773F Off-Highway Truck And 775F Off-Highway Truck Assembly Procedure {7000, 7006, 7960} Caterpillar

Off-Highway Truck/Tractor

773F (S/N: EED1-UP)

Quarry Truck

775F (S/N: DLS1-UP)

Introduction

This publication contains assembly procedures and commissioning procedures in order to prepare 773F and 775F Off-Highway Trucks for operation.

Read the entire publication. Understand the information before you perform any procedures. Understand the information before you order any parts.

Note: In this publication, some photos are for illustrative purposes. Photos for illustrative purposes may not be in sequence with the assembly procedure.

After assembly is complete, refer to the Operation and Maintenance Manual in order to prepare the machine. Use the Parts Manual and use the Service Manual in addition to this publication.

Note: A thorough coating of corrosion protection is now being applied to Quarry Trucks and Off-Highway Truck/Tractors. The coating of corrosion protection is applied to any surface of the machine that is not painted. The addition of the corrosion protection may result in a slippery film around the coated areas. The areas that are treated with the coating should be cleaned with soapy water before final delivery.

Note: Refer to Special Instruction, REHS4445, "Servicing the Suspension Cylinders for Off-Highway Trucks" for any information concerning suspension cylinders. The Special Instruction includes Tooling, pressures, and the correct procedures for purging (oil and nitrogen) and charging (oil and nitrogen).

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Personal injury or death can result from improper assembly procedures. Do not attempt any assembly until you have read and understand the assembly instructions.

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

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NOTICE
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat® products. Dispose of all fluids according to local regulations and mandates.

Parts List

Table 1

Required Parts for Installation of 245-1116 Ladder Group
Qty	Part Number	Description
2	223-4469	Step Group
8	8T-4192	Bolt (M12X1.75)
8	8T-4223	Hard Washer

Table 2

Required Parts for Installation of 274-7535 Walkway Group
Qty	Part Number	Description
1	274-7536	Catwalk Assembly
8	8T-4193	Bolt (M16X2)
8	7X-0583	Hard Washer

Table 3

Required Parts for Installation of the 274-7545 Step Group
Qty	Part Number	Description
1	274-7546	Stair Assembly
4	115-6433	Washer
2	7T-8332	Mount
6	7X-0590	Hard Washer
2	8T-4244	Nut (M12X1.75)
2	8T-4648	Bolt (M12X1.75)
4	8T-4956	Bolt (M12X1.75)

Table 4

Required Parts for Installation of 276-3111 Handhold Group
Qty	Part Number	Description
1	276-3112	Left-hand Handrail Assembly
1	276-3113	Handrail Assembly
1	276-3168	Handrail Assembly
1	276-3114	Handrail Assembly
2	255-2560	Handrail Assembly
1	277-7702	Handrail Assembly
68	8T-4121	Hard Washer
44	8T-4136	Bolt (M10X1.5)
24	8T-4195	Bolt (M10X1.5)
1	281-2807	Handrail Assembly
6	8T-7087	Grommet
6	5P-7468	Clip
6	5P-7469	Clip
6	8T-4223	Hard Washer
3	8T-4183	Bolt (M12X1.75)
3	8T-4244	Nut (M12X1.75)

Table 5

Required Parts for Installation of the 276-4002 Mirror Group
Qty	Part Number	Description
4	7D-9969	Support
1	134-0987	Bracket Assembly
2	134-0989	Block
2	144-2227	Mirror Assembly
1	322-7277	Sticky Mirror Assembly
2	284-1188	Tube Assembly
1	295-8899	Plate
1	129-3180	Locknut (M12X1.5)
1	279-0476	Mirror Assembly
1	3K-6060	Locknut (3/8 - 16)
5	5P-1075	Hard Washer
2	5P-1076	Hard Washer
1	5P-7468	Clip
1	5P-7469	Clip
4	5S-7379	Bolt (3/8 - 16)
4	7X-3391	Hard Washer
1	7X-7468	Convex Mirror Assembly
7	8T-4121	Hard Washer
3	8T-4136	Bolt (M10X1.5)
1	8T-4183	Bolt (M12X1.75)
4	8T-4186	Bolt (M10X1.5)
4	8T-6868	Bolt (M12X1.75)
1	8T-7087	Grommet
14	3S-2093(1)	Wiring Harness
1	284-5263(1)	Wiring Harness
1	2G-1133(1)	Grommet
1	7G-7053(1)	Grommet

(1)	These parts make up the 247-5612 Mirror Wiring Gp.

Table 6

Required Parts for Installation of 328-9833 Mirror Group (if equipped)
Qty	Part Number	Description
1	330-5264	Tube As
2	329-7328	Convex Mirrors
10	7Y-5262	U-bolts (M10X1.5)
32	8T-4121	Hard Washers
24	8T-4133	Nuts (M10X1.5)
1	331-4027	Tube As
4	8T-4182	Bolts (M10X1.5)
4	198-4777	Hard Washers
2	334-1004	Tube Assemblies
2	144-2227	Mirror Assemblies
4	5P-1075	Hard Washers
4	5S-7379	Bolts (3/8 - 16)
4	8T-4223	Hard Washers
4	7X-0326	Bolts (1/2 - 13)
4	7D-9969	Supports
11	3S-2093(1)	Cable Straps
1	284-5263(1)	Wiring Harness
1	2G-1133(1)	Grommet
1	298-7329	Bracket As
1	300-5512	Mirror As
4	8T-4186	Bolts (M10X1.5)
4	8T-4195	Bolts (M10X1.5)
1	300-0560	Mirror As
2	134-0989	Blocks
1	7G-7053(1)	Grommet

(1)	Part of 247-5612 Mirror Wiring Gp

Table 7

Required Parts for Installation of 272-2552 Antenna Mounting Group Which is a Part of the 268-7809 Communication Installation Group (if equipped)
Qty	Part Number	Description
1	284-8533	Antenna Assembly
1	283-5837	Plate
18	3S-2093	Cable Straps
1	7G-7053	Grommet
1	2G-1133	Grommet

Table 8

Required Parts for Installation of 281-2928 Bracket Assembly and the 251-4160 Camera Group Which is a Part of the 247-5616 Monitor Wiring Group (if equipped)
Qty		Part Number	Description
1		281-2928	Bracket Assembly
1		251-4160	Camera Group
1		251-4169	Coaxial Cable Assembly
37		7K-1181	Cable Straps
1		4P-7581	Clip
1		4P-8134	Clip
1		8T-4121	Hard Washer
1		8T-4137	Bolt (M10X1.5)
1		4P-7428	Clip

Table 9

Required Parts for Installation of 282-4404 Guard Which is a Part of the 276-4866 Fender Group
Qty	Part Number	Description
1	282-4404	Guard
1	282-4402	Plate
1	282-4403	Plate
10	8T-4195	Hard Washer
10	8T-4136	Bolt (M10X1.5)

Table 10

Required Parts for Installation of 297-3277 Guard Which is a Part of the 276-4866 Fender Group
Qty	Part Number	Description
1	297-3277	Guard
1	255-2603	Plate
7	8T-4121	Hard Washer
7	8T-4136	Bolt (M10X1.5)

Table 11

Required Parts for Installation of 255-7619 Guard Which is a Part of the 276-4866 Fender Group
Qty	Part Number	Description
1	255-7619	Guard
1	255-7631	Plate
1	255-7629	Plate Assembly
7	8T-4195	Bolt (M10X1.5)
7	8T-4121	Hard Washer

Table 12

Required Parts for Installation of 255-2571 Guard Which is a Part of the 276-4866 Fender Group
Qty	Part Number	Description
1	255-2571	Guard
1	282-3051	Plate
1	282-2124	Plate
1	255-2514	Plate
8	8T-4195	Bolt (M10X1.5)
8	8T-4121	Hard Washer

Table 13

Required Parts for Installation of 281-4529 Plate Which is a Part of the 276-4866 Fender Group
Qty	Part Number	Description
1	281-4529	Plate
4	8T-4137	Bolt (M10X1.5)
4	7X-7729	Washer

Table 14

Required Parts for Installation of Canopy Assembly
Qty		Part Number	Description	Model
1		262-5970 or 286-1562	Canopy Assembly	773F
1		284-1550 or 258-4750	Canopy Assembly	775F
1		277-2171 or 291-4370 247-6182 or 264-7805 286-5661	Body and Canopy Assembly	773F
1		291-4372 or 291-4371 264-7806 or 265-3805 285-2100 or 247-6200	Body and Canopy Assembly	775F

Table 15

Required Parts for the Installation of the Guards for the 773F on the 247-6184 Truck Body, 247-6185 Truck Body, 247-6186 Truck Body, and the 262-5975 Truck Body
Qty	Part Number	Description
1	293-3626	Guard
1	293-3627	Guard
1	262-5965	Guard
25	5P-2228	Bolts (1/2-13x1 inch)
25	8T-4223	Hard Washers
1	264-4519	Guard
1	264-4520	Guard
28	7X-0349	Bolts (5/8-11x3 inch)
28	7X-0515	Hard Washers
28	3R-8530	Bosses

Table 16

Required Parts for the Installation of Guards for the 775F on the 247-6201 Export Body, 247-6202 Truck Body, 247-6203 Truck Body, and the 283-1091 Truck Body
Qty	Part Number	Description
1	234-8690	Guard
1	291-4488	Guard
1	291-4493	Guard
25	5P-2228	Bolt (1/2-13x1 inch)
25	8T-4223	Hard Washer

Table 17

Required Parts for the Installation of Body Plug.
Qty	Part Number	Description
1	234-8689	Plug

Table 18

Required Parts for Installation of 113-1216 Baffle Which Is a Part of the 308-0615 Body Mounting Group and the 308-0617 Body Mounting Group
Qty	Part Number	Description
1	113-1216	Baffle
2	031-9831	Screw (3/8-16X3/4)

Table 19

Required Parts for Installation of 132-6650 Pin Assembly Which is a Part of the 308-0615 Body Mounting Group and the 308-0617 Body Mounting Group
Qty	Part Number	Description
2	132-6650	Pin
2	7D-7488	Thrust Washer
2	124-9014	Thrust Washer
2	8W-8456	Plate
4	5P-2566	Bolt (1/2-13X1.5)
4	5P-1076	Hard Washer
2	3B-8489	Grease Fitting

Table 20

Required Parts for Installation of 145-5252 Hoist Cylinder and Mounting Group
Qty	Part Number	Description
2	8W-1367	Pin
4	7D-2955	Spacer
2	8W-1342	Plate
4	5P-2566	Bolt (1/2-13X1.5)
4	8T-4223	Hard Washer

Table 21

Required Parts for Installation of the 307-8767 Plate Assembly Which Is a Part of the 308-0615 Body Mounting Group and the 308-0617 Body Mounting Group
Qty	Part Number	Description
1	307-8767	Plate Assembly
2	5S-7379	Bolt
2	8T-4896	Hard Washer

Table 22

Required Parts for Installation of Pads and of Shims Which Is a Part of the 308-0615 Body Mounting Group and the 308-0617 Body Mounting Group
Qty	Part Number	Description
30	106-8224	Shim
8	229-6176	Pad Assembly
24	5P-2566	Bolt (1/2-13X1.5)
24	8T-4223	Hard Washer

Table 23

Required Parts for Installation of 253-7493 Rock Ejector Assembly Which is a Part of the 308-0615 Body Mounting Group and the 308-0617 Body Mounting Group
Qty	Part Number	Description
2	253-7493	Rock Ejector
2	6G-7773	Pin
4	3B-4647	Cotter Pin
16	1D-0503	Washer
2	137-1995(1)	Bracket
1	266-0674	Bracket
1	266-0672	Bracket

(1)

This bracket is used in the following situations: 773F Trucks with the 247-6182 Body and Canopy, 773F Trucks with the 264-7805 Body and Canopy, 773F Trucks with the 266-5661 Body and Canopy, 775F Trucks with the 264-7806 Body and Canopy, 775F Trucks with the 285-2100 Body and Canopy, 775F Trucks with the 291-4371 Body and Canopy and 775F Trucks with the 247-6200 Body and Canopy.

