777F (JRP)

OFF-HIGHWAY TRUCKS

New Product Introduction

(NPI)

© 2006 Caterpillar Inc.

 SIMILARITIES AND DIFFERENCES

FEATURES DIFFERENT SIMILAR SAME

Machine Appearance X
Operator’s Station X
Engine X
Power Train X
Hoist System X
Steering System X
Brake System X
Monitoring System X
Air System X
Maintenance Items X
 CATERPILLAR MONITORING SYSTEM
777D OFF-HIGHWAY TRUCKS
Message Center Action
Gauge Cluster Speed/tach Module Lamp
Module Module - Gauges
- Monitoring
- Warnings
- Clock Synchronization cKpaMilesKmRpmLiterServ
1f - Machine Id . . . C ode
X10
Display Action
Data Link Alarm Input
Service Components
Tool
Cat Data Link

Brake ECM
Engine ECM (ARC) (TCS)

- Emissions Control
- Traction Assist
- Fuel Injection
- Retarding
- Ether Injection
- Overspeed Retarding
- Fan Control
- Retarding Lamp
- Engine Pre-lube
RS232 Link
Transmission /
Chassis ECM TPMS
- ICM Control - Top Gear Limit
- Neutral-start - Reverse Neutralize
- Back-up Alarm - Load Counter
- Overspeed Protection - Neutral Coast Inhibit - Payload Measurement
- CTS - Body Up Gear Limit - Strut Diagnostics
- Engine Pre-lube - Starter Protection
- Directional Shift Management - Body Hoist Control
- Autolube - Secondary Steering
- Speed Limiter
 100T ELECTRONIC SYSTEM BLOCK DIAGRAM

VIMS-PC
Telemetry GPS
Antenna Antenna
(Attachment) (Attachment)

15 20
10 25
5 30
0 35

X100

VIMS ECM
Inclinometer
(ABL2M)
TCS

(Attachment)
(Attachment)

Road Analysis ECM

(RAC) (ABL2M)
(Attachment)
Engine ECM
(A4:E4)
Brake ECM (TCS)
(A4:M1)
(Standard)
Minestar
Minestar
Control Trans / Chassis ECM
Display
(Attachment) (A4:M1)
(Standard)

Product Link ECM

CAT Datalink
(Attachment(
CAN SAE J1939 Datalink
RS232 19200 Baud Serial Link
ET Service Tool
 3500B ELECTRONIC CONTROL SYSTEM
Engine COMPONENT DIAGRAM
ECM Disconnect
Ground Switch
Electronic Unit
Bolt
Injectors
24 V
Main Key Start
15 Amp Power Relay Switch
Breaker
Throttle Position Sensor
Timing Calibration
Coolant Temperature Connector
Engine Oil
Aftercooler Temperature Level Switch
Speed / Timing Sensor

Engine Oil Pressure (Filtered) Engine Oil Pressure

Manual Ether (Unfiltered)
Aid Switch Ether Aid Relays And Solenoid
Atmospheric Pressure

Throttle Override Switch

Turbo Outlet Pressure (Boost) Fuel Filter
Bypass Switch Ground Level
Shutdown Switch
Right Turbo Inlet Pressure
Cat Data Link
Crankcase
Service Tool
Pressure
Left Turbo Inlet Pressure Transmission / Chassis ECM
Brake ECM
Right Turbo Exhaust A/C Pressure Caterpillar Monitoring System
Switch
Shutter Solenoid
Left Turbo Exhaust
Coolant Flow Pre-lubrication Relay
Switch
 CAT Data Link
ENGINE ECM SYSTEM DIAGRAM

EUI Injectors (12)

7E6513

left Bank (Odd) Engine Retarder Solenoids

066-8391 (Connector PN)
Ether Start Relay

Right Bank (Even) Engine Retarder Solenoids

Rockford Fan Solenoid ( At t achment )
066-8391 (Connector PN)
Outputs
Outputs
Inputs Speed Sensor No. 1 (Crank)
Inputs
Speed Sensor No. 2 (Cam) Key Start Switch

Timing Cal Probe Connector

Throttle Pedal Position Sensor

Intake Air Temperature

Back-up Throttle Switch
Coolant Temperature

Intake Manifold Air Pressure

Engine Oil Pressure

Ground Level Shutdown Switch
Atmospheric Pressure
Rockford Fan Speed Sensor (Attachment)
Fuel Temp Sensor
Left Air Filter Restriction (Turbo Inlet Left)
Fuel Pressure Sensor

Diff. Fuel Pressure Switch Right Air Filter Restriction (Turbo Inlet Right)

J2 (ENGINE) CONNECTOR J1 (MACHINE) CONNECTOR

 COOLING SYSTEM FLOW
Thermostat Radiator
Housing

Engine Block

ATAAC
Engine Oil Cooler

Hoist and Brake

Oil Cooler

Transmission and
Torque Converter
Oil Cooler Water Pump
 POWER TRAIN HYDRAULIC SYSTEM

