769D Off-Highway Truck And 771D Quarry Truck Assembly Procedure{7000, 7006, 7960} Caterpillar

Off-Highway Trucks:

769D (S/N: 5SS1-UP)

Quarry Trucks:

771D (S/N: 6YS1-UP)

Off-Highway Truck/Tractor:

769D (S/N: BBB1-238)

Quarry Truck:

771D (S/N: BCA1-193)

Introduction

This publication contains assembly procedures and commissioning procedures in order to prepare 769D Off-Highway Trucks for operation.

This publication also contains assembly procedures and commissioning procedures in order to prepare 771D Quarry 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 for the applicable machine in order to prepare the machine. Use the Parts Manual and the Service Manual in addition to this publication.

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

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

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

Parts Lists

Table 1

Required Parts for the Preparation of the Machine
Qty	Part Number	Description
4	1D-4639	Bolt (1-8x4 inch)
8	3K-5234	Hard Washer
4	2J-3507	Full Nut

Table 2

Required Parts for Installation of Tire and Rim Assemblies
Qty	Part Number	Description
24	5D-0765	Full Nut
24	5D-0764	Hard Washer

Table 3

Required Parts for Installation of Left Hand Catwalk and Handholds
Qty	Part Number	Description
1	- (1)	Catwalk Assembly
28	4L-6454	Bolt (3/8-16x1.0 inch)
18	8T-4896	Hard Washer
12	5S-7379	Bolt (3/8-16x.875 inch)
1	6G-0115	Brace
2	8T-8917	Bolt (1/2-13x1.25 inch)
4	8T-4223	Hard Washer
22	5P-1075	Hard Washer
1	8W-4484	Pipe
1	116-6671	Rail Assembly
1	161-2605	Handle
2	8T-9383	Bolt (1/2-13x0.75 inch)
1	161-2606	Handle

( 1 )

The 128-5120 Catwalk and the 116-4690 Catwalk are shipped as an assembly.

Table 4

Required Parts for Installation of the Hood Latch
Qty	Part Number	Description
1	5T-3865	Bracket
1	2G-9399	Rod
1	0T-0883	Washer
1	3B-4615	Cotter Pin
1	6F-8499	Spring
2	5S-7379	Bolt (3/8-16x.875 inch)
2	8T-2561	Hard Washer

Table 5

Required Parts for Installation of Rearview Mirror
Qty	Part Number	Description
1	9D-7289	Bracket
6	4M-5283	Bolt (1/4-20x0.625 inch)
8	5P-0537	Washer
1	2G-1254	Brace
2	5S-7349	Bolt (3/8-16x0.875 inch)
1	6V-6962	Mirror
2	6V-6961	Knob
2	5P-9865	Spacer
2	2K-4973	Locknut
2	8T-2502	Bolt (3/8-16x1.125 inch)
2	6V-8801	Nut
4	5M-2894	Washer
2	8D-8011	Plate
2	0L-1351	Bolt (3/8-16x0.875 inch)
1	153-9136	Bracket
1	8D-8011	Locknut
1	5P-6872	Mirror

Table 6

Required Parts for Installation of Handholds
Item	Qty	Part Number	Description
1	20	4L-6454	Bolt (3/8-16x1.0 inch)
2	4	8T-4896	Hard Washer
3	1	9D-4721	Rail Assembly
4	- (1)	5P-1075	Hard Washer
5	1	- (2)	Rail Assembly
6	1	8T-8917 (3)	Bolt (1/2-13x1.25 inch)
7	1	8T-4223 (3)	Hard Washer
8	1	153-7094 (3)	Bracket
9	2	9B-7237 (3)	Bolt (3/8-16x1.25 inch)

( 1 )	The 769D Off-Highway Truck (S/N: 5SS406-UP) and (S/N: BBB1-UP) use 16 washers. Also, the 771D Quarry Truck (S/N: 6YS255-UP), and (S/N: BCA1-UP) use 16 washers. The 769D Off-Highway Truck (S/N: 5SS1-405) and the 771D Quarry Truck (S/N: 6YS1-254) use 18 washers.
( 2 )	The 143-0025 Rail Assembly is used on the 769D Off-Highway Truck (S/N: 5SS1-406) and the 771D Quarry Truck (S/N: 6YS1-254). The 769D Off-Highway Truck (S/N: 5SS407-UP), and the 769D Off-Highway Truck (S/N: BBB1-UP) use the 112-6087 Rail Assembly . Also, the 771D Quarry Truck (S/N: 6YS255-UP) and the 771D Quarry Truck (S/N: BCA1-UP) use the 112-6087 Rail Assembly .
( 3 )	Parts are used only on the 769D Off-Highway Truck (S/N: 5SS1-405) and the 771D Quarry Truck (S/N: 6YS1-254).

Table 7

Required Parts for Installation of Handholds
Qty	Part Number	Description
2	5K-4549	U-Bolt
4	6V-8185	Nut
4	8T-4205	Hard Washer
1	2G-2345	Bracket
2	3B-4615	Cotter Pin
2	0T-0883	Washer
1	5D-3887	Rod
1	6F-8499	Spring

Table 8

Required Parts for Installation of Rearview Mirror
Qty	Part Number	Description
2	7D-9969	Support
2	7X-0326	Bolt (1/2-13x3 inch)
2	8T-4223	Hard Washer
1	8W-7904	Tube
2	3B-4605	Cotter
2	5S-7379	Bolt (3/8-16x.875 inch)
2	5P-1075	Hard Washer
1	8T-2287	Mirror

Table 9

Required Parts for Installation of Deflector
Qty	Part Number	Description
1	8W-6062	Deflector

Table 10

Required Parts for Installation of Front Fender Guards
Qty	Part Number	Description
1	6G-3218	Guard
2	2G-3424	Strip
10	8T-2502	Bolt (3/8-16x1.125 inch)
10	5P-1075	Hard Washer
1	164-9553	Guard

Table 11

Required Parts for Installation of the Lamps that Monitor the Payload
Qty	Part Number	Description
1	8K-1433	Grommet
1	8W-4812	Bracket (1)
4	5M-3062	Bolt (3/8-16x.75 inch)
4	8T-4896	Hard Washer
2	9G-9150	Clip

( 1 )

The 8T-9683 Signal Lamp and the 8T-9684 Signal Lamp are assembled in the 8W-4812 Bracket . The 8W-4812 Bracket is stored in the operator's compartment for shipment.

Table 12

Required Parts for Installation of Guards
Qty	Part Number	Description
1	113-1764	Guard
1	113-1765	Guard
27	5P-2228	Bolt (1/2-13x1 inch)
27	8T-4223	Hard Washer

Table 13

Required Parts for Installation of Baffle
Qty	Part Number	Description
1	113-1216	Baffle
2	031-9831	Screw (Hex Head 3/8x16)

Table 14

Required Parts for Installation of Canopy
Qty	Part Number	Description
1	- (1)	Canopy Assembly

( 1 )

The 146-2261 Canopy Assembly is used on the 769D Off-Highway Truck and the 153-3967 Canopy Assembly is used on 771D Quarry Truck.

