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SERV1828 January 2007 TECHNICAL PRESENTATION 777F (JRP) OFF-HIGHWAY TRUCK INTRODUCTION Service Training Meeting Guide (STMG) GLOBAL SERVICE LEARNING
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SERV1828 January 2007

GLOBAL SERVICE LEARNINGTECHNICAL PRESENTATION

777F (JRP) OFF-HIGHWAY TRUCKINTRODUCTION

Service Training Meeting Guide (STMG)

777F (JRP) OFF-HIGHWAY TRUCKINTRODUCTION MEETING GUIDE 828 VISUALS AND SCRIPTAUDIENCELevel II - Service personnel who understand the principles of machine system operation, diagnostic equipment, and procedures for testing and adjusting.

CONTENTThis presentation provides basic maintenance information and describes the systems operation of the monitoring system, engine, power train, steering, hoist and brakes for the 777F Offhighway Truck. The Automatic Retarder Control (ARC) and the Traction Control System (TCS) are also discussed. This presentation may also be used for self-paced and self-directed learning. OBJECTIVES After learning the information in this meeting guide, the serviceman will be able to: 1. locate and identify the major components in the engine, power train, steering, and brakes; 2. explain the operation of the major components in the systems; and 3. trace the flow of oil through the systems. REFERENCES 777F (JRP) Operation and Maintenance Manual 777F (JRP) Parts Manual PREREQUISITES "Fundamentals of Engines Self Study Course" "Fundamentals of Mobile Hydraulics Self Study Course" "Fundamentals of Power Trains Self Study Course" "Fundamentals of Electrical Systems Self Study Course" Estimated Time: 24 Hours Visuals: 224 Handouts: 30 Form: SERV1828 Date: 01/07 2007 Caterpillar Inc.

SEBU7790 SEBP4305

TEMV3001 TEMV3002 TEMV3003 TEMV3004

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SUPPLEMENTAL MATERIALReference Manuals Fluid Power Graphic Symbols User's Guide Cold Weather Recommendations for Caterpillar Machines Caterpillar Machine Fluids Recommendations Salesgrams and Product Bulletins Training Bulletin "Caterpillar Transmission/Drive Train Oil" Product Bulletin "Reporting Particle Count By ISO Code" Salesgram "Caterpillar Extended Life Coolant" Product Data Sheet "Caterpillar Extended Life Coolant" Technical Instruction Modules on Legacy DVDs SERV1000-01 (These materials can not be ordered separately.) Automatic Retarder Control System Automatic Electronic Traction Aid 769C - 793B Off-highway Trucks--Suspension System Truck Payload Measurement System Service Training Meeting Guides STMG 721 "777D Update (AGC) Off-highway Truck" (CD ROM) Video Tapes Suspension Cylinder Charging TPMS Management/Technical Information TPMS Operating Tips Introduction to the Automatic Electronic Traction Aid Mining Trucks--Cleanliness and Component Life Oil Sampling--The Right Way Booklets Know Your Cooling System Diesel Fuels and Your Engine Oil and Your Engine Understanding The SOS Report SEBD0518 SEBD0717 SEBD0640 TEJB1015 TEVN2155 AEVN2211 AEVN2212 SEVN9187 SEVN4142 PEVN4638 SERV1721 SEGV2593 SEGV2585 SEGV2599 SEGV2579 TEJB1002 PEJT5025 TEKQ0072 PEHP4036 SENR3981 SEBU5898 SEBU6250

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SUPPLEMENTAL MATERIAL (Continued)Special Instructions Accessing Flash Software for Machines Caterpillar Electronic Controls Service Code Information Description List Using the 7X1700 Communication Adapter Group Using the 261-3363 Wireless Communications Adapter Use of CE Connector Tools Servicing DT Connectors Parts Listing Of The Deutsch Connectors And Components Use of 6V3000 Sure-Seal Repair Kit Use of 8T5200 Signal Generator/Counter Group Suspension Cylinder Servicing 777F Assembly Procedure Brochures Caterpillar Electronic Technician Caterpillar DataView Diesel Engine Oil (CH4) Product Data Sheet How to Take a Good Oil Sample SOS Coolant Analysis Air Filter Service Indicator Cat Oil Cooled, Multiple Disc Brakes Caterpillar Automatic Retarder Control Caterpillar "D" Series Truck Cabs Caterpillar Truck Frames Mining Truck Bodies: Selecting The Right Body System For Your Job Caterpillar Truck Production Management System: Answering your questions about TPMS Miscellaneous Pocket Card "Electronic Diagnostic Codes" Chart "Practical Pressure Conversions" "Cleaning Rear Axle Housing Assemblies (785/789)" Training CD-ROM "Caterpillar Electronic Technician (ET) for Off-highway Trucks" Training CD-ROM "Truck Production Management System (TPMS) for Off-highway Trucks" NEEG2500 SEES5677 SEBF8366 SERV7003 SERV7004 NEHP5614 NEHP5622 PEHP8038 PEHP6001 PEHP5033 PEHP9013 AECQ5980 AEDK0075 AEDK0706 AEDK0707 AEDK0083 AEDK2953 REHS0494 REHS0126 SEHS9264 NEHS0926 SEHS9065 SEHS9615 REHS0148 SMHS7531 SEHS8579 SEHS9411 REHS2594

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TABLE OF CONTENTSINTRODUCTION ........................................................................................................................7 MAINTENANCE .......................................................................................................................11 OPERATOR'S STATION............................................................................................................38 MONITORING SYSTEM ..........................................................................................................47 Messenger Display Module ..................................................................................................52 Advisor/VIMS Display .........................................................................................................63 ENGINE......................................................................................................................................83 Engine Electronic Control System .......................................................................................84 Engine Derates......................................................................................................................94 Engine Compression Brake ................................................................................................101 Cooling System...................................................................................................................106 Lubrication System .............................................................................................................108 Fuel System.........................................................................................................................109 Air Intake and Exhaust System ..........................................................................................116 POWER TRAIN .......................................................................................................................124 Torque Converter Hydraulic System ..................................................................................127 Transmission Hydraulic System .........................................................................................138 Rear Axle ............................................................................................................................150 Transmission/Chassis Electronic Control System ..............................................................152 STEERING SYSTEM ..............................................................................................................163 HOIST SYSTEM ......................................................................................................................177 BRAKE SYSTEM ....................................................................................................................197 Brake Electronic Control System .......................................................................................224 Automatic Retarder Control System...................................................................................229 Traction Control System.....................................................................................................231 CONCLUSION.........................................................................................................................238 VISUAL LIST ..........................................................................................................................239 HYDRAULIC SCHEMATIC COLOR CODE.........................................................................242 HANDOUTS.............................................................................................................................243 POSTTEST ...............................................................................................................................268 POSTTEST ANSWERS ...........................................................................................................272

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NOTES

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777F (JRP) OFF-HIGHWAY TRUCKINTRODUCTION

2006 Caterpillar Inc.

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INTRODUCTION Shown is the right side of a 777F Truck. The fuel tank is located on the right side of the truck. The 777F Truck comes standard with oil-cooled multiple disc brakes, front and rear. Front caliper type disc brakes are available as an option. The major features added to the 777F Truck are: the new cab, the Messenger or VIMS Advisor monitoring system, the Tier 2 compliant C32 ACERT engine and cooling system, the ECPC transmission, and the hydraulic brakes. Some of the specifications of the 777F Truck are: - Serial No. Prefix: JRP - Empty weight: 73976 kg (163090 lb) - Load carrying capacity: 90.9 tonnes (100 tons) - Gross Machine Weight (GMW): 163293 kg (360000 lb) - Length: 10.5 m (34.5 ft) - Operating Width: 6.5 m (21.3 ft) - Height: 5.2 m (17.0 ft) - Body Up Height: 10.4 m (34.0 ft) - Top speed, loaded: 64.5 km/h (40.1 mph)

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Shown is the left side of a 777F Truck. The hydraulic tank group is visible. The hydraulic tank group consists of two separate tanks: the hoist, brake, and torque converter hydraulic tank (front) and the transmission hydraulic tank (rear). The transmission hydraulic system is separated from all of the other hydraulic systems. The Individual Clutch Modulation (ICM) transmission has been replaced with Electronic Clutch Pressure Control (ECPC) transmission. The Chassis/Transmission Electronic Control System controls most of the same functions as on the 777D truck. The air system has been eliminated on the 777F Truck. The brakes are completely hydraulic.

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Shown is the front of a 777F Truck. The 777F Truck uses a Next Generation Modular Radiator (NGMR). Its modular design, similar to the previous folded core radiator, permits easy removal of a single core without having to remove the entire radiator.

