770 Off-Highway Truck and 772 Off-Highway Truck Assembly Procedure {7000, 7006, 7960} Caterpillar

Off-Highway Truck/Tractor

770 (S/N: BZZ1-UP)

770G (S/N: ECM1-UP)

772 (S/N: RLB1-UP)

772G (S/N: LTS1-UP)

Introduction

This publication contains assembly procedures to prepare 770 and 772 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.

After assembly is complete, refer to the Operation and Maintenance Manual for (S/N: BZZ1-UP) and (S/N: RLB1-UP) to prepare the machine. Use the Parts Manual and the Service Manual in addition to this publication.

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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
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.

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).

Chains and Cables

Use approved cables, chains, and lifting devices to lift the components. Refer to the manufacturer's literature 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 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.

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 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 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 to maneuver the lifting device. Carefully remove parts for inspection. Refer to the tables in this publication 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 to prevent lost hardware.

Parts Lists

Table 1

Required Parts for Installation of the Mirror Gp (If Equipped)
Qty	Part Number	Description
2	250-7605	Bracket As (1)
16	8T-4185	Bolt (1)
40	8T-4121	Hard Washer (1)
2	298-7329	Bracket As (2)
4	134-0989	Block (2)
8	8T-4186	Bolt (2)
2	300-5512	Mirror As (2)(3)
2	245-8946	Mirror As (2)(4)
8	8T-4195	Bolt (2)
8	8T-4133	Nut (2)
2	300-0560	Mirror As (2)(3)
2	298-8533	Mirror As (2)(4)

(1)	These parts are shipped under the buddy seat in the cab.
(2)	These parts are already assembled. These parts are bolted to the inside of the handrails.
(3)	Part of 277-0641 Heated Rear View Mirror Gp
(4)	Part of 269-8720 Rear View Mirror Gp

Table 2

Required Parts for Installation of the Product Link Antenna
Qty	Part Number	Description
1	284-8533	Antenna As (1)
1	283-5837	Plate (1)

(1)	These parts are attached to the right front of the handrail assembly. These parts are ready to be installed.

Table 3

Required Parts for Installation of the Radio Antenna
Qty	Part Number	Description
1	279-7299	Plate
1	9W-3072	Antenna As

Table 4

Required Parts for Installation of the Mud Guards
Qty	Part Number	Description
2	311-0278	Mud Guard (1)
2	279-1147	Plate (2)
8	8T-4136	Bolt (2)
4	7X-7729	Washer (2)
8	8T-3490	Weld Nut (2)
4	131-5879	Washer (2)

(1)	This part is shipped under the buddy seat in the cab.
(2)	These parts are installed in the flanges and tabs on the fenders.

Table 5

Required Parts for Assembly of the Truck Body
Qty	Part Number	Description
1	273-8419	Canopy As
1	234-8689	Plug(1)
1	273-8547	Plug(2)

(1)	Part of 268-9496 Body and Canopy As and 270-1622 Body and Canopy As
(2)	Part of 268-9661 Body and Canopy As and 268-9662 Body and Canopy As

Installation of the Mirror Gp (If Equipped)

Table 6

Required Parts for Installation of the Mirror Gp
Item	Qty	Part Number	Description
1	2	250-7605	Bracket As
2	16	8T-4185	Bolt
3	40	8T-4121	Hard Washer
4	2	298-7329	Bracket As
5	4	134-0989	Block
6	8	8T-4186	Bolt
7	2	300-5512	Mirror As(1)
	2	245-8946	Mirror As(2)
8	8	8T-4195	Bolt
9	8	8T-4133	Nut
10	2	300-0560	Mirror As(1)
	2	298-8533	Mirror As(2)

(1)	Part of 277-0641 Heated Rear View Mirror Gp
(2)	Part of 269-8720 Rear View Mirror Gp

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Illustration 2	g01340116
View of right side of truck

1. Locate bracket assembly (1).
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   Illustration 3	g01340194

2. Secure bracket assembly (1) with bolts (2) and washers (3).
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   Illustration 4	g01340229

3. Secure bracket assembly (4) with blocks (5), bolts (6), and washers (3).

4. Repeat Step 1 through Step 3 for the left side mirror assembly.

Installation of the Product Link Antenna

Table 7

Required Parts for Installation of the Product Link Antenna
Item	Qty	Part Number	Description
1	1	283-5837	Plate (1)
2	1	284-8533	Antenna As (1)

(1)	These parts are attached to the right front of the handrail assembly. These parts are ready to be installed.