To
Variable To To
Speed Hoist Pilot Traction
Clutch Signal Control
Control Resolver Pilot

Lockup
Valve
To
Brake
Cooling

Torque
Converter

Hydraulic
Controls

Transmission
 TRANSMISSION / CHASSIS CONTROL MODULE SYSTEM DIAGRAM

Cat Data Link

INPUTS OUTPUTS

Key Start Switch Torque Converter Oil Start Relay

Temperature Sensor
Machine Lockout Switch Primary Steering
Transmission
Pressure Swit ch Solenoid 1-7
Starter Lockout Switch
Secondary Steering
Motor State
Engine Oil Evacuation Enable
Engine Oil Evacuation Transmission Input
Speed Sensor

Secondary Steer Test Switch R-Terminal

Steering System
Disable Solenoid
Drive Gear Select Switches Transmission
Charge Filter
Bypass Switch Parking Brake
Shift Lever Proportional Solenoid
Transmission Output Lockup Clutch
Speed Sensor 1 Solenoid
Hoist Lever

Transmission Output
Hoist Raise Solenoid
Speed Sensor 2
Fuel Level Sender

Transmission Oil Hoist Lower Solenoid

Level Switch
Engine Speed Sensor
Secondary St eering /
Location Codes QuickEvac /
Manual Ret arder Prelube Relay

Secondary Steering System Back-up Alarm Relay

Inclinometer Steering Switch

Secondary Brake Secondary Brake Starter Lockout Lamp

Posit ion Sensor Pressure Switch

Machine Lockout Lamp

 Crossover
Relief Valves STEERING HYDRAULIC
SYSTEM

HMU

Load Secondary
Sensing Pressure
Resolver Switch
Pressure Load
Reducing Sensing
Valve Valve
Steering
Pressure
Switch

Transmission
Chassis
Secondary ECM
Steering M
Steering Back-up Relief
Valve Valve

Secondary Secondary
Primary Steering
Steering Steering
Back-up Relief Valve
Primary Relief Pump
Valve

Steering
Piston Pump and
Disable
Load Sensing
Valve
Controller

Steering
Filter

Case Drain
Filter
 Left
Front
777F HOIST AND BRAKE COOLING SCHEMATICS

From Torque Converter Right

Lockup Clutch Pilot Front

Main Relief Dump Spool

From Tow Pump Circuit

Left
Rear
Lower /
Float /
Snub
Solenoid
From
Torque Converter From From
Lockup Clutch Torque Brake
Pump Converter System

RAISE

Right SNUB
Rear Brake Cooling
Pressure
Test Port Cylinder FLOAT
Rod End
Pressure
Test Port
LOWER
Brake
Cooling
Relief
 BRAKE HYDRAULIC SYSTEM

Purge
ARC Service
Valve
Parking Parking Brake Cont rol Brake
Brake Solenoid Valve
Valve

Divert er
Valve
Left ECM
Rear Brake Relief
Valve Left
Front Brake

Cab Manifold
M
Secondary
Pump

From TC Lockup
Swit ch
Clut ch Pump
TCS Valve
Cut -In /
Cut -Out
Spool Accumulat or
Charging Valve
Unloading
Valve
Relief
Slack Adjust er
Valve

Brake
To Brake Filt er
Cooling

Right
From TC Valve Front Brake

Right
Rear Brake
 BRAKE SYSTEM
TCS Valve
Rear Brake Front
Brake
Check
Valve

Brake
Park Accumulat ors
Brake
Valve
Switch

ARC
Manifold
Diverter Relief
Accumulator
Charging Valve
To Brake Cooling Brake
Slack Control
Adjuster Valve
To Brake
Cooling Brake
Secondary Filter
Pump
Pump
Slack
Adjust er

Tank Front
Rear Brake Brake
 HYDRAULIC SCHEMATIC COLOR CODE

Black - Mechanical connection. Seal Red - High pressure oil

Dark Gray - Cutaway section Red/White Stripes - 1st pressure reduction

Light Gray - Surface color Red Crosshatch - 2nd reduction in pressure

White - Atmosphere or Pink - 3rd reduction in pressure

Air (No pressure)

Purple - Pneumatic pressure Red/Pink Stripes - Secondary source oil pressure

Yellow - Moving or activated components Orange - Pilot, charge, or Torque Converter oil

Cat Yellow - (R estricted usage) Orange / White Stripes -

Identification of components Reduced pilot, charge, or TC oil pressure
within a moving group
Orange Crosshatch - 2nd reduction in
Brown - Lubricating oil pilot, charge, or TC oil pressure.

Green - Tank, sump, or return oil Blue - Trapped oil

Green / White Stripes -

Scavenge Oil or Hydraulic Void