773G and 775G Off-Highway Truck Assembly Procedure {7000, 7006, 7960} Caterpillar

Quarry Truck

773G (S/N: MWH1-UP; JWS1-UP; T5S1-UP; T5T1-UP)

775G (S/N: T5F1-UP; RFM1-UP; MJS1-UP; T5W1-UP)

Introduction

Table 1

Revision History
Revision	Summary of Changes
09	Added information on removing the protective decals on the rear wheel flanges in Section "Install the Rear Tire and Rim Assemblies".

This publication contains assembly procedures and commissioning procedures to prepare 773G and 775G 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 to prepare the machine. Use the Parts Manual and use the Service Manual in addition to this publication.

Illustration 1	g06094436

Note: A protective coating 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 and also to certain areas of the machine that may be affected by corrosive environments during transportation to its final destination. The coating can be left on the machine to provide long lasting component protection, however it can be removed using a high pressure 8275 kPa (1200 psi) hot alkaline washing (PH of 11 or higher) followed by a water rinse or by using low-pressure steam.

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, PERJ1017, "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.

Required Parts

Table 2

Required Parts for Installation of the Left-Hand Catwalk
Qty	Part Number	Description
1	N/A	Left-Hand Catwalk Assembly
8	8T-4193	Bolt
8	7X-0583	Hard Washer

Table 3

Required Parts for Installation of the Left-Hand Catwalk
Qty	Part Number	Description
1	354-0298	Stair As
4	8T-4956	Bolt
10	7X-0590	Hard Washer
2	8T-4648	Bolt
2	7T-8332	Mounting
2	8T-4244	Nut

Table 4

Required Parts for Installation of the 372-4535 Handrail Gp
Qty	Part Number	Description
1	354-8431	Handrail As
20	8T-4139	Bolt
20	7X-3392	Hard Washer
1	355-6060	Handrail As
1	355-5902	Handrail As
8	8T-4194	Bolt
8	198-4778	Hard Washer
10	8T-4195	Bolt
4	198-4777	Hard Washer
1	314-7228	Handrail As
6	8T-4121	Hard Washer
1	355-5918	Handrail As
1	355-5917	Handrail As
1	337-9038	Handrail As
2	8T-4136	Bolt
10	5P-7468	Clip
10	5P-7469	Clip
10	6V-1874	Grommet
5	8T-4183	Bolt
10	8T-4223	Hard Washer
5	8T-4244	Nut

Table 5

Required Parts for Installation of the 323-0366 Platform Wiring Gp (Type 1)
Qty	Part Number	Description
1	N/A	Box for ground level shutdown switch
2	8T-4136	Bolt
2	4B-4278	Washer

Table 6

Required Parts for Installation of the 323-0366 Platform Wiring Gp (Type 2)
Item	Qty	Part Number	Description
1	14	7K-1181	Cable Strap
2	1	2G-1133	Grommet
3	1	297-8752	Toggle Switch Gp (ENGINE SHUTOFF)
4	1	353-4515	Toggle Switch Gp (LIGHTS)
5	1	3E-5169	Switch Guard
6	1	271-4532	Film
7	1	281-7268	Film

Table 7

Required Parts for Installation of the 312-0860 Mirror Gp or the 358-1619 Mirror Gp
Qty	Part Number	Description
2	357-9681(1) 357-9682(2)	Mirror Gp Mirror Gp (HEATED, 24-VOLT)
3	8T-4137	Bolt
9	8T-4121	Hard Washer
4	8T-4186	Bolt
2	134-0989	Block
1	7Y-5262	U-Bolt
2	8T-0389	Locknut
1	7X-7468	Convex Mirror
1	295-8899	Plate
3	8T-4223	Hard Washer
1	3K-6060	Locknut
1	8T-4183	Bolt
1	129-3180	Locknut
1	5P-7468	Clip
1	5P-7469	Clip
1	6V-1874	Grommet

(1)	Used in the 358-1619 Mirror Gp
(2)	Used in the 312-0860 Mirror Gp

Table 8

Required Parts for Installation of the 336-4470 Mirror Gp or the 358-1620 Mirror Gp
Qty	Part Number	Description
2	357-9681(1) 357-9682(2)	Mirror Gp Mirror Gp (HEATED, 24-VOLT)
3	8T-4137	Bolt
29	8T-4121	Hard Washer
4	8T-4186	Bolt
2	134-0989	Block
11	7Y-5262	U-Bolt
22	8T-0389	Locknut
1	353-4621	Tube As
4	8T-4182	Bolt
4	198-4777	Hard Washer
2	329-7328	Convex Mirror
1	330-5264	Tube As

(1)	Used in the 358-1620 Mirror Gp
(2)	Used in the 336-4470 Mirror Gp

Table 9

Required Parts for Installation of the 321-6472 Lighting Wiring Gp
Qty	Part Number	Description
1	N/A	Flood lamp assembly
1	8T-4137	Bolt
1	5P-1075	Hard Washer

Table 10

Required Parts for Installation of the Antenna and Mounting/Communiction Wiring Group
Qty	Part Number	Description
1	283-5837	Plate
1	284-8533(1) 346-9376(2)	Antenna As Antenna As
1	9X-7345	Grommet
1	341-7961(2)	Cable As
2	8S-7583	Grommet
2	3K-5178	Grommet

(1)	Used on the 321-6471 Antenna and Mounting Gp
(2)	Used on the 341-7960 Communication Wiring Gp

Table 11

Required Parts for Installation of the 314-7140 Fender Gp
Qty	Part Number	Description
1	340-1319	Guard
12	8T-4196	Bolt
63	7X-7729	Washer
35	8T-4195	Bolt
9	340-3616	Plate
5	357-0497	Plate
1	340-1318	Guard
1	339-2076	Guard
1	333-4801	Guard
2	319-5435	Plate
1	355-9827	Bracket
22	8T-4183	Bolt
22	198-4778	Hard Washer
6	8T-4956	Bolt
12	5P-1076	Hard Washer
6	8T-4244	Nut
1	355-9824	Bracket
1	355-9825	Bracket
1	339-6647	Mud Deflector
2	115-6433	Washer
14	8T-4133	Nut
1	339-6646	Mud Deflector
1	417-0162	Guard
1	417-0161	Plate
2	8T-4186	Bolt
3	6V-7744	Locknut
1	115-6433	Washer

Table 12

Required Parts for Installation of the 368-0674 Mud Guard Gp
Qty	Part Number	Description
1	367-5462	Guard
4	8T-4195	Bolt
4	7X-7729	Washer
2	319-5435	Plate

Table 13

Required Parts for Installation of 132-6650 Pin Assembly Which is a Part of the 337-0909 Truck Body Mounting Gp
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 14

Required Parts for the Installation of the 337-0909 Truck Body Mounting Gp
Qty	Part Number	Description
2	322-4728	Plate
34	5P-2566	Bolt
64	8T-4223	Hard Washer
30	6V-8188	Nut
2	322-4729	Strip
2	322-4726	Mud Guard
2	372-0745	Ejector
2	6G-7773	Pin
4	3B-4647	Cotter Pin
8	1D-0503	Washer
1	113-1216	Baffle As
2	031-9831	Bolt
2	8W-1367	Pin As
2	303-1871	Plate
4	7D-2955	Spacer

Table 15

Required Parts for the Installation of the Guards on the Truck Body
Qty	Part Number	Description
1	264-4520	Guard
28	7X-0349	Bolt
28	7X-0515	Hard Washer
28	3R-8530	Boss
1	364-7200	Guard As
33	5P-2228	Bolt
33	8T-4223	Hard Washer
1	364-7190	Guard As
1	264-4519	Guard
1	262-5965	Guard As

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 773G Off-Highway Truck Tier 4 (RM807) without the body is 34823 kg (76771 lb).

• The approximate weight of the 773G Off-Highway Truck Tier 4 (RM807) body is 10940 kg (24119 lb).

• The approximate weight of the 773G Off-Highway Truck Tier 4 (RM807) with the body and no body liner is 45765 kg (100894 lb).

• The approximate weight of the 773G Off-Highway Truck Tier 4 (RM807) with the body and the body liner is 49492 kg (109111 lb).

• The approximate weight of the 773G Off-Highway Truck DRC (RM879) is without the body is 34496 kg (76051 lb).

• The approximate weight of the 773G Off-Highway Truck DRC (RM879) body is 10942 kg (24123 lb).

• The approximate weight of the 773G Off-Highway Truck DRC (RM879) with the body and no body liner is 45438 kg (100174 lb).

• The approximate weight of the 773G Off-Highway Truck DRC (RM879) with the body and the body liner is 49165 kg (108390 lb).

• The approximate weight of the 775G Off-Highway Truck Tier 4 (RM808) without the body is 34823 kg (76771 lb).

• The approximate weight of the 775G Off-Highway Truck Tier 4 (RM808) body is 11700 kg (25794 lb).

• The approximate weight of the 775G Off-Highway Truck Tier 4 (RM808) with the body and no body liner is 46523 kg (102566 lb).

• The approximate weight of the 775G Off-Highway Truck Tier 4 (RM808) with the body and the body liner is 50673 kg (111715 lb).

• The approximate weight of the 775G Off-Highway Truck DRC (RM880) without the body is 34496 kg (76051 lb).

• The approximate weight of the 775G Off-Highway Truck DRC (RM880) body is 11700 kg (25794 lb).

• The approximate weight of the 775G Off-Highway Truck DRC (RM880) with the body and no body liner is 46196 kg (101845 lb).

• The approximate weight of the 775G Off-Highway Truck DRC (RM880) with the body and the body liner is 50346 kg (110994 lb).

• The weight of each tire and rim is approximately 1270 kg (2800 lb).

Machine Specifications

Illustration 2	g02725805
Side view (1) Height to Top of ROPS (2) Overall Body Length (3) Inside Body Length (4) Overall Length (5) Wheel base (6) Rear Axle to Trail (7) Ground Clearance (8) Dump Clearance (9) Loading Height - Empty (10) Inside Body Depth - Max (11) Overall Height - Body Raised

Illustration 3	g02725612
Front view (12) Operating Width (13) CL Front Tire Width (14) Engine Guard Clearance

Illustration 4	g02725757
Rear view (15) Overall Canopy Width (16) Outside Body Width (17) Inside Body Width (18) Front Canopy Height (19) Rear Axle Clearance (20) CL Rear Dual Tire Width (21) Overall Tire Width

