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

Off-Highway Truck:

773E (S/N: BDA1-258)

Off-Highway Truck:

775E (S/N: BEC1-201)

Introduction

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

This publication also contains assembly procedures and commissioning procedures in order to prepare 775E Off-Highway Truck for operation.

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

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

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

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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 List

Table 1

Required Parts for Installation of 113-0656 Catwalk
Qty	Part Number	Description
1	128-5530	Catwalk
26	4L-6454	Bolt (3/8-16X1 IN)
18	8T-4896	Hard Washer
1	116-4690	Catwalk
12	5S-7379	Bolt (3/8-16X0.875 IN)
1	8W-4484	Pipe
20	5P-1075	Hard Washer
1	116-6671	Rail Assembly
1	6G-0115	Brace
1	7F-5462 (1)	Lug
2	8T-8917	Bolt (1/2-13X1.25 IN)
2	8T-4223	Hard Washer

( 1 )

The lug is already welded to the catwalk.

Table 2

Required Parts for Installation of 155-4437 Rear View Mirror Gp
Qty	Part Number	Description
1	9D-7289	Bracket
6	4M-5283	Bolt (1/4-20X.625 IN)
8	5P-0537	Washer
1	2G-1254	Brace
2	5S-7349	Bolt (1/4-20X0.5 IN)
1	6V-6962	Mirror
2	6V-6961	Knob
2	5P-9865	Spacer
1	153-9136	Bracket
2	0L-1351	Bolt (3/8-16X0.875 IN)
2	2K-4973	Locknut
2	8T-2502	Bolt (3/8-16X1.125 IN)
2	6V-8801	Nut
4	5M-2894	Washer
1	5P-6872	Mirror
2	8D-8011	Plate
1	3K-6060	Locknut

Table 3

Required Parts for Installation of 136-1799 Handhold Gp
Qty	Part Number	Description
1	9D-4721	Rail Assembly
20	4L-6454	Bolt (3/8-16X1 IN)
4	8T-4896	Hard Washer
1	143-0025	Rail Assembly
18	5P-1075	Hard Washer
2	5K-4549	U-Bolt (1/4-20X2.12 IN)
1	2G-2345	Bracket
4	6V-8185	Nut
4	8T-4205	Hard Washer
1	5D-3887	Rod
1	6F-8499	Spring
2	0T-0883	Washer
2	3B-4615	Cotter Pin
2	9B-7237	Bolt (3/8-16X1.25 IN)
1	8T-8917	Bolt (1/2-13X1.25 IN)
1	8T-4223	Hard Washer
1	153-7094	Bracket

Table 4

Required Parts for Installation of 155-4464 Rear View Mirror Gp
Qty	Part Number	Description
2	7D-9969	Support
2	7X-0326	Bolt (1/2-13X3 IN)
2	8T-4223	Hard Washer
1	8W-7904	Tube
1	8T-2287	Mirror
2	5S-7379	Bolt (3/8-16X0.875 IN)
2	5P-1075	Hard Washer

Table 5

Required Parts for Installation of 8W-6062 Deflector Which is a Part of 136-1810 Fender Group
Qty	Part Number	Description
9	9B-7237	Bolt (3/8-16X1.25 IN)
9	5P-1075	Hard Washer
1	8W-6062	Deflector
1	8W-6063	Strip
1	8W-6064	Strip

Table 6

Required Parts for Installation of 8W-6387 Guard Which is a Part of 136-1810 Fender Gp
Qty	Part Number	Description
1	137-5834	Plate
2	5P-2228	Bolt (1/2-13X1 IN)
2	8T-4223	Hard Washer
1	8W-6387	Guard
1	5T-6553	Plate
2	9B-7237	Bolt (3/8-16X1.25 IN)
2	8T-2561	Washer
2	6V-8801	Nut
1	2G-2258	Strip
9	5S-7379	Bolt (3/8-16X0.875 IN)
9	5P-1075	Hard Washer

Table 7

Parts for Installation of 6G-3218 Guard Which is a Part of 136-1810 Fender Gp
Qty	Part Number	Description
1	6G-3218	Guard
2	2G-3424	Strip
10	8T-2502	Bolt (3/8-16X1.125 IN)
10	5P-1075	Hard Washer

Table 8

Required Parts for Installation of 143-0028 Payload Wiring
Qty	Part Number	Description
1	8K-1433	Grommet
1	8W-4812	Bracket
4	5M-3062	Bolt (3/8-16X0.75 IN)
4	8T-4896	Hard Washer
2	9G-9150	Clip