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Shown is the rear of a 777F Truck. Two body options are available for the 777F Truck: - A dual-slope steel design with a "V" bottom main floor to reduce shock loading, center the load, and reduce spills. - The dual-slope steel body above, with the addition of a rubber liner for increased resistance to impact and wear. All internal wear surfaces of the truck body are made with 400 Brinell hardness steel. The steel attachment body liner is also made with 400 Brinell hardness steel. The external components of the body are made of steel with a yield strength of 6205 bar (90000 psi). The rubber liner is one-fifth the density of steel, but absorbs impact four times better. The rear suspension cylinders absorb bending and twisting stresses rather than transmitting them to the main frame.

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777F MAINTENANCEe 777F Servic Procedure

WALK AROUND INSPECTION5 MAINTENANCE Before working on or operating the truck, read the Operation and Maintenance Manual thoroughly for information on safety, maintenance, and operating techniques. Safety precautions and Warnings are provided in the manual and on the truck. Be sure to identify and understand all symbols before starting the truck. The first step to perform when approaching the truck is to make a thorough walk around inspection. Look around and under the truck for loose or missing bolts, trash build-up and for coolant, fuel or oil leaks. Look for indications of cracks. Pay close attention to high stress areas as shown in the Operation and Maintenance Manual.

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10 HOURS DAILY MAINTENANCE CHECKSSteering Oil Level Primary Fuel Filter Disconnect Switch Engine Oil Level Batteries Air Filters and Precleaners Radiator Debris Fan Belts and Ether Cylinder Coolant Level Inspect Frame for Cracks and Body Support Pads Check For Leaks and Trash Build-up Rear Axle Breather Suspension Cylinder Height Fuel Level and Drain Moisture

Wash Windows, Cab Fresh Air Filters, Seat Belt, Indicators, Gauges, Brake Tests, Secondary Steering and Back-up Alarm Windshield Washer Level Suspension Cylinder Height and Grease Breathers Wheel Nuts Hoist, Converter And Brake Oil Level Transmission Oil Level

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The following list identifies the items that must be serviced every 10 Hours or Daily. - Walk-Around Inspection: Check for loose or missing bolts, leaks, trash build-up, and cracks in frame structures and body support pads. - Back-up alarm: test - Brakes, indicators, gauges: test - Braking system: test - Coolant level - Differential / final drive oil level - Engine air filter service indicator - Engine oil level - Engine oil level (ORS) - Engine oil level: log additions - Fuel filter: drain water separator - Fuel tank: drain water / sediment - Hoist, converter, brake oil level - Seat belt: inspect - Secondary steering: test - Steering system oil level - Transmission oil level

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The front wheel bearing oil level is checked and filled by removing the plug (1) in the center of the wheel bearing cover. The oil should be level with the bottom of the plug hole. The fill plug is a magnetic plug. Inspect the fill plug weekly for metal particles. If any metal particles are found, remove the wheel cover and inspect the bearings for wear. When draining the oil, rotate the wheel so the drain plug (2) is at its lowest position. The service interval for changing the front wheel bearing oil is 500 hours. Use Final Drive and Axle Oil (FDAO) or commercial FD-1. As a substitute, Transmission Drive Train Oil (TDTO) with a commercial TO-4 may be used. Check the tire inflation pressure. Operating the truck with the wrong tire inflation pressure can cause heat build-up in the tire and accelerate tire wear. Caterpillar recommends inflating tires with dry nitrogen instead of air to reduce heat build-up and potential combustion. Nitrogen also slows rubber deterioration and rim corrosion. NOTE: Care must be taken to ensure that fluids are contained while performing any inspection, maintenance, testing, adjusting, and repair of the machine. Be prepared to collect the fluid in suitable containers before opening any compartment or disassembling any component containing fluids. Refer to the "Tools and Shop Products Guide" (Form NENG2500) for tools and supplies suitable to collect and contain fluids in Caterpillar machines. Dispose of fluids according to local regulations and mandates.

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Check the front suspension cylinders for leaks or structural damage. Check the charge condition of the front suspension cylinders when the truck is empty and on level ground. Measure the charge height of the suspension cylinders and compare the dimension with the dimension that was recorded the last time the cylinders were charged. Recharge the cylinders with oil and nitrogen if necessary. A grease outlet fitting (arrow) is located on one side of each front suspension cylinder. The grease supply fitting is located on the opposite side of the suspension cylinder. No grease outlet fittings should be located on the same side of the suspension cylinder as the grease fill location. Having an outlet fitting on the same side of the suspension cylinder as the grease fill location will prevent proper lubrication of the cylinder. Make sure that grease is flowing from the outlet fittings to verify that the suspension cylinders are being lubricated and that the pressure in the cylinders is not excessive. NOTE: For more detailed information on servicing the suspension system, refer to the Special Instruction "Suspension Cylinder Servicing" (Form SEHS9411).

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If the machine is equipped with the optional caliper type front brakes, inspect the brake linings (1) for wear. The thickness of the brake linings (not including carrier) must not be less than 3.15 mm (.125 in). Measure the lining at both ends because one end can wear more than the other. The clearance between the brake carrier guide pins (2) and the brake disc (3) must not be less than 1.5 0.5 mm (.06 .02 in.).

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The primary fuel filter (1) is mounted between the right front wheel and the engine cooling fan. A reusable fuel/water separator mounts directly to the filter element. Periodically open the valve (2) under the separator bowl and drain any water into an approved container. After changing fuel filters, hold the switch (3) upward to activate the electric fuel priming pump to refill the fuel lines and filters with fuel.

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The dual engine oil filters (1) are located on the right front of the engine. Engine oil samples can be taken at the SOS tap (2) located on the front of the oil filter base. The secondary fuel filter (3) is located at the right front of the engine, in front of the engine oil filters. A fuel filter bypass switch (4) is located on the filter base. The bypass switch provides an input signal to the Engine ECM indicating if the filters are restricted. Jacket water coolant samples can be taken at the Scheduled Oil Sampling (SOS) coolant analysis tap (5). The coolant tap is located behind the engine oil filters. The bottom illustration shows the coolant tap with the filter removed.

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The transmission filters (1) are located behind the fuel tank and under the center tube. Transmission oil samples can be taken at the SOS tap (2). The oil filter bypass switch (3) provides input signals to the Transmission/Chassis ECM. The ECM sends a signal to the monitoring system in the cab to warn the operator when the filter is restricted. A pressure test port (4) is available for monitoring charge pressure for the transmission control valves.

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Located in front of the fuel tank on the right side of the truck is the torque converter charging filter (1). Hoist, converter, and brake oil samples can be taken at the SOS tap (2) at the base of the filter.

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The fuel tank is located on the right side of the truck. The fuel level sight gauge (1) is used to check the fuel level during the walk around inspection. A fuel level sender is located on the fuel level sight gauge. The fuel level sender provides input signals to the monitoring system, which informs the operator of the fuel level. Open the drain valve below the tank to remove condensation and sediment from the fuel tank. Inspect the condition of the fuel tank breather (above tank) and the fuel fill cap (2) at regular intervals. Fuel can be added at the attachment quick service fuel fill connector (3).

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The rear axles are equipped with planetary-type final drives. Rotate the final drive until the drain plug (1) is at the lowest position, as shown. The final drive oil level is checked and filled by removing the magnetic plug (2). The oil should be level with the bottom of the plug hole. Fill the rear axle housing with oil before filling the final drives with oil. Allow enough time for the oil to settle in all of the compartments. This time allowance can be as much as 20 minutes during cold temperatures. The oil is drained by removing the drain plug. The magnetic inspection plugs should be removed weekly from the final drives and checked for metal particles. For some conditions, checking the magnetic plugs is the only way to identify a problem which may exist. Use FDAO (Final Drive and Axle Oil) or Transmission Drive Train Oil (TDTO) with a specification of TO-4 or newer. These oils provide: - Maximum frictional capability required for gears - Increased lubrication capability for bearings NOTE: The rear axle is a common sump for the differential and both final drives. If a final drive or the differential fails, the other final drive components must also be checked for contamination and then flushed. Failure to completely flush the rear axle after a failure can cause a repeat failure within a short time.

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Check the differential oil level by removing the magnetic inspection plug (1). The oil should be level with the bottom of the fill plug opening. Inspect the rear suspension cylinders for leaks or structural damage. Check the charge condition of the rear suspension cylinders when the truck is empty and on level ground. Measure the charge height of the suspension cylinders, and compare the dimension with the dimension that was recorded the last time the cylinders were charged. Recharge the cylinders if necessary. Inspect the condition of the rear axle breather (2) at regular intervals. The breather prevents pressure from building up in the axle housing. Excessive pressure in the axle housing can cause brake cooling oil to leak through the Duo-Cone seals in the wheel brake assemblies. NOTE: For more detailed information on servicing the suspension system, refer to the Special Instruction "Suspension Cylinder Servicing" (Form SEHS9411).

