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


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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} [REHS3708]
BRAKING SYSTEM
LINES GP
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}
1.1. Introduction
2.1. Safety
3.1. Parts List
4.1. Installation of the Speed Sensor
5.2. Installation of the 204-0761 Speed Sensor Gp
6.2. Installation of the 279-9017 Speed Sensor Gp
7.1. Installation of the Traction Control Valve
8.2. Installation of the 222-4744 Traction Control Valve Gp
9.1. Lines Group Installation
10.2. Installation of 270-1756 Attachment Lines
11.1. Installation of the Traction Control Wiring Group
12.2. Installation of 270-1509 Traction Control Wiring Gp
13.1. Installation of the 259-8902 Rocker Switch
14.2. Installation of the Test Switch
15.1. Software Enabling Process
16.2. Support Information
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

------ WARNING! ------

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.

----------------------

------ WARNING! ------

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.

----------------------

------ WARNING! ------

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.

----------------------

------ WARNING! ------

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.

----------------------


NOTICE

Do not allow any dirt or foreign material to get into the hydraulic system during assembly, connection of lines, when components are filled with fluid, or during any maintenance operation.



NOTICE

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.

Refer to Special Publication, NENG2500, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat products.

Dispose of all fluids according to local regulations and mandates.


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

Table 1
Required Part for Installation of 204-0761 Speed Sensor Gp    
Qty     Part Number     Description    
2     204-0761     Speed Sensor Gp    
2     3K-0360     O-Ring Seals    

Table 2
Required Parts for Installation of 279-9017 Speed Sensor Gp    
Qty     Part Number     Description    
2     6G-0969     Rings    
2     6G-1999     Clamps    
2     279-8822     Plates    
2     279-8823     Housings    
4     1T-0284     Bolts    
12     6V-5839     Washers    
12     6V-5842     Bolts    

Table 3
Required Parts for Installation of 222-4744 Traction Control Valve Gp    
Qty     Part Number     Description    
1     222-4744     Traction Control Valve Gp    
2     148-8360     Elbow As (1)    
1     153-6242     Connector As (1)    
1     131-5681     Connector (1)    
1     148-8315     Connector (1)    
1     148-8393     Elbow As (1)    
1     148-8340     Connector As (1)    
2     7X-0299     Bolts (1)    
3     8T-4896     Hard Washers (1)    
1     7X-0301     Bolt (1)    
( 1 ) This item is from the 270-1756 Attachment Lines .

Table 4
Required Parts for Installation of 270-1756 Attachment Lines    
Qty     Part Number     Description    
1     148-8436     Tee As    
1     275-9247     Hose As    
2     153-6231     Union As    
2     150-3035     Elbow As    
1     275-9249     Hose As    
1     275-9250     Hose As    
1     280-7533     Hose As    
1     280-4116     Tube As    
1     7J-9108     O-Ring Seal    
1     302-1499     Hose As    
2     9X-8250     Clips    
3     6V-1889     Clips    
1     8T-4136     Bolt    
5     8T-4121     Hard Washers    
1     8T-4133     Nut    
3     8T-4137     Bolts    
1     6K-8178     Clip    

Table 5
Required Parts for Installation of 270-1509 Traction Control Wiring Gp    
Qty     Part Number     Description    
1     235-0078     Solenoid Harness As    
1     149-9129     Clip    
1     272-8406     Sensor Harness As    
2     8T-4137     Bolts    
18     8T-4121     Hard Washers    
2     6D-3479     Clips    
8     4P-7581     Clips    
8     3S-2093     Cable Straps    
8     8T-4136     Bolts    
8     3S-2093     Cable Straps    
8     174-5907     Clips    
2     130-5300     Clips    

Table 6
Required Parts for Installation of 259-8902 Rocker Switch    
Qty     Part Number     Description    
1     232-0314     Rocker Switch    

Table 7
Required Parts for the Software Enabling Process    
Qty     Part Number     Description    
1     271-9383     Premium Configuration (1)    
( 1 ) This attachment will be charged to the customer when the factory level security password is obtained.

Installation of the Speed Sensor

Installation of the 204-0761 Speed Sensor Gp

Table 8
Required Parts for Installation of 204-0761 Speed Sensor Gp    
Item     Qty     Part Number     Description    
1     2     204-0761     Speed Sensor Gp    
2     2     3K-0360     O-Ring Seals    



    Illustration 1g01308545

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

  1. Remove plug (A) .



    Illustration 2g01309148

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

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

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

Installation of the 279-9017 Speed Sensor Gp

Table 9
Required Parts for Installation of 279-9017 Speed Sensor Gp    
Item     Qty     Part Number     Description    
1     2     6G-0969     Rings    
2     2     6G-1999     Clamps    
3     2     279-8822     Plates    
4     2     279-8823     Housings    
5     4     1T-0284     Bolts    
6     12     6V-5839     Washers    
7     12     6V-5842     Bolts    

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



    Illustration 3g01309335



    Illustration 4g01309259

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

  1. 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).