Table 15

Required Parts for Installation of Plug
Qty	Part Number	Description
1	7D-2607	Plug

Table 16

Required Parts for Installation of Pivot Pins
Qty	Part Number	Description
2	132-6650	Pin
2	7D-7488	Thrust Washer
2	124-9014 (1)	Thrust Washer
2	8W-8456	Plate
4	5P-2566	Bolt (1/2-13x1.50 inch)
4	5P-1076	Hard Washer
2	3B-8489	Grease Fitting

( 1 )

Use the thin washer if the standard washer will not fit.

Table 17

Required Parts for Installation of Hoist Cylinders
Qty	Part Number	Description
2	9M-2321	Pin
2	2K-0703	Bar
4	5P-2228	Bolt (1/2-13x1 inch)
4	8T-4223	Hard Washer

Table 18

Required Parts for Installation of Pads and of Shims
Qty	Part Number	Description
30	106-8224	Shim
6	106-8223	Pad Assembly
18	5P-2566	Bolt (1/2-13x1.50 inch)
18	8T-4223	Hard Washer

Table 19

Required Parts for Installation of Magnetic Assembly
Qty	Part Number	Description
1	3E-0461	Electronic Control
1	167-4356	Bracket
4	4M-6425	Bolt (5/16-18x1 inch)
4	5P-4116	Washer
4	5S-7379	Bolt (3/8-16x.875 inch)
2	5P-1075	Hard Washer
1	5G-7820	Magnet Assembly
1	140-8883	Bracket
2	6V-8189	Nut
2	8T-4896	Hard Washer
1	8T-4896 (1)	Hard Washer
1	5S-7379 (1)	Bolt (3/8-16x.875 inch)
1	9G-9152 (1)	Clip

( 1 )

Part of the 131-3757 Lighting and Wiring Group

Table 20

Required Parts for Installation of Rock Ejector
Qty	Part Number	Description
1	142-5843	Bracket
1	142-5842	Bracket
2	6G-7773	Pin
4	3B-4647	Cotter Pin
16	1D-0503	Washer
2	8W-1165	Rock Ejector

Table 21

Required Parts for Installation of Rock Ejector
Qty	Part Number	Description
2	136-1627	Bracket
2	6G-7773	Pin
4	3B-4647	Cotter Pin
16	1D-0503	Washer
2	8W-1165	Rock Ejector

Table 22

Required Parts for Installation of Retainer Pin
Qty	Part Number	Description
2	5D-3887	Rod
2	6F-8499	Spring
4	054-3788	Orifice
4	3B-4615	Cotter Pin
2	5T-5519	Pin

Table 23

Required Parts for Installation of Guards for Rear Wheels
Qty	Part Number	Description
1	149-2086	Baffle
1	149-2085	Baffle
2	2G-7826	Strip
14	5P-2566	Bolt (1/2-13x1.50 inch)
14	8T-4223	Hard Washer
14	6V-8188	Nut

Table 24

Required Parts for Installation of Connection for Heated Body
Qty	Part Number	Description
1	5T-2751	Elbow
1	2G-9142	Plate
4	3D-0472	Taperlock Stud
8	5P-8245	Washer
7	6V-8188	Nut
1	6G-0248	Elbow
4	0S-1585	Bolt (1/2-13x1.25 inch)
8	1D-5965	Washer
1	4B-3586	Setscrew
2	3D-0490	Taperlock Stud

Table 25

Required Parts for Installation of Films
Qty	Part Number	Description
1	8C-5574	Film (CATERPILLAR)
1	130-2702	Film
1	129-5184	Film
1	129-5185	Film
1	8C-5563	Film
1	8C-5353	Film
1	140-0091	Film
1	140-0092	Film

Table 26

Required Parts for Installation of Films
Qty	Part Number	Description
1	140-0095	Film
1	8C-5579	Film (CATERPILLAR)
1	140-0095	Film
1	8C-5563	Film
1	129-5188	Film
1	129-5189	Film
1	8C-5353	Film
1	8C-5574	Film

Approximate Weights and Dimensions

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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.

• The approximate weight of the 771D Quarry Truck is 36100 kg (79600 lb).

• The approximate weight of the 771D Quarry Truck canopy is 1075 kg (2370 lb).

• The approximate weight of the 771D Quarry Truck body and canopy is 10350 kg (22820 lb).

• The approximate weight of the 769D Off-Highway Truck is 36100 kg (79600 lb).

• The approximate weight of the 769D Off-Highway Truck canopy is 1060 kg (2340 lb).

• The approximate weight of the 769D Off-Highway Truck body and canopy is 7800 kg (17200 lb).

• The weight of the tire and rim is 711 kg (1570 lb).

• The approximate length of the 771D Quarry Truck is 8.7 m (28.5 ft).

• The approximate length of the 769D Off-Highway Truck is 8.5 m (28 ft).

• The approximate height of the 769D Off-Highway Truck and the 771D Quarry Truck is 4.0 m (13.1 ft).

• The approximate width of the 769D Off-Highway Truck and the 771D Quarry Truck is 5.0 m (16.4 ft).

Inspect the Parts and Prepare the Machine for Assembly

Table 27

Required Parts for the Preparation of the Machine
Item	Qty	Part Number	Description
1	4	1D-4639	Bolt (1-8x4 inch)
2	8	3K-5234	Hard Washer
3	4	2J-3507	Full Nut

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

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

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

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

3. Remove the shipping brackets from the front wheel spindles and front suspension cylinders.

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Illustration 1	g00821515

4. Install two bolts (1), four washers (2), and two nuts (3) in each front suspension cylinder. The bolts are stored in the operator's compartment. Tighten the bolts to a torque of 945 ± 35 N·m (695 ± 25 lb ft).

Install the Rear Tire and Rim Assemblies

Table 28

Required Parts for Installation of Tire and Rim Assemblies
Item	Qty	Part Number	Description
1	24	5D-0765	Full Nut
2	24	5D-0764	Hard Washer

Illustration 2	g00518943

Illustration 3	g00518945
Remove the tire and rim assembly from the truck body.

1. Remove the cable assembly and remove the shipping bracket from the bottom of the truck body.

2. Remove the tire and rim assembly from the truck body. Remove the paint from the contact surfaces of the rim.

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Illustration 4	g00518946
Remove the nuts and the hard washers from the wheel studs.

3. Remove the nuts and the washers from the wheel studs. Remove the paint from the contact surfaces around the wheel studs.

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Personal injury can result working with the tire and rim without precautions. Personal injury can result if the weight shifts and causes movement of the tire and rim. When starting nuts on the studs, do not put your arm between the rim and final drive without first wedging a block of hardwood between the rim and final drive.

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

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Illustration 5	g00518947
Use a tire handler in order to install wheels.

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

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Illustration 6	g00518949
Install the tire and rim assembly.