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The body up retaining pins are stored inside a cross-tube (1) in a body support beam directly above the retaining bracket (2). When work is to be performed while the body is raised, the body up retaining pins must be installed through the holes in the body retaining bracket and the rear frame support (3) to hold the body in the raised position. The body is shown in the lowered position.

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Shown are the transmission hydraulic tank (1) and the hoist, converter, and brake hydraulic tank (2). Both tanks are equipped with oil level sight gauges. The oil level of both hydraulic tanks should first be checked with cold oil and the engine stopped. The level should again be checked with warm oil and the engine running. The lower sight gauge (3) on the hoist, converter, and brake hydraulic tank can be used to check the tank level when the hoist cylinders are in the RAISED position. When the hoist cylinders are lowered, the hydraulic oil level will increase. After the hoist cylinders are lowered, check the hydraulic tank oil level with the upper sight gauge (4). Check lower transmission oil sight gauge (5) with the engine off and oil cold. Use the upper gauge (6) with engine at idle and oil warm. Inspect the hoist, converter, and brake hydraulic tank breather for plugging. The breather is located on the frame rail above the hydraulic tank. Inspect the condition of both hydraulic tank fill cap vents (located on top of the tank) at regular intervals. When filling the hydraulic tanks after an oil change, fill the tanks with oil to the FULL COLD mark on the sight gauge. Turn on the engine manual shutdown switch so the engine will not start. Crank the engine for approximately 15 seconds. The oil level will decrease as oil fills the hydraulic systems. Add more oil to the tanks to raise the oil level to the FULL COLD mark. Crank the engine for an additional 15 seconds. Repeat this step as required until the oil level stabilizes at the FULL COLD mark.

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Turn off the engine manual shutdown switch and start the engine. Warm the hydraulic oil. Add more oil to the tank as required to raise the oil level to the FULL WARM mark. In both tanks, use only Transmission Drive Train Oil (TDTO) with a specification of TO-4 or newer. TDTO TO-4 oil has the following features: - Provides maximum frictional capability required for clutch discs used in the transmission, torque converter and brakes. - Increases rimpull because of reduced slippage. - Increases brake holding capability by reducing brake slippage. - Controls brake chatter. - Provides maximum frictional capability required for gears.

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Before climbing the truck ladder, make sure that the manual engine shutdown switch (1) is OFF. The switch is located below the cab at the base of the left stairway. The engine will not start if the manual shutdown switch is ON. If necessary, the switch can be used to stop the engine from the ground level. The access light switch (2) is used to turn on or turn off the lighting in the area around the stairs. There is a second access light switch on the left side of the dash in the cab.

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While climbing the ladder, make a thorough inspection of the radiator. Be sure that no debris or dirt is trapped in the radiator cores. The battery disconnect switch is located under a cover (1) on the front bumper near the right access ladder. If the machine is being parked for an extended period (overnight, etc.) turn off the disconnect switch and remove the key. The machine lockout and engine lockout switches are located behind an access cover (2) between the radiator cowling and the right stairway.

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This illustration shows the engine disconnect switch (1) and the auxiliary start receptacle (2).

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The engine lockout control switch (1) allows the engine to be safely locked out while service is performed. The engine must be stopped to activate the engine lockout mode. When the engine lockout mode is activated, the following conditions exist: - The engine starter is disabled. - The secondary steering is disabled. - The prelube function is disabled. The following conditions must be met before the engine lockout mode will activate: - The transmission control must be in the PARK position. - The engine must be OFF. When the switch is activated, one of the following results will occur: - The indicator lamp (2) will illuminate continuously to indicate that the machine is in the engine lockout mode. - The indicator lamp will flash to indicate that the engine lockout mode will not activate until the transmission control is in the PARK position and the engine is OFF.

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The machine lockout control switch (3) allows the machine to be safely locked out while service is performed. When the machine lockout mode is activated, the following conditions exist: - The engine will start. - The transmission is disabled. - The hoist is disabled. - The steering is disabled. - The machine lockout mode indicator (4) will illuminate after the key start switch is turned on. NOTE: The lockout mode indicator on the dash panel will illuminate when the engine lockout control or the machine lockout control is activated. Also located near the lockout switches are the following circuit breakers: - 90 Amp Alternator (5) - 15 Amp Engine (6) - 80 Amp Starter Solenoid (7)

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24 The batteries are located inside the front bumper, at the base of the radiator cowling (1). Inspect the battery connections for corrosion or damage. Keep the battery terminals clean and coated with petroleum jelly. Inspect the electrolyte level in each battery cell, except maintenance free batteries. Maintain the level to the bottom of the fill openings with distilled water. The coolant level on the 777F is checked with the jacket water coolant sight gauge (2) located below the cab on the side of the front cowling. Coolant is added by removing the radiator cap (3) located inside an access door on the upper deck. The water used in the cooling system is critical for good cooling system performance. Use distilled or deionized water whenever possible to prevent acids or scale deposits in the cooling system. Acids and scale deposits result from contaminants that are found in most common water sources. Never use water alone. All water is corrosive at engine operating temperatures without coolant additives. Also, water alone has none of the lubrication properties that are required for water pump seals. Cat trucks are filled at the factory with Extended Life Coolant (ELC). If ELC is maintained in the radiator, it is not necessary to use a supplemental coolant additive. Do not use a conventional coolant to top-off a system filled with Cat ELC. An acceptable substitute for ELC is a Cat DEAC (Diesel Engine AntiFreeze/Coolant) or a commercial heavy-duty coolant/antifreeze that meets ASTM D4985 or ASTM D6210 specifications.

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The steering system hydraulic tank is located on the right platform. Check the steering system oil level at the sight gauge (1), on the side of the tank. The steering system oil filter (2) cleans the oil before it enters the hydraulic tank. The steering system uses a pressure compensated piston-type pump mounted to the rear of the engine. Case drain oil from the steering pump returns to the steering tank through a case drain filter (3). Before removing the fill cap (4) to add oil to the steering system, depress the pressure release button (5) on top of the breather to release any pressure from the tank. The steering system filter base and the case drain filter base have bypass valves that allow the steering oil to bypass the filters if they are plugged.

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Shown are the air intake system components. Check the air filter restriction indicator (1). If the yellow piston is in the red zone, the air filters are restricted and must be serviced. The air filter housing covers serve as the precleaner assemblies. When servicing the filter elements, clean the precleaners (2) and dust valves (3) using air or water pressure, or detergent wash. The dust valve is OPEN when the engine is OFF and closes when the engine is running. The dust valve must be flexible and closed when the engine is running or the precleaner will not function properly and the air filters will have a shortened life. Two filter elements are installed in the filter housings. The large element is the primary element and the small element is the secondary element. Air intake system tips: - The primary element can be cleaned a maximum of six times. - Never clean the secondary element for reuse. Always replace the secondary element. - Air filter restriction causes black exhaust smoke and low power.

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The engine oil level dipstick (1) and the engine oil fill tube (2) are located inside the access cover for the air filters. Check the engine oil level with the dipstick and add engine oil at the fill tube. Caterpillar recommends multigrade Diesel Engine Oil (DEO) with a specification of ECF-1. API CH-4, CI-4, and CI-4 Plus oils are only acceptable if they meet ECF-1 specifications. DEO oils with a CG-4 specification are acceptable, but should be limited to 250-hour oil change intervals. CF and older oils should not be used in Caterpillar diesel engines. Cat ECF-1 Specification was established by Caterpillar in 2003 and requires excellent soot dispersion, wear control, and piston deposit control.

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To check the fluid level of the windshield washer reservoir, open the access door located at the left rear of the cab, behind the cab door. Open the filler cap (1) to check the fluid level and fill as necessary. To the left of the filler spout is the air conditioner filter (2). Clean or replace the filter element when a reduction of circulation in the cab is noticed.

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The remaining 10 Hours or Daily checks are performed in the operator's compartment: - Brakes: Check operation - Indicators and gauges: Test operation - Seat belt: Inspect - Back-up alarm: Test operation - Secondary steering: Test operation The service brakes are checked by depressing the pedal (1) and placing the shift lever in FIRST FORWARD. Accelerate the engine until the truck moves. The truck must not move below 1200 rpm. This procedure should be repeated to test the secondary brakes by depressing the secondary brake pedal (2). The cab air filter (3) is located inside the cab door, in the left-rear corner behind the trainer seat. Clean or replace the cab fresh air filter when necessary. NOTE: Refer to the Operation and Maintenance Manual for information on the remaining tests performed in the cab.

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This illustration shows the cab air filter (1) located behind the trainer seat (2).