Table 24

Required Parts for Installation of 8W-7481 Guard Which is a Part of the 308-0615 Body Mounting Group and the 308-0617 Body Mounting Group
Qty	Part Number	Description
2	8W-7481	Guard
2	2G-7826	Strip
28	5P-2566	Bolt (1/2-13X1.5)
56	8T-4223	Hard Washer
28	6V-8188	Nut
2	288-1763	Plate

Table 25

Required Parts for Installation of 288-2367 Guard Which is a Part of the 308-0615 Body Mounting Group and the 308-0617 Body Mounting Group
Qty	Part Number	Description
1	288-2367	Guard
1	2G-7826	Strip
10	5P-2566	Bolt (1/2-13X1.5)
20	8T-4223	Hard Washer
10	6V-8188	Nut
1	292-0126(1) 288-1762(2)	Plate

(1)	This plate is used with the Dual Slope Body .
(2)	This plate is used with the Flat Floor Body .

Table 26

Required Parts for Installation of 293-6642 Wheel Chock Group
Qty		Part Number	Description
1		293-6637	Bracket Assembly
1		293-6638	Bracket Assembly
2		105-1385	Wheel Chock
4		8T-4195	Bolt
4		8T-4121	Hard Washer
2		5P-8837	Lock Pin

Table 27

Required Parts for Installation of 287-6651 Film Group that is used on the 773F Dual-Slope bodies
Qty	Part Number	Description
1	289-9267	Film
1	290-3465	Film
1	290-3464	Film

Table 28

Required Parts for the Installation of the 287-6650 Film Group that is Used on 773F Flat-Floor Bodies
Qty	Part Number	Description
1	289-9271	Film
1	289-9269	Film
1	289-9267	Film

Table 29

Required Parts for Installation of the 287-6652 Film Group that is Used on 775F Flat-Floor Bodies
Qty	Part Number	Description
1	289-9277	Film
1	289-9276	Film
1	289-9275	Film

Table 30

Required Parts for the Installation of the 287-6653 Film Group that is Used on 775F Dual-Slope Bodies
Qty	Part Number	Description
1	290-3466	Film
1	290-3467	Film
1	289-9275	Film

Weights and Specifications

Machine Weights

Note: Weight of body varies depending on the configuration.

Note: Truck weight with 100% fuel, hoist, body mounting group, rims, and tires

• The approximate weight of the 773F Off-Highway Truck is 45200 kg (99650 lb).

• The approximate weight of the 773F Off-Highway Truck canopy is 1170 kg (2580 lb).

• The approximate weight of the 773F Off-Highway Truck body and canopy is 12700 kg (28000 lb).

• The approximate weight of the 775F Off-Highway Truck is 46200 kg (101850 lb).

• The approximate weight of the 775F Off-Highway Truck canopy is 1220 kg (2690 lb).

• The approximate weight of the 775F Off-Highway Truck body and canopy is 13660 kg (30100 lb).

• The weight of each tire and rim is 1400 kg (3090 lb).

Machine Specifications

• The approximate length of the 773F and 775F Off-Highway Machines is 10.3 m (33.90 ft).

• The approximate height of the 773F Off-Highway Machine and the 775F Off-Highway Machine is 4.5 m (14.80 ft).

• The approximate width of the 773F Off-Highway Machine and the 775F Off-Highway Machine is 5.4 m (17.80 ft).

Torque Specifications

• Tighten the bolts on the front suspension cylinders to a torque of 945 ± 35 N·m (695 ± 25 lb ft).

• Tighten the full nuts on the rim assembly to a torque of 1210 ± 100 N·m (893 ± 73.8 lb ft).

• Tighten the locknut on the rear view mirror to a torque of 25 ± 5 N·m (220 ± 45 lb in).

Chains and Cables

Use approved cables, chains, and lifting devices in order to lift the components. Refer to the manufacturer's literature in order to determine the application when you select the items that follow: cable, chain and lifting devices. When you lift a component, the lift angle is critical. Refer to the Illustration that follows in order to see the effect of the lift angle on the working load limit.

Illustration 1	g00629745
(A) The load capacity is 100% of the working load limit for the sling. (B) The load capacity is 86% of the working load limit for the sling. (C) The load capacity is 70% of the working load limit for the sling. (D) The load capacity is 50% of the working load limit for the sling.

Necessary Hoist Capacity

Chassis Assembly

When the differential housing is on supports, a hoist with a capacity of 10000 kg (22000 lb) is necessary in order to lift the chassis at the front lifting point.

When the front frame crossmember is on supports, a hoist with a capacity of 8600 kg (19000 lb) is necessary in order to lift the chassis at the rear lifting point.

Assembled Machine Without Body

When the rear tires are on the ground, a hoist with a capacity of 17000 kg (38000 lb) is necessary in order to lift the machine at the front lifting point.

When the front tires are on the ground, a hoist with a capacity of 16000 kg (35000 lb) is necessary in order to lift the machine at the rear lifting points.

Access to Cab

A handle is supplied on the right side cab window of the machine. This handle is used to open the window on the right side of the truck. The window is used for access to the cab until the left side catwalk has been installed. Upon installation of the catwalk, the external handle (1) should be removed from the window.

Illustration 2	g01302161

Illustration 3	g01302163
Remove the outside lever.

Inspect the Parts and Prepare the Machine for Assembly

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

Properly prepare an area in order to assemble the machine in a way that is safe and efficient.

1. Select an appropriate area for assembly. Select an area that is flat, smooth, and well drained. Make sure that there is sufficient space for the following items: machine, components, tools and lifting devices.

2. When you unload the components, set the components near the machine. Leave enough space around the machine in order to maneuver the lifting device. Carefully remove parts for inspection. Refer to the tables in this publication in order to ensure that all parts are present and that all parts are undamaged.

   Note: Do not open the bags of hardware for inspection. Open the bags when the hardware is needed in order to prevent lost hardware.

Remove the Shipping Brackets

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Illustration 4	g01209754

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Illustration 5	g01209768

1. Remove bolts (2) from shipping brackets (1) on the front wheel spindles and on the front suspension cylinders.

   Note: Install the two bottom bolts (A) in each front suspension cylinder. The bolts are stored in the operator's compartment. Tighten the bolts to a torque of 945 ± 35 N·m (695 ± 25 lb ft).

Install the Rear Tire and Rim Assemblies

Illustration 6	g00997017

Illustration 7	g00518945
Remove the tire and rim assembly from the truck body.

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NOTICE
Failure to remove the shipping bracket from the floor of the body prior to removing the tire and rim will result in damage to the tire.

1. Remove the rod and the nut that is holding the tire assembly to the body. Remove the shipping bracket from the bottom of the truck body.

2. Remove the tire and rim assembly from the truck body. Remove the paint from the contact surfaces of the rim.
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   Illustration 8	g01209839
   Remove the nuts from the wheel studs.

3. Remove the full nuts and the hard washers from the wheel studs. Remove the paint from the contact surfaces around the wheel studs.
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   Personal injury can result working with the tire and rim without precautions. Personal injury can result if the weight shifts and causes movement of the tire and rim. When starting nuts on the studs, do not put your arm between the rim and final drive without first wedging a block of hardwood between the rim and final drive.

4. Use a suitable hydraulic lifting device under the main frame in order to raise the machine enough to install the tire and rim assembly.
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   Illustration 9	g00518947
   Use a tire handler in order to install tire and rim assembly.

5. Use a tire handler or use a suitable lifting device in order to install the tire and rim assembly on the truck.
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   Illustration 10	g00518949
   Install the tire and rim.

6. Install 14 full nuts (1) and 14 hard washers (2). Tighten the 14 full nuts to a torque of 1210 ± 100 N·m (893 ± 73.8 lb ft).

   Note: Apply anti-seize compound to washers (2). Apply anti-seize compound to the studs.

   Note: Refer to the Operation and Maintenance Manual in order to find tire inflation instructions.

7. Repeat Step 1 through Step 6 for the tire and rim assembly on the opposite side of the machine.

8. Carefully lower the machine to the ground.

Install the 245-1116 Ladder Group

Table 31

Required Parts for Installation of 245-1116 Ladder Group
Item	Qty	Part Number	Description
1	2	223-4469	Step Group
2	8	8T-4192	Bolt (M12X1.75)
3	8	8T-4223	Hard Washer

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Illustration 11	g01294648
Install the ladders to the front bumper.

1. Install each step group (1) with four bolts (2) and four washers (3).

Install the 274-7535 Walkway Group

Table 32

Required Parts for Installation of 274-7535 Walkway Group
Item	Qty	Part Number	Description
1	1	274-7536	Catwalk Assembly
2	8	8T-4193	Bolt (M16X2)
3	8	7X-0583	Hard Washer

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Illustration 12	g01302083
Install the catwalk.

1. Use a suitable lifting device in order to position catwalk (1). Install the catwalk (1) with eight bolts (2) and eight washers (3). The catwalk weighs 82 kg (181 lb).
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   Illustration 13	g01312596

2. If the machine is equipped with the Payload Monitoring System, remove bolt (B), washer (C), and clip (D).

3. Install plug (A) into the receptacle and tighten mounting screw. Install the clip (D), washer (C), and bolt (B).

Install the 274-7545 Ladder Group

Table 33

Required Parts for Installation of 274-7545 Ladder Group
Item	Qty	Part Number	Description
1	1	274-7546	Stair Assembly
2	4	115-6433	Washer
3	2	7T-8332	Mount
4	6	7X-0590	Hard Washer
5	2	8T-4244	Nut (M12X1.75)
6	2	8T-4648	Bolt (M12X1.75)
7	4	8T-4956	Bolt (M12X1.75)

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Illustration 14	g01302762
Install the left-hand stairs.

1. Use a suitable lifting device in order to position stairs (1). Secure the stairs (1) to the catwalk with four bolts (7) and four washers (2). The stairs weigh 44 kg (97 lb).

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Illustration 15	g01305041

1. Secure the stairs (1) to the support assembly with two mounts (3), six washers (4), two bolts (6), and two nuts (5).
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   Illustration 16	g01624496

2. Secure wiring harness (A) with straps (B) to the mounting weld links on the side of stair assembly (1).
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   Illustration 17	g01624499
   View of Area Z

3. Connect the electrical connections on wiring harness (A). Install connector (C) to the ground level engine shutdown switch. Install connector (D) to the courtesy light switch. Install connector (E) to the left front wiring harness. Secure lower end of wiring harness (A) with strap (B) and clip (F). Secure connector (C) with clip (G). Secure connector (D) with clip (G). Secure connector (E) with clip (H).