6. Install 12 nuts (1) and 12 washers (2). Tighten the 12 nuts to a torque of 1210 ± 55 N·m (890 ± 40 lb ft).

   Note: Before you install the nuts and the washers, apply 5P-3931 Anti-Seize Compound to the faces of the washers and to the threads of the nuts.

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

7. Carefully lower the machine to the ground. Repeat this procedure for the tire and rim assembly on the opposite side.

Install the Components That are Around the Cab

Install the Catwalks and the Handholds

Table 29

Required Parts for Installation of Left Hand Catwalk and Handholds
Item	Qty	Part Number	Description
1	1	- (1)	Catwalk Assembly
2	28	4L-6454	Bolt (3/8-16x1.0 inch)
3	18	8T-4896	Hard Washer
4	12	5S-7379	Bolt (3/8-16x.875 inch)
5	1	6G-0115	Brace
6	2	8T-8917	Bolt (1/2-13x1.25 inch)
7	4	8T-4223	Hard Washer
8	22	5P-1075	Hard Washer
9	1	8W-4484	Pipe
10	1	116-6671	Rail Assembly
11	1	161-2605	Handle
12	2	8T-9383	Bolt (1/2-13x0.75 inch)
13	1	161-2606	Handle

( 1 )

The 128-5120 Catwalk and the 116-4690 Catwalk are shipped as an assembly.

1. Use a suitable lifting device in order to position the catwalk assembly on the cab. The approximate weight of the catwalk assembly is 55 kg (121 lb).

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Illustration 7	g00804049

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Illustration 8	g00804095

2. Use six bolts (2), 18 washers (3), and 12 bolts (4) to install catwalk assembly (1) .

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Illustration 9	g00818565

3. Use brace (5) in order to support catwalk assembly (1). Use two bolts (6) and two washers (7) in order to secure brace (5) to the fender and to catwalk assembly (1) .

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Illustration 10	g00804149

4. Use eight bolts (2) and eight washers (8) in order to install pipe (9) .

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Illustration 11	g00804157

5. Use 12 bolts (2) and 12 washers (8) in order to install rail assembly (10) .

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Illustration 12	g00804263

6. Use two bolts (2) and two washers (8) in order to install handle (11) .

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Illustration 13	g00804286

7. Use two washers (7) and two bolts (12) in order to install handle (13) .

Install the Latch for the Hood

Table 30

Required Parts for Installation of the Hood Latch
Item	Qty	Part Number	Description
1	1	5T-3865	Bracket
2	1	2G-9399	Rod
3	1	0T-0883	Washer
4	1	3B-4615	Cotter Pin
5	1	6F-8499	Spring
6	2	5S-7379	Bolt (3/8-16x.875 inch)
7	2	8T-2561	Hard Washer

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Illustration 14	g00804399

1. Assemble the following parts into bracket (1) : rod (2), washer (3), cotter pin (4) and spring (5) .

2. Use two bolts (6) and two washers (7) in order to attach bracket (1) to the cab.

Install the Left Hand Rearview Mirrors

Table 31

Required Parts for Installation of Rearview Mirror
Item	Qty	Part Number	Description
1	1	9D-7289	Bracket
2	6	4M-5283	Bolt (1/4-20x0.625 inch)
3	8	5P-0537	Washer
4	1	2G-1254	Brace
5	2	5S-7349	Bolt (3/8-16x0.875 inch)
6	1	6V-6962	Mirror
7	2	6V-6961	Knob
8	2	5P-9865	Spacer
9	2	2K-4973	Locknut
10	2	8T-2502	Bolt (3/8-16x1.125 inch)
11	2	6V-8801	Nut
12	4	5M-2894	Washer
13	2	8D-8011	Plate
14	2	0L-1351	Bolt (3/8-16x0.875 inch)
15	1	153-9136	Bracket
16	1	8D-8011	Locknut
17	1	5P-6872	Mirror

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Illustration 15	g00822997

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Illustration 16	g00822998

1. Install bracket (1) with six bolts (2) and six washers (3) .

2. Install brace (4) with two bolts (5) and two washers (3) .

3. Use the following parts to install mirror (6) : two knobs (7), two spacers (8), two locknuts (9), two bolts (10), two nuts (11), two washers (12) and two plates (13) .

   Note: Adjust the rearview mirror and tighten the rearview mirror. After you tighten the mirror, slightly loosen knobs (7) .

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Illustration 17	g00823101

4. Use two bolts (14) and two washers (12) to install bracket (15) .

5. Use one locknut (16) in order to install mirror (17) on bracket (15). Tighten locknut (16) to a torque of 12 ± 5 N·m (110 ± 45 lb in).

   Note: Adjust the mirror.

Install the Components that are on the Right Side of the Hood

Install the Right Hand Side Handholds

Table 32

Required Parts for Installation of Handholds
Item	Qty	Part Number	Description
1	20	4L-6454	Bolt (3/8-16x1.0 inch)
2	4	8T-4896	Hard Washer
3	1	9D-4721	Rail Assembly
4	- (1)	5P-1075	Hard Washer
5	1	- (2)	Rail Assembly
6	1	8T-8917 (3)	Bolt (1/2-13x1.25 inch)
7	1	8T-4223 (3)	Hard Washer
8	1	153-7094 (3)	Bracket
9	2	9B-7237 (3)	Bolt (3/8-16x1.25 inch)

( 1 )	The 769D Off-Highway Truck (S/N: 5SS406-UP) and (S/N: BBB1-UP) use 16 washers. Also, the 771D Quarry Truck (S/N: 6YS255-UP), and (S/N: BCA1-UP) use 16 washers. The 769D Off-Highway Truck (S/N: 5SS1-405) and the 771D Quarry Truck (S/N: 6YS1-254) use 18 washers.
( 2 )	The 143-0025 Rail Assembly is used on the 769D Off-Highway Truck (S/N: 5SS1-406) and the 771D Quarry Truck (S/N: 6YS1-254). The 769D Off-Highway Truck (S/N: 5SS407-UP), and the 769D Off-Highway Truck (S/N: BBB1-UP) use the 112-6087 Rail Assembly . Also, the 771D Quarry Truck (S/N: 6YS255-UP) and the 771D Quarry Truck (S/N: BCA1-UP) use the 112-6087 Rail Assembly .
( 3 )	Parts are used on the 769D Off-Highway Truck (S/N: 5SS1-405) and the 771D Quarry Truck (S/N: 6YS1-254).

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Illustration 18	g00804616

1. Use four bolts (1) and four washers (2) to install rail assembly (3) .

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Illustration 19	g00804704

2. Use 16 bolts (1) and 16 washers (4) in order to secure rail assembly (5) to the right hand platform.

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Illustration 20	g00818907

Note: Step 3 and Step 4 are only for the following trucks:769D (S/N: 5SS1-406) and 771D (S/N: 6YS1-254).

