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770G and 772G Off-Highway Trucks TA2 Technical Inspection {0372, 1000, 7000, 753T, 7565} Caterpillar


770G and 772G Off-Highway Trucks TA2 Technical Inspection {0372, 1000, 7000, 753T, 7565}

Usage:

770G ECM
Off-Highway Truck/Tractor
770G (S/N: TWA1-UP; ECM1-UP; ECX1-UP)
772G (S/N: LTS1-UP; LTX1-UP)

Introduction

Inspections are the most basic form of condition monitoring. They are easy to do and surprisingly effective at helping you spot equipment health issues. Proactive monitoring and analysis of equipment information will allow Dealers to effectively intervene before problems occur.

Note: Before adjusting product settings to comply with listed baseline TA2 values, consult SIS for the latest specification values.

Creating an Electronic Copy

Use the following procedure to create an editable electronic copy from SIS Web.

  1. Click format to print.

  2. Save the document as an HTML format.

  3. Open the document with Microsoft Word.

Electrical System

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Table 1
Status(1)  Description  Specification  Actual  Comments 
  Inspect Battery Cables  Cables between the battery, the starter, and the engine ground must be the correct size. Wires and cables must be free of corrosion. Wires and cables must have cable support clamps to prevent stress on battery connections (terminals).     
  Battery Test  12.4 VDC or more    Refer to Special Instruction, SEHS7633, "Battery Test Procedure". 
  Charging System Test  18 VDC to 32 VDC    Refer to Special Instruction, REHS0354, "Charging System Troubleshooting". 
  Electric Starting System Test  12 to 16 V at −23° C (−10° F) to −7° C (19° F)    Refer to Testing and Adjusting, SENR3581, "37-MT, 41-MT, and 42-MT Series Starting Motors". 
14 to 18 V at −7° C (19° F) to 10° C (50° F)
16 to 24 V at 10° C (50° F) to 27° C (80° F)
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(1) N = Normal, M = Monitor, A = Action

Engine

Cooling System

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Table 2
Status(1)  Description  Specification  Actual  Comments 
  Radiator Pressure Relief (Radiator Cap)(2)  -     
  Freezing Point of Engine Coolant  -     
  Conditioner Test of Engine Coolant  -     
  Belt Tension  -    Refer to Operation and Maintenance Manual. 
  Difference between the Upper and Lower Radiator Tank Temperatures  -     
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(1) N = Normal, M = Monitor, A = Action
(2) Test for the pressure that is listed on the cap.

Fuel System

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Table 3
Status(1)  Description  Specification  Actual  Comments 
  Fuel Pressure  717 ± 241 kPa (104 ± 35 psi)     
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(1) N = Normal, M = Monitor, A = Action

Lubrication System

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Table 4
Status(1)  Description  Specification  Actual  Comments 
  Engine Oil Pressure at Low Idle  -     
  Engine Oil Pressure at Full Load Speed (1800 rpm)  -     
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(1) N = Normal, M = Monitor, A = Action

Basic Engine

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Table 5
Status(1)  Description  Specification  Actual  Comments 
  Engine Speed at Low Idle  650 ± 20 rpm     
  Engine Speed at High Idle  2200 ± 10 rpm     
  Torque Converter Stall Test Engine RPM  1300 ± 10 rpm     
  Cylinder Cutout Test  -    Caterpillar Electronic Technician 
  Engine Crankcase Pressure (Blowby)  -     
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(1) N = Normal, M = Monitor, A = Action

Air Inlet and Exhaust System

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Table 6
Status(1)  Description  Specification  Actual  Comments 
  Torque Converter Stall Test Boost Pressure  45.3 IN_HG     
  Cylinder # 1 Exhaust Temperature(2)  -     
  Cylinder # 2 Exhaust Temperature(2)  -     
  Cylinder # 3 Exhaust Temperature(2)  -     
  Cylinder # 4 Exhaust Temperature(2)  -     
  Cylinder # 5 Exhaust Temperature(2)  -     
  Cylinder # 6 Exhaust Temperature(2)  -     
  Cylinder # 7 Exhaust Temperature(2)  -     
  Cylinder # 8 Exhaust Temperature(2)  -     
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(1) N = Normal, M = Monitor, A = Action
(2) Compare the exhaust temperature variance at each exhaust port.