   Note: The left front wiring harness contains connections to the lower LH high beam headlight, the lower LH low beam headlight, and the horn.

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   Illustration 18	g01625993

4. Route wiring harness (A) through the grommet in the cowling and through the left-hand radiator cowling support assembly. Attach connector (J) to the main chassis wiring harness. Route wiring harness (A) upward. Then route wiring harness (A) back through the cowling. Secure wiring harness (A) with straps (B) and clips (F).
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   Illustration 19	g01625994

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   Illustration 20	g01626613

5. Install connector (M) to the courtesy light.
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   Illustration 21	g01626620

6. Install connector (K) to the upper LH high beam headlight. Install connector (L) to the upper LH low beam headlight.
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   Illustration 22	g01626033

7. Route the upper portion of wiring harness (A) up the stairs and through the grommet in plate (N). Install connector (P) to the rectangular turn signal light. Secure wiring harness (A) with straps (B), straps (R), and clip (S). Secure connector (P) with clip (C).

   Note: Plate (N) is part of the catwalk assembly.

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   Illustration 23	g01626034
   View of Area Y

8. Install connector (T) to the LH mirror. Install connector (U) to the TPMS interface. Install connector (V) to the round amber light. Secure connector (T) with clip (G). Secure connector (V) with clip (G). Secure connector (U) with clip (C).

Install the 276-3111 Handhold Group

Table 34

Required Parts for Installation of 276-3111 Handhold Group
Item	Qty	Part Number	Description
1	1	276-3112	Left hand Handrail Assembly
2	1	276-3113	Handrail Assembly
3	1	276-3168	Handrail Assembly
4	1	276-3114	Handrail Assembly
5	2	255-2560	Handrail Assembly
6	1	277-7702	Handrail Assembly
7	68	8T-4121	Hard Washer
8	44	8T-4136	Bolt (M10X1.5)
9	24	8T-4195	Bolt (M10X1.5)
10	1	281-2807	Handrail Assembly
11	6	8T-7087	Grommet
12	6	5P-7468	Clip
13	6	5P-7469	Clip
14	6	8T-4223	Hard Washer
15	3	8T-4183	Bolt (M12X1.75)
16	3	8T-4244	Nut (M12X1.75)

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Illustration 24	g01303846

1. Use eight bolts (8) and eight washers (7) to install the two rail assemblies (5) to the front bumper.
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   Illustration 25	g01303871

2. Use four bolts (8) and four washers (7) to install the rail assembly (10) to the left side of the front support assembly.

3. Use eight bolts (9) and eight washers (7) to install the rail assembly (4) to the stairs.
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   Illustration 26	g01305157

   Note: Orient the hardware in order to prevent a potential hazard or pinch point.

4. Install four grommets (11) on the rail assemblies. Use four of clip (12) and four of clip (13) on each pair of grommets (11) to secure rail assemblies together. Use two bolts (15), four washers (14), and two nuts (16) to secure clip (12) to clip (13).
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   Illustration 27	g01303789

5. Use 12 bolts (8) and 12 washers (7) to install the rail assembly (1) to the left side catwalk. Also use four bolts (9) and four washers (7) to secure rail (1) to the catwalk.
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   Illustration 28	g01304227

6. Use four bolts (8) and four washers (7) to install the rail assembly (6) to the right side of the front support assembly.
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   Illustration 29	g01304008

   Note: Orient the hardware in order to prevent a potential hazard or pinch point.

7. Use six bolts (8) and six washers (7) to install the rail assembly (2) to the right side of the truck. Also use 12 bolts (9) and 12 washers (7) to secure the rail assembly (2) to the machine.

8. Install two grommets (11) on the rail assemblies. Use four of clip (12) and two of clip (13) on each pair of grommets (11) to secure rail assemblies together. Use two bolts (15), four washers (14), and two nuts (16) to secure clip (12) to clip (13).
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   Illustration 30	g01304177

9. Use six bolts (8) and six washers (7) to install the handrail assembly (3) to the catwalk on the right side of the hood assembly.

Install the 276-4002 Mirror Group

Table 35

Required Parts for Installation of 276-4002 Mirror Group
Item	Qty	Part Number	Description
1	4	7D-9969	Support
2	1	134-0987	Bracket Assembly
3	2	134-0989	Block
4	2	144-2227	Mirror Assembly
5	1	322-7277	Sticky Mirror Assembly
6	2	284-1188	Tube Assembly
7	1	295-8899	Plate
8	1	129-3180	Locknut (M12X1.5)
9	1	279-0467	Mirror Assembly
10	1	3K-6060	Locknut (3/8 - 16)
11	5	5P-1075	Hard Washer
12	2	5P-1076	Hard Washer
13	1	5P-7468	Clip
14	1	5P-7469	Clip
15	4	5S-7379	Bolt (3/8 - 16)
16	4	7X-3391	Hard Washer
17	1	7X-7468	Convex Mirror Assembly
18	7	8T-4121	Hard Washer
19	3	8T-4136	Bolt (M10X1.5)
20	1	8T-4183	Bolt (M12X1.75)
21	4	8T-4186	Bolt (M10X1.5)
22	4	8T-6868	Bolt (M12X1.75)
23	1	8T-7087	Grommet
24	14	3S-2093(1)	Cable Straps
25	1	284-5263(1)	Wiring Harness
26	1	2G-1133(1)	Grommet
27	1	7G-7053(1)	Grommet

(1)	These parts make up the 247-5612 Mirror Wiring Gp.

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Illustration 31	g01304769

1. Use the following parts to install mirror (17): one grommet (23), one clip (13), one clip (14), one plate (7), one bolt (20), two washers (12), one locknut (8) and one locknut (10) and one washer (11). Torque the locknut (10) to 25 ± 5 N·m (18.4 ± 3.7 lb ft).
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   Illustration 32	g01304796

2. Use four bolts (15) and four washers (11) to assemble each right-hand mirror assembly (4) to each tube assembly (6).
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   Illustration 33	g01305790

3. Use four bolts (22) and four washers (16) to secure the tube assembly (6) and support (1) to the rail assembly.
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   Illustration 34	g01529513
   RH side view of the mirror

4. Attach wiring harness (25) to the handrail.

5. Use cable straps (24) to secure the wiring for the mirror to the appropriate locations on the hand rail, and beneath the catwalk.
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   Illustration 35	g01530505
   View of grommet (26) on the RH side of the catwalk

6. Install the grommet (26) on the right-hand side of the catwalk. Run the wiring for the mirror through grommet (26) in the catwalk. Connect the wiring for the mirror beneath the catwalk.
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   Illustration 36	g01304718

7. Assemble the left-hand mirror assembly (9) to the bracket assembly (2). Use three bolts (19) and three washers (18).
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   Illustration 37	g01530514

8. Install the left-hand mirror assembly to the rail assembly. Use four bolts (21) and four washers (18) to secure two blocks (3) to the mirror assembly.

9. Repeat Step 8 in order to attach the wiring harness to the LH handrail and through grommet (27).
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   Illustration 38	g01307472

10. Insert the wiring for the left-hand mirrors through grommet (27) in the catwalk. Connect the wiring for the mirror beneath the catwalk.
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    Illustration 39	g01450713

11. In order to install mirror group (5), the following conditions need to be met:

    • Surface temperature is between 21 °C (70 °F) and 38 °C (100 °F).

    • The surface is clean and dry. Clean the surface with a 50:50 solution of isopropyl alcohol and water. Wipe the surface with a clean paper towel until the surface is dry.

12. Remove the backing from the adhesive on mirror assembly (5). Position mirror assembly (5) to dimension (A) and dimension (B) on mirror (9).
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    Illustration 40	g01450711

13. Install the mirror assembly (5) to mirror (9). Apply a minimum pressure of 105 kPa (15 psi) in two locations in order to secure legs of mirror assembly (5). Ensure that the legs of the new mirror fully contact the surface of the mirror group (A).

Install the 328-9833 Mirror Group (if equipped)

Table 36

Required Parts for Installation of 328-9833 Mirror Group (if equipped)
Item	Qty	Part Number	Description
1	1	330-5264	Tube As
2	2	329-7328	Convex Mirrors
3	10	7Y-5262	U-Bolts (M10X1.5)
4	32	8T-4121	Hard Washers
5	24	8T-4133	Nuts (M10X1.5)
6	1	331-4027	Tube As
7	4	8T-4182	Bolts (M10X1.5)
8	4	198-4777	Hard Washers
9	2	334-1004	Tube Assemblies
10	2	144-2227	Mirror Assemblies
11	4	5P-1075	Hard Washers
12	4	5S-7379	Bolts (3/8 - 16)
13	4	8T-4223	Hard Washers
14	4	7X-0326	Bolts (1/2 - 13)
15	4	7D-9969	Supports
16	11	3S-2093(1)	Cable Straps
17	1	284-5263(1)	Wiring Harness
18	1	2G-1133(1)	Grommet
19	1	298-7329	Bracket As
20	1	300-5512	Mirror As
21	4	8T-4186	Bolts(M10X1.5)
22	4	8T-4195	Bolts(M10X1.5)
23	1	300-0560	Mirror As
24	2	134-0989	Blocks
25	1	7G-7053(1)	Grommet

(1)	Part of 247-5612 Mirror Wiring Gp

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Illustration 41	g01627115
View of catwalk assembly next to cab

1. Use the following parts in order to install tube as (1): six U-bolts (3), 12 hard washers (4) and 12 nuts (5).

2. Install front left convex mirror (2) onto tube as (1).
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   Illustration 42	g01627524
   View of front right corner of truck

3. Use the following parts in order to install tube as (6): four U-bolts (3), eight hard washers (4), eight nuts (5), four bolts (7) and four hard washers (8).

4. Install front right convex mirror (2) onto tube as (6).
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   Illustration 43	g01627861

5. Use four bolts (12) and four hard washers (11) in order to assemble each right-hand mirror as (10) to one of the tube assemblies (9).
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   Illustration 44	g01627863

6. Use four bolts (14) and four hard washers (13) in order to secure both tube assemblies (9) and four supports (15) to the rail assembly.
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   Illustration 45	g01628354

7. Attach the connectors from each mirror as (10) to wiring harness (17). Use cable straps (16) in order to secure the wiring harness to the appropriate locations on the hand rail.
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   Illustration 46	g01629515

8. Install grommet (18) on the right-hand side of the catwalk. Run wiring harness (17) through grommet (18). Connect wiring harness (17) to the appropriate connector on platform harness as (A) beneath the catwalk.
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   Illustration 47	g01629517

9. Assemble upper left mirror as (20) to bracket as (19). Use two bolts (22), four hard washers (4), and two nuts (5).

10. Assemble lower left mirror as (23) to bracket as (19). Use two bolts (22), four hard washers (4), and two nuts (5).

11. Install bracket as (19) to the rail assembly. Use four bolts (21) and four hard washers (4) in order to secure two blocks (24) to bracket as (19).
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    Illustration 48	g01629519

12. Use cable straps (16) in order to secure the wiring harness to the appropriate locations on the hand rail.
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    Illustration 49	g01631794

13. Install grommet (25) on the left-hand side of the catwalk. Insert the wiring for the left-hand mirror through grommet (25). Connect the wiring for the mirror to the appropriate connector on platform harness as (B) beneath the catwalk.