3. Use one bolt (6) and one washer (7) in order to install bracket (8) to rail assembly (5) .

4. Use two bolts (9) and two washers (4) in order to secure the other end of bracket (8) to plate. The plate holds the air tanks and the brake master cylinders.

Install the Retainer for the Cover of the Battery Compartment

Table 33

Required Parts for Installation of Handholds
Item	Qty	Part Number	Description
1	2	5K-4549	U-Bolt
2	4	6V-8185	Nut
3	4	8T-4205	Hard Washer
4	1	2G-2345	Bracket
5	2	3B-4615	Cotter Pin
6	2	0T-0883	Washer
7	1	5D-3887	Rod
8	1	6F-8499	Spring

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Illustration 21	g00804716

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Illustration 22	g00804855

1. Use two U-Bolts (1), four nuts (2), and four washers (3) to install bracket (4) on rail assembly. Hand tighten the nuts.

2. Use two cotter pins (5) and two washers (6) in order to install rod (7) and spring (8) on the bracket.

3. Slide the retainer assembly forward.

4. Open the cover of the battery compartment. Lean the cover against the rail assembly.

5. Slide the retainer assembly rearward. Position the end of rod (7) 25 mm (1.0 inch) past the cover of the battery compartment.

6. Tighten four nuts (2) .

7. Pull rod (7) in order to compress spring (8). Close the cover of the battery compartment. Release rod (7) .

Install the Right Hand Rearview Mirror

Table 34

Required Parts for Installation of Rearview Mirror
Item	Qty	Part Number	Description
1	2	7D-9969	Support
2	2	7X-0326	Bolt (1/2-13x3 inch)
3	2	8T-4223	Hard Washer
4	1	8W-7904	Tube
5	2	3B-4605	Cotter
6	2	5S-7379	Bolt (3/8-16x.875 inch)
7	2	5P-1075	Hard Washer
8	1	8T-2287	Mirror

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Illustration 23	g00804931

1. Use two bolts (1) and two washers (2) in order to install two supports (3) on the rail assembly.

   Note: Do not tighten bolts (1) until the rearview mirror is completely installed.

2. Insert tube (4) in two supports (3) .

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Illustration 24	g00804947

3. Insert two cotters (5) into tube (4) .

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Illustration 25	g00804980

4. Use two bolts (6) and two washers (7) in order to install mirror (8) .

   Note: Adjust the rearview mirror and tighten the rearview mirror.

Install the Deflector on the Right Hand Fender

Table 35

Required Parts for Installation of Deflector
Item	Qty	Part Number	Description
1	1	8W-6062	Deflector

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Illustration 26	g00809462

1. Remove deflector (1) from the grill.

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Illustration 27	g00809518

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Illustration 28	g00809476

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Illustration 29	g00820996

2. Use nine bolts (A) and nine washers (B) in order to install strip (C), strip (D), and deflector (1) to the platform.

   Note: Place strip (C) above the deflector and place strip (D) below the deflector.

Install Front Fender Guards

Table 36

Required Parts for Installation of Front Fender Guards
Item	Qty	Part Number	Description
1	1	6G-3218	Guard
2	2	2G-3424	Strip
3	10	8T-2502	Bolt (3/8-16x1.125 inch)
4	10	5P-1075	Hard Washer
5	1	164-9553	Guard

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Illustration 30	g00540992

1. At the left side of the machine, use five bolts (3) and five washers (4) in order to install guard (1) and one strip (2) on the fender.

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Illustration 31	g00540997

2. At the right side of the machine, use five bolts (3) and five washers (4) in order to install guard (5) and one strip (2) on the fender.

Install the Lamps for Monitoring the Payload

Table 37

Required Parts for Installation of the Lamps that Monitor the Payload
Item	Qty	Part Number	Description
1	1	8K-1433	Grommet
2	1	8W-4812	Bracket (1)
3	4	5M-3062	Bolt (3/8-16x.75 inch)
4	4	8T-4896	Hard Washer
5	2	9G-9150	Clip

( 1 )

The 8T-9683 Signal Lamp and the 8T-9684 Signal Lamp are assembled in the 8W-4812 Bracket . The 8W-4812 Bracket is stored in the operator's compartment for shipment.

1. Remove the cover at the rear of the cab. Locate the wiring for the lamps that monitor the payload.

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Illustration 32	g00541098

2. Install grommet (1) in the side wall of the cab.

3. Maneuver the wiring connections through grommet (1) .

4. Connect the plug housing and the receptacle housing of the harness to the corresponding lamps that monitor the payload. Use two clips (5) in order to secure the connections.

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Illustration 33	g00541019

5. Use four bolts (3) and four washers (4) in order to secure bracket (2) to the cab.

Install the Guards on the Sides of the Canopy

Table 38

Required Parts for Installation of Guards
Item	Qty	Part Number	Description
1	1	113-1764	Guard
2	1	113-1765	Guard
3	27	5P-2228	Bolt (1/2-13x1 inch)
4	27	8T-4223	Hard Washer

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Illustration 34	g00540840

1. Use a suitable lifting device in order to position guard (1) on the left side of the canopy.

2. Use fifteen bolts (3) and fifteen washers (4) in order to attach guard (1) to the canopy.

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Illustration 35	g00540842

3. Use a suitable lifting device in order to position guard (2) on the right side of the canopy.

4. Use twelve bolts (3) and twelve washers (4) in order to attach guard (2) to the canopy.

Install the Baffle on the Canopy

Table 39

Required Parts for Installation of Baffle
Item	Qty	Part Number	Description
1	1	113-1216	Baffle
2	2	031-9831	Screw (Hex Head 3/8x16)

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Illustration 36	g00519177
Install the body down indicator.

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

Install the Canopy on the Body

Table 40

Required Parts for Installation of Canopy
Item	Qty	Part Number	Description
1	1	- (1)	Canopy Assembly

( 1 )

The 146-2261 Canopy Assembly is used on the 769D Off-Highway Truck and the 153-3967 Canopy Assembly is used on 771D Quarry Truck.

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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

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Illustration 37	g00819129

1. Before you align the canopy on the truck body, remove the paint from the mating surfaces.

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Illustration 38	g00821028

2. Tack weld the canopy to the truck body. Visually verify the alignment of the canopy from a distance.

   Note: The front plate of canopy (1) fits against front wall (A) of the truck body.

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

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Illustration 39	g00819125

3. Complete weld (W1) in order to weld the canopy to the truck body at location (B). Repeat the procedure for the opposite side. Refer to Illustration 39 and refer to Table 41.

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

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   Table 41

   Weld Tolerances
   Weld	Description
   W1	8 mm (0.32 inch) fillet weld

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Illustration 40	g00819717
View of area B

4. Complete weld (W2) in order to weld the canopy to the truck body at location (B). Grind the face of the weld in order to make a contour that is smooth and concave. Repeat the procedure for the opposite side. Refer to Illustration 40 and refer to Table 42.
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   Table 42

   Weld Tolerances
   Weld	Description
   W2	16 mm (0.63 inch) fillet weld

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Illustration 41	g00804740

5. Complete weld (W3). Refer to Illustration 41 and refer to Table 43.

   Note: Weld (W3) includes the welded joint inside the truck body and the welded joint outside the truck body.