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OPERATOR'S STATION Shown is a view of the 777F operator compartment. The operator's station for the 777F has been changed to improve operator comfort and ergonomics. The operator seat (1) is centered in the cab with the trainer's seat (2) positioned to the left. The hoist control lever (3) is now on the right console next to the transmission control lever (4). The 777F is equipped with a standard Messenger Monitoring System or optional VIMS/Advisor Monitoring System (shown). The optional Caterpillar Work Area Vision System (WAVS) is a closed circuit video monitoring system. WAVS consists of a 178mm (7 inch) LCD color display (5) and may include one, two, or three cameras. The display is mounted in the machine cab. The cameras are mounted on the frame of the machine. The location of the camera(s) is dependent on the machine type.

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The Truck Production Management System (TPMS) on the 777F is controlled by a TPMS ECM if the machine is equipped with Messenger or a VIMS ECM if the machine is equipped with VIMS/Advisor. There are two sets of TPMS external loading lamps on the truck. One set of lamps is on the left side of the cab (arrow) and the other set is on the right platform. The lamps are green and red. The lamps inform the loader operator of the loading progress toward a target payload weight. The lamps are active only during the loading cycle and are off at all other times. During loading, the green (continue loading) lamps will be ON until the payload is 95% of the target weight setting. Then, the red (stop loading) lamp will light. A "last pass" indication can be programmed into the system. With last pass indication, the TPMS calculates an average loader pass size and predicts payload weight. If the predicted weight after the NEXT loader pass will be above 95% of the target weight setting, the red lamps FLASH. The red lamps will be ON continuously after the last pass (when fully loaded). A minimum of three loader passes are required for the "last pass" indication option to function correctly. The actual measured weight of the material in the truck body is displayed on the Messenger display or the VIMS/Advisor display.

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Located on the left side of the front panel are: - Telescopic/tilt steering column adjustment lever (1): Push for telescoping and pull for tilt. - Intermittent wiper/washer, turn signal control, and dimmer switch (2). - Steering wheel mounted electric horn control (3). - Light switches and hazard warning switch (4). The instrument panel (5) includes a tachometer, four gauges, and several indicators that display the machine systems status. An LCD screen displays the service hour meter, machine ground speed, actual gear, and direction.

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8 9 10

7

1 2 3

4

5

6

34

Located on the right side of the steering column is the retarder lever (1). The retarder lever is used to modulate engagement of the service brakes. The retarder lever engages the front and rear brakes on trucks with the standard oil-cooled front brakes but engages but only the rear brakes on trucks with the optional caliper disc front brakes. The retarder lever can control the modulation of the service brakes more precisely than the service brake pedal located on the cab floor. Located on the dash to the right of the retarder lever are the key start switch (2), fan speed switch (3), temperature variable knob (4), air conditioner switch (5), and cigarette lighter (6). Above the HVAC controls is the optional VIMS/Advisor display (7). Switches to the left of the VIMS/Advisor display are the ARC ON/OFF switch (8), compression brake switch (9), and front brake switch (10) (if equipped).

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Text Reference

2 4

3 1 5

35

To the right of the operator's seat is the shift console which contains the transmission shift lever (1) and the hoist control lever (2). The 777F truck has SEVEN speeds FORWARD and ONE REVERSE. The top gear limit and body up gear limit are programmable through the Transmission/Chassis ECM. The top gear limit can be changed from THIRD to SEVENTH. The body up gear limit can be changed from FIRST to THIRD. The 777F truck hoist system is electronically controlled. The hoist control lever activates the four positions of the hoist control valve. The four positions are: RAISE, HOLD, FLOAT, and LOWER. A fifth position of the hoist valve is called the SNUB position. The operator does not have control over the SNUB position. The body up switch controls the SNUB position of the hoist valve. When the body is lowered, just before the body contacts the frame, the Transmission/Chassis ECM signals the hoist solenoids to move the hoist valve spool to the SNUB position. In the SNUB position, the body float speed is reduced to prevent hard contact of the body with the frame. The truck should normally be operated with the hoist lever in the FLOAT position. Traveling with the hoist in the FLOAT position will make sure the weight of the body is on the frame and body pads and not on the hoist cylinders. The hoist valve will actually be in the SNUB position.

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Text Reference

If the transmission is in REVERSE when the body is being raised, the hoist lever sensor is used to shift the transmission to NEUTRAL. The transmission will remain in NEUTRAL until: 1. the hoist lever is moved into the HOLD or FLOAT position; and 2. the shift lever has been cycled into and out of NEUTRAL. The hoist lever is also used to start a new TPMS cycle. NOTE: If the truck is started with the body raised and the hoist lever in FLOAT, the lever must be moved into HOLD and then FLOAT before the body will lower. The throttle backup and throttle lock switch (3), the WAVS alternate camera system switch (4) (if equipped), and a 12V power port (5) are also located on the shift console.

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Text Reference

1

2

3

36

The overhead console can be equipped with four switches. The optional heated mirrors switch (1) controls the heated mirrors. The TCS test switch (2) is used to perform the TCS test when the switch is held. The brake release/secondary steering switch (3) manually activates the brake release and secondary steering pump when the switch is held.

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Text Reference

3 1 2

37

Located on the floor of the cab are: - Secondary brake pedal (1): Used to modulate application of the parking brakes on the rear wheels. A position sensor is attached to the secondary brake pedal that provides input signals to the Brake ECM. - Service brake pedal (2): The service brake pedal is used to modulate engagement of the service brakes on all four wheels if the front brake ON/OFF switch is in the ON position. A position sensor is attached to the service brake pedal that provides input signals to the Brake ECM. - Throttle pedal (3): A throttle position sensor is attached to the throttle pedal. The throttle position sensor provides the throttle position input signals to the Engine ECM.

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Text Reference

1

2 3

6

5

4

38

Located behind the trainer's seat are the fuse panels (1), the Cat ET service port (2), the TPMS or VIMS service port (3), the Product Link service port (4), a 12V power receptacle (5), and the 20 amp heater/air conditioner fan circuit breaker (6).

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Text Reference

777F ELECTRONIC SYSTEM BLOCK DIAGRAMVIMS-PC

Telemetry Antenna (Attachment)

GPS Antenna (Attachment)

Inclinometer (Attachment)

Instrument Cluster

10 5 0

15

20

25 30 35X100

OK

TCS

Messenger Module ( St andard)

VIMS ECM (Advisor) (ABL2M) (Attachment) Road Analysis ECM (RAC) (ABL2M) (Attachment) Brake ECM (TCS) (A4:M1) (Standard) Trans / Chassis ECM (A4:M1) (Standard) TPMS ECM ( ABL2 M) ( At t achment )

Engine ECM (A4:E4)

VIMS / Advisor ( Opt ional)

Minestar Display

Minestar Control (Attachment)

CAT Datalink CAN SAE J1939 Datalink RS232 19200 Baud Serial Link

Product Link ECM (Attachment) ET Service Tool

39

MONITORING SYSTEM The monitoring system on the 777F Off-highway Trucks monitors various machine systems and then conveys the machine status to the operator. The 777F can be equipped with the standard monitoring system which includes a Messenger display module, or the optional monitoring system which includes a VIMS/Advisor display module. Both monitoring systems include an instrument cluster. The instrument cluster is a cab display that shows the operator the status of various machine parameters and alerts the operator of specific machine conditions. The ECMs and monitor display modules communicate over the Cat Data Link. The display modules communicate with the instrument cluster over the Can Data Link. The monitoring system receives information from machine switches and sensors via the ECMs shown in this illustration of the Machine Electronic Control System. The 777F can also have the following attachments: Minestar, RAC, Product Link, Inclinometer, Telemetry antenna, and GPS antenna.

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Text Reference

1

2

40

The instrument cluster (1) and optional VIMS/Advisor display panel (2) are shown is this illustration. The standard Messenger module (not shown) is installed in the same location as the VIMS/Advisor display panel. Problems from the machine systems are classified into four warning categories (1, 2, 2S, and 3) similar to other Caterpillar monitoring systems. During the normal operation mode and the menu mode, the Messenger or VIMS/Advisor display may be interrupted by a warning message. Warning messages are displayed when important instructions or information need to be displayed. The Messenger or VIMS/Advisor provides three Warning Categories. The first category requires only operator awareness. The second category states that the operation of the machine and the maintenance procedure of the machine must be changed. The third Warning Category states that the machine must be safely shut down immediately. Warning Category 1 For a Category 1 Warning, an indicator light will illuminate or a gauge will be in the red zone. The indicator that illuminates or the gauge that is in the red zone identifies the machine system that needs attention. The "OK" key on the Messenger or VIMS/Advisor panel can be used to acknowledge the warning. Some warnings will be silenced for a predetermined period. After this time period, if the abnormal condition is still present, the warning will reappear.

