777F (JRP)

777F (JRP)
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OFF
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HIGHWAY TRUCK
HIGHWAY TRUCK
INTRODUCTION
INTRODUCTION
2007 Caterpillar Inc.
777F MAINTENANCE
7
7
7
F
S
e
rv
ic
e
P
ro
c
e
d
u
re
WALK AROUND INSPECTION
FueI LeveI and Drain Moisture
WindshieId Washer LeveI
Hoist, Converter
And Brake OiI LeveI
Transmission
OiI LeveI
Steering OiI LeveI
Radiator Debris
Suspension CyIinder
Height
Air FiIters and PrecIeaners
Batteries
Primary FueI FiIter
Disconnect Switch
Rear AxIe Breather
Wash Windows,
Cab Fresh Air FiIters,
Seat BeIt, Indicators,
Gauges, Brake Tests,
Secondary Steering and
Back-up AIarm
Inspect Frame
for Cracks and
Body Support Pads
Check For Leaks
and Trash BuiId-up
Tire InfIation
Pressure
WheeI Nuts
Suspension CyIinder Height
and Grease Breathers
Fan BeIts and Ether CyIinder
Engine OiI LeveI
10 HOURS DAILY MAINTENANCE CHECKS
CooIant LeveI
TCS
0
5
10
15 20
25
30
35
X100
TeIemetry
Antenna
(Attachment)
GPS
Antenna
(Attachment)
IncIinometer
(Attachment)
Engine ECM
(A4:E4)
Minestar
DispIay
Minestar
ControI
(Attachment)
Product Link ECM
(Attachment)
ET Service TooI
VIMS ECM (Advisor)
(ABL2M)
(Attachment)
Road AnaIysis ECM
(RAC) (ABL2M)
(Attachment)
Brake ECM (TCS)
(A4:M1)
(Standard)
Trans / Chassis ECM
(A4:M1)
(Standard)
777F ELECTRONIC SYSTEM BLOCK DIAGRAM
VIMS-PC
CAT DataIink
CAN SAE J1939 DataIink
RS232 19200 Baud SeriaI Link

VIMS / Advisor
( Opt ionaI)
Instrument
CIuster
Messenger ModuIe
( St andard)
OK
TPMS ECM
( ABL2M)
( At t achment )
0
5
10
15
20
25
30
n/min
X100
R
Brake System
Check
Park Brake
Engaged
Power Train
System Check
Action
Lamp
Check Engine
Engine
RPM
EIectricaI
System
Body Up
Transmission in Reverse
Machine Lockout Active
High Beam
Retarder Engaged
Machine
ImmobiIizer
Traction ControI
System Engaged
Primary Steering
Loss
Secondary Steering
Engaged
Torq Converter
OiI Temperature
Gauge
Engine CooIant
Temperature Gauge
ThrottIe Lock
Left Turn SignaI
Right Turn SignaI
Brake OiI
Temperature Gauge
FueI LeveI Gauge
LCD DispIay
Window
Truck Speed
Active Gear
and Direction
Service Hour
Meter
INSTRUMENT CLUSTER
mph
km/h
kPa psi
n/min
OK
Message Bar
P R N 1 2 3 4 5 6 7
MESSENGER DISPLAY MODULE
DEFAULT SCREEN

Service
Settings
Service Mode
TotaIs
Performance
DefauIt
OK
Main Menu
Performance
MAIN MENU SELECTION
OK
Eng CooIant Temp Shift Lever
85 C N
PERFORMANCE SCREEN SUBMENU
Torque
Converter
Temperature
HydrauIic OiI
Temperature
Engine Speed
Engine CooIant
Temperature
Engine OiI
Pressure
FueI LeveI
InIet Air
Temperature
Performance
PERFORMANCE MENU SELECTION
Battery VoItage
OK
Main Menu
Performance
TotaIs
PayIoad
Machine
Reset Load
Count
Yes
TotaI
Load Count
Load Count
Accum Wght
Loaded Time
Loaded Dist
Machine Hrs
Distance
TraveIed
TotaI FueI
BIank
TOTALS MENU SELECTIONS
Reset Load
Count
No
OK
Main Menu
TotaIs
SETTINGS MENU SELECTION
OK
Main Menu
Settings
SERVICE MENU SELECTION
OK
Service
Diagnostic Events
OK
Engine ECM 91-8
ThrottIe Pos Snsr
AbnormaI CIr
OK
OK
SRC
36
36
36
CODE
91-8
168-0
168-1
OCC ACT
10
5
5
OK
Service
Diagnostic Events
SERVICE MENU
DIAGNOSTIC EVENTS
OK
Main Menu
Svc Mode Password
SERVICE MODE
OK
Copyright 2005 CaterpiIIar Inc.
AII Rights Reserved
2612809V13
OK
Normal

