Field Installation of the Traction Control System for the 770, and 772 Off-Highway Trucks{1408, 3288, 4257, 4294, 4801, 4811, 5057, 7610, 7620, 7960} Caterpillar

Off-Highway Truck/Tractor:

770 (S/N: BZZ1-UP)

772 (S/N: RLB1-UP)

Introduction

This Special Instruction contains the necessary information for installing the Traction Control System in the field.

The suggested tools and equipment should be present prior to starting the installation procedures. If the recommended tools and equipment are not present, installation will be more difficult and more time will be necessary to complete the assembly.

Safety

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Do not attempt to assemble this machine until you read and you understand the assembly instructions. Improper assembly procedures could result in injury or death.

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Personal injury or death can result from improper lifting or blocking. When a hoist or jack is used to lift any part or component, stand clear of the area. Be sure the hoist or jack has the correct capacity to lift a component. Install blocks or stands before performance of any work under a heavy component. Approximate weights of the components are shown. Clean all surfaces where parts are to be installed.

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Sudden movement or accidental starting of the machine can cause personal injury or death to persons on or near the machine. To prevent personal injury or death, perform the following: Park the machine on a smooth level surface. Lower the bucket and or attachments to the ground. Stop the engine and engage the parking brake. Block the wheels and install the steering frame lock. Turn the battery disconnect switch to the OFF position and remove the key. Place a Special Instruction, SEHS7332, "Do Not Operate" tag at the battery disconnect switch location to inform personnel that the machine is being worked on.

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Personal injury can result from hydraulic oil pressure and hot oil. Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic system. Make sure all of the work tools have been lowered to the ground, and the oil is cool before removing any components or lines. Remove the oil filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand.

Do not perform any procedures in this publication or order any parts until you understand the information that is included in this publication.

ReferenceSystems Operation, Testing and Adjusting, and Troubleshooting, "770, and 772 Off-Highway Truck/Tractors Chassis Electronic Control System"

ReferenceOperation and Maintenance Manual, "770 Off-Highway Truck"

ReferenceOperation and Maintenance Manual, "772 Off-Highway Truck"

ReferenceParts Manual, "770 S/N:BZZ1-UP Off-Highway Truck"

ReferenceParts Manual, "772 S/N:RLB1-UP Off-Highway Truck"

Parts List

Installation of the Speed Sensor

Installation of the 204-0761 Speed Sensor Gp

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Illustration 1	g01308545

Note: The plug is installed in order to prevent contaminants from entering the housing.

1. Remove plug (A) .

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Illustration 2	g01309148

2. Install speed sensor (1) and O-ring (2) .

3. Tighten sensor (1) to a torque value of 30 ± 4 N·m (265 ± 35 lb in).

4. Repeat Step 1 through Step 3 for the other sensor.

Installation of the 279-9017 Speed Sensor Gp

1. Remove tires, wheels, brake lines, the axle, and the rear spindle. Refer to the Power Train Disassembly and Assembly, "Spindle - Remove".

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Illustration 3	g01309335

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Illustration 4	g01309259

2. Position ring (1) into the rear spindle.

3. Position housing (4) onto the spindle. Position plate (3) over housing (4). Apply 155-0695 Thread Lock Compound to the threads of six bolts (7). Install six bolts (7) and six washers (6) in order to hold assembly to the spindle. Tighten bolts (7) to a torque value of 30 ± 5 N·m (266 ± 44 lb in).

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Illustration 5	g01416804

4. Position clamp (2) onto the axle shaft.

   Note: The distance (A) from the outward end of the axle shaft to clamp (2) is 1017 mm (40.04 inch) for a 770 truck.

   Note: The distance (A) from the outward end of the axle shaft to clamp (2) is 1099 mm (43.27 inch) for a 772 truck.

5. Apply 155-0695 Thread Lock Compound to the threads of two bolts (5). Tighten bolts (5) to a torque value of 30 ± 5 N·m (265 ± 45 lb in) in order to secure clamp (2) on the axle shaft.