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Illustration 5	g01340381
View of right side of truck (A) ( Qty 2) 8T-4186 Bolt (B) ( Qty 2) 8T-4121 Hard Washer

1. Attach plate (1) with bolts (A) and washers (B).
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   Illustration 6	g01340742

2. Attach antenna assembly (2) to plate (1) with nut (C) that is provided. Tighten nut (C) to 5 ± 0.5 N·m (45 ± 5 lb in).

Installation of the Radio Antenna

Table 8

Required Parts for Installation of the Radio Antenna
Item	Qty	Part Number	Description
1	1	279-7299	Plate
2	1	9W-3072	Antenna As

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Illustration 7	g01340388
View of left side of truck (A) ( Qty 2) 8T-4185 Bolt (B) ( Qty 2) 8T-4121 Hard Washer

1. Remove existing bolts (A) and washers (B) to install plate (1).
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   Illustration 8	g01340718

2. Attach antenna assembly (2) to plate (1) with nut (C) that is provided.
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   Illustration 9	g01340712

3. Attach existing cable (D) to antenna assembly (2).

Installation of the Fender Mounted Mud Guards

Table 9

Required Parts for Installation of the Mud Guards Which are Mounted on the Fender
Item	Qty	Part Number	Description
1	2	311-0278	Mud Guard (1)
2	2	279-1147	Plate (2)
3	8	8T-4136	Bolt (2)
4	4	7X-7729	Washer (2)
5	4	131-5879	Washer (2)

(1)	This part is shipped under the buddy seat in the cab.
(2)	These parts are installed in the flanges and tabs on the fenders.

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Illustration 10	g01689940
View of right side of truck

1. Install mud guard (1) with plates (2), bolts (3) and washers (4).
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   Illustration 11	g01689953

2. Install mud guard (1) with bolts (3) and washers (5).

Assemble the Truck Body

Note: The truck body only requires assembly on trucks that are exported.

Table 10

Required Parts for Assembly of the Truck Body
Item	Qty	Part Number	Description
1	1	273-8419	Canopy As
2	1	234-8689	Plug(1)
	1	273-8547	Plug(2)

(1)	Part of 268-9496 Body and Canopy As and 270-1622 Body and Canopy As
(2)	Part of 268-9661 Body and Canopy As and 268-9662 Body and Canopy As

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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

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

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Illustration 12	g01768217
Top view of the canopy assembly

1. Locate canopy assembly (1).
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   Illustration 13	g01768218
   Bottom view of the canopy assembly

2. Use a grinder to clean the weld areas of the canopy assembly. Completely remove all paint, rust, scale, slag, dirt, moisture, and so on, before welding.
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   Illustration 14	g01768219
   Front view of the body

3. Use a grinder to clean the weld areas of the body assembly. Completely remove all paint, rust, scale, slag, dirt, moisture, and so on, before welding.
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   Illustration 15	g01768220

4. Attach a suitable lifting device to canopy assembly (1). Use three cables in the configuration that is shown in Illustration 15. Canopy assembly (1) weighs approximately 1050 kg (2310 lb).
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   Illustration 16	g01769333
   Front view of the canopy assembly that is being installed on the body

5. Position canopy assembly (1) to the body.

   Note: When you position the canopy, a guide line may be necessary.

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   Illustration 17	g01769334

6. Use angles or wedges to help align the canopy assembly to the front wall.

   Note: Before tack welding any angles to the body assembly, use a grinder to clean the welding areas. Completely remove all paint, rust, scale, slag, dirt, moisture, and so on, before welding.

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   Illustration 18	g01769335

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   Illustration 19	g01769673

7. Once the canopy assembly is aligned, tack weld the canopy assembly to the body.

8. Preheat the seams between canopy assembly (1) and the body.

   Note: Use a 164-3310 Infrared Thermometer to check for the proper preheat temperature.

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   Illustration 20	g01769927
   (W1) 8 mm (0.315 inch) Fillet weld with 1.5 mm (0.06 inch) (W2) 8 mm (0.315 inch) Fillet weld with 1.5 mm (0.06 inch) (W3) 8 mm (0.315 inch) Bevel groove weld (W4) 8 mm (0.315 inch) Double side fillet weld with 1.5 mm (0.06 inch)

9. Weld canopy assembly (1) to the body.

   Note: Remove slag after every weld pass.

   Note: Repeat weld (W1) for the eight remaining ribs.

   Note: Repeat weld (W2) for the other side of the body.

