SENR1532-03

September 2004

Systems Operation
Testing and Adjusting
789C Off-Highway Truck
Hydraulic System
2BW1-Up (Machine)
 i01658146

Important Safety Information

Most accidents that involve product operation, maintenance and repair are caused by failure to observe
basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous
situations before an accident occurs. A person must be alert to potential hazards. This person should also
have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings
are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or pictorially
presented.
Operations that may cause product damage are identified by “NOTICE” labels on the product and in
this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
The warnings in this publication and on the product are, therefore, not all inclusive. If a tool,
procedure, work method or operating technique that is not specifically recommended by Caterpillar
is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that
the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
The information, specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before you
start any job. Caterpillar dealers have the most current information available.

When replacement parts are required for this

product Caterpillar recommends using Caterpil-
lar replacement parts or parts with equivalent
specifications including, but not limited to, phys-
ical dimensions, type, strength and material.

Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or
death.
SENR1532-03 3
Table of Contents

Table of Contents

Systems Operation Section

Hydraulic System ...................................................... 4
General Information .................................................. 5
Hydraulic Tank (Torque Converter, Hoist, Brake, and
Transmission) ......................................................... 6
Gear Pump (Hoist and Rear Brake Cooling) ............ 7
Hoist Control ............................................................. 7
Position Sensor (Hoist Control) ................................ 8
Position Sensor (Dump Body) .................................. 8
Position Sensor (Dump Body) .................................. 9
Control Valve (Hoist) ................................................. 9
Hoist Cylinder.......................................................... 15

Testing and Adjusting Section

Troubleshooting
General Information ................................................ 19
Hoist System Troubleshooting ................................ 19
Hoist, Torque Converter, and Brake System
Troubleshooting .................................................... 20
Brake Oil Overheating Troubleshooting .................. 28

Testing and Adjusting

Hoist Cylinder Performance - Test .............................. 31
Relief Valve (Hoist Dual Stage) - Test and Adjust .. 31
Relief Valve (Rear Brake Oil Cooler) - Test and
Adjust .................................................................... 34
Gear Pump (Hoist and Rear Brake Cooling) Efficiency
- Test ................................................................................ 34
Position Sensor (Dump Body) - Adjust ................... 35
Position Sensor (Dump Body) - Adjust ................... 36
Worksheets ............................................................. 37

Index Section
Index ....................................................................... 39
4 SENR1532-03
Systems Operation Section

Systems Operation Section

i01288699

Hydraulic System
SMCS Code: 5050

Hydraulic Schematic

g00500066
Illustration 1
SENR1532-03 5
Systems Operation Section

(1) Left rear wheel brake
(2) Air breathers
(3) Left front wheel brake
(4) Torque converter lockup clutch and
synchronizing valve
(5) Makeup tank for brake oil
(6) Torque converter and front brake cooling
oil cooler
(7) Torque converter
(8) Torque converter outlet relief valve
(9) Pump drive
(10) Rear brake cooling pump section
(11) Parking brake release pump section
(12) Torque converter charging pump
section
(13) Torque converter scavenge pump
section
(14) Transmission hydraulic control
(15) Torque converter inlet relief valve
(16) Transmission cooler inlet relief valve
(17) Transmission oil cooler
(18) Parking and secondary brake valve
(19) Torque converter and front brake
cooling diverter valve
(20) Brake master cylinder (front)
(21) Brake master cylinders (rear)
(22) Transmission planetary
(23) Electric drive pump check valve
(24) Parking and secondary brake release
electric drive pump
(25) Transmission charging section of the
gear pump
(26) Transmission lubrication section of the
gear pump
(27) Transmission scavenge section of the
gear pump
(28) Rear slack adjuster
(29) Traction control valve
(30) Rear brake oil cooler relief valve
(31) Hoist control valve
(32) Front section of the hoist and rear brake
cooling gear pump
(33) Rear section of the hoist and rear brake
cooling gear pump
(34) Front slack adjuster
(35) Right rear wheel brake
(36) Rear brake oil coolers
(37) Hoist counterbalance valve
(38) Hoist cylinders
(39) Check valve
(40) Torque converter, hoist, brake, and
transmission hydraulic tank
(41) Right front wheel brake

Location of Components

g00501496
Illustration 3
(31) Hoist control valve
(32) Front section of the hoist and rear brake cooling gear pump
(33) Rear section of the hoist and rear brake cooling gear pump
(38) Hoist cylinders
(40) Torque converter, hoist, brake, and transmission hydraulic
tank
(55) Hoist screens

g00501494
Illustration 2
i00970791
(9) Pump drive
(18) Parking and secondary brake valve
(31) Hoist control valve General Information
(32) Front section of the hoist and rear brake cooling gear pump
(33) Rear section of the hoist and rear brake cooling gear pump SMCS Code: 5050
(38) Hoist cylinders
(40) Torque converter, hoist, brake, and transmission hydraulic
tank The hydraulic system includes the following systems.
(55) Hoist screens
• Hydraulic Tank (Torque Converter, Hoist, Brake,
and Transmission)

• Hoist
• Torque Converter
• Brakes and Brake Cooling
This service module covers the following systems.

• Hydraulic Tank (Torque Converter, Hoist, Brake,

and Transmission)

• Hoist
6 SENR1532-03
Systems Operation Section

For information about the torque converter, see
Systems Operation, SENR1522, “789C Off-Highway
Truck Power Train”.
For information about the brakes and brake cooling,
see Systems Operation/Testing And Adjusting,
SENR1528, “789C Off-Highway Truck Air System
and Brakes”.
The steering hydraulic system is separate from other
hydraulic systems.
The torque converter, hoist, and brake section (2) has
two sight gauges. The top sight gauge is generally
used for checking the oil level. The bottom sight
gauge can be used when the hoist cylinders are in
the RAISE position. The transmission section (3) also
has two sight gauges. The bottom sight gauge is
used for checking the oil level with cold oil. The top
sight gauge is used for checking the oil level with hot
oil. See the Operation and Maintenance Manual for
lubrication viscosities and for refill capacities for both
sections of the hydraulic tank.

For information about the steering system, Tank Ports

see Systems Operation/Testing and Adjusting,
SENR1526, “789C Off-Highway Truck Steering
System”.

i00970796

Hydraulic Tank (Torque

Converter, Hoist, Brake, and
Transmission)
SMCS Code: 3177; 5056

g00317611
Illustration 4
(1) Torque converter, hoist, brake, and transmission hydraulic tank
(2) Torque converter, hoist, and brake section
(3) Transmission section
The torque converter, hoist, brake, and transmission
hydraulic tank (1) is located on the outside of the
right side of the frame. The transmission section (3)
is separated from the torque converter, hoist, and
brake section (2) by a wall inside the hydraulic tank
(1). The transmission section (3) supplies oil for the
operation of the transmission. The torque converter,
hoist, and brake section (2) supplies oil to the brakes,
to the brake cooling system, to the torque converter
system, and to the hoist hydraulics. An air breather
for section (2) and an air breather for section (3) are
located on the vertical frame member on the right
side of the truck.
g00486260
Illustration 5
(4) Breather ports for the transmission section of the hydraulic tank
(5) Breather port for the hydraulic section of the hydraulic tank
(6) Return port for the transmission
(7) Return port for the torque converter inlet relief valve
(8) Return port for brake cooling
(9) Return port for the hoist control valve
(10) Return port from torque converter scavenge pump
(11) Drain port for the parking and secondary brake control valve
(12) Drain port for the lip seal case of the parking brake
(13) Drain port for the brake makeup oil tank
(14) Suction port for the transmission
(15) Suction ports for the hoist and rear brake cooling gear pump
(16) Suction port for the brake cooling pump section
(17) Suction port for torque converter pump
(18) Outlet port to brake cooling system for the rear brakes
SENR1532-03 7
Systems Operation Section

The hoist and rear brake cooling gear pump is a

two-section gear pump. The front section (2) is rated
at 390 L/min (103 US gpm). Oil from the torque
converter, hoist, and brake section of the hydraulic
tank flows through line (4) to the pump inlet. Pump
section (2) then pumps oil through line (6) to a
screen. The oil goes from the screen to the hoist
control valve.

