SESV1661

Service Training
Meeting Guide 661 SESV1661
TECHNICAL PRESENTATION
769C/771C/773B/775B
MAINTENANCE
ice
769C Serv
Procedu re
769C/771C/773B/775B
OFF-HIGHWAY TRUCKS
MAINTENANCE
769C/771C/773B/775B OFF-HIGHWAY TRUCKS
MAINTENANCE
MEETING GUIDE 661 SLIDES AND SCRIPT
AUDIENCE
Level I - Operators and service personnel responsible for performing daily maintenance and scheduled
preventive maintenance on Off-highway Trucks.
CONTENT
This presentation illustrates graphics and machine views similar to those used in the Operation and
Maintenance Manuals. The Operation and Maintenance Manual must be used in conjunction with this
presentation.
OBJECTIVES
After learning the information in this presentation, the student will be able to:
1. identify and explain the coolant, fuel and lubrication requirements;
2. locate and identify all filters and service points in a walk-around inspection; and
3. perform the proper maintenance procedures.
REFERENCES
768C/769C Operation and Maintenance Manual SEBU6747
772B/773B Operation and Maintenance Manual SEBU6748
771C Operation and Maintenance Manual SEBU6749
775B Operation and Maintenance Manual SEBU6750
Cold Weather Recommendations Operation and Maintenance Manual SEBU5898
Estimated Time: 4 Hours

Visuals: 101 (2 X 2) Slides
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SUPPLEMENTAL MATERIAL
Specification Sheets
769C Off-highway Truck AEHQ3871

771C Off-highway Truck AEHQ3872
773B Off-highway Truck AEHQ3873
775B Off-highway Truck AEHQ3874
Salesgrams
Cat Truck Update 769C/773B/771C/775B TELQ3903

Cat 769C/773B/771C/775B/777C Automatic Retarder Control TELQ3731
Caterpillar Thermostatic Fan for Construction/Mining Trucks TELQ3727
Video Tapes
"769/773/777 Truck Operating Tips" TEVN1757

"771C/775B Quarry Truck Introduction" TEVN2296
"Oil In Your Engine" LEVN9001
"Contamination Control In Power Train and Hydraulic Systems" PEVN2368
Service Training Meeting Guide
STMG 512 "Battery Maintenance" SESV1512
Technical Instruction Module
"769C - 793B Off-highway Trucks--Suspension System" SEGV2599
Booklets
Application Guide 769C/773B vs 771C/775B AEDK2975

Time and Cost Record SEBD0694
Daily Work and Cost Record (small booklet) SEDA0536
Questions and Answers About Batteries PEDP2105
Know Your Cooling System SEBD0518
Diesel Fuels and Your Engine SEBD0717
Oil and Your Engine SEBD0640
Engine Oils: Today and Tomorrow PEDP9107
A Guide for Managing Your Hydraulics PEDP1137
Caterpillar Hose and Couplings Reference Guide PECP3301
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SUPPLEMENTAL MATERIAL
Product Support Bulletins
How Diesel Engines Work and Wear TECB6006

Introduction To Transmissions TECB9119
Product Training Bulletin
Cat Diesel Engine Oil (CF-4) TEJB0913
Special Instructions
Battery Test Procedure SEHS7633

Use of 6V4040 Nitrogen Tire Inflation Group SMHS7867
Cleaning Drivetrain Systems After Transmission Oil To Water Cooler Failure SEHS9054
Suspension Cylinder Servicing SEHS9411
Using the 6V2150 Starting Charging Analyzer SEHS7768
Brochures
Caterpillar Batteries--The Tough Performers PEDP1164

Six Ways to Keep Your Cooling System Working Right PEDP9113
How to Take a Good Oil Sample PEHP6001
Air Filter Service Indicator PEHP9013
Cat Diesel Engine Oil...an integral part of our engines PEDP2209
Fight Fuel Sulfur SEBD0598
How to Reduce Your Engine Costs PEDP0050
How to Reduce Your Transmission Costs PEDP0051
Intelligence of Powerful Connections AEDK2966
A Guide for Managing Engine Performance and Life PEDP7101
Caterpillar Oil-cooled Multiple Disc Brakes AEDK2546
Caterpillar Automatic Retarder Control AEDK2926
769C/773B/771C/775B Truck Bodies AEDK0115
769C/773B/771C/775B Improved Operator Environment AEDK0116
Customer Meeting Parts Sales Slide Package
Cat Filters, Batteries, Fluids and Hardware PEKP4052
Miscellaneous
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TABLE OF CONTENTS
INTRODUCTION ........................................................................................................................7
Material Overview ..................................................................................................................8
SAFETY .......................................................................................................................................9
GENERAL INFORMATION .....................................................................................................20

Specifications and Model Views...........................................................................................20
Product Identification and Serial Number Locations............................................................28
MACHINE OPERATION...........................................................................................................34
Monitoring Systems and Cab Features .................................................................................34
Machine Controls..................................................................................................................41
Machine Walk-around Inspection .........................................................................................49
After Starting the Engine ......................................................................................................50
Towing Information ..............................................................................................................52
MAINTENANCE .......................................................................................................................60
Tire Inflation ........................................................................................................................60
Cooling System.....................................................................................................................62
Fuel Specifications................................................................................................................66
Lubrication System ...............................................................................................................68
Scheduled Oil Sampling (S•O•S)..........................................................................................69
Lubrication Specifications ....................................................................................................71
Lubrication Viscosities and Refill Capacities .......................................................................74
MAINTENANCE INTERVALS.................................................................................................79
When Required .....................................................................................................................80
10 Service Hours or Daily.....................................................................................................85
50 Service Hours or Weekly .................................................................................................92
250 Service Hours or Monthly..............................................................................................95
500 Service Hours or Three Months.....................................................................................99
1000 Service Hours or Six Months.....................................................................................104
2000 Service Hours or One Year.........................................................................................110
3000 Service Hours or Two Years.......................................................................................113
SLIDE LIST..............................................................................................................................116
SERVICEMAN'S HANDOUTS ...............................................................................................118

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INSTRUCTOR NOTES
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INTRODUCTION
• Refer to Operation and The maintenance procedures for the 769C/771C/773B/775B Off-highway
Maintenance Manual Trucks will be discussed in detail throughout this presentation. This
training material is to be used in conjunction with the Operation and
Maintenance Manual for the particular truck being discussed.
NOTE TO THE INSTRUCTOR: See "References" on Page 2 for the

Operation and Maintenance Manual that corresponds with the
particular truck being discussed.
All component locations and maintenance information for the 769C

and 771C trucks are identical, and the same is true for the 773B and
the 775B. Whenever the 769C or the 773B trucks are referenced, it
should be assumed that the information is also valid for the 771C or
775B Quarry Trucks.
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769C/771C/773B/775B
MAINTENANCE
ice
769C Serv
Procedure
Material Overview
• Subjects parallel This presentation is to be used in conjunction with the Operation and
manual Maintenance Manual. The subject matter and the order of topics
discussed parallel the Operation and Maintenance Manual. Some topics
covered in the Operation and Maintenance Manual will not be discussed
in this presentation, but other material available in the Caterpillar
• Supplementary
literature distribution system will be referenced for supplementary
material is referenced
information.
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WARNING
SAFETY
3
SAFETY
Safe work habits must be second nature while working on or around

heavy equipment. Personal safety must be of utmost concern while
performing maintenance procedures. Critical safety points are highlighted
in the following pages.
• Safety Alert Symbol
This slide illustrates the safety alert symbol. The meaning of this safety
alert symbol is as follows:
WARNING
Attention! Become Alert! Your Safety is Involved. Failure to Follow

Safety Procedures Could Result in Injury or Death.
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• Read Operation and Located in the cab, this warning label (arrow) informs the operator that he
Maintenance Manual must read and understand the Operation and Maintenance Manual before
Warning (arrow)
operating the machine. Improper machine operation is dangerous and
could result in injury or death.
• Manual located in seat

back
The warning also tells the operator that the Operation and Maintenance
Manual is located in the holder located on the seat back.
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• ROPS warning (arrow) The Rollover Protective Structure (ROPS) warning label (arrow), located
above the right cab door, informs service personnel that altering (such as
welding on or drilling holes in the structural members) the ROPS may
weaken the ROPS.
The protection offered by the ROPS will be impaired if it has been

subjected to structural damage such as an overturn accident.
A ROPS is designed to provide operator crush protection in a rollover by

controlled bending of its structural members.
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1. Front suspension The front suspension cylinder upper warning label (1) informs service
cylinder warning personnel that removal of the front suspension cylinder cover or valves
will cause the truck to drop suddenly if not properly blocked. Serious
injury or death could result if a person is trapped between the tire and the
platform or fender.
2. Front suspension
cylinder warning The front suspension cylinder lower warning label (2) informs service
personnel that the front suspension cylinder contains high pressure. Do
not remove any valve, hydraulic fitting or valve cover, nor disassemble
any parts until all pressure has been relieved.
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• Rear suspension The rear suspension cylinder warning labels (arrows) inform service
cylinder warning personnel that the rear suspension cylinders contain high pressure. Do not
(arrows)
remove any valve, hydraulic fitting or valve cover, nor disassemble any
parts until all pressure has been relieved.
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• Brake cylinder The brake cylinder warning label (arrow) informs service personnel that
warning (arrow) the brake cylinders contain compressed spring force. Improper
disassembly can cause the chamber parts to separate with enough force to
cause personal injury.
The brake cylinders are located behind the hydraulic tank on the left side
of the truck.
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1. Battery warning The battery warning label (1) informs service personnel that improper
jumper cable connections can cause explosions resulting in personal
injury.
The brown information label located just below the battery warning label
informs service personnel how to connect battery jumper cables.
When jump starting the vehicle is necessary, proper safety precautions

must be followed to avoid personal injury, or to avoid damaging the
electrical system of the starting vehicle or the one being jump started. Be
sure to read and understand the warnings on the machine and in the
Operation and Maintenance Manual before jump starting the machine.
2. Battery disconnect
switch
The battery disconnect switch (2) is located in the battery compartment.
NOTICE
Never turn the disconnect key off with the engine running. Engine
damage could result.
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WARNING
Batteries give off flammable fumes that can explode resulting in

personal injury.
Prevent sparks near batteries. They could cause vapors to explode.