Table 16

General Machine Dimensions
		773G		775G
		Flat Floor	Dual Slope Floor	Flat Floor	Dual Slope Floor	Quarry
1	Height to Top of ROPS	4108 mm (162 inch)	4108 mm (162 inch)	4108 mm (162 inch)	4108 mm (162 inch)	4108 mm (162 inch)
2	Overall Body Length	9293 mm (366 inch)	9216 mm (363 inch)	9293 mm (366 inch)	9215 mm (363 inch)	9295 mm (366 inch)
3	Inside Body Length	6100 mm (240 inch)	6100 mm (240 inch)	6100 mm (240 inch)	6100 mm (240 inch)	6100 mm (240 inch)
4	Overall Length	10146 mm (399 inch)	10070 mm (396 inch)	10151 mm (400 inch)	10073 mm (397 inch)	10151 mm (400 inch)
5	Wheel base	4215 mm (166 inch)	4215 mm (166 inch)	4215 mm (166 inch)	4215 mm (166 inch)	4215 mm (166 inch)
6	Rear Axle to Trail	3006 mm (118 inch)	2925 mm (115 inch)	3005 mm (118 inch)	2925 mm (115 inch)	3005 mm (118 inch)
7	Ground Clearance	759 mm (29.8 inch)	759 mm (29.8 inch)	759 mm (29.8 inch)	759 mm (29.8 inch)	759 mm (29.8 inch)
8	Dump Clearance	640 mm (25 inch)	639 mm (25 inch)	639 mm (25 inch)	650 mm (25.5 inch)	639 mm (25 inch)
9	Loading Height - Empty	3771 mm (148.5 inch)	3771 mm (148.5 inch)	3964 mm (156 inch)	3964 mm (156 inch)	3968 mm (156.2 inch)
10	Inside Body Depth - Max	1727 mm (68 inch)	1773 mm (70 inch)	1892 mm (74.5 inch)	1945 mm (76.5 inch)	1892 mm (74.5 inch)
11	Overall Height - Body Raised	9280 mm (365 inch)	9284 mm (365.5 inch)	9279 mm (365 inch)	9279 mm (365 inch)	9284 mm (365.5 inch)
12	Operating Width	5673 mm (223.3 inch)	5673 mm (223.3 inch)	5673 mm (223.3 inch)	5673 mm (223.3 inch)	5673 mm (223.3 inch)
13	CL Front Tire Width	3205 mm (126 inch)	3205 mm (126 inch)	3205 mm (126 inch)	3205 mm (126 inch)	3205 mm (126 inch)
14	Engine Guard Clearance	703 mm (27.7 inch)	703 mm (27.7 inch)	703 mm (27.7 inch)	703 mm (27.7 inch)	703 mm (27.7 inch)
15	Overall Canopy Width	4886 mm (192.4 inch)	4886 mm (192.4 inch)	5012 mm (197 inch)	5012 mm (197 inch)	5012 mm (197 inch)
16	Outside Body Width	3922 mm (154.4 inch)	3922 mm (154.4 inch)	4254 mm (167.5 inch)	4254 mm (167.5 inch)	4254 mm (167.5 inch)
17	Inside Body Width	3654 mm (144 inch)	3654 mm (144 inch)	3986 mm (157 inch)	3986 mm (157 inch)	3986 mm (157 inch)
18	Front Canopy Height	4459 mm (175.5 inch)	4459 mm (175.5 inch)	4457 mm (175.4 inch)	4459 mm (175.5 inch)	4463 mm (175.7 inch)
19	Rear Axle Clearance	560 mm (22 inch)	560 mm (22 inch)	560 mm (22 inch)	560 mm (22 inch)	560 mm (22 inch)
20	CL Rear Dual Tire Width	2929 mm (115 inch)	2929 mm (115 inch)	2929 mm (115 inch)	2929 mm (115 inch)	2929 mm (115 inch)
21	Overall Tire Width	4411 mm (173.7 inch)	4411 mm (173.7 inch)	4411 mm (173.7 inch)	4411 mm (173.7 inch)	4411 mm (173.7 inch)

Chains and Cables

Use approved cables, chains, and lifting devices to lift the components. Refer to the literature from the manufacturer 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 5	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.

Remove the Shipping Brackets

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Illustration 6	g02790593
View of the rear of the front right wheel (A) Bracket (B) Bolt (C) Nut (D) Washer

1. Remove bolt (B), nut (C), and washer (D) that secure bracket (A). Discard bracket (A) and bolt (B). Retain nut (C) and washer (D).
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   Illustration 7	g02790602
   View of the rear of the front right wheel (C) Nut (D) Washer

2. Reinstall nut (C) and washer (D) onto the bolt. Tighten the bolt to a torque of 945 ± 35 N·m (695 ± 25 lb ft).

3. Repeat Step 1 and Step 2 for the other side of the machine.

Unload the Truck Components

Illustration 8	g02722966
Typical view of the truck as delivered

Illustration 9	g02722977
Typical view of the two shipping boxes

Illustration 10	g02722979
Typical view of shipping pallet and outer tires and rims

1. Unload all the truck components.

Install the Rear Tire and Rim Assemblies

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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.

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Illustration 11	g02723009
Typical view of the rear inner tire

1. Raise the rear axle of the truck approximately 200 mm (8 inch).

   Raising the rear axle is necessary to provide clearance to install the outer tires.

   Note: In Illustration11the truck was driven on blocks.

   Note: A suitable hydraulic lifting device under the main frame can also be used to raise the rear axle.

2. Chock the front wheels.
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   Illustration 12	g06357916
   Typical view of the rear inner tire (A) 339-3284 Hex Nut (B) 322-1942 Hard Washer (C) Protective decal

3. Remove hex nuts (A) and hard washers (B) from the wheel studs.

   Using the tab, peel off protective decals (C) from the wheel flanges.

   Clean the contact surfaces of the mounting flanges and the mating surfaces of the wheel rim of paint, dirt, rust, debris, or oil.

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   Illustration 13	g00518947
   Typical view of a tire handler

4. Use a tire handler or use a suitable lifting device to install the tire and rim assembly on the truck.

   Note: The approximate weight of each tire and rim is 1180 kg (2600 lb).

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   Illustration 14	g02723033
   Typical view of the rear inner tire (A) 339-3284 Hex Nut (B) 322-1942 Hard Washer

5. Apply 4C-5592 Anti-Seize Compound to the face of the hard washers (B) and to the threads of the wheel bolts.

6. Secure the rim and tire to the wheel group by using hex nuts (A) and hard washers (B). Tighten hex nuts to a torque of 1700 ± 200 N·m (1254 ± 148 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 to find tire inflation instructions.

7. Repeat Step 3 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 Left-Hand Catwalk Assembly

Table 17

Required Parts for Installation of the Left-Hand Catwalk
Item	Qty	Part Number	Description
1	1	N/A	Left-Hand Catwalk Assembly
2	8	8T-4193	Bolt
3	8	7X-0583	Hard Washer

1. Remove paint from the mating surfaces. Clean the mating surfaces and remove any burrs that are present.
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   Illustration 15	g02723111
   View of the left-hand catwalk assembly on the shipping pallet

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   Illustration 16	g02723114

2. Attach a suitable lifting device to left-hand catwalk assembly (1).

   Note: The approximate weight of the left-hand catwalk assembly is 195 kg (430 lb).

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   Illustration 17	g02723130
   View of the left-hand side of the cab (1) Left-hand catwalk assembly (2) 8T-4193 Bolt (3) 7X-0583 Hard Washer

3. Secure left-hand catwalk assembly (1) to the left side of the machine by using eight bolts (2) and eight hard washers (3).

Install the 314-7100 Step Gp

Table 18

Required Parts for Installation of the Left-Hand Catwalk
Item	Qty	Part Number	Description
1	1	354-0298	Stair As
2	4	8T-4956	Bolt
3	10	7X-0590	Hard Washer
4	2	8T-4648	Bolt
5	2	7T-8332	Mounting
6	2	8T-4244	Nut

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Illustration 18	g02723150
View of stair assembly (1) in the shipping box (1) 354-0298 Stair As

1. Attach a suitable lifting device to stair assembly (1).

   Note: The approximate weight of stair assembly (1) is 35 kg (77 lb).

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   Illustration 19	g02723142
   View of the left side of the bumper (1) 354-0298 Stair As (2) 8T-4956 Bolt (3) 7X-0590 Hard Washer (4) 8T-4648 Bolt (5) 7T-8332 Mounting (6) 8T-4244 Nut

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   Illustration 20	g02723165
   Section view of the front of the bumper (1) 354-0298 Stair As (3) 7X-0590 Hard Washer (4) 8T-4648 Bolt (5) 7T-8332 Mounting (6) 8T-4244 Nut

2. Secure stair assembly (1) to the left-hand catwalk assembly and the left side of the bumper. Use four bolts (2), ten hard washers (3), two bolts (4), two mountings (5), and two nuts (6) to secure stair assembly (1).

Install the 372-4535 Handrail Gp

Table 19

Required Parts for Installation of the 372-4535 Handrail Gp
Item	Qty	Part Number	Description
1	1	354-8431	Handrail As
2	20	8T-4139	Bolt
3	20	7X-3392	Hard Washer
4	1	355-6060	Handrail As
5	1	355-5902	Handrail As
6	8	8T-4194	Bolt
7	8	198-4778	Hard Washer
8	10	8T-4195	Bolt
9	4	198-4777	Hard Washer
10	1	314-7228	Handrail As
11	6	8T-4121	Hard Washer
12	1	355-5918	Handrail As
13	1	355-5917	Handrail As
14	1	337-9038	Handrail As
15	2	8T-4136	Bolt
16	10	5P-7468	Clip
17	10	5P-7469	Clip
18	10	6V-1874	Grommet
19	5	8T-4183	Bolt
20	10	8T-4223	Hard Washer
21	5	8T-4244	Nut

Illustration 21	g02723057
View of the shipping pallet

The handrail assemblies are all shipped on the pallet.

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Illustration 22	g02723192
(1) 354-8431 Handrail As (2) 8T-4139 Bolt (3) 7X-3392 Hard Washer

1. Secure handrail assembly (1) to the front of the stair assembly by using four bolts (2) and four hard washers (3).
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   Illustration 23	g02723206
   (2) 8T-4139 Bolt (3) 7X-3392 Hard Washer (4) 355-6060 Handrail As

2. Secure handrail assembly (4) to the left-hand catwalk assembly by using four bolts (2) and four hard washers (3).
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   Illustration 24	g02723214
   View of the left side of the left-hand catwalk assembly (2) 8T-4139 Bolt (3) 7X-3392 Hard Washer (5) 355-5902 Handrail As (6) 8T-4194 Bolt (7) 198-4778 Hard Washer (8) 8T-4195 Bolt (9) 198-4777 Hard Washer

3. Secure handrail assembly (5) to the side of the left-hand catwalk assembly by using four bolts (2), four hard washers (3), four bolts (6), four hard washers (7), four bolts (8), and four hard washers (9).
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   Illustration 25	g02723235
   View of the front right-hand side of the truck (2) 8T-4139 Bolt (3) 7X-3392 Hard Washer (8) 8T-4195 Bolt (10) 314-7228 Handrail As (11) 8T-4121 Hard Washer

4. Secure handrail assembly (10) to the right side of the bumper by using two bolts (2), two hard washers (3), two bolts (8), and two hard washers (11).
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   Illustration 26	g02723276
   View of the front right-hand side of the truck (2) 8T-4139 Bolt (3) 7X-3392 Hard Washer (12) 355-5918 Handrail As

5. Secure handrail assembly (12) to the side of the right-hand stair assembly by using four bolts (2) and four hard washers (3).
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   Illustration 27	g02723283
   View of the right side of the truck (2) 8T-4139 Bolt (3) 7X-3392 Hard Washer (6) 8T-4194 Bolt (7) 198-4778 Hard Washer (13) 355-5917 Handrail As

6. Secure handrail assembly (13) to the right-hand platform by using two bolts (2), two hard washers (3), four bolts (6), and four hard washers (7).
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   Illustration 28	g02723288
   View of the top of the hood assembly (8) 8T-4195 Bolt (11) 8T-4121 Hard Washer (14) 337-9038 Handrail As (15) 8T-4136 Bolt

7. Secure handrail assembly (14) to the top of the hood assembly by using four bolts (8), six hard washers (11), and two bolts (15).
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   Illustration 29	g02723309
   View of the left side of the truck (A) Handrail assembly (1) 354-8431 Handrail As (4) 355-6060 Handrail As (5) 355-5902 Handrail As (16) 5P-7468 Clip (17) 5P-7469 Clip (18) 6V-1874 Grommet (19) 8T-4183 Bolt (20) 8T-4223 Hard Washer (21) 8T-4244 Nut

8. Secure handrail assembly (A) to handrail assembly (1) by using two clips (16), two clips (17), two grommets (18), one bolt (19), two hard washers (20), and one nut (21).

9. Secure handrail assembly (1) to handrail assembly (4) by using two clips (16), two clips (17), two grommets (18), one bolt (19), two hard washers (20), and one nut (21).

10. Secure handrail assembly (4) to handrail assembly (5) by using two clips (16), two clips (17), two grommets (18), one bolt (19), two hard washers (20), and one nut (21).
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    Illustration 30	g02723339
    View of the right side of the truck (10) 314-7228 Handrail As (12) 355-5918 Handrail As (13) 355-5917 Handrail As (16) 5P-7468 Clip (17) 5P-7469 Clip (18) 6V-1874 Grommet (19) 8T-4183 Bolt (20) 8T-4223 Hard Washer (21) 8T-4244 Nut

11. Secure handrail assembly (10) to handrail assembly (12) by using two clips (16), two clips (17), two grommets (18), one bolt (19), two hard washers (20), and one nut (21).