Table 9

Required Parts for Installation of Guards
Qty	Part Number	Description
1	113-1765	Guard
27	5P-2228	Bolt (1/2-13X1 IN)
27	8T-4223	Hard Washer
1	113-1764	Guard
1	138-6406 (1)	Guard
1	8X-9366 (2)	Guard

( 1 )	773E Off-Highway Truck
( 2 )	775E Quarry Truck

Table 10

Required Parts for Installation of Shields
Qty	Part Number	Description
2	146-3750	Plate
28	8T-9393	Bolt (5/8-11X1.5 IN)
28	7X-0515	Hard Washer

Table 11

Required Parts for Installation of Baffle
Qty	Part Number	Description
1	113-1216	Baffle
2	031-9831	Bolt (3/8-16X3/4 IN)

Table 12

Required Parts for Installation of Canopy
Qty	Part Number	Description	Model
1	143-5561	Canopy Assembly	773E
1	155-3057 or 137-3311	Canopy Assembly	775E

Table 13

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

Table 14

Required Parts for Installation of 132-6650 Pin As Which is a Part of 136-4627 Body Mounting Group
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 (1/2-13X1.5 IN)
4	5P-1076	Hard Washer
2	3B-8489	Grease Fitting

( 1 )

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

Table 15

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

Table 16

Parts for Installation of Pads and of Shims
Qty	Part Number	Description
30	106-8224	Shim
8	106-8223	Pad Assembly
24	5P-2566	Bolt (1/2-13X1.5 IN)
24	8T-4223	Hard Washer

Table 17

Required Parts for Installation of 3E-0461 Electronic Control Which is a Part of 136-4627 Body Mounting Group
Qty	Part Number	Description
1	3E-0461	Electronic Control
1	167-4357	Bracket
4	4M-6425	Bolt (5/16-18X1 IN)
4	5P-4116	Washer
4	5S-7379	Bolt (3/8-16X0.875 IN)
2	5P-1075	Hard Washer
1	5G-7820	Magnet Assembly
1	146-1845	Bracket
2	6V-8189	Nut
2	8T-4896	Hard Washer
1	8T-4896 (1)	Hard Washer
1	5S-7379 (1)	Bolt (3/8-16X0.875 IN)
1	9G-9152 (1)	Clip

( 1 )

Part of the 199-3416 Lighting and Wiring Group

Table 18

Required Parts for Installation of 8W-1155 Rock Ejector Assembly Which is a Part of 136-4627 Body Mounting Group
Qty	Part Number	Description
2	8W-1155	Rock Ejector
2	6G-7773	Pin
4	3B-4647	Cotter Pin
16	1D-0503	Washer
2	137-1995 (1)	Bracket
1	143-7114	Bracket
1	143-7115	Bracket

( 1 )

This bracket is used in the following situations: 773E Trucks with the 136-3162 Body and Canopy , 773E Trucks with the 137-7266 Body and Canopy and 775E Quarry Trucks.

Table 19

Required Parts for Installation of 5D-3887 Rod Which is a Part of 136-4627 Body Mounting Group
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 20

Required Parts for Installation of 8W-7481 Guard Which is a Part of 136-4627 Body Mounting Group
Qty	Part Number	Description
2	8W-7481	Guard
2	2G-7826	Strip
14	5P-2566	Bolt (1/2-13X1.5 IN)
14	8T-4223	Hard Washer
14	6V-8188	Nut

Table 21

Required Parts for Installation of 142-5676 Exhaust Pipe Gp
Qty	Part Number	Description
1	5T-2750	Elbow
1	2G-9142	Plate
4	3D-0472	Taperlock Stud
10	5P-8245	Washer
7	1D-7958	Nut
1	2G-9582	Elbow
4	7B-3235	Bolt (1/2-13X1.375 IN)
8	1D-5965	Washer
1	4B-3586	Setscrew
2	3D-0490	Taperlock Stud

Table 22

Required Parts for Installation of 208-6548 Film Gp
Qty	Part Number	Description
1	8C-5574	Film (CATERPILLAR)
1	130-2702	Film
1	129-5194	Film
1	129-5195	Film
1	8C-5563	Film
1	8C-5353	Film
1	140-0096	Film
1	140-0097	Film

Table 23

Required Parts for Installation of 208-6549 Film Gp
Qty	Part Number	Description
1	8C-5574	Film (CATERPILLAR)
1	8C-5579	Film
1	140-0099	Film
1	129-5199	Film
1	8C-5563	Film
1	8C-5353	Film
1	129-5198	Film
1	140-0098	Film

Weights and Specifications

Machine Weights

• The approximate weight of the 775E Off-Highway Truck is 43470 kg (95835 lb).