    Illustration 5g01416804

  1. 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.

  1. 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.

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

  1. 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.

  1. 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

Table 10
Required Parts for Installation of 222-4744 Traction Control Valve Gp    
Item     Qty     Part Number     Description    
1     1     222-4744     Traction Control Valve Gp    
2     2     148-8360     Elbow As (1)    
3     1     153-6242     Connector As (1)    
4     1     131-5681     Connector (1)    
5     1     148-8315     Connector (1)    
6     1     148-8393     Elbow As (1)    
7     1     148-8340     Connector As (1)    
8     2     7X-0299     Bolts (1)    
9     3     8T-4896     Hard Washers (1)    
10     1     7X-0301     Bolt (1)    
( 1 ) This item is from the 270-1756 Attachment Lines .



    Illustration 6g01416943

  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) .



    Illustration 7g01310859

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



    Illustration 8g01104788

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



    Illustration 9g01417127

  1. 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

Table 11
Required Parts for Installation of 270-1756 Attachment Lines    
Item     Qty     Part Number     Description    
1     1     148-8436     Tee As    
2     1     275-9247     Hose As    
3     2     153-6231     Union As    
4     2     150-3035     Elbow As    
5     1     275-9249     Hose As    
6     1     275-9250     Hose As    
7     1     280-7533     Hose As    
8     1     280-4116     Tube As    
9     1     7J-9108     O-Ring Seal    
10     1     302-1499     Hose As    
11     2     9X-8250     Clips    
12     3     6V-1889     Clips    
13     1     8T-4136     Bolt    
14     5     8T-4121     Hard Washers    
15     1     8T-4133     Nut    
16     3     8T-4137     Bolts    
17     1     6K-8178     Clip    



    Illustration 10g01417313

    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) .



    Illustration 11g01417333

    Top view of the slack adjuster

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



    Illustration 12g03014043

    Right side view of the brake valve

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



    Illustration 13g01417450

    Right side view of the parking brake valve

  1. Remove plug (K). Discard plug (K) .



    Illustration 14g01417489

    Left side view of the brake valve

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



    Illustration 15g01417499

    Left side view of the brake valve

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



    Illustration 16g01417526

    Right side view of the traction control valve

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



    Illustration 17g01417549

    Front view of the slack adjuster

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



    Illustration 18g01417577

    Front view of the slack adjuster

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



    Illustration 19g01417590

    Right side view of the traction control valve

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



    Illustration 20g01417596

    Right side view of the parking brake valve

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



    Illustration 21g01417632

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

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




    Illustration 22g01417640

    Right side view of the traction control valve

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



    Illustration 23g01417643

    Left side view of the parking brake valve

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



    Illustration 24g01417924

    Right side view of the traction control valve

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



    Illustration 25g01417925

    Top view of the service brake lines group

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



    Illustration 26g01417941

    Top view of the service brake lines group

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



    Illustration 27g01417955

    Top view of the service brake lines group

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



    Illustration 28g01417958

    Right side view of the service brake lines group

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



    Illustration 29g01417968

    Right side view of the service brake lines group

  1. 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

Table 12
Required Parts for Installation of 270-1509 Traction Control Wiring Gp    
Item     Qty     Part Number     Description    
1     1     235-0078     Solenoid Harness As    
2     1     149-9129     Clip    
3     1     272-8406     Sensor Harness As    
4     2     8T-4137     Bolts    
5     18     8T-4121     Hard Washers    
6     2     6D-3479     Clips    
7     8     4P-7581     Clips    
8     8     3S-2093     Cable Straps    
9     8     8T-4136     Bolts    
10     8     3S-2093     Cable Straps    
11     8     174-5907     Clips    
12     2     130-5300     Clips    



Illustration 30g01418008

Top view




    Illustration 31g01418009

    View A-A

    (A) 222-4744 Traction Control Valve Gp

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

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

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



    Illustration 32g01418045

    View B-B

  1. Install harness (3) to the chassis.

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

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

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



    Illustration 33g01418061

    View C-C

  1. 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.

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

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

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

Installation of the 259-8902 Rocker Switch

Table 13
Required Parts for Installation of 259-8902 Rocker Switch    
Item     Qty     Part Number     Description    
1     1     232-0314     Rocker Switch    

Installation of the Test Switch




    Illustration 34g01417202

    Front view of dash (A)

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



    Illustration 35g01417208

    Rear view of dash (A)

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

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



    Illustration 36g01417230

    Front view of dash (A)

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

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

Software Enabling Process

Table 14
Required Parts for the Software Enabling Process    
Qty     Part Number     Description    
1     271-9383     Premium Configuration (1)    
( 1 ) This attachment will be charged to the customer when the factory level security password is obtained.

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

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

  1. 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.




    Illustration 37g01322629

    View of typical factory password screen

  1. 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




    Illustration 38g01322635

    View of web site for Factory Password System

  1. 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.

  1. Reconnect Cat ET.

  1. Reopen the Cat ET Configuration screen.

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

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

  1. 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

https://fps.cat.com/

  • 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.

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