Global Manpower Development

777G Off-Highway Truck

Engine and Support Systems
Module 3 - 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.
Caterpillar: Confidential Yellow
SERV1934 - 12/11 -2- Module 3 - Engine and Support Systems

LEARNING OUTCOMES
Participants will meet the following learning outcomes during the presentations, lab
exercises, and post-assessment of this Engine and Support Systems module for
the 777G Off-Highway Truck course:
-- Given the presentation of the 777G Engine and Support Systems module, the participant
will take notes in the classroom on the identification, location, and basic functionality of
the major components and service points of the machine’s engine and support systems
using the Lab 1 Worksheet.
-- Given a 777G machine and the Lab 1 Worksheet, the participant will identify the location
and explain the basic functionality of the major components of the machine’s engine and
support systems.
-- Given the post-assessment for Module 3 and all reference materials and class notes, the
participant will answer questions regarding the flow of fuel through the 777G engine fuel
delivery system.
-- Given the post-assessment for Module 3 and all reference materials and class notes, the
participant will identify the components involved in the air flow through the 777G engine
air and exhaust systems.
-- Given the post-assessment for Module 3 and all reference materials and class notes, the
participant will answer questions regarding the flow of coolant through the 777G cooling
system.

Pre-module Learning Outcomes
(objectives):
• This slide and statement for
the 777G Engine and Support
Systems module should be
shown at the beginning of the
module.
Participants will meet the following learning outcomes during the presentations, lab
exercises, and post-assessment of this Engine and Support Systems module for the
777G Off-Highway Truck course:
• Given the presentation of the 777G Engine and Support Systems
module, the participant will take notes in the classroom on the
identification, location, and basic functionality of the major components
and service points of the machine’s engine and support systems using
the Lab 1 Worksheet.

• Given a 777G machine and the Lab 1 Worksheet, the participant will
identify the location and explain the basic functionality of the major
components of the machine’s engine and support systems.

• Given the post-assessment for Module 3 and all reference materials

and class notes, the participant will answer questions regarding the flow
of fuel through the 777G engine fuel delivery system.

• Given the post-assessment for Module 3 and all reference materials

and class notes, the participant will identify the components involved in
the air flow through the 777G engine air and exhaust systems.

• Given the post-assessment for Module 3 and all reference materials

and class notes, the participant will answer questions regarding the flow
of coolant through the 777G cooling system.

Caterpillar: Confidential Yellow

SERV1934 - 12/11 -3- Module 3 - Engine and Support Systems

3_1

INTRODUCTION

• Identify the engine features Shown is the C32 Tier 4 Final engine used in the 777G Off-Highway Truck.

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 Tier 4 Final regulations. The C32 Tier 4 engine is equipped
with a NOX Reduction System (NRS) and a Diesel Oxidation Catalyst (DOC).

The updated C32 engine is also equipped with the MEUI-C fuel injector. The MEUI-C
injector has a Directed Operated Check valve, which more accurately controls the
start of injection to help meet emissions.

The C32 engine also utilizes the A4:E4 Engine Electronic Control Module (ECM),
which is air cooled. The engine is rated at 1025 gross horsepower (764 kW) at 1800
rpm.

The C32 engine is equipped with a redesigned turbocharger, which provides a

more consistent boost pressure over a wide range of engine operating speeds.
The turbocharger improves engine response and peak torque, as well as providing
outstanding low rpm performance.

Caterpillar: Confidential Yellow

SERV1934 - 12/11 -4- Module 3 - Engine and Support Systems

4_1

• Explain the LRC models In markets with less stringent emissions regulations, an updated truck is offered
without the extensive emissions system. These LRC (Lesser Regulated Countries)
models are built to meet Tier 2/Stage II emissions regulations.

Not having the aftertreatment and NOX Reduction System (NRS) reduces machine
weight and service requirements. These models are able to use lower quality diesel
fuel with higher sulfur content that cannot be burned in a Tier 4 engine.

The LRC models have a slightly different cooling system since there are no NRS
coolers.

NOTE: Differences between the engine in the LRC models and the Tier 4 Final
emissions engine will be noted throughout this module. The Emissions Systems
module (Module 4) does not apply to the LRC models.