Performance Checks

Reference: Refer to Testing & Adjusting, UENR1122 and Testing & Adjusting, UENR3506 for more detail on the following checks.

Operational Checks

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Table 7
Status(1)  Description  Specification  Actual  Comments 
  Raise the Dump Body  18 seconds     
  Rear Suspension Collapsed Pin to Pin Length (Approximate)(2)  681 mm (27 inch)     
  Front Suspension Collapsed Chrome Length (Approximate)(2)  18 mm (0.71 inch)     
  Toe Out Measurement  50.80 mm (2.00 inch)     
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(1) N = Normal, M = Monitor, A = Action
(2) Refer to Special Instruction, REHS4445, "Servicing the Suspension Cylinders for Off-Highway Trucks."

Hydraulic System

Reference: Refer to Testing & Adjusting, UENR1122, "Hydraulic and Braking System" and Testing & Adjusting, UENR3506, "Hydraulic and Braking System" for more detail on the following tests.

Service Brakes and Retarder System Pressure - Test

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Table 8
Status(1)  Description  Specification  Actual  Comments 
  Pressure at Slack Adjuster for Service Brakes (Retarder in OFF Position at Low Idle)  6065 ± 345 kPa (880 ± 50 psi)     
  Pressure at Front Pressure Tap for Service Brakes (Retarder in OFF Position at Low Idle)  7000 ± 690 kPa (1015 ± 100 psi)     
  Slack Adjuster for Service Brakes (Retarder in ON Position at Low Idle)  5000 ± 690 kPa (725 ± 100 psi)     
  Pressure at Front Pressure Tap for Service Brakes (Retarder in ON Position at Low Idle)  0 kPa (0 psi)     
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(1) N = Normal, M = Monitor, A = Action

Service Brakes and Retarder System Pressure - Test for S/N:TWA1-UP machines

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Table 9
Status(1)  Description  Specification  Actual  Comments 
  Pressure at Slack Adjuster for Service Brakes (Retarder in OFF Position at Low Idle)  6065 ± 690 kPa (880 ± 100 psi)     
  Pressure at Front Pressure Tap for Service Brakes (Retarder in OFF Position at Low Idle)  8140 ± 700 kPa (1181 ± 102 psi)     
  Slack Adjuster for Service Brakes (Retarder in ON Position at Low Idle)  5000 ± 690 kPa (720 ± 100 psi)     
  Pressure at Front Pressure Tap for Service Brakes (Retarder in ON Position at Low Idle)  0 kPa (0 psi)     
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(1) N = Normal, M = Monitor, A = Action

Secondary Brake System Pressure Test

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Table 10
Status(1)  Description  Specification  Actual  Comments 
  Secondary Brake pressure Test (Brakes are not applied, at Low Idle, in the Neutral position)  5033 ± 690 kPa (730 ± 100 psi)     
  Secondary Brake pressure Test (Secondary Brakes fully applied at Low Idle, in the Neutral position)  less than 140 kPa (20 psi)     
  Secondary Brake pressure Test (Brakes are not applied, engine off, in the Neutral position)  3800 kPa (550 psi) or above     
  Secondary Brake pressure Test (Secondary Brakes fully applied at Low Idle, in the Neutral position)  less than 140 kPa (20 psi)     
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(1) N = Normal, M = Monitor, A = Action

