777G Off-Highway Truck TA2 Technical Inspection{0372, 1000, 7000, 753T, 7565} Caterpillar


777G Off-Highway Truck TA2 Technical Inspection{0372, 1000, 7000, 753T, 7565}

Usage:

777G RDR
Off-Highway Truck/Tractor:
777G (S/N: RDR1-UP)

Introduction

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

  1. Save the document as an HTML format.

  1. Open the document with Microsoft Word.

Electrical System

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 in order 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 Special Instruction, REHS0354, "Charging System Troubleshooting".    
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)
( 1 ) N = Normal, M = Monitor, A = Action

Engine

Cooling System

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                
    Jacket Water Outlet Temperature                
    Aftercooler Water Outlet Temperature                
    Jacket Water Inlet Temperature from Cooling System                
    Oil Cooler Water Outlet Temperature                
( 1 ) N = Normal, M = Monitor, A = Action
( 2 ) Test for the pressure that is listed on the cap.

Fuel System

Table 3
Status (1)     Description     Specification     Actual     Comments    
    Fuel Pressure    
752 ± 248 kPa (109 ± 36 psi)    
       
( 1 ) N = Normal, M = Monitor, A = Action

Lubrication System

Table 4
Status (1)     Description     Specification     Actual     Comments    
    Engine Oil Pressure at Low Idle                
    Engine Oil Pressure at High Idle                
( 1 ) N = Normal, M = Monitor, A = Action

Basic Engine

Table 5
Status (1)     Description     Specification     Actual     Comments    
    Engine Speed at Low Idle     700 ± 10 rpm            
    Engine Speed at High Idle     2000 ± 10 rpm            
    Torque Converter Stall Test Engine RPM     1200 ± 10 rpm            
    Cylinder Cutout Test     -         Caterpillar Electronic Technician    
( 1 ) N = Normal, M = Monitor, A = Action

Air Inlet and Exhaust System

Table 6
Status (1)     Description     Specification     Actual     Comments    
    Torque Converter Stall Test Boost Pressure     68.1 ± 10 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)                
( 1 ) N = Normal, M = Monitor, A = Action
( 2 ) Compare the exhaust temperature variance at each exhaust port.

Performance Checks

Operational Checks

Table 7
Status (1)     Description     Specification     Actual     Comments    
    Raise the Dump Body     15 seconds            
    Front Suspension Group measurement (exposed rod)    
170 mm (6.7 inch)    
       
    Rear Suspension Group measurement from Pin to Pin    
780 mm (30.7 inch)    
       
    Rear Suspension Group measurement fully extended    
830.6 mm (32.7 inch)    
       
    Toe Out Measurement    
64.3 mm (2.53 inch)    
       
( 1 ) N = Normal, M = Monitor, A = Action

Hydraulic System

ReferenceRefer to Testing & Adjusting, KENR9933, "Hydraulic and Braking System" for more detail on the following test.

Service Brakes and Retarder System Pressure - Test

Service Brakes and Retarder System Pressure - Test

Table 8
Status (1)     Description     Specification     Actual     Comments    
    Pressure at the Rear Slack Adjuster with Service Brakes Released (Retarder in ON Position at Low Idle)    
4274.75 kPa (620 psi) to
5653.7 kPa (820 psi)    
       
    Pressure at the Front Slack Adjuster with Service Brakes Released (Retarder in ON Position at Low Idle)    
4274.75 kPa (620 psi) to
5653.7 kPa (820 psi)    
       
    Pressure for Front and Rear Slack Adjuster (With Retarder to the OFF Position)    
138 kPa (20 psi)    
       
    Pressure at the Rear Slack Adjuster with Service Brakes Applied (at Low Idle)    
6067.4 ± 703.3 kPa (880 ± 102 psi)    
       
    Pressure at the Rear Slack Adjuster with Service Brakes Applied (at Low Idle)    
6067.4 ± 703.3 kPa (880 ± 102 psi)    
       
    Pressure for Front and Rear Slack Adjuster (with Service Brakes Released)    
138 kPa (20 psi)    
       
( 1 ) N = Normal, M = Monitor, A = Action

Secondary Brake System Pressure Test

Table 9
Status (1)     Description     Specification     Actual     Comments    
    Secondary Brake pressure Test (Service Brakes 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)    
       
( 1 ) N = Normal, M = Monitor, A = Action

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

Table 10
Status (1)     Description     Specification     Actual     Comments    
    Relief Valve Test ((High Pressure) Engine at high idle, Dump bed fully RAISED)    
18950 ± 520 kPa (2750 ± 75 psi)    
       
    Relief Valve Test (Low Pressure) Engine at high idle, Hoist control lever in the LOWER position)    
3450 ± 350 kPa (500 ± 50 psi)    
       
( 1 ) N = Normal, M = Monitor, A = Action

Relief Valve (Brake Oil Cooler) - Test and Adjust

Table 11
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)    
       
( 1 ) N = Normal, M = Monitor, A = Action

Power Train System

ReferenceRefer to Testing & Adjusting, KENR9927, "Power Train System" for more detail on the following test.