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Warning Category 2 For a Category 2 Warning, an indicator will illuminate or a gauge will indicate in the red zone, the action light will flash, and a popup screen appears on the Messenger or VIMS/Advisor display screen. A Category 2 warning alerts the operator that a change in machine operation is required to avoid possible damage to the indicated system. The "OK" key on the Messenger or VIMS/Advisor panel can be used to acknowledge the warning. Some warnings will be silenced for a predetermined period. After this time period, if the abnormal condition is still present, the warning will reappear. Warning Category 2-S For a Category 2-S Warning, an indicator will illuminate or a gauge will indicate in the red zone, the action light will flash, a popup screen appears on the Messenger or VIMS/Advisor display screen, and an action alarm will sound continuously. The 2-S Warning indicates a SEVERE Category 2 Warning. A Category 2-S Warning alerts the operator to immediately change the operation of the machine to avoid possible damage to the indicated system. When the change in operation is made to an acceptable condition, the action alarm will turn off. Warning Category 3 For a Category 3 Warning, an indicator will illuminate or a gauge will indicate in the red zone, the action light will flash, a popup screen appears on the Messenger or VIMS/Advisor display screen, and an action alarm will sound intermittently. A Category 3 Warning alerts the operator that the machine must be safely shut down immediately to avoid damage to the machine or prevent personal injury. Some Category 3 Warnings cannot be stopped by pressing the "OK" key.

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Text Reference

4 3

1 5 6

2

41

Shown is the Instrument Cluster located in the center of the front dash panel. The Instrument Cluster includes 18 dash indicators, five analog gauges, and an LCD digital display (1). The LCD display window in the lower center of the dash includes the truck speed, gear, and direction on the top of the display and the service hour meter on the bottom of the display. The five parameters monitored by the analog gauges are: - Brake oil temperature (2) - Engine coolant temperature (3) - Engine speed (4) - Torque Converter oil temperature (5) - Fuel Level (6)

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Text Reference

INSTRUMENT CLUSTERPark Brake Engaged Brake System Check Check Engine Secondary Steering Engaged Primary Steering Loss Engine Coolant Temperature Gauge Throttle Lock Power Train System Check Action Lamp Engine RPM Electrical System Body Up Transmission in Reverse Machine Lockout Active High Beam Retarder Engaged

15 10 5X100 n/min

20 25 R

Traction Control System Engaged Transmission Oil Temperature Gauge Machine Immobilizer Right Turn Signal Active Gear and Direction kPa psi Fuel Level Gauge

Left Turn Signal Truck Speed Brake Oil Temperature Gauge

0mph km/h

30

n/min

LCD Display Window

Service Hour Meter

42 The indicator lamps and gauges are shown in this illustration.

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Text Reference

MESSENGER DISPLAY MODULEDEFAULT SCREEN

Message Bar P R N 1 2 3 4 5 6 7OK

43

Messenger Display Module Shown is the standard Messenger display module, which is located in the right side of the front dash. The purpose of the Messenger is to display relevant machine information to the operator or service personnel. The Messenger display is used in conjunction with the instrument cluster to act as the monitoring system for the machine. The Messenger has a menu structure that allows the user to access the desired machine information. The default screen will display under normal machine operating conditions without any intervention from the operator or service personnel. This illustration shows the default screen of the Messenger module that shows the shift lever and the gear position. The default screen is displayed at machine start up and until the operator or the technician navigates to another screen. The Messenger consists of the display and four navigation buttons that are used to navigate through the menu structure. The button functions from left to right are as follows: Back: Used to navigate to the previous screen that was accessed in the Messenger. Left/Up: Allows the user to scroll left or up. Scroll direction is dependent on the specific data that is being displayed on the screen. Right/Down: Allows the user to scroll right or down. Scroll direction is dependent on the specific data that is being displayed on the screen. OK: Acts as a confirmation function for the Messenger.

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Text Reference

MAIN MENU SELECTION

Performance

Main Menu PerformanceDefault

Totals

Settings

OKService

Service Mode

44

The Messenger Menu Screen is divided into three sections. The top section identifies the name of the current menu. If the current name is split by a colon ":" then this indicates that the name after the colon ":" is the current menu and the name before the colon ":" is the parent menu of the current menu. The center section displays the current menu option that can be selected by pressing the OK button. The arrows at the left of the screen indicate whether you can scroll to the next screen to see further menu options. There are a total of five main menus that are available for navigation. Only one menu can be displayed at a time. The menus are accessed from the default menu by pressing the back arrow button. The five menus are: - Performance - Totals - Settings - Service - Service mode

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Text Reference

PERFORMANCE SCREEN SUBMENU

Eng Coolant Temp

Shift Lever

85 C

N

OK

45

This illustration of a performance screen submenu shows the engine coolant temperature and shift lever position. A typical Messenger information screen normally displays the information in pairs. The headers at the top of the screen identify the information. The current values are displayed below the headers. The arrows at the left of the screen indicate whether you can scroll to the next screen to see additional information.

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Text Reference

PERFORMANCE MENU SELECTION

Engine Coolant Temperature

Engine Oil Pressure

Main Menu PerformancePerformance Engine Speed Inlet Air Temperature

OK

Hydraulic Oil Temperature

Fuel Level

Torque Converter Temperature

Battery Voltage

46

The Performance menu allows the operator or technician to view two pages of information. These pages of information monitor vital machine system data during machine operation. This information can only be viewed. The Performance menu uses two screens to show the real time status of the information listed above on the right side of the illustration.

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Text Reference

TOTALS MENU SELECTIONS

Total Load Count

Load Count

Reset Load Count Yes

Main Menu TotalsOK

Payload

Accum Wt

Loaded Time

Loaded Dist

Totals

Reset Load Count No

Distance Traveled

Machine Hrs Machine Total Fuel

Blank

47

The Totals main menu allows the operator or the technician to access information about the machine systems. The totals data can be used to determine when scheduled maintenance is required. The Totals menu shows accumulated values and includes two submenus. The two submenus are Payload and Machine. The Payload and Machine submenus display the information listed on the right side of the above illustration.

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Text Reference

SETTINGS MENU SELECTIONMain Menu SettingsOK

48

Parameters are normally adjusted for specific operating conditions, operator preferences, and machine operating efficiency. The machine setup affects the parameters that are displayed. The attachments that are on the machine determine the software that is contained in the ECMs. Messenger looks at the software versions to determine the parameters that will be displayed and the parameters that will be variable. NOTE: Cat ET can also be used to access the parameters. The Settings menu allows the user to adjust the parameters for the following: - Messenger Display - Machine Identification - Transmission Operation - Brake Operation - Payload Operation - Engine Operation

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Text Reference

The Messenger Display parameters relate to the operators preferences for the Messenger display. The following parameters may be adjusted: - Language: Six standard languages (other languages available). - Units: Metric or English. - Contrast: Screen contrast. - Headlights On: Screen brightness with headlights ON. - Headlights Off: Screen brightness with headlights OFF. The Machine settings allow the user to set the machine serial number. The following parameters may be adjusted: - Product ID: Allows the user to set the machine serial number (password protected). - Equipment ID: Allows the name of the truck to be changed (password protected). The Transmission setting allows the following parameters to be adjusted: - Top Gear Limit: Allows the user to set the highest gear performance level. - Body Up Gear Limit: Adjusts the gear limit during truck operation when the body is raised. - Machine Speed Limit: Sets the highest truck speed. - Fuel Economy Mode: Allows the fuel usage to be changed. - Machine Overload Speed Limit: Limits transmission gear and engine speed when excessive payloads are detected (if machine is equipped with TPMS). The Brake setting allows the user to set the desired ARC speed and is password protected. The Payload menu allows the configuration of the Payload settings and is password protected. The Payload settings include the following: - Target Payload: Read and program the truck target payload. - Overload Limit: Read and program the percent overload. - Green TPMS Lamp: Read and program the installation of the green TPMS lamp. - Red TPMS Lamp: Read and program the installation of the red TPMS lamp. - Last Pass Enabled: Read and program the installation of the Last Pass indicator. The Last Pass indicator informs the shovel operator of the last load before the payload is over the rated load. The Engine setting allows the user to change the ether solenoid configuration to "No Ether Solenoid Installed" or "Continuous Flow" and is password protected.

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Text Reference

SERVICE MENU SELECTIONService Diagnostic EventsOK

49

The Service menu allows the technician to access the machine parameters. The technician may also make selections for viewing or clearing logged events or codes. The Service menu will allow the technician to view data for the following systems: the brake, the steering, the implement, and the power train. The status of electronic components in the machines major systems can also be viewed. The Service menu option is displayed by selecting Service from the Main Menu. Press the Left/Up arrow button or the Right/Down arrow button until Service is displayed. Then press the OK button. The Service menu contains the following six submenus: - Diagnostic Events: Displays a complete list of all active and inactive event codes and diagnostic codes. - System Parameters: Allows the technician to view the status of system components. - Calibrations: Allows the technician to perform a payload calibration. The payload system must be calibrated if new TPMS software is installed or the suspension is charged. - System Tests: Allows the user to perform a transmission stall test or a system self test on the machine. - Systems Information: Allows the user to display information on all of the ECMs installed on the machine, such as ECM Part Number, etc. - Tattletale: The Messenger display module records the extreme value for each condition of the machine that is monitored.