The rear section (3) of the pump is also rated

g00486261
Illustration 6
(6) Return port for the transmission
(7) Return port for the torque converter inlet relief valve
(8) Return port for brake cooling
(9) Return port for the hoist control valve
(10) Return port from torque converter scavenge pump
(11) Drain port for the parking and secondary brake control valve
(12) Drain port for the lip seal case of the parking brake
(13) Drain port for the brake makeup oil tank
(14) Suction port for the transmission
(15) Suction ports for the hoist and rear brake cooling gear pump
(16) Suction port for the brake cooling pump section
(17) Suction port for torque converter pump
(18) Outlet port to brake cooling system for the rear brakes
i00970829
at 390 L/min (103 US gpm). Oil from the torque
converter, hoist, and brake section of the hydraulic
tank flows through line (5) to the pump inlet. Pump
section (3) then pumps oil through line (7) to a
screen. The oil goes from the screen to the hoist
control valve. The oil from pump section (2) combines
with the oil from pump section (3) in the hoist control
valve. The hoist control valve will send pump oil to
one of two locations. When the dump body is being
raised or lowered, the hoist cylinders receive the oil.
If the hoist is not being used, the oil flows to the oil
cooling system for the rear brakes.
i00970843
Hoist Control
SMCS Code: 5063

Gear Pump (Hoist and Rear

Brake Cooling)
SMCS Code: 5073; 5083

g00494625
Illustration 8
(1) RAISE position
(2) HOLD position
(3) FLOAT position
(4) LOWER position

g00317783
The hoist control is located to the left of the operator’s
Illustration 7 seat. The hoist control has four positions: RAISE,
(1) Pump drive HOLD, FLOAT, and LOWER. The machine should
(2) Hoist and rear brake cooling gear pump (front section) normally be operated with the hoist control in the
(3) Hoist and rear brake cooling gear pump (rear section)
(4) Inlet from the hydraulic tank FLOAT position.
(5) Inlet from the hydraulic tank
(6) Outlet to the hoist control valve The hoist control is connected to the hoist control
(7) Outlet to the hoist control valve position sensor. The hoist control position sensor
sends electrical signals to the Power Train Electronic
Control Module (Power Train ECM). See the hydraulic
system System Operation, “Position Sensor (Hoist
Control)” for additional information.
8 SENR1532-03
Systems Operation Section
When the hoist control is released a spring will move
the hoist control from the RAISE position to the
HOLD position or from the LOWER position to the
FLOAT position.
i00980958
Position Sensor (Hoist Control)
SMCS Code: 1408-NS
g00498290
Illustration 9
Location of the hoist control position sensor
The hoist control position sensor is located on the left
side of the operator’s seat. The hoist control position
sensor is a Pulse Width Modulation position sensor.
The hoist control postion sensor sends duty cycle
signals to the Power Train Electronic Control Module
(Power Train ECM).
When the hoist control is used, the hoist control
position sensor sends an electrical signal to the
Power Train Electronic Control Module (Power Train
ECM). The Power Train ECM uses this signal to
energize the appropriate hoist proportioning solenoid
on the hoist control valve. These hoist propertioning
solenoids will move the spool in the hoist control
valve. This will cause oil to be sent to the hoist
cylinders in order to move the dump body.
The signal from the hoist control position sensor is
also used to neutralize the transmission. The Power
Train ECM will allow only a forward speed position
or the NEUTRAL position when the hoist control
position sensor is in the RAISE position. The Power
Train ECM will not allow a shift to the REVERSE
position until the hoist control position sensor has
been moved from the RAISE position and the
transmission shift lever is in the NEUTRAL position.
Note: If the machine is in REVERSE and the hoist
position sensor is in the RAISE position the Power
Train ECM will shift the transmission to NEUTRAL.
The machine will remain in NEUTRAL until the
hoist control is moved into the HOLD or the FLOAT
position and the transmission control has been cycled
through NEUTRAL.
i00980987
Position Sensor (Dump Body)
SMCS Code: 1408-NS
S/N: 2BW1-555
g00498361
Illustration 10
(1) Rod
(2) Dump body position sensor
The dump body position sensor (2) is located on the
left rear frame near the pivot pin for the dump body.
The rod (1) is connected between the dump body
position sensor (2) and the dump body. When the
dump body is raised, the rod (1) rotates the dump
body position sensor (2), which changes the Pulse
Width Modulated signal that is sent to the Power
Train Electronic Control Module (Power Train ECM).
The adjustment of the rod between the sensor and
the dump body is very important. The length of the
rod should be 350.0 ± 3.0 mm (13.78 ± 0.12 inch)
from the center of both rod ends.
After rod (1) has been adjusted, the Power Train
ECM will perform a calibration. The dump body
position sensor (2) is calibrated by the Power Train
ECM when all of the following conditions exist:
• The engine is running for one minute with no
ground speed.
• The hoist control is in the FLOAT position.
• The signal from the dump body position sensor is 6
degrees different from the previous calibration.
SENR1532-03
The dump body position sensor (2) is used to limit the
top gear while the dump body is up. The Power Train
ECM comes from the factory with the top gear value
that is set to FIRST gear. The transmission will not
shift past FIRST gear until the dump body is down.
The top gear value is programmable by utilizing the
Electronic Control Analyzer Programmer (ECAP) or
the Electronic Technician (ET). The top gear value
can be changed to SECOND gear, THIRD gear, or
FOURTH gear.
The signal from dump body position sensor (2) is also
used to control the SNUB position of the hoist control
valve. The Power Train ECM will signal the hoist
proportioning solenids to move the hoist control valve
to the SNUB position when the dump body that is
being lowered nears the frame. The speed in FLOAT
is reduced in the SNUB position in order to prevent
the dump body from contacting the frame too hard.
The signal from the dump body position sensor (2) is
used to provide warnings to the operator when the
truck is moving with the dump body UP.
i01777230
Position Sensor (Dump Body)
SMCS Code: 1408-NS
S/N: 2BW556-Up
g00908522
Illustration 11
(1) Rod
(2) Dump body position sensor
The dump body position sensor (2) is located on the
left rear frame near the pivot pin for the dump body.
The rod (1) is connected between the dump body
position sensor (2) and the dump body. When the
dump body is raised, the rod (1) rotates the dump
body position sensor (2), which changes the Pulse
Width Modulated signal that is sent to the Power
Train Electronic Control Module (Power Train ECM).
The adjustment of the rod between the sensor and
the dump body is very important. The length of the
rod should be 350.0 ± 3.0 mm (13.78 ± 0.12 inch)
from the center of both rod ends.
9
Systems Operation Section
After rod (1) has been adjusted, the Power Train
ECM will perform a calibration. The dump body
position sensor (2) is calibrated by the Power Train
ECM when all of the following conditions exist:
• The engine is running for one minute with no
ground speed.
• The hoist control is in the FLOAT position.
• The signal from the dump body position sensor is 6
degrees different from the previous calibration.
The dump body position sensor (2) is used to limit the
top gear while the dump body is up. The Power Train
ECM comes from the factory with the top gear value
that is set to FIRST gear. The transmission will not
shift past FIRST gear until the dump body is down.
The top gear value is programmable by utilizing the
Electronic Control Analyzer Programmer (ECAP) or
the Electronic Technician (ET). The top gear value
can be changed to SECOND gear, THIRD gear, or
FOURTH gear.
The signal from dump body position sensor (2) is also
used to control the SNUB position of the hoist control
valve. The Power Train ECM will signal the hoist
proportioning solenids to move the hoist control valve
to the SNUB position when the dump body that is
being lowered nears the frame. The speed in FLOAT
is reduced in the SNUB position in order to prevent
the dump body from contacting the frame too hard.
The signal from the dump body position sensor (2) is
used to provide warnings to the operator when the
truck is moving with the dump body UP.
i00985948
Control Valve (Hoist)
SMCS Code: 5051; 5136
Illustration 12
g00502079
(1) Hoist and rear brake cooling gear pump
(2) Hoist screen
(3) Hoist screen bypass switch
10 SENR1532-03
Systems Operation Section

All of the oil from the hoist and rear brake cooling
gear pump (1) is sent through the two hoist screens
(2). Each hoist screen (2) has a hoist screen bypass
switch (3). The hoist screen bypass switches (3)
will alert the Vital Information Management System
(VIMS) of any restrictions in the hoist screens (2).
Pump oil from the hoist screens (2) enters the hoist
control valve through two hoses.

The pilot oil lines for the hoist proportioning solenoids

on the hoist control valve use oil from the parking
brake release system.

g00502080
Illustration 13
(4) Outlet to the torque converter, hoist, and brake section of the
hydraulic tank
(5) Test port for the rear brake oil cooler relief valve
(6) Hoist dual stage relief valve
(7) Inlet for pump oil
(8) Hoist proportioning solenoid for RAISE
(9) Outlet to the rod end of the hoist cylinder
(10) Outlet to the rear brake oil cooling system
(11) Outlet to the head end of the hoist cylinder

g00502081
Illustration 14
(8) Hoist proportioning solenoid for RAISE
(9) Outlet to the rod end of the hoist cylinder
(10) Outlet to the rear brake oil cooling system
(11) Outlet to the head end of the hoist cylinder
(12) Hoist proportioning solenoid for SNUB, FLOAT, and LOWER
(13) Hoist counterbalance valve
(14) Test port for the hoist counterbalance valve
(15) Rear brake oil cooler relief valve
SENR1532-03 11
Systems Operation Section

g00501884
Illustration 15
(1) Hoist and rear brake cooling gear pump (12) Hoist proportioning solenoid for SNUB, (23) Centering springs
(2) Hoist screen FLOAT, and LOWER (24) Pump oil supply port
(3) Hoist screen bypass switch (13) Hoist counterbalance valve (25) Signal line
(4) Outlet to the torque converter, hoist, and (15) Rear brake oil cooler relief valve (26) Check valve (rod end)
brake section of the hydraulic tank (16) Pilot oil line from the parking brake (27) Dump spool
(6) Hoist dual stage relief valve release system (28) Two load check valves
(7) Inlet for pump oil (17) Screen (29) Torque converter, hoist, and brake
(8) Hoist proportioning solenoid for RAISE (18) Orifice section of the hydraulic tank
(9) Line to the rod end of the hoist cylinder (19) Stem (dual stage) (30) Actuator
(10) Outlet to the rear brake oil cooling (20) High pressure relief valve (31) Hoist cylinder
system (21) Low pressure relief valve
(11) Line to the head end of the hoist cylinder (22) Directional spool
12 SENR1532-03
Systems Operation Section

