Global Manpower Development

777G Off-Highway Truck

Operator’s Station
Module 1 - INSTRUCTOR MATERIALS (COMPETENCY STANDARD)

SERV1934

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and may not be used without permission. © 2011 Caterpillar Inc. All Rights Reserved.
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TABLE OF CONTENTS
MODULE DESCRIPTION ......................................................................................................... 3
MODULE PRE-WORK............................................................................................................... 4
RECOMMENDED DELIVERY.................................................................................................... 5
PREPARATION CHECKLIST..................................................................................................... 6
LESSON PLAN ......................................................................................................................... 8
LEARNING OUTCOMES........................................................................................................... 9
LABORATORY EXERCISES..................................................................................................... 10
POST-ASSESSMENT............................................................................................................... 17

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MODULE DESCRIPTION
MODULE OBJECTIVE This module is designed to prepare the technician to locate, identify, and explain the
functions of the components for the 777G Off-Highway Truck Operator’s Station.

Lab exercises and a written post-assessment will be used for skills development and
a knowledge check. Participants will be expected to demonstrate understanding and
proficiency in each major area of instruction.

This module is comprised of approximately 40% theory (classroom presentation)

and 60% practical application (lab exercises).

AUDIENCE Level II--Field service personnel, resident mechanics, Technical Communicators,

and shop technicians. All participants should have a working knowledge of basic
electrical, electronic, and hydraulic control systems on Cat machines.

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MODULE PRE-WORK
PREREQUISITE COURSES Prerequisite courses should be completed prior to participating in this course.

777G Off-Highway Trucks NPI Service Training Course No. 41395

PREREQUISITE TESTS There are no prerequisite tests for this module.

SUGGESTED READING There is no suggested reading for this module.

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RECOMMENDED DELIVERY
TIME Estimated Delivery Time

1 hrs, 45 min

ENVIRONMENT Classroom

Minimum four participants; maximum eight participants

______ Four tables; two-three participants/table

______ Projector

______ Whiteboard

______ Reference materials

Lab

Participant/Instructor ratio = 8:1 (suggested maximum)

______ 777G Off-Highway Truck

REFERENCES Service Manual Modules Form No.

777G Operation and Maintenance Manual (Tier 4) SEBU8095

777G Operation and Maintenance Manual (LRC) SEBU8227

Specalog

777G Off-Highway Truck AEHQ6553

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PREPARATION CHECKLIST
MODULE Prior to conducting the module, gather the following materials:

______ PDF: “777G Off-Highway Truck Introduction,” SERV1934 (included in this

package)

______ PDF: “777G Off-Highway Truck Operator’s Station,” SERV1934 (This PDF
includes the Instructor and Student Material and the Text Reference.)

A printed copy of the following for the classroom or access to SIS Web:

______ “777G Operation and Maintenance Manual (Tier 4)” (SEBU8095)

______ “777G Operation and Maintenance Manual (LRC)” (SEBU8227)

CLASSROOM Prior to delivering the classroom module, perform the following steps:

______ Prepare a safety briefing containing the following information:

-- emergency phone numbers

-- first aid responders
-- location of exits and fire extinguisher
-- room alerts or hazards
-- designated location for evacuation
-- storm shelter
-- hazardous materials

______ Review the 777G Off-Highway Truck Introduction and the 777G Operation
and Maintenance Manual (SEBU8095 or SEBU8227) to become familiar
with the topic.

______ Review the 777G Off-Highway Truck Operator’s Station Text Reference to
become familiar with the topic.

______ Duplicate enough 777G Off-Highway Truck Operator’s Station Student

Materials for each participant in the training session (this includes material
from the Text Reference and Student PDFs).

______ Review the Post-Assessment questions and answers.

­______ Check for applicable Service Magazine articles, Service Letters, and
Technical Information Bulletins related to the topic.

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LAB Prior to conducting the lab exercises, perform the following steps:

______ Prepare a safety briefing for each of the labs to be conducted.

______ Select the 777G Off-Highway Truck to be used in the lab exercises.

______ Review the lab exercises to ensure that participants can demonstrate their
ability to accomplish the objectives.

______ Gather the following tools and material:

1. Mechanic’s tool box with hand tools

2. Make tags for Laboratory Exercise 1

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LESSON PLAN
•P
 rovide each participant with a Participant Introduction, Module Objective, and Learning Outcomes
copy of the module objective and
learning outcomes Instructor and participant introductions, if not already done

Safety briefing, objectives, class agenda, and hand out participant materials,
if not already done

Time Estimate: 15 min

• Visual Presentation Visual Presentation:

• Distribute Lab 1 Worksheets
Classroom visual presentation of machine introduction (as required) and
the operator’s station; participants take notes on component location and
functionality using the Lab 1 Worksheet.

