775F Off-Highway Truck TA2 Technical Inspection{0372, 1000, 7000, 753T, 7565} Caterpillar

Quarry Truck:

775F (S/N: DLS1-UP)

Introduction

Inspections are the most basic form of condition monitoring. The inspections 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 intervene before problems occur.

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

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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 Testing and Adjusting, SENR9937, "Electric Starting System - Test".
		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	-		Use 245-5829 Coolant/Battery Tester Gp .
	Conditioner Test of Engine Coolant	-		Use 8T-5296 Coolant Conditioner Test Kit .
	Belt Tension	Auto-tension
	Difference between the Upper Radiator Tank Temperature and Lower Radiator Tank Temperature	5° + 5° - 5° C (41° + 41° - 41°F)
	Jacket Water Inlet Temperature from Cooling System	94° ± 3°C (201° ± 37°F)

( 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 at LOW IDLE	-
	Fuel Pressure at HIGH IDLE	772 ± 258 kPa (112 ± 37 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Lubrication System

Table 4

Status (1)	Description	Specification	Actual	Comments
	Engine Oil Pressure at Low Idle	211 + 389 - 151 kPa (31 + 56 - 22 psi)
	Engine Oil Pressure at High Idle	334 + 266 - 154 kPa (48 + 39 - 22 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Basic Engine

Table 5

Status (1)	Description	Specification	Actual	Comments
	Engine Speed at Low Idle	800 ± 10 rpm
	Engine Speed at High Idle	2285 ± 40 rpm
	Cylinder Cutout Test			Cat® Electronic Technician (Cat ET) Service Tool
	Engine Crankcase Pressure (Blowby)

( 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	111.3 kPa (16.1 psi)
	Engine Speed	1831 rpm		The stall rpm for the torque converter without torque limiting for the 775F is 1922 ± 65 rpm.
	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)
	Cylinder # 9 Exhaust Temperature (2)
	Cylinder # 10 Exhaust Temperature (2)
	Cylinder # 11 Exhaust Temperature (2)
	Cylinder # 12 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
	Rear Suspension Nitrogen Charged Pin to Pin Length (2)	1015 mm (40 inch)
	Front Suspension Nitrogen Charged Chrome Length (2)	170 mm (6.69 inch)
	Toe Out Measurement	58.67 mm (2.31 inch)

( 1 )	N = Normal, M = Monitor, A = Action
( 2 )	Refer to Special Instruction, REHS4445, "Servicing the Suspension Cylinders for Off-Highway Trucks"

Hydraulic System

ReferenceRefer to Testing & Adjusting, RENR8294, "Hydraulic Systems" for more detail on the following tests.

Hoist Cylinder Performance - Test

Table 8

Acceptable Cylinder Drift
Status (1)	Minutes	Oil Temperature	Cylinder Drift	Actual	Comments
	7.0	38° to 48°C (100° to 119°F)	6.35 mm (0.25 inch)
	4.1	49° to 64°C (120° to 149°F)	6.35 mm (0.25 inch)
	3.0	65° C (150° F)	6.35 mm (0.25 inch)

( 1 )

N = Normal, M = Monitor, A = Action

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

Table 9

Status (1)	Description	Specification	Actual	Comments
	High Pressure	18950 ± 520 kPa (2750 ± 75 psi)
	Low Pressure	3450 ± 350 kPa (500 ± 50 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Power Train System

ReferenceRefer to Testing & Adjusting, RENR8283, "Power Train System" for more detail on the following test.