Do not allow jump cable ends to contact each other or the machine.
Do not smoke when checking battery electrolyte levels. Electrolyte is

an acid and can cause personal injury if it contacts skin or eyes.
Always wear eye protection when starting a machine with jumper

cables.
Always connect the battery positive (+) to battery positive (+) and the
battery negative (-) to stalled machine frame (-).
NOTE TO THE INSTRUCTOR: For additional information on

battery maintenance, see the following publications:
STMG 512 "Battery Maintenance" Form SESV1512

Special Instruction "Battery Test Procedure" Form SEHS7633
Booklet "Questions and Answers About
Batteries" Form PEDP2105
Brochure "Caterpillar Batteries--The Tough
Performers" Form PEDP1164
Slide Package "Cat Filters, Batteries, Fluids
and Hardware" Form PEKP4052
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WARNING WARNING
do not do not remove

operate this tag
signed by
see other side
date
SEHS7332
Side 1 Side 2
10
• Do Not Operate Tag This slide illustrates the DO NOT OPERATE tag.
WARNING
Attach a DO NOT OPERATE or similar warning tag to the start

switch or controls before servicing or repairing the machine.
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AT LEAST 500 m (1500 ft) AT LEAST 15 m (50 ft)
TIRE
EXPLOSION
ZONE
11
• Tire explosion zone This slide illustrates the tire explosion zone. It is important that service
personnel stay out of the zone as much as possible when adjusting the
• Stand behind tread
pressure in the tires. Service personnel should stand behind the tread and
use a self-connecting chuck when inflating a tire.
• Use self-connecting
chuck
Dry nitrogen (N2) gas is recommended by Caterpillar for inflation of tires.
• Inflate with dry
nitrogen
WARNING
To prevent possible personal injury, do not approach a warm tire

closer than the outside of the area represented by the shaded area in
the above illustration.
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2
1
12
1. Body up retaining Body up retaining pins (1) must always be installed through the pin holes
pins in the frame and the body before working under the body.
• Disconnect hoist lever

The hoist lever linkage must also be disconnected to prevent lowering of
linkage when body is
up
the body while the engine is running. The retaining pins may not prevent
the body from lowering if the hoist lever is moved to the LOWER
position while the engine is running.
2. Back-up alarm
The back-up alarm (2) will sound when the transmission control lever is
in the reverse position. The alarm is used to alert people behind the
machine that it is backing up.
• Back-up alarm volume
is adjustable
The volume of the back-up alarm can be regulated with a switch at the
rear of the alarm.
WARNING
To prevent personal injury or death, do not work under the truck

with the body (bed) raised. When it is necessary to work under the
truck with the body raised, install the body retaining pins through the
pin holes in the frame and the body, and disconnect the hoist lever
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STEERING HYDRAULIC TANK FUEL TANK
BATTERIES
AIR FILTERS
RADIATOR BODY LOCK

PINS
DIFFERENTIAL
ENGINE
AIR RESERVOIRS FINAL DRIVES
RADIATOR
BODY LOCK
ENGINE PINS
FRONT FINAL
WHEEL BEARINGS HOIST, CONVERTER TRANSMISSION DRIVES
AND BRAKE OIL TANK
HYDRAULIC TANK
13
GENERAL INFORMATION
Specifications and Model Views
• 769C/771C
This slide illustrates a top and side view of the 769C/771C Off-highway
Components
Trucks. Some of the truck components are identified.
NOTE: The major differences between the 769C/771C and the

773B/775B are the locations of the hoist cylinders and the
transmission. On the 769C/771C, the hoist cylinders are located
inside of the main frame rails and the transmission is mounted near
the frame crosstube toward the center of the machine.

machine specifications, see the following:
Specification Sheet "769C Off-highway Truck" Form AEHQ3871

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769C/771C POWER FLOW
14
• 769C/771C Power train Power flows from the engine to the rear wheels through the power train.
components In this illustration, the power train components and their locations on the
769C/771C are identified by their color. The components of the
769C/771C power train are:
Gray - Engine
Red - Torque Converter
Blue - Transfer Gears
Orange - Front and Rear Drive Shafts
Green - Transmission
Brown - Differential
Yellow - Final Drive
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3
2
1
5
6 4
15
• 769C Model view - Shown is the right side of the 769C truck. Some of the components that
right side are visible from the right side of the truck are:
1. Battery compartment
2. Air filters 2. Air filters
3. Steering tank 3. Steering tank
4. Front wheel bearings
4. Front wheel bearings (behind access cover)
5. Fuel tank
5. Fuel tank
6. Final drive
6. Final drive
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3 2
16
• 769C Model view - left Shown is the left side of the 769C truck. Some of the components that are
side visible from the left side of the truck are:
1. Body lock pins

1. Body lock pins
2. Transmission oil 2. Transmission oil tank
tank
3. Hoist, converter and brake hydraulic tank
3. Hoist, converter and 4. Air reservoirs
brake hydraulic tank
4. Air reservoirs NOTE: Two service/retarder brake air reservoirs are located below
the cover on top of the hoist, converter and brake hydraulic tank.
One parking/secondary brake air reservoir is located in the
compartment behind the operator's cab.
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STEERING HYDRAULIC TANK FUEL TANK
BATTERIES
AIR FILTERS
RADIATOR BODY LOCK

PINS
DIFFERENTIAL
ENGINE
AIR RESERVOIRS FINAL DRIVES
RADIATOR
BODY LOCK
ENGINE PINS
FRONT FINAL
WHEEL BEARINGS HOIST, CONVERTER TRANSMISSION DRIVES
AND BRAKE OIL TANK
HYDRAULIC TANK
17
• 773B/775B This slide illustrates a top and side view of the 773B/775B Off-highway
Components Trucks. Some of the truck components are identified.
NOTE: The major differences between the 769C/771C and the

773B/775B are the locations of the hoist cylinders and the
transmission. On the 769C/771C, the hoist cylinders are located
inside of the main frame rails and the transmission is mounted near
the frame crosstube toward the center of the machine.
On the 773B/775B, the hoist cylinders are located outside of the main
frame rails and the transmission is mounted to the differential on the
rear axle housing.

machine specifications, see the following:
Specification Sheet "773B Off-highway Truck" Form AEHQ3873

Specification Sheet "775B Off-highway Truck" Form AEHQ3874
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773B/775B POWER FLOW
18
• 773B/775B Power train Power flows from the engine to the rear wheels through the power train.
components In this illustration, the power train components and their locations on the
773B/775B are identified by their color. The components of the
773B/775B power train are:
Gray - Engine
Red - Torque Converter
Blue - Transfer Gears
Orange - Drive Shaft
Green - Transmission
Brown - Differential
Yellow - Final Drive
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2
3
5 4
6
19
• 773B Model view - Shown is the right side of the 773B truck. Some of the components that
right side are visible from the right side of the truck are:
2. Air filters 2. Air filters
3. Steering tank 3. Steering tank
4. Front wheel bearings (behind access cover)
4. Front wheel bearings
5. Fuel tank
5. Fuel tank 6. Final drive
6. Final drive
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3 2
20
• 773B Model view - left Shown is the left side of the 773B truck. Some of the components that are
side visible from the left side of the truck are:
1. Body lock pins

1. Body lock pins
2. Transmission oil 2. Transmission oil tank
tank
3. Hoist, converter and brake hydraulic tank
3. Hoist, converter and 4. Air reservoirs
brake hydraulic tank
4. Air reservoirs NOTE: Two service/retarder brake air reservoirs are located below
the cover on top of the hoist, converter and brake hydraulic tank.
One parking/secondary brake air reservoir is located in the
compartment behind the operator's cab.
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PRODUCT IDENTIFICATION AND SERIAL NUMBER LOCATIONS
COMBINATION SERVICE
INFORMATION PLATE
ENGINE
INFORMATION
PLATE
ENGINE
SERIAL
NUMBER
PRODUCT IDENTIFICATION TRANSMISSION

NUMBER (PIN) SERIAL NUMBER
769C/771C FRONT ARROW
773B/775B REAR ARROW
21
Product Identification and Serial Number Locations
• Serial number plate This slide illustrates the location of the Product Identification Number
locations (PIN), Engine Serial Number, Transmission Serial Number, Combination
Service Information plate and the Engine Information plate on the Off-
highway Trucks.
• Serial numbers
required for ordering
When performing maintenance on the trucks, it may be necessary to order
parts and service replacement parts. To be assured of receiving the correct parts, the Dealer
information needs the identification numbers from your specific machine. The serial
number of the machine and the major components (transmission, engine,
etc.) should be recorded for ordering parts, service specifications and
maintenance procedures.
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22
• Product Identification The Product Identification Number (PIN) plate (arrow) is located on the
Number (PIN) plate left side of the machine frame in front of the left tire.
(arrow)
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23
• Engine Serial Number The Engine Serial Number plate (arrow) is located on the left side of the
plate (arrow) engine block near the front of the engine.
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24
• Transmission Serial The Transmission Serial Number plate (arrow) is located on the left side
Number plate (arrow) of the transmission near the top of the housing.
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25
• Combination Service The Combination Service Information plate (arrow) is located on the left
Information plate side of the steering column in the cab. The Combination Service
(arrow)
Information plate contains the model number, serial number, and the
arrangement number of the machine, the engine and the transmission.
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26
• Engine Information The Engine Information plate (arrow) is located on the right side of the
plate (arrow) engine on a valve cover. The Engine Information plate contains the
model number, serial number, arrangement number, performance
specifications (commonly referred to as the "0T" specifications),
maximum altitude, static fuel setting (rack setting), rated horsepower,
high idle rpm and full load rpm of the engine.
• Engine performance
specs are on the The information on the Engine Information plate is critical if the
Engine Information performance of the engine must be tested or adjusted.
plate
NOTE TO THE INSTRUCTOR: The engine information plate
location is not shown in the Operation and Maintenance Manual.
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27
MACHINE OPERATION
Monitoring Systems and Cab Features
• Front panel
Shown is the right side of the front panel. The engine start switch is
components:
shown at the lower left. To the right of the engine start switch are several
rocker switches. The rocker switches control (from left to right):
• Rocker switches (left
to right) - Park, tail and head lights
- Park, tail and head
lights - Supplemental steering and brake retraction (for towing)
- Supplemental
steering and brake - Starting aid (ether solenoid)
retraction (towing)
- Starting aid (ether - Push down on BOTTOM half--Electronic Monitoring System (EMS)
solenoid) functional test
Push down on TOP half--Automatic Electronic Traction Aid (AETA)
- Bottom half--EMS
functional test functional test
Top half--AETA
functional test - Automatic Retarder Control (ARC)
- ARC
- Not used
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• Electronic Monitoring Directly above the rocker switches is the Electronic Monitoring System
System panel (arrow) (EMS) panel (arrow). This panel, combined with an action light and an
action sound indicator, provides three categories of information to the
operator.
Category 1: Only the Light Emitting Diode (LED) on the panel turns on,
requiring operator awareness. Examples of Category 1 information are:
parking brake ENGAGED, alternator not charging, and plugged or
restricted fuel filter.
Category 2: The LED on the panel and the action light turn on, requiring
operator response. Examples of Category 2 information are: high coolant
temperature, high torque converter/brake oil temperature, and plugged or
restricted transmission filter.
Category 3: The LED on the panel, the action light and the action sound
indicator turn on, requiring immediate shutdown of the truck. Examples
of Category 3 information are: low coolant flow, low engine oil pressure,
low brake air pressure, brake system failure (overstroke of the brake
cylinder), and low steering oil flow.
• EMS LED's (top row): The LED's on the EMS panel represent the following systems:
- Transmission oil
filter Top row (from left to right)
- Brake air pressure
- Transmission oil filter
- Engine oil pressure
- Brake air pressure
- Coolant flow - Engine oil pressure
- Coolant flow
• EMS LED's (bottom - Coolant temperature
row):
- Steering Bottom row (from left to right)

- Fuel
- Steering
- Alternator - Fuel
- Brake ON - Alternator
- Converter/retarder
- Brake ON
- Converter/retarder temperature
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28
• Front panel Located on the left side of the front panel are (from top to bottom):
components:
- Front brake ON/OFF - Front brake ON/OFF switch

switch - Air system pressure gauge
- Air system pressure - Windshield wiper/washer switch
gauge
- Windshield
wiper/washer switch
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29
• Front panel gauges: Located in the center of the front panel are four gauges. The gauges
- Converter/retarder monitor the following:
oil temperature
(upper left) - Converter/retarder oil temperature (upper left)
- Brake air pressure - Brake air pressure (lower left)
(lower left) - Tachometer
- Tachometer
- Speedometer
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FRONT DASH PANEL