   Note: Repeat weld (W3) for the other side of the body.

   Note: Repeat weld (W4) for the seven remaining gussets.

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   Illustration 21	g01769930
   (W5) 6 mm (0.24 inch) Bevel groove weld (W6) 8 mm (0.315 inch) Fillet weld with 1.5 mm (0.06 inch)

10. Weld canopy assembly (1) to the body.

    Note: Remove slag after every weld pass.

    Note: Repeat weld (W5) for the other side of the body.

    Note: Repeat weld (W6) for the other side of the body.

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    Illustration 22	g01769932
    (W7) 8 mm (0.315 inch) Fillet weld with 1.5 mm (0.06 inch) (W8) 8 mm (0.315 inch) Fillet weld with 1.5 mm (0.06 inch)

11. Weld canopy assembly (1) to the body.

    Note: Remove slag after every weld pass.

    Note: Repeat weld (W8) for the other side of the body.

    Note: When canopy (1) is installed to the body, remove all lifting eyes.

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    Illustration 23	g01770373

12. Locate plug (2). Use a grinder to clean the weld areas of plug (2). Completely remove all paint, rust, scale, slag, dirt, moisture, and so on, before welding.
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    Illustration 24	g01770375

13. Use a grinder to clean the weld areas of the body. Completely remove all paint, rust, scale, slag, dirt, moisture, and so on, before welding.
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    Illustration 25	g01770376

14. Position plug (2) to the body.

15. Preheat the seams between plug (2) and the body.

    Note: Use a 164-3310 Infrared Thermometer to check for the proper preheat temperature.

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    Illustration 26	g01770554
    (W9) 8 mm (0.315 inch) Double side bevel groove weld

16. Weld plug (2) to the body.

    Note: Remove slag after every weld pass.

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

1. Raise the dump body and install the body retaining pins to secure the dump body in the UP position.
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   Illustration 27	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. 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 to secure the dump body in the UP position.
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   Illustration 28	g02765556
   (1) Body up switch (2) Magnet (3) Plate

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   Illustration 29	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. 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.

Perform the Commissioning Procedure for the Machine

Checks Before Delivery of 770 Off-Highway Truck and 772 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 30	g01690314
Diagnostic connector

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

2. 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 TRUCK.

3. Start the Electronic Technician (ET). ET will list all 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. 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 to correspond to the Product Identification Number (PIN) of the truck.

   2. Choose "ACTIVE CODES" from the ET menu. Click 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 ET menu. Click 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 ET menu. Click 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 ET menu, select"DATA LINK". Next, select "SELECT ECM". Next, select "CHASSIS / TRANSMISSION CONTROL". Next, select "CONFIGURATION".

   1. Change the Equipment ID Number 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 Gp will set the parameters for the hoist system.

Note: The software for the Electronic Technician (ET) must be used to set these parameters. Use the latest version of the 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 Gp 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 11

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	This 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 Electronic Technician (ET).

2. Disconnect 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 ET Software 3.0 when the parameter connects. Occasionally, the flexed parameter is missed by ET at the time of the connection.

   Note: The hoist enable parameter is standard on the configuration screen of the 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 to change the "Hoist Enable Status".

   • The truck should not be moving.

   Note: Press the "F5" key on the laptop computer to access the configuration screen on 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 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 the Suspension Cylinder and Charge the Suspension Cylinders

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), that are used on all off-highway truck suspension cylinders.

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: The TPMS needs proper calibration before operation. Refer to Service Manual, RENR8284.

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).

Use the calibration procedure through the monitoring system.

Ton Mile Per Hour (TMPH)/Tonne Kilometer Per Hour (TKPH) Configuration

1. Verify that TPMS is applicable (MSO), installed, and calibrated.

2. Configure the TMPH/TKPH. Refer to Service Manual, KENR8744, "770G and 772G Off-Highway Trucks and 773G and 775G Quarry Trucks VIMS 3G and Payload" for configuration instructions and information.

Check the Service Brake Discs

Refer to the Testing and Adjusting, "770 Off-Highway Truck and 772 Off-Highway Truck Hydraulic System - Service Brake Discs - Check". Also, refer to Guideline for Reusable Parts and Salvage, SEBF8095, "Service Brakes for Off-Highway Trucks and Tractors" 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 31	g01690414
Diagnostic connector

1. Connect a laptop computer to the Caterpillar Diagnostic Connector on the fuse panel to the right of 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 to connect the laptop computer.

2. 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 TRUCK.