Caterpillar: Confidential Yellow

SERV1934 - 12/11
• Identify the components on the
right side of the engine
-5- Module 3 - Engine and Support Systems
5_1
The main components on the right side of the engine are:
• Crankcase breather (1)
• Turbocharger (2)
• Engine oil S•O•S port (3)
• Tertiary fuel filter (4)
• Secondary fuel filter (5)
• Engine oil filters (6)
• Brake oil cooler (7)
• Power train oil cooler (8)
• NRS cooler (9)
• Exhaust manifold (10)
• DOC and muffler (11)
The secondary fuel filter is located next to the tertiary fuel filter and is not visible in
this image.
Caterpillar: Confidential Yellow
SERV1934 - 12/11
• Identify the components on the
left side of the engine
-6- Module 3 - Engine and Support Systems
6_1
The main components on the left side of the engine are:
• Crankcase breather (1)
• NRS cooler (2)
• Engine oil drain plug (3)
• Turbocharger (4)
• Exhaust manifold (5)
• Engine ECM (6)
• DOC and muffler (7)
NOTE: The NRS cooler and the DOC are NOT installed on the engine in the
LRC models.
Caterpillar: Confidential Yellow
SERV1934 - 12/11 -7- Module 3 - Engine and Support Systems
ENGINE ELECTRONIC CONTROL SYSTEM
INPUT COMPONENTS

Throttle Position Sensor (2)

Engine ECM (1)

Ground Level Shutdown Switch (3)

Throttle Lock Switch (4)

TIMING
Fan speed sensor (5)
Engine Speed/Timing Sensor (crank) (14)

Atmospheric Pressure Sensor (6)

Engine Speed/Timing Sensor (cam) (15)

OIL

Oil Pressure Sensor (7) AIR/EXHAUST

2 Turbocharger Air Inlet
Temperature Sensors (17)
3 Oil Level Switches (8)
2 Turbocharger Air Inlet
Pressure Sensors (17)

Intake Manifold Air

COOLING Pressure Sensor (18)

Intake Manifold Air

Coolant Temperature Sensor (9)
Temperature Sensors (2) (19)

3 Coolant Level Switches (10)

4 Exhaust Temperature Sensors (20)

NRS (Tier 4 only) FUEL

NRS Differential Pressure Sensor (11) Fuel Pressure Sensor (21)

NRS Air Temperature Sensor (12) Fuel Temperature Sensor (22)

NRS Air Pressure Sensor (13) Fuel Differential Pressure Switch (23)

Water in Fuel Switch (24)

7_1

ENGINE ELECTRONIC CONTROL SYSTEM

• Identify and explain the function The C32 engine consists of input components, output components, and the Engine
of the Engine ECM input ECM (1) to control the quality and the amount of fuel to efficiently operate the engine
components within the emission requirements. The A4:E4 ECM has a 120-pin connector (J2) and
a 70-pin connector (J1).

The engine is equipped with both active and passive sensors, which take pressure,
temperature, and speed/timing data from the engine systems and relay that information
to the Engine ECM. The Engine ECM processes the data and sends corresponding
output signals to the output components to control the engine functions.

Throttle Position Sensor (2) - This sensor sends a signal to the Engine ECM
indicating throttle pedal position.

Ground Level Shutdown Switch (3) - This switch is an input to the Engine ECM to
shut down the engine.

Throttle Lock and Back-up Switch (4) - The throttle back-up section is used if there
is a malfunction with the accelerator pedal. The operator can use the switch to raise
the engine speed to 1300 rpm to drive the truck to the service area. The throttle lock
section maintains engine speed at full throttle without depressing the accelerator
pedal.

Caterpillar: Confidential Yellow

SERV1934 - 12/11 -10- Module 3 - Engine and Support Systems

ENGINE ELECTRONIC CONTROL SYSTEM

OUTPUT COMPONENTS

Engine ECM (1)

Electronic Unit
Ether Aid Solenoid (2) Injectors (7)

Rockford Fan Solenoid

(attachment) (3)

Fuel Priming Pump Relay (4)

NRS Valve Actuator

Engine Brake
Solenoid (Tier 4 only) (5)
Solenoids (8)
NRS Balance Valve
Actuator Solenoid
(Tier 4 only) (6)

10_1

• Identify the Engine ECM output Based on the input signals, the Engine ECM (1) analyzes the input information and
components energizes the electronic unit injectors (7) to control fuel delivery to the engine by
sending current to the coils on the electronic unit injectors.