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

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   Table 43

   Weld Tolerances
   Weld	Description
   W3	10 mm (0.40 inch) fillet weld

Install the Plug in the Truck Body

Table 44

Required Parts for Installation of Plug
Item	Qty	Part Number	Description
1	1	7D-2607	Plug

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Illustration 42	g00819132

1. Complete weld (W4) on both sides of plug (1) in order to secure the plug in the truck body. Refer to Illustration 42 and refer to Table 45.
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   Table 45

   Weld Tolerances
   Weld	Description
   W4	8 mm (0.32 inch) fillet weld

Install the Pivot Pins for the Body

Table 46

Required Parts for Installation of Pivot Pins
Item	Qty	Part Number	Description
1	2	132-6650	Pin
2	2	7D-7488	Thrust Washer
3	2	124-9014 (1)	Thrust Washer
4	2	8W-8456	Plate
5	4	5P-2566	Bolt (1/2-13x1.50 inch)
6	4	5P-1076	Hard Washer
7	2	3B-8489	Grease Fitting

( 1 )

Use the thin washer if the standard washer will not fit.

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Illustration 43	g00540853

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

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

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

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Illustration 44	g00540878

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Illustration 45	g00821051

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Illustration 46	g00540889

2. Insert one pin (1) through the holes for the pivot pins. Also insert pin (1) through one thrust washer (2). Locate thrust washer (2) inside the ear of the truck body. If thrust washer (2) is too thick, use one thrust washer (3) .

   Note: Thrust washers are used between the outer ear of the truck body and the truck frame only. Refer to Illustration 45.

   Note: Apply 5P-3931 Anti-Seize Compound to the pin before installation.

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

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

5. Repeat Steps 1 through 4 for the opposite side.

Install the Hoist Cylinders for the Body

Table 47

Required Parts for Installation of Hoist Cylinders
Item	Qty	Part Number	Description
1	2	9M-2321	Pin
2	2	2K-0703	Bar
3	4	5P-2228	Bolt (1/2-13x1 inch)
4	4	8T-4223	Hard Washer

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Illustration 47	g00519164

1. Remove the shipping brackets from the hoist cylinders.

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

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

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Illustration 48	g00540894

3. Remove the plastic caps from the threaded holes in the truck body. Install one pin (1) through the holes in the truck body and in the hoist cylinder.

   Note: Apply 5P-3931 Anti-Seize Compound to the pin before installation.

4. Use one bar (2), two bolts (3), and two washers (4) in order to secure pin (1) in place.

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Illustration 49	g00540923

5. Use four bolts (A) and four clips (B) in order to install hose (C) to the truck body.

   Note: Hose (C) is already attached to the hoist cylinder.

   Note: Use hose (C) in order to supply grease to the bushings of the hoist cylinder.

6. Repeat Step 1 through Step 4 on the opposite side.

Install the Pads and Shims for the Body

Table 48

Required Parts for Installation of Pads and of Shims
Item	Qty	Part Number	Description
1	30	106-8224	Shim
2	6	106-8223	Pad Assembly
3	18	5P-2566	Bolt (1/2-13x1.50 inch)
4	18	8T-4223	Hard Washer

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

1. Use the center mounting block on the body as a guide in order to mark the pad locations on the frame rail.

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Illustration 50	g00519168
Install pads and shims on the truck body.

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Install dump body prop before working under a raised dump body to prevent it from falling which could result in personal injury or death.

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 four locations on the rail in order to mount pads .

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

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

4. Raise the body approximately 305 mm (12 inch). Use suitable material in order to block the body in position. Use three bolts (3) and three washers (4) in order to secure the pads and shims to the body. Raise the body. Remove the material that was used to block the body. Lower the body firmly against the frame.

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Illustration 51	g00519167
Install pads and shims on the shoe assemblies.

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

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

6. Raise the body. Install the pins that retain the body. Use bolts (3) and washers (4) in order to secure the mounting pads and the shims to the shoe assemblies. 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 Body Position Sensor

Table 49

Required Parts for Installation of Magnetic Assembly
Item	Qty	Part Number	Description
1	1	3E-0461	Electronic Control
2	1	167-4356	Bracket
3	4	4M-6425	Bolt (5/16-18x1 inch)
4	4	5P-4116	Washer
5	4	5S-7379	Bolt (3/8-16x.875 inch)
6	2	5P-1075	Hard Washer
7	1	5G-7820	Magnet Assembly
8	1	140-8883	Bracket
9	2	6V-8189	Nut
10	2	8T-4896	Hard Washer
11	1	8T-4896 (1)	Hard Washer
12	1	5S-7379 (1)	Bolt (3/8-16x.875 inch)
13	1	9G-9152 (1)	Clip

( 1 )

Part of the 131-3757 Lighting and Wiring Group

Illustration 52	g00540993

1. Use two bolts (3) and two washers (4) in order to install electronic control (1) to bracket (2) .

   Note: Do not tighten the bolts completely in order to allow an adjustment.

2. Use two bolts (5) and two washers (6) in order to install bracket (2) to the truck frame.

   Note: Do not tighten the bolts completely in order to allow an adjustment.

3. Attach the wiring connector of electronic control (1) to the connector plug on the transmission harness. Use a plug lock wedge in order to secure the connection. Use one bolt (12), one washer (11), and one clip (13) in order to secure the wiring connection to bracket (2) .

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Illustration 53	g00540928

4. Use two nuts (9), two bolts (3), and two washers (4) in order to secure magnet assembly (7) to bracket (8) .

5. Use two bolts (5) and two washers (10) in order to install bracket (8) and magnet assembly (7) to the truck body.

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Illustration 54	g00541736
Dimension (B) is 4.0 mm (0.16 inch). Dimension (C) is a reference dimension that is 6.0 mm (0.24 inch).

Note: Refer to dimension (C) when the truck body is lowered to the frame.

6. Use a 4.0 mm (0.16 inch) shim in order to set the gap at the magnet assembly and at the electronic control. Slide the bracket forward. Remove the shim and tighten the bolts.

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Illustration 55	g00540982
Dimension (A) is 360 mm (14.2 inch).

7. Carefully raise the truck body to the specified dimension. Use suitable material to block the body in position.

8. Slide the electronic control on the bracket until the yellow light illuminates on the top of the electronic control. Tighten the bolts.

9. Raise the truck body. Remove the material that was used to block the body in position.

10. Lower the truck body.

Install the Rock Ejectors

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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

769D Off-Highway Trucks

Table 50

Required Parts for Installation of Rock Ejector
Item	Qty	Part Number	Description
1	1	142-5843	Bracket
2	1	142-5842	Bracket
3	2	6G-7773	Pin
4	4	3B-4647	Cotter Pin
5	16	1D-0503	Washer
6	2	8W-1165	Rock Ejector

Illustration 56	g00819134

Illustration 57	g00818887
Dimension (A) is 592 mm (23 inch).