• The approximate weight of the 775E Off-Highway Truck canopy is 975 kg (2150 lb).

• The approximate weight of the 775E Off-Highway Truck body and canopy is 14150 kg (31195 lb).

• The approximate weight of the 773E Off-Highway Truck is 39750 kg (87633 lb).

• The approximate weight of the 773E Off-Highway Truck canopy is 973 kg (2145 lb).

• The approximate weight of the 773E Off-Highway Truck body and canopy is 9550 kg (21054 lb).

• The weight of each tire and rim is 1200 kg (2650 lb).

Machine Specifications

• The approximate length of the 775E Off-Highway Truck is 9.2 m (30 ft).

• The approximate length of the 773E Off-Highway Truck is 9.2 m (30.2 ft).

• The approximate height of the 773E Off-Highway Truck and the 775E Quarry Truck is 4.4 m (14.4 ft).

• The approximate width of the 773E Off-Highway Truck and the 775E Off-Highway Truck is 5.1 m (16.7 ft).

Torque Specifications

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

• Tighten the full nuts on the rim assembly to a torque of 1200 ± 50 N·m (885 ± 37 lb ft).

• Tighten the locknut on the rear view mirror to a torque of 12 ± 5 N·m (110 ± 45 lb in).

Chains and Cables

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

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

Necessary Hoist Capacity

Chassis Assembly

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

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

Assembled Machine Without Body

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

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

Inspect the Parts and Prepare the Machine for Assembly

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

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

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

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

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

Remove the Shipping Brackets

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Illustration 2	g00851302

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Illustration 3	g00851918

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

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

Install the Rear Tire and Rim Assemblies

Illustration 4	g00979406

Illustration 5	g00518945
Remove the tire and rim assembly from the truck body.

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

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

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Illustration 6	g00518946
Remove the nuts from the wheel studs.

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

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

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

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Illustration 7	g00518947
Use a tire handler in order to install tire and rim assembly.

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

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Illustration 8	g00518949
Install the tire and rim.

6. Install 14 full nuts (1) and 14 hard washers (2). Tighten the 14 full nuts to a torque of 1200 ± 50 N·m (885 ± 37 lb ft).

   Note: Before you install the full nuts and the hard washers, apply 4C-5593 Anti-Seize Compound to the faces of the hard washers and to the threads of the full nuts.

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

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

8. Carefully lower the machine to the ground.

Install the 113-0656 Catwalk

Table 24

Required Parts for Installation of 113-0656 Catwalk
Item	Qty	Part Number	Description
1	1	128-5530	Catwalk
2	30	4L-6454	Bolt (3/8-16X1 IN)
3	22	8T-4896	Hard Washer
4	1	116-4690	Catwalk
5	12	5S-7379	Bolt (3/8-16X0.875 IN)
6	1	8W-4484	Pipe
7	20	5P-1075	Hard Washer
8	1	116-6671	Rail Assembly
9	1	6G-0115	Brace
10	1	7F-5462 (1)	Lug
11	2	8T-8917	Bolt (1/2-13X1.25 IN)
12	2	8T-4223	Hard Washer

( 1 )

The lug is already welded to the catwalk.

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Illustration 9	g00851719

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Illustration 10	g00518910
Install the catwalks.

1. Use a suitable lifting device in order to position catwalk (1) and catwalk (4) on the cab. The weight of catwalk (4) is 46 kg (102 lb).

   Note: The catwalks are shipped as a unit.

2. Use six bolts (2) and six washers (3) in order to install catwalk (1) .

3. Use 12 bolts (5) and 12 hard washers (3) in order to install catwalk (4) .

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Illustration 11	g00851754

4. Use one brace (9) in order to support catwalk (4). Use two bolts (11) and two hard washers (12) in order to secure the brace to the fender and to the lug (10) on the catwalk.

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Illustration 12	g00518912
Install the pipe.

5. Use eight bolts (2) and eight hard washers (7) in order to install pipe (6) .

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Illustration 13	g00851953
Install the rail assembly.

