7 7 7 F ( J R P ) O F F - H I G H WAY T R U C K

P O W E R T R A I N , S T E E R I N G, H O I S T,
AND BRAKING SYSTEMS

© 2006 Caterpillar Inc.

 POWER TRAIN HYDRAULIC SYSTEM
To
Torque Brake
Converter Cooling
Outlet Relief
Valve
To
Variable To To
Speed Hoist Pilot Traction Transmission
Clutch Signal Control Charge Filters
Control Resolver Pilot

Lockup
Valve To
Brake
Cooling
Lockup
Lockup Clutch Relief
Clutch Valve Valve
Torque Filter
Converter
Torque Converter
Charge Filter
Hydraulic
Controls

Transmission

Torque
Converter
Inlet Relief
Valve

Transmission Oil
Level Switch
 TORQUE CONVERTER HYDRAULIC SYSTEM
To Brake Cooling

Torque Converter
Charging Filter

To Brake
Cooling Inlet
Relief Valve

Outlet
Relief Valve
Lockup
Clutch
Valve
Lockup
Relief
Valve Lockup
Clutch
To
Filter
Variable
Speed
Fan To TCS
Clutch Valve
Control
Converter
To Hoist Pilot Scavenge Screen
Signal Resolver
Lockup Piston Turbine Impeller
TORQUE CONVERTER
CONVERTER DRIVE
Stator Torque Converter
Inlet Oil

Torque Converter
Freewheel Lockup Oil Passage
Assembly
Lockup Piston Turbine Impeller
TORQUE CONVERTER
DIRECT DRIVE
Stator Torque Converter
Inlet Oil

Torque Converter
Freewheel Lockup Oil Passage
Assembly
LOCKUP CLUTCH MODULATING VALVE
TORQUE CONVERTER DRIVE

Lockup Clutch
Pressure Tap

T/C Lockup
Solenoid
From Lockup
Clutch Pump
To Lockup Clutch
LOCKUP CLUTCH MODULATING VALVE
DIRECT DRIVE

Lockup Clutch
Pressure Tap

T/C Lockup
Solenoid
From Lockup
Clutch Pump
To Lockup Clutch
 TRANSMISSION HYDRAULIC SYSTEM
NEUTRAL

Transmission 1
5
Oil Temperature
Sensor

Bypass
Switch
Transmission
Cooler
Transmission
Transmission Charge
Scavenge Pump 2
Pump
6
Screen
Screen

Transmission Transmission
Sump Hydraulic Tank
Main
Relief
Valve
3

Transmission
Lube Relief
7
Valve

4
 ENGAGEMENT OF TRANSMISSION CLUTCHES

Engaged Clutches in
Transmission Speed
the Transmission

NEUTRAL 1

REVERSE 1 and 7

FIRST speed 2 and 6

SECOND speed 1 and 6

THIRD speed 3 and 6
FOURTH speed 1 and 5
FIFTH speed 3 and 5

SIXTH speed 1 and 4

SEVENTH speed 3 and 4

TRANSMISSION MODULATING VALVE
NO COMMANDED SIGNAL
Test Port

Valve
Ball Orifice Spool Spring

Solenoid Pin Drain From

Orifice Pump
To To
Tank Clutch
TRANSMISSION MODULATING VALVE
COMMANDED SIGNAL BELOW MAXIMUM
Test Port

Valve
Ball Orifice Spool Spring

Solenoid Pin Drain From

Orifice Pump
To To
Tank Clutch
TRANSMISSION MODULATING VALVE
COMMANDED SIGNAL AT MAXIMUM
Test Port

Ball Orifice Valve

Spool Spring

Solenoid Pin Drain From

Orifice Pump
To To
Tank Clutch
 MAIN RELIEF VALVE
Adjusting
Screw

Ball

Slug

From
Pump
 TRANSMISSION/ C HASSIS CONTROL MODULE SYSTEM DIAGRAM

Cat Data Link

INPUTS OUTPUTS

Key Start Switch Torque Converter Oil Start Relay

Temperature Sensor
Machine Lockout Switch
Transmission Oil Transmission
Temperature Sensor Solenoids 1-7
Starter Lockout Switch
Primary Steering
Pressure Switch
QuickEvac Service
Tool Input Secondary Steering
Motor State Steering System
Disable Solenoid
Secondary Steer Test Switch Transmission Input
Speed Sensor
Service Brake Accumulator
Drive Gear Select Switches Alternator R-Terminal Bleed Solenoid
Lockup Clutch
Shift Lever Position Sensor Solenoid
Transmission
Charge Filter
Bypass Switch
Hoist Raise Solenoid
Hoist Lever Position Sensor
Transmission Output
Speed Sensor 1
Hoist Lower Solenoid
Fuel Level Sender
Transmission Output
Secondary Steering /
Speed Sensor 2
QuickEvac /
Engine Speed Sensor Prelube Relay
Transmission Oil
Level Switch
Back-up Alarm
Head Lamp Sense
Location Codes
Autolube Relay
Inclinometer
Secondary Steering
Body Pressure Switch Stop Lamp Relay
Up Switch
Secondary Brake Backup Lamp Relay
Autolube Pressure Sensor Pressure Switch