769C/771C/773B/775B
RPM
MPH
MAN.
CAT P
AUT.
AUT
30
• Front panel back lit Located above the gauges are several indicators that cannot normally be
indicators: seen but will illuminate when their function is selected. The indicators are
- Left directional and as follows:
warning hazard
- Retarder ON Starting in the upper left corner (from left to right)
- High beam
- Left directional and warning hazard indicator
- EMS action light - Retarder ON indicator
- Right directional and - High beam indicator
warning hazard - EMS action light (Categories 2 and 3)
- Right directional and warning hazard indicator
To the right of the speedometer (above the key start switch)

- Engine overspeed
- Engine overspeed indicator
- Supplemental
steering ON - Supplemental steering ON indicator
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31
• Transmission actual On top of the console is the transmission actual gear indicator (arrow).
gear indicator (arrow) The actual gear indicator displays to the operator the gear in which the
transmission is operating.
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1 2
32
1. Starting and Behind the operator's seat are the starting and charging diagnostic
charging diagnostic connector (1), the service hour meter (2) and the CAT Data Link
connector
connector (3).
2. Service hour meter
3. CAT Data Link A service tool can be connected to the starting and charging diagnostic
connector connector which allows a serviceman to check for existing or potential
problems in the starting and charging electrical system.
Another service tool can be connected to the CAT Data Link connector
which allows a serviceman to program, diagnose faults or retrieve logged
information from the Electronically Programmable Transmission Control
(EPTC II).
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33
Machine Controls
1. Transmission shift To the right of the operator's seat is the shift console. Located on the shift
lever
console are the transmission shift lever (1) and the parking brake air
2. Parking brake air switch (2).
switch
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2
1
34
1. Service brake pedal On the floor are the service brake pedal (1) and the accelerator pedal (2).
2. Accelerator pedal
Above the brake and accelerator pedals are the fuses and circuit breakers.
• Fuses and circuit
breakers
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35
• Secondary brake lever Operator controls on the steering column are the secondary brake lever
(red) (red) and the retarder lever (black).
• Retarder lever (black)
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36
1. Tilt steering lock On the left side of the steering column are the tilt steering lock (1) and the
2. Turn signal and turn signal and hazard switch (2).
hazard switch
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37
1. Dimmer switch On the floor to the left of the steering column are the dimmer switch (1)
2. Horn button and the horn button (2).
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38
• Heating and air Shown are the heating and air conditioning controls located on the front
conditioning controls of the passenger (buddy) seat.
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39
• Hoist control lever The hoist control lever (arrow) activates the four positions of the hoist
(arrow) control valve. The four positions are: RAISE, HOLD, FLOAT and
LOWER.
• Reverse inhibitor
operation
A reverse inhibitor switch is located in the cab behind the operator’s seat
on the hoist lever linkage. If the transmission is in REVERSE when the
body is being raised, the reverse inhibitor switch is used to shift the
transmission to NEUTRAL. The transmission will remain in NEUTRAL
until:
1. The hoist lever is moved into the HOLD or FLOAT position; and
2. the shift lever has been cycled into and out of NEUTRAL.
• Operator's seat
Also shown is the operator's seat, which includes the seat belt and
numerous seat adjustment levers.
STMG 661 - 48 -
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40
• Operator cab Shown is an overall view of the operator's compartment.
NOTE TO THE INSTRUCTOR: For additional information on the

operator's compartment, the Electronic Monitoring System (EMS),
machine controls and operating techniques, see the video tape:
"Truck Operating Tips--769/773/777 Trucks" Form TEVN1757
The video tape listed above shows earlier trucks with a different dash
design. Although the dash is a different design, all switches and
controls operate the same.
STMG 661 - 49 -
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STEERING OIL LEVEL CHECK FUEL LEVEL

AND DRAIN MOISTURE
BATTERIES
AIR FILTER
RESTRICTION INDICATOR
SUSPENSION
COOLANT LEVEL CYLINDER HEIGHT
ENGINE OIL LEVEL REAR AXLE

BREATHER
BELTS INSPECT FRAME

FOR CRACKS
CHECK FOR LEAKS

AND TRASH BUILD-UP
WALK-AROUND
INSPECTION DRAIN
AIR RESERVOIR WHEEL
MOISTURE NUTS
WINDOWS
SEAT BELT
SUSPENSION
CYLINDER
HEIGHT TIRE INFLATION
PRESSURE
HOIST, CONVERTER TRANSMISSION

AND BRAKE OIL LEVEL OIL LEVEL
41
• Walk-around Machine Walk-around Inspection

Inspection
For maximum service life of the machine, make a thorough walk-around
inspection before mounting the truck or starting the engine.
In addition to checking the items listed above during the walk-around

inspection, look around and under the truck for loose or missing bolts,
trash build-up or coolant, fuel or oil leaks. Look for indications of cracks.
Pay close attention to high stress areas as shown in the Operation and
Maintenance Manual.
NOTE TO THE INSTRUCTOR: Slides of the walk-around

inspection items are included in the maintenance interval slides.
These slides can be shown following slide No. 40 to emphasize the
points, or wait and discuss the walk-around items later in the
presentation.
STMG 661 - 50 -
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AFTER STARTING THE ENGINE
• Engine oil indicator must go off in 15 seconds
• Idle engine for five minutes
• All EMS indicators must be off
• Warm up engine and hydraulic system
• Check oil levels at low idle with warm oil
• Test parking/secondary brake system
• Test service/retarder brake system
• Check all gauges are in safe operating range
42
• After starting the After Starting the Engine

engine
After starting the engine, several important checks must be made before
operating the machine. They are as follows:
1. EMS engine oil
indicator must go 1. The EMS engine oil pressure indicator must go off within 15
seconds. If not, stop the engine immediately and investigate.
2. Idle engine for five
minutes 2. Allow the engine to operate at LOW IDLE for a minimum of five
minutes without engaging any controls. Operating at LOW IDLE
will ensure that lubrication oil reaches all necessary components.
3. All EMS indicators
must be OFF 3. All EMS indicators must be OFF, except the parking brake
indicator, which will be ON until the parking brake is released.
STMG 661 - 51 -
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4. Warm up engine 4. Warm up the engine and hydraulic systems by steering left to right
and hydraulic against the stops and raising and lowering the body.
5. Check oil levels at

5. After all oil compartments are at operating temperature, with the
idle with warm oil
engine at LOW IDLE, check the engine oil, steering oil level,
transmission oil level and the hoist, converter and brake oil level.
6. Test
parking/secondary 6. Test the parking/secondary brake system. With air pressure at
brake system maximum and the parking brake engaged, put the shift lever in
FIRST GEAR. Accelerate the engine until the machine moves.
The machine must not move below 1200 rpm.
7. Test
service/retarder
brake system
7. Test the service/retarder brake system. Repeat step six with the
parking brakes released and the service brakes engaged.
8. Check gauges are
in safe operating
range 8. Check that all gauges are in a safe operating range.
NOTE: In temperatures above 0°C (32°F), warm-up requires

approximately 15 minutes.
In temperatures below 0°C (32°F), warm-up requires approximately

30 minutes or until the hydraulic functions are not sluggish.
STMG 661 - 52 -
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1 2
3 4
43
• Towing information Towing Information
The applicable machine warnings must be read and understood before

transporting or towing the machine. Refer to the Operation and
Maintenance Manual for additional information.
• Use cables with
strength 1.5 times Connect a towing machine to the front and/or rear of the truck using
weight of towing cables with a strength of at least 1.5 times the gross weight of the towing
machine machine.
1. Truck towing points
Connect cables to the front of the truck at the designated towing points.
2. Front towing
Connect cables to the rear of the truck with the pin located in the rear
3. 769C rear towing pin
frame. The 769C pin location (3) and the 773B pin location (4) are
4. 773B rear towing pin shown.
NOTE: When towing a truck downhill, it is recommended that a

second machine is connected to the rear of the disabled truck to
prevent it from rolling toward the towing machine.
STMG 661 - 53 -
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AIR SUPPLY
PARK BRAKE RELEASE FROM PARKING BRAKE
AIR SWITCH
NORMAL OPERATION
PARKING
RELIEF VALVE
BRAKE
RELEASE
PARKING BRAKE VALVE
RELEASE PUMP
CHECK VALVE
DIVERTER
VALVE TOWING
PUMP
DIVERTER VALVE SUPPLEMENTAL

CLAMP BOLTS STEERING
PUMP
44
• Parking brake system Shown is a schematic of the parking brake system during NORMAL
- Normal operation OPERATION with the parking brakes released.
Normally, oil flows from the parking brake release pump through the
parking brake release filter and a check valve to the parking brake release
valve. Oil also flows to a diverter valve and is blocked at the diverter
valve. When the parking brakes are released, an air supply from the
parking brake air switch in the cab moves a spool in the parking brake
release valve down. Supply oil can then flow to the parking brake piston
and release the parking brakes.
• Towing pump oil flows
to hydraulic tank When the key start switch is turned ON, the supplemental steering system
during supplemental
is energized for three seconds to check the system. Since the towing
steering test
pump is driven by the same electric motor as the supplemental steering
pump, the diverter valve allows the towing pump oil to flow directly to
the hydraulic tank during the supplemental steering test.
STMG 661 - 54 -
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AIR SUPPLY
AIR SWITCH
DURING TOWING
RELIEF VALVE PARKING
BRAKE
RELEASE
PARKING BRAKE VALVE
RELEASE PUMP
CHECK VALVE
DIVERTER
VALVE TOWING
PUMP

PUMP
45
• Parking brake system Shown is a schematic of the parking brake system during TOWING with
- During towing the parking brakes released.
• Towing pump is
If the parking brakes need to be released for service work or towing, an
energized with
supplemental
electric motor can be energized with the supplemental steering/brake
steering/brake retraction switch on the dash in the cab. The electric motor then drives
two pumps. One pump provides supply oil for releasing the parking
brakes and the second pump supplies oil for supplemental steering.
• Diverter valve must be
shifted before towing A diverter valve must be shifted before the towing pump can supply oil to
the parking brake system. To shift the diverter valve, loosen the two
diverter valve clamp bolts and slide the plate and the spool to the left.
After the spool is shifted, tighten the diverter valve clamp bolts. Now,
when the electric motor is energized, supply oil will flow from the towing
STMG 661 - 55 -
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• Check valve prevents A check valve prevents supply oil from the towing pump from flowing to
oil flow to normal the normal parking brake release pump.
parking brake release
Towing supply oil flows through the parking brake release valve to
• Air supply required for
towing release the parking brakes as long as supply air is available from the
parking brake air switch in the cab.
• Brake release
pressure controlled During towing and normal operation, the brake release pressure is
by relief valve in controlled by the relief valve located in the parking brake release valve.
NOTE: Before normal operation of the parking brake release system

can occur, the diverter valve must be shifted back to its normal
operating position.
STMG 661 - 56 -
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2
1
46
1. Supplemental The supplemental steering pump (1) and the towing pump (2) are located
steering pump above the torque converter (below the frame).
2. Towing pump
STMG 661 - 57 -
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47
• Diverter valve (arrow) The diverter valve (arrow) must be shifted before towing. On the
769C/771C, the diverter valve is located on the left hoist cylinder bracket
(769C shown). On the 773B/775B, the diverter valve is located on the
left frame behind the hydraulic tank.
To shift the diverter valve, loosen the two diverter valve clamp bolts and
slide the plate and the spool to the left. After the spool is shifted, tighten
the diverter valve clamp bolts. Now, when the electric motor is energized,
supply oil can flow from the towing pump through the diverter valve to
the parking brake release valve.
STMG 661 - 58 -
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1 2
3 4
48
1. Diverter valve clamp To review, the basic steps required to tow a truck are:
bolts
2. 6V3965 Pressure Tap - Connect a towing machine to the front and/or rear of the truck with
3. Parking brake air
cables of acceptable strength.
switch
- Loosen the diverter valve clamp bolts (1) and shift the diverter valve
4. Supplemental
steering/brake
bracket and spool to the left (as you face the valve).
retraction switch
- Install a 6V3965 Pressure Tap and an 8T0856 Gauge [0 - 6000 kPa
• Steps to tow a truck:
(0 - 870 psi)] on the parking brake release filter (2) with a gauge hose
- Connect towing long enough to permit monitoring of the parking brake release
machine pressure in the cab.
- Shift diverter valve
- Monitor parking
- Put the parking brake air switch (3) in the RELEASE position.
brake release
pressure in cab - Turn the key start switch to the ON position and energize the
- Put parking brake air supplemental steering/brake retraction switch (4) on the dash. The
switch in RELEASE parking brake release pressure should increase to 3790 kPa (550 psi).
position
- Put key start switch

