769D/771D/773E TIER II AND 775E TIER I EMISSSIONS O F F - H I G H WAY T R U C K S

2002 Caterpillar Inc.

769D/771D/773E/775E MAINTENANCE

ice 773E Serv Procedure

WALK AROUND INSPECTION

10 HOURS DAILY MAINTENANCE CHECKS

AIR FILTERS AND PRECLEANERS BATTERIES DISCONNECT SWITCH PRIMARY FUEL FILTER/ WATER SEPARATOR RADIATOR DEBRIS AND COOLANT LEVEL BELTS AND ETHER CYLINDERS ENGINE OIL LEVEL WINDSHIELD WASHER LEVEL AIR RESERVOIR MOISTURE WASH WINDOWS, CAB FRESH AIR FILTERS, SEAT BELT, INDICATORS, GAUGES AND BRAKE TESTS, SECONDARY STEERING AND BACK-UP ALARM STEERING OIL LEVEL BRAKE CYLINDER BREATHERS TRANSMISSION AND TORQUE CONVERTER OIL LEVEL HOIST AND BRAKE OIL LEVEL

SUSPENSION CYLINDER HEIGHT REAR AXLE BREATHER

INSPECT FRAME FOR CRACKS AND BODY SUPPORT PADS CHECK FOR LEAKS AND TRASH BUILD-UP

775D

SUSPENSION CYLINDER HEIGHT AND GREASE BREATHERS

CHECK FUEL LEVEL AND DRAIN MOISTURE

WHEEL NUTS

TIRE INFLATION PRESSURE

CATERPILLAR MONITORING SYSTEM

769D/771D/773E/775E OFF-HIGHWAY TRUCKS
GAUGE CLUSTER MODULE SPEED/TACH MODULE - GAUGES - MONITORING - WARNINGS - CLOCK SYNCHRONIZATION 1F - MACHINE ID DISPLAY DATA LINK SERVICE TOOL CAT DATA LINK BRAKE ECM (ARC) (TCS) - EMISSIONS CONTROL - FUEL INJECTION - ETHER INJECTION - FAN CONTROL - ENGINE PRE-LUBE TRANSMISSION/ CHASSIS ECM - TRACTION ASSIST - RETARDING - OVERSPEED RETARDING - RETARDING LAMP RS232 LINK - ICM CONTROL - NEUTRAL-START - BACK-UP ALARM - OVERSPEED PROTECTION - CTS - ENGINE PRE-LUBE - DIRECTIONAL SHIFT MANAGEMENT - AUTOLUBE - TOP GEAR LIMIT - REVERSE NEUTRALIZE - LOAD COUNTER - NEUTRAL COAST INHIBIT - BODY UP GEAR LIMIT - STARTER PROTECTION - BODY HOIST CONTROL - SECONDARY STEERING - SPEED LIMITER ACTION ALARM MESSAGE CENTER MODULE ACTION LAMP

C kPa MilesKMRPM Liter SERV CODE X10

. . .

INPUT COMPONENTS

ENGINE ECM

TPMS

- PAYLOAD MEASUREMENT - STRUT DIAGNOSTICS

CATERPILLAR MONITORING SYSTEM

FOUR-GAUGE CLUSTER MODULE SPEEDOMETER/ TACHOMETER MODULE ACTION LAMP OPERATOR MODE SCROLL SWITCH MESSAGE CENTER MODULE ALERT INDICATORS

15 10 5 20 25 X100

TCS AUT

R
24 V 0 MPH km/h 30

41.4
TCS

SERV CODE

GROUND SPEED

ACTUAL GEAR

DISPLAY WINDOW

CATERPILLAR MONITORING SYSTEM

MESSAGE CENTER MODULE

INPUT COMPONENTS
HARNESS CODE PLUG OPERATOR MODE SWITCH SERVICE SWITCH CLEAR SWITCH FUEL LEVEL SENDER BRAKE OVERSTROKE SWITCH TRANSMISSION FILTER SWITCH BRAKE OIL TEMP SENSOR TORQUE CONVERTER OIL TEMP SENSOR ALTERNATOR R-TERMINAL BRAKE AIR PRESSURE

C kPa Miles KM RPM Liter SERV CODE X10

CAT DATA LINK

ELECTRONIC SERVICE TOOL ENGINE ECM BRAKE ECM TRANSMISSION/CHASSIS ECM

OUTPUT COMPONENTS
GAUGE CLUSTER MODULE

1F

SPEED/TACH MODULE

ACTION LAMP

ACTION ALARM

OPERATOR MODES
INPUTS
SERVICE METER MODE ODOMETER MODE DIGITAL TACHOMETER MODE RESETTABLE LOAD COUNTER MODE DIAGNOSTIC SCROLLING MODE
MILES or KM SERV CODE