Install the 272-2552 Antenna Mounting Group Which is a Part of the 268-7809 Communication Installation Gp (if equipped)

Table 37

Required Parts that are Needed for the Installation of the 272-2552 Antenna Mounting Group Which is Part of the 268-7809 Communication Installation GP (if equipped)
Item	Qty	Part Number	Description
1	1	284-8533	Antenna Assembly
2	1	283-5837	Plate
3	18	3S-2093	Cable Straps
4	1	7G-7053	Grommet
5	1	2G-1133	Grommet

Illustration 50	g01623899

1. Install plate (2) to the mirror with the hardware for mounting the mirror.

2. Install antenna assembly (1) to plate (2).

3. Use cable straps (3) in order to secure the wire to the weld links on the handrail.

4. Route the wire from antenna assembly (1) downward through grommet (4).
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   Illustration 51	g01623900
   Bottom View

5. Secure wire from antenna assembly (1) to the weld links beneath the catwalk with cable straps (3).

6. Route antenna assembly (1) through the hole in the cab floor by using grommet (5).

7. Connect the reverse TNC connector to the port closest to the LED output on the radio.

8. Connect the TNC connector to the remaining port on the radio.

Install the 281-2928 Bracket Assembly and the 251-4160 Camera Group Which is a Part of the 247-5616 Monitor Wiring Group (if equipped)

Table 38

Required Parts for Installation of 281-2928 Bracket Assembly and the 251-4160 Camera Group Which is a Part of the 247-5616 Monitor Wiring Group (if equipped)
Item	Qty	Part Number	Description
1	1	281-2928	Bracket Assembly
2	1	251-4160	Camera Group
3	1	251-4169	Coaxial Cable Assembly
4	37	7K-1181	Cable Straps
5	1	4P-7581	Clip
6	1	4P-8134	Clip
7	1	8T-4121	Hard Washer
8	11	8T-4137	Bolt (M10X1.5)
9	1	4P-7428	Clip

Illustration 52	g01324682

1. Route the coaxial cable assembly (3) along the routing of the main wiring harness for the chassis.

2. Secure cable assembly (3) to the main harness with cable straps (4). Start at the rear of the chassis harness and follow the main chassis harness completely up to the connection at the cab.

3. Install clip (9) to the frame near the mount for the hoist cylinder.

4. Secure cable assembly (3) to clip (9) by using cable strap (4).

5. Install clip (5) to the frame of the machine. Secure cable assembly (3) to clip (5).

6. In order to install bracket (1) and clip (6) to the machine, use a hard washer (7) and bolt (8).

7. Secure cable assembly (3) to clip (6) by using cable strap (4).

8. Use the supplied hardware in order to mount the camera group (2) to bracket (1).

Install the 282-4404 Guard Which is a Part of the 276-4866 Fender Group

Table 39

Required Parts for Installation of 282-4404 Guard Which is a Part of the 276-4866 Fender Group
Item	Qty	Part Number	Description
1	1	282-4404	Guard
2	1	282-4402	Plate
3	1	282-4403	Plate
4	10	8T-4121	Hard Washer
5	10	8T-4136	Bolt (M10X1.5)

Illustration 53	g01304798

1. Use plate (2) and plate (3) in order to assemble guard (1). Use 10 bolts (5) and 10 washers (4).

Install the 297-3277 Guard Which is a Part of the 276-4866 Fender Group

Table 40

Required Parts for Installation of 297-3277 Guard Which is a Part of the 276-4866 Fender Group
Item	Qty	Part Number	Description
1	1	297-3277	Guard
2	1	255-2603	Plate
3	7	8T-4121	Hard Washer
4	7	8T-4136	Bolt (M10X1.5)

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Illustration 54	g01304799

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Illustration 55	g01304800

1. Use seven bolts (4) and seven washers (3) in order to install guard (1) and plate (2).

Install the 255-7619 Guard Which is a Part of the 276-4866 Fender Group

Table 41

Required Parts for Installation of 255-7619 Guard Which is a Part of the 276-4866 Fender Group
Item	Qty	Part Number	Description
1	1	255-7619	Guard
2	1	255-7631	Plate
3	1	255-7629	Plate Assembly
4	7	8T-4195	Bolt (M10X1.5)
5	7	8T-4121	Hard Washer

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Illustration 56	g01305077

1. Install the guard (1), plate (2), and plate (3). Use 7 bolts (4) and 7 washers (5).

Install the 255-2571 Guard Which is a Part of the 276-4866 Fender Group

Table 42

Required Parts for Installation of 255-2571 Guard Which is a Part of the 276-4866 Fender Group
Item	Qty	Part Number	Description
1	1	255-2571	Guard
2	1	282-3051	Plate
3	1	282-2124	Plate
4	1	255-2514	Plate
5	8	8T-4195	Bolt (M10X1.5)
6	8	8T-4121	Hard Washer

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Illustration 57	g01305147

1. Install the guard (1), plate (4), and plate (3). Use eight bolts (5) and eight washers (6).

Install the 281-4529 Plate Which is a Part of the 276-4866 Fender Group

Table 43

Required Parts for Installation of 281-4529 Plate Which is a Part of the 276-4866 Fender Group
Item	Qty	Part Number	Description
1	1	281-4529	Plate
2	4	8T-4137	Bolt (M10X1.5)
3	4	7X-7729	Washer

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Illustration 58	g01305150

1. Install the plate (1). Using four bolts (2) and four washers (3).

Install the Canopy on the Body

Table 44

Parts for Installation of Canopy
Qty		Part Number	Description	Model
1		262-5970 or 286-1562	Canopy Assembly	773F
1		284-1550 or 258-4750	Canopy Assembly	775F
1		277-2171 or 291-4370 247-6182 or 264-7805 286-5661	Body and Canopy Assembly	773F
1		291-4372 or 291-4371 264-7806 or 265-3805 285-2100 or 247-6200	Body and Canopy Assembly	775F

Table 45

Weld Specifications
Weld	Description	Body and Canopy Assembly Usage for 773F	Body and Canopy Assembly Usage for 775F
W1	6 mm (0.24 inch)fillet weld with 1.5 mm (0.06 inch) of penetration	277-2171 291-4370 247-6182 264-7805 286-5661	285-2100 247-6200 264-7806 265-3805 291-4372
W1	8 mm (0.32 inch)fillet weld with 1.5 mm (0.06 inch) of penetration		291-4371
W2	6 mm (0.24 inch) fillet weld with 2.5 mm (0.10 inch) of penetration	286-5661
W2	6 mm (0.24 inch)fillet weld	264-7805 247-6182 291-4370 277-2171	291-4372 265-3805 264-7806 247-6200
W2	8 mm (0.32 inch)fillet weld		291-4371 285-2100
W3	8 mm (0.32 inch)fillet weld with 1.5 mm (0.06 inch) of penetration	291-4370	291-4372
W3	10 mm (0.40 inch)fillet weld with 1.5 mm (0.06 inch) of penetration	286-5661 264-7805 247-6182 277-2171	264-7806 247-6200 265-3805
W3	16 mm (0.63 inch)fillet weld with 1.5 mm (0.06 inch) of penetration		285-2100 291-4371
W4	10 mm (0.40 inch)fillet weld with 1.5 mm (0.06 inch) of penetration	277-2171	265-3805
W4	8 mm (0.32 inch)fillet weld with 1.5 mm (0.06 inch) of penetration	291-4370	291-4372
W4	16 mm (0.63 inch)fillet weld	247-6182 264-7805	264-7806
W4	16 mm (0.63 inch)fillet weld with 2.5 mm (0.10 inch) of penetration	286-5661
W4	16 mm (0.63 inch)fillet weld with 1.5 mm (0.06 inch) of penetration		291-4371 285-2100 247-6200
W5	6 mm (0.24 inch)fillet weld with 1.5 mm (0.06 inch) of penetration	291-4370 286-5661 264-7805 247-6182 277-2171	291-4372 265-3805 264-7806 247-6200
W5	8 mm (0.32 inch)fillet weld with 1.5 mm (0.06 inch) of penetration		285-2100 291-4371
W6	8 mm (0.32 inch)fillet weld with 1.5 mm (0.06 inch) of penetration	286-5661 264-7805 247-6182 291-4370 277-2171	265-3805 264-7806 291-4371 247-6200 285-2100 291-4372

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

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Personal injury or death can result from fumes, gases and ultraviolet rays from the weld arc. Welding can cause fumes, burn skin and produce ultraviolet rays. Keep your head out of the fumes. Use ventilation, exhaust at the arc, or both, to keep fumes and gases from your breathing area. Wear eye, ear and body protection before working. Protect yourself and others; read and understand this warning. Fumes and gases can be dangerous to your health. Ultraviolet rays from the weld arc can injure eyes and burn skin. Electric shock can cause death. Read and understand the manufacturer's instructions and your employer's safety practices. Do not touch live electrical parts. See "American National Standard Z49.1, Safety in Welding and Cutting" published by the American Welding Society. American Welding Society 2501 N.W. 7th Street Miami, Florida 33125 See "OSHA Safety and Health Standards, 29 CFR 1910", available from U.S. Department of Labor. U.S. Department of Labor Washington, D.C. 20210

Refer to Special Instruction, REHS1841, "General Welding Procedures" for more information regarding any welding procedure.

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Illustration 59	g01307761
Prepare the body without the canopy.

1. Before you align the canopy on the body, remove the paint from the mating surfaces. The front plate of the canopy fits against front wall (A) of the body.
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   Illustration 60	g01313546

2. Attach a suitable lifting device to canopy assembly (B).
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   Table 46

   Approximate Shipping Weight of Canopy
   Part Number	Weight
   262-5970	900 kg (1985 lb)
   286-1562	1170 kg (2580 lb)
   284-1550	1225 kg (2700 lb)
   258-4750	950 kg (2100 lb)

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   Illustration 61	g01307762

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   Illustration 62	g01307763

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   Illustration 63	g01310174

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   Illustration 64	g01310258

3. Tack weld the canopy (B) to the body (A). Visually verify the alignment of the canopy from a distance.

   Note: The top of the body (A) and the top of the canopy (B) must be parallel. The gap at the base of the canopy must be even. Trim the base of the canopy in order to maintain an even gap. The gap for welding should be 1.5 mm (0.06 inch).

   Note: Before welding, preheat the welding areas to the proper temperature. Refer to Special Instruction, REHS1841, "General Welding Procedures" for more information regarding any welding procedure. Use 164-3310 Infrared Thermometer in order to check for the proper preheat temperature.

4. At location (W1), weld the joint between the body (A) and the canopy (B).

   Note: Location (W1) includes both sides of the side wall of the canopy.

5. At location (W2), weld the joint between the body (A) and the canopy (B).

   Note: Location (W2) includes both the front and rear sides of the side wall of the canopy.