and supplemental
steering/brake
retraction switch in
ON positions
STMG 661 - 59 -
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• Minimum pressures NOTE: The parking brake release hydraulic pressure must increase
required to release the to a minimum of 3170 kPa (460 psi) on 769C/771C trucks and
parking brakes
3790 kPa (550 psi) on 773B/775B trucks. During towing, the
supplemental steering/brake retraction switch on the dash must be
energized whenever the parking brake release pressure decreases
below these pressures or the brakes will drag.
At least 550 kPa (80 psi) air pressure must be available at the parking
brake release valve to ensure full release of the brakes for towing.
The operator can stop the truck during towing with the parking
brake air switch in the cab.
STMG 661 - 60 -
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TIRE INFLATION
49
MAINTENANCE
• Tire inflation
Tire Inflation
The topic of this section is tire inflation, tire shipping pressure, and proper
inflation procedures. Be sure to use the Operation and Maintenance
Manual to obtain the proper inflation techniques and pressure
recommendations.
• Radial tires use "Star"
rating system The term "Two Star" is used by tire manufacturers to represent the
strength index (load carrying capacity) for large industrial radial tires.
The "Star" rating system is similar to the "Ply Rating" system used for
bias ply tires.
STMG 661 - 61 -
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• Dry nitrogen gas is Dry nitrogen (N2) gas is recommended by Caterpillar for tire inflation on
recommended for tire all rubber tire machines. Nitrogen is an inert gas and will not support
inflation
combustion inside the tire.
• Dry nitrogen reduces
risk of explosion, tire
In addition to reducing the risk of explosion, using nitrogen to inflate tires
oxidation and rim lessens the slow oxidation of the rubber and gradual tire deterioration.
Corrosion of rim components is reduced and, therefore, disassembly is
easier.
A tire inflated in a warm shop area, 18°C to 21°C (65°F to 70°F), will be
underinflated if the machine works in freezing temperatures. Low tire
pressure shortens the life of a tire.
• Adjust tire inflation
pressures for cold
When operating in freezing temperatures, refer to the "Cold Weather
weather
Recommendations Operation and Maintenance Manual" (Form
SEBU5898) for adjusted tire inflation pressures.
• Always obtain The operating tire inflation pressure is based on the weight of a
inflation pressure ready-to-work machine without attachments, at rated payload, and in
from tire manufacturer average operating conditions. Operating tire pressures may vary for each
application or job site. Always obtain the correct operating tire inflation
pressure from the tire manufacturer.
NOTE TO THE INSTRUCTOR: For additional information on tire

inflation, see the Special Instruction:
"Use of 6V4040 Nitrogen Tire Inflation Group" Form SMHS7867

STMG 661 - 62 -
8/94
COOLING SYSTEM
50
• Cooling system Cooling System
This section covers cooling system maintenance. Diesel engine operating

temperatures have increased to improve engine efficiency and meet new
emission requirements. Proper maintenance of the cooling system is
essential to engine life.
• Cooling system
problems Cooling system related problems are:
- Overheating
- Overcooling
- Pitting
- Cavitation Erosion
- Cracked Heads
- Piston Seizures
• 40% of engine failures - Plugged Radiators
result from cooling
Over 40% of engine failures result from cooling system problems.
STMG 661 - 63 -
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WATER REQUIREMENTS
• Use distilled water whenever possible
• Use water analysis
• Never use salt water
• Never use water alone
51
• Water is critical to The water used in the cooling system is critical for good cooling system
cooling system performance.
performance
• Water requirements Some important water requirements are:
- Use distilled or deionized water whenever possible to prevent acids

- Use distilled water
or scale deposits in the cooling system. Acids and scale deposits
result from contaminants that are found in most common water
- Use water analysis sources.
- Use water analysis. If distilled water is not available, select the best
- Never use salt water
quality fresh water available and use water analysis to define the
water quality.
- Never use water
- Never use salt water.
- Never use water alone. All water is corrosive at engine operating

temperatures without supplemental coolant additives. Also, water
STMG 661 - 64 -
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CRITICAL COOLING SYSTEM POINTS
• 3 to 6% Coolant Conditioner
• 30 to 60% Caterpillar Antifreeze
• Correct Operating Temperature
• Correct Operating Pressure
• Fill System Slowly
• Adjust Fan Belts
• Keep Radiator Fins Straight and Clean
52
• Critical Cooling Some critical points to remember when servicing the cooling system are:
System Points
• Maintain 3 - 6%
• Maintain a 3 - 6% concentration of coolant conditioner.
coolant conditioner
- Too much conditioner will form insoluble salts that cause water
pump seal wear, plugging and will coat parts with excessive
deposits that prevent heat transfer.
- Not enough conditioner will result in severe cavitation erosion
which will pit and corrode cylinder liner and block surfaces.
- To prevent overinhibitting, never use both the liquid supplemental
coolant additive and the supplemental coolant additive element at
the same time.
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• Maintain 30 - 60% • Maintain a 30 - 60% concentration of Caterpillar Antifreeze.

Caterpillar Antifreeze
- More than 60% antifreeze concentration will reduce freeze
protection and cause radiator plugging.
- Less than 30% antifreeze concentration will result in cavitation
erosion which will pit and corrode cylinder liner and block
surfaces and decrease water pump life.
- Most commercial antifreezes are formulated with high silicate
content for gasoline engines and are not recommended for diesel
engines.
• Maintain correct
operating temperature • The engine should operate between 88 and 99°C
(190 and 210°F).
- Operating below this temperature range will cause overcooling
problems.
- Operating above this temperature range will cause overheating
problems.
• Maintain correct
cooling system
pressure • Cooling system pressure should be between 55 and 110 kPa
(8 and 16 psi).
- Raising the pressure raises the boiling point. If the pressure is
inadequate, the coolant will boil over and the engine will
• Do not fill cooling overheat.
system too fast
• Do not fill the cooling system faster than 20 l/min. (5 gpm).

- Filling the cooling system faster than 20 l/min. (5 gpm) will cause
• Adjust fan belts
air pockets that could produce damaging steam.
• Keep radiator fins

straight and clean • Keep fan belts adjusted.
• Keep radiator cooling fins straight and clean.

cooling system, see the following publications:
Product Support Bulletin "How Diesel

Engines Work and Wear" Form TECB6006
Booklet "Know Your Cooling System" Form SEBD0518
Brochure "Six Ways to Keep Your
Cooling System Working Right" Form PEDP9113
STMG 661 - 66 -
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D
FUEL SPECIFICATIONS
53
Fuel Specifications
This section provides information on the fuel recommendations by

Caterpillar to keep the Off-highway Trucks running properly.
NOTE TO THE INSTRUCTOR: For additional information on fuel,

see the following publications:
Product Support Bulletin "How Diesel

Engines Work and Wear" Form TECB6006
Booklet "Diesel Fuels and Your Engine" Form SEBD0717
Brochure "Fight Fuel Sulfur" Form SEBD0598
STMG 661 - 67 -
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D PREFERRED DISTILLATE FUEL FOR DIESEL ENGINES

Specifications Requirements
Aromatics (ASTM D1319) 35% Maximum
Ash (ASTM D482) 0.02% Weight Maximum
Cetane Number (ASTM D613) 35 Minimum for PC Engines

40 Minimum for DI Engines
Not Above Lowest Expected Ambient
Cloud Point (ASTM D97)
Temperature
Gravity API (ASTM D287) 30 Minimum and 45 Maximum
Pour Point (ASTM D97) 6°C (10°F) Below Ambient Minimum
Sulfur (ASTM D2788, D3605 or D1552) 0.5% Maximum (See Sulfur Topic)
Viscosity, Kinematic @ 38°C (100°F) 20.0 centistokes Maximum
(ASTM D445) 1.4 centistokes Minimum
Water & Sediment (ASTM D1796) 0.1% Maximum
54
• Fuel Specifications Caterpillar diesel engines have the ability to burn a wide variety of fuels.
These fuels are divided into two general groups: preferred and
permissible. The preferred fuels provide maximum engine service life
and performance. The chart above lists the specifications for preferred
distillate fuel for diesel engines.
The permissible fuels are crude oils or blended fuels. Use of permissible
fuels can result in higher maintenance costs and reduced engine service
life. Using permissible fuels can significantly reduce service interval
hours.
The percentage of sulfur in the fuel will affect the engine oil
recommendations. The following is a summary of fuel sulfur and oil
recommendations:
1. Use API CF-4 performance oils.
2. With fuel sulfur below 0.5%, any API CF-4 oils will have a
sufficient Total Base Number (TBN) for acid neutralization.
3. For fuel sulfur values above 0.5%, the new oil TBN should be a
minimum of 10 times the fuel sulfur.
STMG 661 - 68 -
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LUBRICATION SYSTEM
55
Lubrication System
The following section covers the proper lubrication of the Off-highway

Trucks. Proper lubrication includes the correct quantity, type and quality
of lubricant for each lubrication compartment. Proper maintenance also
includes Scheduled Oil Sampling (S•O•S) of each lubricated
compartment.

lubrication, see the following publications:
Brochure "How to Take a Good Oil Sample" Form PEHP6001

Booklet "Oil and Your Engine" Form SEBD0640
Booklet "Engine Oils: Today and Tomorrow" Form PEDP9107
Brochure "Cat Diesel Engine Oil ... an
integral part of our engines" Form PEDP2209
Video Tape "Oil In Your Engine" Form LEVN9001
Slide Package "Cat Filters, Batteries,
Fluids and Hardware" Form PEKP4052
Product Training Bulletin "Cat Diesel
Engine Oil (CF-4)" Form TEJB0913
STMG 661 - 69 -
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S•O•S INTERVAL CHART

Compartment Interval
Engine Oil 250 Hours
Steering Oil 500 Hours
Differential/Final Drive Oil 500 Hours
Transmission Oil 500 Hours
Hoist, Torque Converter

and Brake Cooling Oil 500 Hours
56
• Scheduled Oil Scheduled Oil Sampling (S•O•S)

Sampling (S•O•S)
Caterpillar recommends using Scheduled Oil Sampling (S•O•S) at

regularly scheduled intervals to compliment a good preventive
maintenance program. An Interval Chart is illustrated above. Sampling
methods recommended are listed below in preferential order. Some of the
systems are equipped with in-line sampling valves.
1. Use an in-line sampling valve
2. Use a sampling gun inserted into the sump
3. Use the drain stream when changing oil.
STMG 661 - 70 -
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1 2
3 4
57
Three oil compartments are equipped with S•O•S oil sample valves.
1. S•O•S sampling Shown are the locations of the engine, the torque converter, hoist and
valve locations: brake cooling, and the transmission oil S•O•S oil sample valves (1).
2. Engine oil
3. Torque converter, - The engine oil sample valve is in a tube near the engine oil cooler on
hoist and brake the right side of the engine (2).
cooling oil
4. Transmission oil - The torque converter, hoist and brake cooling oil sample valve is
located on the torque converter in the torque converter outlet
manifold (3).
- The transmission oil sample valve is located on the left side of the
transmission in a manifold with the transmission lube oil pressure
tap (4).
STMG 661 - 71 -
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LUBRICANT SPECIFICATION TERMINOLOGY
SAE - Society of Automotive Engineers