Oil flows through two lines from the hoist and rear
brake cooling gear pump (1). This oil flows through
hoist screens (2) and into pump oil supply ports (7).
This oil combines inside the hoist control valve. Two
load check valves (28) protect the pump from reverse
oil flow from the lines for the hoist cylinders.
Rear brake oil cooler relief valve (15) limits the
pressure in the lines to the rear brake oil coolers.
Rear brake oil cooler relief valve (15) will vent oil to
the torque converter, hoist, and brake section (29) of
the hydraulic tank, when the pressure in lines (10)
is too high.
RAISE Position
In the RAISE position, hoist proportioning solenoid
(8) is receiving a current of 1.9 amperes. Pilot oil in
the actuator (30) for hoist proportioning solenoid (8)
is allowed to drain to the torque converter, hoist, and
brake section (29) of the hydraulic tank. Pilot oil in
the actuator (30) for the hoist proportioning solenoid
(12) will now push directional spool (22) to the left.
When directional spool (22) moves, the pump oil that
is coming through port (24) flows through load check
valves (28), to lines (11), and to the head end of the
hoist cylinders (31).

Hoist counterbalance valve (13) prevents cavitation Load check valves (28) will block the pump pressure
of the hoist cylinders. If the load shifts suddenly until the pump pressure is higher than the pressure
and the hoist and rear brake cooling gear pump in the hoist cylinders. Load check valves (28) also
(1) cannot supply enough oil to the hoist cylinders prevent reverse flow into the pump port.
(31) for pressure compensation, the pressure in the
head end of the hoist cylinders (31) will drop. Hoist Some of the oil is also sent as signal oil through signal
counterbalance valve (13) is set to shift if the pressure line (25) to stem (19) and to hoist counterbalance
in the head end of the hoist cylinders (31) drops valve (13). The signal pressure shifts stem (19) so
below 6900 kPa (1000 psi). The counterbalance that low pressure relief valve (21) is blocked. This
valve is not adjustable. allows all of the pump oil that is flowing through dump
spool (27) to flow to high pressure relief valve (20). If
Pump oil also flows through dump spool (27) to hoist the oil pressure opens high pressure relief valve (20),
dual stage relief valve (6). If either low pressure relief dump spool (27) will shift upward and the pump oil
valve (21) or high pressure relief valve (20) is opened, will be vented to lines (10) for rear brake cooling oil.
dump spool (27) will release pump oil to the rear
brake oil cooling lines. Low pressure relief valve (21)
is set to open at 3450 + 350 − 0 kPa (500 + 51 − 0 psi).
High pressure relief valve (20) is set to open at
17225 + 700 − 0 kPa (2500 + 102 − 0 psi). A signal
line to stem (19) closes low pressure relief valve (21)
while hoist proportioning solenoid (8) for the RAISE
position is energized.

HOLD Position
In the HOLD position, neither of the hoist
proportioning solenoids are receiving current. All of
the pilot oil is blocked in actuators (30). Centering
springs (23) hold directional spool (22) so that lines g00502322
Illustration 16
(11) to the head end of the hoist cylinders (31) are
blocked by directional spool (22). A small notch in (13) Hoist counterbalance valve
(25) Signal line
directional spool (22) connects the lines to the rod (32) Spool
end of the hoist cylinders (9) with the rear brake (33) Passage to directional spool
cooling oil. (34) Check valve
(35) Passage to the line for the rod ends of the hoist cylinders
(36) Passage to the line for the rod ends of the hoist cylinders
Because no signal oil is sent to stem (19), the pump
oil is open to low pressure relief valve (21). The
pressure will not increase enough in order to open
low pressure relief valve (21). The directional spool
(22) is in a position that allows all of the oil to flow
to the rear brake cooling system. The maximum
pressure in the lines to the rear brake cooling system
is controlled by rear brake oil cooler relief valve (15).
If the rear brake oil cooler relief valve (15) opens, the
oil will vent through line (4) to the torque converter,
hoist, and brake section (29) of the hydraulic tank.
SENR1532-03
Signal pressure to hoist counterbalance valve (13)
pushes spool (32) in hoist counterbalance valve
valve (13) to the open position. In this position, oil
from the rod ends of the hoist cylinders can flow from
passage (35) and into passage (33), which goes to
the directional spool. This oil is routed to lines (10)
for rear brake cooling oil. If the pressure in the head
ends of the hoist cylinders drops below 6900 kPa
(1000 psi), spool (32) in hoist counterbalance valve
(13) will shift and the flow of oil from the rod ends will
be restricted. This keeps oil in the rod ends of the
hoist cylinders. Check valve (34) blocks passage (36)
due to the spring force.
LOWER Position
In the LOWER position, hoist proportioning solenoid
(12) is receiving a current of 1.9 amperes. Pilot oil in
the actuator (30) for hoist proportioning solenoid (12)
is allowed to drain to the torque converter, hoist, and
brake section (29) of the hydraulic tank. Pilot oil in
the actuator (30) for the hoist proportioning solenoid
(8) will now push directional spool (22) to the right.
When directional spool (22) moves, the pump oil that
is coming through port (24) flows through load check
valves (28) and into the lines (9) that go to the rod
ends of the hoist cylinders (31).
Load check valves (28) prevent any reverse flow
into the pump port. Pump oil flows past check valve
(26), into lines (9), and to the rod ends of the hoist
cylinders (31).
Oil in lines (11) to the head end of the hoist cylinders
is vented to the torque converter, hoist, and brake
section (29) of the hydraulic tank.
Because no signal pressure is sent to stem (19),
pump oil can flow to low pressure relief valve (21). If
low pressure relief valve (21) opens, dump spool (27)
will shift upward and the pump oil will be vented to
lines (10) for rear brake cooling oil.
13
Systems Operation Section
Illustration 17
g00502344
(13) Hoist counterbalance valve
(25) Signal line
(32) Spool
(33) Passage to directional spool
(34) Check valve
(35) Passage to the line for the rod ends of the hoist cylinders
(36) Passage to the line for the rod ends of the hoist cylinders
Because no signal pressure is sent to the hoist
counterbalance valve (13), spool (32) blocks passage
(35). Pump oil that is coming into passage (33)
pushes check valve (34). This opens passage (36)
to the rod ends of the hoist cylinders (31). Oil flows
freely through hoist counterbalance valve (13) and to
the rod ends of the hoist cylinders (31).
FLOAT Position
In the FLOAT position, hoist proportioning solenoid
(12) is receiving a current of 1.55 amperes. Pilot oil in
the actuator (30) for hoist proportioning solenoid (12)
is allowed to drain to the torque converter, hoist, and
brake section (29) of the hydraulic tank. Pilot oil in
the actuator (30) for the hoist proportioning solenoid
(8) will now push directional spool (22) to the right.
Because a smaller amount of pilot oil is allowed to
drain from the actuator (30) for hoist proportioning
solenoid (12), directional spool (22) does not move
all the way to the LOWER position. When directional
spool (22) moves, some of the pump oil that is
coming through port (24) flows through load check
valves (28) and into the passages to the rod ends
of the hoist cylinders (31). Load check valves (28)
prevent any reverse flow into the pump port.
Oil in lines (11) to the head end of the hoist cylinders
(31) is vented to the torque converter, hoist, and rear
brake cooling section (29) of the hydraulic tank.
Because no signal pressure is sent to stem (19),
pump oil can flow to low pressure relief valve (21).
Because the pressure will not increase enough in
order to open low pressure relief valve (21), all of the
remaining oil is sent to the rear brake cooling system.
14 SENR1532-03
Systems Operation Section

Oil in lines (11) to the head end of the hoist cylinders

(31) is vented to the torque converter, hoist, and rear
brake cooling section (29) of the hydraulic tank.

