Global Manpower Development

777G Off-Highway Truck

Introduction
Text Reference

SERV1934

CAT, CATERPILLAR, their respective logos, ACERT, “Caterpillar Yellow” and the POWER EDGE
trade dress, as well as corporate and product identity used herein, are trademarks of Caterpillar
and may not be used without permission. © 2011 Caterpillar Inc. All Rights Reserved.
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• Safety Briefing
-- Emergency Phone Numbers
-- First Aid Responders
-- Location of Exits
-- Location of Fire Extinguisher
-- Room Alerts or Hazards
-- Designated Location for Evacuation
-- Storm Shelter
-- Hazardous Materials

Safely Home. Everyone. Every Day.™

Safety Briefing • Emergency Phone Numbers

• First Aid Responders
• Location of Exits
• Location of Fire Extinguisher
• Room Alerts or Hazards
• Designated Location for Evacuation
• Storm Shelter
• Hazardous Materials

Safely Home. Everyone. Every Day.™

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PURPOSE

This 777G Machine Service Training course is

designed to prepare participants to quickly and
accurately diagnose problems, to test and properly
adjust components, and to demonstrate knowledge
of the methods and strategies used in all of the major
systems of the 777G Off-Highway Truck.

Purpose of course

• Course Purpose This 777G Machine Service Training course is designed to prepare participants to
quickly and accurately diagnose problems, to test and properly adjust components,
and to demonstrate knowledge of the methods and strategies used in all of the major
systems of the 777G Off-Highway Truck.

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REASON

It is necessary for participants to be able to quickly

and accurately diagnose problems, to test and
properly adjust components, and to know the methods
and strategies used in all of the major systems of
the 777G Off-Highway Truck. Use of the knowledge
gained in this course will ensure that participants will
be able to provide more effective customer service,
which enhances customer satisfaction.

reason for course

• Course reason It is necessary for participants to be able to quickly and accurately diagnose problems,
to test and properly adjust components, and to know the methods and strategies
used in all of the major systems of the 777G Off-Highway Truck. Use of the knowledge
gained in this course will ensure that participants will be able to provide more effective
customer service, which enhances customer satisfaction.

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COMPETENCY STANDARD
Upon completion of this course, the participant will be able to locate,
identify, and briefly explain the function of components:
• in the operator’s station;
• in the monitoring system;
• on the engine, and to demonstrate knowledge of the fuel, cooling, and
air systems;
• in the emissions system;
• in the power train, and to test and properly adjust the power train;
• in the steering system, and to test and properly adjust the steering
system;
• in the hoist system, and to test and properly adjust the hoist system;
• in the brake system, and to test and properly adjust the brake system.
Course Competency Standard

• Course competency standard Upon completion of this course, the participant will be able to locate, identify, and
briefly explain the function of components:

• in the operator’s station;

• in the monitoring system;

• on the engine, and to demonstrate knowledge of the fuel, cooling, and

air systems;

• in the emissions system;

• in the power train, and to test and properly adjust the power train;

• in the steering system, and to test and properly adjust the steering
system;

• in the hoist system, and to test and properly adjust the hoist system;

• in the brake system, and to test and properly adjust the brake system.

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6_1

NEW FEATURES

• Identify 777G machine features The 777G Off-Highway Truck will replace the 777F. Below are the updates to the
777G truck.

• C32 engine: The power is supplied by the updated C32 engine with
ACERT™ technology. The 777G will be equipped with either the C32
Tier 4 engine or the C32 engine for Lesser Regulated Countries (LRC).
The Tier 4 C32 engine is now equipped with an Economy Power Mode,
which reduces fuel costs without losing productivity.
• VIMS™ 3G with Advisor: The monitoring system will change from
the standard Messenger panel and optional VIMS with Advisor to the
standard VIMS 3G with Advisor. VIMS 3G will communicate with each
of the individual ECMs on the truck.

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8_1

MACHINE WALKAROUND

• Identify the components and The following components are accessible from the right front of the truck:
service points at the front of the
truck • Steering oil tank (1)

• Hydraulic oil tank breather (2)

• Torque converter sump breather (3)

• Engine precleaners (4)

• Remote switch panel (5)

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9_1

9_2

• Identify the remote switch panel The remote switch panel is located on the right side of the front bumper.
and lockout lamps
The battery disconnect switch (12) in the OFF position disconnects electrical power
to the truck.

The machine lockout switch (8) initiates NEUTRAL through the Transmission/
Chassis Electronic Control Module (ECM) allowing the technician to service the
machine with a running engine. The machine lockout switch also disables the hoist
function. When the machine lockout switch is ON, the parking brake is ON and
the ground speed is zero. The machine lockout lamp (3) will be ON solid and the
machine will be locked out. The machine lockout lamp will flash when the machine
lockout switch is activated, but either the parking brake is OFF or the ground speed
indication is not zero.