12. Secure handrail assembly (12) to handrail assembly (13) by using two clips (16), two clips (17), two grommets (18), one bolt (19), two hard washers (20), and one nut (21).

Install the 323-0366 Platform Wiring Gp

Installation of the 323-0366 Platform Wiring Gp (Type 1)

Table 20

Required Parts for Installation of the 323-0366 Platform Wiring Gp
Item	Qty	Part Number	Description
1	1	N/A	Box for ground level shutdown switch
2	2	8T-4136	Bolt
3	2	4B-4278	Washer

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Illustration 31	g02723576
View of the front of the truck (A) Wiring harness assembly

1. Remove the bag and the cable straps that secure wiring harness assembly (A).
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   Illustration 32	g02723605
   View from under the left-hand catwalk assembly (B) Plate assembly

2. Remove plate assembly (B) from the side of the stair assembly. Retain plate assembly (B) and the mounting hardware.
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   Illustration 33	g02723626
   View of the front of the truck (C) Cover assembly

3. Remove cover assembly (C) from the front of the truck. Retain cover assembly (C) and the mounting hardware.
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   Illustration 34	g02723726
   View of the front of the truck (A) Wiring harness assembly

4. Route one section of wiring harness assembly (A) along the stair assembly and the other end under the left-hand platform assembly.

   Use 7K-1181 Cable Straps to secure wiring harness assembly (A).

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   Illustration 35	g02723746
   View under the stair assembly (A) Wiring harness assembly (1) Box for ground level shutdown switch

5. Connect the two deutsch connectors from wiring harness assembly (A) to two connectors from box (1).
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   Illustration 36	g02723798
   View of the front of the cab (A) Wiring harness assembly (D) Wiring harness assembly

6. Connect two deutsch connectors from wiring harness assembly (A) to two connectors from chassis wiring harness assembly (D).
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   Illustration 37	g02723805
   View of the front of the cab (A) Wiring harness assembly (C) Cover assembly (E) Lamp group

7. Connect the remaining two deutsch connectors from wiring harness assembly (A) to two lamp groups (E).

   Note: Lamp groups (E) are connected to cover assembly (C).

   Note: Cover assembly (C) is partially transparent in Illustration 37.

8. Reinstall cover assembly (C) by using the hardware that was removed in Step 3.
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   Illustration 38	g02723756
   (1) Box for ground level shutdown switch (2) 8T-4136 Bolt (3) 4B-4278 Washer

9. Secure box (1) to the left side of the front bumper by using two bolts (2) and two washers (3).

Installation of the 323-0366 Platform Wiring Gp (Type 2)

Table 21

Required Parts for Installation of the 323-0366 Platform Wiring Gp
Item	Qty	Part Number	Description
1	14	7K-1181	Cable Strap
2	1	2G-1133	Grommet
3	1	297-8752	Toggle Switch Gp (ENGINE SHUTOFF)
4	1	353-4515	Toggle Switch Gp (LIGHTS)
5	1	3E-5169	Switch Guard
6	1	271-4532	Film
7	1	281-7268	Film

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Illustration 39	g06314612
View of the front of the truck (A) Wiring harness assembly

1. Remove the bag and the cable straps that secure wiring harness assembly (A).
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   Illustration 40	g02723605
   View from under the left-hand catwalk assembly (B) Plate assembly

2. Remove plate assembly (B) from the side of the stair assembly. Retain plate assembly (B) and the mounting hardware.
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   Illustration 41	g02723626
   View of the front of the truck (C) Cover assembly

3. Remove cover assembly (C) from the front of the truck. Retain cover assembly (C) and the mounting hardware.
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   Illustration 42	g06314628
   View of the front of the truck (A) Wiring harness assembly (1) 7K-1181 Cable Strap (2) 2G-1133 Grommet

4. Route one section of wiring harness assembly (A) along the stair assembly and the other end under the cover in front of the cab assembly.

   Use seven cable straps (1) to secure wiring harness assembly (A).

   Route harness assembly (A) through the hole at the bottom of the stair assembly with one grommet (2).

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   Illustration 43	g06314646
   View of the bottom of the stair assembly (A) Wiring harness assembly (1) 7K-1181 Cable Strap (3) 297-8752 Toggle Switch Gp (ENGINE SHUTOFF) (4) 353-4515 Toggle Switch Gp (LIGHTS)

5. Connect toggle switch group (3) and toggle switch (4) to wiring harness assembly (A). Secure toggle switch group (3), toggle switch (4), and wiring harness assembly (A) to the bottom of the stair assembly by using four cable straps (1).
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   Illustration 44	g06314652
   View of the bottom of the stair assembly (3) 297-8752 Toggle Switch Gp (ENGINE SHUTOFF) (4) 353-4515 Toggle Switch Gp (LIGHTS) (5) 3E-5169 Switch Guard (GROUND LEVEL SHUTDOWN) (6) 271-4532 Film (7) 281-7268 Film

6. Secure toggle switch group (3) and toggle switch group (4) to the stair assembly. Tighten to a maximum of 3.8 N·m (33 lb in).

   Secure switch guard (5) to toggle switch group (3).

   Attach film (6) around toggle switch group (4).

   Attach film (7) to the stair assembly directly above toggle switch group (3).

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   Illustration 45	g02723798
   View of the front of the cab (A) Wiring harness assembly (D) Wiring harness assembly

7. Connect two deutsch connectors from wiring harness assembly (A) to two connectors from chassis wiring harness assembly (D).
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   Illustration 46	g02723805
   View of the front of the cab (A) Wiring harness assembly (C) Cover assembly (E) Lamp group

8. Connect the remaining two deutsch connectors from wiring harness assembly (A) to two lamp groups (E).

   Note: Lamp groups (E) are connected to cover assembly (C).

   Note: Cover assembly (C) is partially transparent in Illustration 37.

9. Reinstall cover assembly (C) by using the hardware that was removed in Step 3.

Install the Mirror Group

There are four mirror group options available. Table 22 shows the options.

Table 22

Mirror Group	Heated (Yes/No)	Description
312-0860 Mirror Gp(1)	Yes	Basic
358-1619 Mirror Gp(1)	No	Basic
336-4470 Mirror Gp(2)	Yes	ISO
358-1620 Mirror Gp(2)	No	ISO

(1)	Installed in the "Install the 312-0860 Mirror Gp or the 358-1619 Mirror Gp" Section
(2)	Installed in the "Install the 336-4470 Mirror Gp or the 358-1620 Mirror Gp (if equipped)"

Install the 312-0860 Mirror Gp or the 358-1619 Mirror Gp

The 312-0860 Mirror Gp is the basic heated mirror group. The 358-1619 Mirror Gp is the basic not heated mirror group.

Table 23

Required Parts for Installation of the 312-0860 Mirror Gp or the 358-1619 Mirror Gp
Item	Qty	Part Number	Description
1	2	357-9681(1) 357-9682(2)	Mirror Gp Mirror Gp (HEATED, 24-VOLT)
2	3	8T-4137	Bolt
3	9	8T-4121	Hard Washer
4	4	8T-4186	Bolt
5	2	134-0989	Block
6	1	7Y-5262	U-Bolt
7	2	8T-0389	Locknut
8	1	7X-7468	Convex Mirror
9	1	295-8899	Plate
10	3	8T-4223	Hard Washer
11	1	3K-6060	Locknut
12	1	8T-4183	Bolt
13	1	129-3180	Locknut
14	1	5P-7468	Clip
15	1	5P-7469	Clip
16	1	6V-1874	Grommet

(1)	Used in the 358-1619 Mirror Gp
(2)	Used in the 312-0860 Mirror Gp

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Illustration 47	g02723838
Typical view of the right side of the truck (1) 357-9681 Mirror Gp (1) 357-9682 Mirror Gp (HEATED, 24-VOLT) (2) 8T-4137 Bolt (3) 8T-4121 Hard Washer

1. Secure one mirror group (1) to the right side of the truck by using three bolts (2) and three hard washers (3).
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   Illustration 48	g02723846
   Typical view of the left side of the truck (1) 357-9681 Mirror Gp (1) 357-9682 Mirror Gp (HEATED, 24-VOLT) (3) 8T-4121 Hard Washer (4) 8T-4186 Bolt (5) 134-0989 Block (6) 7Y-5262 U-Bolt (7) 8T-0389 Locknut

2. Secure one mirror group (1) to the left side of the truck by using four bolts (4), six hard washers (3), two blocks (5), one U-bolt (6), and two locknuts (7).
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   Illustration 49	g02723865
   View of the front of the truck (A) Handrail assembly (8) 7X-7468 Convex Mirror (9) 295-8899 Plate (10) 8T-4223 Hard Washer (11) 3K-6060 Locknut (12) 8T-4183 Bolt (13) 129-3180 Locknut (14) 5P-7468 Clip (15) 5P-7469 Clip (16) 6V-1874 Grommet

3. Secure one convex mirror (8) to handrail assembly (A) by using one plate (9), three hard washers (10), one locknut (11), one bolt (12), one locknut (13), one clip (14), one clip (15), and one grommet (16).

4. Refer to Section "Connect the Heated Mirrors Assemblies (If Equipped)"for instructions on electrically connecting the heated mirror assemblies.

Install the 336-4470 Mirror Gp or the 358-1620 Mirror Gp (if equipped)

Refer to "Install the 321-6472 Lighting Wiring Gp (if equipped)".

Table 24

Required Parts for Installation of the 336-4470 Mirror Gp or the 358-1620 Mirror Gp
Item	Qty	Part Number	Description
1	2	357-9681(1) 357-9682(2)	Mirror Gp Mirror Gp (HEATED, 24-VOLT)
2	3	8T-4137	Bolt
3	29	8T-4121	Hard Washer
4	4	8T-4186	Bolt
5	2	134-0989	Block
6	11	7Y-5262	U-Bolt
7	22	8T-0389	Locknut
8	1	353-4621	Tube As
9	4	8T-4182	Bolt
10	4	198-4777	Hard Washer
11	2	329-7328	Convex Mirror
12	1	330-5264	Tube As

(1)	Used in the 358-1620 Mirror Gp
(2)	Used in the 336-4470 Mirror Gp

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Illustration 50	g02723838
Typical view of the right side of the truck (1) 357-9681 Mirror Gp (1) 357-9682 Mirror Gp (HEATED, 24-VOLT) (2) 8T-4137 Bolt (3) 8T-4121 Hard Washer

1. Secure one mirror group (1) to the right side of the truck by using three bolts (2) and three hard washers (3).
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   Illustration 51	g02723846
   Typical view of the left side of the truck (1) 357-9681 Mirror Gp (1) 357-9682 Mirror Gp (HEATED, 24-VOLT) (3) 8T-4121 Hard Washer (4) 8T-4186 Bolt (5) 134-0989 Block (6) 7Y-5262 U-Bolt (7) 8T-0389 Locknut

2. Secure one mirror group (1) to the left side of the truck by using four bolts (4), six hard washers (3), two blocks (5), one U-bolt (6), and two locknuts (7).
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   Illustration 52	g02724204
   View of the right side of the front bumper (A) Handrail assembly (B) Handrail assembly (3) 8T-4121 Hard Washer (6) 7Y-5262 U-Bolt (7) 8T-0389 Locknut (8) 353-4621 Tube As (9) 8T-4182 Bolt (10) 198-4777 Hard Washer (11) 329-7328 Convex Mirror

3. Secure tube assembly (8) to the front bumper, handrail assembly (A), and handrail assembly (B). Use four bolts (9), four hard washers (10), four U-bolts (6), eight hard washers (3), and eight locknuts (7) to secure tube assembly (8).

4. Secure convex mirror (11) to the top of tube assembly (8) with the hardware that is on convex mirror (11).

   Note: Tighten the screws on convex mirror (11) to 2.25 ± 0.5 N·m (20 ± 4.4 lb in).