Relief Valve (Hoist Raise, Hoist Lower) - Test and Adjust

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Table 11
Status(1)  Description  Specification  Actual  Comments 
  Relief Valve Test ((High Pressure) Engine at high idle, Dump bed fully RAISED)  18950 +1000 - 500 kPa (2750 +145 -73 psi)     
  Relief Valve Test (Low Pressure) Engine at high idle, Hoist control lever in the LOWER position)  3450 ± 350 kPa (500 ± 50 psi)     
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(1) N = Normal, M = Monitor, A = Action

Relief Valve (Brake Oil Cooler) - Test and Adjust

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Table 12
Status(1)  Description  Specification  Actual  Comments 
  Brake cooler relief valve at low idle, hoist control lever in the Float position, while body is in the SNUB position  1725 kPa (250 psi)     
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(1) N = Normal, M = Monitor, A = Action

Power Train System

Reference: Refer to Testing & Adjusting, UENR1122, "Power Train System" and Testing & Adjusting, UENR2824, "Power Train System" for more detail on the following tests.

Torque Converter Lockup Clutch Supply Pressure - Test and Adjust

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Table 13
Status(1)  Description  Specification  Actual  Comments 
  Modulating valve for the torque converter lockup clutch test (engine running at 1700 rpm, in the NEUTRAL position with the parking brake engaged)  2068 ± 69 kPa (300 ± 10 psi)     
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(1) N = Normal, M = Monitor, A = Action

Torque Converter Lockup Clutch Supply Pressure - Test and Adjust for S/N:TWA1-UP machines

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Table 14
Status(1)  Description  Specification  Actual  Comments 
  Torque Converter Lockup Clutch Supply Pressure  1585 ± 70 kPa (230 ± 10 psi)     
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(1) N = Normal, M = Monitor, A = Action

Gear Pump (Power Train Charging) Pressure - Test and Adjust

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Table 15
Status(1)  Description  Specification  Actual  Comments 
  Main Relief Valve Pressure at high idle in the NEUTRAL Position and Parking Brakes are Engaged. The lockup clutch is deactivated.  3240 ± 69 kPa (470 ± 10 psi) maximum     
  Main Relief Valve Pressure at low idle in the NEUTRAL Position and Parking Brakes are Engaged. The lockup clutch is deactivated.  2515 kPa (365 psi) minimum     
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(1) N = Normal, M = Monitor, A = Action

Gear Pump (Power Train Charging) Pressure - Test and Adjust for S/N:TWA1-UP machines

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Table 16
Status(1)  Description  Specification  Actual  Comments 
  Main Relief Valve Pressure at high idle in the NEUTRAL Position and Parking Brakes are Engaged. The lockup clutch is deactivated.  3240 ± 69 kPa (470 ± 10 psi) maximum     
  Main Relief Valve Pressure at low idle in the NEUTRAL Position and Parking Brakes are Engaged. The lockup clutch is deactivated.  2725 ± 69 kPa (395 ± 10 psi) minimum     
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(1) N = Normal, M = Monitor, A = Action

Transmission Lubrication Oil Pressure - Test

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Table 17
Status(1)  Description  Specification  Actual  Comments 
  Transmission lubrication Relief Valve pressure in the NEUTRAL position at 700 rpm  20.5 ± 14 kPa (3 ± 2 psi)     
  Transmission lubrication Relief Valve pressure in the NEUTRAL position at 2200 rpm  172 ± 34 kPa (25 ± 5 psi)     
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(1) N = Normal, M = Monitor, A = Action

Transmission Lubrication Oil Pressure - Test

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Table 18
Status(1)  Description  Specification  Actual  Comments 
  Transmission lubrication Relief Valve pressure in the NEUTRAL position at 700 rpm  20.5 ± 14 kPa (3 ± 2 psi)     
  Transmission lubrication Relief Valve pressure in the NEUTRAL position at 2200 rpm  172 ± 34 kPa (25 ± 5 psi)     
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(1) N = Normal, M = Monitor, A = Action

