773F (EED)/775F (DLS)

OFF-HIGHWAY TRUCKS
INTRODUCTION

© 2007 Caterpillar Inc.

 773F/775F MAINTENANCE

Servic e
773F/775F
Procedure

WALK AROUND INSPECTION

 10 HOURS DAILY MAINTENANCE CHECKS
Air Filters and Transmission and Torque
Precleaners Converter Oil Level
Steering Oil Level Hoist And Brake Oil Level
Disconnect Switch
Engine Oil Level
Suspension Cylinder Height
Primary Fuel Filter/
Water Separator Rear Axle Breather
Batteries
Radiator Debris
And Coolant Level Inspect Frame
Belts and for Cracks and
Ether Cylinders Body Support Pads

Check For Leaks

and Trash Build-up

Wash Windows,
Cab Fresh Air Filters,
Seat Belt, Indicators,
Gauges and Brake Tests,
Secondary Steering and
Back-up Alarm

Windshield Washer Level

Suspension Cylinder Height

and Grease Breathers
Tire Inflation
Wheel Nuts Pressure
Fuel Level
and Drain Moisture
 773F/775F ELECTRONIC SYSTEM BLOCK DIAGRAM

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

Instrument
15 20
10 25
5 30

VIMS ECM (Advisor)

35 OK
0
X100

Inclinometer Cluster Messenger Module (ABL2M)

TCS

(Attachment) ( St andard) (Attachment)

Road Analysis ECM

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

Product Link ECM

CAT Datalink TPMS ECM
(Attachment)
CAN SAE J1939 Datalink ( ABL2 M)
( At t achment )
RS232 19200 Baud Serial Link ET Service Tool
 INSTRUMENT CLUSTER

Power Train Action Engine Electrical

Park Brake System Check Lamp RPM System
Engaged
Body Up
Brake System
Check Transmission in Reverse

Check Engine Machine Lockout Active

High Beam
Secondary Steering
Retarder Engaged
Engaged
15 Traction Control
Primary Steering System Engaged
Loss 10 20
Engine Coolant Transmission
Temperature Gauge R Oil Temperature
X100 Gauge
5 n/min 25
Machine
Throttle Lock Immobilizer

0 30
Right Turn Signal
Left Turn Signal

mph Active Gear

Truck Speed n/min km/h and Direction

Brake Oil kPa psi

Fuel Level Gauge
Temperature Gauge

LCD Display Service Hour

Window Meter
 MAIN MENU SELECTION

Performance

Main Menu Totals

Performance
Default Settings

OK

Service

Service Mode
PERFORMANCE SCREEN SUBMENU

Eng Coolant Temp Shift Lever

85° C N

OK
 PERFORMANCE MENU SELECTION

Engine Coolant Engine Oil

Temperature Pressure

Main Menu
Inlet Air
Engine Speed
Performance Temperature
Performance

Hydraulic Oil
OK Temperature
Fuel Level

Torque
Converter Battery Voltage
Temperature
 TOTALS MENU SELECTIONS Total
Load Count

Load Count

Reset Load
Count
Yes
Main Menu
Payload Accum Wt
Totals

Loaded Time
OK

Loaded Dist

Reset Load
Count
No
Totals

Distance
Traveled

Machine Hrs

Machine

Total Fuel

Blank
SETTINGS MENU SELECTION

Main Menu
Settings

OK
SERVICE MENU SELECTION

Service
Diagnostic Events

OK
 Service

SERVICE MENU Diagnostic Events

DIAGNOSTIC EVENTS OK

SRC CODE OCC ACT Engine ECM 91-8

36 91-8 10
36 168-0 5
Throttle Pos Snsr
36 168-1 5 Abnormal Clr OK

OK OK
 SERVICE MODE

Main Menu
Svc Mode Password

OK
 2612809V13

Copyright 2005 Caterpillar Inc.

All Rights Reserved
OK
 P P R N 3 2 1
Normal 03:55:46 07/7/2006 0%

Operator
Service
Settings

Payload OK
 Operator

ADVISOR HOME
MENU SELECTIONS Service

Settings
Home Menu
Screen
Payload

Monitor

Grade

Service Mode
 P P R N 3 2 1
Normal 03:55:46 07/7/2006 0%

Operator
Service
Settings

Payload OK
 P P R N 3 2 1
Operator
Current Profile =
Select Profile Glen
View/Save Current Press OK

Create Profile to select a

Delete Profile profile.
OK
 OPERATOR MENU SELECTION

Units

Profile Name
Select Profile Selection Screen Language
(Up to 10 Names)