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Text Reference

Service

SERVICE MENUDIAGNOSTIC EVENTS

Diagnostic EventsOK

SRC 36 36 36

CODE 91-8 168-0 168-1

OCC ACT 10 5 5OK

Engine ECM

91-8

Throttle Pos SnsrAbnormal ClrOK

OK

50 These illustrations show the information available within the Diagnostic Events menu. From the Service menu, use the appropriate arrow button to highlight the Diagnostic Events option and press the OK button to access the Diagnostic Events. Select the View Diagnostics display by pressing the OK button. The View Diagnostics option will display a complete list of codes (bottom left illustration). Each line on the list will show the following information: - SRC (Source ID) - CODE - OCC (Number of occurrences of the event or code) - ACT (if the code is active or inactive). Use the appropriate arrow button to highlight a diagnostic code or an event code on the list. Press the OK button to display the codes Detailed View (bottom right illustration). The Detailed View will display a text message that shows the following information: reporting ECM, failed component code, and explanation of the event.

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Text Reference

The technician can clear logged codes one at a time. Active codes are indicated with a mark under the "ACT" column. Active codes cannot be cleared until the faults have been corrected. To clear a code, access the Detailed View of the code, press the OK button and follow the prompts and directions. NOTE: Only Level I and Level II codes may be cleared with Messenger. When a code is cleared from Messenger, the memory from the reporting ECM is cleared. The code is not cleared from the Messenger ECM. Once the code has been cleared from the reporting ECM, Messenger will update the code list. Messenger is an interface between the technician and the machine ECMs.

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Text Reference

SERVICE MODEMain Menu Svc Mode PasswordOK

51

The Service Mode Password menu is used to enter the Service mode. The Service Mode Password protects certain features from access by the operator. Features that need to be protected from the operator can be enabled or disabled with a password. NOTE: For more information on the Messenger Monitoring System, refer to the 773F, 775F, 777F Off-highway Truck Monitoring Systems Operation, Troubleshooting, Testing, and Adjusting Service Manual module (RENR8344).

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Text Reference

1 2 3 4 5

52

Advisor/VIMS Display Shown above is the Advisor/VIMS graphical display module. It is located on the right side of the dash. It is the operator and technicians interface with the Advisor Monitoring System, including VIMS. Information is displayed on a backlit LCD display screen. The top portion of the screen is called the "Top Banner" and it displays vital machine information at all times. The Top Banner may display different information from machine to machine, depending on the model and the attachments that are installed. At the right of the display screen is a column of five user interface buttons. These buttons are used to navigate through the numerous Advisor screens, to make menu selections, or to enter data. The five buttons, from top to bottom, are: - LEFT/UP Arrow Button (1) - This button is used for screen navigation or data entry. It can be used: to scroll up a vertical list or scroll left across a horizontal list; to decrease a setting value, such as decreasing brightness/contrast. - DOWN/RIGHT Arrow Button (2) - This button is also used for screen navigation or data entry. It can be used: to scroll down a vertical list or scroll right across a horizontal list; to increase a setting value, such as increasing brightness/contrast.

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Text Reference

- BACK Button (3) - This button is used: to go up one level in a stair-step (hierarchical) menu structure, or to return to the previous screen; as a backspace, or cancel key when the operator or technician wishes to delete entered characters. - HOME Button (4) - This button is used to return to the home menu screen, regardless of what screen is currently displayed. - OK Button (5) - This button is used: to make selections from a screen; to confirm an entry, such as a password, or for saving an operator profile entry. Navigation through the menus and sub-menus is accomplished by using the ARROW Buttons to highlight the desired selection, then pressing the OK Button. The ARROW Buttons are also used to highlight a mode or to set a parameter. Pressing the OK Button selects that option. NOTE: The left buttons are used to display a screen without scrolling. If a screen is selected and one of the left buttons is pressed and held for at least three seconds, the screen is saved (programmed). Whenever the button is pressed again the "saved" screen will appear.

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Text Reference

2612809V13

53Copyright 2005 Caterpillar Inc. All Rights Reserved

OK

PNormal

P

R

N

3

2

1

03:55:46 07/7/2006 0%

Operator Service Settings PayloadOK

54

Upon machine start-up (key ON), an introduction screen appears as shown in the top illustration and Advisor performs a self-test routine. After a few seconds the main screen will appear as shown in the bottom illustration. NOTE: The time and date is set with VIMSpc software. Also displayed to the right of the time and date is the inclinometer value.

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Text Reference

55

The illustration above shows a "pop-up" warning screen generated by the Transmission/Chassis ECM and reported by Advisor. There may be more warning screens if there are any other active faults or events reported to Advisor by the Transmission/Chassis ECM, or any other ECM on the machine. Advisor will scroll through all of the warning screens generated by all of the active faults and events. Each of these warning screens must be individually acknowledged by pressing the "OK" button. Each of these warning screens contains the following information: - The reporting ECM (in text) - The reporting MID (module identifier, or ECM code) - The ID (Component ID and Failure Mode Identifier) - A text message stating the failed component - A text message stating the failure mode of the component - A prompt for the operator to acknowledge the warning Acknowledging these warnings does not clear them from the reporting ECM's memory, but only clears them from the screen, or "snoozes" them. The warnings remain an active event or fault until the problem is resolved. Advisor will display the message again after a pre-determined amount of time, depending on the severity of the event.

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Text Reference

ADVISOR HOME MENU SELECTIONS

Operator

Service

Settings

Home Menu Screen

Payload

Monitor

Grade

Service Mode

56

Advisors menu structure is arranged in a stair-step, or hierarchical list format. When the operator or technician selects an option from a menu or list, the resulting screen is one level down from that selection. More selections, or options, may be available from that screen as well. There may also be more than one page of information or options to be displayed from any level. This is indicated by the "More Options" icon, which may point left, right, up, or down, depending upon how the data or list is arranged. The illustration above shows the options that are available from Advisor's Home Menu screen. The Home Menu screen and its options will be displayed upon pressing the HOME button from any screen within Advisor.

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Text Reference

PNormal

P

R

N

3

2

1

03:55:46 07/7/2006 0%

Operator Service Settings PayloadOK

57

P

P

R

N

3

2

1

OperatorCurrent Profile = Select Profile View/Save Current Create Profile Delete Profile Glen Press profile.OK

to select a

58OK

The Operator menu allows the user to perform the following: - Select a profile - Create a profile - Delete a profile - View/save a current profile - Factory Set (recalls default settings) The profile of an operator is a saved set of preferences that is identified by a name. Once the profile is created, the operator may associate various display settings and settings for the power train to that profile. After all of the parameters have been adjusted to the operator's preference, the operator may then save the parameters for future use.

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Text Reference

OPERATOR MENU SELECTIONUnits

Select Profile

Profile Name Selection Screen (Up to 10 Names)

Language

View/Save Current Profile Name Creation Screen (Numbers/Letters) Profile Name Deletion Screen (Up to 10 Names) Selects the Factory Default Settings

Lights ON Dimming

Operator

Create Profile

Lights OFF Dimming

Delete Profile

Contrast

Factory Set

59

This illustration shows the options within the Operator Menu.

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Text Reference

PNormal

P

R

N

3

2

1

03:55:46 07/7/2006 0%

Operator Service Settings PayloadOK

60

P

P

R

N

3

2

1

ServiceCalibrations System Tests PressOK

System Information to enter the calibrations Service Parameters menu.

61

OK

The Service menu contains six submenus. The following is a list of the submenus: - Diagnostics - Calibrations - System Information - Tattletale - System Tests - Service Parameters

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Text Reference

DIAGNOSTICS SUBMENUActive Events Logged Events Trigger Snapshot Data Logger Start Data Logger Reset

SERVICE MENU

Diagnostics

62

This illustration shows the diagnostics submenu within the service menu. The Active Events menu option shows the ECM and the service hours for each event. The following is a list of information that is displayed for the active event: - Electronic Control Module - Event Code - Date of occurrence - Time of occurrence - Warning Level - Number of occurrences The Logged Events menu option shows the list of events and diagnostic codes that have been recorded. Logged events can only be cleared by downloading and resetting the VIMS ECM with VIMSpc. The Trigger Snapshot menu option allows the user to manually initiate a snapshot of the system in addition to the snapshots that are already programmed. The snapshot will remain active until the time has elapsed.