Transmission Pressures - Test and Adjust for S/N:TWA1-UP machines

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Table 19
Status(1)  Description  Specification  Actual  Comments 
  Clutch 1(2)  3100 ± 35 kPa (450 ± 5 psi)     
  Clutch 2(2)  1550 ± 35 kPa (225 ± 5 psi)     
  Clutch 3(2)  3100 ± 35 kPa (450 ± 5 psi)     
  Clutch 4(2)  1895 ± 35 kPa (275 ± 5 psi)     
  Clutch 5(2)  3100 ± 35 kPa (450 ± 5 psi)     
  Clutch 6(2)  3100 ± 35 kPa (450 ± 5 psi)     
  Clutch 7(2)  3100 ± 35 kPa (450 ± 5 psi)     
  Transmission System Pressure at 700 rpm  2725 ± 69 kPa (395 ± 10 psi)     
  Transmission System Pressure at 1817 rpm  3100 ± 35 kPa (450 ± 5 psi)     
  Transmission System Pressure at 2200 rpm  3240 ± 69 kPa (470 ± 10 psi)     
Show/hide table
(1) N = Normal, M = Monitor, A = Action
(2) Pressure should be measured at high idle

Steering System

Reference: Refer to Testing & Adjusting, UENR1122, "Steering System" and Testing & Adjusting, UENR3508, "Steering System" for more detail on the following tests.

Control Manifold (Steering) - Test and Adjust

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Table 20
Status(1)  Description  Specification  Actual  Comments 
  Main Relief Valve Secondary Steering pressure at high idlePark position  26000 ± 400 kPa (3770 ± 58 psi)     
  Back up Relief Valve for Secondary Steering pressure at high idle in the Park position  20700 ± 400 kPa (3002 ± 58 psi)     
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(1) N = Normal, M = Monitor, A = Action

Piston Pump (Steering, Fan) - Test and Adjust

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Table 21
Status(1)  Description  Specification  Actual  Comments 
  High-Pressure Cutoff Valve pressure at high idle  20850 kPa (3024 psi)Minimum     
  High-Pressure Cutoff Valve pressure at high idle  21550 kPa (3126 psi)Maximum     
  Flow Compensator Valve pressure at high idle  2000 kPa (290 psi)Minimum     
  Flow Compensator Valve pressure at high idle  3600 kPa (522 psi)Maximum     
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(1) N = Normal, M = Monitor, A = Action

Hydraulic Fan Drive System

Reference: Refer to Testing & Adjusting, UENR1122, "Hydraulic Fan Drive System" and Testing & Adjusting, UENR3504, "Hydraulic Fan Drive System" for more detail on the following tests.

Piston Pump (Steering, Fan) - Test and Adjust

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Table 22
Status(1)  Description  Specification  Actual  Comments 
  High-Pressure Cutoff Valve pressure at high idle  20850 kPa (3024 psi)Minimum     
  High-Pressure Cutoff Valve pressure at high idle  21550 kPa (3126 psi)Maximum     
  Flow Compensator Valve pressure at high idle  2000 kPa (290 psi)Minimum     
  Flow Compensator Valve pressure at high idle  3600 kPa (522 psi)Maximum     
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(1) N = Normal, M = Monitor, A = Action

Generator System

Reference: Refer to Testing & Adjusting, KENR####, "Generator System" for more detail on the following test.

Generator Set - Test

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Table 23
Status(1)  Description  Specification  Actual  Comments 
  AC Voltage Across Terminals 1 and 2
Half the Rated Speed 		 Enter Value     
  AC Voltage Across Terminals 1 and 3
Half the Rated Speed 		 Enter Value     
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(1) N = Normal, M = Monitor, A = Action

Winding - Test

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Table 24
Status(1)  Description  Specification  Actual  Comments 
  Exciter Armature (Rotor)  Enter Value     
  Main Armature (Stator)  Enter Value     
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(1) N = Normal, M = Monitor, A = Action

Insulation - Test

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Table 25
Status(1)  Description  Specification  Actual  Comments 
  Main Armature  Enter Value     
  Exciter Field  Enter Value     
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(1) N = Normal, M = Monitor, A = Action

S.O.S

Reference: Refer to Operation and Maintenance Manual, SEBU8718, "Maintenance Interval Schedule" and Operation and Maintenance Manual, SEBU9006, "Maintenance Interval Schedule" for more detail on the following test.