6. Stake the top edge of the counterbore on clamp (2) in order to retain bolts (5) .

7. Install the spindle, the axle, brake lines, the wheel, and the tire. Refer to Disassembly and Assembly, "Service and Parking Brake (Rear) - Install".

   Note: Align clamp (2) on the axle to the notches in timing gear (1) in order to install the axle.

8. Repeat Step 1 through Step 7 for the other side.

Installation of the Traction Control Valve

Installation of the 222-4744 Traction Control Valve Gp

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Illustration 6	g01416943

1. Install hose fitting (2), hose fitting (3), hose fitting (4), hose fitting (5), hose fitting (6), and hose fitting (7) on traction control valve (1) .

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Illustration 7	g01310859

2. Locate the mounting plate on the inside of the frame.

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Illustration 8	g01104788

3. Position traction control valve (1) with a suitable lifting device. The weight of the traction control valve is 25 kg (55 lb).

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Illustration 9	g01417127

4. Use three washers (9), one bolt (10), and two bolts (8) to mount the traction control valve to the frame.

Lines Group Installation

Installation of 270-1756 Attachment Lines

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Illustration 10	g01417313
Top view of the service brake lines group

1. Remove bolt (A), washer (B), and clip (C), in order to remove hose (D). Retain bolt (A), washer (B), and clip (C). Discard hose (D) .

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Illustration 11	g01417333
Top view of the slack adjuster

2. Remove elbow (E), two connectors (F), and block assembly (G). Discard all hardware.

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Illustration 12	g03014043
Right side view of the brake valve

3. Disconnect hose (H) from elbow (J). Remove elbow (J). Discard elbow (J) .

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Illustration 13	g01417450
Right side view of the parking brake valve

4. Remove plug (K). Discard plug (K) .

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Illustration 14	g01417489
Left side view of the brake valve

5. Install tee assembly (1). Connect hose (H) that was removed in Step 3 to tee assembly (1) .

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Illustration 15	g01417499
Left side view of the brake valve

6. Connect hose (2) to tee assembly (1) .

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Illustration 16	g01417526
Right side view of the traction control valve

7. Connect hose (2) to traction control valve (L) .

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Illustration 17	g01417549
Front view of the slack adjuster

8. Install two elbows (3) and two elbows (4) .

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Illustration 18	g01417577
Front view of the slack adjuster

9. Connect hose (5) and hose (6) to two elbows (4) .

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Illustration 19	g01417590
Right side view of the traction control valve

10. Connect hose (5) to elbow (M). Connect hose (6) to elbow (N) .

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Illustration 20	g01417596
Right side view of the parking brake valve

11. Connect hose (7) to the parking brake valve.

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Illustration 21	g01417632

12. Connect tube (8) to hose (7) .

    Note: Ensure that O-ring (9) is between hose (7) and tube (8) prior to assembly.

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Illustration 22	g01417640
Right side view of the traction control valve

13. Connect tube (8) to the traction control valve.

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Illustration 23	g01417643
Left side view of the parking brake valve

14. Connect hose (10) to the parking brake valve.

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Illustration 24	g01417924
Right side view of the traction control valve

15. Connect hose (10) to the traction control valve.

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Illustration 25	g01417925
Top view of the service brake lines group

16. Reinstall bolt (A), washer (B), and clip (C). These parts were removed in Step 1.

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Illustration 26	g01417941
Top view of the service brake lines group

17. Use one bolt (13), two washers (14), and one nut (15) in order to secure clip (11) and clip (12) .

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Illustration 27	g01417955
Top view of the service brake lines group

18. Use bolt (16) and washer (14) in order to secure clip (12) .

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Illustration 28	g01417958
Right side view of the service brake lines group

19. Use bolt (16) and washer (14) in order to secure clip (17) .

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Illustration 29	g01417968
Right side view of the service brake lines group

20. Use bolt (16) and washer (14) in order to secure clip (12) .

Installation of the Traction Control Wiring Group

Installation of 270-1509 Traction Control Wiring Gp

Illustration 30	g01418008
Top view

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Illustration 31	g01418009
View A-A (A) 222-4744 Traction Control Valve Gp