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   Illustration 53	g02724225
   View of the front left side of the truck (C) Handrail assembly (D) Handrail assembly (3) 8T-4121 Hard Washer (6) 7Y-5262 U-Bolt (7) 8T-0389 Locknut (11) 329-7328 Convex Mirror (12) 330-5264 Tube As

5. Secure tube assembly (12) to handrail assembly (C) and handrail assembly (D) by using six U-bolts (6), 12 hard washers (3), and 12 locknuts (7).

6. Secure convex mirror (11) to the top of tube assembly (12) with the hardware that is on convex mirror (11).

   Note: Tighten the screws on convex mirror (11) to 2.25 ± 0.5 N·m (20 ± 4.4 lb in).

7. Refer to the"Connect the Heated Mirrors Assemblies (If Equipped)"for instructions on electrically connecting the heated mirror assemblies.

Install the 321-6472 Lighting Wiring Gp (if equipped)

The 321-6472 Lighting Wiring Gp is used on machines equipped with the 358-1620 Mirror Gp and the 336-4470 Mirror Gp.

Table 25

Required Parts for Installation of the 321-6472 Lighting Wiring Gp
Item	Qty	Part Number	Description
1	1	N/A	Flood lamp assembly
2	1	8T-4137	Bolt
3	1	5P-1075	Hard Washer

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Illustration 54	g02724454
View of the right side of the truck (A) Tube assembly (1) Flood lamp assembly (2) 8T-4137 Bolt (3) 5P-1075 Hard Washer

1. Secure flood lamp assembly (1) to tube assembly (A) by using one bolt (2) and one hard washer (3).

   Note: Flood lamp assembly (1) is shipped already assembled.

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   Illustration 55	g02724506
   View of the right side of the truck (B) 321-7442 Lighting Harness As (1) Flood lamp assembly

2. Connect flood lamp assembly (1) to lighting harness assembly (B).

   Note: Lighting harness assembly (B) is shipped coiled under the right-hand platform. Lighting harness assembly (B) must be routed up to flood lamp assembly (1).

3. Secure the harness assemblies with cable straps.

Connect the Heated Mirrors Assemblies (If Equipped)

The heated mirror assemblies are used on the 336-4470 Mirror Gp and the 312-0860 Mirror Gp.

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Illustration 56	g02724468
View of the right-hand mirror assembly (A) Mirror assembly

1. Route the wiring harness for mirror assembly (A) along the handrail assembly. Connect the wiring harness to the 321-7581 Auxiliary Harness As that is located under the right-hand platform.
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   Illustration 57	g02724529
   View of the left-hand mirror assembly (B) Mirror assembly

2. Route the wiring harness for mirror assembly (B) along the handrail assembly. Connect the wiring harness to the 321-7582 Lighting Harness As that is located under the left-hand catwalk assembly.

3. Secure the harness assemblies with cable straps.

Install the Antenna and Mounting/Communiction Wiring Group (if equipped)

There are two options available:

• 321-6471 Antenna and Mounting Gp

• 341-7960 Communication Wiring Gp

Table 26

Required Parts for Installation of the Antenna and Mounting/Communiction Wiring Group
Item	Qty	Part Number	Description
1	1	283-5837	Plate
2	1	284-8533(1) 346-9376(2)	Antenna As Antenna As
3	1	9X-7345	Grommet
4	1	341-7961(2)	Cable As
5	2	8S-7583	Grommet
6	2	3K-5178	Grommet

(1)	Used on the 321-6471 Antenna and Mounting Gp
(2)	Used on the 341-7960 Communication Wiring Gp

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Illustration 58	g02724573
View of the left side of the truck (A) Bolt (B) Washer (C) Bracket assembly (1) 283-5837 Plate (2) 284-8533 Antenna As (2) 346-9376 Antenna As (3) 9X-7345 Grommet (4) 341-7961 Cable As if required

1. Secure plate (1) to the back of bracket assembly (C) by using existing bolt (A) and existing washer (B).

   Note: Antenna assembly (2) is shipped already secured to plate (1).

2. Route the cable assembly for antenna assembly (2) down the handrail assembly.

   Note: For 341-7960 Communication Wiring Gp, one 341-7961 Cable As (4) must be secured to the antenna assembly.

3. Insert one grommet (3) into the available hole on the side of the left-hand catwalk assembly.

4. Route the cable assembly through grommet (3).
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   Illustration 59	g02724597
   View of the bottom of the left-hand catwalk assembly (5) 8S-7583 Grommet

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   Illustration 60	g02724616
   View of the bottom of the left-hand catwalk assembly

5. Insert two grommets (5) into the bottom of the catwalk assembly. Route the cable assembly through grommets (5) and along the bottom of the catwalk assembly.
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   Illustration 61	g02724618
   View of the bottom of the catwalk assembly and the cab (6) 3K-5178 Grommet

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   Illustration 62	g02724621
   View of the rear of the cab (D) Communication electronic control module (6) 3K-5178 Grommet

   Note: The back panel at the rear of the cab is removed in Illustration 62.

6. Insert two grommets (6) into the bottom of the cab. Route the cable assembly through two grommets (6) and along the back of the cab.

7. Connect the cable assembly to communication electronic control module (D).

8. Secure the cable assembly with 3S-2093 Cable Straps and 7K-1181 Cable Straps.

Install the 314-7140 Fender Gp

Table 27

Required Parts for Installation of the 314-7140 Fender Gp
Item	Qty	Part Number	Description
1	1	340-1319	Guard
2	12	8T-4196	Bolt
3	63	7X-7729	Washer
4	35	8T-4195	Bolt
5	9	340-3616	Plate
6	5	357-0497	Plate
7	1	340-1318	Guard
8	1	339-2076	Guard
9	1	333-4801	Guard
10	2	319-5435	Plate
11	1	355-9827	Bracket
12	22	8T-4183	Bolt
13	22	198-4778	Hard Washer
14	6	8T-4956	Bolt
15	12	5P-1076	Hard Washer
16	6	8T-4244	Nut
17	1	355-9824	Bracket
18	1	355-9825	Bracket
19	1	339-6647	Mud Deflector
20	2	115-6433	Washer
21	14	8T-4133	Nut
22	1	339-6646	Mud Deflector
23	1	417-0162	Guard
24	1	417-0161	Plate
25	2	8T-4186	Bolt
26	3	6V-7744	Locknut
27	1	115-6433	Washer

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Illustration 63	g02724724
View of the bottom of the left-hand catwalk assembly (1) 355-9827, 340-1319 Guard (2) 8T-4196 Bolt (3) 7X-7729 Washer (4) 8T-4195 Bolt (5) 340-3616 Plate (6) 357-0497 Plate (7) 340-1318 Guard

1. Secure guard (1) to the bottom of the left-hand catwalk assembly by using two bolts (2), seven washers (3), five bolts (4), one plate (5), and one plate (6).

2. Secure guard (7) to the bottom of the left-hand catwalk assembly by using four bolts (4), four washers (3), and two plates (6).
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   Illustration 64	g02724775
   View of the bottom of the right-hand platform (3) 7X-7729 Washer (4) 8T-4195 Bolt (5) 340-3616 Plate (8) 339-2076 Guard

3. Secure guard (8) to the bottom of the right-hand platform by using six bolts (4), six washers (3), and two plates (5).
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   Illustration 65	g02724787
   View of the right side of the truck (2) 8T-4196 Bolt (3) 7X-7729 Washer (4) 8T-4195 Bolt (5) 340-3616 Plate (9) 333-4801 Guard (10) 319-5435 Plate

4. Secure guard (9) to the right side of the step assembly by using two bolts (2), eight washers (3), six bolts (4), two plates (5), and one plate (10).
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   Illustration 66	g02724792
   (11) 355-9827 Bracket

5. Attach a suitable lifting device to bracket (11).

   Note: The approximate weight of bracket (11) is 50 kg (110 lb).

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   Illustration 67	g02724810
   View of the rear of the right-hand platform (11) 355-9827 Bracket (12) 8T-4183 Bolt (13) 198-4778 Hard Washer (14) 8T-4956 Bolt (15) 5P-1076 Hard Washer (16) 8T-4244 Nut

6. Secure bracket (11) to the right side of the truck by using eight bolts (12), eight hard washers (13), six bolts (14), 12 hard washers (15), and six nuts (16).
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   Illustration 68	g02724914
   (12) 8T-4183 Bolt (13) 198-4778 Hard Washer (17) 355-9824 Bracket

7. Attach a suitable lifting device to bracket (17).

   Note: The approximate weight of bracket (17) is 49 kg (108 lb).

8. Secure bracket (17) to the left side of the truck by using ten bolts (12) and ten hard washers (13).
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   Illustration 69	g02724918
   (12) 8T-4183 Bolt (13) 198-4778 Hard Washer (18) 355-9825 Bracket

9. Secure bracket (18) to the rear of the left-hand catwalk assembly by using four bolts (12) and four hard washers (13).
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   Illustration 70	g02724959
   (3) 7X-7729 Washer (4) 8T-4195 Bolt (5) 340-3616 Plate (17) 355-9824 Bracket (18) 355-9825 Bracket (19) 339-6647 Mud Deflector (20) 115-6433 Washer (21) 8T-4133 Nut

10. Secure mud deflector (19) to the bottom of bracket (17) and bracket (18) by using seven bolts (4), 13 washers (3), two plates (5), one washer (20), and seven nuts (21).
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    Illustration 71	g02724977
    (3) 7X-7729 Washer (4) 8T-4195 Bolt (5) 340-3616 Plate (6) 357-0497 Plate (11) 355-9827 Bracket (20) 115-6433 Washer (21) 8T-4133 Nut (22) 339-6646 Mud Deflector

11. Secure mud deflector (22) to the bottom of bracket (11) by using seven bolts (4), 13 washers (3), one plate (5), one plate (6), one washer (20), and seven nuts (21).
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    Illustration 72	g03408705
    View of the right-hand platform (2) 8T-4196 Bolt (3) 7X-7729 Washer (8) 339-2076 Guard (23) 417-0162 Guard (24) 417-0161 Plate (25) 8T-4186 Bolt (26) 6V-7744 Locknut (27) 115-6433 Washer

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    Illustration 73	g03409014
    Bottom view of the right-hand platform (2) 8T-4196 Bolt (3) 7X-7729 Washer (5) 340-3616 Plate (6) 357-0497 Plate (23) 417-0162 Guard (26) 6V-7744 Locknut

12. Secure the front left portion of guard (23) to the right-hand platform using plate (24), three bolts (2), and three washers (3). Secure the front right portion of guard (23) to guard (8) and plate (24), using plate (10), two bolts (25), four washers (3), and two locknuts (26).

13. Secure the rear portion of guard (23) to the bottom of the exhaust diverter with plate (5) and plate (6) using four bolts (2) and four washers (3).

14. Secure the end of guard (23) to plate (5) using one bolt (2), washer (3), washer (27), and locknut (26).

Install the 368-0674 Mud Guard Gp (if equipped)

Note: The 368-0674 Mud Guard Gp is only used on machines that are equipped with the 352-8527 SERVICE CENTER AR.