6. Use 12 bolts (2) and 12 hard washers (7) in order to install rail assembly (8) .

Install the 155-4437 Rear View Mirror Gp

Table 25

Required Parts for Installation of 155-4437 Rear View Mirror Gp
Item	Qty	Part Number	Description
1	1	9D-7289	Bracket
2	6	4M-5283	Bolt (1/4-20X0.625 IN)
3	8	5P-0537	Washer
4	1	2G-1254	Brace
5	2	5S-7349	Bolt (1/4-20X0.5 IN)
6	1	6V-6962	Mirror
7	2	6V-6961	Knob
8	2	5P-9865	Spacer
9	1	153-9136	Bracket
10	2	0L-1351	Bolt (3/8-16X0.875 IN)
11	2	2K-4973	Locknut
12	2	8T-2502	Bolt (3/8-16X1.125 IN)
13	2	6V-8801	Nut
14	4	5M-2894	Washer
15	1	5P-6872	Mirror
16	2	8D-8011	Plate
17	1	3K-6060	Locknut

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Illustration 14	g00884965

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Illustration 15	g00518915
Install the left hand rearview mirror.

1. Use six bolts (2) and six washers (3) in order to install bracket (1) .

2. Use two bolts (5) and two washers (3) in order to install brace (4) .

3. In order to install the mirror (6), use the following parts: two knobs (7), two plates (16), two spacers (8), two locknuts (11), two bolts (12), two washers (14) and two nuts (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 16	g00541526
Install the upper left hand rearview mirror.

4. Use two bolts (10) and two washers (14) in order to install bracket (9) .

5. Use one locknut (17) in order to install mirror (15) on bracket (9). Tighten locknut (17) to a torque of 12 ± 5 N·m (110 ± 45 lb in).

   Note: Adjust the mirror.

Install the 136-1799 Handhold Gp

Table 26

Required Parts for Installation of 136-1799 Handhold Gp
Item	Qty	Part Number	Description
1	1	9D-4721	Rail Assembly
2	20	4L-6454	Bolt (3/8-16X1 IN)
3	4	8T-4896	Hard Washer
4	1	143-0025	Rail Assembly
5	18	5P-1075	Hard Washer
6	2	5K-4549	U-Bolt (1/4-20X2.12 IN)
7	1	2G-2345	Bracket
8	4	6V-8185	Nut
9	4	8T-4205	Hard Washer
10	1	5D-3887	Rod
11	1	6F-8499	Spring
12	2	0T-0883	Washer
13	2	3B-4615	Cotter Pin
14	2	9B-7237	Bolt (3/8-16X1.25 IN)
15	1	8T-8917	Bolt (1/2-13X1.25 IN)
16	1	8T-4223	Hard Washer
17	1	153-7094	Bracket

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Illustration 17	g00518938
Install the rail assembly.

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

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Illustration 18	g00874989

2. Use 16 bolts (2) and 16 hard washers (5) in order to install rail assembly (4) .

Install the Retainer for the Cover of the Battery Compartment

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Illustration 19	g00884982
Install the retainer for the cover of the battery compartment.

1. Use two U-Bolts (6) in order to install bracket (7) on rail assembly (4). Install four nuts (8) and four hard washers (9) finger tight on two U-Bolts (6) .

2. Use two cotter pins (13) and two washers (12) in order to install rod (10) and spring (11) on bracket (7) .

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 (10) 25 mm (1.0 inch) past the cover of the battery compartment.

6. Tighten four nuts (8) .

7. Pull rod (10) in order to compress spring (11). Close the cover of the battery compartment. Release rod (10) .

Install the 155-4464 Rear View Mirror Gp

Table 27

Required Parts for Installation of 155-4464 Rear View Mirror Gp
Item	Qty	Part Number	Description
1	2	7D-9969	Support
2	2	7X-0326	Bolt (1/2-13X3 IN)
3	2	8T-4223	Hard Washer
4	1	8W-7904	Tube
5	1	8T-2287	Mirror
6	2	5S-7379	Bolt (3/8-16X0.875 IN)
7	2	5P-1075	Hard Washer

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Illustration 20	g00518942
Install the right hand rearview mirror.

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

   Note: Do not tighten bolts (2) until the rearview mirror is completely installed.