Operator
PayIoad
03:55:46 07/7/2006 0%
Service
Settings
P 1 2 R P N 3
Home Menu
Screen
Settings
PayIoad
Service
Service Mode
ADVISOR HOME
MENU SELECTIONS
Operator
Grade
Monitor
OK
Normal

Operator
PayIoad
03:55:46 07/7/2006 0%
Service
Settings
P 1 2 R P N 3
OK

SeIect ProfiIe
View/Save Current
Create ProfiIe
DeIete ProfiIe
Operator
Current ProfiIe =
GIen
Press
to seIect a
profiIe.
OK
P 1 2 R P N 3
Operator
Create ProfiIe
SeIect ProfiIe
View/Save
Current
DeIete ProfiIe
Units
ProfiIe Name
SeIection Screen
(up to 10 names)
Language
Lights ON
Dimming
Lights OFF
Dimming
Contrast
Factory Set
ProfiIe Name
Creation Screen
(numbers/Ietters)
ProfiIe Name
DeIetion Screen
(up to 10 names)
SeIects the factory
DefauIt Settings
OPERATOR MENU SELECTION
OK
Normal

Operator
PayIoad
03:55:46 07/7/2006 0%
Service
Settings
P 1 2 R P N 3
OK

CaIibrations
System Information
System Tests
Service Parameters
Service

Press
to enter the
caIibrations
menu.
OK
P 1 2 R P N 3
Diagnostics
Trigger
Snapshot
Active
Events
Logged
Events
Data Logger
Start
Data Logger
Reset
SERVICE MENU
DIAGNOSTICS SUBMENU
CaIibrations
Truck
PayIoad
IncIinometer
SERVICE MENU
CALIBRATIONS SUBMENU
System
Information
Chassis
Advisor
Engine
Brake
VIMS
SERVICE MENU
SYSTEM INFORMATION SUBMENU
TattIe TaIe
Brake OiI
Temperature
Active
Engine
Speed
Engine
CooIant Temp
Torque
Converter
Temp
FueI
LeveI
SERVICE MENU
TATTLE TALE SUBMENU
System
Tests
StaII
Diagnostic
Test
SeIf Test
SERVICE MENU
SYSTEM TESTS SUBMENU
Service
Parameters
Sort by Type
Sort by ECM
AII Parameters
SERVICE MENU
SERVICE PARAMETERS SUBMENU
OK
Normal

Operator
PayIoad
03:55:46 07/7/2006 0%
Service
Settings
P 1 2 R P N 3
OK
P 1 2 R P N 3

DispIay Setup
Machine
Chassis
Settings

Press
to enter the
dispIay setup
menu.
OK
OK
Normal

PayIoad
03:55:46 07/7/2006 0%
Service
Settings
Monitor
P 1 2 R P N 3
OK

PayIoad State: Loading
PayIoad
90 T
Target
350 T
TON
P 1 2 R P N 3
OK
Normal

PayIoad
03:55:46 07/7/2006 0%
Service
Settings
Monitor
P 1 2 R P N 3
OK

Monitor: Parameter Screen 1
Brake OiI
Temperature

45 C
Torque Converter
Temperature

37 C
Boost
Pressure

20 kPa
Atmospheric
Pressure

23 kPa
OK
Normal

PayIoad
03:55:46 07/7/2006 0%
Settings
Monitor
Grade
P 1 2 R P N 3
OK

% GRADE

00
P 1 2 R P N 3
20
30
10
0
-30
-20
-10
OK
Normal

PayIoad
03:55:46 07/7/2006 0%
Monitor
Grade
Service Mode
P 1 2 R P N 3
OK
Service Mode
Service Mode: DisabIed