Table 51

Weld Tolerances
Weld	Description
W5	10 mm (0.40 inch) Fillet Weld

1. Position bracket (1) on the left side of truck body. Use dimension (A) as a reference. Tack weld the bracket in place. Complete weld (W5) between the bracket and the truck body. Refer to Illustration 57 and Table 51.

2. Position bracket (2) on the right side of truck body. Use dimension (A) as a reference. Tack weld the bracket in place. Complete weld (W5) between the bracket and the truck body. Refer to Illustration 57 and Table 51.

   Note: Position the brackets in order to allow the rock ejectors to hang centrally between the two wheels at each side of the truck. Use dimension (A) as a reference.

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Illustration 58	g00819520

3. Use one pin (3), two cotter pins (4), and eight washers (5) in order to install each rock ejector (6) .

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

771D Quarry Trucks

Table 52

Required Parts for Installation of Rock Ejector
Item	Qty	Part Number	Description
1	2	136-1627	Bracket
2	2	6G-7773	Pin
3	4	3B-4647	Cotter Pin
4	16	1D-0503	Washer
5	2	8W-1165	Rock Ejector

Illustration 59	g00819521

Illustration 60	g00821085
Dimension (A) is 592 mm (23 inch).

Table 53

Weld Tolerances
Weld	Description
W5	10 mm (0.40 inch) Fillet Weld

1. Position one of bracket (1) on the left side of truck body. Use dimension (A) as a reference. Tack weld the bracket in place. Complete weld (W5) between the bracket and the truck body. Refer to Illustration 60 and Table 53. Repeat the procedure for welding the remaining bracket on the right side of the truck body.

   Note: Position the brackets in order to allow the rock ejectors to hang centrally between the two wheels at each side of the truck. Use dimension (A) as a reference.

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Illustration 61	g00820903

2. Use one pin (2), two cotter pins (3), and eight washers (4) in order to install each rock ejector (5). Refer to Illustration 58.

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

Store Retainer Pins for the Body

Table 54

Required Parts for Installation of Retainer Pin
Item	Qty	Part Number	Description
1	2	5D-3887	Rod
2	2	6F-8499	Spring
3	4	054-3788	Orifice
4	4	3B-4615	Cotter Pin
5	2	5T-5519	Pin

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Illustration 62	g00519175
Install the retainer.

1. Use one spring (2), two orifices (3), and two cotter pins (4) in order to install rod (1) on the truck body.

2. Pull rod (1) outward. Install pin (5) in the storage hole of the truck body. Release rod (1) in order to secure pin (5) .

3. Repeat Step 1 and Step 2 for the pin on the opposite side.

Install Guards for Rear Wheels

Table 55

Required Parts for Installation of Guards for Rear Wheels
Item	Qty	Part Number	Description
1	1	149-2086	Baffle
2	1	149-2085	Baffle
3	2	2G-7826	Strip
4	14	5P-2566	Bolt (1/2-13x1.50 inch)
5	14	8T-4223	Hard Washer
6	14	6V-8188	Nut

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Illustration 63	g00540937

1. At the left side of the machine, install baffle (1) to the mounting bar on the bottom of the truck body. Use seven bolts (4), seven nuts (6), and seven washers (5) in order to install baffle (1) with a strip (3) .

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Illustration 64	g00540962

2. At the right side of the machine, install baffle (2) to the mounting bar on the bottom of the truck body. Use seven bolts (4), seven nuts (6), and seven washers (5) in order to install baffle (2) with a strip (3) .

Install the Elbow that Connects the Exhaust for the Heated Body

Table 56

Required Parts for Installation of Connection for Heated Body
Item	Qty	Part Number	Description
1	1	5T-2751	Elbow
2	1	2G-9142	Plate
3	4	3D-0472	Taperlock Stud
4	8	5P-8245	Washer
5	7	6V-8188	Nut
6	1	6G-0248	Elbow
7	4	0S-1585	Bolt (1/2-13x1.25 inch)
8	8	1D-5965	Washer
9	1	4B-3586	Setscrew
10	2	3D-0490	Taperlock Stud

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Illustration 65	g00540967

1. Use one plate (2), four taperlock studs (3), two taperlock studs (10), four washers (4), and six nuts (5) in order to install elbow (1) on the truck body.

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Install dump body prop before working under a raised dump body to prevent it from falling which could result in personal injury or death.

2. Raise the truck body and install the pins that retain the truck body in position.

3. Use four bolts (7), four washers (8), and four washers (4) in order to install elbow (6) to the truck frame.

4. Remove the pins that retain the truck body. Lower the truck body to the frame.

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Illustration 66	g00540985
Dimension (A) is 56 mm (2.2 inch).

5. Use one nut (5) and one setscrew (9) in order to align elbow (6) .

   Note: Make sure that the clearance between the flanges of the connection is 56 mm (2.2 inch).

Install the Films on 769D Off-Highway Trucks

Table 57

Required Parts for Installation of Films
Item	Qty	Part Number	Description
1	1	8C-5574	Film (CATERPILLAR)
2	1	130-2702	Film
3	1	129-5184	Film
4	1	129-5185	Film
5	1	8C-5563	Film
6	1	8C-5353	Film
7	1	140-0091	Film
8	1	140-0092	Film

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Illustration 67	g00519180

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Illustration 68	g00519181
Install films on the machine.

1. Install film (1) and film (2) on the front of the canopy.

2. Install film (3) and film (4) on the front and on each side of the radiator.

3. Install film (5) to the front fender on the right side of the machine.

4. Install film (6) to the front fender on the left side of the machine.

5. Install film (7) on the left side of the truck body.

6. Install film (8) on the right side of the truck body.

Installation of the Films on 771D Quarry Trucks

Table 58

Required Parts for Installation of Films
Item	Qty	Part Number	Description
1	1	140-0095	Film
2	1	8C-5579	Film(CATERPILLAR)
3	1	140-0095	Film
4	1	8C-5563	Film
5	1	129-5188	Film
6	1	129-5189	Film
7	1	8C-5353	Film
8	1	8C-5574	Film

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Illustration 69	g00818911

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Illustration 70	g00818916
Install the films on the machine.

1. Install film (2) and film (3) on the front of the canopy.

2. Install film (5) and film (6) on the front and on each side of the radiator.

3. Install film (4) to the front fender on the right side of the machine.

4. Install film (7) to the front fender on the left side of the machine.

5. Install film (8) on the left side of the truck body.

6. Install film (1) on the right side of the truck body.

Perform the Commissioning Procedure for the Machine

Checks Before Delivery of 769D Off-Highway Truck and 771D Quarry Truck

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

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Personal injury or death can result from being too close to machine during test. Make sure all personnel that are not approved are kept off the machine and in view of the operator during test, because the machine could move. Stay clear of the machine when taking readings for the machine.