2. Insert tube (4) in two supports (1) .

3. Use two bolts (6) and two hard washers (7) in order to install mirror (5) .

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

Install the 8W-6062 Deflector Which is a Part of 136-1810 Fender Gp

Table 28

Required Parts for Installation of 8W-6062 Deflector Which is a Part of 136-1810 Fender Gp
Item	Qty	Part Number	Description
1	9	9B-7237	Bolt (3/8-16X1.25 IN)
2	9	5P-1075	Hard Washer
3	1	8W-6062	Deflector
4	1	8W-6063	Strip
5	1	8W-6064	Strip

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Illustration 21	g00540990

1. Use strip (4) and strip (5) in order to assemble deflector (3). Place strip (4) above the deflector and place strip (5) below the deflector.

   Note: Prior to installation, remove deflector (3) from the grill.

2. Use nine bolts (1) and nine hard washers (2) in order to install strip (4), strip (5), and deflector (3) to the platform.

Install the 8W-6387 Guard Which is a Part of 136-1810 Fender Gp

Table 29

Required Parts for Installation of 8W-6387 Guard Which is a Part of 136-1810 Fender Gp
Item	Qty	Part Number	Description
1	1	137-5834	Plate
2	2	5P-2228	Bolt (1/2-13X1 IN)
3	2	8T-4223	Hard Washer
4	1	8W-6387	Guard
5	1	5T-6553	Plate
6	2	9B-7237	Bolt (3/8-16X1.25 IN)
7	2	8T-2561	Washer
8	2	6V-8801	Nut
9	1	2G-2258	Strip
10	9	5S-7379	Bolt (3/8-16X0.875 IN)
11	9	5P-1075	Hard Washer

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Illustration 22	g00518952

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Illustration 23	g00518954
Install the top fender guard.

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

2. In order to secure guard (4) to plate (1), use the parts that follow: one plate (5), two bolts (6), two washers (7) and two nuts (8) .

3. In order to secure guard (4) to the frame, use the parts that follow: one strip (9), nine bolts (10) and nine hard washers (11) .

Install the 6G-3218 Guard Which is a Part of 136-1810 Fender Gp

Table 30

Required Parts for Installation of 6G-3218 Guard Which is a Part of 136-1810 Fender Gp
Item	Qty	Part Number	Description
1	1	6G-3218	Guard
2	2	2G-3424	Strip
3	10	8T-2502	Bolt (3/8-16X1.125 IN)
4	10	5P-1075	Hard Washer

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Illustration 24	g00518960

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

Install the 143-0028 Payload Wiring

Table 31

Required Parts for Installation of 143-0028 Payload Wiring
Item	Qty	Part Number	Description
1	1	8K-1433	Grommet
2	1	8W-4812	Bracket
3	4	5M-3062	Bolt (3/8-16X0.75 IN)
4	4	8T-4896	Hard Washer
5	2	9G-9150	Clip

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 25	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.

   Note: The 8T-9683 Signal Lamp and the 8T-9684 Signal Lamp are assembled in bracket (2). Bracket (2) is stored in the operator's compartment for shipment.

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Illustration 26	g00541019

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

Install the Guards on the Canopy

Table 32

Parts for Installation of Guards
Item	Qty	Part Number	Description
1	1	113-1765	Guard
2	27	5P-2228	Bolt
3	27	8T-4223	Hard Washer
4	1	113-1764	Guard
5	1	138-6406 (1)	Guard
5	1	8X-9366 (2)	Guard

( 1 )	773E Off-Highway Truck
( 2 )	775E Quarry Truck

1. Use a suitable lifting device in order to position guard (4) on the left side of the canopy.

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Illustration 27	g00519379

2. Use 15 bolts (2) and 15 hard washers (3) in order to attach the guard (4) .

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

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Illustration 28	g00519378

4. Use 12 bolts (2) and 12 hard washers (3) in order to attach guard (1) .

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Illustration 29	g00852185

5. Use a suitable lifting device in order to position guard (5) on the front of the canopy.

6. Use a 4.0 mm (0.16 inch) bevel weld (W1) and a 4.0 mm (0.16 inch) fillet weld (W2) in order to secure guard (5) .

   Note: Weld outward from the center of the canopy.