Press OK to EnabIe
P 1 2 R P N 3
Ether Start ReIay
Key Start Switch
ThrottIe PedaI Position Sensor
Back-up ThrottIe Switch
Ground LeveI Shutdown Switch
Rockford Fan Speed Sensor (Attachment)
Left Air FiIter Restriction (Turbo InIet Left)
Right Air FiIter Restriction (Turbo InIet Right)
MEUI Injectors (12)
7E6513
Right Bank (Even) Engine Retarder SoIenoids
066-8391 (Connector PN)
Speed Sensor No. 1 (Crank)
Speed Sensor No. 2 (Cam)
Timing CaI Probe Connector
CooIant Temperature Sensor
Right Turbo OutIet Pressure Sensor
Engine OiI Pressure
Atmospheric Pressure
FueI Temp Sensor
FueI Pressure Sensor
DifferentiaI FueI Pressure Switch
J2 (ENGINE) CONNECTOR
J1 (MACHINE) CONNECTOR
Outputs
Inputs
Outputs
Inputs
CAT Data Link
ENGINE ECM SYSTEM DIAGRAM
Left Bank (Odd) Engine Retarder SoIenoids
066-8391 (Connector PN)
Rockford Fan SoIenoid
( At t achment )
ORS LeveI ReIay ( at t achment )
ORS SoIenoid (attachment)
Air Conditioning Status
OiI LeveI Switch
Left Intake ManifoId Temperature Sensor
Exhaust Temperature Sensors (4)
Right Intake ManifoId Temperature Sensor
Left Turbo OutIet Pressure Sensor
LOSS OF ENGINE SPEED/TIMING SIGNAL
- Engine wiII start and run with one speed/timing sensor signaI

- Engine wiII NOT start or run without at Ieast one
speed/timing sensor signaI

- If crank sensor faiIs during engine operation:
- SIight change in engine performance

- If crank sensor signaI is not present at engine start up:
- Engine starts normaIIy

- If cam sensor faiIs during engine operation:
- No noticeabIe change in engine performance

- If cam sensor signaI is not present at engine start up:
- Engine wiII start with crank sensor signaI, but may
take Ionger to start and run rough for a few seconds
110 111 111.5 112 112.5 113 113.5 114
120%
100%
80%
60%
40%
20%
0%
CooIant Temperature
%

D
e
r
a
t
e
HIGH COOLANT TEMPERATURE DERATE
114.5
LeveI 1Warning LeveI 2 Warning/ Derat es
C
F 230 232 233 234 235 235.5 236.5 237 238
82 86 87 88 89 90 91 92
18%
15%
12%
9%
6%
3%
0%
Intake ManifoId Temperature
%

D
e
r
a
t
e
C11-C32 ENGINE INTAKE MANIFOLD TEMPERATURE DERATE
93
21%
LeveI 1Warning LeveI 2 Warning / Derat es
C
F 180 187 189 190 192 194 196 198 199
760 805 810 815 820 825 830 835
60%
50%
40%
30%
20%
10%
0%
Exhaust ManifoId Temperature
%

D
e
r
a
t
e
ENGINE EXHAUST MANIFOLD TEMPERATURE DERATE
840
70%
LeveI 1Warning LeveI 2 Warning / Derat es
C
F 1400 1481 1490 1499 1508 1517 1526 1535 1544
500
120
100
80
60
40
20
0
O
i
I

P
r
e
s
s
u
r
e

1000 1500 2000 2340
140
160
180
0
Engine rpm
kPa Warning LeveI 1 kPa Shut down LeveI 3
LOW OIL PRESSURE
35% Derate
kPa
17.0
15.0
12.0
9.0
6.0
3.0
0
20.0
23.0
26.0
psi
0 2 4 6 8 10
12%
10%
8%
6%
4%
2%
0%
%

D
e
r
a
t
e
12 14 16
14%
16%
Air Restriction Difference
LeveI 1Warning
LeveI 2 Warning/ Derat es
AIR INLET RESTRICTION DERATE
kPa
psi
0 0.3 0.6 0.9 1.2 1.5 1.7 2.0 2.3
90.8 91.0 91.2 91.4 91.6 91.8 92.0 92.2
30%
25%
20%
15%
10%
5%
0%
FueI Temperature
%

D
e
r
a
t
e
FUEL TEMPERATURE DERATE
90.6 89.8 90.4 90.2 90.0
LeveI 1 Warning LeveI 2 Warning / Derates
195.4 195.8 196.2 196.5 196.9 197.2 197.6 198.0 195.0 193.6 194.7 194.4 194.0
C
F
0 3 min 3 hr
60%
50%
40%
30%
20%
10%
0%
%