The Engine ECM controls the compression brake by sending current to the coils on
the engine brake solenoids (8).

The Engine ECM controls the NRS by sending current to the coils on the NRS valve
actuator solenoid (5) and the NRS balance valve actuator solenoid (6).

NOTE: The NRS valve actuator solenoid and the NRS balance valve actuator
solenoid are NOT installed on the engine in the LRC models.

The Engine ECM also sends signals to the following components:

• Ether aid solenoid (2)

• Optional Rockford fan solenoid (3)
• Fuel priming pump relay (4)

Caterpillar: Confidential Yellow

SERV1934 - 12/11 -11- Module 3 - Engine and Support Systems

11_1

• Identify the electronic Fuel injection and system monitoring are controlled by the A4:E4 Engine ECM (1),
components at the front of the which is located above the left front valve cover. The J2 engine harness
engine connector (2) is a 120-pin connector. The J1 machine harness connector (3) is a
70-pin connector.

The Engine ECM responds to engine inputs by sending a signal to the appropriate
output component to initiate an action. For example, the Engine ECM receives a high
coolant temperature signal. The Engine ECM interprets the input signal, evaluates
the current operating status, and derates the fuel supply under load.

The Engine ECM receives three different types of input signals:

• Switch input: Provides the signal line to battery, ground, or open.

• PWM input: Provides the signal line with a rectangular wave of a

specific frequency and a varying positive duty cycle.

• Speed signal: Provides the signal line with either a repeating, fixed
voltage level pattern signal, or a sine wave of varying level and
frequency.

Caterpillar: Confidential Yellow

SERV1934 - 12/11 -13- Module 3 - Engine and Support Systems

13_1

• Identify the sensors on top of the
engine
The atmospheric pressure sensor (1) 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.

The intake air temperature sensors (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 intake manifold pressure sensor (3) is used for calculating boost.

The coolant temperature sensor (4) 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.

Caterpillar: Confidential Yellow

SERV1934 - 12/11 -14- Module 3 - Engine and Support Systems

14_1

• Identify the cam speed/timing The cam speed/timing sensor (arrow) is located on the right side of the engine in the
sensor rear of the timing gear housing. 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.

Caterpillar: Confidential Yellow

SERV1934 - 12/11 -15- Module 3 - Engine and Support Systems

15_1

15_2

• Identify the expansion tank There are three coolant level sensors that monitor the coolant level in the expansion
coolant level sensors tank. The LOW coolant level sensors are installed in the front (1) and rear (2) of the
expansion tank. One LOW sensor is installed on each side of the tank to ensure an
accurate signal is sent to the Engine ECM when the truck is on an incline.

The FULL coolant level sensor (not shown) is installed on the right side of the
expansion tank.

Caterpillar: Confidential Yellow

SERV1934 - 12/11
• Identify the components of the
compression brake assembly
-16- Module 3 - Engine and Support Systems
16_1
ENGINE COMPRESSION BRAKE (OPTIONAL)
The 777G Truck can be equipped with the optional engine compression brake. The
engine brake provides higher downhill travel speeds and reduces brake wear in
addition to the Automatic Retarder Control (ARC) system. The engine brake uses a
master/slave hydraulic actuation system to open exhaust valves on the compression
stroke, which releases pressurized air and creates a net braking force at the
flywheel.
The engine brake assembly, as shown in this illustration, controls two cylinders.
The engine brake assembly is mounted to the rocker arm shaft supports below the
engine valve covers. The engine brake is pressurized with engine oil from the rocker
arm shaft and uses a solenoid valve to control oil flow in the brake housing.
The engine brake is activated by a signal from the Engine ECM to the solenoid
valve (1). As the fuel injector rocker arm pushes up on the master piston (2), the
corresponding slave piston (3) is pressurized to push down on the exhaust valve
bridge, decompressing the cylinder and preventing the normal power stroke.
On the C32 engine, up to six brake assemblies are used. The control circuit for the
engine brake permits the operation of either two, four, or all six of the engine brake
assemblies, which provides progressive braking capabilities with the retarding effect
of four, six, or all 12 of the engine cylinders.
The only engine brake system service is periodic valve lash checks.
Caterpillar: Confidential Yellow
SERV1934 - 12/11 -17- Module 3 - Engine and Support Systems

