter Screen Gp - Hoist Switch As - Filter By pass Switch As - Filter By pass Switch As - Low Steer. Pressure Tank Gp - Brake Make Up Tank Gp - Hyd. and Transmission Tank Gp - Steering Valve As - Shuttle Valve Gp - Check Valve Gp - Check Valve Gp - Check, Brake Retract Valve Gp - Check, Steering Valve Gp - Diverter Valve Gp - Hyd. A.R.C. Valve Gp - Lock Up Clutch Valve Gp - Proportional Control Valve Gp - Rear Axle Oil Diverter Valve Gp - Relief, Brake Retract Valve Gp - Relief, Cooler Inlet Valve Gp - Relief, Cross-Over Valve Gp - Relief, T/C Inlet Valve Gp - Relief, T/C Outlet Valve Gp - Solenoid, Relief

TRANSMISSION SYSTEM TAP LOCATIONS

Part Number
241-3147 219-2539 205-0226 205-0557 205-0559 6G-0078 253-1675 200-5975 141-4108 4W-5056 7W-1713 311-7786 8W-3406 1U-3182 8X-4575 172-3889 245-6555 4T-4760 8X-7851 186-6317 312-3165 312-0357 1T-0936 5T-1060 211-6626 214-1555 6T-6147 232-1835 9T-4247 3T-0259 6E-5065 9T-3838 9T-3850 3S-3875 224-3895 186-6434 6E-5471 144-5661 164-7577 307-6719 6E-1851 161-0536 155-4127 305-5410 9T-3096 9T-3752 138-4732 176-6448 105-0170 177-8840 8E-6146 245-1662 313-9544 113-1543 7T-0297 3G-4667 3P-0348 3P-0349 6E-6298

Machine Location
1 2 2 3 4 5 6 7 7 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59

Schematic Location
D-4 B-7 B-8 D-1 D-5 C-6 E-4 C-5, F-1 C-5 A-8 C-6 B-3, C-3 E-1, E-5 F-8 C-2 B-6, C-6, E-3 D-8 E-3 B-8 C-2 C-8 D-7 F-3 E-3 D-2 D-8 E-2 A-7 E-8 B-6 F-3 D-3 D-3 D-8 C-4 F-2 C-2 E-2 B-7, C-6, D-8, E-3 B-8 F-3 A-6, D-3 A-7 D-1, D-5 E-3 D-4 E-4 B-8 F-2 C-4 E-2 C-2 to C-3 D-8 F-4 C-6 F-8 E-3 E-2 B-8

Tap Locations Pressure and Sampling

Tap Number
AA BB CC DD EE SOS FF GG HH SOS II JJ KK LL MM NN OO PP SOS QQ RR SS TT UU VV

LL
Schematic Location
F-8 F-8 D-8 B-7 B-8 B-7 A-7 D-6 C-6 C-6 F-5 F-4 D-5 B-4 E-4 D-4 C-3 C-3 E-3 E-3 E-2 E-2 D-2 D-2 D-1

16
CC

RR

Electrical Symbols Table

Hydraulic Symbols (Electrical)

Description
Right Steering Cylinder Pressure Left Steering Cylinder Pressure FD Drive Pressure Aux. Power Unit Port Steering Pressure Steering Oil Aux. Power Unit Port Transmission Charge Pressure Transmission Lube Pressure Transmission Oil Rear Brake Cooling Pressure Left Rear Parking Brake Pressure Rear Service Brake Pressure Right Rear Parking Brake Pressure Left Brake Pressure Right Brake Pressure Aux Power Port Aux Power Port Transmission Oil Torque Converter Charge Pressure Lock Up Clutch Pressure Torque Converter Outlet Pressure Hoist Pump Pressure Hoist Pump Pressure Front Sevice Brake Pressure

M
Electric Motor

SS
Torque Converter Area

Pressure Switch

Pressure Switch (Adjustable)

Temperature Switch

Electrical Wire

Top of Rear Axle

Electrical Symbols (Electrical)

KK

JJ

UU VV

TT

24

Pressure Symbol

Temperature Symbol

Level Symbol

Flow Symbol

Wire Number Identification Codes

Electrical Schematic Example

Hydraulic Schematic Example

Current Standard

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

KENR8311-01

Wire Color

325-AG135 PK-14 325-PK

Circuit Identification Number Wire Color Wire Gauge

AA

BB

56
Wire

Previous Standard
Wire Color

Hoist System Components

325-PK-14
B
Circuit Number Identification Wire Gauge
(EXAMPLE VALVE)

Oil Makeup Tank Area

6 48 59
DD
SOS

QQ NN II

EE

MM
Inside Rear of the Left Frame Rail

Front, Right, Inside Frame near Left Front Wheel

15

17

Left Rear Brake Housing

Note : Always check Parts Manual for your specific machine.

STEERING SYSTEM TAP LOCATIONS

TRANSMISSION SYSTEM TAP LOCATIONS

HOIST, BRAKE COOLING & TORQUE CONVERTER TAP LOCATIONS

30 Page,

(Dimensions: 39 inches x 28 inches)

53

57

58

Transducer (Fluid)

Transducer (Gas / Air)