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Text Reference

The Data Logger Start menu option allows the user to initiate the data logger. If the information for the data logger is being downloaded from the machine, the data logger cannot be started. The operator can initiate and stop the data logger numerous times until the total time for logging the data is thirty minutes. The Data Logger Reset menu option allows the user to reset the data logger, which clears all of the logged information. Thirty minutes will be available after the data logger has been reset. NOTE: The Data Logger is the only onboard file that can be reset through the Advisor display. The Advisor must be either in the Service Mode or Cat ET must be connected to the data link to reset the data logger. The VIMSpc software is not needed to reset the data logger.

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Text Reference

CALIBRATIONS SUBMENUTruck Payload Calibrations Inclinometer

SERVICE MENU

SYSTEM INFORMATION SUBMENUAdvisor

SERVICE MENU

Engine

System Information

Chassis

Brake

VIMS

TATTLE TALE SUBMENUActive Brake Oil Temperature Engine Coolant Temp Engine Speed Torque Converter Temp Fuel Level

SERVICE MENU

SYSTEM TESTS SUBMENUStall Diagnostic Test System Tests Self Test

SERVICE MENU

Tattle Tale

63 These illustrations show four of the submenus within the service menu. The Calibrations option consists of the Truck Payload and Inclinometer calibrations. The System Information menu option allows the user to view the information for the following machine ECMs: - Advisor - Engine - Transmission/Chassis - Brake - VIMS The ECM information contains the following: - ECM serial number - Software part number - Software release date - Software description

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Text Reference

The following options are available under the tattletale menu: - Active - Brake Oil Temperature - Engine Coolant Temperature - Engine Speed - Torque Converter Temperature - Fuel Level The Active option will display the tattletale value for each gauge. The five specific options will display the tattletale value for the gauge that is specified. NOTE: The tattletale is password protected. The value for each gauge is protected from being cleared. The System Tests option will allow the technician to perform the Stall Diagnostic Test or the Self Test. The instrument cluster will initiate a self test when the key start switch is moved to the START position. The gauge needles will move to the maximum right position for 0.5 seconds and then return to the minimum left position. This action prevents the gauge needles from circling to the bottom side of the gauge if the display is inverted.

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Text Reference

SERVICE PARAMETERS SUBMENU

SERVICE MENU

Sort by ECM

Service Parameters

Sort by Type

All Parameters

64

This illustration shows the Service Parameters submenu within the service menu. The following Service Parameters options will be displayed: - Sort By ECM - Sort By Type - All parameters The Sort By ECM menu option allows the user to view the parameters that are associated with each ECM. All of the parameters for the specific ECM are listed. The following ECMs can be selected: - Advisor - Engine - Transmission/Chassis - Brake - VIMS

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Text Reference

The Sort By Type menu option allows the user to view the parameters that are associated with different components. The following types of parameters can be chosen: - Temperatures - Pressures - Speeds - Filter Switches - Operator Inputs - Sensor Duty Cycles - Totals The All Parameters menu option allows the user to view the entire list of parameters.

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Text Reference

PNormal

P

R

N

3

2

1

03:55:46 07/7/2006 0%

Operator Service Settings PayloadOK

65

P

P

R

N

3

2

1

SettingsDisplay Setup Machine Chassis PressOK

to enter the display setup menu.

66

OK

The Settings menu allows the user to view the parameters for the following the same as the Messenger Settings menu: - Display Setup - Machine - Transmission/Chassis - Brake - VIMS (same as Messenger Payload submenu) - Engine

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Text Reference

The Display Setup parameters relate to the operators preferences for the Advisor display. The following parameters may be adjusted: - Language (same as Messenger) - Units (same as Messenger) - Contrast (same as Messenger) - Headlights On (same as Messenger) - Headlights Off (same as Messenger) - Date format: (Advisor only) - Time format: (Advisor only) The Machine setting allows the user to set the machine serial number. The following parameters may be adjusted and are the same as the Messenger Display: - Product ID - Equipment ID The Transmission/Chassis setting allows the following parameters to be adjusted: - Top Gear Limit (same as Messenger) - Body Up Gear Limit (same as Messenger) - Machine Speed Limit (same as Messenger) - Fuel Economy Mode (same as Messenger) - Machine Overload Speed Limit (same as Messenger) - Load Count (Advisor only) The Brake setting is the same as the Messenger display. The VIMS/Payload menu allows the configuration of the Payload settings and is password protected. The following payload settings are the same as the Messenger Display: - Target Payload - Overload Limit - Green TPMS Lamp - Red TPMS Lamp - Last Pass Enabled The Engine setting allows the user to change the ether solenoid configuration to "No Ether Solenoid Installed" or "Continuous Flow" and is the same as the Messenger Display.

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Text Reference

PNormal

P

R

N

3

2

1

03:55:46 07/7/2006 0%

Service Settings Payload MonitorOK

67

PPayload 90 T

P

R

N

3

2

1

Payload State: Loading Target 350 T

68

TON

OK

The Payload menu option is entered by selecting Payload from the Main menu. The Payload menu option allows the user to view the information for the payload. The user can view the following information: - Target for the payload - Calculated gauge for the payload

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Text Reference

PNormal

P

R

N

3

2

1

03:55:46 07/7/2006 0%

Service Settings Payload MonitorOK

69

Monitor: Parameter Screen 1Brake Oil Temperature 45 C Torque Converter Temperature 37 C

70Boost Pressure 20 kPa Atmospheric Pressure 23 kPa

OK

The Monitor menu option allows the user to view four parameters. The navigation button is used to select the parameter or view a different parameter. Press the OK button to obtain a list of available parameters.

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Text Reference

PNormal

P

R

N

3

2

1

03:55:46 07/7/2006 0%

Settings Payload Monitor GradeOK

71

P

P

R

N

3

230

120 10 0 -30 -20

% GRADE 00

72

-10

OK

The Grade menu option allows the user to view the grade of the hill. The user can view the following information: - Percentage of the grade value - Image of the truck that represents the grade

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Text Reference

PNormal

P

R

N

3

2

1

03:55:46 07/7/2006 0%

Payload Monitor Grade Service ModeOK

73

P

P

R

N

3

2

1

Service ModeService Mode: Disabled

74

Press OK to Enable

OK

The Service Mode menu option allows the user to enable and disable the service mode. The password entry screen will appear if the password has been entered in Cat ET. The Advisor will enter the service mode after the password has been entered correctly. NOTE: For more information on the Advisor/VIMS Monitoring System, refer to the 773F, 775F, 777F Off-highway Truck Vital Information Management System (VIMS) Systems Operation, Troubleshooting, Testing, and Adjusting Service Manual module (KENR5955).

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Text Reference

75

ENGINE Shown is the C32 engine with ACERT Technology used in the 777F Off-highway Truck. The engine performance specifications for the 777F Truck are: - Serial No. Prefix: LJW - Performance spec: 0K5981 - Gross power: 758 kW (1016 hp) - Full load rpm: 1750 - High idle rpm: 1938 10 - Low idle rpm: 650 - Overspeed rpm: 2800 This V-12 engine uses twin turbochargers, Air to Air AfterCooler (ATAAC) and Mechanical Electronic Unit Injection (MEUI) for power, reliability, and fuel economy. The C32 is compliant with U.S. EPA Tier 2 and European Union Stage II emissions regulations.

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Text Reference

ENGINE ECM SYSTEM DIAGRAM

CAT Data Link

MEUI Injectors (12) 7E6513 ORS Solenoid (attachment) Left Bank (Odd) Engine Retarder Solenoids 066-8391 (Connector PN) Right Bank (Even) Engine Retarder Solenoids 066-8391 (Connector PN) Outputs Inputs Speed Sensor No. 1 (Crank) Speed Sensor No. 2 (Cam) Timing Cal Probe Connector Right Intake Manifold Temperature Sensor Left Intake Manifold Temperature Sensor Coolant Temperature Sensor Right Turbo Outlet Pressure Sensor Left Turbo Outlet Pressure Sensor Engine Oil Pressure Atmospheric Pressure Exhaust Temperature Sensors (4) Oil Level Switch Fuel Temp Sensor Fuel Pressure Sensor Differential Fuel Pressure Switch J2 (ENGINE) CONNECTOR J1 (MACHINE) CONNECTOR Key Start Switch Throttle Pedal Position Sensor Back-up Throttle Switch ORS Level Relay ( at t achment ) Ground Level Shutdown Switch Rockford Fan Speed Sensor (Attachment) Left Air Filter Restriction (Turbo Inlet Left) Right Air Filter Restriction (Turbo Inlet Right) Air Conditioning Status Ether Start Relay Rockford Fan Solenoid ( At t achment )

Outputs Inputs

76

Engine Electronic Control System Shown is the electronic control system component diagram for the C32 engine used in the 777F Truck. Fuel injection is controlled by the Engine Electronic Control Module (ECM). Many electronic signals are sent to the Engine ECM by sensors, switches, and senders. The Engine ECM analyzes these signals and sends signals to various output components. Output components can be relays, lamps, other controls, or solenoids. For example, based on the various input signals, the Engine ECM determines when and for how long to energize the injector solenoids. When the injector solenoids are energized determines the timing of the engine. How long the solenoids are energized determines the engine speed.