Service Brake Secondary Steering Relay

Pressure Switch

Lockup Clutch Starter Lockout Lamp

Filter Bypass Switch

Machine Lockout Lamp

Backlight Intensity
TRANSMISSION/CHASSIS ECM
SYSTEMS CONTROLLED BY ECM
• Transmission Shifting • Torque Converter Lockup
• Top Gear Limit • Machine Overload Speed Limit
• Anti-hunt • Machine Speed Limit
• Reverse Inhibitor • Body Hoist
• Machine Lockout • Engine Oil Pre-lubrication
• Engine Lockout • Sound Reduction
• Neutral Start • Backup Alarm
• Shift Counter • Control Throttle Shifting (CTS)
• Throttle Lock • Directional Shift Management
• Secondary Steering • Neutral Coast Inhibiting
 Load Sensing To Steering
Pressure Valve STEERING PUMP
from HMU and HMU
LOW PRESSURE STANDBY

High Pressure
Cutoff Valve Actuator
Piston

Flow
Compensator

Load Sensing
Controller

Swashplate
Piston
Case Drain
Filter
 Load Sensing
Pressure
To Steering STEERING PUMP
Valve
from HMU and HMU MAXIMUM FLOW

High Pressure
Cutoff Valve
Actuator Piston

Flow
Compensator

Load Sensing
Controller

Swashplate
Piston
Case Drain
Filter
 Crossover
Relief Valves

STEERING HYDRAULIC
SYSTEM
HMU

Primary Steering
Back-up Relief Valve
Pressure
Reducing Valve
Load Primary Steering
Sensing Valve Pressure Switch
Secondary Secondary Steering
Pressure Back-up Relief Valve
Switch

Transmission
Chassis Steering
ECM Valve
Piston Pump and
M Load Sensing
Controller

Secondary Secondary
Steering Steering
Primary Relief Pump
Valve
Flow
Compensator

Steering
Disable Valve Actuator
Piston

Swashplate
Piston
Steering
Filter

Case Drain
Filter
 Raise Brake Cooling
Solenoid Relief Valve

Low Parking Brake

Pressure Release Pressure
Relief Valve

Main Relief
Dump Valve
To Brake
High Cooling
Pressure
Relief Valve

To Hoist Cylinder
Dual Stage Rod End
Relief Valve
Signal Stem

To Hoist Cylinder
Load Head End
Check
Valve

HOIST CONTROL VALVE

HOLD
Parking Brake
Release Pressure

Lower
Solenoid
 ON
Raise Brake Cooling
Solenoid Relief Valve

Low Parking Brake

Pressure Release Pressure
Relief Valve

Main Relief
Dump Valve
To Brake
High Cooling
Pressure
Relief Valve

Dual Stage From Hoist Cylinder

Relief Valve Rod End
Signal Stem

To Hoist Cylinder
Load Head End
Check
Valve

HOIST CONTROL VALVE

RAISE
Parking Brake
Release Pressure
Lower
Solenoid
 Raise Brake Cooling
Solenoid Relief Valve

Low Parking Brake

Pressure Release Pressure
Relief Valve

Main Relief
Dump Valve
To Brake
High Cooling
Pressure
Relief Valve

To Hoist Cylinder
Dual Stage Rod End
Relief Valve
Signal Stem

From Hoist Cylinder

Load Head End
Check
Valve

HOIST CONTROL VALVE

LOWER/POWER DOWN
Parking Brake
Release Pressure

Lower
Solenoid

ON
 Raise Brake Cooling
Solenoid Relief Valve
Low Parking Brake
Pressure Release Pressure
Relief Valve

Main Relief
Dump Valve
To Brake
High Cooling
Pressure
Relief Valve

To Hoist Cylinder
Dual Stage Rod End
Relief Valve
Signal Stem

From Hoist Cylinder

Load Head End
Check
Valve

HOIST CONTROL VALVE

FLOAT
Parking Brake
Release Pressure

Lower
Solenoid

ON
 Raise Brake Cooling
Solenoid Relief Valve
Low Parking Brake
Pressure Release Pressure
Relief Valve

Main Relief
Dump Valve
To Brake
High Cooling
Pressure
Relief Valve

To Hoist Cylinder
Dual Stage
Rod End
Relief Valve
Signal Stem

From Hoist Cylinder

Load Head End
Check
Valve

HOIST CONTROL VALVE

SNUB
Parking Brake
Release Pressure

Lower
Solenoid

ON
 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 Actuation
Pressure
777F
STANDARD
FRONT BRAKE