D
e
r
a
t
e
1 hr 2 hr 5 hr 4 hr
FUEL FILTER RESTRICTION DERATE
FUEL TEMP ABOVE 30 C (86 F)
AND FUEL PRESSURE ABOVE 138 kPa (20 psi)
Time
LeveI 1Warning
LeveI 2 Warning/Derates
6hr
Check VaIve
FueI Injector
Rocker Arm
Master
Piston
Exhaust VaIve
Rocker Arm
Rocker Arm
Shaft OiI
Passage
Engine OiI
Pump
Exhaust
VaIve
SIave Piston
Compression
Brake
SoIenoid
VaIve
ENGINE COMPRESSION BRAKE HYDRAULIC CIRCUIT
COMPRESSION BRAKE OFF
To SIave Piston and
Master CyIinder
Cat Data Link +
Cat Data Link -
Compression Brake EnabIe
Sensor Return
10
20
34
45
Cat Data Link -
Cat Data Link +
9
8
Compression Brake Med / Hi
Compression Brake Low / Hi
8
1
P1/J1
P1/J1
Compression Brake Med / Hi
Compression Brake Low / Hi
Compression Brake Return
5
3
14
P2/J2
J700-BR
J701-GN
K739-BU
K737-BR
K738-GN
K739-BU
10
11
12
10
11
12

Compression
Brake
SoIenoid
5 and 7
Compression
Brake
SoIenoid
9 and 11
Compression
Brake
SoIenoid
1 and 3

Compression
Brake
SoIenoid
6 and 8
Compression
Brake
SoIenoid
2 and 4
Compression
Brake
SoIenoid
10 and 12
Left Bank VaIve Cover
Entry Connector
Right Bank VaIve Cover
Entry Connector
Engine ECM
Brake ECM
893-GN
892-BR
772-BR
A235-BK
892-BR
893-GN
Compression Brake
EnabIe Switch
ENGINE COMPRESSION BRAKE SCHEMATIC
100000
200000
300000
400000
500000
600000
700000
800000
900000
1/3
2/3
1/3
0
0 5 10 15 20 25 30 35 40 45 50 55 60
ARC POWER AND COMPRESSION BRAKING LEVELS VS TIME
Time (Seconds)
B
r
a
k
i
n
g

P
o
w
e
r

(
W
a
t
t
s
)
ARC ramps up current,
ARC braking power
aIso increases.
TotaI braking power =
ARC brake power onIy
Enough Instantaneous braking
power avaiIabIe to AIIow 1/3
Compression on.
(ARC Power-offset) Leaves enough
brake power for 1/3 compression
braking. ARC brake power shouId
drop by equivaIent amount.
TotaI brake power = ARC brake
power + 1/3 comp brake power
TotaI brake
power = ARC
brake power
+ 2/3 comp
brake
ARC power began
to drop enough
that we had to Iose
1/3 compression
power.
TotaI brake power
= ARC brake power
+ 1/3 compression
TotaI brake
power = ARC
brake power

Not
enough
power to
keep
comp
enabI ed.
ARC power
dropped enough
that we don't have
compression
braking at aII.
TotaI brake
ARC
brake 0 ARC
shut Off