View/Save Lights ON
Current Dimming

Profile Name Lights OFF

Operator Create Profile Creation Screen Dimming
(Numbers/Letters)

Profile Name
Delete Profile Deletion Screen Contrast
(Up to 10 Names)

Selects the Factory

Factory Set Default Settings
 P P R N 3 2 1
Normal 03:55:46 07/7/2006 0%

Operator
Service
Settings

Payload OK
 P P R N 3 2 1
Service

Calibrations Press OK

System Information to enter the

System Tests calibrations
Service Parameters menu.
OK
 SERVICE MENU
DIAGNOSTICS SUBMENU

Active
Events

Logged
Events

Trigger
Diagnostics
Snapshot

Data Logger
Start

Data Logger
Reset
 SERVICE MENU
SERVICE MENU SYSTEM INFORMATION SUBMENU

CALIBRATIONS SUBMENU Advisor

Engine
Truck
Payload
System
Chassis
Information

Calibrations
Brake

Inclinometer
VIMS

SERVICE MENU
TATTLE TALE SUBMENU
SERVICE MENU
Active
SYSTEM TESTS SUBMENU
Brake Oil
Temperature

Engine
Stall
Coolant Temp Diagnostic
Tattle Tale
Test
Engine
Speed System
Tests
Torque
Converter
Temp Self Test
Fuel
Level
 SERVICE MENU
SERVICE PARAMETERS SUBMENU

Sort by ECM

Service
Sort by Type
Parameters

All Parameters
 P P R N 3 2 1
Normal 03:55:46 07/7/2006 0%

Operator
Service
Settings

Payload OK
 P P R N 3 2 1
Settings

Press OK
Display Setup
to enter the
Machine
display setup
Chassis
menu.
OK
 P P R N 3 2 1
Normal 03:55:46 07/7/2006 0%

Service
Settings
Payload
Monitor OK
 P P R N 3 2 1
Payload State: Loading

Payload Target
90 T 350 T

TON OK
 P P R N 3 2 1
Normal 03:55:46 07/7/2006 0%

Service
Settings

Payload
Monitor OK
Monitor: Parameter Screen 1
Brake Oil Torque Converter
Temperature Temperature

45 C 37 C

Boost Atmospheric
Pressure Pressure

20 kPa 23 kPa
OK
 P P R N 3 2 1
Normal 03:55:46 07/7/2006 0%

Settings

Payload
Monitor
Grade OK
P P R N 3 2 1

30
20
% GRADE 10
00 0

-30
-20
-10
OK
 P P R N 3 2 1
Normal 03:55:46 07/7/2006 0%

Payload
Monitor
Grade
Service Mode OK
 P P R N 3 2 1
Service Mode
Service Mode: Disabled

Press OK to Enable
OK
 CAT Data Link
ENGINE ECM SYSTEM DIAGRAM

EUI Injectors (12)

7E6513

Left Bank (Odd) Engine Retarder Solenoids

066-8391 (Connector PN) Ether Start Relay

Right Bank (Even) Engine Retarder Solenoids Rockford Variable

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

Timing Cal Probe Connector Throttle Pedal Position Sensor

Intake Air Temperature
Back-up Throttle Switch (Throttle Lock)
Coolant Temperature

Intake Manifold Air Pressure

Engine Oil Pressure

Ground Level Shutdown Switch
Atmospheric Pressure
Rockford Fan Speed Sensor
Fuel Temp Sensor
Air Filter pressure sensor
Fuel Pressure Sensor
Diff. Fuel Pressure Switch

J2 (ENGINE) CONNECTOR J1 (MACHINE) CONNECTOR

 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
 HIGH COOLANT TEMPERATURE DERATE
120%

100%

80%
% Derate

60%

40%

20%

0%
C 110 111 111.5 112 112.5 113 113.5 114 114.5
F 230 232 233 234 235 235.5 236.5 237 238
Coolant Temperature
Level 1 Warning Level 2 Warning / Derates
 C11-C32 ENGINE INTAKE MANIFOLD TEMPERATURE DERATE
21%

18%

15%

12%
% Derate

9%

6%

3%

0%
C 82 86 87 88 89 90 91 92 93
F 180 187 189 190 192 194 196 198 199

Intake Manifold Temperature

Level 1 Warning Level 2 Warning / Derat es
 LOW OIL PRESSURE
psi kPa
26.0 180

23.0 160

20.0 140

17.0 120
Oil Pressure

15.0 100

12.0 80
35% Derate
9.0 60

6.0 40

3.0 20

0 0
0 500 1000 1500 2000 2340
Engine rpm
kPa Warning Level 1 kPa Shut down Level 3
 AIR INLET RESTRICTION DERATE
16%