API - American Petroleum Institute
ASTM - American Society for Testing and Materials
MIL - U.S.A. Military Specifications
NLGI - National Lubricating Grease Institute
SPC - Special Synthetic Oils
HYDO - Cat Hydraulic Oil
TDTO - Transmission Drive Train Oil
DEO - Diesel Engine Oil
"C" - Diesel (Compression ignition) i.e. CD, CE and CF-4
"S" - Gasoline (Spark ignition) i.e. SE, SF and SG
58
• Lubrication Lubrication Specifications

specifications
To increase machine life and decrease maintenance costs, always use the
recommended lubricants. Specifications for lubricants are listed in the
Operation and Maintenance Manual. Some lubrication specification
terminology is listed below:
SAE - Society of Automotive Engineers

API - American Petroleum Institute
ASTM - American Society for Testing and Materials
MIL - U.S.A. Military Specifications
NLGI - National Lubricating Grease Institute
SPC - Special Synthetic Oils
HYDO - Cat Hydraulic Oil
TDTO - Transmission Drive Train Oil
DEO - Diesel Engine Oil
"C" - Diesel (Compression ignition) i.e. CD, CE and CF-4
STMG 661 - 72 -
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LUBRICATION SPECIFICATIONS
Compartment Specification
Engine DEO CF-4
Steering TDTO T0-4
Transmission TDTO T0-4
Hoist, Converter
TDTO T0-4
and Brake Cooling
Differential, Final Drives
TDTO T0-4
and Front Wheels
59
• Off-highway Truck Higher performance ratings and new emission standards require better
lubrication oils. Older oil technology (API CD and CE) cannot withstand the higher
temperatures required to obtain the new emission standards.
Currently, the oil specifications for the various systems on Off-highway

Trucks are as follows:
• Engine oil (DEO CF-4)
• Engine Oil (DEO CF-4)
- Higher temperature
capability - CF-4 engine oil requires more performance tests than previous oils,
such as CD or CE, and has a narrower performance band.
- Better soot control
- Handles higher - CF-4 engine oil can withstand higher temperatures before coking
and has better dispersing capability for controlling soot.
- CF-4 engine oil has better fuel sulfur neutralization capability.

STMG 661 - 73 -
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• Steering system oil • Steering System Oil (TDTO TO-4)

(TDTO TO-4)
- TDTO TO-4 oil provides a broader temperature capability than other
- Broader temperature oils.
• Transmission system
oil (TDTO TO-4) • Transmission System Oil (TDTO TO-4)
- Maximum frictional - TDTO TO-4 provides maximum frictional capability required for
capability clutch discs used in transmissions.
- Increases rimpull
- Increases rimpull because of reduced slippage.
- Use straight weight
oil only
- Use only mono-viscosity (straight weight) oils. Multi-viscosity oils
- Never use engine oil use viscosity improvers which, when subjected to shearing
situations, are reduced to the lower weight rating. For example,
when a 10W-30 oil is used in a sheer condition, after time the oil
will only perform to 10W specifications.
- Never use engine oil in transmissions. Engine oils are formulated to

minimize friction. Oils used in transmissions must allow adequate
friction to reduce slippage.
• Hoist, converter and
brake cooling oil
(TDTO TO-4)
• Hoist, Converter and Brake Cooling Oil (TDTO TO-4)
- Maximum frictional
- TDTO TO-4 provides maximum frictional capability required for
capability
clutch discs used in the torque converter and brakes.
- Increases brake
holding
- Increases brake holding capability by reducing brake slippage.
- Controls brake
- Controls brake chatter.
• Differential, final
drives and front
wheels (TDTO TO-4)
- Maximum frictional • Differentials, Final Drives and Front Wheels (TDTO TO-4)
capability
- TDTO TO-4 provides maximum frictional capability required for
- Increased bearing gears.
- Provides increased lubrication capability for bearings.
NOTE: Sometimes more than one type of oil can be used in a system.
In this presentation, the preferred oil is discussed.
STMG 661 - 74 -
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LUBRICANT VISCOSITIES
FOR AMBIENT (OUTSIDE) TEMPERATURES
Compartment Oil °C °F
or System Viscosities Min. Max. Min. Max.
SAE 0W30*(SPC) -40 +30 -40 +86
Engine SAE 0W20*(SPC) -40 +10 -40 +50

Crankcase
CAT DEO SAE 5W20*(SPC) -30 +10 -22 +50
API CF-4
SAE 10W30 -20 +40 -4 +104
SAE 15W40 -15 +50 +5 +122
*(SPC) Special oils with synthetic base stocks that do not contain
polymer viscosity index improvers. The higher viscosity index of
the "synthetic" oils provide natural multiviscosity properties.
60
Lubrication Viscosities and Refill Capacities
• Engine lubrication The table above illustrates the lubrication viscosities for the engine
crankcase on Off-highway Trucks.
NOTE: "SPC" denotes special oils with synthetic base stocks that do
not contain polymer viscosity index improvers. The high viscosity
index of the "synthetic" oils provides natural multi-viscosity
properties.
STMG 661 - 75 -
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Transmission SAE 0W30*(SPC) -40 +20 -40 +68
CAT TDTO SAE 0W20*(SPC) -40 +10 -40 +50
CAT TO-4 -22
SAE 5W20*(SPC) -30 +10 +50
All Trucks SAE 10W -25 +10 -13 +50
except SAE 30 -15 +35 +5 +95
768C, 769C,
771C SAE 50 -5 +50 +23 +122
Transmission SAE 10W -20 +22 -4 +75
768C,769C,
771C SAE 30 +10 +35 +50 +95
SAE 0W30*(SPC) -40 +40 -40 +104
Steering
Hydraulic SAE 0W20*(SPC) -40 +40 -40 +104
System SAE 5W20*(SPC) -30 +40 -22 +104
CAT HYDO SAE 5W20 -25 +10 -13 +50
CAT TDTO
SAE 10W -25 +40 -13 +104
CAT TO-4
CAT DEO SAE 10W30 -20 +40 -4 +104
API CF-4 SAE 15W40 -15 +50 +5 +122
61
• Transmission and The above table lists the lubrication viscosities for the transmission and
steering system steering system.
properties.
STMG 661 - 76 -
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SAE 0W30*(SPC) -40 0 -40 +32
Differential, SAE 0W20*(SPC) -40 -10 -40 +14
Final Drives,
and Front SAE 5W20*(SPC) -30 -10 -22 +14
Wheels SAE 10W -35 -10 -31 +14
CAT TDTO
CAT TO-4 SAE 30 -25 +15 -13 +59
SAE 50 -15 +50 +5 +122
Hoist, SAE 0W30*(SPC) -40 +20 -40 +68
Converter, SAE 0W20*(SPC) -40 +10 -40 +50
and Brake SAE 5W20*(SPC) -30 -22 +50
+10
CAT TDTO
CAT TO-4 SAE 10W -25 +50 -13 +122
*(SPC) Special oils with synthetic base stocks that do not contain
polymer viscosity index improvers. The higher viscosity index of
the "synthetic" oils provide natural multiviscosity properties.
62
• Differential, final The above table list the lubrication viscosities for the differential, final
drives, front wheels, drives, front wheels, and the hoist, converter and brake systems.
hoist, converter and
brake systems
properties.
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769C/771C REFILL CAPACITIES

SUSPENSION CYLINDER OIL STEERING OIL FUEL TANK
Front Capacity - 3.6 gal. Tank Capacity - 15 gal. Refill Capacity - 140 gal.
Rear Capacity - 2.9 gal. System Capacity - 22 gal.
Type: HYDO, DEO, TDTO (TO-4) Type: HYDO, DEO, TDTO (TO-4)
10W 10W: -4°F to +104°F
COOLING SYSTEM
Refill Capacity - 30 gal.
Conditioner: 3% to 6%
Antifreeze: 30% to 60%
DIFFERENTIAL AND
FINAL DRIVE OIL
ENGINE OIL Refill Capacity - 22 gal.
Refill Capacity - 12 gal. Type: TDTO (TO-4)
Type: DEO CF-4 30W: -13°F to +59°F
10W30: -4°F to +104°F 50W: +5°F to +122°F
15W40: +5 to +122°F
FRONT WHEEL OIL HOIST, CONVERTER AND BRAKE OIL TRANSMISSION OIL
Refill Capacity - .62 gal. (each) Tank Capacity - 58 gal. Tank Capacity - 22 gal.
Type: TDTO (TO-4) System Capacity - 96 gal. System Capacity - 27 gal.
30W: -13°F to +59°F Type: TDTO (TO-4) Type: TDTO (TO-4)
50W: +5°F to +122°F 10W: -13°F to +122°F 10W: -4°F to +75°F
30W: +50°F to +95°F
63
• 769C/771C refill The approximate refill capacities for the 769C/771C Off-highway Trucks
capacities are shown on the above chart. The preferred oil specifications are also
shown.
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773B/775B REFILL CAPACITIES

10W 10W: -4°F to +104°F
COOLING SYSTEM
DIFFERENTIAL AND
FINAL DRIVE OIL
10W30: -4°F to +104°F 50W: +5°F to +122°F
15W40: +5 to +122°F
Refill Capacity - 1 gal. (each) Tank Capacity - 58 gal. Tank Capacity - 22 gal.
30W: +5°F to +95°F
50W: +23°F to +122°F
64
• 773B/775B refill The approximate refill capacities for the 773B/775B Off-highway Trucks
capacities are shown on the above chart. The preferred oil specifications are also
shown.
STMG 661 - 79 -
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MAINTENANCE INTERVALS
65
MAINTENANCE INTERVALS
This section identifies the items that must be maintained on Off-highway

Trucks and the intervals at which the service must be performed.
NOTE TO THE INSTRUCTOR: Before beginning the maintenance

interval items, it may be helpful to have an in-class exercise to
identify, with the Operation and Maintenance Manual, specific
service interval items. For example: Using the Operation and
Maintenance Manual, identify all 10 hours or daily service interval
items.
STMG 661 - 80 -
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OIL COOLER ENGINE

SCREEN AIR INTAKE
ETHER
STARTING AID
WINDSHIELD
WASHER
FUSES AND
CIRCUIT BREAKERS
MAINTENANCE
WHEN REQUIRED
WINDSHIELD BODY AND FRAME

WIPER
ENGINE OIL
FILTER INSPECTION
TORQUE CONVERTER HOIST RETURN AND

SCAVENGE SCREEN SUCTION SCREENS
66
• Maintenance When Required

- When required
This slide introduces the When Required maintenance interval items.
The following list identifies the items that must be serviced When
Required.
- Engine air intake: Service when indicated

- Fuses and circuit breakers: Replace when necessary
- Windshield wiper and washer: Replace when necessary
- Ether starting aid: Replace when necessary
- Body and frame: Inspect/repair
- Oil cooler screen: Clean
- Oil filters: Inspect for debris
- Hoist return and suction screens: Clean
- Torque converter scavenge screen: Clean
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67
• Engine air intake Shown are the air intake system components.
system components:
1. Precleaner bowls The precleaner bowls (1) must be emptied whenever dirt reaches the full
mark.
2. Air service indicator
Service the air filter elements when the yellow piston in the air service
indicator (2) moves into the red zone [approximately 760 mm (30 in.) of
water].
3. Primary element
4. Secondary element Two filter elements are installed in the filter housings. The large element
is the primary element (3) and the small element is the secondary
element (4).
Air intake system tips:
- The primary element can be cleaned a maximum of six times.