The engine lockout switch (7) disconnects battery power to the starter relays. When
the engine lockout switch is ON and the ground speed is zero, the engine lockout
lamp (1) will be ON solid and the starter will be disabled. The engine lockout lamp
will flash when the engine lockout switch is activated but the ground speed indication
is not zero.

The engine lockout also transfers power to the ECMs so the VIMS download can be
performed without entering the cab.

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• Identify the components and
service points on the right side of
the truck
-11- Introduction
11_1
The following components and service points are located on the right side of the
engine and machine:
• Front strut (1)
• Engine oil filters (2)
• Secondary fuel filters (3)
• Primary fuel filter and electric priming pump (4)
• Steering return oil filter (5)
• Steering case drain oil filter (6)
• Brake charging oil filter (7)
• Fuel tank (8)
• Hoist cylinder (9)
• Fuel tank breather (10)
• Fuel tank sight gauges (new for the 777G) (11)
NOTE: The steering return oil filter, the steering case drain oil filter, and the brake
charging oil filter are located inside a filter compartment. The compartment door
has been removed in this image to show the location of the filters.
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• Identify the components and
service points at the rear of the
truck
-12- Introduction
12_1
The following components and service points are located at the rear of the
machine:
• Backup alarm (1)
• WAVS camera (2)
• Rear struts (3), which are now positioned with the cylinder rod and boot
pointing downward to extend seal life
• Autolube injectors (4)
• Differential fill plug (5)
• Rear Axle Lubrication (RAX) oil filter (6)
The 777G is now equipped with a sight glass (7) for checking the differential and final
drive oil level.
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• Identify the components and
service points below the truck
bed
-13- Introduction
13_1
The following components and service points are visible from above with the truck
bed removed:
• Pump group (hoist/brake cooling/brake charging) (1)
• Steering pump (2)
• Torque converter (3)
• Hoist valve (4)
• Fuel tank (5)
• Fuel tank breather (6)
• Fuel level sensor (7)
• Transmission oil filter (torque converter oil filter is not visible, but is in
front of the transmission oil filter) (8)
• Optional RAX motor and pump (9)
• Transmission (10)
• Hydraulic oil tank (11)
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• Identify the components and
service points on the left side of
truck
-14- Introduction
14_1
The following components and service points are on the left side of the truck:
• Service brake accumulator (1)
• Hydraulic oil tank fill cap (2)
• Hoist and brake cooling oil level sight gauges (3)
• Torque converter sump oil level sight gauges (4)
• Torque converter sump oil fill tube (5)
• Parking brake accumulator (6)
• Front strut (7)
NOTE: The hydraulic oil tank stores the oil for the hoist and brake cooling
hydraulic systems. The torque converter sump stores the oil for the torque
converter and transmission.
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15_1

• Identify the TPMS scoreboard The Truck Payload Measurement System (TPMS) status can be displayed with
external loading lamps, or an optional scoreboard display (arrow), on the left side of
the cab, as shown in this image. The scoreboard displays the actual payload
weight.

There is a scoreboard display mounted on each side of the truck. When the truck is
equipped with the TPMS external loading lamps, there is one set of lamps on each
side of the truck. 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.

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16_1

• Identify the fast fill service center The fast fill service center is located on the left side of the truck at the rear of the front
components bumper.

The service center allows individual fluid levels to be filled directly from the front of
the truck. The fill ports are:

• Engine oil (1)

• Engine coolant (2)
• Hydraulic oil (hoist and brake cooling) (3)
• Power train oil (torque converter and transmission) (4)
• Steering oil (5)
• Autolube grease (6)
• Fuel (7)

The keypad (8) includes fluid level indicators and a test button for each indicator.
The lamp (9) provides lighting for the service center.

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17_1

• Identify the keypad indicators The keypad indicates fluid levels using a three-level LCD system next to each system
icon. When the engine start switch is moved to the ON position, all LED indicators on
the keypad will flash briefly before displaying the actual fluid levels.

After that, three solid lights indicate a FULL level, two solid lights indicate a NORMAL
operating level, and one flashing light indicates the need to ADD fluids.

Each icon on the keypad is also a test button. While a button is depressed, the
indicators for the corresponding system will flash once and then illuminate
continuously if the indicators are working properly. The indicators should be tested to
ensure all three lights are working before filling any system using the corresponding
fast fill port.

The fluid level indicators are:

• Hydraulic oil (1)

• Steering oil (2)
• Torque converter and transmission oil (3)
• Differential and final drive oil (4)
• Fuel (5)
• Engine oil (6)
• Engine coolant (7)
• Autolube grease (8)

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18_1

• Identify the engine shutdown The engine shutdown switch (1) and the stairway access light switch (2) are located
switch and the stairway access on the left side of the front bumper.
light switch

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