Time Estimate: 30 min

• Conduct Lab 1 Lab 1: Operator’s Station Component Identification

Give safety briefing.

 articipants locate and identify the components inside and outside of the
P
operator’s station completing the Lab 1 Worksheets.

Review completed Lab 1 Worksheet with the class and answer questions.

Time Estimate: 30 min

• Administer Post-Assessment Post-Assessment

Administer post-assessment - Time Estimate: 10 min

Review correct answers with class - Time Estimate: 10 min

Restore Machine

Time Estimate: 10 min

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LEARNING OUTCOMES
Visual Presentation 1. Given a visual presentation in the classroom of the 777G Off-Highway Truck
operator’s station, the participant will take notes on the identification, location, and
functionality of the major components of the operator’s station.

Lab 1 1. Given a 777G Off-Highway Truck and Lab 1 Worksheets, the participant will locate
and identify the operator’s station components during a lab exercise.

Post-Assessment 1. Given a 777G Off-Highway Truck, the participant will identify the correct answers
during a post-assessment.

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LABORATORY EXERCISES
INSTRUCTOR NOTE The following section provides directions to set up, facilitate, and assist during the
lab exercises.

Some lab exercises are the written type with worksheets, while other labs are the
traditional “on the iron” labs. Answers are provided in this document for the worksheet
exercises.

The participant lab sheets, along with accompanying materials, are located in the
Student Material PDF (included in the module PDF).

At the beginning of each lab, review the lab description.

NOTE: Discuss safety procedures with the participants for each shop lab (i.e.
safety glasses, clothing). Safely Home. Everyone. Every Day.™

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LAB 1: Operator’s Station Component Identification

INSTRUCTOR NOTE Lab Exercise

Ensure participants understand the safety zones around the machine. Ensure
participants understand the safe number of people that can be on top of the machine
at the same time. Ensure that participants stay outside the identified safety zones if
the machine is started.

SAFETY Participants will adhere to all applicable safety regulations.

EXERCISE Participants will identify the operator’s station components by matching the lettered
or numbered tags on the components on the class machine with the names on the
Lab 1 Worksheet.

Procedure:

Explain the process for filling out the worksheet (distributed during the slide
presentation).

Inform participants that they may refer to the Operation and Maintenance Manual
or class notes while completing the worksheet, but that they may not confer among
themselves.

Discuss completed worksheets with class.

MATERIALS NEEDED ______ 777G Off-Highway Truck

______ Lab 1 Worksheets

______ Lettered or numbered tags

______ 777G Off-Highway Truck Operation and Maintenance Manual (SEBU8095

or SEBU8227)

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LAB 1: Operator’s Station Component Identification Worksheet

Instructions: Locate and explain the purpose of the following components.

Example: Pilot Pump

Function: controls the operation of the power train hydrostatic transmission

Location: left seat pod

_____ Cab fresh air filter

Function: [Filters operator’s station air]

Location: [Behind the companion seat]

_____ Traction control test switch

Function: [Used to test the traction control system]

Location: [On the overhead switch panel in the operator’s station]

_____ Brake release and secondary steering switch

Function: [Activates the brake release pump and the secondary steering pump]

Location: [On the overhead switch panel in the operator’s station]

_____ Service brake pedal

Function: [Used to modulate the hydraulic engagement of the service brakes on all four wheels]

Location: [On the floor of the operator’s station]

_____ Accelerator pedal

Function: [Controls the engine rpm]

Location: [On the floor of the operator’s station]

_____ Manual retarder control lever

Function: [Regulates the machine speed as the truck is traveling down a grade]

Location: [On the right side of the steering column]

_____ Secondary brake pedal

Function: [Used to quickly stop the machine if the service brake does not function properly]

Location: [On the floor of the operator’s station]

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LAB 1: Operator’s Station Component Identification Worksheet (continued)

_____ Multifunction lever

Function: [Controls the window wipers, the window washer, the headlight brightness, and the turn signals]

Location: [On the left side of the steering column]

_____ Instrument panel

Function: [Contains numerous indicator lights and gauges, which show the operator the status of various machine
parameters and alert the operator of specific machine conditions]

Location: [On the front dash]

_____ Advisor display

Function: [Used to access the data from the VIMS modules, the Engine ECM, and the Machine ECMs]

Location: [On the front dash panel below the instrument panel]

_____ Hazard flasher switch

Function: [Turns the hazard lights on and off]

Location: [Left side of the front dash panel]

_____ Running lights switch

Function: [Controls the headlights, parking lights, and taillights]

Location: [Left side of front dash panel]

_____ Three-way access lights switch

Function: [Activates the right and left stairway lights]

Location: [Left side of front dash panel]

_____ Heated mirror switch

Function: [Controls the heated mirrors]

