Global Manpower Development

773G/775G Off-Highway Truck

Introduction
Text Reference

SERV1921

2011 Caterpillar Inc.

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SERV1921 - 08/11 -2- Introduction - Safety Briefing

Safety Briefing
-- Emergency Phone Numbers
-- First Aid Responders
-- Location of Exits
-- Location of Fire Extinguisher
-- Room Alerts or Hazards
-- Designated Location for Evacuation
-- Storm Shelter

Safely Home. Everyone. Every Day.

Safety Briefing Emergency Phone Numbers

First Aid Responders
Location of Exits
Location of Fire Extinguisher
Room Alerts or Hazards
Designated Location for Evacuation
Storm Shelter

Safely Home. Everyone. Every Day.

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SERV1921 - 09/11 -3- Introduction

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NEW FEATURES

C27 engine with ACERT The 773G/775G Off-Highway Trucks will replace the previous F-Series models. The
technology power is supplied by the updated C27 engine with ACERT technology. The
773G/775G will be equipped with either the C27 Tier 4 engine or the C27 engine for
Lesser Regulated Countries (LRC). The Tier 4 C27 engine is now equipped with an
Economy Power Mode, which reduces fuel costs without losing productivity.

The 773G Tier 4 engine is rated (gross engine power) at 578 kW (775 hp) and the
775G Tier 4 engine is rated at 615 kW (825 hp). The 773G LRC engine is rated at
536 kW (719 hp) and the 775G LRC is rated at 582 kW (787 hp).

VIMS 3G with Advisor The monitoring system will change from the standard Messenger panel and optional
VIMS with Advisor to the standard VIMS 3G with Advisor. VIMS 3G will communicate
with each of the individual ECMs on the truck. VIMS 3G with Advisor will be equipped
with a tire monitoring system.

Power train features The 773G/775G Transmission/Chassis ECM contains software called Advanced
Productivity Electronic Control Strategy (APECS). This strategy enhances productivity,
fuel efficiency, and drive train durability, and enables enhanced machine control.

1. Added supply orifices to the Electronic Clutch Pressure Control (ECPC) manifold
plate to improve clutch fill consistency;
2. Added intermediate speed sensor for additional information;

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MACHINE WALKAROUND

Front of machine This view of the truck shows the following components and service points:

Steering oil tank (1)

Engine precleaners and filters (2)

Remote switch panel (3)

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SERV1921 - 09/11 -6- Introduction

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Front of machine This view of the truck shows the following components and service points:

Primary and secondary air filters (1)

Steering hydraulic tank (2)

Steering pump case drain filter (to the rear of the tank) (3)

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Front of machine on/above front
bumper
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The remote switch panel is located on the right side of the front bumper.
The primary battery disconnect switch (13) in the OFF position disconnects electrical
power to the truck.

The machine lockout switch (9) initiates NEUTRAL through the Transmission/Chassis
Electronic Control Module (ECM) allowing the technician to service the machine
with a running engine. The machine lockout switch also disables the hoist function.
When the machine lockout switch is ON, the parking brake is ON, and the ground
speed is zero, the machine lockout lamp (3) will be ON solid and the machine will be
locked out. The machine lockout lamp will flash when the machine lockout switch is
activated, but either the parking brake is OFF or the ground speed indication is not
zero.

The engine lockout switch (8) disconnects battery power to the starter relays. When
the engine lockout switch is ON and the ground speed is zero, the engine lockout
lamp (1) will be ON solid and the starter will be disabled. The engine lockout lamp will
flash when the engine lockout switch is activated, but the ground speed indication
is not zero.

The engine lockout also transfers power to the ECMs so the VIMS download can be
performed without entering the cab.

Both stairs have LED lights (4) for illumination. The switch is located on the left
corner of the bumper. Refer to image 21-1

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Secondary battery disconnect The batteries (2) have been relocated from the front bumper to above the transmission
switch and a secondary battery disconnect switch (1) has been added. The switch is located
on the right rear frame pedestal, just behind the right front tire.

If the batteries are dead and the engine is needed to raise the body, the engine
can be started using the auxiliary start receptacle and the secondary disconnect is
moved to the OFF position. See the Operation and Maintenance Manual for specific
instructions.