Because no signal pressure is sent to stem (19),

pump oil can flow to low pressure relief valve (21).
Because the pressure will not increase enough in
order to open low pressure relief valve (21), all of the
oil is sent to the rear brake cooling system.

g00502344
Illustration 18
(13) Hoist counterbalance valve
(25) Signal line
(32) Spool
(33) Passage to directional spool
(34) Check valve
(35) Passage to the line for the rod ends of the hoist cylinders
(36) Passage to the line for the rod ends of the hoist cylinders

Because no signal pressure is sent to the hoist

counterbalance valve (13), spool (32) blocks passage Illustration 19
g00502344

(35). Pump oil that is coming into passage (33)
pushes check valve (34). This opens passage (36)
to the rod ends of the hoist cylinders (31). Oil flows
freely through hoist counterbalance valve (13) and to
the rod ends of the hoist cylinders (31).
SNUB Position
The SNUB position is activated by the Power Train
Electronic Control Module (Power Train ECM). The
operator has no control over this position. The SNUB
position will slow the rate of lowering the dump body
as the dump body nears the frame of the truck. The
dump body position sensor will signal the Power
Train ECM when the dump body is between 12
degrees and 6.5 degrees from the frame. The speed
of lowering the dump body will determine the exact
degree. The Power Train ECM will then send a signal
in order to move the hoist control valve to the SNUB
position.
(13) Hoist counterbalance valve
(25) Signal line
(32) Spool
(33) Passage to directional spool
(34) Check valve
(35) Passage to the line for the rod ends of the hoist cylinders
(36) Passage to the line for the rod ends of the hoist cylinders
Because no signal pressure is sent to the hoist
counterbalance valve (13), spool (32) blocks passage
(35). Pump oil that is coming into passage (33)
pushes check valve (34). This opens passage (36)
to the rod ends of the hoist cylinders (31). Oil flows
freely through hoist counterbalance valve (13) and to
the rod ends of the hoist cylinders (31).

In the SNUB position, hoist proportioning solenoid

(12) is receiving a current of 0.925 amperes. Pilot oil
in the actuator (30) for hoist proportioning solenoid
(12) is allowed to drain to the torque converter, hoist,
and brake section (29) of the hydraulic tank. Pilot
oil in the actuator (30) for the hoist proportioning
solenoid (8) will now push directional spool (22) to the
right. This moves the directional spool (22) out of the
FLOAT position. When directional spool (22) moves,
the oil from the head ends of the hoist cylinders is
restricted. This lowers the speed of movement of the
dump body.
SENR1532-03 15
Systems Operation Section

i00990775

Hoist Cylinder
SMCS Code: 5102

g00281530
Illustration 20
Hoist cylinders
(1) Rod assembly
(2) Cylinder (second stage)
(3) Cylinder (first stage)

g00281531
Illustration 21
Cross section of hoist cylinder
(1)Rod assembly
(2)Cylinder (second stage)
(3)Cylinder (first stage)
(4)Grooves in the end of the cylinder (second stage)
(5)Chamber in the head end of the hoist cylinder
(6)Opening to the head end of the hoist cylinder
(7)Opening to the rod end of the hoist cylinder
(8)Chamber between cylinders (first stage and second stage)
(9)Chamber between the rod assembly and cylinder (second
stage)
(10) Orifices in the rod assembly
(11) Head
(12) Internal head
(13) Piston
16 SENR1532-03
Systems Operation Section

Raising the Dump Body

g00281955
Illustration 22
Hoist cylinder (first stage) to extended length
(1) Rod assembly (6) Opening to the head end of the hoist (10) Orifices in the rod assembly
(2) Cylinder (second stage) cylinder (11) Head
(3) Cylinder (first stage) (7) Opening to the rod end of the hoist (12) Internal head
(4) Grooves in the end of the cylinder cylinder (13) Piston
(second stage) (8) Chamber between cylinders (first stage (AA) Pump oil
(5) Chamber in the head end of the hoist and second stage) (LL) Return oil
cylinder (9) Chamber between the rod assembly and
cylinder (second stage)

g00281956
Illustration 23
Extended hoist cylinder
(1) Rod assembly (6) Opening to the head end of the hoist (10) Orifices in the rod assembly
(2) Cylinder (second stage) cylinder (11) Head
(3) Cylinder (first stage) (7) Opening to the rod end of the hoist (12) Internal head
(4) Grooves in the end of the cylinder cylinder (13) Piston
(second stage) (8) Chamber between cylinders (first stage (AA) Pump oil
(5) Chamber in the head end of the hoist and second stage) (LL) Return oil
cylinder (9) Chamber between the rod assembly and
cylinder (second stage)
SENR1532-03 17
Systems Operation Section

Two hydraulic cylinders are used to move the dump

body away from the truck. When the hoist control is
held in the RAISE position, the pump oil extends the
two-stage cylinders and the dump body is raised to
the dump position.

The hoist cylinders raise the dump body in two

stages. The pump oil flows into opening (6) to the
head ends of the hoist cylinders. The oil flows
through a tube in rod assembly (1) and into chamber
(5) in the head end of cylinder (3). The pressure of
the pump oil in chamber (5) moves cylinder (3).

The oil in chamber (8) must now flow through grooves

(4) in the end of cylinder (2) and into chamber (5).

When head (11) on the end of cylinder (3) reaches

a lip on the end of cylinder (2), the cylinder is also
pushed up by the oil in chamber (5). The oil in
chamber (9) now flows through orifices (10), through
the tube in rod assembly (1), and through opening (7)
to the hoist control valve.

Cylinder (2) is pushed until internal head (12) on

the end of cylinder (2) contacts piston (13), which is
bolted to the top of rod assembly (1). When cylinder
(3) is against the end of cylinder (2) and cylinder
(2) is against the end of rod assembly (1), the hoist
cylinder is fully extended.

Lowering the Dump Body

g00281957
Illustration 24
Retracted hoist cylinder (second stage)
(1) Rod assembly (7) Opening to the rod end of the hoist (13) Piston
(2) Cylinder (second stage) cylinder (AA) Pump oil
(3) Cylinder (first stage) (8) Chamber between cylinders (first stage (LL) Return oil
(4) Grooves in the end of the cylinder and second stage)
(second stage) (9) Chamber between the rod assembly and
(5) Chamber in the head end of the hoist cylinder (second stage)
cylinder (10) Orifices in the rod assembly
(6) Opening to the head end of the hoist (11) Head
cylinder (12) Internal head
18 SENR1532-03
Systems Operation Section

Move the hoist control to the LOWER position or to

the FLOAT position in order to lower the dump body
to the truck frame.

When the hoist cylinders are fully extended and the

hoist control is moved to the LOWER position, pump
oil retracts only cylinder (2). When cylinder (2) is fully
retracted, gravity moves cylinder (3) and the dump
body lowers onto the truck frame.

The dump body is lowered when the pump oil flows

through opening (7), into rod assembly (1), through
orifices (10), and into chamber (9) between the rod
assembly and cylinder (2). The oil pushes cylinder
(2) and cylinder (3) downward as chamber (9) is
filled with pump oil. When the dump body gets to
a specified position, flow that is leaving opening
(6) will be restricted. This traps oil in chamber (5).
The weight of the dump body continues to move
cylinder (3) slowly. The weight of the dump body
moves cylinder (3) downward until the cylinder is fully
retracted. The oil in chamber (5) is pushed through
the tube in rod assembly (1) and through opening
(6) to the hoist control valve. The hoist control valve
routes the oil to the hydraulic tank.
SENR1532-03 19
Testing and Adjusting Section

Testing and Adjusting 7. Make sure that all air pressure and all oil pressure
is released before you perform any work on the
Section hydraulic system.

Note: The hydraulic system involves the hoist, the

torque converter, the brakes, and the brake cooling.
Troubleshooting For more detailed information about the torque
converter, about the brakes, or about brake cooling,
see the following modules:
i00985625

General Information • Testing and Adjusting, SENR1523, “789C

Off-Highway Truck Power Train”
SMCS Code: 5050
• Systems Operation/Testing and Adjusting,
SENR1528, “789C Off-Highway Truck Air System
and Brakes”

Sudden movement of the machine or release of air Note: The steering system is separate from other
or oil under pressure can cause possible injury or hydraulic systems. For more detailed information
death to persons on or near the machine. about the steering system, see the following module:

To prevent possible injury or death, do the proce- • Systems Operation/Testing and Adjusting,
dure that follows before testing and adjusting the SENR1526, “789C Off-Highway Truck Steering
Hydraulic System. System”

Note: Permit only one operator on the machine. i00985642

Keep all other personnel away from the machine or
in the operator’s sight. Hoist System Troubleshooting
1. Move the machine to a smooth, horizontal SMCS Code: 5050
location. Move away from operating machines and
away from other personnel.

2. Move the transmission control lever to NEUTRAL.

Stop the engine.

3. Engage the parking brake.

4. Put wheel blocks in front of the wheels and behind

the wheels.

g00321238
Illustration 26
(1) Two-section gear pump for the hoist and rear brake cooling

g00282855
Illustration 25
Retaining cable

5. Fully raise the dump body and connect the

retaining cable to the rear of the truck.

6. Make sure that the transmission rotary selector

spool is in the “N-1” position.
20 SENR1532-03
Testing and Adjusting Section

Problem : The output of the hoist

and rear brake cooling gear pump
is too low.
Probable Cause

• The hydraulic tank oil level is too low.

• The viscosity of the oil is incorrect.
• The two-section gear pump (1) is too worn.