14%

12%

10%
% Derate

8%

6%

4%

2%

0%
kPa 0 2 4 6 8 10 12 14 16
psi 0 0.3 0.6 0.9 1.2 1.5 1.7 2.0 2.3
Air Restriction Difference
Level 1 Warning Level 2 Warning / Derates
 FUEL TEMPERATURE DERATE
30%

25%

20%
% Derate

15%

10%

5%

0%
C 89.8 90.0 90.2 90.4 90.6 90.8 91.0 91.2 91.4 91.6 91.8 92.0 92.2
F 193.6 194.0 194.4 194.7 195.0 195.4 195.8 196.2 196.5 196.9 197.2 197.6 198.0

Fuel Temperature
Level 1 Warning Level 2 Warning / Derates
 FUEL FILTER RESTRICTION DERATE
FUEL TEMP ABOVE 30 C (86 F)
AND FUEL PRESSURE ABOVE 138 kPa (20 psi)
60%

50%

40%
% Derate

30%

20%

10%

0%
0 3 min 1 hr 2 hr 3 hr 4 hr 5 hr 6hr
Time
Level 1 Warning Level 2 Warning / Derates
 ENGINE COMPRESSION BRAKE HYDRAULIC CIRCUIT
COMPRESSION BRAKE OFF

Slave Piston
Check Valve

To Slave Piston and

Master Cylinder Master
Exhaust Valve Piston
Compression Rocker Arm
Brake
Solenoid
Valve Fuel Injector
Rocker Arm
Rocker Arm
Shaft Oil
Passage

Engine Oil
Pump Exhaust
Valve
 ENGINE COMPRESSION BRAKE SCHEMATIC

Left Bank Valve Cover Engine ECM

Entry Connector P2/J2
Compression Compression Compression 10 J700-BR 5 Compression Brake Med / Hi
Brake Brake Brake 11 J701-GN 3 Compression Brake Low / Hi
Solenoid Solenoid Solenoid 12 K739-BU 14 Compression Brake Return
1 and 3 9 and 11 5 and 7
Right Bank Valve Cover
Entry Connector
Compression Compression Compression 10 K737-BR 8 Compression Brake Med / Hi
Brake Brake Brake 11 K738-GN 1 Compression Brake Low / Hi
Solenoid Solenoid Solenoid 12 K739-BU
10 and 12 2 and 4 6 and 8
P1/J1
892-BR 9 Cat Data Link -
893-GN 8 Cat Data Link +

Brake ECM
P1/J1
Compression Brake 893-GN 10 Cat Data Link +
Enable Switch 892-BR 20 Cat Data Link -
772-BR 34 Compression Brake Enable
A235-BK 45 Sensor Return
 ARC POWER AND COMPRESSION BRAKING LEVELS VS TIME

Enough Instantaneous braking ARC power began ARC power Not

power available to Allow 1/3 to drop enough dropped enough enough
ARC ramps up current, Compression on. that we had to lose that we don't have power to
ARC braking power (ARC Power-offset) Leaves enough 1/3 compression compression keep
900000 brake power for 1/3 compression power. braking at all. comp
also increases.
Total braking power = braking. ARC brake power should enabled.
ARC brake power only drop by equivalent amount.
800000 Disable CB

Total brake power = ARC brake Total brake Total brake power Total brake Total brake
700000 power + 1/3 comp brake power power = ARC = ARC brake power power = ARC ARC
brake power + 1/3 compression brake power brake 0 ARC
Braking Power (Watts)

+ 2/3 comp shut Off

brake
600000

500000
2/3

400000
1/3 1/3
300000

200000

100000

0
0 5 10 15 20 25 30 35 40 45 50 55 60

Time (Seconds)
 COOLING SYSTEM FLOW
Thermostat Radiator
Housing

Engine Block

ATAAC
Engine Oil Cooler

Brake
Oil Cooler

Transmission and
Torque Converter
Oil Cooler Water Pump
 ENGINE OIL SYSTEM

Engine
Block

Engine Bypass
Oil Filters Valve
Engine
Oil Cooler

Engine
Oil Pump
 LOW PRESSURE FUEL SYSTEM
Fuel Cooler

Fuel
Priming
Pump
Fuel
Primary Pressure
Fuel Regulator
Filter Cylinder
Head
Fuel Tank Fuel
Transfer
Pump