Table 28

Required Parts for Installation of the 368-0674 Mud Guard Gp
Item	Qty	Part Number	Description
1	1	367-5462	Guard
2	4	8T-4195	Bolt
3	4	7X-7729	Washer
4	2	319-5435	Plate

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Illustration 74	g02725445
View of the right side of the truck (1) 367-5462 Guard (2) 8T-4195 Bolt (3) 7X-7729 Washer (4) 319-5435 Plate

1. Secure guard (1) to the right side of the truck by using four bolts (2), four washers (3), and two plates (4).

Install the Canopy on the Body

Table 29

Parts for Installation of Canopy
Qty		Part Number	Description	Model
1		354-7792 or 368-5504	Canopy Assembly	773G
1		354-4810, 368-5504, or 362-8164	Canopy Assembly	775G
1		362-8174, 354-7830, or 368-5500	Body and Canopy Assembly	773G
1		354-6740, 368-4718, 362-0580, or 368-5500	Body and Canopy Assembly	775G

Table 30

Weld Specifications
Weld	Description	Body and Canopy Assembly Usage for 773G	Body and Canopy Assembly Usage for 775G
W1	6 mm (0.24 inch) flare-bevel groove weld	362-8174 354-7830	368-4718
W1	5 mm (0.197 inch) flare-bevel groove weld		354-6740 362-0580
W2	8 mm (0.32 inch) fillet weld	362-8174 354-7830	368-4718 354-6740 362-0580
W3	12 mm (0.472 inch) fillet weld with 1.5 mm (0.06 inch) of penetration	362-8174 354-7830	368-4718 354-6740 362-0580
W4	12 mm (0.472 inch) fillet weld with 1.5 mm (0.06 inch) of penetration	362-8174 354-7830	368-4718 354-6740 362-0580
W5	6 mm (0.24 inch) fillet weld with 1.5 mm (0.06 inch) of penetration	362-8174 354-7830	368-4718 354-6740 362-0580
W6	6 mm (0.24 inch) all around fillet weld with 1.5 mm (0.06 inch) of penetration	362-8174 354-7830	368-4718 354-6740 362-0580

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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 75	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 76	g01313546

2. Attach a suitable lifting device to canopy assembly (B).
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   Table 31

   Approximate Shipping Weight of Canopy
   Part Number	Weight
   354-7792	1073 kg (2365 lb)
   368-5504	1104 kg (2435 lb)
   354-4810	1116 kg (2460 lb)
   362-8164	1236 kg (2725 lb)

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   Illustration 77	g01307762

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   Illustration 78	g01307763

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   Illustration 79	g01310174

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   Illustration 80	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 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 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 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 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 81	g01310808

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

10. Repaint the welded areas.

Install the Plug in the Body

Table 32

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

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Illustration 82	g01308065

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

Install the 132-6650 Pin Assembly Which is a Part of the 337-0909 Truck Body Mounting Gp

Table 33

Required Parts for Installation of 132-6650 Pin Assembly Which is a Part of the 337-0909 Truck Body Mounting Gp
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 83	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 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 84	g00540878

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   Illustration 85	g00544513

2. Insert pin (1) through the holes for the pivot pins. As required, use thrust washer (2), and thrust washer (3) to reduce the gap at the outside pivot pin area to less than 3.0 mm (0.12 inch). Locate the thrust washers inside the ear of the truck body. The thrust washers should be used to equally space the body and the frame assemblies on both sides.

   If the gap at the outside pivot pin area is less than 3.0 mm (0.12 inch), no thrust washers are required.

   If the gap at the outside pivot pin area is 3.0 to 5.0 mm (0.12 to 0.20 inch), use one 3.0 mm (0.12 inch) thrust washer (3).

   If the gap is larger than 5.0 mm (0.20 inch), use one 5.0 mm (0.20 inch) thrust washer (2).

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

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

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

5. Repeat the procedure for the opposite side.

Install the 337-0909 Truck Body Mounting Gp

Table 34

Required Parts for the Installation of the 337-0909 Truck Body Mounting Gp
Item	Qty	Part Number	Description
1	2	322-4728	Plate
2	34	5P-2566	Bolt
3	64	8T-4223	Hard Washer
4	30	6V-8188	Nut
5	2	322-4729	Strip
6	2	322-4726	Mud Guard
7	2	372-0745	Ejector
8	2	6G-7773	Pin
9	4	3B-4647	Cotter Pin
10	8	1D-0503	Washer
11	1	113-1216	Baffle As
12	2	031-9831	Bolt
13	2	8W-1367	Pin As
14	2	303-1871	Plate
15	4	7D-2955	Spacer

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Illustration 86	g02725518
View of the right side of the truck (1) 322-4728 Plate (2) 5P-2566 Bolt (3) 8T-4223 Hard Washer (4) 6V-8188 Nut (5) 322-4729322-4729 Strip (6) 322-4726 Mud Guard

1. Secure plate (1) to the right side of the body by using seven bolts (2), 14 hard washers (3), and seven nuts (4).

2. Secure mud guard (6) to plate (1) by using eight bolts (2), 16 hard washers (3), eight nuts (4), and one strip (5).
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   Illustration 87	g02725529
   View of the left side of the truck (1) 322-4728 Plate (2) 5P-2566 Bolt (3) 8T-4223 Hard Washer (4) 6V-8188 Nut (5) 322-4729 Strip (6) 322-4726 Mud Guard

3. Secure plate (1) to the left side of the body by using seven bolts (2), 14 hard washers (3), and seven nuts (4).

4. Secure mud guard (6) to plate (1) by using eight bolts (2), 16 hard washers (3), eight nuts (4), and one strip (5).
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   Illustration 88	g02725580
   View of the left rear of the truck body (7) 372-0745 Ejector (8) 6G-7773 Pin (9) 3B-4647 Cotter Pin (10) 1D-0503 Washer

5. Attach a suitable lifting device to ejector (7).

   Note: The approximate weight of ejector (7) is 34 kg (75 lb).

6. Position ejector (7) onto the bottom of the truck body.

7. Secure ejector (7) to the truck body by using one pin (8), two cotter pins (9), and four washers (10).

8. Repeat Step 5 through Step 7 for the other side of the truck body.
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   Illustration 89	g02791296
   View of the front of the body (11) 113-1216 Baffle As (12) 031-9831 Bolt

9. Secure baffle assembly (11) to the bottom of the canopy assembly by using two bolts (12).

Connect the Hoist Cylinders

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Illustration 90	g02791357
View of the right side of the bottom of the body (2) 5P-2566 Bolt (3) 8T-4223 Hard Washer (13) 8W-1367 Pin As (14) 303-1871 Plate (17) 7D-2955 Spacer

1. Secure the right-hand hoist cylinder to the bottom of the truck body. Use one pin assembly (13), one plate (14), two bolts (2), two hard washers (3), and two spacers (15).

2. Repeat Step 1 for the left-hand side of the machine.

Install the Pads and Shims for the Body

Table 35

Parts for Installation of Pads and of Shims
Item	Qty	Part Number	Description
1	30	106-8224	Shim
2	8	347-5472	Pad As
3	24	5P-2566	Bolt
4	24	8T-4223	Hard Washer

Note: Ensure that the body is assembled to the chassis and hoist cylinders prior to installing the pads and shims for the body.

1. Use the center mounting block on the body as a guide to mark the pad locations on the frame rail.
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   Illustration 91	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 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 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) 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 92	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) 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 to keep the body centered.

6. Raise the body. Install the pins that retain the body. Use bolts (3) and hard washers (4) 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.

Install the Guards on the Truck Body

The are two body options available.

• 354-7800 Truck Body

• 354-7810 Truck Body

Table 36

Required Parts for the Installation of the Guards on the Truck Body
Item	Qty	Part Number	Description
1	1	264-4520	Guard
2	28	7X-0349	Bolt
3	28	7X-0515	Hard Washer
4	28	3R-8530	Boss
5	1	364-7200	Guard As
6	33	5P-2228	Bolt
7	33	8T-4223	Hard Washer
8	1	364-7190	Guard As
9	1	264-4519	Guard
10	1	262-5965	Guard As

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Illustration 93	g02725492
View of the left side of the truck body (1) 264-4520 Guard (2) 7X-0349 Bolt (3) 7X-0515 Hard Washer (4) 3R-8530 Boss (5) 364-7200 Guard As (6) 5P-2228 Bolt (7) 8T-4223 Hard Washer (8) 364-7190 Guard As

1. Attach a suitable lifting device to guard (1).

   Note: The approximate weight of guard (1) is 130 kg (286 lb).

2. Secure guard (1) to the truck body by using 14 bolts (2), 14 hard washers (3), and 14 bosses (4).

3. Attach a suitable lifting device to guard assembly (5).

   Note: The approximate weight of guard assembly (5) is 40 kg (88 lb).

4. Secure guard assembly (5) to the left side of the truck body by using six bolts (6) and six hard washers (7).

5. Attach a suitable lifting device to guard assembly (8).

   Note: The approximate weight of guard assembly (8) is 91 kg (200 lb).

6. Secure guard assembly (8) to the left side of the truck body by using 15 bolts (6) and 15 hard washers (7).
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   Illustration 94	g02725506
   View of the right side of the truck body (2) 7X-0349 Bolt (3) 7X-0515 Hard Washer (4) 3R-8530 Boss (6) 5P-2228 Bolt (7) 8T-4223 Hard Washer (9) 264-4519 Guard (10) 262-5965 Guard As

7. Attach a suitable lifting device to guard (9).

   Note: The approximate weight of guard (9) is 130 kg (286 lb).

8. Secure guard (9) to the truck body by using 14 bolts (2), 14 hard washers (3), and 14 bosses (4).

9. Attach a suitable lifting device to guard assembly (10).

   Note: The approximate weight of guard assembly (10) is 58 kg (128 lb).

10. Secure guard assembly (10) to the left side of the truck body by using 12 bolts (6) and 12 hard washers (7).

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 95	g02765556
   (1) Body up switch (2) Magnet (3) Plate

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   Illustration 96	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. Inorder 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

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

Check the Fluid Levels

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

Reference: Refer to Operation and Maintenance Manual, SEBU8561, "773G and 775G Off-Highway Truck (S/N: JWS; MJS)" or Operation and Maintenance Manual, SEBU8547, "773G and 775G Off-Highway Truck (S/N: MWH; RFM)" for additional information on fluid capacities and level check procedures.

Table 37

Fluid Level Checklist
Description	Fluid Full Yes or No
Engine Coolant System(1)
Transmission and Torque Converter
Hydraulic Tank
Steering Hydraulic Tank
Engine Crankcase
Left Rear Final Drive
Right Rear Final Drive
Rear Axle
Auto Lube Grease (if equipped)
Left Front Wheel Station
Right Front Wheel Station
Window Washer Reservoir
Fuel

(1)	Check the jacket water level

Tire Inflation - Check

Measure the tire pressure of each tire. Adjust the tire pressure, if necessary. Consult your tire supplier for the correct tire operating pressures and load ratings.

Reference: Refer to Operation and Maintenance Manual, SEBU8561, "773G and 775G Off-Highway Truck (S/N: JWS; MJS)" or Operation and Maintenance Manual, SEBU8547, "773G and 775G Off-Highway Truck (S/N: MWH; RFM)" for additional information on tire inflation.

