Hydraulic and Braking 777G
Hydraulic and Braking 777G
Hydraulic and Braking 777G
December 2011
Specifications
777G Off-Highway Truck
Hydraulic and Braking System
TNM1-Up (Machine)
RDR1-Up (Machine)
SAFETY.CAT.COM
i03991620
In the United States, the maintenance, replacement, or repair of the emission control devices and
systems may be performed by any repair establishment or individual of the owner's choosing.
KENR9932-02 3
Table of Contents
Table of Contents
Specifications Section
Hydraulic Tank (Brake, Brake Cooling, Hoist) ....... 4
Pump and Motor (Parking Brake Release, Secondary
Steering) ............................................................. 4
Control Manifold (Parking Brake Release) (For
Towing) ................................................................ 5
Gear Pump (Brake, Brake Cooling, Hoist) ............ 6
Gear Pump (Brake Cooling) ................................. 6
Control Manifold (Brake Accumulator Charge) ..... 7
Pressure Sensor (Brake Oil Accumulator) ............ 7
Brake Accumulator (Parking) ................................ 8
Brake Valve (Parking) ........................................... 8
Pressure Switch (Parking Brake) .......................... 9
Brake Accumulator (Service) ................................ 9
Brake Valve (Front Service Brake) ....................... 10
Position Sensor (Foot Brake Control) ................... 10
Service and Parking Brake (Front) (Extended
Life) ..................................................................... 11
Service and Parking Brake (Front) (Standard) ..... 12
Brake Valve (Rear Service Brake, Retarder Control,
Traction Control) ................................................. 14
Slack Adjuster (Rear Brakes) ............................... 15
Slack Adjuster (Front Brakes) ............................... 15
Service and Parking Brake (Rear) (Standard) ...... 16
Service and Parking Brake (Rear) (Extended
Life) ..................................................................... 17
Oil Filter (Brake System) ....................................... 19
Control Valve (Hoist) ............................................. 20
Position Sensor (Hoist Control) ............................ 22
Hoist Cylinder ...................................................... 23
Hoist Cylinder and Mounting ................................. 24
Cab Mounting ...................................................... 24
Truck Body Mounting ............................................ 25
Limit Switch (Truck Body Up) ................................ 26
Index Section
Index ..................................................................... 28
4 KENR9932-02
Specifications Section
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Illustration 3
View of Area C
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Illustration 2 Illustration 4
View of Area A
KENR9932-02 5
Specifications Section
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Illustration 5
View A-A
(2) Plug
Torque for two plugs ...... 15 2 Nm (11 1 lb ft)
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Illustration 7
View of 255-5478 Gear Pump (Brake, Brake Cooling, Hoist)
(1) Torque for four bolts ..... 115 7 Nm (85 5 lb ft) g02322849
Illustration 8
View of Gear Pump (Brake Cooling) with Gear Pump (Power
(2) Torque for four bolts ... 228 7 Nm (170 5 lb ft) Train) sections
(1) Gear Pump (Brake Cooling)
(3) Torque for eight nuts .. 400 7 Nm (295 5 lb ft) (A) Gear Pump (Transmission Charge)
(B) Gear Pump (Torque Converter Charge)
(4) Hoist Pump (C) Gear Pump (Scavenge)
Displacement Per Revolution ................. 0.264 L Before running, lubricate the pump with oil.
(16.11 in3)
Maximum Pressure ........ 19000 kPa (2750.0 psi) The pump must rotate freely by hand.
Minimum flow rate at 17240 kPa (2500.5 psi) and
at 2100 RPM ....... 511.4 L/min (135.10 US gpm) Table 1
Minimum flow rate at 17240 kPa (2500.5 psi) and Pump Test Data for Gear Pump (Brake Cooling)
at 650 RPM ........... 145.5 L/min (38.44 US gpm)
Max Revolutions Per Minute ....................... 2500 Rotation CCW
RPM (Test Stand) 900
(5) Brake Cooling Pump
Pressure 700 kPa (101.5 psi)
Displacement Per Revolution ............... 0.2003 L
Flow (Minimum) 223 L/min (58.9 US gpm)
(12.223 in3)
Maximum Pressure .............. 690 kPa (100.0 psi)
Minimum flow rate at 6900 kPa (1000.8 psi) and
at 2100 RPM ........ 389.1 L/min (102.79 US gpm)
Minimum flow rate at 6900 kPa (1000.8 psi) and
at 650 RPM ............ 109.8 L/min (29.01 US gpm)
Max Revolutions Per Minute ....................... 2500
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Illustration 9 Illustration 10
Note: Limits are factory set. Readjustment may result Maximum operating pressure .. 35500 kPa (5150 psi)
in system damage or failure.