Cylinder
Secondary Head
Fuel Filter
 From Air
Muffler
Filters

AIR INDUCTION
AND
EXHAUST SYSTEM ATAAC

From Air
Filters
 POWER TRAIN HYDRAULIC SYSTEM

Transmission and Torque

Converter Charge Filter

Lockup
Valve

Torque
Converter
Hydraulic
Controls

Transmission Oil
Level Switch Transmission

Torque Transmission and Torque

Converter Converter Oil Cooler
Outlet Relief
Valve To Transmission Lube
Lockup Piston Turbine Impeller
TORQUE CONVERTER
CONVERTER DRIVE
Stator Torque Converter
Inlet Oil

Freewheel Torque Converter

Assembly Lockup Oil Passage
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 Torque Converter and
Transmission Charge Pump
To Lockup Clutch
 LOCKUP CLUTCH MODULATING VALVE
DIRECT DRIVE

Lockup Clutch
Pressure Tap

T/C Lockup
Solenoid
From Torque Converter and
Transmission Charge Pump
To Lockup Clutch
 TRANSMISSION HYDRAULIC SYSTEM
NEUTRAL

Transmission 1
5
Oil Temperature
Sensor

Torque Converter
Bypass Lockup Clutch
Switch

Scavenge Charge 2
Pump Pump
6
Screen
Screen

Transmission Torque Converter

Sump Sump
Main
Relief
Valve
3

Transmission
Lube Relief
Valve 7

To Torque
Converter

4
 ENGAGEMENT OF TRANSMISSION CLUTCHES

Engaged Clutches in
Transmission Speed
the Transmission

NEUTRAL 4

REVERSE 1 and 7

FIRST speed 1 and 6

SECOND speed 3 and 6

THIRD speed 2 and 6
FOURTH speed 3 and 5
FIFTH speed 2 and 5

SIXTH speed 3 and 4

SEVENTH speed 2 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

To Transmission Clutches
and Torque Converter Inlet
 TRANSMISSION / CHASSIS 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
Starter Lockout Switch Solenoids 1-7
Primary Steering
QuickEvac Service Pressure Switch
Tool Input Secondary Steering Steering System
Motor State Disable Solenoid
Secondary Steer Test Switch Transmission Input
Speed Sensor Service Brake Accumulator
Drive Gear Select Switches Bleed Solenoid
Alternator R-Terminal Lockup Clutch
Shift Lever Position Sensor Solenoid
Transmission Charge Filter
Bypass Switch
Hoist Lever Position Sensor Hoist Raise Solenoid
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
Inclinometer Autolube Relay
Secondary Steering
Body Pressure Switch Stop Lamp Relay
Up Switch
Secondary Brake Back-up Lamp Relay
Autolube Pressure Sensor Pressure Switch
Service Brake Secondary Steering Relay
Pressure Switch
Starter Lockout Lamp

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
Pressure
To Steering
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 To Steering
Pressure Valve STEERING PUMP
from HMU and HMU
MAXIMUM FLOW
High Pressure
Cutoff Valve
Actuator Piston

Flow
Compensator

Load Sensing
Controller

Swashplate
Piston
Case Drain
Filter
 Crossover
Relief
STEERING HYDRAULIC Valves

SYSTEM
LOW PRESSURE STANDBY
HMU
Secondary Steering
Back-up Relief Valve

Pressure
Primary Steering Reducing Valve
Load
Sensing Valve Pressure Switch

Primary Steering
Back-up Relief Valve
Transmission Steering
Chassis ECM Valve
Secondary Piston Pump and
Pressure
M Load Sensing Controller
Switch
Secondary
Secondary
Steering
Steering
Primary
Pump Flow
Relief Valve
Compensator

Steering Actuator
Disable Valve Piston

Swashplate
Piston
Steering
Filter
Case
Drain
Filter
 Raise Brake Cooling
Solenoid Relief Valve
Low
Pressure Pressure Reducing Valve
Relief Valve

Main Relief
Dump Valve
To Brake
High
Cooling
Pressure
Relief Valve
Dual Stage To Hoist Cylinder
Relief Valve Rod End
Signal Stem

Load To Hoist Cylinder

Check Head End
Valve

HOIST CONTROL VALVE

HOLD
Pressure Reducing Valve

Lower
Solenoid
 ON
Raise Brake Cooling
Solenoid Relief Valve
Low
Pressure Pressure Reducing Valve
Relief Valve

Main Relief
Dump Valve
To Brake
High Cooling
Pressure
Relief Valve
Dual Stage From Hoist Cylinder
Relief Valve Rod End
Signal Stem