Relief Valve (Torque Converter Inlet) - Test and Adjust

Table 12
Status (1)     Description     Specification     Actual     Comments    
    Torque Converter Inlet Pressure at Stall rpm    
380 kPa (55 psi) to
520 kPa (75 psi)    
       
    Torque Converter Oil Temperature During Test    
71° C (160° F) to
94° C (201° F)    
       
( 1 ) N = Normal, M = Monitor, A = Action

Gear Pump (Torque Converter Charging) Pressure - Test and Adjust

Table 13
Status (1)     Description     Specification     Actual     Comments    
    Torque Converter Inlet Relief Valve Pressure (Lockup Clutch Solenoid Deactivated)     Minimum of
103 kPa (15 psi)    
    Engine at low idle rpm, parking brakes engaged, transmission in the NEUTRAL position    
    Torque Converter Inlet Relief Valve Pressure (Lockup Clutch Solenoid Deactivated)     Maximum of
930 kPa (135 psi)    
    Engine at high idle rpm, transmission in the NEUTRAL position    
( 1 ) N = Normal, M = Monitor, A = Action

Gear Pump (Transmission Charging) Pressure - Test and Adjust

Table 14
Status (1)     Description     Specification     Actual     Comments    
    Main Relief Valve Pressure (Lockup Clutch Solenoid Deactivated)     Minimum of
2515 kPa (365 psi)    
    Engine at low idle rpm, parking brakes engaged, transmission in the NEUTRAL position    
    Main Relief Valve Pressure (Lockup Clutch Deactivated)     Maximum of
3175 kPa (461 psi)    
    Engine at high idle rpm, transmission in the NEUTRAL-1 position    
( 1 ) N = Normal, M = Monitor, A = Action

Transmission Lubrication Oil Pressure - Test

Table 15
Status (1)     Description     Specification     Actual     Comments    
    Transmission lubrication Relief Valve pressure in the NEUTRAL position at Low Idle rpm    
7 kPa (1 psi) to
55 kPa (8 psi)    
       
    Transmission lubrication Relief Valve pressure in the NEUTRAL position at High Idle rpm    
170 kPa (25 psi) to
275 kPa (40 psi)    
       
( 1 ) N = Normal, M = Monitor, A = Action

Transmission Pressures - Test and Adjust (Low Idle)

Table 16
Status (1)     Description     Specification     Actual     Comments    
    Clutch 1    
3103 ± 35 kPa (450 ± 5 psi)    
       
    Clutch 2    
1724 ± 35 kPa (250 ± 5 psi)    
       
    Clutch 3    
2275 ± 35 kPa (330 ± 5 psi)    
       
    Clutch 4    
1931 ± 35 kPa (280 ± 5 psi)    
       
    Clutch 5    
3103 ± 35 kPa (450 ± 5 psi)    
       
    Clutch 6    
3103 ± 35 kPa (450 ± 5 psi)    
       
    Clutch 7    
3103 ± 35 kPa (450 ± 5 psi)    
       
    Pressure of the Transmission System    
3103 ± 35 kPa (450 ± 5 psi)    
       
    Transmission Lubrication System    
21 kPa (3 psi)    
       
( 1 ) N = Normal, M = Monitor, A = Action

Transmission Pressures - Test and Adjust (High Idle)

Table 17
Status (1)     Description     Specification     Actual     Comments    
    Clutch 1    
3241 kPa (470 psi)    
       
    Clutch 2    
1724 kPa (250 psi)    
       
    Clutch 3    
2413 kPa (350 psi)    
       
    Clutch 4    
1965 kPa (285 psi)    
       
    Clutch 5    
3241 kPa (470 psi)    
       
    Clutch 6    
3241 kPa (470 psi)    
       
    Clutch 7    
3241 kPa (470 psi)    
       
( 1 ) N = Normal, M = Monitor, A = Action

Steering System

ReferenceRefer to Testing & Adjusting, KENR9935, "Steering System" for more detail on the following test.

Control Manifold (Steering) - Test and Adjust

Table 18
Status (1)     Description     Specification     Actual     Comments    
    Main Relief Valve Secondary Steering (engine stopped)    
260 ± 4 bar (3770 ± 58 psi)    
       
    Backup Relief Valve (engine stopped)    
20700 ± 400 kPa (3002 ± 58 psi)    
       
( 1 ) N = Normal, M = Monitor, A = Action

Piston Pump (Steering, Fan) - Test and Adjust

Table 19
Status (1)     Description     Specification     Actual     Comments    
    High Pressure Cutoff Valve pressure at high idle and zero flow    
20850 kPa (3024 psi) to
21550 kPa (3125 psi)    
       
    Flow Compensator Valve pressure at high idle    
2000 kPa (290 psi) to
3600 kPa (522 psi)    
       
( 1 ) N = Normal, M = Monitor, A = Action

Hydraulic Fan Drive System

ReferenceRefer to Testing & Adjusting, KENR9935, "Steering System" for more detail on the following test.

Piston Pump (Steering, Fan) - Test and Adjust

Table 20
Status (1)     Description     Specification     Actual     Comments    
    High Pressure Cutoff Valve pressure at high idle and zero flow    
20850 kPa (3024 psi) to
21550 kPa (3125 psi)    
       
    Flow Compensator Valve pressure at high idle    
2000 kPa (290 psi) to
3600 kPa (522 psi)    
       
( 1 ) N = Normal, M = Monitor, A = Action

S.O.S

ReferenceRefer to Operation and Maintenance Manual, SEBU8095 for more detail on the following test.

Table 21
Status (1)     Description     Obtain     Comments    
    Engine Coolant Sample (Level II)     Initial 500 Hours        
    Engine Coolant Sample (Level I)     Every 500 Service Hours        
    Differential and Final Drive Oil Sample     Every 500 Service Hours        
    Engine Oil Sample     Every 500 Service Hours        
    Front Wheel Oil Sample     Every 500 Service Hours        
    Hoist and Brake Tank Oil Sample     Every 500 Service Hours        
    Steering System Oil Sample     Every 500 Service Hours        
    Torque Converter and Transmission Oil Sample     Every 500 Service Hours        
    Engine Coolant Sample (Level II)     Every Year        
( 1 ) N = Normal, M = Monitor, A = Action

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