Problem : The pressure of the oil

Illustration 27
g00397683 is too low.
(2) Four-section gear pump for the torque converter, parking brake
release, and brake cooling Probable Cause

Performance tests can be used for diagnosing poor • The hoist dual stage relief valve opens at low oil
performance and for finding the source of oil leakage pressure.
inside the hydraulic system.
• The two-section gear pump (1) is too worn.
Problem : The hoist and rear brake
• An O-ring seal failed in the hydraulic system.
cooling gear pump makes noise
and the cylinder rods do not move i02194471
evenly. Also, there are air bubbles Hoist, Torque Converter, and
in the oil.
Brake System Troubleshooting
Probable Cause
SMCS Code: 3101; 4250; 5050
• The hoist dual stage relief valve opens at low oil
pressure.

• There is a loose connection in the oil line of the Personal injury or death can result from sudden
inlet side of two-section gear pump (1). machine movement.

• The two-section gear pump (1) is too worn.
Problem : The temperature of the
oil is too hot.
Probable Causes
• The viscosity of the oil is incorrect.
• The hoist dual stage relief valve opens at low oil
pressure.
• The two-section gear pump (1) is too worn.
• The brake cooling section on the four-section gear
pump (2) is too worn.
Sudden movement of the machine or release of
air pressure or oil pressure can cause injury to
persons on or near the machine.
To help prevent possible injury before testing and
adjusting any air system or hydraulic system, per-
form the procedure in the Testing and Adjusting,
“General Information” section.
Perform the visual checks before you troubleshoot a
problem. Make sure that the transmission is in neutral
and stop the engine. During the visual checks, use
a magnet to separate ferrous particles (iron and
steel) from nonferrous particles (aluminum, rubber
and paper).

• There is a restriction in an oil passage.

• The load on the system is too high.
SENR1532-03 21
Testing and Adjusting Section

Check: Check the oil level in the • There is a leakage in the oil lines. See “Check for
oil leakage”.
hydraulic tank
Problem: The oil level is too low
Probable Cause

• There is a leakage in the oil lines. See “Check for

oil leakage”. Add oil before you perform any tests.

• Brake cooling oil can leak into the final drive.

Check the oil level in each final drive.

Problem: The oil level is too high

Probable Cause
g00327367
Illustration 28 • The engine crankshaft rear seal is allowing engine
(1) Torque converter and front brake oil cooler oil into the torque converter housing.

Check: Check for oil leakage

Inspect all oil lines, all hoses and all connections for
damage or for leaks. Look for oil on the ground under
the machine.

Note: If oil can leak out of a fitting or out of a

connection, air can enter the system. Air in the
system can be as harmful as having too little oil.

Check: Check the parking brake

release hydraulic filter
g00352772
Illustration 29
(2) Rear brake oil coolers
(3) Screens for the rear brake oil coolers

Check the oil level in the hydraulic tank. Look for air
or water in the sight gauge. Many problems in the
torque converter are caused by low oil level or air
in the oil. Add oil to the hydraulic tank, if necessary.
See the Operation and Maintenance Manual for the
correct type of oil.

Problem: There is an indication of water

in the oil
g00482131
Probable Cause Illustration 30
(6) Parking brake release hydraulic filter
• Failure of torque converter and front brake oil (23) Bypass switch
cooler (1)
Remove parking brake release hydraulic filter (6).
• Failure of the rear brake oil coolers (2) Inspect parking brake release hydraulic filter (6) for
foreign material. Cut the filter open, if necessary.
Problem: There is an indication of air in
the oil
Probable Cause
22 SENR1532-03
Testing and Adjusting Section

Note: Parking brake release hydraulic filter (6) has an Check: Check the torque converter
oil bypass valve. The bypass valve allows the oil to
bypass the oil filter element or the screen whenever
hydraulic filter
the pressure difference between the inlet oil and the
outlet oil becomes too high. Any oil that does not flow
through the filter element or through the screen goes
directly into the hydraulic circuit. Dirty oil can cause
sticking valves and restrictions in valve orifices.

The pressure setting of the bypass valve in parking

brake release hydraulic filter (6) is 248 ± 21 kPa
(36 ± 3 psi).

Problem: Rubber particles are found

Probable Cause

• Seal failure Illustration 32

g00672880

(12) Torque converter hydraulic filter

• Hose failure (23) Bypass switch

Problem: Shiny steel particles are found Remove torque converter hydraulic filter (12). Inspect
torque converter hydraulic filter (12) for foreign
material. Cut the filter open, if necessary.

Note: Torque converter hydraulic filter (12) has an

oil bypass valve. The bypass valve allows the oil to
bypass the oil filter element or the screen whenever
the pressure difference between the inlet oil and the
outlet oil becomes too high. Any oil that does not flow
through the filter element or through the screen goes
directly into the hydraulic circuit. Dirty oil can cause
sticking valves and restrictions in valve orifices.

The pressure setting of the bypass valve in torque

converter hydraulic filter (12) is 140 kPa (20 psi).
g00313886
Illustration 31 Problem: Rubber particles are found
Pump for the torque converter, the parking brake release, and
brake cooling. Probable Cause
(7) Cover for the torque converter scavenge screen
(8) Torque converter scavenge pump section
(9) Torque converter charging pump section
• Seal failure
(10) Parking brake release pump section
(11) Section for rear brake cooling • Hose failure

Probable Cause

• Mechanical failure of parking brake release pump

section (10).
SENR1532-03 23
Testing and Adjusting Section

Problem: Shiny steel particles are found

NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.

Refer to Special Publication, NENG2500, “Caterpillar

Tools and Shop Products Guide” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.

Dispose of all fluids according to local regulations and

g00313886
mandates.
Illustration 33
Pump for the torque converter, the parking brake release, and
brake cooling.
Remove torque converter scavenge screen (7).
Inspect torque converter scavenge screen (7) for
(7) Cover for the torque converter scavenge screen
(8) Torque converter scavenge pump section
foreign material or restrictions.
(9) Torque converter charging pump section
(10) Parking brake release pump section Problem: Rubber particles are found
(11) Section for rear brake cooling

Probable Cause
Probable Cause
• Seal failure
• Mechanical failure of the torque converter charging
pump section (9)
• Hose failure
Check: Check the torque converter Problem: Shiny steel particles are found
scavenge screen

g00313886
Illustration 35
g00313886
Illustration 34 Pump for the torque converter, the parking brake release, and
brake cooling.
Pump for the torque converter, the parking brake release, and
brake cooling. (7) Cover for the torque converter scavenge screen
(8) Torque converter scavenge pump section
(7) Cover for the torque converter scavenge screen
(9) Torque converter charging pump section
(8) Torque converter scavenge pump section
(10) Parking brake release pump section
(9) Torque converter charging pump section
(11) Section for rear brake cooling
(10) Parking brake release pump section
(11) Section for rear brake cooling

Make sure that the oil has been drained from the
hydraulic oil tank and from the torque converter for
the next check.
24 SENR1532-03
Testing and Adjusting Section

Check: Check the torque converter

and front brake cooling screen.
Check the screens for the rear
brake oil coolers.

g00313889
Illustration 36
(13) Oil pump drive
(14) Hoist and rear brake cooling gear pump

Probable Cause
g00352772
Illustration 37
• Mechanical failure of the oil pump drive (13).
(2) Rear brake oil coolers
(3) Screens for the rear brake oil coolers
• Mechanical failure of the parking brake release oil
pump section (10). See “Check the parking brake
release hydraulic filter”.

• Mechanical failure of the torque converter charging

pump section (9). See “Check the torque converter
hydraulic filter”.

Problem: Aluminum particles are found

Probable Cause

• Mechanical failure of the torque converter

Problem: Black fiber is found
g00484126
Illustration 38
Probable Cause (16) Torque converter and front brake cooling screen
(23) Bypass switch
• Worn lockup clutch in the torque converter
Remove screens (3) and (16) for the front and rear
brake oil coolers. Inspect screens (3) and (16).

Problem: Rubber particles are found

Probable Cause

• Seal failure
• Hose failure
SENR1532-03
Problem: Shiny steel particles are found
in the torque converter and front brake
cooling screen
g00313886
Illustration 39
Pump for the torque converter, the parking brake release, and
brake cooling.
(7) Cover for the torque converter scavenge screen
(8) Torque converter scavenge pump section
(9) Torque converter charging pump section
(10) Parking brake release pump section
(11) Section for rear brake cooling
Probable Cause
• There is a mechanical failure of torque converter
charging pump section (9). See “Check the torque
converter hydraulic filter”.
Problem: Large quantities of aluminum
particles are found in the torque
converter and front brake cooling screen
Probable Cause
• Mechanical failure of the torque converter
Problem: Black fiber is found in the
torque converter and front brake cooling
screen
Probable Cause
• Worn lockup clutch in the torque converter
25
Testing and Adjusting Section
Problem: Shiny steel particles are found
in the screens for the rear brake oil
coolers
g00313886
Illustration 40
Pump for the torque converter, the parking brake release, and
brake cooling.
(7) Cover for the torque converter scavenge screen
(8) Torque converter scavenge pump section
(9) Torque converter charging pump section
(10) Parking brake release pump section
(11) Section for rear brake cooling
Probable Cause
• Mechanical failure of the rear brake cooling section
of the torque converter pump (11)
Problem: Aluminum particles are found
in the screens for the rear brake oil
coolers
g00313886
Illustration 41
Pump for the torque converter, the parking brake release, and
brake cooling.
(7) Cover for the torque converter scavenge screen
(8) Torque converter scavenge pump section
(9) Torque converter charging pump section
(10) Parking brake release pump section
(11) Section for rear brake cooling
Note: A small amount of aluminum particles is
normal.
Probable Cause
26 SENR1532-03
Testing and Adjusting Section

• Mechanical failure of the gear pump for the hoist Note: A small amount of aluminum particles is
and rear brake cooling (14). See “Check the hoist normal.
screens”.
Probable Cause
Check: Check the hoist screens
• Mechanical failure of the gear pump for the hoist
and rear brake cooling (14).