Cab Instrumentation and Functional Checks

Operators Seat

Table 38

Check for Seat Adjustability	Check if OK
Check the range of the light to heavy dampening for the seat
Full range of the back reclining positions
Full range of the seat suspension travel

Operators Seat Belt

Table 39

Check Seat Belt Latch and Seat Belt Adjustability	Check if OK
Adjust the length of the seat belt
Fasten the seat belt catch into the buckle
The seat belt must not be able to slip after adjusting
The seat belt catch should unlatch from the buckle when required

Engine Start

Table 40

Check the Ignition Switch, Horn, and Engine Start	Check if OK
Turn the ignition key to the ON position(1)
Sound the horn for all clear
Turn the key to the START position to activate the starting motor.
After the diesel engine starts, release the key. The key should return to the ON position
Turn the ignition key to the OFF position. The engine should stop

(1)	The key in the ON position will enable the electrical circuits in the cab and activate the VIMS self test

Pressurize the Cab

Table 41

Check the Operation of the Blower Motor to Pressurize the Cab(1)	Check if OK
Turn the ignition key to the ON position
Check the four settings for the blower speed(2)
Turn the ignition key to the OFF position

(1)	Pressurizing the Cab helps to eliminate dust in the operators compartment
(2)	There should be an audible sound between the different settings

Climate Control

Table 42

Check the operation of the Heater and the Air Conditioner	Check if OK
Sound the horn for all clear
Start the engine
Turn the climate control to cool
Push the top of the A/C switch to activate
Air from the dash vents should be cold(1)
Push the top of the A/C switch to deactivate
Turn the climate control to warm
The lines for the heater valves should be open
Air from the dash vents should be warm (1)
Turn the ignition key to the OFF position

(1)	When the engine is at operating temperature

Window Wipers

Table 43

Check the Operation of the Window Wiper and Washer	Check if OK
Turn the ignition key to the ON position
From the OFF position, turn the window wipers to the LOW setting
Turn the window wiper to the HIGH setting
Press the button to activate the window washer fluid
Turn the window wiper to the first INTERMITTENT setting
Turn the window wiper to the second INTERMITTENT setting
Turn the window wiper to the third INTERMITTENT setting
Turn the window wipers to the OFF position
Turn the ignition key to the OFF position

Panel and Running Lights

Illustration 97	g03225219
View of the left-hand side of the operator control panel (1) Switch for headlights, parking lights, and taillights (2) Panel light switch

Illustration 98	g03225897
(3) Multifunction switch

Table 44

Check the operation of the Panel Lights and the Headlights(1)	Check if OK
Turn the ignition key to the OFF position
Push switch (1) to activate low beam headlights
Push the top half of switch (2) to the first detent to activate the instrument panel lights, marker lights, and the tail lights
Use multifunction switch (3) to toggle between low beam lights and high beam lights
Push the bottom half of switch (1) to the OFF position to deactivate the headlights

(1)	The tail lights should be on any time a light switch is activated

Hazard Lights

Illustration 99	g03226040
(4) Hazard flasher switch

Table 45

Check the Operation of the Hazard Lights	Check if OK
Turn the ignition key to the OFF position
Push the top half of switch (4) to activate the hazard lights
Push the bottom half of switch (4) to deactivate the hazard lights

Access Lights

Illustration 100	g03226076
(5) Switch for the access lights in the cab

Illustration 101	g03226716
(6) Switch for the access lights at ground level

Table 46

Check the operation of the Access Lights(1)	Check if OK
Turn the ignition key to the OFF position
Push the top half of switch (5) or switch (6) to activate the access lights
If necessary, adjust the access light to provide light for the steps
Push the bottom half of switch (5) or switch (6) to deactivate the access lights

(1)	The access lights can be activated from two places on the machine. The position of one switch will determine whether the other switch is in the ON position or in the OFF position.

Engine Shutdown Switch

Illustration 102	g03226737
(7) Engine shutdown switch

Table 47

Check the operation of the Engine Shutdown Switch	Check if OK
Start the engine
Activate engine shutdown switch (7)
Engine shuts down
Deactivate engine shutdown switch (7)

Cab Dome Light and Map Light

Table 48

Check the operation of the Cab Dome Light Switch and the Map Light(1)	Check if OK
Turn the ignition key to the OFF position
Push the dome light switch to the ON position to turn on the light
Push the dome light switch to the OFF position to turn off the light
Push the map light switch to the ON position to turn on the light
Push the map light switch to the OFF position to turn off the light

(1)	The dome light and map light are located above the operator in the cab

Cigar Lighter

Table 49

Check the operation of the Cigar Lighter(1)	Check if OK
Turn the ignition key to the ON position
Push the lighter inward and release the lighter
When the lighter is ready to use, the lighter will move outward.

(1)	The lighter can also be used as a 12 V power receptacle

Backup Alarm

Table 50

Check the operation of the backup alarm(1)	Check if OK
Turn the ignition key to the ON position
Move the transmission direction and the speed control lever to the REVERSE position
The backup alarm should sound immediately(2)

(1)	Make sure that the area behind the machine is clear of personnel and clear of obstacles
(2)	The backup alarm should sound until the transmission direction and speed control lever are moved to the NEUTRAL position or the FORWARD

Check the Configuration of the Electronic Control Module's (ECM's)

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Illustration 103	g03198777
View of the Caterpillar Diagnostic Connectors located to the left rear of the operator seat (A) Electronic Technician (ET) service connector (B) Vital Information Management System (VIMS) service connector

1. Connect a laptop computer to ET service connector (A). The laptop computer should have "JERD2142" or "JERD2129" Electronic Subscription. Use a 317-7484 Communication Adapter Gp to communicate with the ECM's on the truck.
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   Illustration 104	g03395255

2. 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 "ADVISOR CONTROL", "BRAKE CONTROL", "ENGINE CONTROL", "CHASSIS CONTROL", "VIMS MAIN CONTROL", and "VIMS APPLICATION CONTROL".

   Note: Series G Series built from 1 October 2011through 31 December 2011only had the VIMS Application ECM if equipped with Truck Payload Monitoring System (TPMS).

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   Illustration 105	g03395259

3. Connect to the "VIMS Main Module".
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   Illustration 106	g03395266

4. When ET connects, the ECM summery screen will appear.
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   Illustration 107	g03395267

5. In the tool bar, select "Service" from the menu.

6. Select "ECM Date/Time".
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   Illustration 108	g03395269

7. Set the time and date for the location that the machine is operating in.

   Note: VIMS Main ECM is the master for the Time and Date on the machine. If the Time and Date are changed on any other ECM on the truck, the updated information will not be retained in the system. The updated information will only be retained if the VIMS Main ECM was selected.

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   Illustration 109	g03395326

8. Return to the ECM summary page and verify that the machine is equipped with the latest software. Service Software Files in Service Information System (SIS) will display the latest software for the truck.

   Note: VIMS flash files are a common part number between multiple product lines. Until all product lines cancel and replace the old VIMS flash files, the wrong files will be shown. If the wrong files are shown, then the current flash files must be downloaded.

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   Illustration 110	g03395427

9. If software updates are required, select the Winflash icon from the tool bar.
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   Illustration 111	g03399558
   CAT ET ECM list

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   Illustration 112	g03398307
   Winflash Screen

10. In Winflash, the naming convention for the ECM's is not the same as when Cat ET connects. Refer to the following table.
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    Table 51

    Cat ET ECM Naming Conventions versus Winflash ECM Naming Conventions
    Winflash	Advisor ET	VIMS Main ET	VIMS Application ET
    "Graphical Display Module"	"Monitor"
    "Gateway #1"		"VIMS Main Module"
    "Gateway #2"			"VIMS Application Module"

11. Update the required software and return to the ECM Configuration screen in Cat ET.

12. Review the configurations for each ECM.
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    Illustration 113	g03398318
    "VIMS MainECM"

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    Illustration 114	g03398321
    "VIMSMain ECM"

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    Illustration 115	g03398324
    "VIMS Main ECM"

13. The recommended setting for the "VIMS Main ECM" configuration is as follows:

    • Update the "Equipment ID" into the main serial number or the customer equipment number.

    • Reconfigure the remaining adjustable parameters to the specific application as required.
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    Illustration 116	g03407680
    "VIMS Application ECM"

14. The recommended setting for the "VIMS Application ECM" configuration is as follows:

    • Update the "Equipment ID" into the main serial number or the customer equipment number.

    • Update the "Target Payload" to "60.1 ton" for the 773G and "70.1 ton" for the 775G.

    • Update the "Payload Overload Limit" to "120.0%".

    • Update the "Green TPMS Lamp Installation Configuration" to "LED".

    • Update the "Red TPMS Lamp Installation Configuration" to "LED".

    • Update the "Truck Last Pass Indicator Enable Status" to "Enabled".

    • Update the "External Payload Indicator" to "Disabled".

    • Update the "OHT Payload Re-weigh" to "Second Gear".
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    Illustration 117	g03398336
    "Brake ECM"

15. The recommended setting for the "Brake ECM" configuration is as follows:

    • Update the "Equipment ID" into the main serial number or the customer equipment number.

    • Reconfigure the remaining adjustable parameters to the specific application as required.
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    Illustration 118	g03399673
    "Chassis ECM"

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    Illustration 119	g03398514
    "Chassis ECM"

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    Illustration 120	g03398515
    "Chassis ECM"

16. The recommended setting for the "Chassis ECM" configuration is as follows:

    • Update the "Equipment ID" into the main serial number or the customer equipment number.

    • Update the "Hoist System Enable Status" to "Enable".

    • Reconfigure the remaining adjustable parameters to the specific application as required.
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    Illustration 121	g03399694
    "Engine ECM"

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    Illustration 122	g03398520
    "Engine ECM"

17. The recommended setting for the "Engine ECM" configuration is as follows:

    • Update the "Equipment ID" into the main serial number or the customer equipment number.

    • Reconfigure the remaining adjustable parameters to the specific application as required.
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    Illustration 123	g03399728
    "Advisor ECM"

18. The recommended setting for the "Advisor ECM" configuration is as follows:

    • Update the "Equipment ID" into the main serial number or the customer equipment number.

    • Update the "Information Units Status" and the "Display Language Status" to the units and language of the region that the truck is operating in.
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    Illustration 124	g03398562
    Clearing Active and Logged Diagnostic Codes and Event Codes

19. Select "Active Diagnostic Codes" from the ET menu. Click on the box at the bottom of the screen that reads, "Include All ECM's". If no "Active Diagnostic Codes" are present, then continue. If "Active Diagnostic Codes" are present, resolve the active codes.
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    Illustration 125	g03398565
    Clearing Active and Logged Diagnostic Codes and Event Codes

20. Select "Logged Diagnostic Codes" from the ET menu. Click on the box at the bottom of the screen that reads, "Include All ECM's". Click on "Clear All" to clear all of the logged diagnostic codes.
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    Illustration 126	g03398583
    Clearing Active and Logged Diagnostic Codes and Event Codes

21. Select "Active Event Codes" from the ET menu. Click on the box at the bottom of the screen that reads, "Include All ECM's". If no "Active Event Codes" are present, then continue. If "Active Event Codes" are present, resolve the active event codes.
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    Illustration 127	g03398565
    Clearing Active and Logged Diagnostic Codes and Event Codes

22. Select "Logged Event Codes" from the ET menu. Click on the box at the bottom of the screen that reads, "Include All ECM's". Click on "Clear All" to clear all of the logged diagnostic codes.

Vital Information Management System (VIMS) Set up

Refer to Testing and Adjusting, KENR8744, "770G and 772G Off-Highway Trucks and 773G and 775G Quarry Trucks VIMS 3G, and Payload".

Refer to Special Instruction, REHS7412, "Software Installation Guide for Large Off-Highway Trucks" for information regarding the software update and installation procedure for the 773G and 775G Off-Highway Trucks.

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Illustration 128	g03394123
View of the Caterpillar Diagnostic Connectors located to the left rear of the operator seat (A) Electronic Technician (ET) service connector (B) Vital Information Management System (VIMS) service connector

1. Connect a laptop computer to the Caterpillar VIMS service connector (B) with a 305-5528 Wiring Harness.

   Note: When the key is in the ON position, VIMS will perform a four to six second self tests. Disregard the VIMS self test at this time.

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   Illustration 129	g03399827

2. Start the VIMSpc software.
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   Illustration 130	g03407693

3. Click on "Connect".

4. Select the "Cab" and click "OK".
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   Illustration 131	g03394324

5. Verify that the "Product ID" matches the machine serial number.

6. Verify that the VIMS configuration files are the latest versions of the software files. Refer to Step 8 and Step 9 of "Check the Configuration of the Electronic Control Module's (ECM's)".

7. Select "Disconnect" in the left-hand column to close the VIMSpc session.

Purge and Charge the Suspension Cylinders

Note: Refer to Special Instruction, REHS4445, "Servicing the Suspension Cylinders for Off-Highway Trucks" for additional information on purging and charging the suspension cylinders.

Calibrate the Truck Payload Measurement System (TPMS)

Note: The Truck Payload Measurement System (TPMS) will not operate properly until a successful payload calibration has been completed

Note: For security, this service program code will only function while Cat ET is connected or the service mode in the Advisor is enabled.

1. Ensure that the truck body is empty. Carryback weight of the material that is stuck in the truck body can affect the payload measurements.

2. Operate the empty truck to a minimum ground speed of 4 MPH on hard level ground.

3. Move the shift control lever to the neutral position and allow the truck to coast to a stop.

4. Do NOT use the service brakes or the retarder.

5. After the truck stops moving, calibrate the payload system. The Advisor display will show a "Calibration Complete" message if the calibration was successful.