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Table 26
Status(1)  Description  Obtain  Comments 
  Engine Coolant Sample (Level I)     
  Differential and Final Drive Oil Sample     
  Engine Oil Sample     
  Front Wheel Oil Sample     
  Hoist and Brake Tank Oil Sample     
  Steering System Oil Sample     
  Torque Converter and Transmission Oil Sample     
  Engine Coolant Sample (Level II)     
Show/hide table
(1) N = Normal, M = Monitor, A = Action

Caterpillar Information System:

Alternator - Bosch K1/N1 Stator - Test
2012/11/27 Improved Conveyor Flashing and Retainer Plates Are Now Used on Certain Cold Planers {6620}
2013/04/30 A New Scraper Spring Is Now Used for Certain Paving Products {6607}
Alternator - Bosch K1/N1 Capacitor - Test
2012/09/25 New Automation Electronic Control Module Now Available for MINEGEM and Cat® Command for Underground Equipped Machines {7610}
2012/09/27 New Lift Arm Grease Track Protection Bar Installation Procedure Now Available for Certain Load Haul Dump Machines {6107, 7510}
2013/09/27 A New Retainer Is Now Used in the Differential Group on 793D and 793F Off-Highway Trucks {3256, 3258, 3281}
2013/04/03 A New Seal Assembly for the Differential and Bevel Gear Group Is Now Used on Certain 793 Off-Highway Trucks {3256, 3258, 3281, 7555}
559C and 579C Knuckleboom Loaders Boom Cylinder
2012/09/19 Improved Debris Protection Is Now Used For The Tilt Position Sensor On Certain Compact Track Loaders And Skid Steer Loaders {1408, 6129}
2012/09/11 The Circle Manufacturing Process Has Been Improved on Certain Motor Graders {6154}
2012/09/21 New O-Ring Seal Is Now Used in the Lift Cylinder Group for 16M Motor Graders {5102}
Alternator - Bosch K1/N1 Field Winding - Test
Health Interface Module Setup and Configuration Guide System Setup
559C and 579C Knuckleboom Loaders Stabilizer Cylinder
CB44B Vibratory Asphalt Compactor Propel System Speed Sensor (Propel Motor) - Test - Solid Drum
793F AC Off-Highway Truck Hydraulic Fan and Steering System Accumulator (Steering) - Test and Charge
CB44B Vibratory Asphalt Compactor Propel System Pump Control (Electronic Displacement Control) Neutral - Test and Adjust - Split Drum
VIMSpc Update Release Information{0785, 7601} VIMSpc Update Release Information{0785, 7601}
MH3049 Material Handler Hydraulic System Relief Valve (Signal Limiter) - Test and Adjust
Field Installation of the 387-6452 Auxiliary Lines Kit , 387-6453 Auxiliary Lines Kit , and 387-6454 Auxiliary Lines Kit {5057} Field Installation of the 387-6452 Auxiliary Lines Kit , 387-6453 Auxiliary Lines Kit , and 387-6454 Auxiliary Lines Kit {5057}
2013/04/12 New Software Is Now Available for Cat® Product Link 522 Systems {7494, 7606, 7620}
2012/10/11 Correction to Custom Service Information , "254-0348 Control Gp-Parking Brake (Automatic) Custom Product Support Literature for the R1700G <B>S/N:</B>8XZ1-UP Load Haul Dump" {1408, 4250}
2012/10/11 Correction to Custom Service Information , "254-0328 Control Gp-Parking Brake (Automatic) Custom Product Support Literature for the R1600G Load Haul Dump" {1408, 4250}
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