Check: Check the inside of the

hydraulic tank

g01108151
Illustration 42
(17) Hoist screen
(23) Bypass switch

Remove hoist screens (17). Inspect hoist screens

(17) for foreign material or for restrictions. g00484160
Illustration 44
(20) Suction screen for torque converter and parking brake release
Problem: Rubber particles are found oil
(21) Suction screens for hoist and rear brake cooling oil
Probable Cause (22) Suction screen for rear brake cooling oil

• Seal failure Drain the oil from the hydraulic tank. Remove the
outer cover from the hydraulic tank. Inspect the
• Hose failure bottom of the hydraulic tank for debris. Remove the
hoses from the back of the hydraulic tank in order to
Problem: A large quantity of aluminum remove suction screens (20), (21) and (22) and clean
particles are found in the hoist screens the suction screens.

NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.

Refer to Special Publication, NENG2500, “Caterpillar

Tools and Shop Products Guide” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.

Dispose of all fluids according to local regulations and

Illustration 43
g00313886 mandates.
Pump for the torque converter, the parking brake release, and
brake cooling.
Problem: Rubber particles are found
(7) Cover for the torque converter scavenge screen
(8) Torque converter scavenge pump section
(9) Torque converter charging pump section Probable Cause
(10) Parking brake release pump section
(11) Section for rear brake cooling • Seal failure
SENR1532-03
• Hose failure
Problem: Shiny steel particles are found
g00313886
Illustration 45
Pump for the torque converter, the parking brake release, and
brake cooling.
(7) Cover for the torque converter scavenge screen
(8) Torque converter scavenge pump section
(9) Torque converter charging pump section
(10) Parking brake release pump section
(11) Section for rear brake cooling
g00313889
Illustration 46
(13) Oil pump drive
(14) Hoist and rear brake cooling gear pump
Probable Cause
• Mechanical failure of the torque converter
scavenge pump section (8)
• Mechanical failure of parking brake release pump
section (10). See “Check the parking brake release
hydraulic filter”.
• Mechanical failure of the torque converter charging
pump section (9). See “Check the torque converter
hydraulic filter”.
• Mechanical failure of oil pump drive (13). See
“Check the torque converter scavenge screen”.
27
Testing and Adjusting Section
• Mechanical failure of rear brake cooling pump
section (11). See “Check the torque converter and
front brake cooling screen. Check the screens for
the rear brake oil coolers.”. Inspect screens (3).
Problem: Aluminum particles are found
Probable Cause
• Mechanical failure of the torque converter See
“Check the torque converter scavenge screen”.
Problem: A large quantity of aluminum
particles are found
g00313889
Illustration 47
(13) Oil pump drive
(14) Hoist and rear brake cooling gear pump
Note: A small amount of aluminum particles is
normal.
Probable Cause
• Mechanical failure of the hoist and rear brake
cooling gear pump (14)
Problem: Black fiber is found
Probable Cause
• Failure of the wheel brakes
• There is a worn lockup clutch in the torque
converter. See “Check the torque converter
scavenge screen”. Also see “Check the torque
converter and front brake cooling screen. Check
the screens for the rear brake oil coolers.”.
Problem: Shiny steel particles and/or
chrome particles are found
Probable Cause
• There is a mechanical failure of a hydraulic cylinder
and/or of a cylinder rod. Inspect the cylinder rods
for scoring.
28
Testing and Adjusting Section
Note: If any of the above particles are found during
any visual checks, all components of the hydraulic
system and of the brake cooling system must be
cleaned. Do not use any damaged parts. Damaged
parts must be replaced with new parts.
i01289049
Brake Oil Overheating
Troubleshooting
SMCS Code: 1365-035; 4250-035; 5083-035
If an overheating condition in the brake system
occurs, the operator will probably become aware
of the overheating condition through the Vital
Information Management System (VIMS).
g00672779
Illustration 48
(1) Brake oil temperature gauge
(2) Action light for the VIMS
g00672790
Illustration 49
(3) Alert indicator for the VIMS
(4) Message area of the VIMS
A truck that has a VIMS module receives signals
from temperature sensors. At each of the four
brakes, there is a temperature sensor that senses the
temperature of the oil. Brake oil temperature gauge
(1) will display this sensor input.
SENR1532-03
g00281171
Illustration 50
(A) Temperature reading of 110°C (230°F)
(B) Temperature reading of 124°C (255°F)
Check brake oil temperature gauge (1) regularly.
During this test sequence, do not allow the
temperature of the brake oil to get too hot. This can
cause damage to the brakes.
When the oil temperature is too hot for the current
conditions, the alert indicator (3) and the action light
(2) come on. An event will be displayed in message
area (4). If the brake oil is too hot, reduce the load
on the machine or slow the machine speed. Also,
downshift the transmission to a lower speed. For
additional cooling, park the truck in a convenient
location. Put the transmission in NEUTRAL, and run
the engine at approximately 1500 rpm. Also, push
down the manual retarder lever all the way in order
to cool the oil.
Problem: The oil temperature
gauge indicates high temperature,
but there are no alarm indicators.
The oil temperature is too hot according to brake oil
temperature gauge (1). Action light (2) and the alert
indicator (3) are off.
Probable Cause
Look at the events in message area (4). Determine
the location of the error in the electrical system. See
Schematic, SENR1535, “789C Off-Highway Truck
Electrical System”. Consult your Caterpillar dealer
for additional information.
SENR1532-03 29
Testing and Adjusting Section

Problem: The oil temperature is

normal, but the action light is on.
The oil temperature is within the normal range, but
action light (2) is on.

Note: Action light (2) is activated when the oil

temperature reaches 124°C (255°F). The action light
remains activated until the oil temperature decreases
to approximately 110°C (230°F). Therefore, brake
oil temperature gauge (1) may indicate a normal oil
temperature while the action light is activated.

Probable Cause
Illustration 51 g00490280
Look at the events in message area (4). Determine (5) Torque converter and front brake cooling diverter valve
the location of the error in the electrical system. See (6) Torque converter and front brake cooling oil cooler
Schematic, SENR1535, “789C Off-Highway Truck
Electrical System”. Consult your Caterpillar dealer
for additional information.

Problem: The oil temperature is

hot.
The oil temperature is too hot according to brake oil
temperature gauge (1). Action light (2) and the alert
indicator (3) are on. Message area (4) displays an
event about brake oil temperature.

Probable Cause

The truck is being operated improperly. Illustration 52

g00313886

Torque converter, parking brake release, and brake cooling gear

Reference: See Operation And Maintenance Manual
for the correct operating techniques of the brake and
retarder system.
Operate the machine again. Make sure that engine
rpm does not drop below 1700 rpm. This ensures
that enough oil flows through the brake oil coolers in
order to keep the oil at normal operating temperature.
pump
(7) Cover for the torque converter scavenge screen
(8) Torque converter scavenge pump section
(9) Torque converter charging pump section
(10) Parking brake release pump section
(11) Rear brake cooling pump section

Problem: The oil temperature is hot

on a properly operated machine.
The oil temperature is too hot according to brake oil
temperature gauge (1). Action light (2) and the alert
indicator (3) are still on after the truck is operated
correctly. Message area (4) displays an event about
the brake oil temperature.

Probable Cause
g00490081
Illustration 53
(12) Rear brake oil cooler relief valve
30 SENR1532-03
Testing and Adjusting Section

g00313889
Illustration 54
(13) Pump drive
(14) Hoist and rear brake cooling gear pump

• There is a restriction in the oil cooling system.

Refer to the air system and brakes Testing and
Adjusting, “Brake Cooling Pressure - Check” in
order to determine if there is proper brake cooling
oil flow.

• The torque converter and front brake cooling

diverter valve (5) is not sending oil through the
torque converter and front brake cooling oil cooler
(6) when the service brakes or the retarder are
used.

• The torque converter charging pump section

(9) has failed. Refer to Testing and Adjusting,
“Hoist, Torque Converter, and Brake System
Troubleshooting” for the checking procedure.

• The rear brake oil cooler relief valve (12) is set

too low. See the hydraulic system Testing and
Adjusting, “Relief Valve (Rear Brake Oil Cooler)
- Test and Adjust”.