DisabIe CB
Thermostat
Housing
Radiator
Water Pump
Engine BIock
ATAAC
COOLING SYSTEM FLOW
Brake OiI CooIer
Brake OiI CooIer
Transmission OiI CooIer
Engine OiI CooIer
Engine
BIock
Engine
OiI CooIer
Engine
OiI FiIters
Engine
OiI Pump
Bypass
VaIve
ENGINE OIL SYSTEM
FueI
Transfer
Pump
FueI Tank
Primary
FueI
FiIter
CyIinder
Head
CyIinder
Head
FueI
Pressure
ReguIator
FueI
Priming
Pump
Secondary
FueI FiIter
LOW PRESSURE FUEL SYSTEM
MuffIer
From Air
FiIters
ATAAC
AIR INDUCTION
AND
EXHAUST SYSTEM
From Air
FiIters
To
Brake
CooIing
HydrauIic
ControIs
Transmission
Torque
Converter
Lockup
VaIve
To
VariabIe
Speed
CIutch
ControI
To
Hoist PiIot
SignaI
ResoIver
To
Traction
ControI
PiIot
POWER TRAIN HYDRAULIC SYSTEM
To
Brake
CooIing
Lockup
CIutch VaIve
FiIter
Lockup
CIutch ReIief
VaIve
Transmission
Charge FiIters
Torque Converter
Charge FiIter
Transmission OiI
LeveI Switch
Torque
Converter
OutIet ReIief
VaIve
Torque
Converter
InIet ReIief
VaIve
To Hoist PiIot
SignaI ResoIver
To TCS
VaIve
InIet
ReIief VaIve
OutIet
ReIief VaIve
Lockup
CIutch
FiIter
Torque Converter
Charging FiIter
Lockup
CIutch
VaIve
Converter
Scavenge Screen
To
VariabIe Speed
Fan CIutch
ControI
Lockup
ReIief
VaIve
To Brake
CooIing
To Brake CooIing
TORQUE CONVERTER HYDRAULIC SYSTEM
FreewheeI
AssembIy
Stator
ImpeIIer Turbine Lockup Piston
Torque Converter
InIet OiI
Torque Converter
Lockup OiI Passage
CONVERTER DRIVE
TORQUE CONVERTER
FreewheeI
AssembIy
ImpeIIer
Turbine
Lockup Piston
DIRECT DRIVE
Stator Torque Converter
InIet OiI
Torque Converter
Lockup OiI Passage
TORQUE CONVERTER
T/C Lockup
SoIenoid
Lockup CIutch
Pressure Tap
To Lockup CIutch
From Lockup
CIutch Pump
LOCKUP CLUTCH MODULATING VALVE
TORQUE CONVERTER DRIVE
T/C Lockup
SoIenoid
Lockup CIutch
Pressure Tap
To Lockup CIutch
From Lockup
CIutch Pump
LOCKUP CLUTCH MODULATING VALVE
DIRECT DRIVE
2
3
4
Torq Converter
InIet ReIief
VaIve
Transmission
CooIer
Transmission
OiI Temperature
Sensor
Main
ReIief
VaIve
Transmission
Charge
Pump
Transmission
HydrauIic Tank
TRANSMISSION HYDRAULIC SYSTEM
NEUTRAL
Transmission
Scavenge
Pump
Transmission
Sump
Screen
Screen
6
7
5
1
Bypass
Switch
ENGAGEMENT OF TRANSMISSION CLUTCHES
Transmission Speed
Engaged CIutches in
the Transmission
NEUTRAL
REVERSE
FIRST speed
SECOND speed
THIRD speed
FOURTH speed
FIFTH speed
SIXTH speed
SEVENTH speed
1
1 and 7
2 and 6
1 and 6
3 and 6
1 and 5
3 and 5
1 and 4
3 and 4
From
Pump
Test Port
BaII
VaIve
SpooI Spring
Drain
Orifice
SoIenoid
Pin
To
Tank
To
CIutch
Orifice
TRANSMISSION MODULATING VALVE
NO COMMANDED SIGNAL
From
Pump
Test Port
BaII
VaIve
SpooI
Spring
Drain
Orifice
SoIenoid Pin
To
Tank
To
CIutch
TRANSMISSION MODULATING VALVE
COMMANDED SIGNAL BELOW MAXIMUM
Orifice
From
Pump
Test Port
BaII
VaIve
SpooI
Spring
Drain
Orifice
SoIenoid
Pin
To
Tank
To
CIutch
Orifice
TRANSMISSION MODULATING VALVE
COMMANDED SIGNAL AT MAXIMUM
From
Pump
SIug
BaII
Adjusting
Screw
MAIN RELIEF VALVE
OUTPUTS
INPUTS
Start ReIay
Transmission
SoIenoids 1-7
Steering System
DisabIe SoIenoid
Service Brake AccumuIator