ENGINE COMPRESSION BRAKE HYDRAULIC CIRCUIT

COMPRESSION BRAKE OFF

Slave Piston (5)

Check Valves (4)

Compression Brake Exhaust Master

for Other Cylinders Valve Piston (6)
Compression Rocker Arm (8)
Solenoid
Valve (3)
Fuel Injector
Rocker Arm (7)

Rocker Arm Shaft

Oil Passage (2)

Engine Oil
Pump (1)
Exhaust
Valve (9)

17_1

•E
 xplain the operation of the
engine compression brake
hydraulic circuit with the
compression brake off
This illustration shows the oil flow in the C32 engine compression brake. Oil from the
engine oil pump (1) flows through the rocker arm shaft oil passage (2). The
compression brake solenoid valve (3) controls the oil flow in the compression brake
hydraulic circuit.

When the Engine ECM energizes the solenoid, oil flows through the check
valves (4) to the slave pistons (5) and the master pistons (6).

Oil pressure overcomes spring force and the master piston moves down and contacts
the fuel injector rocker arm (7). The master piston will follow the movement of the
fuel injector rocker arm. As the fuel injector rocker arm moves up, the master piston
moves up and causes the oil to close the check valve.

With the check valve closed, oil pressure increases in the engine brake hydraulic
circuit and the slave piston is forced down. The slave piston makes contact with
the exhaust valve rocker arm (8) and causes the exhaust valve (9) to open. As
the exhaust valve opens, the engine cylinder pressure is relieved through the open
exhaust valve, which creates a net braking force at the flywheel.

When the fuel injector rocker arm moves down, the master piston moves down and
the hydraulic pressure decreases. The exhaust valves are returned to the closed
position by the exhaust rocker arm. The check valve opens and relieves the oil
pressure.

When the Engine ECM de-energizes the compression brake solenoid, oil is drained
from the slave and master pistons to the tank. The exhaust valves close and the
slave piston returns to the starting position.

Caterpillar: Confidential Yellow

SERV1934 - 12/11 -18- Module 3 - Engine and Support Systems

18_1

COOLING SYSTEM

• Identify the components at the The jacket water cooling system on the 777G uses a Next Generation Modular
front of the radiator Radiator (1). The radiator is a single-pass flow design, which is the same as the
777F. The radiator cores size has increased on the 777G.

The coolant enters at the top left and flows out at the bottom right, similar to an
automotive design. Being modular, individual cores may be removed for service
while the radiator remains in place.

The aftercooler cooling system in the 777G Trucks is an ATAAC system. The
ATAAC cores (2) are located in front of the radiator. Intake air is cooled after being
compressed by the turbocharger before being routed to the engine combustion
chamber.

Below the ATAAC cores is the air conditioning condenser (3) and behind the
condenser is the new fuel cooler (4).

Caterpillar: Confidential Yellow

SERV1934 - 12/11 -19- Module 3 - Engine and Support Systems

19_1

• Identify the cooling system Jacket water coolant flows from the water pump (1) through the engine oil cooler (2),
components the brake oil coolers, and the transmission oil cooler (4) to the right side of the engine
cylinder block. Only one brake oil cooler (3) is shown in this image.

Coolant flows through the engine block to the cylinder heads. From the cylinder
heads, the coolant flows to the two temperature regulators located inside the
regulator housing (7). When the engine reaches operating temperature, the coolant
flows to the radiator. Before the engine reaches operating temperature, coolant flows
through the bypass tube (9) to the water pump to recirculate until the engine reaches
operating temperature.