   Reference: Refer to Testing and Adjusting, KENR8744, "770G and 772G Off-Highway Trucks and 773G and 775G Quarry Trucks VIMS 3G and Payload" for additional information on the payload 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.

Adjustment for Hoist Lower Valve

The command for the hoist lower valve is adjustable. This command 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 adjustment causes the body to come down harder. A negative adjustment factor will decrease the lower valve command. The lower valve command will cause the truck body to softly lower.

Note: A high adjustment setting will allow too much oil to be diverted to the hoist system, while the hoist system is in float mode. This incorrect adjustment 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 high pressure causes too much oil to be diverted to the hoist valve. Too much oil 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.Lowering the adjustment 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 frame of the truck. The body up switch detects the position of the body when the body is close to the rail of the truck. The body detection causes the ECM to go into snub mode.

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

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

Service Brake Check

Note: The cab brake valve activates the front brakes and the rear brakes.

1. Upon starting of the engine, allow the brake accumulators to charge and allow the accumulator charging valve to reach the cut out pressure.

2. Move the transmission control to the NEUTRAL position. When the transmission control is moved from the PARK position, the parking brakes are automatically disengaged.

3. Depress the service brake control fully.

4. Move the transmission control to the FIRST GEAR position.

5. Increase engine speed to 1200 rpm. The machine should not move.

6. If the machine moves, inspect the brake system for wear or for damage.

   Reference: Refer to Systems Operation/Testing and Adjusting, "Braking System Troubleshooting".

Parking Brake Check

Note: The parking brake valve activates the rear wheel brakes. The wheel brakes are applied by spring pressure and the wheel brakes are released by oil pressure. The parking brake is applied when the transmission is in the PARK position. The parking brakes are applied proportionally by the secondary brake pedal. The parking brake test consists of the following two tests.

Brake Drive Trough Test

Note: This test should be conducted when the truck is empty.

1. Fasten the seat belt before you test the brakes.

2. Check the area around the machine. Make sure that the machine is clear of personnel and clear of obstacles.

3. Test the brakes on a dry, level surface.

4. Start the engine.
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   Illustration 132	g01519336

5. Depress button (3) for the high gear limit RAISE and depress button (4) for the high gear limit LOWER at the same time.

6. While both buttons are depressed, Move the transmission control lever to the D position.

   Note: The buttons can now be released and the parking brake will remain on.

7. Gradually increase the engine speed to 1200 rpm. The machine should not move.

8. Reduce the engine speed to low idle. Move the transmission control lever to the PARK position. Stop the engine.

9. If the machine moves, inspect the parking brake system for wear or for damage.

   Reference: Refer to Systems Operation/Testing and Adjusting, "Braking System Troubleshooting".

Brake Slope Test

Note: This test should be conducted when the truck is loaded to the normal rated capacity.

1. Load the truck to the normal rated capacity.

2. Park the machine on a slope of no more than 15 percent.

3. Depress the service brake pedal.

4. Shift the transmission control to PARK. Shifting the transmission to PARK will apply the parking brakes.

5. Release the service brake pedal.

6. If the machine moves, inspect the parking brake system for wear or for damage.

   Reference: Refer to Systems Operation/Testing and Adjusting, "Braking System Troubleshooting".

Retarder Brake Check

Note: The cab brake valve activates the rear wheel brakes and the front wheel brakes.

1. Stop the machine on a level area.

2. Pull the manual retarder control lever completely to the DOWN position.

3. Move the transmission control to the FIRST GEAR position.

4. Increase the engine speed to 1050 rpm. The machine should not move.

5. If the machine moves, inspect the brake system for wear or for damage.

   Reference: Refer to Systems Operation/Testing and Adjusting, "Braking System Troubleshooting".

   Reference: Refer to Testing and Adjusting, RENR8294, "Quarry Truck Hydraulic System" for additional information on the braking system.

Enable The Autolube Grease System – (If Equipped)

1. Identify the type of autolube system that the machine is equipped with. (Lincoln or Groeneveld). (The Groeneveld system can be identified as a yellow canister with a black top located on the RH platform, the Lincoln system can be identified as a clear canister located on the RH platform).

2. "Lincoln Equipped Machines" – Connect to ET and select "Chassis Configuration" screen.

   1. Set "Autolube System Installation Status" to "Enabled".

   2. Set "Autolube Configuration Code" to "1".

   3. Set "Autolube Interval" to "60 Min".

   4. Set "Autolube Duration" to "600 Sec".

3. "Groeneveld Equipped Machines" – Connect to ET and select "Chassis Configuration" screen.

   1. Set "Autolube System Installation Status" to "Enabled".

   2. Set "Autolube Configuration Code" to "2".

Test Product Link (if equipped)

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Illustration 133	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 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 Off-Highway Truck.

3. Start the Caterpillar Electronic Technician (ET). Cat ET will list all 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 134	g03400337

5. Choose the "Product Link" ECM.
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   Illustration 135	g01421936

   Note: The communication status of product link must be tested. Since there can be up to a 15 minute gap in satellite coverage, the wiggle test in Cat ET can be used. The wiggle test can 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"Commissioning Checklist"at the end of this Special Instruction.

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 136	g01421938

7. Read the warning and select the "OK" button.
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   Illustration 137	g01421939

8. From the "Wiggle Test" screen, select the "Groups" button on the second row from the bottom.
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   Illustration 138	g01421940

9. Choose the "New" button to create a 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 139	g01421942

10. Type "Product Link" and select the "OK" button.
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    Illustration 140	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 141	g01421944

13. Select the "OK" button.
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    Illustration 142	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 that satellite communications are established.

    1. If the "Number of GPS Satellites" are greater than "0" and the "Satellite Communications Status" is "Established", the communication of product link is confirmed. Record this information in the"Commissioning Checklist"at the back of this Special Instruction.
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       Illustration 143	g01421947

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

    2. Select "Start", 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 144	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 145	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: To establish communication, the antenna for the product link must have a clear view of the sky. Objects that are obstructing the antennas 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"Commissioning Checklist"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. 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".

Product Link Setup

Note: Caterpillar highly recommends registering and subscribing to Product Link. Product link enables remote monitoring of customer equipment. Remote monitoring helps keep jobs on schedule, maintain machine health, and reduce the cost of owning and operating a customer fleet. First year subscription to Product Link is at no charge to the customer. Contact a Caterpillar representative with questions.

Product link is set up using the latest version of Caterpillar Electronic Technician.

The Communications Adapter II hardware is connected between the service connector of the machine and the PC serial port of the PC parallel port. The Cat ET "Communications Interface Device" is found under the "Utilities" menu, "Preferences" drop-down menu.

PL121SR/PL321SR, Satellite PL Setup (If Equipped)

Refer to Service Manual, RENR7911, "Product Link 121S/300" for information and procedures regarding the setup and configuration for the PL121SR/PL321SR, Satellite-based Product Link systems.

Configuration

Connecting a Computer to the Product Link System

Verify that Product Link has installed the latest flash file.

Supported Connections for Hardware

The PL121SR Radio and PL300 ECM are configured with CAT ET by using the following communications interfaces:

PL121SR Installations Only - The 245-7310 Control Harness As (Serial Service Cable) is connected between the PC serial port and the serial service connector on the radio legacy harness or the conversion harness. The CAT ET "Communications Interface Device" is configured for "Embedded Communications Adapter".

PL121SR plus the PL300 Installations Only - The 317-7484 Communication Adapter Gp hardware is connected between the machine service connector and the PC serial port or parallel port. The CAT ET "Communications Interface Device" is configured for the "Caterpillar Communications Adapter II (RP1210)".

Note: The configuration parameters for the "Communications Interface Device" are found in CAT ET under "Utilities" menu, "Preferences" drop-down menu.

Configure Computer Interface Communications for CAT ET

The following examples of screens show configuring communications for the computer to use CAT ET.

1. Use the 245-7310 Serial Service cable to connect a computer with the required CAT ET software to the serial service connector of the wiring harness.

2. Select "Utility" on the tool bar.
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   Illustration 146	g01361214
   "Preference" Section for CAT ET

3. From the drop-down menu, select "Preference".
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   Illustration 147	g01361220
   "Preference" Section for CAT ET

4. From the "Communications" tab, click the drop-down menu and select "Caterpillar Embedded Communication Adaptor".

Configure Product Link PL121SR Radio and PL300 ECM

This section provides information for the user to configure the parameters required for the Product Link system during installation. After the "Machine Serial Number","Machine Make Code", and the "Dealer ID" are set, the unit will auto-register the Product Link system.

There are a number of parameters that need configured for the Product Link. There are default values that are loaded. Many of the default values are acceptable in most applications. However, care must be followed in setting these parameters to ensure proper operation. Also, care will help avoid increased costs for messaging. Enter the "Product Link Module (PLM) Installation Parameters" last to ensure proper registration. Select the configuration screen by selecting the icon on the tool bar or by using the pull-down menus from the menu bar.

Two communications adapters are available to flash program the electronic control modules. The 7X-1700 Communications Adapter can be used, or the 171-4400 Communication Adapter II can be used.

After the Product Link has been configured, the radio must be registered with the Equipment Manager system. If installing only the PL121SR Radio (no PL300 ECM), configure the radio as described in PL121SR "Installation Parameters Configure - Radio Only" section. If installing the PL121SR and the PL300 ECM, configure the radio and ECM as described in the "Installation Parameters Configure for PL321SR System (PL121SR Radio and PL300 ECM)".

1. There are three ways to access the configuration screen. Select one of the following options:

   • Select "Service" and select "Configure" on the menu bar.

   • Press the "F5" key.

   • Select "ECM Configuration Icon" on the tool bar.

2. Ensure that steps have been taken to connect the computer with CAT ET software properly to the Product Link system.

3. Click the "Connect" icon or click "File" on the menu bar. Click "Connect" from the pull-down menu to establish communication with the PL121SR radio.

4. After the computer has connected to the PL121SR radio, click the "Configuration Tool" icon. Select the "Service" menu, "Configuration" drop-down menu to view the Configuration screen.

5. Double click the desired parameter or select the desired parameter. Click "Change". A dialog box will appear with a scroll down list that will show all of the possible parameter values.

6. Click "OK" after changing each parameter to return to the Configuration screen.

Refer to the Systems Operation, Troubleshooting, Testing and Adjusting, "Commands" for information about registering the Product Link system.

Commands

"Synchronize Service Hour Meters" for PL321

To perform the "Synchronize Service Hour Meters" function, select the "Service" menu, and "Synchronize Service Hour Meters" from the drop-down menu.

The machine maintains a function that is called "Sync Clock". In a PL321 system, the Product Link clock can be the master or the slave. This criteria is automatically determined by the priority that is provided to each ECM when the machine is designed. In most cases, Product Link will not be the master ECM. If Product Link is not the master, then the user must use the "Synchronize" button to synchronize the Product Link SMH to the master ECM SMH. Product Link could be the master ECM if the following scenarios occur:

• No other ECM on the machine is SYNC clock capable/enabled.

• No other ECM on the machine has a priority higher than Product Link.

If Product Link is the master ECM, the user should select the "Set Master Hours" button. Once the master hours have been set, click the"Synchronize" button to synchronize any other sync-clock capable/enabled ECM. Refer to Illustration 148.

Note: To change the SMH to a value lower than the current value, a factory password will be required.

Note: In a PL321 system using sync-clock where Product Link is not the master ECM, the Product Link module will automatically sync to the master ECM hours if the difference is not greater than 50 hours. If the difference is greater than 50 hours, a diagnostic will be generated in Cat ET that indicates that a manual sync is required. In that instance, sync the hours (Service/Synchronize Service Meter Hours) unless the master ECM hours are incorrect.

If Product Link is not the master ECM, and the master ECM hours are not correct, troubleshoot on machine side. Do not replace the Product Link module.

Illustration 148	g01362745
"Synchronize Service Hour Meters" Screen

"PLM Commands"

Illustration 149	g01362129
"PLM Commands" Menu for Cat ET

There are ten commands that can be completed by selecting "Service/PLM Commands" from the menu bar in Cat ET.