Prepare the Machine Before the Machine Is Started

1. Connect a laptop computer to the Caterpillar Diagnostic Connector on the fuse panel behind the operator seat. The laptop computer should have JERD2142 or JERD2129 Electronic Subscription. Use a 7X-1570 Data Link Cable , 7X-1700 Communication Adapter , "NEXG4523" Service Program Module, and a 7X-1688 Cable in order to connect the laptop computer.

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

   1. Connect the batteries.

   2. Turn the battery disconnect switch ON.

   3. Turn the engine start switch ON.

   4. Do not start the truck.

3. Start the Electronic Technician (ET). ET will list all of the electronic control modules for the machine. There will be at least an engine control and a transmission control. If the truck is equipped with the Automatic Retarder Control (ARC), the Integrated Brake Control (IBC), or the Traction Control System (TCS), the ET screen should show the features.

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

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

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

   2. If the truck has the prelubrication system, choose "ENGINE PRELUBE". Turn on the engine prelube. Engine prelube should be off if the system is not on the truck.

   3. If the truck has the starting aid system, choose "ETHER CONTROL" or "STARTING AID". Turn on ether control or starting aid. Starting aids should be off if the systems are not on the truck.

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

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

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

   7. Choose "DIAGNOSTICS", "DIAGNOSTIC TESTS", and" OVERRIDE PARAMETERS" from the ET menu.

6. If the truck has the prelubrication system, choose "PRELUBRICATION". Choose" CHANGE". Turn on the engine prelube. The pump for the engine prelube should start. Choose "CHANGE" again and turn off the feature.

7. If the truck has starting aid or ether aid, choose "STARTING AID" or choose "ETHER AID". Choose "CHANGE" and turn on the feature. You should hear the click of the ether aid or the starting aid solenoid on the chassis. Choose "CHANGE" again and turn off the feature.

8. From the ET menu, select" DATA LINK". Next, select "SELECT ECM". Next, select "TRANSMISSION CONTROL". Next, select "CONFIGURATION".

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

   2. Check the "ECONOMY MODE" parameter. The parameter should read OFF.

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

9. If the truck has the Automatic Retarder Control (ARC), select "DATA LINK" from the ET menu. Next, select "CHOOSE ECM". Next, select "AUTOMATIC RETARDER". Finally select "CONFIGURATION".

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

Check the Monitoring System

1. Turn the engine start switch to the OFF position for two seconds. Turn the engine start switch to the ON position. Do not start the engine. Watch the lights of the machine monitoring system. When the engine start switch is in the ON position, all ten lights of the machine monitoring system should illuminate for approximately one second. Also, all LCD segments in the digital LCD display should be illuminated. Also, the warning buzzer that indicates a fault should sound for approximately one second.

2. Turn the engine start switch OFF for two seconds. Turn the engine start switch ON. Do not start the engine. Watch the quad gauge. All four gauges should jump to one half of full scale and all four gauges should return to zero. Next, the four gauges should move to full scale. After reaching full scale, the gauges should return to the current values of the machine. Allow a three seconds test cycle in order to perform the check.

3. Turn the engine start switch OFF for two seconds. Turn the engine start switch ON. Do not start the engine. Watch the tachometer gauge. The indicator needle should jump to one half of full scale and the indicator needle should return to zero. Next, the indicator needle should move to full scale. After reaching full scale, the indicator needle will return to zero since the engine is not running. When you perform the check procedure, the actual gear readout should illuminate all segments of the readout. The readout should display two spaces.

4. Turn the engine start switch OFF for two seconds. Turn the engine start switch ON. Do not start the engine. Watch the speedometer. The speedometer will turn on every segment of the display. Next, the numbers will scroll to zero.

5. Check the gauges now. The gauges should read the following values:
   • The coolant temperature gauge should have the indicator needle between the far left and the center.

   • The brake oil temperature gauge should have the indicator needle between the far left and the center.

   • The gauge for the system air pressure should have the indicator needle between the far left and the center.

   • The fuel level gauge should have a reading at the indicator needle that matches the gauge on the side of the tank.

   • The speedometer should read zero. If the speedometer reading is blank, there is a problem.

   • The gear indicator should read "N". If the gear indicator is blank, there is a problem.

   • The hour meter should read zero to 50 hours.

6. Clear the faults and set the units.

   1. Locate the S switch and the C switch behind the operator seat. Push the S switch and the C switch at the same time. When the display of the Caterpillar Monitoring System shows "-1-", release both switches. The code that is displayed indicates the model. Refer to the following information.
      Show/hide table

      Table 59

      Machine Model	PIN	Code
      769D	(S/N: 5SS)	62
      	(S/N: BBB)	54
      771D	(S/N: 6YS)	61
      	(S/N: BCA)	53

   2. Push the "S" switch and push the "C" switch at the same time. When the display of the Caterpillar Monitoring System shows "-3-", release both switches. The display should show "---". If the display does not show "---", there are still logged faults or active faults that are present. If faults are present, a number will flash on the screen. If the "SERV CODE" indicator is not illuminated in the upper right corner of the screen, the fault is a logged fault. Clear the fault by pressing the "C" switch until the fault disappears. Continue to clear the faults until the "---" appears on the screen. If you reach a fault that illuminates the "SERV CODE" indicator, you will need to resolve the problem before you may clear the fault.

   3. Push the "S" switch and push the "C" switch at the same time. When the display of the Caterpillar Monitoring System shows "-4-", release both switches. Press the "C" switch only and hold the "C" switch for approximately two seconds. All of the gauges should go to readings of zero.

   4. Push the "S" switch and the "C" switch at the same time. When the display of the Caterpillar Monitoring System shows "-5-", release both switches. If the truck's destination is the United States, the display will probably read US. If the truck's destination is not the United States, hold down the "C" switch until the screen reads "SI". When the screen reads "SI", all readouts will display metric units.

   5. Turn the engine start switch OFF.

Check the Suspension Cylinders

Make sure that the suspension cylinders are charged correctly. Refer to Testing and Adjusting, "769D Off-Highway Truck and 771D Quarry Truck Suspension Cylinder".

Check the Truck Payload Measurement System (TPMS)

Note: The Truck Payload Measurement System (TPMS) will not operate properly until the suspension cylinders are charged correctly. Refer to Testing and Adjusting, "769D Off-Highway Truck and 771D Quarry Truck Suspension Cylinder".

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

1. Remove the four screws that hold the TPMS display in the overhead panel. Pull out the display. Do not disconnect the display.

2. Turn on the TPMS display. Use the rocker switch at the far left of the display.

3. Turn the engine start switch to the ON position in order to permit the TPMS display to perform a check procedure. When the check procedure is complete, the screen will be blank. If the red lights and green lights are not flashing on the display, the system is operating correctly.

4. Set the truck model. Press the button on the rear of the display until the display shows" 1". Release the button. The number that is displayed is the model of the truck. The models should be set to the following values:
   • 769D: "10h"

   • 771D: "11h"

   Use the set switch on the front of the display in order to change the model. Make sure that the model corresponds to the truck.