BIeed SoIenoid
Lockup CIutch SoIenoid
Hoist Raise SoIenoid
Hoist Lower SoIenoid
Secondary Steering /
QuickEvac / PreIube ReIay
Starter Lockout Lamp
Back-up AIarm
Torque Converter OiI
Temperature Sensor
Primary Steering
Pressure Switch
Secondary Steering
Motor State
AIternator R-TerminaI
Secondary Steering
Pressure Switch
Transmission
Charge FiIter
Bypass Switch
Transmission Output
Speed Sensor 1
Key Start Switch
Machine Lockout Switch
Starter Lockout Switch
QuickEvac Service
TooI Input
Secondary Steer Test Switch
Drive Gear SeIect Switches
Shift Lever Position Sensor
FueI LeveI Sender
Engine Speed Sensor
Hoist Lever Position Sensor
Secondary Brake
Pressure Switch
IncIinometer
Transmission Output
Speed Sensor 2
Transmission OiI
LeveI Switch
Location Codes
Machine Lockout Lamp
Cat Data Link
Transmission Input
Speed Sensor
Body Up Switch
Head Lamp Sense
AutoIube Pressure Sensor
Lockup CIutch
FiIter Bypass Switch
Service Brake
Pressure Switch
AutoIube ReIay
Stop Lamp ReIay
BackIight Intensity
Backup Lamp ReIay
Secondary Steering ReIay
Transmission OiI
Temperature Sensor
TRANSMISSION/CHASSIS CONTROL MODULE SYSTEM DIAGRAM
TRANSMISSION / CHASSIS ECM
SYSTEMS CONTROLLED BY ECM
- Transmission Shifting - Torque Converter Lockup
- Top Gear Limit - Machine OverIoad Speed Limit
- Anti-hunt - Machine Speed Limit
- Reverse Inhibitor - Body Hoist
- Machine Lockout - Engine OiI Pre-Iubrication
- Engine Lockout - Sound Reduction
- NeutraI Start - Back-up AIarm
- Shift Counter - ControI ThrottIe Shifting (CTS)
- ThrottIe Lock - DirectionaI Shift Management
- Secondary Steering - NeutraI Coast Inhibiting
Load Sensing
ControIIer
FIow
Compensator
SwashpIate
Piston
Actuator
Piston
LOW PRESSURE STANDBY
STEERING PUMP
High Pressure
Cutoff VaIve
To Steering
VaIve
and HMU
Load Sensing
Pressure
from HMU
Case Drain
FiIter
Actuator Piston
SwashpIate
Piston
MAXIMUM FLOW
STEERING PUMP
Load Sensing
ControIIer
FIow
Compensator
High Pressure
Cutoff VaIve
Case Drain
FiIter
To Steering
VaIve
and HMU
Load Sensing
Pressure
from HMU
Secondary
Steering
Primary
ReIief VaIve
Secondary
Steering
Pump
M
Secondary
Pressure
Switch
Crossover
ReIief
VaIves
HMU
Steering
VaIve
STEERING HYDRAULIC
SYSTEM
LOW PRESSURE STANDBY
Case
Drain
FiIter
Secondary Steering
Back-up ReIief VaIve
Pressure
Reducing VaIve
Primary Steering
Pressure Switch
Steering
DisabIe VaIve
Primary Steering
Back-up ReIief VaIve
Piston Pump
and
Load Sensing
ControIIer
SwashpIate
Piston
Actuator
Piston
Load
Sensing VaIve
Steering
FiIter
FIow
Compensator
Transmission
Chassis ECM
To Hoist CyIinder
Rod End
To Hoist CyIinder
Head End
To Brake
CooIing
Brake CooIing
ReIief VaIve
Raise
SoIenoid
Lower
SoIenoid
Load
Check
VaIve
High
Pressure
ReIief VaIve
Low
Pressure
ReIief VaIve
DuaI Stage
ReIief VaIve
SignaI Stem
Main ReIief
Dump VaIve
HOIST CONTROL VALVE
HOLD
Torque Converter
Lockup CIutch Pressure
Torque Converter
Lockup CIutch Pressure
From Hoist CyIinder
Rod End
To Hoist CyIinder
Head End
To Brake
CooIing
Brake CooIing
ReIief VaIve
Raise