Coolant from the water pump also flows through the right NRS tube (5) to the front of
the right NRS cooler (6) and to the cab heater core (not shown).

Coolant flows through the right NRS cooler, through a tube (10) and a passage in the
back of the rear housing (11), to the left NRS cooler (not visible). From the left NRS
cooler, the coolant flows through a tube (8) to the thermostat housing.

NOTE: NRS components are NOT installed on the engine in the LRC models.

Caterpillar: Confidential Yellow

SERV1934 - 12/11 -20- Module 3 - Engine and Support Systems

ENGINE FUEL DELIVERY SYSTEM Electric Fuel

Priming Pump
(1)

Primary
Fuel Filter
(2)

Fuel
Right Fuel Gallery (4) Tank (8)

Tertiary
Fuel Filter
(10)

Secondary Fuel
Fuel Filter Transfer
(3) Pump (7)
Fuel
Pressure
Regulator (5)
Fuel
Cooler (9)
Left Fuel Gallery (6)

20_1

FUEL SYSTEM

•E
 xplain the operation of the fuel This illustration shows a block diagram of the fuel system.
system
Fuel is drawn from the fuel tank (8) through the primary fuel filter (2) by the transfer
pump (7). The transfer pump sends the fuel through the secondary fuel filter (3) and
tertiary fuel filter (10) before reaching the right fuel gallery (4), left fuel gallery (6),
and the fuel injectors.

Fuel not used for injection flows around each injector body to cool the injector and then
flows through the fuel pressure regulator (5) and the fuel cooler (9) before returning
to the fuel tank. The fuel pressure regulator maintains a fuel system pressure of
approximately 560 kPa (80 psi).

The electric priming pump (1) provides fuel to the transfer pump and secondary
and tertiary fuel filters to purge any air that may have entered the system during
servicing.

Caterpillar: Confidential Yellow

SERV1934 - 12/11 -21- Module 3 - Engine and Support Systems

21_1

• Identify the MEUI-C fuel injector The new MEUI-C injector includes two solenoids stacked on top of each other. Four
wires are used to control the injector. The MEUI-C injector uses a 108 volt supply,
the same as the MEUI-A injector.

A new Direct Operated Check (DOC) valve controls the fuel pressure at start-up and
the spill valve controls the pressure upon fuel delivery. The spill valve on the MEUI-C
injector is the same as the spill valve on the MEUI-A injector.

The DOC valve controls the start of injection by varying the time delay between spill
and DOC solenoid actuation. The DOC solenoid more accurately controls the start
of injection to help meet emissions. The MEUI-C injector is actuated the same as
the MEUI-A injector.

NOTE: The engine in the LRC models contains the MEUI-A fuel injector, which
is the same as the 777F truck.

Caterpillar: Confidential Yellow

SERV1934 - 12/11 -22- Module 3 - Engine and Support Systems

22_1

• Identify the fuel system This image shows the location of the fuel transfer pump (1), the fuel pressure
components regulator manifold (2), the secondary fuel filter (3), and the tertiary fuel filter (4).

Fuel from the primary fuel filter flows to the fuel transfer pump at the top rear of the
engine. The fuel transfer pump is installed in the front side of the timing gear cover
and is driven by a gear in the rear gear train. The fuel transfer pump contains a
bypass valve to protect the fuel system components from excessive pressure. The
bypass valve setting is higher than the setting of the fuel pressure regulator. Fuel
flows from the transfer pump to the secondary fuel filter and tertiary fuel filter.

From the fuel filters, the fuel flows through the hoses at the front of the engine to the
MEUI-C fuel injectors. Return fuel from the injectors flows through the fuel hoses at
the rear of the engine to the fuel pressure regulator before returning to the fuel tank
via the fuel cooler. The fuel pressure regulator contains a check valve that is installed
in the front of the manifold. The fuel pressure regulator maintains the fuel pressure at
approximately 550 kPa (80 psi) with a full load on the engine.

Caterpillar: Confidential Yellow

SERV1934 - 12/11 -23- Module 3 - Engine and Support Systems

23_1

• Identify the fuel sensors The primary fuel filter (1) is mounted to the right frame upright. The fuel filter includes
a water separator (2) and a water-in-fuel switch (3). The water-in-fuel switch provides
an indication to the Engine ECM if there is water in the fuel.