5. Turn the engine start switch to the OFF position.

6. Install the TPMS module in the overhead compartment.

Check the Engine Prelube System When the Truck Is Running

1. Turn the engine start switch to the ON position. Turn the engine start switch to the START position. The engine prelube system will run for one to 17 seconds if the truck is cold and if the truck has not started in the last two minutes. After the pump for the engine prelube system runs, the engine will start. If the above conditions are not met or if the truck does not have an engine prelube system, the engine will start immediately.

Activation of the Body Hoist Control

The truck might appear to have a problem with the body hoist controls. The 184-4671 Software Group will set the parameters for the hoist system.

Note: The software for the Electronic Technician (ET) must be used to set these parameters.

Note: On the ET Software 2.4, when the hoist control parameters are not visible or accessible on the configuration screen, disconnect the connection and reconnect the connection until the parameters appear. This establishes the communication to the transmission control.

Note: The hoist control parameters appear automatically on the configuration screens for the ET Software 3.0 and for the ET Software 3.1.

Adjustment for Hoist Lower Valve

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

The adjustment for the hoist lower valve may not be available on earlier systems of the Engine Control Module. The adjustment range may be from 0 to 10 with 5 as the default on some early ECM systems.

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

1. Place a tetragauge or place a 3.45 MPa (500 psi) gauge with a hose extension on the outlet port of the hoist pump.

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

3. Enter the configuration parameters screen through the service menu in the Electronic Technician (ET).

4. Adjust 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.

5. Raise the body to the middle position.

6. Lower the body to the frame.

7. If a 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.

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

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

Note: When the pressure is greater than 1724 kPa (250 psi), the adjustment is set too high. This causes too much oil to be diverted to the hoist control valve. This causes the brake oil to overheat when the body is in the FLOAT position. Lower the adjustment setting and repeat Step 3 through Step 9. This lowers the pressure below 1724 kPa (250 psi).

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

Enable the Hoist System (An Adjustable Parameter)

The hoist enable parameter is set at a value of "2" for all trucks that are shipped from the factory with the 184-4671 Software Group and with a body that is not installed. Parameter Value 2 will prevent the hoist cylinders from being activated by accident. After the body is installed, change the Parameter Value to "1". The hoist system should function properly. When the hoist system does not work, check the items below.

Table 60

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

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

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

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

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

   • The truck should not be moving.

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

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

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

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

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

Connect the Electronic Technician In Order To Prepare the Truck for the Final Check

1. Connect a laptop computer to the Caterpillar Diagnostic Connector on the fuse panel behind the operator seat. The laptop computer should have JERD2142 or JERD2129 Electronic Subscription. Use a 7X-1570 Data Link Cable , 7X-1700 Communication Adapter , "NEXG4523" Service Program Module, and a 7X-1688 Cable in order to connect the laptop computer.

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

   1. Connect the batteries.

   2. Turn the battery disconnect switch ON.

   3. Turn the engine start switch ON.

   4. Do not start the truck.

3. Start the Electronic Technician (ET). ET will list all of the electronic control modules for the machine. There will be at least an engine control and a transmission control. If the truck has the Automatic Retarder Control (ARC), the Integrated Brake Control (IBC), or the Traction Control System (TCS), the ET screen should show the features.

4. Choose" ACTIVE CODES" from the ET menu. Click on the button on the bottom of the screen. The button reads "INCLUDE ALL ECMS". If "NO ACTIVE CODES "appears, then continue. If active fault codes are present, resolve the active faults.

5. Choose"LOGGED CODES " from the ET menu. Click on the button at the bottom of the screen that reads" INCLUDE ALL ECM's". Identify the cause of all logged faults. Make sure that the causes of the logged faults have been resolved. Clear all logged codes.

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

7. Locate the "S" switch and the "C" switch behind the operator seat. Push the "S" switch and push the "C" switch at the same time. When the display of the Caterpillar Monitoring System shows" -3-", release both switches. The display should show "---". If the display does not show" ---", there are still logged faults or active faults that are present. If there are faults, a number will flash on the screen. If the "SERV CODE" indicator is not illuminated in the upper right corner of the screen, the fault is a logged fault. Identify the cause of the fault. Make sure that the cause of the fault has been resolved. Clear the fault by pressing the "C" switch until the fault disappears. Continue to clear the faults until the "---" appears on the screen. If you reach a fault that illuminates the"SERV CODE " indicator, you will need to resolve the problem before you may clear the fault.

Check the Service Brake Discs

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

Final Check

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

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

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

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

Caterpillar Inc.
Attention: CMT Product Support
769D Truck and 771D Quarry 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. 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 ____

3. Check the machine lights.
   • Operational

   • YES ____ NO ____

   • Cab and Dash

   • YES ____ NO ____

4. Check the controls in the cab.
   • Check if the cab door opens. Check if the cab door closes.

   • YES ____ NO ____

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

   • YES ____ NO ____

   • Check if the horn functions.

   • YES ____ NO ____

   • Check if the windshield 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 the test light. The test light is for the EMS.

   • 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 ____

5. Check if all fluid levels are full.
   • YES ____ NO ____

6. Correct any unusual noises or unusual leaks.
   • YES ____ NO ____

7. Check if all lubrication lines are filled with grease.
   • YES ____ NO ____

8. Check if all quality requirements are fulfilled. Check if all variances have been corrected.
   • YES ____ NO ____

9. Check if the backup alarms function.
   • YES ____ NO ____

10. Check if the machine is repainted to the factory specifications.
    • YES ____ NO ____

11. Check if there was damage to the machine from shipment.
    • YES ____ NO ____

12. Check if all required parts were shipped with the machine.
    • YES ____ NO ____

13. Sign your name in the space below.
    • Hydraulic

    • Electrical

    • Structural

    • Other

14. Comments
    • ________________________________________

    • ________________________________________

    • ________________________________________

    • ________________________________________

    • ________________________________________

    • ________________________________________

    • ________________________________________

    • ________________________________________

    • ________________________________________

    • ________________________________________

Table 61

Specifications for the Commissioning Procedure
Description	Specifications	Actual	Comments
Engine Low Idle rpm	650 +30 -10 rpm
Engine High Idle	2285 ± 30 rpm
Pressure of Brake Retract Pump @ High Idle	3170 ± 200 kPa (460 ± 30 psi)
Relief Pressure of Hoist Pump	17230 ± 520 kPa (2500 ± 75 psi)
Steering Pressure Relief	23430 ± 520 kPa (3400 ± 75 psi)
Steering Cycle Time	6.5 seconds @ 66 °C (150 °F)
Relief Pressure of Transmission Pressure @ High Idle	3445 kPa (500 psi) Maximum
Pressure of Transmission Lubrication @ High Idle	224 ± 52 kPa (32.5 ± 7.5 psi)
Torque Converter Outlet Pressure @ Stall	415 ± 105 kPa (60 ± 15 psi)