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SERV1921 - 09/11 -10- Introduction

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Right side of machine The following components and service points are located on the right side of the
engine and machine:

Hoist cylinder (1)

Hydraulic oil tank (2)

Fill tube with plastic cover (3)

Secondary brake accumulator (4)

Service brake accumulator (5)

Transmission and torque converter fill tube (6)

Primary fuel filter (7)

Service Center (8)

Fluid level keypad monitor (9)

Engine oil fast fill port (10)

Transmission/torque converter oil fast fill port (11)

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Right side of engine The engine oil filters (1) and the secondary fuel filters (2) are located on the right side
of the C27 engine.

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SERV1921 - 09/11 -13- Introduction

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Rear of machine The following components and service points are located at the rear of the
machine:

Backup alarm (1)

Rear struts (2)

Differential and final drive oil level sight glass (3)

Differential thrust pin cover (4)

Differential magnetic drain valve plug (5)

The 773G/775G is now equipped with a sight glass (3) for checking the differential
and final drive oil level.

NOTE: The rear struts are now installed with the head end of the strut at the top
and the rod end of the strut at the bottom, which increases seal life.

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Above truck with bed removed The following components and service points are visible from above with the truck
bed removed:

Pump group (hoist/brake cooling/brake charging) (1)

Steering pump (2)

Torque converter (3)

Hoist valve (4)

Fuel tank (5)

Hydraulic oil tank (6)

Secondary battery disconnect switch (7)

Transmission (located below the batteries) (8)

Battery box (must be removed to access the transmission control

valves) (9)

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SERV1921 - 09/11 -15- Introduction

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Manual towing valve The manual towing valve (1) is located on the inside of the right frame, in between
the hydraulic tank and rear tires. If the engine is inoperable and the brake oil pressure
from the secondary accumulator is depleted, the parking brakes can be released by
moving the red knob (2) down and using the electric brake release/secondary
steering pump. Refer to the Operation and Maintenance Manual for more
information.

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Left side of truck The following components and service points are on the left side of the truck:

Filters (transmission/torque converter, steering, and hoist and brake) (1)

Fuel tank (2)

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Left side of truck, front of left front Three filters are conveniently grouped in front of the left front tire in compartments
tire with access doors. The filters are:

Transmission/torque converter filter (1)

Steering filter (2)

Hoist/brake filter (3)

Compartment for steering and hoist/brake filters (4)

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Left side of truck, front of left rear The fuel tank is located in front of the left rear tire. The components are:
tire
Fuel cap (1)

Upper sight gauge (2)

Lower sight gauge (3)

Fast fill fuel adaptor (4)

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SERV1921 - 09/11 -19- Introduction

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Fast fill keypad When the key start switch is moved to the ON position, all LED indicators on the
keypad will flash briefly. The key start switch does not need to be ON to supply power
to the keypad. Each fluid level, except the differential oil level, includes three indicator
lights.

When a fluid level is FULL, all indicator lights will illuminate continuously. The center
and bottom indicator lights will illuminate when the corresponding fluid is at or above
normal operating level. The bottom indicator light will flash when the corresponding
fluid is below normal operating level.

There is a test button for each fluid level. When the test button is pressed and held,
the indicator light for the corresponding system will flash once and then illuminate
continuously if the indicators are working properly.

NOTE: The differential oil level indicator has only a center and bottom indicator
light. There is no port for the differential oil in the fast fill service center. A top
indicator is only present when the system fluid has a corresponding port in the
fast fill service center.

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SERV1921 - 09/11 -21- Introduction

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Left side of front bumper The engine shutdown switch (1) and the stairway access light switch (2) are located
on the left side of the front bumper. There are two separate two-way switches that
activate the access lights. One switch is on the left front bumper and the other is on
the dash panel.

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TIRE MONITORING SYSTEM

Tire monitoring system The optional tire monitoring system allows individual tire pressures to be displayed
components on the Advisor screen and provides warnings for low tire pressure, high tire pressure,
and high tire temperature.

A sensor (2) is mounted to the inside wall of each truck tire. The sensors send RFI
signals to one antenna (1), which is mounted on the bottom of the drive shaft guard
at the rear of the torque converter. The antenna transmits the signals through coax
cables to the receiver, which is mounted to the inboard wall of the cab on the right
side. The receiver communicates with the Transmission/Chassis ECM over the CAN
A Data Link.

The tire monitoring system must be configured using Cat ET.

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