SoIenoid
Lower
SoIenoid
Load
Check
VaIve
High
Pressure
ReIief VaIve
Low
Pressure
ReIief VaIve
DuaI Stage
ReIief VaIve
SignaI Stem
Main ReIief
Dump VaIve
HOIST CONTROL VALVE
RAISE
ON
Torque Converter
Lockup CIutch Pressure
Torque Converter
Lockup CIutch Pressure
To Hoist CyIinder
Rod End
From Hoist CyIinder
Head End
To Brake
CooIing
Brake CooIing
ReIief VaIve
Raise
SoIenoid
Lower
SoIenoid
Load
Check
VaIve
High
Pressure
ReIief VaIve
Low
Pressure
ReIief VaIve
DuaI Stage
ReIief VaIve
SignaI Stem
Main ReIief
Dump VaIve
HOIST CONTROL VALVE
LOWER/POWER DOWN
ON
Torque Converter
Lockup CIutch Pressure
Torque Converter
Lockup CIutch Pressure
To Hoist CyIinder
Rod End
From Hoist CyIinder
Head End
To Brake
CooIing
Brake CooIing
ReIief VaIve
Raise
SoIenoid
Lower
SoIenoid
Load
Check
VaIve
High
Pressure
ReIief VaIve
Low
Pressure
ReIief VaIve
DuaI Stage
ReIief VaIve
SignaI Stem
Main ReIief
Dump VaIve
HOIST CONTROL VALVE
FLOAT
ON
Torque Converter
Lockup CIutch Pressure
Torque Converter
Lockup CIutch Pressure
To Hoist CyIinder
Rod End
From Hoist CyIinder
Head End
To Brake
CooIing
Brake CooIing
ReIief VaIve
Raise
SoIenoid
Lower
SoIenoid
Load
Check
VaIve
High
Pressure
ReIief VaIve
Low
Pressure
ReIief VaIve
DuaI Stage
ReIief VaIve
SignaI Stem
Torque Converter
Lockup CIutch Pressure
Main ReIief
Dump VaIve
HOIST CONTROL VALVE
SNUB
ON
Torque Converter
Lockup CIutch Pressure
From Torque Converter
Lockup Clutch Pilot
From Tow Pump Circuit
Left
Front
Right
Front
Main Relief Dump Spool
Lower /
Float /
Snub
Solenoid
RAISE
SNUB
FLOAT
LOWER
Brake
Cooling
Relief
Cylinder
Rod End
Pressure
Test Port
Right
Rear
Brake
Cooling
Pressure
Test Port
From
Torque Converter
Lockup Clutch
Pump
From
Torque
Converter
From
Brake
System
Left
Rear
777F HOIST AND BRAKE COOLING SCHEMATICS
777F
STANDARD
FRONT BRAKE
DisassembIy
Service PIug
Brake Actuation
Pressure
CaIiper
Carrier Lining
Piston
Disc
From Brake CyIinder
BIeed VaIve
777F OPTIONAL CALIPER DISC BRAKE
UnIoading
VaIve
Cut-In /
Cut-out
SpooI
AccumuIator
OiI Pressure Switch
ReIief
VaIve
To Brake
AccumuIators
From Brake
Charging Pump
To Brake
CooIing System
ACCUMULATOR CHARGING VALVE
CUT-IN
UnIoading
VaIve
Cut-In /
Cut-out
SpooI
AccumuIator
OiI Pressure Switch
ReIief
VaIve
To Brake
AccumuIators
From Brake
Charging Pump
To Brake
CooIing System
ACCUMULATOR CHARGING VALVE
CUT-OUT
OiI FIow
To Brake
CyIinder
OiI FIow
From Brake
CyIinder
From
WheeI
Brakes
To
WheeI
Brakes
To
WheeI
Brakes
BRAKES ENGAGED BRAKES RELEASED
Large
Piston
SmaII
Piston
From
WheeI
Brakes
BRAKE SLACK ADJUSTER
Screen
Hoist VaIve
Hoist, Converter, and
Brake OiI CooIers
To Hoist PiIot
SignaI ResoIver
To TCS
VaIve
InIet
ReIief VaIve
OutIet
ReIief VaIve
Lockup
CIutch
FiIter
Torque Converter
Charging FiIter
Lockup
CIutch VaIve
Converter
Scavenge
Screen
Rear
Brakes
To
VariabIe Speed
CIutch ControI
Lockup
ReIief VaIve
Screen
From Brake CooIing Pump
Right
Left
Front Brakes
Right
Left
BRAKE COOLING SYSTEM
OIL COOLED FRONT BRAKES
From Brake
AccumuIator
Charging
VaIve
To Brake
CooIing