Relief Valve (Torque Converter Outlet) Pressure - Test and Adjust

Table 10

Status (1)	Description	Specification	Actual	Comments
	Relief Pressure at Stall rpm of 1922 ± 65 rpm	310 to 517 kPa (45 to 75 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Transmission Pump Pressure (Information can be found in "Worksheet")

Table 11

Status (1)	Description	Specification	Actual	Comments
	Transmission Pump Pressure at LOW IDLE	2480 kPa (360 psi) minimum
	Transmission Pump Pressure at HIGH IDLE	3240 kPa (470 psi) maximum

( 1 )

N = Normal, M = Monitor, A = Action

Lubrication Pressure (Information can be found in "Worksheet")

Table 12

Status (1)	Description	Specification	Actual	Comments
	Lubrication Pressure at LOW IDLE	10 to 69 kPa (1.5 to 10 psi)
	Lubrication Pressure at HIGH IDLE	138 to 241 kPa (20 to 35 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Clutch Pressure (Information can be found in "Worksheet")

Table 13

Status (1)	Description	Specification	Actual	Comments
	Clutch 4 Pressure at LOW IDLE	2100 ± 140 kPa (305 ± 20 psi)
	Clutch 1 Pressure at LOW IDLE	2860 ± 140 kPa (415 ± 20 psi)
	Clutch 7 Pressure at LOW IDLE
	Clutch 6 Pressure at LOW IDLE
	Pump Pressure at LOW IDLE	2480 kPa (360 psi) minimum

( 1 )

N = Normal, M = Monitor, A = Action

Pressure Calibrations for the Transmission Clutch (Information can be found in "Worksheet")

Table 14

Status (1)	Description	Specification	Actual	Comments
	Clutch 1 Pressure	2860 ± 140 kPa (414 ± 20 psi)
	Clutch 2 Pressure	2140 ± 140 kPa (310 ± 20 psi)
	Clutch 3 Pressure	2275 ± 140 kPa (330 ± 20 psi)
	Clutch 4 Pressure	2100 ± 140 kPa (305 ± 20 psi)
	Clutch 5 Pressure	2140 ± 140 kPa (310 ± 20 psi)
	Clutch 6 Pressure	2860 ± 140 kPa (414 ± 20 psi)
	Clutch 7 Pressure	2860 ± 140 kPa (414 ± 20 psi)
	Lockup Pressure	2070 ± 140 kPa (300 ± 20 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Worksheet

Table 15

Status (1)	Description	Specification	Actual	Comments
	Torque Converter Inlet Relief Pressure	955 ± 95 kPa (139 ± 14 psi) maximum at high idle with cold oil

( 1 )

N = Normal, M = Monitor, A = Action

Steering System

ReferenceRefer to Testing & Adjusting, RENR8292, "Steering System" for more detail on the following test.

Check and Relief Valve (Steering) - Test and Adjust

Table 16

Status (1)	Description	Specification	Actual	Comments
	Main Relief Valve Pressure for Secondary Steering	17580 ± 1035 kPa (2550 ± 150 psi)
	Backup Relief Valve Pressure for Secondary Steering	20700 ± 400 kPa (3002 ± 58 psi)
	Backup Relief Valve for the Primary Steering (2)	26000 ± 400 kPa (3771 ± 58 psi)

( 1 )	N = Normal, M = Monitor, A = Action
( 2 )	This information can be found in "Worksheet".

Piston Pump (Steering) Pressure - Test and Adjust

Table 17

Status (1)	Description	Specification	Actual	Comments
	High Pressure Cutoff Valve Pressure	20685 to 22065 kPa (3000 to 3200 psi)
	Flow Compensator Valve Pressure	2000 to 3600 kPa (290 to 522 psi)
	Cutoff Pressure (Pressure Compensator Valve) (2)	21200 ± 350 kPa (3050 ± 50 psi)
	Low Pressure Standby (Pressure Compensator Valve) (2)	3600 kPa (520 psi)

( 1 )	N = Normal, M = Monitor, A = Action
( 2 )	This information can be found in "Worksheet".

Pressure Reducing Valve (Steering) - Test (Information can be found in "Worksheet")

Table 18

Status (1)	Description	Specification	Actual	Comments
	Pressure Reducing Valve Pressure	2600 + 500 - 200 kPa (375 + 73 - 29 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Relief Valve (Steering Cylinder) - Test (Information can be found in "Worksheet")

Table 19

Status (1)	Description	Specification	Actual	Comments
	Steering Cylinder Relief Valve Pressure	27200 ± 690 kPa (3945 ± 100 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Braking System

ReferenceRefer to Testing & Adjusting, RENR8294, "Hydraulic System" for more detail on the following test.