Install the Shields on the Truck Body of 773E Off-Highway Trucks

Table 33

Parts for Installation of Shields
Item	Qty	Part Number	Description
1	2	146-3750	Plate
2	28	8T-9393	Bolt
3	28	7X-0515	Hard Washer

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Illustration 30	g00885000

1. Use a suitable lifting device in order to position plate (1) on the right side of the truck body.

2. Use 14 bolts (2) and 14 washers (3) in order to secure plate (1) .

3. Repeat Step 1 and Step 2 on the left side of the truck.

Install the 113-1216 Baffle Which is a Part of 136-4627 Body Mounting Group

Table 34

Required Parts for Installation of 113-1216 Baffle Which is a Part of 136-4627 Body Mounting Group
Item	Qty	Part Number	Description
1	1	113-1216	Baffle
2	2	031-9831	Bolt (3/8-16X3/4 IN)

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Illustration 31	g00519177

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

Install the Canopy on the Body

Table 35

Parts for Installation of Canopy
Item	Qty	Part Number	Description	Model
1	1	143-5561	Canopy Assembly	773E
1	1	155-3057 or 137-3311	Canopy Assembly	775E

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Illustration 32	g00885043
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 33	g00852514

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Illustration 34	g00852507

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Illustration 35	g00852569
Grind the weld at location (W3) to the contour shown.

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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

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

   Note: The top of the canopy (W4) and the top of the body (W5) 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).

3. Use (W1) 8.0 mm (0.32 inch) fillet welds in order to secure the canopy to the body.

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

4. Use 16.0 mm (0.63 inch) welds in order to weld the canopy to the body at location (W3). Grind the face of the weld in order to make a contour that is smooth and concave.

5. Use (W2) 10.0 mm (0.40 inch) fillet welds for 773E Off-Highway Trucks with the 143-7111 Body and Canopy . Use (W2) 10.0 mm (0.40 inch) fillet welds for 775E Off-Highway Trucks with the 137-7306 Body and Canopy .

   Note: Location (W2) includes the welded joint inside the body and the welded joint outside the body.

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

6. Use (W2) 16.0 mm (0.63 inch) fillet welds for 773E Off-Highway Trucks with the 137-7266 Body and Canopy . Use (W2) 16.0 mm (0.63 inch) fillet welds for 775E Off-Highway Trucks with the 137-7315 Body and Canopy .

   Note: Location (W2) includes the welded joint inside the body and the welded joint outside the body.

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

Install the Plug in the Body

Table 36

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

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Illustration 36	g00885047

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

Install the 132-6650 Pin As Which is a Part of 136-4627 Body Mounting Group

Table 37

Required Parts for Installation of 132-6650 Pin As Which is a Part of 136-4627 Body Mounting Group
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 (1/2-13X1.5 IN)
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 37	g00874809

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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 38	g00540878

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Illustration 39	g00544513

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

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

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

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

5. Repeat the procedure for the opposite side.

Install the 145-5252 Hoist Cylinder and Mounting Gp

Table 38

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

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Illustration 40	g00519380

1. Remove the shipping brackets from the hoist cylinders.

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

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

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Illustration 41	g00543702

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

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

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

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

5. Repeat the procedure on the opposite side.

Install the Pads and Shims for the Body

Table 39

Parts for Installation of Pads and of Shims
Item	Qty	Part Number	Description
1	30	106-8224	Shim
2	8	106-8223	Pad Assembly
3	24	5P-2566	Bolt (1/2-13X1.5 IN)
4	24	8T-4223	Hard Washer

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

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

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Illustration 42	g00519168
Install pads and shims on the truck body.

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

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

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

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

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Illustration 43	g00519167
Install pads and shims on the rockers.

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

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

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

Install the 3E-0461 Electronic Control Which is a Part of 136-4627 Body Mounting Group

Table 40

Required Parts for Installation of 3E-0461 Electronic Control Which is a Part of 136-4627 Body Mounting Group
Item	Qty	Part Number	Description
1	1	3E-0461	Electronic Control
2	1	167-4357	Bracket
3	4	4M-6425	Bolt (5/16-18X1 IN)
4	4	5P-4116	Washer
5	4	5S-7379	Bolt (3/8-16X0.875 IN)
6	2	5P-1075	Hard Washer
7	1	5G-7820	Magnet Assembly
8	1	146-1845	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 (3/8-16X1.125 IN)
13	1	9G-9152 (1)	Clip

( 1 )

Part of the 199-3416 Lighting and Wiring Group

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Illustration 44	g00543703

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

2. Use two bolts (5) and two hard washers (10) in order to install bracket (8) and magnet assembly (7) .

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Illustration 45	g00543704

3. 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.