BRAKE HYDRAULIC SYSTEM
UnIoading
VaIve
Cut -In /
Cut -Out
SpooI
ReIief
VaIve
ARC
Cont roI
Service
Brake
VaIve
Cab Brake
ManifoId
AccumuIat or
Charging VaIve
SIack Adjust er
Secondary
Pump
Divert er
VaIve
ReIief
VaIve
Purge
VaIve
Parking Brake VaIve
Parking Brake
SoIenoid
TCS VaIve
Swit ch
Left
Rear Brake
Right
Rear Brake
M
ECM

Left
Front Brake
Right
Front Brake
From TC VaIve
From TC Lockup
CIut ch Pump
Brake
FiIt er
Service Brake
AccumuIat ors
Parking Brake
AccumuIat or
Service Brake
PedaI Posit ion Sensor
Secondary Brake
PedaI Posit ion Sensor
OUTPUTS
INPUTS
Key Start Switch
Front Brake
Lockout Switch
Cat Data Link
AccumuIator OiI
Pressure Switch
Brake FiIter
Bypass Switch
TCS Test Switch
ARC ON /OFF Switch
Compression
ON /OFF Switch
Secondary Brake PedaI
Position Sensor
Service Brake PedaI
Position Sensor
Retarder Lever
Engine Speed Sensor
Left Rear WheeI
Speed Sensor
Right Rear WheeI
Speed Sensor
Brake OiI
Temperature Sensor
ARC ControI SoIenoid
TCS ProportionaI
SoIenoid
TCS SeIector
SoIenoid
Front Service
Brake SoIenoid
Parking Brake
SoIenoid
BRAKE CONTROL MODULE SYSTEM DIAGRAM
ARC
SoIenoid
Service
Brake
VaIve
Cab ManifoId
Brake ECM
Service Brake PedaI
Position Sensor
From Service
Brake
AccumuIat ors
To Rear
Service Brakes
Front Service
Brake SoIenoid
To Front
Service Brakes
Front Brake
Lockout Swit ch
(CaIiper Type Front Brakes)
Retarder Lever
SERVICE / RETARDER BRAKE CIRCUIT
BRAKES RELEASED
ARC
SoIenoid
Service
Brake
VaIve
Brake ECM
From Service
Brake
AccumuIators
To Rear
Service Brakes
Front Service
Brake SoIenoid
To Front
Service Brakes
ARC ON/OFF
Switch
Engine Speed
Sensor
Cab ManifoId
AUTOMATIC RETARDER CONTROL
(ARC)
OUTPUTS
INPUTS
Cat Data Link
TCS Test Swit ch
Left Rear WheeI
Speed Sensor
Right Rear WheeI
Speed Sensor
TCS Proport ionaI SoIenoid
TCS SeIect or SoIenoid
Service Brake
Pressure Swit ch
Transmission Out put
Speed Sensor 1
Transmission Out put
Speed Sensor 2
TRACTION CONTROL SYSTEM
( TCS)
From TC Lockup
CIutch Pump
Brake Reducing
VaIve
Brake Reducing
VaIve
SeIector
SoIenoid
ProportionaI
SoIenoid
From Parking
Brake VaIve
To Left
Rear Brake
To Right
Rear Brake
TCS VALVE
ENGINE RUNNING / BRAKES RELEASED
From TC Lockup
CIutch Pump
Brake Reducing
VaIve
Brake Reducing
VaIve
SeIector
SoIenoid
ProportionaI
SoIenoid
From Parking
Brake VaIve
To Left
Rear Brake
To Right
Rear Brake
TCS VALVE
ENGINE RUNNING / LEFT BRAKE ENGAGED
Dark Gray - Cutaway section
Light Gray - Surface color
Red - High pressure oil
Red/White Stripes - 1st pressure reduction
Red Crosshatch - 2nd reduction in pressure
Pink - 3rd reduction in pressure
Red/Pink Stripes - Secondary source oil pressure
Orange - Pilot, charge, or Torque Converter oil
Orange / White Stripes -
Reduced pilot, charge, or TC oil pressure
Green - Tank, sump, or return oil Blue - Trapped oil
Brown - Lubricating oil
Purple - Pneumatic pressure
Orange Crosshatch - 2nd reduction in
pilot, charge, or TC oil pressure.
White - Atmosphere or
Air (No pressure)
Yellow - Moving or activated components
Cat Yellow - (Restricted usage)
Identification of components
within a moving group
Black - Mechanical connection. Seal
Green / White Stripes -
Scavenge Oil or Hydraulic Void
HYDRAULIC SCHEMATIC COLOR CODE