3. Start the Electronic Technician (ET). 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 ET screen should show the features.

4. 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 32	g01421991

5. Choose the "Product Link" ECM.
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   Illustration 33	g01421936

   Note: Test the communication status of product link. There can be up to a 15 minute gap in satellite coverage. The wiggle test 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.

   Note: The wires do not need to be wiggled.

6. Choose "Diagnostics" from the ET menu.

7. Select the "Diagnostic Tests" tab.

8. Select the "Wiggle Test" tab.
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   Illustration 34	g01421938

9. Read the warning.

10. Select the "OK" button.
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    Illustration 35	g01421939

11. Select the "Groups" button.
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    Illustration 36	g01421940

12. Select the "New" button to create a new group for the product link.

    Note: A product link group must be created to test the product link for the first time.

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    Illustration 37	g01421942

13. Type "Product Link" and select the "OK" button.
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    Illustration 38	g01421943

14. Select "Number of GPS Satellites" in the left hand column.

15. Select the right arrow. This will move the selected parameter to the product link group.

16. Select "Satellite Communications Status" in the left hand column.

17. Select the right arrow. This will move the selected parameter to the product link group.

18. Select the "OK" button.
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    Illustration 39	g01421944

19. Select the "OK" button.
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    Illustration 40	g01421951

    Note: 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 the satellite communication is 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 41	g01421947

       Note: If the "Number of GPS Satellites" is greater than "0" and the "Satellite Communication Status" is not established, use the wiggle test to monitor the communication status.

    2. Select the "Start" button to start the wiggle test.

       Note: Only use the wiggle test if the parameters do not confirm the communication status.

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

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       Illustration 42	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 43	g01421955
       The parameter will stay red even if “the parameter” changes back to the original value. If the“Satellite Communication Status” is red, then communication was established during the wiggle test.

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

       Note: To establish communication, the product link antenna must have a clear view of the sky. Objects that obstruct 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 address 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.

       Note: The test must operate for a minimum of 15 minutes. If communication is established, you will not need to operate the test. 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.

       Note: If the connection from the antenna to the radio is good and no communication is established, refer to Troubleshooting, RENR7911, "Product Link 121/321".

Final Check

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

Note: After eight hours of continuous operation, replace the cleanout filter elements with standard filter elements for the systems that follow: the parking brake filter, the transmission filter, the steering system filter and the torque converter charging oil filter.

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
770 / 772 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. If the machine is equipped with the product link, then establish satellite communication.

   • YES ____NO ____

3. If the machine is equipped with the product link, then 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 the 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 12

    Specifications for the Commissioning Procedure
    Description	Specifications	Actual	Comments
    Engine Low Idle rpm	650 +30 -10 rpm
    Engine High Idle	2200 ± 30 rpm
    Pressure of Brake Retract Pump at High Idle	4690 ± 690 kPa (680 ± 100 psi)
    Relief Pressure of Hoist Pump	17230 ± 520 kPa (2500 ± 75 psi)
    Steering High Pressure Cutoff	26000 ± 400 kPa (3800 ± 60 psi)
    Steering Cycle Time	6.5 seconds at 66 °C (150 °F)
    Relief Pressure of Transmission at High Idle	3200 ± 150 kPa (465 ± 20 psi)
    Pressure of Transmission Lubrication at High Idle	138 to 241 kPa (20 to 35 psi)
    Torque Converter Outlet Pressure at Stall	205 ± 70 kPa (30 ± 10 psi)

Predelivery Worksheet

Table 13

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

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

Table 14

	Visual Inspection	Service Points and Fluid Levels	Operation	After Operation
Engine (1) (2)	_ Paint _ Outside Damage	_ Oil _ Coolant _ Fuel _ Batteries OVC > (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 (Oil, Air, Fuel, Coolant) _ Friction on Hoses _ Friction on Wires _ Loose Wire Connections _ Loose or Lost Fasteners
Power Train	_ Paint _ Outside Damage _ Tires - Cuts, gouges	_ Transmission _ Differential _ Final Drives _ Tire Pressure _ Grease Fittings _ Front & Rear Axle Bolt Torques _ Front & Rear Universal Torques _ Wheel to Rim Torques	_ Transmission - Each Gear _ Neutral Start _ Transmission Lever Lock _ Back - Up Alarm _ Unusual Noise	_ Leaks (Oil) _ Loose or lost Fasteners _ Tires - Cuts, 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	_ Front 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 _ Front Window Wipers _ Front 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
Misc. and 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.