Generator

CYLINDER GP STEERING 1U-3182

VALVE GP RELIEF CROSS- OVER 3G-4667

II

ORIFICE 1T-0936 SCREEN 6E-5065

AA

BB JJ
LEFT REAR

GG
LEFT FRONT

HYDRAULIC CONTROLS

TRANSMISSION

VALVE GP RELIEF BRAKE RETRACT 113-1543

TANK GP BRAKE MAKE UP 6E-1851 VALVE GP RELIEF T/C INLET 3P-0348

SCREEN GP CONVERTER 186-6434 FILTER GP CONVERTER 4T-4760 SWITCH AS FILTER BY PASS 144-5661

COOLER GP BRAKE 200-5975

HH
VALVE GP DIVERTER 105-0170 COOLER GP TRANSMISSION 7W-1713 BREATHER GP TRANSMISSION CASE / TANK 6G-0078

PUMP GP HMU STEERING 9T-4247

QQ

SWITCH AS FILTER BY PASS 164-7577

FILTER GP 245-6555

VALVE GP CHECK BRAKE RETRACT 138-4732 CYLINDER GP MASTER BRAKE 8W-3406

FILTER GP 172-3889

VALVE GP LOCK UP CLUTCH 8E-6146

RR

VALVE GP RELIEF T/C OUTLET 3P-0349

sos

VALVE GP RELIEF COOLER INLET 7T-0297

SS
TORQUE CONVERTER
CYLINDER GP MASTER BRAKE 8W-3406 SWITCH AS FILTER BY PASS 164-7577

VALVE GP DIVERTER REAR AXLE OIL 313-9544

MM
MOTOR GP REAR AXLE LUBE 312-0357

SOS
SWITCH AS FILTER BY PASS 164-7577 VALVE GP CHECK 9T-3096

PUMP GP SCAVENGE, T/C 6T-6147 FILTER GP BREATHER 8X-4575 FILTER GP 172-3889

CC

PUMP GP REAR AXLE LUBE 214-1555

TT KK
VALVE AS SHUTTLE 305-5410 ADJUSTER GP REAR SERVICE BRAKE SLACK 205-0559 CONTROL GP PARK BRAKES 253-1675
M

PUMP GP HOIST 211-6626

UU
PUMP DRIVE BOX

VV

SCREEN AS 3S-3875
DIFFERENTIAL FD DRIVE

NN

PUMP GP DEAD ENG. TOWING 5T-1060 SCREEN 9T-3838 SCREEN 9T-3850

VALVE AS SHUTTLE 305-5410 ADJUSTER GP FRONT SERVICE BRAKE SLACK 205-0557 PUMP GP TRANSMISSION 3T-0259

PUMP DRIVE BOX

BANJO HOUSING SUMP

(Dimensions: 39 inches x 28 inches)

ACCUMULATOR GP H. A.R.C. 241-3147 MANIFOLD GP FLOW CONTROL 312-3165

VALVE GP CHECK 9T-3752

KENR8311-01

C
VALVE GP CHECK STEERING 176-6448

TANK GP HYDRAULIC / TRANSMISSION 161-0536

HIGH PRESS. RELIEF

DUAL STAGE SIGNAL SPOOL MAIN RELIEF DUMP SPOOL

C
TANK GP HYDRAULIC / TRANSMISSION 161-0536

SWITCH AS LOW STEERING PRESSURE 307-6719

ACCUMULATOR GP STEERING STD: 205-0226 PED: 219-2539

DD

ACCUMULATOR GP STEERING STD: 205-0226 PED: 219-2539 VALVE GP HYD. A.R.C. 177-8840

VALVE GP PROPORTIONAL CONTROL 245-1662

BRAKE COOLING RELIEF

MANIFOLD GP DIFF. SWITCH 186-6317

LOW PRESS. RELIEF

SCREEN GP HOIST 6E-5471

TRANSMISSION

RAISE

EE
FITTING ORIFICE 8X-7851 VALVE GP SOLENOID RELIEF 6E-6298 COOLER GP BRAKE 200-5975 HIGH ALT. OPT. 141-4108 SCREEN GP BRAKE COOLERS 224-3895

ROD END VENT SLOT ACROSS STEM HOLD

30 Page,

OO
AUX. POWER UNIT PORT

PP

SNUB SIGNAL ORIFICE #1 SIGNAL ORIFICE #2 FLOAT

LOWER

sos LL
RIGHT REAR

CYLINDER GP HOIST 311-7786

VENT ORIFICE FOR COUNTERBALANCE VALVE

SCREEN GP HOIST 6E-5471

MANIFOLD GP DIFF. SWITCH 186-6317

HYDRAULIC CIRCUIT COLOR DESCRIPTIONS

RIGHT FRONT
DEAD ENGINE TOWING CIRCUIT SCAVENGE PUMPS, T/C AND TRANSMISSION TRANSMISSION LUBE PUMP OUTPUT TRANSMISSION CHARGE PUMP OUTPUT STEERING PUMP AND CIRCUIT HOIST PUMP AND CIRCUIT TORQUE CONVERT CHARGE PUMP AND CIRCUIT SUPPLY LINE DRAIN / RETURN LINE DRAIN / BRAKE COOLING STEERING CIRCUIT REAR AXLE LUBE PUMP AND CIRCUIT BRAKE PUMP AND CIRCUIT PARKING BRAKE CIRCUIT

PUMP DRIVE BOX

COOLER GP STEERING / RAXL 4W-5056

PUMP GP STEERING 232-1835

PARKING BRAKE AND SERVICE BRAKE HOIST, BRAKE COOLING, AND TORQUE CONVERTER SYSTEMS

LINE PATTERNS
Pressure Line Pilot / Load Sensing Pressure Drain / Return Lines Component Group

TANK GP STEERING 155-4127

Attachment Air Line

CALLOUTS
YY

Taps (Pressure, Sampling,Sensor) by letter Components by number

52

FF

STEERING AND RAX SYSTEM

THIS SCHEMATIC IS FOR THE 785D OFF-HIGHWAY TRUCK MEDIA # : KENR8311-01 PART NUMBER: 285-0704, CHANGE: 00, VERSION: Components are shown installed on a fully operable machine. Refer to the appropriate Service Manual for Troubleshooting, Specifications and Systems Operations.