Location: [On the overhead switch panel in the operator’s station]

_____ WAVS cameras

Function: [Used to view areas around the truck when there is no clear area of sight]

Location: [Mounted at the front, rear, and right side of the machine]

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LAB 1: Operator’s Station Component Identification Worksheet (continued)

_____ Panel dimmer switch

Function: [Changes the intensity of the panel lights]

Location: [Left side of front dash panel]

_____ Key start switch

Function: [Controls engine starting]

Location: [Lower right of front dash panel]

_____ Fan speed switch

Function: [Controls the fan speed]

Location: [Lower right of front dash panel]

_____ Temperature variable control switch

Function: [Sends an input to the Brake ECM to control the temperature in the cab]

Location: [Lower right of front dash panel]

_____ Air conditioner switch

Function: [Three position switch that controls whether the air in the cab will be heated, cooled, or controlled
automatically]

Location: [Lower right of front dash panel]

_____ Fuse/relay panel

Function: [Contains the machine fuses and relays]

Location: [Behind the companion seat in the operator’s station]

_____ Cat ET service connector

Function: [Provides a connection point for Cat ET]

Location: [On the rear panel above the companion seat]

_____ VIMS service connector

Function: [Provides a connection point for VIMSpc]

Location: [On the rear panel above the companion seat]

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LAB 1: Operator’s Station Component Identification Worksheet (continued)

_____ Transmission shift lever

Function: [Allows the operator to select transmission speed and direction]

Location: [On the right console]

_____ Hoist control lever

Function: [Raises and lowers the truck body]

Location: [On the right console]

_____ ARC ON/OFF switch

Function: [Activates the ARC feature]

Location: [To the left of the Advisor panel]

_____ Throttle backup and lock switch

Function: [Used to raise engine rpm above low idle and to maintain engine rpm at full throttle]

Location: [On the right console]

_____ Left window switch

Function: [Raise and lower the left door window]

Location: [On the right console]

_____ WAVS switch

Function: [Overrides the front and rear WAVS cameras]

Location: [On the center console stand in the cab]

____ WAVS monitor

Function: [Displays the views received from the WAVS cameras]

Location: [Overhead or to the right of the steering wheel in the operator’s station]

_____ Air conditioning filter

Function: [Filters air into the air conditioning system]

Location: [Below the left side exterior panel]

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LAB 1: Operator’s Station Component Identification Worksheet (continued)

_____ Work light switch

Function: [Used to turn on the lights on the right and left sides of the machine]

Location: [On the overhead switch panel in the operator’s station]

_____ Economy mode switch

Function: [Three position switch to select either the automatic or manual engine power derate mode]

Location: [On the overhead switch panel in the operator’s station]

_____ Engine brake switch

Function: [Activates the engine compression braking feature used in conjunction with the ARC switch in the ON
position]

Location: [To the left of the Advisor panel]

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POST-ASSESSMENT
INSTRUCTOR NOTE The following post-assessment is a paper test designed to measure the participant’s
understanding of the 777G Off-Highway Truck Operator’s Station. The answers are
provided on the following pages. The actual participant post-assessments are
provided in the Student Materials section.

The module post-assessment may be used as a pre-assessment.

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777G Off-Highway Truck Operator’s Station POST-

ASSESSMENT
INSTRUCTOR NOTE Classroom Post-Assessment

Participants may refer to their course materials and class notes when taking the
post-assessment.

Participants may not consult with others during the post-assessment.

INDIVIDUAL EXERCISE Procedure:

Give participants a copy of the “777G Off-Highway Truck Operator’s Station Post-
Assessment.”

Explain the post-assessment.

MATERIALS NEEDED _______ 777G Off-Highway Truck Operator’s Station Post-Assessment

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777G Off-Highway Truck Operator’s Station Post-Assessment

Instructions: Select the correct answer(s) for each question.

1. The parking brakes are engaged when ________________________.

a. the parking brake button is pressed

b. [the transmission shift lever is moved to PARK]

c. the hoist control lever is moved to FLOAT

d. the service brake pedal is depressed

2. The ET connector is located __________.

a. inside a box, which is installed near the front of the engine

b. [behind the companion seat]

c. behind the operator’s seat

d. in the engine compartment

3 If the ARC switch is in the ON position and on a downgrade, the machine is slowed down using the __________.

a. retarder lever

b. front and rear mechanical brakes

c. [engine braking system]

d. front brakes

4. The engine idle shutdown function is activated by the operator by moving the key start switch to the __________ position.

a. START

b. OFF

c. [STOP]

d. ON

5. The parking brakes are designed to hold the truck stationary, in gear, with the engine at __________ RPM.

a. 1400

b. 1300

c. [1200]

d. 1100
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