Service Brake Discs - Check

Table 20

Table For Determining The Wear Of Friction Disc
Percentage Of Disc Wear	Disc Thickness
0 percent	5.08 mm (0.200 inch)
10 percent	5.03 mm (0.198 inch)
20 percent	4.98 mm (0.196 inch)
30 percent	4.93 mm (0.194 inch)
40 percent	4.88 mm (0.192 inch)
50 percent	4.83 mm (0.190 inch)
60 percent	4.78 mm (0.188 inch)
70 percent	4.72 mm (0.186 inch)
80 percent	4.67 mm (0.184 inch)
90 percent	4.63 mm (0.182 inch)
100 percent	4.57 mm (0.180 inch)

Table 21

Table For Determining The Wear Of The Grooves In The Friction Disc (1)
Percentage Of Disc Wear	Disc Groove Depth
0 percent	0.64 mm (0.025 inch)
10 percent	0.62 mm (0.024 inch)
20 percent	0.60 mm (0.024 inch)
30 percent	0.59 mm (0.023 inch)
40 percent	0.57 mm (0.022 inch)
50 percent	0.55 mm (0.022 inch)
60 percent	0.53 mm (0.021 inch)
70 percent	0.51 mm (0.020 inch)
80 percent	0.50 mm (0.020 inch)
90 percent	0.48 mm (0.019 inch)
100 percent	0.46 mm (0.018 inch)

( 1 )

This measurement is based on three measurements per side and the measurements are taken at 25.4 mm (1.00 inch) from the outside of the disc.

Service Brakes and Retarder System Pressure - Test

Table 22

Status (1)	Description	Specification	Actual	Comments
	Oil Pressure at Rear Slack Adjuster Retarder Full ON	5000 ± 690 kPa (720 ± 100 psi)
	Oil Pressure at Front Brakes Retarder Full ON	0
	Oil Pressure at Rear Slack Adjuster Retarder OFF	6065 ± 345 kPa (880 ± 50 psi)
	Oil Pressure at Front Brakes Retarder OFF	7000 ± 690 kPa (1015 ± 100 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Slack Adjuster - Test and Adjust

Table 23

Status (1)	Description	Specification	Actual	Comments
	Residual Pressure	127 kPa (18 psi)
	Force to move piston	220 N (50 lb)

( 1 )

N = Normal, M = Monitor, A = Action

Brake Cooling Pressure - Check

Table 24

Status (1)	Description	Specification	Actual	Comments
	Low Idle	14 kPa (2 psi)
	High Idle	172 kPa (25 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Brake Accumulator - Test and Charge

Table 25

Accumulator Precharge Pressure/Temperature Relationship for the 5500 kPa (800 psi) Brake Accumulator
Temperature	Pressure (1)
−7°C (20°F)	5000 kPa (725 psi)
−1°C (30°F)	5105 kPa (740 psi)
4°C (40°F)	5235 kPa (760 psi)
10°C (50°F)	5340 kPa (775 psi)
16°C (60°F)	5420 kPa (785 psi)
21°C (70°F)	5500 kPa (800 psi)
27°C (80°F)	5605 kPa (815 psi)
32°C (90°F)	5735 kPa (830 psi)
38°C (100°F)	5840 kPa (845 psi)
43°C (110°F)	5920 kPa (860 psi)
49°C (120°F)	6000 kPa (875 psi)

( 1 )

Nominal allowable tolerance equals ± 70 kPa (± 10 psi).

S.O.S

ReferenceRefer to Operation and Maintenance Manual, SEBU7794, "Maintenance Interval Schedule" for more detail on performing S.O.S samples.

Table 26

Status (1)	Description	Obtain		Comments
	Engine Oil Sample
	Cooling System Coolant Sample (Level I)
	Cooling System Coolant Sample (Level II)
	Hoist, Torque Converter, and Brake Tank Oil Sample
	Front Wheel Oil Sample
	Differential and Final Drive Oil Sample
	Transmission Tank Oil Sample
	Steering System Oil Sample

( 1 )

N = Normal, M = Monitor, A = Action