1. Install harness (1) at two locations (B) on valve (A) .

2. Install clip (2) in order to secure harness (1) to valve (A) .

3. Connect harness (1) to the existing chassis harness.

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Illustration 32	g01418045
View B-B

4. Install harness (3) to the chassis.

5. Use bolts (4), washers (5), and clips (6) in order to secure harness (3) .

6. Use clip (7) and strap (8) in order to secure harness (3) .

7. Connect harness (3) to the existing chassis harness.

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Illustration 33	g01418061
View C-C

8. Connect harness (3) to the speed sensors.

   Note: The sensor harness must be secured no more than 104 mm (4.1 inch) from the sensor and a minimum radius of 10 mm (0.4 inch) from the sensor. The harness connector should be oriented horizontally. Point the connector downward in order to prevent water and debris from collecting inside the connector.

9. Use bolts (9), washers (5), and nuts (10) in order to secure clips (7) .

10. Use bolts (9), washers (5), and nuts (10) in order to secure clip (12) .

11. Use straps (8) in order to attach harness (3) to clips (7) and clip (12) .

Installation of the 259-8902 Rocker Switch

Installation of the Test Switch

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Illustration 34	g01417202
Front view of dash (A)

1. Remove five bolts (B) in order to loosen dash (A). Retain five bolts (B) .

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Illustration 35	g01417208
Rear view of dash (A)

2. Compress the tabs on cover (C). Remove cover (C) from dash (A). Remove cover (C) from existing harness (D). Discard cover (C) .

3. Connect rocker switch (1) to existing harness (D) .

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Illustration 36	g01417230
Front view of dash (A)

4. Reinstall harness (D) and rocker switch (1) into dash (A) .

5. Reinstall five bolts (B) that were removed in Step 1.

Software Enabling Process

1. All of the components and the attachments must be installed in order to complete the software enabling process.

2. Connect Cat Electronic Technician (ET) with the Cat Communications Adapter and necessary cables.

3. Select the "Traction Control System" feature in order to enable the system from the Cat ET configuration screen. Click the "change" tab.

   Note: The Cat ET configuration screen may not list the feature that needs enabled. The ECM will need to be flashed to the latest machine or engine software.

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Illustration 37	g01322629
View of typical factory password screen

4. Record the following data from the Cat ET screen. This data is required to obtain the Factory Level Security Passwords.
   • Serial Number for the Service Tool

   • Machine or Engine Serial Number

   • ECM Serial Number

   • Total Tattletale

   • Reason Code

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Illustration 38	g01322635
View of web site for Factory Password System

5. Go to the Factory Password System:
   https://fps.cat.com
   

   You may also click the hyperlink at the bottom of Illustration 37 if you have an internet browser and access to Corporate Web Security. Enter the required data from Step 4 into the Factory Password System in order to receive the passwords. If you do not have access to the Factory Password System, contact your Technical Communicator.

   In the "Invoiced Dealer" field, enter the dealer code that is registered to the license for your Cat ET. If you enter any other dealer code, an error message will be displayed, and no passwords will be issued. The price of the "CONFIG-PREMIUM" part number will be shown in the parts system. Clicking "SUBMIT" will initiate the invoicing process to the dealer.

   If you are uncertain of the dealer code for your Cat ET, go to the following web site:

   https://on-linelicensing.cat.com
   

   Search on your Cat ET license number. Record the bill to the dealer code that is assigned to your license. You will need an internet browser and access to Corporate Web Security to go to this site.

6. Reconnect Cat ET.

7. Reopen the Cat ET Configuration screen.

8. Select the desired parameter and click on the "Change" button.

9. Enter the passwords that were obtained from the Factory Password System in Step 5 in order to enable the feature.

10. The key start switch will need to be cycled from "ON" to "OFF" to "ON" in order to enable the "CONFIG-PREMIUM" feature. You can verify that the feature is enabled by viewing the ET configuration screen.

Support Information

For support for the Factory Level Security Password, contact the following sources:

• Internet Browser with access to Corporate Web Security

• Phone (24 hours per day and 7 days per week)

309-636-8500

Available Literature

• The Special Instruction, REHS1238 provides basic instructions on obtaining Factory Level Security Passwords.