- Never clean the secondary element for reuse. Always replace the
secondary element.
- Air filter restriction causes black exhaust smoke and low power.
- A .6°C (1°F) increase in intake temperature increases exhaust
temperature 1.8°C (3°F).
- For every 250 mm (10 in.) of water restriction above 500 mm
(20 in.) of water in an air filter, the inlet temperature increases 60°C
(100°F).
- Exhaust temperature should not exceed 650°C (1200°F).
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68
1. Fuses and circuit The fuses and circuit breakers are located in the cab below the right side
of the dash (1).
2. Windshield wiper
Inspect the windshield wiper located in front of the windshield (2).
and body and frame
inspection
Inspect the body and frame for cracks. Always pay particular attention to
locations on the frame where castings and fabricated plates meet (2).
3. Windshield washer
reservoir The windshield washer reservoir is located in the engine compartment at
the right rear corner of the cab (3).
4. Ether cylinder
The ether starting aid system ether cylinder is located in the engine
compartment on the right side of the radiator shroud (4).
Ether starting tips:
- A full ether cylinder weighs approximately 1047 g (37 oz.) and an

empty cylinder weighs approximately 453 g (16 oz.).
- Cold weather causes rough combustion and white exhaust smoke

from unburned fuel. Ether injection will reduce the duration and
severity of unburned fuel symptoms.
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69
1. Oil cooler screen The oil cooler screen is located in the black manifold below the oil cooler
(1).
2. Oil filter inspection

Whenever an oil filter is removed for replacement (engine filter shown)
(2), cut the filter open and inspect for metal or other debris. Use a magnet
to differentiate between ferrous and nonferrous metals.
3. Hoist return screen
The hoist return screen is located in the hydraulic tank. The screen is
connected to the hoist valve (3).
4. Suction screens
Suction screens are located at the rear of the hydraulic tank behind the
suction tubes (4).
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70
• Torque converter The torque converter scavenge screen (arrow) is located in the torque
scavenge screen converter sump.
(arrow)
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STEERING FUEL
OIL TANK
RADIATOR
ENGINE SUSPENSION
OIL CYLINDERS
SEAT BELTS MAINTENANCE

SUPPLEMENTAL STEERING TEST
BRAKE TESTS
AIR RESERVOIRS 10 HOURS/DAILY
INDICATORS AND GAUGES
BACKUP ALARM TEST
SUSPENSION
CYLINDERS

AND BRAKE COOLING OIL OIL
71
• Maintenance 10 Service Hours or Daily

- 10 hours/daily
The following list identifies the items that must be serviced every 10
Hours or Daily.
- Engine crankcase oil: Check level

- Transmission oil: Check level
- Hoist, converter and brake cooling oil: Check level
- Steering system oil: Check level
- Walk-Around Inspection
- Radiator: Check level
- Air reservoirs: Drain moisture
- Fuel tank: Drain moisture
- Brakes: Check operation
- Indicators and gauges: Test operation
- Seat belt: Inspect
- Back-up alarm: Test operation
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72
• Engine oil level The engine oil level is checked with the dipstick (1) which can be
1. Dipstick accessed by opening a small door in the rear engine cover. To add oil,
open the rear engine cover and fill through the tube (2).
3. Transmission and
The transmission tank and the hoist, converter and brake cooling tank (3)
hoist, converter and
brake cooling tanks are located on the left side of the truck. The oil levels are checked by
opening the small doors on the side of the tanks (4).
4. Oil level window
doors
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73
1. Steering tank The steering tank (1) is located on the right platform. Check the steering
system oil level at the sight gauge on the side of the tank.
2. Walk-around Make a thorough walk-around inspection of the entire truck. Inspect

inspection
under and around the machine for leaks, loose or missing bolts, trash
buildup, broken lights or low tire pressure (2).
3. Radiator cap
The coolant level can be checked by removing the radiator cap (3 and 4).
4. Top of radiator
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74
1. Parking/secondary The parking/secondary brake air reservoir (1) is located in a compartment

brake reservoir behind the cab. The drain valve (2) for draining the moisture from the
2. Drain valve parking/secondary brake reservoir is located on the right rear corner of the
cab.
3. Service/retarder
brake reservoir
The service/retarder brake reservoirs (3) are located on top of the
hydraulic tanks on the left side of the truck. The drain valve (4) for
4. Drain valve
draining the moisture from the service/retarder brake reservoirs is located
behind a small door on the reservoir cover.
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75
1. Fuel tank The fuel tank (1) is located on the right side of the truck. The fuel level
2. Fuel level gauge can be checked at the fuel level gauge (2).
3. Fuel shutoff valve

When changing fuel filters, turn the fuel off with the shutoff valve (3).
4. Fuel drain valve Drain moisture from the tank by opening the drain valve (4).
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76
• Suspension cylinders Check the front and rear suspension cylinders for leaks or structural
1. Front suspension damage. Measure the charge height of the suspension cylinders and
cylinder compare the dimension with the dimension that was recorded the last time
2. Check charge of
the cylinders were charged. Recharge the cylinders if necessary.
front cylinders
3. Rear suspension
cylinders
suspension system, see the following publications:
4. Check charge of rear Technical Instruction Module "769C - 793B

cylinders
Off-highway Trucks--Suspension System" Form SEGV2599
Special Instruction "Suspension Cylinder
Servicing" Form SEHS9411
STMG 661 - 91 -
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77
• 10 hours/daily checks The remaining 10 Hours or Daily checks are performed in the operator's
performed in the compartment. They are as follows:
operator's cab
- Brakes: Check operation

- Indicators and gauges: Test operation
- Seat belt: Inspect
- Back-up alarm: Test operation
- Supplemental steering: Test operation
The brakes are checked by engaging one of the brake systems and placing
the shift lever in FIRST FORWARD. Accelerate the engine until the
truck moves. The truck must not move below 1200 rpm. This procedure
should be repeated for each brake lever or pedal.
See the Operation and Maintenance Manual for more information on the
remaining tests performed in the cab.
STMG 661 - 92 -
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REAR SUSPENSION
CYLINDER BEARINGS
REAR AXLE HOUSING

LATERAL CONTROL ROD
BEARINGS
BODY PIVOT
BEARINGS
STEERING CYLINDER REAR AXLE HOUSING

BEARINGS "A" FRAME BEARING MAINTENANCE
STEERING TIE ROD
AND PIN BEARINGS
50 HOURS/WEEKLY
CAB AIR SYSTEM
FRONT SUSPENSION
CYLINDER RODS
HOIST CYLINDER
BEARINGS
78
• Maintenance 50 Service Hours or Weekly

- 50 hours/weekly
Hours or Weekly.
- Cab air system: Clean filter

- Rear axle housing lateral control rod bearings: Lubricate
- Rear suspension cylinder bearings: Lubricate
- Body pivot bearings: Lubricate
- Front suspension cylinder rods: Lubricate
- Rear axle housing "A" frame bearing: Lubricate
- Steering cylinder bearings: Lubricate
- Steering tie rod and pin bearings: Lubricate
- Hoist cylinder bearings: Lubricate
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79
1. Cab air filter The cab air filter (1) is located in a compartment behind the operator's
seat.
2. Front suspension
Lubricate the front suspension cylinders at the grease fitting (2).
grease fitting
3. Suspension cylinder,
Located at the rear of the truck are the rear axle housing lateral control
body pivot, and
control rod bearings rod bearings, the rear suspension cylinder bearings and the body pivot
bearings, which all require grease (3 and 4).
4. Rear axle housing
lateral control rod
bearings
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80
1. Rear axle and rear The rear axle connects to the frame and pivots at the "A" frame bearings
suspension cylinder (1 and 2). The rear suspension cylinders and the rear axle "A" frame
2. Rear axle "A" frame bearings require lubrication through the grease fittings.
3. Steering cylinder, tie The steering cylinder, tie rod and pin bearings (3) require lubrication
rod and pin bearings through the appropriate grease fittings.
4. Hoist cylinder
bearings The hoist cylinder bearings (4) require lubrication through the grease
fittings at the frame and body connections.
STMG 661 - 95 -
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DRIVE SHAFT UNIVERSAL JOINTS

BATTERIES AND SPLINES
COOLING SYSTEM
CONDITIONER ELEMENT
FAN DRIVE
BEARING
ENGINE VLALVE LASH

(NEW/REBUILT ONLY)
DIFFERENTIAL
ALTERNATOR AND
FAN BELTS
MAINTENANCE
250 HOURS/MONTHLY
AIR CONDITIONER
BELT
ENGINE OIL
AND FILTERS
FINAL DRIVES
AIR DRYER
FRONT WHEEL HOIST CONTROL

BEARINGS BELLCRANK
81
• Maintenance 250 Service Hours or Monthly

- 250 hours/monthly
The following items must be serviced every 250 Hours or Monthly.
- Engine oil and filters: Change

- Engine valve lash: Adjust on new or rebuilt engines only
- Cooling system conditioner: Change element
- Batteries: Check
- Air conditioner: Test and adjust belt
- Fan drive bearing and belt tightener: Lubricate
- Alternator and fan belts: Test and adjust
- Air dryer: Check desiccant
- Hoist control bellcrank: Lubricate
- Drive shaft universal joints and spline: Lubricate
- Front wheel bearings: Check oil level
- Differential and final drives: Check oil level
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82
1. Engine oil filters and The engine oil filters and the engine oil drain valve are located on the left
drain valve side of the engine (1).
2. Cooling system
The cooling system conditioner element is located on the right side of the
conditioner element
engine below the fuel filters (2).
3. Batteries
The batteries are located in the compartment on the right front platform
(3).
4. Air conditioner,
alternator and fan The air conditioner and alternator belts are adjusted by tightening a nut on
a threaded rod. The fan belts are kept tight with springs connected to a
belt tightener pulley. The fan bearings and the belt tightener bearings are
lubricated through grease fittings located on the right side of the fan
pulley (4).
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83
1. Air dryer and hoist The air dryer (1) is located on the frame behind the left front tire. Check
control bellcrank the desiccant for saturation. The humidity of the local climate will
determine how often the desiccant must be changed.
2. Hoist control
bellcrank
The hoist control bellcrank (1and 2) requires lubrication through the
grease fitting.
3. Drive shaft universal
joints and splines The drive shaft universal joints and splines (3) require lubrication through
the appropriate grease fittings.
4. Differential oil level
Check the differential oil level (4) by removing the fill plug in the center
of the rear axle housing. The oil should be level with the bottom of the
fill plug opening.
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84
1. Front wheel bearing Check the oil level of the front wheel bearings (1 and 2) by removing the
fill plug in the center of the wheel cover. The oil should be level with the
2. Front wheel bearing
bottom of the fill plug opening.
oil level
3. Final drive oil level

Check the final drive oil level (3 and 4) by positioning the truck with the
4. Final drive oil level
final drive cover oil level line horizontal and the drain plug at the bottom.
Remove the fill plug from the final drive cover. The oil should be level
with the bottom of the fill plug opening.
STMG 661 - 99 -
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MAINTENANCE 500 HOURS/3 MONTHS

ENGINE CRANKCASE STEERING FUEL TANK
BREATHERS FILTER CAP AND SCREEN
PRIMARY AND
SECONDARY
FUEL FILTERS
TORQUE CONVERETER PARKING TRANSMISSION