4. Use two bolts (5) and two hard 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.

5. Attach the wiring connector of electronic control (1) to the connector plug on the 160-2235 Transmission Harness . Use a 3E-3362 Plug Lock Wedge in order to secure the connection. Use bolt (12), hard washer (11), and clip (13) in order to secure the wiring connection to bracket (2) .

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Illustration 46	g00885059
Dimension (B) is 4.0 mm (0.16 inch). Dimension (C) 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 5G-7820 Magnet Assembly and at the 3E-0461 Electronic Control . Slide the 167-4356 Bracket forward. Remove the shim and tighten the bolts.

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Illustration 47	g00540982
Dimension (A) is 360 mm (14.2 inch).

7. Slide the 3E-0461 Electronic Control on the 167-4356 Bracket until the yellow light illuminates on the top of the 3E-0461 Electronic Control . Tighten the bolts.

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

9. Lower the truck body.

Install the 8W-1155 Rock Ejector Assembly Which is a Part of 136-4627 Body Mounting Group

Table 41

Required Parts for Installation of 8W-1155 Rock Ejector Assembly Which is a Part of 136-4627 Body Mounting Group
Item	Qty	Part Number	Description
1	2	8W-1155	Rock Ejector
2	2	6G-7773	Pin
3	4	3B-4647	Cotter Pin
4	16	1D-0503	Washer
5	2	137-1995 (1)	Bracket
6	1	143-7114	Bracket
7	1	143-7115	Bracket

( 1 )

This bracket is used in the following situations: 773E Trucks with the 136-3162 Body and Canopy , 773E Trucks with the 137-7266 Body and Canopy and 775E Quarry Trucks.

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

Illustration 48	g00519171

Illustration 49	g00519174

Illustration 50	g00885243
Refer to dimensions (C) and dimension (D) in order to position the rock ejectors.

773E Off-Highway Trucks With Dual Sloped Truck Body

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

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

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

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

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

775E Off-Highway Truck and 773E Off-Highway Trucks with the Flat Bottom Truck Body

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

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

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

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

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

Use 136-4627 Body Mounting Group to Install the Body Retaining Pins

Table 42

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 51	g00519175
Install the retainer.

1. Use 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 the procedure for the pin on the opposite side.

Install the 8W-7481 Guard Which is a Part of 136-4627 Body Mounting Group

Table 43

Required Parts for Installation of 8W-7481 Guard Which is a Part of 136-4627 Body Mounting Group
Item	Qty	Part Number	Description
1	2	8W-7481	Guard
2	2	2G-7826	Strip
3	14	5P-2566	Bolt (1/2-13X1.5 IN)
4	14	8T-4223	Hard Washer
5	14	6V-8188	Nut

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Illustration 52	g00543707

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

Install the 5T-2750 Elbow Which is a Part of 136-4627 Body Mounting Group (if Equipped)

Table 44

Required Parts for Installation of 5T-2750 Elbow Which is a Part of 136-4627 Body Mounting Group
Item	Qty	Part Number	Description
1	1	5T-2750	Elbow
2	1	2G-9142	Plate
3	4	3D-0472	Taperlock Stud
4	10	5P-8245	Washer
5	7	1D-7958	Nut
6	1	2G-9582	Elbow
7	4	7B-3235	Bolt (1/2-13X1.375 IN)
8	8	1D-5965	Washer
9	1	4B-3586	Setscrew
10	2	3D-0490	Taperlock Stud

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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.

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

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Illustration 53	g00540967

2. Use 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.

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 54	g00885373
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 208-6548 Film Gp

Table 45

Required Parts for Installation of 136-4627 Body Mounting Group
Item	Qty	Part Number	Description
1	1	8C-5574	Film (CATERPILLAR)
2	1	130-2702	Film
3	1	208-6609	Film
4	1	208-6610	Film
5	1	8C-5563	Film
6	1	8C-5353	Film
7	1	208-6611	Film
8	1	208-6612	Film

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Illustration 55	g00873953

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Illustration 56	g00874222

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Illustration 57	g00874215

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 208-6549 Film Gp

Table 46

Required Parts for Installation of 208-6549 Film Gp
Item	Qty	Part Number	Description
1	1	8C-5574	Film (CATERPILLAR)
2	1	216-1289	Film
3	1	208-6605	Film
4	1	208-6606	Film
5	1	8C-5563	Film
6	1	8C-5353	Film
7	1	208-6607	Film
8	1	208-6608	Film

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Illustration 58	g00874366

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Illustration 59	g00874370

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Illustration 60	g00874377

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

2. Install film (7) 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 (3) on the left side of the truck body.

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

Perform the Commissioning Procedure for the Machine

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

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

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

Prepare the Machine Before the Machine Is Started

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 of the machine ON.