Operating voltage ......................... 7 VDC to 14 VDC
Note: Excessive pressure at the tank port may result
in system damage or failure. (1) Final installation torque ...................... 30 3 Nm
(270 27 lb in)
Pressure of cut-in of charging
valve ............... 16100 345 kPa (2335.1 50.0 psi)
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Illustration 11 Illustration 12
(1) 293-6585 Solenoid Valve
(1) Torque for two end caps ................ 300 15 Nm (2) 342-2410 Solenoid Valve
(221.3 11.1 lb ft)
Precharge pressure at 21 C
(70.0 F) .............. 5517 276 kPa (800.2 40.0 psi)
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Illustration 14
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Precharge pressure at 21 C
(70.0 F) .............. 5516 250 kPa (800.0 36.3 psi)
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Illustration 15
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Illustration 18
Connector Pins
(A) + Battery (red)
(B) Ground (black)
(C) Signal (white)
SMCS Code: 4251; 4267 Note: Install one damper assembly so that the facing
material faces toward the endplate. Install the other
Part No.: 330-9471
damper assembly so that the facing material faces
toward the service piston.
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Illustration 19
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Illustration 21
Section B-B
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Illustration 20
Section A-A
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Illustration 23
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(6) Torque for nine studs ....................... 65 10 Nm Illustration 24
(50.0 7.0 lb ft)
(1) 355-9679 Service and Parking Brake Gp
(7) Torque for five studs ...................... 110 20 Nm
(81 15 lb ft)
KENR9932-02 13
Specifications Section
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Illustration 25
Section A-A
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Illustration 28
Note: Retighten six bolts (9) in a crisscross pattern to (5) Final installation torque for cartridge .. 72 3 Nm
270 40 Nm (199 30 lb ft). (53 2 lb ft)
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Illustration 31
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Illustration 30
SMCS Code: 4251-RE; 4267-RE Note: Install one damper assembly with the facing
material towards the end plate. Install the other
Part No.: 355-9680
damper assembly with the facing material towards
the service piston.
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Illustration 33
Section A-A
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Illustration 36
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(7) Torque for nine studs ....................... 65 10 Nm Illustration 37
(50.0 7.0 lb ft)
(1) 308-3208 Service and Parking Brake Gp
(8) Torque for five studs ...................... 110 20 Nm
(80 15 lb ft)
18 KENR9932-02
Specifications Section
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Illustration 38
Section A-A
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Illustration 41
Note: Tighten five hat nuts (9) in a crisscross pattern Final installation torque ...................... 30 3 Nm
to the specified torque. Ensure that the piston (266 27 lb in)
housing is seated against the anchor. Maximum actuation pressure at40C to 120C
(40F to 248F) ... 276 28 kPa (40.0 4.0 psi)
(10) Torque for six bolts ...................... 270 40 Nm Deactuation pressure at 40C to 120C
(199 30 lb ft) (40F to 248F) .................... 179 kPa (26.0 psi)
Current draw at 28 VDC ............................. 1.5 A
Note: Tighten six bolts (10) in a crisscross pattern to
the specified torque. The switch is normally closed.