CHARGE FILTER BRAKE CHARGE FILTER
RELEASE FILTER
85
• Maintenance 500 Service Hours or Three Months

- 500 hours/3 months
Hours or Three Months.
- Steering hydraulic system: Change filters

- Fuel system: Change filters
- Fuel tank cap and fill screen: Clean
- Engine crankcase breathers: Clean
- Transmission filter: Change filter
- Torque converter filter: Change filter
- Parking brake charge filter: Change filter
NOTE: The parking brake release filter is located behind the right
front tire on the 769C and 771C Trucks (see slide No. 88).
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86
1. Steering filter The steering filter (1) is located on top of the steering tank on the right
platform.
2. Primary fuel filter The primary fuel filter (2) is located inside the right frame near the front
suspension cylinder.
3. Secondary fuel
filters The secondary fuel filters (3) are located on the right side of the engine.
4. Fuel priming pump

The fuel priming pump (4) is located above the secondary fuel filters.
NOTE: The 769C and 771C have only one secondary fuel filter.
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87
1. Fuel tank cap and fill The fuel tank cap is equipped with a breather that must be kept clean. If
screen the breather becomes plugged, fuel flow will be restricted and the engine
will have low power. The fill screen is located in the fill tube (1).
2. Engine crankcase
breathers
The engine crankcase breathers (2) are located on the valve covers. If the
breathers become plugged, pressure in the crankcase will be forced out at
other locations causing oil leakage.
• 773B/775B:
On the 773B/775B, the torque converter charge filter and the parking
3. Torque converter
charge filter and
brake release filter (3) are located on the inside of the right frame in front
parking brake of the crosstube. The transmission charge filter (4) is located on the
release filter inside of the right frame behind the crosstube.
4. Transmission
charge filter
STMG 661 - 102 -
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88
• 769C/771C: On the 769C/771C, the transmission charge filter (1) and the torque
1. Transmission converter charge filter (2) are located on the inside of the right frame near
charge filter the torque converter.
2. Torque converter
charge filter
STMG 661 - 103 -
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89
• Parking brake release On the 769C/771C, the parking brake release filter (arrow) is located
filter (arrow) outside of the right frame behind the right front tire.
STMG 661 - 104 -
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STEERING OIL
DIFFERENTIAL
MAINTENANCE
1000 HOURS/6 MONTHS
ROLLOVER PROTECTION
STRUCTURE (ROPS) MAIN FRAME AND
BODDY SUPPORT PADS
AIR
DRYER
FINAL DRIVES
FRONT WHEEL
BEARINGS
AND BRAKE COOLING OIL OIL
90
• Maintenance 1000 Service Hours or Six Months

- 1000 hours/6 months
Hours or Six Months.
- Transmission: Change oil, wash breather and magnetic screen

- Hoist, converter and brake cooling oil: Change oil, wash breather
- Air dryer: Change desiccant
- Differential and final drives: Change oil and wash breather
- Front wheel bearings: Change oil
- Rollover Protective Structure (ROPS): Torque bolts
- Steering hydraulic system: Change oil
- Rear service brakes: Inspect
- Main frame and body support pads: Inspect and repair
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91
1. Transmission and The transmission tank and the hoist, torque converter, and brake cooling
hoist, torque oil tank are located on the left side of the truck (1). Drain the oil from the
converter, and brake
tanks by removing the plugs in the bottom of the tanks (2) and installing a
2. Drain plugs 25 mm (1.0 in.) NPT pipe nipple.
Wash the fill caps and the fill screens located inside the fill tubes.
3. Transmission case
The transmission case must also be drained by removing the plug (3).
4. Transmission
magnetic screen Remove and clean the transmission magnetic screen The magnetic
screen is located in the transmission case behind the cover (4).
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92
1. Transmission tank Clean the transmission tank breather located on top of the transmission
breather tank (1).
• Hoist, torque Clean the hoist, torque converter, and brake cooling oil tank breather. On
converter, and brake
the 769C/771C, the breather (2) is located below the rear engine hood.
cooling oil tank
breather: On the 773B/775B, the breather (3) is located below the frame to the right
of the supplemental steering/brake retraction motor.
2. 769C/771C
Repack or replace the desiccant cartridge in the air dryer (4) when it can
4. Replace desiccant in no longer absorb water. The humidity of the local climate will determine
air dryer how often the desiccant needs to be replaced.
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93
1. Change final drive Change the oil in both final drives (1). Position the wheels with the final
drive drain plug at the bottom and remove the drain plug. Fill the final
drives with oil to the bottom of the fill hole.
2. Change differential
Change the oil in the differential (2). Fill the differential with oil to the
bottom of the fill hole.
3. Clean rear axle
housing breather Clean the rear axle housing breather (3). The breather prevents pressure
from building up in the axle housing. Pressure in the axle housing may
cause brake cooling oil to leak through the Duo-Cone seals in the wheel
brake assemblies.
4. Change front wheel
bearing oil Change the oil in the front wheel bearings (4). Position the wheels with
the front wheel bearing drain plug at the bottom and remove the drain
plug. Fill the final drives with oil to the bottom of the fill hole.
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94
1. Inspect ROPS and Inspect the ROPS and the mounting supports and bolts (1 and 2). Tighten
mounting supports the ROPS bolts to a torque of 720 ± 25 N•m (530 ± 20 lb. ft.).
3. Steering tank drain Change the steering system oil. Drain the oil through the valve at the
valve
bottom rear of the tank (3).
4. Steering tank
Wash the steering tank fill cap and the fill screen located inside the fill
tube. Fill the steering tank (4) with oil to the FULL mark on the sight
gauge.
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95
1. Front brakes Inspect the front brakes (1) and the rear brakes (2) for wear and system
2. Rear brakes leakage.
3. Main frame Clean and inspect the main frame (3) and the body support pads (4).
4. Body support pads
STMG 661 - 110 -
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DIFFERENTIAL
ENGINE VALVE THRUST PIN
LASH
ENGINE VALVE
ROTATORS
MAINTENANCE
2000 HOURS/1 YEAR
FRONT WHEEL
BEARINGS
REAR WHEEL
BEARINGS
96
• Maintenance 2000 Service Hours or One Year

- 2000 hours/1 year
Hours or One Year.
- Engine valve lash: Adjust

- Engine valve rotators: Check
- Differential thrust pin: Adjust
- Front wheel bearings: Adjust
- Rear wheel bearings: Adjust
STMG 661 - 111 -
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2
1
97
• Adjust bridges and Adjust the bridge (1) and the valve lash (clearance) (2).
valve lash
1. Bridge Run the engine at LOW IDLE and observe the valve rotators (3). The
2. Valve lash
valve rotators should turn slightly each time the valve closes.
• Check valve rotators
3. Valve rotators
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98
1. Adjust differential Adjust the clearance of the differential thrust pin (1).
2. Front and rear wheel Adjust the front wheel bearings (3).
3. Adjust front wheel Adjust the rear wheel bearings (4).

4. Adjust rear wheel
bearings
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MAINTENANCE 3000 HOURS/2 YEARS
COOLING
SYSTEM COOLANT
99
• Maintenance 3000 Service Hours or Two Years

- 3000 hours/2 years
Hours or Two Years.
- Cooling system: Change coolant and clean radiator fins

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100
• Change cooling Remove the radiator cap slowly to relieve pressure. Inspect the radiator
cap gasket. Clean or replace the cooling system relief valve (1).
1. Radiator relief valve Drain the coolant with the radiator drain valve (2)
2. Radiator drain valve
Drain the coolant from all three coolers (engine, transmission and
3. Oil coolers
brake/torque converter) (3).
4. Air compressor
Drain the coolant from the air compressor (4).
NOTE: The 773B and 775B coolers are shown. The 769C and 771C
transmission coolers are mounted on the engine front support.
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101
• Inspect and clean Inspect and clean the radiator fins.

radiator fins
STMG 661 - 116 -
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SLIDE LIST
1. Model View 42. After Starting Engine

2. Maintenance Intro 43. Towing Attachment Locations
3. Safety Warning 44. Parking Brake Release Schematic (normal)
4. Cab Warning 45. Parking Brake Release Schematic (towing)
5. ROPS Warning 46. Supplemental Steering and Towing Pump
6. Front Suspension Cylinder Warning 47. Brake Release Diverter Valve
7. Rear Suspension Cylinder Warning 48. Towing Components
8. Brake Cylinder Warning 49. Tire Inflation (subtitle)
9. Battery Warning 50. Cooling System (subtitle)
10. Do Not Operate Tag 51. Water Requirements
11. Tire Explosion Zone 52. Critical Cooling Points
12. Body Up Safety Pin 53. Fuel Specifications (subtitle)
13. 769C/771C Model View 54. Diesel Fuel Specifications (chart)
14. 769C/771C Power Flow 55. Lubrication System (subtitle)
15. 769C Model View (Right) 56. S•O•S Interval Chart
16. 769C Model View (Left) 57. S•O•S Sample Valve Locations
17. 773B/775B Model View Graphic 58. Lubricant Terminology
18. 773B/775B Power Flow 59. Lubricant Specifications (chart)
19. 773B/775B Model View (Right) 60. Lubricant Viscosities (chart)
20. 773B/775B Model View (Left) 61. Lubricant Viscosities (chart)
21. Product/Component Serial Numbers 62. Lubricant Viscosities (chart)
22. Machine Serial Number Location 63. 769C/771C Refill Capacities
23. Engine Serial Number Location 64. 773B/775B Refill Capacities
24. Transmission Serial Number Location 65. Maintenance Intervals (subtitle)
25. Combination Service Plate Location 66. Maintenance When Required Model View
26. Engine Information Plate Location Graphic
27. Cab Front Panel Components 67. Air Intake Components
28. Cab Front Panel Components 68. Maintenance When Required Components
29. Cab Front Panel Gauges 69. Maintenance When Required Components
30. Cab Front Dash Panel Graphic 70. Torque Converter Scavenge Screen
31.. Actual Gear Indicator 71. Maintenance 10 Hours/Daily Model View
32. Diagnostic Connectors 72. Maintenance 10 Hours/Daily Components
33. Shift Lever and Parking Switch 73. Maintenance 10 Hours/Daily Components
34. Brake Pedal, Accelerator Pedal and Fuses 74. Maintenance 10 Hours/Daily Components
35. Secondary and Retarder Brake Levers 75. Fuel Tank and Components
36. Steering Lock and Turn Signal/Hazard 76. Suspension Cylinders
Switch 77. Maintenance 10 Hours/Daily Cab
37. Dimmer Switch and Horn Button Components
38. Heating and A/C Controls 78. Maintenance 50 Hours/Weekly Model View
39. Hoist Lever and Operator Seat 79. Maintenance 50 Hours/Weekly Components
STMG 661 - 117 -
8/94
SLIDE LIST
81. Maintenance 250 Hours/Monthly Model

View
82. Maintenance 250 Hours/Monthly
Components
Components
Components
85. Maintenance 500 Hours/3 Months Model
View
86. Maintenance 500 Hours/3 Months
Components
Components
88. 769C/771C Transmission and Torque
Converter Charge Filters
89. 769C/771C Parking Brake Release Filter
90. Maintenance 1000 Hours/6 Months Model
View
Components
Components
Components
Components
Components
96. Maintenance 2000 Hours/1 Year Model
View
97. Engine Valve Bridge and Rotators
98. Maintenance 2000 Hours/1 Year
Components
99. Maintenance 3000 Hours/2 Years Model
View
100. Cooling System Components
101. Radiator
8/94
STMG 661
STEERING OIL LEVEL CHECK FUEL LEVEL