   4. DO NOT START THE TRUCK.

3. Start the Electronic Technician (ET). ET will list all of the electronic control modules for the machine. There will be at least an ENGINE CONTROL and a TRANSMISSION CONTROL. If the truck has the automatic retarder attachment, IBC, or 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 the ENGINE CONTROL. Next, choose "CONFIGURATION".

   1. Change the EQUIPMENT IDENTIFICATION NUMBER in order to correspond to the 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. Check the "HORSEPOWER" parameter. The choices are 920 HP or 1000 HP. Select 1000 HP.

   5. 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.

   6. 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.

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

   8. Choose "DIAGNOSTICS" and choose "DIAGNOSTIC TESTS" from the ET menu. Next, choose "OVERRIDE PARAMETERS".

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 INDENTIFICATION 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 system, select "DATA LINK" from the ET menu. Next, select "CHOOSE ECM". Next, select "AUTOMATIC RETARDER". Finally select "CONFIGURATION".

   1. Change the EQUIPMENT IDENTIFICATION NUMBER in order to correspond to the PIN number 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 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 fifty 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 47

      Machine Model	PIN	Code
      773E	(S/N: BDA)	52
      775E	(S/N: BEC)	51

   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. 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 "-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. 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 "-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 Special Instruction, "Off-Highway Truck/Tractor Suspension Cylinder Charging Procedure".

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 Special Instruction, "Off-Highway Truck/Tractor Suspension Cylinder Charging Procedure".

Note: 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: 773E: 12h and 775E: 13h. 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. Set units mode of the system. Press the button on the rear of the display until the display shows "2". If the truck's destination is the United States, the display will probably read "1u". The display will read US tons. Use the switch on the front of the display in order to set the units mode. If the truck's destination is not the United States, the display should read "0u". The display will read Metric tonnes.

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

7. 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 under the following conditions if the truck has not started in the last two minutes and if the truck is cold. 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 Hoist Controls for the Truck Body

The truck might appear to have a problem with the body hoist controls. The 218-4865 Power Train Software will set the parameters for the hoist system.

Note: ET Software must be used to set these parameters.

Note: On the 2.4 ET Software, when the 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: On the 3.0 ET Software and the 3.1 ET Software, the parameters appear on the configuration screen.

Adjustment for the Hoist Lower Valve

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

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

1. 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.

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

3. Enter the configure parameter screen through the service menu in the Electronic Technician (ET).

4. Change the adjustment on 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 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.

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

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

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

Enabling 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 218-4865 Power Train Software 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 48

Setting for the 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 3.0 ET Software when the parameter connects. Occasionally, ET misses the flexed parameters at the time of the connection.

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

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 (Not an Adjustable Parameter)

The body down snub function cushions the shock when the body hits the frame 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 Engine Control Module (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 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 body goes above the body up switch activation level.

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 attachment, IBC, or 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.

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
773D Truck and 775D 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 49

Specifications for the Commissioning Procedure
Description	Specifications	Actual	Comments
Engine Low Idle rpm	635 +30 -10 rpm
Engine High Idle	2285 ± 30 rpm
Pressure of Brake Retract Pump @ High Idle	4690 ± 200 kPa (680 ± 30 psi)
Relief Pressure of Hoist Pump	17230 ± 520 kPa (2500 ± 75 psi) (1) 18950 ± 520 kPa (2750 ± 75 psi) (2)
Steering Pressure Relief	21270 ± 517 kPa (3085 ± 75 psi)
Steering Cycle Time	6.5 seconds @ 66 °C (150 °F)
Relief Pressure of Transmission Pressure @ High Idle	3200 kPa (465 psi) Maximum
Pressure of Transmission Lubrication @ High Idle	175 ± 30 kPa (25 ± 4 psi)
Torque Converter Outlet Pressure @ Stall	415 ± 105 kPa (60 ± 15 psi)

( 1 )	773D Off-Highway Trucks
( 2 )	775D Off-Highway Trucks