• The hoist and rear brake cooling gear pump

(14) has failed. Refer to Testing and Adjusting,
“Hoist, Torque Converter, and Brake System
Troubleshooting” for the checking procedure.
SENR1532-03 31
Testing and Adjusting Section

Testing and Adjusting The acceptable time for cylinder drift is relative to the
temperature of the hydraulic oil in the hoist cylinders.
See the following table.
i00725096
Table 1
Hoist Cylinder Performance - Acceptable Cylinder Drift
Test Minutes Oil Temperature Cylinder Drift
SMCS Code: 5102-081 12.4 38°C (100°F) 6.40 mm (0.25 inch)
9.6 43°C (110°F) 6.40 mm (0.25 inch)
7.8 49°C (120°F) 6.40 mm (0.25 inch)
Personal injury or death can result from sudden 6.4 54°C (130°F) 6.40 mm (0.25 inch)
machine movement.
5.3 60°C (140°F) 6.40 mm (0.25 inch)
Sudden movement of the machine or release of 4.4 66°C (150°F) 6.40 mm (0.25 inch)
air pressure or oil pressure can cause injury to
3.8 71°C (160°F) 6.40 mm (0.25 inch)
persons on or near the machine.
3.2 77°C (170°F) 6.40 mm (0.25 inch)
To help prevent possible injury before testing and
adjusting any air system or hydraulic system, per- 2.8 82°C (180°F) 6.40 mm (0.25 inch)
form the procedure in the Testing and Adjusting,
“General Information” section. Excessive cylinder drift can be caused by the
following conditions:
1. Start the engine. Operate the engine at high idle.
• Leaks in the lines between the hydraulic oil tank
and the hoist cylinders
2. Move the hoist control to the RAISE position. Hold
the hoist control in the RAISE position for five
seconds after the dump body is fully raised. Then, • Worn control valve spool
lower the dump body all the way to the truck frame.
• Worn seals in the hoist cylinders
3. Repeat Step 2 until the temperature of the
hydraulic oil is above 38°C (100°F). i01957271

Relief Valve (Hoist Dual Stage)

Lift Time for Hoist Cylinders
- Test and Adjust
1. Lower the dump body to the truck frame.
SMCS Code: 5117-036; 5136-036
2. Operate the engine at high idle.

3. Raise the dump body to the fully raised position.

Use a stopwatch to measure the required time.
The required time for full extension of the hoist
cylinders is approximately 19 seconds.
Cylinder Drift
Personal injury or death can result from sudden
machine movement.
Sudden movement of the machine or release of
air pressure or oil pressure can cause injury to
persons on or near the machine.

Note: Perform this test with an empty dump body To help prevent possible injury before testing and
and hydraulic oil above 38°C (100°F). adjusting any air system or hydraulic system, per-
form the procedure in the Testing and Adjusting,
1. Move the hoist control to the RAISE position. “General Information” section.

2. When the first stage of the hoist cylinders is

extended by 305 mm (12 inch), move the hoist
control to the HOLD position.

3. The dump body will push the cylinder head of the

first stage by 6.40 mm (0.25 inch) onto the second
stage of the hoist cylinders. Use a stopwatch and
record the required time.
32 SENR1532-03
Testing and Adjusting Section

3. Connect two hose assemblies to two 8T-0860

NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
Refer to Special Publication, NENG2500, “Caterpillar
Tools and Shop Products Guide” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Dispose of all fluids according to local regulations and
mandates.
Note: Before you perform any tests, visually inspect
the entire hydraulic system for oil leaks and for
damaged components.
The 8T-5320 Hydraulic Test Group and the
4C-4890 Hydraulic Test Group may be used to test
the pressure at the pressure taps.
Pressure Gauges. Connect the hose assemblies
to both of the pressure taps on the hoist and rear
brake cooling gear pump. Make sure that the
hoses for the pressure gauges are long enough to
be extended into the cab.
4. Start the engine. Operate the dump body
repeatedly until the temperature of the hydraulic
oil is above 38 °C (100.0 °F).
5. Run the engine at LOW IDLE. Move the hoist
control to the RAISE position until the cylinders
are fully extended. Attach the safety cable for the
dump body.
6. Slowly accelerate the engine to the HIGH IDLE
position. Hold the hoist control in the RAISE
position. The pressure range for the 785C
and 789C machines is 17225 to 17925 kPa
(2500 to 2600 psi). The pressure range for
the 793C machines is 20370 to 21070 kPa
(2955 to 3057 psi). Record the highest pressure
that is read on the gauge. If the pressure exceeds
this range, investigate the cause of the higher
pressure.

7. If the pressure setting is incorrect, adjust the relief

valve on the hoist diverter valve. Refer to “Relief
Valve Adjustment” within the original Service
Module for the correct procedure.

8. Raise the dump body completely. Remove the

safety cable.

g00502899
Illustration 55
Location of pressure taps for the hoist and rear brake cooling
gear pump

The hoist dual stage relief valve is part of the hoist

control valve. The hoist control valve is located under
the truck. The relief pressure for the RAISE position
is different from the relief pressure for the LOWER
position.

Relief Valve Test (High Pressure)

1. Lower the dump body completely. Stop the engine.

2. Relieve any system pressure that may be present.

Move the hoist control to the RAISE and LOWER
positions. Place the hoist control in the FLOAT
position.
SENR1532-03 33
Testing and Adjusting Section

5. After the dump body is fully lowered, look at the

gauge and hold the hoist control in the LOWER
position. The high pressure gauge reading is the
relief valve pressure setting. The correct pressure
setting is 3450 to 3800 kPa (500 to 550 psi).

g00283734
Illustration 56
High pressure relief valve
(1) 5J-2721 Shim
(2) 5J-2722 Shim

g00283735
9. As needed, adjust the number of shims in order to Illustration 57
achieve the correct relief valve pressure setting. Low pressure relief valve

Table 2 (3) 5J-2721 Shim

(4) 5J-2722 Shim
Shims for Adjusting the Relief Valve Pressure Setting
Part Pressure 6. As needed, adjust the number of shims in order to
Thickness achieve the correct relief valve pressure setting.
Number Change
5J-2721 0.13 mm (0.005 inch) 65 kPa (9 psi) Table 3

5J-2722 1.22 mm (0.048 inch) 610 kPa (88 psi) Shims for Adjusting the Relief Valve Pressure Setting
Part Pressure
Thickness
Number Change
Relief Valve Test (Low Pressure)
5J-2721 0.13 mm (0.005 inch) 13 kPa (2 psi)
1. Lower the dump body. Stop the engine. 5J-2722 1.22 mm (0.048 inch) 125 kPa (18 psi)

2. Connect a hose assembly with an 8T-0856

Pressure Gauge (0 to 6000 kPa (0 to 870 psi)) to
either of the pressure taps on the hoist and rear
brake cooling gear pump.

3. Start the engine. Operate the dump body

repeatedly until the temperature of the hydraulic
oil is above 38°C (100°F).

4. Run the engine at high idle and move the hoist

control to the LOWER position.
34 SENR1532-03
Testing and Adjusting Section

i00987601 6. As needed, adjust the number of shims (5) in

order to achieve the correct relief valve pressure
Relief Valve (Rear Brake Oil setting. Do not adjust shims (6).
Cooler) - Test and Adjust Table 4

SMCS Code: 5117-036 Shims for Adjusting the Relief Valve Pressure Setting
Part Pressure
Thickness
Number Change
8B-4624 0.81 mm (0.032 inch) 30 kPa (4 psi)
8B-4624 0.81 mm (0.032 inch) Do not adjust.

i00713021

Gear Pump (Hoist and Rear

Illustration 58
g00502953
Location of test port for the rear brake oil cooler relief valve
1. Remove the plug from the test port. Install a
2P-8421 O-Ring Adapter into the test port.
2. Install a 6V-3965 Nipple Assembly to the adapter.
Connect a hose to the nipple.
3. Install an 8T-0854 Pressure Gauge (0 to 1000 kPa
(0 to 145 psi)) to the hose.
4. Move the hoist control lever to the HOLD position
and start the engine.
Brake Cooling) Efficiency -
Test
SMCS Code: 5073-081; 5083-081
This test is designed to determine if a pump is
operating within the designed parameters.
For any pump test at a given rpm, the pump flow at
690 kPa (100 psi) will be larger than the pump flow
at 6900 kPa (1000 psi).
The difference between the pump flow of the two
operating pressures is the flow loss.
Flow loss is used as a measure of pump performance
when the flow loss is expressed as a percent of
pump flow.

5. Look at the pressure gauge. The maximum Table 5

pressure reading should be 790 ± 20 kPa Percent flow loss
(115 ± 3 psi).
[(A − B) ÷ C] × 100 = D

A Pump flow at 690 kPa (100 psi)

B Pump flow at 6900 kPa (1000 psi)
C Pump flow at 690 kPa (100 psi)
D Percent flow loss

g00283757
Illustration 59
Rear brake oil cooler relief valve
(5) 8B-4624 Shim
(6) 8B-4624 Shim
SENR1532-03 35
Testing and Adjusting Section

Table 6 b. Measure the pump flow at 690 kPa (100 psi).