6. At location (W3), weld the joint between the body (A) and the canopy (B).

   Note: Location (W3) includes the welded joint outside the body.

   Note: Weld outward from the center of the body. Weld in even segments. Weld on alternate sides in order to minimize residual stresses in the canopy.

7. At location (W4), weld the joint between the body (A) and the canopy (B).

   Note: Location (W4) includes the welded joint outside the body.

   Note: Weld outward from the center of the body. Weld in even segments. Weld on alternate sides in order to minimize residual stresses in the canopy.

8. At location (W5), weld the joint between the body (A) and the canopy (B).

   Note: Location (W5) includes both sides of each plate.

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   Illustration 65	g01310808

9. At location (W6), weld plates (C) to the body and canopy on each side of the body.
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   Illustration 66	g00714920

10. Use 4C-4200 Paint in order to touch up the area of the weld.

Install the Guards on the Body

Table 47

Required Parts that are used for the Installation of Guards for the 773F on the 247-6184 Export Body, 247-6185 Truck Body, 247-6186 Truck Body, and the 262-5975 Truck Body
Item	Qty	Part Number	Description
1	1	293-3626	Guard
2	1	293-3627	Guard
3	1	262-5965	Guard
4	25	5P-2228	Bolt
5	25	8T-4223	Hard Washer
6	1	264-4519	Guard
7	1	264-4520	Guard
8	28	7X-0349	Bolts
9	28	7X-0515	Hard Washers
10	28	3R-8530	Bosses

Table 48

Required Parts for the Installation of Guards for the 775F on the 247-6201 Export Body, 247-6202 Truck Body, 247-6203 Truck Body, and the 283-1091 Truck Body
Item	Qty	Part Number	Description
1	1	291-4488	Guard
2	1	291-4493	Guard
3	1	234-8690	Guard
4	25	5P-2228	Bolt
5	25	8T-4223	Hard Washer

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Illustration 67	g01306737

1. Use a suitable lifting device in order to position guard (1) on the left side of the canopy. Guard (1) weighs 59 kg (130 lb).

2. Use ten bolts (4) and ten washers (5) in order to attach guard (1) to the canopy.

3. Position guard (2) on the left side of the canopy. Guard (2) weighs 13 kg (29 lb).

4. Use three bolts (4) and three washers (5) in order to attach guard (2) to the canopy.
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   Illustration 68	g01306740

5. Use a suitable lifting device in order to position guard (3) on the right side of the canopy. Guard (3) weighs 57 kg (126 lb).

6. Use 12 bolts (4) and 12 washers (5) in order to attach guard (3) to the canopy.

Illustration 69	g02494717

1. On 773F Off-Highway Trucks, use a suitable lifting device in order to position guard (6) on the right side of the body. Guard (6) weighs 128 kg (282 lb).

2. Use 14 bolts (8), 14 washers (9), and 14 bosses (10) in order to attach guard (6) to the body.

Illustration 70	g02494719

1. On 773F Off-Highway Trucks, use a suitable lifting device in order to position guard (7) on the right side of the body. Guard (7) weighs 128 kg (282 lb).

2. Use 14 bolts (8), 14 washers (9), and 14 bosses (10) in order to attach guard (7) to the body.

Install the Plug in the Body

Table 49

Part for Installation of Plug
Item	Qty	Part Number	Description
1	1	234-8689	Plug

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Illustration 71	g01308065

1. Use an 8.0 mm (0.32 inch) fillet weld (A) on both sides of plug (1) in order to secure the plug in the truck body.

Installation of the 113-1216 Baffle Which is a Part of the 308-0615 Body Mounting Group and the 308-0617 Body Mounting Group

Table 50

Required Parts for Installation of 113-1216 Baffle Which Is a Part of the 308-0615 Body Mounting Group and the 308-0617 Body Mounting Group
Item	Qty	Part Number	Description
1	1	113-1216	Baffle
2	2	031-9831	Bolt (3/8-16X3/4)

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Illustration 72	g00519177

1. Use two bolts (2) in order to install baffle (1) on the canopy.

Install the 132-6650 Pin Assembly Which is a Part of the 308-0615 Body Mounting Group and the 308-0617 Body Mounting Group

Table 51

Required Parts for Installation of 132-6650 Pin Assembly Which is a Part of the 308-0615 Body Mounting Group and the 308-0617 Body Mounting Group
Item	Qty	Part Number	Description
1	2	132-6650	Pin
2	2	7D-7488	Thrust Washer
3	2	124-9014	Thrust Washer
4	2	8W-8456	Plate
5	4	5P-2566	Bolt (1/2-13X1.5)
6	4	5P-1076	Hard Washer
7	2	3B-8489	Grease Fitting

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Illustration 73	g01308231

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

1. Remove the paint from the mating surfaces of the truck body and of the chassis. Connect a suitable lifting device to the truck body. Use the suitable lifting device in order to align the truck body on the chassis. Align the holes for the pivot pins.

   Note: When you align the truck body on the chassis, make sure that other chassis components are not damaged by contact against the truck body.

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   Illustration 74	g00540878

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   Illustration 75	g00544513

2. Insert pin (1) through the holes for the pivot pins. Also insert pin (1) through a thrust washer (2). Locate the thrust washer (2) inside the ear of the truck body. Thrust washer (2) and thrust washer (3) should be used in order to equally space the body and the frame assemblies on both sides.

   Note: Apply 5P-3931 Anti-Seize Compound to pin (1).

3. Use one plate (4), two bolts (5), and two hard washers (6) in order to lock pin (1) in place.

4. Install grease fitting (7) in pin (1).

5. Repeat the procedure for the opposite side.

Install the 145-5252 Hoist Cylinder and Mounting Group

Table 52

Required Parts for Installation of 145-5252 Hoist Cylinder and Mounting Group
Item	Qty	Part Number	Description
1	2	8W-1367	Pin
2	4	7D-2955	Spacer
3	2	8W-1342	Plate
4	4	5P-2566	Bolt (1/2-13X1.5)
5	4	8T-4223	Hard Washer

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Illustration 76	g00519380

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

2. Remove the paint from the mating surfaces of the truck body and the hoist cylinders. Use a suitable lifting device in order to align the holes of the truck body and of the hoist cylinders.
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   Illustration 77	g00543702

3. Remove the plastic caps from the threaded holes in the truck body. Install one pin (1) through the holes in the truck body and in the hoist cylinder. Place one spacer (2) on each side of the bearing of the hoist cylinder.

   Note: Apply 5P-3931 Anti-Seize Compound to pin (1).

   Note: If you do not use the spacers, the bearing of the hoist cylinder will prematurely fail.

4. Use one plate (3), two bolts (4), and two hard washers (4) in order to secure pin (1) in place.

5. Repeat the procedure on the opposite side.

Installation of the 307-8767 Plate Assembly Which Is a Part of the 308-0615 Body Mounting Group and the 308-0617 Body Mounting Group

Table 53

Required Parts for the Installation of the 307-8767 Plate Assembly Which Is a Part of the 308-0615 Body Mounting Group and the 308-0617 Body Mounting Group
Item	Qty	Part Number	Description
1	1	307-8767	Plate Assembly
2	2	5S-7379	Bolt
3	2	8T-4896	Hard Washer

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Illustration 78	g01436498

1. Use two bolts (2) and two hard washers (3) in order to install plate assembly (1).

Install the Pads and Shims for the Body

Table 54

Parts for Installation of Pads and of Shims
Item	Qty	Part Number	Description
1	30	106-8224	Shim
2	8	229-6176	Pad Assembly
3	24	5P-2566	Bolt (1/2-13X1.5)
4	24	8T-4223	Hard Washer

Note: Before you install pads and shims for the body, make sure that the machine is level and make sure that the body is assembled to the chassis and to the hoist cylinders.

1. Use the center mounting block on the body as a guide in order to mark the pad locations on the frame rail.
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   Illustration 79	g00519168
   Install pads and shims on the truck body.

2. Raise the body. Install the pins that retain the body. Stack one pad assembly (2) and one shim (1) at each location on the frame rail. There are six locations in order to mount pads on the rail.

3. Remove the pins that retain the body. Lower the body firmly against the pads. Locate any gaps. Add enough shims in order to close the gaps.

   Note: Add shims in 2.0 mm (0.08 inch) increments.

4. Raise the body. Install the pins that retain the body. Use three bolts (3) and three hard washers (4) in order to secure the pads and shims to the body. Raise the body. Remove the pins that retain the body. Lower the body firmly against the frame.
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   Illustration 80	g00519167
   Install pads and shims on the rockers.

5. Place one pad assembly (2) on each rocker at the front of the body. Install enough shims (1) in order to fill the gap at each rocker. Remove the pads and shim stacks. Add one shim (1) to each stack.

   Note: The extra shim provides a positive load against the rocker. Also, the extra shim is needed in order to keep the body centered.

6. Raise the body. Install the pins that retain the body. Use bolts (3) and hard washers (4) in order to secure the pads and shim stacks to the rockers. Remove the pins that retain the body. Lower the body firmly against the frame. No gaps should be visible at the locations of the pads.

Adjust the Position Sensor for the Dump Body (Lever Switch)

1. Raise the dump body and install the body retaining pins in order to secure the dump body in the UP position.
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   Illustration 81	g02765358
   (A) 45 degrees (1) Body down or up switch (2) Lever (3) Plate

2. Adjust lever (2) initially to a 45 degree angle from horizontal.

   Note: Ensure that plate (3) is adjusted all the way toward the rear of the truck.

3. Remove the body retaining pins and lower the dump body into the DOWN position.

4. In order to adjust the snub position of the dump body to approximately 200 to 300 mm (8 to 12 inch) between the front of the body pads and the frame rail, cycle the dump body and observe the SNUB position. If the dump body reaches the SNUB position too early, move lever (2) downward by one notch. If the dump body reaches the SNUB position too late, move lever (2) upward by one notch.

5. Repeat Step 4 until the desired SNUB position of the dump body is obtained.

Adjust the Position Sensor for the Dump Body (Magnetic Switch)

1. Raise the dump body and install the body retaining pins in order to secure the dump body in the UP position.
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   Illustration 82	g02765556
   (1) Body up switch (2) Magnet (3) Plate

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   Illustration 83	g02765558
   (A) 10 mm (0.394 inch) (1) Body up switch (2) Magnet

2. Adjust plate (3) so the gap between switch (1) and magnet (2) is 10 mm (0.394 inch).

3. Remove the body retaining pins and lower the dump body into the DOWN position.

4. In order to adjust the snub position of the dump body to approximately 200 to 300 mm (8 to 12 inch) between the front of the body pads and the frame rail, cycle the dump body and observe the SNUB position. If the dump body reaches the SNUB position too early, move magnet (2) upward. If the dump body reaches the SNUB position too late, move magnet (2) downward.