Disassembly
Service Plug
 777F OPTIONAL CALIPER DISC BRAKE

Piston
Bleed Valve

Caliper

Carrier Lining
From Brake Cylinder

Disc
 ACCUMULATOR CHARGING VALVE
CUT-IN
To Brake
Accumulators Accumulator
Oil Pressure Switch

Cut-In /
Cut-Out
Spool

Unloading Relief
Valve Valve

To Brake
Cooling System
From Brake
Charging Pump
 ACCUMULATOR CHARGING VALVE
CUT-OUT
To Brake
Accumulators Accumulator
Oil Pressure Switch

Cut-In /
Cut-Out
Spool

Unloading Relief
Valve Valve

To Brake
Cooling System
From Brake
Charging Pump
 BRAKE SLACK ADJUSTER

Oil Flow Oil Flow

To Brake From Brake
Cylinder Small Large Cylinder
Piston Piston

From From To
Wheel Wheel Wheel
Brakes Brakes Brakes

To
Wheel
Brakes

BRAKES RELEASED BRAKES ENGAGED

 BRAKE COOLING SYSTEM
Front Brakes OIL COOLED FRONT BRAKES

Right Hoist, Converter, and

Brake Oil Coolers

Rear
Brakes
Left Screen

Right
Hoist Valve

From Brake Cooling Pump Screen

Left
Torque Converter
Charging Filter

Inlet
Relief Valve
Lockup
Outlet Clutch Valve
Lockup Relief Valve
Relief Valve

To Lockup
Variable Speed Clutch
Clutch Control Filter

To Hoist Pilot To TCS Converter

Signal Resolver Valve Scavenge
Screen
 BRAKE HYDRAULIC SYSTEM

Service Brake
ARC Service Pedal Position Sensor
Purge Brake
Control
Valve Valve

Secondary Brake
Diverter
Pedal Position Sensor
Parking Brake Valve
Left ECM
Rear Brake Solenoid Relief
Parking Brake Valve Valve
Left
Front Brake
Cab Brake
M
Manifold
Secondary Parking Brake
Pump Accumulator
Service Brake
From TC Lockup
Accumulators Switch
Clutch Pump
TCS Valve
Cut-In /
Cut-Out
Spool Accumulator
Charging Valve
Unloading
Valve
Relief
Slack Adjuster
Valve

Brake
To Brake Filter
Cooling

Right
From TC Valve Front Brake

Right
Rear Brake
 BRAKE CONTROL MODULE SYSTEM DIAGRAM

Cat Data Link

INPUTS OUTPUTS

Key Start Switch

ARC Control Solenoid
Accumulator Oil Secondary Brake Pedal
Pressure Switch Position Sensor
Front Service
Brake Filter Service Brake Pedal Brake Solenoid
Bypass Switch Position Sensor
Parking Brake
Retarder Lever Solenoid
TCS Test Switch
TCS Proportional
Engine Speed Sensor Solenoid

ARC ON/OFF Switch

Left Rear Wheel TCS Selector
Speed Sensor Solenoid
Compression
ON/OFF Switch Right Rear Wheel
Speed Sensor

Front Brake Brake Oil

Lockout Switch Temperature Sensor
 SERVICE / RETARDER BRAKE CIRCUIT
BRAKES RELEASED

Service Brake Pedal

Position Sensor

To Rear
Service Brakes
ARC
Service
Solenoid
Brake
Valve

From Service
Brake Retarder Lever
Accumulators Brake ECM

Front Brake
Front Service Lockout Switch
Brake Solenoid To Front (Caliper Type Front Brakes)
Service Brakes

Cab Manifold
 AUTOMATIC RETARDER CONTROL
(ARC)

To Rear
Service Brakes
ARC
Service
Solenoid
Brake
Valve

From Service Engine Speed

Brake Sensor
Accumulators Brake ECM

ARC ON/OFF
Front Service Switch
Brake Solenoid To Front
Service Brakes

Cab Manifold
 TRACTION CONTROL SYSTEM
( TCS)

INPUTS OUTPUTS

Left Rear Wheel

TCS Proportional Solenoid
Speed Sensor

Right Rear Wheel

Speed Sensor TCS Selector Solenoid

TCS Test Switch

Service Brake Cat Data Link

Pressure Switch

Transmission Output
Speed Sensor 1

Transmission Output
Speed Sensor 2
 TCS VALVE
ENGINE RUNNING / BRAKES RELEASED
To Left From TC Lockup
Rear Brake Clutch Pump
From Parking
Brake Valve

Brake Reducing
Valve

Proportional
Solenoid

Selector
Solenoid

Brake Reducing
Valve

To Right
Rear Brake
 TCS VALVE
ENGINE RUNNING / LEFT BRAKE ENGAGED
To Left From TC Lockup
From Parking Rear Brake Clutch Pump
Brake Valve

Brake Reducing
Valve

Proportional
Solenoid

Selector
Solenoid
Brake Reducing
Valve

To Right
Rear Brake