Example
5. Use the measurement from Step 4.b for the value
[(A − B) ÷ C] × 100 = D of C in Table 5.

A 217.6 L/min (57.5 US gpm) i00990955

B 196.8 L/min (52.0 US gpm) Position Sensor (Dump Body)

C 217.6 L/min (57.5 US gpm) - Adjust
D Percent of flow loss
SMCS Code: 1408-025
[(217.6 L/min (57.5 US gpm) − 196.8 L/min (52.0 US
gpm)) ÷ 217.6 L/min (57.5 US gpm)] × 100 = D S/N: 2BW1-555
D = 9.6 percent

If the percent of loss is more than 10 percent for the

machine test or 15 percent for the bench test, the
pump performance is not good enough.

Note: The numbers in the formula are only examples.

These numbers are not values for any specific
pump nor for any particular pump condition. See the
Specifications for the pump flow of a new pump at
690 kPa (100 psi) and at 6900 kPa (1000 psi).

Machine Test
g00504968
Illustration 60
1. Install a 4C-9437 Flow Measuring Tool. (1) Rod end
(2) Nut
2. Start the engine. (3) Rod

3. Run the engine at high idle.
4. Measure the pump flow at 690 kPa (100 psi) and
at 6900 kPa (1000 psi).
5. Use the values that were measured in Step 4 in
Table 5.
Bench Test
If the bench test can be run at 6900 kPa (1000 psi)
and at full rpm, determine the percent flow loss.
Note: The dump body position sensor must be
correctly adjusted for the proper operation of the gear
limit when the dump body is raised. Also, the dump
body position sensor is used to control the SNUB
position of the hoist control valve.
The distance between the centers of the rod ends
must be 350.0 ± 3.0 mm (13.78 ± 0.12 inch).
Rod Adjustment
1. Disconnect rod (3) from the dump body.

If the bench test cannot be run at 6900 kPa (1000 psi) 2. Loosen nut (2) on rod (3).
and at full rpm, use the following procedure:
3. Adjust rod end (1) in order to get a distance of
1. Run the pump shaft at 1000 rpm. 350.0 ± 3.0 mm (13.78 ± 0.12 inch) between the
centers of the rod ends.
2. Measure the pump flow at 690 kPa (100 psi) and
at 6900 kPa (1000 psi). 4. Tighten nut (2).

3. Use the measurements from Step 2 for the values 5. Reattach rod (3) to the dump body.
of A and B in Table 5.

4. To determine the value of C, use Steps 4.a

through 4.b.

a. Run the pump shaft at 2000 rpm.

36 SENR1532-03
Testing and Adjusting Section

i01777271

Position Sensor (Dump Body)

- Adjust
SMCS Code: 1408-025
S/N: 2BW556-Up

g00908567
Illustration 61
(1) Rod end
(2) Nut
(3) Rod

Note: The dump body position sensor must be

correctly adjusted for the proper operation of the gear
limit when the dump body is raised. Also, the dump
body position sensor is used to control the SNUB
position of the hoist control valve.

The distance between the centers of the rod ends

must be 350.0 ± 3.0 mm (13.78 ± 0.12 inch).

Rod Adjustment
1. Disconnect rod (3) from the dump body.

2. Loosen nut (2) on rod (3).

3. Adjust rod end (1) in order to get a distance of

350.0 ± 3.0 mm (13.78 ± 0.12 inch) between the
centers of the rod ends.

4. Tighten nut (2).

5. Reattach rod (3) to the dump body.

SENR1532-03 37
Testing and Adjusting Section

i02199634

Worksheets
SMCS Code: 5102-081

Table 7

Hoist Test
Machine Model Today’s Date
Machine Serial
Machine Hours
Number
Flash File
ECM Flash File
Date

Table 8

Visual Checks
Oil level Oil Viscosity
Oil Filter
Air in Oil
Examination
Water in Oil
38 SENR1532-03
Testing and Adjusting Section

Table 9

Test Specification Actual Value

Hoist >65 °C (150 °F)
Oil Temperature <121 °C (250 °F)
Drift For The Hoist 6.40 mm (0.25 inch) per specified
Cylinders time(1)
1.
RAISE
2.
Hoist Time 17 to 19 Seconds
3.
@ High Idle
Average
1.
LOWER
2.
Hoist Time 14 to 16 Seconds
3.
@ High Idle
Average
1.
FLOAT
2.
Hoist Time 14 to 16 Seconds
3.
@ High Idle
Average
Pilot Pressure
Low Idle
Parking Brake 4700 ± 200 kPa (680 ± 30 psi)
High Idle
Retraction
RAISE
Front Tap
Pressure 17225 ± 345 kPa (2500 ± 50 psi)
Rear Tap
@ High Idle
Cast pump
RAISE Front Tap
18950 ± 345 kPa (2750 ± 50 psi)
Pressure Rear Tap
@ High Idle
LOWER
Front Tap
Pressure 3450 + 350 - 0 kPa (500 + 50 - 0 psi)
Rear Tap
@ High Idle
HOLD
Front Tap
Maximum 790 ± 20 kPa (115 ± 3 psi)
Rear Tap
Pressure
FLOAT
Front Tap
Maximum 790 ± 20 kPa (115 ± 3 psi)
Rear Tap
Pressure
SNUB
Front Tap
Maximum 790 ± 20 kPa (115 ± 3 psi)
Rear Tap
Pressure
(1) Refer to the Hydraulic System Testing and Adjusting, “Hoist Cylinder Performance - Test” for the specifications of time.

Run the engine at high idle and record the observed

data into the charts that are provided.

The rod for the body position sensor must be

disconnected from the body, and the body position
sensor must be rotated to the RAISE position before
the LOWER relief pressure can be tested.
SENR1532-03
Index
B Hoist, Torque Converter, and Brake System
Brake Oil Overheating Troubleshooting .................. 28
Problem: The oil temperature gauge indicates
high temperature, but there are no alarm
indicators ........................................................... 28
Problem: The oil temperature is hot on a properly
operated machine. ............................................. 29
Problem: The oil temperature is hot. ................... 29
Problem: The oil temperature is normal, but the
action light is on. ................................................ 29
C Check: Check the torque converter scavenge
Control Valve (Hoist) ................................................. 9
FLOAT Position ................................................... 13
HOLD Position .................................................... 12
LOWER Position ................................................. 13
RAISE Position .................................................... 12
SNUB Position .................................................... 14
G I
Gear Pump (Hoist and Rear Brake Cooling) ............ 7
Gear Pump (Hoist and Rear Brake Cooling) Efficiency
- Test ................................................................................ 34
Bench Test ................................................................... 35
Machine Test ............................................................... 35
General Information........................................... 5, 19
H Position Sensor (Hoist Control) ................................ 8
Hoist Control ............................................................. 7
Hoist Cylinder.......................................................... 15
Lowering the Dump Body .................................... 17
Raising the Dump Body ...................................... 16
Hoist Cylinder Performance - Test .............................. 31
Cylinder Drift ....................................................... 31
Lift Time for Hoist Cylinders ................................ 31
Hoist System Troubleshooting ................................ 19
Problem : The hoist and rear brake cooling gear
pump makes noise and the cylinder rods do not
move evenly. Also, there are air bubbles in the
oil ....................................................................... 20
Problem : The output of the hoist and rear brake
cooling gear pump is too low ............................. 20
Problem : The pressure of the oil is too low ........ 20
Problem : The temperature of the oil is too hot... 20
39
Index Section
Troubleshooting .................................................... 20
Check: Check for oil leakage .............................. 21
Check: Check the hoist screens ......................... 26
Check: Check the inside of the hydraulic tank ... 26
Check: Check the oil level in the hydraulic tank.. 21
Check: Check the parking brake release hydraulic
filter ....................................................................21
Check: Check the torque converter and front brake
cooling screen. Check the screens for the rear
brake oil coolers ................................................ 24
Check: Check the torque converter hydraulic
filter.................................................................... 22
screen ............................................................... 23
Hydraulic System. ..................................................... 4
Hydraulic Schematic ............................................. 4
Location of Components ....................................... 5
Hydraulic Tank (Torque Converter, Hoist, Brake, and
Transmission) ......................................................... 6
Tank Ports ............................................................. 6
Important Safety Information .................................... 2
P
Position Sensor (Dump Body) .............................. 8–9
Position Sensor (Dump Body) - Adjust ............. 35–36
Rod Adjustment ............................................ 35–36
R
Relief Valve (Hoist Dual Stage) - Test and Adjust.. 31
Relief Valve Test (High Pressure) ....................... 32
Relief Valve Test (Low Pressure) ........................ 33
Relief Valve (Rear Brake Oil Cooler) - Test and
Adjust .................................................................... 34
S
Systems Operation Section ...................................... 4
T
Table of Contents ...................................................... 3
Testing and Adjusting ............................................. 31
Testing and Adjusting Section ................................ 19
Troubleshooting ...................................................... 19
W

Worksheets ............................................................. 37

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