5. Repeat Step 4 until the desired SNUB position of the dump body is obtained.

Install the 253-7493 Rock Ejector Assembly Which is a Part of the 308-0615 Body Mounting Group and the 308-0617 Body Mounting Group

Table 55

Required Parts for Installation of 253-7493 Rock Ejector Assembly Which is a Part of the 308-0615 Body Mounting Group and the 308-0617 Body Mounting Group
Item	Qty	Part Number	Description
1	2	253-7493	Rock Ejector
2	2	6G-7773	Pin
3	4	3B-4647	Cotter Pin
4	16	1D-0503	Washer
5	2	137-1995(1)	Bracket
6	1	266-0674	Bracket
7	1	266-0672	Bracket

(1)

This bracket is used in the following situations: 773F Trucks with the 247-6182 Body and Canopy, 773F Trucks with the 264-7805 Body and Canopy, 773F Trucks with the 266-5661 Body and Canopy, 775F Trucks with the 264-7806 Body and Canopy, 775F Trucks with the 285-2100 Body and Canopy, 775F Trucks with the 291-4371 Body and Canopy and 775F Trucks with the 247-6200 Body and Canopy.

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Personal injury or death can result from fumes, gases and ultraviolet rays from the weld arc. Welding can cause fumes, burn skin and produce ultraviolet rays. Keep your head out of the fumes. Use ventilation, exhaust at the arc, or both, to keep fumes and gases from your breathing area. Wear eye, ear and body protection before working. Protect yourself and others; read and understand this warning. Fumes and gases can be dangerous to your health. Ultraviolet rays from the weld arc can injure eyes and burn skin. Electric shock can cause death. Read and understand the manufacturer's instructions and your employer's safety practices. Do not touch live electrical parts. See "American National Standard Z49.1, Safety in Welding and Cutting" published by the American Welding Society. American Welding Society 2501 N.W. 7th Street Miami, Florida 33125 See "OSHA Safety and Health Standards, 29 CFR 1910", available from U.S. Department of Labor. U.S. Department of Labor Washington, D.C. 20210

Illustration 84	g00519171

Illustration 85	g00519174

Illustration 86	g00885243
Refer to dimensions (A) and dimension (B) in order to position the rock ejectors.

Install the 137-1995 Brackets Which are a Part of the Body and Canopy Assembly

1. Use a 10.0 mm (0.40 inch) fillet weld (W2) in order to weld bracket (5) to each side of the truck body.

   Note: Make sure that the fillet weld (W1) penetrates to 1.5 mm (0.06 inch) .

   Note: Position the brackets in order to allow the rock ejectors to hang centrally between the two wheels at each side of the truck. Use dimension (A) as a reference. Dimension (A) is 1409 ± 5 mm (55.5 ± 0.2 inch) and dimension (A) is measured from the center of the truck body.

2. Use pin (2), two cotter pins (3), and eight washers (4) in order to install each rock ejector (1).

   Note: Distribute the washers in order to position the rock ejector between the two wheels.

Install the 266-0672 Bracket and the 266-0674 Bracket Which are a Part of the Body and Canopy Assembly

1. Use (W2) 10.0 mm (0.40 inch) fillet weld in order to weld bracket (6) to the right side of the truck body. Also, Use (W2) 10.0 mm (0.40 inch) fillet weld in order to weld bracket (7) to the left side of the truck body.

   Note: Make sure that (W1) fillet weld penetrates to 1.5 mm (0.06 inch).

   Note: Position the brackets in order to allow the rock ejectors to hang centrally between the two wheels at each side of the truck. Use dimension (B) as a reference. Dimension (B) is 782 ± 2 mm (30.8 ± 0.08 inch).

2. Use pin (2), two cotter pins (3), and eight washers (4) in order to install each rock ejector (1).

   Note: Distribute the washers in order to position the rock ejector between the two wheels.

Install the 8W-7481 Guard Which is a Part of the 308-0615 Body Mounting Group and the 308-0617 Body Mounting Group

Table 56

Required Parts for Installation of 8W-7481 Guard Which is a Part of the 308-0615 Body Mounting Group and the 308-0617 Body Mounting Group
Item	Qty	Part Number	Description
1	2	8W-7481	Guard
2	2	2G-7826	Strip
3	28	5P-2566	Bolt (1/2-13X1.5)
4	56	8T-4223	Hard Washer
5	28	6V-8188	Nut
6	2	288-1763	Plate

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Illustration 87	g01308242

1. At each side of the machine, install one plate (6) to the mounting bar on the bottom of the truck body. Use seven bolts (3), seven nuts (5), and 14 hard washers (4) in order to install plate (6). Next, assemble guard (1) to the plate (6). Use seven bolts (3), seven nuts (5), and 14 hard washers (4) in order to install guard (1) with a strip (2).

Install the 288-2367 Guard Which is a Part of the 308-0615 Body Mounting Group and the 308-0617 Body Mounting Group

Table 57

Required Parts for Installation of 288-2367 Guard Which is a Part of the 308-0615 Body Mounting Group and the 308-0617 Body Mounting Group
Item	Qty	Part Number	Description
1	1	288-2367	Guard
2	1	2G-7826	Strip
3	10	5P-2566	Bolt (1/2-13X1.5)
4	20	8T-4223	Hard Washer
5	10	6V-8188	Nut
6	1	292-0126(1) 288-1762(2)	Plate

(1)	This plate is used with the Dual Slope Body .
(2)	This plate is used with the Flat Floor Body .

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Illustration 88	g01308245

1. On the right-hand side of the machine, install one plate (6) to the mounting bar on the bottom of the truck body. Use six bolts (3), six nuts (5), and 12 hard washers (4) in order to install plate (6). Next, assemble guard (1) to the plate (6). Use four bolts (3), four nuts (5), and eight hard washers (4) in order to install guard (1) with a strip (2).

Install the 293-6642 Wheel Chock Group (if equipped)

Table 58

Required Parts for Installation of 293-6642 Wheel Chock Group
Item	Qty	Part Number	Description
1	1	293-6637	Bracket Assembly
2	1	293-6638	Bracket Assembly
3	2	105-1385	Wheel Chock
4	4	8T-4195	Bolt
5	4	8T-4121	Hard Washer
6	2	5P-8837	Lock Pin

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Illustration 89	g01312593

1. On the front bumper of the machine, install one bracket (1) and (2) to the mounting block on the bumper. Use two bolts (4) and two hard washers (5) per side, in order to install bracket (1) and (2). Next, install the wheel chocks (3) to the brackets (1) and (2). Use a lock pin (6) on each bracket (1) and (2) in order to secure the wheel chocks (3) to the machine.

Procedure for Installation of Film Groups

The following conditions need to be met in order to install the films:

• Surface temperature is between 15 °C (60 °F) and 27 °C (80 °F).

• The painted surface is fully dried.

• The surface is clean and dry.

Preparation for Installing the Films

1. Clean the surfaces with a 50:50 solution of isopropyl alcohol and water.

2. For oily surfaces or muddy surfaces, use one of the following agents:heptane, mineral spirits and naphta. After the surface has been cleaned with the agent, use a solution of isopropyl alcohol and water in order to remove the agent.

3. Wipe the surface with a clean paper towel until the surface is dry.

Procedure for Installing the Films

1. Apply an application fluid.

   Note: Use only a clean water and a soap solution that is mixed in a low concentration. The recommended amount of solution is 1 to 3 drops of Ivory soap per 1 L (1 qt). For information on a supplier of Ivory soap, consult:

   The Procter & Gamble Company
   1 Proctor & Gamble Plaza
   Cincinnati, OH 45201
   USA
   

   When a truck is moved to a location with temperatures below 0 °C (32 °F) within 72 hours of application of the films, use Rapid Tac adhesive. For information about a Rapid Tac supplier, consult:

   Rapid Tac Inc.
   186 Combs Drive
   Merlin, Or 97532
   USA
   

2. Expose the adhesive by peeling back the liner from the back of the film. Align that end of the film and position and lightly press onto the sprayed surface.

3. Remove the rest of the paper and press the other end into position.

4. Use a squeegee to apply pressure to the film. Start from the middle and work outward toward the edges. Use firm, overlapping strokes with the squeegee.

5. Wait for three to five minutes. Waiting will allow the adhesive to start bonding to the surface.

6. If the film has a mask, spray the film with an application fluid in order to loosen the mask. Peel the mask, starting in a top corner and pulling at a 45 degree angle.

7. Use a squeegee on the film after the mask has been removed. Use a squeegee along the edges in order to ensure a proper installation.

8. Wipe the film and the surrounding area in order to remove excess application fluid.

Install the 287-6650 Film Group for the 773F Flat Floor Body

Table 59

Required Parts for Installation of 287-6650 Film Group
Item	Qty	Part Number	Description
1	1	289-9267	Film
2	1	289-9269	Film
3	1	289-9271	Film

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Illustration 90	g01308233

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Illustration 91	g01308239

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Illustration 92	g01308238

1. Install film (1) on the front of the canopy. Center the film in the available space on the front lip of the canopy.

2. Install film (2) on the left side of the truck body. Center the film in the available space on the side of the dump body.

3. Install film (3) on the right side of the truck body. Center the film in the available space on the side of the dump body.

Install the 287-6651 Film Group for the 773F Dual Slope Body

Table 60

Required Parts for Installation of 287-6651 Film Group
Item	Qty	Part Number	Description
1	1	289-9267	Film
2	1	290-3465	Film
3	1	290-3464	Film

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Illustration 93	g01308233

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Illustration 94	g01308239

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Illustration 95	g01308238

1. Install film (1) on the front of the canopy. Center the film in the available space on the front lip of the canopy.

2. Install film (2) on the left side of the truck body. Center the film in the available space on the side of the dump body.

3. Install film (3) on the right side of the truck body. Center the film in the available space on the side of the dump body.

Installation of the 287-6652 Film Group for the 775F Flat Floor Body

Table 61

Required Parts for Installation of 287-6652 Film Group
Item	Qty	Part Number	Description
1	1	289-9275	Film
2	1	289-9276	Film
3	1	289-9277	Film

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Illustration 96	g01308233

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Illustration 97	g01308234

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Illustration 98	g01308235

1. Install film (1) on the front of the canopy. Center the film in the available space on the front lip of the canopy.

2. Install film (2) on the left side of the truck body. Center the film in the available space on the side of the dump body.

3. Install film (3) on the right side of the truck body. Center the film in the available space on the side of the dump body.

Installation of the 287-6653 Film Group for the 775F Dual Slope Body

Table 62

Required Parts for Installation of 287-6653 Film Group
Item	Qty	Part Number	Description
1	1	289-9275	Film
2	1	290-3467	Film
3	1	290-3466	Film

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Illustration 99	g01308233

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Illustration 100	g01308234

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Illustration 101	g01308235

1. Install film (1) on the front of the canopy. Center the film in the available space on the front lip of the canopy.

2. Install film (2) on the left side of the truck body. Center the film in the available space on the side of the dump body.

3. Install film (3) on the right side of the truck body. Center the film in the available space on the side of the dump body.

Perform the Commissioning Procedure for the Machine

Checks Before Delivery of 773F Off-Highway Truck and 775F Off-Highway Truck

This section contains assembly checks and functional checks of systems. Perform the checks before you deliver the machine to a customer.

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To prevent personal injury when checks are made while the machine is in operation, make sure only approved personnel are on the machine. Keep other personnel off the machine and in view of the operator. Make sure checks are done in an open area.