The fuel priming pump (4) is located at the top of the fuel filter. The priming switch
has been removed. To prime the fuel system, turn the key start switch ON. The
electric fuel priming pump will cycle if the fuel pressure is low. As the air is purged
from the fuel system, fuel pressure will increase. The fuel priming pump will operate
until adequate fuel pressure is reached. The fuel pressure can be monitored using
Advisor or Cat ET.

Caterpillar: Confidential Yellow

SERV1934 - 12/11 -24- Module 3 - Engine and Support Systems

24_1

24_2

• Identify the components at the The secondary fuel filter (1) and the tertiary fuel filter (2) are located on the front, right
front, right side of the engine side of the engine.

The differential fuel pressure switch (3), fuel pressure sensor (4), and the fuel
temperature sensor (5) are located in the top of the fuel filter base.

This differential fuel pressure switch will indicate a restriction in the fuel filter. A
warning will be sent by the Engine ECM to the monitoring system.

The fuel pressure sensor sends a signal to the Engine ECM indicating fuel pressure
after the filters.

The fuel temperature sensor sends a signal to the Engine ECM indicating fuel
temperature. The Engine ECM uses the fuel temperature measurement to make
corrections to the fuel rate and maintain power regardless of fuel temperature (within
certain parameters). This feature is called “Fuel Temperature Compensation.”

A fuel pressure test port (6) can be used to check the fuel pressure at the outlet of
the fuel filters.

Caterpillar: Confidential Yellow

SERV1934 - 12/11
• Identify the fuel level sensor
-25- Module 3 - Engine and Support Systems
25_1
A new capacitive type fuel level sensor (arrow) is located in the fuel tank on the 777G
trucks. A capacitor is formed inside the level sensor by a capacitive plate and the
aluminum tube of the sensor. As the fuel level decreases, the amount of air between
the capacitive plate and aluminum tube increases. The capacitance between the
plates varies with the fuel level, and the electronics inside the sensor convert the
capacitance measurement into one of three different type of signals.
The fuel level sensor is an active sensor that produces a variable voltage output
signal. The voltage signal is sent to the Transmission/Chassis ECM for interpretation.
The ECM converts the voltage signal from the level sensor into a CAN message and
communicates the message to the monitoring system, via the CAN A Data Link.
The fuel level sensor will accurately read fuel tank levels regardless of the type of
diesel fuel used. Sensor accuracy is assured with diesel fuel, bio-diesels, or eco-
diesel fuels in the tank. The presence of water in the fuel tank, however, will cause
the sensor to read inaccurately since the electrical capacitance of water differs
significantly from that of diesel fuels.
Caterpillar: Confidential Yellow
SERV1934 - 12/11 -26- Module 3 - Engine and Support Systems

26_1

Air Intake and Exhaust System

• Identify the air filter housings and Outside air enters the precleaners (1) and flows through the air filter elements located
precleaners inside the air filter housings (2). The filter housings can be accessed by opening a
panel on the right side of the platform. The panel is removed in this image.

Two filter elements are installed in each filter housing. The large element is the
primary element and the small element is the secondary element.

Caterpillar: Confidential Yellow

SERV1934 - 12/11 -27- Module 3 - Engine and Support Systems

27_1

• Identify the precleaner housing When servicing the air filter elements, clean the precleaner housing (1) and the dust
and dust valve valve (2). The dust valve is located behind the right front tire and is serviceable from
ground level.

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.