Load To Hoist Cylinder

Check Head End
Valve

HOIST CONTROL VALVE

RAISE
Pressure Reducing Valve

Lower
Solenoid
 Raise Brake Cooling
Solenoid Relief Valve
Low
Pressure Pressure Reducing Valve
Relief Valve

Main Relief
Dump Valve
To Brake
High Cooling
Pressure
Relief Valve
To Hoist Cylinder
Dual Stage
Rod End
Relief Valve
Signal Stem

Load From Hoist Cylinder

Check Head End
Valve

HOIST CONTROL VALVE

LOWER / POWER DOWN
Pressure Reducing Valve

Lower
Solenoid
ON
 Raise Brake Cooling
Solenoid Relief Valve
Low
Pressure Pressure Reducing Valve
Relief Valve

Main Relief
Dump Valve
To Brake
High
Cooling
Pressure
Relief Valve
Dual Stage To Hoist Cylinder
Relief Valve Rod End
Signal Stem

Load From Hoist Cylinder

Check Head End
Valve

HOIST CONTROL VALVE

FLOAT
Pressure Reducing Valve

Lower
Solenoid
ON
 Raise Brake Cooling
Solenoid Relief Valve
Low
Pressure Pressure Reducing Valve
Relief Valve

Main Relief
Dump Valve
To Brake
High Cooling
Pressure
Relief Valve
Dual Stage To Hoist Cylinder
Relief Valve Rod End
Signal Stem

Load From Hoist Cylinder

Check Head End
Valve

HOIST CONTROL VALVE

SNUB
Pressure Reducing Valve

Lower
Solenoid
ON
 773F / 775F HOIST AND BRAKE COOLING SCHEMATIC
From
Pressure
Main Relief Dump Spool Reducing Valve

Raise Relief Valve

Dual
Stage
Left Lower Relief Valve Signal
Rear Spool
Brake Lower,
Float,
Snub
Solenoid
From
Brake
System

RAISE

Brake
HOLD
Cooler

SNUB
Hoist
Right
Pump
Rear
Brake
FLOAT

LOWER
Orifice Brake
Plate Cooling
Relief
Valve
Orifice Plate

Raise
Solenoid
 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
Valve Relief
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

 773F / 775F HOIST AND BRAKE COOLING SCHEMATIC
From
Pressure
Main Relief Dump Spool Reducing Valve

Raise Relief Valve

Dual
Stage
Left Lower Relief Valve Signal
Rear Spool
Brake Lower,
Float,
Snub
Solenoid
From
Brake
System

RAISE

Brake
HOLD
Cooler

SNUB
Hoist
Right
Pump
Rear
Brake
FLOAT

LOWER
Orifice Brake
Plate Cooling
Relief
Valve
Orifice Plate

Raise
Solenoid
 BRAKE HYDRAULIC SYSTEM

Parking Brake Valve

Purge
Valve
Parking Brake Cab ARC
Solenoid Manifold Solenoid
Left Rear
Brake

Service Brake
Relief Valve
Front Brake
Diverter Valve Solenoid
Valve

Left Front
Brake
Parking Brake
Accumulator Right Front
Secondary Brake
Pump M
Pressure
TCS Valve Reducing Service Brake
Accumulator Switch
Valve

To Hoist
Pilot
Valve Cut-In /Cut-out
Spool

Slack Adjuster Accumulator

Charging Valve
Unloading
Valve Relief
Valve

To Brake
Right Rear Cooling
Brake

Brake
Brake Charge
Filter
Pump
 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 Switch Brake Oil

Temperature Sensor
 SERVICE / RETARDER BRAKE CIRCUIT
BRAKES RELEASED

Service Brake Pedal

Position Sensor

To Rear
Service Brakes
ARC
Service
Solenoid
Brake
Valve

From Service Retarder Lever

Brake Accumulator Brake ECM

Front Service
Brake Solenoid To Front Front Brake
Service Brakes Switch

Cab Manifold
 AUTOMATIC RETARDER CONTROL
(ARC)

To Rear
Service Brakes
ARC
Service
Solenoid
Brake
Valve

Engine Spe
From Service Sensor
Brake Accumulator
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 Pressure
Rear Brake Reducing Valve
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
 HYDRAULIC SCHEMATIC COLOR CODE

Black - Mechanical connection. Seal Red - High pressure oil

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

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

White - Atmosphere or Pink - 3rd reduction in pressure

Air (No pressure)

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

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

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

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

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

Green / White Stripes -

Scavenge Oil or Hydraulic Void