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Text Reference

3

2

1

77

Fuel injection and some other systems are controlled by the Engine ECM (1) located at the front of the engine. Other systems controlled by the Engine ECM are: ether injection, engine start function, engine oil pre-lubrication, variable speed Rockford fan, engine retarding, and engine derate. The Engine ECM has two main connectors for diagnostics. The larger 120-pin connector (2) known as J2 connects to the engine harness. The smaller 70-pin connector (3) is identified on schematics as J1 and connects to the machine harness. A 2-pin timing calibration connector is located to the right of the ECM. If the engine requires timing calibration, a timing calibration sensor (magnetic pickup) is installed in the flywheel housing and connected to the timing calibration connector. Using the Caterpillar ET (Cat ET) service tool, timing calibration is performed automatically for the speed/timing sensors. This step is performed to avoid instability and ensures that no backlash is present in the timing gears during the calibration process. Timing calibration improves fuel injection accuracy by correcting for any slight tolerances between the crankshaft, timing gears, and timing wheel. Timing calibration is normally performed after ECM replacement, cam or crank sensor replacement, or timing wheel replacement. Occasionally, Caterpillar will make changes to the internal software that controls the performance of the engine. These changes can be performed by using the WinFlash program in Cat ET. Cat ET is used to diagnose and program the electronic controls used in Off-highway Trucks. If using the WinFlash program, a "flash" file must be obtained from Caterpillar and uploaded to the ECM.

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Text Reference

4 1

3

2

6 5

78

The left intake air temperature sensor (1) and right intake air temperature sensor (2) are located on top of the engine. The intake air temperature sensors produce an analog signal that is monitored by the Engine ECM. The ECM monitors intake air temperature for derating the engine at high temperatures, for engine shutdown at high temperatures, and for signaling the monitoring system in the event of a problem. NOTE: If a high temperature event is severe enough, the monitoring system will issue a Level 3 warning. The operator must park the machine as soon as possible. When the Engine ECM determines that the ground speed is zero and the transmission is in PARK, the engine will automatically shut down. The coolant temperature sensor (3) is located on top of the engine toward the front left side. The coolant temperature sensor is an analog sensor that is monitored by the Engine ECM. When the coolant temperature is too high, the Engine ECM will signal the monitoring system to display a warning. The Engine ECM also uses the coolant temperature sensor information for cold mode functions such as timing changes, elevated idle, cold cylinder cut-out, and ether injection. The left turbo outlet pressure sensor (4) and right turbo outlet pressure sensor (5) are used for calculating boost. The atmospheric pressure sensor (6) is located on top of the engine toward the front right side. The atmospheric pressure sensor is an analog sensor that is monitored by the Engine ECM. The ECM monitors atmospheric pressure for the following: altitude derate, air inlet restriction derate, and calibration reference for other sensors.

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Text Reference

2

1 3

79 The crankshaft speed/timing sensor (1) is located on the lower left of the engine toward the front side. The crank sensor measures engine speed and timing for control of the timing and delivery of fuel to each of the engine's cylinders. Sensing engine speed allows engine speed governing, fuel limiting, and fuel injection timing. If the crank speed/timing sensor fails, the cam speed/timing sensor allows for continuous operation. The oil pressure sensor (2) is located on the left side of the engine. The oil pressure sensor is an analog sensor that is monitored by the Engine ECM. When the oil pressure is too low, the Engine ECM will signal the monitoring system to display a warning. The ECM will also log an event that requires a factory password to clear. The oil level switch (3) monitors the oil level in the pan. The C32 engine in the 777F Truck can be equipped with an optional Oil Renewal System (ORS). The ORS increases the oil change interval and decreases the amount of used oil in need of disposal. The life of the engine is not shortened and the availability of the machine is increased. The ORS meters engine oil that has been filtered into the fuel supply. The metered oil is consumed in the engine during the normal combustion process. The Engine ECM controls the amount of oil that is metered based on the actual load factor or on the fuel that is consumed by the engine. Whenever the old oil from the oil pan is injected into the return fuel line, new oil from a makeup tank is added to the oil pan. Regular additions of new oil will allow the oil change level to be extended. Reviewing the reports of the SOS Oil Analysis will determine if a problem has occurred and if the oil needs to be changed.

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Text Reference

80

The cam speed/timing sensor (arrow) is located on the right side of the engine in the rear of the timing gear housing behind the primary fuel filter. The cam sensor is used as a back-up for the crank speed/timing sensor. If the crank speed/timing sensor fails, the cam speed/timing sensor allows for continuous operation.

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Text Reference

LOSS OF ENGINE SPEED/TIMING SIGNAL - Engine will start and run with one speed/timing sensor signal - Engine will NOT start or run without at least one speed/timing sensor signal - If crank sensor fails during engine operation: - Slight change in engine performance - If crank sensor signal is not present at engine start up: - Engine starts normally - If cam sensor fails during engine operation: - No noticeable change in engine performance - If cam sensor signal is not present at engine start up: - Engine will start with crank sensor signal, but may take longer to start and run rough for a few seconds

81

The engine will start and run when only one sensor signal is present from either the crank or cam sensor. During engine operation, if both speed/timing sensors fail, the Engine ECM will stop fuel injection and the engine will shut down. During start-up, the loss of both sensors will prevent the engine from starting. If the engine is running and the signal from the crank speed/timing sensor is lost, a slight change in engine performance will be noticed when the Engine ECM performs the changeover to the cam speed/timing sensor. If the signal from the crank speed/timing sensor is not present during start up, the engine will start normally. Loss of the cam speed/timing sensor during engine operation will not result in any noticeable change in engine performance. However, if the signal from the cam speed/timing sensor is not present during start up, the engine may require a slightly longer period of time to start and may run rough for a few seconds until the ECM determines the proper firing order by using only the crank engine speed/timing sensor.

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Text Reference

The teeth configuration in the crankshaft timing wheel are not the same as the camshaft timing wheel. The camshaft timing wheel includes 37 timing teeth with 36 of the teeth spaced equally at 10 apart. One tooth is spaced 5 apart from the other teeth. There are only 35 teeth on the crankshaft gear spaced equally at 10 apart. Two of the teeth are spaced at 20 apart, which creates a "gap" in the gear teeth. When the Engine ECM uses the cam speed sensor to determine timing for engine starting, the ECM knows exactly what cylinder is at TDC. The following cylinders are at TDC at the same time (one cylinder bank only): - Cylinder No. 1 (compression stroke) and No. 6 (exhaust stroke) - Cylinder No. 2 (compression stroke) and No. 5 (exhaust stroke) - Cylinder No. 3 (compression stroke) and No. 4 (exhaust stroke) When the Engine ECM uses the crank speed sensor to determine timing for engine starting, the ECM does not know which of the two cylinders is at TDC. As an example, the Engine ECM will attempt to fire Cylinder No. 1 and check if there is any increase in the engine RPM. If there is no increase in rpm, the ECM determines that the TDC timing position at that firing moment is Cylinder No. 6. This action may result in a longer engine start time.

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Text Reference

82

Located behind the right pedal, the throttle position sensor (arrow) provides the desired throttle position to the Engine ECM. If the Engine ECM detects a fault in the throttle position sensor, the throttle back-up switch in the cab can be used to increase the engine speed to 1300 rpm. The throttle position sensor receives a regulated 8.0 0.5 Volts from the Engine ECM. The throttle position sensor output signal is a Pulse Width Modulated (PWM) signal that varies with throttle position and is expressed as a percentage between 0 and 100%. To check the output signal of the throttle position sensor, connect a multimeter between Pins B and C of the throttle position sensor connector. Set the meter to read "Duty Cycle." The duty cycle output of the throttle position sensor should be: - Low Idle: 16 6% - High Idle: 85 4%

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Text Reference

1

2

83

The pre-lubrication (QuickEvac) pump (1) is located on the end of the secondary steering/brake release pump and motor assembly (2). The pump and motor assembly is now located on the front of the front frame crossmember. The engine oil pre-lubrication QuickEvac pump is controlled by the Transmission/Chassis ECM. The Transmission/Chassis ECM energizes the pre-lubrication pump relay located behind the cab. The relay behind the cab then energizes the pre-lube relay on the left frame. The QuickEvac mode is used to allow the technician to quickly evacuate the oil for an oil change. The QuickEvac mode can only be performed when the engine lockout is activated. Engine starting and pre-lubrication functions are also inhibited when the engine lockout is activated.

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Text Reference

84

If the truck is equipped with an ether start system, the Engine ECM will automatically inject ether from the ether valve (arrow)