- 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
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Electrical System
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
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
Status (1)     | Description     | Specification     | Actual     | Comments     |
    | Fuel Pressure     | 752 ± 248 kPa (109 ± 36 psi)     |
    |     |
( 1 ) | N = Normal, M = Monitor, A = Action |
Lubrication System
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
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
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
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
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
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
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
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
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
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
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
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)
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)
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
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
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
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.
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 |