Prepare the Machine Before the Machine Is Started

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NOTICE
An improper hydraulic oil level can result in machine damage.

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Illustration 102	g01201270
Diagnostic connector

1. Connect a laptop computer to the Caterpillar Diagnostic Connector on the fuse panel behind the buddy seat. The laptop computer should have JERD2142 or JERD2129 Electronic Subscription. Use a 139-4166 Data Link Cable Assembly, 171-4400 Communication Adapter Group, NEXG4523 Service Program Module, and a 7X-1425 Data Link Cable Assembly in order to connect the laptop computer.

2. In order to power the electrical system of the truck, perform the steps that follow:

   1. Turn the battery disconnect switch ON.

   2. Turn the key of the machine ON.

   3. Do not start the Off-Highway Truck.

3. Start the Caterpillar Electronic Technician (ET). Cat ET will list all of the electronic control modules for the machine. There will be at least an "ENGINE CONTROL", a "MONITOR CONTROL", a "BRAKE CONTROL", and a "CHASSIS / TRANSMISSION CONTROL".

4. Cat ET should also display the truck model for each control. Make sure that the model is correct for each control.

5. Choose "ENGINE CONTROL". Next, choose"CONFIGURATION" .

   1. Change the Equipment Identification Number in order to correspond to the Product Identification Number (PIN) of the truck.

   2. Choose "ACTIVE CODES" from the Cat ET menu. Click on the button on the bottom of the screen. The button reads"INCLUDE ALL ECM's" . If "NO ACTIVE CODES" appear, then continue. If active fault codes are present, resolve the active faults.

   3. Choose "LOGGED CODES" from the Cat ET menu. Click on the button at the bottom of the screen that reads "INCLUDE ALL ECM's". Clear all logged codes.

   4. Choose "DIAGNOSTICS" and choose "EVENTS" from the Cat ET menu. Click on the button that reads "INCLUDE ALL ECM's". Clear all logged events.

   5. Choose "DIAGNOSTICS" from the Electronic Technician menu.

   6. Choose "DIAGNOSTIC TESTS" from the Electronic Technician menu. Next, choose "OVERRIDE PARAMETERS".

6. From the Cat ET menu, select"DATA LINK". Next, select "SELECT ECM". Next, select "CHASSIS / TRANSMISSION CONTROL". Next, select "CONFIGURATION".

   1. Change the Equipment ID Number in order to correspond to the PIN of the truck.

   2. Check the "BODY UP GEAR LIMIT"parameter. The parameter should be set to 1.

Check the Monitoring System

1. Turn the ignition key to ON.

2. Check if all the pixels in the monitor are working.

3. "Testing in Progress" should be displayed on the monitor when the ECMs are being flashed.

4. Check that the instrument panel is working and that the gauges sweep the full range. When the ignition switch is turned on, the gauges will sweep.

Activation of the Hoist Controls for the Truck Body

The truck might appear to have a problem with the body hoist controls. The 297-6905 Machine Software Group will set the parameters for the hoist system.

Note: The software for the Caterpillar Electronic Technician (ET) must be used to set these parameters. Use the latest version of the Cat ET software.

Enable the Hoist System (An Adjustable Parameter)

The hoist enable parameter is set at a value of "2" for all trucks that are shipped from the factory with the 297-6905 Machine Software Group and with a body that is not installed. Parameter Value "2" will prevent the hoist cylinders from being activated by accident. After the body is installed, change the Parameter Value to "1". The hoist system should function properly. When the hoist system does not work, check the items below.

Table 63

Settings for Hoist Enable Parameter
Parameter Value	Description
0	This value is used when the hoist system is not installed. The hoist lever will not function, and no diagnostics will be logged on the hoist lever or on the solenoids.
1	This value is used for normal operation when the hoist system is installed and enabled.
2	Two is the default value that is set in the factory when the hoist system is installed but disabled. The solenoids and the hoist lever have diagnostics, but the hoist lever is ignored. The solenoids are kept in the HOLD position.

1. Verify that the hoist system is enabled in the Configurable Parameters Screen through the service menu in the Caterpillar Electronic Technician (ET).

2. Disconnect Cat ET and then reconnect the line if the"Hoist Enable Status" does not appear on the configuration screen. The hoist enable parameter flexes with the Cat ET Software 3.0 when the parameter connects. Occasionally, the flexed parameter is missed by Cat ET at the time of the connection.

   Note: The hoist enable parameter is standard on the configuration screen of the Cat ET Software 3.1.

3. If the "Hoist Enable Status" does not change, check the following potential causes:

   • The engine should not be running. When the engine is running, the engine may cause the signal from the Transmission Output Speed (TOS) to fluctuate. The TOS must be zero in order to change the "Hoist Enable Status".

   • The truck should not be moving.

   Note: Press the "F5" key on the laptop computer in order to access the configuration screen on Cat ET.

Adjustment for Hoist Lower Valve

The command for the hoist lower valve is adjustable. This compensates for the differences between the valves. The adjustment range is "-5" to +5 with zero as the default. A positive adjustment factor will increase the lower valve command. This causes the body to come down harder. A negative adjustment factor will decrease the lower valve command. This causes the truck body to softly lower.

The Adjustment for the Hoist Lower Valve may not be available on earlier ECM systems. The adjustment range may be from 0 to 10 with 5 as the default on some early ECM systems.

Note: When the Adjustment for the Hoist Lower Valve is set too high, too much oil can be diverted to the hoist system while the hoist system is in float mode. This causes the brake oil to heat up faster. Retarding capability is also decreased. To set the Adjustment for the Hoist Lower Valve, follow the procedure below.

1. Raise the body of the truck and install the body retaining pins.

2. Place a 6V-7830 Tetragauge or place a 3.45 MPa (500 psi) gauge with a hose extension on the outlet port of the hoist pump.

   Note: Remove the body pins and lower the body to the frame.

3. While the body is down, place the hoist lever in the HOLD position.

4. Enter the configure parameter screen through the pull-down service menu in the Caterpillar Electronic Technician (ET).

5. Change the Adjustment for the Hoist Lower Valve to a setting that is desired from -5 to 5. The procedure begins at 0. Adjust the settings in increments of 1 in the positive position or in the negative position.

   Note: If you are using a 3.45 MPa (500 psi) gauge, remove the gauge from the extension.

6. Raise the body to the middle position.

7. Lower the body to the frame.

8. If a 6V-7830 Tetragauge is not installed, shut off the engine and install a 3.45 MPa (500 psi) gauge. Start the engine and run the engine to high idle. Cycle the hoist lever to the FLOAT position and to the HOLD position. Do not power down or raise the bed if you are using a 3.45 MPa (500 psi) gauge. Damage may occur to the gauge.

9. While the engine is running, place the hoist lever in the FLOAT position.

10. Run the engine to high idle. Verify that the pressure at the hoist outlet port is less than 1724 kPa (250 psi).

Note: When the pressure is greater than 1724 kPa (250 psi), the adjustment is set too high. This causes too much oil to be diverted to the hoist valve. This causes the brake oil to overheat when the body is in the FLOAT position. Lower the adjustment setting and repeat Step 4 through Step 9. This lowers the pressure below 1724 kPa (250 psi).

Note: If you change the adjustment setting and there is no corresponding change in pressure, cycle the hoist lever again. A change will occur in the settings between 2 and 5.

Body Down Snub Function (A Parameter that is not Adjustable)

The body down snub function cushions the shock when the body hits the bed of the truck. When the body is lowered, the body up switch detects the position of the body when the body is close to the rail of the truck. This causes the ECM to go into snub mode.

When the operator's request is less than the snub mode, the ECM will use the operator's request. This ensures that the body down snub function will never cause the body to go down faster than the hoist lever modulation (operator's request).

The body down snub function will be canceled as the operator moves the hoist lever out of the FLOAT position or out of the LOWER position. The body down snub function will not start until the truck body goes above the activation level for the body up switch.

Purge and Charge the Suspension Cylinders

Note: Refer to Special Instruction, REHS4445, "Servicing the Suspension Cylinders for Off-Highway Trucks" for any information concerning suspension cylinders. The Special Instruction includes Tooling, pressures, and the correct procedures for purging (oil and nitrogen) and charging (oil and nitrogen).

Calibrate the Truck Payload Measurement System (TPMS)

Note: The Truck Payload Measurement System (TPMS) will not operate properly until the suspension cylinders are charged correctly.

Note: Refer to Special Instruction, REHS4445, "Servicing the Suspension Cylinders for Off-Highway Trucks" for any information concerning suspension cylinders. The Special Instruction includes Tooling, pressures, and the correct procedures for purging (oil and nitrogen) and charging (oil and nitrogen).

Note: The TPMS needs proper calibration before operation. Refer to Systems Operation, RENR8284, "Truck Payload - Calibrate".

Use the calibration procedure through the monitoring system.

Check the Work Area Vision System (if equipped)

1. Turn the ignition key to ON.

2. Connect the 258-0845 Work Area Vision System to the bracket on the rear of the truck.

3. Turn the monitor ON.

4. Check that the image is visible in the screen.

5. Adjust the orientation of the camera on the back of the truck if the image in the screen is misadjusted.

Check the Service Brake Discs

Refer to Testing and Adjusting, RENR8294, "Service Brake Discs - Check". Also, refer to Guideline for Reusable Parts and Salvage, SEBF8095, "Service Brakes for Off-Highway Trucks and Tractors" in order to determine the service intervals. Record all data in the Brake SystemTesting and Adjusting, "Worksheets".

Test Product Link (if equipped)

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Illustration 103	g01378238
Diagnostic connector

1. Connect a laptop computer to the Caterpillar Diagnostic Connector (1) on the fuse panel behind the operator seat. The laptop computer should have JERD2142 or JERD2129 data subscription. Use a 139-4166 Data Link Cable As, 171-4400 Communication Adapter Gp, NEXG4523 Service Program Module, and a 7X-1425 Data Link Cable As in order to connect the laptop computer.

2. In order to power the electrical system of the truck, perform the steps that follow:

   1. Connect the batteries.

   2. Turn the battery disconnect switch ON.

   3. Turn the key of the machine ON.

   4. Do not start the Off-Highway Truck.

3. Start the Caterpillar Electronic Technician (ET). Cat ET will list all of the electronic control modules for the machine. There will be at least an "ENGINE CONTROL" and a "TRANSMISSION CONTROL". If the truck has the Automatic Retarder Control (ARC) or the Automatic Electronic Traction Aid (AETA), the Cat ET screen should show the features.

4. Cat ET should also display the truck model for each control. Make sure that the model is correct for each control.
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   Illustration 104	g01421991

5. Choose the "Product Link" ECM.
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   Illustration 105	g01421936

   Note: The communication status of product link needs to be tested. Since there can be up to a 15 minute gap in satellite coverage, the wiggle test in Cat ET can be used to save time by detecting status changes while other commissioning procedures are performed. Use the following steps to set up the wiggle test: Leave the wiggle test running and check the status during the "Final Check" at the end of this Special Instruction. The wires do not need to be wiggled.