Registration - This command automatically queues a registration message and an administration message. The registration message will queue up and wait for the next available satellite to complete the process. The parameters "Queued Registration Messages"and "Queued Administration Messages" in "Message Queue" will show a value of "1". When the registration message and administration messages has been successfully transmitted, the value will change back to "0". This registration process can take from 15 minutes to 1 hour. The time frame is dependent on the performance of the communications network.

Note: Performing the registration process will activate the installed system. Complete the configuration process prior to performing the registration process.

Note: To register Product Link, the Product Link antenna must have a clear view of the sky for detecting satellites. If the machine is inside of a building or another structure that would prevent a clear view of the sky, the machine must be moved outside. The yellow LED and the orange LED on the PL121SR radio should be solid to ensure that a lock has been established with the satellite. If the LED indicators for the radio cannot be observed, then the user can look in Cat ET at "Satellite Information" and "Satellite Communication Status" to determine that satellite communication has been established.

De-registration - This command de-registers the Product Link before removing the unit for installation on another machine. This command will set all of the fields back to the default values. This command will clear the memory of the unit. All of the Fence settings and diagnostics in the memory are erased. After the message is "queued", the message should enter the Message Queue. This message can be viewed by observing "Message Queue" for the Product Link ECM. After the message has been transmitted, the unit can be removed. The unit can be reinstalled on another machine.

Status Message - This command queues the following status descriptions: SMH, location and fuel.

Fuel Report - This command queues a fuel report.

Position Report - This command queues a position report.

Time and Geo-Fencing Report - This command queues a "Time and Geo-Fencing Report" report.

SMH Report - This command queues a "SMH" report.

Empty Message Queue - This command clears all messages out of the message queue. This command can be used to clear messages that are inadvertently added to the queue.

ECM List - This command queues up an "ECM List Report" after a wait of a few minutes. The "ECM List Report" includes a list of all ECM modules (and the associated serial numbers, software part numbers, and sync-clock status) detected by the Product Linkthat are connected to the Cat Datalink. The "ECM List" is automatically sent at the time of registration. The "ECM List" contains a unique identifier for each ECM that is detected by the Cat Datalink

Administration Message - This command queues an Administration message. This message contains data from the "Configuration"screen. The following examples are data examples: "PLM Report Configuration Parameters", "System Settings"and "Digital Input Configurations".

Note: Once these entries have been entered, the Product Link Module will automatically queue an Administration message after 15 minutes. The Product Link can be forced to queue a message sooner by using this command.

To register a module for the first time, follow the procedure that is listed below.

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Illustration 150	g01362222
"Registration" Screen

1. Click "Service" on the toolbar. Select "Product Link Registration". Refer to Illustration 150.

2. Enter information in the following fields: "Machine Make Code", "Machine Serial Number", "Dealer Code", "Confirmation Email Address"(optional) and "Service Meter Hours". Refer to Illustration 150.

   Note: In a PL321 system, the machine serial number will be auto filled via information from the other ECMs on the CDL. The user can "Synchronize Service Meter Hours" if the PL321 is considered a "slave". The user can "Set Master Hours" if the PL321 is considered the "master". Refer to Illustration 150.

   Note: The setting will not change the SMH on other ECMs. Only the SMH on Product Link will be modified.

3. Click "Register".

4. After "Registration" is selected, a dialog box will appear. The message will ask "Are you sure?". Click "Yes" or click "No". Clicking "Yes" will queue the registration messages and administration messages.

5. A confirmation message will be displayed. Click "OK"

   Note: After receiving a confirmation, you will be returned to the "Registration" screen.

Illustration 151	g03315676
PL321 "Registration Configuration" Screen

Illustration 152	g03315716
PL121 "Registration Configuration" Screen

To register the system again, follow the procedure that is listed below.

1. Click "Service" on the tool bar. Select "PLM Commands". Click "Registration" on the pull-down menu to start the registration process.

2. After "Registration" is selected, a dialog box will appear. The message will ask "Are you sure?". Click "Yes" or click "No".

3. The registration message and administration message will "queue up".The parameters "Queued Registration Messages" and "Queued Administration Messages" in "Message Queue" will show a value of "1". When the registration message has been successfully transmitted, the value will change back to "0". This registration process can take from 15 minutes to 1 hour. This time frame depends on performance of the communications network.

   Note: The "Status Parameters" PLM Registration Status will change immediately to "Confirmation Pending". The "PLM Registration Status" will change to "Registered" once the module receives the confirmation that "the message was received and processed successfully in the backoffice (EM)". If the message was not processed successfully in the BackOffice, the "PLM Registration Status" will change to "Failed". If the "Failed" message occurs, the parameters should be verified for accuracy. If changes are required, repeat the original registration process via "Service", "Product Link Registration".

Illustration 153	g01362236
"Queue Status" Screen (PL121SR)

Note: The "Queued Registration Messages" and the "Queued Administration Messages" value will be "1" while the messages are still in the queue.

Illustration 154	g01362237
"Queue Status" Screen (PL321SR)

PL522/PL523, Cellular (GSM) PL Setup ( If Equipped)

Refer to Service Manual, RENR8143, "Product Link PL522/523" for information and procedures regarding the setup and configuration for the PL522/PL523, Cellular based Product Link systems.

Installation Parameters Configured for PL522 and 523

1. Ensure that the correct steps have been taken to connect the computer with Cat ET software to the Product Link system. Refer to Systems Operation, "Configuration".

2. Click the "Connect" icon or click "File" on the menu bar. Click "Connect" from the selections on the pull-down menu to establish communication with the PL522 or 523.
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   Illustration 155	g02168713
   "Select an ECM" Screen

3. The PL523 device is listed as "VIMS Main Module". As the Cat Data Link connection is made with the gateway board within the device. Select "VIMS Main Module" or "Product Link" from the list of available ECMs. Refer to Illustration 155.

4. Click "OK".
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   Illustration 156	g02666356

5. Once you are connected, click the "Configuration Tool" icon or select "Service" from the menu. Click "Configuration" from the drop-down menu to view the configuration screen.
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   Illustration 157	g02666396
   PL522 and 523 Configuration Screen

6. Highlight "VIMS Main Module" and then click "Expand All". Refer to Illustration 157.

   Note: Internet Protocol parameters should NOT be modified.

7. Double click the desired parameter or select the desired parameter and click "Change". A dialog box will appear. Also, a list will appear that will show all of the possible parameter values.

8. Click "OK" after changing each parameter to return to the configuration screen.

Reference: Refer to the "Machine Serial Number" section that follows for information about the "Product ID" that is used in the PL522 and 523 system. Refer to Illustration 158 for an example of a machine serial number.

Machine Serial Number

The Machine Serial Number is used by the PL522 and 523 system for routing information by the machine and displaying information by the machine.

Note: The serial number for a non-Caterpillar machine can be any alphanumeric characters up to 17 characters long such as "147433789DBS".

Illustration 158	g03394603
(1) Caterpillars World Manufacturing Code (characters 1 - 3) (2) Machine description (characters 4 - 8) (3) Check character (character 9) (4) Machine Indicator Section (MIS) or Product Sequence Number (characters 10 - 17). These characters were previously referred to as the Serial Number.

For Caterpillar machines, enter only the last eight characters of the "Machine Serial Number". Refer to Illustration 158 for an example of a machine serial number. For Non-Caterpillar machines, enter the entire machine serial number.

First Quarter 2001, the Caterpillar Product Identification Number (PIN) changed from 8 characters to 17 characters. The "Product ID" that is required by the PL522 and 523 system is the last eight digits. Do not start the serial number with a space. Do not abbreviate the serial number. For example, "1AA00123"should not be shortened to "1AA123". Do not use uppercase "O" instead of zero "0". Refer to Item (4) in Illustration 158.

"Machine Maintenance Mode" Screen

Illustration 159	g01361626
"Machine Maintenance Mode" Screen

The maintenance mode is used to prevent diagnostic and event messages from being reported when performing maintenance on the machine. This value should be reverted to "Off" after the servicing is complete. This value also reverts to "Off" after 12 calendar hours to ensure proper operation (long term) of the system. If an event or diagnostic does occur when the maintenance mode is active, the event is ignored until the maintenance mode is turned off. Remember to clear any diagnostic codes that were created during maintenance. If you do not remember, the diagnostic codes will be transmitted once the maintenance mode is turned off.

To disable the PLM from sending any diagnostic or event messages while performing maintenance, select the "On" value. To continue normal operation of the system after maintenance is done, select the "Off" (default) value.

"Synchronize Service Hour Meters" for PL522 and 523

The machine maintains a function that is called "Sync Clock". In a PL522 or 523 system, the PL522 or 523 clock can be the master or the slave. This criteria is automatically determined by the priority that is provided to each ECM when the machine is designed. In most cases, the PL522 and 523 will not be the master ECM. If PL522 or 523 is not the master, use the "Synchronize" button to synchronize the PL522 or 523 SMH to the master ECM SMH. The PL522 or 523 can be the master ECM if the following scenarios occur:

• No other ECM on the machine is SYNC clock capable/enabled as displayed in Cat ET.

• No other ECM on the machine has a priority higher than Product Link. This priority cannot be changed and is automatically determined when the machine is first powered.

Illustration 160	g02270617
"Synchronize Service Hour Meters" Screen

To perform the "Synchronize Service Hour Meters" function, select the "Service" menu, and "Synchronize Service Hour Meters" from the drop-down menu. When the PL522 or 523 is the master ECM, select the "Set Master Hours" button. Once the master hours have been set, click the"Synchronize" button to synchronize any other sync-clock capable/enabled ECM. Refer to Illustration 160.

Note: To change the SMH to a value lower than the current value, a factory password will be required.

Note: When a PL522 or a 523 is not the master ECM, the PL522 or 523 module will automatically sync to the master ECM hours if the difference is not greater than 50 hours. If the difference is greater than 50 hours, a MID 122 - EID 0861 - WCI 01 diagnostic will be generated in Cat ET indicating that a manual sync is required. In that instance, sync the hours (Service/Synchronize Service Meter Hours) unless the master ECM hours are incorrect.

If a PL522 or a 523 is not the master ECM, and the master ECMs hours are not correct, troubleshoot on machine side. Do not replace the PL522 or 523 module.

Commands

Product Link Module (PLM) Commands

Illustration 161	g02696836

There are five commands that can be completed by selecting "Service" from the menu bar and "PLM Commands" from the drop-down menu in Cat ET . Refer to Illustration 161.

Fuel Report - This command sends a fuel report.

ECM List - This command sends up an "ECM List Report" after waiting a few minutes. The "ECM List Report" includes a list of all ECM modules connected to the Cat Data Link. The report also lists the associated serial numbers, software part numbers, and sync-clock status detected by the PL522 and 523. The "ECM List" is automatically sent at the time of registration. The "ECM List" contains a unique identifier for each ECM that is detected by the Cat Data Link.

Administration Message - This command sends an Administration message.

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.

Commissioning Checklist

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

After you complete the final check, 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: Jason Brunner
773G / 775G Off-Highway 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 operators 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 52

    Specifications for the Commissioning Procedure
    Description	Specifications	Actual	Comments
    Engine Low Idle rpm	700 +30/-10 rpm
    Engine High Idle	2050 ± 30 rpm
    Pressure of Brake Retract Pump at High Idle	4000 to 5380 kPa (580 to 780 psi)
    Relief Pressure of 775G Hoist Pump in RAISED position	18950 +1000/-500 kPa (2750 +145/-70 psi)(1)
    Relief Pressure of 773G Hoist Pump in RAISED position	17250 +1000/-500 kPa (2500 +145/-70 psi)(2)
    Steering High Pressure Cutoff	21380 ± 690 kPa (3100 ± 100 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 255 kPa (20 to 37 psi)
    Pressure of Transmission Lubrication at Low Idle	21 to 76 kPa (3 to 11 psi)
    Torque Converter Outlet Pressure at Stall	345 to 483 kPa (50 to 70 psi)

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

Predelivery Worksheet

Table 53

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

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

Table 54

	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.