Caterpillar: Confidential Yellow

SERV1934 - 12/11
• Identify the air and exhaust
system components
-28- Module 3 - Engine and Support Systems
28_1
This image shows the main components in the air intake and exhaust systems.
The turbochargers (1) are driven by the exhaust gas from the cylinders, which enters
the turbine side of the turbochargers from the exhaust manifolds (2). The exhaust
gas flows through the turbochargers and the exhaust piping (3) to the DPF canister
and the mufflers.
The clean air from the air filters enters the compressor side of the turbochargers
through the turbocharger inlet hoses (4). The compressed air from the turbochargers
flows to the ATAAC cores (5). After the air is cooled by the ATAAC, the air flows to
the intake manifolds (6) and cylinders and combines with the fuel for combustion.
Caterpillar: Confidential Yellow
SERV1934 - 12/11 -29- Module 3 - Engine and Support Systems

29_1

• Identify the engine inlet air The engine inlet air temperature sensors (1) are mounted to the outlet tube of the air
temperature sensors and the filter housing on the inboard side of the housing. The output of the sensors is
turbocharger air inlet pressure monitored by the Engine ECM. The inlet air sensor output voltage is used by the
sensors Engine ECM to increase or decrease NRS flow.

Two turbocharger air inlet pressure sensors (2) are mounted to the outlet of the air
filter housing. The signal from the pressure sensors is monitored by the Engine
ECM. Based on the sensor signals, the Engine ECM can determine when the air
filter has become restricted with dirt and contaminants. The Engine ECM will send
an alert message to the monitoring system when the air filter requires servicing.
Engine derate can occur if the engine air filter is restricted.

Caterpillar: Confidential Yellow

SERV1934 - 12/11 -30- Module 3 - Engine and Support Systems

30_1

• Identify the exhaust temperature Two exhaust temperature sensors (arrows) are located in each exhaust manifold.
sensors The exhaust temperature sensors send a signal to the Engine ECM indicating the
exhaust temperature.

When the engine runs at low idle, the temperature of an exhaust manifold port can
indicate the condition of a fuel injection nozzle. A low temperature indicates that no
fuel is flowing to the cylinder. An inoperative fuel injection nozzle or a problem with
the fuel injection pump could cause this low temperature.

A very high temperature can indicate that too much fuel is flowing to the cylinder.
A malfunctioning fuel injection nozzle, plugged air filters, or a restriction in the
turbochargers or the muffler could cause this very high temperature.

Caterpillar: Confidential Yellow

SERV1934 - 12/11 -31- Module 3 - Engine and Support Systems

LEARNING OUTCOMES
Participants have met the following learning outcomes during the presentations,
lab exercises, and post-assessment of this Engine and Support Systems module
for the 777G Off-Highway Truck course:
-- Given the presentation of the 777G Engine and Support Systems module, the participant
took notes in the classroom on the identification, location, and basic functionality of the
major components and service points of the machine’s engine and support systems
using the Lab 1 Worksheet.
-- Given a 777G machine and the Lab 1 Worksheet, the participant identified the location
and explained the basic functionality of the major components of the machine’s engine
and support systems.
-- Given the post-assessment for Module 3 and all reference materials and class notes, the
participant answered questions regarding the flow of fuel through the 777G engine fuel
delivery system.
-- Given the post-assessment for Module 3 and all reference materials and class notes, the
participant identified the components involved in the air flow through the 777G engine air
and exhaust systems.
-- Given the post-assessment for Module 3 and all reference materials and class notes, the
participant answered questions regarding the flow of coolant through the 777G cooling
system.

Post-module Learning Outcomes
(objectives):
• This slide and statement for
the 777G Engine and Support
Systems module should be
shown at the end of the post-
assessment..
Participants have met the following learning outcomes during the presentations, lab
exercises, and post-assessment of this Engine and Support Systems module for the
777G Off-Highway Truck course:
• Given the presentation of the 777G Engine and Support Systems
module, the participant took notes in the classroom on the identification,
location, and basic functionality of the major components and service
points of the machine’s engine and support systems using the Lab 1
Worksheet.

• Given a 777G machine and the Lab 1 Worksheet, the participant

identified the location and explained the basic functionality of the major
components of the machine’s engine and support systems.

• Given the post-assessment for Module 3 and all reference materials

and class notes, the participant answered questions regarding the flow
of fuel through the 777G engine fuel delivery system.

• Given the post-assessment for Module 3 and all reference materials

and class notes, the participant identified the components involved in
the air flow through the 777G engine air and exhaust systems.

• Given the post-assessment for Module 3 and all reference materials

and class notes, the participant answered questions regarding the flow
of coolant through the 777G cooling system.

Caterpillar: Confidential Yellow