41.4 170
RPM

- ENGINE SPEED/TIMING SENSOR - ALTERNATOR "R" TERMINAL - ENGINE OIL PRESSURE - TRANSMISSION OUTPUT SPEED SENSOR

700 L 027
MID

- ENGINE SPEED/TIMING SENSOR

74
SERV CODE

- BODY UP SWITCH (AFTER 10 SECONDS ACTIVATION) USE "C" SERVICE SWITCH TO CLEAR
SERV CODE

0709.05
CID FMI

End
- "P" DURING PRE-LUBRICATION

- "E" DURING ETHER INJECTION

SERVICE MODES
HARNESS CODE MODE NUMERIC READOUT MODE

-1C

52 88

SERV CODE

USE "S" SERVICE SWITCH TO SCROLL GAUGES C kPa

-2-

95
GA-2 (brake oil)
SERV CODE

715
GA-3 (system air)
SERV CODE

75
GA-4 (fuel) USE "S" SERVICE SWITCH TO SCROLL FAULTS USE "C" SERVICE SWITCH TO CLEAR FAULTS USE "C" SERVICE SWITCH TO CLEAR

GA-1 (engine coolant) SERVICE MODE

-3-

---

027
MID

0709.05
CID FMI

LOG MODE

-4-5-6-7L n

LOG
MILES

ALL GAUGES AND INDICATORS DISPLAY EXTREME CONDITIONS RECORDED

KM

UNITS MODE PERMANENT LOAD COUNT MODE DIAGNOSTIC AND PROGRAMMING MODE

US 1057 n 3 F

SI

USE "C" SERVICE SWITCH TO CHANGE UNITS

3FL

USE "S" SERVICE SWITCH TO SCROLL SUB-MODES

MODE 7 SUB-MODES MODES - 7.1 n n

RPM USE "S" SERVICE SWITCH TO SCROLL SUB-MODES SHIFT MONITORING MODE

1 r

1 r

3 F

3F L

LEFT SIDE--SHIFT LEVER

RIGHT SIDE--TRANSMISSION GEAR

- 7.2 - 7.3 - 7.4 - 7.5 -

T C E HL

1 8 3 4
RPM

TRANSMISSION OUTPUT SPEED (TOS) DISPLAY MODE TORQUE CONVERTER OUTPUT SPEED (COS) DISPLAY MODE ENGINE OUTPUT SPEED (EOS) DISPLAY MODE

- - - RPM

1 8 3 4 0 H

USE OPERATOR SCROLL SWITCH TO TOGGLE FROM INPUT TO OUTPUT

HL

4 0 L

HL

8 0 R
FIRST

HL 1 0 0 F
SECOND

HO
THIRD

0 S

HOIST DISPLAY MODE--SENSOR INPUT TO ECM or ECM OUTPUT TO SOLENOIDS NEUTRAL REVERSE

- 7.6 -

0 0 01 11

0 0 1 0 11

0 0 1 1 01
ECONOMY SHIFT MODE FIRST

0 0 1 1 10
J1 PINS

0 1 0 0 11
36 33 32 31 30 29

TRANSMISSION GEAR SWITCH INPUT MODE

1 = OPEN 0 = GROUNDED

- 7.7 -

OFF
REVERSE

ON
NEUTRAL

USE "C" SERVICE SWITCH TO TURN ON or OFF SECOND THIRD

- 7.8 -

0 0 0 1 11

0 0 10 11

0 0 1 1 01

0 0 1 1 10
J1 PINS

0 1 0 0 11
23 27 19 35 24 14

TRANSMISSION SHIFT LEVER SWITCH INPUT MODE

1 = OPEN 0 = GROUNDED

8 OR 12 INJECTORS

3408E/3412E HEUI SYSTEM

ELECTRONIC CONTROL MODULE (ECM) ENGINE HARNESS MACHINE HARNESS TDC TIMING PROBE CONNECTOR MACHINE INTERFACE CONNECTOR

COMPONENT DIAGRAM
GROUND BOLT 15 AMP BREAKER DISCONNECT SWITCH 24 V

INJECTION ACTUATION PRESSURE (IAP) CONTROL VALVE INJECTION ACTUATION PRESSURE (IAP) PRESSURE SENSOR PRIMARY SPEED/TIMING SENSOR SECONDARY SPEED/TIMING SENSOR COOLANT TEMPERATURE SENSOR TURBO OUTLET PRESSURE SENSOR ATMOSPHERIC PRESSURE SENSOR ENGINE OIL PRESSURE SENSOR ENGINE OIL TEMPERATURE SENSOR FUEL TEMPERATURE SENSOR COOLANT FLOW SWITCH

MAIN POWER RELAY

KEY SWITCH

CRANK WITHOUT INJECTION PLUG

THROTTLE SENSOR

TURBO INLET PRESSURE SENSOR ENGINE PRELUBE RELAY ATA AND CAT DATA LINK ELECTRONIC SERVICE TOOL START AID ON RELAY TRANSMISSION/CHASSIS ECM BRAKE ECM

THROTTLE BACK-UP THROTTLE LOCK

C kPaMilesKM RPM Liter SERV CODE X10

MESSAGE CENTER MODULE

. ..

MANUAL ETHER INJECTION