6. Choose "Diagnostics" from the Cat ET menu. Choose "Diagnostic Tests" from the "Diagnostics" menu. Then choose the "Wiggle Test" from the "Diagnostics Tests" menu.
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   Illustration 106	g01421938

7. Read the warning and select the "OK" button.
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   Illustration 107	g01421939

8. From the "Wiggle Test" screen, select the "Groups" button on the second row from the bottom.
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   Illustration 108	g01421940

9. Choose the "New" button in order to create a new group for the product link.

   Note: You will only need to create a group for the product link during the first test of product link in Cat ET.

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   Illustration 109	g01421942

10. Type "Product Link" and select the "OK" button.
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    Illustration 110	g01421943

11. In the left-hand column of available parameters, select the "Number of GPS Satellites" under "Product Link" and then select the right arrow. In the left-hand column, select "Satellite Communications Status" under "Product Link" and then select the right arrow.

12. Select the "OK" button.
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    Illustration 111	g01421944

13. Select the "OK" button.
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    Illustration 112	g01421951

    Note: In order to confirm the two types of the satellite communication, the "Number of GPS Satellites" should be greater than "0" and the "Satellite Communication Status" should be "Established". This screen shows that the GPS communication is established and that satellite communications are established.

    1. If the "Number of GPS Satellites" is greater than "0" and the "Satellite Communications Status" is "Established", the communications of product link is confirmed. Record this information in the "Final Check" at the back of this Special Instruction.
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       Illustration 113	g01421947

       Note: If the "number of GPS satellites" is greater than 0 and the "Satellite Communication Status" is "Not Established", the wiggle test can be run while the commissioning procedures continue in order to monitor the communication status.

    2. Select"Start", in order to start the wiggle test.

       Note: Leave Cat ET running and do not navigate to a different screen in Cat ET while the wiggle test is running. These actions will end the wiggle test.

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       Illustration 114	g01421954
       When a parameter changes during a wiggle test the parameter will be highlighted in red. A two second beep will sound an alert.

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       Illustration 115	g01421955
       The parameter will stay red even if the parameter changes back to the original value. Communications are established during the wiggle test because the "Satellite Communication Status" is red.

       Note: Satellite communication may have a 15 minute lag in communication. Make sure that you leave the wiggle test running longer than 15 minutes before you fail the product link.

       Note: In order to establish communication, the antenna for the product link must have a clear view of the sky. Objects that are obstructing the antenna's view of the sky may result in a failure. If the antenna was obstructed during the test, retest the product link with an unobstructed view of the sky. Satellites can be seen from the horizon to 15 degrees above the horizon. Check the following web site for satellite coverage in your area:

       http://corneroftheuniverse.net/orbcomm/sats/sat_coverage.html
       

    3. Check the parameters later during the commissioning procedure. Record this information in the"Final Check" at the back of this Special Instruction. Leave the test running for at least 15 minutes or leave the test running until communication is established. The parameters will be highlighted in red if the status changed during the test.

    4. If no communication is established and the test has been running longer than 15 minutes, check the antenna for damage and check the connection from the antenna to the radio. If the cable did not have a good connection to the radio, establish a good connection and repeat the test.

    5. If the connection is good and no communication is established, refer to Troubleshooting, RENR7911, "Product Link 121/321".

Body Serial Number

Record the body serial number in SIMS. Refer to Special Instruction, SEHS0046, "A Procedure to Link a Body Serial Number to Product Configuration in SIMS for Certain Off-Highway Trucks" for the procedure.

Final Check

Use the Service Manual and use the Operation and Maintenance Manual in order to correct any system problems before you deliver the truck.

After you complete the final check, please sign your name and the name of the dealer.

Make copies of the check procedure. Mail the copies to the following address:

Caterpillar Inc.
Attention: CMT Product Support
773F / 775F Truck
N. 27th and Pershing Road
Decatur, IL 62525

Dealer:____________________

Customer:____________________

Product Identification Number:____________________

1. Before you start the engine, make sure that all hydraulic systems are full. Also, make sure that all pump case drains are full.

2. Establish a satellite communication.

   • YES ____NO ____

3. Establish a GPS communication.

   • Number of GPS Satellites ____

4. Check that the system pressures are set correctly.

   • Pump

   • YES ____NO ____

   • Brake

   • YES ____NO ____

   • Steering Pressure

   • YES ____NO ____

   • Transmission

   • YES ____NO ____

   • Torque Converter

   • YES ____NO ____

   • Differential

   • YES ____NO ____

5. Check that the brake accumulators are correctly charged.

   • YES ____NO ____

6. Check the machine lights.

   • Operational

   • YES ____NO ____

   • Cab and Dash

   • YES ____NO ____

7. Check the controls in the cab.

   • Check if the cab door opens. Check if the cab door closes.

   • YES ____NO ____

   • Check if the Operation and Maintenance Manual is in the literature pouch on the back of the operator's seat.

   • YES ____NO ____

   • Check if the horn functions.

   • YES ____NO ____

   • Check if the window wipers and washers function.

   • YES ____NO ____

   • Check if the seat belts operate.

   • YES ____NO ____

   • Check if the fan switch operates.

   • YES ____NO ____

   • Check if the heater functions.

   • YES ____NO ____

   • Check if the air conditioner functions.

   • YES ____NO ____

   • Check if the hour meter operates.

   • YES ____NO ____

   • Check if the implements operate:

   • Hoist

   • YES ____NO ____

   • Steering Action

   • YES ____NO ____

   • Check if the steering column functions.

   • YES ____NO ____

   • Check if the parking brake functions.

   • YES ____NO ____

8. Check if all fluid levels are full.

   • YES ____NO ____

9. Correct any unusual noises or leaks.

   • YES ____NO ____

10. Check if all lubrication lines are filled with grease.

    • YES ____NO ____

11. Check if all quality requirements are fulfilled. Check if all variances have been corrected.

    • YES ____NO ____

12. Check if the backup alarms function.

    • YES ____NO ____

13. Check if the machine is repainted to the factory specifications.

    • YES ____NO ____

14. Check if there was damage to the machine from shipment.

    • YES ____NO ____

15. Check if all required parts were shipped with the machine.

    • YES ____NO ____

16. Sign your name in the space below.

    • Hydraulic

    • ____________________

    • Electrical

    • ____________________

    • Structural

    • ____________________

    • Other

    • ____________________

17. Comments

    • ________________________________________

    • ________________________________________

    • ________________________________________

    • ________________________________________

    • ________________________________________

    • ________________________________________

    • ________________________________________

    • ________________________________________

    • ________________________________________

    • ________________________________________
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    Table 64

    Specifications for the Commissioning Procedure
    Description	Specifications	Actual	Comments
    Engine Low Idle rpm	800 ± 10 rpm
    Engine High Idle	2285 ± 40 rpm
    Pressure of Brake Retract Pump at High Idle	4000 to 5380 kPa (580 to 780 psi)
    Relief Pressure of Hoist Pump	18445 to 19480 kPa (2675 to 2825 psi) (1)
    Relief Pressure of Hoist Pump	16720 kPa (2425 psi) to 17754 kPa (2575 psi) (2)
    Steering High Pressure Cutoff	20850 to 22045 kPa (3024 to 3197 psi)
    Steering Cycle Time	5.0 to 6.0 seconds at 39° to 93°C (100° to 200°F)
    Relief Pressure of Transmission Pressure at High Idle	3240 kPa (470 psi) Maximum
    Pressure of Transmission Lubrication at High Idle	138 to 241 kPa (20 to 35 psi)
    Pressure of Transmission Lubrication at Low Idle	10 to 69 kPa (1.5 to 10 psi)
    Torque Converter Outlet Pressure at Stall	310 to 517 kPa (45 to 75 psi)

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    (1)	This only applies to the 775 truck.
    (2)	This only applies to the 773 truck.

Predelivery Worksheet

Table 65

Date	Employee I.D.	Model	Serial Number	Hours	Inspector Name

Note: All safety product improvement programs (PIP) must be completed.

Table 66

	Visual Inspection	Service Points and Fluid Levels	Operation	After Operation
Engine (1) (2)	_ Paint _ Outside Damage	_ Oil _ Coolant _ Fuel _ BatteriesOVC > (12.45) _ VDC1 _ VDC2 _ Air Filters _ Drain Water from Fuel Tank _ Drain Water Separator _ Open Coolant conditioner Valves _ Grease Fittings	_ Priming Pump _ AC Compressor _ Smoke Color _ Unusual Noise	_ Air Cleaner Indicator _ V-Belt Tension _ Leaks of Oil, Air, Fuel, or Coolant _ Friction on Hoses _ Friction on Wires _ Loose Wire Connections _ Loose or Lost Fasteners
Power Train	_ Paint _ Outside Damage _ Tires for Cuts or Gouges	_ Transmission _ Differential _ Final Drives _ Tire Pressure _ Grease Fittings _ Front Axle Bolt Torque and Rear Axle Bolt Torque _ Front Universal Torque and Rear Universal Torque _ Wheel to Rim Torques	_ Transmission - Each Gear _ Neutral Start _ Transmission Lever Lock _ Back Up Alarm _ Unusual Noise	_ Leaks (Oil) _ Loose fasteners and lost fasteners _ Tires for Cuts or Gouges
Steering and Brakes	_ Paint _ Outside Damage _ Cylinder Rods	_ Brake Fluid _ Grease Fittings	_ Steering _ Retarder _ Service Brakes _ Parking Brakes _ Unusual Noise	_ Leaks - Oil _ Loose or Lost Fasteners
Chassis	_ Sheet Metal _ Paint _ Damage	_ Grease Fittings	_ Enclosure Doors - Locks and Latches	_ Loose or Lost Fasteners _ Welds
Hydraulic	_ Cylinder Rods	_ Hydraulic Tank _ Grease Fittings	_ Controls _ Too much Drift _ Unusual Noise	_ Leaks - Oil _ Friction or Lost Fasteners
Truck Body	_ Paint _ Damage _ Liners	_ Grease Fittings _ Body Pads _ Body Retaining Pins	_ Body Positions	_ Welds _ Loose or Lost Fasteners _ Damage
Cab	_ Sheet Metal _ Paint _ Glass	_ Window Washer _ Air Filters _ Grease Fittings _ Torque on ROPS Support	_ Disconnect Switch _ VIMS _ Hoist Control _ Horn _Seat Belts _ Seat Adjustments _ All Switches & Controls _ Doors and Windows _ Locks and Latches _ Mirror Adjustment _ Window Wipers _ Window Washers _ Heater _ (Air Conditioner/Pressurizer) Lights - Outside and Cab _ Gauges _ Unusual Noise _ Steering Column Adjustment	_ Operation Guide _ Maintenance Guide _ Parts Book _ Seat Cover _ Steps & Handrails _ Loose or Lost Fasteners _ Loose Wire Connections _ Leaks - Water
Miscellaneous Attachments	_ Special Assembly Parts _ S/N Plates _ Correct Attachments _ Hand Tools _ Paint _ Films	_ Attachment Fluid Levels _ Grease Fittings _ Automatic Lubrication System	_ Attachments _ Engine Shutdown Switch	_ Warning Plates _ Films _ Leaks _ Loose or Lost Fasteners

(1)	If the machine was in storage, lubricate the engine before starting the engine.
(2)	For cold-weather operation, refer to Operation and Maintenance Manual, SEBU7794.