Note: Retighten five hat nuts (9) in a crisscross Bypass valve differential pressure setting at
pattern to 270 40 Nm (199 30 lb ft). 10.4 L/min (2.75 US gpm) .................... 345 17 kPa
(50.0 2.5 psi)
Note: Retighten six bolts (10) in a crisscross pattern
to 270 40 Nm (199 30 lb ft). (2) Torque for housing ....................... 23.5 3.5 Nm
(208 31 lb in)
20 KENR9932-02
Specifications Section
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Illustration 44
Free length after test .......... 76.2 mm (3.00 inch) (14) Torque for the nut ...... 60 10 Nm (44 7 lb ft)
Outside diameter ................ 49.2 mm (1.94 inch)
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Illustration 46
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Illustration 45 View C-C
View B-B
Length under test force ... 37.47 mm (1.475 inch) (15) 6J-3380 Spring
Test force ........ 43.34 3.00 N (9.743 0.674 lb)
Free length after test .......... 40.0 mm (1.57 inch) Length under test force ....... 60.5 mm (2.38 inch)
Outside diameter ............ 12.50 mm (0.492 inch) Test force .......... 653.9 51.6 N (147.0 11.6 lb)
Free length after test .......... 86.6 mm (3.41 inch)
(12) 2J-6089 Spring Outside diameter ............ 30.18 mm (1.188 inch)
Length under test force ... 36.25 mm (1.427 inch) (16) Torque for plug ....... 125 15 Nm (92 11 lb ft)
Test force .......................... 278 14 N (62 3 lb)
Free length after test ............... 44.12 0.50 mm (17) 8B-4624 Shim
(1.737 0.020 inch)
Outside diameter ............ 12.50 mm (0.492 inch) Quantity ............................................................ 4
Thickness ......................... 0.81 mm (0.032 inch)
(13) Torque for the nut ...... 60 10 Nm (44 7 lb ft) Pressure change with one shim ... 30 kPa (4 psi)
22 KENR9932-02
Specifications Section
Relief valve pressure setting ......... 586 14 kPa Position Sensor (Hoist Control)
(85 2 psi)
Torque for valve body .................... 185 15 Nm SMCS Code: 1408
(136 11 lb ft)
Part No.: 351-6942
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Illustration 48
Section E-E
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Hoist Cylinder
SMCS Code: 5102
Part No.: 296-0608
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Illustration 50
(1) Torque for the six bolts .................. 475 50 Nm Note: Before assembling internal head (5) to internal
(350 37 lb ft) cylinder (3), apply the following two sealants. Apply
green Loctite 609 anaerobic bearing mount retaining
(2) Rod compound to the internal threads on the rod end
of internal cylinder (3). Apply red Loctite 596 high
Outside diameter of the rod (over temperature RTV silicone sealant to the last three
coating) .............................. 139.650 0.038 mm threads on internal head (5).
(5.4980 0.0015 inch)
(6) External head
(3) Internal cylinder
Inside diameter of head ......... 215.98 0.03 mm
Inside diameter of the (8.503 0.001 inch)
cylinder .. 190.55 0.10 mm (7.502 0.004 inch)
Outside diameter of the cylinder (over (7) Lubricate the sealing lip with a small amount of
coating) .............................. 215.850 0.038 mm the lubricant that is being sealed.
(8.4980 0.0015 inch)
Outside diameter of the cylinder end (two (8) Piston
places) .. 240.00 0.13 mm (9.449 0.005 inch)
Outside diameter of piston (two
(4) External cylinder places) .. 190.00 0.03 mm (7.480 0.001 inch)
Inside diameter of the (9) Torque for the 12 bolts ................... 430 60 Nm
cylinder .. 241.30 0.10 mm (9.500 0.004 inch) (317 44 lb ft)
(5) Internal head Note: Before 12 bolts (9) on the external head are
tightened, rod (2) must be fully extended.
Torque for internal head ............... 870 130 Nm
(642 96 lb ft)
Inside diameter of the internal head (three
places) .... 140.20 .05 mm (5.520 0.002 inch)
24 KENR9932-02
Specifications Section
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Illustration 51
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Cab Mounting
SMCS Code: 7266; 7301
Part No.: 343-8791
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Illustration 52
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Illustration 53
Typical left-hand side view
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Illustration 54 Illustration 55
View A-A View B
(2) Shim
Thickness ............................. 2.0 mm (0.08 inch)
(3) Plate
26 KENR9932-02
Specifications Section
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Illustration 56
View C-C
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Illustration 57
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Specifications Section
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