AND DRAIN MOISTURE
BATTERIES
AIR FILTER
RESTRICTION INDICATOR
SUSPENSION
COOLANT LEVEL CYLINDER HEIGHT
ENGINE OIL LEVEL REAR AXLE

BREATHER
BELTS INSPECT FRAME

FOR CRACKS
CHECK FOR LEAKS

AND TRASH BUILD-UP
WALK-AROUND
- 118 -
DRAIN
INSPECTION AIR RESERVOIR WHEEL
MOISTURE NUTS
WINDOWS
SEAT BELT
SUSPENSION
CYLINDER
HEIGHT TIRE INFLATION
PRESSURE

Serviceman's Handout No. 1
AND BRAKE OIL LEVEL OIL LEVEL

8/94
STMG 661
AFTER STARTING THE ENGINE WATER REQUIREMENTS
• Engine oil indicator must go off in 15 seconds • Use distilled water whenever possible
• Idle engine for five minutes • Use water analysis
• All EMS indicators must be off • Never use salt water
• Warm up engine and hydraulic system • Never use water alone
• Check oil levels at idle with warm oil
• Test parking/secondary brake system
• Test service/retarder brake system

- 119 -
• Check all gauges are in safe operating range LUBRICANT SPECIFICATION TERMINOLOGY
• SAE - Society of Automotive Engineers

• API - American Petroleum Institute
CRITICAL COOLING SYSTEM POINTS • ASTM - American Society for Testing and Materials
• MIL - U.S.A. Military Specifications
• 3 to 6% Coolant Conditioner
• NLGI - National Lubricating Grease Institute
• 30 to 60% Caterpillar Antifreeze
• SPC - Special Synthetic Oils
• Correct Operating Temperature
• HYDO - Cat Hydraulic Oil
• Correct Operating Pressure
• TDTO - Transmission Drive Train Oil
• Fill System Slowly
• DEO - Diesel Engine Oil
• Adjust Fan Belts
• "C" is for diesel (Compression ignition) i.e. CD, CE and CF-4
• Keep Radiator Fins Straight and Clean

• "S" is for gasoline (Spark ignition) i.e. SE, SF and SG
8/94
STMG 661
AIR SUPPLY
AIR SWITCH
DURING TOWING
RELIEF VALVE PARKING
BRAKE
RELEASE
PARKING BRAKE VALVE
RELEASE PUMP
CHECK VALVE
- 120 -
DIVERTER
VALVE TOWING
PUMP

PUMP
8/94
STMG 661
769C/771C REFILL CAPACITIES

10W 10W: -4°F to +104°F
COOLING SYSTEM
- 121 -
DIFFERENTIAL AND
FINAL DRIVE OIL
10W30: -4°F to +104°F 50W: +5°F to +122°F
15W40: +5 to +122°F
Refill Capacity - .62 gal. (each) Tank Capacity - 58 gal. Tank Capacity - 22 gal.
30W: +50°F to +95°F
8/94
STMG 661
773B/775B REFILL CAPACITIES

10W 10W: -4°F (-13°F) to +104°F
COOLING SYSTEM
- 122 -
DIFFERENTIAL AND
FINAL DRIVE OIL
10W30: -4°F to +104°F 50W: +5°F to +122°F
15W40: +5 to +122°F
Refill Capacity - 1 gal. (each) Tank Capacity - 58 gal. Tank Capacity - 22 gal.
30W: +5°F to +95°F
50W: +23°F to +122°F
STMG 661 - 123 - Serviceman's Handout No. 6
8/94
COOLING SYSTEM GENERAL SPECIFICATIONS
• 40% of engine failures result from cooling system problems.
• 0.8 mm (1/32 in.) of calcium on cooling system walls insulates as

much as 50 mm ( 2.0 in.) of iron.
• At sea level, a 7 kPa (1.0 psi) increase in cooling system pressure

will raise the boiling point of the coolant 1.8°C (3°F).
• Shrouded fans should have the fan blades fit 2/3 inside the shroud.
• 2260 square cm (350 square in.) of radiator area are required for
every 75 kW (100 hp).
• Coolant temperature gauges usually go into the "Red" range at

110°C (230°F).
• Torque converter temperature gauges usually go into the "Red"

range at 132°C (270°F).
• Torque converter heat and cool times between 91°C (195°F) and
129°C (265°F) should equal one another. Time is approximately 30
seconds.
• Average pressures found in a Caterpillar Cooling System with

thermostats open and system under normal pressure and engine
running at high idle:
- radiator relief pressure 90 to 104 kPa (13 to 15 psi)
- before water pump 48 to 55 kPa (7 to 8 psi)
- after the water pump 172 to 193 kPa (25 to 28 psi)
- top of cylinder head before thermostat 104 to 124 kPa (15 to 18 psi)
• Pressure drop through an oil cooler at 93°C (200°F):

- 28 kPa (4 psi) for water
- 139 kPa (20 psi) for oil
• Engine oil temperature at cooler outlet will be 12°C (20°F) above

cooling system temperature.
• Temperature difference between radiator top and bottom tanks:

- 12°C (20°F) folded core
- 6°C (10°F) conventional core
• Cooling system functioning correctly if top tank temp is 60°C

(100°F) over ambient or less.
8/94
MISCELLANEOUS SPECIFICATIONS
• Engine oil consumption for engines in good condition:

- 3.8 L (1 gal.) of oil per 760 L (200 gal.) of fuel.
- Rebuild engine when consumption is 22 L (8 gal.) of oil per 760 L
(200 gal.) of fuel.
• From fuel burned in an engine:

- 1/3 of the energy is available as usable horsepower at the flywheel
- 1/3 of the energy is lost in cooling
- 1/3 of the energy is lost out the exhaust
• Diesel engines require approximately 4750 L (1250 gal.) of air for

each 3.8 L (1 gal.) of fuel.
• If the supply flow of a hydraulic pump between 690 and 6900 kPa
(100 and 1000 psi) is reduced no more than:
- 10%: the pump is in like-new condition
- 15%: the pump is in good condition
- 20%: the pump is in poor condition
• In cold weather, if oil drips off the dipstick at starting temperature,

it is the correct viscosity. If the oil does not drip off the dipstick, it
is too heavy for that temperature.
• For naturally aspirated engines, 3% of the horsepower is lost each

300 m (1000 ft.) above sea level.
• Engine crankcase pressure should not exceed 50 mm (2.0 in.) of

water.
• Every 250 mm (10 in.) of water restriction above 500 mm (20 in.) of
water in an air filter increases intake air temperature 60°C (100°F).
• A .6°C (1°F) increase in intake air temperature increases exhaust

temperature 1.8°C (3°F).
• Exhaust temperature should not exceed 650°C (1200°F).
• Never cool a bearing below 10°C (50°F).

Never heat a bearing over 120 to 150°C (250 to 300°F).
• Temperature indications:
- below 60°C (140°F): about the threshold of pain (can hold hand on
piece)
- 60 to 100°C (140 to 212°F): too hot to touch/will not "fry"
(vaporize) small traces of moisture (water or saliva)
- 100 to 150°C (212 to 300°F): will fry moisture, no paint
discoloration
- over 150°C (300°F): Caterpillar Yellow starts discoloring
8/94
MAINTENANCE TOOLS
4C9301 Coolant Conditioner Test Kit

5P0957 Coolant and Battery Tester (°F)
4C5084 Filter Cutting Tool
2P8250 Filter Strap Wrench
1P0545 Tire Gauge
7F8240 Tire Valve Repair Tool
7S9394 Tire Fill Air Hose (6 ft.)
6V4040 Nitrogen Tire Inflation Kit
5P1720 Seal Pick
9U5617 Suspension Oil Fill Unit
5P8610 Nitrogen Charge Adapter (for charging two cylinders
7S5437 Nitrogen Charging Group
FT1680 Suspension Gauge Block
9S9082 Engine Turning Tool
8T2700 Blowby/Air Flow Group
8T2844 Temperature Recorder Stickers
1U8865 Infrared Thermometer
9U5828 Infrared Thermometer with Laser Sight
4C3406 Deutsch Connector Kit (HD10) (with crimp tool)
9U7246 Deutsch Connector Kit (DT) (without crimp tool)
9U7250 Deutsch Connector Kit (DT) (with crimp tool)
6V3000 Sure-Seal Repair Kit
1P2305 Terminal and Connector Repair Kit
4C4911 Battery Load Tester
1U9921 Battery Post Cleaner
6V2150 Starting Charging Analyzer
NOTE: S•O•S sample bottles and tooling are only sold in large quantities. For S•O•S sample
bottles and tooling, see your Caterpillar Dealer.
STMG 661 - 126 -
8/94
INSTRUCTOR NOTES
STMG 661 - 127 -
8/94
INSTRUCTOR NOTES
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Service Training

Meeting Guide 661 SESV1661

MEETING GUIDE 661 SLIDES AND SCRIPT

Estimated Time: 4 Hours

769C Off-highway Truck AEHQ3871

Cat Truck Update 769C/773B/771C/775B TELQ3903

"769/773/777 Truck Operating Tips" TEVN1757

Service Training Meeting Guide

STMG 512 "Battery Maintenance" SESV1512

Technical Instruction Module

"769C - 793B Off-highway Trucks--Suspension System" SEGV2599

Application Guide 769C/773B vs 771C/775B AEDK2975

Product Support Bulletins

How Diesel Engines Work and Wear TECB6006

Product Training Bulletin

Cat Diesel Engine Oil (CF-4) TEJB0913

Battery Test Procedure SEHS7633

Caterpillar Batteries--The Tough Performers PEDP1164

Customer Meeting Parts Sales Slide Package

Cat Filters, Batteries, Fluids and Hardware PEKP4052

GENERAL INFORMATION .....................................................................................................20

SERVICEMAN'S HANDOUTS ...............................................................................................118

NOTE TO THE INSTRUCTOR: See "References" on Page 2 for the

All component locations and maintenance information for the 769C

Safe work habits must be second nature while working on or around

Attention! Become Alert! Your Safety is Involved. Failure to Follow

• Manual located in seat

The protection offered by the ROPS will be impaired if it has been

A ROPS is designed to provide operator crush protection in a rollover by

When jump starting the vehicle is necessary, proper safety precautions

Batteries give off flammable fumes that can explode resulting in

Prevent sparks near batteries. They could cause vapors to explode.

Do not smoke when checking battery electrolyte levels. Electrolyte is

Always wear eye protection when starting a machine with jumper

NOTE TO THE INSTRUCTOR: For additional information on

STMG 512 "Battery Maintenance" Form SESV1512

do not do not remove

Attach a DO NOT OPERATE or similar warning tag to the start

AT LEAST 500 m (1500 ft) AT LEAST 15 m (50 ft)

To prevent possible personal injury, do not approach a warm tire

• Disconnect hoist lever

To prevent personal injury or death, do not work under the truck

STEERING HYDRAULIC TANK FUEL TANK

RADIATOR BODY LOCK

AIR RESERVOIRS FINAL DRIVES

Specifications and Model Views

NOTE: The major differences between the 769C/771C and the

NOTE TO THE INSTRUCTOR: For additional information on

Specification Sheet "769C Off-highway Truck" Form AEHQ3871

769C/771C POWER FLOW

1. Body lock pins

STEERING HYDRAULIC TANK FUEL TANK

RADIATOR BODY LOCK

AIR RESERVOIRS FINAL DRIVES

NOTE: The major differences between the 769C/771C and the

NOTE TO THE INSTRUCTOR: For additional information on

Specification Sheet "773B Off-highway Truck" Form AEHQ3873

773B/775B POWER FLOW

1. Body lock pins